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 cor-
rect 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 man-
ual.
(Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
• This manual contains the revision information
to the 17, December 2009.

ADDITIONAL REFERENCES

• Please refer to the other materials (operator’s

manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.

MANUAL COMPOSITION

• This manual consists the Technical Manual and the
Workshop Manual.
• Information included in the Technical Manual:
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems, 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 assem-
ble/disassemble procedures.

PAGE NUMBER

• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.

UNITS USED

• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

IN-02
 SAFETY
RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in

this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe operating
practices.
001-E01A-000

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 do not use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.

• To avoid confusing machine protection with personal SA-1223

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-E01A-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.
• Allow only trained, qualified, authorized personnel to
operate the machine.
• Keep your machine in proper working condition. SA-003

• Unauthorized modifications of the machine may impair

its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety,
function, and/or service life. In addition, personal
accident, machine trouble, and/or damage to material
caused by unauthorized modifications will void Hitachi
Warranty Policy.
• Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident,
machine trouble, and/or damage to material caused
by using unauthorized attachments and/or optional
parts or equipment will void Hitachi Warranty Policy.
• 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 fire-extinguisher
at the recommended intervals as specified in the
fire-extinguisher manual.
• Establish emergency procedure guidelines to cope with
fires and accidents.
• Keep emergency numbers for doctors, ambulance SA-437
service, hospital, and fire department posted near your
telephone.
004-E01A-0437

SA-2
 SAFETY
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for SA-438

the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
• Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating the machine.
005-E01A-0438

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment

or loss of hearing.

• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.

006-E01A-0434

SA-434

INSPECT MACHINE

• Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.

• In the walk-around inspection be sure to cover all

points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.

007-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.
• Do not leave parts and/or tools lying around the
operator’s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not
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.
• Do not 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 get on and off 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 leaving the machine. SA-439

008-E01A-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

• Adjust the rear view mirror position so that the best

rear visibility is obtained from the operator’s seat. If
the mirror is broken, immediately replace it with a new
one.
009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR

LEAVING OPERATOR’S SEAT

• Before rising from the operator’s seat to open/close

either side window or to adjust the seat position, be sure
to first lower the front attachment to the ground and then
move the pilot control shut-off lever to the LOCK position.
Failure to do so may allow the machine to unexpectedly
move when a body part unintentionally comes in contact
with a control lever, possibly resulting in serious personal
injury or death.

• Before leaving the machine, be sure to first lower the

front attachment to the ground and then move the pilot
control shut-off lever to the LOCK position. Turn the
key switch OFF to stop the engine.
• Before leaving the machine, close all windows, doors,
and access covers and lock them up.

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.
SA-237

• We recommend that the seat belt be replaced every

three years regardless of its apparent condition.
010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging, or
operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas. Coordinate
hand signals before starting the machine.
SA-426
• Use appropriate illumination. Check that all lights are
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
011-E01A-0398

HANDLE STARTING AIDS SAFELY

Starting fluid:

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not
need starting fluid.
• To prevent accidental discharge when storing a
pressurized container, keep the cap on the container,
and store it in a cool, well-protected location. SA-293

• Do not incinerate or puncture a starting fluid container.

036-E01A-0293-3

SA-6
 SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the

machine to runaway, possibly resulting in serious injury
or death.

• Start the engine only when seated in the operator's

seat.
• NEVER start the engine while standing on the track or
on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control SA-444
levers are in neutral.
• Before starting the engine, confirm the safety around
the machine and sound the horn to alert bystanders.
012-E01B-0431

JUMP STARTING

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to follow

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

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-0427

SA-379

SA-7
 SAFETY
PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.

• Be sure to wear close fitting clothing and safety

equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
• Clear all persons and obstacles from area of operation
and machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by
obstacles, take care not to hit the upperstructure
against obstacles.
• When loading onto trucks, bring the bucket over the
truck beds from the rear side. Take care not to swing
the bucket over the cab or over any person.

M104-05-015

SA-8
 SAFETY
INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road

shoulder, the machine could tip over, possibly resulting
in serious injury or death.

• Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
SA-0380
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder,
employ a signal person as required.
• Confirm that your machine is equipped a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing becomes loose
and slippery.
• Beware the possibility of fire when operating the
machine near flammable objects such as dry grass.
• Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks
positioned perpendicular to the cliff face with travel
motors at the rear, so that the machine can more easily
evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is
required, be sure to investigate the area first and confirm
that no danger of the cliff or bank collapsing exists. If any
possibility of cliff or bank collapsing exists, do not work
on the area.
• Soft ground may collapse when operating the machine
on it, possibly causing the machine to tip over. When
working on a soft ground is required, be sure to reinforce
the ground first using large pieces of steel plates strong
and firm enough to easily support the machine.
• Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes.
Prevent machine tipping over from occurring. When
operating on rough terrain or on slopes:

• Reduce the engine speed.

• Select slow travel speed mode.
• Operate the machine slowly and be cautious with
machine movements.

SA-9
 SAFETY
PROTECT AGAINST FALLING STONES AND
DEBRIS

• Confirm that your machine is FOPS cab equipped before

working in areas where the possibility of falling stones or
debris exist.

SA-490

PROVIDE SIGNALS FOR JOBS INVOLVING

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-10
 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
A
rocks, and/or metal pieces may scatter around the
machine.
Don’t allow personnel to stay around the machine
while traveling.
• Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.

• Never attempt to ascend or descend 35 degrees or

steeper slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 0.5 to 1.0
m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop. A

SA-658

SA-441

WRONG

SA-442

SA-11
 SAFETY
• 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 safe
operation.
• Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
• If the engine stalls on a slope, immediately lower the Travel Mark
bucket to the ground. Return the control levers to
neutral. Then, restart the engine.
• Be sure to thoroughly warm up the machine before M104-05-008
ascending steep slopes. If hydraulic oil has not
warmed up sufficiently, sufficient performance may not
be obtained.
• Use a signal person when moving, swinging or
operating the machine in congested areas. Coordinate
hand signals before starting the machine.
• Before moving machine, determine which way to
move travel pedals/levers for the direction you want to
go. When the travel motors are in the rear, pushing
down on the front of the travel pedals or pushing the Arrow -mark
levers forward moves the machine forward, towards M178-03-001

the idlers.
An arrow-mark seal is stuck on the inside surface of
the side frame to indicate the machine front direction.
• Select a travel route that is as flat as possible. Steer
the machine as straight as possible, making small
gradual changes in direction.
• Before traveling on them, check the strengths of
bridges and road shoulders, and reinforce if
necessary.
• Use wood plates in order not to damage the road
surface. Be careful of steering when operating on
asphalt roads in summer.
• When crossing train tracks, use wood plates in order SA-011
not to damage them.
• Do not make contact with electric wires or bridges.
• When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the
river when the depth of the river is deeper than the
upper edge of the upper roller.
• When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
• Avoid operations that may damage the track and
undercarriage components.
• During freezing weather, always clean snow and ice
from track shoes before loading and unloading
machine, to prevent the machine from slipping.

SA-12
 SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS

• Death or serious injury may result if you attempt to

mount or stop a moving machine.

To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch and the H/P mode switch off.
• Run the engine at slow idle speed without load for 5 SA-391

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-392

020-E02A-0493

SA-13
 SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS

• If any person is present near the machine when backing

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

• Always look around BEFORE YOU BACK UP AND

SWING THE MACHINE. BE SURE THAT ALL
BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING SA-383
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.
• 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 SA-384
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.
021-E01A-0494

SA-14
 SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA

• A person may be hit severely by the swinging front

attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.

• Keep all persons clear from the area of operation and

machine movement.
• Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.

022-E01A-0386

SA-386

NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a

truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

023-E01A-0487

SA-487

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if the

footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not

possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.

024-E01A-0488

SA-488

SA-15
 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.

To avoid tipping:
• Be extra careful before operating on a grade. SA-012

• 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.

025-E03B-0463

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur

causing serious injury or death.
026-E01A-0519

SA-489

SA-16
 SAFETY
DIG WITH CAUTION

• Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting in
serious injury or death.

• Before digging check the location of cables, gas lines,

and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally severed,
do not look into the end. Doing so may result in
serious eye injury.
SA-382

• Contact your local “diggers hot line” if available in your

area , and/or the utility companies directly. Have them
mark all underground utilities.

027-E01A-0382

OPERATE WITH CAUTION

• If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the

boom or arm.

028-E01A-0389

SA-389

SA-17
 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 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

PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.

• In the event of an electrical storm, immediately stop

operation, and lower the bucket to the ground.
Evacuate to a safe place far away from the machine.
• After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only
after repairing them.
SA-1088

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. SA-014

• Never attach a sling or chain to the bucket teeth. They

may come off, causing the load to fall.

032-E01A-0132

SA-18
 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 switch and H/P mode switch OFF.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK SA-390

position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.

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.
SA-018
• All fuels, most lubricants, and some coolants are
flammable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
SA-019
034-E01A-0496

SA-19
 SAFETY
TRANSPORT SAFELY

• Take care the machine may turn over when loading or

unloading the machine onto or off of a truck or trailer.

• Observe the related regulations and rules for safe

transportation.
• Select an appropriate truck or trailer for the machine to
be transported.
• Be sure to use a signal person.
• Always follow the following precautions for loading or
unloading:
1. Select solid and level ground. SA-395

2. Always use a ramp or deck strong enough to support

the machine weight.
3. Turn auto-idle switch OFF.
4. Always select the slow speed mode with the travel
mode switch.
5. Never load or unload the machine onto or off a truck
or trailer using the front attachment functions when
driving up or down the ramp.
6. Never steer the machine while on the ramp. If the
traveling direction must be changed while the ramp,
unload the machine from the ramp, reposition the
machine on the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is
a sudden bump. Take care when traveling over it.
8. Place blocks in front of and behind the tracks.
Securely hold the machine to the truck or trailer deck
with wire ropes.

Be sure to further follow the details described in the

TRANSPORTING section.

035-E07A-0454

SA-20
 SAFETY
PRACTICE SAFE MAINTENANCE

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

Before servicing the machine:

1. Park the machine on a level surface.
SA-028

2. Lower the bucket to the ground.

3. Turn the auto-idle switch 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 SA-527

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 100˚
angle between the boom and arm. Securely support
any machine elements that must be raised for service
work.
• Inspect certain parts periodically and repair or replace
as necessary. Refer to the section discussing that part
in the “MAINTENANCE” chapter of this 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 flammable oil such as
fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02C-0520

SA-21
 SAFETY
• Sufficiently illuminate the work site. Use a
maintenance 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

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. This tag is
available from your authorized dealer.
501-E01A-0287

SS2045102

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-22
 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.
• Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster may
cause the parts such as a spring to fly off, possibly SA-344

resulting in severe personal injury or death.

• 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.

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.

504-E01A-0034

SA-034

SA-23
 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. SA-039
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.
Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
SA-225
• Wait for the oil and components to cool before starting
any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under

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

• Periodically replace the rubber hoses. (See the page

of “Periodic replacement of parts” in the operator’s
manual.)
• Failure to periodically replace rubber hoses may cause a
fire, fluid injection into skin, or the front attachment to fall SA-019
on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.

S506-E01A-0019

SA-24
 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 high-pressure fluids.
Wear a face shield or goggles for eye protection. SA-031

• 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.

507-E03A-0499

SA-292

SA-044

SA-25
 SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler flange
bolts.
• Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange
bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or hoses.
Check for Shorts: SA-019

• Short circuits can cause fires.

• Clean and tighten all electrical connections.
• Check before each shift or after eight(8) to ten(10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
• Check before each shift or after eight (8) to ten (10)
hours operation 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.
Check 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 engine stop switch function every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the engine stop switch to the 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.
508-E02B-0019

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.
508-E02A-0393

SA-26
 SAFETY
EVACUATING IN CASE OF FIRE

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

way:

• Stop the engine by turning the key switch to the OFF

position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
SA-393
• In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with the
emergency evacuation hammer to escape from the cab.
Refer the explanation pages on the Emergency
Evacuation Method.

18-E02B-0393
SS-1510

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 uses 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.
SA-818
• After finishing welding and grinding, recheck that there
are no abnormalities such as the area surrounding the
welded area still smoldering.

523-E01A-0818

SA-27
 SAFETY
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 SA-030
other materials before engaging in welding, soldering,
etc..

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030

REMOVE PAINT BEFORE WELDING OR

HEATING

• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
• Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust. SA-029
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove solvent
or paint stripper containers and other flammable
material from area. Allow fumes to disperse at least
15 minutes before welding or heating.

511-E01A-0029

SA-28
 SAFETY
BEWARE OF ASBESTOS DUST
• Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer.

• Depending on the work site conditions, the risk of

inhaling asbestos fiber may exist. Spray water to
prevent asbestos from becoming airborne. Do not use
compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask rated
to prevent the inhalation of asbestos. SA-029

• Keep bystanders out of the work site during operation.

• Asbestos might be present in imitation parts. Use only
genuine Hitachi Parts.

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. SA-032

• Loose terminals may produce sparks. Securely tighten

all terminals.
• Battery electrolyte is poisonous. If the battery should
explode, battery electrolyte may be splashed into eyes,
possibly resulting in blindness.

• Be sure to wear eye protection when checking

electrolyte specific gravity.
512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM

SAFELY
• If spilled onto skin, refrigerant may cause a cold contact
burn.

• Refer to the instructions described on the container for

proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405 SA-405

SA-29
 SAFETY
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 SA-309
what the risks are and how to do the job safely. Then
follow procedures and use recommended equipment.
• See your authorized dealer for MSDS’s (available only
in English) on chemical products used with your
machine.
515-E01A-0309

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 SA-226

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, or from your authorized dealer.
516-E01A-0226

SA-30
 SAFETY
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

SA-435

S517-E01A-0435

SA-31
 SAFETY
(Blank)

SA-32
 SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic
Oil Tank
SECTION 2 UPPERSTRUCTURE
WORKSHOP MANUAL
Group 1 Cab
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 Pilot Valve
Group 7 Pilot Shut-Off Solenoid Valve
Group 8 Shuttle Valve
Group 9 Solenoid Valve
Group 10 Signal Control Valve
Group 11 Fan Motor
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 Rollers
Group 7 Track
All information, illustrations and speci- SECTION 4 FRONT ATTACHMENT
fications in this manual are based on Group 1 Front Attachment
the latest product information available
at the time of publication. The right is Group 2 Cylinder
reserved to make changes at any time Group 3 Bushing and Point
without notice.

COPYRIGHT(C)2008
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Controller Group 5 Travel Device
Group 2 Control System Group 6 Signal Control Valve
Group 3 Hydraulic System Group 7 Others(Upperstructure)
Group 4 Electrical System Group 8 Others(Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
Group 1 Introduction Group 2 Monitor Unit
Group 2 Standard Group 3 Dr. ZX
Group 3 Engine Test Group 4 Component Layout
Group 4 Excavator Test Group 5 Troubleshooting A
Group 5 Component Test Group 6 Troubleshooting B
Group 7 Troubleshooting C
Group 8 Electrical System Inspection
 SECTION 1
GENERAL

―CONTENTS―
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Maintenance Standard Terminology......... W1-1-7

Group 2 Tightening
Tightening Torque Specification ............... W1-2-1
Torque Chart............................................ W1-2-3
Piping Joint.............................................. W1-2-6
Periodic Replacement of Parts .............. W1-2-10

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

Group 4 Bleeding Air from Hydraulic Oil

Tank
Bleed Air from Hydraulic Oil Tank ............ W1-4-1

18JW-1-1
(Blank)

18JW-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
disassem-bling/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
Prepare the necessary tools to be used and the
area for disassembling work.
W1-1-1
• 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.
 GENERAL / Precautions for Disassembling and Assembling
• 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.
W1-1-2
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and in-
stallation 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 hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the mo-
tor may result.
If the cylinder is operated with air
trapped in the cylinder tube, dam-
age 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 en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.
 GENERAL / Precautions for Disassembling and Assembling
• 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
W18J-01-04-002
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

W18J-01-04-003

Wooden Block

W1-1-3
 GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:

(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.

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

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

uneven wear.

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

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting

bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect

(2) Clean the floating seal and seal mounting

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

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

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal a a
mating face (C) by measuring the distances
A
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating. B

b b

a=b a≠b
W110-03-05-004

W1-1-4
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings

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

lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008

slings or pushing slings with a metal object.

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

W1-1-5
 GENERAL / Precautions for Disassembling and Assembling

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.

W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Separation of W162-01-01-006
Scoring
Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W1-1-6
 GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies

adjusted to specification.

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

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.

W1-1-7
 GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
 GENERAL / Tightening

TIGHTENING TORQUE SPECIFICATION

Bolt Dia Wrench Torque

No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
Engine cushion rubber mounting bolt (F) 22 2 32 750 (75) (540)
1
Engine cushion rubber mounting bolt (R) 33 2 50 2600 (260) (1880)
2 Engine bracket mounting bolt (R) 27 12 41 1050 (105) (760)
3 Radiator mounting bolt 27 4 41 1050 (105) (760)
4 Hydraulic oil tank mounting bolt 20 8 30 550 (55) (400)
5 Fuel tank mounting bolt 24 8 36 950 (95) (690)
7
1 − 16 − 12UNF 41 210 (21) (152)
6 ORS fittings for hydraulic hoses and piping 11
1 − 16 − 12UNF 50 350 (35) (255)
1
7 Pump transmission mounting bolt 2 − 13 UNC 19 120 (12) (87)
Pump mounting bolt (Main) 20 12 Hexagonbar wrench 17 400 (40) (290)
8
Pump mounting bolt (Fan) 16 4 Hexagonbar wrench 14 210 (21) (152)
9 Gear pump mounting bolt 14 2 22 140 (14) (101)
10 Control valve mounting bolt (Main) 20 4 30 400 (40) (290)
Control valve mounting bolt (Swing) 16 3 24 270 (27) (195)
11 Swing device mounting bolt 27 16×2 41 1400 (140) (1010)
12 Swing motor mounting bolt 12 12×2 19 90 (9) (65)
13 Battery mounting bolt 12 2 19 35 (3.5) (26)
14 Cab mounting bolt 16 6 24 210 (21) (152)
15 Cab-bed mounting bolt 12 27 19 110 (11) (81)
16 Swing bearing mounting bolt to upperstructure 36 52 55 2800 (280) (2030)
Swing bearing mounting bolt to undercarriage 36 50 55 2800 (280) (2030)
17 Travel device mounting bolt 27 52 41 1400 (140) (1010)
18 Travel motor mounting bolt 18 8 27 300 (30) (215)
19 Sprocket mounting bolt 27 60 41 1400 (140) (1010)
20 Upper roller mounting bolt 22 24 32 750 (75) (540)
21 Lower roller mounting bolt 27 64 41 1400 (140) (1010)
22 Track shoe mounting bolt 33 392 50 3500 (350) (2230)
23 Track guard mounting bolt 27 28 41 1400 (140) (1010)
24 Side frame mounting bolt 42 52 65 4000 (400) (2890)
25 Counterweight mounting bolt 45 8 65 4000 (400) (2890)
26 Oil cooler mounting bolts 24 12 36 950 (95) (690)
Front pin lock bolt (Loading shovel)
A Front pin lock bolt 20 14 30 400 (40) (290)
27 B Bucket pin lock bolt 20 4 *17 400 (40) (290)
C Bucket pin lock bolt 16 18 24 270 (27) (195)
D Bucket pin lock bolt 12 6 19 90 (9) (65)
Front pin lock bolt (Backhoe)
28 A Front pin lock bolt 20 12 30 400 (40) (290)
B Stopper bolt 20 12 30 400 (40) (290)
29 Side cutter mounting bolt 33 12 50 2600 (260) (1880)
NOTE: * Hexagonal socket wrench

W1-2-1
 GENERAL / Tightening

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.
3. Apply LOCTITE to threads before
installilng and tightening swing bearing
mounting bolts and lower roller mounting
bolts.

W1-2-2
 GENERAL / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.

Bolt Types

Tighten nuts or bolts correctly to torque specifica-

tions.
Four different types and grades of bolt are em- SA-040

ployed.
Make sure to employ correct bolts and tighten them
correctly when assembling the machine or compo-
nents.

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M552-07-092

Socket Bolt
N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)
M8 13 6 30 (3.0) (21.5) 20 (2.0) (14.5) 10 (1.0) (7.2)
M10 17 8 65 (6.5) (47) 50 (5.0) (36) 20 (2.0) (14.5)
M12 19 10 110 (11) (80) 90 (9.0) (65) 35 (3.5) (25.5)
M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40)
M16 24 14 270 (27) (195) 210 (21) (152) 80 (8.0) (58)
M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87)
M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123)
M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159)
M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205)
M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290)
M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400)
M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540)
M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)

W1-2-3
 GENERAL / Tightening
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 lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.

Tighten from center and diagonally

Equally tighten upper and lower alternately Tighten diagonally

1 12 9 4 1 6 7 14
6 3
1st to 4th

4 5
2 13 8 5 2 3 10 11

2nd to 3rd
W105-01-01-003

W1-2-4
 GENERAL / Tightening
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 extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
Incorrect
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
W105-01-01-016
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 di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008

an air wrench often causes tight- Correct Incorrect

ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply

Nut and Bolt Locking Correct Correct Incorrect

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

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

Correct Correct Incorrect

ening, not while loosening.

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

Tighten

W105-01-01-010

W1-2-5
 GENERAL / Tightening
PIPING JOINT 1 4 3 5 2

IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint

Metal sealing surfaces (4) and (5) of adapter (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37°

30°
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017

2. Scratches or other damage to

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

Wrench Size Wrench Size mm Tightening

Description mm Torque
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30° male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,22)
22 22 39 (4.0,29)
27 27 78 (8.0,58)
32 32 137 (14,101)
36 36 175 (18,129)
41 41 205 (21,151)
37° female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,22)
22 19 39 (4.0,29)
27 22 78 (8.0,58)
32 27 137 (14,101)
36 32 175 (18,129)
41 36 205 (21,151)
NOTE: Tightening torque of 37° male coupling without union is similar
to tightening torque of 37° female.

W1-2-6
 GENERAL / Tightening
O-ring Seal Joint 9
7 6

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

to seal pressure oil.

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

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 1
in O-ring groove (e). Tightening
nut (9) with O-ring (6) displaced M104-07-033

will damage O-ring (6), resulting

in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (e) or sealing surface mm mm
(10). Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
Damage to O-ring (6) will cause 19 17 29.5 (3.0,21.5)
oil leakage. 22 19 69 (7.0,51)
4. If nut (9) is loose and oil is leak- 27 22 93 (9.5,69)
ing, do not re-tighten nut (9). Re- 32 27 137 (14,101)
place O-ring (6) with a new one 36 30,32 175 (18,129)
and check that O-ring (6) is cor- 41 36 205 (21,151)
rectly seated in place, tighten nut 46 41 205 (21,151)
(9).

W1-2-7
 GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread

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

Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up External Thread
thread clearances. Do not overwrap. Clearance

• Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

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.

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs

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

M114-07-043 M114-07-042

W1-2-8
 GENERAL / Tightening
Connecting Hose

Incorrect Correct
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.

Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print Incorrect Correct
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other

If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012

Take care so that hoses do not come into Incorrect Correct

contact with moving parts or sharp objects. Clamp Clamp

Rubbing Against
Each Other

W105-01-01-013

Incorrect Correct

Rubbing Against
Each Other Clamp
W105-01-01-014

W1-2-9
 GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Base Machine
Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Arm cylinder line hose Every 2 years
Working Device
Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years

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

and gaskets, when replacing hoses.

W1-2-10
 GENERAL / Painting
PAINTING

Surfaces to be Painted Painting Color

• Main surface of upperstructure, YR-01 [Taxi yellow]
counterweight, main frame except
specified masked position, hydraulic oil
tank, fuel tank, duct, and front
• Mirror, swing bearing, track N-10 [Black]
• Muffler, muffler cover M/F Beige deep
• Tank upper, handrail on cover upper HG Black
• Fender, fender handrail HG Beige deep
• Inside surface of upperstructure, Inner
parts, undercover, lower part of main
frame, and lower part of bed

W1-3-1
 GENERAL / Painting

Do not paint on heat sink such as oil

cooler, pump transmission cooler,
fuel cooler, and condenser.

Handrail on Fuel Tank

Muffler
Handrail on Oil Cooler Cover
Muffler Cover
Handrail on Battery Box
M/F Beige Deep
HG Black [Urethane]
[Heatproof Painting]
(Same on Toe Strap)

Right Fender
HG Beige Deep
[Urethane]

Duct
Taxi Yellow [YR-01]
(Paint the fly screen in grey; N40)
Paint clearly on duct and the fry
screen not to be clogged.
W18J-01-03-001

Step Right Fender Handrail

HG Beige Deep HG Beige Deep
[Urethane] [Urethane]

Cab: Manufacture
Painted
Carry out refinish
paint later.

Do not paint on the

urethane part under
cab.

Paint light guard in W18J-01-03-002

black.

W1-3-2
 GENERAL / Painting

Front of Engine Cover [Shaded Area]

Taxi Yellow [YR-01]

Center Step Stairs W18J-01-03-004

View D

Handrail on Left Fender

Handrail on Oil Tank
HG Beige Deep
[Urethane] Handrail on Oil Tank
HG Black [Urethane]

Plate
HG Beige Deep
[Urethane]

Plate W18J-01-03-003

HG Beige Deep
[Urethane]
Step
Cab Side Fender
Left Fender
HG Beige Deep
[Urethane]

W1-3-3
 GENERAL / Painting
Shaded Part
Taxi Yellow [YR-01]
[Urethane]

W18J-01-03-005
A B B C

Shaded Part
Taxi Yellow [YR-01]
[Urethane]

W18J-01-03-006
View B

Shaded Part
Taxi Yellow [YR-01]
[Urethane]

W18J-01-03-007 W18J-01-03-008

View A View C

W1-3-4
 GENERAL / Bleeding Air From Hydraulic Oil Tank
BLEED AIR FROM HYDRAULIC OIL TANK

CAUTION: Escaping fluid under pressure

may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing hydraulic or other lines.
Hot hydraulic oil just after operation may
spout and cause severe burns. Wait for oil in
order to cool before starting any work.
Do not turn the cap on hydraulic oil tank
quickly. The cap may fly off by internal
pressure. Release any remaining pressure
and remove the cap.

Preparation W18J-01-04-002

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

the front attachment onto the ground.

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

hydraulic oil tank and release any remaining
pressure in the hydraulic oil tank.
W18J-01-04-003
3. Remove the cap on the hydraulic oil tank. Install
an adapter of vacuum pump to the cap mounting Air Bleed Valve
part in hydraulic oil tank. Operate the vacuum
pump in order to maintain negative pressure in
the hydraulic oil tank.

NOTE: Run the vacuum pump continuously while

working。

W18J-01-04-001

Vacuum Pump

Hose

Adapter

W562-02-03-008

W1-4-1
 GENERAL / Bleeding Air From Hydraulic Oil Tank
(Blank)

W1-4-2
 MEMO

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 MEMO

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 SECTION 2
UPPERSTRUCTURE

―CONTENTS―
Group 1 Cab Group 4 Control Valve
Removal and Installation of Cab ............... W2-1-1
Dimensions of the Cab Glass.................. W2-1-13
Group 2 Counterweight
Removal and Installation of
Counterweight ......................................... W2-2-1
Group 3 Pump Device
Removal and Installation of
Pump Device........................................... W2-3-1
Disassembly of Pump Transmission........ W2-3-20
Assembly of Pump Transmission ............ W2-3-24
Disassembly of Main Pump ..................... W2-3-30
Assembly of Main Pump.......................... W2-3-34
Disassembly of Main Regulator............... W2-3-40
Assembly of Main Regulator ................... W2-3-42
Disassembly of Fan Pump ...................... W2-3-46
Assembly of Fan Pump ........................... W2-3-50
Disassembly of Fan Regulator ................ W2-3-54
Assembly of Fan Regulator ..................... W2-3-60
Maintenance Standard ............................ W2-3-66
Structure of Pilot Pump ........................... W2-3-68
Structure of Pump Transmission
Oil Circulation Pump ............................. W2-3-70
Structure of Solenoid Valve ..................... W2-3-72
Removal and Installation of
Control Valve ...........................................W2-4-1
Disassembly of Control Valve
(Side of 4-Spool Housing)......................W2-4-28
Assembly of Control Valve
(Side of 4-Spool Housing)......................W2-4-34
Disassembly of Control Valve
(Side of 5-Spool Housing)......................W2-4-40
Assembly of Control Valve
(Side of 5-Spool Housing)......................W2-4-44
Disassembly of Control Valve
(Top and Bottom Sides of
4-Spool Housing) ...................................W2-4-50
Assembly of Control Valve
(Top and Bottom Sides of
4-Spool Housing) ...................................W2-4-56
Disassembly of Control Valve
(Top and Bottom Sides of
5-Spool Housing) ...................................W2-4-64
Assembly of Control Valve
(Top and Bottom Sides of
5-Spool Housing) ...................................W2-4-72
Disassembly of Control Valve
(4-Spool Control Valve)..........................W2-4-84
Assembly of Control Valve
(4-Spool Control Valve)..........................W2-4-88
Disassembly of Control Valve
(5-Spool Control Valve)..........................W2-4-90
Assembly of Control Valve
(5-Spool Control Valve)..........................W2-4-94
Disassembly of Housing ..........................W2-4-96
Assembly of Housing...............................W2-4-98
Disassembly of Swing Control Valve .....W2-4-100
Assembly of Swing Control Valve ..........W2-4-106

18JW-2-1
 Disassembly of Swing Control Valve
(Side) .................................................. W2-4-112
Assembly of Swing Control Valve
(Side) .................................................. W2-4-114
Group 5 Swing Device
Removal and Installation of
Swing Device .......................................... W2-5-1
Disassembly of Swing Device ................... W2-5-6
Assembly of Swing Device ...................... W2-5-12
Disassembly of Swing Motor ................... W2-5-18
Assembly of Swing Motor........................ W2-5-22
Structure of Swing Parking Brake
Valve ..................................................... W2-5-28
Maintenance Standard ............................ W2-5-29
Group 9 Solenoid Valve
Removal and Installation of
4-Spool Solenoid Valve............................W2-9-1
Structure of 4-Spool Solenoid Valve ..........W2-9-3
Disassembly and Assembly of
4-Spool Solenoid Valve ..........................W2-9-4
Group 10 Signal Control Valve
Removal and Installation of
Signal Control Valve ..............................W2-10-1
Structure of Signal Control Valve .............W2-10-4
Group 11 Fan Motor
Removal and Installation of Fan Motor .... W2-11-1
Structure of Fan Motor............................. W2-11-9

Group 6 Pilot Valve

Removal and Installation of Pilot Valve ..... W2-6-1
Disassembly of Pilot Valves
(Left and Right) ..................................... W2-6-20
Assembly of Pilot Valves
(Left and Right) ..................................... W2-6-24
Disassembly of Travel Pilot Valve ........... W2-6-28
Assembly of Travel Pilot Valve ................ W2-6-32
Disassembly of Bucket Open / Close
Pilot Valve ............................................. W2-6-38
Assembly of Bucket Open / Close
Pilot Valve ............................................. W2-6-40

Group 7 Pilot Shut-Off Solenoid Valve

Removal and Installation of
Pilot Shut-off Solenoid Valve ................... W2-7-1
Structure of Pilot Shut-Off
Solenoid Valve ........................................ W2-7-3

Group 8 Shuttle Valve

Removal and Installation of
Shuttle Valve ........................................... W2-8-1
Structure of Shuttle Valve.......................... W2-8-3

18JW-2-2
 UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION OF CAB

Removal 1 2, 3 4 1
1. Remove bolts (2) (13 used) and washers (3) (13
used). Remove covers (1) (2 used) from main
frame (4).
: 19 mm

W18J-02-07-003

2. Disconnect vinyl hose (5) from washer tank (6).

Cap the open ends.

W18J-02-01-004

3. Disconnect connectors (8) (7 used) from harness

(7).

7, 8

W18J-02-01-001

4. Open cover (12). Remove air filter (13) from the 9, 10

inside. Shut cover (12).

5. Open door (11). Remove mat (10) from the inside

of cab (9).
11

12, 13

W18J-02-01-020

W2-1-1
 UPPERSTRUCTURE / Cab

CAUTION: Seat (14) weight: 40 kg (88 lb)

6. Remove bolts (16) (2 used) from seat belt (15). 14

Remove seat belt (15) from bracket (18).
：16 mm

15
17

16
W1JB-02-01-008

7. Remove socket bolts (17) (4 used) from seat (14). 14 17

Remove seat (14) from bracket (18).
：6 mm

18

W1JB-02-07-007

8. Remove screws (19) (9 used). Remove cover (20) 9 19 20

from cab (9).

W18J-02-01-006
21, 22
9. Remove bolts (25) (2 used) from cover (23).
：13 mm 9

10. Remove caps (21) (5 used) from cover (23).

Remove screws (22) (6 used) from cover (23). 23

11. Remove cover (23) and the duct from cab (9).
Disconnect a connector from cigar lighter (24).

24

W18J-02-01-022
22 25

W2-1-2
 UPPERSTRUCTURE / Cab
12. Remove bolt (26) and bolts (30) (2 used). Remove 26 27
cover (28) from brackets (27, 29). 28
：13 mm, 17 mm

29

W18J-02-01-019
30

13. Remove bolts (31) (4 used). Remove cover (33) 31, 32

from cab (9). Disconnect connector (32).
：13 mm

33

W18J-02-01-003

9
14. Remove cap (35) (3 used) from cover (34).
Remove screws (36) (3 used) from cover (34).
Remove cover (34) from cab (9). 34

35, 36

36

W18J-02-01-004

9 37
15. Remove screws (37) (6 used). Remove cover (38)
from cab (9).

W18J-02-01-005
38

W2-1-3
 UPPERSTRUCTURE / Cab
16. Remove bolt (40) from ground wire (39).
Disconnect ground wire (39) from cab (9).
：17 mm 9

39

40

41 W18J-02-01-007
17. Remove bolts (42) (2 used) from clips (43) (2
42
used). Remove clips (43) (2 used) from harness
(44).
：17 mm 43

18. Disconnect harness (45) from buzzer (46). 42

19. Disconnect connectors (41) (5 used). 44

45
20. Remove bolt (48) from duct (47).
：13 mm
46 W18J-02-01-002

21. Remove bolts (50) (2 used) from bracket (49). 47 48

Remove bracket (49) and duct (47) from bracket
(27).
：10 mm

49

W18J-02-01-021

50
27

W18J-02-01-001

W2-1-4
 UPPERSTRUCTURE / Cab
22. Remove bolts (51) (4 used) from bracket (27). 51 27 9 51 52, 53
Remove the bracket (27) assembly From brackets
(52) (2 used).
：17 mm

23. Remove bolts (53) (4 used) from brackets (52) (2

used). Remove brackets (52) (2 used) from
bracket (27) and cab (9).
：17 mm

52, 53
W18J-02-01-001

24. Remove bolts (56) (2 used) from duct (54) and 54 55 56 57 56 58 59 9

bracket (57). Remove bracket (57) from bracket
(55) and duct (54). 60
：13 mm

25. Remove bolts (61) (2 used) and spacers (62) (2

used) from bracket (60).
：13 mm

26. Remove bolts (59) (2 used) from bracket (60).

Remove bracket (60) from cab (9) and duct (58).
：17 mm W18J-02-01-021
63 61, 62
27. Remove ducts (54, 58) from duct (63) and cab (9).

W2-1-5
 UPPERSTRUCTURE / Cab
64, 65 9
CAUTION: The cab (9) assembly weight: 650
kg (1440 lb)

28. Remove nuts (64) (6 used) and washers (65) (6

used) from cab (9).
：24 mm
66
29. Remove bolts (67) (6 used) from cab (9).
：17 mm

W18J-02-01-004

66 67 9

64, 65

W18J-02-01-008

Lifting Bracket Lifting Bracket

CAUTION: The cab (9) assembly weight: 650 9
kg (1440 lb)

30. Attach a nylon sling onto the lifting bracket of cab

(9). Hoist and remove the cab (9) assembly from
floor plate (66).

W18J-02-01-009

W2-1-6
 UPPERSTRUCTURE / Cab
Installation

CAUTION: The cab (9) assembly weight: 650

kg (1440 lb)
Lifting Bracket 9 Lifting Bracket

1. Attach a nylon sling onto the lifting braket of cab

(9) assembly. Hoist and fit the cab (9) assembly to
the mounting hole on floor plate (66).

W18J-02-01-009

2. Install cab (9) to floor plate (66) with washers (65) 66 67 9

(6 used) and nuts (64) (6 used).
：24 mm
：210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

3. Install cab (9) to floor plate (66) with bolts (67) (6

used).
：17 mm
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
64, 65

W18J-02-01-008

64, 65 9

66

W18J-02-01-004

54 55 56 57 56 58 9
4. Install ducts (54, 58) to duct (63) and cab (9).

5. Install duct (54) to bracket (55) with bracket (57)

and bolts (56) (2 used).
：13 mm
：20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W18J-02-01-021
63

W2-1-7
 UPPERSTRUCTURE / Cab
6. Install bracket (60) to cab (9) with bolts (59) (2 58 59 9
used).
：17 mm 60
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

7. Install duct (58) to bracket (60) with bolts (61) (2

used) and spacers (62) (2 used).
：13 mm
：20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W18J-02-01-021
61, 62

8. Install brackets (52) (2 used) to cab (9) with bolts 51 27 9 51 52, 53

(53) (4 used).
：17 mm
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

9. Fit the mounting hole of the bracket (27) assembly

to brackets (52) (2 used).
Install the bracket (27) assembly to brackets (52)
(2 used) with bolts (51) (4 used).
：17 mm
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

52, 53
W18J-02-01-001

47 48
10. Install duct (47) to the duct (63) assembly.

11. Install bracket (49) to bracket (27) with bolts (50)

(2 used).
：10 mm
：3.3 to 4.2 N⋅m (0.3 to 0.4 kgf⋅m, 2.4 to 3.1 49
lbf⋅ft)

12. Install duct (47) to bracket (49) with bolt (48).

：13 mm W18J-02-01-021

：20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 50 63

W2-1-8
 UPPERSTRUCTURE / Cab
13. Connect connectors (41) (5 used). 41 9

42
14. Connect harness (45) to buzzer (46).

43
15. Install clips (43) (2 used) to harness (44). Install
clips (43) (2 used) to cab (9) with bolts (42) (2
used). 42
：17 mm
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 44

45

46 W18J-02-01-002

16. Connect ground wire (39) to cab (9) with bolt (40).
：17 mm 9
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

39

40

W18J-02-01-007

26 27
17. Install bracket (28) to bracket (29) with bolts (30)
(2 used). 28
：17 mm
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

29
18. Install bracket (29) to bracket (27) with bolt (26).
：13 mm
：20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) W18J-02-01-019
30

19. Install cover (38) to cab (9) with screws (37) (6

used). 9 37

W18J-02-01-005
38

W2-1-9
 UPPERSTRUCTURE / Cab
20. Install cover (34) to cab (9) with screws (36) (3
9
used). Install cap (35) (3 used) to cover (34).

34

35, 36

36

W18J-02-01-004

21. Connect connector (32). 31, 32

22. Install cover (33) to cab (9) with bolts (31) (4

used).
：13 mm
：20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
33

W18J-02-01-003

23. Fit cover (23) to the mounting hole on cab (9). 21, 22
Connect the connector of cigar lighter (24).
9
24. Install cover (23) to cab (9) with screws (22) (6
used). Install caps (21) (5 used) to cover (23).
23
25. Install cover (23) to bracket (27) with bolts (25) (2
used).
：13 mm
：20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
24
26. Install cover (20) to cab (9) with screws (19) (9
used).
W18J-02-01-022
22 27 25
9 19 20

W18J-02-01-006

W2-1-10
 UPPERSTRUCTURE / Cab

CAUTION: Seat (14) weight: 40 kg (88 lb) 14 17

15
27. Install seat (14) to bracket (18) with socket bolts
(17) (4 used).
：6 mm
：20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
18

W1JB-02-07-007

28. Install seat belts (15) (2 used) to bracket (18) with

bolts (16) (2 used).
：16 mm
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

15

16
W1JB-02-01-008

29. Connect vinyl hose (5) to washer tank (6).

W18J-02-01-004

30. Connect connectors (8) (7 used) to harness (7).

7, 8

W18J-02-01-001

W2-1-11
 UPPERSTRUCTURE / Cab
31. Install covers (1) (2 used) to main frame (4) with 1 2, 3 4 1
bolts (2) (13 used) and washers (3) (13 used).
：19 mm
：90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-07-003

32. Open cover (12). Install air filter (13) to the inside.
Shut cover (12). 9, 10

33. Install mat (10) to the inside of cab (9). Shut door
(11).

11

12, 13

W18J-02-01-020

W2-1-12
 UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
Unit: mm
NOTE: Material: JIS R3211, R3212 or equivalent
NOTE: 1 mm = 0.03937 in

51 398 ± 1.0 51 346 ±1.0

Chamfer here.

Chamfer here. Chamfer here. Chamfer here.

2-R79 2-R5 2-R5 2-R79

Light-Chamfering Light-Chamfering
along Periphery 2-φ12.2 ± 1.0 2-φ12.2 ±1.0 along Periphery
756 ±1.0

756 ±1.0
except for except for
40 40
Chamfered Surface (4 mm) (4 mm) Chamfered Surface

+0
39.5 -1
+0
39.5
291.5

291.5
-1

1.0
398 ± 51 397 ±1.0

W18J-02-01-014

560 ± 1.0

R61 R61
659.7 ±1.0

(5 mm)
758.6 ± 1.0
822.4 ± 1.0

W18J-02-01-010

R91
50
777.9 ± 1.0
Mark Position
50

162.7

28.9 749 ± 1.0 R61

R61
R61 R61 432.3 ±1.0
191.8

(5 mm) R61 W18J-02-01-018

460 ± 1.0

Mark Position Straight Line

158.7

70 Intersection Point
R759
50

R61 (6.9) 285 420.5

55.5

W18J-02-01-016
Parallel-Straight Line to Upper
Surface

W2-1-13
 UPPERSTRUCTURE / Cab
Unit: mm
NOTE: Material: JIS R3211, R3212 or equivalent
NOTE: 1 mm = 0.03937 in

Light-
Chamfering 4-R91
along
Periphery

1530 +1.5-0.5

(8.8 mm)

W18J-02-01-010

887 +1.5-0.5

W18J-02-01-013

382 ± 1.0

4-R61
728.8 ±1.0

W18J-02-01-011
(5 mm)
618.5 ±1.0

1080 ±1.0

1025.5 ±1.0 54.5

Mark Position

R61 R61
70

50 W18J-02-01-015
1.0
758.9 ± 1.0

767.5 ±

(5 mm)
1209.2 ±1.0

Mark Position
50

R61
149.2

R129
R241

100
124.6 176.5

R209
441.7

R81

321.7 100 135 523.3 ± 1.0

W18J-02-01-017

W2-1-14
 UPPERSTRUCTURE / Cab
Unit: mm
NOTE: Material: JIS R3211, R3212 or equivalent
NOTE: 1 mm = 0.03937 in

Light-Chamfering
along Periphery

582 ±1.0
(5 mm)

4-R61

W18J-02-01-012
902 ±1.0

W18J-02-01-020

W2-1-15
 UPPERSTRUCTURE / Cab
Installation of Cab Glass
1. Install the mounting rubber to the periphery of the Section of Mounting Rubber
glass. Adhere the rubber connecting part by using
Mounting Glass
the adhere (Cemedine 366 Standard). Rubber
NOTE: When the rubber deteriorates, it may shrink.
Adhere the longer rubber by pushing.

2. After installing the glass assembly to the cab, Stopper

install a stopper to the rubber.

Cab
W216-02-01-003

W2-1-16
 UPPERSTRUCTURE / Counterweight
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT
4 5 6 4 3
Removal
1. Remove sems bolts (1) (14 used) from clips (2)
(14 used). Remove clips (2) (14 used) from
harness (7). 3
: 17 mm 1, 2
1, 2
2. Disconnect plugs (3) (3 used) and connectors (6)
(2 used) from lights (4) (2 used) and camera (5).

CAUTION: Counterweight (8) weight: 17500 W18J-02-02-003

kg (38600 lb) 7

3. Install a wire rope to a lifting hole (2 places) on the

upper side of counterweight (8). Hoist
counterweight (8).

W18J-02-02-001

CAUTION: When using a power wrench, do

not injure hands by the reaction bar. 8

4. Remove bolts (11) (8 used) and washers (10) (8

used) from main frame (9) by using a power
wrench. Remove counterweight (8) from main
frame (9).
: 65 mm 9

10

W18J-02-02-002

11

W2-2-1
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight (8) weight: 17500

kg (38600 lb)

1. Install a wire rope to a lifting hole (2 places) on the

upper side of counterweight (8). Hoist
counterweight (8).
8
2. Align counterweight (8) with the mounting hole on
mani frame (9). Place counterweight (8) on mani
frame (9).

9 W18J-02-02-001

CAUTION: When using a power wrench, do

8
not injure hands by the reaction bar.

3. Install counterweight (8) to main frame (9) with

bolts (11) (8 used) and washers (10) (8 used).
: 65 mm
: 2350 N⋅m (240 kgf⋅m, 1730 lbf⋅ft)
9
4. Remove the lifting tool from counterweight (8).

10

W18J-02-02-002

11

5. Connect plugs (3) (3 used) and connectors (6) (2 4 5 6 4 3

used) to lights (4) (2 used) and camera (5).

6. Install clips (2) (14 used) to harness (7). Install

clips (2) (14 used) to counterweight (8) with sems 3
bolts (1) (14 used).
1, 2
: 17 mm
1, 2
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W18J-02-02-003

W2-2-2
 UPPERSTRUCTURE / Pump Device
REMOVAL AND INSTALLATION OF PUMP
DEVICE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal 1 2 3
1. Remove bolts (1) (20 used). Remove covers (3, 4)
from left side frame (2).
: 19 mm 4

W18J-02-03-007

5, 6 7
2. Remove plug (9) from manifold (8). Open ball
valve (7). Drain oil from pump transmission (6). 8
Close ball valve (7). Install plug (9) to manifold (8).
: 30 mm
: 95 N⋅m (9.5 kgf⋅m, 70 lbf⋅ft) 9
NOTE: Pump transmission oil: 15L (3.96 US gal)

3. Disconnect hose (5) from pump transmission (6).

Cap the open ends.
: 36 mm
W18J-02-03-021

CAUTION: Door (11) weight: 23 kg (51 lb)

4. Open doors (11, 14). Attach a nylon sling onto

door (11). Hoist and hold door (11). Remove bolts 10 11, 12, 13 14
(12) (4 used) and shim (13) from door (11).
Remove door (11) from left cover (10).
: 13 mm

W18J-02-03-008

W2-3-1
 UPPERSTRUCTURE / Pump Device

CAUTION: Door (15) weight: 22 kg (49 lb)

15, 16 10
5. Open door (15). Attach a nylon sling onto door
(15). Hoist and hold door (15). Remove bolts (16)
(4 used) from door (15). Remove door (15) from
left cover (10).
: 13 mm

W18J-02-03-008

6. Remove bolts (18) (11 used) from cover (19). 17 18 19 20 21 10

Remove cover (19) from panel (17), stay (20), and
beam (22).
: 19 mm

7. Remove bolts (18) (11 used) from cover (21). 18

Remove cover (21) from left cover (10), panel (17),
stay (20), and beam (22).
: 19 mm

8. Remove bolts (23) (8 used), spring washers (24)

(8 used), and washers (25) (8 used) from stay (20).
Remove stay (20) from panel (17) and beam (22).
: 22 mm 23, 24, 25 22 W18J-02-03-010

9. Remove clamp bands (26) (2 used) from rubber

hoses (27) (2 used). 26
: 11 mm

W18J-02-03-016
27

W2-3-2
 UPPERSTRUCTURE / Pump Device
10. Remove bolts (29) (8 used) from pipes (33) (2 28 29 30 10
used). Disconnect the pipe (33) assemblies (2
used) from cover (30).
: 17 mm Handle
17
CAUTION: Cover (30) weight: 40 kg (88 lb)
31
11. Attach a nylon sling onto the handle (2 places) of
cover (30). Hoist and hold cover (30). Remove
bolts (31) (10 used) from cover (30). Remove
cover (30) from left cover (10), panel (17), beam
(32), and support (28).
: 19 mm 33 32
W18J-02-03-009

12. Remove bolts (35) (17 used). Remove covers (34)

34 35 34 32 35
(3 used) from panel (17), beam (32), and covers
(36) (2 used).
: 19 mm 17
36

W18J-02-03-017
35 34

13. Loosen hose clamps (37) (3 used) from rubber 37 38 39, 40 37 37 41, 42, 43
hoses (38, 41, and 45).

14. Remove bolts (43) (2 used) from clamp (42).

Remove clamp (42) from rubber hose (41) and 44
bracket (44).
: 17 mm

15. Remove bolts (40) (2 used) from pipe (39).

Disconnect the pipe (39) assembly from air
cleaners (46) (2 used) and bracket (44).
: 17 mm

46 45 W18J-02-03-014

W2-3-3
 UPPERSTRUCTURE / Pump Device
16. Remove bolts (49) (2 used) from clips (48) (2 47 47 48, 49
used). Remove clips (48) (2 used) from bracket
(44) and hose (47). 44
: 17 mm

17. Disconnect hose (47) from pump device (50). Cap

the open ends.
: 36 mm 50

18. Remove bolt (52) from clip (51). Remove clip (51)
from hose (53) and pump device (50).
: 17 mm

19. Disconnect hose (53) from pump device (50). Cap 53 51, 52 W18J-02-03-014

the open ends.

: 36 mm

20. Disconnect plugs (56) (2 used) from indicator (57). 54 55 56 57 58

21. Remove clamp band (55) from rubber hose (54).

Disconnect rubber hose (54) from air duct (58).
: 11 mm

CAUTION: Bracket (44) weight: 125 kg (280

lb)

22. Attach a nylon sling onto bracket (44). Hoist and

hold bracket (44).

23. Remove bolts (61) (3 used) from bracket (63).

Disconnect bracket (63) from bracket (62).
: 19 mm W18J-02-03-018

63 62 61 60 59 44

59 60
24. Remove bolts (60) (8 used) from brackets (59) (2
used). Remove the bracket (44) assembly from
pump device (50).
: 19 mm 50

W18J-02-03-013

W2-3-4
 UPPERSTRUCTURE / Pump Device
25. Remove bolt (65) from clamp (66). Remove clamp 64, 65, 66, 67
(66) from hose (64) and bracket (67).
: 17 mm

26. Disconnect hose (64) from manifold (68). Cap the 68

open ends.
: 36 mm

27. Remove nuts (71) (7 used) and spring washers 73

(70) (7 used) from bolts (69) (7 used). Remove 69, 70, 71
bolts (69) (7 used) and clamps (73) (14 used) from
pipes (72) (10 used). 72
: 13 mm

W18J-02-03-019

28. Remove bolts (74) (2 used) from clamps (75) (2 50 68

used). Remove clamps (75) (2 used) and rubbers
(76) (2 used) from pipes (72) (4 used).
: 17 mm

29. Disconnect pipes (72) (11 used) from manifold

(68) and pump device (50). Cap the open ends.
Attach an identification tag onto the disconnected 72
pipes for assembling.
: 17 mm
74

W18J-02-03-019
75, 76

50 68
30. Remove bolts (78) (3 used) from bracket (77).
Remove the manifold (68) assembly from pump
device (50).
: 17 mm

77, 78

W18J-02-03-019

W2-3-5
 UPPERSTRUCTURE / Pump Device
31. Remove socket bolts (82) (12 used) from split 79 80 81 82 81
flanges (80) (6 used). Remove split flanges (80) (6
used) and oil mufflers (79) (3 used) from blocks
(81) (3 used). Cap the open ends.
: 10 mm

W18J-02-03-015
83
32. Remove bolts (85) (6 used) and spring washers 84 83
(86) (6 used) from brackets (83) (2 used). Remove
the bracket (83) assemblies (2 used) from
brackets (84) (2 used).
: 24 mm
79

84

85, 86 79
W18J-02-03-012 W18J-02-03-011
85, 86

88
33. Remove socket bolts (88) (12 used) from suction
pipes (87) (3 used). Remove suction pipes (87) (3
used) from pump device (50). Cap the open ends.
: 10 mm

87
87

W18J-02-03-014

34. Remove clip bands (92) (4 used) from rubber 50 50

hoses (91) (2 used). Disconnect rubber hoses
(91) (2 used) from pump device (50). Cap the
open ends.

35. Disconnect connectors (90) (10 used) from

pressure sensors (89) (10 used). 89, 90

88 87 91, 92 W18J-02-03-015

W2-3-6
 UPPERSTRUCTURE / Pump Device
36. Remove socket bolts (94) (12 used) from split 50 93
flanges (93) (6 used). Remove split flanges (93) (6
used) and disconnect hoses (95) (3 used) from
pump device (50). Cap the open ends. 94
: 12 mm 95

37. Disconnect hoses (96) (10 used) from pump

device (50). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm, 22 mm, 27 mm, 41 mm

W18J-02-03-015
94 95 96

38. Install the shackles (4 used) to brackets (97) (2 97

used). Attach wire ropes onto the shackles (4
used). Hoist and hold brackets (97) (2 used).

50

W18J-02-03-020

CAUTION: Pump device (50) weight: 1100 kg

(2430 lb)
98 99 84 50
39. Remove bolts (100) (14 used) and spring washers
(101) (14 used) from brackets (99) (2 used).
Remove brackets (99) (2 used) from engine (98)
and brackets (84) (2 used).
: 24 mm, 27 mm

W18J-02-03-013
100, 101

W2-3-7
 UPPERSTRUCTURE / Pump Device

CAUTION: Pump device (50) weight: 1100 kg

(2430 lb)
50 84
40. Remove U-nuts (105) (2 used) and washers (104)
(2 used) from bolts (103) (2 used). Remove bolts
(103) (2 used) and washers (102) (2 used) from
brackets (84) (2 used).
: 50 mm

W18J-02-03-013
103, 104, 105 102

41. Slightly hoist pump device (50). Place a wooden

block between engine (98) and main frame (106).
Lower engine (98).

98

106

Wooden Block W1JB-02-04-007

CAUTION: Bracket (84) weight: 22 kg (49 lb)

50 84
42. Remove bolts (107) (6 used) and washers (108)
(6 used) from bracket (84). Remove bracket (84),
plates (109) (4 used), and cushions (110) (2 used)
from pump device (50) and main frame (106).
(Remove bracket (84) on only the cab side.)
: 41 mm

109, 110 107, 108 W18J-02-03-013

W2-3-8
 UPPERSTRUCTURE / Pump Device

CAUTION: Pump device (50) weight: 1100 kg

(2430 lb)
98 111, 112 50
43. Remove bolts (111) (16 used) and spring washers
(112) (16 used) from pump device (50). Remove
pump device (50) from engine (98).
: 19 mm

W18J-02-03-013

CAUTION: Main pump (113) weight: 160 kg

(360 lb) 113 Eyebolt 6

44. Attach the nylon slings onto the eyebolts (6 used).

Hoist and hold main pumps (113) (3 used).

45. Remove socket bolts (114) (12 used) and spring

washers (115) (12 used) from main pumps (113) 114, 115
(3 used). Remove main pumps (113) (3 used)
from pump device (50).
: 17 mm

CAUTION: The fan pump (118) assembly 116, 117

weight: 65 kg (150 lb)
118 W18J-02-03-020
46. Attach a nylon sling onto fan pump (118). Hoist
and hold fan pump (118).

47. Remove socket bolts (116) (4 used) and spring

washers (117) (4 used) from fan pump (118).
Remove fan pump (118) from pump device (50).
: 14 mm

W2-3-9
 UPPERSTRUCTURE / Pump Device
Installation

CAUTION: The fan pump (118) assembly

weight: 65 kg (150 lb)
CAUTION: Pump transmission (6) weight:
530 kg (1170 lb)
6
1. Attach a nylon sling onto fan pump (118). Hoist fan
pump (118). Fit fan pump (118) to the mounting
hole on pump transmission (6). Install fan pump
(118) to pump transmission (6) with spring
washers (117) (4 used) and socket bolts (116) (4
used).
: 14 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

116, 117

118 W18J-02-03-020

CAUTION: Main pump (113) weight: 160 kg

(360 lb)
113 Eyebolt 6
2. Attach a nylon sling onto the eyebolts (6 used) of
main pumps (113) (3 used). Hoist main pumps
(113) (3 used). Fit main pumps (113) (3 used) to
the mounting hole on pump transmission (6).
Install main pumps (113) (3 used) to pump
transmission (6) with spring washers (115) (12 114, 115
used) and socket bolts (114) (12 used).
: 17 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

W18J-02-03-020

84
3. Place plates (109) (4 used) and cushions (110) (2
used) onto the mounting parts of main frame (106)
and brackets (84) (2 used).

106 109, 110 W18J-02-03-013

W2-3-10
 UPPERSTRUCTURE / Pump Device

CAUTION: Pump device (50) weight: 1100 kg

(2430 lb)
98 111, 112 50
4. Attach a wire rope onto pump device (50). Hoist
pump device (50). Fit pump device (50) to the
mounting hole on engine (98).

5. Install pump device (50) to engine (98) with spring

washers (112) (16 used) and bolts (111) (16 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-03-013

6. Hoist pump device (50). Remove a wooden block

between engine (98) and main frame (106). Lower
engine (98).

98

106

W1JB-02-04-007
Wooden Block

CAUTION: Bracket (84) weight: 22 kg (49 lb)

50 84
7. Install bracket (84) to pump device (50) with
washers (108) (6 used) and bolts (107) (6 used).
: 41 mm
: 1050 N⋅m (105 kgf⋅m, 760 lbf⋅ft)

8. Install brackets (84) (2 used) to main frame (106)

with bolts (103) (2 used), washers (102) (2
used), washers (104) (2 used), and U-nuts (105)
(2 used).
: 50 mm
: 1950 N⋅m (195 kgf⋅m, 1410 lbf⋅ft)
106 W18J-02-03-013

103, 104, 105 102 107, 108

W2-3-11
 UPPERSTRUCTURE / Pump Device
9. Install brackets (99) (2 used) to engine (98) and 98 99 84 50
brackets (84) (2 used) with bolts (100) (14 used)
and washers (101) (14 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 27 mm
: 300 N⋅m (30 kgf⋅m, 215 lbf⋅ft)

W18J-02-03-013
100, 101

10. Connect hoses (95) (3 used) to pump device (50) 50 93

with split flanges (93) (6 used) and socket bolts
(94) (12 used).
: 12 mm 94
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 95

11. Connect hoses (96) (10 used) to pump device

(50).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 94 95 96 W18J-02-03-015

: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

12. Connect connectors (90) (10 used) to pressure

sensors (89) (10 used).

50
13. Connect rubber hoses (91) (2 used) to pump
device (50) with clip bands (92) (4 used).

14. Connect suction pipe (87) to pump device (50)

with socket bolts (88) (4 used).
: 10 mm 89, 90
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

88 87 91, 92 W18J-02-03-015

W2-3-12
 UPPERSTRUCTURE / Pump Device
15. Connect suction pipes (87) (2 used) to pump 88
device (50) with socket bolts (88) (8 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

50

87
87

83 W18J-02-03-014
16. Install the bracket (83) assemblies (2 used) to 84 83
bracket (84) with spring washers (86) (6 used) and
bolts (85) (6 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
79

84

85, 86 79
W18J-02-03-012 W18J-02-03-011
85, 86

17. Connect hoses (79) (3 used) to blocks (81) (3 79 80 81 82 81

used) with split flanges (80) (6 used) and socket
bolts (82) (12 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-03-015

18. Install the bracket (77) assembly to pump device

(50) with bolts (78) (3 used).
: 17 mm 50
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
77, 78

W18J-02-03-019

W2-3-13
 UPPERSTRUCTURE / Pump Device
19. Connect pipes (72) (11 used) to manifold (68) and 50 68
pump device (50).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

20. Secure pipes (72) (4 used) with clamps (75) (2

used), rubbers (76) (2 used), and bolts (74) (2
used). 72
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
74

W18J-02-03-019
75, 76

21. Secure pipes (72) (10 used) with clamps (73) (14 64, 65, 66, 67
used), bolts (69) (7 used), spring washes (70) (7
used), and nuts (71) (7 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
68
22. Connect hose (64) to manifold (68).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
73
69, 70, 71
23. Connect hose (64) to bracket (67) with clamp (66)
and bolt (65). 72
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W18J-02-03-019

W2-3-14
 UPPERSTRUCTURE / Pump Device

CAUTION: Bracket (44) weight: 125 kg (280

lb)
54 55 56 57 58
24. Attach a nylon sling onto the bracket (44)
assembly. Hoist the bracket (44) assembly. Fit the
bracket (44) assembly to the mounting hole on
pump device (50) and bracket (62).

25. Install brackets (59, 63) to pump device (50) and

bracket (62) with bolts (60) (8 used) and bolts (61)
(3 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-03-018

63 62 61 60 59 44

59 60
26. Connect rubber hose (54) to air duct (58) with
clamp band (55).
: 11 mm
: 3.3 to 4.2 N⋅m 50
(0.3 to 0.4 kgf⋅m, 2.4 to 3 lbf⋅ft)

27. Connect plugs (56) (2 used) to indicator (57).

W18J-02-03-013

34 35 34 32 35

28. Install covers (34) (3 used) to panel (17), beam 17

(32), and covers (36) (2 used) with bolts (35) (17 36
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-03-017
35 34

W2-3-15
 UPPERSTRUCTURE / Pump Device
29. Connect hoses (47, 53) to pump device (50). 47 47 48, 49
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) 44

30. Install clip (51) to hose (53). Install clip (51) to

pump device (50) with bolt (52).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 50

31. Install clips (48) (2 used) to hose (47). Install clips

(48) (2 used) to bracket (44) with bolts (49) (2
used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 53 51, 52 W18J-02-03-014

32. Connect rubber hoses (38, 41, and 45) to air 37 38 39, 40 37 37 41, 42, 43
cleaners (46) (2 used) and pipe (39). Secure
rubber hoses (38, 41, and 45) to air cleaners (46)
(2 used) and pipe (39) with hose clamps (37) (3
used). 44

33. Connect pipe (39) to bracket (44) with bolts (40) (2

used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

34. Install clamp (42) to rubber hose (41). Install

clamp (42) to bracket (44) with bolts (43) (2 used).
: 17 mm 46 45 W18J-02-03-014

: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W2-3-16
 UPPERSTRUCTURE / Pump Device

CAUTION: Cover (30) weight: 40 kg (88 lb)

28 30 10
35. Attach a nylon sling onto the handle of cover (30).
Hoist cover (30). Fit cover (30) to the mounting
holes on left cover (10), panel (17), beam (32), Handle
and support (28). 17

36. Install cover (30) to left cover (10), panel (17), 31

beam (32), and support (28) with bolts (31) (10
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

37. Connect pipes (33) (2 used) to rubber hoses (27) 32

W18J-02-03-009

(2 used) and cover (30). Secure rubber hoses (27)

(2 used) to pipes (33) (2 used) with clamp band 26
(26).
: 11 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.4 to 3 lbf⋅ft)

W18J-02-03-016
27

29 30

38. Connect pipes (33) (2 used) to cover (30) with

bolts (29) (8 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W18J-02-03-009
33 32

17 20
39. Install stay (20) to panel (17) and beam (22) with
washers (25) (8 used), spring washers (24) (8
used), and bolts (23) (8 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

23, 24, 25 22 W18J-02-03-010

W2-3-17
 UPPERSTRUCTURE / Pump Device
40. Install covers (19, 21) to panel (17), stay (20), left 17 18 19 20 21 10
cover (10), and beam (22) with bolts (18) (22
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
18

22 W18J-02-03-010
CAUTION: Door (15) weight: 22 kg (49 lb)
15, 16 10
41. Attach a nylon sling onto door (15). Hoist door
(15). Fit door (15) to the mounting hole on left
cover (10). Install door (15) to left cover (10) with
bolts (16) (4 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W18J-02-03-008

5, 6
42. Install hose (5) to case (6).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

W18J-02-03-021

50
43. Remove plug (119) from pipe (120). Add gear oil
to pump device (50). Install plug (119) to pipe
(120).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
Gear oil: 15 L (3.96 US gal) 119

120

W18J-02-03-020

W2-3-18
 UPPERSTRUCTURE / Pump Device
44. Install covers (3, 4) to left side frame (2) with bolts 1 2 3
(1) (20 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 4

CAUTION: Door (11) weight: 23 kg (51 lb) W18J-02-03-007

45. Attach a nylon sling onto door (11). Hoist door (11).
Fit door (11) to the mounting holes on left cover
(10). Install door (11) to left cover (10) with shim 10 11, 12, 13 14
(13) and bolts (12) (4 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

46. Shut doors (11, 14).

W18J-02-03-008

W2-3-19
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF PUMP TRANSMISSION

1
3
4
5
6
7
8
2 9
10
9

13 23
24
14 22
12 15 18
19 21
16
20
17 25 26
11 27
28
29
30
31
32
33
35 34
36
37
38
39
38
44 40
45 46 47 41
26 42
27 43
28
29
30 33
31
32
34
26
27
28
29
30 33
31
32
34
W18J-02-03-001

1- Oil Seal 13 - Air Breather 25 - Plug 37 - Spacer

2- Bolt (10 Used) 14 - Reducer 26 - Nozzle (3 Used) 38 - Ball Bearing (2 Used)
3- Cartridge 15 - Reducer 27 - Retaining Ring (3 Used) 39 - Gear
4- Roller Bearing 16 - Pipe 28 - Spacer (3 Used) 40 - O-Ring
5- Gear 17 - Elbow 29 - Ball Bearing (3 Used) 41 - Cartridge
6- Stopper 18 - Bracket (2 Used) 30 - Gear (3 Used) 42 - Spring Washer (4 Used)
7- Retaining Ring 19 - Bolt (8 Used) 31 - Ball Bearing (3 Used) 43 - Bolt (4 Used)
8- Roller Bearing 20 - O-Ring 32 - O-Ring (3 Used) 44 - O-Ring
9- Spacer (2 Used) 21 - Socket Bolt (4 Used) 33 - Cartridge (3 Used) 45 - Cover
10 - Disc Spring 22 - Pipe 34 - Socket Bolt (12 Used) 46 - Spring Washer (3 Used)
11 - Casing 23 - Plug 35 - Nozzle 47 - Bolt (3 Used)
12 - Pipe 24 - Level Gauge 36 - Retaining Ring

W2-3-20
 UPPERSTRUCTURE / Pump Device
Disassembly of Pump Transmission

CAUTION: The pump transmission assembly CAUTION: The cartridge (33) assembly
weight: 530 kg (1170 lb) weight: 55 kg (130 lb)

1. Place the pump transmission on a wooden block 8. Remove cartridges (33) (6 used) from casing (11)
with the pump side up. by using a plastic hammer.

2. Remove level gauge (24) from pipe (22).

3. Remove socket bolts (21) (4 used) from pipe (22).
Disconnect pipe (22) from casing (11). Remove
O-ring (20).
: 10 mm
4. Disconnect pipe (12) from casing (11).
: 24 mm
10. Remove O-rings (32) (3 used) from cartridges
5. Remove air breather (13), reducers (14, 15), pipe
(16), and elbow (17) from casing (11).
: 23 mm, 46 mm
CAUTION: Cartridge (33) weight: 25 kg (55
lb)
Cover (30) weight: 21 kg (46 lb)
9. Remove ball bearings (29) (3 used), gears (30) (3
used), and ball bearings (31) (3 used) from
cartridges (33) (3 used).
(33) (3 used).
CAUTION: Gear (30) weight: 21 kg (46 lb)

CAUTION: The cartridge (33) assembly 11. Remove retaining rings (27) (3 used) and spacers
(28) (3 used) from gears (30) (3 used).
weight: 55 kg (130 lb)
12. Remove nozzles (26) (3 used) from casing (11).
6. Remove socket bolts (34) (12 used) from
: 14 mm
cartridge (33).
: 17 mm

7. Install eyebolts (M20, Pitch 2.5 mm) (6 used) to

cartridges (33) (3 used). Attach nylon slings onto
the eyebolts (6 used). Hoist and hold cartridges
(33) (3 used).

W2-3-21
 UPPERSTRUCTURE / Pump Device

1
3
4
5
6
7
8
2 9
10
9

11

35
36
37
38
39
38
44 40
45 46 47 41
42
43

W18J-02-03-001

W2-3-22
 UPPERSTRUCTURE / Pump Device
CAUTION: The cartridge (41) assembly
weight: 35 kg (77 lb)
13. Remove bolts (43) (4 used) and spring washers
(42) (3 used) from cartridge (41).
: 24 mm
14. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
cartridge (41). Attach a nylon sling onto the
eyebolts (2 used). Hoist and hold cartridge (41).
15. Remove cartridge (41) from casing (11) by using a
plastic hammer.
16. Remove ball bearing (38), gear (39), and ball
bearing (38) from cartridge (41).
17. Remove O-ring (40) from cartridge (41).
18. Remove retaining ring (36) and spacer (37) from
gear (39).
19. Remove nozzle (35) from casing (11).
: 14 mm
20. Remove bolts (47) (3 used) and spring washers
(46) (3 used) from cover (45). Remove cover (45)
and O-ring (44) from casing (11).
: 22 mm
W2-3-23
CAUTION: Pump transmission weight: 325
kg (720 lb)
21. Place casing (11) with the engine mounting side
up.
22. Remove bolts (2) (10 used) from cartridge (3).
Install bolts (M12, Pitch 1.75 mm) (2 used) to the
pulling-out hole on cartridge (3). Install the bolts (2
used). Remove cartridge (3) from casing (11).
: 19 mm
23. Remove the bolts (2 used), oil seal (1), and the
outer race of roller bearing (4) from cartridge (3).
: 19 mm
CAUTION: The gear (5) assembly weight: 40
kg (88 lb)
24. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
gear (5). Attach a nylon sling onto the eyebolts (2
used). Hoist and remove the gear (5) assembly
from casing (11).
25. Remove the inner races of roller bearings (4, 8)
from gear (5) by using a gear puller.
26. Remove retaining ring (7) and stopper (6) from
gear (5).
27. Remove the outer race of roller bearing (8),
spacer (9), disc spring (10), and spacer (9) from
casing (11).
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF PUMP TRANSMISSION
13 19 18
11 44, 45 12
14
A 16
15

17

33

23
34
42, 43
33

34

24
41

33

11
B

46, 47 42, 43 41 25 22, 20 21 W18J-02-03-002

33 31 30 29
27, 28
34

32 26

9, 10 1

6 4
38
39

7 3
35
38
8
5
36, 37

31

11 41 40 11 W18J-02-03-003
Section B

32 Section A 30 29 W18J-02-03-004

W2-3-24
 UPPERSTRUCTURE / Pump Device

1- Oil Seal 13 - Air Breather 25 - Plug 37 - Spacer

2- Bolt (10 Used) 14 - Reducer 26 - Nozzle (3 Used) 38 - Ball Bearing (2 Used)
3- Cartridge 15 - Reducer 27 - Retaining Ring (3 Used) 39 - Gear
4- Roller Bearing 16 - Pipe 28 - Spacer (3 Used) 40 - O-Ring
5- Gear 17 - Elbow 29 - Ball Bearing (3 Used) 41 - Cartridge
6- Stopper 18 - Bracket (2 Used) 30 - Gear (3 Used) 42 - Spring Washer (4 Used)
7- Retaining Ring 19 - Bolt (8 Used) 31 - Ball Bearing (3 Used) 43 - Bolt (4 Used)
8- Roller Bearing 20 - O-Ring 32 - O-Ring (3 Used) 44 - O-Ring
9- Spacer (2 Used) 21 - Socket Bolt (4 Used) 33 - Cartridge (3 Used) 45 - Cover
10 - Disc Spring 22 - Pipe 34 - Socket Bolt (12 Used) 46 - Spring Washer (3 Used)
11 - Casing 23 - Plug 35 - Nozzle 47 - Bolt (3 Used)
12 - Pipe 24 - Level Gauge 36 - Retaining Ring

W2-3-25
 UPPERSTRUCTURE / Pump Device

13
19 18
11 44, 45 12 14

15 A 16

17

33

23

34
42, 43
33

34

24
41

33

11
B

46, 47 42, 43 41 25 22, 20 21 W18J-02-03-002

33 31 30 29
27, 28
34

32 26

9, 10 1

6 4
38
39

7 3
35
38
8
5
36, 37

31

11 41 40 11 W18J-02-03-003
Section B

32 Section A 30 29 W18J-02-03-004

W2-3-26
 UPPERSTRUCTURE / Pump Device
Assembly of Pump Transmission
CAUTION: Casing (11) weight: 260 kg (580
lb)
1. Place casing (11) on a wooden block with the
engine mounting side up.
2. Install spacer (9), disc spring (10), spacer (9), and
the outer race of roller bearing (8) to casing (11).
CAUTION: Gear (5) weight: 34 kg (75 lb)
3. Install the inner races of roller bearings (4, 8) to
gear (5) by using a press.
4. Install stopper (6) and retaining ring (7) to gear
(5).
CAUTION: The gear (5) assembly weight: 40
kg (88 lb)
5. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
gear (5). Attach a nylon sling onto eyebolts (2
used). Hoist and fit gear (5) to the mounting hole
of casing (11).
6. Install the outer race of roller bearing (4) and oil
seal (1) to cartridge (3).
7. Install the cartridge (3) assembly to casing (11)
with bolts (2) (10 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
W2-3-27
CAUTION: Casing (11) weight: 325 kg (720
lb)
8. Place casing (11) on a wooden block with the
engine mounting side down.
9. Install O-ring (44) to cover (45).
10. Install cover (45) to casing (11) with spring
washers (46) (3 used) and bolts (47) (3 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
11. Install nozzle (35) to casing (11).
: 14 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
12. Install ball bearings (38) (2 used) to gear (39) by
using a press.
13. Install spacer (37) and retaining ring (36) to gear
(39).
14. Install the gear (39) assembly to casing (11).
15. Install O-ring (40) to cartridge (41).
16. Install cartridge (41) to casing (11) with spring
washers (42) (4 used) and bolts (43) (4 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
 UPPERSTRUCTURE / Pump Device

13

11 12 14

15 A 16

17

33

34

33

34

24

33

11
B

25 22, 20 21 W18J-02-03-002

33 31 30 29
27, 28
34

32 26

31

11 W18J-02-03-003
Section B

32 Section A 30 29 W18J-02-03-004

W2-3-28
 UPPERSTRUCTURE / Pump Device
CAUTION: Casing (11) weight: 360 kg (800
lb)
17. Install nozzles (26) (3 used) to casing (11).
: 14 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
CAUTION: Gear (30) weight: 21 kg (46 lb)
18. Install ball bearings (29, 31) (3 used for each) to
gears (30) (3 used).
19. Install spacers (28) (3 used) and retaining rings
(27) (3 used) to gears (30) (3 used).
CAUTION: The gear (30) assembly weight: 30
kg (66 lb)
20. Install eyebolts (M18, Pitch 1.25 mm) (6 used) to
gears (30) (3 used). Attach nylon slings onto
eyebolts (6 used). Hoist and fit gears (30) (3
used) to the mounting hole of casing (11).
24. Install cartridges (33) (3 used) to casing (11) by
using a plastic hammer. Install cartridges (33) (3
used) to casing (11) with socket bolts (34) (12
used).
: 17 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
25. Install O-ring (20) to casing (11). Connect pipe
(22) to casing (11) with socket bolts (21) (4 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
26. Install level gauge (24) to pipe (22).
27. Connect pipe (12) to casing (11).
: 24 mm
: 80 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
28. Install elbow (17), pipe (16), reducers (14, 15),
and air breather (13) to casing (11).
: 23 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft)
: 46 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft)

21. Install gears (30) (3 used) to casing (11) by using

a plastic hammer.

CAUTION: Cartridge (33) weight: 25 kg (55

lb)

22. Install O-rings (32) (3 used) to cartridges (33) (3

used).

23. Install eyebolts (M20, Pitch 2.5 mm) (6 used) to

cartridges (33) (3 used). Attach a nylon sling onto
the eyebolts (6 used). Fit cartridges (33) (3 used)
to the mounting hole of casing (11).

W2-3-29
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF MAIN PUMP
16

17

15

21
20
19
14 18
13
12
10
9 11 22
23

24
8
7 25
6
26 47
46
27 45
5 44
28
4 42 43
3 41
2
29
1
40
39
38 48
37 49
36
35
34 40
39
33
30 11 52 51 50
32
27 53

31
W1JB-02-04-017

1 - Socket Bolt (4 Used) 15 - Tilt Pin 28 - Support 41 - Adjusting Screw

2 - Cover 16 - Regulator 29 - Socket Bolt (4 Used) 42 - Nut
3 - O-Ring 17 - Socket Bolt (6 Used) 30 - Swash Plate 43 - Booster
4 - Oil Seal 18 - Servo Piston 31 - Shoe Plate 44 - O-Ring
5 - Drive Shaft 19 - O-Ring 32 - Plunger (9 Used) 45 - O-Ring
6 - Roller Bearing 20 - Backup Ring 33 - Retainer 46 - Cover
7 - Spacer 21 - Stopper 34 - Spherical Bushing 47 - Socket Bolt (6 Used)
8 - Retaining Ring 22 - O-Ring (2 Used) 35 - Spring (9 Used) 48 - Cover
9 - Nut 23 - Plug (2 Used) 36 - Cylinder Block 49 - Socket Bolt (3 Used)
10 - Adjusting Screw 24 - Plug (2 Used) 37 - Valve Plate 50 - Plug (2 Used)
11 - Spring Pin (2 Used) 25 - Orifice (2 Used) 38 - Needle Bearing 51 - O-Ring (2 Used)
12 - Stopper 26 - Pump Casing 39 - O-Ring (10 Used) 52 - Cover
13 - Backup Ring 27 - O-Ring (2 Used) 40 - O-Ring (3 Used) 53 - Pin
14 - O-Ring

W2-3-30
 UPPERSTRUCTURE / Pump Device
Disassembly of Main Pump
IMPORTANT: Do not remove adjusting screws (10,
41) and nuts (9, 42) with support (28)
and cover (52) attached. If removing
adjusting screws (10, 41) and nuts (9,
42), the set flow rate changes.
1. Remove plugs (23) (2 used) and O-rings (22) (2
used) from pump casing (26). Drain hydraulic oil
from the pump.
: 36 mm
2. Remove socket bolts (17) (6 used) from regulator
(16). Remove regulator (16) from pump casing
(26).
: 6 mm
3. Remove socket bolts (47) (6 used) from cover
(46). Remove cover (46), booster (43), and
O-rings (44, 45) from pump casing (26).
: 8 mm
4. Place pump casing (26) with the regulator (16)
mounting surface down.
IMPORTANT: When removing cover (52), valve
plate (37) may be removed with
cover (52) together.
Do not remove needle bearing (38)
unless necessary. When needle
bearing (38) has been removed,
replace with a new one.
5. Remove socket bolts (29) (4 used) from support
(28). Remove cover (52), O-ring (27), O-rings (39)
(8 used), O-ring (40), spring pin (11), valve plate
(37), and pin (53) from pump casing (26).
: 17 mm
W2-3-31
6. Remove cylinder block (36) from pump casing
(26). At this time, plungers (32) (9 used), spherical
bushing (34), and retainer (33) are removed with
cylinder block (36) together.
NOTE: Slowly remove cylinder block (36) while
lightly turning cylinder block (36) to the left
and the right by hands.
7. Remove retainer (33) from the cylinder block (36)
assembly. At this time, plungers (32) (9 used) are
removed with retainer (33) together.
8. Remove plungers (32) (9 used) from retainer (33).
9. Remove spherical bushing (34) from cylinder
block (36). Remove springs (35) (9 used) from
cylinder block (36).
IMPORTANT: Do not remove oil seal (4) unless
necessary. When oil seal (4) has
been removed, replace with a new
one.
Cover (2) is equipped with oil seal (4).
Do not damage the lip part of oil seal
(4) when removing cover (2).
10. Remove socket bolts (1) (4 used) from cover (2).
Remove cover (2) and O-ring (3) from support
(28).
: 6 mm
NOTE: For easy removal, install the bolt to the
pulling-out hole (M8) on cover (2).
 UPPERSTRUCTURE / Pump Device

15

21
20
19
14 18
13
12

11

24
8
7 25
6
26

27
5
28

40
39
38 48
49

40
39
30 52

31
W1JB-02-04-017

W2-3-32
 UPPERSTRUCTURE / Pump Device
11. Tap and remove support (28) from pump casing
(26) by using a plastic hammer. At this time,
remove O-rings (27, 39, and 40) and spring pin
(11).
12. Remove swash plate (30) and shoe plate (31)
from pump casing (26).
13. Tap and remove drive shaft (5) from support (28)
by using a plastic hammer.
14. Remove plugs (24) (2 used) and orifices (25) (2
used) from pump casing (26).
: 2.5 mm, 5 mm
IMPORTANT: Do not remove needle bearing (38)
unless necessary.
18. Remove needle bearing (38) from cover (52).
19. Remove socket bolts (49) (3 used) from cover
(48). Remove cover (48) and O-rings (39, 40)
from cover (52).
: 5 mm
20. Remove retaining ring (8) from drive shaft (5).
Remove spacer (7) and roller bearing (6) from
drive shaft (5).

15. Install the bolt (M5, Pitch 0.8 mm) to stoppers (12,
21). Remove stoppers (12, 21) from pump casing
(26).

16. Remove backup rings (13, 20) and O-rings (14,

19) from stoppers (12, 21).

IMPORTANT: LOCTITE has been applied onto the

joint part between servo piston (18)
and tilt pin (15). Do not disassemble
them unless necessary.
17. Warm up tilt pin (15) by using a drier. Secure
servo piston (18) in order not to damage by using
a pair of pliers. Turn and remove tilt pin (15) from
servo piston (18). Remove servo piston (18) from
pump casing (26).

W2-3-33
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF MAIN PUMP A

22, 23 19, 20
11 13, 14 26 12 7 8 30 15 18 21 39 27 38 42 41 46

10

28 47

27
1
3
50, 51
2
4

45

43
6
5 37

44
29
52

W1JB-02-04-030

31 33 32 34 35 36 11 39 53
B

40

26

48 W1JB-02-04-032
24 25 24
W1JB-02-04-031
49 39 40 Section B

View A

W2-3-34
 UPPERSTRUCTURE / Pump Device

1- Socket Bolt (4 Used) 15 - Tilt Pin 28 - Support 41 - Adjusting Screw

2- Cover 16 - *Regulator 29 - Socket Bolt (4 Used) 42 - Nut
3- O-Ring 17 - *Socket Bolt (6 Used) 30 - Swash Plate 43 - Booster
4- Oil Seal 18 - Servo Piston 31 - Shoe Plate 44 - O-Ring
5- Drive Shaft 19 - O-Ring 32 - Plunger (9 Used) 45 - O-Ring
6- Roller Bearing 20 - Backup Ring 33 - Retainer 46 - Cover
7- Spacer 21 - Stopper 34 - Spherical Bushing 47 - Socket Bolt (6 Used)
8- Retaining Ring 22 - O-Ring (2 Used) 35 - Spring (9 Used) 48 - Cover
9- Nut 23 - Plug (2 Used) 36 - Cylinder Block 49 - Socket Bolt (3 Used)
10 - Adjusting Screw 24 - Plug (2 Used) 37 - Valve Plate 50 - Plug (2 Used)
11 - Spring Pin (2 Used) 25 - Orifice (2 Used) 38 - Needle Bearing 51 - O-Ring (2 Used)
12 - Stopper 26 - Pump Casing 39 - O-Ring (10 Used) 52 - Cover
13 - Backup Ring 27 - O-Ring (2 Used) 40 - O-Ring (3 Used) 53 - Pin
14 - O-Ring

NOTE: As for the parts with mark *, refer to W2-3-30.

W2-3-35
 UPPERSTRUCTURE / Pump Device

22, 23 19, 20
11 13, 14 26 12 7 8 30 15 18 21 39 27 38 42 41 46

10

28 47

27
1
3
50, 51
2
4

45

43
6
5 37

44
29
52

W1JB-02-04-030

31 33 32 34 35 36 11 39 53
B

40

26

48 W1JB-02-04-032
24 25 24
W1JB-02-04-031
49 39 40 Section B

View A

W2-3-36
 UPPERSTRUCTURE / Pump Device
Assembly of Main Pump
1. Apply THREEBOND #1305N onto the joint part
between servo piston (18) and tilt pin (15). Install
orifices (25) (2 used) and plugs (24) (2 used) to
pump casing (26).
: 2.5 mm
: 8.8 N⋅m (0.9 kgf⋅m, 6.5 lbf⋅ft)
: 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
2. Install O-rings (14, 19) and backup rings (13, 20)
to stoppers (12, 21).
3. Install tilt pins (15), servo piston (18), and the
stopper (21, 30) assemblies to pump casing (26).
4. Install roller bearing (6), spacer (7), and retaining
ring (8) to drive shaft (5).
5. Install O-rings (39, 40) to pump casing (26). Install
spring pin (20) and O-ring (27) to support (28).
Lightly tap and install support (28) to pump casing
(26) by using a plastic hammer.
W2-3-37
6. Place pump casing (26) with the regulator
mounting surface down.
7. Install swash plate (30) with shoe plate (31)
attached to pump casing (26) while fitting to tilt pin
(15).
NOTE: After installing swash plate (30), check that
swash plate (30) can move smoothly by
hand.
8. Apply lubricant (SEALUB L101) onto the outer
surface of oil seal (4). Apply grease onto the lip
part in oil seal (4). Install oil seal (4) and O-ring (3)
to cover (2).
9. Install drive shaft (5) to support (28). Install cover
(2) to support (28) with socket bolts (1) (4 used).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
10. Install springs (35) (9 used) and spherical bushing
(34) to cylinder block (36).
11. Install plungers (32) (9 used) to retainer (33).
Install the retainer (33) assembly to cylinder block
(36).
12. Install the cylinder block (36) assembly to drive
shaft (5).
 UPPERSTRUCTURE / Pump Device

26 15 22, 23 39 27 46

47

45

43

5 37

44
29
52

W1JB-02-04-030

11 39 53
B

40

48

W1JB-02-04-031
49 39 40

View A

W2-3-38
 UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the inlet and outlet direction
of valve plate (37).
13. Apply grease onto valve plate (37). Install O-rings
(39) (8 used) and O-rings (40) (2 used) to pump
casing (26).
14. Install spring pin (11), pin (53), and O-ring (27) to
cover (52). Install valve plate (37) to cover (52).
NOTE: Install valve plate (37) while fitting the pin
hole on valve plate (37) to pin (53).
15. Install cover (52) to the pump casing (26)
assembly with socket bolts (29) (4 used).
: 17 mm
: 490 N⋅m (50 kgf⋅m, 360 lbf⋅ft)
16. Install booster (43) to drive shaft (5) while fitting
the splines.
17. Install O-rings (44, 45) to cover (46). Install cover
(46) to cover (52) with socket bolts (47) (6 used).
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft)
W2-3-39
18. Fit the feedback lever of regulator (16) to tilt pin
(15). Install regulator (16) to pump casing (26)
with socket bolts (17) (6 used).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
NOTE: As for the positions of regulator (16) and
socket bolt (17), refer to W2-3-30.
19. Install O-rings (22) (2 used) to plugs (23) (2 used).
Install the plug (23) assemblies (2 used) to pump
casing (26).
: 36 mm
: 170 N⋅m (17 kgf⋅m, 123 lbf⋅ft)
20. Install O-rings (39, 40) to cover (48). Install cover
(48) to cover (52) with socket bolts (49) (3 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF MAIN REGULATOR
6
5

7
4 8
3

2
1

18 11 19

12
17
16
15 20
14 21

11
13 22
25
10 4 23
28
29 24
9 30 27
26
31

33
32 W1JB-02-04-016

34

1- Spring Seat 10 - Valve Casing 19 - Casing 27 - Pin

2- Spring 11 - Plug (9 Used) 20 - O-Ring 28 - Sleeve
3- Stopper 12 - Solenoid Valve 21 - Plug 29 - Pin
4- O-Ring (2 Used) 13 - Socket Bolt (2 Used) 22 - Pin 30 - Sleeve
5- Cover 14 - O-Ring (2 Used) 23 - O-Ring 31 - O-Ring
6- Socket Bolt (4 Used) 15 - Seat (2 Used) 24 - O-Ring 32 - Plug
7- Lock Nut 16 - Steel Ball (2 Used) 25 - Spool 33 - O-Ring
8- Screw 17 - Stopper (2 Used) 26 - Feedback Lever 34 - Socket Bolt (4 Used)
9- Socket Bolt 18 - Socket Bolt (6 Used)

W2-3-40
 UPPERSTRUCTURE / Pump Device
Disassembly of Main Regulator

1. Remove socket bolts (18) (6 used) from casing
(19). Remove the casing (19) assembly from the
pump casing.
: 6 mm
2. Remove O-rings (4, 23, and 24) and pin (22) from
casing (19).
IMPORTANT: Do not loosen screw (7) and nut (8).
If loosening screw (7) and nut (8),
the pump flow rate control may
change.
7. Remove socket bolts (6) (4 used) from cover (5).
Remove the cover (5) assembly from casing (19).
: 5 mm

3. Remove socket bolts (13) (2 used) from solenoid
valve (12). Remove solenoid valve (12) from
valve casing (10).
: 4 mm
4. Remove socket bolt (9) and socket bolts (34) (4
used) from valve casing (10). Remove valve
casing (10) from casing (19).
: 5 mm
5. Remove O-rings (14) (2 used), seats (15) (2 used),
steel balls (16) (2 used), and stoppers (17) (2
used) from casing (19).
8. Install the pulling-out bolt (M4, Pitch 0.7 mm) to
stopper (3). Remove stopper (3), spring (2), and
spring seat (1) from casing (19).
9. Remove plug (21) from casing (19). Remove
feedback lever (26), pin (27), sleeve (28), and
spool (25) from casing (19).
: 6 mm
NOTE: Feedback lever (26) is removed with pin
(27) together.

6. Remove O-ring (31), sleeve (30), and pin (29)

from casing (19).
NOTE: As for the positions of O-ring (14), seat (15),
steel ball (16), and stopper (17), refer to
W2-3-42.

W2-3-41
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF MAIN REGULATOR
A

10 11 16 17 25

1 3 2 4 5

14

9
7
15
8

34
6

30 31 29 4 28 22 23

W1JB-02-04-028
A

12 13

11 18

27 19

11

17
21
16

15

20 24 26 14
W1JB-02-04-029
Section A-A

W2-3-42
 UPPERSTRUCTURE / Pump Device

1- Spring Seat 10 - Valve Casing 19 - Casing 27 - Pin

2- Spring 11 - Plug (9 Used) 20 - O-Ring 28 - Sleeve
3- Stopper 12 - Solenoid Valve 21 - Plug 29 - Pin
4- O-Ring (2 Used) 13 - Socket Bolt (2 Used) 22 - Pin 30 - Sleeve
5- Cover 14 - O-Ring (2 Used) 23 - O-Ring (5 Used) 31 - *O-Ring
6- Socket Bolt (4 Used) 15 - Seat (2 Used) 24 - O-Ring 32 - *Plug
7- Lock Nut 16 - Steel Ball (2 Used) 25 - Spool 33 - O-Ring
8- Screw 17 - Stopper (2 Used) 26 - Feedback Lever 34 - Socket Bolt (4 Used)
9- Socket Bolt 18 - Socket Bolt (6 Used)

NOTE: As for the parts with mark *, refer to W2-3-40.

W2-3-43
 UPPERSTRUCTURE / Pump Device

10 11 16 17 25

1 3 2 4 5

14

9
7
15
8

34
6

30 31 29 4 28 22 23

W1JB-02-04-028
A

12 13

11 18

27 19

11

17
21
16

15

20 24 26 14
W1JB-02-04-029
Section A-A

W2-3-44
 UPPERSTRUCTURE / Pump Device
Assembly of Main Regulator

1. Install stopper (17), steel ball (16), seat (15), and
O-ring (14) to the valve casing mounting surface
of casing (19).
IMPORTANT: Check the direction to insert sleeve
(28) and spool (25).
2. Install sleeve (28) and spool (25) to casing (19).
Install feedback lever (26) to sleeve (28) with pin
(27).
7. Install solenoid valve (12) to valve casing (10)
with socket bolts (13) (2 used).
: 4 mm
: 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)
8. Install valve casing (10) to casing (19) with socket
bolt (9) and socket bolts (34) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)

3. Install O-ring (20) to plug (21). Install plug (21) to

casing (19) while fitting to the pin hole on
feedback lever (26).
: 6 mm
: 36 N⋅m (3.7 kgf⋅m, 26.5 lbf⋅ft)
NOTE: After installing plug (21), check that
feedback lever (26) moves smoothly.

4. Install spring seat (1), spring (2), stopper (3), and

O-ring (4) to casing (19). Install cover (5) to
casing (19) with socket bolts (6) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)

5. Install piston (29), sleeve (30), and O-ring (31) to

casing (19).

6. Install stopper (17), steel ball (16), seat (15), and

O-ring (14) to casing (19).

W2-3-45
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF FAN PUMP
20 21

15
16
17
18 19

25
24
23
14 22
13
12 26
10 11
9 18
17

8
6
7
6 27
26
28
5 29
30 45
4
3 44
2 31
1
43
42 29

41
40
39
38
37
36
47 11 46
35
34 54 55
32
52 53

51

50
49
33 48

W18J-02-03-005

1 - Socket Bolt (4 Used) 15 - Eyebolt 29 - Plug (7 Used) 43 - O-Ring

2 - Cover 16 - Nut 30 - Support 44 - Adjusting Screw
3 - O-Ring 17 - Plug (2 Used) 31 - Socket Bolt (4 Used) 45 - Nut
4 - Oil Seal 18 - O-Ring (2 Used) 32 - Swash Plate 46 - Cover
5 - Drive Shaft 19 - Tilt Pin 33 - Shoe Plate 47 - Pin
6 - Spacer (2 Used) 20 - Regulator 34 - Plunger (9 Used) 48 - Coupling
7 - Roller Bearing 21 - Socket Bolt (6 Used) 35 - Retainer 49 - Retaining Ring
8 - Retaining Ring 22 - Servo Piston 36 - Spherical Bushing 50 - O-Ring
9 - Nut 23 - O-Ring 37 - Spring (9 Used) 51 - Sub Plate
10 - Adjusting Screw 24 - Backup Ring 38 - Cylinder Block 52 - Socket Bolt (4 Used)
11 - Split Pin (2 Used) 25 - Stopper 39 - Valve Plate 53 - O-Ring
12 - Stopper 26 - O-Ring (9 Used) 40 - Needle Bearing 54 - Sub Plate
13 - Backup Ring 27 - Pump Casing 41 - O-Ring 55 - Socket Bolt (4 Used)
14 - O-Ring 28 - O-Ring 42 - Plug

W2-3-46
 UPPERSTRUCTURE / Pump Device
Disassembly of Fan Pump

IMPORTANT: Do not remove adjusting screws (10,
44) and nuts (9, 45) that are attached
to support (30) and cover (46). If
removing adjusting screws (10, 44)
and nuts (9, 45), the set flow rate
changes.
1. Remove plugs (17) (2 used) and O-rings (18) (2
used) from pump casing (27). Drain hydraulic oil
from the pump.
: 27 mm
2. Remove socket bolts (21) (6 used) from regulator
(20). Remove regulator (20) from pump casing
(27).
: 6 mm
3. Remove socket bolts (55) (4 used) from sub plate
(54). Remove sub plate (54) from sub plate (51).
: 10 mm
4. Remove socket bolts (52) (4 used) from sub plate
(51). Remove sub plate (51) and coupling (48)
from cover (46).
: 8 mm
5. Remove O-rings (50, 53) from sub plates (51, 54).
6. Place pump casing (27) with the regulator (20)
mounting surface down.
IMPORTANT: When removing cover (46), valve
plate (39) may be removed with
cover (46) together.
Do not remove needle bearing (40)
unless necessary. When needle
bearing (40) has been removed,
replace with a new one.
7. Remove socket bolts (31) (4 used) from support
(30). Remove cover (46), O-ring (41), O-rings (26)
(4 used), split pin (11), valve plate (39), and pin
(47) from pump casing (27)
: 14 mm
8. Remove cylinder block (38) from pump casing
(27). At this time, plungers (34) (9 used), spherical
bushing (36), and retainer (35) are removed with
cylinder block (38) together.
NOTE: Slowly remove cylinder block (38) while
lightly turning cylinder block (38) to the left
and the right by hands.
9. Remove retainer (35) from the cylinder block (38)
assembly. At this time, plungers (34) (9 used) are
removed with retainer (35) together.
10. Remove plungers (34) (9 used) from retainer (35).
11. Remove spherical bushing (36) from cylinder
block (38). Remove springs (37) (9 used) from
cylinder block (38).
IMPORTANT: Do not remove oil seal (4) unless
necessary. When oil seal (4) has
been removed, replace with a new
one.
Cover (2) is equipped with oil seal (4).
Do not damage the lip part of oil seal
(4) when removing cover (2).
12. Remove socket bolts (1) (4 used) from cover (2).
Remove cover (2) and O-ring (3) from support
(30).
: 5 mm
NOTE: For easy removal, install a bolt to the
pulling-out hole (M8) to cover (2).

W2-3-47
 UPPERSTRUCTURE / Pump Device

19

25
24
23
14 22
13
12 26
11

8
6
7
6 27
26
28
5
30

40

11 46

32

33

W18J-02-03-005

W2-3-48
 UPPERSTRUCTURE / Pump Device
13. Tap and remove support (30) from pump casing IMPORTANT: Do not remove needle bearing (40)
(27) by using a plastic hammer. At this time, unless necessary.
remove O-ring (28), O-rings (26) (5 used), and 19. Remove needle bearing (40) from cover (46).
split pin (11).
20. Remove retaining ring (8) from drive shaft (5).
14. Remove swash plate (32) and shoe plate (33) Remove spacer (6), roller bearing (7), and spacer
from pump casing (27). (6) from drive shaft (5).

15. Tap and remove drive shaft (5) from support (30)
by using a plastic hammer.

16. Install a bolt (M5, Pitch 0.8 mm) to stoppers (12,

25). Remove stoppers (12, 25) from pump casing
(27).

17. Remove backup rings (13, 24) and O-rings (14,

23) from stoppers (12, 25).

IMPORTANT: LOCTITE has been applied onto the

joint part between servo piston (22)
and tilt pin (19). Do not disassemble
servo piston (22) and tilt pin (19)
unless necessary.
18. Warm up tilt pin (19) by using a drier. Secure
servo piston (22) in order not to damage by using
a pair of pliers. Turn and remove tilt pin (19).
Remove servo piston (22) from pump casing (27).

W2-3-49
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF FAN PUMP

11 12 13 14 6 32 19 22 23 24 25 26 45 44 40 46 51 52

10
54
28

30
1

3 50
5
2

4
49

48
8

53
6

55

W18J-02-03-006

7 31 27 33 35 36 34 37 38 41 11 47 42, 43 39

1- Socket Bolt (4 Used) 15 - *Eyebolt 29 - *Plug (7 Used) 43 - O-Ring

2- Cover 16 - *Nut 30 - Support 44 - Adjusting Screw
3- O-Ring 17 - *Plug (2 Used) 31 - Socket Bolt (4 Used) 45 - Nut
4- Oil Seal 18 - *O-Ring (2 Used) 32 - Swash Plate 46 - Cover
5- Drive Shaft 19 - Tilt Pin 33 - Shoe Plate 47 - Pin
6- Spacer (2 Used) 20 - *Regulator 34 - Plunger (9 Used) 48 - Coupling
7- Roller Bearing 21 - *Socket Bolt (6 Used) 35 - Retainer 49 - Retaining Ring
8- Retaining Ring 22 - Servo Piston 36 - Spherical Bushing 50 - O-Ring
9- Nut 23 - O-Ring 37 - Spring (9 Used) 51 - Sub Plate
10 - Adjusting Screw 24 - Backup Ring 38 - Cylinder Block 52 - Socket Bolt (4 Used)
11 - Split Pin (2 Used) 25 - Stopper 39 - Valve Plate 53 - O-Ring
12 - Stopper 26 - O-Ring (9 Used) 40 - Needle Bearing 54 - Sub Plate
13 - Backup Ring 27 - Pump Casing 41 - O-Ring 55 - Socket Bolt (4 Used)
14 - O-Ring 28 - O-Ring 42 - Plug

NOTE: As for the parts with mark *, refer to W2-3-46.

W2-3-50
 UPPERSTRUCTURE / Pump Device
Assembly of Fan Pump
1. Apply THREEBOND #1305N onto the joint part
between servo piston (22) and tilt pin (19). Install
O-rings (14, 23) and backup rings (13, 24) to
stoppers (12, 25).
2. Install tilt pins (19), servo piston (22), and the
stopper (12, 25) assemblies to pump casing (27).
3. Install spacer (6), roller bearing (7), spacer (6),
and retaining ring (8) to drive shaft (5).
4. Install O-rings (26) (2 used) to pump casing (27).
Install split pin (11) and O-ring (28) to support (30).
Tap and install support (30) to pump casing (27)
by using a plastic hammer.
10. Install plungers (34) (9 used) to retainer (35).
11. Install the cylinder block (38) assembly to drive
W2-3-51
5. Place pump casing (27) with the regulator
mounting surface down.
6. Install swash plate (32) that is attached to shoe
plate (33) to pump casing (27) while fitting to tilt
pin (19).
NOTE: After installing swash plate (32), check that
swash plate (32) can move smoothly by
hand.
7. Apply lubricant (SEALUB L101) onto the outer
surface of oil seal (4). Apply grease onto the lip
part of oil seal (4). Install oil seal (4) and O-ring (3)
to cover (2).
8. Install drive shaft (5) to support (30). Install cover
(2) to support (30) with socket bolts (1) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
9. Install springs (37) (9 used) and spherical bushing
(36) to cylinder block (38).
Install the retainer (35) assembly to cylinder block
(38).
shaft (5).
 UPPERSTRUCTURE / Pump Device

11 19 26 46 51 52

54

50

49

48

53

55

W18J-02-03-006

31 27 41 47 39

W2-3-52
 UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the inlet and outlet direction
of valve plate (39).
12. Apply grease onto valve plate (39). Install O-rings
(26) (8 used) to pump casing (27).
13. Install split pin (11), pin (47), and O-ring (41) to
cover (46). Install valve plate (39) to cover (46).
NOTE: Install valve plate (39) while fitting the pin
hole on valve plate (39) to pin (47).
14. Install cover (46) to the pump casing (27)
assembly with socket bolts (31) (4 used).
: 14 mm
: 240 N⋅m (24.5 kgf⋅m, 175 lbf⋅ft)
17. Install O-rings (50, 53) to sub plates (51, 54).
18. Install coupling (48) to drive shaft (5).
19. Install sub plate (51) to cover (46) with socket
bolts (52) (4 used).
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft)
20. Install sub plate (54) to sub plate (51) with socket
bolts (55) (4 used).
: 10 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

15. Install the feedback lever of regulator (20) to

pump casing (27) while fitting to tilt pin (19). Install
regulator (20) to pump casing (27) with socket
bolts (21) (6 used).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
NOTE: As for the positions of regulator (20) and
socket bolt (21), refer to W2-3-46.

16. Install O-rings (18) (2 used) to plugs (17) (2 used).

Install the plug (17) assemblies (2 used) to pump
casing (27).
: 27 mm
: 110 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

W2-3-53
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF FAN REGULATOR
12
11
10
9
8

7
6 14
5 15
4 16
3 17
2 13 18
1 19 20
25 21
26 22
27 23
28
29
30
31 24

46
45

44

43
42
41 47
38 40 48
39
36
35
33 34
32
37

66

67 49
50
51
68 52
57 53
56
65 55
54
69 62 59
63 58
64 60
61
W1JB-02-04-027

W2-3-54
 UPPERSTRUCTURE / Pump Device

1- Pin 19 - Pin 36 - Socket Bolt (2 Used) 53 - Lock Ring

2- Sleeve 20 - O-Ring 37 - Casing 54 - Lock Ring
3- O-Ring 21 - Stopper 38 - Socket Bolt (2 Used) 55 - O-Ring
4- O-Ring 22 - Spring 39 - O-Ring 56 - Supporting Plug
5- Sleeve 23 - Spring Seat 40 - Adjusting Screw 57 - Pin
6- Compensating Piston 24 - Pilot Spin 41 - Adjusting Screw 58 - Plug
7- Compensating Rod 25 - Spool 42 - Lock Nut 59 - O-Ring
8- Spring Seat 26 - Sleeve 43 - O-Ring 60 - O-Ring
9- Spring 27 - Retaining Ring 44 - Cover 61 - O-Ring
10 - Spring 28 - Spring 45 - Socket Bolt (4 Used) 62 - O-Ring
11 - Stopper 29 - Spring 46 - Lock Nut 63 - O-Ring
12 - O-Ring 30 - Spring Seat 47 - Lock Nut 64 - O-Ring
13 - Pin 31 - Retaining Ring 48 - Adjusting Screw 65 - O-Ring
14 - Lever 32 - Socket Bolt (4 Used) 49 - Pin 66 - Socket Bolt (2 Used)
15 - Feedback Lever 33 - Cover 50 - Pin 67 - Solenoid Valve
16 - Pin 34 - O-Ring 51 - Supporting Plug 68 - Cover
17 - Pin 35 - O-Ring (3 Used) 52 - O-Ring 69 - Socket Bolt (4 Used)
18 - Lever

W2-3-55
 UPPERSTRUCTURE / Pump Device

12
11
10
9
8

7
6 14
5 15
4 16
3 17
2 13 18
1 19 20
25 21
26 22
27 23
28
29
30
31 24

46
45

44

43
42
41 47
38 40 48
39
36
35
33 34
32
37

66

67 49
50
51
68 52
57 53
56
65 55
54
69 62 59
63 58
64 60
61
W1JB-02-04-027

W2-3-56
 UPPERSTRUCTURE / Pump Device
Assembly of Fan Regulator
1. Remove socket bolts (36, 38) (2 used for each)
from casing (37). Remove the regulator from the
pump body.
Remove pin (57) and O-rings (60, 61) from casing
(37).
: 6 mm
2. Remove socket bolts (66) (2 used) from solenoid
valve (67). Remove solenoid valve (67) from
cover (68).
: 4 mm
3. Remove socket bolts (32) (4 used) from cover
(33). Remove cover (33), O-ring (34), and O-rings
(35) (3 used) from casing (37).
: 5 mm
CAUTION: When removing cover (44),
springs (9, 10) inside may fly out.
IMPORTANT: Do not disassemble lock nuts (42, 46,
and 47) and adjusting screws (40, 41,
and 48). The set flow rate changes.
4. Remove socket bolts (45) (4 used) from cover
(44). Remove the cover (44) assembly and O-ring
(43) from casing (37).
: 5 mm
5. Remove springs (9, 10) and spring seat (8) from
casing (37).
6. Remove stopper (11) and O-ring (12) from the
cover (44) assembly.
W2-3-57
7. Remove socket bolts (69) (4 used) from cover
(68). Remove cover (68) from casing (37).
: 5 mm
8. Remove O-rings (62, 63, 64, and 65) and spring
(28) from casing (37).
9. Remove retaining ring (31) from spool (25).
Remove spring seat (30), spring (29), and sleeve
(26) from spool (25).
10. Remove retaining ring (27) from sleeve (26).
11. Remove pin (1), sleeve (2), and O-ring (3) from
casing (37).
12. Remove lock rings (53, 54) from casing (37).
IMPORTANT: Supporting plug (51) and supporting
plug (56) look quite similar. Put the
matching marks in order to install
correctly.
13. Insert a bolt (M6, Pitch 1.0 mm) into the center
hole of supporting plugs (51, 56). Remove
supporting plugs (51, 56) from casing (37).
At this time, pin (50) is removed with supporting
plug (51) together.
14. Remove pin (50) from supporting plug (51).
 UPPERSTRUCTURE / Pump Device

7
6 14
5 15
4 16
17
13 18
19 20
25 21
22
23

24

40

37

51
52

56
55

W1JB-02-04-027

W2-3-58
 UPPERSTRUCTURE / Pump Device
15. Remove O-rings (52, 55) from supporting plugs
(51, 56).

IMPORTANT: Do not remove pin (19) from lever

(18).
16. Remove lever (18) from casing (37) by using a
pair of pincers.

17. Remove pin (16) from feedback lever (15) by

using a round bar (3 mm (0.12 in)). Remove
feedback lever (15) from casing (37).

IMPORTANT: Do not remove pin (13) from lever

(14).
18. Remove lever (14) from casing (37).

19. Remove pilot piston (24) from casing (37).

20. Insert a round bar (3 mm (0.12 in)) into casing

(37) from the pilot piston (24) side. Remove spring
seat (23), spring (22), and stopper (21) from
casing (37).

21. Remove O-ring (20) from stopper (21).

22. Insert a round bar (3 mm (0.12 in)) into casing

(37) from the adjusting screw (40) side. Remove
compensating rod (7) and the sleeve (5) assembly
from casing (37).

23. Remove compensating rod (7), compensating

piston (6), and O-ring (4) from sleeve (5).

24. Remove spool (25) from casing (37).

W2-3-59
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF FAN REGULATOR

49 50 A 51 52 53
B
16

38

17
54

A 55
13

56
14
B
18 19
W1JB-02-04-003

65 28 29 27 26 25 8 9 10

43 39 12 46 40
30

31

3
C

1 41

42

11

2 4 5 6 7 57

Section A-A W1JB-02-04-002

W2-3-60
 UPPERSTRUCTURE / Pump Device

66 67 15 19

22 20 44

45

21

48

47

64 24 18 23 60 37
Section B-B
W1JB-02-04-004

34 36

32

33 58, 59

69

35 61 63 62
View C
W1JB-02-04-005

1- Pin 19 - Pin 36 - Socket Bolt (2 Used) 53 - Lock Ring

2- Sleeve 20 - O-Ring 37 - Casing 54 - Lock Ring
3- O-Ring 21 - Stopper 38 - Socket Bolt (2 Used) 55 - O-Ring
4- O-Ring 22 - Spring 39 - O-Ring 56 - Supporting Plug
5- Sleeve 23 - Spring Seat 40 - Adjusting Screw 57 - Pin
6- Compensating Piston 24 - Pilot Spin 41 - Adjusting Screw 58 - Plug
7- Compensating Rod 25 - Spool 42 - Lock Nut 59 - O-Ring
8- Spring Seat 26 - Sleeve 43 - O-Ring 60 - O-Ring
9- Spring 27 - Retaining Ring 44 - Cover 61 - O-Ring
10 - Spring 28 - Spring 45 - Socket Bolt (4 Used) 62 - O-Ring
11 - Stopper 29 - Spring 46 - Lock Nut 63 - O-Ring
12 - O-Ring 30 - Spring Seat 47 - Lock Nut 64 - O-Ring
13 - Pin 31 - Retaining Ring 48 - Adjusting Screw 65 - O-Ring
14 - Lever 32 - Socket Bolt (4 Used) 49 - Pin 66 - Socket Bolt (2 Used)
15 - Feedback Lever 33 - Cover 50 - Pin 67 - Solenoid Valve
16 - Pin 34 - O-Ring 51 - Supporting Plug 68 - Cover
17 - Pin 35 - O-Ring (3 Used) 52 - O-Ring 69 - Socket Bolt (4 Used)
18 - Lever

W2-3-61
 UPPERSTRUCTURE / Pump Device

49 50 A 51 52 53
B
16

54
55
37
56
A
13 19

18

14
B 15

W1JB-02-04-003

28 29 27 26 25 37

30

31

Section A-A W1JB-02-04-002

NOTE: As for No. 24, refer to W2-3-54.

W2-3-62
 UPPERSTRUCTURE / Pump Device
Assembly of Fan Regulator
IMPORTANT: Check the direction to install
compensating rod (7) as illustrated.
1. Install compensating rod (7) to casing (37).
2. Insert lever (14) into casing (37). Install pin (13)
while fitting to the groove of compensating rod (7).
3. Install retaining ring (27) to sleeve (26).
IMPORTANT: After installing, check that spool (25)
moves smoothly.
4. Install sleeve (26) and spool (25) to casing (37).
IMPORTANT: Check the direction to install
feedback lever (15).
5. Fit the pin hole (the hole in the upper side) on
feedback lever (15) to the pin hole on spool (25).
Install pin (16).
Compensating Rod (7) Lever (26) Side
Side
W18B-02-04-018
W2-3-63
IMPORTANT: After installing, check that pilot
piston (24) moves smoothly.
6. Install pilot piston (24) to casing (37).
7. Install O-rings (52, 55) to supporting plugs (51,
56).
IMPORTANT: Supporting plug (51) and supporting
plug (56) look quite similar.
Fit the matching marks made when
disassembling and install correctly.
8. Fit pin (19) of lever (18) to the groove on pilot
piston (24).
9. Install pin (50) to supporting plug (51). Install
supporting plug (51) while fitting to the lever (18)
hole.
10. Install lock ring (53) to the lock groove on
supporting plug (51) of casing (37).
11. Install supporting plug (56) to casing (37). Install
lock ring (54) to the lock groove on supporting
plug (56).
12. Install spring (29) and spring seat (30) to spool
(25). Secure spring seat (30) to spool (25) with
retaining ring (31).
13. Install spring (28) to casing (37).
 UPPERSTRUCTURE / Pump Device

8 9 10
68

37 43 12
65

3
C
1

11

2 4 5 6 7 60 57
Section A-A
W1JB-02-04-002

34 36 38

32

33

35 61 63 62 69
View C
68 66 67 37 W1JB-02-04-005

22 20 44

45

21

64 23 60
Section B-B

W1JB-02-04-004

W2-3-64
 UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the direction to install 25. Install pin (57) and O-rings (60, 61) to casing (37).
compensating piston (6) as
illustrated. 26. Install the regulator to the pump with socket bolts
14. Install O-ring (4) and compensating piston (6) to (36, 38) (2 used for each).
sleeve (5). : 6 mm
: 29 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
15. Install sleeve (5), O-ring (3), sleeve (2), and pin
(1) to casing (37). 27. Install solenoid valve (67) to cover (68) with
socket bolts (66) (2 used).
16. Install O-rings (62, 63, 64, and 65) to casing (37). : 4 mm
: 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)
17. Install cover (68) to casing (37) with socket bolts
(69) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)

18. Install O-ring (34) and O-rings (35) (3 used) to

cover (33).

19. Install cover (33) to casing (37) with socket bolts

(32) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)

20. Install O-ring (20) to stopper (21).

21. Install spring seat (23), spring (22), and stopper

(21) to casing (37).

22. Install O-ring (12) to stopper (11).

23. Install spring seat (8) and springs (9, 10) to casing
(37).

24. Install stopper (11) and O-ring (43) to the cover

(44) assembly. Install the cover (44) assembly to
casing (37) with socket bolts (45) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)

W2-3-65
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD
1. Clearance between plungers (32, 34) outer
diameter (d) and cylinder blocks (36, 38) bore (D)
d D
D-d Unit: mm (in)
Standard Allowable Limit
0.047 (0.002) 0.094 (0.004)

W117-02-02-009

2. Springs (35, 37) free length (L)

L Unit: mm (in)
Standard Allowable Limit
49.5 (1.95) 48.0 (1.89)

W117-02-02-010

3. Clearance (δ) between plungers (32, 34) and the

shoe bottom, and shoe thickness (t)

δ Unit: mm (in)
Standard Allowable Limit
0 to 0.1 (0 to 0.004) 0.35 (0.014)
δ
t
t Unit: mm (in)
Standard Allowable Limit
6.5 (0.26) 6.3 (0.25) W117-02-02-011

4. Distance between retainers (33, 35) and spherical Stand

bushings (34, 36)

H-h Unit: mm (in) h H

Standard Allowable Limit
33.0 (1.3) 32.0 (1.26) W117-02-02-012

W2-3-66
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-3-67
 UPPERSTRUCTURE / Pump Device
STRUCTURE OF PILOT PUMP

1 2 3 4 5 C 6 7
A B

W183-02-04-007

15 14 13 12 11 10 C 9 8

16 17

17 16 16 17

Part A Part B

Section C-C

W183-02-04-019

W2-3-68
 UPPERSTRUCTURE / Pump Device

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
(3.5 to (25 to
1 Socket bolt 4 12 34 to 39
4.0) 28.5)
2 Washer 4
3 Plate 1
4 Pressure plate 2
5 Gear plate 1
6 Gear 1
7 Flange 1
8 Retaining ring 1
Apply grease onto the lip
9 Oil seal 1
part when assembling.
10 Gear 1
11 Coupling 1
12 Knock pin 1
Apply grease onto the lip
13 O-ring 1
part when assembling.
14 Plate 1
Apply grease onto the lip
15 O-ring 1
part when assembling.
Apply grease onto the lip
16 Backup ring 2
part when assembling.
Apply grease onto the lip
17 Seal plate 2
part when assembling.

W2-3-69
 UPPERSTRUCTURE / Pump Device
STRUCTURE OF PUMP TRANSMISSION
OIL CIRCULATION PUMP

2 3 4 5 6 C

View D
12 11 10 9 8 7

Detail C

13 14 15

Section B-B Section A-A W117-02-02-020

W2-3-70
 UPPERSTRUCTURE / Pump Device

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
(3.5 to (25 to
1 Bolt 4 17 34 to 39
4.0) 28.5)
2 Cover 1
3 Driven gear 1
4 Knock pin 2
5 Plate 1
6 Flange 1
7 Snap ring 1
8 Oil seal 1
9 Side plate A 1
10 Side plate B 1
11 O-ring 1
12 Drive gear 1
13 Gasket A 1
14 Gasket B 1
15 Balance seal 1

Maintenance Standard

Drive Gear (12), Driven Gear (3)

Plate (5) Dia.b>Dia14.96 mm (0.59 in)
a≥0.15 mm a
(0.006 in) b

W117-02-02-022

W117-02-02-021

W2-3-71
 UPPERSTRUCTURE / Pump Device
STRUCTURE OF SOLENOID VALVE

1 2 3 4

W1JB-02-04-019

11 10 9 8 7 6 5

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Orifice 1
2 Spool 1
3 Retaining ring 1
4 Spring 1
5 Nut 1 : 10 7.4±0.5 (0.76±0.05) (5.5±0.4)
6 Solenoid 1
7 O-ring 1 1B P20
8 O-ring 1 1B
9 O-ring 1 1B
10 O-ring 1 1B
11 Sleeve 1

W2-3-72
 UPPERSTRUCTURE / Control Valve
REMOVAL AND INSTALLATION OF
CONTROL VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal of Main Control Valve

CAUTION: Step (2) weight: 28 kg (62 lb)

1. Attach a nylon sling onto step (2). Hoist and hold 1 2 3

step (2). Remove bolts (1) (4 used) from step (2).
Remove step (2) from brackets (3) (2 used).
: 19 mm

W18J-02-11-003

2. Remove bolts (5) (4 used) from bracket (6).

Remove the bracket (6) assembly from brackets 4 5 6 5
(4, 7). 7
: 19 mm
8
3. Remove bolts (8) (8 used) from clamps (10) (4
used).
Remove clamps (10) (4 used) from pipes (9) (6 9
used).
: 19 mm

10 W18J-02-05-004

4. Remove bolts (12) (9 used) from clamps (13) (6

used). Remove clamps (13) (6 used) from pipes 11
(11) (6 used).
: 19 mm

12

13 W18J-02-04-008

W2-4-1
 UPPERSTRUCTURE / Control Valve
5. Remove bolts (14) (4 used) from handrail (15). 14 15
Remove handrail (15) from brackets (16, 17).
: 19 mm

W18J-02-11-002
17 16

18, 19, 20
6. Remove bolts (21) (2 used) from cover (18).
21 22 23, 24 25 23, 24 26
Remove cover (18) from bracket (27).
: 17 mm

7. Remove bolt (20) from clip (19). Remove clip (19) 27

from bracket (27) and hoses (26) (16 used).
: 17 mm

8. Remove bolts (25) (4 used) from cover (22).

Remove cover (22) from bracket (27).
: 17 mm

9. Remove bolts (24) (2 used) from clips (23) (2

used). Remove clips (23) (2 used) from bracket
(27) and hoses (26) (16 used).
: 17 mm
W18J-02-04-007

10. Remove signal control valve (29) from main

control valve (28). (Refer to REMOVAL AND 28
INSTALLATION OF SIGNAL CONTROL VALVE
on W2-11-1.)
29
11. Remove 4-spool solenoid valve (30) from main
control valve (28). (Refer to REMOVAL AND
INSTALLATION OF 4-SPOOL SOLENOID VALVE
on W2-9-1.)

30 W18J-02-04-007

W2-4-2
 UPPERSTRUCTURE / Control Valve
12. Remove bolt (32) from clip (31). Remove clip (31) 27, 31, 32 33 26 28
from bracket (27) and hose (26)
: 17 mm
34

13. Remove bolts (33) (3 used) from bracket (27).

Remove bracket (27) from main control valve (28).
: 17 mm, 19 mm

14. Remove bolt (36) from clip (37). Remove clip (37)
from bracket (38) and hoses (35) (12 used). 35
: 17 mm 36

37

15. Disconnect hoses (34) (12 used) from main

control valve (28). Cap the open ends. Attach an 38 W18J-02-04-007

identification tag onto the disconnected hoses for

assembling.
: 17 mm

16. Remove bolts (39) (2 used) from bracket (38).

Remove bracket (38) from main control valve (28).
: 17 mm 28

39 38 W18J-02-04-007

W2-4-3
 UPPERSTRUCTURE / Control Valve
40
CAUTION: Step (41) weight: 21 kg (46 lb)

17. Remove bolts (40) (4 used) from step (41).

Remove step (41) from brackets (16, 17).
: 19 mm
41

W18J-02-11-002
17 16

18. Remove bolts (43) (8 used) from steps (42, 44). 42 43 43

Remove steps (42, 44) from brackets (16, 17, 45,
and 46).
: 19 mm

44

W18J-02-11-002
17 16 45

42

W18J-02-04-002

46 43

19. Remove couplings (47, 53, and 56) from pipes (52, 49 50, 51 28
54, 55, 57, and 58). Cap the open ends. 52
48
: 13 mm

20. Remove bolts (50) (4 used), spring washers (51) 47 53

(4 used), and bolts (48) (4 used) from pipe (49).
Disconnect pipe (49) from pipe (57) and main 54
control valve (28).
: 19 mm
55

58

57 56 W18J-02-04-006

W2-4-4
 UPPERSTRUCTURE / Control Valve
21. Remove bolts (59) (4 used) and spring washers 59, 60 28
(60) (4 used) from pipe (52). Disconnect pipe (52)
from main control valve (28).
: 19 mm 57 52

CAUTION: The bracket (62) assembly weight:

23 kg (51 lb)

22. Attach a nylon sling onto pipe (57). Hoist and hold
pipe (57). Remove bolts (63) (2 used) from
bracket (62). Remove the bracket (62) assembly
from support (64).
: 19 mm

23. Disconnect connector (61).

64 63 62 61 W18J-02-04-006

24. Remove socket bolts (65) (4 used) from pipe (66). 65 66

Disconnect pipe (66) from block (67). Cap the
open ends.
: 12 mm

W18J-02-11-002
67

25. Remove socket bolts (68) (4 used) from block (67). 67 28

Remove block (67) from main control valve (28).
: 12 mm

68

W18J-02-04-006

W2-4-5
 UPPERSTRUCTURE / Control Valve
Front Side 28, 69
26. Disconnect hoses (69) (2 used) from main control
valve (28). Cap the open ends.
: 41 mm

Right Side
27. Remove socket bolts (74) (20 used) from pipes
(73) (5 used). Disconnect pipes (73) (5 used) from
main control valve (28). Cap the open ends. 28, 70,
: 12 mm 71, 72

28. Remove socket bolts (71) (8 used) and split

flanges (72) (4 used) from hoses (70) (2 used). 28, 73, 74
Disconnect hoses (70) (2 used) from main control
valve (28). Cap the open ends. Attach an
W18J-02-04-007
identification tag onto the disconnected hoses for
assembling.
: 12 mm

Left Side
29. Remove socket bolts (76) (24 used) from pipes
(75) (6 used). Disconnect pipes (75) (6 used) from
main control valve (28). Cap the open ends.
: 12 mm

30. Remove socket bolts (71) (8 used) and split

flanges (72) (4 used) from hoses (70) (2 used).
Disconnect hoses (70) (2 used) from main control
valve (28). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 12 mm

28, 70, 71, 72 28, 75, 76 W18J-02-04-007

W2-4-6
 UPPERSTRUCTURE / Control Valve

CAUTION: Line filter (77) weight: 25 kg (55 lb)

77, 78, 79, 80
31. Remove socket bolts (80) (2 used) from covers
(79) (2 used). Install eyebolts (M12, Pitch 2.0 mm)
(2 used) to line filters (77) (2 used). 28
: 12 mm

32. Attach a nylon sling onto the eyebolts (2 used).

Hoist and hold line filters (77). Remove socket
bolts (78) (8 used) from line filters (77) (2 used).
Hoist and remove line filters (77) (2 used) from
main control valve (28).
: 12 mm
NOTE: Line filters (77) are provided at the rear of
the front right and left sides.

W18J-02-04-007
CAUTION: The main control valve (28)
assembly weight: 610 kg (1350 lb)

33. Attach wire rope onto supports (64, 81). Hoist and
hold the main control valve (28) assembly.
28
Remove bolts (82) (10 used) and spacers (83) (10
used) from supports (64, 81). Remove the main
control valve (28) assembly from main frame (84).
: 24 mm

81

82

83

W18J-02-04-006
64 82, 83 84

W2-4-7
 UPPERSTRUCTURE / Control Valve
34. Remove bolts (86) (2 used) from clips (85) (2
used). Remove clips (85) (2 used) from support 26
28
(64) and hose (26).
: 17 mm

35. Disconnect hoses (26) (11 used) from main

control valve (28). Cap the open ends. Attach an
identification tag onto the disconnected hoses for 85
assembling.
: 17 mm, 19 mm

W18J-02-04-009
64 86 85

CAUTION: Main control valve (28) weight: 28

415 kg (920 lb)
CAUTION: Support (64) weight: 120 kg (270
lb)
CAUTION: Support (81) weight: 75 kg (170 lb)

36. Attach a nylon sling onto main control valve (28).

Hoist and hold main control valve (28).
81, 87, 88
37. Remove bolts (87) (4 used) and spacers (88) (4
used) from supports (64, 81). Remove supports
(64, 81) from main control valve (28).
: 30 mm

W18J-02-04-006
64, 87, 88

W2-4-8
 UPPERSTRUCTURE / Control Valve
Installation of Main Control Valve

CAUTION: Main control valve (28) weight:

415 kg (920 lb)
CAUTION: Support (64) weight: 120 kg (270
lb)
CAUTION: Support (81) weight: 75 kg (170 lb) 28

1. Attach a nylon sling onto main control valve (28).

Hoist main control valve (28). Fit main control
valve (28) to the mounting holes of supports (64,
81).

2. Install main control valve (28) to supports (64, 81)

with bolts (87) (4 used) and spacers (88) (4 used).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft) 81, 87, 88

W18J-02-04-006
64, 87, 88

26
28
3. Connect hoses (26) (11 used) to main control
valve (28).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 85

4. Install clips (85) (2 used) to hoses (26) (9 used).

Install clips (85) (2 used) to support (64) with bolts
(86) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W18J-02-04-009
64 86 85

W2-4-9
 UPPERSTRUCTURE / Control Valve

CAUTION: The main control valve (28)

assembly weight: 610 kg (1350 lb) 28

5. Attach a wire rope onto supports (64, 81). Hoist

the main control valve (28) assembly. Fit the main
control valve (28) assembly to the mounting hole
of main frame (84).

6. Install supports (64, 81) to main frame (84) with

bolts (82) (10 used) and spacers (83) (10 used). 81
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
82

83

W18J-02-04-006
64 82, 83 84

CAUTION: Line filter (77) weight: 25 kg (55 lb)

7. Install eyebolts (M12, Pitch 2.0 mm) (2 used) to 77, 78, 79, 80
line filters (77) (2 used). Attach a nylon sling onto
the eyebolts (2 used). Hoist line filters (77). Fit line
filters (77) (2 used) to the mounting holes of main 28
control valve (28).

8. Install line filters (77) (2 used) to main control

valve (28) with socket bolts (78) (8 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

9. Remove the eyebolts (2 used) from line filters (77)

(2 used). Install covers (79) (2 used) to line filters
(77) (2 used) with socket bolts (80) (2 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
W18J-02-04-007

W2-4-10
 UPPERSTRUCTURE / Control Valve
Left Side
10. Connect pipes (75) (6 used) to main control valve
(28) with socket bolts (76) (24 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

11. Connect hoses (70) (2 used) to main control valve

(28) with split flanges (72) (4 used) and socket
bolts (71) (8 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

28, 70, 71, 72 28, 75, 76 W18J-02-04-007

Front Side
12. Connect hoses (69) (2 used) to main control valve 28, 69
(28).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

Right Side
13. Connect pipes (73) (5 used) to main control valve
(28) with socket bolts (74) (20 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 28, 70,
71, 72
14. Connect hoses (70) (2 used) to main control valve
(28) with split flanges (72) (4 used) and socket
bolts (71) (8 used). 28, 73, 74
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
W18J-02-04-007

W2-4-11
 UPPERSTRUCTURE / Control Valve
15. Install block (67) to main control valve (28) with 67 28
socket bolts (68) (4 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
68

W18J-02-04-006

65 66
16. Connect pipe (66) to block (67) with socket bolts
(65) (4 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

W18J-02-11-002
67

59, 60 28
17. Connect connector (61).

57 52
CAUTION: The bracket (62) assembly weight:
23 kg (51 lb)

18. Attach a nylon sling onto pipe (57). Hoist pipe (57).
Fit pipe (57) to the mounting holes of support (64).
Install the bracket (62) assembly to support (64)
with bolts (63) (2 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

19. Connect pipe (52) to main control valve (28) with

bolts (59) (4 used) and spring washers (60) (4
used). 64 63 62 61 W18J-02-04-006

: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W2-4-12
 UPPERSTRUCTURE / Control Valve
20. Connect pipe (49) to main control valve (28) and
pipe (57) with bolts (50) (4 used), spring washers 49 50, 51 28
(51) (4 used), and bolts (48) (4 used).
52
: 19 mm 48
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
47 53
21. Connect pipes (52, 57) to pipes (54, 55, and 58)
with couplings (47, 53, and 56).
: 13 mm 54
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

55

58

57 56 W18J-02-04-006

CAUTION: Step (41) weight: 21 kg (46 lb)

22. Attach a nylon sling onto step (41). Hoist step (41). 40 43
Fit step (41) to the mounting holes of brackets (16,
17).

23. Install step (41) to brackets (16, 17) with bolts (40)
(4 used).
: 19 mm 44
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-11-002
17 41 16 45

24. Install steps (44, 42) to brackets (45, 16, 17, and 42
46) with bolts (43) (8 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-04-002

46 43 17

W2-4-13
 UPPERSTRUCTURE / Control Valve
25. Install bracket (38) to main control valve (28) with 27, 31, 32 33 26 28
bolts (39) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

26. Install bracket (27) to main control valve (28) with

bolts (33) (3 used). 38
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

27. Install clip (31) to hose (26). Install clip (31) to

bracket (27) with bolt (32).
: 17 mm 39 W18J-02-04-007

: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

28. Connect hoses (34) (12 used) to main control 28

valve (28).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 34

29. Install clip (37) to hoses (35) (12 used). Install the
clip (37) assembly to bracket (38) with bolt (36).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

35
36

37

38 W18J-02-04-007

W2-4-14
 UPPERSTRUCTURE / Control Valve
30. Install signal control valve (29) to main control 28
valve (28). (Refer to REMOVAL AND
INSTALLATION OF SIGNAL CONTROL VALVE
on W2-11-1.)
29
31. Install 4-spool solenoid valve (30) to main control
valve (28). (Refer to REMOVAL AND
INSTALLATION OF 4-SPOOL SOLENOID VALVE
on W2-9-1.)

30 W18J-02-04-007

32. Install clip (19) and clips (23) (2 used) to hoses 18, 19, 20
(26) (16 used). 21 22 23, 24 25 23, 24 26

33. Install clip (19) to bracket (27) with bolt (20).

: 17 mm 27
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

34. Install clips (23) (2 used) to bracket (27) with bolts

(24) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

35. Install covers (18, 22) to bracket (27) with bolts

(21) (2 used) and bolts (25) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

36. Install handrail (15) to brackets (16, 17) with bolts W18J-02-04-007

(14) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

14 15

W18J-02-11-002
17 16

W2-4-15
 UPPERSTRUCTURE / Control Valve
37. Install clamps (13) (6 used) to pipes (11) (6 used) 11
with bolts (12) (9 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

12

13 W18J-02-04-008

38. Install clamps (10) (4 used) to pipes (9) (6 used) 4 5 6 5

with bolts (8) (8 used). 7
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
8
39. Install the bracket (6) assembly to brackets (4, 7)
with bolts (5) (4 used). 9
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

10 W18J-02-05-004

CAUTION: Step (2) weight: 28 kg (62 lb)

40. Attach a nylon sling onto step (2). Hoist step (2).
Fit step (2) to the mounting holes on brackets (3) 1 2 3
(2 used). Install step (2) to brackets (3) (2 used)
with bolts (1) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-11-003

W2-4-16
 UPPERSTRUCTURE / Control Valve
Removal of Swing Control Valve

1. Remove bolts (6) (6 used) from handrail (5). 1 2, 3 4 5

Remove handrail (5) from tool box (2) and
hydraulic oil tank (4).
: 19 mm
6
CAUTION: Tool box (2) weight: 22 kg (49 lb) 7

2. Attach a nylon sling onto tool box (2). Hoist and 8, 9

hold tool box (2). Remove bolts (3) (5 used) and 10
bolts (7) (2 used) from tool box (2). Remove tool
box (2) from cover (1), hydraulic oil tank (4), and
bracket (11). 11
W18J-02-04-001

: 19 mm

3. Remove bolts (10) (6 used) from step (8). Remove

step (8) from brackets (11, 9) and hydraulic oil
tank (4).
: 19 mm

4. Remove bolts (12) (14 used) from steps (13, 15,

and 17). Remove steps (13, 15, and 17) from 12
brackets (14, 16, and 18).
: 19 mm

W18J-02-04-002

18 17 16 15 14 13

W2-4-17
 UPPERSTRUCTURE / Control Valve
5. Remove bolts (19) (2 used) from plate (20). 19 20 21 22 11
Remove plate (20) and spacers (22) (2 used) from
hose (21) and bracket (24).
: 19 mm 23

6. Remove bolts (23) (2 used) from bracket (11).

Remove the bracket (11) assembly from bracket
(14).
: 19 mm
24 14 W18J-02-04-003

7. Remove bolts (27) (2 used) from clamp (28). 4

Remove clamp (28) from pipe (26).
: 17 mm

8. Remove coupling (25) from hydraulic oil tank (4)

and pipe (26). Cap the open ends.
25
: 13 mm

26

27

W18J-02-04-004
28

9. Remove socket bolts (30) (4 used) from pipe (26). 26 21, 29

Disconnect pipe (26) from swing control valve (31).
Cap the open ends.
: 10 mm

10. Disconnect hose (21) from swing control valve

(31) and pipe (29). Cap the open ends.
: 41 mm

31 30 W18J-02-04-005

W2-4-18
 UPPERSTRUCTURE / Control Valve
11. Remove socket bolts (33) (12 used) from pipes 32
(32) (3 used). Disconnect pipes (32) (3 used) from
swing control valve (31).
: 12 mm

31 33 W18J-02-04-005

34, 35, 36 32
12. Remove socket bolts (38) (12 used) and split
flanges (39) (6 used) from hoses (37) (3 used).
Disconnect hoses (37) (3 used) from pipes (32) (3 37
used). Cap the open ends.
: 12 mm

13. Remove bolts (34) (6 used), spring washers (35)

(6 used), and washers (36) (6 used) from clamps
(40) (6 used). Disconnect pipes (32) (3 used) and
remove clamps (40) (6 used) from bracket (41). 40 38, 39
W18J-02-04-002

: 19 mm
40 34, 35, 36

41

32 W18J-02-04-003

14. Remove socket bolts (42) (8 used) from pipes (43) 42

(2 used). Disconnect pipes (43) (2 used) from
swing control valve (31).
: 12 mm

43

31

W18J-02-04-005

W2-4-19
 UPPERSTRUCTURE / Control Valve
15. Remove bolts (45) (2 used) and spring washers 44 45, 46 43 47, 48 49
(46) (2 used) from clamp (44). Remove clamp (44),
rubber (53), and spacer (54) from pipes (43) (2
used) and bracket (52).
: 22 mm

16. Remove bolts (47) (2 used) and spring washers

(48) (2 used) from clamp (49). Remove clamp (49)
and plate (50) from pipes (43) (2 used) and
bracket (51).
: 22 mm 53, 54 52 51 50
W18J-02-04-010

17. Disconnect pipes (43) (2 used) from swing control

valve (31). Cap the open ends.

18. Remove socket bolts (57) (4 used) and split

flanges (55) (2 used) from hose (58). Disconnect 43 55
hose (57) from line filter (56). Cap the open ends.
: 12 mm

CAUTION: Line filter (56) weight: 25 kg (55 lb)

19. Attach a nylon sling onto line filter (56). Hoist and
hold line filter (56). Remove socket bolts (59) (4 56
used) from line filter (56). Remove line filter (56)
from swing control valve (31).
: 12 mm
57

58

31 59 W18J-02-04-005

W2-4-20
 UPPERSTRUCTURE / Control Valve
20. Disconnect pilot hoses (62) (9 used) from swing 60, 61
control valve (31). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm

CAUTION: Swing control valve (31) weight:

150 kg (340 lb)

21. Remove bolts (60) (3 used) and washers (61) (3

used) from swing control valve (31). Remove
swing control valve (31) from main frame (63).
: 24 mm

63 31 62 W18J-02-04-005

W2-4-21
 UPPERSTRUCTURE / Control Valve
Installation of Swing Control Valve

CAUTION: Swing control valve (31) weight:

150 kg (340 lb)

1. Attach a nylon sling onto swing control valve (31).

Hoist swing control valve (31). Fit swing control 60, 61
valve (31) to the mounting hole on main frame
(63).

2. Install swing control valve (31) to main frame (63)

with bolts (60) (3 used) and washers (61) (3
used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

3. Connect pilot hoses (62) (9 used) onto swing

control valve (31).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

63 31 62 W18J-02-04-005

CAUTION: Line filter (56) weight: 25 kg (55 lb)

4. Attach a nylon sling onto line filter (56). Hoist line 55

filter (56). Fit line filter (56) to the mounting holes
on swing control valve (31).

5. Install line filter (56) to swing control valve (31)

with socket bolts (59) (4 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 56

6. Connect hose (58) to line filter (56) with split

flanges (55) (2 used) and socket bolts (57) (4
used).
: 12 mm 57
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 58

31 59 W18J-02-04-005

W2-4-22
 UPPERSTRUCTURE / Control Valve
7. Connect pipes (43) (2 used) to swing control valve 42
(31) with socket bolts (42) (8 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

43

W18J-02-04-005
31

8. Install pipes (43) (2 used) to bracket (51) with

44 45, 46 43 47, 48 49
plate (50), clamp (49), spring washers (48) (2
used), and bolts (47) (2 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

9. Install pipes (43) (2 used), spacer (54), rubber

(53), and clamp (44) to bracket (52) with bolts (45)
(2 used) and spring washers (46) (2 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
W18J-02-04-010
53, 54 52 51 50
10. Connect pipes (32) (3 used) to swing control valve
(31) with socket bolts (33) (12 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
32

31 33 W18J-02-04-005

W2-4-23
 UPPERSTRUCTURE / Control Valve
11. Connect hoses (37) (3 used) to pipes (32) (3 34, 35, 36 32
used) with split flanges (39) (6 used) and socket
bolts (38) (12 used). 37
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

12. Connect pipes (32) (3 used) to bracket (41) with

clamps (40) (6 used), spring washers (35) (6
used), washers (36) (6 used), and bolts (34) (6
used). W18J-02-04-002

: 19 mm 40 38, 39
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 40 34, 35, 36

41

32 W18J-02-04-003

13. Connect hose (21) to swing control valve (31) and 21, 29
pipe (29).
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

31 W18J-02-04-005

14. Install the bracket (11) assembly to bracket (14) 19 20 21 22 11

with bolts (23) (2 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 23

15. Install hose (21) to bracket (24) with spacers (22)

(2 used), plate (20), and bolts (19) (2 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

24 14 W18J-02-04-003

W2-4-24
 UPPERSTRUCTURE / Control Valve
16. Connect pipe (26) to swing control valve (31) with 26
socket bolts (30) (4 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

31 30 W18J-02-04-005

4
17. Connect pipe (26) to hydraulic oil tank (4) with
coupling (25).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

18. Secure pipe (26) to hydraulic oil tank (4) with 25

clamp (28) and bolts (27) (2 used).
: 17 mm 26
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
27
CAUTION: Tool box (2) weight: 22 kg (49 lb)
W18J-02-04-004

19. Attach a nylon sling onto tool box (2). Hoist tool 28
box (2). Fit tool box (2) to the mounting holes on
cover (1), hydraulic oil tank (4), and bracket (11).
1 2, 3 4
20. Install tool box (2) to cover (1), hydraulic oil tank
(4), and bracket (11) with bolts (3) (5 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

21. Install tool box (2) to bracket (11) with bolts (7) (2 7
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-04-001
11

W2-4-25
 UPPERSTRUCTURE / Control Valve
22. Install handrail (5) to hydraulic oil tank (4) and tool
box (2) with bolts (6) (4 used). 2 4 5
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

23. Install step (8) to brackets (9, 11) with bolts (10) (6 6
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 8, 9

10

W18J-02-04-001
11

24. Install steps (13, 15, and 17) to brackets (14, 16, 12
and 18) with bolts (12) (14 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-04-002

18 17 16 15 14 13

W2-4-26
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-4-27
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE (SIDE OF 4-SPOOL HOUSING)

11
10
9
8
7

12

6
5
4
2 3
43
Check Valve

1 37
36
35
34
33
13
14
26 Load Check
15 32 Valve
16 31 38
30 39
29 40
17 28
18
27 42
19 41
44
21 31
22 30
20 23 29
25
24 24 28
Arm Flow Rate 25 23 27
Control Valve 22 26
(Selector Valve) 53 52 21
51 48
50
49
45 18
54 46 19 17
55 47
56 20 16
60 15 Boom Flow Rate
62 Control Valve
58 14 (Selector Valve)
59
57 64 13
61
Boom Anti-Drift Valve
(Selector Valve) 63 66
65 W18J-02-04-025

W2-4-28
 UPPERSTRUCTURE / Control Valve

1- Socket Bolt (4 Used) 18 - O-Ring (2 Used) 35 - O-Ring 51 - Spring

2- Flange 19 - Cover (2 Used) 36 - Spring 52 - O-Ring
3- Backup Ring 20 - Socket Bolt (8 Used) 37 - Check Valve 53 - Cap
4- O-Ring 21 - Spool (2 Used) 38 - O-Ring 54 - Cap
5- Spring 22 - Guide (2 Used) 39 - Backup Ring 55 - O-Ring
6- Poppet 23 - Spring (2 Used) 40 - Cap 56 - Piston
7- Manifold 24 - O-Ring (2 Used) 41 - Cap 57 - Socket Bolt (4 Used)
8- Cap 25 - Cap (2 Used) 42 - O-Ring 58 - Backup Ring
9- O-Ring 26 - O-Ring (2 Used) 43 - Housing 59 - O-Ring
10 - Cap 27 - O-Ring (2 Used) 44 - Poppet 60 - Sleeve
11 - O-Ring 28 - Piston (2 Used) 45 - Poppet 61 - Backup Ring
12 - O-Ring 29 - Spring Guide (2 Used) 46 - Spring 62 - O-Ring
13 - Cap (4 Used) 30 - Spring (2 Used) 47 - O-Ring 63 - Poppet
14 - O-Ring (2 Used) 31 - Check Valve (2 Used) 48 - O-Ring (3 Used) 64 - Spring
15 - Spring (2 Used) 32 - Poppet 49 - Cover 65 - O-Ring
16 - Check Valve (2 Used) 33 - Cap 50 - Check Valve 66 - Cap
17 - Cap (2 Used) 34 - Backup Ring

W2-4-29
 UPPERSTRUCTURE / Control Valve

12

6
5
4
2 3
43
Check Valve

13
14
26 Load Check
15 32 Valve
16 31
30
29
17 28
18
27
19
44
21 31
22 30
20 23 29
25
24 24 28
Arm Flow Rate 25 23 27
Control Valve 22 26
(Selector Valve) 21

18
19 17
20 16
15 Boom Flow Rate
Control Valve
14 (Selector Valve)
13
Boom Anti-Drift Valve
(Selector Valve)
W18J-02-04-025

W2-4-30
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve
(Side of 4-Spool Housing)

Disassembly of Check Valve

1. Remove socket bolts (1) (4 used) from flange (2).
Remove flange (2), backup ring (3), O-ring (4),
spring (5), and poppet (6) from manifold (7).
: 12 mm
2. Remove manifold (7) and O-ring (12) from
housing (43).
Disassembly of Arm Flow Rate Control Valve
3. Remove socket bolts (20) (4 used) from cover
(19). Remove cover (19) and O-rings (26, 27)
from housing (43).
: 12 mm
4. Remove piston (28), spring guide (29), spring (30),
check valve (31), and poppet (32) from housing
(43).
5. Remove cap (25), spring (23), guide (22), and
spool (21) from cover (19). Remove O-ring (24)
from cap (25).
: 30 mm
6. Remove cap (13), spring (15), and check valve
(16) from cover (19). Remove O-ring (14) from
cap (13).
: 5 mm
Disassembly of Boom Flow Rate Control Valve
8. Remove socket bolts (20) (4 used) from cover
(19). Remove cover (19) and O-rings (26, 27)
from housing (43).
: 12 mm
9. Remove piston (28), spring guide (29), spring (30),
check valve (31), and poppet (44) from housing
(43).
10. Remove cap (25), spring (23), guide (22), and
spool (21) from cover (19). Remove O-ring (24)
from cap (25).
: 30 mm
11. Remove cap (13), spring (15), and check valve
(16) from cover (19). Remove O-ring (14) from
cap (13).
: 5 mm
12. Remove cap (17) from cover (19).
Remove O-ring (18) from cap (17).
: 5 mm

7. Remove cap (17) from cover (19).

Remove O-ring (18) from cap (17).
: 5 mm

W2-4-31
 UPPERSTRUCTURE / Control Valve

11
10
9
8

43
Check Valve
37
36
35
34
33

Load Check
Valve
38
39
40

42
41

Arm Flow Rate

Control Valve
(Selector Valve) 53 52
51 48
50
49
45
54 46
55 47
56
60 Boom Flow Rate
62 Control Valve
58 (Selector Valve)
59
57 64
61
Boom Anti-Drift Valve
(Selector Valve) 63 66
65 W18J-02-04-025

W2-4-32
 UPPERSTRUCTURE / Control Valve
Disassembly of Boom Anti-Drift Valve Disassembly of Load Check Valve
13. Remove socket bolts (57) (4 used) from cover 19. Remove cap (33), spring (36), and check valve
(49). Remove cover (49) and O-rings (48) (3 (37) from housing (43). Remove backup ring (34)
used), and O-ring (47) from housing (43). and O-ring (35) from cap (33).
: 12 mm : 14 mm

14. Remove spring (46) and poppet (45) from housing 20. When replacing O-ring (38), remove cap (40) from
(43). housing (43).

15. Remove cap (66), spring (64), and poppet (63) 21. When replacing O-ring (42), remove cap (41) from
from cover (49). Remove O-ring (65) from cap housing (43).
(66).
: 8 mm 22. When replacing O-ring (11), remove cap (10) from
housing (43).
16. Remove cap (54) and piston (56) from cover (49).
Remove O-ring (55) from cap (54).
: 30 mm

17. Insert a pipe (inner diameter: 7 mm (0.28 in),

outer diameter: 10 mm (0.39 in), length: 15 mm
(0.59 in)) from the mounting hole of cap (54). Tap
and remove sleeve (60) from the mounting hole of
cap (66). Remove backup rings (58, 61) and
O-rings (59, 62) from sleeve (60).

18. Remove cap (53), spring (51), and check valve

(50) from cover (49). Remove O-ring (52) from
cap (53).
: 5 mm

W2-4-33
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE (SIDE OF 4-SPOOL HOUSING)
3, 4, 5, 6, 7, 12
Arm Flow Rate 7
1 20 Control Valve
10 8, 9
11

20
43
43
Boom Flow Rate
Control Valve 12
Check Load Check Valve
Valve
57
2
Boom Anti-Drift Valve

8, 9 10, 11 Section of Check Valve

External View of Control Valve Right Side Boom Flow Rate Control Valve
Boom Anti-Drift Valve (Refer to the Closeup.)
(Refer to the Closeup.)
Arm Flow Rate Control Valve
43 (Refer to the Closeup.)
43

Sections of Boom Flow Rate Control Valve and

Section of Arm Flow Rate Control Valve Boom Anti-Drift Valve

24 22 21 19 13 15 19 55 56 58, 59 60 61, 62 64
18 54 65
25
17 66

63
23 28
29 53
49
30 52
14 16 26 27
43 47
31 32, 34
Closeups of Boom and Arm
Flow Rate Control Valves 46

34, 35 33 36 37 51

43 45

50 48
Closeup of Boom Anti-Drift Valve

Section of Load Check Valve

W18J-02-04-042

W2-4-34
 UPPERSTRUCTURE / Control Valve

1- Socket Bolt (4 Used) 18 - O-Ring (2 Used) 35 - O-Ring 51 - Spring

2- Flange 19 - Cover (2 Used) 36 - Spring 52 - O-Ring
3- Backup Ring 20 - Socket Bolt (8 Used) 37 - Check Valve 53 - Cap
4- O-Ring 21 - Spool (2 Used) 38 - O-Ring 54 - Cap
5- Spring 22 - Guide (2 Used) 39 - Backup Ring 55 - O-Ring
6- Poppet 23 - Spring (2 Used) 40 - Cap 56 - Piston
7- Manifold 24 - O-Ring (2 Used) 41 - Cap 57 - Socket Bolt (4 Used)
8- Cap 25 - Cap (2 Used) 42 - O-Ring 58 - Backup Ring
9- O-Ring 26 - O-Ring (2 Used) 43 - Housing 59 - O-Ring
10 - Cap 27 - O-Ring (2 Used) 44 - Poppet 60 - Sleeve
11 - O-Ring 28 - Piston (2 Used) 45 - Poppet 61 - Backup Ring
12 - O-Ring 29 - Spring Guide (2 Used) 46 - Spring 62 - O-Ring
13 - Cap (4 Used) 30 - Spring (2 Used) 47 - O-Ring 63 - Poppet
14 - O-Ring (2 Used) 31 - Check Valve (2 Used) 48 - O-Ring (3 Used) 64 - Spring
15 - Spring (2 Used) 32 - Poppet 49 - Cover 65 - O-Ring
16 - Check Valve (2 Used) 33 - Cap 50 - Check Valve 66 - Cap
17 - Cap (2 Used) 34 - Backup Ring

W2-4-35
 UPPERSTRUCTURE / Control Valve

Arm Flow Rate

20 Control Valve

20
43
Boom Flow Rate
Control Valve
Load Check Valve

Boom Anti-Drift Valve

External View of Control Valve Section of Check Valve

Right Side
Boom Flow Rate Control Valve
Boom Anti-Drift Valve (Refer to the Closeup.)
Arm Flow Rate Control Valve (Refer to the Closeup.)
43 (Refer to the Closeup.)
43

Section of Arm Flow Rate Control Valve Section of Boom Flow Rate Control Valve and
Boom Anti-Drift Valve

24 22 21 19 13 15 19
18
25
17

23 28
29
30
14 16 26 27
31 32, 34
Closeups of Boom and Arm Flow
Rate Control Valves

34, 35 33 36 37

43

Closeup of Boom Anti-Drift Valve

Section of Load Check Valve

W18J-02-04-042

W2-4-36
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve
(Side of 4-Spool Housing)

Assembly of Load Check Valve
1. Install O-ring (35) and backup ring (34) to cap (33).
Install check valve (37), spring (36), and cap (33)
to housing (43).
: 14 mm
: 350 N⋅m (36 kgf⋅m, 260 lbf⋅ft)
Assembly of Arm Flow Rate Control Valve
2. Install poppet (32), check valve (31), spring (30),
spring guide (29), and piston (28) to housing (43).
3. Install O-ring (18) to cap (17). Install cap (17) to
cover (19).
: 5 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
4. Install O-ring (24) to cap (25). Install spool (21),
guide (22), spring (23), and cap (25) to cover (19).
: 30 mm
: 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft)
5. Install O-ring (14) to cap (13). Install check valve
(16), spring (15), and cap (13) to cover (19).
: 5 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
Assembly of Boom Flow Rate Control Valve
7. Install poppet (44), check valve (31), spring (30),
spring guide (29), and piston (28) to housing (43).
8. Install O-ring (18) to cap (17). Install cap (17) to
cover (19).
: 5 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
9. Install O-ring (24) to cap (25). Install spool (21),
guide (22), spring (23), and cap (25) to cover (19).
: 30 mm
: 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft)
10. Install O-ring (14) to cap (13). Install check valve
(16), spring (15), and cap (13) to cover (19).
: 5 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
11. Install O-rings (26, 27) to cover (19). Install cover
(19) to housing (43) with socket bolts (20) (4
used).
: 12 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)

6. Install O-rings (26, 27) to cover (19). Install cover

(19) to housing (43) with socket bolts (20) (4
used).
: 12 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)

W2-4-37
 UPPERSTRUCTURE / Control Valve

3, 4, 5, 6, 7, 12
Arm Flow Rate 7
1 20 Control Valve

20
43
Boom Flow Rate
Control Valve
Check Load Check Valve
Valve
57
2
Boom Anti-Drift Valve

External View of Control Valve Section of Check Valve

Right Side
Boom Anti-Drift Valve Boom Flow Rate Control Valve
(Refer to the Closeup.) (Refer to the Closeup.)
Arm Flow Rate Control Valve
(Refer to the Closeup.)
43

Sections of Boom Flow Rate Control Valve and

Section of Arm Flow Rate Control Valve Boom Anti-Drift Valve

55 56 58, 59 60 61, 62 64
54 65

66

63

53
49
52

43 47
Closeups of Boom and Arm Flow
Rate Control Valves 46

51

45

50 48
Closeup of Boom Anti-Drift Valve

Section of Load Check Valve

W18J-02-04-042

W2-4-38
 UPPERSTRUCTURE / Control Valve
Assembly of Boom Anti-Drift Valve Assembly of Check Valve
12. Install poppet (45) and spring (46) to housing (43). 18. Install O-rings (4, 12), poppet (6), spring (5),
backup ring (3), and flange (2) to manifold (7).
13. Install O-rings (59, 62) and backup rings (58, 61)
to sleeve (60). Install sleeve (60) to cover (49). 19. Install the manifold (7) assembly to housing (43)
with socket bolts (1) (4 used).
14. Install O-ring (65) to cap (66). Install poppet (63), : 12 mm
spring (64), and cap (66) to cover (49). : 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)
: 8 mm 1
: 50 N⋅m (5.1 kgf⋅m, 36 lbf⋅ft) 2
5
15. Install O-ring (55) to cap (54). Install piston (56) 3
and cap (54) to cover (49). 6
: 30 mm 4
: 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft)

16. Install O-ring (52) to cap (53). Install check valve

(50), spring (51), and cap (53) to cover (49). 12 7
: 5 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
W18J-02-04-034

17. Install O-ring (47) and O-rings (48) (3 used) to

cover (49). Install cover (49) to housing (43) with
socket bolts (57) (4 used).
: 12 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)

W2-4-39
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE (SIDE OF 5-SPOOL HOUSING)

2 3 4

1 5
6

11
10
9
8
7 Load Check
Valve-5

19 18
17 15
16
20 12 Load Check Valve-4
13
21 14
22 26
28 Load Check Valve-3
23
30
25 32 Load Check Valve-2
24
27
Arm Anti-Drift Valve 29
(Selector Valve) 31 Load Check Valve-1
33
34
35
36
37
38
43
42
39 41
40

W18J-02-04-023

W2-4-40
 UPPERSTRUCTURE / Control Valve

1- Socket Bolt (8 Used) 12 - Poppet 23 - Cover 34 - Check Valve (4 Used)

2- Flange (2 Used) 13 - Spring 24 - Socket Bolt (4 Used) 35 - Spring (4 Used)
3- O-Ring (2 Used) 14 - O-Ring 25 - Backup Ring 36 - Check Valve (4 Used)
4- Housing 15 - O-Ring (4 Used) 26 - O-Ring 37 - O-Ring (4 Used)
5- O-Ring 16 - Check Valve 27 - Sleeve 38 - Cap (4 Used)
6- Cap 17 - Spring 28 - Backup Ring 39 - Backup Ring (4 Used)
7- Cap 18 - O-Ring 29 - O-Ring 40 - Cap
8- Backup Ring 19 - Cap 30 - Poppet 41 - O-Ring
9- O-Ring 20 - Cap 31 - Spring 42 - Cap
10 - Spring 21 - O-Ring 32 - O-Ring 43 - O-Ring
11 - Check Valve 22 - Piston 33 - Cap

W2-4-41
 UPPERSTRUCTURE / Control Valve

2 3 4

11
10
9
8
7 Load Check
Valve-5

19 18
17 15
16
20 12 Load Check Valve-4
13
21 14
22 26
28 Load Check Valve-3
23
30
25 32 Load Check Valve-2
24
27
Arm Anti-Drift Valve 29
(Selector Valve) 31 Load Check Valve-1
33
34
35
36
37
38
43
42
39 41
40

W18J-02-04-023

W2-4-42
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve
(Side of 5-Spool Housing)
Disassembly of Load Check Valve-1
1. Remove cap (38), spring (35), and check valves
(34, 36) from housing (4). Remove backup ring
(39) and O-ring (37) from cap (38).
: 14 mm
Disassembly of Load Check Valve-2
2. Remove cap (38), spring (35), and check valves
(34, 36) from housing (4). Remove backup ring
(39) and O-ring (37) from cap (38).
: 14 mm
Disassembly of Load Check Valve-3
3. Remove cap (38), spring (35), and check valves
(34, 36) from housing (4). Remove backup ring
(39) and O-ring (37) from cap (38).
: 14 mm
Disassembly of Load Check Valve-4
4. Remove cap (38), spring (35), and check valves
(34, 36) from housing (4). Remove backup ring
(39) and O-ring (37) from cap (38).
: 14 mm
Disassembly of Load Check Valve-5
5. Remove cap (7), spring (10), and check valve (11)
from housing (4). Remove backup ring (8) and
O-ring (9) from cap (7).
: 14 mm
W2-4-43
Disassembly of Arm Anti-Drift Valve
6. Remove socket bolts (24) (4 used) from cover
(23). Remove cover (23), O-rings (15) (4 used),
and O-ring (14) from housing (4).
: 12 mm
7. Remove spring (13) and poppet (12) from housing
(4).
8. Remove cap (33), spring (31), and poppet (30)
from cover (23). Remove O-ring (32) from cap
(33).
: 8 mm
9. Remove cap (20) and piston (22) from cover (23).
Remove O-ring (21) from cap (20).
: 30 mm
10. Insert a pipe (inner diameter: 7 mm (0.28 in),
outer diameter: 10 mm (0.39 in), length: 15 mm
(0.59 in)) from the mounting hole of cap (20). Tap
and remove sleeve (27) from the mounting hole of
cap (33).
11. Remove cap (19), spring (17), and check valve
(16) from cover (23). Remove O-ring (18) from
cap (19).
: 5 mm
12. When replacing O-rings (3) (2 used), remove
socket bolts (1) (8 used) from flanges (2) (2 used).
13. When replacing O-rings (41, 43), remove caps (40,
42) from housing (4).
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE (SIDE OF 5-SPOOL HOUSING)
Load Check Load Check Arm Anti Drift Load Check
Valve-2 Valve-3 Valve Valve-4 4 40, 41 42
Load Check 2, 3
Valve-1
Load Check 43
Valve-5

2, 3
4
1
Section A
A External View of Control Valve
24
Right Side
8, 9 7
37, 39 38 36 35
10 4

4 11

34
Section of Load Check Valve-1 Section of Load Check Valve-5

38 36 37, 39
37, 39 38 36 35
Arm Anti-Drift Valve
(Refer to the Closeup.)
4 35

34
34
4
Section of Load Check Valve-3 Section of Arm Anti Drift Valve and
Load Check Valve-4

21 22 25, 26 27 28, 29 31

37, 39 38 36 34 20 32

4 17 30

33
19
23, 24
4 14

15
18
Section of Load Check Valve-2 13

12
16
Closeup of Arm Anti-Drift Valve W18J-02-04-041

W2-4-44
 UPPERSTRUCTURE / Control Valve

1- Socket Bolt (8 Used) 12 - Poppet 23 - Cover 34 - Check Valve (4 Used)

2- Flange (2 Used) 13 - Spring 24 - Socket Bolt (4 Used) 35 - Spring (4 Used)
3- O-Ring (2 Used) 14 - O-Ring 25 - Backup Ring 36 - Check Valve (4 Used)
4- Housing 15 - O-Ring (4 Used) 26 - O-Ring 37 - O-Ring (4 Used)
5- O-Ring 16 - Check Valve 27 - Sleeve 38 - Cap (4 Used)
6- Cap 17 - Spring 28 - Backup Ring 39 - Backup Ring (4 Used)
7- Cap 18 - O-Ring 29 - O-Ring 40 - Cap
8- Backup Ring 19 - Cap 30 - Poppet 41 - O-Ring
9- O-Ring 20 - Cap 31 - Spring 42 - Cap
10 - Spring 21 - O-Ring 32 - O-Ring 43 - O-Ring
11 - Check Valve 22 - Piston 33 - Cap

W2-4-45
 UPPERSTRUCTURE / Control Valve

Load Check Load Check Arm Anti Drift Load Check

Valve-2 Valve-3 Valve Valve-4

Load Check
Valve-1
Load Check
Valve-5

Section A
A External View of Control Valve
Right Side
8, 9 7
37, 39 38 36 35
10 4

4 11

34
Section of Load Check Valve-1 Section of Load Check Valve-5

38 36 37, 39
37, 39 38 36 35
Arm Anti-Drift Valve
(Refer to the Closeup.)
4 35

34
34
4
Section of Load Check Valve-3 Section of Arm Anti Drift Valve and
Load Check Valve-4

37, 39 38 36 34

Section of Load Check Valve-2

Closeup of Arm Anti-Drift Valve W18J-02-04-041

W2-4-46
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve
(Side of 5-Spool Housing)

Assembly of Load Check Valve-1 Assembly of Load Check Valve-5

1. Install O-ring (37) and backup ring (39) to cap (38).
Install check valves (34, 36), spring (35), and cap
(38) to housing (4).
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)
5. Install O-ring (9) and backup ring (8) to cap (7).
Install check valve (11), spring (10), and cap (7) to
housing (4).
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)

Assembly of Load Check Valve-2

2. Install O-ring (37) and backup ring (39) to cap (38).
Install check valves (34, 36), spring (35), and cap
(38) to housing (4).
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)

Assembly of Load Check Valve-3

3. Install O-ring (37) and backup ring (39) to cap (38).
Install check valves (34, 36), spring (35), and cap
(38) to housing (4).
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)

Assembly of Load Check Valve-4

4. Install O-ring (37) and backup ring (39) to cap (38).
Install check valves (34, 36), spring (35), and cap
(38) to housing (4).
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)

W2-4-47
 UPPERSTRUCTURE / Control Valve

Load Check Load Check Arm Anti Drift Load Check

Valve-2 Valve-3 Valve Valve-4

Load Check
Valve-5

Section A
A
24
External View of Control Valve
Right Side

Section of Load Check Valve-1 Section of Load Check Valve-5

Arm Anti-Drift Valve

(Refer to the Closeup.)
4

Section of Load Check Valve-3 Section of Arm Anti Drift Valve and
Load Check Valve-4

21 22 25, 26 27 28, 29 31

20 32

17 30

33
19
23, 24

4 14

15
18
Section of Load Check Valve-2 13
12
16
Closeup of Arm Anti-Drift Valve
W18J-02-04-041

W2-4-48
 UPPERSTRUCTURE / Control Valve
Assembly of Arm Anti-Drift Valve
6. Install poppet (12) and spring (13) to housing (4).

7. Install O-rings (26, 29) and backup rings (25, 28)

to sleeve (27). Install sleeve (27) to cover (23).

8. Install O-ring (32) to cap (33). Install poppet (30),

spring (31), and cap (33) to cover (23).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 36 lbf⋅ft)

9. Install O-ring (21) to cap (20). Install piston (22)

and cap (20) to cover (23).
: 30 mm
: 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft)

10. Install O-ring (18) to cap (19). Install check valve

(16), spring (17), and cap (19) to cover (23).
: 5 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

11. Install O-ring (14) and O-rings (15) (3 used) to

cover (23). Install cover (23) to housing (4) with
socket bolts (24) (4 used).
: 12 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)

W2-4-49
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE (TOP AND BOTTOM SIDES OF 4-SPOOL HOUSING)
1
2
3
4 Arm Regenerative
5 Valve
6
7
8
12 9
10
13
14
15
16 11
71
17
18

12
13 13
12

19 29
30
20 31
Flow 21 32
33
Combiner 22 34
Valve 23 35
24 36
37
Check 25 59 38
70 Valve-2 26 58 39
69 27 40
68 28 57
41
67 56 42
66 60 55 43
47 61 54 44
62 53 45
48 63
49 52 46
64 51
50 50
51 Main Relief
52 65 49 Valve
Overload Relief 53 48
Valve 54
55 Check Valve-1
47
56 66
67
57 68 Overload
58 69 Relief Valve
59 70

W18J-02-04-024

W2-4-50
 UPPERSTRUCTURE / Control Valve

1- Sleeve 19 - Cap 37 - O-Ring 55 - Main Poppet (4 Used)

2- O-Ring 20 - O-Ring 38 - Cap 56 - Sleeve (4 Used)
3- Backup Ring 21 - Spring 39 - Lock Nut 57 - O-Ring (4 Used)
4- Piston 22 - Spacer 40 - O-Ring 58 - Backup Ring (4 Used)
5- Spool 23 - Spool 41 - O-Ring 59 - O-Ring (4 Used)
6- O-Ring 24 - Cap 42 - Sleeve 60 - Check Valve
7- Sleeve 25 - Backup Ring 43 - Piston 61 - Spring
8- Spring 26 - O-Ring 44 - Lock Nut 62 - O-Ring
9- Spring Guide 27 - Spring 45 - O-Ring 63 - Backup Ring
10 - O-Ring 28 - Check Valve 46 - Adjusting Screw 64 - O-Ring
11 - Cap 29 - Sleeve 47 - Seat (4 Used) 65 - Cap
12 - Cap (3 Used) 30 - Main Poppet 48 - Spring (4 Used) 66 - Pilot Poppet (4 Used)
13 - O-Ring (3 Used) 31 - Spring 49 - O-Ring (4 Used) 67 - Spring (4 Used)
14 - Plug 32 - O-Ring 50 - Backup Ring (4 Used) 68 - O-Ring (4 Used)
15 - Backup Ring 33 - Backup Ring 51 - Backup Ring (4 Used) 69 - Adjusting Screw (4 Used)
16 - O-Ring 34 - Pilot Seat 52 - O-Ring (4 Used) 70 - Lock Nut (4 Used)
17 - Cap 35 - Pilot Poppet 53 - Spring (4 Used) 71 - Housing
18 - O-Ring 36 - Spring 54 - Piston (4 Used)

W2-4-51
 UPPERSTRUCTURE / Control Valve

1
2
3
4 Arm Regenerative
5 Valve
6
7
8
9
10

11
71

Flow
Combiner
Valve

Check 59
70 Valve-2 58
69 57
68
67 56
66 60 55
47 61 54
62 53
48 63
49 52
64 51
50 50
51 Main Relief
52 65 49 Valve
Overload Relief 53 48
Valve 54
55 Check Valve-1
47
56 66
67
57 68 Overload
58 69 Relief Valve
59 70

W18J-02-04-024

W2-4-52
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve
(Top and Bottom Sides of 4-Spool Housing)
Disassembly of Overload Relief Valve
IMPORTANT: Do not disassemble the overload
relief valve unless necessary. When
the overload relief valve has been
disassembled, adjust the pressure.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
1. Remove the sleeve (56) assembly (47 to 59, 66 to
70) from housing (71).
: 41 mm
2. Secure sleeve (56) in a vise. Remove the seat
(47) assembly (47 to 51, 66 to 70) from sleeve
(56). Remove springs (48, 53), piston (54), and
poppet (55) from sleeve (56).
: 36 mm
IMPORTANT: Put the matching marks onto ad-
justing screw (69) and seat (47).
Record a turning number of the ad-
justing screw (69).
3. Loosen lock nut (70). Remove adjusting screw
(69), spring (67), and pilot poppet (66) from seat
(47).
: 19 mm
: 6 mm, 10 mm
W2-4-53
Disassembly of Arm Regenerative Valve
4. Remove the sleeve (7) assembly (1 to 11) from
housing (71).
: 46 mm
5. Secure sleeve (7) in a vise. Remove cap (11) from
sleeve (7). Remove O-ring (10) from cap (11).
: 14 mm
NOTE: Cap (11) is kept pushed outward by spring
(8). Remove cap (11) while pushed against
sleeve (7).
6. Remove spring guide (9), spring (8), and spool (5)
from sleeve (7).
7. Remove sleeve (1) and piston (4) from sleeve (7).
Remove backup ring (3) and O-ring (2) from
sleeve (1).
Disassembly of Check Valve-1
8. Remove cap (65), check valve (60), and spring
(61) from housing (71). Remove backup ring (63)
and O-rings (62, 64) from cap (65).
: 14 mm
 UPPERSTRUCTURE / Control Valve

Arm Regenerative
Valve

71

19 29
30
20 31
Flow 21 32
Combiner 33
22 34
Valve 23 35
24 36
37
Check 25 38
Valve-2 26 39
27 40
28 41
42
43
44
45
46
Main Relief
Valve
Overload Relief
Valve
Check Valve-1

Overload
Relief Valve

W18J-02-04-024

W2-4-54
 UPPERSTRUCTURE / Control Valve
Disassembly of Check Valve-2
9. Remove cap (24), check valve (28), and spring
(27) from housing (71). Remove backup ring (25)
and O-ring (26) from cap (24).
: 14 mm
Disassembly of Main Relief Valve
IMPORTANT: Do not disassemble the main relief
valve unless necessary. When the
main relief valve has been disas-
sembled, adjust the pressure.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
10. Remove the cap (38) assembly (29 to 46) from
housing (71).
: 41 mm
IMPORTANT: Put the matching marks onto sleeve
(42), lock nut (39), and cap (38). Re-
cord a turning number of sleeve (42).
14. Loosen lock nut (39). Remove sleeve (42) from
cap (38). Remove O-rings (40, 41) from sleeve
(42).
: 41 mm
Disassembly of Flow Combiner Valve
15. Remove cap (19), spring (21), spacer (22), and
spool (23) from housing (71). Remove O-ring (20)
from cap (19).
: 46 mm

IMPORTANT: As pilot seat (34) is installed to cap

(38), do not disassemble pilot seat
(34).
11. Remove sleeve (29) from cap (38). Remove
spring (31) and main poppet (30) from sleeve
(29).

IMPORTANT: Put the matching marks onto ad-

justing screw (46), lock nut (44), and
sleeve (42). Record a turning num-
ber of adjusting screw (46).
12. Loosen lock nut (44). Remove adjusting screw
(46) from sleeve (42). Remove piston (40), spring
(36), and poppet (35) from sleeve (42).
: 22 mm, 30 mm

13. Remove O-ring (45) and lock nut (44) from ad-
justing screw (46).

W2-4-55
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE (TOP AND BOTTOM SIDES OF 4-SPOOL HOUSING)
Check Valve-2 69
Overload Arm Regenerative Overload
Check Valve-1 Relief Valve Valve Relief Valve Flow 70
Combiner 47
Valve 68
Main Relief
Valve
49 56

67 66

50, 51, 52 48

71 57 53

54

58, 59 55
External View of Control Valve External View of Control Valve Closeup of Overload Relief Valve
Top Side Bottom Side

Overload Arm Regenerative Valve Overload

Relief Valve (Refer to the Closeup.) Relief Valve

71 71

71

Main Relief Valve Overload Relief

(Refer to the Closeup.) Overload Relief
Valve 11 Valve 46 44

10
Check Valve-1 71
42
65 7
39 45
64
61 9
6 38 41
62, 63 8
43 37
60
35 36
23 5
34 40
28
32, 33
27 22
2, 3 31
25, 26 21
4 30
20
Check 1 29
24 Valve-2 19
Flow Combiner Valve W18J-02-04-040

Section of Check Valve-1, Main Relief Valve, Closeup of Arm Regenerative Valve Closeup of Main Relief Valve
Check Valve-2, and Flow Combiner Valve

W2-4-56
 UPPERSTRUCTURE / Control Valve

1- Sleeve 19 - Cap 37 - O-Ring 55 - Main Poppet (4 Used)

2- O-Ring 20 - O-Ring 38 - Cap 56 - Sleeve (4 Used)
3- Backup Ring 21 - Spring 39 - Lock Nut 57 - O-Ring (4 Used)
4- Piston 22 - Spacer 40 - O-Ring 58 - Backup Ring (4 Used)
5- Spool 23 - Spool 41 - O-Ring 59 - O-Ring (4 Used)
6- O-Ring 24 - Cap 42 - Sleeve 60 - Check Valve
7- Sleeve 25 - Backup Ring 43 - Piston 61 - Spring
8- Spring 26 - O-Ring 44 - Lock Nut 62 - O-Ring
9- Spring Guide 27 - Spring 45 - O-Ring 63 - Backup Ring
10 - O-Ring 28 - Check Valve 46 - Adjusting Screw 64 - O-Ring
11 - Cap 29 - Sleeve 47 - Seat (4 Used) 65 - Cap
12 - *Cap (3 Used) 30 - Main Poppet 48 - Spring (4 Used) 66 - Pilot Poppet (4 Used)
13 - *O-Ring (3 Used) 31 - Spring 49 - O-Ring (4 Used) 67 - Spring (4 Used)
14 - *Plug 32 - O-Ring 50 - Backup Ring (4 Used) 68 - O-Ring (4 Used)
15 - *Backup Ring 33 - Backup Ring 51 - Backup Ring (4 Used) 69 - Adjusting Screw (4 Used)
16 - *O-Ring 34 - Pilot Seat 52 - O-Ring (4 Used) 70 - Lock Nut (4 Used)
17 - *Cap 35 - Pilot Poppet 53 - Spring (4 Used) 71 - Housing
18 - *O-Ring 36 - Spring 54 - Piston (4 Used)
NOTE: As for parts with mark*, refer to W2-4-28.

W2-4-57
 UPPERSTRUCTURE / Control Valve
69
Overload Overload Check Valve-2
Arm Regenerative
Check Valve-1 Relief Valve Valve Relief Valve Flow 70
Combiner 47
Main Relief Valve 68
Valve
49 56

67 66

50, 51, 52 48

71 57 53

54

58, 59 55
External View of Control Valve External View of Control Valve Closeup of Overload Relief Valve
Top Side Bottom Side

Overload Arm Regenerative Valve Overload

Relief Valve (Refer to the Closeup.) Relief Valve

71 71

71

Overload
Main Relief Valve Relief Valve Overload
(Refer to the Closeup.) 11 Relief Valve

10
Check Valve-1

9
6
8

2, 3

4
Check 1
Valve-2
Flow Combiner W18J-02-04-040
Valve
Section of Check Valve-1, Main Relief Valve, Closeup of Arm Regenerative Valve Closeup of Main Relief Valve
Check Valve-2, and Flow Combiner Valve

W2-4-58
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve
(Top and Bottom Sides of 4-Spool Housing)

Assembly of Overload Relief Valve Assembly of Arm Regenerative Valve

IMPORTANT: Turn adjusting screw (69) by the
same turning for disassembly. Fit
adjusting screw (69) to the matching
mark. Install adjusting screw (69).
1. Install pilot poppet (66), spring (67), adjusting
screw (69), and lock nut (70) to seat (47).
IMPORTANT: Cap (11) is kept pushed outward by
2. Install O-ring (57), backup ring (58), and O-ring
(57) to sleeve (56).
3. Install piston (54) to main poppet (55). Install main
poppet (55) to sleeve (56).
4. Secure sleeve (56) in a vise. Install springs (48,
58) to the seat (47) assembly. Install the seat (47)
assembly to sleeve (56).
: 36 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
6. Install O-ring (2) and backup ring (3) to sleeve (1).
Install piston (4) and sleeve (1) to sleeve (7).
7. Install spool (5), spring (8), and spring guide (9) to
sleeve (7).
spring (8). Install cap (11) to sleeve
(7) while pushed against sleeve (7).
8. Install O-ring (10) to cap (11). Secure sleeve (7) in
a vise. Install cap (11) to sleeve (7).
: 14 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)
9. Install O-ring (6) to sleeve (7). Install sleeve (7) to
housing (71).
: 46 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)

IMPORTANT: Install the overload relief valve to the

original position before disassembly.
Adjust the pressure of the overload
relief valve by using a test bench.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
5. Install the overload relief valves (4 used) to hous-
ing (71).
: 41 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
NOTE: Tighten the hexagonal part of sleeve (56).

W2-4-59
 UPPERSTRUCTURE / Control Valve

Overload Arm Regenerative Overload

Check Valve-1 Relief Valve Relief Valve Check Valve-2
Valve
Flow Combiner
Main Valve
Relief Valve

71

External View of Control Valve External View of Control Valve Closeup of Overload Relief Valve
Top Side Bottom Side

Overload Arm Regenerative Valve Overload

Relief Valve (Refer to the Closeup.) Relief Valve

Main Relief Valve Overload Overload

(Refer to the Closeup.) Relief Valve Relief Valve 46 44

Check Valve-1 71
42

39 45

38 41

43 37

35 36

34 40

32, 33

31

30
Check 29
Valve-2
Flow Combiner Valve W18J-02-04-040
Section of Check Valve-1, Main Relief Valve, Closeup of Arm Regenerative Valve Closeup of Main Relief Valve
Check Valve-2, and Flow Combiner Valve

W2-4-60
 UPPERSTRUCTURE / Control Valve
Assembly of Main Relief Valve
IMPORTANT: Turn sleeve (42) by the same turning
for disassembly. Fit sleeve (42) to
the matching mark. Install sleeve
(42).
10. Install lock nut (39) and O-rings (40, 41) to sleeve
(42). Install sleeve (42) to cap (38). Tighten lock
nut (39).
: 41 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
IMPORTANT: Adjust the pressure of the main re-
lief valve.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
17. Install the main relief valve to housing (71).
: 41 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
NOTE: Tighten the hexagonal part of cap (38).

11. Install poppet (35), spring (36), and piston (43) to

cap (38).

IMPORTANT: Turn adjusting screw (46) by the

same turning for disassembly. Fit
adjusting screw (46) to the matching
mark. Install adjusting screw (46).
12. Install lock nut (44) and O-ring (45) to adjusting
screw (46). Install adjusting screw (46) to sleeve
(42). Tighten lock nut (44).
: 30 mm
: 60 N⋅m (6 kgf⋅m, 44 lbf⋅ft)

13. Install backup ring (33) and O-ring (32) to pilot

seat (34).

14. Install main poppet (30) and spring (31) to sleeve

(29).

15. Install the sleeve (29) assembly to cap (38).

16. Install O-ring (37) to cap (38).

W2-4-61
 UPPERSTRUCTURE / Control Valve

Overload Arm Regenerative Overload Check Valve-2

Check Valve-1 Relief Valve Valve Relief Valve
Flow Combiner
Main Relief Valve
Valve

71

External View of Control Valve External View of Control Valve Closeup of Overload Relief Valve
Top Side Bottom Side

Overload Arm Regenerative Valve Overload

Relief Valve (Refer to the Closeup.) Relief Valve

Main Relief Valve Overload Relief

(Refer to the Closeup.) Overload Relief
Valve Valve

Check Valve-1 71

65
64
61
62, 63

60

23

28

27 22

25, 26 21

20
Check
24 Valve - 2 19
Flow Combiner W18J-02-04-040
Valve
Section of Check Valve-1, Main Relief Valve, Closeup of Arm Regenerative Valve Closeup of Main Relief Valve
Check Valve-2, Flow and Combiner Valve

W2-4-62
 UPPERSTRUCTURE / Control Valve
Assembly of Flow Combiner Valve
18. Install O-ring (20) to cap (19). Install spool (23),
spacer (22), spring (21), and cap (19) to housing
(71).
: 46 mm
: 250 N⋅m (26 kgf⋅m, 185 lbf⋅ft)

Assembly of Check Valve-1

19. Install O-rings (62, 64) and backup ring (63) to
housing (65). Install check valve (60), spring (61),
and cap (65) to housing (71).
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)

Assembly of Check Valve-2

20. Install O-ring (26) and backup ring (25) to cap (24).
Install check valve (28), spring (27), and cap (24)
to housing (71).
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)

W2-4-63
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE (TOP AND BOTTOM SIDES OF 5-SPOOL HOUSING)

23
17
1 22
2 Make-Up Valve 18
3 19 21 24
4 16 20
5 25
6
7 26
Boom 2 Anti-
45 8 27 Drift Valve
44 9 28
43 10 29
42 11
41 15
40 14 30
46 13
39 31
47 12
48 38 Check Valve-1
49 37 32
Overload Relief 50 33
51 34
Valve-1 37 35
52
53 38 36
54 39
40
41
42
54 43
53 44
52 45
51
50 Overload Relief
49 Valve-1
48
47
46
57

58
59
55 56

Overload Relief 83
Valve-2 82
81
80
79
78
77
76
75
84 74
85 73
86 72
87 71 68
88 70
12 89 69
11 90 67
10 91 66
9 92
8 93 65 62
7 94 61
6 95
5 96 60
97 64
Make-Up Valve 4 98 Check Valve-2
3 63
2
1 W18J-02-04-022

W2-4-64
 UPPERSTRUCTURE / Control Valve

1- O-Ring (2 Used) 26 - O-Ring 51 - Seat (3 Used) 75 - Backup Ring

2- Backup Ring (2 Used) 27 - Sleeve 52 - Spring (3 Used) 76 - O-Ring
3- O-Ring (2 Used) 28 - O-Ring 53 - O-Ring (3 Used) 77 - Piston
4- Sleeve (2 Used) 29 - Backup Ring 54 - Backup Ring (3 Used) 78 - Spring
5- Poppet (2 Used) 30 - Socket Bolt (4 Used) 55 - Cap 79 - Spring
6- Backup Ring (2 Used) 31 - Cap 56 - O-Ring 80 - Pilot Seat
7- Backup Ring (2 Used) 32 - O-Ring 57 - Housing 81 - Backup Ring
8- O-Ring (2 Used) 33 - Backup Ring 58 - O-Ring 82 - O-Ring
9- Spring (2 Used) 34 - O-Ring 59 - Cap 83 - O-Ring
10 - O-Ring (2 Used) 35 - Spring 60 - Spring 84 - Cap
11 - Backup Ring (2 Used) 36 - Check Valve 61 - Poppet 85 - O-Ring
12 - Cap (2 Used) 37 - O-Ring (3 Used) 62 - O-Ring (3 Used) 86 - Piston
13 - Cap 38 - Backup Ring (3 Used) 63 - O-Ring 87 - Sleeve
14 - O-Ring 39 - O-Ring (3 Used) 64 - Cap 88 - Backup Ring
15 - Piston 40 - Sleeve (3 Used) 65 - Backup Ring 89 - O-Ring
16 - Cover 41 - Main Poppet (3 Used) 66 - O-Ring 90 - Poppet
17 - Cap 42 - Piston (3 Used) 67 - Spring 91 - Spring
18 - O-Ring 43 - Spring (3 Used) 68 - Check Valve 92 - Spring Guide
19 - Spring 44 - O-Ring (3 Used) 69 - O-Ring 93 - Spring
20 - Check Valve 45 - Backup Ring (3 Used) 70 - Backup Ring 94 - Pilot Poppet
21 - Backup Ring 46 - Lock Nut (3 Used) 71 - O-Ring 95 - Lock Nut
22 - Poppet 47 - Adjusting Screw (3 Used) 72 - Sleeve 96 - Backup Ring
23 - O-Ring 48 - O-Ring (3 Used) 73 - Main Poppet 97 - O-Ring
24 - Cap 49 - Spring (3 Used) 74 - Backup Ring 98 - Sleeve
25 - Spring 50 - Pilot Poppet (3 Used)

W2-4-65
 UPPERSTRUCTURE / Control Valve

Make-Up Valve

Boom 2 Anti-
45 Drift Valve
44
43
42
41
40
46 31
47 39
48 38 Check Valve-1
49 37 32
Overload Relief 50 33
51 34
Valve-1 37 35
52
53 38 36
54 39
40
41
42
54 43
53 44
52 45
51
50 Overload Relief
49 Valve-1
48
47
46
57

58
59
55 56

Overload Relief
Valve-2

68

67
66
65

64
Make-Up Valve Check Valve-2

W18J-02-04-022

W2-4-66
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve
(Top and Bottom Sides of 5-Spool Housing)

Disassembly of Overload Relief Valve-1

IMPORTANT: Do not disassemble the overload
relief valve unless necessary. When
the overload relief valve has been
disassembled adjust the pressure.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
Attach a tag to the overload relief
valves (3 used) for assembling.
1. Loosen sleeve (40). Remove overload relief
valve-1 from housing (57).
: 41 mm
Disassembly of Check Valve-1
4. Remove cap (31), spring (35), and check valve
(36) from housing (57).
: 14 mm
5. Remove backup ring (33) and O-rings (32, 34)
from cap (31).
Disassembly of Check Valve-2
6. Remove cap (64), spring (67), and check valve
(68) from housing (57).
: 14 mm

2. Secure the hexagonal part of sleeve (40) in a vise. 7. Remove backup ring (65) and O-ring (66) from
Loosen the hexagonal part of seat (51). Remove cap (64).
the seat (51) assembly (46 to 50, 44, 45, 53, and
54). Remove springs (43, 52), piston (42), and 8. When replacing O-ring (58), remove cap (59) from
poppet (41) from sleeve (40). housing (57).
: 36 mm
9. When replacing O-ring (56), remove cap (55) from
IMPORTANT: Put a matching mark on adjusting housing (57).
screw (47) and seat (51). Record a
turning number of adjusting screw
(47).
3. Remove lock nut (46) from adjusting screw (47).
Remove adjusting screw (47), spring (49), and
pilot poppet (50) from seat (51).
: 19 mm
: 6 mm

W2-4-67
 UPPERSTRUCTURE / Control Valve

1
2 Make-Up Valve
3
4
5
6
7 Boom 2 Anti-
8 Drift Valve
9
10
11

12
Check Valve-1
Overload
Relief Valve-1

Overload Relief
Valve-1

57

Overload Relief 83
Valve-2 82
81
80
79
78
77
76
75
84 74
85 73
86 72
87 71
88 70
12 89 69
11 90
10 91
9 92
8 93
7 94
6 95
5 96
97
Make-Up Valve 4 98 Check Valve-2
3
2
1 W18J-02-04-022

W2-4-68
 UPPERSTRUCTURE / Control Valve
Disassembly of Overload Relief Valve-2
IMPORTANT: Do not disassemble the overload
relief valve unless necessary. When
the overload relief valve has been
disassembled adjust the pressure.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
10. Remove the overload relief valve assembly (69 to
98) from housing (57) while turning sleeve (72).
: 41 mm
IMPORTANT: Put the matching marks onto
sleeves (72, 98). Record a turning
number of sleeve (98).
11. Secure sleeve (72) in a vise. Loosen sleeve (98).
Remove the sleeve (98) assembly (84 to 97) from
sleeve (72). Remove backup ring (70) and O-rings
(69, 71) from sleeve (98).
: 36 mm
12. Remove spring guide (92), pilot poppet (94), pilot
seat (80), springs (78, 79, and 93), piston (77),
and main poppet (73) from sleeve (72).
NOTE: Push and remove main poppet (73) from
the housing (57) side of sleeve (72) by us-
ing a round bar.
13. Remove spring (91) and poppet (90) from sleeve
(98).
W2-4-69
IMPORTANT: Put the matching marks on sleeves
(87, 98) and lock nut (95). Record a
turning number of sleeve (87).
14. Secure sleeve (98) in a vise. Loosen lock nut (95).
Remove sleeve (87) and lock nut (95) from sleeve
(98).
: 36 mm
15. Secure sleeve (87) in a vise. Remove cap (84)
and piston (86) from sleeve (87). Remove O-ring
(85) from cap (84).
: 27 mm
NOTE: Insert a round bar (dia.: approx. 3 mm (0.12
in)) from the poppet (90) hole of sleeve (87)
and remove piston (86).
Disassembly of Make-Up Valve
16. Remove the sleeve (4) assembly from housing
(57). Remove backup ring (2) and O-rings (1, 3)
from sleeve (4).
17. Secure sleeve (4) in a vise. Remove cap (12),
spring (9), and poppet (5) from sleeve (4).
18. Remove backup ring (11) and O-ring (10) from
cap (12).
19. Remove backup rings (6, 7) and O-ring (8) from
poppet (5).
 UPPERSTRUCTURE / Control Valve

23
17
Make-Up Valve 18 22
19 21 24
16 20 25
26
Boom 2 Anti-
27 Drift Valve
28
29

15
14 30
13

Check Valve-1

Overload
Relief Valve-1

Overload Relief
Valve-1

57

Overload Relief
Valve-2

62
61
60
Make-Up Valve Check Valve-2
63
W18J-02-04-022

W2-4-70
 UPPERSTRUCTURE / Control Valve
Disassembly of Boom 2 Anti-Drift Valve
20. Remove socket bolts (30) (4 used) from cover
(16). Remove cover (16) and O-rings (62, 63)
from housing (57).
: 12 mm

21. Remove spring (60) and poppet (61) from housing

(57).

22. Remove cap (24), spring (25), and poppet (22)

from cover (16). Remove O-ring (23) from cap
(24).
: 8 mm

23. Remove cap (13) and piston (15) from cover (16).
Remove O-ring (14) from cap (13).
: 27 mm

24. Insert a pipe (inner diameter: 7 mm (0.28 in),

outer diameter: 10 mm (0.39 in), length: 15 mm
(0.59 in)) from the hole of cap (13). Tap and re-
move sleeve (27) from the cap (24) side.

25. Remove cap (17), spring (19), and check valve

(20) from cover (16). Remove O-ring (18) from
cap (17).
: 5 mm

W2-4-71
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE (TOP AND BOTTOM SIDES OF 5-SPOOL HOUSING)
Overload Relief
Valve-2
Overload Relief
Valve-1

Make-Up Valve Check

Valve-1

Overload Relief 57
Valve-1

57 Make-Up
Check Valve-2 Valve
External View of Control Valve External View of Control Valve Overload Relief
Top Side Bottom Side Valve-2
(Refer to the
Check Valve-1 Overload Relief Valve-1 Closeup.)
(Refer to the Closeup.) (Refer to the Closeup.)

57 57

57

Boom 2
Overload Relief Anti-Drift Valve
Overload Relief Valve-1
Valve-1 (Refer to the
(Refer to the Closeup.)
Closeup.)

Section of Check Valve-1 and Section of Overload Relief Section of Overload Relief
Overload Relief Valve-1 Valve-1 Valve-2 and
31 Boom 2 Anti-Drift Valve
84
32
Make-Up Valve
85
(Refer to the Closeup.)
87
46 47
86
57 51 48 35 95
96
49 53 33, 34
90 97
40 50 36
98 91
52 Closeup of 88, 89
Check Valve-1 92 83
44, 45, 54 12
39 72 93
43 4 10, 11 81, 82
9 94 80
41
6, 7, 8 71
37, 38 42 3 74, 75, 76 78, 79
Closeup of Overload Relief 5 73
Valve-1 1, 2 77 69, 70
Section of Closeup of Closeup of Overload
Make-Up Valve Make-Up Valve Make-Up Valve Relief Valve-2 W18J-02-04-039

(Refer to the Closeup.)

W2-4-72
 UPPERSTRUCTURE / Control Valve

1- O-Ring (2 Used) 26 - *O-Ring 51 - Seat (3 Used) 75 - Backup Ring

2- Backup Ring (2 Used) 27 - *Sleeve 52 - Spring (3 Used) 76 - O-Ring
3- O-Ring (2 Used) 28 - *O-Ring 53 - O-Ring (3 Used) 77 - Piston
4- Sleeve (2 Used) 29 - *Backup Ring 54 - Backup Ring (3 Used) 78 - Spring
5- Poppet (2 Used) 30 - *Socket Bolt (4 Used) 55 - *Cap 79 - Spring
6- Backup Ring (2 Used) 31 - Cap 56 - *O-Ring 80 - Pilot Seat
7- Backup Ring (2 Used) 32 - O-Ring 57 - Housing 81 - Backup Ring
8- O-Ring (2 Used) 33 - Backup Ring 58 - *O-Ring 82 - O-Ring
9- Spring (2 Used) 34 - O-Ring 59 - *Cap 83 - O-Ring
10 - O-Ring (2 Used) 35 - Spring 60 - *Spring 84 - Cap
11 - Backup Ring (2 Used) 36 - Check Valve 61 - *Poppet 85 - O-Ring
12 - Cap (2 Used) 37 - O-Ring (3 Used) 62 - *O-Ring (3 Used) 86 - Piston
13 - *Cap 38 - Backup Ring (3 Used) 63 - *O-Ring 87 - Sleeve
14 - *O-Ring 39 - O-Ring (3 Used) 64 - *Cap 88 - Backup Ring
15 - *Piston 40 - Sleeve (3 Used) 65 - *Backup Ring 89 - O-Ring
16 - *Cover 41 - Main Poppet (3 Used) 66 - *O-Ring 90 - Poppet
17 - *Cap 42 - Piston (3 Used) 67 - *Spring 91 - Spring
18 - *O-Ring 43 - Spring (3 Used) 68 - *Check Valve 92 - Spring Guide
19 - *Spring 44 - O-Ring (3 Used) 69 - O-Ring 93 - Spring
20 - *Check Valve 45 - Backup Ring (3 Used) 70 - Backup Ring 94 - Pilot Poppet
21 - *Backup Ring 46 - Lock Nut (3 Used) 71 - O-Ring 95 - Lock Nut
22 - *Poppet 47 - Adjusting Screw (3 Used) 72 - Sleeve 96 - Backup Ring
23 - *O-Ring 48 - O-Ring (3 Used) 73 - Main Poppet 97 - O-Ring
24 - *Cap 49 - Spring (3 Used) 74 - Backup Ring 98 - Sleeve
25 - *Spring 50 - Pilot Poppet (3 Used)
NOTE: As for parts with mark*, refer to W2-4-64.

W2-4-73
 UPPERSTRUCTURE / Control Valve

Overload Relief Valve-2

Overload Relief
Valve-1

Make-Up Valve Check

Valve-1

Check Valve-2 Overload Relief 57

Valve-1

57 Make-Up
Valve
External View of Control Valve External View of Control Valve
Top Side Bottom Side Overload Relief
Valve-2
Overload Relief Valve-1 (Refer to the
Check Valve-1 (Refer to the Closeup.) Closeup.)
(Refer to the Closeup.)

57 57

57

Boom 2
Overload Relief Anti-Drift Valve
Overload Relief Valve-1
Valve-1 (Refer to the
(Refer to the Closeup.)
Closeup.)

Section of Check Valve-1 and Section of Overload Relief Section of Overload Relief
Overload Relief Valve-1 Valve-1 Valve-2 and
31 Boom 2 Anti-Drift Valve

32
Make-Up Valve
(Refer to the Closeup.)
46 47

51 48 35

49 53 33, 34
40 50 36

52 Closeup of
Check Valve-1
44, 45, 54
39
43

41

37, 38 42
Closeup of Overload
Relief Valve-1

Section of Closeup of Make-Up Valve Closeup of Overload

Make-Up Valve Make-Up Valve Relief Valve-2 W18J-02-04-039
(Refer to the Closeup.)

W2-4-74
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve
(Top and Bottom Sides of 5-Spool Housing)

Assembly of Overload Relief Valve-1 Assembly of Check Valve-1

1. Install backup rings (54) (2 used) and O-rings (44, 7. Install O-rings (32, 34) and backup ring (33) to
53) to seat (51). Install O-ring (48) to adjusting cap (31).
screw (47).
8. Install check valve (36), spring (35), and cap (31)
IMPORTANT: Turn adjusting screw (47) by the to housing (57).
same turning for disassembly. Fit : 14 mm
adjusting screw (47) to the matching : 350 N⋅m (36 kgf⋅m, 260 lbf⋅ft)
mark. Install adjusting screw (47).
2. Install pilot poppet (50), spring (49), adjusting
screw (47), and lock nut (46) to seat (51).

3. Install backup ring (38) and O-rings (37, 39) to

sleeve (40).

4. Install piston (42) to main poppet (41). Install main

poppet (41) to sleeve (40).

5. Install springs (49, 52) to the seat (51) assembly.

Install the seat (51) assembly to sleeve (40).
: 36 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)

IMPORTANT: Install overload relief valve-1 to the

original position before disassembly.
Adjust the pressure of overload re-
lief valve-1 by using a test bench.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
6. Install overload relief valves-1 (3 used) to housing
(57).
: 41 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
NOTE: Tighten the hexagonal part of sleeve (40).

W2-4-75
 UPPERSTRUCTURE / Control Valve

Overload Relief Valve-2

Overload Relief
Valve-1

Make-Up Valve
Check Valve-1

Overload Relief 57
Check Valve-2
Valve-1

57 Make-Up
Valve
External View of Control Valve External View of Control Valve
Top Side Bottom Side Overload Relief
Valve-2
Overload Relief Valve-1 (Refer to the
Check Valve-1 (Refer to the Closeup.) Closeup.)
(Refer to the Closeup.)

57

Boom 2
Anti-Drift Valve
Overload Relief Overload Relief
Valve-1 Valve-1
(Refer to the (Refer to the
Closeup.) Closeup.)

Section of Check Valve-1 and Section of Overload Relief Section of Overload Relief
Overload Relief Valve-1 Valve-1 Valve-2 and
Boom 2 Anti-Drift Valve
84
Make-Up Valve 85
(Refer to the Closeup.) 87

86
95
96

90 97
98 91
Closeup of 88, 89
Check Valve-1 92 83
72 93
81, 82
94 80
71
74, 75, 76 78, 79
Closeup of Overload 73
Relief Valve-1 77 69, 70
Closeup of Overload
Section of Closeup of Relief Valve-2
Make-Up Valve Make-Up Valve Make-Up Valve W18J-02-04-039

(Refer to the Closeup.)

W2-4-76
 UPPERSTRUCTURE / Control Valve
Assembly of Overload Relief Valve-2
9. Install O-ring (85) to cap (84). Install piston (86)
and cap (84) to sleeve (87).
: 27 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
10. Install lock nut (95), backup ring (96), and O-ring
(97) to sleeve (87). Install backup ring (88), O-ring
(89), and poppet (90) to sleeve (87).
IMPORTANT: Turn sleeve (87) by the same turning
for disassembly. Fit sleeve (87) to
the matching mark. Install sleeve
(87).
11. Install the sleeve (87) assembly to sleeve (98).
Tighten lock nut (95).
: 36 mm
: 80 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
12. Install O-ring (83), spring guide (92), and springs
(91, 93) to the sleeve (98) assembly.
13. Install O-rings (69, 71) and backup ring (70) to
sleeve (72).
14. Install backup rings (74, 75), O-ring (71), and
piston (77) to main poppet (73).
15. Install the poppet (73) assembly to sleeve (72).
16. Install backup ring (81) and O-ring (82) to pilot
seat (80).
W2-4-77
17. Install springs (78, 79) to main poppet (73). Install
pilot seat (80) to sleeve (72). Install pilot poppet
(94) to pilot seat (80).
18. Fit the sleeve (98) assembly to the sleeve (72)
assembly and tighten temporarily.
Secure sleeve (72) in a vise. Install sleeve (98) to
sleeve (72).
: 36 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
IMPORTANT: Install overload relief valve-2 to the
original position before disassembly.
Adjust the pressure of overload re-
lief valve-2 by using a test bench.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
19. Install overload relief valve-2 to housing (57).
: 41 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
NOTE: Tighten the hexagonal part of sleeve (72).
 UPPERSTRUCTURE / Control Valve

Overload Relief Valve-2

Overload Relief
Valve-1

Make-Up Valve Check

Valve-1

Check Valve-2 Overload Relief 57

Valve-1

57 Make-Up
Valve
External View of Control Valve Top Side External View of Control Valve Bottom Side
Overload Relief
Valve-2
Overload Relief Valve-1 (Refer to the
Check Valve-1 (Refer to the Closeup.) Closeup.)
(Refer to the Closeup.)

Boom 2
Anti-Drift Valve
Overload Relief Overload Relief
Valve-1 Valve-1
(Refer to the (Refer to the
Closeup.) Closeup.)

Section of Check Valve-1 and Section of Overload Relief Section of Overload Relief
Overload Relief Valve-1 Valve-1 Valve-2 and
Boom 2 Anti-Drift Valve

Make-Up Valve
(Refer to the Closeup.)

57

Closeup of
Check Valve-1
12

4 10, 11
9
6, 7, 8
3
Closeup of Overload 5
Relief Valve-1 1, 2
Closeup of Overload
Section of Closeup of Relief Valve-2
Make-Up Valve Make-Up Valve Make-Up Valve W18J-02-04-039

(Refer to the Closeup.)

W2-4-78
 UPPERSTRUCTURE / Control Valve
Assembly of Make-Up Valve
20. Install O-rings (1, 3) (2 used for each), and
backup rings (2) (2 used) to sleeves (4) (2 used).

21. Install O-rings (10) (2 used) and backup rings (11)

(2 used) to caps (12) (2 used).

22. Install O-rings (8) (2 used), and backup rings (6,

7) (2 used for each) to poppets (5) (2 used).

23. Install poppet (5) (2 used), springs (9) (2 used),

and caps (12) (2 used) to sleeves (4) (2 used).

24. Install the make-up valve assemblies (2 used) to

housing (57).

W2-4-79
 UPPERSTRUCTURE / Control Valve

Boom Anti-Drift Valve

57
57

30
External View of Control Valve Top Side External View of Control Valve Bottom Side

16
61

57 60 62

15
63
14

23 13
20
18
19 24

16
17 25 22 21, 26 27 28, 29
Boom Anti-Drift Valve
(Refer to the Closeup.) Closeup of Boom 2 Anti-Drift
Valve
Section of Boom Anti-Drift W18J-02-04-038

Valve

13 - Cap 19 - Spring 25 - Spring 57 - Housing

14 - O-Ring 20 - Check Valve 26 - O-Ring 60 - Spring
15 - Piston 21 - Backup Ring 27 - Sleeve 61 - Poppet
16 - Cover 22 - Poppet 28 - O-Ring 62 - O-Ring (3 Used)
17 - Cap 23 - O-Ring 29 - Backup Ring 63 - O-Ring
18 - O-Ring 24 - Cap 30 - Socket Bolt (4 Used)

W2-4-80
 UPPERSTRUCTURE / Control Valve
Assembly of Boom 2 Anti-Drift Valve
25. Install poppet (61) and spring (60) to housing
(57).

26. Install O-rings (26, 28) and backup rings (21, 29)
to sleeve (27). Install sleeve (27) to cover (16).

27. Install O-ring (23) to cap (24). Install poppet (22),

spring (25), and cap (24) to cover (16).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 36 lbf⋅ft)

28. Install O-ring (14) to cap (13). Install piston (15)

and cap (13) to cover (16).
: 27 mm
: 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft)

29. Install O-ring (18) to cap (17). Install check valve

(20), spring (19), and cap (17) to cover (16).
: 5 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

30. Install O-ring (63), O-rings (62) (3 used), and

cover (16) to housing (57) with socket bolts (30)
(4 used).
: 12 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)

W2-4-81
 UPPERSTRUCTURE / Control Valve

57 57

Check
Valve-2

External View of Control Valve Rear Side W18J-02-04-029

External View of Control Valve Front Side W18J-02-04-030

64

65

66

67

68
Closeup of Check Valve-2 W18J-02-04-031

57 - Housing 65 - Backup Ring 67 - Spring 68 - Check Valve

64 - Cap 66 - O-Ring

W2-4-82
 UPPERSTRUCTURE / Control Valve
Assembly of Check Valve-2
31. Install O-ring (66) and backup ring (65) to cap (64).
Install check valve (68), spring (67), and cap (64)
to housing (57).
: 14 mm
: 350 N⋅m (36 kgf⋅m, 260 lbf⋅ft)

W2-4-83
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE (4-SPOOL CONTROL VALVE)

1
4
2
3
5

16 7
15
14 8
13
7
12
11 9

10

17 8
7
9
7
18 8
1 7
7 9
19
3 8
7
9

W18J-02-04-024

W2-4-84
 UPPERSTRUCTURE / Control Valve

1- Socket Bolt (13 Used) 6- Spool 11 - Check Valve 16 - Cap

2- Cover 7- Spring Guide (8 Used) 12 - Spring 17 - Spool
3- O-Ring (8 Used) 8- Spring (4 Used) 13 - Spacer 18 - Spool
4- Cover 9- Bolt (4 Used) 14 - O-Ring 19 - Cover
5- Housing 10 - Spool 15 - Backup Ring

W2-4-85
 UPPERSTRUCTURE / Control Valve

1
4
2
3
5

16 7
15
14 8
13
7
12
11 9

10

7
17 8
7
9
7
18 8
1 7
9
7
19 8
3
7
9

W18J-02-04-024

W2-4-86
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve
(4-Spool Control Valve)

Disassembly of Spool
1. Remove socket bolts (1) (6 used) from cover (4).
Remove cover (4) and O-rings (3) (4 used) from
housing (5).
: 10 mm

2. Remove socket bolts (1) (7 used) from covers (2,

19). Remove covers (2, 19) and O-rings (3) (4
used) from housing (5).
: 10 mm

IMPORTANT: Turn and remove the spool (6, 10, 17,

and 18) assemblies.
Do not disassemble the spool (6, 10,
17, and 18) assemblies unless nec-
essary.
3. Remove the spool (6, 10, 17, and 18) assemblies
(4 used) from housing (5).

4. Remove bolts (9) (4 used), springs (8) (4 used),

and spring guides (7) (8 used) from spools (6, 10,
17, and 18).
: 10 mm

5. Remove cap (16), spacer (13), spring (12), and

check valve (11) from spool (10).
: 10 mm

6. Remove backup ring (15) and O-ring (14) from

cap (16).

W2-4-87
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE (4-SPOOL CONTROL VALVE)
5 1 4 2 1 19 5

External View of Control Valve W18J-02-04-033 External View of Control Valve W18J-02-04-032
Top Side Bottom Side

9
4
7

1
3
5

10 7

17 18

11

12 3

13
19
3

14, 15 1

2 16
W18J-02-04-036

4-Spool Section

1- Socket Bolt (13 Used) 6- Spool 11 - Check Valve 16 - Cap

2- Cover 7- Spring Guide (8 Used) 12 - Spring 17 - Spool
3- O-Ring (8 Used) 8- Spring (4 Used) 13 - Spacer 18 - Spool
4- Cover 9- Bolt (4 Used) 14 - O-Ring 19 - Cover
5- Housing 10 - Spool 15 - Backup Ring

W2-4-88
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve
(4-Spool Control Valve)

1. Install O-rings (3) (8 used) to housing (5). Install

cover (19) to housing (5) with socket bolts (1) (2
used). Install cover (2) to housing (5) with socket
bolts (1) (5 used).
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)

2. Install O-ring (14) and backup ring (15) to cap (16).

Install check valve (11), spring (12), and spacer
(13) to spool (10). Install cap (16) to spool (10).
: 10 mm
: 80 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

3. Apply LOCTITE #262 onto the thread part of bolts

(4) (4 used). Install spring guides (7) (4 used),
springs (8) (4 used), and spring guides (7) (4
used) to spools (6, 10, 17, and 18) with bolts (9)
(4 used).
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)

4. Apply hydraulic oil onto the surface of spools (6,

10, 17, and 18). Slowly turn and install spools (6,
10, 17, and 18) to housing (5).

5. Install O-rings (3) (8 used) to housing (5). Install

cover (4) to housing (5) with bolts (1) (6 used).
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)

W2-4-89
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE (5-SPOOL CONTROL VALVE)
2
3

4
5
4 6
5 5
6
7
4 5
5 9
6
5
8

17 10
11
12 3 20
13
4 14 1
16 15
5 11
12
6 13
14
4 5 15 3
5 18
6
21
5

19
3 1

20

W18J-02-04-022

W2-4-90
 UPPERSTRUCTURE / Control Valve

1- Socket Bolt (15 Used) 7- Spool 12 - Spacer (2 Used) 17 - Spool

2- Cover 8- Housing 13 - O-Ring (2 Used) 18 - Spool
3- O-Ring (10 Used) 9- Spool 14 - Backup Ring (2 Used) 19 - Spool
4- Bolt (5 Used) 10 - Check Valve 15 - Cap (2 Used) 20 - Cover (2 Used)
5- Spring Guide (10 Used) 11 - Spring (2 Used) 16 - Check Valve 21 - Cover
6- Spring (5 Used)

W2-4-91
 UPPERSTRUCTURE / Control Valve

2
3

4
5
4 6
5 5
6
7
4 5
5 9
6
5
8

17 10
11
3 20
12
13
4 14 1
16 15
5 11
12
6 13
14
4 5 15 3
5 18
6
21
5

19
3
1

20

W18J-02-04-022

W2-4-92
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve
(5-Spool Control Valve)

Disassembly of Spool
1. Remove socket bolts (1) (6 used) from cover (2).
Remove cover (2) and O-rings (3) (5 used) from
housing (8).
: 10 mm

2. Remove socket bolts (1) (9 used) from covers

(20) (2 used) and cover (21). Remove covers (20)
(2 used), cover (21), and O-rings (3) (5 used) from
housing (8).
: 10 mm

IMPORTANT: Turn and remove the spool (7, 9, 17,

18, and 19) assemblies.
Do not disassemble the spool (7, 9,
17, 18, and 19) assemblies unless
necessary.
3. Remove the spool (7, 9, 17, 18, and 19)
assemblies (5 used) from housing (8).

4. Remove bolts (4) (5 used), spring guides (5) (5

used), springs (6) (5 used), and spring guides (5)
(5 used) from spools (7, 9, 17, 18, and 19).
: 10 mm

5. Remove cap (15), spacer (12), spring (11), and

check valve (10) from spool (9).
: 10 mm

6. Remove cap (15), spacer (12), spring (11), and

check valve (16) from spool (17).

7. Remove backup rings (14) (2 used) and O-rings

(13) (2 used) from caps (15) (2 used).

W2-4-93
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE (5-SPOOL CONTROL VALVE)
1 1

20
8
20 8

21

External View of Control Valve Top Side W18J-02-04-033 External View of Control Valve Bottom Side W18J-02-04-032

18 17 9 4

5
2
6

1
3
5
19 7

16
10

11
11

12 12

13, 14 13, 14

W18J-02-04-035

1 20 15 21 15 20
5-Spool Section

1- Socket Bolt (15 Used) 7- Spool 12 - Spacer (2 Used) 17 - Spool

2- Cover 8- Housing 13 - O-Ring (2 Used) 18 - Spool
3- O-Ring (10 Used) 9- Spool 14 - Backup Ring (2 Used) 19 - Spool
4- Bolt (5 Used) 10 - Check Valve 15 - Cap (2 Used) 20 - Cover (2 Used)
5- Spring Guide (10 Used) 11 - Spring (2 Used) 16 - Check Valve 21 - Cover
6- Spring (5 Used)

W2-4-94
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve
(5-Spool Control Valve)

1. Install O-rings (3) (5 used) to housing (8). Install
covers (20) (2 used) and cover (21) to housing (8)
with socket bolts (1) (9 used).
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
6. Install O-rings (3) (5 used) to housing (8). Install
cover (2) to housing (8) with socket bolts (1) (6
used).
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)

2. Install O-ring (13) and backup ring (14) to cap (15).

Install check valve (10), spring (11), spacer (12),
and cap (15) to spool (9).
: 10 mm
: 80 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

3. Install O-ring (13) and backup ring (14) to cap (15).

Install check valve (16), spring (11), spacer (12),
and cap (15) to spool (17).
: 8 mm
: 80 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

4. Apply LOCTITE #262 onto the thread part of bolts

(4) (5 used). Install springs (6) (5 used) and spring
guides (5) (10 used) to spools (7, 9, 17, 18, and
19) with bolts (4) (5 used).
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)

5. Apply hydraulic oil onto the surface of spools (7, 9,

17, 18, and 19). Slowly turn and install spools (7,
9, 17, 18, and 19) to housing (8).

W2-4-95
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF HOUSING

2 6
3 7
5
6
2 8
1 4
9
9

2
9
3
6

6
8
7

2
1

2
1

W18J-02-04-043

1 - Socket Bolt (8 Used) 4 - Housing (4-Spool Side) 6 - O-Ring (6 Used) 8 - O-Ring (3 Used)
2 - Washer (14 Used) 5 - Housing (5-Spool Side) 7 - O-Ring (2 Used) 9 - O-Ring (6 Used)
3 - Socket Bolt (6 Used)

W2-4-96
 UPPERSTRUCTURE / Control Valve
Disassembly of Housing

1. Remove all valves at top, bottom, and side of

5-spool and 4-spool side housings.

CAUTION: Control valve weight: 410 kg (910

lb)

IMPORTANT: Before placing 5-spool side housing

(5) and 4-spool side housing (4) on a
workbench, put a cloth in order not
to damage.
2. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the eyebolt mounting hole on the control valve.
Hoist the control valve. Place the control valve
onto a workbench with housing (4) down.

3. Remove socket bolts (1) (8 used) and washers (2)

(8 used) from housing (5).
: 14 mm

CAUTION: Control valve weight: 410 kg (910

lb)

4. Hoist the control valve. Place the control valve

onto a workbench with housing (5) down.

5. Remove socket bolts (3) (6 used) and washers

(2) (6 used) from housing (4).
: 14 mm

CAUTION: Housing (4) weight: 200 kg (450

lb)

6. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to

the eyebolt mounting hole on housing (4). Hoist
and slowly remove housing (4) from housing (5).

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

O-rings (8) (3 used), and O-rings (9) (6 used) from
housing (5) or housing (4).

W2-4-97
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF HOUSING
2, 3 4
5

1, 2 1, 2

1, 2 W18J-02-04-027
W18J-02-04-026
2, 3

6 5

9
8

6
6

W18J-02-04-028

7 8

1 - Socket Bolt (8 Used) 4 - Housing (4-Spool Side) 6 - O-Ring (6 Used) 8 - O-Ring (3 Used)
2 - Washer (14 Used) 5 - Housing (5-Spool Side) 7 - O-Ring (2 Used) 9 - O-Ring (6 Used)
3 - Socket Bolt (6 Used)

W2-4-98
 UPPERSTRUCTURE / Control Valve
Assembly of Housing

IMPORTANT: Before placing housing (5) and

housing (4) on a workbench, put a
cloth in order not to damage.

CAUTION: Housing (5) weight: 210 kg (470

lb)

1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to

the eyebolt mounting hole on housing (5). Hoist
housing (5). Place housing (5) onto a workbench
with the side of housing (5) down.

2. Apply grease onto O-rings (6) (6 used), O-rings

(7) (2 used), O-rings (8) (3 used), and O-rings (9)
(6 used). Install O-rings (6) (6 used), O-ring (7) (2
used), O-rings (8) (3 used), and O-rings (9) (6
used) to housing (5).

CAUTION: Housing (4) weight: 200 kg (450

lb)

3. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to

the eyebolt mounting hole on housing (4). Hoist
housing (4). Install housing (4) to housing (5) with
socket bolts (1) (7 used), socket bolts (3) (6 used),
and washers (2) (13 used).
: 14 mm
: 250 N⋅m (25.5 kgf⋅m, 185 lbf⋅ft)

4. Hoist the control valve. Place the control valve

onto a workbench with the side of housing (4)
down.

5. Install socket bolt (1) and washer (2) to housing

(5).
: 14 mm
: 250 N⋅m (25.5 kgf⋅m, 185 lbf⋅ft)

W2-4-99
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF SWING CONTROL VALVE

14
13
12
11 Make-Up Valve
4 10
5 Make-Up Valve 9
6 8
7 7
8 6
9 5
10 3 4
18 11
16 12
13
17 14
16
18
16 15 1
43
17 42
41
16
18 40
16 19
17
16
18
16 20
17
2
16
1
21

3
22
24
26
28
23 30
25 32 3
27 34 1
44
29 36
Main Relief Valve 38
31
33
35
37
W18J-02-04-012
39

W2-4-100
 UPPERSTRUCTURE / Control Valve

1- Socket Bolt (16 Used) 12 - O-Ring (2 Used) 23 - O-Ring 34 - Pilot Seat

2- Cover (4 Used) 13 - Backup Ring (2 Used) 24 - Lock Nut 35 - Backup Ring
3- O-Ring (8 Used) 14 - O-Ring (2 Used) 25 - Piston 36 - O-Ring
4- Cap (2 Used) 15 - Spool 26 - Sleeve 37 - Spring
5- Backup Ring (2 Used) 16 - Spring Guide (8 Used) 27 - O-Ring 38 - Poppet
6- O-Ring (2 Used) 17 - Spring (4 Used) 28 - O-Ring 39 - Sleeve
7- Spring (2 Used) 18 - Bolt (4 Used) 29 - Lock Nut 40 - Housing
8- O-Ring (2 Used) 19 - Spool 30 - Cap 41 - Plug (2 Used)
9- Backup Ring (4 Used) 20 - Spool 31 - O-Ring 42 - O-Ring (2 Used)
10 - Poppet (2 Used) 21 - Spool 32 - Spring 43 - Cover (2 Used)
11 - Sleeve (2 Used) 22 - Adjusting Screw 33 - Pilot Poppet 44 - Cover (2 Used)

W2-4-101
 UPPERSTRUCTURE / Control Valve

14
13
12
11 Make-Up Valve
4 10
5 Make-Up Valve 9
6 8
7 7
8 6
9 5
10 3 4
18 11
16 12
13
17 14
16
18
16 15 1
43
17 42
41
16
18 40
16 19
17
16
18
16 20
17
2
16
1
21

3
1
44
Main Relief Valve

W18J-02-04-012

W2-4-102
 UPPERSTRUCTURE / Control Valve
Disassembly of Swing Control Valve
• Attach an identification tag onto the spool in the
housing for correct assembly.

Disassembly of Spool
1. Remove socket bolts (1) (8 used) from covers (2) Disassembly of Make-Up Valve
(4 used). Remove covers (2) (4 used) and O-rings 6. Remove the sleeve (11) assemblies (2 used) from
(3) (4 used) from housing (40). housing (40).
: 10 mm : 41 mm

2. Remove socket bolts (1) (8 used) from covers (43,
44) (2 used for each). Remove covers (43, 44) (2
used for each) and O-rings (3) (4 used) from
housing (40).
: 10 mm
IMPORTANT: Slowly turn and straight remove the
spool (15, 19, 20, and 21) assemblies.
Do not disassemble the spool (15, 19,
20, and 21) assemblies unless nec-
essary.
3. Remove the spool (15, 19, 20, and 21) assem-
blies (4 used) from housing (40).
4. Remove bolts (18) (4 used), springs (17) (4 used),
and spring guides (16) (8 used) from spools (15,
19, 20, and 21).
: 10 mm
7. Remove caps (4) (2 used) and springs (7) (2
used) from sleeves (11) (2 used).
: 36 mm, 41 mm
8. Remove poppets (10) (2 used) from sleeves (11)
(2 used). Remove backup rings (9) (4 used) and
O-rings (12) (2 used) from sleeves (11) (2 used).
9. Remove backup rings (13) (2 used) and O-rings
(12, 14) (2 used for each) from sleeves (11) (2
used).
10. Remove backup rings (5) (2 used) and O-rings (6)
(2 used) from caps (4) (2 used).

5. Remove plugs (41) (2 used) from covers (43) (2

used). Remove O-rings (42) (2 used) from plugs
(41) (2 used).

W2-4-103
 UPPERSTRUCTURE / Control Valve

Make-Up Valve

Make-Up Valve

40

22
24
26
28
23 30
25 32
27 34
29 36
Main Relief Valve 38
31
33
35
37
W18J-02-04-012
39

W2-4-104
 UPPERSTRUCTURE / Control Valve
Disassembly of Main Relief Valve
IMPORTANT: Do not disassemble the main relief
valve unless necessary. When the
main relief valve has been disas-
sembled, adjust the pressure.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
11. Remove the cap (30) assembly from housing (40).
: 41 mm

IMPORTANT: As pilot seat (34) is installed to cap

(30), do not disassemble pilot seat
(34).
12. Loosen lock nuts (24, 29). Remove sleeve (39)
from cap (30). Remove spring (37) and poppet
(38) from sleeve (39).
: 30 mm, 41 mm

IMPORTANT: Put a matching mark on adjusting

screw (22) and sleeve (26). Record a
turning number of adjusting screw
(22).
13. Remove adjusting screw (22) from sleeve (26).
Remove piston (25), spring (32), and poppet (33)
from sleeve (26).
: 22 mm

IMPORTANT: Put a matching mark on sleeve (26)

and cap (30). Record a turning
number of sleeve (26).
14. Remove sleeve (26) from cap (30).
: 27 mm

W2-4-105
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF SWING CONTROL VALVE
2, 3 2, 3
1 1

Main Relief Valve

Make-Up Valve

40

Make-Up Valve

1
3, 43 3, 44 1 3, 43 W18J-02-04-013

18 18
2, 3
16 2, 3 16

17 17
Make-Up Valve

16 16 40
40
40

15

19

Make-Up
3 Valve
3
41, 42
44 43 Section of Make-Up Valve
W18J-02-04-014
Section of Spool (19) Section of Spool (15) and Make-Up Valve
22
18 18
16 16 24
2, 3 2, 3 13, 14 10
17 17 26

16 16 29
40 40 23
9 30
20 8 27, 28
25
12 31
21 7
11 32
34 33
5, 6 35
36
4
Closeup of 37
3 3
Make-Up Valve
41, 42 38
43 44 39
Section of Spool (21) Section of Spool (20) Closeup of
Main Relief Valve
W18J-02-04-015 W18J-02-04-016 W18J-02-04-017

W2-4-106
 UPPERSTRUCTURE / Control Valve

1- Socket Bolt (16 Used) 12 - O-Ring (2 Used) 23 - O-Ring 34 - Pilot Seat

2- Cover (4 Used) 13 - Backup Ring (2 Used) 24 - Lock Nut 35 - Backup Ring
3- O-Ring (8 Used) 14 - O-Ring (2 Used) 25 - Piston 36 - O-Ring
4- Cap (2 Used) 15 - Spool 26 - Sleeve 37 - Spring
5- Backup Ring (2 Used) 16 - Spring Guide (8 Used) 27 - O-Ring 38 - Poppet
6- O-Ring (2 Used) 17 - Spring (4 Used) 28 - O-Ring 39 - Sleeve
7- Spring (2 Used) 18 - Bolt (4 Used) 29 - Lock Nut 40 - Housing
8- O-Ring (2 Used) 19 - Spool 30 - Cap 41 - Plug (2 Used)
9- Backup Ring (4 Used) 20 - Spool 31 - O-Ring 42 - O-Ring (2 Used)
10 - Poppet (2 Used) 21 - Spool 32 - Spring 43 - Cover (2 Used)
11 - Sleeve (2 Used) 22 - Adjusting Screw 33 - Pilot Poppet 44 - Cover (2 Used)

W2-4-107
 UPPERSTRUCTURE / Control Valve

Main Relief Valve

Make-Up Valve

40

Make-Up Valve

W18J-02-04-013

Make-Up Valve

40
40

19

Make-Up
Valve

Section of Make-Up Valve

Section of Spool (19) Section of Spool (15) and Make-Up Valve W18J-02-04-014

22

24
13, 14 10
26

29
23
9 30
8 27, 28
25
12 31
7
11 32
34 33
5, 6 35
36
4
Closeup of 37
Make-Up Valve
38
Section of Spool (20) 39
Section of Spool (21) Closeup of
Main Relief Valve
W18J-02-04-015 W18J-02-04-016 W18J-02-04-017

W2-4-108
 UPPERSTRUCTURE / Control Valve
Assembly of Swing Control Valve

Assembly of Main Relief Valve Assembly of Make-Up Valve

IMPORTANT: Turn sleeve (26) by the same turning
for disassembly. Fit sleeve (26) to
the matching mark. Install sleeve
(26).
1. Install lock nut (29) and O-rings (27, 28) to sleeve
(26). Install sleeve (26) to cap (30).
: 41 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
7. Install O-ring (8) and backup rings (9) (2 used) to
poppet (10). Install O-ring (6) and backup ring (5)
to cap (4).
8. Install poppet (10), spring (7), and cap (4) to
sleeve (11).
: 36 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

2. Install poppet (33), spring (32), and piston (25) to 9. Install O-rings (12, 14) and backup ring (13) to
cap (30). sleeve (11). Install the make-up valve to housing
(40).
IMPORTANT: Turn adjusting screw (22) by the : 41 mm
same turning for disassembly. Fit : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
adjusting screw (22) to the matching
mark. Install adjusting screw (22).
3. Install lock nut (24) and O-ring (23) to adjusting
screw (22). Install adjusting screw (22) to sleeve
(26).
: 22 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)

4. Install O-ring (36) and backup ring (35) to pilot

seat (34).

5. Install poppet (38) and spring (37) to sleeve (39).

Install sleeve (39) to cap (30).

IMPORTANT: Adjust the pressure of the main re-

lief valve. (Refer to TROUBLE-
SHOOTING / Operational Perform-
ance Test in the separated volume,
T/M.)
6. Install the main relief valve to housing (40).
: 41 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

W2-4-109
 UPPERSTRUCTURE / Control Valve
2, 3 2, 3
1 1

Main Relief Valve

Make-Up Valve

40

Make-Up Valve

1
3, 43 3, 43 3, 43 W18J-02-04-013

18 18
2, 3
16 2, 3 16

17 17
Make-Up Valve

16 16
40
40

15

19

Make-Up
3 Valve
3
41, 42
44 43 Section of Make-Up Valve
Section of Spool (19) Section of Spool (15) and Make-Up Valve W18J-02-04-014

18 18
16 16
2, 3 2, 3
17 17

16 16
40 40

20

21

3 Closeup of
3 Make-Up Valve
41, 42
43 44
Section of Spool (21) Section of Spool (20) Closeup of Main Relief Valve
W18J-02-04-015 W18J-02-04-016 W18J-02-04-017

W2-4-110
 UPPERSTRUCTURE / Control Valve
Assembly of Spool IMPORTANT: Install the spool (15, 19, 20, and 21)
10. Install O-rings (42) (2 used) to plugs (41) (2 used). assemblies (4 used) to the original
Install plugs (41) (2 used) to covers (43) (2 used). position before disassembly. Install
spools (5, 19, 20, and 21) so that
11. Install O-rings (3) (4 used) to the bottom side of stopper plug (41) of cover (43)
housing (40). Install cover (43) and covers (44) (3 should enter the spool groove.
used) to housing (40) with socket bolts (1) (8
used).
: 10 mm 43
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
41
12. Secure spool (15) in a vise by using wooden
pieces. Install spring (17) and spring guides (16)
(2 used) to bolt (18). Install bolt (18) to spool (15).
: 10 mm 15, 21
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
W183-02-05-031

13. Assemble spools (19, 20, and 21) in the same

way as step 12. 15. Hold the spring part of the spool (15, 19, 20, and
21) assemblies. Slowly turn and install the spool
14. Install O-rings (3) (4 used) to housing (40). assemblies to housing (40).

16. Install covers (2) (4 used) to housing (40) with

socket bolts (1) (8 used).
: 10 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

W2-4-111
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF SWING CONTROL VALVE (SIDE)

6
5
4
3
2
1 6
5
3
Load Check 2
Valve-1
7
9
Load Check
5
3
Valve-2 2
8

Load Check
Valves-3, 4
12
10 11

13
14
15

Slow Return Valve

16
39 17
38
37
36
35
34 23
33 24
32 25
31
22

30 21
29
Boom Anti-Drift Valve 20
(Selector Valve) 19
18
27 26
28
W18J-02-04-011

1- Cap 11 - Cap 21 - O-Ring 31 - Backup Ring

2- Backup Ring (4 Used) 12 - O-Ring 22 - Poppet 32 - O-Ring
3- O-Ring (4 Used) 13 - Poppet 23 - Spring 33 - O-Ring
4- Check Valve 14 - Spring 24 - O-Ring 34 - Backup Ring
5- Spring (4 Used) 15 - O-Ring 25 - Backup Ring 35 - Sleeve
6- Check Valve (2 Used) 16 - Flange 26 - Cover 36 - Poppet
7- Cap 17 - Socket Bolt (4 Used) 27 - Washer (4 Used) 37 - Spring
8- Cap (2 Used) 18 - Cap 28 - Socket Bolt (4 Used) 38 - O-Ring
9- Check Valve (2 Used) 19 - O-Ring 29 - O-Ring 39 - Cap
10 - Housing 20 - Piston 30 - Cap

W2-4-112
 UPPERSTRUCTURE / Control Valve
Disassembly of Swing Control Valve (Side)

Disassembly of Boom Anti-Drift Valve Disassembly of Load Check Valve

1. Remove socket bolts (28) (4 used) and washers
(27) (4 used) from cover (26). Remove the cover
(26) assembly from housing (10).
: 12 mm
2. Remove O-rings (21, 24), backup ring (25), spring
(23), and poppet (22) from housing (10).
IMPORTANT: After long-time operation, poppet
(36) cannot be removed from sleeve
(35). In this case, as the seat surface
is deformed, replace sleeve (35) and
poppet (36).
3. Remove cap (39) from cover (26). Remove spring
(37) and poppet (36) from cover (26).
4. Remove cap (18) from cover (26). Remove piston
(20) from cover (26).
: 10 mm
8. Remove caps (1, 7) and caps (8) (2 used) from
housing (10).
: 14 mm
9. Remove check valve (4), spring (5), and check
valve (6) from housing (10).
10. Remove springs (5) (3 used), check valve (6), and
check valves (9) (2 used) from housing (10).
Disassembly of Slow Return Valve
11. Remove socket bolts (17) (4 used) from flange
(16). Remove flange (16) from housing (10).
: 12 mm
12. Remove O-ring (15), spring (14), and poppet (13)
from housing (10).

5. Tap sleeve (35) from the cap (18) side by using a

pipe (inner diameter: 10 mm (0.39 in), outer
diameter: 14 mm (0.55 in)). Remove sleeve (35)
from cover (26).

6. Remove backup rings (31, 34) and O-rings (32,

33) from sleeve (35).

7. Remove O-rings (19, 38) from caps (18, 39).

W2-4-113
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF SWING CONTROL VALVE (SIDE)

Load Check Valve-3

Load Check Valve-2

10
Load Check Valve-4

Load Check Valve-1

Boom Anti-Drift Valve

(Selector Valve)
Slow Return Valve

24, 25, 26
W18J-02-04-013
27, 28

29 37 36 33, 34 31, 32 20
30
26
38 10 8
8 39 18

2 19 2, 3
21
3 5
24, 25
5
23 9

9
22

10 Closeup of Load Check Valve-3 W18J-02-04-020

35
Closeup of Load Check W18J-02-04-020

Valve-4 and 2, 3 1 16 17
Boom Anti-Drift Valve
7 10

2 11 15
4
3 12
14
5
5 13

6 6 10

Closeup of Load Check Valve-1 W18J-02-04-020

Closeup of Load Check Valve-2 W18J-02-04-020
and Slow Return Valve

1- Cap 11 - Cap 21 - O-Ring 31 - Backup Ring

2- Backup Ring (4 Used) 12 - O-Ring 22 - Poppet 32 - O-Ring
3- O-Ring (4 Used) 13 - Poppet 23 - Spring 33 - O-Ring
4- Check Valve 14 - Spring 24 - O-Ring 34 - Backup Ring
5- Spring (4 Used) 15 - O-Ring 25 - Backup Ring 35 - Sleeve
6- Check Valve (2 Used) 16 - Flange 26 - Cover 36 - Poppet
7- Cap 17 - Socket Bolt (4 Used) 27 - Washer (4 Used) 37 - Spring
8- Cap (2 Used) 18 - Cap 28 - Socket Bolt (4 Used) 38 - O-Ring
9- Check Valve (2 Used) 19 - O-Ring 29 - O-Ring 39 - Cap
10 - Housing 20 - Piston 30 - Cap

W2-4-114
 UPPERSTRUCTURE / Control Valve
Assembly of Swing Control Valve (Side)
Assembly of Slow Return Valve
1. Install poppet (13) and spring (14) to housing
(10).
2. Install O-ring (15) to flange (16). Install flange (16)
to housing (10) with socket bolts (17) (4 used).
: 12 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
Assembly of Load Check Valve
3. Install springs (5) (4 used) and check valves (6, 9)
to housing (10).
NOTE: Do not use check valve (4) for cap (7) and
caps (8) (2 used).
4. Install O-rings (3) (4 used) and backup rings (2) (4
used) to caps (1, 7) and caps (8) (2 used). Install
caps (1, 7) and caps (8) (2 used) to housing (10).
: 14 mm
: 345 N⋅m (35 kgf⋅m, 255 lbf⋅ft)
W2-4-115
Assembly of Boom Anti-Drift Valve
5. Install poppet (22) and spring (23) to housing
(10).
6. Install O-rings (32, 33) and backup rings (31, 34)
to sleeve (35).
7. Install piston (20), sleeve (35), poppet (36), and
spring (37) to cover (26).
8. Install backup ring (25) and O-rings (21, 24) to
cover (26).
9. Install O-rings (19, 38) to caps (18, 39). Install
caps (18, 37) to cover (26).
: 10 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
10. Install cover (26) to housing (10) with socket bolts
(28) (4 used) and washers (27) (4 used).
: 12 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-4-116
 UPPERSTRUCTURE / Swing Device
REMOVAL AND INSTALLATION OF SWING
DEVICE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal

CAUTION: The bracket (3) assembly weight:

23 kg (51 lb)

1. Attach a nylon sling onto the bracket (3) assembly. 1 2 3 2 1

Hoist and hold the bracket (3) assembly.

2. Remove bolts (2) (4 used) from bracket (3).

Remove the bracket (3) assembly from brackets
(1) (2 used).
: 19 mm

W18J-02-05-004

4
3. Open cocks (5) (2 used) with drain hoses (4) (2
used) attached. Drain gear oil from swing devices
(7) (2 used).
5
4. Disconnect drain hoses (4) (2 used) from swing
devices (7) (2 used). Cap the open ends.
: 36 mm

5. Disconnect hoses (6) (6 used) from swing devices

(7) (2 used). Cap the open ends. W18J-02-05-005
: 22 mm, 27 mm, 41 mm
6 7 8 9
6. Remove socket bolts (8) (16 used) and split
flanges (9) (8 used) from swing devices (7) (2
used). Disconnect hoses (10) (4 used) from swing
devices (7) (2 used). Cap the open ends. Attach 10
an identification tag onto the disconnected hoses
for assembling.
: 8 mm

W18J-02-05-003
5

W2-5-1
 UPPERSTRUCTURE / Swing Device
7. Remove bolts (12) (32 used) and washers (13) 7
(32 used) from swing devices (7) (2 used).
: 41 mm

8. Remove corks (11) (4 used) from swing devices

(7) (2 used). Shave the holes where corks (11) (4
used) have been removed with a screw tap (M27,
Pitch 3.0 mm) in order to remove rust.

11

W18J-02-05-003
15 14 12, 13

Swing Device (Front)

9. Install pulling-out bolts (M27, Pitch 3.0 mm) (4
used) to the pulling-out holes at step 8. Attach a 15 Pulling-Out
Bolt Hole
nylon sling onto swing devices (7) (2 used). Hoist
and hold swing devices (7) (2 used).
Nylon sling (eye-type at both ends): 2 used Front Side
: 41 mm 7

CAUTION: Swing device (7) weight: 690 kg

(1530 lb) Pulling-Out 15
Bolt Hole
W183-02-06-004
10. Tighten the pulling-out bolts (4 used) while taking
up slack of the nylon sling. Slowly float swing Swing Device (Rear)
devices (7) (2 used) until knock pins (15) (4 used) Pulling-Out
15
are removed from main frame (14). Bolt Hole

11. Remove swing devices (7) (2 used) from main

Front Side
frame (14). Remove the pulling-out bolts (4 used) 7
and knock pins (15) (4 used) from swing devices
(7) (2 used).
: 41 mm
Pulling-Out
Bolt Hole
15

W183-02-06-005

Nylon Sling

W155-02-06-012

W2-5-2
 UPPERSTRUCTURE / Swing Device
Installation
1. Clean the mounting surfaces of swing devices (7) 7
12
(2 used) and main frame (14).
13 11

CAUTION: Swing device (7) weight: 690 kg

15
(1530 lb)

2. Lower swing devices (7) (2 used) onto the

mounting surface while fitting the swing gear teeth
to the holes on knock pins (15) (4 used) in main W183-02-06-006

frame (14).
Swing Device (Front)
3. Secure swing devices (7) (2 used) to main frame
15 Pulling-Out
(14) with knock pins (15) (4 used). Remove a Bolt Hole
nylon sling from swing devices (7) (2 used).
14
Front Side
4. Install swing devices (7) (2 used) to main frame
7
(14) with bolts (12) (32 used) and washers (13)
(32 used).
: 41 mm
: 1400 N⋅m (140 kgf⋅m, 1010 lbf⋅ft) Pulling-Out 15
Bolt Hole
5. Install corks (11) (4 used) to swing devices (7) (2 W183-02-06-004

used).
Swing Device (Rear)
15 Pulling-Out
Bolt Hole
14
Front Side
7

Pulling-Out 15
Bolt Hole
W183-02-06-005

6 7
6. Connect hoses (4) (2 used) to swing devices (7)
(2 used).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

7. Connect hoses (6) (6 used) to swing devices (7)

(2 used).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft) W18J-02-05-003
4

W2-5-3
 UPPERSTRUCTURE / Swing Device
8. Connect hoses (10) (4 used) to swing devices (7) 7 8 9
(2 used) with split flanges (8) (8 used) and socket
bolts (9) (16 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 10

W18J-02-05-003

9. Close cocks (5) (2 used).

W18J-02-05-005

10. Add gear oil to swing devices (7) (2 used).

Gear oil: 25 L (6.6 US gal)

CAUTION: The bracket (3) assembly weight: W18J-02-05-003

23 kg (51 lb)

11. Attach a nylon sling onto the bracket (3) assembly. 1 2 3 2 1

Hoist the bracket (3) assembly. Fit the bracket (3)
assembly to the mounting hole on brackets (1) (2
used). Install bracket (3) to brackets (1) (2 used)
with bolts (2) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-05-004

W2-5-4
 UPPERSTRUCTURE / Swing Device
(Blank)

W2-5-5
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING DEVICE
1, 2, 3

27 5

28 7
8

10
11

12

29 13

14

12
30

15

31 16

17
39 32
18
38 33
19
34 20
35 21

36 22
23

24

22

21

37 25

26 W18J-02-05-001

1- Motor 11 - Spring Pin (3 Used) 21 - Thrust Plate (8 Used) 31 - Cover

2- Bolt (12 Used) 12 - Thrust Plate (6 Used) 22 - Needle Bearing (8 Used) 32 - Screw (4 Used)
3- Washer (12 Used) 13 - Needle Bearing (3 Used) 23 - Spacer (4 Used) 33 - Magnet (4 Used)
4- Bolt (16 Used) 14 - First Stage Planetary Gear 24 - Second Stage Planetary 34 - Sleeve
(3 Used) Gear (4 Used)
5- Washer (16 Used) 15 - Ring Gear 25 - Ring Gear 35 - O-Ring
6- Cover 16 - Second Stage Sun Gear 26 - Knock Pin (2 Used) 36 - Oil Seal (2 Used)
7- First Stage Sun Gear 17 - Thrust Plate 27 - Retaining Ring 37 - Shaft
8- Thrust Plate 18 - Pin (4 Used) 28 - Bearing 38 - Bolt (10 Used)
9- Pin (3 Used) 19 - Second Stage Carrier 29 - Housing 39 - Spring Washer (10 Used)
10 - First Stage Carrier 20 - Spring Pin (4 Used) 30 - Bearing

W2-5-6
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Device
CAUTION: Motor (1) weight: 70 kg (160lb)
1. Drain gear oil from the swing device. Put the
matching marks on the mating surfaces of motor
(1), cover (6), ring gears (15, 25), and housing
(29). Remove bolts (24) (12 used)
2. Remove bolts (2) (12 used) and washers (3) (12
used) from motor (1). Install an eyebolt (M22,
Pitch 1.5 mm) to motor (1). Attach a nylon sling
onto the eyebolt. Hoist and remove motor (1) from
cover (4).
: 19 mm
3. Remove bolts (4) (16 used) and washers (5) (16
used) from cover (6).
: 32 mm
CAUTION: Cover (6) weight: 23 kg (51 lb)
4. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
cover (6). Attach a nylon sling onto the eyebolt.
Hoist and remove cover (6) from ring gear (15).
5. Remove first stage sun gear (7) from first stage
carrier (10).
10. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
W2-5-7
CAUTION: The first stage carrier (10)
assembly weight: 40 kg (88 lb)
6. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to
first stage carrier (10). Attach nylon slings onto
the eyebolts. Hoist and remove the first stage
carrier (10) assembly from ring gear (15).
CAUTION: Ring gear (15) weight: 50 kg (110
lb)
7. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
ring gear (15). Attach a nylon sling onto the
eyebolt. Hoist and remove ring gear (15) from ring
gear (25).
8. Remove second stage sun gear (16) from second
stage carrier (19).
CAUTION: The second stage carrier (19)
assembly weight: 85 kg (190 lb)
9. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
second stage carrier (19). Attach a nylon sling
onto the eyebolt. Hoist and remove the second
stage carrier (19) assembly from ring gear (25).
CAUTION: Ring gear (25) weight: 56 kg (130
lb)
ring gear (25). Attach a nylon sling onto the
eyebolt. Hoist and remove the ring gear (25)
assembly from housing (29).
 UPPERSTRUCTURE / Swing Device

27

28

29

31

39

38

36

37

26 W18J-02-05-001

W2-5-8
 UPPERSTRUCTURE / Swing Device
11. Remove knock pins (26) (2 used) from housing
CAUTION: If pushing shaft (37) by using a
(29).
press, provide a protection cover (outer
12. Remove retaining ring (27) from shaft (37). diameter: 520 mm (20.5 in), inner diameter:
130 mm (5.12 in), thickness: 25 to 30 mm
(0.98 to 1.18 in)). When housing (29) and/or
CAUTION: The housing (29) assembly bearing (28) are broken and flown off without
weight: 355 kg (790 lb) the cover, the metal fragments may result in
personal injury.
13. Attach a nylon sling onto the body of housing (29). Press at 30 ton or less.
Hoist housing (29). Turn over the housing (29) Degrease the housing inside before heating
assembly. bearing (28). Failure to degrease may cause a
fire.
14. Remove bolts (38) (10 used) and spring washers
(39) (10 used) from cover (31). 29 37 28
Remove cover (31) from housing (29).
: 24 mm

15. Remove oil seals (36) (2 used) from cover (31). Protection Cover

CAUTION: The housing (29) assembly

weight: 345 kg (770 lb)

16. Attach a nylon sling onto the body of housing (29).

Hoist housing (29). Turn over the housing (29) W157-02-06-010

assembly.
17. Remove shaft (37) from housing (29) by using a
press.
Press

Protection Cover

29

W157-02-06-011

W2-5-9
UPPERSTRUCTURE / Swing Device

28

10
11

12

29 13

14

12
30

17
32
18
33
19
34 20

35 21
22
23

24

22
21

37

W18J-02-05-001

W2-5-10
 UPPERSTRUCTURE / Swing Device
21. Remove O-rings (35), screws (32) (4 used), and
CAUTION: Shaft (37) + bearing (30) weight:
magnets (33) (4 used) from sleeve (34).
145 kg (320 lb)

18. Turn over shaft (37). Install the special tool (ST CAUTION: Housing (29) + others weight: 200
5082) to shaft (37). kg (450 lb)

37
22. Attach a nylon sling onto the body of housing (29).
Hoist housing (29). Turn over housing (29).
30 23. Remove bearing (28) from housing (29) by using
34 a press.

24. Remove spring pins (11) (3 used) from first stage

ST 5082
carrier (10) by using a round bar.
Round bar: Diameter 5.0 mm (0.2 in), Length 50
mm (1.97 in) or more

W142-02-06-006
25. Remove pins (9) (3 used), first stage planetary
gears (14) (3 used), thrust plates (12) (6 used),
19. Insert the special tool (ST 5082) into the guide. needle bearings (13) (3 used), and thrust plate (8)
from first stage carrier (10).
NOTE: Use the following parts as a guide when
removing bearing (30).
26. Remove spring pins (20) (4 used) from second
Guide: Height: 290 mm (11.4 in), Outer
stage carrier (19) by using a round bar.
diameter: 360 mm (14.2 in), Inner diameter:
Round bar: Diameter 5.0 mm (0.2 in), Length 50
340 mm (13.4 in)
mm (1.97 in) or more

CAUTION: Push shaft (37) by using a press 27. Remove pins (18) (4 used), second stage
inside the guide. planetary gears (24) (4 used), thrust plates (21) (8
used), needle bearings (22) (8 used), spacers
20. Install shaft (37) to a press. Remove bearing (30) (23) (4 used), and thrust plate (17) from second
and sleeve (34) from shaft (37). stage carrier (19).
Press
37

30

34
ST 5082

Guide

W183-02-06-002

W2-5-11
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING DEVICE

10 7 20 11 9 1 2, 3 4

12
8
13

15 14
16 12

25 21

26 22

23
19
22
17

27 21

28 24 18

30
29

32

31

36
39

33 38
34

35 W18J-02-05-002

37
1- Motor 11 - Spring Pin (3 Used) 21 - Thrust Plate (8 Used) 31 - Cover
2- Bolt (12 Used) 12 - Thrust Plate (6 Used) 22 - Needle Bearing (8 Used) 32 - Screw (4 Used)
3- Washer (12 Used) 13 - Needle Bearing (3 Used) 23 - Spacer (4 Used) 33 - Magnet (4 Used)
4- Bolt (16 Used) 14 - First Stage Planetary Gear 24 - Second Stage Planetary 34 - Sleeve
(3 Used) Gear (4 Used)
5- Washer (16 Used) 15 - Ring Gear 25 - Ring Gear 35 - O-Ring
6- Cover 16 - Second Stage Sun Gear 26 - Knock Pin (2 Used) 36 - Oil Seal (2 Used)
7- First Stage Sun Gear 17 - Thrust Plate 27 - Retaining Ring 37 - Shaft
8- Thrust Plate 18 - Pin (4 Used) 28 - Bearing 38 - Bolt (10 Used)
9- Pin (3 Used) 19 - Second Stage Carrier 29 - Housing 39 - Spring Washer (10 Used)
10 - First Stage Carrier 20 - Spring Pin (4 Used) 30 - Bearing

W2-5-12
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Device
1. Install needle bearings (13) (3 used) to first stage
planetary gears (14) (3 used).
IMPORTANT: Install thrust plate (8) with the oil
groove up.
2. Install thrust plate (8) to first stage carrier (10).
IMPORTANT: Install thrust plate (12) with the oil
groove facing the planetary gear (14)
side.
3. Install first stage planetary gears (14) (3 used)
and thrust plates (12) (6 used) to first stage carrier
(10).
4. Fit to the spring pin holes on first stage carrier
(22) and install pins (9) (3 used).
IMPORTANT: Install spring pin (11) with the slit of
spring pin (11) facing the end of pin
(9).
5. Install spring pins (11) (3 used) to first stage
carrier (10) and pins (7) (3 used).
9
Slit
11
W18J-03-02-005
6. Install spacers (23) (4 used) and needle bearings
(22) (8 used) to second stage planetary gears
(24) (4 used).
7. Install thrust plate (17) to second stage carrier
(19) with the oil groove up.
8. Install second stage planetary gears (24) (4 used)
and thrust plates (21) (4 used) to second stage
carrier (19) with the oil groove up.
W2-5-13
9. Fit to the spring pin holes on second stage carrier
(19) and install pins (18) (4 used).
10. Install second stage carrier (19) to pins (18) (4
used) with spring pins (20) (4 used) facing the
end.
11. Apply LOCTITE #262 onto screws (32) (4 used).
Install magnets (33) (4 used) to sleeve (34) with
screws (32) (4 used).
12. Apply grease onto O-ring (35). Install O-ring (35)
to sleeve (34).
13. Apply THREEBOND #1215 onto the oil seal (36)
mounting surface of cover (31).
Install oil seals (36) (2 used) to cover (31). Apply
grease onto the lip part of oil seals (36) (2 used).
14. Install sleeve (34) to shaft (37).
15. Warm up bearing (30) to about 110°C (230°F) in
an oil bath. Install bearing (30) to shaft (37) by
using the special tool (ST 5082) and a press.
Press
ST 5082
30
34
37
W183-02-06-001
 UPPERSTRUCTURE / Swing Device

15

16

25

26

19

27

28

29

31

39

38

W18J-02-05-002

37

W2-5-14
 UPPERSTRUCTURE / Swing Device
CAUTION: Housing (29) weight: 190 kg (420
lb)
16. Place housing (29) on a press stand with the
motor side down. Install the shaft (37) assembly
to housing (29) by using a press.
17. Temporarily tighten cover (31) to housing (29)
with bolts (38) (10 used) and washers (39) (10
used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
CAUTION: The housing (29) assembly
weight: 345 kg (770 lb)
18. Turn over the housing (29) assembly. Place the
housing (29) assembly on the press stand.
19. Apply grease onto the inner and the outer
surfaces of bearing (28). Warm up bearing (28) to
about 80 to 100 °C (176 to 212 °F) in an oil bath.
Install bearing (28) to shaft (37) by using a plate
and a press.
20. Install retaining ring (27) to shaft (37).
21. Turn over housing (29). Tighten bolts (38) (10
used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
22. Apply THREEBOND #1215 onto the ring gear
(25) mounting surface of housing (29).
W2-5-15
CAUTION: Ring gear (25) weight: 56 kg (130
lb)
23. Install ring gear (25) to housing (29) while fitting
the matching marks when disassembling. Secure
housing (29) and ring gear (25) with knock pins
(26) (2 used).
CAUTION: The second stage carrier (19)
assembly weight: 85 kg (190 lb)
24. Install an eyebolt (M12, Pitch 1.75 mm) to the
lifting hole (3 places) on the second stage carrier
(16) assembly. Attach nylon slings onto the
eyebolts. Hoist the second stage carrier (16)
assembly. Fit the second stage carrier (16)
assembly to the matching mark on housing (29).
Install the second stage carrier (16) assembly.
25. Install second stage sun gear (16) to second
stage carrier (19).
26. Apply THREEBOND #1215 onto the ring gear
(15) mounting surface of ring gear (25).
CAUTION: Ring gear (15) weight: 50 kg (110
lb)
27. Install an eyebolt (M12, Pitch 1.75 mm) to the
lifting hole (2 places) on ring gear (15). Attach a
nylon sling onto the eyebolts. Hoist the ring gear
(15). Fit ring gear (15) to the matching marks on
ring gear (25). Install ring gear (15).
 UPPERSTRUCTURE / Swing Device

10 7 1 2, 3 4

15

29

W18J-02-05-002

W2-5-16
 UPPERSTRUCTURE / Swing Device
34. Install motor (1) to cover (6) with bolts (2) (12
CAUTION: The first stage carrier (10)
used) and washers (3) (12 used).
assembly weight: 40 kg (88 lb) : 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
28. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to
the first stage carrier (10) assembly. Attach nylon
slings onto the eyebolts. Hoist the first stage
carrier (10) assembly. Install the first stage carrier
(10) assembly to second stage sun gear (16).

IMPORTANT: Install first stage sun gear (7) with

the stepped side down.
29. Install first stage sun gear (7) to first stage carrier
(10).

30. Apply THREEBOND #1215 onto the cover (6)

mounting surface of ring gear (15). Install cover
(6) to ring gear (15) with washers (5) (16 used)
and bolts (4) (16 used).
: 32 mm
: 750 N⋅m (75 kgf⋅m, 540 lbf⋅ft)

31. Install the seal tape onto the drain plug. Install the
drain plug to housing (29). Add gear oil.
: 17 mm
Gear oil: 25 L (6.6 US gal)

CAUTION: Motor (1) weight: 70 kg (160 lb)

32. Apply THREEBOND #1215 onto the motor (1)

mounting surface of cover (6).

33. Install an eyebolt (M22, Pitch 1.5 mm) to motor (1).

Attach a nylon sling onto the eyebolt. Hoist motor
(1). Install motor (1) while fitting to the matching
mark on cover (6).

W2-5-17
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING MOTOR

9
3
10
11
2 12

1 13
5
6
7
8

17
14
15 18
16
28 19
20
21
22
23 30
24
25
26
27
29

31
32
33
34
33
32
39, 40, 41
35
36
37
42
38

W1JB-02-06-001

1- Roller Bearing 12 - O-Ring 23 - Rotor 34 - Roller Bearing

2- O-Ring 13 - Friction Plate (3 Used) 24 - Push Rod (12 Used) 35 - O-Ring
3- Valve Casing 14 - Relief Valve (2 Used) 25 - Spacer 36 - Oil Seal
4- Socket Bolt (4 Used) 15 - Pin (2 Used) 26 - Holder 37 - Seal Cover
5- Poppet (2 Used) 16 - Retaining Ring 27 - Retainer Plate 38 - Retaining Ring
6- Spring (2 Used) 17 - O-Ring 28 - Plunger (9 Used) 39 - Swing Parking Brake Valve
7- O-Ring (2 Used) 18 - Plate (4 Used) 29 - Shoe Plate 40 - O-Ring
8- Plug (2 Used) 19 - Retaining Ring 30 - Casing 41 - O-Ring
9- Valve Plate 20 - Spacer (3 Used) 31 - Shaft 42 - Socket Bolt (3 Used)
10 - Spring (16 Used) 21 - Spring 32 - Retaining Ring (2 Used)
11 - Brake Piston 22 - Spacer 33 - Spacer (2 Used)

W2-5-18
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Motor
CAUTION: The swing motor assembly
weight: 70 kg (160 lb)
1. Drain hydraulic oil from the drain port of casing
(30) in the swing motor.
IMPORTANT: Do not disassemble relief valve (14).
2. Remove relief valves (14) (2 used) from valve
casing (3).
: 41 mm
3. Remove plugs (8) (2 used) from valve casing (3).
: 14 mm
4. Remove springs (6) (2 used) and poppets (5) (2
used) from valve casing (3).
5. Put the matching marks on the mating surfaces of
valve casing (3) and casing (30). Remove socket
bolts (4) (4 used) from valve casing (3).
: 17 mm
NOTE: Valve casing (3) is floated by springs (10)
(16 used).
6. Remove valve casing (3) from casing (30).
NOTE: At this time, as valve plate (9) may fall,
remove valve casing (3) carefully. Do not
drop valve plate (9).
W2-5-19
7. Remove valve plate (9) from valve casing (3).
8. Remove springs (10) (16 used) from brake piston
(11).
NOTE: Before removing springs (10) (16 used),
record the mounting position of springs (10)
(16 used).
9. Remove socket bolts (42) (3 used) from swing
parking brake valve (39). Remove swing parking
brake valve (39) and O-rings (40, 41) from casing
(30).
: 5 mm
IMPORTANT: Do not damage the mating surfaces
when prying the mating surfaces by
using a screwdriver.
Put the matching marks on brake
piston (11) and casing (30). Measure
and record the dimension between
the upper surfaces of casing (30)
and the upper surfaces of brake
piston (11).
10. Apply air through part A by using an air
compressor. Float and remove brake piston (11)
from casing (30).
11
30
W1JB-02-06-006
 UPPERSTRUCTURE / Swing Device

11
2 12

1 13

17
14
15 18
16
28 19
20
21
22
23 30
24
25
26
27
29

31
32
33
34
33
32
39
35
36
37
38

W1JB-02-06-001

W2-5-20
 UPPERSTRUCTURE / Swing Device
11. Remove O-rings (12, 17) from casing (30).
12. Place casing (30) horizontally with the swing
parking brake valve (39) side up. At this time,
place the wooden blocks under casing (30) so
that casing (30) should be level.
13. Remove rotor (23) from shaft (31). At this time,
plunger (28) and retainer plate (27) are removed
with rotor (23) together.
NOTE: If it is difficult to remove rotor (23), plate
(18) and friction plate (13) are tilted. Push
plate (18) and friction plate (13) to the end
by using a round bar.
14. Remove plates (18) (4 used) and friction plates
(13) (3 used) from casing (30).
15. Remove retaining ring (38) from casing (30).
Remove seal cover (37) from casing (30).
16. Tap the roller bearing (1) side of shaft (31) by
using a plastic hammer. Remove shaft (31) from
casing (30). At this time, roller bearing (34) is
removed with shaft (31) together.
17. Remove shoe plate (29) from casing (30).
18. Remove oil seal (36) from seal cover (37) by
using a screwdriver and a hammer.
W2-5-21
19. Remove the outer race of roller bearing (1) from
valve casing (3) by using a puller. Remove
O-rings (2) and pins (15) (2 used) from valve
casing (3).
IMPORTANT: Do not remove the inner race of
roller bearing (1) unless necessary.
20. Remove retaining ring (16) from shaft (31).
21. Remove retaining rings (32) (2 used), spacers
(33) (2 used), and the inner ring plate and the
outer race of roller bearing (34) from shaft (31).
22. Remove the inner race of roller bearing (34) from
shaft (31) by using a press.
At this time, remove the inner race toward the
roller bearing (1) side.
23. Remove plungers (28) (9 used), retainer plate
(27), holder (26), spacer (25), and push rods (24)
(12 used) from rotor (23).
CAUTION: When removing retaining ring (19),
push spacer (20) by using a press.
If removing only retaining ring (19), spacer
(20) and spring (21) may fly out.
24. Push spacer (20) by using a press and remove
retaining ring (19).
25. Remove spacers (20, 22) and spring (21) from
rotor (23).
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING MOTOR
8 7

4
6

3 14

W1JB-02-06-002

1 20 3 16 19 9 40

15

10 42
2
39
11
12 41

17 21
18
13 22
23
28
24

26 25

27
29
33
W1JB-02-06-003

34 33 32 31 36 37 38 35 32 30

1- Roller Bearing 12 - O-Ring 23 - Rotor 34 - Roller Bearing

2- O-Ring 13 - Friction Plate (3 Used) 24 - Push Rod (12 Used) 35 - O-Ring
3- Valve Casing 14 - Relief Valve (2 Used) 25 - Spacer 36 - Oil Seal
4- Socket Bolt (4 Used) 15 - Pin (2 Used) 26 - Holder 37 - Seal Cover
5- Poppet (2 Used) 16 - Retaining Ring 27 - Retainer Plate 38 - Retaining Ring
6- Spring (2 Used) 17 - O-Ring 28 - Plunger (9 Used) 39 - Swing Parking Brake Valve
7- O-Ring (2 Used) 18 - Plate (4 Used) 29 - Shoe Plate 40 - O-Ring
8- Plug (2 Used) 19 - Retaining Ring 30 - Casing 41 - O-Ring
9- Valve Plate 20 - Spacer (3 Used) 31 - Shaft 42 - Socket Bolt (3 Used)
10 - Spring (16 Used) 21 - Spring 32 - Retaining Ring (2 Used)
11 - Brake Piston 22 - Spacer 33 - Spacer (2 Used)

W2-5-22
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Motor
1. Install retaining ring (32) and spacer (33) to shaft
(31) on the rotor (23) side. Install the inner race of
roller bearing (34) to shaft (31) by using a press.
2. Install the outer race and the inner ring plate to
the inner race of roller bearing (34). At this time,
face the stamped mark of the inner ring plate to
the rotor (23) side.
3. Install spacer (33) and retaining ring (32) to shaft
(31) on the another side.
4. Install the inner race of roller bearing (1) to shaft
(31). Install retaining ring (16) to shaft (31).
5. Install the shaft (31) assembly to casing (30) by
using a plastic hammer.
6. Install oil seal (36) to seal cover (37) by using a
plate.
7. Install O-ring (35) to casing (30).
IMPORTANT: Do not damage oil seal (36).
8. Apply grease onto the inner surface of oil seal
(36). Install tape onto the spline part at the end of
shaft (31). Install seal cover (37) and retaining
ring (38) to casing (30).
9. Place casing (30) horizontally with the swing
parking brake valve (39) side up.
W2-5-23
IMPORTANT: Install shoe plate (29) with the larger
chamfered surface of shoe plate (29)
facing casing (30).
10. Apply grease onto the mating surfaces of casing
(30) and shoe plate (29). Install shoe plate (29) to
casing (30).
11. Install spacer (22), spring (21), and spacer (20) to
rotor (23) in this order.
12. Push spacer (20) to the position where retaining
ring (19) can be inserted by using a press. Install
retaining ring (19).
13. Install push rods (24) (12 used) to rotor (23).
Install spacer (25) and holder (26) in this order.
14. Apply hydraulic oil onto the plunger hole on rotor
(23). Install plungers (28) (9 used) to retainer plate
(27). Install the plunger (28) assembly to rotor
(23).
15. Install the rotor (23) assembly to shaft (31). While
holding the rotor (23) assembly by one hand, turn
shaft (31) by another hand and fit the spline.
16. Place the casing (30) assembly vertically.
 UPPERSTRUCTURE / Swing Device

W1JB-02-06-002

1 3 9

15
10
42
2
11
12
17
18
13

30 W1JB-02-06-003

W2-5-24
 UPPERSTRUCTURE / Swing Device
IMPORTANT: There are the notches (4 places) on IMPORTANT: Install valve plate (9) with part R
the outer surface of plate (18), and opposite to the flange surface of
the notches (4 places) on the spline valve casing (3).
side teeth of friction plate (13). Fit 22. Install O-ring (2) and pins (15) (2 used) to valve
each notch at the same place when casing (3). Install valve plate (9) to valve casing
installing. (3).
17. Place casing (30) on the wooden blocks with the Flange Surface
reduction gear side down. Alternately install 3
plates (18) (4 used) and friction plates (13) (3
used).
9
18. Install O-rings (12, 17) to casing (30). At this time,
apply grease onto O-rings sufficiently.

IMPORTANT: Fit the slit on brake piston (11) as Part R

illustrated.
19. Install brake piston (11) to casing (30). W17V-02-06-004

Screw
Hole
NOTE: Apply grease onto valve plate (9) in order
Slit to prevent valve plate (9) from falling off
from valve casing (3).

IMPORTANT: Do not drop valve plate (9). Fit the

matching marks made when
disassembling.
Swing Parking Brake 11
Valve (39) Mounting W142-02-06-011
23. Install valve casing (3) to casing (30).
Position Install valve casing (3) to casing (30) with socket
bolts (4) (4 used).
NOTE: If it is not easy to install brake piston (11) : 17 mm
due to the resistant force of O-rings (12, : 627 N⋅m (64 kgf⋅m, 460 lbf⋅ft)
17), install a bolt (M8, Pitch 1.25 mm) to
brake piston (11). Evenly tap the upper side
of the bolt by using a plastic hammer.

20. Install springs (10) (16 used) to brake piston (11).

IMPORTANT: Tap the bearing type indicated

surface by using a plastic hammer
and install roller bearing (1).
21. Install the outer race of roller bearing (1) to valve
casing (3) by using a plastic hammer.

W2-5-25
 UPPERSTRUCTURE / Swing Device

8 7

14

W1JB-02-06-002

40

39

41

W1JB-02-06-003

W2-5-26
 UPPERSTRUCTURE / Swing Device
24. Install O-rings (40, 41) to swing parking brake
valve (39). Install swing parking brake valve (39)
to casing (30) with socket bolts (42) (3 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)

25. Install poppets (5) (2 used) and springs (6) (2

used) to valve casing (3). Install O-rings (7) (2
used) to plugs (8) (2 used). Install plugs (8) (2
used) to valve casing (3).
: 17 mm
: 539 N⋅m (55 kgf⋅m, 400 lbf⋅ft)

26. Install relief valves (14) (2 used) to valve casing

(3).
: 41 mm
: 177 N⋅m (18 kgf⋅m, 131 lbf⋅ft)

W2-5-27
 UPPERSTRUCTURE / Swing Device
STRUCTURE OF SWING PARKING BRAKE
VALVE

1 2

W1JB-02-06-007

1 - Plug 3 - Casing 5 - Spring

2 - O-Ring 4 - Spool 6 - Steel Ball

W2-5-28
 UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD
Swing Motor

1. Clearance between plunger outer diameter and

rotor inner bore
D-d
Standard Allowable Limit
0.032 mm (0.001 in) 0.062 mm (0.002 in) d

W107-02-06-138

D D

W107-02-06-139

2. Clearance between plunger and shoe bottom

Standard Allowable Limit
0 mm (0 in) 0.3 mm (0.012 in)

W107-02-06-140

W2-5-29
 UPPERSTRUCTURE / Swing Device
3. Shoe thickness
Standard Allowable Limit
6.0 mm (0.24 in) 5.8 mm (0.23 in)
t

W107-02-06-142

4. Friction plate thickness

Standard Allowable Limit
4.0 mm (0.16 in) 3.6 mm (0.14 in)

W107-02-06-143

2
5. Combination of retainer plate (1) and holder (2)
Height H-h 1
Standard Allowable Limit
7.0 mm (0.28 in) 6.5 mm (0.26 in)
When H-h is 6.5 mm (0.26 in) or less, replace
retainer plate (1) and holder (2).

hH

W107-02-06-146

W2-5-30
 UPPERSTRUCTURE / Pilot Valve
REMOVAL AND INSTALLATION OF PILOT
VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal of Pilot Valve (Left)

CAUTION: Seat (1) weight: 40 kg (88 lb)

1. Remove bolts (3) (2 used) from seat belts (2) (2

1
used).
: 16 mm

2
4

3
W1JB-02-01-008

2. Remove socket bolts (4) (4 used) from seat (1).

Remove seat (1) from bracket (5). 1 4
: 6 mm

W1JB-02-07-007

W2-6-1
 UPPERSTRUCTURE / Pilot Valve
3. Remove cap (8) from lever (6). Remove screw (9)
from cover (7). Remove cover (7) from lever (6). 6 7

W1JB-02-07-013

8, 9
4. Remove socket bolts (11) (2 used) from lever (6).
6
Remove lever (6) from bracket (10).
: 6 mm
10

11 W1JB-02-07-012

12
5. Remove screws (13) (4 used) from boot (12).
Raise boot (12) from bracket (10).
10

13

W1JB-02-07-002

6. Remove screw (15) from covers (14, 16). 15

14
16

W1JB-02-07-014

W2-6-2
 UPPERSTRUCTURE / Pilot Valve
7. Remove bolts (17) (2 used) and screw (18) from
covers (14, 16). Remove covers (14, 16) from
bracket (10).
: 10 mm

17 14 16

18

10
W1JB-02-07-011

8. Remove clip bands (21) (2 used) from lever (19) 19 20 21

and harness (22). Disconnect the connector of
harness (22).

9. Loosen lock nut (20). Remove the lever (19)

assembly from pilot valve (23).
: 19 mm, 22 mm 22

W1JB-02-07-005

23
10. Disconnect hoses (24) (6 used) from pilot valve
(23). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm 23

W1JB-02-07-006

24

W2-6-3
 UPPERSTRUCTURE / Pilot Valve
11. Remove bolts (25) (4 used) from bracket (10).
25 10
Remove pilot valve (23) from bracket (10).
: 13 mm

23

W1JB-02-07-005

25

W2-6-4
 UPPERSTRUCTURE / Pilot Valve
Installation of Pilot Valve (Left)
25 10

1. Install pilot valve (23) to bracket (10) with bolts

(25) (4 used).
: 13 mm
: 20 N･m (2 kgf･m, 14.5 lbf･ft)
23

25 W1JB-02-07-005

2. Connect hoses (24) (6 used) to pilot valve (23).

: 19 mm 23
: 29.5 N･m (3 kgf･m, 21.5 lbf･ft)

24 W1JB-02-07-006
19 20 21

3. Install the lever (19) assembly to pilot valve (23).

Secure the lever (19) assembly to pilot valve (23)
with lock nut (20).
22
: 22 mm
: 55 N･m (5.5 kgf･m, 40 lbf･ft)

4. Connect the connector of harness (22). 10

5. Secure harness (22) to bracket (10) and lever (19)

with clip bands (21) (2 used).

6. Install covers (14, 16) to bracket (10) with bolts

W1JB-02-07-005
(17) (2 used) and screw (18). 23
: 10 mm
: 3.3 to 4.2 N･m
(0.3 to 0.4 kgf･m, 2.4 to 3 lbf･ft)

17 14 16

18

10
W1JB-02-07-011

W2-6-5
 UPPERSTRUCTURE / Pilot Valve
7. Install covers (14, 16) to bracket (10) with screw
(15).
15 10 16

8. Install boot (12) to bracket (10) with screws (13) (4 14

W1JB-02-07-014
used). 12 10

13

9. Install lever (6) to bracket (10) with socket bolts

W1JB-02-07-002
(11) (2 used).
: 6 mm
: 20 N･m (2 kgf･m, 14.5 lbf･ft)
6

10

11 W1JB-02-07-012

10. Install cover (7) to lever (6) with screw (9). Install
cap (8) to cover (7).
6 7

W1JB-02-07-013

8, 9

W2-6-6
 UPPERSTRUCTURE / Pilot Valve

CAUTION: Seat (1) weight: 40 kg (88 lb)

11. Install seat (1) to bracket (5) with socket bolts (3)
(4 used). 1
: 6 mm
: 20 N･m (2 kgf･m, 14.5 lbf･ft)

12. Install seat belt (2) to bracket (5) with bolts (2) (2 2 4
used).
: 16 mm 3
W1JB-02-01-008
: 50 N･m (5 kgf･m, 36 lbf･ft)

1 4

W1JB-02-07-007

W2-6-7
 UPPERSTRUCTURE / Pilot Valve
Removal of Pilot Valve (Right)

1. Remove the seat. (Refer to W2-6-1.)

2. Remove caps (1) (2 used) from cover (3). Remove

screws (2, 4) (2 used for each) from cover (3). 1, 2
Remove cover (3) from bracket (5).

5 4 W1JB-02-07-009

3. Remove screw (6) from cover (7).

1, 2

4
7 6
5
W1JB-02-07-008

8
4. Remove screws (9) (4 used) from boot (8). Raise
boot (8) from bracket (5). Remove screw (10) from
cover (7).
5

5. Remove cover (7) from bracket (5). 9

W1JB-02-07-002

10
8

W1JB-02-07-016

W2-6-8
 UPPERSTRUCTURE / Pilot Valve
6. Remove clip bands (13) (2 used) from lever (11) 11 12 13
and harness (14). Disconnect the connector of
harness (14).

7. Loosen lock nut (12). Remove the lever (11) 14

assembly from pilot valve (15).
: 19 mm, 22 mm

W1JB-02-07-005
15
8. Remove bolts (17) (3 used) from bracket (5).
Remove the bracket (5) assembly from stand (16).
Lay down the bracket (5) assembly.
: 17 mm

17
16
W1JB-02-07-008

18 19
9. Remove bolt (19) from cover (18). Remove cover
(18) from bracket (5).
: 10 mm
5

W1JB-02-07-010

10. Disconnect hoses (20) (6 used) from pilot valve 15

(15). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm

W1JB-02-07-006

20

W2-6-9
 UPPERSTRUCTURE / Pilot Valve
11. Remove bolts (21) (4 used) from bracket (5).
21 5
Remove pilot valve (15) from bracket (5).
: 13 mm

15

W1JB-02-07-005

21

W2-6-10
 UPPERSTRUCTURE / Pilot Valve
Installation of Pilot Valve (Right) 21 5

1. Install pilot valve (15) to bracket (5) with bolts (21)

(4 used).
: 13 mm 15
: 20 N･m (2 kgf･m, 14.5 lbf･ft)

21 W1JB-02-07-005

2. Connect hoses (20) (6 used) to pilot valve (15).

: 19 mm 15
: 29.5 N･m (3 kgf･m, 21.5 lbf･ft)

W1JB-02-07-006
20

3. Install the lever (11) assembly to pilot valve (15). 11 12 13

Secure the lever (11) assembly to pilot valve (15)
with lock nut (12).
: 22 mm
: 56 N･m (5.5 kgf･m, 41 lbf･ft) 14

4. Connect the connector of harness (14).

5. Connect harness (14) to pilot valve (15) and 15

bracket (5) with clip bands (13) (2 used).

W1JB-02-07-005

6. Install cover (18) to bracket (5) with bolt (19).

: 10 mm
18 19
: 3.3 to 4.2 N･m
(0.3 to 0.4 kgf･m, 2.4 to 3 lbf･ft)

W1JB-02-07-010

W2-6-11
 UPPERSTRUCTURE / Pilot Valve
7. Install cover (7) to bracket (5) with screw (6).

8. Install the bracket (5) assembly to stand (16) with

bolts (17) (3 used).
: 17 mm
7
: 50 N･m (5 kgf･m, 36 lbf･ft)

5
17
16
W1JB-02-07-008
9. Install covers (18, 7) to bracket (5) with screw
(10).
10
5

7 18

W1JB-02-07-016
8
10. Install boot (8) to bracket (5) with screws (9) (4
used). 5

W1JB-02-07-002

11. Install cover (3) to bracket (5) with screws (2, 4) (2

used for each). Install caps (1) (2 used) to cover
(3).
1, 2

5 4
W1JB-02-07-009

W2-6-12
 UPPERSTRUCTURE / Pilot Valve

CAUTION: Seat (1) weight: 40 kg (88 lb)

12. Install seat (1) to bracket (5) with socket bolts (4) 1
4
(4 used).
: 6 mm
: 20 N･m (2 kgf･m, 14.5 lbf･ft)
5

W1JB-02-07-007
13. Install seat belts (2) (2 used) to bracket (5) with
bolts (3) (2 used).
: 16 mm 1
: 50 N･m (5 kgf･m, 36 lbf･ft)

2
4

3
W1JB-02-01-008

W2-6-13
 UPPERSTRUCTURE / Pilot Valve
Removal of Travel Pilot Valve 1 2 3

1. Remove bolts (1) (7 used). Remove cover (2) from

main frame (3).
: 19 mm

W18J-02-07-003

2. Disconnect hoses (4) (6 used) from pilot valve (5).

Cap the open ends. Attach an identification tag 4 4
onto the disconnected hoses for assembling.
: 17 mm, 19 mm

3. Remove floor mat from the cab floor.

W1JB-02-07-001

W2-6-14
 UPPERSTRUCTURE / Pilot Valve
4. Remove bolts (8) (4 used) from levers (7) (2 used).
Remove levers (7) (2 used) and pedals (6) (2
used) from pilot valve (5). 7
: 17 mm 6

8 5 W1JB-02-07-003

5. Remove socket bolts (10) (2 used) from pilot valve

(5). Remove pilot valve (5) from floor plate (9).
: 8 mm 9

5 10
W1JB-02-07-004

W2-6-15
 UPPERSTRUCTURE / Pilot Valve
Installation of Travel Pilot Valve
9
1. Install pilot valve (5) to floor plate (9) with socket
bolts (10) (2 used).
: 8 mm
: 50 N･m (5 kgf･m, 36 lbf･ft)

5 10
W1JB-02-07-004

2. Install levers (7) (2 used) and pedals (6) (2 used)

to pilot valve (5) with bolts (8) (4 used).
: 17 mm 7
6
: 50 N･m (5 kgf･m, 36 lbf･ft)

8 5 W1JB-02-07-003

3. Connect hoses (4) (6 used) to pilot valve (5).

4 4
: 17 mm
: 24.5 N･m (2.5 kgf･m, 18 lbf･ft)
: 19 mm
: 29.5 N･m (3 kgf･m, 21.5 lbf･ft)

W1JB-02-07-001

4. Install cover (2) to main frame (3) with bolts (1) (7 1 2 3

used).
: 19 mm
: 90 N･m (9 kgf･m, 65 lbf･ft)

5. Install a floor mat to the inside of the cab.

W18J-02-07-003

W2-6-16
 UPPERSTRUCTURE / Pilot Valve
Removal of Bucket Open/Close Pilot Valve 1 2 3

1. Remove bolts (1) (7 used). Remove cover (2) from

main frame (3).
: 19 mm

W18J-02-07-003

2. Remove bolts (6) (6 used) from floor plate (8). 7 8 5 4 7

Remove covers (7) (2 used) from floor plate (8).
: 17 mm
6
3. Remove bolts (4) (4 used) from pedals (5) (2
9
used). Remove pedals (5) (2 used) from bucket
open/close pilot valves (9) (2 used). 10
: 13 mm 6
11
5
4. Disconnect hoses (12) (8 used) from bucket
open/close pilot valves (9) (2 used). Cap the open
4 12
ends. Attach an identification tag onto the
disconnected hoses for assembling. 10
: 19 mm
11
5. Remove socket bolts (10) (4 used) and spring 9
washers (11) (4 used) from bucket open/close 12
W18J-02-06-001

pilot valves (9) (2 used). Remove bucket

open/close pilot valves (9) (2 used) from floor
plate (8).
: 8 mm

W2-6-17
 UPPERSTRUCTURE / Pilot Valve
Installation of Bucket Open/Close Pilot Valve
7 8 5 4 7
1. Install bucket open/close pilot valves (9) (2 used)
to floor plate (8) with socket bolts (10) (4 used)
and spring washers (11) (4 used).
: 8 mm 6
: 50 N⋅m (5 kgf⋅m, 36 lbf･ft) 9

10
2. Connect hoses (12) (8 used) to bucket open/close 6
pilot valves (9) (2 used). 11
: 19 mm 5
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf･ft)
4 12
3. Install pedals (5) (2 used) to bucket open/close
10
pilot valves (9) (2 used) with bolts (4) (4 used).
: 13 mm 11
: 20 N⋅m (2 kgf⋅m, 14.5 lbf･ft)
9
W18J-02-06-001
4. Install covers (7) (2 used) to floor plate (8) with 12
bolts (6) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf･ft)
1 2 3
5. Install cover (2) to main frame (3) with bolts (1) (7
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf･ft)

W18J-02-07-003

W2-6-18
 UPPERSTRUCTURE / Pilot Valve

(Blank)

W2-6-19
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLY OF PILOT VALVES (LEFT AND RIGHT)

17

16

15

14

13

12

11
10

9 18

7
6 19
5 20
4 21
3 22

W178-02-07-064

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Casing

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Spool (4 Used)
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Plug
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Retaining Ring
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)

W2-6-20
 UPPERSTRUCTURE / Pilot Valve
Disassembly of Pilot Valves (Left and Right)
IMPORTANT: Casing (18) is made of aluminum. As
strong force deforms or damages it,
handle it with care.
IMPORTANT: Spools (19) has been selected to
match the hole on casing (18). The
dimensions of balance springs A (3),
B (4) and return springs A (5), B (6)
as well as those of pushers A (9), B
(10) are different. Arrange the
disassembled parts together with
each port in order not to confuse.
The port number is stamped on the
outer surface of casing (18).
IMPORTANT: When removing screw joint (17), do
not secure casing (18) in a vise. The
strong torque may act on screw joint
(17).
1. Secure screw joint (17) in a vise. Attach a spanner
onto cam (16). Remove screw joint (17) from cam
(16).
: 19 mm, 32 mm
2. Secure the flat surface of casing (18) in a vise.
Remove cam (16) from universal joint (15).
: 32 mm
W2-6-21
3. Attach a spanner onto the upper part of universal
joint (15). Remove universal joint (15) from casing
(18).
: 17 mm
NOTE: LOCTITE #262 has been applied onto
universal joint (15).
4. Remove plate (14) from casing (18).
IMPORTANT: Do not damage the surface of sleeve
(12). Insert a soft rubber between
sleeve (12) and a tool.
Oil seal (11) cannot be removed from
sleeve (12). Sleeve (12) and oil seal
(11) should be replaced as an
assembly.
5. Remove sleeves (12) (4 used) from casing (18)
by using a plier.
IMPORTANT: The dimensions of pushers A (9) (2
used), pusher B (10) (2 used) for
ports (1, 3) and for ports (2, 4) are
different. Keep the disassembled
parts together by the port number.
6. Remove pushers A (9) (2 used) and pushers B
(10) (2 used) from casing (18).
 UPPERSTRUCTURE / Pilot Valve

18

7
6 19
5
4 21
3 22

W178-02-07-064

W2-6-22
 UPPERSTRUCTURE / Pilot Valve
7. When compressing return springs A (5) (2 used)
and return springs B (6) (2 used), do not lower
spools (19) (4 used). Install the special tool (ST
4145) to the port hole on casing (18).
: 6 mm
8. Install the special tool (ST 4146) to the pusher A
(9) holes (2 used) and the pusher B (10) holes (2
used) on casing (18). Push the special tool (ST
4146) and compress return springs A (5) (2 used)
and return springs B (6) (2 used). Tighten the
special tool (ST 4146) with a socket bolt (M14,
Pitch 2.0 mm). Remove retaining rings (8) (4
used) from spools (19) (4 used) by using a
screwdriver.
: 12 mm
ST 4146
IMPORTANT: Spools (19) (4 used) have been
selected to match the hole on casing
(18). Spools (19) (4 used) and casing
(18) should be replaced as an
assembly.
11. Remove the special tool (ST 4145) from casing
(18). Slowly rotate and remove spools (19) (4
used) from casing (18).
IMPORTANT: Retaining ring (22) may come off
while disassembling. Do not lose
retaining ring (22).
12. Remove retaining ring (22) from casing (18) by
using a screwdriver. Install a bolt (M8, Pitch 1.25
mm) to plug (21). Remove plug (21) from casing
(18).
: 13 mm

18

W178-02-07-048
ST 4145

9. Remove the special tool (ST 4146) from casing

(18). Remove spring guides (7) (4 used), return
springs A (5) (2 used), return springs B (6) (2
used), balance springs A (3) (2 used), and
balance springs B (4) (2 used) from spools (19) (4
used).

IMPORTANT: The quantity of shims (2) has been

determined for each port during the
performance testing at the factory.
Do not lose shim (2). Keep shim (2)
carefully in order to install shim (2)
to the original port when
assembling.
10. Remove shim (2) and spacers (1) (4 used) from
spools (19) (4 used).

W2-6-23
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLY OF PILOT VALVES (LEFT AND
RIGHT)

17

16 15

11 9, 10
14
13 12
8
7

3, 4

5, 6
2

21

20 19
18
22

W1V1-02-07-001

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Casing

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Spool (4 Used)
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Plug
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Retaining Ring
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)

W2-6-24
 UPPERSTRUCTURE / Pilot Valve
Assembly of Pilot Valves (Left and Right)

IMPORTANT: The pilot valve is the susceptible IMPORTANT: Refer to the table in order to
hydraulic component to assemble the parts correctly.
contamination. Keep the parts clean 3. Install spacers (1) (4 used), shim (2), balance
when assembling. springs A (3) (2 used), and balance springs B (4)
(2 used) to spools (19) (4 used). Install return
NOTE: The table shows the relations between springs A (5) (2 used) and return springs B (6) (2
each port and the parts. Do not confuse used) to casing (18).
them when assembling.
Port Spool Shim Pushers A (9), 4. Install spring guides (7) (4 used) to return springs
No. (19) (2) B (10) A (5) (2 used) and return springs B (6) (2 used)
with the protrusion up.
Outer groove
1
(3 used)
5. Install the special tool (ST 4146) to the pusher A
Without outer
2 Same to Same to (9) holes (2 used) and the pusher B (10) holes (2
groove
the former the former used) of casing (18). Push the special tool (ST
Outer grooves
3 one one 4146) and compress the spring. Tighten the
(3 used)
special tool (ST 4146) by using a bolt (M14, Pitch
Without outer 2.0 mm).
4
groove : 12 mm

Port Return Springs A Balance Springs

No. (5), B (6) A (3), B (4)
1 Short Short
2 Long Long ST 4146
3 Short Short
4 Long Long ST 4144

1. Check the port hole number of spools (19) (4

used). Slowly rotate and insert the thinner end of
spools (19) (4 used) into the port holes (4 used) of
casing (18).

NOTE: Spool (19) has been selected to match the

port hole. Spool (19) and casing (18)
should be replaced as an assembly.
W178-02-07-049
2. Install the special tool (ST 4145) to the port hole ST 4145
of casing (18) in order not to lower spools (19) (4 6. Install retaining rings (8) (4 used) to the special
used) when return springs A (5) (2 used) and tool (ST 4144).
return springs B (6) (2 used) are compressed.
: 6 mm

W2-6-25
 UPPERSTRUCTURE / Pilot Valve

17

15
16

11 9, 10
14
12
13
8

3, 4

18

W1V1-02-07-001

W2-6-26
 UPPERSTRUCTURE / Pilot Valve
7. Install retaining rings (8) (4 used) to the head of
spools (19) (4 used) projecting from the special
tool (ST 4146).
IMPORTANT: Check the positions to install
pushers A (9) (2 used) and pushers
B (10) (2 used).
8. Install pushers A (9) (2 used) and pushers B (10)
(2 used) to casing (18).
After pushing pushers A (9) (2 used) and pushers
B (10) (2 used) several times by hand, remove
them. Check if retaining ring (8) fall off or balance
springs A (3) (2 used), and balance springs B (4)
(2 used) are located correctly.
After checking, install pushers A (9) (2 used) and
pushers B (10) (2 used) to casing (18).
9. Apply grease onto the ball at the end of pushers A
(9) (2 used) and pushers B (10) (2 used).
IMPORTANT: Fit the bolt holes on plate (14) and
casing (18).
14. Apply LOCTITE #262 onto the screw part of
universal joint (15). Install plate (14) to casing (18)
with universal joint (15).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
IMPORTANT: Check the tightness of cam (16).
15. Install cam (16) to universal joint (15). The
clearance between cam (16) and pushers A (9) (2
used) and pushers B (10) (2 used) should be 0 to
0.2 mm (0 to 0.008 in).
16. Secure cam (16) by using a spanner. Tighten
screw joint (17) by using a spanner.
: 19 mm, 32 mm
: 68.4 N⋅m (6.98 kgf⋅m, 50 lbf⋅ft)

10. Apply grease onto the joint part of universal joint

(15).

11. Apply grease onto the inner surface of oil seals

(11) (4 used).

IMPORTANT: Sleeve (12) and oil seal (11) should

be replaced as an assembly.
12. Install the sleeve (12) assemblies (4 used) to
casing (18). Push the sleeve (12) assemblies (4
used) by hand until O-rings (13) (4 used) are
inserted into the hole on casing (18).

13. Secure casing (18) in a vise.

W2-6-27
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLY OF TRAVEL PILOT VALVE
1

3
4

35
7 34
33
32
8
9 31
30
10
29
11
28

14 27

26
12
13 15
25
16

24
17

18

23
19

20
21 22
W178-02-07-063

1- Bolt (2 Used) 10 - Spring Pin (2 Used) 19 - O-Ring (2 Used) 28 - Oil Seal (4 Used)
2- Cover 11 - Bracket (2 Used) 20 - Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring (4 Used) 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool (4 Used) 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Return Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (16 Used) 26 - Spacer (4 Used) 35 - Pin (2 Used)
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)

W2-6-28
 UPPERSTRUCTURE / Pilot Valve
Disassembly of Travel Pilot Valve
IMPORTANT: Casing (23) is made of aluminium.
As strong force deforms or damages
casing (23), handle casing (23) with
care.
IMPORTANT: Spool (24) has been selected to
match the hole on casing (23).
Arrange the disassembled parts
together with each port in order not
to confuse. The port number is
stamped on the outer surface of
casing (23).
1. Secure casing (23) in a vise. Remove bolts (1) (2
used) from cover (2). Remove cover (2) from
holder (7).
: 10 mm
2. Remove socket bolts (30) (2 used) and spring
washers (29) (2 used) from holder (7). Remove
the holder (7) assembly from casing (23).
: 8 mm
3. Remove the pusher (16) assemblies (4 used)
from casing (23).
4. Remove bushings (15) (4 used) from pushers (16)
(4 used). Remove oil seals (28) (4 used) and
O-rings (14) (4 used) from bushings (15) (4 used)
by using a bamboo spatula.
W2-6-29
IMPORTANT: Put the mark on spools (24) (4 used)
when keeping in order to easily
install spools (24) (4 used) to the
original hole.
IMPORTANT: Spool (24) has been selected to
match the hole on casing (23). Spool
(24) and casing (23) should be
replaced as an assembly.
5. Rotate and remove the spool (24) assemblies (4
used) from casing (23).
Spring guides (17) (4 used), balance springs (18)
(4 used), shims (27) (12 used), and spacers (26)
(4 used) are removed with spools (24) (4 used)
together.
IMPORTANT: The quantity of shims (27) has been
determined for each port during the
performance testing. When keeping,
pair shim (27) with each spool.
6. Compress balance springs (18) (4 used). Remove
spring guides (17) (4 used), balance springs (18)
(4 used), shims (27) (12 used), and spacers (26)
(4 used) from spools (24) (4 used).
7. Remove return springs (25) (4 used) from casing
(23).
 UPPERSTRUCTURE / Pilot Valve

3
4
6
3
4

5
6
6
35
7 34
33
32
9 31

10

11

12
13

23
19

20
21 22
W178-02-07-063

W2-6-30
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Place a stand under brackets (11) (2
used) and reduce a reaction force. If
holder (7) bears the reaction force,
strong force acts on pins (35) (2
used) and pins (35) (2 used) may be
deformed.
8. Place a stand under brackets (11) (2 used).
As the inner surfaces of the spring pins (12, 13)
holes (2 used) on brackets (11) (2 used) are
stepped-shape, they can only be removed in one
direction.
Tap and remove spring pins (12, 13) (2 used for
each) from brackets (11) (2 used) at the same
time by using the special tool (ST 1237). Remove
brackets (11) (2 used) from pin (35).
Do not remove spring pins (10) (2 used) with
brackets (11) (2 used) attached unless necessary.
The hole end of spring pins (10) (2 used) has
been crimped.
12, 13
11
35 10
Crimped Position
Stand
W176-02-07-019
9. Remove socket bolts (9) (4 used) and spring
washer (8) (4 used) from dampers (32) (2 Used).
Remove dampers (32) (2 used) and rubber seats
(31) (2 used) from pin (35). At this time, O-rings
(34) (2 used) are removed together.
: 5 mm
W2-6-31
10. Remove O-rings (33) (2 used) from pin (35).
11. Place holder (7) with the casing (23) mounting
surface up.
12. Tap the bottom of cams (5) (2 used) and remove
spring pins (3, 4) (2 used for each) from cams (5)
(2 used) at the same time by using the special tool
(ST 1237). The holes of spring pins (3, 4) (2 used
for each) are stepped-shape.
13. Remove pins (35) (2 used) from holder (7). Tap
from the bottom of cam (5). As the spring pins (3,
4) (2 used for each) are crimped, they may feel
tight when removing by using a bar and a hammer.
At the same time, cams (5) (2 used) are also
removed.
Do not remove bushings (6) (4 used) with holder
(7) attached unless necessary.
Tap and remove bushings (6) (4 used) from holder
(7) by using the special tool (ST 7256) if
necessary.
14. Remove plugs (20) (2 used) from casing (23).
Remove O-rings (19) (2 used) from plugs (20) (2
used).
: 5 mm
15. Remove plugs (21) (2 used) from casing (23).
Remove O-rings (22) (2 used) from plugs (21) (2
used).
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLY OF TRAVEL PILOT VALVE

11 32 31 2 35 6 12 10 13 5 3, 4 30 1

29
34 15
9 33 28
17
8 18
14
25
19, 20
27
16
21, 22
26

24
23

W178-02-11-316

1- Bolt (2 Used) 10 - Spring Pin (2 Used) 19 - O-Ring (2 Used) 28 - Oil Seal (4 Used)
2- Cover 11 - Bracket (2 Used) 20 - Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring (4 Used) 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool (4 Used) 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Return Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (16 Used) 26 - Spacer (4 Used) 35 - Pin (2 Used)
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)

W2-6-32
 UPPERSTRUCTURE / Pilot Valve
Assembly of Travel Pilot Valve

IMPORTANT: Check the direction to install spring
guides (17) (16 used).
1. Assemble spools (24) (4 used) into an assembly.
• Insert spacers (26) (4 used), shims (27) (12 used),
and balance springs (18) (4 used) into spools (24)
(4 used) in this order. Install shims (27) (12 used),
as the same condition before disassembling.
• Compress balance springs (18) (4 used) by hand.
Install spring guides (17) (4 used) to spools (24)
(4 used) with the stepped part down.
IMPORTANT: Before inserting the parts into holder
(7) and casing (23), apply hydraulic
oil.
2. Insert return springs (25) (4 used) into casing
(23).
3. Insert the spool (24) assemblies (4 used) into the
6. If bushing (6) has been removed from holder (7),
install bushings (6) (4 used) to holder (7) by using
the special tool (ST 7256) in the following
procedures.
NOTE: Bushings (6) (4 used) are identical.
• Insert bushing (6) into the special tool (ST 7256).
Insert bushing (6) to the end of the hole of holder
(7) by using the special tool (ST 7256) and a
hammer.
Stop tapping when the bushing (6) end is flush
with the hole end.
7 ST 7256
6
W178-02-11-310

former port before disassembling. Rotate and

insert the spool (24) assemblies (4 used) into • Install bushing (6) on the opposite side in the
casing (23). same way. 6
7
ST 7256

4. Assemble pushers (16) (4 used) into an

assembly.
• Install oil seals (28) (4 used) to bushings (15) (4
used).
• Apply grease onto the inner surface of oil seals W178-02-11-311

(28) (4 used). • Install bushing (6) in the near side as illustrated.

• Install O-rings (14) (4 used) to bushings (15) (4 Stop tapping when the bushing (6) end is flush
used). with the outside of holder (7).
• Install pushers (16) (4 used) to bushings (15) (4
used).
• Apply grease onto the head of pushers (16) (4 6
used). 7 ST 7256

5. Insert the pusher (16) assemblies (4 used) into

casing (23).
Outside of
Holder
W178-02-11-312

• Install bushing (6) in the near and opposite side

as illustrated. 6
7
ST 7256

W178-02-11-313

W2-6-33
 UPPERSTRUCTURE / Pilot Valve

32 31 35 5 3, 4 30

29
34

9 33

23

W178-02-11-316

W2-6-34
 UPPERSTRUCTURE / Pilot Valve
7. Install O-rings (33) (2 used) to pins (35) (2 used).
Apply grease onto O-rings (33) (2 used). Install
and cams (5) (2 used) to holder (7) with pins (35)
(2 used).
IMPORTANT: Check the direction to install spring
pins (3, 4) (2 used for each).
8. Install spring pins (3, 4) (2 used for each) to cams
(5) (2 used) by using the special tool (ST 1237).
Secure cams (5) (2 used) and pins (35) (2 used).
At this time, the slits of spring pins (3, 4) (2 used
for each) should be positioned 90° away each
other.
Tap and install spring pins (3, 4) (2 used for each)
until spring pins (3, 4) come in contact with the
stepped part in the hole.
11. Install rubber seats (31) (2 used) to pins (35) (2
used).
IMPORTANT: Check the direction of damper (32).
The inner surface of damper (32) is
edged-shape. If damper (32) is pried
when installing, O-ring (33) may be
damaged.
12. Install dampers (32) (2 used) to pins (35) (2 used)
with the lever up.
13. Secure dampers (32) (2 used) and rubber seats
(31) (2 used) to holder (7) with socket bolts (9) (4
used) and spring washers (8) (4 used).
: 5 mm
: 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)

3 Slit Slit 14. Apply grease onto O-ring (34) (2 used). Push
O-rings (34) (2 used) to the end of pins (35) (2
used).

W178-02-07-050
4

9. Crimp the hole end of cams (5) (2 used) where

spring pins (3, 4) (2 used for each) are inserted by
using a punch.

10. Install holder (7) to the casing (23) assembly with

socket bolts (30) (2 used) and spring washers (29)
(2 used).
Check the mark direction and install holder (7).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W2-6-35
 UPPERSTRUCTURE / Pilot Valve

11 32 2 35 12 10 13 1

19, 20

21, 22

W178-02-11-316

W2-6-36
 UPPERSTRUCTURE / Pilot Valve
15. As for the direction to install brackets (11) (2 used), 19. Apply grease onto the spring pins (10) (2 used)
refer to the figure in Disassembly of Travel Pilot contact part of dampers (32) (2 used).
Valve on W2-6-28. Install brackets (11) (2 used) to
pins (35) (2 used). Fit the holes to insert spring 20. Install O-rings (19) (2 used) to plugs (20) (2 used).
pins (12, 13) (2 used for each). Install plugs (20) (2 used) to casing (23).
: 5 mm
IMPORTANT: Place a stand under brackets (11) (2 : 10 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
used) and reduce a reaction force. If
holder (7) bears the reaction force, 21. Install O-rings (22) (2 used) to plugs (21) (2 used).
strong force acts on pins (35) (2 Install plugs (21) (2 used) to casing (23).
used) and pins (35) (2 used) may be : 6 mm
deformed. : 19.6 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
16. Place a stand under brackets (11) (2 used).
Install spring pins (12, 13) (2 used for each) to
brackets (11) (2 used) until they come in contact
with the stepped part by using the special tool (ST
1237). The slits of spring pins (2 used) should be
positioned 90° away each other.

Crimped Position
Crimped Position

11 35

Stand 12, 13

W176-02-07-011

17. Crimp the hole end of brackets (11) (2 used)

where spring pins (12, 13) (2 used for each) are
inserted by using a punch.

18. Install cover (2) to holder (7) with bolts (1) (2

used).
: 10 mm
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)

W2-6-37
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLY OF BUCKET OPEN /
CLOSE PILOT VALVE

18
2

17

10

11

12

13

14

15

W183-02-07-004
16

1- Set Screw 6- O-Ring (2 Used) 11 - Shim (Several) 15 - Casing

2- Cam 7- Bushing (2 Used) 12 - Spacer (2 Used) 16 - Cap (4 Used)
3- Bushing (2 Used) 8- Pusher (2 Used) 13 - Spring (2 Used) 17 - Pin
4- Holder 9- Spring Guide (2 Used) 14 - Spool (2 Used) 18 - Socket Bolt (2 Used)
5- Oil Seal (2 Used) 10 - Balance Spring (2 Used)

W2-6-38
 UPPERSTRUCTURE / Pilot Valve
Disassembly of Bucket Open / Close Pilot valve

1. Secure casing (15) in a vise. Remove set screw 8. Remove springs (13) (2 used) from casing (15).
(1) from cam (2).
: 5 mm

2. Remove pin (17) from holder (4) with a bar and a

hammer. Remove cam (2) from holder (4).

3. Remove socket bolts (18) (2 used) from holder (4).

Remove holder (4) from casing (15).

4. Remove pushers (8) (2 used) from casing (15). At

this time, bushings (7) (2 used) and oil seals (5) (2
used) are removed with pushers (8) (2 used)
together.

5. Remove pushers (8) (2 used) from bushings (7)

(2 used). Remove oil seals (5) (2 used) from
bushings (7) (2 used).

IMPORTANT: Put the mark on spools (14) (2 used)

when keeping in order to correctly
install them to the original hole.
6. Rotate and remove the spool (14) assemblies (2
used) from casing (15).
Spring guides (9) (2 used), balance springs (10)
(2 used), shim (11), and spacers (12) (2 used) are
removed with spools (14) (2 used) together.

IMPORTANT: Spool (14) has been selected to

match the hole on casing (15). Spool
(14) and casing (15) should be
replaced as an assembly.

IMPORTANT: The quantity of shims (11) has been

determined for each port during the
performance testing at the factory.
Do not lose shim (11). Keep shim
(11) carefully in order to install shim
(11) to the original port when
assembling.

7. Compress balance springs (10) (2 used). Remove

spring guides (9) (2 used), balance springs (10) (2
used), shim (11), and spacers (12) (2 used) from
spools (14) (2 used).

W2-6-39
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLY OF BUCKET OPEN / CLOSE
PILOT VALVE

2
1

3 8

5
17 18
7

6 9

10

14 13

16 11, 12

15
W183-02-07-001

1- Set Screw 6- O-Ring (2 Used) 11 - Shim (Several) 15 - Casing

2- Cam 7- Bushing (2 Used) 12 - Spacer (2 Used) 16 - Cap (4 Used)
3- Bushing (2 Used) 8- Pusher (2 Used) 13 - Spring (2 Used) 17 - Pin
4- Holder 9- Spring Guide (2 Used) 14 - Spool (2 Used) 18 - Socket Bolt (2 Used)
5- Oil Seal (2 Used) 10 - Balance Spring (2 Used)

W2-6-40
 UPPERSTRUCTURE / Pilot Valve
Assembly of Bucket Open / Close Pilot valve

IMPORTANT: Install spring guides (9) (2 used) with
the stepped part facing the spring
(13) side.
IMPORTANT: Insert the same quantity of shims
(11) before disassembling.
1. Insert spacers (12) (2 used), shim (11), and
balance springs (10) (2 used) to spools (14) (2
used) in this order.
2. Compress balance springs (10) (2 used). Install
spring guides (9) (2 used) to spools (14) (2 used)
with the stepped part down.
3. Install springs (13) (2 used) to casing (15).
8. If bushings (3) (2 used) have been removed from
holder (4), install bushings (3) (2 used) to holder
(4) by using the special tool (ST 7131) in the
following procedures.
NOTE: Bushings (3) (2 used) are identical.
・Insert bushing (3) into the special tool (ST 7131).
Tap and install the special tool (ST 7131) to holder
(4) by using a hammer.
Stop tapping when the bushing (3) end is flush
with the hole end.
ST 7131
4

IMPORTANT: Install the spool (14) assembly to the 3 W183-02-07-003

original port when disassembling.

4. Rotate and install the spool (14) assemblies (2 ・ Install bushing (3) on the opposite side in the
used) to casing (15). same way.

5. Install oil seals (5) (2 used) to bushings (7) (2

used). At this time, apply grease onto the inner
9. Install holder (4) on the casing (15) assembly with
surface of oil seals (5) (2 used).
socket bolts (18) (2 used).
: 6 mm
6. Install O-ring (6) to bushings (7) (2 used). Install : 20 N･m(2 kgf⋅m, 14.5 Ibf⋅ft)
pushers (8) (2 used) to bushings (7) (2 used). At
this time, apply grease onto the head of pushers
10. Fit the pin holes of cam (2) and holder (4). Secure
(8) (2 used).
cam (2) to holder (4) with pin (17).
7. Install the pusher (8) assemblies (2 used) to
11. Secure cam (2) to pin (17) with set screw (1).
holder (4).
: 5 mm
: 12 N･m(1.2 kgf⋅m, 8.9 Ibf⋅ft)

W2-6-41
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-6-42
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
REMOVAL AND INSTALLATION OF PILOT
SHUT-OFF SOLENOID VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED 1 2 3
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Remove bolts (1) (7 used). Remove cover (2) from
main frame (3).
: 19 mm

W18J-02-07-003

2. Remove bolt (8) from clip (6). Remove clip (6) 4 5 6 7 8

from floor plate (7).
：17 mm 9

3. Disconnect connector (9).

4. Disconnect hoses (4) (9 used) from pilot shut-off

solenoid valve (5). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
：19 mm, 27 mm W18J-02-07-001
4
5. Remove the mat from the inside of the cab.
Footrest Travel Pilot Valve
6. Remove bolts (10) (2 used) from floor plate (7).
Remove pilot shut-off solenoid valve (5) from floor
plate (7).
：17 mm
7

10 W18J-02-07-002

W2-7-1
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
Installation Footrest Travel Pilot Valve
1. Install pilot shut-off solenoid valve (5) to floor plate
(7) with bolts (10) (2 used).
：17 mm
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
7

10 W18J-02-07-002

2. Connect connector (9).

4 5 6 7 8
3. Install clip (6) to floor plate (7) with bolt (8). 9
：17 mm
：50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

4. Connect hoses (4) (9 used) to pilot shut-off

solenoid valve (5).
：19 mm
：29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
：27 mm
：78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) W18J-02-07-001
4

5. Install cover (2) to main frame (3) with bolts (1) (7 1 2 3

used).
：19 mm
：90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

6. Install the mat to the inside of the cab.

W18J-02-07-003

W2-7-2
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
STRUCTURE OF PILOT SHUT-OFF SOLENOID VALVE

W1JB-02-08-001

3 4 5 6 7 8

W1JB-02-08-002

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 :6 26.5 (2.7) (19.5)
2 O-ring 1 (1B P11)
3 Spring 1
4 Spool 1
5 Filter 1
6 Body 1
7 O-ring 1 (1A P16)
8 Solenoid 1
9 Socket bolt 2 :4 3.92 (0.4) (2.9)

W2-7-3
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve

(Blank)

W2-7-4
 UPPERSTRUCTURE / Shuttle Valve
REMOVAL AND INSTALLATION OF
SHUTTLE VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal 1 2
1. Remove bolts (2) (6 used). Remove cover (3) from
main frame (1).
: 19 mm 3

W18J-02-07-003

4 5 6, 7 8
2. Disconnect hoses (5) (8 used) from shuttle valve
(4). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm

3. Remove bolts (9) (2 used) from cab bed (8).

Remove the bracket (6) assembly from cab bed
(8). Remove bolts (7) (2 used) from bracket (6). 9
Remove shuttle valve (4) from bracket (6).
: 13 mm, 17 mm

4. Remove pressure sensors (10) (2 used) from

shuttle valve (4). W18J-02-08-001
10 5 10
: 24 mm

W2-8-1
 UPPERSTRUCTURE / Shuttle Valve
Installation 4 5 6, 7 8
1. Install pressure sensors (10) (2 used) to shuttle
valve (4).
: 24 mm
: 16±1.6 N⋅m (1.6±0.16 kgf⋅m, 12±1.2 lbf⋅ft)

2. Install shuttle valve (4) to bracket (6) with bolts (7)

(2 used).
: 13 mm
9
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

3. Install the bracket (6) assembly to cab bed (8) with

bolts (9) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 10 5 10
W18J-02-08-001

4. Connect hoses (5) (8 used) to shuttle valve (4).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

5. Install cover (3) to main frame (1) with bolts (2) (6 1 2

used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 3

W18J-02-07-003

W2-8-2
 UPPERSTRUCTURE / Shuttle Valve
STRUCTURE OF SHUTTLE VALVE

2
1

3
4
3 5
4
6

5
6

5
6 W18J-02-08-002

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Body 1
2 Steel ball 2 4
3 Steel ball 2
4 Seat 2 : 5 1.5 0.15 1.1
5 O-ring 3 1B P11
6 Plug 3 : 6 20 2 15

W2-8-3
 UPPERSTRUCTURE / Shuttle Valve
(Blank)

W2-8-4
 UPPERSTRUCTURE / Solenoid Valve
REMOVAL AND INSTALLATION OF
4-SPOOL SOLENOID VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal 1 2, 3 4
1. Remove bolts (1) (2 used). Remove cover (4) from
bracket (8).
: 17 mm

2. Disconnect connectors (3) (4 used) from 4-spool

solenoid valve (5).

3. Remove bolt (7) from clip (6). Remove clip (6) and
disconnect harness (2) from bracket (8).
: 17 mm

4. Disconnect hoses (10) (13 used) from 4-spool

solenoid valve (5). Cap the open ends. Attach an W18J-02-09-001
identification tag onto the disconnected hoses for 8 7 6 5
assembling.
: 17 mm, 19 mm, 27 mm
5, 9
5. Remove bolts (9) (2 used) from 4-spool solenoid
valve (5). Remove bracket (8) and 4-spool
solenoid valve (5) from control valve (11). 10
: 17 mm

W18J-02-09-001
8 10 11

W2-9-1
 UPPERSTRUCTURE / Solenoid Valve
Installation
5, 9
1. Install bracket (8) and 4-spool solenoid valve (5)
to control valve (11) with bolts (9) (2 used).
: 17 mm
10
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

2. Connect hoses (10) (13 used) to 4-spool solenoid

valve (5).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
W18J-02-09-001
8 10 11
3. Connect connectors (3) (4 used) to 4-spool
solenoid valve (5).

1 2, 3 4
4. Connect harness (2) to bracket (8) with clip (6)
and bolt (7).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

5. Install cover (4) to bracket (8) with bolts (1) (2

used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W18J-02-09-001
8 7 6 5

W2-9-2
 UPPERSTRUCTURE / Solenoid Valve
STRUCTURE OF 4-SPOOL SOLENOID VALVE

W1JB-02-09-001

Proportional Solenoid Valve

Proportional Solenoid Valve

W1JB-02-09-002

Filter Plug
Filter Plug

W1JB-02-09-004

W1JB-02-09-003

W2-9-3
 UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLY AND ASSEMBLY OF 4-SPOOL SOLENOID VALVE
1
2
3
4
5

7
8
9
12
13
10
11 14
15
16

17
18
19

W18G-02-08-012

4 2 3, 5 6 1 8 12 13 17 10 18

7 9 14 15 16 11 9 W18G-02-08-013

1- Socket Bolt (4 Used) 6- Solenoid 11 - Orifice 16 - O-Ring

2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
4- Adjusting Bolt 9- Diaphragm 14 - O-Ring 19 - Wave Spring
5- Spring 10 - Spool 15 - O-Ring

W2-9-4
 UPPERSTRUCTURE / Solenoid Valve
Disassembly of 4-Spool Solenoid Valve
1. Remove socket bolts (1) (2 used) from solenoid
(6). Remove solenoid (6) and O-ring (8) from the
housing.
: 4 mm
IMPORTANT: Do not lose spring (7) inside
solenoid (6) when removing solenoid
(6).
Do not disassemble lock nut (2) and
adjusting bolt (4) for pressure
adjustment.
2. Remove spool (10) from sleeve (17). Remove
diaphragm (9), washer (12), and spring (13) from
sleeve (17).
3. Remove sleeve (17) from the housing. Remove
plate (18) and wave spring (19) from the housing.
IMPORTANT: Do not remove orifice (11) from
sleeve (17).
4. Remove O-rings (14, 15, and 16) from sleeve
(17).
W2-9-5
Assembly of 4-Spool Solenoid Valve
1. Install wave spring (19) and plate (18) to the
housing.
IMPORTANT: Fit the hole on sleeve (17) to that on
the housing when inserting sleeve
(17) into the housing.
2. Install O-rings (14, 15, and 16) to sleeve (17).
Install sleeve (17) to the housing.
IMPORTANT: Do not damage the edge inside of
sleeve (17) when inserting spool (10)
into sleeve (17).
After inserting spool (10), push
about 3 to 5 mm by fingers. Check
that spool (10) moves smoothly.
3. Install diaphragm (9), washer (12), and spring (13)
to spool (10). Install spool (10) to sleeve (17).
IMPORTANT: When installing solenoid (6), do not
drop spring (7).
4. Install spring (7) to solenoid (6). Install solenoid
(6) to the housing with socket bolts (1) (2 used).
: 4 mm
: 5+2-0 N⋅m (0.5+0.2-0 kgf⋅m, 3.7+1.5-0 lbf⋅ft)
 UPPERSTRUCTURE / Solenoid Valve
(Blank)

W2-9-6
 UPPERSTRUCTURE / Signal Control Valve
REMOVAL AND INSTALLATION OF
SIGNAL CONTROL VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
1 2, 3
Removal
1. Disconnect connector (5) from signal control valve
(2).
4
2. Disconnect hoses (4) (32 used) from signal
control valve (2). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm

3. Remove bolts (8) (6 used). Remove the bracket

(6) assembly from control valve (1) and bracket
(7). W18J-02-10-001

: 19 mm 8 7 6 5

4. Remove socket bolts (3) (4 used) from signal

control valve (2). Remove signal control valve (2)
from bracket (6).
: 8 mm

W2-10-1
 UPPERSTRUCTURE / Signal Control Valve
Installation
1. Install signal control valve (2) to bracket (6) with
socket bolts (3) (4 used). 1 2, 3
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
4
2. Install the brackets (6) assembly to control valve
(1) and brackets (7) (2 used) with bolts (8) (6
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

3. Connect hoses (4) (32 used) to signal control

valve (2).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) W18J-02-10-001

: 19 mm 8 7 6 5
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

4. Connect connector (5) to signal control valve (2).

W2-10-2
 UPPERSTRUCTURE / Signal Control Valve
(Blank)

W2-10-3
 UPPERSTRUCTURE / Signal Control Valve
STRUCTURE OF SIGNAL CONTROL VALVE

4 13

12

11
7

4 10

7 8
7 7

4
4

W1JB-02-10-002

W2-10-4
 UPPERSTRUCTURE / Signal Control Valve

15

14 16
17
18
19
16 20
17
21
19
16 20
17
18
19
20

14
22
23
24
25

26
27
19
28
17
16
20 29
19
18 14
5 17
20 16
19
21
17
20 16
19
18
17
16 W1JB-02-10-003

Detail of Body 2 (5)

1- Bolt (3 Used) 9- Body 3 17 - O-Ring (7 Used) 25 - O-ring

2- Body 1 10 - Gasket 18 - Spring (4 Used) 26 - Spring
3- Gasket 11 - Body 4 19 - Spring Guide (7 Used) 27 - Spool
4- Filter (17 Used) 12 - Gasket 20 - Spool (6 Used) 28 - Spring
5- Body 2 13 - Body 5 21 - Spring (2 Used) 29 - Plate
6- Gasket 14 - Socket Bolt (11 Used) 22 - Plate
7- Shuttle Valve (2 Used) 15 - Plate 23 - O-ring
8- Spring (4 Used) 16 - Plug (7 Used) 24 - Shuttle Valve

W2-10-5
 UPPERSTRUCTURE / Signal Control Valve
(Blank)

W2-10-6
 UPPERSTRUCTURE / Fan Motor
REMOVAL AND INSTALLATION OF FAN
MOTOR

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal 2 3 4 5
1. Remove bolts (3) (4 used) from handrail (2).
Remove handrail (2) from shroud (1).
: 19 mm
1
2. Remove bolts (4) (7 used). Remove cover (5) from
shroud (1).
: 19 mm

W18J-02-11-001

6 7 8 9 10 11 12
3. Disconnect hoses (10) (2 used) from water tank
(12). Cap the open ends.

4. Remove bolts (11) (4 used) from water tank (12).

Remove water tank (12) from shroud (1). 10
: 17 mm

5. Remove bolts (6, 9) (2 used for each) from 1

brackets (7, 8). Remove bracket (7) from shroud W18J-02-11-004
(1) and bracket (8). 13
: 19 mm

6. Remove bolts (14) (4 used) from step (13).

Remove step (13) from brackets (15) (2 used). 14
: 19 mm

15

W18J-02-11-002

W2-11-1
 UPPERSTRUCTURE / Fan Motor

CAUTION: Step (17) weight: 20 kg (44 lb)

16 8 17, 18 10 19, 20
7. Attach a nylon sling onto step (17). Hoist and hold
step (17).

8. Remove bolts (16) (4 used) from step (17).

Remove step (17) from brackets (18) (2 used).
: 19 mm

9. Remove bolts (20) (5 used) from clips (19) (5

used). Remove clips (19) (5 used) from bracket
(8) and hose (10).
: 17 mm
W18J-02-11-003

10. Disconnect hose (23) from fan motor (22). Cap the 21 22 23
open ends.
: 27 mm

11. Disconnect hose (25) from adapter (26). Cap the

open ends.
: 27 mm

12. Remove socket bolts (24) (8 used) and split

flanges (21) (4 used) from hoses (27) (2 used). 24
Disconnect hoses (27) (2 used) from fan motor
(22). Cap the open ends.
: 8 mm
W18J-02-11-005
27, 28 26 25
13. Disconnect hoses (27) (2 used) from elbows (28)
(2 used).
: 36 mm

W2-11-2
 UPPERSTRUCTURE / Fan Motor
14. Remove bolts (32) (8 used) from nets (29, 31).
1 29 8 30 31 32
: 19 mm

CAUTION: The bracket (8) assembly weight:

98 kg (220 lb)

15. Attach a nylon sling onto bracket (8). Hoist and

hold bracket (8).

16. Remove bolts (30) (6 used) from bracket (8). W18J-02-11-004

Remove the bracket (8) assembly from shroud

(1).

17. Remove bolts (33) (4 used) from net (31). 29 8 33

Remove nets (29, 31) from bracket (8).
: 19 mm

31

W18J-02-11-004

18. Remove socket bolts (35) (4 used) from fan (36).

Remove fan (36) from coupling (34). 34
: 8 mm

35

36
W1JB-02-12-010

W2-11-3
 UPPERSTRUCTURE / Fan Motor
19. Remove lock pin (37) from fan motor (22).

20. Remove nut (38) and washer (39) from fan motor
(22).
22
: 24 mm

21. Remove coupling (34) from fan motor (22).

22

37

38

39
CAUTION: Fan motor (22) weight: 20 kg (44
W1JB-02-12-017
lb)
Bracket (8) weight: 35 kg (77 lb) 8 34

22. Remove nuts (42) (2 used) and washers (41) (2

used) from bolts (40) (2 used). Remove bolts (40) 40, 41, 42 22
(2 used) and washers (41) (4 used) from bracket
(8).
: 19 mm 37

23. Remove fan motor (22) from bracket (8).

39

W1JB-02-12-015
38 34

W2-11-4
 UPPERSTRUCTURE / Fan Motor
Installation

CAUTION: Fan motor (22) weight: 20 kg (44

lb)
Bracket (8) weight: 35 kg (77 lb)
40, 41, 42 22
1. Install fan motor (22) to bracket (8) with bolts (40)
(2 used), washers (41) (4 used), and nuts (42) (2 37
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
39

2. Install coupling (34) to fan motor (22). Secure

coupling (34) to fan motor (22) with washer (39), 8
nut (38), and lock pin (37).
: 24 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
W1JB-02-12-015
38 34
3. Install fan (36) to coupling (34) with socket bolts
(35) (4 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

34 36

35

W1JB-02-12-017

4. Install nets (29, 31) between fan (36) and bracket

(8) from both right and left sides. 36 29

31 W1JB-02-12-010

W2-11-5
 UPPERSTRUCTURE / Fan Motor
5. Secure net (31) to net (29) with bolts (33) (4 29 33
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
31

CAUTION: The bracket (8) assembly weight: W18J-02-11-004

98 kg (220 lb)

6. Attach a nylon sling onto the bracket (8) assembly. 1 29 8 30 31 32

Hoist the bracket (8) assembly. Fit the bracket (8)
assembly to the mounting hole on shroud (1).

7. Install the bracket (8) assembly to shroud (1) with

bolts (30) (6 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
W18J-02-11-004

8. Install nets (29, 31) to shroud (1) with bolts (32) (8

used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

9. Connect hoses (27) (2 used) to elbows (28) (2 21 22 23

used).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

10. Connect hoses (27) (2 used) to fan motor (22) with

split flanges (21) (4 used) and socket bolts (24) (8
used).
: 8 mm 24
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

11. Connect hoses (23, 25) to fan motor (22) and W18J-02-11-005
adapter (26). 27, 28 26 25
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

W2-11-6
 UPPERSTRUCTURE / Fan Motor
12. Install bracket (7) to shroud (1) and bracket (8) 6 7 8 9
with bolts (6, 9) (2 used for each).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

1
W18J-02-11-004

13. Connect hose (10) to bracket (8) with clips (19) (5 16 8 17, 18 10 19, 20
used) and bolts (20) (5 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

CAUTION: Step (17) weight: 20 kg (44 lb)

14. Attach a nylon sling onto step (17). Hoist step (17).
Fit step (17) to the mounting hole on brackets (18)
(2 used).

15. Install step (17) to brackets (18) (4 used) with bolts W18J-02-11-003

(16) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

16. Install step (13) to brackets (15) (2 used) with 13

bolts (14) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft) 14

15

W18J-02-11-002

W2-11-7
 UPPERSTRUCTURE / Fan Motor
17. Install water tank (12) to shroud (1) with bolts (11) 1 10 11 12
(4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

18. Connect hoses (10) (2 used) to water tank (12). 10

W18J-02-11-004

2 3 4 5
19. Install cover (5) to shroud (1) with bolts (4) (7
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
1
20. Install handrail (2) to shroud (1) with bolts (3) (4
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W18J-02-11-001

W2-11-8
 UPPERSTRUCTURE / Fan Motor
STRUCTURE OF FAN MOTOR
7

21

22

23

W1JB-02-12-002

1 2 3 4 5 6 7 8 9 10 11

W1JB-02-12-001
20 19 18 17 16 15 14 13 12

1- End Cap 7- Pressure Port Plate 13 - Retaining Ring 19 - Needle Bearing

2- Rotor Insert Assembly 8- O-Ring 14 - Retaining Ring 20 - Socket Bolt (4 Used)
3- Vane Spring (24 Used) 9- Housing 15 - Seal 21 - Ball
4- Vane Pin Hold Mount 10 - Ball Bearing 16 - Seal 22 - Valve
(12 Used)
5 - Vane (12 Used) 11 - Key 17 - Pin (2 Used) 23 - Screw
6 - Cam Ring 12 - Shaft 18 - Seal

NOTE: Tightening Torque

20- Socket Bolt 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
23- Screw 11.5 to 12.6 N⋅m (1.2 to 1.3 kgf⋅m, 8.5 to 9.3 lbf⋅ft)

W2-11-9
 UPPERSTRUCTURE / Fan Motor
(Blank)

W2-11-10
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 MEMO

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 SECTION 3
UNDERCARRIAGE

—CONTENTS—
Group 1 Swing Bearing
Removal and Installation of
Swing Bearing ....................................... W3-1-1
Disassembly of Swing Bearing ................ W3-1-4
Assembly of Swing Bearing ..................... W3-1-6
Group 2 Travel Device
Removal and Installation of
Travel Device......................................... W3-2-1
Disassembly of Travel Device.................. W3-2-6
Assembly of Travel Device .................... W3-2-14
Disassembly of Travel Motor ................. W3-2-22
Assembly of Travel Motor ...................... W3-2-26
Disassembly of Brake Valve .................. W3-2-32
Assembly of Brake Valve ....................... W3-2-34
Maintenance Standard........................... W3-2-36
Group 6 Upper and Lower Roller
Removal and Installation of
Upper Roller........................................... W3-6-1
Removal and Installation of
Lower Roller........................................... W3-6-4
Disassembly of Upper Roller ................... W3-6-8
Assembly of Upper Roller ...................... W3-6-10
Disassembly of Lower Roller ................. W3-6-12
Assembly of Lower Roller ...................... W3-6-14
Maintenance Standard ......................... W3-6-16
Group 7 Track
Removal and Installation of Track ............ W3-7-1
Maintenance Standard ........................... W3-7-7

Group 3 Center Joint

Removal and Installation of
Center Joint ........................................... W3-3-1
Disassembly of Center Joint .................... W3-3-4
Assembly of Center Joint......................... W3-3-6
Maintenance Standard............................W3-3-11

Group 4 Track Adjuster

Removal and Installation of
Track Adjuster........................................ W3-4-1
Disassembly of Track Adjuster................. W3-4-4
Assembly of Track Adjuster ................... W3-4-10

Group 5 Front Idler

Removal and Installation of Front Idler .... W3-5-1
Disassembly of Front Idler ....................... W3-5-4
Assembly of Front Idler............................ W3-5-8
Maintenance Standard........................... W3-5-12

18JW-3-1
(Blank)

18JW-3-2
 UNDERCARRIAGE / Swing Bearing
REMOVAL AND INSTALLATION OF
SWING BEARING

The procedure starts on the premise that the front

attachment, the counterweight, and the cab have
already been removed.
Matching Mark

Removal
1. Put the matching marks on inner race (1) of the
swing bearing and track frame (2).

1 2

2. Remove bolts (3) (50 used). W1JB-03-01-001

: 55 mm
3

CAUTION: Swing bearing weight: 1820 kg

(4020 Ib)
W105-03-01-002

3. Install special tools (ST 9050) (3 used) to outer

race (4) of the swing bearing with bolts (3) (3
used) and nuts (M33, Pitch 3.0 mm) (3used). 5
: 55 mm

4. Attach a nylon sling to the special tool (ST 9050).

Hoist and remove the swing bearing from track ST 9050
frame (5).

4 W105-03-01-003

W3-1-1
 UNDERCARRIAGE / Swing Bearing
Installation
Clean the mounting surfaces of the track frame and
the swing bearing.

1. Apply THREEBOND #1102 onto the swing bear-

ing mounting surface of the track frame.

CAUTION: Swing bearing weight: 1820 kg

(4020 Ib)

IMPORTANT: If the matching marks do not fit, the 4

W105-03-01-003
soft zone position of inner race (1)
Machine Front
will be dislocated.
2. Hoist the swing bearing. Fit the matching marks
on inner race (1) of the swing bearing and track
frame (5).

Soft Zone Position

(Outer Race) Soft Zone Position
(Inner Race)

Greasing Hole Position W18J-03-01-001

(4 Places)

1
3. Apply LOCTITE #262 to bolts (3) (50 used). In-
stall inner race (1) of the swing bearing to track 3
frame (5) with bolts (3) (50 used).
: 55 mm
5
: 2800 N⋅m (280 kgf⋅m, 2070 Ibf⋅ft)

W105-03-01-002

W3-1-2
 UNDERCARRIAGE / Swing Bearing
5. After installing the swing bearing, add grease to
the grease bath until the pinion of the swing
device is covered 15 mm (0.59 in) in grease. Swing Bearing Grease Level Pinion

NOTE: Grease amount: 49 L (13 US gal.)

15 mm

W175-03-01-002
Grease Bath

W3-1-3
 UNDERCARRIAGE / Swing Bearing
DISASSEMBLY OF SWING BEARING

1 2 3 4

W1JB-03-01-002
9 8 7 6

11

10

3
7
8

W111-03-01-008
1 - Outer Race 4- Pin 7- Inner Race 10 - Bolt (50 Used)
2 - Seal 5- Plug 8- Support (86 Used) 11 - Grease Fitting (4 Used)
3 - Ball (86 Used) 6- Seal 9- Rod and Turnbuckle
(3 Used)

W3-1-4
 UNDERCARRIAGE / Swing Bearing
Disassembly of Swing Bearing
1. Tap and remove pin (4) of plug (5) upward.
NOTE: After installing pin (4), pin (4) was crimped. CAUTION: Swing bearing weight: 1820 kg
Grind off the crimped part. (4020 Ib)

3. Hoist outer race (1) of the swing bearing hori-

zontally and slightly by using the special tool (ST
9051). Remove rod and turnbuckles (9) (3 used)
4 which tighten seal (6).

4. Remove seals (2, 6) from outer race (1) and in-

ner race (7).

5. Place inner race (7) of the swing bearing on a

wooden block. Hoist and hold outer race (1)
slightly.
5
6. Remove balls (3) (86 used) and supports (8) (86
used) from the plug (5) hole while rotating outer
W105-03-01-007
race (1).
Use magnet (A) and remove balls (3). Use wire
2. Remove plug (5) from outer race (1). (B) and remove supports (8) (86 used).
NOTE: Install the bolt into the screw hole (M10,
Pitch 1.5 mm) of plug (5). Tap or pull the
bolt from the inner side. 1
2

A
5 7

W105-03-01-009
6

W105-03-01-008

8 W105-03-01-010

W3-1-5
 UNDERCARRIAGE / Swing Bearing
ASSEMBLY OF SWING BEARING

1 2 3 4

W1JB-03-01-002
9 8 7 6

11

10

3
7
8

W111-03-01-008

1 - Outer Race 4- Pin 7- Inner Race 10 - Bolt (50 Used)

2 - Seal 5- Plug 8- Support (86 Used) 11 - Grease Fitting (4 Used)
3 - Ball (86 Used) 6- Seal 9- Rod and Turnbuckle (3 Used)

W3-1-6
 UNDERCARRIAGE / Swing Bearing
Assembly of Swing Bearing
3. Degrease the groove part for seals (2, 6) com-
CAUTION: Outer race (1) weight: 770 kg pletely. Apply THREEBOND #1735 onto seals (2,
(1700 lb) 6). Install seal (2) to outer race (1). Install seal (6)
Inner race (7) weight: 890 kg (1970 lb) to the groove part on inner race (7). Tighten seal
(6) with rod and turnbuckle (9) evenly by 10 to 15
1. Fit inner race (7) of the swing bearing to the ball turns.
groove on outer race (1). NOTE: When tightening the turnbuckle, use a
round bar (Dia.: 2 to 2.3 mm (0.079 to
2. Apply grease onto balls (3) (86 used) and 0.091 in).
supports (8) (86 used). Install balls (3) (86 used) CAUTION: Swing bearing weight: 1820 kg
and supports (8) (86 used) alternately from the (4020 lb)
plug hole. Install ball (3) first.
4. Install plug (5) to outer race (1). Secure plug (5)
with pin (4). Crimp the head of pin (4) by using a
punch.

4
2

3 1

6 W142-03-01-005

W142-03-01-007

5. Apply grease onto the swing bearing through

8
grease fittings (11) (4 used).
W142-03-01-006
NOTE: Grease amount: 5.73 L (1.5 US gal.)
40±10 mm (1.6±0.39 in)
3 8

W142-03-01-004

NOTE: Dia. of support (8): 36 mm (1.4 in)

Dia. of ball (3): 7602 mm (299 in)

W3-1-7
 UNDERCARRIAGE / Swing Bearing
(Blank)

W3-1-8
 UNDERCARRIAGE / Travel Device
REMOVAL AND INSTALLATION OF
TRAVEL DEVICE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Before removing and installing the travel device, the

tracks should be removed first. Refer to REMOVAL
AND INSTALLATION OF TRACK on W3-7-1.
Therefore, the procedure starts on the premise that the
tracks have already been removed here.

Removal
1. Remove bolt (5). Install an eyebolt (M12, Pitch
1.75 mm) to the hole. Attach a nylon sling onto an
eyebolt. Hoist and hold cover (4).
: 19 mm 1 2, 3

CAUTION: Cover (4) weight: 50 kg (110lb) 4

2. Remove bolts (2) (8 used) and washers (3) (8

used). Remove cover (4) from track frame (1).
: 24 mm
5
3. Disconnect hoses (6) (2 used) from travel device
(7). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 22 mm, 27 mm W18J-03-02-003

4. Remove socket bolts (9) (8 used) and split 1 6

flanges (8) (4 used) from hoses (10) (2 used).
Disconnect hoses (10) (2 used) from travel device
(7). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 10 mm

10 9 8 W18J-03-02-004

W3-2-1
 UNDERCARRIAGE / Travel Device

CAUTION: Travel device (7) weight: 1700 kg

(3750 lb)
1
5. Attach nylon slings onto travel device (7). Hoist
and hold travel device (7).
7
6. Put the matching marks on travel device (7) and
track frame (1).
Remove bolts (11) (26 used) and washers (12)
(20 used) from track frame (1). Remove travel
device (7) from track frame (1).
: 41 mm

11, 12
W111-03-02-002

W3-2-2
 UNDERCARRIAGE / Travel Device
Installation

CAUTION: Travel device (7) weight: 1700 kg

(3750 lb) 1

IMPORTANT: Fit the matching marks made when

disassembling. 7
1. Attach nylon slings onto travel device (7). Hoist
and fit travel device (7) to the mounting hole of
track frame (1). Install travel device (7) to track
frame (1) with bolts (11) (26 used) and washers
(12) (26 used).
: 41 mm
: 1400 N⋅m (140 kgf⋅m, 1010 lbf⋅ft)
11, 12
W111-03-02-002

2. Connect hoses (10) (2 used) to travel device (7)

with split flanges (8) (4 used) and socket bolts (9)
(8 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

10 9 8 W18J-03-02-004

3. Connect hoses (6) (2 used) to travel device (7). 6

: 22 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

W18J-03-02-004

W3-2-3
 UNDERCARRIAGE / Travel Device

CAUTION: Cover (4) weight: 50 kg (110 lb)

1 2, 3
4. Install an eyebolt (M12, Pitch 1.75 mm) to cover
(4). Attach a nylon sling onto an eyebolt. Hoist
and fit cover (4) to the mounting hole of track 4
frame (1).

5. Install cover (4) to track frame (1) with bolts (2) (8

used) and washers (3) (8 used).
: 24 mm 5
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

6. Remove an eyebolt. Install bolt (5) to cover (4).

W18J-03-02-003
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

IMPORTANT: After completing the work, check the

hydraulic oil level. Start the engine
and check for any oil leaks.
Perform break-in operation after
installing in order to prevent the
travel motor from seizing.
CONDITION: 1. Engine control dial: Slow idle
2. Travel mode switch: Slow speed
3. Operation duration: Over 2 minutes

W3-2-4
 UNDERCARRIAGE / Travel Device
(Blank)

W3-2-5
 UNDERCARRIAGE / Travel Device
DISASSEMBLY OF TRAVEL DEVICE
16 17
18
9 15
11
10 14
9

4 7
6
8
5 19
4 12 13 20

21

3 22
24 23
2
25
1
26
27
28
29 42
41

30 40
31
32
34 33 30
39 43
44
38 45
46
37

47
36
35
48

50 49

51 W18J-03-02-001

52

1- Third Stage Carrier 14 - O-Ring 27 - Second Stage Sun Gear 40 - Cork (2 Used)
2- Spacer 15 - Ring Gear 28 - Spacer 41 - Spring Washer (30 Used)
3- Third Stage Sun Gear 16 - Cover 29 - Second Stage Carrier 42 - Bolt (30 Used)
4- Thrust Plate (8 Used) 17 - Cork (2 Used) 30 - Roller Bearing (8 Used) 43 - Bolt (2 Used)
5- Needle Bearing (4 Used) 18 - Plug (3 Used) 31 - Third Stage Planetary Gear 44 - Lock Plate
(4 Used)
6 - Second Stage Planetary 19 - Bolt (26 Used) 32 - Retaining Ring (4 Used) 45 - Bearing Nut
Gear (4 Used)
7 - Spring Pin (4 Used) 20 - Spring Washer (26 Used) 33 - Spring Pin (4 Used) 46 - Roller Bearing
8 - Pin (4 Used) 21 - Socket Bolt (28 Used) 34 - Spring Pin (4 Used) 47 - Sprocket
9 - Thrust Plate (6 Used) 22 - Ball Bearing 35 - Bolt (4 Used) 48 - Drum
10 - Needle Bearing (3 Used) 23 - Stopper Pin 36 - Spring Washer (4 Used) 49 - Socket Bolt (18 Used)
11 - First Stage Planetary Gear 24 - Propeller Shaft 37 - Housing 50 - Floating Seal
(3 Used)
12 - Spring Pin (3 Used) 25 - Spacer 38 - Support 51 - O-Ring
13 - Pin (3 Used) 26 - First Stage Carrier 39 - Roller Bearing 52 - Motor

W3-2-6
 UNDERCARRIAGE / Travel Device
Disassembly of Travel Device

CAUTION: The pressure may be applied to
the inside of the travel device. Loosen the air
bleed plug slowly. Release any remaining
pressure. Remove the drain plug and drain
gear oil.
If the air bleed plug is loosened suddenly, the
plug may be fly out and gear oil may gush out.
Keep body and face away from the plug.
CAUTION: Travel device weight: 1720 kg
(3800 lb)
1. Loosen air bleed plug (16-A) by 2 to 3 turns from
the travel device. Remove drain plug (16-B).
Drain gear oil from the travel device. Place the
travel device on a workbench with the motor (52)
side up.
: 17 mm
CAUTION: Travel device weight except
motor (52): 1570 kg (3470 lb)
4. Hoist and place the travel device on a workbench
with the cover (16) side up.
CAUTION: Cover (16) weight: 81 kg (180 lb)
5. Remove corks (40) (2 used), bolts (19) (26 used),
and spring washers (20) (26 used) from cover
(16). Install an eyebolt (M14, Pitch 2.0 mm) to the
lifting hole (2 places) on cover (16). Hoist and
remove cover (16) from ring gear (15).
: 22 mm
6. Remove socket bolts (21) (28 used) from ring
gear (15).
: 17 mm

16-A CAUTION: Ring gear (15) weight: 195 kg (430

lb)

7. Install an eyebolt (M14, Pitch 2.0 mm) to the bolt

(19) hole on ring gear (15). Remove ring gear (15)
from drum (48).

8. Remove O-ring (14) and propeller shaft (24) from

drum (48).
16-B

W111-03-02-006

2. Install an eyebolt (M12, Pitch 1.75 mm) to the

lifting hole (3 places) on motor (52). Attach a wire
onto eyebolts.

CAUTION: Motor (52) weight: 135 kg (300 lb)

3. Remove bolts (35) (4 used) and spring washers

(36) (4 used) from motor (52). Remove motor (52)
from housing (37). Remove O-ring (51) from
motor (52).
: 27 mm

W3-2-7
 UNDERCARRIAGE / Travel Device

21

1
26
27
29

39 43
44
45
46
37

48

W18J-03-02-001

W3-2-8
 UNDERCARRIAGE / Travel Device
CAUTION: The first stage carrier (26)
assembly weight: 45 kg (99 lb)
9. Install an eyebolt (M12, Pitch 1.75 mm) to the
lifting hole (3 places) on the first stage carrier (26)
assembly. Attach nylon slings onto eyebolts. Hoist
and remove the first stage carrier (26) assembly
from second stage carrier (29).
10. Remove second stage sun gear (27) from second
stage carrier (29).
CAUTION: The second stage carrier (29)
assembly weight: 85 kg (190 lb)
11. Install an eyebolt (M12, Pitch 1.75 mm) to the
lifting hole (2 places) on the second stage carrier
(29) assembly. Attach a nylon sling onto eyebolts.
Hoist and remove the second stage carrier (29)
assembly from third stage carrier (1).
CAUTION: Third stage sun gear (3) weight:
20 kg (44 lb)
12. Attach a nylon sling onto the gear part (2 places)
of third stage sun gear (3). Hoist and remove third
stage sun gear (3) from third stage carrier (1).
W3-2-9
CAUTION: The third stage carrier (1)
assembly weight: 195 kg (430 lb)
13. Install an eyebolt (M12, Pitch 1.75 mm) to the
lifting hole (2 places) on the third stage carrier (1)
assembly. Attach a nylon sling onto eyebolts.
Hoist and remove the third stage carrier (1)
assembly from housing (37).
14. Remove bolts (43) (2 used) from lock plate (44).
Remove lock plate (44) from bearing nut (45).
: 22 mm
15. Install the special tool (ST 3142) to bearing nut
(45). Remove bearing nut (45) from housing (37).
ST 3142
45
W1JB-03-02-003
CAUTION: Drum (48) + sprocket (47) + others
weight: 750 kg (1660 lb)
16. Install an eyebolt (M22, Pitch 2.5 mm) to the
socket bolt (21) hole (2 places) on drum (48).
Attach a nylon sling onto eyebolts. Hoist and
remove drum (48) from hosing (37). At this time,
the outer race of roller bearing (39) and rotor
bearing (46) are removed with the drum (48) side
together.
 UNDERCARRIAGE / Travel Device

2
1

42
41

30 40
31
32
34 33 30
39
38
46
37

47

48

50 49

W18J-03-02-001

W3-2-10
 UNDERCARRIAGE / Travel Device
17. Remove floating seal (50) from housing (37) and 24. Remove the outer race of roller bearing (39) from
support (38) respectively. drum (48).

18. Remove the inner race of roller bearing (46) from 25. Remove spring pins (34) (4 used) from third stage
drum (48). carrier (1) by using a round bar (8 mm (0.31 in)).

19. Remove corks (40) (2 used) from sprocket (47).

CAUTION: The third stage carrier (1)
Remove bolts (42) (30 used) and spring washers
(41) (30 used) from sprocket (47). assembly weight: 195 kg (430 lb)

26. Remove pins (33) (4 used) from third stage carrier

CAUTION: Sprocket (47) weight: 200 kg (450 (1). Remove third stage planetary gears (31) (4
lb) used) and spacer (2).

20. Install a pulling-out bolt (M27, Pitch 3.0 mm, 27. Remove roller bearings (30) (8 used) and
Length 70 mm) (2 used) to the pulling-out hole (2 retaining rings (32) (4 used) from third stage
places) on sprocket (47). Slowly float sprocket planetary gears (31) (4 used).
(47) from drum (48).
: 41 mm
NOTE: Adhesive has been applied between
sprocket (47) and drum (48).

21. Install an eyebolt (M27, Pitch 3.0 mm) to the lifting

hole (2 places) on sprocket (47). Attach a nylon
sling onto eyebolts. Hoist and remove sprocket
(47) from drum (48).
: 41 mm

CAUTION: Drum (48) + others weight: 320 kg

(710 lb)

22. Hoist and turn over drum (48).

23. Remove socket bolts (49) (18 used) from support

(38). Remove support (38) from drum (48).
: 10 mm

W3-2-11
 UNDERCARRIAGE / Travel Device

9
11
10
9

4 7
6
8
5
4 12 13

25
26
27
28
29

W18J-03-02-001

W3-2-12
 UNDERCARRIAGE / Travel Device
28. Remove spring pins (7) (4 used) from second
stage carrier (29) by using a round bar (6 mm
(0.24 in)).

CAUTION: The second stage carrier (29)

assembly weight: 85 kg (190 lb)

29. Remove pins (8) (4 used) from second stage

carrier (29). Remove second stage planetary
gears (6) (4 used) and spacer (28) from second
stage carrier (29).

30. Remove thrust plates (4) (8 used) and needle

bearings (5) (4 used) from second stage planetary
gears (6) (4 used).

31. Remove spring pins (12) (3 used) from first stage

carrier (26) by using a round bar (5 mm (0.5 in)).

CAUTION: The first stage carrier (26)

assembly weight: 45 kg (99 lb)

32. Remove pins (13) (3 used) from first stage carrier

(26). Remove first stage planetary gears (11) (3
used) and spacer (25) from first stage carrier (26).

33. Remove thrust plates (9) (6 used) and needle

bearings (10) (3 used) from first stage planetary
gears (11) (3 used).

W3-2-13
 UNDERCARRIAGE / Travel Device
ASSEMBLY OF TRAVEL DEVICE
47, 40 41 42

50 49 39 46 45 48 14 21 1 15 29 26

18
37

16, 17

51 28

27

35, 36 25

24

3 22

23

52 11

10

2 12

13

44
9

43
8

19, 20

W18J-03-02-002
38 33 31 32 30 34 4 6 5 7

1- Third Stage Carrier 14 - O-Ring 27 - Second Stage Sun Gear 40 - Cork (2 Used)
2- Spacer 15 - Ring Gear 28 - Spacer 41 - Spring Washer (30 Used)
3- Third Stage Sun Gear 16 - Cover 29 - Second Stage Carrier 42 - Bolt (30 Used)
4- Thrust Plate (8 Used) 17 - Cork (2 Used) 30 - Roller Bearing (8 Used) 43 - Bolt (2 Used)
5- Needle Bearing (4 Used) 18 - Plug (3 Used) 31 - Third Stage Planetary Gear 44 - Lock Plate
(4 Used)
6 - Second Stage Planetary 19 - Bolt (26 Used) 32 - Retaining Ring (4 Used) 45 - Bearing Nut
Gear (4 Used)
7 - Spring Pin 20 - Spring Washer (26 Used) 33 - Spring Pin (4 Used) 46 - Roller Bearing
8 - Pin (4 Used) 21 - Socket Bolt (28 Used) 34 - Spring Pin (4 Used) 47 - Sprocket
9 - Thrust Plate (6 Used) 22 - Ball Bearing 35 - Bolt (4 Used) 48 - Drum
10 - Needle Bearing (3 Used) 23 - Stopper Pin 36 - Spring Washer (4 Used) 49 - Socket Bolt (18 Used)
11 - First Stage Planetary Gear 24 - Propeller Shaft 37 - Housing 50 - Floating Seal
(3 Used)
12 - Spring Pin (3 Used) 25 - Spacer 38 - Support 51 - O-Ring
13 - Pin (3 Used) 26 - First Stage Carrier 39 - Roller Bearing 52 - Motor

W3-2-14
 UNDERCARRIAGE / Travel Device
Assembly of Travel Device
1. Install retaining rings (32) (4 used) and roller
bearings (30) (8 used) to third stage planetary
gears (31) (4 used).
2. Install spacer (2) and third stage planetary gears
(31) (4 used) to third stage carrier (1).
3. Fit with the spring pin (32) mounting holes on third
stage carrier (1) and install pins (33) (4 used).
4. Install spring pins (34) (4 used) to third stage
carrier (1) and pins (33) (4 used).
NOTE: Install spring pin (34) with the slit part of
spring pin (34) facing the end of pin (33).
33
Slit
34
W18J-03-02-005
5. Install needle bearings (5) (4 used) to second
stage planetary gears (6) (4 used).
6. Fit thrust plates (4) (8 used) to both ends of the
pin (8) mounting holes on second stage planetary
gear (6). Install spacer (28) and second stage
planetary gears (6) (4 used) to second stage
carrier (29).
7. Fit with the spring pin (7) mounting holes on
second stage carrier (29) and install pins (8) (4
used).
W3-2-15
8. Install spring pins (7) (4 used) to second stage
carrier (29) and pins (8) (4 used).
NOTE: Install spring pin (7) with the slit part of
spring pin (7) facing to the end of pin (8) at
this time.
8
Slit
7
W18J-03-02-005
9. Install needle bearings (10) (3 used) to first stage
planetary gears (11) (3 used).
10. Fit thrust plates (9) (6 used) to both ends of the
pin (13) mounting holes on first stage planetary
gear (11). Install spacer (25) and first stage
planetary gears (11) (3 used) to first stage carrier
(26).
11. Fit with the spring pin (12) mounting holes on first
stage carrier (26) and install pins (13) (3 used).
12. Install spring pins (12) (3 used) to first stage
carrier (26) and pins (13) (3 used).
NOTE: Install spring pin (12) with the slit part of
spring pin (12) facing the end of pin (13).
13
Slit
12
W18J-03-02-005
13. Install the outer race of roller bearing (39) to drum
(48).
 UNDERCARRIAGE / Travel Device

47, 40 41 42

50 49 46 45 48

37

W18J-03-02-002
38

W3-2-16
 UNDERCARRIAGE / Travel Device
14. Install support (38) to drum (48) with socket bolts
CAUTION: Drum (48) + sprocket (47) + others
(49) (18 used).
: 10 mm weight: 750 kg (1660 lb)
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
19. Hoist and turn over drum (48).

CAUTION: Drum (48) weight: 290 kg (640 lb) 20. Hoist and install drum (48) to housing (37). At this
time, the clearance between housing (37) and
15. Hoist and turn over drum (48). drum (48) should be even all around.

16. Install the outer race of roller bearing (46) to drum 21. Install the inner race of roller bearing (46) to
(48). housing (37) by using a bar and a hammer.

22. Install bearing nut (45) to housing (37). Tighten

CAUTION: Sprocket (47) weight: 200 kg (450
bearing nut (45) by hand.
lb)
23. Install the special tool (ST 3142) to bearing nut
IMPORTANT: Fit the chamfered side of sprocket (45). Tighten bearing nut (45) by using a torque
(47) to the drum (48) side. wrench.
17. Apply LOCTITE #262 onto bolt (42). Install : 41 mm
sprocket (47) to drum (48) with bolts (42) (30 : 800 N⋅m (80 kgf⋅m, 590 lbf⋅ft)
used) and spring washers (41) (30 used). Install
corks (40) (2 used) to the pulling-out hole (2 ST 3142
places) on sprocket (47).
: 41 mm
: 1400 N⋅m (140 kgf⋅m, 1010 lbf⋅ft)

CAUTION: Drum (48) + sprocket (47) + others

weight: 750 kg (1660 lb)

18. Hoist and turn over drum (48). Install floating seal
(50) to support (38) and housing (37) by using a
W1JB-03-02-003
bamboo spatula.
24. After tightening bearing nut (45), tap the top of
sprocket (47) by using a plastic hammer and
reduce play. Turn drum (48) both clockwise and
counterclockwise by 3 turns.

W3-2-17
 UNDERCARRIAGE / Travel Device

45 48 14 1 29 26

37

27

24

11

44

43

W18J-03-02-002

W3-2-18
 UNDERCARRIAGE / Travel Device
25. Tighten bearing nut (45) to the specified torque in
CAUTION: The second stage carrier (29)
the same way as step 24 again.
: 41 mm assembly weight: 85 kg (190 lb)
: 800 N⋅m (80 kgf⋅m, 590 lbf⋅ft)
30. Install an eyebolt (M12, Pitch 1.75 mm) to the
26. Install the claw part of lock plate (44) to the lifting hole (2 places) on the second stage carrier
groove on housing (37). Tighten bearing nut (45) (29) assembly. Attach a nylon sling onto eyebolts.
to the tightening direction so that the lock plate Hoist and install the second stage carrier (29)
(44) hole fit to the bearing nut (45) screw hole. assembly to third stage carrier (1).

27. Apply LOCTITE #262 onto bolt (43). Install lock 31. Install second stage sun gear (27) to second
plate (44) to bearing nut (45) with bolts (43) (2 stage carrier (29) with the lower gear tooth side
used). up.
: 22 mm
Upper Side
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

CAUTION: The third stage carrier (1)

assembly weight: 195 kg (430 lb)

28. Install an eyebolt (M12, Pitch 1.75 mm) to the 27 W166-03-02-002

lifting hole (2 places) on the third stage carrier (1)

assembly. Attach a nylon sling onto eyebolts. CAUTION: The first stage carrier (26)
Hoist and install the third stage carrier (1) assembly weight: 45 kg (99 lb)
assembly to housing (37).
32. Install an eyebolt (M12, Pitch 1.75 mm) to the
29. Attach a nylon sling onto the gear part (2 places) lifting hole (3 places) on the first stage carrier (26)
of third stage sun gear (3). Install third stage sun assembly. Attach nylon slings onto eyebolts. Hoist
gear (3) to the third stage carrier (1) assembly. and install the first stage carrier (26) assembly to
Install third stage sun gear (3) with the lower gear second stage carrier (29).
tooth side up.
33. Install propeller shaft (24) to the center of first
Upper Side stage carrier (26). At this time, engage propeller
shaft (24) with first stage planetary gear (11).

34. Install O-ring (14) to drum (48).

3 W166-03-02-002

W3-2-19
 UNDERCARRIAGE / Travel Device

48 21 15

18
37

16, 17

51

35, 36

24

22

23

52

19, 20

W18J-03-02-002

W3-2-20
 UNDERCARRIAGE / Travel Device
CAUTION: Ring gear (15) weight: 195 kg (430
lb)
35. Install an eyebolt (M14, Pitch 2.0 mm) to ring gear
(15). Attach a nylon sling onto an eyebolt. Hoist
and install ring gear (15) to drum (48).
36. Apply LOCTITE #262 onto socket bolts (21) (28
used). Install ring gear (15) to drum (48) with
socket bolts (21) (28 used).
: 19 mm
: 950 N⋅m (95 kgf⋅m, 690 lbf⋅ft)
42. Install a seal tape onto plugs (18) (3 used). Install
plugs (18) (3 used) to cover (16).
: 17 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
CAUTION: Travel device weight except for
motor (52): 1570 kg (3470 lb)
43. Hoist and turn over the travel device.
44. Add gear oil to the travel device.
Gear oil: 43 L (11.4 US gal)

37. When bearing (22) and stopper pin (23) have
been removed, install bearing (22) and stopper
pin (23) to cover (16).
NOTE: Install bearing (22) with the stamped mark
side facing the near side.
38. Apply THREEBOND #1215 onto the cover (16)
mounting surface of ring gear (15).
39. Apply LOCTITE #262 onto bolt (19).
CAUTION: Cover (16) weight: 81 kg (180 lb)
45. Install O-ring (51) to motor (52).
CAUTION: Motor (52) weight: 135 kg (300 lb)
46. Hoist motor (52). Install motor (52) to housing (37)
while fitting the spline part of propeller shaft (24)
to the spline of the motor (52) shaft.
47. Install motor (52) to housing (37) with bolts (35) (4
used) and spring washers (36) (4 used).
: 27 mm
: 300 N⋅m (30 kgf⋅m, 215 lbf⋅ft)

40. Install an eyebolt (M14, Pitch 2.0 mm) to the lifting

hole on cover (16). Attach a nylon sling onto an
eyebolt. Hoist cover (16). Install cover (16) to ring
gear (15) with bolts (19) (26 used) and spring
washers (20) (26 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

41. Install corks (17) (2 used) to the lifting hole (2

places) on cover (16).

W3-2-21
 UNDERCARRIAGE / Travel Device
DISASSEMBLY OF TRAVEL MOTOR

4
3

1 17
5
15 16
6
2 7 14

13
11 12

10

9
20
8

19

31
18
32

21

29 30
28

27

26

25
24
23 W17P-03-02-002
22
1- Case 9- Swash Plate 17 - Roller Bearing 25 - Backup Ring
2- O-Ring (4 Used) 10 - Piston (9 Used) 18 - Disc Plate 26 - Brake Piston
3- Spring (2 Used) 11 - Retainer 19 - Disc Plate (4 Used) 27 - O-Ring
4- Piston (2 Used) 12 - Holder 20 - Disc Plate 28 - Spring (10 Used)
5- Shaft 13 - Spring (9 Used) 21 - Friction Plate (5 Used) 29 - Pin (4 Used)
6- Roller Bearing 14 - Cylinder Block 22 - Backup Ring 30 - Valve Housing
7- Oil Seal 15 - Valve Plate 23 - O-Ring 31 - Socket Bolt (9 Used)
8- Steel Ball (2 Used) 16 - Collar 24 - O-Ring 32 - Pin

W3-2-22
 UNDERCARRIAGE / Travel Device
Disassembly of Travel Motor
CAUTION: Valve housing (30) weight: 40 kg
(88 lb)
IMPORTANT: Loosen socket bolts (31) (9 used)
evenly. When loosening socket bolt
(31), valve housing (30) is floated
from case (1) by the reaction force of
spring (13) and spring (28). At this
time, record the clearance between
case (1) and valve housing (30).
Valve plate (15) is removed with
valve housing (30) together when
removing valve housing (30) from
case (1). Do not drop valve plate (15)
1. Put the matching marks on the jointed part of
valve housing (30) and case (1). Install an eyebolt
(M12, Pitch 1.75 mm) to valve housing (30).
Remove socket bolts (31) (9 used). Remove valve
housing (30) from case (1). At this time, the outer
race of roller bearing (17) is removed with valve
housing (30) together.
: 14 mm
1 30
31
Eyebolt
Mounting Hole
W16J-03-02-002
IMPORTANT: Do not damage valve plate (15).
2. Remove valve plate (15) and collar (16) from
valve housing (30).
W3-2-23
3. Remove springs (28) (10 used), O-rings (2) (4
used), pins (29) (4 used), and O-ring (27) from
case (1).
IMPORTANT: Case (1) may be floated. Secure case
(1) tightly.
4. Install an eyebolt (M12, Pitch 1.75 mm) to the pin
(29) hole (2 places) on brake piston (26). Attach a
nylon sling onto eyebolts. Remove brake piston
(26) from case (1).
NOTE: When case (1) is floated, tap the outer
circumference of case (1) by using a plastic
hammer.
5. Remove O-rings (23, 24) and backup rings (22,
25) from brake piston (26).
CAUTION: The cylinder block (14) assembly
weight: 20 kg (44 lb)
IMPORTANT: Replace cylinder block (14) as
assembly an including valve plate
(15).
6. Place case (1) horizontally with the brake
releasing oil passage down. Remove the cylinder
block (14) assembly (10 to 15) from case (1).
NOTE: Hold cylinder block (14) by hands. Slowly
remove cylinder block (14) while lightly
turning cylinder block (14) clockwise and
counterclockwise.
7. Remove pistons (10) (9 used), retainer (11),
holder (12), and springs (13) (9 used) from
cylinder block (14).
 UNDERCARRIAGE / Travel Device

4
3

1 17
5

6
2 7

9
20
8

19

18

21

30

W17P-03-02-002

W3-2-24
 UNDERCARRIAGE / Travel Device
IMPORTANT: The thicknesses of disc plates (18,
19, and 20) are different. The
assembling order of disc plates (18,
19, and 20) has been determined.
Place and keep them in the
disassembled order.
8. Remove disc plate (20) from case (1). Alternately
remove friction plates (21) (5 used) and disc
plates (19) (4 used). Remove disc plate (18).
IMPORTANT: Do not damage the sliding surface of
swash plate (9).
Piston (4) and steel ball (8) may be
removed with swash plate (9)
together. In that case, do not drop
piston (4) and steel ball (8).
9. Remove swash plate (9) from case (1).
10. Remove pistons (4) (2 used), springs (3) (2 used),
and steel balls (8) (2 used) from case (1).
NOTE: If it is difficult to remove steel ball (8),
degrease by using a white kerosene or
thinner with the steel ball installed to case
(1). Then, remove steel ball (8) from case
(1) by using a magnet.
IMPORTANT: Keep the outer race of roller bearing
(6) so that the outer race of roller
bearing (6) can be installed in the
same direction when assembling.
13. Remove the outer race of roller bearing (6) from
case (1) by using a bar and a hammer.
14. Remove oil seal (7) from case (1).
IMPORTANT: Do not remove the inner race of
roller bearing (17) from shaft (5) and
the outer race of roller bearing (17)
from valve housing (30) unless
necessary.
IMPORTANT: When replacing roller bearing (17),
do not damage the shaft (5) surface
and the valve housing (30) surface.
15. Make a clearance between shaft (5) and the inner
race of roller bearing (17) by using a flat chisel
and a hammer. Remove the inner race by using a
gear puller.
Insert a pry bar between roller bearing (17) and
valve housing (30). Remove the outer race of
roller bearing (17) valve housing (30) attached
with by using a pry bar.

IMPORTANT: Do not damage the spline of shaft (5)

and the contact part of oil seal (7). If
the spline of shaft (5) and the
contact part of oil seal (7) are
damaged, oil leakage may occur.
11. Tap the inner bore spline hole end of shaft (5) by
using a bar and a hammer. Remove shaft (5) from
case (1). At this time, the inner race of roller
bearing (6) is removed with shaft (5) together.

IMPORTANT: Do not remove the inner race of

roller bearing (6) from shaft (5) and
the outer race of roller bearing (6)
from case (1) unless necessary.
12. Remove the inner race of roller bearing (6) from
shaft (5) by using a press.

W3-2-25
 UNDERCARRIAGE / Travel Device
ASSEMBLY OF TRAVEL MOTOR

3 4 5 18 20 22, 23 24, 25 26 28

31

8 32

16

30

17

1
15

29

7
27
2
6 9 12 11 13 19 21 10 14 Brake Releasing Oil
Passage

W17V-03-02-002

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

2- O-Ring (4 Used) 10 - Piston (9 Used) 18 - Disc Plate 26 - Brake Piston
3- Spring (2 Used) 11 - Retainer 19 - Disc Plate (4 Used) 27 - O-Ring
4- Piston (2 Used) 12 - Holder 20 - Disc Plate 28 - Spring (10 Used)
5- Shaft 13 - Spring (9 Used) 21 - Friction Plate (5 Used) 29 - Pin (4 Used)
6- Roller Bearing 14 - Cylinder Block 22 - Backup Ring 30 - Valve Housing
7- Oil Seal 15 - Valve Plate 23 - O-Ring 31 - Socket Bolt (9 Used)
8- Steel Ball (2 Used) 16 - Collar 24 - O-Ring 32 - Pin

W3-2-26
 UNDERCARRIAGE / Travel Device
Assembly of Travel Motor

IMPORTANT: Install oil seal (7) straight in order
not to create a distortion.
1. Apply grease onto the inner surface of oil seal (7)
mounting part of case (1) and the inner surface
and outer surface of oil seal (7). Install oil seal (7)
to case (1).
IMPORTANT: There is a stamped mark on the
outer race of roller bearing (6).
Install with the stamped mark facing
the swash plate (9) side.
2. Install the outer race of roller bearing (6) to case
(1) by using a bar and a hammer while tapping
evenly.
NOTE: Tap and listen to ring in order to check that
the outer race is installed to the end of case
(1).
IMPORTANT: Install with the flange part of the
inner race of roller bearing (6) facing
the swash plate (9) side.
3. Install the inner race of roller bearing (6) to shaft
(5) by using a bar and a hammer while tapping
evenly.
Install the shaft (5) assembly to case (1) while
tapping by using a hammer.
4. Apply hydraulic oil onto the piston (4) outer
surface, the steel ball (8) outer surface, the piston
(4) mounting part, and the steel ball (8) mounting
part in case (1). Install springs (3) (2 used),
pistons (4) (2 used), and steel balls (8) (2 used) to
case (1).
IMPORTANT: Install swash plate (9) while fitting
the spherical hole to steel ball (8).
6. Apply grease onto the case (1) contact surface on
swash plate (9). Install swash plate (9) to case (1)
with the swash plate (9) thicker side down.
IMPORTANT: Put the notches on friction plates
(21) (5 used) in the same direction.
Install friction plates (21) (5 used) to
case (1).
7. Install disc plate (18) to case (1). Alternately insert
friction plates (21) (5 used) and disc plates (19) (4
used). Finally install disc plate (20).
NOTE: The thicknesses of disc plates (18, 20, and
19) are different.
(18, 20): 4.8 mm (0.19 in)
(19): 3 mm (0.12 in)
Install the disc plate while fitting to the
notch on case (1).
IMPORTANT: Check the direction to install retainer
(11).
8. Apply hydraulic oil onto the piston (10) mounting
hole on cylinder block (14). Install springs (13) (9
used) and holder (12) to cylinder block (14).
Install pistons (10) (9 used) and retainer (11) to
cylinder block (14).

CAUTION: The case (1) assembly weight: 55

kg (130 lb)

5. Install an eyebolt (M18, Pitch 2.5 mm) to the bolt

(31) hole (2 places) on case (1). Attach a nylon
sling onto eyebolts. Hoist and place the case (1)
assembly with the brake releasing oil passage
down.

W3-2-27
 UNDERCARRIAGE / Travel Device

5 22, 23 24, 25 28

31

32

16

30

17

1
15

29

9 12 21 10 14

W17V-03-02-002

W3-2-28
 UNDERCARRIAGE / Travel Device
IMPORTANT: Check the direction to install brake
CAUTION: The cylinder block (14) assembly
piston (26). Install brake piston (26)
weight: 20 kg (44 lb) with the notch vertical
corresponding to the pin (29)
IMPORTANT: The inner race of roller bearing (17) mounting hole on case (1).
is attached to the shaft (5) end. Do
not damage the inner race.
1
Fit the splines of shaft (5), cylinder
block (14), and friction plate (21).
9. Apply hydraulic oil onto the piston (10) sliding 26
surface of swash plate (9) and the spherical
surface of holder (12). Install the cylinder block
(14) assembly to shaft (5). Notch

CAUTION: The case (1) assembly weight: 55

kg (130 lb)

10. Install an eyebolt (M18, Pitch 2.5 mm) to the 29 W16J-03-02-003

socket bolt (31) hole (2 places) on case (1). Attach

a nylon sling onto eyebolts. Hoist and place case
(1) vertically.
IMPORTANT: Check the position to install O-rings
(23, 24) and backup rings (22, 25).
11. Apply grease onto O-rings (23, 24) and backup
rings (22, 25). Install backup rings (25, 22) and
O-rings (24, 23) to brake piston (26).
NOTE: Install backup ring (22) to the reduction
gear side corresponding to O-ring (23), and
install backup ring (25) to the valve housing
(30) side corresponding to O-ring (24).
12. Apply grease onto the outer surface of brake
piston (26) and the inner diameter of case (1). Tap
and install brake piston (26) to case (1) by using a
plastic hammer.
IMPORTANT: The spring (28) mounting hole (12
places) on brake piston (26) are
located corresponding to springs
(28) (10 used). (Check the position to
install spring (28).) Install spring (28)
so that the hole without spring (28)
(blank) is in the diagonal position.

26
Blank

28

28

W16J-03-02-003
Blank
13. Install springs (28) (10 used) to brake piston (26).

W3-2-29
 UNDERCARRIAGE / Travel Device

5 26

31

32

16

30

17

1
15

29

27
2

W17V-03-02-002

W3-2-30
 UNDERCARRIAGE / Travel Device
IMPORTANT: There is a stamped mark on the
outer race of roller bearing (17).
Install with the stamped mark facing
the valve plate (15) side.
14. Install the outer race of roller bearing (17) to valve
housing (30) by using a bar and a hammer while
tapping evenly.
Install the inner race to shaft (5).
NOTE: Tap and listen to ring in order to check that
the outer race is installed to the end of
valve housing (30).
15. Apply grease onto the valve housing (30) contact
surface on valve plate (15). Install collar (16) to
valve housing (30). Fit the pin holes on pin (32)
and valve plate (15). Install valve plate (15) to
valve housing (30).
16. Apply grease onto O-rings (2, 27). Install O-ring
(27) and O-rings (2) (4 used) to case (1). Install
pins (29) (4 used) to valve housing (30).
CAUTION: Valve housing (30) weight: 40 kg
(88 lb)
IMPORTANT: When installing valve housing (30)
to case (1), check that the
clearance between case (1) and
valve housing (30) is the dimension
recorded before disassembling.
If the dimension differs,
disassemble valve housing (30) and
assemble valve housing (30) again.
IMPORTANT: Fit the matching marks made when
disassembling. If the matching mark
does not fit, the installing direction
of brake piston (26) may differ.
17. Install an eyebolt (M12, Pitch 1.75 mm) to the bolt
hole on valve housing (30).
Hoist valve housing (30). Place valve housing
(30) onto case (1) while fitting the pin (29) hole on
brake piston (26).
Install valve housing (30) to case (1) with socket
bolts (31) (9 used).
: 14 mm
: 440±22 N⋅m (45±2.2 kgf⋅m, 320±16 lbf⋅ft)
NOTE: Tighten socket bolts (31) (9 used) evenly.

1 30

31

Eyebolt
Mounting Hole

W16J-03-02-002

W3-2-31
 UNDERCARRIAGE / Travel Device
DISASSEMBLY OF BRAKE VALVE

6
1 7
2 8
3 5
4 9
10 Plug
11

10 9
35

Orifice

12

36 13
37 14
38 16 15
39 18
40 20
21
48
17 22
19
24
26 5
47
49
46 28 23
10 30 25
9
41 32
27 33
42 34
43 29
44 31
4
45 3
Orifice 2
1
44
43
36 42
41
50
40
39
35
38
37

W183-03-02-010

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

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 40 - Spring Seat (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 41 - Plug (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 42 - O-Ring (2 Used)
5- Overload Relief Valve (2 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 43 - Spring (2 Used)
Used)
6- Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 44 - Check Valve (2 Used)
7- O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 45 - Spool
8- Spring 21 - Relief Housing (2 Used) 34 - Set Screw (2 Used) 46 - Valve Housing
9- Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 47 - Pin (4 Used)
10 - O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 48 - Pin
11 - Orifice 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 49 - Orifice
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 50 - Spool Assembly
13 - Valve Assembly 26 - Spring Seat (2 Used)

W3-2-32
 UNDERCARRIAGE / Travel Device
Disassembly of Brake Valve

6. Hold caps (36) (2 used). Evenly loosen and

CAUTION: The valve housing (46) assembly
weight: 40 kg (88 lb)
1. Secure the valve housing (46) assembly on a
workbench.
2. Remove plugs (6, 15) and spring (8) from valve
housing (46).
: 10 mm
IMPORTANT: Turn and remove valve assembly
(13). If they stick even a little, try
again instead of pulling them
roughly.
Do not disassemble valve assembly
(13). Replace valve housing (46)
assembly including spool assembly
(50), valve assembly (13), orifices (11,
49), and the orifice plug.
3. Lightly push out valve assembly (13). Turn and
remove valve assembly (13) from valve housing
(46) by hand.
remove caps (36) (2 used) and socket bolts (35)
(8 used) from valve housing (46).
: 10 mm
NOTE: If cap (36) cannot be removed, tap by using
a plastic hammer. Tap cap (36) with socket
bolt (35) attached (loosened).
7. Remove spring seats (38) (2 used), springs (39)
(2 used), and spring seats (40) (2 used) from vale
housing (46).
IMPORTANT: Turn and remove spool assembly
(50). If they stick even a little, try
again instead of pulling them
roughly.
8. Lightly push out spool assembly (50) from valve
housing (46). Turn and remove spool assembly
(50) by hand.
9. Secure spool assembly (50) in a vise by using
wooden pieces.

4. Remove plugs (1) (2 used), springs (3) (2 used), 10. Remove plugs (41) (2 used), springs (43) (2 used),
and check valves (4) (2 used) from vale housing and check valves (44) (2 used) from spool (45).
(46).
: 14 mm 11. Remove O-rings (7, 14) from plugs (6, 15).
Remove O-rings (2) (2 used) from plugs (1) (2
IMPORTANT: Do not disassemble overload relief used).
valves (5) (2 used). Replace overload
relief valve (5) as an assembly. 12. Remove O-rings (37) (2 used) from caps (36) (2
Attach the identification tag onto used).
overload relief valve (5) and keep
overload relief valve (5) in order to
install to the original position.
Do not turn set screw (34). The set
pressure changes.
5. Remove plugs (32) (2 used) and overload relief
valves (5) (2 used) from valve housing (46).
: 36 mm

W3-2-33
 UNDERCARRIAGE / Travel Device
ASSEMBLY OF BRAKE VALVE
Overload Relief Valve (5)

16 18 21 26 24 27 31 29 32 33
34

17, 19 20 22 23, 25 28 30

36 38

41
6
37

35 39
42
A A A
7
40
43
8
44
45
13
50

14

48 47
12
15

46
5 2 1 3 4 W17P-03-02-004

Section A-A-A

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

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

W3-2-34
 UNDERCARRIAGE / Travel Device
Assembly of Brake Valve

1. Install O-rings (7, 14) to plugs (6, 15) respectively.

Install valve assembly (13) and plugs (6, 15) to
valve housing (46).
: 10 mm
: 64±4.9 N⋅m (6.5±0.5 kgf⋅m, 47±3.6 lbf⋅ft)

2. Install O-rings (2) (2 used) to plugs (1) (2 used).

Install check valves (4) (2 used), springs (3) (2
used), and plugs (1) (2 used) to vale housing (46).
: 14 mm
: 410±20 N⋅m (42±2 kgf⋅m, 300±14.5 lbf⋅ft)

IMPORTANT: Install overload relief valve (5) to the

original position.
3. Install overload relief valves (5) (2 used) to valve
housing (46).
: 36 mm
: 410±20 N⋅m (42±2 kgf⋅m, 300±14.5 lbf⋅ft)

4. Slowly turn and insert spool assembly (50) into

valve housing (46).

5. Install O-rings (37) (2 used) to caps (36) (2 used).

6. Install spring seats (40) (2 used), springs (39) (2

used), and spring seat (38) to vale housing (46).
Install caps (36) (2 used) to valve housing (46)
with socket bolts (35) (8 used).
: 10 mm
: 108±4.9 N⋅m (11±0.5 kgf⋅m, 80±3.6 lbf⋅ft)

W3-2-35
 UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
1. Clearance between cylinder block inner diameter
Cylinder
(D) and piston outer diameter (d) Block

(D-d): 0.06 mm (0.002 in) or less

D d

W507-02-04-009
Piston

2. Clearance between piston and shoe bottom Piston

δ: 0.4 mm (0.016 in) or less

Shoe
δ

W107-02-06-140

Piston
3. Clearance between inner diameter (D) of the
piston mounting part in case and piston outer
diameter (d) d

(D-d): 0.03 mm (0.001 in)or less

Case

W162-03-02-005

4. Wear amount of sliding surface against valve

plate of cylinder block.
Check that there are no damage, wear, or seizure.
Damage or wear amount: 0.02 mm (0.0008 in) or
less

W3-2-36
 UNDERCARRIAGE / Travel Device
Sprocket

C
D

E
A

W105-03-02-241

Unit: mm (in)
Standard Allowable Limit Remedy
A 120 (4.72) 110 (4.33)
B 1026.9 (40.4) 1017 (40) Cladding by
C 1125.9 (44.3) - welding and
D 1145 (45.1) 1135 (44.7) hand finishing
E 280 (11) -

W3-2-37
 UNDERCARRIAGE / Travel Device
(Blank)

W3-2-38
 UNDERCARRIAGE / Center Joint
REMOVAL AND INSTALLATION OF CEN-
TER JOINT

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal
1. Disconnect hoses (1) (4 used) and remove 1, 2 3 4, 5 6 1, 2
adapters (2) (4 used) from center joint (6). Cap
the open ends. Attach an identification tag onto
the disconnected hoses for assembling. Install
eyebolts (PF1) to the adapter (2) hole (2 places)
on center joint (6).
: 41 mm

2. Attach a nylon sling onto the eyebolts (2 used).

W16J-03-03-002
Hoist and hold center joint (6). 7

3. Disconnect hoses (7) (2 used) from center joint

(6). Cap the open ends.
: 19 mm

4. Remove bolts (4) (2 used) and washers (5) (2

used) from stopper (3). Remove stopper (3) from
center joint (6).
: 22 mm

CAUTION: Center joint (6) weight: 52 kg (120

lb)

5. Disconnect hoses (8) (8 used) from center joint

(6). Cap the open ends. Attach an identification
8 6 8
tag onto the disconnected hoses for assembling.
: 19 mm, 27 mm, 50 mm

W16J-03-03-003

W3-3-1
 UNDERCARRIAGE / Center Joint

CAUTION: Center joint (6) weight: 52 kg (120

9, 10 6 11
lbf⋅ft)

6. Remove bolts (9) (4 used) and washers (10) (4

used) from center joint (6). Remove center joint
(6) from track frame (11).
: 24 mm

W16J-03-03-003

W3-3-2
 UNDERCARRIAGE / Center Joint
Installation

CAUTION: Center joint (6) weight: 52 kg (120

lbf⋅ft)

1. Hoist center joint (6). Fit center joint (6) to the

mounting hole of track frame (11).
8 9, 10 6 11 8
2. Install center joint (6) to track frame (11) with
bolts (9) (4 used) and washers (10) (4 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

3. Connect hoses (8) (8 used) to center joint (6).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) W16J-03-03-003

: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 50 mm
: 340 N⋅m (35 kgf⋅m, 250 lbf⋅ft)

4. Install stopper (3) to center joint (6) with bolts (4)

(2 used) and washers (5) (2 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

3 4, 5 6
5. Install adapters (2) (4 used) to center joint (6).
: 50 mm
: 340 N⋅m (35 kgf⋅m, 250 lbf⋅ft)

6. Connect hoses (1) (4 used) and (7) (2 used) to

center joint (6).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 41 mm W16J-03-03-002

: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

IMPORTANT: After completing the work, start the 1 6 2 1

engine and check for any oil leaks.

W16J-03-03-002
7

W3-3-3
 UNDERCARRIAGE / Center Joint
DISASSEMBLY OF CENTER JOINT

3
4

9
6
10

11

12

W16J-03-03-001

1 - Plug 4 - O-Ring 7 - Body 10 - O-Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - Retaining Ring 12 - Bolt (4 Used)

W3-3-4
 UNDERCARRIAGE / Center Joint
Disassembly of Center Joint

CAUTION: Spindle (2) weight: 22 Kg (49 lb)

CAUTION: Center joint weight: 52 kg (120 lb)
1. Remove bolts (12) (2 used) from cover (11) di-
agonally. Install eyebolts (M12, Pitch 1.75 mm) (2
used) to the bolt (12) hole.
Attach a nylon sling onto eyebolts (2 used). Hoist
and secure the center joint onto a workbench.
: 19 mm
2. Remove bolts (12) (2 used) and eyebolts (2
used) from cover (11). Remove cover (11) from
body (7).
: 19 mm
IMPORTANT: For easy removal of oil seal (6), use
3. Remove O-ring (10), retaining ring (9), and ring
(8) from body (7).
4. Put the matching marks on body (7) and spindle
(2).
Body (7) weight: 29 kg (64 lb)
6. Install the bolt (ST1020) to the special tool
(ST1033). Tighten the bolt (ST 1020). Push body
(7) from spindle (2) upward. Just before spindle
(2) is separated from body (7), stop pushing body
(7) and remove the special tool. Install eyebolts
(M12, Pitch 1.75 mm) (2 used) into the bolt (12)
hole (2 places) on body (7). Attach a nylon sling
onto the eyebolts (2 used). Hold spindle (2). Hoist
and remove body (7).
the pins (2 used). Do not damage
the seal groove by the pin.
7. Remove oil seals (6) (6 used) from body (7).

5. Install the special tool (ST 1033) to body (7) with

bolts (12) (2 used).
: 19 mm
7
ST 1020
ST 1033 12
6

7
W105-03-03-015

8. Remove dust seal (3) and O-ring (4) from body

(7).

IMPORTANT: While welding, cover the seal sur-

W183-03-03-004
face in order to prevent from weld-
ing spatter.
9. When replacing bushing (5), weld four places 90°
away from each other on the bushing (5) bore by
using a welding bar. Shrink and remove bushing
(5)

W3-3-5
 UNDERCARRIAGE / Center Joint
ASSEMBLY OF CENTER JOINT

8
10

12
9
11
W183-03-08-001

1 - *Plug 4 - O-Ring 7 - Body 10 - O-Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - Retaining Ring 12 - Bolt (4 Used)

NOTE: As for the item with mark*, refer to W3-3-4.

W3-3-6
 UNDERCARRIAGE / Center Joint
Assembly of Center Joint

1. Apply grease onto the bushing (5) mounting part
on body (7). If bushing (5) has been removed,
in-stall bushing (5) first. (Refer to W3-3-10.)
IMPORTANT: Face the metal part of dust seal (3)
to the body (7) side.
2. Apply grease onto the dust seal (3) mounting part
on body (7). Install O-ring (4) and dust seal (3) to
body (7).
IMPORTANT: The clearance between body (7) and
spindle (2) is not much. Install body
(7) along the axis straight.
As the seal may be damaged, slowly
install body (7).
Install body (7) in order not to form
the step at position A (the mounting
position for ring (8)) as illustrated.

Metal Part 3 2
A

W800-03-03-001
7

3. Install oil seals (6) (6 used) to body (7).

W800-03-03-002

W3-3-7
 UNDERCARRIAGE / Center Joint

8
10

12
9
11
W183-03-08-001

W3-3-8
 UNDERCARRIAGE / Center Joint

CAUTION: Spindle (2) weight: 22 kg (49 lb)

Body (7) weight: 29 kg (64 lb)

4. Apply grease onto the inner surfaces of oil seal

(6) and bushing (5) and the sliding surface of
dust seal (3) on spindle (2). Place spindle (2) on
a workbench with its upside down. Install an
eyebolt (M12, Pitch 1.75 mm) to the bolt (12) hole
(2 places) on body (7). Hoist body (7). Fit the
matching mark and place body (7) on spindle (2).

5. Tap the circumference of body (7) evenly by us-

ing a plastic hammer and insert body (7) into
spindle (2).

IMPORTANT: Install ring (8) with the chamfered

side facing the inner surface of
body (7).
6. Install ring (8) to body (7).

IMPORTANT: Install retaining ring (9) with its

chamfered side facing the ring (8)
side.
7. Install retaining ring (9) to spindle (2).

8. Install O-ring (10) to body (7). Install cover (11) to

body (7) with bolts (12) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)

W3-3-9
 UNDERCARRIAGE / Center Joint
When replacing body (7) with a new one, the following
procedures are required.
ST 2670

Install bushing (5) to body (7).

1. Clean body (7) and bushing (5). 7
2. Apply grease or molybdenum disulphide onto the
fitting surface of bushing (5) on body (7).
3. Install bushing (5) to body (7) by using a press.
Pushing force: 0.5 to 1.5 t (1100 to 3300 lb) 5
Pushing tool: ST 2670

W105-03-03-029

W3-3-10
 UNDERCARRIAGE / Center Joint
MAINTENANCE STANDARD

Item Allowable Limit (basis of judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Seizure and abnormal wear Replace
3. Uneven wear within 180° Replace
Wear Area Within Half
Range
Bushing

T157-01-01-040

Sliding surface with Heavily damaged one by seizure or foreign mat- Replace
seals ter
1) Excessively worn one by seizure or foreign Replace
Sliding surface be- matter, or one having the score of 0.1 mm
tween body and spin- (0.004 in) or more
dle other than sliding 2) One having the score of less than 0.1 mm Repair the surface
surfaces with seals (0.004 in) smooth by using
an oil stone
Body, Spindle
1) One that has worn 0.5 mm (0.02 in) or Replace
more, or excessively worn
2) One that has worn 0.5 mm (0.02 in) or less Repair the surface
Sliding surface with smooth
ring 3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less than smooth
the allowable wear limit 0.5 mm (0.02 in)
and is repairable
1) One that has worn 0.5 mm (0.02 in) or Replace
more
2) One that has worn less than 0.5 mm (0.02 Repair the surface
Sliding surface with in) smooth
Cover
ring 3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less than smooth
the allowable wear limit 0.5 mm (0.02 in)
and is repairable

W3-3-11
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-12
 UNDERCARRIAGE / Track Adjuster
REMOVAL AND INSTALLATION OF
TRACK ADJUSTER

Before removing and installing the track adjuster, the

track and the front idler should be removed first. (Refer
to REMOVAL AND INSTALLATION OF TRACK on
W3-7-1, REMOVAL AND INSTALLATION OF FRONT
IDLER on W3-5-1.)
Therefore, the procedure starts on the premise that the
track and the front idler have already been removed
here.

Removal
2
1
CAUTION: Track adjuster (1) weight: 760 kg
(1680 lb)
CAUTION: Track adjuster (1) may fly out due
to the spring force when removing track
adjuster (1). Do not stand in the same
direction to remove track adjuster (1) or W142-03-04-002
where track adjuster (1) may fly out.
Particularly, the spring force is always
applied to the thread part of the rod. If the rod
3 4
and/or the threads are damaged, metal
fragments due to the spring force may fly out.

1. Pry and remove track adjuster (1) from side frame

(2) by using a pry bar.
A

W17V-03-04-002

2 3

W1JB-03-04-004
View A

W3-4-1
 UNDERCARRIAGE / Track Adjuster
Installation
2
1. Insert track adjuster (1) into spring guide (3) of
side frame (2) as illustrated. 1
At this time, check that track adjuster (1) comes
into contact with the end of plate (4).

W142-03-04-002

2 3

W1JB-03-04-004
View A

3 4

W17V-03-04-002

W3-4-2
 UNDERCARRIAGE / Track Adjuster
(Blank)

W3-4-3
 UNDERCARRIAGE / Track Adjuster
DISASSEMBLY OF TRACK ADJUSTER
1
3

5
6
7
2 8
9

10

12

11

14

13

15

16

18

W167-03-04-004

17

1- O-Ring 6- Backup Ring 11 - O-Ring 15 - Bracket

2- Socket Bolt (6 Used) 7- U-Ring 12 - Cylinder 16 - Nut
3- Guide 8- Plate 13 - Spring 17 - Bolt
4- Piston Rod 9- Retaining Ring 14 - Spacer 18 - Valve
5- Wear Ring (2 Used) 10 - Rod

W3-4-4
 UNDERCARRIAGE / Track Adjuster
Disassembly of Track Adjuster
• When disassembling and assembling, use a
pump unit which has the maximum pressure of 69
MPa (700 kgf/cm2, 10000 psi) and the oil amount
of 8 to 10 L (2.1 2.6 US gal). Set the main relief
pressure to 49 MPa (500 kgf/cm2, 7120 psi) and
the thrust force to 80 t or lower.
IMPORTANT: Compress spring (13) until the
clearance between bracket (15) and
nut (16) is about 10 mm (0.39 in).
2. Loosen valve (17). Compress spring (13) in the
track adjuster by using the special tool (ST 4932).
: 24 mm

IMPORTANT: Use the special tool (ST 4932) when Clearance: 10 mm (0.39 in)
assembling and disassembling the
track adjuster.

15
CAUTION: As the spring force is too strong,
carry out the disassembly and assembly 16
work carefully. Inspect the special tool for
any damage thoroughly in order to perform 17
the work safely.
18

CAUTION: Track adjuster weight: 760 kg

W142-03-04-020
(1680 lb)
IMPORTANT: Put the mating marks on rod (10)
1. Hoist the track adjuster. Place the track adjuster
and nut (16).
on the holder of the special tool (ST 4932).
3. Remove valve (18) and bolt (17) from rod (10).
Remove nut (16) from rod (10).
ST 4932 : 24 mm, 150 mm

Holder

W142-03-04-019

W3-4-5
UNDERCARRIAGE / Track Adjuster

12

14

13

15

W167-03-04-004

W3-4-6
 UNDERCARRIAGE / Track Adjuster
4. Slowly turn the piston of the special tool (ST
CAUTION: The cylinder (12) assembly
4932) and extend spring (13) to the free length.
weight: 230 kg (510 lb)
NOTE: Free length of spring (13): 1110 mm (43.7
in) 7. Hoist and remove the cylinder (12) assembly from
spring (13).

ST 4932 Eyebolt
13
12

15

13

Holder
W142-03-04-005

CAUTION: Track adjuster weight (without

nut): 750 kg (1660 lb)
5. Secure bracket (15) and spring (13) by using a W142-03-04-007
wire. Attach a nylon sling onto spring (13) in the
track adjuster. Hoist the track adjuster. Remove
the track adjuster from the special tool (ST 4932). CAUTION: Spring (13) weight: 425 kg (940 lb)
6. Install an eyebolt (M16, Pitch 2.0 mm) to piston
rod (4). Attach a nylon sling onto spring (13). Pass 7. Remove the wire securing spring (13) and bracket
a nylon sling through the eyebolt (M16, Pitch 2.0 (15). Hoist and remove spring (13).
mm). Hoist piston rod (4). Place the track adjuster
on the holder. CAUTION: Bracket (15) weight: 47 kg (110 lb)
Eyebolt
8. Remove spacer (14) and bracket (15) from the
4 holder.

13

Holder

W142-03-04-006

W3-4-7
 UNDERCARRIAGE / Track Adjuster

1
3

5
6
7
2 8
9

10

12

11

W167-03-04-004

W3-4-8
 UNDERCARRIAGE / Track Adjuster
14. Remove wear rings (5) (2 used), retaining ring (9),
CAUTION: The cylinder (12) assembly
plate (8), U-ring (7), and backup ring (6) from
weight: 230 kg (600 lb) piston rod (4).
10. Place a wooden block under the flange part of
cylinder (12). Secure the cylinder (12) assembly 4
on a workbench. Remove socket bolts (1) (6
used). Remove guide (3) from cylinder (12). 5
: 14 mm 6
7
1 8
9
3
2

W142-03-04-008

12

10

W142-03-04-010

CAUTION: Piston rod (4) weight: 41 kg (90 lb)

11. Remove piston rod (4) from cylinder (12).

12. Remove O-ring (1) from guide (3).

CAUTION: Cylinder (12) weight: 111 kg (250

lb)
Rod (10) weight: 66 kg (150 lb)

13. Install an eyebolt (M16, Pitch 1.5 mm) to the

cylinder (12) side of rod (10). Attach a nylon sling
onto the eyebolt (M16, Pitch 1.5 mm). Hoist rod
(10). Remove rod (10) from cylinder (12).
Remove O-ring (11) from the inside of cylinder
(12).

W3-4-9
 UNDERCARRIAGE / Track Adjuster
ASSEMBLY OF TRACK ADJUSTER

16 13 10 11 6, 7 5 2 3

18

Grease
Outlet

W18J-03-04-001

17 15 14 8, 9 12 1 4

1- O-Ring 6- Backup Ring 11 - O-Ring 15 - Bracket

2- Socket Bolt (6 Used) 7- U-Ring 12 - Cylinder 16 - Nut
3- Guide 8- Plate 13 - Spring 17 - Bolt
4- Piston Ring 9- Retaining Ring 14 - Spacer 18 - Valve
5- Wear Ring (2 Used) 10 - Rod

W3-4-10
 UNDERCARRIAGE / Track Adjuster
Assembly of Track Adjuster
Lifting Hole

IMPORTANT: Apply grease onto wear rings (5) (2

used), backup ring (6), U-ring (7),
and plate (8). Install U-ring (7) with 10
its lip part facing the rod (10) side.
12
Apply hydraulic oil onto the cylinder
(12) inside, rod (10), and piston rod
(4) before assembling.
11
1. Clean all the parts. Install wear rings (5) (2 used),
backup ring (6), U-ring (7), plate (8), and retaining
ring (9) to piston rod (4).
W17V-03-04-001

4
CAUTION: The piston rod (4) assembly
5 weight: 41 kg (90 lb)
6
7 IMPORTANT: Fill chamber (B) in cylinder (12) with
8 grease. Push piston rod (4) into
9
cylinder (12) and bleed air from
cylinder inside (B) and rod (10).
3. Fill cylinder (12) with grease. Install an eyebolt
(M16, Pitch 2.0 mm) to the lifting hole on piston
rod (4). Attach a nylon sling onto the eyebolt.
Apply grease onto piston rod (4). Hoist piston rod
W142-03-04-008
(4). Install piston rod (4) to cylinder (12).

CAUTION: Cylinder (12) weight: 111 kg (250
lb)
Rod (10) weight: 66 kg (150 lb)
CAUTION: Do not tip over cylinder (12).
2. Install an eyebolt (M14, Pitch 2.0 mm) to the
diagonal position (2 places) of the socket bolt (2)
hole on cylinder (12). Attach a nylon sling onto the
eyebolt. Hoist and set cylinder (12) on a
workbench. Apply grease onto O-ring (11). Install
O-ring (11) to cylinder (12). Install an eyebolt
(M16, Pitch 1.5 mm) to the lifting hole on rod (10).
Attach a nylon sling onto the eyebolt. Hoist rod
(10). Install rod (10) to cylinder (12).
NOTE: Keep the space about 120 mm (4.72 in)so
that rod (10) can be put under cylinder (12).
IMPORTANT: Fill V-shaped grooves (2 places) in
the inner surface of guide (3) with
grease.
4. Apply grease onto O-ring (1). Install O-ring (1) to
guide (3). Apply LOCTITE #262 onto socket bolts
(2) (6 used). Install guide (3) to piston rod (4) with
socket bolts (2) (6 used).
: 14 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
1
3 2
4 Lifting Hole

W142-03-04-018

W3-4-11
 UNDERCARRIAGE / Track Adjuster

13

W18J-03-04-001

15 14 12 4

W3-4-12
 UNDERCARRIAGE / Track Adjuster

CAUTION: Bracket (15) weight: 47 kg (110 lb) CAUTION: Track adjuster weight (without
Spring (13) weight: 425 kg (940 lb) nut): 750 kg (1660 lb)

5. Set a wire on a holder. Place bracket (15), spacer 7. Attach a nylon sling onto spring (13). Pass a nylon
(14), and spring (13) on the holder by using a sling through the eyebolt of piston rod (4). Hoist
nylon sling. Secure bracket (15) and spring (13) the track adjuster and lay down the track adjuster
by using the wire. horizontally.

Eyebolt

12
4

13
14

13

Holder
15
W142-03-04-006

8. Hoist and place the track adjuster on the special

W142-03-04-007
tool (ST 4932).Remove the eyebolt and the nylon
sling.
CAUTION: The cylinder (12) assembly
weight: 230 kg (510 lb)

6. Install an eyebolt (M16, Pitch 2.0 mm) to piston

rod (4). Attach a nylon sling onto the cylinder (12) ST 4932
assembly. Hoist the cylinder (12) assembly. Install
the cylinder (12) assembly while fitting to spacer
(14) and bracket (15).

W142-03-04-005

W3-4-13
 UNDERCARRIAGE / Track Adjuster

16 13 10

18

907 mm (35.7 in) W18J-03-04-001

(Free Length 1110 mm (43.7 in))
17 15
1229 mm (48.4 in)

W3-4-14
 UNDERCARRIAGE / Track Adjuster
IMPORTANT: When compressing spring (13),
slowly compress spring (13) while
fitting the center of rod (10) to the
center of bracket (15) by using a pry
bar.
Do not damage the thread part of rod
(10).
9. Operate the cylinder of the special tool (ST 4932).
Remove the wire. Compress spring (13) to the
specified length.
(Specified length: 907 mm (35.7 in))
IMPORTANT: Fit the matching marks made when
disassembling. Check that the
grease outlet in rod (10) fits to that in
nut (16).
10. After installing nut (16) to rod (10), install bolt (17).
: 150 mm
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
16

13 10

ST 4932

17
15
18

Wire
W142-03-04-020

11. Install valve (18).

: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

12. Operate the cylinder of the special tool (ST 4932)

W142-03-04-015
to the original condition.

CAUTION: Track adjuster weight: 760 kg

(1680 lb)

13. Attach a nylon sling onto the track adjuster. Hoist

the track adjuster. Remove the track adjuster from
the special tool (ST 4932).

14. If only the spring assembly is transported, handle

it with care and use a solid box in order to
transport the spring assembly safely.

W3-4-15
 UNDERCARRIAGE / Track Adjuster
(Blank)

W3-4-16
 UNDERCARRIAGE / Front Idler
REMOVAL AND INSTALLATION OF
FRONT IDLER

Before removing the front idler, the tracks should be

removed first. As for removal and installation of the
tracks, refer to REMOVAL AND INSTALLATION OF
TRACK on W3-7-1.
Therefore, in this section the procedure starts on the
premise that the tracks have already been removed.

Removal

CAUTION: Front idler weight: 825 kg (1820 W142-03-05-002

lb)
CAUTION: The front idler may fly out due to
the spring force when removing the front
idler. Do not stand in the same direction to
remove the front idler or where the front idler
may fly out. Direction to
Remove

1. Remove the front idler with yoke (2) together

from track frame (1) by using a pry bar.
1

2. Attach a nylon sling onto the bearing (3) part and

the yoke (2) part as illustrated. Hoist and remove
the front idler assembly from track frame (1). 3
2

W142-03-05-003

3. When keeping the front idler temporarily, place

the front idler on the wooden blocks as
illustrated.
Wooden
Block

Wooden
Block

W105-03-05-003

W3-5-1
 UNDERCARRIAGE / Front Idler
Installation
Direction to
Install
CAUTION: Front idler weight: 825 kg (1820
lb)
1
1. Install the front idler in the reverse way of
removal. Check the followings.
• Clean and apply grease onto track frame (1) and
the sliding surface of bearing (3).
3

W142-03-05-005

W3-5-2
 UNDERCARRIAGE / Front Idler
(Blank)

W3-5-3
 UNDERCARRIAGE / Front Idler
DISASSEMBLY OF FRONT IDLER

1
2
8
3
4
6
7

6 9
5
10
4
3
2 11

14 13 12 W18J-03-05-001
8

1- Pin (2 Used) 5- Axle 9 - Guard 12 - Yoke

2- Bearing (2 Used) 6- Bushing (2 Used) 10 - Bolt (4 Used) 13 - Bolt (4 Used)
3- Floating Seal (2 Used) 7- Idler 11 - Spring Washer (4 Used) 14 - Spring Washer (4 Used)
4- O-Ring (2 Used) 8- Plug (2 Used)

W3-5-4
 UNDERCARRIAGE / Front Idler
Disassembly of Front Idler

1. Remove bolts (10) (4 used) and spring washers

(11) (4 used) from guard (9). Remove guard (9) CAUTION: Bearing (2) weight: 65 kg (150 lb)
from yoke (12). Idler (7): 505 kg (1120 lb)
: 24 mm Axle (5) + bearing (2) weight: 135 kg (300 lb)

4. Set the idler (7) assembly on a press. Remove

CAUTION: The idler (7) assembly weight: axle (5) from the idler (7) assembly by using a
715 kg (1580 lb) press. At this time, bearing (2) at the opposite
yoke (12) weight: 95 kg (210 lb) side removed with axle (5) together.

IMPORTANT: Support idler (7) in order to prevent

from turn over. Press
2. Attach a nylon sling onto yoke (12). Secure idler
(7) vertically. Remove bolts (13) (4 used) and 2 5
spring washers (14) (4 used) from yoke (12).
Remove yoke (12) from idler (7). 1
Remove plugs (8) (2 used) from the end of
bearing (2). Tilt idler (7) and drain oil.
: 36 mm 7
: 6 mm

3. Put the matching marks on bearing (2) and axle

(5). Remove pin (1) from bearing (2) by using a 2
round bar (Dia.: 25 mm (1 in)) and a hammer.
W17P-03-05-002

3
7

4
5

W105-03-05-009

5. Remove O-ring (4) from axle (5).

W3-5-5
 UNDERCARRIAGE / Front Idler

1
2
3
4
6

6
5

4
3
2

W18J-03-05-001

W3-5-6
 UNDERCARRIAGE / Front Idler
6. Remove floating seal (3) from idler (7) and IMPORTANT: Do not remove bushing (6) unless
bearing (2). necessary.
9. When replacing bushing (6), remove bushing (6)
7. Put the matching marks on bearing (2) and axle by using the special tool (ST 1915) and a press.
(5). Remove pin (1) from bearing (2) by using a
round bar (Dia.: 25 mm (1 in)) and a hammer.

CAUTION: Axle (5) + bearing (2)

weight: 135 kg (300 lb) ST 1915

CAUTION: Axle (5) weight: 68 kg (150 lb)

IMPORTANT: Place a wooden block under bearing

(2) in order not to damage bearing
(2). 6
8. Attach a nylon sling onto the axle (5) assembly.
Hoist and set the axle (5) assembly to the press.
Remove axle (5) from bearing (2) by using a
press. Remove O-ring (4) from axle (5).
W105-03-05-011

Press
4

1
2
Wooden
Block

W105-03-05-010

W3-5-7
 UNDERCARRIAGE / Front Idler
ASSEMBLY OF FRONT IDLER

2 3 6 7 4 1 10, 11 9 14 2

W18J-03-05-002
W800-03-05-002
12 13 8

1- Pin (2 Used) 5- Axle 9 - Guard 12 - Yoke

2- Bearing (2 Used) 6- Bushing (2 Used) 10 - Bolt (4 Used) 13 - Bolt (4 Used)
3- Floating Seal (2 Used) 7- Idler 11 - Spring Washer (4 Used) 14 - Spring Washer (4 Used)
4- O-Ring (2 Used) 8- Plug (2 Used)

W3-5-8
 UNDERCARRIAGE / Front Idler
Assembly of Front Idler

4. Apply grease onto floating seal (3). Install floating

CAUTION: Idler (7) weight: 505 kg (1120 lb) seal (3) to idler (7) and bearing (2).
1. Install bushings (6) (2 used) to both sides of idler
(7) with a press. CAUTION: The axle (5) assembly: 135 kg
(300 lb)
CAUTION: Axle (5) weight: 68 kg (150 lb) IMPORTANT: Support idler (7) in order to prevent
turn over.
IMPORTANT: Support axle (5) in order to prevent 5. Attach a nylon sling onto bearing (2) of the axle
turn over. (5) assembly. Hoist and insert the axle (5)
2. Attach a nylon sling onto axle (5). Hoist and place assembly into idler (7) where floating seal (3)
axle (5) vertically. Apply grease onto O-ring (4). has been installed.
Install O-ring (4) to the upper side of axle (5).
7
3. Apply grease onto the inner surface of bearing
(2). Fit the matching marks made when 3
disassembling and install bearing (2) from the 2
O-ring (4) mounting side of axle (5). Evenly tap
the end of bearing (2) by using a plastic hammer.
Insert pin (1) into bearing (2) by using a bar and
a hammer.

1
W157-03-05-006

5
2 CAUTION: The idler (7) assembly weight:
640 kg (1420 lb)

6. Attach a nylon sling onto the idler (7) assembly.

Hoist and place the idler (7) assembly with the
bearing (2) side down.
Apply grease onto O-ring (4). Install O-ring (4) to
4 W105-03-05-014 axle (5).

W3-5-9
 UNDERCARRIAGE / Front Idler

2 3 7 4 1 10, 11 9 14

W18J-03-05-002
W800-03-05-002
12 13 8

W3-5-10
 UNDERCARRIAGE / Front Idler
7. Apply grease onto floating seal (3). Install other 12. Apply LOCTITE #503 onto plug (8). Install plug
floating seal (3) to idler (7) and bearing (2). (8) to bearing (2).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
CAUTION: Bearing (2) weight: 65 kg (150 lb)

8. Apply grease onto the inner surface of bearing CAUTION: Yoke (12) weight: 95 kg (210 lb)
(2). Evenly tap the end of bearing (2) by using the
plastic hammer. Fit the matching marks made 13. Attach a nylon sling onto yoke (12). Hoist yoke
when disassembling and insert pin (1) into (12). Fit yoke (12) to the bolt (13) hole on bearing
bearing (2) by using a bar and a hammer. (2).
2
14. Install yoke (12) to bearings (2) (2 used) with
3 bolts (13) (4 used) and spring washers (14) (4
5 used).
4
: 36 mm
: 700 N⋅m (70 kgf⋅m, 510 lbf⋅ft)

15. Install guard (9) to yoke (12) with bolts (10) (4

used) and spring washers (14) (4 used).
: 24 mm
7 : 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
W17P-03-05-003

9. Add engine oil (API CD class SAE30) (1.0 L (0.3

US gal)) through the plug (8) hole on bearing (2).

10. Apply LOCTITE #503 onto plug (8). Install plug

(8) to bearing (2).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

CAUTION: The idler (7) assembly weight:

715 kg (1580 lb)

11. Attach a nylon sling onto the idler (7) assembly.

Hoist and turn over the idler (7) assembly.

W3-5-11
 UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD

Idler

C D

A W166-03-05-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 128 (5.04) [120 (4.72)]
Cladding by
B 290 (11.4) -
welding and hand
C 884 (34.8) 872 (34.3)
finishing, or
D 930 (36.6) - Replace
E 23 (0.91) 29 (1.14)

Axle and Bushing

Unit: mm (in)
Standard Allowable Limit Remedy
Axle Outer Dia. 140 (5.51) [139.2 (5.48)]
Inner Dia. 140 (5.51) [141 (5.55)] Replace
Bushing
Flange Thickness 6 (0.24) [5.2 (0.21)]

NOTE: The values in [ ] are just for reference.

W3-5-12
 UNDERCARRIAGE / Upper and Lower Roller
REMOVAL AND INSTALLATION OF UP-
PER ROLLER

Removal
CAUTION: The pressure inside the adjuster
cylinder is high. As valve (1) may fly out and
the high-pressure grease may spout out, do
not loosen valve (1) quickly and/or exces-
sively.
Keep body parts and face away from valve
(1) and loosen valve (1) carefully. Do not
loosen grease fitting (2). W105-03-06-001

IMPORTANT: Loosening valve (1) 1 to 1.5 turns is 2 1

enough. Do not loosen valve (1)
over those turns.
IMPORTANT: When gravel or mud is packed be-
tween sprockets and track links,
remove them before loosening.
1. Loosen valve (1) of the track adjuster. Drain
grease and release the tension of the track link.
: 24 mm
Grease Outlet

W1JB-03-07-002

2. Raise track (4) until enough clearance is ob- Oil Jack

served between upper roller (3) and track (4) by
using a hydraulic jacks and wooden blocks.

Wooden Block
3. Insert a wooden block under upper roller (3).
5 3
W116-03-06-001

Wooden Block
W116-03-06-002

W3-6-1
 UNDERCARRIAGE / Upper and Lower Roller
4. Remove bolts (6) (4 used) and washers (7) (4
used) from upper roller (3).
3
: 32 mm

6, 7
W116-03-06-002

CAUTION: Upper roller (3) weight: 82 kg

(190 lb)

5. Attach a nylon sling onto the roller part of upper

roller (3). Hoist and remove upper roller (3) from
track frame (5).

3 5
W116-03-06-003

W3-6-2
 UNDERCARRIAGE / Upper and Lower Roller
Installation

4
CAUTION: Upper roller (3) weight: 82 kg
(190 lb)

1. Apply LOCTITE #262 onto bolts (6) (4 used).

2. Hoist and insert upper roller (3) between track

frame (5) and track (4).
Insert the wooden blocks between upper roller
(3) and track frame (5), and hold upper roller (3).
Fit the bolt (6) holes. Install upper roller (3) to
track frame (5) with bolts (6) (4 used) and wash- 3
W116-03-06-003
ers (7) (4 used). 5
: 32 mm
: 750 N⋅m (75 kgf⋅m, 540 lbf⋅ft)

3. Remove wooden blocks and oil jacks.

6
W116-03-06-002

4. Tighten valve (1) of the track adjuster.

: 24 mm 2 1
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

CAUTION: If track sag should be measured

with the machine raised, support the bottom
of the track frame machine firmly by using
the blocks.

5. Raise the track to be measured. Apply grease

through grease fitting (2) and adjust track tension.
Track sag specification (A): 530 to 590 mm W1JB-03-07-002
(20.9 to 23.2 in)
NOTE: Before measuring track sag, clean the
track frame and the tracks, and rotate the
track by a half turn in reverse direction.

W1JB-03-06-001

W3-6-3
 UNDERCARRIAGE / Upper and Lower Roller
REMOVAL AND INSTALLATION OF
LOWER ROLLER 1

Removal
1. Remove the track guard. Remove bolts (2) (4
used) and washers (3) (4 used) from lower roller
2, 3
(1).
: 41 mm

CAUTION: Securely support the raised ma-

chine by using wooden blocks.
W105-03-06-008

2. Raise the machine by using the front attachment.

Place wooden blocks under track frame (4).

W105-03-06-009

CAUTION: The pressure inside the adjuster

cylinder is high. As valve (5) may fly out and
the high-pressure grease may spout out, do
not loosen valve (5) quickly and/or exces-
sively.
Keep body parts and face away from valve
(5) and loosen valve (5) carefully. Do not
loosen grease fitting (6).

IMPORTANT: Loosening valve (5) 1 to 1.5 turns is

enough. Do not loosen valve (5)
over those turns.
IMPORTANT: When gravel or mud is packed be- W105-03-06-001
tween sprockets and track links,
6 5
remove them before loosening.
3. Loosen valve (5) of the track adjuster. Drain
grease until the clearance is enough to remove
the lower roller.
: 24 mm

Grease Outlet

W1JB-03-07-002

W3-6-4
 UNDERCARRIAGE / Upper and Lower Roller
4
CAUTION: Lower roller (1) weight: 215 kg
(480 lb)

4. Remove lower roller (1) from track frame (4) by

using a forklift.

1
W105-03-06-010

W3-6-5
 UNDERCARRIAGE / Upper and Lower Roller
Installation

CAUTION: Lower roller (1) weight: 215 kg

(480 lb) 4

1. Set lower roller (1) under track frame (4) by using

a forklift.

1
W105-03-06-012

2. Lower the machine so that track frame (4) may

keep a little away from the collar of lower roller
(1). Fit lower roller (1) to the mounting hole of
1
track frame (4). Install lower roller (1) to track
frame (4) with bolts (2) (4 used) and washers (3)
(4 used). 2, 3
: 41 mm
: 1400 N⋅m (140 kgf⋅m, 1010 lbf⋅ft)

W105-03-06-008

6 5

3. Tighten valve (5) of the track adjuster.

: 24 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

CAUTION: If track sag should be measured

with the machine raised, support the bottom
of the track frame machine firmly by using
blocks.
W1JB-03-07-002
4. Apply grease through grease fitting (6) and adjust
track tension.
Track sag specification (A): 530 to 590 mm
(20.9 to 23.2 in)
NOTE: Before measuring track sag, clean the
track frame and the tracks, and rotate the
track by a half turn in reverse direction.

W1JB-03-06-001

W3-6-6
 UNDERCARRIAGE / Upper and Lower Roller
(Blank)

W3-6-7
 UNDERCARRIAGE / Upper and Lower Roller
DISASSEMBLY OF UPPER ROLLER

10

9
8

11
7
6
5
4
3
2
1

W1JB-03-06-003

1 - Socket Bolt (3 Used) 4 - O-Ring 7 - Bushing 10 - Axle

2 - Plug 5 - Socket Bolt (3 Used) 8 - Roller 11 - Floating Seal
3 - Cover 6 - Thrust Plate 9 - Bushing

W3-6-8
 UNDERCARRIAGE / Upper and Lower Roller
Disassembly of Upper Roller
6. When replacing bushings (7, 9), remove bush-
1. Remove plug (2) from cover (3). Drain oil. ings (7, 9) by using the special tool (ST 1967)
: 6 mm and a press.

2. Put the matching marks on roller (8) and cover

(3). Remove socket bolts (1) (3 used) from cover
(3). Remove cover (3) from roller (8). ST 1967
: 8 mm
7
NOTE: Insert a screwdriver between cover (3) and
roller (8). Pry and remove cover (3) from
roller (8) by using a screwdriver.
90
3. Remove socket bolts (5) (3 used) from thrust
plate (6). Remove thrust plate (6) from roller (8).
: 8 mm
W17V-03-06-002

CAUTION: The axle (10) assembly weight:

48 kg (110 lb) NOTE: If the special tool (ST 1967) is not avail-
able, weld four places, 90° apart from
4. Remove roller (8) from the axle (10) assembly. each others on the bushing bore. Shrink
and remove the bushing.
5. Remove floating seal (11) from the axle (10) as-
sembly and roller (8).
90°
NOTE: If floating seal (11) is reused, floating seal
(11) should be kept with its seal surface
covered with cardboard.
90°

W105-03-05-012

W3-6-9
 UNDERCARRIAGE / Upper and Lower Roller
ASSEMBLY OF UPPER ROLLER

10 11 6

8 9 7 4 W1JB-03-06-002

1 - Socket Bolt (3 Used) 4 - O-Ring 7 - Bushing 10 - Axle

2 - Plug 5 - Socket Bolt (3 Used) 8 - Roller 11 - Floating Seal
3 - Cover 6 - Thrust Plate 9 - Bushing

W3-6-10
 UNDERCARRIAGE / Upper and Lower Roller
Assembly of Upper Roller
IMPORTANT: The force can be applied to press in
the bushing of roller (8) when re-
placing bushings (7, 9).
Force for bushing (7): 20 t
Force for bushing (9): 2.1 to 3.7 t
1. Install bushings (7, 9) to roller (8).
2. Apply grease onto the O-ring part of floating seal
(11). Apply oil onto the steel ring. Install floating
seal (11) to the axle (10) assembly and roller (8).
NOTE: Install O-ring with grease applied to the
seal ring. Install O-ring to the axle and the
roller by using a screwdriver.
Do not damage O-ring when the screw-
driver is used.
CAUTION: Roller (8) weight: 43 kg (95 lb)
6. Fit the matching marks made when disassem-
bling. Install cover (3) to roller (8). Install cover
(3) to roller (8) with socket bolts (1) (3 used).
: 8 mm
: 65 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
NOTE: If the socket bolt (1) holes do not fit, move
cover (3) by using a bar and fit the socket
bolt (1) holes on roller (8) and cover (3).
7. Add engine oil through the plug (2) hole on cover
(3).
Engine oil: API CD class SAE#30
Oil amount: 280 mL (0.3 US qt)
8. Apply LOCTITE #503 or equivalent onto plug (2).
Install plug (2) to cover (3).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

3. Install roller (8) to the axle (10) assembly.

4. Install thrust plate (6) to the axle (10) assembly.

Install thrust plate (6) to axle (10) with socket
bolts (5) (3 used).
: 8 mm
: 65 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

5. Apply grease onto O-ring (4). Install O-ring (4) to

cover (3).

W3-6-11
 UNDERCARRIAGE / Upper and Lower Roller
DISASSEMBLY OF LOWER ROLLER

5
4

3 6

7
5

6 7

1
3
4

W166-03-06-006

1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller

W3-6-12
 UNDERCARRIAGE / Upper and Lower Roller
Disassembly of Lower Roller
6. Set the axle (2) assembly to a press. Remove
IMPORTANT: Put the matching marks on collar (4) axle (2) from collar (4).
and axle (2) at both sides.
1. Remove plugs (6) (2 used) from the end of collar 4
(4). Drain oil. Remove pins (5) (2 used) from col-
lars (4) (2 used) by using a bar (Dia. 25 mm (1.0
in)) and a hammer.
: 6 mm

2
CAUTION: Lower roller weight: 215 kg (480
Ib)

2. Set the roller (8) assembly to a press. Push axle

(2) until O-ring (3) is removed from collar (4) by
using a press. Remove collar (4) from axle (2).
W105-03-06-027
NOTE: Collar (4) can be removed if axle (2) is
7. Remove O-ring (3) from axle (2).
pushed in approx. 70 mm (2.8 in) by using
a press. 8. When replacing bushing (7), remove bushing (7)
by using the special tool (ST 1921) and a press.
3. Remove floating seal (1) from collar (4) and roller
(8).
Remove O-ring (3) from axle (2). ST 1921

CAUTION: Axle (2) + collar (4) weight: 67 kg

(150 lb)
7
4. Remove the axle (2) assembly from roller (8).

5. Remove floating seal (1) from roller (8) and collar

(4).

4 1 8 1 W105-03-06-028

W105-03-06-026

W3-6-13
 UNDERCARRIAGE / Upper and Lower Roller
ASSEMBLY OF LOWER ROLLER

4 5 6

8 2 7 1 3

W162-03-06-002

1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller

W3-6-14
 UNDERCARRIAGE / Upper and Lower Roller
Assembly of Lower Roller

CAUTION: Roller (8) weight: 127 kg (280 lb) CAUTION: The axle (2) assembly weight: 68 kg
Axle (2) weight: 53 kg (120 lb) (150 Ib)

1. Install bushings (7) (2 used) to roller (8). Do not 4. Insert axle (2) into roller (8). Apply grease onto
dent the flange surface of bushing (7). O-ring (3). Install O-ring (3) to axle (2). Install col-
Apply grease onto O-ring (3). Install O-ring (3) to lar (4) and floating seal (1) on the other side in
axle (2). the same way and secure with pin (5).

5 1 2 8

IMPORTANT: Fit the matching marks made when

disassembling.
2. Install one of collar (4) to axle (2). At this time, do
not damage O-ring (3). Install pin (5) to the pin
hole and secure collar (4) on axle (2).
5 4 3
2

3 W157-03-06-009

5. Add engine oil (API CD class SAE30) 1.4 L (0.37

gal.) through the plug (6) hole on collar (4) on
both sides.

4 W16J-03-06-001
6. Apply LOCTITE #503 or equivalent onto plugs (6)
(2 used). Install plugs (6) (2 used) to collars (4)
CAUTION: The roller (8) assembly weight: on both sides.
131 kg (290 lb) : 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
3. Apply grease onto the O-ring part of floating seal
(1). Install floating seal (1) to roller (8) and collar 5 8
(4).
8 1

1 4

W105-03-06-024

W157-03-06-008

W3-6-15
 UNDERCARRIAGE / Upper and Lower Roller
MAINTENANCE STANDARD
Upper Roller
• Roller

B
W166-03-06-007

Unit: mm (in)

Standard Allowable Limit Remedy

A 116 (4.57) − Cladding by welding
B 260 (10.2) − and hand finishing,
C 210 (8.27) 202 (7.95) or replace

• Axle and Bushing

Unit: mm (in)

Standard Remedy
Axle Outer Dia. 85 (3.35)
Inner Dia. 85 (3.35) Replace
Bushing
Flange Thickness 4.5 (0.18)

W3-6-16
 UNDERCARRIAGE / Upper and Lower Roller

Lower Roller
• Roller

W157-03-06-003

Unit: mm (in)

Standard Allowable Limit Remedy

A 302 (11.9) −
Cladding by welding
B 378 (14.9) −
and hand finishing,
C 38 (1.5) −
or replace
D 290 (11.4) 270 (10.6)

• Axle and Bushing

Unit: mm (in)

Allowable Limit Remedy

Axle Outer Dia. 125 (4.92)
Inner Dia. 125 (4.92) Replace
Bushing
Flange Thickness 6 (0.24)

W3-6-17
 UNDERCARRIAGE / Upper and Lower Roller
(Blank)

W3-6-18
 UNDERCARRIAGE / Track
REMOVAL AND INSTALLATION OF
TRACK 1
2
Removal

1. Rotate the tracks so that master pin (3) is

positioned over front idler (2). Place a wooden
block under shoe (1) and support shoe (1).

Wooden
Block W105-03-07-006

CAUTION: The pressure inside the adjuster

cylinder is high. As valve (4) may fly out and
the high-pressure grease may spout out, do
not loosen valve (4) quickly and/or 4
excessively.
Keep body parts and face away from valve
(4) and loosen valve (4) carefully. Do not
loosen grease fitting (5).

IMPORTANT: Loosening valve (4) 1 to 1.5 turns is

enough. Do not loosen valve (4)
over those turns.
W105-03-07-002
IMPORTANT: When gravel or mud is packed
between sprockets and track links,
remove them before loosening. 5 4
2. Loosen the track tension.
: 24 mm

W1JB-03-07-027

W3-7-1
 UNDERCARRIAGE / Track
3. Remove snap ring (6) from master pin (3).
7
NOTE: If snap ring (6) cannot be removed, push
master pin (3) to the installing direction in
order to make clearance between snap 3
ring (6) and master pin (3).

CAUTION: The front idler may fly out due to

the spring force when installing the track. 6
Particularly, strong force is always applied to
the thread part of the rod. If the rod and/or
the threads are damaged, metal fragments
due to the spring force may fly out. W105-03-07-009

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary Corner Part
Collar
protection, such as goggles and hard hats.
Direction to Direction
Remove to Install
IMPORTANT: Master pin (3) can be removed to
only one direction. Check the
removing direction.
4. Remove master pin (3) by using the special tool 3
(ST 1970) and a hammer.
Snap Ring
Track Link
Master Link

W105-03-07-010
ST 1970

W1V1-03-07-001

W3-7-2
 UNDERCARRIAGE / Track
5. Operate the boom and the arm so that the angle
between them is 90 to 110°. Lower the boom with
the round bottom contacting with the ground.
Raise the track frame and pull out the track. At
this time, place a stand under the track frame and
support the machine. 90 to 110°

CAUTION: The track assembly weight:

5400 kg (12000 lb)
M1CC-07-014

6. Slowly operate the travel lever on the side with

the track to be removed to the reverse position
and extend the track.

W105-03-07-011

W3-7-3
 UNDERCARRIAGE / Track
Installation

CAUTION: The track assembly weight:

5400 kg (12000 lb)
Front Idler Sprocket
1. Set the track under the machine so that sprocket (2) Side (8) Side
(8) meshes with the track end. Check the
direction of the track at this time.

2. Hoist and mesh the track with the claws of

sprocket (8) by using a forklift. W105-03-07-013

W105-03-07-014

3. Slowly operate the lever for the track to be 9

installed in the forward direction. Turn travel
device (9) and wind the track.

W105-03-07-015

4. Wind the track link until the connection part of the

track link reaches the front idler (2) side. Lower 2
the machine. Place a wooden block under shoe
(1) and support shoe (1).

W105-03-07-016

Wooden
Block

W3-7-4
 UNDERCARRIAGE / Track
IMPORTANT: Master pin (3) can be installed to
only one direction. Check the 10 Corner Part
installing direction.
Direction to Direction
5. Install collars (10) (2 used) to master links (7) (2 to Install
Remove
used). Fit the hole of master link (7) to track link
(8). Install master pin (3) to master link (7).

3
Snap Ring
8 7

W105-03-07-010

IMPORTANT: As snap ring (6) is easy to deform, 7

replace snap ring (6) with a new one
rather than reuse.
6. Install snap ring (6) to master link (7).
Snap ring (6) has the direction to install. Install
snap ring (6) to the groove of master link (7) with
the flat surface of a pair of pliers hole facing 6
inside.
8

W105-03-07-009

Inner Diameter:
7. After installing, check that the inner diameter of Flat Surface 58.8 to 59.35 mm
snap ring (6) is 58.8 to 59.35 mm. If not, remove
snap ring (6). Clean the groove of master link (7).
Install snap ring (6) again.
3

7
W18J-03-07-002

W3-7-5
 UNDERCARRIAGE / Track
8. Tighten adjuster valve (4). Apply grease through
grease fitting (5). Adjust the track tension. 5 4
: 24 mm
: 80 N⋅m (8.2 kgf⋅m, 58 lbf⋅ft)
NOTE: Track sag specification (A): 530 to 590 mm
(21 to 23 in)

W1JB-03-07-027

W1R7-03-07-005

W3-7-6
 UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Link Pin and Track Bushing

Measure the length of four links:

• Do not include the master pin.
• Measure the length with tension on the track.

A
W155-03-07-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 1122.3 (44.1) 1145.2 (45.1) Clad by welding
and finish or
B 181 (7.13) [171 (6.73)]
replace

Master Pin

W105-03-07-021

Unit: mm (in)
Standard Allowable Limit Remedy
A 308.4 (12.1) -
Replace
B 61.8 (2.43) [51.8 (2.04)]

NOTE: Values in [ ] are just for reference.

W3-7-7
 UNDERCARRIAGE / Track
Master Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Limit Remedy
A 208.4 (8.20) -
B 62.72 (2.49) [68.7 (2.70)] Replace
C 98.57 (3.88) [90 (3.54)]

Grouser Shoe

W105-03-07-024

Unit: mm (in)
Shoe 700 mm Grouser
Standard Allowable Limit Remedy
A 302 (11.89) -
B 25 (0.98) - Replace
C 50 (1.97) [35 (1.38)]

NOTE: Values in [ ] are just for reference.

W3-7-8
 UNDERCARRIAGE / Track
Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Limit Remedy
A 225.6 (8.88) -
B 61.52 (2.42) [67.5 (2.66)] Replace
C 98.57 (3.88) 90 (3.54)

Pin

W105-03-07-020

Unit: mm (in)
Standard Allowable Limit Remedy
A 321.5 (12.66) -
Peplace
B 60.376 (2.38) [50.4 (1.98)]

NOTE: Values in [ ] are just for reference.

W3-7-9
 UNDERCARRIAGE / Track
(Blank)

W3-7-10
 MEMO

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 MEMO

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FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Removal and Installation of
Front Attachment ................................... W4-1-1
Removal of Bucket and Arm (Backhoe) ... W4-1-2
Installation of Bucket and Arm
(Backhoe) .............................................. W4-1-6
Removal of Bucket and Arm
(Loading Shovel) ................................. W4-1-10
Installation of Bucket and Arm
(Loading Shovel) ................................. W4-1-14
Removal of Boom
(Backhoe and Loading Shovel) ............ W4-1-18
Installation of Boom
(Backhoe and Loading shovel) ............ W4-1-20
Lubrication (Backhoe)............................ W4-1-22
Lubrication (Loading Shovel) ................. W4-1-23
18JW-4-1
SECTION 4
Group 2 Cylinder
Removal and Installation of Cylinder........ W4-2-1
Removal and Installation of
Boom Cylinder ....................................... W4-2-2
Removal and Installation of
Arm Cylinder (Backhoe) ......................... W4-2-6
Removal and Installation of
Arm Cylinder (Loading shovel) ............. W4-2-10
Removal and Installation of
Bucket Cylinder (Backhoe)................... W4-2-14
Removal and Installation of
Bucket Cylinder (Loading Shovel) ........ W4-2-18
Removal and Installation of
Level Cylinder (Loading Shovel) .......... W4-2-22
Removal and Installation of
Dump Cylinder (Loading Shovel) ......... W4-2-26
Disassembly of Cylinder ........................ W4-2-34
Assembly of Cylinder ............................. W4-2-40
Main Points to Bleed Air ......................... W4-2-48
Maintenance Standard ........................... W4-2-49
Group 3 Bushing and Point
Removal and Installation of Bushing ........ W4-3-1
Maintenance Standard ............................. W4-3-6
(Blank)

18JW-4-2
 FRONT ATTACHMENT / Front Attachment
REMOVAL AND INSTALLATION OF FRONT
ATTACHMENT

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

W4-1-1
 FRONT ATTACHMENT / Front Attachment
REMOVAL OF BUCKET AND ARM
(BACKHOE)

1
5

D
6

7 W18J-04-01-001
B
C

1 12 2 13 14 6 7 15

10, 11

9
16, 17

8
Section A Section B
W18J-04-01-004 W18J-04-01-005

6 5 18
1 26 27 6

24, 25 19, 20

23 21

22
Section C
W18J-04-01-003
Section D W18J-04-01-006

1- Bucket 8- O-Ring (2 Used) 15 - Stopper 22 - O-Ring (2 Used)

2- Link A 9- Cover (2 Used) 16 - Bolt (3 Used) 23 - Cover (2 Used)
3- Bucket Cylinder 10 - Bolt (10 Used) 17 - Spring Washer (3 Used) 24 - Bolt (10 Used)
4- Arm Cylinder 11 - Spring Washer (10 Used) 18 - Plate 25 - Spring Washer (10 Used)
5- Boom 12 - O-Ring (2 Used) 19 - Bolt (2 Used) 26 - O-Ring (2 Used)
6- Arm 13 - Pin 20 - Spring Washer (2 Used) 27 - Pin
7- Link B (2 Used) 14 - Pin 21 - Pin

W4-1-2
 FRONT ATTACHMENT / Front Attachment
Removal of Bucket and Arm
(Backhoe)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.
1. Remove O-rings (12, 26) (2 used for each) from
connection A of bucket (1) and link A (2) and
connection C of bucket (1) and arm (6).
145 mm (5.71 in)
Bolt
(M5, Pitch 0.8 mm)
Double Nut and
Washer on Both
Right and Left
Split Type O-Ring
Detail of O-Rings (12, 26) W18G-04-01-014
NOTE: O-rings (12, 26) cannot be reused. Replace
O-rings (12, 26) with new ones when
assembling.
CAUTION: Cover (9) weight: 20 kg (44 lb)
2. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
covers (9) (2 used). Attach a nylon sling onto
eyebolts (2 used). Hoist and hold covers (9) (2
used).
3. Remove bolts (10) (10 used) and spring washers
(11) (10 used) from covers (9) (2 used). Remove
covers (9) (2 used) from bucket (1).
: 32 mm
W4-1-3
CAUTION: Link A (2) weight: 570 kg (1260 lb)
CAUTION: Pin (13) weight: 115 kg (260 lb)
4. Attach a nylon sling onto link A (2). Hoist and hold
link A (2). Remove pin (13) from bucket (1).
5. Place link A (2). Remove a nylon sling from link A
(2).
CAUTION: Cover (23) weight: 24 kg (53 lb)
6. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
covers (23) (2 used). Attach a nylon sling onto
eyebolts (2 used). Hoist and hold covers (23) (2
used).
7. Remove bolts (24) (10 used) and spring washers
(25) (10 used) from covers (23) (2 used). Remove
covers (23) (2 used) from bucket (1).
: 32 mm
CAUTION: Bucket (1) weight:
Bucket (1) capacity 5.2 m3 (6.8 yd3): 4950 kg
(11000 lb)
Bucket (1) capacity 6.7 m3 (8.8 yd3): 6700 kg
(14800 lb)
CAUTION: Pin (27) weight: 145 kg (320 lb)
8. Attach a nylon sling onto the arm (6) assembly.
Hoist and hold the arm (6) assembly.
9. Remove pin (27) from bucket (1). Remove bucket
(1) from arm (6).
 FRONT ATTACHMENT / Front Attachment

D
6

W18J-04-01-001
B
C

Section A Section B
W18J-04-01-004 W18J-04-01-005

6 5 18

19, 20

21

Section C
W18J-04-01-003
Section D W18J-04-01-006

W4-1-4
 FRONT ATTACHMENT / Front Attachment
10. Disconnect the hoses from bucket cylinder (3). 13. Remove bolts (30) (2 used) and spring washers
Cap the open ends. (Refer to W4-2-14.) (29) (2 used) from plate (28). Remove plate (28)
from pin (31).
11. Disconnect the lubrication hoses (4 used) at the : 30 mm
mounting part of arm (6) and boom (5). Cap the
open ends. 4 28 29
: 19 mm
30
Lubrication Hose

31

6
W18J-04-01-008
W18J-04-01-013

Lubrication Hose CAUTION: Pin (31) weight: 76 kg (170 lb)

14. Remove pin (31) from arm (6). Place arm cylinder
(4) onto boom (5).

CAUTION: The arm (6) assembly weight:

6100 kg (13500 lb)
CAUTION: Pin (21) weight: 180 kg (400 lb)

15. Remove bolts (19) (2 used) and spring washers

(20) (2 used) from plate (18). Remove plate (18)
W18J-04-01-012
from pin (21).
: 30 mm
CAUTION: Arm cylinder (4) weight: 1680 kg
(3710 lb) 16. Attach a nylon sling onto the arm (6) assembly.
Hoist and hold the arm (6) assembly.
12. Attach a nylon sling onto arm cylinder (4). Hoist
and hold arm cylinder (4). 17. Remove pin (21) from boom (5). Remove the arm
(6) assembly from boom (5).

18. Place boom (5) on a wooden block.

W4-1-5
 FRONT ATTACHMENT / Front Attachment
INSTALLATION OF BUCKET AND ARM
(BACKHOE)

1
5

D
6

7 W18J-04-01-001
B
C

1 12 2 13 14 6 7 15

10, 11

9
16, 17

8
Section A Section B
W18J-04-01-004 W18J-04-01-005

6 5 18
1 26 27 6

24, 25 19, 20

23 21

22
Section C
W18J-04-01-003
Section D W18J-04-01-006

1- Bucket 8- O-Ring (2 Used) 15 - Stopper 22 - O-Ring (2 Used)

2- Link A 9- Cover (2 Used) 16 - Bolt (3 Used) 23 - Cover (2 Used)
3- Bucket Cylinder 10 - Bolt (10 Used) 17 - Spring Washer (3 Used) 24 - Bolt (10 Used)
4- Arm Cylinder 11 - Spring Washer (10 Used) 18 - Plate 25 - Spring Washer (10 Used)
5- Boom 12 - O-Ring (2 Used) 19 - Bolt (2 Used) 26 - O-Ring (2 Used)
6- Arm 13 - Pin 20 - Spring Washer (2 Used) 27 - Pin
7- Link B (2 Used) 14 - Pin 21 - Pin

W4-1-6
 FRONT ATTACHMENT / Front Attachment
Installation of Bucket and Arm
(Backhoe)

CAUTION: Metal fragments may fly off when CAUTION: Arm cylinder (4) weight: 1680 kg
a hammer is used. Wear necessary (3710 lb)
protection, such as goggles, hard hats, etc in
CAUTION: Pin (31) weight: 76 kg (170 lb)
order to prevent personal injury.
5. Attach a nylon sling onto arm cylinder (4). Hoist
CAUTION: The arm (6) assembly weight: arm cylinder (4). Fit arm cylinder (4) to the
6100 kg (13500 lb) mounting hole on arm (6).

1. Start the engine and raise boom (5). 6. Install arm cylinder (4) to arm (6) with pin (31).
Install pin (31) to arm (6) with plate (28), spring
2. Attach a nylon sling onto the arm (6) assembly. washers (29) (2 used), and bolts (30) (2 used).
Hoist the arm (6) assembly. Fit the arm (6) : 30 mm
assembly to the mounting hole on boom (5). : 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
4 28 29
CAUTION: Pin (21) weight: 180 kg (400 lb)
30
3. Install arm (6) to boom (5) with pin (21). Install pin
(21) to boom (5) with plate (18), spring washers
(20) (2 used), and bolts (19) (2 used).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
31
4. Connect the hoses to bucket cylinder (3). (Refer
to REMOVAL AND INSTALLATION OF BUCKET
CYLINDER (BACKHOE) on W4-2-14.) 6
W18J-04-01-008

CAUTION: Bucket (1) weight:

Bucket (1) capacity 5.2 m3 (6.8 yd3): 4950 kg
(11000 lb)
Bucket (1) capacity 6.7 m3 (8.8 yd3): 6700 kg
(14800 lb)

7. Install O-rings (12, 26) (2 used for each) to bucket

(1).

8. Start the engine and raise boom (5). Fit the end of
arm (6) to the mounting hole on bucket (1).

W4-1-7
 FRONT ATTACHMENT / Front Attachment

D
6

W18J-04-01-001
B
C

1 12 2 13

10, 11

8
Section A Section B
W18J-04-01-004 W18J-04-01-005

1 26 27 6

24, 25

23

22
Section C
W18J-04-01-003
Section D W18J-04-01-006

W4-1-8
 FRONT ATTACHMENT / Front Attachment
15. Install covers (9) (2 used) to bucket (1) with bolts
CAUTION: Pin (27) weight: 145 kg (320 lb)
(10) (10 used) and spring washers (11) (10 used).
: 32 mm
9. Install arm (6) to bucket (1) with pin (27). : 550 N⋅m (55 kgf⋅m, 400 lbf⋅ft)

CAUTION: Cover (23) weight: 24 kg (53 lb) 16. Move O-rings (12, 26) (2 used for each) to the
specified position. Install O-rings (12, 26) (2 used
10. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to for each) to bucket (1).
covers (23) (2 used). Attach a nylon sling onto 145 mm (5.71 in)
eyebolts (2 used). Hoist covers (23) (2 used). Fit
Bolt
covers (23) (2 used) to the mounting hole on (M5, Pitch 0.8 mm)
bucket (1).
Double Nut and
11. Install covers (23) (2 used) to bucket (1) with bolts Washer on Both
(24) (10 used) and spring washers (25) (10 used). Right and Left
: 32 mm
: 550 N⋅m (55 kgf⋅m, 400 lbf⋅ft)
Split Type O-Ring
CAUTION: Link A (2) weight: 570 kg (1260 lb)
Detail of O-Rings (12, 26)
W18G-04-01-014
12. Attach a nylon sling onto link A (2). Hoist link A (2).
Fit link A (2) to the mounting hole on bucket (1). 17. Connect the lubrication hoses (4 used) at the
mounting part of boom (5) and arm (6).
CAUTION: Pin (13) weight: 115 kg (260 lb) : 19 mm
: 35 N⋅m (3.5 kgf⋅m, 25.5 lbf⋅ft)
13. Install link A (2) to bucket (1) with pin (13).
Lubrication Hose

CAUTION: Cover (9) weight: 20 kg (44 lb)

14. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to

covers (9) (2 used). Attach a nylon sling onto
eyebolts (2 used). Hoist covers (9) (2 used). Fit
covers (9) (2 used) to the mounting hole on
bucket (1).

W18J-04-01-013

Lubrication Hose

W18J-04-01-012

W4-1-9
 FRONT ATTACHMENT / Front Attachment
REMOVAL OF BUCKET AND ARM
(LOADING SHOVEL)

A
4
3

W18J-04-01-002

Wooden Block

Lubrication
Hydraulic Hose
Hose

W183-04-02-023
W183-04-02-027

W183-04-02-010

Wooden Block

12

13

9
11 14
8

6, 7

Section A W183-04-01-007
10
Section B W166-04-01-015

1- Dump Cylinder (2 Used) 5- Pin (2 Used) 9 - Shim (Several) 12 - Spring Washer (4 Used)
2- Bucket Cylinder (2 Used) 6- Bolt (6 Used) 10 - O-Ring (2 Used) 13 - Bolt (4 Used)
3- Arm Cylinder 7- Spring Washer (6 Used) 11 - Pin (2 Used) 14 - Plate (2 Used)
4- Level Cylinder 8- Stopper (2 Used)

W4-1-10
 FRONT ATTACHMENT / Front Attachment
Removal of Bucket and Arm
(Loading Shovel)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.
1. Remove O-rings (10 used) (2 used) from the
connecting part of the bucket and the arm.
145 mm (5.71 in)
Bolt
(M5, Pitch 0.8 mm)
Double Nut and
Washer on Both
Right and Left
Split Type O-Ring
Detail of O-Ring (10) W18G-04-01-014
NOTE: O-ring (10) cannot be reused. Replace
O-ring (10) with a new one when
assembling.
2. Remove bucket cylinders (2) (2 used) from the
boom and the bucket. (Refer to W4-2-18.)
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining pressure before removing.
3. Stop the engine. Operate the control lever several
times and release the remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Disconnect the hydraulic hoses (2 used)
and the lubrication hose at the mounting part of
the arm and the bucket.
: 12 mm
: 19 mm
W4-1-11
CAUTION: Pin (5) weight: 65 kg (150 lb)
4. Start the engine and hold the arm. Remove bolts
(6) (6 used) and spring washers (7) (6 used) from
stoppers (8) (2 used). Remove stoppers (8) (2
used) from the bucket. Remove pins (5) (2 used)
and shim (9) from the bucket.
: 24 mm
CAUTION: Bucket (6.5 m3 (8.5 yd3)) + dump
cylinder weight: 9520 kg (21000 lb)
5. Remove the bucket from the arm. Place the arm
onto a wooden block.
6. Remove arm cylinder (3) and level cylinder (4).
Refer to REMOVAL AND INSTALLATION OF
ARM CYLINDER on W4-2-10. Refer to
REMOVAL AND INSTALLATION OF LEVEL
CYLINDER on W4-2-22.
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining pressure before removing.
7. Stop the engine. Operate the control lever several
times and release the remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Disconnect the hydraulic hoses (6 used)
and the lubrication hoses (2 used) at the
mounting part of the boom and the arm. Cap the
open ends.
: 12 mm
: 19 mm
 FRONT ATTACHMENT / Front Attachment

W18J-04-01-002

Wooden Block

Lubrication Hose
Hydraulic Hose

W183-04-02-023
W183-04-02-027

W183-04-02-010

Wooden Block

12

13

11 14

Section A W183-04-01-007

Section B W166-04-01-015

W4-1-12
 FRONT ATTACHMENT / Front Attachment

CAUTION: Arm weight: 4200 kg (9300 lb)

CAUTION: Pin (11) weight: 80 kg (180 lb)

8. Attach a nylon sling onto the arm. Hoist and hold

the arm.

9. Remove bolts (13) (4 used) and spring washers

(12) (4 used) from plates (14) (2 used). Hoist and
remove pins (11) (2 used) from the boom.
: 30 mm

10. Remove the arm from the boom.

W4-1-13
 FRONT ATTACHMENT / Front Attachment
INSTALLATION OF BUCKET AND ARM
(LOADING SHOVEL)

A
4
3

W18J-04-01-002

Wooden Block

Lubrication Hose
Hydraulic Hose

W183-04-02-023
W183-04-02-027

W183-04-02-010

Wooden Block

12

13

9
11 14
8

6, 7

Section A W183-04-01-007
10
Section B W166-04-01-015

1- Dump Cylinder (2 Used) 5- Pin (2 Used) 9 - Shim (Several) 12 - Spring Washer (4 Used)
2- Bucket Cylinder (2 Used) 6- Bolt (6 Used) 10 - O-Ring (2 Used) 13 - Bolt (4 Used)
3- Arm Cylinder 7- Spring Washer (6 Used) 11 - Pin (2 Used) 14 - Plate (2 Used)
4- Level Cylinder 8- Stopper (2 Used)

W4-1-14
 FRONT ATTACHMENT / Front Attachment
Installation of Bucket and Arm
(Loading Shovel)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.
CAUTION: Arm weight: 4200 kg (9300 lb)
1. Start the engine and raise the boom. Hoist the
arm. Fit the mounting holes on the boom and the
arm.
CAUTION: Pin (11) weight: 80 kg (180 lb)
2. Install the arm to the boom with pins (11) (2 used).
Install pins (11) (2 used) to the boom with plates
(14) (2 used), spring washers (12) (4 used), and
bolts (13) (4 used).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining pressure before removing.
3. Stop the engine. Operate the control lever several
times and release the remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Connect the hydraulic hoses (6 used)
and the lubrication hoses (2 used) at the
mounting part of the boom and the arm.
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
: 19 mm
: 35 N⋅m (3.5 kgf⋅m, 25.5 lbf⋅ft)
W4-1-15
4. Install level cylinder (4) and arm cylinder (3) to the
boom and the arm. (Refer to REMOVAL AND
INSTALLATION OF LEVEL CYLINDER on
W4-2-22. Refer to REMOVAL AND
INSTALLATION OF ARM CYLINDER on
W4-2-10.)
5. Install O-rings (10) (2 used) to the bucket.
CAUTION: Bucket (6.5 m3 (8.5 yd3)) + dump
cylinder weight: 9520 kg (21000 lb)
6. Start the engine and raise the arm. Fit the
mounting holes on the arm and the bucket. Install
shim (9) between the arm and the bucket.
CAUTION: Pin (5) weight: 65 kg (150 lb)
7. Install the bucket to the arm with pins (5) (2 used).
Install pins (5) (2 used) to the bucket with
stoppers (8) (2 used), spring washers (7) (6 used),
and bolts (6) (6 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining pressure before removing.
8. Stop the engine. Operate the control lever several
times and release the remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Connect the hydraulic hoses (2 used)
and the lubrication hose at the mounting part of
the arm and the bucket.
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
: 19 mm
: 35 N⋅m (3.5 kgf⋅m, 25.5 lbf⋅ft)
 FRONT ATTACHMENT / Front Attachment

W18J-04-01-002

Wooden Block

Lubrication Hose
Hydraulic Hose

W183-04-02-023
W183-04-02-027

W183-04-02-010

Wooden Block

Section A W183-04-01-007
10
Section B W166-04-01-015

W4-1-16
 FRONT ATTACHMENT / Front Attachment
9. Move O-rings (10) (2 used) to the specified
position. Install O-rings (10) (2 used) to the
bucket.
145 mm (5.71 in)

Bolt
(M5, Pitch 0.8 mm)

Double Nut and

Washer on Both
Right and Left

Split Type O-Ring

Detail of O-Ring (10) W18G-04-01-014

10. Remove bucket cylinders (2) (2 used). (Refer to

W4-2-18.)

W4-1-17
 FRONT ATTACHMENT / Front Attachment
REMOVAL OF BOOM
(BACKHOE AND LOADING SHOVEL)
A

W18J-04-01-015

W18J-04-01-016

Hydraulic
Hose
Lubrication
Hose
Hydraulic
Hose

Lubrication Hose

Loading Shovel
Backhoe W183-04-02-024
W183-04-02-025

4 5
3
2

Section A W18J-04-01-022

1 - Boom Cylinder (2 Used) 3- Spring Washer (4 Used) 5- Pin (2 Used)

2 - Plate (2 Used) 4- Bolt (4 Used)

W4-1-18
 FRONT ATTACHMENT / Front Attachment
Removal of Boom
(Backhoe and Loading Shovel)

5. Remove bolts (3) (4 used), spring washers (4) (4

CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury.
1. Remove the bucket and the arm. Refer to W4-1-2
as for backhoe. Refer to W4-1-10 as for loading
shovel.
used), and plates (5) (2 used) from pins (2) (2
used). Hoist and remove pins (2) (2 used) from
the main frame.
: 30 mm
6. Hoist and remove the boom from the main frame.

2. Remove boom cylinder (1). Refer to W4-2-2.

CAUTION: If turning the hydraulic oil tank

cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining pressure before removing.

3. Stop the engine. Operate the control lever several

times and release the remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Disconnect the hydraulic hoses (11
used) and the lubrication hose of the main frame
side. Cap the open ends.
: 12 mm, 14 mm

CAUTION: Boom weight

Backhoe: 8860 kg (19600 lb)
BE backhoe: 8580 kg (19000 lb)
Loading shovel: 5690 kg (12600 lb)
Pin (2) weight: 70 kg (160 lb)

4. Attach a nylon sling onto the boom. Hoist and

hold the boom.

W4-1-19
 FRONT ATTACHMENT / Front Attachment
INSTALLATION OF BOOM
(BACKHOE AND LOADING SHOVEL)
A

W18J-04-01-015

W18J-04-01-016

Hydraulic
Hose
Lubrication
Hose
Hydraulic
Hose

Lubrication Hose

Loading Shovel
Backhoe W183-04-02-024
W183-04-02-025

2 3
4

Section A W18J-04-01-007

1 - Boom Cylinder (2 Used) 3- Spring Washer (4 Used) 5- Pin (2 Used)

2 - Plate (2 Used) 4- Bolt (4 Used)

W4-1-20
 FRONT ATTACHMENT / Front Attachment
Installation of Boom
(Backhoe and Loading Shovel)

4. Install boom cylinder (1). Refer to W4-2-2.

CAUTION: Boom weight
Backhoe: 8860 kg (19600 lb)
BE backhoe: 8580 kg (19000 lb)
Loading shovel: 5690 kg (12600 lb)
1. Hoist the boom. Fit the boom to the mounting hole
on the main frame. Install shim (6) to the main
frame.
5. Install the bucket and the arm. Refer to W4-1-2 as
for backhoe. Refer to W4-1-10 as for loading
shovel.
IMPORTANT: Perform the following procedures
after installing the bucket, the arm,
and the boom.

CAUTION: Pin (2) weight: 70 kg (160 lb)
2. Install the boom to the main frame with pins (2) (2
used). Install pins (2) (2 used) to the main frame
with plates (5) (2 used), spring washers (4) (4
used), and bolts (3) (4 used).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
6. Apply grease onto all grease fittings as illustrated
after installing the bucket, the arm, and the boom.
Refer to W4-1-22.
NOTE: Install a cap to the grease fitting around the
bucket for protection. Apply grease after
removing the cap by using a cap driver.

CAUTION: If turning the hydraulic oil tank

cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining pressure before removing.

3. Stop the engine. Operate the control lever several

times and release the remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Place a wooden block and place the
boom. Connect the hydraulic hoses (11 used) and
lubrication hose of the main frame side.
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
: 14 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

W4-1-21
 FRONT ATTACHMENT / Front Attachment
LUBRICATION
(BACKHOE)

B
C

A
Bucket, Link
Joint Pin

Arm, Link
Joint Pin

W18J-04-01-015
Bucket, Arm
Joint Pin

Bucket Cylinder
Rod Side

Closeup A W18J-04-01-014

Boom Cylinder Boom Foot Arm Cylinder

Rod Side Arm Side Bottom Side

Boom Cylinder
Bottom Side
Bucket Cylinder
Bottom Side
Arm Cylinder
Rod Side
Boom Cylinder
Rod Side

Closeup C Boom Foot W18J-04-01-010

Closeup B W18J-04-01-011
Machine Side

W4-1-22
 FRONT ATTACHMENT / Front Attachment
LUBRICATION
(LOADING SHOVEL)

E C

W18J-04-01-017

Arm Cylinder Level Cylinder Bucket Cylinder Arm Foot Arm Foot Arm Foot
Bottom Pin Bottom Side Rod Side Bucket Side Boom Side Bucket Side

W18J-04-01-018
Boom Foot Boom Cylinder
Bottom Side Bucket Cylinder Level Cylinder Arm Cylinder W18J-04-01-019

Bottom Side Rod Side Rod Pin

Closeup D
Closeup E

Dump Cylinder
Rod Pin

Bucket
Joint Pin

W18J-04-01-021
W18J-04-01-020
Dump Cylinder
Bottom Pin

W4-1-23
 FRONT ATTACHMENT / Front Attachment
(Blank)

W4-1-24
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF
CYLINDER

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

W4-2-1
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF BOOM
CYLINDER B

Backhoe A

W18J-04-01-015
B
Loading Shovel A

W18J-04-01-016

A: Rod Side Lubrication Hose B: Bottom Side

1 6

Hydraulic
Hose

Lubrication
Hydraulic
Hose
Hoses

W183-04-02-013

10
1 2

3 W183-04-02-004

5 6
4
7

10
11

12
Section A W166-04-01-015
10 Section B
W18J-04-01-007

1 - Pin (2 Used) 4 - Plate (2 Used) 7 - Spring Washer (4 Used) 10 - Boom Cylinder (2 Used)
2 - Spring Washer (4 Used) 5 - Pin (2 Used) 8 - Plate (2 Used) 11 - Boom
3 - Bolt (4 Used) 6 - Bolt (4 Used) 9 - Spacer (2 Used) 12 - Main Frame

W4-2-2
 FRONT ATTACHMENT / Cylinder
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection such as goggles and hard hats, in
order to prevent personal injury.
Removal
1. Disconnect lubrication hoses (2 used for each)
from boom cylinders (10) (2 used). Cap the open
ends.
: 19 mm
CAUTION: Boom cylinder (10) weight: 1130
kg (2500 lb)
Pin (1) weight: 62 kg (140 lb)
2. Attach a nylon sling onto boom cylinders (10) (2
used). Hoist and hold boom cylinders (10) (2
used).
3. Remove bolts (3) (4 used) and spring washers (2)
(4 used) from plates (4) (2 used). Remove plates
(4) (2 used) from pins (1) (2 used). Remove pins
(1) (2 used) from boom (11) to the position where
boom cylinders (10) (2 used) can be removed.
: 30 mm
4. Start the engine and retract boom cylinders (10)
(2 used). In order not to extend boom cylinders
(10) (2 used), pass a wire through the piston rod
hole and secure the piston rod.
W4-2-3
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining Pressure before removing.
5. Stop the engine. Operate the control lever several
times and release any remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Disconnect hydraulic hoses (2 used for
each) from boom cylinders (10) (2 used). Cap the
open ends.
: 12 mm, 14 mm
CAUTION: Pin (5) weight: 70 kg (160 lb)
6. Remove bolts (6) (4 used) and spring washers (7)
(4 used) from plates (8) (2 used). Remove plates
(8) (2 used) from pin (5). Remove pins (5) (2
used) and spacers (9) (2 used) from main frame
(12).
: 30 mm
7. Hoist and remove boom cylinders (10) (2 used)
from main frame (12).
 FRONT ATTACHMENT / Cylinder
Backhoe B
A

W18J-04-01-015
B

Loading Shovel A

W18J-04-01-016

A: Rod Side Lubrication Hose B: Bottom Side

1 6

Hydraulic
Hose

Lubrication
Hydraulic
Hose
Hoses

W183-04-02-013

10
1 2

3 W183-04-02-004

5 6
4
7

10
11

12
Section A W166-04-01-015
10 Section B
W18J-04-01-007

W4-2-4
 FRONT ATTACHMENT / Cylinder
Installation

CAUTION: Boom cylinder (10) weight: 1130
kg (2500 lb)
Pin (5) weight: 70 kg (160 lb)
1. Attach a nylon sling onto boom cylinders (10) (2
used). Hoist boom cylinders (10) (2 used). Fit
boom cylinders (10) (2 used) to the mounting hole
on main frame (12).
CAUTION: Pin (1) weight: 62 kg (140 lb)
5. Install the piston rod side of boom cylinders (10)
(2 used) to boom (11) with pins (5) (2 used),
plates (8) (2 used), spring washers (7) (4 used),
and bolts (6) (4 used).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

2. Install boom cylinders (10) (2 used) to main frame 6. Connect lubrication hoses (2 used for each).
(12) with spacers (9) (2 used), pins (5) (2 used), : 19 mm
plates (8) (2 used), spring washers (7) (4 used), : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
and bolts (6) (4 used).
: 30 mm 7. Bleed air from the cylinder.
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft) (Refer to MAIN POINTS TO BLEED AIR on
W4-2-48.)
3. Connect hydraulic hoses (2 used for each) to
boom cylinders (10) (2 used). Remove a wire
which secures the piston rod.
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
: 14 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

4. Hoist the rod side of boom cylinders (10) (2 used).

Adjust the height and extend the piston rod. Fit
the pin hole of the piston rod side to the mounting
hole of boom (11).

W4-2-5
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF ARM
CYLINDER (BACKHOE)

W18J-04-01-015

A: Rod Side B: Bottom Side

2 Hydraulic
Hose Lubrication
Lubrication Hose
Hose

W183-04-02-016

Lubrication
W166-04-01-020
Hose 1
W183-04-02-001

2 3
4

6, 7
Section A and B W18J-04-01-008

1 - Pin (2 Used) 3 - Plate (2 Used) 5 - Bolt (4 Used) 7 - Arm

2 - Arm Cylinder 4 - Spring Washer (4 Used) 6 - Boom

W4-2-6
 FRONT ATTACHMENT / Cylinder
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection such as goggles and hard hats, in
order to prevent personal injury.
Removal
1. Disconnect a lubrication hose from the piston rod
side of arm cylinder (2). Cap the open ends.
: 19 mm
CAUTION: Arm cylinder (2) weight: 1680 kg
(3710 lb)
Pin (1) weight: 76 kg (170 lb)
2. Attach a nylon sling onto arm cylinder (2). Hoist
and hold arm cylinder (2).
3. Remove bolt (5) and spring washer (4) from plate
(3). Remove plate (3) from pin (1). Remove pin (1)
from arm (7).
: 30 mm
4. Start the engine and retract arm cylinder (2). In
order not to extend the piston rod, pass a wire
through the piston rod hole and secure the piston
rod.
W4-2-7
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining Pressure before removing.
5. Stop the engine. Operate the control lever several
times and release any remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Disconnect hydraulic hoses (3 used)
and a lubrication hose at the bottom side. Cap the
open ends.
: 12 mm, 14 mm
: 19 mm
CAUTION: Arm cylinder (2) weight: 1680 kg
(3710 lb)
Pin (1) weight: 76 kg (170 lb)
6. Remove bolt (5) and spring washer (4) from plate
(3). Remove plate (3) from pin (1). Remove pin (1)
from boom (6).
: 30 mm
7. Remove arm cylinder (2) from boom (6).
 FRONT ATTACHMENT / Cylinder

W18J-04-01-015

A: Rod Side B: Bottom Side

2 Hydraulic
Hose Lubrication
Lubrication Hose
Hose

W183-04-02-016

Lubrication Hose
W166-04-01-020
1
W183-04-02-001

2 3
4

6, 7
Section A and B W18J-04-01-008

W4-2-8
 FRONT ATTACHMENT / Cylinder
Installation

CAUTION: Arm cylinder (2) weight: 1680 kg CAUTION: Pin (1) weight: 76 kg (170 lb)
(3710 lb)
6. Install the piston rod side of arm cylinder (2) to
1. Attach a nylon sling onto arm cylinder (2). Hoist arm (7) with pin (1), plate (3), spring washers (4)
arm cylinder (2). Fit arm cylinder (2) to the (2 used), and bolts (5) (2 used).
mounting hole of boom (6). : 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
CAUTION: Pin (1) weight: 76 kg (170 lb)
7. Connect a lubrication hose to pin (1) at the rod
side of arm cylinder (2).
2. Install arm cylinder (2) to boom (6) with pin (1), : 19 mm
plate (3), spring washers (4) (2 used), and bolts : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
(5) (2 used).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft) 8. Bleed air from arm cylinder (2).
(Refer to MAIN POINTS TO BLEED AIR on
3. Connect hydraulic hoses (3 used) and a W4-2-48.)
lubrication hose to the bottom side of arm cylinder
(2).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
: 14 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

4. Remove a wire which secures the piston rod of

arm cylinder (2).

5. Start the engine. Adjust the height and extend the

piston rod. Fit the pin hole on the piston rod side
to the pin hole of arm (7).

W4-2-9
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF ARM
CYLINDER (LOADING SHOVEL)

B
A

W18J-04-01-016

A: Rod Side B: Bottom Side

2
Lubrication Hose Lubrication
Hose
3
1 Hydraulic
Hose

3 4
3 W183-04-02-018
W183-04-02-017
3
W183-04-02-008

6
4
7

Section A and B W118-04-01-005

1 - Arm 3- Pin (2 Used) 5- Spring Washer (4 Used) 7- Plate (2 Used)

2 - Boom 4- Arm Cylinder 6- Bolt (4 Used) 8- Dust Seal (4 Used)

W4-2-10
 FRONT ATTACHMENT / Cylinder

CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection such as goggles and hard hats, in
order to prevent personal injury.
Removal
1. Disconnect a lubrication hose from the piston rod
side of arm cylinder (4). Cap the open ends.
: 19 mm
CAUTION: Arm cylinder (4) weight: 980 kg
(2170 lb)
Pin (3) weight: 50 kg (110 lb)
2. Attach a chain block onto arm cylinder (4). Hoist
and hold arm cylinder (4).
3. Remove bolts (6) (2 used) and spring washers (5)
(2 used) from plate (7). Remove plate (7) from pin
(3). Remove pin (3) from arm (1).
: 30 mm
4. Remove dust seals (8) (2 used) from arm cylinder
(4).
5. Start the engine and retract the piston rod of arm
cylinder (4). In order not to extend the piston rod,
pass a wire through the piston rod hole and
secure the piston rod.
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining Pressure before removing.
6. Stop the engine. Operate the control lever several
times and release any remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Disconnect hydraulic hoses (3 used)
and a lubrication hose at the bottom side. Cap the
open ends.
: 12 mm, 14 mm
: 19 mm
CAUTION: Arm cylinder (4) weight: 980 kg
(2170 lb)
Pin (3) weight: 50 kg (110 lb)
7. Remove bolts (6) (2 used) and spring washers (5)
(2 used) from plate (7). Remove plate (7) from pin
(3). Remove pin (3) from boom (2).
: 30 mm
8. Remove arm cylinder (4) from boom (2).

W4-2-11
 FRONT ATTACHMENT / Cylinder

B
A

W18J-04-01-016

A: Rod Side B: Bottom Side

2
Lubrication Hose Lubrication
Hose
3
1 Hydraulic
Hose

3 4
3 W183-04-02-018
W183-04-02-017
3
W183-04-02-008

6
4
7

Section A and B W118-04-01-005

W4-2-12
 FRONT ATTACHMENT / Cylinder
Installation

CAUTION: Arm cylinder (4) weight: 980 kg CAUTION: Pin (3) weight: 50 kg (110 lb)
(2170 lb)
6. Install the piston rod side of arm cylinder (4) to
1. Attach a chain block onto arm cylinder (4). Hoist arm (1) with pin (3), plate (7), spring washers (5)
arm cylinder (4). Fit arm cylinder (4) to the (2 used), and bolts (6) (2 used).
mounting hole of boom (2). : 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
CAUTION: Pin (3) weight: 50 kg (110 lb)
7. Connect a lubrication hose to pin (3) at the rod
side of arm cylinder (4).
2. Install arm cylinder (4) to boom (2) with pin (3), : 19 mm
plate (7), spring washers (5) (2 used), and bolts : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
(6) (2 used).
: 30 mm 8. Bleed air from arm cylinder (4).
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft) (Refer to MAIN POINTS TO BLEED AIR on
W4-2-48.)
3. Connect hydraulic hoses (3 used) and a
lubrication hose to the bottom side of arm cylinder
(4).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
: 14 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

4. Remove a wire which secures the piston rod of

arm cylinder (4). Install dust seals (8) (2 used) to
the piston rod.

5. Start the engine. Adjust the height and extend the

piston rod. Fit the pin hole on the piston rod side
to the mounting hole of arm (1).

W4-2-13
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF
BUCKET CYLINDER (BACKHOE)

W18J-04-01-015

A: Rod Side B: Bottom Side Hydraulic Hose

10 10
9 Lubrication
Hose

12

Wooden Block
1 11 5
W166-04-01-008

W166-04-01-009

9 10 11 5 10
6

1 7

8
2, 3

Section A W18J-04-01-009
12

W166-04-01-015
Section B

1 - Pin 4- Stopper 7- Bolt (2 Used) 10 - Bucket Cylinder

2 - Spring Washer (3 Used) 5- Pin 8- Plate 11 - Link B (2 Used)
3 - Bolt (3 Used) 6- Spring Washer (2 Used) 9- Link A 12 - Arm

W4-2-14
 FRONT ATTACHMENT / Cylinder
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection such as goggles and hard hats, in
order to prevent personal injury.
Removal
1. Disconnect a lubrication hose from the bottom
side of bucket cylinder (10).
: 19 mm
2. Set a wooden block to the clearance between arm
(12) and bucket cylinder (10). In order not to drop
links B (11) (2 used) when removing pin (1),
secure link A (9) and links B (11) (2 used) by using
a wire and a chain block.
CAUTION: Bucket cylinder (10) weight: 1080
kg (2390 lb)
Pin (1) weight: 140 kg (310 lb)
3. Attach a nylon sling onto bucket cylinder (10).
Hoist and hold bucket cylinder (10).
4. Remove bolts (3) (3 used) and spring washers (2)
(3 used) from stopper (4). Remove stopper (4)
from link B (11).
: 30 mm
5. Push out pin (1) from link B (11) and link A (9)
halfway. Attach a nylon sling onto pin (1). Hoist
and hold pin (1). Remove pin (1) from links B (11)
(2 used), link A (9), and bucket cylinder (10).
6. Start the engine and retract bucket cylinder (10).
In order not to extend bucket cylinder (10), pass a
wire through the piston rod hole and secure the
piston rod.
W4-2-15
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining Pressure before removing.
7. Stop the engine. Operate the control lever several
times and release any remaining pressure in the
circuit. Bleed air from hydraulic oil tank. (Refer to
BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Disconnect hydraulic hoses (2 used)
and a lubrication hose at the bottom side of
bucket cylinder (10). Cap the open ends.
: 12 mm, 14 mm
CAUTION: Bucket cylinder (10) weight: 1080
kg (2390 lb)
Pin (5) weight: 60 kg (140 lb)
8. Attach a nylon sling onto bucket cylinder (10).
Hoist and hold bucket cylinder (10). Remove bolts
(7) (2 used) and spring washers (6) (2 used) from
plate (8). Remove plate (8) from pin (5).
: 30 mm
9. Remove pin (5) from arm (12). Remove bucket
cylinder (10) from arm (12).
 FRONT ATTACHMENT / Cylinder

W18J-04-01-015

A: Rod Side B: Bottom Side Hydraulic

Hose
10 10
9 Lubrication
Hose

12

Wooden Block
1 11 5
W166-04-01-008

W166-04-01-009

9 10 11 5 10
6

1 7

8
2, 3

Section A W18J-04-01-009
12

W166-04-01-015
Section B

W4-2-16
 FRONT ATTACHMENT / Cylinder
Installation

CAUTION: Bucket cylinder (10) weight: 1080 CAUTION: Pin (1) weight: 140 kg (310 lb)
kg (2390 lb)
5. Hoist and install pin (1) to the pin hole at the
1. Attach a nylon sling onto bucket cylinder (10). piston rod side. Install pin (1) to link B (11) with
Hoist bucket cylinder (10). Fit bucket cylinder (10) stopper (4), spring washers (2) (3 used), and bolts
to the mounting hole of arm (12). (3) (3 used).
: 30 mm
CAUTION: Pin (5) weight: 60 kg (140 lb)
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft))
2. Install bucket cylinder (10) to arm (12) with pin (5), 6. Remove a wire and a chain block which secure
plate (8), spring washers (6) (2 used), and bolts links B (11) (2 used) in order not to fall off. Start
(7) (2 used). the engine. Remove a wooden block between
: 30 mm arm (12) and bucket cylinder (10).
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
7. Bleed air from bucket cylinder (10).
3. Connect hydraulic hoses (2 used) and a (Refer to MAIN POINTS TO BLEED AIR on
lubrication hose to the bottom side of bucket W4-2-48.)
cylinder (10).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
: 14 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

4. Remove a wire which secures the piston rod of

bucket cylinder (10). Start the engine. Extend the
piston rod. Attach a nylon sling onto link A (9) and
links B (11) (2 used). Hoist link A (9) and links B
(11) (2 used).Fit the pin holes of link (A), links (B)
(2 used), and the piston rod side.

W4-2-17
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF
BUCKET CYLINDER (LOADING SHOVEL)

W18J-04-01-016

A: Rod Side B: Bottom Side

Hydraulic
Lubrication Hose Lubrication
Hose Hose

9 W183-04-02-020

2 W183-04-02-007
9 W183-04-02-018
1

11 2 7

8 2

3
9 1

4, 5
10

6
W142-04-01-013
12 Section B

Section A W183-04-02-014

1 - Pin (2 Used) 4 - Bolt (6 Used) 7 - Plate (2 Used) 10 - Pin (2 Used)

2 - Bucket Cylinder (2 Used) 5 - Spring Washer (6 Used) 8 - Bolt (4 Used) 11 - Spacer (2 Used)
3 - Stopper (2 Used) 6 - Bucket 9 - Spring Washer (4 Used) 12 - Boom

W4-2-18
 FRONT ATTACHMENT / Cylinder
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection such as goggles and hard hats, in
order to prevent personal injury.
Removal
1. Disconnect a lubrication hose from the bottom
side of bucket cylinder (10).
: 19 mm
CAUTION: Bucket cylinder (2) weight: 920 kg
(2030 lb)
Pin (9) weight: 50 kg (110 lb)
2. Attach a nylon sling onto bucket cylinders (2) (2
used). Hoist and hold bucket cylinders (2) (2
used). Remove bolts (8) (4 used) and spring
washers (9) (4 used) from plates (7) (2 used).
Remove plates (7) (2 used) from pins (10) (2
used).
: 30 mm
3. Remove pins (10) (2 used) from boom (12).
Remove piston rods (2 used) of bucket cylinders
(2) (2 used) and spacers (11) (2 used) from boom
(12).
4. Start the engine and retract bucket cylinders (2) (2
used). In order not to extend bucket cylinders (2)
(2 used), pass a wire through the piston rod hole
and secure the piston rod.
W4-2-19
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining Pressure before removing.
5. Stop the engine. Operate the control lever several
times and release any remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Connect hydraulic hoses (4 used) and
lubrication hoses (2 used) to the bottom side of
bucket cylinders (2) (2 used). Cap the open ends.
: 12 mm, 14 mm, 17 mm
CAUTION: Bucket cylinder (2) weight: 920 kg
(2030 lb)
Pin (1) weight: 70 kg (160 lb)
6. Attach a nylon sling onto bucket cylinders (2) (2
used). Hoist and hold bucket cylinders (2) (2
used). Remove bolts (4) (6 used) and spring
washers (5) (6 used) from stopper (3). Remove
stoppers (3) (2 used) from bucket (6).
: 24 mm
7. Remove pins (1) (2 used) from bucket (6).
Remove bucket cylinders (2) (2 used) from bucket
(6).
 FRONT ATTACHMENT / Cylinder

W18J-04-01-016

A: Rod Side B: Bottom Side

Hydraulic
Lubrication Hose Lubrication
Hose Hose

9 W183-04-02-020

2 W183-04-02-007
9 W183-04-02-018
1

11 2 7

8 2

3
9 1

4, 5
10

12 Section B W142-04-01-013

Section A W183-04-02-014

W4-2-20
 FRONT ATTACHMENT / Cylinder
Installation

CAUTION: Bucket cylinder (2) weight: 920 kg CAUTION: Pin (9) weight: 50 kg (110 lb)
(2030 lb)
6. Install bucket cylinders (2) (2 used) to boom (12)
1. Attach a nylon sling onto bucket cylinders (2) (2 with pins (1) (2 used), stoppers (3) (2 used),
used). Hoist bucket cylinders (2) (2 used). Fit spring washers (5) (6 used), and bolts (4) (6
bucket cylinders (2) (2 used) to the mounting hole used).
on bucket (6). : 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
CAUTION: Pin (1) weight: 70 kg (160 lb)
7. Bleed air from bucket cylinders (2) (2 used).
(Refer to MAIN POINTS TO BLEED AIR on
2. Install bucket cylinders (2) (2 used) to bucket (6) W4-2-48.)
with pins (10) (2 used), plates (7) (2 used), spring
washers (9) (4 used), and bolts (8) (4 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

3. Connect hydraulic hoses (4 used) and lubrication

hoses (2 used) to the bottom side of bucket
cylinders (2) (2 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
: 14 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
: 17 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

4. Hoist the rod side of bucket cylinders (2) (2 used).

Remove a wire which secures the piston rod.

5. Start the engine. Extend the piston rod. Fit the pin
hole on the piston rod side to the pin hole of boom
(12). Install spacers (11) (2 used).

W4-2-21
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF LEVEL
CYLINDER (LOADING SHOVEL)

B
A

W18J-04-01-016

A: Rod Side B: Bottom Side

2
Lubrication Hydraulic
Hose Hoses

Lubrication W166-04-01-021
Hose
2
W166-04-01-024

W183-04-02-009

1 2 3

7, 8
6
W166-04-01-015
Section A and B

1 - Pin (2 Used) 3 - Spring Washer (4 Used) 5 - Plate (2 Used) 7 - Boom

2 - Level Cylinder 4 - Bolt (4 Used) 6 - Dust Seal (4 Used) 8 - Arm

W4-2-22
 FRONT ATTACHMENT / Cylinder
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary
protection such as goggles and hard hats, in
order to prevent personal injury.
Removal
IMPORTANT: After removing the arm cylinder,
remove level cylinder (2). (Refer to
REMOVAL AND INSTALLATION OF
ARM CYLINDER on W4-2-10.)
1. Disconnect lubrication hoses (2 used) from level
cylinder (2). Cap the open ends.
: 19 mm
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining Pressure before removing.
2. Stop the engine. Operate the control lever several
times and release any remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
6. Remove dust seals (6) (2 used) from the piston
rod side of level cylinder (2). Start the engine and
slowly retract level cylinder (2). In order not to
extend the piston rod, pass a wire through the rod
hole and secure the piston rod.
CAUTION: If turning the hydraulic oil tank
cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining Pressure before removing.
7. Stop the engine. Operate the control lever several
times and release any remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
8. Disconnect hydraulic hoses at the bottom side of
boom cylinders (2 used), and the rod side and the
bottom side of of the level cylinder (2). (Refer to
REMOVAL AND INSTALLATION OF BOOM
CYLINDER on W4-2-2.)
: 10 mm, 12 mm
CAUTION: Pin (1) weight: 50 kg (110 lb)

3. Disconnect hydraulic hoses (2 used) at the rod
sides of boom cylinders (2 used). (Refer to
REMOVAL AND INSTALLATION OF BOOM
CYLINDER on W4-2-2.)
: 12 mm, 14 mm
CAUTION: Level cylinder (2) weight: 710 kg
(1570 lb)
Pin (1) weight: 50 kg (110 lb)
9. Remove bolts (4) (2 used) and spring washers (3)
(2 used) from plate (5) at the bottom side of level
cylinder (2). Remove plate (5) from pin (1).
: 30 mm
10. Remove pin (1) from boom (7). Remove level
cylinder (2) from boom (7).

4. Attach a chain block onto level cylinder (2). Hoist

and hold level cylinder (2). Remove bolts (4) (2
used) and spring washers (3) (2 used) from plate
(5) at the rod side of level cylinder (2). Remove
plate (5) from pin (1).
: 30 mm

5. Remove level cylinder (2) from arm (8).

W4-2-23
 FRONT ATTACHMENT / Cylinder

B
A

W18J-04-01-016

A: Rod Side B: Bottom Side

2
Lubrication Hydraulic
Hose Hose

Lubrication
Hose W166-04-01-021

2
W166-04-01-024

W183-04-02-009

1 2 3

7, 8
6
W166-04-01-015
Section A and B

W4-2-24
 FRONT ATTACHMENT / Cylinder
Installation
CAUTION: Level cylinder (2) weight: 710 kg
(1570 lb)
Pin (1) weight: 50 kg (110 lb)
1. Attach a chain block onto level cylinder (2). Hoist
level cylinder (2). Fit level cylinder (2) to the
mounting hole of boom (7).
2. Install the bottom side of level cylinder (2) to
boom (7) with pin (1), plate (5), spring washers (3)
(2 used), and bolts (4) (2 used).
: 30 mm
: 400 N⋅m (40 kgf⋅m 290 lbf⋅ft)
3. Connect at hydraulic hoses the bottom side of
boom cylinders (2 used), and the rod side and the
bottom side of level cylinder (2). (Refer to
REMOVAL AND LNSTALLATION OF BOOM
CYLINDER on W4-2-2.)
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80lbf⋅ft)
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101lbf⋅ft)
4. Remove a wire which secures the piston rod of
level cylinder (2). Install dust seals (6) (2 used) to
the piston rod side.
5. Start the engine. Extend the piston rod slowly. Fit
the pin hole of the piston rod to the mounting hole
of arm (8).
W4-2-25
CAUTION: Pin (1) weight: 50 kg (110 lb)
6. Install the piston rod side of level cylinder (2) to
arm (8) with pin (1), plate (5), spring washers (3)
(2 used), and bolts (4) (2 used).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)
7. Connect a hydraulic hose at the rod side of boom
cylinders (2 used). (Refer to REMOVAL AND
LNSTALLATION OF CYLINDER on W4-2-2.)
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
: 12 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
8. Connect lubrication hoses (2 used) to level
cylinder (2).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
9. Bleed air from level cylinder (2).
(Refer to Main Points to Bleed Air on W4-2-48.)
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF DUMP
CYLINDER (LOADING SHOVEL)

Hydraulic
1 Hose
B

W183-04-02-010

Wooden Block

W183-04-02-005

A: Rod Side B: Bottom Side

1 2

6
3
10 7

4
8 11
W183-04-02-011
5
Section B
W166-04-01-028
Section A

1 - Damp Cylinder (2 Used) 4 - Socket Bolt (4 Used) 7 - Pin (2 Used) 10 - Grease Fitting (2 Used)
2 - Pin (2 Used) 5 - Lock Plate (2 Used) 8 - Stopper (2 Used) 11 - Spacer (4 Used)
3 - Grease Fitting (2 Used) 6 - Adapter (2 Used) 9 - Bolt (6 Used)

W4-2-26
 FRONT ATTACHMENT / Cylinder
Removal
Dump Cylinder Cover

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary
protection such as goggles and hard hats, in
order to prevent personal injury.

1. Set a wooden block to the bucket.

2. Remove the cover in the front and the side of the

bucket.
: 17 mm, 24 mm

3. Remove grease fitting (3) from pin (2) at the

Front W166-04-01-029
piston rod side of dump cylinder (1).
: 10 mm

CAUTION: Dump cylinder (1) weight: 160 kg

(360 lb)
Pin (2) weight: 20 kg (44 lb)
Cover
4. Attach a chain block onto dump cylinders (1) (2
used). Hoist and hold dump cylinders (1) (2 used).
Remove socket bolts (4) (4 used) from lock plates
(5) (2 used). Remove lock plates (5) (2 used) and
pins (2) (2 used) from the bucket.
: 17 mm

5. Start the engine and retract damp cylinders (1) (2

used). In order not to extend the piston rod, pass
a wire through the rod hole and secure the piston
rod. Side

M113-07-012

W4-2-27
 FRONT ATTACHMENT / Cylinder

Hydraulic B
1 Hose

W183-04-02-010

Wooden Block

W183-04-02-005

A: Rod Side B: Bottom Side

10 7

8 11
W183-04-02-011

Section B

Section A
W166-04-01-028

W4-2-28
 FRONT ATTACHMENT / Cylinder

CAUTION: If turning the hydraulic oil tank

cap quickly, the hydraulic oil tank cap flies
out due to internal pressure. Slowly turn the
hydraulic oil tank cap and release any
remaining Pressure before removing.

6. Stop the engine. Operate the control lever several

times and release any remaining pressure in the
circuit. Bleed air from the hydraulic oil tank. (Refer
to BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.) Disconnect hydraulic hoses (4 used)
from dump cylinders (1) (2 used). Cap the open
ends.
: 8 mm

CAUTION: Pin (7) weight: 20 kg (44 lb)

7. Remove adapters (6) (2 used) and grease fittings

(10) (2 used) from pins (7) (2 used) at the bottom
side of dump cylinders (1) (2 used).
: 19 mm

CAUTION: Dump cylinder (1) weight: 160 kg

(360 lb)

8. Attach a chain block onto dump cylinders (1) (2

used). Hoist and hold dump cylinders (1) (2 used).
Remove bolts (9) (6 used) from stoppers (8) (2
used). Remove stoppers (8) (2 used) from pins
(7) (2 used).
: 19 mm

9. Remove dump cylinders (1) (2 used) and spacers

(11) (4 used) from the bucket.

W4-2-29
 FRONT ATTACHMENT / Cylinder

Hydraulic B
1 Hose

W183-04-02-010

Wooden Block

W183-04-02-005

A: Rod Side B: Bottom Side

1 2

6
3
10 7

4 8 11
W183-04-02-011

5 Section B

Section A
W166-04-01-028

W4-2-30
 FRONT ATTACHMENT / Cylinder
Installation

CAUTION: Dump cylinder (1) weight: 160 kg

(360 lb)
Pin (7) weight: 20 kg (44 lb)

1. Attach a chain block onto dump cylinders (1) (2

used). Hoist dump cylinders (1) (2 used). Fit
dump cylinders (1) (2 used) to the mounting hole
on the bucket. Install spacers (11) (4 used).

2. Install dump cylinders (1) (2 used) to the bucket

with pins (7) (2 used), stoppers (8) (2 used), and
bolts (9) (6 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

3. Install adapters (6) (2 used) and grease fittings

(10) (2 used) to pins (7) (2 used) at the bottom
side of dump cylinders (1) (2 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

4. Connect hydraulic hoses (4 used) to dump

cylinders (1) (2 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

5. Attach a chain block onto the rod side of dump

cylinders (1) (2 used). Hoist dump cylinders (1) (2
used). Remove a wire which secures the piston
rod. Start the engine and extend the piston rod. Fit
the mounting hole on the piston rod side to the
mounting hole on the bucket.

W4-2-31
 FRONT ATTACHMENT / Cylinder

Hydraulic B
1 Hose

W183-04-02-010

Wooden Block

W183-04-02-005

A: Rod Side B: Bottom Side

1 2

6
3
10 7

4 8 11
W183-04-02-011

5 Section B

Section A W166-04-01-028

W4-2-32
 FRONT ATTACHMENT / Cylinder

CAUTION: Pin (2) weight: 20 kg (44 lb) Cover

6. Install the piston rod side of dump cylinders (1) (2

used) to the bucket with pins (2) (2 used), lock
plates (5) (2 used), and socket bolts (4) (4 used).
: 17 mm
: 400 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

7. Install grease fittings (3) (2 used) to pins (2) (2

used).
: 10 mm
: 5.9 N⋅m (0.6 kgf⋅m, 4.4 lbf⋅ft)

8. Start the engine. Remove the wooden block from

Front W166-04-01-029
the bucket.

9. Remove a air bleed plug from dump cylinders (1)

(2 used) and bleed air from the cylinders. (Refer
to Main Points to Bleed Air on W4-2-48.)

10. Install the cover to the front and the side of the
bucket. Cover
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
: 24 mm
: 210 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

Side

M113-07-012

W4-2-33
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF CYLINDER
Boom Cylinder

12

13

14

15

16

17
1
14 18

13
19

20

21

5
6
7
8
9
10
11

W18J-04-02-001

1- Piston Rod 7- Buffer Ring 12 - Cushion Bearing 17 - O-Ring

2- Socket Bolt (8 Used) 8- Bushing 13 - Slide Ring (2 Used) 18 - Nut
3- Wiper Ring 9- Retaining Ring 14 - Slide Ring (2 Used) 19 - Steel Ball
4- Cylinder Head 10 - Backup Ring 15 - Piston 20 - Set Screw
5- Backup Ring 11 - O-Ring 16 - Seal Ring 21 - Cylinder Tube
6- U-Ring

W4-2-34
 FRONT ATTACHMENT / Cylinder
Arm Cylinder

12

13

14

15

16

17
1
14 18

13 19

20

21

5
6
7
8
9
10
11

W18J-04-02-002

1- Piston Rod 7- Buffer Ring 12 - Cushion Bearing 17 - O-Ring

2- Socket Bolt (11 Used) 8- Bushing 13 - Slide Ring (2 Used) 18 - Nut
3- Wiper Ring 9- Retaining Ring 14 - Slide Ring (2 Used) 19 - Steel Ball
4- Cylinder Head 10 - Backup Ring 15 - Piston 20 - Set Screw
5- Backup Ring 11 - O-Ring 16 - Seal Ring 21 - Cylinder Tube
6- U-Ring

W4-2-35
 FRONT ATTACHMENT / Cylinder
Bucket Cylinder

13

14

15

16

17

18 1

15

14 19
20
21

22

10

11

12

W18J-04-02-003

1- Piston Rod 7- U-Ring 13 - Cushion Bearing 18 - O-Ring

2- Socket Bolt (8 Used) 8- Buffer Ring 14 - Slide Ring (2 Used) 19 - Nut
3- Wiper Ring 9- Bushing 15 - Slide Ring (2 Used) 20 - Steel Ball
4- Cylinder Head 10 - Retaining Ring 16 - Piston 21 - Set Screw
5- Slide Ring 11 - Backup Ring 17 - Seal Ring 22 - Cylinder Tube
6- Backup Ring 12 - O-Ring

W4-2-36
 FRONT ATTACHMENT / Cylinder
Disassembly of Cylinder
• The structure of each hydraulic cylinder is similar.
CAUTION: Piston rod (1) weight:
The procedure of the bucket cylinder is explained
as an example. Loading shovel Backhoe
• The disassembling procedure starts on the Boom: 650 kg (1440 lb) 660 kg (1460 lb)
premise that the hydraulic pipe and the bands Arm: 540 kg (1190 lb) 950 kg (2100 lb)
securing the pipe have been removed. Bucket: 520 kg (1150 lb) 610 kg (1350 lb)
640 kg (1420 lb) (BE)
CAUTION: Cylinder weight: Level: 390 kg (860 lb)
Loading shovel Backhoe Dump: 100 kg (220 lb)

Boom: 1170 kg (2580 lb) 1130 kg (2500 lb) 2. Fully extend piston rod (1). Hoist and hold piston
Arm: 980 kg (2170 lb) 1680 kg (3710 lb) rod (1). Remove socket bolts (2) (8 used) from
Bucket: 920 kg (2030 lb) 1080 kg (2390 lb) cylinder head (4).
1170 kg (2580 lb) (BE) Loading shovel
Level: 710 kg (1570 lb) : Boom, level 27 mm
Dump: 160 kg (360 lb) : Arm 24 mm
: Bucket 22 mm
1. Hoist the cylinder. Secure the cylinder horizontally : Dump 17 mm
on a workbench. Drain hydraulic oil from the Backhoe
cylinder. : Boom, bucket 27 mm
: Arm 24 mm

IMPORTANT: Remove piston rod (1) straight in

order not to damage the sliding
surface.
3. Tap and remove cylinder head (4) and piston rod
(1) from cylinder tube (22) by using a plastic
hammer.

W102-04-02-027 4. Secure piston rod (1) on the special tool (ST

5908). Put the matching marks on piston rod (1)
and the end of nut (19).

ST 5908

W158-04-02-022

W4-2-37
 FRONT ATTACHMENT / Cylinder

13

14

15

16

17
18 1

15

14 19
20
21

7
8

10

11

12

W18J-04-02-003

W4-2-38
 FRONT ATTACHMENT / Cylinder
5. Remove set screw (21) and steel ball (20) from 8. Remove cushion bearing (13) and cylinder head
nut (19). (4) from piston rod (1).
NOTE: Set screw (21) has been crimped by using NOTE: Cushion bearing (19) is not equipped for
a punch at two places after installing. Cut the level cylinder (loading shovel).
away the crimped part by using a hand drill
and remove set screw (21). 9. Remove wiper ring (3), slide ring (5), backup ring
Loading shovel (6), U-ring (7), and buffer ring (8) from cylinder
: Boom, level 10 mm head (4).
: Arm, bucket 14 mm NOTE: Slide ring (5) is not equipped for the boom
: Dump 10 mm cylinder and the arm cylinder (backhoe).
Backhoe
: Boom, arm, bucket 10 mm 10. Remove retaining ring (9) and bushing (8) from
cylinder head (4).
6. Remove nut (19) from piston rod (1) by using the
special tool (ST 5908). Remove piston rod (16) 11. Remove O-ring (11) and backup ring (10) from
from piston rod (1). cylinder head (4).
Special tool when turning nut:
Loading shovel Backhoe
Boom: 180 mm (ST 3278) 180 mm (ST 3278)
Arm: 155 mm (ST 3285) 200 mm (ST 3279)
Bucket: 155 mm (ST 3285) 180 mm (ST 3278)
Level: 180 mm (ST 3278)
Dump: 95 mm (ST 3075)

ST 5908

W158-04-02-022

7. Remove slide rings (14, 15) (2 used for each),

seal ring (20), and O-ring (18) from piston (16).

W4-2-39
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF CYLINDER
Boom Cylinder Arm Cylinder

3 3

5 5

6 6

7 7

4 4
8
8 2 2
9
9
10
10
11
11

21
21

1
1

12
12

15 13

15 13 14
17
14 16
17
16 14

14 13
19
13 18

19 18 20

20
W18J-04-02-004
W18J-04-02-005

1 - Piston Rod 5- Backup Ring 11 - O-Ring 17 - O-Ring

2 - Socket Bolt 6- U-Ring 12 - Cushion Bearing 18 - Nut
Boom Cylinder (8 Used) 7- Buffer Ring 13 - Slide Ring (2 Used) 19 - Steel Ball
Arm Cylinder (11 Used) 8- Bushing 14 - Slide Ring (2 Used) 20 - Set Screw
3 - Wiper Ring 9- Snap Ring 15 - Piston 21 - Cylinder Tube
4 - Cylinder Head 10 - Backup Ring 16 - Seal Ring

W4-2-40
 FRONT ATTACHMENT / Cylinder
Bucket Cylinder

6
8
7
9
4
10
2

11
12

22

13

14

16 15

17
18
15

20 14

19

21

W166-04-02-020

1- Piston Rod 7- U-Ring 13 - Cushion Bearing 18 - O-Ring

2- Socket Bolt (8 Used) 8- Buffer Ring 14 - Slide Ring (2 Used) 19 - Nut
3- Wiper Ring 9- Bushing 15 - Slide Ring (2 Used) 20 - Steel Ball
4- Cylinder Head 10 - Retaining Ring 16 - Piston 21 - Set Screw
5- Slide Ring 11 - Backup Ring 17 - Seal Ring 22 - Cylinder Tube
6- Backup Ring 12 - O-Ring

W4-2-41
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF CYLINDER
Bucket Cylinder

6
8
7
9
4
10

11

12

22

13

14

16 15

17
18
15

14

W166-04-02-020

W4-2-42
 FRONT ATTACHMENT / Cylinder
Assembly of Cylinder

• The structure of each hydraulic cylinder is similiar.

CAUTION: Piston rod (1) weight:
The procedure of the bucket cylinder is explained
as an example. Loading shovel Backhoe
1. Install bushing (9) and retaining ring (10) to Boom: 650 kg (1440 lb) 660 kg (1460 lb)
cylinder head (4) by using the special tool (ST Arm: 540 kg (1190 lb) 1000 kg (2210 lb)
8020). Bucket: 520 kg (1150 lb) 610 kg (1350 lb)
Special tool: 640 kg
Dump (only loading shovel): (1420 lb) (BE)
85 mm (ST 8020) Level: 390 kg (860 lb)
Dump: 100 kg (220 lb)
IMPORTANT: Install buffer ring (8) with the lip part
facing the cylinder bottom side.
9. Secure piston rod (1) to the special tool (ST
2. Install buffer ring (8) to cylinder head (4).
5908).
IMPORTANT: Install U-ring (7) with the lip part
ST 5908
facing the cylinder bottom side.
3. Install backup ring (6) and U-ring (7) to cylinder
head (4).

4. Install slide ring (5) to cylinder head (4).

5. Install wiper ring (3) to cylinder head (4) by using

the special tool (ST 8020). W158-04-02-022

Special tool:
Dump (only loading shovel): 10. Install a protection tape onto the thread part of
85 mm (ST 8020) piston rod (1). Turn and install the cylinder head
(4) assembly to piston rod (1).
6. Install O-ring (12) and backup ring (11) to cylinder
head (4). IMPORTANT: Install cushion bearing (19) with the
slit facing the cylinder head (4) side.
7. Install O-ring (18) and seal ring (17) to piston (16) 11. Install cushion bearing (13) to piston rod (1).
by using a spatula in order not to install to the NOTE: Cushion bearing (13) is not equipped for
other seal groove. the level cylinder (loading shovel).

IMPORTANT: Install slide rings (14, 15) with their 13

slits positions 180° away each other.
8. Install slide rings (14, 15) (2 used for each) to
piston (16). Slit W183-04-02-012

12. Install piston (16) to piston rod (1).

W4-2-43
FRONT ATTACHMENT / Cylinder

13

16

19

W166-04-02-020

W4-2-44
 FRONT ATTACHMENT / Cylinder
13. Install nut (19) to piston rod (1). IMPORTANT: If the parts are not degreased
thoroughly and if nut (19) is
14. Tighten nut (22) by using the special tool. tightened at specified torque,
Special tool: cushion bearing (13) may expand as
Backhoe the parts are tightened too much due
Boom: 180 mm (ST 3278) to the oil slip.
: 38000 N⋅m (3880 kgf⋅m, 28030 lbf⋅ft) (3) After nut (19) is tightened at specified torque,
Arm: 200 mm (ST 3279) measure the outer diameter dimensions of
: 68650 N⋅m (7000 kgf⋅m, 50630 lbf⋅ft) cushion bearing (13) at four places of A, B, C, and
Bucket: 180 mm (ST 3278) D as illustrated on figure E. Check that the
: 43050 N⋅m (4390 kgf⋅m, 31750 lbf⋅ft) dimension is within the specification and there is
Loading shovel no deformation.
Boom: 180 mm (ST 3278)
: 38000 N⋅m (3880 kgf⋅m, 28030 lbf⋅ft) IMPORTANT: If the measured values are not within
Arm: 155 mm (ST 3285) the specification, disassemble again
: 40300 N⋅m (4110 kgf⋅m, 29720 lbf⋅ft) and repeat the work from step (1).
Bucket: 155 mm (ST 3285)
: 26200 N⋅m (2670 kgf⋅m, 19320 lbf⋅ft) Fig. E
Level: 180 mm (ST 3278)
A B C D
: 38000 N⋅m (3880 kgf⋅m, 28030 lbf⋅ft)
Dump: 95 mm (ST 3075)
: 9800 N⋅m (1000 kgf⋅m, 7230 lbf⋅ft)

Precaution when tightening nut (19)

IMPORTANT: The outer diameter dimensions of
cushion bearing (13) are not the
same before and after nut (19) are
tightened. Check if the outer
diameter dimension is within the
specification when tightening nut
(19). W115-04-01-093

(1) Measure the outer diameter dimension of cushion

bearing (13) at four places of A, B, C, and D as Standard Unit: mm
illustrated on figure E. Check that the dimension Before After
is within the specification and there is no Cylinder
Tightening Tightening
deformation. Boom (Loading shovel, -0.235 -0.235
Dia.168-0.260 Dia.168-0.218
Backhoe)
IMPORTANT: If the measured values are not within
Arm -0.340 -0.284
the specification or there is any Dia.198-0.369 Dia.198-0.313
(Backhoe)
deformation, replace cushion
bearing (13) with a new one. Arm -0.235 -0.188
Dia.158-0.260 Dia.158-0.213
(2) Clean and degrease piston rod (1), nut (19), (Loading shovel)
piston (16), and cushion bearing (13) by using Bucket -0.270 -0.227
Dia.178-0.295 Dia.178-0.252
kerosene or thinner. (BE backhoe)
Bucket -0.170 -0.140
Dia.158-0.195 Dia.158-0.165
(Loading shovel)
-0.270 -0.226
Bucket (STD backhoe) Dia.168-0.295 Dia.168-0.251
Dump -0.170 -0.135
Dia.91-0.192 Dia.91-0.157
(Loading shovel)
NOTE: 1 mm = 0.03937 in

W4-2-45
FRONT ATTACHMENT / Cylinder

22

20

19

21

W166-04-02-020

W4-2-46
 FRONT ATTACHMENT / Cylinder
15. Install steel ball (20) and set screw (21) to nut 19. Install cylinder head (4) to cylinder tube (22) with
(19). socket bolts (2) (8 used).
: 10 mm Backhoe
: 180±36.3 N⋅m (18±3.7 kgf⋅m, 130±27 lbf⋅ft) : 27 mm (Boom, bucket)
: 14 mm : 2460±461 N⋅m
: 97 N⋅m (9.85 kgf⋅m, 72 lbf⋅ft) (251±47 kgf⋅m, 1810±340 lbf⋅ft)
: 10 mm : 24 mm (Arm)
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft) : 1910±353 N⋅m
(195±35 kgf⋅m, 1410±260 lbf⋅ft)
16. Crimp the outer surface of set screw (21) at two Loading shovel
places by using a punch. : 27 mm (Boom, level)
: 2460 N⋅m (251 kgf⋅m, 1810 lbf⋅ft)
CAUTION: Cylinder tube (22) weight: : 24 mm (Arm)
Loading shovel Backhoe : 1910 N⋅m (195 kgf⋅m, 1410 lbf⋅ft)
: 22 mm (Bucket)
Boom: 520 kg (1150lb) 520 kg (1150 lb) : 1590 N⋅m (162 kgf⋅m, 1170 lbf⋅ft)
Arm: 440 kg (970 lb) 680 kg (1500 lb) : 17 mm (Dump)
Bucket: 400 kg (890 lb) 480 kg (1060 lb) : 640 N⋅m (65.1 kgf⋅m, 470 lbf⋅ft)
530 kg
(1170 lb) (BE)
Level: 320 kg (710 lb)
Dump: 60 kg (140 lb)

17. Secure cylinder tube (22) on a workbench

horizontally.

CAUTION: Piston rod (1) weight:

Loading shovel Backhoe
Boom: 650 kg (1440 lb) 660 kg (1460 lb)
Arm: 540 kg (1190 lb) 950 kg (2100 lb)
Bucket: 520 kg (1150 lb) 610 kg (1350 lb)
640 kg
(1420 lb) (BE)
Level: 390 kg (860 lb)
Dump: 100 kg (220 lb)

IMPORTANT: Fit to the center of cylinder tube (22)

and insert piston rod (1) straight in
order not to damage the rings.
18. Install piston rod (1) to cylinder tube (22).

W4-2-47
 FRONT ATTACHMENT / Cylinder
MAIN POINTS TO BLEED AIR

NOTE: Main points of the loading shovel front are 2. Stop the engine. Operate the control lever several
almost the same. times and release any remaining pressure in the
circuit.

CAUTION: Escaping fluid under pressure
may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing the hydraulic pipings or other
equipment.
Hot hydraulic oil or other equipment just after
operation may spout and cause severe burns.
Wait for oil in order to cool before starting
any work.
1. Park the machine on a solid and level surface.
Lower the front attachment onto the ground.
3. Remove a rubber cap. Remove a air bleed plug
from each cylinder.
: 19 mm
4. Bleed air until only oil comes out from the hole.
5. Install a plug to each cylinder. Install a rubber cap
to each plug.
: 19 mm
: 44±2.9 N⋅m (4.5±0.3 kgf⋅m, 32.5±2.1 lbf⋅ft)

Air Bleed Plug

Air Bleed Plug
(Arm Cylinder)
(Boom Cylinder)

Air Bleed Plug

(Bucket Cylinder)

W18J-04-01-001
Air Bleed Plug Air Bleed Plug
Air Bleed Plug (Level Cylinder) (Boom Cylinder)
(Boom Cylinder)

Air Bleed Plug

(Bucket Cylinder)

Air Bleed Plug

(Dump Cylinder)

Air Bleed Plug

(Arm Cylinder)

W18J-04-01-002

W4-2-48
 FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
Cylinder Tube a b
1. Tube (a)
• Check the inside and outside for any damage.

2. Pin, Bushing (b)

• Check whether the wear on the inner diameter A B
surface is 0.5 mm (0.02 in) or more for specified
dimension (B).
• Check the inside for any damage.
W145-04-01-015
IMPORTANT: It is difficult to check the inner
diameter of the tube.
d c Piston
Cylinder Rod
1. Rod (c)
• Place V blocks (2 used) onto the flat ground at 1
m (39.4 in) away between V blocks. Place the
D C
cylinder rod onto V blocks. Install a dial gauge.
Check if straightness of the cylinder rod is over
0.5 mm (0.02 in) when operating the cylinder rod
by 1 turn. W166-04-02-023
Repeat the measurement at three places. If any
part is over 0.5 mm (0.02 in), replace the rod.
• Check whether the wear on the outer diameter
surface is 0.02 mm (0.001 in) or more at length of Dial Gauge
200 mm (7.87 in) for specified dimension (c). Cylinder Rod
• Check the plated part for any rust.
• Check the cushion part for any damage.

2. Pin, Bushing (d)

• Check whether the wear on the inner diameter 1 mm W166-04-02-022
surface is 0.2 mm (0.008 in) or more for specified
dimension (D). V Block
• Check the inside for any damage.

W4-2-49
 FRONT ATTACHMENT / Cylinder
Piping
1. Piping (e)
• Check for any damage in depth more than 0.1 e f e f
mm (0.004 in).
• Check for any deformation and damage.

2. Socket Bolt (f)

• Check for any heavy rust.
• Check the thread part for any damage.
g g
3. O-ring (g)
• Replace O-ring when disassembling. T182-05-02-004

Piston/Cylinder Head
• Check the inside and outside for any damage.
• Check the groove for any damage.
• When the internal leakage is found, check the
seals for damage.
• Replace when the base metal of the bushing
sliding surface can be seen.

Standard Unit: mm
Loading Shovel Backhoe
Boom Level Arm Bucket Dump Boom Arm Bucket
+0.072
230
Inner Dia. (A) Of Cylinder +0.072 +0.072 +0.072 +0.072 +0.063 +0.072 +0.081 0
230 230 215 200 140 230 260
Tube 0 0 0 0 0 0 0 +0.072
240
0 (BE)

+0.25
150
Pin and Bushing Inner Dia. +0.006 +0.25 +0.25 +0.25 +0.25 +0.006 +0.25 +0.05
160 150 150 130 90 160 170
(B) of Cylinder Tube -0.071 +0.05 +0.05 +0.05 +0.05 -0.071 +0.05 +0.25
150
+0.05 (BE)

-0.014
Recommended Dimension 160
-0.014 -0.014 -0.014 -0.014 -0.014 -0.014 -0.014 -0.032
after Regeneration of Rod 160 160 150 150 85 160 180
-0.032 -0.032 -0.032 -0.032 -0.032 -0.032 -0.032 -0.014
Outer Diameter (C) 170
-0.032 (BE)

+0.25
160
Pin and Bushing Inner Dia. +0.25 +0.25 +0.25 +0.006 +0.25 +0.25 +0.25 +0.05
160 150 150 130 90 160 170
(D) of Piston Rod +0.05 +0.05 +0.05 -0.071 +0.05 +0.05 +0.05 +0.25
160
+0.05 (BE)

NOTE: 1 mm = 0.03937 in

W4-2-50
 FRONT ATTACHMENT / Bushing and Point
REMOVAL AND INSTALLATION OF
BUSHING

Backhoe
B D

A C W18J-04-01-015

1 Bucket 2 1 Arm 1 Bucket 2 1 Link A

W18J-04-03-001

B: Link A and Bucket

W18J-04-03-002

A: Bucket and Arm

1 Arm 1 Boom Arm 1 2 Bucket Cylinder

W18J-04-03-003 W18J-04-03-006
C: Arm and Boom D: Arm and Bucket Cylinder

1 - Bushing 2 - Dust Seal

W4-3-1
 FRONT ATTACHMENT / Bushing and Point

F H

E G W18J-04-01-015

Link B Link A
Link B 1 2 1 Arm 1 2 1 Bucket Cylinder

W18J-04-03-004 W18J-04-03-005
E: Arm and Link B F: Link A and Link B

Main Frame Boom Cylinder 1 Main Frame 1 Boom

1 1 1 1

2 W166-04-02-009
2
W18J-04-03-006
G: Main Frame H: Boom and Main Frame

W4-3-2
 FRONT ATTACHMENT / Bushing and Point
Loading Shovel

A B C

D W18J-04-01-016

2 1 1
Rear Bucket Bucket

1 2 1

Front Bucket Dump Cylinder

W166-04-02-009 W166-04-02-009

A: Front Bucket and Rear Bucket B: Bucket

2 1 2 1 1
Bucket Bucket

1 1
Arm
Bucket Cylinder
W166-04-02-018 2 W166-04-02-009
C: Bucket and Arm D: Bucket

1- Bushing 2- Dust Seal

W4-3-3
 FRONT ATTACHMENT / Bushing and Point

E F

G W18J-04-01-016

2 1 1 1 Boom Main Frame 1

Arm

Boom

1
2
W18J-04-03-007

F: Boom and Main Frame

W166-04-02-014

E: Arm and Boom

2 1
Main Frame

Boom Cylinder 1
W166-04-02-009

G: Main Frame

W4-3-4
 FRONT ATTACHMENT / Bushing and Point
Removal
1. Remove bushing (1) and dust seal (2).

NOTE: In case bushing (1) cannot be removed,

use a torch.

Installation
1. Cool bushing (1) by using dry ice.

2. Install bushing (1) and dust seal (2).

Install bushing (1) by using the tools below.

Tools by when installing bushing (1).

Backhoe
A: Bucket Side.................................... ST 2842
Arm Side ........................................ ST 2843
B: Link A Side ..................................... ST 2836
Bucket Side.................................... ST 2838
C: Arm Side ........................................ ST 2841
Boom Side ..................................... ST 2839
D: Arm ................................................ ST 2839
E: Arm Side ........................................ ST 2840
Link B Side..................................... ST 2837
F: Link A Side ..................................... ST 2843
Link B Side..................................... ST 2842
G: Main Frame.................................... ST 2832
H: Main Frame Side............................ ST 2832
Boom Side ..................................... ST 2843
Loading Shovel
A: Bucket (Front) Side ........................ST 2840
Bucket (Rear )Side .........................ST 2829
B: Bucket ............................................ST 2831
C: Bucket Side ....................................ST 2833
Arm Side ........................................ST 2834
D: Bucket ............................................ST 2829
E: Arm Side ........................................ST 2843
Boom Side......................................ST 2832
F: Boom Side......................................ST 2843
Main Frame Side ............................ST 2832
G: Main Frame ....................................ST 2832

W4-3-5
 FRONT ATTACHMENT / Bushing and Point
MAINTENANCE STANDARD
Pin and Bushing (Backhoe)

I H G F E C A

W18J-04-01-001
J K D B

W4-3-6
 FRONT ATTACHMENT / Bushing and Point

Unit: mm ( in)
Allowable
Part Name Location Specification
Limit
Pin Dia. 160 (6.3) 158. 5 (6.2)
Bushing Inner Dia. (Frame Side) 160 (6.3) 161.5 (6.4)
A: Boom and Main Frame Bushing Outer Dia. 180 (7.1) -
Bushing Inner Dia. (Boom Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Frame Side) 160 (6.3) 161.5 (6.4)
B: Boom Cylinder and Main Frame Bushing Outer Dia. 180 (7.1) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 161.5 (6.4)
Pin Dia. 160 (6.3) 158. 5 (6.2)
C: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 160 (6.3) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 161.5 (6.4)
Pin Dia. 170 (6.7) 168. 5 (6.6)
Bushing Inner Dia. (Boom Side) 170 (6.7) 171.5 (6.8)
D: Boom and Arm Bushing Outer Dia. 200 (7.9) -
Bushing Inner Dia. (Arm Side) 170 (6.7) 171.5 (6.8)
Bushing Outer Dia. 200 (7.9) -
Pin Dia. 170 (6.7) 168. 5 (6.6)
E: Arm Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 170 (6.7) -
Bearing Inner Dia. (Cylinder Side) 170 (6.7) 171.5 (6.8)
Pin Dia. 170 (6.7) 168.5 (6.6)
Bushing Inner Dia. (Arm Side) 170 (6.7) 171.5 (6.8)
F: Arm Cylinder and Arm Bushing Outer Dia. 195 (7.7) -
Bearing Inner Dia. (Cylinder Side) 170 (6.7) 171.5 (6.8)
Pin Dia. 150 (5.9) 148.5 (5.8)
G: Arm and Bucket Cylinder Pin Hole Inner Dia. (Arm Side) 150 (5.9) -
Bearing Inner Dia. (Cylinder Side) 150 (5.9) 151.5 (6.0)

W4-3-7
 FRONT ATTACHMENT / Bushing and Point

Unit: mm (in)
Allowable
Part Name Location Specification
Limit
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Link A Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
H: Bucket Cylinder and Link
Bushing Inner Dia (Link B Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 161.5 (6.4)
Pin Dia. 140 (5.5) 138.5 (5.5)
Bushing Inner Dia.( Link A Side) 140 (5.5) 141.5 (5.6)
I: Link and Bucket Bushing Outer Dia. 170 (6.7) -
Bushing Inner Dia. (Bucket Side) 140 (5.5) 141.5 (5.6)
Bushing Outer Dia. 170 (6.7) -
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Arm Side) 160 (6.3) 161.5 (6.4)
J: Arm and Bucket Bushing Outer Dia. 190 (7.5) -
Bushing Inner Dia. (Bucket Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
Pin Dia. 130 (5.1) 128.5 (5.1)
Bushing Inner Dia. (Arm Side) 130 (5.1) 131.5 (5.2)
K: Arm and Link Bushing Outer Dia. 155 (6.1) -
Bushing Inner Dia. (Link B Side) 130 (5.1) -
Bushing Outer Dia. 155 (6.1) -

W4-3-8
 FRONT ATTACHMENT / Bushing and Point
(Blank)

W4-3-9
 FRONT ATTACHMENT / Bushing and Point
Pin and Bushing (Loading Shovel)

I H G F E D C A

W18J-04-01-002
J K C B

W4-3-10
 FRONT ATTACHMENT / Bushing and Point

Unit: mm (in)
Allowable
Part Name Location Specification
Limit
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Boom Side) 160 (6.3) 161.5 (6.4)
A: Boom and Main Frame Bushing Outer Dia. 190 (7.5) -
Bushing Inner Dia. (Frame Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 180 (7.1) -
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Frame Side) 160 (6.3) 161.5 (6.4)
B: Boom Cylinder and Main Frame Bushing Outer Dia. 180 (7.1) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 111.5 (4.4)
Pin Dia. 150 (5.9) 148.5 (5.8)
Pin Hole Inner Dia. (Boom Side) 150 (5.9) -
C: Level Cylinder and Boom and Arm
Pin Hole Inner Dia. (Arm Side) 150 (5.9) -
Arm Cylinder and Boom and Arm
Bearing Inner Dia. ( Cylinder Rod Side) 150 (5.9) 151.5 (6.0)
( Cylinger Bottom Side) 150 (5.9) 151.5 (6.0)
Pin Dia. 160 (6.3) 158.5 (6.2)
D: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 160 (6.3) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 161.5 (6.4)
Pin Dia. 130 (5.1) 128.5 (5.1)
E: Bucket Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 130 (5.1) -
Bearing Inner Dia. (Cylinder Side) 130 (5.1) 131.5 (5.2)
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Arm Side) 160 (6.3) 161.5 (6.4)
F: Arm and Boom Bushing Outer Dia. 190 (7.5) -
Bushing Inner Dia. (Boom Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
Pin Dia. 140 (5.5) 138.5 (5.5)
Bushing Inner Dia. (Bucket Side) 140 (5.5) 139.5 (5.5)
G: Bucket and Arm Bushing Outer Dia. 165 (6.5) -
Bushing Inner Dia. (Arm Side) 140 (5.5) 141.5 (5.6)
Bushing Outer Dia. 165 (6.5) -

W4-3-11
 FRONT ATTACHMENT / Bushing and Point

Unit: mm (in)
Allowable
Part Name Location Specification
Limit
Pin Dia. 90 (3.5) 88.5 (3.5)
Bushing Inner Dia. (Bucket Side) 90 (3.5) 91.5 (3.6)
H: Dump Cylinder and Front Bucket
Bushing Outer Dia. 110 (4.3) -
Bearing Inner Dia. (Cylinder Side) 90 (3.5) 91.5 (3.6)
Pin Dia. 130 (5.1) 128.5 (5.1)
Bushing Inner Dia. (Rear Side) 130 (5.1) 131.5 (5.2)
I: Rear Bucket and Front Bucket Bushing Outer Dia. 155 (6.1) -
Bushing Inner Dia. (Front Side) 130 (5.1) 131.5 (5.2)
Bushing Outer Dia. 155 (6.1) -
Pin Dia. 90 (3.5) 88.5 (3.5)
J: Rear Bucket and Dump Cylinder Pin Hole Inner Dia. (Bucket Side) 90 (3.5) -
Bearing Inner Dia. (Cylinder Side) 90 (3.5) 91.5 (3.6)
Pin Dia. 130 (5.1) 128.5 (5.1)
Bushing Inner Dia. (Bucket Side) 130 (5.1) 131.5 (5.2)
K: Bucket Cylinder and Rear Bucket 155 (6.1) -
Bushing Outer Dia.
Bearing Inner Dia. (Cylinder Side) 130 (5.1) 131.5 (5.2)

W4-3-12
 FRONT ATTACHMENT / Bushing and Point
Side Cutter

W142-04-01-020

Unit: mm (in)
Standard Allowable Limit Remedy
B 450 (18.0) 280 (11.0)
Replace
C 145 (6.0) 90 (3.5)

Point (Backhoe)

B C

W142-04-01-021

Unit: mm (in)
Standard Allowable Limit Remedy
A 315 (12.5) 153 (6.0)
B 154 (6.1) −
Replace
C 170 (6.7) −
D 171 (6.7) −

W4-3-13
 FRONT ATTACHMENT / Bushing and Point
Point (Loading Shovel)

B C

W142-04-01-022

Unit: mm (in)
Standard Allowable Limit Remedy
A 329 (13.0) 206 (8.1)
B 159 (6.3) −
Replace
C 204 (8.0) −
D 204 (8.0) −

W4-3-14
 MEMO

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 MEMO

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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com

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