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

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition • The Engine Manual
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

MANUAL COMPOSITION

• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.

• Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
• 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-0001

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 spe-
cific hazards. General precautions are listed on CAUTION
safety signs.
• Some safety signs don’t use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.

• To avoid confusing machine protection with personal safety

messages, a signal word IMPORTANT indicates a situation
which, if not avoided, could result in damage to the ma- SA-1223
chine.

• 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 oper- SA-003
ate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, func-
tion, 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 equip-
ment 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 hazard-
ous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your autho-
rized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003

SA-2
 SAFETY

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 service,
SA-437
hospital, and fire department posted near your tele-
phone.
004-E01A-0437

WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment appropri-
ate to the job.

You may need:

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

• 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 ear-
muffs or earplugs to protect against objectionable or
uncomfortably loud noises.

006-E01A-0434
SA-434

SA-3
 SAFETY

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

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 ac-
cident.
• 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 at-
tach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly start-
ing a fire.
• Refrain from listening to the radio, or using music head-
phones 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 tem-
perature 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 dis-
mount 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 op-
erator 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.
• Adjust the rear view mirror position so that the best rear
SA-378
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 LEAV-

ING 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 opera-
tor may be crushed by the overturning machine, resulting in
serious injury or death.
• Prior to operating the machine, thoroughly examine web-
bing, buckle and attaching hardware. If any item is dam-
aged 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 oper-
ating the machine.
• Always keep the travel alarm and horn in working condi-
tion (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-083
• Use appropriate illumination. Check that all lights are op-
erable before operating the machine. If any faulty illumi-
nation 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 pressur-
ized container, keep the cap on the container, and store it
in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
SA-293

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 levers
are in neutral.
• Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-084

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” chap-
ter in the operator’s manual.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032

S013-E01A-0032

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-091

SA-7
 SAFETY

PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety equip-
ment 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.

M202-05-014

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 fall-
ing 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 edges of excava-
tions and road shoulders.
• When working on an incline or on a road shoulder, em- SA-085
ploy 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 sup-
port the machine.
When working close to an excavation or at road shoulders,
operate the machine with the tracks positioned perpendicu-
lar 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 M202-05-015
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 ma-
chine movements.

SA-9
 SAFETY

EQUIPMENT OF HEAD GUARD, ROPS, FOPS

In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)

ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure

SA-686

PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

TIPLE 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 steering wheel/forward/reverse pedal 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 steering wheel is operated to
the front.

SA-092
017-E01A-0491

SA-10
 SAFETY

DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the steer-
ing wheel/forward/reverse switch direction corresponds to
the direction you wish to drive.
• Be sure to detour around any obstructions.
• Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do
not allow personnel to stay around the machine while
traveling.

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

SA-090
turn, possibly resulting in serious injury or death.
• Never attempt to ascend or descend 35 degrees or steep-
er slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket fac-
ing the direction of travel, approximately 0.5 to 1.0 m (A)
above the ground.
• If the machine starts to skid or becomes unstable, imme-
diately lower the bucket to the ground and stop.

SA-288

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.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 5 min-
utes 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 tires and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
SA-278
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.

020-E02A-0493

SA-11
 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 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 SA-383
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 used
on the job and confirm who has the responsibility for
signaling.
• Keep windows, mirrors, and lights clean and in good con-
dition.
• Dust, heavy rain, fog, etc., can reduce visibility. As visibility SA-384

decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the
operator’s manual.

021-E01A-0494

SA-12
 SAFETY
KEEP PERSON CLEAR FROM WORKING AREA
• A person may be hit severely by the swinging front attach-
ment 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 any-
one from entering the work area.

022-E01A-0386

M202-05-014

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-682

AVOID UNDERCUTTING
• Always confirm that ground conditions are strong enough
to support the machine weight when operating near a cliff.
Operate the machine with the chassis frame positioned
perpendicular to the cliff face so that the machine can more
easily evacuate if the cliff face collapses.
• If the footing starts to collapse and if retreat is not pos-
sible, do not panic. Often, the machine can be secured by
lowering the front attachment, in such cases.

024-E01A-0488 SA-683

SA-13
 SAFETY

AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA-
CHINE---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.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to the ma-
SA-088
chine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
• Reduce swing speed as necessary when swinging loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become
soft and make ground travel unstable.

025-E03B-0463
SA-684

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur causing
serious injury or death.

026-E01A-0519

SA-685

SA-14
 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.
• Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities. SA-086

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-087

SA-15
 SAFETY

AVOID POWER LINES

• Serious injury or death can result if the machine or front at-
tachments 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 ap-
ply.
• 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-089
029-E01A-0381

PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately stop op-
eration, 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 repair-
ing them.

SA-1241

OBJECT HANDLING
• If a lifted load should fall, any person nearby may be struck
by the falling load or may be crushed underneath it, result-
ing 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 sud-
denly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
• Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.

032-E01A-0132
SA-014

SA-16
 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 strik-
ing 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.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn auto-idle switch OFF.
• Run engine at slow idle speed without load for 5 minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK position. SA-093

• 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.

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

SA-018
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spontane-
ously.
• Securely tighten the fuel and oil filler cap.

034-E01A-0496

SA-019

SA-17
 SAFETY

TRANSPORT SAFELY
• Take care the machine may turn over when loading or un-
loading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe trans-
portation.
• 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:
Less than 15°
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the SA-094
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 travel-
ing 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 Less than 15°
sudden bump. Take care when traveling over it.
SA-095
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.

Be sure to further follow the details described in the TRANS-

PORTING section.

035-E07A-0454

SA-18
 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.
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 min-
utes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving SA-028
the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.

• If a maintenance procedure must be performed with the

engine running, do not leave machine unattended.
• If the machine must be raised, maintain a 90 to 100˚ angle
between the boom and arm. Securely support any ma-
chine 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 SA-527
“MAINTENANCE” chapter in the operator’s manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable detergent
oil. Never use highly 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-19
 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
SS3076175 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 sup-
port 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-20
 SAFETY

PREVENT PARTS FROM FLYING

• 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
SA-344

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

SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can cause seri-
ous injury or death.
• Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
• Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
• When inflating tires, use a chip-on chuck and exten-sion
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
it available.
• Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
• Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and SA-249
may result in tire explosion.

521-E02A-0249

SA-21
 SAFETY

PREVENT BURNS
Hot spraying fluids:

• After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
• To avoid possible injury from hot spraying water. DO NOT
remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all pres-
sure to be released before removing the cap.
SA-039
• 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.
• Wait for the oil and components to cool before starting
any maintenance or inspection work.

SA-225
505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the page of
“Periodic replacement of parts” in the operator’s manual.)

• Failure to periodically replace rubber hoses may cause a fire,

fluid injection into skin, or the front attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.

S506-E01A-0019

SA-22
 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 disconnect-
ing 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.
• If an accident occurs, see a doctor familiar with this type
of injury immediately. Any fluid injected into the skin
SA-031
must be surgically removed within a few hours or gan-
grene may result.

507-E03A-0499

SA-292

SA-044

SA-23
 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.

SA-019
Check for Shorts:
• 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 ma-
chine 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.

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-24
 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.
• 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. SA-393
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 sick-
ness or death.
• If you must operate in a building, be sure there is ad-
equate ventilation. Either use an exhaust pipe extension
to remove the exhaust fumes or open doors and windows
to bring enough outside air into the area.

509-E01A-0016

SA-016

PRECAUTIONS FOR WELDING AND GRINDING

• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated and pre-
pared area. Store flammable objects in a safe place before
starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
• After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818

523-E01A-0818

SA-25
 SAFETY

AVOID HEATING NEAR PRESSURIZED FLUID LINES

• Flammable spray can be generated by heating near pres-
surized fluid lines, resulting in severe burns to yourself and
bystanders.
• Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
• Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary fire-
resistant guards to protect hoses or other materials before
engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAINING SA-030

FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain flam-
mable fluids.
• Clean them thoroughly with nonflammable solvent be-
fore 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. Dis-
pose of paint and solvent properly.

• Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with
SA-029
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-26
 SAFETY

BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work site. Inha-
lation of asbestos fibers may be the cause of lung cancer.
• Depending on the wok 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 asbes-
tos might be present, be sure to operate the machine
from the upwind side and wear a mask rated to prevent
the inhalation of asbestos.
• Keep bystanders out of the work site during operation.
• Asbestos might be present in imitation parts. Use only SA-029
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 elec-
trolyte level is lower than specified. Explosion of the bat-
tery may result.
• Loose terminals may produce sparks. Securely tighten all SA-032
terminals.

• Battery electrolyte is poisonous. If the battery should ex-

plode, battery electrolyte may be splashed into eyes, pos-
sibly 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-27
 SAFETY

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your ma-
chine include such items as lubricants, coolants, paints, and
adhesives.
• A Material Safety Data Sheet (MSDS) provides specific de-
tails on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
• Check the MSDS before you start any job using a hazard-
ous chemical. That way you will know exactly what the
risks are and how to do the job safely. Then follow proce-
dures and use recommended equipment.
SA-309
• 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 environ-
ment and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel, coolant,
brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
• Do not pour waste onto the ground, down a drain, or into
any water source.
• Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to SA-226

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-28
 SAFETY

BEFORE RETURNING THE MACHINE TO THE CUS-

TOMER
• After maintenance or repair work is complete, confirm that:
• The machine is functioning properly, especially the safety
systems.
• Worn or damaged parts have been repaired or replaced

S517-E01A-0435

SA-435

SA-29
 SAFETY
(Blank)

SA-30
 SECTION 1 GENERAL INFORMATION
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
Group 1 Cab
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Electric Lever
Group 9 Signal Control Valve
Group 10 Travel Shockless Valve
Group 11 Solenoid Valve
Group 12 Pilot Shut-Off Solenoid Valve
Group 13 Steering Valve
Group 14 Brake Valve
Group 15 Accumulator Charging Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Motor
Group 3 Center Joint
Group 4 Transmission
All information, illustrations and speci-
fications in this manual are based on Group 5 Axle
the latest product information available Group 6 Axle Lock Cylinder
at the time of publication. The right is
reserved to make changes at any time Group 7 Operate-Check Valve
without notice.
Group 8 Solenoid Valve
Group 9 Transmission Changeover Solenoid Valve
Group 10 Propeller Shaft
SECTION 4 FRONT ATTACHMENT
COPYRIGHT(C)2007
Hitachi Construction Machinery Co., Ltd.
Group 1 Front Attachment
Tokyo, Japan
Group 2 Cylinder
All rights reserved
Group 3 Hose-Rupture Valve
Group 4 Operate-Check Valve
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 Electric Lever
Group 2 Control System Group 6 Transmission
Group 3 ECM System Group 7 Axle
Group 4 Hydraulic System Group 8 Travel Motor
Group 5 Electrical System Group 9 Signal Control Valve
Group 10 Steering Valve
Group 11 Brake Valve
Group 12 Others (Upperstructure)
Group 13 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 ICF
Group 4 Excavator Test Group 5 Component Layout
Group 5 Component Test Group 6 Troubleshooting A
Group 7 Troubleshooting B
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
Bleeding Air from Hydraulic Oil tank ...........W1-4-1

CJBW-1-1
(Blank)

CJBW-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
will be bled while performing the above operation
WCJB-01-04-001
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.

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

CAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may re- Damaged Appearance
Broken Sewing Thread
sult. Be sure to visually check the nylon sling
for any damage before using.

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

lon sling for any damage corresponding to exam- W162-01-01-002
Scuffing
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) N⋅m (kgf⋅m) (lbf⋅ft)
Engine cushion rubber mounting (Pump Upper) 18 2 27 360 (37) (265)
1 bolt (Pump Lower) 16 4 24 210 (21.5) (155)
Engine cushion rubber mounting nut (Fan Side) 14 4 22 140 (14.0) (103)
2 Engine bracket mounting bolt and nut 10 8 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
17 24.5 (2.5) (18)
19 30 (3.1) (22)
22 40 (4.1) (30)
ORS and metal face seal fittings for hydraulic hoses
5 27 95 (9.7) (70)
and piping
32 140 (14.3) (105)
36 175 (17.8) (130)
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 16 4 24 210 (21.5) (155)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 12 30 500 (51) (370)
12
10 Swing motor mounting bolt (Hex. 8 10 90 (9.2) (66)
Wrench)
11 Battery mounting nut 10 2 17 50 (5.1) (37)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
13 Swing bearing mounting bolt to upperstructure 20 32 30 510 (52) (380)
Swing bearing mounting bolt to chassis 20 36 30 490 (50) (360)
14 Center joint lock mounting bolts Ú 16 5 24 270 (27.5) (200)
15 - - - - - -
16
16 Travel motor mounting bolts Ú (Hex. 4 14 270 (27.5) (200)
Wrench)
17 Propel shaft mounting nuts Ú 10 16 14 76 (8) (60)
18 Center Bearing mounting bolt 10 2 17 50 (5.1) (37)
19 Rear axle mounting bolts Ú 24 8 36 950 (97.0) (700)
20 Wheel pin nuts 22 40 30 600 (61) (440)
6 - 10 10 (1) (7.4)
21 Cover mounting bolt 10 - 17 50 (6.1) (37)
12 - 19 90 (9.2) (66)
(1.05 to (7.59 to
22 Flexible master coupling of piping 8 4 pairs 13 10.3 to 12.4
1.26) 9.11)
Jubilee Clamp of low pressure piping - - 7 5.9 (0.6) (4.3)
23
T-bolt clamp of low pressure piping - - 11 5.9 (0.6) (4.3)
Ú Apply LOCTITE to the threads.

W1-2-1
 GENERAL / Tightening
NOTE 1.Apply lubricant (e.g. white zinc B dis-
solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
(Except for Sprocket mounting bolt.)
2.Make sure bolt and nut threads are clean
before installing.

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 specifications.

Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them SA-040

correctly when assembling the machine or compo-

nents.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

W162-01-01-001

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 Split 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.
WRONG
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- RIGHT WRONG

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 RIGHT RIGHT WRONG

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

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

RIGHT RIGHT WRONG

ening, not while loosening.

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

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 Joint Body N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5, 18)
19 19 29.5 (3.0, 21.5)
22 22 39 (4.0, 28.5)
27 27 78 (8.0, 58)
32 32 137 (14.0,101)
36 36 175 (18.0, 129)
41 41 205 (21.0,1 51)
37°female 17 14 24.5 (2.5, 18)
19 17 29.5 (3.0, 21.5)
22 19 39 (4.0, 28.5)
27 22 78 (8.0, 58)
32 27 137 (14.0, 101)
36 32 175 (18.0, 129)
41 36 205 (21.0, 151)
NOTE: Tightening torque of 37° male coupling without union is similar
to tightening torque of 37° female.

W1-2-6
 GENERAL / Tightening Torque
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 in Hose Fittings
8 1
O-ring groove (e). Tightening nut (9) M104-07-033

with O-ring (6) displaced will damage

O-ring (6), resulting in oil leakage.
3. Take care not to damage O-ring
groove (e) or sealing surface (10). Wrench Size Wrench Size Tightening Torque
Damage to O-ring (6) will cause oil mm mm
leakage. Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft)
4. If nut (9) is loose and oil is leaking, 19 17 29.5 (3.0, 21.5)
do not re-tighten nut (9). Replace 22 19 69 (7.0, 51)
O-ring (6) with a new one and check 27 22 93 (9.5, 69)
that O-ring (6) is correctly seated in 32 27 137 (14.0, 101)
place, tighten nut (9). 36 30, 32 175 (18.0, 129)
41 36 205 (21.0, 151)
46 41 205 (21.0, 151)

W1-2-7
 GENERAL / Tightening Torque
Screw-In Connection
PT PF
Depending on types of screw and sealing, different types 30°
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 using any Male Tapered Thread Male Straight Thread
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 between
threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.

• 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 de-

pending 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 Torque
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to use
only genuine Hitachi service parts. Using hoses
other than genuine Hitachi hoses may cause oil
leaks, hose rupture or Separation of fitting, pos-
sibly resulting in a fire on the machine.

Do not install hoses kinked. Application of high

oil pressure, vibration, or an impact to a kinked W105-01-01-011
hose may result in oil leaks, hose rupture or
separation of fitting. Utilize Print marks on hoses
when installing to prevent hose from being WRONG RIGHT
kinked. Rubbing Against
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 rub-
bing against each other.
W105-01-01-012

Take care so that hoses do not come into contact

WRONG RIGHT
with moving parts or sharp objects.
Clamp Clamp

Rubbing Against
Each Other

W105-01-01-013

WRONG RIGHT

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

W1-2-9
 GENERAL / Tightening Torque
PERIODIC REPLACEMENT OF PARTS
The parts listed below deteriorate as the machine ages
and are worn out or fatigued by repeated loads, resulting
in possible severe personal injury and/or machine trouble.
The service life of these parts cannot be detected
through machine operation or visual inspection.
Therefore, these parts should be replaced at regular in-
tervals even if no abnormalities are noticed. In case any
abnormalities are found on a part at any time regardless
of its specified replacement interval, immediately replace
the part.

Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Pump delivery hose Every 2 years
Base Machine
Swing hose Every 2 years
Hydraulic
Travel Hose Every 2 years
System
Boom cylinder line hose Every 2 years
Front-End Arm cylinder line hose Every 2 years
Attachment 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

Painting specification
Surfaces to Be Painted Painting Colour
• Main surface of upperstructure (except cab) YR-01 [TAXI yellow]
Main frame HG Beige Deep
Internal parts Black
• Front attachment YR-01 [TAXI yellow]
• Track (including swing bearing) N1.0 [Black]
• Floor plate M/F Cation (allowed)

Final painted color

• Inside and outside surface of cab HG Beige Deep
• Shaded area on cab outside Shining Silver
• Right window guards, U-Bolt [KANSAI PAINT LF-113-230B
(Charcoal series black, half glossy)]
• Suspension lifter (chair bottom) [N2.0 (Black)]
• Lever (Pilot shut-off, foot rest) High Grade Black
• Engine cover High Grade Black
• Cover, Step HG Beige Deep
• Handrail on upperstructure right side HG Beige Deep
• Mirror stay: cab side, right side High Grade Brack
• Nonslip cover KANSAI PAINT Amilac 1400 (Deep Black)
• Rear camera cover HG Beige Deep
• Head light bracket HG Beige Deep

W1-3-1
 GENERAL / Painting

Mirror Stay Engine Cover

Camera Cover

WCJB-01-03-002

Head Light Bracket Decal

[TAXI Yellow]

Mirror Stay Handrail Step

Mirror Stay

WCJB-01-03-001

Decal Decal Right Side Head Light Bracket

[Shining Silver] [Shining Silver] Cover

W1-3-2
 GENERAL / Painting

Paint all circumference in the hinge

swing position shining silver.

Shaded Area
[Shining Silver]

Door
Panel Behind the
Door

10
A Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)

Section A

WCJB-01-03-004
Nonslip Cover
KANSAI PAINT
Amilac 1400
(Deep Black)
Align with the panel.
[Shining Silver]

Panel

WCEB-01-03-003 WCJB-01-03-003

Front Attachment
YR-01 (TAXI Yellow) IMPORTANT: When cleaning arm, cylinder, etc.
fitted with HN bushing, take care not
to pour washing liquid directly on
them. The ambient temperature
should not exceed 70 °C when paint-
ing and drying.

W178-01-03-007

W1-3-3
 GENERAL / Painting
(Blank)

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

CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.

Preparation
1. Place the machine on a firm, level surface and WCJB-01-04-001

lower the bucket to the ground.

1

2. Stop the engine. Push the air bleed valve (1) on

the air breather to release any remaining pressure
from hydraulic oil tank (3).

3. Remove cap (2) of hydraulic oil tank (3).

WCEB-01-04-001

4. Connect a vacuum pump with the hole removed Vacuum Pump

cap (2) to maintain negative pressure in the
hydraulic oil tank (3). Hose

NOTE: Be sure to run the vacuum pump

continuously while working. 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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UPPERSTRUCTURE
— CONTENTS —
Group 1 Cab
Removal and Installation of Cab ............ W2-1-1
Dimensions of Cab Glass .................... W2-1-12
Group 2 Counterweight
Removal and Installation of
Counterweight ...................................... W2-2-1
Group 3 Main Frame
Removal and Installation of
Main Frame .......................................... W2-3-1
Group 4 Pump Device
Removal and Installation of
Pump Device ........................................ W2-4-1
Disassembly of Pump Device .............. W2-4-14
Assembly of Pump Device ................... W2-4-26
Disassembly of Regulator .................... W2-4-46
Assembly of Regulator......................... W2-4-48
Structure of Pilot Pump ........................ W2-4-50
CJBW-2-1
SECTION 2
Group 5 Control Valve
Removal and Installation of
Control Valve ........................................W2-5-1
Disassembly of Control Valve
4-Spool Side .........................................W2-5-6
Assembly of Control Valve
4-Spool Side .......................................W2-5-18
Disassembly of Control Valve
5-Spool Side .......................................W2-5-36
Assemble of Control Valve
5-Spool Side .......................................W2-5-48
Disassembly of Housing.......................W2-5-60
Assembly of Housing............................W2-5-62
Removal and Installation of
Positioning Control Valve....................W2-5-65
Disassembly of Position
Control Valve ......................................W2-5-66
Assembly of Positioning
Control Valve ......................................W2-5-68
Group 6 Swing Device
Removal and Installation of
Swing Device ........................................W2-6-1
Disassembly of Swing Device ................W2-6-4
Assembly of Swing Device ...................W2-6-10
Disassembly of Swing Motor ..............W2-6-18
Assembly of Swing Motor .....................W2-6-22
Structure of Swing Dampener Valve.....W2-6-26
Maintenance Standard..........................W2-6-27
Group 7 Pilot Valve
Removal and Installation of Pilot Valve.. W2-7-1
Removal and Installation of
Travel Pilot Valve................................ W2-7-11
Disassembly of Front/Swing
Pilot Valves......................................... W2-7-16
Assembly of Front/Swing Pilot Valves.. W2-7-20
Disassembly of Travel and
Auxiliary/Positioning Pilot Valves ....... W2-7-24
Assembly of Travel and
Auxiliary/Positioning Pilot Valves ....... W2-7-26
Group 8 Electric Lever
Removal and Installation of
Electric Lever........................................ W2-8-1
Disassembly of Electric Lever................ W2-8-8
Assembly of Electric Lever................... W2-8-10
Group 9 Signal Control Valve
Removal and Installation of Signal
Control Valve ........................................ W2-9-1
Structure of Signal Control Valve ........... W2-9-4
Group 12 Pilot Shut-Off Solenoid Valve
Removal and Installation of Pilot
Shut-Off Solenoid Valve......................W2-12-1
Structure of Pilot Shut-Off
Solenoid Valve ....................................W2-12-3
Group 13 Steering Valve
Removal and Installation of
Steering Valve.....................................W2-13-1
Group 14 Brake Valve
Removal and Installation of
Brake Valve.........................................W2-14-1
Disassembly of Brake Valve .................W2-14-4
Assembly of Brake Valve......................W2-14-8
Group 15 Accumulator Charge Valve
Removal and Installation of
Accumulator Charge Valve .................W2-15-1
Structure of Accumulator
Charge Valve ......................................W2-15-4

Group 10 Travel Shockless Valve

Removal and Installation of
Travel Shockless Valve ...................... W2-10-1
Structure of Travel Shockless Valve .... W2-10-4

Group 11 Solenoid Valve

Removal and Installation of 4-Spool
Solenoid Valve Unit ............................ W2-11-1
Structure of 4-Spool Solenoid Valve
Unit ..................................................... W2-11-3
Disassembly and Assembly of
4-Spool Solenoid Valve Unit.............. W-2-11-4
Removal and Installation of Solenoid Valve
Unit (For Electric Lever Operation) .... W2-11-6
Structure of Solenoid Valve Unit
(For Electric Lever Operation)............ W2-11-8

CJBW-2-2
 UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION OF CAB

Removal

CAUTION: Seat (1) weight: 40 kg (90 lb)

1 2 3 4 5
1. Remove sems bolts (4) (2 used) from safety belts
(6) (2 used). Remove safety belts (6) (2 used)
from brackets (5) (2 used).
: 16 mm

WCEB-02-01-001

4 5 2 3

WCEB-02-01-017

2. Remove socket bolts (3) (4 used) from seat (1).

Remove seat (1) from plate (2). 3 1
: 6 mm

2
WCEB-02-01-002

7
3. Remove mat (8) from the inside of cab (7).

8 WCEB-02-01-003

W2-1-1
 UPPERSTRUCTURE / Cab
4. Remove sems bolts (10) (2 used) from cover (9).
: 13 mm

10

W1JB-02-01-004

5. Remove caps (11) (6 used) from cover (9).

Remove screws (12) (6 used) from cover (9). 7

6. Remove cover (9) from cab (7). 11, 12

11, 12

7. Remove sems bolts (16) (4 used) from cover (14). W1JB-02-01-005

Remove cover (14) from brackets (13, 15). 13
: 17 mm

14

WCEB-02-01-008
16 16 15

8. Remove sems bolts (17) (5 used) from bracket 13

13 17
(13). Move the bracket (13) assembly forward
from bracket (15).
: 13 mm, 17 mm
17

15

17 WCEB-02-01-018 WCEB-02-01-019

W2-1-2
 UPPERSTRUCTURE / Cab
9. Remove screws (19) (2 used) from cover (18). 18 19
Remove cap (20) and screw (21) from cover (18).
Remove cover (18) from cab (7).

W1JB-02-01-001
20, 21 7

22 7
10. Remove sems bolts (23) (2 used) from bracket
(24). Remove bracket (24) from cab (7) and duct
(22). Remove duct (22) from bracket (15).
: 13 mm 23

24

15

WCEB-02-01-016
23

25 26
11. Open covers (25, 26).

WCJB-02-01-001

12. Attach a nylon sling onto cover (25). Hoist and

hold cover (25). 25

13. Remove nuts (28) (4 used), spring washers (29)

(4 used) and washers (30) (4 used) from cover 27
(25). Remove cover (25) from support (27).
: 17 mm

28, 29, 30

WCJB-02-01-003

W2-1-3
 UPPERSTRUCTURE / Cab
14. Disconnect vinyl hose (32) from washer tank (31). 31
Cap the open ends.

32

WCJB-02-01-004

15. Remove sems bolts (35) (7 used) from cover (33). 33 34 35

Remove cover (33) from main frame (34).
: 17 mm

WCJB-02-01-005

16. Remove anchor bolt (38), washer (37) and spacer

(36) from cab (7) and main frame (34).
: 32 mm
7

36

37

WCEB-02-01-013
34 38

17. Remove vinyl hose (32) through the cab (7) side.

32

WCJB-02-01-004

W2-1-4
 UPPERSTRUCTURE / Cab
18. Open cover (40). 39 40 41 42

19. Remove sems bolts (41) (4 used) from cover (39).

Remove cover (39) from stay (42).
: 17 mm

WCJB-02-01-002

20. Remove clamps (44) (3 used) from the outside of 43

the cab (7) rear. Disconnect connectors (43) (5 44
used).

WCEB-02-01-014

CAUTION: Cab (7) weight: 550 kg (1220 lb) Lifting Bracket 47 7 Lifting Bracket

21. Attach a nylon sling onto the bracket in cab (7).

Hold cab (7).

22. Remove nuts (45) (4 used) and washers (46) (4

used) from cab (7).
: 24 mm
45, 46
45, 46
23. Remove socket bolts (47) (6 used) from cab (7).
: 8 mm
47
24. Remove bolts (48) (5 used) and washers (49) (5 45, 46
used) from cab (7). W1JB-02-01-006
: 17 mm
48, 49 47

CAUTION: Cab (7) weight: 550 kg (1220 lb)

25. Remove cab (7) from main frame (34).

34

WCJB-02-01-006

W2-1-5
 UPPERSTRUCTURE / Cab
Installation

CAUTION: Cab (7) weight: 550 kg (1220 lb)

1. Attach a nylon sling onto cab (7). Hoist and align

cab (7) with the mounting hole on main frame
(34).

34

WCJB-02-01-006

Lifting Bracket 47 7 Lifting Bracket

2. Install cab (7) to main frame (34) with nuts (45) (4
used) and washers (46) (4 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

3. Install cab (7) to main frame (34) with socket bolts

(47) (6 used).
: 8 mm 45, 46
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 45, 46

4. Install cab (7) to main frame (34) with bolts (48) (5 47

used) and washers (49) (5 used).
: 17 mm 45, 46
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) W1JB-02-01-006

48, 49 47

22 7
5. Install duct (22) to bracket (15).

6. Install bracket (24) to cab (7) and duct (22) with

23
sems bolts (23) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 24

15

WCEB-02-01-016
23

W2-1-6
 UPPERSTRUCTURE / Cab
7. Install cover (18) to cab (7) with screws (19) (2 18 19
used). Install cover (18) to cab (7) with screw (21).
Install cap (20) to screw (21).

20, 21 7 W1JB-02-01-001

8. Align the bracket (13) assembly with the mounting

13
hole on bracket (15). Install the bracket (13) 13 17
assembly to bracket (15) with sems bolts (17) (5
used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 17
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
15

17 WCEB-02-01-018 WCEB-02-01-019

9. Install cover (14) to brackets (13, 15) with sems 13

bolts (16) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

14

WCEB-02-01-008
16 16 15

10. Install cover (9) to cab (7) with screw (12) (6 used). 7
Install caps (11) (6 used) to screws (12) (6 used).
11, 12

11, 12

W1JB-02-01-005

W2-1-7
 UPPERSTRUCTURE / Cab
11. Install cover (9) to cab (7) with sems bolts (10) (2
used). 7
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
9

10

W1JB-02-01-004

12. Connect connectors (43) (5 used). Secure

connectors (43) (3 used) with clamps (44) (3 43
used). 44

WCEB-02-01-014

13. Secure cab (7) to main frame (34) with anchor bolt
(38), washer (37) and spacer (36).
: 32 mm
: 550 N⋅m (55 kgf⋅m, 406 lbf⋅ft) 7

36

37

WCEB-02-01-013
34 38

31
14. Pass vinyl hose (32) through main frame (34).
Connect vinyl hose (32) to washer tank (31).

32

WCJB-02-01-004

W2-1-8
 UPPERSTRUCTURE / Cab
15. Install cover (33) to main frame (34) with sems 33 34 35
bolts (35) (7 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-01-005

16. Attach a nylon sling onto cover (25). Hoist and

25
align cover (25) with the mounting hole on support
(27). Secure cover (25) to support (27) with
washers (30) (4 used), spring washers (29) (4
27
used) and nuts (28) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

28, 29, 30

WCJB-02-01-003

25 26
17. Shut covers (25, 26).

WCJB-02-01-001

3 1
CAUTION: Seat (1) weight: 40 kg (90 lb)

18. Install seat (1) to plate (2) with socket bolts (3) (4
used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

2
WCEB-02-01-002

W2-1-9
 UPPERSTRUCTURE / Cab
19. Install safety belts (6) (2 used) to brackets (5) (2 1 2 3 4 5
used) with sems bolts (4) (2 used).
: 16 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-01-001

4 5 2 3

WCEB-02-01-017

7
20. Install mat (8) to the inside of cab (7).

8 WCEB-02-01-003

21. Install cover (39) to stay (42) with sems bolts (41) 39 40 41 42
(4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

22. Shut cover (40).

WCJB-02-01-002

W2-1-10
 UPPERSTRUCTURE / Cab
(Blank)

W2-1-11
 UPPERSTRUCTURE / Cab
DIMENSIONS OF CAB GLASS

Black Ceramic
NOTE: Unit: mm (1 mm=0.039 in) 115 Coating Range

70

21

107
60 2-R50 2-R50
C0.5 2-R250
2-R127 2-R20
2-R10

70
C0.5
106.6 A
Black Ceramic W1JB-02-01-013 1081
Coating Surface R50
R2975 (4 mm)
Section A R800
φ28
R75 B
R120
Black
R40 268
Ceramic 20 70
Coating
Surface 16.5
50 W1JB-02-01-011
2R-5
271 21
214 21
847

Black Ceramic
Coating Range

R1075

W1JB-02-01-009
C
372.9
(4 mm)
22
50

54.1 25 W1JB-02-01-012

25 84

865

C0.5
R2

W1JB-02-01-014 W1JB-02-01-019
C0.5
Black Ceramic
Coating Surface
Section C
Section B

W2-1-12
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

360.7

4-R4
3-R4

2-φ12.2 +0.5
(4 mm) 139.7 -0
R150 6445
50 (4 mm)
50 WCEB-02-01-012 40±0

631
37 228.2

50

50 WCEB-02-01-011
383.2

312.6

C0.5
4Ｒ-4

C0.5
R2800
Black Ceramic
Coating Surface
(4 mm)
Section A W1JB-02-01-013
644.5
40±0.5

WCEB-02-01-004
228.2

93°
50

50 WCEB-02-01-010

460.2

Glass Mark (Back)

860.8
Black Ceramic 833
Coating Range 506
63.5 581
50 438.5 26.5
2-φ21 353.5
2-R4
R150 64.5
R2854
R50 109.5 336
R25 102.5
A

498.5 448 1
R58 R75 (4 mm) R60 152.5
R250 185
R964 R103
R5031 34
R42 R329
R10
118
R5004 82

327.5
R10 R60 W1JB-02-01-018
17 173

W2-1-13
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

Black Ceramic
Coating Range

R30 30
39
29

652
87.5 (4 mm) R200
87.5
R200
R500 R500 A
R50 185 185
45
70
R50
4-R10 205
848 W1JB-02-01-021

WCEB-02-01-015

567.5 Black Ceramic

Coating Range
496

123.5 80 59.5
C0.5
3-R4 85
75.5 100 R25

C0.5 R25
R20 R25 R25 B
Black Ceramic W1JB-02-01-013 87.7° R75
Coating Surface
Section A R4139.5
887 1008
1099
1145.5
R4044.5
1127.3 19.5

(4 mm)

R40
R35
C0.5 R100
R35
R550
R135 φ83
13°
A
W1JB-02-01-014 228
112
C0.5 109°
105
65° R250
R20 102°
Section B R70 R60
W1JB-02-01-017
76
140
78.5 57 195
447
483

W2-1-14
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

C1

C1
Black Ceramic W1JB-02-01-013
Coating Surface
Section A

W1JB-02-01-009

1646.47

1599.44

187 Black Ceramic Coating Range 313.6

R20
80 50

106 R300
2-R25
R2145 50
R30
696.73 R75
50
1230

R2940
900

(5 mm) 1205
A
R25
90 1496.7
40 R30
R3025
1636.3
R30 R50
R20 158 R10
873.14

R2875
150 145

R575 R50
R125

R1040 R30 R50

R1525 28°
W1JB-02-01-020
R55 R30
393
400

807.65

963.7

W2-1-15
 UPPERSTRUCTURE / Cab
Removal of Cab Glass
Right-Hand Glass

Procedures to Remove Right-Hand Glass, Rear

Left-Hand Glass, Lower Door Glass and Rear Glass

CAUTION: When removing the broken or

cracked glass, the glass shards may cause
serious injury.
Before removing, use the gummed tape or
something like in order to paste the broken or
cracked glass and reinforce them. Remove
the glass pieces away.
W1JB-02-01-009

1. Remove the resin panel, garnish and spacer

around the glass. Rear Glass

Rear
Left-Hand
Garnish Glass

Garnish

2. Prick a hole in the adhesive by using an awl (or

cutter knife). Lower Door Resin Panel WCEB-02-01-015
Glass

3. Pass a piano wire (or a wire) through the hole.

Cab
Cab Glass
Awl

Adhesive W1SE-02-01-033

Piano Wire
(or Metal Wire)

W1SE-02-01-034

W2-1-16
 UPPERSTRUCTURE / Cab
4. Wind the both ends of piano wire onto the
screwdriver. Draw the wire back and forth in order
to cut the adhesive between cab and glass.
Remove the glass from the cab. Cab Glass (Cab Outside)

NOTE: Cut off the middle of adhesive between Cab Glass

glass and cab.
Piano wire is easily broken if a part of piano
wire turns hot. Change the position and cut
the adhesive.

Adhesive
(Cab Inside)

W1SE-02-01-035

W2-1-17
 UPPERSTRUCTURE / Cab
Installation of Cab Glass
Right-Hand Glass

Procedures to Install Right-Hand Glass, Rear

Left-Hand Glass, Lower Door Glass and Rear Glass

1. Cut off residual adhesive at the cab side to make

1 to 2 mm (0.04 to 0.08 in) deep all around by
using a cutter knife or similar.
NOTE: Do not damage the cab paint.

W1JB-02-01-009

Rear Glass

Lower Door Rear Left-Hand W1JB-02-01-010

Glass Glass

Cab

2. Clean the cutting edge of adhesive at cab side by

Cutter Knife
using white spirit.

Cut off adhesive by 1 to 2 mm

（0.04 to 0.08 in） deep.
W1SE-02-01-036

IMPORTANT: Primer should be shaken for about 1

minute and mix thoroughly before Cab
Apply Primer 24 by
opening the cap. using a brush.
After opening Primer, apply Primer
as quickly as possible and replace Cutting Edge of
the cap immediately after using. Adhesive at Cab
After opening Primer, all the Side
contents should be used within 180
W1SE-02-01-038
days (or 2 hours with the cap off).
3. Apply Primer for paint (Sika Aktivator DM-1) to the
cutting edge of adhesive at cab side by using a
brush. Wait for about 15 minutes in order to let it
dry by itself.
NOTE: The painting primer should be applied
evenly in order to leave no blemishes.

W2-1-18
 UPPERSTRUCTURE / Cab
4. Clean the mating edge of new glass by using
clean rag and ethyl alcohol.
IMPORTANT: Primer (Sika Primer Z06G+P) should
be shaken for about 1 minute and
mix thoroughly before opening the
cap.
After opening Primer, apply Primer
as quickly as possible and replace
the cap immediately after using.
After opening Primer, all the
contents should be used within 180
days (or 2 hours with the cap off).
5. Apply Primer for glass (Sika Primer Z06G+P) to
the cutting edge of adhesive at cab side by using
a brush. Wait for about 15 minutes in order to let it
dry by itself.
(As for the position to apply Primer, refer to
W2-1-21.)
11. Suck, raise the glass by using sucker lifter
4355282 (refer to W2-1-21), and adhere it to the
cab within 5 minutes.
NOTE: Install the glass while aligning the spacer
position on the glass. Remove all adhesive
except the mounting surface, before
solidifying by using white spirit.
12. Secure the glass by using the gummed tape until
the adhesive becomes solid in order to prevent
them from being mispositioned or coming off.
(Refer to W2-1-20.)
NOTE: Time for adhesive (Sika Tack-Drive) to
become solid: 8 hours (just for reference)

6. Install the spacer with facing to the glass surface

by using the instant adhesive.
(As for the positions to install spacers A, B and C
dam rubber, refer to W2-1-21.)

7. Cut off the nozzle of adhesive cartridge (Sika

Tack-Drive) into V-shaped by using a knife. (Refer
to W2-1-21.)

8. Remove the seal of cartridge. Install the V-shaped

nozzle.

9. Install the cartridge to the manual coking gun.

10. Evenly apply adhesive to the old adhesive left at

cab side.
(As for the position to apply adhesive, refer to
W2-1-21.)

W2-1-19
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

Rear Glass Right-Hand Glass

350 500
250 300

100

200
200 200 500

200

200 200

250 300
W1JB-02-01-029

200
200
100
100 W1JB-02-01-030

Rear Left-Hand Glass

150 200

Lower Door Glass

200

500

200
W1JB-02-01-035
W1JB-02-01-038

W2-1-20
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm Spacer C

(1 mm=0.039 in) Spacer B
Spacer A 20
2
6
20 6
4 R0.5
20 6 4
8 78°
R8 75° R10
4 6 R0.5
3
R5 84°
6 R0.5 12 10.5

Two Side W1JB-02-01-024

3 Adhesive Tape
Two Side W1JB-02-01-023
10.5
Adhesive Tape
W1JB-02-01-022

Dam Rubber

30 6.4

W1JB-02-01-025
Lower Door Grass

Rear Left-Hand Glass

Right-Hand Glass
Suction Lifter
Spacer A
Rubber
Dam
Rubber
Spacer B Spacer A
Spacer B
Spacer A Dam W1JB-02-01-039
Rubber
Spacer B
Rear Glass

Spacer C
W1JB-02-01-027
W1JB-02-01-026

W1JB-02-01-042
8 to 9 mm

13 to 15 mm
Adhesive
Cut nozzle
end into
V-shaped.

W1SE-02-01-027

Apply adhesive
9 evenly.

12 Remove
the seal.
W1JB-02-01-031

Adhesive
W1SE-02-01-043
Cartridge
Panel

W1SE-02-01-028

W2-1-21
 UPPERSTRUCTURE / Cab
13. The required amount (just for reference) of adhesive and primer

Painted Surface or Glass Surface

Adhesive Surface
Adhesive Primer Primer
Sika Tack-Drive Sika Aktivator DM-1 Sika Primer 206G+P
(Sika Tack-Drive) (Sika Aktivator DM-1) 30 ml Bottle
310 ml Cartridge 250 ml Can
Upper Front Glass 310 ml 0.75 ml 0.67 ml
Lower Door Glass 150 ml 0.5 ml 0.45 ml
Rear Left-Hand Glass 250 ml 0.65 ml 0.6 ml
Rear Right-Hand Glass 100 ml 1 ml 0.9 ml
Rear Glass 210 ml 0.5 ml 0.45 ml

W2-1-22
 UPPERSTRUCTURE / Cab
Installation of Upper Door Glass
Sash
1. Before installing the glass, remove the garnish Assembly
around sash assembly from the cab inside for
easy removal. Push the sash assembly by hands
and remove the sash outside.
Garnish

2. Install glass A and glass B into the sash grooves.

3. Install the sash assembly, which the glass is

Glass A Glass B
installed on, onto the door from the outside of cab.
Secure the sash assembly at the inside of cab by W1JB-02-01-010

using the garnish.

W2-1-23
 UPPERSTRUCTURE / Cab
Installation of Upper Front Glass
Adhere the glass in the same method as
right-hand glass.
1. Stick seal (1) to the lower side of front upper glass
by using Cemedine Super X.
Stick and secure both right and left ends (the
thicker part) of seal (1) to the glass by using
Cemedine Super X.
Stick the mating surface of seal (1) and the glass
by using Cemedine Super X so that no visible
undulation or boss can be found.

NOTE: Cemedine Super X Black No.8008

Glue-state adhesive, tubed

IMPORTANT: The upper front glass is

arched-fringed. When replacing the
glass, contact with the nearest
HITACHI Office and replace it as an
assembly.

W1JB-02-01-034

Cemedine Super Upper Cemedine Super X Upper

X Seal Here Glass Glass

Seal (1) Seal (1)

Lower Lower
Glass Glass
W1JB-02-01-032 W1JB-02-01-033

W2-1-24
 UPPERSTRUCTURE / Counterweight
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT

Removal 1
1. Open cover (1).

WCJB-02-02-002

2. Disconnect plugs (2, 3).

WCJB-02-02-003

WCJB-02-02-004

3. Open cover (4).

WCJB-02-02-001

4. Disconnect connector (5).

WCJB-02-02-005

W2-2-1
 UPPERSTRUCTURE / Counterweight
5. Open covers (6, 7). 6 7

WCJB-02-01-001

6. Disconnect connector (8).

WCEB-02-02-006

CAUTION: Counterweight (10) weight: 9

10
ZX210W-3: 3850 kg (8490 lb)
ZX220W-3: 4950 kg (11000 lb)

7. Remove caps (9) (2 used) from counterweight

(10). Install FLENO RINK BOLT into the holes
where caps (9) (2 used) were removed.
NOTE: Dimension of FLENO RINK BOLT (B-42,
M42, Pitch 4.5 mm)

8. Attach a wire rope onto FLENO RINK BOLT. Hoist 11

and hold counterweight (10).
12
CAUTION: When using a power wrench, do
not pinch your fingers by its reaction bar. WCEB-02-02-004

9. Remove bolts (12) (4 used) and washers (11) (4

used) from counterweight (10) by using a power
wrench. 10
: 60 mm

10. Hoist and remove counterweight (10) from main

frame (13).
11

12

13 WCEB-02-02-005

W2-2-2
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight (10) weight:

ZX210W-3: 3850 kg (8490 lb)
ZX220W-3: 4950 kg (11000 lb)

1. Hoist and align counterweight (10) with the

mounting holes on main frame (13). 10

2. Temporarily tighten counterweight (10) to main

frame (13) with bolts (12) (4 used) and washers
(11) (4 used).
11
CAUTION: When using a power wrench, do
not pinch your fingers by its reaction bar.
12
3. Remove the wire rope and FLENO RINK BOLT
13 WCEB-02-02-005
from counterweight (10). Tighten bolts (12) (4
used) by using a power wrench and torque
wrench.
: 60 mm
: 3600 N⋅m (367 kgf⋅m, 2660 lbf⋅ft) 10

Torque Wrench

Power Wrench WCEB-02-02-006

9
4. Install caps (9) (2 used) to counterweight (10).
10

WCEB-02-02-007

W2-2-3
 UPPERSTRUCTURE / Counterweight
5 8
5. Connect connectors (5, 8).

WCJB-02-02-005 WCEB-02-02-006

6. Shut cover (4).

WCJB-02-02-001

6 7

7. Shut covers (7, 6).

WCJB-02-01-001

8. Connect plug (3).

WCJB-02-02-004

W2-2-4
 UPPERSTRUCTURE / Counterweight
9. Connect plug (2).

WCJB-02-02-003

10. Shut cover (1).

WCJB-02-02-002

W2-2-5
 UPPERSTRUCTURE / Counterweight
(Blank)

W2-2-6
 UPPERSTRUCTURE / Main Frame
REMOVAL AND INSTALLATION OF MAIN
FRAME

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 Counterweight

CAUTION: Counterweight weight:

ZX210W-3: 3850 kg (8490 lb)
ZX220W-3: 4950 kg (11000 lb)
Washer
1. Remove the counterweight.
(Refer to the REMOVAL AND INSTALLATION OF Bolt
COUNTERWEIGHT on W2-2-1.)
: 60 mm
WCEB-02-02-005

Monoblock Boom
CAUTION: The front attachment assembly
weight:
Monoblock boom: 3430 kg (7570 lb)
2-piece boom: 4190 kg (9240 lb)

2. Remove the front attachment assembly.

(Refer to the REMOVAL AND INSTLLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 27 mm, 30 mm, 36 mm
WCJB-02-03-001

2-Piece Boom

WCJB-02-03-002

W2-3-1
 UPPERSTRUCTURE / Main Frame
Connector Slip Ling Hose
CAUTION: Center joint weight: 90 kg (200 lb)

3. Remove the bolts, the stopper and the slip ring

from the center joint. Disconnect the hose from
the center joint. (Refer to the Remove and Install Stopper
Center Joint group on W3-3-1.)
: 10 mm, 19 mm, 22 mm, 27 mm, 36 mm
Bolt

Center Joint WCJB-03-03-001

CAUTION: Upperstructure weight: 5400 kg

(12000 lb) Wire Rope

IMPORTANT: IMPORTANT: Do not damage the

engine due to the wire ropes
attached from the rear side of the
frame.
4. Attach the wire ropes onto the rear side of the
frame and the boom mounting part. Take up slack
of the wire rope.
NOTE: If chain block is used, it is not only easy to
Rear Side of Frame WCEB-02-03-003
adjust the length of wire rope, but also
easy to level the center of gravity.
Wire Rope

WCEB-02-03-005

5. Put the matching marks on the upperstructure

and the outer race of the swing bearing.
Remove the swing bearing mounting bolt.
: 30 mm

6. Adjust a chain block in order to level the center of

gravity. Hoist and remove the frame.

WCJB-02-03-003
Bolt

W2-3-2
 UPPERSTRUCTURE / Main Frame
Installation

CAUTION: Upperstructure weight: 5400 kg

(12000 lb)

1. Attach the wire ropes onto the frame. Adjust the

chain block in order to level the center of gravity.
Hoist and place the frame onto the undercarriage.
(Refer to the Removal procedures.)

2. Align the matching marks on the upperstructure

and the outer race of the swing bearing.
Install and temporarily tighten the mounting bolts
for the swing bearing. Remove the wire ropes.
Tighten the mounting bolts for the swing bearing.
: 30 mm
: 520 N·m (53 kgf·m, 390 lbf·ft)

WCJB-02-03-003
Bolt
Connector Slip Ling Hose
3. Connect the hoses (13 used) to the center joint.
: 10 mm
: 3.3 to 4.2 N·m
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)
: 19 mm Stopper
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
: 22 mm
: 39 N·m (4 kgf·m, 29 lbf·ft) Bolt
: 27 mm
: 78 N·m (8 kgf·m, 58 lbf·ft)
: 36 mm
: 175 N·m (18 kgf·m, 129 lbf·ft)

4. Apply LOCTITE #262 onto the bolts (5 used).

Install the stopper to the center joint. Center Joint WCJB-03-03-001

: 24 mm
: 265 N·m (27 kgf·m, 195 lbf·ft)

5. Install the slip ring to the stopper.

: 10 mm
: 3.3 to 4.2 N·m
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

W2-3-3
 UPPERSTRUCTURE / Main Frame

CAUTION: Counterweight weight:

ZX210W-3: 3850 kg (8490 lb)
Counterweight
ZX220W-3: 4950 kg (11000 lb)

6. Install the counterweight.

(Refer to the REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
: 60 mm Washer
: 3530 N·m (360 kgf·m, 2610 lbf·ft)
Bolt

WCEB-02-02-005

CAUTION: The front attachment assembly Monoblock Boom

weight:
Monoblock boom: 3430 kg (7570 lb)
2-piece boom: 4190 kg (9240 lb)

7. Install the front attachment assembly to the

upperstructure. Add hydraulic oil.
(Refer to the REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 27 mm
: 93 N·m (9.5 kgf·m, 69 lbf·ft) WCJB-02-03-001

: 30 mm
: 540 N·m (55 kgf·m, 398 lbf·ft) 2-Piece Boom
: 36 mm
: 175 N·m (18 kgf·m, 129 lbf·ft)

8. Start the engine. Set the front attachment in

posture for checking hydraulic oil level. Check for
hydraulic oil level and any oil leakage.

WCJB-02-03-002

W2-3-4
 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
1. Open cover (1).

WCJB-02-02-002

2. Open cover (2).

WCJB-02-02-001

3 4 5
3. Remove sems bolts (3) (4 used) from cover (4).
Remove cover (4) from main frame (5).
: 17 mm

WCJB-02-04-007

W2-4-1
 UPPERSTRUCTURE / Pump Device
4. Remove sems bolts (6) (2 used) from bracket (7). 6 7
: 17 mm

WCJB-02-04-003
5. Remove sems bolts (9) (6 used) from cover (8). 7 8 9
Remove cover (8) from bracket (7) and supports
(10, 11). 10
: 17 mm

11 9 WCJB-02-04-001

7 12 13
6. Remove sems bolts (12) (6 used) and sems bolts
(15) (2 used) from bracket (7). Remove bracket
(7) from supports (13, 14) and cover (16).
: 17 mm

WCJB-02-04-001
14 12 7

15

WCJB-02-04-002

16

WCJB-02-04-003

W2-4-2
 UPPERSTRUCTURE / Pump Device
7. Disconnect hoses (18) (2 used) from filter (19). 18 19 18
Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 27 mm 17 16

8. Remove sems bolts (20) (2 used) from clips (21)

(2 used). Remove clips (21) (2 used) from hoses 20, 21
(22) (4 used). 22
: 17 mm

WCJB-02-04-003

9. Disconnect connector (17).

: 17 mm 23

10. Disconnect connectors (24) (7 used) from pump

device (23). 24

WCEB-02-04-009

11. Remove socket bolts (26) (3 used) and clips (28)

(3 used). Remove harness (27) from pump device
(23).
: 5 mm 24

23

WCJB-02-04-004
28 27 26

29 29
12. Remove socket bolts (30) (8 used) and split
flanges (31) (4 used). Disconnect hoses (29) (2 30
used) from pump device (23). Cap the open ends.
: 10 mm 31

23

WCEB-02-04-009

W2-4-3
 UPPERSTRUCTURE / Pump Device
13. Disconnect hose (34) from suction pipe (32). Cap 32 33
the open ends.
: 41 mm 23

14. Remove socket bolts (33) (4 used) from suction

pipe (32). Disconnect suction pipe (32) from pump
device (23).
: 10 mm

34 WCEB-02-04-009

15. Disconnect hoses (35) (2 used) from regulators

(36) (2 used). Cap the open ends.
: 19 mm 35

WCJB-02-04-003

36

16. Disconnect hoses (38) (4 used) from pilot pump

(37). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 27 mm 37

38 WCEB-02-04-009

17. Disconnect hoses (39) (3 used) from filter (40).

Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 22 mm, 27 mm

WCJB-02-04-003
40 39

W2-4-4
 UPPERSTRUCTURE / Pump Device
18. Remove sems bolts (42) (5 used) from covers (41) 13 41 42 16
(2 used). Remove covers (41) (2 used) from
support (13) and cover (16).
: 17 mm

WCJB-02-04-004

19. Remove sems bolts (43) (2 used) from cover (16). 43

Remove the cover (16) assembly from support
(13).
: 17 mm
16

WCJB-02-04-003

20. Remove socket bolts (45) (8 used) and split 23

flanges (44) (4 used). Disconnect hoses (46) (2
used) from pump device (23). Cap the open ends.
: 8 mm 44

45

46

WCEB-02-04-009

21. Remove sems bolts (47) (2 used) from plate (48). 47 48 23 46

Remove plate (48) and the bracket (49) assembly
from pump device (23).
: 17 mm

49

WCEB-02-04-008

W2-4-5
 UPPERSTRUCTURE / Pump Device
22. Remove nuts (51) (2 used), spring washers (52) 51, 52, 53
(2 used) and bolts (53) (2 used) from clamp (55).
: 19 mm
50

CAUTION: The muffler (50) assembly weight:

23 kg (51 lb)
54
23. Attach a nylon sling onto muffler (50). Hoist and
hold muffler (50).
55
24. Remove sems bolts (56) (3 used) from bracket
(57). Remove the muffler (50) assembly from
WCJB-02-04-006
pump device (23).

50

CAUTION: Pump device (23) weight: 164 kg 57 56 23

WCJB-02-04-005

(370 lb)
23
25. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
pump device (23). Attach a nylon sling onto Eyebolt
Mounting
eyebolt. Hoist and hold pump device (23). Hole

26. Remove sems bolts (59) (3 used) from pump WCEB-02-04-003

device (23). Remove pump device (23) from

engine (58). 58
: 17 mm

59

WCJB-02-04-005
23

W2-4-6
 UPPERSTRUCTURE / Pump Device
Installation

CAUTION: Pump device (23) weight: 164 kg 23

(370 lb)
Eyebolt
1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to Mounting
Hole
pump device (23). Attach a nylon sling onto
eyebolt. Hoist and hold pump device (23).

WCEB-02-04-003

2. Align pump device (23) with the mounting hole on

engine (58). Install pump device (23) to engine
58
(58) with sems bolts (59) (3 used).
: 17 mm
: 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)
50

CAUTION: The muffler (50) assembly weight:

23 kg
59
3. Attach a nylon sling onto muffler (50). Hoist and
align muffler (50) with the mounting hole on pump
device (23). Install bracket (57) to pump device
(23) with bolts (56) (3 used). WCJB-02-04-005
: 17 mm 57 56 23
: 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)

4. Align clamp (55) with the center of exhaust pipe 51, 52, 53
(54) and the muffler (50) pipe. Secure exhaust
pipe (54) and muffler (50) with bolts (53) (2 used),
spring washers (52) (2 used) and nuts (51) (2 50
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
54

55

WCJB-02-04-006

W2-4-7
 UPPERSTRUCTURE / Pump Device
5. Install the bracket (49) assembly to pump device 47 48 23
(23) with sems bolts (47) (2 used) and plate (48).
: 17 mm
: 65 N⋅65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)

49

WCEB-02-04-008

23 32 33
6. Connect suction pipe (32) to pump device (23)
with socket bolts (33) (4 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

7. Connect hose (34) to suction pipe (32).

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

8. Connect hoses (46) (2 used) to pump device (23)

with split flanges (44) (4 used) and socket bolts 34 WCEB-02-04-009

(45) (8 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 23

9. Connect hoses (39) (4 used) to pilot pump (37).

37 44
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 45

46

WCEB-02-04-009

38

W2-4-8
 UPPERSTRUCTURE / Pump Device
10. Install the cover (16) assembly to support (13) with 43
sems bolts (43) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
16

WCJB-02-04-003

11. Install covers (41) (2 used) to support (13) and 13 41 42 16

cover (16) with sems bolts (42) (5 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
36

24
12. Install clips (28) (3 used) to harness (27). Install
clips (28) (3 used) to pump device (23) with socket
bolts (26) (3 used).
: 5 mm 23
: 10 N⋅m (1 kgf⋅m, 7 lbf⋅ft)

WCJB-02-04-004

13. Connect connectors (24) (7 used) to regulator (36) 28 27 26

and pump device (23).
29 29

14. Connect hoses (29) (2 used) to pump device (23) 30

with split flanges (31) (4 used) and socket bolts
(30) (8 used). 31
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
23

24

WCEB-02-04-009

W2-4-9
 UPPERSTRUCTURE / Pump Device
15. Connect hoses (39) (3 used) to filter (40).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm 35
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

16. Connect hoses (35) (2 used) to regulators (36) (2

used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

WCJB-02-04-003

40 39 36

17. Connect hoses (18) (2 used) to filter (19).

: 27 mm 18 19 18
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

18. Connect connector (17) to filter (19). 17 16

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

19. Install clips (21) (2 used) to hoses (22) (4 used). 20, 21

Secure clips (21) (2 used) to cover (16) with sems
bolts (20) (2 used). 22
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCJB-02-04-003

W2-4-10
 UPPERSTRUCTURE / Pump Device
20. Install bracket (7) to supports (13, 14) and cover 7 12 13
(16) with sems bolts (12) (6 used) and sems bolts
(15) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-04-001
14 12 7

15

WCJB-02-04-002

16

21. Install cover (8) to supports (10, 11), cover (16) 7 8 9

WCJB-02-04-003

and bracket (7) with sems bolts (9) (6 used) and

sems bolts (6) (2 used). 10
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

11 9 WCJB-02-04-001

16

WCJB-02-04-003

W2-4-11
 UPPERSTRUCTURE / Pump Device
3 4 5
22. Install cover (4) to main frame (5) with sems bolts
(3) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-04-007

23. Shut covers (2, 1).

WCJB-02-02-001

WCJB-02-02-002

W2-4-12
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-4-13
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF PUMP DEVICE 4

1 2 3 5

18
15 16 17
6 14

13

12
58 11
7 10

9 14
57
15 16 17
56
55
54 19
8

53 12
20
11
51 10
9

21
52 22
23 28
51 50 24
21
22

27

26

49 25

37
29
30 38
26 35 39
40
31 36
48 34
47
32
33

41
42
43
44

46 45
44 WCEB-02-04-014

W2-4-14
 UPPERSTRUCTURE / Pump Device

72
71
70 73
69
68
67 74
66 71
65
75

60 62
63
64 69
63
62 68
60 60
61 62 78
82 63 76
59 81
60 63 77
62
60
83 61 79
82
60 80
59 60
72

83
WCEB-02-04-011

1 - Socket Bolt (4 Used) 22 - Plug (2 Used) 43 - Retaining Ring 64 - Right Valve Plate
2 - Right Regulator 23 - O-Ring 44 - Ball Bearing (2 Used) 65 - Backup Ring
3 - Socket Bolt (2 Used) 24 - Stopper 45 - Gear 66 - O-Ring
4 - Socket Bolt (2 Used) 25 - Plug 46 - Gear Shaft 67 - Spring Pin (2 Used)
5 - Socket Bolt (2 Used) 26 - Retaining Ring (2 Used) 47 - Retaining Ring 68 - Pressure Sensor (2 Used)
6 - Left Regulator 27 - Gear 48 - Oil Seal 69 - O-Ring (2 Used)
7 - O-Ring (4 Used) 28 - Gasket 49 - Gear Casing 70 - Selector Head
8 - O-Ring (6 Used) 29 - Gear 50 - Spring Pin (2 Used) 71 - O-Ring (4 Used)
9 - Bearing Nut (2 Used) 30 - Plug 51 - Oil Seal (2 Used) 72 - Socket Bolt (16 Used)
10 - Bearing (2 Used) 31 - Elbow 52 - Retaining Ring (2 Used) 73 - Stopper S (2 Used)
11 - Ring (2 Used) 32 - Plug 53 - Pump Casing 74 - O-Ring (2 Used)
12 - Bearing (2 Used) 33 - O-Ring 54 - Spring Washer (6 Used) 75 - Socket Bolt (12 Used)
13 - Shaft 34 - Gasket 55 - Bolt (6 Used) 76 - Set Screw (2 Used)
14 - Pin (2 Used) 35 - Socket Bolt (2 Used) 56 - Spring Pin (2 Used) 77 - Servo Piston (2 Used)
15 - Center Shaft (2 Used) 36 - Pipe 57 - O-Ring (2 Used) 78 - Pin (2 Used)
16 - Spring (2 Used) 37 - Level Gauge 58 - O-Ring (2 Used) 79 - O-Ring (2 Used)
17 - Plunger (14 Used) 38 - Socket Bolt (2 Used) 59 - Pin (2 Used) 80 - Stopper L (2 Used)
18 - Rotor (2 Used) 39 - Spring Washer (2 Used) 60 - Retaining Ring (12 Used) 81 - Left Valve Plate
19 - Shaft 40 - Washer (2 Used) 61 - Pin (2 Used) 82 - Pin (4 Used)
20 - Slide Ring 41 - Pilot Pump 62 - Lever (4 Used) 83 - Link (2 Used)
21 - O-Ring (2 Used) 42 - Retaining Ring 63 - Pin (4 Used)

W2-4-15
 UPPERSTRUCTURE / Pump Device
4
1 2 3 5

70

58
7

57

53

49
25

37
30 38
35 39
40
31 36
34

32

41

WCEB-02-04-013

W2-4-16
 UPPERSTRUCTURE / Pump Device
Disassembly of Pump Device
1. Remove plug (25) from gear casing (49).
: 17 mm
2. Remove plug (32) from gear casing (49). Drain off
gear oil from gear casing (49). (Approx. 1.0 L, 0.3
US gal)
: 22 mm
3. Remove socket bolts (1) (4 used) from right
regulator (2). Raise right regulator (2) to the
direction of selector head (70). Remove right
regulator (2) from pump casing (53).
: 8 mm
4. Remove socket bolts (3) (2 used) and socket bolts
(5) (2 used) from left regulator (6). Raise left
regulator (6) to the direction of selector head (70).
Remove left regulator (6) from pump casing (53).
Do not remove socket bolt (4).
: 8 mm
5. Remove O-rings (7) (4 used) and O-rings (57, 58)
(2 used for each) from pump casing (53).
7. Hoist the pump casing (53) assembly. Place the
pump casing (53) assembly with gear casing (49)
facing downward. Place the wooden block (80
mm (3.1 in) or more square) under gear casing
(49).
8. Remove socket bolts (35) (2 used) from pipe (36).
Remove level gauge (37), pipe (36) and gasket
(34) from gear casing (49).
: 6 mm
9. Remove socket bolts (38) (2 used), spring
washers (39) (2 used) and washers (40) (2 used)
from pilot pump (41). Tap the flange of pilot pump
(41) by using a plastic hammer and remove pilot
pump (41) from gear casing (49).
: 8 mm
NOTE: THREEBOND has been applied onto the
mounting surface of pilot pump (41).
10. Remove plug (30) and elbow (31) from gear
casing (49).
: 30 mm

CAUTION: The pump casing (53) assembly

weight: 160 kg (360 lb)

CAUTION: When hoisting the pump casing

(53) assembly, turn to the gear
casing (49) side and do not take
pump casing (53) off the ground.

6. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to

the thread hole for socket bolts (1, 3) of pump
casing (53). Attach a nylon sling onto eyebolts (2
used).

W2-4-17
 UPPERSTRUCTURE / Pump Device

16

8 16

53

72

71 73
70
69 74
68
71
66
65 75

69

68

79
80

72

WCEB-02-04-012

W2-4-18
 UPPERSTRUCTURE / Pump Device
11. Remove the pressure sensors (68) (2 used)
assembly from selector head (70).
: 27 mm
12. Remove socket bolts (72) (16 used) from stoppers
S (73) (2 used) and stoppers L (80) (2 used).
Remove stoppers S (73) (2 used) and stoppers L
(80) (2 used) from selector head (70).
: 6 mm
NOTE: O-rings (74, 79) are installed to stopper S
(73) and stopper L (80). If it is difficult to
remove the stopper, tap the outer periphery
of the stopper. Turn the stopper until about
half of the hole for the mounting bolt can be
seen. Insert a screwdriver into the
mounting bolt hole. Remove the stopper by
using a screwdriver.
Stopper
W178-02-11-082
13. Remove O-rings (71) (4 used) from selector head
(70).
14. Remove O-rings (74, 79) (2 used for each) from
stoppers S (73) (2 used) and stoppers L (80) (2
used).
W2-4-19
15. Record the clearance between pump casing (53)
and selector head (70). Remove socket bolts (75)
(12 used) from selector head (70).
: 10 mm
NOTE: While loosening socket bolt (75), selector
head (70) will push out due to the force of
spring (16).
CAUTION: Selector head (70) weight: 28 kg
(62 lb)
16. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the bolt hole on the upper surface of selector
head (70). Hoist and remove selector head (70)
from pump casing (53). O-ring (66) may be
removed with the lower surface of selector head
(70) attached. Check O-ring (66).
17. Remove O-rings (8) (6 used), O-ring (66) and
backup ring (65) from pump casing (53).
 UPPERSTRUCTURE / Pump Device

18
15 16 17

13

15 16 17
55
54 19

53

50
28

27

49 70

29 75

60 62
63
64
63
62
60 60
61 62 78
82 63 76
59 81
60 63 77
62
60
83 61
82
60
59 60

83
WCEB-02-04-012

W2-4-20
 UPPERSTRUCTURE / Pump Device
18. Warm up set screws (76) (2 used) by using a drier.
Remove set screws (76) (2 used) from servo CAUTION: Pump casing (53) weight: 105 kg
pistons (77) (2 used). Remove pins (78) (2 used) (240 lb)
from servo pistons (77) (2 used).
: 6 mm 24. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the socket bolt (75) hole on pump casing (53).
19. Remove servo pistons (77) (2 used) from selector Hoist and remove pump casing (53) from gear
head (70). casing (49). Shafts (13, 19) and gears (27, 29) are
removed with pump casing (53) together.
20. Both right valve plate (64) and left valve plate (81) Place pump casing (53) with the mounting surface
are very similar and their installing directions are for the regulator facing upward.
determined. Record the position and the direction
of right valve plate (64) and left valve plate (81) 25. Remove spring pins (50) (2 used) and gasket (28)
before removing. Remove retaining rings (60) (4 from gear casing (49).
used) from pins (63) (4 used). Remove right valve
plate (64) and left valve plate (81) from links (83)
(2 used). Do not remove pins (63) (4 used) unless
necessary.

21. Remove rotor (18), spring (16), the center shaft

(15) assembly and plungers (17) (7 used) from
pump casing (53) in this order. (Both right and left
pumps)
NOTE: When removing plunger (17), turn plunger
(17) inside and remove plunger (7).

IMPORTANT: As the pump performance may be

changed, do not deform link (83).
22. Remove the link (83) assemblies (2 used) from
pump casing (53). Do not disassemble the link
(83) assembly unless necessary.
NOTE: If it is difficult to remove the link (83)
assembly, use a screwdriver.

23. Remove bolts (55) (6 used) and spring washer

(54) from pump casing (53).
: 24 mm

W2-4-21
 UPPERSTRUCTURE / Pump Device

13

12

10

19

53 12

10

21
22
23
24
21
22

27
26

70

29
26

WCEB-02-04-012

W2-4-22
 UPPERSTRUCTURE / Pump Device
26. Put the matching marks on the meshed position
of splines on shafts (13, 19) and gears (27, 29). CAUTION: Pump casing (53) weight: 70 kg
Put the matching marks on the meshed position (160 lb)
of gears (27, 29).
31. Attach a nylon sling onto pump casing (53). Hoist
27 29 and place pump casing (53) on the wooden
blocks with the pump transmission side facing
downward. Use the wooden block: 100 mm (3.9
in) or more square.

32. Remove shafts (13, 19) from pump casing (53) by

19
using special tools (ST 1470, ST 1471). Bearings
13
(10, 12) are removed with shafts (13, 19) together.
W137-02-04-007 ST 1470

27. Remove retaining rings (26) (2 used) from shafts ST 1471

(13, 19). Remove gears (27, 29) from shafts (13,
19).
13

CAUTION: Pump casing (53) weight: 70 kg 19

(160 lb)

28. Attach a nylon sling onto pump casing (53). Hoist 53

and place pump casing (53) with the mounting
side for selector head (70) facing downward.

29. Remove stoppers (24) (2 used) from pump casing W178-02-04-054

(53). Remove O-rings (23) (2 used) from stoppers
(24) (2 used).
: 19 mm

30. Remove plugs (22) (2 used) from pump casing

(53). Remove O-rings (21) (2 used) from plugs
(22) (2 used).
: 8 mm

W2-4-23
 UPPERSTRUCTURE / Pump Device

13

12
11
10

19

53 12
20
11
51 10
9

52

51

49

48
47

42
43
44

46 45
44 WCEB-02-04-014

W2-4-24
 UPPERSTRUCTURE / Pump Device
33. Remove slide ring (20) from pump casing (53).
34. Remove bearing nuts (9) (2 used) from shafts (13,
19) by using special tool (ST 3058).
39. Remove ball bearing (44) and gear shaft (46)
from the upper side of gear casing (49) by using
special tool (ST 1393).

ST 3058

9
46

44

W137-02-04-023

W178-02-11-085

35. Remove bearings (10, 12) (2 used for each) and

rings (11) (2 used) from shafts (13, 19) by using a 40. Remove gear (45) and ball bearing (44) from gear
press. casing (49).

41. Install a shackle to the bolt hole on the periphery

CAUTION: Pump casing (53) weight: 42 kg of gear casing (49). Hoist and turn over gear
(93 lb) casing (49) by using a nylon sling.

36. Attach a nylon sling onto pump casing (53). Hoist 42. Remove retaining ring (47) and oil seal (48) from
and place pump casing (53) with the mounting gear casing (49).
surface for the regulator facing upward.

37. Remove retaining rings (52) (2 used) and oil seals

(51) (2 used) from pump casing (53).

38. Remove retaining ring (42) from gear casing (49).

Remove retaining ring (43) from gear shaft (46).

W2-4-25
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF PUMP DEVICE
81 66 65 18 16 15 17 12 20 11 10 9 51 29

26

19

52

13

26

27

64 60, 63 62 18 82 16 15 17 12 11 10 9 51

72 73 71 74 8 7 56 57 61 60 59 58 53

70

79

76

78

79
W178-02-11-086

72 67 22 21 83 14 24 23
80

W2-4-26
 UPPERSTRUCTURE / Pump Device

38, 39, 40 41 34, 35, 36 43 42 45 44

32, 33 31 30 6 5 4 3 37

46

25

47

48

50

49

WCEB-02-04-004
68 75 2 1 55 54 28

1- Socket Bolt (4 Used) 22 - Plug (2 Used) 43 - Retaining Ring 64 - Right Valve Plate
2- Right Regulator 23 - O-Ring 44 - Ball Bearing (2 Used) 65 - Backup Ring
3- Socket Bolt (2 Used) 24 - Stopper 45 - Gear 66 - O-Ring
4- Socket Bolt (2 Used) 25 - Plug 46 - Gear Shaft 67 - Spring Pin (2 Used)
5- Socket Bolt (2 Used) 26 - Retaining Ring (2 Used) 47 - Retaining Ring 68 - Pressure Sensor (2 Used)
6- Left Regulator 27 - Gear 48 - Oil Seal 69 - O-Ring (2 Used)
7- O-Ring (4 Used) 28 - Gasket 49 - Gear Casing 70 - Selector Head
8- O-Ring (6 Used) 29 - Gear 50 - Spring Pin (2 Used) 71 - O-Ring (4 Used)
9- Bearing Nut (2 Used) 30 - Plug 51 - Oil Seal (2 Used) 72 - Socket Bolt (16 Used)
10 - Bearing (2 Used) 31 - Elbow 52 - Retaining Ring (2 Used) 73 - Stopper S (2 Used)
11 - Ring (2 Used) 32 - Plug 53 - Pump Casing 74 - O-Ring (2 Used)
12 - Bearing (2 Used) 33 - O-Ring 54 - Spring Washer (6 Used) 75 - Socket Bolt (12 Used)
13 - Shaft 34 - Gasket 55 - Bolt (6 Used) 76 - Set Screw (2 Used)
14 - Pin (2 Used) 35 - Socket Bolt (2 Used) 56 - Spring Pin (2 Used) 77 - Servo Piston (2 Used)
15 - Center Shaft (2 Used) 36 - Pipe 57 - O-Ring (2 Used) 78 - Pin (2 Used)
16 - Spring (2 Used) 37 - Level Gauge 58 - O-Ring (2 Used) 79 - O-Ring (2 Used)
17 - Plunger (14 Used) 38 - Socket Bolt (2 Used) 59 - Pin (2 Used) 80 - Stopper L (2 Used)
18 - Rotor (2 Used) 39 - Spring Washer (2 Used) 60 - Retaining Ring (12 Used) 81 - Left Valve Plate
19 - Shaft 40 - Washer (2 Used) 61 - Pin (2 Used) 82 - Pin (4 Used)
20 - Slide Ring 41 - Pilot Pump 62 - Lever (4 Used) 83 - Link (2 Used)
21 - O-Ring (2 Used) 42 - Retaining Ring 63 - Pin (4 Used)

W2-4-27
 UPPERSTRUCTURE / Pump Device

43 42 44 45 44

32, 33

49
WCEB-02-04-004

12 11 10

19

13

12 11 10 W178-02-11-089

W2-4-28
 UPPERSTRUCTURE / Pump Device
Assembly of Pump Device

1. Tap and install ball bearing (44) into gear casing

(49) with the stamped mark facing inside by using
a bar and hammer. Tap and listen to ring in order
to check that ball bearing (44) is installed
completely.
2. Place gear (45) on ball bearing (44). Insert gear
shaft (46) while aligning with the spline.
CAUTION: Be careful as bearing (10) is too
hot.
9. Apply hydraulic oil onto the inside of bearings (10)
(2 used). Install bearings (10) (2 used) to shafts
(13, 19) by using a press.

3. Tap and install ball bearing (44) into gear shaft

(46) with the stamped mark facing outside by
using a bar and hammer. Tap and listen to ring in
order to check that ball bearing (44) is installed
completely.

4. Install retaining ring (42) to gear casing (49).

Install retaining ring (43) to gear shaft (46).

5. Install O-ring (33) to plug (32). Install plug (32) to

gear casing (49).
: 22 mm
: 70 N⋅m (7 kgf⋅m, 52 lbf⋅ft)

6. Warm up bearings (10, 12) (2 used for each) to 50

to 80 °C (122 to 176 °F).

CAUTION: Be careful as bearing (12) is too

hot.

7. Apply hydraulic oil onto the inside of bearings (12)

(2 used). Install bearings (12) (2 used) to shafts
(13, 19) by using a press.

8. Install rings (11) (2 used) to shafts (13, 19).

W2-4-29
UPPERSTRUCTURE / Pump Device

WCEB-02-04-004

53 12 20 10 9

19

13

12 10 9 W178-02-11-089

W2-4-30
 UPPERSTRUCTURE / Pump Device
10. Set the pre-loads of bearings (10, 12) installed on
shaft (13) according to the following procedures.
• Apply hydraulic oil onto the thread part of bearing
nut (9). Tighten bearing nut (9) until bearing nut
(9) comes in contact with bearing (10) by using
special tool (ST 3058).
ST 3058

9
10

W178-02-11-090

• Install special tool (ST 3070) to bearing (10).

Rotate 2 to 3 turns and measure the starting
torque.

ST 3070

10

W178-02-11-091

• Adjust bearing nut (9) until the starting torque

reaches specification.
: 1.96±0.49 N⋅m
(0.20±0.05 kgf⋅m, 1.45±0.36 lbf⋅ft)
NOTE: If the starting torque is higher than the limit
of specified torque, loosen bearing nut (9).
Tap the shaft end and release the load of
bearing (10).

11. Set the pre-loads of bearings (10, 12) installed on

shaft (19) in the same way as step 10.

12. Install slide ring (20) to the side to insert shaft (19)
in pump casing (53).

W2-4-31
UPPERSTRUCTURE / Pump Device

53 12 10 51

19

52

13

51

Regulator Mounting Surface 53

W178-02-11-092
24 23

W2-4-32
 UPPERSTRUCTURE / Pump Device
13. Warm up pump casing (53) to 50 to 80 °C (122 to 19. Install special tools (ST 2649, ST 2650) over the
176 °F). spline parts of shafts (13, 19).
NOTE: If special tools are not available, wind the
14. Apply hydraulic oil onto the outside of bearings vinyl tape over the spline part of the shaft in
(10, 12) installed on shaft (19). Install shaft (19) to order not to damage oil seal (51).
pump casing (53) by using special tool.
If it is difficult to insert shaft (19), tap shaft (19) by
using a bar.
Special Tool
ST 2650

51
M8, Pitch 1.25 mm

53

19

W178-02-11-094
ST 2649
Wooden Block
Wooden Block 20. Apply grease onto the inside of oil seals (51) (2
used). Evenly tap and install oil seals (51) (2
W178-02-11-093
used) to shafts (13, 19).

15. Install shaft (13) to pump casing (53) in the same 21. Remove special tools (ST 2649, ST 2650) from
way as step 14. shafts (13, 19).

16. Wait for pump casing (53) in order to cool down to 22. Install retaining rings (52) (2 used) to pump casing
the temperature lower than 40 °C (104 °F). (53).

17. Install O-ring (23) to stopper (24). Install stopper

(24) to pump casing (53).
: 19 mm
: 34.5 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

CAUTION: Pump casing (53) weight: 65 kg

(150 lb)

18. Attach a nylon sling onto pump casing (53). Hoist

and place pump casing (53) with the mounting
surface for the regulator facing upward.

W2-4-33
UPPERSTRUCTURE / Pump Device

45

50

49
WCEB-02-04-004

75 53 55 54 28

53 29

26

19

13

26

17 27 W178-02-11-096

W2-4-34
 UPPERSTRUCTURE / Pump Device
23. Align the matching marks and install gears (27,
29) to shafts (13, 19). Install retaining rings (26) (2
used) to shafts (13, 19).
When replacing the shaft and the gear, install the
gear according to the following procedure.
• Secure special tool (ST 7934) to the plunger (17)
mounting side of shafts (13, 19).
19
ST 7934 13
CAUTION: Pump casing (53) weight: 70 kg
(160 lb)
25. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the socket bolt (75) hole on pump casing (53).
Hoist pump casing (53).
While engaging gear (45) with gear (29), install
pump casing (53) to gear casing (49) with bolts
(55) and spring washers (54) (6 used for each).
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)

M8, Pitch 1.25 mm W178-02-11-097

• Turn shafts (13, 19) clockwise, viewed from the

mounting side for gears (27, 29), until shafts (13,
19) come into contact with special tool. (Remove
a play in periphery direction.)
• Install gear (27) and retaining ring (26) to the
spline of shaft (13).
• Insert gear (29) into the spline of shaft (19) and
engage with gear (27). If gear (29) does not
engage, turn and adjust shaft (19) in a play range
of special tool.
• Install retaining ring (26) to the spline of shaft
(19).
• Remove special tool (ST 7934).

24. Install spring pins (50) (2 used) to gear casing

(49). Install gasket (28).

W2-4-35
 UPPERSTRUCTURE / Pump Device
34, 35, 36
38, 39, 40 41 41 38 39, 40

49
WCEB-02-04-004

62 83 15 14 17 53
70

19

13

W178-02-11-096
62 59, 61 83 15 14 17

W2-4-36
 UPPERSTRUCTURE / Pump Device
26. Apply THREEBOND #1215 onto the mounting 30. Insert plungers (17) (7 used for each) into shafts
surface of pilot pump (41). Install pilot pump (41) (13, 19).
to gear casing (49) with socket bolts (38), spring
washers (39) and washers (40) (2 used for each). 31. Apply grease onto pins (14) (2 used). Install pin
: 8 mm (14) to center shafts (15) (2 used).
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
32. Apply grease onto the spherical surface of center
27. Install gasket (34) and pipe (36) to gear casing shafts (15) (2 used). Install center shafts (15) (2
(49) with socket bolts (35) (2 used). used) to shafts (13, 19).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

IMPORTANT: As the pump performance may be

changed, do not deform link (83).
28. Align with the groove for pin (59) on pump casing
(53) and install the link (83) assemblies (2 used)
with lever (62) facing to the selector head (70)
side.
NOTE: Both surfaces of pin (59) are parallel to
each other. Align the parallel surface with
the groove.
59
83
61
53

Parallel Parallel W178-02-11-098

Surface Surface
29. Apply hydraulic oil onto the plunger (17) mounting
surface of shafts (13, 19).

W2-4-37
 UPPERSTRUCTURE / Pump Device

60 62 16 79 18 15 14 17 53

63

81

64 60, 63 62 18 83 16 15 14 17 W178-02-11-099

8 65 18 53

70 19

W178-02-04-016
67 14

W2-4-38
 UPPERSTRUCTURE / Pump Device
33. Install springs (16) (2 used) to center shafts (15) 38. Install backup ring (65), O-ring (66) and O-rings
(2 used). (8) (6 used) to pump casing (53).

34. Insert center shafts (15) (2 used) and plungers 39. Install spring pins (67) (2 used) to pump casing
(17) (14 used) into rotors (18) (2 used). (53).

35. Insert the round file into the center hole on center
shaft (15). While rotating center shaft (15) by
using the round file, insert pin (14) into the groove
of rotor (18). (Both right and left pumps)
NOTE: If pin (14) does not enter into the groove on
rotor (18), selector head (70) cannot be
installed to pump casing (53).

36. Insert pins (63) (2 used) of right valve plate (64)

into the hole on levers (62) (2 used) for right
regulator (2). Install retaining rings (60) (2 used).
Check the direction to install right valve plate (64).
81 64
Upward

W178-02-11-100

37. Insert pins (63) (2 used) of left valve plate (81)

into the hole on levers (62) (2 used) for left
regulator (6). Install retaining rings (60) (2 used).
Check the direction to install left valve plate (81).

W2-4-39
 UPPERSTRUCTURE / Pump Device

Eyebolt
Mounting Hole

75

WCEB-02-04-004

70 75

72 71 73 74 18 53

70

77

76

78

Mounting Surface for

Suction Pipe
W178-02-04-016

79 72 64, 81 80 67 14

W2-4-40
 UPPERSTRUCTURE / Pump Device
40. Apply hydraulic oil onto servo pistons (77) (2
used). Insert servo pistons (77) (2 used) into
selector head (70).
41. Apply LOCTITE LI829 onto the thread part of set
screws (76) (2 used). Install pins (78) (2 used) to
servo pistons (77) (2 used) with set screws (76) (2
used).
: 6 mm
: 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
CAUTION: Selector head (70) weight: 29 kg
(64 lb)
45. Install O-rings (74) (2 used) to stoppers S (73) (2
used). Apply grease onto O-rings (74) (2 used).
Install stoppers S (73) (2 used) to selector head
(70) with socket bolts (72) (8 used).
: 6 mm
: 19.5 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
46. Install O-rings (79) (2 used) to stoppers L (80) (2
used). Apply grease onto O-rings (79) (2 used).
Install stoppers L (80) (2 used) to selector head
(70) with socket bolts (72) (8 used).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

42. Install eyebolts (M12, Pitch 1.75 mm) (2 used)

into the thread hole for the suction pipe on
selector head (70). Attach a nylon sling onto
eyebolts (2 used). Hoist selector head (70).
Place selector head (70) on pump casing (53)
while aligning selector head (70) with spring pin
(67).
NOTE: Check the clearance between selector
head (70) and pump casing (53) in order to
compare with the clearance before
disassembling. If the clearance is larger,
pin (14) may not be inserted into the groove
on rotor (18), or pin (78) may not be
inserted into the holes on valve plates (64,
81).

43. Install selector head (70) to pump casing (53) with

socket bolts (75) (12 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

44. Install O-rings (71) (4 used) to selector head (70).

W2-4-41
 UPPERSTRUCTURE / Pump Device

47

19

48

49
WCEB-02-04-004

53 7 56 57 61 58

5 6 3

83 2 1
WCEB-02-04-015

W2-4-42
 UPPERSTRUCTURE / Pump Device
47. Install O-rings (58) (2 used), O-rings (57) (2 used),
O-rings (7) (4 used) and spring pins (56) (2 used) CAUTION: Pump device weight: 160 kg (360
to pump casing (53). lb)

48. Install right regulator (2) to pump casing (53)
according to the following procedure.
• Adjust the sleeve position so that two grooves in
both sleeves on right regulator (2) are in a line.
• Place right regulator (2) on pump casing (53).
Insert pin (61) for link (83) into two grooves on the
sleeve.
• Move right regulator (2) so that spring pin (56) out
of pump casing (53) can enter into right regulator
(2).
• Install right regulator (2) to pump casing (53) with
socket bolts (1) (4 used).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
61
2 Sleeve
50. Hoist and place selector head (70) with the
regulator mounting side facing upward.
51. Insert special tool (ST 2650) to shaft (19). Apply
grease onto oil seal (48). Install oil seal (48) to
shaft (19).
Remove special tool (ST 2650). Tap and install oil
seal (48).
NOTE: If special tool (ST 2650) is not available,
wind the vinyl tape over the spline parts of
shaft (19) in order to protect oil seal (48).
Install oil seal (48).
ST 2650
48

53 W178-02-11-101
83 56
W178-02-11-103
49. Install left regulator (6) to pump casing (53) with
socket bolts (3) (2 used) and socket bolts (5) (2 52. Install retaining ring (47) to gear casing (49).
used) in the same way as step 48.
: 8 mm
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W2-4-43
 UPPERSTRUCTURE / Pump Device

31 30 37 36 25

49

WCEB-02-04-004

68

W178-02-04-016

W2-4-44
 UPPERSTRUCTURE / Pump Device
53. Wind the seal tape onto elbow (31). Install elbow
(31) to gear casing (49). Add engine oil (1.0 L, 0.3
US gal) through the elbow (31) hole.

54. Wind the seal tape onto plug (30). Install plug (30)
to elbow (31).
: 30 mm
: 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

49 30

31

W1V1-02-04-010

IMPORTANT: The breather hole of plug (25) is

located at the left side, viewed from
the front of gear casing (49).
55. Wind the seal tape onto plug (25). Install plug (25)
to gear casing (49).
: 17 mm
: 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

56. Insert level gauge (37) into pipe (36).

57. Install pressure sensors (68) (2 used) to selector

head (70).
: 27 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

W2-4-45
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF REGULATOR

Left Regulator

Right Regulator 2 14
13
3 12
WCEB-02-04-016
11
10
9

4 15

16

17

5 6
7
8

18
19 28
20
23
24 21
22

31 32
25 30 33
29 34
26
35
27 36
37
28 38
39
40
41
WCEB-02-04-019
42

1- Pipe 12 - Cylinder 23 - Lock Nut 33 - Lock Nut

2- Socket Bolt (2 Used) 13 - O-Ring 24 - Lock Nut 34 - Lock Nut
3- Solenoid Valve 14 - Piston 25 - Cover 35 - Cover
4- O-Ring 15 - Sleeve 26 - Set Bolt 36 - Adjuster
5- Low Pressure Sensor 16 - Spool 27 - Lock Nut 37 - O-Ring
6- O-Ring 17 - Spring 28 - Socket Bolt (8 Used) 38 - Stopper
7- O-Ring 18 - Spring 29 - O-Ring 39 - O-Ring
8- O-Ring 19 - O-Ring 30 - Cylinder 40 - Spring
9- Piston 20 - Stopper 31 - Piston 41 - Spool
10 - O-Ring 21 - O-Ring 32 - Casing 42 - Sleeve
11 - Backup Ring 22 - Adjuster

W2-4-46
 UPPERSTRUCTURE / Pump Device
Disassembly of Regulator IMPORTANT: As the setting changes, do not turn
• The regulators are used for right pump and left lock nuts (33, 34).
pump. The inner structure in the regulator is fully 4. Remove socket bolts (28) (4 used) from cover
identical, and the difference is only in its (35). Remove cover (35) and piston (14) from
accessories. casing (32). The stopper (38) assembly is
Here the left regulator is explained. removed with cover (35) together.
: 6 mm
IMPORTANT: As the setting changes, do not
disassemble adjusting screws (23, 5. Remove springs (17, 18) from casing (32).
24, 26, 27, 33 and 34).
When adjusting screws (23, 24, 26, 6. Insert a round bar into the hole on casing (32).
27, 33 and 34) must be disassembled, Push the spool (16) end. Remove cylinder (12),
carry out adjustment according to sleeve (15) and spool (16) from casing (32).
the procedure of performance test Piston (9) is removed with cylinder (12) together.
after assembling.
7. Remove piston (9) from cylinder (12).
1. Clamp casing (32) in a vise. Remove pipe (1)
from casing (32). 8. Remove spring (40) from casing (32).
: 22 mm
9. Insert a round bar into the hole on casing (32).
2. Remove socket bolts (2) (2 used) from solenoid Push the spool (41) end. Remove cylinder (30),
valve (3). Remove the solenoid valve (3) sleeve (42) and spool (41) from casing (32).
assembly and O-rings (6, 7, 8) from casing (32). Piston (31) is removed with cylinder (30) together.
: 8 mm
10. Remove piston (31) from cylinder (30).
IMPORTANT: As the setting changes, do not turn
set bolt (26), lock nuts (23, 24 and
27).
3. Remove socket bolts (28) (4 used) from cover
(25). Remove cover (25) from casing (32). Set
bolt (26) and the stopper (20) assembly are
removed with cover (25) together.
: 6 mm

W2-4-47
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF REGULATOR
2 3, 6, 7, 8

4, 5

WCEB-02-04-016

24 23 22 19 21 20 18 17 15 16 32 9 10 11 12 13 14

35

26
38
27

28 WCEB-02-04-017

25 29 30 31 42 41 40 37 39 34 36 33

1 - Pipe 12 - Cylinder 23 - Lock Nut 33 - Lock Nut

2 - Socket Bolt (2 Used) 13 - O-Ring 24 - Lock Nut 34 - Lock Nut
3 - Solenoid Valve 14 - Piston 25 - Cover 35 - Cover
4 - O-Ring 15 - Sleeve 26 - Set Bolt 36 - Adjuster
5 - Low Pressure Sensor 16 - Spool 27 - Lock Nut 37 - O-Ring
6 - O-Ring 17 - Spring 28 - Socket Bolt (8 Used) 38 - Stopper
7 - O-Ring 18 - Spring 29 - O-Ring 39 - O-Ring
8 - O-Ring 19 - O-Ring 30 - Cylinder 40 - Spring
9 - Piston 20 - Stopper 31 - Piston 41 - Spool
10 - O-Ring 21 - O-Ring 32 - Casing 42 - Sleeve
11 - Backup Ring 22 - Adjuster

W2-4-48
 UPPERSTRUCTURE / Pump Device
Assembly of Regulator
IMPORTANT: Two holes for sleeves (15, 42) on
casing (32) are the same bores. The
shapes of various parts in casing
(32) are very similar. Check the
illustration and assemble the
regulator.
1. Clean all parts and apply hydraulic oil.
2. Insert spool (41) into sleeve (42). Install sleeve
(42) to the center of casing (32) by using a round
bar. Check the direction to install sleeve (42),
spool (41) and piston (31).
3. Install O-ring (29) to cylinder (30).
4. Insert piston (31) into cylinder (30). Install cylinder
(30) to casing (32).
5. Insert spool (16) into sleeve (15). Install sleeve
(15) to the center of casing (32) by using a round
bar. Check the direction to install sleeve (15) and
spool (16).
6. Install O-rings (10, 13) and backup ring (11) to
cylinder (12).
7. Insert piston (9) into cylinder (12). Install cylinder
(12) to casing (32).
8. Install piston (14) to cover (35) from the mounting
side for casing (32).
W2-4-49
9. Install O-ring (37) and spring (40) to the stopper
(38) assembly with cover (35) attached. Install
cover (35) to casing (32) with socket bolts (28) (4
used).
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
10. Install O-ring (21) and springs (17, 18) to the
stopper (20) assembly with cover (25) attached.
Install cover (25) to casing (32) with socket bolts
(28) (4 used).
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
11. Apply grease onto O-rings (6, 7 and 8). Install
O-rings (6, 7 and 8) to solenoid valve (3). Install
solenoid valve (3) to casing (32) with socket bolts
(2) (2 used).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
12. Apply grease onto the thread part of pipe (1).
Install pipe (1) to casing (32).
: 22 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
 UPPERSTRUCTURE / Pump Device
STRUCTURE OF PILOT PUMP 9
8
6
1
2
3
7
6
5
4
3
2
1

10
11
13 12
6
1
2
3
7
6
14

3
2
1
15 WCEB-02-04-018

16
17

3 3 3 15

9
13

5
17

16

14

8 7 10 12 7

1 2 1 2 WCEB-02-04-010

W2-4-50
 UPPERSTRUCTURE / Pump Device

Wrench Size Tightening Torque

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
1 Plate Seal 4
2 Backup Ring 4
3 Side Plate 4
4 Rear Drive Gear 1
5 Driven Gear 1
6 Kmock Pin 8
7 Gear Plate 2
8 Cover 1
9 Socket Bolt 4
10 Coupling 1
11 Stabilizer 2
12 Center Plate 1
13 Driven Gear 1
14 Front Drive Gear 1
15 Flange 1
16 Oil Seal 1
17 Retaining Ring 1

W2-4-51
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-4-52
 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 1 2 3 2 4
1. Open cover (3).

2. Remove sems bolts (2) (4 used) from cover (4).

Remove cover (4) from bracket (1).
: 17 mm

WCJB-02-01-002

3. Disconnect hoses (5) (3 used) from piping (6). 5 6

Cap the open ends.
: 19 mm, 27 mm, 50mm

4. Remove signal control valve (7) from bracket (8).

(Refer to REMOVAL AND INSTALLATION OF 7
SIGNAL CONTROL VALVE on W2-9-1.)

5. Remove 4-spool solenoid valve unit from control

valve (9). (Refer to REMOVAL AND
INSTALLATION OF 4-SPOOL SOLENOID VALVE
UNIT on W2-11-1.)

6. Disconnect all connectors, hoses and pipings from

control valve (9). Cap the open ends. Attach an
identification tag onto the disconnected hoses for 10 9 8 WCJB-02-05-001
assembling.
: 17 mm, 19 mm, 22 mm, 36 mm
: 8 mm

W2-5-1
 UPPERSTRUCTURE / Control Valve
Eyebolt Mounting Hole Eyebolt Mounting Hole
CAUTION: The control valve (9) assembly
9
weight: 238 kg (560 lb)

7. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to

control valve (9). Attach a nylon sling onto
eyebolts. Hoist and hold control valve (9).

WCJB-02-05-022

8. Remove bolts (12) (4 used) and washers (11) (4

used) from brackets (13, 16). Hoist and remove 9
the control valve (9) assembly from the main
frame.
: 24 mm 12

11 12
CAUTION: Control valve (9) weight: 216 kg
(480 lb) 11

9. While holding the control valve (9) assembly, 16

remove bolts (15) (4 used) and spacers (14) (4 13
14
used) from brackets (13, 16). Remove brackets
(13, 16) from control valve (9). 15 14
: 24 mm 15

WCJB-02-05-002

W2-5-2
 UPPERSTRUCTURE / Control Valve
Eyebolt Mounting Hole Eyebolt Mounting Hole
Installation
9

CAUTION: Control valve (9) weight: 216 kg

(480 lb)

1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to

control valve (9). Attach a nylon sling onto the
eyebolt. Hoist and hold control valve (9).

WCJB-02-05-022

9
2. Install brackets (13, 16) to control valve (9) with
bolts (15) (4 used) and spacers (14) (4 used).
: 24 mm 12
: 210 N⋅m (21.5 kgf⋅m, 165 lbf⋅ft)
11 12

CAUTION: The control valve (9) assembly 11

weight: 238 kg (560 lb)
16
3. Hoist and align the control valve (9) assembly with 13
14
the mounting hole on the main frame. Install the
control valve (9) assembly to the main frame with 15 14
bolts (12) (4 used) and washers (11) (4 used). 15
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft) WCJB-02-05-002

W2-5-3
 UPPERSTRUCTURE / Control Valve
4. Connect all connectors, hoses and pipings to
control valve (9).
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 40 N⋅m (4 kgf⋅m, 30 lbf⋅ft)
: 36 mm
: 180 N⋅m (18 kgf⋅m, 133 lbf⋅ft)
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

9 WCJB-02-05-001

5. Install the 4-spool solenoid valve unit to control

valve (9). (Refer to REMOVAL AND
INSTALLATION OF 4-SOOL SOLENOID VALVE
on W2-11-1.)

6. Install signal control valve (7) to control valve (9). 7

(Refer to REMOVAL AND INSTALLATION OF
SIGNAL CONTROL VALVE on W2-9-1.)

WCJB-02-05-001
10 9

5 6

7. Connect hoses (5) (3 used) to piping (6).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 50 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

WCJB-02-05-001

W2-5-4
 UPPERSTRUCTURE / Control Valve
1 2 3 2 4
8. Install cover (4) to bracket (1) with sems bolts (2)
(4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

9. Shut cover (3).

WCJB-02-01-002

W2-5-5
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE 4-SPOOL SIDE
6
5

4 Check Valve
3 (Arm Regenerative 13 6
2 Circuit)
7
12
8
11
10
4
9 3
1 14

12
11

15
16

15

17
18 24
19 25
8 26
27
11 15 7 20 28 Boom Anti-Drift Valve
12 21 29
17 22 30
23
31
42 32
43 35 33
44 34
45
48 46 36
43 37
44 38 6
45 47 39
49
51 40
50 39 39
40
39 Travel 41
52 39 39
53 40 Bucket 41
40 39
52 Boom (1) 41
54 39
55 59
56 Arm (2) 41
57 63
59
58
Arm Regenerative Valve

62
4 60
61

WCJB-02-05-003

W2-5-6
 UPPERSTRUCTURE / Control Valve

68
69
4 Flow Combiner Valve
63 70
67 71
63 72
71
67
63 73
67
59
59
16
63 59 15
74
1

66
65
15
64 74
15
59

Bypass
103 Shut-Out
Valve
106 11
104
4 107 11
11
105 12
108
12
6
12
99
109
Arm 2 Flow Rate Bucket Flow Rate
110 100 Control Valve
Control Valve Boom Anti-Drift Valve
(Switch Valve) 111 101 84
112 102 75
113 85
87 87
86 76
114 77
77 87
18 83 82 77
115 77 78 88
18
119 18 89
116 127 18
117 77 78
128
115 118 92
129 90 79
120 121 93
116 121 91 80
120 94
122 95
117 81
125 96
123 126 97
116 6
124
121 120 115
98
117
98 WCJB-02-05-004

W2-5-7
 UPPERSTRUCTURE / Control Valve

1- Housing 34 - Plug 66 - Plug 98 - Socket Bolt (12 Used)

2- Poppet 35 - Spool 67 - Cap (3 Used) 99 - Poppet
3- Spring (2 Used) 36 - O-Ring 68 - Socket Bolt (2 Used) 100 - Poppet
4- O-Ring (4 Used) 37 - Backup Ring 69 - Cap 101 - Spring
5- Flange 38 - Plug 70 - Bolt 102 - Plug
6- Socket Bolt (13 Used) 39 - Spring Seat (8 Used) 71 - Spring Seat (2 Used) 103 - Spool
7- Plug (2 Used) 40 - Spring (4 Used) 72 - Spring 104 - Spring
8- O-Ring (2 Used) 41 - Bolt (4 Used) 73 - Spool 105 - Flange
9- Poppet 42 - Plug 74 - Overload Relief Valve (2 Used) 106 - O-Ring
10 - Spring 43 - Backup Ring (2 Used) 75 - Poppet 107 - Cap
11 - O-Ring (6 Used) 44 - O-Ring (2 Used) 76 - Spring 108 - Socket Bolt (4 Used)
12 - Plug (6 Used) 45 - Spring (2 Used) 77 - O-Ring (5 Used) 109 - Poppet
13 - Flange 46 - Poppet 78 - O-Ring (2 Used) 110 - Poppet
14 - Poppet 47 - Spool 79 - Body 111 - Spring
15 - O-Ring (6 Used) 48 - Plug 80 - O-Ring 112 - Plug
16 - Valve (2 Used) 49 - Poppet 81 - Plug 113 - Poppet
17 - Overload Relief Valve (2 Used) 50 - Spool 82 - O-Ring 114 - Spring
18 - O-Ring (12 Used) 51 - Spool 83 - Plug 115 - Plug (3 Used)
19 - O-Ring 52 - Spring Seat (2 Used) 84 - Poppet 116 - O-Ring (3 Used)
20 - Spring 53 - Spring 85 - Poppet 117 - Spring Seat (3 Used)
21 - Seat 54 - Spool 86 - Spring 118 - Spring
22 - Poppet 55 - O-Ring 87 - Plug 119 - Spool
23 - Backup Ring 56 - Backup Ring 88 - Spring (3 Used) 120 - Plug (3 Used)
24 - O-Ring 57 - Spool 89 - Sleeve 121 - O-Ring (3 Used)
25 - O-Ring 58 - Spring 90 - Plug 122 - Spring
26 - Backup Ring 59 - O-Ring (8 Used) 91 - O-Ring 123 - Spool
27 - Sleeve 60 - O-Ring 92 - Body 124 - Body
28 - Spool 61 - Plug 93 - Spool 125 - Spool
29 - O-Ring 62 - Cap 94 - Spring 126 - Spring
30 - Body 63 - Socket Bolt (14 Used) 95 - Spring Seat 127 - Plug
31 - Spring 64 - Cap 96 - O-Ring 128 - Plug
32 - Poppet 65 - O-Ring 97 - Plug 129 - O-Ring
33 - O-Ring

W2-5-8
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-9
 UPPERSTRUCTURE / Control Valve

6
5

4 Check Valve
3 (Arm Regenerative 13 6
2 Circuit)
7
12
8
11
10
4
9 3
1 14

12
11

15
16

15

17
18 24
25
26
8 27
11 15 7 20 28 Boom Anti-Drift Valve
21 29
12 22
17 30
23
31
32
35 33
34

6
47

51
50

54
55 59
56
57 63
59
58
Arm Regenerative Valve

62
4

WCJB-02-05-003

W2-5-10
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 4-Spool Side
• Disassembly of Spool
1. Remove socket bolts (63) (6 used) from cap (62).
Remove cap (62), O-rings (59) (4 used) and
O-ring (4) from housing (1).
: 8 mm
2. Put the matching marks on the spool (35, 47, 50,
51, 54) assemblies and housing (1). Remove the
spool (35, 47, 50, 51) assemblies, spring (58) and
the spool (54) assembly from housing (1).
NOTE: Do not disassemble the spool (54)
assembly unless necessary.
• Disassembly of Boom Anti-Drift Valve
3. Loosen plug (34) from body (30).
: 38 mm
4. Remove socket bolts (6) (3 used) from body (30).
Remove the body (30) assembly, O-rings (18) (6
used) and O-ring (29) from housing (1).
: 8 mm
5. Remove piston (32) and spring (31) from body
(30).
6. Remove the sleeve (27) assembly, seat (21) and
spring (20) from housing (1).
Remove backup rings (23, 26), O-rings (24, 25),
poppet (22) and spool (28) from sleeve (27).
W2-5-11
• Disassembly of Overload Relief Valve (17)
IMPORTANT: Do not disassemble the overload
relief valve. When disassembling the
overload relief valve, pressure must
be adjusted. (Refer to
TROUBLESHOOTING / Operational
Performance Test)
7. Remove overload relief valves (17) (2 used) from
housing (1).
: 32 mm
8. Remove valve (16) from housing (1).
: 32 mm
• Disassembly of Check Valve
9. Remove plug (12), spring (10) and poppet (9)
from housing (1).
: 6 mm
10. Remove socket bolts (6) (2 used) from flange (5).
Remove flange (5), O-ring (4), spring (3) and
poppet (2) from housing (1).
: 8 mm
11. Remove socket bolts (6) (2 used) from flange (13).
Remove flange (13), O-ring (4), spring (3) and
poppet (14) from housing (1).
: 8 mm
12. Remove plugs (7, 12) (2 used for each) from
housing (1).
: 6 mm, 10 mm
 UPPERSTRUCTURE / Control Valve

42
43 35
44
45
48 46 36
43 37
44 38
45 47 39
49
51 40
50 39 39
40
39 Travel 41
52 39 39
53 40 Bucket
41
40 39
52 Boom (1) 41
39
Arm (2) 41

WCJB-02-05-003

W2-5-12
 UPPERSTRUCTURE / Control Valve
• Disassembly of Travel Spool (35)
13. Clamp spool (35) in a vise by using wooden
pieces. Remove bolt (41), spring seat (39), spring
(40) and spring seat (39) from spool (35).
: 8 mm
• Disassembly of Bucket Spool (47)
14. Clamp spool (47) in a vise by using wooden
pieces. Remove bolt (41), spring seat (39), spring
(40) and spring seat (39) from spool (47).
: 8 mm
15. Warm up the plug (42) part of spool (47) by using
a drier. Remove plug (42) from spool (47) by using
special tool (ST 5909). Remove O-ring (44) and
backup ring (43) from plug (42).
ST 5909
W157-02-05-049
16. Remove spring (45) and poppet (46) from spool
(47).
W2-5-13
• Disassembly of Boom 1 Spool (50)
17. Clamp spool (50) in a vise by using wooden
pieces. Remove bolt (41), spring seat (39), spring
(40) and spring seat (39) from spool (50).
: 8 mm
18. Warm up the plug (48) part of spool (50) by using
a drier. Remove plug (48) from spool (50) by
using special tool (ST 5909). Remove O-ring (44)
and backup ring (43) from plug (48).
19. Remove spring (45) and poppet (49) from spool
(50).
• Disassembly of Arm 2 Spool (51)
20. Clamp spool (51) in a vise by using wooden
pieces. Remove bolt (41), spring seats (39, 52),
springs (53, 40) and spring seats (52, 39) from
spool (51).
: 8 mm
 UPPERSTRUCTURE / Control Valve

68
69
4 Flow Combiner Valve
63 70
67 71
63 72
71
67
63 73
67
59
59
16
63 59 15
74
1

66
65
15
64 74
15
59

99
109 Bucket Flow Rate
Arm 2 Flow Rate
100 Control Valve
Control Valve 110
(Switch Valve) 111 101 84
112 102
113 85
87 87
86
114 77
77 87
18
115 77 78 88
119 18 89
116 127 18
117 77
128
115 118 92
129 90
120 121 93
116 121 91
120 94
122 95
117 125 96
123 126 97
116
124
121 120 115
98
117
98 WCJB-02-05-004

W2-5-14
 UPPERSTRUCTURE / Control Valve
21. Remove socket bolts (63) (8 used) from caps (67)
(3 used) and cap (64). Remove caps (67) (3 used),
cap (64) and O-rings (59) (4 used) from housing
(1).
: 8 mm
• Disassembly of Flow Combiner Valve
22. Remove socket bolts (68) (2 used) from cap (69).
Remove cap (69), O-ring (4) and the spool (73)
assembly from housing (1). Remove bolt (70),
spring seats (71) (2 used) and spring (72) from
spool (73).
: 5 mm
• Disassemble Overload Relief Valve
IMPORTANT: Do not disassemble the overload
relief valve. When disassembling the
overload relief valve, pressure must
be adjusted. (Refer to
TROUBLESHOOTING / Operational
Performance Test)
23. Remove overload relief valves (74) (2 used) from
housing (1).
: 32 mm
24. Remove valve (16) from housing (1).
: 32 mm
27. Remove sleeve (89), spring (88), plug (87), spring
(86) and poppets (85, 84) from housing (1).
• Disassembly of Arm 2 Flow Rate Control Valve
28. Remove socket bolts (98) (8 used) from body
(124). Remove body (124), O-rings (77) (3 used),
O-rings (18) (2 used) (78) and plug (127) from
housing (1).
: 8 mm
29. Remove plugs (115) (3 used), spring seats (117)
(3 used), springs (118, 122, 126) and spools (119,
123, 125) from body (124).
: 24 mm
30. Remove plugs (120) (3 used) and plug (129) from
body (124).
31. Remove poppet (113) and spring (114) from
housing (1).
32. Remove the poppets (99, 109) assemblies and
springs (87) (2 used) from housing (1). Remove
plugs (102, 112), springs (101, 111) and poppets
(100, 110) from poppets (99, 109).

• Disassembly of Bucket Flow Rate Control Valve

25. Remove socket bolts (98) (4 used) from body (92).
Remove body (92) and O-rings (18, 77) from
housing (1).
: 8 mm

26. Remove plug (97), spring seat (95), spring (94)

and spool (93) from body (92). Remove plug (90)
from body (92).
: 27 mm

W2-5-15
 UPPERSTRUCTURE / Control Valve

Bypass
103 Shut-Out
Valve
106 11
104
4 107 11
11
105 12
108
12
6
12

Boom Anti-Drift Valve

75

76

77
18

78
79

WCJB-02-05-004

W2-5-16
 UPPERSTRUCTURE / Control Valve
• Disassembly of Boom Anti-Drift Valve
33. Remove socket bolts (6) (4 used) from body (79).
Remove body (79), O-rings (18) (3 used) and
O-rings (78, 77) from housing (1).
: 8 mm

34. Remove spring (76) and poppet (75) from housing

(1).

• Disassembly of Bypass Shut-Out Valve

35. Remove socket bolts (6) (2 used) from flange
(105). Remove flange (105) and O-ring (4) from
housing (1).
: 8 mm

36. Remove spring (104) and spool (103) from

housing (1).

37. Remove socket bolts (108) (4 used) from cap

(107). Remove cap (107) and O-ring (106) from
housing (1).
: 8 mm

38. Remove plugs (12) (3 used) from housing (1).

: 8 mm

W2-5-17
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE
4-SPOOL SIDE

63 63 1
60, 61 15, 16 63 1
59, 67 59, 67 63 59, 64 65, 66
15, 17 124 34 6 15, 17 59, 62
WCJB-02-05-006

A WCJB-02-05-005 Control Valve (Lower)

Control Valve (Upper)

15, 17 79 6 15, 17 11, 12 9, 10, 11, 12 6 3, 4, 13, 14

6
105

92

11, 12

7, 8 6 2, 3, 4, 5
106, 107 108 98 124 15, 74 98 1
WCJB-02-05-008
WCJB-02-05-007 View B
View A

W2-5-18
 UPPERSTRUCTURE / Control Valve

J I H G F E D C

A
W1V1-02-05-038

J I H G F E D C WCJB-02-05-005 Section C-C

Control Valve (Upper) (4-Spool Side)

Travel Bucket Boom 1

41
39
C

40
17
39
16 1
15 15 50
47

35
49 D
46
1
45 45
15 15
16 43, 44 15 43, 44 74
42 74 48
WCJB-02-05-020

Section D-D Section E-E W1V1-02-05-036

Section F-F W1V1-02-05-028

(4-Spool Side) (4-Spool Side) (4-Spool Side)

W2-5-19
 UPPERSTRUCTURE / Control Valve

Arm 2
61
62
60
41
39
17
52
53
52
39 15
1
51
F
E

65
W1V1-02-05-029
Section G-G 66 W1V1-02-05-030

(4-Spool Side) Section H-H

(4-Spool Side)

62

58
57 103 104 4

56, 55 105

54

107, 108

106

W1V1-02-05-071
Section I-I Section J-J WCJB-02-05-021

(4-Spool Side) (4-Spool Side)

W2-5-20
 UPPERSTRUCTURE / Control Valve

97
1
73 96

95
4 94
92
71 93
1 72
91
71
90
69 89
84 85 77 18 86 87 88
70 W1V1-02-05-033

W1V1-02-05-040
Detail A Detail B

34
33
30
32 77 18 1 120
31 121
28 29 1
119
27 22 18
78 124
18
26 81 118
25
24 80 117
23
21 116
20 79
115
82 99 100 101 102 87
83 W1V1-02-05-032

75 76 77
Detail C W1V1-02-05-031
Detail D

78 127 115 1
116 120
117
121
126

125
123

122
121 117
120 116
109 110 77
115
111 112 87 124
113 114 77 18 124
W1V1-02-05-042 W1V1-02-05-034
Detail E Detail F

W2-5-21
 UPPERSTRUCTURE / Control Valve

1 - Housing 34 - Plug 66 - Plug 98 - Socket Bolt (12 Used)

2 - Poppet 35 - Spool 67 - Cap (3 Used) 99 - Poppet
3 - Spring (2 Used) 36 - O-Ring 68 - Socket Bolt (2 Used) 100 - Poppet
4 - O-Ring (4 Used) 37 - Backup Ring 69 - Cap 101 - Spring
5 - Flange 38 - Plug 70 - Bolt 102 - Plug
6 - Socket Bolt (13 Used) 39 - Spring Seat (8 Used) 71 - Spring Seat (2 Used) 103 - Spool
7 - Plug (2 Used) 40 - Spring (4 Used) 72 - Spring 104 - Spring
8 - O-Ring (2 Used) 41 - Bolt (4 Used) 73 - Spool 105 - Flange
9 - Poppet 42 - Plug 74 - Overload Relief Valve (2 Used) 106 - O-Ring
10 - Spring 43 - Backup Ring (2 Used) 75 - Poppet 107 - Cap
11 - O-Ring (6 Used) 44 - O-Ring (2 Used) 76 - Spring 108 - Socket Bolt (4 Used)
12 - Plug (6 Used) 45 - Spring (2 Used) 77 - O-Ring (5 Used) 109 - Poppet
13 - Flange 46 - Poppet 78 - O-Ring (2 Used) 110 - Poppet
14 - Poppet 47 - Spool 79 - Body 111 - Spring
15 - O-Ring (6 Used) 48 - Plug 80 - O-Ring 112 - Plug
16 - Valve (2 Used) 49 - Poppet 81 - Plug 113 - Poppet
17 - Overload Relief Valve (2 Used) 50 - Spool 82 - O-Ring 114 - Spring
18 - O-Ring (12 Used) 51 - Spool 83 - Plug 115 - Plug (3 Used)
19 - O-Ring 52 - Spring Seat (2 Used) 84 - Poppet 116 - O-Ring (3 Used)
20 - Spring 53 - Spring 85 - Poppet 117 - Spring Seat (3 Used)
21 - Seat 54 - Spool 86 - Spring 118 - Spring
22 - Poppet 55 - O-Ring 87 - Plug 119 - Spool
23 - Backup Ring 56 - Backup Ring 88 - Spring (3 Used) 120 - Plug (3 Used)
24 - O-Ring 57 - Spool 89 - Sleeve 121 - O-Ring (3 Used)
25 - O-Ring 58 - Spring 90 - Plug 122 - Spring
26 - Backup Ring 59 - O-Ring (8 Used) 91 - O-Ring 123 - Spool
27 - Sleeve 60 - O-Ring 92 - Body 124 - Body
28 - Spool 61 - Plug 93 - Spool 125 - Spool
29 - O-Ring 62 - Cap 94 - Spring 126 - Spring
30 - Body 63 - Socket Bolt (14 Used) 95 - Spring Seat 127 - Plug
31 - Spring 64 - Cap 96 - O-Ring 128 - O-Ring
32 - Poppet 65 - O-Ring 97 - Plug 129 - Plug
33 - O-Ring

W2-5-22
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-23
 UPPERSTRUCTURE / Control Valve

K
K

1 63 65, 66
WCJB-02-05-005

1 59, 67 63 59, 67 63 59, 64

Control Valve (Upper) Control Valve (Lower) WCJB-02-05-006

Arm 2 Boom 1 Buckets Travel

41
39 41
39
52
40 40
53
39 1
52 39

47
51

35

50

49
46
45
45
43, 44
43, 44

59 59
63
64 67
WCJB-02-05-009
65 66 63 48 42
Section K-K

W2-5-24
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 4-Spool Side
• Assembly of Travel Spool
1. Clamp spool (35) in a vise by using wooden
pieces. Install spring seat (39), spring (40), spring
seat (39) and bolt (41) to spool (35).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
• Assembly of Bucket Spool
2. Clamp spool (47) in a vise by using wooden
pieces.
Install poppet (46) and spring (45) to the lower
side of spool (47).
3. Install O-ring (44) and backup ring (43) to plug
(42). Apply LOCTITE #271 onto the thread part of
plug (42).
4. Install plug (42) to spool (47) by using special tool
(ST 5909).
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
ST 5909
W157-02-05-049
5. Install spring seat (39), spring (40), spring seat
(39) and bolt (41) to the upper side of spool (47).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
W2-5-25
• Assembly of Boom 1 Spool
6. Clamp spool (50) in a vise by using wooden
pieces.
Install poppet (49) and spring (45) to the lower
side of spool (50).
7. Install O-ring (44) and backup ring (43) onto plug
(48). Apply LOCTITE #271 onto the thread of part
of plug (48).
8. Install plug (48) to spool (50) by using special tool
(ST 5909).
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
9. Install spring seat (39), spring (40), spring seat
(39) and bolt (41) to the upper side of spool (50).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
• Assembly of Arm 2 Spool
10. Clamp spool (51) in a vise by using wooden
pieces. Install spring seats (39, 52), springs (53,
40), spring seats (52, 39) and bolt (41) to spool
(51).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
11. Install O-ring (65) to plug (66). Install plug (66)
into cap (64).
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
12. Install O-rings (59) (4 used) onto housing (1).
Install caps (67) (3 used) and cap (64) to housing
(1) with socket bolts (63) (8 used).
 UPPERSTRUCTURE / Control Valve

63 60, 61 59, 62 63 1
Control Valve (Upper) WCJB-02-05-005
Control Valve (Lower)
WCJB-02-05-006

61
60
62

58

57 59
59 1
4

55, 56

54

WCJB-02-05-009

Section K-K

W2-5-26
 UPPERSTRUCTURE / Control Valve
13. Clamp spool (54) in a vise by using wooden
pieces. Install O-ring (55) and backup ring (56)
onto spool (57). Install spool (57) to spool (54).
Install spool (54) and spring (58) to housing (1).

14. Install the spool (51, 50, 47, 35) assemblies,

O-rings (59) (4 used) and O-ring (4) to housing (1).
Install cap (62) to housing (1) with socket bolts
(63) (6 used).
: 8 mm
: 42 N⋅m (4.3 kgf⋅m, 31 lbf⋅ft)

15. Install O-ring (60) to plug (61). Install plug (61)

into cap (62).
: 22 mm
: 54±3 N⋅m (5.5±0.3 kgf⋅m, 40±2 lbf⋅ft)

W2-5-27
 UPPERSTRUCTURE / Control Valve

15, 17

6
105
98

92

15, 74 69 68 1
Control Valve (Side) WCJB-02-05-007
Control Valve (Front) WCJB-02-05-008

103 104 4
97
1
96

95
105, 6
94
92
93

91
1
90
89
W1V1-02-05-033
84 85 77 18 86 87 88
WCJB-02-05-021

Bucket Flow Rate Control Valve (Detail B) Section of Bypass Shut-Out Valve

73
4

71

1 72
71

70 68, 69

W1V1-02-05-040
Section of Flow Combiner Valve
(Detail A)

W2-5-28
 UPPERSTRUCTURE / Control Valve
• Assembly of Bucket Flow Rate Control Valve
16. Install O-rings (96, 91) to plugs (97, 90).
17. Install spring (94), spool (93), spring seat (95) and
plug (97) to body (92).
18. Install plug (90) to body (92).
19. Install poppet (85), spring (86) and plug (87) to
poppet (84). Install the poppet (84) assembly,
spring (88) and sleeve (89) into housing (1).
20. Install O-rings (18, 77) into housing (1). Install
body (92) to housing (1) with socket bolts (98) (4
used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
• Assembly of Flow Combiner Valve
21. Install spring seat (71), spring (72) and spring
seat (71) to bolt (70). Install bolt (70) to spool (73).
22. Install spool (73) and O-ring (4) to housing (1).
Install cap (69) to housing (1) with socket bolts
(68) (2 used).
: 5 mm
: 10 N⋅m (1 kgf⋅m, 7 lbf⋅ft)
W2-5-29
• Assembly of Bypass Shut-Out Valve
23. Install spool (103), spring (104) and O-ring (4) to
housing (1). Install flange (105) to housing (1)
with socket bolts (6) (4 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
• Assembly of Overload Relief Valve
IMPORTANT: If the overload relief valve is
disassembled, pressure must be
adjusted.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
24. Install O-rings (15) (4 used) to overload relief
valves (17, 74) (2 used for each). Install overload
relief valves (17, 74) (2 used for each) to housing
(1).
: 32 mm
: 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)
 UPPERSTRUCTURE / Control Valve

9, 10, 11, 12 6 3, 4, 13, 14

11, 12

7, 8

106, 107 108 1 6 2, 3, 4, 5

Control Valve (Side) WCJB-02-05-007
Control Valve (Front) WCJB-02-05-008

W1V1-02-05-033
WCJB-02-05-021

Bucket Flow Rate Control Valve (Detail B) Section of Bypass Shut-Out Valve

Section of Flow Combiner Valve W1V1-02-05-040

(Detail A)

W2-5-30
 UPPERSTRUCTURE / Control Valve
• Assembly of Check Valve
25. Install O-ring (11) to plug (12). Install poppets (9)
(2 used), spring (10) and plug (12) into housing
(1).
: 6 mm
: 76±3 N⋅m (7.7±0.3 kgf⋅m, 56±2 lbf⋅ft)

26. Install plugs (7, 12) (2 used for each) to housing

(1).
: 6 mm
: 76±3 N⋅m (7.7±0.3 kgf⋅m, 56±2 lbf⋅ft)
: 10 mm
: 106 to 141 N⋅m
(10.8 to 14.4 kgf⋅m, 78 to 104 lbf⋅ft)

27. Install poppets (2, 14), springs (3) (2 used) and

O-rings (4) (2 used) to housing (1).

28. Install flanges (5, 13) to housing (1) with socket

bolts (6) (4 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

29. Install O-ring (106) to housing (1). Install cap

(107) to housing (1) with socket bolts (108) (4
used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

W2-5-31
 UPPERSTRUCTURE / Control Valve

79 6 34 30 6

(Arm 2 Flow Rate Control Valve) 124 1 WCJB-02-05-007

Control Valve (Side)

34
33
30
32 77 18 1 120
31 121
28 29 1 119
27 22 18
124
78
18
26 81 118
25
24 80 117
23
21 116
20 79 115
82 99 100 101 102 87
W1V1-02-05-032
83
75 76 77
Boom Anti-Drift Valve (Detail C) W1V1-02-05-031 Arm 2 Flow Rate Control Valve (Detail D)

78 127 115 1
120
116
117
121
126

125 123

122
121 117
116
120
109 110 77
W1V1-02-05-042
115
111 112 87 124 113 114 77 18 124
W1V1-02-05-034
Arm 2 Flow Rate Control Valve (Detail E) Arm 2 Flow Rate Control Valve (Detail F)

W2-5-32
 UPPERSTRUCTURE / Control Valve
• Assembly of Boom Anti-Drift Valve
30. Install backup rings (23, 26) and O-rings (24, 25)
to sleeve (27).
31. Face the hole on spool (28) to the poppet (22)
side. Install spool (28), poppet (22), seat (21) and
spring (20) to sleeve (27). Install the sleeve (27)
assembly to housing (1).
NOTE: Apply grease onto seat (21) and spring
(20)in order to fall off.
32. Install O-ring (33) to plug (34). Install spring (31),
piston (32), O-ring (29) and plug (34) to body (30).
33. Install O-rings (18) (3 used) to housing (1). Install
the body (30) assembly to housing (1) with socket
bolts (6) (3 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
34. Tighten plug (34).
35. Install O-rings (80, 82) to plugs (81, 83).
36. Install poppet (75), spring (76), O-rings (77, 78)
and O-rings (18) (3 used) to housing (1).
37. Install body (79) to housing (1) with socket bolts
(6) (4 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
38. Tighten plugs (81, 83).
W2-5-33
• Assembly of Arm 2 Flow Rate Control Valve
39. Install O-rings (116, 121) (3 used for each) to
plugs (115, 120) (3 used for each) as shown in
detail D, E and F.
40. Install spool (119), spring (118) and spring seat
(117) to body (124) as shown in detail D.
Temporarily tighten plugs (115, 120) to body
(124).
41. Install spool (123), spring (122) and spring seat
(117) to body (124) as shown in detail F.
Temporarily tighten plugs (115, 120) to body
(124).
42. Install plug (127), spool (125), spring (126) and
spring seat (117) to body (124) as shown in detail
E. Temporarily tighten plugs (115, 120) to body
(124).
43. Install poppet (100), spring (101) and plug (102)
to poppet (99)as shown in detail D. Install the
poppet (99) assembly, spring (87) O-rings (18, 77)
to housing (1).
44. Install poppet (99), poppet (110), spring (111) and
plug (112) to poppet (109) as shown in detail E.
Install the poppet (109) assembly, spring (87),
O-ring (77, 78) into housing (1).
45. Install poppet (113), spring (114) and O-rings (77,
18) to housing (1) as shown in detail F.
 UPPERSTRUCTURE / Control Valve

(Arm 2 Flow Rate Control Valve)124 98 WCJB-02-05-007

Control Valve (Side)

120

124

115

W1V1-02-05-032
Boom Anti-Drift Valve (Detail C) W1V1-02-05-031 Arm 2 Flow Rate Control Valve (Detail D)

115
120

120
W1V1-02-05-042
115
W1V1-02-05-034

Arm 2 Flow Rate Control Valve (Detail E) Arm 2 Flow Rate Control Valve (Detail F)

W2-5-34
 UPPERSTRUCTURE / Control Valve
46. Install body (124) to housing (1) with socket bolts
(98) (8 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

47. Tighten plugs (115, 120) (3 used for each) to body

(124).

W2-5-35
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE 5-SPOOL SIDE

3 7 8
2 7 8
6
5 9
4 10 13
11 12
14
15
1
16
17
14 18
15

12
13 19

20
21
31 26
27 33 25
28 24
35 23 Check Valve
29
37 22
30 (5-Spool Side Parallel Circuit)
32
34 38
Arm Anti-Drift Valve 36 39
40
41
42
8
46 43
44
48 47 43 43
44 45
43
49 43 43 Blade/Outrigger
50 44 45
51 43
44 Auxiliary
45
49
43 43 Boom 2
44 45
43 Arm 1
45
52 53
Swing

54
52 55

56
WCJB-02-05-010

W2-5-36
 UPPERSTRUCTURE / Control Valve
Auxiliary Flow Rate
58 Control Valve
57 59
60

Arm 1 Flow Rate Control Valve 79

58 80
57 59 63
60 20 64
65
61 9
62 Load Check Valve
63 66
(Boom 2 Parallel Circuit) 8
20 64 67
65 8 81
9 82
66 77 7
8 83
67
72 84
68 73 6
69
70 9 5
71 10 Check Valve 85
74
9
78
75
Load Check Valve 8
76 (Blade/Outrigger)
20
92 Arm Anti-Drift Valve
88 86
93 92
89 87
6 93
90 Load Check Valve
94 6 (Travel)
97 94 91
95
98 13
101 96 12
53 13
102 25
103
99 12 107
104 53
3 105 100 52 13
101
2 106 12
107
53 52

102 99 1
53
52
53
99
52
13
52 12

99

WCJB-02-05-011

W2-5-37
 UPPERSTRUCTURE / Control Valve

1- Housing 28 - Seat 55 - Plug 82 - Spring

2- O-Ring 29 - Poppet 56 - Cap 83 - Poppet
3- Plug 30 - Backup Ring 57 - Socket Bolt (8 Used) 84 - Poppet
4- Poppet 31 - O-Ring 58 - Plug (2 Used) 85 - Poppet
5- Spring 32 - O-Ring 59 - O-Ring (2 Used) 86 - Cover (2 Used)
6- O-Ring (3 Used) 33 - Backup Ring 60 - Body (2 Used) 87 - O-Ring (2 Used)
7- Flange (3 Used) 34 - Sleeve 61 - Spool 88 - Plug
8- Socket Bolt (22 Used) 35 - Spool 62 - Spring 89 - O-Ring
9- O-Ring (5 Used) 36 - O-Ring 63 - Spring Seat (2 Used) 90 - Spring
10 - Spring (2 Used) 37 - Body 64 - O-Ring (2 Used) 91 - Poppet
11 - Poppet 38 - Spring 65 - Plug (2 Used) 92 - Socket Bolt (4 Used)
12 - O-Ring (4 Used) 39 - Piston 66 - Sleeve (2 Used) 93 - Cap (2 Used)
13 - Plug (4 Used) 40 - O-Ring 67 - Spring (2 Used) 94 - Spring Seat (2 Used)
14 - O-Ring (2 Used) 41 - Plug 68 - Plug 95 - Spring
15 - Overload Relief Valve (2 Used) 42 - Spool 69 - Spring 96 - Spool
16 - O-Ring 43 - Spring Seat (10 Used) 70 - Poppet 97 - Spring
17 - Backup Ring 44 - Spring (5 Used) 71 - Poppet 98 - Spool
18 - Plug 45 - Bolt (5 Used) 72 - Plug 99 - Cap (4 Used)
19 - Main Relief Valve 46 - Spool 73 - O-Ring 100 - Cap
20 - O-Ring (6 Used) 47 - Spool 74 - Flange 101 - Overload Relief Valve (2 Used)
21 - O-Ring 48 - Spool 75 - Spring 102 - O-Ring (2 Used)
22 - Spacer 49 - Spring Seat (2 Used) 76 - Poppet 103 - Plug
23 - Backup Ring 50 - Spring 77 - Flange (2 Used) 104 - Backup Ring
24 - O-Ring 51 - Spool 78 - Poppet (2 Used) 105 - O-Ring
25 - Spring 52 - O-Ring (10 Used) 79 - Spool 106 - Plug
26 - Poppet 53 - Socket Bolt (16 Used) 80 - Spring 107 - O-Ring
27 - Spring 54 - O-Ring 81 - Plug

W2-5-38
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-39
 UPPERSTRUCTURE / Control Valve

7 8
7 8
6
5 9
4 10
11
14
15
1

14
15

19

20
21
31 26
27 33 25
24 Check Valve
28 35 23 (5-Spool Side Parallel Circuit)
29
30 37 22
32
34 38
Arm Anti-Drift Valve 36 39
40
41
42
8
46

48 47

Blade/Outrigger

51 Auxiliary

Boom 2

Arm 1

52 53
Swing

52

56
WCJB-02-05-010

W2-5-40
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 5-Spool Side
• Disassembly of Spool
1. Remove socket bolts (53) (6 used) from cap (56).
Remove cap (56) and O-rings (52) (5 used) from
housing (1).
: 8 mm
2. Put the matching marks on spools (42, 46, 47, 48,
51) and housing (1). Remove the spools (42, 46,
47, 48, 51) assemblies from housing (1).
• Disassembly of Arm Anti-Drift Valve
3. Remove plug (41) from body (37).
: 38 mm
4. Remove socket bolts (8) (3 used) from body (37).
Remove the body (37) assembly, O-rings (21, 36)
and O-rings (20) (4 used) from housing (1).
: 8 mm
5. Remove piston (39) and spring (38) from body
(37).
: 38 mm
6. Remove spool (35), sleeve (34), poppet (29), seat
(28) and spring (27) from housing (1).
Remove backup rings (30, 33) and O-rings (31,
32) from sleeve (34).
W2-5-41
• Disassembly of Overload Relief Valve (15)
IMPORTANT: Do not disassemble the overload
relief valve. When disassembling the
overload relief valve, pressure must
be adjusted. (Refer to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
7. Remove overload relief valves (15) (2 used) from
housing (1). Remove O-rings (14) (2 used) from
overload relief valves (15) (2 used).
: 32 mm
• Disassembly of Main Relief Valve (19)
IMPORTANT: Do not disassemble the main relief
valve. When disassembling the main
relief valve, pressure must be
adjusted. (Refer to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
8. Remove main relief valve (19) from housing (1).
: 32 mm
• Disassembly of Check Valve
9. Remove spacer (22), spring (25) and poppet (26)
from housing (1). Remove backup ring (23) and
O-ring (24) from spacer (22).
10. Remove socket bolts (8) (2 used) from flange (7).
Remove flange (7), O-ring (6), spring (5) and
poppet (4) from housing (1).
: 8 mm
11. Remove socket bolts (8) (2 used) from flange (7).
Remove flange (7), O-ring (9), spring (10) and
poppet (11) from housing (1).
: 8 mm
 UPPERSTRUCTURE / Control Valve

3
2

13
12

1
16
17
18

12
13

42

46 43
44
48 47 43 43
44 45
43
49 43 43
Blade/Outrigger
50 44 45
51 43
44 Auxiliary
45
49
43 43 Boom 2
44 45
43 Arm 1
45
Swing

WCJB-02-05-010

W2-5-42
 UPPERSTRUCTURE / Control Valve
12. Remove plugs (13) (2 used) and plug (3) from • Disassembly of Swing Spool (51)
housing (1). Remove O-rings (12) (2 used) and 18. Clamp spool (51) in a vise by using wooden
O-ring (2) from plugs (13) (2 used) and plug (3). pieces. Remove bolt (45), spring seat (43), spring
: 8 mm (44) and spring seat (43) from spool (51).
: 8 mm
13. Remove plug (18) from housing (1). Remove
backup ring (17) and O-ring (16) from plug (18).
: 24 mm

• Disassembly of Blade/Outrigger Spool (42)

14. Clamp spool (42) in a vise by using wooden
pieces. Remove bolt (45), spring seat (43), spring
(44) and spring seat (43) from spool (42).
: 8 mm

• Disassembly of Auxiliary Spool (46)

15. Clamp spool (46) in a vise by using wooden
pieces. Remove bolt (45), spring seat (43), spring
(44) and spring seat (43) from spool (46).
: 8 mm

• Disassembly of Boom 2 Spool (47)

16. Clamp spool (47) in a vise by using wooden
pieces. Remove bolt (45), spring seat (43), spring
(44) and spring seat (43) from spool (47).
: 8 mm

• Disassembly of Arm 1 Spool (48)

17. Clamp spool (48) in a vise by using wooden
pieces. Remove bolt (45), spring seats (43, 49),
springs (44, 50) and spring seats (43, 49) from
spool (48).
: 8 mm

W2-5-43
 UPPERSTRUCTURE / Control Valve

Auxiliary Flow Rate Control Valve

58
57 59
60

Arm 1 Flow Rate Control Valve 79

58 80
57 59 63
60 20 64
65
61 9
62
63 66
8
20 64 67
65 81
9 82
66 7
8 83
67
84
68 6
69
70 5
71 Check Valve 85
74
9

75

76 20
Arm Anti-Drift Valve
92
Digging Regenerative Valve
93 92
6 93 Auxiliary Flow Combiner Valve
94 6
97 94
95
98
101 96
53
102
99
53
100 52
101

53 52

102 99 1
53
52
53
99
52

52

99

WCJB-02-05-011

W2-5-44
 UPPERSTRUCTURE / Control Valve
19. Remove socket bolts (53) (10 used) from caps
(99) (4 used) and cap (100). Remove caps (99) (4
used), cap (100) and O-rings (52) (5 used) from
housing (1).
: 8 mm
• Disassembly of Digging Regenerative Valve and
Auxiliary Flow Combiner Valve
20. Remove socket bolts (92) (4 used) from caps (93)
(2 used). Remove caps (93) (2 used), O-rings (6)
(2 used), spring seats (94) (2 used), springs (95,
97) and spools (96, 98) from housing (1).
: 5 mm
• Disassembly of Overload Relief Valve (101)
IMPORTANT: Do not disassemble overload relief
valve (101). When disassembling the
overload relief valve, pressure must
be adjusted. (Refer to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
21. Remove overload relief valves (101) (2 used)
from housing (1). Remove O-rings (102) (2 used)
from overload relief valves (101) (2 used).
: 32 mm
• Disassembly of Check Valve
22. Remove socket bolts (8) (2 used) from flange (7).
Remove flange (7), O-ring (6), spring (5) and
poppet (85) from housing (1).
: 8 mm
W2-5-45
• Disassembly of Arm Anti-Drift Valve
23. Remove socket bolts (8) (4 used) from flange (74).
Remove flange (74), O-rings (20) (3 used), O-ring
(9), spring (75) and poppet (76) from housing (1).
: 8 mm
• Disassembly of Arm 1 Flow Rate Control Valve and
Auxiliary Flow Rate Control Valve
24. Loosen plugs (58, 65) (2 used for each) from
bodies (60) (2 used).
25. Remove socket bolts (57) (8 used) from body (60)
(2 used). Remove O-rings (20, 9) (2 used for
each) from housing (1).
: 8 mm
26. Remove plugs (65) (2 used), spring seats (63) (2
used), springs (63, 80) and spools (61, 79) from
bodies (60) (2 used). Remove plugs (58) (2 used)
from bodies (60) (2 used).
27. Remove O-rings (59, 64) (2 used for each) from
plugs (58, 65) (2 used for each).
28. Remove sleeves (66) (2 used), springs (67) (2
used), plugs (68, 81), springs (69, 82) and
poppets (70, 71, 83, 84) from housing (1).
 UPPERSTRUCTURE / Control Valve

Load Check Valve

(Boom 2 Parallel Circuit)
8

77

10

78

Load Check Valve 8

(Blade/Outrigger)

88 86

89 87
90
Load Check Valve
91 (Travel)

13
12
13
25
103
12 107
104
3 105 13
2 12

99

WCJB-02-05-011

W2-5-46
 UPPERSTRUCTURE / Control Valve
• Disassembly of Load Check Valve 35. Remove plugs (13) (2 used) from housing (1).
29. Remove socket bolts (8) (4 used) from flange (77). Remove O-rings (12) (2 used) from plugs (13) (2
Remove flange (77), O-ring (9), spring (10) and used).
poppet (78) from housing (1). : 8 mm
: 8 mm

30. Remove socket bolts (8) (4 used) from cover (86).

Remove cover (86) and O-ring (87) from housing
(1).
: 8 mm

31. Remove plug (88), spring (90) and poppet (91)

from housing (1). Remove O-ring (89) from plug
(88).
: 24 mm

32. Remove plug (13), spring (25) and poppet (107)

from housing (1). Remove O-ring (12) from plug
(13).
: 8 mm

12 25 107
13

W1V1-02-05-016

33. Remove plug (103) from housing (1). Remove

backup ring (104) and O-ring (105) from plug
(103).
: 24 mm

34. Remove plug (3) from housing (1). Remove

O-ring (2) from plug (3).
: 10 mm

W2-5-47
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE
5-SPOOL SIDE
A

53 52, 99 53 52, 100 53 52, 99 53 52, 99

53 54, 55 52, 56 53 1
53
52, 99

WCJB-02-05-006

Control Valve (Upper) WCJB-02-05-005

Control Valve (Lower)

12, 13 8
19 15 18 15 41 37
7, 9, 10, 11

8
1
8
8
74

2, 3
57

57 4, 5, 6, 7
12, 13

93 W1V1-02-05-068

101 60 103 77 93 60 101 99 53

View B
View A WCJB-02-05-012

W2-5-48
 UPPERSTRUCTURE / Control Valve

J I H G F E D C

19
1

12, 13
5

7
98

6
85
97
94
93
W1V1-02-05-043
J I H G F E D C WCJB-02-05-005
Section C-C
Control Valve (Upper)
(5-Spool Side)

Blade/Outrigger Auxiliary Boom 2

56
45 55

43 54
14, 15 14, 15
44

43 86 78
10
52 8 47
9
46
A 77
42 8

1 8 107 1
52
99
99 86 1 106
W1V1-02-05-046

101, 102
WCJB-02-05-013
101, 102 Section F-F
WCJB-02-05-014 (5-Spool Side)
Section D-D Section E-E
(5-Spool Side) (5-Spool Side)

W2-5-49
 UPPERSTRUCTURE / Control Valve

Arm 1 Swing
45
43
49
C
50
44
15 49 78
43 10 51
14 48

9
D 8

77

B 1
102
1
101
W1V1-02-05-052
W1V1-02-05-051

Section G-G W1V1-02-05-050

Section H-H Section I-I
(5-Spool Side) (5-Spool Side) (5-Spool Side)

88 89 90 91

65
1
64

63
80
60 1
79

59
58
66
W1V1-02-05-033 W1V1-02-05-053
84 83 9 20 82 81 67 13 12 2 3
Detail A Detail B

W2-5-50
 UPPERSTRUCTURE / Control Valve

41
40
39
37
65 66 67 1 9 70 71
38
29
35
64
36
34 63
33 62
20 32
20 31 61
30
28
27

60 58 59 68 20 69 WCJB-02-05-015

73 72 9 75 76
W1V1-02-05-054 Detail D
Detail C

1- Housing 28 - Seat 55 - Plug 82 - Spring

2- O-Ring 29 - Poppet 56 - Cap 83 - Poppet
3- Plug 30 - Backup Ring 57 - Socket Bolt (8 Used) 84 - Poppet
4- Poppet 31 - O-Ring 58 - Plug (2 Used) 85 - Poppet
5- Spring 32 - O-Ring 59 - O-Ring (2 Used) 86 - Cover (2 Used)
6- O-Ring (3 Used) 33 - Backup Ring 60 - Body (2 Used) 87 - O-Ring (2 Used)
7- Flange (3 Used) 34 - Sleeve 61 - Spool 88 - Plug
8- Socket Bolt (22 Used) 35 - Spool 62 - Spring 89 - O-Ring
9- O-Ring (5 Used) 36 - O-Ring 63 - Spring Seat (2 Used) 90 - Spring
10 - Spring (2 Used) 37 - Body 64 - O-Ring (2 Used) 91 - Poppet
11 - Poppet 38 - Spring 65 - Plug (2 Used) 92 - Socket Bolt (4 Used)
12 - O-Ring (4 Used) 39 - Piston 66 - Sleeve (2 Used) 93 - Cap (2 Used)
13 - Plug (4 Used) 40 - O-Ring 67 - Spring (2 Used) 94 - Spring Seat (2 Used)
14 - O-Ring (2 Used) 41 - Plug 68 - Plug 95 - Spring
15 - Overload Relief Valve (2 Used) 42 - Spool 69 - Spring 96 - Spool
16 - O-Ring 43 - Spring Seat (10 Used) 70 - Poppet 97 - Spring
17 - Backup Ring 44 - Spring (5 Used) 71 - Poppet 98 - Spool
18 - Plug 45 - Bolt (5 Used) 72 - Plug 99 - Cap (4 Used)
19 - Main Relief Valve 46 - Spool 73 - O-Ring 100 - Cap
20 - O-Ring (6 Used) 47 - Spool 74 - Flange 101 - Overload Relief Valve (2 Used)
21 - O-Ring 48 - Spool 75 - Spring 102 - O-Ring (2 Used)
22 - Spacer 49 - Spring Seat (2 Used) 76 - Poppet 103 - Plug
23 - Backup Ring 50 - Spring 77 - Flange (2 Used) 104 - Backup Ring
24 - O-Ring 51 - Spool 78 - Poppet (2 Used) 105 - O-Ring
25 - Spring 52 - O-Ring (10 Used) 79 - Spool 106 - Plug
26 - Poppet 53 - Socket Bolt (16 Used) 80 - Spring 107 - O-Ring
27 - Spring 54 - O-Ring 81 - Plug

W2-5-51
 UPPERSTRUCTURE / Control Valve

53 54, 55 52, 56 53 1 53 52, 99 53 52, 100 53 52, 99 53 52, 99

53
52, 99

L L

WCJB-02-05-005 WCJB-02-05-006
Control Valve (Upper) Control Valve (Lower)

Blade/Outrigger Auxiliary Boom 2 Arm 1 Swing

55
54 45
45
56 43 43
49
50 44
44 43
49 52
1 43

51

42

48

46

47

52 52
53

99 107 106 100 99 99 99

WCJB-02-05-016
Section L-L

W2-5-52
 UPPERSTRUCTURE / Control Valve
• Assembly of Blade/Outrigger Spool
1. Secure spool (42) in a vise by using wooden
pieces. Install spring seat (43), spring (44), spring
seat (43) and bolt (45) to spool (42).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
• Assembly of Auxiliary Spool
2. Secure spool (46) in a vise by using wooden
pieces. Install spring seat (43), spring (44), spring
seat (43) and bolt (45) to spool (46).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
• Assembly of Boom 2 Spool
3. Secure spool (47) in a vise by using wooden
pieces. Install spring seat (43), spring (44), spring
seat (43) and bolt (45) to spool (47).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
10. Install plug (55) to cap (56).
• Assembly of Arm 1 Spool
4. Secure spool (48) in a vise by using wooden
pieces. Install spring seats (43, 49), springs (44,
50), spring seats (43, 49) and bolt (45) to spool
(48).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
6. Install O-rings (52) (5 used) onto housing (1).
Install cap (100) and cap (99) (4 used) to housing
(1) with socket bolts (53) (10 used).
: 8 mm
: 42±2 N⋅m (4.3±0.2 kgf⋅m, 31±1 lbf⋅ft)
7. Install the spools (42, 46, 47, 48, 51) assemblies
to housing (1).
8. Install O-rings (52) (5 used) to housing (1). Install
cap (56) to housing (1) with socket bolts (53) (6
used).
: 8 mm
: 42±2 N⋅m (4.3±0.2 kgf⋅m, 13±1 lbf⋅ft)
9. Install O-rings (54, 107) to plugs (55, 106). Install
plug (106) to cap (100).
: 22 mm
: 53±3 N⋅m (5.4±0.3 kgf⋅m, 39±2lbf⋅ft)
: 22 mm
: 54±3 N⋅m (5.5±0.3 kgf⋅m, 40±2 lbf⋅ft)

• Assembly of Swing Spool

5. Secure spool (51) in a vise by using wooden
pieces. Install spring seat (43), spring (44), spring
seat (43) and bolt (45) into spool (51).
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

W2-5-53
 UPPERSTRUCTURE / Control Valve
8 16, 17, 18

86, 87
7 6 5 85

57

60

8
92

1
Check Valve W1V1-02-05-047

WCJB-02-05-012
93 86, 87 8 77 8
Control Valve (Side)

65 66 67 1 9 83 84

64

63
98
80
6
79
1
97

94
66 58 59 81 20 82 WCJB-02-05-015

93

Auxiliary Flow Combiner Valve

WCJB-02-05-017 Section of Auxiliary Flow Rate Control Valve
(Detail A)

8 77 9 10 78

1
Load Check Valve W1V1-02-05-049

W2-5-54
 UPPERSTRUCTURE / Control Valve
• Assembly of Auxiliary Flow Rate Control Valve
11. Install O-rings (59, 64) to plugs (58, 65).
12. Install spring (80), spool (79), spring seat (63) and
plug (65) to body (60).
13. Install plug (58) to body (60).
14. Install poppet (83), spring (82) and plug (81) to
poppet (84). Install the poppet (84) assembly,
spring (67) and sleeve (66) to housing (1).
• Assembly of Load Check Valve
18. Install poppet (78), spring (10) and O-ring (9) to
housing (1).
19. Install flange (77) to housing (1) with socket bolts
(8) (4 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
20. Install O-ring (16) and backup ring (17) to plug
(18). Install plug (18) to housing (1).

15. Install O-rings (9, 20) into housing (1). Install body 21. Install O-rings (87) (2 used) to housing (1). Install
(60) to housing (1) with socket bolts (57) (4 used). covers (86) (2 used) to housing (1) with socket
: 8 mm bolts (8) (8 used).
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft) : 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
• Assembly of Check Valve
16. Install poppet (85), spring (5) and O-ring (6) to
housing (1). Install flange (7) to housing (1) with
socket bolts (8) (2 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

• Assembly of Auxiliary Flow Combiner Valve

17. Install spool (96), spring (95) and spring seat (94)
to housing (1). Install cap (93) to housing (1) with
socket bolts (92) (2 used).
: 5 mm
: 10±1 N⋅m (1±0.1 kgf⋅m, 7±4 lbf⋅ft)

W2-5-55
 UPPERSTRUCTURE / Control Valve
37 8

60

57

Control Valve (Front) W1V1-02-05-068

Control Valve (Side) WCJB-02-05-012

41
40
39
78
29 38
1 35
36
34
33
20
32
20 31
30
28
27

Section of Load Check Valve (Detail B)

W1V1-02-05-053
73 72 9 75 76 W1V1-02-05-054

Section of Anti-Drift Valve (Detail C)

65 66 67 1 9 70 71

64

63

62

61

W1V1-02-05-055
60 58 59 68 20 69 WCJB-02-05-015 Section of Load Check Valve

Section of Arm Flow Rate Control Valve (Detail D)

W2-5-56
 UPPERSTRUCTURE / Control Valve
• Assembly of Arm Anti-Drift Valve 31. Install O-rings (20) (3 used) and O-ring (9) to
22. Install backup rings (30, 33) and O-rings (31, 32) housing (1). Install body (60) to housing (1) with
to sleeve (34). socket bolts (57) (4 used).
: 8 mm
23. Face the hole on spool (35) to the poppet (29) : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
side. Install spool (35), poppet (29), seat (28) and
spring (27) to sleeve (34). Install the sleeve (34)
assembly to housing (1).
NOTE: Apply grease to seat (28) and spring (27) in
order not to drop.

24. Install O-ring (40) onto plug (41). Install spring

(38), piston (39), O-ring (36) and plug (41) to body
(37).

25. Install O-rings (20) (3 used) and O-ring (21) to

housing (1). Install the body (37) assembly to
housing (1) with socket bolts (8) (2 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

26. Tighten plug (41).

• Assembly of Arm Flow Rate Control Valve

27. Install O-rings (59, 64) to plugs (58, 65).

28. Install spring (62), spool (61), spring seat (63) and
plug (65) to body (60).

29. Install plug (58) to body (60).

30. Install poppet (70), spring (69) and plug (68) to

poppet (71). Install the poppet (71) assembly,
spring (67) and sleeve (66) to housing (1).

W2-5-57
 UPPERSTRUCTURE / Control Valve
19 14, 15 14, 15
12, 13 8
7, 9, 10, 11

2, 3

1 4, 5, 6, 7
12, 13
101, 102 103, 104, 105 101, 102
Control Valve (Front)
W1V1-02-05-068
Control Valve (Side) WCJB-02-05-012

88 89 90 91

13

W1V1-02-05-053
12 2 3

Section of Load Check Valve (Detail B)

W1V1-02-05-054
Section of Arm Anti-Drift Valve (Detail C)

8 77 9 10 78

1
WCJB-02-05-015
Section of Load Check Valve W1V1-02-05-055

Section of Arm Flow Rate Control Valve (Detail D)

W2-5-58
 UPPERSTRUCTURE / Control Valve
• Assembly of Load Check Valve
32. Install O-ring (89) to plug (88). Install poppet (91),
spring (90) and plug (88) to housing (1).
33. Install poppet (78), spring (10) and O-ring (9) to
housing (1). Install flange (77) to housing (1) with
socket bolts (8) (4 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
34. Install O-rings (2, 12) to plugs (3, 13). Install plugs
(3, 13) to housing (1).
• Assembly of Overload Relief Valve
IMPORTANT: If the overload relief valve is
disassembled, pressure must be
adjusted. (Refer to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
35. Install O-rings (14, 102) (2 used for each) to
overload relief valves (15, 101) (2 used for each).
Install overload relief valves (15, 101) (2 used for
each) to housing (1).
: 32 mm
: 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)
36. Install O-ring (105) and backup ring (104) to plug
(103). Install plug (103) to housing (1).
W2-5-59
• Assembly of Main Relief Valve
IMPORTANT: If the main relief valve is
disassembled, pressure must be
adjusted. (Refer to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
37. Install main relief valve (19) to housing (1).
: 32 mm
: 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)
• Assembly of Check Valve
38. Install poppet (4), spring (5) and O-ring (6) to
housing (1). Install flange (7) to housing (1) with
socket bolts (8) (2 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
39. Install poppet (11), spring (10) and O-ring (9) to
housing (1). Install flange (7) to housing (1) with
socket bolts (8) (2 used).
: 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
40. Install O-rings (12) (2 used) to plugs (13) (2 used).
Install plugs (13) (2 used) to housing (1).
41. Install O-ring (2) to plug (3). Install plug (3) into
housing (1).
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF HOUSING

3
3

4
4 5
4
5
4
5 4
4 6
4
6
4

5
5 4

W1V1-02-05-023

1 - Housing (5-Spool Side) 3 - Socket Bolt (9 Used) 5 - O-Ring (12 Used) 6- O-Ring (3 Used)
2 - Housing (4-Spool Side) 4 - O-Ring (16 Used)

W2-5-60
 UPPERSTRUCTURE / Control Valve
Disassembly of Housing

CAUTION: Housing (1, 2) weight: 150 kg (340

lb) for each

1. Remove socket bolts (3) (9 used) from housing

(1). Remove O-rings (4) (16 used), O-rings (5) (12
used) and O-rings (6) (3 used) from housing (1 or
2).
: 14 mm

2. Divide housing (1) and (2).

W2-5-61
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF HOUSING
4 5 2

4
4

5 6

4 5
6
6
5
5

4
4

4 5 W1V1-02-05-011

3
3

3
WCJB-02-05-018

1 - Housing (5-Spool Side) 3 - Socket Bolt (9 Used) 5 - O-Ring (12 Used) 6- O-Ring (3 Used)
2 - Housing (4-Spool Side) 4 - O-Ring (16 Used)

W2-5-62
 UPPERSTRUCTURE / Control Valve
Assembly of Housing

1. Install O-rings (4) (16 used), O-rings (5) (12 used)

and O-rings (6) (3 used) to the housing (2)
mounting surface.

CAUTION: Housing (1, 2) weight: 150 kg (340

lb) for each

2. Install housing (1) to housing (2) with socket bolts

(3) (9 used).
: 14 mm
: 205 to 215 N·m
(21 to 22 kgf·m, 152 to 159 lbf⋅ft)

W2-5-63
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-64
 UPPERSTRUCTURE / Control Valve
REMOVAL AND INSTALLATION OF
POSITIONING 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 3
1. Disconnect hoses (1) (6 used) from valve (3).
Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 19 mm, 27 mm

2. Remove sems bolts (2) (3 used) from valve (3).

Remove valve (3) from bracket (4).
: 17 mm

WCJB-02-05-019

1 2 3 4

WCEB-02-05-011

Installation 1 2 3 4
1. Install valve (3) to bracket (4) with sems bolts (2)
(3 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 1

2. Connect hoses (1) (6 used) to valve (3).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

WCEB-02-05-011

W2-5-65
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF POSITIONING
CONTROL VALVE 19
10 20
21
9 22
8 23
7
6 24
25
5 26
4 27
3 28
2
1

37

38 29
30
39 31
18 32
17 33
40 34
16
15 41 35
14 36
13 42
12 43
11 44

56 45
55
54
53 46
52 47
51
48 62
61
60

50
49
59
58
57
W198-02-05-001

1- Nut 17 - Sleeve 33 - Backup Ring (2 Used) 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring (2 Used) 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring (2 Used) 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Poppet 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Rivet
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring (2 Used) 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring

W2-5-66
 UPPERSTRUCTURE / Control Valve
Disassembly of Positioning Control Valve 6. Remove sleeve assembly (37 to 42) from
housing (62).
1. Remove socket bolts (45) (2 used) and socket : 36 mm
bolts (48, 49) from covers (46, 50). Remove
covers (46, 50) and O-rings (47, 56) from 7. Remove spring (43) and poppet (44) from
housing (62). housing (62).

IMPORTANT: Turn and remove the spools. If they
stick even a little, try again instead
of pulling roughly.
2. Remove spool assembly (51 to 59) from housing
(62).
8. Secure seat (37) in a vise. Remove sleeve (41),
spring (40) valve (39) and O-rings (38, 42) from
seat (37).
: 36 mm

3. Clamp spool (57) in a vise by using wooden

pieces. Remove end spool (51), seat (52),
springs (53, 54) and seat (55) from spool (57).
: 8 mm

4. Remove plug (59) from spool (57). Remove

O-ring (58) from plug (59).

IMPORTANT: Do not disassemble overload relief

valve assemblies (1 to 18), (19 to 36)
as since they have been preset at
the set pressures.
5. Remove overload relief valve assemblies (1 to
18), (19 to 36) from housing (62).
: 32 mm
NOTE: Each of overload relief valve assemblies (1
to 18), (19 to 36) has a different set
pressure. Thus they should be identified
for reassembling.

W2-5-67
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF POSITIONING CONTROL
VALVE
Section X-X 37 39 40 38
41

43
62
42
44
1 to 18 A1 B1 19 to 36

A1 B1
X X

W198-02-05-003

57

W198-02-05-002

Section W-W

54 53 55 56 62
50 51 52 47

48 45

W W

W198-02-05-004 57 59 58 46
49 W198-02-05-005

1- Nut 17 - Sleeve 33 - Backup Ring (2 Used) 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring (2 Used) 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring (2 Used) 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Poppet 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Rivet
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring (2 Used) 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring

W2-5-68
 UPPERSTRUCTURE / Control Valve
Assembly of Positionnig Control Valve
1. Clamp seat (37) in a vise. Install O-ring (38),
valve (39), spring (40), sleeve (41) and O-ring
(42) to seat (37).
: 36 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
2. Insert poppet (44) and spring (43) into housing
(62).
3. Install the seat (37) assembly to housing (62).
: 36 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
IMPORTANT: Each of overload relief valve
assemblies (1 to 18), (19 to 36) has a
different set pressure. Do not install
at an incorrect position.
4. Install overload relief valve assemblies (1 to 18),
(19 to 36) to housing (62).
: 32 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
IMPORTANT: Install the spool (57) assembly into
housing (62) and check if it moves
smoothly by hand.
7. Insert spool (57) assemblies (51 to 59) into
housing (62) from the port A1 side.
NOTE: If any of spool assembly (51 to 59) is not
straight inserted, forced insertion can
result in flaws on the bore of housing (62)
or spool (57). Insert it straight.
8. Install O-rings (47, 56) to covers (46, 50). Install
covers (46, 50) to housing (62) with socket bolts
(45) (2 used) and socket bolts (48, 49).
: 6 mm
: 25.5 N⋅m (2.6 kgf⋅m, 19 lbf⋅ft)

5. Install O-ring (58) to plug (59).

6. Clamp spool (57) in a vise by using wooden

pieces. Install plug (59) to spool (57). Install seat
(55), springs (53, 54), seat (52) and end spool
(51) from the opposite side.
: 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft)
: 8 mm
: 18.6 N⋅m (1.9 kgf⋅m, 14 lbf⋅ft)

W2-5-69
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-70
 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 1 2 3 4
1. Open cover (2).

2. Remove sems bolts (3) (4 used) from cover (1).

Remove cover (1) from stay (4).
: 17 mm

3. Remove socket bolts (7) (8 used) and split flanges

(6) (4 used). Disconnect hoses (8) (12 used) from
swing motor (2). Remove O-rings (9) (2 used)
from hose (8). Remove swing dampener valve WCJB-02-01-002

(10) and O-ring (11) from swing motor (12).

5 6 7 8, 9
: 8 mm

4. Disconnect hoses (5) (4 used) from swing motor

(12). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm, 36 mm

5. Disconnect connector (14) from pressure switch

(13). 10, 11

6. Remove pressure switch (13) from swing motor 5

(12).
: 24 mm

7. Attach a nylon sling onto the body of swing motor 12

(12). Hoist and hold the swing motor (12)
assembly.
WCJB-02-06-005
Nylon sling (eye-type at both ends): 2 pieces 14 13

W2-6-1
 UPPERSTRUCTURE / Swing Device

CAUTION: Swing device (15) weight: 220 kg

(490 lb)

8. Disconnect hose (19) from center joint (20). Cap

the open ends.
: 27 mm

9. Remove bolts (16) (12 used) and washers (17) 16, 17

15
(12 used) from swing device (15). Remove swing
device (15) from main frame (18). 18
: 30 mm
19
NOTE: When hoisting swing device (15), the
20
machine may float up. If this occurs,
remove plugs (21) (2 places) and float 21 WCJB-02-06-006

swing device (15) from main frame (18) by

using the pulling-out bolts (M20, Pitch 2.5
mm) (2 used).
NOTE: The number of hoses around the swing
device is different according to specification
of the front attachment. Do not damage the
hoses when removing and installing the
swing device.

Installation

CAUTION: Swing device (15) weight: 220 kg

(490 lb)

1. Hoist and align swing device (15) with the

mounting holes on main frame (18). Install swing
device (15) to main frame (18) with bolts (16) (12 16, 17
15
used) and washers (17) (12 used).
: 30 mm 18
: 500 N⋅m (50 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: Apply THREEBOND #1102 onto the

mounting surface of the swing
device and main frame (18). WCJB-02-06-006

W2-6-2
 UPPERSTRUCTURE / Swing Device
2. Connect hose (19) to center joint (20). 14 13
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

3. Install pressure switch (13) to swing motor (12).

: 24 mm
: 16 N⋅m (1.6 kgf⋅m, 12 lbf⋅ft)
12
4. Connect connector (14) to pressure switch (13).

19

20
WCJB-02-06-006

5 6 7 8, 9
5. Connect hoses (5) (4 used) to swing motor (12).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

6. Apply grease onto O-rings (9, 11). Install O-rings

(9, 11) to hoses (8) (2 used) and swing dampener
valve (10). 10, 11

5
7. Install swing dampener valve (10) and hoses (8)
(2 used) to swing motor (12) with split flanges (6)
(4 used) and socket bolts (7) (8 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 12

WCJB-02-06-005

1 2 3 4
8. Install cover (1) to stay (4) with sems bolts (3) (4
used). Shut cover (2).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: After completing the work, fill the

swing motor with hydraulic oil.
Check the hydraulic oil level. Start
the engine and check for any oil
leaks. WCJB-02-01-002

W2-6-3
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING DEVICE

22
23 1

24

32 21
25 4

31 5

20 6

26 7
19
8

27
18 9

28 10
17
11
29
16
12

30 15 13

14

W178-02-06-004

1- Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- First Stage Planetary Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (8 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe

W2-6-4
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Device 5. Put the matching marks at the jointed part
between motor (1) and ring gear (24), between
ring gear (24) and housing (25).
CAUTION: Swing device weight: 220 kg (490
lb)
CAUTION: Motor (1) weight: 47 kg (110 Ib)
CAUTION: When hoisting the swing device,
do not string the rope suddenly. 6. Remove socket bolts (22) (8 used) from motor (1).
Remove motor (1) from ring gear (24).
1. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to : 10 mm
motor (1). Attach a nylon sling onto eyebolts.
Hoist motor (1). NOTE: THREEBOND has been applied onto the
jointed surface. For easy removal, insert a
Eyebolt
Mounting
screwdriver into the gap around the jointed
Position part in order to float.

7. Remove first stage sun gear (2) from first stage

carrier (21).

8. Remove the first stage carrier (21) assembly from

W178-02-06-005
ring gear (24).

2. Place the swing device on bracket (ST 5097).
Secure the swing device onto the bracket by
using the bolts (M22, Pitch 2.5 mm) (2 used). At
this time, insert the stopper at the bottom of the
bracket between teeth of the pinion gear. Secure
the bracket on a workbench in order to reduce the
reaction force.
: 30 mm
Swing Device
ST 5097
Stopper
9. Remove socket bolts (23) (12 used) from ring
gear (24).
: 14 mm
CAUTION: Ring gear (24) weight: 23 kg (51
Ib)
10. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the motor (1) mounting thread part on ring gear
(24). Attach a nylon sling onto eyebolts. Hoist and
remove ring gear (24) from housing (25).
NOTE: THREEBOND has been applied onto the
jointed surface. For easy removal, insert a
screwdriver into the gap around the jointed
part in order to float.

W178-02-06-012 11. Remove second stage sun gear (20) from second
stage carrier (18).
3. Remove drain plug (31) from pipe (32). Drain off
oil from the swing device.
: 8 mm

4. Remove pipe (32) from housing (25).

: 18 mm

W2-6-5
UPPERSTRUCTURE / Swing Device

23

25 21
4

18

10
17
11
16
12

30 15

W178-02-06-004

W2-6-6
 UPPERSTRUCTURE / Swing Device
12. Remove the second stage carrier (18) assembly 20. Remove bearing nut (15) from shaft (30), by using
from shaft (30). special tool (ST 2926).
ST 2926
IMPORTANT: The hole for spring pin (5) located on
first stage carrier (21) is not a 15
through one. Check the tapping-in
distance of spring pin (5).
13. Tap spring pins (5) (3 used) installed to the first
stage carrier (21) assembly into pin (4) by using
special tool (ST 1462). At this time, stop tapping
when spring pin (5) reaches the middle of pin (4)
hole and do not tap spring pin (5) to the end.

14. Remove pin (4), planetary gear (7), needle

bearing (6) and thrust plate (8) from first stage W178-02-06-008

carrier (21).
CAUTION: The housing (25) assembly
15. Remove other two sets of pin (4), planetary gear weight: 122 kg (270 lb)
(7), needle bearing (6) and thrust plate (8) from
first stage carrier (21) in the same order as steps 21. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
13 and 14. the bolt (23) hole on housing (25). Attach a nylon
sling onto eyebolts. Hoist and remove bracket (ST
16. Remove thrust plate (3) from first stage carrier 5097) from housing (25).
(21). : 30 mm

IMPORTANT: Do not damage the rotating surface 22. After removing bracket (ST 5097), install bracket
for the needle bearing of pin (4) (ST 1464). Set housing (25) to a press.
except for the both ends. : 30 mm
17. Secure the end of pins (4) (3 used) opposite the Press
spring pin (5) hole in a vise. Tap and remove
spring pins (5) (3 used) by using special tool
(ST 1462).

18. Disassemble the second stage carrier (18)

assembly in the same way as the first stage carrier 25
(21) assembly. Note that second stage carrier (18)
assembly includes of needle bearings (12) (6
used) and thrust plates (11) (6 used). Use special
ST 1464
tool (ST 1463) when removing spring pins (10) (3
used).

19. Remove bolts (17) (2 used) from lock plate (16).

Remove lock plate (16) from bearing nut (15).
W178-02-06-006

W2-6-7
UPPERSTRUCTURE / Swing Device

25

26

27

28

29

30

14

W178-02-06-004

W2-6-8
 UPPERSTRUCTURE / Swing Device
23. Push shaft (30) by using a press. Remove shaft
(30) from housing (25). At this time, the inner race
of roller bearing (26) and sleeve (28) are removed
with shaft (30) together.
24. Place special tool (ST 1460) for removing roller
bearing (26) onto the stepped part of special tool
(ST 1461) for removing roller bearing (26).
ST 1460
26. Remove the splined side of shaft (30) by using a
press. Remove the inner race of roller bearing
(26) and sleeve (28) from shaft (30).
27. Remove O-ring (29) from sleeve (28).
28. Insert a round bar into the oil passage in housing
(25). Tap and remove outer race of roller bearing
(26).

ST 1461 Outer Race of Oil Passage

Roller Bearing
(26)

W178-02-06-010 W178-02-06-001

CAUTION: Housing (25) weight: 60 kg (140

lb)
CAUTION: Shaft (30) weight: 40 kg (90 lb)
29. Fasten the body of housing (25) by using a nylon
25. Insert the pinion gear of shaft (30) into tooth-hole sling. Hoist and turn over housing (25).
of special tool (ST 1460). Set them onto a press.
30. Insert a screwdriver into the notch on housing
Press (25), where oil seal (27) is mounted. Remove oil
seal (27) from housing (25).
NOTE: THREEBOND has been applied onto the
periphery of oil seal (27). Therefore, oil seal
(27) cannot be reused.
30
31. Tap and remove the outer race of roller bearing
(14) from housing (25) by using a bar and
26
hammer.

ST 1460 28
ST 1461

W178-02-06-009

W2-6-9
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING DEVICE

1
4 5

2 22

21 7

6
20
8
18
10
24
11
19
12
23

13
17
11

16
9

15 14

32

26

25 31

27
28

29
30 WCJB-02-06-001

1- Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- First Stage Planetary Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (8 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe

W2-6-10
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Device

1. Apply grease onto O-ring (29). Install O-ring (29)

onto sleeve (28).
CAUTION: Shaft (30) + sleeve (28) + roller
bearing (26) outer race weight: 36 kg (80 lb)
2. Install sleeve (28) and the inner race of roller
bearing (26) to shaft (30). Install sleeve (28) and
the inner race together by using special tool (ST
2923) and a press.
NOTE: The press-in distance of inner race of roller
bearing (26) can be assured by using
special tool.
5. Apply THREEBOND #1215 onto the outer surface
of oil seal (27). Place oil seal (27) flat on housing
(25) and push by hands in gently. Place special
tool (ST 2925) on oil seal (27). Tap in special tool
by using a hammer straight.
NOTE: The seal can be replaced by using special
tool (ST2925) without removing the sleeve.
ST 2925
27
25

Press

W178-02-06-007

6. Apply grease onto the inner surface of oil seal

ST 2923
(27). Apply grease onto the outer surface of
26 sleeve (28) attached with shaft (30).
NOTE: Apply grease carefully when installing shaft
28
(30) in order not to curl the lip.
30
CAUTION: Housing (25) + outer race weight:
63 kg (140 lb)

W178-02-06-013 7. Fasten the body of housing (25) by using a nylon

sling. Hoist and place housing (25) with the ring
gear (24) side facing upward.
CAUTION: Housing (25) weight: 60 kg (140
lb)
8. Tap and install the outer race of roller bearing (14)
to housing (25) by using a bar and hammer. Tap
3. Fasten the body of housing (25) by using a nylon
and listen to ring in order to check if the
sling. Hoist and place housing (25) with the
installation is completed.
sleeve (28) mounting side facing upward.

4. Evenly tap and install the outer race of roller

bearing (26) into housing (25) by using a bar and
hammer. Tap and listen to ring in order to check if
the installation is completed.

W2-6-11
 UPPERSTRUCTURE / Swing Device

24

23

15 14

25

27

30 WCJB-02-06-001

W2-6-12
 UPPERSTRUCTURE / Swing Device
14. Place special tool (ST 2924) on the inner race of
CAUTION: Housing (25) + outer races (2
roller bearing (14). Install the inner race by using a
used) weight: 65 kg (150 lb) press.
9. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to NOTE: The press-in distance of inner race can be
the bolt (23) hole on housing (25). Hoist and place assured by using special tool.
housing (25) on shaft (30) so that they are ST 2924
matched. At this time, check and align carefully in
order to prevent the oil seal (27) lip from curling.
14
10. Tap and install the inner race of roller bearing (14)
into shaft (30) by using a bar and hammer. Tap the
inner race until the upper end of inner race
reaches two threads for bearing nut (15) in shaft
(30).
NOTE: The fitting between inner race and shaft
(30) is tight. W178-02-06-011

11. Tighten bearing nut (15) to shaft (30) by hand.

NOTE: Prevent shaft (30) from falling off when
hoisting housing (25).
CAUTION: Housing (25) + shaft (30)
bearing total weight: 122 kg (270 lb)
12. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
the ring gear (24) mounting thread part on
housing (25). Hoist and place housing (25) on a
press.
13. Remove bearing nut (15) from shaft (30).
15. Hoist and place the housing (25) assembly on
bracket (ST 5097). Install bolts (M20, Pitch 2.5
mm) (2 used). At this time, insert the stopper at
the bottom of the bracket between teeth of the
+ pinion gear. Secure the bracket on a workbench in
order to reduce the reaction force.
: 30 mm
25
ST 5097

Stopper W178-02-06-012

W2-6-13
 UPPERSTRUCTURE / Swing Device

4 5

22

21 7

8
18
10

11
19
12

13
17
11

16
9

15

30 WCJB-02-06-001

W2-6-14
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Check the direction to install bearing
nut (15).
16. Apply a film of grease onto the thread part of
bearing nut (15). Install bearing nut (15) to shaft
(30). At this time, face the stepped side of bearing
nut (15) to the roller bearing (14) side. Tighten
bearing nut (15) by using special tool (ST 2926) to
the specified torque.
: 490 N⋅m (50 kgf⋅m, 361 lbf⋅ft)
NOTE: Apply grease for keeping correct tightening
torque.
ST 2926 15
W178-02-06-008
17. Install lock plate (16) to bearing nut (15) with bolts
(17) (2 used). In case the splines of lock plate (16
and shaft (30) are not aligned, tighten bearing nut
(15) in tightening direction until both splines are
aligned.
IMPORTANT: Check the direction to install thrust
plate (19).
18. Install thrust plate (19) to second stage carrier
(18) with the oil groove surface facing outside.
19. Clamp planetary gear (13) and needle bearings
(12) (2 used) with thrust plates (11) (2 used).
Install them to second stage carrier (18).
W2-6-15
20. Install pin (9) to the position where planetary gear
(13) has been installed onto second stage carrier
(18) with the spring pin hole facing front. At this
time, the spring pin holes both in second stage
carrier (18) and pin (9) should be in line.
IMPORTANT: Check the direction of spring pin
(10).
21. Install spring pin (10) to second stage carrier (18)
by using spring pin removal and installation
special tool (ST 1463). At this time, face the slit of
spring pin to the end of pin (9).
10
9
Slit
W178-02-06-002
22. Install planetary gears (13) (2 used), needle
bearings (12) (4 used), thrust plates (11) (4 used),
pins (9) (2 used) and spring pins (10) (2 used) into
other holes (2 places) on second stage carrier
(18) in the same way as steps 19 to 21.
IMPORTANT: Check the position to install thrust
plate (8).
23. Install thrust plate (3), planetary gears (7) (3 used),
needle bearings (6) (3 used), thrust plates (8) (3
used), pins (4) (3 used) and spring pins (5) (3
used) to the first stage carrier (21) in the same
way as steps 19 to 21. At this time, install thrust
plate (8) under needle bearing (6). Use special
tool (ST 1462).
 UPPERSTRUCTURE / Swing Device

2 22

21

20

18

24

23

16

32

31
25

30 WCJB-02-06-001

W2-6-16
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Check the direction to install second IMPORTANT: Check the direction to install first
stage carrier (18). stage sun gear (2).
24. Install the second stage carrier (18) assembly to 30. Install first stage sun gear (2) into the first stage
the spline of shaft (30). At this time, the concave carrier (21) assembly. At this time, face the
part of the boss in bottom side of second stage stepped part facing downward.
carrier (18) should come in contact with lock plate
(16). Concave 18 31. Wind the seal tape onto the thread part of pipe
Part (32). Install pipe (32) to housing (25). Face the
16
30
pipe (32) downward.
: 18 mm

32. Wind the seal tape onto drain plug (31). Install
drain plug (31) to pipe (32).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

33. Add gear oil to ring gear (24) until gear oil reaches
W178-02-06-014
the middle part of first stage sun gear (2). (Approx.
6.9 L, 1.8 US gal)
25. Install second stage sun gear (20) to the second
34. Apply THREEBOND #1215 onto the motor (1)
stage carrier (18) assembly with the small
mounting surface of ring gear (24). Clean old
diameter part facing upward.
adhesive in advance.
26. Apply THREEBOND #1215 onto the ring gear
(24) mounting surface of housing (25). Clean off CAUTION: Motor (1) weight: 47 kg (110 Ib)
old adhesive in advance.
35. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
27. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to motor (1). Hoist and install motor (1) to ring gear
the motor mounting thread part on ring gear (24). (24) with socket bolts (22) (8 used) while aligning
Hoist and align ring gear (24) with the mounting the matching marks.
holes on housing (25). At this time, align the : 10 mm
matching marks made when disassembling. : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
Eyebolt
28. Install ring gear (24) into housing (25) with socket Mounting
bolts (23) (12 used). Position
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 16 lbf⋅ft)

29. Install the first stage carrier (21) assembly onto

the spline of second stage sun gear (20).
W178-02-06-005

W2-6-17
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING MOTOR

10

8
7
6
5

4 11

3
2
24
25 29
26 30
1 27 31
28

23 27
26
25
24

12
13
14 22
15 21 32
16 20
W178-02-06-015
19
18
17

1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Friction Plate (3 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Plate (4 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)

W2-6-18
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Motor

IMPORTANT: Do not damage the mating surfaces

CAUTION: The swing motor assembly
when separating valve plate (21)
weight: 47 kg (110 lb) from valve casing (28) or rotor (9) by
using a screwdriver. (Check the
IMPORTANT: Do not disassemble relief valve (32). surfaces of valve plate (2) in order
1. Remove relief valves (32) (2 used) from valve not to make a mistake for
casing (28). assembling.)
: 41 mm 7. If valve plate (21) is still on rotor (9) in step 5,
remove valve plate (21) from the rotor (19) side.
2. Remove plugs (24) (2 used) from valve casing Remove springs (20) (24 used) from brake piston
(28). (19).
: 14 mm

3. Remove springs (26) (2 used) and poppets (27) CAUTION: There is also a method of
(2 used) from valve casing (28). applying air from port B in order to float
brake piston (19). Prevent piston (13) from
4. Put the matching marks on the jointed surface flying out.
between valve casing (28) and casing (1).
Remove socket bolts (29) (4 used) from valve 8. Install special tool (ST 1468) to notch A of brake
casing (28). At this time, as the clearance exists piston (19). Remove brake piston (19) from
between valve casing (28) and casing (1), record casing (1).
this clearance.
: 17 mm
Notch A
5. Remove valve casing (28) from casing (1).
NOTE: At this time, as valve casing (28) may be
removed with valve plate (21) together, do
not drop valve plate (21).

6. Remove O-ring (23) from valve casing (28).

Port B

WCJB-02-06-003

9. Remove O-rings (17, 18) from casing (1).

W2-6-19
 UPPERSTRUCTURE / Swing Device

10

8
7
6
5

4 11

3
2

13
14
15
W178-02-06-015

W2-6-20
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Do not damage the sliding surfaces
of rotor (9) and plunger (6).
10. Place casing (1) horizontally. Remove rotor (9),
retainer (8), plate (7) and plungers (6) (9 used)
from shaft (4).

11. Remove plates (11) (4 used) and friction plates

(10) (3 used) from casing (1).

IMPORTANT: Do not damage the sliding surface of

shoe plate (5).
12. Remove shoe plate (5) from casing (1).

13. Lightly tap and remove shaft (4) from casing (1)
by using a plastic hammer.

14. Remove the outer race of bearing (3) from casing

(1) by using a bar.

15. Remove oil seal (2) from casing (1).

16. Remove the inner race of roller bearing (3) from

shaft (4) by using a press.

IMPORTANT: Although the filter and the orifice are

installed to piston (13), do not
disassemble piston (13) unless they
are clogged or deformed.
When replacing the internal parts,
replace as an assembly.
17. Remove piston (13) from casing (1) by using a
pair of pliers.

18. Remove spring (14) and ball (15) from casing (1).

W2-6-21
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING MOTOR

27 26 25

12

24 13

14

15

16
29

WCJB-02-06-003
WCJB-02-06-002

31

30
32
28

22 21

23 20

18 19

17 11

10 6

9
8
7

5
3

1
2

4
WCJB-02-06-004

1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Friction Plate (3 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Plate (4 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)

W2-6-22
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Motor
IMPORTANT: Install the inner race of bearing (3)
with the flange part facing to the
stepped side of shaft (4).
1. Install the inner races of bearings (3, 22) to shaft
(4) by using a press.
IMPORTANT: Install oil seal (2) with the lip part
facing upward.
2. Install oil seal (2) to casing (1) by using a plate.
3. Install the outer race of bearing (3) into casing (1)
by using a bar.
IMPORTANT: Wind the tape onto the spline at the
end of shaft (4) in order not to
damage oil seal (2).
4. Install shaft (4) with casing (1).
5. Place casing (1) with the valve casing (28)
mounting surface facing upward. Install shoe
plate (5) with the chamfered surface facing inside.
IMPORTANT: Install retainer (8) to plunger (6) with
the notch facing to the shoe plate (5)
side.
6. Align the notches on plate (7) and retainer (8).
Install plungers (6) (9 used).
8. Place casing (1) horizontally. Install the rotor (9)
assembly to shaft (4) by turning shaft (4).
IMPORTANT: There are 4 notches on the outer
side of plate (11), and 4 notches at
the spline teeth side of friction plate
(10). Align each notch at the same
place when installing.
9. Place casing (1) vertically. Alternately install
plates (11) (4 used) and friction plates (10) (3
used) to casing (1).
10. Install O-rings (17, 18) onto casing (1).
11. Align the matching marks and install brake piston
(19) into casing (1).
NOTE: If it is not easy to install brake piston (19)
due to the resistant force from O-rings (17,
18), tap them evenly by using a plastic
hammer.
12. Install springs (20) (24 used) to brake piston (19).

IMPORTANT: Install plunger (6) to after applying

hydraulic oil onto the plunger (6)
hole on rotor (9).
7. Install plungers (6) (9 used) to rotor (9).

W2-6-23
 UPPERSTRUCTURE / Swing Device

27 26 25

24 13

14

15

29

WCJB-02-06-003
WCJB-02-06-002

32
28

22 21

23

4
WCJB-02-06-004

W2-6-24
 UPPERSTRUCTURE / Swing Device
IMPORTANT: When replacing the inner parts of 18. Install valve casing (28) to casing (1) with socket
piston (13), replace the piston (13) bolts (29) (4 used).
as an assembly. : 17 mm
Install so that the ends of piston (13) : 430 N⋅m (44 kgf⋅m, 317 lbf⋅ft)
and casing (1) may be in the same
position. 19. Install poppets (27) (2 used) and springs (26) (2
13. Install ball (15), spring (14) and piston (13) to used) into valve casing (28). Install plug (24) with
casing (1). O-ring (25) attached.
: 14 mm
IMPORTANT: Tap the bearing type indicated : 330 N⋅m (34 kgf⋅m, 243 lbf⋅ft)
surface by using a plastic hammer
and install roller bearing (22). 20. Install relief valves (32) (2 used) into valve casing
14. Install the outer race of bearing (22) to valve (28).
casing (28) by using a plastic hammer. : 41 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
IMPORTANT: Check the surfaces of valve plate
(21).
(Face the notch of the port to rotor
(9).)
15. Install O-ring (23) to valve casing (28). Install
valve plate (21) to valve casing (28).
NOTE: Apply grease onto valve plate (21) in order
to prevent valve plate (21) from falling off
from valve casing (28).

16. Apply grease onto the needle part of bearing (22).

NOTE: Shaft (4) can be inserted easily by holding
the needle with grease.

17. Align the matching marks on valve casing (28)

and casing (1). Place valve casing (28) onto
casing (1). Check that the clearance between
valve casing (28) and casing (1) is equal to that
before disassembling. At this time, if the
clearance is larger than that before disassembling,
repeat the installation from step 5.

W2-6-25
 UPPERSTRUCTURE / Swing Device
STRUCTURE OF SWING DAMPENER VALVE

1 2 3

4 5 6 7

WCJB-02-06-007

Wrench Size Tightening Torque

Item Parts Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
Swing Damperner valve
1 2
Assembly
2 Plug 3 : 4 9 (0.9) (7)
3 Casing 1
4 O-Ring 2
5 Backup Ring 2
6 Case 2 : 24 69 (7) (51)
7 Plug 2 : 8

W2-6-26
 UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD
Swing Motor

1. Clearance between plunger outer diameter and

d
rotor inner bore

D-d
Standard Allowable Limit
0.027 mm (0.001 in) 0.052 mm (0.002 in)
W107-02-06-138

D D

W107-02-06-139

2. Clearance between plunger and shoe bottom

Standard Allowable Limit Plunger

0 mm 0.3 mm (0.012 in)

Shoe
δ

W107-02-06-140

W2-6-27
 UPPERSTRUCTURE / Swing Device
3. Shoe thickness

Standard Allowable Limit

5.5 mm (0.22 in) 5.3 mm (0.2 in)

W107-02-06-142
4. Friction plate thickness

Standard Allowable Limit

2.0 mm (0.08 in) 1.8 mm (0.07 in)

W107-02-06-143

W2-6-28
 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 Left Pilot Valve 1 2 3 4 5

CAUTION: Seat (1) weight: 40 kg (90 lb)

1. Remove sems bolts (4) (2 used) from seat belts

(6) (2 used). Remove seat belt (6) from brackets 6
(5) (2 used).
: 16 mm

WCEB-02-01-001

6 4 5 2 3

WCEB-02-01-017

2. Remove socket bolts (3) (4 used) from seat (1).

Remove seat (1) from plate (2).
: 6 mm 3

WCEB-02-01-002

2
7

3. Remove screws (9) (4 used) from boot (7). Raise

boot (7) from bracket (8). 8

W1JB-02-07-002

W2-7-1
 UPPERSTRUCTURE / Pilot Valve
4. Remove screw (10) from covers (11, 12).

10

12
11

WCEB-02-07-001

5. Remove sems bolt (14) from cover (11). Remove

screws (13) (3 used) from covers (11, 12). Re-
move covers (11, 12) from bracket (8).
: 10 mm 12

11

13

14 WCEB-02-07-003

11

13

12

8 13 WCEB-02-07-004

W2-7-2
 UPPERSTRUCTURE / Pilot Valve
6. Remove clip bands (17) (2 used) from lever (15) 15 16 17
and harness (18). Disconnect a connector from
harness (18).

7. Loosen lock nut (16). Remove lever (15) assem-

bly from pilot valve (19).
: 19 mm, 22 mm 18

8. Disconnect hoses (20) (6 used) from pilot valve

(6). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling. 19
: 19 mm

20

W1JB-02-07-005

9. Remove sems bolts (21) (4 used) from bracket (8). 21 8

Remove pilot valve (19) from bracket (8).
: 13 mm

19

W1JB-02-07-005

21

W2-7-3
 UPPERSTRUCTURE / Pilot Valve
Installation of Left Pilot Valve
21 8
1. Install pilot valve (19) to bracket (8) with sems
bolts (21) (4 used).
: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)

2. Connect hoses (20) (6 used) onto pilot valve (6).

: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
19

20

W1JB-02-07-005

21

15 16 17
3. Install lever (15) assembly to pilot valve (19). Se-
cure lever (15) assembly to pilot valve (19) with
lock nut (16).
: 22 mm
: 55 N·m (5.5 kgf·m, 41 lbf·ft)
18
4. Connect harness (18) connector.

5. Install harness (18) to bracket (8) of pilot valve

(19) with clip band (17).
8

19

W1JB-02-07-005

6. Install cover (11, 12) to bracket (8) with round

head screws (13) (3 used) and sems bolt (14).
: 10 mm
: 3.3 to 4.2 N·m 12
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)
11

13

14
WCEB-02-07-003

W2-7-4
 UPPERSTRUCTURE / Pilot Valve
7. Install cover (11, 12) to bracket (8) with round
head screw (10).

10 8

12

11 WCEB-02-07-001

7
8. Install boot (7) to bracket (8) with round head
screws (9) (4 used).

W1JB-02-07-002

1
CAUTION: Seat (1) weight: 40 kg (90 lb)

9. Install seat (1) to plate (2) with socket bolts (3) (4

used).
3
: 6 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)

10. Install seat belt (6) (2 used) to bracket (5) (2 used)

with sems bolts (4) (2 used).
: 16 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 2
WCEB-02-01-002

1 2 3 4 5

WCEB-02-01-001

W2-7-5
 UPPERSTRUCTURE / Pilot Valve
Removal of Right Pilot Valve

1. Remove the seat. (Refer to W2-7-1.)

2. Remove cap (3) (2 used) and round head screws 1 2

(1, 4) (1 each used) from cover (2). Remove cover 3, 4
(2) from bracket (7).

3. Remove sems bolt (6) from cover (5). 5

: 10 mm

4. Remove round head screw (9) from cover (8).

7 6
WCEB-02-07-006

8
3, 4

9
WCEB-02-07-005

5. Remove round head screws (11) (4 used) from 10

boot (10). Remove boot (10) from bracket (7).
7

11

W1JB-02-07-002

6. Remove round head screw (12) from cover (5, 8).

Remove covers (5, 8) from bracket (7). 12

8 5

W1JB-02-07-016

W2-7-6
 UPPERSTRUCTURE / Pilot Valve
7. Remove clip bands (15) (2 used) from lever (13)
and harness (16). Disconnect a connector from 13 14 15
harness (16).

8. Loosen lock nut (14). Remove lever (13) assem- 16

bly from pilot valve (17).
: 19 mm, 22 mm

17

W1JB-02-07-005

9. Remove sems bolts (19) (3 used) from bracket (7).

Remove bracket (7) assembly from stand (18).
Hoist bracket (7) assembly.
: 17 mm

19 18
WCEB-02-07-009

10. Disconnect hoses (20) (6 used) from pilot valve (6).

21 7
Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 19 mm

11. Remove sems bolts (21) (4 used) from bracket (7). 17

Remove pilot valve (17) from bracket (7).
: 13 mm

20

W1JB-02-07-005

21

W2-7-7
 UPPERSTRUCTURE / Pilot Valve
Installation of Right Pilot Valve 21 7

1. Install pilot valve (17) to bracket (7) with sems

bolts (21) (4 used).
: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft) 17

2. Connect hoses (20) (6 used) onto pilot valve (6).

: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
20

W1JB-02-07-005

21

13 14 15
3. Install lever (13) assembly to pilot valve (17). Se-
cure lever (13) assembly to pilot valve (17) with
lock nut (14).
: 22 mm 16
: 56 N·m (5.5 kgf·m, 41 lbf·ft)

4. Connect harness (16) connector.

7
5. Install harness (16) to pilot valve (17) and bracket
(7) with clip band (15) (2 used).
17

W1JB-02-07-005

6. Install cover (5) to bracket (7) with sems bolts (6).

: 10 mm
: 3.3 to 4.2 N·m
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

7 6
WCEB-02-07-006

W2-7-8
 UPPERSTRUCTURE / Pilot Valve
7. Install bracket (7) assembly to stand (18) with
sems bolts (19) (3 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

8. Install cover (8) to bracket (7) with round head

screw (9).

9
19
18 8 WCEB-02-07-009

9. Install covers (5, 8) to bracket (7) with round head

screw (12). 12

8 5

W1JB-02-07-016

10
10. Install boot (10) to bracket (7) with round head
screws (11) (4 used).
7

11

W1JB-02-07-002

11. Install cover (2) to bracket (7) with round head

screws (1, 4) (2 each used). Attach cap (3) (2
2
used) to cover (2).
1
3, 4

8
5

7 6
WCEB-02-07-006

W2-7-9
 UPPERSTRUCTURE / Pilot Valve

21
CAUTION: Seat (21) weight: 40 kg (90 lb)

12. Install seat (21) to plate (23) with socket bolts (22)
(4 used).
22
: 6 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)

WCEB-02-01-002

23

13. Install seat belts (26) (2 used) to brackets (25) (2 21 23 22 24 25

used) with sems bolts (24) (2 used).
: 16 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

26

WCEB-02-01-001

26 24 25 23 22

WCEB-02-01-017

W2-7-10
 UPPERSTRUCTURE / Pilot Valve
REMOVAL AND INSTALLATION OF
TRAVEL 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
1. Remove mat (1) from cab (2) inside.

WCEB-02-01-003

2. Remove sems bolts (4) (2 used) from pedal (3).

Remove pedal (3) from bracket (5).
: 13 mm

WCEB-02-07-002
Auxiliary Brake Pedal
Pedal

3. Remove sems bolts (7) (2 used) from bracket (5).

Remove bracket (5) from travel pilot valve (6). 3
: 13 mm
4

7 6 WCEB-02-07-007

W2-7-11
 UPPERSTRUCTURE / Pilot Valve
4. Remove sems bolts (8) (6 used) from cover (9). 8 9 8
Remove cover (9) from main frame (10).
: 17 mm
10

WCEB-02-13-001

11 12 13
5. Disconnect hoses (11) (4 used) from travel pilot
valve (14). Cap the open ends. Attach an identifi-
cation tag onto the disconnected hoses for as-
14
sembling.
: 19 mm

6. Remove sems bolts (12) (2 used) from travel pilot

valve (14). Remove travel pilot valve (14) from
plate (13).
11
: 17 mm
WCEB-02-07-008

W2-7-12
 UPPERSTRUCTURE / Pilot Valve
Installation
1. Install travel pilot valve (14) to plate (13) with 11 12 13
sems bolts (12) (2 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 14

2. Connect hoses (11) (4 used) onto travel pilot valve

(14).
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
11
WCEB-02-07-008

3. Install bracket (5) to travel pilot valve (6) with

sems bolts (7) (2 used). 3
: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft) 4

4. Install pedal (3) to bracket (5) with sems bolts (4)

(2 used).
: 13 mm 5
: 20 N·m (2 kgf·m, 15 lbf·ft)

7 6 WCEB-02-07-007

WCEB-02-07-002
Auxiliary Brake Pedal
Pedal

5. Install mat (1) to the cab (2) inside.

WCEB-02-01-003

W2-7-13
 UPPERSTRUCTURE / Pilot Valve
6. Install cover (9) to main frame (10) with sems bolts 8 9 10
(8) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf·ft)

WCJB-02-13-001

W2-7-14
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-7-15
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLY OF FRONT/SWING PILOT VALVES

10

10
11
1

11 12

12
2 13

13

14

5
5

6 15
6

16
7
7
17

8
8

18

9
9

19

19

20

20

W1F3-02-07-001

1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing

2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Sealing Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)

W2-7-16
 UPPERSTRUCTURE / Pilot Valve
Disassembly of Front/Swing Pilot Valves 3. Install special tool (ST 7260) to universal joint (3).
• Spool (13) has been selected to match the hole of Remove universal joint (3) from casing (14) by
casing (14). Therefore, the parts cannot be re- turning.
placed individually. : 24 mm
• Indicate the port number of the removed in order
not to confuse parts. The port numbers are
stamped on the outer surface of casing (14).

1. Clamp the pilot valve in a vice. Secure the plot

valve with the port plate (18) facing downward. Section A-A

2. Put the matching marks on plate (4) and casing

(14). Secure cam (2) by using a spanner. Remove
screw joint (1) and cam (2) from universal joint ST 7260
(3).
: 32 mm

CAUTION: Springs (10) (4 used) are in the

compressed condition. Therefore, when A A
loosening universal joint (3), plate (4), bush-
ings (6) (4 used), and pushers (8) (4 used) are 3
raised at the same time. Do not fly out them.

W577-02-06-003

4. Remove plate (4) from casing (14).

IMPORTANT: When bushing (6) (4 used) are still in

casing (14), remove pusher (8) by
moving left and right. Do not dam-
age pusher (8).
IMPORTANT: Indicate the port numbers of the
spool (13) assembly and springs (10)
(4 used) in order not to confuse the
parts. Do not damage spool (13).
5. Remove the pusher (8) assembly, the spool (13)
assembly and springs (10) (4 used) from casing
(14).

6. Remove pushers (8) (4 used), O-rings (7) (4

used) and oil seals (5) (4 used) from bushings (6)
(4 used).

W2-7-17
 UPPERSTRUCTURE / Pilot Valve

11

11 12

12
13

13

14

15

16

17

18

9
9

20

W1F3-02-07-001

W2-7-18
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Do not disassemble the spool (13)
assembly unless necessary.
IMPORTANT: When removing spring seats (9) (4
used) from spool (13), push in
spring seat (9) once and remove it
by moving to a larger hole of 2 holes
on spring seat (9). At this time, do
not push in spring seat (9) for more
than 6 mm (0.2 in).

13

WCEB-02-07-010
11 9

7. Remove spring seats (9) (4 used), springs (11) (4

used) and washers (12) (4 used) from spool (13).

8. Clamp the pilot valve in a vice. Secure the pilot

valve with port plate (18) facing upward.

9. Remove socket bolts (20) (2 used) and seal

washers (19) (2 used) from port plate (18).

10. Remove port plate (18), O-ring (15), bushing (16)

and spring pin (17) from casing (14).

W2-7-19
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLY OF FRONT/SWING PILOT VALVES

1
3

8
5

4
6

11

10
12
13

14

16
15

17
18
19

20 W1F3-02-07-002

1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing

2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Sealing Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)

W2-7-20
 UPPERSTRUCTURE / Pilot Valve
Assembly of Front/Swing Pilot Valves
• Replace the seals with the new ones.
1. Install bushing (16) and O-ring (15) to casing (14).
2. Install spring pin (17) to port plate (18). Install port
plate (18) to casing (14) with socket bolts (20) (2
used) and seal washers (19) (2 used).
: 20.5±2 N·m (2.1±0.2 kgf·m, 15±2 lbf·ft)
IMPORTANT: When installing spring seats (9) (4
used) to spool (13), insert spool (13)
from a larger hole of 2 holes on
spring seat (9) and move to a smaller
hole direction. At this time, do not
push in spool (13) for more than 6
mm (0.2 in).
13
WCEB-02-07-010
9
3. Install washers (12) (4 used), springs (11) (4
used) and spring seats (9) (4 used) to spools (13)
(4 used) in this order.
W2-7-21
IMPORTANT: Install spring (10) to the same posi-
tion before disassembling.
4. Install springs (10) (4 used) to casing (14).
IMPORTANT: Install the spool (13) assemblies (4
used) to the same position as it was
before disassembling.
5. Install the spool (13) assemblies (4 used) to cas-
ing (14).
6. Install O-rings (7) (4 used) and oil seals (5) (4
used) to bushings (6) (4 used).
IMPORTANT: Apply hydraulic oil onto the outer
surface of pushers (8) (4 used).
7. Install pushers (8) (4 used) to bushings (6) (4
used).
IMPORTANT: If installing plate (4) is difficult due
to strong springs (10) (4 used), place
the bushing (6) assemblies (4 used)
on 4 holes of casing (14). Place plate
(4) on them. Temporarily secure the
bushing (6) assemblies (4 used).
While holding it with universal joint
(3).
8. Install the bushing (6) assemblies (4 used) to
casing (14), by aligning the matching marks be-
fore disassembly.
UPPERSTRUCTURE / Pilot Valve

1
3

14

W1F3-02-07-002

W2-7-22
 UPPERSTRUCTURE / Pilot Valve
9. Install universal joint (3) to casing (14) by using
special toll (ST 7260).
: 24 mm
: 47.1±2.9 N·m
(4.8±0.3 kgf·m, 35±2 lbf·ft)

10. Screw in universal joint (3) until pushers (8) (4

used) come in contact with cam (2) evenly.

IMPORTANT: When tightening screw joint (1), do

not move cam (2).
11. Secure cam (2) by using a spanner. Install screw
joint (1) to universal joint (3).
: 32 mm
: 68.6±4.9 N·m
(7.0±0.5 kgf·m, 51±4 lbf·ft)

12. Apply grease onto the rotating part of universal

joint (3) and the top of pusher (8).

W2-7-23
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLY OF TRAVEL AND AUXIL-
IARY/POSITIONING PILOT VALVES

20

7 20

8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15

15
4
11
14
14
3

3 12
13
2
2

21
1
1

W1LA-02-06-001

1- O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3- Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4- Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6- Socket Bolt (2 Used)

W2-7-24
 UPPERSTRUCTURE / Pilot Valve
Disassembly of Travel and Auxiliary/Positioning
Pilot Valves
• Spool (15) has been selected to match the hole of
casing (21). Therefore, the parts cannot be re-
placed individually.
• Indicate the port number of the removed in order
not to confuse.
IMPORTANT: Before disassembling, put the
matching marks on cam (9), pin (10),
cover (11) and casing (21).
1. Secure the pilot valve in a vise. Remove boot (7)
from cover (11).
2. Remove set screw (8) from cam (9). Remove pin
(10) from cover (11). Remove cam (9) from cover
(11).
NOTE: LOCTITE is applied onto the set screw
part.
NOTE: Steel ball (5) cannot be disassembled from
cam (9).
7. Remove spring guides (19) (2 used), springs (18)
(2 used), washers (16) (2 used) and shims (17) (2
used) from the spool (15) assemblies (2 used).
IMPORTANT: As the spool (15) assemblies (2
used) are adjusted by shim (17), do
not disassemble the spool (15) as-
sembly unless necessary. If the
spool (15) assembly is disassem-
bled, record the quantity and thick-
ness of shim (17).
IMPORTANT: Do not remove bushing (4) from
cover (11) unless bushing (4) is
damaged.
8. Remove bushings (4) (2 used) from cover (11).

3. Loosen and remove socket bolts (6) (2 used) from

cover (11) alternately. Remove cover (11) from
casing (21).

4. Remove the pusher (20) assemblies (2 used)

from casing (21).

5. Remove bushings (2) (2 used) from the pusher

(20) assembly. Remove O-rings (1) (2 used) and
packings (3) (2 used) from bushings (2) (2 used).

IMPORTANT: Indicate the port numbers in order

not to confuse the parts.
6. Remove the spool (15) assemblies (2 used) and
springs (14) (2 used) from casing (21).

W2-7-25
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLY OF TRAVEL AND AUXIL-
IARY/POSITIONING PILOT VALVES
7 8 10 9

20

11

19

18

14

17

16

12

13

15
W1LA-02-06-002

21

1- O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3- Packin (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4- *Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6- Socket Bolt (2 Used)

NOTE: *Refer to W2-7-24.

W2-7-26
 UPPERSTRUCTURE / Pilot Valve
Assembly of Travel and Auxiliary/Positioning Pi- 8. Apply LOCTITE #241 onto setscrew (8). Secure
lot Valve cam (9) to pin (10) with setscrew (8).
• Clean not to confuse the parts. Arrange the parts : 5 N·m (0.5 kgf·m, 41 lbf·ft)
by port in order.
9. Install boot (7) to cover (11).
1. Install bushings (4) (2 used) to cover (11).

IMPORTANT: Install shim (17) as its thickness

becomes same before disassem-
bling.
2. Install washers (16) (2 used), shims (17) (2 used),
springs (18) (2 used) and spring guides (19) (2
used) to spools (15) (2 used) in this order.

IMPORTANT: Install the spool (15) assembly into

the same hole before disassembling.
3. Install spring (14) (2 used) to casing (21). Install
the spool (15) assemblies (2 used) to casing (21).

4. Install O-rings (1) (2 used) and packings (3) (2

used) to bushings (2) (2 used).
3

W585-02-06-005
Lip

5. Install pushers (20) (2 used) to the bushing (2)

assemblies (2 used). Install the pusher (20) as-
semblies (2 used) to casing (21).

6. Secure casing (21) in a vise. Install cover (11) to

casing (21) with socket bolts (6) (2 used).
: 23.5 N·m (2.4 kgf·m, 17 lbf·ft)

7. Install cam (9) to cover (11). Secure cam (9) to

cover (11) with pin (10).

W2-7-27
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-7-28
 UPPERSTRUCTURE / Electric Lever
REMOVAL AND INSTALLATION OF
ELECTRIC LEVER

Removal of Auxiliary/Positioning Electric Lever 1 2

1. Remove sems bolts (2) (6 used) from cover (1). 3

Remove cover (1) from main frame (3).
: 17 mm

WCJB-02-13-001

2. Disconnect connector (4).

4

WCEB-02-08-002

5
3. Remove mat (6) from the inside of cab (5).

WCEB-02-01-003

4. Remove sems bolts (8) (2 used) from pedal (9).

Remove pedal (9) from bracket (10). 8
: 13 mm

7 9
5. Remove sems bolts (7) (2 used) from bracket (10).
Remove bracket (10) from electric lever (11).
: 13 mm

11 10
WCEB-02-08-001

W2-8-1
 UPPERSTRUCTURE / Electric Lever
6. Remove sems bolts (13) (4 used) from bracket
(12). Remove the bracket (12) assembly from
plate (14).
: 17 mm

WCEB-02-08-001
14 13 12

11
7. Remove sems bolts (15) (2 used) from electric
lever (11). Remove electric lever (11) from bracket
(12).
15
: 17 mm

WCEB-02-08-002

Installation of Auxiliary/Positioning Electric Lever

1. Install electric lever (11) to bracket (12) with sems 11

bolts (15) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
15

WCEB-02-08-002

2. Install the bracket (12) assembly to plate (14) with

sems bolts (13) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-08-001
14 13 12

W2-8-2
 UPPERSTRUCTURE / Electric Lever
3. Install bracket (10) to electric lever (11) with sems
bolts (7) (2 used).
: 13 mm 8
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

4. Install pedal (9) to bracket (10) with sems bolts (8) 7 9

(2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

11 10
WCEB-02-08-001

5. Install mat (6) to the inside of cab (5). 5

WCEB-02-01-003

6. Connect connector (4).

WCEB-02-08-002

1 2

7. Install cover (1) to main frame (3) with sems bolts 3

(2) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-13-001

W2-8-3
 UPPERSTRUCTURE / Electric Lever
Removal of Blade/Outrigger Electric Lever

1. Remove caps (4) (2 used) from cover (2). Remove

screws (5, 7) (2 used for each) from cover (2). 2
: 17 mm 3
1

2. Remove sems bolt (6) from cover (3).

: 10 mm 4, 5

8 7 6 WCEB-02-07-006

3. Remove screw (9) from cover (1).

9
WCEB-02-07-009

4. Remove screws (11) (4 used) from boot (10). 10

Raise boot (10) from bracket (8).
8

11

W1JB-02-07-002

5. Remove screw (12) from cover (1). Remove

covers (1, 3) from bracket (8).
12 10

W1JB-02-07-016

W2-8-4
 UPPERSTRUCTURE / Electric Lever
6. Disconnect connector (13).

WCEB-02-08-004
13

7. Remove socket bolts (18) (2 used) from lever (14). 14 15

Remove lever (14) from electric lever (17).
: 6 mm

8. Remove sems bolts (16) (2 used) from bracket

(15). Remove the bracket (15) assembly from
bracket (8).
16
: 17 mm

WCEB-02-08-003
18 17 8

9. Remove sems bolts (19) (2 used) from electric

lever (17). Remove electric lever (17) from bracket
(15). 19
: 17 mm

15

17

WCEB-02-08-004

W2-8-5
 UPPERSTRUCTURE / Electric Lever
Installation of Blade/Outrigger Electric Lever

1. Install electric lever (17) to bracket (15) with sems 19

bolts (19) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect connector (13).

15

17

WCEB-02-08-004
13

3. Install the bracket (15) assembly to bracket (8) 14 15

with sems bolts (16) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

4. Install lever (14) to electric lever (17) with socket

bolts (18) (2 used).
: 6 mm 16
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

WCEB-02-08-003
18 17 8

5. Install covers (1, 3) to bracket (8) with screw (12). 12 10

3
1

6. Install boot (10) to bracket (8) with screws (11) (4 W1JB-02-07-016

used). 10

11

W1JB-02-07-002

W2-8-6
 UPPERSTRUCTURE / Electric Lever
7. Install cover (1) to bracket (8) with screw (9).

1 WCEB-02-07-009

8. Install cover (3) to bracket (8) with sems bolt (6).

: 10 mm
: 3.3 to 4.2 N⋅m 2
3
(0.3 to 0.4 kgf⋅m, 2.4 to 3 lbf⋅ft)

9. Install cover (2) to bracket (8) with screws (5, 7) (2

used for each). 4, 5

10. Install caps (4) (2 used) to cover (2).

8 7 6 WCEB-02-07-006

W2-8-7
 UPPERSTRUCTURE / Electric Lever
DISASSEMBLY OF ELECTRIC LEVER

10

8 11
7

12

6
5 13
14

15

16

17

4 18
3
2
1
19

20

W1MG-02-07-003

1- Screw (2 Used) 6- Bushing (2 Used) 11 - Cam 16 - Bushing (2 Used)

2- Plate 7- Screw 12 - Socket Bolt (2 Used) 17 - Spring (2 Used)
3- Screw (2 Used) 8- Arm 13 - Holder 18 - Housing
4- Potentiometer 9- Boot 14 - O-Ring (2 Used) 19 - Clip
5- Pin 10 - Set Screw 15 - Bushing (2 Used) 20 - Screw

W2-8-8
 UPPERSTRUCTURE / Electric Lever
Disassembly of Electric Lever

IMPORTANT: Housing (18) is made of aluminum. IMPORTANT: Keep the disassembled parts
As too strong a force may deform or carefully in order to install them to
damage it, handle it with care. their original ports.

1. Secure housing (18) in a vise. 10. Remove the pusher (16) assemblies (2 used) and
springs (17) (2 used) from housing (18).
2. Remove screws (1) (2 used) from plate (2).
Remove plate (2) from housing (18). IMPORTANT: Do not damage bushing (15).

3. Remove screws (20) from clip (19). Remove clip 11. Remove pushers (16) (2 used) and O-rings (14) (2
(19) from housing (18). used) from bushings (15) (2 used).

4. Remove screws (3) (2 used) from potentiometer IMPORTANT: Bushing (6) cannot be reused.
(4). Remove potentiometer (4) from housing (18).
12. Remove bushings (6) (2 used) from holder (13).
5. Remove boot (9) from holder (13).

6. Remove set screw (10) from cam (11).

: 2.5 mm

7. Remove pin (5) from holder (13). Remove cam

(11) from holder (13).

8. Remove screw (7) from arm (8). Remove arm (8)

from cam (11).

IMPORTANT: The pusher (16) assembly may fly

out by spring (17).

9. Remove socket bolts (12) (2 used) from holder

(13). Remove holder (13) from housing (18).
: 5 mm

W2-8-9
 UPPERSTRUCTURE / Electric Lever
ASSEMBLY OF ELECTRIC LEVER

7 8 9

11
5, 6
16
14
12
15

3 13
17
4
18

T1MG-03-09-008

20 19

1- *Screw (2 Used) 6- Bushing (2 Used) 11 - Cam 16 - Pusher (2 Used)

2- *Plate 7- Screw 12 - Socket Bolt (2 Used) 17 - Spring (2 Used)
3- Screw (2 Used) 8- Arm 13 - Holder 18 - Housing
4- Potentiometer 9- Boot 14 - O-Ring (2 Used) 19 - Clip
5- Pin 10 - *Set Screw 15 - Bushing (2 Used) 20 - Screw

NOTE: As for the item with mark*, refer to W2-7-8.

W2-8-10
 UPPERSTRUCTURE / Electric Lever
Assembly of Electric Lever
1. Apply grease onto O-rings (14) (2 used).
2. Install O-rings (14) (2 used) to bushings (15) (2
used).
3. Apply grease onto the inner surface of bushings
(15) (2 used).
4. Install pushers (16) (2 used) to bushings (15) (2
used).
5. Install springs (17) (2 used) and the pusher (16)
assemblies (2 used) to housing (18).
6. Install bushings (6) (2 used) to holder (13).
7. Install holder (13) to housing (18) with socket bolts
(12) (2 used).
: 5 mm
: 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)
8. Apply grease onto the end of pushers (16) (2
used).
9. Install arm (8) to cam (11) with screw (7).
: 3 N⋅m (0.3 kgf⋅m, 2 lbf⋅ft)
10. Apply grease onto the mounting surfaces of holder
(13) and cam (11).
11. Install cam (11) to holder (13).
12. Apply LOCTITE #262 onto screw (10).
W2-8-11
13. Install pin (5) to holder (13). Secure pin (5) to cam
(11) with screw (10).
: 2.5 mm
: 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)
14. Apply grease to the gap between arm (8) and the
link part of potentiometer (4).
15. Apply LOCTITE #262 onto screws (3) (2 used).
IMPORTANT: Adjust the gap between arm (8) and
the link of potentiometer (4) to 0.4
mm on one side.
16. Install potentiometer (4) to housing (18) with
screws (3) (2 used).
: 1.0 N⋅m (0.1 kgf⋅m, 0.7 lbf⋅ft)
17. Secure the harness of potentiometer (4) with clip
(19).
18. Apply LOCTITE #262 onto screw (20).
19. Install clip (19) to housing (18) with screw (20).
: 0.8 N⋅m (0.1 kgf⋅m, 0.6 lbf⋅ft)
20. Apply THREEBOND #1104 onto the mating
surfaces of housing (18) and plate (2).
21. Install plate (2) to housing (18) with screws (1) (2
used).
22. Install boot (9) to holder (13).
 UPPERSTRUCTURE / Electric Lever
(Blank)

W2-8-12
 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.)

Removal 1 2 3 4
1. Open cover (2).

2. Remove sems bolts (3) (4 used) from cover (1).

Remove cover (1) from stay (4).
: 17 mm

WCJB-02-01-002

3. Disconnect connectors (5) (2 used) from signal

control valve (6).

4. Disconnect hoses (7) (32 used) from signal 5 6 7

control valve (6). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm

5. Remove socket bolts (8) (4 used) from signal

control valve (6). Remove signal control valve (6)
from bracket (9).
: 8 mm

WCJB-02-09-001
7

W2-9-1
 UPPERSTRUCTURE / Signal Control Valve
Installation
1. Install signal control valve (6) to bracket (9) with 5 6 7
socket bolts (8) (4 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect hoses (7) (32 used) to signal control

valve (6).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
8
3. Connect connectors (5) (2 used) to signal control
valve (6). 9

WCJB-02-09-001
7

4. Install cover (1) to stay (4) with sems bolts (3) (4 1 2 3 4

used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

5. Shut cover (2).

WCJB-02-01-002

W2-9-2
 UPPERSTRUCTURE / Signal Control Valve
(Blank)

W2-9-3
 UPPERSTRUCTURE / Signal Control Valve
STRUCTURE OF SIGNAL CONTROL VALVE
4 13

12

11
7

4
10

9
7 8
7 7

4
4

W1JB-02-10-002

W2-9-4
 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

W2-9-5
 UPPERSTRUCTURE / Signal Control Valve
(Blank)

W2-9-6
 UPPERSTRUCTURE / Travel Shockless Valve
REMOVAL AND INSTALLATION OF
TRAVEL SHOCKLESS VALVE 1 2 3

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 Travel Shockless Valve

WCJB-02-15-001
1. Remove sems bolts (1) (6 used) from cover (2).
Remove cover (2) from main frame (3).
: 17 mm
4 5 6 7

2. Disconnect connector (4) from pressure sensor

(5).
8

3. Disconnect connectors (6) (2 used).

4. Disconnect hoses (7) (6 used) from travel

shockless valve (8). Cap the open ends. Attach an WCEB-02-10-003
identification tag onto the disconnected hoses for 7
assembling.
: 19 mm
10 9

10

5. Remove sems bolts (10) (4 used) from bracket (9). 8, 11

Remove the travel shockless valve (8) assembly
from main frame (3).
: 17 mm
WCEB-02-10-003
6. Remove sems bolts (11) (2 used) from bracket (9).
Remove travel shockless valve (8) from bracket
(9).
: 17 mm

W2-10-1
 UPPERSTRUCTURE / Travel Shockless Valve
Installation of Travel Shockless Valve
10 9
1. Install travel shockless valve (8) to bracket (9) with
sems bolts (11) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
10
2. Install the bracket (9) assembly to main frame (3)
with sems bolts (10) (4 used).
: 17 mm 3
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
8, 11

WCEB-02-10-003

3. Connect hoses (7) (6 used) to travel shockless 4 5 6 7

valve (8).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

4. Connect connector (4) to pressure sensor (5).

5. Connect connectors (6) (2 used).

WCEB-02-10-003
7

6. Install cover (2) to main frame (3) with sems bolts 2 3

1
(1) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-15-001

W2-10-2
 UPPERSTRUCTURE / Travel Shockless Valve
(Blank)

W2-10-3
 UPPERSTRUCTURE / Travel Shockless Valve
STRUCTURE OF TRAVEL SHOCKLESS
VALVE

13

1
14

4
4
T1F3-03-08-004

T1F3-03-08-005
5
Section A

7
T1F3-03-08-006

8 9 10 11 12

Section B

W2-10-4
 UPPERSTRUCTURE / Travel Shockless Valve

Tightening Torque
Part Name Q’ ty Wrench Size
N⋅m (kgf⋅m) (lbf⋅ft)
1 Solenoid 2
2 O-Ring 2 1B P14
3 Spool 2
4 Body 1
5 Spring 2
6 Plug 6
7 Orifice 2 1.6 to 2.0 (0.16 to 0.2) (1.2 to 1.5)
8 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13)
9 Steel Ball 2 9/32
10 Spring 2
11 O-Ring 4 1B P8
12 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13)
13 Nut 2 : 19 mm 4.9 (0.5) (3.6)
14 Tube 2 30 to 37 (3 to 4) (22 to 27)

W2-10-5
 UPPERSTRUCTURE / Travel Shockless Valve
(Blank)

W2-10-6
 UPPERSTRUCTURE / Solenoid Valve
REMOVAL AND INSTALLATION OF
4-SPOOL SOLENOID VALVE UNIT

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. Open cover (2).

2. Remove sems bolts (3) (4 used) from cover (1).

Remove cover (1) from stay (4).
: 17 mm

WCJB-02-01-002

3. Disconnect connectors (9) (4 used). 5 6 7

4. Disconnect hoses (6) (16 used) from 4-spool

solenoid valve unit (8). Cap the open ends. Attach
an identification tag onto the disconnected hoses
for assembling.
: 19 mm, 22 mm

5. Disconnect pipings (5) (3 used) from 4-spool 6

solenoid valve unit (8).
: 19 mm

9 8 WCJB-02-11-001

8
6. Remove socket bolts (10) (2 used) and washers
(11) (2 used) from 4-spool solenoid valve unit (8).
Remove 4-spool solenoid valve unit (8) from
control valve (7).
: 8 mm

WCJB-02-11-002

10, 11 7

W2-11-1
 UPPERSTRUCTURE / Solenoid Valve
Installation
1. Install 4-spool solenoid valve unit (8) to control 8
valve (7) with socket bolts (10) (2 used) and
washers (11) (2 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-11-002

10, 11 7

2. Connect pipings (5) (3 used) to 4-spool solenoid

5 6 7
valve unit (8).
: 19 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Connect hoses (6) (16 used) to 4-spool solenoid

valve unit (8).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
6
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

4. Connect connectors (9) (4 used).

9 8 WCJB-02-11-001

5. Install cover (1) to stay (4) with sems bolts (3) (4 1 2 3 4

used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

6. Shut cover (2).

WCJB-02-01-002

W2-11-2
 UPPERSTRUCTURE / Solenoid Valve
STRUCTURE OF 4-SPOOL SOLENOID VALVE UNIT

WCJB-02-11-003

Proportional Solenoid Valve

Proportional Solenoid Valve

WCJB-02-11-004

Filter Plug

Plug Filter

WCEB-02-11-011

View A Section B
WCEB-02-11-010

W2-11-3
 UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLY AND ASSEMBLY OF 4-SPOOL SOLENOID VALVE UNIT

1
2
3
4
5

7
8
9
12
13 14
10 15
11 16

17
18
19

W18G-02-08-012

4 2 3, 5 6 1 8 12 13 17 10 18

19
W18G-02-08-013
7 9 14 15 16 11

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

W2-11-4
 UPPERSTRUCTURE / Solenoid Valve
Disassembly of 4-Spool Solenoid Valve Unit
IMPORTANT: Do not lose spring (7) in the hole of
solenoid (6) when removing
solenoid (6).
Do not disassemble pressure
adjusting lock nut (2) and adjusting
bolt (4).
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 remove orifice (11) from
spool (10).
2. Remove spool (10) from sleeve (17). Remove
diaphragm (9), washer (12) and spring (13) from
spool (10).
3. Remove sleeve (17) from the housing. Remove
plate (18) and wave spring (19) from the housing
by using a magnet.
4. Remove O-rings (14, 15, 16) from sleeve (17).
W2-11-5
Assembly of 4-Spool Solenoid Valve Unit
1. Install wave spring (19) and plate (18) to the
housing.
IMPORTANT: When inserting sleeve (17) into the
housing, align the hole on sleeve
(17) with that on the housing.
2. Install O-rings (14, 15, 16) to sleeve (17). Insert
sleeve (17) into the housing.
IMPORTANT: When inserting spool (10) into
sleeve (17), do not damage the edge
on sleeve (17).
After inserting spool (10), try to push
it about 3 to 5 mm (0.1 to 0.2 in) by
fingers. Check if spool (10) moves
smoothly.
3. Install diaphragm (9), washer (12) and spring (13)
to spool (10). Insert spool (10) into sleeve (17).
IMPORTANT: When installing solenoid (6), prevent
spring (7) from falling off.
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, 4+1.5−0 lbf⋅ft)
 UPPERSTRUCTURE / Solenoid Valve
REMOVAL AND INSTALLATION OF
SOLENOID VALVE UNIT (FOR ELECTRIC
LEVER OPERATION)

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. Open cover (1).

WCEB-02-05-002

2. Remove sems bolts (3) (2 used) from cover (4).

Remove cover (2) from cover (4).
: 17 mm 2

WCJB-02-11-005

3. Disconnect connectors (7) (5 used) from solenoid

valve unit (6).
5 6
4. Disconnect hoses (5) (12 used) from solenoid
valve unit (6). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm
NOTE: The number of solenoid valve units, the
7
connectors and the hoses differ depending
on the front attachment specifications.

WCJB-02-11-006

W2-11-6
 UPPERSTRUCTURE / Solenoid Valve
5. Remove bolts (8) (4 used) and washers (9) (4 6
used) from bracket (10). Remove solenoid valve
unit (6) from bracket (10).
: 17 mm
8, 9

10

Installation WCJB-02-11-006
1. Install solenoid valve unit (6) to bracket (10) with 5 6
bolts (8) (4 used) and washers (9) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
8, 9
2. Connect hoses (5) (12 used) to solenoid valve
unit (6). 7
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Connect connectors (7) (5 used) to solenoid valve

unit (6). 10

WCJB-02-11-006
4. Install cover (2) to cover (4) with sems bolts (3) (2
used).
: 17 mm 2
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-11-005

5. Shut cover (1)

WCEB-02-05-002

W2-11-7
 UPPERSTRUCTURE / Solenoid Valve
STRUCTURE OF SOLENOID VALVE UNIT (FOR ELECTRIC LEVER OPERATION)

2 3 4 5 6 7

A A

A A

A A

WCEB-02-11-006

Section A WCEB-02-11-007

Wrench Size Tightening Torque

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Solenoid Valve Assembly 1
2 Solenoid Valve Assembly 2
3 Solenoid Valve Assembly 1
4 Socket Bolt 4 :6 19.5+5−0 (2+0.5−0) (14+4−0)
5 Washer 4
6 End Plate 1
7 Socket Bolt 18 4.9+5−0 (0.5+0.5−0) (4+4−0)
8 Lock Nut 8 4.9+5−0 (0.5+0.5−0) (4+4−0)

W2-11-8
 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
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Remove sems bolts (1) (6 used) from cover (2).
Remove cover (2) from main frame (3). 1 2 3
: 17 mm

WCJB-02-15-001

2. Disconnect hoses (4) (9 used) from pilot shut-off 4 3 5 6

solenoid valve (5). Cap the open ends. Attach an
identification tag onto the disconnected hoses for 7
assembling.
: 17 mm, 19 mm
8
3. Disconnect connector (8).

4. Remove sems bolts (6) (4 used) from bracket (7).

Remove the bracket (7) assembly from main
frame (3).
: 17 mm
WCEB-02-12-001

5 7, 9

5. Remove sems bolts (9) (2 used) from bracket (7).

Remove bracket (7) from pilot shut-off solenoid
valve (5).
: 17 mm

WCEB-02-12-001

W2-12-1
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
3 5 7, 9
Installation 6
1. Install bracket (7) to pilot shut-off solenoid valve
(5) with sems bolts (9) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install the bracket (7) assembly to main frame (3)

with sems bolts (6) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-12-001

3. Connect hoses (4) (9 used) to pilot shut-off

4 5
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, 22 lbf⋅ft)
8
4. Connect connector (8).

WCEB-02-12-001

1 2 3
5. Install cover (2) to main frame (3) with sems bolts
(1) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-15-001

W2-12-2
 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

Item Part Name Q’ty Remarks
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 : 6 26.5 (2.7) (20)
2 O-Ring 1
3 Spring 1
4 Spool 1
5 Filter 1
6 Body 1
7 O-Ring 1
8 Solenoid 1
9 Socket Bolt 2 : 4 3.92 (0.4) (3)

W2-12-3
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
(Blank)

W2-12-4
 UPPERSTRUCTURE / Steering Valve
REMOVAL AND INSTALLATION OF
STEERING 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.) 2 3

Removal
1. Open door (4) and upper front glass (2).

2. Remove lower front glass (1) from cab (3).

WCEB-02-01-004

3. Remove mat (5) from the inside of cab (3).

4. Remove sems bolts (6) (2 used) from pedal (7).

Remove pedal (7) from bracket (8). WCEB-02-01-003

: 13 mm

8 WCEB-02-08-001

W2-13-1
 UPPERSTRUCTURE / Steering Valve
5. Remove caps (10) (5 used) from cover (9).
Remove screws (11) (5 used) from cover (9). 10, 11
Remove cover (9) from stand (15).

6. Remove caps (13) (3 used) from cover (12). 12, 13, 14

Remove screws (14) (5 used) from cover (12).
9
Remove cover (12) from stand (15).

15

WCEB-02-13-002

7. Remove screws (17) (4 used) from cover (16).

Remove cover (16) from stand (15).

16

15 17 WCEB-02-13-003

8. Remove sems bolts (18) (6 used) from cover (19). 18 19 20

Remove cover (19) from main frame (20).
: 19 mm

WCJB-02-13-001

9. Disconnect hoses (22) (5 used) from steering 21

valve (21). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 22 mm, 27 mm 22

WCEB-02-13-006

W2-13-2
 UPPERSTRUCTURE / Steering Valve
10. Remove sems bolts (23) (4 used) from stand (15).
Remove the steering valve (21) assembly from
stand (15).
: 17 mm
23

15

WCEB-02-13-004

21

WCEB-02-13-006

24

11. Remove socket bolts (24) (2 used) from priority

valve (25). Remove priority valve (25) and O-rings 25, 26
(26) (5 used) from steering valve (21).

21

WCEB-02-13-005

W2-13-3
 UPPERSTRUCTURE / Steering Valve
Installation 24
1. Install priority valve (25) to steering valve (21) with
O-rings (26) (5 used) and socket bolts (24) (2
used). 25, 26
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

21

WCEB-02-13-005

2. Install the steering valve (21) assembly to stand

(15) with sems bolts (23) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
23

15

WCEB-02-13-004

3. Connect hoses (22) (5 used) to steering valve 21

(21).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm 22
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

WCEB-02-13-006

4. Install cover (19) to main frame (20) with sems 18 19 20

bolts (18) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-13-001

W2-13-4
 UPPERSTRUCTURE / Steering Valve
5. Install cover (16) to stand (15) with screws (17) (4
used).

16

15 17 WCEB-02-13-003

10, 11
6. Install cover (9) to stand (15) with screws (11) (5
used). Install caps (10) (5 used) to cover (9).

15

WCEB-02-13-002

7. Install cover (12) to stand (15) with screws (14) (5

used). Install caps (13) (3 used) to cover (12).
12, 13, 14

15

WCEB-02-13-002

6
8. Install pedal (7) to bracket (8) with sems bolts (6)
(2 used).
: 13 mm
7
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

8 WCEB-02-08-001

W2-13-5
 UPPERSTRUCTURE / Steering Valve
9. Install mat (5) to the inside of cab (3).
3

WCEB-02-01-003

2 3

10. Install lower front glass (1) to cab (3).

11. Shut upper front glass (2) and door (4).

WCEB-02-01-004

W2-13-6
 UPPERSTRUCTURE / Brake Valve
REMOVAL AND INSTALLATION OF
BRAKE 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. Remove mat (1) from the inside of cab (2). 1

WCEB-02-01-003

3 4 5
2. Remove sems bolts (4) (6 used) from cover (3).
Remove cover (3) from main frame (5).
: 17 mm

WCJB-02-13-001

3. Disconnect connector (11). 6, 7 8 9

10
4. Remove socket bolts (7) (2 used) from bracket (6).
Remove the bracket (6) assembly from bracket
(8).
: 6 mm

5. Disconnect hoses (9) (6 used) from brake valve

(10). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 17 mm, 22 mm, 27 mm
11 WCEB-02-14-005

6. Remove rubber (14) from brake pedal (15). 12 10 13

7. Remove sems bolts (12) (4 used) from plate (13).

Remove the brake valve (10) assembly from plate
(13).
: 17 mm

14, 15 12
WCEB-02-14-006

W2-14-1
 UPPERSTRUCTURE / Brake Valve
Installation 12 10 13
1. Align the brake valve (10) assembly with the
mounting hole on plate (13). Install the brake valve
(10) assembly to plate (13) with sems bolts (12) (4
used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install rubber (14) to brake pedal (15).

14, 15 12
WCEB-02-14-006

6, 7 8 9
3. Connect hoses (9) (6 used) to brake valve (10). 10
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m,58 lbf⋅ft)

4. Install the bracket (6) assembly to bracket (8) with

socket bolts (7) (2 used).
: 6 mm 11 WCEB-02-14-005

: 58.8 to 73.5 N⋅m

(6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)

5. Connect connector (11).

6. Install cover (3) to main frame (5) with sems bolts 3 4 5

(4) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-13-001

7. Install mat (1) to the inside of cab (2).

WCEB-02-01-003

W2-14-2
 UPPERSTRUCTURE / Brake Valve
(Blank)

W2-14-3
 UPPERSTRUCTURE / Brake Valve
DISASSEMBLY OF BRAKE VALVE
1

11
29 3

28
8
5 7
4

6 10
27
9
12

13
14
15

16
26

25

17
3
3
30 24 16
31
32 23
33 22
34 18
43
35
36

42 37 19
41
38
20

44 40 21
45
46
47 29
48

39

44
45
46
47
49
WCEB-02-14-004
48

W2-14-4
 UPPERSTRUCTURE / Brake Valve

1- Rubber 14 - Bushing 26 - Bracket 38 - Push Rod

2- Brake Pedal 15 - Yoke 27 - Oil Seal 39 - Cylinder
3- Split Pin (4 Used) 16 - Pin (2 Used) 28 - Flange 40 - Cylinder
4- Stopper Bolt 17 - Link 29 - O-Ring (2 Used) (1B, G45) 41 - O-Ring (1B, P32)
5- Bushing 18 - Roller Assembly 30 - Rod 42 - Plug
6- Lock Nut 19 - Bracket 31 - Return Spring 43 - Socket Bolt (4 Used)
7- Bushing (2 Used) 20 - Brake Switch 32 - Holder 44 - Spring (2 Used)
8- Pin 21 - Socket Bolt (2 Used) 33 - Spring 45 - Retaining Ring (2 Used)
9- Bushing (2 Used) 22 - Seat 34 - Balance Spring 46 - Retainer (2 Used)
10 - Pin 23 - Stopper 35 - Retainer 47 - Plunger (2 Used)
11 - Boot 24 - Boot 36 - Retainer 48 - Spool (2 Used)
12 - Pin 25 - Socket Bolt (4 Used) 37 - Pilot Piston 49 - Spring
13 - Spring Pin

W2-14-5
 UPPERSTRUCTURE / Brake Valve

11
29 3

28

4 5 7 8

6 10
27
9
12

13
14
15

16
26

25

17
3
3
30 24 16
31
32 23
33 22
34 18
43
35
36

42 37 19
41
38
20

44 40 21
45
46
47 29
48

39

44
45
46
47
49
WCEB-02-14-004
48

W2-14-6
 UPPERSTRUCTURE / Brake Valve
Disassembly of Brake Valve
IMPORTANT: Put the matching marks onto
bracket (26), flange (28), cylinder
(39) and cylinder (40) before disas-
sembling.
1. Secure the brake valve in a vise with the cylinder
(40) side facing downward.
2. Remove socket bolts (21) (2 used) from bracket
(19). Remove bracket (19) and brake switch (20)
from bracket (26).
: 6 mm
3. Remove split pins (3) (3 used) from pins (8, 10
and 16) except the roller assembly (18) part.
Remove pins (8, 10 and 16) from bracket (26) and
link (17).
4. Remove spring pin (13) from yoke (15). Remove
pin (12) from yoke (15).
5. Remove split pin (3) from pin (16). Remove pin
(16) and the roller (18) assembly from link (17).
6. Remove seat (22), stopper (23) and boot (24)
from flange (28).
7. Remove socket bolts (25) (4 used) from bracket
(26). Remove bracket (26) from flange (28).
8. Secure the flange (28) part in a vise with the push
rod (38) side facing downward.
W2-14-7
IMPORTANT: The spool (48) assembly is also used
inside cylinder (39). Keep them in
order not to confuse.
9. Remove plug (42), spring (44) and the spool (48)
assembly from cylinder (40).
10. Remove plunger (47), retaining ring (45) and re-
tainer (46) from the spool (48) assembly.
IMPORTANT: The reaction force of spring (44) acts
on socket bolt (43). While holding
cylinder (40), slowly remove socket
bolt (43).
11. Remove socket bolts (43) (4 used) from cylinder
(40).
12. Remove cylinder (40) and the cylinder (39) as-
sembly from flange (28).
13. Remove the spool (48) assembly from cylinder
(39).
14. Remove plunger (47), spring (44), retaining ring
(45) and retainer (46) from the spool (48) assem-
bly.
15. Remove return spring (31), holder (32), rod (30),
balance spring (34), spring (33), retainers (35, 36),
pilot piston (37) and push rod (38) from flange
(28).
16. Remove oil seal (27) from flange (28).
17. Remove O-rings (29) (2 used) from flange (28)
and cylinder (39).
 UPPERSTRUCTURE / Brake Valve
ASSEMBLY OF BRAKE VALVE
1
12
2
11
8
15

14 26 28 39 43 40

16

10
A 42
21

17

19

16

18

20
22 23 31 30 29 48 49 47 45 46 44 WCEB-02-14-001

22 24 25

42

47

41

WCEB-02-14-002
38 27 37 36 35 33 34 32 46 29 48 45

13 5

12
7
15

3 8
9
26

17
10
21

3
16

3 18

19
View A WCEB-02-14-003

W2-14-8
 UPPERSTRUCTURE / Brake Valve

1- Rubber 14 - Bushing 26 - Bracket 38 - Push Rod

2- Brake Pedal 15 - Yoke 27 - Oil Seal 39 - Cylinder
3- Split Pin (4 Used) 16 - Pin (2 Used) 28 - Flange 40 - Cylinder
4- * Stopper Bolt 17 - Link 29 - O-Ring (2 Used) (1B, G45) 41 - O-Ring (1B, P32)
5- Bushing 18 - Roller Assembly 30 - Rod 42 - Plug
6- * Lock Nut 19 - Bracket 31 - Return Spring 43 - Socket Bolt (4 Used)
7- Bushing (2 Used) 20 - Brake Switch 32 - Holder 44 - Spring (2 Used)
8- Pin 21 - Socket Bolt (2 Used) 33 - Spring 45 - Retaining Ring (2 Used)
9- Bushing (2 Used) 22 - Seat 34 - Balance Spring 46 - Retainer (2 Used)
10 - Pin 23 - Stopper 35 - Retainer 47 - Plunger (2 Used)
11 - Boot 24 - Boot 36 - Retainer 48 - Spool (2 Used)
12 - Pin 25 - Socket Bolt (4 Used) 37 - Pilot Piston 49 - Spring
13 - Spring Pin
NOTE: As for the item with mark *, refer to W2-14-4.

W2-14-9
 UPPERSTRUCTURE / Brake Valve

1
12
2
11
8
15

14 26 28 39 43 40

16

10
A 42
21

17

19

16

18

20
22 22 23 24 25 31 30 29 48 49 47 45 46 44 WCEB-02-14-001

42

47

41

WCEB-02-14-002
38 27 37 36 35 33 34 32 46 29 48 45

13 5

12
7
15

3 8
9
26

17
10
21

3
16

3 18

19
WCEB-02-14-003
View A

W2-14-10
 UPPERSTRUCTURE / Brake Valve
Assembly of Brake Valve
1. Install oil seal (27) to flange (28).
2. Secure flange (28) in a vise with the oil seal (27)
side facing downward.
3. Install O-ring (29) to flange (28).
4. Apply hydraulic oil onto rod (30), pilot piston (37),
push rod (38), plungers (47) (2 used) and spools
(48) (2 used).
5. Install push rod (38), pilot piston (37), retainer (36),
retainer (35), return spring (31), balance spring
(34), spring (33), holder (32) and rod (30) to flange
(28) in this order.
6. Install O-ring (29) to cylinder (39).
7. Align the matching marks and place cylinder (39)
onto the flange (28) assembly.
8. Install retainer (46) and retaining ring (45) to spool
(48).
9. Install the spool (48) assembly to cylinder (39).
W2-14-11
10. Install spring (49), plunger (47) and spring (44) to
cylinder (39).
11. Align the matching marks and place cylinder (40)
onto cylinder (39).
12. Install retainer (46) and retaining ring (45) to spool
(48).
13. Install the spool (48) assembly to cylinder (40).
14. Install plunger (47), spring (44) and plug (42) to
cylinder (40).
: 130 to 180 N⋅m
(13 to 18 kgf⋅m, 96 to 133 lbf⋅ft)
15. Connect flange (28), cylinder (39) and cylinder
(40) with socket bolts (43) (4 used).
: 60 to 75 N⋅m
(6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft)
 UPPERSTRUCTURE / Brake Valve

1
12
2
11
8
15

26 28 40

16

10
A
21

17

19

16

18

20
22 23 WCEB-02-14-001

22 24 25

WCEB-02-14-002

13

12

15

3 8

26

17
10
21

3
16

3 18

19
View A WCEB-02-14-003

W2-14-12
 UPPERSTRUCTURE / Brake Valve
16. Secure the cylinder assembly in a vise with the
cylinder (40) side facing downward.
17. Install flange (28) to bracket (26) with socket bolts
(25) (4 used).
: 60 to 75 N⋅m (6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft)
18. Install boot (24), stopper (23) and seat (22) to
flange (28).
19. Apply grease onto all pin holes on brake pedal (2),
bracket (26), yoke (15) and link (17).
26. Secure stopper bolt (4) to link (17) with lock nut
(6).
: 6.0 to 10 N⋅m (0.6 to 1 kgf⋅m, 4 to 7 lbf⋅ft)
27. Install rubber (1) to brake pedal (2).
28. Install brake switch (20) to bracket (19). Install the
bracket (19) assembly to bracket (26) with socket
bolts (21) (2 used).
: 6 mm
: 58.8 to 73.5 N⋅m
(6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)

20. Install yoke (15) to brake pedal (2) with pin (12)
and spring pin (13).

21. Install roller assembly (18) to link (17) with pin (16).
Secure pin (16) to link (17) with split pin (3).

22. Install the link (17) assembly to bracket (26) with

pin (10). Secure pin (10) to bracket (26) with split
pin (3).

23. Install boot (11) to the brake pedal (2) assembly.

Install brake pedal (2) to bracket (26) with pin (8).
Secure pin (8) to bracket (26) with split pin (3).

24. Install yoke (15) to link (17) with pin (16). Secure
pin (16) to link (17) with split pin (3).

25. Adjust play of link (17) to 0 mm with stopper bolt

(4).

W2-14-13
 UPPERSTRUCTURE / Brake Valve
(Blank)

W2-14-14
 UPPERSTRUCTURE / Accumulator Charge Valve
REMOVAL AND INSTALLATION OF AC-
CUMULATOR CHARGE 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. Remove sems bolts (1) (6 used) from cover (2).
Remove cover (2) from main frame (3). 1 2 3
: 17 mm

WCJB-02-15-001

2. Disconnect hoses (4) (8 used) from accumulator

charge valve (5). Cap the open ends. Attach an 4 5, 6 7
identification tag onto the disconnected hoses for
assembling. 8
: 17 mm, 22 mm, 27 mm

3. Remove sems bolts (7) (4 used) from bracket (8).

Remove the bracket (8) assembly from main frame
(3).
: 17 mm

4. Remove sems bolts (6) (4 used) from bracket (8).

Remove accumulator charge valve (5) from 3 WCEB-02-15-001

bracket (8).
: 17 mm

W2-15-1
 UPPERSTRUCTURE / Accumulator Charge Valve
Installation
1. Install accumulator charge valve (5) to bracket (8)
with sems bolts (6) (4 used). 4 5, 6 7
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 8

2. Install the bracket (8) assembly to main frame (3)

with sems bolts (7) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Connect hoses (4) (8 used) to accumulator charge

valve (5).
: 17 mm 3 WCEB-02-15-001

: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

4. Install cover (2) to main frame (3) with sems bolts 1 2 3

(7) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-15-001

W2-15-2
 UPPERSTRUCTURE / Accumulator Charge Valve
(Blank)

W2-15-3
 UPPERSTRUCTURE / Accumulator Charge Valve
STRUCTURE OF ACCUMULATOR CHARGE VALVE
1, 2 3, 4 5, 6 1, 2

3, 4

5, 6

WCEB-02-15-002

8 8

9 9

10 10

11 11

1 6

Section A 2 Section B

18 19 20 5 6
26
15 16 17 21 22 23 24 6 9

14 5
27
13
25 28

12 29

37

36
WCEB-02-15-003
35 34 33 32 31 1 2 30 3 4
Section C
Section D

W2-15-4
 UPPERSTRUCTURE / Accumulator Charge Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 4 4.9 (0.5) (4)
2 O-Ring 4
3 Plug 3 26.5 (3) (20)
4 O-Ring 3
5 Plug 5 9.8 (1) (7)
6 O-Ring 5
7 Body 1
8 Plug 2 12 (1.2) (9)
9 O-Ring 3
10 Spring 2
11 Plunger 2
12 Plug 1 58.8 (6) (43)
13 Screw 1
14 Lock Nut 1
15 O-Ring 1
16 Spring 1
17 Needle Valve 1
18 O-Ring 1
19 Backup Ring 1
20 O-Ring 1
21 O-Ring 1
22 Backup Ring 1
23 Sleeve 1
24 Piston 1
25 Orifice 1 9.8 (1) (7)
26 Plug 1 12 (1.2) (9)
27 Spring 1
28 Plunger 1
29 Sleeve 1
30 Plunger 1
31 O-Ring 1
32 Washer 1
33 Spring 1
34 Spring 1
35 Plug 1 48.5 (5) (36)
36 O-Ring 1
37 Plug 1 48.5 (5) (36)
NOTE: Tools : 22 mm, 24 mm, 32 mm
: 1/8, 4 mm, 5 mm, 6 mm

W2-15-5
 UPPERSTRUCTURE / Accumulator Charge Valve
(Blank)

W2-15-6
 MEMO

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 MEMO

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 SECTION 3
UNDERCARRIAGE

―CONTENTS―
Group 1 Swing Bearing Group 6 Axle Lock Cylinder
Removal and Installation of Removal and Installation of
Swing Bearing ......................................W3-1-1 Axle Lock Cylinder .............................. W3-6-1
Disassembly of Swing Bearing ................W3-1-4 Disassembly and Assembly of
Assembly of Swing Bearing.....................W3-1-6 Axle Lock Cylinder .............................. W3-6-4

Group 2 Travel Motor Group 7 Operate Check Valve

Removal and Installation of
Travel Motor .........................................W3-2-1
Disassembly of Travel Motor...................W3-2-4
Assembly of Travel Motor ..................... W3-2-12
Disassembly of Brake Valve.................. W3-2-20
Assembly of Brake Valve ...................... W3-2-22
Group 3 Center Joint
Removal and Installation of
Cebter Joint ..........................................W3-3-1
Disassembly of Center Joint....................W3-3-6
Assembly of Center Joint ......................W3-3-8
Group 4 Transmission
Removal and Installation of
Transmission.........................................W3-4-1
Disassembly of Transmission ..................W3-4-6
Assembly of Transmission..................... W3-4-18
Removal and Installation of Operate Check
Valve (for Axle Lock Cylinder) .................W3-7-1
Structure of Operate Check Valve
(For Axle Lock Cylinder)..........................W3-7-2
Group 8 Solenoid Valve
Removal and Installation of
Outrigger/BladeSolenoid Valve Unit......W3-8-1
Structure of Solenoid Valve Unit ...............W3-8-3
Group 9 Transmission Changeover
Solenoid Valve
Removal and Installation of Transmission
Changeover Solenoid Valve..................W3-9-1
Group 10 Propeller Shaft
Removal and Installation of
Propeller Shaft.....................................W3-10-1

Group 5 Axle
Removal and Installation of Axle .............W3-5-1
Disassembly of Front Axle .................... W3-5-10
Assembly of Front Axle......................... W3-5-18
Disassembly of Rear Axle ..................... W3-5-28
Assembly of Rear Axle ......................... W3-5-34
Disassembly of Differential ................... W3-5-42
Assembly of Differential........................ W3-5-44
Disasembly of Steering Cylinder ........... W3-5-46
Assembly of Steering Cylinder .............. W3-5-48

CJBW-3-1
(Blank)

CJBW-3-2
 UNDERCARRIAGE / Swing Bearing
REMOVAL AND INSTALLATION OF
SWING BEARING

Before removing and installing the swing bearing, the

upperstructure must be removed first. For removal
and installation of the upperstructure, refer to the
REMOVAL AND INSTALLATION OF MAIN FRAME on
W2-3-1.
The procedure starts on the premise that the upper-
structure has already been removed.
Matching Mark 1
Removal
1. Put the matching marks on inner race (1) of the
swing bearing and track frame (2).

WCJB-02-03-003

2. Remove knock pin (3) from outer race (4) of the 3 4 5

swing bearing.

3. Remove bolts (5) (36 used) from track frame (2).

: 30 mm 2

WCJB-03-01-003

CAUTION: Swing bearing weight: 230 kg

(510 lb)

4. Install special tools (ST 0050) (3 used) to swing

bearing. Attach a wire rope onto special tool.
Hoist and remove swing bearing from track frame
(2).

ST 0050
W110-03-01-004
Swing Bearing

W3-1-1
 UNDERCARRIAGE / Swing Bearing
Installation
Clean the mounting surfaces of track frame (2) and
Swing Bearing
swing bearing.

1. Apply THREEBOND #1102 onto the swing bear-

ing mounting surface of track frame (2). 2

W110-03-01-004

CAUTION: Swing bearing weight: 230 kg

(510 lb) Position for Machine
Grease Fitting Front

IMPORTANT: If the matching mark do not align,

the soft zone position of the inner
race will be dislocated. 25°
2. Hoist and align swing bearing with the mounting
holes on track frame (2).

49°

25.8°
31°
Position for
“S” (Soft Zone) Grease Fitting
Marking Position
WCJB-03-01-002
Position for Position for
Plug Knock Pin

3 4 5 1
3. Install inner race (1) of the swing bearing to track
fame (2) with bolts (5) (36 used).
: 30 mm 2
: 500 N⋅m (51 kgf⋅m, 368 lbf⋅ft)

4. Install knock pin (3) to outer race (4) of the swing

bearing.

WCJB-03-01-003

W3-1-2
 UNDERCARRIAGE / Swing Bearing
5. After installing swing bearing, add grease (Shell
Swing Bearing Grease Level Pinion
Alvania EP2 or equivalent) up to 28 mm (1.1 in)
height from the bottom of the grease bath.

28 mm (1.1 in)

Grease Bath WCEB-03-01-004

W3-1-3
 UNDERCARRIAGE / Swing Bearing
DISASSEMBLY OF SWING BEARING

2 3 4

8 7 6 5 WCJB-03-01-001

8
7

W157-03-01-002

1- Plug 4- Outer Race 6- Seal 8- Support (111 Used)

2- Pin 5- Ball (111 Used) 7- Inner Race 9- Grease Fitting (2 Used)
3- Seal

W3-1-4
 UNDERCARRIAGE / Swing Bearing
Disassembly of Swing Bearing

1. Tap and remove pin (3) of plug (4) upward from
the bottom side.
NOTE: After installing pin (3), pin (3) was crimped.
Grind off the crimped part.
CAUTION: Swing bearing weight: 230 kg
(510 lb)
3. Place inner race (7) of the swing bearing onto a
wooden block by using special tool (ST 0050).
Hoist and hold outer race (4) slightly.

2 4. Remove balls (5) (111 used) and supports (8)

(111 used) from the plug hole while rotating outer
race (4).
Use magnet (A) when removing ball (5). Use wire
(B) and remove support (8).
1

4
3

A
W105-03-01-007 7

2. Remove plug (1) from outer race (5).

NOTE: Install the bolt into the screw hole (M10,
Pitch 1.5 mm) of plug (1). Tap or pull the
bolt from the inner side. 5 6
W105-03-01-009

W105-03-01-010
8
W105-03-01-008

5. Separate outer race (4) from inner race (7).

6. Remove seals (3, 6) from outer race (4) and in-

ner race (7) respectively by using a scrapper.

W3-1-5
 UNDERCARRIAGE / Swing Bearing
ASSEMBLY OF SWING BEARING

2 3 4

8 7 6 5 WCJB-03-01-001

8
7

W157-03-01-002

1- Plug 4- Outer Race 6- Seal 8- Support (111 Used)

2- Pin 5- Ball (111 Used) 7- Inner Race 9- Grease Fitting (2 Used)
3- Seal

W3-1-6
 UNDERCARRIAGE / Swing Bearing
Assembly of Swing Bearing

IMPORTANT: Apply grease onto balls (5) (111
used) and supports (8) (111 used)
CAUTION: Outer race (4) weight: 96 kg (211
lb)
Inner race (7) weight: 114 kg (251 lb)
2. Tap and install plug (1) into outer race (4). Secure
plug (1) to outer race (4) with pin (2). Crimp the
head of pin (2) by using a punch.
2

1. Hoist outer race (4) horizontally and align outer 4

race (4) with inner race (7) coaxially.
While rotating outer race (4), insert balls (5) and
supports (8) into the plug hole by using a round
bar.

1
4

W142-03-01-007

3
CAUTION: Swing bearing weight: 230 kg
(510 lb)

3. Install lifting tool (ST 0050) to outer race (4).

Hoist outer race (4). Thoroughly degrease the
5
slots for seals (3, 6). Apply THREEBOND #1745
6 W142-03-01-005 to seal (3) and #1530D to seal (6). Install seals (3,
6) to outer race (4) and inner race (7).

4 4. Add grease 0.5 L (0.1 US gal.) (Alvania EP2

grease or equivalent) to the swing bearing
through grease fitting (9). At this time, rotate
outer race (4) and add grease.

W142-03-01-006

W3-1-7
 UNDERCARRIAGE / Swing Bearing
(Blank)

W3-1-8
 UNDERCARRIAGE / Travel Motor
REMOVAL AND INSTALLATION OF
TRAVEL 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.)

Before removing and installing travel motor (7), the

propeller shaft must be removed first. For removal and
installation of the propeller shaft, refer to REMOVAL
AND INSTALLATION OF PROPELLER SHAFT on
W3-10-1.
Therefore, in this section, the procedure starts from the
premise that the propeller shaft has already been
removed.

Removal

IMPORTANT: Attach an identification tag onto the

disconnected hoses for assembling. 2
1. Disconnect hoses (1) (7 used) and connector (3)
from travel motor (2). Cap the disconnected
hoses. 3
: 19 mm, 22 mm, 27 mm 1

CAUTION: Travel motor (2) weight: 80 kg

4
(180 lb)

2. Loosen socket bolts (4) (4 used) of travel motor

(2). While holding the lower side of travel motor WCGB-03-05-030

(2) by using a forklift, remove socket bolts (4) (4 5

used).
: 14 mm

3. Remove travel motor (2) from transmission (5).

W3-2-1
 UNDERCARRIAGE / Travel Motor
Installation

CAUTION: Travel motor (2) weight: 80 kg

(180 lb) 2

1. Install travel motor (2) to transmission (5) with

3
socket bolts (4) (4 used).
: 14 mm 1
: 270 N·m (27.5 kgf·m, 199 lbf·ft)

2. Connect hoses (1) (7 used) and connector (3) to 4

travel motor (2).
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft) WCGB-03-05-030
: 22 mm
5
: 39 N·m (4 kgf·m, 29 lbf·ft)
: 27 mm
: 64 N·m (6.5 kgf·m, 47 lbf·ft)
: 12 mm
: 180 N·m (18 kgf·m, 133 lbf·ft)

3. Install the propeller shaft to transmission (5).

(Refer to REMOVAL AND INSTALLATION OF
PROPELLER SHAFT on W3-10-1.)

IMPORTANT: After installing the travel motor (2),

fill hydraulic oil into the travel motor
(2). Perform break-in operation after
installing the travel motor (2) in order
to prevent the travel motor (2) and/or
travel reduction gear from seizuring.
Condition 1.Engine control dial: Slow idle
2.Travel speed mode switch: Slow
speed
3.Operation duration: Over 2 minutes

W3-2-2
 UNDERCARRIAGE / Travel Motor
(Blank)

W3-2-3
 UNDERCARRIAGE / Travel Motor
DISASSEMBLY OF TRAVEL MOTOR

47 1 2 3 4 5 6 7 8 9 10 11 12 13

46

45

44
14
43

42 15

41

40

39

16
37, 38
17

36
18

35
19

34
20

WCGB-03-02-004
33 32 31 30 29 28 27 26 25 24 23 22 21

A
48 37, 38 37, 38
View A

56

28, 53, 54
49 4, 55 49

52
50 50

51 WCGB-03-02-001
WCGB-03-02-002
51 8

W3-2-4
 UNDERCARRIAGE / Travel Motor

1- Adjusting Screw 15 - Shim 29 - Socket Bolt 43 - Spring Collar

2- Lock Nut 16 - Retaining Ring 30 - Ring (2 Used) 44 - Retaining Ring
3- Pin 17 - Adjusting Shim 31 - Servo Piston 45 - Control Piston
4- Solenoid Valve 18 - Retaining Ring 32 - Lock Pin 46 - Sleeve
5- O-Ring 19 - Screw Bolt (7 Used) 33 - Pin 47 - Retaining Ring
6- Adjusting Screw 20 - Drive Shaft 34 - Valve Plate 48 - Socket Bolt (2 Used)
7- Lock Nut 21 - Center Shaft 35 - Spring 49 - Relief Valve (2 Used)
8- Housing 22 - Spring 36 - Head Cover 50 - Plug (2 Used)
9- Plunger (7 Used) 23 - Rotor 37 - Brake Valve 51 - Socket Bolt (8 Used)
10 - Retainer Plate 24 - Lock Nut 38 - O-Ring (2 Used) 52 - Socket Bolt (4 Used)
11 - Bearing 25 - Adjusting Screw 39 - Spring 53 - O-Ring
12 - Ring 26 - O-Ring 40 - Collar 54 - O-Ring
13 - Bearing 27 - Piston 41 - Bushing 55 - O-Ring (4 Used)
14 - Oil Seal 28 - Cover 42 - Spring 56 - Socket Bolt (4 Used)

W3-2-5
 UNDERCARRIAGE / Travel Motor

47 1 2 3 4 5

46

45

44

43
42

41

40

39

37, 38

36

35

20

WCGB-03-02-004
28

48 37, 38 37, 38
View A

56

28, 53, 54
49 4, 55 49
52
50 50

WCGB-03-02-001
WCGB-03-02-002

W3-2-6
 UNDERCARRIAGE / Travel Motor
Disassembly of Travel Motor

CAUTION: Travel motor weight: 80 kg (180
lb)
1. Set the travel motor onto a wooden block
(100×500 mm, 3.9×19.7 in) with the drive shaft
(20) side facing downward.
NOTE: When the workbench is used.
Workbench: ST 5092
Upper Plate: ST 7333
2. Remove socket bolts (48) (2 used). Remove
brake valve (37) and O-rings (38) (2 used).
: 5 mm
6. Remove the bushing (41) assembly, spring (39),
collar (40) and spring (35) from head cover (36)
in this order.
7. Remove spring collar (43) and spring (42) from
the bushing (41) assembly.
8. Remove O-ring (5), O-rings (55) (4 used),
adjusting screw (1), lock nut (2) and pin (3) from
solenoid valve (4).
9. Remove retaining ring (44) from solenoid valve
(4). Remove the sleeve (46) assembly.

IMPORTANT: Do not disassemble relief valves
(49) (2 used).
3. Remove relief valves (49) (2 used) and plugs
(50) (2 used) from head cover (36).
: 27 mm, 32 mm
4. Before removing, record the dimension of part A.
1 2
10. Remove control piston (45) from sleeve (46).
Remove retaining ring (47) from control piston
(45).
11. Remove socket bolts (52) (4 used). Remove
cover (28) and O-rings (53, 54) from head cover
(36).
: 6 mm

W1GL-03-02-006

5. Remove socket bolts (56) (4 used). Remove

solenoid valve (4) from head cover (36).
When removing solenoid valve (4), prevent
spring (39) from flying out.
: 6 mm

W3-2-7
 UNDERCARRIAGE / Travel Motor

6 7 8 9

14

15

16

36

20

WCGB-03-02-004
26 25 24 23 21

View A

51 WCGB-03-02-001
WCGB-03-02-002
51 8

W3-2-8
 UNDERCARRIAGE / Travel Motor
12. Before removing, record the dimensions of part B 16. Secure rotor (23), center shaft (21) and plungers
and part C. (9) (7 used) by using a screw bar (M8, Pitch 1.25
mm, Length 120 mm). Remove adjusting screw
B (25) from housing (8).
Screw Bar
23
Lock Nut
Washer
C

9 21
26 25
9

7 6
8

W1GL-03-02-003
W1GL-03-02-005

13. Loosen lock nuts (7, 24). Remove adjusting 17. Remove retaining ring (16) and shim (15) from
screws (6, 25) from housing (8). housing (8).

14. Install adjusting screw (25) (M12, Pitch 1.75 mm,
Length 100 mm) to adjusting screw (6) mounting
part, so that the angle of center shaft (21) should
be zero.
18. Set the housing (8) assembly in a vise with the
rotor (23) side facing downward. Remove the
drive shaft (20) assembly from housing (8).
19. Remove oil seal (14) from housing (8).

25
W1GL-03-02-004
21
15. Put the matching marks on the contacting surface
of head cover (36) and housing (8). Remove
socket bolts (51) (8 used). Remove head cover
(36) from housing (8).

W3-2-9
 UNDERCARRIAGE / Travel Motor

36

34

WCGB-03-02-004
33 32 31 30 29 27

View A

WCGB-03-02-001
WCGB-03-02-002

W3-2-10
 UNDERCARRIAGE / Travel Motor
20. Set head cover (36) in a vise with the valve plate
(34) side facing upward.

21. Remove socket bolt (29) and piston (27) from

servo piston (31).

22. Remove rings (30) (2 used) from piston (27).

CAUTION: Warm up lock pin (32). Take care

not to burn yourself.

23. Warm up the mounting part of lock pin (32) by

using a torch.
NOTE: Adhesive has been applied onto lock pin
(32). Warm up the adhesive by using slow
fire.

24. Remove pin (33) from servo piston (31).

25. Remove servo piston (31) from head cover (36).

W3-2-11
 UNDERCARRIAGE / Travel Motor
ASSEMBLY OF TRAVEL MOTOR

47 1 2 3 4 5 6 7 8 9 10 11 12 13

46

45

44
14
43

42 15

41

40

39

16
37, 38
17

36
18

35
19

34
20
WCGB-03-02-004

33 32 31 30 29 28 27 26 25 24 23 22 21

A
48 37, 38 37, 38
View A

56

28, 53, 54
49 4, 55 49

52
50 50

51 WCGB-03-02-001
WCGB-03-02-002
51 8

W3-2-12
 UNDERCARRIAGE / Travel Motor

1 - Adjusting Screw 15 - Shim 29 - Socket Bolt 43 - Spring Collar

2 - Lock Nut 16 - Retaining Ring 30 - Ring (2 Used) 44 - Retaining Ring
3 - Pin 17 - Adjusting Shim 31 - Servo Piston 45 - Control Piston
4 - Solenoid Valve 18 - Retaining Ring 32 - Lock Pin 46 - Sleeve
5 - O-Ring 19 - Screw Bolt (7 Used) 33 - Pin 47 - Retaining Ring
6 - Adjusting Screw 20 - Drive Shaft 34 - Valve Plate 48 - Socket Bolt (2 Used)
7 - Lock Nut 21 - Center Shaft 35 - Spring 49 - Relief Valve (2 Used)
8 - Housing 22 - Spring 36 - Head Cover 50 - Plug (2 Used)
9 - Plunger (7 Used) 23 - Rotor 37 - Brake Valve 51 - Socket Bolt (8 Used)
10 - Retainer Plate 24 - Lock Nut 38 - O-Ring (2 Used) 52 - Socket Bolt (4 Used)
11 - Bearing 25 - Adjusting Screw 39 - Spring 53 - O-Ring
12 - Ring 26 - O-Ring 40 - Collar 54 - O-Ring
13 - Bearing 27 - Piston 41 - Bushing 55 - O-Ring (4 Used)
14 - Oil Seal 28 - Cover 42 - Spring 56 - Socket Bolt (4 Used)

W3-2-13
 UNDERCARRIAGE / Travel Motor

47 1 2 3 4 5

46

45

44

43

42

41

40

39

36

35

34

WCGB-03-02-004
33 32 31 30 29 28 27

View A

56

28, 53, 54
4, 55
52

WCGB-03-02-001
WCGB-03-02-002

W3-2-14
 UNDERCARRIAGE / Travel Motor
Assembly of Travel Motor
1. Set head cover (36) in a vise with the valve plate
(34) side facing upward.
2. Apply hydraulic oil onto servo piston (31). Insert
servo piston (31) into head cover (36). Install pin
(33).
3. Apply LOCTITE #241 onto lock pin (32). Insert
lock pin (32) into servo piston (31). Secure pin
(33).
4. Install rings (30) (2 used) to piston (27). Install
piston (27) to servo piston (31) with socket bolt
(29).
5. Install O-rings (53, 45) and cover (28) to head
cover (36). Install cover (28) to head cover (36)
with socket bolts (52) (4 used).
: 6 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
6. Install adjusting screw (1) and lock nut (2) to
solenoid valve (4) with the dimension of part A
recorded before disassembling.
1 2
W1GL-03-02-006
W3-2-15
7. Install retaining rings (47, 44) to control piston
(45) and sleeve (46).
8. Apply hydraulic oil onto solenoid valve (4), control
piston (45) and sleeve (46).
9. Install O-ring (5) to solenoid valve (4).
10. Install control piston (45) to sleeve (46). Insert the
sleeve (46) assembly and pin (3) into solenoid
valve (4).
11. Install spring collar (43) and spring (42) to the
solenoid valve (4) assembly.
12. Install O-rings (55) (4 used) to the mounting
surface of head cover (36) and solenoid valve (4).
13. Install springs (35, 39), collar (40) and bushing
(41) to the large chamber side of head cover
(36).
14. Install the solenoid valve (4) assembly to head
cover (36) with socket bolts (56) (4 used).
 UNDERCARRIAGE / Travel Motor

6 7 8

14

15

16

36

20

WCGB-03-02-004
25 24 23 21

View A

51 WCGB-03-02-001
WCGB-03-02-002
51 8

W3-2-16
 UNDERCARRIAGE / Travel Motor
19. Temporarily install adjusting screw (25) (M12,
CAUTION: After warming up housing (8), Pitch 1.75 mm, Length 100 mm) to the adjusting
start the work. screw (6) mounting part, so that the angle of
center shaft (21) should be zero.
15. Warm up housing (8) to 50 to 80 °C (122 to
176 °F). Install the drive shaft (20) assembly to
housing (8). If the drive shaft (20) assembly
cannot be inserted, insert it by using a bar.
21
16. Face the rotor (23) side in housing (8) downward.
Install oil seal (14), shim (15) and retaining ring
(16) to housing (8). 25

17. Set the travel motor onto a wooden block

(100×500 mm, 3.9×19.7 in) with the drive shaft
(20) side facing downward. W1GL-03-02-008

NOTE: When the workbench is used.

Workbench: ST 5092 20. Align the matching marks. Install head cover (36)
Upper Plate: ST 7333 to housing (8) with socket bolts (51) (8 used).

18. Remove the screw bar, the lock nut and the 21. Remove temporarily installed adjusting screw
washer from rotor (23). (25) from housing (8).

22. Install adjusting screw (25), lock nut (24),

23 Screw Bar adjusting screw (6) and lock nut (7) to housing
Lock Nut
(8) so that the dimensions of part B and part C
Washer
should be the same dimensions before
disassembling.
B

W1GL-03-02-003

25 24

8 7 6

W1GL-03-02-005

W3-2-17
 UNDERCARRIAGE / Travel Motor

WCGB-03-02-004

48 37, 38 37, 38
View A

49 49

50 50

WCGB-03-02-001
WCGB-03-02-002

W3-2-18
 UNDERCARRIAGE / Travel Motor
23. Install relief valves (49) (2 used) and plugs (50)
(2 used) to head cover (36).
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 32 mm
: 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)

24. Install brake valve (37) and O-rings (38) (2 used)

to head cover (36) with socket bolts (48) (2
used).
: 5mm

W3-2-19
 UNDERCARRIAGE / Travel Motor
DISASSEMBLY OF BRAKE VALVE
A
View A
B
Brake Valve
7
Brake Valve
5, 6

WCGB-03-02-001

WCGB-03-02-002

2 3 4 8 9

10
1

Section C

11

12

13

17 16 15 14

Section B
7

WCGB-03-02-005

1- Cover 6- Orifice 10 - Socket Bolt (4 Used) 14 - O-Ring (2 Used)

2- Socket Bolt (4 Used) 7- Plug 11 - Plug 15 - O-Ring
3- Valve Casing 8- O-Ring (2 Used) 12 - Spring (2 Used) 16 - Shuttle Valve
4- Counterbalance Valve 9- Cover 13 - Check Valve 17 - Check Valve (2 Used)
5- Plug

W3-2-20
 UNDERCARRIAGE / Travel Motor
Disassembly of Brake Valve 7. Remove shuttle valve (16) from valve casing (3)
by using a socket wrench.
1. Remove socket bolts (2) (4 used). Remove cover : 4 mm
(1) and O-ring (8) from valve casing (3).
: 10 mm 8. Remove plug (5) from valve casing (3).

2. Remove socket bolts (10) (4 used). Remove 9. Remove orifice (6) from valve casing (3).
cover (9) and O-ring (8) from valve casing (3). : 3 mm
: 10 mm

IMPORTANT: When removing counterbalance

valve (4), remove counterbalance
valve (4) by turning in order to
prevent it from bounding.
3. Slowly remove counterbalance valve (4) from
valve casing (3) by turning.

CAUTION: When removing plug (11), prevent

spring (12) from flying out.

4. Remove plugs (11) (2 used), O-rings (14) (2

used), springs (12) (2 used) and check valve
(13).
: 36 mm

5. Remove check valve (17) from valve casing (3)

by using a socket wrench.

6. Remove plug (7) and O-ring (15) from valve

casing (3).

W3-2-21
 UNDERCARRIAGE / Travel Motor
ASSEMBLY OF BRAKE VALVE
A
View A
B
Brake Valve

7
Brake Valve
5, 6

WCGB-03-02-001
WCGB-03-02-002

2 3 4 8 9

10

Section C

11

12

13
17 16 15 14

7
Section B

WCGB-03-02-005

1- Cover 6- Orifice 10 - Socket Bolt (4 Used) 14 - O-Ring (2 Used)

2- Socket Bolt (4 Used) 7- Plug 11 - Plug 15 - O-Ring
3- Valve Casing 8- O-Ring (2 Used) 12 - Spring (2 Used) 16 - Shuttle Valve
4- Counterbalance Valve 9- Cover 13 - Check Valve 17 - Check Valve (2 Used)
5- Plug

W3-2-22
 UNDERCARRIAGE / Travel Motor
Assembly of Brake Valve

1. Install orifice (6) and plug (5) to valve casing (3).

: 3 mm

2. Install shuttle valve (16) and plug (7) to valve

casing (3).

3. Install check valves (17) (2 used) to valve casing

(3).

4. Install check valve (13) to check valve (17).

5. Install springs (12) (2 used) to plugs (11) (2 used).

Install the plug (11) assemblies (2 used) and
O-rings (14) (2 used) to valve casing (3).
: 36 mm
: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)

IMPORTANT: Slowly insert counterbalance valve

(4) into valve casing (3) by turning.
Check if counterbalance valve (4)
moves smoothly.
6. Insert counterbalance valve (4) into valve casing
(3).

7. Install cover (1) and O-ring (8) to valve casing (3)

with socket bolts (2) (4 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

8. Install cover (9) and O-ring (8) to valve casing (3)

with socket bolts (10) (4 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

W3-2-23
 UNDERCARRIAGE / Travel Motor
(Blank)

W3-2-24
 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
NOTE: If disconnecting the hoses (5 used) for the
front attachment, the center joint can be
removed easily. The number of hoses dif-
fers depending on the front attachment
specifications.

1. Disconnect connectors (2) (2 used).

2 3, 4 5
2. Remove bolt (3) and washer (4) from clips (1) (2
used). Remove clips (1) (2 used) from center joint
(5). 1
: 10 mm

WCJB-03-03-002
2

6 7 8
3. Disconnect connector (6).

4. Remove bolt (9) and washer (10) from clip (7).

Remove clip (7) from stopper (8).
: 17 mm
9, 10
5. Remove sems bolts (11) (3 used) from slip ring
(12). Remove the slip ring (12) assembly from 11
stopper (8). (Length: approx. 670 mm (26.4 in))
: 10 mm
12

WCJB-03-03-001

W3-3-1
 UNDERCARRIAGE / Center Joint
6. Remove bolts (14) (5 used) and washers (15) (5 5 13 8
used) from stopper (8). Remove stopper (8) from
center joint (5).
: 24 mm

7. Disconnect hoses (13) (13 used) from center joint

(5). Cap the open ends. Attach an identification 14, 15
tag onto the disconnected hoses for assembling.
: 19 mm, 22 mm, 27 mm, 36 mm

13

WCJB-03-03-001

8. Disconnect hoses (16) (23 used) from center joint

(5). Cap the open ends. Attach an identification 5
tag onto the disconnected hoses for assembling.
: 19 mm, 22 mm, 27 mm, 41 mm

9. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to

the hole on bolt (14) of center joint (5). Attach a 16
nylon sling onto eyebolts. Hoist and hold center
joint (1).

CAUTION: The center joint (1) assembly 16 WCJB-03-03-002

weight: 90 kg (200 lb)

IMPORTANT: The propeller shaft and the travel

transmission are located under cen-
ter joint (5). When hoisting and re-
moving center joint (5), do not hit
them.
10. Remove bolts (18) (4 used) and washers (19) (4
used) from center joint (5). Hoist and remove the
center joint (5) assembly from track frame (17). 18, 19
: 22 mm 5

17

WCJB-03-03-003

W3-3-2
 UNDERCARRIAGE / Center Joint
Installation

CAUTION: The center joint (5) assembly

weight: 90 kg (200 lb)

IMPORTANT: The propeller shaft and the travel

transmission are located under the
center joint (5). Hoist center joint (5)
in order not to hit them.
1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
16
center joint (5). Attach a nylon sling onto eyebolt.
Hoist and align center joint (5) with the mounting 18, 19
hole on track frame (17). 5

2. Apply LOCTITE #262 onto bolts (18) (4 used). 17

Install center joint (5) to track frame (17) with bolts
(18) (4 used) and washers (19) (4 used).
: 22 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) 16

WCJB-03-03-003

3. Connect hoses (16) (23 used) to center joint (5). 5

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
16
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

16 WCJB-03-03-002

W3-3-3
 UNDERCARRIAGE / Center Joint
4. Connect hoses (13) (13 used) to center joint (5). 5 13 8
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 14, 15
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

5. Apply LOCTITE #262 onto bolts (14) (5 used).

Install stopper (8) to center joint (5) with bolts (14)
13
(5 used) and washers (15) (5 used).
: 24 mm
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
WCJB-03-03-001

6 7 8
6. Install the slip ring (12) assembly to center joint
(5). Install slip ring (12) to stopper (8) with sems
bolts (11) (3 used).
: 10 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft) 9, 10

7. Install clip (7) to stopper (8) with bolt (9) and 11

washer (10).
: 17 mm
12
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

8. Connect connector (6).

WCJB-03-03-001
5

W3-3-4
 UNDERCARRIAGE / Center Joint
9. Install clips (1) (2 used) to center joint (5) with bolt 2 3, 4 5
(3) and washer (4).
: 10 mm
: 3.3 to 4.2 N⋅m 1
(0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft)

10. Connect connectors (2) (2 used).

WCJB-03-03-002
2

W3-3-5
 UNDERCARRIAGE / Center Joint
DISASSEMBLY OF CENTER JOINT

1, 2

3
3

5
5

13

12
7
11 11

11 8
WCGB-03-03-001

7 10 9 7

1- Plug (2 Used) 5- Body 8 - Bolt (4 Used) 11 - Socket Bolt (4 Used)

2- O-Ring (2 Used) 6- Oil Seal (15 Used) 9 - O-Ring 12 - O-Ring
3- Spindle 7- Cover 10 - Plate 13 - O-Ring
4- O-Ring

W3-3-6
 UNDERCARRIAGE / Center Joint
Disassembly of Center Joint
CAUTION: Center joint weight: 90 kg (200 lb)
1. Attach a nylon sling onto the body of body (5).
Hoist the center joint. Secure the center joint on a
workbench (ST 5109).
2. Remove socket bolts (11) (4 used) from cover (7).
Remove cover (7) and O-ring (12) from body (5).
: 12 mm
3. Remove bolts (8) (4 used) from plate (10). Re-
move plate (10) from spindle (3).
: 19 mm
6. Install eyebolts (M14, Pitch 1.75 mm) (2 used) to
the bolt (8) hole (2 places) on spindle (3). Hoist
and place spindle (3) onto the wooden blocks
horizontally.
7. Remove O-ring (9), plugs (1) (2 used) and O-rings
(2) (2 used) from spindle (3).
: 12 mm
IMPORTANT: For easy removal, use the pins (2
used).
Do not damage the seal groove by
the pins.
8. Remove O-rings (4, 13) and oil seals (6) (15
used) from body (5).

4. Install eyebolts (M14, Pitch 2.0 mm) (2 used) to

the socket bolt (11) hole (2 places) on body (5).
Hoist and hold body (5).

IMPORTANT: Do not damage the seal sliding sur-

face of spindle (3).
5. Install the puller to the body (5). Remove body (5)
5
from spindle (3).
NOTE: There is a hole for the harness at the cen- 4, 13, 6
ter of spindle (3). Prepare a cover in order
to cover the hole on spindle (3). Place the
cover between the puller and spindle (3).
Remove spindle (3).
Puller W105-03-03-015

W202-03-03-011

W3-3-7
 UNDERCARRIAGE / Center Joint
ASSEMBLY OF CENTER JOINT

1, 2

3
3

5
5

13

12
7
11 11

11 8
WCGB-03-03-001

7 10 9 7

1- Plug (2 Used) 5- Body 8 - Bolt (4 Used) 11 - Socket Bolt (4 Used)

2- O-Ring (2 Used) 6- Oil Seal (15 Used) 9 - O-Ring 12 - O-Ring
3- Spindle 7- Cover 10 - Plate 13 - O-Ring
4- O-Ring

W3-3-8
 UNDERCARRIAGE / Center Joint
Assembly of Center Joint 8. Install plate (10) to spindle (3) with bolts (8) (4
used).
IMPORTANT: After installing the seals, apply : 19 mm
grease onto the inner surface of : 51 to 59 N⋅m
body (5), the inner surface of the (5.2 to 6.0 kgf⋅m, 38 to 44 lbf⋅ft)
circuit and the seals.
1. Install O-rings (4, 13) and oil seals (6) (15 used) 9. Install O-ring (12) to cover (7).
to body (5).
10. Install cover (7) to body (5) with socket bolts (11)
2. Apply grease onto O-rings (2) (2 used). Install (4 used).
O-rings (2) (2 used) to plugs (1) (2 used). : 12 mm
: 206 to 216 N⋅m
3. Apply grease onto O-ring (9). Install plugs (1) (2 (21 to 22 kgf⋅m, 152 to 159 lbf⋅ft)
used) and O-ring (9) to spindle (3).
: 12 mm
: 147±14.7 N·m
(15±1.5 kgf·m, 108±11 lbf⋅ft)

4. Install eyebolts (M14, Pitch 1.75 mm) (2 used)

into the bolt (8) hole (2 places) on spindle (3).

5. Hoist spindle (3). Secure spindle (3) on a work-

bench (ST 5109).

IMPORTANT: There is almost no clearance be-

tween body (5) and spindle (3). In-
sert body (5) along the axis straight
and slowly.
6. Apply hydraulic oil onto the outer surface of spin-
dle (3). Install eyebolts (M14, Pitch 2.0 mm) (2
used) to the bolt (8) hole (2 places) on body (5).
Hoist and install body (5) to spindle (3).

7. Lightly tap body (5) by using a plastic hammer.

Insert body (5) until body (5) comes in contact
with the flange of spindle (3).

W3-3-9
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-10
 UNDERCARRIAGE / Transmission
REMOVAL AND INSTALLATION OF
TRANSMISSION

CAUTION: Bleed air from the hydraulic oil

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

When removing and installing the transmission, the

propeller shaft, the pipings of the travel motor and one
part of the rear axle should be removed first.
Refer to REMOVAL AND INSTALLATION OF
PROPELLER SHAFT on W3-10-1, REMOVAL AND
INSTALLATION OF TRAVEL MOTOR on W3-2-1 and
REMOVAL AND INSTALLATION OF AXLE on W3-5-1.

IMPORTANT: When removing and installing the 4

3
transmission, bleed air from the
hydraulic port and the brake before
doing any work.
Refer to TROUBLESHOOTING / T5-7
Troubleshooting B in Technical
Manual.
2
Removal
1 3 W1GL-03-05-003
IMPORTANT: Remove the transmission with the
travel motor together in order to
keep the balance of weight.
1. Loosen nuts (1) (20 used). Raise the machine
until tire (3) at the rear axle side is raised. Place a
stand under frame (4).

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb)

2. Remove nuts (1) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used).

W3-4-1
 UNDERCARRIAGE / Transmission
3. Remove plugs (8, 9). Drain oil from the
6 7 Transmission
transmission.
: 14 mm
5

CAUTION: Propeller shaft (11) weight: 35 kg

(80 lb)
8
4. Place a wooden block under propeller shaft (11).
Remove nuts (10) (8 used). Remove propeller
shaft (11) from the transmission.
: 14 mm

5. Disconnect hoses (7) (9 used) and connectors (6) 12 WCGB-03-05-033

11 10 9
(2 used) from the transmission and travel motor
(5). Cap the disconnected hoses.
: 19 mm, 22 mm, 27 mm
: 12 mm

CAUTION: The transmission assembly Transmission

weight: 220 kg (490 lb)

6. Loosen bolts (13) (14 used). Rear Axle

: 19 mm

7. Support the travel motor (5) part by using a forklift 13

and remove bolts (13) (14 used). Remove the
transmission assembly from the rear axle.
: 19 mm

CAUTION: Travel motor (5) weight: 80 kg WCGB-03-05-032

(180 lb)

8. Remove socket bolts (12) (4 used). Remove travel

motor (5) from the transmission.
: 14 mm

W3-4-2
 UNDERCARRIAGE / Transmission
Installation

6 7
CAUTION: Transmission weight: 135 kg (300 Transmission
lb) 5

1. Install plug (9) to the transmission. Temporarily

install plug (8).
: 14 mm 8
: 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

CAUTION: Travel motor (5) weight: 80 kg

(180 lb)
12 WCGB-03-05-033
2. Install travel motor (5) onto the transmission with 11 10 9
socket bolts (12) (4 used).
: 14 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) Transmission

3. Install the transmission assembly to the rear axle

with bolts (13) (14 used). Rear Axle
: 19 mm
: 230 N⋅m (23 kgf⋅m, 170 lbf⋅ft)
13
4. Connect hoses (7) (9 used) and connectors (6) (2
used) to the transmission.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm WCGB-03-05-032
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 12 mm
: 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft)

W3-4-3
 UNDERCARRIAGE / Transmission

CAUTION: Propeller shaft (11) weight: 35 kg

(80 lb)
Transmission
5. Install propeller shaft (11) to the transmission with
nuts (10) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

6. Remove temporarily installed plug (8). Add oil to

the transmission. After adding oil, install plug (8) to
the transmission.
NOTE: Gear oil: 2.5 L (0.7 US gal.)
: 14 mm
: 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft) WCGB-03-05-033

11 10 9

W3-4-4
 UNDERCARRIAGE / Transmission
(Blank)

W3-4-5
 UNDERCARRIAGE / Transmission
DISASSEMBLY OF TRANSMISSION

Part A

WCGB-03-04-001

Part A

3 4 5 6 7 8 9 10 9 11 12 13 14, 15 16, 17, 18, 19 20 21 22 23

2 24

1 25

26
54
27, 28
52, 53

51

50
27, 28

49
29
48
30, 31
47

46 45 44 43 42 41 40 39 38 37 36 35 34 33 32

WCGB-03-04-002

W3-4-6
 UNDERCARRIAGE / Transmission

Part B WCGB-03-04-001

Part B 55 56 57 58
59

60

74 61

62
73

72

70, 71

63
69

WCGB-03-04-003
68 22 67 66 65 64

W3-4-7
 UNDERCARRIAGE / Transmission

1- Cover 21 - Bearing 41 - Friction Plate (10 Used) 61 - Bearing

2- Bolt (5 Used) 22 - Housing 42 - O-Ring 62 - Pinion
3- O-Ring (5 Used) 23 - Bearing 43 - Ring 63 - Shim
4- Oil Seal 24 - O-Ring (2 Used) 44 - Ring 64 - Bushing
5- Pin (2 Used) 25 - Bolt (4 Used) 45 - Brake Piston 65 - Shaft Seal
6- Oil Seal 26 - Shift Interlock Controller 46 - Disc Spring 66 - Cover
7- Oil Seal 27 - Socket Bolt (5 Used) 47 - Clutch Piston 67 - Screen Sheet
8- Seal Ring 28 - Washer (5 Used) 48 - Oil Seal 68 - Flange
9- O-Ring (2 Used) 29 - Plate 49 - Shaft 69 - O-Ring
10 - Gasket 30 - Bearing 50 - Spring 70 - Bolt (2 Used)
11 - Plate (7 Used) 31 - Washer (2 Used) 51 - Holder 71 - Washer (2 Used)
12 - Friction Plate (6 Used) 32 - Planetary Carrier 52 - Bearing 72 - Plate
13 - Disc Plate 33 - Slot Pin (6 Used) 53 - Plate (2 Used) 73 - Plate
14 - Retaining Ring 34 - Ring Gear 54 - Disc Spring 74 - Shaft Seal
15 - Shim 35 - Retaining Ring 55 - Bearing
16 - Planetary Gear (3 Used) 36 - Retaining Ring 56 - Ring
17 - Retaining Ring (3 Used) 37 - Bearing 57 - Final Gear
18 - Washer (3 Used) 38 - Collar 58 - O-Ring (3 Used)
19 - Bearing 39 - Disc Plate 59 - O-Ring
20 - Retaining Ring 40 - Plate (9 Used) 60 - Cover

W3-4-8
 UNDERCARRIAGE / Transmission
(Blank)

W3-4-9
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A
22 24

26

27, 28

27, 28

WCGB-03-04-002

W3-4-10
 UNDERCARRIAGE / Transmission
Disassembly of Transmission

CAUTION: Transmission weight: 135 kg (300

lb)
1. Attach a nylon sling onto the transmission. Hoist
the transmission. Lower the transmission onto a
workbench.
2. Remove bolts (75, 77) (2 used for each) and seal
rings (76, 78) (2 used for each) from the
transmission. Disconnect pipes (79) (2 used) from
the transmission.
: 22 mm, 24 mm
Transmission
4. Remove socket bolts (27) (5 used) and washers
(28) (5 used).
: 6 mm
5. Remove shift interlock controller (26) and O-rings
(24) (2 used) from the transmission.
6. Remove socket bolt (83). Remove travel N sensor
(82) and O-rings (84) (2 used) from housing (22).
: 6 mm

83, 84

82

22

79 77, 78 75, 76
WCGB-03-04-006
WCGB-03-04-005

3. Remove plugs (80) (2 used) and seal rings (81) (2

used) from housing (22).
: 8 mm 80, 81 22

WCGB-03-04-013

W3-4-11
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

3 4 5 7 22

54

47

46 45

WCGB-03-04-002

W3-4-12
 UNDERCARRIAGE / Transmission
7. Remove bleeder (85), spring (87), steel ball (88), 10. Remove spring (94), O-ring (95) and piston (96)
plug (90) and O-rings (86, 89) from housing (22). from housing (22).
: 27 mm 22
: 8 mm 2
85

1 94, 95, 96

86
22
87
88
90
89
WCGB-03-04-014

WCGB-03-04-007
11. Remove disc springs (46, 54) from housing (22).
8. Remove bleeder valve (93) and plugs (91, 92) Remove clutch piston (47).
from housing (22).
: 17 mm 12. Remove pins (5) (2 used) from housing (22).
: 8 mm
22 13. Apply air to the hole of bleeder valve (93) on
housing (22). Remove brake piston (45). Remove
fitting (97) from housing (22).
: 17 mm
22

91

97
93 92 WCGB-03-04-013

9. Remove bolts (2) (5 used). Remove cover (1) and

O-ring (3) from housing (22).
93
: 19 mm WCGB-03-04-013

14. Remove oil seals (4, 7) from housing (22).

W3-4-13
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

6 8 9 10 11 12 13 14, 15 16, 17, 18, 19 20 21 22

23

25

52, 53

51

50

49
29
48
30, 31

45 44 43 42 41 40 39 38 37 36 35 34 33 32

WCGB-03-04-002

W3-4-14
 UNDERCARRIAGE / Transmission
15. Remove oil seals (6, 48) from brake piston (45).
IMPORTANT: Do not remove bearing (52) unless
necessary.
16. Remove bearing (52) and plales (53) (2 used)
from shaft (49).
17. Remove holder (51) and spring (50) from shaft
(49).
18. Remove the ring (44) assembly from housing (22).
19. Remove ring (43), seal ring (8), O-rings (9) (2
used), O-ring (42) and gasket (10) from the ring
(44) assembly.
20. Remove friction plates (12) (6 used), plates (11) (7
used) and disc plate (13) from housing (22).
21. Remove retaining ring (14) and shim (15) from
housing (22).
22. Remove friction plates (41) (10 used) and plates
(40) (9 used) from housing (22).
23. Remove disc plate (39) from housing (22).
24. Remove the shaft (49) assembly from housing
(22).
25. Remove shaft (49) from ring gear (34).
W3-4-15
26. Remove retaining ring (20) from shaft (49).
Remove collar (38).
IMPORTANT: Do not remove bearing (37) unless
necessary.
27. Remove retaining rings (35, 36) from ring gear
(34). Remove bearing (37).
28. Remove bearing (30) and washers (31) (2 used)
from planetary carrier (32).
29. Remove bolts (25) (4 used). Remove plate (29)
from housing (22).
: 17 mm
30. Remove planetary carrier (32) from housing (22).
IMPORTANT: Do not remove bearings (21, 23)
unless necessary.
31. Remove the inner races of bearings (21, 23) from
planetary carrier (32).
IMPORTANT: Do not remove bearings (21, 23)
unless necessary.
32. Remove the outer races of bearings (21, 23) from
housing (22).
IMPORTANT: Do not remove bearing (19) unless
necessary.
33. Remove retaining rings (17) (3 used), washers
(18) (3 used) and bearings (19) (3 used) from
planetary gears (16) (3 used).
34. Remove slot pins (33) (6 used) from planetary
gear (16).
 UNDERCARRIAGE / Transmission

Part B WCGB-03-04-001

Part B 55 56 57 58
59

60

74 61

62
73

72

70, 71

63
69

WCGB-03-04-003
68 22 67 66 65 64

W3-4-16
 UNDERCARRIAGE / Transmission
35. Remove bleeder valves (98) (2 used), plugs (99) 40. Remove O-ring (59) and bushing (64) from pinion
(2 used), plugs (101) (3 used), seal rings (100) (2 (62).
used) and O-rings (102) (3 used) from housing
(22). IMPORTANT: Do not remove bearing (61) unless
: 17 mm necessary.
: 8 mm 22 99, 100 41. Remove the inner race of bearing (61) from pinion
(62).

IMPORTANT: Do not remove bearing (61) unless

necessary.
98 42. Remove shim (63) and the outer race of bearing
(61) from cover (60).

43. Remove cover (60) from housing (22).

44. Remove O-rings (58) (3 used) and shaft seal (65)

from cover (60).
101, 102
WCGB-03-04-008 45. Remove the final gear (57) assembly from
housing (22).
36. Remove bolts (70) (2 used) and washers (71) (2
used). Remove plate (72) and O-ring (69) from 46. Remove cover (66) from final gear (57).
housing (22).
: 17 mm 47. Remove screen sheet (67) from housing (22).

37. Remove flange (68) and plate (73) from housing IMPORTANT: Do not remove bearing (55) unless
(22). necessary.
48. Remove bearing (55) and ring (56) from housing
38. Remove shaft seal (74) from housing (22). (22).

39. Remove pinion (62) from housing (22).

W3-4-17
 UNDERCARRIAGE / Transmission
ASSEMBLY OF TRANSMISSION

Part A

WCGB-03-04-001

Part A

4 5 6 7 8 9 10 9 11 12 13 14, 15 16, 17, 18, 19 20 21 22

3 23
24
2

25
1
26

54
27, 28
52, 53

51

50
27, 28

49
29
48
30, 31
47

46 45 44 43 42 41 40 39 38 37 36 35 34 33 32

WCGB-03-04-002

W3-4-18
 UNDERCARRIAGE / Transmission

Part B WCGB-03-04-001

Part B 55 56 57 58
59

60

74 61

62
73

72

70, 71

63
69

WCGB-03-04-003
68 22 67 66 65 64

W3-4-19
 UNDERCARRIAGE / Transmission

1- Cover 21 - Bearing 40 - Friction Plate (10 Used) 61 - Bearing

2- Bolt (5 Used) 22 - Housing 41 - O-Ring 62 - Pinion
3- O-Ring (5 Used) 23 - Bearing 42 - Ring 63 - Shim
4- Oil Seal 24 - O-Ring (2 Used) 43 - Ring 64 - Bushing
5- Pin (2 Used) 25 - Bolt (4 Used) 44 - Brake Piston 65 - Shaft Seal
6- Oil Seal 26 - Shift Interlock Controller 45 - Disc Spring 66 - Cover
7- Oil Seal 27 - Socket Bolt (5 Used) 46 - Clutch Piston 67 - Screen Sheet
8- Seal Ring 28 - Washer (5 Used) 47 - Oil Seal 68 - Flange
9- O-Ring (2 Used) 29 - Plate 48 - Shaft 69 - O-Ring
10 - Gasket 30 - Bearing 49 - Spring 70 - Bolt (2 Used)
11 - Plate (7 Used) 31 - Washer (2 Used) 50 - Holder 71 - Washer (2 Used)
12 - Friction Plate (6 Used) 32 - Planetary Carrier 51 - Bearing 72 - Plate
13 - Disc Plate 33 - Slot Pin (6 Used) 52 - Plate (2 Used) 73 - Plate
14 - Retaining Ring 34 - Ring Gear 53 - Disc Spring 74 - Shaft Seal
15 - Shim 35 - Retaining Ring 54 - Bearing
16 - Planetary Gear (3 Used) 36 - Retaining Ring 55 - Ring
17 - Retaining Ring (3 Used) 37 - Bearing 56 - Final Gear
18 - Washer (3 Used) 38 - Collar 57 - O-Ring (3 Used)
19 - Bearing 39 - Disc Plate 58 - O-Ring
20 - Retaining Ring 40 - Plate (9 Used) 59 - Cover

W3-4-20
 UNDERCARRIAGE / Transmission
(Blank)

W3-4-21
 UNDERCARRIAGE / Transmission

Part B WCGB-03-04-001

Part B 55 57 58

60

61

63

WCGB-03-04-003
22 67 66 65

W3-4-22
 UNDERCARRIAGE / Transmission
Assembly of Transmission

1. Hoist housing (22) with the rear axle mounting
side facing upward.
2. Install the outer race of bearing (55) to housing
(22).
5. Apply grease onto the seal and the dust lip part of
shaft seal (65). Apply gear oil onto the outer
circumference of shaft seal (65). Install shaft seal
(65) to cover (60).
NOTE: Dimension A: 69.5-0.5 mm (2.7-0.02 in)

3. Install screen sheet (67) to housing (22). At this 65

time, the slot pin should pass through the hole on
screen sheet (67).

60

22
WCGB-03-04-015

6. Install shim (63) to cover (60).

7. Install the outer race of bearing (61) to cover (60).

WCGB-03-04-009
Slot Pin
8. Apply hydraulic oil onto O-ring (58). Install O-rings
4. Install final gear (57) to housing (22). (58) (3 used) to cover (60).

IMPORTANT: Install cover (66) so that the convex

part of the cover (60) back side can
enter the groove of cover (60).
9. Install cover (66) to cover (60).

66

60

WCGB-03-04-016

W3-4-23
 UNDERCARRIAGE / Transmission

Part B WCGB-03-04-001

Part B 55 56
59

60

61

62

72

70

69

WCGB-03-04-003
68 22 64

W3-4-24
 UNDERCARRIAGE / Transmission
10. Install the cover (60) assembly to housing (22). 15. Install O-ring (69) and plate (72) to housing (22).
Temporarily tighten with nuts (103) (2 used) and Temporarily tighten with bolts (70) (2 used). At this
washers (104) (2 used). time, turn pinion (62) to both directions 7 times
: 19 mm and take up slack.
60 : 17 mm
: 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft)

16. Turn pinion (62) and measure the preload. If the

22 proper preload cannot be obtained, reassemble
103, 104 from step 14.
NOTE: Proper preload: 1.5 to 3.0 N⋅m (0.2 to 0.3
kgf⋅m, 1.0 to 2.0 lbf⋅ft)

17. Tighten pinion (62) in a direction opposite to step

12 by using special tool (ZF special tool No. 5870
654 049). Remove special tool (ZF special tool No.
WCGB-03-04-010 5870 654 049).

11. Install the inner race of bearing (61), bushing (64) 18. Turn pinion (62) and measure the preload. If the
and O-ring (59) to pinion (62). proper preload cannot be obtained, reassemble
from step 14.
12. Install pinion (62) to housing (22). Install special
NOTE: Proper preload: 1.5 to 3.0 N⋅m (0.2 to 0.3
tool (ZF special tool No. 5870 654 049) to housing
kgf⋅m, 1.0 to 2.0 lbf⋅ft)
(22). Tighten pinion (62).
19. Remove temporarily installed bolts (70) (2 used).
13. Hoist and turn over housing (22) with the rear axle
Remove flange (68) and plate (72) from housing
mounting side facing downward.
(22).
: 17 mm
14. Install ring (56) and the inner race of bearing (55)
to pinion (62).

W3-4-25
 UNDERCARRIAGE / Transmission

Part B WCGB-03-04-001

Part B 55

60

74

62
73

72

70, 71

69

WCGB-03-04-003
68 22

W3-4-26
 UNDERCARRIAGE / Transmission
20. Apply grease onto the seal and the dust lip part of
shaft seal (74). Apply gear oil onto the outer
circumference of shaft seal (74). Install shaft seal
(74) to housing (22).
23. Remove nuts (103) (2 used) and washers (104) (2
used) which are installed temporarily.
: 19 mm

21. Install plate (73) to housing (22).

NOTE: Dimension B: 17.6-0.5 mm (0.7-0.02 in)
Dimension C: 27.5+0.3 mm(1.1+0.01 in) 22
103, 104
74 55

22

B
C
WCGB-03-04-010

73 24. Hoist housing (22) with the rear axle mounting

side facing upward.
WCGB-03-04-011
25. Install the steel ball (diameter: 7.0 mm (0.3 in)) to
the center hole on pinion (62). Measure the
22. Install flange (68), O-ring (69) and plate (72) to
dimension. If the proper dimension cannot be
housing (22) with bolts (70) (2 used) and washers
obtained, reassemble from step 12.
(71) (2 used).
: 17 mm NOTE: Dimension D: 115.6 mm (4.6 in)
: 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft) Dimension E: 73±0.05 mm (2.9±0.002 in)
62

D
E 60
22

WCGB-03-04-012

W3-4-27
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

13 14, 15 16, 17, 18, 19 20 21 22

23

25

49
29

30, 31

39 38 37 36 35 34 33 32

WCGB-03-04-002

W3-4-28
 UNDERCARRIAGE / Transmission
26. Install the outer race of bearing (23) to housing
(22).
27. Hoist housing (22) with the rear axle mounting
side facing downward.
28. Install the outer race of bearing (21) to housing
(22).
29. Apply grease onto slot pin (33). Install slot pins
(33) (6 used) to planetary carrier (32).
NOTE: Dimension F: 28-1.0 mm (1.1-0.04 in)
33
32
F
WCGB-03-04-017
30. Install planetary gears (16) (3 used), bearings
(19) (3 used) and washers (18) (3 used) to
planetary carrier (32) with retaining rings (17) (3
used).
31. Install the inner race of bearing (21) to planetary
carrier (32).
32. Install planetary carrier (32) to housing (22).
33. Tighten planetary carrier (32) to housing (22) by
using special tool (ZF special tool No. 5870 654
049).
W3-4-29
34. Hoist housing (22) with the rear axle mounting
side facing upward.
35. Install the inner race of bearing (23) to housing
(22).
36. Install plate (29) to housing (22) with bolts (25) (4
used). At this time, turn planetary carrier (32) to
both directions several times.
: 17 mm
: 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft)
37. Install collar (38) to shaft (49). Secure with
retaining ring (20).
38. Secure bearing (37) to ring gear (34) with
retaining rings (36) (2 used).
39. Install shaft (49) to ring gear (34). Secure with
retaining ring (35).
40. Hoist housing (22) with the rear axle mounting
side facing downward.
41. Install bearing (30) and washers (31) (3 used) to
planetary carrier (32).
42. Install the shaft (49) assembly to housing (22).
43. Secure the shaft (49) assembly to housing (22)
with retaining ring (14) and shim (15).
44. Install disc plates (13, 39) to housing (22).
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

11 12 22

54

52, 53

51

49

47

46 45 41 40

WCGB-03-04-002

W3-4-30
 UNDERCARRIAGE / Transmission
45. Install friction plates (12) (6 used) and plates (11) 52. Measure dimension I of housing (22) and clutch
(7 used) to housing (22). piston (47).
NOTE: Dimension I: 22.5 mm (0.9 in)
46. Remove friction plates (41) (10 used) and plates
(40) (9 used) from housing (22).

47. Apply hydraulic oil onto plate (53). Install holder

(51), bearing (52) and plates (53) (2 used) to shaft
(49). I

48. Install brake piston (45) without the seals to

housing (22). 47

22
49. Install clutch piston (47) without the seals to
housing (22). WCGB-03-04-018

53. Measure dimension J of housing (22) and brake

50. Install disc springs (46, 54) to housing (22).
piston (45).
51. Install special tool (ZF special tool No. 5870 200 NOTE: Dimension J: 11.9 mm (0.47 in)
131) to housing (22) with the bolts (2 used).
Measure dimensions G and H of disc springs (46,
54).
: 19 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft) J
NOTE: Dimension G: 2.4+0.3 mm (0.09+0.01 in)
45
Dimension H: 1.8+0.3 mm (0.07+0.01 in)

54 46 22

WCGB-03-04-018

54. Remove the bolts (2 used). Remove special tool

H (ZF special tool No. 5870 200 131) and disc
G springs (46, 54) from housing (22).
: 19 mm

22 55. Remove brake piston (45), clutch piston (47),

holder (51), bearing (52) and plates (53) (2 used)
WCGB-03-04-018
from housing (22).

W3-4-31
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

4 5 6 7 8 9 10 9 22
3
2

54

52, 53

51

50

49

48
47

46 45 44 43 42

WCGB-03-04-002

W3-4-32
 UNDERCARRIAGE / Transmission
56. Apply hydraulic oil onto the seal surface of ring 66. Install clutch piston (47) to housing (22). Push
(43) and O-ring (9). Install O-ring (9) to ring (43). clutch piston (47) toward the shaft. Install plugs
(80) (2 used) and seal rings (81) (2 used) to
57. Install ring (43) to housing (22) by using a plastic housing (22).
hammer.
80, 81 22
58. Apply hydraulic oil onto the seal surface of ring
(44) and O-rings (9, 42). Install O-rings (9, 42), oil
seal (8) and gasket (10) to ring (44).

59. Install ring (44) to housing (22) by using a plastic

hammer.

60. Install spring (50) and holder (51) to shaft (49).

61. Apply hydraulic oil onto bearing (52). Install

bearing (52) and plates (53) (2 used) to shaft (49).
WCGB-03-04-013

62. Apply hydraulic oil onto the seal surface of

housing (22). Install oil seals (4, 7) to housing
(22).
63. Apply hydraulic oil onto the seal surface of brake
piston (45). Install oil seals (6, 48) to brake piston
(45).
67. Install disc springs (46, 54) to housing (22).
68. Install piston (96), spring (94) and O-ring (95) to
housing (22).
22

64. Install brake piston (45) to housing (22) by using a 94, 95, 96
plastic hammer.

65. Install pins (5) (2 used) to brake piston (45).

WCGB-03-04-014

69. Apply hydraulic oil onto O-ring (3). Install O-ring

(3) to cover (1).

70. Install cover (1) to housing (22) with bolts (2) (5

used).
: 19 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)

W3-4-33
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

22

WCGB-03-04-002

W3-4-34
 UNDERCARRIAGE / Transmission
71. Install O-rings (86, 89), plug (90), steel ball (88) 73. Install bleeder (85), bleeder valve (93), fitting (97)
and spring (87) to housing (22). and plugs (91, 92) to housing (22).
: 8 mm Bleeder (85)
: 24 N⋅m (2.4 kgf⋅m, 18 lbf⋅ft) : 27 mm
2 : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)
Bleeder valve (93)
: 17 mm
1 : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)
Fitting (97)
86 : 17 mm
22 : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)
87
Plugs (91, 92)
88 : 8 mm
90 : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
89
22
WCGB-03-04-007

72. Install bleeder valves (98) (2 used), plugs (99) (2

used), plugs (101) (3 used), seal rings (100) (2
used) and O-rings (102) (3 used) to housing (22). 97
Bleeder valve (98) 85
: 17 mm
: 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)
Plug (99)
: 8 mm
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft) 93 92 91
WCGB-03-04-013
Plug (102)
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

22 99, 100

98

101, 102
WCGB-03-04-008

W3-4-35
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

22

26

27, 28

27, 28

WCGB-03-04-002

W3-4-36
 UNDERCARRIAGE / Transmission
74. Install travel N sensor (82) to housing (22) with
socket bolt (83) and O-ring (84).
: 6 mm
: 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft)

85, 86

84

22

WCGB-03-04-006

75. Install shift interlock controller (26) to housing (22)

with socket bolts (27) (5 used) and washers (28)
(5 used).
: 6 mm
: 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft)

76. Connect pipes (81) (2 used) to the transmission

with bolts (75, 77) (2 used for each) and seal rings
(76, 78) (2 used for each).
: 22 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 24 mm
: 45 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft)
Transmission

79 77, 79 75, 76
WCGB-03-04-005

W3-4-37
 UNDERCARRIAGE / Transmission
(Blank)

W3-4-38
 UNDERCARRIAGE / Axle
REMOVAL AND INSTALLATION OF AXLE

Removal of Front Axle 3 2 3 3 2 3 4

1. Loosen nuts (1) (20 used) for tires (3) (4 used)

and tire rings (2) (2 used).
: 30 mm

1
2. Swing the machine by 90º. Raise the front axle
side of frame (4) until tire (3) is raised. Place a
stand under frame (4).
W1GL-03-05-003

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb) 5 Steering Cylinder Front Axle

3. Remove nuts (1) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used) from frame (4).
: 30 mm

4. Disconnect brake hoses (5) (2 used) from the

right and left sides of the front axle.
: 22 mm

WCEB-03-05-021

W3-5-1
 UNDERCARRIAGE / Axle
5. Disconnect grease hose (8) from pin (7). 4 6 7 8
: 17 mm

6. Disconnect steering hoses (6) (2 used) from the

steering cylinder.
: 22 mm

CAUTION: Propeller shaft (11) weight: 35 kg

(80 lb)
Steering Cylinder WCGB-03-05-024

7. Place a wooden block under propeller shaft (11). Front Axle

Remove bolts (10) (8 used) and nuts (9) (8 used).
Remove propeller shaft (11) from the front axle. 11
: 14 mm
9, 10

WCGB-03-05-028

4 13
8. Remove nuts (12) (2 used). Remove bolt (13)
from pin (7).
: 24 mm
7
9. Hold the lower side of the front axle by using a
forklift. 12

CAUTION: Front axle weight:

ZX210W-3: 750 kg (1660 lb)
ZX220W-3: 770 kg (1700 lb) WCGB-03-05-027

CAUTION: Pin (7) weight: 18 kg (40 lb) (outer

diameter 70 mm (2.8 in))

10. Remove pin (7) from the front axle. Remove the
front axle from frame (4).

W3-5-2
 UNDERCARRIAGE / Axle
Installation of Front Axle

CAUTION: Front axle weight: 4 13

ZX210W-3: 750 kg (1660 lb)
ZX220W-3: 770 kg (1700 lb)
CAUTION: Pin (7) weight: 18 kg (40 lb) (outer
7
diameter 70 mm (2.8 in))

1. Hold the front axle by using a forklift. Install the 12

front axle to frame (4) with pin (7).

2. Secure pin (7) with bolt (13) and nuts (12) (2 WCGB-03-05-027

used). 4 6 7 8
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

3. Connect steering hoses (6) (2 used) to the

steering cylinder.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
Steering Cylinder WCGB-03-05-024

4. Connect brake hoses (5) (2 used) to the right and

Front Axle
left sides of the front axle. 5 6
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

5. Connect grease hose (8) to pin (7). Steering Cylinder

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

WCEB-03-05-021

CAUTION: Propeller shaft (11) weight: 35 kg Front Axle

(80 lb)
11

6. Install propeller shaft (11) to the front axle with 9, 10

bolts (10) (8 used) and nuts (9) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

WCGB-03-05-028

W3-5-3
 UNDERCARRIAGE / Axle

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb) 3 2 3 3 2 3 4

7. Install tire (3), tire ring (2) and tire (3) to the front
axle in this order. Temporarily tighten with nuts (1)
(10 used).
: 30 mm

8. Install tire ring (2) and tires (3) (2 used) to the

other side of the front axle in the same way as 1
step 7.

9. Remove the stand from frame (4).

W1GL-03-05-003

10. Tighten tires (3) (4 used) and tire rings (2) (2

used) with nuts (1) (20 used).
: 30 mm
: 600 N⋅m (60 kgf⋅m, 440 lbf⋅ft)

W3-5-4
 UNDERCARRIAGE / Axle
Removal of Rear Axle

1. Loosen nuts (1) (20 used) for tires (3) (4 used) 4

and tire rings (2) (2 used). 3
: 30 mm

2. Swing the machine by 90°. Raise the rear axle

side of frame (4) until tire (3) is raised. Place a
stand under frame (4).
2

1 3 W1GL-03-05-003

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb) 5

3. Remove nuts (1) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used) from frame (4).
: 30 mm
7, 8

CAUTION: Propeller shaft (6) weight: 30 kg

(70 lb)
6 WCGB-03-05-033

10
4. Place a wooden block under propeller shaft (6).
Remove bolts (8) (8 used) and nuts (7) (8 used).
Remove propeller shaft (6) from transmission (5). 11
: 14 mm 9

5. Disconnect hoses (9) (9 used) and connectors 5

(11) (2 used) from transmission (5) and travel
motor (10). WCGB-03-05-030
: 19 mm, 22 mm, 27 mm

W3-5-5
 UNDERCARRIAGE / Axle

CAUTION: The transmission (5) assembly

weight: 220 kg (490 lb) Rear Axle

6. Hold the lower side of the transmission (5)

5
assembly by using a forklift. Remove bolts (12)
(14 used). Remove the transmission (5) assembly
from the rear axle. 12
: 19 mm

WCGB-03-05-032
7. Disconnect brake pipings (13) (2 used) from the
right and left sides of the rear axle.
: 19 mm 4 13

CAUTION: Rear axle weight:

ZX210W-3: 600 kg (1330 lb)
ZX220W-3: 630 kg (1390 lb)

8. Hold the lower side of the rear axle by using a

forklift. WCGB-03-05-023

14
9. Remove nuts (15) (8 used) from the right and left 15
sides of the rear axle. Remove bolts (14) (8 used)
from frame (4).
: 30 mm 4

10. Remove the rear axle from frame (4).

WCGB-03-05-022

W1GL-03-05-003

W3-5-6
 UNDERCARRIAGE / Axle
Installation of Rear Axle 4 13

CAUTION: Rear axle weight:

ZX210W-3: 600 kg (1330 lb)
ZX220W-3: 630 kg (1390 lb)

1. Hold the rear axle by using a forklift. Install the

rear axle to frame (4) with bolts (14) (8 used) and
nuts (15) (8 used).
: 30 mm WCGB-03-05-023

: 560 N⋅m (57 kgf⋅m, 410 lbf⋅ft)

14

15
2. Connect brake pipings (13) (2 used) to the right
and left sides of the rear axle.
: 19 mm 4
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

CAUTION: The transmission (5) assembly

weight: 220 kg (490 lb)
WCGB-03-05-022

3. While holding the transmission (5) assembly by Rear Axle

using a forklift, align it with the rear axle. Install
the transmission (5) assembly to the rear axle
5
with bolts (12) (14 used).
: 19 mm
: 250 N⋅m (26 kgf⋅m, 185 lbf⋅ft) 12

4. Connect hoses (9) (9 used) and connector (11) to

WCGB-03-05-032
transmission (5) and travel motor (10).
(Hose): 10
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm 11
: 39 N⋅m (4 kgf⋅m, lbf⋅ft) 9
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
(Socket bolt):
: 12 mm
: 140 N⋅m (14 kgf⋅m, 105 lbf⋅ft) WCGB-03-05-030

W3-5-7
 UNDERCARRIAGE / Axle

CAUTION: Propeller shaft (6) weight: 35 kg

(80 lb)
5
5. Install propeller shaft (6) to transmission (5) with
nuts (7) (8 used) and bolts (8) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
7, 8
CAUTION: Tire (3) weight: 98 kg (220 lb)
Tire ring (2) weight: 25 kg (60 lb)

6. Install tire (3), tire ring (2) and tire (3) to the rear
axle in this order. Temporarily tighten with nuts (1) 6 WCGB-03-05-033

(10 used).
: 30 mm

7. Install tire ring (2) and tires (3) (2 used) to the

4
other side of the rear axle in the same way as 3
step 6.

8. Remove the stand from frame (4).

9. Tighten tires (3) (4 used) and tire rings (2) (2

used) with nuts (1) (20 used).
: 30 mm 2
: 600 N⋅m (60 kgf⋅m, 440 lbf⋅ft)
1 3 W1GL-03-05-003

W3-5-8
 UNDERCARRIAGE / Axle
(Blank)

W3-5-9
 UNDERCARRIAGE / Axle
DISASSEMBLY OF FRONT AXLE
1 10
9
7 8
6
5
4

3 11
2
1

12
7
8
9
21
20
22
19
13 23 25 26 27
24

18
17 28
29
16
14 15
30
31
32
33
43

41 42
40
39
37 38

36 44
35 45
34

46

47
48
49
50
51
56 55 54 53 52
57
59 58
62 61 60 WCGB-03-05-001
69 68 67 66 65 64 63

W3-5-10
 UNDERCARRIAGE / Axle

1 - Axle Casing 19 - Knuckle 37 - Hub Carrier 55 - Washer

2 - Bolt (16 Used) 20 - Bolt (4 Used) 38 - Bushing 56 - O-Ring
3 - Washer (16 Used) 21 - Bearing Pin 39 - Bearing 57 - Ring Gear
4 - Plug (2 Used) 22 - O-Ring 40 - O-Ring 58 - Knock Pin (4 Used)
5 - O-Ring (2 Used) 23 - Seal 41 - Friction Plate (6 Used) 59 - Backup Ring
6 - Drive Housing 24 - O-Ring 42 - Plate (5 Used) 60 - U-Ring
7 - Roller Bearing 25 - Bearing Nut 43 - Disc Plate 61 - U-Ring
8 - Shim 26 - Thrust Plate 44 - Planetary Carrier 62 - Backup Ring
9 - O-Ring 27 - Thrust Plate 45 - Plug 63 - Piston
10 -Bearing 28 - Socket Bolt 46 - O-Ring 64 - Spring (8 Used)
11 -Bearing 29 - Retaining Ring 47 - Socket Bolt (2 Used) 65 - Spring (8 Used)
12 -Tie Rod 30 - Seal 48 - Retaining Ring (3 Used) 66 - Spring Seat (8 Used)
13 -Tie Rod 31 - O-Ring 49 - Planetary Gear (3 Used) 67 - Bolt (8 Used)
14 -Bushing 32 - Shim 50 - Washer (3 Used) 68 - Disc Carrier
15 -Shaft Seal 33 - Bearing Pin 51 - Roller Bearing (3 Used) 69 - O-Ring
16 -Double Joint Shaft 34 - O-Ring 52 - Washer (3 Used)
17 -Shaft Seal 35 - Shaft Seal 53 - Retaining Ring (3 Used)
18 -Bushing 36 - Bearing 54 - Retaining Ring (3 Used)

W3-5-11
 UNDERCARRIAGE / Axle

6
5
4

12

19
13 25 26 27

28
29

43

41 42
40
37

44
45

46
47
48
49
51 50
54 53 52
57 56 55
58
60 59
61 WCGB-03-05-001
62
69 68 67 66 65 64 63

W3-5-12
 UNDERCARRIAGE / Axle
Disassembly of Front Axle

8. Remove retaining ring (29) and thrust plates (26,

CAUTION: Front axle weight:
ZX210W-3: 750 kg (1660 lb)
ZX220W-3: 770 kg (1700 lb)
1. Hoist the front axle. Lower the front axle on a
workbench.
2. Remove plugs (4) (2 used) and O-rings (5) (2
used) from drive housing (6). Remove plug (45)
and O-ring (46) from planetary carriers (44) in the
left and right sides. Drain gear oil from the front
axle.
: 14 mm
3. Disassemble tie rods (12, 13). (Refer to
DISASSEMBLY OF STEERING CYLINDER on
W3-5-46.)
CAUTION: Planetary carrier (44) weight: 30
kg (70 lb)
4. Attach a nylon sling onto planetary carrier (44).
Hoist and hold planetary carrier (44).
5. Remove socket bolts (47) (2 used) from planetary
carrier (44). Hoist and remove planetary carrier
(44) from the front axle.
: 8 mm
6. Remove retaining rings (54) (3 used). Remove
planetary gears (49) (3 used) and washer (55)
from planetary carrier (44).
27) from knuckle (19).
9. Remove socket bolt (28) from bearing nut (25).
: 8 mm
10. Remove bearing nut (25) and O-ring (56) from
knuckle (19).
: 41 mm
11. Pry the clearance between piston (63) and hub
carrier (37) by using a pry bar. Remove the ring
gear (57) assembly from hub carrier (37).
IMPORTANT: Before removing bolt (67), record the
dimension of bolt (67) extended from
piston (63).
12. Remove bolts (67) (8 used), spring seats (66) (8
used) and springs (64, 65) (8 used for each) from
ring gear (57).
13. Remove piston (63) from ring gear (57). Remove
U-rings (60, 61), backup rings (59, 62) and knock
pins (58) (4 used) from ring gear (57).
14. Remove disc plate (43) from hub carrier (37).
Remove plates (42) (5 used) and friction plates
(41) (6 used).
15. Remove O-ring (40). Remove disc carrier (68)
from knuckle (19). Remove O-ring (69).

IMPORTANT: Do not remove roller bearing (51)

unless necessary.
7. Remove retaining rings (48, 53) (3 used for each),
washers (50, 52) (3 used for each) and roller
bearings (51) (3 used) from planetary gears (49)
(3 used).

W3-5-13
 UNDERCARRIAGE / Axle

1 10

11

21
20
22
19
23
24

16

30
31
32
33

39
37 38

36
35
34

WCGB-03-05-001

W3-5-14
 UNDERCARRIAGE / Axle
CAUTION: Hub carrier (37) weight: 38 kg (84
lb)
16. Attach a nylon sling onto hub carrier (37). Hold
hub carrier (37). Hoist and remove hub carrier
(37) from knuckle (19).
17. Remove O-ring (34) from knuckle (19).
IMPORTANT: Do not remove bearings (36, 39)
unless necessary.
18. Remove shaft seal (35) from hub carrier (37).
Remove the outer race of bearing (36) and
bearing (39).
IMPORTANT: Do not remove bearing (36) unless
necessary.
19. Remove bushing (38). Remove the inner race of
bearing (36) from knuckle (19).
IMPORTANT: When removing bearing pin (21), the
inner race of bearing (10) is removed
with bearing pin (21) together. Do
not damage the inner race of bearing
(10) and bearing pin (21).
20. Remove bolts (20) (4 used) from the upper side of
knuckle (19). Remove bearing pin (21), O-rings
(22, 24) and seal (23) from knuckle (19).
: 24 mm
IMPORTANT: When removing bearing pin (33), the
inner race of bearing (11) is removed
with bearing pin (33) together. Do
not damage the inner race of bearing
(11) and bearing pin (33).
22. Remove bolts (20) (4 used) from the lower side of
knuckle (19). Remove bearing pin (33), shim (32),
O-ring (31) and seal (30) from knuckle (19).
: 24 mm
IMPORTANT: Do not remove bearings (10, 11)
unless necessary.
23. Remove the inner races of bearings (10, 11) from
bearing pins (21, 33).
IMPORTANT: When removing double joint shaft
(16), do not damage the seal of axle
casing (1).
24. Pull out knuckle (19) with double joint shaft (16)
attached about 200 mm from axle casing (1). Hold
the axis of double joint shaft (16). Hoist and
remove the knuckle (19) assembly.
16 19

CAUTION: The knuckle (19) assembly: 76 kg

(170 lb) WCGB-03-05-002

21. Install eyebolts (M16, Pitch 1.75 mm) (2 used) to

the bolt (20) hole on the upper side of knuckle (19).
Attach a nylon sling onto eyebolts (2 used). Hoist
and hold knuckle (19).

W3-5-15
 UNDERCARRIAGE / Axle

1 10
9
7 8
6

3 11
2
1

7
8
9

19

18
17

16
14 15

WCGB-03-05-001

W3-5-16
 UNDERCARRIAGE / Axle
25. Remove double joint shaft (16) from knuckle (19). 32. Remove differential (70) from drive housing (6).

26. Remove shaft seal (17) and bushing (18) from 6

knuckle (19).

27. Remove shaft seal (15) and bushing (14) from

axle casing (1).

IMPORTANT: Do not remove bearings (10, 11) 70

unless necessary.
28. Remove the outer races of bearings (10, 11) from
axle casing (1).

WCGB-03-05-003
CAUTION: Axle casing (1) weight:
ZX210W-3: 98 kg (220 lb)
ZX220W-3: 107 kg (240 lb)

29. Attach a nylon sling onto axle casing (1). Hoist

and hold axle casing (1). Remove bolts (2) (16
used) and washers (3) (16 used). Hoist and
remove axle casing (1) from drive housing (6).
: 27 mm

IMPORTANT: Do not remove roller bearing (7)

unless necessary.
30. Remove O-ring (9), shim (8) and roller bearing (7)
from axle casing (1).

31. Disassemble the other side of the front axle in the

same way as steps 4 to 30.

W3-5-17
 UNDERCARRIAGE / Axle
ASSEMBLY OF FRONT AXLE
Detail of Drive Housing Inside 6

9 9

2, 3
2, 3

16

Planetary Carrier

WCGB-03-05-019
8 7 7 8

Detail of Planetary Carrier Inside

A Detail A
21 35 24 36 40 38 37 68 41 42 43 61, 62 63 50
54 53 52
22, 23
44
10
48
1
49
51
Drive
Housing 25
27

16 29

55
14 26
15
28
30, 31 45
WCGB-03-05-005
64, 65, 66, 67 59, 60
20 11 33 32 19 17 18 39 69 34 56 57 46

W3-5-18
 UNDERCARRIAGE / Axle

1 - Axle Casing 19 - Knuckle 37 - Hub Carrier 55 - Washer

2 - Bolt (16 Used) 20 - Bolt (4 Used) 38 - Bushing 56 - O-Ring
3 - Washer (16 Used) 21 - Bearing Pin 39 - Bearing 57 - Ring Gear
4* - Plug (2 Used) 22 - O-Ring 40 - O-Ring 58*- Knock Pin (4 Used)
5* - O-Ring (2 Used) 23 - Seal 41 - Friction Plate (6 Used) 59 - Backup Ring
6 - Drive Housing 24 - O-Ring 42 - Plate (5 Used) 60 - U-Ring
7 - Roller Bearing 25 - Bearing Nut 43 - Disc Plate 61 - U-Ring
8 - Shim 26 - Thrust Plate 44 - Planetary Carrier 62 - Backup Ring
9 - O-Ring 27 - Thrust Plate 45 - Plug 63 - Piston
10 - Bearing 28 - Socket Bolt 46 - O-Ring 64 - Spring (8 Used)
11 - Bearing 29 - Retaining Ring 47* - Socket Bolt (2 Used) 65 - Spring (8 Used)
12* - Steering Cylinder 30 - Seal 48 - Retaining Ring (3 Used) 66 - Spring Seat (8 Used)
13* - Steering Cylinder 31 - O-Ring 49 - Planetary Gear (3 Used) 67 - Bolt (8 Used)
14 - Bushing 32 - Shim 50 - Washer (3 Used) 68 - Disc Carrier
15 - Shaft Seal 33 - Bearing Pin 51 - Roller Bearing (3 Used) 69 - O-Ring
16 - Double Joint Shaft 34 - O-Ring 52 - Washer (3 Used)
17 - Shaft Seal 35 - Shaft Seal 53 - Retaining Ring (3 Used)
18 - Bushing 36 - Bearing 54 - Retaining Ring (3 Used)

NOTE: As for the item with mark*, refer to W3-5-10.

W3-5-19
 UNDERCARRIAGE / Axle

9 9

2, 3
2, 3

16

Planetary Carrier

WCGB-03-05-019
8 7 7 8

A Detail A
21

22, 23
10

1
Drive
Housing

16

14

15

30, 31
WCGB-03-05-005
11 33 32 19 17 18

W3-5-20
 UNDERCARRIAGE / Axle
Assembly of Front Axle

1. Install differential (70) to drive housing (6). 5. Tap and install the outer races of bearings (10, 11)
to axle casing (1) by using a plastic hammer.
6
IMPORTANT: When installing double joint shaft
(16), do not damage the seal of axle
casing (1).
6. Install double joint shaft (16) to axle casing (1).
70
7. Apply grease onto the seal and the dust lip part of
shaft seal (17). Apply LOCTITE #574 onto the
shaft seal (17) contact surface on knuckle (19).
Install bushing (18) and shaft seal (17) to knuckle
WCGB-03-05-003 (19).

2. Install roller bearing (7), shim (8) and O-ring (9) to 8. Install seal (30), O-ring (31), the inner race of
the drive housing (6) mounting side on axle casing bearing (11) and washer (32) to bearing pin (33).
(1).
9. Apply anticorrosive (Weicon Antiseize (Never
Seez) ZF special tool No. 0671 196 001) onto the
CAUTION: Axle casing (1) weight:
collar part of bearing pin (33). Install seal (23) and
ZX210W-3: 98 kg (220 lb)
O-ring (22) to bearing pin (21).
ZX220W-3: 107 kg (240 lb)

3. Hoist axle casing (1). Install axle casing (1) to

drive housing (6) with bolts (2) (16 used) and
washers (3) (16 used).
: 27 mm
: 390 N⋅m (40 kgf⋅m, 860 lbf⋅ft)

4. Apply grease onto the seal and the dust lip part of
shaft seal (15). Apply LOCTITE #574 onto the
shaft seal (15) contact surface on axle casing (1).
Install bushing (14) and shaft seal (15) to axle
casing (1).

W3-5-21
 UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-019

A Detail A
21 35 24 36 40 38 37 68

Drive
Housing 25

16

WCGB-03-05-005
20 33 19 39 69 57

W3-5-22
 UNDERCARRIAGE / Axle
CAUTION: Knuckle (19) weight: 55.5 kg (130
lb)
IMPORTANT: When inserting double joint shaft
(16) to knuckle (19), do not damage
the seal.
10. Apply grease onto bearing pin (33). Install
eyebolts (M16, Pitch 1.75 mm) (2 used) to the bolt
(20) hole on the upper side of knuckle (19). Hoist
knuckle (19). Install knuckle (19) to axle casing (1).
Install bearing pin (33) to the lower side of knuckle
(19) with bolts (20) (4 used).
: 24 mm
: 280 N⋅m (28 kgf⋅m, 205 lbf⋅ft)
11. Apply grease onto bearing pin (21). Remove
eyebolts (2 used) from the upper side of knuckle
(19). Install bearing pin (21) and O-ring (24) to
knuckle (19) with bolts (20) (4 used).
: 24 mm
: 280 N⋅m (28 kgf⋅m, 205 lbf⋅ft)
12. Install the inner race of bearing (36) and bushing
(38) to knuckle (19).
13. Apply hydraulic oil onto O-ring (40). Install O-ring
(40), the outer race of bearing (36) and bearing
(39) to hub carrier (37).
W3-5-23
IMPORTANT: When installing shaft seal (35),
check the mounting position and
dimension A. Install shaft seal (35)
with the marking of OUT-SIDE facing
upward and outward.
14. Apply LOCTITE #574 onto the shaft seal (35)
contact surface on hub carrier (37). Install shaft
seal (35) to hub carrier (37).
NOTE: Dimension A: 0 to 0.3 mm (0 to 0.01 in)
37
A
35
WCGB-03-05-006
CAUTION: Hub carrier (37) weight: 38 kg (84
lb)
15. Hoist hub carrier (37). Install hub carrier (37) to
knuckle (19).
16. Install O-ring (69) and disc carrier (68) to knuckle
(19).
17. Install ring gear (57) to knuckle (19).
18. When installing bearing nut (25), apply lubricant
(ZF special tool No. 0671 195 042 MOLYKOTE
PASTE 1000) onto the thread part of knuckle (19).
Install bearing nut (25) to knuckle (19) by using
special tool (ZF special tool No. 5870 656 097). At
this time, turn hub carrier (37) in both directions
several times in order to fit the rotor.
: 1400 N⋅m (140 kgf⋅m, 1040 lbf⋅ft)
 UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-019

Detail A
A
37 41 42 43 61, 62 63

44

Drive
Housing 25
27
29

55

26

28

64, 65, 66, 67 59, 60 WCGB-03-05-005

19 56 57

W3-5-24
 UNDERCARRIAGE / Axle
19. Remove bearing nut (25) from knuckle (19). 25. Align the marks and install the ring gear (57)
Remove ring gear (57) from knuckle (19). assembly to knuckle (19).
: 41 mm
Mark
57 19
IMPORTANT: Check the mounting positions of
friction plate (41) and plate (42).
20. Install friction plates (41) (6 used) and plates (42)
(5 used) to hub carrier (37) alternately. Install disc
plate (43).

21. Apply grease onto O-ring (34). Install O-ring (34)

to knuckle (19).

22. Apply hydraulic oil onto U-rings (60, 61) and

backup rings (59, 62). Install U-rings (60, 61) and WCGB-03-05-008
backup rings (59, 62) to ring gear (57).
26. Apply hydraulic oil onto O-ring (56). Install O-ring
23. Install knock pins (58) (4 used) to piston (63). (56) to knuckle (19).
NOTE: Dimension B: 16 mm (0.6 in)
27. When installing bearing nut (25), apply lubricant
63 58 (ZF special tool No. 0671 195 042 MOLYKOTE
PASTE 1000) onto the thread part of knuckle (19).
Install bearing nut (25) to knuckle (19) by using
B
special tool (ZF special tool No. 5870 656 097).
Align the socket bolt (28) holes on knuckle (19)
and bearing nut (25). If it is difficult to align the
holes, retighten bearing nut (25).
: 1400+200 N⋅m (140+20 kgf⋅m, 1040+150 lbf⋅ft)
WCGB-03-05-007
28. Install socket bolt (28) to bearing nut (25).
: 8 mm
IMPORTANT: When tightening bolt (67), align with
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
the dimension before
disassembling.
29. Install thrust plates (26, 27) to knuckle (19).
24. Install piston (63) to ring gear (57). Secure piston
Secure with retaining ring (29).
(63) with bolts (67) (8 used), spring seats (66) (8
used) and springs (64, 65).
30. Install washer (55) to planetary carrier (44).
: 10 mm
: 11 N⋅m (1 kgf⋅m, 8 lbf⋅ft)

W3-5-25
 UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-019

A Detail A

54 53 52 50

44

48

49
Drive 51
Housing

45
WCGB-03-05-005
46

W3-5-26
 UNDERCARRIAGE / Axle
31. Install retaining rings (48, 53) (3 used for each),
washers (50, 52) (3 used for each) and roller
bearings (51) (3 used) to planetary gears (49) (3
used).

32. Install planetary gears (49) (3 used) to planetary

carrier (44) with retaining rings (54) (3 used).

CAUTION: Planetary carrier (44) weight: 30

kg (70 lb)

33. Hoist planetary carrier (44). Install planetary

carrier (44) to the front axle with socket bolts (47)
(2 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

34. Assemble the other side of the front axle in the

same way as steps 2 to 33.

35. Assemble tie rods (12, 13). (Refer to ASSEMBLY

OF STEERING CYLINDER on W3-5-48.)

36. Add gear oil to drive housing (6) and planetary

carriers (44) in the left and right sides. Install plugs
(4) (2 used) and O-rings (5) (2 used) to drive
housing (6). Install plug (45) and O-ring (46) to
planetary carriers (44) in the left and right sides.
: 14 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W3-5-27
 UNDERCARRIAGE / Axle
DISASSEMBLY OF REAR AXLE

1
2
3
4
5
4
3
2
1 6
7

10 8
9

11
12 28

26 27
25
24
21 22 23 29
8 20
17 18 19
16
15 30
13 14
31

32
33
34
35
40 39 38 37 36
43 42
45 44 41
54 53 52 51 50 49 48 47 46
WCGB-03-05-009

W3-5-28
 UNDERCARRIAGE / Axle

1 - Axle Casing 15 - Bearing Nut 29 - Planetary Carrier 43 - Knock Pin (4 Used)

2 - O-Ring 16 - Washer 30 - Plug 44 - Backup Ring
3 - Shim 17 - Socket Bolt 31 - O-Ring 45 - U-Ring
4 - Roller Bearing 18 - Sun Gear Shaft 32 - Socket Bolt (2 Used) 46 - U-Ring
5 - Drive Housing 19 - O-Ring 33 - Retaining Ring (3 Used) 47 - Backup Ring
6 - Washer (14 Used) 20 - Shaft Seal 34 - Planetary Gear (3 Used) 48 - Piston
7 - Bolt (14 Used) 21 - Bearing 35 - Washer (3 Used) 49 - Spring (8 Used)
8 - Axle Shaft 22 - Hub Carrier 36 - Roller Bearing (3 Used) 50 - Spring (8 Used)
9 - Plug 23 - Bushing 37 - Washer (3 Used) 51 - Spring Seat (8 Used)
10 - O-Ring 24 - Bearing 38 - Retaining Ring (3 Used) 52 - Bolt (8 Used)
11 - Washer (16 Used) 25 - O-Ring 39 - Retaining Ring (3 Used) 53 - Disc Carrier
12 - Bolt (16 Used) 26 - Friction Plate (6 Used) 40 - Washer 54 - O-Ring
13 - O-Ring 27 - Plate (5 Used) 41 - O-Ring
14 - Knuckle 28 - Disc Plate 42 - Ring Gear

W3-5-29
 UNDERCARRIAGE / Axle

10
9

22 29
18
17
15 30
14

31

33 32
34
35
36
41 39 38 37
45 44 43 42 40
46 WCGB-03-05-009

52 50 49 48 47
51

W3-5-30
 UNDERCARRIAGE / Axle
Disassembly of Rear Axle
1. Remove transmission (55) from the rear axle.
(Refer to REMOVAL OF TRANSMISSION on
W3-4-1.)
CAUTION: Rear axle weight:
ZX210W-3: 600 kg (1330 lb)
ZX220W-3: 630 kg (1390 lb)
2. Hoist the rear axle. Lower the rear axle on a
workbench.
3. Remove plugs (9, 30) and O-rings (10, 31) from
drive housing (5) and planetary carriers (29) in the
left and right sides. Drain gear oil from the rear
axle.
: 14 mm
CAUTION: Planetary carrier (29) weight: 30
kg (70 lb)
4. Attach a nylon sling onto planetary carrier (29).
Hoist and hold planetary carrier (29).
5. Remove socket bolts (32) (2 used) from planetary
carrier (29). Hoist and remove planetary carrier
(29) from the rear axle.
: 8 mm
6. Remove retaining rings (39) (3 used). Remove
planetary gears (34) (3 used) and washer (40)
from planetary carrier (29).
W3-5-31
IMPORTANT: Do not remove roller bearing (36)
unless necessary.
7. Remove retaining rings (33, 38) (3 used for each),
washers (35, 37) (3 used for each) and roller
bearings (36) (3 used) from planetary gears (34)
(3 used).
8. Remove sun gear shaft (18) from axle casing (1).
9. Remove socket bolt (17) from bearing nut (15).
: 8 mm
10. Remove O-ring (41) from knuckle (14).
11. Pry the clearance between piston (48) and hub
carrier (22) by using a pry bar. Remove the ring
gear (42) assembly from hub carrier (22).
IMPORTANT: Before removing bolt (52), record the
dimension of bolt (52) extended from
piston (48).
12. Remove bolts (52) (8 used), spring seats (51) (8
used) and springs (49, 50) (8 used for each) from
ring gear (42).
13. Remove piston (48) from ring gear (42). Remove
U-rings (45, 46), backup rings (44, 47) and knock
pins (43) (4 used) from ring gear (42).
 UNDERCARRIAGE / Axle

1
2
3
4
5
4
3
2
1 6
7
8

11
12 28

26 27
25
23 24
8 22
21
20
19
14
13

54 53 WCGB-03-05-009

W3-5-32
 UNDERCARRIAGE / Axle
14. Remove disc plate (28) from hub carrier (22). 21. Remove axle shaft (8) from axle casing (1).
Remove plates (27) (5 used) and friction plates
(26) (6 used).
CAUTION: Axle casing (1) weight:
15. Remove disc carrier (53) from knuckle (14). ZX210W-3: 108 kg (240 lb)
Remove O-ring (54). ZX220W-3: 122 kg (270 lb)

22. Attach a nylon sling onto axle casing (1). Hold

CAUTION: Hub carrier (22) weight: 38 kg (84
lb)
16. Attach a nylon sling onto hub carrier (22). Hold
hub carrier (22). Hoist and remove hub carrier
(22) from knuckle (14).
17. Remove O-ring (19) from knuckle (14).
IMPORTANT: Do not remove bearings (21, 24)
unless necessary.
18. Remove shaft seal (20), O-ring (25), the outer
race of bearing (21) and bearing (24) from hub
carrier (22).
axle casing (1). Remove bolts (12) (16 used) and
washers (11) (16 used). Hoist and remove axle
casing (1) from drive housing (5).
: 27 mm
IMPORTANT: Do not remove roller bearing (4)
unless necessary.
23. Remove O-ring (2), shim (3) and roller bearing (4)
from axle casing (1).
24. Disassemble the other side of the rear axle in the
same way as steps 4 to 23.
25. Remove differential (55) from drive housing (5).

IMPORTANT: Do not remove bearing (21) unless

necessary. 5
19. Remove bushing (23) and the inner race of
bearing (21) from knuckle (14).

CAUTION: Knuckle (14) weight: 34 kg (75 lb)

20. Attach a nylon sling onto knuckle (14). Hold

knuckle (14). Remove bolts (7) (14 used) and
washers (6) (14 used). Hoist and remove knuckle
(14) and O-ring (13) from the rear axle.
: 24 mm 55 WCGB-03-05-011

W3-5-33
 UNDERCARRIAGE / Axle
ASSEMBLY OF REAR AXLE

Detail of Drive Housing Inside

3 4 5 4 3 2 11
1 12 11 2 12 1

Planetary Carrier

8 8

WCGB-03-05-012

Detail of Planetary Carrier Inside

6 13 14 20 21 22 25 23 24 26 27 28 49, 50, 51, 52 48 44, 45
7
42
1 29

46, 47
41

15

40
Drive
Housing 16

18

34

8 54 53 19

T21W-03-05-022

W3-5-34
 UNDERCARRIAGE / Axle

1 - Axle Casing 15 - Bearing Nut 29 - Planetary Carrier 43* - Knock Pin (4 Used)
2 - O-Ring 16 - Washer 30* -Plug 44 - Backup Ring
3 - Shim 17* - Socket Bolt 31* -O-Ring 45 - U-Ring
4 - Roller Bearing 18 - Sun Gear Shaft 32* -Socket Bolt (2 Used) 46 - U-Ring
5 - Drive Housing 19 - O-Ring 33* -Retaining Ring (3 Used) 47 - Backup Ring
6 - Washer (14 Used) 20 - Shaft Seal 34 - Planetary Gear (3 Used) 48 - Piston
7 - Bolt (14 Used) 21 - Bearing 35* -Washer (3 Used) 49 - Spring (8 Used)
8 - Axle Shaft 22 - Hub Carrier 36* -Roller Bearing (3 Used) 50 - Spring (8 Used)
9* - Plug 23 - Bushing 37* -Washer (3 Used) 51 - Spring Seat (8 Used)
10* - O-Ring 24 - Bearing 38* -Retaining Ring (3 Used) 52 - Bolt (8 Used)
11 - Washer (16 Used) 25 - O-Ring 39* -Retaining Ring (3 Used) 53 - Disc Carrier
12 - Bolt (16 Used) 26 - Friction Plate (6 Used) 40 - Washer 54 - O-Ring
13 - O-Ring 27 - Plate (5 Used) 41 - O-Ring
14 - Knuckle 28 - Disc Plate 42 - Ring Gear

NOTE: As for the item with mark*, refer to W3-5-28.

W3-5-35
 UNDERCARRIAGE / Axle

1 2 3 4 5 4 3 2 11 12 1

Planetary Carrier

8 8

WCGB-03-05-012

7 6 13 14 20 21 22 23 24

42
1

Drive
Housing 16

18

8 54 53 19

T21W-03-05-022

W3-5-36
 UNDERCARRIAGE / Axle
Assembly of Rear Axle

1. Install differential (55) to drive housing (5). 6. Install the inner race of bearing (21) and bushing
(23) to knuckle (14).
5
IMPORTANT: When installing shaft seal (20), check
the mounting position and
dimension A. Install shaft seal (20)
with the marking of OUT-SIDE facing
upward and outward.
7. Apply LOCTITE #574 onto the shaft seal (20)
contact surface on hub carrier (22). Install shaft
seal (20) to hub carrier (22).
NOTE: Dimension A: 0 to 0.3 mm (0 to 0.01 in)
55 A 22
WCGB-03-05-011

2. Install O-ring (2), shim (3) and roller bearing (4) to

axle casing (1). 20

CAUTION: Axle casing (1) weight:

ZX210W-3: 108 kg (240 lb)
ZX220W-3: 122 kg (270 lb) WCGB-03-05-006

3. Attach a nylon sling onto axle casing (1). Hoist 8. Install the outer race of bearing (21) and bearing
axle casing (1). Install axle casing (1) to drive (24) to hub carrier (22).
housing (5) with bolts (12) (16 used) and washers
(11) (16 used). 9. Apply hydraulic oil onto O-ring (19). Install O-rings
: 27 mm (19, 54) and disc carrier (53) to knuckle (14).
: 300 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
10. Install ring gear (42) to knuckle (14).
4. Install axle shaft (8) to axle casing (1).
11. Install washer (16) to sun gear shaft (18).
CAUTION: Knuckle (14) weight: 34 kg (75 lb)

5. Install O-ring (13) to knuckle (14). Hoist knuckle

(14). Install knuckle (14) to the rear axle with bolts
(7) (14 used) and washers (6) (14 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

W3-5-37
 UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-012

14 22 25 26 27 28 49, 50, 51, 52 48 44, 45

42

46, 47
41

15

Drive
Housing

18

T21W-03-05-022

W3-5-38
 UNDERCARRIAGE / Axle
12. When installing bearing nut (15), apply lubricant IMPORTANT: When tightening bolt (52), align with
(ZF special tool No. 0671 195 042 MOLYKOTE the dimension before
PASTE 1000) onto the thread part of knuckle (14). disassembling.
Install sun gear shaft (18) and bearing nut (15) to 18. Install piston (48) to ring gear (42). Secure piston
knuckle (14) by using special tool (ZF special tool (48) with bolts (52) (8 used), spring seats (51) (8
No. 5870 656 097). At this time, turn hub carrier used) and springs (49, 50).
(22) in both directions several times in order to fit : 10 mm
the rotor. : 11 N⋅m (1 kgf⋅m, 8 lbf⋅ft)
: 1400 N⋅m (140 kgf⋅m, 1040 lbf⋅ft)
19. Align the marks and install the ring gear (42)
13. Remove bearing nut (15) from knuckle (14). assembly to knuckle (14).
Remove ring gear (42).
Mark
: 41 mm 42 14

IMPORTANT: Check the mounting positions of

friction plate (26) and plate (27).
14. Install friction plates (26) (6 used) and plates (27)
(5 used) to hub carrier (42) alternately. Install disc
plate (28).

15. Apply grease onto O-ring (25). Install O-ring (25)

to hub carrier (42).

16. Apply hydraulic oil onto U-rings (45, 46) and
backup rings (44, 47). Install U-rings (45, 46) and
backup rings (44, 47) to ring gear (42).
17. Install knock pins (43) (4 used) to piston (48).
NOTE: Dimension B: 16 mm (0.6 in)
48 43
B
WCGB-03-05-008
20. Apply hydraulic oil onto O-ring (41). Install O-ring
(41) to knuckle (14).
21. When installing bearing nut (15), apply lubricant
(ZF special tool No. 0671 195 042 MOLYKOTE
PASTE 1000) onto the thread part of knuckle (14).
Install bearing nut (15) to knuckle (14) by using
special tool (ZF special tool No. 5870 656 097).
Align the holes on knuckle (14) and bearing nut
(15). Secure with socket bolt (17).
: 1400+200 N⋅m (140+20 kgf⋅m, 1040+150 lbf⋅ft)

WCGB-03-05-007

W3-5-39
 UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-012

14

29

15

40
Drive
Housing

34

T21W-03-05-022

W3-5-40
 UNDERCARRIAGE / Axle
22. Install socket bolt (17) into bearing nut (15). If it is
difficult to align the holes on knuckle (14) and
bearing nut (15), retighten bearing nut (15).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

23. Install washer (40) to planetary carrier (29).

24. Install retaining rings (33, 38) (3 used for each),

washers (35, 37) (3 used for each) and roller
bearings (36) (3 used) to planetary gears (34) (3
used).

25. Install planetary gears (34) (3 used) to planetary

carrier (29) with retaining rings (39) (3 used).

CAUTION: Planetary carrier (29) weight: 30

kg (70 lb)

26. Hoist planetary carrier (29). Install planetary

carrier (29) to the rear axle with socket bolts (32)
(2 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

27. Assemble the other side of the rear axle in the

same way as steps 2 to 26.

28. Add gear oil to drive housing (5) and planetary

carriers (29) in the left and right sides. Install plugs
(9, 30) and O-rings (8, 31) to drive housing (5) and
planetary carriers (29) in the left and right sides.
: 14 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W3-5-41
 UNDERCARRIAGE / Axle
DISASSEMBLY OF DIFFERENTIAL

NOTE: Disassembly of the differential is common

to the front axle and the rear axle.
The illustration shows the front axle.

13

12
8
7 10 11
6 9
5
3 4
2

1
14
15
7
16 8
5
6
17
18

19
20
21
22
23
24
25
26
27
28

WCGB-03-05-013

1- Bevel Gear 8- Pinion Gear (2 Used) 15 - Washer (12 Used) 22 - Spacer

2- Differential Case 9- Spider 16 - Spider 23 - Bearing
3- Washer (2 Used) 10 - Side Gear (2 Used) 17 - Spring Pin (4 Used) 24 - Seal
4- Side Gear (2 Used) 11 - Washer (2 Used) 18 - Spring Pin (4 Used) 25 - Guard
5- Pinion Gear (2 Used) 12 - Differential Case 19 - Drive Pinion 26 - Flange
6- Washer (2 Used) 13 - Drive Housing 20 - Bearing 27 - Washer
7- Washer (2 Used) 14 - Socket Bolt (12 Used) 21 - Shim 28 - Nut

W3-5-42
 UNDERCARRIAGE / Axle
Disassembly of Differential

1. Remove nut (28) and washer (27) from drive IMPORTANT: Do not remove bearings (29, 30)
pinion (19). unless necessary.
: 41 mm 8. Secure the differential in a vise. Remove the inner
races of bearings (29, 30) from the differential.
2. Remove flange (26) and guard (25) from drive
housing (13).
30 Differential

3. Float seal (24) by using a screwdriver. Remove

drive pinion (19) from drive housing (13).
29
4. Remove spacer (22) from drive pinion (19).

IMPORTANT: Do not remove bearing (20) unless

necessary.
5. Remove the inner race of bearing (20) from drive WCGB-03-05-014

pinion (19).
9. Remove socket bolts (14) (12 used) and washers
IMPORTANT: Do not remove bearing (20) unless (15) (12 used). Remove differential case (12).
necessary. : 10 mm
6. Remove the outer race of bearing (20) from drive
pinion (19). 10. Remove spring pins (17, 18) (4 used for each),
washers (3, 6, 7, 11) (2 used for each), pinion
IMPORTANT: Do not remove bearing (23) unless gears (5, 8) (2 used for each), side gears (4, 10)
necessary. (2 used for each) and spiders (9, 16) from
7. Remove shim (21) and bearing (23) from drive differential case (2).
pinion (19).
11. Secure differential case (2) in a vise with bevel
gear (1) facing upward. Remove bevel gear (1)
from differential case (2).

W3-5-43
 UNDERCARRIAGE / Axle
ASSEMBLY OF DIFFERENTIAL

NOTE: Assembly of the differential is common to

the front axle and the rear axle.
The illustration shows the front axle.

14 15 12 13 7 8 2 17, 18 1 3

11

10 4

16

19

20
21

22 23

24
25

WCGB-03-05-015
27 28 26

1 - Bevel Gear 8 - Pinion Gear (2 Used) 15 - Washer (12 Used) 22 - Spacer

2 - Differential Case 9 - Spider 16 - Spider 23 - Bearing
3 - Washer (2 Used) 10 - Side Gear (2 Used) 17 - Spring Pin (4 Used) 24 - Seal
4 - Side Gear (2 Used) 11 - Washer (2 Used) 18 - Spring Pin (4 Used) 25 - Guard
5* - Pinion Gear (2 Used) 12 - Differential Case 19 - Drive Pinion 26 - Flange
6* - Washer (2 Used) 13 - Drive Housing 20 - Bearing 27 - Washer
7 - Washer (2 Used) 14 - Socket Bolt (12 Used) 21 - Shim 28 - Nut

NOTE: As for the item with mark*, refer to W3-5-42.

W3-5-44
 UNDERCARRIAGE / Axle
Assembly of Differential

1. Install spring pins (17, 18) (4 used for each) to 6. Install shim (21) and bearing (23) to drive pinion
differential case (2). (19).

2. Secure differential case (2) in a vise. Install bevel 7. Install the outer race of bearing (20) to drive
gear (1) to differential case (2). pinion (19).

IMPORTANT: Install washers (3, 11) and washers
(7) (2 used) with the lugs facing
upward.
3. Install washers (3, 6, 7, 11) (2 used for each),
pinion gears (5, 8) (2 used for each), side gears (4,
10) (2 used for each) and spiders (9, 16) to
differential case (2).
4. Install differential case (12) to the differential case
(2) assembly. Secure socket bolt (14) and washer
(15).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
5. Secure the differential in a vise. Install the inner
races of bearings (29, 30).
8. Install the inner race of bearing (20) to drive pinion
(19).
9. Install spacer (22) to drive pinion (19).
10. Install drive pinion (19) to drive housing (13).
11. Install guard (26) and flange (25) to drive housing
(13).
12. Install washer (27) and nut (28) to drive pinion
(19).
: 41 mm
: 1050 N⋅m (105 kgf⋅m, 770 lbf⋅ft)

30 Differential

29

WCGB-03-05-014

W3-5-45
 UNDERCARRIAGE / Axle
DISASSEMBLY OF STEERING CYLINDER

1 2 1

T1GL-03-05-020

3 Connection 4 Connection Part 3

Part

11
9 10
7 8
5 6

12
13
14
15

16

17
18
19

20
WCGB-03-05-016

1- Axle Casing 6 - U-Ring 11 - Rod 16 - Cylinder Tube

2- Drive Housing 7 - Wiper Ring 12 - Wiper Ring 17 - Guide Ring
3- Tie Rod 8 - O-Ring 13 - U-Ring 18 - Guide Ring
4- Piston Rod 9 - Guide Ring 14 - Retaining Ring 19 - Seal
5- Retaining Ring 10 - Piston 15 - Flange 20 - Bolt (5 Used)

W3-5-46
 UNDERCARRIAGE / Axle
Disassembly of Steering Cylinder

1. Remove nut (21). Remove tie rod (3) from axle 5. Remove bolts (20) (5 used). Warm up the
casing (1). connection part of the piston rod (4) assembly and
: 41 mm drive housing (2) by using a drier.
3 21
6. Tap and remove the piston rod (4) assembly from
drive housing (2) by using a plastic hammer.

7. Remove bolts (20) (5 used). Remove flange (15)

and retaining ring (14) from the piston rod (4)
assembly.

1 8. Remove retaining ring (5) from the piston rod (4)

WCGB-03-05-017
2. Warm up the connection part of piston rod (4) and
tie rod (3) by using a drier. Attach a spanner onto
the connection part. Remove tie rod (3) from
piston rod (4).
: 46 mm
assembly. Tap piston (10) to the position where
O-ring (8) can be removed by using a plastic
hammer. Remove O-ring (8) from the piston rod
(4) assembly.
9. Remove rod (11) and piston (10) from cylinder
tube (16). Remove piston (10) from rod (11).

3. Remove other tie rod (3) in the same way as steps 10. Remove U-ring (13) and wiper ring (12) from
1 to 2. cylinder tube (16).

4. Remove elbows (22) (2 used) from drive housing 11. Remove U-ring (6), wiper ring (7), guide rings (9,
(2). 17, 18) and seal (19) from piston (10) and rod
(11).
2 22

4
Connection
Part
WCGB-03-05-018

W3-5-47
 UNDERCARRIAGE / Axle
ASSEMBLY OF STEERING CYLINDER

1 2 1

T1GL-03-05-020

3 Connection 4 Connection Part 3

Part

11 6 7 9 15 14 16 19 18 17 13 12

T21W-03-05-020
5 8 10

1- Axle Casing 6 - U-Ring 11 - Rod 16 - Cylinder Tube

2- Drive Housing 7 - Wiper Ring 12 - Wiper Ring 17 - Guide Ring
3- Tie Rod 8 - O-Ring 13 - U-Ring 18 - Guide Ring
4- Piston Rod 9 - Guide Ring 14 - Retaining Ring 19 - Seal
5- Retaining Ring 10 - Piston 15 - Flange 20* - Bolt (5 Used)

NOTE: As for the item with mark*, refer to W3-5-46.

W3-5-48
 UNDERCARRIAGE / Axle
Assembly of Steering Cylinder

1. Install U-ring (13) and wiper ring (12) to cylinder 9. Install elbows (22) (2 used) to drive housing (2).
tube (16).
2 22
2. Install U-ring (6), wiper ring (7), guide rings (9, 17,
18) and seal (19) to piston (10) and rod (11).

3. When installing the rod (11) assembly to cylinder

tube (16), apply hydraulic oil onto the seals. Install
the rod (11) assembly to cylinder tube (16). 1

4. When installing piston (10) to rod (11), apply

4
hydraulic oil onto the seals. Install piston (10) to
rod (11). Push piston (10) to the position where
Connection Part
O-ring (8) can be installed.
WCGB-03-05-018

5. Install retaining ring (5) to the piston rod (4)

IMPORTANT: Check the direction to install tie rod
assembly.
(3).
10. Apply LOCTITE #243 onto the tie rod (3)
6. Install flange (15) and retaining ring (14) to the
connection part of piston rod (4). Attach a spanner
piston rod (4) assembly.
onto the connection part of piston rod (4) and tie
rod (3). Install tie rod (3) to piston rod (4).
7. Apply LOCTITE #574 onto the drive housing (2)
: 46 mm
contact surface (2 places) on the piston rod (4)
: 450 N⋅m (45 kgf⋅m, 330 lbf⋅ft)
assembly. Install piston rod (4) to drive housing
(2).
11. Secure tie rod (3) to axle casing (1) with nut (21).
: 41 mm
8. Apply LOCTITE #243 onto bolt (20). Install bolts
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
(20) (5 used).
: 19 mm 3 21
: 79 N⋅m (7.9 kgf⋅m, 58 lbf⋅ft)

1
WCGB-03-05-017

12. Install other tie rod (3) in the same way as steps
10 to 11.

W3-5-49
 UNDERCARRIAGE / Axle
(Blank)

W3-5-50
 UNDERCARRIAGE / Axle Lock Cylinder
REMOVAL AND INSTALLATION OF AXLE
LOCK CYLINDER

CAUTION: Release any pressure in the

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

The procedure starts on the premise that the front axle

has already been removed.
1 2 3
Removal
1. Disconnect hoses (1) (2 used) from operate check
valve (3). Cap the open ends.
: 19 mm

IMPORTANT: Do not remove operate check valve

(3). If removing operate check valve
(3), rod (4) may come off due to the
entering air.
2. Remove socket bolts (2) (2 used) from operate
check valve (3). Install eyebolts (M8, Pitch 1.25
mm) (2 used) into the hole. Attach a nylon sling
onto eyebolts. Hoist and hold operate check valve
(3).
: 6 mm 4 WCEB-03-06-001

WCEB-03-06-003

CAUTION: Axle lock cylinder (5) weight: 61

kg (134 lb) 5

3. Remove socket bolts (6) (3 used), washers (7) (3 Pulling-Out Hole

used), bolt (8) and spacer (9) from axle lock
cylinder (5). 6, 7
: 19 mm
: 36 mm
9
Pulling-Out Hole
8

WCEB-03-06-001

W3-6-1
 UNDERCARRIAGE / Axle Lock Cylinder
10
CAUTION: Axle lock cylinder (5) weight: 61
kg (134 lb)

4. Install the bolts (M12, Pitch 1.75 mm) (2 used) into 5

the pulling-out hole on axle lock cylinder (5). Pulling-Out Hole
Tighten the bolts (2 used) alternately. Remove axle
lock cylinder (5) from track frame (10).
: 19 mm

Pulling-Out Hole

WCEB-03-06-001

W3-6-2
 UNDERCARRIAGE / Axle Lock Cylinder
Installation

CAUTION: Axle lock cylinder (5) weight: 61 10

kg (134 lb)

1. Apply LOCTITE #262 onto socket bolts (6) (3

used) and bolt (8). 5

2. Hoist and align axle lock cylinder (5) with the

mounting hole on track frame (10). Install axle lock
6, 7
cylinder (5) to track frame (10) with socket bolts (6) 9
(3 used), washers (7) (3 used), bolt (8) and spacer
(9).
: 19 mm
: 950 N⋅m (97 kgf⋅m, 701 lbf⋅ft)
: 36 mm
: 950 N⋅m (97 kgf⋅m, 701 lbf⋅ft)

8 WCEB-03-06-001

3. Remove eyebolts (2 used) from axle lock cylinder 2 3 5

(5).

4. Install operate check valve (3) to axle lock cylinder

(5) with socket bolts (2) (2 used).
: 6 mm
: 29.4 to 34.3 N⋅m
(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

WCEB-03-06-003

1 3

5. Connect hoses (1) (2 used) to operate check valve

(3).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

WCEB-03-06-001

W3-6-3
 UNDERCARRIAGE / Axle Lock Cylinder
DISASSEMBLY AND ASSEMBLY OF AXLE
LOCK CYLINDER

8, 9 10

8, 9 10 7

2 View A WCEB-03-06-003

1 WCEB-03-06-002

1- Retaining Ring 4- Dust Seal 7- Housing 9 - O-Ring

2- Dust Seal 5- Seal Ring 8- Operate Check Valve 10 - Socket Bolt (4 Used)
3- Air Ring (4 Used) 6- Rod

W3-6-4
 UNDERCARRIAGE / Axle Lock Cylinder
Disassembly of Axle Lock Cylinder Assembly of Axle Lock Cylinder

CAUTION: Axle lock cylinder weight: 61 kg
(134 lb)
1. Place the axle lock cylinder onto the workbench
horizontally.
IMPORTANT: Apply hydraulic oil onto the inner
2. Remove socket bolts (10) (4 used) from operate
check valve (8). Remove operate check valve (8)
and O-ring (9) from housing (7).
3. Apply air to the port hole on housing (7) and
remove rod (6).
4. Remove retaining ring (1) and dust seal (2) from
housing (7).
5. Remove air rings (3) (4 used), dust seal (4) and
seal ring (5) from housing (7).
1. Install seal ring (5), dust seal (4) and air rings (3)
(4 used) to housing (7).
2. Install dust seal (2) and retaining ring (1) to
housing (7).
surface of housing (7), dust seals (2,
4), seal ring (5) and air ring (3).
3. Install rod (6) to housing (7).
CAUTION: Axle lock cylinder weight: 61 kg
(134 lb)
4. Install operate check valve (8) to housing (7) with
socket bolts (10) (4 used) and O-ring (9).
: 6 mm
: 29.4 to 34.3 N⋅m
(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

W3-6-5
 UNDERCARRIAGE / Axle Lock Cylinder
(Blank)

W3-6-6
 UNDERCARRIAGE / Operate Check Valve
REMOVAL AND INSTALLATION OF
OPERATE CHECK VALVE (FOR AXEL
LOCK 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.)
1 2
Removal 3, 4
1. Disconnect hoses (1) (2 used) from operate check
valve (3). Cap the open ends.
: 19 mm
5
2. Remove socket bolts (2) (4 used) from operate
check valve (3). Remove operate check valve (3)
and O-ring (4) from axle lock cylinder (5). Cap the
open ends.
: 6 mm

WCEB-03-06-001

Installation 1 2 3, 4
1. Apply grease onto O-ring (4). Install O-ring (4) to
operate check valve (3).

2. Install operate check valve (3) to axle lock cylinder

5
(5) with socket bolts (2) (4 used).
: 6 mm
: 29.4 to 34.3 N⋅m
(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

3. Connect hoses (1) (2 used) to operate check valve

(3).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

WCEB-03-06-001

W3-7-1
 UNDERCARRIAGE / Operate Check Valve
STRUCTURE OF OPERATE CHECK VALVE (FOR AXEL LOCK CYLINDER)

1 2 3 4 5 6 7 8 9 10 11 12 13

WCEB-03-06-004

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 : 6.2 2±0.5 (0.2±0.05) (1.5±0.4)
2 O-Ring 1 1A P11
3 Plug 1 : 27 120±12 (12±1.2) (89±9)
4 O-Ring 1 1B P18
5 Piston 1
6 Body 1
7 Poppet 1
8 Sleeve 1
9 Spring 1
10 O-Ring 1 1B P11
11 Plug 1 : 36 500±50 (51±5) (369±37)
12 O-Ring 1 1B P26
13 Plug 1 :6 34.3±3.4 (3.5±0.3) (25±2.5)

W3-7-2
 UNDERCARRIAGE / Solenoid Valve
REMOVAL AND INSTALLATION OF
OUTRIGGER / BLADE SOLENOID VALVE
UNIT

CAUTION: Bleed air from the hydraulic oil

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

IMPORTANT: One side of the solenoid valve unit Solenoid Valve Unit
cannot be removed. Remove the
plate (2) assembly.

Removal
1. Disconnect hoses (3) (8 used) from solenoid valve
units (4) (2 used). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm, 22 mm

2. Disconnect connectors (1) (4 used) from solenoid

W1F3-04-04-004
valve units (4) (2 used).

3. Remove sems bolts (7) (4 used) from plate (2).

Remove the plate (2) assembly from track frame 1 Solenoid Valve Unit 2 3 Solenoid Valve Unit
(6).
: 17 mm

4. Remove sems bolts (5) (4 used) from plate (2).

Remove solenoid valve units (4) (2 used) from 1
plate (2).
: 17 mm
3

7 3 6 4, 5 WCEB-03-08-001

W3-8-1
 UNDERCARRIAGE / Solenoid Valve
Installation
1. Install solenoid valve units (4) (2 used) to plate (2)
with sems bolts (5) (4 used). Solenoid Valve Unit
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) Solenoid Valve Unit

2. Install the plate (2) assembly to track frame (6)

with sems bolts (7) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Connect hoses (3) (8 used) to solenoid valve units

(4) (2 used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) W1F3-04-04-004

4. Connect connectors (1) (4 used) to solenoid valve

units (4) (2 used).
1 Solenoid Valve Unit 2 3
Solenoid Valve Unit

7 3 6 4, 5 WCEB-03-08-001

W3-8-2
 UNDERCARRIAGE / Solenoid Valve
STRUCTURE OF SOLENOID VALVE UNIT

T1F3-03-08-001
5

Wrench Tightening Torque

No. Part Name Q’ty Remarks
Size (mm) N·m (kgf·m) (lbf·ft)
1 Solenoid 2
2 Piston 2
3 O-Ring 2 1B P14
4 Body 1
5 Spool 2
6 Spring 2

W3-8-3
 UNDERCARRIAGE / Solenoid Valve
(Blank)

W3-8-4
 UPPERSTRUCTURE / Transmission Changeover Solenoid Valve
REMOVAL AND INSTALLATION OF
TRANSMISSION CHANGEOVER
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.)
1 2
Removal
1. Disconnect connectors (1) (2 used).

2. Disconnect hoses (2) (4 used) from transmission

changeover solenoid valve (3). Cap the open ends.
Attach an identification tag onto the disconnected
hoses for assembling.
: 19 mm

3. Remove socket bolts (4) (3 used) from WCEB-03-09-001

transmission changeover solenoid valve (3). 5 4 3
Remove transmission changeover solenoid valve
(3) from bracket (5).
: 6 mm

Installation 1 2
1. Install transmission changeover solenoid valve (3)
to bracket (5) with socket bolts (4) (3 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

2. Connect hoses (2) (4 used) to transmission

changeover solenoid valve (3).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Connect connectors (1) (2 used) to transmission 5 4 3

WCEB-03-09-001

changeover solenoid valve (3).

W3-9-1
 UPPERSTRUCTURE / Transmission Changeover Solenoid Valve
(Blank)

W3-9-2
 LOWERSTRUCTURE / Propeller Shaft
REMOVEAL AND INSTALLATION OF
PROPELLER SHAFT

Preparation
1. Place the machine on a solid, level surface.
Lower the front attachment onto the ground.

2. Lower the blade and the outrigger onto the

ground.

3. Place the blocks in front of and behind the axle in

order to secure the machine.
WCJB-03-10-004

W3-10-1
 LOWERSTRUCTURE / Propeller Shaft
Removal and Installation of Propeller Shaft
Front Axle

5
3

6 Rear Axle

B 8
A

W1GL-03-08-001

3 4 5 8
2 6
9
3
10
1 7

WCJB-03-10-001
View A
WCJB-03-10-002 WCJB-03-10-003
View B View D

12 11 8

13

WCEB-03-10-007
3 14 15 16
Detail B
Detail C
WCJB-03-10-005

1- Flange 5- Sems Bolt (2 Used) 9- Nut (8 Used) 13 - Nut

2- Nut (8 Used) 6- Bracket 10 - Flange 14 - Spline Seal
3- Propeller Shaft 7- Flange 11 - Bearing Assembly 15 - Grease Fitting
4- Socket Bolt (4 Used) 8- Propeller Shaft 12 - Yoke 16 - Fork

W3-10-2
 LOWERSTRUCTURE / Propeller Shaft
Removal
1. Remove grease fitting (15) from propeller shaft
(3).
: 10 mm
IMPORTANT: Propeller shaft (3) cannot be
removed individually. If removing
propeller shaft (3) individually,
spline seal (14) is damaged. Remove
the propeller shaft (3) assembly.
2. Remove nuts (2) (8 used) from the flange part of
propeller shaft (3).
: 14 mm
3. Insert a pry bar between flange (1) and the flange
part of propeller shaft (3). Pry propeller shaft (3)
toward fork (16) and place propeller shaft (3) on
the ground.
4. Remove socket bolts (4) (4 used) from the flange
part of propeller shaft (3). Remove propeller shaft
(3) from flange (7).
: 8 mm
W3-10-3
5. Remove nuts (9) (8 used) from the flange part of
propeller shaft (8).
: 14 mm
6. Remove sems bolts (5) (2 used) from bracket (6).
Place bearing assembly (11) onto bracket (6).
: 17 mm
7. Move propeller shaft (8) toward bracket (6) side.
Pull out propeller shaft (8).
IMPORTANT: Do not remove bearing assembly
(11) unless necessary. When
removing bearing assembly (11),
follow the procedure below. Dispose
removed bearing assembly (11).
8. Remove nut (13) from propeller shaft (8).
Remove yoke (12) from propeller shaft (8).
: 32 mm
9. Remove bearing assembly (11) from propeller
shaft (8).
 LOWERSTRUCTURE / Propeller Shaft

Front Axle

5
3

6 Rear Axle

B 8
A

W1GL-03-08-001

3 4 5 8
2 6
9
3
10
1 7

WCJB-03-10-001
View A
WCJB-03-10-002 WCJB-03-10-003
View B View D

12 11 8

13

WCEB-03-10-007
3 14 15 16
Detail B
Detail C
WCJB-03-10-005

W3-10-4
 LOWERSTRUCTURE / Propeller Shaft
Installation
1. Install bearing assembly (11) to propeller shaft
(8).
2. Install yoke (12) to propeller shaft (8). Secure
yoke (12) to propeller shaft (8) with nut (13).
: 32 mm
: 370 to 440 N⋅m (38 to 45 kgf⋅m, 273 to
325 lbf⋅ft)
3. Apply LOCTITE #262 onto nuts (9) (8 used).
4. Insert the yoke (12) mounting side of propeller
shaft (8) into bracket (6). Install the flange part of
propeller shaft (8) to flange (10). Install propeller
shaft (8) to flange (10) with nuts (9) (8 used).
: 14 mm
: 76 N⋅m (7.8 kgf⋅m, 56 lbf⋅ft)
5. Apply LOCTITE #262 onto sems bolts (5) (2
used). Install the propeller shaft (8) assembly to
bracket (6) with sems bolts (5) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m,37 lbf⋅ft)
W3-10-5
6. Apply LOCTITE #262 onto socket bolts (4) (4
used). Align the flange part of propeller shaft (3)
with the mounting hole on flange (7). Secure
propeller shaft (3) to flange (7) with socket bolts
(4) (4 used).
: 8 mm
: 62 N⋅m (6.3 kgf⋅m, 46 lbf⋅ft)
7. Apply LOCTITE #262 onto nuts (2) (8 used).
Align the flange part of propeller shaft (3) with the
mounting hole on flange (1). Secure propeller
shaft (3) to flange (1) with nuts (2) (8 used).
: 14 mm
: 76 N⋅m (7.8 kgf⋅m, 56 lbf⋅ft)
8. Install grease fitting (15) to fork (16). Apply
grease.
 LOWERSTRUCTURE / Propeller Shaft
(Blank)

W3-10-6
 MEMO

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 MEMO

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FRONT ATTACHMENT
— CONTENTS —
Group 1 Front Attachment
Hydraulic Circuit Pressure
Release Procedure .............................. W4-1-1
Removal and Installation of
Front Attachment .................................. W4-1-2
Maintenance Standard ......................... W4-1-12
Standard Dimensions for
Arm and Bucket Connection .............. W4-1-15
Standard Dimensions for
Arm and Boom Connection ................ W4-1-16
Group 2 Cylinder
Hydraulic Circuit Pressure
Release Procedure .............................. W4-2-1
Removal and Installation of Cylinder ..... W4-2-2
Disassembly of Boom, Arm and
Bucket Cylinders ................................ W4-2-26
Assembly of Boom, Arm and
Bucket Cylinders ................................ W4-2-32
Disassembly of Positioning Cylinder.... W4-2-38
Assembly of Positioning Cylinder ........ W4-2-42
Disassembly of Outrigger and
Blade Cylinders .................................. W4-2-46
Assembly of Outrigger and
Blade Cylinder .................................... W4-2-48
Maintenance Standard ......................... W4-2-54
CJBW-4-1
SECTION 4
Group 3 Hose Rupture Valve
Hydraulic Circuit Pressure
Release Procedure ...............................W4-3-1
Removal and Installation of Hose
Rupture Valve for Arm Cylinder ............W4-3-2
Removal and Installation of Hose Rupture
Valve for Positioning Cylinder ...............W4-3-3
Removal and Installation of Hose
Rupture Valve for Boom Cylinder .........W4-3-5
Structure of Hose Rupture Valve
for Arm Cylinder ....................................W4-3-8
Structure of Hose Rupture Valves
for Boom Cylinder ...............................W4-3-12
Structure of Hose Rupture Valves
for Positioning Cylinder.......................W4-3-16
Group 4 Operate Check Valve
Remove and Install Operate Check
Valve (for Blade and Outrigger) ............W4-4-1
Structure of Operate Check Valve ..........W4-4-3
(Blank)

CJBW-4-2
 FRONT ATTACHMENT / Front Attachment
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE

NOTE: Operate the pilot pump by using the power

from the battery without starting the engine
and deliver the pilot pressure to the spool
of the control valve.

1. Turn the pilot shut-off lever to the UNLOCK posi-

tion.

2. Turn the engine stop switch ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.

IMPORTANT: The battery will deplete. Operate the

key switch for short period.
3. With the key switch in the START position, oper- WCEB-02-01-002
Engine Stop Switch
ate the lever 4 to 5 times in order to release any
pressure in the hydraulic circuit.

4. Return the pilot shut-off lever to the LOCK posi-

tion.

5. Turn the engine stop switch OFF.

W4-1-1
 FRONT ATTACHMENT / Front Attachment
REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT
Removal
1 1
1. As for the lubrication hoses to the front attach-
ment, disconnect hoses (1) (2 used) to the boss
at the boom cylinder (3) rod side from the
adapter.
: 17 mm

3 3
WCGB-04-01-001
2. Remove nuts (7) (4 used) from bolts (4) (2 used).
Remove bolts (4) (2 used) and stoppers (5) (2
used) from pin (6).
: 24 mm 1 2 3 4

CAUTION: Boom cylinder (3) weight: 5

Mono block boom: 172kg (380 lb)
6
2-piece boom: 161kg (360 lb)
CAUTION: Metal fragments may fly off when 7
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.
WCGB-04-01-002
3. Attach a nylon sling onto the end of the boom
cylinder (3) tube. Hoist and hold the boom cylin-
der (3) tube. By using a bar and a hammer, tap
pin (6) into the position where thrust plate (2) can
be removed. Remove thrust plate (2).
NOTE: When pin (6) cannot be removed, start the
engine and operate the boom lever. Adjust
the rod pin hole on the boom cylinder.

W4-1-2
 FRONT ATTACHMENT / Front Attachment
4. Place the tube end of boom cylinder (3) on a
stand of 1 m (39 in) height.
Start the engine. Operate the boom lever and re- Stand
tract boom cylinder (3). In order not to extend the
rod, pass a wire through the rod hole and secure
the rod to the cylinder tube.
Stop the engine.
3
Wire
5. Remove boom cylinder (3) from the boom.
Refer to Removal of Boom Cylinder on W4-2-10.

6. Remove other boom cylinder (3) in the same way

as steps 3, 4 and 5.
W554-02-03-007

CAUTION: Do not stand toward the removal

2 3
direction of the pins as the pins may fly off
suddenly.

7. Slowly tap and remove pin (6) by using a bar and

a hammer. Remove thrust plate (2). 6

8. After stopping the engine, push the air bleed

valve. Bleed air from the hydraulic oil tank and
remove the cap.
Release the pressure in the hydraulic circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE WCGB-04-01-002

RELEASE PROCEDURE on W4-1-1.

Air Bleed Valve Cap
Hydraulic
Oil Tank

WCJB-01-04-002

9. Disconnect hoses (8) (6 used), (9) (4 used) (2)

from the bucket cylinder and the arm cylinder.
Cap the disconnected hoses and pipings.
: 19 mm, 27 mm, 36 mm, 41 mm

NOTE: The number of the hoses may differ de-

pending on the front attachment specifica-
tions.

WCJB-04-01-001

8 9 8 9

W4-1-3
 FRONT ATTACHMENT / Front Attachment
10. Open cover (10).

10

WCEB-02-05-002

11. Remove sems bolts (12) (4 used) from cover 11 12 13

(13).
: 17 mm

12. Remove sems bolts (16) (5 used) from cover

(15). 14
: 17 mm

13. Remove cover (13) from cover (11), bracket (14) 16 15 WCJB-04-01-002

and support (117).

13 12
15

16
17

WCJB-04-01-003
18
WCJB-04-01-004

14. Disconnect harness (20) from clips (21) (4 used)

at the back of cover (15). 19 20
15

15. Remove sems bolts (22) (2 used) from bracket 21

(19). Remove cover (15) from bracket (19) cover
(18).

22

WCJB-04-01-005

W4-1-4
 FRONT ATTACHMENT / Front Attachment

CAUTION: Boom foot pin (26) weight: 46 kg

26

16. Remove bolt (23), spring washer (27), plate (24)

and block (25) from the plate of boom foot pin
(26).
: 27 mm
25
24
23
27
W178-04-01-001

Mono block Boom

CAUTION: Front attachment weight:
Mono block boom: 3430 kg (7570lb) Boom
2-piece boom: 4190 kg (9240 lb)

17. Attach a wire rope onto the boom. Hoist and hold
the boom.

WCJB-02-03-001

2-Piece Boom
Boom

WCJB-02-03-002

W4-1-5
 FRONT ATTACHMENT / Front Attachment

CAUTION: Boom foot pin (26) weight: 46 kg

18. Insert a pry bar between the plate of boom foot 26

pin (26) and the bracket. Pull out the plate a little.
: 30 mm

19. While turning the plate gradually by hand, re-

move boom foot pin (26).
NOTE: When boom foot pin (26) cannot be re- Plate
moved, adjust the position by using a lifting Insert a Bar.
rope for the front attachment.
Bracket

20. Hoist the front attachment assembly and move

the machine backward.
W178-04-01-001

21. Place a wooden block. Lower the front attach-

ment assembly onto the wooden block.

W4-1-6
 FRONT ATTACHMENT / Front Attachment
Installation
Mono block Boom
Boom
CAUTION: Front attachment weight:
Mono block boom: 3430 kg (7570lb)
2-piece boom: 4190 kg (9240 lb)

1. Hoist the front attachment assembly and move

the machine forward. Align the boom foot with the
mounting hole on the frame.
Insert the thrust plate into the left and right sides
of the boom. Adjust the clearance between the
plate and the frame within 1 mm (0.04 in).
WCJB-02-03-001
(Adjust the position by using a lifting rope for the
front attachment.)
2-Piece Boom
Boom
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.
CAUTION: Boom foot pin (26) weight: 46 kg
(101 lb)

2. Install boom foot pin (26).Secure boom foot pin

(26) to the main frame with bolt (23), washer (27).
Plate (24) and block (25).
WCJB-02-03-002
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
26

25
24
23
27
W178-04-01-001

W4-1-7
 FRONT ATTACHMENT / Front Attachment
3. Install cover (15) to bracket (19) with sems bolts
19 20
(22) (2 used). 15
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
21

4. Secure harness (20) to cover (15) with clips (21)

(4 used).
22

WCJB-04-01-005

5. Align cover (13) with the mounting holes on cover 13 12

(11), bracket (14) and support (17).Install cover 15
(13) to cover (11), bracket (14) and support (17)
with sems bolts (12) (4 used).
: 17 mm 16
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 17

WCJB-04-01-003
18
WCJB-04-01-004

6. Install cover (15) to covers (13, 18) with sems 11 12 13

bolts (16) (5used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
14

16 15 WCJB-04-01-002

7. Shut cover (10).

10

WCEB-02-05-002

W4-1-8
 FRONT ATTACHMENT / Front Attachment
8. Remove the caps from the hoses and the pipings.
Connect hoses (8) (6 used) and hoses (9) (4
used) to the bucket cylinder and the arm cylinder.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft) 8

CAUTION: Boom cylinder (3) weight: WCJB-04-01-001

Mono block boom: 172kg (380 lb) 8 9 8 9

2-piece boom: 161kg (360 lb)

9. Install boom cylinder (3).

Refer to Installation of Boom Cylinder on
W4-2-12. Wire

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury. 3

10. Remove the wire from boom cylinder (3). Attach a

nylon sling onto the end of the boom cylinder (3) WCEB-04-01-003
tube. Hoist and align the boom cylinder (3) tube
with the mounting hole on the boom.
6 2
11. Insert thrust plate (2) between the boom and
boom cylinder (3), and between boom cylinder
(3) and collar (5). Install pin (6). Install boom cyl-
inder (3) to the both sides. 4 3

12. Install stoppers (5) (2 used) to pin (6). Secure

stoppers (5) (2 used) to pin (6) with bolts (4) (2
used) and nuts (7) (4 used).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
5
7
W178-04-01-004

W4-1-9
 FRONT ATTACHMENT / Front Attachment
13. Connect lubrication hoses (1) (2 used) to the
boom cylinder (3) rod side. 1 1
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

3 3
WCGB-04-01-001

Left Boom Cylinder Arm Cylinder Right Boom

Rod Side Bottom Side Cylinder
Boom Foot Side Rod Side
14. Apply grease onto the boom cylinder (3) rod side,
the bottom side and the boom foot side.

WCGB-04-01-004

W4-1-10
 FRONT ATTACHMENT / Front Attachment

CAUTION: Arm bucket assembly weight: Mono block Boom

Mono block boom: 1650 kg (3640 lb)
2-piece boom : 1560 kg (3440lb) Boom

IMPORTANT: When removing the arm from the

boom, perform the following steps Arm
when installing the arm.
15. Install thrust plates (28) to the left and right sides
of the arm. Adjust total clearance of the left and
right sides within 1.5 mm (0.06 in).

16. After installing the arm, apply grease onto grease

fitting (29) in the boom connecting boss of the WCJB-02-03-001

arm.

IMPORTANT: For handling of HN bushing for the

front attachment, check the follow-
ings. Piece Boom Boom
Precautions when installing the bushing
If a hammer is used, the bushing may be damaged. Arm
Use a press.

Precautions when reinforcing the arm

The heat when welding in order to reinforce the arm
may cause oil leakage from HN bushing and decrease
lubrication performance.
When the welding heat causes the oil leakage of the
bushing, replace the bushing.
WCJB-02-03-002

Use the special tool when removing or installing the

bushing.
Special tool: ST 1454

23 23

24 24

M157-07-157

W4-1-11
 FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD
Pin and Bushing
C
F F

C E
A D M A
B B
E D
D K G
I J I K
G J
H
WCJB-02-03-001 H
WCJB-02-03-002

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
Pin 90 (3.5) 89.0 (3.5)
A
Bushing 90 (3.5) 91.5 (3.6)
Pin 80 (3.1) 79.0 (3.1)
B Boss (Main Frame) 80 (3.1) 81.5 (3.2)
Bushing (Boom Cylinder) 80 (3.1) 81.5 (3.2)
Pin 90 (3.5) 89.0 (3.5)
C Bushing (Boom Cylinder) 90 (3.5) 91.5 (3.6)
Boss (Boom) 90 (3.5) 91.5 (3.6)
Replace
Pin 90 (3.5) 89.0 (3.5)
D
Bushing 90 (3.5) 91.5 (3.6)
Pin 80 (2.8) 79.0 (3.1)
E Boss (Arm) 80 (2.8) 81.5 (3.2)
Bushing (Arm Cylinder) 80 (2.8) 81.5 (3.2)
Pin 80 (2.8) 79.0 (3.1)
F Boss (Boom) 80 (2.8) 81.5 (3.2)
Bushing (Arm Cylinder) 80 (2.8) 81.5 (3.2)

W4-1-12
 FRONT ATTACHMENT / Front Attachment

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
Pin 71 (2.8) 70.0 (2.9)
G Boss (Arm) 71 (2.8) 72.5 (2.9)
Bushing (Bucket Cylinder) 71 (2.8) 72.5 (2.9)
Pin 80 (3.1) 79.0 (3.1)
H Bushing 80 (3.1) 81.5 (3.2)
Bushing (Bucket Cylinder) 80 (3.1) 81.5 (3.2)
Pin 71 (2.8) 70.0 (2.9)
I
Bushing 71 (2.8) 72.5 (2.9)
Replace
Pin 80 (3.1) 79.0 (3.1)
J
Bushing 80 (3.1) 81.5 (3.2)
Pin 80 (3.1) 79.0 (3.1)
K
Bushing 80 (3.1) 81.5 (3.2)
Pin 100 (3.9) 99.0 (3.9)
L
Bushing 100 (3.9) 101.5 (4.0)
Pin 100 (3.9) 99.0 (3.9)
M
Bushing 100 (3.9) 101.5 (4.0)

IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a
press and special tool (ST 1454).

W4-1-13
 FRONT ATTACHMENT / Front Attachment
Point

B C

W105-04-01-020

Unit: mm (in)
Standard Allowable Limit Remedy
A 215 107.5 (4.2)
B 95 (3.7) -
Replace
C 108 -
D 95 -

Side Cutter

C
D

W155-04-01-002

Unit: mm (in)
Standard Allowable Limit Remedy
A 278 (10.9) 181 (7.0)
B 295 (11.6) -
Replace
C 433 (17) -
D 135 (5.3) -

W4-1-14
 FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION

Section B
Section A
W1CF-04-01-007

Unit: mm (in)
a 450 (17.7)
b 0
c 604 (23.8)
d 580 (22.8)
e -
f 1471 (57.9)
g 433 (17)
h 305.5 (12)
i 80 (3.2)
j 475 (18.7)
k 31 (1.2)
l 433 (17)
m 307 (12)
n 80 (3.2)
o 3.7°
p 3.7°
q 449 (17.7)

W4-1-15
 FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION

WCJB-04-01-006

Section C

W1GL-04-01-010

Unit: mm (in)
s 90 (3.5)
t 352 (13.9)
u 490 (19.3)

W4-1-16
 FRONT ATTACHMENT / Cylinder
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE

NOTE: Operate the pilot pump by using the power

from the battery without starting the engine
and deliver the pilot pressure to the spool
of the control valve.

1. Turn the pilot shut-off lever to the UNLOCK posi-

tion.

2. Turn the engine stop switch ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.

IMPORTANT: The battery will deplete. Operate the

key switch for short period.
3. With the key switch in the START position, oper- WCEB-02-01-002
Engine Stop Switch
ate the lever 4 to 5 times in order to release any
pressure in the hydraulic circuit.

4. Return the pilot shut-off lever to the LOCK posi-

tion.

5. Turn the engine stop switch OFF.

W4-2-1
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF CYL-
INDER
1
Removal of Bucket Cylinder

1. Insert wooden block (3) between the ground and

the end of arm (2), and between arm (2) and
bucket cylinder (1). 3

2. Stop the engine. Push the air bleed button and 2

bleed air from the hydraulic oil tank. Remove the 3
cap.
Release the pressure in the bucket circuit. W554-04-02-006

Refer to HYDRAULIC CIRCUIT PRESSURE

RELEASE PROCEDURE on W4-2-1.

CAUTION: Before removing pin (7), fasten

the link by using a wire in order not to fall
off.
CAUTION: Metal fragments may fly off when 4 5
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

3. Remove nuts (6) (2 used) and bolt (4). Remove

pin (7) by tapping. Remove thrust plates (5) (4
used).
: 30 mm

4. In order not to extend rod (8) of bucket cylinder

7 6
(1), pass wire (9) through the cylinder rod hole
and secure to the bucket cylinder (1) tube. W158-04-02-006
8 1

9 W102-04-02-005

W4-2-2
 FRONT ATTACHMENT / Cylinder
5. Disconnect bucket cylinder hoses (12) (2 used)
10
at the bottom of bucket cylinder (1). Cap the open
ends
: 30 mm

CAUTION: Bucket cylinder (1) weight: 150

kg (340 lb) 15
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec- 11
tion, such as goggles, hard hats, etc in order 13
to prevent personal injury.

6. Hoist and hold bucket cylinder (1). Remove nuts

(13) (2 used) and bolt (15). Remove pin (11) by
tapping. Remove thrust plates (10) (2 used). 1
: 24 mm

7. Remove bucket cylinder (1).

12 W187-04-02-004

W4-2-3
 FRONT ATTACHMENT / Cylinder
Installation of Bucket Cylinder
10

CAUTION: Bucket cylinder (1) weight: 150

kg (340 lb)
CAUTION: Metal fragments may fly off when
a hammer is used when installing pin (11).
Wear necessary protection, such as goggles, 15
hard hats, etc in order to prevent personal 14
injury. 11
13
1. Hoist bucket cylinder (1). Align the hole on the
cylinder tube side with the cylinder mounting hole
on the arm. Install thrust plates (10) (2 used) and
pin (11).
1
Arm
2. Install stopper (14) and pin (11) to the arm. Se-
cure with bolt (15) and nuts (13) (2 used).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf·ft)
12 W187-04-02-004

3. Connect bucket cylinder hoses (12) (2 used).

: 36 mm
: 175 N⋅m (18 kgf⋅m, 140 lbf·ft) 8 1

4. Remove wire (9) from rod (8) of bucket cylinder

(1).

9 W102-04-02-005

W4-2-4
 FRONT ATTACHMENT / Cylinder

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec- 16 4 17 5
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

5. Start the engine. Operate the lever and align the

hole on the bucket cylinder (1) rod side with
those on links (16, 18). Install thrust plates (5) (4
used) and pin (7).

6. Secure stopper (17) and pin (7) with bolt (4) and
7 18 6
nuts (6) (2 used).
: 30 mm W158-04-02-006

: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

IMPORTANT: In case link (18) has been removed

19 19
from the arm, insert thrust plate (19)
when installing link (18).
IMPORTANT: After completing the work, add hy-
draulic oil to the specified level.
Operate bucket cylinder (1) to the
stroke end several times and bleed
air from the circuit.
At the same time, check each con- W157-04-01-015
18 18
nection of the hoses for any oil
leaks.

W4-2-5
 FRONT ATTACHMENT / Cylinder
Removal of Arm Cylinder
1
1. Insert wooden block (3) between arm cylinder (1)
and boom (2).

2. Stop the engine. Push the air bleed button and

bleed air from the hydraulic oil tank. Remove the
2
cap.
Release the pressure in the arm circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.
3 W187-04-02-005

3. Remove nuts (8) (2 used) and bolt (10) from pin 10 4 5

(5) at the rod side in arm cylinder (1).
: 30 mm
1

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

4. Remove pin (5) by tapping. Remove thrust plates

(4) (4 used).
8

W187-04-02-006

6 1
5. In order not to extend rod (6) of arm cylinder (1),
pass wire (7) through the cylinder rod hole and
secure to the arm cylinder (1) tube.

7 W187-04-02-010

W4-2-6
 FRONT ATTACHMENT / Cylinder
6. Disconnect pipings (11) (2 used) at the bottom of
1
arm cylinder (1). Cap the open ends. (When a
hose rupture valve is provided, refer to RE-
MOVAL AND INSTALLATION OF HOSE RUP- 11
TURE VALVE on W4-3-1.)
: 36 mm, 41 mm

7. Disconnect lubrication hose (12) from arm cylin-

der (1).
: 17 mm 12

CAUTION: Arm cylinder (1) weight: 255 kg

(570 lb)
WCGB-04-01-001
8. Attach a nylon sling at the center of gravity of arm
cylinder (1). Hoist and hold arm cylinder (1).
1

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

9. Remove nuts (15) (2 used) and bolt (17) from the

tube side in arm cylinder (1). Remove pin (14).
Remove thrust plate (13). Hoist and remove arm
cylinder (1).
: 30 mm W102-04-02-016

17 13 14

15

W187-04-02-007

W4-2-7
 FRONT ATTACHMENT / Cylinder
Installation of Arm Cylinder
17 13 14

CAUTION: Arm cylinder (1) weight: 255 kg 1

(5700 lb)

1. Attach a nylon sling at the center of gravity of arm

cylinder (1). Hoist arm cylinder (1). Align the hole
on the cylinder tube side hole with the cylinder 16
15
mounting hole on the boom.

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec- W187-04-02-007

tion, such as goggles, hard hats, etc in order 1

to prevent personal injury.

2. Install thrust plate (13) and pin (14). Secure pin 11

(14) and stopper (16) with bolt (17) and nuts (15)
(2 used).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)
12
3. Connect lubrication hose (12) and pipings (11) (2
used) of arm cylinder (1).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf·ft) WCGB-04-01-001

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

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine and check for
any oil leaks at the hose connec-
tions.

W4-2-8
 FRONT ATTACHMENT / Cylinder
4. Remove wire (7) from rod (6) of arm cylinder (1).
6 1
Hold arm cylinder (1) and start the engine. Oper-
ate the lever and align the hole at the rod (6) side
with the mounting hole on arm (18).

1
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.
3
5. Install thrust plate (4) and pin (5). Secure pin (5) W187-04-02-010

and stopper (9) with bolt (10) and nuts (8) (2 9 10 4 5

used).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

IMPORTANT: When completing the work, operate

arm cylinder (1) to the stroke end 18
several times and bleed air from the
circuit.

W187-04-02-006

W4-2-9
 FRONT ATTACHMENT / Cylinder
Removal of Boom Cylinder
1
1. Disconnect lubrication hose (1) from boom cylin-
der (2).
: 17 mm

CAUTION: Boom cylinder (2) weight:

Monoblock boom: 175 kg (390 lb)
2-piece boom: 165 kg (370 lb)
2
2. Attach a wire rope onto boom cylinder (2). Hoist
Boom
and hold boom cylinder (2). WCGB-04-01-002

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

3. Remove nuts (5) (2 used), bolt (7) and stopper

(6) from the boom cylinder (2) rod side. Remove
pin (4) by tapping. Remove thrust plates (3) (2 7
used).
: 30 mm

4. Place the rod side of boom cylinder (2) on a

stand. Remove other boom cylinder (2) in the
same way.
6
5. Operate the lever and retract boom cylinder (2). 5 3 4 3 2
In order not to extend the rod, pass a wire W158-04-02-013
through the rod hole and secure to the cylinder
tube.

6. Stop the engine. Push the air bleed button and

bleed air from the hydraulic oil tank.
Release the pressure in the circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.

2
Stand

W105-04-02-035

W4-2-10
 FRONT ATTACHMENT / Cylinder
7. Disconnect hoses (12) (4 used) at the bottom of
boom cylinder (2). Attach a plug onto the open
end of the hose. Cap the open end of boom cyl-
inder (2). (When a hose rupture valve is provided,
refer to REMOVEAL AND INSTALLATION OF
HOSE RUPTURE VALVE on W4-3-1.)
Plug 1 3/16-12UN
: 36 mm

CAUTION: Metal fragments may fly off when 2

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order W105-04-02-036
to prevent personal injury.
2 8
11
8. Remove nuts (10) (2 used) and bolt (8) from the
cylinder bottom side of the main frame.
Remove pin (9) by tapping. Remove thrust plate
(11).
: 24 mm

9
CAUTION: Boom cylinder (2) weight:
Monoblock boom: 175 kg (390 lb) 9 10
2-piece boom: 165 kg (370 lb)
12 10
9. Attach a wire rope at the center of gravity of W178-04-02-009

boom cylinder (2). Hoist and remove boom cyl-

inder (2).
Remove other boom cylinder (2) in the same
way.

W105-04-02-040

W4-2-11
 FRONT ATTACHMENT / Cylinder
Installation of Boom Cylinder

CAUTION: Boom cylinder (2) weight:

Monoblock boom: 175 kg (390 lb)
2-piece boom: 165 kg (370 lb)

1. Attach a wire rope at the center of gravity of

boom cylinder (2). Hoist boom cylinder (2). Align
the hole at the boom cylinder tube side with the
mounting hole on the main frame.

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury. 2

W105-04-02-040
2. Install thrust plate (11) and pin (9). Secure with
bolt (8) and nuts (10) (2 used).
: 24 mm
2 8
: 270 N⋅m (27.5 kgf⋅m, 200 lbf·ft) 11

3. Install other boom cylinder (2) in the same way.

4. Connect hoses (12) (4 used) to boom cylinders

(2) (2 used).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf·ft) 9

IMPORTANT: Fill hydraulic oil to the specified 9 10

level. Start the engine and check for
any oil leaks at the hose connec- 12 10
W178-04-02-009
tions.

W4-2-12
 FRONT ATTACHMENT / Cylinder
5. Hoist boom cylinder (2). Start the engine. Oper-
ate the lever and align the hole at the cylinder rod
side with the mounting hole on the boom.
7
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

6. Insert thrust plate (3) and install pin (4).

6
7. Secure pin (4) and stopper (6) with bolt (7) and 5 3 4 3 2
nut (5). W158-04-02-013
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)
1 7
8. Connect lubrication hose (1).
: 17 mm 4
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft)
6
9. Install other boom cylinder (2) in the same way.
5
IMPORTANT: When completing the work, operate
boom cylinder (2) to the stroke end
several times and bleed air from the
2
circuit.
Boom WCGB-04-01-002

W4-2-13
 FRONT ATTACHMENT / Cylinder
Removal of Positioning Cylinder
(2-Piece Boom Only)
1 2
1. Disconnect lubrication hose (1) from positioning
cylinders (3) (2 used).
: 17 mm, 19 mm

CAUTION: Positioning cylinder (3) weight:

170 kg (375 lb)

2. Attach a nylon sling onto positioning cylinder (3).

3
Hoist and hold positioning cylinder (3).
6, 7 4, 5
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

3. Remove nuts (7) (2 used) and bolt (6) from stop-

W1GL-04-01-008
per (4) of the second boom.
: 30 mm

4. Install pin (2) 160 mm by tapping. Remove thrust

plate (5).

5. Disconnect hoses (8) (3 used) and hoses (9) (3

8 9
used) from positioning cylinder (3). Cap the open
ends of the disconnected hoses.
: 22 mm, 36 mm

9 3 W1GL-04-03-004

W4-2-14
 FRONT ATTACHMENT / Cylinder
6. Remove nuts (13) (2 used) and bolt (14) from
stopper (11) of the first boom.
Install pin (12) 160 mm by tapping by using a ham-
mer and a bar. Remove thrust plate (10). 10
: 30 mm

CAUTION: Positioning cylinder (3) weight:

170 kg (375 lb) 11

7. Hoist and remove positioning cylinder (3).

3 14 13 12
8. Remove other positioning cylinder (3) in the
same way steps 2 to 7. W1GL-04-03-004

W4-2-15
 FRONT ATTACHMENT / Cylinder
Installation of Positioning Cylinder
(2-Piece Boom Only)
8 9
CAUTION: Positioning cylinder (3) weight:
170 kg (375 lb)
CAUTION: Metal fragments may fly off when 10
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.
11
1. Hoist positioning cylinder (3). Align the pin holes
at the bottom side with those of the first boom.
Insert thrust plate (10) and install pin (12) by tap- 9 3 14 13 12
ping.
W1GL-04-03-004
2. Align the pin holes of stopper (11) and pin (12).
Install and secure with bolt (14) and nuts (13) (2
used).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine and check for
any oil leaks at the hose connec-
tions.
3. Connect hoses (8) (3 used) and hoses (9) (3
used) to positioning cylinder (3).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf·ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf·ft)

W4-2-16
 FRONT ATTACHMENT / Cylinder
4. Start the engine and extend positioning cylinder
(3). Align the rod hole of positioning cylinder (3)
with the hole of the second boom. Insert thrust
1 2
plate (5) and install pin (4) by tapping.

5. Align the pin holes of stopper (4) and pin (2). In-
stall bolt (6) and nuts (7) (2 used).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

6. Connect lubrication hose (1) to positioning cylin-

der (3). 3
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 6, 7 4, 5
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

IMPORTANT: When completing the work, operate

positioning cylinder (3) to the stroke
end several times and bleed air from
the circuit. W1GL-04-01-008

W4-2-17
 FRONT ATTACHMENT / Cylinder
Removal of Blade Cylinder

IMPORTANT: Before starting the work, lower the

blade onto the ground.

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.

Removal 1 2, 3
1. Remove bolts (2) (4 used) and washers (3) (4
4
used) from cover (4). Remove cover (4) from
bracket (1).
: 19 mm

WCEB-04-02-001

5 6 7 8 9
2. Disconnect hoses (5) (4 used) from blade cylinder
10
(6). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm, 27 mm 11

CAUTION: Blade cylinder (6) weight: 50 kg

(110 lb)

3. Attach a nylon sling onto blade cylinder (6). Hoist

and hold blade cylinder (6).

4. Remove nuts (10) (4 used) from bolts (8) (2 used). WCEB-04-02-002

Remove bolts (8) (2 used) from pins (9, 13). Re-
move pins (9, 13) from bracket (11) and link (12).
: 24 mm
6
5. Remove thrust plates (7) (6 used) between the
bottom part and bracket (11) and between the rod
part and link (12) in blade cylinder (6).
8
7

12

13 10 WCEB-04-02-001

W4-2-18
 FRONT ATTACHMENT / Cylinder

CAUTION: Blade cylinder (6) weight: 50 kg 6 11

(110 lb)

6. Remove blade cylinder (6) from bracket (11) and

link (12).

12

WCEB-04-02-002

6 7 8 9
Installation of Blade Cylinder 10

CAUTION: Blade cylinder (6) weight: 50 kg 11

(110 lb)

1. Attach a nylon sling onto blade cylinder (6). Hoist

blade cylinder (6). Align the bottom and rod parts
of blade cylinder (6) with the mounting holes on
bracket (11) and link (12).

2. Install thrust plates (7) (6 used) to the bottom and

rod parts of blade cylinder (6). Install blade cylin- WCEB-04-02-002

der (6) to bracket (11) and link (12) with pins (9,
13).
6
3. Secure pins (9, 13) to bracket (11) and link (12)
with bolts (8) (2 used) and nuts (10) (4 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft) 8
7

12

13 10 WCEB-04-02-001
5 6
4. Connect hoses (5) (4 used) to blade cylinder (6).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf·ft)

WCEB-04-02-002

W4-2-19
 FRONT ATTACHMENT / Cylinder
5. Install cover (4) to bracket (1) with bolts (2) (4 2, 3
1
used) and washers (3) (4 used).
: 19 mm 4
: 90 N⋅m (9.2 kgf⋅m, 66 lbf·ft)

IMPORTANT: When completing the work, operate

the blade cylinder to the stroke end
several times and bleed air from the
circuit.

WCEB-04-02-001

W4-2-20
 FRONT ATTACHMENT / Cylinder
Removal of Outrigger Cylinder

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 sems bolts (4) (3 used), washers (5) (2

used) and collars (6) (2 used) from cover (3).
Remove cover (3) from outrigger cylinder (2).
: 17 mm 1 2 3 4, 5, 6 4

2. Disconnect hoses (1) (4 used) from outrigger cyl-

inder (2). Cap the open ends. Attach an identifica-
tion tag onto the disconnected hoses for assem-
bling.
: 19 mm, 27 mm

3. Remove operate check valve (9) from outrigger

cylinder (2). (Refer to REMOVAL AND INSTAL-
9 7, 8 WCEB-04-02-004
LATION OF OPERATE CHECK VALVE on
W4-4-1.)

4. Disconnect piping (7) from outrigger cylinder (2).

Remove O-ring (8) from piping (7).
: 6 mm

2
CAUTION: Outrigger cylinder (2) weight: 90
kg (200 lb)

5. Attach a nylon sling onto the rod side of the out-

rigger cylinder (2) tube. Hoist and hold outrigger
cylinder (2).

WCEB-04-02-003

W4-2-21
 FRONT ATTACHMENT / Cylinder

CAUTION: Outrigger cylinder (2) weight: 90

kg (200 lb) 2 10, 11

6. Remove bolts (14) (3 used) and washers (15) (3

used) from pin (13). Remove pin (13) and thrust
plates (14) (3 used) from outrigger (12). 12
: 19 mm
13, 14
7. Hoist outrigger cylinder (2) a little. Insert a wooden
block under outriger cylinder (2). Lower outrigger 15, 16
cylinder (2).

CAUTION: The outrigger (12) assembly 17 WCEB-04-02-003

weight: 145 kg (320 lb)

8. Attach a nylon sling onto outrigger (12). Hoist and 17 10, 11

hold outrigger (12). Remove lock pin (11) from pin
(10). Remove pin (10) from outrigger beam (17).
Lower the outrigger (12) assembly.

Wooden Block
12

W1GL-04-02-006

CAUTION: Outrigger cylinder (2) weight: 90 18 17

kg (200 lb)

9. Attach a nylon sling onto outrigger cylinder (2).

Hoist and hold outrigger cylinder (2).

10. Remove ring (18) from pin (19). Remove lock pin
(20) from pin (19). Remove pin (19) and thrust
plates (21) (3 used) from outrigger beam (17).

11. Remove outrigger cylinder (2) from outrigger

beam (17).
19, 20, 21 2 WCEB-04-02-003

W4-2-22
 FRONT ATTACHMENT / Cylinder
Installation of Outrigger Cylinder

CAUTION: Outrigger cylinder (2) weight: 90

kg (200 lb) 18 17

1. Attach a nylon sling onto outrigger cylinder (2).

Hoist and align the hole on the bottom side with
the outrigger beam (17) mounting hole. Install
outrigger cylinder (2) to outrigger beam (17) with
thrust plates (21) (3 used) and pin (19).

2. Secure pin (19) to outrigger beam (17) with lock

pin (20) and ring (18).

19, 20, 21 2 WCEB-04-02-003

3. Install O-ring (8) to piping (7). Connect piping (7)

1 2
to outrigger cylinder (2).
: 6 mm
: 78±19 N⋅m (8±2 kgf⋅m, 58±6 lbf·ft)

4. Install operate check valve (9) to outrigger cylin-

der (2). (Refer to REMOVAL AND INSTALLATION
OF OPERATE CHECK VALVE on W4-4-1.)

5. Connect hoses (1) (4 used) to operate check

valve (9). 9 7, 8 WCEB-04-02-004
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf·ft)
2 3 4, 5, 6 4
6. Install cover (3) to outrigger cylinder (2) with sems
bolts (4) (3 used), washers (5) (2 used) and col-
lars (6) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf·ft)

WCEB-04-02-004

W4-2-23
 FRONT ATTACHMENT / Cylinder
IMPORTANT: After the hose is connected, operate 17 10, 11
the outrigger cylinder to the stroke
end several times and bleed air from
the circuit.
7. Extend the rod of outrigger cylinder (2) and align
with the mounting hole on outrigger (12). Install
the rod part of outrigger cylinder (2) to outrigger
(12) with thrust plates (14) (3 used) and pin (13). 13, 14

2
8. Install pin (13) to outrigger (12) with bolts (15) (3 15, 16
used) and washers (16) (3 used).
: 19 mm Wooden Block
: 90 N⋅m (9 kgf⋅m, 66 lbf·ft) 12

W1GL-04-02-006

9. Remove the wooden block from the inside of out-

rigger beam (17).
17 10, 11
10. Operate outrigger cylinder (2) and align the
mounting hole on outrigger (12) with that on out-
rigger beam (17). Secure outrigger (12) to outrig-
ger beam (17) with pin (10) and lock pin (11). 12

2 WCEB-04-02-003

W4-2-24
 FRONT ATTACHMENT / Cylinder
(Blank)

W4-2-25
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF BOOM, ARM AND
BUCKET CYLINDERS
Boom Cylinder
1 2 3 4 5 6 7 8 9 10 11

22 20 19 12
23

W1V1-04-02-007
26 25 17 18 24 19 21 18 17

Arm Cylinder 1 2 3 4 5 6 7 8 9 10 11

20 19 16 15 14 13 12
22
23

W1V1-04-02-008
26 25 17 18 24 19 21 18 17

W4-2-26
 FRONT ATTACHMENT / Cylinder
Bucket Cylinder

1 2 3 4 5 6 7 8 9 10 11

19 18 12
22
23

W1V1-04-02-009

17 18 24 19 21 20 17

1- Piston Rod 8- Bushing 15 - Cushion Seal 21 - Seal Ring

2- Wiper Ring 9- Snap Ring 16 - Snap Ring 22 - Set Screw
3- Backup Ring 10 - Backup Ring 17 - Slide Ring (2 Used) 23 - Steel Ball
4- U-Ring 11 - O-Ring 18 - Slide Ring (2 Used) 24 - Piston Nut
5- Buffer Ring 12 - Cylinder Tube 19 - Backup Ring (2 Used) 25 - Cushion Bearing
6- Socket Bolt (12 Used) 13 - Stopper (2 Used) 20 - O-Ring 26 - Cushion Seal
7- Cylinder Head 14 - Cushion Bearing

W4-2-27
 FRONT ATTACHMENT / Cylinder

1 6 7

14 12

W1V1-04-02-008

24

W4-2-28
 FRONT ATTACHMENT / Cylinder
Disassembly of Boom, Arm and Bucket Cylinders
• The disassembling procedure starts on the
premise that the hydraulic pipings and the bands
securing the pipings have been removed.
NOTE: The procedure for the arm cylinder is ex-
plained.
IMPORTANT: Pull out piston rod (1) straight in
order not to damage the sliding
surface.
3. Tap and remove cylinder head (7) with piston rod
(1) together from cylinder tube (12) by using a
plastic hammer.

4. Secure piston rod (1) to special tool (ST 5908).

CAUTION: Boom cylinder weight: Put the matching marks on piston rod (1) and the
Monoblock boom: 175 kg (390 lb) end of piston (24) (Arm cylinder: cushion bearing
2-piece boom: 165 kg (370 lb) (14)).
Arm cylinder weight: 225 kg (550 lb)
Bucket cylinder weight: 150 kg (335 lb)

1. Hoist the cylinder. Secure the cylinder horizontally

on a workbench. Drain hydraulic oil from the cyl-
inder.

Special Tool: ST 5908

W158-04-02-022

W102-04-02-027

2. Fully extend piston rod (1). Attach a nylon sling

onto piston rod (1). Hold piston rod (1). Remove
socket bolts (6) (12 used) from cylinder head (7).
: 14 mm

W4-2-29
 FRONT ATTACHMENT / Cylinder

1 2 3 4 5 6 7 8 9 10 11

20 19 16 15 14 13
22
23

W1V1-04-02-008

26 25 17 18 24 19 21 18 17

W4-2-30
 FRONT ATTACHMENT / Cylinder
5. Cut away the crimped part by using a hand drill
and remove set screw (22). Remove steel ball
(23).
NOTE: Set screw (22) has been crimped by using
a punch at 2 places after installing.
: 6 mm
6. Remove piston nut (24) by using special tool (ST
5908) and the special tool.
Remove cushion bearing (25) and cushion seal
(26) from piston rod (1).
(Cushion bearing (25) and cushion seal (26) are
not equipped for the bucket cylinder.)
Special tool (outer diameter at nut part):
Bucket cylinder: (ST 3244: 90 mm)
Boom cylinder:
Monoblock boom: (ST 3245: 95 mm)
2-piece boom: (ST 3246: 100 mm)
Arm cylinder: (ST 3249: 110 mm)
Special Tool: ST 5908
W158-04-02-022
W4-2-31
7. Remove slide rings (17) (2 used), slide rings (18)
(2 used), backup rings (19) (2 used), O-ring (20)
and seal ring (21) from piston nut (24).
8. Remove cylinder head (7) from piston rod (1).
9. Remove O-ring (11) and backup rings (10, 3) from
cylinder head (7). Remove wiper ring (2), U-ring
(4), buffer ring (5), snap ring (9) and bushing (8)
by using the special tool.
Special tool (rod outer diameter):
Bucket cylinder: (ST 8019: 80 mm)
Boom cylinder: (ST 8020: 85 mm)
Arm cylinder: (ST 8025: 95 mm)
10. (Arm cylinder only)
Remove stoppers (13) (2 used) from piston rod
(1) by using a screwdriver. Remove cushion
bearing (14), cushion seal (15) and snap ring (16).
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF BOOM, ARM AND BUCKET CYLINDERS

Boom Cylinder
1 2 4 5 6 7 12 25 17 18 19 18 17 22

3 8 9 10, 11 26 24 20, 21 23 W1V1-04-02-005

Arm Cylinder
1 2 4 5 6 7 12 25 17 18 19 18 17 22 14

3 8 9 10, 11 26 24 20, 21 23 16 15 W1V1-04-02-003

Bucket Cylinder
1 2 4 5 6 7 12 17 18 19 18 17

22

3 8 9 10, 11 20, 21 23
W1V1-04-02-001

W4-2-32
 FRONT ATTACHMENT / Cylinder

1- Piston Rod 8- Bushing 15 - Cushion Seal 21 - Seal Ring

2- Wiper Ring 9- Snap Ring 16 - Snap Ring 22 - Set Screw
3- Backup Ring 10 - Backup Ring 17 - Slide Ring (2 Used) 23 - Steel Ball
4- U-Ring 11 - O-Ring 18 - Slide Ring (2 Used) 24 - Piston Nut
5- Buffer Ring 12 - Cylinder Tube 19 - Backup Ring (2 Used) 25 - Cushion Bearing
6- Socket Bolt (12 Used) 13 - Stopper (2 Used) 20 - O-Ring 26 - Cushion Seal
7- Cylinder Head 14 - Cushion Bearing

W4-2-33
 FRONT ATTACHMENT / Cylinder

1 2 4 5 7 17 18 19 18 17 14

13

3 8 9 10, 11 24 20, 21 16 15 W1V1-04-02-003

NOTE: The illustration shows the arm cylinder.

W4-2-34
 FRONT ATTACHMENT / Cylinder
Assembly of Boom, Arm and Bucket Cylinders
NOTE: The procedure for the arm cylinder is ex-
plained.
1. Install bushing (8) to cylinder head (7) by using
the special tool.
Special tool (rod outer diameter):
Bucket cylinder: (ST 8019: 80 mm)
Boom cylinder: (ST 8020: 85 mm)
Arm cylinder: (ST 8025: 90 mm)
IMPORTANT: Check the direction to install.
2. Install U-ring (4), backup ring (3), buffer ring (5)
and snap ring (9) to cylinder head (7).
3. Install wiper ring (2) to cylinder head (7) by using
the special tool and a plastic hammer.
Special tool (rod outer diameter):
Bucket cylinder: (ST 8019: 80 mm)
Boom cylinder: (ST 8020: 85 mm)
Arm cylinder: (ST 8025: 90 mm)
4. Install O-ring (11) and backup ring (10) to cylinder
head (7).
W4-2-35
5. Install O-ring (20) and seal ring (21) to piston nut
(24) by using special tool A.
After installing seal ring (21), adjust seal ring (21)
by using special tool B.
Special tools A and B (tube inner diameter):
Bucket cylinder: (ST 2963, 2207: 115 mm)
Boom cylinder:
Monoblock boom: (ST 2964, 2208: 120 mm)
2-piece boom: (ST 2965, 2088: 125 mm)
Arm cylinder: (ST 2978, 2535: 135 mm)
6. Install backup rings (19) (2 used), slide rings (17)
(2 used) and slide rings (18) (2 used) to piston nut
(24).
7. Install the cylinder head (7) assembly to piston
rod (1) by using the special tool.
Special tool (rod outer diameter):
Bucket cylinder: (ST 8019: 80 mm)
Boom cylinder: (ST 8020: 85 mm)
Arm cylinder: (ST 8025: 90 mm)
IMPORTANT: Face the slit in cushion seal (15) to
the piston nut (24) side. Check the
direction of the oil groove in cushion
bearing (14).
8. (Arm cylinder only)
Install snap ring (16) and cushion seal (15) to
piston rod (1). Install cushion bearing (14) and
stoppers (13) (2 used).
 FRONT ATTACHMENT / Cylinder

1 6 7 12 25 22

26 24 23 W1V1-04-02-003

NOTE: The illustration shows the arm cylinder.

W4-2-36
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Face the slit in cushion seal (26) to
the piston nut (24) side. Check the
direction of the oil groove in cushion
bearing (25).
9. Install cushion seal (26) and cushion bearing (25)
to piston rod (1).
(Cushion bearing (25) and cushion seal (26) are
not equipped for the bucket cylinder.)
10. Align the matching marks and tighten piston nut
(24) by using special tool (ST 5908) and the spe-
cial tool.
Special tool (outer diameter at nut part):
Bucket cylinder: (ST 3244: 90 mm)
: 5600 N⋅m (570 kgf⋅m, 4130 lbf·ft)
Boom cylinder:
Monoblock boom: (ST 3245: 95 mm)
: 5340 N⋅m (545 kgf⋅m, 3940 lbf·ft)
2-picece boom: (ST 3245: 95 mm)
: 6000 N⋅m (610 kgf⋅m, 4430 lbf·ft)
Arm cylinder:
Monoblock boom: (ST 3245: 95 mm)
: 8860 N⋅m (900 kgf⋅m, 6540 lbf·ft)
2-picece boom: (ST 3245: 95 mm)
: 7900 N⋅m (810 kgf⋅m, 5380 lbf·ft)
Special Tool: ST 5908 W158-04-02-022
W4-2-37
11. Install steel ball (23) to piston rod (1). Tighten with
set screw (22). Crimp set screw (22) by using a
punch at 2 places.
: 6 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf·ft)
CAUTION: Align the piston rod (1) assembly
with the center of cylinder tube (12) and in-
sert straight in order not to damage the rings.
12. Secure cylinder tube (12) horizontally on a work-
bench. Insert the piston rod (1) assembly into
cylinder tube (12).
13. Install cylinder head (7) to cylinder tube (12) with
socket bolts (6) (12 used).
: 14 mm
: 265 N⋅m (27 kgf⋅m, 195 lbf·ft)
IMPORTANT: When replacing the bushing from
piston rod (1) or cylinder tube (12)
by using a hammer, the bushing may
be damaged. Use a press and spe-
cial tool (ST 1454) when removing
and installing the bushing.
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF POSITIONING CYLIN-
DER

1
2 3 4
5
6 7
8 9
10
11
12
13

14 15
16
17
18
19 20 21

22

WCGB-04-02-010

1- Piston Rod 7- U-Ring 13 - Backup Ring 18 - O-Ring

2- Socket Bolt (14 Used) 8- Buffer Ring 14 - Piston 19 - Backup Ring (2 Used)
3- Cylinder Head 9- Bushing 15 - Slide Ring (2 Used) 20 - Set Screw
4- Retaining Ring 10 - Retaining Ring 16 - Wear Ring (2 Used) 21 - Piston Nut
5- Dust Seal 11 - O-Ring 17 - Seal Ring 22 - Cylinder Tube
6- Backup Ring 12 - O-Ring

W4-2-38
 FRONT ATTACHMENT / Cylinder
Disassembly of Positioning Cylinder
NOTE: The disassembling procedure starts on the
premise that the hydraulic pipings and the
bands securing the pipings have been re-
moved.
CAUTION: Positioning cylinder weight: 170
kg (375 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the cyl-
inder.
CAUTION: Do not drop piston rod (1) by tilt-
ing.
IMPORTANT: Pull out piston rod (1) straight in
order not to damage the sliding
surface.
4. Slowly remove piston rod (1) from cylinder tube
(22). At this time, cylinder head (3) is removed
with piston rod (1) together. Set a cloth onto a
wooden block. Place piston rod (1) horizontally on
the wooden block.

W102-04-02-027

2. Fully extend piston rod (1). Attach a nylon sling

onto piston rod (1). Hold piston rod (1). Remove
socket bolts (2) (14 used) from cylinder head (3).
: 14 mm

3. Remove cylinder head (3) from cylinder tube (22)

by using a pry bar.

W4-2-39
FRONT ATTACHMENT / Cylinder

1
2 3 4
5
6 7
8 9
10
11
12
13

14 15
16
17
18
19 20 21

22

WCGB-04-02-010

W4-2-40
 FRONT ATTACHMENT / Cylinder
5. Cut away the crimped part by using a hand drill 9. Remove bushing (9) from cylinder head (3) by
and remove set screw (20) from piston nut (21). using special tool (ST 2613). Remove O-rings (11,
NOTE: Set screw (20) has been crimped by using 12), backup rings (6, 13), dust seal (5), U-ring (7),
a punch at 2 places after installing. buffer ring (8) and retaining rings (4, 10) from
: 4 mm bushing (9).

6. Remove piston nut (21) from piston rod (1) by

using special tool (ST 3327). Remove piston (14)
from piston rod (1) by using special tool (ST
3339).

7. Remove seal ring (17), slide ring (15), wear ring

(16), O-ring (18), retaining rings (19) (2 used) and
backup rings (17) (2 used) from piston (14).

8. Remove cylinder head (3) from piston rod (1).

W4-2-41
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF POSITIONING CYLINDER

6, 7 8 9, 10 2, 11 3 12, 13 22 14 15 16 17 18, 19 21 20
4, 5

WCJB-04-02-002

1- Piston Rod 7- U-Ring 13 - Backup Ring 18 - O-Ring

2- Socket Bolt (14 Used) 8- Buffer Ring 14 - Piston 19 - Backup Ring (2 Used)
3- Cylinder Head 9- Bushing 15 - Slide Ring (2 Used) 20 - Set Screw
4- Retaining Ring 10 - Retaining Ring 16 - Wear Ring 21 - Piston Nut
5- Dust Seal 11 - O-Ring 17 - Seal Ring 22 - Cylinder Tube
6- Backup Ring 12 - O-Ring

W4-2-42
 FRONT ATTACHMENT / Cylinder
Assembly of Positioning Cylinder
1. Install bushing (9) to cylinder head (3) by using 5. Install O-ring (18), backup rings (19) (2 used),
special tool (ST 2613). Install retaining ring (10). seal ring (17), slide rings (15) (2 used) and wear
ring (16) to piston (14) by using special tools (ST
2. Tap and install dust seal (5) to cylinder head (3) 2588, 2589).
by using special tool (ST 2614) and a plastic
hammer. 6. Install the cylinder head (3) assembly to piston
rod (1) by using special tool (ST 2696).
IMPORTANT: Check the installing direction.
3. Install U-ring (7), backup ring (2), buffer ring (8)
and retaining ring (4) to cylinder head (3).

4. Install O-rings (11, 12) and backup ring (13) to

cylinder head (3).

W4-2-43
 FRONT ATTACHMENT / Cylinder

2 3 22 14 21 20

WCJB-04-02-002

W4-2-44
 FRONT ATTACHMENT / Cylinder
6. Apply hydraulic oil onto the inner surface of piston
(14). Install piston (14) to piston rod (1) by using
special tool (ST 3339).
: 980±98 N⋅m (100±10 kgf⋅m, 720±72 lbf·ft)
7. Apply hydraulic oil onto piston nut (21). Install
piston nut (21) to piston rod (1) by using special
tool (ST 3327).
: 1860±185 N⋅m
(190±19 kgf⋅m, 1380±137 lbf·ft)
8. Apply LOCTITE #242 onto two to three threads of
set screw (20). Install set screw (20) to piston nut
(21). After tightening set screw (20), crimp set
screw (20) by using a punch at 2 places.
: 4 mm
: 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)
W4-2-45
IMPORTANT: Align the piston rod (1) assembly
with the center of cylinder tube (22)
and insert straight in order not to
damage the rings.
10. Apply hydraulic oil onto the outer surface of piston
(14). Hoist cylinder tube (22). Secure cylinder
tube (22) horizontally on a workbench. Insert the
piston rod (1) assembly into cylinder tube (22).
11. Install cylinder head (3) to cylinder tube (22) by
using special tool (ST 2696). Tighten cylinder
head (3) with socket bolts (2) (14 used).
: 14 mm
: 340 to 360 N⋅m
(35 to 37 kgf⋅m, 255 to 270 lbf·ft)
IMPORTANT: When replacing the bushing from
piston rod (1) or cylinder tube (22)
by using a hammer, the bushing may
be damaged. Use a press and spe-
cial tool (ST 1454) when removing
and installing the bushing.
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF OUTRIGGER AND BLADE CYLINDERS

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16 17

18

19

20

WCGB-04-02-002

1- Piston Rod 6- Seal 11 - O-Ring 16 - O-Ring

2- Cylinder Head 7- Bushing 12 - Piston 17 - Set Screw
3- Retaining Ring 8- Retaining Ring 13 - Seal Ring 18 - Piston Nut
4- Dust Seal 9- O-Ring 14 - Wear Ring 19 - Backup Ring (2 Used)
5- U-Ring 10 - Backup Ring 15 - Dust Ring 20 - Cylinder Tube

W4-2-46
 FRONT ATTACHMENT / Cylinder
Disassembly of Outrigger and Blade Cylinders
NOTE: The disassembling procedure starts on the
premise that the hydraulic pipings and the
bands securing the pipings have been re-
moved.
CAUTION: Outrigger cylinder weight: 90 kg
(200 lb)
Blade cylinder weight: 50 kg (110 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the cyl-
inder.
4. Cut away the crimped part by using a hand drill
and remove set screw (17) from piston nut (18).
NOTE: Set screw (17) has been crimped by using
a punch at 2 places after installing.
: 4 mm
5. Remove piston nut (18) by using special tool (ST
3334). Remove piston (12) from piston rod (1) by
using special tool (ST 3337).
6. Remove cylinder head (2) from piston rod (1).
IMPORTANT: When removing the seals, do not
damage the parts.
7. Remove seal ring (13), wear ring (14), dust ring
(15) and O-ring (16) from piston (12).

8. Remove retaining rings (3, 8), U-ring (5), dust seal

(4) and backup ring (10) from the inside of cylin-
der head (2). Remove bushing (7) by using spe-
cial tool (ST 2685).

9. Remove O-rings (9, 11) and backup ring (10) from

W102-04-02-027
the outside of cylinder head (2).
2. Raise a detent (a part of cylinder tube (20)) in the
groove on cylinder head (2). Pry and remove cyl-
inder head (2) from cylinder tube (20) by using a
pry bar.
R wrench: (ST 3221)

CAUTION: Do not drop piston rod (1) by tilt-

ing.

IMPORTANT: Remove piston rod (1) straight in

order not to damage the rod surface.
3. Fully extend piston rod (1). Attach a nylon sling
onto piston rod (1). Hold piston rod (1). Slowly
remove piston rod (1) from cylinder tube (20). Set
a cloth onto a wooden block. Place piston rod (1)
horizontally on the wooden block.

W4-2-47
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF OUTRIGGER AND BLADE CYLINDER
Outrigger Cylinder

1 3, 4 5 9 6 7, 8 2 10, 11 20 12 13 14 15 16, 19 18 17

WCGB-04-02-004

Blade Cylinder

1 3, 4 5 9 6 7, 8 2 10, 11 20 12 13 14 15 16, 19 18 17

WCGB-04-02-003

W4-2-48
 FRONT ATTACHMENT / Cylinder

1- Piston Rod 6- Seal 11 - O-Ring 16 - O-Ring

2- Cylinder Head 7- Bushing 12 - Piston 17 - Set Screw
3- Retaining Ring 8- Retaining Ring 13 - Seal Ring 18 - Piston Nut
4- Dust Seal 9- O-Ring 14 - Wear Ring 19 - Backup Ring (2 Used)
5- U-Ring 10 - Backup Ring 15 - Dust Ring 20 - Cylinder Tube

W4-2-49
 FRONT ATTACHMENT / Cylinder

1 3, 4 5 9 6 7, 8 2 10, 11 12 13 14 15 16, 19 18 17

WCGB-04-02-004

NOTE: The illustration shows the outrigger cylinder.

W4-2-50
 FRONT ATTACHMENT / Cylinder
Assembly of Outrigger and Blade Cylinders
1. Install bushing (7) to cylinder head (2) by using
special tool (ST 2685). Install retaining ring (8).
IMPORTANT: Install U-ring (5) with its lip part fac-
ing to the bushing (7) side.
Install seal (6) with its projection part
and slit part facing to the bushing (7)
side.
2. Install U-ring (5) and seal (6) to cylinder head (2).
3. Install dust seal (4) and retaining ring (3) to cyl-
inder head (2) by using special tool (ST 2689).
IMPORTANT: Install backup ring (10) to the pin
hole side on piston rod (1).
4. Install O-rings (9, 11) and backup ring (10) to cyl-
inder head (2).
5. Install the cylinder head (2) assembly to piston
rod (1) by using special tool (ST 2693).
W4-2-51
IMPORTANT: After installing O-ring (16), check
that O-ring (16) is not twisted.
6. Install O-ring (16), backup rings (19) (2 used),
seal ring (13), wear ring (14) and dust ring (15) to
piston (12).
7. Apply hydraulic oil onto the inner surface of piston
(12). Install piston (12) to piston rod (1) by using
special tool (ST 3337).
: 740±69 N⋅m (75±7 kgf⋅m, 550±51 lbf·ft)
8. Apply hydraulic oil onto the threads of piston nut
(18). Install piston nut (18) to piston rod (1) by
using special tool (ST 3334).
: 1270±98 N⋅m
(130±10 kgf⋅m, 940±72 lbf·ft)
9. Apply LOCTITE #242 onto set screw (17). Install
set screw (17). After tightening set screw (17),
crimp set screw (17) by using a punch at 2 places.
: 4 mm
: 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)
 FRONT ATTACHMENT / Cylinder

1 2 20

WCGB-04-02-004

NOTE: The illustration shows the outrigger cylinder.

W4-2-52
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Align the piston rod (1) assembly
with the center of cylinder tube (20)
and insert straight in order not to
damage the rings.

10. Secure cylinder tube (20) horizontally on a work-

bench. Insert the piston rod (1) assembly into
cylinder tube (20).

11. Apply hydraulic oil onto the threads of cylinder

head (2). Install cylinder head (2) to cylinder tube
(20). Bend the detent and secure cylinder head
(2).
R wrench: (ST 3223)
: 490 to 690 N⋅m
(50 to 70 kgf⋅m, 360 to 510 lbf·ft)

IMPORTANT: When replacing the bushing from

piston rod (1) or cylinder tube (20)
by using a hammer, the bushing may
be damaged. Use a press and spe-
cial tool (ST 1454) when removing
and installing the bushing.

W4-2-53
 FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD

Piston Rod Rod Bend and Run Out of Piston Rod

A Dial Gauge

Piston Rod

W105-04-02-094 W166-04-02-022

1m
V Block
Unit: mm (in) Unit: mm (in)
Recommended Size After Bend Run Out Remedy
Cylinder Name
Re-Manufacturing (A)
+0.027 +0.001 0.5 (0.02) 1.0 (0.04) Repair
Boom 85 (3.3 )
-0.057 -0.002
+0.027 +0.001 1.0 (0.04) 2.0 (0.08) Replace
Arm 95 (3.7 )
-0.057 -0.002
+0.027 +0.001
Bucket 80 (3.1 )
-0.053 -0.002
+0.027 +0.001
Positioning 95 (3.7 )
-0.057 -0.002
+0.023 +0.001
Blade 120 (4.7 )
-0.043 -0.002
+0.023 +0.001
Outrigger 120 (4.7 )
-0.043 -0.002

W4-2-54
 FRONT ATTACHMENT / Hose Rupture Valve
HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE

NOTE: Operate the pilot pump by using the power

from the battery without starting the engine
and deliver the pilot pressure to the spool of
the control valve.

1. Turn the pilot shut-off lever to the UNLOCK

position.

2. Turn the engine stop switch ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.

IMPORTANT: The battery will deplete. Operate the

key switch for short period.
3. With the key switch in the START position, WCEB-02-01-002
Engine Stop Switch
operate the lever 4 to 5 times in order to release
any pressure in the hydraulic circuit.

4. Return the pilot shut-off lever to the LOCK

position.

5. Turn the engine stop switch OFF.

W4-3-1
 FRONT ATTACHMENT / Hose Rupture Valve
REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR ARM CYLINDER

CAUTION: Loosen the relief valve of hose 5

1 2 3, 4
rupture valve (3) slowly and release the
pressure.

Removal
1. Disconnect hoses (1) (2 used) from hose rupture
valve (3). Cap the open ends. 6
: 19 mm

2. Remove socket bolts (6) (4 used) from piping (5).

: 8 mm

3. Remove socket bolts (2) (4 used) from hose

rupture valve (3). Remove hose rupture valve (3) 7
and O-ring (4) from arm cylinder (7).
: 8 mm WCEB-04-03-003

1 2 3, 4 5
Installation
1. Apply grease onto O-ring (4). Install O-ring (4) to
hose rupture valve (3).

2. Align hose rupture valve (3) with the mounting

holes on arm cylinder (7) and piping (5). Install
hose rupture valve (3) to arm cylinder (7) and 6
piping (5) with socket bolts (2, 6) (4 used for
each).
: 8 mm
: 52±10 N⋅m (5.2±1 kgf⋅m, 38±7 lbf⋅ft)

3. Connect hoses (1) (2 used) to hose rupture valve

7
(3).
: 19 mm WCEB-04-03-003

: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

W4-3-2
 FRONT ATTACHMENT / Hose Rupture Valve
REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR POSITIONING
CYLINDER

CAUTION: Loosen the relief valve of hose

1 2 3 4
rupture valve (8) slowly and release the
pressure.

Removal 5
1. Remove bolts (4) (2 used) from clamp (5).
Remove clamp (5) from bracket (6).
: 22 mm 6

2. Disconnect hoses (3) (3 used) from hose rupture

valve (8). Cap the open ends. Attach an
identification tag onto the disconnected hoses for 8, 9 7 WCJB-04-03-003

assembling.
: 19 mm

3. Remove socket bolts (1) (4 used). Disconnect

piping (2) from positioning cylinder (7). Remove
hose rupture valve (8) and O-ring (9) from
positioning cylinder (7). Cap the open ends.
: 10 mm

W4-3-3
 FRONT ATTACHMENT / Hose Rupture Valve
Installation
1. Apply grease onto O-ring (9). Install O-ring (9) to 1 2 3 4
hose rupture valve (8).

2. Install hose rupture valve (8) and piping (2) to

positioning cylinder (7) with socket bolts (1) (4 5
used).
: 10 mm
: 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft) 6

3. Connect hoses (3) (3 used) to hose rupture valve

(8).
: 19 mm 8, 9 7 WCJB-04-03-003

: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

4. Secure piping (2) to bracket (6) with clamp (5) and

bolts (4) (2 used).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

W4-3-4
 FRONT ATTACHMENT / Hose Rupture Valve
REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR BOOM CYLINDER

CAUTION: Loosen the relief valve of hose

1 2 3 4 5
rupture valve (8) slowly and release the
pressure.

Removal
1. Remove bolt (4) from clamps (3) (2 used).
Remove clamps (3) (2 used) from bracket (2) and
piping (5).
: 19 mm

2. Disconnect hoses (6) (6 used) from hose rupture 6

valve (8). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm, 27 mm

3. Remove socket bolts (7) (4 used) from piping (5).

Disconnect piping (5) from boom cylinder (1).
Remove hose rupture valve (8) and O-ring (9) 8, 9 6 7 WCEB-04-03-002

from boom cylinder (1). Cap the open ends.

: 10 mm

W4-3-5
 FRONT ATTACHMENT / Hose Rupture Valve
Installation 1 2 3 4 5
1. Apply grease onto O-ring (9). Install O-ring (9) to
hose rupture valve (8).

2. Install hose rupture valve (8) and piping (5) to

boom cylinder (1) with socket bolts (7) (4 used).
: 10 mm
: 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft)

3. Connect hoses (6) (6 used) to hose rupture valve

(8). 6
: 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)
8, 9 6 7 WCEB-04-03-002

4. Secure piping (5) to bracket (2) with clamps (3) (2

used) and bolt (4).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

W4-3-6
 FRONT ATTACHMENT / Hose Rupture Valve
(Blank)

W4-3-7
 FRONT ATTACHMENT / Hose Rupture Valve
STRUCTURE OF HOSE RUPTURE VALVE FOR ARM CYLINDER

9 10 11 12 13 14 15 16

3 4 5 6 7 8
2
17

1 18

19
47
20

21
46

22
45

23
44
24
43
25
42
26
41
27

40 28

29
39
30

38 31

37

32
36

35
33

34 WCEB-04-03-006

W4-3-8
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
1 Spacer 1
2 Plug 3 :5
3 O-Ring 3
4 Backup Ring 1
5 O-Ring 1
6 Orifice 2
7 Backup Ring 2
8 O-Ring 1
9 Lock Nut 1 : 17
10 Poppet 1
11 Set Screw 1 :6
12 Spring 1
13 O-Ring 1
14 Washer 1
15 Adapter 1 : 24
16 O-Ring 1
17 Backup Ring 1
18 O-Ring 1
19 Casing 1
20 O-Ring 1
21 Plug 1 : 32
22 Stopper 1
23 Spool 1
24 Sleeve 1
25 Backup Ring 1
26 O-Ring 1
27 O-Ring 3
28 Plug 1

W4-3-9
 FRONT ATTACHMENT / Hose Rupture Valve

47

46

45

44

43

42

41

40

29
39
30

38 31

37

32
36

35
33

34 WCEB-04-03-006

W4-3-10
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
29 Backup Ring 1
30 Spring 1
31 Holding Valve 1
32 Orifice 2
33 Body 1
34 O-Ring 1
35 O-Ring 1
36 Backup Ring 1
37 O-Ring 1
38 Backup Ring 1
39 Spring Seat 1
40 O-Ring 1
41 Piston 1
42 O-Ring 1
43 Cover 1 : 32
44 Stopper 1
45 Set Screw 1 :3
46 Lock Nut 1 : 10
47 Spring 1
Casing (19) and body (33)
4 :8
mounting socket bolt

W4-3-11
 FRONT ATTACHMENT / Hose Rupture Valve
STRUCTURE OF HOSE RUPTURE VALVES
FOR BOOM CYLINDER

9 10 11 12 13 14 15 16

17
3 4 5 6 7 8
2

18
1

19

47
20

46
21

45 22

23

44 24
25

43 26

27
42
28

41 29

40
30
39

38 31

37
32

36

35
33

34
W1V1-04-03-001

W4-3-12
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
1 Spacer 1
2 Plug 3 :5

3 O-Ring 3
4 Backup Ring 1
5 O-Ring 1
6 Orifice 2
7 Backup Ring 2
8 O-Ring 1
9 Lock Nut 1 : 17

10 Poppet 1
11 Set Screw 1 :6

12 Spring 1
13 O-Ring 1
14 Washer 1
15 Adapter 1 : 24

16 O-Ring 1
17 Backup Ring 1
18 O-Ring 1
19 Casing 1
20 O-Ring 1
21 Plug 1 : 32

22 Stopper 1
23 Spool 1
24 Sleeve 1
25 Backup Ring 1
26 O-Ring 1
27 O-Ring 3
28 Plug 1

W4-3-13
 FRONT ATTACHMENT / Hose Rupture Valve

47

46

45

44

43

42

41 29

40
30
39

38 31

37
32

36

35

33

34
W1V1-04-03-001

W4-3-14
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
29 Backup Ring 1
30 Spring 1
31 Holding Valve 1
32 Orifice 2
33 Body 1
34 O-Ring 1
35 O-Ring 1
36 Backup Ring 1
37 O-Ring 1
38 Backup Ring 1
39 Spring Seat 1
40 O-Ring 1
41 Piston 1
42 O-Ring 1
43 Cover 1 : 32
44 Stopper 1
45 Set Screw 1 :3
46 Lock Nut 1 : 10
47 Spring 1
Casing (19) and body (33)
4 :8
mounting socket bolt

W4-3-15
 FRONT ATTACHMENT / Hose Rupture Valve
STRUCTURE OF HOSE RUPTURE VALVES
FOR POSITIONING CYLINDER

9 10 11 12 13 14 15 16

17
3 4 5 6 7 8
2

18
1
19

50
20

49
21

48 22

23
47 24

46 25
26
45
27
44
28
29
43
30

42 31

32
41

33
40
34

39

35
38

36
37

WCJB-04-03-002

W4-3-16
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
1 Spacer 1
2 Plug 3 :5

3 O-Ring 3
4 Backup Ring 1
5 O-Ring 1
6 Orifice 2
7 Backup Ring 2
8 O-Ring 1
9 Lock Nut 1 : 17

10 Poppet 1
11 Set Screw 1 :6

12 Spring 1
13 O-Ring 1
14 Washer 1
15 Adapter 1 : 24

16 O-Ring 1
17 Backup Ring 1
18 O-Ring 1
19 Casing 1
20 O-Ring 1
21 Plug 1 : 32

22 Stopper 1
23 Spool 1
24 Sleeve 1
25 Backup Ring 1
26 O-Ring 1
27 O-Ring 3
28 Plug 1
29 Backup Ring 1
30 O-Ring 1
31 Plug 1
32 Orifice 1

W4-3-17
 FRONT ATTACHMENT / Hose Rupture Valve

50

49

48

47

46

45

44

43

42

41

33
40
34

39

35
38

36
37

WCJB-04-03-002

W4-3-18
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
33 Spring 1
34 Holding Valve 1
35 Orifice 2
36 Body 1
37 O-Ring 1
38 O-Ring 1
39 Backup Ring 1
40 O-Ring 1
41 Backup Ring 1
42 Spring Seat 1
43 O-Ring 1
44 Piston 1
45 O-Ring 1
46 Cover 1 : 32
47 Stopper 1
48 Set Screw 1 :3
49 Lock Nut 1 : 10
50 Spring 1
Casing (19) and body (36)
4 :8
mounting socket bolt

W4-3-19
 FRONT ATTACHMENT / Hose Rupture Valve
(Blank)

W4-3-20
 FRONT ATTACHMENT / Operate Check Valve
REMOVAL AND INSTALLATION OF OP- Outrigger Beam Lock Pin Float
ERATE CHECK VALVE (FOR BLADE AND
OUTRIGGER)

Removal
CAUTION: Lower the blade onto the ground
before doing any work. Outrigger

CAUTION: Secure the outrigger beam and

the outrigger by using the lock pin before
doing any work.
WCEB-04-04-002
1. Remove bolts (1) (4 used) and washers (2) (4
used) from guard cover (3). Remove guard cover 1, 2
(3) from brackets (4) (2 used).
: 19 mm 3

WCEB-04-02-001

5 6

2. Disconnect hoses (5) (4 used) from operate check

valve (7). Cap the open ends.
: 19 mm, 27 mm 7, 8

3. Remove socket bolts (10) (4 used) from piping (9). 9

: 6 mm

4. Remove socket bolts (6) (4 used) from operate 10

check valve (7). Remove operate check valve (7)
and O-rings (8) (2 used) from cylinder (11). Cap
11
the open ends. 5
WCEB-04-02-002

: 6 mm
9

10

11

6 7, 8 WCEB-04-04-001

W4-4-1
 FRONT ATTACHMENT / Operate Check Valve
Installation
1. Apply grease onto O-rings (8) (2 used). 5 6

2. Install O-rings (8) (2 used) to operate check valve

(7).
7, 8
3. Install operate check valve (7) to cylinder (11) with
socket bolts (6) (4 used).
: 6 mm 9
: 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft)

4. Connect piping (9) to operate check valve (7) with 10

socket bolts (10) (4 used).
: 6 mm
11
: 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft) 5
WCEB-04-02-002

5. Connect hoses (5) (4 used) to operate check 9

valve (7).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm 10
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

6. Install guard cover (3) to brackets (4) (2 used) with

bolts (1) (4 used) and washers (2) (4 used).
: 19 mm 11
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
6 7, 8 WCEB-04-04-001

1, 2

WCEB-04-02-001

Outrigger Beam Lock Pin Float

11
Outrigger

WCEB-04-04-002

W4-4-2
 FRONT ATTACHMENT / Operate Check Valve
STRUCTURE OF OPERATE CHECK VALVE

1 2 3 4 5 6 7 8 9 10

11

12

13

WCEB-04-03-001

Wrench Size Tightening Torque

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 2 : 6 mm 34.3±3.4 (3.5±0.3) (25±3)
2 O-Ring 2 1B P11
3 Plug 2 : 36 mm 500±50 (51±5) (369±37)
4 O-Ring 2 1B P26
5 Spring 2
6 Sleeve 2
7 Poppet 2
8 Piston 2
9 O-Ring 1 1B P18
10 Plug 1 : 36 mm 240±24 (24±2.4) (18±2)
11 Casing 1
12 Plug 1 : 36 mm 240±24 (24±2.4) (18±2)
13 O-Ring 1B P18

W4-4-3
 FRONT ATTACHMENT / Operate Check Valve
(Blank)

W4-4-4
 MEMO

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 MEMO

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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162

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