EX40U

Technical Manual
EX40u, 50u
SECTION 1
GENERAL
; CONTENTS;
;
Group 1 Specification
Specifications ............................................T1-1-1
Working Ranges and Machine
Dimensions for Transportation ..................T1-1-4
Engine Specification ..................................T1-1-6
Group 2 Component Layout

Main Component ......................................T1-2-1
Electrical System......................................T1-2-2
Relays ......................................................T1-2-4
Monitor and Switches ...............................T1-2-6
585T-1-1
(Blank)
585T-1-2
GENERAL / Specifications
SPECIFICATIONS
(40u Type A) … Refer to INTRODUCTION (IN-01) for

the corresponding serial numbers.
Item Unit Canopy Cab

Front Attachment ҥ Boom swing type
3 3
Bucket Capacity (Heaped) m 0.13 (0.17 yd ): PCSA (0.12: CECE)
Operating Weight kg (lb) 3980 (8775) 4130 (9105)
Base Machine Weight kg (lb) 3070 (6770) 3220 (7100)
-1
Engine − ISUZU 4LE1 25.0 kW/1900 min (34 PS/1900 rpm)
A: Overall Width mm (ft in) 1865 (6′ 1″)
B: Cab Height mm (ft in) 2570 (8′ 5″) 2640 (8′ 8″)
C: Rear End Swing Radius mm (ft in) 975 (3′ 2″)
D: Minimum Ground Clearance mm (ft in) 335 (1′ 1.1″)
E: Counterweight Clearance mm (ft in) 650 (2′ 2″) (Rubber Crawler)
F: Engine Cover Height mm (ft in) 1580 (5′ 2″)
G: Undercarriage Length mm (ft in) 2445 (8′) (Rubber Crawler)
H: Undercarriage Width mm (ft in) 1950 (6′ 5″)
I: Sprocket Center to Idler Center mm (ft in) 1955 (6′ 7″)
J: Track Shoe Width mm (ft in) 400 (16″) (Rubber Crawler)
Ground Pressure kPa (kgf/cm , psi)
2
22.9 (0.23, 3.3) 23.8 (0.24, 3.4)
-1
Swing Speed min (rpm) 8.3
Travel Speed (Fast/Slow) km/h (mph) 4.3/2.6 (2.69/1.63)
Gradeability % (deg.) 58 (30)
A C
E
D
J
H I
G
M571-11-001
T1-1-1
(40u Type B) … Refer to INTRODUCTION (IN-01) for


3 3
-1
D: Minimum Ground Clearance mm (ft in) 335 (1′ 1″)
E: Counterweight Clearance mm (ft in) 650 (2′ 2″) (Rubber Crawler)
2
22.9 (0.23, 3.3) 23.9 (0.24, 3.4)
-1
A C
E
D
J
H I
G
M571-11-001
T1-1-2
(50u)

3 3
-1
D: Minimum Ground Clearance mm (ft in) 335 (1′ 1″)
E: Counterweight Clearance mm (ft in) 600 (2′) (Rubber Crawler)
2
25.7 (0.23, 3.3) 26.6 (0.24, 3.4)
-1
A C
E
D
J
H I
G
M571-11-001
T1-1-3
WORKING RANGES AND MACHINE
DIMENSIONS FOR TRANSPORTATION
(40u)
L(L) L(R)
M570-11-002
T573-01-01-001
Category 40u Type A 40u Type B

Item Canopy Cab Canopy Cab
A: Maximum Digging Reach mm (ft in) 5550 (18′ 3″) ←
B: Maximum Digging Depth mm (ft in) 3400 (11′ 2″) ←
C: Maximum Cutting Height mm (ft in) 5350 (17′ 7″) 5220 (17′ 2″) 5350 (17′ 7″) 4890 (16′ 1″)
D: Maximum Dumping Height mm (ft in) 3690 (12′ 1″) 3570 (11′ 9″) 3690 (12′ 1″) 3290 (10′ 10″)
E: Overall Transport Height mm (ft in) 2570 (8′ 5″) 2640 (8′ 8″) 2570 (8′ 5″) 2665 (8′ 9″)
F: Overall Transport Length mm (ft in) 5155 (16′ 9″) 5155 (16′ 9″)
G: Minimum Swing Radius mm (ft in) 2100 (6′ 11″) 2200 (7′ 3″) 2100 (6′ 11″) 2485 (8′ 2″)
I: Blade Bottom Highest Position mm (ft in) 400 (1′ 3.7″) 400 (1′ 3.7″)
J: Blade Bottom Lowest Position mm (ft in) 365 (1′ 2.4″) 365 (1′ 2.4″)
K: Maximum Boom Swing Angle ° L 65, R 75 L 60, R 80
L: Offset Distance mm (ft in) L 780 (2′ 7″), R 800 (2′ 8″) L 800 (2′ 8″), R 800 (2′ 8″)
T1-1-4
(50u)
L(L) L(R)
M570-11-002
T573-01-01-001

A: Maximum Digging Reach mm (ft in) 5800 (19′ 2″)
B: Maximum Digging Depth mm (ft in) 3600 (11′ 10″)
C: Maximum Cutting Height mm (ft in) 5640 (18′ 6″) 5145 (16′ 11″)
D: Maximum Dumping Height mm (ft in) 3950 (12′ 11″) 3515 (11′ 6″)
E: Overall Transport Height mm (ft in) 2570 (8′ 5″) 2665 (8′ 9″)
F: Overall Transport Length mm (ft in) 5325 (17′ 6″)
G: Minimum Swing Radius mm (ft in) 2100 (6′ 11″) 2655 (8′ 9″)
I: Blade Bottom Highest Position mm (ft in) 400 (1′ 3.7″)
J: Blade Bottom Lowest Position mm (ft in) 365 (1′ 2.4″)
K: Maximum Boom Swing Angle ° L 60, R 80
L: Offset Distance mm (ft in) L 800 (2′ 8″), R 800 (2′ 8″)
T1-1-5
ENGINE SPECIFICATION
Category
40u 50u
Item
Engine ←
Manufacturer ISUZU ←
Model 4LE1PA-01 ←
Type 4 cycle, water cooled, whirl chamber ←
type
Cyl. Number − bore×stroke 4−85 mm × 96 mm (4−3.3 in × 3.8 in) ←
3
Piston displacement 2.179 L (132 in ) ←
Rated power 25.0 kW/1900 min−1(34 PS/1900 rpm) 27.9 kW/2000 min−1(38 PS/2000 rpm)
Compression ratio 21.5 ←
Dry weight 163 kg (360 lb) ←
Firing order 1−3−4−2 ←
Rotation direction Clockwise (viewed from fan side) ←
Starting system
Manufacturer HITACHI ←
Motor Solenoid pinion shift type ←
Voltage x Output 12 V x 2.0 kW ←
Alternator
Manufacturer NIPPON DENSO ←
Type AC type (with IC regulator) ←
Voltage x Output 12 V x 35 A ←
Fuel system
Type ZEXEL PFR1KX type ←
Governor Centrifugal full speed range control, ←
spray type
T1-1-6
GENERAL / Component Layout
MAIN COMPONENTS
1
3
5
6
7
18
8
17
16
10
15 11
14
13
12
T571-01-02-001
1- Bucket Cylinder 6- Hydraulic Oil Tank 11 - Solenoid Valve 16 - Swing Device

2- Arm Cylinder 7- Oil Cooler 12 - Travel Device 17 - Boom Swing Cylinder
3- Boom Cylinder 8- Radiator 13 - Pump Device 18 - Blade Cylinder
4- Pilot Valve 9- Engine 14 - Center Joint
5- Control Valve 10 - Pilot Filter 15 - Fuel Tank
T1-2-1
ELECTRICAL SYSTEM

2
3
20 7
19
8
18
17 9
10
16
15 11
14
13
12 T571-01-02-002
1 - Work Light (Boom) 6 - Overheat Switch 11 - Engine Stop Solenoid 16 - Fuel Sensor
2 - Horn Switch 7 - Coolant Temperature Sensor 12 - Solenoid Valve 17 - Fusible Link
(for Coolant Temperature Gauge)
3 - Pilot Shut-Off Switch 8 - Coolant Temperature Sensor 13 - Starter 18 - Horn
(for Glow Timer)
4 - Alternator 9 - Glow Plug 14 - Fuel Pump 19 - Work Light (Base Machine)
5 - Air Cleaner Restriction 10 - Engine Oil Pressure Switch 15 - Fast Speed Travel 20 - Battery
Switch Pedal
T1-2-2
(40u Type B, 50u) … Refer to INTRODUCTION (IN-

01) for the corresponding serial numbers.
2
3
19 6
18
7
17
16 8
9
15
14 10
13
12
11 T571-01-02-002
1 - Work Light (Boom) 6 - Coolant Temperature Sensor 11 - Solenoid Valve 16 - Fusible Link
(for Coolant Temperature Gauge)
2 - Horn Switch 7 - Coolant Temperature Sensor 12 - Starter 17 - Horn
(for Glow Timer)
3 - Pilot Shut-Off Switch 8 - Glow Plug 13 - Fuel Pump 18 - Work Light (Base Machine)
4 - Alternator 9 - Engine Oil Pressure Switch 14 - Fast Speed Travel 19 - Battery
Pedal
5 - Overheat Switch 10 - Engine Stop Solenoid 15 - Fuel Sensor
T1-2-3
RELAYS

1
4
8
7 T571-01-02-003
6
1 - Fuse Box 3 - Glow Relay 5 - Starter Relay 2 7 - Horn Relay
2 - Glow Timer 4 - Starter Relay 1 6 - Pilot Shut-Off Relay 8 - Work Light Relay
T1-2-4

2 3
1
4
8 7 6
T573-01-02-002
1 - Fuse Box 3 - Glow Relay 5 - Starter Relay 7 - Horn Relay

2 - Glow Timer 4 - Starter Relay 6 - Pilot Shut-Off Relay 8 - Work Light Relay
T1-2-5
MONITOR AND SWITCHES

the corresponding of serial numbers.
1 2 3
13
12
T570-04-01-001
11 10 9 8 7 6 5 4
1 - Hour Meter 5 - Air Filter Restriction Indi- 8 - Fuel Level Indicator 11 - Work Light Switch
cator
2 - Fuel Gauge 6 - Overheat Indicator 9 - Engine Oil Pressure Indi- 12 - Wiper Switch (Optional)
cator
3 - Coolant Temperature 7 - Preheat Indicator 10 - Alternator Indicator 13 - Auto-Idle Switch (Optional)
Gauge
4 - Fast Speed Travel Indicator
T1-2-6

01) for abbreviations of serial numbers.
4 5 6
2
M573-01-025
8 7
1 - Hour Meter 3 - Coolant Temperature 5 - Engine Oil Pressure 7 - Work Light Switch
Gauge (Indicator) Indicator
2 - Fuel Gauge (Indicator) 4 - Preheat Indicator 6 - Alternator Indicator 8 - Auto-Idle Switch (Optional)
T1-2-7
(Blank)
T1-2-8
SECTION 2
SYSTEM
; CONTENTS;
;
Group 1 Hydraulic System
Outline ......................................................T2-1-1
Main Circuit ...............................................T2-1-2
Pilot Circuit................................................T2-1-4
585T-2-1
(Blank)
585T-2-2
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system consists of the main circuit and

pilot circuit.
Main Circuit:
This circuit controls pressure oil from the main pump
by the control valve, and actuates the cylinders and
motors.
Pilot Circuit:
This circuit supplies pressure oil from the pilot pump
into the operation circuit and the travel speed
changeover circuit.
T2-1-1
MAIN CIRCUIT
Main pumps (PG, P1, P2) draw hydraulic oil from the
hydraulic oil tank and discharge pressure oil to the con-
trol valve.
The pressure oil from main pump (PG) flows to the
spools of blade (10), swing (9) and boom swing (8) in
the control valve.
The pressure oil from main pump (P2) flows to the
spools of travel (right) (1), boom 1 (2) and bucket (3) in
the control valve.
The pressure oil from main pump (P1) flows to the
spools of boom 2 (4), travel (left) (5), arm (6) and auxil-
iary (7) in the control valve.
The pressure oil in the control valve, depending on
which spools are selected, flows to the cylinders or
motors actuating them.
The return oil from cylinders or motors returns to con-

trol valve and flows through the valve. The return oil
from the control valve flows through the oil cooler, then
returns to the hydraulic oil tank.
When the temperature of the hydraulic oil is low
(viscosity is high), hydraulic oil restriction increases in
the oil cooler passages. Therefore, a bypass check
valve opens to return the hydraulic oil directly to the
hydraulic oil tank.
T2-1-2
Travel Motor (Left) Travel Motor (Right)
Blade
Cylinder Bucket
Cylinder
Swing Motor
Arm
Cylinder Boom
Cylinder
Boom
Swing
Cylinder
5 4
10 9 8 7 6 3 2 1
Bypass Check
Valve
Engine
PG P1 P2
Hydraulic Oil Tank Main Pump

Oil Cooler ȴȕȗȑȍȐȒȍȐȑȍȐȐȑ
1 - Travel (Right) 4 - Boom 2 7 - Auxiliary 10 - Blade

2 - Boom 1 5 - Travel (Left) 8 - Boom Swing
3 - Bucket 6 - Arm 9 - Swing
T2-1-3
PILOT CIRCUIT

The pressure oil from the pilot pump is supplied to the

following circuits:
NOTE: Pilot relief valve is built-in the pilot pump.
• Operation Circuit
This circuit controls pressure oil from the pilot
pump by pilot valve, and moves the spools in the
control valve.
• Valve Control Circuit

This circuit switches the flow combiner valve and
boom anti-drift valve by opening or closing the pi-
lot signal circuit.
• Travel Speed Changeover Circuit

(Refer to TRAVEL DEVICE group in
COMPONENT OPERATION section)
Travel speed changeover solenoid valve is
switched ON-OFF by the travel speed changeover
switch (fast speed travel pedal) to deliver travel
speed changeover pressure to the travel motor.
• Swing Parking Brake Release Circuit (Refer to

SWING DEVICE group in COMPONENT
OPERATION section)
This circuit releases the swing parking brake
when the pilot signal circuit in the control valve
closes.
T2-1-4
Swing Motor Travel Motor
Boom Anti-
Drift Valve
Control Valve Pilot Valve (Right)
Pilot Valve (Left)
Flow Combiner
Valve
Pilot Filter Pilot Pump

ȴȕȗȑȍȐȒȍȐȑȍȐȐȒ
Travel Speed
Changeover
Solenoid Valve
T2-1-5

The pressure oil from the pilot pump is supplied to the

following circuits:
NOTE: Pilot relief valve is built-in the pilot pump.
• Operation Circuit
This circuit controls pressure oil from the pilot
pump by the pilot valve, and moves the spools in
the control valve.
• Valve Control Circuit

This circuit switches the flow combiner valve and
boom anti-drift valve by opening or closing the pi-
lot signal circuit.
• Travel Speed Changeover Circuit

(Refer to TRAVEL DEVICE group in
COMPONENT OPERATION section)
Travel speed changeover solenoid valve is
switched ON-OFF by the travel speed changeover
switch (fast speed travel pedal) to deliver travel
speed changeover pressure to the travel motor.
• Swing Parking Brake Release Circuit (Refer to

SWING DEVICE group in COMPONENT
OPERATION section)
The pilot shut-off valve solenoid valve is switched
ON-OFF by the pilot shut-off switch to deliver
swing parking brake release pressure.
T2-1-6
Boom Anti-
Drift Valve
Pilot Valve (Right)
Pilot Valve (Left)
Flow Combiner
Valve
Pilot Pump
Pilot Filter
T573-03-03-001
Travel Speed
Changeover
Solenoid Valve
T2-1-7
(Blank)
T2-1-8
SECTION 3
COMPONENT OPERATION
; CONTENTS;
;
Group 1 Pump Device Group 4 Pilot Valve
Outline ......................................................T3-1-1 Outline ........................................................... T3-4-1
Main Pump................................................T3-1-2 Operation ...................................................... T3-4-2
Pilot Pump ................................................T3-1-5
Group 5 Travel Device
Group 2 Swing Device Outline ........................................................... T3-5-1
Outline ......................................................T3-2-1 Travel Motor .................................................. T3-5-2
Swing Motor ..............................................T3-2-2 Travel Brake Valve ........................................ T3-5-3
Parking Brake Changeover Valve................T3-2-3 Travel Reduction Gear .................................. T3-5-8
Valve Unit......................................................T3-2-5
Group 6 Others (Upperstructure)
Swing Reduction Gear..................................T3-2-7
Solenoid Valve............................................... T3-6-1
Group 3 Control Valve Group 7 Others (Undercarriage)

Outline ......................................................T3-3-1 Swing Bearing ............................................... T3-7-1
Hydraulic Circuit............................................ T3-3-2 Center Joint................................................... T3-7-2
Boom Anti-Drift Valve.................................... T3-3-6 Track Adjuster ............................................... T3-7-4
Flow Combiner Valve.................................... T3-3-8
Main Relief Valve .......................................... T3-3-9
Overload Relief Valve ................................. T3-3-10
Make-up Valve ............................................ T3-3-12
585T-3-1
(Blank)
585T-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device is a direct-engine-drive type, consist- NOTE: The pump devices of 40u and 50u are iden-
ing of main pumps (P1, P2, PG) and pilot pump (PP). tical in structure. Only difference is the de-
The main pump consists of two different types, vari- livery capacity of the main pump (PG).
able displacement axial plunger pump swash plate
type (P1, P2) and gear pump (PG). They supply high
pressure oil to the control valve. The plunger pump has
a dual delivery port design, so it functions as two
pumps.
The pilot pump is a trochoid-type, it supplies pressure
oil to the pilot circuit.
Pilot Pump
Main Pump (PG) (PP) Main Pump (P1, P2)
T571-03-01-001
T3-1-1
MAIN PUMP
Main Pump (P1, P2):

The shaft is splined to the cylinder block, and plungers In the cylinder block, suction/delivery ports are placed
are inserted in the cylinder block. on the inside and outside of cylinder block alternately.
The engine rotation drives the shaft directly, and it ro- Also, there are delivery ports on each side (inside and
tates the cylinder block and plungers together. The outside) of valve plate (there is only one suction port).
plungers slide on the shoe plate, and reciprocate in the The dual outlet port design allows one pump to func-
cylinder block by the tilt of the swash plate. tion like two pumps having equal oil displacement.
Cylinder Shoe
Plate Swash Plate
Block
Shaft
Valve Plate Plunger Shoe T571-03-01-001
Delivery Port Suction Port

(Inside)
Delivery Port Valve Plate

(Outside)
Suction, Delivery Port

(Outside)
Suction, Delivery Port

(Inside)
T563-02-02-003
Cylinder Block
T3-1-2
Main Pump (PG):

The drive gear is mounted on the shaft engaging the
driven gear.
The engine rotation drives the shaft directly, and it ro-
tates along with the drive gear.
When the drive gear rotates, the driven gear also ro-
tates. The hydraulic oil from the suction port fills the
spaces between the gears, then it flows along the inner
surfaces of housing and discharges through the deliv-
ery ports.
Main Pump (PG)
T571-03-01-001
Suction Port
Driven Gear Drive Gear
Housing
Delivery Port
T137-02-03-005
T3-1-3
Horse Power Control Operation
To prevent the load of main pumps (P1, P2, PG) from As the discharged pressure from the pump increases,
exceeding the engine torque, the plunger pumps (P1, the load on the pump also increases. At this time, the
P2) regulates its delivery flow rate. control pin moves the swash plate slightly by dis-
The discharged pressure from each main pump is di- charged pressure from the pump. The swash plate is
rected to the control pin through a passage in the moved to decrease the swash plate tilt until it bal-
housing. The control pin is pressed toward the swash ances with spring force.
plate by the springs installed on the opposite side of As a result of this movement, delivery flow rate from
control pin. pump decreases so the load of pump decreases.
P1 P2 PG
Control Pin
Swash
Plate
T571-03-01-002
Spring
T3-1-4
PILOT PUMP
The inner rotor is splined to the shaft, and engages the The rotational center of outer rotor is eccentric to the
outer rotor. rotation center of the shaft.
The engine rotation drives the shaft directly, and it ro- Thereby, the hydraulic oil from the suction port fills the
tates the inner rotor. When the inner rotor rotates, the spaces between the rotors, then discharges through
outer rotor also rotates. the delivery ports.
Pilot Pump
T571-03-01-001
Rotation Direction
Outer Rotor
Shaft
Inner Rotor
Suction Port Delivery Port
Rotation Center of Shaft
Rotation Center of Outer Rotor

T571-03-01-004
T3-1-5
Pilot Relief Valve
Pilot relief valve is located in the delivery circuit in the
pilot pump. It prevents the pressure in the circuit from
exceeding the set pressure.
The pressure in pilot circuit acts on the poppet.
When the pressure exceeds the set pressure (spring
force), the poppet moves to relieve hydraulic oil from
the poppet hole. The oil then returns into the suction
circuit through an internal passage.
Spring Poppet Hole
Pilot Circuit
To Hydraulic Oil Tank T571-03-01-005
T3-1-6
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, parking The swing motor is a swash-plate-type axial plunger
brake changeover valve, swing motor and swing re- motor incorporating a parking brake. The swing motor,
duction gear. driven by pressure oil from the pump, transmits the
The valve unit prevents cavitation and overload in the rotation force to the swing reduction gear. The swing
swing circuit. reduction gear converts the swing motor rotation
The parking brake changeover valve controls the power to a slow but large torque which rotates the up-
brake release pressure. It switches the brake perstructure.
changeover.
Valve Unit
Swing Motor
Parking Brake
Changeover Valve
Swing Reduction
Gear
T571-03-02-001
T3-2-1
SWING MOTOR
The inner rotor is splined to the shaft, and the plunger

is inserted in the rotor.
When the pump supplies pressure oil to the swing mo-
tor, plungers are pushed down with pressure oil while
sliding along the swash plate, developing turning force.
As the shaft is splined to the first stage sun gear in the
swing reduction gear, the rotor torque is transmitted to
the swing reduction gear unit.
Valve Plate
Rotor
Shoe
Plunger
Swash
Plate
Retainer
Shaft
T525-02-03-002
T3-2-2
PARKING BRAKE CHANGEOVER VALVE
The parking brake is a wet-negative-type multiple disc

brake which is released only when the brake release
pressure oil is routed into the brake piston chamber.
Also, the parking brake is automatically applied when
the engine stops.
When releasing the brake:

• (40u Type A) … Refer to INTRODUCTION (IN-01) Port SH
for the corresponding serial numbers. Spool
When the swing or front attachment control lever Brake Piston
is operated, the brake release signal pressure is Chamber
guided to port SH from the control valve. Then,
the brake release signal pressure is to move the
Port PG Brake
spool downward. Piston
On the other hand, the pilot pressure is always fed
to port PG while the engine is running. Therefore,
when the spool is moved downward and the oil Friction
Plate
port to the brake piston chamber is connected to
port PG, the pilot pressure is guided to the brake Spring Plate
piston chamber.
Thereby, the brake piston is pushed upward, al-
lowing the plate and the friction plate contact to Orifice
free which releases the brake.
T571-03-02-002
• 40u (Type B) and EX50u ... Refer to Port SH
INTRODUCTION (IN-01) for the corresponding
serial numbers. Spool
When the pilot control shut-off lever is in the re- Brake Piston
Chamber
leased position, the pilot shut-off switch is ON.
By this action, the pilot shut-off valve solenoid
valve is ON, so that the brake release signal Port PG Brake
pressure (pilot pressure) is guided to port SH of Piston
the parking brake changeover valve. Then, the
brake release signal pressure is to move the Friction
spool downward. Plate
On the other hand, the pilot pressure is always
fed to port PG while the engine is running.
Plate
Thereby, the brake release pressure is led to the
brake piston chamber to push the brake piston
upward, allowing the plate and the friction plate
contact to free which releases the brake.
T571-03-02-003
T3-2-3
When the brake is applied:
When the control lever is returned to the neutral po- Port SH
sition, the brake release signal pressure is not
guided to port SH so that the spool is moved up- Spool
ward.
At this time, the brake release pressure oil in brake
piston chamber flows back via the orifice.
Port PG Brake
Accordingly, the brake piston gradually moves
Piston
downward, allowing the plates to slowly come in con-
tact with the friction plates enabling the swing
movement to stop smoothly. Friction
Plate
• 40u (Type B) and EX50u ... Refer to Plate

Orifice
INTRODUCTION (IN-01) for the corresponding
serial numbers.
When the pilot control shut-off lever is in the
LOCKED position, the pilot shut-off switch is OFF.
T571-03-02-004
By this action, the pilot shut-off valve solenoid
valve is OFF, so that the brake release signal
pressure (pilot pressure) is not guided to port SH.
Then, the brake release signal pressure is to
move the spool upward.
The brake release pressure oil in brake piston
chamber flows back via the orifice.
Accordingly, by the function of spring, the brake
piston gradually moves downward, allowing the
plates to slowly come in contact with the friction
plates to make the swing brake applies.
T3-2-4
VALVE UNIT
The valve unit consists of the make-up valves and re-

lief valves.
The make-up valve prevents the occurrence of cavita-
tion in the circuit. The relief valve also protects the cir-
cuit from surge pressure and overloading.
Make-Up Valve
When the upperstructure is swung downward on a
slope, the upperstructure is accelerated by its own
weight and moves quicker than the swing motor drive
speed developed by the pump oil flow rate. Therefore,
cavitation can occur in the circuit.
To prevent cavitation, when the oil pressure in the cir-
cuit is lower than the pressure at port M (hydraulic oil
tank pressure), the poppet opens drawing hydraulic
oil into the circuit so that the pump oil flow rate is re-
plenished.
Poppet
Port M
Make-Up Valve
Relief Valve
T523-02-03-003
T3-2-5
Relief Valve
The relief valve functions to reduce shocks developed
when starting or stopping swing movement
(shockless) and to protect the circuit from overloading
(relief).
Poppet Orifice Piston Spring
• Shockless Operation Orifice
When the pressure in the circuit increases, the pres-
sure oil enters in the piston chamber via orifice of LP
poppet and housing, to move the piston.
The pressure in the spring chamber is kept low dur-
ing the movement of piston. Therefore, when the HP
pressure on port HP exceeds the spring set force a
poppet opens to relieve the hydraulic oil.
When the piston moves to the stroke end, the pres-

T561-02-03-001
sure in the spring chamber becomes equal to the S1 S2 Housing Spring
pressure on port HP. As a result, the relief set force Chamber
becomes to the normal pressure, so the poppet
closes. Piston
To secure the response capability when operating

the swing suddenly in the reverse direction, there is LP
a function to return the piston to the original position
by leading the pressure in the opposite side (port LP, HP
in this case) of the piston.
• Relief Operation
When the pressure in the circuit exceeds the relief T561-02-03-001
Poppet
set pressure, the force which acting on poppet
(Pressurized Area (S1-S2)×Pressure on Port HP)
exceeds the spring force, so poppet opens to allow ㈡㈥
the hydraulic oil to be relieved.
㈝㈥
㈨㈍㈨㈎
T561-02-03-001
T3-2-6
SWING REDUCTION GEAR
The swing reduction gear is a two-stage planetary-gear

reduction type.
The swing motor rotation force is transmitted to the
first stage sun gear via shaft.
The rotation of first stage sun gear is reduced by the
first stage planetary gear and the first stage carrier.
This in turn rotates the second stage sun gear.
The rotation of the second stage sun gear is reduced
by second stage planetary gear and second stage car-
rier. This in turn rotates the shaft.
First Stage Sun

Gear First Stage Planetary
Gear
Second Stage First Stage Carrier
Sun Gear
Second Stage Planetary

Ring Gear Gear
Second Stage Carrier
Shaft
T571-03-02-001
T3-2-7
(Blank)
T3-2-8
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls oil pressure, flow rate and Spools in the sections for travel, blade, boom swing
flow direction of the hydraulic circuit. and auxiliary are operated mechanically. Spools in the
The main components are: main relief valve, overload sections for the boom, arm, bucket and swing are op-
relief valve, make-up valve and spool. erated by pilot oil pressure system.
Main Relief Make-Up Overload Main Relief Overload Main Relief

Valve Valve Relief Valve Valve Relief Valve Valve
Make-Up Overload Overload T571-03-03-001

Valve Relief Valve Relief Valve
Blade Swing Boom Auxiliary Arm Travel Boom 2 Bucket Boom 1 Travel (Right)
Swing (Left)
T571-03-03-001
T3-3-1
HYDRAULIC CIRCUIT
The hydraulic circuit in the control valve is divided into

3 parts: main circuit, pilot operation circuit and pilot
signal circuit.
Main Circuit
Pressure oil from main pump (PG, P1, P2) flows into
the control valve, respectively.
When the spool is neutral (i.e. control levers are in
neutral), the pressure oil from main pump returns to
the hydraulic oil tank via neutral circuit.
When the spool is operated (i.e. control lever is oper-
ated), pressure oil from main pump flows into the ac-
tuator via spool.
The main circuit has a parallel circuit and a flow com-
bining circuit. Combined operation become possible
using these circuits.
The pressure in main circuit (between pump and ac-

tuator) is controlled by main relief valve, to prevent
the pressure in main circuit from exceeding the set
pressure when the spool (the control lever) is operat-
ing.
The pressure in actuator circuit (between control
valve and actuator) is controlled by overload relief
valve, to prevent surge pressure from exceeding the
set pressure at the spool (the control lever) is in neu-
tral.
T3-3-2
Travel Motor (Left) Travel Motor (Right)
Blade
Cylinder
Bucket
Swing Cylinder
Motor Arm
Cylinder
Boom
Cylinder
Boom
Swing
Cylinder
Overload Main Relief Overload
Relief Valve Valve Relief Valve
Main Relief
Main Relief Valve
Valve
Parallel Neutral Parallel Flow Combin- Neutral Parallel

Circuit Circuit Circuit ing Circuit Circuit Circuit
PG P2 P1
Hydraulic Oil Tank Main Pump

T571-02-01-001
T3-3-3
Pilot Operation Circuit
The spool operation is controlled by pressure oil from
the pilot valve.
It switches the boom anti-drift valve while operating
boom lower operation.
Pilot Signal Circuit

The pilot signal circuit flows inside each spool.
If an operation other than travel is operated, pilot sig-
nal circuit is blocked by a spool, to raise the pressure
in the circuit.
(The circuit will not be blocked even if the travel spool
switches.)
As a result, the combiner valve switches, and the re-
lease pressure is delivered to the swing parking
brake.
Boom Anti-
Drift Valve
Pilot Valve
(Right)
Pilot Valve
(Left)
Flow Combiner
Valve
Pilot
Pump T571-02-01-002
T3-3-4
Pilot Signal Circuit

The pilot signal circuit flows inside each spool.
If an operation other than travel is operated, pilot sig-
nal circuit is blocked by a spool, to raise the pressure
in the circuit.
(The circuit will not be blocked even if the travel spool
switches.)
As a result, the combiner valve switches.
Boom Anti-
Drift Valve
Pilot Valve
(Right)
Pilot Valve
(Left)
Flow Combiner
Valve
Pilot
Pump T573-03-03-001
T3-3-5
BOOM ANTI-DRIFT VALVE
To reduce boom cylinder drift, a boom anti-drift valve is

provided on the bottom side circuit of boom cylinder.
When Boom Spool in Neutral

When stopping engine with the boom raised, pres-
sure occurs in the bottom side circuit of boom cylin-
der. This is caused by the weight of the front attach-
ment.
At this time, the pressure on the bottom side circuit
acts on spring chamber via hole of poppet, and
pushes the poppet to the left.
Thereby, pressure oil in the bottom side circuit is
blocked by a poppet, so the cylinder drift is reduce.
Boom Raise Operation

When boom raise operation is performed, the pres-
sure oil from boom spool pushes the poppet to open,
so hydraulic oil flows into the bottom side circuit of the
boom cylinder.
Boom Lower Operation

When boom lower operation is performed, the boom
lower pilot pressure from the release port acts on the
piston. As the piston and valve are connected by ring,
the piston and valve moves to the right.
Thereby, the return oil from the bottom side circuit of
boom cylinder acts on the ball from the hole of poppet.
When ball opens, return oil flows to the spool side.
When this occurs, the pressure in spring chamber
decreases, so the poppet moves to the right.
As a result, the return oil from the bottom side circuit
of boom cylinder pushes the poppet open, and allows
hydraulic oil to flow to the spool side .
T3-3-6
Bottom Side Circuit of

Boom Cylinder
Hole
Spool Side Circuit

T571-03-03-003
Poppet Spring Room
Bottom Side Circuit

of Boom Cylinder
Spool Side Circuit T571-03-03-005
Poppet
Bottom Side Circuit Release To Hydraulic
Port Piston Oil Tank
Ball of Boom Cylinder
Hole
Spool Side
T571-03-03-006
Circuit Poppet Spring Room Valve Ring
T3-3-7
FLOW COMBINER VALVE
When any operation, other than travel, is performed, NOTE: The circuit for the blade, swing and boom
the pilot signal passage is blocked, so the pressure in swing is separated from circuit for travel.
circuit increases, and the flow combiner valve spool Therefore, combined operation is possible.
switches.
When travel operation is performed at the same time,
the pressure oil from main pump (P2) flows to travel
(right) spool. It also flows to travel (left) spool through
flow combiner valve.
Therefore, travel straight during combined operation is
secured.
Flow Combiner Valve
Pressure Oil
from Main
Pump (P2)
T571-03-03-002
Spool Other Pilot Signal Travel (Left) Spool
than Travel Circuit
T3-3-8
MAIN RELIEF VALVE
1 2 3 4 6 7 8
Main relief valve prevents the pressure in main circuit
from exceeding the set pressure.
The pressure on port HP acts on pilot poppet (5)
through orifice (2) in main poppet (1) and orifice (4) in
seat (6).
When the pressure on port HP reaches the set pres- HP
sure, pilot poppet (5) opens to release a small quantity
of pressure oil to port LP via passage (7) of seat (6).
At this time, the pressure difference between port HP
and spring chamber (9) occurs, caused by orifice (2). LP
By this pressure difference, main poppet (1) opens
when it becomes larger than spring (3) force, to relieve 9 5
T563-02-04-002
the pressure oil from port HP to port LP. 1- Main Poppet 6- Seat
2- Orifice 7- Passage
3- Spring 8- Spring
4- Orifice 9- Spring Chamber
5- Pilot Poppet
T3-3-9
OVERLOAD RELIEF VALVE
The overload relief valve has two operations; one is the

relief operation which prevents the pressure in actuator
circuit from exceeding the set pressure, and the other
is the make-up operation which prevents cavitation.
Overload relief valve is provided in boom, arm and
bucket circuit. Only the overload relief valve provided in
the boom bottom circuit has a different construction.
Relief Operation
When the pressure in actuator circuit rises, the pres- For Boom Rod Side, Arm and Bucket Circuit
sure oil is relieved to the hydraulic oil tank.
1 2 3 4 5 6 7 8 9
• For Boom Rod Side, Arm and Bucket Circuit
The pressure on port HP acts on pilot poppet (8)
via orifice (4) in main poppet (3) and orifice (6) in
seat (7).
When the pressure on port HP reaches the set
HP
pressure, pilot poppet (8) opens to release a small
quantity of pressure oil to port LP via passage (10)
in seat (7).
At this time, the pressure difference between port
LP
HP and spring chamber (11) occurs, caused by 11 10
orifice (4). By this pressure difference, main pop-
pet (3) opens when it becomes larger than spring T563-02-04-003
1- Spring 8- Poppet
(5) force, to relieve the pressure oil from port HP
2- Sleeve 9- Spring
to port LP. 3- Main Poppet 10 - Passage
4- Orifice 11 - Spring Chamber
• For Boom Bottom Side Circuit 5- Spring 12 - Orifice
The pressure on port HP acts on pilot poppet (8) 6- Orifice 13 - Piston
7- Seat 14 - Sleeve
via orifice (12) in piston (13).
When the pressure on port HP reaches the set
pressure, pilot poppet (8) opens to release a small For Boom Bottom Side Circuit
quantity of pressure oil to port LP via passage (10)
in seat (7). 12 3 13 5 7 8 9
At this time, the pressure difference between port
HP and spring chamber (11) occurs, caused by
orifice (12). By this pressure difference, piston
(13) and main poppet (3) open when it becomes
larger than spring (5) force, to relieve the pressure
oil from port HP to port LP. HP
LP
T571-03-03-004
14 11 10
T3-3-10
Make-Up Operation
When the boom is suddenly lowered, for example, For Boom Rod Side, Arm, Bucket Circuit
the delivery pressure oil from pump may not be suffi-
cient for actuator circuit. Accordingly, the oil is sup- 1 2 3 4 5 6 7 8 9
plied to actuator circuit from hydraulic oil tank.
Also, the pressure on the opposite circuit decreases
when the relief operation acts by the external force as
described on previous page. At this time, the hydrau-
lic oil is supplied to actuator circuit from hydraulic oil
tank. HP
When the pressure on port HP becomes lower than

port LP, sleeve (2) [sleeve (14) for boom bottom cir-
LP
cuit] opens. Thereby, the hydraulic oil is replenished 11 10
to port HP from port LP, so cavitation is prevented
(make-up). T563-02-04-003
For Boom Bottom Circuit
12 3 13 5 7 8 9
HP
LP
T571-03-03-004
14 11 10
1- Spring 8- Poppet
2- Sleeve 9- Spring
3- Main Poppet 10 - Passage
4- Orifice 11 - Spring Chamber
5- Spring 12 - Orifice
6- Orifice 13 - Piston
7- Seat 14 - Sleeve
T3-3-11
MAKE-UP VALVE
The make-up valve prevents cavitation in the main

circuit.
It is provided in the bottom circuit of blade and boom Passage Poppet Spring Spring Chamber
swing.
The pressure on port HP acts on spring chamber

through poppet passage, so the pressure on port HP
and spring chamber become equal. Accordingly, when
the pressure on port HP is higher, the closing force
[Pressure in Spring Chamber × Pressurized Area S2]
becomes larger than the opening force of poppet [Port HP
HP × Pressurized Area S1], which closes the poppet.
When the pressure on port HP is lower than the pres-

sure on port LP (pressure on port HP is almost zero),
the closing force of the poppet becomes only by the LP
spring force. Therefore, when the opening force of
poppet [Pressure on Port LP x (Pressurized Area S2 -
S1 S2 T563-02-04-004
S1)] becomes larger than the closing force [Spring
Force], which opens the poppet to supply hydraulic oil
to port HP. Thereby, cavitation at the port HP side is
prevented.
T3-3-12
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve regulates pilot oil pressure from which

the control spools are operated. As standard, this type
has four output pressure ports for operating front and
swing functions.
• Front and Swing Pilot Valve

Port No HITACHI ISO Standard
Standard
1 Boom Raise ←
2 Bucket Roll-out ←
Right
3 Boom Lower ←
4 Bucket Roll-in ←
1 Arm Roll-out Swing Left 2
P
2 Swing Left Arm Roll-in T
Left
3 Arm Roll-in Swing Right
4 Swing Right Arm Roll-out
1
3
T532-02-05-001
4
P ㈩
1 3 2 4
T105-02-07-020
T3-4-1
OPERATION
Control Lever-In Neutral (Pusher Stroke: A to B) Control Lever-Full Stroke (Pusher Stroke: E to F)
When the control lever is in neutral, spool (6) blocks When the control lever is moved to full stroke, pusher
the pressure oil on port P completely. The output port (2) is moved down until spring guide (3) comes into
is connected to port T, so the pressure at the output contact with the shoulder of casing.
port becomes equal to the hydraulic tank pressure. Thereby, spool (6) is pressed directly by the bottom of
When the control lever is moved slightly, pusher (2) pusher (2). As a result, the lower notch of spool (6)
and spring guide (3) move downward together, does not close even if the pressure on output port
compressing return spring (5) and balancing spring rises.
(4). At this time, as the pressure under spool (6) As a result, the pressure at the output port side
(output port) is equal to the hydraulic oil tank pressure, becomes equal to the pressure on port P.
spool (6) moves downwards by balance spring (4),
the top of the spool is kept with spring guide (3). This
state is maintained until clearance A of spool (6)
becomes zero.
Control Lever-Operated (Pusher Stroke: C to D-

Metering)
Delivery Port E F
When the control lever is moved further, the lower Pressure
notch of spool (6) reaches port P. The pressure oil in (Pilot Pressure)
port P flows into the output port via the passage in D
spool (6), so the pressure at the output port
increases. C
The pressure at the output port acts on the bottom of
spool (6), to push spool (6) upwards. A B
If the acting force on spool (6) is smaller than the
Pusher Stroke
spring force of balance spring (4), balance spring (4)
will not be pressed. As a result, spool (6) will not be OUTPUT DEAGRAM
pushed up, and the pressure at the output port
increases continuously.
If the pressure at the output port increases further,
the force to push up spool (6) increases. When this
force becomes larger than the spring force of balance
spring (4), spool (6) pushes balance spring (4), and
moves upwards.
When spool (6) moves upwards, the lower notch
closes, so the pressure oil does not flow into output
port from port P. Thereby, the pressure at port P stops
raising.
Accordingly, the amount the balance spring (4) is
compressed is equal to the amount the spool (6) is
pressed down, so the balanced pressure between the
spring force and the force on spool (6) becomes the
pressure on output port.
T3-4-2
Pusher Stroke: A to B
1
2
3
Lower Notch
4
Port T (Clearance A: 0)
ЁAЂ
Port P
ȴȕȕȔȍȐȒȍȐȗȍȐȐȕ
Output Port
ȴȕȕȔȍȐȒȍȐȗȍȐȐȓ
Pusher Stroke: C to D Pusher Stroke: E to F
5
Port T Port T
(A)
Port P Port P
6
Output Port ȴȕȕȔȍȐȒȍȐȗȍȐȐȖ

ȴȕȕȔȍȐȒȍȐȗȍȐȐȗ
1 - Cam 3 - Spring Guide 5 - Return Spring 6 -Spool

2 - Pusher 4 - Balance Spring
T3-4-3
(Blank)
T3-4-4
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of travel motor, travel

reduction gear and travel brake valve.
The travel motor is a variable displacement axial
plunger swash plate type. This motor is operated by
pressure oil from the pump, and transmits the rotation
to the travel reduction gear.
The travel reduction gear is a two-stage planetary-gear
reduction type, reducing travel motor speed, increasing
travel motor torque, and allowing the sprocket and
track to rotate.
The travel brake valve functions to protect the travel
circuit.
Travel Reduction Gear Travel Brake Valve
Travel Motor
T571-03-05-001
T3-5-1
TRAVEL MOTOR
The travel motor consists of valve plate, rotor, plungers,

shoes, swash plate and shaft. The rotor is connected
to the shaft by a spline joint, and the plungers are
inserted in the rotor.
When the pressure oil is supplied from the pump, the
plungers are pushed. The swash plate is installed at an
angle toward the plungers, the shoe slides on the
swash plate, so the rotor rotates. This rotation is
transmitted to the travel reduction gear via the shaft.
Swash Plate Rotor Valve Plate
Shaft
T571-03-05-002
Shoe Plunger
T3-5-2
TRAVEL BRAKE VALVE
The travel brake valve consists of counterbalance

valve, relief valves and travel speed changeover valve.
The counterbalance valve has two functions; one is to
start and stop the travel smoothly, and the other is to
prevent the machine from running away while
descending slopes.
The relief valve prevents the pressure in travel circuit
from exceeding the set pressure.
The travel speed changeover valve is switched by
pressure oil from the travel speed changeover solenoid
valve. It switches the travel speed by the control piston.
Counterbalance Valve
Travel Speed Changeover Valve
Relief Valve
T571-03-05-003
T3-5-3
Counterbalance Valve
• Travel Operation • Descending Operation

When pressure oil from control valve is supplied When the machine travels down a slope, the
to port P1, the pressure oil flows to motor port AM travel motors are forcibly driven by the machine
through the inside of the spool and opens the weight so that the motor draws oil like a pump.
check valve. On the other hand, the return oil from The pressure oil in port P1 is drawn into the travel
motor port BM is blocked by the check valve and motor, so the pressure on port P1 decreases.
spool. Thereby, the spool returns to the left, and
Thereby, the pressure on port P1 side increases returning oil from port BM to port P2 is restricted,
gradually, so the pressure on port P1 enters into so the oil pressure brake is activated.
the spring chamber from the orifice, and moves When the returning oil from port BM is restricted,
the spool to the right by the pressure at the end the pressure on port P1 increases again, and
surface of the spool. moves spool to the right, so the motor rotates.
As a result, spool notch opens so port BM and
port P2 connect, so the travel motor rotates.
Control Valve
Spool
Orifice Orifice
P1 P2
Spring Chamber Spring Chamber

AM BM
Check Valve Check Valve T571-03-05-006
T3-5-4
Relief Valve
By the following two staged relief operation, relief valve

functions to reduce shocks developed when the travel
motor is started on stopped, and prevent overload in
the travel circuit.
NOTE: The force equal to [Pressure on Port HP ×

Pressurized Area of Poppet S1] is applied
on the poppet to the opening direction, and
force equal to [Pressure in Spring Chamber
× Pressurized Area of Poppet S2 + Spring
Force] is applied to the closing direction.
The pressurized area of poppet S2 is Poppet Piston Seat
smaller than S1. Orifice Spring
LP
• Shockless Operation
When the pressure in the circuit the increases, the
pressure oil enters into the piston chamber
through the orifices of the poppet and seat, to
move the piston. HP
While the piston moves, the pressure in the spring
chamber is kept low. For this reason, the force
applied in the closing direction of poppet becomes
almost the spring force only.
Accordingly, when the force acting in the opening
direction of poppet [Pressure on Port HP × S1 S2 Spring Chamber
Pressurized Area of Poppet S1] becomes larger T571-03-05-007
than the set force of spring, the poppet opens to Piston Chamber Orifice
relieve the hydraulic oil.
• Relief Operation
When the piston moves to the stroke end, the
pressure in the spring chamber becomes equal to
the pressure on port HP. (The relief set force
becomes as the normal setting pressure, so
poppet closes.).
For this reason, the force equal to [Pressure on
Port HP × Pressurized Area of Poppet S1] acts on
the opening direction, and the force equal to
[(Pressure in Spring Chamber × Pressurized Area
of Poppet S2) + Spring Force] acts on the closing
direction.
Accordingly, when the force acting on the opening
direction of the poppet [Pressure on Port HP ×
Pressurized Area of Poppet S1] becomes larger
than [(Pressure on Spring Chamber × Pressurized
Area of Poppet S2) + Spring Force], the poppet
opens to relieve the hydraulic oil.
T3-5-5
Travel Speed Changeover Valve
There are two surfaces on the swash plate; surface (a)

and surface (b). Surface (a) makes contact with the
housing at slow speed, and surface (b) makes contact
with the housing at fast speed.
Two balls are located off the center line on the swash
plate, so they can roll freely.
• Slow Speed Operation

When the travel is in slow speed, the pressure oil
from the travel speed changeover solenoid valve
is not supplied to the travel speed changeover
valve. Thereby, surface (a) of the swash plate
makes contact with the housing by the oil
pressure acting on the plunger, and the spring
force in the rotor.
As a result, the angle of the swash plate increases
which makes the stoke of plunger longer. As a
consequence, the motor capacity becomes larger,
so the travel motor rotates in slow speed.
• Fast Speed Operation

When the travel is in fast speed, the pressure oil
from the travel speed changeover solenoid valve
is supplied to the travel speed changeover valve.
Thereby, the travel speed changeover valve
switches to supply the pressure oil to the control
piston. The swash plate is pushed by the control
piston, which makes surface (b) contact with the
housing.
As a result, the angle of swash plate decreases
which makes the stroke of the plunger shorter. As
a consequence, the motor capacity becomes
smaller, so the travel motor rotates in fast speed.
• When Engine Stops

When engine stops, pressure oil applied to the
control piston returns to the hydraulic oil tank
through the travel speed changeover valve. As a
consequence, surface (a) of the swash plate
makes contact with the housing by the spring
force in the rotor.
As a result, the travel motor always rotates in slow
speed whenever the engine is started.
T3-5-6
From Travel Speed

Changeover Solenoid Valve
To Control Piston Travel Speed Changeover Valve T571-03-05-006
Swash Swash
At Slow Speed: Plate Rotor Plunger At Fast Speed: Plate Rotor Plunger
Surface (b)
Surface (b)
From
Travel
Speed
Change-
Surface (a) over
Valve
Surface (a)
Control
T571-03-05-005
T571-03-05-004
Piston
T3-5-7
TRAVEL REDUCTION GEAR
The travel motor rotates the shaft, and the rotation is

transmitted to the first stage sun gear. The rotation of
the first stage sun gear is reduced by the first stage
planetary gear and the first stage carrier, and is
transmitted to the second stage sun gear. The rotation
of the second stage sun gear is reduced by the second
stage planetary gear and the second stage carrier
(united with the travel motor housing).
As second stage carrier and travel motor housing is
united into one part, the rotation of the second stage
planetary gear is transmitted to sprocket via the ring
gear.
First Stage Second Stage Second Stage

Planetary Gear Planetary Gear Carrier
First Stage Sun

Gear
First Stage
Carrier
Ring Gear Second Stage Sun Gear
T571-03-05-001
T3-5-8
COMPONENT OPERATION / Others (Upperstructure)
SOLENOID VALVE
Solenoid Valve for pilot Solenoid Valve for Travel
There are two kinds of solenoid valves; one is the so- Shut-Off Speed Changeover
lenoid valve for shutting off the pilot pressure, the other
is the solenoid valve for the travel speed changeover
which switches the travel speed.
Solenoid Valve for Pilot Shut-off

The solenoid valve is switched ON/OFF by the posi-
tion of the pilot control shut-off lever to control the pi-
lot pressure to the pilot valve.
When the pilot control shut-off lever is in the LOCK From Pilot From Pilot
position, the pilot shut-off switch is OFF. By this action, Pump Pump
solenoid valve is OFF, so that pilot pressure is To Pilot To Travel
blocked by the solenoid valve spool. As a conse- Valve Motor
quence, the pressure oil is not delivered to the pilot To Hy- To Hydraulic
valve. draulic Oil Tank
When the pilot control shut-off lever is in the Oil Tank
UNLOCK position, the pilot shut-off switch is ON. By
this action, the solenoid valve is ON, so the pilot Spool T532-02-06-004
pressure is supplied to the pilot valve through the so-
lenoid valve spool.
Solenoid Valve for Travel Speed Changeover

Pilot Control
The travel speed is controlled by the fast speed travel Shut-Off Lever
pedal.
When the fast speed travel pedal is in the slow speed
position (released position), the travel speed
changeover switch is OFF. By this action, the sole-
noid valve is OFF, so that pilot pressure is blocked by
the solenoid valve spool. As a consequence, the
travel speed changeover pressure is not delivered to
the travel motor.
When the fast speed travel pedal is in the fast speed
position (step-on position), the travel speed changeo-
ver switch is ON. By this action, the solenoid valve is
ON, so that pilot pressure is delivered to the travel
motor as the travel speed changeover pressure
through the solenoid valve spool. Pilot Shut-Off Switch
T532-02-06-002
Fast Speed Travel Pedal
T532-02-06-005
T3-6-1
COMPONENT OPERATION / Others (Upperstructure)
(Blank)
T3-6-2
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure on the Outer race (1) is bolted to the upperstructure.
undercarriage and allows the upperstructure to rotate Inner race (2) is bolted to the undercarriage.
smoothly. The internal gear meshes with the pinion of the swing
The swing bearing is a single-row ball-type. device.
The major parts of the swing bearing are outer race (1),
inner race (2) with internal gear, ball (5), support (4)
and seal (3)
3 5
ȴȕȐȗȍȐȓȍȐȒȍȐȐȑ
1 - Outer Race 3 - Seal 4 - Support 5 - Ball

2 - Inner Race
T3-7-1
CENTER JOINT
The center joint is a 360° rotating joint. It allows oil to Body (5) rotates together with the upperstructure
flow to and from travel motors (12) and blade cylinder around spindle (10) during swing operation.
(13) without twisting hoses when the upperstructure is Oil flows into and through the passages in body (5) to
rotated. spindle (10) and then out of spindle (10) to travel motor
Spindle (10) is fastened to the undercarriage using four (12) and blade cylinder (13).
bolts and body (5) is fastened to the upperstructure Oil seal (11) prevents oil leaks from the clearance be-
using lock pins. tween spindle (10) and body (5).
DR
A
B
C
D
E
F
G
4 D
13 8 G C
F B
E
9 A
1 6 DR
7 Hydraulic Circuit
1 6
3
2
2
9
7
8
4 3
12
ȴȕȕȔȍȐȓȍȐȓȍȐȐȑ
T3-7-2
5
A
B
9
6
1
C
E D
7
F 2
G
11
3
Mounting face to the track

frame
4 10
3
9
2 1
ȴȕȕȔȍȐȓȍȐȓȍȐȐȒ
1 - Port E (Blade Lower) / 5 - Body 8 - Port B (Travel Right For- 11 - Seal
Pressure Oil from Port E ward) / Pressure Oil from
Port B
2 - Port F (Blade Raise) / 6 - Port A (Travel Right Re- 9 - Port D (Travel Left For- 12 - Travel Motor
Pressure Oil from Port F verse) / Pressure Oil from ward) / Pressure Oil from
Port A Port D
3 - Port G (for Travel Speed 7 - Port C (Travel Left Re- 10 - Spindle 13 - Blade Cylinder
Changeover) / Pressure Oil verse) / Pressure Oil from
from Port G Port C
4 - Port DR (Drain) / Pressure
Oil from Port DR
T3-7-3
TRACK ADJUSTER
The track adjuster located on the side frame is com-

CAUTION: Do not loosen valve (1) quickly or
posed of spring (4) and adjuster cylinder (5). Spring (4)
loosen it too much as high-pressure grease
absorbs loads applied to the front idler. Adjuster cylin-
in the adjusting cylinder may spout out.
der (5) adjusts track sag.
Loosen carefully, keeping body parts and
face away from valve (1).
• Grease is applied through the grease fitting into
Never loosen grease fitting.
chamber (A) of adjuster cylinder (5) as illustrated be-
low. The pressure of the grease pushes piston rod
(6) out and decreases track sag.
• To increase track sag, loosen valve (1) 1 to 1.5 turns 1
counterclockwise to release grease from the track Grease Fitting
adjuster cylinder through the grease discharge out-
let.
Grease Discharge Outlet
ȭȑȐȔȍȐȗȍȑȑș
Track Adjuster (Rubber Crawler)

1 2 3
4 A 5 6
Grease Discharge Track Adjuster (Iron Crawler)

Outlet 8 7
ȴȕȐȗȍȐȓȍȐȕȍȐȐȑ
1 - Valve 4 - Spring 6 - Piston Rod 8 - Plug

2 - Nut 5 - Adjuster Cylinder 7 - Flange 9 - Rod
3 - Washer
T3-7-4
SECTION 4
OPERATIONAL PERFORMANCE TEST
; CONTENTS;
;
Group 1 Introduction Group 4 Component Test
Operational Performance Test ....................T4-1-1 Primary Pilot Pressure .................................. T4-4-1
Preparation for Performance Tests..............T4-1-2 Secondary Pilot Pressure.............................. T4-4-2
Main Relief Valve Set Pressure..................... T4-4-4
Group 2 Engine Test Overload Relief Valve Set Pressure .............. T4-4-6
Engine Speed ............................................... T4-2-1 Pump Driving Torque..................................... T4-4-7
Engine Compression Pressure..................... T4-2-2 Swing Motor Drainage................................... T4-4-8
Valve Clearance............................................ T4-2-3 Travel Motor Drainage................................. T4-4-10
Nozzle Check................................................ T4-2-4
Injection Timing............................................. T4-2-6 Group 5 Standard
Operational Performance Standard .............. T4-5-1
Group 3 Excavator Test
Travel Speed................................................. T4-3-1
Track Revolution Speed ............................... T4-3-2
Mistrack Check ............................................. T4-3-3
Travel Motor Leakage................................... T4-3-4
Swing Speed................................................. T4-3-5
Swing Function Drift Check .......................... T4-3-6
Swing Motor Leakage ................................... T4-3-7
Maximum Swingable Slant Angle ................. T4-3-8
Swing Bearing Play....................................... T4-3-9
Hydraulic Cylinder Cycle Time .................... T4-3-10
Dig Function Drift ........................................ T4-3-12
Control Lever Operating Force ................... T4-3-13
Control Lever Stroke................................... T4-3-14
585T-4-1
(Blank)
585T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TEST
Use operational performance test procedure to quanti-

tatively check all system and functions on the machine.
Purpose of Performance Tests

1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machine’s performance to the desired
standard.
3. To economically operate the machine under opti-
mal conditions.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
The machine performance does not always deteriorate

as the working hours increase. However, the machine
performance is normally considered to reduce in pro-
portion to the increase of the operation hours. Accord-
ingly, restoring the machine performance by repair,
adjustment, or replacement shall consider the number
of the machine’s working hours.
Definition of “Performance Standard”

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components ad-
justed to specifications. Allowable errors will be
indicated as necessary.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on, be-
fore starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to communi- ȴȑȐȕȍȐȖȍȐȑȍȐȐȓ
cate with each other using these signals, and to

follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
T505-06-01-003
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Be sure to check the engine speed before performing

all other tests, since it always affects test results.
Preparation:
1. Warm up the machine, until the engine coolant
temperature reaches 50 °C (122 °F) or more, and
hydraulic oil temperature is 50±5 °C (122±9 °F).
2. Move the engine speed control lever from slow
idle to fast idle. Confirm that the fuel injection
pump governor lever comes into contact with the
slow-idle and fast-idle stoppers.
3. Connect an engine tachometer to the fuel injec-
tion line.
Measurement:
1. Slow idle.
Start the engine. Place the engine speed control
lever in the slow idle position and measure the
speed of the engine.
2. Fast idle.
Start the engine. Place the engine speed control
lever in the fast idle position and measure the
speed of the engine.
3. Repeat measurement three times and calculate
the mean value.
Evaluation:
Refer to T4-5 Standard.
T4-2-1
ENGINE COMPRESSION PRESSURE
1. Measure compression pressure in the cylinders to

check for a reduction in engine power.
2. Check exhaust gas color and the amount of blow-
by gas from the crankcase. Keep track of engine
oil consumption.
3. Check for abnormalities in the intake system, in-
cluding the air cleaner.
Preparation:
1. Warm up the engine.
2. Disconnect the negative terminal at the battery,
then remove all glow plugs and engine stop sole-
noid connectors.
Reconnect the negative terminal to battery.
3. Install on pressure gauge to the glow plug bore
with an adapter (Isuzu: 5-8840-9100-0). (Be sure
to tighten them sufficiently to prevent air leakage.)
4. Confirm that the batteries are charged.
IMPORTANT: Use the fully charged battery to keep

the engine speed over 250 min− .
1
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times and calculate
the mean value. ȴȕȗȑȍȐȔȍȐȒȍȐȐȑ
Evaluation:
T4-2-2
VALVE CLEARANCE
Summary:
1. Perform the measurement when the engine is
cold.
2. Before removing the head cover, clean the area
around the head cover to prevent the entry of dust
into the engine. Mark Groove
Preparation:
1. Remove the head cover.
2. Locate the top dead center (TDC) in the compres-
sion stroke. Align "Mark Groove" on crank pulley
with "TDC Mark" on timing gear case cover.
In this position, cylinder No.1 is at the top dead
center in the compression stroke. Crank Pulley
TDC Mark
NOTE: The flywheel can be easily turned after the

glow plugs are removed.
Measurement: ȴȕȓȓȍȐȖȍȐȒȍȐȐȑ
1. Measure the valve clearance between the rocker
arm and the valve.
2. When the measurement is started from cylinder
No.1, measure the clearances of the valves
marked ({) in the table below.
Valve
Cylinder No. 1 2 3 4 Clearance
Valve I E I E I E I E
Cylinder No.1 at top dead center { { { {
Cylinder No.4 at top dead center × × × ×
3. Turn flywheel 360°, then measure the valve clear-

ances marked (×) in the above table.
Evaluation:
Refer to T4-5 Standard. ȴȕȓȒȍȐȖȍȐȒȍȐȐȑ
Adjustment:
If the measured value is not within specification, loosen
the lock nut and adjust valve clearance by turning the
adjusting screw, then tighten lock nut while holding the
adjusting screw.
T4-2-3
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pat-
tern with a nozzle tester.
2. Before starting work, clean the nozzle holder

mounting area to avoid contamination in the en-
gine.
Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection pip-
ings from the engine.
2. Attach a nozzle holder to the nozzle tester
Measurement:
CAUTION: Never touch spray directly. The
fuel spray from the nozzle may penetrate the
ȴȕȐșȍȐȒȍȑȐȍȐȐȓ
skin, resulting in serious injury. If fuel pene-
trates into the blood stream, it may cause
blood toxication.
Adjusting Shim
1. Injection pressure
After attaching the nozzle holder to the nozzle
tester, strongly make several strokes of the tester
to inject fuel. Then, while operating the tester at
approx. 60 time strokes a minute, measure the
fuel injection pressure. ȴȕȒȓȍȐȖȍȐȒȍȐȐȒ
Use shims to adjust the pressure. Increasing the
number of the shims increases the pressure, and
vice versa.
NOTE: Pressure variation per shim 0.1 mm =

2
206 kPa (2.1 kgf/cm , 30 psi)
2. Spray pattern
For this test, turn the pressure tester knob to by-
pass the pressure gauge. Attach the nozzle holder
to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray pat-
tern.
NOTE: Use clean diesel oil.
T4-2-4
Evaluation:
Normal Abnormal
1. Standard Injection Pressure:
2. Spray pattern standards

(1) No visibly coarse distribution
(2) No stray sideways sprays.
(3) Fine spray size and intermittent injection dur-
ing initial injection stage.
(4) No post-injection dripping
(5) Correct injection angles
T523-06-02-001
T4-2-5
INJECTION TIMING
Preparation
1. Rotate the crank pulley until No.1 cylinder is at Mark Groove
TDC of the compression stroke.
Align "Mark Groove" on the crank pulley with
"TDC Mark" on the timing gear case cover.
2. Rotate the crank pulley approx. 100° counter-
clockwise.
3. Remove No. 1 injection pipe (1).
4. Remove No. 1 delivery valve holder (2) on injec- Crank Pulley
tion pump (5) to pull out delivery valve (4) and
spring (3). Reinstall delivery valve holder (2) to in- TDC Mark
jection pump (5).
Tightening Torque: 39 to 44 Nxm (4 to 4.5 kgfxm, ȴȕȓȓȍȐȖȍȐȒȍȐȐȑ
29 to 33 lbfxft)
5. Turn the key switch to "ON". While supplying fuel 1
from fuel pump, rotate the crank pulley clockwise
slowly until the fuel leak stops at the tip of the de-
livery valve holder. At this moment, the "Mark
Groove" on the crank pulley should be aligned
with "TDC Mark" on the timing gear case cover. If
not, adjust the injection timing.
(12° BTDC [Before Top Dead Center] of the com-
pression stroke)
Adjustment:
1. Remove bolt (7) and nut (6) from injection pump ȴȕȓȓȍȐȖȍȐȒȍȐȐȔ
(5).
2. Adjust timing position by increasing or decreasing 2 5
the number of shims (8) between injection pump
(5) and body (9).
3. When delaying timing, increase the number of
shims (8). When advancing timing, decrease the 3
number of shims (8).
4
NOTE: The crank angle will vary 1° per shim 0.1
mm.
ȴȕȓȓȍȐȖȍȐȒȍȐȐȓ
7
5
6
8 9
ȴȕȓȓȍȐȖȍȐȒȍȐȐȒ
T4-2-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
To check overall performance of travel drive system
(between main pump and travel motor), measure the
time required for the excavator to travel a test track.
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Prepare a level and solid test track 20 m (65.5 ft)
in length, with an extra length of 3 to 5 m (9.8 to
16 ft) on both ends for machine acceleration and
deceleration.
3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above
the ground with the arm and bucket rolled in.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
End
Arm roll-in, Bucket roll-in
Start
Raise bucket 0.3 to 0.5 m

(1.0 to 1.6 ft) above the
ground.
3 to 5 m (9.8 to 16 ft)
extra length for accelera-
20 m (65.5 ft) tion/deceleration
3 to 5 m (9.8 to 16 ft)
extra length for accelera- T570-06-03-001
tion/deceleration
Measurement:
1. The test should be performed with each mode
(slow and fast travel speeds) in the fast-idle
speed.
2. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
3. Measure the time required to travel 20 m (65 ft 7
in).
4. After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed.
5. Repeat steps (2) and (4) three times in each direc-
tion and calculate the mean values.
Evaluation:
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-3-1
TRACK REVOLUTION SPEED
Summary:
With the track raised off ground, measure the track
revolution cycle time to check the total track drive
system.
Preparation:
1. Adjust the track sag of both side tracks equally.
2. On the track to be measured, mark one shoe with
chalk.
CAUTION: Support the lifted track securely
using wooden blocks.
3. Swing the upperstructure 90° and lower the

bucket to raise the track off ground. Keep the 90 to 110°
boom-arm angle between 90 to 110° as shown.
Mark
Measurement:
(slow and fast travel speeds) in the fast-idle T570-06-03-009
speed.
2. Operate the travel control lever of the raised track
in the full forward or reverse stroke.
3. Measure the time required for 3 revolutions of
shoe in both directions.
4. Raise the other track and repeat the procedures.
5. Repeat steps (2) and (3) three times for each
track and calculate the mean values.
Evaluation:
NOTE: The measured values may vary widely. The

evaluation based on the results obtained
from the 20 m travel speed check is more
recommendable.
Remedy:
T4-3-2
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.5 ft). Meas-
ure the maximum tread deviation from the tread
chord line drawn between the travel start and end
points to check the performance equilibrium be-
tween both sides of the travel device systems
(from the main pump to the travel motor).
2. If measured on a concrete surface, the tread de-
viation has a trend to decrease.
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and decel-
eration.
3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above
the ground with the arm and bucket rolled in.
(122±9 °F).
Max Distance
20 m T570-06-03-002
Measurement:
(slow and fast travel speeds) in the fast-idle
speed.
2. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
3. Measure the distance between a straight 20 m
(65.5 ft) line and the tread made by the machine.
4. After measuring the tracking in forward travel,
swing the upperstructure 180° and measure that
in reverse travel.
5. Repeat steps (3) and (4) three times in each direc-
tion and calculate the mean values.
Evaluation:
Refer to T 4-5 Standard.
Remedy:
T4-3-3
TRAVEL MOTOR LEAKAGE
Summary:
Measure the amount of travel motor slippage on a
slope, which is due to travel motor inner oil leak.
Preparation:
1. The surface of the test slope must be even, with a
gradient of 15±1°.
2. Mark a white line on the travel device cover.
3. Raise the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above
the ground with the arm and bucket cylinders fully
extended (rolled in)
(122±9 °F).
Measurement:
1. Measure the moving (rotation) amount before T570-06-03-010
parking brake starts to operate.

1-1. Climb the slope and set travel levers in neutral. Position when the
1-2. Measure the moving (rotation) amount of the machine stops moving.
Position when the travel levers
mark on the cover of travel reduction gear be- are in neutral.
tween the positions when the levers are placed
Moving
in neutral and when the machine stops moving. (rotation)
amount Mark
2. Measure the slip amount of travel motor at park-
ing.
2-1. Climb the slope and place the travel levers in
neutral.
2-2. Stop the engine.
2-3. After parking the machine, makes aligning T107-06-03-002
marks on the side frame and a track link or

shoe.
2-4. After 3 minutes, measure discrepancy between
the marks.
Evaluation:
Amount of slippage after 3 minutes
T505-06-03-005
T4-3-4
SWING SPEED
Summary:
Measure the time required to swing three complete
turns to check the total swing drive system.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on level, solid ground with am-
ple space for swinging. Do not conduct this test on
slopes.
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the arm top pin is Even with
the Boom
even with the boom foot pin. The bucket must be Foot Pin.
empty.
4. Maintain the hydraulic oil temperature at 50±5 °C T570-06-03-003
(122±9 °F)
CAUTION: Before starting the measurement,

make sure that there are no person or obsta-
cles within the rotating area.
Measurement:
1. Run engine at fast idle speed. Operate swing con-
trol lever fully.
2. Measure the time required to swing 3 turns in one
direction.
3. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
4. Repeat steps (2) and (3) three times each and
calculate the average values.
Evaluation
Remedy:
T4-3-5
SWING FUNCTION DRIFT CHECK
Summary:
To check the valve unit performance, measure the
swing drift on the bearing outer circumference when
stopping after a 90° full speed swing.
Mechanical brake for swing parking is installed on
swing motor.
Preparation:
bearing. Make aligning marks on the
2. Place the machine on level, solid ground with am- swing bearing outer circum-
ference and track frame.
ple space for swinging. Do not conduct this test on
slopes. T570-06-03-004
the bucket so that the height of the bucket pin is
even with the boom foot pin. The bucket must be
empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 90°.
(122±9 °F).
CAUTION: Before starting the measurement,

make sure that there are no person or obsta- Swing the upperstructure 90°
to the test start position.
cles within the rotating area.
T570-06-03-005
Measurement:
1. Start and run engine at fast idle speed. Operate
the swing control lever fully to swing the upper-
structure. When the marks on the swing bearing
and track frame meet, return the swing lever to Measure the arc length along the
the neutral position. circumference of the swing bearing.
2. After the swing movement stops, measure the arc
length between two aligning marks along the cir-
cumference of the swing bearing.
3. Align the marks again, swing 90° then test in the
opposite direction.
4. Repeat steps (1) and (2) three times each and Mark on the track frame
calculate the mean values.
Mark on the swing bearing
Evaluation:
T105-06-03-010
Remedy:
T4-3-6
SWING MOTOR LEAKAGE
Summary:
To check swing parking brake performance, meas-
ure the upperstructure drift after parking the machine
on a slope with the upperstructure positioned 90° to
the slope.
(Mechanical brake for swing parking is installed on
swing motor.)
Preparation:
bearing.
2. Load the bucket with either soil or a weight equiva-
lent to the weight standard.
With: 40u (Type A) : 180 kg (397 lb)
40u (Type B) : 195 kg (430 lb)
50u : 210 kg (463 lb)
NOTE: Refer INTRODUCTION (IN-01) for the cor-
responding serial numbers.
3. Roll the arm out, roll the bucket in, and position
the arm top pin height flush with the boom foot
pin.
4. Park the machine on a flat slope with a gradient of
15±1°.
5. Climb the slope, then swing the upperstructure
90ѯtoward the slope. Make aligning marks on the
swing bearing circumference and track frame. T570-06-03-006

(122±9 °F).
Measurement:
1. Start the engine and maintain engine speed at
slow idle. After 5 minutes, measure the difference
Measure the arc length along the
between the marks along the swing bearing cir- swing bearing circumference.
cumference and the track frame.
2. Measure the 40u typeB and 50u under the follow-
ing two conditions:
⋅When the brake is applied(with the pilot control
shut-off lever in the LOCK position).
⋅When the brake is released(with the pilot control Mark on the track frame
shut-off lever in the UNLOCK position).
3. Perform the measurement on both right and left
Mark on the swing bearing
swing directions.
4. Perform the measurement three times in each di- T105-06-03-010
rection and calculate the average values.
Evaluation:
Remedy:
T4-3-7
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
To measure the maximum slope angle on which the
upperstructure can swing, park the machine on a
slope with the upperstructure positioned 90° to the
slope.
Preparation:
bearing.
With: 40u (Type A) : 180 kg (397 lb)
40u (Type B) : 195 kg (430 lb)
50u : 210 kg (463 lb)
NOTE: Refer INTRODUCTION (IN-01) for the cor-
responding serial numbers. T570-06-03-006
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, position the arm
top pin height flush with the boom foot pin.
4. Climb the slope, then set the upperstructure 90°
to the slope.
(122±9 °F).
Measurement:
1. Run engine at fast-idle speed. Operate the swing
control lever fully to swing the upperstructure to
the uphill side of slope.
2. If swing is possible, measure the slant angle on
the cab floor.
3. Increase the slope angle. Measure on both right
and left swing directions.
4. Perform the measurement three times.
Evaluation:
Remedy:
T4-3-8
SWING BEARING PLAY
Summary:
Measure the swing play using a dial gauge to check
the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolt for looseness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and noiseless.
3. Install a dial gauge on the track frame as shown,
T105-06-03-014
employing a magnetic base.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
Measurement:
the bucket so that the height of the bucket pin is
even with the boom foot pin. Record the dial indi- T105-06-03-015
cator reading (h1).

Measurement : (h 1)
2. Lower the bucket to the ground and use it to raise
the front idler 0.5 m (20 in). Record the dial gauge
reading (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H = h2 − h1
Evaluation: Even with the

Boom Foot
Refer to T4-5 Standard. Pin.
T570-06-03-003
Measurement : (h 2)
T570-06-03-007
T4-3-9
HYDRAULIC CYLINDER CYCLE TIME
Boom Cylinder
Summary:
1. To totally check the front attachment function per-
formance by measuring each cylinder cycle time.
2. Bucket should be empty.
Preparation:
1. Take the following machine position:
1-1. When measuring the boom cylinder: T570-06-03-011
With the arm cylinder fully retracted and the Arm Cylinder
bucket cylinder fully extended, lower the bucket
to the ground.
1-2. When measuring the arm cylinder:

With the bucket cylinder fully extended, adjust
the boom and arm cylinder strokes so that
when the arm is moved half the full stroke, the
arm longitudinal center line perpendicularly 0.5 m
points to the ground and the bucket bottom
clearance above the ground is approx. 0.5 m T570-06-03-012
(20 in).
Bucket Cylinder
1-3. When measuring the bucket cylinder:
Adjust the boom and arm cylinder strokes so
that when the bucket is moved half the full
stroke, the bucket edge points to the ground
perpendicularly.
1-4. When measuring the boom swing cylinder:

Set the boom swing cylinder in either the right
or left swing stroke end position.
T105-06-03-020
1-5. When measuring the blade cylinder:
Lower the bucket to the ground to raise the
Boom Swing Cylinder
machine front off the ground and secure the
height space to allow the blade to move up-
and-down full stroke.
2. Maintain hydraulic oil temperature at 50±5 °C

(122±9 °F).
T523-06-03-006
Blade Cylinder
T570-06-03-007
T4-3-10
Measurement:
1. Run engine at fast idle speed
2. Operate each cylinder as follows:

(The cylinder stroke excludes the cushion range.)
2-1. Measure the boom cylinder.

Measure the time required to raise or lower the
boom while operating the boom control lever
full stroke.
2-2. Measuring the arm cylinder.

Measure the time required to roll in or out the
arm while operating the arm control lever full
stroke.
2-3. Measuring the bucket cylinder.

Measure the time required to roll in or out the
bucket while operating the bucket control lever
full stroke.
2-4. Measuring the boom swing cylinder

Measure the time required to swing the front at-
tachment from right to left or vice versa while
operating the boom swing pedal full stroke.
2-5. Measuring the blade cylinder

Measure the time required to raise or lower the
blade while operating the blade control lever
full stroke.
3. Repeat each measurement three times and calcu-

late the average values.
Evaluation:
Refer to T 4-5 Standard.
Remedy:
T4-3-11
DIG FUNCTION DRIFT
Summary:
With the bucket loaded, measure dig function drift,
which can be caused by oil leakage in the control
valve and / or boom, arm, and bucket cylinders.
NOTE: When testing the dig function drift just after

cylinder replacement, slowly operate each
Extension
cylinder to its stroke end to purge trapped Retraction
air prior to testing.
Retraction
Preparation:
With: 40u (Type A) : 180 kg (397 lb)
40u (Type B) : 195 kg (430 lb) Arm Top Pin is Front Drift
even with Boom
50u : 210 kg (463 lb) Foot Pin.
NOTE: Refer INTRODUCTION (IN-01) for the cor- Extension T570-06-03-008
responding serial numbers.

2. With the arm cylinder fully retracted and the
bucket cylinder fully extended, position the arm
top pin height flush with the boom foot pin. Boom and Bucket Cylinder Retraction
3. Retract arm cylinder and bucket cylinder approx.
50 mm to away from the cushion range. Mark Mark
(122±9 °F).
Measurement:
1. Stop the engine.
2. After five minutes, measure boom and bucket cyl-
inder retraction, arm and blade cylinder extension,
and amount of bucket drift. T110-06-03-002
3. Repeat step 2. three times and calculate the

mean values.
Arm and Blade Cylinder
Extension
Evaluation:
Remedy: Mark
T110-06-03-001
T4-3-12
CONTROL LEVER OPERATING FORCE
Summary:
Use a spring scale to measure the maximum force
needed to move each control lever and pedal.
Measure the operating force at the center of each
lever grip.
Preparation:
(122±9 °F).
CAUTION: Before the measurement, make

sure there are no personnel or obstacles
within the swing area.
Measurement:
1. Start the engine.
2. Measure the maximum operating force for each T107-06-03-003
boom, arm, bucket, swing lever, blade and engine

speed control full stroke using a spring scale.
3. When measuring the operating force of the travel
levers, raise one track off the ground with the front
attachment, and operate the travel lever of the
raised side track full stroke. Measure the maxi-
mum operating force.
4. Repeat each measurement three times and calcu-
late the mean values.
Evaluation:
T107-06-03-004
T4-3-13
CONTROL LEVER STROKE
Measure each lever stroke at the center of each lever

grip. Measure the boom swing pedal stroke at the top
of the pedal.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Stop the engine.
2. Measure the boom, arm, bucket, swing and travel
control lever strokes at the grip top center from
the neutral position to the stroke end.
On the swing pedal, measure the straight distance T107-06-03-005
between the center and fully depressed positions

at tip of the pedal.
On the engine speed control lever, measure the
distance between the slow and fast idle positions
at center of the top on the grip.
3. Take the measurements by the straight stroke dis-
tances.
4. Conduct the measurement three times.
Calculate the average values.
Evaluation:
T4-3-14
Travel / Blade Lever Adjustment
Lock Nut
IMPORTANT: The standards of the stopper de-
Stopper
scribed in this page are used at the
factory for production.
Therefore, be sure to adjust the
stoppers so that the control valve
spool or the governor becomes the Standard
stroke end. Length (A)
Standard
Length (B)
T573-04-03-003
Standard length (A): 40u (Type A) : 12 mm (0.5″)
40u (Type B)Е50u : 11 mm (0.4″)
Standard length (B): 40u (Type A) : 12 mm (0.5″)
40u (Type B)Е50u :19 mm (0.7″)
NOTE: Refer to INTRODUCTION (IN-01) for the
corresponding serial numbers.
Lock
Nut Stopper
T573-04-03-001
T573-04-03-002
Length of Bolt Tip: Standard (C)
Swing Pedal Adjustment Standard length (C): 14 mm (0.6″)
Stopper
Lock
Nut
Standard Standard
Length (D) Length (E)
T525-06-03-008
T573-04-03-005
Standard length (DЕE): 47 mm (2″)
T4-3-15
Engine Speed Control Lever Adjustment
IMPORTANT: Never adjust the idle adjusting

screws (slow idle and fast idle) on
the governor lever.
1. Remove the cover of the engine speed control

lever.
2. Loosen the lock nut fixing the stopper bolts to
loosen the stopper bolts.
3. Adjust the length (G) of the stopper bolt tip (lower)
on the slow idle side to standard, then secure it
with the lock nuts.
Standard length (G): T573-04-03-006
40u (Type A) : 23 mm (0.9 in)

40u (Type B), 50u : 30 mm (1.2 in) Fast Idle Slow Idle
4. Move the engine speed control lever until it con- Adjusting Adjusting
Screw Screw
tacts against the stopper on the slow idle side.
Make sure that the governor lever contacts with
the slow idle adjusting screw. If it does not contact
with the stopper, adjust the length of the cable.
5. Move the engine speed control lever until the gov-
ernor lever contacts with the fast idle adjustment
screw.
Adjust the length (F) of the stopper bolt tip (upper)
on the fast idle side so that the clearance between
the engine speed control lever and the stopper
bolt with 1-2 mm (0.04 -0.08 in), then secure it
with the lock nuts.
Standard length (F):
40u (Type A) : 22 mm (0.87 in)
40u (Type B), 50u : 24 mm (0.94 in)
Lock Nut Governor
NOTE: Refer to INTRODUCTION (IN-01) for the Lever T573-04-03-007
Stopper
Engine Con-
Fast Idle Side trol Cable
Stopper
F G
Stopper
Lock Nut
T573-04-03-004
Engine Control Cable

T573-04-03-001
T4-3-16
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C Pilot Filter
(122±9 °F).
2. Stop the engine.
3. Turn the filling cap on the hydraulic oil tank to
bleed air.
4. Disconnect the hose at the pilot filter. Install pres-
sure gauge assembly (ST 6932) with adapter (ST Hose
(UNF9/16)
6450) to the pilot filter.
: 22 mm
5. Start the engine and check for oil leakage from

the gauge connection.
Measurement:
1. Run engine at fast-idle speed.
2. Measure the pressure without load.
3. Perform the measurement three times and calcu-
late the average value.
Evaluation: T571-04-04-001
T4-4-1
SECONDARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Install pressure gauge (ST 6942) and tee (ST
6451) to the end of pilot line (1) at the respective
control valve spool end, as illustrated.
: 17 mm, 19 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
(122±9 °F).
T157-05-04-011
Measurement:
CAUTION: Before measuring, check that
there are no obstacles or personnel within
the swing radius. When measuring the boom
lower pilot pressure, raise the machine off
the ground while paying attention not to al-
low the base machine (counterweight) to con-
tact with the ground. Be careful not to tip-
over due to a loss of balance.
1. Operate the lever to be measured. Measure the

pilot pressure at its full stroke using the pressure
gauge.
NOTE: Travel, blade and swing are controlled by
the mechanical acting spool, therefore the
pilot secondary pressure is unable to be
measured.
2. Perform the measurement three times and calcu-
late the average valve.
Evaluation:
T4-4-2
(Blank)
T4-4-3
MAIN RELIEF VALVE SET PRESSURE
Preparation: Main Pump Main Pump Main Pump
1. Maintain the hydraulic oil temperature at 50±5 °C P2 Port P1 Port PG Port
(122±9 °F). (PT 1/8) (PT 1/8) (PT 1/4)
2. Stop the engine.
3. Turn the filling cap on the hydraulic oil tank to
bleed air.
Remove the plug from the pressure check port
provided in the main pump delivery port.
4. Install nipple (ST 6077) and pressure gauge as-
sembly (ST 6933).
: 6 mm
: 4 mm
5. Start the engine and check for oil leakage from

the pressure gauge connection.
Measurement:
1. Run engine at fast-idle speed.
2. Slowly operate each control lever or pedal to fully
extend or retract each cylinder to relieve pressure.
Measure the relief pressure at this time.
T571-04-04-002
NOTE: When measuring main pump P1, operate

the travel control (left).
When measuring main pump P2, operate
the bucket control.
When measuring main pump PG, operate
the blade control or boom swing control.
When measuring main pump P1 and P2 at
the same time, operate the arm control.
When measuring main pumps P1, P2 and
P3 at the same time, operate the arm and
blade controls, or arm and boom swing con-
trols.
3. Repeat the measurement three times and calcu-

late the average values.
Evaluation:
T4-4-4
Adjustment:
Adjust the main relief valves if necessary. The main
Main Relief Main Relief Main Relief
relief valves are installed on the position as illus- Valve (PG) Valve (P1) Vale (P2)
trated.
NOTE: Before loosening the lock nut, make the

alignment marks on the adjusting screw,
lock nut and valve. Using this alignment
marks, the number of turns of the adjusting
screw can be checked easily.
1. Loosen the lock nut on the main relief valve.

T571-03-03-001
IMPORTANT: Adjust the pressure setting so that it Lock Nut

does not exceed the upper limit of Adjusting
Screw
the standard.
2. Turn adjusting screw to adjust the pressure set-

ting.
3. Tighten lock nut.

: 14 mm
: 19.6 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
T563-02-04-002
4. After completing the adjustment, recheck the set
pressure.
Lock Nut Adjusting Screw
NOTE: Standard change in pressure.
Screw Turns 1/4 1/2 3/4 1

Change in MPa 3.06 6.13 9.19 12.3
Relief kgf/cm
2
31.3 62.5 93.8 125
Pressure
psi 445 890 1335 1780 Pressure Increases Pressure Decreases
T505-06-04-006
T4-4-5
OVERLOAD RELIEF VALVE SET
PRESSURE
Checking the pressure setting of the overload relief

valves on the machine is not recommended for the
following reasons:
1. With the return circuit from the control valve

blocked, the circuit pressure must be increased by
applying an external load. This checking method
is hazardous and the results obtained with this
method are unreliable.
2. Pressure setting of the overload relief valve must

be made at a specified oil flow rate normally far
smaller than the delivery flow rate of the main
pump. Accordingly, even if the main relief vale
pressure setting can be reset higher than the set-
ting pressure of the overload relief valve, the main
pump supplies too much oil to correctly measure
the setting pressure of the overload valve.
Therefore, when the setting pressure of the over-
load relief valve must be checked correctly, re-
move the overload relief valve from the machine
and check the overload relief valve unit perform-
ance using the test stand prepared for this pur-
pose.
3. As an easier method, however, measure the relief

pressure of each cylinders in the same method as
of main relief pressure setting in previous section.
Then, when each relief pressure meets its respec-
tive specifications, judge that the setting pressure
of the overload relief valve is correct.
T4-4-6
PUMP DRIVING TORQUE
If the adjustment of pump driving torque is necessary

(ex. when installing air conditioner), perform the follow-
ing procedures. Adjusting
Screw
Adjustment:
1. Loosen the lock nut.
2. Turn the adjusting screw to adjust. (Turn clock-

wise to decrease the driving torque. Turn counter-
clockwise to increase the driving torque)
: 4 mm
3. Tighten the lock nut.
: 32 mm (Hooked spanner) T571-04-04-001
: 29 Nxm (3 kgfxm, 22 lbfxft)
Lock Nut Adjusting

Screw
NOTE: Standard change in pressure (for reference
only)
Screw Turns 1/4 1/2 3/4 1

Pressure MPa 0.37 0.74 1.1 1.47
2 Torque Torque
change kgf/cm 3.8 7.5 11.3 15 Decreases
Increases
(difference
psi 54 107 161 213
from point A) T571-04-04-006
Point A
Flow
Volume
(Q)
Torque Torque
decreases increases
Pressure
(P)
T4-4-7
SWING MOTOR DRAINAGE
Summary:
To check the performance of swing motor, measure
the amount of oil draining from the swing motor while
swinging the upperstructure.
NOTE: The amount of drain oil will change depend-

ing on hydraulic oil temperature. Maintain
hydraulic oil temperature at 50±5 °C (122±9
°F).
Preparation: Drain Hose

1. Warm the hydraulic oil temperature to 50±5 °C.
Rotate the swing motor to warm up the inside of
motor.
2. Stop the engine. Turn the filling cap to bleed air
from the hydraulic oil tank.
3. Disconnect the drain hose at the swing motor.
Install a plug (9/16-18 UNF) to the disconnected
hose end. Connect hose (ST 6627) onto the drain
port of the swing motor.
: 19 mm
CAUTION: Before the measurement, make

sure there are no personnel or obstacles
T571-04-04-003
within the swing area.
Make sure not to fall off from machine during
the measurement.
4. Disconnect the make-up line at the swing motor.

Install plugs on the disconnected line end and mo-
tor port.
Measurement Condition:
1. Before the measurement, set the fuel lever to the
fast idle position, then measure it.
T4-4-8
Measurement:
1. Drain Oil Volume at Swing Operation
(1) With the arm rolled out and bucket rolled in,
hold the bucket so that the height of the arm
top pin is even with the boom foot pin. The
bucket must be empty.
(2) Start the engine. Operate swing lever to the full
stroke. After swing speed reaches a constant Even with the
maximum speed, collect the hydraulic oil from Boom Foot
Pin.
drain hose. Measure the time also.
(3) Repeat the measurement more than 3 times in T570-06-03-003
both clockwise and counterclockwise direc-
tions, and calculate the average value.
(4) The measurement should be at least 45 sec-
onds.
2. Drain Oil Volume at Swing Lock Operation

(1) Seize the ground with bucket so that the ma-
chine does not move.
(2) Start the engine. Operate the swing lever to the
full stroke. Collect the hydraulic oil from the
drain hose. Measure the time also.
(3) Repeat the measurement more than 3 times in
both clockwise and counterclockwise direc-
tions, and calculate the average value.
onds.
Evaluation:
Refer to T4-5 Standard. T571-04-04-005
* Conversion of Measured Value into the Per-

Minute Value
Measure the amount of drain oil using a calibrated
container. Then, convert the measured drain oil
into the per-minute value using the following for-
mula;
∆QȀȝȀȖȐȀ×Ȁq ȏȀɔ
∆Q : Per-Minute Drain Volume (L/min)

t : Time Measured (sec)
q : Measured Drain Oil Volume (L)
T4-4-9
TRAVEL MOTOR DRAINAGE
To check the performance of the travel motor, measure

the amount of oil draining from the travel motor, while
rotating the travel motor with the measuring side track
jacked up.
Always secure the test personnel’s safe during the
measurement. Before the measurement, make sure
there are no personnel or obstacles within the test
track. The amount of drain oil will change depending
on hydraulic oil temperature. Maintain hydraulic oil
temperature at 50±5 °C (122±9 °F).
Evaluate the overall performance of the travel motor
taking the test results such as travel speed and mis-
track amount into consideration together with this test
results.
Drain Hose
Preparation:
1. Warm the hydraulic oil results temperature to
50±5 °C. Rotate the travel motor to warm up the
inside of motor.
2. Stop the engine. Turn the filling cap to bleed air
from the hydraulic oil tank.
3. Disconnect the drain hose at the travel motor. In-
stall a plug (9/16-18UNF) to the disconnected
hose end. Connect hose (ST 6627) onto the drain
port of the travel motor.
: 22 mm
Measurement Condition:
1. Set the fuel lever to the fast idle position and
measure at slow travel speed.
T571-04-04-004
T4-4-10
Measurement:
CAUTION: When approaching to the rotation

parts, take care that hands, legs or clothes
are not entangled.
Support the lifted machine securely by using
wooden block.
(1) Start the engine. Jack-up the measuring side 90 to 110°

track.
(2) Rotate the raised track. Collect the hydraulic oil
from drain hose. Measure the time also.
(3) Repeat the measurement more than 3 times in
both forward and reverse directions, and calcu- T570-06-03-009
late the average value.

onds.
Evaluation:
* Conversion of Measured Value into the Per-
Minute Value
Measure the amount of drain oil using a calibrated
container. Then, convert the measured drain oil
into the per-minute value using the following for-
mula;
∆QȀȝȀȖȐȀ×Ȁq ȏȀɔ
∆Q : Per-Minute Drain Volume (L/min)

t : Time Measured (sec)
q : Measured Drain Oil Volume (L)
T157-05-04-019
T4-4-11
(Blank)
T4-4-12
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD
This Operational Performance Standard values are The value in ( ) is shown for reference only.
listed below. * The standard measurement condition is as follows;
Refer to the correspondence section in T4-2 and after Engine Speed Control Lever: Full Stroke
for the details of measurement method. Hydraulic Oil Temperature: 50±5 °C
Operational Remarks
Item Performance Standard Refer to INTRODUCTION (IN-
01) for the corresponding serial
(40u Type A) numbers.
ENGINE SPEED (min-1)
Maximum Speed 2030±50
When 1 pump is relieved (bucket) 1980±50
When 2 pumps are relieved (boom) 1980±50
Minimum Speed 1000±50
ENGINE COMPRESSION PRESSURE (kgf/cm2) 31 or more
VALVE CLEARANCE (IN, EX) (mm) 0.4
NOZZLE INJECTION PRESSURE MPa (kgf/cm2) 13.2 (135)
INJECTION TIMING (Before Top Dead Center) (deg.) 12°
TRAVEL SPEED (sec/20 m)
Fast Speed Mode (Rubber Crawler/Steel Crawler) 17.5±1.5/19.0±1.5
Slow Speed Mode (Rubber Crawler/Steel Crawler) 28.0±1.5/30.0±1.5
TRACK REVOLUTION SPEED (sec/3 rev)
Fast Speed Mode (Rubber Crawler/Steel Crawler) 13.0±1.5/14.0Ѱ1.5
MISTRACK (Fast Speed]Slow Speed) (mm/20 m) 200 or less
TRAVEL PARKING FUNCTION (rev) 1/6 or less
TRAVEL MOTOR LEAKAGE (mm/3 min) 60 or less
SWING SPEED (sec/3 rev) 22.0±1.5
SWING FUNCTION DRIFT (mm/90°) 300 or less NOTE: Angle 25°
SWING MOTOR LEAKAGE (mm/5 min) 0
MAXIMUM SWINGABLE SLANT ANGLE (angle) 20 or possibly more
SWING BEARING PLAY (mm) 0.4 or less
HYDRAULIC CYLINDER CYCLE TIME (sec)
Boom Raise 2.0±0.3
Boom Lower 3.0±0.3
Arm Roll-in 2.6±0.3
Arm Roll-out 2.0±0.3
Bucket Roll-in 3.1±0.3
Bucket Roll-out 2.2±0.3
Right Boom Swing 8.1±0.5
Left Boom Swing 6.1±0.5
Blade Raise 2.0±0.5
Blade Lower 2.6±0.5
T4-5-1
Operational Remarks
Performance Refer to INTRODUCTION (IN-01)
Item for the corresponding serial
Standard numbers.
(40u Type A)
DIG FUNCTION DRIFT (mm/5 min)
Boom Cylinder 5 or less
Arm Cylinder 8 or less
Bucket Cylinder 5 or less
Bucket Bottom 70 or less
Blade Cylinder 3 or less
Blade Cylinder (When jacking up the base machine) 8 or less
CONTROL LEVER/PEDAL OPERATING FORCE (kgf)
Boom Lever 1.5 or less
Arm Lever 1.5 or less
Bucket Lever 1.5 or less
Swing Lever 1.5 or less
Travel Lever 2.0 or less
Blade Lever 3.5 or less
Boom Swing Pedal 8.0 or less
Fuel Lever 5.0 or less
CONTROL LEVER/PEDAL STROKE (mm)
Boom Lever 93±5
Arm Lever 93±5
Bucket Lever 93±5
Swing Lever 93±5
Travel Lever 90±10
Blade Lever 65±10
Boom Swing Pedal 20
PRIMARY PILOT PRESSURE (kgf/cm2) 40±5
SECONDARY PILOT PRESSURE 30±5
MAIN RELIEF VALVE SET PRESSURE (kgf/cm2)
1 Pump Relief (P1, P2) 260±10
1 Pump Relief (PG) 210±10
2 Pumps Relief (P1, P2) 245±10
OVERLOAD RELIEF VALVE SET PRESSURE (kgf/cm2)
+10
Boom, Arm, Bucket (280 0) Flow Rate: 20 L/min
Travel (260±10)
Swing (200±10)
SWING MOTOR DRAINAGE (L/min)
at constant maximum speed (0.5 or less) Maximum Allowable Limit:
(1.0 or less)
with the motor relieved (7 or less) Maximum Allowable Limit:
(15 or less)
TRAVEL MOTOR DRAINAGE (L/min) (0.5) NOTE: With the motor
relieved (5 L/min)
NOTE: 1 kgfҧ9.8 N
2
1 kgf/cm = 0.09807 MPa
T4-5-2
Operational Remarks
(40u Type B) numbers.
Maximum Speed 2030±50
VALVE CLEARANCE (IN, EX) (mm) 0.4±0.05
INJECTION TIMING (Before Top Dead Center) (deg.) 12°±1.5°
SWING FUNCTION DRIFT (mm/90°) 150 or less
SWING MOTOR LEAKAGE (mm/5 min) Brake on : 0
Brake off : 120 or less
Boom Raise 2.0±0.3
Boom Lower 3.0±0.3
T4-5-3
Operational Remarks
Standard numbers.
(40u Type B)
DIG FUNCTION DRIFT (mm/5 min) With 195 kg
Fuel Lever 4.0±1.0
Boom Lever 93±5
Arm Lever 93±5
Bucket Lever 93±5
Swing Lever 93±5
Travel Lever 90±10
Blade Lever 65±10
Boom Swing Pedal 25±5
Fuel Lever 110±10
1 Pump Relief (P1, P2) 250±10 Flow Rate: 44 L/min
1 Pump Relief (PG) 210±10 Flow Rate: 44 L/min
+10
Boom, Arm, Bucket 280 0 Flow Rate: 20 L/min
Swing 180±10 Flow Rate: 38 L/min
(1.0 or less)
(15 or less)
relieved (5 L/min)
NOTE: 1 kgfҧ9.8 N
2
1 kgf/cm = 0.09807 MPa
T4-5-4
Operational Remarks
(50u) numbers.
+50
Maximum Speed 2130 -25
VALVE CLEARANCE (IN, EX) (mm) 0.4±0.05
INJECTION TIMING (Before Top Dead Center) (deg.) 12°±1.5°
SWING FUNCTION DRIFT (mm/90°) 150 or less
SWING MOTOR LEAKAGE (mm/5 min) Brake on : 0
Brake off : 120
Boom Raise 2.1±0.3
Boom Lower 3.1±0.3
T4-5-5
Operational Remarks
Standard numbers.
(50u)
DIG FUNCTION DRIFT (mm/5 min) With 210 kg
Fuel Lever 4.0±1.0
Boom Lever 93±5
Arm Lever 93±5
Bucket Lever 93±5
Swing Lever 93±5
Travel Lever 90±10
Blade Lever 65±10
Boom Swing Pedal 25±5
Fuel Lever 130±10
1 Pump Relief (P1, P2) 260±10 Flow Rate: 44 L/min
1 Pump Relief (PG) 210±10 Flow Rate: 44 L/min
Boom, Arm, Bucket (280) Flow Rate: 20 L/min
Swing 195±10 Flow Rate: 38 L/min
(1.0 or less)
(15 or less)
relieved (5 L/min)
NOTE: 1 kgfҧ9.8 N
2
1 kgf/cm = 0.09807 MPa
T4-5-6
SECTION 5
TROUBLESHOOTING
; CONTENTS;
;
Group 1 Diagnosing Procedure Group 4 Electrical System Inspection
Introduction ...............................................T5-1-1 Precautions for Inspection and
Diagnosing Procedure................................T5-1-2 Maintenance................................................ T5-4-1
Fuse Continuity Test...................................... T5-4-3
Group 2 Troubleshooting A Battery Voltage Check................................... T5-4-4
Troubleshooting A Procedure ....................... T5-2-1 Voltage Check ............................................... T5-4-5
Engine system Troubleshooting ................... T5-2-2 Continuity Check ........................................... T5-4-6
Actuator Operating System
Troubleshooting .......................................... T5-2-6
Front Attachment System
Troubleshooting .......................................... T5-2-8
Swing System Troubleshooting .................. T5-2-12
Travel System Troubleshooting .................. T5-2-13
Blade System Troubleshooting ................... T5-2-16
How to Lower Boom When Engine Stops .. T5-2-17
Group 3 Troubleshooting B
Troubleshooting B Procedure ....................... T5-3-1
Malfunction of Coolant
Temperature Gauge.................................... T5-3-2
Malfunction of Fuel Gauge............................ T5-3-6
Malfunction of Alternator Indicator .............. T5-3-10
Malfunction of Engine Oil Pressure
Indicator .....................................................T5-3-11
Malfunction of Overheat Indicator............... T5-3-12
Malfunction of Fuel Level Indicator ............. T5-3-14
Malfunction of Air Filter Restriction
Indicator .................................................... T5-3-16
Malfunction of Buzzer ................................. T5-3-17
Malfunction of Hour Meter .......................... T5-3-19
585T-5-1
(Blank)
585T-5-2
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Troubleshooting charts shown in this section indicate

the orderly procedures for inspecting and finding out
the cause(s) of problems in the machine.
This section is comprised of three groups:

Troubleshooting A (diagnosis of machine by symptom),
Troubleshooting B (diagnosis of monitor) and Electric
System Check.
• Troubleshooting A (diagnosis of machine by

symptom)
This procedure is used when operating the
diagnosis by the symptom.
Example: Starter does not rotate.
• Troubleshooting B (diagnosis of monitor)

This procedure is used when there are
malfunction on components regarding monitor,
such as gauges or indicators.
Example: Fuel gauge does not operate.
• Electric System Check

This procedure is used when the information on
precaution for electric system inspection or
inspection method is needed.
Example: Fuse inspection.
T5-1-1
DIAGNOSING PROCEDURE
Follow the five basic steps shown below for efficient

troubleshooting.
1. Know the system

Study the appropriate technical manuals. Know
what the system is composed of and how it works,
as well as the construction, functions and
specifications of the system components.
2. Ask the operator

ȴȑȐȗȍȐȗȍȐȑȍȐȐȑ
Before inspecting, get the full story of
malfunctions from a witness --- the operator.
(a) How the machine has been used and properly
operated?
(b) When was the trouble noticed, and what work
was the machine doing at that time?
(c) What is the character of the trouble? Did the
trouble slowly get worse, or did it appear
suddenly for the first time?
(d) Did the machine have any trouble previously?
If so, which parts were repaired or replaced
before?
3. Inspect the machine
Before starting troubleshooting, check the
machine's daily maintenance points, as shown in
the operator's manual.
Check the electrical system, including batteries.

Trouble in the electrical system such as low ȴȑȐȗȍȐȗȍȐȑȍȐȐȒ
battery voltage, loose connections and blown
fuses will result in malfunction of the controllers,
causing total operational failure of the machine.
Note that if the troubleshooting is performed

without noticing that the fuse is blown, it may lead
to the incorrect diagnosis results which causes
significant loss of time. Make sure to check the
fuse before performing the troubleshooting.
Fuse failure is often caused by a fine crack in the
fuse, and such fine cracks are very hard to detect
by visual inspection.
ȴȑȐȗȍȐȗȍȐȑȍȐȐȓ
T5-1-2
4. Inspect the actual trouble on the machine
Reproduce the trouble on the machine and make
sure the actual phenomenon.
In case some trouble cannot be actually
confirmed, obtain the details of the malfunction
from the operator.
Also check for any incomplete connections of the
wire harnesses.
5. Check by Each System

CAUTION: Always stop the engine before
disconnecting the harnesses or lines. If they ȴȑȐȗȍȐȗȍȐȑȍȐȐȔ
are disconnected while the engine running, it

may cause improper operation of the
machine, or the pressurized oil may spout.
Use "Troubleshooting A, B" in this chapter to

confirm the operation condition for each
equipment.
6. Trace causes
Before reaching a conclusion, check the most
suspectable causes again. Try to trace what the
real cause of the trouble is.
Make a plan of appropriate repairing procedure, to ȴȑȐȗȍȐȗȍȐȑȍȐȐȕ
avoid consequential malfunctions.
ȴȑȐȗȍȐȗȍȐȑȍȐȐȖ
ȴȑȐȗȍȐȗȍȐȑȍȐȐȗ
T5-1-3
(Blank)
T5-1-4
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
(DIAGNOSIS OF MACHINE BY SYMPTOM)
This procedure is used when operating the diagnosis

by the symptom.
• How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
ѕ (1) After checking or measuring item (1), select either YES (OK) or NO
(NOT OK) and proceed to item (2) or (3) next.
(3)
NO (NOT OK)
ѕ As shown to the left, measuring methods or items to be referred to are indicated in the
spaces under the box. Take care to measure or check correctly. Incorrect measuring or
ѕʝ Key switch: ON
checking methods may result in making troubleshooting impossible, and may damage
components.
ѕ The thick-line box indicates the causes. Scanning through thick-line boxes, possible
causes can be focused.
NOTE: The connector drawings show the harness

end connectors seen from the open end
side.
Wire Harness Side
Open End Harness End Connector

Side
ȴȑȕȘȍȐȕȍȐȓȍȐȐȑ
T5-2-1
ENGINE SYSTEM TROUBLESHOOTING
Starter does not rotate
YES
No voltage or less
than 12 V at termi-
nal B.
With key switch
positioned as
shown in the table
YES below, check if
each terminal volt-
age on starter is
normal.
Unit: V
Key Switch
OFF ON START NO
Terminal
B(M8) 12 12 12
Check if battery #50 0 0 12
No voltage or less
voltage and elec- than 12 V at termi-
trolyte density are nal No. #50 (S)
normal. with key switch at
·Voltage: 12 volts START position.
or more ·Key switchϖ START
·Density: 1.28 or
more
NO (When key switch is turned to the START position, if voltage at

terminal B is lower than 9 volts, battery may be faulty.)
Starter voltage check

B
50 (S)
1. Turn key switch to the ON or START position.
2. Contact minus (−) probe of a circuit tester to the
machine (ground to unpainted area like bolt head)
and plus (+) probe terminals to the starter terminal
respectively, and check voltages.
(Measure with the harness connected.)
T533-07-02-001
T5-2-2
Faulty starter.
Faulty harness between bat-

tery and starter, or incorrect
connection.
YES Faulty harness between

starter relay and key switch or
fusible link.
Voltage at terminal No.
3: 0 V
Check if fusible link b (45 A) is
normal (not blown).
·Visual Inspection
Faulty fusible link (b).
NO
Measure voltage at terminals

No. 3 and No. 6 on starter
relay. Faulty starter relay.
·Key switchϖ START Voltage at terminal
No. 3: 12 V
No. 6: 0 V
Faulty harness between ter-

minal No. 6 on starter relay
Voltage at terminal and terminal #50 on starter.
No. 3: 12 V
No. 6: 12 V
Faulty battery.
Starter Relay
Connector (View A)
#1
#2
#5 Not Harness
#3
#6
View A
T573-05-02-001 T573-05-02-002
T5-2-3
Starter rotates but engine does not start.
• The faulty engine and the faulty electrical circuit

are suspected. This page describes the trouble-
shooting of electrical circuit (fuel pump, engine
stop solenoid).
In case of faulty engine, refer to "Engine Shop
Manual".
• Check the connection of wiring first.
YES
Engine Stop
Solenoid
Disconnect fuel line Pin

that goes to engine at T573-05-02-005
fuel pump. Check if
fuel is delivered when
key switch is turned
ON.
YES
Check if fuel filter is YES

NO restricted.
Disconnect fuel pump

connector. Check if
terminal #1 on har-
NO
ness end connector
is 12V.
·Key switch: ON
NO
T5-2-4
Remove engine stop YES Faulty engine.

solenoid from engine.
Remove terminal B
YES (M8) from starter
motor. Check if pin
on solenoid top
Disconnect solenoid moves when key
stop valve connector. Faulty engine stop
switch is turned to solenoid.
YES Check if there are START. NO
continuity between
terminal #1 on har-
Disconnect engine ness end connector
stop solenoid connec- and vehicle.
Broken harness be-
tor. Check if terminal tween engine stop
#2 on harness end NO solenoid and ground.
connector is 12V.
·Key switch: START
Broken harness be-
tween engine stop
NO solenoid and key
switch.
Faulty fuel filter.
YES Faulty fuel pump.

Check if there are
continuity between
terminal #1 on har-
ness end connector
of fuel pump and Broken harness be-
vehicle. tween fuel pump and
NO
ground.
Broken harness be-

YES
tween fuse box and
fuel pump.
Check if fuse #5 on
fuse box is 12V. Faulty key switch, or
·Key switch: ON broken harness be-
NO tween key switch and
fuse box.
T5-2-5
ACTUATOR OPERATING SYSTEM
TROUBLESHOOTING
All machine functions are slow.
• As the main circuit consists of 3 systems (3 main

relief valves are located), the possibility of failure
in all main relief valve is small.
• As the mechanical acting spool systems are in-
volved, the failure in pilot system cannot be sus-
pected.
YES Failure in main pump.
Check if engine speed

is normal.
·Refer to
"OPERATIONAL Failure in engine.
PERFORMANCE NO
TEST".
The actuator does not stop even if the control

lever is returned to the neutral position.
YES Stuck pilot valve spool.
Check if actuator stops

when the pilot control
shut-off lever is raised.
Stuck control valve

NO spool.
T5-2-6
Front and swing function does not operate.
YES Faulty pilot shut-off
• Check the connection of wiring first. switch (left).
Check if malfunction
YES is corrected by con-
necting terminal #2
on harness side con-
nector of pilot shut-off Broken harness be-
switch (left) to vehi- tween pilot shut-off
Reconnect the dis- cle. NO valve relay and pilot
connected connector. shut-off switch (left).
YES Check if malfunction
is corrected by con-
necting terminal #85 YES Faulty pilot shut-off
on pilot shut-off valve valve relay.
Check if terminal #86
relay to vehicle. on harness end con-
·Ground the connec- nector of pilot shut-off
NO valve relay is 12V.
tor to the vehicle us- Broken harness be-
Remove pilot shut-off ing a clip without dis- ·Key switch: ON tween harness end
valve relay connec- connecting. terminal #86 on pilot
tor. Check if malfunc- NO shut-off valve relay
tion is corrected by and fuse box.
connecting terminal
#87 and terminal #30
on harness end con- Check if there are YES Faulty pilot shut-off
nector. continuity between valve relay.
YES
terminal #87 on har-
·Key switch: ON ness end connector
·Pilot control shut-off of pilot shut-off valve
lever: UNLOCK relay and vehicle.
Check if terminal #30 (1)
on harness end con- NO
NO nector of pilot shut-off
valve relay is 12V. Broken harness be-
tween terminal #30 of
·Key switch: ON NO pilot shut-off valve
relay and fuse box.
Check if there are

continuity between
YES Faulty pilot shut-off
terminal #87 on har- valve solenoid valve.
ness end connector
(1) of pilot shut-off valve
relay and terminal #1 Broken harness be-
on harness end con- tween pilot shut-off
nector of pilot shut-off NO valve relay and pilot
valve solenoid valve. shut-off valve sole-
noid valve.
Connector
Pilot Shut-Off Valve Relay
#85 #86
#87
#30
T573-05-02-006
T5-2-7
FRONT ATTACHMENT SYSTEM
TROUBLESHOOTING
All front attachment function power is weak, or its
seed is slow.
• As the main circuit consists of 3 systems (3 main

relief valves are located), the possibility of failure
in all main relief valve is small.
• If the swing is also slow, refer to T5-2-7 "Front and
swing function does not operate".
YES Failure in main pump.
YES Check if pilot primary

pressure is normal. NO Completion. (Faulty pilot
·Refer to relief valve)
Check if malfunction
"OPERATIONAL
still occurs after pilot
PERFORMANCE
relief valve is, dis-
TEST". NO
assembled, cleaned
Check if engine and re-adjusted.
speed is normal. Failure in pilot pump or
YES pilot filter is clogged.
·Refer to
"OPERATIONAL
PERFORMANCE
TEST".
Failure in engine.
NO
T5-2-8
Only cylinder(s) in one system does not move.
• The main circuit consists of 3 systems (3 main re-

lief valves are located). If one of the main relief
valve is faulty, it may lead to failure in the actuator
operation of the corresponding system.
Blade, turn, swing: Main relief valve on main
pump PG
Arm, boom, travel left: Main relief valve on main
pump P1
Bucket, boom, travel right: Main relief valve on
main pump P2
YES Completion. (Stuck

Check if problem dis- control valve spool)
appears after control
YES valve spool corre-
sponding to cylinder is
disassembled and
cleaned. Faulty seal of cylinder.
Check if relief pres-
YES sure corresponding to NO
cylinder is normal.
·Refer to
"OPERATIONAL Faulty overload relief
PERFORMANCE valve corresponding to
NO cylinder.
TEST".
Check if pilot secon-
dary pressure corre-
sponding to cylinder
is normal.
·Refer to
"OPERATIONAL
PERFORMANCE
TEST".
Faulty pilot valve cor-

responding to cylinder.
NO
T5-2-9
Front attachment cylinders leaking (drift) is large.
YES Normal.
YES Faulty seal in cylinder.

Check if each front
attachment cylinder
drift is within stan-
dards. NO Check if oil leaks
inside cylinder.
Faulty boom anti-drift
valve, scored control
Check if phenomenon valve spool, damaged
disappears when pilot NO spring, or loosed spool
control shut-off lever end.
NO is raised.
Faulty pilot valve.

YES
Boom cylinder inner leak check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tip to the
ground.
2. Disconnect the hydraulic hose at the rod side of
boom cylinder, and drain the oil in the cylinder and
hose. (Install a plug on disconnected hose end.)
3. Retract the rod of the arm cylinder to raise the
bucket from the ground.
If the oil comes out from the hose disconnected
line and the rod of the boom cylinder is retracted,
the oil is leaking in the boom cylinder. T571-05-02-001
If the oil does not come out from the hose discon-
nected line and the rod of the boom cylinder is re-
tracted, the oil is leaking in the control valve.
T5-2-10
When the arm control lever is operated (boom
raise, arm roll-out), front attachment drops briefly,
then begins to move.
YES Internal leakage in cylinder.
Check if load check

valve in control valve is
normal.
·Visually check after
disassembling. Faulty load check valve.
NO
NOTE: 1. During the initial stage of operation, the

oil pressure and the flow rate from the
pump are low. If the load check valve is
failed, the oil in the bottom side of the (B)
cylinder flows back into the circuit
through the load check valve, causing
the boom cylinder to temporarily retract At failure in load
check valve (A)
because of the load on the boom cylin-
der.
2. If the oil is leaking from bottom side (A)

to rod side (B) due to the failed piston or
tube of the boom cylinder, the boom cyl-
inder temporarily retracts as oil pressure
and flow rate from the pump is low dur-
ing the initial stage of operation. Then,
the cylinder cannot support the load, re- T105-07-04-012
ducing cylinder force and increasing the

cylinder drift in this case.
T5-2-11
SWING SYSTEM TROUBLESHOOTING
Upperstructure does not swing, its speed is slow,
or weak power.
• In case the blade and boom swing cylinders,
along with the awing function move slowly, have
no power, or do not move at all, the main relief
valve for pump PG may be faulty. Completion. (Faulty
YES
control valve spool)
Check if problem
YES
disappears after
control valve spool NO Failure in swing
is disassembled Check if oil pressure motor.
and cleaned. at port PG and SH in
swing motor is 40
NO kgf/cm2.
Check if swing Faulty swing park-
YES motor relief pres- ·Engine Running
YES ing brake.
sure is normal. ·40u (Type A): Bucket
full stroke
·Refer to ·40u (Type B), 50u: Pilot
Check if swing "OPERATIONAL control shut-off lever
pilot secondary PERFORMANCE UNLOCK position Faulty swing motor
pressure is nor- TEST". NO relief valve.
mal.
·Refer to
"OPERATIONAL Faulty pilot valve.
PERFORMANCE
NO
TEST".
T5-2-12
TRAVEL SYSTEM TROUBLESHOOTING
Machine does not moves, move slowly, or weak
power.
• Both right and left travel motors seldom become

faulty at the same time.
• The troubleshooting here is for the vehicle that
both right and left travel motors become faulty. If
only one side is faulty, then refer to "The excava-
tor mistracks".
• If travel speed does not become fast, then refer to
"Travel speed does not change to the fast speed".
During a Combined Operation of Travel and Front

Function, the Machine Mistracks
• When operating the front function during travel,

the flow combiner valve switches to the other side,
so that hydraulic oil from the main pump P2 is de-
livered to the other spool. Therefore, if the flow
combiner valve is stuck at its closed position, or if
the check valve on the travel right parallel circuit is
stuck at its closed position, the machine can mis-
track only when the combined operation is oper-
ated.
T5-2-13
Travel speed does not change to the fast speed

• Refer to INTRODUCTION (IN-01) regarding the
YES Faulty travel speed
Disconnect plug changeover switch.
(yellowish green)
YES from travel speed
changeover switch.
Check if harness end Broken harness be-
plug is 12V. tween travel speed
Check if travel speed changeover switch
changes to fast NO and travel speed
YES speed when terminal changeover solenoid
#2 on travel speed valve.
changeover solenoid
·For 40u (Type A),
valve connector is
faulty diode is
connected to vehicle.
also suspected.
Check if terminal #1 ·Ground the connector
Faulty travel speed
on harness end to the vehicle using a
changeover solenoid
connector of travel clip without discon- NO
valve.
speed changeover necting.
solenoid valve is
12V.
Broken harness be-

tween travel speed
changeover solenoid
NO valve and key switch.
Travel speed does not change to the slow speed

YES Faulty travel speed

changeover switch.
Check if problem
disappears after dis-
NO connecting the travel
speed changeover
switch plug (yellowish
green). Short circuited har-
ness between travel
speed changeover
Check if problem
NO solenoid valve and
disappears after
travel speed
disconnecting travel
changeover switch.
speed changeover
solenoid valve con- ·For 40u (Type A),
nector. faulty diode is
also suspected.
Faulty travel speed

YES changeover solenoid
valve (stuck).
T5-2-14
The excavator mistracks.
NOTE: If the machine mistracks to the right (only

the travel right moves slowly, has no power
or does not move), a faulty main relief valve
on the main pump P2 is suspected.
If the machine mistracks to the left (only the
travel left moves slowly, has no power or YES Faulty center joint.
does not move), a faulty main relief valve
Check if problem is
on the main pump P1 is suspected.
YES reversed when the
travel hoses under the
center joint are
Failure in travel motor,
switched.
or faulty travel motor
YES Check if cycle time of NO
displacement angle
all hydraulic cylinder control system.
is normal.
·Refer to Failure in
"OPERATIONAL NO main pump.
Check if control valve PERFORMANCE
spool moves to its TEST". ·If the bucket moves
stroke end. slowly, main pump 2 is
faulty.
·If the arm moves
slowly, main pump 1 is
faulty.
Stuck of control valve

spool, or incorrect track
NO link adjustment.
Right Travel Forward
Left Travel Reverse
Left Travel Forward
Right Travel Reverse
T563-05-03-002
T5-2-15
BLADE SYSTEM TROUBLESHOOTING
Blade does not move, or its speed is slow.
• The actuators for the blade, swing and boom
swing are actuated by pressure oil from the main
pump PG. Therefore, the faulty main relief valve
on the main pump PG is also suspected.
YES Completion. (Faulty

spool)
Check if problem
disappears after
blade spool of control
valve is disassembled
Remove blade cylinder, YES Oil leaks in cylinder.
and cleaned.
and fully retract the
blade cylinder.
Connect only the line to
NO
the rod side. Check for
oil leaks from bottom
side port of cylinder Faulty center joint.
when blade is raised.
NO
T5-2-16
HOW TO LOWER BOOM WHEN ENGINE
STOPS
With the boom raised if the engine stops and is impos-

sible to restart by some reason lower the boom in the
following procedures.
If the front attachment is not loaded.

1. Put alignment marks on the overload relief valve
and control valve in the boom lower circuit.
CAUTION: Loosen overload relief valve

slowly. If it is loosened rapidly, the boom may
also lower rapidly.
Do not loosen it more than 3/4 turns, as the
hydraulic oil may spout.
2. Loosen the overload relief valve slowly by check- T571-03-03-001

ing the movement of boom.
Overload Relief Valve in
: 24 mm the Boom Lower Circuit
: 42 to 49 Nxm
(4.2 to 5 kgfxm, 30 to 36 lbfxft)
Valve Body Lock Nut
3. After checking that boom is lowered completely, Adjusting
Screw
tighten the overload relief valve.
If the front attachment is loaded.

1. Put alignment marks on the overload relief valve
lock nut and adjusting screw in the boom lower
circuit.
T571-03-03-004
CAUTION: Loosen the adjusting screw
slowly. If it is loosened rapidly, the boom may
also lower rapidly.
2. Loosen the lock nut. Loosen adjusting screw

slowly by checking the movement of boom.
: 14 mm
: 19.6 Nxm (2 kgfxm, 14.5 lbfxft)
IMPORTANT: After re-tightening the overload re-

lief valve or lock nut, check the set
pressure of the overload relief valve.
3. After checking that the boom is lowered com-

pletely, align the marks and tighten the lock nut.
T5-2-17
(Blank)
T5-2-18
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
(DIAGNOSIS OF MONITOR)
This procedure is used when there are malfunction on

components regarding monitor, such as gauge or indi-
cators.
• How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
ѕ (1) After checking or measuring item (1), select either Yes (OK) or No
(NOT OK) and proceed to item (2) or (3) next.
(3)
NO (NOT OK)
As shown to the left, measuring methods or items to be referred to are indicated in the
ѕ spaces under the box. Take care to measure or check correctly. Incorrect measuring or
checking methods may result in making troubleshooting impossible, and may damage
·Key switch: ON components.
ѕ The thick-line box indicates the causes. Scanning through thick-line boxes, possible
causes can be focused.
NOTE: The connector drawings show the harness

end connectors, seen from the open end
side.
Wire Harness Side
Open End Harness End Connector

Side
T158-05-03-001
T5-3-1
MALFUNCTION OF COOLANT
TEMPERATURE GAUGE

Checking Instruction
• Check the connection of wire first.
YES
Disconnect coolant tempera-

ture sensor, and connect har-
Gauge pointer does
ness end terminal to the vehi-
not move at all.
cle ground. Does pointer
With coolant temperature sen-
swings to the (H) side?
sor disconnected, remove 20P
·Key switch: ON connector from monitor panel.
NO Is there continuity between
terminal #3 and sensor side
harness end terminal?
YES
When coolant tem-

perature sensor is YES
Gauge pointer swings
disconnected, does
over scale.
pointer swing back to
zero?
·Key switch: ON sor disconnected, disconnect
20P connector from monitor
NO panel. Is there continuity be-
tween sensor harness end ter-
minal and vehicle?
NO
YES
Disconnect coolant temperature

sensor, and connect harness
Gauge pointer swings
end terminal to vehicle. Does
unstably.
pointer swings to the (H) side,
and stays stably?
·Key switch: ON
NO
T5-3-2
Coolant Temperature Gauge
103 °C 135 °C
Faulty coolant temperature 50 °C

sensor. ȭȕȕȔȍȐȑȍȐȑȓ
Resistance of Coolant Temperature Sensor
YES Faulty monitor panel. Coolant Temperature °C (°F) Resistance (Ω)

80 (176 °F) 51.9 +4.9
-4.4
100 (212 °F) 27.4 +1.9

-1.2
Broken harness between (120) (248 °F) (16.1±1.2)

monitor panel and sensor.
NO
Faulty coolant temperature

sensor. Connector
Monitor Panel
Short-circuited harness be-
tween monitor panel and
10 9 8 7 6 5 4 3 2 1
sensor.
20 19 18 17 16 15 14 13 12 11

gauge.

sensor.

gauge.
T5-3-3
40u (Type B), 50u: Refer to INTRODUCTION (IN-01)
regarding the corresponding serial numbers.
NOTE: The troubleshooting here only covers the

malfunction of the coolant temperature
gauge. For the malfunction of the overheat
indicator, refer to T5-3-13.

YES
Coolant temperature Disconnect coolant temperature

monitor segment light sensor terminal, and connect har-
does not move from 1. ness end terminal to the vehicle
ground. Does all segments light?
·Key switch: ON sor terminal disconnected, re-
move 12P connector from moni-
NO tor panel. Is there continuity be-
tween terminal #12 and sensor
harness end terminal?
YES
When coolant tem-

perature sensor termi-
All the segments on
nal is disconnected,
coolant temperature YES
does only one coolant
monitor light up.
temperature monitor
segment lights up?
·Key switch: ON sor terminal disconnected, dis-
NO connect 12P connector from
monitor panel. Is there continuity
between harness end terminal
#12 and vehicle?
NO
YES
Disconnect coolant temperature

Coolant temperature sensor terminal, and connect
monitor segment light harness end terminal to vehicle.
moves its position un- Does all coolant temperature
suitably. monitor segments light up?
·Key switch: ON NO
T5-3-4
Coolant Temperature Gauge

50 °C 108 °C
(122 °F) (226 °F) 115°C(239°F) or over
1 2 3 4 5 6 7 8 9 10
Faulty coolant temperature Segment Number T573-05-02-004
sensor.
YES Faulty coolant temperature

gauge or faulty monitor
controller.
Coolant
Segment
Temperature Resistance (Ω)
Number
Broken harness between °C (°F)
coolant temperature 50
NO gauge and coolant tem- C 1 174±10
perature sensor.
(122 °F)
65
2 97±6
(149 °F)
Faulty coolant temperature 80
sensor. 3 58±4
(176 °F)
90
4 42±4
(194 °F)
Short-circuited harness 95
between monitor panel 5 35±3
(203 °F)
and coolant temperature
sensor. 100
6 30±3
(212 °F)
104
7 27±3
(219 °F)
108
Faulty coolant temperature 8 26±3
gauge or faulty monitor
(226 °F)
controller. 115
9 23±3
(239 °F)
115°C
H 10 (239 °F)
or over
sensor.
Connector
Faulty coolant temperature Monitor Panel

gauge or faulty monitor 40u (Type B), 50u
controller.
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-5
MULFUNCTION OF FUEL GAUGE

• Check the connection of wire first.
YES
Disconnect fuel sensor unit,

and connect terminals #1 to
Gauge pointer does
#2 on harness end connector.
not swing.
Does pointer swings to the With fuel sensor unit discon-
(FULL) side? nected, disconnect 20P connec-
·Key switch: ON tor from monitor panel. Is there
·Use a clip to connect termi- continuity between terminal #4
nals. NO on monitor panel side harness
end connector and terminal #2
on sensor side harness end
connector?
YES
When fuel sensor

connector is discon- YES
Gauge pointer swing nected, does pointer
over scale. swing back to zero
point? With fuel sensor discon-
·Key switch: ON nected, remove 20P connec-
tor from monitor panel. Is
there continuity between ter-
NO minal #2 on sensor side har-
ness end connector and vehi-
cle?
NO
YES
Disconnect fuel sensor, and

connect terminals between #1
Gauge pointer and #2 on harness end con-
swings unstably. nector. Does pointer swings to
the (FULL) side, and stays
stably?
·Key switch: ON
·Use a clip to connect termi-
nals. NO
T5-3-6
Fuel Gauge
FULL
1/2
EMPTY
Faulty fuel sensor.
YES Faulty monitor panel.
M190-01-012
Disconnected harness be-

tween monitor panel and Resistance of Fuel Sensor
NO fuel sensor.
Float Position Resistance (Ω)
FULL 10 +0
-4
Faulty fuel sensor.
1/2 38±5
+10
EMPTY 90 -0
Short-circuited harness be-
tween fuel gauge and fuel
sensor.
Connector
Fuel Sensor
3 2 1
Faulty monitor panel. Monitor Panel
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Faulty fuel sensor.
Faulty fuel gauge.
T5-3-7
40u (Type B), 50u: Refer to INTRODUCTION (IN-01)
NOTE: The troubleshooting here only covers the

malfunction of the fuel level gauge. For the
malfunction of the fuel level indicator, refer
to T5-3-15.
YES
Disconnect fuel level sensor con-

Fuel gauge monitor nector, and connect harness end
segment light does not terminal #1 to #2. Does all seg-
move from 1. ments on fuel gauge monitor light With fuel level sensor connector
·Buzzer does not up? disconnected, remove 12P con-
sound. nector from monitor panel. Is
·Key switch: ON there continuity between harness
·Use a clip to connect terminals. NO end connector #11 on monitor
panel and harness end connector
terminal #2 on sensor?
YES
When fuel level sensor

All segments on fuel connector is discon-
gauge monitor light up. nected, does only fuel
gauge monitor seg- YES
ment 1 lights up? With fuel level sensor connector
·Key switch: ON disconnected, disconnect 12P
connector from monitor panel. Is
NO
there continuity between termi-
nal #11 on harness end connec-
tor and vehicle?
NO
YES
Disconnect fuel level sensor con-
Fuel gauge monitor nector, and connect harness end
segment light moves connector #1 to terminal #2. Does
its position unsuitably. all fuel gauge monitor segments
light up stably?
·Key switch: ON
·Use a clip to connect terminals. NO
T5-3-8
Fuel Gauge
Lower Upper
Limit Limit
Faulty fuel level sensor.
YES Faulty fuel gauge or faulty

monitor controller. 1 2 3 4 5 6 7 8 9 10
Segment Number T573-05-02-003
Broken harness between

fuel gauge and fuel level
NO sensor.
Faulty fuel level sensor. Segment Number Resistance (̓)

F 10 13±2
9 20±2
8 27±2
7 34±2
6 40±2
Short-circuited harness 5 48±2
between fuel gauge and 4 56±2
fuel level sensor.
3 67±2
2 79±2
E 1
Faulty fuel gauge or faulty
monitor controller.
Connector
Fuel Level Sensor

Faulty fuel level sensor.
3 2 1
Monitor Panel
Faulty fuel gauge or faulty 40u (Type B), 50u
monitor controller.
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-9
MALFUNCTION OF ALTERNATOR
INDICATOR

NO Broken harness between
Is there continuity be- alternator and monitor.
tween harness end
NO
terminal on alternator
and below indicated
monitor panel terminal?
Disconnect terminal L on Burnt indicator bulb.
When key switch is alternator, and check if YES Or broken harness in
turned ON, alternator in- the voltage on harness monitor.
dicator does not light. end terminal is 12 V. ·40u (Type A): Terminal
·Engine: Stop #5
·Key switch: ON ·40u (Type B), 50u: Ter-
·Engine: Stop minal #3 Faulty alternator
YES (regulator).
YES Faulty alternator

(regulator).
Even if engine rotates, When alternator is dis-

indicator does not go out. connected, does indica-
tor go out?
·Key switch: ON
·Engine: Stop
Short-circuited harness
between alternator and
NO indicator.
Connector
Monitor Panel
40u (Type A)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Monitor Panel
40u (Type B), 50u
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-10
MALFUNCTION OF ENGINE OIL
PRESSURE INDICATOR

NOTE: 1 kgf/cm2=98.07 kPa
NOTE: The indicator comes on when engine oil
2
pressure is below 0.5±0.1 kgf/cm .
YES Faulty engine oil pressure

switch.
When oil pressure switch
is disconnected, and
When key switch is harness end terminal is
turned ON, indicator connected to vehicle, Burnt indicator bulb.
does not light. does indicator comes YES Or broken harness in
·Engine: Stop on? Reconnect the removed monitor.
·The pressure might not terminal.
·Key switch: ON When terminal #6 on
be released for 1 to 2
minutes just after the NO monitor panel is con-
engine stops. nected to vehicle, does
indicator comes on? Broken harness between
This is normal.
engine oil pressure switch
·Key switch: ON NO and indicator.
·Ground the connector to
the vehicle using a clip
without disconnecting.
·40u (Type A): Terminal #6
on 20P connector.
·40u (Type B), 50u: Termi-
nal #4 on 12P connector.
YES Faulty engine oil pressure

switch.
After engine is started, When oil pressure switch

indicator does not go out. is disconnected, does in-
dicator go out?
·Check if oil filter is ·Key switch: ON
clogged or not. ·Engine: Stop Short-circuited harness
between engine oil pres-
sure switch and indicator.
NO
Connector
Monitor Panel
40u (Type A) Monitor Panel
40u (Type B), 50u
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-11
MALFUNCTION OF OVERHEAT
INDICATOR
40u (Type A), 50u: Refer to INTRODUCTION (IN-01)

NOTE: The indicator comes on when coolant tem-

perature is above 110±3 °C (230±37 °F).
YES Faulty overheat switch.
When overheat switch

When key switch is is disconnected, and
turned ON, indicator harness end terminal is
does not light. connected to vehicle, Broken harness between
does indicator comes YES
overheat switch and indi-
·Engine: Stop on? Reconnect the discon- cator.
·Key switch: ON nected terminal.
When terminal #7 on
NO monitor panel is con-
nected to vehicle, does
indicator comes on? Burnt indicator bulb
NO blown.
·Key switch: ON
·Ground the connector
to the vehicle using a
clip without discon-
necting.

Indicator stays ON. is disconnected, does
indicator go out?
·Key switch: ON ·Key switch: ON
between overheat switch
NO and indicator.
Connector
Monitor Panel
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-3-12
40u (Type B), 50u: Refer to INTRODUCTION (IN-
01) regarding the corresponding serial numbers.
NOTE: The indicator comes on when coolant tem-

perature is above 110Ѱ 2 °C(230±35 °F)
and keeps its temperature more than 2
seconds.

Even though all seg- terminal is discon-
ments of coolant tem- nected, and harness
perature gauge monitor end terminal is con- Broken harness between
nected to vehicle, do YES
light up, they do not overheat switch and
blink for warning. segments blink for Reconnect the discon- monitor.
warning? nected terminal. When
·Engine: Running terminal #2 on monitor
·Buzzer does not ·Key switch: ON panel is connected to
NO
sound. vehicle, does indicator
blink? Faulty coolant tempera-
·Key switch: ON NO ture gauge or faulty moni-
·Ground the connector to tor controller.
Segments on coolant When overheat switch

temperature gauge terminal is discon-
monitor do not stop to nected, does indicator Short-circuited harness
YES
blink. stop to blink? With overheat switch between overheat switch
terminal disconnected, and monitor.
·Key switch: ON ·Key switch: ON remove 12P connector
from monitor panel. Is
NO there continuity be-
tween terminal #2 on
harness end connector Faulty coolant tempera-
and vehicle? NO ture gauge or faulty moni-
tor controller.
Connector ·Key switch: ON
Monitor Panel
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-13
MALFUNCTION OF FUEL LEVEL
INDICATOR
40u (Type A): Refer to INTRODUCTION (IN-01) re-

garding the corresponding serial numbers.
NOTE: The indicator comes on when remaining

fuel in the tank is below 6.0 L.

YES Faulty fuel sensor.
When fuel sensor is

disconnected, and
When key switch is terminal #3 on harness
turned ON, indicator end connector is con- Faulty diode, or broken
does not light. nected to vehicle, does YES harness between fuel
indicator comes on? Reconnect the dis- sensor and indicator.
·Engine: Stop connected terminal.
·Key switch: ON When terminal #9 on
monitor panel is con-
NO nected to vehicle,
does indicator comes
on? Burnt indicator bulb.
NO
·Key switch: ON
clip without disconnect-
ing.
YES Faulty fuel sensor.
Even if sufficient fuel When fuel sensor is

is in fuel tank, indica- disconnected, does in-
tor lights. dicator go out?
·Key switch: ON ·Key switch: ON
between fuel sensor
NO and indicator.
Connector
Fuel Sensor Monitor Panel
3 2 1 10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-3-14
YES Faulty fuel level sensor.
When fuel level sensor

connector is discon-
Even if fuel is empty, nected, and terminal
lowest segment does #3 on harness end
not blink for warning. connector is connected YES Broken harness between
to vehicle, does indica- Reconnect the discon- fuel level sensor and
·Key switch: ON monitor.
tor blink for warning? nected terminal. When
terminal #1 on monitor
·Key switch: ON NO panel is connected to
vehicle, does indicator
blink? Faulty fuel gauge or
·Key switch: ON NO faulty monitor controller.
·Ground the connector to
YES Faulty fuel level sensor.
Even if sufficient fuel is When fuel level sensor

With fuel level sensor
in fuel tank, segment is disconnected, does
connector disconnect, Short-circuited harness
blinks for warning. segment stop to blink? YES
disconnect 12P connec- between fuel level sensor
·Key switch: ON tor from monitor panel. and monitor.
·Key switch: ON
Is there continuity be-
tween terminal #1 on
NO harness end connector
and vehicle?
Faulty fuel gauge or
·Key switch: ON NO faulty monitor controller.
Connector
Monitor Panel Monitor Panel
3 2 1
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-15
MALFUNCTION OF AIR FILTER
RESTRICTION INDICATOR
YES Faulty air filter restric-

tion switch.
After air filter restriction
switch is once discon-
When key switch is
nected, when the
turned ON, indicator
switch is reconnected, Broken harness be-
does not light. YES
does indicator comes tween air filter restric-
·Engine: Stop on? Reconnect the switch. tion switch and indica-
When terminal #10 on tor .
·Key switch: ON
monitor panel is con-
NO nected to vehicle, does
indicator comes on?
Burnt indicator bulb.
·Key switch: ON NO
clip without disconnect-
ing.
YES Faulty air filter restric-

tion switch.
When air filter restric-

Indicator stays ON. tion switch is discon-
nected, does indicator
go out?
·Key switch: ON
·Check that air filter is ·Key switch: ON
dry. between air filter restric-
NO tion switch and indica-
tor.
Connector
Monitor Panel
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-3-16
MALFUNCTION OF BUZZER

Failure in engine oil lu-

YES brication system or fail-
ure in engine oil pres-
sure indicator system.
After engine is started, Does engine oil pres-

buzzer continues to sure indicator stay
sound. ON? YES Engine is overheated, or
failure in overheat indica-
·Engine: Running tor system.
Does overheat indica-
NO tor stay ON?
·Key switch: ON Short-circuited harness
between buzzer and di-
NO ode unit, or faulty buzzer.
Harness between buzzer

YES and diode unit is
opened, or failure in di-
ode unit.
Even if engine oil When negative termi-
pressure indicator or nal on buzzer is con-
overheat indicator nected to vehicle,
comes ON, buzzer does buzzer sound? YES Faulty buzzer.
does not sound.
·Engine: Running Disconnect buzzer
·Engine: Running check if the voltage at
to the vehicle using a positive terminal on
clip without discon- NO harness end connec-
necting. tor is 12 V. Broken power supply
·Engine: Running harness to positive ter-
NO minal on buzzer.
T5-3-17

Faulty engine oil lubrica-

YES tion system or faulty en-
gine oil pressure indica-
tor system (Refer to T5-
3-11).
After engine is started, Does engine oil pres-
buzzer continues to sure indicator stay ON? Engine is overheated, or
sound. YES faulty overheat indicator
·Engine: Running system (Refer to T5-3-
Does all segments of 13).
coolant temperature
NO gauge monitor blink?
Faulty monitor controller,
·Key switch: ON faulty buzzer, or faulty
NO buzzer circuit.
YES Not enough fuel, or faulty

fuel level indicator sys-
tem (Refer to T5-3-15).
Does the lowest seg-
YES ment of fuel gauge
monitor blink?
·Engine: Running Faulty monitor controller,
faulty buzzer, or faulty
After engine is started, Does buzzer stop after NO buzzer circuit.
buzzer continues to sounding 5 times?
sound.
·Engine: Running
Faulty monitor controller,
faulty buzzer, or faulty
NO buzzer circuit.
Even if engine oil pres-

sure indicator, overheat Faulty monitor controller,
indicator or fuel level faulty buzzer, or faulty
indicator lights up or buzzer circuit.
blinks, buzzer does not
sound.
·Engine: Running
T5-3-18
MALFUNCTION OF HOUR METER

Faulty alternator, or failure

YES
in alternator indicator sys-
tem. (Refer to T5-3-10)
While engine is run- Does alternator indica-

ning, hour meter does tor stay ON?
not operate.
·Engine: Running
Faulty hour meter.
(Faulty monitor controller
NO could be suspected for
40u Type B and 50u)
40u (Type B), 50u
Faulty hour meter, or

YES
faulty monitor controller.
Disconnect L terminal
Hour meter operates on alternator. Is there
with key switch turned continuity between
ON. harness end terminal
and terminal #3 on
monitor panel?
Broken harness between
NO monitor panel and alterna-
tor.
T5-3-19
(Blank)
T5-3-20
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Be sure to remove the negative terminals from the
batteries first when taking wire harnesses and
connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting. Code Color Code Color
2. Color coding of wire harnesses. R Red W White
The color codes of the wire harnesses in the L Blue G Green
electrical system are shown below. Or Orange Lg Light Green
In cases on the design sheet where two colors are Y Yellow B Black
indicated for one wire, the left initial stands for the Br Brown P Pink
Gr Gray V Violet
base color, while the right initial stands for the
marking color.
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials "O" and "Or" both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure
not to confuse them with color coded
wires
Right Wrong
3. Precautions for connecting and disconnecting
terminal connectors.
(1) When disconnecting harnesses, grasp them by
their connectors. Do not pull on the wire itself.
Be sure to release the lock first before ȴȑȐȗȍȐȗȍȐȖȍȐȐȑ
attempting to separate connectors, if a lock is

provided.
(2) Water-resistant connectors keep water out so
that if water enters them, water will not easily
Right
drain from them. When checking water
Rust
resistant connectors, take extra care not to
allow water to enter the connectors. In case Wrong
(Deformation)
water should enter the connectors, reconnect
only after the connectors are thoroughly dried.
Wrong (Coming off, Separation)
(3) Before connecting terminal connectors, check
that no terminals are bent or coming off. In ȴȑȐȗȍȐȗȍȐȖȍȐȐȒ
addition, as, most connectors are made of

brass, check that no terminals are rusting.
(4) When connecting terminal connectors
provided with a lock, be sure to insert them
together until the lock "clicks."
T5-4-1
4. Precaution for using a circuit tester.
Wind a piece of wire Tester Probe
(1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current
polarity.
Sharpen the end of the wire
(2) Before starting the connector test, always ȴȑȐȗȍȐȗȍȐȖȍȐȐȓ
check the connector terminal numbers,
referring to the circuit diagram.
When the connector size is very small, and the
standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
T5-4-2
FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse,

and such fine cracks are very hard to detect by visual
inspection.
Checking fuse continuity with a tester is far superior to
sight inspection.
1. Turn the key switch ON

When key switch is turned ON, the power is
supplied to all circuit from key switch R2 and Acc
1
Terminal (Refer to Circuit Diagram).
2. Remove the fuse box cover and set the correct 2
voltage measurement range of the tester. 3
(Measurement range: 0 to 14.5 V)
3. Connect the negative probe to the vehicle ground,
and touch the outside terminal of each fuse with 4
the positive probe of the tester. 5
When normal continuity of a fuse is intact, the
tester will indicate 12 volts.
M585-07-043
Number Capacity Connected to

1 15A Air Conditioner, Window Washer, Wiper Motor, Wiper Relay
Travel Speed Changeover Solenoid Valve, Horn Relay, Pilot Shuft-Off Valve Relay, Auto
2 15A
Idle Unit
3 20A Work Light Relay, Room Lamp
4 15A Monitor Panel, Fuel Pump
5 20A Air Conditioner, Heater
T5-4-3
BATTERY VOLTAGE CHECK
1. Turn key switch OFF

2. Measure between battery plus terminal and the
ground (vehicle) using a voltmeter.
Correct Voltage Reading: 12 V
NOTE: If voltage is abnormal, re-charge or replace

the battery.
3. Start the engine. V

4. Measure the battery voltage again.
Correct Voltage Reading: Approximately 14.5 V
NOTE: If voltage is abnormal, check the charging

system.
T505-07-01-002
T5-4-4
VOLTAGE CHECK
Turn switches ON so that the specified voltage is

supplied to the check point. Measure voltage.
Diagnose the circuit by checking it specified voltage is
supplied or not.
12 volt circuit Evaluation

(example: the horn circuit) Measured voltage must equal 12 V (battery voltage).
Check the circuit in either the upstream (from the If the measured voltage is less than the battery
power source) or downstream (from the accessory) voltage by 0.5 V or more, some incorrect contacts
order to locate the failed section in the circuit. may exist at connectors.
Set the following check conditions:
• Key switch position:
ON (When checking points (4) to (8)
• Horn switch position:
ON (When checking points (9) or (10)
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
Connected to the checking point
• Power source:
Batteries (12 volts)
B BR ACC R2 C R1
Fusible Link
OFF
ON
START
1 2
4
3
5
8 7 9
10
An example of the checking order (horn circuit)

1 2 3 4 5 6 7 8 9 10
T5-4-5
CONTINUITY CHECK Harness
A
Single-line continuity check Ɂ
Disconnect both end connectors of the harness and
check continuity between ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity ̓
NOTE: When the one end connector is far apart Connect to the
vehicle frame. A
from the other, connect one end of Ɂ
connector (A) or the vehicle frame using a
clip. Then, check continuity of the harness
through the vehicle frame as illustrated.
Connect to the
vehicle frame. ̓
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and Short circuit
check continuity between one end connector of the ѱ between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: ̓ frame.
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
ȴȑȐȗȍȐȗȍȐȕȍȐȐȓ
Multi-line continuity check ȀFirst Connected
Disconnect both end connectors of the harness, and
connect two terminals (A) and (B), using a jumper
wire at one end of the connector, as illustrated. Then, ȡ Ɂ
check continuity between terminals (a) and (b) at the Ȣ ɂ
other connector. If the ohm-meter reading is ҁ̓, ȣ Ƀ
either line (A)-(a), or (B)-(b) is in discontinuity. To find
out which line is discontinued, conduct the single line Second Connected
continuity check on both lines individually, or after
changing the connected terminals from (A)-(B) to (A)-
(C). Check continuity once more between terminals ̓
(a) and (c).
NOTE: By Conducting the multi-line continuity ȴȑȐȗȍȐȗȍȐȕȍȐȐȔ
check twice, it is possible to find out which

line is discontinued. With terminals (A) and Short circuit between harnesses.
(C) shortcircuited, check continuity
A Ɂ
between terminals (a) and (c). B ѱ ɂ
C Ƀ
If the ohm-meter reading is:
0 Ω = Line (B)-(b) has discontinuity.
∞ Ω = Line (A)-(a) has discontinuity.
Multi-lines short circuit check ̓

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or (C).
If the ohm-metor reading is:
0 Ω = Short circuit exists between the lines. ȴȑȐȗȍȐȗȍȐȕȍȐȐȕ
∞ Ω = No Short circuit exists between the lines.
T5-4-6
5V System Circuit Power Source Signal or Ground
• Voltage between Terminal No. 1 and the vehicle
Turn OFF the key switch, and disconnect the ȑ Ȓ
Two-Polarities
connector. Measure the voltage between terminal
No. 1 (5 V power supply) on the machine harness
end connector and the vehicle (ground) under the
following conditions.
Key Switch: ON V
Black (Negative) Terminal of Tester: Vehicle
(Ground)
Red (Positive) Terminal of Tester: Terminal No. 1
Power ȴȑȐȗȍȐȗȍȐȕȍȐȐȖ
Standard Voltage: If 5±0.5 V, the circuit is normal Source Signal Ground
up to terminal No. 1.
Three-Polarities ȑ Ȓ ȓ
• Voltage between Terminal No.1 and Ground

Terminal
Turn OFF the key switch, and disconnect the ȴȑȐȗȍȐȗȍȐȕȍȐȐȗ
sensor connector. Measure the voltage between

terminal No. 1 (5 V power supply) on the machine ȑ Ȓ
harness end connector and the ground terminal Two-Polarities
(terminal No. 2 for two-polarities or terminal No. 3
for three-polarities connector) under the following
conditions. V
Key Switch: ON
Black (Negative) Terminal of Tester: Connected to
the ground Terminal (Terminal No. 2 or No. 3)
Red (Positive) Terminal of Tester: Connect to
Terminal No. 1 ȴȑȐȗȍȐȗȍȐȕȍȐȐȘ
Standard Voltage: If 5±0.5 V, the circuit is normal ȑ Ȓ ȓ

up to terminal No. 1 or ground terminal (terminal Three-Polarities
No. 2 or No. 3).
ȴȑȐȗȍȐȗȍȐȕȍȐȐș
T5-4-7
(Blank)
T5-4-8
Attach to Vol.No.T585E-00
EX40u (Serial Number 1001 or later) HYDRAULIC CIRCUIT Hitachi Authorized Dealer Use Only
Travel Device
Swing Device
Blade Cylinder
Bucket Cylinder
Arm Cylinder
Boom Cylinder
Boom Swing Pilot Valve (R)
Cylinder Boom Bucket
Raise Lower Roll-Out Roll-In
Center Joint
Pilot Valve (L)

Arm Swing
Travel Boom 2 Roll-Out Roll-In Left Right
(L)
Auto-Idle Port
Boom
Blade Swing Aux. Arm Bucket Boom 1 Travel
Swing
(R)
Boom Combinating Port (IN)

Boom Combinating Port (OUT)
Pump Device
Pilot Filter
Oil Cooler
ISUZU
Deisel Engine
100 Mesh
Hyd. Oil Tank

EX40u (Serial No.from 101 to 1000) MAIN HARNESS
Lock
Panel Gauge
Connector
Diode a
Key Switch
Panel Gauge Diode b
Key Switch
DETAIL
Key Switch Pilot Shut-Off Switch (L)
Key Switch
Key Switch
Key Switch
Diode b
Diode a
Diode b @Travel Speed
Diode a Diode b Horn Switch Changeover Switch
Tie up by tape Auto-Idle Auto-Idle

Panel Power
Pilot Shut-Off Switch (R)
Cab/Radio A/C
Aux. Power Aux. Power

AI Panel
Relay a Cab/ A/C Body Ground

Radio
AI Power
Relay a
Relay b Fuse Box Tie up Tie up

by tape by tape
Relay c
Diode a
Tie up
Key Switch by tape
Starter Relay 1 Diode c

Relay c Glow Relay Fuel Sensor
Relay c
Glow Timer
Work Light
Relay b
@(Boom)
Battery
Relay a
Relay a Boom Light
Relay b Horn Engine Harness
Relay b Horn SW Engine Harness
Base Light
Relay c
Diode c
Diode c Travel Speed Work Light (Base)
Body Ground
Horn SW Horn
Key Switch Horn
Relay a Relay b @Relay c Starter Relay 2
(Light) (Horn) (Pilot Shut-Off)
Key Switch Travel Speed
Body Ground
LV Bypass
LV Bypass
Tie up by tape
EX40u,EX50u AIR CONDITIONER HARNESS
Power ( )
Thermo Amplifier
Power (+)
Power (+)
Thermister
Receiver Drier
Relay
Full Open
Full Close
Compressor
Water Valve Actuator
Resister
Blower Fan Motor
Air Conditioner Unit
HI
MID
LOW
A/C SW Volume Micro SW
Fan Switch
Control Panel
Solenoid Valve
Relay for Solenoid Valve

EX40u (Serial No.from 101 to 1000) ELECTRICAL CIRCUIT
CONNECTOR TERMINAL LOCATIONS
(Drawing are shown in face
view of the connector)
Relay a Relay b @ @ @R e l a y c Starter Glow Starter Cab, Radio (Option)

(Work light) (Horn) (Pilot shut-off) Relay 2 Timer Glow relay Relay 1
Connectors Fuel Sensor Engine Harness
Engine Harness
(Male side)
(Engine harness side) @ @ @
Cab
Heater
A/C
Heater Heater Heater SW

Battery Terminal Engine Stop Engine Harness Engine Harness Heater Air Dome Light
Panel Gauge
(Male side) Alternator Solenoid Fuel Pump @ (Main harness side) (Female side) Fuse Box Conditioner
Panel Gauge
Speaker
Hour Meter
Window Washer
Slide SW. 2
Battery Terminal Slide SW. 1

(Female side) Diode Unit Diode Unit Diode Unit
Coolant
Fuel
@D i o d e c @D i o d e b Diode a Wiper Motor
Temp.
Key Switch Light SW.
Low Fuel
Alternator
Monitor
Cleaner
Overheat
Heater
Eng.Oil.
Wiper
Glow Signal
Travel Speed
Valve
Light
Horn
Level
Press.
Wiper SW.
A/C
A/C
Air
Buzzer
Timer
Unit
START
Relay
Pilot Shut-Off Pilot Shut-Off
Switch (Right) Switch (Left) Travel Speed Pilot Shut-Off
Radio
Radio
Light
Fusible Link Power
Back-up
Battery
Auto-Decel.
Starter Decel.
Accel.
12V
Motor (+)
Motor ( - )
Acceleration
Actuator
Alternator
12V - 35A
Diode a @ @ Diode b
Engine Stop
Solenoid
Fuel Pump
Coolant
Temperature
Sensor
(For gauge)
Engine Oil
Pressure
Switch
Overheat Auto-Idle Unit

Switch
Air Cleaner SYMBOL

Restriction
Switch Body Plug
Diode c Ground Connector
Glow Plug Harness Flat

Ground Terminal
Waterproof
Connector Plug
Flat Terminal
Screw (With lock)
Terminal
Coolant
Temperature
Sensor
(For glow
timer)
Starter Relay 2 Glow Timer Glow Relay

Horn
Solenoid Valve Travel Speed
Starter Relay 1 @R e l a y a Relay b @ @R e l a y c
Travel Speed Pilot Shut-Off Pilot Shut-Off (Work light) (Horn) (Pilot shut-off)
Changeover Switch (Right) Switch (Left)
Switch Work Light Work Light
Horn Switch Fuel Sensor
Pilot Shut-Off
EX40u (Serial Number 1001 or later), EX50u ELECTRICAL CIRCUIT
Battery Harness
CONNECTOR TERMINAL LOCATIONS (Male side)
(Drawing are shown in face view
Starter Glow Starter Relay 1 Cab, Radio
of the connector) Relay a Relay b Relay c Relay 2 Glow Timer BOX Harness Side
Engine Harness (work light) (Horn) (Pilot Shut-off) Relay Housing
Battery Harness
Terminal
(Male Side) Lubber Plug (Female side)
Connectors Fuel Sensor CN Engine Harness
(Engine harness side)
A/C Cab
Heater
Heater Air Heater Heater Heater Switch Main Harness Side Heater Switch
Panel CN F Housing
Conditioner
BOX Harness side Terminal
Battery Terminal CN E(BOX harness side) Engine Harness Lubber Plug Dome Light
Engine Stop
(Female side)
Fuse Box
(Male Side) Alternator Solenoid Fuel Pump
Panel Gauge
Speaker
Buzzer Monitor
Illumination
Window Washer
Buzzer
Fuel
Circuit
Coolant Temp.
Power Supply
Battery Terminal
(Female side) Hour Meter
Glow Glow Relay Wiper Motor
Circuit
Key Switch Circuit
(Female side) (Male side)
Relay
Monitor
Eng. Oil. Press.

Alternator
Glow Signal
Circuit
Heater
Wiper
B Switch
Valve
Light
Horn
A/C
A/C
LED
Low Fuel Level

Circuit
Power supply
Coolant Temp.
Light SW.
Light
START Relay
Alternator
AI SW.
Wiper SW
Fuel
Pilot Shut-off Pilot Shut-off
Switch(Right) Switch(Left) Travel Speed Pilot Shut-off
Radio
Radio
Light
Fusible Link Power
Back-up
Aux. Power(5A or less)
Battery
Starter
Auto-Decel
Decel
Accel
Motor [+]
Motor [ ]
Acceleration
Actuator
Alternator
ISUZU
Engine Stop
Solenoid
Fuel Pump
Coolant Temperature
Sensor(For gauge)
Engine Oil Pressure

Switch
Coolant Auto-Idle Unit

Temperature
Switch
SYMBOL
Body Plug
Ground Connector
Glow Plug Harness Flat
Ground Terminal
Connector Water
Proof Plug
Screw Flat Terminal
Coolant (with lock)
Tirminal
Temperature
Sensor
(For glow timer)
Horn Starter Relay 2 Glow Timer

Solenoid Valve Glow Relay
Travel Speed Starter Relay 1 Relay a Relay b Relay c
Travel Speed Pilot Pilot
(work light) (Horn) (Pilot Shut-off)
Changeover Shut-off Shut-off
Horn Switch Fuel Sensor Work light Work light
Switch Switch(Right) Switch(Left)
Pilot Shut-Off
EX40u ,EX50u ENGINE HARNESS
Main Harness
Solenoid Valve
Solenoid Valve for Travel Speed
for Pilot Shut-Off Changeover
Main Harness
Starter
Engine Stop Solenoid

Starter Fuel Pump
Alterna-
tor LG
Alterna-
tor L Air Cleaner Restriction SW
Engine Oil
Pressure SW
Coolant Temp. Gauge Coolant Temp.
Hyd. Press. SW Gauge
Coolant Temp. SW Alternator B
Air Cleaner Rest. SW
Air Cleaner Rest. SW
Coolant Temp. Sensor
Alternator B
Coolant Temp.
Glow Plug Sensor (for glow timer)
Coolant Temp. SW
Glow Plug
Alternator
Coolant Temp. SW
EX40u (Serial Number 1001 or later),,EX50u MAIN HARNESS
Key Switch
Panel Gauge
AMP
Key Switch Auto-Idle Auto-Idle

Panel Power
Water Proof Water Proof

Key Switch
Key Switch
Key Switch
Glow Relay
Glow Timer
Cab/Radio
A/C
Aux. Power
Water Proof
Aux. Power Cab/ A/C

AI Panel Radio
Relay a
AI Power Fuse Box
Relay a Tie up by tape
Relay b
Housing
Terminal
Lubber Plug
Relay c Tie up by tape Tie up by tape
Key Switch
Starter Relay 2
Relay c
Relay c
Relay b Engine Harness

Relay a Battery Harness
Relay a
Relay b
Relay b
Relay c
Starter Relay 1
Relay a Relay b Relay C
(Light) (Horn) (Pilot Shut-off)
Key Switch
Key Switch
Water Proof
LV Bypass
LV Bypass Water Proof

LV Bypass
Tie up by tape
EX40u (Serial Number 1001 or later), EX50u FRAME HARNESS
Pilot Shut-Off Switch (L)
Travel Speed
Horn Switch Changeover Switch
Water Proof Water Proof Water Proof Water Proof
Pilot Shut-off Switch (R)
Boom Light
Body Ground
Horn
Horn SW
Body Ground
Housing
Travel Speed Terminal
Lubber Plug
Body Ground
Horn
Horn SW
Travel Speed
Base Light
Fuel Sensor
Boom Light
Water Proof
Work Light (Base)
Water Proof
Horn
Terminal
Sleeve
EX50u HYDRAULIC CIRCUIT Hitachi Authorized Dealer Use Only
Travel Device
Swing Device
Blade Cylinder
Bucket Cylinder
Arm Cylinder
Boom Cylinder
Boom Swing Pilot Valve (R)
Cylinder Boom Bucket
Raise Lower Roll-Out Roll-In
Center Joint
Pilot Valve (L)

Arm Swing
Travel Boom Roll-Out Roll-In Left Right
(L) 2
Auto-Idle Port
Boom
Blade Swing Aux. Arm Bucket Boom 1 Travel
Swing (R)
Boom Combinating Port (OUT) Boom Combinating Port (IN)
Pump Device
Pilot Filter
Oil Cooler
ISUZU
Deisel Engine
100 Mesh
Hyd. Oil Tank

EX40u (Serial No.from 101 to 1000) HYDRAULIC CIRCUIT
Hitachi Authorized Dealer Use Only
Travel Device
Swing Device
Blade Cylinder
Bucket Cylinder
Arm Cylinder
Boom Cylinder Pilot Valve (R)

Boom Swing Boom Bucket
Cylinder Roll Roll
Raise Lower -Out -In
Center Joint
Pilot Valve (L)

Arm Swing
Roll Roll Left Right
-Out -In
Travel Boom 2
(L)
Boom Aux. Arm Bucket Boom 1 Travel

Blade Swing
Swing (R)
Auto-Idle Port
Swing Parking Port Boom Combinating
Port (OUT)
Pump Device
Pilot Filter
Oil Cooler
ISUZU
Deisel Engine
100 Mesh Solenoid Valve
Hyd. Oil Tank

Workshop Manual
EX40u, 50u
SECTION 1
GENERAL INFORMATION
—CONTENTS—
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Group 2 Tightening
Tightening Torque Specification.............. W1-2-1
Torque Chart .......................................... W1-2-2
Piping Joint ............................................ W1-2-5
585W-1-1
ϑBlankϒ
585W-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING • If a part or component cannot be removed after its
AND ASSEMBLING securing nuts and bolts are removed, do not at-
tempt to remove it forcibly. Find the cause(s), then
Preparations for Disassembling take appropriate measures to remove it.
• Orderly arrange disassembled parts. Put marks
• Clean the Machine and tags as necessary.
• Store common parts, such as nuts and bolts with
Thoroughly wash the machine before bringing it into reference to where they are to be used and in a
the shop. Bringing a dirty machine into the shop may manner that will prevent loss.
cause machine components to be contaminated • Inspect contact or sliding surfaces of
during disassembling/assembling, resulting in disassembled parts for abnormal wear, sticking,
damage to machine components, as well as or other damage.
decreased efficiency in service work. • Measure and record degrees of wear and
clearances.
• Inspect the Machine

• Precautions for Assembling
Be sure to thoroughly understand disassembling
procedures beforehand, to help avoid incorrect • Be sure to clean all parts and inspect them for any
disassembling of components as well as the damage. If any damage is found on a part, repair
purchase of unnecessary service parts. or replace it with a new one.
Check and record the items listed below to help • Dirt or debris on contact or sliding surfaces may
prevent problems from occurring in the future. shorten the service life of the machine. Take care
not to contaminate any contact or sliding surfaces
• The machine model, machine serial number, and of the parts to be assembled.
hour meter reading. • To prevent parts from seizure, coat with clean
• Reason for disassembly (symptoms, failed parts, hydraulic oil or gear oil to the internal components,
and causes). especially sliding surfaces, when assembling.
• Clogging of filters and oil or air leaks, if any. • Always replace O-rings, backup rings and oil
• Loose or damaged parts. seals with new ones, after removing them, and
coat with grease before assembling.
• Be sure that liquid-gasket-applied surfaces are
• Prepare and Clean Tools and Disassembly Area clean and dry.
• If an anti-corrosive agent has been used on a new
Prepare tools to be used and an area for part, be sure to thoroughly clean the part.
disassembling and for disassembled parts. Clean • Utilize matching marks when assembling.
the tools and repair area. • Be sure to use designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
Precautions for Disassembling and Assembling disassembling/assembling. After assembling is
complete, count the number of tools to make sure
• Precautions for Disassembling that no tools are left in the machine.
• Make sure to place caps or plugs on all

disconnected hose ends to prevent
contamination.
• Clean the outside of the part before
disassembling, then place it on a work stand.
• Before disassembling, drain the gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
catching and storing drained fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
W1-1-1
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and
installation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system in
the following procedures:
• Bleeding Air from Hydraulic Pump
IMPORTANT: If the engine is started with air

trapped in the hydraulic pump
housing, damage to the pump may
result. Be sure to bleed air before
starting the engine.
• Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the
engine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each
operation (never fully stroke the cylinders during
initial operation stage). As the pilot oil circuit has
an air bleed device, air trapped in the pilot oil
circuit will be bled while performing the above
operation for approx. 5 minutes.
• Reposition the front attachment to check hydraulic
oil level.
• Stop the engine. Recheck hydraulic oil level.
Replenish oil as necessary.
ȴȕȗȐȍȐȖȍȐȓȍȐȑȑ
W1-1-2
Floating Seal Precautions
A
1. In general, replace the floating seal with a new one.
If the floating 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 seal ring face (A) for scuffing,

scoring, corrosion, deformation or uneven B W105-03-05-019
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 floating seal (A) and seal mounting

bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Correct
(2) Clean the floating seal and seal mounting

bores, as dust on them tends to enter the Incorrect
Twist of
O-ring
floating seal when installing it.
Bent of
(3) Check that the O-ring is not twisted, and that it O-ring
is installed correctly on the seal ring.
(4) After installing the floating seal, check that seal ȷȑȐȕȍȐȓȍȐȕȍȐȒȐ
surface (C) is parallel with seal mating face (D)

D
by measuring the distances at point (a) and (b),
as illustrated. If these distances differ, correct Correct IIncorrect
C
the O-ring seating. a a
B
b b
aҧb aҐb ȷȑȑȐȍȐȓȍȐȕȍȐȐȔ
W1-1-3
ϑBlankϒ
W1-1-4
GENERAL INFORMATION / Tightening
TIGHTENING TORQUE SPECIFICATIONS
Bolts and Nuts of Machine: Standard Torque Chart

Wrench Torque
Bolt Dia
No. Descriptions Q'ty Size
mm N]m kgf]m Ibf⋅ft
mm
ȥɎɇɉɎɅȀɃɕɓɈɉɏɎȀɒɕɂɂɅɒȀɍɏɕɎɔɉɎɇȀɎɕɔ 14 4 22 137 14 101
1
ȥɎɇɉɎɅȀɃɕɓɈɉɏɎȀɒɕɂɂɅɒȀɍɏɕɎɔɉɎɇȀɂɏɌɔȌȀɎɕɔ 12 2 19 88 9 65
10 9 17 49 5 36
ȥɎɇɉɎɅȀɂɒɁɃɋɅɔȀɍɏɕɎɔɉɎɇȀɂɏɌɔȀȈȦɒɏɎɔȉȀȊ 14 1 22 137 14 101
2
ȥɎɇɉɎɅȀɂɒɁɃɋɅɔȀɍɏɕɎɔɉɎɇȀɂɏɌɔȀȈȲɅɁɒȉȊ 10 8 17 49 5 36
3 ȨəɄɒɁɕɌɉɃȀɏɉɌȀɔɁɎɋȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 12 4 19 88 9 65
4 ȦɕɅɌȀɔɁɎɋȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 10 2 17 20 2 15
19 29.5 3 22
5 ȨəɄɒɁɕɌɉɃȀɈɏɓɅɓȀɁɎɄȀɕɎɉɏɎȀɊɏɉɎɔɓ 22 39 4 29
27 64 6.5 47
6 ȰɕɍɐȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 12 2 19 88 9 65
7 ȰɕɍɐȀɃɏɖɅɒȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 10 6 17 49 5 36
ȣɏɎɔɒɏɌȀɖɁɌɖɅȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 10 4 17 49 5 36
8
ȣɏɎɔɒɏɌȀɖɁɌɖɅȀɂɒɁɃɋɅɔȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 12 4 19 88 9 65
9 ȳɗɉɎɇȀɄɅɖɉɃɅȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 16 8 24 205 21 151
ȢɁɔɔɅɒəȀɍɏɕɎɔɉɎɇȀɎɕɔ 6 2 10 5 0.5 3.7
10
ȢɁɔɔɅɒəȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 10 2 17 49 5 36
11 ȣɁɎɏɐəȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 16 4 24 205 21 151
12 ȣɁɂȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 16 4 24 205 21 151
ȳɗɉɎɇȀɂɅɁɒɉɎɇȀɍɏɕɎɔɉɎɇȀɂɏɌɔ Swing Device 14 22 22 175 18 129
13 Track 12 20 19 108 11 80
14 ȴɒɁɖɅɌȀɄɅɖɉɃɅȀɍɏɕɎɔɉɎɇȀɂɏɌɔȀȊ 12 26 19 128 13 94
15 ȳɐɒɏɃɋɅɔȀɍɏɕɎɔɉɎɇȀɂɏɌɔȊ 12 24 19 128 13 94
16 ȵɐɐɅɒȀɒɏɌɌɅɒȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 14 2 22 137 14 101
17 ȬɏɗɅɒȀɒɏɌɌɅɒȀɍɏɕɎɔɉɎɇȀɂɏɌɔȊ 18 8 27 451 46 333
6 10 5 0.5 3.7
18 ȣɏɖɅɒȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 8 13 9.8 1 7.2
10 17 49 5 36
16 1 24 208 21 153
ȔȐɕ
19 ȣɏɕɎɔɅɒɗɅɉɇɈɔȀɍɏɕɎɔɉɎɇȀɂɏɌɔ 18 2 27 295 30 218
50u 20 3 30 390 40 289
NOTE: (1) Apply lubricant (i.e. white zinc B (3) Apply LOCTITE to threads of fasteners
dissolved into spindle oil) to reduce their indicated with * marks in the above
friction coefficients. chart.
(2) Remove rust, dirt, and dust before
installing fasteners.
W1-2-1
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and
procedures can create safety hazards. For
loosening and tightening nuts and bolts, use
correct size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them ȳȡȍȐȔȐ
correctly when assembling the machine or

components.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart

Hexagon T Bolt, Socket bolt H Bolt M Bolt
Bolt Wrench
Wrench
Dia. Size N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft
Size
M 8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2
M 10 17 8 64 6.5 47 49 5 36 19.5 2 14.5
M 12 19 10 108 11 80 88 9 65 34 3.5 25.5
M 14 22 12 175 18 130 137 14 101 54 5.5 40
M 16 24 14 265 27 195 205 21 152 78 8 58
M 18 27 14 390 40 290 295 30 220 118 12 87
M 20 30 17 540 55 400 390 40 290 167 17 123
M 22 32 17 740 75 540 540 55 400 215 22 159
M 24 36 19 930 95 690 690 70 505 275 28 205
M 27 41 19 1370 140 1010 1030 105 760 390 40 290
M 30 46 22 1910 195 1410 1420 145 1050 540 55 400
M 33 50 24 2550 260 1880 1910 195 1410 740 75 540
M 36 55 27 3140 320 2310 2400 245 1770 930 95 690
W1-2-3
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to nuts
and bolts to reduce their friction
coefficients.
The plated bolts require no
lubricant.
2. Torque tolerance is Ѱ 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts that
are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific
application.
5. Make sure that nut and bolt
threads are clean before
installing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.
Tighten from center and
Equally tighten upper and lower 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
ȷȑȐȕȍȐȑȍȐȑȍȐȐȓ
W1-2-4
Service Recommendations for Spilt Flange
IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal
extrusion. If defects cannot be
polished out, replace the
ȷȑȐȕȍȐȑȍȐȑȍȐȑȕ
component.
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
centered and perpendicular to ȷȑȐȕȍȐȑȍȐȑȍȐȑȖ
the port. Hand-tighten bolts to

hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and
diagonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes ȷȑȐȕȍȐȑȍȐȑȍȐȐȘ
RIGHT WRONG
tightening of one bolt fully before
tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.
Bend along edge sharply Do not bend it round
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
holes in the bolt and nut while Bend along edge sharply
ȷȑȐȕȍȐȑȍȐȑȍȐȐș
tightening, not while loosening. WRONG
RIGHT RIGHT
• 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
PIPING JOINT 1 4 3 5 2
Union Joint
Metal sealing surfaces (4) and (5) of adaptor (l) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
ȭȒȐȒȍȐȗȍȐȕȑ
Joint Body
IMPORTANT: 1. Do not over-tighten nut (3).
Excessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be
sure to tighten nut (3) to 37ѯ
specifications.
30ѯ
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them Male Union Joint Female Union Joint
when connecting/disconnecting.
ȷȑȐȕȍȐȑȍȐȑȍȐȑȗ
Wrench Size Wrench Size Tightening

Description mm mm Torque
Union Nut Hose Fittings N]m (kgf]m,Ibf⋅ft)
30ѯmale 19 19 59 (6,44)
22 22 98 (10,72)
27 27 118 (12,87)
36 36 235 (24,173)
41 41 295 (30,218)
50 50 490 (50,361)
60 60 670 (68,494)
70 70 980 (100,723)
37ѯfemale 19 17 44 (4.5,32)
22 19 59 (6,44)
27 22 118 (12,87)
36 30,32 235 (24,173)
41 36 295 (30,218)
50 46 490 (50,361)
NOTE: Tightening torque of 37ѯmale coupling without union is similar
to tightening torque of 37ѯfemale.
W1-2-6
O-ring Seal Joint 7 6 9
O-ring (6) seats against the end face of adaptor (7) to

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

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 10
in O-ring groove (e). Tightening ȭȑȐȔȍȐȗȍȐȓȓ
nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening
groove (e) or sealing surface (10). mm mm Torque
Damage to O-ring (6) will cause Union Nut Hose Fittings N]m (kgf]m,Ibf⋅ft)
oil leakage. 19 17 59 (6,44)
4. If nut (9) is loose and oil is 22 19 98 (10,72)
leaking, do not re-tighten nut (9). 27 22 118 (12,87)
Replace O-ring (6) with a new one 36 30,32 235 (24,173)
and check that O-ring (6) is 41 36 295 (30,218)
correctly seated in place, tighten 50 46 490 (50,361)
nut (9).
W1-2-7
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30ѯ
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread

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

Wrench Size Tightening
mm Torque
Hose Fittings N]m (kgf]m,Ibf⋅ft)
17,19 59 (6,44)
19,22 98 (10,72)
27,22 118 (12,87)
36,32 235 (24,173)
41 295 (30,218)
50 490 (50,301)
60 670 (68,494)
70 980 (100,723)
Seal Tape Application
Seal tape is used to seal clearances between male and Internal Thread
female threads, so as to prevent any leaks between
threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap. External Thread
Clearance
• Application Procedure
ȷȑȐȕȍȐȑȍȐȑȍȐȑș
Confirm that the thread surface is clean and, free of dirt

Leave one to two pitch threads uncovered
or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs

depending on the type of clamp.
T-Bolt Type Band Clamp: 4.4 N]m ( 0.45 kgf]m, ȭȑȑȔȍȐȗȍȐȔȑ
3.25 lbf]ft )
Worm Gear Type Band Clamp:5.9 to 6.9 N]m (0.6 to
T-Bolt Type Worm Gear Type
0.7 kg]m, 4.3 to 5.1 lbf]ft)
ȀȭȑȑȔȍȐȗȍȐȔȓ ȀȀȭȑȑȔȍȐȗȍȐȔȒ
W1-2-8
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, possibly resulting in a fire on the
machine.
Do not install hoses kinked. Application of ȷȑȐȕȍȐȑȍȐȑȍȐȑȑ

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print WRONG RIGHT
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other
If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. ȷȑȐȕȍȐȑȍȐȑȍȐȑȒ
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
ȷȑȐȕȍȐȑȍȐȑȍȐȑȓ
WRONG RIGHT
Rubbing Against
Each Other Clamp
ȷȑȐȕȍȐȑȍȐȑȍȐȑȔ
W1-2-9
SECTION 2
UPPERSTRUCTURE
—CONTENTS—
Group 1 Canopy Group 6 Pilot Valve
Remove and Install Canopy............... W2-1-1 Remove and Install Pilot Valve ............ W2-6-1
Disassemble Pilot Valve ...................... W2-6-4
Group 2 Counterweight Assemble Pilot Valve ........................... W2-6-8
Remove and Install
Counterweight ................................. W2-2-1 Group 7 Solenoid Valve
Disassemble and Assemble
Group 3 Pump Device Solenoid Valve ...................................... W2-7-1
Remove and Install
Pump Device ................................... W2-3-1
Disassemble Pump Device................ W2-3-3
Assemble Pump Device .................... W2-3-8
Maintenance Standard .................... W2-3-14
Group 4 Control Valve

Remove and Install
Control Valve ................................... W2-4-1
Disassemble And Assemble
Control Valve ................................... W2-4-4
Group 5 Swing Device

Remove and Install
Swing Device................................... W2-5-1
Disassemble Swing
Reduction Gear ............................... W2-5-4
Assemble Swing
Reduction Gear ............................... W2-5-6
Disassemble Swing Motor ............... W2-5-12
Assemble Swing Motor .................... W2-5-14
Disassemble And Assemble
Parking Brake Switch Valve ........... W2-5-18
Maintenance Standards................... W2-5-20
585W-2-1
ϑBlankϒ
585W-2-2
UPPERSTRUCTURE / Canopy
REMOVE AND INSTALL CANOPY
2
(The illustration shows 40u type A) ... Refer to
INTRODUCTION (IN-01) for the corresponding serial 1
numbers.
Removal
1. Attach sling belt (2) to canopy (1).
ȷȕȒȗȍȐȒȍȐȑȍȐȐȑ
3
2. Loosen four bolts (3) to remove canopy (1). 1
: 24 mm
NOTE: For 40u type B and 50u, remove cover and

left handrail first.
CAUTION: Canopy weight: ȷȕȒȗȍȐȒȍȐȑȍȐȐȒ
41 kg (90 lb) (40u) 2

44 kg (97 lb) (50u)
1
Installation
1. Attach sling belt (2) to canopy (1).
Mount the canopy onto the frame with a crane.
ȷȕȒȗȍȐȒȍȐȑȍȐȐȑ
3 1
2. Loosen bolt (3) to remove canopy (2).
:24 mm
:205 N]m (21 kgf]m , 150 lbf]ft)
NOTE: For 40u type B and 50u, install cover and

left handrail.
ȷȕȒȗȍȐȒȍȐȑȍȐȐȒ
: 17 mm
W2-1-1
UPPERSTRUCTURE / Canopy
ϑBlankϒ
W2-1-2
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT

INTRODUCTION (IN-01) for the corresponding serial
numbers.
Removal
CAUTION: Counterweight weight:
366 kg (807 lb) (40u)
597 kg (1316 lb) (50u)
2
1. Remove the canopy.
NOTE: Refer to "REMOVE AND INSTALL
CANOPY".
2. Loosen bolt (1) and remove engine cover (2).
: 13 mm 1
ȷȕȗȑȍȐȒȍȐȒȍȐȐȑ
3. Remove tank cover (3).

3
: 13 mm
ȷȕȗȑȍȐȒȍȐȒȍȐȐȒ
4. Attach eye bolt (M16, Pitch 2.0) onto

counterweight (4) to removale.
ȷȕȗȑȍȐȒȍȐȒȍȐȐȓ
W2-2-1
5. Remove counterweight (4) mounting bolts (5).
: 24 mm, 27 mm (40u) 5
30 mm (50u)
ȷȕȗȑȍȐȒȍȐȒȍȐȐȔ
6. Raise counterweight (4) using a crane.
W2-2-2
Installation
CAUTION: Counterweight weight:

366 kg (807 lb) (40u)
597 kg (1316 lb) (50u)
1. Attach counterweight (4) to a crane with lifting

straps and move it forward onto the frame.
4
2. Tighten bolt (5) to hold counter weight (4) in
position.
5
: 24 mm (40u)
: 205 N⋅m (21 kgf⋅m , 150 lbf⋅ft)
: 27 mm (40u) 4
: 295 N⋅m (30 kgf⋅m , 220 lbf⋅ft)
: 30 mm (50u)
: 390 N⋅m (40 kgf⋅m , 290 lbf⋅ft)
ȷȕȗȑȍȐȒȍȐȒȍȐȐȔ
3. Install tank cover (3).
: 13 mm 3
: 9.8 N]m (1 kgf]m , 7.2 lbf]ft)
ȷȕȗȑȍȐȒȍȐȒȍȐȐȒ
4. Install engine cover (2) and tighten bolts (1). 2
: 13 mm
: 9.8 N]m (1 kgf]m , 7.2 lbf]ft)
5. Install the canopy.

CANOPY".
ȷȕȗȑȍȐȒȍȐȒȍȐȐȑ
W2-2-3
ϑBlankϒ
W2-2-4
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

numbers.
CAUTION: Escaping hydraulic fluid under

pressure can penetrate the skin or eyes,
causing serious injury. Avoid this hazard by
relieving pressure before disconnecting
hydraulic or other lines.
Hydraulic oil and components may be hot
just after operation. Hot hydraulic oil may
spout, possibly causing severe burns. Be
sure to wait for hydraulic oil and components
to cool before starting repair work.
Preparation
1. Place the machine on a solid, level surface and
lower the bucket to the ground.
2. Stop the engine. Loosen the hydraulic oil tank cap

to release the air in the hydraulic oil tank.
3. Remove the cap. Install a vacuum pump on the

hydraulic oil tank. Operate the vacuum pump to
create negative pressure in the tank. ȴȕȗȐȍȐȖȍȐȓȍȐȑȑ
Keep the vacuum pump running continuously

while working on the hydraulic system.
W2-3-1
Removal
1. Remove engine cover.
NOTE: Refer to "REMOVE AND INSTALL 1
COUNTERWEIGHT".
2. Remove cover (1) and (2).

2
: 13 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
ȷȕȗȑȍȐȒȍȐȓȍȐȐȑ
3. Disconnect all hoses from the pump. Plug each

disconnected hose end.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm 3
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
: 8 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
CAUTION: Pump device weight: 33 kg (73 lb)
4. Attach sling belts to the pump. Slightly raise the ȷȕȗȑȍȐȒȍȐȓȍȐȐȒ

pump using a crane and sling belts and remove
bolts(3). Remove with a crane.
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
Installation
NOTE: Refer to "Removal" for wrench size and
tightening torque.
1. Tighten bolts (3) to secure the pump in position.

2. Connect all hoses to the pump device.
3. Install covers (1), (2) and the engine cover.
COUNTERWEIGHT".
IMPORTANT: Bleed air from the pump. (Refer to

W1-1-2)
After connecting the hoses, check
the hydraulic oil level. Start the
engine and check the hoses for oil
leaks.
W2-3-2
DISASSEMBLE PUMP DEVICE
33
11
10 46
9
8 32
7 33
6 30 31
5 29
4 28
27
3 26
25
12 24
2 23
71 22
1 21
13 20 34
19 35
14
15 36
16 50 53 37 57
38
54
55 15
51
17 56
18 73 52
48 59
39
40 47
41 60
42 15 61 54
58 62 70
49 63 52
43
45 44 72 15
69
68
67 57
66
65
64
W571-02-03-003
1- Socket Bolt 19 - Needle Bearing 37 - Spring Seat 55 - O-Ring

2- Washer 20 - Valve Plate 38 - O-Ring 56 - Bushing
3- Gear Pump 21 - Thrust Washer 39 - Spring Seat 57 - Plug
4- Bushing 22 - Snap Ring 40 - Set Bolt 58 - Gasket
5- O-Ring 23 - Spring Holder 41 - O-Ring 59 - Housing
6- Socket Bolt 24 - Spring 42 - Set Screw 60 - Stopper
7- Cover 25 - Collar 43 - Port Block 61 - Oil Seal
8- O-Ring 26 - Cylinder Block 44 - Nut 62 - Needle Bearing
9- Loading Plate 27 - Pin 45 - Socket Bolt 63 - Thrust Washer
10 - Trochoid Rotor Assembly 28 - Retainer Holder 46 - Swash Plate 64 - Shaft
11 - Bushing 29 - Retainer Plate 47 - Backup Ring 65 - Screw
12 - O-Ring 30 - Plunger Assembly 48 - Pin 66 - Plate
13 - O-Ring 31 - Thrust Plate 49 - Pin 67 - Stopper
14 - Plug 32 - Pin 50 - Nut 68 - Spring
15 - O-Ring 33 - Bearing 51 - Set Screw 69 - Bushing
16 - Shim 34 - Spring Seat 52 - Socket Bolt 70 - Trunnion Cover
17 - Spring 35 - Spring 53 - Trunnion Cover 71 - Spring Pin
18 - Poppet 36 - Spring 54 - O-Ring 72 - Plug
73 - Pin
W2-3-3
33
11
10 46
9
8
7 33
6 31
5
4
3 26
2
1 21
20 34
35
36
50 53 57
15
51
56
73 52
48 59
47
15 61 54
58 62 70
49 63 52
43
45
57
64
W571-02-03-003
W2-3-4
• Read PRECAUTIONS FOR DISASSEMBLING 8. Remove gasket (58), springs (36), (35) and spring
AND ASSEMBLING (W1-1-1) carefully before sheet (34) from housing (59).
disassembling.
9. Remove backup ring (47), O-ring (15), shaft (64)
1. Remove plug (57) and O-ring (15) from housing and thrust washer (63) from housing (59).
(59).
Ȁ 10. Remove four socket bolts (52) on the trunnion
: 6 mm covers (53) and (70). Loosen nut (50) and turn
set screw (51) clockwise 360ѯto lift the trunnion
2. Remove socket bolts (1) and washers (2), then cover (53).
remove gear pump (3) and O-ring (5) from port
block (43). Remove bushing (4) that will come out : 6 mm
with gear pump (3) or remain on port block (43)
side. 11. Remove trunnion covers (53) and (70) from
housing (59). Remove bushing (56), O-ring (54)
: 8 mm and (55).
3. Remove socket bolt (6), cover (7) and O-ring,

then remove loading plate (9) from port block (43).
IMPORTANT: Be careful not to drop pins (49) and
: 4 mm (48). Pins (49) and (48) may come off
when removing swash plate (46).
4. Remove trochoid rotor assembly (10) from port
block (43). 12. Remove the outer race of bearing (33) from
housing (59). Remove swash plate (46) and thrust
NOTE: Do not remove bushing (11) unless plate (31).
necessary.
13. Remove oil seal (61) and needle bearing (62)
IMPORTANT: Valve plate (20) may come out with from housing (59) using a press.
port block (43) on its back when
removing the port block. Take care
not to let valve plate (20) fall.
5. Place port block (43) horizontally, remove socket

bolt (45) and take out port block (43).
: 10 mm
NOTE: If port block (43) does not remove easily,

lightly tap with a plastic hammer.
6. Remove thrust washer (21) from shaft (64).
IMPORTANT: Take care not to make scratches

when removing cylinder block (26)
from housing (59).
7. Remove plunger assembly (30), retainer plate

(29), retainer holder (28) and cylinder block (26)
as assembly from housing (59).
W2-3-5
14
15
16 37
38
17
18
59
39
40
41 60
42
58
43
45 44 72
69
68
67
66
65
W571-02-03-003
W2-3-6
14. Remove screw (65), plate (66), stopper (67), Ȁ
bushing (69) and spring (68) from housing (59).
: 3 mm
IMPORTANT: Do not disassemble nut (44), spring

seat (37), set bolt (40) and set screw
(42) unless necessary, because they
are used for adjusting power setting.
15. Remove plug (14), shim (16), O-ring (15), spring

(17) and poppet (18) from housing (59).
: 6 mm
W2-3-7
ASSEMBLE PUMP DEVICE
17 16 15 14 15 58 47 48 56 53 52 55 54
T571-03-01-003
18 13 4 1 2 72 45 73 49 70 52 54 33
3 8 9 7 11 10 19 21 20 23 26 57 15 32 30 46 27 31 59
28
60
62
61
64
63
29
71
69
12
68
5 6 44 42 41 40 39 38 43 37 36 21 22 35 24 25 34 66 65 67
T571-03-01-001
W2-3-8
50
51
W571-02-03-004
1- Socket Bolt 19 - Needle Bearing 37 - Spring Seat 55 - O-Ring

2- Washer 20 - Valve Plate 38 - O-Ring 56 - Bushing
3- Gear Pump 21 - Thrust Washer 39 - Spring Seat 57 - Plug
4- Bushing 22 - Snap Ring 40 - Set Bolt 58 - Gasket
5- O-Ring 23 - Spring Holder 41 - O-Ring 59 - Housing
6- Socket Bolt 24 - Spring 42 - Set Screw 60 - Stopper
7- Cover 25 - Collar 43 - Port Block 61 - Oil Seal
8- O-Ring 26 - Cylinder Block 44 - Nut 62 - Needle Bearing
9- Loading Plate 27 - Pin 45 - Socket Bolt 63 - Thrust Washer
10 - Trochoid Rotor Assembly 28 - Retainer Holder 46 - Swash Plate 64 - Shaft
11 - Bushing 29 - Retainer Plate 47 - Backup Ring 65 - Screw
12 - O-Ring 30 - Plunger Assembly 48 - Pin 66 - Plate
13 - O-Ring 31 - Thrust Plate 49 - Pin 67 - Stopper
14 - Plug 32 - Pin 50 - Nut 68 - Spring
15 - O-Ring 33 - Bearing 51 - Set Screw 69 - Bushing
16 - Shim 34 - Spring Seat 52 - Socket Bolt 70 - Trunnion Cover
17 - Spring 35 - Spring 53 - Trunnion Cover 71 - Spring Pin
18 - Poppet 36 - Spring 54 - O-Ring 72 - Plug
73 - Pin
W2-3-9
15 15 58 47 48 56 53 55 54
T571-03-01-003
73 49 70 52 33
20 26 30 46 27 31 59
28
62
61
64
63
69
12
68
43 36 35 34 66 65 67
T571-03-01-001
W2-3-10
• Read PRECAUTIONS FOR DISASSEMBLING 9. Install cylinder block (26) assembly to shaft (64)
AND ASSEMBLING (W1-1-1) carefully before while aligning the splines.
assembling.
IMPORTANT: Apply grease to the spherical part of
IMPORTANT: Apply grease to pin (27). spring seat (34).
Do not tap plunger assembly (30)
with a hammer etc., when installing 10. Install spring seat (34), spring (36), (35), pin (49),
into cylinder block (26). (48), backup ring (47) and O-ring (15) in housing
(59) in this order.
1. Install pin (27), retainer holder (28), retainer plate
(29) and plunger assembly (30) in cylinder block 11. Install valve plate (20) on port block (43).
(26).
NOTE: Apply grease to the back of valve plate (20)
2. Install bushing (69), spring (68), stopper (67), to prevent it from falling when the port block
plate (66) and screw (65) in housing (59). is positioned upside down.
: 3 mm 12. Install pin (73) and gasket (58) in housing (59).

: 6 N⋅m (0.6 kgf⋅m, 4.4 lbf⋅ft) Install thrust washer (52) on shaft (64).
3. Install oil seal (61), needle bearing (62), swash

plate (46), thrust plate (31) and bearing (33) in
housing (59) in this order.
4. Install O-ring (55) on bushing (56), and assemble

it on trunnion cover (53).
IMPORTANT: After tightening socket bolt (52),

make sure that swash plate (46)
swings correctly.
5. Install O-rings (54) on trunnion cover (70) and (53).

Install trunnion cover (53) to the left, and trunnion
cover (70) to the right of housing (59) with 3 holes
on housing (59) facing up. Tighten them using
socket bolts (52).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 21 lbf⋅ft)
6. Install set screw (51) in trunnion cover (53).

Tighten lock nut (50) to 2 N⋅m (0.2 kgf⋅m).
: 4 mm
: 13 mm
: 14 N⋅m (1.4 kgf⋅m, 10 lbf⋅ft)
7. Insert thrust washer (63) in shaft (64).
8. Apply grease to the lip of oil seal (61). Insert shaft

(64) into needle bearing (62) from swash plate
(46) side.
W2-3-11
17 16 15 14
T571-03-01-003
18 13 4 1 2 72 45
3 8 9 7 10 19 57 15 59
64
12
6 43 37 35
T571-03-01-001
W2-3-12
IMPORTANT: Align shaft (64) with needle bearing
(19) and spring (35) with spring seat
(37) and assemble them. Gradually
tighten socket bolt (45) so that both
mating faces on port block (43) and
housing (59) are parallel.
13. Install port block (43) into housing (59), and

tighten socket bolt (45).
: 10 mm
: 107 N⋅m (10.9 kgf⋅m, 80 lbf⋅ft)
14. Install trochoid rotor assembly (10) into port block

(43).
15. Temporarily install gear pump (3) onto port block

(43) to align the splines between shaft (64) and
trochoid rotor assembly (10).
16. Install O-ring (8) and (12) onto loading plate (9)
and install into cover (7).
17. Install cover (7) into port block (43), and tighten
socket bolt (6).
: 4 mm
: 7.3 N⋅m (0.75 kgf⋅m, 5.4 lbf⋅ft)
18. Install O-ring (13) into bushing (4). Insert it into

port block (43). Install gear pump (3) onto port
block (43) using socket bolt (1) and washer (2).
: 8 mm
: 44 N⋅m (4.5 kgf⋅m, 32 lbf⋅ft)
19. Install plug (57) and O-ring (15) on housing (59).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 21 lbf⋅ft)
20. Wrap threads of plug (72) with seal tape and

tighten it onto port block (43).
: 5 mm
: 7.8 N⋅m (0.8 kgf⋅m, 5.7 lbf⋅ft)
21. Install poppet (18), spring (17), shim (16), O-ring

(15) and plug (14) into port block (43) in this order.
: 6 mm
: 29 N⋅m (3 kgf⋅m, 21 lbf⋅ft)
W2-3-13
MAINTENANCE STANDARDS
Main Pump
1. Clearance between the cylinder block bore and

plunger
(D-d): 0.040 mm or less.
ȷȕȗȑȍȐȒȍȐȓȍȐȐȖ
2. Clearance between the plunger tip and shoe

bottom
̗: 0.2 mm or less.
ȷȕȗȑȍȐȒȍȐȓȍȐȐȕ
3. Shoe thicknes
t: 2.9 mm or more.
ȷȕȗȑȍȐȒȍȐȓȍȐȐȗ
4. Cylinder block, valve plate

thrust plate, retainer plate
retainer holder
Make sure that there is no damage, wear, or

seizure on the sliding surfaces.
If damage depth is deep replace with a new
one.
NOTE: 1 mm = 0.03937 in
W2-3-14
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE

numbers.

Preparation


create negative pressure in the tank. ȴȕȗȐȍȐȖȍȐȓȍȐȑȑ

while working on the system.
W2-4-1
Removal
1. Remove the tank cover and cover (1).
COUNTERWEIGHT" .
: 13 mm 1
ȷȕȗȑȍȐȒȍȐȔȍȐȐȑ
2. Disconnect all hoses from the control valve.
Cap each disconnected hose end. Attach
identification tags to the disconnected hoses to
aid reassembly.
: 19 mm, 22 mm, 27 mm
ȷȕȗȑȍȐȒȍȐȔȍȐȐȒ
3. Remove cotter pin (2), then remove joint pin (3) 3

from the travel, blade and swing spools.
CAUTION: Control valve weight: 46 kg

(101 lb) 2
4. Remove bolts (4). Attach control valve (5) to a 5

crane to remove it.
4
: 17 mm
ȷȕȗȑȍȐȒȍȐȔȍȐȐȓ
W2-4-2
Installation
3
CAUTION: Control valve weight:
46 kg (101 lb)
1. Install control valve (5) and tighten bolts (4).

2
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
5
2. Insert joint pins (3) into the travel, blade and swing
4
spools, and install cotter pin (2) onto each joint
pin. ȷȕȗȑȍȐȒȍȐȔȍȐȐȓ
3. Connect all hoses to the control valve.
: 19 mm
: 29 N⋅m (3 kgf⋅m, 21 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
ȷȕȗȑȍȐȒȍȐȔȍȐȐȒ
4. Install the tank cover and cover (1).

COUNTERWEIGHT". 1
: 13 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
IMPORTANT: After connecting the hoses, check

leaks. ȷȕȗȑȍȐȒȍȐȔȍȐȐȑ
W2-4-3
DISASSEMBLE AND ASSEMBLE CONTROL VALVE
23c
C
23b B
14b A
6a
33 1f
A 13c
11a 34
19b 25 Arm
13b
10 21 24 1e
19a 7 32 23a
A
B 14a Auxiliary
28 22
29 26
9 C 30 A
18 27 12 1d
31
17 Boom Swing
13a
15 1c
20 Blade
5a A
B
C
2 1b
16 8 Blade
4 1a
3 W571-02-04-004
Relief
1a - Body (Relief) 1m - Body (Relief) 6a - Overload Relief Valve (5 Used) 8 - Socket Bolt (10 Used)
1b - Body (Blade) 2 - O-Ring (13 Used) A- O-Ring (5 Used) 9 - Socket Bolt (43 Used)
1c - Body (Swing) 3 - Nut (6 Used) B- Backup Ring (5 Used) 10 - Cover (5 Used)
1d - Body (Boom Swing) 4 - Rod (3 Used) C- O-Ring (5 Used) 11a -Cover (5 Used)
1e - Body (Auxiliary) 5a - Main Relief Valve 6b - Overload Relief Valve 11b -Cover
1f - Body (Arm) A - O-Ring A- O-Ring 12 - Cover (5 Ued)
1g - Body (Travel) B - Backup Ring B- Backup Ring 13a -Spool (Blade)
1h - Body (Boom 2) C - O-Ring C- O-Ring 13b -Spool (Boom Swing)
1i - Body (Flow Combiner 5b - Main Relief Valve (2 Used) 7- Makeup Valve (2 Used) 13c -Spool (Auxiliary)
Valve)
1j - Body (Bucket) A - O-Ring (2 Used) A - O-Ring (2 Used) 13d -Spool (Travel)
1k - Body (Boom 1) B - Backup Ring (2 Used) B - Backup Ring (2 Used) 13e -Spool (Travel)
1l - Body (Travel) C - O-Ring (2 Used) C - O-Ring (2 Used) 13f - Spool (Travel)
W2-4-4
13e 23e
14f Relief
1m
5b
A 14e 1l Travel
11b B
C
14d 1k
14c
35 1j Bucket
37
A
23d A Boom 1
36
1i Flow Combiner Valve 6b
13d
1h Boom 2
1g
Travel
1GW571-02-04-006
14a -Spool (Swing) 19a -Socket Bolt (5 Used) 23e -Check Valve 31 - O-Ring
14b -Spool (Arm) 19b -Socket Bolt (6 Used) 24 - Spring (6 Used) 32 - Bushing
14c -Spool (Boom 2) 20 - O-Ring 25 - Check Valve (6 Used) 33 - Plug
14d -Spool (Flow Combiner 21 - Spring 26 - Plug (13 Used) A- O-Ring
Valve)
14e -Spool (Bucket) 22 - Plate A- O-Ring (13 Used) 34 - Bushing
14f - Spool (Boom 1) 23a -Check Valve (3 Used) 27 - Spring (9 Used) 35 - Plug
15 - Plate (10 Used) 23b -Check Valve 28 - Orifice A- O-Ring
16 - Oil Seal (10 Used) 23c -Check Valve (3 Used) 29 - Backup Ring 36 - Spring
17 - Spring (17 Used) 23d -Check Valve 30 - O-Ring 37 - Spool
18 - Spring Seat (22 Used)
W2-4-5
Remove and Install Relief Valve and Make-up Valve
5 7 6 5 6 6 5
7 6 6 6 T571-03-03-001
5 - Main Relief Valve 6 - Overload Relief Valve 7 - Make-up Valve
W2-4-6
Removal Ȁ
• Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before
disassembling.
1. Remove main relief valve (5) and overload relief

valve (6).
: 19 mm
+5 +0.5 +3.7
: 34 -0 N]m (3.5 -0 kgf]m , 25 -0 lbf]ft)
2. Remove make-up valve (7).
: 24 mm
+4 +0.4 +3
: 20 -0 N]m (2 -0 kgf]m , 14 -0 lbf]ft)
Installation

assembling.
NOTE: Refer to REMOVE section for wrench size

and tightening torque.
1. Install main relief valve (5) and overload relief

valve (6).
2. Install make-up valve (7).
W2-4-7
Disassemble and Assemble Direct Acting Spool
(Travel Right, Travel Left, Blade, Boom Swing, Auxiliary)
NOTE: The illustration shows the left travel.
18 17 15 15 8 13
19
W532-02-04-002
10 9 18 16 16
1 - Housing 10 - Cover 16 - Oil Seal 18 - Spring Seat

8 - Socket Bolt 13 - Spool 17 - Spring 19 - Socket Bolt
9 - Socket Bolt 15 - Plate
W2-4-8
Disassemble Assemble
• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before
disassembling. assembling.
1. Remove socket bolts (8), (9), cover (10), and NOTE: Refer to DISASSEMBLE section for wrench
plate (15). size and tightening torque.
: 5 mm 1. Attach wooden pieces on both sides of spool (13)

+3 +0.3 +2.2
: 9.8 -0 N]m (1 -0 kgf]m , 7.2 -0 lbf]ft) for protection and clamp spool (13) in a vise.
Install socket bolt (19), two spring seats (18),
2. Remove spool (13) together with socket bolt (19), spring (17), and plate (15) onto spool (13).
spring seats (18), spring (17) and plate (15) .
2. Install oil seal (16) into housing (1).
3. Remove oil seals (16) from housing (1).
3. Insert the spool assembly into housing (1).
IMPORTANT: Socket bolt (19) and spring seats
(18) may fly off by spring force when 4. Install cover (10) and plate (15) on housing (1),
removing the socket bolt. Slowly and tighten socket bolts (8) and (9).
loosen socket bolt (19) while holding
spring seats (18) and spring (17) to
avoid personal injury.
4. Attach wooden pieces on both sides of spool (13)

for protection and clamp spool (13) in a vise.
Remove socket bolt (19), spring seats (18), spring
(17) and plate (15) from spool (13).
: 5 mm
+3 +0.3 +2.2
: 9.8 -0 N]m (1 -0 kgf]m , 7.2 -0 lbf]ft)
W2-4-9
Disassemble and Assemble Pilot Operated Spool
(Boom 1, Boom 2, Arm, Bucket, Swing, Flow Combiner Valve)
NOTE: The illustration shows the swing section.
18 21 18 14 9 12
19
W527-02-04-014
11 9 20 20
1 - Housing 12 - Cover 18 - Spring Seat 20 - O-Ring

9 - Socket Bolt 14 - Spool 19 - Socket Bolt 21 - Spring
11 - Cover
W2-4-10
Disassemble Assemble
• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before
disassembling. assembling.
1. Remove socket bolts (9), covers (11), (12) and O- NOTE: Refer to DISASSEMBLE section for wrench
rings (20). size and tightening torque.
: 5 mm IMPORTANT: Apply LOCTITE #271 to the threads

+3 +0.3 +2.2
: 9.8 -0 N]m (1 -0 kgf]m , 7.2 -0 lbf]ft) of socket bolt (19).
2. Remove spool (14) together with socket bolt (19), 1. Attach wooden pieces on both sides of spool (14)
spring seats (18) and spring (21). for protection and clamp spool (14) in a vise.
Install spring (21) and spring seat (18) and tighten
IMPORTANT: Socket bolt (19) and spring seats socket bolt (19).
(18) may fly off by spring (21) force
when removing socket bolt (19). 2. Insert the spool assembly into housing (1).
Slowly loosen socket bolt (19) while
holding spring seats (18) and spring 3. Install O-ring (20) onto cover (11), (12). Install
(21) to avoid personal injury. cover (11), (12) onto housing (1) using socket bolt
(19).
3. Attach wooden pieces on both sides of spool (14)
for protection and clamp spool (14) in a vise.
Remove socket bolt (19), two spring seat (18) and
spring (21) from spool (14)
: 5 mm
+3 +0.3 +2.2
: 9.8 -0 N]m (1 -0 kgf]m , 7.2 -0 lbf]ft)
W2-4-11
Disassemble and Assemble Flow Combiner Valve
NOTE: The illustration shows the left travel section.
35 37
36 1
W532-02-04-002
1 - Housing 35 - Plug 36 - Spring 37 - Spool
W2-4-12
Disassemble

disassembling.
1. Remove plug (35), spring (36) and spool (37) from

housing (1).
: 14 mm
Assemble

assembling.
1. Insert spool (37) and spring (36) into body (1).

Tighten plug (35) into housing (1).
: 14 mm
+5 +0.5 +3.7
: 29 -0 N]m (3 -0 kgf]m , 21 -0 lbf]ft)
W2-4-13
Disassemble and Assemble Housing
3
4
T571-03-03-001
NOTE: The illustration shows the travel left section.
24
25
ȷȕȓȒȍȐȒȍȐȔȍȐȐȓ
A
Section A ȷȕȒȗȍȐȒȍȐȔȍȐȑȗ
1 - Housing 3 - Nut 24 - Check Valve 25 - Spring

2 - O-Ring 4 - Rod
W2-4-14
Disassemble

disassembling.
1. Remove nuts (3) and rods (4). Separate housing

(1) into each section.
: 17 mm
2. Remove O-ring (2), spring (24) and check valve

(25) from housing (1).
Assemble

assembling.
1. Install check valve (25) and spring (24) into each

section of housing (1). Install O-ring (2) onto
housing (1).
IMPORTANT: Apply LOCTITE #271 to the threads

of rod (4).
2. Position each section of housing (1) in same order

before disassembling, then tighten them using
rods (4) and nuts (3).
: 17 mm
+5 +0.5 +3.7
: 59 -0 N]m (6 -0 kgf]m , 44 -0 lbf]ft)
W2-4-15
ϑBlankϒ
W2-4-16
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

numbers.
CAUTION: Escaping hydraulic fluid pressure

can penetrate the skin or eyes, causing
serious injury. Avoid this hazard by relieving
pressure before disconnecting hydraulic or
other lines.
Hydraulic oil and components may be hot just
after operation. Hot hydraulic oil may spout,
possibly causing severe burns. Be sure to
wait for hydraulic oil and components to cool
before starting repair work.
Preparation
lower bucket to the ground.


hydraulic oil tank. Operate the vacuum pump to ȴȕȗȐȍȐȖȍȐȓȍȐȑȑ
create negative pressure in the tank. Keep the

vacuum pump running continuously while working
on the system.
W2-5-1
Removal
1. Remove floor plate (1) and stay (2) by loosening
bolts.
: 13 mm, 17 mm
1
2
ȷȕȗȑȍȐȒȍȐȕȍȐȐȑ
3
2. Loosen bolts and slide floor plate (3) forward.
: 17 mm
ȷȕȗȑȍȐȒȍȐȕȍȐȐȒ
3. Disconnect all hoses from the swing device. Cap

each disconnected hose end.
: 19 mm, 22 mm
CAUTION: Swing device weight:

50 kg (110 lb)
4. Remove swing device mounting bolt (4). Attach

swing device to a crane with sling belts. Remove
the swing device using the crane. ȷȕȗȑȍȐȒȍȐȕȍȐȐȓ
4
: 24 mm
W2-5-2
Installation
CAUTION: Swing device weight:
50 kg (110 lb)
1. Install the swing device and tighten bolts (4).
: 24 mm
: 205 N⋅m (21 kgf⋅m, 150 lbf⋅ft)
2. Connect all hoses to the swing device.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 4
: 22 mm ȷȕȗȑȍȐȒȍȐȕȍȐȐȓ
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
IMPORTANT: After connecting the hoses, fill the

3
hydraulic oil tank with oil to the
correct level. Start the engine and
check all hose connections for oil
leaks.
3. Install floor plate (3).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
ȷȕȗȑȍȐȒȍȐȕȍȐȐȒ
4. Install floor plate (1) and stay (2).
: 13 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
1
2
ȷȕȗȑȍȐȒȍȐȕȍȐȐȑ
W2-5-3
DISASSEMBLE SWING REDUCTION GEAR
20
21
1
22
23 2
4
29
24 5
25 6
7
26
8
9
27
10
11
28 12
13
14
15
19
16
17
18
ȷȕȗȑȍȐȒȍȐȕȍȐȐȕ
1- Socket Bolt 9- Retaining Ring 17 - Socket Bolt 25 - Spring Plate

2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing
W2-5-4
• Read PRECAUTIONS FOR DISASSEMBLING 11. Remove oil seal (22) from housing (23).
disassembling. IMPORTANT: Do not remove the outer races of
roller bearings (21) and (24) from
housing (23). Failure to follow these
CAUTION: Swing motor weight: approx. 13
instructions will shorten service life
kg
of the bearings as press-fit force of
roller bearing (21 and 24) outer races
1. Remove socket bolt (1) from the swing motor,
is reduced. Always replace housing
then remove the swing motor.
(23) with a new one if the bearings
are removed.
: 6 mm
2. Remove socket bolt (17) from ring gear (18).
: 8 mm
3. Remove ring gear (18), first stage carrier (8)

assembly, second stage sun gear (10) and
second stage carrier (13) assembly from the
swing reduction gear.
4. Remove retaining ring (3) from first stage carrier

(8) assembly. Remove plate (4), first stage sun
gear (5), first stage planetary gear (6) and needle
bearing (7).
5. Drive spring pin (19) at second stage carrier (13)

assembly into pin (12) using a round bar (length:
100 mm or more, diameter: 5 mm).
6. Remove pin (12), second stage planetary gear

(14), needle bearing (15), thrust plate (16) and
plate (11) from second stage carrier (13)
assembly.
7. Securely hold shaft (28). Remove nut (20) from

shaft (28) using a special tool.
8. Remove plug (29) from housing (23).
: 5 mm
9. Remove shaft (28) from housing (23) using a

press.
10. Remove the inner race of roller bearing (24),

spring plate (25), thrust plate (26) and plate (27)
from shaft (28) using a press.
W2-5-5
ASSEMBLE SWING REDUCTION GEAR
30
2
3
17
6
4
7
5
8
18
15
9
14
10
12
11
16
13
19 20
23 21
22 29
25 24
26
27
28
ȷȕȗȑȍȐȒȍȐȕȍȐȐȔ
1- Socket Bolt 9- Retaining Ring 17 - Socket Bolt 25 - Spring Plate

2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal 30 - Swing Motor
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing
•
W2-5-6
assembling.
IMPORTANT: Install oil seal (22) with the lip of the

oil seal facing upward (motor side).
1. Install oil seal (22) into housing (23).
2. If roller bearings (21 and 24) are replaced with

new ones together with housing (23), press the
outer race of roller bearings (21) and (24) into
housing (23).
3. Press plate (27), thrust plate (26), spring plate

(25) and the inner race of roller bearing (24) onto
shaft (28).
IMPORTANT: Be careful not to damage oil seal

(22) by shaft (28) during installation.
Also, make sure that plug (29) has
been removed. If plug is not
removed, distortion of oil seal (22)
may result.
4. Install shaft (28) assembly into housing (23).
IMPORTANT: Install nut (20) with the grooved face

upward (motor side).
5. Install the inner race of roller bearing (21) into

housing (23), and temporarily tighten nut (20).
6. Install plug (29).
: 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
W2-5-7
3
17
6
4
7
5
8
18
15
14
12 10
16
20
23
28
W2-5-8
7. Adjust the roller bearing pre-load.
1) Securely hold shaft (28), then loosen nut (20).

Starting Torque
2) Tap the outer diameter of housing (22) (shown
with * to the right) 3 to 4 turns with a plastic
hammer.
3) Install one socket bolt (17) into housing (23).
4) After turning housing (23) in both directions

several times, measure rotation starting torque
(A) of housing (23) at socket bolt (17).
5) Tighten nut (20) onto shaft (28) using a special ㈍
tool.
: 150 N⋅m (15.5 kgf⋅m, 110 lbf⋅ft)

23 20
6) After turning housing (23) to both directions
several times, measure rotation starting torque
(B) of housing (23) at socket bolt (17).
7) Confirm that the measured torpue value is within ң

standards.
(If not, repeat procedure from 1).
Torpue difference Standard value

B-A +1.0 to +3.3 kgf
IMPORTANT: Install retaining ring (3) with the 28

chamfered corner facing toward
plate (4). ȷȕȗȑȍȐȒȍȐȕȍȐȐȘ
8. Install needle bearing (7), first stage planetary

gear (6), first stage sun gear (5), plate (4) and
retaining ring (3) onto first stage carrier (8).
9. Install thrust plates (11), (16), needle bearing (15),

second stage planetary gear (14) and pin (12)
onto second stage carrier (13).
W2-5-9
30
18
14 9
12
18
19 20
23
28
W2-5-10
IMPORTANT: Drive in spring pin (19) with its slit
facing upward (motor side).
10. Align pin holes on second stage carrier (13) and

pin (12), then drive spring pin (19) into the carrier.
12
IMPORTANT: Install second stage carrier (13)

aligning splines so that the pin on
second stage carrier (13) is inserted 19
into the hole of nut (20). Confirm
dimension A shown in the right ȷȕȗȑȍȐȒȍȐȕȍȐȐȗ
illustration is approx. 18.5 mm. If

13
dimension A is approx. 27.5 mm, it
indicates that pin is not inserted into ㈖ Pin
the hole on nut (20).
11. Install second stage carrier (13) assembly onto

shaft (28) aligning the holes on nut (20) with the
pin. 20
IMPORTANT: Install retaining ring (9) with its

chamfered corner facing upwards.
12. Install retaining ring (9) onto second stage sun

gear (10).
13. Install first stage carrier (8) assembly into second

stage carrier (13) assembly.
14. Apply THREEBOND #1215 to the counter bore on ȷȕȗȑȍȐȒȍȐȕȍȐȐȖ

the housing (23). Install ring gear (18) into
housing (23), and tighten it using socket bolt (17).
: 8 mm
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
15. Add approx. 0.7 litter of hydraulic oil into the swing
reduction gear.
16. Install O-ring (2) onto swing motor (30). Install the
swing motor onto ring gear (18). Tighten socket
bolts (1).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 21 lbf⋅ft)
W2-5-11
DISASSEMBLE SWING MOTOR
8
7
6
5
4
3 9
2
1 10
13 11
14
15 12
16
17
18
19
20
21
22
33
32
31
30
29
28
27
26
25
24
23
W527-02-05-005
1- Friction Plate 10 - Socket Bolt 19 - Spring 28 - Spring

2- Disc Plate 11 - O-Ring 20 - Washer 29 - Brake Piston
3- Swash Plate 12 - Socket Bolt 21 - Retaining Ring 30 - O-Ring
4- Shaft 13 - Plunger 22 - Pin 31 - Collar
5- Bearing 14 - Retainer 23 - Socket Bolt 32 - O-Ring
6- O-Ring 15 - Holder 24 - Cover 33 - O-Ring
7- Case 16 - Pin 25 - Pin
8- O-Ring 17 - Rotor 26 - Bearing
9- Parking Brake Switching 18 - Collar 27 - Valve Plate
Valve
W2-5-12
disassembling.
1. Remove socket bolt (10), parking brake switch

valve (9) and O-rings (11) from case (7).
: 5 mm
IMPORTANT: Be careful not to allow valve plate

(27) to fall when removing cover
(24).
2. Loosen socket bolts (23). Remove cover (24) and

valve plate (27) in this order.
: 12 mm
3. Remove springs (28) and O-Ring (30) from case

(7).
4. Remove brake piston (29) and O-ring (6) from

case (7) by applying compressed air into the pilot
port on case (7).
5. Remove collar (31), and O-rings (32),(33).
6. Remove rotor (17) and plungers (13) assembly.

Remove swash plates (3), friction plates (1) and
disc plates (2).
NOTE: Take care not to damage the sliding surface

of swash plate (3).
7. Remove plungers (13) (9 used), retainer (14),

holder (15) and pins (16) (3 used) from rotor (17).
IMPORTANT: Always use a special tool on washer

(20) to press spring (19) when
removing retaining ring (21). If
spring (19) retaining ring (21) is
removed without pressing, washer
(20) and spring (19) may fly out,
possibly causing serious injury.
8. Remove retaining ring (21) to remove washer (20),

spring (19) and collar (18) from rotor (17).
9. Remove shaft (4) from case (7) by tapping shaft

(4) with a plastic hammer.
10. Remove O-ring (8) from case (7).
W2-5-13
ASSEMBLE SWING MOTOR
22 23 28 27 21 20 26 24
25
9
30
10 6
29
11 17
32
33
19 31
18
1
16
2
7
13
8
15 5 4 3 14
T525-02-03-002
1- Friction Plate 10 - Socket Bolt 19 - Spring 28 - Spring

2- Disc Plate 11 - O-Ring 20 - Washer 29 - Brake Piston
3- Swash Plate 12 - Socket Bolt 21 - Retaining Ring 30 - O-Ring
4- Shaft 13 - Plunger 22 - Pin 31 - Collar
5- Bearing 14 - Retainer 23 - Socket Bolt 32 - O-Ring
6- O-Ring 15 - Holder 24 - Cover 33 - O-Ring
7- Case 16 - Pin 25 - Pin
8- O-Ring 17 - Rotor 26 - Bearing
9- Parking Brake Switch Valve 18 - Collar 27 - Valve Plate
W2-5-14
assembling.
IMPORTANT: If ball bearing (5) has been removed,

press bearing (5) onto shaft (4)
beforehand.
Press ball bearing (5) until the end of
ball bearing (5) is flush with the end
surface of case (7).
1. Press shaft (4) and ball bearing (5) assembly into

case (7).
2. Install collar (18), spring (19) and washer (20) into

rotor (17).
3. While depressing washer (20) and spring (19),

install retaining ring (21).
4. Install pins (16) into rotor (17). Put holder (15)

onto pins (16).
5. Install plungers (13) and retainer (14) assembly

into rotor (17).
6. Install swash plate (3) into case (7).
7. Install rotor (17) and plungers (13) assembly into

case (7).
8. Install friction plates (1) (2 used) and disc plates

(2) (2 used) one by one alternately in place.
IMPORTANT: Do not tap collar (31) with a plastic

hammer or similar instrument to
install collar (31). Collar (31) and / or
case (7) may be damaged. Be sure to
use a press to install collar (31) into
case (7).
9. Install O-rings (32) and (33) onto collar (31), and

press them into case (7).
W2-5-15
23 28 27 24
9
30
10 6
29
11
T525-02-03-002
W2-5-16
IMPORTANT: Do not tap brake piston (29) with a
plastic hammer or similar instrument 31
to install brake piston (29). Brake
piston (29) and / or case (7) may be
damaged. Be sure to use a press to
install brake piston (29) into case (7).
10. Install O-ring (6) onto brake piston (29). Press

Mounting Surface of
brake piston (29) into case (7). Parking Brake Switch
Valve (9)
11. Install springs (28) (14 used) and O-ring (30) into
case (7).
12. Attach valve plate (27) to cover (24). Install cover

M6 Threaded Hole
(24) on case (7) while aligning the matching
marks on cover (24) and case (7). Tighten socket
ȷȕȒȗȍȐȒȍȐȕȍȐȐȓ
bolts (23) (3 used).
: 12 mm
: 175±10 N⋅m (18±1 kgf⋅m, 130±7 lbf⋅ft)
NOTE: Apply grease to valve plate (27) before

attaching it to cover (24) in order to prevent
it from falling.
13. Install O-ring (11) in case (7). Install parking brake

switch valve (9) on case (7) and tighten socket
bolts (10) (2 used).
: 5 mm
: 9.8±1.0 N⋅m (1±0.1 kgf⋅m, 7.2±0.7 lbf⋅ft)
W2-5-17
DISASSEMBLE AND ASSEMBLE PARKING
BRAKE SWITCH VALVE
Disassemble Parking Brake Switch Valve
IMPORTANT: Do not clamp the mating surface of 1 2 3 4 5 6

body (9) when clamping body (9) in a
vise.
1. Clamp body (9) in a vise. Remove plug (6), spring

(8) and valve (1) from body (9).
: 8 mm
IMPORTANT: When clamping valve (9) in a vise,

take care not to damage and / or 9 8 7
deform its sliding surfaces by W102-02-06-020
applying an excessive force.
2. Clamp valve (1) in a vise and loosen orifice (7), to

remove orifice (4), washer (3) and filter (2).
: 3 mm
W2-5-18
Assemble Parking Brake Switch Valve 1 2 3 4 7
IMPORTANT: Do not apply too much LOCTITE to

the orifice, otherwise plugging may
occur. Take care not to deform valve
(1) by applying excessive force or to
damage its sliding surfaces when
clamping it in a vise.
W102-02-06-023
1. Clamp valve (1) in a vise. Install filter (2), washer
(3) and orifice (4) into valve (1).
Apply LOCTITE #572 to orifice (7). Install orifice
(7) into valve (1) and tighten to specification. 7
: 3 mm
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
IMPORTANT: Do not clamp the mating surface of

body (9) with the motor housing
when clamping body (9) in a vise. 1
2. Clamp body (9) in a vise. Install valve (1) and

spring (8) into body (9). W102-02-06-022
Install O-ring (5) on plug (6). Install plug (6) into

body (9) and tighten to specification.
6
: 8 mm
: 39.2 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 8
W102-02-06-021
W2-5-19
1. The clearance between the plunger diameter and

Rotor
the rotor bore diameter
(D-d): 0.40 mm or less.
D d
ȷȕȐȗȍȐȒȍȐȔȍȐȐș
2. The clearance between the plunger and the shoe

̗: 0.4 mm or less.
ȷȑȐȗȍȐȒȍȐȖȍȑȔȐ
ȷȑȐȗȍȐȒȍȐȖȍȑȔȑ
3. The wear amount of the oil seal mounting

surfaces no damage and / or wear is allowed.
D0 D1
(D0 - D1): 0.25 mm or less.
ȷȕȐșȍȐȒȍȐȔȍȐȑȐ
W2-5-20
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL PILOT VALVE
CAUTION: Escaping hydraulic fluid pressure

can penetrate the skin or eyes, causing
serious injury. Avoid this hazard by relieving
pressure before disconnecting hydraulic or
other lines.
Preparation
1. Place the machine on a solid, level surface, and

W2-6-1
Removal
3
1. Remove pins (1). Loosen nut (2). Disconnect
wires in the boot, and remove lever (3).
1
: 22 mm 2
ȷȕȓȒȍȐȒȍȐȖȍȐȐȑ
2. Loosen bolt (7) and remove pilot valve (6).
ȷȕȓȒȍȐȒȍȐȖȍȐȐȒ
3. Disconnect all hoses and harnesses from pilot

valve (6).
Cap the end of each disconnected hose.
: 19 mm
4. Loosen mounting bolt (7) and remove pilot valve

(6). 7
: 13 mm
6
ȷȕȓȒȍȐȒȍȐȖȍȐȐȓ
W2-6-2
Installation
1. Install pilot valve (6) and tighten bolts (7).
: 13 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
2. Connect all hoses and harnesses.
: 19 mm
: 29 N⋅m (3 kgf⋅m, 21 lbf⋅ft) 7
6
ȷȕȓȒȍȐȒȍȐȖȍȐȐȓ
3. Install cover (5).
ȷȕȓȒȍȐȒȍȐȖȍȐȐȒ
3
4. Connect harnesses in the boot. Install lever (3)
and tighten nut (2). Install pins (1) to secure the 1
boot. 2
: 22 mm
: 135 N⋅m (14 kgf⋅m, 100 lbf⋅ft)

hydraulic oil tank with oil to the
correct level. Start the engine and
check the hoses for oil leaks.
ȷȕȓȒȍȐȒȍȐȖȍȐȐȑ
W2-6-3
DISASSEMBLE PILOT VALVE
5
1
17
18
15
19
㈓
14
8 4
10
16
11
13
12
ȷȕȕȔȍȐȒȍȐȗȍȐȐȑ
1- Screw Joint 6- Spring Guide 11 - Housing 16 - Plate

2- Cam 7- Spring (1,3) 12 - Plug (Side) 17 - Bushing
3- Oil Seal 8- Spacer 13 - O-Ring (Side) 18 - Pusher
4- Socket Bolt 9- Shim 14 - Spring (2,4) 19 - Universal Joint
5- O-Ring 10 - Spool 15 - Spring (Balance)
W2-6-4
Disassemble Pilot Valve

disassembling.
• As housing (11) and spool (10) are finished in
the selective fit dimension, they must be replaced
as a set. Do not attempt to replace only one part.
• Springs (7) in ports (1 and 3) are different from
springs (14) in ports (2 and 4). Be careful not mix
up the springs.
• Keep put identification tags to the disassembled
parts by port in order not to mix them when
reassembling. Port numbers are imprinted by
casting on the periphery of housing (11).
1. Loosen cam (2), to remove universal joint (19)

from housing (11).
: 50 mm
2. Remove cam (2) and screw joint (1) from

universal joint (19).
: 19 mm, 50 mm
3. Remove plug (12) from housing (11).
: 6 mm
ST 7924
4. Install a special tool to the universal joint mounting
hole on casing (11), to tighten plate (16).
5. Remove four socket bolts (4).
: 5 mm 4
16
6. Gradually loosen the special tool. Spool (10)
assembly and plate (16) are raised by spring
force.
7. Remove tool and plate from casing (11), then

remove plate (16).
ȷȕȕȔȍȐȒȍȐȗȍȐȐȖ
W2-6-5
17
18
15
10
13
12
ȷȕȕȔȍȐȒȍȐȗȍȐȐȑ
W2-6-6
8. Remove the pusher assembly. Remove pusher
(18), O-ring (5) and oil seal (3) from bushing (17).
9. Remove spool (10) assemblies from each ports.
IMPORTANT: In order to avoid mixing parts up, be

sure to indicate the number of the
ports from which parts were
removed.
10. Compress spring (15) to remove spring guide (6)

from spool (10).
11. Remove spacer (8) and shims (9) from spool (10).
W2-6-7
ASSEMBLE PILOT VALVE
1
19
18
3
17 4
16
5
7
15
8,9
14
10
12,13 11
ȷȕȕȔȍȐȒȍȐȗȍȐȐȒ
1- Screw Joint 6- Spring Guide 11 - Housing 16 - Plate

2- Cam 7- Spring (1,3) 12 - Plug (Side) 17 - Bushing
3- Oil Seal 8- Spacer 13 - O-Ring (Side) 18 - Pusher
4- Socket Bolt 9- Shim 14 - Spring (2,4) 19 - Universal Joint
5- O-Ring 10 - Spool 15 - Spring (Balance)
W2-6-8
Assemble Pilot Valve
• Clean all disassembled parts with cleaning

solvent. In order to avoid mixing them up, arrange
them by port number.
1. Install shim (9), spacer (8) and spring (15) on

spool (10). Compress spring (15) and install
spring guide (6) between spool (10) and spring
(15).
IMPORTANT: Since the numbers of shims (9) are

determined at the factory perfor-
mance test, take care not to lose
them.
One face of spring guide (6) is the
spring seat. Be sure to install spring
guide (6) with the spring seat side
downward (facing spring(14)).
2. Install springs (7) and (14) into housing (11).
3. Insert spool (10) assemblies into housing (11).
IMPORTANT: Be sure to confirm the port number

before inserting each spool (10) to
make sure that the spool assembly
is inserted into its correct port.
4. Install oil seal (3) and O-ring (5) on bushing (17).

Insert pusher (18) into bushing (16).
IMPORTANT: Install oil seal (3) in the correct

direction. Apply grease to the lip of
oil seal (3) and the inside of bushing.
Use one of the following greases:

• Apolloil Autorex (Idemitsu),
• Ocean 7 (Nihon Ore Louve),
• Screw Bar L 60 (NOK)
5. Place pushers (18) (4 used) on each spool (10)

assembly.
W2-6-9
1
19
18
16
12,13 11
ȷȕȕȔȍȐȒȍȐȗȍȐȐȒ
W2-6-10
6. Install plate (16) on pushers (18). Install special

tool ST7924 to mounting hole for universal joint
(19) on housing (11). ST7924 16
7. Tighten four socket bolts (4) (4 used) to secure
plate (16).
11
: 5 mm
: 14.7 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
8. Remove special tool ST7924. Apply a locking

agent to threads of universal joint (19), and install
it onto housing (11) using screw joint (1).
IMPORTANT: In order not to loosen universal joint

ȷȕȕȔȍȐȒȍȐȗȍȐȐȗ
(19), securely hold universal joint
(19) using a proper tool such as a
screw driver when removing joint
screw (1).
: 19 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
9. Apply sufficient grease to the articulation of

universal joint (19).
10. Apply grease to the top of pushers (18).
11. Install cam (2) on universal joint (19).
12. Tighten cam (2) so that the clearance between

pushers (18) and cam (2) is 0 to 0.2 mm.
: 19 mm, 50 mm
: 68.6 to 88.3 N⋅m
(7 to 9 kgf⋅m, 51 to 65 lbf⋅ft)
13. Install plug (12) to housing (11).
: 6 mm
: 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
W2-6-11
ϑBlankϒ
W2-6-12
UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE AND ASSEMBLE SOLENOID VALVE
ȷȕȗȑȍȐȒȍȐȗȍȐȐȑ
1 - ON-OFF Solenoid Valve 2 - ON-OFF Solenoid Valve 3 - Housing

(Travel Speed Selector) (Pilot Control Shut-Off
Lever)
W2-7-1
1
7
W571-02-07-002
1 - ON-OFF Solenoid Valve 4 - Solenoid 6 - Spool 8 - O-Ring

(Travel Speed Selector)
3 - Housing 5 - Socket Bolt 7 - Spring
W2-7-2
Disassemble Solenoid Valve

disassembling.
1. Clamp housing (3) in a vise.
IMPORTANT: Take care not to lose the solenoid (4)

pin when removing.
2. Loosen socket bolts (5), then remove solenoid (4).
: 3 mm
3. Remove spool (6), spring (7) and O-ring (8) from

housing (3).
Assemble Solenoid Valve

assembling.
1. Install O-ring (8), spool (6) and spring (7) into

housing (3).
2. Secure solenoid (4) with socket bolts (5) onto

housing (3).
: 3 mm
: 3.3 to 4.4 N⋅m
(0.35 to 0.45 kgf⋅m, 2.4 to 3.2 lbf⋅ft)
W2-7-3
ϑBlankϒ
W2-7-4
SECTION 3
UNDERCARRIAGE
—CONTENTS—
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing ......... W3-1-1 Remove and Install Upper Roller ............ W3-6-1
Remove and Install Lower Roller ............ W3-6-3
Group 2 Travel Device Maintenance Standards .......................... W3-6-5
Remove and Install Travel Device .......... W3-2-1
Disassemble Travel Device .................... W3-2-3 Group 7 Track
Assemble Travel Device ......................... W3-2-8 Remove and Install Rubber Crawler ....... W3-7-1
Maintenance Standards........................ W3-2-18 Maintenance Standards .......................... W3-7-3
Group 3 Center Joint

Remove and Install Center Joint............. W3-3-1
Disassemble Center Joint....................... W3-3-4
Assemble Center Joint ........................... W3-3-6
Group 4 Track Adjuster

Remove and Install Track Adjuster ......... W3-4-1
Group 5 Front Idler

Remove and Install Front Idler................ W3-5-1
Maintenance Standards.......................... W3-5-2
585W-3-1
ϑBlankϒ
585W-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
The procedures described below starts after removing

the upper structure.
Removal
Aligning Mark
1. Make alignment marks on inner race (1) of the
swing bearing and track frame (2).
1 2 ȷȑȐȕȍȐȓȍȐȑȍȐȐȑ
2. Remove swing bearing inner race mounting bolts
(3) (22 used).
3
: 19 mm
CAUTION: Swing bearing weight: 56 kg

(123 lb)
ȷȕȐȗȍȐȒȍȐȓȍȐȐȒ
3. Attach swing bearing (4) to a crane to remove it.
ȷȕȐȗȍȐȓȍȐȑȍȐȐȑ
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
Clean the mating surfaces of the track frame and
swing bearing.
1. Apply THREEBOND #1102 onto the swing

bearing mating surfaces of the track frame.
CAUTION: Swing bearing weight: 56 kg Front Side

(123 lb)
"S"
(the soft zone)
IMPORTANT: Align the marks correctly. Other wise, Marking Position
the soft zone position will be
dislocated.
2. Lift the swing bearing using a crane. Align the

marks on the track frame and swing bearing inner 9ѯ
race.
9ѯ
Grease Fitting
Position
ȷȕȗȑȍȐȓȍȐȑȍȐȐȑ
3. Tighten swing inner race mounting bolts (3) (22

used).
: 19 mm
: 108 N⋅m (11 kgf⋅m 80 lbf⋅ft)
ȷȕȐȗȍȐȒȍȐȓȍȐȐȒ
W3-1-2
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE

pressure can penetrate the skin or eyes
relieving pressure before disconnecting any
hydraulic lines.
Hydraulic oil and components may be not
Preparation


create negative pressure in the tank.
W3-2-1
Removal
1. Remove cover mounting bolts (1) to remove travel
motor cover (2).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2. Disconnect all hoses from the travel device.

Cap all disconnected hose end.
2
: 19 mm
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 1
ȷȕȐȗȍȐȓȍȐȒȍȐȐȑ
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
CAUTION: Travel device weight: 65 kg

(143 lb)
3. Remove travel device mounting bolts (3). Remove

travel device using a crane.
: 19 mm
: 110 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
3
ȷȕȕȔȍȐȓȍȐȒȍȐȐȕ
Installation
NOTE: Refer to "Removal" section for wrench size
and tightening torque.
1. Install the travel device with mounting bolts (3).

2. Connect all hoses to the travel device.
3. Install the travel motor cover (2) onto the track
frame with the cover mounting bolts (1).
IMPORTANT: After connecting the hoses, check

leaks.
To prevent the travel motor from
seizing, be sure to perform break-in
operation after installation.
Break-in operation conditions

1.Engine speed: Slow idle speed
2.Travel pedal : Slow speed range
3.Operating time: 2 minutes or more
W3-2-2
DISASSEMBLE TRAVEL DEVICE 1 2
3
29 4
30 5
30
29 6
27 7
28 8
27 9
15 10
18 11
17
26 16
15
25 14
24
23
22
21 13
12
20
19
37 36
W571-03-02-004
55 35
49
54 51 50
53 52
58 34
33
32
48
47
46
45 31
43
44
71 43
42
41
70 40
39
59 57 38
60 56
61
62
63
66 64
67 65
68
50
49 69
51 52
W571-03-02-005
1- Sun Gear 19 - Retaining Ring 37 - Swash Plate 55 - Socket Bolt
2- Thrust Collar 20 - Thrust Washer 38 - Plunger 56 - O-Ring
3- First Stage Carrier 21 - Second Stage Planetary Gear 39 - Holder 57 - Choke
4- Retaining Ring 22 - Needle Bearing 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring 41 - Pin 59 - Ball
6- Slide Ring 24 - Thrust Washer 42 - Rotor 60 - Spring
7- O-Ring 25 - Retaining Ring 43 - Retainer 61 - Spring Guide
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring
9- Stopper Ring 27 - Bearing 45 - Retaining Ring 63 - Plug
10 - O-Ring 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug 29 - O-Ring 47 - O-Ring 65 - Spring
12 - Plug 30 - Seal Ring 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug 67 - O-Ring
14 - Retaining Ring 32 - Control Piston 50 - O-Ring 68 - Plug
15 - Thrust Washer 33 - Oil Seal 51 - Spring 69 - Spring
16 - Pin 34 - Bearing 52 - Ring 70 - O-Ring
17 - Needle Bearing 35 - Shaft 53 - Socket Bolt 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball 54 - Relief Valve
W3-2-3
1
2
3
4
5
6
7
8
9
15 10
18 11
17
26 16
15
25 14
24
23
22
21 13
12
20
19
37 36
W571-03-02-004
55
49
54
53 52 51 50
58
32
48
47
46
45 31
43
44
71 43
42
41
70 40
39
59 57 38
60 56
61
62
63
66 64
67 65
68
50
49 69
51 52
W571-03-02-005
W3-2-4
Disassemble Travel Device
• Read PRECAUTIONS FOR DISASSEMBLING 10. Remove stopper ring (9) from cover (8) using a
AND ASSEMBLING (W1-1-1) carefully before screwdriver, then remove cover (8) from ring gear
disassembling. (26).
1. Remove socket bolts (55), relief valves (54)

assembly, O-rings (70) and (71).
11. Remove O-ring (7) and slide ring (6) from cover
: 6 mm (8).
12. Remove drive gear (5), first stage carrier (3)

CAUTION: Valve plate (46) may stick to body
assembly, retaining ring (4) and sun gear (1) from
(58). Take care not to drop valve plate (46)
ring gear (26).
when removing body (58).
13. Remove retaining rings (14) (3 used), thrust
2. Removes socket bolts (53) (6 used) to remove
washers (15) (3 used), first stage planetary gears
body (58) and valve plate (46).
(18) (3 used) and needle bearings (17) (3 used)
from first stage carrier (3).
: 10 mm
14. Remove thrust collar (2) from body (31).
3. Remove O-ring (56) (1 used), bearing (48) and
Remove retaining rings (19) (4 used), thrust
choke (57) from brake valve body (58).
washers (20) (4 used), second stage planetary
gears (21) (4 used), needle bearings (22) (4 used),
4. Install eye bolts (M10ѱLength 25 mm) into socket
rings (23) (4 used) and thrust washers (24) (4
bolt (53) holes on body (31). Remove the body
used).
from the vise using a crane.
5. Remove O-ring (47) from body (31).
6. Remove rotor (42) assembly, swash plate (37),

balls (36) (2 used), and control piston (32) (1
used) from body (31).
7.
CAUTION: Always hold retainer (43) and
spring (44) with a press when removing
retaining ring (45). If retaining ring (45) is
removed without holding retainer (43) and
spring (44), retainer (43) and spring (44) may
fly out potentially causing serious injury.
7. Remove plungers (38) (9 used), holder (39),

barrel holder (40) and pins (41) (3 used) from
rotor (42).
8. Remove retaining ring (45) from rotor (42), then

remove retainer (43) and spring (44).
9. Remove plug (12) (1 used), O-ring (13) (1 used),

plugs (11) (2 used) and O-rings (10) (2 used) from
cover (8).
: 5 mm, 8 mm
W3-2-5
29
30
30
29
27
28
27
26
25
24
23
22
21
20
19
37 36
W571-03-02-004
35
34
33
32
31
W571-03-02-005
W3-2-6
CAUTION: Attach a bar to shaft (35)

assembly. While tapping the end of the bar
with a hammer, remove shaft (35) assembly.
Do not remove bearing (34) unless
replacement is repaired.
15. Remove retaining ring (25) from body (31).
16. Remove body (31) from ring gear (26).
IMPORTANT: Attach a bar to bearing (24). While

tapping the end of the bar with a
hammer, remove bearing (24).
Replace bearing (27) with a new one
if removed.
17. Remove seal ring (30), O-ring (29), bearing (27)

and retaining ring (28) from ring gear (26).
18. Remove O-ring (29) and seal ring (30) from body
(31).
19. Remove oil seal (33) from body (31).
W3-2-7
ASSEMBLE TRAVEL DEVICE
18 17 16 19 20 21 22 24 25 33 28 34 29 37 36 40 41 47 53 44 48
15
23
14
55
13 54
12
6
8
10
11
9 7 4 3 2 1 5 26 32 27 39 30 38 42 31 43 56 35 57 45 46 58
T571-03-05-001
1- Sun Gear 19 - Retaining Ring 37 - Swash Plate 55 - Socket Bolt

2- Thrust Collar 20 - Thrust Washer 38 - Plunger 56 - O-Ring
3- First Stage Carrier 21 - Second Stage Planetary Gear 39 - Holder 57 - Choke
4- Retaining Ring 22 - Needle Bearing 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring 41 - Pin 59 - Ball
6- Slide Ring 24 - Thrust Washer 42 - Rotor 60 - Spring
7- O-Ring 25 - Retaining Ring 43 - Retainer 61 - Spring Guide
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring
9- Stopper Ring 27 - Bearing 45 - Retaining Ring 63 - Plug
10 - O-Ring 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug 29 - O-Ring 47 - O-Ring 65 - Spring
12 - Plug 30 - Seal Ring 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug 67 - O-Ring
14 - Retaining Ring 32 - Control Piston 50 - O-Ring 68 - Plug
15 - Thrust Washer 33 - Oil Seal 51 - Spring 69 - Spring
16 - Pin 34 - Bearing 52 - Ring 70 - O-Ring
17 - Needle Bearing 35 - Shaft 53 - Socket Bolt 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball 54 - Relief Valve
W3-2-8
69 69
52
49
51
50 68
59
60
61
64 62 63 65 66 67
W571-03-02-001
W3-2-9
19 20 21 22 24 25 33 28 29
23
2 26 27 30 31
T571-03-05-001
W3-2-10
Assemble Travel Device
assembling.
1. Install oil seal (33) into body (31).
2. Install O-ring (24) onto seal ring (30), then install

them into the body (31).
3. Install bearing (27), retaining ring (28), bearing

(27) and the assembly of seal ring (30) and O-ring
(29) into ring gear (26) in this order.
NOTE: Apply grease to O-ring (29) for easy

assembling. Degrease the seating surface
of seal ring (30).
4. Install ring gear (26) into body (31) while tapping

the ring gear with a plastic hammer, then secure
the ring gear with retaining ring (25).
NOTE: If ring gear (26) is difficult to install, tap 26

around the circumference of ring gear (26)
evenly with a plastic hammer.
NOTE: Install retaining ring (25) while depressing

clearance between the flanges of body (31)
and ring gear (26) using a hydraulic press.
Adjust the bearing pre-load by changing the
thickness of retaining ring (25).
5. Install rings (23) (4 used), thrust washers (24) (4

used), second stage planetary gears (21) (4 used), 31
needle bearings (22) (4 used) and thrust washers
(20) (4 used) onto body (31) in this order. Secure
them with retaining rings (19) (4 used), then install ȷȕȗȑȍȐȓȍȐȒȍȐȐȖ
thrust collar (2).
W3-2-11
18 17 16
15
14
13
12
6
8
10
11
9 7 4 3 1 5 26
T571-03-05-001
W3-2-12
6. Install pin (16) onto first stage carrier (3). Install
sun gear (1) and secure it with retaining ring (4).
7. Install thrust washer (15), first stage planetary

gear (18), needle bearing (17) and thrust washer
(15) onto first stage carrier (3) in this order, then
install retaining ring (14).
8. Install first stage carrier (3) assembly onto ring

gear (26), then install drive gear (5) into first stage
carrier (3) assembly.
9. Install O-ring (7) onto ring gear (26). Add 0.6 litter
of lubrication oil into ring gear (26).
CAUTION: Apply grease to cover (8) and

slide ring (6) to hold them. Apply grease to O-
ring (7), then install it horizontally with care to
avoid damage. Install cover (8) so that its
plug hole aligns with the notch on ring gear
(26).
10. Install the assembly of cover (8) and slide ring (6)
onto ring gear (26), then secure them using
stopper ring (9).
11. Install plug (11), O-ring (10), plug (12) and O-ring
(13) onto cover (8).
: 5 mm
: 12 to 13 N⋅m
(1.2 to 1.3 kgf⋅m, 8.6 to 9.4 lbf⋅ft)
: 8 mm
: 46 to 51 N⋅m
(4.7 to 5.2 kgf⋅m, 34 to 37 lbf⋅ft)
W3-2-13
34 37 36 40 41 47 53 44 48
71
55
54
70
32 39 38 42 31 43 56 35 57 45 46 58
T571-03-05-001
W3-2-14
12. Install control pistons (32) (2 used), shaft (35)
assembly, balls (36) (2 used) and swash plate
(37) into body (31) in this order.
NOTE: Do not remove bearing (34) on shaft (35)

assembly unless replacing it.
13. Install retainer (43), spring (44) and retainer (43)

into rotor (42) in this order.
14. Depress retainer (43) and spring (44) downward

with a press, and install retaining ring (45).
15. Install pin (41) and holder (40) into rotor (42).
16. Install plungers (38) (9 used) and holder (39) onto

rotor (42).
17. Install rotor (42) assembly into body (31). Add 0.2
litter of hydraulic oil into body (31).
18. Install bearing (48), O-ring (47) and valve plate

(46) onto body (58) in this order. Install choke (57)
and O-ring (56).
19. Install body (58) onto body (31), and tighten using
socket bolts (53) (6 used).
: 10 mm
: 51 to 65 N⋅m
(5.2 to 6.6 kgf⋅m, 37 to 48 lbf⋅ft)
20. Install O-ring (70), O-ring (71), relief valve (54)

and socket bolt (55) onto body (58).
: 6 mm
: 25 to 32 N⋅m
(2.6 to 3.3 kgf⋅m, 19 to 24 lbf⋅ft)
W3-2-15
69 58 69
52
49
51
50 68
59
60
61
64 62 63 65 66 67
W571-03-02-001
W3-2-16
21. Install spools (65) (2 used), springs (64) (2 used)
and spacers (66) (2 used) into body (58), then
install O-rings (67) (2 used) and plugs (68) (2
used).
: 8 mm
: 46 to 51 N⋅m
(4.7 to 5.3 kgf⋅m, 34 to 38 lbf⋅ft)
22. Install spool (69), rings (52) (2 used), springs (51)

(2 used) and O-rings (50) (2 used) into body (58),
then install plugs (49) (2 used).
: 36 mm
: 196 to 245 N⋅m
(20 to 25 kgf⋅m, 144 to 180 lbf⋅ft)
23. Install balls (59) (2 used), springs (60) (2 used),

spring guides (61) (2 used), O-rings (62) (2 used)
and plugs (63) (2 used) into body (58) in this
order.
: 6 mm
: 5.9 N⋅m (0.6 kgf⋅m, 4.3 lbf⋅ft)
W3-2-17
Sprocket
C
D
E
A
ȷȑȐȕȍȐȓȍȐȒȍȒȔȑ
Unit: mm
Allowable
Dimension Standard Remedy
Limit
A 47.6 42.6
B 356.2 351.2
C PCD394.7 - Replace
D 402.1 397.1
E 135.0 -
NOTE: 1 mm = 0.03937 in
W3-2-18
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT

spout, possibly causing sever burns. Be sure
to wait for hydraulic oil and components to
cool before starting repair work.
Preparation


W3-3-1
Removal
1. Remove floor plates.
NOTE: Refer to "REMOVE AND INSTALL SWING
DEVICE" for removing floor plates.
2. Attach tags to all hoses connected to the center

joint (1), to identify for reassembling in the same
positions.
Remove all hoses from body (10). Cap all
disconnected hose ends.
: 19 mm, 22 mm, 27 mm 1
3. Remove the center joint lock mounting bolt to

remove the center joint lock.
: 19 mm
ȷȕȐȗȍȐȓȍȐȓȍȐȐȑ
4. Loosen the undercover mounting bolts to remove 2

undercover (2).
: 19 mm
ȷȕȕȔȍȐȓȍȐȓȍȐȐȒ
5. Disconnect all hoses from spindle (8). Cap all

disconnected hose ends.
: 19 mm, 22 mm, 27 mm
CAUTION: Center joint weight: 19 kg (42 lb)
ȷȕȐȗȍȐȓȍȐȓȍȐȐȔ
6. Remove center joint mounting bolts (3). Lift and

remove center joint (1) using a crane.
3
: 17 mm
ȷȕȗȑȍȐȓȍȐȓȍȐȐȑ
W3-3-2
Installation
1. Install the center joint with bolts (3).
CAUTION: Center joint weight: 19 kg (42 lb)
3
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
ȷȕȗȑȍȐȓȍȐȓȍȐȐȑ
2. Connect all hoses to the spindle.
: 19 mm
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
ȷȕȐȗȍȐȓȍȐȓȍȐȐȔ
3. Install undercover (2) with mounting bolt.
: 19 mm 2
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
4. Install the center joint lock with the mounting bolt.
: 19 mm
ȷȕȕȔȍȐȓȍȐȓȍȐȐȒ
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
5. Connect all hoses to the body.
: 19 mm
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 1
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
6. Install the floor plates.

NOTE: Refer to "REMOVE AND INSTALL SWING ȷȕȐȗȍȐȓȍȐȓȍȐȐȑ
DEVICE" for installing the floor plates.

hydraulic oil tank to the correct level.
Start the engine and check the hose
connections for oil leaks.
W3-3-3
DISASSEMBLE CENTER JOINT
1
12
2
11 3
4
10
9 6
8
7
ȷȕȕȔȍȐȓȍȐȓȍȐȐȗ
1 - Bolt (4 Used) 4 - Ring 7 - Plug 10 - Body

2 - Spring Washer (4 Used) 5 - Oil Seal (8 Used) 8 - Spindle 11 - O-Ring
3 - Retaining Ring 6 - O-Ring 9 - Dust Seal 12 - Cover
W3-3-4
Disassemble Center Joint
disassembling.
1. Clamp the center joint in a vise.
2. Remove bolt (1), to remove cover (12).
: 13 mm
3. Remove O-ring (11), retaining ring (3) and ring (4).
1
4. Install a center joint puller onto body (10) using
bolt (1).
: 13 mm 10
5. Remove body (10) from spindle (8) using a puller.
IMPORTANT: Take care not to damage the seal

sliding surface of spindle (8), when
removing body (10). When laying
spindle (8) horizontally on the ȷȕȐȖȍȐȓȍȐȓȍȐȐȒ
ground, take extra care not to

damage or contaminate the spindle
surfaces with hard materials such as
sand. Put alignment marks on body
(10) and spindle (8).
6. Remove oil seals (5) from body (10).
IMPORTANT: Use two pins to easily remove oil

seals (5). Take care not to damage
the seal groove with the pins.
7. Remove dust seal (9) and O-ring (6) from body

(10).
ȷȑȐȕȍȐȓȍȐȓȍȐȑȕ
W3-3-5
ASSEMBLE CENTER JOINT
1
12
2
11 3
4
10
9 6
8
7
ȷȕȕȔȍȐȓȍȐȓȍȐȐȗ
1 - Bolt (4 Used) 4 - Ring 7 - Plug 10 - Body

2 - Spring Washer (4 Used) 5 - Oil Seal (8 Used) 8 - Spindle 11 - O-Ring
3 - Retaining Ring 6 - O-Ring 9 - Dust Seal 12 - Cover
W3-3-6
Assemble Center Joint
disassembling.
IMPORTANT: Before installing kinds of seals into

the seating grooves, coat the seals
with grease or hydraulic oil. After
installing O-ring (6), dust seal (9),
and oil seals (5), coat the lips of
them with grease.
1. Install O-ring (6), dust seal (9) and oil seal (5) onto
body (10).
IMPORTANT: Align the alignment marks when

installing body (10).
2. Place spindle (8) on a work bench, then install

body (10) onto spindle (8).
IMPORTANT: Install body (10) from the upward

position. Push spindle (8) into body
(10) slowly. If spindle (8) is rapidly
pushed in the seal may be damaged.
3. Install body (10) until body (10) comes into contact

with spindle (8) flange while tapping the outside of
body (10) with a plastic hammer.
4. Install ring (4) onto body (10).
IMPORTANT: Install retaining ring (3) with the

chamfered corner downward.
Confirm that retaining ring (3) is
correctly seated.
5. Install O-ring (11) and retaining ring (3) onto

spindle (8).
6. Secure cover (12) to body (10) with bolts (1).
: 13 mm
: 10.8 N⋅m (1.1 kgf⋅m, 8.0 lbf⋅ft)
W3-3-7
ϑBlankϒ
W3-3-8
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER
Before removing or installing the track adjuster, the

rubber crawler and front idler must be removed or
installed beforehand. Refer to the corresponding
sections for the removal and installation of the rubber
crawler and front idler
The procedures described below start after the rubber
crawler and front idler are removed.
Removal
CAUTION: Truck adjuster weight: approx.

13.3 kg (29 lb)
1. After moving the front idler assembly, remove

track adjuster (1) from the track frame.
2
Installation ȷȕȐȗȍȐȓȍȐȔȍȐȐȑ
IMPORTANT: Make sure that the track adjuster (1)

is not hung on spring guide (3) on
track frame (2) and correctly seated
on the plate (4).
1. Insert track adjuster (1) into track frame (2) as

illustrated.
ȷȕȐȗȍȐȓȍȐȔȍȐȐȑ
3 3
ȷȕȐȗȍȐȓȍȐȔȍȐȐȓ
ȷȕȐȗȍȐȓȍȐȔȍȐȐȒ
W3-4-1
UNDERCARRIAGE / Track Adjuster
ϑBlankϒ
W3-4-2
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Before removing or installing the front idler, the rubber

crawler must be removed or installed beforehand.
Refer to "REMOVE AND INSTALL RUBBER
CRAWLER".
The procedures described below start after the rubber
crawler is removed.
Removal
CAUTION: Front idler weight: 41 kg (90 lb)
ȷȕȐȗȍȐȓȍȐȕȍȐȐȑ
1. Remove the idler assembly from the track frame.

Remove the front idler and yoke assembly from
the track frame using a crowbar.
CAUTION: When storing the front idler, lay

the front idler on wooden blocks to keep
balance.
ȷȕȖȒȍȐȓȍȐȕȍȐȐȑ
Installation
1. To install the front idler, simply perform the

removal procedures in reverse. Take care on
following points:
• Before installing, check that the yoke is correctly

positioned.
• Apply grease to the sliding surfaces of the track
frame and bearing after cleaning them.
ȷȕȖȒȍȐȓȍȐȕȍȐȐȑ
W3-5-1
UNDERCARRIAGE / Front Idler
C D F
A
B
W503-03-05-001
Unit: mm
Standard Allowable Limit Remedy
A 53 48
B 92 -
C 44 - Cladding by welding
D 300 295 and Hand Finishing
E 10 -
F 344 -
NOTE: 1 mm = 0.03937 in
Unit: mm
Axle and Bushing

Outer
Axle 40.0 39.2
Diameter
Inner
40.0 40.0 Replace
Diameter
Bushing
Flange
2 1.5
Thickness
Lubrication Oil
Engine Oil Grade: API Class CD, SAE30
3
Oil Capacity: 60 cm (0.63 US qt)
W3-5-2
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
1
CAUTION: Grease pressure in the track
adjuster is high. Do not loosen valve (1)
quickly or loosen it too much. Valve (1) may
fly out or high pressure grease in the track
adjuster may spout out. Loosen carefully,
keeping body parts and face away from valve
(1). Never loosen grease fitting (2).
2
Grease Outlet
IMPORTANT: If gravel or mud is packed between ȭȑȐȔȍȐȗȍȑȑș

sprockets and tracks, be sure to
remove it before loosening.
1. Slowly loosen track adjuster valve (1) to discharge

grease.
: 19 mm
IMPORTANT: Place pads between track frame (3) 1

and oil jack (4) when jacking up to
prevent the jack from slipping.
ȷȕȐȗȍȐȓȍȐȖȍȐȐȑ
2. Jack up track (6) until the clearance between 6 5 7 3

track (6) and upper roller (5) is wide enough to
remove upper roller (5). Then place wooden
blocks (6) on track frame (3) to support track (6).
3. Loosen bolt (7) and remove upper roller (5).
: 22 mm 4
ȷȕȐȗȍȐȓȍȐȖȍȐȐȓ
W3-6-1
Installation
1. Install upper roller (5) onto track frame (3) with
6 5 7 3
bolt (7).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 100 lbf⋅ft)
2. Remove wooden blocks and oil jack (4).

4
ȷȕȐȗȍȐȓȍȐȖȍȐȐȓ
㈍ 8
3. Tighten track adjuster valve (1) and add grease
via grease fitting (8) until the track sag is within
specifications.
Track Sag Specifications (A).

Steel Track: 140 to 160 mm (5.5 to 6.3 in)
Rubber Crawler: 10 to 15 mm (0.4 to 0.6 in)
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
ȷȕȐȗȍȐȓȍȐȖȍȐȐȕ
Roller
Rubber Cralwer
ȭȕȐȓȍȐȕȍȐȕȐ A
Steel Track
ȭȕȕȒȍȐȗȍȐȓȗ
W3-6-2
REMOVE AND INSTALL LOWER ROLLER
Removal
CAUTION: Support the raised track securely

1. Raise the one side track off the ground using the 90 to 110ѯ
front attachment.

ȭȕȗȐȍȐȗȍȐȐȑ
adjuster is high. Do not loosen valve (1) 1
adjuster may spout. Loosen carefully,
keeping body parts and face well away from
valve (1). Never loosen grease fitting (2).
2
IMPORTANT: If gravel or mud is packed between
sprockets and tracks, remove it Grease Outlet
before loosening.
1
2. Loosen track adjuster valve (1) slowly to let
grease flow out until the clearance between the
track frame and crawler is wide enough to remove
lower roller (3).
3
3. Loosen bolt (4) and remove lower roller (3). 4
: 27 mm
W3-6-3
Installation
1
1. Install lower roller (3) to the underside of the track
frame, aligning the bolt holes.
3
2. Apply LOCTITE #262 to bolt (4) threads and
4
tighten to specifications.
: 27 mm
: 450 N⋅m (46 kgf⋅m, 330 lbf⋅ft)
3. Jack up the one side track using the front
attachment and remove wooden blocks.
90 to 110ѯ
4. Tighten track adjuster valve (1) and add grease ȭȕȗȐȍȐȗȍȐȐȑ
1 2
via fitting (2) until the track sag is within
specifications.
Track Sag Specifications (A).

Steel Crawler: 140 to 160 mm (5.5 to 6.3 in)
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
Roller
Rubber Crawler
A
ȭȕȐȓȍȐȕȍȐȕȐ
Steel Crawler
ȭȕȕȒȍȐȗȍȐȓȗ
W3-6-4
Upper Roller
W554-03-06-001
Unit: mm
A 110 -
Replace
B 80 74
NOTE: 1 mm = 0.03937 in
W3-6-5
Lower Roller
C D E
A
B
ȷȕȐȓȍȐȓȍȐȖȍȐȐȑ
Unit: mm
A 53 45
B 200 - Cladding by
welding and
C 35 -
Hand Finishing,
D 95 87 or Replace
E 122 -
NOTE: 1 mm = 0.03937 in
Axle and Bushing

Unit: mm

Outer
Axle 35 34.2 Replace
Diameter
Inner
Bushing 35 35.5
Diameter
Flange
2 1.5
Thickness
Lubrication Oil
Engine Oil Grade: API Class CD, SAE30
3
Oil Capacity: 45 cm (0.48 US qt)
W3-6-6
UNDERCARRIAGE / Track
REMOVE AND INSTALL RUBBER CRAWLER
1
Removal

adjuster is high. Do not loosen valve (1)
2
adjuster may spout. Loosen carefully,
keeping body parts and face well away from
Grease Outlet
valve (1). Never loosen grease fitting (2).
1. Jack up the one side track using the front

attachment, and place wooden blocks under the
track frame.
90 to 110ѯ
ȭȕȗȐȍȐȗȍȐȐȑ
IMPORTANT: If debris such as rock fragments is

packed between the sprocket tooth
and the rubber crawler, remove
packed material before loosening
the valve.
2. Slowly loosen track adjuster valve (1) to allow

grease to escape.
: 19 mm
ȷȑșȐȍȐȓȍȐȖȍȐȐȑ
Rotate Direction
Insert steel pipes into the gaps between the

rubber crawler and track frame.
Then, rotate the sprocket in reverse direction.
After the rubber crawler is raised off the front
idler with the steel pipes, slide the rubber track
Steel pipe
away from the track frame and remove it. ȭȕȐȓȍȐȗȍȐȖȒ
W3-7-1
Installation
CAUTION: Support the raised track securely

1. Using the front attachment, raise the one side

track of the machine off the ground, and place
wooden blocks under the track frame to securely 90 to 110ѯ
support the machine.
2. Reinstall the rubber crawler on the sprocket and

hang the other end of the rubber track over the
front idler. ȭȕȗȐȍȐȗȍȐȐȑ
Rotate the sprocket in the reverse direction to

Rotate Direction
sufficiently remesh the rubber crawler back onto
the sprocket.
IMPORTANT: Check that the rubber crawler is

securely engaged onto both the
sprocket and front idler.
3. After inserting a steel pipe into the gap between

the rubber crawler and track frame, rotate the Steel pipe
ȭȕȐȓȍȐȗȍȐȖȓ
sprocket again. Then, completely install the
rubber track onto the front idler. ㈍ 2
4. Tighten the track adjuster valve. Add grease into

the adjuster cylinder via the grease fitting to adjust
track sag.
Track Sag Specification (A)

Steel Track: 140 to 160 mm (5.5 to 6.3 in)
NOTE: With the joint section of the rubber track

placed just under the lower roller, measure ȷȕȐȗȍȐȓȍȐȖȍȐȐȕ
track sag at the lower center roller as

illustrated.
Roller
A
Joint
Joint
Track (Rubber Crawler) ȭȑȐȒȍȐȗȍȐȗȐ
ȭȑȐȒȍȐȗȍȐȗȕ
ȭȕȐȓȍȐȕȍȐȕȐ
W3-7-2
MAINTENANCE STANDARD
Outside of Rubber Crawler
1. If there is a crack on lug base (1) with depth of 10
mm (0.4 in) or more, repair crawler. 1
4
If there is a crack between lugs (2) with depth of
10 mm (0.4 in) or more, repair crawler. 5
2
If there is a crack on rugs (3) or between lugs (2)
that reaches to steel code (5) or steel core (4) with
length of 30 mm (1.2 in) or more, immediately
repair crawler. 3
2. 2Inside of Rubber Crawler (Roller Side)

If there is a crack that reaches to steel code (5) or
steel core (4), immediately repair crawler.
W190-03-07-001
5 W190-03-07-002
Lower Roller
Lug Wear
1. If the lug height (A) is less than 5 mm, replace the Rubber Track
rubber crawler as an assembly.
Lug W190-03-07-003
2. If any portion of steel code (5) appeared on

crawler, replace worn rubber crawler as an
assembly.
5
W190-03-07-004
W3-7-3
Rubber Crawler and Steel Code Cutting
1. When either of the two rows of the steel code (5)
has cut, replace rubber crawler as an assembly.
5
W190-03-07-005
Steel Core Separation

2. When any steel core (4) has separated, replace
rubber crawler as an assembly.
W190-03-07-006
W3-7-4
SECTION 4
FRONT ATTACHMENT
—CONTENTS—
Group 1 Front Attachment
Remove and Install Front Attachment..... W4-1-1
Maintenance Standards.......................... W4-1-6
Group 2 Cylinder
Remove and Install Cylinders ................. W4-2-1
Disassemble Boom And Arm Cylinders .. W4-2-9
Assemble Boom And Arm Cylinders ..... W4-2-12
Disassemble Bucket, Swing And
Blade Cylinders .................................... W4-2-17
Assemble Bucket, Swing And Blade
Cylinders .............................................. W4-2-20
Maintenance Standards........................ W4-2-22
585W-4-1
ϑBlankϒ
585W-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT
ATTACHMENT

numbers.

Preparation

3. Remove the cap. Install a vacuum pump on the ȴȕȗȑȍȐȕȍȐȒȍȐȐȑ

W4-1-1
Removal
4 3
1. Loosen bolt (1) to remove cover (2).
: 19 mm
2. Connect boom cylinder (3) to a crane with sling

belts. Remove bolt (4) and pin (5) while slightly
lifting the boom cylinder.
: 22 mm
CAUTION: Boom cylinder weight: 1 5 2

51 kg (112 lb) (40u) ȷȕȗȑȍȐȔȍȐȑȍȐȐȑ
55.5 kg (122 lb) (50u)
3. Place a support under the cylinder tube top end. 3

Operate the boom lever to retract the boom
cylinder fully. Thread a piece of wire through the
rod hole and tie it to the cylinder tube so that the
cylinder rod can not be extended.
Wire
ȷȕȕȔȍȐȒȍȐȓȍȐȐȗ
6
4. Remove hose cover (6).
: 17 mm
5. Disconnect all hoses. Cap each disconnected

hose end.
: 22 mm, 27 mm
ȷȕȗȑȍȐȔȍȐȑȍȐȐȓ
CAUTION: Front attachment weight:

490 kg (1078 lb) (40u)
513 kg (1131 lb) (50u)
6. Attach sling belts around the boom at the gravity

center of the front attachment. Be sure to place a
protector between the boom and the sling belts,
as illustrated. After connecting the sling belt ends
to a crane, taut the sling bolts to securely support
the front attachment.
ȷȕȐȗȍȐȔȍȐȑȍȐȐȕ
W4-1-2
7. Loosen nut (9) for stopper bolt (8) on boom foot

pin (7), then remove stopper bolt (8).
: 22 mm
8. Remove boom foot pin (7).
9 7
ȷȕȒȗȍȐȔȍȐȑȍȐȐȔ
9. Lay the front attachment in a good balanced

position using the crane.
W4-1-3
Installation
CAUTION: Front attachment weight:

490 kg (1078 lb) (40u)
513 kg (1131 lb) (50u)
1. Attach sling belts around the boom at the gravity

center of the front attachment. Be sure to place a
protector between the boom and the sling belts,
as illustrated. After connecting the sling the sling
belt ends to a crane, lift the front attachment.
2. Drive in boom foot pin (7) while aligning the boom

foot with the pin holes on the frame bracket.
3. Install stopper bolt (8) into boom foot pin (7). 8

Tighten stopper bolt (8) with nut (9).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 100 lbf⋅ft) 9 7
ȷȕȒȗȍȐȔȍȐȑȍȐȐȔ
IMPORTANT: After filling the hydraulic oil tank
with oil to the correct level, start the
6
engine and check hoses for oil
leaks.
4. Uncap the ends of hoses routed on the machine.

Connect all hoses.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
5. Install hose cover (6).

ȷȕȗȑȍȐȔȍȐȑȍȐȐȓ
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
4 3
6. Attach a sling belt to boom cylinder. Align the
cylinder rod hole with the pin hole on the bracket.
Drive pin into the hole. Install bolt.
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
7. Install cover using bolts.
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
1 5 2
ȷȕȗȑȍȐȔȍȐȑȍȐȐȑ
W4-1-4
ϑBlankϒ
W4-1-5
Pin Bushing
M N
W533-04-01-002
A
C
B
E D P
I K Q
J
O
G
H
W571-04-01-004
Unit: mm
Key Letter Part Name Standard Allowable Limit Remedy

Pin 50 49.0
A
Bushing (Boom) 50 51.5
Pin 50 49.0
B
Bushing (Boom Cylinder) 50 51.5
Pin 50 49.0
C
Bushing (Boom Cylinder) 50 51.5
Pin 50 49.0
D Replace
Bushing (Arm) 50 51.5
Pin 45 44.0
E
Bushing (Arm Cylinder) 45 46.5
Pin 45 44.0
F
Bushing (Arm Cylinder) 45 46.5
Pin 45 44.0
G
Bushing (Bucket Cylinder) 45 46.5
NOTE: 1 mm = 0.03937 in
W4-1-6
Unit: mm
Key Letter Part Name Standard Allowable Limit Remedy

Pin 45 44.0
Bushing (Bucket Cylinder) 45 46.5
H
Bushing 45 46.5
Link B 45 46.5
Pin 45 44.0
I Bushing (Arm) 45 46.5
Link B 45 46.5
Pin 45 44.0
J
Bushing (Link A) 45 46.5
Pin 45 44.0
K
Bushing (Arm) 45 46.5
Pin 90 89.0
L
Bushing (Main Frame) 90 91.5 Replace
Pin 45 44.0
M Bushing
45 46.5
(Boom Swing Cylinder)
Pin 50 49.0
N Bushing
50 51.5
(Boom Swing Cylinder)
Pin 45 44.0
O
Bushing (Blade) 45 46.5
Pin 55 54.0
P
Bushing (Blade Cylinder) 55 56.5
Pin 55 54.0
Q
Bushing (Blade Cylinder) 55 56.5
NOTE: 1 mm = 0.03937 in
W4-1-7
Side Cutter
C
A
ȷȕȐȕȍȐȔȍȐȑȍȐȐȑ
Unit: mm

A 127 85
B 163 -
Replace
C 223 -
D 130 -
Point
B C
Unit: mm
ȷȕȕȔȍȐȔȍȐȑȍȐȐȓ

A 128 65
B 56 -
Replace
C 62 -
D 51 -
NOTE: 1 mm = 0.03937 in
W4-1-8
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDERS

numbers.

Preparation
the lower bucket to the ground.


hydraulic oil tank. Operate the vacuum pump to ȴȕȗȑȍȐȕȍȐȒȍȐȐȑ

W4-2-1
Remove Bucket Cylinder
3 1
1. Insert a wooden block between bucket cylinder (1)
and arm (2).
IMPORTANT: Secure the link using a wire to

prevent the link from falling before
removing pin (3).
2 ȷȕȗȑȍȐȔȍȐȒȍȐȐȑ
4 6
2. Remove ring (4) and stopper pin (5) from the link,
then remove pin (3).
5
3. Secure cylinder rod (6) using a wire to prevent rod
(6) from extending.
3
ȷȕȒȗȍȐȔȍȐȒȍȐȐȒ
CAUTION: Bucket cylinder weight:

26.5 kg (58 lb) (40u)
29 kg (64 lb) (50u) 1
4. Attach bucket cylinder (1) to crane using sling belt

and hold it.
5. Remove bolt (7). Remove pin (8) to remove

cylinder (1). ȷȕȗȑȍȐȔȍȐȒȍȐȐȒ
1 8 7
: 22 mm
6. Disconnect hoses (9) (2 used) from bucket

cylinder (1) at the cylinder bottom. Cap hoses (9)
end.
: 22 mm
7. Lift and remove bucket cylinder (1) using a crane.

9 ȷȕȗȑȍȐȔȍȐȒȍȐȐȓ
W4-2-2
Install Bucket Cylinder
1 8 7

26.5 kg (58 lb) (40u)
29 kg (64 lb) (50u)
1. Lift bucket cylinder (1) using a crane. Connect

hoses (9) (2 used) bucket cylinder (1).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
2. Align the pin holes on cylinder tube and arm. 9 ȷȕȗȑȍȐȔȍȐȒȍȐȐȓ

Insert pin (8), and secure it using bolt (7).
3 1
: 22 mm
: 137 N⋅m (14 kgf⋅m, 100 lbf⋅ft)
3. Start the engine, and extend bucket cylinder (1).

Align the rod hole of bucket cylinder (1) with the
link hole, then insert pin (3).
ȷȕȐȗȍȐȔȍȐȒȍȐȐȔ
4
4. Insert stopper pin (5), then install ring (4).
IMPORTANT: After installation, bleed air from the

hydraulic system by moving the 5
bucket cylinder full stroke several
times.
ȷȕȒȗȍȐȔȍȐȒȍȐȐȒ
W4-2-3
Remove Arm Cylinder
3 4 1
1. Insert a wooden block between arm cylinder (1)
and boom (2).
2. Remove bolt (3), then remove pin (4).
: 22 mm
3. Secure the cylinder rod using a wire to prevent the

rod from extending.
2
ȷȕȗȑȍȐȔȍȐȒȍȐȐȔ
4. Disconnect two cylinder hoses (4) from arm 1

cylinder (1). Cap hose (4) ends.
: 27 mm
CAUTION: Arm cylinder weight:

40 kg (88 lb) (40u)
41 kg (90 lb) (50u) 4
ȷȕȒȗȍȐȔȍȐȒȍȐȐȖ
5. Attach lifting belts onto arm cylinder (1), and hole

it using a crane.
ȷȕȗȑȍȐȔȍȐȒȍȐȐȖ
6. Remove bolt (5), then remove pin (6).
: 22 mm
7. Lift and remove arm cylinder (1) using a crane.
6 5
ȷȕȒȗȍȐȔȍȐȒȍȐȐȘ
W4-2-4
Install Arm Cylinder
1
CAUTION: Arm cylinder weight:
40 kg (88 lb) (40u)
41 kg (90 lb) (50u)
1. Lift arm cylinder (1) using a crane. Align the pin

holes on the cylinder tube side and arm.
2. Insert pin (6) and secure it with bolt (5).
: 22 mm 6 5
ȷȕȒȗȍȐȔȍȐȒȍȐȐȘ
: 137 N⋅m (14 kgf⋅m, 100 lbf⋅ft) 1
3. Connect hoses (4) (2 used) to arm cylinder (1).
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
4
ȷȕȒȗȍȐȔȍȐȒȍȐȐȖ
3 4 1
4. Start engine and extend arm cylinder (1) so that

the rod hole on arm cylinder (1) is aligned with the
hole on the arm.
5. Insert pin (4) and secure it with bolt (3).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 100 lbf⋅ft)

hydraulic system by moving the
2
bucket cylinder full stroke several ȷȕȗȑȍȐȔȍȐȒȍȐȐȔ
times.
W4-2-5
Remove Boom Cylinder
4 3
1. Loosen bolt (1) to remove cover (2).
: 19 mm
2. Attach a sling belt to boom cylinder (3). While

holding boom cylinder (3) using a crane, remove
bolt (4) and pin (5).
: 22 mm
1 5 2
CAUTION: Boom cylinder weight:

51 kg (112 lb) (40u)
55.5 kg (122 lb) (50u)
3
3. Place a support under the end of the cylinder tube.

Operate the boom control lever to fully retract the
rod. Thread a piece of wire through the rod hole,
and tie it to the boom cylinder (3) tube to prevent
the cylinder rod from extending. Wire
ȷȕȕȔȍȐȒȍȐȓȍȐȐȗ
6 3
4. Disconnect hose (6) from boom cylinder (3). Cap
disconnected hose (6) end.
: 27 mm
3 ȷȕȗȑȍȐȔȍȐȒȍȐȐȗ
5. Remove bolt (7) and pin (8).
: 19 mm
6. Lift and remove boom cylinder (3) using a crane.
8 7 ȷȕȗȑȍȐȔȍȐȒȍȐȐȘ
W4-2-6
Install Boom Cylinder

51 kg (112 lb) (40u)
55.5 kg (122 lb) (50u) 3
1. Lift boom cylinder (3) using a crane. Align the

pin holes on the cylinder tube side and swing post.
2. Insert pin (8) and secure it using bolt (7).
: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
8 7 ȷȕȗȑȍȐȔȍȐȒȍȐȐȘ
6 3
3. Connect hoses (6) (2 used) to boom cylinder (3).
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
ȷȕȗȑȍȐȔȍȐȒȍȐȐȗ
4 3
4. Lift boom cylinder (3) using a crane. Start engine

and extend boom cylinder (3) until mounting holes
are aligned.
5. Insert pin (5) and secure it using bolt (4).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 100 lbf⋅ft)
6. Install cover (2) using bolt (1). 1 5 2

: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

hydraulic system by moving the
boom cylinder full stroke several
times.
W4-2-7
(Blank)
W4-2-8
DISASSEMBLE BOOM AND ARM
CYLINDERS

numbers.
Boom Cylinder
2
3
4
5
6
7
8
9
10 30
11
1 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
ȷȕȗȑȍȐȔȍȐȒȍȐȑȓ
1- Cylinder Tube 8- Backup Ring 15 - Cushion Ring 22 - Steel Ball
2- Wiper Ring 9- U-Ring 16 - Spacer 23 - Set Screw
3- Cylinder Head 10 - Connector 17 - Stopper 24 - Seal Ring
4- O-Ring 11 - Stopper 18 - Cushion Bearing 25 - O-Ring
5- Backup Ring 12 - Retainer 19 - Shim 26 - Slide Ring
6- O-Ring 13 - Backup Ring 20 - Slide Ring 30 - Piston Rod
7- Bushing 14 - O-Ring 21 - Piston
W4-2-9
Arm Cylinder
3
4
5
6
7
8
9
10 30
11
1 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
W571-04-02-014
1- Cylinder Tube 9- U-Ring 17 - Stopper 25 - O-Ring

2- Wiper Ring 10 - Connector 18 - Cushion Bearing 26 - Slide Ring
3- Cylinder Head 11 - Stopper 19 - Shim 27 - Cushion Bearing
4- O-Ring 12 - Retainer 20 - Slide Ring 28 - Washer
5- Backup Ring 13 - Backup Ring 21 - Piston 29 - Bolt
6- O-Ring 14 - O-Ring 22 - Steel Ball 30 - Piston Rod
7- Bushing 15 - Cushion Ring 23 - Set Screw
8- Backup Ring 16 - Spacer 24 - Seal Ring
W4-2-10
Disassemble Boom Cylinder and Arm Cylinder
• Read PRECAUTIONS FOR DISASSEMBLING 7. Remove cylinder head (3) from piston rod (30).
disassembling. IMPORTANT: Take care not to damage other parts
• Start the following procedures after disconnecting when removing seals.
the lines.
8. Remove slide rings (20), (26), seal ring (24) and
O-ring (25) from piston (21) using a screwdriver.
51 kg (112 lb) (40u)
9. Remove stopper (11), connector (10) and retainer
55.5kg (122 lb) (50u)
(12) from cylinder head (3).
Arm Cylinder weight: 40 kg (88 lb) (40u)
41 kg (90 lb) (50u)
10. Remove backup ring (13) and O-ring (14) from
the outside of retainer (12).
1. Clamp the pin mounting part of cylinder tube (1)
11. Remove stopper (17), spacer (16) and cushion
and hold it horizontally in a vise to drain hydraulic
bearing (15) from the inside of retainer (12).
oil from the cylinder.
12. Remove wiper ring (2), backup ring (8) and U-ring
IMPORTANT: Be careful not to damage cylinder
(9) from the inside of cylinder head (3).
tube (1) when locking or unlocking
cylinder head.
13. Remove O-ring (4), backup ring (5) and O-ring (6)
Be sure to pull piston rod (30)
from the outside of cylinder head (3).
straight out so as not to damage the
sliding surfaces.
14. Remove bushing (7) from the inside of cylinder
head (3) using a special tool.
2. Pull out piston rod (30) approximately 200 mm
and loosen cylinder head (3) using a hook
spanner. Remove piston rod (30) from cylinder
tube (1).
3. Secure piston rod (30) horizontally.
4. Remove set screw (23) and steel ball (22) from

piston (21).
: 4 mm
NOTE: As set screw (23) head is mushroomed

after being installed, cut the mushroomed
part with a hand drill before loosening set
screw (23).
5. Remove piston (21), shim (19) and cushion

bearing (18) from piston rod (30).
: 65 mm [Boom]
60 mm [Arm]
6. Remove bolt (29) from piston rod (26) to remove

washer (28) and cushion bearing (27).
NOTE: Bolt (29) is coated with an adhesive. Heat it

for 10 to 15 seconds to ease removal.
Bolt (29), washer (28) and cushion bearing
(27) are not installed in the boom cylinder.
W4-2-11
ASSEMBLE BOOM AND ARM CYLINDERS
Boom Cylinder
2 3 4 8 9 5 6 15 16 17 1 18 21 20 26 23 22
7 10 11 12 13 14 30 19 24 25 W571-04-02-009
Arm Cylinder
2 3 4 8 9 5 6 15 16 17 1 18 21 20 26 23 22
7 10 11 12 13 14 30 19 24 25 27 28 29 W571-04-02-010
NOTE: The parts for each cylinder are different in

size even if their names are equal. Always
use the correct parts for each cylinder.

W4-2-12
Assemble Boom Cylinder and Arm Cylinder
• Read PRECAUTIONS FOR DISASSEMBLING 10. Install cushion bearing (18), shim (19) and piston
AND ASSEMBLING (W1-1-1) carefully before (21) onto piston rod (26).
assembling. [Boom]
• Clean, remove grease disassembled parts and : 65 mm
dry them completely. : 1670 N⋅m (170 kgf⋅m, 1220 lbf⋅ft) (40u)
• Warm seals to 80ѵ to ease installation. 1720 N⋅m (175 kgf⋅m, 1270 lbf⋅ft) (50u)
[Arm]
IMPORTANT: After pressing bushing (7) in, : 60 mm
confirm that the bushing end : 1180 N⋅m (120 kgf⋅m, 865 lbf⋅ft) (40u)
surface is flush with that of cylinder 1230 N⋅m (125 kgf⋅m, 905 lbf⋅ft) (50u)
head (3).
IMPORTANT: After tightening set screw (23),
1. Press bushing (7) into cylinder head (3). mushroom the screw head in two
places to lock it.
IMPORTANT: Press U-ring (9) in the correct
direction. 11. Insert steel ball (22) into piston (21). Install set
screw (23).
2. Install backup ring (8), U-ring (9) and wiper ring
(2) into cylinder head (3). : 4 mm
: 16.7 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft)
3. Install O-ring (6), backup ring (5) and O-ring (4)
into cylinder head (3). IMPORTANT: Apply an adhesive to the threads of
bolt (29).
4. Install cushion bearing (15), spacer (16) and
stopper (17) in the bore of retainer (12). 12. Install cushion bearing (27), washer (28) and bolt
(29) onto piston rod (30).
5. Install O-ring (14) and backup ring (13) onto the
outer diameter of retainer (12). : 8 mm
: 41 N⋅m (4.2 kgf⋅m, 30 lbf⋅ft)
6. Install retainer (12), connector (10) and stopper
(11) into cylinder head (3). NOTE: Cushion bearing (27), washer (28) and bolt
(29) are not installed in boom cylinder.
IMPORTANT: Be sure that O-ring (25) is not
twisted after installation.
7. Install O-ring (25) and seal ring (24) onto piston

(21), then correct the seating position using a
special tool.
IMPORTANT: Install the slide rings so that the slits

are not aligned in the same position.
8. Install slide rings (26) and (20) onto piston (21).
9. Install cylinder head (3) onto piston rod (26).
W4-2-13
Boom Cylinder
2 3 4 8 9 5 6 15 16 17 1 18 21 20 26 23 22
7 10 11 12 13 14 30 19 24 25 W571-04-02-009
Arm Cylinder
2 3 4 8 9 5 6 15 16 17 1 18 21 20 26 23 22
7 10 11 12 13 14 30 19 24 25 27 28 29 W571-04-02-010


W4-2-14
IMPORTANT: Take care that slide rings (24) and
(26) will not come off the piston
when inserting piston rod (30).
13. Clamp cylinder tube (1) horizontally in a vise.

Insert piston rod (30) assembly into cylinder tube
(1).
14. Tighten cylinder head (3). Bend the lock washer to

secure the cylinder head.
[Boom]
: 357 N⋅m (36.4 kgf⋅m, 260 lbf⋅ft) (40u)
370 N⋅m (37.8 kgf⋅m, 275 lbf⋅ft) (50u)
[Arm]
: 330 N⋅m (33.6 kgf⋅m, 240 lbf⋅ft)
W4-2-15
(Blank)
W4-2-16
DISASSEMBLE BUCKET, SWING AND
BLADE CYLINDERS
Bucket Cylinder
2
3
4 30
1 5
6
8
20
21
22
23
24
25
26
W571-04-02-015
1- Cylinder Tube 6- O-Ring 21 - Piston 26 - Slide Ring

2- Wiper Ring 7- Bushing 22 - Steel Ball 30 - Piston Rod
3- Cylinder Head 8- Backup Ring 23 - Set Screw
4- O-Ring 9- U-Ring 24 - Seal Ring
5- Backup Ring 20 - Slide Ring 25 - O-Ring
W4-2-17
Swing Cylinder and Blade Cylinder

NOTE: The illustration shows the swing cylinder.
5 30
6
1
9
31
32
20
21
22
23
24
25
26
W571-04-02-016
1- Cylinder Tube 6- O-Ring 22 - Steel Ball 30 - Piston Rod
2- Wiper Ring 7- Bushing 23 - Set Screw 31 - Packing Header
3- Cylinder Head 9- U-Ring 24 - Seal Ring 32 - Retaining Ring
4- O-Ring 20 - Slide Ring 25 - O-Ring
5- Backup Ring 21 - Piston 26 - Slide Ring
W4-2-18
Disassemble Bucket Cylinder, Swing Cylinder
and Blade Cylinder
• Read PRECAUTIONS FOR DISASSEMBLING 6. Remove cylinder head (3) from piston rod (30).
disassembling. IMPORTANT: Take care not to damage other parts
• Start the following procedures after disconnecting when removing seals.
the lines.
7. Remove slide rings (20), (26), seal ring (24) and
O-ring (25) from piston (21) using a screwdriver.
26.5 kg (58 lb) (40u)
8. Remove wiper ring (2), retaining ring (32), packing
29 kg (64 lb) (50u)
header (31), backup ring (8) and U-ring (9) from
Swing cylinder weight: 44 kg (97 lb)
the inside of cylinder head (3).
(40u, 50u)
Blade cylinder weight: 35.5 kg (78 lb)
(40u, 50u) NOTE: Retaining ring (32) and packing header (31)
are not installed in the bucket cylinder.
1. Clamp the pin mounting part of cylinder tube (1) Also, backup ring (8) is not installed in
and hold it horizontally in a vise to drain hydraulic swing cylinder and blade cylinder.
oil from the cylinder.
9. Remove O-ring (4), backup ring (5) and O-ring (6)
IMPORTANT: Be careful not to damage cylinder from the outside of cylinder head (3).
tube (1) when locking or unlocking
cylinder head. 10. Remove bushing (7) from the inside of cylinder
Be sure to pull piston rod (30) head (3) using a special tool.
straight out so as not to damage the
sliding surfaces.
2. Pull out piston rod (30) approximately 200 mm

and loosen cylinder head (3) using a hook
spanner. Remove piston rod (30) from cylinder
tube (1).
3. Secure piston rod (30) horizontally.
4. Remove set screw (23) and steel ball (22) from

piston (21).
: 3 mm [Bucket]
4 mm [Swing, Blade]
NOTE: NOTE: As set screw (23) head is

mushroomed after being installed, cut the
mushroomed part with a hand drill before
loosening set screw (23).
5. Remove piston (21) from piston rod (30).
: 50 mm [Bucket] (40u)
55 mm [Bucket] (50u)
60 mm [Swing]
65 mm [Blade]
W4-2-19
ASSEMBLE BUCKET, SWING AND BLADE
CYLINDERS
Bucket Cylinder
2 3 4 5 6 1 21 20 26 23 22
W571-04-02-009
8 9 7 30 24 25
Swing Cylinder and Blade Cylinder
2 3 4 7 5 6 1 21 20 26 23 22
9 31 32 30 24 25 W571-04-02-010

1- Cylinder Tube 6- O-Ring 21 - Piston 26 - Slide Ring

2- Wiper Ring 7- Bushing 22 - Steel Ball 30 - Piston Rod
3- Cylinder Head 8- Backup Ring 23 - Set Screw 31 - Packing Header
4- O-Ring 9- U-Ring 24 - Seal Ring 32 - Retaining Ring
5- Backup Ring 20 - Slide Ring 25 - O-Ring
W4-2-20
Assemble Bucket Cylinder, Swing Cylinder and
Blade Cylinder
• Read PRECAUTIONS FOR DISASSEMBLING 7. Install piston (21) onto piston rod (26).
AND ASSEMBLING (W1-1-1) carefully before [Bucket]
disassembling. : 50 mm (40u), 55 mm (50u)
• Clean, remove grease from disassembled parts, : 718 N⋅m (80 kgf⋅m, 575 lbf⋅ft) (40u)
and dry them completely. 1030 N⋅m (105 kgf⋅m, 760 lbf⋅ft) (50u)
• Warm seals to 80 °C (176 °F) to ease installation. [Swing]
Ȁ: 60 mm
IMPORTANT: After pressing bushing (7) in, : 1325 N⋅m (135 kgf⋅m, 970 lbf⋅ft)
confirm that the bushing end [Blade]
surface is flush with that of cylinder : 65 mm
head (3). : 1910 N⋅m (195 kgf⋅m, 1400 lbf⋅ft)
1. Press bushing (7) into cylinder head (3). IMPORTANT: After tightening set screw (23),
mushroom the screw head in two
IMPORTANT: Press U-ring (9) in the correct places to lock it.
direction.
8. Insert steel ball (22) into piston (21). Install set
2. Install backup ring (8), U-ring (9), packing header screw (23).
(31), retaining ring (32) and wiper ring (2) into [Bucket]
cylinder head (3). : 3 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
NOTE: Packing header (31) and retaining ring (32) [Swing, Blade]
are not installed in the bucket cylinder. Also, : 4 mm
backup ring (8) is not installed in the swing : 16.7 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft)
or blade cylinder.
IMPORTANT: Take care that slide rings (24) and
3. Install O-ring (6), backup ring (5) and O-ring (4) (26) will not come off piston when
onto cylinder head (3). inserting piston rod (30).
IMPORTANT: Be sure that O-ring (25) is not 9. Clamp cylinder tube (1) horizontally in a vise.
twisted after installation. Insert piston rod (30) assembly into cylinder tube
(1).
4. Install O-ring (25) and seal ring (24) onto piston
(21), then correct the seating position using a 10. Tighten cylinder head (3). Bend the lock washer to
special tool. secure the cylinder head.
[Bucket]
IMPORTANT: Install the slide rings so that the slits : 300 N⋅m (30.8 kgf⋅m, 220 lbf⋅ft) (40u)
are not aligned in the same position. 315 N⋅m (32.2 kgf⋅m, 235 lbf⋅ft) (50u)
[Swing]
5. Install slide rings (26) and (20) onto piston (21). : 385 N⋅m (39.2 kgf⋅m, 280 lbf⋅ft)
[Blade]
6. Install cylinder head (3) onto piston rod (26). : 410 N⋅m (42 kgf⋅m, 300 lbf⋅ft)
W4-2-21
ȷȑȐȕȍȐȔȍȐȒȍȐșȔ
40u
Cylinder Name Recommended O.D. size after Re-plating (A)
ȍȐȎȐȓ
Boom 55-0.076 mm
ȍȐȎȐȒȕ
Arm 50-0.064 mm
ȍȐȎȐȒȕ
Bucket 40-0.064 mm
Swing 50ȍȐȎȐȒȕ
-0.064 mm
Blade 60ȍȐȎȐȓ
-0.076 mm
50u
Cylinder Name Recommended O.D. size after Re-plating (A)
ȍȐȎȐȓ
Boom 55-0.076 mm
ȍȐȎȐȒȕ
Arm 50-0.064 mm
Bucket 45ȍȐȎȐȒȕ
-0.064 mm
ȍȐȎȐȒȕ
Swing 50-0.064 mm
Blade 60ȍȐȎȐȓ
-0.076 mm
NOTE: 1 mm = 0.03937 in
W4-2-22

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Technical Manual

Group 2 Component Layout

(40u Type A) … Refer to INTRODUCTION (IN-01) for

Item Unit Canopy Cab

(40u Type B) … Refer to INTRODUCTION (IN-01) for

Item Unit Canopy Cab

Item Unit Canopy Cab

Category 40u Type A 40u Type B

Item Unit Canopy Cab

1- Bucket Cylinder 6- Hydraulic Oil Tank 11 - Solenoid Valve 16 - Swing Device

(40u Type A) … Refer to INTRODUCTION (IN-01) for

(40u Type B, 50u) … Refer to INTRODUCTION (IN-

(40u Type A) … Refer to INTRODUCTION (IN-01) for

(40u Type B, 50u) … Refer to INTRODUCTION (IN-

1 - Fuse Box 3 - Glow Relay 5 - Starter Relay 7 - Horn Relay

(40u Type A) … Refer to INTRODUCTION (IN-01) for

(40u Type B, 50u) … Refer to INTRODUCTION (IN-

The hydraulic system consists of the main circuit and

The return oil from cylinders or motors returns to con-

Travel Motor (Left) Travel Motor (Right)

Hydraulic Oil Tank Main Pump

1 - Travel (Right) 4 - Boom 2 7 - Auxiliary 10 - Blade

(40u Type A) … Refer to INTRODUCTION (IN-01) for

The pressure oil from the pilot pump is supplied to the

NOTE: Pilot relief valve is built-in the pilot pump.

• Valve Control Circuit

• Travel Speed Changeover Circuit

• Swing Parking Brake Release Circuit (Refer to

Swing Motor Travel Motor

Control Valve Pilot Valve (Right)

Pilot Valve (Left)

Pilot Filter Pilot Pump

(40u Type B, 50u) … Refer to INTRODUCTION (IN-

The pressure oil from the pilot pump is supplied to the

NOTE: Pilot relief valve is built-in the pilot pump.

• Valve Control Circuit

• Travel Speed Changeover Circuit

• Swing Parking Brake Release Circuit (Refer to

Swing Motor Travel Motor

Pilot Valve (Right)

Pilot Valve (Left)

Outline ......................................................T3-2-1 Travel Motor .................................................. T3-5-2

Swing Motor ..............................................T3-2-2 Travel Brake Valve ........................................ T3-5-3

Parking Brake Changeover Valve................T3-2-3 Travel Reduction Gear .................................. T3-5-8

Group 3 Control Valve Group 7 Others (Undercarriage)

Main Pump (P1, P2):

Valve Plate Plunger Shoe T571-03-01-001

Delivery Port Suction Port

Delivery Port Valve Plate

Suction, Delivery Port

Suction, Delivery Port

Main Pump (PG):

Main Pump (PG)

Suction Port Delivery Port

Rotation Center of Shaft

Rotation Center of Outer Rotor

Spring Poppet Hole

To Hydraulic Oil Tank T571-03-01-005

The inner rotor is splined to the shaft, and the plunger

The parking brake is a wet-negative-type multiple disc

When releasing the brake:

• 40u (Type B) and EX50u ... Refer to Plate

The valve unit consists of the make-up valves and re-

When the piston moves to the stroke end, the pres-