Professional Documents
Culture Documents
WADS50-EN-00
ZX38U-6
HYDRAULIC EXCAVATOR
Workshop Manual
WORKSHOP MANUAL
ZX38U-6
Hydraulic Excavator
URL:http://www.hitachi-c-m.com
WADS50-EN-00
To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this
machine.
The machine specification and description according to destination may be explained on this manual.
● Be sure to thoroughly read this manual for correct product information and service procedures.
● If you have any questions or comments, at if you found any errors regarding the contents of this manual, please
contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy
this form for usage.)
• PS Information Center (PSI) Hitachi Construction Machinery Co., Ltd.
• TEL: 81-29-832-7084
• FAX: 81-29-831-1162
• E-mail: HCM-TIC-GES@hitachi-kenki.com
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training
material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
● Information included in the Technical Manual: Technical information needed for redelivery and delivery
• Operation and activation of all devices and systems, operational performance tests, and troubleshooting
procedures.
● Information included in the Workshop Manual: Technical information needed for maintenance and repair of the
machine
• Tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and
assemble / disassemble procedures
● Information included in the Engine Manual: Technical information needed for redelivery and delivery and
maintenance and repair of the machine
• Operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures
Page Number
Each page has a number, located on the center lower part of the page. Each number contains the following information:
● Technical Manual: T 1-3-5
T Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
● Workshop Manual: W 1-3-2-5
W Workshop Manual
1 Section Number
3 Group Number
2 Sub Group Number
WADS50-EN-00(07/05/2019) IN-1
INTRODUCTION
WADS50-EN-00(07/05/2019) IN-2
INTRODUCTION
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal
injury of machine damage.
WARNING
This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow
the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw
attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and
equipment when lifting heavy parts.
CAUTION
Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death. This is also
provided before the indication of mass to draw attention to safety during handling of the machine.
IMPORTANT
Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. This header is
given to matters that are important in terms of operation and management.
NOTE
Units Used
A table for conversion from SI units to other system units is shown below for reference purposes.
Quantity To Convert From Into Multiply By
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3 yd3 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm2 10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min-1 rpm 1.0
WADS50-EN-00(07/05/2019) IN-3
INTRODUCTION
WADS50-EN-00(07/05/2019) IN-4
SYMBOLS AND ABBREVIATIONS
WADS50-EN-00(07/05/2019) SY-1
SYMBOLS AND ABBREVIATIONS
WADS50-EN-00(07/05/2019) SY-2
CONTRASTING LIST OF PART NAME
Contrasting List of Part Name between Technical Manual and Parts Catalog
Part name in technical manual Part name in part catalog Part No.
Fuel Sensor (float) FLOAT YD00011791
Engine Speed Sensor SENSOR YNM158557-61720
Coolant Temperature Sensor SENSOR;THERMO 4677180
Auto-Idle Pressure Sensor SENSOR;PRESSURE 4436535
WADS50-EN-00(07/05/2019) CO-1
CONTRASTING LIST OF PART NAME
MEMO
WADS50-EN-00(07/05/2019) CO-2
SAFETY
SA-2644 ja
WADS50-EN-00(07/05/2019) SA-1
SAFETY
WADS50-EN-00(07/05/2019) SA-2
SAFETY
WADS50-EN-00(07/05/2019) SA-3
SAFETY
SA-434 ja
Inspect Machine
SA-435 ja
WADS50-EN-00(07/05/2019) SA-4
SAFETY
● Always keep inside the cab clean by observing instructions below, to prevent any personal accidents from occurring.
• Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones from the soles of
your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator's
work boots, the operator's foot may slip off the pedal, possibly resulting in a personal accident.
• Do not mess up around the operator's seat with parts, tools, soil, stones, obstacles that may fold up or turn over,
cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the travel levers/
pedals, pilot control shut-off lever or control levers, which may result in serious injury or death.
• Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly starting a fire.
• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating
the machine.
• Keep all flammable materials and/or explosives away from the machine.
• After using the ashtray, always cover it to extinguish the match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.
• Correctly lay the floor mat specific to the machine. If another floor mat is used, it may be displaced and contact
with the travel pedals during operation, resulting in serious injury or death.
WADS50-EN-00(07/05/2019) SA-5
SAFETY
● Before rising from the operator's seat to open/close either side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a
control lever and/or pedal, possibly resulting in serious personal injury or death.
● Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.
● Before leaving the machine, close all windows, doors, and access covers and lock them.
● If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine, resulting in serious injury or death.
• Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item
is damaged or worn, replace the seat belt or
component before operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in
operation to minimize the chance of injury from an
accident.
• We recommend that the seat belt is replaced every
three years regardless of its apparent condition.
SA-237 ja
WADS50-EN-00(07/05/2019) SA-6
SAFETY
● Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or
death.
• Start the engine only when seated in the operator's seat.
• Never start the engine while standing on the track or ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control
levers are in neutral.
• Before starting the engine, confirm the safety around
the machine and sound the horn to alert bystanders.
SA-444 ja
WADS50-EN-00(07/05/2019) SA-7
SAFETY
Jump Starting
SA-1292 ja
WADS50-EN-00(07/05/2019) SA-8
SAFETY
WADS50-EN-00(07/05/2019) SA-9
SAFETY
WADS50-EN-00(07/05/2019) SA-10
SAFETY
Do not install an attachment which exceeds the specified weight for the machine structure.
SA-481 ja
WADS50-EN-00(07/05/2019) SA-11
SAFETY
SA-1294 ja
WADS50-EN-00(07/05/2019) SA-12
SAFETY
MZX5-04-002 ja
WADS50-EN-00(07/05/2019) SA-13
SAFETY
M586-05-002 ja
WADS50-EN-00(07/05/2019) SA-14
SAFETY
SA-1297 ja
WADS50-EN-00(07/05/2019) SA-15
SAFETY
WADS50-EN-00(07/05/2019) SA-16
SAFETY
● People around the operating machine may be hit severely by the swinging front attachment or counterweight, be
caught in other objects, and/or be struck by flying objects, resulting in serious injury or death.
• Set up barriers and/or put a "NO ADMISSION" sign at
the machine operating site and areas exposed by
flying objects to prevent anyone from entering the
work area.
• Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.
SA-667 ja
SA-668 ja
WADS50-EN-00(07/05/2019) SA-17
SAFETY
Avoid Undercutting
SA-1300 ja
Avoid Tipping
WADS50-EN-00(07/05/2019) SA-18
SAFETY
SA-1302 ja
SA-673 ja
WADS50-EN-00(07/05/2019) SA-19
SAFETY
WADS50-EN-00(07/05/2019) SA-20
SAFETY
Object Handling
● If flying debris hit eyes or any other part of the body, serious injury may result.
• Guard against injury from flying pieces of metal or
debris exist, or when removing or installing pins
using a hammer; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
SA-432 ja
WADS50-EN-00(07/05/2019) SA-21
SAFETY
• To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket and/or blade to the ground.
• Pull the pilot control shut-off lever to the LOCK
position.
• Turn the auto-idle switch OFF. Failure to do so may
create a hazardous condition as the engine speed
may unexpectedly increase.
• Run engine at slow idle speed without load for 5
minutes.
M1M7-05-024 ja
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Close windows, roof vent and cab door.
• Lock all access doors and compartments.
● Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in
serious injury or death.
• Do not refuel the machine while smoking or when
near open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
● All fuels, most lubricants, and some coolants are
flammable.
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
SA-018 ja
• Securely tighten the fuel and oil filler caps.
SA-019 ja
Transport Safely
WADS50-EN-00(07/05/2019) SA-22
SAFETY
WADS50-EN-00(07/05/2019) SA-23
SAFETY
• If moisture permeates into the electrical system, malfunction and/or erroneous movement of the machine may
result. Do not clean sensors, cable connectors, and the cab inside using water and/or steam.
• Wait to begin to work until the engine and hydraulic oil temperatures have cooled down to the safety range.
• In case inspection/maintenance must be performed with the engine running, be sure to appoint an overseer.
• Never lubricate or service the machine while moving it.
• Repair the cracked windowpane before servicing the machine. Failure to do so may cause personal injury.
• When raising the machine above the ground using
the front attachment function, maintain the angle
between the boom and the arm in the range of 90 to
110°. Never allow anyone to enter under the machine
raised with the front attachment function.
• In case working under the machine raised above the 90 to 110°
ground is unavoidably required, securely hold the
machine with stays or blocks strong enough to
support the machine weight.
• Never work under the raised bucket. M1M7-04-006-2 en_GB
M1MW-07-031-1 ja
WADS50-EN-00(07/05/2019) SA-24
SAFETY
• Be careful not to allow the operator’s station to tilt down without first stowing the fall prevention bars. Damage to
the tilt mechanism may result.
SS2045102-4 ja
WADS50-EN-00(07/05/2019) SA-25
SAFETY
● Never attempt to work on the machine without securing the machine first.
• Always lower the attachment to the ground before you work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do
not work under a machine that is supported solely by
a jack.
SA-527 ja
SA-026 ja
SA-2294 ja
WADS50-EN-00(07/05/2019) SA-26
SAFETY
SA-034 ja
WADS50-EN-00(07/05/2019) SA-27
SAFETY
Prevent Burns
SA-225 ja
● Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the page of "Periodic replacement of parts" in the operator's manual.)
● Failure to periodically replace rubber hoses may cause a
fire, fluid injection into skin, or the front attachment to
fall on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.
SA-019 ja
WADS50-EN-00(07/05/2019) SA-28
SAFETY
SA-292 ja
SA-044 ja
WADS50-EN-00(07/05/2019) SA-29
SAFETY
Prevent Fires
WADS50-EN-00(07/05/2019) SA-30
SAFETY
SS-1510 ja
SA-016 ja
WADS50-EN-00(07/05/2019) SA-31
SAFETY
● Do not weld or flame cut pipes or tubes that contain flammable fluids.
● Clean pipes and tubes thoroughly with non-flammable solvent before welding or flame cutting.
WADS50-EN-00(07/05/2019) SA-32
SAFETY
High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause
explosion, possibly resulting in serious injury or death.
Strictly comply with the following items:
● Do not disassemble the unit.
● Keep the units away from open flames and fire.
● Do not bore a hole, do not cut by torch.
● Avoid giving shocks by hitting or rolling the unit.
● Before disposing of the unit, sealed gas must be released. Consult your authorized dealer.
WADS50-EN-00(07/05/2019) SA-33
SAFETY
WADS50-EN-00(07/05/2019) SA-34
SAFETY
SA-405 ja
WADS50-EN-00(07/05/2019) SA-35
SAFETY
WADS50-EN-00(07/05/2019) SA-36
SAFETY
Never allow anyone to ride on attachments or the load. This is an extremely dangerous practice.
Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices.
Inquire to the device manufacturer for information on electrical wave disturbance when using an electronic device near
the communication terminal.
WADS50-EN-00(07/05/2019) SA-37
SAFETY
* The measurement results above are based on a distance of 3 cm between a person's body and the communica
tions terminal installed in the machine.
* The term specific absorption rate (SAR) is used in the evaluation of the affect of radio waves emitted by wireless
devices, such as cell phones, when used close to the human body.
In Japan: *Under the Japanese Radio Act and other regulations governing wireless equipment, the SAR is limited to 2
W/kg or less (as of March 2012).
In Europe: the SAR is limited to 2 W/kg or less according to "Council Recommendation 1999/519/EC 12 July 1999."
● Do not disassemble, repair, modify or move communication equipment, antennas or cables. Doing so may damage
the machine itself or the communication equipment, and/or cause a fire. (Consult your authorized dealer for the
removal or installation of communication equipment.
● Do not pinch, bind or pull on cables, cords or connectors with excessive force, as doing so will damage them. A short
circuit or break in wiring may damage the machine itself or the communication equipment, and/or cause a fire.
WADS50-EN-00(07/05/2019) SA-38
SAFETY
Precautions about Operator’s Seat Protections when Overturned (4-pillar Canopy or Cab
Models)
A
Cab
MADB-00-030-4 ja
WADS50-EN-00(07/05/2019) SA-39
SAFETY
SA-435 ja
WADS50-EN-00(07/05/2019) SA-40
SECTION AND GROUP SECTION1 GENERAL
CONTENTS Group1 Precautions
Group2 Tightening
Group3 Painting
Group4 Bleeding Air
Group5 Preparation
WORKSHOP MANUAL
SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure
Group2 Undercarriage
Group3 Front Attachment
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Group2 Counterweight
Group3 Pump Device
Group4 Control Valve
Group5 Swing Device
Group6 Pilot Valve
Group7 Solenoid Valve
SECTION4 UNDERCARRIAGE
Group1 Swing Bearing
Group2 Travel Device
Group3 Center Joint
Group4 Track Adjuster
Group5 Front Idler
Group6 Upper and Lower Rollers
Group7 Track
Group8 Blade Cylinder
MEMO
WADS50-EN-00(07/05/2019)
SECTION AND GROUP SECTION5 FRONT ATTACHMENT
CONTENTS Group1 Front Attachment
Group2 Cylinder
Group3 Hose Rupture Valve
WORKSHOP MANUAL
MEMO
WADS50-EN-00(07/05/2019)
1
GENERAL
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
2
MAINTENANCE STANDARD
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
3
UPPERSTRUCTURE
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
4
UNDERCARRIAGE
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
5
FRONT ATTACHMENT
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
1
GENERAL
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
SECTION1 GENERAL
Group1 Precautions
WADS50-EN-00(07/05/2019) W1-1-1-1
SECTION1 GENERAL
Group1 Precautions
MEMO
WADS50-EN-00(07/05/2019) W1-1-1-2
SECTION1 GENERAL
Group1 Precautions
1. In general, replace the floating seal with a new one after disassembling.
If the floating seal is required to be reused, follow these procedures:
• Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil onto sliding surface (e) of
seal ring (1).
• Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
• Check O-ring (2) 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.
• Clean the floating seal and seal mounting bores with cleaning solvent.
Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with
compressed air.
• Clean seal ring (1) and O-ring (2) mounting bores. Check the bore surface for scuffing or scoring. (by touching the
surface with finger)
• After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1).
• After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating
surface (f ) by measuring the distances (e) and (f ) at point (A) and (B), as illustrated. If these distances differ, correct
O-ring (2) seating.
1
2
f
a A b A
c
b
d B B
A=B A≠B
WDDQ-04-02-001-1 ja
WADS50-EN-00(07/05/2019) W1-1-2-1
SECTION1 GENERAL
Group1 Precautions
MEMO
WADS50-EN-00(07/05/2019) W1-1-2-2
SECTION1 GENERAL
Group1 Precautions
WDDQ-01-01-001-1 ja
c
W162-01-01-009-1 ja
c- Bent of Sling
• When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with
protrusions.
• Avoid dragging slings on the ground, throwing slings, or pushing slings with a metal object.
• When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling
is not damaged.
• Store the nylon slings indoors so that they won’t deteriorate with heat, sun light, or chemicals.
2. CAUTION
If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the
nylon sling for any damage before using.
WADS50-EN-00(07/05/2019) W1-1-3-1
SECTION1 GENERAL
Group1 Precautions
Before using a nylon sling, visually check the nylon sling for any damage corresponding to following examples. If any
damage is found, cut and discard the sling. If any damage is found, cut and discard the sling.
Even if no damage is found, do not use slings older than 7 years.
Damaged Appearance
a a
b f
c
c g
WDDQ-01-01-002-1 ja
WADS50-EN-00(07/05/2019) W1-1-3-2
SECTION1 GENERAL
Group1 Precautions
• "Standard dimension" is the dimension under the conditions below. Allowable errors will be indicated if necessary.
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies adjusted to specification
• “Allowable Limit” is the dimension under the conditions below. Therefore, in consideration of operation efficiency and
maintenance expense, proper maintenance shall be carried out before reaching the "Allowable Limit".
1. Normal machine performance cannot be accomplished after exceeding this limit.
2. Repair or adjustment is difficult after exceeding this limit.
3. Repair or adjustment is impossible after exceeding this limit.
WADS50-EN-00(07/05/2019) W1-1-4-1
SECTION1 GENERAL
Group1 Precautions
MEMO
WADS50-EN-00(07/05/2019) W1-1-4-2
SECTION1 GENERAL
Group2 Tightening
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 injure.
WDAA-01-02-001-1 ja
WADS50-EN-00(07/05/2019) W1-2-1-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-1-2
SECTION1 GENERAL
Group2 Tightening
Bolt Types
WADS50-EN-00(07/05/2019) W1-2-2-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-2-2
SECTION1 GENERAL
Group2 Tightening
2013/09
Bolt Hexagon Head Bolt Socket Bolt
Dia. Wrench Socket Bolt Wrench
mm Size mm Size mm
WDAA-01-02-002 ja WDAA-01-02-003 ja
WDAA-01-02-004 ja
IMPORTANT
The following items are applied to both fine and coarse pitch threads.
• Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil
with white zinc B dissolved in it)
• Torque tolerance is ±10 %.
• Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into
contact with the bottom of bolt hole. Also the bolts that are too short cannot develop sufficient tightening
force.
• The torque given in the previous table are for general use only, however, a different torque is given for a
specific application. Use the specified torque.
• Clean the nut and bolt threads and remove dirt or corrosion before installing.
WADS50-EN-00(07/05/2019) W1-2-3-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-3-2
SECTION1 GENERAL
Group2 Tightening
Tightening Order
When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
a b c
1 12 9 4 1 6 7 14
1, 4 6 3
4 5
2 13 8 5 2 3 10 11
2, 3
W105-01-01-003-1 ja
a- Equally tighten upper and lower al b- Tighten diagonally c- Tighten from center diagonally
ternately
WADS50-EN-00(07/05/2019) W1-2-4-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-4-2
SECTION1 GENERAL
Group2 Tightening
IMPORTANT
• Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause
oil leaks and damage to the O-ring.
WDAA-01-02-005-1 ja
• Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces. When installing O-
ring into a groove, use grease in order to hold O-ring in place.
• While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring.
WDAA-01-02-006-1 ja
• Tighten the bolts up and down, right and left alternately, in order to ensure even tightening to the specified
torque.
W105-01-01-008-1 ja
• Do not use an impact wrench. It is difficult to evenly tighten the bolts by using an impact wrench. Using an
impact wrench often causes uneven tightening of bolts or damage to O-rings.
WADS50-EN-00(07/05/2019) W1-2-5-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-5-2
SECTION1 GENERAL
Group2 Tightening
● Lock Plate
IMPORTANT
Do not reuse the lock plates. Do not try to bend the same point twice.
Í
a b
Í
a
WDAA-01-02-007-1 ja
● Wire
IMPORTANT
Attach wires to bolts in the bolt-tightening direction (c). Do not reuse the wires.
Í
d Í
c
WDAA-01-02-008-1 ja
WADS50-EN-00(07/05/2019) W1-2-6-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-6-2
SECTION1 GENERAL
Group2 Tightening
IMPORTANT
• The torque given in the following table are for general use only, however, a different torque is given for a
specific application. Use the specified torque.
• Apply lubricant, such as the Grease Spray to the bolts and nuts in order to reduce friction coefficient of them.
• Torque tolerance is ±10 %.
• Slightly apply lubricant onto the threads first by using the Grease Spray.
WADS50-EN-00(07/05/2019) W1-2-7-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-7-2
SECTION1 GENERAL
Group2 Tightening
Union Joint
Metal sealing surfaces (4, 5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-
diameter lines.
IMPORTANT
• Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly
cracking the adapter. Tighten union nut (3) to the specifications.
• Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to
damage them when connecting / disconnecting.
1 4 3 5 2
37 º
30 º
b c
a
WDDQ-01-02-001-1 ja
2013/09
Description Wrench Size (mm) Tightening Torque
Union Nut N·m (lbf·ft)
30° male 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
55 380 (280)
60 380 (280)
37° female 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
NOTE
Tightening torque of 37° male coupling without union is similar to tightening torque of 37° female.
WADS50-EN-00(07/05/2019) W1-2-8-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-8-2
SECTION1 GENERAL
Group2 Tightening
Pipe Joint
Pipe Connection (Metal Joint) (Union Nut Wrench Size: 17, 19, 22, 27): Metal (3) of adapter (1) and pipe (2) seals pressure
oil.
● Precautions for use: Do not damage sealing surfaces (4) and (5) when disassembling and assembling.
1 4 5 3 2
M1M7-07-005-1 ja
● Tightening Torque: Use the specified tightening torque in the following table.
2013/09
Wrench Size (mm) 17 19 22 27
Tightening Torque N·m 25 30 40 80
(lbf·ft) (18.5) (22) (29.5) (59)
WADS50-EN-00(07/05/2019) W1-2-9-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-9-2
SECTION1 GENERAL
Group2 Tightening
O-ring (6) is installed against the end surface of adapter (7) and seals pressure oil.
IMPORTANT
• Replace O-ring (6) with the new one when reinstalling.
• Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening
union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.
• Do not damage O-ring groove (8) of adapter (7) or sealing surface (10) on the hose side. Damage to O-ring (6)
may cause oil leakage.
• If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-
ring (6) with the new one, and then tighten union nut (9) after confirming that O-ring (6) is securely seated in
O-ring groove (8).
7 6 9
8 10 a
WDAA-01-02-011-1 ja
a- Joint Body
2013/09
Wrench Size (mm) Tightening Torque
Union Nut N·m (lbf·ft)
19 30 (22)
22 70 (52)
27 95 (70)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
WADS50-EN-00(07/05/2019) W1-2-10-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-10-2
SECTION1 GENERAL
Group2 Tightening
Quick Coupling
1. Coupling procedure
• Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you.
• Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked
completely by ball (2). At this time, check if socket ring (1) is returned to the original position (to the rightmost
direction).
2. Separating procedure
• Remove the hose by rotating socket ring (1) fully counterclockwise and then pulling it. Because no check function
is attached inside, be careful that oil flows out.
• Cap the removed hoses using special plug.
M1M7-07-006-1 ja
CAUTION
• When disconnecting, do not damage joint surface.
• When disconnecting, clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign
material from entering.
• Complete the joint disconnecting / connecting procedure. Check enough if oil leaks especially after
installation.
• After installation, check if socket ring (1) is returned to the original position (to the rightmost direction).
WADS50-EN-00(07/05/2019) W1-2-11-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-11-2
SECTION1 GENERAL
Group2 Tightening
Screw-In Connection
Depending on types of screw and sealing, different types of screw-in connection are used.
IMPORTANT
Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in
connection.
R(PTᲣ G(PF)
a b
W105-01-01-018-1 ja
2013/09
Wrench Size (mm) Tightening Torque (N・m (lbf・ft))
Joint Body Cast iron Structural rolled steel
19 15 (11) 35 (26)
22 30 (22) 50 (37)
27 50 (37) 95 (70)
36 70 (52) 160 (118)
41 110 (81) 200 (148)
50 160 (118) 330 (245)
60 200 (148)
WADS50-EN-00(07/05/2019) W1-2-12-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-12-2
SECTION1 GENERAL
Group2 Tightening
Seal tape is used in order to seal clearances (e) between male (d) and female (c) threads so that any leaks between threads
may be prevented. Therefore, apply just enough seal tape to fill up thread clearances (e). Do not overwrap.
c
d e
W105-01-01-019-1 ja
Application Procedure
Check that the thread surface is clean and, free of dirt or damage. Apply the seal tape around threads in order to leave
one to two pitch threads uncovered. Wrap the seal tape in the same direction as the threads.
f
M114-07-041-1 ja
WADS50-EN-00(07/05/2019) W1-2-13-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-13-2
SECTION1 GENERAL
Group2 Tightening
Low-pressure-hose clamp tightening torque differs depending on the type of clamp. Tighten them according to each
step.
● T-Bolt Type Band Clamp (g)
g
WDAA-01-02-012-1 ja
● Worm Gear Type Band Clamp (h)
h
M114-07-043-1 ja
WADS50-EN-00(07/05/2019) W1-2-14-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-14-2
SECTION1 GENERAL
Group2 Tightening
Connecting Hose
CAUTION
When replacing the hoses, 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
kinked hoses. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks,
hose rupture or separation of fitting. Utilize the print marks on hoses when installing in order to prevent hose
from being kinked. Take necessary measures to protect hoses from rubbing against each other. If the hoses rub
against each other, wear to the hoses may result and lead to hose rupture. Take care so that the hoses do not come
into contact with the moving parts or sharp objects.
Í
Í a
Í
b b
Í
a
b
WDDQ-01-02-002-1 ja
WADS50-EN-00(07/05/2019) W1-2-15-1
SECTION1 GENERAL
Group2 Tightening
MEMO
WADS50-EN-00(07/05/2019) W1-2-15-2
SECTION1 GENERAL
Group3 Painting
Painting
WADS50-EN-00(07/05/2019) W1-3-1-1
SECTION1 GENERAL
Group3 Painting
MEMO
WADS50-EN-00(07/05/2019) W1-3-1-2
SECTION1 GENERAL
Group4 Bleeding Air
Bleeding Air from Hydraulic System
Bleed air from the hydraulic system when hydraulic oil has been drawn, the suction filter and suction pipe have been
replaced, or the pump device, swing motor, travel motor, cylinders have been removed/installed.
WADS50-EN-00(07/05/2019) W1-4-1-1
SECTION1 GENERAL
Group4 Bleeding Air
MEMO
WADS50-EN-00(07/05/2019) W1-4-1-2
SECTION1 GENERAL
Group4 Bleeding Air
IMPORTANT
If air is accumulated inside of the pump and the engine starts in lacking of hydraulic oil, the pump may be
damaged.
1. Remove the air bleed plug on top of the pump. Add hydraulic oil to the pump.
2. After the pump is filled with hydraulic oil, temporarily tighten air bleed plug on each pump.Then, start the engine and
run it at slow idle speed.
3. Slightly loosen the plug and bleed air from the pump until hydraulic oil comes out from the gap. After bleeding all air,
securely tighten the plug.
: 30 to 40 N·m
WADS50-EN-00(07/05/2019) W1-4-2-1
SECTION1 GENERAL
Group4 Bleeding Air
MEMO
WADS50-EN-00(07/05/2019) W1-4-2-2
SECTION1 GENERAL
Group4 Bleeding Air
IMPORTANT
If air is accumulated inside of the motor and the motor starts in lacking of hydraulic oil, the motor may be
damaged.
1. Remove the air bleed plug (top) from the travel motor or swing motor.Fill the motor case with hydraulic oil.
WADS50-EN-00(07/05/2019) W1-4-3-1
SECTION1 GENERAL
Group4 Bleeding Air
MEMO
WADS50-EN-00(07/05/2019) W1-4-3-2
SECTION1 GENERAL
Group4 Bleeding Air
IMPORTANT
If air is accumulated inside of the cylinder and the cylinder is operated suddenly in lacking of hydraulic oil, the
seal may be damaged or the cylinder may seize.
1. After refilling hydraulic oil, start the engine.While operating each cylinder, swing motor, or travel motors evenly,
operate the machine under light loads for about 10 to 15 minutes. Slowly start each operation at first.
2. As the pilot circuit has an air bleed device, air in the pilot circuit will be bled while performing the step 1 operation for
approx. 5 minutes.
3. Return the position to check hydraulic oil level.
4. Stop the engine. Check hydraulic oil level. Add hydraulic oil if necessary.
WADS50-EN-00(07/05/2019) W1-4-4-1
SECTION1 GENERAL
Group4 Bleeding Air
MEMO
WADS50-EN-00(07/05/2019) W1-4-4-2
SECTION1 GENERAL
Group4 Bleeding Air
Air in the fuel system may make the engine hard to start or make it run irregularly.
After draining water and sediment from the fuel filter, replacing the fuel filter, or running the fuel tank dry, be sure to
bleed the air from the fuel system.
Air Bleeding Procedures
This machine is equipped with an automatic air bleed device.
1. Check that fuel level is over half of the fuel tank. If fuel is lack, add fuel.
2. Set the key switch to the ON position and hold it in that position for about 10 to 15 seconds.
3. Start the engine and check the fuel system for fuel leaks.
WADS50-EN-00(07/05/2019) W1-4-5-1
SECTION1 GENERAL
Group4 Bleeding Air
MEMO
WADS50-EN-00(07/05/2019) W1-4-5-2
SECTION1 GENERAL
Group4 Bleeding Air
CAUTION
Do not loosen cap when the coolant temperature of radiator is too high. Hot steam may spout out and cause
severe burns. Wait until coolant cools and loosen the cap slowly. Release all pressure and remove the cap.
Preparation
1. Park the machine on a solid and level surface. Set the front attachment in position for checking hydraulic oil level.
2. Stop the engine. Remove the radiator cap.
WADS50-EN-00(07/05/2019) W1-4-6-1
SECTION1 GENERAL
Group4 Bleeding Air
MEMO
WADS50-EN-00(07/05/2019) W1-4-6-2
SECTION1 GENERAL
Group5 Preparation
Preparation before Inspection and Maintenance
CAUTION
Components, hydraulic oil, lubricant, and coolant just after operation are too hot. Wait until they cool. Then, start
the work.
M1M7-05-024 ja
3. Turn OFF the auto-idle switch.
4. Set the engine control dial to the slow idle position and run the engine for 5 minutes in order to cool the engine.
5. Set the key switch to the OFF position and stop the engine. Remove the key.
6. Set pilot shut-off lever (1) to the LOCK position.
7. Before performing any work on the machine, attach tag (2) in a highly visible place such as the door or control lever.
1
WDAA-01-06-001-1 ja
CAUTION
Never attempt to maintain the machine when the engine is running in order to prevent the accident. If
maintenance work while engine running is unavoidable, strictly comply with the following items.
WADS50-EN-00(07/05/2019) W1-5-1-1
SECTION1 GENERAL
Group5 Preparation
• One person should take the operator's seat to be ready to stop the engine any time while communicating
with other workers.
• When working around the moving parts is unavoidable, do not approach hands, feet, and clothes which are
easy to be entangled.
• If parts or tools are dropped or inserted into the fan or the belt, they may fly off or be cut off. Do not drop or
insert parts and tools into the moving parts.
• Set pilot shut-off lever (1) to the LOCK position so that the front attachment will not move.
• Never touch the control levers and pedals. If operating the control levers or pedals is unavoidable, give the
hand signals to co-workers and evacuate them to the safer place.
WDDQ-01-05-001 ja
WADS50-EN-00(07/05/2019) W1-5-1-2
SECTION1 GENERAL
Group5 Preparation
Release any remaining pressure as follows before removing/installing the front attachment.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
CAUTION
Each attachment may move rapidly in case the overload relief valve is loosened rapidly. Check that the
machine has been set in the position for inspection and maintenance, then loosen it slowly. Do not loosen it
more than 3/4 turns as hydraulic oil may spout.
1 2
6 5 4 3
WADR-01-05-100-1 ja
1- Overload Relief Valve (Arm 3- Overload Relief Valve (Buck 5- Overload Relief Valve (Boom
Roll-Out) et Roll-In) Raise)
2- Overload Relief Valve (Buck 4- Overload Relief Valve (Boom 6- Overload Relief Valve (Arm
et Roll-Out) Lower) Roll-In)
IMPORTANT
Do not turn lock nut (11) and adjusting screw (10). Failure to do so can change the setting.
3. Slowly loosen body (9) of the overload relief valve in which any remaining pressure to be released.
: 24 mm
: 70 to 80 N·m
9 10
11
T152-03-03-015-3 ja
9- Body 10- Adjusting Screw 11- Lock Nut
WADS50-EN-00(07/05/2019) W1-5-2-1
SECTION1 GENERAL
Group5 Preparation
MEMO
WADS50-EN-00(07/05/2019) W1-5-2-2
SECTION1 GENERAL
Group5 Preparation
CAUTION
Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release pressure before
disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may
spout out and cause severe burns. Allow oil to cool before starting any work. Do not turn cap (2) of hydraulic oil
tank (3) quickly. Cap (2) may fly off by internal pressure. Release any remaining pressure before removing cap (2).
Preparation
1. Park the machine on a solid and level surface. Set the front attachment in position for checking hydraulic oil level.
2. Stop the engine. Slowly loosen cap (2) of hydraulic oil tank (3) and bleed air from hydraulic oil tank (3).
3. Remove cap (2) of hydraulic oil tank (3).
NOTE
Hydraulic oil tank (3) becomes negative pressure by installing vacuum pump (a) to the position where cap (2) is
removed and operating vacuum pump (a). This operation prevents hydraulic oil from draining when disconnecting
hoses. Operate vacuum pump (a) continuously while working.
3 2
b
WABA-01-05-003-1 ja
WADS50-EN-00(07/05/2019) W1-5-3-1
SECTION1 GENERAL
Group5 Preparation
MEMO
WADS50-EN-00(07/05/2019) W1-5-3-2
2
MAINTENANCE STANDARD
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure
Maintenance Standard for Pump Device
1 2
WADR-02-01-100-1 ja
1- Cylinder Block 2- Plunger (10 Used)
1. Clearance between outer diameter (d) of plunger (2) and inner diameter (D) of cylinder block (1)
D d
1 2
W507-02-04-009-2 ja
2. Clearance (ε) between plunger (2) and shoe (a) bottom
ε
2
W1V1-03-02-005-1 ja
WADS50-EN-00(07/05/2019) W2-1-1-1
SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure
a- Shoe
3. Wear amount of oil seal mounting surface
Check that there are no damage and/or abnormal wear.
D0 D1
WAEJ-02-01-101-1 ja
WADS50-EN-00(07/05/2019) W2-1-1-2
SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure
WAEJ-02-01-102-1 ja
1- Rotor 2- Plunger (9 Used)
1. Clearance between outer diameter (d) of plunger (2) and cylinder inner diameter (D) of rotor (1)
D d
1 2
W507-02-04-009-2 ja
2. Clearance (ε) between plunger (2) and shoe (a) bottom
WADS50-EN-00(07/05/2019) W2-1-2-1
SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure
ε
a
WAEJ-02-01-103-1 ja
a- Shoe
WADS50-EN-00(07/05/2019) W2-1-2-2
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
Maintenance Standard for Travel Motor
3
1
WADR-02-02-100-1 ja
1- Valve Plate 2- Cylinder Block 3- Plunger (9 Used)
1. Clearance between outer diameter (d) of plunger (3) and inner diameter (D) of cylinder block (2)
D d
2 3
W507-02-04-009-1 ja
2. Clearance (ε) between shoe (a) and plunger (3) bottom
WADS50-EN-00(07/05/2019) W2-2-1-1
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
ε
3
W1V1-03-02-005-3 ja
a- Shoe
3. Wear amount of sliding surface against valve plate of cylinder block (2)
Check that there are no damage, abnormal wear, and/or seizure.
Damage and/or wear: 0.02 mm (0.001 in) or less
4. Wear amount of sliding surface against cylinder block (2) of valve plate
Check that there are no damage, abnormal wear, and/or seizure.
Damage and/or wear: 0.02 mm (0.001 in) or less
WADS50-EN-00(07/05/2019) W2-2-1-2
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
D C B
W503-03-02-004-1 ja
WADS50-EN-00(07/05/2019) W2-2-2-1
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
MEMO
WADS50-EN-00(07/05/2019) W2-2-2-2
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
C D F
A
B
W503-03-05-001-1 ja
Lubrication Oil
Engine Oil (SAE #30, CD class)
Amount of engine oil: 30 mL (30 cm3)
WADS50-EN-00(07/05/2019) W2-2-3-1
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
MEMO
WADS50-EN-00(07/05/2019) W2-2-3-2
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
WAEJ-02-02-101-1 ja
Lubrication Oil
Engine Oil (API CD class, SAE #30)
Amount of engine oil: 40 to 50 mL (40 to 50 cm3)
WADS50-EN-00(07/05/2019) W2-2-4-1
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
MEMO
WADS50-EN-00(07/05/2019) W2-2-4-2
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
C D E
WAEJ-02-02-102-1 ja
Lubrication Oil
Engine Oil (API GL 4 or 5, SAE #30)
Oil amount: 40 to 50 mL (40 to 50 cm3)
WADS50-EN-00(07/05/2019) W2-2-5-1
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
MEMO
WADS50-EN-00(07/05/2019) W2-2-5-2
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
1 4
5
2
W190-03-07-001-1 ja
2. Inside of Rubber Crawler (Roller (6) Side)
If there is a crack that reaches steel code (5) or steel core (4), immediately repair the track.
4 6
WABA-02-02-003-1 ja
Lug Wear
1. If height (A) of lug (8) is less than 5 mm (0.2 in), replace rubber crawler (7) as an assembly.
W190-03-07-003-1 ja
2. If any part of steel code (5) appeared on the track, replace the worn rubber crawler as an assembly.
WADS50-EN-00(07/05/2019) W2-2-6-1
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
W190-03-07-004-1 ja
A
A
A-A 2
W1LA-03-07-001-2 ja
W190-03-07-005-1 ja
WADS50-EN-00(07/05/2019) W2-2-6-2
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
W190-03-07-006-1 ja
WADS50-EN-00(07/05/2019) W2-2-6-3
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
MEMO
WADS50-EN-00(07/05/2019) W2-2-6-4
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
Link
• Measure the length of four links.
• Do not measure the part included the master pin.
• Measure the length with tension on the track link.
A
W155-03-07-001-1 ja
Grouser shoe
W105-03-07-024-2 ja
Master pin
J P
I
WADR-02-02-101-1 ja
WADS50-EN-00(07/05/2019) W2-2-7-1
SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
Pin
L
B
AK
W142-03-07-004-2 ja
Bushing
N O
M
WDDQ-02-02-002-1 ja
WADS50-EN-00(07/05/2019) W2-2-7-2
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
Maintenance Standard for Pin and Bushing (Front Parts)
G
A
D
B
F E
L M
H N J
WABA-02-03-100-2 ja
WADS50-EN-00(07/05/2019) W2-3-1-1
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
IMPORTANT
When replacing HN bushing for the front attachment, install it by using a press.
WADS50-EN-00(07/05/2019) W2-3-1-2
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
A
WADR-02-03-100-1 ja
WADS50-EN-00(07/05/2019) W2-3-2-1
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
MEMO
WADS50-EN-00(07/05/2019) W2-3-2-2
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
D A
WACK-02-03-100-1 ja
WADS50-EN-00(07/05/2019) W2-3-3-1
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
MEMO
WADS50-EN-00(07/05/2019) W2-3-3-2
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
D
A
W505-04-01-001-1 ja
WADS50-EN-00(07/05/2019) W2-3-4-1
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
MEMO
WADS50-EN-00(07/05/2019) W2-3-4-2
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
B C
WAEQ-02-03-001-1 ja
WADS50-EN-00(07/05/2019) W2-3-5-1
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
MEMO
WADS50-EN-00(07/05/2019) W2-3-5-2
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
IMPORTANT
If the front attachment of a previous model machine is used, use the grease intervals for previous model machine.
B
A
A h p
n
A B
i m
k
j
WAEQ-02-03-002-1 ja
Dimension (mm)
a 152
b 13
c 251
d 230
e 185
f 714
g 140
h 185
i 0
j 234.5
k 140.5
m 40
n 90°
p 90°
NOTE
Dimensions n, p: 90° means the angle for the bolt hole.
WADS50-EN-00(07/05/2019) W2-3-6-1
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
MEMO
WADS50-EN-00(07/05/2019) W2-3-6-2
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
Rod
W105-04-02-094-1 ja
c d
W166-04-02-022-1 ja
WADS50-EN-00(07/05/2019) W2-3-7-1
SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
MEMO
WADS50-EN-00(07/05/2019) W2-3-7-2
3
UPPERSTRUCTURE
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
1, 2, 3 4 5
WADB-03-01-028-1 ja
3. Remove bolts, washers (7) (2 used). Remove cover (6).
: 13 mm
6
WAEQ-03-01-001-1 ja
WADS50-EN-00(07/05/2019) W3-1-1-1
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
4. Remove clip (10) from harness (8). Disconnect connectors (9) (2 used).
8
9
10
WADB-03-01-029-1 ja
5. Remove bolts (15) (4 used), washers (16) (4 used), and collars (17) (2 used) from canopy (18).
: 19 mm
CAUTION
Canopy (18) weight: 80 kg
6. Install shackles (4 used) to canopy (18). Attach nylon slings onto shackles (4 used). Hoist and hold canopy (18).
7. Remove caps (13) (2 used), bolts (11) (7 used), and washers (12) (7 used) from canopy (18).
: 19 mm
8. Hoist and remove canopy (18) from floor (14).
a
18
11, 12, 13
15, 16, 17
11, 12
15, 16
14
WADB-03-01-022-1 ja
WADS50-EN-00(07/05/2019) W3-1-1-2
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
CAUTION
Canopy (18) weight: 80 kg
1. Install shackles (4 used) to canopy (18). Attach nylon slings onto shackles (4 used). Hoist and hold canopy (18).
2. Install canopy (18) to floor (14) with washers (12) (7 used), bolts (11) (7 used), and caps (13) (2 used).
: 19 mm
: 110 N·m
3. Install canopy (18) to floor (14) with collars (17) (2 used), washers (16) (4 used), and bolts (15) (4 used).
: 19 mm
: 110 N·m
a
18
11, 12, 13
15, 16, 17
11, 12
15, 16
14
WADB-03-01-022-1 ja
8
9
10
WADB-03-01-029-1 ja
WADS50-EN-00(07/05/2019) W3-1-2-1
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
6
WAEQ-03-01-001-1 ja
7. Install floor mat (4).
8. Install floor mat (5) with bolt (1), washer (2), and spacer (3).
1, 2, 3 4 5
WADB-03-01-028-1 ja
WADS50-EN-00(07/05/2019) W3-1-2-2
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Removal of Cab
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, install identification tags
onto the connectors, hoses, and pipes for assembling. If the clips that secure the hoses have been removed, install
the clips after connecting the hoses.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1)
2. Open door (1).
3. Remove floor mats (2, 3).
3 2
WAEJ-03-01-100-1 ja
4. Disconnect connector (7).
CAUTION
The cab (11) assembly weight: 205 kg
5. Install shackles (3 used) to cab (11). Attach nylon slings onto shackles (3 used). Hoist and hold cab (11).
6. Remove caps (4) (2 used), bolts (12, 5, 10) (2 used for each), bolt (6), bolts (8) (4 used), washers (13) (5 used), and
washers (9) (6 used) from cab (11).
: 19 mm
WADS50-EN-00(07/05/2019) W3-1-3-1
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
7. Hoist and remove the cab (11) assembly from the floor.
a
11
8
4
12
13 6
5
10
12 13 4 7 13
WAEJ-03-01-101-1 ja
WADS50-EN-00(07/05/2019) W3-1-3-2
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Installation of Cab
CAUTION
The cab (11) assembly weight: 205 kg
1. Install shackles (3 used) to cab (11). Attach nylon slings onto shackles (3 used). Hoist and hold the cab (11) assembly.
2. Fit the cab (11) assembly to the mounting holes on the floor.
3. Install cab (11) to the floor with washers (13) (5 used), washers (9) (6 used), bolts (12, 5, 10) (2 used for each), bolt (6),
bolts (8) (4 used), and caps (4) (2 used).
: 19 mm
: 110 N·m
4. Connect connector (7).
a
11
8
4
12
13 6
5
10
12 13 4 7 13
WAEJ-03-01-101-1 ja
WADS50-EN-00(07/05/2019) W3-1-4-1
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
3 2
WAEJ-03-01-100-1 ja
WADS50-EN-00(07/05/2019) W3-1-4-2
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
CAUTION
Use the genuine parts for the glasses
WADS50-EN-00(07/05/2019) W3-1-5-1
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Unit: mm
WAEJ-03-01-102-1 ja
WADS50-EN-00(07/05/2019) W3-1-5-2
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Unit: mm
WAEJ-03-01-103-1 ja
WADS50-EN-00(07/05/2019) W3-1-5-3
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Unit: mm
WAEQ-03-02-001-1 ja
WADS50-EN-00(07/05/2019) W3-1-5-4
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Unit: mm
WAEJ-03-01-105-1 ja
WADS50-EN-00(07/05/2019) W3-1-5-5
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Unit: mm
WAEJ-03-01-106-1 ja
WADS50-EN-00(07/05/2019) W3-1-5-6
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Unit: mm
WAEJ-03-01-107-1 ja
WADS50-EN-00(07/05/2019) W3-1-5-7
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
MEMO
WADS50-EN-00(07/05/2019) W3-1-5-8
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Procedures to Remove Overhead Window (1), Lower Right-Hand Glass (6), Upper Right-Hand Glass (9), Rear Left-Hand
Glass (3), Upper Door Glass (5), Lower Door Glass (4), and Rear Glass (2)
CAUTION
When removing the broken or cracked glass, the glass shards may cause serious injury. Before removing, use the
duct tape or equivalent in order to paste the broken or cracked glass and reinforce them. Remove the glass pieces
away.
1. Remove resin panel, garnish, and the spacer around the glass.
9
1
5 4 3
6
WAEJ-03-01-113-2 ja
2. Prick a hole in adhesive (b) by using awl (a) (or a knife).
7
8
a
b
W1SE-02-01-033-1 ja
7- Cab 8- Glass
a- Awl b- Adhesive
3. Pass piano wire (c) (or a metal wire) through the hole.
W1SE-02-01-034-1 ja
c- Piano Wire
WADS50-EN-00(07/05/2019) W3-1-6-1
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
IMPORTANT
The piano wire is easily broken if a part of the piano wire turns hot. Change the position and cut the adhesive
while cooling the piano wire.
4. Wind the both ends of the piano wire onto the screwdriver. Draw the wire back and forth in order to cut adhesive (b)
between cab (7) and glass (8). Remove glass (8) from cab (7).
NOTE
Cut off the middle of adhesive between glass and cab.
7 d
e
f
W1SE-02-01-035-1 ja
WADS50-EN-00(07/05/2019) W3-1-6-2
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
Procedures to Install Lower Right-Hand Glass (6), Upper Right-Hand Glass (9), Rear Left-Hand Glass (3), Upper Door Glass
(5), Lower Door Glass (4), and Rear Glass (2)
1. Cut off the residual adhesive from the cab (7) side by 1 to 2 mm deep all around by using knife (a) or similar.
NOTE
Do not damage the cab (7) paint.
2. Clean the cutting edge of adhesive at the cab (7) side by using white spirit.
7
2
5 4 3 6
WAEJ-03-01-108-1 ja
a- Knife b- 1 to 2 mm
IMPORTANT
Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer,
apply Primer as quickly as possible and close the cap immediately after using. After opening the cap, all the
contents should be used within 180 days (or 2 hours with the cap off).
3. Apply Primer for paint to the cutting edge of adhesive at the cab (7) side by using a brush. Wait for about 15 minutes
in order to let it dry by itself.
7
c
W1SE-02-01-038-1 ja
WADS50-EN-00(07/05/2019) W3-1-7-1
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
IMPORTANT
Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer,
apply Primer as quickly as possible and close the cap immediately after using. After opening the cap, all the
contents should be used within 180 days (or 2 hours with the cap off).
5. Apply Primer for glass to the cutting edge of adhesive at cab side by using a brush. Wait for about 15 minutes in order
to let it dry by itself.
6. Put dam rubber (10) onto the cab (7) side.
7 10
WAEQ-03-01-100-1 ja
7. Cut off the nozzle of adhesive cartridge (c) (Sikaflex 250-2) into V-shaped by using a knife.
8 mm
12 mm
e
W1SE-02-01-027-3 ja
e- V-shaped
8. Remove the seal of the adhesive cartridge end. Install the V-shaped nozzle.
9. Install the adhesive cartridge to the manual coking gun.
10. Evenly apply adhesive (h) to the cutting edge of the residual adhesive at the cab (7) side.
h
f
g
7
WAEJ-03-01-109-2 ja
NOTE
Remove all adhesive except the mounting surface before solidifying by using white spirit.
WADS50-EN-00(07/05/2019) W3-1-7-2
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
12. Secure the glass by using the duct tape until the adhesive becomes solid in order to prevent them from being
mispositioned or coming off.
NOTE
Time for adhesive (Sikaflex 250-2) to become solid: 12 hours in spring, 24 hours in winter (just for reference)
13. Evenly apply adhesive (SUNSTAR Penguin Seal #2505) to part A of rear left-hand glass (3).
WAEJ-03-01-110-1 ja
WADS50-EN-00(07/05/2019) W3-1-7-3
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
MEMO
WADS50-EN-00(07/05/2019) W3-1-7-4
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
1. Cut off the residual adhesive from the cab (7) side by 1 to 2 mm deep by using knife (a) or similar.
NOTE
Do not damage the cab (7) paint.
WAEJ-03-01-111-1 ja
a- Knife b- 1 to 2 mm
2. Clean the cutting edge of adhesive at the cab (7) side by using white spirit.
IMPORTANT
Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer,
apply Primer as quickly as possible and close the cap immediately after using. After opening the cap, all the
contents should be used within 180 days (or 2 hours with the cap off).
3. Apply Primer for paint (SUNSTAR #580) to the cutting edge of adhesive at the cab (7) side by using a brush. Wait from
5 minutes to 24 hours in order to let it dry by itself.
NOTE
The painting primer should be applied evenly in order to leave no blemishes.
7
c
W1SE-02-01-038-1 ja
WADS50-EN-00(07/05/2019) W3-1-8-1
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
IMPORTANT
Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer,
apply Primer as quickly as possible and close the cap immediately after using. After opening the cap, all the
contents should be used within 180 days (or 2 hours with the cap off).
5. Apply Primer for overhead window (SUNSTAR ##435-41) to the cutting edge of adhesive of overhead window (1) by
using a brush. Wait from 5 minutes to 24 hours in order to let it dry by itself.
6. Evenly apply adhesive (SUNSTAR Penguin Seal #560) to the cutting edge of the residual adhesive at the cab (7) side.
WADS50-EN-00(07/05/2019) W3-1-8-2
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
7. Raise the overhead window (1) by using the suction lifter (rubber sucker 4355282), and adhere it to the cab (7) within
5 minutes.
D
7 1
D
B B
C C
E
B-B C-C
39 mm
42 mm
D-D E-E
4 mm 21 mm
NOTE
Remove all adhesive except the mounting surface before solidifying by using white spirit.
8. Secure the overhead window (1) by using the duct tape until adhesive becomes solid in order to prevent them from
being mispositioned or coming off.
WADS50-EN-00(07/05/2019) W3-1-8-3
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
MEMO
WADS50-EN-00(07/05/2019) W3-1-8-4
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
1. Stick seal (11) to port C, at lower side of the front Window glass by using adhesive. Stick and secure both right and left
ends (the thicker part) of seal (11) to the glass by using adhesive. Adhere part B at mating surface of seal (11) and front
window glass (a) by using adhesive so that no visible undulation or boss can be found.
A-A
a
B C
A 11
WAEJ-03-01-114-1 ja
WADS50-EN-00(07/05/2019) W3-1-9-1
SECTION3 UPPERSTRUCTURE
Group1 Canopy/Cab
MEMO
WADS50-EN-00(07/05/2019) W3-1-9-2
SECTION3 UPPERSTRUCTURE
Group2 Counterweight
Removal of Counterweight
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
2. Tilt up the floor. (Refer to the operator's manual.)
3. Remove bolts, washers (4) (3 used) Remove cover (8).
: 17 mm
4. Remove bolts (5) (5 used) and washers (6) (5 used). Remove cover (7).
: 19 mm
4
5, 6
8 7
WADR-03-02-100-1 ja
5. Remove bolts, washers (1) (4 used) Remove cover (2).
: 17 mm
1 2
WAEJ-03-02-100-1 ja
WADS50-EN-00(07/05/2019) W3-2-1-1
SECTION3 UPPERSTRUCTURE
Group2 Counterweight
WAEJ-03-02-101-1 ja
CAUTION
Counterweight (10) weight : 540 kg
7. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to eyebolt mounting holes (9) (2 places). Hoist and hold counterweight
(10).
8. Remove bolts (11) (3 used) and washers (12) (3 used) from counterweight (10).
: 32 mm
9. Raise counterweight (10) a little. Slide counterweight (18) to the rear side. Remove counterweight (10) from the main
frame.
9
10
11, 12
WADR-03-02-101-1 ja
WADS50-EN-00(07/05/2019) W3-2-1-2
SECTION3 UPPERSTRUCTURE
Group2 Counterweight
Installation of Counterweight
CAUTION
Counterweight (10) weight : 540 kg
1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to eyebolt mounting holes (9) (2 places). Hoist counterweight (10). Place
counterweight (10) onto the main frame and slide it to the front side.
2. Install counterweight (10) to the main frame with bolts (11) (3 used) and washers (12) (3 used).
: 32 mm
: 750 N·m
3. Remove eyebolts (2 used) from eyebolt mounting hole (9) (2 places).
9
10
11, 12
WADR-03-02-101-1 ja
WADS50-EN-00(07/05/2019) W3-2-2-1
SECTION3 UPPERSTRUCTURE
Group2 Counterweight
WAEJ-03-02-101-1 ja
5. Install cover (2) with bolts, washers (1) (4 used).
: 17 mm
: 50 N·m
1 2
WAEJ-03-02-100-1 ja
6. Install cover (7) with bolts (5) (5 used) and washers (6) (5 used).
: 19 mm
: 110 N·m
WADS50-EN-00(07/05/2019) W3-2-2-2
SECTION3 UPPERSTRUCTURE
Group2 Counterweight
5, 6
8 7
WADR-03-02-100-1 ja
8. Tilt down the floor. (Refer to the operator's manual.)
WADS50-EN-00(07/05/2019) W3-2-2-3
SECTION3 UPPERSTRUCTURE
Group2 Counterweight
MEMO
WADS50-EN-00(07/05/2019) W3-2-2-4
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
1 2
WAEJ-03-02-100-1 ja
4. Disconnect hoses (4) (3 used) and hose (7).
: 22 mm, 27 mm
5. Disconnect hose (10).
: 19 mm
WADS50-EN-00(07/05/2019) W3-3-1-1
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
CAUTION
Pump device (3) weight: 21 kg
7. Attach nylon slings onto the center of gravity of pump device (3). Hoist and hold pump device (3).
8. Remove socket bolts (6) (2 used). Hoist and remove pump device (3) from engine (5).
: 10 mm
9. Remove the adapters from pump device (3) if necessary.
5 6
4
7
3 9
10
WADR-03-03-100-1 ja
WADS50-EN-00(07/05/2019) W3-3-1-2
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
CAUTION
Pump device (3) weight: 21 kg
2. Attach nylon slings onto the center of gravity of pump device (3) and hoist it.
3. Install pump device (3) to engine (5) with socket bolts (6) (2 used).
: 10 mm
: 90 N·m
IMPORTANT
Apply grease onto O-ring (11).
4. Install O-ring (11) to the groove of the suction pipe (8) flange part. Connect suction pipe (8) to pump device (3) with
socket bolts (9) (4 used).
: 8 mm
: 50 N·m
5. Connect hose (10).
: 19 mm
: 30 N·m
6. Connect hoses (4) (3 used) and hose (7).
: 22 mm
: 40 N·m
: 27 mm
: 80 N·m
5 6
4
7
3 9
11
10
WADR-03-03-100-2 ja
7. Tilt down the floor. (Refer to the operator's manual.)
8. Bleed air from the hydraulic system. (Refer to "Bleeding Air from Hydraulic System"W1-4-1-1.)
WADS50-EN-00(07/05/2019) W3-3-2-1
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
1 2
WAEJ-03-02-100-1 ja
WADS50-EN-00(07/05/2019) W3-3-2-2
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
WADR-03-03-101-1 ja
1- Retaining Ring 16- Stopper Pin B 28- Needle Bearing 40- O-Ring
2- Oil Seal 17- Ball (2 Used) 29- Spring Holder 41- O-Ring
3- Shaft 18- Plunger (10 Used) 30- Spring 42- Collar
4- Ball Bearing 19- Retainer 31- Spring Guide 43- Coupling
5- Retaining Ring 20- Holder 32- Pin 44- Gear Pump
8- Pin (2 Used) 21- Needle (3 Used) 33- O-Ring 45- Spring Washer (2 Used)
9- Body S 22- Cylinder Block 34- Body H 46- Bolt (2 Used)
10- Packing 23- Washer (2 Used) 35- Seal Washer 47- Plug (5 Used)
11- Spring (4 Used) 24- Spring 36- Bolt 50- Rod
12- Stopper Pin A 25- Retaining Ring 37- Nut
13- Rod 26- Valve Plate 38- Socket Bolt (5 Used)
14- Swash Plate 27- Spring Pin 39- O-Ring
WADS50-EN-00(07/05/2019) W3-3-3-1
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
1. Remove bolts (46) (2 used) and spring washers (45) (2 used). Remove gear pump (44) from body H (34).
: 13 mm
IMPORTANT
Do not turn bolt (36) and nut (37). Failure to do so can change the setting.
2. Remove O-rings (39, 40, 41), collar (42), and coupling (43) from body H (34).
CAUTION
Prevent spring (30) from jumping out by using temporary assembly bolt (M10, Length: 65 mm).
3. Remove socket bolts (38) (2 used) from the socket bolt (38) mounting holes (a) (2 places) of body H (34).
: 8 mm
a
a
34
WACK-03-04-107-1 ja
IMPORTANT
Do not drop valve plate (26) while removing body H (34).
IMPORTANT
Do not remove spring pin (27).
IMPORTANT
Packing (10) cannot be reused.
10. Remove packing (10), pin (32), pins (8) (2 used), and valve plate (26) from body S (9).
11. Remove spring guide (31), spring (30), spring holder (29), and the cylinder block (22) assembly from body S (9).
12. Remove plungers (18) (10 used), retainer (19), holder (20), and needles (21) (3 used) from cylinder block (22).
WADS50-EN-00(07/05/2019) W3-3-3-2
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
CAUTION
When removing retaining ring (25), push washers (23) (2 used) and spring (24) by using a press to prevent them
from jumping out.
IMPORTANT
Do not disassemble cylinder block (22), retaining ring (25), washers (23) (2 used), and spring (24) unless necessary.
13. Remove retaining ring (25), washers (23) (2 used), and spring (24) from cylinder block (22) by using a press.
14. Remove swash plate (14) and balls (17) (2 used) from body S (9).
15. Remove stopper pin A (12), stopper pin B (16), springs (11) (4 used), and rods (13, 50) from body S (9).
16. Remove retaining ring (1) from body S (9).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
17. Remove the shaft (3) assembly from body S (9) by using a hammer.
IMPORTANT
Oil seal (2) cannot be reused.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
20. Remove ball bearing (4) from shaft (3) by using a bar and a hammer.
WADS50-EN-00(07/05/2019) W3-3-3-3
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
MEMO
WADS50-EN-00(07/05/2019) W3-3-3-4
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
9 42
43
13
50 44
17
3
1
2
4
5
16 11 14 21 23 28 26 27 32 33 41 39
WADR-03-03-102-1 ja
1- Retaining Ring 16- Stopper Pin B 28- Needle Bearing 40- *1O-ring
2- Oil Seal 17- Ball (2 Used) 29- Spring Holder 41- O-Ring
3- Shaft 18- Plunger (10 Used) 30- Spring 42- Collar
4- Ball Bearing 19- Retainer 31- Spring Guide 43- Coupling
5- Retaining Ring 20- Holder 32- Pin 44- Gear Pump
8- *1Pin (2 Used) 21- Needle (3 Used) 33- O-Ring *1Spring Washer (2 Used)
45-
9- Body S 22- Cylinder Block 34- Body H
46- *1Bolt (2 Used)
10- Packing 23- Washer (2 Used) 35- Seal Washer
47- *1Plug (5 Used)
11- Spring (4 Used) 24- Spring 36- Bolt
12- Stopper Pin A 25- Retaining Ring 37- Nut 50- Rod
13- Rod 26- Valve Plate 38- *1Socket Bolt (5 Used)
14- Swash Plate 27- Spring Pin 39- O-Ring
As for the item with mark *1, refer to "Disassembly of Pump Device"W3-3-3-1.
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
1. Evenly tap and install ball bearing (4) to shaft (3) by using a bar and a hammer.
2. Install retaining ring (5) to shaft (3).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
3. Place body S (9) with the gear pump (44) mounting side down. Evenly tap and install the shaft (3) assembly and ball
bearing (4) to body S (9) by using a bar and a hammer.
4. Apply grease on oil seal (2). Install oil seal (2) to body S (9) by using special tool (ST 7712).
WADS50-EN-00(07/05/2019) W3-3-4-1
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
IMPORTANT
The lengths of stopper pin A (12) and stopper pin B (16) are different. Do not mistake the position to install.
6. Install springs (11) (2 used) to stopper pin A (12). Install stopper pin A (12) to body S (9).
7. Install springs (11) (2 used) to stopper pin B (16). Install stopper pin B (16) to body S (9).
12
11
9
16
11
WACK-03-04-109-1 ja
8. Install rods (13, 50) to body S (9).
9. Apply grease onto balls (17) (2 used). Install balls (17) (2 used) to swash plate (14). Install swash plate (14) to body S (9).
CAUTION
When installing retaining ring (25), push washers (23) (2 used) and spring (24) by using a press to prevent them
from jumping out.
10. Install washers (23) (2 used), spring (24), and retaining ring (25) to cylinder block (22) by using a press.
11. Install needles (21) (3 used) to cylinder block (22). Install holder (20) onto needle (21).
12. Install retainer (19) and plungers (18) (10 used) to cylinder block (22).
13. Turn and install the cylinder block (22) assembly to shaft (3).
14. Install spring holder (29), spring (30), and spring guide (31) to body S (9).
IMPORTANT
Check the direction to install valve plate (26).
15. Apply grease onto the body H (34) side of valve plate (26). Fit spring pin (27) and install valve plate (26) to body H (34).
16. Install needle bearing (28) to shaft (3).
17. Install pin (32), pins (8) (2 used), and packing (10) to body S (9).
18. Install O-ring (33) to body H (34).
WADS50-EN-00(07/05/2019) W3-3-4-2
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
19. Fit the socket bolt (38) mounting hole (a) of body H (34) to body S (9). Alternately install temporary assembly bolts
(M10, Length: 65 mm) (2 used) to the socket bolt (38) mounting holes (a) (2 places).
: 17 mm
a
a
34
WACK-03-04-107-1 ja
WADS50-EN-00(07/05/2019) W3-3-4-3
SECTION3 UPPERSTRUCTURE
Group3 Pump Device
MEMO
WADS50-EN-00(07/05/2019) W3-3-4-4
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
2
WADR-03-04-100-1 ja
4. Disconnect connector (5).
5. Disconnect hoses (3) (40 used) from control valve (6).
: 17 mm, 19 mm, 22 mm, 27 mm, 36 mm
CAUTION
Control valve (6) weight: 45 kg
6. Attach nylon slings onto control valve (6), then hoist and hold it.
7. Remove bolts (8) (4 used) and washers (9) (4 used). Remove control valve (6) from plate (7).
: 17 mm
8. Remove pressure sensor (4) from control valve (6).
: 24 mm
WADS50-EN-00(07/05/2019) W3-4-1-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
3
6
4 8, 9
5
WADR-03-04-101-1 ja
WADS50-EN-00(07/05/2019) W3-4-1-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
CAUTION
Control valve (6) weight: 45 kg
3. Attach nylon slings onto control valve (6) and hoist it. Install control valve (6) to plate (7) with bolts (8) (4 used) and
washers (9) (4 used).
: 17 mm
: 50 N·m
4. Connect hoses (3) (40 used) to control valve (6).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 22 mm
: 40 N·m
: 27 mm
: 80 N·m
: 36 mm
: 180 N·m
5. Connect connector (5).
7
3
6
4 8, 9
5
WADR-03-04-101-1 ja
6. Tilt down the floor. (Refer to the operator's manual.)
7. Bleed air from the hydraulic system. (Refer to "Bleeding Air from Hydraulic System"W1-4-1-1.)
WADS50-EN-00(07/05/2019) W3-4-2-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)
2
WADR-03-04-100-1 ja
WADS50-EN-00(07/05/2019) W3-4-2-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
5 8
b
4 1
15 14
16 3
81 17 19
9
18 20
3
2 21
1 10 c
1
11 15
3 14
12 14 16
82
9 17 3
13 22 19
1 18
20
21 21
20 d
79 1
13
3
14 15 20
23 83 9 16
1 17
19
21 18
24 14
20 21
13 25
3
15
3 16 e
14 15 1
17
26 84 16
9 17 18 30
1 14
27
21 31
19
20 20
13
30 21
3 3
14
1
32 85
21
20
13
WADR-03-04-102-1 ja
WADS50-EN-00(07/05/2019) W3-4-3-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
f
1
15 20
36 m
16 33 21
35 17
34
37
9 19
14
33 38 3
39 g
1
40 n
3 41
14 42 14
1 3
86
43 28
21 19
20
20 9 21
13 45
3 h
14 44 47 1 48 56
1 57
46 29
87 58
21 50 59
20 9 i 60
13 19 1
47 3 61
9 62
3 14 p
1 28 63
3
64
88
49 65
19
44 20 66
13 67
45 21 j
9 68
3 15
16 55 69
14
17 54
1 89 37 70
51 52
74 71
21 20
14
20 21 k
13 73 1
33 53 72 3
20
33 15
9 16 33 21
14 90 15 17
1 16 76
75 19
17
3 37 14
21
20 33 3
13
3
14
91
1
78
21 5
20 77
13
WADR-03-04-103-1 ja
a- Flow Combiner Valve Sec e- Auxiliary Section i- Travel (Left) Section n- Arm Regenerative Valve
tion
b- Blade Section f- Arm Section j- Boom Section p- Boom Anti-Drift Valve
c- Swing Section g- Travel (Right) Section k- Bucket Section
d- Boom Swing Section h- Inlet Section m- Arm Check Valve
WADS50-EN-00(07/05/2019) W3-4-3-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
1- Socket Bolt (42 Used) 24- Spring 47- Main Relief Valve (2 Used) 70- Socket Bolt (5 Used)
2- Spring 25- Check Valve 48- Washer 71- Body
3- O-Ring (22 Used) 26- Spool 49- Spool 72- Backup Ring
4- Main Relief Valve 27- Plug (2 Used) 50- Filter 73- Spring
5- Nut (8 Used) 28- Plug (2 Used) 51- Spool 74- Check Valve
6- Plug 29- Plug 52- Plug (2 Used) 75- Spool
7- Filter 30- Plug (2 Used) 53- O-Ring 76- Check Valve
8- Cover 31- Check Valve 54- Spacer 77- Rod (4 Used)
9- O-Ring (10 Used) 32- Spool 55- O-Ring (2 Used) 78- Spool
10- Spool 33- Overload Relief Valve (6 Used) 56- Plug 79- Make-Up Valve
11- Spring Seat 34- O-Ring 57- Piston 81- Body (Flow Combiner Valve)
12- Spring Seat 35- Orifice 58- Spring 82- Body (Blade)
13- Cover (11 Used) 36- O-Ring 59- Plug 83- Body (Swing)
14- Spring (18 Used) 37- Check Valve (3 Used) 60- O-Ring 84- Body (Boom Swing)
15- Plug (9 Used) 38- Plug 61- Spool 85- Body (Auxiliary)
16- O-Ring (9 Used) 39- Check Valve 62- Sleeve 86- Body (Arm)
17- Spring (9 Used) 40- Spring 63- Backup Ring 87- Body (Travel (Right))
18- Check Valve (4 Used) 41- O-Ring 64- O-Ring 88- Body (Inlet)
19- Cover (9 Used) 42- Plug 65- O-Ring 89- Body (Travel (Left))
20- Spring Seat (18 Used) 43- Spool 66- Backup Ring 90- Body (Boom)
21- Spring Seat (18 Used) 44- Spring (2 Used) 67- Check Valve 91- Body (Bucket)
22- Spool 45- Check Valve (2 Used) 68- Spring Seat
23- Spool 46- Spool 69- Spring
WADS50-EN-00(07/05/2019) W3-4-3-3
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
MEMO
WADS50-EN-00(07/05/2019) W3-4-3-4
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
Disassembly of Body
6 a
4 9
b
15
16
81 17
18
9
c
15
16
82 17
18
9
79
d
15
83 16
17
18
24
25
9
15
16
15
17
18 30
16 e
84
17 27
31
30
85
WADR-03-04-102-2 ja
WADS50-EN-00(07/05/2019) W3-4-4-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
f
15
36 16 33
34 17
37
9
33
86
28
9
45
44 47
29 h
87
9
47 9 i
28
88
44
45
9
15 j
16
17
89 37
52
9
33 k
15
16 33
90 15 17
16 76
17
37
33
91
5
77
WADR-03-04-103-2 ja
a- Flow Combiner Valve Sec d- Boom Swing Section g- Travel (Right) Section j- Boom Section
tion
b- Blade Section e- Auxiliary Section h- Inlet Section k- Bucket Section
c- Swing Section f- Arm Section i- Travel (Left) Section
WADS50-EN-00(07/05/2019) W3-4-4-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
4- Main Relief Valve 27- Plug (2 Used) 45- Check Valve (2 Used) 85- Body (Auxiliary)
5- Nut (8 Used) 28- Plug (2 Used) 47- Main Relief Valve (2 Used) 86- Body (Arm)
6- Plug 29- Plug 52- Plug (2 Used) 87- Body (Travel (Right))
9- O-Ring (10 Used) 30- Plug (2 Used) 76- Check Valve 88- Body (Inlet)
15- Plug (9 Used) 31- Check Valve 77- Rod (4 Used) 89- Body (Travel (Left))
16- O-Ring (9 Used) 33- Overload Relief Valve (6 Used) 79- Make-Up Valve 90- Body (Boom)
17- Spring (9 Used) 34- O-Ring 81- Body (Flow Combiner Valve) 91- Body (Bucket)
18- Check Valve (4 Used) 36- O-Ring 82- Body (Blade)
24- Spring 37- Check Valve (3 Used) 83- Body (Swing)
25- Check Valve 44- Spring (2 Used) 84- Body (Boom Swing)
CAUTION
Control valve weight: 45 kg
IMPORTANT
Do not remove plugs (6, 27, 28, 29, 52).
1. Remove plugs (15) (9 used) from sections (b, c, d, e, f, j, k). Remove O-rings (16) (9 used) from plugs (15) (9 used).
: 14 mm
2. Remove springs (17) (9 used) from sections (b, c, d, e, f, j, k).
3. Remove check valves (18) (4 used) from sections (b, c, d, e).
4. Remove check valve (31), check valves (37) (3 used), and check valve (76) from sections (e, f, j, k).
IMPORTANT
Do not disassemble main relief valves (4, 47).
5. Remove main relief valve (4) and main relief valves (47) (2 used) from sections (a, h)
: 24 mm
IMPORTANT
Do not disassemble overload relief valve (33).
6. Remove overload relief valves (33) (6 used) and make-up valve (79) from sections (d, f, j, k)
: 24 mm
7. Remove plugs (30) (2 used) from section (e).
: 17 mm
IMPORTANT
Do not drop O-rings (9, 34, 36), check valves (25, 45), and springs (24, 44) when removing rod (77).
8. Remove nuts (5) (8 used) and rods (77) (4 used) from the body. Divide the control valves into each section.
: 13 mm
9. Remove O-rings (9) (10 used) and O-rings (34, 36) from each section.
10. Remove spring (24), springs (44) (2 used), check valve (25), and check valves (45) (2 used) from sections (d, g, i).
WADS50-EN-00(07/05/2019) W3-4-4-3
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
MEMO
WADS50-EN-00(07/05/2019) W3-4-4-4
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
Assembly of Body
A B D
77
q
5
!
16
16
6 15
15 83
17
81 17
82 18
18
" # $
WADR-03-04-104-1 ja
WADS50-EN-00(07/05/2019) W3-4-5-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
a- Flow Combiner Valve Sec b- Blade Section c- Swing Section q- Machine Front Side
tion
4- Main Relief Valve 9- *1O-Ring (10 Used) 17- Spring (9 Used) 81- Body (Flow Combiner Valve)
5- Nut (8 Used) 15- Plug (9 Used) 18- Check Valve (4 Used) 82- Body (Blade)
6- Plug 16- O-Ring (9 Used) 77- Rod (4 Used) 83- Body (Swing)
WADS50-EN-00(07/05/2019) W3-4-5-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
79 30 33
E F G
77
q
5
30 33
# $
27
31
16 16
16
15 15
84 17 85 86
17 15 17
18 17 37
16
18
27
! "
WADR-03-04-105-1 ja
WADS50-EN-00(07/05/2019) W3-4-5-3
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
d- Boom Swing Section e- Auxiliary Section f- Arm Section q- Machine Front Side
5- Nut (8 Used) 18- Check Valve (4 Used) 34- *1O-ring 79- Make-Up Valve
9- *1O-Ring (10 Used) 27- Plug (2 Used) *1O-ring 84- Body (Boom Swing)
36-
15- Plug (9 Used) 30- Plug (2 Used) 85- Body (Auxiliary)
37- Check Valve (3 Used)
16- O-Ring (9 Used) 31- Check Valve 86- Body (Arm)
77- Rod (4 Used)
17- Spring (9 Used) 33- Overload Relief Valve (6 Used)
WADS50-EN-00(07/05/2019) W3-4-5-4
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
&'
# $
''
%
(
&'
# $
28
87 88 89
28 29
! "
WADR-03-04-106-1 ja
WADS50-EN-00(07/05/2019) W3-4-5-5
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
g- Travel (Right) Section h- Inlet Section i- Travel (Left) Section q- Machine Front Side
5- Nut (8 Used) 29- Plug 45- *1Check Valve (2 Used) 87- Body (Travel (Right))
9- *1O-Ring (10 Used) 44- *1Spring (2 Used) 47- Main Relief Valve (2 Used) 88- Body (Inlet)
28- Plug (2 Used) 77- Rod (4 Used) 89- Body (Travel (Left))
WADS50-EN-00(07/05/2019) W3-4-5-6
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
!!
""
#
!! !! !!
52 90
76
17
16 16
15
90 91
15
17
37
17
16
37
WADR-03-04-107-1 ja
WADS50-EN-00(07/05/2019) W3-4-5-7
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
5- Nut (8 Used) 16- O-Ring (9 Used) 37- Check Valve (3 Used) 77- Rod (4 Used)
9- *1O-Ring (10 Used) 17- Spring (9 Used) 52- Plug (2 Used) 90- Body (Boom)
15- Plug (9 Used) 33- Overload Relief Valve (6 Used) 76- Check Valve 91- Body (Bucket)
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Install check valve (25), check valves (45) (2 used), spring (24), and springs (44) (2 used) to sections (d, g, i).
2. Install O-rings (9) (10 used) and O-rings (34, 36) to each section.
3. Arrange bodies (81 to 91) of each section in the same order of before disassembling. Assemble bodies (81 to 91) with
rods (77) (4 used) and nuts (5) (8 used).
: 13 mm
: 27 to 30 N·m
4. Install plugs (30) (2 used) to section (e).
: 17 mm
: 59 to 69 N·m
5. Install overload relief valves (33) (6 used) to sections (f, j, k).
: 24 mm
: 59 to 69 N·m
6. Install make-up valve (79) to section (d).
: 24 mm
: 59 to 69 N·m
7. Install main relief valve (4) and main relief valves (47) (2 used) to sections (a, h).
: 24 mm
: 59 to 69 N·m
8. Install check valve (31), check valves (37) (3 used), and check valve (76) to sections (e, f, j, k). Install check valves (18) (4
used) to sections (b, c, d, e).
9. Install springs (17) (9 used) to sections (b, c, d, e, f, j, k).
10. Install O-rings (16) (9 used) to plugs (15) (9 used). Install plugs (15) (9 used) to sections (b, c, d, e, f, j, k).
: 14 mm
: 30 to 32 N·m
WADS50-EN-00(07/05/2019) W3-4-5-8
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
56
57
58
59
60
61
62
63
64
65
66
67
68
69
55
54
53 70
20 71
14
72 21
73 3
74
90
WADR-03-04-108-1 ja
3- O-Ring 56- Plug 63- Backup Ring 70- Socket Bolt (5 Used)
14- Spring 57- Piston 64- O-Ring 71- Body
20- Spring Seat 58- Spring 65- O-Ring 72- Backup Ring
21- Spring Seat 59- Plug 66- Backup Ring 73- Spring
53- O-Ring 60- O-Ring 67- Check Valve 74- Check Valve
54- Spacer 61- Spool 68- Spring Seat 90- Body (Boom)
55- O-Ring (2 Used) 62- Sleeve 69- Spring
IMPORTANT
Do not drop spring (14) and spring seats (20, 21) when removing body (71).
1. Secure the body (90) assembly in a vise. Remove socket bolts (70) (5 used). Remove body (71) from body (90).
: 5 mm
2. Remove O-ring (3), O-rings (55) (2 used), spring (14), and spring seat (20) from body (71).
3. Remove spacer (54) from body (90). Remove O-ring (53) and backup ring (72) from spacer (54).
4. Remove spring (73) and check valve (74) from body (90).
WADS50-EN-00(07/05/2019) W3-4-6-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
5. Secure the body (71) assembly in a vise. Remove plug (56) from body (71).
: 24 mm
6. Remove piston (57) and spring (58) from plug (59) by using a screw driver.
7. Remove plug (59) from body (71). Remove O-ring (60) from plug (59).
: 24 mm
8. Remove spool (61) from sleeve (62).
9. Remove the sleeve (62) assembly from body (71).
10. Remove backup rings (63, 66) and O-rings (64, 65) from sleeve (62).
11. Remove check valve (67), spring seat (68), and spring (69) from body (71) by using a magnet.
WADS50-EN-00(07/05/2019) W3-4-6-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
59
57 3 21
90 61
58
60
62
64
90
63
55 66
65
68
69
74 73 72 53 54 67 71
WADR-03-04-109-1 ja
3- O-Ring 56- Plug 63- Backup Ring 70- *1Socket Bolt (5 Used)
14- Spring 57- Piston 64- O-Ring 71- Body
20- Spring Seat 58- Spring 65- O-Ring 72- Backup Ring
21- Spring Seat 59- Plug 66- Backup Ring 73- Spring
53- O-Ring 60- O-Ring 67- Check Valve 74- Check Valve
54- Spacer 61- Spool 68- Spring Seat
55- O-Ring (2 Used) 62- Sleeve 69- Spring
As for the item with mark *1, refer to "Disassembly of Boom Anti-Drift Valve"W3-4-6-1.
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Install backup rings (63, 66) and O-rings (64, 65) to sleeve (62).
2. Install check valve (67) to sleeve (62).
3. Install spring seat (68) and spring (69) to the sleeve (2) assembly.
4. Place body (71) with the O-ring (55) mounting surface side up. Install the sleeve (62) assembly to body (71).
5. Secure body (71) in a vise. Install O-ring (60) to plug (59). Install plug (59) to body (71).
: 24 mm
: 30 N·m
6. Install spool (61) and spring (58) to sleeve (62).
7. Install piston (57) and plug (56) to plug (59).
: 24 mm
: 30 N·m
8. Install check valve (74) and spring (73) to body (90).
9. Install backup ring (72) and O-ring (53) to spacer (54). Install spacer (54) to body (90).
10. Install spring seat (20), spring (14), O-ring (3), and O-rings (55) (2 used) to body (71).
WADS50-EN-00(07/05/2019) W3-4-7-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
11. Secure body (90) in a vise. Install body (71) to body (90) with socket bolts (70) (5 used).
: 10 mm
: 7 to 10 N·m
WADS50-EN-00(07/05/2019) W3-4-7-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
Disassembly of Spool
NOTE
The illustration shows the arm section.
20
21
19
14
3 86
14
13
1
43
21
20
WADR-03-04-110-1 ja
1- Socket Bolt (4 Used) 14- Spring (2 Used) 21- Spring Seat (2 Used)
3- O-Ring (2 Used) 19- Cover 43- Spool
13- Cover 20- Spring Seat (2 Used) 86- Body (Arm)
NOTE
As an example, the arm spool is explained here.
IMPORTANT
Do not drop spring (14) and spring seats (20, 21) when removing covers (13, 19).
1. Remove socket bolts (1) (4 used). Remove covers (13, 19) and O-rings (3) (2 used) from body (86).
: 5 mm
IMPORTANT
Each body has its own spool. Arrange the disassembled parts together with each body, in order not to confuse.
2. Remove springs (14) (2 used) and springs (20) (2 used) from covers (13, 19).
3. Remove spring seats (21) (2 used) from spool (43).
4. Turn and remove spool (43) from body (86).
WADS50-EN-00(07/05/2019) W3-4-8-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
MEMO
WADS50-EN-00(07/05/2019) W3-4-8-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
Assembly of Spool
NOTE
The illustration shows the arm section.
20 19 3 21 14 13
14 1 21 43 3 20
86
WADR-03-04-111-1 ja
1- Socket Bolt (4 Used) 14- Spring (2 Used) 21- Spring Seat (2 Used)
3- O-Ring (2 Used) 19- Cover 43- Spool
13- Cover 20- Spring Seat (2 Used) 86- Body (Arm)
NOTE
As an example, the arm spool is explained here.
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
WADS50-EN-00(07/05/2019) W3-4-9-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
MEMO
WADS50-EN-00(07/05/2019) W3-4-9-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
35
39
40
41
42
86
WADR-03-04-110-2 ja
35- Orifice 40- Spring 42- Plug
39- Check Valve 41- O-Ring 86- Body (Arm)
1. Remove plug (42) from body (86). Remove O-ring (41) from plug (42).
: 6 mm
2. Remove spring (40) and check valve (39) from body (86).
3. Remove orifice (35) from body (86).
: 2.5 mm
WADS50-EN-00(07/05/2019) W3-4-10-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
MEMO
WADS50-EN-00(07/05/2019) W3-4-10-2
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
86
35
39
40
42 41
WADR-03-04-112-1 ja
35- Orifice 40- Spring 42- Plug
39- Check Valve 41- O-Ring 86- Body (Arm)
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
WADS50-EN-00(07/05/2019) W3-4-11-1
SECTION3 UPPERSTRUCTURE
Group4 Control Valve
MEMO
WADS50-EN-00(07/05/2019) W3-4-11-2
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
4. Remove bolts (3) (6 used) and washers (4) (6 used). Remove swing device (2) from main frame (5).
: 22 mm
5. Remove the adapters attached to swing device (2) if necessary.
1 2
5 3, 4
WADR-03-05-100-1 ja
WADS50-EN-00(07/05/2019) W3-5-1-1
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
MEMO
WADS50-EN-00(07/05/2019) W3-5-1-2
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
CAUTION
The swing device (2) weight: 38 kg
2. Install swing device (2) to main frame (5) with bolts (3) (6 used) and washers (4) (6 used).
: 22 mm
: 140 N·m
3. Connect hoses (1) (5 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 22 mm
: 40 N·m
4. Tilt down the floor. (Refer to the operator's manual.)
IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)
1 2
5 3, 4
WADR-03-05-100-1 ja
WADS50-EN-00(07/05/2019) W3-5-2-1
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
MEMO
WADS50-EN-00(07/05/2019) W3-5-2-2
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
WADR-03-05-101-1 ja
1- Housing 9- Collar 16- Screw (4 Used) 23- Thrust Plate
2- Shaft 10- Second Stage Carrier 17- Second Stage Sun Gear 24- First Stage Sun Gear
3- Plate 11- Thrust Plate (4 Used) 18- First Stage Carrier 35- Plug
4- Collar 12- Inner Race (4 Used) 19- Thrust Plate (4 Used) 36- O-Ring
5- Roller Bearing 13- Needle Bearing (4 Used) 20- Inner Race (4 Used) 37- O-Ring
6- Oil Seal 14- Second Stage Planetary Gear 21- Needle Bearing (4 Used) 38- Socket Bolt (2 Used)
7- Roller Bearing (4 Used) 22- First Stage Planetary Gear (4 39- Swing Motor
8- Plate (2 Used) 15- Thrust Plate Used)
WADS50-EN-00(07/05/2019) W3-5-3-1
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
IMPORTANT
Shaft (2), collar (4), plate (3), roller bearings (5, 7), plates (8) (2 used), and collar (9) cannot be replaced as a single
part. Replace housing (1) as an assembly.
CAUTION
Swing device weight: 38 kg
CAUTION
Swing motor (39) weight : 21 kg
1. Remove socket bolts (38) (2 used) from swing motor (39). Remove swing motor (39) from housing (1).
: 10 mm
2. Remove O-ring (37) from housing (1).
3. Remove plug (35) from housing (1). Remove O-ring (36) from plug (35).
: 5 mm
4. Remove thrust plate (23) and first stage sun gear (24) from housing (1).
5. Remove the first stage carrier (18) assembly from housing (1).
6. Remove first stage planetary gears (22) (4 used), needle bearings (21) (4 used), inner races (20) (4 used), and thrust
plates (19) (4 used) from first stage carrier (18).
7. Remove second stage sun gear (17) from second stage carrier (10).
8. Remove the second stage carrier (10) assembly from housing (1).
9. Remove screws (16) (4 used) and thrust plate (15) from second stage carrier (10).
10. Remove second stage planetary gears (14) (4 used), needle bearings (13) (4 used), inner races (12) (4 used), and thrust
plates (11) (4 used) from second stage carrier (10).
11. Remove collar (9) and plates (8) (2 used) from shaft (2).
IMPORTANT
Do not remove the inner race of roller bearing (5), plate (3), and collar (4) from shaft (2).
12. Remove the shaft (2) assembly from housing (1) by using a plastic hammer.
IMPORTANT
Do not remove the outer races of roller bearings (5, 7) from housing (1).
WADS50-EN-00(07/05/2019) W3-5-3-2
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
39
22
23
37
38
21
24
20
15 19
18
14
17
13
12
11
8 10
9
7
35
6
36
5 1
3 4
2
WADR-03-05-102-1 ja
1- Housing 9- Collar 16- Screw (4 Used) 23- Thrust Plate
2- Shaft 10- Second Stage Carrier 17- Second Stage Sun Gear 24- First Stage Sun Gear
3- Plate 11- Thrust Plate (4 Used) 18- First Stage Carrier 35- Plug
4- Collar 12- Inner Race (4 Used) 19- Thrust Plate (4 Used) 36- O-Ring
5- Roller Bearing 13- Needle Bearing (4 Used) 20- Inner Race (4 Used) 37- O-Ring
6- Oil Seal 14- Second Stage Planetary Gear 21- Needle Bearing (4 Used) 38- Socket Bolt (2 Used)
7- Roller Bearing (4 Used) 22- First Stage Planetary Gear (4 39- Swing Motor
8- Plate (2 Used) 15- Thrust Plate Used)
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
IMPORTANT
Collar (4), plate (3), and the inner race of roller bearing (5) have been installed to shaft (2).
1. Place shaft (2) with the roller bearing (5) mounting side up.
2. Apply grease (Shell Alvania Grease 2) onto the inner race of roller bearing (5).
WADS50-EN-00(07/05/2019) W3-5-4-1
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
IMPORTANT
The outer races of roller bearings (5, 7) have been installed to housing (1)
IMPORTANT
Install oil seal (6) with the metal surface facing to the swing motor side.
90
24
9
63
40+0.20
50.2+0.20
ST 7711
WADR-03-05-103-1 ja
7. Install thrust plates (11) (4 used), inner races (12) (4 used), needle bearings (13) (4 used), and second stage planetary
gears (14) (4 used) to second stage carrier (10).
8. Apply LOCTITE #242 onto screws (16) (4 used).
IMPORTANT
Install thrust plate (15) with the chamfered side facing to the swing motor side.
9. Install thrust plate (15) to second stage carrier (10) with screws (16) (4 used).
: 4 ± 0.5 N·m
10. Install the second stage carrier (10) assembly to housing (1).
11. Install second stage sun gear (17) to second stage carrier (10).
12. Install thrust plates (19) (4 used), inner races (20) (4 used), needle bearings (21) (4 used), and first stage planetary gears
(22) (4 used) to first stage carrier (18).
13. Install the first stage carrier (18) assembly to housing (1).
IMPORTANT
Install thrust plate (23) with the chamfered side facing to the swing motor side.
14. Install first stage sun gear (24) and thrust plate (23) to first stage carrier (18).
WADS50-EN-00(07/05/2019) W3-5-4-2
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
15. Install O-ring (36) to plug (35). Install plug (35) to housing (1).
: 5 mm
: 16 ± 1 N·m
16. Install O-ring (37) to housing (1).
17. Install swing motor (39) to housing (1) with socket bolts (38) (2 used).
: 10 mm
: 130 ± 7 N·m
WADS50-EN-00(07/05/2019) W3-5-4-3
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
MEMO
WADS50-EN-00(07/05/2019) W3-5-4-4
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
WAEJ-03-07-107-1 ja
1- Casing 11- Holder 21- Cover 40- Spring (2 Used)
2- Ball Bearing 12- Retainer 22- Ball Bearing 41- Plug (2 Used)
3- Shaft 13- Plunger (9 Used) 23- Pin 42- O-Ring (2 Used)
4- Swash Plate 14- Disc Plate 24- Valve Plate 43- Plug
5- Rotor 15- Brake Piston 25- Pin (2 Used) 44- O-Ring
6- Collar 16- O-Ring 26- O-Ring (2 Used) 45- Plug
7- Spring 17- O-Ring 27- Socket Bolt (5 Used) 46- O-Ring
8- Washer 18- Spring Seat (2 Used) 28- Orifice 47- Retaining Ring
9- Retaining Ring 19- Disc Spring (2 Used) 38- Relief Valve (2 Used)
10- Pin (3 Used) 20- O-Ring 39- Check Valve (2 Used)
WADS50-EN-00(07/05/2019) W3-5-5-1
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
IMPORTANT
Do not disassemble the relief valve (38), since the setting value changes.
IMPORTANT
Do not remove ball bearing (22) unless necessary.
IMPORTANT
Do not drop valve plate (24) while removing cover (21).
IMPORTANT
Do not damage the mating surfaces when separating valve plate (24) from cover (21) or rotor (5) by using a
screwdriver.
IMPORTANT
Do not remove pin (23) and pins (25) (2 used) unless necessary.
WADS50-EN-00(07/05/2019) W3-5-5-2
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
CAUTION
When applying air and removing brake piston (15), hold brake piston (15) with a cloth to prevent it from flying
out.
12. Put the matching marks on casing (1) and brake piston (15). Apply air through parking brake port (a) of casing (1).
Raise and remove brake piston (15).
WAEJ-03-07-108-1 ja
IMPORTANT
Do not damage the sliding surfaces of rotor (5) and plunger (13).
IMPORTANT
Replace rotor (5) and plunger (13) as an assembly.
15. Remove plungers (13) (9 used), retainer (12), holder (11), and pins (10) (3 used) from rotor (5).
CAUTION
When removing retaining ring (9), push washer (8) and spring (7) by using a press to prevent them from jumping
out.
16. Remove retaining ring (9), washer (8), spring (7), and collar (6) from rotor (5) by using a press.
IMPORTANT
Do not damage the sliding surface of swash plate (4).
17. Remove disc plate (14) and swash plate (4) from casing (1).
18. Place the casing (1) assembly horizontally with the orifice (28) mounting side down. Tap the ball bearing (2) mounting
side by using a plastic hammer and remove the shaft (3) assembly from casing (1).
19. Remove ball bearing (2) from shaft (3) by using a press.
20. Remove retaining ring (47) from ball bearing (2).
WADS50-EN-00(07/05/2019) W3-5-5-3
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
MEMO
WADS50-EN-00(07/05/2019) W3-5-5-4
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
44 21
43
5
26
7 17
16
28
14
6 13
12
1
4
10 47
11
2
45
46
38
41
42
39 40
WADR-03-05-104-1 ja
1- Casing 11- Holder 21- Cover 40- Spring (2 Used)
2- Ball Bearing 12- Retainer 22- Ball Bearing 41- Plug (2 Used)
3- Shaft 13- Plunger (9 Used) 23- Pin 42- O-Ring (2 Used)
4- Swash Plate 14- Disc Plate 24- Valve Plate 43- Plug
5- Rotor 15- Brake Piston 25- Pin (2 Used) 44- O-Ring
6- Collar 16- O-Ring 26- O-Ring (2 Used) 45- Plug
7- Spring 17- O-Ring 27- Socket Bolt (5 Used) 46- O-Ring
8- Washer 18- Spring Seat (2 Used) 28- Orifice 47- Retaining Ring
9- Retaining Ring 19- Disc Spring (2 Used) 38- Relief Valve (2 Used)
10- Pin (3 Used) 20- O-Ring 39- Check Valve (2 Used)
WADS50-EN-00(07/05/2019) W3-5-6-1
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
IMPORTANT
Install bearing (2) with the attached retaining ring (47) side up as shown in Figure A.
3 47
A
WAEJ-03-07-110-1 ja
2. Install retaining ring (47) to ball bearing (2).
IMPORTANT
Install shaft (3) until retaining ring (47) of ball bearing (2) comes into contact with casing (1). When shaft (3) is
installed further, retaining ring (47) is deformed.
3. Tap the cover (21) mounting side by using a plastic hammer and install the shaft (3) assembly to casing (1).
IMPORTANT
Install swash plate (4) with the chamfered side facing to the casing (1) side.
4. Apply grease onto the chamfered side of swash plate (4). Install swash plate (4) to casing (1).
IMPORTANT
Install collar (6) with the chamfered side facing to the casing (1) side.
5. Install collar (6), spring (7), and washer (8) to rotor (5).
CAUTION
When installing retaining ring (9) to rotor (5), push washer (8) and spring (7) by using a press to prevent them
from jumping out.
6. Push washer (8) and spring (7) by using a press. Install retaining ring (9) to rotor (5). Turn over rotor (5).
7. Apply grease to pins (10) (3 used). Install pins (10) (3 used) to rotor (5). Install holder (11) onto pin (10).
8. Install retainer (12) and plungers (13) (9 used) to rotor (5).
9. Place the casing (1) assembly horizontally with the orifice (28) mounting surface side down. While turning shaft (3),
install the rotor (5) assembly to casing (1). Place casing (1) with the cover (21) mounting side up.
10. Install disc plate (14) to casing (1).
WADS50-EN-00(07/05/2019) W3-5-6-2
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
11. Install O-rings (16, 17) to brake piston (15). Fit the matching marks made when disassembling and install brake piston
(15) to casing (1).
NOTE
If it is not easy to install brake piston (15) to casing (1) due to the friction from O-rings (16, 17), evenly tap and install
brake piston (15) by using a plastic hammer.
12. Install spring seats (18) (2 used) and disc springs (19) (2 used) to brake piston (15) as illustrated in Figure B.
18
19
18
B
WAEJ-03-07-111-1 ja
13. Install pin (23) and pins (25) (2 used) to cover (21).
14. Apply grease onto valve plate (24) with care not to drop valve plate (24) from cover (21).
IMPORTANT
Check the direction to install valve plate (24).
15. Fit pin (23) and install valve plate (24) to cover (21).
IMPORTANT
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
16. Evenly tap and install ball bearing (22) to cover (21) by using a bar and a hammer.
17. Install O-rings (26) (2 used) to cover (21).
18. Install O-ring (20) to casing (1).
19. Fit the matching marks made when disassembling and install cover (21) to casing (1).
20. Install cover (21) to casing (1) with socket bolts (27) (5 used).
: 10 mm
: 130 ± 7 N·m
21. Install O-ring (44) to plug (43). Install plug (43) to cover (21).
: 5 mm
: 16 N·m
22. Install O-ring (46) to plug (45). Install plug (45) to casing (1).
: 6 mm
: 23 ± 1 N·m
23. Install orifice (28) to casing (1).
: 2.5 mm
: 2.5 ± 0.5 N·m
WADS50-EN-00(07/05/2019) W3-5-6-3
SECTION3 UPPERSTRUCTURE
Group5 Swing Device
24. Install check valves (39) (2 used) and springs (40) (2 used) to casing (1). Install O-rings (42) (2 used) to plugs (41) (2
used). Install plugs (41) (2 used) onto casing (1).
: 8 mm
: 40 ± 2 N·m
25. Install relief valves (38) (2 used) to casing (1).
: 32 mm
: 160 ± 10 N·m
WADS50-EN-00(07/05/2019) W3-5-6-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
3 7
6
4
8
5
14
2
9 13
10
11
12
1
15
WAEJ-03-08-100-1 ja
WADS50-EN-00(07/05/2019) W3-6-1-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-1-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
5. Install the lever (3) assembly and boot (4). Holding up boot (4) and install the lever (3) assembly with lock nut (13).
: 19 mm
: 90 N·m
6. Install cover (1) with bolts, washers (15) (3 used).
: 10 mm
: 5 N·m
7. Install covers (8) with bolts (7) (3 used), bolts (14), and washers (6) (4 used).
: 10 mm
: 5 N·m
3 7
6
4
8
5
14
2
9 13
10
11
12
1
15
WAEJ-03-08-100-1 ja
WADS50-EN-00(07/05/2019) W3-6-2-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-2-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
2. Raise boot (3). Loosen lock nut (5). Remove clip band (6) from the shaft mounting part of pilot valve (4). Disconnect
connector (2).
3. Remove the lever (1) assembly and boot (3) from pilot valve (4).
6
2
5
WAEJ-03-08-101-1 ja
4. Remove bolts, washer (7), screws (9) (4 used), and washers (10) (4 used).
: 13 mm
: 5 mm
WADS50-EN-00(07/05/2019) W3-6-3-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
5. Raise cover (8). Disconnect all connectors (11). Remove cover (8).
9 10
11
WAEJ-03-08-102-1 ja
6. Disconnect hoses (19) (6 used).
: 17 mm
7. Put the matching marks on bracket (15) and pilot valve (4). Remove spring pin (18), bolt (12), washer (17), and bolts,
washers (16) (3 used). Remove pilot valve (4) from bracket (15).
: 13 mm
8. Remove clip band (13) and glass wool (14).
9. Remove the adapters attached to pilot valve (4) if necessary.
18 12
17 19
4
13
16
15 14
WAEJ-03-08-103-1 ja
WADS50-EN-00(07/05/2019) W3-6-3-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
18 12
17 19
4
13
16
15 14
WAEJ-03-08-103-1 ja
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
WADS50-EN-00(07/05/2019) W3-6-4-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
7. Install cover (8) with washers (10) (4 used), bolts (9) (4 used), and bolts, washer (7).
: 13 mm
: 10 N·m
: 5 mm
: 10 N·m
9 10
11
WAEJ-03-08-102-1 ja
8. Secure harness to the shaft mounting part of pilot valve (4) with clip band (6).
9. Install boot (3) and the lever (1) assembly to pilot valve (4). Connect connector (2). Holding up boot (3), install the lever
(1) assembly with locknut (5).
6
2
5
WAEJ-03-08-101-1 ja
WADS50-EN-00(07/05/2019) W3-6-4-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
17
16
15
14
13
12
11
10
18
9
7
6 19
5 20
4 21
22
3
WAEQ-03-06-001-1 ja
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing
WADS50-EN-00(07/05/2019) W3-6-5-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Casing (18) is made of aluminium. A strong force deforms it. Handle with care.
IMPORTANT
Spool (19) has been selected to match the hole on casing (18). The dimensions of balance springs (3, 4) and return
springs (5, 6) as well as those of pushers (9, 10) are different. Arrange the disassembled parts together by the port
number in order not to confuse. The port number is stamped on the outer surface of casing (18).
IMPORTANT
Do not remove screw joint (17) while securing casing (18) in a vice. The strong torque may act on screw joint (17).
1. Secure screw joint (17) in a vice. Turn cam (16) by using a spanner. Remove screw joint (17).
: 19 mm, 32 mm
2. Lightly secure the flat surface of casing (18) in a vice. Remove cam (16) from universal joint (15).
: 32 mm
3. Attach a spanner onto the upper part of universal joint (15). Remove universal joint (15).
: 17 mm
NOTE
LOCTITE #262 has been applied onto universal joint (15).
IMPORTANT
Do not damage the sleeve (12) surface. Insert a soft rubber between sleeve (12) and a tool. Oil seal (11) cannot be
removed from sleeve (12). Sleeve (12) and oil seal (11) should be replaced as an assembly.
5. Remove sleeves (12) (4 used) upward by using a pair of pliers. Remove O-rings (13) (4 used) from sleeves (12) (4 used).
IMPORTANT
The dimensions of pushers (9, 10) for ports (1, 3) and for ports (2, 4) are different. Arrange the disassembled parts
together by the port number in order not to confuse.
6. Remove pushers (9, 10) (2 used for each) from casing (18).
7. When compressing the spring, do not lower spool (19). Install special tool (ST 4145) to the port hole on casing (18) as
illustrated in Figure A.
: 6 mm
18
ST 4145
A
W178-02-07-048-1 ja
WADS50-EN-00(07/05/2019) W3-6-5-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
8. Install special tool (ST 4146) to the pusher hole on casing (18). Push special tool (ST 4146) and compress the spring.
Tighten special tool (ST 4146) by using a socket bolt (M14, Pitch 2.0 mm). Remove retaining rings (8) (4 used) from
spools (19) (4 used) by using a screw driver.
: 12 mm
ST 4146
18
W178-02-07-048-2 ja
IMPORTANT
The quantity of shims (2) has been determined for each port. Arrange them by the port number.
9. Remove special tool (ST 4146). Remove spring guides (7) (4 used), return springs (5, 6) (2 used for each), and balance
springs (3, 4) (2 used for each) from spools (19) (4 used).
10. Remove shim (2) and spacers (1) (4 used) from spools (19) (4 used).
IMPORTANT
Spool (19) has been selected to match the hole on casing (18). Spool (19) and casing (18) should be replaced as an
assembly.
11. Remove special tool (ST 4145) from casing (18). Slowly turn and remove spool (19) from casing (18).
IMPORTANT
Retaining ring (22) may come off while disassembling. Do not drop retaining ring (22) inside casing (18). If
retaining ring (22) falls inside casing (18), remove retaining ring (22) completely. Removed retaining ring (22)
cannot be reused.
12. Remove retaining ring (22) from casing (18) by using a screw driver. Install a bolt (M8, Pitch 1.25 mm) to plug (21).
Remove plug (21) from casing (18). Remove O-ring (20) from plug (21).
: 13 mm
WADS50-EN-00(07/05/2019) W3-6-5-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-5-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
16 15
9, 10
11 12
14
13 8
7
3, 4
5, 6
2
1
20
21
22 19
18
W178-02-06-055-1 ja
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing
NOTE
The following table shows the relations between each port and the parts. Do not confuse them when assembling.
IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.
1. Check the port hole number and insert same spools (19) (4 used) before disassembling. Install the thinner ends of
spools (19) (4 used) into the port hole on casing (18) by rotating them slowly.
NOTE
Spools (19) (4 used) has been selected to match the port hole. Spools (19) (4 used) and casing (18) should be replaced
as an assembly.
WADS50-EN-00(07/05/2019) W3-6-6-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
2. Install special tool (ST 4145) to the port hole on casing (18) in order not to lower spools (19) (4 used) when the spring
is compressed.
: 6 mm
IMPORTANT
Refer to the table in order to assemble the parts correctly.
3. Install spacers (1) (4 used), shim (2), and balance springs (3, 4) (2 used for each) to spools (19) (4 used). Install return
springs (5, 6) (2 used for each) to casing (18).
4. Install spring guides (7) (4 used) onto return springs (5, 6) (2 used for each) with the protrusion side up.
5. Install special tool (ST 4146) to the pusher (9, 10) holes on casing (18). Push special tool (ST 4146) and compress the
spring. Tighten special tool (ST 4146) by using a bolt (M14, Pitch 2.0 mm).
: 12 mm
6. Install retaining ring (8) to special tool (ST 4144).
7. Install retaining rings (8) (4 used) to the grooves on the heads of spools (19) (4 used) extending from special tool (ST
4146).
ST 4146
ST 4144
ST 4145
W178-02-07-049-1 ja
IMPORTANT
Check the position to install pushers (9, 10).
8. Install pushers (9, 10) (2 used for each). After pushing pushers (9, 10) (2 used) several times by hand, remove them.
Check if retaining rings (8) (4 used) come off or balance springs (3, 4) (2 used for each) are located correctly. After
checking, install pushers (9, 10) (2 used for each) to casing (18).
9. Apply grease onto the ball part at the ends of pushers (9, 10) (2 used for each).
10. Apply grease onto the joint part of universal joint (15).
11. Apply grease onto the inner surface of oil seals (11) (4 used).
NOTE
Sleeve (12) and oil seal (11) should be replaced as an assembly.
12. Install oil seals (11) (4 used) and O-rings (13) (4 used) to sleeves (12) (4 used). Push the sleeve (12) assemblies (4 used)
by hand until O-rings (13) (4 used) are inserted into the holes on casing (18).
13. Secure casing (18) in a vise lightly.
WADS50-EN-00(07/05/2019) W3-6-6-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Fit the bolt hole on plate (14) to the screw hole on casing (18).
14. Apply LOCTITE #262 onto the thread part of universal joint (15). Place plate (14) on casing (18). Install universal joint
(15).
: 17 mm
: 25 N·m
IMPORTANT
Check the tighting amount of cam (16).
15. Install cam (16) to universal joint (15). The clearance between cam (16) and pushers (9, 10) (2 used for each) should be
0 to 0.2 mm.
16. Secure cam (16) by using a spanner. Tighten screw joint (17) by using a spanner.
: 19 mm, 30 mm
: 70 N·m
17. Install O-ring (20) to plug (21). Install plug (21) and retaining ring (22) to casing (18).
WADS50-EN-00(07/05/2019) W3-6-6-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-6-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
4 3 2
WAEQ-03-06-002-1 ja
WADS50-EN-00(07/05/2019) W3-6-7-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
3. Remove bolts and washers (8) (4 used). Remove the pedal (6) assemblies (2 used) and the lever (5) assemblies (2 used)
from pilot valve (7).
: 17 mm
8 7
WAEJ-03-08-105-1 ja
4. Tilt up the floor. (Refer to the operator's manual.)
WAEJ-03-08-106 ja
WADS50-EN-00(07/05/2019) W3-6-7-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
10
10
10
WAEJ-03-08-107-1 ja
6. Tilt down the floor. (Refer to the operator's manual.)
7. Remove socket bolts (12) (2 used) and washers (13) (2 used). Remove pilot valve (9) from floor (11).
: 8 mm
8. Remove the adapters attached to pilot valve (9) if necessary.
12, 13
9
11
WAEJ-03-08-108-1 ja
WADS50-EN-00(07/05/2019) W3-6-7-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-7-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
12, 13
9
11
WAEJ-03-08-108-1 ja
3. Tilt up the floor. (Refer to the operator's manual.)
WADS50-EN-00(07/05/2019) W3-6-8-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
10
10
10
WAEJ-03-08-107-1 ja
5. Tilt down the floor. (Refer to the operator's manual.)
WAEJ-03-08-106 ja
WADS50-EN-00(07/05/2019) W3-6-8-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)
6. Install the lever (5) assemblies (2 used) and the pedal (6) assemblies (2 used) to pilot valve (7) with bolts, washers (8) (4
used).
: 17 mm
: 50 N·m
8 7
WAEJ-03-08-105-1 ja
7. Install floor mats (1, 2, 3, 4).
1
4 3 2
WAEQ-03-06-002-1 ja
WADS50-EN-00(07/05/2019) W3-6-8-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-8-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
2
6d
3
4 6c
6b
5
6a
7 35
34
33
32
8 31
9
30
10 29
11
28
14
27
12
15 26
13
25
16
17 24
18
19 23
20
21 22
WAEQ-03-06-003-1 ja
1- Bolt, Washer (2 Used) 8- Spring Washer (4 Used) 18- Balance Spring (4 Used) 28- Oil Seal (4 Used)
2- Cover 9- Socket Bolt (4 Used) 19- O-Ring (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 10- Spring Pin (2 Used) 20- Plug (2 Used) 30- Socket Bolt (2 used)
4- Spring Pin (2 Used) 11- Bracket (2 Used) 21- Plug (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 12- Spring Pin (2 Used) 22- O-Ring (2 Used) 32- Damper (2 Used)
6a- Bushing 13- Spring Pin (2 Used) 23- Casing 33- O-Ring (2 Used)
6b- Bushing 14- O-Ring (4 Used) 24- Spool (4 Used) 34- O-Ring (2 Used)
6c- Bushing 15- Bushing (4 Used) 25- Spring (4 Used) 35- Pin (2 Used)
6d- Bushing 16- Pusher (4 Used) 26- Spacer (4 Used)
7- Holder 17- Spring Guide (4 Used) 27- Shim (12 Used)
WADS50-EN-00(07/05/2019) W3-6-9-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Casing (23) is made of aluminium. A strong force deforms it. Handle with care.
IMPORTANT
Spool (24) has been selected to match the hole on casing (23). Arrange the disassembled parts together by the
port number in order not to confuse. The port number is stamped on the outer surface of casing (23).
1. Remove bolts and washers (1) (2 used). Remove cover (2) from holder (7).
: 10 mm
2. Remove socket bolts (30) (2 used) and spring washers (29) (2 used). Remove the holder (7) assembly from casing (23).
: 8 mm
3. Remove the pusher (16) assemblies (4 used) from casing (23).
4. Remove pushers (16) (4 used) from bushings (15) (4 used). Remove oil seals (28) (4 used) and O-rings (14) (4 used) from
bushings (15) (4 used) by using a spatula.
IMPORTANT
Spool (24) has been selected to match the hole of casing (23). Spool (24) and casing (23) should be replaced as an
assembly.
IMPORTANT
Put the mark on spools (24) (4 used) when keeping in order to easily install spools (24) (4 used) to the original
hole.
5. Turn and remove the spool (24) assemblies (4 used) from casing (23). Spring guides (17) (4 used), balance springs (18)
(4 used), shims (27) (12 used), and spacers (26) (4 used) are removed with spools (24) (4 used) together.
IMPORTANT
The quantity of shims (27) has been determined for each port. Arrange them by the port number.
6. Compress balance springs (18) (4 used). Remove spring guides (17) (4 used), balance springs (18) (4 used), shims (27)
(12 used), and spacers (26) (4 used) from spools (24) (4 used).
7. Remove springs (25) (4 used) from casing (23).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
IMPORTANT
Place a stand under bracket (11) and receive a reaction force. If holder (7) bears the reaction force, strong force
acts on pin (35). Therefore, pin (35) may be deformed.
8. Place stand (b) under brackets (11) (2 used). The inner diameter parts of the spring pin (12, 13) holes on brackets (11)
(2 used) are stepped-shape. The spring pin can only be removed in one direction. Tap and remove spring pins (12, 13)
(2 used for each) together from brackets (11) (2 used) by using special tool (ST 1237) and a hammer. Remove brackets
(11) (2 used) from pins (35) (2 used). Do not remove spring pins (10) (2 used) installed into brackets (11) (2 used) unless
necessary. The hole end of spring pin (10) has been crimped.
WADS50-EN-00(07/05/2019) W3-6-9-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
12, 13
11
35
10
W176-02-07-019-1 ja
9. Remove socket bolts (9) (4 used) and spring washers (8) (4 used). Remove dampers (32) (2 used) and rubber seats (31)
(2 used) from pins (35) (2 used). O-rings (34) (2 used) are removed together.
: 5 mm
10. Remove O-rings (33) (2 used) from pins (35) (2 used).
11. Place holder (7) with the casing (23) mounting surface up.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
12. The holes of spring pins (3, 4) in cams (5) (2 used) are stepped-shape. Tap the bottom of cam (5) and remove spring
pins (3, 4) (2 used for each) together from cams (5) (2 used) by using special tool (ST 1237) and a hammer. As the holes
of spring pins (3, 4) are crimped, spring pins (3, 4) may feel tight when removing.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
13. Remove pins (35) (2 used) by using a bar and a hammer. At the same time, cams (5) (2 used) are removed. Do not
remove bushings (6a, 6b, 6c, 6d) installed to holder (7) unless necessary. If necessary, remove bushings (6a, 6b, 6c, 6d)
by tapping by using special tool (ST 7256) and a hammer.
14. Remove plugs (20) (2 used) from casing (23). Remove O-ring (19) (2 used) from plug (20) (2 used).
: 5 mm
15. Remove plugs (21) (2 used) from casing (23). Remove O-ring (22) (2 used) from plug (21) (2 used).
: 6 mm
WADS50-EN-00(07/05/2019) W3-6-9-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-9-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
6a
29
34 15
9
33
8 17
28
18
14
25
27
16
26
24
23
WAEQ-03-06-004-2 ja
1- Bolt, Washer (2 Used) 8- Spring Washer (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used)
2- Cover 9- Socket Bolt (4 Used) 19- *1O-Ring (2 Used) 28- Oil Seal (4 Used)
3- Spring Pin (2 Used) 10- Spring Pin (2 Used) *1Plug (2 Used) 29- Spring Washer (2 Used)
20-
4- Spring Pin (2 Used) 11- Bracket (2 Used) 30- Socket Bolt (2 used)
21- *1Plug (2 Used)
5- Cam (2 Used) 12- Spring Pin (2 Used) 31- Rubber Seat (2 Used)
22- *1O-Ring (2 Used)
6a- Bushing 13- Spring Pin (2 Used) 32- Damper (2 Used)
6b- Bushing 14- O-Ring (4 Used) 23- Casing 33- O-Ring (2 Used)
6c- Bushing 15- Bushing (4 Used) 24- Spool (4 Used) 34- O-Ring (2 Used)
6d- Bushing 16- Pusher (4 Used) 25- Spring (4 Used) 35- Pin (2 Used)
7- Holder 17- Spring Guide (4 Used) 26- Spacer (4 Used)
*1Refer to "Disassembly of Travel Pilot Valve"W3-6-9-1.
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.
1. Install spacers (26) (4 used), shims (27) (12 used), and balance springs (18) (4 used) into spools (24) (4 used) in
sequence. Install shims (27) (12 used) as the same condition before disassembling.
IMPORTANT
Check the direction to install spring guide (17).
2. Compress balance springs (18) (4 used) by hand. Install spring guides (17) (4 used) to spools (24) (4 used) with the
stepped part down.
WADS50-EN-00(07/05/2019) W3-6-10-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Before inserting the parts into holder (7) and casing (23), apply hydraulic oil.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
10. When bushings (6a, 6b, 6c, 6d) have been removed from holder (7), install bushings (6a, 6b, 6c, 6d) to holder (7) by
using special tool (ST 7256) and a hammer.
11. Install bushing (6c) to special tool (ST 7256). Tap special tool (ST 7256) by using a hammer and install bushing (6c) to
the end of hole on holder (7). Stop tapping when the bushing (6c) end is flush with the hole end.
7 ST 7256
6c
W178-02-11-310-2 ja
D
W178-02-11-311-2 ja
13. Install bushing (6d) as illustrated in Figure A. Stop tapping when the bushing (6d) end is flush with the outside of
holder (7).
6b 6c 6d
7 ST 7256
A
W178-02-11-312-3 ja
c- Outside of Holder
WADS50-EN-00(07/05/2019) W3-6-10-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
ST 7256 7
B
W178-02-11-313-2 ja
NOTE
Bushings (6a, 6b, 6c, 6d) are identical.
15. Install O-rings (33) (2 used) to pins (35) (2 used). Apply grease onto O-rings (33) (2 used). Install pins (35) (2 used) and
cams (5) (2 used) to holder (7).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
IMPORTANT
Check the direction to install spring pins (3, 4).
16. Install spring pins (3,4) (2 used for each) to cams (5) (2 used) and pins (35) (2 used) by using special tool (ST 1237) and a
hammer. At this time, slits (d) of spring pins (3, 4) (2 used for each) should be positioned 90° away each other. Tap and
install spring pins (3, 4) (2 used for each) until spring pins (3, 4) come in contact with the stepped part in the hole.
3 d d
4
W178-02-07-050-2 ja
d- Slit
17. Crimp the outer circumferences of the cams’ (5) (2 used) holes where spring pins (3, 4) are inserted by using a punch.
18. Place holder (7) on the casing (23) assembly. Install holder (7) to casing (23) with socket bolts (30) (2 used) and spring
washers (29) (2 used). Check the mark direction and install holder (7).
: 8 mm
: 50 N·m
19. Install rubber seats (31) (2 used) to pins (35) (2 used).
IMPORTANT
Check the direction of damper (32). The inner surface of damper (32) is edged-shape. If damper (32) is pried when
installing, O-ring (33) may be damaged.
20. Install dampers (32) (2 used) to pins (35) (2 used) with the lever up.
WADS50-EN-00(07/05/2019) W3-6-10-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
21. Secure dampers (32) (2 used) and rubber seats (31) (2 used) to holder (7) with socket bolts (9) (4 used) and spring
washers (8) (4 used).
: 5 mm
: 7 N·m
22. Apply grease onto O-rings (34) (2 used). Install O-rings (34) (2 used) to the end of pins (35) (2 used).
23. As for the installing direction of brackets (11) (2 used), refer to the figure of travel pilot valve disassembling. (Refer to
"Disassembly of Travel Pilot Valve"W3-6-9-1.) Install brackets (11) (2 used) to pins (35) (2 used). Fit the holes to insert
spring pins (12, 13).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
IMPORTANT
Place a stand under bracket (11) and receive a reaction force. If holder (7) bears the reaction force, strong force
acts on pin (35). Therefore, pin (35) may be deformed.
24. Place a stand (b) under brackets (11) (2 used). Install spring pins (12,13) (2 used for each) to brackets (11) (2 used) and
pins (35) (2 used) until they come in contact with the stepped part by using special tool (ST 1237) and a hammer. The
slits of spring pins (12, 13) (2 used for each) should be positioned 90° away each other.
a a
11 35
b
12, 13
W176-02-07-011-1 ja
25. Crimp the outer circumferences of the brackets’ (11) (2 used) holes where spring pins (12, 13) are inserted by using a
punch.
26. Install cover (2) to holder (7) with bolts, washers (1) (2 used).
: 10 mm
: 5 N·m
27. Apply grease onto the spring pin (10) contact part of dampers (32) (2 used).
28. Install O-rings (19) (2 used) to plugs (20) (2 used). Install plugs (20) (2 used) onto casing (23).
: 5 mm
: 10 N·m
29. Install O-rings (22) (2 used) to plugs (21) (2 used). Install plugs (21) (2 used) onto casing (23).
: 6 mm
: 20 N·m
WADS50-EN-00(07/05/2019) W3-6-10-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
11 12
WAEQ-03-06-002-2 ja
3. Remove bolts and washers (2) (2 used). Remove pedal (3).
: 13 mm
WADS50-EN-00(07/05/2019) W3-6-11-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
4. Remove socket bolts (4) (2 used) and spring washers (5) (2 used). Remove Bracket (6).
: 6 mm
2 3
4, 5
WAEJ-03-08-111-3 ja
5. Tilt up the floor. (Refer to the operator's manual.)
WAEJ-03-08-106 ja
WADS50-EN-00(07/05/2019) W3-6-11-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
7 1
WAEJ-03-08-110-1 ja
7. Remove the adapters attached to pilot valve (1) if necessary.
8. Remove bolts and washers (8) (2 used). Remove pilot valve (1) and cover (9) from floor (10).
: 13 mm
10 9 8
WAEJ-03-08-111-1 ja
WADS50-EN-00(07/05/2019) W3-6-11-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-11-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
1. Install cover (9) and pilot valve (1) to floor (10) with bolts, washers (8) (2 used).
: 13 mm
: 10 N·m
10 9 8
WAEJ-03-08-111-1 ja
2. Install all removed adapters to pilot valve (1).
3. Connect hoses (7) (4 used) to pilot valve (1).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
7 1
WAEJ-03-08-110-1 ja
WADS50-EN-00(07/05/2019) W3-6-12-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
WAEJ-03-08-106 ja
IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)
5. Install bracket (6) with socket bolts (4) (2 used) and spring washers (5) (2 used).
: 6 mm
: 20 N·m
6. Install pedal (3) with bolts, washers (2) (2 used).
: 13 mm
: 10 N·m
2 3
4, 5
WAEJ-03-08-111-3 ja
WADS50-EN-00(07/05/2019) W3-6-12-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
11 12
WAEQ-03-06-002-2 ja
WADS50-EN-00(07/05/2019) W3-6-12-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-12-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
11
09
05
10
10 07
06
08
07
b
b
a
a 04
04 c
c
d
d 03
03
02
02
01
01 00
00
16
16
15
WABA-03-07-104-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot
WADS50-EN-00(07/05/2019) W3-6-13-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Casing (15a) is made of aluminium. A strong force deforms it. Handle it with care.
IMPORTANT
Spool (15b) has been selected to match the hole on casing (15a). Arrange the disassembled parts together by the
port number in order not to confuse. The port number is stamped on the outer surface of casing (15a).
1. Secure the pilot valve in a vise. Remove boot (11) from holder (06).
2. Remove set screw (09) from cam (05).
: 2.5 mm
NOTE
LOCTITE #262 has been applied onto set screw (09).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
IMPORTANT
Do not remove bushing (07) unless necessary.
IMPORTANT
Bushing (07) cannot be reused.
4. Remove bushings (07) (2 used) from holder (06) by using a hammer and special tool (ST 7690).
IMPORTANT
The pusher (04d) assembly may fly out when removing holder (06).
5. Put the matching marks on casing (15a) and holder (06). Loosen and remove socket bolts (10) (2 used) alternately.
Remove holder (06) from casing (15a).
: 5 mm
6. Remove the pusher (04d) assemblies (2 used) from casing (15a).
IMPORTANT
Do not damage bushing (04a).
7. Remove pushers (04d) (2 used), O-rings (04c) (2 used), and oil seals (04b) (2 used) from bushings (04a) (2 used).
IMPORTANT
Spool (15b) has been selected to match the hole of casing (15a). Spool (15b) and casing (15a) should be replaced
as an assembly.
IMPORTANT
Put the mark on spools (15b) (2 used) when keeping in order to easily install spools (15b) (2 used) to the original
hole.
8. Turn and remove the spool (15b) assemblies (2 used) from casing (15a).
WADS50-EN-00(07/05/2019) W3-6-13-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
The quantity of shims (01) has been determined for each port. Arrange them by the port number.
9. Compress balance springs (02) (2 used). Remove spring guides (03) (2 used), balance springs (02) (2 used), shims (01)
(6 used), and spacers (00) (2 used) from spools (15b) (2 used).
10. Remove return springs (16) (2 used) from casing (15a).
WADS50-EN-00(07/05/2019) W3-6-13-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-13-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
05
11
04d
04b 10
06
03
04c
16
04a
E
15b
02
01
00
15a
WABA-03-07-105-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.
IMPORTANT
Install shims (01) as the same condition before disassembling.
1. Install spacers (00) (2 used), shims (01) (6 used), and balance springs (02) (2 used) to spools (15b) (2 used) in sequence.
2. Compress balance springs (02) (2 used) by hand. Install spring guides (03) (2 used) to spools (15b) (2 used) with the
stepped part down.
3. Secure casing (15a) in a vise. Install return springs (16) (2 used) to casing (15a).
WADS50-EN-00(07/05/2019) W3-6-14-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Install the spool (15b) assembly into the original port before disassembling.
4. Turn and install the spool (15b) assemblies (2 used) to casing (15a).
IMPORTANT
Do not deform and damage the sliding surface when installing oil seal (04b).
IMPORTANT
Check the direction to install oil seal (04b).
5. Apply grease onto oil seals (04b) (2 used). Install oil seals (04b) (2 used) to bushings (04a) (2 used).
04b
04a
WDAD-03-11-003-2 ja
6. Apply grease onto the sliding surfaces of bushings (04a) (2 used) and O-rings (04c) (2 used). Install O-rings (04c) (2
used) and pushers (04d) (2 used) to bushings (04a) (2 used).
7. Install the pusher (04d) assemblies (2 used) into casing (15a).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
8. Install bushings (07) (2 used) to holder (06) by using a hammer and special tool (ST 7690).
9. Fit the matching marks made when disassembling and install holder (06) to casing (15a) by tightening socket bolts
(10) (2 used) alternately.
: 5 mm
: 7.0 N·m
10. Apply grease onto A part of pushers (04d) (2 used). Install cam (05) to holder (06) with pin (08).
A
04d
WDAD-03-11-004-2 ja
11. Apply LOCTITE #262 onto set screw (09). Install set screw (09) to cam (05).
: 2.5 mm
: 7 N·m
12. Install boot (11) to holder (06).
WADS50-EN-00(07/05/2019) W3-6-14-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
IMPORTANT
The stopper has been installed to the screw (2) tip in order to prevent it from coming off. Do not loosen screw (2)
excessively.
WAEJ-03-08-112-2 ja
4. Remove bolts and washers (13) (2 used). Remove the lever (12) assembly.
: 13 mm
5. Disconnect hoses (8) (6 used).
: 17 mm, 19 mm
WADS50-EN-00(07/05/2019) W3-6-15-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
6. Remove bolts and washers (11) (2 used). Remove pilot valve (10) from bracket (9).
: 13 mm
7. Remove clip bands (6) (2 used) and glass wool (7) from pilot valve (10).
8. Remove the adapters attached to pilot valve (10) if necessary.
A
10 A 11
9 6
7
13
8
12
8
6 11
WAEQ-03-06-005-1 ja
WADS50-EN-00(07/05/2019) W3-6-15-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
5. Install the lever (12) assembly with bolts, washers (13) (2 used).
: 13 mm
: 10 N·m
A
10 A 11
9 6
7
13
8
12
8
6 11
WAEQ-03-06-005-1 ja
6. Install covers (1, 4) with bolts, washers (5) (7 used).
WADS50-EN-00(07/05/2019) W3-6-16-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
WAEJ-03-08-112-2 ja
WADS50-EN-00(07/05/2019) W3-6-16-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
11
09
05
10
10 07
06
08
07
b
b
a
a 04
04 c
c
d
d 03
03
02
02
01
01 00
00
16
16
15
WABA-03-07-104-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot
WADS50-EN-00(07/05/2019) W3-6-17-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Casing (15a) is made of aluminium. A strong force deforms it. Handle it with care.
IMPORTANT
Spool (15b) has been selected to match the hole on casing (15a). Arrange the disassembled parts together by the
port number in order not to confuse. The port number is stamped on the outer surface of casing (15a).
1. Secure the pilot valve in a vise. Remove boot (11) from holder (06).
2. Remove set screw (09) from cam (05).
: 2.5 mm
NOTE
LOCTITE #262 has been applied onto set screw (09).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
IMPORTANT
Do not remove bushing (07) unless necessary.
IMPORTANT
Bushing (07) cannot be reused.
4. Remove bushings (07) (2 used) from holder (06) by using a hammer and special tool (ST 7690).
IMPORTANT
The pusher (04d) assembly may fly out when removing holder (06).
5. Put the matching marks on casing (15a) and holder (06). Loosen and remove socket bolts (10) (2 used) alternately.
Remove holder (06) from casing (15a).
: 5 mm
6. Remove the pusher (04d) assemblies (2 used) from casing (15a).
IMPORTANT
Do not damage bushing (04a).
7. Remove pushers (04d) (2 used), O-rings (04c) (2 used), and oil seals (04b) (2 used) from bushings (04a) (2 used).
IMPORTANT
Spool (15b) has been selected to match the hole of casing (15a). Spool (15b) and casing (15a) should be replaced
as an assembly.
IMPORTANT
Put the mark on spools (15b) (2 used) when keeping in order to easily install spools (15b) (2 used) to the original
hole.
8. Turn and remove the spool (15b) assemblies (2 used) from casing (15a).
WADS50-EN-00(07/05/2019) W3-6-17-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
The quantity of shims (01) has been determined for each port. Arrange them by the port number.
9. Compress balance springs (02) (2 used). Remove spring guides (03) (2 used), balance springs (02) (2 used), shims (01)
(6 used), and spacers (00) (2 used) from spools (15b) (2 used).
10. Remove return springs (16) (2 used) from casing (15a).
WADS50-EN-00(07/05/2019) W3-6-17-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-17-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
05
11
04d
04b 10
06
03
04c
16
04a
E
15b
02
01
00
15a
WABA-03-07-105-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.
IMPORTANT
Install shims (01) as the same condition before disassembling.
1. Install spacers (00) (2 used), shims (01) (6 used), and balance springs (02) (2 used) to spools (15b) (2 used) in sequence.
2. Compress balance springs (02) (2 used) by hand. Install spring guides (03) (2 used) to spools (15b) (2 used) with the
stepped part down.
3. Secure casing (15a) in a vise. Install return springs (16) (2 used) to casing (15a).
WADS50-EN-00(07/05/2019) W3-6-18-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Install the spool (15b) assembly into the original port before disassembling.
4. Turn and install the spool (15b) assemblies (2 used) to casing (15a).
IMPORTANT
Do not deform and damage the sliding surface when installing oil seal (04b).
IMPORTANT
Check the direction to install oil seal (04b).
5. Apply grease onto oil seals (04b) (2 used). Install oil seals (04b) (2 used) to bushings (04a) (2 used).
04b
04a
WDAD-03-11-003-2 ja
6. Apply grease onto the sliding surfaces of bushings (04a) (2 used) and O-rings (04c) (2 used). Install O-rings (04c) (2
used) and pushers (04d) (2 used) to bushings (04a) (2 used).
7. Install the pusher (04d) assemblies (2 used) into casing (15a).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
8. Install bushings (07) (2 used) to holder (06) by using a hammer and special tool (ST 7690).
9. Fit the matching marks made when disassembling and install holder (06) to casing (15a) by tightening socket bolts
(10) (2 used) alternately.
: 5 mm
: 7.0 N·m
10. Apply grease onto A part of pushers (04d) (2 used). Install cam (05) to holder (06) with pin (08).
A
04d
WDAD-03-11-004-2 ja
11. Apply LOCTITE #262 onto set screw (09). Install set screw (09) to cam (05).
: 2.5 mm
: 7 N·m
12. Install boot (11) to holder (06).
WADS50-EN-00(07/05/2019) W3-6-18-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
11 12
WAEQ-03-06-002-2 ja
WADS50-EN-00(07/05/2019) W3-6-19-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
3. Remove socket bolts (1) (2 used) and spring washers (2) (2 used). Remove pedal (3).
: 6 mm
1, 2
WAEQ-03-06-006-1 ja
4. Tilt up the floor. (Refer to the operator's manual.)
WAEJ-03-08-106 ja
WADS50-EN-00(07/05/2019) W3-6-19-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
4
WAEQ-03-06-007-1 ja
6. Remove the adapters attached to pilot valve (5) if necessary.
7. Remove bolts and washers (6) (2 used). Remove pilot valve (5) from floor (7).
: 13 mm
6
WAEQ-03-06-008-1 ja
WADS50-EN-00(07/05/2019) W3-6-19-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-19-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
1. Install pilot valve (5) to floor (7) with bolts, washers (6) (2 used).
: 13 mm
: 10 N·m
2. Install all removed adapters to pilot valve (5).
6
WAEQ-03-06-008-1 ja
3. Connect hoses (4) (5 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
4
WAEQ-03-06-007-1 ja
WADS50-EN-00(07/05/2019) W3-6-20-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
WAEJ-03-08-106 ja
IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)
5. Install pedal (3) with socket bolts (1) (2 used) and spring washers (2) (2 used).
: 6 mm
: 20 N·m
1, 2
WAEQ-03-06-006-1 ja
WADS50-EN-00(07/05/2019) W3-6-20-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
11 12
WAEQ-03-06-002-2 ja
WADS50-EN-00(07/05/2019) W3-6-20-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-20-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
11
09
05
10
10 07
06
08
07
b
b
a
a 04
04 c
c
d
d 03
03
02
02
01
01 00
00
16
16
15
WABA-03-07-104-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot
WADS50-EN-00(07/05/2019) W3-6-21-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Casing (15a) is made of aluminium. A strong force deforms it. Handle it with care.
IMPORTANT
Spool (15b) has been selected to match the hole on casing (15a). Arrange the disassembled parts together by the
port number in order not to confuse. The port number is stamped on the outer surface of casing (15a).
1. Secure the pilot valve in a vise. Remove boot (11) from holder (06).
2. Remove set screw (09) from cam (05).
: 2.5 mm
NOTE
LOCTITE #262 has been applied onto set screw (09).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
IMPORTANT
Do not remove bushing (07) unless necessary.
IMPORTANT
Bushing (07) cannot be reused.
4. Remove bushings (07) (2 used) from holder (06) by using a hammer and special tool (ST 7690).
IMPORTANT
The pusher (04d) assembly may fly out when removing holder (06).
5. Put the matching marks on casing (15a) and holder (06). Loosen and remove socket bolts (10) (2 used) alternately.
Remove holder (06) from casing (15a).
: 5 mm
6. Remove the pusher (04d) assemblies (2 used) from casing (15a).
IMPORTANT
Do not damage bushing (04a).
7. Remove pushers (04d) (2 used), O-rings (04c) (2 used), and oil seals (04b) (2 used) from bushings (04a) (2 used).
IMPORTANT
Spool (15b) has been selected to match the hole of casing (15a). Spool (15b) and casing (15a) should be replaced
as an assembly.
IMPORTANT
Put the mark on spools (15b) (2 used) when keeping in order to easily install spools (15b) (2 used) to the original
hole.
8. Turn and remove the spool (15b) assembly from casing (15a).
WADS50-EN-00(07/05/2019) W3-6-21-2
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
The quantity of shims (01) has been determined for each port. Arrange them by the port number.
9. Compress balance springs (02) (2 used). Remove spring guides (03) (2 used), balance springs (02) (2 used), shims (01)
(6 used), and spacers (00) (2 used) from spools (15b) (2 used).
10. Remove return springs (16) (2 used) from casing (15a).
WADS50-EN-00(07/05/2019) W3-6-21-3
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
MEMO
WADS50-EN-00(07/05/2019) W3-6-21-4
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
05
11
04d
04b 10
06
03
04c
16
04a
E
15b
02
01
00
15a
WABA-03-07-105-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.
IMPORTANT
Install shims (01) as the same condition before disassembling.
1. Install spacers (00) (2 used), shims (01) (6 used), and balance springs (02) (2 used) to spools (15b) (2 used) in sequence.
2. Compress balance springs (02) (2 used) by hand. Install spring guides (03) (2 used) to spools (15b) (2 used) with the
stepped part down.
3. Secure casing (15a) in a vise. Install return springs (16) (2 used) to casing (15a).
WADS50-EN-00(07/05/2019) W3-6-22-1
SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve
IMPORTANT
Install the spool (15b) assembly into the original port before disassembling.
4. Turn and install the spool (15b) assemblies (2 used) to casing (15a).
IMPORTANT
Do not deform and damage the sliding surface when installing oil seal (04b).
IMPORTANT
Check the direction to install oil seal (04b).
5. Apply grease onto oil seals (04b) (2 used). Install oil seals (04b) (2 used) to bushings (04a) (2 used).
04b
04a
WDAD-03-11-003-2 ja
6. Apply grease onto the sliding surfaces of bushings (04a) (2 used) and O-rings (04c) (2 used). Install O-rings (04c) (2
used) and pushers (04d) (2 used) to bushings (04a) (2 used).
7. Install the pusher (04d) assemblies (2 used) into casing (15a).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
8. Install bushings (07) (2 used) to holder (06) by using a hammer and special tool (ST 7690).
9. Fit the matching marks made when disassembling and install holder (06) to casing (15a) by tightening socket bolts
(10) (2 used) alternately.
: 5 mm
: 7.0 N·m
10. Apply grease onto A part of pushers (04d) (2 used). Install cam (05) to holder (06) with pin (08).
A
04d
WDAD-03-11-004-2 ja
11. Apply LOCTITE #262 onto set screw (09). Install set screw (09) to cam (05).
: 2.5 mm
: 7 N·m
12. Install boot (11) to holder (06).
WADS50-EN-00(07/05/2019) W3-6-22-2
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
WAEJ-03-08-106 ja
3. Remove clip band (4). Disconnect connectors (5) (2 used).
4. Disconnect hoses (3) (6 used).
: 17 mm, 19 mm, 22 mm
5. Remove socket bolts (2) (2 used). Remove 2-spool solenoid valve (1) from bracket (6).
: 6 mm
WADS50-EN-00(07/05/2019) W3-7-1-1
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
3
6
5 4
WAEQ-03-07-001-1 ja
WADS50-EN-00(07/05/2019) W3-7-1-2
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
3
6
5 4
WAEQ-03-07-001-1 ja
5. Tilt down the floor. (Refer to the operator's manual.)
WAEJ-03-08-106 ja
WADS50-EN-00(07/05/2019) W3-7-2-1
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)
WADS50-EN-00(07/05/2019) W3-7-2-2
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
7 7
2
4 2 4
12
6 12 6
5 5
9 13 9
13
8
8
9 9
3 3
1 11 1
14
15
17
16
18
10
10
WABA-03-08-100-1 ja
1- Piston (2 Used) 6- Wave Washer (2 Used) 11- Body 16- Adjuster
2- Pin (2 Used) 7- Lock Nut (2 Used) 12- Spool (2 Used) 17- O-Ring
3- Plate (2 Used) 8- Solenoid (2 Used) 13- Spring (2 Used) 18- Lock Nut
4- Casing (2 Used) 9- O-Ring (4 Used) 14- Check Valve
5- Plate (2 Used) 10- O-Ring (2 Used) 15- Spring
IMPORTANT
Arrange the disassembled parts together by the port number in order not to confuse.
1. Remove lock nuts (7) (2 used) from the piston (1) assemblies (2 used). Remove casing (4) (2 used) from body (11).
: 17 mm
2. Remove wave washers (6) (2 used), plates (5, 3) (2 used for each), O-rings (9) (4 used), and solenoids (8) (2 used) from
pistons (1) (2 used).
IMPORTANT
When removing piston (1), pin (2) may fall off. Do not lose pin (2).
3. Remove the piston (1) assemblies (2 used) from body (11). Remove pins (2) (2 used) and O-rings (10) (2 used) from the
piston (1) assemblies (2 used).
4. Remove spools (12) (2 used) and springs (13) (2 used) from body (11) by using a magnet.
WADS50-EN-00(07/05/2019) W3-7-3-1
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
IMPORTANT
Do not disassemble lock nut (18) and adjuster (16).
WADS50-EN-00(07/05/2019) W3-7-3-2
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
4 7 6 5
9
1
8
2
9
3
11
10
14
12
13
15
17
11 18
16
WABA-03-08-101-1 ja
1- Piston (2 Used) 6- Wave Washer (2 Used) 11- Body 16- Adjuster
2- Pin (2 Used) 7- Lock Nut (2 Used) 12- Spool (2 Used) 17- O-Ring
3- Plate (2 Used) 8- Solenoid (2 Used) 13- Spring (2 Used) 18- Lock Nut
4- Casing (2 Used) 9- O-Ring (4 Used) 14- Check Valve
5- Plate (2 Used) 10- O-Ring (2 Used) 15- Spring
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
IMPORTANT
Do not disassemble adjuster (16) and lock nut (18).
WADS50-EN-00(07/05/2019) W3-7-4-1
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
7. Install casings (4) (2 used) to the piston (1) assemblies (2 used). Install the piston (1) assemblies (2 used) to body(11)
with lock nuts (7) (2 used).
: 17 mm
: 15 to 20 N·m
WADS50-EN-00(07/05/2019) W3-7-4-2
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
Removal of Torque Control Solenoid Valve (Only Machine with Air Conditioner (Option)
Attached)
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
1 2
WAEJ-03-02-100-1 ja
3. Remove clip band (3). Disconnect connector (4).
WADS50-EN-00(07/05/2019) W3-7-5-1
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
5
WADR-03-07-100-1 ja
5. Remove bolts, washers (8) (2 used) Remove the torque control solenoid valve (7) from frame (6).
: 13 mm
6. Remove the adapters attached to the torque control solenoid valve (7) if necessary.
6 7
8
WADR-03-07-101-1 ja
WADS50-EN-00(07/05/2019) W3-7-5-2
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
Installation of Torque Control Solenoid Valve (Only Machine with Air Conditioner (Option)
Attached)
1. Install all removed adapters to the torque control solenoid valve (7).
2. Install the torque control solenoid valve (7) to frame (6) with bolts, washers (8) (2 used).
: 13 mm
: 10 N·m
6 7
8
WADR-03-07-101-1 ja
3. Connect hoses (5) (3 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
4. Connect connector (4). Install clip band (3).
3 4
5
WADR-03-07-100-1 ja
WADS50-EN-00(07/05/2019) W3-7-6-1
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
1 2
WAEJ-03-02-100-1 ja
WADS50-EN-00(07/05/2019) W3-7-6-2
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
Disassembly of Torque Control Solenoid Valve (Only Machine with Air Conditioner (Option)
Attached)
7
10
12 4
13
6
5
11
9
WAEJ-03-09-101-1 ja
1- Piston 5- Plate 9- O-Ring (2 Used) 13- Spring
2- Pin 6- Wave Washer 10- O-Ring
3- Plate 7- Lock Nut 11- Body
4- Casing 8- Solenoid 12- Spool
1. Remove lock nut (7) from the piston (1) assembly. Remove casing (4) from body (11).
: 17 mm
2. Remove wave washer (6), plates (5, 3), O-rings (9) (2 used), and solenoid (8) from piston (1).
IMPORTANT
When removing piston (1), pin (2) may fall off. Do not lose pin (2).
3. Remove the piston (1) assembly from body (11). Remove pin (2) and O-ring (10) from piston (1).
4. Remove spool (12) and spring (13) from body (11) by using a magnet.
WADS50-EN-00(07/05/2019) W3-7-7-1
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
MEMO
WADS50-EN-00(07/05/2019) W3-7-7-2
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
Assembly of Torque Control Solenoid Valve (Only Machine with Air Conditioner (Option)
Attached)
B B-B 6 7
5
4
9
9
1
2 8
10
3
11
12
13
B
WAEJ-03-09-102-1 ja
1- Piston 5- Plate 9- O-Ring (2 Used) 13- Spring
2- Pin 6- Wave Washer 10- O-Ring
3- Plate 7- Lock Nut 11- Body
4- Casing 8- Solenoid 12- Spool
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
WADS50-EN-00(07/05/2019) W3-7-8-1
SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve
MEMO
WADS50-EN-00(07/05/2019) W3-7-8-2
4
UNDERCARRIAGE
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
SECTION4 UNDERCARRIAGE
Group1 Swing Bearing
Before removing and installing the swing bearing, the upperstructure must be removed first.
Therefore, the procedure starts on the premise that the upperstructure has already been removed here.
1. Put matching marks (a) on inner race (3) of swing bearing (1) and track frame (4).
2. Remove knock pins (2) (2 used).
NOTE
THREEBOND #1102 has been applied onto knock pin (2).
3. Remove bolts (5) (20 used).
: 19 mm
1
5
2
2
4 a 3
WABA-04-01-100-1 ja
a- Matching Mark
WADS50-EN-00(07/05/2019) W4-1-1-1
SECTION4 UNDERCARRIAGE
Group1 Swing Bearing
CAUTION
Swing bearing (1) weight: 47 kg
4. Install special tools (ST 0052) (3 used) to swing bearing (1). Attach wire ropes onto special tools (ST 0052) (3 used).
Hoist swing bearing (1). Remove swing bearing (1) from track frame (4).
NOTE
THREEBOND #1102 has been applied onto the contacting surface.
ST 0052
WABA-04-01-101-1 ja
WADS50-EN-00(07/05/2019) W4-1-1-2
SECTION4 UNDERCARRIAGE
Group1 Swing Bearing
1. Clean the mounting surfaces of track frame (4) and swing bearing (1).
2. Apply THREEBOND #1102 onto the swing bearing (1) mounting surface of track frame (4).
CAUTION
Swing bearing (1) weight: 47 kg
3. Install special tools (ST 0052) (3 used) to swing bearing (1). Attach wire ropes onto special tools (ST 0052) (3 used).
Hoist swing bearing (1).
ST 0052
WABA-04-01-101-1 ja
IMPORTANT
If matching marks (a) do not fit, the soft zone position of the inner race will be dislocated.
4. Fit matching marks (a) on track frame (4) and inner race (3) of swing bearing (1).
5. Install swing bearing (1) with bolts (5) (20 used).
: 19 mm
: 110 N·m
WADS50-EN-00(07/05/2019) W4-1-2-1
SECTION4 UNDERCARRIAGE
Group1 Swing Bearing
IMPORTANT
Check the position to install knock pin (5).
6. Apply THREEBOND #1102 onto knock pin (2). Install knock pins (2) (2 used) by using a plastic hammer.
d c
5 b
7.5°
2
2
4 a 3
WAEQ-04-01-100-1 ja
a- Matching Mark b- Soft Zone Marking Posi c- Machine Front Side d- Position for Knock Pin
tion
WADS50-EN-00(07/05/2019) W4-1-2-2
SECTION4 UNDERCARRIAGE
Group2 Travel Device
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
The procedure starts on the premise that the track links have been removed. (Refer to "Removal of Track (Rubber
Crawler)"W4-7-1-1 / "Removal of Track (Steel Crawler)"W4-7-3-1.)
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
2. Remove bolts (3) (3 used) and washers (4) (3 used). Remove cover (2) from track frame (1).
: 17 mm
1
3, 4
WAEJ-04-02-100-1 ja
3. Disconnect hoses (8) (4 used) from travel device (7).
: 17 mm, 27 mm
CAUTION
Travel device (7) weight: 46 kg
4. Attach nylon slings onto travel device (7), then hoist and hold it. Remove bolts (5) (12 used) and washers (6) (12 used).
Hoist and remove travel device (7).
: 19 mm
NOTE
LOCTITE #262 has been applied onto bolt (5).
WADS50-EN-00(07/05/2019) W4-2-1-1
SECTION4 UNDERCARRIAGE
Group2 Travel Device
7 5, 6
WAEJ-04-02-101-1 ja
6. Remove other travel device in the same way.
WADS50-EN-00(07/05/2019) W4-2-1-2
SECTION4 UNDERCARRIAGE
Group2 Travel Device
CAUTION
Travel device (7) weight: 46 kg
2. Apply LOCTITE #262 onto bolt (5). Attach nylon slings onto travel device (7) and hoist it. Install travel device (7) with
washers (6) (12 used) and bolts (5) (12 used).
: 19 mm
: 110 N·m
3. Connect hoses (8) (4 used) to travel device (7).
: 17 mm
: 25 N·m
: 27 mm
: 80 N·m
7 5, 6
WAEJ-04-02-101-1 ja
4. Connect the track link. (Refer to "Installation of Track (Rubber Crawler)"W4-7-2-1 / "Installation of Track (Steel
Crawler)"W4-7-4-1.)
5. Install other travel device in the same way.
6. Bleed air from the hydraulic system. (Refer to "Bleeding Air from Hydraulic System"W1-4-1-1.)
WADS50-EN-00(07/05/2019) W4-2-2-1
SECTION4 UNDERCARRIAGE
Group2 Travel Device
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage. In order to prevent the
travel motor from seizing, perform the break-in operation after installing.
7. Install cover (2) to track frame (1) with bolts (3) (3 used) and washers (4) (3 used).
: 17 mm
: 65 N·m
3, 4
WAEJ-04-02-100-1 ja
8. Install other cover in the same way.
WADS50-EN-00(07/05/2019) W4-2-2-2
SECTION4 UNDERCARRIAGE
Group2 Travel Device
1
2
3
4
5
6
7
8
9
19 15
10
18 11
17
16 34
20 15
14
21
22
23
24
25
13
12 36
26 35
27
28
29
30
31
32
33
WACK-04-02-102-1 ja
1- Sun Gear 11- Plug (2 Used) 20- Floating Seal 30- Second Stage Planetary Gear
2- Thrust Washer 12- Plug 21- Floating Seal (4 Used)
3- Carrier 13- O-Ring 22- Ball Bearing 31- Thrust Washer (4 Used)
4- Retaining Ring 14- Retaining Ring (3 Used) 23- Retaining Ring 32- Retaining Ring (4 Used)
5- Drive Gear 15- Thrust Washer (6 Used) 24- Ball Bearing 33- Travel Motor
6- Slide Ring 16- Pin (3 Used) 25- Ring Gear 34- Sprocket
7- O-Ring 17- Needle Bearing (3 Used) 26- Retaining Ring 35- Bolt (12 Used)
8- Cover 18- First Stage Planetary Gear (3 27- Thrust Washer (4 Used) 36- Washer (12 Used)
9- Stopper Ring Used) 28- Inner Race (4 Used)
10- O-Ring (2 Used) 19- Spring Pin (3 Used) 29- Needle Bearing (4 Used)
WADS50-EN-00(07/05/2019) W4-2-3-1
SECTION4 UNDERCARRIAGE
Group2 Travel Device
• The following procedures should be performed before travel motor disassembling. (Refer to "Disassembly of Travel
Motor"W4-2-5-1.)
CAUTION
There may be pressure accumulated inside the travel device. Loosen the air bleed plug slowly. Release any
remaining pressure completely. Remove the drain plug and drain gear oil. If the air bleed plug is loosened
suddenly, the plug may fly out and gear oil may gush out. Keep body and face away from plug.
1. Remove plugs (11) (2 used) and O-rings (10) (2 used) from cover (8). Drain gear oil from the travel device.
: 8 mm
NOTE
Oil amount: 0.6 L
CAUTION
Travel device weight: 46 kg
2. Attach nylon slings onto the travel device and hoist it. Place the travel device onto a workbench with the cover (8) side
up.
8
34
WACK-04-02-103-1 ja
CAUTION
The travel device may move without securing it when removing sprocket (34). Receive a reaction force in order
not to move the travel device when disassembling.
3. Remove bolts (35) (12 used) and washers (36) (12 used). Remove sprocket (34) from ring gear (25).
: 19 mm
NOTE
LOCTITE #262 has been applied onto bolt (35).
IMPORTANT
Carrier (3) should be replaced as the carrier (3) assemblies ((1) to (4) and (14) to (19)).
8. Remove drive gear (5), the carrier (3) assembly, and thrust washer (2) from ring gear (25).
WADS50-EN-00(07/05/2019) W4-2-3-2
SECTION4 UNDERCARRIAGE
Group2 Travel Device
IMPORTANT
Spring pin (19) and pin (16) cannot be removed because they are installed to carrier (3).
9. Remove retaining rings (14) (3 used), thrust washers (15) (6 used), first stage planetary gears (18) (3 used), and needle
bearings (17) (3 used) from carrier (3).
10. Remove retaining ring (4) and sun gear (1) from carrier (3).
11. Remove retaining rings (32) (4 used), thrust washers (31) (4 used), second stage planetary gears (30) (4 used), needle
bearings (29) (4 used), inner races (28) (4 used), and thrust washers (27) (4 used) from travel motor (33).
12. Install a C-clamp to the flange parts of travel motor (33) and ring gear (25). Tighten the C-clamp and remove retaining
ring (26) from travel motor (33).
25
a
a
33
WACK-04-02-104-1 ja
a- C-clamp
IMPORTANT
Do not remove ball bearings (22, 24) and retaining ring (23) unless necessary.
IMPORTANT
Ball bearings (22, 24) cannot be reused. If ball bearings (22, 24) has been removed, replace them with the new
ones.
13. Remove the ring gear (25) assembly from travel motor (33).
IMPORTANT
Handle floating seals (20, 21) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)
WADS50-EN-00(07/05/2019) W4-2-3-3
SECTION4 UNDERCARRIAGE
Group2 Travel Device
MEMO
WADS50-EN-00(07/05/2019) W4-2-3-4
SECTION4 UNDERCARRIAGE
Group2 Travel Device
34 36 35 25 1 2 3 4 7
33
6
8
13
12
18
15
14
10
11
9
26 27 28 29 30 31 32 19 16 17
20 21 22 23 24
WACK-04-02-105-1 ja
1- Sun Gear 11- Plug (2 Used) 20- Floating Seal 30- Second Stage Planetary Gear
2- Thrust Washer 12- Plug 21- Floating Seal (4 Used)
3- Carrier 13- O-Ring 22- Ball Bearing 31- Thrust Washer (4 Used)
4- Retaining Ring 14- Retaining Ring (3 Used) 23- Retaining Ring 32- Retaining Ring (4 Used)
5- Drive Gear 15- Thrust Washer (6 Used) 24- Ball Bearing 33- Travel Motor
6- Slide Ring 16- Pin (3 Used) 25- Ring Gear 34- Sprocket
7- O-Ring 17- Needle Bearing (3 Used) 26- Retaining Ring 35- Bolt (12 Used)
8- Cover 18- First Stage Planetary Gear (3 27- Thrust Washer (4 Used) 36- Washer (12 Used)
9- Stopper Ring Used) 28- Inner Race (4 Used)
10- O-Ring (2 Used) 19- Spring Pin (3 Used) 29- Needle Bearing (4 Used)
WADS50-EN-00(07/05/2019) W4-2-4-1
SECTION4 UNDERCARRIAGE
Group2 Travel Device
• The following procedures should be performed after both brake valve assembling and travel motor assembling. (Refer
to "Assembly of Brake Valve"W4-2-8-1, "Assembly of Travel Motor"W4-2-6-1.)
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Place ring gear (25) with the travel motor (33) side up.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
2. Evenly tap and install ball bearing (24) to ring gear (25) by using a bar and a hammer. At this time, make the thinner
part of the inner race of ball bearing (24) face to the retaining ring (23) side.
3. Install retaining ring (23) to ring gear (25).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
4. Evenly tap and install ball bearing (22) to ring gear (25) by using a bar and a hammer. At this time, make the thinner
part of the inner race of ball bearing (22) face to the retaining ring (23) side.
IMPORTANT
Handle floating seals (20, 21) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)
5. Apply grease onto the O-rings of floating seals (20, 21). Install floating seal (20) to travel motor (33). Install floating seal
(21) to ring gear (25).
6. Fit ring gear (25) to travel motor (33). Evenly tap and install ring gear (25) to travel motor (33) by using a plastic
hammer.
7. Install a C-clamp to the flange parts of travel motor (33) and ring gear (25). Tighten the C-clamp and install retaining
ring (26) to travel motor (33).
NOTE
Check ring gear (25) can rotate. If ring gear (25) cannot rotate, disassemble ball bearings (22, 24) and floating seal (20) and
assemble them again.
25
a
a
33
WACK-04-02-104-1 ja
a- C-clamp
WADS50-EN-00(07/05/2019) W4-2-4-2
SECTION4 UNDERCARRIAGE
Group2 Travel Device
8. Install inner races (28) (4 used), thrust washers (27) (4 used), second stage planetary gears (30) (4 used), needle
bearings (29) (4 used), thrust washers (31) (4 used), and retaining rings (32) (4 used) to travel motor (33).
IMPORTANT
Carrier (3) should be replaced as the carrier (3) assemblies ((1) to (4) and (14) to (19)).
9. Install sun gear (1) to carrier (3) with retaining ring (4).
10. Install thrust washers (15) (3 used), first stage planetary gears (18) (3 used), needle bearings (17) (3 used), thrust
washers (15) (3 used), and retaining rings (14) (3 used) to pins (16) (3 used).
11. Place thrust washer (2) on the step part of sun gear (1). Install the carrier (3) assembly and drive gear (5) to ring gear
(25).
12. Apply grease onto O-ring (7). Install O-ring (7) to ring gear (25).
13. Add gear oil (Apolo oil gear HE90 or SAE #30 CD) to ring gear (25).
NOTE
Oil amount: 0.6 L
14. Apply grease onto slide ring (6). Install slide ring (6) to cover (8).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
15. Fit the plug (11) hole of cover (8) to the notch of ring gear (25). Install the cover (8) assembly and stopper ring (9) to
ring gear (25) by using a screw driver and a hammer.
NOTE
Put the tip of the screw driver on the end surface of stopper ring (9). Tap stopper ring (9) in the circumference direction
through the driver by using the hammer.
16. Install O-rings (10) (2 used) onto plugs (11) (2 used). Install plugs (11) (2 used) to cover (8).
: 8 mm
: 47 to 52 N·m
17. Install O-ring (13) to plug (12). Install plug (12) to cover (8).
: 5 mm
: 12 to 18 N·m
CAUTION
The travel device may move without securing it when installing sprocket (34). Receive a reaction force in order not
to move the travel device when disassembling.
IMPORTANT
Fit the chamfered side of sprocket (34) onto the ring gear (25) side.
18. Degrease the bolt (35) holes of ring gear (25) and bolts (35) (12 used). Apply LOCTITE #262 to bolts (35) (12 used).
Install sprocket (34) to ring gear (25) with washers (36) (12 used) and bolts (35) (12 used).
: 19 mm
: 130 N·m
WADS50-EN-00(07/05/2019) W4-2-4-3
SECTION4 UNDERCARRIAGE
Group2 Travel Device
MEMO
WADS50-EN-00(07/05/2019) W4-2-4-4
SECTION4 UNDERCARRIAGE
Group2 Travel Device
15
19
11
02
10
20
17
05
32
30
27
31
33
26
25
26
28
21
14
13
14
04
12
09
08
06
22
01
24
16
23
18 18
29
WACK-04-02-106-1 ja
01- Brake Valve 10- Swash Plate 18- O-Ring (2 Used) 26- Plate (2 Used)
02- Housing 11- Piston 19- Oil Seal 27- Brake Piston
03- Shaft 12- Pin (3 Used) 20- Steel Ball (2 Used) 28- Spacer
04- Cylinder Block 13- Spring 21- Retaining Ring 29- Spring (8 Used)
05- Valve Plate 14- Washer (2 Used) 22- Socket Bolt (7 Used) 30- O-Ring
06- Plunger (9 Used) 15- Bearing 23- Spring Pin 31- O-Ring
08- Retainer 16- Bearing 24- Pin 32- Backup Ring
09- Holder 17- O-Ring 25- Friction Plate 33- Backup Ring
WADS50-EN-00(07/05/2019) W4-2-5-1
SECTION4 UNDERCARRIAGE
Group2 Travel Device
• The following procedures should be performed after travel reduction gear disassembling. (Refer to "Disassembly of
Travel Reduction Gear"W4-2-3-1.)
IMPORTANT
Valve plate (05) and spring (29) may be kept attaching to the brake valve side when removing brake valve (01)
from housing (02). Do not drop valve plate (05) and spring (29).
IMPORTANT
The open end of brake valve (01) is the seat surface for pressure oil when releasing the parking brake. Do not
damage seat surface (a) when brake valve (5) is placed with the open end down.
1. Place the travel motor with the brake valve (01) side up. Remove socket bolts (22) (7 used). Remove the brake valve
(01) assembly from housing (02).
: 8 mm
NOTE
If it is difficult to remove brake valve (01), remove brake valve (5) by tapping it by using a plastic hammer.
01
WABA-04-02-102-2 ja
a- Seat Surface
IMPORTANT
Do not remove bearing (16), spring pin (23), and pin (24). Replace bearing (16), spring pin (23), and pin (24) as the
brake valve (01) assembly.
2. Remove O-ring (17) and O-rings (18) (2 used) from brake valve (01).
3. Remove valve plate (05) and springs (29) (8 used) from housing (02).
CAUTION
When removing brake piston (27) by using air, hold brake piston (27) with a cloth in order not to fly out.
4. Supply an air pressure of 1.8 MPa or less into the oil line for travel parking brake releasing to raise break piston (27).
Remove break piston (10).
5. Remove backup rings (32, 33) and O-rings (30, 31) from brake piston (27).
6. Remove plates (26) (2 used), friction plate (25), and spacer (28) from housing (02).
7. Place housing (02) horizontally with the oil passage (b) side for parking brake releasing down. Remove the cylinder
block (04) assembly from housing (02).
WADS50-EN-00(07/05/2019) W4-2-5-2
SECTION4 UNDERCARRIAGE
Group2 Travel Device
02
04
WACK-04-02-107-1 ja
CAUTION
When removing retaining ring (21), push washer (14) and spring (13) by using a press to prevent them from
jumping out.
IMPORTANT
Do not disassemble retaining ring (21), washer (14), and spring (13) from cylinder block (04) unless necessary.
8. Remove retaining ring (21), washer (14), and spring (13) from cylinder block (04) by using a press.
9. Remove plungers (06) (9 used), retainer (08), holder (09), and pins (12) (3 used) from cylinder block (04).
10. Remove swash plate (10) from housing (02).
11. Remove steel balls (20) (2 used) and piston (11) from housing (02) by using a magnet.
12. Remove shaft (03) with bearing (15) together from housing (02) by tapping the inner spline side of shaft (03) by using
a bar and a plastic hammer.
IMPORTANT
Oil seal (19) cannot be reused.
13. Remove oil seal (19) from the shaft (03) mounting hole side of housing (02) by using a screwdriver.
NOTE
An adhesive has been applied to the outer surface of oil seal (19).
WADS50-EN-00(07/05/2019) W4-2-5-3
SECTION4 UNDERCARRIAGE
Group2 Travel Device
MEMO
WADS50-EN-00(07/05/2019) W4-2-5-4
SECTION4 UNDERCARRIAGE
Group2 Travel Device
19 15
11 20
08 10
09 12
04 14
28 13
26 02
25 06
31
33
32 30
24 17
27
23 05 16 03 21 01 29 22
WACK-04-02-108-1 ja
01- Brake Valve 10- Swash Plate 18- *1O-Ring (2 Used) 26- Plate (2 Used)
02- Housing 11- Piston 19- Oil Seal 27- Brake Piston
03- Shaft 12- Pin (3 Used) 20- Steel Ball (2 Used) 28- Spacer
04- Cylinder Block 13- Spring 21- Retaining Ring 29- Spring (8 Used)
05- Valve Plate 14- Washer (2 Used) 22- Socket Bolt (7 Used) 30- O-Ring
06- Plunger (9 Used) 15- Bearing 23- Spring Pin 31- O-Ring
08- Retainer 16- Bearing 24- Pin 32- Backup Ring
09- Holder 17- O-Ring 25- Friction Plate 33- Backup Ring
As for the item with mark *1, refer to "Disassembly of Travel Motor"W4-2-5-1.
WADS50-EN-00(07/05/2019) W4-2-6-1
SECTION4 UNDERCARRIAGE
Group2 Travel Device
• The following procedures should be performed before travel reduction gear assembling. (Refer to "Assembly of Travel
Reduction Gear"W4-2-4-1.)
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Place housing (02) with the brake valve (01) mounting side up.
2. Clean the oil seal (19) mounting part of housing (02). Apply THREEBOND #1104 or #1215 onto the outer circumference
of oil seal (19). Install oil seal (19) to housing (02) with paying attention not to deform it by using special tool (ST
7713) .
3. Apply OCEAN grease #7 onto the inner surface of oil seal (19).
IMPORTANT
Bearing (15) has been installed to shaft (03).
IMPORTANT
The lip contacting surface of oil seal (19) is located on the bearing (15) mounting side of shaft (03). Do not
damage.
4. Tap and install the shaft (03) assembly to housing (02) by using a plastic hammer.
IMPORTANT
Install piston (11) into the piston (11) hole with the stepped part down.
5. Apply grease onto steel balls (20) (2 used). Install piston (11) and steel balls (20) (2 used) to housing (02).
6. Fit the hollow (2 places) on the back side of swash plate (10) to the steel ball (20) position.Install swash plate (10) to
housing (02).
7. Place housing (02) horizontally with the oil passage (b) side for parking brake releasing down. At this time, check that
the centers of swash plate (10) and housing (02) are fitted.
NOTE
When oil passage (b) for parking brake releasing is up, the thicker part of swash plate (10) is up and the centers may be
not fitted.
02
04
WACK-04-02-107-1 ja
WADS50-EN-00(07/05/2019) W4-2-6-2
SECTION4 UNDERCARRIAGE
Group2 Travel Device
CAUTION
When installing retaining ring (21), push washer (14) and spring (13) by using a press to prevent them from
jumping out.
8. Install washers (14) (2 used), spring (13), and retaining ring (21) to cylinder block (04) by using a press.
9. Apply grease to pins (12) (3 used) in order not to drop them. Install pins (12) (3 used) to cylinder block (04). Install
holder (09) on pins (12) (3 used).
10. Install retainer (08) and plungers (06) (9 used) to cylinder block (04).
11. Fit the splines of shaft (03) and cylinder block (04). Install the cylinder block (04) assembly to shaft (03).
12. Place housing (02) with the brake valve (01) mounting side up.
IMPORTANT
Alternately install plates (26) (2 used) and friction plate (25).
13. Install spacer (28), plates (26) (2 used), and friction plate (25) to housing (02).
IMPORTANT
Brake piston (27) protrudes just a little because the O-ring and backup ring on the outer surface of brake piston
(27) do not completely enter. When brake piston (27) is pressed, do that evenly by hand. Do not use a hammer or
other tools to press brake piston (27).
14. Install O-rings (30, 31) and backup rings (32, 33) to brake piston (27).
15. Install brake piston (27) to housing (02) with notch (d) of brake piston (27) facing to the hydraulic oil passage (c) side of
piston (11).
c 27 d b
11
WACK-04-02-109-1 ja
WADS50-EN-00(07/05/2019) W4-2-6-3
SECTION4 UNDERCARRIAGE
Group2 Travel Device
IMPORTANT
Bearing (16) and spring pin (23) have been installed to brake valve (01).
IMPORTANT
Install valve plate (05) with its brass thrust surface up.
17. Apply grease onto the back side of valve plate (5) in order not to drop. Install valve plate (05) to brake valve (01) with
fitting the spring pin (23) positions.
18. Apply grease to springs (29) (8 used) in order not to drop. Install springs (29) (8 used), O-ring (17), and O-rings (18) (2
used) to brake valve (01).
IMPORTANT
Do not drop valve plate (05). If valve plate (05) is damaged, oil leakage may occur.
19. Place housing (02) horizontally with the oil passage (b) side for parking brake releasing down. Install brake valve (01)
by fitting the socket bolt (22) hole position of housing (02). At this time, there is a clearance of approximately 10 mm
between brake valve (01) and housing (02) because brake piston (27) is not completely pressed into housing (02).
Install brake valve (01) to housing (02) with socket bolts (22) (7 used) by evenly tightening them.
: 8 mm
: 52 to 66 N·m
02
04
WACK-04-02-107-1 ja
WADS50-EN-00(07/05/2019) W4-2-6-4
SECTION4 UNDERCARRIAGE
Group2 Travel Device
4
3
2
1
8
9 11
10 10
11 9
8
15
1
2
17
18
19
18
17
WACK-04-02-110-1 ja
1- Plug (2 Used) 5- Spool 9- Spring (2 Used) 17- Plug (2 Used)
2- O-Ring (2 Used) 6- Piston 10- O-Ring (2 Used) 18- O-Ring (2 Used)
3- Piston 7- Counter Balance Valve 11- Plug (2 Used) 19- Shuttle
4- Spring 8- Plate (2 Used) 15- Body
WADS50-EN-00(07/05/2019) W4-2-7-1
SECTION4 UNDERCARRIAGE
Group2 Travel Device
IMPORTANT
Do not disassemble the brake valve unless necessary. The brake valve is replaced as an assembly.
1. Remove plugs (11) (2 used) from body (15). Remove O-rings (10) (2 used) from plugs (11) (2 used).
: 36 mm
IMPORTANT
Do not disassemble counter balance valve (7).
2. Remove springs (9) (2 used), plates (8) (2 used), and counter balance valve (7) from body (15).
3. Remove plugs (1) (2 used) from body (15). Remove O-rings (2) (2 used) from plugs (1) (2 used).
: 8 mm
IMPORTANT
Do not drop pistons (3, 6) and spring (4) when removing spool (5).
4. Remove pistons (3, 6), spring (4), and spool (5) from body (15).
5. Remove plugs (17) (2 used) from body (15). Remove O-rings (18) (2 used) from plugs (17) (2 used).
: 5 mm
6. Remove shuttle (19) from body (15).
WADS50-EN-00(07/05/2019) W4-2-7-2
SECTION4 UNDERCARRIAGE
Group2 Travel Device
10
11
1
2
6
4
3 17
5
19 18
WACK-04-02-100-1 ja
1- Plug (2 Used) 5- Spool 9- Spring (2 Used) 17- Plug (2 Used)
2- O-Ring (2 Used) 6- Piston 10- O-Ring (2 Used) 18- O-Ring (2 Used)
3- Piston 7- Counter Balance Valve 11- Plug (2 Used) 19- Shuttle
4- Spring 8- Plate (2 Used) 15- Body
WADS50-EN-00(07/05/2019) W4-2-8-1
SECTION4 UNDERCARRIAGE
Group2 Travel Device
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
WADS50-EN-00(07/05/2019) W4-2-8-2
SECTION4 UNDERCARRIAGE
Group3 Center Joint
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
2. Tilt up the floor. (Refer to the operator's manual.)
3. Disconnect hoses (1) (8 used).
: 17 mm, 19 mm, 22 mm, 27 mm
4. Remove bolts (4) (2 used) and washers (5) (2 used). Remove stopper (3).
: 19 mm
NOTE
LOCTITE #262 has been applied onto bolt (4).
1
4,5
3 2 1
WAFA-04-03-001-1 ja
WADS50-EN-00(07/05/2019) W4-3-1-1
SECTION4 UNDERCARRIAGE
Group3 Center Joint
CAUTION
Remove cover (6) while holding cover (6). Do not drop cover (6).
5. Remove bolts (7) (4 used), collars (8) (4 used) and washers (9) (4 used) from track frame (10). Remove cover (6) from
track frame (10).
: 17 mm
10
7, 8, 9
WAEJ-04-03-101-1 ja
6. Disconnect hoses (11) (10 used) from center joint (2).
: 17 mm, 22 mm, 27 mm
CAUTION
Center joint (2) weight: 22 kg
7. Install special tool (ST 0261) to adapter (14) of center joint (2). Attach nylon slings onto special tool (ST 0261). Hoist and
hold center joint (2).
8. Remove bolts (12) (4 used) and washers (13) (4 used). Lower and remove center joint (2).
: 22 mm
NOTE
LOCTITE #262 has been applied onto bolt (12).
WADS50-EN-00(07/05/2019) W4-3-1-2
SECTION4 UNDERCARRIAGE
Group3 Center Joint
11 14
12, 13
11
2
WAEJ-04-03-102-1 ja
WADS50-EN-00(07/05/2019) W4-3-1-3
SECTION4 UNDERCARRIAGE
Group3 Center Joint
MEMO
WADS50-EN-00(07/05/2019) W4-3-1-4
SECTION4 UNDERCARRIAGE
Group3 Center Joint
CAUTION
Center joint (2) weight: 22 kg
2. Install special tool (ST 0261) to adapter (14) of center joint (2). Attach nylon slings onto special tool (ST 0261). Hoist
center joint (2).
3. Apply LOCTITE #262 to bolt (12). Install center joint (2) to the track frame with bolts (12) (4 used) and washers (13) (4
used).
: 22 mm
: 140 N·m
4. Connect hoses (11) (10 used) to center joint (2).
: 17 mm
: 25 N·m
: 22 mm
: 40 N·m
: 27 mm
: 80 N·m
11 14
12, 13
11
2
WAEJ-04-03-102-1 ja
5. Apply LOCTITE #262 to bolt (4). Install stopper (3) with bolts (4) (2 used) and washers (5) (2 used).
: 19 mm
: 90 N·m
WADS50-EN-00(07/05/2019) W4-3-2-1
SECTION4 UNDERCARRIAGE
Group3 Center Joint
4,5
3 2 1
WAFA-04-03-001-1 ja
7. Tilt down the floor. (Refer to the operator's manual.)
WADS50-EN-00(07/05/2019) W4-3-2-2
SECTION4 UNDERCARRIAGE
Group3 Center Joint
IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)
8. Install cover (6) to track frame (10) with washers (9) (4 used), collars (8) (4 used), and bolts (7) (4 used).
: 17 mm
: 65 N·m
10
7, 8, 9
WAEJ-04-03-101-1 ja
WADS50-EN-00(07/05/2019) W4-3-2-3
SECTION4 UNDERCARRIAGE
Group3 Center Joint
MEMO
WADS50-EN-00(07/05/2019) W4-3-2-4
SECTION4 UNDERCARRIAGE
Group3 Center Joint
1
2
12
13
11 8
10
7
3
17
15
6 14
WAEJ-04-03-103-1 ja
1- Spindle 5- Pin 9- O-Ring 13- Plug (3 Used)
2- Body 6- Oil Seal (4 Used) 10- Backup Ring 14- Bolt (4 Used)
3- Flange 7- O-Ring 11- Dust Seal 15- Spring Washer (4 Used)
4- Ring 8- O-Ring 12- Retaining Ring 17- Oil Seal (3 Used)
WADS50-EN-00(07/05/2019) W4-3-3-1
SECTION4 UNDERCARRIAGE
Group3 Center Joint
CAUTION
Center joint weight: 22 kg
IMPORTANT
Do not disassemble pin (5) and plug (13).
1. Remove bolts (14) (2 used) and spring washers (15) (2 used) diagonally. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
the bolt (14) holes (2 places) of body (2). Attach nylon slings onto the eyebolts. Hoist the center joint. Secure the
center joint on a workbench.
: 17 mm
2. Put the matching marks on body (2) and spindle (1). Remove bolts (14) (4 used) and spring washers (15) (4 used).
Remove flange (3) from body (2).
: 17 mm
3. Remove O-ring (8), retaining ring (12), and ring (4) from body (2).
4. Install special tool (ST 1033) and special tool (ST 1020) to body (2) with bolts (14) (2 used) and spring washers (15) (2
used).
: 17 mm
ST 1020
14, 15
ST 1033
W506-03-03-002-2 ja
IMPORTANT
Do not damage the seal sliding surface of spindle (1).
WADS50-EN-00(07/05/2019) W4-3-3-2
SECTION4 UNDERCARRIAGE
Group3 Center Joint
IMPORTANT
For easy removal of oil seals (6, 17), use the pins (2 used). Do not damage the seal groove.
6. Remove oil seals (6) (4 used), oil seals (17) (3 used), O-rings (7, 9), backup ring (10), and dust seal (11) from body (2).
W178-02-11-240-1 ja
WADS50-EN-00(07/05/2019) W4-3-3-3
SECTION4 UNDERCARRIAGE
Group3 Center Joint
MEMO
WADS50-EN-00(07/05/2019) W4-3-3-4
SECTION4 UNDERCARRIAGE
Group3 Center Joint
11
7 9
10
17
15 14 3 13 12 8
WAEJ-04-03-104-1 ja
1- Spindle 5- Pin 9- O-Ring 13- Plug (3 Used)
2- Body 6- Oil Seal (4 Used) 10- Backup Ring 14- Bolt (4 Used)
3- Flange 7- O-Ring 11- Dust Seal 15- Spring Washer (4 Used)
4- Ring 8- O-Ring 12- Retaining Ring 17- Oil Seal (3 Used)
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
IMPORTANT
When assembling the seals, lightly apply grease (Apolloil Autolex C) to the seals. Install the seals to the grooves.
1. Place body (2) with the dust seal (11) mounting side up. Install oil seals (6) (4 used) and oil seals (17) (3 used) to body
(2).
2. Install O-rings (7, 9) and backup ring (10) to body (2).
WADS50-EN-00(07/05/2019) W4-3-4-1
SECTION4 UNDERCARRIAGE
Group3 Center Joint
3. Install dust seal (11) to spindle (1) with lip part (a) facing to the body (2) side.
11
a
2
WAEJ-04-03-105-1 ja
a- Lip Part
IMPORTANT
The clearance between body (2) and spindle (1) is approximately 0.1 mm. Install straight and slowly. Do not
damage the seals.
IMPORTANT
Do not make a step on ring (4) mounting part (b).
4. Place spindle (1) with the pin (5) mounting side down on a workbench. Fit the matching marks made when
disassembling. Evenly tap and install body (2) to spindle (1) by using a plastic hammer.
1
b
2
WAEJ-04-03-106-1 ja
WADS50-EN-00(07/05/2019) W4-3-4-2
SECTION4 UNDERCARRIAGE
Group3 Center Joint
IMPORTANT
Install ring (4) with chamfered surface (c) facing to the flange (3) side.
c 3 12 4
WAEJ-04-03-107-1 ja
c- Chamfered Side
6. Install O-ring (8) to body (2).
7. Install flange (3) to body (2) with bolts (14) (4 used) and spring washers (15) (4 used).
: 17 mm
: 55 N·m
WADS50-EN-00(07/05/2019) W4-3-4-3
SECTION4 UNDERCARRIAGE
Group3 Center Joint
MEMO
WADS50-EN-00(07/05/2019) W4-3-4-4
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
Before removing and installing the track adjuster, the track links and front idler must be removed first. (Refer to "Removal
of Track (Rubber Crawler)"W4-7-1-1 / "Removal of Track (Steel Crawler)"W4-7-3-1, "Removal of Front
Idler"W4-5-1-1) Therefore, the procedure starts on the premise that the track links and front idler have already been
removed here.
CAUTION
Track adjuster (1) may fly out due to the spring (b) force when removing track adjuster (1). Do not stand in the
same direction to remove track adjuster (1) or where it may fly out. Thread part (c) of rod (d) is always under a load
of spring (b). When rod (d) or thread part (c) is broken, the load of spring (b) could fly the broken parts out;
especially pay attention to it.
1. Pry and remove track adjuster (1) from track frame (2) by using a bar.
2 1 2
b a
d c
WAEJ-04-04-100-1 ja
a- Nut b- Spring c- Thread Part d- Rod
WADS50-EN-00(07/05/2019) W4-4-1-1
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
MEMO
WADS50-EN-00(07/05/2019) W4-4-1-2
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
CAUTION
Install track adjuster (1) with the oil supplying part of grease fitting (4) facing to the hole (5) side of side frame (2).
1. Install track adjuster (1) to track frame (2). At this time, check bracket (3) of track adjuster (1) touches the plate surface.
2. Install the front idler. (Refer to "Installation of Front Idler"W4-5-2-1.)
3. Connect the track. (Refer to "Installation of Track (Rubber Crawler)"W4-7-2-1 / "Installation of Track (Steel
Crawler)"W4-7-4-1.)
2 1 2
3
4
WAEJ-04-04-100-2 ja
WADS50-EN-00(07/05/2019) W4-4-2-1
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
MEMO
WADS50-EN-00(07/05/2019) W4-4-2-2
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
WAEJ-04-04-101-1 ja
00- Cylinder 04- Plug 07- Dust Seal 10- Washer
01- Spring 05- Piston Rod 08- Valve
03- Nut 06- Seal 09- Grease Fitting
WADS50-EN-00(07/05/2019) W4-4-3-1
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
CAUTION
Special tool (ST 4943) weight: 225 kg
CAUTION
The spring force is extremely large. Carry out the disassembly and assembly work carefully. In addition, inspect
the special tool for any damage thoroughly in order to perform the work safely.
1. Place oil jack (c) (30 tons (66200 lb)) between holder (b) and base (d) of the special tool (ST 4943).
CAUTION
Special tool (ST 4140) weight: 36 kg
2. Remove nuts (a) (4 used) from special tool (ST 4943). Attach nylon slings onto the eyebolts (2 used) of special tool (ST
4140). Hoist special tool (ST 4140). Remove special tool (ST 4140) from special tool (ST 4943).
: 46 mm
ST 4140
c
ST 4943
d
WABA-04-04-102-1 ja
WADS50-EN-00(07/05/2019) W4-4-3-2
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
4. Install special tool (ST 4140) to special tool (ST 4943) in order to cover track adjuster (e). Operate the oil jack. Raise until
nut (03) comes out from the center hole of the special tool (ST 4140).
ST 4140
e
03
b
e
WABA-04-04-103-1 ja
CAUTION
As spring (01) is compressed, a strong force is applied. Check if track adjuster (e) is installed correctly when jacked
up.
5. Install nuts (a) (4 used) of special tool (ST 4943). Secure track adjuster (e). Slowly operate the hydraulic jack. Compress
track adjuster (e) until the clearance between washer (10) and nut (03) becomes approx. 10 mm.
: 46 mm
NOTE
Spring (01) compressed length:
CAUTION
Sometimes, cylinder (00) is under an internal pressure. As valve (08) may fly out and the high-pressure grease may
spout out, do not loosen valve (08) quickly. Keep body parts and face away from valve (08) and loosen it gradually.
WADS50-EN-00(07/05/2019) W4-4-3-3
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
CAUTION
Before removing nut (a) and special tool (ST 4140), lower the hydraulic jack and then remove it. Prevent washer
(10) and spring (01) from flying out due to the spring (01) force.
9. Slowly lower an oil jack until spring (01) reaches the free length.
NOTE
Spring (01) free length: 242.3 mm
WABA-04-04-104-1 ja
CAUTION
Special tool (ST 4140) weight: 36 kg
10. Attach nylon slings onto the eyebolts (2 used) of special tool (ST 4140). Hoist and hold special tool (ST 4140). Remove
nuts (a) (4 used) from special tool (ST 4943). Hoist and remove special tool (ST 4140) from special tool (ST 4943).
: 46 mm
ST 4140
WABA-04-04-105-1 ja
11. Remove washer (10) from spring (01).
12. Install eyebolts (M16, Pitch 1.5 mm) to the valve (08) hole of cylinder (00). Attach nylon slings onto the eyebolts. Hoist
the spring (01) assembly.
13. Remove the spring (01) assembly from special tool (ST 4943). Place it horizontally.
14. Remove spring (01) from cylinder (00).
15. Remove piston rod (05) from the cylinder (00) assembly.
WADS50-EN-00(07/05/2019) W4-4-3-4
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
IMPORTANT
Do not damage seal (06) and dust seal (07).
16. Remove dust seal (07) and seal (06) from cylinder (00).
WADS50-EN-00(07/05/2019) W4-4-3-5
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
MEMO
WADS50-EN-00(07/05/2019) W4-4-3-6
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
05 07 06 00 01 10 04 03 08 09
WAEJ-04-04-102-1 ja
00- Cylinder 04- Plug 07- Dust Seal 10- Washer
01- Spring 05- Piston Rod 08- Valve
03- Nut 06- Seal 09- Grease Fitting
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Apply grease onto the inner circumference of seal (06) and dust seal (07). Install seal (06) and dust seal (07) to cylinder
(00).
2. Apply grease to the inner surface of cylinder (00) thinly. Fill grease in entire A part of the bottom surface of cylinder
(00).
00 A
WABA-04-04-107-2 ja
3. Install piston rod (05) to the cylinder (00) assembly. Bleed air from the inside of cylinder (00).
4. Install spring (01) to cylinder (00).
5. Install eyebolts (M16, Pitch 1.5 mm) to the valve (08) hole of cylinder (00). Attach nylon slings onto the eyebolts. Hoist
the spring (01) assembly. Place the spring (01) assembly onto special tool (ST 4943).
6. Remove eyebolts from cylinder (00).
7. Install washer (10) to spring (01).
WADS50-EN-00(07/05/2019) W4-4-4-1
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
CAUTION
Special tool (ST 4140) weight: 36 kg
8. Attach nylon slings onto eyebolts (2 used) of special tool (ST 4140) and hoist it. Install special tool (ST 4140) to special
tool (ST 4943).
ST 4140
ST 4943
WABA-04-04-105-2 ja
9. Install nuts (a) (4 used) of special tool (ST 4943). Secure the spring (01) assembly.
: 46 mm
WABA-04-04-104-2 ja
a- Nut
10. Operate the oil jack. Compress spring (01) to the specified length.
NOTE
WADS50-EN-00(07/05/2019) W4-4-4-2
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
CAUTION
Special tool (ST 4140) weight: 36 kg
15. Attach nylon slings onto the eyebolts (2 used) of special tool (ST 4140). Hoist and hold special tool (ST 4140). Remove
nuts (a) (4 used) from special tool (ST 4943). Hoist and remove special tool (ST 4140) from special tool (ST 4943).
: 46 mm
16. Attach nylon slings onto track adjuster (e). Hoist track adjuster (e). Remove track adjuster (e) from special tool (ST
4943).
ST 4943
WABA-04-04-108-1 ja
WADS50-EN-00(07/05/2019) W4-4-4-3
SECTION4 UNDERCARRIAGE
Group4 Track Adjuster
MEMO
WADS50-EN-00(07/05/2019) W4-4-4-4
SECTION4 UNDERCARRIAGE
Group5 Front Idler
Before removing and installing the front idler, the track links must be removed first. (Refer to "Removal of Track (Rubber
Crawler)"W4-7-1-1 / "Removal of Track (Steel Crawler)"W4-7-3-1) Therefore, the procedure starts on the premise that
the track links have already been removed here.
CAUTION
Front idler (1) weight: 35 kg
CAUTION
Front idler (1) may fly out due to the spring force when removing front idler (1). Do not stand in the same direction
to remove front idler (1) or where it may fly out.
1. Attach nylon sling (A) onto front idler (1). Hoist and hold front idler (1).
2. Hoist and remove front idler (1) with yoke (2) together from track frame (3) by using a bar.
A 1
3 2
WAEJ-04-05-100-1 ja
3. When keeping front idler (1) temporarily, place front idler (1) on wooden block (a) as illustrated in figure B.
1
2
B
WAEJ-04-05-101-1 ja
a- Wooden Block
WADS50-EN-00(07/05/2019) W4-5-1-1
SECTION4 UNDERCARRIAGE
Group5 Front Idler
MEMO
WADS50-EN-00(07/05/2019) W4-5-1-2
SECTION4 UNDERCARRIAGE
Group5 Front Idler
IMPORTANT
Clean track frame (3) and sliding part (b) of yoke (2) thoroughly. Then apply grease.
3
A 1
3 2
WAEJ-04-05-102-1 ja
b- Sliding Part
WADS50-EN-00(07/05/2019) W4-5-2-1
SECTION4 UNDERCARRIAGE
Group5 Front Idler
MEMO
WADS50-EN-00(07/05/2019) W4-5-2-2
SECTION4 UNDERCARRIAGE
Group5 Front Idler
05
06
04
00a 02
00b
03a
03b
01
08
00b
02
03c 07
03d
05 08
06
04
WAEJ-04-05-103-2 ja
00a- Idler 03a- Floating Seal 04- Yoke (2 Used) 08- Bolt, Washer (4 Used)
00b- Bushing (2 Used) 03b- Floating Seal 05- Bolt (2 Used)
01- Axle 03c- Floating Seal 06- Washer (2 Used)
02- O-Ring (2 Used) 03d- Floating Seal 07- Plate
CAUTION
The idler (00a) assembly weight: 35 kg
1. Attach nylon slings onto the idler (00a) assembly. Hoist the idler (00a) assembly. Place the idler (00a) assembly on the
wooden block horizontally.
NOTE
Wooden Block: 85 mm or more square
2. Remove bolts and washers (08) (4 used). Remove plate (07) from yokes (04) (2 used).
: 19 mm
NOTE
LOCTITE #262 has been applied onto bolts and washer (08).
3. Remove bolt (05) and washer (06) from yoke (04) at the upper side.
: 17 mm
NOTE
LOCTITE #262 has been applied onto bolt (05).
WADS50-EN-00(07/05/2019) W4-5-3-1
SECTION4 UNDERCARRIAGE
Group5 Front Idler
CAUTION
The idler (00a) assembly weight: 30 kg
4. Attach nylon slings onto the idler (00a) assembly. Hoist the idler (00a) assembly. Set the idler (00a) assembly on a press
with the side where bolt (05) and washer (06) have been removed up.
5. Put the matching marks on yoke (04) and axle (01). Remove the axle (01) assembly from idler (00a) by using a press.
04 01
00a
W105-03-05-008-3 ja
IMPORTANT
Handle floating seals (03a to 03d) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)
6. Remove yoke (04) from idler (00a). Remove floating seals (03a to 03d) from idler (03A) and yokes (04) (2 used). Drain
off engine oil from idler (00a)
NOTE
Oil amount: 30 mL
04
03a
03b
00a
03c
03d 02
01
04
W105-03-05-009-4 ja
WADS50-EN-00(07/05/2019) W4-5-3-2
SECTION4 UNDERCARRIAGE
Group5 Front Idler
IMPORTANT
Place wooden block (a) under yoke (04) in order not to damage yoke (04).
7. Place yoke (04) on wooden block (a). Remove bolt (05) and washer (06) from other yoke (04). Put the matching marks
on yoke (04) and axle (01). Remove axle (01) from yoke (04) by using a press.
: 17 mm
NOTE
LOCTITE #262 has been applied onto bolt (05).
05 06
02
04
01
02
WAEJ-04-05-104-1 ja
a- Wooden Block
8. Remove O-rings (02) (2 used) from axle (01).
WADS50-EN-00(07/05/2019) W4-5-3-3
SECTION4 UNDERCARRIAGE
Group5 Front Idler
CAUTION
Idler (00a) weight: 21 kg
IMPORTANT
Do not remove bushing (00b) unless necessary.
9. When replacing bushing (00b), remove bushings (00b) (2 used) from idler (00a) by using special tool (ST 1120) and a
press.
00a b
00b
W105-03-05-011-6 ja
WADS50-EN-00(07/05/2019) W4-5-3-4
SECTION4 UNDERCARRIAGE
Group5 Front Idler
00b 00a 04 02
07
08
01
03a 03d
03b 03c
05 06
WAEJ-04-05-105-2 ja
00a- Idler 03a- Floating Seal 04- Yoke (2 Used) 08- Bolt, Washer (4 Used)
00b- Bushing (2 Used) 03b- Floating Seal 05- Bolt (2 Used)
01- Axle 03c- Floating Seal 06- Washer (2 Used)
02- O-Ring (2 Used) 03d- Floating Seal 07- Plate
IMPORTANT
Before assembly, apply engine oil onto parts in order to prevent them from seizing.
CAUTION
Idler (00a) weight: 21 kg
2. Attach nylon slings onto idler (00a). Hoist idler (00a). Place idler (00a) on the wooden block horizontally.
NOTE
Wooden Block: 85 mm or more square
WADS50-EN-00(07/05/2019) W4-5-4-1
SECTION4 UNDERCARRIAGE
Group5 Front Idler
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
4. Fit the matching marks made when disassembling and install yoke (04) to axle (01) by using a hammer. Apply LOCTITE
#262 to bolt (05). Install bolt (05) and washer (06) to axle (01) and yoke (04).
: 17 mm
: 65 N·m
05
06
01
04
02
WAEJ-04-05-106-1 ja
IMPORTANT
Handle floating seals (03a, 03b) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)
5. Apply engine oil to the sliding surface of floating seals (03a, 03b) and the outer surface of the O-ring. Install floating
seals (03a, 03b) to idler (00a) and yoke (04).
6. Install the axle (01) assembly to idler (00a) from the side where floating seal (03b) has been installed by using a press.
CAUTION
The idler (00a) assembly weight: 26 kg
7. Attach nylon slings onto the idler (00a) assembly. Hoist the idler (00a) assembly. Turn over and place the idler (00a)
assembly on the wooden block horizontally.
8. Add engine oil (SAE #30, CD class) to the B part of idler (00a).
NOTE
Oil amount: 30 mL
B 00a
WABA-04-05-104-2 ja
WADS50-EN-00(07/05/2019) W4-5-4-2
SECTION4 UNDERCARRIAGE
Group5 Front Idler
IMPORTANT
Handle floating seals (03c to 03d) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)
9. Install other O-ring (02) to axle (01). Apply engine oil to the sliding surface of floating seals (03c, 03d) and the outer
surface of the O-ring. Install floating seals (03c, 03d) to idler (00a) and other yoke (04).
04
03d 02
03c
01 00a
04
WABA-04-05-105-3 ja
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
10. Fit the matching marks made when disassembling and install yoke (04) to axle (01) by using a hammer. Apply LOCTITE
#262 to bolt (05). Install bolt (05) and washer (06) to axle (01) and yoke (04).
: 17 mm
: 65 N·m
11. Apply LOCTITE # 262 onto bolts and washers (08) (4 used). Install plate (07) to yokes (04) (2 used) with bolts, washers
(08) (4 used).
: 19 mm
: 90 N·m
WADS50-EN-00(07/05/2019) W4-5-4-3
SECTION4 UNDERCARRIAGE
Group5 Front Idler
MEMO
WADS50-EN-00(07/05/2019) W4-5-4-4
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
IMPORTANT
The upper roller cannot be disassembled. Replace it as an assembly.
CAUTION
Pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or too much as valve (1)
may fly out or high-pressure grease may spout out. Keep body parts and face away from valve (1) and loosen it
gradually. Do not loosen grease fitting (2).
IMPORTANT
Loosening valve (1) by 1 to 1.5 turns is enough. Do not loosen it over those turns.
IMPORTANT
When gravel or mud is packed between the sprocket, remove it before loosening.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
2. Loosen valve (1) in the track adjuster. Drain grease and loosen the track tension.
: 19 mm
1
2 1 a 1
WAEJ-04-06-100-1 ja
a- Grease Outlet
IMPORTANT
Use the cushion pad between track frame (3) and hydraulic jack (4) to prevent them from slipping.
3. Jack up track link (6) in order to get clearance between upper roller (5) and track link (6) by using hydraulic jack (4).
Place wooden block (10) between track link (6) and track frame (3).
WADS50-EN-00(07/05/2019) W4-6-1-1
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
4. Remove bolt (7), nut (9), and spring washer (8). Remove upper roller (5).
: 24 mm
NOTE
LOCTITE #262 has been applied onto bolt (7).
6 10 5 7, 8, 9 3
WAEJ-04-06-101-1 ja
WADS50-EN-00(07/05/2019) W4-6-1-2
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
1. Apply LOCTITE #262 onto bolt (7). Install upper roller (5) to track frame (3) with bolt (7), nut (9), and spring washer (8).
: 24 mm
: 210 N·m
2. Remove wooden block (10).
3. Lower hydraulic jack (4). Remove hydraulic jack (4) and the cushion pad from track frame (3).
6 10 5 7, 8, 9 3
WAEJ-04-06-101-1 ja
4. Tighten valve (1) of the track adjuster.
: 19 mm
: 90 N·m
WAEJ-04-06-102-1 ja
CAUTION
Support the raised machine surely by blocks.
5. Jack up the track link to be adjusted. Rotate the track link in the reverse direction a little.
WADS50-EN-00(07/05/2019) W4-6-2-1
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
6. Supply grease to the grease fitting and adjust the track tension.
NOTE
Joint part (b) of the track link (rubber crawler (d)) should be in the center when measuring the track link (rubber
crawler (d)) tension. At this time, turn the track in reverse direction so that the track sag should be located down.
Track Sag Specification (Y): 10 to 15 mm (rubber crawler (d)) (A): 140 to 160 mm (steel crawler (e))
X c
b d
Y
b
d
A
e
WAFF-04-06-001-1 ja
WADS50-EN-00(07/05/2019) W4-6-2-2
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
IMPORTANT
The lower roller cannot be disassembled. Replace it as an assembly.
CAUTION
Securely support the raised machine by using the blocks.
1. Raise the machine off the ground by using the front attachment. Place the blocks under the track frame and support
the machine.
WABA-04-06-100-1 ja
a- 90 to 110 °
CAUTION
Pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or too much as valve (1)
may fly out or high-pressure grease may spout out. Keep body parts and face away from valve (1) and loosen it
gradually. Do not loosen grease fitting (2).
IMPORTANT
Loosening valve (1) by 1 to 1.5 turns is enough. Do not loosen it over those turns.
IMPORTANT
When gravel or mud is packed between the sprocket, remove it before loosening.
2. Loosen valve (1) in the track adjuster carefully. Drain grease until the clearance in the track link is enough to remove
lower roller (4).
: 19 mm
3. Tighten valve (1) clockwise to the original condition.
: 19 mm
: 90 N·m
WADS50-EN-00(07/05/2019) W4-6-3-1
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
4. Remove bolts (3) (2 used) and washers (6) (2 used). Remove lower roller (4).
: 24 mm
NOTE
LOTITE #262 has been applied onto bolt (3).
2 1 b
3, 6
WAEJ-04-06-104-1 ja
b- Grease Outlet
WADS50-EN-00(07/05/2019) W4-6-3-2
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
• The following procedures are to be performed with the machine jacked up.
1. Set lower roller (4) under the lower surface of track frame (5). Fit lower roller (4) to the mounting hole of track frame
(5).
2. Apply LOCTITE #262 to bolts (3) (2 used). Install lower roller (4) with washers (6) (2 used) and bolts (3) (2 used).
: 24 mm
: 270 N·m
3, 6
WAEJ-04-06-105-1 ja
WADS50-EN-00(07/05/2019) W4-6-4-1
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
3. Supply grease to the grease fitting and adjust the track tension.
NOTE
Joint part (b) of the track link (rubber crawler (d)) should be in the center when measuring the track link (rubber
crawler (d)) tension. At this time, turn the track in reverse direction so that the track sag should be located down.
Track Sag Specification (Y): 10 to 15 mm (rubber crawler (d)) (A): 140 to 160 mm (steel crawler (e))
X c
b d
Y
b
d
A
e
WAFF-04-06-001-1 ja
WADS50-EN-00(07/05/2019) W4-6-4-2
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
4. Jack up the front of the base machine. Remove the block from the lower part of track frame (5).
WAEQ-04-06-100-1 ja
5. Add engine oil (SAE #30, API-CD class) through the plug (8) hole of cover (7).
NOTE
Before adding engine oil, remove the lower roller from track frame.
Oil amount: 65±10mL
WACK-04-06-100-1 ja
WADS50-EN-00(07/05/2019) W4-6-4-3
SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers
MEMO
WADS50-EN-00(07/05/2019) W4-6-4-4
SECTION4 UNDERCARRIAGE
Group7 Track
CAUTION
Rubber crawler weight: 125 kg
CAUTION
Securely support the raised machine by using the blocks.
1. Raise the machine off the ground by using the front attachment.
a
WABA-04-06-100-1 ja
a- 90 to 110°
WADS50-EN-00(07/05/2019) W4-7-1-1
SECTION4 UNDERCARRIAGE
Group7 Track
CAUTION
Pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or too much as valve (1)
may fly out or high-pressure grease may spout out. Keep body parts and face away from valve (1) and loosen it
gradually. Do not loosen grease fitting (2).
IMPORTANT
Loosening valve (1) by 1 to 1.5 turns is enough. Do not loosen it over those turns.
IMPORTANT
When gravel or mud is packed between the sprocket, remove it before loosening.
2. Loosen valve (1) in the track adjuster slowly and drain grease.
: 19 mm
NOTE
If rotating the track in forward and reverse direction with valve (1) loosened, the track can be removed and installed
easily.
2 1 b
WABA-04-07-100-1 ja
b- Grease Outlet
CAUTION
Rubber crawler weight: 125 kg
3. Insert steel pipe (3) into the track link. Rotate the sprocket in the reverse direction. When the track link comes off from
the front idler by steel pipe (3), slide and remove it in the transverse direction.
3
WABA-04-07-101-1 ja
c- Rotating Direction
WADS50-EN-00(07/05/2019) W4-7-1-2
SECTION4 UNDERCARRIAGE
Group7 Track
CAUTION
Securely support the raised machine by using the blocks.
1. Raise the machine off the ground by using the front attachment.
CAUTION
Rubber crawler weight: 125 kg
2. Mesh the track with the sprocket. Attach the track onto the front idler. Rotate the sprocket in reverse direction and
push the track.
3. Insert steel pipe (3) into the track link. Rotate the sprocket in reverse direction. Attach the track link onto the front
idler. Check that the track is securely engaged with the sprocket and the front idler.
WABA-04-07-102-1 ja
c- Rotating Direction
4. Tighten valve (1).
: 19 mm
: 90 N·m
WADS50-EN-00(07/05/2019) W4-7-2-1
SECTION4 UNDERCARRIAGE
Group7 Track
5. Apply grease through grease fitting (2) and adjust the track tension.
1
2
WABA-04-07-001-1 ja
NOTE
Joint part (b) of the track link (rubber crawler (d)) should be in the center when measuring the track link (rubber
crawler (d)) tension. At this time, turn the track in reverse direction so that the track sag should be located down.
Track Sag Specification (Y): 10 to 15 mm (Rubber crawler (d))
X e
b d
Y
b
d
WAEJ-04-06-103-2 ja
WADS50-EN-00(07/05/2019) W4-7-2-2
SECTION4 UNDERCARRIAGE
Group7 Track
CAUTION
Steel crawler weight: 190 kg
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
2. Rotate the track so that master pin (3) is positioned over front idler (2). Place wooden block (a) under shoe (1) to
support shoe (1).
CAUTION
The pressure inside cylinder of track adjuster (4) is high. Do not loosen valve (6) quickly or too much as valve (6)
may fly out or high-pressure grease may spout out. Keep body parts and face away from valve (6) and loosen it
gradually. Do not loosen grease fitting (5).
IMPORTANT
Loosening valve (6) by 1 to 1.5 turns is enough. Do not loosen it over those turns.
IMPORTANT
When gravel or mud is packed between the sprocket, remove it before loosening.
3. Loosen valve (6). Drain grease and loosen the track links.
: 19 mm
1
2
5 6 b
3 4
a
WAFF-04-07-001-1 ja
WADS50-EN-00(07/05/2019) W4-7-3-1
SECTION4 UNDERCARRIAGE
Group7 Track
CAUTION
The front idler part may fly out due to the spring force when removing the track. Do not stand in the same
direction to remove the front idler or where it may fly out. Particularly, strong force is always applied to the thread
part of the rod of the track adjuster. If the rod and/or the threads are damaged, metal fragments may fly out due
to the spring force.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
IMPORTANT
Master pin (3) can be installed/removed to only one direction. Check direction (d) to remove master pin (3).
4. Put the matching marks onto master pin (3) and master link (e). Remove master pin (3) by using special tool (ST 1653)
and a hammer.
ST 1653
3 e
WADR-04-07-001-1 ja
CAUTION
Steel crawler weight: 190 kg
6. Slowly operate the travel control lever for the track link to be removed to the reverse position and extend the track
link.
f
WAFF-04-07-003-1 ja
f- Stand g- 90 to 100°
WADS50-EN-00(07/05/2019) W4-7-3-2
SECTION4 UNDERCARRIAGE
Group7 Track
1. Jack up the machine. Set the track under the machine so that sprocket (8) meshes with the track end. Check the
direction of the tracks.
CAUTION
Steel crawler weight: 190 kg
2. Hoist and mesh the track link with the claws of sprocket (8).
3. Slowly operate a travel control lever on the side to install the track link in the forward direction with the machine
jacked up. Wind the track link while rotating travel device (9).
h i 8
WAFF-04-07-004-1 ja
WADS50-EN-00(07/05/2019) W4-7-4-1
SECTION4 UNDERCARRIAGE
Group7 Track
IMPORTANT
Master pin (3) can be installed/removed to only one direction. Check direction (c) to install master pin (3).
5. Fit the matching marks made when removing. Install master pin (3) to the track link.
2
10
1 e 3
a
WADR-04-07-002-1 ja
IMPORTANT
If master link (e) has been disassembled, fill grease (Daphne Eponex SR) into the clearance between bushing (11)
and master pin (3).
IMPORTANT
If master link (e) has been disassembled, after installing master pin (3), proceed up to the procedure to wipe off
excess grease.
CAUTION
Do not to drop master link (e).
WADS50-EN-00(07/05/2019) W4-7-4-2
SECTION4 UNDERCARRIAGE
Group7 Track
11. Tighten valve (6) of track adjuster (4). Apply grease through grease fitting (5) and adjust the track tension.
: 19 mm
: 90 N·m
NOTE
Track sag specification (j): 120 to 140 mm
5 6
11 12
4
3
e e
l l
k
12
WADR-04-07-003-2 ja
WADS50-EN-00(07/05/2019) W4-7-4-3
SECTION4 UNDERCARRIAGE
Group7 Track
MEMO
WADS50-EN-00(07/05/2019) W4-7-4-4
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Park the machine on a solid and level surface. Make the machine swing to the right by 90 degrees. Lower the end of
blade onto the ground.
2. Remove bolts, washers (1) (2 used) Remove cover (2).
: 17 mm
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
CAUTION
Blade cylinder (3) weight: 29 kg
3. Attach nylon slings onto blade cylinder (3), then hoist and hold it. Remove bolts (7) (2 used) and washers (6) (2 used).
Remove lock (5). Remove pin (8) from track frame (4) by using a bar and a hammer.
: 19 mm
NOTE
LOCTITE #262 has been applied onto bolt (7).
4. Start the engine. Operate the blade control lever and retract blade cylinder (3). In order not to extend the rod, pass
wires through the rod hole and secure the rod to the cylinder tube. Stop the engine.
1 2 3
4
7 6 5
WACK-04-08-100-1 ja
WADS50-EN-00(07/05/2019) W4-8-1-1
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)
CAUTION
Blade cylinder (3) weight: 29 kg
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
7. Remove bolts (13) (2 used) and washers (14) (2 used). Remove lock (15). Remove pin (12) by using a bar and a hammer.
Hoist and remove blade cylinder (3) from blade (16).
: 19 mm
NOTE
LOCTITE #262 has been applied onto bolt (13).
9 10 3 11
16
15
14
13
12
WACK-04-08-100-2 ja
WADS50-EN-00(07/05/2019) W4-8-1-2
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
1. Apply grease onto the bushing inside and the lip part of the dust seal for blade cylinder (3) (both bottom and rod
sides).
CAUTION
Blade cylinder (3) weight: 29 kg
2. Attach nylon slings onto blade cylinder (3) and hoist it. Fit the hole on the cylinder bottom side to the cylinder
mounting holes on blade (16).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
3. Apply grease to the surface of pin (12). Install pin (12) by using a bar and a hammer.
4. Apply LOCTITE #262 to bolts (13) (2 used). Install lock (15) with bolts (13) (2 used) and washers (14) (2 used).
: 19 mm
: 110 N·m
3
16
15
14
13
12
WACK-04-08-100-3 ja
5. Apply grease to grease fitting (a) at the cylinder bottom side.
a
WAEQ-04-08-100-1 ja
WADS50-EN-00(07/05/2019) W4-8-2-1
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
WACK-04-08-100-4 ja
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
NOTE
When the work is finished, air in the cylinder has been released.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
10. Apply grease to the surface of pin (8). Install pin (8) by using a bar and a hammer.
11. Apply LOCTITE #262 to bolts (7) (2 used). Install lock (5) with bolts (7) (2 used) and washers (6) (2 used).
: 19 mm
: 110 N·m
WADS50-EN-00(07/05/2019) W4-8-2-2
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
7 6 5
WACK-04-08-100-1 ja
13. Supply grease to grease fitting (b) of the blade cylinder rod side.
b
WAEQ-04-08-100-2 ja
IMPORTANT
After completing all the work, operate the blade cylinder to the stroke end several times and bleed air from the
circuit.
WADS50-EN-00(07/05/2019) W4-8-2-3
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
MEMO
WADS50-EN-00(07/05/2019) W4-8-2-4
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
10
12b 12a
13
15
11
10
6
5
9
8
7
14
WACK-04-08-101-1 ja
1- Cylinder Rod 6- U-Ring 10- Piston Ring (2 Used) 13- Steel Ball
3- Wiper Ring 7- O-Ring 11- Piston 14- Cylinder Tube
4- Cylinder Head 8- Backup Ring 12a- Seal Ring 15- Set Screw
5- Bushing 9- O-Ring 12b- O-Ring
WADS50-EN-00(07/05/2019) W4-8-3-1
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
CAUTION
Blade cylinder weight: 29 kg
IMPORTANT
The seals cannot be reused. Replace them with the new ones.
1. Secure the cylinder on a workbench horizontally. Drain off hydraulic oil from the cylinder.
W102-04-02-027-1 ja
IMPORTANT
The lock washer of cylinder head (4) is integrated with cylinder tube (14). Do not damage cylinder tube (14) and
cylinder head (4) when lock washer (a) is bended and extended.
2. Pull out cylinder rod (1) about 200 mm. Install a protective cover to cylinder rod (1). Extend lock washer (a) of cylinder
head (4).
1 4
WABA-04-09-103-2 ja
a- Lock Washer
WADS50-EN-00(07/05/2019) W4-8-3-2
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
IMPORTANT
Remove cylinder rod (1) straight in order not to damage the sliding surface.
3. Loosen cylinder head (4) by using hook wrench (b). Remove the cylinder rod (1) assembly from cylinder tube (14).
Remove a protective cover from cylinder rod (1).
Cylinder head (4) diameter: 115 mm
14
4
1
WABA-04-09-104-2 ja
b- Hook Wrench
4. Secure the cylinder rod (1) assembly to special tool (ST 5908).
ST 5908
W158-04-02-022-1 ja
5. Cut away the crimped parts by using a hand drill. Remove set screw (15). Remove steel ball (13).
: 4 mm
NOTE
Set screw (15) has been crimped by using a punch (2 places) after installing.
6. Remove the piston (11) assembly by using special tool (ST 3239).
Special Tool: ST 3239 (Wrench Size: 60 mm)
7. Install a protective tape onto the thread part of cylinder rod (1) in order to protect the seal of cylinder head (4).
Remove the cylinder head (4) assembly from cylinder rod (1).
NOTE
THREEBOND #1901 has been applied to cylinder head (4).
IMPORTANT
Do not damage the seal groove.
8. Secure piston (11) in a vice. Remove piston rings (10) (2 used) from piston (11).
WADS50-EN-00(07/05/2019) W4-8-3-3
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
9. Cut seal ring (12a) by using a screwdriver. Remove seal ring (12a) and O-ring (12b) from piston (11).
11
12a
WACK-04-08-102-1 ja
10. Remove U-ring (6), wiper ring (3), O-rings (7, 9), and backup ring (8) from cylinder head (4).
IMPORTANT
Bushing (5) cannot be reused. If bushing (5) has been removed, replace it with a new one when assembling.
WADS50-EN-00(07/05/2019) W4-8-3-4
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
12b 6 5
WACK-04-08-103-1 ja
1- Cylinder Rod 6- U-Ring 10- Piston Ring (2 Used) 13- Steel Ball
3- Wiper Ring 7- O-Ring 11- Piston 14- Cylinder Tube
4- Cylinder Head 8- Backup Ring 12a- Seal Ring 15- Set Screw
5- Bushing 9- O-Ring 12b- O-Ring
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Install bushing (5) to cylinder head (4) by using a press and special tool (ST 8040).
Special Tool: ST 8040 ( Rod Outer Diameter: 50 mm)
WABA-04-08-102-4 ja
WADS50-EN-00(07/05/2019) W4-8-4-1
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
IMPORTANT
Check the direction to install U-ring (6).
IMPORTANT
Check that bushing (5) does not protrude into the U-ring (6) installing part in cylinder head (4). Do not damage U-
ring (6).
6
4
WACK-04-08-109-1 ja
3. Install wiper ring (3) to cylinder head (4) by using special tool (ST 8047) and a plastic hammer.
Special Tool: ST 8047 ( Rod Outer Diameter: 50 mm)
WACK-04-08-110-1 ja
WADS50-EN-00(07/05/2019) W4-8-4-2
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
5. Install O-ring (12b) to piston (11). Install seal ring (12a) to piston (11) by using special tools (ST 2335) and (ST 2334).
Special Tool: ST 2335 (Tube Inner Diameter: 95 mm)
Special Tool: ST 2334 (Tube Inner Diameter: 95 mm)
h
12a
11
12b
WABA-04-08-103-4 ja
12a
11
i
WABA-04-09-106-6 ja
W158-04-02-022-1 ja
10. Install steel ball (13) to piston (11). Install set screw (15). Crimp set screw (15) by using a punch (2 place).
: 4 mm
: 17 N·m
WADS50-EN-00(07/05/2019) W4-8-4-3
SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder
CAUTION
Fit the cylinder rod (1) assembly with the center of cylinder tube (14) and install in order not to damage the rings.
11. Secure cylinder tube (14) to a workbench horizontally. Install the cylinder rod (1) assembly to cylinder tube (14) by
using special tool (ST 7989).
Special Tool: ST 7989 (Tube Inner Diameter: 95 mm)
12. Tighten cylinder head (4) to cylinder tube (14) by using hook wrench (b). Bend the lock washer in order to prevent it
from loosening.
Cylinder head (4) diameter: 115 mm
: 650 N·m
14
WABA-04-09-107-2 ja
b- Hook Wrench
WADS50-EN-00(07/05/2019) W4-8-4-4
5
FRONT ATTACHMENT
WADS50-EN-00(07/05/2019)
MEMO
WADS50-EN-00(07/05/2019)
SECTION5 FRONT ATTACHMENT
Group1 Front Attachment
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder extended to
the maximum. Lower the end of arm to the ground.
2. Stop the engine. Remove the rod side of the boom cylinder. (Refer to "Removal of Boom Cylinder"W5-2-1-1.)
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)
13
16
14, 15
WAEJ-05-01-101-2 ja
CAUTION
Front attachment weight: 420 kg
5. Attach nylon slings onto the boom. Reduce slack of the nylon slings. Hoist and hold the boom at the center of gravity.
WADS50-EN-00(07/05/2019) W5-1-1-1
SECTION5 FRONT ATTACHMENT
Group1 Front Attachment
18 18
WADR-05-01-100-1 ja
7. Remove clip bands (20) (5 used). Disconnect hoses (19) (5 used).
: 19 mm, 22 mm
19 20
20
19
WADR-05-01-101-1 ja
8. Remove bolts, washers (22) (2 used) Remove the bracket (21) assembly.
: 13 mm
WADS50-EN-00(07/05/2019) W5-1-1-2
SECTION5 FRONT ATTACHMENT
Group1 Front Attachment
9. Remove bolts, washers (24) (2 used) Remove the bracket (23) assembly.
: 13 mm
21 22
23
24
WADR-05-01-102-1 ja
10. Remove nuts (26) (2 used) and bolt (28).
: 19 mm
NOTE
LOCTITE #262 has been applied onto bolt (28).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
11. Put the matching marks on the boss of the swing post and boom foot pin (27). Remove boom foot pin (27) by using a
bar and a hammer.
WADS50-EN-00(07/05/2019) W5-1-1-3
SECTION5 FRONT ATTACHMENT
Group1 Front Attachment
12. Hoist and remove the front attachment from the swing post. Remove shims (25).
28
27
26
25
WADR-05-01-103-1 ja
WADS50-EN-00(07/05/2019) W5-1-1-4
SECTION5 FRONT ATTACHMENT
Group1 Front Attachment
CAUTION
Front attachment weight: 420 kg
IMPORTANT
Use one or more shims (25) respectively at the right and left sides.
1. Attach nylon slings onto the boom. Hoist the front attachment. Fit the boom foot to the boom mounting hole on the
swing post. Fit shims (25) to the right and left sides of the boom foot. Make each of the right and left clearances
between the boom and the swing post 1 mm or less.
NOTE
Shim thickness: 0.5 mm
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
2. Fit the matching marks on the boss of the swing post and boom foot pin (27). Install boom foot pin (27) by using a
hammer.
IMPORTANT
Install nut (26) with a clearance of 3 to 5 mm between nut (26) and the boss of the swing post.
3. Apply LOCTITE #262 to bolt (28). Install bolt (28) and nuts (26) (2 used). Supply grease to grease fitting (a) of the boom
foot.
: 19 mm
: 90 N·m
28
27
26
25
WADR-05-01-103-2 ja
WADS50-EN-00(07/05/2019) W5-1-2-1
SECTION5 FRONT ATTACHMENT
Group1 Front Attachment
4. Install the bracket (23) assembly with bolts, washers (24) (2 used).
: 13 mm
: 10 N・m
5. Install the bracket (21) assembly with bolts, washers (22) (2 used).
: 13 mm
: 10 N・m
21 22
23
24
WADR-05-01-102-1 ja
6. Connect hoses (19) (5 used). Install clip bands (20) (5 used).
: 19 mm
: 30 N・m
: 22 mm
: 40 N・m
19 20
20
19
WADR-05-01-101-1 ja
WADS50-EN-00(07/05/2019) W5-1-2-2
SECTION5 FRONT ATTACHMENT
Group1 Front Attachment
18 18
WADR-05-01-100-1 ja
8. Connect connector (15). Install clip band (14).
9. Install harness (16) with clip bands (13) (4 used).
13
16
14, 15
WAEJ-05-01-101-2 ja
10. Install the rod side of the boom cylinder. (Refer to "Installation of Boom Cylinder"W5-2-2-1.)
IMPORTANT
After completing all the work, add hydraulic oil to the specified level. Operate each cylinder to the stroke end
several times and bleed air in the circuit. Check for any oil leak of each hose connection.
WADS50-EN-00(07/05/2019) W5-1-2-3
SECTION5 FRONT ATTACHMENT
Group1 Front Attachment
MEMO
WADS50-EN-00(07/05/2019) W5-1-2-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder retracted to
the maximum. Lower the end of arm to the ground.
2. Remove bolts (7) (2 used), spring washers (8) (2 used), and washers (9) (2 used). Remove cover (6) from boom cylinder
(5).
: 17 mm
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
CAUTION
Boom cylinder (5) weight: 46 kg
3. Attach nylon slings onto boom cylinder (5), then hoist and hold it. Remove bolt (1), spring washer (2), and bushing (3).
Remove pin (4) by using a bar and a hammer. Remove shims (12).
: 22 mm
NOTE
LOCTITE #262 has been applied onto bolt (1).
WADS50-EN-00(07/05/2019) W5-2-1-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
5. Start the engine. Operate the boom control lever and retract boom cylinder (5). In order not to extend rod (10), pass
wires through the rod (10) hole and secure rod (10) to the cylinder tube.
1, 2, 3
4 10
12
5
7, 8, 9
WAEJ-05-01-100-1 ja
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)
18
19
WADR-05-02-100-1 ja
7. Remove clip band (22). Disconnect connector (23).
WADS50-EN-00(07/05/2019) W5-2-1-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
8. Remove clip bands (21) (3 used) and clips band (24). Disconnect hoses (20) (4 used).
: 19 mm, 22 mm
20
24
20
21
23 22
WADR-05-02-101-1 ja
9. Remove bolt (15) and nuts (17) (2 used).
: 17 mm
NOTE
LOCTITE #262 has been applied onto bolt (15).
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
10. Put the matching marks on swing post (16) and pin (14). Remove pin (14) by using a bar and a hammer. Remove shims
(26).
WADS50-EN-00(07/05/2019) W5-2-1-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
11. Hoist and remove boom cylinder (5) from swing post (16).
14, 26 15 16 5
17
WABA-05-02-100-3 ja
WADS50-EN-00(07/05/2019) W5-2-1-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
1. Apply grease to the lip part of the dust seal, the side of the boss, and the inner surface of the bushing (both the
bottom and rod sides) of boom cylinder (5).
CAUTION
Boom cylinder (5) weight: 46 kg
IMPORTANT
Use one or more shims (26) respectively at the right and left sides.
2. Attach nylon slings onto boom cylinder (5) and hoist it. Fit the hole on the cylinder bottom side to the cylinder
mounting hole on swing post (16). Fit shims (26) to the right and left sides of the hole of the cylinder bottom side.
Make the total of the left and right clearances up to 0.5 mm.
NOTE
Shim (26) thickness: 0.5 mm
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
3. Apply grease to the surface of pin (14). Fit the matching marks on swing post (16) and pin (14). Install pin (14) by using
a hammer.
IMPORTANT
Install nut (17) with a clearance of 3 to 5 mm between nut (17) and the boss of swing post (16) .
4. Apply LOCTITE #262 to bolt (15). Install bolt (15) and nuts (17) (2 used).
: 17 mm
: 50 N·m
14, 26 15 16 5
17
WABA-05-02-100-3 ja
WADS50-EN-00(07/05/2019) W5-2-2-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
5. Apply grease to grease fittings (a) at the boom cylinder bottom side.
WABK-05-02-100-1 ja
24
20
21
23 22
WADR-05-02-101-1 ja
WADS50-EN-00(07/05/2019) W5-2-2-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
18
19
WADR-05-02-100-1 ja
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
NOTE
When the work is finished, air in the cylinder has been released.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
IMPORTANT
Use one or more shims (12) respectively at the right and left sides.
11. Fit shims (12) to the right and left sides of the hole of the cylinder rod side. Make the total of the left and right
clearances up to 0.5 mm. Install pin (4) by using a hammer. Apply LOCTITE #262 to bolt (1). Install bolt (1), spring
washer (2), and bushing (3).
: 22 mm
: 140 N·m
NOTE
Shim (12) thickness: 0.5 mm, 1 mm
WADS50-EN-00(07/05/2019) W5-2-2-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
12. Install cover (6) to boom cylinder (5) with bolts (7) (2 used), spring washers (8) (2 used), and washers (9) (2 used).
: 17 mm
: 50 N·m
1, 2, 3
12
5
7, 8, 9
WAEQ-05-02-007-1 ja
13. Supply grease to grease fitting (b) of the boom cylinder rod side.
WABK-05-02-101-1 ja
IMPORTANT
After completing all the work, operate the boom cylinder to the stroke end several times and bleed air from the
circuit.
WADS50-EN-00(07/05/2019) W5-2-2-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
16
19 21a
21b
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
23
WADR-05-02-106-1 ja
1- Cylinder Rod 7- Bushing 13- Backup Ring 19- Set Screw
2- Wiper Ring 8- U-Ring 14- O-Ring 21a- Seal Ring
3- Cylinder Head 9- Collar 15- Cushion Bearing 21b- O-Ring
4- O-Ring 10- Cushion Seal 16- Slide Ring (2 Used) 23- Cylinder Tube
5- Backup Ring 11- Spacer 17- Piston
6- O-Ring 12- Holder 18- Steel Ball
WADS50-EN-00(07/05/2019) W5-2-3-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
CAUTION
Boom cylinder weight: 42 kg
IMPORTANT
The seals cannot be reused. Replace them with the new ones.
1. Hoist the cylinder and secure it on a workbench horizontally. Drain off hydraulic oil from the cylinder.
W102-04-02-027-1 ja
IMPORTANT
Lock washer (a) of cylinder head (3) is integrated with cylinder tube (23). Do not damage cylinder tube (23) and
cylinder head (3) when lock washer (a) is bended and extended.
2. Pull out cylinder rod (1) about 200 mm. Install a protective cover to cylinder rod (1). Extend lock washer (a) of cylinder
head (3).
1 3
WABA-04-09-103-3 ja
a- Lock Washer
WADS50-EN-00(07/05/2019) W5-2-3-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Remove cylinder rod (1) straight in order not to damage the sliding surface.
3. Loosen cylinder head (3) by using hook wrench (b). Remove the cylinder rod (1) assembly from cylinder tube (23).
Remove a protective cover from cylinder rod (1).
Cylinder head (3) diameter: 105 mm
NOTE
THREEBOND #1901 has been applied to cylinder head (3).
23
3
1
WABA-04-09-104-3 ja
b- Hook Wrench
4. Secure the cylinder rod (3) assembly to special tool (ST 5908).
ST 5908
W158-04-02-022-1 ja
5. Cut away the crimped parts by using a hand drill. Remove set screw (19). Remove steel ball (18).
: 4 mm
NOTE
Set screw (19) has been crimped by using a punch (2 places) after installing.
6. Remove the piston (17) assembly by using special tools (ST 5908) and (ST 3239). Remove cushion bearing (15) from
cylinder rod (1).
Special Tool: ST 3239 (Wrench Size: 60 mm)
7. Install a protective tape onto the thread part of cylinder rod (1) in order to protect the seal of cylinder head (3).
Remove the cylinder head (3) assembly from cylinder rod (1).
WADS50-EN-00(07/05/2019) W5-2-3-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Do not damage the seal groove.
8. Secure the piston (17) assembly in a vice. Remove slide rings (16) (2 used) from piston (17). Cut seal ring (21a) by using
a screwdriver. Remove seal ring (21a) and O-ring (21b) from piston (17).
16 21a 16 17
21b
WACK-05-02-101-1 ja
IMPORTANT
Bushing (7) cannot be reused. If bushing (7) has been removed, replace it with a new one when assembling.
WADS50-EN-00(07/05/2019) W5-2-3-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
A
12 9 13 14 10 11
2
3 4 7 8 5 6 1 23 15 17 16 21a 16 19 18
21b
WACK-05-02-102-1 ja
1- Cylinder Rod 7- Bushing 13- Backup Ring 19- Set Screw
2- Wiper Ring 8- U-Ring 14- O-Ring 21a- Seal Ring
3- Cylinder Head 9- Collar 15- Cushion Bearing 21b- O-Ring
4- O-Ring 10- Cushion Seal 16- Slide Ring (2 Used) 23- Cylinder Tube
5- Backup Ring 11- Spacer 17- Piston
6- O-Ring 12- Holder 18- Steel Ball
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Install bushing (7) to cylinder head (3) by using a press and special tool (ST 8040).
Special Tool: ST 8040 ( Rod Outer Diameter: 50 mm)
WABA-04-08-102-5 ja
WADS50-EN-00(07/05/2019) W5-2-4-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Check the direction to install U-ring (8).
IMPORTANT
Check that bushing (7) does not protrude into the U-ring (8) installing part in cylinder head (3). Do not damage U-
ring (8).
8
3
WACK-04-08-109-2 ja
3. Install wiper ring (2) to cylinder head (3) by using special tool (ST 8047) and a plastic hammer.
Special Tool: ST 8047 ( Rod Outer Diameter: 50 mm)
WACK-04-08-110-2 ja
3 4 5 6
WABA-05-02-008-2 ja
5. Install collar (9), cushion seal (10), spacer (11), O-ring (14), and backup ring (13) to holder (12).
6. Install the holder (12) assembly to cylinder head (3).
WADS50-EN-00(07/05/2019) W5-2-4-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
7. Install O-ring (21b) to piston (17). Install seal ring (21a) to piston (17) by using special tools (ST 2591) and (ST 2595).
Special Tool: ST 2591 (Tube Inner Diameter: 85 mm)
Special Tool: ST 2595 (Tube Inner Diameter: 85 mm)
h
21a
17
21b
WABA-04-08-103-2 ja
21a
17
i
WABA-04-09-106-4 ja
IMPORTANT
Check the direction to install cushion bearing (15).
WADS50-EN-00(07/05/2019) W5-2-4-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
12. Install the piston (17) assembly to cylinder rod (1) by using special tool (ST 3239).
Special Tool: ST 3239 (Wrench Size: 60mm)
: 1620 N·m
ST 5908
W158-04-02-022-1 ja
13. Install steel ball (18) to piston (17). Install set screw (19). Crimp set screw (19) by using a punch (2 place).
: 4 mm
: 17 N·m
CAUTION
Fit the cylinder rod (1) assembly with the center of cylinder tube (23) and install in order not to damage the rings.
IMPORTANT
When installing the cylinder rotor (1) assembly, keep valve plate (16) not to drop from piston (17).
14. Secure cylinder tube (23) to a workbench horizontally. Install the cylinder rod (1) assembly to cylinder tube (23) by
using special tool (ST 7988).
Special Tool: ST 7988 (Tube Inner Diameter: 85 mm)
15. Apply THREEBOND #1901 to cylinder head (3). Tighten cylinder head (3) to cylinder tube (23) by using hook wrench
(b). Bend the lock washer in order to prevent it from loosening.
Cylinder head (3) diameter: 105 mm
: 490 N·m
23
WABA-04-09-107-3 ja
b- Hook Wrench
WADS50-EN-00(07/05/2019) W5-2-4-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder retracted to
the maximum. Lower the end of arm to the ground.
2. Place wooden block (3) between arm cylinder (1) and boom (2). Stop the engine.
3 2
WAEJ-05-02-106-1 ja
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
3. Remove bolt (4), spring washer (5), and bushing (6). Remove pin (7) by using a bar and a hammer. Remove shims (20).
: 22 mm
NOTE
LOCTITE #262 has been applied onto bolt (4).
NOTE
If pin (7) is hard to be removed, raise boom (2) a little then remove pin (7).
4. Start the engine. Operate the arm control lever and retract arm cylinder (1). In order not to extend rod (12), pass wire
(17) through the rod (12) hole and secure rod (8) to the cylinder tube. Stop the engine.
WADS50-EN-00(07/05/2019) W5-2-5-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
18
1
20
7 17
4, 5, 6
12
19
WADR-05-02-102-1 ja
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)
8 21
WADR-05-02-103-1 ja
CAUTION
Arm cylinder (1) weight: 36 kg
7. Attach nylon slings onto arm cylinder (1), then hoist and hold it.
WADS50-EN-00(07/05/2019) W5-2-5-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
8. Remove bolt (14), spring washer (15), and bushing (16). Remove pin (13) by using a bar and a hammer. Remove shims
(23).
: 22 mm
NOTE
LOCTITE #262 has been applied onto bolt (14).
WAEJ-05-02-108-2 ja
WADS50-EN-00(07/05/2019) W5-2-5-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
MEMO
WADS50-EN-00(07/05/2019) W5-2-5-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
1. Apply grease to the lip part of the dust seal, the side of the boss, and the inner surface of the bushing (both the
bottom and rod sides) of arm cylinder (1).
CAUTION
Arm cylinder (1) weight: 36 kg
IMPORTANT
Use one or more shims (23) respectively at the right and left sides.
2. Attach nylon slings onto arm cylinder (1) and hoist it. Fit the hole on the cylinder bottom side to the cylinder
mounting holes on boom (2). Fit shims (23) to the right and left sides of the hole of the cylinder bottom side. Make the
total of the right and left clearances between boom (2) and arm cylinder (1) 0.5 mm or less.
NOTE
Shim (23) thickness: 0.5 mm, 1 mm
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
3. Apply LOCTITE #262 to bolt (14). Install pin (13) by using a hammer. Install bolt (14), spring washer (15), and bushing
(16).
: 22 mm
: 140 N·m
WAEJ-05-02-108-2 ja
WADS50-EN-00(07/05/2019) W5-2-6-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
4. Supply grease to grease fitting (a) of the arm cylinder boom side.
a
WABK-05-02-102-1 ja
8 21
WADR-05-02-103-1 ja
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
WADS50-EN-00(07/05/2019) W5-2-6-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
8. Start the engine. Operate the arm control lever and extend arm cylinder (1) slowly. Fit the hole on the cylinder rod side
to the cylinder mounting holes on arm (24).
NOTE
When the work is finished, air in the cylinder has been released.
NOTE
When the mounting holes do not fit, raise boom (2) a little and fit the mounting holes.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
IMPORTANT
Use one or more shims (20) respectively at the right and left sides.
9. Fit shims (20) to the right and left sides of the hole of the cylinder rod side. Make the total of the right and left
clearances between arm (24) and arm cylinder (1) 0.5 mm or less. Install pin (7) by using a hammer. Apply LOCTITE
#262 to bolt (4). Install bolt (4), spring washer (5), and bushing (6).
: 22 mm
: 140 N·m
NOTE
Shim (20) thickness: 0.5 mm, 1 mm
18
1
20
7 17
4, 5, 6
12
2
24
19
WADR-05-02-102-2 ja
WADS50-EN-00(07/05/2019) W5-2-6-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
10. Supply grease to grease fitting (b) of the arm cylinder rod side.
b
WABK-05-02-103-1 ja
IMPORTANT
After completing all the work, operate the arm cylinder to the stroke end several times and bleed air from the
circuit.
WADS50-EN-00(07/05/2019) W5-2-6-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
18
17
16
9 19
14a
14b
12
11
10
9
8
7
6
5
4
3
2
15
WADR-05-02-107-1 ja
1- Cylinder Rod 6- O-Ring 11- Steel Ball 16- Cushion Bearing
2- Wiper Ring 7- Bushing 12- Set Screw 17- Cushion Seal
3- Cylinder Head 8- U-Ring 14a- Seal Ring 18- Stopper (2 Used)
4- O-Ring 9- Slide Ring (2 Used) 14b- O-Ring 19- Retaining Ring
5- Backup Ring 10- Piston 15- Cylinder Tube
CAUTION
Arm cylinder weight: 32 kg
IMPORTANT
The seals cannot be reused. Replace them with the new ones.
WADS50-EN-00(07/05/2019) W5-2-7-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
1. Hoist the cylinder and secure it on a workbench horizontally. Drain off hydraulic oil from the cylinder.
W102-04-02-027-1 ja
IMPORTANT
Lock washer (a) of cylinder head (3) is integrated with cylinder tube (15). Do not damage cylinder tube (15) and
cylinder head (3) when lock washer (a) is bended and extended.
2. Pull out cylinder rod (1) about 200 mm. Install a protective cover to cylinder rod (1). Extend lock washer (a) of cylinder
head (3).
1 3
WABA-04-09-103-3 ja
a- Lock Washer
WADS50-EN-00(07/05/2019) W5-2-7-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Remove cylinder rod (3) straight in order not to damage the sliding surface.
3. Loosen cylinder head (3) by using hook wrench (b). Remove the cylinder rod (1) assembly from cylinder tube (15).
Remove a protective cover from cylinder rod (1).
Cylinder head (3) diameter: 90 mm
NOTE
THREEBOND #1901 has been applied to cylinder head (3).
15
3
1
WABA-04-09-104-4 ja
b- Hook Wrench
4. Secure the cylinder rod (3) assembly to special tool (ST 5908).
ST 5908
W158-04-02-022-1 ja
5. Cut away the crimped parts by using a hand drill. Remove set screw (12). Remove steel ball (11).
: 4 mm
NOTE
Set screw (12) has been crimped by using a punch (2 places) after installing.
6. Remove the piston (10) assembly by using special tools (ST 5908) and (ST 3451).
Special Tool: ST 3451 (Wrench Size: 55 mm)
7. Install a protective tape onto the thread part of cylinder rod (1) in order to protect the seal of cylinder head (3).
Remove the cylinder head (3) assembly from cylinder rod (1).
WADS50-EN-00(07/05/2019) W5-2-7-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Do not damage the seal groove.
8. Secure the piston (10) assembly in a vice. Remove slide rings (9) (2 used) from piston (10). Cut seal ring (14a) by using a
screwdriver. Remove seal ring (14a) and O-ring (14b) from piston (10).
9 14a 9 10
14b
WACK-05-02-101-2 ja
9. Remove wiper ring (2), U-ring (8), O-rings (4, 6), and backup ring (5) from cylinder head (3).
IMPORTANT
Bushing (7) cannot be reused. If bushing (7) has been removed, replace it with a new one when assembling.
WADS50-EN-00(07/05/2019) W5-2-7-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
7 8 14b 11
17
WACK-05-02-104-1 ja
1- Cylinder Rod 6- O-Ring 11- Steel Ball 16- Cushion Bearing
2- Wiper Ring 7- Bushing 12- Set Screw 17- Cushion Seal
3- Cylinder Head 8- U-Ring 14a- Seal Ring 18- Stopper (2 Used)
4- O-Ring 9- Slide Ring (2 Used) 14b- O-Ring 19- Retaining Ring
5- Backup Ring 10- Piston 15- Cylinder Tube
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Install bushing (7) to cylinder head (3) by using a press and special tool (ST 8039).
Special Tool: ST 8039 ( Rod Outer Diameter: 45 mm)
WABA-04-08-102-5 ja
WADS50-EN-00(07/05/2019) W5-2-8-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Check the direction to install U-ring (8).
IMPORTANT
Check that bushing (7) does not protrude into the U-ring (8) installing part in cylinder head (3). Do not damage U-
ring (8).
8
3
WACK-04-08-109-2 ja
3. Install wiper ring (2) to cylinder head (3) by using special tool (ST 8046) and a plastic hammer.
Special Tool: ST 8046 ( Rod Outer Diameter: 45 mm)
WACK-04-08-110-2 ja
3 4 5 6
WABA-05-02-008-2 ja
WADS50-EN-00(07/05/2019) W5-2-8-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
5. Install O-ring (14b) to piston (10). Install seal ring (14a) to piston (15) by using special tools (ST 2592) and (ST 2596).
Special Tool: ST 2592 (Tube Inner Diameter: 75 mm)
Special Tool: ST 2596 (Tube Inner Diameter: 75 mm)
h
14a
10
14b
WABA-04-08-103-3 ja
14a
10
i
WABA-04-09-106-5 ja
W158-04-02-022-1 ja
10. Install steel ball (11) to piston (10). Install set screw (12). Crimp set screw (12) by using a punch (2 place).
: 4 mm
: 17 N·m
WADS50-EN-00(07/05/2019) W5-2-8-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
11. Install cushion seal (17) to cylinder rod (1). Install cushion bearing (16) as illustrated in Figure A. Install stoppers (18) (2
used) and retaining ring (19).
19 17 16 18
A
WACK-05-02-115-1 ja
CAUTION
Fit the cylinder rod (1) assembly with the center of cylinder tube (15) and install in order not to damage the rings.
IMPORTANT
When installing the cylinder rotor (1) assembly, keep valve plate (9) not to drop from piston (10).
12. Secure cylinder tube (15) to a workbench horizontally. Install the cylinder rod (1) assembly to cylinder tube (15) by
using special tool (ST 7986).
Special Tool: ST 7986 (Tube Inner Diameter: 75 mm)
13. Apply THREEBOND #1901 to cylinder head (3). Tighten cylinder head (3) to cylinder tube (15) by using hook wrench
(b). Bend the lock washer in order to prevent it from loosening.
Cylinder head (3) diameter: 90 mm
: 422 N·m
15
WABA-04-09-107-4 ja
b- Hook Wrench
WADS50-EN-00(07/05/2019) W5-2-8-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Place the machine on a firm level ground and lower the boom with the arm cylinder and bucket cylinder (1) retracted
to the minimum. Lower the end of arm (2) to the ground.
2. Insert wooden block (a) between the end of arm (2) and the ground and between bucket cylinder (1) and arm (2).
a
2
a
W178-02-11-287-1 ja
a- Wooden Block
WADS50-EN-00(07/05/2019) W5-2-9-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
CAUTION
Before removing pin (7), secure the links using wires to prevent them from falling off.
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
3. Put the matching marks on link B (17) and pin (7). Remove nuts (6) (2 used) and stopper pin (4). Remove pin (7) by
using a bar and a hammer. Remove shims (5).
: 24 mm
NOTE
LOCTITE #262 has been applied onto stopper pin (4).
4 5
7 17
WABA-05-02-109-4 ja
4. Start the engine. Operate the bucket control lever and retract bucket cylinder (1). In order not to extend rod (8), pass
wire (3) through the rod (8) hole and secure rod (8) to the cylinder tube. Stop the engine.
8 1
3
W102-04-02-005-2 ja
WADS50-EN-00(07/05/2019) W5-2-9-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)
14
WAEJ-05-02-112-3 ja
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
CAUTION
Bucket cylinder (1) weight: 23 kg
6. Attach nylon slings onto bucket cylinder (1), then hoist and hold it. Remove bolt (10), spring washer (11), and bushing
(12). Remove pin (9) by using a bar and a hammer. Remove shims (15).
: 19 mm
NOTE
LOCTITE #262 has been applied onto bolt (10).
WADS50-EN-00(07/05/2019) W5-2-9-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
10, 11, 12
15
9
WAEJ-05-02-112-2 ja
WADS50-EN-00(07/05/2019) W5-2-9-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
1. Apply grease to the lip part of the dust seal, the side of the boss, and the inner surface of the bushing (both the
bottom and rod sides) of bucket cylinder (1).
CAUTION
Bucket cylinder (1) weight: 23 kg
IMPORTANT
Use one or more shims (15) respectively at the right and left sides.
2. Attach nylon slings onto bucket cylinder (1) and hoist it. Fit the hole at the cylinder bottom side to the cylinder
mounting holes of arm (2). Fit shims (15) to the right and left sides of the hole of the cylinder bottom side. Make the
total of the right and left clearances between arm (2) and arm cylinder (1) 0.5 mm or less.
NOTE
Shim (15) thickness: 0.5 mm, 1 mm
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
3. Apply LOCTITE #262 to bolt (10). Install pin (9) by using a hammer. Install bolt (10), spring washer (11), and bushing
(12).
: 19 mm
: 90 N·m
10, 11, 12
15
9
WAEJ-05-02-112-2 ja
WADS50-EN-00(07/05/2019) W5-2-10-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
4. Apply grease to grease fitting (b) at the bucket cylinder bottom side.
WABK-05-02-103-2 ja
14
WAEJ-05-02-112-3 ja
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
3
W102-04-02-005-2 ja
WADS50-EN-00(07/05/2019) W5-2-10-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
7. Start the engine. Operate the bucket control lever and extend bucket cylinder (1) slowly. Fit the hole on the cylinder
rod side to the cylinder mounting holes on link A (16) and links B (17) (2 used).
NOTE
When the work is finished, air in the cylinder has been released.
IMPORTANT
Use one or more shims (5) respectively at the right and left sides.
8. Fit shims (5) to the right and left sides of the link A (16) hole. Make the total of the right and left clearances between
bucket cylinder (1) and link A (16) 0.5 mm or less.
NOTE
Shim (5) thickness: 0.5 mm, 1 mm
CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.
9. Remove the wires which secure link B (17). Fit the matching marks on link B (17) and pin (7). Install pin (7) by using a
bar and a hammer.
10. Apply LOTITE #262 to stopper pin (4). Install stopper pin (4) to link B (17) and pin (7) with nuts (6) (2 used).
: 24 mm
: 270 N·m
16 4 5 1
7 17
WABA-05-02-109-5 ja
WADS50-EN-00(07/05/2019) W5-2-10-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
11. Supply grease to grease fittings (c) (2 places) at the bucket cylinder rod side.
c
WABK-05-02-104-1 ja
IMPORTANT
After completing all the work, operate the bucket cylinder to the stroke end several times and bleed air from the
circuit.
WADS50-EN-00(07/05/2019) W5-2-10-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
9
14a
14b
12
11
10
9
8
20
7
6
5
4
3
2
15
WACK-05-02-105-1 ja
1- Cylinder Rod 5- Backup Ring 9- Slide Ring (2 Used) 14a- Seal Ring
2- Wiper Ring 6- O-Ring 10- Piston 14b- O-Ring
3- Cylinder Head 7- Bushing 11- Steel Ball 15- Cylinder Tube
4- O-Ring 8- U-Ring 12- Set Screw 20- Backup Ring
• The procedure starts on the premise that the pipes and bands securing the pipes have been removed.
WADS50-EN-00(07/05/2019) W5-2-11-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
CAUTION
Bucket cylinder weight: 23 kg
IMPORTANT
The seals cannot be reused. Replace them with the new ones.
1. Hoist the cylinder and secure it on a workbench horizontally. Drain off hydraulic oil from the cylinder.
W102-04-02-027-1 ja
IMPORTANT
Lock washer (a) of cylinder head (3) is integrated with cylinder tube (15). Do not damage cylinder tube (15) and
cylinder head (3) when lock washer (a) is bended and extended.
2. Pull out cylinder rod (1) about 200 mm. Install a protective cover to cylinder rod (1). Extend lock washer (a) of cylinder
head (3).
1 3
WABA-04-09-103-3 ja
a- Lock Washer
WADS50-EN-00(07/05/2019) W5-2-11-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Remove cylinder rod (1) straight in order not to damage the sliding surface.
3. Loosen cylinder head (3) by using hook wrench (b). Remove the cylinder rod (1) assembly from cylinder tube (15).
Remove a protective cover from cylinder rod (1).
Cylinder head (3) diameter: 82 mm
NOTE
THREEBOND #1901 has been applied to cylinder head (3).
15
3
1
WABA-04-09-104-4 ja
b- Hook Wrench
4. Secure the cylinder rod (1) assembly to special tool (ST 5908).
ST 5908
W158-04-02-022-1 ja
5. Cut away the crimped parts by using a hand drill. Remove set screw (12). Remove steel ball (11).
: 4 mm
NOTE
Set screw (12) has been crimped by using a punch (2 places) after installing.
6. Remove the piston (10) assembly by using special tools (ST 5908) and (ST 3450).
Special Tool: ST 3450 (Wrench Size: 50 mm)
7. Install a protective tape onto the thread part of cylinder rod (1) in order to protect the seal of cylinder head (3).
Remove the cylinder head (3) assembly from cylinder rod (1).
WADS50-EN-00(07/05/2019) W5-2-11-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Do not damage the seal groove.
8. Secure the piston (10) assembly in a vice. Remove slide rings (9) (2 used) from piston (10). Cut seal ring (14a) by using a
screwdriver. Remove seal ring (14a) and O-ring (14b) from piston (10).
9 14a 9 10
14b
WACK-05-02-101-2 ja
9. Remove wiper ring (2), U-ring (8), backup ring (20), O-rings (4, 6), and backup ring (5) from cylinder head (3).
IMPORTANT
Bushing (7) cannot be reused. If bushing (7) has been removed, replace it with a new one when assembling.
WADS50-EN-00(07/05/2019) W5-2-11-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
20 8 7 14b
WACK-05-02-106-1 ja
1- Cylinder Rod 5- Backup Ring 9- Slide Ring (2 Used) 14a- Seal Ring
2- Wiper Ring 6- O-Ring 10- Piston 14b- O-Ring
3- Cylinder Head 7- Bushing 11- Steel Ball 15- Cylinder Tube
4- O-Ring 8- U-Ring 12- Set Screw 20- Backup Ring
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Install bushing (7) to cylinder head (3) by using a press and special tool (ST 8038).
Special Tool: ST 8038 ( Rod Outer Diameter: 40 mm)
WABA-04-08-102-5 ja
IMPORTANT
Check the direction to install U-ring (8).
2. Install U-ring (8) and backup ring (20) to cylinder head (3).
WADS50-EN-00(07/05/2019) W5-2-12-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
3. Install wiper ring (2) to cylinder head (3) by using special tool (ST 8045) and a plastic hammer.
Special Tool: ST 8045 ( Rod Outer Diameter: 40 mm)
WACK-04-08-110-2 ja
3 4 5 6
WABA-05-02-008-2 ja
5. Install O-ring (14b) to piston (10). Install piston seal (14a) to piston (10) by using special tools (ST 2481) and (ST 2482).
Special Tool: ST 2481 (Tube Inner Diameter: 65 mm)
Special Tool: ST 2482 (Tube Inner Diameter: 65 mm)
h
14a
10
14b
WABA-04-08-103-3 ja
WADS50-EN-00(07/05/2019) W5-2-12-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
14a
10
i
WABA-04-09-106-5 ja
W158-04-02-022-1 ja
10. Install steel ball (11) to piston (10). Install set screw (12). Crimp set screw (12) by using a punch (2 place).
: 4 mm
: 17 N·m
CAUTION
Fit the cylinder rod (1) assembly with the center of cylinder tube (15) and install in order not to damage the rings.
IMPORTANT
When installing the cylinder rotor (1) assembly, keep valve plate (9) not to drop from piston (10).
11. Secure cylinder tube (15) to a workbench horizontally. Install the cylinder rod (1) assembly to cylinder tube (15) by
using special tool (ST 7984).
Special Tool: ST 7984 (Tube Inner Diameter: 65 mm)
WADS50-EN-00(07/05/2019) W5-2-12-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
12. Apply THREEBOND #1901 to cylinder head (3). Tighten cylinder head (3) to cylinder tube (15) by using hook wrench
(b). Bend the lock washer in order to prevent it from loosening.
Cylinder head (3) diameter: 82 mm
: 320 N·m
15
WABA-04-09-107-4 ja
b- Hook Wrench
WADS50-EN-00(07/05/2019) W5-2-12-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
• The following procedures start after the front swings to the left.
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Park the machine on a solid and level surface. Make the machine swing to the right by 90 degrees. Lower the boom
with the arm cylinder and bucket cylinder retracted to the maximum. Lower the end of arm to the ground.
CAUTION
Boom swing cylinder (4) weight: 33 kg
2. Insert a wooden block between boom swing cylinder (4) and main frame (5). Put the matching marks on the boss of
the swing post and pin (2). Remove nuts (3) (2 used) and bolt (1). Remove pin (2).
: 17 mm
NOTE
LOCTITE #262 has been applied onto bolt (1).
NOTE
Removing bolt (1) could lead to pin (2) dropping.
5 4
WAEJ-05-02-115-1 ja
3. Start the engine. Operate the boom swing pedal and retract boom swing cylinder (4). In order not to extend the rod,
pass wires through the rod hole and secure the rod to the cylinder tube.
WADS50-EN-00(07/05/2019) W5-2-13-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
CAUTION
Remove cover (6) while holding cover (6). Do not drop cover (6).
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)
CAUTION
Remove cover (9) while holding cover (9). Do not drop cover (9).
WADS50-EN-00(07/05/2019) W5-2-13-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
9. Hoist and remove boom swing cylinder (4) from the main frame.
8
7
10, 11
13
12
4 14
WADR-05-02-104-1 ja
WADS50-EN-00(07/05/2019) W5-2-13-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
MEMO
WADS50-EN-00(07/05/2019) W5-2-13-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
1. Apply grease to the lip part of the dust seal of boom swing cylinder (4).
CAUTION
Boom swing cylinder (4) weight: 33 kg
2. Place a wooden block on the main frame. Attach nylon slings onto boom swing cylinder (4) and hoist it. Place boom
swing cylinder (4) on the wooden block.
3. Fit the hole on the cylinder bottom side to the cylinder mounting hole on the main frame. Apply grease to the surface
of pin (12). Install pin (12) by using a plastic hammer. Install bolt (10) and bushing (11).
: 19 mm
: 90 N·m
4. Connect hose (13) to the bottom side of boom swing cylinder (4). Connect hose (14) to the cylinder rod side.
: 19 mm
: 30 N·m
10, 11
13
12
4 14
WAEJ-05-02-117-1 ja
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
5. Remove the wire from the rod of boom swing cylinder (4).
6. Start the engine. Operate the boom swing pedal and extend boom swing cylinder (4) slowly. Fit the hole on the
cylinder rod side to the cylinder mounting hole on the swing post.
NOTE
When the work is finished, air in the cylinder has been released.
7. Apply grease to the surface of pin (2). Fit the matching marks on the boss of the swing post and pin (2). Install pin (2).
WADS50-EN-00(07/05/2019) W5-2-14-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Install nut (3) with a clearance of 2 to 3 mm between nut (3) and the boss of the swing post.
8. Apply LOCTITE #262 to bolt (1). Install bolt (1) to the swing post and the pin with nuts (3) (2 used).
: 17 mm
: 50 N·m
5 4
WAEJ-05-02-115-1 ja
9. Install cover (9) with bolts, washers (8) (4 used).
: 17 mm
: 50 N·m
10. Install cover (6) with bolts, washers (7) (5 used).
: 17 mm
: 50 N·m
8
7
WADR-05-02-105-1 ja
WADS50-EN-00(07/05/2019) W5-2-14-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
11. Supply grease to grease fitting (a) at the rod side of the boom swing cylinder.
a
WABK-05-02-105-1 ja
IMPORTANT
After completing the work, operate the boom swing cylinder to the stroke end several times and bleed air from
the circuit.
WADS50-EN-00(07/05/2019) W5-2-14-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
MEMO
WADS50-EN-00(07/05/2019) W5-2-14-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
9
14a
14b
12
11
10
9
8
7
6
5
4
3
15
WACK-05-02-107-1 ja
1- Cylinder Rod 5- Backup Ring 9- Slide Ring (2 Used) 14a- Seal Ring
2- Wiper Ring 6- O-Ring 10- Piston 14b- O-Ring
3- Cylinder Head 7- Bushing 11- Steel Ball 15- Cylinder Tube
4- O-Ring 8- U-Ring 12- Set Screw
IMPORTANT
The seals cannot be reused. Replace them with the new ones.
WADS50-EN-00(07/05/2019) W5-2-15-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
CAUTION
Boom swing cylinder weight: 33 kg
1. Hoist the cylinder and secure it on a workbench horizontally. Drain off hydraulic oil from the cylinder.
W102-04-02-027-1 ja
IMPORTANT
Lock washer (a) of cylinder head (3) is integrated with cylinder tube (15). Do not damage cylinder tube (15) and
cylinder head (3) when lock washer (a) is bended and extended.
2. Pull out cylinder rod (1) about 200 mm. Install a protective cover to cylinder rod (1). Extend lock washer (a) of cylinder
head (3).
1 3
WABA-04-09-103-3 ja
a- Lock Washer
WADS50-EN-00(07/05/2019) W5-2-15-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Remove cylinder rod (1) straight in order not to damage the sliding surface.
3. Loosen cylinder head (3) by using hook wrench (b). Remove the cylinder rod (1) assembly from cylinder tube (15).
Remove a protective cover from cylinder rod (1).
Cylinder head (3) diameter: 105 mm
NOTE
THREEBOND #1901 has been applied to cylinder head (3).
15
3
1
WABA-04-09-104-4 ja
b- Hook Wrench
4. Secure the cylinder rod (3) assembly to special tool (ST 5908).
ST 5908
W158-04-02-022-1 ja
5. Cut away the crimped parts by using a hand drill. Remove set screw (12). Remove steel ball (11).
: 4 mm
NOTE
Set screw (12) has been crimped by using a punch (2 places) after installing.
6. Remove piston (10) by using special tools (ST 5908) and (ST 3451).
Special Tool: ST 3451 (Wrench Size: 55 mm)
7. Install a protective tape onto the thread part of cylinder rod (1) in order to protect the seal of cylinder head (3).
Remove the cylinder head (3) assembly from cylinder rod (1).
WADS50-EN-00(07/05/2019) W5-2-15-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Do not damage the seal groove.
8. Secure piston (10) in a vice. Remove slide rings (9) (2 used) from piston (10). Cut seal ring (14a) by using a screwdriver.
Remove seal ring (14a) and O-ring (14b) from piston (10).
9 14a 9 10
14b
WACK-05-02-101-2 ja
9. Remove wiper ring (2), U-ring (8), O-rings (4, 6), and backup ring (5) from cylinder head (3).
IMPORTANT
Bushing (7) cannot be reused. If bushing (7) has been removed, replace it with a new one when assembling.
WADS50-EN-00(07/05/2019) W5-2-15-4
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
7 8 14b 11
WACK-05-02-108-1 ja
1- Cylinder Rod 5- Backup Ring 9- Slide Ring (2 Used) 14a- Seal Ring
2- Wiper Ring 6- O-Ring 10- Piston 14b- O-Ring
3- Cylinder Head 7- Bushing 11- Steel Ball 15- Cylinder Tube
4- O-Ring 8- U-Ring 12- Set Screw
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.
1. Install bushing (7) to cylinder head (3) by using a press and special tool (ST 8039).
Special Tool: ST 8039 ( Rod Outer Diameter: 45 mm)
WABA-04-08-102-5 ja
WADS50-EN-00(07/05/2019) W5-2-16-1
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
IMPORTANT
Check the direction to install U-ring (8).
8
3
WACK-04-08-109-2 ja
3. Install wiper ring (2) to cylinder head (3) by using special tool (ST 8046) and a plastic hammer.
Special Tool: ST 8046 ( Rod Outer Diameter: 45 mm)
WACK-04-08-110-2 ja
3 4 5 6
WABA-05-02-008-2 ja
WADS50-EN-00(07/05/2019) W5-2-16-2
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
5. Install O-ring (14b) to piston (10). Install piston seal (14a) to piston (10) by using special tools (ST 2591) and (ST 2595).
Special Tool: ST 2591 (Tube Inner Diameter: 85 mm)
Special Tool: ST 2595 (Tube Inner Diameter: 85 mm)
h
14a
10
14b
WABA-04-08-103-3 ja
14a
10
i
WABA-04-09-106-5 ja
W158-04-02-022-1 ja
10. Install steel ball (11) to piston (10). Install set screw (12). Crimp set screw (12) by using a punch (2 place).
: 4 mm
: 17 N·m
WADS50-EN-00(07/05/2019) W5-2-16-3
SECTION5 FRONT ATTACHMENT
Group2 Cylinder
CAUTION
Fit the cylinder rod (1) assembly with the center of cylinder tube (15) and install in order not to damage the rings.
IMPORTANT
When installing the cylinder rotor (1) assembly, keep valve plate (9) not to drop from piston (10).
11. Secure cylinder tube (15) to a workbench horizontally. Install the cylinder rod (1) assembly to cylinder tube (15) by
using special tool (ST 7988).
Special Tool: ST 7988 (Tube Inner Diameter: 85 mm)
12. Apply THREEBOND #1901 to cylinder head (3). Tighten cylinder head (3) to cylinder tube (15) by using hook wrench
(b). Bend the lock washer in order to prevent it from loosening.
Cylinder head (3) diameter: 105 mm
: 490 N·m
15
WABA-04-09-107-4 ja
b- Hook Wrench
WADS50-EN-00(07/05/2019) W5-2-16-4
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
Removal of Hose Rupture Valve for Boom Cylinder
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder retracted to
the maximum. Lower the end of arm to the ground.
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)
18
19
WADR-05-02-100-1 ja
3. Remove clip band (22). Disconnect connector (23).
WADS50-EN-00(07/05/2019) W5-3-1-1
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
21
23 22
WADR-05-02-101-2 ja
5. Remove adapter (28).
: 22 mm
6. Remove bolts (25) (2 used), spring washers (26) (2 used), and washers (27) (2 used). Remove the hose rupture valve
(24) assembly from the boom cylinder.
: 17 mm
24
25, 26, 27
28
WADR-05-03-100-1 ja
7. Remove nuts (29) (2 used), washers (30) (2 used), bolts (33) (2 used), spring washers (34) (2 used), and washers (35) (2
used). Remove shim (32) and hose rupture valve (24) from bracket (31).
: 13 mm
WADS50-EN-00(07/05/2019) W5-3-1-2
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
29, 30 32
33, 34 ,35
WADR-05-03-101-1 ja
WADS50-EN-00(07/05/2019) W5-3-1-3
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
MEMO
WADS50-EN-00(07/05/2019) W5-3-1-4
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
29, 30 32
33, 34 ,35
WADR-05-03-101-1 ja
3. Install the hose rupture valve (24) assembly to the boom cylinder with bolts (25) (2 used), spring washers (26) (2 used),
and washers (27) (2 used).
: 17 mm
: 50 N·m
4. Install adapter (28).
: 22 mm
: 40 N·m
24
25, 26, 27
28
WADR-05-03-100-1 ja
WADS50-EN-00(07/05/2019) W5-3-2-1
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
21
23 22
WADR-05-02-101-2 ja
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
18
19
WADR-05-02-100-1 ja
WADS50-EN-00(07/05/2019) W5-3-2-2
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
A-A 3
WADR-05-03-102-1 ja
WADS50-EN-00(07/05/2019) W5-3-3-1
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
MEMO
WADS50-EN-00(07/05/2019) W5-3-3-2
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.
1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder retracted to
the maximum. Lower the end of arm to the ground.
2. Remove bolts, washers (19) (2 used) Remove cover (18).
: 17 mm
18
19
WADR-05-03-103-1 ja
WADS50-EN-00(07/05/2019) W5-3-4-1
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)
21
8
WADR-05-03-104-1 ja
4. Disconnect pipe (26).
: 27 mm
5. Remove socket bolts (22) (2 used), spring washers (23) (2 used), and washers (24) (2 used). Remove the hose rupture
valve (25) assembly from the arm cylinder.
: 8 mm
22, 23, 24 25
26
22, 23, 24
WADR-05-03-105-1 ja
6. Remove nuts (28) (2 used), washers (29) (2 used), bolts (30) (2 used), spring washers (31) (2 used), and washers (32) (2
used). Remove hose rupture valve (25) from bracket (27).
: 13 mm
WADS50-EN-00(07/05/2019) W5-3-4-2
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
NOTE
THREEBOND #1324 has been applied to bolt (30).
A
A
25
27
WADR-05-03-106-1 ja
WADS50-EN-00(07/05/2019) W5-3-4-3
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
MEMO
WADS50-EN-00(07/05/2019) W5-3-4-4
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
WADS50-EN-00(07/05/2019) W5-3-5-1
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
A
A
25
27
22, 23, 24 25
26
22, 23, 24
WADR-05-03-107-1 ja
WADS50-EN-00(07/05/2019) W5-3-5-2
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
10. Connect hoses (8) (3 used). Install clip bands (21) (3 used).
: 19 mm
: 30 N·m
: 27 mm
: 80 N·m
21
8
WADR-05-03-104-1 ja
IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.
18
19
WADR-05-03-103-1 ja
WADS50-EN-00(07/05/2019) W5-3-5-3
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
MEMO
WADS50-EN-00(07/05/2019) W5-3-5-4
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
A-A 3
WADR-05-03-102-1 ja
WADS50-EN-00(07/05/2019) W5-3-6-1
SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
MEMO
WADS50-EN-00(07/05/2019) W5-3-6-2
Hitachi Construction Machinery Co., Ltd. Hitachi ref. No.
Attn: PS Information Center
Tel: 029-832-7084
Fax: 029-831-1162
E-mail: HCM-TIC-GES@hitachi-kenki.com
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