PART NO.

WDCD-EN-00

ZX200-5G • 200LC-5G • 210H-5G • 210LCH-5G • 210K-5G • 210LCK-5G

Workshop Manual

ZX
200-5G
200LC-5G

HYDRAULIC EXCAVATOR
210H-5G
210LCH-5G
WORKSHOP MANUAL
URL:http://www.hitachi-c-m.com 210K-5G
210LCK-5G
Hydraulic Excavator
Service Manual consists of the following separate Part No.
WDCD-EN-00

Technical Manual (Operational Principle) : Vol. No.TODCD-EN

Technical Manual (Troubleshooting) : Vol. No.TTDCD-EN
Workshop Manual : Vol. No.WDCD-EN
PRINTED IN JAPAN (K) 2012, 02 Engine Manual : Vol. No.EDCD-EN
 INTRODUCTION
To The Reader
This manual is written for an experienced technician to
provide technical information needed to maintain and
repair this machine.
 Be sure to thoroughly read this manual for correct
product information and service procedures.
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.
Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
 Technical Manual: T 1-3-5
T Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
IN-01
 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 it for usage.):
 Publications Marketing & Product Support Hitachi
Construction Machinery Co. Ltd.
 TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: dc@hitachi-kenki.com
 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.
 Workshop Manual: W 1-3-2-5
W Workshop Manual
1 Section Number
3 Group Number
2 Sub Group Number
5 Consecutive Page Number for Each Group
 INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential d CAUTION:
Indicated potentially hazardous situation which could, if
for personal injury of machine damage.
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed
instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention to
component/part weights. f NOTE:
Indicates supplementary technical information or know-
To avoid injury and damage, be sure to use appropriate
how.
lifting techniques and equipment when lifting heavy
parts.

Units Used
SI Units (International System of Units) are used in this
manual. MKSA system units and English units are also
indicated in parentheses just behind SI units.
Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
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/cm 2
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
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0

fNOTE: The numerical value in this manual might be

different from the above-mentioned table.

IN-02
 SYMBOL AND ABBREVIATION

Symbol / Name Explanation

Abbreviation
TO Technical manual (Operational principle)Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECF Engine Controller Engine controller. ECF controls EC motor according to the
machine operating condition.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.

SY-1
 SYMBOL AND ABBREVIATION
(Blank)

SY-2
 SAFETY

Recognize Safety Information

 These are the SAFETY ALERT SYMBOLS.
 When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
 Follow recommended precautions and safe operating
practices.

SA-688

Understand Signal Words

 On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
 DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
 WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
 CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
 DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
 Some safety signs do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.

SA-1223
 To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.

 NOTE: indicates an additional explanation for an

element of information.

SA-1
 SAFETY

Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
 Learn how to operate the machine and its controls correctly
and safely.
 Allow only trained, qualified, authorized personnel to
operate the machine.
 Keep your machine in proper working condition. SA-003
 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Never attempt to modify or disassemble the inlet/exhaust
parts and the muffler filter. Avoid giving shocks on the
muffler filter by striking elements with other objects or
dropping the elements. Failure to do so may affect the
exhaust gas purifying device, possibly damaging it or
lowering its performance.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.

SA-2
 SAFETY

Prepare for Emergencies

 Be prepared if a fire starts or if an accident occurs.
 Keep a first aid kit and fire extinguisher on hand.
 Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
 To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
 Establish emergency procedure guidelines to cope with
fires and accidents.
 Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone. SA-437

Wear Protective Clothing

 Wear close fitting clothing and safety equipment
appropriate to the job.

You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing SA-438
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
 Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
 Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.

SA-3
 SAFETY

Protect Against Noise

 Prolonged exposure to loud noise can cause impairment or
loss of hearing.
 Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.

SA-434

Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
 In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.

SA-435

SA-4
 SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not leave parts and/or tools lying around the
operator’s seat. Store them in their specified locations.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
 Keep all flammable objects and/or explosives away from
the machine.
 After using the ashtray, always cover it to extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.

SA-5
 SAFETY

Use Handholds and Steps

 Falling is one of the major causes of personal injury.
 When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
 Do not use any controls as hand-holds.
 Never jump on or off the machine. Never mount or
dismount a moving machine.
 Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
 Never get on and off the machine with tools in your
hands.
SA-439

Adjust the Operator's Seat

 A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
 The seat should be adjusted whenever changing the
operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror SA-378
is broken, immediately replace it with a new one.

SA-6
 SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with
a control lever 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 up.

Fasten Your Seat Belt

 If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
 Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
 Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to SA-237
minimize the chance of injury from an accident.
 We recommend that the seat belt be replaced every three
years regardless of its apparent condition.

SA-7
 SAFETY

Move and Operate Machine Safely

 Bystanders can be run over.
 Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or
operating the machine.
 Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
 Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Use appropriate illumination. Check that all lights are SA-426
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
 Ensure the cab door, windows, doors and covers are
securely locked.
 Check the mirrors and the monitor in the CAB for
problems.
If there is, replace the problem part (s) or clean the mirror,
camera and the monitor.
Refer to Rear View Monitor section on the cleaning of the
camera and the monitor in the operator’s manual.

Operate Only from Operator's Seat

 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
 Start the engine only when seated in the operator's seat.
 NEVER start the engine while standing on the track or on
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders. SA-444

SA-8
 SAFETY

Jump Starting
 Battery gas can explode, resulting in serious injury.
 If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
 The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
 Never use a frozen battery.
 Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032

Keep Riders off Machine

 Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
 Only the operator should be on the machine. Keep riders
off.
 Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.

SA-379

SA-9
 SAFETY

Precautions for Operations

 Investigate the work site before starting operations.
 Be sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
 Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
 When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.

M178-05-007

SA-10
 SAFETY

Investigate Job Site Beforehand

 When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
 Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles or banks
from collapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
 When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.

SA-11
 SAFETY
 Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
 If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
 Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
 Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent M104-05-016
machine tipping over from occurring. When operating on
rough terrain or on slopes:
 Reduce the engine speed.
 Select slow travel speed mode.
 Operate the machine slowly and be cautious with
machine movements.

Install OPG Guard

In case the machine is operated in areas where the possibilities
of falling stones or debris exist, equip Hitachi OPG guard.
Consult your authorized dealer for installing the OPG guard.
The guard can be compliant with ROPS standards depending
on the machine specifications.
In order not to impair operator protective structure:
Replace damaged ROPS or OPG guard. Never attempt to repair
or modify the guard.

ROPS: Roll Over Protective Structure

OPG: Operator Protective Guard

SA-490

SA-12
 SAFETY

Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.

SA-481

Confirm Direction of Machine to Be Driven

 Incorrect travel pedal/lever operation may result in serious
injury or death.
 Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when travel pedals/levers are
operated to the front.

SA-491

SA-13
 SAFETY

Drive Machine Safely

 Before driving the machine, always confirm that the travel
levers/pedals direction corresponds to the direction you
wish to drive.
 Be sure to detour around any obstructions.
 Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do A
not allow personnel to stay around the machine while
traveling.

 Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.
 Never attempt to ascend or descend 35 degrees or
steeper slopes.
 Be sure to fasten the seat belt.
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 0.2 to 0.3 m (A)
above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If A SA-658
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.

SA-441

WRONG

SA-590

SA-14
 SAFETY
 Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
 Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
 Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
 Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
 Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
 Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
 When crossing train tracks, use wood plates in order not
to damage them.
 Do not make contact with electric wires or bridges.
 When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
 When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
 Avoid operations that may damage the track and
undercarriage components.
 During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.

SA-15
 SAFETY

Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.

To avoid rollaways:
 Select level ground when possible to park the machine.
 Do not park the machine on a grade.
 Lower the bucket and/or other work tools to the ground.
 Turn the auto-idle switch OFF and the power mode switch
E or P.
 Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
 Stop the engine and remove the key from the key switch.
SA-391
 Pull the pilot control shut-off lever to LOCK position.
 Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.

SA-2273

SA-16
 SAFETY

Avoid Injury from Back-Over and Swing

Accidents
 If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
 Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
 Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
 USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW. SA-383
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
 No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
 Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
 Keep windows, mirrors, and lights clean and in good
condition.
 Dust, heavy rain, fog, etc., can reduce visibility. As visibility
decreases, reduce speed and use proper lighting.
 Read and understand all operating instructions in the SA-384
operator’s manual.

SA-17
 SAFETY

Keep Person Clear from Working Area

 A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or death.
 Keep all persons clear from the area of operation and
machine movement.
 Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to prevent
anyone from entering the work area.

SA-386

Never Position Bucket Over Anyone

 Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.

SA-487

SA-18
 SAFETY
Avoid Undercutting
 In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage
perpendicular to the edge of the excavation with the travel
motors at the rear.
 If the footing starts to collapse and if retreat is not
possible, do not panic. Often, the machine can be secured
by lowering the front attachment, in such cases.

SA-488

Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE
--- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
 The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
 Be extra careful before operating on a grade.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the SA-012
machine.
 Reduce operating speeds to avoid tipping or slipping.
 Avoid changing direction when traveling on grades.
 NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
 Reduce swing speed as necessary when swinging loads.

 Be careful when working on frozen ground.

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

SA-440

SA-19
 SAFETY

Never Undercut a High Bank

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

SA-489

Dig with Caution

 Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
 Before digging check the location of cables, gas lines, and
water lines.
 Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
 If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
 Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
SA-382
Have them mark all underground utilities.

Operate with Caution

 If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
 Take care to avoid hitting overhead obstacles with the
boom or arm.

SA-389

SA-20
 SAFETY

Avoid Power Lines

 Serious injury or death can result if the machine or front
attachments are not kept a safe distance from electric lines.
 When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
 Check and comply with any local regulations that may
apply.
 Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.

SA-381

Precautions for Lightning

 The machine is vulnerable to lightning strikes.
 In the event of an electrical storm, immediately stop
operation, and lower the bucket to the ground. Evacuate
to a safe place far away from the machine.
 After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only after
repairing them.

SA-1088

SA-21
 SAFETY

Object Handling
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
resulting in serious injury or death.
 When using the machine for craning operations, be sure
to comply with all local regulations.
 Do not use damaged chains or frayed cables, sables,
slings, or ropes.
 Before craning, position the upperstructure with the
travel motors at the rear.
 Move the load slowly and carefully. Never move it
suddenly.
 Keep all persons well away from the load.
 Never move a load over a person’s head.
 Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
 Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.

SA-014

Protect Against Flying Debris

 If flying debris hit eyes or any other part of the body, serious
injury may result.
 Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
 Keep bystanders away from the working area before
striking any object.
 Always close the front windows, doors, door windows and
the overhead window when operating the machine.

SA-432

SA-22
 SAFETY

Park Machine Safely

To avoid accidents:
 Park machine on a firm, level surface.
 Lower bucket to the ground.
 Turn auto-idle switch OFF and power mode switch E or P.
 Run engine at slow idle speed without load for 5 minutes.
 Turn key switch to OFF to stop engine.
 Remove the key from the key switch.
 Pull the pilot control shut-off lever to the LOCK position.
 Close windows, roof vent, and cab door.
 Lock all access doors and compartments.

SA-390

Handle Fluids Safely−Avoid Fires

 Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and/or a fire may occur, possibly resulting in
serious injury or death.
 Do not refuel the machine while smoking or when near
open flame or sparks.
 Always stop the engine before refueling the machine.
 Fill the fuel tank outdoors.

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

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

SA-019

SA-23
 SAFETY

Transport Safely
 Take care the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
 Observe the related regulations and rules for safe
transportation.
 Select an appropriate truck or trailer for the machine to
be transported.
 Be sure to use a signal person.
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight. SA-395

3. Turn auto-idle switch OFF and turn mode switch to PWR

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

Be sure to further follow the details described in the

TRANSPORTING section in the operator’s manual.

SA-24
 SAFETY

Practice Safe Maintenance

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

Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5
minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving
the control levers several times. SA-028

7. Remove the key from the key switch.

8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.

 If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
 If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support any
machine elements that must be raised for service work.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter in the operator’s manual. SA-527
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.

SA-25
 SAFETY
 Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
 Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.

SA-037

Warn Others of Service Work

 Unexpected machine movement can cause serious injury.
 Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.

SS3076175 SS2045102

Support Machine Properly

 Never attempt to work on the machine without securing
the machine first.
 Always lower the attachment to the ground before you
work on the machine.
 If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
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

SA-26
 SAFETY

Stay Clear of Moving Parts

 Entanglement in moving parts can cause serious injury.
 To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.

SA-026

SA-2294

Prevent Parts from Flying

 Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in serious
injury, blindness, or death.
 Do not attempt to remove GREASE FITTING or VALVE
ASSEMBLY.
 Do not attempt to remove grease fitting securing cover.
 As pieces may fly off, be sure to keep body and face away
from valve.
 Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster may
cause the parts such as a spring to fly off, possibly SA-344
resulting in severe personal injury or death.

 Travel reduction gears are under pressure.

 As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
 GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.

SA-27
 SAFETY

Store Attachments Safely

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.

SA-034

Prevent Burns
Hot spraying fluids:

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

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
 To avoid possible injury from hot spraying water. DO
NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to SA-039
release all pressure before removing the cap.

Hot fluids and surfaces:

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

SA-225

SA-28
 SAFETY

Replace Rubber Hoses Periodically

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

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

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

Avoid High-Pressure Fluids

 Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
 Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044

SA-29
 SAFETY

Prevent Fires
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to fires.
 Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
 Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
 Do not bend or strike high-pressure lines.
 Never install bent or damaged lines, pipes, or hoses.
 Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
SA-019
Check for Shorts:
 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
 Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.

SA-30
 SAFETY
Clean up Flammables:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammables immediately. Check and clean high
temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammables away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammables such as
dead leaves from entering. However, flammables which
have passed through the wire screen may cause fires.
Check and clean the machine every day and immediately
remove accumulated flammables.

Check Key Switch:

 If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
 If any abnormalities are found, be sure to repair them
before operating the machine.

Check Heat Shields:

 Damaged or missing heat shields may lead to fires.

 Damaged or missing heat shields must be repaired or

replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as mufflers may cause fire. Always close the engine cover
while operating the machine.

SA-31
 SAFETY

Evacuating in Case of Fire

 If a fire breaks out, evacuate the machine in the following
way:
 Stop the engine by turning the key switch to the OFF
position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method in the operator’s manual.

SS-1510

Beware of Exhaust Fumes

 Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
 If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.

SA-016

SA-32
 SAFETY
Precautions for Welding and Grinding
 Welding may generate gas and/or small fires.
 Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe place
before starting welding.
 Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
 Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
 After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818

SA-33
 SAFETY

Avoid Heating Near Pressurized Fluid Lines

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

SA-030

Avoid Applying Heat to Lines Containing

Flammable Fluids
 Do not weld or flame cut pipes or tubes that contain
flammable fluids.
 Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.

Precautions for Handling Accumulator and Gas

Damper
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 the unit, sealed gas must be released.
Consult your nearest Hitachi dealer.

SA-34
 SAFETY

Remove Paint Before Welding or Heating

 Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
 Avoid potentially toxic fumes and dust.
 Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
 Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.

Beware of Asbestos and Silicon Dust and Other

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silicon dust or other contamination
may cause sickness.
 Depending on the work site conditions, the risk
of inhaling asbestos fiber, silicon dust or other
contamination may exist. Spray water to prevent asbestos
fibers, silicon dust or other contamination from becoming
airborne. Do not use compressed air.
 When operating the machine in a work site where
asbestos fibers, silicon dust or other contamination SA-029
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contamination.
 Keep bystanders out of the work site during operation.
 Asbestos fibers might be present in imitation parts. Use
only genuine Hitachi Parts.

SA-35
 SAFETY

Prevent Battery Explosions

 Battery gas can explode.
 Keep sparks, lighted matches, and flame away from the
top of battery.
 Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
 Do not charge a frozen battery; it may explode. Warm the
battery to 16 ˚C ( 60 ˚F ) first.
 Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the
battery may result.
 Loose terminals may produce sparks. Securely tighten all
terminals. SA-032
 Connect terminals to the correct electrical poles. Failure
to do so may cause damage to the electrical parts or fire.

 Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into eyes,
possibly resulting in blindness.
 Be sure to wear eye protection when checking electrolyte
specific gravity.

Service Air Conditioning System Safely

 If spilled onto skin, refrigerant may cause a cold contact
burn.
 Refer to the instructions described on the container for
proper use when handling the refrigerant.
 Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
 Never touch the refrigerant.

SA-405

SA-36
 SAFETY

Handle Chemical Products Safely

 Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.
 A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
 Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and use recommended equipment. SA-309
 See your authorized dealer for MSDS’s (available only in
English) on chemical products used with your machine.

Dispose of Waste Properly

 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
 Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
 Do not pour waste onto the ground, down a drain, or into
any water source.
 Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations SA-226
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
 Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.

SA-37
 SAFETY

Never Ride Attachment

Never allow anyone to ride attachments or load. This is an
extremely dangerous practice.

Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.

SA-38
 SAFETY
Precaution for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which is
situated at the back of the driver's seat. There is a possibility
that a medical device, including an implantable device
such as a cardiac pacemaker, would be affected and would
malfunction by the electrical waves emitted from the
communication terminal equipment.

Any person affixed with a medical device such as the above SA-2302
should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.662 inches) apart at
all times. If such condition cannot be met, please contact our
company's nearest dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.

Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipments:
E-GSM900 0.573 W/Kg (914.80 MHz)
DCS-1800 0.130 W/Kg (1710.20 MHz)
WCDMA Band I 0.271 W/Kg (1950.00 MHz)

*This data was measured by having each type of

communication terminal equipment, such as the
communication terminal equipment used with this machine,
and a human body set apart by 3 cm (1.18 inches).
* SAR is a measure of the amount of radio frequency energy
absorbed by the body when using a wireless application such
as a mobile phone.

In Japan: *Under the Japanese Radio Act and other relevant

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).

In EU Member nation: *Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).

SA-39
 SAFETY
Before Returning the Machine to the Customer
 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced.

SA-435

SA-40
 SECTION AND GROUP SECTION 1 GENERAL INFORMATION
CONTENTS Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Pressure Release Procedure
WORKSHOP MANUAL Group 6 Preparation
SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure
Group 2 Undercarriage
Group 3 Front Attachment
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Engine
Group 5 Radiator Assembly
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Swing Device
Group 11 Pilot Valve
Group 12 Solenoid Valve
All information, illustrations and Group 13 Signal Control Valve
specifications in this manual are based on
the latest product information available SECTION 4 UNDERCARRIAGE
at the time of publication. The right is Group 1 Swing Bearing
reserved to make changes at any time
without notice. Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Upper and Lower Rollers
Group 6 Track
SECTION 5 FRONT ATTACHMENT
COPYRIGHT(C)2012 Group 1 Front Attachment
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan Group 2 Cylinder
All rights reserved
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Controller
Group 2 Control System
Group 3 Hydraulic System
Group 4 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner
SECTION 1

GENERAL
CONTENTS
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling and
Assembling..................................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Painting..............................................................................W1-3-1-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1
Bleeding Air from Hydraulic System........................W1-4-1-2
Bleeding Air from Fuel System...................................W1-4-1-3
Group 5 Pressure Release Procedure
Hydraulic Circuit Pressure Release Procedure......W1-5-1-1
Group 6 Preparation
Preparation before Inspection and
Maintenance...............................................................W1-6-1-1

DCDW-1-1
(Blank)

DCDW-1-2
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Disassembling and  If a part or component cannot be removed after

Assembling removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), then take the
Precautions for Disassembling appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and tag
 Clean the Machine
them if necessary.
Thoroughly wash the machine before bringing it
 Store common parts, such as bolts and nuts with
into the shop. Bringing a dirty machine into the shop
reference to where they are to be used and in a
may cause machine components to be contaminated
manner that will prevent loss.
during disassembling / assembling, resulting in
 Inspect the contact or sliding surfaces of
damage to machine components, as well as decreased
disassembled parts for abnormal wear, sticking, or
efficiency in service work.
other damage.
 Measure and record the degree of wear and
 Inspect the Machine
clearances.
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
 Precautions for Assembling
incorrect disassembling of components as well as
 Be sure to clean all parts and inspect them for any
personal injury.
damage. If any damage is found, repair or replace
Check and record the items listed below to prevent
part.
problems from occurring in the future.
 Dirt or debris on the contact or sliding surfaces may
 The machine model, machine serial number, and
shorten the service life of the machine. Take care not
hour meter reading.
to contaminate any contact or sliding surfaces.
 Reason for disassembly (symptoms, failed parts, and
 Apply appropriate lubricant oil onto parts in order to
causes).
prevent them from seizing.
 Clogging of filters and oil, water or air leaks, if any.
 Be sure to replace O-rings, backup rings, oil seals, and
Capacities and condition of lubricants.
floating seals with new ones once they have been
 Loose or damaged parts.
disassembled. Apply grease before installing
 Be sure that liquid-gasket-applied surfaces are clean
 Prepare and Clean Tools and Disassembly Area
and dry.
Prepare the necessary tools to be used and the area for
 If an anti-corrosive agent has been used on a new
disassembling work.
part, be sure to thoroughly clean the part to remove
the agent.
Precautions for Disassembling and Assembling
 Fit the matching marks made when disassembling
 Precautions for Disassembling and assemble them.
 Cap the open ends in case the hoses and pipes  Be sure to use the designated tools to assemble
have been disconnected. In addition, attach an bearings, bushings, and oil seals.
identification tag onto the connectors, hoses, and  Keep a record of the number of tools used for
pipes for assembling. disassembly / assembly. After assembling is
 Before disassembling, clean the exterior of the completed, count the number of tools so as to make
components and place on a workbench. sure that no forgotten tools remain in the assembled
 Drain hydraulic oil and gear oil from the hydraulic machine.
components and reduction gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling if
necessary.
 Be sure to use the specified special tools when
instructed.

W1-1-1-1
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Using Floating Seal 1

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). W178-02-11-001
2
 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. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a - Correct c - Twist of O-Ring
 After installing the floating seal, check that O-ring b - Incorrect d - Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
(e) and (f ) at point (A) and (B), as illustrated. If these
distances differ, correct O-ring (2) seating. a A b A

B B

A=B A≠B

W178-02-11-003

a - Correct e - Sliding Surface

b - Incorrect f - Seal Mating Surface

W1-1-1-2
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings a
safely.
 Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
 Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load with
a temperature of 100 °C (212 °F) or more, reduce the
load weight.
 Do not lift acid or alkali chemicals. W102-04-02-016
 Take care not to allow the sling to become wet. The
a - Correct Eyehole Lifting
load may slip.
Method
 When required to use more than one sling, use slings
with the same width and length to keep the lifted b
load balanced.
 When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
 Avoid using twisted, bound, connected, or hitched
slings.
 Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
 When removing the slings from under the load, take
care not to damage the nylon slings. Avoid contact W105-04-01-008
with protrusions.
 Avoid dragging slings on the ground, throwing b - Incorrect Eyehole Lifting
Method
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.

c W162-01-01-009

c - Bent of Sling

W1-1-1-3
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

dCAUTION: 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.

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

sling for any damage corresponding to examples
shown to the right. If any damage is found, cut and
discard the sling.
Even if no damage is found, do not use slings older
than 7 years.

Damaged Appearance a
a

W162-01-01-002 W162-01-01-006
e
a - Broken Sewing Thread a - Broken Sewing Thread e - Separation of Belt

b f

W162-01-01-003 W162-01-01-007
b
b - Scuffing b - Scuffing f - Scoring

c
c g

W162-01-01-004
W162-01-01-008
c - Fuzz d - Broken Sewing Thread
c - Fuzz g - Broken Warp

W162-01-01-005

a - Broken Sewing Thread

W1-1-1-4
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Maintenance Standard Terminology

“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification. Allowable errors will be
indicated if necessary.

“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.
Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.

W1-1-1-5
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

(Blank)

W1-1-1-6
 SECTION 1 GENERAL
Group 2 Tightening

Tightening Bolts and Nuts

dCAUTION: 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.
fNOTE:
 Apply lubricant (e.g. white zinc B dissolved into spindle

oil) to bolts and nuts to reduce friction coefficient of
them.
 Make sure bolt and nut threads are clean before
WDAA-01-02-001
installing.

Bolt Types
Tighten the nuts or bolts correctly to the torque
specifications.
As the different types and grades of bolt are used,
use and tighten the correct bolts correctly when
assembling the machine or components.

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench WDAA-01-02-002 WDAA-01-02-003 WDAA-01-02-004
Size
Size
Socket Bolt
N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft)
M6 10 5 3 to 4 (0.3 to 0.4) (2.2 to 3)
M8 13 6 30 (3) (22) 20 (2) (15) 10 (1) (7.4)
M10 17 8 65 (6.5) (48) 50 (5) (37) 20 (2) (15)
M12 19 10 110 (11) (81) 90 (9) (66) 35 (3.5) (26)
M14 22 12 180 (18) (133) 140 (14) (103) 55 (5.5) (41)
M16 24 14 270 (27) (200) 210 (21) (155) 80 (8) (59)
M18 27 14 400 (40) (300) 300 (30) (220) 120 (12) (89)
M20 30 17 550 (55) (410) 400 (40) (300) 170 (17) (125)
M22 32 750 (75) (550) 550 (55) (410) 220 (22) (162)
M24 36 950 (95) (700) 700 (70) (520) 280 (28) (205)
M27 41 1400 (140) (1030) 1050 (105) (770) 400 (40) (300)
M30 46 1950 (195) (1440) 1450 (145) (1070) 550 (55) (410)
M33 50 2600 (260) (1920) 1950 (195) (1440) 750 (75) (550)
M36 55 3200 (320) (2360) 2450 (245) (1810) 950 (95) (700)

W1-2-1-1
 SECTION 1 GENERAL
Group 2 Tightening

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 chart on the previous
page 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.

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

a - Equally tighten upper and b - Tighten diagonally c - Tighten from center

lower alternately diagonally

W1-2-1-2
 SECTION 1 GENERAL
Group 2 Tightening

Precautions for Spilt Flange

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
WDAA-01-02-005
O-ring.
Use only specified O-rings. Inspect O-rings for

any damage. Do not file the O-ring surfaces. Incorrect
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.
Tighten the bolts up and down, left and right

alternately, in order to ensure even tightening
WDAA-01-02-006
to the specified torque.
Do not use air wrenches. Using an impact

wrench often causes tightening of one bolt fully
before tighten the others, resulting in damage
to O-rings or uneven tightening of bolts.

Nut and Bolt Locking

 Lock Plate
W105-01-01-008
IMPORTANT: Do not reuse the lock plates. Do not try
to bend the same point twice.
Correct Incorrect
 Split Pin
IMPORTANT: Do not turn in the loosening direction
in order to align the grooves and holes on the nut.
a b
Always turn in the tightening direction. Do not
reuse the split pins.
Correct Correct Incorrect

 Wire
IMPORTANT: Attach wire to bolts in the bolt-
tightening direction. Do not reuse the wire.

a
WDAA-01-02-007

a- Bend along edge sharply b- Do not bend it round

Correct Correct
Incorrect

Correct d Incorrect
c

WDAA-01-02-008

c- Tighten d- Loosen

W1-2-1-3
 SECTION 1 GENERAL
Group 2 Tightening

Piping Joint
IMPORTANT: The torque given in table below are for
general use only, however, a different torque is
given for a specific application. Use the specified
1 4 3 5 2
torque.

Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
a - Joint Body WDAA-01-02-009
IMPORTANT: a

Do not over-tighten union nut (3). Excessive


force will be applied to metal sealing surfaces (4)
and (5), possibly cracking the adapter. Tighten 37°
union nut (3) to the specifications. 30°
Scratches or other damage to sealing surfaces

(4) or (5) will cause oil leakage at the joint. Take
b c
care not to damage them when connecting /
disconnecting. b - Male Union Joint c - Female Union Joint
WDAA-01-02-010

Wrench Size mm Tightening Torque

Description
Union Nut N·m (kgf·m) (lbf·ft)
30° male 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 270 (27) (200)
55 380 (38) (280)
60 380 (38) (280)
37° female 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)

fNOTE: Tightening torque of 37° male coupling without

union is similar to tightening torque of 37° female.

W1-2-1-4
 SECTION 1 GENERAL
Group 2 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

Tightening Torque
Use the specified tightening torque in the table below.
Wrench Size (mm) 17 19 22 27
N·m 25 30 40 80
Tightening
(kgf·m) (2.5) (3) (4) (8) M1M7-07-005
Torque
(lbf·ft) (18) (22) (30) (59)

O-ring Seal Joint

O-ring (6) is installed against the end surface of adapter
(7) and seals pressure oil.

IMPORTANT:
7 6 9
Replace O-ring (6) with a 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)
 8 10 a
WDAA-01-02-011
or sealing surface (10) on the hose side. Damage a - Joint Body
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. Wrench Size mm Tightening Torque
Instead, replace O-ring (6) with a new one, then Union Nut N·m (kgf·m) (lbf·ft)
tighten union nut (9) after confirming that 19 30 (3) (22)
O-ring (6) is securely seated in O-ring groove (8). 22 70 (7) (52)
27 95 (9.5) (70)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 350 (35) (260)

W1-2-1-5
 SECTION 1 GENERAL
Group 2 Tightening

Quick Coupling
3 1
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
M1M7-07-006
the rightmost direction). 2

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.

dCAUTION:
 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).

W1-2-1-6
 SECTION 1 GENERAL
Group 2 Tightening

Screw-In Connection R G
30°
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. (In general, a b
the screw-in connection of male tapered thread is a - Male Tapered Thread b - Male Straight Thread
used except for measurement purpose.) W105-01-01-018

Wrench Size mm Tightening Torque

Joint Body FC material SS material
19 15 (1.5, 11) 35 (3.5, 26)
22 30 (3, 22) 50 (5, 37)
27 50 (5, 37) 95 (9.5, 70)
36 70 (7, 52) 160 (16, 118)
Seal Tape Application 41 110 (11, 81) 200 (20, 148)
Seal tape is used in order to seal clearances between 50 160 (16, 118) 330 (33, 245)
male and female threads so that any leaks between 60 200 (20, 148)
threads may be prevented. Therefore, apply just
enough seal tape to fill up thread clearances. Do not
overwrap.
fNOTE: Unit: N·m (kgf·m, lbf·ft)

 Application Procedure
Check that the thread surface is clean and, free of dirt c
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.
d e
W105-01-01-019
c - Internal Thread e - Clearance
d - External Thread
Low-Pressure-Hose Clamp Tightening f
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.

T-Bolt Type Band Clamp:

4.5 N·m (0.45 kgf·m, 3.3 lbf·ft)

Worm Gear Type Band Clamp:

6 to 7 N·m (0.6 to 0.7 kgf·m, 4.4 to 5.2 lbf·ft)

f - Leave one to two pitch

M114-07-041
threads uncovered
g h

WDAA-01-02-012 M114-07-043
g - T-Bolt Type Band Clamp h - Worm Gear Type Band Clamp

W1-2-1-7
 SECTION 1 GENERAL
Group 2 Tightening

Connecting Hose

dCAUTION: When replacing the hoses, use only

genuine Hitachi service parts. Using hoses other
Incorrect Correct

than genuine Hitachi hoses may cause oil leaks,

hose rupture or separation of fitting, possibly
resulting in a fire on the machine. Do not install
hoses kinked. Application of 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 W105-01-01-011
installing in order to prevent hose from being
kinked. Take necessary measures to protect hoses
from rubbing against each other. If the hoses rub Incorrect a Correct
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.
W105-01-01-012

a - Rubbing Against Each Other

Incorrect Correct
b b

W105-01-01-013
a - Rubbing Against Each Other b - Clamp

Incorrect Correct

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

W1-2-1-8
 SECTION 1 GENERAL
Group 3 Painting

Painting
Painting specification
Surfaces to Be Painted Painting Colour
Main surface of upperstructure (except cab) YR-01 [TAXI yellow]
Main frame High Grade Black
Inner Gray
Front YR-01 [TAXI yellow]
Track (including swing bearing) N1.0 [Black]
Floor plate M/F Cation (allowed)

Final painted color

Inside and outside surface of cab High Grade Black
Shaded area on cab (Only the left side) (11) Shining Silver
Right window beam Charcoal Black
Seat stand [N2.0 (Black)]
Lever (Travel, pilot shut-off ) [N2.5 (Warm Gray)]
Engine cover (8) High Grade Black
Tool box (6), Tool box cover (4) High Grade Black
Cover (2), Step (3) High Grade Black
Handrail on upperstructure right side (1) High Grade Black
Mirror stay (5) High Grade Black
Nonslip plate KANSAI PAINT CO., LTD. 1400 (Deep Black)
Rear camera cover (9) High Grade Black

W1-3-1-1
 SECTION 1 GENERAL
Group 3 Painting

WDCD-01-03-001

WDCD-01-03-002

WDAA-01-03-003

a - Paint all circumference in the lower hinge swing position shining

silver
1- Handrail on Upperstructure 3- Step 6- Tool Box 9- Camera Cover
Right Side 4- Tool Box Cover 7- Decal (TAXI Yellow) 10- Decal (TAXI Yellow)
2- Cover 5- Mirror Stay 8- Engine Cover 11- Shaded Area (Shining Silver)

W1-3-1-2
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Hydraulic Oil Tank

dCAUTION: Escaping fluid under pressure may

penetrate the skin and eyes, and cause serious
injury. Release the pressure before disconnecting
the hydraulic pipings or removing other
equipment. Hot hydraulic oil just after operation
may spout out and cause severe burns. Wait until
oil cools 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 1 2 3
hydraulic oil level.

2. Stop the engine. Push air bleed button (1) of

hydraulic oil tank (3) and bleed air from hydraulic oil
tank (3).

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

W1R7-01-04-001

4. Install vacuum pump (a) to the position where cap

(2) has been removed. Operate vacuum pump (a) a
and maintain negative pressure in hydraulic oil tank
(3).
b
fNOTE: Operate vacuum pump (a) continuously while
working. c

W1R7-01-04-002

a - Vacuum Pump
b - Hose
c - Adapter

W1-4-1-1
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Hydraulic System

Bleed air from the hydraulic system as follows 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.

IMPORTANT: If air is accumulated inside of the pump
and if the engine starts in lacking of hydraulic oil,
the pump may be damaged.
 Bleeding Air from Pump
 Remove the air bleed plugs on top of the pump. Add
hydraulic oil to the pump.
 After the pump is filled with hydraulic oil, temporarily
tighten the plugs. Then, start the engine and run it at
slow idle speed.
 Slightly loosen the plugs and bleed air from the
pump until hydraulic oil comes out from the gap.
 After bleeding all air, securely tighten the plugs.
IMPORTANT: If air is accumulated inside of the motor
and if the engine starts in lacking of hydraulic oil,
the motor may be damaged.
 Bleeding Air from Travel Motor, Swing Motor
 Remove the air bleed plug (top) from the travel
motor and swing motor. Fill the motor case with
hydraulic oil.
IMPORTANT: If air is accumulated inside of the
cylinder and if the cylinder is operated suddenly
in lacking of hydraulic oil, the seal may be
damaged or the cylinder may seize.
 Bleeding Air from Hydraulic Circuit
 After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor, and travel
motor evenly, operate the machine under light loads
for 10 to 15 minutes. Slowly start each operation
(never fully stroke the cylinders during initial
operation stage).
 As the pilot circuit has an air bleed device, air in the
pilot circuit will be bled while performing the above
operation for approx. 5 minutes.
 Reset the front attachment in position for checking
hydraulic oil level.
 Stop the engine. Check hydraulic oil level. Replenish
hydraulic oil if necessary.

W1-4-1-2
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Fuel System

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,
cleaning the fuel solenoid pump strainer or running
the fuel tank dry, be sure to bleed the air from the fuel
system.

Air Bleeding Procedures

This machine is equipped with a fuel solenoid pump.
d CAUTION: Fuel leaks may lead to fires.
1
1. Check that fuel cock (1) on bottom of the fuel tank is
opened.
2. Set the key switch to the ON position and hold it in
that position for approx. three minutes. Therefore,
the fuel solenoid pump operates and starts to bleed
air.
M1U1-07-015
3. While holding the key switch in the ON position,
reciprocate fuel main filter priming pump (2). After
air is bled from the main filter, return priming pump
(2) to the original position. 2

4. After the main filter is filled with fuel, hold the key
switch in the ON position for 30 seconds.
5. Start the engine. Check the fuel system for fuel
leaks.
IMPORTANT: Even if air is not thoroughly bled,
do not hold the key switch in the ON position
for more than five minutes. In case air is not
thoroughly bled, first return the key switch to the
OFF position. Then, after waiting for more than
30 seconds, set the key switch to the ON position
again. Failure to do so may cause damage to
the fuel solenoid pump and/or discharging the
batteries.

M81U-07-030

W1-4-1-3
 SECTION 1 GENERAL
Group 4 Bleeding Air

Air Bleeding by Priming Pump

In case air is not bled due to malfunction of the fuel
solenoid pump, operating the priming pump only can
1
bleed air.
1. Check that fuel cock (1) on bottom of the fuel tank is
opened.
2. Loosen air bleed plug (4) on the fuel main filter.

j : 10 mm
3. Supply fuel by reciprocating priming pump (2). After M1U1-07-015
no air bubbles are spouted through air bleed plug
(4), tighten air bleed plug (4).

j : 10 mm
4. After tightening air bleed plug (4), reciprocate
priming pump (2) approx. 150 strokes. 3

5. Wipe off any spilled fuel.

6. Start the engine. Check that no fuel leaks are
present. If the engine does not start, repeat the
above procedures from step 1.

4
Air Bleeding by Cranking
M1GR-07-010
Bleed air from the fuel system after changing the
common rail.
1. Bleed air until the engine supply pump entrance
enough according to the above-mentioned 2
procedures.
2. Operate the starter motor for long cranking within
20 seconds. If the engine falls to start, return the key
switch to the OFF position. Wait more than about 60
seconds, then try again.

M81U-07-030

W1-4-1-4
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Radiator

dCAUTION: Do not loosen the radiator cap until

the system has cooled. 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.

W1-4-1-5
 SECTION 1 GENERAL
Group 4 Bleeding Air

(Blank)

W1-4-1-6
 SECTION 1 GENERAL
Group 5 Pressure Release Procedure

Hydraulic Circuit Pressure Release Procedure

Release any remaining pressure as follows before
removing/installing the front attachment.

1. Set pilot shut-off lever (1) to the UNLOCK position.

2. Turn engine stop switch (2) ON.

fNOTE: Perform step 1 and step 2, and set the key switch
to the START position. Although the starter rotates, the
engine does not start.
IMPORTANT: Battery will deplete. Operate the key
switch for short period.
3. With the key switch set in the START position, 1 2
operate the control lever in order to release any M1U1-01-029
pressure in the hydraulic circuit 4 to 5 times.
4. Return pilot shut-off lever (1) to the LOCK position.
5. Turn engine stop switch (2) OFF.

W1-5-1-1
 SECTION 1 GENERAL
Group 5 Pressure Release Procedure

(Blank)

W1-5-1-2
 SECTION 1 GENERAL
Group 6 Preparation

Preparation before Inspection and

Maintenance
Before performing the maintenance procedures given in
the following chapters, park the machine as described
below, unless otherwise specified.

1. Park the machine on a level surface.

2. Lower the bucket to the ground. M104-07-021

3. Turn the auto-idle switch OFF.

4. Set the engine control dial to the slow idle position.
1
Run the engine at slow idle speed without load for
five minutes.
5. Set the key switch to the OFF position. Stop the
engine. Remove the key from the key switch. If
maintenance should be performed with the engine
running, do not leave the machine unattended.
6. Set pilot shut-off lever (1) to the LOCK position.
7. Before performing any work on the machine, attach
tag (2) on the door or control lever.

WDAA-01-06-001

W1-6-1-1
 SECTION 1 GENERAL
Group 6 Preparation

(Blank)

W1-6-1-2
MEMO
MEMO
SECTION 2

MAINTENANCE STANDARD
CONTENTS
Group 1 Upperstructure
Pump Device....................................................................W2-1-1-1
Swing Motor.....................................................................W2-1-2-1
Group 2 Undercarriage
Travel Motor......................................................................W2-2-1-1
Sprocket.............................................................................W2-2-1-3
Front Idler..........................................................................W2-2-2-1
Upper Roller......................................................................W2-2-3-1
Lower Roller......................................................................W2-2-3-2
Track.....................................................................................W2-2-4-1
Group 3 Front Attachment
Pin and Bushing...............................................................W2-3-1-1
Side Cutter (2014503, 2014504)................................W2-3-1-3
Point (4427919)...............................................................W2-3-1-4
Standard Dimensions for Arm and Bucket
Connection..................................................................W2-3-1-5
Standard Dimensions for Arm and Boom
Connection..................................................................W2-3-1-6
Cylinder..............................................................................W2-3-2-1

DCDW-2-1
(Blank)

DCDW-2-2
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Pump Device

8 7 6 5

WDCD-02-01-002
10

1- Gear 4- Shaft 7- Valve Plate (Right, Left) 10- Servo Piston (2 Used)
2- Shaft 5- Plunger (14 Used) 8- Pin (2 Used)
3- Gear 6- Rotor (2 Used) 9- Gear

W2-1-1-1
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Pump Device

Unit: mm (in)
Standard Allowable Limit Remedy
Backlash of gears (1, 3, and 9) 0.68 (0.027) 1.5 (0.059) Replace

Main Pump
1. Spline tooth thickness of shafts (2, 4) (T1)
Unit: mm (in)
Standard Allowable Limit T1
T1 5.4 (0.213) 3.8 (0.150) d1

d2 d2
2. Oil seal outer diameter (d1, d2) of shafts (2, 4)
Unit: mm (in)
Standard Allowable Limit
d1 45 (1.77) 44.8 (1.76)
d2 55 (2.17) 54.8 (2.16)
4 2 W157-02-04-015
3. Clearance between plunger (5) and shafts (2, 4)
Unit: mm (in)
Standard Allowable Limit 5
0.058 (0.002) 0.4 (0.016)

4. Clearance between outer diameter (a) of plunger (5) 2, 4

and inner diameter (D) of rotor (6)
Unit: mm (in)
Standard Allowable Limit
D-a 0.043 (0.002) 0.08 (0.003)

W178-02-11-105

5 a

W178-02-11-106

W2-1-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

5. Clearance between plunger (5) and connecting rod

(b)
5
Unit: mm (in)
Standard Allowable Limit
0.15 (0.006) 0.4 (0.016)
b

6. Clearance between inner diameter (D) of servo b- Connecting Rod

small chamber and outer diameter (a) of servo W178-02-11-107
piston (10)
D
Unit: mm (in)
a c
Standard Allowable Limit
D-a 0.083 (0.003) 0.2 (0.008)

7. Clearance between inner diameter (D) of servo large

chamber and outer diameter (a) of servo piston (10)
Unit: mm (in)
10
Standard Allowable Limit
D-a 0.079 (0.003) 0.2 (0.008)

d
a
W178-02-11-108
D
c- Small Diameter Side
d- Large Diameter Side
8. Clearance between inner diameter (D) of valve plate
(7) and outer diameter (a) of pin (8)
7
Unit: mm (in)
Standard Allowable Limit 8
D-a 0.051 (0.002) 0.3 (0.012)
D

WDCD-02-01-003

W2-1-1-3
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

(Blank)

W2-1-1-4
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Swing Motor

2 3

W178-02-11-153

1- Rotor 2- Plunger (9 Used) 3- Friction Plate (3 Used)

W2-1-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

1. Clearance between outer diameter (d) of plunger (2)

and inner diameter (D) of rotor (1)
Unit: mm (in)
Standard Allowable Limit 2

D-d 0.027 (0.001) 0.052 (0.002)

d

W178-02-11-155

D D

W178-02-11-156

2. Clearance (δ) between plunger (2) and shoe (a)

bottom 2

Unit: mm (in)
Standard Allowable Limit
a
0 (0) 0.3 (0.012) δ

a- Shoe

W107-02-06-140

W2-1-2-2
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

3. Shoe (a) thickness (t)

Unit: mm (in)
Standard Allowable Limit
5.5 (0.22) 5.3 (0.21) a

a- Shoe
W178-02-11-157

4. Friction plate (3) thickness (t) 3

Unit: mm (in)
Standard Allowable Limit t
2.0 (0.08) 1.8 (0.07)

W178-02-11-158

W2-1-2-3
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

(Blank)

W2-1-2-4
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Travel Motor

1 2

WDCD-04-02-004

1- Rotor 2- Plunger (9 Used)

W2-2-1-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

1. Clearance (ε) between shoe (a) and plunger (2)

bottom a

Unit: mm (in)
Standard Allowable Limit
0 (0) 0.5 (0.02)

ε
2
a- Shoe

W1V1-03-02-005

2. Clearance between outer diameter (d) of plunger (2) D

and inner diameter (D) of rotor (1)
Unit: mm (in)
Standard Allowable Limit
0.03 (0.001) 0.08 (0.003)
D-d≤0.08 mm (0.003 in)

W105-02-06-134

W105-02-06-135

3. Shoe (a) thickness (t) a

Unit: mm (in)
Standard Allowable Limit
6.0 (0.236) 5.6 (0.220)

t
2
a- Shoe

W1V1-03-02-005

W2-2-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Sprocket

C'

B
C

D
A
W178-02-11-235 W178-02-11-236

Unit: mm (in)
Standard Allowable Limit
A 70 (2.8) [62 (2.4)] Build up
B 80.3 (3.2) 75.3 (3.0) welding and
C 119.7 (4.7) 114.7 (4.5) hand finishing
C' 644.6 (25.4) -
D 190.0 (7.5) -
fNOTE: Values in [ ] are just for reference.

W2-2-1-3
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

(Blank)

W2-2-1-4
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Front Idler

C D

W166-03-05-001
A

Unit: mm (in)
Standard Allowable Remedy
Limit
A 84 (3.31) [68 (2.67)] Build up
B 159 (6.26) - welding and
C 500 (19.7) [488 (19.2)] hand finishing
D 538 (21.2) -
E 19 (0.75) 25 (0.98)

Axle and Bushing

Unit: mm (in)
Standard Allowable Remedy
Limit
Axle Outer 75.0 (2.95) [74.2 (2.93)] Replace
Diameter
Bushing Inner 75.0 (2.95) [76 (2.99)]
Diameter
Flange 2 (0.08) [1.2 (0.05)]
Thickness

fNOTE: Values in [ ] are just for reference.

W2-2-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

(Blank)

W2-2-2-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Upper Roller

A
B
WDDE-02-02-001

Unit: mm (in)
Standard Allowable Remedy
Limit
A 84 (3.3) - Replace
B 165 (6.5) -
C 120 (4.7) [110 (4.3)]

fNOTE: Values in [ ] are just for reference.

W2-2-3-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Lower Roller

W157-03-06-003

Roller
Unit: mm (in)
Standard Allowable Remedy
Limit
A 169.0 (6.7) [187 (7.4)] Build up
B 218.0 (8.6) - welding and
C 24.5 (1.0) [15.5 (0.6)] hand finishing
D 150.0 (5.9) 132 (5.2) or replace

fNOTE: Values in [ ] are just for reference.

Axle and Bushing

Unit: mm (in)
Standard Allowable Remedy
Limit
Axle Outer 65 (2.6) [64.2 (2.5)] Replace
Diameter
Bushing Inner 65 (2.6) [66.0 (2.6)]
Diameter
Flange 2 (0.08) [1.2 (0.05)]
Thickness

fNOTE: Values in [ ] are just for reference.

W2-2-3-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Track
Link
Measure the length of four links.
 Do not measure the part included the master pin.
 Measure the length with tension on the track.

A
W155-03-07-001

Unit: mm (in)
Standard Allowable Remedy
Limit
A 762 (30.0) 786 (30.9) Build up
B 105 (4.1) [98 (3.9)] welding and
hand finishing
or replace

fNOTE: Values in [ ] are just for reference.

Grouser Shoe

W105-03-07-024

ZX210H-5G, 210K-5G
ZX200-5G, 200LC-5G Unit: mm (in) ZX210LCH-5G, 210LCK-5G Unit: mm (in)
Shoe Size 600 mm Grouser Shoe Size 600 mm Grouser
Standard Allowable Remedy Standard Allowable Remedy
Limit Limit
A 219 (8.6) - Build up A 219 (8.6) - Build up
B 8.5 (0.34) - welding or B 10 (0.39) - welding or
C 26 (1.02) [18 (0.71)] replace C 26 (1.02) [18 (0.71)] replace

fNOTE: Values in [ ] are just for reference.

W2-2-4-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Master Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Remedy
Limit
A 129.2 (5.08) - Replace
B 38.7 (1.52) [41.7 (1.64)]
C 59 (2.32) [54 (2.13)]

fNOTE: Values in [ ] are just for reference.

Master Pin

W105-03-07-021

Unit: mm (in)
Standard Allowable Remedy
Limit
A 203 (7.99) - Replace
B 38.4 (1.51) [35.4 (1.39)]

fNOTE: Values in [ ] are just for reference.

W2-2-4-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Pin

W142-03-07-004
A

Unit: mm (in)
Standard Allowable Remedy
Limit
A 212 (8.35) - Replace
B 38 (1.50) [35 (1.4)]

fNOTE: Values in [ ] are just for reference.

Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Remedy
Limit
A 137.5 (5.41) - Replace
B 38.7 (1.52) [39.7 (1.56)]
C 59 (2.32) [54 (2.13)]

fNOTE: Values in [ ] are just for reference.

W2-2-4-3
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

(Blank)

W2-2-4-4
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Pin and Bushing

C F
E
A G

H
J

B I K
W1V1-04-01-012

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Pin 90 (3.54) 89.0 (3.50) Replace
Bushing (Main Frame) 90 (3.54) 91.5 (3.60)
Bushing (Boom) 90 (3.54) 91.5 (3.60)
B Pin 80 (3.15) 79.0 (3.11)
Boss (Main Frame) 80 (3.15) 81.5 (3.21)
Bushing (Boom Cylinder) 80 (3.15) 81.5 (3.21)
C Pin 90 (3.54) 89.0 (3.50)
Bushing (Boom Cylinder) 90 (3.54) 91.5 (3.60)
Boss (Boom) 90 (3.54) 91.5 (3.60)
D Pin 90 (3.54) 89.0 (3.50)
Bushing (Boom) 90 (3.54) 91.5 (3.60)
Bushing (Arm) 90 (3.54) 91.5 (3.60)
E Pin 80 (3.15) 79.0 (3.11)
Boss (Arm) 80 (3.15) 81.5 (3.21)
Bushing (Arm Cylinder) 80 (3.15) 81.5 (3.21)
F Pin 80 (3.15) 79.0 (3.11)
Boss (Boom) 80 (3.15) 81.5 (3.21)
Bushing (Arm Cylinder) 80 (3.15) 81.5 (3.21)

W2-3-1-1
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
G Pin 71 (2.80) 70.0 (2.76) Replace
Boss (Arm) 71 (2.80) 72.5 (2.85)
Bushing (Bucket Cylinder) 71 (2.80) 72.5 (2.85)
H Pin 80 (3.15) 79.0 (3.11)
Boss (Link B) 80 (3.15) 81.5 (3.21)
Bushing (Link A) 80 (3.15) 81.5 (3.21)
Bushing (Bucket Cylinder) 80 (3.15) 81.5 (3.21)
I Pin 71 (2.80) 70.0 (2.76)
Boss (Link B) 71 (2.80) 72.5 (2.85)
Bushing (Arm) 71 (2.80) 72.5 (2.85)
J Pin 80 (3.15) 79.0 (3.11)
Boss (Bucket) 80 (3.15) 81.5 (3.21)
Bushing (Link A) 80 (3.15) 81.5 (3.21)
K Pin 80 (3.15) 79.0 (3.11)
Boss (Bucket) 80 (3.15) 81.5 (3.21)
Bushing (Arm) 80 (3.15) 81.5 (3.21)
IMPORTANT: When replacing HN bushing for the
front attachment, install it by using a press.

W2-3-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Side Cutter (2014503, 2014504)

C
D

W155-04-01-002

Unit: mm (in)
Standard Allowable Remedy
Limit
A 278 (10.9) 181 (7.1) Replace
B 295 (11.6) -
C 433 (17.0) -
D 135 (5.3) -

W2-3-1-3
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Point (4427919)

B C

W105-04-01-020

Unit: mm (in)
Standard Allowable Remedy
Limit
A 215 (8.5) 107.5 (4.2) Replace
B 95 (3.7) -
C 108 (4.3) -
D 95 (3.7) -

W2-3-1-4
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Standard Dimensions for Arm and Bucket

Connection
IMPORTANT: If the front attachment of a previous
model machine is used, use the grease intervals
for previous model machine.

WDCD-02-03-005

Section A Section B

WDCD-02-03-003
Unit: mm (in)
ZX200-5G Class ZX200-3 Class
a 450 (17.7) 
b 10 (0.39) 
c 604 (23.8) 
d 580 (22.8) 
e 476 (18.7) 
f 1471 (57.9) 
g 433 (17.0) 
h 305 (12.00) 
i 80 (3.15) 
j 475 (18.7) 
k 31 (1.2) 
l 433 (17.0) 
m 307 (12.1) 
n 80 (3.1) 
o 15 ° -3.7 °
p 15 ° 3.7 °
q 449 (17.7) 

W2-3-1-5
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Standard Dimensions for Arm and Boom

Connection

WDCD-02-03-001

Section C
Unit: mm (in)
ZX200-5G Class ZX200-3 Class
s 90 (3.54) 
t 354 (13.93) 352 (13.85)
u 490 (19.3) 

IMPORTANT: If the front attachment of a previous

model machine is used, use the grease intervals
for previous model machine.

WDCD-02-03-004

s- Pin Hole Inner Diameter

W2-3-1-6
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Cylinder

Rod Rod Bend and Run Out

b
a
A

W166-04-02-022
c d
W105-04-02-094 a- Cylinder Rod c- V Block
b- Dial Gauge d- 1 m (39.4 in)

Unit: mm (in) Unit: mm (in)

Cylinder Name Recommended Size After Re- Bend Run Out Remedy
manufacturing (A) 0.5 (0.020) 1.0 (0.039) Repair
Boom 85-0.012-0.027 (3.35-0.0005-0.001) 1.0 (0.039) 2.0 (0.079) Replace
Arm 95-0.012-0.027 (3.74-0.0005-0.001)
Bucket 80-0.01-0.023 (3.15-0.0004-0.0009)

W2-3-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

(Blank)

W2-3-2-2
MEMO
MEMO
SECTION 3

UPPERSTRUCTURE
CONTENTS
Group 1 Cab Group 11 Pilot Valve
Removal and Installation of Cab...............................W3-1-1-1 Removal and Installation of Pilot Valve (Left).... W3-11-1-1
Dimensions of Cab Glass..............................................W3-1-2-1 Removal and Installation of Pilot Valve
(Right)......................................................................... W3-11-2-1
Group 2 Counterweight Removal and Installation of Travel Pilot Valve... W3-11-3-1
Removal and Installation of Counterweight.........W3-2-1-1 Disassembly of Pilot Valves (Right and Left)...... W3-11-4-1
Group 3 Main Frame Assembly of Pilot Valves (Right and Left)............ W3-11-4-4
Removal and Installation of Main Frame................W3-3-1-1 Disassembly of Travel Pilot Valve............................ W3-11-5-1
Assembly of Travel Pilot Valve................................. W3-11-5-5
Group 4 Engine
Removal and Installation of Engine.........................W3-4-1-1 Group 12 Solenoid Valve
Removal and Installation of Pilot Shut-Off
Group 5 Radiator Assembly Solenoid Valve......................................................... W3-12-1-1
Replacement of Radiator, Oil Cooler, and Removal and Installation of 3-Spool
Intercooler ..................................................................W3-5-1-1 Solenoid Valve Unit................................................ W3-12-2-1
Group 6 Hydraulic Oil Tank Disassembly of Pilot Shut-Off Solenoid Valve... W3-12-3-1
Removal and Installation of Hydraulic Oil Tank...W3-6-1-1 Assembly of Pilot Shut-Off Solenoid Valve......... W3-12-3-3
Structure of 3-Spool Solenoid Valve Unit............ W3-12-4-1
Group 7 Fuel Tank
Removal and Installation of Fuel Tank.....................W3-7-1-1 Group 13 Signal Control Valve
Removal and Installation of Signal Control
Group 8 Pump Device Valve............................................................................ W3-13-1-1
Removal and Installation of Pump Device.............W3-8-1-1 Structure of Signal Control Valve........................... W3-13-2-1
Removal and Installation of Coupling.....................W3-8-2-1
Disassembly of Pump Device.....................................W3-8-3-1
Assembly of Pump Device...........................................W3-8-3-8
Disassembly of Regulator............................................W3-8-4-1
Assembly of Regulator..................................................W3-8-4-3
Disassembly of Solenoid Valve...................................W3-8-5-1
Assembly of Solenoid Valve........................................W3-8-5-3
Structure of Pilot Pump................................................W3-8-6-1
Group 9 Control Valve
Removal and Installation Control Valve..................W3-9-1-1
Disassembly of Housing...............................................W3-9-2-1
Assembly of Housing.....................................................W3-9-2-3
Disassembly of Control Valve (4-Spool Side)........W3-9-3-1
Assembly of Control Valve (4-Spool Side)..............W3-9-3-8
Disassembly of Control Valve (5-Spool Side)........W3-9-4-1
Assembly of Control Valve (5-Spool Side)..............W3-9-4-8
Group 10 Swing Device
Removal and Installation of Swing Device......... W3-10-1-1
Disassembly of Swing Device.................................. W3-10-2-1
Assembly of Swing Device....................................... W3-10-2-6
Disassembly of Swing Motor................................... W3-10-3-1
Assembly of Swing Motor......................................... W3-10-3-4

DCDW-3-1
(Blank)

DCDW-3-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Removal and Installation of Cab

6 2

5 4 1 WDAA-03-01-023

3 WDAA-03-01-047

IMPORTANT: Cap the open ends in case the hoses 4. Remove floor mat (4).
and pipes have been disconnected. In addition,
5. Remove bolts, washers (5) (4 used). Remove travel
attach an identification tag onto the connectors,
control levers (6) (2 used).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which j : 17 mm
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Open door (1).

dCAUTION: Seat (2) weight: 42 kg (93 lb)

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

l : 6 mm

W3-1-1-1
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

9 11 10 11

A Detail A

13 WDAA-03-01-051

14 12 WDAA-03-01-050

6. Remove cover (9).

7. Disconnect plug (10) and connectors (11) (2 used).
8. Remove bolt, washer (12) and screw (13). Remove
cover (14).

j : 13 mm

W3-1-1-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

15 29 26, 27, 28 68 69 33 31

A B

25

20, 21

20, 21 22, 23, 24

WDAA-03-01-052
WDAA-03-01-053
32 30
17, 18
71 70
Detail A Detail B

WDAA-03-01-062 WDAA-03-01-065
19 16, 17, 18

9. Open cover (15). 14. Remove bolts, washers (30) (2 used).

10. Remove caps (16) (2 used). Remove seals (17) (2 j : 17 mm
used) and screws (18) (3 used). Remove cover (19).
15. Remove bolt, washer (31). Remove cover (32).
11. Remove bolts, washers (20) (2 used) and washers
(21) (2 used). j : 13 mm

j : 13 mm 16. Remove screws (68) (2 used). Remove duct (69).

12. Remove caps (22) (3 used). Remove seals (23) (3 17. Remove bolt, washer (70). Remove duct (71).
used) and screws (24) (3 used). Remove cover (25).
j : 13 mm
13. Remove caps (26) (2 used). Remove seals (27) (2
used) and screws (28) (2 used). Remove cover (29)
and duct (33).

W3-1-1-3
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

A B

WDAA-03-01-063 WDAA-03-01-064

34
Detail A Detail B

34 35 34 WDAA-03-01-054 37 36 37 WDAA-03-01-055

18. Remove clip (35).

19. Disconnect connectors (34) (7 used).
20. Remove clip (36).
21. Disconnect connectors (37) (4 used).

W3-1-1-4
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

1 41

WDCD-03-01-003 WDCD-03-01-002
38 40 39 43 44

Detail A 46 45

42 79 80 WDCD-03-01-001
48 47
TDAA-05-08-006

22. Shut door (1). 28. Remove bolts, washers (43) (2 used). Remove cover
(44).
23. Open cover (38).
24. Remove filter (39). j : 17 mm

25. Remove screws (40) (6 used). Remove filter case (41). 29. Remove bolt (45). Disconnect connector (46).

26. Open engine cover (42). j : 13 mm

27. Remove bolts, washers (79) (5 used). Remove cover 30. Push the lock and shift lever (47). Disconnect
(80). connector (48).

j : 17 mm 31. Open door (1).

W3-1-1-5
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

a a 49

a - Lifting Bracket WDAA-03-01-058 73 72 WDAA-03-13-005

dCAUTION:
(930 lb)
The cab (49) assembly weight: 420 kg

32. Attach nylon slings onto lifting brackets (a) (4

places) of cab (49). Hoist and hold the cab (49)
assembly.

dCAUTION: Remove cover (72) while holding it.

Do not drop cover (72).
33. Remove bolts, washers (73) (6 used). Remove cover
(72).

j : 17 mm

W3-1-1-6
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

49 55, 56 54 55, 56 52, 53

74, 75, 76 WDAA-03-01-066 54 52, 53 54 55, 56 50, 51 55, 56

WDAA-03-01-059

34. Remove bolt (74), washer (75), and spacer (76) at the
rear side.

j : 32 mm
35. Remove socket bolts (50) (2 used) and washers (51)
(2 used).

l : 8 mm
36. Remove socket bolts (52) (5 used) and washers (53)
(5 used).

l : 8 mm
37. Remove bolts, washers (54) (5 used).

j : 17 mm
38. Remove nuts (55) (4 used) and washers (56) (4 used).
Remove the cab (49) assembly.

j : 24 mm

W3-1-1-7
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

57 60 61 62 63 Detail A 66

66

64

59
65
WDAA-03-01-061
58

64

57 60 77 62 WDAA-03-01-060

67
WDAA-03-01-067

39. Disconnect connectors (57) (5 used).

40. Remove screws (58) (4 used). Remove monitor
controller (59).
41. Remove bolt, washer (77).

j : 17 mm
42. Remove screws (60) (4 used). Disconnect connector
(61).
43. Remove screws (62) (4 used). Remove cover (63).
44. Remove bolts, washers (64) (4 used). Remove MC
(65).

j : 13 mm

dCAUTION:
(64 lb)
Bracket assembly (67) weight: 29 kg

45. Remove bolts, washers (66) (6 used). Remove

bracket assembly (67).

j : 17 mm

W3-1-1-8
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

57 60 61 62 63 Detail A 66

66

64

59
65
WDAA-03-01-061
58

64

57 60 77, 78 62 WDAA-03-01-060

67
WDAA-03-01-067

Installation

dCAUTION:
(64 lb)
Bracket assembly (67) weight: 29 kg

1. Install bracket assembly (67) with bolts, washers (66)

(6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

2. Install MC (65) with bolts, washers (64) (4 used).

j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Install cover (63) with screws (62) (4 used).
4. Connect connector (61) with screws (60) (4 used).
5. Install clamp (78) with bolt, washer (77).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

6. Install monitor controller (59) with screws (58) (4
used).
7. Connect connectors (57) (5 used).

W3-1-1-9
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

a a 49 55, 56 54 55, 56 52, 53

54 52, 53 54 55, 56 50, 51 55, 56

a - Lifting Bracket WDAA-03-01-058 WDAA-03-01-059

dCAUTION:
(930 lb)
The cab (49) assembly weight: 420 kg

8. Attach nylon slings onto lifting brackets (a) (4

places) of cab (49). Hoist the cab (49) assembly.
9. Install the cab (49) assembly with washers (56) (4
used) and nuts (55) (4 used).

j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

10. Install bolts, washers (54) (5 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

11. Install washers (53) (5 used) and socket bolts (52) (5
used).

j : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

12. Install washers (51) (2 used) and socket bolts (50) (2
used).

j : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-10
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

74, 75, 76 WDAA-03-01-066

73 72 WDAA-03-13-005

13. Install spacer (76), washer (75), and bolt (74) at the
rear side.

j : 32 mm

m : 550 N·m (55 kgf·m, 410 lbf·ft)

14. Install cover (72) with bolts, washers (73) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-11
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

1 41

WDCD-03-01-003 WDCD-03-01-002
38 40 39 43 44

Detail A 46 45

42 79 80 WDCD-03-01-001
48 47
TDAA-05-08-006

15. Connect connector (48). Shift lever (47) and lock it. 18. Install cover (80) with bolts (79) (5 used).
IMPORTANT: Do not use an impact wrench when j : 17 mm
tightening bolt (45). Using an impact wrench may
result in damage to the cover. m : 50 N·m (5 kgf·m, 37 lbf·ft)
16. Connect connector (46) with bolt (45). 19. Shut engine cover (42).
j : 13 mm 20. Open cover (38).

m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 21. Install filter case (41) with screws (40) (6 used).

17. Install cover (44) with bolts, washers (43) (2 used). 22. Install filter (39).
23. Shut cover (38).
j : 17 mm
24. Open door (1).
m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-12
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

A B

WDAA-03-01-063 WDAA-03-01-064

34
Detail A Detail B

34 35 34 WDAA-03-01-054 37 36 37 WDAA-03-01-055

25. Connect connectors (37) (4 used).

26. Install clip (36).
27. Connect connectors (34) (7 used).
28. Install clip (35).

W3-1-1-13
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

15 29 26, 27, 28 68 69 33 31

A B

25

20, 21

20, 21 22, 23, 24

WDAA-03-01-052
WDAA-03-01-053
32 30
17, 18
71 70
Detail A Detail B

WDAA-03-01-062 WDAA-03-01-065
19 16, 17, 18

29. Install duct (71) with bolt, washer (70).
j : 13 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
30. Install duct (69) with screws (68) (2 used).
31. Install cover (32) with bolt, washer (31).
j : 13 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
32. Install bolts, washers (30) (2 used).
34. Install cover (25) with screws (24) (3 used). Install
seals (23) (3 used) and caps (22) (3 used).
35. Install washers (21) (2 used) and bolts, washers (20)
(2 used).
j : 13 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
36. Open cover (15).
37. Install cover (19) with screws (18) (3 used). Install
seals (17) (2 used) and caps (16) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

33. Install duct (33) and cover (29) with screws (28) (2
used). Install seals (27) (2 used) and caps (26) (2
used).

W3-1-1-14
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

9 11 10 11

A Detail A

13 WDAA-03-01-051

14 12 WDAA-03-01-050

38. Install cover (14) with screw (13) and bolt, washer
(12).

j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

39. Connect connectors (11) (2 used) and plug (10).
40. Install cover (9).

W3-1-1-15
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

6 2

5 4 1 WDAA-03-01-023

3 WDAA-03-01-047

41. Install travel control levers (6) (2 used) with bolts,

washers (5) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

42. Install floor mat (4).

dCAUTION: Seat (2) weight: 42 kg (93 lb)

43. Install seat (2) with socket bolts (3) (4 used).

j : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

44. Close door (1).

W3-1-1-16
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Dimensions of Cab Glass

Unit: mm Section A

WDAA-03-01-036

WDAA-03-01-030

a - Black Ceramic Painted b - Black Ceramic Painted Range WDAA-03-01-001

Surface

Section B Detail C

a - Black Ceramic Painted

WDAA-03-01-035 WDAA-03-01-002
Surface

W3-1-2-1
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

WDAA-03-01-030

a - Black Ceramic Painted

WDAA-03-01-034
Surface

Section A

a - Black Ceramic Painted WDAA-03-01-037

Surface

W3-1-2-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Section A

WDAA-03-01-004

WDAA-03-01-031

a - Chamfer along the Periphery WDAA-03-01-003

W3-1-2-3
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Section A

WDAA-03-01-006

WDAA-03-01-031

a - Chamfer along the Periphery WDAA-03-01-005

W3-1-2-4
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm Section A

a - Black Ceramic Painted WDAA-03-01-038

WDAA-03-01-031 Surface
d - Shaded Paint along the
Periphery Here

a - Black Ceramic Painted c - Chamfer here. WDAA-03-01-007

Surface
b - Black Ceramic Painted Range

Section B Section C

WDAA-03-01-008 WDAA-03-01-009

W3-1-2-5
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

WDAA-03-01-031

a - Black Ceramic Painted b - Black Ceramic Painted Range WDAA-03-01-010

Surface

Section A Detail B

a - Black Ceramic Painted WDAA-03-01-038 WDAA-03-01-011

Surface
d - Dotted edge along the
Periphery Here

W3-1-2-6
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

WDAA-03-01-031

a - Black Ceramic Painted WDAA-03-01-012

Surface
b - Black Ceramic Painted Range
c - Chamfer here.

Section A Section B

a - Black Ceramic Painted WDAA-03-01-038 WDAA-03-01-008

Surface
d - Dotted edge along the
Periphery Here

W3-1-2-7
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm Section A

a - Black Ceramic Painted WDAA-03-01-038

WDAA-03-01-030 Surface
d - Shaded Paint along the
Periphery Here

a - Black Ceramic Painted WDAA-03-01-013

Surface
b - Black Ceramic Painted Range

W3-1-2-8
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedure to Remove Cab Glass

Procedures to Remove Right-Hand Glass (1), Rear Left- 1

Hand Glass (2), Lower Door Glass (3), and Rear Glass (4)

d glass,
CAUTION: When removing the broken or cracked
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. WDAA-03-01-030
1. Remove resin panel (5), garnish (6), and the spacer
around the glass.

6
2

3
5 WDAA-03-01-031

2. Prick a hole in adhesive (b) by using awl (a) (or a 7

knife). 8
a

b
W1SE-02-01-033

7 - Cab a - Awl
8 - Glass b - Adhesive

3. Pass piano wire (c) (or a metal wire) through the

hole.

c - Piano Wire W1SE-02-01-034

W3-1-2-9
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

IMPORTANT: The piano wire is easily broken if a part

of the piano wire turns hot. Change the position 7 a
and cut the adhesive.
4. Wind the both ends of the piano wire onto the 8
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).

fNOTE: Cut off the middle of adhesive between glass

and cab. b
c

a - Cab Outside W1SE-02-01-035

b - Adhesive
c - Cab Inside

W3-1-2-10
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedure to Install Cab Glass

Procedures to Install Right-Hand Glass (1), Rear Left-Hand 1

Glass (2), Lower Door Glass (3), and Rear Glass (4)

1. Cut off the residual adhesive from the cab (7) side
by 1 to 2 mm deep all around by using a knife or
similar.

fNOTE: Do not damage the cab (7) paint.

WDAA-03-01-030

3
2 WDAA-03-01-031
2. Clean the cutting edge of adhesive at cab (7) side by
using white spirit. 7

W1SE-02-01-036
IMPORTANT: Primer should be shaken for about 1
minute and mix thoroughly before opening the a - Knife b - Cut off adhesive by 1 to 2 mm
cap. After opening Primer, apply Primer as quickly deep.
as possible and close the cap immediately after
using. After opening Primer, all the contents
should be used within 180 days (or 2 hours with
the cap off). 7
3. Apply Primer for paint (Sika Aktivator DM-1) to the c
cutting edge of adhesive at cab (7) side by using a
brush. Wait for about 15 minutes in order to let it d
dry by itself.

W1SE-02-01-038

c - Apply Primer by using a d - Cutting edge of adhesive at

brush. cab (7) side

W3-1-2-11
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

4. Clean the mating edge of the new glass by using

clean rag and ethyl alcohol.

IMPORTANT: Primer (Sika Primer 206G+P) should

be shaken for about 1 minute and mix thoroughly
before opening the cap. After opening Primer,
apply Primer as quickly as possible and close
the cap immediately after using. After opening
Primer, all the contents should be used within 180
days (or 2 hours with the cap off).
5. Apply Primer for glass (Sika Primer 206G+P) to the
cutting edge of adhesive at cab side by using a
brush. Wait for about 15 minutes in order to let it
dry by itself.
6. Install the spacer with facing to the glass surface by
using the instant adhesive. (As for the positions to
install spacers A, B, and C dam rubber, refer to W3-1-
2-14 to W3-1-2-16.)
7. Cut off the nozzle of adhesive cartridge (Sika Tack
Go!) into V-shaped by using a knife. (As for the
cutting procedure of nozzle, refer to W3-1-2-17.)
8. Remove the seal of the cartridge end. Install the
V-shaped nozzle.
9. Install the cartridge to the manual coking gun.
10. Apply adhesive to the adhesive position at cab side
so that the bead triangle may be even. (As for the
position to apply adhesive, refer to W3-1-2-17.)
11. Raise the glass by using the suction lifter (rubber
sucker 4355282), and adhere it to the cab within 5
minutes.

fNOTE: Install the glass while fitting the spacer position

on the glass. Remove all adhesive except the mounting
surface, before solidifying by using white spirit.
12. Secure the glass by using the duct tape until the
adhesive becomes solid in order to prevent them
from being mispositioned or coming off. (Refer to
W3-1-2-13.)

fNOTE: Time for adhesive (Sika Tack Go!) to become

solid: 8 hours (just for reference)

W3-1-2-12
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Rear Glass Right-Hand Glass

WDAA-03-01-039

Rear Left-Hand Glass

WDAA-03-01-040

Lower Door Glass

WDAA-03-01-041 WDAA-03-01-042

Spacer A Spacer B Spacer C

WDAA-03-01-043 WDAA-03-01-044 WDAA-03-01-045

a - Two-Side Adhesive Tape a - Two-Side Adhesive Tape

Dam Rubber

WDAA-03-01-046

W3-1-2-13
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Left-Hand Glass

1 - Spacer A a - From Radius Curve End

WDAA-03-01-014
2 - Dam Rubber b - Glass External Form Line
3 - Stopper c - Adhesive Range

Section A Section B Section C

WDAA-03-01-017 WDAA-03-01-018 WDAA-03-01-019

d - Clearance between glass and panel: 6 mm e - Glass e - Glass
e - Glass

Section D Detail E

WDAA-03-01-020 WDAA-03-01-024
e - Glass f - Apply Super X.

W3-1-2-14
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Right-Hand Glass

1 - Spacer A a - From Radius Curve End WDAA-03-01-016

2 - Spacer C b - Glass External Form Line
3 - Dam Rubber c - Adhesive Range

Section A Section B Section C

WDAA-03-01-022 WDAA-03-01-027 WDAA-03-01-028

e - Glass d - Glass and panel: Clearance OR-02: 8 mm a - From Radius Curve End
e - Glass e - Glass

W3-1-2-15
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Rear Glass

Section A

WDAA-03-01-021

a - From Radius Curve End

e - Glass

WDAA-03-01-015

1 - Spacer B b - Glass External Form Line

a - From Radius Curve End c - Adhesive Range

Section B Section C

WDAA-03-01-025 WDAA-03-01-026

d - Glass and panel: Clearance e - Glass

OR-02: 8 mm
e - Glass

W3-1-2-16
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

8~9 mm

a
13~15 mm
b

W1SE-02-01-027
12
W1SE-02-01-043
b - Cut nozzle end into V-shaped. f
W1JB-02-01-031
a - Apply adhesive (bead) here. e - Apply bead so that bead triangle may be
even.
f - Panel

W1SE-02-01-028

c - Remove the seal.

d - Adhesive Cartridge

13. The required amount (just for reference) of adhesive and primer

Painted Surface or Glass Surface

Adhesive Surface
Adhesive Primer Primer
Sika Tack Go! Sika Aktivator DM-1 Sika Primer 206G+P
(Sika Tack Go!) (Sika Aktivator DM-1) (Sika Primer-206G+P)

310 ml Cartridge 250 ml Can 30 ml Bottle

Lower Door Glass 170 ml 0.6 ml 0.5 ml
Rear Left-Hand Glass 220 ml 0.55 ml 0.5 ml
Rear Right-Hand Glass 105 ml 1 ml 0.9 ml
Rear Glass 205 ml 0.5 ml 0.45 ml

W3-1-2-17
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedures to Install Upper Door Glass

1. Before installing the glass, remove garnish (2) 1
around sash assembly (1) from the cab inside for
easy removal. Push sash assembly (1) by hands and
remove the sash outside.
2

2. Install glass A (3) and glass B (4) into the sash

grooves.

3 4
WDAA-03-01-031
3. Install sash assembly (1) onto the door from the
outside of cab. Secure sash assembly (1) at the
inside of cab by using garnish (2).

W3-1-2-18
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedures to Install Upper Front Glass

1. Stick the seal to the lower side of the front upper

glass by using Cemedine Super X.
Stick and secure both right and left ends (the thicker
part) of the seal to the glass by using adhesive.
Stick the mating surface of seal (1) and the glass
by using Cemedine Super X so that no visible
undulation or boss can be found.

fNOTE: Cemedine Super X No. 8008

Glue-state adhesive, tubed
Cemedine 366 Deluxe
IMPORTANT: The front glass is arched-fringed. When
replacing the glass, contact with the nearest
HITACHI Office and replace it as an assembly.

WDAA-03-01-029

Detail A (Inside) Detail A (Outside)

WDAA-03-01-032 WDAA-03-01-033

a - Cemedine Super X No. 8008 a - Cemedine Super X No. 8008

b - Cemedine 366 Deluxe b - Cemedine 366 Deluxe
c - Fill seal for the inside of installation point here. e - No gap between drainage and wedge
d - Do not apply seal to this groove.

W3-1-2-19
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

(Blank)

W3-1-2-20
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

Removal and Installation of Counterweight

5

1 2 3

4
9 8

7
7 6
WDCD-03-02-003
6
WDCD-03-02-002

Removal
1. Set the machine position for inspection and
dCAUTION: Counterweight (4) weight:
maintenance. (Refer to W1-6-1.) ZX200-5G, 200LC-5G: 4260 kg (9400 lb)
2. Open the engine cover. ZX210H-5G, 210LCH-5G: 4670 kg (10300 lb)
3. Remove bolts, washers (8) (2 used). Remove cover ZX210K-5G, 210LCK-5G: 5480 kg (12100 lb)
(9). 6. Remove caps (5) (2 used). Install Freno-Linkbolts
(B-42: M42, Pitch: 4.5 mm) (2 used) to the cap (5)
j : 17 mm mounting hole (2 places). Attach wire ropes onto
4. Disconnect connector (1). the Freno-Linkbolts. Hoist and hold counterweight
(4).
5. Remove bolts, washers (2) (4 used). Remove the
rearview camera (3) assembly. 7. Remove bolts (6) (4 used) and washers (7) (4 used).
Remove counterweight (4).
j : 17 mm
j : 46 mm

W3-2-1-1
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

1 2 3

4
9 8

7
7 6
WDCD-03-02-003
6
WDCD-03-02-002

Installation 4. Install the rearview camera (3) assembly with bolts,

washers (2) (4 used).
dCAUTION: Counterweight (4) weight: j : 17 mm
ZX200-5G, 200LC-5G: 4260 kg (9400 lb)
ZX210H-5G, 210LCH-5G: 4670 kg (10300 lb) m : 50 N·m (5 kgf·m, 37 lbf·ft)

ZX210K-5G, 210LCK-5G: 5480 kg (12100 lb) 5. Connect connector (1).

1. Install Freno-Linkbolts (B-42: M42, Pitch: 4.5 mm) 6. Install cover (9) with bolts, washers (8) (2 used).
(2 used) to the cap (5) mounting hole (2 places).
Attach wire ropes onto the Freno-Linkbolts. Hoist j : 17 mm
counterweight (4).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
2. Install counterweight (4) with washers (7) (4 used)
7. Shut the engine cover.
and bolts (6) (4 used).

j : 46 mm

m : 1570 N·m (157 kgf·m, 1160 lbf·ft)

3. Remove the Freno-Linkbolts (2 used) from the cap
(5) mounting hole (2 places). Install caps (5) (2 used).

W3-2-1-2
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

Removal and Installation of Main Frame

3 4 1

WDCD-03-03-001

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove cab (1). (Refer to W3-1-1.)
3. Remove counterweight (2). (Refer to W3-2-1.)
4. Remove front attachment (3). (Refer to W5-1-1.)
5. Remove boom cylinder (4). (Refer to W5-2-1.)

W3-3-1-1
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

12

WDAA-03-03-002 WDCD-03-03-002

a - Counterweight Mounting b - Boom Mounting Bracket Hole

Part

6. Place a container under center joint (5). Disconnect

hoses (6) (4 used). dCAUTION: Main frame (12) weight:
j : 36 mm ZX200-5G, 200LC-5G: 4620 kg (10200 lb)
7. Disconnect hose (7). ZX210H-5G, 210LCH-5G: 4780 kg (10600 lb)
j : 27 mm
ZX210K-5G, 210LCK-5G: 4880 kg (10800 lb)
10. Attach wire ropes onto counterweight mounting
8. Disconnect hose (8). part (a) (2 places) of the main frame (12) rear side
and boom mounting bracket hole (b) (2 places).
j : 17 mm
9. Remove bolts (9) (2 used) and spring washers (10) (2
used). Remove stopper (11).

j : 22 mm

W3-3-1-2
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

12 13

15, 16

14
WDAB-03-03-003

11. Reduce slack of wire ropes by using a chain block.

Put the matching marks onto main frame (12) and
outer race (13) of the swing bearing.
12. Remove bolts (14) (32 used), bolts (15) (5 used), and
spacers (16) (5 used).

j : 30 mm
13. Adjust the chain block in order to level main frame
(12). Hoist and remove main frame (12).

W3-3-1-3
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

12 13

15, 16

12

14
WDCD-03-03-002 WDAB-03-03-003

a - Counterweight Mounting b - Boom Mounting Bracket Hole

Part

Installation 3. Fit the matching marks made when disassembling

and install main frame (12) to outer race (13) of the
dCAUTION: Main frame (12) weight: swing bearing. Install spacers (16) (5 used), bolts
ZX200-5G, 200LC-5G: 4620 kg (10200 lb) (15) (5 used), and bolts (14) (32 used).

ZX210H-5G, 210LCH-5G: 4780 kg (10600 lb) j : 30 mm

ZX210K-5G, 210LCK-5G: 4880 kg (10800 lb) m : 510 N·m (51 kgf·m, 380 lbf·ft)
1. Attach wire ropes onto counterweight mounting
part (a) (2 places) of the main frame (12) rear side
and boom mounting bracket hole (b) (2 places).
2. Adjust the chain block in order to level main frame
(12).

W3-3-1-4
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

WDAA-03-03-005

4. Install stopper (11) with spring washers (10) (2 used)

and bolts (9) (2 used).

j : 22 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

5. Connect hose (8).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

6. Connect hose (7).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

7. Connect hoses (6) (4 used).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

W3-3-1-5
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

3 4 1

WDCD-03-03-001

8. Install boom cylinder (4). (Refer to W5-2-1.)

9. Install front attachment (3). (Refer to W5-1-1.)
10. Install counterweight (2). (Refer to W3-2-1.)
11. Install cab (1). (Refer to W3-1-1.)
12. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.

W3-3-1-6
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

Removal and Installation of Engine

112, 113, 114

1
2

WDCD-03-04-019 WDCD-03-04-009

IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts, washers (112) (6 used). Remove the
and pipes have been disconnected. In addition, cover (113) assembly and O-ring (114) from the top
attach an identification tag onto the connectors, of hydraulic oil tank.
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which j : 17 mm
secure the hoses have been removed. 6. Place a container. Drain off hydraulic oil by using an
oil feed pump.
Removal
1. Set the machine position for inspection and
fNOTE: Total oil amount of hydraulic oil tank: 201 L (53.1
US gal)
maintenance. Close the fuel cock. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open covers (1, 2).
3. Remove wing nuts (3) (4 used) and washers (4) (4
used). Remove covers (5) (2 used).
4. Remove bolt (6) and washer (7). Disconnect ground
(8).

j : 17 mm

W3-4-1-1
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

9 13 11 Detail A
118 115, 116 117

10
WDCD-03-04-019 WDDE-03-04-002

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

dCAUTION: Engine cover (9) weight: 31 kg (69 lb) washers (12) (2 used). Remove cover (13).
7. Attach nylon slings onto engine cover (9). Hoist and
hold engine cover (9). j : 17 mm

8. Remove pins (115) (2 used) and washers (116) (2

used). Remove the support (118) side of stopper
(117).
9. Remove bolts, washers (10) (4 used) from the inside
of engine cover (9). Remove engine cover (9).

j : 17 mm

W3-4-1-2
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

WDCD-03-04-005

Detail A

WDCD-03-04-004

34 35 WDCD-03-04-006

11. Remove bolt (14) and washer (15). Disconnect 16. Remove pins (27) (2 used). Remove cover (28).
terminal (16).
17. Remove bolts, washers (29, 30) (2 used for each).
j : 17 mm Remove cover (31).

12. Remove bolt (17) and washer (18). Disconnect j : 17 mm

terminal (19).
18. Remove bolts, washers (32) (2 used). Remove cover
j : 17 mm (33).

13. Remove bolt (20) and washer (21). Disconnect j : 17 mm

terminal (22).
19. Place a container under hose (34). Loosen cock (35).
j : 17 mm Drain off coolant.

dCAUTION: Battery (24) weight: 28 kg (62 lb) fNOTE: Coolant amount: 26 L (6.87 US gal)
14. Remove bolts, washers (23) (2 used). Remove
batteries (24) (2 used).

j : 17 mm
15. Open stoppers (25) (2 used). Remove net (26).

W3-4-1-3
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

46 45 52 43 50 49 51 41 40

39
WDCD-03-04-015 44 42 55 53, 54 WDCD-03-04-003

20. Remove bolts, washers (45) (2 used). Remove cover 26. Remove nuts (49) (4 used). Disconnect exhaust pipe
(46). (50).
21. Remove counterweight (38). (Refer to W3-2-1.) j : 13 mm
22. Open cover (39).
23. Remove bolts, washers (40) (2 used).
dCAUTION:
kg (56 lb)
The muffler (52) assembly weight: 25

27. Attach nylon slings onto muffler (52). Hoist and hold
j : 17 mm
the muffler (52) assembly.
24. Remove bolts, washers (41) (5 used). Remove cover
28. Remove bolts (53) (3 used) and spring washers (54)
(42).
(3 used). Remove the muffler (52) assembly and
j : 17 mm gasket (51).
25. Remove bolts, washers (43) (3 used). Remove cover j : 17 mm
(44).
29. Remove pump device (55). (Refer to W3-8-1.)
j : 17 mm 30. Remove the coupling of the engine. (Refer to W3-
8-2.)

W3-4-1-4
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

Detail A

WDCD-03-04-008

WDCD-03-04-007

31. Disconnect connector (56) and terminals (57) (3 36. Remove clamps (68) (2 used). Disconnect the
used). radiator side of hose (69) and the engine side of
hose (70).
32. Remove bolts, washers (58) (4 used). Remove
bracket (59). 37. Remove bolts, washers (71) (2 used). Remove the
pipe (72) assembly.
j : 17 mm
j : 17 mm
33. Remove clamps (60, 61). Disconnect the radiator
side of hose (62) and the engine side of hose (63). 38. Remove clamps (73) (2 used). Disconnect hose (74).
34. Remove bolts, washers (64) (2 used). Remove the
pipe (65) assembly.

j : 17 mm
35. Remove clamps (66) (2 used). Disconnect hose (67).

W3-4-1-5
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

77 78 79 75 76 80
WDCD-03-04-010 WDCD-03-04-011

39. Remove bolts, washers (75) (2 used). Remove cover 42. Remove clamps (81, 82). Remove bolts, washers (83)
(76). (2 used). Remove the duct (84) assembly.

j : 13 mm j : 17 mm
40. Remove bolts, washers (77) (5 used). Remove cover 43. Remove band (85). Remove rubber (86).
(78).

j : 17 mm
41. Remove bolts, washers (79) (7 used). Remove cover
(80).

j : 17 mm

W3-4-1-6
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

94 91, 92

93 87 88 89, 90 WDCD-03-04-012

44. Disconnect cables (87, 88).

45. Remove clips (89) (2 used). Disconnect hoses (90) (2
used).
46. Remove clips (91) (2 used). Disconnect hoses (92) (2
used).
47. Disconnect hoses (93) (2 used).

j : 36 mm
48. Disconnect terminal (94).

W3-4-1-7
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

96 95 97 98

b c
WDCD-03-04-020

a- 8 to 12 mm (0.31 to 0.47 in), b- Crank Pulley

100 N (10 kgf, 23 lbf ) c- Compressor Pulley
119, 120, 121

108
109
110
WDCD-03-04-013 M1G6-07-013
102 99, 100, 101

49. Disconnect connector (95). 55. Remove bolts (99, 119) (2 used for each), spring
washers (100, 120) (2 used for each), and washers
50. Disconnect terminals (96) (2 used).
(101, 121) (2 used for each). Place the compressor
51. Disconnect connector (97). (102) assembly horizontally.
52. Disconnect terminals (98) (2 used). j : 17 mm
53. Loosen lock bolt (109) of tension pulley (108).
54. Release the belt tension by moving tension pulley
(108) by using adjusting bolt (110).

W3-4-1-8
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

a 103 a

104, 105 106, 107

a- Lifting Bracket WDCD-03-04-014

59. Hoist engine (103) by 15 mm.

d CAUTION: Engine (103) weight: 490 kg (1090 lb)
60. Move engine (103) to the pump device mounting
56. Install shackles to lifting brackets (a) (2 places) of
side by 50 mm. Remove engine (103).
engine (103). Attach nylon slings onto the shackles.
Hoist and hold engine (103). 61. Remove the adapter with engine (103) attached if
necessary.
57. Remove nuts (104) (2 used) and washers (105)
(2 used) from the front attachment side and
counterweight side of engine (103).

j : 22 mm
58. Remove bolts (106) (2 used) and washers (107)
(2 used) from the front attachment side and
counterweight side of engine (103).

j : 27 mm

W3-4-1-9
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

a 103 a

104, 105 106, 107

a- Lifting Bracket WDCD-03-04-014

Installation 4. Install engine (103) with washers (105) (2 used) and

nuts (104) (2 used).
1. Install all removed adapters to engine (103).
j : 22 mm
dCAUTION: Engine (103) weight: 490 kg (1090 lb)
2. Install shackles to lifting brackets (a) (2 places) of m : 140 N·m (14 kgf·m, 103 lbf·ft)
engine (103). Attach nylon slings onto the shackles.
Hoist engine (103).
3. Install engine (103) with washers (107) (2 used) and
bolts (106) (2 used).

j : 27 mm

m : 360 N·m (36 kgf·m, 265 lbf·ft)

W3-4-1-10
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

96 95 97 98

b c
WDCD-03-04-020

a- 8 to 12 mm (0.31 to 0.47 in), b- Crank Pulley

100 N (10 kgf, 23 lbf ) c- Compressor Pulley
119, 120, 121

108
109
110
WDCD-03-04-013 M1G6-07-013
102 99, 100, 101

5. Install the compressor (102) assembly with washers
(101, 121) (2 used for each), spring washers (100,
120) (2 used for each), and bolts (99, 119) (2 used for
each).
9. Connect terminals (98) (2 used).
10. Connect connector (97).
11. Connect terminals (96) (2 used).

j : 17 mm 12. Connect connector (95).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

6. Loosen lock bolt (109) of tension pulley (108).
7. Adjust the belt tension by moving tension pulley
(108) by using adjusting bolt (110).
8. Tighten lock bolt (109) of tension pulley (108).
IMPORTANT: The belt does not fit when replacing
with a new one. Therefore, adjust the belt tension
again after running the engine at slow idle for 3 to
5 minutes.

W3-4-1-11
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

94 91, 92

93 87 88 89, 90 WDCD-03-04-012

13. Connect terminal (94).

14. Connect hoses (93) (2 used).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

15. Connect hoses (92) (2 used) with clips (91) (2 used).
16. Connect hoses (90) (2 used) with clips (89) (2 used).
17. Connect cables (88, 87).

W3-4-1-12
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

77 78 79 75 76 80
WDCD-03-04-010 WDCD-03-04-011

18. Install rubber (86) with band (85).
19. Install the duct (84) assembly with bolts, washers
(83) (2 used) and clamps (82, 81).
j : 17 mm
22. Install cover (76) with bolts, washers (75) (2 used).
j : 13 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

20. Install cover (80) with bolts, washers (79) (7 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

21. Install cover (78) with bolts, washers (77) (5 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-13
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

Detail A

WDCD-03-04-008

WDCD-03-04-007

23. Connect hose (74) with clamps (73) (2 used). 29. Install bracket (59) with bolts, washers (58) (4 used).
24. Install the pipe (72) assembly with bolts, washers j : 17 mm
(71) (2 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
30. Connect terminals (57) (3 used) and connector (56).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
25. Connect the engine side of hose (70) and the
radiator side of hose (69) with clamps (68) (2 used).
26. Connect hose (67) with clamps (66) (2 used).
27. Install the pipe (65) assembly with bolts, washers
(64) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

28. Connect the engine side of hose (63) and the
radiator side of hose (62) with clamps (61, 60).

W3-4-1-14
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

52 43 50 49 51 41 40, 108

39
WDCD-03-04-002 44 42 55 53, 54 WDCD-03-04-003

31. Install the coupling of the engine. (Refer to W3-8-2.) 36. Install cover (44) with bolts, washers (43) (3 used).
32. Install pump device (55). (Refer to W3-8-1.) j : 17 mm

dCAUTION:
kg (56 lb)
The muffler (52) assembly weight: 25 m : 50 N·m (5 kgf·m, 37 lbf·ft)
37. Install cover (42) with bolts, washers (41) (5 used).
33. Attach nylon slings onto muffler (52). Hoist the
muffler (52) assembly. j : 17 mm
34. Install the muffler (52) assembly with spring
m : 50 N·m (5 kgf·m, 37 lbf·ft)
washers (54) (3 used) and bolts (53) (3 used).
38. Install clamps (108) (2 used) with bolts, washers (40)
j : 17 mm (2 used).
m : 65 N·m (6.5 kgf·m, 48 lbf·ft) j : 17 mm
35. Connect gasket (51) and exhaust pipe (50) with nuts
m : 50 N·m (5 kgf·m, 37 lbf·ft)
(49) (4 used).
39. Shut cover (39).
j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-4-1-15
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

WDCD-03-04-016

WDCD-03-04-004

40. Install cover (33) with bolts, washers (32) (2 used). 45. Connect terminal (22) with washer (21) and bolt
(20).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 20 N·m (2 kgf·m, 15 lbf·ft)
41. Install cover (31) with bolt, washer (29, 30) (2 used
for each). 46. Connect terminal (19) with washer (18) and bolt
(17).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 20 N·m (2 kgf·m, 15 lbf·ft)
42. Install cover (28) with pins (27) (2 used).
47. Connect terminal (16) with washer (15) and bolt
43. Install net (26). Close stoppers (25) (2 used).
(14).
dCAUTION: Battery (24) weight: 28 kg (62 lb)
j : 17 mm
44. Install batteries (24) (2 used) with bolts, washers (23)
(2 used). m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-4-1-16
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

112, 113, 114

WDCD-03-04-019 WDCD-03-04-009

48. Connect ground (8) with washer (7) and bolt (6). 52. Install O-ring (114).

j : 17 mm 53. Install the cover (113) assembly to the top of

hydraulic oil tank with bolts, washers (112) (6 used).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
j : 17 mm
49. Install covers (5) (2 used) with washers (4) (4 used)
and wing nuts (3) (4 used). m : 50 N·m (5 kgf·m, 37 lbf·ft)
50. Add coolant to the radiator. 54. Bleed air from the fuel system. (Refer to W1-4-1.)
51. Fill hydraulic oil to the hydraulic oil tank. 55. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
fNOTE: Total oil amount of hydraulic oil tank: 201 L (53.1
IMPORTANT: Check the hydraulic oil level. Start the
US gal)
engine and check for any oil leaks.

W3-4-1-17
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

Detail A

9 12 13 11 38
46 45
WDCD-03-04-017

B Detail B
A
118 115, 116 117

1
2
10
WDCD-03-04-001

WDDE-03-04-002

56. Install counterweight (38). (Refer to W3-2-1.)

57. Install cover (46) with bolts, washers (45) (2 used).
dCAUTION: Engine cover (9) weight: 31 kg (69 lb)
59. Attach nylon slings onto engine cover (9). Hoist
j : 17 mm engine cover (9).
60. Install engine cover (9) with bolts, washers (10) (4
m : 50 N·m (5 kgf·m, 37 lbf·ft)
used).
58. Install cover (13) with bolts, washers (12) (2 used)
and bolts, washers (11) (8 used). j : 17 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

61. Install the support (118) side of stopper (117) with
m : 50 N·m (5 kgf·m, 37 lbf·ft)
washers (116) (2 used) and pins (115) (2 used).
62. Shut covers (2, 1).

W3-4-1-18
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

Replacement of Radiator, Oil Cooler, and

Intercooler

1
2

WDCD-03-04-019 WDCD-03-04-009

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open covers (1, 2).
3. Remove wing nuts (3) (4 used) and washers (4) (4
used). Remove covers (5) (2 used).
4. Remove bolt (6) and washer (7). Disconnect ground
(8).

j : 17 mm

W3-5-1-1
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

76 77 9 Detail A
72 11, 12 13

10
WDCD-03-04-019 WDDE-03-04-002

7. Remove bolts, washers (10) (4 used) from the inside

dCAUTION: Engine cover (9) weight: 31 kg (69 lb) of engine cover (9). Remove engine cover (9).
5. Attach nylon slings onto engine cover (9). Hoist and
hold engine cover (9). j : 17 mm

6. Remove pins (11) (2 used) and washers (12) (2 used). 8. Remove bolts, washers (76) (5 used). Remove cover
Remove the support (72) side of stopper (13). (77).

j : 17 mm

W3-5-1-2
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

WDCD-03-04-005

Detail A

WDCD-03-04-004

34 35 WDCD-03-04-006

9. Remove bolt (14) and washer (15). Disconnect 14. Remove pins (27) (2 used). Remove cover (28).
terminal (16).
15. Remove bolts, washers (29, 30) (2 used for each).
j : 17 mm Remove cover (31).

10. Remove bolt (17) and washer (18). Disconnect j : 17 mm

terminal (19).
16. Remove bolts, washers (32) (2 used). Remove cover
j : 17 mm (33).

11. Remove bolt (20) and washer (21). Disconnect j : 17 mm

terminal (22).
17. Bleed air from radiator. (Refer to W1-4-1.)
j : 17 mm 18. Place a container under hose (34). Loosen cock (35).
12. Remove bolts, washers (23) (2 used). Remove Drain off coolant.
batteries (24) (2 used).
fNOTE: Coolant amount: 26 L (6.87 US gal)
j : 17 mm
13. Open stoppers (25) (2 used). Remove net (26).

W3-5-1-3
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

42 44

43 45

37 36 WDCD-03-05-001

39 41
Detail A 74 73
38 40 WDCD-03-05-002

WDCD-03-05-017

21. Remove clamps (42, 43). Disconnect the radiator

dCAUTION: Remove cover (36) while holding it.
Do not drop cover (36).
side of hoses (44, 45).

19. Remove bolts, washers (37) (7 used). Remove cover dCAUTION: Remove cover (73) while holding it.
Do not drop cover (73).
(36).
22. Remove bolts, washers (74) (2 used). Remove cover
j : 17 mm (73).
20. Remove clamps (38, 39). Disconnect the radiator
j : 17 mm
side of hoses (40, 41).

W3-5-1-4
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

50 52 46, 47 49 58 56

51

48
51

49

57 55
75 54 53 WDCD-03-05-014 WDCD-03-05-015

23. Remove clamp (46). Disconnect hose (47).
24. Remove clips (48) (2 used).
25. Remove bolts, washers (50) (2 used) and bolts,
washers (51) (4 used). Remove the cover (52)
assembly.
j : 17 mm
26. Remove bolts, washers (49) (3 used). Remove the
cover (75) assembly.
27. Remove bolts, washers (53) (7 used). Remove cover
(54).
j : 17 mm
28. Place a container under the disconnecting part
of pipes (55, 56). Remove couplings (57, 58).
Disconnect the oil cooler side of pipes (55, 56).
j : 17 mm

j : 17 mm

W3-5-1-5
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

Detail A
71 c
65 66 A 63
62 a
63 b
69

WDCD-03-05-018

a- Lifting Hole
b- Lifting Hole
64 c- Eyebolt Mounting Hole

70 59 60 67 61 68

WDCD-03-05-012

29. Install shackles (2 used) to lifting holes (a) (2 places)
of radiator (62). Attach nylon slings onto shackles.
Hoist and hold radiator (62).
30. Remove bolts (59) (4 used), rubbers (60) (4 used),
and collars (61) (4 used). Remove radiator (62).
j : 13 mm
31. Remove packings (63, 64) (2 used for each) from
radiator (62).
33. Remove bolts (65) (2 used), rubbers (66, 67), and
collars (68) (2 used). Remove intercooler (69).
j : 13 mm
dCAUTION: Oil cooler (71) weight: 26 kg (58 lb)
34. Install eyebolts (M8, Pitch 1.25 mm) (3 used) to
eyebolt mounting holes (c) (3 places) of oil cooler
(71). Attach nylon slings onto the eyebolts. Hoist
and hold oil cooler (71).

j : 13 mm 35. Remove bolts, washers (70) (6 used). Move oil cooler

(71) to the radiator (62) side. Remove oil cooler (71).
32. Install shackles to lifting hole (b) of intercooler (69).
Attach nylon slings onto shackles. Hoist and hold j : 14 mm
intercooler (69).

W3-5-1-6
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

Detail A
71 c
65 66 A 63
62 a
63 b
69

WDCD-03-05-018

a- Lifting Hole
b- Lifting Hole
64 c- Eyebolt Mounting Hole

70 59 60 67 61 68

WDCD-03-05-012

Installation 4. Install intercooler (69) with collars (68) (2 used),

dCAUTION: Oil cooler (71) weight: 26 kg (58 lb)
1. Install eyebolts (M8, Pitch 1.25 mm) (3 used) to
eyebolt mounting holes (c) (3 places) of oil cooler
(71). Attach nylon slings onto the eyebolts. Hoist oil
cooler (71).
2. Install oil cooler (71) with bolts, washers (70) (6
used).
j : 14 mm
m : 36 N·m (3.6 kgf·m, 26.5 lbf·ft)
3. Install shackles to lifting hole (b) of intercooler (69).
Attach nylon slings onto shackles. Hoist intercooler
(69).
rubbers (66, 67), and bolts (65) (2 used).
j : 13 mm
m : 18 N·m (1.8 kgf·m, 13.5 lbf·ft)
5. Install packings (64, 63) (2 used for each) to radiator
(62).
6. Install shackles (2 used) to lifting holes (a) (2 places)
of radiator (62). Attach nylon slings onto shackles.
Hoist radiator (62).
7. Install radiator (62) with collars (61) (4 used), rubbers
(60) (4 used), and bolts (59) (4 used).
j : 13 mm
m : 18 N·m (1.8 kgf·m, 13.5 lbf·ft)

W3-5-1-7
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

50 52 46, 47 49 58 56

51

48
51

49

57 55
75 54 53 WDCD-03-05-014 WDCD-03-05-015

8. Connect pipes (56, 55) with couplings (58, 57). 11. Install the cover (52) assembly with bolts, washers
(51) (4 used) and bolts, washers (50) (2 used).
j : 13 mm
j : 17 mm
m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
9. Install cover (54) with bolts, washers (53) (7 used).
12. Install hose (47) with clamp (46).
j : 17 mm
13. Install clips (48) (2 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
10. Install the cover (75) assembly with bolts, washers
(49) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-8
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

42 44

43 45

39 41

38 40 WDCD-03-05-002 WDCD-03-05-016

14. Connect the radiator side of hoses (45, 44) with 17. Install cover (33) with bolts, washers (32) (2 used).
clamps (43, 42).
j : 17 mm
15. Connect the radiator side of hoses (41, 40) with
clamps (39, 38). m : 50 N·m (5 kgf·m, 37 lbf·ft)
16. Add coolant to the radiator. 18. Install cover (31) with bolts, washers (30, 29) (2 used
for each).
fNOTE: Coolant amount: 26 L (6.87 US gal)
j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

19. Install cover (28) with pins (27) (2 used).

W3-5-1-9
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

WDCD-03-04-004 WDCD-03-04-009

20. Install batteries (24) (2 used) with bolts, washers (23) 24. Connect ground (8) with washer (7) and bolt (6).
(2 used).
j : 17 mm
21. Connect terminal (22) with washer (21) and bolt
(20). m : 20 N·m (2 kgf·m, 15 lbf·ft)

j : 17 mm 25. Install covers (5) (2 used) with washers (4) (4 used)

and wing nuts (3) (4 used).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
26. Install net (26). Close stoppers (25) (2 used).
22. Connect terminal (19) with washer (18) and bolt
(17).

j : 17 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

23. Connect terminal (16) with washer (15) and bolt
(14).

j : 17 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-5-1-10
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

Detail A 74 73

WDCD-03-05-017

37 36 WDCD-03-05-001

27. Bleed air from the hydraulic system. (Refer to W1-4-

1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
28. Install cover (73) with bolts, washers (74) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

29. Install cover (36) with bolts, washers (37) (7 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-11
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator Assembly

76 77 9 Detail A
72 11, 12 13

1
2
10
WDCD-03-04-019 WDDE-03-04-002

30. Install cover (77) with bolts, washers (5 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
33. Install the support (13) side of stopper (72) with
washers (12) (2 used) and pins (11) (2 used).
34. Close covers (2, 1).

dCAUTION: Engine cover (9) weight: 31 kg (69 lb)

31. Attach nylon slings onto engine cover (9). Hoist
engine cover (9).
32. Install engine cover (9) with bolts, washers (10) (4
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-12
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

Removal and Installation of Hydraulic Oil

Tank

1 3, 4 WDCD-03-06-001

dCAUTION: Escaping fluid under pressure may

penetrate the skin and eyes, and cause serious
dCAUTION: Bleed air from hydraulic oil tank (1).
(Refer to W1-4-1.)
injury. Release the pressure before disconnecting 2. Remove bolts, washers (2) (6 used). Remove the
the hydraulic pipings or removing other cover (3) assembly and O-ring (4) from the upper
equipment. Hot hydraulic oil just after operation part of hydraulic oil tank (1).
may spout out and cause severe burns. Wait for oil
in order to cool before starting any work. Do not j : 17 mm
turn the cap of hydraulic oil tank (1) quickly. The
3. Place a container. Drain off hydraulic oil by using an
cap may fly off by internal pressure. Release any
oil feed pump.
remaining pressure and remove the cap.
fNOTE: Hydraulic oil tank (1) capacity: 201 L (53.1 US
IMPORTANT: Cap the open ends in case the hoses gal)
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

W3-6-1-1
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

5 10 9 8 11 13 12

WDCD-03-06-002 15 14 WDCD-03-06-003
6 7

4. Open cover (5). 7. Remove bolts, washers (10) (2 used).

dCAUTION: Remove cover (7) while holding it. Do

not drop cover (7).
j : 17 mm
8. Open engine cover (11).
5. Remove bolts, washers (6) (6 used). Remove cover
(7). 9. Remove bolts, washers (12) (5 used). Remove cover
(13).
j : 17 mm
j : 17 mm
d CAUTION: Remove cover (9) while holding it. Do
not drop cover (9).
10. Remove bolts, washers (14) (6 used). Remove cover
(15).
6. Remove bolts, washers (8) (3 used). Remove cover
(9). j : 17 mm

j : 17 mm

W3-6-1-2
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

WDCD-03-06-004

11. Place a container under hydraulic oil tank (1) and

suction pipe (16). Slowly turn drain plug (17). Drain
off hydraulic oil completely.

j : 27 mm
12. Remove hose clamps (18) (4 used). Disconnect hose
(19).
13. Remove bolts, washers (20) (4 used). Move cover
assembly (21).

j : 17 mm

W3-6-1-3
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

WDCD-03-06-006

a - Lifting Hole

14. Disconnect connector (23) of hydraulic oil

temperature sensor (22). dCAUTION:
(215 lb)
Hydraulic oil tank (1) weight: 97 kg

15. Remove bolts, washers (24) (2 used).

18. Install eyebolts (2 used) and nuts (2 used) to lifting
j : 17 mm holes (a) (2 places) of hydraulic oil tank (1). Attach
nylon slings onto the eyebolts. Hoist and hold
16. Remove couplings (25) (2 used). Disconnect pipes hydraulic oil tank (1).
(26, 27) at the hydraulic oil tank (1) end.
19. Remove bolts, washers (29) (4 used). Hoist and
j : 13 mm remove hydraulic oil tank (1).
17. Disconnect hoses (28) (4 used). j : 27 mm
j : 19 mm

W3-6-1-4
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

WDCD-03-06-007

a - Lifting Hole

Installation 4. Connect pipes (27, 26) with couplings (25) (2 used).

dCAUTION:
(215 lb)
Hydraulic oil tank (1) weight: 97 kg j : 13 mm

m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft)

1. Install eyebolts (2 used) and nuts (2 used) to lifting
holes (a) (2 places) of hydraulic oil tank (1). Attach 5. Install clamps (30) (2 used) with bolts, washers (24)
nylon slings onto the eyebolts. Hoist hydraulic oil (2 used).
tank (1).
j : 17 mm
2. Install hydraulic oil tank (1) with bolts, washers (29)
(4 used). m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 27 mm 6. Connect connector (23) of hydraulic oil temperature

sensor (22).
m : 400 N·m (40 kgf·m, 300 lbf·ft)
3. Connect hoses (28) (4 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-6-1-5
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

1 3, 4
WDCD-03-06-005 WDCD-03-06-001

7. Install cover assembly (21) with bolts, washers (20) 11. Install O-ring (4).
(4 used).
12. Install the cover (3) assembly to the upper part of
j : 17 mm hydraulic oil tank (1) with bolts, washers (2) (6 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 17 mm

8. Connect hose (19) with hose clamps (18) (4 used). m : 50 N·m (5 kgf·m, 37 lbf·ft)
9. Check that drain plug (17) is tightened.
10. Fill hydraulic oil tank (1) with hydraulic oil.

fNOTE: Hydraulic oil tank (1) capacity: 201 L (53.1 US

gal)

W3-6-1-6
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

11 13 12
5 10 9 8

15 14
WDCD-03-06-002 WDCD-03-06-001
6 7

13. Bleed air from the hydraulic system. (Refer to W1-4- 18. Install bolts, washers (10) (2 used).
1.)
j : 17 mm
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks. m : 50 N·m (5 kgf·m, 37 lbf·ft)
14. Install cover (15) with bolts, washers (14) (2 used). 19. Install cover (9) with bolts, washers (8) (3 used).
j : 17 mm j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)
15. Install bolts, washers (14) (4 used). 20. Install cover (7) with bolts, washers (6) (6 used).
j : 17 mm j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)
16. Install cover (13) with bolts, washers (12) (5 used). 21. Shut cover (5).
j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

17. Shut engine cover (11).

W3-6-1-7
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

(Blank)

W3-6-1-8
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

Removal and Installation of Fuel Tank

2
5, 6

9 10

8 11

3, 4

WDCD-03-07-001

IMPORTANT: Cap the open ends in case the hoses 6. Remove bolts (5) (2 used) and washers (6) (2 used).
and pipes have been disconnected. In addition, Remove handrail (7).
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the j : 19 mm
hoses and install the clips in case the clips which 7. Remove bolts, washers (8) (4 used). Remove step (9).
secure the hoses have been removed.
j : 17 mm
Removal 8. Remove bolts, washers (10) (4 used). Remove cover
(11).
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.) j : 17 mm
2. Remove cap (1).
3. Place a container. Drain off fuel by using an oil feed
pump.

fNOTE: Amount of oil: 400 L (106 US gal)

4. Open cover (2).
5. Remove bolts (3) (2 used) and washers (4) (2 used).

j : 22 mm

W3-7-1-1
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

a b
12 13 19
19 17

18

WDCD-03-07-002 WDCD-03-07-003
14 15, 16
a - Mounting Hole b- Mounting Hole

9. Remove bolts, washers (12) (2 used). Remove cover

(13). dCAUTION: Fuel tank (19) weight: 160 kg (355 lb)
13. Install an eyebolt (M10, Pitch 1.5 mm) to mounting
j : 17 mm hole (a) of fuel tank (19). Install an eyebolt (M10,
10. Disconnect connector (14). Pitch 1.5 mm) and a nut to mounting hole (b) of
fuel tank (19). Attach nylon slings onto the eyebolts.
11. Remove bolt, washer (15). Remove clip (16). Hoist and hold fuel tank (19).
j : 17 mm
12. Remove hose clip (17). Disconnect hose (18).

W3-7-1-2
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

19

WDCD-03-07-004
WDCD-03-07-005
20 21 23 22

16. Place a container under fuel tank (19). Remove hose

d CAUTION: Remove cover (21) while holding it.
Do not drop cover (21).
clips (24, 25). Disconnect hoses (26, 27). Drain fuel
completely.
14. Remove bolts, washers (20) (6 used). Remove cover
17. Remove bolts (28) (6 used) and washers (29) (6
(21).
used). Remove fuel tank (19).
j : 17 mm
j : 24 mm
d CAUTION: Remove cover (23) while holding it.
Do not drop cover (23).
15. Remove bolts, washers (22) (2 used). Remove cover
(23).

j : 17 mm

W3-7-1-3
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

a b
19
19

WDCD-03-07-002 WDCD-03-07-003

a - Mounting Hole b- Mounting Hole

Installation

dCAUTION: Fuel tank (19) weight: 160 kg (355 lb)

1. Install an eyebolt (M10, Pitch 1.5 mm) to mounting
hole (a) of fuel tank (19). Install an eyebolt (M10,
Pitch 1.5 mm) and a nut to mounting hole (b) of
fuel tank (19). Attach nylon slings onto the eyebolts.
Hoist fuel tank (19).

W3-7-1-4
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

19

WDCD-03-07-004
WDCD-03-07-005
20 21 23 22

2. Install fuel tank (19) with washers (29) (6 used) and

bolts (28) (6 used).

j : 24 mm

m : 270 N·m (27 kgf·m, 200 lbf·ft)

3. Connect hoses (27, 26) with hose clips (25, 24).
4. Install cover (23) with bolts, washers (22) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

5. Install cover (21) with bolts, washers (20) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-7-1-5
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

12 13 19
19 17

18

WDCD-03-07-002 WDCD-03-07-003
14 15, 16

6. Connect hose (18) with hose clip (17).

7. Install clip (16) with bolt, washer (15).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

8. Connect connector (14).
9. Install cover (13) with bolts, washers (12) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-7-1-6
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

2
5, 6

9 10

8 11

3, 4

19

WDCD-03-07-001

10. Install cover (11) with bolts, washers (10) (4 used). 13. Install washers (4) (2 used) and bolts (3) (2 used).

j : 17 mm j : 22 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 180 N·m (18 kgf·m, 133 lbf·ft)

11. Install step (9) with bolts, washers (8) (4 used). 14. Shut cover (2).

j : 17 mm 15. Fill fuel tank (19) with fuel.

m : 50 N·m (5 kgf·m, 37 lbf·ft) fNOTE: Amount of oil: 400 L (106 US gal)

16. Install cap (1).
12. Install handrail (7) with washers (6) (2 used) and
bolts (5) (2 used). 17. Bleed air from the fuel system. (Refer to W1-4-1.)

j : 19 mm

m : 110 N·m (11 kgf·m, 81 lbf·ft)

W3-7-1-7
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

(Blank)

W3-7-1-8
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Removal and Installation of Pump Device

7 9 6 8 2 13 11 10

WDCD-03-06-001 14 12 WDCD-03-08-009
5 1 3, 4

IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts, washers (7) (8 used) and bolts,
and pipes have been disconnected. In addition, washers (8) (2 used). Remove cover (9).
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the j : 17 mm
hoses and install the clips in case the clips which 6. Remove bolts, washers (10) (2 used).
secure the hoses have been removed.
j : 17 mm
Removal 7. Remove bolts, washers (11) (5 used). Remove cover
1. Set the machine position for inspection and (12).
maintenance. (Refer to W1-6-1.) j : 17 mm

dCAUTION: Bleed air from hydraulic oil tank (1).

(Refer to W1-4-1.)
8. Remove bolts, washers (13) (3 used). Remove cover
(14).
2. Remove bolts, washers (2) (6 used). Remove the
cover (3) assembly and O-ring (4) from the top of j : 17 mm
hydraulic oil tank (1).

j : 17 mm
3. Place a container. Drain off hydraulic oil by using an
oil feed pump.

fNOTE: Total oil amount of hydraulic oil tank (1): 201 L

(53.1 US gal)
4. Open cover (5) and engine cover (6).

W3-8-1-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

WDCD-03-08-010 WDCD-03-08-011

9. Remove bolts, washers (15) (3 used). 14. Disconnect hose (28).

j : 10 mm j : 27 mm
10. Disconnect connectors (16) (7 used). 15. Remove clamps (21) (4 used). Disconnect rubber
hose (22).
11. Place a container under pump device (17) and pipe
(24). Disconnect hose (18). 16. Remove socket bolts (23) (4 used). Disconnect pipe
(24).
j : 36 mm
l : 10 mm
12. Disconnect hoses (19) (2 used).
17. Remove socket bolts (25) (8 used) and flanges (26)
j : 19 mm (4 used). Disconnect hoses (27) (2 used).
13. Disconnect hose (20).
l : 10 mm
j : 17 mm

W3-8-1-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

29, 30, 31, 32 33 36, 37 38, 39 36, 37

34, 35 WDCD-03-08-012 17 WDCD-03-08-013

18. Remove bolts (29) (2 used) and nuts (30) (2 used).

Remove clamp (31) and gasket (32). dCAUTION:
lb)
Pump device (17) weight: 170 kg (375

j : 17 mm 21. Remove bolts (36) (2 used) and washers (37) (2

dCAUTION:
kg (56 lb)
The muffler (33) assembly weight: 25
19. Attach nylon slings onto muffler (33). Hoist and hold
the muffler (33) assembly.
20. Remove bolts (34) (3 used) and spring washers (35)
(3 used). Remove the muffler (33) assembly.
used). Install eyebolts (M12, Pitch 1.75 mm) (2 used)
to the bolt (36) holes (2 places). Attach nylon slings
onto the eyebolts. Hoist and hold pump device (17).
j : 19 mm
22. Remove bolts (38) (5 used) and spring washers (39)
(5 used). Remove pump device (17).

j : 17 mm j : 17 mm
23. Remove the adapter with pump device (17)
attached if necessary.

W3-8-1-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

29, 30, 31, 32 40 33 36, 37 38, 39 36, 37

34, 35 WDCD-03-08-012 17 WDCD-03-08-013

Installation 6. Install the muffler (33) assembly with spring

washers (35) (3 used) and bolts (34) (3 used).
1. Install all removed adapters to pump device (17).
j : 17 mm
dCAUTION:
lb)
Pump device (17) weight: 170 kg (375
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
2. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
7. Install gasket (32) and clamp (31) to muffler (33) and
bolt (36) holes (2 places). Attach nylon slings onto
exhaust pipe (40) with nuts (30) (2 used) and bolts
the eyebolts. Hoist pump device (17).
(29) (2 used).
3. Install pump device (17) with spring washers (39) (5
used) and bolts (38) (5 used). j : 17 mm

j : 17 mm m : 7 to 10 N·m (0.7 to 1 kgf·m, 5.2 to 7.4 lbf·ft)

m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

4. Remove the eyebolts (2 used) from the bolt (36)
holes (2 places). Install washers (37) (2 used) and
bolts (36) (2 used).

j : 19 mm

dCAUTION:
kg (56 lb)
The muffler (33) assembly weight: 25

5. Attach nylon slings onto muffler (33). Hoist the

muffler (33) assembly.

W3-8-1-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

WDCD-03-08-020 WDCD-03-08-015

8. Connect hoses (27) (2 used) with flanges (26) (4 13. Connect hoses (19) (2 used).
used) and socket bolts (25) (8 used).
j : 19 mm
l : 10 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
m : 110 N·m (11 kgf·m, 81 lbf·ft)
14. Connect hose (18).
9. Connect pipe (24) with socket bolts (23) (4 used).
j : 36 mm
l : 10 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
15. Connect connectors (16) (7 used).
10. Connect rubber hose (22) with clamps (21) (4 used).
16. Install clamps (41) (3 used) with bolts, washers (15)
11. Connect hose (28). (3 used).

j : 27 mm j : 10 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft) m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

12. Connect hose (20).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

W3-8-1-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

7 9 6 8 2 13 11 10, 42

WDCD-03-06-001 14 12 WDCD-03-08-009
5 1 3, 4

17. Fill hydraulic oil to hydraulic oil tank (1). 22. Install cover (12) with bolts, washers (11) (5 used).

fNOTE: Total oil amount of hydraulic oil tank (1): 201 L j : 17 mm

(53.1 US gal)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
18. Install O-ring (4).
23. Install clamps (42) (2 used) with bolts, washers (10)
19. Install the cover (3) assembly to the top of hydraulic
(2 used).
oil tank (1) with bolts, washers (2) (6 used).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
24. Install cover (9) with bolts, washers (8) (2 used) and
20. Bleed air from the hydraulic system. (Refer to W1-4-
bolts, washers (7) (8 used).
1.)
IMPORTANT: Check the hydraulic oil level. Start the j : 17 mm
engine and check for any oil leaks.
m : 50 N·m (5 kgf·m, 37 lbf·ft)
21. Install cover (11) with bolts, washers (13) (3 used).
25. Shut engine cover (6) and cover (5).
j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-8-1-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Removal and Installation of Coupling

6
7
5
8
7

8
4

WDCD-03-08-021 WDCD-03-09-001

Removal 4. Remove spring pins (7) (4 used) from the engine

flywheel.
1. Remove element (2) from insert (1) at the pump
side. 5. Remove clamping screws (8) (2 used) from cylinder
hub (4). Remove cylinder hub (4) from the pump
2. Remove socket bolts (3) (4 used) from insert (1).
device.
Remove inserts (1) (4 used) from cylinder hub (4).
l : 10 mm
l : 14 mm
3. Remove socket bolts (6) (4 used) from insert
(5). Remove inserts (5) (4 used) from the engine
flywheel.

l : 14 mm

W3-8-2-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

6
7
5
8
7

8
4

WDCD-03-08-021 WDCD-03-09-001

Installation 5. Install inserts (1) (4 used) to cylinder hub (4) with

socket bolts (3) (4 used).
1. Install cylinder hub (4) to the pump device.
2. Secure cylinder hub (4) with clamping screws (8) (2 l : 14 mm
used).
m : 210 to 230 N·m (21 to 23 kgf·m, 155 to 170
l : 10 mm lbf·ft)
6. Install element (2) to inserts (1) (4 used) at the pump
m : 45 to 55 N·m (4.5 to 5.5 kgf·m, 33 to 41
side.
lbf·ft)
3. Install spring pins (7) (4 used) to the engine
flywheel.
4. Install inserts (5) (4 used) to the engine flywheel
with socket bolts (6) (4 used).

l : 14 mm

m : 210 to 230 N·m (21 to 23 kgf·m, 155 to 170

lbf·ft)

W3-8-2-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Pump Device

4
2 3
5
1
17
16 18
15
14
6
13
11 12
10
56 7 9

55
54 17
8
15 14 16
19
51
49 12
50 20
27 11 68
10
9 67 69
26
66 70
67
80
64 71
21 63
49 65
50 21 22
60 22 23
26 29 58 61 24
62 81
61
58 60
74 72
59 58
60
57 61
77 73

58 61
58 60 75
59 76
78
68
57 58
58

78
WDCD-03-08-019

W3-8-3-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

79
91
92
93
53
52
90
89
88

93
87 92
28
86 91

85
25
84

33 35
47
48
34

36
32 37
38
82
30 83
31
39
46 40
45 41
42
43
44
42
WDCD-03-08-018

1- Socket Bolt (4 Used) 26- Retaining Ring (2 Used) 51- Pump Casing 76- Stopper L (2 Used)
2- Regulator 27- Gear 52- Spring Washer (6 Used) 77- Valve Plate
3- Socket Bolt (2 Used) 28- Gasket 53- Bolt (6 Used) 78- Link (2 Used)
4- Socket Bolt (2 Used) 29- Gear 54- Spring Pin (4 Used) 79- Pipe
5- Socket Bolt (2 Used) 30- Plug 55- O-Ring (10 Used) 80- Pump 1 Delivery Pressure
6- Regulator 31- O-Ring 56- O-Ring (2 Used) Sensor
7- O-Ring (4 Used) 32- Gasket 57- Pin (2 Used) 81- Pump 2 Delivery Pressure
8- O-Ring (6 Used) 33- Socket Bolt (2 Used) 58- Retaining Ring (12 Used) Sensor
9- Bearing Nut (2 Used) 34- Pipe 59- Pin (2 Used) 82- Plug
10- Bearing (2 Used) 35- Level Gauge 60- Lever (4 Used) 83- Elbow
11- Ring (2 Used) 36- Socket Bolt (2 Used) 61- Pin (4 Used) 84- O-Ring
12- Bearing (2 Used) 37- Spring Washer (2 Used) 62- Valve Plate 85- N Sensor
13- Shaft 38- Washer (2 Used) 63- Backup Ring 86- Washer
14- Pin (2 Used) 39- Pilot Pump 64- O-Ring 87- Socket Bolt
15- Center Shaft (2 Used) 40- Retaining Ring 65- Spring Pin (2 Used) 88- Bracket
16- Spring (2 Used) 41- Retaining Ring 66- Selector Head 89- Spring Washer
17- Plunger (14 Used) 42- Ball Bearing (2 Used) 67- O-Ring (4 Used) 90- Socket Bolt
18- Rotor (2 Used) 43- Gear 68- Socket Bolt (16 Used) 91- Socket Bolt (8 Used)
19- Shaft 44- Gear Shaft 69- Stopper S (2 Used) 92- Cover (2 Used)
20- Thrust Ring 45- Retaining Ring 70- O-Ring (2 Used) 93- O-Ring (2 Used)
21- O-Ring (2 Used) 46- Oil Seal 71- Socket Bolt (12 Used)
22- Plug (2 Used) 47- Gear Casing 72- Set Screw (2 Used)
23- O-Ring 48- Spring Pin (2 Used) 73- Servo Piston (2 Used)
24- Plug 49- Oil Seal (2 Used) 74- Pin (2 Used)
25- Plug 50- Retaining Ring (2 Used) 75- O-Ring (2 Used)

W3-8-3-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Pump Device

1. Disconnect the both ends of pipe (79) from
regulators (2, 6).
j : 17 mm
2. Remove pump 1 delivery pressure sensor (80) and
pump 2 delivery pressure sensor (81) from selector
head (66).
j : 27 mm
3. Remove socket bolts (87, 90), washer (86), and
spring washer (89). Remove N sensor (85), O-ring
(84), and bracket (88) from pump casing (51).
l : 5 mm
4. Remove plug (25) from gear casing (47).
j : 17 mm
5. Remove plug (30) from gear casing (47). Drain off
engine oil.
j : 22 mm
fNOTE: Amount of oil: 1 L (1.06 US qt)
6. Remove socket bolts (1) (4 used). Raise regulator
(2) to the direction of selector head (66). Remove
regulator (2) from pump casing (51).
7. Remove socket bolts (3, 5) (2 used for each). Raise
regulator (6) to the direction of selector head (66).
Remove regulator (6) from pump casing (51). Do not
remove socket bolt (4).
l : 8 mm
8. Remove O-rings (56) (2 used), O-rings (55) (10 used),
O-rings (7) (4 used), and spring pins (54) (4 used)
from pump casing (51).
dCAUTION: Pump device weight: 160 kg (355 lb)
dCAUTION: When hoisting the pump device, do
not take pump casing (51) off the ground but turn
to the gear casing (47) side.
9. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to the
socket bolt (1, 3) holes of pump casing (51). Hoist
the pump device. Place the pump device with gear
casing (47) down. Place a wooden block (80 mm or
more square) under gear casing (47).
10. Remove socket bolts (33) (2 used) from gear casing
(47). Remove level gauge (35), pipe (34), and gasket
(32).
l : 6 mm

l : 8 mm

W3-8-3-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

11. Remove socket bolts (36) (2 used) from gear casing
(47). While tapping the flange part of pilot pump
(39) by using a plastic hammer, remove pilot pump
(39) from gear casing (47).
l : 8 mm
fNOTE: O-rings (70, 75) are installed on stopper S (69)
fNOTE: THREEBOND has been applied onto the
mounting surface of pilot pump (39).
12. Remove plug (82) and elbow (83) from gear casing
(47).
j : 30 mm
13. Remove socket bolts (91) (8 used) from covers (92)
(2 used). Remove covers (92) (2 used) and O-rings
(93) (2 used).
14. Remove socket bolts (68) (16 used) from selector
head (66). Remove stoppers S (69) (2 used) and
stoppers L (76) (2 used) from selector head (66).
l : 6 mm
and stopper L (76). If it is difficult to remove stopper (c),
tap the outer periphery of stopper (c) by using a plastic
hammer. Turn stopper (c) until the half of socket bolt (68)
hole can be seen. Insert a screwdriver into the socket bolt
(68) hole. Remove stopper (c).
c

l : 8 mm

W178-02-11-082

c- Stopper

W3-8-3-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

15. Remove socket bolts (71) (12 used) from selector
head (66). Measure and record the clearance
between pump casing (51) and selector head (66).
l : 10 mm
fNOTE: When loosening socket bolts (71) (12 used),
selector head (66) will be pushed out due to the force of
spring (16).
dCAUTION: The selector head (66) assembly
weight: 29 kg (64 lb)
16. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
screw holes (a) (2 places) of selector head (66). Hoist
and remove the selector head (66) assembly from
pump casing (51).
a
66
20. Both valve plates (62, 77) are very similar and their
installing directions are determined. Record the
position and the direction to install valve plates (62,
77) before removing. Remove retaining rings (58) (4
used) from pins (61) (4 used). Remove valve plates
(62, 77) from links (78) (2 used). Do not remove pins
(61) (4 used) unless necessary.
21. Remove rotors (18) (2 used), springs (16) (2 used),
center shafts (15) (2 used), and plungers (17) (14
used) from pump casing (51) in sequence. Remove
pins (14) (2 used) from center shafts (15) (2 used).
fNOTE: Remove plunger (17) with it tilted inside.
IMPORTANT: As the pump performance is changed,
do not deform link (78).
22. Remove the link (78) assemblies (2 used) from
pump casing (51). Do not disassemble the link (78)
assembly unless necessary.

fNOTE: If it is difficult to remove the link (78) assembly,

use a screwdriver.
23. Remove bolts (53) (6 used) and spring washers (52)
(6 used) from pump casing (51).

j : 24 mm

WDBE-03-08-006

a- Screw Hole

17. Warm up set screw (72) by using a drier. Remove set

screw (72) from servo piston (73). Remove pins (74)
(2 used).

l : 6 mm
18. Remove servo pistons (73) (2 used) from selector
head (66).
19. Remove backup ring (63) and O-rings (8, 64) from
pump casing (51).

W3-8-3-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

dCAUTION: The pump casing (51) assembly

weight: 71 kg (160 lb)
dCAUTION: The pump casing (51) assembly
24. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
socket bolt (71) hole (2 places) of pump casing (51).
Attach nylon slings onto the eyebolts. Hoist and
remove the pump casing (51) assembly from gear
casing (47). Shafts (13, 19) and gears (27, 29) are
removed with pump casing (51) together.
Place pump casing (51) with the regulator mounting
surface up.
25. Remove spring pins (48) (2 used) and gasket (28)
dCAUTION: The pump casing (51) assembly
from gear casing (47).
26. Put the matching marks on the meshed position
of the splines on shafts (13, 19) and gears (27, 29).
Put the matching marks on the meshed position of
gears (27, 29).
27 29
weight: 65 kg (145 lb)
28. Attach nylon slings onto pump casing (51). Hoist
and place the pump casing (51) assembly with the
selector head (66) mounting side down.
29. Remove plug (24) from pump casing (51). Remove
O-ring (23) from plug (24).
j : 19 mm
weight: 65 kg (145 lb)
30. Attach nylon slings onto pump casing (51). Hoist
and place the pump casing (51) assembly on a
wooden block with the pump transmission side
down. Use the wooden block (100 mm or more
square).
31. Remove the shaft (13, 19) assembly from pump
casing (51) by using the special tools (ST 1470, ST
1471). Bearings (10, 12) are removed with shafts (13,
19) together.

ST 1470

19 ST 1471
13
W137-02-04-007
13
27. Remove retaining rings (26) (2 used) from shafts (13,
19). Remove gears (27, 29) from shafts (13, 19). 19

51

W178-02-04-054

W3-8-3-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

32. Remove thrust ring (20) from pump casing (51).
33. Remove bearing nut (9) from shaft (13) by using the
special tool (ST 3058).
ST 3058
38. Remove retaining ring (40) from gear casing (47).
Remove retaining ring (41) from gear shaft (44).
39. Remove ball bearing (42) at the upper side and gear
shaft (44) from gear casing (47) by using the special
tool (ST 1393).

44

42

W137-02-04-023

34. Remove bearings (10, 12) and ring (11) from shaft
(13) by using a press.
35. Remove bearing nut (9), bearings (10, 12), and ring W178-02-11-085
(11) from shaft (19) in the same way as step 33 and
40. Remove gear (43) and ball bearing (42) from gear
step 34.
casing (47).
dCAUTION: Pump casing (51) weight: 42 kg (93 lb) 41. Install shackles to the outer bolt holes of gear
36. Attach nylon slings onto pump casing (51). Hoist casing (47). Hoist and turn over gear casing (47) by
and place pump casing (51) with the regulator using nylon slings.
mounting side up.
42. Remove retaining ring (45) and oil seal (46) from
37. Remove retaining rings (50) (2 used) and oil seals gear casing (47).
(49) (2 used) from pump casing (51).

W3-8-3-7
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Pump Device

77 64 63 18 16 15 17 12 20 11 10 9 49 29

26

19

50

13

26

27

62 58, 61 60 18 16 15 17 12 11 10 9 49

68 69 67 70 8 7 54 55 59 58 57 56 51

66

73

72

74

75
76
W178-02-11-086
68 65 22 21 78 14 24 23

W3-8-3-8

30, 31
81
71
80
1- Socket Bolt (4 Used)
2- Regulator
3- Socket Bolt (2 Used)
4- Socket Bolt (2 Used)
5- Socket Bolt (2 Used)
6- Regulator
7- O-Ring (4 Used)
8- O-Ring (6 Used)
9- Bearing Nut (2 Used)
10- Bearing (2 Used)
11- Ring (2 Used)
12- Bearing (2 Used)
13- Shaft
14- Pin (2 Used)
15- Center Shaft (2 Used)
16- Spring (2 Used)
17- Plunger (14 Used)
18- Rotor (2 Used)
19- Shaft
20- Thrust Ring
21- O-Ring (2 Used)
22- Plug (2 Used)
23- O-Ring
24- Plug
25- Plug
SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device
32, 33, 34
39 36, 37, 38
91 6 5 4 35 3 41 40 43 42
92, 93
44
25
45
82
83
46
48
79
84, 85
86, 87
47
2 1 88, 89, 90 53 52 28 WDCD-03-08-002
26- Retaining Ring (2 Used) 51- Pump Casing 76- Stopper L (2 Used)
27- Gear 52- Spring Washer (6 Used) 77- Valve Plate
28- Gasket 53- Bolt (6 Used) 78- Link (2 Used)
29- Gear 54- Spring Pin (4 Used) 79- Pipe
30- Plug 55- O-Ring (10 Used) 80- Pump 1 Delivery Pressure
31- O-Ring 56- O-Ring (2 Used) Sensor
32- Gasket 57- Pin (2 Used) 81- Pump 2 Delivery Pressure
33- Socket Bolt (2 Used) 58- Retaining Ring (12 Used) Sensor
34- Pipe 59- Pin (2 Used) 82- Plug
35- Level Gauge 60- Lever (4 Used) 83- Elbow
36- Socket Bolt (2 Used) 61- Pin (4 Used) 84- O-Ring
37- Spring Washer (2 Used) 62- Valve Plate 85- N Sensor
38- Washer (2 Used) 63- Backup Ring 86- Washer
39- Pilot Pump 64- O-Ring 87- Socket Bolt
40- Retaining Ring 65- Spring Pin (2 Used) 88- Bracket
41- Retaining Ring 66- Selector Head 89- Spring Washer
42- Ball Bearing (2 Used) 67- O-Ring (4 Used) 90- Socket Bolt
43- Gear 68- Socket Bolt (16 Used) 91- Socket Bolt (8 Used)
44- Gear Shaft 69- Stopper S (2 Used) 92- Cover (2 Used)
45- Retaining Ring 70- O-Ring (2 Used) 93- O-Ring (2 Used)
46- Oil Seal 71- Socket Bolt (12 Used)
47- Gear Casing 72- Set Screw (2 Used)
48- Spring Pin (2 Used) 73- Servo Piston (2 Used)
49- Oil Seal (2 Used) 74- Pin (2 Used)
50- Retaining Ring (2 Used) 75- O-Ring (2 Used)
W3-8-3-9
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Pump Device

6. Warm up bearings (10, 12) to 50 to 80 °C (122 to 176
IMPORTANT: Before assembling, apply hydraulic oil
°F).
onto parts in order to prevent them from seizing.
1. Install ball bearing (42) to gear casing (47) by using
a bar and a hammer. Tap and listen to ring in order
dCAUTION: Take care as bearing (12) is too hot.
7. Install bearing (12) to shaft (19) by using a press.
to check that ball bearing (42) is installed to the end.
8. Install ring (11) to shaft (19).
fNOTE: Insert ball bearing (42) with the stamped mark
facing to the engine side. dCAUTION: Take care as bearing (10) is too hot.
2. Place gear (43) onto ball bearing (42). Fit the splines 9. Install bearing (10) to shaft (19) by using a press.
and insert gear shaft (44). 10. Install bearings (12, 10) and ring (11) to shaft (13) in
3. Install ball bearing (42) to gear shaft (44) by using a the same way as step 6 to step 9.
bar and a hammer. Tap and listen to ring in order to
check that ball bearing (42) is installed to the end.

fNOTE: Insert ball bearing (42) with the stamped mark

facing to the engine side.
4. Install retaining ring (40) to gear casing (47). Install
retaining ring (41) to gear shaft (44).
5. Install O-ring (31) to plug (30). Install plug (30) to
gear casing (47).

j : 22 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-8-3-10
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

11. Set the preload of bearings (10, 12) (2 used for 12. Set the preload of bearings (10, 12) with shaft (19)
each) with shafts (13, 19) attached according to the attached in the same way as step 11.
following procedures.
13. Install thrust ring (20) to the side to insert shaft (19)
 Apply hydraulic oil onto the thread part of bearing in pump casing (51).
nut (9). Tighten bearing nut (9) until it comes in
contact with bearing (10) by using the special tool
(ST 3058).
ST 3058
9
10

W178-02-11-090

 Install the special tool (ST 3070) to bearing (10). After

rotating 2 to 3 turns, measure the starting torque.

ST 3070

10

W178-02-11-091

 Adjust bearing nut (9) until the starting torque

reaches the specification.
m : 2±0.5 N·m (0.2±0.05 kgf·m, 1.5±0.4 lbf·ft)

fNOTE: If the starting torque is higher than the limit of

specified torque, loosen bearing nut (9). Tap the shaft
end and release the load of bearing (10).

W3-8-3-11
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

14. Warm up pump casing (51) to 50 to 80 °C (122 to 19. Install the special tools (ST 2649, ST 2650) over the
176 °F). spline parts of shafts (13, 19).

dhot.
CAUTION: Take care as pump casing (51) is too fNOTE: If the special tools are not available, install a
vinyl tape onto the spline part of the shaft in order not to
15. Apply hydraulic oil onto bearings (10, 12) (2 used for damage oil seal (49).
each) with shafts (13, 19) attached. Install shafts (13,
19) to pump casing (51) by using special tool (a).
If it is difficult to insert shafts (13, 19), tap them by
using a bar. ST 2650
a
49

51
19

ST 2649 W178-02-11-094

c 20. Apply grease onto the inside of oil seals (49) (2

c used). Evenly tap and install oil seals (49) (2 used) to
shafts (13, 19).
W178-02-11-093 21. Remove the special tools (ST 2649, ST 2650) from
shafts (13, 19).
a- Special Tool c- Wooden Block
b- M8, Pitch 1.25 mm 22. Install retaining rings (50) (2 used) to pump casing
(51).
16. Wait for pump casing (51) in order to cool down to
the temperature lower than 40 °C (104 °F).
17. Install O-ring (23) to plug (24). Install plug (24) to
pump casing (51).

j : 19 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

dweight:
CAUTION: The pump casing (51) assembly
65 kg (145 lb)
18. Attach nylon slings onto pump casing (51). Hoist
and place the pump casing (51) assembly with the
regulator mounting side up.

W3-8-3-12
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

23. Fit the matching marks on shafts (13, 19) and
gears (27, 29). Install retaining rings (26) (2 used)
to shafts (13, 19). When replacing the shaft and the
gear, install the gear according to the following
procedures.
 Secure the special tool (ST 7934) to the plunger (17)
mounting side of shafts (13, 19) with the socket bolt
(M8, Pitch 1.25 mm).
19
ST 7934 13
24. Install spring pins (48) (2 used) to gear casing (47).
Install gasket (28).
dweight:
CAUTION: The pump casing (51) assembly
71 kg (160 lb)
25. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the socket bolt (71) holes (2 places) of pump casing
(51). Hoist the pump casing (51) assembly. While
engaging gear (43) with gear (29), install the pump
casing (51) assembly to gear casing (47) with bolts
(53) (6 used) and spring washers (52) (6 used).
j : 24 mm

m : 150 N·m (15 kgf·m, 111 lbf·ft)

a W178-02-11-097

a- M8, Pitch 1.25 mm

 Turn shafts (13, 19) clockwise, viewed from the gear

(27, 29) mounting side, until shafts (13, 19) come
in contact with the special tool. (Remove a play in
periphery direction.)
 Install gear (27) and retaining ring (26) to the spline
of shaft (13).
 Install gear (29) to the spline of shaft (19) and engage
it with gear (27). If gear (29) does not engage, adjust
shaft (19) within a play of the special tool by turning.
 Install retaining ring (26) to the spline of shaft (19).
 Remove the special tool (ST 7934).

W3-8-3-13
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

26. Apply THREEBOND #1215 onto the mounting 30. Insert plungers (17) (7 used for each) into shafts (13,
surface of pilot pump (39). Install pilot pump (39) 19).
to gear casing (47) with socket bolts (36) (2 used),
31. Apply grease onto pins (14) (2 used). Install pins (14)
spring washers (37) (2 used), and washers (38) (2
(2 used) to center shafts (15) (2 used).
used).
32. Apply grease onto the spherical surface of center
l : 8 mm shafts (15) (2 used). Install center shafts (15) (2 used)
to shafts (13, 19).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
27. Install gasket (32) and pipe (34) to gear casing (47)
with socket bolts (33) (2 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

IMPORTANT: As the pump performance is changed,
do not deform link (78).
28. Install the link (78) assemblies (2 used) to the
grooves of pins (57) (2 used) in pump casing (51).

fNOTE: Install the link (78) assemblies (2 used) with

lever (60) facing to the selector head (66) side. Fit parallel
surface (a) of pin (57) to the groove.

59 57

78 51

a a W178-02-11-098

a- Parallel Surface

29. Apply hydraulic oil onto the plunger (17) mounting

surface of shafts (13, 19).

W3-8-3-14
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

33. Install springs (16) (2 used) to center shafts (15) (2 39. Install regulator (2) to pump casing (51) according
used). to the following procedures.
34. Insert center shafts (15) (2 used) and plungers (17)  Adjust sleeves (b) (2 used) in regulator (2) so that the
(14 used) into rotors (18) (2 used). grooves of pin (59) are in a line.
 Place regulator (2) onto pump casing (51). Insert
35. Insert a grip of a file into the center hole of center
pin (59) of link (79) into the grooves of sleeves (b) (2
shafts (15) (2 used). While turning center shafts (15)
used).
(2 used), insert pin (14) into the grooves of rotors
 Move regulator (2) while fitting to spring pin (54) in
(18) (2 used).
pump casing (51).
fNOTE: If pin (14) (2 used) does not enter the grooves  Install regulator (2) to pump casing (51) with socket
bolts (1) (4 used).
of rotors (18) (2 used), selector head (66) cannot be
installed to pump casing (51). l : 8 mm
IMPORTANT: Check the direction to install valve
m : 50 N·m (5 kgf·m, 37 lbf·ft)
plate (62).
36. Insert pins (61) (2 used) of valve plate (62) into the 59
hole of levers (60) (2 used) at the regulator (2) side. b
Install retaining rings (58) (2 used). 2

77 62
a

51
W178-02-11-101
78 54
b- Sleeve

W178-02-11-100
40. Install regulator (6) to pump casing (51) with socket
a- Upward bolts (3, 5) (2 used for each) in the same way as step
39.

IMPORTANT: Check the direction to install valve l : 8 mm

plate (77).
37. Insert pins (61) (2 used) of valve plate (77) into the
hole of levers (60) (2 used) at the regulator (6) side.
Install retaining rings (58) (2 used).
38. Install O-rings (56) (2 used), O-rings (55) (10 used),
O-rings (7) (4 used), and spring pins (54) (4 used) to
pump casing (51).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
41. Install backup ring (63), O-rings (64), and O-rings (8)
(6 used) to pump casing (51).
42. Insert servo piston (73) (2 used) into selector head
(66).

W3-8-3-15
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

43. Apply LOCTITE LI829 onto set screw (72). Install pins
(74) (2 used) to servo pistons (73) (2 used) with set
screws (72) (2 used).
l : 6 mm
47. Install O-rings (67) (4 used) to selector head (66).
48. Install O-rings (70) (2 used) to stoppers S (69) (2
used). Install stoppers S (69) (2 used) to selector
head (66) with socket bolts (68) (8 used).

m : 35 N·m (3.5 kgf·m, 26 lbf·ft) l : 6 mm

44. Install spring pins (65) (2 used) to selector head (66). m : 20 N·m (2 kgf·m, 15 lbf·ft)

dweight:
CAUTION: The selector head (66) assembly
29 kg (64 lb)
49. Install O-rings (75) (2 used) to stoppers L (76) (2
used). Install stoppers L (76) (2 used) to selector
head (66) with socket bolts (68) (8 used).
45. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
screw holes (a) (2 places) of selector head (66). Hoist l : 6 mm
the selector head (66) assembly. Place selector head
(66) onto pump casing (51) while fitting to spring m : 20 N·m (2 kgf·m, 15 lbf·ft)
pin (65).
50. Install O-rings (93) (2 used) and covers (92) (2 used)
fNOTE: Check the clearance between selector head with socket bolts (91) (8 used).
(66) and pump casing (51) in order to compare with the
l : 8 mm
clearance before disassembling. When the clearance is
larger, pins (14) (2 used) may not be inserted into the m : 20 N·m (2 kgf·m, 15 lbf·ft)
grooves of rotors (18) (2 used), or pins (74) (2 used) may
not be inserted into the holes of valve plates (62, 77). d CAUTION: Pump device weight: 160 kg (355 lb)
51. Hoist and place the selector head (66) assembly
a
with the regulator mounting side up.
66

WDBE-03-08-006

a- Screw Hole

46. Install selector head (66) to pump casing (51) with

socket bolts (71) (12 used).

l : 10 mm

m : 110 N·m (11 kgf·m, 81 lbf·ft)

W3-8-3-16
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

52. Insert the special tool (ST 2650) into shaft (19).
Apply grease onto oil seal (46). Install oil seal (46) to
shaft (19). Remove the special tool (ST 2650). Install
oil seal (46).
fNOTE: If the special tool (ST 2650) is not available,
install a vinyl tape onto the spline part of shaft (19) in
order to protect. Install oil seal (46).
ST 2650
46
IMPORTANT: The breather hole of plug (25) is
located at the left side, viewed from the front of
gear casing (47).
56. Install a seal tape onto plug (25). Install plug (25) to
gear casing (47).
j : 17 mm
m : 40 N·m (4 kgf·m, 30 lbf·ft)
57. Install bracket (88), O-ring (84), and N sensor (85) to
pump casing (51) with spring washer (89), washer
(86), and socket bolts (90, 87).

j : 5 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

58. Install pump 2 delivery pressure sensor (81) and
pump 1 delivery pressure sensor (80) to selector
head (66).
W178-02-11-103
j : 27 mm
53. Install retaining ring (45) to gear casing (47).
m : 100 N·m (10 kgf·m, 74 lbf·ft)
54. Install a seal tape onto elbow (83). Install elbow
59. Connect the both ends of pipe (79) to regulators (2,
(83) to gear casing (47). Add engine oil (Nippon Oil
6).
Corporation DH-1 15W-40 or equivalent) through
the elbow (83) hole. j : 17 mm

fNOTE: Amount of oil: 1 L (1.06 US qt) m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

55. Install a seal tape onto plug (82). Install plug (82) to
60. Insert level gauge (35) into pipe (34).
elbow (83).

j : 30 mm

m : 40 N·m (4 kgf·m, 30 lbf·ft)

W3-8-3-17
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

(Blank)

W3-8-3-18
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Regulator

Pump 1 Regulator Pump 2 Regulator 2

3

WDCD-03-08-003 WDCD-03-08-004

6 7 8 9 10 11 12 13 14 15 16 17
4 5

24 23 22 21 20 19 18
1 31 30 29 27 28 26 25

TDCD-03-01-007

1- Cover 10- Spool 19- Lock Nut 28- Cylinder

2- Socket Bolt (2 Used) 11- Sleeve 20- Socket Bolt (8 Used) 29- O-Ring
3- Solenoid Valve 12- Piston 21- Stopper Assembly 30- Backup Ring
4- Lock Nut 13- Cylinder 22- O-Ring 31- O-Ring
5- Lock Nut 14- O-Ring 23- Spring
6- Stopper Assembly 15- Cover 24- Spring
7- O-Ring 16- Set Bolt 25- Sleeve
8- Spring 17- Lock Nut 26- Spool
9- Casing 18- Lock Nut 27- Piston

W3-8-4-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Regulator
5. Remove O-ring (7) from stopper assembly (6).
 The regulators are used for pump 1 and pump 2. The
inner structure in the regulator is fully identical, and 6. Remove springs (23, 24) from casing (9).
the difference is only in its accessories. The regulator
7. Insert a round bar into the hole of casing (9). Push
for pump 2 is explained here.
the spool (26) end. Remove cylinder (28), sleeve
(25), and spool (26) from casing (9). Piston (27) is
IMPORTANT: As the setting changes, do not
removed with cylinder (28) together at this time.
disassemble regulator adjusting screw parts
(4, 5, 16, 17, 18, and 19). When it should be 8. Remove piston (27), O-rings (29, 31), and backup
disassembled, adjust according to the procedures ring (30) from cylinder (28).
of performance test after assembling.
9. Remove spring (8) from casing (9).

1. Remove socket bolts (2) (2 used). Remove solenoid 10. Insert a round bar into the hole of casing (9). Push
valve (3) from casing (9). the spool (10) end. Remove cylinder (13), sleeve
(11), and spool (10) from casing (9). Piston (12) is
l : 8 mm removed with cylinder (13) together at this time.
11. Remove piston (12) and O-ring (14) from cylinder
IMPORTANT: Do not turn set bolt (16) and lock nuts (13).
(17, 18, 19). If turning, the setting changes.
2. Remove socket bolts (20) (4 used) from cover (15).
Remove the cover (15) assembly from casing (9). Set
bolt (16) and stopper assembly (21) are removed
with the cover (15) assembly together at this time.

l : 6 mm
3. Remove O-ring (22) from stopper assembly (21).

IMPORTANT: Do not turn lock nuts (4, 5). If turning,

the setting changes.
4. Remove socket bolts (20) (4 used) from cover (1).
Remove the cover (1) assembly from casing (9).
Stopper assembly (6) is removed with the cover (1)
assembly together at this time.

l : 6 mm

W3-8-4-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Regulator

Pump 1 Regulator Pump 2 Regulator 2

3

WDCD-03-08-003 WDCD-03-08-004

6 7 8 9 10 11 12 13 14 15 16 17
4 5

24 23 22 21 20 19 18
1 31 30 29 27 28 26 25

TDCD-03-01-007

1- Cover 10- Spool 19- Lock Nut 28- Cylinder

2- Socket Bolt (2 Used) 11- Sleeve 20- Socket Bolt (8 Used) 29- O-Ring
3- Solenoid Valve 12- Piston 21- Stopper Assembly 30- Backup Ring
4- Lock Nut 13- Cylinder 22- O-Ring 31- O-Ring
5- Lock Nut 14- O-Ring 23- Spring
6- Stopper Assembly 15- Cover 24- Spring
7- O-Ring 16- Set Bolt 25- Sleeve
8- Spring 17- Lock Nut 26- Spool
9- Casing 18- Lock Nut 27- Piston

W3-8-4-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Regulator
7. Install O-ring (7) and spring (8) to stopper assembly
IMPORTANT: The sleeve (11, 25) holes of casing (9)
(6) with cover (1) attached. Install the cover (1)
are the same bores. The shapes of various parts
assembly to casing (9) with socket bolts (20) (4
are very similar. Assemble it while checking the
used).
illustration in order not to confuse.
IMPORTANT: Before assembling, apply hydraulic oil l : 6 mm
onto parts in order to prevent them from seizing.
m : 20 N·m (2 kgf·m, 15 lbf·ft)
IMPORTANT: Check the direction to install sleeve
(11), spool (10), and piston (12). 8. Install O-ring (22) and springs (23, 24) to stopper
assembly (21) with cover (15) attached. Install the
cover (15) assembly to casing (9) with socket bolts
1. Insert spool (10) into sleeve (11). Install sleeve (11)
(20) (4 used).
to the center of casing (9) by using a round bar.
2. Install O-ring (14) to cylinder (13). l : 6 mm

3. Insert piston (12) into cylinder (13). Install cylinder m : 20 N·m (2 kgf·m, 15 lbf·ft)
(13) to casing (9).
9. Install solenoid valve (3) to casing (9) with socket
bolts (2) (2 used).
IMPORTANT: Check the direction to install sleeve
(25) and spool (26). l : 8 mm
4. Insert spool (26) into sleeve (25). Install sleeve (25) m : 50 N·m (5 kgf·m, 37 lbf·ft)
to the center of casing (9) by using a round bar.
5. Install O-rings (29, 31) and backup ring (30) to
cylinder (28).
6. Insert piston (27) into cylinder (28). Install cylinder
(28) to casing (9).

W3-8-4-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Solenoid Valve

2
1 3 4 5 6

7
8
9

WDCD-03-08-007

10 12 13 14

10

WDCD-03-08-006 WDCD-03-08-005
11

1- Solenoid (2 Used) 5- O-Ring 9- O-Ring 13- O-Ring

2- Socket Bolt 6- Wave Washer 10- Filter (3 Used) 14- Body
3- Sleeve 7- Plate 11- O-Ring (2 Used)
4- O-Ring 8- O-Ring 12- O-Ring

W3-8-5-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Solenoid Valve

 Take care not to damage the mounting surface for
the regulator.
 When replacing the parts, replace them as an
assembly.
 Take care not to hit the solenoid part.
 When disconnecting the connector, do not pry it, but
disconnect it straight.
1. Remove socket bolts (2) (2 used). Remove solenoid
(1) and O-ring (9).
4. Remove filters (10) (3 used), O-rings (11) (2 used),
and O-rings (12, 13) from body (14).
l : 6 mm
fNOTE: When cleaning filter (10), blow it from the both
surfaces by using air. Finally blow it from the outside
(screw side) by using air.
5. Disassemble another solenoid (1) in the same way
as step 1 to step 4.

l : 4 mm

IMPORTANT: Do not drop plate (7) and wave washer

(6).
2. Remove plate (7) and wave washer (6) from body
(14).
3. Remove O-rings (4, 5, and 8) from sleeve (3).

W3-8-5-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Solenoid Valve

2
1 3 4 5 6

7
8
9

WDCD-03-08-007

10 12 13 14

10

WDCD-03-08-006 WDCD-03-08-005
11

1- Solenoid (2 Used) 5- O-Ring 9- O-Ring 13- O-Ring

2- Socket Bolt 6- Wave Washer 10- Filter (3 Used) 14- Body
3- Sleeve 7- Plate 11- O-Ring (2 Used)
4- O-Ring 8- O-Ring 12- O-Ring

W3-8-5-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Solenoid Valve

1. Install O-rings (12, 13), O-rings (11) (2 used), and
filters (10) (3 used) to body (14).

l : 6 mm

m : 10+3 N·m (1+0.3 kgf·m, 7.4+2.2 lbf·ft)

2. Install wave washer (6) and plate (7) to body (14).

fNOTE: When assembling body (14) in a horizontal

position, apply grease onto wave washer (6) and plate
(7) in order not to fall off. After assembling, check that
plate (7) is installed straight.

3. Install O-rings (4, 5, and 8) to sleeve (3).

4. Install O-ring (9) to body (14).
5. Install solenoid (1) to body (14) with socket bolts (2)
(2 used).

l : 4 mm

m : 5+2 N·m (0.5+0.2 kgf·m, 3.7+1.5 lbf·ft)

6. Assemble another solenoid (1) in the same way as
step 1 to step 5.

W3-8-5-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Structure of Pilot Pump

6

14

15

1
15

2 10
3
4

6
3
2

8
9

13
12

11 W137-02-04-034
10

W3-8-6-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

IMPORTANT: The housing is made of aluminum. Take

care not to damage the housing. Take extreme
care in order to control the tightening torque.
No. Part Name Q’ty Wrench Size Tightening Torque Remark
(mm) N·m (kgf·m) (lbf·ft)
1 Housing 1
2 Backup Ring 2 Apply grease when
installing
3 Seal 2 Apply grease when
installing
4 Bushing 2 Apply hydraulic oil when
installing
5 Gear 1
6 Bushing 2 Apply hydraulic oil when
installing
7 Flange 1
8 Oil Seal 1 Apply grease onto the lip
part when installing
9 Retaining Ring 1
10 O-Ring 2 Apply grease when
installing
11 Cover 1
12 Washer 4
13 Bolt 4 j : 17 35+5 3.5+0.5 2.6+3.7
14 Gear 1
15 Key 2

W3-8-6-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Removal and Installation Control Valve

1 5 4 6

7 2 3
WDCD-03-06-001 WDCD-03-04-010

IMPORTANT: The hose and pipe contain hydraulic 3. Remove bolts, washers (2) (2 used). Remove cover
oil. When removing the hose and pipe, receive oils (3).
with a container in order to avoid spilling oils.
j : 17 mm
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition, 4. Remove bolts, washers (4) (5 used). Remove cover
attach an identification tag onto the connectors, (5).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which j : 17 mm
secure the hoses have been removed. 5. Remove bolts, washers (6) (7 used). Remove cover
(7).
Removal
j : 17 mm
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
2. Open engine cover (1).

W3-9-1-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

9 10 11

8, 77 11

WDCD-03-09-012 WDCD-03-09-002

6. Remove bolts, washers (8) (3 used) and clamps (77)

(3 used).

j : 17 mm
7. Remove 3-spool solenoid valve unit (9). (Refer to
W3-12-2.)
8. Disconnect the connectors and hoses connected to
signal control valve (10). (Refer to W3-13-1.)
9. Disconnect connectors (11) (2 used).

W3-9-1-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WDCD-03-09-003 WDCD-03-09-004

10. Disconnect hoses (12) (2 used). 14. Place a container under the disconnecting part of
pipe (19). Remove coupling (20). Disconnect the oil
j : 27 mm cooler side of pipe (19).
11. Disconnect hose (13).
j : 13 mm
j : 19 mm 15. Remove socket bolts (21) (2 used). Disconnect the
12. Remove bolts, washers (14) (2 used) and clamps (15) control valve (22) side of pipe (19). Remove O-ring
(2 used). (23).

j : 19 mm l : 8 mm
13. Place a container under the disconnecting part of
pipe (16). Remove couplings (17, 18). Disconnect
the both ends of pipe (16).

j : 13 mm

W3-9-1-3
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WDCD-03-09-005 WDCD-03-09-006

16. Place a container under control valve (22). 21. Remove socket bolts (35) (16 used), flanges (36) (2
Disconnect the both ends of pipes (24) (3 used). used), and flanges (37) (6 used). Disconnect hoses
(38) (4 used). Remove O-ring (39) and O-rings (40) (3
j : 17 mm used).
17. Disconnect hose (25).
l : 8 mm
j : 19 mm 22. Place a container under the disconnecting part of
18. Disconnect hose (26). pipe (41). Remove coupling (42). Disconnect the
hydraulic oil tank side of pipe (41).
j : 36 mm
j : 13 mm
19. Remove socket bolts (27) (8 used) and flanges (28)
(4 used). Disconnect hoses (29) (2 used). Remove 23. Remove socket bolts (43) (2 used). Disconnect the
O-rings (30) (2 used). control valve (22) side of pipe (41). Remove O-ring
(44).
l : 8 mm
l : 8 mm
20. Remove socket bolts (31) (4 used) and flanges (32)
(2 used). Disconnect hose (33). Remove O-ring (34).

l : 10 mm

W3-9-1-4
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WDCD-03-09-007

a- Eyebolt Mounting Hole

24. Remove socket bolts (45) (4 used) and flanges (46)

(2 used). Disconnect hose (47). Remove O-ring (48).
l : 10 mm
25. Remove socket bolts (49) (8 used) and flanges (50)
(4 used). Disconnect hoses (51) (2 used). Remove
O-ring (52).
l : 8 mm
26. Disconnect the front attachment side of hose (53).
j : 36 mm
27. Disconnect the front attachment side of hose (54).
dCAUTION: The control valve (22) assembly
weight: 280 kg (620 lb)
29. Install eyebolts (M10, Pitch 1.75 mm) (2 used) to
eyebolt mounting holes (a) (2 places) of control
valve (22). Attach nylon slings onto the eyebolts.
Hoist and hold the control valve (22) assembly.
30. Remove bolts (56) (2 used), bolts (57) (2 used),
washers (58) (2 used), and washers (59) (2 used).
Place the control valve (22) assembly on a
workbench.
j : 24 mm

j : 41 mm
28. Disconnect the center joint side of hoses (55) (2
used).

j : 36 mm

W3-9-1-5
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

67

68

WDCD-03-09-008 WDCD-03-09-009

31. Remove bolts (60) (2 used) and washers (61) 34. Disconnect hoses (68) (2 used).
(2 used). Remove the signal control valve (10)
assembly. j : 17 mm

j : 22 mm
32. Remove socket bolts (62) (24 used), flanges (63) (10
used), and flanges (64) (2 used). Disconnect hoses
(51) (2 used), hoses (55) (2 used), and hoses (53, 54).
Remove O-rings (65) (5 used) and O-ring (66).

l : 8 mm
33. Disconnect the both ends of hose (67).

j : 17 mm

W3-9-1-6
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

71 71 a

70

78 69 79

WDCD-03-09-010 WDCD-03-09-011

a- Eyebolt Mounting Hole

35. Disconnect hoses (69) (3 used).

j : 17 mm
dCAUTION:
lb)
Control valve (22) weight: 240 kg (530

36. Disconnect the both ends of hose (70).
j : 17 mm
37. Disconnect hoses (71) (6 used).
j : 19 mm
38. Disconnect the both ends of hose (72).
41. Install eyebolts (M10, Pitch 1.75 mm) (2 used) to
eyebolt mounting holes (a) (2 places) of control
valve (22). Attach nylon slings onto the eyebolts.
Hoist and hold control valve (22).
42. Remove bolts (75) (4 used) and washers (76) (4
used). Remove control valve (22) from brackets (78,
79).

j : 17 mm j : 24 mm
39. Disconnect hoses (73) (2 used). 43. Remove the adapter with control valve (22)
attached if necessary.
j : 17 mm
40. Disconnect hoses (74) (6 used).

j : 19 mm

W3-9-1-7
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

71 71 a

70

78 69 79

WDCD-03-09-010 WDCD-03-09-011

a- Eyebolt Mounting Hole

Installation 5. Connect the control valve (22) side of hoses (73) (2

used).
1. Install all removed adapters to control valve (22).
j : 17 mm
dCAUTION:
lb)
Control valve (22) weight: 240 kg (530
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
2. Install eyebolts (M10, Pitch 1.75 mm) (2 used) to
6. Connect the both ends of hose (72).
eyebolt mounting holes (a) (2 places) of control
valve (22). Attach nylon slings onto the eyebolts. j : 17 mm
Hoist and hold control valve (22).
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
3. Install control valve (22) to brackets (78, 79) with
washers (76) (4 used) and bolts (75) (4 used). 7. Connect the control valve (22) side of hoses (71) (6
used).
j : 24 mm
j : 19 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
m : 30 N·m (3 kgf·m, 22 lbf·ft)
4. Connect the control valve (22) side of hoses (74) (6
used). 8. Connect the both ends of hose (70).

j : 19 mm j : 17 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft) m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

9. Connect the control valve (22) side of hoses (69) (3
used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

W3-9-1-8
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

22 67

68

WDCD-03-09-008 WDCD-03-09-009

10. Connect the control valve (22) side of hoses (68) (2 13. Install the signal control valve (10) assembly with
used). washers (61) (3 used) and bolts (60) (3 used).

j : 17 mm j : 22 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft) m : 140 N·m (14 kgf·m, 103 lbf·ft)
11. Connect the both ends of hose (67).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

12. Install O-ring (66) and O-rings (65) (5 used). Connect
the control valve (22) side of hoses (54, 53) and
hoses (55, 51) with flanges (64) (2 used), flanges (63)
(10 used), and socket bolts (62) (24 used).

l : 8 mm

m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

W3-9-1-9
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WDCD-03-09-007

a- Eyebolt Mounting Hole

18. Connect hose (53).

dCAUTION: The control valve (22) assembly
weight: 280 kg (620 lb)
14. Install eyebolts (M10, Pitch 1.75 mm) (2 used) to
eyebolt mounting holes (a) (2 places) of control
valve (22). Attach nylon slings onto the eyebolts.
Hoist the control valve (22) assembly.
15. Install the control valve (22) assembly with washers
(59) (2 used), washers (58) (2 used), bolts (57) (2
used), and bolts (53) (2 used).
j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
19. Install O-ring (52). Connect hoses (51) (2 used) with
flanges (50) (4 used) and socket bolts (49) (8 used).
l : 8 mm
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

j : 24 mm 20. Install O-ring (48). Install hose (47) with flanges (46)
(2 used) and socket bolts (45) (4 used).
m : 270 N·m (27 kgf·m, 200 lbf·ft)
l : 10 mm
16. Connect hoses (55) (2 used).
m : 110 N·m (11 kgf·m, 81 lbf·ft)
j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

17. Connect hose (54).

j : 41 mm

m : 200 N·m (20 kgf·m, 148 lbf·ft)

W3-9-1-10
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WDCD-03-09-005 WDCD-03-09-006

21. Install O-ring (44). Connect the control valve (22) 25. Install O-rings (30) (2 used). Connect hoses (29) (2
side of pipe (41) with socket bolts (43) (2 used). used) with flanges (28) (4 used) and socket bolts
(27) (8 used).
l : 8 mm
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
22. Connect the hydraulic oil tank side of pipe (41) with
coupling (42). 26. Connect hose (26).

j : 13 mm j : 36 mm

m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft) m : 180 N·m (18 kgf·m, 133 lbf·ft)
23. Install O-rings (40) (3 used) and O-ring (39). Connect 27. Connect hose (25).
hoses (38) (4 used) with flanges (37) (6 used),
flanges (36) (2 used), and socket bolts (35) (16 used). j : 19 mm

l : 8 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

28. Connect the both ends of pipe (24).
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
24. Install O-ring (34). Connect hose (33) with flanges j : 17 mm
(32) (2 used) and socket bolts (31) (4 used).
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
l : 10 mm

m : 110 N·m (1.1 kgf·m, 81 lbf·ft)

W3-9-1-11
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WDCD-03-09-003 WDCD-03-09-004

29. Install O-ring (23). Connect the control valve (22) 32. Install clamp (15) with bolts, washers (14) (2 used).
side of pipe (19) with socket bolts (21) (2 used).
j : 19 mm
l : 8 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
33. Connect hose (13).
30. Connect the oil cooler side of pipe (19) with
coupling (20). j : 19 mm

j : 13 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

34. Connect hoses (12) (2 used).
m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft)
31. Connect pipe (16) with couplings (18, 17). j : 27 mm

j : 13 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft)

W3-9-1-12
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

9 10 11

8, 77 11

WDCD-03-09-012 WDCD-03-09-002

35. Connect connectors (11) (2 used).

36. Connect all removed connectors and hoses to signal
control valve (10). (Refer to W3-13-1.)
37. Install 3-spool solenoid valve unit (9). (Refer to W3-
12-2.)
38. Install clamps (77) (3 used) with bolts, washers (8) (3
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-9-1-13
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

1 5 4 6

7 2 3
WDCD-03-06-001 WDCD-03-04-010

39. Bleed air from the hydraulic system. (Refer to W1-4-

1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
40. Install cover (7) with bolts, washers (6) (7 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

41. Install cover (5) with bolts, washers (4) (5 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

42. Install cover (3) with bolts, washers (2) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

43. Shut engine cover (1).

W3-9-1-14
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Housing

4
4 5
5
4
5 4
4
4 4
6

4 6

5
5
4

W1V1-02-05-023

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

2- Housing (4-Spool Side) 4- O-Ring (16 Used) 6- O-Ring (3 Used)

W3-9-2-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Housing

dCAUTION:
kg (290 lb)
The housing (1) assembly weight: 130

The housing (2) assembly weight: 120 kg (265 lb)

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

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

W3-9-2-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Housing
4 5 2

4
4

5 6

4 5

6 6
5 5

4
4

W1V1-02-05-011
4 5

3
3

3
3

3
W1V1-02-05-001

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

2- Housing (4-Spool Side) 4- O-Ring (16 Used) 6- O-Ring (3 Used)

W3-9-2-3
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Housing

IMPORTANT: Before assembling, apply hydraulic oil

onto parts in order to prevent them from seizing.
1. Install O-rings (4) (16 used), O-rings (5) (12 used),
and O-rings (6) (3 used) to the mounting surface of
housing (2).

dCAUTION:
kg (290 lb)
The housing (1) assembly weight: 130

The housing (2) assembly weight: 120 kg (265 lb)

2. Install housing (1) to housing (2) with socket bolts
(3) (9 used).

l : 14 mm

m : 210 to 220 N·m(21 to 22 kgf·m, 155 to 162

lbf·ft)

W3-9-2-4
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Control Valve (4-Spool Side)

6
a
5
10 8
4 9 7
3
2 16 6

12
1 11

4
3
8
7 15

13 19
14 20 b

21
22
13 23
30
24
25
26
7 28
29 d
8 19 9 10
20 32
c 33
34
42 35
43 36
44 37 31
45
48
43 46
44 47 38 6
45
49 39
51
50 38 38
39 41
38
52 38 38
53 39 41
e
39 38
41 f
54 52
38 59
55 41
56 g
63
57
58 h 59

4
62

W1V1-02-05-024

W3-9-3-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

68
69
4
j
70
63 71
67 72
63 71
67 59 73
63
67

59 k
74
59
74
1
63

64
19
59

102
103
104
105 7
106 m 7
4 7 8
107 8
8
6
98

108 99
p 100 o n
109
110 111 101
83
87 75
112 84
87 77
77 76
113 13 85
13 78 86 82 81
77 77
114 128 87
118 13
88
89 13
115 77
78
127 91
116 117 40
126 92
114 119 120 79
120 93
119 90 94 80
95
115 96
124 6
115
121 116 114
122 97
123 120 119
116
97 125
W1V1-02-05-025

W3-9-3-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

1- Housing 35- O-Ring 70- Bolt 101- Plug

2- Poppet 36- Plug 71- Spring Seat (2 Used) 102- O-Ring
3- Spring (2 Used) 37- Spool 72- Spring 103- Cap
4- O-Ring (5 Used) 38- Spring Seat (8 Used) 73- Spool 104- Socket Bolt (4 Used)
5- Flange 39- Spring (4 Used) 74- Overload Relief Valve (2 Used) 105- Spool
6- Socket Bolt (13 Used) 40- Body 75- Poppet 106- Spring
7- O-Ring (6 Used) 41- Bolt (4 Used) 76- Spring 107- Flange
8- Plug (6 Used) 42- Plug 77- O-Ring (5 Used) 108- Poppet
9- O-Ring (2 Used) 43- Backup Ring (2 Used) 78- O-Ring (2 Used) 109- Poppet
10- Plug (2 Used) 44- O-Ring (2 Used) 79- O-Ring 110- Spring
11- Poppet 45- Spring (2 Used) 80- Plug 111- Plug
12- Spring 46- Poppet 81- O-Ring 112- Poppet
13- O-Ring (12 Used) 47- Spool 82- Plug 113- Spring
14- O-Ring 48- Plug 83- Poppet 114- Plug (3 Used)
15- Poppet 49- Poppet 84- Poppet 115- O-Ring (3 Used)
16- Flange 50- Spool 85- Spring 116- Spring Seat (3 Used)
19- O-Ring (4 Used) 51- Spool 86- Plug 117- Spring
20- Overload Relief Valve (2 Used) 52- Spring Seat (2 Used) 87- Spring (3 Used) 118- Spool
21- Spring 53- Spring 88- Sleeve 119- Plug (3 Used)
22- Seat 54- Spool 89- Plug 120- O-Ring (3 Used)
23- Poppet 55- O-Ring 90- O-Ring 121- Spring
24- Backup Ring 56- Backup Ring 91- Body 122- Spool
25- O-Ring 57- Spool 92- Spool 123- Body
26- O-Ring 58- Spring 93- Spring 124- Spool
28- Backup Ring 59- O-Ring (8 Used) 94- Spring Seat 125- Spring
29- Sleeve 62- Cap 95- O-Ring 126- O-Ring
30- Spool 63- Socket Bolt (14 Used) 96- Plug 127- Plug
31- O-Ring 64- Cap 97- Socket Bolt (12 Used) 128- Orifice
32- Body 67- Cap (3 Used) 98- Poppet
33- Spring 68- Socket Bolt (2 Used) 99- Poppet
34- Piston 69- Cap 100- Spring

a- Check Valve (Main Relief
Circuit)
b- Overload Relief Valve (Bucket:
Rod Side)
c- Overload Relief Valve (Boom:
Bottom Side)
d- Boom Anti-Drift Valve
e- Travel (Right) k- Overload Relief Valve (Bucket: p- Arm 2 Flow Rate Control Valve
f- Bucket Bottom Side) (Poppet Valve)
g- Boom 1 l- Overload Relief Valve (Boom:
h- Arm 2 Rod Side)
i- Arm Regenerative Valve m- Bypass Shut-Out Valve
j- Flow Combiner Valve n- Boom Anti-Drift Valve
o- Bucket Flow Rate Control Valve

W3-9-3-3
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve
Disassembly of Control Valve (4-Spool Side)
 Disassembly of Spool
1. Remove socket bolts (63) (6 used). Remove cap (62),
O-rings (59) (4 used), and O-rings (4, 13, 14) from
housing (1).
l : 8 mm
IMPORTANT: Do not disassemble the spool (54)
assembly unless necessary.
2. Put the matching marks on the spool (37, 47, 50, 51,
54) assemblies and housing (1). Remove the spool
(37, 47, 50, 51, 54) assemblies and spring (58) from
housing (1).
 Disassembly of Boom Anti-Drift Valve (Selector Valve)
3. Remove plug (36) and O-ring (35) from body (32).
j : 38 mm
4. Remove socket bolts (6) (3 used). Remove the body
(32) assembly, O-rings (13) (5 used), and O-ring (31)
from housing (1).
l : 8 mm
5. Remove piston (34) and spring (33) from body (32).
6. Remove the sleeve (29) assembly, seat (22), and
spring (21) from housing (1). Remove backup rings
(24, 28), O-rings (25, 26), poppet (23), and spool (30)
from sleeve (29).
W3-9-3-4
 Disassembly of Overload Relief Valve (20)
IMPORTANT: Do not disassemble the overload
relief valve. If the overload relief valve has been
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
7. Remove overload relief valves (20) (2 used) and
O-rings (19) (2 used) from housing (1).
j : 32 mm
 Disassembly of Check Valve
8. Remove plug (8), O-ring (7), spring (12), and poppet
(11) from housing (1).
l : 10 mm
9. Remove socket bolts (6) (2 used). Remove flange (5),
O-ring (4), spring (3), and poppet (2) from housing
(1).
l : 8 mm
10. Remove socket bolts (6) (2 used).
Remove flange (16), O-ring (4), spring (3), and
poppet (15) from housing (1).
l : 8 mm
11. Remove plugs (8) (2 used) and O-rings (7) (2 used)
from housing (1).
l : 10 mm
12. Remove plugs (10) (2 used) and O-rings (9) (2 used)
from housing (1).
l : 6 mm
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

 Disassembly of Travel (Right) Spool (37)  Disassembly of Boom 1 Spool (50)

13. Secure spool (37) in a vise by using wooden pieces. 17. Secure spool (50) in a vise by using wooden pieces.
Remove bolt (41), spring seats (38) (2 used), and Remove bolt (41), spring seats (38) (2 used), and
spring (39) from spool (37). spring (39) from spool (50).

l : 8 mm
 Disassembly of Bucket Spool (47)
14. Secure spool (47) in a vise by using wooden pieces.
Remove bolt (41), spring seats (38) (2 used), and
spring (39) from spool (47).
l : 8 mm
15. Warm the plug (42) part of spool (47) by using a
drier. Remove plug (42) by using the special tool
(ST 5909). Remove O-ring (44) and backup ring (43)
from plug (42).
l : 8 mm
18. Warm the plug (48) part of spool (50) by using a
drier. Remove plug (48) by using the special tool
(ST 5909). Remove O-ring (44) and backup ring (43)
from plug (48).
19. Remove spring (45) and poppet (49) from spool (50).
 Disassembly of Arm 2 Spool (51)
20. Secure spool (51) in a vise by using wooden pieces.
Remove bolt (41), spring seats (38, 52) (2 used for
each), and springs (53, 39) from spool (51).

ST 5909 l : 8 mm

 Disassembly of Arm Regenerative Valve

21. Secure spool (54) in a vise by using wooden pieces.
Remove spool (57) from spool (54). Remove backup
W157-02-05-049
ring (55) and O-ring (56) from spool (57).

16. Remove spring (45) and poppet (46) from spool (47).

W3-9-3-5
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

22. Remove socket bolts (63) (8 used). Remove caps (67)
(3 used), cap (64), and O-rings (59) (4 used) from
housing (1).
l : 8 mm
 Disassembly of Flow Combiner Valve
23. Remove socket bolts (68) (2 used). Remove cap
(69), O-ring (4), and the spool (73) assembly from
housing (1). Remove bolt (70), spring seats (71) (2
used), and spring (72) from spool (73).
l : 5 mm
 Disassembly of Overload Relief Valve (74)
IMPORTANT: Do not disassemble the overload
relief valve. If the overload relief valve has been
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
24. Remove overload relief valves (74) (2 used) and
O-rings (19) (2 used) from housing (1).
 Disassembly of Arm 2 Flow Rate Control Valve
28. Remove socket bolts (97) (8 used). Remove the body
(123) assembly, O-rings (77) (3 used), O-rings (13) (2
used), O-ring (78), and orifice (128) from housing (1).
l : 8 mm
29. Remove plugs (114) (3 used), O-rings (115) (3 used),
spring seats (116) (3 used), springs (117, 121, 125),
and spools (118, 122, 124) from body (123).
j : 24 mm
30. Remove plugs (119) (3 used), plug (127), O-rings
(120) (3 used), and O-ring (126) from body (123).
31. Remove spring (113) and poppet (112) from
housing (1).
32. Remove springs (87) (2 used) and the poppet (98,
108) assemblies from housing (1). Remove plugs
(101, 111), springs (100, 110), and poppets (99, 109)
from poppets (98, 108).

j : 32 mm

 Disassembly of Bucket Flow Rate Control Valve

25. Remove socket bolts (97) (4 used). Remove the body
(91) assembly and O-rings (13, 77) from housing (1).

l : 8 mm
26. Remove plug (96), O-ring (95), spring seat (94),
spring (93), and spool (92) from body (91). Remove
plug (89) and O-ring (90) from body (91).

j : 27 mm
27. Remove sleeve (88), springs (85, 87), plug (86), and
poppets (84, 83) from housing (1).

W3-9-3-6
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

 Disassembly of Boom Anti-Drift Valve (Check Valve)

33. Remove socket bolts (6) (4 used). Remove body
(40), O-rings (13) (3 used), and O-rings (77, 78) from
housing (1).

l : 8 mm
34. Remove plugs (80, 82) and O-rings (79, 81) from
body (40).
35. Remove spring (76) and poppet (75) from housing
(1).

 Disassembly of Bypass Shut-Out Valve

36. Remove socket bolts (6) (2 used). Remove flange
(107) and O-ring (4) from housing (1).

l : 8 mm
37. Remove spring (106) and spool (105) from housing
(1).
38. Remove socket bolts (104) (4 used). Remove cap
(103) and O-ring (102) from housing (1).

l : 8 mm
39. Remove plugs (8) (3 used) and O-rings (7) (3 used)
from housing (1).

l : 8 mm

W3-9-3-7
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Control Valve (4-Spool Side)

Control Valve (Upper) Control Valve (Lower)

59, 62 63
63 63
19, 20 19, 20

123 36 6 59, 67 63 59, 67 63 59, 67 59, 64

W1V1-02-05-065 W1V1-02-05-066

Control Valve (Side) Control Valve (Front)

19, 20 40 6 19, 20 7, 8, 11, 12 6 3, 4, 15, 16

6
107

7, 8

1
7, 8, 11, 12

103 104 97 123 19, 74 91 97 1 6 2, 3, 45

W1V1-02-05-067 W1V1-02-05-068

W3-9-3-8
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Control Valve (Upper) Section C-C (4-Spool Side)

J I H G F E D C

A 7

W1V1-02-05-038
J I H G F E D C
W1V1-02-05-065

Section D-D (4-Spool Side) Section E-E (4-Spool Side) Section F-F (4-Spool Side)

f g
e

41
38 C

20
39 1
38
47
19
51 50
B

46 49 D
45 45 1
19
43, 44 19 43, 44
74
74 48
42

W1V1-02-05-035 W1V1-02-05-036 W1V1-02-05-028

W3-9-3-9
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Section G-G (4-Spool Side) Section H-H (4-Spool Side)

h
61
60
41
38
52
20
53
52
1 19
38
37
E F

65

66

W1V1-02-05-029 W626-02-05-001

Section I-I (4-Spool Side) Section J-J (4-Spool Side)

105 106 4
58

57
107
56, 55

54

W1V1-02-05-071 W1V1-02-05-037

W3-9-3-10
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Detail A Detail B

1 96
73
95
70
94
93
4
91
71 92
1
72 90
71 89
88
69 83 84 77 13 85 86 87

W1V1-02-05-040 W1V1-02-05-033

Detail C Detail D
36
35 77 13
32 1 119
34 120
33
118
30
31 123
29
23 1
13
13 78
28 80 117
26
116
25 79
24 115
22 114
21 40
81 98 99 100 101 87

82 W1V1-02-05-032
75 76 77
W1V1-02-05-031

Detail E Detail F
114 1 119
128
78 115
120
116
125

122
124
121
116
120 115
114
119
108 109 77
112 113 77 13 123
110 111 87 123 W1V1-02-05-042 W1V1-02-05-034

W3-9-3-11
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

1- Housing 35- O-Ring 70- Bolt 101- Plug

2- Poppet 36- Plug 71- Spring Seat (2 Used) 102- O-Ring
3- Spring (2 Used) 37- Spool 72- Spring 103- Cap
4- O-Ring (5 Used) 38- Spring Seat (8 Used) 73- Spool 104- Socket Bolt (4 Used)
5- Flange 39- Spring (4 Used) 74- Overload Relief Valve (2 Used) 105- Spool
6- Socket Bolt (13 Used) 40- Body 75- Poppet 106- Spring
7- O-Ring (6 Used) 41- Bolt (4 Used) 76- Spring 107- Flange
8- Plug (6 Used) 42- Plug 77- O-Ring (5 Used) 108- Poppet
9- O-Ring (2 Used) 43- Backup Ring (2 Used) 78- O-Ring (2 Used) 109- Poppet
10- Plug (2 Used) 44- O-Ring (2 Used) 79- O-Ring 110- Spring
11- Poppet 45- Spring (2 Used) 80- Plug 111- Plug
12- Spring 46- Poppet 81- O-Ring 112- Poppet
13- O-Ring (12 Used) 47- Spool 82- Plug 113- Spring
14- O-Ring 48- Plug 83- Poppet 114- Plug (3 Used)
15- Poppet 49- Poppet 84- Poppet 115- O-Ring (3 Used)
16- Flange 50- Spool 85- Spring 116- Spring Seat (3 Used)
19- O-Ring (4 Used) 51- Spool 86- Plug 117- Spring
20- Overload Relief Valve (2 Used) 52- Spring Seat (2 Used) 87- Spring (3 Used) 118- Spool
21- Spring 53- Spring 88- Sleeve 119- Plug (3 Used)
22- Seat 54- Spool 89- Plug 120- O-Ring (3 Used)
23- Poppet 55- O-Ring 90- O-Ring 121- Spring
24- Backup Ring 56- Backup Ring 91- Body 122- Spool
25- O-Ring 57- Spool 92- Spool 123- Body
26- O-Ring 58- Spring 93- Spring 124- Spool
28- Backup Ring 59- O-Ring (8 Used) 94- Spring Seat 125- Spring
29- Sleeve 62- Cap 95- O-Ring 126- *O-Ring
30- Spool 63- Socket Bolt (14 Used) 96- Plug 127- *Plug
31- O-Ring 64- Cap 97- Socket Bolt (12 Used) 128- Orifice
32- Body 67- Cap (3 Used) 98- Poppet
33- Spring 68- Socket Bolt (2 Used) 99- Poppet
34- Piston 69- Cap 100- Spring

e- Travel (Right) f- Bucket g- Boom 1 h- Arm 2

fNOTE: As for the item with mark *, refer to W3-9-3-2.

W3-9-3-12
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Control Valve (4-Spool Side)  Assembly of Boom 1 Spool (50)

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
 Assembly of Travel (Right) Spool (37)
1. Secure spool (37) in a vise by using wooden pieces.
Install spring seats (38) (2 used), spring (39), and
bolt (41) to spool (37).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
 Assembly of Bucket Spool (47)
2. Secure spool (47) in a vise by using wooden pieces.
Install poppet (46) and spring (45) to the bottom of
spool (47).
3. Install O-ring (44) and backup ring (43) to plug (42).
Apply LOCTITE #271 onto the thread part of plug
(42).
4. Install plug (42) to spool (47) by using the special
tool (ST 5909).
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
ST 5909
6. Secure spool (50) in a vise by using wooden pieces.
Install poppet (49) and spring (45) to the bottom of
spool (50).
7. Install O-ring (44) and backup ring (43) to plug (48).
Apply LOCTITE #271 onto the thread part of plug
(48).
8. Install plug (48) to spool (50) by using the special
tool (ST 5909).
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
9. Install spring seats (38) (2 used), spring (39), and
bolt (41) to the top of spool (50).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
 Assembly of Arm 2 Spool (51)
10. Secure spool (51) in a vise by using wooden pieces.
Install spring seats (38, 52) (2 used for each), springs
(39, 53), and bolt (41) to spool (51).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
11. Install O-rings (59) (4 used) to housing (1). Install
caps (67) (3 used) and cap (64) to housing (1) with
socket bolts (63) (8 used).

W157-02-05-049

5. Install spring seats (38) (2 used), spring (39), and

bolt (41) to the top of spool (47).

l : 8 mm

m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

W3-9-3-13
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

 Assembly of Arm Regenerative Valve

12. Secure spool (54) in a vise by using wooden pieces.
Install O-ring (56) and backup ring (55) to spool (57).
Install spool (57) to spool (54). Install the spool (54)
assembly and spring (58) to housing (1).

 Assembly of Spool
13. Install the spool (51, 50, 47, 37) assemblies, O-rings
(59) (4 used), and O-ring (4) to housing (1). Install
cap (62) to housing (1) with socket bolts (63) (6
used).

l : 8 mm

m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft)

W3-9-3-14
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

 Assembly of Bucket Flow Rate Control Valve
14. Install O-rings (95, 90) to plugs (96, 89).
15. Install spring (93), spool (92), spring seat (94), and
plug (96) to body (91).
j : 27 mm
16. Install plug (89) to body (91).
 Assembly of Bypass Shut-Out Valve
21. Install spool (105), spring (106), and O-ring (4) to
housing (1). Install flange (107) to housing (1) with
socket bolts (6) (4 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

17. Install poppets (83, 84), springs (85, 87), plug (86), 22. Install plugs (8) (3 used) and O-rings (7) (3 used) to
and sleeve (88) to housing (1). housing (1).

18. Install O-rings (13, 77) to housing (1). Install body

(91) to housing (1) with socket bolts (97) (4 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
 Assembly of Flow Combiner Valve
19. Install spring seats (71) (2 used) and spring (72) to
bolt (70). Install bolt (70) to spool (73).
20. Install spool (73) and O-ring (4) to housing (1).
Install cap (69) to housing (1) with socket bolts (68)
(2 used).
 Assembly of Overload Relief Valves (20, 74)
IMPORTANT: If the overload relief valve has been
disassembled, pressure should be adjusted.
(Refer to TROUBLESHOOTING / Operational
Performance Test in the separated volume, T/M.)
23. Install O-rings (19) (4 used) to overload relief valves
(20, 74) (2 used for each). Install overload relief
valves (20, 74) (2 used for each) to housing (1).
j : 32 mm
m : 85 N·m (8.5 kgf·m, 63 lbf·ft)

l : 5 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W3-9-3-15
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

 Assembly of Check Valve

24. Install O-rings (9) (2 used) to plugs (10) (2 used).
Install plugs (10) (2 used) to housing (1).

l : 6 mm
25. Install O-rings (7) (2 used) to plugs (8) (2 used).
Install plugs (8) (2 used) to housing (1).

l : 10 mm
26. Install O-ring (7) to plug (8). Install poppet (11),
spring (12), and plug (8) to housing (1).

l : 10 mm
27. Install poppets (2, 15), springs (3) (2 used), and
O-rings (4) (2 used) to housing (1).
28. Install flanges (5, 16) to housing (1) with socket
bolts (6) (4 used).

l : 8 mm

m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

29. Install O-ring (102) to housing (1). Install cap (103)
to housing (1) with socket bolts (104) (4 used).

l : 8 mm

m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

W3-9-3-16
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

 Assembly of Boom Anti-Drift Valve (Selector Valve)
30. Install backup rings (24, 28) and O-rings (25, 26) to
sleeve (29).
31. Apply grease onto seat (22) and spring (21) in
order to prevent from falling off. Face the hole on
spool (30) to the poppet (23) side. Install spool (30),
poppet (23), seat (22), and spring (21) to sleeve (29).
Install the sleeve (29) assembly to housing (1).
32. Install O-ring (35) to plug (36). Install spring (33),
piston (34), O-ring (31), and plug (36) to body (32).
33. Install O-rings (13) (5 used) to housing (1). Install the
body (32) assembly with socket bolts (6) (3 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
34. Tighten plug (36).
j : 38 mm
 Assembly of Boom Anti-Drift Valve (Check Valve)
35. Install O-rings (79, 81) to plugs (80, 82).
36. Install poppet (75), spring (76), O-rings (77, 78), and
O-rings (13) (3 used) to housing (1).
37. Install body (40) to housing (1) with socket bolts (6)
(4 used).
 Assembly of Arm 2 Flow Rate Control Valve
39. Install O-rings (115, 120) (3 used for each) to plugs
(114, 119) (3 used for each) as shown in detail D, E,
and F.
40. Install spool (118), spring (117), and spring seat
(116) to body (123) as shown in detail D. Temporarily
tighten plugs (114, 119) to body (123).
j : 24 mm
41. Install spool (122), spring (121), and spring seat
(116) to body (123) as shown in detail F. Temporarily
tighten plugs (114, 119) to body (123).
42. Install spool (124), spring (125), and spring seat
(116) to body (123) as shown in detail E. Temporarily
tighten plugs (114, 119) to body (123).
43. Install poppets (98, 99), spring (100), plug (101),
spring (87), orifice (128), and O-rings (13, 77) to
housing (1) as shown in detail D.
44. Install poppets (108, 109), spring (110), plug (111),
spring (87), and O-rings (77, 78) to housing (1) as
shown in detail E.
45. Install poppet (112), spring (113), and O-rings (77,
13) to housing (1) as shown in detail F.
46. Install plug (127) and O-ring (126) to body (123).

l : 8 mm

m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

38. Tighten plugs (80, 82).

W3-9-3-17
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

47. Install body (123) to housing (1) with socket bolts

(97) (8 used).

l : 8 mm

m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

48. Tighten plugs (114, 119) (3 used for each) to body
(123).

j : 24 mm

W3-9-3-18
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Control Valve (5-Spool Side)

7
3 6
2 5
4
8
13
12
1 11 8
7

17
10 14
9 15

a
16
10
9 18
19

20 22 b
23
24
30
25
20 27
20 28
21 c
29
37 31
38 32
39 26 33
d 34
28
40 35
36
41

8
45 42
43
47 46 42 42
43 44
42 42
48 42 e

49 43 44
50 42
f
43
44
48
42 42 g
43 44
42 51
h
44 52
51
i

W1V1-02-05-026
55

W3-9-4-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

56 57
k
104
j 58
77
56 78
57 61
62
63
104
20
58
59 13
60 64
61 o
62 65
20 63
79 8
13 8 80
81 7
64 75
65 82
70
66 71 6
67
68 8 5
13
69 83
12
72 l
76
73 13

74
8
p n
91 20
87 84
r 85
88
6
91 89
93
92 90
96 q
6 m
92
97 93 10
94
16 10 9
95
15 9 38
14 52
86
s 98
3
2 52 51 10
98 9
52
99 51
100 52

98 103
52 51
98
51

51
10
9

W1V1-02-05-027

W3-9-4-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

1- Housing 28- Backup Ring (2 Used) 57- O-Ring (2 Used) 84- Cover (2 Used)
2- O-Ring (2 Used) 29- Sleeve 58- Socket Bolt (8 Used) 85- O-Ring (2 Used)
3- Plug (2 Used) 30- Spool 59- Spool 86- Poppet
4- Poppet 31- O-Ring 60- Spring 87- Plug
5- Spring (2 Used) 32- Body 61- Spring Seat (2 Used) 88- O-Ring
6- O-Ring (4 Used) 33- Spring 62- O-Ring (2 Used) 89- Spring
7- flange (3 Used) 34- Piston 63- Plug (2 Used) 90- Poppet
8- Socket Bolt (29 Used) 35- O-Ring 64- Sleeve (2 Used) 91- Socket Bolt (4 Used)
9- O-Ring (6 Used) 36- Plug 65- Spring (2 Used) 92- Cap (2 Used)
10- Plug (6 Used) 37- Poppet 66- Plug 93- Spring Seat (2 Used)
11- Poppet 38- Spring (2 Used) 67- Spring 94- Spring
12- Spring (3 Used) 39- O-Ring 68- Poppet 95- Spool
13- O-Ring (6 Used) 40- Spacer 69- Poppet 96- Spring
14- O-Ring (2 Used) 41- Spool 70- Plug 97- Spool
15- Backup Ring (2 Used) 42- Spring Seat (10 Used) 71- O-Ring 98- Cap (4 Used)
16- Plug (2 Used) 43- Spring (5 Used) 72- Flange 99- Overload Relief Valve
17- Main Relief Valve 44- Bolt (5 Used) 73- Spring 100- O-Ring
18- O-Ring 45- Spool 74- Poppet 103- Cap
19- Overload Relief Valve 46- Spool 75- Flange (2 Used) 104- Body (2 Used)
20- O-Ring (11 Used) 47- Spool 76- Poppet (2 Used)
21- O-Ring 48- Spring Seat (2 Used) 77- Spool
22- Spring 49- Spring 78- Spring
23- Seat 50- Spool 79- Plug
24- Poppet 51- O-Ring (10 Used) 80- Spring
25- Backup Ring 52- Socket Bolt (16 Used) 81- Poppet
26- O-Ring 55- Cap 82- Poppet
27- O-Ring 56- Plug (2 Used) 83- Poppet

a- Main Relief Valve
b- Overload Relief Valve (Arm:
Rod Side)
c- Arm Anti-Drift Valve
d- Load Check Valve (Arm
Regenerative Circuit)
e- Travel (Left)
f- Auxiliary l- Check Valve (Auxiliary Flow o- Load Check Valve (Boom 2
g- Boom 2 Combiner Circuit) Parallel Circuit, Swing Circuit)
h- Arm 1 m- Load Check Valve (Travel (Left) p- Arm Anti-Drift Valve
i- Swing Parallel Circuit) q- Auxiliary Flow Combiner Valve
j- Arm 1 Flow Rate Control Valve n- Check Valve (Digging r- Digging Regenerative Valve
k- Auxiliary Flow Rate Control Regenerative Circuit) s- Overload Relief Valve (Arm:
Valve Bottom Side)

W3-9-4-3
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve
Disassembly of Control Valve (5-Spool Side)
 Disassembly of Spool
1. Remove socket bolts (52) (6 used). Remove cap
(55), O-rings (51) (5 used), and O-rings (20, 21) from
housing (1).
l : 8 mm
2. Put the matching marks on spools (41, 45, 46, 47,
50) and housing (1). Remove the spool (41, 45, 46,
47, 50) assemblies from housing (1).
 Disassembly of Arm Anti-Drift Valve
3. Remove plug (36) and O-ring (35) from body (32).
j : 38 mm
4. Remove socket bolts (8) (3 used). Remove the body
(32) assembly, O-rings (31), and O-rings (20) (5 used)
from housing (1).
l : 8 mm
5. Remove piston (34) and spring (33) from body (32).
6. Remove spool (30), sleeve (29), poppet (24), seat
(23), and spring (22) from housing (1).
Remove backup rings (25, 28) and O-rings (26, 27)
from sleeve (29).
W3-9-4-4
 Disassembly of Overload Relief Valve (19)
IMPORTANT: Do not disassemble the overload
relief valve. If the overload relief valve has been
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
7. Remove overload relief valve (19) and O-ring (18)
from housing (1).
j : 32 mm
 Disassembly of Main Relief Valve (17)
IMPORTANT: Do not disassemble the main
relief valve. If the main relief valve has been
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
8. Remove main relief valve (17) from housing (1).
j : 32 mm
 Disassembly of Load Check Valve (Arm Regenerative
Parallel Circuit)
9. Remove spacer (40), spring (38), and poppet (37)
from housing (1). Remove backup ring (28) and
O-ring (39) from spacer (40).
10. Remove socket bolts (8) (2 used). Remove flange (7),
O-ring (6), spring (5), and poppet (4) from housing
(1).
l : 8 mm
11. Remove socket bolts (8) (2 used). Remove flange
(7), O-ring (13), spring (12), and poppet (11) from
housing (1).
l : 8 mm
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

12. Remove plugs (10) (2 used) and O-rings (9) (2 used)  Disassembly of Arm 1 Spool (47)
from housing (1). 18. Secure spool (47) in a vise by using wooden pieces.
Remove bolt (44), spring seats (42, 48) (2 used for
l : 8 mm each), and springs (49, 43) from spool (47).
13. Remove plug (3) and O-ring (2) from housing (1).
l : 8 mm
l : 10 mm
14. Remove plug (16), backup ring (15), and O-ring (14)  Disassembly of Swing Spool (50)
from housing (1). 19. Secure spool (50) in a vise by using wooden pieces.
Remove bolt (44), spring seats (42) (2 used), and
j : 24 mm spring (43) from spool (50).

l : 8 mm
 Disassembly of Travel (Left) Spool (41)
15. Secure spool (41) in a vise by using wooden pieces.
Remove bolt (44), spring seats (42) (2 used), and
spring (43) from spool (41).

l : 8 mm

 Disassembly of Auxiliary Spool (45)

16. Secure spool (45) in a vise by using wooden pieces.
Remove bolt (44), spring seats (42) (2 used), and
spring (43) from spool (45).

l : 8 mm

 Disassembly of Boom 2 Spool (46)

17. Secure spool (46) in a vise by using wooden pieces.
Remove bolt (44), spring seats (42) (2 used), and
spring (43) from spool (46).

l : 8 mm

W3-9-4-5
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

20. Remove socket bolts (52) (10 used). Remove caps
(98) (4 used), cap (103), and O-rings (51) (5 used)
from housing (1).
l : 8 mm
 Disassembly of Arm Anti-Drift Valve
24. Remove socket bolts (8) (4 used). Remove flange
(72), O-rings (20) (3 used), spring (73), and poppet
(74) from housing (1). Remove plug (70) and O-ring
(71) from flange (72).

 Disassembly of Digging Regenerative Valve and
Auxiliary Flow Combiner Valve
21. Remove socket bolts (91) (4 used). Remove caps
(92) (2 used), O-rings (6) (2 used), spring seats (93)
(2 used), springs (96, 94), and spools (97, 95) from
housing (1).
l : 8 mm
 Disassembly of Arm 1 Flow Rate Control Valve and
Auxiliary Flow Rate Control Valve
25. Loosen plugs (56, 63) (2 used for each) from bodies
(104) (2 used).

l : 5 mm 26. Remove socket bolts (58) (8 used). Remove the body

(104) assemblies (2 used) and O-rings (20, 13) (2
used for each) from housing (1).
 Disassembly of Overload Relief Valve (99)
IMPORTANT: Do not disassemble the overload l : 8 mm
relief valve. If the overload relief valve has been
27. Remove plugs (63) (2 used), O-rings (62) (2 used),
disassembled, pressure should be adjusted. (Refer
spring seats (61) (2 used), springs (60, 78), and
to TROUBLESHOOTING / Operational Performance
spools (59, 77) from bodies (104) (2 used). Remove
Test in the separated volume, T/M.)
plugs (56) (2 used) and O-rings (57) (2 used) from
22. Remove overload relief valve (99) and O-ring (100) bodies (104) (2 used).
from housing (1).
28. Remove sleeves (64) (2 used), springs (65) (2 used),
j : 32 mm springs (67, 80), plugs (66, 79), and poppets (68, 69,
81, 82) from housing (1).
 Disassembly of Check Valve (Auxiliary Flow Combiner
Circuit)
23. Remove socket bolts (8) (2 used). Remove flange (7),
O-ring (6), spring (5), and poppet (83) from housing
(1).

l : 8 mm

W3-9-4-6
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

 Disassembly of Load Check Valve (Boom 2 Parallel 33. Remove plug (16), backup ring (15), and O-ring (14)
Circuit, Swing Circuit) from housing (1).
29. Remove socket bolts (8) (8 used) from housing (1).
Remove flanges (75) (2 used), O-rings (13) (2 used), j : 24 mm
springs (12) (2 used), and poppets (76) (2 used). 34. Remove plug (3) and O-ring (2) from housing (1).
l : 8 mm l : 10 mm
30. Remove socket bolts (8) (8 used). Remove covers 35. Remove plugs (10) (3 used) and O-rings (9) (3 used)
(84) (2 used) and O-rings (85) (2 used) from housing from housing (1).
(1).
l : 8 mm
l : 8 mm

 Disassembly of Load Check Valve (Travel (Left) Parallel

Circuit)
31. Remove plug (10), O-ring (9), spring (38), and
poppet (86) from housing (1).

l : 8 mm

38 86

10

W1V1-02-05-016

 Disassembly of Check Valve (Digging Regenerative

Circuit)
32. Remove plug (87), O-ring (88), spring (89), and
poppet (90) from housing (1).

j : 24 mm

W3-9-4-7
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Control Valve (5-Spool Side)

Control Valve (Upper) Control Valve (Lower)

51, 55 52 52 51, 98 52 51, 98 52 51, 103 52 51, 98

52
51, 98

W1V1-02-05-065 W1V1-02-05-066

Control Valve (Side) Control Valve (Front)

17 19 36 32 9, 10 8

7, 11, 12, 13

8
8
72
75
8

2, 3
58

4, 5, 6, 7

10 104 99, 100 9, 10

W1V1-02-05-070 W1V1-02-05-068

W3-9-4-8
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Control Valve (Upper) Section C-C (5-Spool Side)

J I H G F E D C

17

1
9, 10

7 97
5
6
83 96
93
92

J I H G F E D C
W1V1-02-05-065 W1V1-02-05-043

Section D-D (5-Spool Side) Section E-E (5-Spool Side) Section F-F (5-Spool Side)

e f
54 g
55
53
44
42
43
14, 15, 16
42 76
84
51
8 12 46
41
45 13
75
A 8

1
8
1 103
51
98 84 1

W1V1-02-05-044 W1V1-02-05-045 W1V1-02-05-046

W3-9-4-9
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

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

h
44 i
42
C
48
49
21 43
19
18 48 76
42
47 12 50

13
D
8
1

75
B
1
100
99
1

W1V1-02-05-050 W1V1-02-05-051 W1V1-02-05-052

Detail A Detail B

88 89 90
1 63
62
61
78
104
77 1

57

56
64
10
82 81 13 20 80 79 65
9 2 3

W1V1-02-05-033 W1V1-02-05-053

W3-9-4-10
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Detail C Detail D
36
35
34 1
32 63
62
33
24 61
30
60
104
13
59
29
28
57
20 27
26 56
20 25 64
23 69 68 67 13 20 66 65
22

W1V1-02-05-033

71 70 13 73 74 W1V1-02-05-054

1- Housing 28- Backup Ring (2 Used) 57- O-Ring (2 Used) 84- Cover (2 Used)
2- O-Ring (2 Used) 29- Sleeve 58- Socket Bolt (8 Used) 85- *O-Ring (2 Used)
3- Plug (2 Used) 30- Spool 59- Spool 86- *Poppet
4- Poppet 31- *O-Ring 60- Spring 87- *Plug
5- Spring (2 Used) 32- Body 61- Spring Seat (2 Used) 88- O-Ring
6- O-Ring (4 Used) 33- Spring 62- O-Ring (2 Used) 89- Spring
7- Flange (3 Used) 34- Piston 63- Plug (2 Used) 90- Poppet
8- Socket Bolt (29 Used) 35- O-Ring 64- Sleeve (2 Used) 91- *Socket Bolt (4 Used)
9- O-Ring (6 Used) 36- Plug 65- Spring (2 Used) 92- Cap (2 Used)
10- Plug (6 Used) 37- *Poppet 66- Plug 93- Spring Seat (2 Used)
11- Poppet 38- *Spring (2 Used) 67- Spring 94- *Spring
12- Spring (3 Used) 39- *O-Ring 68- Poppet 95- *Spool
13- O-Ring (6 Used) 40- *Spacer 69- Poppet 96- Spring
14- O-Ring (2 Used) 41- Spool 70- Plug 97- Spool
15- Backup Ring (2 Used) 42- Spring Seat (10 Used) 71- O-Ring 98- Cap (4 Used)
16- Plug (2 Used) 43- Spring (5 Used) 72- Flange 99- Overload Relief Valve
17- Main Relief Valve 44- Bolt (5 Used) 73- Spring 100- O-Ring
18- O-Ring 45- Spool 74- Poppet 103- Cap
19- Overload Relief Valve 46- Spool 75- Flange (2 Used) 104- Body (2 Used)
20- O-Ring (11 Used) 47- Spool 76- Poppet (2 Used)
21- O-Ring 48- Spring Seat (2 Used) 77- Spool
22- Spring 49- Spring 78- Spring
23- Seat 50- Spool 79- Plug
24- Poppet 51- O-Ring (10 Used) 80- Spring
25- Backup Ring 52- Socket Bolt (16 Used) 81- Poppet
26- O-Ring 55- Cap 82- Poppet
27- O-Ring 56- Plug (2 Used) 83- Poppet

e- Travel (Left) g- Boom 2 i- Swing

f- Auxiliary h- Arm 1

fNOTE: As for the item with mark *, refer to W3-9-4-1

and W3-9-4-2.

W3-9-4-11
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Control Valve (5-Spool Side)
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
 Assembly of Travel (Left) Spool (41)
1. Secure spool (41) in a vise by using wooden pieces.
Install spring seats (42) (2 used), spring (43), and
bolt (44) to spool (41).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
6. Install O-rings (51) (5 used) to housing (1). Install
cap (103) and caps (98) (4 used) to housing (1) with
socket bolts (52) (10 used).
l : 8 mm
m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft)
7. Install the spool (41, 45, 46, 47, 50) assemblies to
housing (1).
8. Install O-rings (51) (5 used) and O-rings (20, 21)
to housing (1). Install cap (55) to housing (1) with
socket bolts (52) (6 used).

l : 8 mm
 Assembly of Auxiliary Spool (45)
2. Secure spool (45) in a vise by using wooden pieces. m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft)
Install spring seats (42) (2 used), spring (43), and
bolt (44) to spool (45).

l : 8 mm

m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

 Assembly of Boom 2 Spool (46)

3. Secure spool (46) in a vise by using wooden pieces.
Install spring seats (42) (2 used), spring (43), and
bolt (44) to spool (46).

l : 8 mm

m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

 Assembly of Arm 1 Spool (47)

4. Secure spool (47) in a vise by using wooden pieces.
Install spring seats (42, 48) (2 used for each), springs
(43, 49), and bolt (44) to spool (47).

l : 8 mm

m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

 Assembly of Swing Spool (50)

5. Secure spool (50) in a vise by using wooden pieces.
Install spring seats (42) (2 used), spring (43), and
bolt (44) to spool (50).

l : 8 mm

m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

W3-9-4-12
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

 Assembly of Auxiliary Flow Rate Control Valve
9. Install O-rings (57, 62) to plugs (56, 63).
10. Install spring (78), spool (77), spring seat (61), and
plug (63) to body (104).
11. Install plug (56) to body (104).
12. Install poppets (81, 82), springs (65, 80), plug (79),
and sleeve (64) to housing (1).
13. Install O-rings (13, 20) to housing (1). Install body
(104) to housing (1) with socket bolts (58) (4 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
 Assembly of Check Valve (Digging Regenerative Circuit)
16. Install O-ring (88) to plug (87). Install poppet (90),
spring (89), and plug (87) to housing (1).
j : 24 mm
 Assembly of Load Check Valve
17. Install poppets (76) (2 used), springs (12) (2 used),
and O-rings (13) (2 used) to housing (1).
18. Install flanges (75) (2 used) to housing (1) with
socket bolts (8) (8 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

 Assembly of Check Valve (Auxiliary Flow Combiner
Circuit)
14. Install poppet (83), spring (5), and O-ring (6) to
housing (1). Install flange (7) to housing (1) with
socket bolts (8) (2 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
19. Install O-ring (14) and backup ring (15) to plug (16).
Install plug (16) to housing (1).
j : 24 mm
20. Install O-rings (85) (2 used) to housing (1). Install
covers (84) (2 used) to housing (1) with socket bolts
(8) (8 used).
l : 8 mm

m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

 Assembly of Digging Regenerative Valve and Auxiliary
Flow Combiner Valve
15. Install spool (97, 95), springs (96, 94), O-rings (6) (2
used), and spring seats (93) (2 used) to housing (1).
Install caps (92) (2 used) to housing (1) with socket
bolts (91) (4 used).

l : 5 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W3-9-4-13
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

21. Install O-ring (9) to plug (10). Install poppet (86),  Assembly of Arm 1 Flow Rate Control Valve
spring (38), and plug (10) to housing (1). 30. Install O-rings (57, 62) to plugs (56, 63).

l : 8 mm 31. Install spring (60), spool (59), spring seat (61), and
plug (63) to body (104).
22. Install O-ring (2) to plug (3). Install plug (3) to
housing (1). 32. Install plug (56) to body (104).
33. Install poppets (69, 68), springs (65, 67), plug (66),
l : 10 mm
and sleeve (64) to housing (1).
23. Install O-rings (9) (3 used) to plugs (10) (3 used).
34. Install O-rings (13, 20) to housing (1). Install body
Install plugs (10) (3 used) to housing (1).
(104) to housing (1) with socket bolts (58) (4 used).
l : 8 mm
l : 8 mm

 Assembly of Arm Anti-Drift Valve m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

24. Install backup rings (25, 28) and O-rings (26, 27) to
sleeve (29).
25. Apply grease onto seat (23) and spring (22) in order
to prevent from falling off.
26. Face the hole on spool (30) to the poppet (24) side.
Install spool (30), poppet (24), seat (23), and spring
(22) to sleeve (29). Install the sleeve (29) assembly to
housing (1).
27. Install O-ring (35) to plug (36). Install spring (33),
piston (34), O-ring (31), and plug (36) to body (32).

j : 38 mm
28. Install O-rings (20) (5 used) and O-ring (31) to
housing (1). Install the body (32) assembly to
housing (1) with socket bolts (8) (3 used).

l : 8 mm

m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

29. Tighten plug (36).

j : 38 mm

W3-9-4-14
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve
 Assembly of Arm Anti-Drift Valve
35. Install O-ring (71) to plug (70). Install plug (70) to
flange (72).
36. Install flange (72), O-rings (20) (3 used), spring (73),
and poppet (74) to housing (1) with socket bolts (8)
(4 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
 Assembly of Overload Relief Valves (19, 99)
IMPORTANT: If the overload relief valve has been
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
37. Install O-rings (18, 100) to overload relief valves (19,
99). Install overload relief valves (19, 99) to housing
(1).
j : 32 mm
m : 85 N·m (8.5 kgf·m, 63 lbf·ft)
 Assembly of Main Relief Valve
IMPORTANT: If the main relief valve has been
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
38. Install main relief valve (17) to housing (1).
j : 32 mm
m : 60 N·m (6 kgf·m, 44 lbf·ft)
W3-9-4-15
 Assembly of Load Check Valve (Arm Regenerative
Circuit)
39. Install poppet (4), spring (5), and O-ring (6) to
housing (1). Install flange (7) to housing (1) with
socket bolts (8) (2 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
40. Install poppet (11), spring (12), and O-ring (13) to
housing (1). Install flange (7) to housing (1) with
socket bolts (8) (2 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
41. Install backup ring (28) and O-ring (39) to spacer
(40). Install spacer (40), spring (38), and poppet (37)
to housing (1).
42. Install O-rings (9) (2 used) to plugs (10) (2 used).
Install plugs (10) (2 used) to housing (1).
l : 8 mm
43. Install O-ring (2) to plug (3). Install plug (3) to
housing (1).
l : 10 mm
44. Install backup ring (15) and O-ring (14) to plug (16).
Install plug (16) to housing (1).
j : 24 mm
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

(Blank)

W3-9-4-16
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Removal and Installation of Swing Device

1 3 2

WDCD-03-06-001

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open engine cover (1).
3. Remove bolts, washers (2) (5 used). Remove cover
(3).

j : 17 mm

W3-10-1-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

WDCD-03-10-001

4. Disconnect connector (4).

5. Place a container under swing device (5).
dCAUTION:
lb)
Swing device (5) weight: 220 kg (490

Disconnect hose (6).

8. Attach a nylon sling onto the body of swing motor.
j : 36 mm Hoist and hold swing device (5).

6. Disconnect hoses (7) (2 used).
j : 19 mm
7. Remove socket bolts (8) (8 used) and flanges (9)
(4 used). Disconnect hoses (10) (2 used). Remove
O-rings (11) (2 used).
9. Remove bolts (12) (14 used) and washers (13) (14
used). Remove swing device (5).
j : 30 mm
10. Remove the adapter with swing device (5) attached
if necessary.

l : 8 mm

W3-10-1-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

WDCD-03-10-001

Installation
1. Install all removed adapters to swing device (5). 5. Connect hoses (7) (2 used).

dCAUTION:
lb)
Swing device (5) weight: 220 kg (490 j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

2. Apply THREEBOND #1215 onto the main frame
mounting surface of swing device (5). Attach a 6. Connect hose (6).
nylon sling onto the body of swing motor. Hoist
swing device (5). j : 36 mm

3. Install swing device (5) with washers (13) (14 used) m : 180 N·m (18 kgf·m, 133 lbf·ft)
and bolts (12) (14 used). 7. Connect connector (4).
j : 30 mm

m : 500 N·m (50 kgf·m, 370 lbf·ft)

4. Install O-rings (11) (2 used). Connect hoses (10) (2
used) with flanges (9) (4 used) and socket bolts (8)
(8 used).

l : 8 mm

m : 58 N·m (5.8 kgf·m, 43 lbf·ft)

W3-10-1-3
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

1 3 2

WDCD-03-06-001

8. Bleed air from the hydraulic system. (Refer to W1-4-

1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
9. Install cover (3) with bolts, washers (2) (5 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

10. Shut engine cover (1).

W3-10-1-4
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Disassembly of Swing Device

23

24
1

25

22
2

3
33
26
21 4
32

20
6
27 7
19
8

28
9
18

29 10

30 17 11
16
12
15
31 13

14

WDAA-03-11-006

1- Motor
2- First Stage Sun Gear
3- Thrust Plate
4- Pin (3 Used)
5- Spring Pin (3 Used)
6- Needle Bearing (3 Used)
7- Planetary Gear (3 Used)
8- Thrust Plate (3 Used)
9- Pin (3 Used)
10- Spring Pin (3 Used) 19- Thrust Plate 28- Oil Seal
11- Needle Bearing (6 Used) 20- Second Stage Sun Gear 29- Sleeve
12- Planetary Gear (3 Used) 21- First Stage Carrier 30- O-Ring
13- Thrust Plate (3 Used) 22- Retaining Ring 31- Shaft
14- Roller Bearing 23- Socket Bolt (8 Used) 32- Drain Plug
15- Bearing Nut 24- Socket Bolt (12 Used) 33- Pipe
16- Lock Plate 25- Ring Gear
17- Bolt (2 Used) 26- Housing
18- Second Stage Carrier 27- Roller Bearing

W3-10-2-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Disassembly of Swing Device

2. Place swing device (b) onto the special tool (ST
d CAUTION: Swing device (b) weight: 220 kg (490
lb)
5097). Secure swing device (b) with bolts (M20,
Pitch 2.5 mm) (2 used) so that stopper (c) at the
dCAUTION: When hoisting swing device (b), do
not sling the rope suddenly.
bottom of special tool (ST 5097) should be inserted
into the clearance between teeth of the pinion gear
in shaft (31). Secure the special tool (ST 5097) on a
1. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
workbench in order to receive the reaction force.
eyebolt mounting positions (a) (2 places) of swing
device (b). Hoist swing device (b). j : 30 mm

b
a

b c
ST 5097

W178-02-11-134

b- Swing Device
c- Stopper

3. Remove drain plug (32). Drain off oil from swing

device (b).
W178-02-06-005 l : 8 mm
4. Disconnect pipe (33) from housing (26).
a- Eyebolt Mounting Position
b- Swing Device j : 18 mm
5. Put the matching marks at the jointed part between
motor (1) and ring gear (25), between ring gear (25)
and housing (26).

W3-10-2-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

IMPORTANT: The hole for spring pin (5) located on

d CAUTION: Motor (1) weight: 48 kg (110 lb)
6. Remove socket bolts (23) (8 used). Insert a
screwdriver into the gap around jointed part. Hoist
and remove motor (1) from ring gear (25).
l : 10 mm
fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been
applied onto the mating surface.
7. Remove first stage sun gear (2) from first stage
carrier (21).
8. Remove the first stage carrier (21) assembly from
ring gear (25).
IMPORTANT: Do not damage the rotating surface for
9. Remove socket bolts (24) (12 used).
l : 14 mm
dCAUTION: Ring gear (25) weight: 23 kg (51 lb)
10. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
motor (1) mounting screw part of ring gear (25).
Insert a screwdriver into the gap around jointed
part. Hoist and remove ring gear (25) from housing
(26).
fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been
applied onto the mating surface.
11. Remove second stage sun gear (20) from second
stage carrier (18).
12. Remove the second stage carrier (18) assembly from
shaft (31).
13. Remove retaining ring (22) from motor (1).
first stage carrier (21) is not a through one. Check
the tapping-in distance of spring pin (5).
14. Install spring pin (5) with the first stage carrier (21)
assembly attached to pin (4) by using the special
tool (ST 1462). Stop tapping when spring pin (5)
reaches the middle of pin (4) hole and do not tap
spring pin (5) to the end.
15. Remove pins (4) (3 used), planetary gears (7) (3
used), needle bearings (6) (3 used), and thrust plates
(8) (3 used) from first stage carrier (21).
16. Remove thrust plate (3) from first stage carrier (21).
needle bearing of pin (4) except for the both ends.
17. Secure the end of pin (4) opposite the spring pin
(5) hole in a vise. Remove spring pins (5) (3 used) by
using the special tool (ST 1462).
18. Disassemble the second stage carrier (18) assembly
in the same way as the first stage carrier (21)
assembly. Remove planetary gears (12) (3 used),
needle bearings (11) (6 used), and thrust plates (13)
(3 used). Remove spring pin (10) from pin (9) by
using the special tool (ST 1463).
19. Remove thrust plate (19) from second stage carrier
(18).
20. Remove bolts (17) (2 used). Remove lock plate (16)
from bearing nut (15).
j : 17 mm

W3-10-2-3
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

21. Remove bearing nut (15) from shaft (31) by using 24. Push the spline side of shaft (31) by using press
the special tool (ST 2926). (a). Remove the shaft (31) assembly and the inner
race of roller bearing (14) from housing (26). The
inner race of roller bearing (27) and sleeve (29) are
15 removed with shaft (31) together.
25. Place the special tool (ST 1460) onto the stepped
part of special tool (ST 1461).

ST 1460

ST 2926
ST 1461

W178-02-11-135

dCAUTION: The housing (26) assembly weight:

110 kg (245 lb)
W178-02-11-137
22. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the
bolt (24) holes (2 places) of housing (26). Remove
bolts (M20, Pitch 2.5 mm) which secure housing (26)
and the special tool (ST 5097). Hoist the housing
(26) assembly and remove the special tool (ST 5097).

j : 30 mm
23. Install the special tool (ST 1464) to housing (26).
Place housing (26) on press (a).

j : 30 mm

26

ST 1464

W178-02-11-136
a- Press

W3-10-2-4
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

dCAUTION:
(89 lb)
The shaft (31) assembly weight: 40 kg
26. Insert the pinion gear of the shaft (31) assembly into
the tooth-hole on the special tool (ST 1460). Install
the pinion gear of shaft (31) to press (a).
a
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
29. Insert a round bar into the oil passage in housing
(26). Remove outer race (a) of roller bearing (27) by
using a round bar and a hammer.

b
a
31

27

29 W178-02-11-139
ST 1460
a- Outer Race b- Hole for Round Bar
ST 1461

dCAUTION:
kg (135 lb)
The housing (26) assembly weight: 60

30. Attach nylon slings onto the body of the housing

W178-02-11-138
(26) assembly. Hoist and turn over the housing (26)
assembly.
a- Press
31. Insert a screwdriver into the notch on housing (26)
where oil seal (28) is mounted. Remove oil seal (28)
27. Push the spline side of shaft (31) by using press (a). from housing (26).
Remove the inner race of roller bearing (27) and
sleeve (29). fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been
applied onto the outer surface of oil seal (28). Oil seal
28. Remove O-ring (30) from sleeve (29). (28) cannot be reused.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
32. Remove the outer race of roller bearing (14) from
housing (26) by using a bar and a hammer.

W3-10-2-5
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Assembly of Swing Device

1 22
2 4
3 5
23
21
6
20 7
18
8
25
19 10
24 12
17 11
16 13
9

15
33
14
27

26
28 32
30
29

31
W1V1-02-06-004

1- Motor
2- First Stage Sun Gear
3- Thrust Plate
4- Pin (3 Used)
5- Spring Pin (3 Used)
6- Needle Bearing (3 Used)
7- Planetary Gear (3 Used)
8- Thrust Plate (3 Used)
9- Pin (3 Used)
10- Spring Pin (3 Used) 19- Thrust Plate 28- Oil Seal
11- Needle Bearing (6 Used) 20- Second Stage Sun Gear 29- Sleeve
12- Planetary Gear (3 Used) 21- First Stage Carrier 30- O-Ring
13- Thrust Plate (3 Used) 22- Retaining Ring 31- Shaft
14- Roller Bearing 23- Socket Bolt (8 Used) 32- Drain Plug
15- Bearing Nut 24- Socket Bolt (12 Used) 33- Pipe
16- Lock Plate 25- Ring Gear
17- Bolt (2 Used) 26- Housing
18- Second Stage Carrier 27- Roller Bearing

W3-10-2-6
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Assembly of Swing Device

IMPORTANT: Before assembling, apply gear oil onto
parts in order to prevent them from seizing.
1. Install O-ring (30) to sleeve (29).
dCAUTION:
(89 lb)
The shaft (31) assembly weight: 40 kg
2. Install sleeve (29) and the inner race of roller
bearing (27) to shaft (31) by using the special tool
(ST 4149) and press (a).
f NOTE: The press-in distance of the inner race can be
assured by using the special tool.
a
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
4. Evenly tap and install the outer race of roller bearing
(27) to housing (26) by using a bar and a hammer.
Tap and listen to ring in order to check if the
installation is completed.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
5. Apply THREEBOND #1215 onto the outer surface of
oil seal (28). Place oil seal (28) flat on housing (26)
and push it by hand in gently. Place the special tool
(ST 2550) on oil seal (28). Install the special tool (ST
2550) by using a hammer straightly.

fNOTE: Oil seal (28) can be replaced by using the special

ST 4149 tool (ST 2550) without removing sleeve (29).

27
29 ST 2550
28
31
26

W178-02-06-013
a- Press

dCAUTION: Housing (26) weight: 58 kg (130 lb) W178-02-11-144

3. Attach nylon slings onto the body of housing (26).
Hoist and place housing (26) with the sleeve (29)
mounting side up.
6. Apply grease onto the inner surface of oil seal (28).
Apply grease onto the outer surface of sleeve (29)
with shaft (31) attached. Apply grease carefully
when installing shaft (31) in order not to curl the lip.

W3-10-2-7
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

11. Tighten bearing nut (15) to shaft (31) by hand in

d CAUTION: The housing (26) assembly weight: 62
kg (140 lb)
order not to drop shaft (31).

7. Attach nylon slings onto the body of the housing
(26) assembly. Hoist and place the housing (26)
assembly with the ring gear (25) side up.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
dCAUTION: The housing (26) assembly weight:
110 kg (245 lb)
12. Install eyebolts (M16, Pitch 2.0 mm) to the ring gear
(25) mounting screw part of housing (26). Hoist and
place housing (26) on a press.

such as goggles, helmets, etc in order to prevent 13. Remove bearing nut (15) from shaft (31).
personal injury. 14. Place the special tool (ST 2924) onto the inner race
8. Install the outer race of roller bearing (14) to of roller bearing (14). Install the inner race by using
housing (26) by using a bar and a hammer. Tap and a press.
listen to ring in order to check if the installation is
completed. fNOTE: The specified press-in distance of the inner race
can be assured by using the special tool (ST 2924).
dCAUTION:
kg (145 lb)
The housing (26) assembly weight: 64
ST 2924
9. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the
bolt (24) holes of housing (26). Hoist housing (26). 14
Slowly place and install housing (26) to shaft (31).
Check and fit carefully in order not to curl the lip of
oil seal (28).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury. W178-02-11-145
10. Install the inner race of roller bearing (14) to shaft
(31) by using a bar and a hammer. Tap the inner
race until the upper end on the inner race of roller
bearing (14) reaches two threads for bearing nut
(15) in shaft (31).

fNOTE: The fitting between the inner race of roller

bearing (14) and shaft (31) is tight.

W3-10-2-8
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

18. Remove the bolts (M20, Pitch 2.5 mm) (2 used)

d CAUTION: The housing (26) assembly weight:
110 kg (245 lb)
IMPORTANT: Check that the flange surface of
housing (26) does not touch the special tool (ST
5097).
15. Hoist and place the housing (26) assembly on
the special tool (ST 5097). Install the housing (26)
assembly with bolts (M20, Pitch 2.5 mm) (2 used)
so that the stopper at the bottom of special tool
(ST 5097) should be inserted into the clearance
between teeth of the pinion gear in shaft (31).
Secure the special tool (ST 5097) on a workbench in
order to receive the reaction force.
j : 30 mm
26
a (14, 27) can fit.
ST 5097
which secure housing (26) and the special tool (ST
5097).
j : 30 mm
19. Turn housing (26) to both sides five times. Tap
housing (26) several times by using a plastic
hammer.
20. Install housing (26) to the special tool (ST 5097) with
bolts (M20, Pitch 2.5 mm) (2 used).
j : 30 mm
21. Tighten bearing nut (15) by using the special tool
(ST 2926).
m : 500 N·m (50 kgf·m, 370 lbf·ft)
22. Repeat step 18 and step 21 two to three times so
that bearings of bearing nut (15) and roller bearings
23. Remove the bolts (M20, Pitch 2.5 mm) (2 used)
which secure housing (26) and the special tool (ST
5097).

j : 30 mm
W178-02-11-134
a- Stopper
dCAUTION:
110 kg
The housing (26) assembly weight:

24. Hoist and place the housing (26) assembly on a flat

IMPORTANT: Check the direction to install bearing stand. When the housing (26) assembly is placed,
nut (15). check that the contacting position of oil seal (28)
on the sleeve (29) outer surface does not move. In
16. Apply grease onto the thread part of bearing nut
case the contacting position of oil seal (28) moves,
(15). Place the thread part of bearing nut (15) onto
bearing nut (15) is tightened insufficiently. Perform
shaft (31). At this time, face the stepped side of
step 17 to step 23 again.
bearing nut (15) to the roller bearing (14) side.
25. Install housing (26) to the special tool (ST 5097) with
17. Tighten bearing nut (15) by using the special tool
bolts (M20, Pitch 2.5 mm) (2 used).
(ST 2926).
j : 30 mm
m : 500 N·m (50 kgf·m, 370 lbf·ft)
15

ST 2926

W178-02-11-146

W3-10-2-9
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

26. Fit the spline part of lock plate (16) to that of shaft
(31). Tighten bearing nut (15) further until the bolt
(17) hole of bearing nut (15) fit to that of lock plate
(16).
27. Remove the bolts (M20, Pitch 2.5 mm) (2 used)
which secure housing (26) and the special tool (ST
5097).
j : 30 mm
28. Install lock plate (16) to bearing nut (15) with bolts
(17) (2 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
IMPORTANT: Check the direction to install thrust
plate (19).
29. Install thrust plate (19) to second stage carrier (18)
with the oil groove facing outside.
IMPORTANT: Check the mounting position of thrust
plate (13).
30. Install needle bearings (11) (2 used) to planetary
gear (12). Install thrust plate (13) and the planetary
gear (12) assembly to second stage carrier (18).
31. Install pin (9) to the position where planetary gear
(12) of second stage carrier (18) has been installed
with the spring pin hole facing the near side. The
spring pin holes of both second stage carrier (18)
and pin (9) should be in line.
33. Install planetary gears (12) (2 used), needle bearings
(11) (4 used), thrust plates (13) (2 used), pins (9) (2
used), and spring pins (10) (2 used) to second stage
carrier (18) in the same way as step 30 to step 32.
IMPORTANT: Check the direction to install thrust
plate (3).
34. Install thrust plate (3) to the first stage carrier (21)
assembly with the oil groove facing outside.
35. Install needle bearing (6) to planetary gear (7).
Install thrust plate (8) and the planetary gear (7)
assembly to first stage carrier (21).
36. Install pin (4) to the position where planetary gear
(7) of first stage carrier (21) has been installed with
the spring pin hole facing the near side. The spring
pin holes of both first stage carrier (21) and pin (4)
should be in line.
IMPORTANT: Check the direction of spring pin (5).
37. Install spring pin (5) to first stage carrier (21) by
using the special tool (ST 1462) with slit (a) of spring
pin (5) facing to the end of pin (4).
5
4
a
W178-02-11-147
a- Slit

IMPORTANT: Check the direction of spring pin (10).

32. Install spring pin (10) to second stage carrier (18) by
using the special tool (ST 1463) with slit (a) of spring
pin (10) facing to the end of pin (9).
10
9

W178-02-11-147
a- Slit

W3-10-2-10
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

IMPORTANT: Check the mounting position of thrust
plate (8).
38. Install planetary gears (7) (2 used), needle bearings
(6) (2 used), thrust plates (8) (2 used), pins (4) (2
used), spring pins (5) (2 used), and thrust plate (3) to
first stage carrier (21) in the same way as step 35 to
step 37.
39. Fit the spline and install the second stage carrier
(18) assembly to shaft (31).
IMPORTANT: Check the direction to install first stage
sun gear (2).
44. Install first stage sun gear (2) to the first stage carrier
(21) assembly with the stepped part down.
45. Install a seal tape onto the thread part of pipe (33).
Install pipe (33) to housing (26). Face pipe (33)
down.
j : 18 mm

40. Install second stage sun gear (20) to the second
stage carrier (18) assembly with the small diameter
part up.
41. Apply THREEBOND #1215 (or LOCTITE #5020) onto
the ring gear (25) mounting surface of housing (26).
dCAUTION: Ring gear (25) weight: 23 kg (51 lb)
42. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
motor (1) mounting screw part of ring gear (25).
Hoist ring gear (25). Fit the matching marks. Install
ring gear (25) to housing (26) with socket bolts (24)
(12 used).
l : 14 mm
46. Install a seal tape onto drain plug (32). Install drain
plug (32) to pipe (33).
l : 8 mm
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
47. Add gear oil to ring gear (25) until gear oil reaches
the middle part of first stage sun gear (2).
Oil amount: 6.9 L (1.82 US gal)
48. Install retaining ring (22) to motor (1).
49. Apply THREEBOND #1212 (or LOCTITE #5020) onto
the motor (1) mounting surface of ring gear (25).

m : 210 N·m (21 kgf·m, 155 lbf·ft)

43. Fit the spline and install the first stage carrier (21)
assembly to second stage sun gear (20).

W3-10-2-11
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

dCAUTION: Motor (1) weight: 48 kg (110 lb)

50. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
motor (1). Hoist motor (1). Fit the matching marks.
Install motor (1) to ring gear (25) with socket bolts
(23) (8 used).

l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W178-02-06-005
a- Eyebolt Mounting Position

W3-10-2-12
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Disassembly of Swing Motor

11

9
8
7
6
5

4 10

3
2 24
25 29
1 26 30
27
31
28

27
23 26
25
24

12
13 22
14 21
15 20 32
16 19
18
17

W178-02-06-015

1- Casing 10- Plate (4 Used) 19- Brake Piston 28- Valve Casing
2- Oil Seal 11- Friction Plate (3 Used) 20- Spring (24 Used) 29- Socket Bolt (4 Used)
3- Bearing 12- O-Ring 21- Valve Plate 30- O-Ring (2 Used)
4- Shaft 13- Piston 22- Bearing 31- Plug (2 Used)
5- Shoe Plate 14- Spring 23- O-Ring 32- Relief Valve (2 Used)
6- Plunger (9 Used) 15- Ball 24- Plug (2 Used)
7- Plate 16- Plug (2 Used) 25- O-Ring (2 Used)
8- Retainer 17- O-Ring 26- Spring (2 Used)
9- Rotor 18- O-Ring 27- Poppet (2 Used)

W3-10-3-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Disassembly of Swing Motor

IMPORTANT: Do not damage the mating surfaces
d CAUTION: The swing motor assembly weight: 48
kg (110 lb)
when separating valve plate (21) from valve
casing (28) or rotor (9) by using a screwdriver.
IMPORTANT: Do not disassemble relief valve (32). 7. If valve plate (21) is still attached on rotor (9) in step
1. Remove relief valves (32) (2 used) from valve casing 7, remove valve plate (21) from the rotor (9) side.
(28). Remove springs (20) (24 used).
j : 41 mm 8. Put the matching marks on casing (1) and brake
piston (19). Attach a claw of the special tool (ST
2. Remove plug (24) from valve casing (28). Remove 1468) onto the brake piston (19) groove by using
O-ring (25) from plug (24). the special tool (ST 1468). Raise and remove brake
l : 14 mm piston (19) straight.

3. Remove spring (26) and poppet (27) from valve

casing (28). ST 1468
4. Remove another poppet (27) in the same way as
step 3 to step 4. 19

5. Put the matching marks at the jointed surface

between valve casing (28) and casing (1). Remove
socket bolts (29) (4 used). Record the clearance
between valve casing (28) and casing (1).

l : 17 mm
IMPORTANT: Do not remove bearing (22) unless W1HH-02-06-006
necessary.
6. Remove valve casing (28) from casing (1). As valve 9. Remove O-rings (17, 18) from casing (1).
plate (21) may be removed with valve casing (28)
together, do not drop valve plate (21). Remove
O-ring (23).

W3-10-3-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

IMPORTANT: Do not damage the sliding surfaces of IMPORTANT: The filter and orifice are installed inside
rotor (9) and plunger (6). piston (13). Do not disassemble piston (13) unless
10. Place casing (1) horizontally. Remove rotor (9), they are clogged or deformed. If the inner parts of
retainer (8), plate (7), and plungers (6) (9 used) from piston (13) are replaced, replace piston (13) as an
shaft (4). assembly.
17. Remove piston (13) from casing (1) by using a pair
11. Remove plates (10) (4 used) and friction plates (11)
of pliers.
(3 used) from casing (1).
18. Remove spring (14) and ball (15) from casing (1).
IMPORTANT: Do not damage the sliding surface of
shoe plate (5). 19. Remove plugs (16) (2 used) from casing (1).
12. Remove shoe plate (5) from casing (1).
l : 6 mm
13. Tap and remove shaft (4) from casing (1) by using a
plastic hammer.
14. Remove oil seal (2) from casing (1).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
15. Remove the outer race of bearing (3) from casing (1)
by using a bar and a hammer.
16. Remove the inner race of bearing (3) from shaft (4)
by using a press.

W3-10-3-3
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Assembly of Swing Motor

27 26 25 24

12

13

14

15

16

29

W178-02-11-152
W178-02-11-151

31
30
28 32

22
21
23 20
18 19
17 10

11

9 6
7 8
5 3
1

4
W178-02-11-153

1- Casing 10- Plate (4 Used) 19- Brake Piston 28- Valve Casing
2- Oil Seal 11- Friction Plate (3 Used) 20- Spring (24 Used) 29- Socket Bolt (4 Used)
3- Bearing 12- O-Ring 21- Valve Plate 30- O-Ring (2 Used)
4- Shaft 13- Piston 22- Bearing 31- Plug (2 Used)
5- Shoe Plate 14- Spring 23- O-Ring 32- Relief Valve (2 Used)
6- Plunger (9 Used) 15- Ball 24- Plug (2 Used)
7- Plate 16- Plug (2 Used) 25- O-Ring (2 Used)
8- Retainer 17- O-Ring 26- Spring (2 Used)
9- Rotor 18- O-Ring 27- Poppet (2 Used)

W3-10-3-4
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Assembly of Swing Motor

8. Place casing (1) horizontally. Install the rotor (9)
IMPORTANT: Before assembling, apply hydraulic oil
assembly to shaft (4).
onto parts in order to prevent them from seizing.
1. Install the inner race of bearings (3, 22) to shaft (4) IMPORTANT: There are four notches on the outer
by using a press. Install the inner race of bearing (3) side of plate (10). There are four notches on the
with the flange part facing to the stepped part of spline teeth side of friction plate (11).
shaft (4). 9. Place casing (1) vertically. Alternately install plates
(10) (4 used) and friction plates (11) (3 used) in order
2. Install oil seal (2) to casing (1) by using a plate with
to align each notch at the same place.
the lip part up.
10. Install O-rings (17, 18) to casing (1).
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, 11. Fit the matching marks and install brake piston (19)
such as goggles, helmets, etc in order to prevent to casing (1).
personal injury.
3. Install the outer race of bearing (3) to casing (1) by
fNOTE: If it is not easy to install brake piston (19) due to
the resistant force from O-rings (17, 18), evenly tap brake
using a bar and a hammer. piston (19) by using a plastic hammer.
4. Install a tape onto the spline at the end of shaft (4) 12. Install springs (20) (24 used) to brake piston (19).
in order not to damage oil seal (2). Place casing (1)
horizontally. Install shaft (4) to casing (1).
5. Place casing (1) vertically with the valve casing (28)
mounting side up. Install shoe plate (5) to casing (1)
with the chamfered surface facing inside.
6. Fit the notches on plate (7) and retainer (8). Install
plungers (6) (9 used). Install retainer (8) to plunger
(6) with the notch facing to the shoe plate (5) side.
7. Apply hydraulic oil onto the plunger hole on rotor
(9). Insert the plunger (6) assembly into rotor (9).

W3-10-3-5
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

IMPORTANT: If the inner parts of piston (13) are
replaced, replace piston (13) as an assembly.
13. Install ball (15), spring (14), and piston (13) to casing
(1) in order to fit the end of piston (13) to that of
casing (1).
14. Tap and install the outer race, the bearing type
indicated surface of bearing (22) to valve casing (28)
by using a plastic hammer.
IMPORTANT: Check the surfaces of valve plate (21).
15. Install O-ring (23) to valve casing (28). Install valve
plate (21) to valve casing (28) with the notch in the
port facing to rotor (9).
Apply grease onto valve plate (21) in order to
prevent from falling off from valve casing (28).
16. Apply grease onto the needle part of bearing (22) in
order to install shaft (4) to bearing (22) easily.
17. FIt the matching marks on valve casing (28) and
casing (1). Place valve casing (28) onto casing (1).
Check that a clearance between valve casing (28)
and casing (1) is equal to that before disassembling.
If the clearance is larger than that before
disassembling, repeat the procedures from step 5.
18. Install valve casing (28) to casing (1) with socket
bolts (29) (4 used).
l : 17 mm
m : 440 N·m (44 kgf·m, 320 lbf·ft)
19. Install poppet (27) and spring (26) to valve casing
(28). Install O-ring (25) to plug (24). Install plug (24)
to valve casing (28).
l : 14 mm
m : 340 N·m (34 kgf·m, 250 lbf·ft)
20. Install another poppet (27) in the same way as step
19.
21. Install relief valves (32) (2 used) to valve casing (28).
j : 41 mm
m : 180 N·m (18 kgf·m, 130 lbf·ft)

W3-10-3-6
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Removal and Installation of Pilot Valve (Left) 3

5 2

3
2

1 WDAA-03-01-023

6 WDAA-03-01-047

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition, dCAUTION: Seat (5) weight: 20 kg (45 lb)
attach an identification tag onto the connectors, 4. Remove socket bolts (6) (4 used). Remove seat (5).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which l : 6 mm
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Remove bolts, washers (2) (2 used). Remove seat
belts (3) (2 used) and spacers (4) (2 used).

j : 24 mm

W3-11-1-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Detail B
14
13
14

21 23 22

15

B
17

10
16
WDAA-03-12-002
9

7, 8 12 11 WDAA-03-12-001
20 18 19

5. Remove socket bolts (7) (2 used) and washers (8) (2

used). Remove lever (9).

l : 6 mm
6. Remove socket bolts (10) (2 used) and washers (11)
(2 used). Remove armrest (12).

l : 6 mm
7. Raise boot (13) and remove screws (14) (3 used).
8. Raise cover (15). Disconnect connector (16). Remove
cover (15).
9. Remove screw (17), bolt, washer (18), and washer
(19). Remove cover (20).

j : 10 mm
10. Remove screws (21, 22) (2 used for each). Remove
cover (23).

W3-11-1-2
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

25 27 26 30, 31

WDAA-03-12-023 WDAA-03-12-019
28 24 29 32

11. Remove clip bands (24, 25).

12. Loosen lock nut (26). Remove the lever (27)
assembly.

j : 19 mm, 22 mm
13. Disconnect hoses (28) (6 used).

j : 19 mm
14. Remove socket bolts (30) (4 used) and washers (31)
(4 used). Remove pilot valve (29) and boot (32).

l : 6 mm
15. Remove the adapter with pilot valve (29) attached if
necessary.

W3-11-1-3
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

25 27 26 30, 31

WDAA-03-12-023 WDAA-03-12-019
28 24 29 32

Installation
1. Install all removed adapters to pilot valve (29).
2. Install pilot valve (29) and boot (32) with washers
(31) (4 used) and socket bolts (30) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Connect hoses (28) (6 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

4. Tighten lock nut (26) and install the lever (27)
assembly.

j : 19 mm, 22 mm

m : 55 N·m (5.5 kgf·m, 40 lbf·ft)

5. Install clip bands (25, 24).

W3-11-1-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Detail B
14
13
14

21 23 22

15

B
17

10
16
WDAA-03-12-002
9

7, 8 12 11 WDAA-03-12-001
20 18 19

6. Install cover (23) with screws (22, 21) (2 used for 13. Install lever (9) with washers (8) (2 used) and socket
each). bolts (7) (2 used).
7. Install cover (20) with washer (19), bolt, washer (18), l : 6 mm
and screw (17).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
j : 10 mm

m : 3.3 to 4.2 N·m (0.3 to 0.4 kgf·m, 2.4 to 3.0

lbf·ft)
8. Install cover (15).
9. Raise cover (15). Connect connector (16).
10. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
11. Install screws (14) (3 used). Lower boot (13).
12. Install armrest (12) with washers (11) (2 used) and
socket bolts (10) (2 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-11-1-5
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

5 2

3
2

1 WDAA-03-01-023

6 WDAA-03-01-047

dCAUTION: Seat (5) weight: 20 kg (45 lb)

14. Install seat (5) with socket bolts (6) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

15. Install spacers (4) (2 used) and seat belts (3) (2 used)
with bolts, washers (2) (2 used).

j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

16. Shut door (1).

W3-11-1-6
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Removal and Installation of Pilot Valve 3

(Right)
5 2

3
2

1 WDAA-03-01-023

6 WDAA-03-01-047

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition, dCAUTION: Seat (5) weight: 20 kg (45 lb)
attach an identification tag onto the connectors, 4. Remove socket bolts (6) (4 used). Remove seat (5).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which l : 6 mm
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Remove bolts, washers (2) (2 used). Remove seat
belts (3) (2 used) and spacers (4) (2 used).

j : 24 mm

W3-11-2-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Detail A
14
13
15 11
10 12

16

WDAA-03-12-006

9 11
7 8
WDAA-03-12-005

5. Remove socket bolts (7) (2 used) and washers (8) (2

used). Remove armrest (9).

l : 6 mm
6. Remove tray (10). Remove screws (11) (3 used).
7. Raise cover (12). Disconnect connectors (13) (2
used). Remove cover (12).
8. Raise boot (14). Remove screws (15) (2 used).
Remove cover (16).

W3-11-2-2
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

19 20 17 18 20 24

23
24

WDAA-03-12-007
21 22 25 24

WDAA-03-12-005

9. Remove clip bands (17, 18).

10. Loosen lock nut (19). Remove the lever (20)
assembly.

j : 19 mm, 22 mm
11. Remove bolts, washers (21) (3 used). Tilt the bracket
(22) assembly with the cover (23) side up.

j : 17 mm
12. Remove screws (24) (3 used) and washer (25).
Remove cover (23).

W3-11-2-3
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

A Detail A
28, 29

30

WDAA-03-12-008
26

27 26 WDAA-03-12-020

13. Disconnect hoses (26) (6 used).

j : 19 mm
14. Remove socket bolts (28) (4 used) and washers (29)
(4 used). Remove pilot valve (27) and boot (30).

l : 6 mm
15. Remove the adapter with pilot valve (27) attached if
necessary.

W3-11-2-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

A Detail A
28, 29

30

WDAA-03-12-008
26

27 26 WDAA-03-12-020

Installation
1. Install all removed adapters to pilot valve (27).
2. Install pilot valve (27) and boot (30) with washers
(29) (4 used) and socket bolts (28) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Connect hoses (26) (6 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-11-2-5
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

19 20 17 18 20 24

23
24

WDAA-03-12-007
21 22 25 24

WDAA-03-12-005

4. Install cover (23) with washer (25) and screws (24) (3

used).
5. Install bracket (22) with bolts, washers (21) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

6. Tighten lock nut (19) and install the lever (20)
assembly.

j : 19 mm, 22 mm

m : 55 N·m (5.5 kgf·m, 40 lbf·ft)

7. Install clip bands (18, 17).

W3-11-2-6
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Detail A
14
13
15 11
10 12

16

WDAA-03-12-006

9 11
7 8
WDAA-03-12-005

8. Install cover (16) with screws (15) (2 used).

9. Install cover (12).
10. Raise cover (12). Connect connectors (13) (2 used).
11. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
12. Install boot (14).
13. Install screws (11) (3 used). Install tray (10).
14. Install armrest (9) with washers (8) (2 used) and
socket bolts (7) (2 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-11-2-7
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

5 2

3
2

1 WDAA-03-01-023

6 WDAA-03-01-047

dCAUTION: Seat (5) weight: 20 kg (45 lb)

15. Install seat (5) with socket bolts (6) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

16. Install spacers (4) (2 used) and seat belts (3) (2 used)
with bolts, washers (2) (2 used).

j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

17. Shut door (1).

W3-11-2-8
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Removal and Installation of Travel Pilot Valve

WDAA-03-13-005 WDAA-03-12-016
3 2

IMPORTANT: Cap the open ends in case the hoses 5. Place a container under pilot valve (4). Disconnect
and pipes have been disconnected. In addition, hoses (5) (4 used).
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the j : 19 mm
hoses and install the clips in case the clips which 6. Disconnect pipes (6) (2 used).
secure the hoses have been removed.
Removal j : 17 mm

1. Swing the upperstructure by 90 degrees and set the

machine position for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Remove the floor mat.

dCAUTION: Remove cover (3) while holding it. Do

not drop cover (3).
4. Remove bolts, washers (2) (6 used). Remove cover
(3).

j : 17 mm

W3-11-3-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

WDAA-03-12-017 WDAA-03-12-018

7. Remove bolts, washers (7) (4 used). Remove levers

(8) (2 used) and pedals (9) (2 used).

j : 17 mm
8. Remove socket bolts (10) (2 used) and washers (11)
(2 used). Remove pilot valve (4).

l : 8 mm
9. Remove the adapter with pilot valve (4) attached if
necessary.

W3-11-3-2
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

WDAA-03-12-017 WDAA-03-12-018

Installation
1. Install all removed adapters to pilot valve (4).
2. Install pilot valve (4) with washers (11) (2 used) and
socket bolts (10) (2 used).

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Install pedals (9) (2 used) and levers (8) (2 used) with
bolts, washers (7) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-11-3-3
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

WDAA-03-13-005 WDAA-03-12-016
3 2

4. Connect pipes (6) (2 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 19 lbf·ft)

5. Connect hoses (5) (4 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

6. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
7. Install cover (3) with bolts, washers (2) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

8. Install the floor mat.
9. Shut door (1).

W3-11-3-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Disassembly of Pilot Valves (Right and Left)

17

16

15

14

13

12

11

10
18
9

7
6 19
23
5 20
4 21
22
3

WDAA-03-12-021

1- Spacer (4 Used)
2- Shim (Several)
3- Balance Spring (2 Used)
4- Balance Spring (2 Used)
5- Return Spring (2 Used)
6- Return Spring (2 Used)
7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
9- Pusher (2 Used) 15- Universal Joint 21- Plug
10- Pusher (2 Used) 16- Cam 22- Retaining Ring
11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
12- Sleeve (4 Used) 18- Casing

W3-11-4-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve
Disassembly of Pilot Valves (Right and Left)
IMPORTANT: Casing (18) is made of aluminium.
Strong force deforms it. Handle it 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 with the port 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 vise. The strong torque
may act on screw joint (17).
1. Secure screw joint (17) in a vise. Turn cam (16) by
using a spanner. Remove screw joint (17).
j : 19 mm, 32 mm
2. Secure the flat surface of casing (18) in a vise.
Remove cam (16) from universal joint (15).
j : 32 mm
W3-11-4-2
3. Attach a spanner onto the upper part of universal
joint (15). Remove universal joint (15).
j : 17 mm
fNOTE: Universal joint (15) has been secured on casing
(18) by using LOCTITE #262.
4. Remove plate (14).
IMPORTANT: Do not damage sleeve (12). Insert a soft
rubber between sleeve (12) and a tool. Oil seal (11)
cannot be removed from sleeve (12).
Sleeve (12) and oil seal (11) should be replaced as
an assembly.
5. Remove sleeves (12) (4 used) upward by using a pair
of pliers. Remove O-rings (19) (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. Keep
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).
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve
7. When compressing the spring, do not lower spool
(19). Install the special tool (ST 4145) to the port
hole on casing (18) as illustrated.
l : 6 mm
18
W178-02-07-048
ST 4145
8. Install the special tool (ST 4146) to the pusher hole
on casing (18). Push the special tool (ST 4146) and
compress the spring. Tighten the special tool (ST
4146) by using the socket bolt (M14, Pitch 2.0 mm).
Remove retaining rings (8) (4 used) from spools (19)
(4 used) by using a screwdriver.
l : 12 mm
ST 4146
18
W178-02-07-048
W3-11-4-3
IMPORTANT: The quantity of shims (2) has been
determined for each port during the performance
testing. Do not lose shim (2). Keep shim (2)
carefully in order to install shim (2) to the original
port when assembling.
9. Remove the special tool (ST4146). 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 the 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.
Retaining ring (22) cannot be reused.
12. Remove retaining ring (22) from casing (18) by
using a screwdriver. Install a bolt (M8, Pitch 1.25
mm) to plug (21). Remove plug (21) from casing
(18). Remove O-ring (20) from plug (21).
j : 13 mm
13. Remove filter (23) from casing (18).
j : 10 mm
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Assembly of Pilot Valves (Right and Left)

17

15
16

11
14 9, 10
13
12
8
7
3, 4
5, 6
2

1
21
20

23 18 19

22

WDAA-03-12-022

1- Spacer (4 Used)
2- Shim (Several)
3- Balance Spring (2 Used)
4- Balance Spring (2 Used)
5- Return Spring (2 Used)
6- Return Spring (2 Used)
7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
9- Pusher (2 Used) 15- Universal Joint 21- Plug
10- Pusher (2 Used) 16- Cam 22- Retaining Ring
11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
12- Sleeve (4 Used) 18- Casing

W3-11-4-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Assembly of Pilot Valves (Right and Left)

IMPORTANT: Refer to the table in the left in order to
IMPORTANT: Before assembling, apply hydraulic oil
assemble the parts correctly.
onto parts in order to prevent them from seizing.
3. Install spacer (1), shim (2), and balance spring (3) to
IMPORTANT: The pilot valve is the susceptible
spool (19). Install return spring (5) to casing (18).
hydraulic component to contamination. Keep the
parts clean when assembling. 4. Install spring guide (7) to return spring (5) with the
protrusion up.

fNOTE: The table below shows the relations between 5. Install other spools (19) (3 used) in the same way as
step 1 to step 4.
each port and the parts. Do not confuse them when
assembling. 6. Install the special tool (ST 4146) to the pusher (9, 10)
Spool Shim holes on casing (18). Push the special tool (ST 4146)
Port No. Pushers (9, 10) and compress the spring. Tighten the special tool
(19) (2)
1 One outer groove (ST 4146) by using a bolt (M14, Pitch 2.0 mm).
Two outer l : 12 mm
2
Same to the Same to the grooves
3 former one former one One outer groove ST 4146
Two outer
4
grooves
ST 4144
Return Springs Balance Springs
Port No.
(5, 6) (3, 4)
1 Short Short
2 Long Long
3 Short Short
4 Long Long

1. Check the port hole number and insert same spool

(19) before disassembling. Install the thinner end W178-02-07-049
of spool (19) into the port hole on casing (18) by ST 4145
turning slowly.
7. Install retaining ring (8) to the ring holder (ST 4144).
fNOTE: Spool (19) has been selected to match the port
hole. Spool (19) and casing (18) should be replaced as an
assembly.
2. Install the special tool (ST 4145) to the port hole on
casing (18) in order not to lower spool (19) when
the spring is compressed.

j : 6 mm

W3-11-4-5
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

8. Install retaining ring (8) to the groove on the head
of spool (21) extending from the special tool (ST
4146).
IMPORTANT: Check the position to install pusher (9).
9. Install pusher (9).
After pushing pusher (9) several times by hand,
remove it. Check if retaining ring (8) comes off or
balance spring (3) is located correctly.
Install pusher (9) to casing (18) after checking.
10. Install other pushers (9, 10) in the same way as step
8 to step 9.
11. Apply grease onto the ball part at the ends of
pushers (9, 10) (2 used for each).
12. Apply grease onto the joint part of universal joint
(15).
13. Apply grease onto the inner surface of oil seals (11)
(4 used).
fNOTE: Sleeve (12) and oil seal (11) should be replaced
as an assembly.
14. Install oil seals (11) (4 used) to sleeves (12) (4 used).
Push the sleeve (12) assemblies (4 used) by hand
until O-ring (13) is inserted into the hole on sleeves
(12) (4 used).
15. Secure casing (18) in a vise lightly.
IMPORTANT: Fit the bolt hole on plate (14) to the
screw hole on casing (18).
16. Apply LOCTITE #262 onto the screw part of
universal joint (15). Place plate (14) on casing (18).
Install universal joint (15).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 19 lbf·ft)
IMPORTANT: Check the tightness of cam (16).
17. 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.
18. Secure cam (16) by using a spanner. Tighten screw
joint (17) by using a spanner.
j : 19 mm, 32 mm
m : 70 N·m (7 kgf·m, 51 lbf·ft)
19. Install plug (23) to casing (18).
l : 10 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-11-4-6
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Disassembly of Travel Pilot Valve

3
4

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
36
20
21 22
WDAA-03-12-024

1- Bolt, Washer (2 Used)
2- Cover
3- Spring Pin (2 Used)
4- Spring Pin (2 Used)
5- Cam (2 Used)
6- Bushing (4 Used)
7- Holder
8- Spring Washer (4 Used)
9- Socket Bolt (4 Used)
10- Spring Pin
11- Bracket (2 Used)
12- Spring Pin (2 Used)
13- Spring Pin (2 Used)
14- O-Ring (4 Used)
15- Bushing (4 Used)
16- Pusher (4 Used)
17- Spring Guide (16 Used)
18- Balance Spring (4 Used)
19- O-Ring (2 Used)
20- Plug (2 Used)
21- Plug (2 Used)
22- O-Ring (2 Used)
23- Casing
24- Spool
25- Spring (4 Used)
26- Spacer (4 Used)
27- Shim (12 Used)
28- Oil Seal (4 Used)
29- Spring Washer (2 Used)
30- Socket Bolt (2 Used)
31- Rubber Seat (2 Used)
32- Damper (2 Used)
33- O-Ring (2 Used)
34- O-Ring (2 Used)
35- Pin
36- Filter

W3-11-5-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve
Disassembly of Travel Pilot Valve
IMPORTANT: Casing (23) is made of aluminium.
Strong force deforms it. Handle it with care.
IMPORTANT: Spool (24) has been selected to match
the hole on casing (23).
Arrange the disassembled parts together with
each port in order not to confuse.
The port number is stamped on the outer surface
of casing (23).
1. Secure casing (23) in a vise. Remove bolts, washers
(1) (2 used). Remove cover (2) from holder (7).
j : 10 mm
2. Remove socket bolts (30) (2 used) and spring
washers (29) (2 used). Remove the holder (7)
assembly from casing (23).
l : 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
bamboo spatula.
W3-11-5-2
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. Remove the spool (24) assembly from casing (23) by
rotating.
Spring guide (17), balance spring (18), shims (27) (3
used), and spacer (26) are removed with spool (24)
together.
IMPORTANT: The quantity of shims (27) have been
determined during the performance testing at the
factory. When keeping, pair shim (27) with each
spool.
6. Compress balance spring (18). Remove spring guide
(17), balance spring (18), shims (27) (3 used), and
spacer (26) from spool (24).
7. Remove spring (25) from casing (23).
8. Remove other spools (24) in the same way as step 5
to step 7.
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

11. Remove O-ring (33) from pin (35).

d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, 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.
9. Place a stand under bracket (11). The inner surfaces
of the spring pins (12, 13) holes on bracket (11) are
stepped-shape. The spring pin can only be removed
in one direction. Tap and remove spring pins (12,
13) from bracket (11) at the same time by using the
special tool (ST 1237). Remove bracket (11) from pin
(35). Do not remove spring pin (10) with bracket (11)
attached unless necessary. The hole end of spring
pin (10) has been crimped.
12. Remove other bracket (11) in the same way as step
9 to step 11.
13. Place holder (7) with the casing (23) mounting
surface up.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
14. The holes of spring pins (3, 4) (2 used for each) in
cam (5) are stepped-shape. Tap the bottom of cam
(5) and remove spring pins (3, 4) (2 used for each)
from cams (5) (2 used) at the same time by using the
special tool (ST 1237).
As the holes of spring pins (3, 4) (2 used for each)
are crimped, spring pins (3, 4) may feel tight when
removing.

12, 13
11
35
10

W176-02-07-019
a - Crimped Position
b - Stand

10. Remove socket bolts (9) (2 used) and spring washers

(8) (2 used). Remove damper (32) and rubber seat
(31) from pin (35). O-ring (34) is removed together.

l : 5 mm

W3-11-5-3
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
15. Remove pin (35) by using a bar and a hammer. At
the same time, cams (5) (2 used) are removed.
Do not remove bushings (6) (4 used) with holder
(7) attached unless necessary. If removing, remove
bushings (6) (4 used) by tapping by using the
special tool (ST 7256).
16. Remove plugs (20) (2 used) from casing (23).
Remove O-rings (19) (2 used) from plugs (20) (2
used).

l : 5 mm
17. Remove plugs (21) (2 used) from casing (23).
Remove O-rings (22) (2 used) from plugs (21) (2
used).

l : 6 mm

W3-11-5-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Assembly of Travel Pilot Valve

11 32 31 1 2 35 6 12 10 13 7 5 3, 4 30

29
34 15
9
33
8 17
28
18
14
25
27
16
26

24
23
36

WDAA-03-12-025

1- Bolt, Washer (2 Used)
2- Cover
3- Spring Pin (2 Used)
4- Spring Pin (2 Used)
5- Cam (2 Used)
6- Bushing (4 Used)
7- Holder
8- Spring Washer (4 Used)
9- Socket Bolt (4 Used)
10- Spring Pin
11- Bracket (2 Used)
12- Spring Pin (2 Used)
13- Spring Pin (2 Used)
14- O-Ring
15- Bushing (4 Used)
16- Pusher (4 Used)
17- Spring Guide (16 Used)
18- Balance Spring (4 Used)
19- *O-Ring (2 Used) 28- Oil Seal (4 Used)
20- *Plug (2 Used) 29- Spring Washer (2 Used)
21- *Plug (2 Used) 30- Socket Bolt (2 Used)
22- *O-Ring (2 Used) 31- Rubber Seat (2 Used)
23- Casing 32- Damper (2 Used)
24- Spool (4 Used) 33- O-Ring (2 Used)
25- Spring (4 Used) 34- O-Ring (2 Used)
26- Spacer (4 Used) 35- Pin
27- Shim (12 Used) 36- Filter

fNOTE: As for the parts with mark *, refer to W3-11-5-1.

W3-11-5-5
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Assembly of Travel Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil
onto 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. Insert spacer (26), shims (27) (3 used), and balance
spring (18) into spool (24) in sequence. Install shim
(27) as the same condition before disassembling.
IMPORTANT: Check the direction to install spring
guide (17).
2. Compress balance spring (18) by hand. Install spring
guide (17) to spool (24) with the stepped part down.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
fNOTE: Bushings (6) (4 used) are identical.
 Insert bushings (6) (4 used) into the special tool
(ST 7256). Tap the special tool (ST 7256) by using a
hammer and install bushing (6) to the end of hole on
holder (7). Stop tapping when the bushing (6) end is
flush with the hole end.
7 ST 7256

IMPORTANT: Before inserting the parts into holder

(7) and casing (23), apply hydraulic oil.
3. Insert spring (25) into casing (23).
6
4. Insert the spool (24) assembly into the original port W178-02-11-310
before disassembling. Insert the spool (24) assembly
into casing (23) by rotating.
5. Install oil seal (28) to bushing (15).
6. Apply grease onto the inner surface of oil seal (28).
7. Install O-ring (14) and pusher (16) to bushing (15).
8. Apply grease onto the head of pusher (16).
9. Insert the pusher (16) assembly into casing (23).
10. Install other spools (24) in the same way as step 1 to
step 9.
11. When bushing (6) has been removed from holder
(7), install bushings (6) (4 used) to holder (7) by
using the special tool (ST 7256) in the following
procedures.

W3-11-5-6
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

 Install bushing (6) on the opposite side in the same 12. Install O-rings (33) (2 used) to pin (35). Apply grease
way. onto O-rings (33) (2 used). Install pin (35) and cams
6 (5) (2 used) to holder (7).
ST 7256 7
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Check the direction to install spring
pins (3, 4).
W178-02-11-311
13. Install spring pins (3, 4) to cam (5) by using the
special tool (ST 1237). Secure cam (5) and pin (35).
 Install bushing (6) in the near side as illustrated. Stop At this time, the slits (a) of spring pins (3, 4) should
tapping when the bushing (6) end is flush with the be positioned 90° away each other. Tap and install
outside of holder (7). spring pins (3, 4) until spring pins (3, 4) come in
contact with the stepped part in the hole.
6
7 ST 7256 3 a a

a
4 W178-02-07-050
W178-02-11-312
a - Slit
a - Outside of Holder

14. Crimp the hole end of cam (5) where spring pins (3,
 Install bushing (6) in the near and opposite side as 4) are inserted by using a punch.
illustrated.
15. Install other cam (5) in the same way as step 13 to
6 step 14.
ST 7256 7

W178-02-11-313

W3-11-5-7
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve
16. 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).
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
17. Install rubber seats (31) (2 used) to pin (35).
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.
18. Install dampers (32) (2 used) to pin (35) with the
lever up.
19. Secure damper (32) and rubber seat (31) to holder
(7) with socket bolts (9) (4 used) and spring washers
(8) (4 used).
l : 5 mm
m : 7 N·m (0.7 kgf·m, 5 lbf·ft)
20. Apply grease onto O-ring (34). Push O-rings (34) (2
used) to the end of pin (35).
W3-11-5-8
21. As for the direction to install bracket (11), refer to
the figure in Disassembly of Travel Pilot Valve on
W3-12-5-1. Install bracket (11) to pin (35). Fit the
holes to insert spring pins (12, 13).
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.
22. Place a stand (b) under bracket (11). Install spring
pins (12, 13) to bracket (11) until they come in
contact with the stepped part by using the special
tool (ST 1237). The slits of spring pins (2 used)
should be positioned 90° away each other.
a a
11 35
b
12, 13
W176-02-07-011
a - Crimped Position
b - Stand
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

23. Crimp the hole edge of bracket (11) where spring

pins (12, 13) are inserted by using a punch.
24. Install other bracket (11) in the same way as step 22
to step 23.
25. Install cover (2) to holder (7) with bolts, washers (1)
(2 used).

j : 10 mm

m : 5 N·m (0.5 kgf·m, 3.5 lbf·ft)

26. Apply grease onto the spring pin (10) contact part
of dampers (32) (2 used).
27. Install O-rings (19) (2 used) to plugs (20) (2 used).
Install plugs (20) (2 used) to casing (23).

j : 5 mm

m : 10 N·m (1 kgf·m, 7.5 lbf·ft)

28. Install O-rings (22) (2 used) to plugs (21) (2 used).
Install plugs (21) (2 used) to casing (23).

j : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

29. Install filter (36) to casing (23).

W3-11-5-9
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

(Blank)

W3-11-5-10
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Removal and Installation of Pilot Shut-Off

Solenoid Valve
1

3 2

WDAA-03-13-005 WDAA-03-13-006

IMPORTANT: Cap the open ends in case the hoses 6. Place a container under pilot shut-off solenoid valve
and pipes have been disconnected. In addition, (5). Disconnect both ends of pipes (6, 7).
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the j : 17 mm
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Swing the upperstructure by 90 degrees and set the
machine position for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Remove the floor mat.

dCAUTION: Remove cover (3) while holding it. Do

not drop cover (3).
4. Remove bolts, washers (2) (6 used). Remove cover
(3).

j : 17 mm
5. Disconnect connector (4).

W3-12-1-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

WDAA-03-13-007 WDAA-03-13-008

7. Disconnect hoses (8) (7 used).

j : 19 mm
8. Remove bolts, washers (9) (2 used). Remove pilot
shut-off solenoid valve (5).

j : 17 mm
9. Remove the adapter with pilot shut-off solenoid
valve (5) attached if necessary.

W3-12-1-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

WDAA-03-13-007 WDAA-03-13-008

Installation
1. Install all removed adapters to pilot shut-off
solenoid valve (5).
2. Install pilot shut-off solenoid valve (5) with bolts,
washers (9) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Connect hoses (8) (7 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-12-1-3
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

3 2

WDAA-03-13-005 WDAA-03-13-006

4. Connect pipes (7, 6).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 19 lbf·ft)

5. Connect connector (4).
6. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
7. Install cover (3) with bolts, washers (2) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

8. Install the floor mat.
9. Shut door (1).

W3-12-1-4
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Removal and Installation of 3-Spool Solenoid

Valve Unit

1 3 2

WDCD-03-06-001

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open engine cover (1).
3. Remove bolts, washers (2) (5 used). Remove cover
(3).

j : 17 mm

W3-12-2-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

WDCD-03-12-001 WDCD-03-12-002

4. Disconnect connectors (4) (3 used).

5. Place a container under 3-spool solenoid valve unit
(5). Disconnect hoses (6) (5 used).

j : 17 mm
6. Disconnect both ends of pipes (7) (6 used).

j : 17 mm
7. Disconnect hoses (8) (3 used).

j : 19 mm
8. Disconnect hoses (9) (2 used).

j : 17 mm
9. Remove socket bolts (10) (2 used). Remove 3-spool
solenoid valve unit (5).

l : 8 mm
10. Remove the adapter with 3-spool solenoid valve
unit (5) attached if necessary.

W3-12-2-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

WDCD-03-12-001 WDCD-03-12-002

Installation
1. Install all removed adapters to 3-spool solenoid 5. Connect pipes (7) (6 used).
valve unit (5).
j : 17 mm
2. Install 3-spool solenoid valve unit (5) with socket
bolts (10) (2 used). m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

l : 8 mm 6. Connect hoses (6) (5 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 17 mm

3. Connect hoses (9) (2 used). m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

j : 17 mm 7. Connect connectors (4) (3 used).

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

4. Connect hoses (8) (3 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-12-2-3
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

1 3 2

WDCD-03-06-001

8. Bleed air from the hydraulic system. (Refer to W1-4-

1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
9. Install cover (3) with bolts, washers (2) (5 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

10. Shut engine cover (1).

W3-12-2-4
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Disassembly of Pilot Shut-Off Solenoid Valve

WDAA-03-13-014

1- Socket Bolt (2 Used) 4- Body 7- O-Ring

2- Solenoid 5- Spool 8- Plug
3- O-Ring 6- Spring 9- Filter

W3-12-3-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Disassembly of Pilot Shut-Off Solenoid Valve

IMPORTANT: Filter (9) cannot be removed.
1. Put the matching marks on body (4) and solenoid
(2). Secure body (4) in a vise. Remove socket bolts
(1) (2 used) from body (4). Remove solenoid (2) and
O-ring (3) from body (4).

l : 4 mm
2. Remove plug (8) from body (4). Remove O-ring (7)
from plug (8).

l : 6 mm
3. Remove spring (6) and spool (5) from body (4).

W3-12-3-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Assembly of Pilot Shut-Off Solenoid Valve

2
1
3

T1V1-03-07-012

1- Socket Bolt (2 Used) 4- Body 7- O-Ring

2- Solenoid 5- Spool 8- Plug
3- O-Ring 6- Spring 9- Filter

W3-12-3-3
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Assembly of Pilot Shut-Off Solenoid Valve

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
1. Secure body (4) in a vise. Insert spool (5) and spring
(6) into body (4).
2. Install O-ring (7) to plug (8). Install plug (8) to body
(4).

l : 6 mm

m : 27 N·m (2.7 kgf·m, 20 lbf·ft)

IMPORTANT: When solenoid (2) is installed after
installing O-ring (3) to body (4), O-ring (3) may be
damaged.
3. Install O-ring (3) to solenoid (2). Fit the matching
marks and install solenoid (2) to body (4).
4. Install solenoid (2) to body (4) with socket bolts (1)
(2 used).

l : 4 mm

m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

W3-12-3-4
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Structure of 3-Spool Solenoid Valve Unit

4
3

WDCD-03-12-003
2

5 6 7 8 9 10

11

15 14 13 12

WDAA-03-13-013

W3-12-4-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Wrench Size Tightening Torque

No. Part Name Q’ty (mm) Remark
N·m (kgf·m) (lbf·ft)
1 Body 1
2 Orifice 3 l:6 10+3 (1+0.3) (7.4+2.2)
3 Orifice 1 l : 10 20+5 (2+0.5) (15+3.7)
4 Socket Bolt 8 l:4 5+2 (0.5+0.2) (3.7+1.5)
5 Solenoid 3
6 Washer 1
7 Spring 1
8 Spool 1
9 Sleeve 1
10 Plate 1
11 Wave Spring 1
12 O-Ring 1
13 O-Ring 1
14 O-Ring 1
15 O-Ring 1

W3-12-4-2
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

Removal and Installation of Signal Control

Valve

1 2

3
WDCD-03-06-001 WDCD-03-13-001

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open engine cover (1).
3. Remove bolts, washers (2) (5 used). Remove cover
(3).

j : 17 mm
4. Disconnect connectors (4) (2 used).

W3-13-1-1
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

WDCD-03-13-002 WDCD-03-13-003

5. Place a container under signal control valve (5).

Disconnect hoses (6) (5 used).

j : 19 mm
6. Disconnect hoses (7) (3 used).

j : 17 mm
7. Disconnect hoses (8) (3 used).

j : 19 mm
8. Disconnect hose (9).

j : 17 mm
9. Disconnect hoses (10) (4 used).

j : 19 mm
10. Disconnect hose (11).

j : 17 mm

W3-13-1-2
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

WDCD-03-13-004 WDCD-03-13-005

11. Disconnect hoses (12) (17 used).

j : 19 mm
12. Remove socket bolts (13) (4 used) and washers (14)
(4 used). Remove signal control valve (5).

l : 8 mm
13. Remove the adapter with signal control valve (5)
attached if necessary.

W3-13-1-3
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

WDCD-03-13-004 WDCD-03-13-005

Installation
1. Install all removed adapters to signal control valve
(5).
2. Install signal control valve (5) with washers (14) (4
used) and socket bolts (13) (4 used).

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Connect hoses (12) (17 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-13-1-4
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

WDCD-03-13-002 WDCD-03-13-003

4. Connect hose (11). 8. Connect hoses (7) (3 used).

j : 17 mm j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft) m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

5. Connect hoses (10) (4 used). 9. Connect hoses (6) (5 used).

j : 19 mm j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft) m : 30 N·m (3 kgf·m, 22 lbf·ft)

6. Connect hose (9).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

7. Connect hoses (8) (3 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-13-1-5
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

1 2

3
WDCD-03-06-001 WDCD-03-13-001

10. Connect connectors (4) (2 used).

11. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
12. Install cover (3) with bolts, washers (2) (5 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

13. Shut engine cover (1).

W3-13-1-6
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

Structure of Signal Control Valve

13

12 4

11

4 10

7 8
7
7

4 4

W1JB-02-10-002

W3-13-2-1
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

15
16
17
18
19
14 16
17 20
21
19
16 20
17
18
19
30

14

22
23
24
25
26
27
19
28
17
16
29
20
19 14
5 18
17
16
20 19
21
17
16
20
19
18
17
16

W1JB-02-10-003

1- Bolt (12 Used) 9- Body 3 17- O-Ring (7 Used) 25- O-Ring

2- Body 1 10- Gasket 18- Spring (4 Used) 26- Spring
3- Gasket 11- Body 4 19- Spring Guide (7 Used) 27- Spool
4- Filter (17 Used) 12- Gasket 20- Spool (5 Used) 28- Spring
5- Body 2 13- Body 5 21- Spring (2 Used) 29- Plate
6- Gasket 14- Socket Bolt (11 Used) 22- Plate 30- Spool
7- Shuttle Valve (21 Used) 15- Plate 23- O-Ring
8- Spring (4 Used) 16- Plug (7 Used) 24- Shuttle Valve

W3-13-2-2
MEMO
MEMO
SECTION 4

UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
Removal and Installation of Swing Bearing..........W4-1-1-1
Disassembly of Swing Bearing...................................W4-1-2-1
Assembly of Swing Bearing.........................................W4-1-2-4
Group 2 Travel Device
Removal and Installation of Travel Device.............W4-2-1-1
Disassembly of Travel Device......................................W4-2-2-1
Assembly of Travel Device...........................................W4-2-2-5
Disassembly of Travel Motor.......................................W4-2-3-1
Assembly of Travel Motor............................................W4-2-3-4
Disassembly of Brake Valve.........................................W4-2-4-1
Assembly of Brake Valve...............................................W4-2-4-3
Precautions for Using Floating Seal.........................W4-2-5-1
Group 3 Center Joint
Removal and Installation of Center Joint...............W4-3-1-1
Disassembly of Center Joint........................................W4-3-2-1
Assembly of Center Joint.............................................W4-3-2-3
Replacement of Body and Spindle...........................W4-3-2-6
Group 4 Track Adjuster
Removal and Installation of Track Adjuster...........W4-4-1-1
Disassembly of Front Idler...........................................W4-4-2-1
Assembly of Front Idler.................................................W4-4-2-4
Disassembly of Track Adjuster....................................W4-4-3-1
Assembly of Track Adjuster.........................................W4-4-3-5
Precautions for Using Floating Seal.........................W4-4-4-1
Group 5 Upper and Lower Rollers
Removal and Installation of Upper Roller..............W4-5-1-1
Removal and Installation of Lower Roller..............W4-5-2-1
Disassembly of Lower Roller.......................................W4-5-3-1
Assembly of Lower Roller.............................................W4-5-3-3
Precautions for Using Floating Seal.........................W4-5-4-1
Group 6 Track
Removal and Installation of Track.............................W4-6-1-1

DCDW-4-1
(Blank)

DCDW-4-2
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Removal and Installation of Swing Bearing

2 1
4, 5

ST 0050
a 3
a- Matching Mark
1
WDAA-04-01-001 W110-03-01-004

Before removing and installing the swing bearing, the

upperstructure must be removed first. (Refer to W3-3-1.) dCAUTION:
lb)
Swing bearing (1) weight: 230 kg (510
Therefore, the procedure starts on the premise that the
upperstructure has already been removed here. 3. Install special tools (ST 0050) (3 used) to swing
bearing (1). Attach a wire rope onto special tools
Removal (ST 0050) (3 used). Hoist swing bearing (1). Remove
swing bearing (1).
1. Put the matching marks (a) on inner race (2) of
swing bearing (1) and track frame (3).
2. Remove bolts (4) (36 used) and spring washers (5)
(36 used).

j : 30 mm

W4-1-1-1
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

2 1

ST 0050

1 W110-03-01-004

d
a

a 3
a- Matching Mark

WDAA-04-01-001

a
WDCD-04-01-001

a- Position for Grease Fitting

b- Soft Zone Marking Position
c- Position for Plug
d- Front Side

Installation IMPORTANT: If the matching marks (a) do not fit, the

soft zone position of inner race will be dislocated.
1. Clean the mounting surfaces of track frame (3) and
swing bearing (1). 4. Fit the matching marks (a) on track frame (3) and
inner race (2) of swing bearing (1).
2. Apply THREEBOND #1102 onto the swing bearing
(1) mounting surface of track frame (3).

dCAUTION:
lb)
Swing bearing (1) weight: 230 kg (510

3. Install special tools (ST 0050) (3 used) to swing

bearing (1). Attach a wire rope onto special tools (ST
0050) (3 used). Hoist swing bearing (1).

W4-1-1-2
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

1
4, 5

a b 7

5mm

WDAA-04-01-001 W175-03-01-002

a- Swing Bearing
b- Grease Level

5. Install swing bearing (1) with spring washers (5) (36

used) and bolts (4) (36 used).

j : 30 mm

m : 500 N·m (50 kgf·m, 370 lbf·ft)

6. After installing swing bearing (1), add grease
(Alvania EP2 or equivalent) to grease bath (6) until
pinion (7) of the swing device is 5 mm (0.2 in) under
grease.

fNOTE: Grease amount: 17 L (4.49 US gal)

W4-1-1-3
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

(Blank)

W4-1-1-4
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Disassembly of Swing Bearing

1 2 3

8 7 6 5

W178-02-11-193

7 8

W178-02-11-194

1- Outer Race 5- Seal 9- Grease Fitting (2 Used)

2- Seal 6- Ball (111 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (111 Used)

W4-1-2-1
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Disassembly of Swing Bearing
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
3. Install bolt (10) to the screw hole (M10, Pitch 1.5
mm) of plug (4). Tap or pull bolt (10) and remove
plug (4) from outer race (1).

such as goggles, helmets, etc in order to prevent

personal injury.
1. Grind off the crimped part of pin (3) by using a
1
grinder. Tap the bottom side of pin (3) of plug (4) by
using a bar and a hammer. Remove pin (3) of plug
(4).
3
4

W178-02-11-196
10

dCAUTION: Swing bearing weight: 230 kg (510 lb)

W178-02-11-195 4. Place inner race (7) of the swing bearing on a
wooden block by using the special tool (ST 0050).
Hoist outer race (1) horizontally. Hold outer race (1).
2. Thread hole (a) of plug (4) by using a tap (M10, Pitch
1.5 mm).

WJAA-04-01-002

a- Hole

W4-1-2-2
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

5. Remove balls (6) (111 used) and supports (8) (111

used) from the plug (4) hole while rotating outer
race (1).

1
2

11 7

6 5
W178-02-11-197

12

8
W178-02-11-198

fNOTE: Remove ball (6) by using magnet (11). Use wire

(12) and remove support (8).
6. Remove seals (2, 5) from outer race (1) and inner
race (7) by using a scrapper.

W4-1-2-3
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Assembly of Swing Bearing

1 2 3

8 7 6 5

W178-02-11-193

7 8

W178-02-11-194

1- Outer Race 5- Seal 9- Grease Fitting (2 Used)

2- Seal 6- Ball (111 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (111 Used)

W4-1-2-4
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Assembly of Swing Bearing

dCAUTION: Swing bearing weight: 230 kg (510 lb)
1. Install special tools (ST 0050) (3 used) to outer race
(1). Attach a wire rope onto special tools (ST 0050)
(3 used). Hoist the swing bearing horizontally. Align
outer race (1) and inner race (7) coaxially.
Apply grease onto balls (6) (111 used) and supports
(8) (111 used).
Install balls (6) (111 used) and supports (8) (111
used) alternately from the plug (4) hole by using a
round bar while turning outer race (1).
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
2. Install plug (4) to outer race (1) by using a hammer.
Secure plug (4) to outer race (1) with pin (3).
Crimp the head of pin (3) by using a punch.
3

1
2

6 W178-02-11-201

3. Degrease the groove part for seals (2, 5) completely.

5
W178-02-11-199
Apply THREEBOND #1530D onto seals (2,5). Install
seals (2, 5) to outer race (1) and inner race (7).
4. Add grease (Alvania EP2 or equivalent) to the swing
bearing through grease fittings (9) (2 used). At this
time, add grease while turning outer race (1).

fNOTE: Grease amount: 0.5 L (0.53 US qt)

W178-02-11-200

W4-1-2-5
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

(Blank)

W4-1-2-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Removal and Installation of Travel Device

WDAA-04-02-001 WDAA-04-02-002

Removal
IMPORTANT: Cap the open ends in case the hoses 5. Disconnect hose (7).
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors, j : 27 mm
hoses, and pipes for assembling. Connect the 6. Disconnect hose (8).
hoses and install the clips in case the clips which
secure the hoses have been removed. j : 17 mm

Removal dCAUTION:
lb)
Travel Device (5) weight: 310 kg (685

1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
dCAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.)
7. Attach a nylon sling onto travel device (5). Hoist and
hold travel device (5). Remove bolts (9) (14 used)
and washers (10) (14 used). Hoist and remove travel
device (5).

2. Disconnect track (1). (Refer to W4-6-1.) j : 30 mm

3. Remove bolts (2) (6 used) and washers (3) (6 used). 8. Remove the adapter with travel device (5) attached
Remove cover (4). if necessary.

j : 22 mm 9. Remove another travel device in the same way as

step 1 to step 7.
4. Place a container under travel device (5). Disconnect
hoses (6) (2 used).

j : 36 mm

W4-2-1-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

WDAA-04-02-002

Installation
1. Install all removed adapters to travel device (5).

dCAUTION:
lb)
Travel Device (5) weight: 310 kg (685

2. Attach a nylon sling onto travel device (5). Hoist

travel device (5). Install travel device (5) with
washers (10) (14 used) and bolts (9) (14 used).

j : 30 mm

m : 630 N·m (63 kgf·m, 460 lbf·ft)

3. Connect hose (8).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

4. Connect hose (7).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

5. Connect hoses (6) (2 used).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

W4-2-1-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

WDAA-04-02-001

6. Connect track (1). (Refer to W4-6-1.)

7. Install another travel device in the same way as step
1 to step 6.
8. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks. In order to
prevent the travel motor from seizing, perform
the break-in operation after installing.

Condition:
1. Engine speed: Slow idle speed
2. Travel mode switch: Slow speed
3. Operation duration: Over 2 minutes
9. Install cover (4) with washers (3) (6 used) and bolts
(2) (6 used).

j : 22 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

10. Install another cover in the same way as step 9.

W4-2-1-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

(Blank)

W4-2-1-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Device

WDAA-04-02-003

00- Travel Motor
02- Floating Seal
03- Roller Bearing (2 Used)
04- Drum
05- Sprocket
06- Bolt (18 Used)
07- Spring Washer (18 Used)
09- Bearing Nut
10- Knock Pin
11- Needle Bearing (6 Used)
12- Third Stage Carrier
13- Planetary Gear (3 Used)
15- Thrust Plate (6 Used)
16- Pin (3 Used)
17- Spring Pin (3 Used)
18- Sun Gear
20- Ring Gear
21- Bolt (24 Used)
23- Second Stage Carrier
24- Spacer
25- Planetary Gear (3 Used)
26- Needle Bearing (3 Used)
27- Thrust Plate (6 Used)
28- Pin (3 Used)
29- Spring Pin (3 Used)
30- Sun Gear
32- First Stage Carrier
33- Spacer
34- Planetary Gear (3 Used)
35- Needle Bearing (3 Used)
36- Thrust Plate (6 Used)
37- Pin (3 Used)
38- Spring Pin (3 Used)
39- Shaft
41- Cover
42- Stopper
43- Bolt, Washer (12 Used)
44- Plug (3 Used)

W4-2-2-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Device

IMPORTANT: Do not remove stopper (42) unless
dCAUTION: There may be pressure accumulated
inside of the travel device. Loosen the air bleed damage and wear are found.
plug slowly. Release any remaining pressure 4. Remove bolts, washers (43) (12 used). Remove cover
completely. Remove the drain plug and drain gear (41).
oil. If the air bleed plug is loosened suddenly, the
plug may be fly out and gear oil may gush out. j : 19 mm
Keep body and face away from plug.
fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been
applied between cover (41) and ring gear (20). For easy
dCAUTION: Travel Device weight: 310 kg (685 lb) removal, insert and tap a chisel between cover (41) and
ring gear (20).
1. Attach a nylon sling onto the body of travel device.
Hoist the travel device. Place the travel device on a 5. Remove shaft (39) and the first stage carrier (32)
workbench with the travel motor (00) side up. Install assembly from second stage carrier (23).
the special tool (ST 5090) to the travel device with
6. Remove sun gear (30) from second stage carrier
bolts (M20, Pitch 2.5 mm) (2 used).
(23).
j : 30 mm 7. Remove the second stage carrier (23) assembly from
ring gear (20).
ST 5090

00

W105-03-02-007

dCAUTION: Travel device weight: 310 kg (685 lb)

2. Attach a nylon sling onto the body of travel device.
Hoist the travel device. Place the travel device on a
workbench with the travel motor (00) side down.

fNOTE: Secure the spacer to the workbench tightly in

order to receive a reaction force when disassembling.
3. Remove plugs (44) (3 used).

l : 10 mm

W4-2-2-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

8. Remove sun gear (18) from third stage carrier (12). IMPORTANT: Do not remove knock pin (10) unless
necessary.
dCAUTION: Ring gear (20) weight: 39 kg (86 lb)
11. Remove bearing nut (09) from travel motor (00) by
9. Remove bolts (21) (24 used). Install eyebolts (M12, using special tools (ST 7248, ST 7249).
Pitch 1.75 mm) (2 used) to the bolt, washer (43)
holes (2 places) of ring gear (20). Attach nylon slings
onto the eyebolts. Hoist and remove ring gear (20).

j : 24 mm ST 7248

fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been

ST 7249
applied between ring gear (20) and drum (04). If it is
difficult to remove, pry it by using a screwdriver.

dCAUTION: The third stage carrier (12) assembly

weight: 31 kg (69 lb)
09

10. Attach claws (a) of the special tool (ST 0916) onto
the outer surface of third stage carrier (12). Hoist the
third stage carrier (12) assembly from drum (04).
W178-03-02-013

ST 0916
dCAUTION:
kg (215 lb)
Sprocket (05) + drum (04) weight: 96
a
IMPORTANT: The travel motor (00) side of drum (04)
is the seal sliding surface for travel motor (00).
Place it on a wooden block after removing.
12. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the
bolt holes (2 places) of drum (04). Attach nylon
slings onto the eyebolts. Hoist and remove the
drum (04) assembly from travel motor (00).
W178-02-11-203
fNOTE: If it is difficult to remove, rotate sprocket (05).
a - Claw

W4-2-2-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device
IMPORTANT: Handle floating seal (02) with care.
(Refer to W4-2-5.)
13. Remove one side of floating seal (02) from travel
motor (00).
14. Remove the inner race of roller bearing (03) from
drum (04).
dCAUTION: Sprocket (05) weight: 46 kg (105 lb)
dCAUTION: When removing sprocket (05),
gather up the nylon sling and hoist sprocket (05)
horizontally. Do not drop sprocket (05).
15. Remove bolts (06) (18 used) and spring washers
(07) (18 used). Attach a nylon sling onto sprocket
(05). Hoist sprocket (05). Remove sprocket (05) from
drum (04).
j : 30 mm
fNOTE: LOCTITE #262 (or THREEBOND #1386) has been
applied on bolt (06).
dCAUTION: Drum (04) weight: 51 kg (115 lb)
16. Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the
bolt (06) holes on drum (04). Attach nylon slings
onto the eyebolts. Hoist drum (04). Place drum (04)
with the ring gear (20) side down.
IMPORTANT: Handle floating seal (02) with care.
(Refer to W4-2-5.)
17. Remove one side of floating seal (02) from drum
(04).
W4-2-2-4
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Do not remove roller bearing (03)
unless necessary.
18. Remove the outer races of roller bearings (03) (2
used) from drum (04) by using a bar and a hammer.
19. Remove spring pins (38) (3 used) from first stage
carrier (32) by using the special tool (ST 1391).
20. Remove pins (37) (3 used), thrust plates (36) (6
used), planetary gears (34) (3 used), needle bearings
(35) (3 used), and spacer (33) from first stage carrier
(32).
21. Remove spring pins (29) (3 used) from second stage
carrier (23) by using the special tool (ST 1391).
22. Remove pins (28) (3 used), thrust plates (27) (6
used), planetary gears (25) (3 used), needle bearings
(26) (3 used), and spacer (24) from second stage
carrier (23).
23. Remove spring pins (17) (3 used) from third stage
carrier (12) by using the special tool (ST 1463).
24. Remove pins (16) (3 used), thrust plates (15) (6
used), planetary gears (13) (3 used), and needle
bearings (11) (6 used) from third stage carrier (12).
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Device

04 09 10
21
12 18 20
24 23 30 33 32

44

41

39

42
34
36

35
37

38

13 11 16 15 17 25 26 28 27 29 43

00 02 03 03

06
05 07

WDCD-04-02-001

00- Travel Motor
02- Floating Seal
03- Roller Bearing (2 Used)
04- Drum
05- Sprocket
06- Bolt (18 Used)
07- Spring Washer (18 Used)
09- Bearing Nut
10- Knock Pin
11- Needle Bearing (6 Used)
12- Third Stage Carrier
13- Planetary Gear (3 Used)
15- Thrust Plate (6 Used)
16- Pin (3 Used)
17- Spring Pin (3 Used)
18- Sun Gear
20- Ring Gear
21- Bolt (24 Used)
23- Second Stage Carrier
24- Spacer
25- Planetary Gear (3 Used)
26- Needle Bearing (3 Used)
27- Thrust Plate (6 Used)
28- Pin (3 Used)
29- Spring Pin (3 Used)
30- Sun Gear
32- First Stage Carrier
33- Spacer
34- Planetary Gear (3 Used)
35- Needle Bearing (3 Used)
36- Thrust Plate (6 Used)
37- Pin (3 Used)
38- Spring Pin (3 Used)
39- Shaft
41- Cover
42- Stopper
43- Bolt, Washer (12 Used)
44- Plug (3 Used)

W4-2-2-5
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device
Assembly of Travel Device
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
d CAUTION: Be careful as roller bearing (03) is too
hot.
IMPORTANT: When roller bearing (03) has been
removed, follow the procedure as steps 1, 3, 5, and
12.
1. Warm up the inner race of roller bearing (03) of the
travel motor (00) side to 50 to 70 °C (122 to 158
°F) by using a heater. Install the inner race of roller
bearing (03) of the travel motor (00) side to travel
motor (00). After roller bearing (03) of the travel
motor (00) side cools, install roller bearing (03) of
the travel motor (00) side to travel motor (00).
fNOTE: Check that the inner race of roller bearing (03)
on the travel motor side is installed completely.
03
00
WDCD-04-02-002
W4-2-2-6
IMPORTANT: Handle floating seal (02) with care.
(Refer to W4-2-5.)
2. Apply grease onto O-ring of one side of floating seal
(02). Install one side of floating seal (02) to travel
motor (00). Apply gear oil onto the whole sliding
surface on floating seal (02).
fNOTE: If it is difficult to install O-ring of floating seal
(02), push O-ring to the periphery direction by using a
bamboo spatula.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Do not tap except for the outer race of
roller bearing (03).
3. Install the outer race of roller bearing (03) of the
cover (41) side to drum (04) by using a bar and a
hammer.
fNOTE: Check that the outer race of roller bearing (03)
on the cover (41) side is installed completely.
03
04
WDCD-04-02-002
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device
d CAUTION: Drum (04) weight: 51 kg (115 lb)
4. Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the
bolt (06) holes on drum (04). Attach nylon slings
onto the eyebolts. Hoist drum (04). Place drum (04)
with the ring gear (20) side down.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Do not tap except for the outer race of
roller bearing (03).
5. Install the outer race of roller bearing (03) of the
travel motor (00) side to drum (04) by using a bar
and a hammer.
fNOTE: Check that the outer race of roller bearing (03)
on the travel motor (00) side is installed completely.
00
04 03
WDCD-04-02-003
W4-2-2-7
IMPORTANT: Handle floating seal (02) with care.
(Refer to W2-4-5.)
6. Apply grease onto O-ring of other side of floating
seal (02). Install one side of floating seal (02) to
drum (04).
fNOTE: If it is difficult to install O-ring of floating seal
(02), push O-ring to the periphery direction by using a
bamboo spatula.
dCAUTION:
(135 lb)
Drum (04) assembly weight: 59 kg
7. Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the
bolt (06) holes on drum (04). Attach nylon slings
onto the eyebolts. Hoist drum (04) assembly. Place
drum (04) assembly with the travel motor (00) side
down.
dCAUTION: Sprocket (05) weight: 46 kg (105 lb)
dCAUTION: When installing sprocket (05),
gather up the nylon sling and hoist sprocket (05)
horizontally. Do not drop sprocket (05).
IMPORTANT: Fit the chamfered side of sprocket (05)
to the drum (04) side.
8. Attach a nylon sling onto sprocket (05). Hoist
sprocket (05). Place sprocket (05) onto drum (04).
9. Degrease the bolt (06) holes on drum (04) and bolts
(06) (18 used). Apply LOCTITE #262 or THREEBOND
#1386B onto bolts (06) (18 used). Install sprocket
(05) to drum (04) with spring washers (07) (18 used)
and bolts (06) (18 used).
j : 30 mm
m : 485 N·m (48.5 kgf·m, 360 lbf·ft)
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: Check the direction to install bearing

d CAUTION: Sprocket (05) + drum (04) assembly
weight: 96 kg (215 lb)
10. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the
bolt (21) holes (2 places) on drum (04). Attach nylon
slings onto the eyebolts. Hoist drum (04) assembly.
Place drum (04) straight on travel motor (00). At this
time, check that the clearance between travel motor
(00) and drum (04) is even all around.
11. While applying the weight and shaking drum (04),
push drum (04) into travel motor (00) straight.
nut (09).
13. Apply grease onto the thread part of bearing nut
(09). Install bearing nut (09) to travel motor (00)
with the turned surface facing to roller bearing (03)
on the cover (41) side. Tighten bearing nut (09) by
hand.
14. Install bearing nut (09) by using special tools (ST
7248, ST 7249) and a torque wrench.
m : 500 N·m (50 kgf·m, 370 lbf·ft)

dCAUTION:
hot.
Be careful as roller bearing (03) is too

12. Warm up the inner race of roller bearing (03) of ST 7248

the cover (41) side to 50 to 70 °C (122 to 158 °F) by
using a heater. Install the inner race of roller bearing ST 7249
(03) of the cover (41) side to travel motor (00). After
roller bearing (03) of the cover (00) side cools, install
roller bearing (03) of the cover (00) side to travel 09
motor (00).

fNOTE: Install roller bearing (03) until the inner race side
of roller bearing (03) reaches three threads for bearing
nut (09).
f NOTE: Check that the inner race of roller bearing (03)
on the cover (41) side is installed completely.
00
03
W178-03-02-013
15. After installing bearing nut (09), tap the sprocket
(05) end by using a hammer and reduce a
play. Rotate sprocket (05) both clockwise and
counterclockwise 4 to 5 turns.
16. Repeat steps 14, 15.
17. Tighten bearing nut in the same way as step 14.

m : 500 N·m (50 kgf·m, 370 lbf·ft)

WDCD-04-02-003

W4-2-2-8
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: When knock pin (10) has been
removed, follow the procedure as step 18.
18. Fit the phases of the spline center in travel motor
(00) and the knock pin (10) center. If the center
phases are not fitted, rotate bearing nut (09) in
tightening direction until both center phases are
fitted.
09 10
00
W178-02-11-208
23. Install other planetary gears (13) (2 used) to third
stage carrier (12) in the same way as steps 19 to 22.
dCAUTION: The third stage carrier (12) assembly
weight: 31 kg (69 lb)
dCAUTION: Third stage carrier (12) falls at the
moment when knock pin (10) is inserted into third
stage carrier (12). Do not catch fingers.
24. Attach claws (a) of the special tool (ST 0916) onto
the outer surface of third stage carrier (12). Hoist
the third stage carrier (12) assembly. Install the third
stage carrier (12) assembly to the spline in travel
motor (00).
ST 0916
a

IMPORTANT: There is an identification groove on

one side of planetary gear (13). Install planetary
gear (13) with the identification groove side facing
to the spring pin (17) hole.
19. Install needle bearings (11) (2 used) to planetary
gear (13).
W178-02-11-203
20. Secure planetary gear (13) between thrust plates a - Claw
(15) (2 used). Install them to third stage carrier (12).
21. Install pin (16) to third stage carrier (12). At this time, 25. Clean the mating surfaces of drum (04) and ring
fit the spring pin (17) hole of third stage carrier (12) gear (20), and apply THREEBOND #1215 or LOCTITE
and the pin (16) hole. #5020.

22. Install spring pin (17) to third stage carrier (12) with
the slit (b) side facing to the second stage carrier
(23) side.
17
16
b

W178-02-11-210
b - Slit

W4-2-2-9
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

34. Install the second stage carrier (23) assembly to ring

d CAUTION: Ring gear (20) weight: 39 kg (86 lb)
26. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
bolt, washer (43) holes (2 places) of ring gear (20).
Attach nylon slings onto the eyebolts. Hoist ring
gear (20). Install ring gear (20) to drum (04) with
bolts (21) (24 used).
j : 24 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft)
27. Install sun gear (18) to third stage carrier (12) with
the thinner diameter part up.
28. Install spacer (24) to second stage carrier (23).
29. Install needle bearing (26) to planetary gear (25).
30. Secure planetary gear (25) between thrust plates
(27) (2 used). Install them to second stage carrier
(23).
gear (20).
35. Install sun gear (30) to second stage carrier (23) with
the thinner diameter part up.
36. Install spacer (33) to first stage carrier (32).
37. Install needle bearing (35) to planetary gear (34).
38. Secure planetary gear (34) between thrust plates
(36) (2 used). Install them to first stage carrier (32).
39. Install pin (37) to first stage carrier (32). At this time,
fit the spring pin (38) hole of first stage carrier (32)
and the pin (37) hole.
40. Install spring pin (38) to first stage carrier (32) with
the slit (b) side facing to the cover (41) side.
38
37
b

31. Install pin (28) to second stage carrier (23). At this

time, fit the spring pin (29) hole of second stage
carrier (23) and the pin (28) hole. W178-02-11-210
b - Slit
32. Install spring pin (29) to second stage carrier (23)
with the slit (a) side facing to the cover (41) side.
29 41. Install other planetary gears (34) (2 used) to first
28 stage carrier (32) in the same way as steps 37 to 40.
a

W178-02-11-210
a - Slit

33. Install other planetary gears (25) (2 used) to second

stage carrier (23) in the same way as steps 29 to 32.

W4-2-2-10
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

42. Insert the spline side of shaft (39) into the center of
sun gear (30). Rotate sprocket (05) slowly by hand.
Engage travel motor (00) and planetary gear (34)
with shaft (39), and install them.
43. Install the first stage carrier (32) assembly to ring
gear (20).
44. Fill ring gear (20) with gear oil (SAE#90(GL-4)).

fNOTE: Oil amount 6.8 L (1.8 US gal)

45. Clean the mating surfaces of ring gear (20) and
cover (41), and apply THREEBOND #1215 or LOCTITE
#5020. Install cover (41) to ring gear (20) with bolts,
washers (43) (12 used).

j : 19 mm

m : 110 N·m (11 kgf·m, 81 lbf·ft)

46. Install a seal tape onto plugs (44) (3 used). Install
plugs (44) (3 used) to cover (41).

l : 10 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-2-2-11
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

(Blank)

W4-2-2-12
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Motor

WDAA-04-02-007

00- Housing 14- Plunger (9 Used) 23- Plate (4 Used) 31- O-Ring (2 Used)
01- Oil Seal 16- Retainer 25- Brake Piston 32- Brake Valve
03- Piston 17- Bushing 26- O-Ring 33- Needle Bearing
07- Shaft 18- Swash Plate 28- O-Ring 37- Knock Pin (2 Used)
08- Retaining Ring 19- Spring (6 Used) 29- Disc Spring 39- Valve Plate
09- Ball (2 Used) 21- Rotor 30- O-Ring 40- Socket Bolt (9 Used)
10- Roller Bearing 22- Friction Plate (4 Used)

W4-2-3-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Motor

dCAUTION: Travel motor weight: 91 kg (205 lb)
1. Attach a nylon sling onto the travel motor. Hoist the
travel motor. Place travel motor with the brake valve
(32) side up.
dCAUTION: Brake valve (32) weight: 21 kg (47 lb)
IMPORTANT: When removing the brake valve (32)
assembly, do not drop valve plate (39).
2. Remove socket bolts (40) (9 used).
l : 14 mm
3. Remove plugs (a) (2 used). Install the adapters
(A852122) (2 used) to the holes of plugs (a) (2 used).
Install the special tools (ST 0261) (2 used) to the
adapters (A852122) (2 used). Attach nylon slings
onto the special tools (ST 0261). Hoist brake valve
(32). Remove brake valve (32) from housing (00).
l : 6 mm
j : 19 mm
4. Remove valve plate (39) and knock pins (37) (2 used)
from brake valve (32).
5. Install a tape onto the thrust surface of shaft (07)
and needle bearing (33) in order to protect.
6. Remove disc spring (29) from housing (00).
7. Remove O-ring (30) and O-rings (31) (2 used) from
housing (00).
dCAUTION: When removing brake piston (25),
hold brake piston (25) with a cloth in order not to
fly out.
IMPORTANT: The upper surface of brake piston (25)
is seat surface (b) for high-pressure oil. Place brake
piston (25) with seat surface (b) for high-pressure
oil up.
8. Apply air 100 to 300 kPa (1.0 to 3.0 kgf/cm2, 15 to
44 psi) to the brake releasing oil passage in housing
(00). Float and remove brake piston (25).
b

23
W178-02-11-215
b - Seat Surface of High-Pressure
Oil

9. Remove O-rings (26, 28) from brake piston (25).

10. Remove plates (23) (4 used) and friction plates (22)
(4 used) from housing (00).
11. Remove rotor (21), springs (19) (6 used), bushing
(17), retainer (16), and plungers (14) (9 used) from
housing (00).

a
WDCD-04-02-007

IMPORTANT: Do not remove needle bearing (33)

unless necessary. Remove needle bearing (33)
by using a small puller if necessary. Needle
bearing (33) cannot be reused as the outer race is
deformed.
IMPORTANT: Do not damage valve plate (39).

W4-2-3-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

15. Attach a bar onto the bottom of the spline hole

d CAUTION: The housing (00) assembly weight: 59
kg (135 lb)
12. Attach a nylon sling onto housing (00). Hoist the
housing (00) assembly. Place the housing (00)
assembly horizontally with the brake releasing oil
passage (a) side down.
fNOTE: If housing (00) is placed with brake releasing oil
passage (a) topside, the thick part of swash plate (18)
becomes topside. If placing housing (00) horizontally,
swash plate (18) may suddenly come out.
a on shaft (07) in a vise opening. Remove shaft (07)
of shaft (07). Tap and remove shaft (07) and roller
bearing (10) from housing (00) by using a bar and a
plastic hammer.
IMPORTANT: Oil seal (01) cannot be reused.
16. Remove oil seal (01) from housing (00) by using a
screwdriver.
fNOTE: THREEBOND #1104 (or #1215) has been applied
onto the outer surface of oil seal.
17. Remove retaining ring (08) from shaft (07).
IMPORTANT: When removing shaft (07) from roller
bearing (10), do not drop shaft (07).
18. Secure the inner race part of roller bearing (10)
from roller bearing (10) by using a bar and a plastic
hammer.

10

07
WDAA-04-02-008
a - Brake Releasing Oil Passage

dCAUTION: When removing swash plate (18) with

applying air, hold piston (03) with a cloth in order
not to fly out.
W178-02-11-212
IMPORTANT: When swash plate (18) cannot be
removed, apply air 100 to 300 kPa (1.0 to 3.0
kgf/cm2, 15 to 44 psi) through the piston oil
passage hole. Swash plate (18) and piston (03) are
removed.
13. Remove swash plate (18) from housing (00).
14. Remove balls (09) (2 used) and piston (03) from
housing (00) by using a magnet.

W4-2-3-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Motor

30
31
37 25

40
21 14 16
18
32
09

10

01

07

00

33

19 17 03 08
39 22

23
29
28
26

WDCD-04-02-004

00- Housing 14- Plunger (9 Used) 23- Plate (4 Used) 31- O-Ring (2 Used)
01- Oil Seal 16- Retainer 25- Brake Piston 32- Brake Valve
03- Piston 17- Bushing 26- O-Ring 33- Needle Bearing
07- Shaft 18- Swash Plate 28- O-Ring 37- Knock Pin (2 Used)
08- Retaining Ring 19- Spring (6 Used) 29- Disc Spring 39- Valve Plate
09- Ball (2 Used) 21- Rotor 30- O-Ring 40- Socket Bolt (9 Used)
10- Roller Bearing 22- Friction Plate (4 Used)

W4-2-3-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Motor

IMPORTANT: Before assembling, apply hydraulic oil
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
onto parts in order to prevent them from seizing. such as goggles, helmets, etc in order to prevent
d CAUTION: Housing (00) weight: 50 kg (115 lb) personal injury.
6. Install roller bearing (10) to shaft (07) from the large
1. Attach a nylon sling onto housing (00). Hoist
housing (00). Place housing (00) with the brake diameter side of shaft (07) by using the special tool
valve (32) side up. (ST 2654) and a hammer.

2. Apply OCEAN grease #7 onto the inner surface of oil
seal (01).
3. Apply THREEBOND #1104 or #1215 onto the outer
surface of oil seal (01).
4. Clean the oil seal (01) mating part of housing
(00). Install oil seal (01) to housing (00) by using
the special tools (ST 2652, ST 7270) and a plastic
hammer.
7. Install retaining ring (08) to shaft (07).
8. Install piston (03) to housing (00) with the stepped
side facing inside.
IMPORTANT: The small diameter side of shaft (07)
is the inner race of needle bearing (33). Do not
damage the inner race of needle bearing (33).
9. Install shaft (07) to housing (00) by using a plastic
hammer.

fNOTE: When center position of shaft (07) is sufficiently

ST 7270 adjusted, shaft (07) will be inserted without hitting it.

ST 2652
00

01

WDCD-04-02-006

5. Install inner ring plate (a) to roller bearing (10) with

the stamped mark facing outside.

10 a

W178-02-11-221
a - Inner Ring Plate

W4-2-3-5
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

10. Install balls (09) (2 used) to housing (00). IMPORTANT: Install retainer (16) with the chamfered
side facing to the bushing (17) side.
11. Apply grease onto the ball (09) hole of swash plate
(18). Fit the position of balls (09) (2 used) and install 13. Install springs (19) (6 used), bushing (17), retainer
swash plate (18) to housing (00). (16), and plungers (14) (9 used) to rotor (21).
16
dCAUTION:
kg (135 lb)
The housing (00) assembly weight: 59

12. Attach a nylon sling onto housing (00). Hoist the

housing (00) assembly. Place the housing (00) b
17
assembly horizontally with the brake releasing oil
passage (a) down. W178-02-11-225
b - Chamfered Side
fNOTE: If housing (00) is placed with brake releasing oil
passage (a) topside, the thick part of swash plate (18)
14. Install the rotor (21) assembly to housing (00).
becomes topside. If placing housing (00) horizontally,
swash plate (18) may suddenly come out.
dCAUTION:
kg (150 lb)
The housing (00) assembly weight: 67

15. Attach a nylon sling onto housing (00). Hoist the

housing (00) assembly. Place the housing (00)
a
assembly with the brake valve (32) mounting
surface up.
IMPORTANT: Check the installation order of friction
plate (22) and plate (23).
16. Install friction plates (22) (4 used) and plates (23) (4
used) to housing (00).
17. Apply grease onto O-rings (28, 26). Install O-rings
WDAA-04-02-008
(28, 26) to brake piston (25).
a - Brake Releasing Oil Passage

W4-2-3-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

20. Install O-rings (31) (2 used) and O-ring (30) to

d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
housing (00).

such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: The upper surface of brake piston (25)
is the seat surface for high-pressure oil. Do not
damage brake piston (25).
IMPORTANT: Install brake piston (25) so that notch
(a) on the disc spring (29) mounting surface is
located opposite the brake releasing oil passage
(b) side.
18. Install brake piston (25) to housing (00) by using the
special tools (ST 7272, ST 7273) and a hammer.
fNOTE: As O-ring (28) is positioned around brake piston
(25), brake piston (25) cannot be fully inserted. When
installing brake valve (32), tighten brake piston (25) with
socket bolt (40).
00 a 25 b
21. Add hydraulic oil to housing (00) until plate (23) is
submerged.
IMPORTANT: Check the direction to install knock pin
(37).
22. Install knock pins (37) (2 used) to brake valve (32)
with the large diameter side facing to the brake
valve (32) side.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Check the direction to install the outer
race of needle bearing (33).
23. Install the outer race of needle bearing (33) to brake
valve (32) with the stamped mark facing outside by
using the special tool (ST 7269) and a hammer.

ST 7269

32 33

W178-02-11-227

WDCD-04-02-005

a - Notch
b - Brake Releasing Oil Passage

IMPORTANT: Check the direction to install disc

spring (29).
19. Place disc spring (29) to brake piston (25) with the
inner diameter contacting to brake piston (25).

W4-2-3-7
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

24. Apply grease onto the flat surface of valve plate

(39). Install valve plate (39) to brake valve (32) while
fitting the knock pin (37) positions.

fNOTE: Valve plate (39) is secured to brake valve (32) in

order not to drop brake valve (32) when turning over.
IMPORTANT: Do not drop valve plate (39). If valve
plate (39) is damaged, oil leakage may occur.

dCAUTION: Brake valve (32) weight: 21 kg (47 lb)

25. Remove plugs (a) (2 used). Install the adapters
(A852122) (2 used) to the holes of plugs (a) (2 used).
Install the special tools (ST 0261) (2 used) to the
adapters (A852122) (2 used). Attach nylon slings
onto the special tools (ST 0261). Hoist brake valve
(32).

l : 6 mm

j : 19 mm
a

a
WDCD-04-02-007

26. Install brake valve (32) to housing (00) with socket

bolts (40) (9 used).

l : 14 mm

m : 300 N·m (30 kgf·m, 220 lbf·ft)

27. Remove the special tools (ST 0261) and adapters
(A852122) (2 used for each).

j : 19 mm
28. Install plugs (a) (2 used).

l : 6 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

W4-2-3-8
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Brake Valve

WDAA-04-02-009

01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug

01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring
01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug
02- Stopper (2 Used) 10- Spring (2 Used) 16- Spring 22A- O-Ring
03- Spring (2 Used)

W4-2-4-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Brake Valve IMPORTANT: As the setting changes, do not

disassemble relief valve (15).
1. Remove plugs (05) (2 used) from casing (01A).
Remove O-rings (07) (2 used) from plugs (05) (2 IMPORTANT: Do not move piston (a) with the outer
used). surface of relief valve (15) attached. O-ring may be
damaged.
j : 36 mm 7. Remove relief valves (15) (2 used) from casing (01A).
2. Remove springs (03) (2 used) and stoppers (02) (2
j : 36 mm
used) from casing (01A) by using a magnet.
15
3. Remove spool (01B) from casing (01A) by using a
magnet.
IMPORTANT: Do not remove plug (22) unless
necessary.
4. Remove plug (22) from casing (01A). Remove O-ring
(22A) from plug (22).

l : 6 mm
a
5. Remove seat (13) from casing (01A).
W1V1-03-02-008
a - Piston
l : 5 mm
6. Remove ball (11) by using a magnet.
8. Remove springs (10) (2 used) and poppet (08) (2
used) from casing (01A) by using a magnet.
9. Remove plug (17) from casing (01A). Remove O-ring
(17A) from plug (17).

l : 6 mm
10. Remove spring (16) and spool (01C) from casing
(01A) by using a magnet.

W4-2-4-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Brake Valve

01B 01A
02
03
07
05
05

22

01C

16

22A 17A 17
08
10
15 11 13 15

WDAA-04-02-010

01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug

01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring
01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug
02- Stopper (2 Used) 10- Spring (2 Used) 16- Spring 22A- O-Ring
03- Spring (2 Used)

W4-2-4-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Brake Valve
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
1. Install spool (01B) into the center of casing (01A).
8. Install springs (10) (2 used) to poppets (08) (2 used).
Install poppets (08) (2 used) to the hole of casing
(01A) completely.
9. Install relief valves (15) (2 used) to casing (01A)
while pushing poppets (2) (2 used).

2. Install O-ring (07), spring (03) and stopper (02) to j : 36 mm

plug (05). Install the plug (05) assembly to casing
(01A) with one thread tighten. m : 450 N·m (45 kgf·m, 330 lbf·ft)
IMPORTANT: Check the direction to install spool
fNOTE: If plug (05) is fully tightened, it is difficult to
(01C).
install other plug (05) as spool (01B) is pushed.
10. Install spool (01C) to casing (01A) with the hole side
3. Install O-ring (07), spring (03) and stopper (02) to
facing the near side.
other plug (05). Install the plug (05) assembly to
casing (01A) and tighten by hand. 11. Install spring (16) to casing (01A).
4. Tighten plugs (05) (2 used). 12. Install O-ring (17A) to plug (17). Install plug (17) to
casing (01A).
j : 36 mm
l : 6 mm
m : 450 N·m (45 kgf·m, 330 lbf·ft)
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
5. Install ball (11) to casing (01A).
6. Install seat (13) to casing (01A).

l : 5 mm

m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

7. Install O-ring (22A) to plug (22). Install plug (22) to
casing (01A).

l : 6 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

W4-2-4-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Precautions for Using Floating Seal 1

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 W178-02-11-001
surface (e) of seal ring (1). 2
 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 a
cleaning solvent.
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2) W178-02-11-002
is not twisted, and that it is installed correctly on seal
a - Correct c - Twist of O-Ring
ring (1).
b - Incorrect d - Bend of O-Ring
 After installing the floating seal, check that O-ring
(2) and seal ring sliding surface (e) is parallel with
f
seal mating surface (f ) by measuring the distances
(e) and (f ) at point (A) and (B), as illustrated. If these a b
A A
distances differ, correct O-ring (2) seating.

B B

A=B A≠B

W178-02-11-003

a - Correct e - Sliding Surface

b - Incorrect f - Seal Mating Surface

W4-2-5-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

(Blank)

W4-2-5-2
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Removal and Installation of Center Joint

WDAA-04-03-001

IMPORTANT: Cap the open ends in case the hoses 4. Disconnect hose (4).
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors, j : 17 mm
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Place a container under center joint (1). Disconnect
hoses (2) (4 used).

j : 36 mm
3. Disconnect hose (3).

j : 27 mm

W4-3-1-1
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

WDCD-04-03-001

5. Disconnect hoses (5) (2 used).

j : 27 mm
6. Disconnect hoses (6) (4 used).

j : 36 mm
7. Disconnect hoses (7) (2 used).

j : 17 mm
8. Remove bolts (8) (2 used) and spring washers (9) (2
used). Remove stopper (10).

j : 22 mm
9. Remove rubber (11).

dCAUTION: Center joint (1) weight: 27 kg (60 lb)

10. Install an eyebolt (M14, Pitch 2.0 mm) to the bolt
(8) hole (2 places) on center joint (1). Attach a nylon
sling onto an eyebolt of center joint (1). Hoist and
hold center joint (1).
11. Remove bolts, washers (12) (4 used). Remove center
joint (1).

j : 19 mm
12. Remove the adapter with center joint (1) attached if
necessary.

W4-3-1-2
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

WDCD-04-03-001

Installation 7. Connect hoses (6) (4 used).

1. Install all removed adapters to center joint (1). j : 36 mm

dCAUTION: Center joint (1) weight: 27 kg (60 lb) m : 180 N·m (18 kgf·m, 133 lbf·ft)
2. Install an eyebolt (M14, Pitch 2.0 mm) to the bolt
8. Connect hoses (5) (2 used).
(8) hole (2 places) on center joint (1). Attach a nylon
sling onto an eyebolt. Hoist center joint (1). j : 27 mm
3. Install the center joint with bolts, washers (12) (4
m : 80 N·m (8 kgf·m, 59 lbf·ft)
used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

4. Install rubber (11).
5. Install stopper (10) with spring washers (9) (2 used)
and bolts (8) (2 used).

j : 22 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

6. Connect hoses (7) (2 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

W4-3-1-3
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

WDAA-04-03-001

9. Connect hose (4).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

10. Connect hose (3).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

11. Connect hoses (2) (4 used).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

12. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.

W4-3-1-4
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Disassembly of Center Joint

WDAA-04-03-003

00A- Spindle 03- O-Ring 06- Ring 09- Cover

00B- Plug (with Ball Attached) 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body 05- Bushing 08- O-Ring
02- Dust Seal

W4-3-2-1
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Disassembly of Center Joint

IMPORTANT: For easy removal of oil seal (04), use the
d CAUTION: Center joint weight: 27 kg (60 lb) pins (2 used). Do not damage the seal groove.
1. Remove bolts, washers (10) (2 used) diagonally. 6. Remove oil seals (04) (6 used), O-ring (03), and dust
Install an eyebolt (M10, Pitch 1.5 mm) to the bolt seal (02) from body (01).
(10) hole (2 places) of body (01). Attach a nylon sling
onto an eyebolt. Hoist the center joint. Secure the
center joint on a workbench.

j : 17 mm
2. Put the matching marks on body (01) and spindle
(00A). Remove other bolts, washers (10) (2 used).
Remove cover (09) from body (01).

j : 17 mm
3. Remove O-ring (08), retaining ring (07), and ring (06)
from body (01).
4. Install the special tools (ST 1033, ST 1020) to body
(01) with bolts, washers (10) (2 used).
W178-02-11-240
j : 17 mm
IMPORTANT: Do not damage the seal groove.
7. When replacing bushing (05), weld four places on
10 the bushing (05) bore by using a welding bar. Shrink
and remove bushing (05).

01

W506-03-03-002

IMPORTANT: Do not damage the seal sliding surface

of spindle (00A).
5. Remove spindle (00A) from body (01).

W4-3-2-2
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Assembly of Center Joint

00B

00A

02
03

05

04
01

06
07
08

09

10
W178-03-03-001

00A- Spindle 03- O-Ring 06- Ring 09- Cover

00B- Plug (with Ball Attached) 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body 05- Bushing 08- O-Ring
02- Dust Seal

W4-3-2-3
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Assembly of Center Joint

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
IMPORTANT: When assembling the seals, apply
grease (Apolloil Autorex C) and install seals to
each groove.
IMPORTANT: If bushing (05) has been removed,
install bushing (05) first. (Refer to W4-3-2-6.)
1. Install dust seal (02) to spindle (00A) with lip part (a)
of dust seal (02) facing to body (01) side.
02
IMPORTANT: Do not damage bushing (05).
IMPORTANT: The clearance between body (01) and
spindle (00A) is approximately 0.1 mm. Insert
body (01) along axis straight and slowly. Do not
damage the seal.
IMPORTANT: Do not make a step on ring (06)
mounting part (b).
3. Place spindle (00A) on a workbench. Fit the
matching marks made when disassembling and
install body (01) to spindle (00A).
b 00A

01

01

W178-03-03-002
a - Lip Part W800-03-03-002
b - Ring (06) Mounting Part

2. Install O-ring (03) and oil seals (04) (6 used) to body

(01).

W4-3-2-4
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

IMPORTANT: Install ring (06) with the chamfered

side facing to the spindle (00A) side.
4. Install ring (06) and O-ring (08) to body (01).
00A
01

06
08

WDAA-04-03-004

5. Install retaining ring (07) to spindle (00A).

6. Install cover (09) to body (01) with bolts, washers
(10) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-3-2-5
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Replacement of Body and Spindle

ST 2558
IMPORTANT: When replacing body (01) or spindle
(00A) with the new one, the following procedures
are required. 01

In case of Body (01)

1. Clean body (01) and bushing (05).
05
2. Install bushing (05) to body (01) by using the special
tool (ST 2558) and a press.

fNOTE: Pushing force: 0.5 to 1.5 t (1110 to 3310 lb)

W178-02-11-242
In case of spindle (00A)
00B C
1. Clean spindle (00A).
00A
2. Install plug (00B) to spindle (00A) by using the
special tool (ST 2559).
3. Install ball (a) of plug (00B) so that the top of each
ball is 0.4 mm (0.02 in) or more lower than the
respective sleeve (c) edge as illustrated in detail C.

WDAA-04-03-005

ST 2559 Detail C

b
c

WDAA-04-03-006 WDAA-04-03-007

a - Ball b - 0.4 mm (0.02 in) or more

c - Sleeve

W4-3-2-6
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Removal and Installation of Track Adjuster

c a 1

ST 1650

7 2

WDCD-04-04-002

a - Hoisting Position
c - Hoisting Position

Before removing and installing the track adjuster, the 3. Attach a weight onto part (b) of the special tool
tracks must be removed first. (Refer to W4-6-1.) (ST 1650). Set the track adjuster (7) assembly
Therefore, the procedure starts on the premise that the horizontally.
tracks have already been removed here.
4. Pull out the track adjuster (7) assembly until nylon
slings can be attached onto hoisting position (c) of
Removal
track adjuster (7).
dCAUTION:
(120 lb)
Special tool (ST 1650) weight: 53 kg 5. Attach nylon slings onto hoisting position (c) of
track adjuster (7). Hoist and hold the track adjuster
1. Install the special tool (ST 1650) to the yoke (2) part (7) assembly.
of front idler (1).
6. Remove the special tool (ST 1650) from the yoke (2)
dCAUTION: The track adjuster (7) assembly
weight: 250 kg (555 lb)
part of front idler (1). Remove the track adjuster (7)
assembly.
2. Attach a vise onto hoisting position (a) of front idler
(1). Hoist and hold the track adjuster (7) assembly.

W4-4-1-1
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

7 3, 4

a 5, 6 a
WDCD-04-04-004 WDCD-04-04-003

a - Block

6. Place track adjuster (7) onto blocks (a) (4 used).

7. Remove bolts (3) (2 used) and washers (4) (2 used).

j : 24 mm

dCAUTION: The track adjuster (7) assembly

weight: 250 kg (555 lb)
8. Turn over the track adjuster (7) assembly.

dCAUTION:
adjuster (7).
Take care not to turn over track

dCAUTION: Front idler (1) weight: 110 kg (245 lb)

9. Remove bolts (5) (2 used) and washers (6) (2 used).
Remove front idler (1).

j : 24 mm

W4-4-1-2
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

7 5, 6

a 3, 4 a
WDCD-04-04-004 WDCD-04-04-003

a - Block

Installation 4. Install washers (4) (2 used) and bolts (3) (2 used).

dCAUTION:
adjuster (7).
Take care not to turn over track j : 24 mm

m : 270 N·m (27 kgf·m, 200 lbf·ft)

dCAUTION: Front idler (1) weight: 110 kg (245 lb)
Track adjuster (7) weight: 140 kg (310 lb)
1. Place track adjuster (7) and front idler (1) onto
blocks (a) (4 used) with the bolt (5) hole side up.
2. Install front idler (1) with washers (6) (2 used) and
bolts (5) (2 used).

j : 24 mm

m : 270 N·m (27 kgf·m, 200 lbf·ft)

dCAUTION: The track adjuster (7) assembly

weight: 250 kg (555 lb)
3. Turn over the track adjuster (7) assembly.

W4-4-1-3
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

c a 1

ST 1650

7 2

WDCD-04-04-002

a - Hoisting Position
c- Hoisting Position

dCAUTION: The track adjuster (7) assembly

weight: 250 kg (555 lb)
dCAUTION: The track adjuster (7) assembly +
Special tool (ST 1650) weight: 310 kg (685 lb)
5. Attach nylon slings onto hoisting position (c) 9. Hoist and hold the track adjuster (7) assembly.
of track adjuster (7). Attach a vise onto hoisting Attach a weight onto part (b) of the special tool
position (a) of front idler (1). Hoist the track adjuster (ST 1650). Set the track adjuster (7) assembly
(7) assembly. horizontally.
6. Install the track adjuster (7) assembly to the track 10. Install the track adjuster (7) assembly to the track
frame until it reaches where nylon slings can be frame.
removed.
7. Remove nylon slings.

dCAUTION:
(120 lb)
Special tool (ST 1650) weight: 53 kg

8. Install the special tool (ST 1650) to the yoke (2) part
of front idler (1).

W4-4-1-4
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Disassembly of Front Idler

WDCD-04-04-006

00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used)
01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used)

W4-4-2-1
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Disassembly of Front Idler

IMPORTANT: Handle floating seals with care. (Refer
dCAUTION:
kg (245 lb)
The idler (03A) assembly weight: 110
to W4-4-4.)
1. Place the idler (03A) assembly horizontally. Remove 4. Remove bearing (00) from the upper side of idler
plug (06) on the lower side. Drain off engine oil from (03A). Remove floating seals (05) (2 used) from idler
the idler (03A) assembly. (03A) and bearing (00).

l : 6 mm

fNOTE: Oil amount: 0.27 L (0.29 US qt)

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent 00
personal injury. 05
2. Remove pin (04) from bearing (00) on the upper
side by using a round bar and a hammer.
03A
fNOTE: Diameter of round bar: 16 mm

dCAUTION:
(56 lb)
The axle (01) assembly weight: 25 kg 05

3. Put the matching marks on bearing (00) and axle 02

(01). Remove the axle (01) assembly from the idler
(03A) assembly by using a press.
01
00

00 01

W105-03-05-009

03A

W105-03-05-008

W4-4-2-2
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

dCAUTION:
(56 lb)
The axle (01) assembly weight: 25 kg dCAUTION: Idler (03A) weight: 70 kg (155 lb)
IMPORTANT: Do not remove bushing (03B) unless
IMPORTANT: Place wooden blocks under bearing necessary.
(00) in order not to damage bearing (00). 9. When replacing bushing (03B), remove it by the
5. Attach nylon slings onto the axle (01) assembly. special tool (ST 1425) and a press.
Hoist the axle (01) assembly. Place the bearing (00)
part of the axle (01) assembly onto wooden blocks.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
6. Remove pin (04) by using a bar and a hammer.
03A ST 1425
fNOTE: Diameter of round bar: 16 mm
7. Put the matching marks on bearing (00) and axle
(01). Remove axle (01) from bearing (00) by using a
press.
8. Remove O-rings (02) (2 used) from axle (01).
03B

W105-03-05-011
04 02

00
a

01

02

W105-03-05-010

a- Wooden Block

W4-4-2-3
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Assembly of Front Idler

03A

03B 04 00
06

01 05 02

WDCD-04-04-005

00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used)
01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used)

W4-4-2-4
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Assembly of Front Idler

dCAUTION: Idler (03A) weight: 70 kg (155 lb)
1. Install bushings (03B) (2 used) to idler (03A).
2. Place axle (01) vertically. Install O-ring (02) to the
upper side of axle (01).
3. Fit the matching marks on axle (01) and bearing
(00). Evenly tap and install bearing (00) to axle (01)
by using a plastic hammer.
d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
4. Install pin (04) by using a bar and a hammer.
IMPORTANT: Handle floating seal (05) with care.
(Refer to W4-4-4.)
5. Apply engine oil onto the O-ring of floating seal
(05). Install floating seal (05) to idler (03A) and
bearing (00).
dCAUTION:
(56 lb)
The axle (01) assembly weight: 25 kg
6. Attach nylon slings onto bearing (00) of the axle (01)
assembly. Hoist the axle (01) assembly. Install the
axle (01) assembly to idler (03A) on the side where
floating seal (05) has already been installed.
05 00

04
01

00
01

03A
W157-03-05-006
02

W105-03-05-014 7. Apply THREEBOND #2353 onto plug (06). Install

plug (06) to bearing (00).

l : 6 mm

m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

W4-4-2-5
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

dCAUTION:
kg (210 lb)
The idler (03A) assembly weight: 95
8. Attach nylon slings onto the idler (03A) assembly.
Hoist the idler (03A) assembly. Turn over the idler
(03A) assembly.
9. Install O-ring (02) to axle (01).
IMPORTANT: Handle floating seal (05) with care.
(Refer to W4-4-4.)
10. Apply engine oil onto the O-ring of floating seal
(05). Install floating seal (05) to idler (03A) and
bearing (00).
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
12. Install pin (04) by using a bar and a hammer.
13. Add engine oil (API CD class, SAE #30) through the
plug (06) hole of bearing (00).
fNOTE: Oil amount: 0.27 L (0.29 US qt)
14. Apply THREEBOND #2353 onto plug (06). Install
plug (06) to bearing (00).
l : 6 mm

00 05 02 03A m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

00

01

W157-03-05-005

11. Fit the matching marks on axle (01) and bearing

(00). Evenly tap and install bearing (00) to axle (01)
by using a plastic hammer.

W4-4-2-6
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Disassembly of Track Adjuster

WDCD-04-04-007

00A- Cylinder 03- Yoke 08- Bracket 15- Valve

00B- Rod 04- Seal 09- Bolt 16- Bracket
01- Spacer 05- Dust Seal 10- Washer
02- Spring 07- Nut 14- Piston Rod

W4-4-3-1
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Disassembly of Track Adjuster

dCAUTION:
(71 lb)
Special tool (ST 4052) weight: 32 kg

dCAUTION: The spring force is extremely large.

Carry out the disassembly and assembly work
5. Remove nuts (d) (4 used) from the special tool (ST
4950). Attach nylon slings onto the eyebolts (2
carefully. In addition, inspect the special tool for used) of the special tool (ST 4052). Hoist the special
any damage thoroughly in order to perform the tool (ST4052). Remove the special tool (ST 4052).
work safely.
1. Remove bolt (09) and washer (10) from bracket (16). j : 46 mm

j : 17 mm
2. Remove valve (15) and bracket (16) from piston rod
(14).

j : 24 mm
ST 4052
3. Remove piston rod (14) from cylinder (00A).

dCAUTION: Check the surfaces of the special tool

(ST 4953). Check the direction to install.
4. Place an oil jack (30 tons) between holder (a) and
base (b) of the special tool (ST 4950).

d
WDCD-04-04-010

dCAUTION:
kg (265 lb)
The spring (02) assembly weight: 120

ST 4953 6. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and

a nuts (2 used) to the bolt holes (2 places) of yoke (03)
diagonally. Attach nylon slings onto the eyebolts.
Hoist the spring (02) assembly.
c
7. Place the spring (02) assembly on holder (a) of the
special tool (ST 4950).

b
WDCD-04-04-009

a- Holder c- Oil Jack

b- Base d- Nut

W4-4-3-2
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

8. Install the special tool (ST 4052) in order to cover
the spring (02) assembly. Install washers (J222016)
(4 used) and bolts (J921650) (4 used) to the bolt
holes (4 places) of yoke (03). Secure the special tool
(ST 4052) and the spring (02) assembly with them.
j : 24 mm
11. Remove nut (07) from rod (00B).
j : 75 mm
12. Lower the oil jack slowly.
13. Remove nuts (a) (4 used) of the special tool (ST
4950).

j : 46 mm

a
J921650,
J222016
dCAUTION:
(71 lb)
Special tool (ST 4052) weight: 32 kg

14. Attach nylon slings onto the eyebolts (2 used) of

the special tool (ST 4052). Hoist and hold the special
tool (ST4052). Remove bolts (J921650) (4 used) and
washers (J222016) (4 used). Remove the special tool
(ST4052).

ST 4052

WDCD-04-04-013
a- Nut

dCAUTION: As spring (02) is compressed, a strong

force is applied. Check if the spring (02) assembly
is installed correctly with compressing spring (02)
by using the oil jack.
9. Tighten nuts (a) (4 used) of the special tool (ST 4950)
and secure the spring (02) assembly. Operate the oil WDCD-04-04-012
jack. Compress spring (02) to the position where nut
(07) is loose.

fNOTE: Spring (02) compressed length:

Spring free length (560 mm (22 in)) - Spring set length
(460 mm (18.1 in)) = Spring compressed length (100 mm
(3.94 in))
10. Remove bolt (09) and washer (10) from bracket (08).
Remove bracket (08) from nut (07).

j : 17 mm

W4-4-3-3
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

dCAUTION: Yoke (03) weight: 21 kg (47 lb)

15. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and
nuts (2 used) to the bolt holes (2 places) of yoke (03)
diagonally. Attach nylon slings onto the eyebolts.
Hoist yoke (03).
16. Remove yoke (03) from the spring (02) assembly.

dCAUTION:
kg (205 lb)
The spring (02) assembly weight: 91

17. Install eyebolts (M10, Pitch 1.5 mm) to rod (00B).

Attach nylon slings onto the eyebolts. Hoist the
spring (02) assembly.
18. Remove the spring (02) assembly from the special
tool (ST 4950).

dCAUTION: Spring (02) weight: 61 kg (135 lb)

19. Remove spring (02) from the rod (00B) assembly.
20. Remove spacer (01) from rod (00B).
IMPORTANT: Rod (06) has been installed in cylinder
(00A).
21. Remove rod (06) from cylinder (00A).
IMPORTANT: Do not damage seal (04) and dust seal
(05).
22. Remove seal (04) and dust seal (05) from cylinder
(00A).

W4-4-3-4
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Assembly of Track Adjuster

08 07 02 00B 00A 04 05 14

WDCD-04-04-008
09 10 03 01

Detail A

15

WDCD-04-04-011
09 10 16

00A- Cylinder 03- Yoke 08- Bracket 15- Valve

00B- Rod 04- Seal 09- Bolt 16- Bracket
01- Spacer 05- Dust Seal 10- Washer
02- Spring 07- Nut 14- Piston Rod

W4-4-3-5
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster
Assembly of Track Adjuster
dCAUTION: Cylinder (00A) weight: 20 kg (45 lb)
dCAUTION:
29 kg (64 lb)
The cylinder (00A) assembly weight:
1. Install rod (00B) to cylinder (00A).
2. Apply grease onto seal (04) and dust seal (05). Install
seal (04) and dust seal (05) to cylinder (00A).
3. Install spacer (01) to rod (00B).
dCAUTION: Spring (02) weight: 61 kg (135 lb)
4. Install spring (02) to rod (00B).
dCAUTION:
kg (210 lb)
The spring (02) assembly weight: 93
5. Install eyebolts (M10, Pitch 1.5 mm) to the bolt (09)
holes of rod (00B). Attach nylon slings onto the
eyebolts. Hoist the spring (02) assembly. Place the
spring (02) assembly on the special tool (ST 4950).
W4-4-3-6
6. Remove the eyebolts from rod (00B).
dCAUTION: Yoke (03) weight: 21 kg (47 lb)
7. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and
nuts (2 used) to the bolt holes (2 places) of yoke (03)
diagonally. Attach nylon slings onto the eyebolts.
Hoist the yoke (03).
8. Place yoke (03) on spring (02). Remove eyebolts (2
used) and nuts (2 used) from yoke (03). Install the
special tool (ST4052). Install bolts (J921650) (4 used)
and washers (J222016) (4 used) to the bolt holes
(4 places) of yoke (03). Secure the special tool (ST
4052) and yoke (03) with them.
j : 24 mm
a
J921650,
J222016
WDCD-04-04-013
a- Nut
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

9. Tighten nuts (a) (4 used) of the special tool (ST 4950) 12. Install bracket (08) to nut (07) with washer (10) and
and secure the spring (02) assembly. bolt (09).

j : 46 mm j : 17 mm

m : 60 N·m (6 kgf·m, 44 lbf·ft)

a 13. Lower the oil jack.
14. Remove nuts (a) (4 used) of the special tool (ST
4950).

dCAUTION:
(71 lb)
Special tool (ST 4052) weight: 32 kg

15. Attach nylon slings onto the eyebolts (2 used) of

the special tool (ST 4052). Hoist and hold the special
tool (ST4052). Remove bolts (J921650) (4 used) and
washers (J222016) (4 used). Remove the special tool
(ST4052).
WDCD-04-04-013
dCAUTION:
kg (265 lb)
The spring (02) assembly weight: 120
a- Nut
16. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and
nuts (2 used) to the bolt holes (2 places) of yoke (03)
10. Operate the oil jack. Compress spring (02) to the diagonally. Attach nylon slings onto the eyebolts.
specified length. Hoist the spring (02) assembly.

fNOTE: Specified spring length: 460 mm (18.1 in) 17. Remove the spring (02) assembly from the special
tool (ST 4950).
11. Install nut (07) to rod (00B).

j : 75 mm

W4-4-3-7
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

18. Fill part A of cylinder (00A) with grease.

A 00A

WDCD-04-04-014

19. Install piston rod (14) to cylinder (00A).

20. Bleed air from part A of cylinder (00A) and cylinder
(00A).
21. Install bracket (16) and valve (15) to piston rod (14).

j : 24 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

22. Install washer (10) and bolt (09) to bracket (16).

j : 17 mm

m : 60 N·m (6 kgf·m, 44 lbf·ft)

W4-4-3-8
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Precautions for Using Floating Seal 1

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 W178-02-11-001
surface (e) of seal ring (1). 2
 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 a
cleaning solvent.
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2) W178-02-11-002
is not twisted, and that it is installed correctly on seal
a - Correct c - Twist of O-Ring
ring (1).
b - Incorrect d - Bend of O-Ring
 After installing the floating seal, check that O-ring
(2) and seal ring sliding surface (e) is parallel with
f
seal mating surface (f ) by measuring the distances
(e) and (f ) at point (A) and (B), as illustrated. If these a b
A A
distances differ, correct O-ring (2) seating.

B B

A=B A≠B

W178-02-11-003

a - Correct e - Sliding Surface

b - Incorrect f - Seal Mating Surface

W4-4-4-1
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

(Blank)

W4-4-4-2
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

Removal and Installation of Upper Roller

1 2

W105-03-06-001 TDAA-03-08-002

dCAUTION: The pressure inside the track adjuster

cylinder is high. Do not loosen valve (1) quickly or
too much as valve (1) may fly out or high-pressure
grease in the adjuster cylinder may gush out.
Keep body parts and face away from valve (1) and
loosen valve (1) carefully. Do not loosen grease
fitting (2).
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
IMPORTANT: Loosening valve (1) by 1 to 1.5 turns is
enough. Do not loosen valve (1) over those turns.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Loosen valve (1) in the track adjuster. Drain grease
from the cylinder.

j : 24 mm

W4-5-1-1
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

6
b a 5
4

W1V7-03-06-001

3 c 4
4
W105-03-06-003

a- Oil Jack
b- Nonskid Cloth
c- Wooden Block

3
W105-03-06-005

dCAUTION: Use nonskid cloth (b) between track

frame (3) and oil jack (a) in order not to slip.
3. Raise the track in order to get clearance between
upper roller (4) and track (5).
4. Place wooden block (c) between track (5) and track
frame (3).
5. Loosen bolts (6) (4 used) of upper roller (4). Remove
upper roller (4).

j : 24 mm

W4-5-1-2
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

b a 5

W1V7-03-06-001
3 c 4

W105-03-06-003

a- Oil Jack
b- Nonskid Cloth
c- Wooden Block
1 2
a

WXXX-03-07-001

a - Track sag specification

TDAA-03-08-002

Installation
1. Install upper roller (4) with bolts (6) (4 used). 5. Apply grease through grease fitting (2) and adjust
the track tension.
j : 24 mm

m : 270 N·m (27 kgf·m, 200 lbf·ft)

fNOTE: Track sag specification (a): 300 to 335 mm (11.8
to 13.2 in)
2. Remove wooden block (c), oil jack (a), and nonskid
cloth (b) between track (5) and track frame (3).
3. Tighten valve (1) in the track adjuster.

j : 24 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

dCAUTION: Securely support the raised machine

by using blocks.
4. Raise the track to be adjusted. Rotate the track in
the reverse direction a little.

W4-5-1-3
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

W158-03-06-001

6. Lower the track.

IMPORTANT: Upper roller (4) cannot be
disassembled. Replace it as an assembly.
7. Add engine oil (API CD class, SAE #30) through the
plug (8) hole of cover (7).

fNOTE: Amount of oil: 65 mL (0.069 US qt)

8. Apply THREEBOND #2353 onto plug (8).
9. Tighten plug (8).

l : 6 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W4-5-1-4
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

Removal and Installation of Lower Roller

3, 4, 5 2 3, 4, 5

90 ˚ to 110 ˚

1 a WDAA-04-05-001 b M104-07-067

a - Wooden Block b - Stand

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Put the matching marks on track guard (1) and track
frame (2).

dCAUTION: When removing bolt (3) without

holding track guard (1), track guard (1) will come
off.
3. Place wooden blocks (a) under track guard (1).
4. Remove bolts (3) (4 used), spring washers (4) (4
used), and washers (5) (4 used).

j : 27 mm
5. Swing the upperstructure by 90° and set the angle
between boom and arm to 90° to 110°. Lower
the boom with the round bottom of the bucket
contacting with the ground. Raise the track frame.
At this time, place stand (b) under the track frame
and support the machine.

W4-5-2-1
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

1 2

TDAA-03-08-002

W105-03-06-001

WDCN-04-05-001
3

dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (1) may fly out
and the high-pressure grease may spout out, do
not loosen valve (1) quickly and/or excessively.
Keep body parts and face away from valve (1) and
loosen it carefully. 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
sprockets and track links, remove them before
loosening.
6. Loosen valve (1) in the track adjuster. Drain grease
and loosen the track tension until the clearance in
the track is enough to remove track guard (3).

j : 24 mm

dCAUTION: Track guard (3) weight: 22 kg (49 lb)

7. Remove track guard (3) by using a forklift.

W4-5-2-2
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

1 2

WDCN-04-05-002
3 a

a - Wooden Block

8. Put the matching marks on lower roller (1) and track

frame (2). dCAUTION: Lower roller (1) weight: 35 kg (78 lb)
11. Remove lower roller (1) by using a forklift.
dCAUTION: When removing bolt (3) without
holding lower roller (1), lower roller (1) will come
off.
9. Place wooden blocks (a) under lower roller (1).
10. Remove bolts (3) (4 used).

j : 27 mm

W4-5-2-3
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

1 2
1

WDCN-04-05-002
WDCN-04-05-003 3 a
4
a - Wooden Block

Installation

dCAUTION: Lower roller (1) weight: 35 kg (78 lb)

1. Set lower roller (1) on track link (4) by using a
forklift.
2. Raise lower roller (1) in order to adjust its mounting
position by using a forklift and place wooden blocks
(a) under it.
3. Fit the bolt (3) holes and the matching marks of
track frame (2) and lower roller (1). Install lower
roller (1) with bolts (3) (4 used).

j : 27 mm

m : 460 N·m (46 kgf·m, 340 lbf·ft)

W4-5-2-4
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

3, 4, 5 6 3, 4, 5

1 2
WDCN-04-05-001 WDAA-04-05-003

dCAUTION: Track guard (1) weight: 22 kg (49 lb)

4. Set track guard (1) on track link (2) by using a
forklift.

dCAUTION: Securely support the raised machine

by using the blocks.
5. Lower the machine in order to adjust the track
guard (1) mounting position.
6. Fit the bolt (3) holes and the matching marks of
track frame (6) and track guard (1) by using a bar.
Install track guard (1) with washers (5) (4 used),
spring washers (4) (4 used), and bolts (3) (4 used).

j : 27 mm

m : 500 N·m (50 kgf·m, 370 lbf·ft)

W4-5-2-5
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

1 2

TDAA-03-08-002 Wxxx-03-07-001

a - Track Sag Specification

7. Tighten valve (1) in the track adjuster.

j : 24 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

dCAUTION: Securely support the raised machine

by using the blocks.
8. Raise the track to be adjusted. Rotate the track in
the reverse direction a little.
9. Apply grease through grease fitting (2) and adjust
the track tension.

fNOTE: Track sag specification (a): 300 to 335 mm (11.8

to 13.2 in)

W4-5-2-6
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

Disassembly of Lower Roller

3
9
4
5

7
6
5
4
3
2
1

W157-03-06-010

1- Plug 4- O-Ring (2 Used) 7- Roller

2- Collar 5- Floating Seal (2 Used) 8- Axle
3- Pin (2 Used) 6- Bushing (2 Used) 9- Collar

W4-5-3-1
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

Disassembly of Lower Roller
dCAUTION: Lower roller weight: 35 kg (78 lb)
1. Remove plug (1) from the end of collar (2). Drain oil
from roller (7).
4. Remove pin (3) from the axle (8) assembly. Remove
axle (8) from collar (2) by using a press.
4 3 9

l : 6 mm

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc. in order to prevent 8
personal injury.
2. Put the matching marks on collar (2) and axle (8).
Remove pin (3) from collar (2) by using a round bar
and a hammer. Remove axle (8) from the side of
roller (7), where pin (3) has been removed, by using
a press. At this time, pin (3) and collar (9) on the
W178-02-11-268
opposite side are removed with axle (8) together.

fNOTE: Diameter of round bar: 14 mm (0.55 in) 5. Remove O-rings (4) (2 used) from axle (8).

dCAUTION: Roller (7) weight: 21 kg (47 lb)

2 5 7 5 IMPORTANT: Do not remove bushing (6) unless
necessary.
6. Remove bushing (6) by using the special tool (ST
1955) and a press.

5
9

ST 1955

8
W105-03-06-026

IMPORTANT: Handle floating seal (5) with care. 6

(Refer to W4-5-4.)
7
3. Remove floating seals (5) (2 used) from both sides of
roller (7) and collars (2, 9).

W178-02-11-269

W4-5-3-2
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

Assembly of Lower Roller

2 7 6 5 4 3 1

8 9

W105-03-06-023

1- Plug 4- O-Ring (2 Used) 7- Roller

2- Collar 5- Floating Seal (2 Used) 8- Axle
3- Pin (2 Used) 6- Bushing (2 Used) 9- Collar

W4-5-3-3
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Rollers

Assembly of Lower Roller

IMPORTANT: Do not dent the flange surface of 5. Install the axle (8) assembly to roller (7).
bushing (6).
6. Apply grease onto O-ring (4) at the other side. Install
1. Install bushings (6) (2 used) to roller (7) by using a O-ring (4) to the roller (7) assembly.
press.
IMPORTANT: Handle floating seal (5) with care.
2. Apply grease onto O-ring (4) at one side. Install (Refer to W4-5-4.)
O-ring (4) to axle (8).
7. Install floating seal (5) to roller (7) and collar (9).
IMPORTANT: Do not damage O-ring (4).
IMPORTANT: Do not damage O-ring (4).
3. Fit the pin (3) hole and install collar (2) of axle (8)
8. Fit the pin (3) hole and install collar (9) to axle (8)
with pin (3).
with pin (3).
9. Apply THREEBOND #2353 onto plug (1). Add engine
8 3 oil (API CD class, SAE #30) through the plug (1) hole
of collar (2). Tighten plug (1).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

fNOTE: Amount of oil: 0.26 L (0.27 US qt)

2
W105-03-06-031

IMPORTANT: Handle floating seal (5) with care.

(Refer to W4-5-4.)
4. Install floating seal (5) to roller (7) and collar (2).

7 5

5 2

W157-03-06-008

W4-5-3-4
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Roller

Precautions for Using Floating Seal 1

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 W178-02-11-001
surface (e) of seal ring (1). 2
 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 a
cleaning solvent.
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2) W178-02-11-002
is not twisted, and that it is installed correctly on seal
a - Correct c - Twist of O-Ring
ring (1).
b - Incorrect d - Bend of O-Ring
 After installing the floating seal, check that O-ring
(2) and seal ring sliding surface (e) is parallel with
f
seal mating surface (f ) by measuring the distances
(e) and (f ) at point (A) and (B), as illustrated. If these a b
A A
distances differ, correct O-ring (2) seating.

B B

A=B A≠B

W178-02-11-003

a - Correct e - Sliding Surface

b - Incorrect f - Seal Mating Surface

W4-5-4-1
 SECTION 4 UNDERCARRIAGE
Group 5 Upper and Lower Roller

(Blank)

W4-5-4-2
 SECTION 4 UNDERCARRIAGE
Group 6 Track

Removal and Installation of Track

3
4 5
2

a
W105-03-07-006 WDCD-04-06-001

a - Wooden Block

Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)
2. Rotate the track so that master pin (1) is positioned
over front idler (2). Place wooden block (a) under
shoe (3) and support shoe (3).

dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (4) may fly out
and the high-pressure grease may spout out, do
not loosen valve (4) quickly and/or excessively.
Keep body parts and face away from valve (4) and
loosen valve (4) carefully. Do not loosen grease
fitting (5).
IMPORTANT: Loosening valve (4) 1 to 1.5 turns is
enough. Do not loosen valve (4) over those turns.
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
3. Loosen valve (4). Drain grease and loosen the track.

j : 24 mm

W4-6-1-1
 SECTION 4 UNDERCARRIAGE
Group 6 Track

7
6
1 1 7
a - Direction to Remove
W105-03-07-010

6
ST 1970

W105-03-07-009

W1V1-03-07-001

4. Remove snap ring (6) from master pin (1).

fNOTE: If snap ring (6) interferes with master link (7),

dCAUTION: The track adjuster may fly out due
to the spring force when removing the track. Do
push master pin (1) to the installing direction in order to not stand in the same direction to remove the
make clearance between snap ring (6) and master pin track adjuster or where it may fly out. Particularly,
(1). Then, remove master pin (1). strong force is always applied to the thread
part of the rod. If the rod and/or the threads are
damaged, metal fragments may fly out due to the
spring force .

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Master pin (1) can be removed to only
one direction. Check direction (a) to remove
master pin (1).
5. Remove master pin (1) by using the special tool (ST
1970) and a hammer.

W4-6-1-2
 SECTION 4 UNDERCARRIAGE
Group 6 Track

90˚~110˚

a
a - Stand

M104-07-067 W105-03-07-011

6. Set the angle between boom and arm to 90˚ to

110˚. Lower the boom with the round bottom of the
bucket contacting with the ground. Raise the track
frame and pull out the track. Place stand (a) under
the track frame and support the machine at this
time.

dCAUTION: The track assembly weight:

ZX200-5G: 1260 kg (2780 lb)
ZX210H-5G, 210K-5G: 1330 kg (2940 lb)
ZX200LC-5G: 1350 kg (2980 lb)
ZX210LCH-5G, 210LCK-5G: 1420 kg (3140 lb)
7. Slowly operate a travel control lever on the side to
be removed the track to the reverse position and
extend the track.

W4-6-1-3
 SECTION 4 UNDERCARRIAGE
Group 6 Track

a b

W105-03-07-014

W105-03-07-013

a - Front Idler Side

b - Sprocket (8) Side

W105-03-07-015

Installation
1. Raise the machine. Set the track under the machine 3. Slowly operate a travel control lever on the side to
so that sprocket (8) meshes with the track end. install the track in the forward direction with the
Check the direction of the track at this time. machine raised off the ground. Wind the track while
rotating travel device (9).
dCAUTION: The track assembly weight:
ZX200-5G: 1260 kg (2780 lb)
ZX210H-5G, 210K-5G: 1330 kg (2940 lb)
ZX200LC-5G: 1350 kg (2980 lb)
ZX210LCH-5G, 210LCK-5G: 1420 kg (3140 lb)
2. Hoist and mesh the track with the claws of sprocket
(8).

W4-6-1-4
 SECTION 4 UNDERCARRIAGE
Group 6 Track

6
1 7
b - Direction to Install
W105-03-07-010

7
3

a
6
W105-03-07-016

a - Wooden Block

W105-03-07-009

4. Wind the track link until the connection part of the

track link reaches the front idler (2) side. Lower the
machine. Place wooden block (a) under shoe (3) and
support shoe (3).
IMPORTANT: Master pin (1) can be installed to only
one direction. Check direction (b) to install master
pin (1).
5. Install master pin (1) to the track.
IMPORTANT: Replace snap ring (6) with the new one.
6. Install snap ring (6). Snap ring (6) has the direction
to install. Install snap ring (6) to the groove of
master link (7) with the flat surface of a pair of pliers
hole facing the near side.

W4-6-1-5
 SECTION 4 UNDERCARRIAGE
Group 6 Track

4 5

11

13
12

10

WDCD-04-06-001

c b c

W197-03-07-001
13
b - Apply grease.
c - Do not apply grease.

WXXX-03-07-001

a - Track Sag Specification

IMPORTANT: If link (10) has been disassembled, fill
grease (Daphne Epones SR) into the clearance
between bushing (11) and pin (12).
IMPORTANT: If link (10) has been disassembled,
perform step 7 to step 11.
IMPORTANT: Check the direction to install seal (13).
7. Install seal (13) to link (10).
8. Apply grease onto the bushing (11) end. Fit the pin
(12) holes on link (10) and bushing (11). Stand them
on a flat plate.
d CAUTION: Take care not to come off link (10).
9. Fill the bushing (11) inside with grease.
10. Install pin (12) to link (10) and bushing (11) while
holding them in order not to move due to grease.
11. Wipe off excess grease after installing pin (12).
12. Tighten valve (4). Apply grease through grease
fitting (5) and adjust the track tension.
j : 24 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
fNOTE: Track sag specification (a): 300 to 335 mm (11.8
to 13.2 in)

W4-6-1-6
MEMO
MEMO
SECTION 5

FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Removal and Installation of Front Attachment....W5-1-1-1
Group 2 Cylinder
Removal and Installation of Boom Cylinder..........W5-2-1-1
Removal and Installation of Arm Cylinder.............W5-2-2-1
Removal and Installation of Bucket Cylinder........W5-2-3-1
Disassembly of Boom, Arm, Bucket Cylinder........W5-2-4-1
Assembly of Boom, Arm, Bucket Cylinder..............W5-2-4-5

DCDW-5-1
(Blank)

DCDW-5-2
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

Removal and Installation of Front

Attachment
Removal
1. Park the machine on a solid, level surface. Fully
retract the bucket and arm cylinders and lower the
arm top onto the ground.

dCAUTION: Bleed air from the hydraulic oil tank

before doing any work. (Refer to W1-4-1.)
2. Disconnect lubrication hose (1) from adapter (a)
connecting to the boss at the boom cylinder rod
side. (2 places on both left and right)

j : 17 mm
W105-04-02-001
dCAUTION:
lb)
Boom cylinder (b) weight: 170 kg (375

3. Hoist and hold boom cylinder (b). Remove nuts 1

(4) (2 used) and bolt (6) from pin (3) of the boom
cylinder rod end. Remove stopper (5). (2 places on
both left and right) a

j : 30 mm b

a- Adaptor
b- Boom Cylinder

W105-04-01-002

3 2

6
b

5
4
b- Boom Cylinder

W178-04-01-004

W5-1-1-1
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

3 2
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
6
4. By using a bar and hammer, tap pin (3) into the
b
position where thrust plate (2) can be removed.
Remove pin (3) and thrust plates (2) (2 used).

fNOTE: When pin (3) is impossible to remove, start the

engine and operate the boom control lever. Adjust the
cylinder rod pin hole of boom cylinder (b) while raising/ 5
lowering the front attachment.
4
5. Place the tube top of boom cylinder (b) on a stand
b- Boom Cylinder
of 1 m (39.4 in) height. Start the engine. Operate the
boom control lever and retract boom cylinder (b). W178-04-01-004
In order not to extend the rod, pass wire (a) through
the rod hole and secure the rod to the cylinder tube.
6. Stop the engine. Remove boom cylinder (b). (Refer
to W5-2-1.)
7. Remove other boom cylinder (b) in the same way as
step 5 to step 6. b

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.) a

a- Wire
b- Boom Cylinder

W178-02-11-274

c- Air Bleed Valve

W1V1-04-01-008

W5-1-1-2
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

8. Disconnect hoses (7, 8) of the bucket cylinder and

arm cylinder. Cap the open ends of the removed
pipes and hoses.

j : 36 mm, 41 mm
7 8
9. Remove the mounting bolts (9 used) for tool box (b)
and cover (a). Remove tool box (b) and cover (a).

j : 17 mm

W1V1-04-01-001

a
b
a- Cover
b- Tool Box

W1V1-04-01-002

W5-1-1-3
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

10. Remove bolt (14), washer (15), plate (13), and block 11
(12) from plate (a) of boom foot pin (11).

j : 27 mm

dCAUTION:
weight:
The front attachment assembly
a

ZX200-5G, 200LC-5G: 3,450 kg (7,610 lb) 12

ZX210H-5G, 210LCH-5G: 3,650 kg (8,050 lb) 13

ZX210K-5G, 210LCK-5G: 3,800 kg (8,380 lb) 14

15
11. Attach wire ropes onto the boom. Reduce slack of
the wire ropes. a- Plate
W178-02-11-280

12. Insert a pry bar between plate (a) of boom foot pin
(11) and bracket (c). Slightly pull out plate (a).

dCAUTION:
lb)
Boom foot pin (11) weight: 45 kg (100

13. Turn plate (a) upward by hand. Turn left and right
and pull out boom foot pin (11). (Adjust the position
by using the lifting ropes for the front attachment.) W178-02-11-281
14. Hoist front attachment assembly (d) and move the 11
machine backward.
15. Place wooden blocks. Place front attachment
assembly (d) onto the wooden blocks.

a b

a- Plate c- Bracket
b- Insert a Pry Bar

W178-02-11-280

d- Front Attachment Assembly

W178-02-11-282

W5-1-1-4
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

Installation a

dCAUTION: Front attachment assembly (a) weight:

ZX200-5G, 200LC-5G: 3,450 kg (7,610 lb)
ZX210H-5G, 210LCH-5G: 3,650 kg (8,050 lb)
ZX210K-5G, 210LCK-5G: 3,800 kg (8,380 lb)
1. Hoist front attachment assembly (a). Move the
machine forward and fit the boom foot with the
a- Front Attachment Assembly
mounting hole on the frame. Insert the thrust plate
into the left and right sides of boom and adjust the W178-02-11-282
clearance between plate and frame within 1 mm.
(0.039 in) (Adjust the position by using the lifting 11
ropes for the front attachment.)

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
2. Install boom foot pin (11) by using a hammer. Install 12
bolt (14), washer (15), plate (13), and block (12). 13
j : 27 mm 14
15
m : 400 N·m (40 kgf·m, 300 lbf·ft)
W178-02-11-280
3. Install tool box (c) and cover (b) with the bolts (9
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

b
c
b- Cover
c- Tool Box

W1V1-04-01-002

W5-1-1-5
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

4. Remove the caps from hoses and pipes. Connect

hoses (7, 8) of the bucket cylinder and arm cylinder.

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft) 7 8

j : 41 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

W1V1-04-01-001

dCAUTION:
lb)
Boom cylinder (a) weight: 170 kg (375

5. Hoist and install boom cylinder (a). (Refer to W5-2-

1.)

a
a- Boom Cylinder

W105-04-02-040

W5-1-1-6
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

3 2
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury. 6
6. Hoist and hold boom cylinder (a). Insert thrust a
plates (2). Install pin (3) by using a bar and hammer.
Install boom cylinders (a) on both sides.
7. Install stopper (5). Tighten bolt (6) and nuts (4) (2
used). (2 places on both left and right)
5
j : 30 mm
4
m : 170 N·m (17 kgf·m, 125 lbf·ft) a- Boom Cylinder
8. Connect hose (1) to boom cylinder rod side (b). (2
places on both left and right) W178-04-01-004

j : 17 mm
1
m : 30 N·m (3 kgf·m, 22 lbf·ft)

9. Apply grease onto rod side (b) and bottom side (d) b- Boom Cylinder Rod Side
of the boom cylinder, and boom foot side (c).
W105-04-01-002

b- Boom Cylinder Rod Side

c- Boom Foot Side

W1V1-04-01-001

WDCR-05-01-002
d
d- Boom Cylinder Bottom Side

W5-1-1-7
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

IMPORTANT: When removing the arm from the 16

boom, perform the following steps when
installing the arm.
10. Install thrust plates (14) into left and right sides
of the arm. Adjust total clearance of left and right
within 1.5 mm (0.059 in).
14 14
11. Install the arm cylinder rod side to the arm. Apply
grease onto grease fittings (15, 16) on the boom
connecting boss of arm and the arm cylinder rod
side.

IMPORTANT: For handling of HN bushing for the 15 15

front attachment, check the followings.
Precautions when installing the bushing
If a hammer is used, the bushing may be damaged. Use a
press.

Precautions when reinforcing the arm

The heat when welding in order to reinforce the arm may W178-02-11-285
cause oil leakage and decrease lubrication performance.
When lubrication oil leaks, replace the bushing.

Use special tool when removing or installing the bushing.

Special tool: ST 1454

W5-1-1-8
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Boom Cylinder

1
Removal
1. Disconnect hose (1) from boom cylinder (2).

j : 17 mm

dCAUTION:
lb)
Boom cylinder (2) weight: 170 kg (375

2. Attach nylon slings onto boom cylinder (2). Hoist

2
and hold boom cylinder (2).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection, W105-04-02-032
such as goggles, helmets, etc in order to prevent
personal injury.
3. Remove nuts (5) (2 used), bolt (7) and stopper (6)
from the boom cylinder (2) rod side. Push pin (4)
into the boom by using a bar and hammer. Remove 7
thrust plates (3).

j : 30 mm

6
5 3 4 3 2

4. Place boom cylinder (2) on a stand. Remove the W158-04-02-013

other boom cylinder in the same way.
5. Operate the boom control lever and retract boom
cylinder (2). In order not to extend the rod, pass a
wire through the rod hole and secure the rod to the
cylinder tube.

2
W105-04-02-035

W5-2-1-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

6. Stop the engine.

2 8
dCAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.)
11

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
7. Disconnect hoses (12) (4 used) from the bottom of
boom cylinder (2). Cap the open ends. 9
j : 36 mm, 41 mm
9 10
d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, 10
12
such as goggles, helmets, etc in order to prevent
personal injury. W178-04-02-009

8. Remove nuts (10) (2 used) and bolt (8) from the

cylinder bottom side. Remove pin (9) by using a bar
and hammer. Remove thrust plates (11).

j : 24 mm

dCAUTION:
lb)
Boom cylinder (2) weight: 170 kg (375

9. Hoist and remove boom cylinder (2).

10. Remove the other boom cylinder in the same way.

2
W105-04-02-040

W5-2-1-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation
IMPORTANT: If a hammer is used to install the
bushing, the bushing may be damaged. Install the
bushing by using a press.

dCAUTION:
lb)
Boom cylinder (2) weight: 170 kg (375

1. Hoist boom cylinder (2). Fit the hole at boom

cylinder tube side to the mounting hole on the
main frame.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury. 2
2. Fit thrust plate (11) and pin (9) with the mounting W105-04-02-040
hole on the main flame. Install pin (9) by using a
hammer. Install bolt (8) to pin (9) with nuts (10) (2
used).

j : 24 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

11 2 8
3. Install the other boom cylinder in the same way.
4. Connect hoses (12) (4 used) to boom cylinders (2) (2
used).

j : 36 mm
9
m : 180 N·m (18 kgf·m, 133 lbf·ft)

j : 41 mm 9 10
m : 210 N·m (21 kgf·m, 155 lbf·ft) 10
12

W178-04-02-009

W5-2-1-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

IMPORTANT: Check the hydraulic oil level. Start the

engine and check for any oil leaks.
5. Remove the wire from the boom cylinder (2) rod
side. Starts the engine. Operate the boom control
lever and fit the hole at cylinder rod side to the
mounting hole on boom.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
6. Fit thrust plates (3) and pin (4) with the mounting 7
hole on boom. Install pin (4) by using a bar and
hammer.
7. Install bolt (7) to pin (4) and stopper (6) with nuts (5)
(2 used).

j : 30 mm
6
m : 170 N·m (17 kgf·m, 125 lbf·ft) 5 3 4 3 2
8. Connect hose (1) to boom cylinder (2). W158-04-02-013

j : 17 mm
1
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
9. Install the other boom cylinder in the same way.
IMPORTANT: After completing the work, operate the
boom cylinder several times to the stroke end and
bleed air from the circuit.

W105-04-02-032

W5-2-1-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Arm Cylinder 1

Removal
1. Place wooden block (3) between arm cylinder (1)
and boom (2).
2
2. Remove nuts (8) (2 used) and bolt (10) from stopper
(9) and pin (5) at the rod side.
3
j : 30 mm

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
W187-04-02-005

such as goggles, helmets, etc in order to prevent

personal injury.
3. Remove pin (5) by using a bar and hammer. Remove 4
10 5
thrust plates (4).
1
4. Operate the arm lever and retract arm cylinder
(1). In order not to extend rod (6), pass a wire (7)
through the rod hole and secure rod (6) to the arm
cylinder (1) tube.
9
5. Stop the engine.

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
8
dCAUTION: Release any pressure in the hydraulic
circuit. (Refer to W1-5-1.)
W187-04-02-006

6 1

W187-04-02-010

W5-2-2-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

6. Disconnect hoses (11) (2 used) and hose (12) from 1

11
the bottom of arm cylinder (1). Cap the open ends.

j : 17 mm, 36 mm
12

W178-02-11-290
dCAUTION:
lb)
Arm cylinder (1) weight: 260 kg (575

7. Attach a nylon sling onto arm cylinder (1). Hoist and

hold arm cylinder (1). 1

W102-04-02-016

W5-2-2-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury. 17 13
8. Remove nuts (15) (2 used) and bolt (17) from 14
1
stopper (16) and pin (14) at the bottom side.

j : 30 mm
9. Remove pin (14) by using a bar and hammer.
Remove thrust plates (13). Hoist and remove arm
16
cylinder (1). 15

W187-04-02-007

W5-2-2-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation
IMPORTANT: If a hammer is used to install the
bushing, the bushing may be damaged. Install the 1
bushing by using a press.

dCAUTION: Arm cylinder weight: 260 kg (575 lb)

1. Hoist arm cylinder (1). Fit the hole at the cylinder
bottom side with the cylinder mounting hole on the
boom.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury. W102-04-02-016

2. Fit thrust plates (13) and pin (14) with the cylinder
mounting hole on the boom. Install pin (14) by
17 13
using a hammer.
1 14
3. Install bolt (17) to pin (14) and stopper (16) with
nuts (15) (2 used).

j : 30 mm

m : 170 N·m (17 kgf·m, 125 lbf·ft) 16

15

W187-04-02-007

W5-2-2-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

4. Connect hose (12) and hoses (11) (2 used) to arm 1

11
cylinder (1).

j : 17 mm
12
m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft)

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
5. Remove the wire from rod (6) of arm cylinder (1).
Hoist the arm cylinder (1). Start the engine. Operate
the arm lever and fit the hole at cylinder rod side W178-02-11-290
with the mounting hole on arm (18).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection, 6 1
such as goggles, helmets, etc in order to prevent
personal injury.
6. Fit thrust plate (4) and pin (5) with the mounting
hole on arm (18). Install pin (5) by using a hammer. 18

7. Install bolt (10) to pin (5) and stopper (9) with nuts
(8) (2 used). 7

j : 30 mm
W187-04-02-010
m : 170 N·m (17 kgf·m, 125 lbf·ft)
IMPORTANT: After completing the work, operate the 4
arm cylinder several times to the stroke end and 10 5
bleed air from the circuit. 9

18

W187-04-02-006

W5-2-2-5
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

(Blank)

W5-2-2-6
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Bucket Cylinder

Removal
1. Insert wooden blocks (3) (2 used) under the arm (2)
1
top and between arm (2) and bucket cylinder (1).

dCAUTION: Before removing pin (7), secure the

link by using a wire in order not to fall off.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
3
2
such as goggles, helmets, etc in order to prevent 3
personal injury.
2. Remove nuts (6) (2 used) and bolt (4). Remove pin W178-02-11-287
(7) with using a bar and hammer. Remove thrust
plates (5). 4 5
j : 30 mm

W158-04-02-006
3. Operate the bucket control lever and retract bucket
cylinder (1). In order not to extend rod (8), pass wire
(9) through the rod hole and secure rod (8) to the 8 1
bucket cylinder (1) tube.
4. Stop the engine.

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)

9 W102-04-02-005

W5-2-3-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

6. Disconnect bucket cylinder hoses (12) (2 used) from 10

the bottom of bucket cylinder (1). Cap the open
ends.

j : 36 mm
15

dCAUTION:
(355 lb)
Bucket cylinder (1) weight: 160 kg
11
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
13

such as goggles, helmets, etc in order to prevent

personal injury.

7. Hoist bucket cylinder (1). Remove nuts (13) (2 used) 1

and bolt (15). Remove pin (11) by using a bar and
hammer. Remove thrust plate (10).

j : 24 mm 12
W187-04-02-004
8. Hoist and remove bucket cylinder (1).

W5-2-3-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation
IMPORTANT: If a hammer is used to install the
bushing, the bushing may be damaged. Install the
bushing by using a press.

dCAUTION:
(355 lb)
Bucket cylinder (1) weight: 160 kg

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
10
such as goggles, helmets, etc in order to prevent
personal injury.
1. Hoist bucket cylinder (1). Fit the hole at the cylinder
bottom side with the cylinder mounting hole on 15
the arm. Fit thrust plate (10) and pin (11) with the
cylinder mounting hole on the arm. Install pin (11)
by using a hammer. 14 11
2. Install bolt (15) to stopper (14) of the arm and pin 13
(11) with nuts (13) (2 used).

j : 24 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft) 1

3. Connect hoses (12) (2 used) to bucket cylinder (1).

j : 36 mm
12
m : 180 N·m (18 kgf·m, 133 lbf·ft) W187-04-02-004

W5-2-3-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

4. Remove wire (9) from rod (8) of bucket cylinder (1).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
8 1

such as goggles, helmets, etc in order to prevent

personal injury.
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
5. Start the engine and operate the bucket control
lever. Fit the hole at cylinder rod side with the holes
of link A (16) and link B (18). Fit thrust plates (5) and
pin (7) with the holes of link A (16) and link B (18).
Install pin (7) by using a hammer. 9 W102-04-02-005

6. Install bolt (4) to stopper (17) and pin (7) with nuts
(6) (2 used).
16 4 17 5
j : 30 mm

m : 170 N·m (17 kgf·m, 125 lbf·ft)

IMPORTANT: In case link B (18) has been removed
from the arm, insert thrust plate (19) when
installing.
IMPORTANT: After completing the work, operate the
bucket cylinder several times to the stroke end
and and bleed air from the circuit. 7 18 6

W158-04-02-006

19 19

W178-02-11-289
18 18

W5-2-3-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Boom, Arm, Bucket Cylinder

Boom Cylinder

1 2 3 4 5 6 7 8 9 10 11

22 20 19 12
23

W1V1-04-02-007
26 25 17 18 24 19 21 18 17

Arm Cylinder

1 2 3 4 5 6 7 8 9 10 11

22 20 19 16 15 14 13 12
23

W1V1-04-02-008
26 25 17 18 24 19 21 18 17

W5-2-4-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Bucket Cylinder

1 2 3 4 5 6 7 8 9 10 11

22 19 18 12
23

W1V1-04-02-009
17 18 24 19 21 20 17

1- Cylinder Rod 9- Snap Ring 15- Cushion Seal (Only Arm 23- Steel Ball
2- Wiper Ring 10- Backup Ring Cylinder) 24- Piston Nut
3- Backup Ring 11- O-Ring 16- Snap Ring (Only Arm Cylinder) 25- Cushion Bearing (Only Boom,
4- U-Ring 12- Cylinder Tube 17- Slide Ring (2 Used) Arm Cylinders)
5- Buffer Ring 13- Stopper (2 Used) (Only Arm 18- Slide Ring (2 Used) 26- Cushion Seal (Only Boom, Arm
6- Socket Bolt (12 Used) (Bucket Cylinder) 19- Backup Ring (2 Used) Cylinders)
Cylinder: 10 Used) 14- Cushion Bearing (Only Arm 20- O-Ring
7- Cylinder Head Cylinder) 21- Seal Ring
8- Bushing 22- Set Screw

W5-2-4-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Boom, Arm, Bucket Cylinder

 The procedure starts on the premise that the
pipes and the bands securing the pipes have been
removed.
IMPORTANT: Pull out cylinder rod (1) straightly in
f NOTE: The arm cylinder is explained here.
dCAUTION: Boom cylinder weight: 175 kg (390 lb)
Arm cylinder weight: 260 kg (575 lb)
Bucket cylinder weight: 160 kg (355 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.
order not to damage the sliding surface.
3. Tap and remove cylinder head (7) with cylinder
rod (1) together from cylinder tube (12) by using a
plastic hammer.
4. Secure cylinder rod (1) on special tool (ST 5908). Put
the matching marks on cylinder rod (1) and the end
of piston nut (24) (arm cylinder: cushion bearing
(14)).

ST 5908

W102-04-02-027 W158-04-02-022

2. Fully extend and support cylinder rod (1). Remove

socket bolts (6) (12 used) (Bucket Cylinder: 10 used)
from cylinder head (7).

l : 14 mm

W5-2-4-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

5. Cut away the crimped part by using a hand drill.
Remove set screw (22). Remove steel ball (23).
fNOTE: Set screw (22) has been caulked by using a
punch at two places after installing.
l : 6 mm
6. Remove piston nut (24) by using special tool (ST
5908) and special tool for piston nut (24). Remove
cushion bearing (25) and cushion seal (26) from
cylinder rod (1). (Cushion bearing (25) and cushion
seal (26) are not equipped for the bucket cylinder.)
Special Tool for Piston Nut:
ST 3352: 95 mm (Boom Cylinder)
ST 3318: 110 mm (Arm Cylinder)
ST 3263: 90 mm (Bucket Cylinder)
ST 5908
7. Remove slide rings (17) (2 used), slide rings (18) (2
used), backup rings (19) (2 used), O-ring (20), and
seal ring (21) from piston nut (24).
8. Remove cylinder head (7) from cylinder rod (1).
9. Remove O-ring (11) and backup rings (10, 3) from
cylinder head (7). Remove wiper ring (2), U-ring (4),
buffer ring (5), snap ring (9), and bushing (8).
Special tool when removing bushing (rod outer
diameter):
ST 8020: 85 mm (Boom Cylinder)
ST 8021: 95 mm (Arm Cylinder)
ST 8019: 80 mm (Bucket Cylinder)
10. (Arm cylinder only)
Remove stoppers (13) (2 used) from cylinder rod (1)
by using a screwdriver. Remove cushion bearing
(14), cushion seal (15), and snap ring (16).

W158-04-02-022

W5-2-4-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Boom, Arm, Bucket Cylinder

Boom Cylinder
1 2 4 5 6 7 12 25 17 18 19 18 17 22

3 8 9 10, 11 26 24 20, 21 23 W1V1-04-02-005

Arm Cylinder
1 2 4 5 6 7 12 25 17 18 19 18 17 22 14

13

3 8 9 10, 11 26 24 20, 21 23 16 15
W1V1-04-02-003

W5-2-4-5
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Bucket Cylinder
1 2 4 5 6 7 12 17 18 19 18 17

22

3 8 9 10, 11 24 20, 21 23
W1V1-04-02-001

1- Cylinder Rod 9- Snap Ring 15- Cushion Seal (Only Arm 23- Steel Ball
2- Wiper Ring 10- Backup Ring Cylinder) 24- Piston Nut
3- Backup Ring 11- O-Ring 16- Snap Ring (Only Arm Cylinder) 25- Cushion Bearing (Only Boom,
4- U-Ring 12- Cylinder Tube 17- Slide Ring (2 Used) Arm Cylinders)
5- Buffer Ring 13- Stopper (2 Used) (Only Arm 18- Slide Ring (2 Used) 26- Cushion Seal (Only Boom, Arm
6- Socket Bolt (12 Used) (Bucket Cylinder) 19- Backup Ring (2 Used) Cylinders)
Cylinder: 10 Used) 14- Cushion Bearing (Only Arm 20- O-Ring
7- Cylinder Head Cylinder) 21- Seal Ring
8- Bushing 22- Set Screw

W5-2-4-6
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder
Assembly of Boom, Arm, Bucket Cylinder
fNOTE: The arm cylinder is explained here.
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
1. Install bushing (8) to cylinder head (7).
Special tool when installing bushing (rod outer
diameter):
ST 8020: 85 mm (Boom Cylinder)
ST 8021: 95 mm (Arm Cylinder)
ST 8019: 80 mm (Bucket Cylinder)
IMPORTANT: Check the direction to install.
2. Install U-ring (4), backup ring (3), buffer ring (5), and
snap ring (9) to cylinder head (7).
3. Install wiper ring (2) to cylinder head (7) by using a
plastic hammer.
Special tool when installing wiper ring (rod outer
diameter):
ST 8020: 85 mm (Boom Cylinder)
ST 8021: 95 mm (Arm Cylinder)
ST 8019: 80 mm (Bucket Cylinder)
4. Install O-ring (11) and backup ring (10) to cylinder
head (7).
W5-2-4-7
5. Install O-ring (20) and seal ring (21) to piston nut
(24) by using the special tool A. After installing seal
ring (21), adjust seal ring (21) by using the special
tool B.
Special tool A, Special tool B (tube inner diameter):
ST 2964, ST 2208: 120 mm (Boom Cylinder)
ST 2978, ST 2535: 135 mm (Arm Cylinder)
ST 2963, ST 2207: 115 mm (Bucket Cylinder)
6. Install backup rings (19) (2 used), slide rings (17) (2
used), and slide rings (18) (2 used) to piston nut (24).
7. Install the cylinder head (7) assembly to cylinder rod
(1).
Special tool when installing cylinder head (rod outer
diameter):
ST 8020: 85 mm (Boom Cylinder)
ST 8021: 95 mm (Arm Cylinder)
ST 8019: 80 mm (Bucket Cylinder)
IMPORTANT: Face the slit in cushion seal (15) to the
piston side. Check the direction of oil groove in
cushion bearing (14).
8. (Arm cylinder only)
Install snap ring (16) and cushion seal (15) to
cylinder rod (1). Install cushion bearing (14) and
stoppers (13) (2 used).
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

IMPORTANT: Face the slit in cushion seal (26) to the
piston side. Check the direction of oil groove in
cushion bearing (25).
9. Install cushion seal (26) and cushion bearing (25) to
cylinder rod (1). (Cushion bearing (25) and cushion
seal (26) are not equipped for the bucket cylinder
10. Fit the matching marks before disassembling and
tighten piston nut (24) by using special tool (ST
5908).
Special tool when turning piston nut:
ST 3352: 95 mm (Boom Cylinder)
m : 5340 N·m (534 kgf·m, 3940 lbf·ft)
ST 3318: 110 mm (Arm Cylinder)
11. Install steel ball (23) to cylinder rod (1) and tighten
with set screw (22). Crimp set screw (22) by using a
punch (2 places).
l : 6 mm
m : 58 N·m (5.8 kgf·m, 43 lbf·ft)
dCAUTION: Fit the cylinder rod (1) assembly with
the center of cylinder tube (12) and install in order
not to damage the rings.
12. Secure cylinder tube (12) on a workbench
horizontally. Insert the cylinder rod (1) assembly to
cylinder tube (12).
13. Install cylinder head (7) to cylinder tube (12) with
socket bolts (6) (12 used) (bucket cylinder: 10 used).

m : 7900 N·m (790 kgf·m, 5830 lbf·ft) l : 14 mm

ST 3263: 90 mm (Bucket Cylinder) Boom Cylinder, Bucket Cylinder

m : 5660 N·m (566 kgf·m, 4170 lbf·ft) m : 270 N·m (27 kgf·m, 200 lbf·ft)
Arm Cylinder

ST 5908 m : 370N·m (37 kgf·m, 275 lbf·ft)

W158-04-02-022

W5-2-4-8
MEMO
MEMO
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com

SERVICE MANUAL REVISION REQUEST FORM

COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:
FAX: (Located at the bottom center in the page. If two or more revisions
are requested, use the comment column)
E-mail:

YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)