Workshop Manual PDF

PART NO.
WACG90-EN-00
ZX20U-5B
HYDRAULIC EXCAVATOR
Workshop Manual
WORKSHOP MANUAL
ZX20U-5B
Hydraulic Excavator
URL:http://www.hitachi-c-m.com
WACG90-EN-00
Service Manual consists of the following separate Part No.

Technical Manual : Vol. No.TACG90-EN
Workshop Manual : Vol. No.WACG90-EN
PRINTED IN JAPAN (K) 2015, 09 Engine Manual : Vol. No.EACG-EN
INTRODUCTION
To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
The machine specification and description according to Form” at the end of this manual. (Note: Do not tear off
destination may be explained on this manual. the form. Copy it for usage.):
 Technical Information Center Hitachi Construction
 Be sure to thoroughly read this manual for correct Machinery Co., Ltd.
product information and service procedures.  TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: HCM-TIC-GES@hitachi-kenki.com
Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures.  Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / disassemble procedures.
Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group
IN-01
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 dCAUTION:
for personal injury of machine damage. Indicates potentially hazardous situation which could, if
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.
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate
fNOTE:
Indicates supplementary technical information or know-
lifting techniques and equipment when lifting heavy
how.
parts.
Units Used
SI Units (International System of Units) are used in this Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
manual. MKSA system units and English units are also
indicated in parentheses just behind SI units. 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).
OP, OPT Option Optional component.
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.
 CAUTION also calls attention to safety message in this

manual.
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.
 fNOTE: 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 operator's manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or operator's 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. SA-003
 Keep your machine in proper working condition.
 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.
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 such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
 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.
 Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.
SA-5
SAFETY
Use Handrails and Steps

 Falling is one of the major causes of personal injury.
 When you get on and off the machine, always use the
crawler instead of the step for safety. Also get on and off
from the position of the crawler that can secure your feet
space enough.
 When you get on and off the machine, always face the
machine.
 Maintain a three-point contact with the steps and
handrails.
 Do not use any controls as handholds.
 Never jump on or off the machine. Never mount or
dismount a moving machine.
SA-439
 In case adhered slippery material such as oil, grease,
or mud is present on steps, handrails, or platforms,
thoroughly remove such material.
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 SA-378
visibility is obtained from the operator’s seat. If the mirror
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, 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
 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-1291
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 for problems.
If there is, replace the problem part(s) or clean the mirror.
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-1292
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. Do not permit persons other than
the operator to enter areas where there is danger such as
flying objects. 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.
M586-12-012
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,
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 SA-1293
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
M586-05-021
enough to easily support the machine.
 Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent
machine tipping over from occurring. When operating on
rough terrain or on slopes:
 Reduce the engine speed.
 Select slow travel speed mode.
 Operate the machine slowly and be cautious with
machine movements.
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
Restriction of Attachment Installation

 Do not install an attachment which exceeds specified
weight for the machine structure.
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-1294
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, A
and/or metal pieces may scatter around the machine. Do
not allow personnel to stay around the machine while
traveling.
SA-1295
 Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
 Never attempt to ascend or descend 25 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 200 to 300 mm (8 to
12 in) (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
the direction must be changed, move the machine to SA-1296
level ground, then, change the direction to ensure safe
operation.
 Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
SA-441
SA-589
SA-14
SAFETY
 When the machine descends a slope at high speed,
machine weight accelerates descending speed. It may
cause collision accident due to misjudging of braking
distance or machine turnover due to running on an
unexpected obstacle.
Before descending a slope, always ensure that engine
control lever (1) is in the slow idle position, and then
reduce the engine speed. Turn the travel mode switch (2)
to slow speed for ZX26U-5A.
 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
obtained. MABA-04-003
1 2
 Use a signal person when moving, swinging or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the 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
machine as straight as possible, making small gradual
changes in direction.
 Before traveling on them, check the strengths of bridges Travel Motor
and road shoulders, and reinforce if necessary. M104-05-008
 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.
 When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
SA-673
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.
M586-05-002
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.
 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.
 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-1297
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 around the operating machine may be hit severely
by the swinging front attachment or counterweight, be
caught in other objects, and/or be struck by flying objects,
 Set up barriers and/or put a NO ADMISSION sign at the
machine operating site and areas exposed by flying
objects to prevent anyone from entering the work area.
 Check that all personnel or obstacles other than the
signal person are not present in the working area before
SA-667
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-668
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-1300
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
machine.
 Reduce operating speeds to avoid tipping or slipping.
SA-1301
 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-19
SAFETY
Never Undercut a High Bank

 The edges could collapse or a land slide could occur causing
SA-1302
Dig with Caution

 Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
 Before digging check the location of cables, gas lines, and
water lines.
 Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
 If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
 Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities. SA-672
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-673
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 (10 ft) 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-1305
Precautions for Lightning

 Lightning may strike the machine.
If lightning comes close, immediately stop the operation,

and take the following action.
 When you are around the machine or operating cab-
less machine, evacuate to a safe place far away from the
machine.
 When you are in the cab, stay in the cab until lightning
has passed and safety is secured. Close the cab doors and
windows. Lower the bucket to the ground, and stop the
engine. Put your hands on your lap to avoid contact with
any metal surfaces. Never go out of the cab.
If lightning strikes the machine or near the machine,

check all of the machine safety devices for any failure after
lightning has passed and safety is secured. If any trouble is SA-1805
found, operate the machine only after repairing it.
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,
 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.
SA-432
SA-22
SAFETY
Park Machine Safely

To avoid accidents:
 Park machine on a firm, level surface.
 Lower bucket to the ground.
 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-1306
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
 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. SA-1307
 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.
3. Select the slow travel mode for loading or unloading the
machine.
Before descending a slope, always ensure that engine
control lever (1) is in the slow idle position, and then
reduce the engine speed. Turn the travel mode switch (2)
to slow speed for ZX26U-5A.
4. 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.
5. 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 MABA-04-003
1 2
machine on the ground, then try loading again.
6. The top end of the ramp where it meets the flatbed is a
sudden bump. Take care when traveling over it.
7. 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. Run the engine at slow idle speed without load for 5
minutes.
4. Turn the key switch to OFF to stop engine.
5. Relieve the pressure in the hydraulic system by moving
the control levers several times.
6. Remove the key from the key switch. SA-028
7. Attach a “Do Not Operate” tag on the control lever.

8. Pull the pilot control shut-off lever to the LOCK position.
9. 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˚ 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 of operator's manual. M1M7-04-006
 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-527
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.
SS2045102
SA-26
SAFETY
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
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
SA-27
SAFETY
Prevent Parts from Flying

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

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 To avoid possible personal injury from attachment falling
accident, use a platform when replacing an attachment.
 Securely store attachments and implements to prevent
falling.
 Keep children and bystanders away from storage areas.
SA-034
SA-28
SAFETY
Prevent Burns
Hot spraying fluids:
 After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
 To avoid possible injury from hot spraying water. DO
NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap. SA-039
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-29
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-30
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-31
SAFETY
Clean up Flammable Materials:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammable materials may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammable materials 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 flammable materials 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 flammable materials
such as dead leaves from entering. However, flammable
materials which have passed through the wire screen
may cause fires. Check and clean the machine every
day and immediately remove accumulated flammable
materials.
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-32
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.
SS4642980
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-33
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-34
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 (ZX26U-

5A)
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 attempt to bore a hole or 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-35
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-36
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.
SA-37
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 Safety Data Sheet (SDS) provides specific details on
chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
 Check the SDS 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.
 See your authorized dealer for SDS’s (available only in SA-2579
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
may require a certified air conditioning service center to SA-226
recover and recycle used air conditioning refrigerants.
 Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
SA-38
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-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
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
Group 7 Connect The Hose
SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure
Group 2 Undercarrlage
Group 3 Front Attachment
SECTION 3 UPPERSTRUCTURE
Group 1 Canopy
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Solenoid Valve
SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
All information, illustrations and Group 3 Center Joint
specifications in this manual are based on
the latest product information available Group 4 Track Adjuster
at the time of publication. The right is Group 5 Front Idler
reserved to make changes at any time
without notice. Group 6 Upper and Lower Roller
Group 7 Track
Group 8 Blade Cylinder
SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder
COPYRIGHT(C)2015
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL
SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Hydraulic System
Group 2 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 4 Pilot Valve
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Troubleshooting B
Group 3 Troubleshooting C
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
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
Bleeding Air from Radiator..........................................W1-4-1-4
Group 5 Releasing Pressure
Releasing Pressure in Hydraulic Circuit...................W1-5-1-1
Group 6 Preparation
Preparation before Inspection and
Maintenance...............................................................W1-6-1-1
Angle to connect the hose..........................................W1-7-1-1
ACG90W-1-1
(Blank)
ACG90W-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
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
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
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
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
(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.
IMPORTANT:
 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) WDAA-01-02-001
 Clean the bolt and nut threads and remove dirt
or corrosion before 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
2013/09
Bolt Hexagon Head Bolt Socket Bolt
Dia. Wrench Socket Bolt Wrench
mm Size mm Size mm
WDAA-01-02-002 WDAA-01-02-003 WDAA-01-02-004

N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft)
6 3 to 4 (2.2 to 3) 10 5
8 30 (22) 20 (15) 10 (7.4) 13 20 (15) 6
10 65 (48) 50 (37) 20 (15) 17 50 (37) 8
12 110 (81) 90 (66) 35 (26) 19 90 (66) 10
14 180 (133) 140 (103) 55 (41) 22 140 (103) 12
16 270 (200) 210 (155) 80 (59) 24 210 (155) 14
18 400 (300) 300 (220) 120 (89) 27 300 (220) 14
20 550 (410) 400 (300) 170 (125) 30 400 (300) 17
22 750 (550) 550 (410) 220 (162) 32
24 950 (700) 700 (520) 280 (205) 36
27 1400 (1030) 1050 (770) 400 (300) 41
30 1950 (1440) 1450 (1070) 550 (410) 46
33 2600 (1920) 1950 (1440) 750 (550) 50
36 3200 (2360) 2450 (1810) 950 (700) 55
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 torque.
Apply lubricant, such as the Grease Spray to

the bolts and nuts in order to reduce friction
coefficient of them.
Torque tolerance is ±10 %.

Slightly apply lubricant onto the threads first by

using the Grease Spray.
W1-2-1-4
SECTION 1 GENERAL
Group 2 Tightening
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.
IMPORTANT: 1 4 3 5 2
 Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces (4)
and (5), possibly cracking the adapter. Tighten
union nut (3) to the specifications.
 Scratches or other damage to sealing surfaces
(4) or (5) will cause oil leakage at the joint. Take
care not to damage them when connecting / a - Joint Body WDAA-01-02-009
a
disconnecting.
37 °
2013/09
Description Wrench Size mm Tightening Torque 30 °
Union Nut N·m (lbf·ft)
30 ° male 17 25 (18.5) b c
19 30 (22)
22 40 (29.5) b - Male Union Joint c - Female Union Joint
27 80 (59) WDAA-01-02-010
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
55 380 (280)
60 380 (280)
37 ° female 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
fNOTE: Tightening torque of 37 ° male coupling without

union is similar to tightening torque of 37° female.
W1-2-1-5
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.
2013/09
Wrench Size (mm) 17 19 22 27
Tightening N·m 25 30 40 80 M1M7-07-005
Torque (lbf·ft) (18.5) (22) (29.5) (59)
O-ring Seal Joint

O-ring (6) is installed against the end surface of adapter
(7) and seals pressure oil.
IMPORTANT:
 Replace O-ring (6) with a new one when 7 6 9
reinstalling.
 Before tightening union nut (9), confirm that
O-ring (6) is seated correctly in O-ring groove
(8). Tightening union nut (9) with O-ring (6)
displaced will damage O-ring (6), resulting in oil
leakage.
 Do not damage O-ring groove (8) of adapter (7)
or sealing surface (10) on the hose side. Damage 8 10 a
WDAA-01-02-011
to O-ring (6) may cause oil leakage. a - Joint Body
 If union nut (9) is found to be loose, causing
oil leakage, do not tighten it to stop the leak.
Instead, replace O-ring (6) with a new one, then 2013/09
tighten union nut (9) after confirming that Wrench Size mm Tightening Torque
O-ring (6) is securely seated in O-ring groove (8). Union Nut N·m (lbf·ft)
19 30 (22)
22 70 (52)
27 95 (70)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
W1-2-1-6
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.
d CAUTION:
 When disconnecting, do not damage joint
surface.
 When disconnecting, clean the joint part and
thoroughly wipe off the cleaning solution to
prevent any foreign material from entering.
 Complete the joint disconnecting / connecting
procedure. Check enough if oil leaks especially
after installation.
 After installation, check if socket ring (1)
is returned to the original position (to the
rightmost direction).
W1-2-1-7
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 (a) a - Male Tapered Thread b - Male Straight Thread
is used except for measurement purpose.) W105-01-01-018
2013/09
Wrench Size mm Tightening Torque
Joint Body Cast iron Structural rolled
steel
19 15 (11) 35 (26)
22 30 (22) 50 (37)
Seal Tape Application 27 50 (37) 95 (70)
Seal tape is used in order to seal clearances between 36 70 (52) 160 (118)
male (d) and female (c) threads so that any leaks 41 110 (81) 200 (148)
between threads may be prevented. Therefore, apply 50 160 (118) 330 (245)
just enough seal tape to fill up thread clearances (e). Do 60 200 (148)
not overwrap.
 Application Procedure
fNOTE: Unit: N·m (lbf·ft)
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 (g):

4.5 N·m (3.3 lbf·ft)
Worm Gear Type Band Clamp (h):

6 to 7 N·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
W1-2-1-8
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
W1-2-1-9
SECTION 1 GENERAL
Group 2 Tightening
(Blank)
W1-2-1-10
SECTION 1 GENERAL
Group 3 Painting
Painting
Surfaces to Be Painted Painting Color

Main surface of upperstructure PB5-01 (SP-424)
(Except the resinated covers) [Dark Gray]
Swing post, Boom swing cylinder
Canopy (Including the front panel)
Seat base, Floor plate
(Except the resinated covers)
Cylinder (Boom, Arm, Bucket)
Track, Blade, Blade Cylinder
Counterweight
Front attachment, Upperstructure cover part YR1-01 [TAXI yellow]
Lever (Travel, Blade) N-10 [Black]
Left stay
W1-3-1-1
SECTION 1 GENERAL
Group 3 Painting
(Blank)
W1-3-1-2
SECTION 1 GENERAL
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
hydraulic oil level.
2. Stop the engine. Slowly loosen cap (2) of hydraulic 3 2
oil tank (3) and bleed air from hydraulic oil tank (3).
3. Remove cap (2) of hydraulic oil tank (3).
W1M9-01-04-001
4. Install vacuum pump (a) to the position where cap a

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

working.
W1R7-01-04-002
a - Vacuum Pump
b - Hose
c - Adapter
W1-4-1-1
SECTION 1 GENERAL
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 IMPORTANT: If air is accumulated inside of the
and if the engine starts in lacking of hydraulic oil, cylinder and if the cylinder is operated suddenly
the pump may be damaged. in lacking of hydraulic oil, the seal may be
 Bleeding Air from Pump damaged or the cylinder may seize.
 Remove the air bleed plug on top of the pump. Add  Bleeding Air from Hydraulic Circuit
hydraulic oil to the pump.  After refilling hydraulic oil, start the engine. While
 After the pump is filled with hydraulic oil, temporarily operating each cylinder, swing motor, and travel
tighten the plug. Then, start the engine and run it at motor evenly, operate the machine under light loads
slow idle speed. for 10 to 15 minutes. Slowly start each operation
 Slightly loosen the plug and bleed air from the pump (never fully stroke the cylinders during initial
until hydraulic oil comes out from the gap. operation stage).
 After bleeding all air, securely tighten the plug.  As the pilot circuit has an air bleed device, air in the
IMPORTANT: If air is accumulated inside of the motor pilot circuit will be bled while performing the above
and if the engine starts in lacking of hydraulic oil, operation for approx. 5 minutes.
the motor may be damaged.  Reset the front attachment in position for checking
 Bleeding Air from Travel Motor, Swing Motor hydraulic oil level.
 Remove the air bleed plug (top) from the travel  Stop the engine. Check hydraulic oil level. Replenish
motor and swing motor. Fill the motor case with hydraulic oil if necessary.
hydraulic oil.
W1-4-1-2
SECTION 1 GENERAL
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, or
running the fuel tank dry, be sure to bleed the air from
the fuel system.
Air Bleeding Procedures

Automatic bleeding deveice is provided on this
machine.
1. Confirm that the fuel level is more than one-half of
the fuel tank capacity. If the fuel is lower, add fuel.
2. Set the key switch to the ON position and hold it for
10 to 15 seconds.
3. Start the engine and check the fuel system for fuel
leaks.
W1-4-1-3
SECTION 1 GENERAL
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
Set the front attachment in position for checking
hydraulic oil level.
2. Stop the engine. Remove the radiator cap.
W1-4-1-4
SECTION 1 GENERAL
Releasing Pressure in Hydraulic Circuit

3 5 6
Release any remaining pressure in the following
procedures when removing and installing the front
attachment.
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: Each attachment may move rapidly in

case the overload relief valve is loosened rapidly.
Check that the machine has set in the position for
inspection and maintenance and loosen it slowly.
Do not loosen it more than 3/4 turns as hydraulic
TACD90-01-02-002
oil may spout. 2 4 1
IMPORTANT: Do not turn lock nut (8) and adjusting
screw (9). If turning, the setting changes.
2. Slowly loosen body (7) of the overload relief valve
and make-up valve in which any remaining pressure 1- Overload Relief Valve (Arm 4- Overload Relief Valve (Boom
will be released. Roll-Out) Lower)
2- Make-up Valve (Bucket Roll- 5- Overload Relief Valve (Boom
j : 24 mm Out) Raise)
3- Overload Relief Valve (Bucket 6- Overload Relief Valve (Arm
m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 52 to 59 Roll-In) Roll-In)
lbf·ft)
7
8
TADB-04-05-004
7- Body 9 - Adjusting Screw

8- Lock Nut
W1-5-1-1
SECTION 1 GENERAL
(Blank)
W1-5-1-2
SECTION 1 GENERAL
Group 6 Preparation
Preparation before Inspection and

Maintenance
dCAUTION: Components, hydraulic oil, lubricant,

and coolant just after operation are too hot. Wait
until they cool. Then, start the work.
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 solid and level surface. M1M7-05-024

2. Lower the bucket and the blade onto the ground.
3. Turn the auto-idle switch OFF.
4. Set the engine control dial to the slow idle position 1
and run the engine for 5 minutes in order to cool
the engine.
5. Set the key switch to the OFF position and stop the
engine. Remove the key.
6. Set pilot shut-off lever (1) to the LOCK position.
7. Before performing any work on the machine, attach
the tag on the door or control lever.
MADB-07-001
W1-6-1-1
SECTION 1 GENERAL
Group 6 Preparation
dCAUTION: Never attempt to maintain the

machine when the engine is running in order to
prevent the accident. If maintenance work while
engine running is unavoidable, strictly comply
with the following items.
 One person should take the operator's seat
to be ready to stop the engine any time while
communicating with other workers.
 When working around the moving parts is
unavoidable, pay special attention to ensure
that hands, feet, and clothing and do not SA-2294
become entangled.
 If parts or tools are dropped or inserted into
the fan or the belt, they may fly off or be cut off.
Do not drop or insert parts and tools into the
moving parts.
 Set pilot control shut-off lever (1) to the LOCK
position so that the front attachment will not
move.
 Never touch the control levers and pedals.
If operating the control levers or pedals is
unavoidable, signal co-workers to evacuate to
the safer place.
SA-026
W1-6-1-2
SECTION1 GENERAL
Angle to connect the hose
Pump Device
a Detail A
25°
A 30°
25°
WACC50-03-04-005 WACC50-01-07-001
a- Front Side
W1-7-1-1
SECTION1 GENERAL
Control Valve
a
WACC50-01-07-002
a- Front Side
Detail A
15°
30°
WACC50-01-07-003
1- 2-Spool Solenoid Valve
W1-7-1-2
SECTION1 GENERAL
View A
35°
WACC50-01-07-002 WACC50-01-07-006
a- Front Side 80°
80°
View B View B View B

25°
55°
25° 45°
50°
45°
30°
45° 45°
70°
50°
50°
50°
WACC50-01-07-007 WACC50-01-07-008 WACC50-01-07-009
W1-7-1-3
SECTION1 GENERAL
Detail A
a 30°
30°
30°
30°
20°
A
35°
35°
25°
WACC50-01-07-002 WACC50-01-07-010
a- Front Side
Detail A Detail A
20°
20°
20°
20°
25°
25°
5°
20°
65°
10° 35°
WACC50-01-07-011 WACC50-01-07-012
W1-7-1-4
SECTION1 GENERAL
Swing Device
a
A
WACC50-01-07-028
a- Front Side
View B
35°
View A
15°
30°
°
10
WACC50-01-07-014
WACC50-01-07-013
W1-7-1-5
SECTION1 GENERAL
Pilot Valve (Boom Swing)
View A
a
WACC50-01-07-016
30° 30°
WACC50-01-07-015
a- Front Side A
View B View B
15°
5°
WACC50-01-07-017 WACC50-01-07-018
W1-7-1-6
SECTION1 GENERAL
Pilot Valve (Travel)
View A
5°
a
5°
c
WACC50-01-07-019 WACC50-01-07-020
a- Front Side
View B View C
90
°
15°
20°
WACC50-01-07-022
WACC50-01-07-021
W1-7-1-7
SECTION1 GENERAL
Pilot Valve (Left)
View A
25°
25°
20°
a
A
15°
10°
WACC50-01-07-019 WACC50-01-07-023
a- Front Side
2-Spool Solenoid Valve Detail B
35°
WACC50-01-07-024
B
WACC50-01-07-005
a- Front Side
W1-7-1-8
SECTION1 GENERAL
Center Joint
Detail A
60°
55°
WACC50-01-07-005
a- Front Side
WACC50-01-07-025
Detail B
a
50°
WACC50-01-07-026
WACC50-01-07-027
a- Front Side
W1-7-1-9
SECTION1 GENERAL
(Blank)
W1-7-1-10
MEMO
MEMO
SECTION 2
MAINTENANCE STANDARD
CONTENTS
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
Lower Roller......................................................................W2-2-3-1
Track.....................................................................................W2-2-4-1
Pin and Bushing...............................................................W2-3-1-1
Side Cutter.........................................................................W2-3-1-4
Standard Dimensions for Arm and Bucket
Connection..................................................................W2-3-1-5
Cylinder..............................................................................W2-3-2-1
ACG90W-2-1
(Blank)
ACG90W-2-2
Pump Device
1 2
TACC-03-01-001
1- Cylinder Block 2- Plunger (10 Used)
W2-1-1-1
1. Clearance between outer diameter (d) of plunger (2)

and inner diameter (D) of cylinder block (1) 2 1
Unit: mm (in)
Allowable Limit 0.05 (0.002)
D-d≤0.05 mm (0.002 in) d D
2. Clearance (ε) between plunger (2) and shoe (a)
bottom
Unit: mm (in)
Allowable Limit 0.2 (0.008) WABAA0-02-01-001
ε≤0.2 mm (0.008 in) a 2

3. Wear amount of oil seal mounting surface
Check that there are no damage and/or abnormal wear.
Unit: mm (in)
Standard Allowable Limit
0 0.025 (0.001) ε
WABAA0-02-01-002
D0-D1≤0.025 mm (0.001 in)
a- Shoe
D1 D0
W507-02-04-010
D1 D0
W2-1-1-2
Swing Motor
TACC-03-02-001
1- Rotor 2- Plunger (9 Used)
W2-1-2-1

and cylinder inner diameter (D) of rotor (1)
Unit: mm (in)
D-d≤0.04 mm (0.002 in)
D d
2. Clearance (ε) between plunger (2) and shoe (a)
bottom
Unit: mm (in) W507-02-04-009
1 2
ε≤0.3 mm (0.012 in)
ε
a
a- Shoe W107-02-06-140
W107-02-06-141
W2-1-2-2
Travel Motor
T1MW-03-05-001
4 3
1- Valve Plate 2- Cylinder Block 3- Plunger (9 Used) 4- Shoe
W2-2-1-1

and inner diameter (D) of cylinder block (2)
Unit: mm (in)
D-d ≤ 0.02 mm (0.001 in)
2. Clearance (ε) between plunger (3) and shoe (a) D d
bottom
W507-02-04-009
Unit: mm (in) 2 3
ε ≤ 0.4 mm (0.012 in)
3. Wear amount of sliding surface against valve plate 3
of cylinder block (2)
Check that there are no damage, abnormal wear,
and/or seizure.
Damage and/or wear: 0.02 mm (0.001 in) or less 4
4. Wear amount of sliding surface against cylinder ε

block (2) of valve plate
WABAA0-02-02-001
Check that there are no damage, abnormal wear,
and/or seizure.
Damage and/or wear: 0.02 mm (0.001 in) or less
W2-2-1-2
Sprocket
D C B
W503-03-02-004
Unit: mm (in)
Standard Allowable Limit Remedy
A 28.5 (1.12) 22.5 (0.886) Replace parts.
B 293 (11.5) 287 (11.3)
C 328.8 (12.9) -
D 337.5 (13.3) 331.5 (13.1)
E 101.6 (4.00) -
W2-2-1-3
(Blank)
W2-2-1-4
Front Idler
C D F
A
B
W503-03-05-001
Unit: mm (in)
A 31 (1.22) 25 (0.984) Replace
B 80 (3.15) -
C 34 (1.34) -
D 278 (10.9) 272 (10.7)
E 10 (0.394) -
F 316 (12.4) -
Axle and Bushing
Unit: mm (in)
Axle Outer 30 (1.18) 29.2 (1.15) Replace
Diameter
Bushing Inner 30 (1.18) 30.5 (1.00)
Diameter
Flange 2 (0.079) 1.5 (0.059)
Thickness
Lubrication Oil
Engine Oil (API CD class, SAE #30)
Amount of engine oil: 30 ml (30 cm3)
W2-2-2-1
(Blank)
W2-2-2-2
Lower Roller
E
C D
WABAA0-02-02-002
Unit: mm (in)
A 31 (1.22) 23 (0.906) Replace
B 120 (4.72) -
C 36 (1.42) -
D 85 (3.35) 77 (3.03)
E 107 (4.21) -
Axle and Bushing
Unit: mm (in)
Axle Outer 30 (1.18) 29.2 (1.15) Replace
Diameter
Bushing Inner 30 (1.18) 30.5 (1.20)
Diameter
Flange 3 (0.118) 2.5 (0.098)
Thickness
fNOTE: Values in [ ] are just for reference.
Lubrication Oil
Engine Oil (API CD class, SAE #30)
Amount of oil: 65±10 ml (65±10 cm3)
W2-2-3-1
(Blank)
W2-2-3-2
Track
Rubber Crawler Crack 1 4
1. Outside of Rubber Crawler
If there is a crack on lug base (1) with depth of 3 mm 5
2
(0.12 in) or more, repair the track.
If there is a crack between lugs (2) with depth of 3
mm (0.12 in) or more, repair the track. 3
If there is a crack on lugs (3) or between lugs (2) and
it reaches steel code (5) or steel core (4) with length
of 30 mm (1.18 in) or more, immediately repair the W190-03-07-001
track.
2. Inside of Rubber Crawler (Roller (6) Side) 4
If there is a crack that reaches steel code (5) or steel
core (4), immediately repair the track.
5
W190-03-07-002
Lug Wear
1. If height (A) of lug (8) is less than 5 mm (0.2 in), 6
replace rubber crawler (7) as an assembly.
2. If any part of steel code (5) appeared on the track, 7
replace the worn rubber crawler as an assembly.
W190-03-07-003
8
W190-03-07-004
W2-2-4-1
A
A
A-A
W1LA-03-07-001
Unit: mm (in)
1 24 (0.945) 5 (0.197) Replace
2 34 (1.34) 42 (1.65)
3 24 (0.945) 20 (0.787)
Rubber Crawler and Steel Code Cutting

1. When either of the two rows of steel code (5) has
cut, replace the rubber crawler as an assembly.
Steel Core Separation W190-03-07-005
1. When any part of steel core (4) has separated,

replace the rubber crawler as an assembly.
W190-03-07-006
W2-2-4-2
Pin and Bushing

Front Parts
B
E D
I J
G K H W1MP-04-01-010
Boom Swing Parts
M
WABAA0-02-03-001
W2-3-1-1
Blade Parts
R P
WACC50-02-03-001
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Pin 40 (1.58) 39 (1.54) Replace
Bushing (Boom) 40 (1.58) 41.5 (1.63)
B Pin 35 (1.38) 34 (1.34)
Bushing (Boom Cylinder) 35 (1.38) 36.5 (1.44)
C Pin 35 (1.38) 34 (1.34)
Bushing (Boom Cylinder) 35 (1.38) 36.5 (1.44)
D Pin 40 (1.58) 39 (1.54)
Bushing (Arm) 40 (1.58) 41.5 (1.63)
E Pin 35 (1.38) 34 (1.34)
Bushing (Arm Cylinder) 35 (1.38) 36.5 (1.44)
F Pin 35 (1.38) 34 (1.34)
Bushing (Arm Cylinder) 35 (1.38) 36.5 (1.44)
G Pin 30 (1.18) 29 (1.14)
Bushing (Bucket Cylinder) 30 (1.18) 31.5 (1.24)
W2-3-1-2
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
H Pin 35 (1.38) 34 (1.34) Replace
Bushing (Bucket Cylinder) 35 (1.38) 36.5 (1.44)
Bushing (Link A) 35 (1.38) 36.5 (1.44)
Link B 35 (1.38) 36.5 (1.44)
I Pin 35 (1.38) 34 (1.34)
Bushing (Arm) 35 (1.38) 36.5 (1.44)
Link B 35 (1.38) 36.5 (1.44)
J Pin 35 (1.38) 34 (1.34)
Bushing (Link A) 35 (1.38) 36.5 (1.44)
K Pin 35 (1.38) 34 (1.34)
Bushing (Arm) 35 (1.38) 36.5 (1.44)
L Pin 71 (2.80) 70 (2.76)
Bushing (Main Frame) 71 (2.80) 72.5 (2.86)
Bushing (Swing Post) 71 (2.80) 72.5 (2.86)
M Pin 71 (2.80) 70 (2.76)
Bushing (Main Frame) 71 (2.80) 72.5 (2.86)
Bushing (Swing Post) 71 (2.80) 72.5 (2.86)
N Pin 40 (1.58) 39 (1.54)
Bushing (Boom Swing 40 (1.58) 41.5 (1.63)
Cylinder)
O Pin 40 (1.58) 39 (1.54)
Bushing (Boom Swing 40 (1.58) 41.5 (1.63)
Cylinder)
P Pin 30 (1.18) 29 (1.14)
Bushing (Blade) 30 (1.18) 31.5 (1.24)
Q Pin 35 (1.38) 34 (1.34)
Bushing (Blade Cylinder) 35 (1.38) 36.5 (1.44)
R Pin 35 (1.38) 34 (1.34)
Bushing (Blade Cylinder) 35 (1.38) 36.5 (1.44)
IMPORTANT: When replacing HN bushing for the
front attachment, install it by using a press.
W2-3-1-3
Side Cutter
C
D
A
W505-04-01-001
Unit: mm (in)
A 104 (4.09) 70 (2.76) Replace
B 138 (5.43) -
C 153 (6.02) -
D 90 (3.54) -
Point
B C
W554-04-01-003
Unit: mm (in)
A 127.5 (5.02) 63 (2.48) Replace
B 56 (2.21) -
C 62 (2.44) -
D 51 (2.01) -
W2-3-1-4
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.
Section A Section B
W1ND-04-01-001
Unit: mm
a 152 (5.98)
b 13 (0.512)
c 244 (9.61)
d 230 (9.06)
e 185 (7.28)
f 640 (25.2)
g 234.5 (9.23)
h 140.5 (5.53)
i 35 (1.38)
j 185 (7.28)
k 0 (0)
l 234.5 (9.23)
m 140.5 (5.53)
n 35 (1.38)
o 90°
p 90°
fNOTE: Dimensions o, p: 90° means the angle for the

bolt hole.
W2-3-1-5
(Blank)
W2-3-1-6
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- Overall Length
Unit: mm (in) Unit: mm (in)

Cylinder Name Recommended Size After Bend Run Out Remedy
Re-manufacturing (A) 1.0 (0.04) 2.0 (0.08) Replace
Boom 40-0.025-0.064 (1.58-0.001-0.003)
Arm 40-0.025-0.064 (1.58-0.001-0.003)
Bucket 35-0.025-0.064 (1.38-0.001-0.003)
Boom Swing 35-0.025-0.064 (1.38-0.001-0.003)
Blade 35-0.025-0.064 (1.38-0.001-0.003)
W2-3-2-1
(Blank)
W2-3-2-2
MEMO
MEMO
SECTION 3
UPPERSTRUCTURE
CONTENTS
Group 1 Canopy and Cab Group 8 Solenoid Valve
Removal and Installation of Canopy........................W3-1-1-1 Removal and Installation of 2-Spool Solenoid
Valve...............................................................................W3-8-1-1
Group 2 Counterweight Disassembly of 2-Spool Solenoid Valve..................W3-8-2-1
Removal and Installation of Counterweight.........W3-2-1-1 Assembly of 2-Spool Solenoid Valve........................W3-8-2-3
Group 3 Main Frame
Removal and Installation of Main Frame................W3-3-1-1
Group 4 Pump Device
Removal and Installation of Pump Device.............W3-4-1-1
Disassembly of Pump Device.....................................W3-4-2-1
Assembly of Pump Device...........................................W3-4-2-4
Removal and Installation of Control Valve.............W3-5-1-1
Disassembly and Assembly of Control Valve........W3-5-2-1
Disassembly of Body......................................................W3-5-3-1
Assembly of Body...........................................................W3-5-3-5
Disassembly of Spool....................................................W3-5-4-1
Assembly of Spool..........................................................W3-5-4-3
Removal and Installation of Swing Device............W3-6-1-1
Disassembly of Swing Reduction Gear...................W3-6-2-1
Assembly of Swing Reduction Gear.........................W3-6-2-3
Disassembly of Swing Motor......................................W3-6-3-1
Assembly of Swing Motor............................................W3-6-3-4
Group 7 Pilot Valve
Removal and Installation of Pilot Valve (Left).......W3-7-1-1
Removal and Installation of Pilot Valve (Right)....W3-7-2-1
Removal and Installation of Travel Pilot Valve......W3-7-3-1
Removal and Installation of Blade Pilot Valve......W3-7-4-1
Removal and Installation of Boom Swing Pilot
Valve...............................................................................W3-7-5-1
Disassembly of Pilot Valves (Right and Left).........W3-7-6-1
Assembly of Pilot Valves (Right and Left)...............W3-7-6-4
Disassembly of Travel Pilot Valve...............................W3-7-7-1
Assembly of Travel Pilot Valve....................................W3-7-7-5
Disassembly of Pilot Valves for Boom Swing,
Blade, Auxiliary (Optional)......................................W3-7-8-1
Assembly of Pilot Valves for Boom Swing,
Blade, Auxiliary (Optional) ....................................W3-7-8-4
ACG90W-3-1
(Blank)
ACG90W-3-2
Group 1 Canopy and Cab
Removal and Installation of Canopy

a
1
2, 3
5
WACC50-03-01-001
a- Shackle Mounting Position
Removal
2. Remove bolts, washers (2) (4 used) and collars (3) (2
used) from canopy (1).
j : 19 mm
dCAUTION: Canopy (1) weight: 64 kg (145 lb)

3. Install shackles (4 used) to canopy (1). Attach nylon
slings onto the shackles (4 used). Hoist and hold
canopy (1).
4. Remove bolts, washers (4) (4 used) from canopy (1).
j : 19 mm
5. Hoist and remove canopy (1) from floor (5).
W3-1-1-1
Group 1 Canopy and Cab
a
1
2, 3
5
WACC50-03-01-001
a- Shackle Mounting Position
Installation
dCAUTION: Canopy (1) weight: 64 kg (145 lb)

1. Install shackles (4 used) to canopy (1). Attach nylon
slings onto the shackles (4 used). Hoist and hold
canopy (1).
2. Install canopy (1) to floor (5) with collars (3) (2 used)
and bolts, washers (2) (4 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

3. Install canopy (1) to floor (5) with bolts, washers (4)
(4 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-1-1-2
Removal and Installation of Counterweight
2 3
WACC50-03-02-001
WACG90-03-02-001
Removal
2. Open covers (1, 2).
3. Remove bolts, washers (4) (3 used). Remove cover
(3).
j : 17 mm
W3-2-1-1
1
3
WACG90-03-02-003
WACG90-03-02-002
4. Remove bolt, washer (1). 5. Remove bolt, washer (2). Remove cover (3).
j : 17 mm j : 17 mm
W3-2-1-2
3
1 4
a
5 6
7 5
6
WACC50-03-02-003 WACC50-03-02-004
a- Matching Mark
6. Put the matching mark (a) onto counterweight (7)

and bracket (1). Remove bolts, washers (2) (2 used). dCAUTION:
lb)
Counterweight (7) weight: 125 kg (280
Remove bracket (1).
7. Install the eyebolts (M12, Pitch 1.75 mm) (2 used)
j : 19 mm to bracket (1) mounting holes (4). Hoist and hold
counterweight (7).
8. Remove bolts (6) (2 used) and washers (5) (2 used)
from counterweight (7).
j : 30 mm
9. Raise counterweight (7) a little. Slide counterweight
(7) to the rear side. Remove counterweight (7) from
main frame (3).
W3-2-1-3
3
4
1
a
5 6
7 5
6
WACC50-03-02-004
WACC50-03-02-003
a- Matching Mark
Installation
dCAUTION:
lb)
Counterweight (7) weight: 125 kg (280 3. Fit the matching mark (a) on bracket (1) and
counterweight (7). Install bracket (1) with bolts,
washers (2) (2 used).
1. Install the eyebolts (M12, Pitch 1.75 mm) (2 used) to
bracket (1) mounting holes (4). Hoist counterweight j : 19 mm
(7). Place counterweight (7) onto main frame (3).
Slide counterweight (7) to the front side. m : 90 N·m (9 kgf·m, 66 lbf·ft)
2. Install counterweight (7) to main frame (3) with
bolts (6) (2 used) and washers (5) (2 used).
j : 30 mm
m : 400 N·m (40 kgf·m, 295 lbf·ft)
W3-2-1-4
WACG90-03-02-003 WACG90-03-02-002
4. Install cover (3) with bolt, washer (2). 5. Install bolt, washer (1).
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)
W3-2-1-5
3
2
WACG90-03-02-001 WACC50-03-02-001
6. Install cover (3) with bolts, washers (4) (3 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

7. Close covers (1, 2).
W3-2-1-6
Group 3 Main Frame
Removal and Installation of Main Frame
2 1
3, 4
WACG90-04-03-001
5, 6
WACC50-03-06-004
IMPORTANT: The hoses and pipes contain hydraulic 4. Remove the canopy. (Refer to W3-1-1.)
oil. When removing the hoses and pipes, receive
5. Slide seat (1).
oil with a container in order to avoid spilling oil.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
dCAUTION: Seat (1) weight: 24 kg (53 lb)
6. Remove socket bolts (2) (4 used). Remove seat (1).
attach identification tags onto the connectors,
hoses, and pipes for assembling. If the clips which l : 6 mm
secure the hoses have been removed, install the 7. Remove bolt (5) and washer (6). Remove floor mat
clips after connecting the hoses. (3) and plate (4).
Removal j : 13 mm

(Refer to W1-4-1.)
2. Remove the front attachment. (Refer to W5-1-1.)
3. Remove the boom cylinder. (Refer to W5-2-1.)
W3-3-1-1
Group 3 Main Frame
3 4
7 2
6
5 WACC50-03-07-009

(4).
j : 13 mm
9. Remove bolts, washers (7) (2 used) and bolt, washer
(5). Remove cover (6).
j : 13 mm
j : 17 mm
(1).
j : 17 mm
11. Remove the swing device. (Refer to W3-6-1.)
W3-3-1-2
Group 3 Main Frame
2 2 4 3 5
2
WACC50-04-03-001 WACC50-04-03-004
12. Disconnect hoses (2) (8 used) from center joint (1).
j : 17 mm, 19 mm
13. Remove bolts, washers (4) (2 used) from main frame
(5). Remove stopper (3) from main frame (5).
j : 19 mm
fNOTE: LOCTITE #263 or equivalent has been applied to

bolt, washer (4).
W3-3-1-3
Group 3 Main Frame
1 2
WACC50-03-03-006
14. Open engine cover (2).

15. Remove bolts, washers (1) (4 used). Remove engine
cover (2).
j : 17 mm
16. Remove the counterweight. (Refer to W3-2-1.)
W3-3-1-4
Group 3 Main Frame
WACC50-03-03-007
a- Boom Mounting Pin Hole b- Counterweight Mounting

Bolt Hole
dCAUTION:
lb)
Main frame (1) weight: 1150 kg (2540
17. Install Freno-Linkbolts (A-20: M20, Pitch 2.5 mm)

to the counterweight mounting bolt holes (b) (2
places). Attach wire ropes onto the Freno-Linkbolts.
18. Attach wire ropes onto boom mounting pin holes
(a) (2 places).
W3-3-1-5
Group 3 Main Frame
WACC50-03-03-003
19. Reduce slack of the wire ropes by using chain

blocks. Put the matching marks onto main frame (1)
and the outer race (2) of the swing bearing.
20. Remove bolts (3) (16 used).
j : 19 mm
21. Adjust the center of gravity of main frame (1) by
using chain blocks. Hoist and remove main frame
(1).
W3-3-1-6
Group 3 Main Frame
WACC50-03-03-007
a- Boom Mounting Pin Hole b- Counterweight Mounting

Bolt Hole
IMPORTANT: Check the angles to connect the hose

and to install the adapter. (Refer to W1-7-1.)
Installation
dCAUTION:
lb)
Main frame (1) weight: 1150 kg (2540
1. Install Freno-Linkbolts (A-20: M20, Pitch 2.5 mm)

to the counterweight mounting bolt holes (b) (2
places). Attach wire ropes onto the Freno-Linkbolts.
2. Attach wire ropes onto boom mounting pin holes
(a) (2 places).
W3-3-1-7
Group 3 Main Frame
WACC50-03-03-003
3. Adjust the center of gravity of main frame (1) by 5. Tighten bolts (3) (16 used).
using chain blocks.
j : 19 mm
4. Fit the matching marks made when disassembling
and the knock pins. Temporarily install main frame m : 110 N·m (11 kgf·m, 81 lbf·ft)
(1) to outer race (2) of the swing bearing with bolts
(3) (16 used).
j : 19 mm
W3-3-1-8
Group 3 Main Frame
1 2
WACC50-03-03-006
6. Install the counterweight. (Refer to W3-2-1.)

7. Install engine cover (2) with bolts, washers (1) (4
used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

8. Close engine cover (2).
W3-3-1-9
Group 3 Main Frame
4 3 5 2 2
2
WACC50-04-03-004 WACC50-04-03-001
9. Apply LOCTITE #263 or equivalent to bolt, washer

(4). Install stopper (3) to main frame (5) with bolts,
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

10. Connect hoses (2) (8 used) to center joint (1).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

11. Install the swing device. (Refer to W3-6-1.)
W3-3-1-10
Group 3 Main Frame
3 4
7 2
6
5 WACC50-03-07-009
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

13. Install cover (6) with bolt, washer (5) and bolts,
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-3-1-11
Group 3 Main Frame
2 1
3, 4
5, 6
WACG90-04-03-001 WACC50-03-06-004
20. Bleed air from the hydraulic system. (Refer to W1-4-

dCAUTION: Seat (1) weight: 24 kg (53 lb) 1.)
15. Install seat (1) with socket bolts (2) (4 used).
IMPORTANT: Check the hydraulic oil level. Start the
l : 6 mm engine and check for any oil leaks.
21. Install plate (4). Install floor mat (3) with washer (6)
m : 20 N·m (2 kgf·m, 15 lbf·ft) and bolt (5).
16. Slide seat (1).
j : 13 mm
17. Install the canopy. (Refer to W3-1-1.)
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
18. Install the boom cylinder. (Refer to W5-2-1.)
19. Install the front attachment. (Refer to W5-1-1.)
W3-3-1-12
Group 4 Pump Device
Removal and Installation of Pump Device

4, 5 3
1
WACG90-03-04-001 WACG90-03-04-002
3. Remove bolts, washers (3) (4 used). Remove the

dCAUTION: Escaping fluid under pressure may
penetrate the skin and eyes, and cause serious
cover (4) assembly and O-ring (5).
injury. Release the pressure before disconnecting j : 13 mm

the hydraulic pipings or removing other
4. Place a container. Drain off hydraulic oil by using an
equipment. Hot hydraulic oil just after operation
oil feed pump.
may spout out and cause severe burns. Allow oil
to cool before starting any work. Do not turn the
cap of hydraulic oil tank (6) quickly. The cap may
fNOTE: Total oil amount of hydraulic oil tank (6): 30 L
(7.93 US gal)
fly off by internal pressure. Release any remaining
pressure and remove the cap.
IMPORTANT: The hoses and pipes contain hydraulic
hoses, and pipes for assembling. If the clips which
secure the hoses have been removed, install the
clips after connecting the hoses.
Removal
2. Open cover (1).
dCAUTION: Bleed air from hydraulic oil tank (6).

(Refer to W1-4-1.)
W3-4-1-1
Group 4 Pump Device
7 6
WACG90-03-02-003
2
WACG90-03-02-001
4
(2).
j : 17 mm
6. Remove bolt, washer (5).
j : 17 mm
7. Remove bolt, washer (6). Remove cover (7).
j : 17 mm
8. Disconnect hose (4) from pump device (3).
j : 22 mm
3
WACC50-03-04-004
W3-4-1-2
Group 4 Pump Device
2
3
WACC50-03-04-009
WACC50-03-04-005
9. Remove clip bands (2) (3 used).

10. Move protectors (4) (3 used) and tubes (1) (3 used)
until hoses (3) (3 used) can be seen.
11. Disconnect hoses (3) (3 used).
j : 19 mm
W3-4-1-3
Group 4 Pump Device
1
5 6
4 3 WACC50-03-04-006 1 5 WACC50-03-04-007
12. Place a container under the disconnection part of

the suction pipe (4) assembly. Remove socket bolts
(3) (4 used). Remove the suction pipe (4) assembly
from pump device (1). Remove O-ring (2).
l : 8 mm
13. Remove bolts, washers (5) (2 used). Remove pump
device (1) from engine (6).
j : 19 mm
14. Remove the adapters with pump device (1)
attached if necessary.
W3-4-1-4
Group 4 Pump Device
5 6 1
1 5 4 3 WACC50-03-04-006
WACC50-03-04-007

Installation
1. Install all removed adapters to pump device (1).
2. Install pump device (1) to engine (6) with bolts,
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

IMPORTANT: Apply grease to O-ring (2).
3. Install O-ring (2) to the groove on flange in suction
pipe (4). Install the suction pipe (4) assembly to
pump device (1) with socket bolts (3) (4 used).
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-4-1-5
Group 4 Pump Device
2
3, 5
WACC50-03-04-009
WACC50-03-04-005
4
4. Connect hoses (3) (3 used).
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

5. Move tubes (1) (3 used) and protectors (6) (3 used)
until adapter (5) are covered with them.
6. Install clip bands (2) (3 used).
W3-4-1-6
Group 4 Pump Device
4 9 7, 8 5
3
WACC50-03-04-004
WACG90-03-04-002
7. Connect hose (4) to pump device (3). IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
j : 22 mm
m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

8. Fill hydraulic oil tank (6) with hydraulic oil.
fNOTE: Total oil amount of hydraulic oil tank (6): 30 L

9. Install O-ring (8). Install the cover (7) assembly with
bolts, washers (5) (4 used).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

10. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
 Pump Air Bleed Plug (9)
j : 6 mm
m : 30 to 34 N·m (3 to 3.4 kgf·m, 22 to 25 lbf·ft)
W3-4-1-7
Group 4 Pump Device
2 3
WACG90-03-02-003
WACG90-03-04-001
11. Close cover (1). 4
12. Install cover (2) with bolt, washer (3).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

13. Install bolt, washer (6).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

6
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
5
WACG90-03-02-001
W3-4-1-8
Group 4 Pump Device
Disassembly of Pump Device
WACB50-03-04-001
1- Retaining Ring 14- Swash Plate 26- Valve Plate 37- Nut
2- Oil Seal 16- Stopper pin B 27- Spring Pin 38- Socket Bolt (5 Used)
3- Shaft 17- Ball (2 Used) 28- Needle Bearing 39- O-Ring
4- Ball Bearing 18- Plunger (10 Used) 29- Spring Holder 40- O-Ring
5- Retaining Ring 19- Retainer 30- Spring 41- O-Ring
8- Pin (2 Used) 20- Holder 31- Spring Guide 42- Collar
9- Body S 21- Needle (3 Used) 32- Pin 43- Coupling
10- Packing 22- Cylinder Block 33- O-Ring 44- Gear Pump
11- Spring (4 Used) 23- Washer (2 Used) 34- Body H 45- Spring Washer (2 Used)
12- Stopper pin A 24- Spring 35- Seal Washer 46- Bolt (2 Used)
13- Rod 25- Retaining Ring 36- Bolt 47- Plug (5 Used)
W3-4-2-1
Group 4 Pump Device
Disassembly of Pump Device

1. Remove bolts (46) (2 used) and spring washers (45) 5. Remove other socket bolts (38) (3 used).
(2 used). Remove gear pump (44) from body H (34).
l : 8 mm
j : 13 mm
6. Loosen and remove the temporary assembly bolts
IMPORTANT: Do not turn bolt (36) and nut (37). If (M10, Length: 65 mm) (2 used) alternately from
turning, the setting changes. body H (34).
2. Remove O-rings (39, 40, and 41), collar (42), and
j : 17 mm
coupling (43) from body H (34).
IMPORTANT: Do not drop valve plate (26) while
dCAUTION: Remove body H (34) by using the
temporary assembly bolts (M10, Length:65 mm) in
removing body H (34).
IMPORTANT: Do not remove spring pin (27).
order not to fly out spring (30).
7. Remove body H (34) from body S (9).
3. Remove socket bolts (38) (2 used) from mounting
holes (a) (2 places) of socket bolt (38). 8. Remove O-ring (33) from body H (34).
l : 8 mm 9. Remove needle bearing (28) from shaft (3).

10. Remove packin (10), pin (32), pins (8) (2 used), and
valve plate (26) from body S (9).
a 11. Remove spring guide (31), spring (30), spring holder
a (29), and the cylinder block (22) assembly from
body S (9).
34 12. Remove plungers (18) (10 used), retainer (19),
holder (20), and needles (21) (3 used) from cylinder
block (22).
WADB-03-05-002
a- Mounting hole of socket bolt (38)
4. Install the temporary assembly bolts (M10, Length:

65 mm) (2 used) to mounting holes (a) (2 places) of
socket bolt (38) of body H (34).
j : 17 mm
W3-4-2-2
Group 4 Pump Device
dCAUTION: When removing retaining ring (25),

hold washers (23) (2 used) and spring (24) by
using the press in order not to fly out.
IMPORTANT: Do not disassemble the cylinder block
(22) assembly (parts No.23 to 25) unless necessary.
13. Remove retaining ring (25), washers (23) (2 used),
and spring (24) from cylinder block (22).
14. Remove swash plate (14) and balls (17) (2 used)
from body S (9).
15. Remove stopper pin A (12), stopper pin B (16),
springs (11) (4 used), and rods (13) from body S (9).
16. Remove retaining ring (1) from body S (9).
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. Tap the gear pump (44) mounting side and remove
the shaft (3) assembly from body S (9) by using a
hammer.
18. Remove oil seal (2) from shaft (3).
19. Remove retaining ring (5) from shaft (3).

personal injury.
20. Remove ball bearing (4) from shaft (3) by using a bar
and a hammer.
W3-4-2-3
Group 4 Pump Device
Assembly of Pump Device
11 29 19 20 22 18 24 23 10 30 31 34 35 37
36
12
9 42
43
13
44
17
3
1
2
4
5
16 11 14 21 25 28 26 27 32 33 41 39 WACB50-03-04-002
1- Retaining Ring 14- Swash Plate 26- Valve Plate 37- Nut
2- Oil Seal 16- Stopper Pin B 27- Spring Pin 38- *Socket Bolt (5 Used)
3- Shaft 17- Ceramic Ball (2 Used) 28- Needle Bearing 39- O-Ring
4- Ball Bearing 18- Plunger (10 Used) 29- Spring Holder 40- *O-Ring
5- Retaining Ring 19- Retainer 30- Spring 41- O-Ring
8- Pin (2 Used) 20- Holder 31- Spring Guide 42- Collar
9- Body S 21- Needle (3 Used) 32- Pin 43- Coupling
10- Packing 22- Cylinder Block 33- O-Ring 44- Gear Pump
11- Spring (4 Used) 23- Washer (2 Used) 34- Body H 45- *Spring Washer (2 Used)
12- Stopper Pin A 24- Spring 35- Seal Washer 46- Bolt (2 Used)
13- Rod 25- Retaining Ring 36- Bolt 47- *Plug (5 Used)
fNOTE: As for the item with mark *, refer to W3-5-2-1.
W3-4-2-4
Group 4 Pump Device
Assembly of Pump Device IMPORTANT: The length of stopper pin A (12)

and stopper pin B (16) are different. Check the
IMPORTANT: Before assembling, apply hydraulic oil
mounting positions.
onto parts in order to prevent them from seizing.
6. Install springs (11) (2 used) to stopper pin A (12).
Install stopper pin A (12) to body S (9).
such as goggles, helmets, etc in order to prevent 12

11
personal injury.
9
1. Evenly tap and install ball bearing (4) to shaft (3) by
using a bar and a hammer.
2. Install retaining rings (5) to shaft (3).

a hammer is used. Wear necessary protection, 16
such as goggles, helmets, etc in order to prevent 11
personal injury.
3. Place body S (9) with the gear pump (44) mounting
side down. Evenly tap ball bearing (4) with the shaft
(3) assembly and install it to body S (9) by using a WADB-03-05-004
bar and a hummer.
4. Apply grease onto oil seal (2). Install oil seal (2) to 7. Install springs (11) (2 used) to stopper pin B (16).
body S (9) by using the special tool (ST 7712). Install stopper pin B (16) to body S (9).
5. Install retaining ring (1) to body S (9). 8. Install rods (13) to body S (9).
9. Apply grease onto balls (17) (2 used). Install balls
(17) (2 used) to swash plate (14). Install swash plate
(14) to body S (9).
dCAUTION: When installing retaining ring (25) to

cylinder block (22), hold washers (23) (2 used) and
spring (24) by using the press in order not to fly
out.
10. Install washers (23) (2 used), spring (24), and
retaining ring (25) to cylinder block (22) by using
the press.
11. Install needles (21) (3 used) to cylinder block (22).
Install holder (20) on needle (21).
W3-4-2-5
Group 4 Pump Device
12. Install retainer (19) and plungers (18) (10 used) to 20. Temporarily tighten body H (34) with socket bolts
cylinder block (22). (38) (3 used).
13. While turning the cylinder block (22) assembly, l : 8 mm
insert the cylinder block (22) assembly into shaft (3).
21. Remove the temporary assembly bolts (M10,
14. Install spring holder (29), spring (30), and spring Length: 65mm) (2 used) from mounting holes (2
guide (31) to body S (9). places) of socket bolt (38).
IMPORTANT: Check the direction to install valve
j : 17 mm
plate (26).
15. Apply grease to body H (34) side of valve plate (26). 22. Temporarily tighten socket bolts (38) (2 used) to
Fit spring pin (27) and install valve plate (26) to body H (34).
body H (34).
l : 8 mm
16. Install needle bearing (28) to shaft (3).
23. Tighten socket bolts (38) (5 used).
17. Install pin (32), pins (8) (2 used), and packing (10) to
body S (9). l : 8 mm
18. Install O-ring (33) to body H (34). m : 50 N·m (5 kgf·m, 37 lbf·ft)

19. Fit the mounting holes (a) of socket bolt (38) 24. Install collar (42), coupling (43), and O-rings (39, 40,
and install body H (34) to body S (9). Install the and 41) to body H (34).
temporary assembly bolts (M10, Length:65 mm) (2 25. Install gear pump (44) to body H (34). Tighten bolts
used) to the mounting holes (a) (2 places) of socket (46) (2 used) and spring washers (45) (2 used).
bolt (38).
l : 13 mm
j : 17 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
a
a
34
WADB-03-05-002
a- Mounting hole of socket bolt (38)
W3-4-2-6
Removal and Installation of Control Valve
1, 2
5 4
WACG90-03-05-004
WACG90-04-03-001
11, 12
IMPORTANT: The hoses and pipes contain hydraulic 6 13 7

Removal

(Refer to W1-4-1.)
dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
10 9 8 WACG90-03-05-007
2. Remove the canopy. (Refer to W3-1-1.)

3. Remove bolt (11) and washer (12). Remove floor 5. Remove bolts, washers (7) (3 used) and bolt, washer
mat (1) and plate (2). (8). Remove covers (13, 6).
j : 13 mm j : 17 mm
4. Remove bolts, washers (3, 4) (2 used for each). 6. Remove bolts, washers (9) (2 used). Remove bracket
Remove cover (5). (10).
j : 17 mm j : 17 mm
W3-5-1-1
5 3 5
WACC50-03-05-008
2
WACG90-03-05-006
7. Remove bolts, washers (2) (4 used). Remove support

(1).
j : 19 mm
8. Remove clip bands (5) (3 used).
9. Disconnect hose (3).
j : 22 mm
W3-5-1-2
3 3 3 3
WACC50-03-05-005 WACC50-03-05-006
1 2 1 4
dCAUTION: Remove cover (2) while holding it. Do

not drop cover (2).
(2).
j : 17 mm
11. Disconnect hoses (3) (42 used) from control valve
(4).
j : 17 mm, 19 mm, 27 mm
W3-5-1-3
5 View A
1 2
1
3
WACC50-03-05-007 WACC50-03-05-009
2 6 6
12. Remove bolts, washers (3) (4 used).
j : 17 mm
dCAUTION:
30 kg (67 lb)
The control valve (5) assembly weight:
13. Attach nylon slings onto control valve (5). Hoist and
hold control valve (5).
14. Lift the control valve (5) assembly a little. Slide and
place the control valve (5) assembly to the rear side.
15. Remove bolts, washers (6) (4 used). Remove control
valve (5) from plate (2).
j : 17 mm

bolt, washer (6).
16. Remove the adapters with control valve (5) attached
if necessary.
W3-5-1-4
5
View A
1 2
WACC50-03-05-007 WACC50-03-05-009
2 6 6

Installation
1. Install all removed adapters to control valve (5).
dCAUTION:
30 kg (67 lb)
The control valve (5) assembly weight:
2. Attach nylon slings onto control valve (5). Hoist

and hold control valve (5). Apply LOCTITE #263
or equivalent to bolts, washers (6) (4 used). Install
control valve (5) to plate (2) with bolts, washers (6)
(4 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Lift the control valve (5) assembly a little. Slide the
control valve (5) assembly to forward and fit the
mounting holes.
4. Install the plate (2) assembly to main frame (1) with
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-1-5
3 3 3 3
WACC50-03-05-006 WACC50-03-05-005
4 1 2 1
5. Connect hoses (3) (42 used) to control valve (4).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
j : 27 mm
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-1-6
5 3 5
WACC50-03-05-008
2
WACG90-03-05-006
7. Connect hose (3).
j : 22 mm
m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

8. Install clip bands (5) (3 used).
9. Install support (1) with bolts, washers (2) (4 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-7
6 13 7 3
5 4
WACG90-03-05-004
10 9 8 WACG90-03-05-007
10. Install bracket (10) with bolts, washers (9) (2 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft) 1, 2

11. Install covers (6, 13) with bolt, washer (8) and bolts,
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

12. Install cover (5) with bolts, washers (3, 4) (2 used for
each).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

WACG90-04-03-001
14. Install plate (2). Install floor mat (1) with washer (12) 11, 12
and bolt (11).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-5-1-8
Disassembly and Assembly of Control Valve
6, 11 3 1
A
5
4
19
3
2
1 1a 13 1
9 15 14
17 B
10 16
21 18
20
8 20
3 21
14 3
1
15 13 1
1b 14
22 9 C
17
21 16
20
18
13
3 20
14 3 21
79
1
1 D
1c 15
9 13
23 16
21 17
18
20 24
13 20
25 14
3 21
14 3
1
15
1d 16
9
26 17 1
16 E
21 76 80, 81
20 17
13 18 7 6, 11
13
7
20
14
3 21
3
14 1e
1
32
21
20
13
6, 11
WACG90-03-05-001
W3-5-2-1
20 1
33 21 F
36 15
35 16
34 a
17
9 18
33 13
38 14
3
39
14
21 40 13 1
b G
16 14
1 42
1f 6, 11 3
43
9
3
20
20 25
13 21
3 24
14
47
1 1g H
46 9
21
9 1
20 47
13 I
6, 11 14
3
1h
13
24
20
25 21
3 33 1 J
14 9
15
1
1i
51 16 13
21 17 20
20 33 18 14
21 15
13 3 16
3 15 17 1 K
14 16 31 20
1 1j 17
9 79 21
75 18
21
20 33
13 13
14
3
3 1k
14
1
78 5
21
20 77
13
WACG90-03-05-002
W3-5-2-2
A- Flow Combiner Valve Section E- Auxiliary Section I- Travel (Left) Section b- Arm Regenerative Valve
B- Blade Section F- Arm Section J- Boom Section
C- Swing Section G- Travel (Right) Section K- Bucket Section
D- Boom Swing Section H- Inlet Section a- Check Valve
1a Body (Flow Combiner Valve) 5- Nut (8 Used) 21- Spring Seat (19 Used) 42- Plug
1b Body (Blade) 6- Plug (5 Used) 22- Spool 43- Spool
1c Body (Swing) 7- Plug (2 Used) 23- Spool 46- Spool
1d Body (Boom Swing) 8- Cover 24- Spring (3 Used) 47- Main Relief Valve (2 Used)
1e Body (Auxiliary) 9- O-Ring (10 Used) 25- Check Valve (3 Used) 51- Spool
1f Body (Arm) 10- Spool 26- Spool 75- Spool
1g Body (Travel (Right) ) 11- O-Ring (5 Used) 31- Check Valve 76- Check Valve
1h Body (Inlet) 13- Cover (18 Used) 32- Spool 77- Rod (4 Used)
1i Body (Travel (Left) ) 14- Spring (18 Used) 33- Overload Relief Valve (5 Used) 78- Spool
1j Body (Boom) 15- Plug (9 Used) 34- O-Ring 79- Make-Up Valve (2 Used)
1k Body (Bucket) 16- O-Ring (10 Used) 35- Orifice 80- Plug (2 Used)
1- Socket Bolt (40 Used) 17- Spring (9 Used) 36- O-Ring 81- O-Ring (2 Used)
2- Spring 18- Check Valve (7 Used) 38- Plug
3- O-Ring (20 Used) 19- Cover 39- Check Valve
4- Main Relief Valve 20- Spring Seat (19 Used) 40- Spring
W3-5-2-3
(Blank)
W3-5-2-4
Disassembly of Body
6, 11
5 A
4
9
1a
15
16 B
17
18
15
1b 16
17 C
18
9
79
1c 15 D
16
17
18
24
25
9
15
1d 16
15 17
16 76 E
17 80, 81
18 7
1e
WACG90-03-05-001
W3-5-3-1
15
36 16 33 F
34 17
18
9
33
39
40
16
42
1f G
6, 11
9
25
24 47
H
1g
9
9
47
I
6, 11
1h
24
25 33
9
15 J
1i 16
17
18
33 9
15
15 16
16 17 K
1j 17 31 79
18
33
1k
5
77
WACG90-03-05-002
W3-5-3-2
A- Flow Combiner Valve Section D- Boom Swing Section G- Travel (Right) Section J- Boom Section
B- Blade Section E- Auxiliary Section H- Inlet Section K- Bucket Section
C- Swing Section F- Arm Section I- Travel (Left) Section
1a- Body (Flow Combiner Valve) 1k- Body (Bucket) 18- Check Valve (7 Used) 47- Main Relief Valve (2 Used)
1b- Body (Blade) 4- Main Relief Valve 24- Spring (3 Used) 76- Check Valve
1c- Body (Swing) 5- Nut (8 Used) 25- Check Valve (3 Used) 77- Rod (4 Used)
1d- Body (Boom Swing) 6- Plug (5 Used) 31- Check Valve 79- Make-Up Valve (2 Used)
1e- Body (Auxiliary) 7- Plug (2 Used) 33- Overload Relief Valve (5 Used) 80- Plug (2 Used)
1f- Body (Arm) 9- O-Ring (10 Used) 34- O-Ring 81- O-Ring (2 Used)
1g- Body (Travel (Right) ) 11- O-Ring (5 Used) 36- O-Ring
1h- Body (Inlet) 15- Plug (9 Used) 39- Check Valve
1i- Body (Travel (Left) ) 16- O-Ring (10 Used) 40- Spring
1j- Body (Boom) 17- Spring (9 Used) 42- Plug
W3-5-3-3
Disassembly of Body
dCAUTION: Control valve weight: 26 kg (58 lb) IMPORTANT: Do not disassemble make-up valve
(79).
IMPORTANT: Do not remove plug (6). IMPORTANT: Do not disassemble overload relief
1. Remove plugs (15) (9 used) from sections (B, C, D, E, valves (7, 33). If it has been disassembled,
F, J, K). Remove O-rings (16) (9 used) from plugs (15) pressure should be adjusted. (Refer to T4-5 in the
(9 used). separated volume, T/M.)
j : 14 mm 8. Remove overload relief valves (33) (5 used), plugs
(7, 80) (2 used for each), O-rings (81) (2 used), and
2. Remove springs (17) (9 used) from sections (B, C, D, make-up valves (79) (2 used) from sections (D, E, F, J,
E, F, J, K). K).
3. Remove check valves (18) (7 used) from sections (B,
j : 24 mm
C, D, E, F, J, K).
IMPORTANT: Do not drop O-rings (9, 34, 36), check
4. Remove check valves (31, 76) from sections (E, K).
valve (25), and spring (24) when removing rod
IMPORTANT: Do not disassemble main relief valves (77).
(4, 47). If it has been disassembled, pressure 9. Remove nuts (5) (8 used) and rods (77) (4 used)
should be adjusted. (Refer to T4-5 in the separated from the body. Divide the control valves into each
volume, T/M.) section.
5. Remove main relief valve (4) and main relief valves
(47) (2 used) from sections (A, H). j : 13 mm
10. Remove O-rings (9) (10 used) and O-rings (34, 36)
j : 24 mm
from each section.
6. Remove plug (42) from section (F). Remove O-ring
11. Remove springs (24) (3 used) and check valves (25)
(16) from plug (42).
(3 used) from sections (D, G, I).
l : 6 mm
7. Remove spring (40) and check valve (39) from
section (F).
W3-5-3-4
Assembly of Body
6, 11
79 7 33 47 33 79
A B C D E F G H I J K
77
WACG90-03-05-003
4 6, 11 7 33 47 33 33
a- Machine Front Side
Section A (Flow Combiner Valve) Section B (Blade)
16
6, 11 15
1a
17 1b
18
WACB-03-05-002 WACB-03-05-003
W3-5-3-5
Section C (Swing) Section D (Boom Swing)
16 16
15 15
1d
17 1c 17
18 18
WACB-03-05-004 WACB-03-05-005
Section E (Auxiliary) Section F (Arm)
80, 81
76
16
16
15
17 1f
1e
15
17
17 18
16
16
18 42
80, 81
39 40
WACB-03-05-006 WACB-03-05-007
W3-5-3-6
Section G (Travel (Right)) Section H (Inlet)
6, 11 1h
1g
WACB-03-05-008 WACB-03-05-009
Section I (Travel (Left))
6, 11
1i
WACB-03-05-010
W3-5-3-7
Section J (Boom) Section K (Bucket)
31
16 16
17
15
1j
15 1k
17
18
17
16
18
WACB-03-05-011 WACB-03-05-012
W3-5-3-8
A- Flow Combiner Valve Section D- Boom Swing Section G- Travel (Right) Section J- Boom Section
B- Blade Section E- Auxiliary Section H- Inlet Section K- Bucket Section
C- Swing Section F- Arm Section I- Travel (Left) Section
1a- Body (Flow Combiner Valve) 1k- Body (Bucket) 18- Check Valve (7 Used) 47- Main Relief Valve (2 Used)
1b- Body (Blade) 4- Main Relief Valve 24- *Spring (3 Used) 76- Check Valve
1c- Body (Swing) 5- Nut (8 Used) 25- *Check Valve (3 Used) 77- Rod (4 Used)
1d- Body (Boom Swing) 6- Plug (5 Used) 31- Check Valve 79- Make-Up Valve (2 Used)
1e- Body (Auxiliary) 7- Plug (2 Used) 33- Overload Relief Valve (5 Used) 80- Plug (2 Used)
1f- Body (Arm) 9- *O-Ring (10 Used) 34- *O-Ring 81- O-Ring (2 Used)
1g- Body (Travel (Right) ) 11- O-Ring (5 Used) 36- *O-Ring
1h- Body (Inlet) 15- Plug (9 Used) 39- Check Valve
1i- Body (Travel (Left) ) 16- O-Ring (10 Used) 40- Spring
1j- Body (Boom) 17- Spring (9 Used) 42- Plug
fNOTE: As for the item with mark *, refer to W3-5-3-1 and W3-5-3-2.
W3-5-3-9
Assembly of Body
IMPORTANT: Before assembling, apply hydraulic oil 8. Install main relief valve (4) and main relief valves
onto parts in order to prevent them from seizing. (47) (2 used) to sections (A, H).
1. Install check valves (25) (3 used) and springs (24) (3
j : 24 mm
used) to sections (D, G, I).
2. Install O-rings (9) (10 used) and O-rings (34, 36) to m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51
each section. lbf·ft)
3. Place bodies (1a to 1k) of each section in the 9. Install check valves (31, 76) to sections (E, K). Install
original sequence before disassembling. Tighten check valves (18) (7 used) to sections (B, C, D, E, F, J,
bodies (1a to 1k) with rods (77) (4 used) and nuts (5) K).
(8 used). 10. Install springs (17) (9 used) to sections (B, C, D, E, F, J,
K).
j : 13 mm
11. Install O-rings (16) (9 used) to plugs (15) (9 used).
m : 26.5 to 29.4 N·m (2.7 to 2.9 kgf·m, 19.5 to 22 Install plugs (15) (9 used) to sections (B, C, D, E, F, J,
lbf·ft) K).
4. Install overload relief valves (33) (5 used) to sections
j : 14 mm
(F, J, K).
m : 29.4 N·m (2.9 kgf·m, 21.5 lbf·ft)
j : 24 mm
12. Install check valve (39) and spring (40) to section (F).
m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51
lbf·ft) 13. Install O-ring (16) to plug (42). Install plug (42) to
section (F).
5. Install plugs (7) (2 used) to section (E).
l : 6 mm
j : 24 mm
m : 29.4 N·m (2.9 kgf·m, 21.5 lbf·ft)
m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51
lbf·ft)
6. Install plugs (80) (2 used) and O-rings (81) (2 used)
to section (E).
l : 8 mm
m : 37 to 41 N·m (3.7 to 4.1 kgf·m, 27.5 to 30

lbf·ft)
7. Install make-up valves (79) (2 used) to sections (D,
K).
j : 24 mm
m : 59 to 69 N·m (5.9 to 6.9 kgf·m, 44 to 51

lbf·ft)
W3-5-3-10
Disassembly of Spool
fNOTE: The illustration shows the arm.
20
21
19
14
3 1g
14
13
1
43
21
20
WADB-03-06-005
a- Arm Regenerative Valve

1g- Body (Arm) 13- Cover 20- Spring Seat (2 Used)
1- Socket Bolt (4 Used) 14- Spring (2 Used) 21- Spring Seat (2 Used)
3- O-Ring (2 Used) 19- Cover 43- Spool
W3-5-4-1
Disassembly of Spool
fNOTE: The arm spool is explained here.
IMPORTANT: Do not drop spring (14) and spring

seats (20, 21) when removing covers (13, 19).
1. Remove socket bolts (1) (4 used) from covers (13,
19).Remove covers (13, 19) and O-rings (3) (2 used)
from body (1g).
l : 4 mm
2. Remove springs (14) (2 used) and spring seats (20)
(2 used) from covers (13, 19).
3. Remove spring seats (21) (2 used) from spool (43).
4. Turn and remove spool (43) from body (1g).
W3-5-4-2
Assembly of Spool
fNOTE: The illustration shows the arm.
20 19 3 21 14 13
T577-03-03-005
14 1 21 a 43 3 20
1g
a- Arm Regenerative Valve

1g- Body 13- Cover 20- Spring Seat (2 Used)
1- Socket Bolt (4 Used) 14- Spring (2 Used) 21- Spring Seat (2 Used)
3- O-Ring (2 Used) 19- Cover 43- Spool
W3-5-4-3
Assembly of Spool
fNOTE: The arm spool is explained here.

1. Turn and install spool (43) to body (1g).
2. Install spring seats (21) (2 used) to spool (43).
3. Install spring seats (20) (2 used), springs (14) (2
used), and O-rings (3) (2 used) to covers (13, 19).
4. Install cover (13) to body (1g) with socket bolts (1) (2
used).
l : 4 mm
m : 7.3 to 10 N·m (0.7 to 1 kgf·m, 5.4 to 7.4 lbf·ft)

5. Install cover (19) in the same way as step 4.
W3-5-4-4
Removal and Installation of Swing Device
3, 4
5, 6 WACG90-04-03-001

Removal

(Refer to W1-4-1.)
3. Remove bolt (5), washer (6). Remove floor mat (3)
and plate (4).
j : 13 mm
W3-6-1-1
2
3
4, 5
WACC50-03-06-002 WACC50-03-06-003
4. Disconnect hoses (2) (6 used) from swing device (3).
j : 17 mm, 19 mm, 22 mm
j : 17 mm, 27 mm
dCAUTION: Swing device (3) weight: 24 kg (53 lb)

6. Attach nylon slings onto swing device (3). Hoist and
hold swing device (3).
7. Remove bolts (4) (4 used) and washers (5) (4 used).
Remove swing device (3) from the main frame.
j : 19 mm

bolt (4).
8. Remove the adapters with swing device (3)
attached if necessary.
W3-6-1-2
2
3
4, 5
WACC50-03-06-003 WACC50-03-06-002
IMPORTANT: Check the angles to connect the hose 5. Connect hoses (2) (6 used) to swing device (3).
j : 17 mm
Installation m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
1. Install all removed adapters to swing device (3).
j : 19 mm
dCAUTION: Swing device (3) weight: 24 kg (53 lb)
m : 30 N·m (3 kgf·m, 22 lbf·ft)
2. Attach nylon slings onto swing device (3). Hoist
swing device (3). j : 22 mm
3. Apply LOCTITE #263 or equivalent to bolts (4) (4 m : 40 N·m (4 kgf·m, 29.5 lbf·ft)
used). Install swing device (3) to the main frame
with bolts (4) (4 used) and washers (5) (4 used). 6. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
j : 19 mm IMPORTANT: Check the hydraulic oil level. Start the
m : 110 N·m (11 kgf·m, 81 lbf·ft) engine and check for any oil leaks.
4. Connect hoses (1) (3 used).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
j : 27 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)
W3-6-1-3
3, 4
5, 6 WACG90-04-03-001
and bolt (5).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W3-6-1-4
Disassembly of Swing Reduction Gear
8
7
6
5 16
4 17
3
2
15
14
13
12
11
10
9 WACB-03-06-001
1- Shaft 6- Roller Bearing 11- Inner Race (3 Used) 16- Swing Motor
2- Seal Ring 7- Collar (2 Used) 12- Needle Bearing (54 Used) 17- Socket Bolt (4 Used)
3- Roller Bearing 8- Plate 13- Planetary Gear (3 Used)
4- Housing 9- Carrier 14- Thrust Plate
5- Oil Seal 10- Thrust Plate 15- O-Ring
W3-6-2-1
Disassembly of Swing Reduction Gear
dCAUTION: There may be pressure accumulated

inside of the swing device. Loosen the air bleed
plug slowly. Release any remaining pressure
completely. Remove the drain plug and drain gear
oil. If the air bleed plug is loosened suddenly, the
plug may be fly out and gear oil may gush out.
Keep body and face away from plug.
1. Remove plug and O-ring from housing (4). Drain
gear oil from the swing device.
l : 6 mm
IMPORTANT: Do not remove shaft (1), seal ring (2),
roller bearings (3, 6), oil seal (5), and collar (7).
Replace them as the housing (4) assembly.
2. Remove socket bolts (17) (4 used). Remove swing
motor (16) from housing (4).
l : 6 mm
fNOTE: THREEBOND #1305 has been applied on socket

bolts (17) (4 used).
3. Remove O-ring (15) from housing (4).
4. Remove thrust plate (14) from housing (4).
5. Remove planetary gears (13) (3 used), needle
bearings (12) (54 used), inner races (11) (3 used),
thrust plate (10), and carrier (9) from housing (4).
6. Remove plate (8) from shaft (1).
W3-6-2-2
Assembly of Swing Reduction Gear
16
17
14
15
13
12
10 11
9
7 8
3 4
2
1
TACC-03-02-001
1- Shaft 6- Roller Bearing 11- Inner Race (3 Used) 16- Swing Motor
2- Seal Ring 7- Collar (2 Used) 12- Needle Bearing (54 Used) 17- Socket Bolt (4 Used)
3- Roller Bearing 8- Plate 13- Planetary Gear (3 Used)
4- Housing 9- Carrier 14- Thrust Plate
5- Oil Seal 10- Thrust Plate 15- O-Ring
W3-6-2-3
Assembly of Swing Reduction Gear 6. Add hydraulic oil (ISO VG46 or equivalent) to
housing (4) until it reaches 3 to 4 mm below the
upper surface of thrust plate (14).
IMPORTANT: Shaft (1,), seal ring (2), roller bearings 7. Install O-ring (15) to housing (4).
(3, 6), oil seal (5), and collar (7) have been installed 8. Apply THREEBOND #1305 onto socket bolts (17) (4
in housing (4). used). Install swing motor (16) to housing (4) with
1. Install plate (8) to shaft (1). socket bolts (17) (4 used).
2. Install carrier (9) to shaft (1). l : 6 mm
IMPORTANT: Install inner race (11) with the
m : 29.4±2.9 N·m (2.9±0.3 kgf·m, 21.5±0.2 lbf·ft)
chamfered surfaces facing to the carrier (9) side.
3. Install inner races (11) (3 used), thrust plate (10), and 9. Install O-ring to plug. Install plug to housing (4).
planetary gears (13) (3 used) to carrier (9).
l : 6 mm
4. Install needle bearings (12) (18 used) to each inside
of planetary gears (13) (3 used). m : 29.4±2.9 N·m (2.9±0.3 kgf·m, 21.5±0.2 lbf·ft)
5. Install thrust plate (14) to carrier (9).
11
WACB-03-06-003
W3-6-2-4
Disassembly of Swing Motor
8
7
6
5
4
3
2 26
1
3
31
25
27
24 28
29 30
23
22
21
20
19
18
17
16
14
15
14
13 WACB-03-06-002
12
11
10
9
1- Socket Bolt (8 Used) 9- Plunger (9 Used) 17- Spring Assembly 25- Spring Pin
2- Plate 10- Retainer 18- Brake Piston 26- Casing
3- Pin (3 Used) 11- Holder 19- O-Ring 27- Check Valve (2 Used)
4- Filter (2 Used) 12- Pin (3 Used) 20- O-Ring 28- O-Ring (2 Used)
5- Ball Bearing 13- Rotor 21- Disc Plate 29- Spring (2 Used)
6- Shaft 14- Retainer (2 Used) 22- Valve Plate 30- Plug (2 Used)
7- Pin 15- Spring 23- O-Ring 31- Relief Valve (2 Used)
8- Swash Plate 16- Retaining Ring 24- Ball Bearing
W3-6-3-1
Disassembly of Swing Motor

IMPORTANT: As the setting changes, do not IMPORTANT: Plunger (9), retainer (10), holder (11),
disassemble relief valve (31). pin (12), retainer (14), spring (15), retaining ring
1. Remove relief valves (31) (2 used) from casing (26). (16), and valve plate (22) cannot be replaced
individually. Replace them as the rotor (13)
j : 36 mm assembly.
IMPORTANT: When removing plate (2), do not drop IMPORTANT: When removing the rotor (13)
swash plate (8). assembly, do not drop valve plate (22).
2. Remove socket bolts (1) (8 used) from plate (2). 6. Remove the rotor (13) assembly from casing (26).
Remove the plate (2) assembly from casing (26). 7. Remove plungers (9) (9 used), retainer (10), holder
(11), and pins (12) (3 used) from rotor (13).
l : 8 mm
8. Remove retaining ring (16), spring (15), and
IMPORTANT: Replace swash plate (8) and pin (7) as
retainers (14) (2 used) from rotor (13).
an assembly.
3. Remove swash plate (8), the shaft (6) assembly,
filters (4) (2 used), and pins (3) (3 used) from plate
dCAUTION: When removing brake piston (18) by
using air, hold brake piston (18) with a cloth in
(2). order not to fly out.
9. Apply air through port PP (a) of casing (26). Raise
fNOTE: If it is difficult to remove the shaft (6) assembly,
and remove brake piston (18) from casing (26).
tap shaft (6) from the swing reduction gear side by using
a plastic hammer when removing.
a
IMPORTANT: Do not remove ball bearing (5) unless
necessary.
4. Remove ball bearing (5) from shaft (6) by using a
press.
WACB-03-06-004
5. Remove O-ring (23) and spring assembly (17) from
a- Port PP
casing (26).
10. Remove O-rings (19, 20) from brake piston (18).
W3-6-3-2
11. Remove disc plate (21) and valve plate (22) from
casing (26).
IMPORTANT: Spring pin (25), check valve (27),
spring (29), and plug (20) cannot be replaced
individually. Replace them as the casing (26)
assembly.
12. Remove plug (30) from casing (26). Remove O-ring
(28) from plug (30).
l : 8 mm
13. Remove spring (29) and check valve (27) from
casing (26).
14. Remove other check valve (27) in the same way as
step 12 to step 13.
15. Remove ball bearing (24) from casing (26).
W3-6-3-3
Assembly of Swing Motor
15 22 6 24 25 26
13
12 16
21
20 14
9 10
18 11
8
23
17
19 2
3 1
4
7
5
WACB-03-06-008
31
30
WACB-03-06-009
29 27 28
1- Socket Bolt (8 Used) 9- Plunger (9 Used) 17- Spring Assembly 25- Spring Pin
2- Plate 10- Retainer 18- Brake Piston 26- Casing
3- Pin (3 Used) 11- Holder 19- O-Ring 27- Check Valve (2 Used)
4- Filter (2 Used) 12- Pin (3 Used) 20- O-Ring 28- O-Ring (2 Used)
5- Ball Bearing 13- Rotor 21- Disc Plate 29- Spring (2 Used)
6- Shaft 14- Retainer (2 Used) 22- Valve Plate 30- Plug (2 Used)
7- Pin 15- Spring 23- O-Ring 31- Relief Valve (2 Used)
8- Swash Plate 16- Retaining Ring 24- Ball Bearing
W3-6-3-4
Assembly of Swing Motor

IMPORTANT: Before assembling, apply hydraulic oil 7. Apply grease onto O-rings (19, 20). Install the brake
onto parts in order to prevent them from seizing. piston (18) assembly and plate (2) with pins (3) (3
1. Install ball bearing (24) to casing (26) by using a used).
press. 8. Install the brake piston (18) assembly to casing (26).
2. Apply grease onto O-rings (28) (2 used). 9. After installing, remove plate (2) and pins (3) (3
3. Install check valve (27) and spring (29) to casing used) from brake piston (18).
(26). Install O-ring (28) to plug (30). Install plug (30) 10. Install retainers (14) (2 used) and spring (15) to rotor
to casing (26). (13). Secure them with retaining ring (16).
l : 8 mm 11. Install plungers (9) (9 used) to retainer (10).
m : 58.8±2.9 N·m (5.9±0.3 kgf·m, 43±2.1 lbf·ft) 12. Install pins (12) (3 used), holder (11), and the
plunger (9) assembly to rotor (13).
4. Install other check valve (27) in the same way as
step 3. 12
IMPORTANT: Check the direction to install valve
plate (22).
5. Install valve plate (22) to casing (26) with steel
surface side (a) of valve plate (22) facing to the valve
casing (26) side. Install disc plate (21) to casing (26).
22 WACB-03-06-006
13. Install the rotor (13) assembly, spring assembly (17),

a and O-ring (23) to casing (26).
a- Steel Surface Side WACB-03-06-005 14. Install ball bearing (5) to shaft (6) by using a press.
6. Install O-rings (19, 20) to brake piston (18).
5
WACB-03-06-007
W3-6-3-5
IMPORTANT: Apply grease onto the back of swash

plate (8) and plate (2) in order not to fall off.
15. Install filters (4) (2 used), pins (3) (3 used), the shaft
(6) assembly, and swash plate (8) to plate (2).
16. Fit shaft (6) to the hole of the rotor (13) assembly.
Install shaft (6) to the rotor (13) assembly. Install the
plate (2) assembly to casing (26) with socket bolts
(1) (8 used).
l : 8 mm
m : 58.8±2.9 N·m (5.9±0.3 kgf·m, 43±2.1 lbf·ft)

17. Install relief valves (31) (2 used) to casing (26).
l : 36 mm
m : 147.1±14.7 N·m (14.5±1.5 kgf·m, 109±11

lbf·ft)
W3-6-3-6
Group 7 Pilot Valve
Removal and Installation of Pilot Valve (Left)
11
1 2
3
2 1 4
2
10 5
2 10 5 12
8 6
9 7 13
WABAA0-03-07-001 WABAA0-03-07-002
IMPORTANT: The hose and pipe contain hydraulic oil. 5. Remove bolts, washers (10) (2 used) and screws (8)
When removing the hose and pipe, receive oil with (2 used). Remove cover (9) and plates (5) (2 used).
a container in order to avoid spilling oil.
j : 10 mm
and pipes have been disconnected. In addition, 6. Remove clip band (7) and glass wool (6).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
2. Raise boot (12). Loosen lock nut (13). Remove the
lever (11) assembly and boot (12) from the pilot
valve.
j : 19 mm
3. Remove caps (2) (4 used) from covers (3, 9).
4. Remove bolts, washers (1) (2 used) and screw (4).
Remove cover (3).
j : 10 mm
W3-7-1-1
Group 7 Pilot Valve
1 1
WABAA0-03-07-003
4 2, 3

(Refer to W1-4-1.)
7. Disconnect hoses (4) (6 used) from pilot valve (5).
j : 17 mm
8. Put the matching marks on frame (6) and pilot valve
(5). Remove socket bolts (2) (4 used) and washers
(3) (4 used) from frame (6). Remove brackets (1) (2
used) and pilot valve (5) from frame (6).
l : 5 mm
9. Remove the adapters with pilot valve (5) attached if
necessary.
W3-7-1-2
Group 7 Pilot Valve
1 1
WABAA0-03-07-003
4 2, 3
Installation
1. Install all removed adapters to pilot valve (5).
2. Fit the matching marks on frame (6) and pilot valve
(5). Install pilot valve (5) to frame (6) with washers
(3) (4 used) and socket bolts (2) (4 used).
l : 5 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

3. Connect hoses (4) (6 used) to pilot valve (5).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W3-7-1-3
Group 7 Pilot Valve
11
1 2
3
2 1 4
2
10 5
2 10 5 12
8 6
9 7 13
WABAA0-03-07-001 WABAA0-03-07-002
4. Secure glass wool (6) to the pilot valve with clip 7. Install caps (2) (4 used) to covers (3, 9).
band (7).
8. Install the lever (11) assembly and boot (12) to the
5. Install cover (9) and plates (5) (2 used) with bolts, pilot valve. Secure the lever (11) assembly to the
washers (10) (2 used) and screws (8) (2 used). pilot valve with lock nut (13).
j : 10 mm j : 19 mm
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3.0 lbf·ft) m : 90 N·m (9 kgf·m, 66 lbf·ft)
6. Install cover (3) with bolts, washers (1) (2 used) and
screw (4).
j : 10 mm
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3.0 lbf·ft)
W3-7-1-4
Group 7 Pilot Valve
Removal and Installation of Pilot Valve (Right)
1
2
WACC50-03-07-001

oil. When removing the hoses and pipes, receive dCAUTION: Seat (2) weight: 24 kg (53 lb)
oil with a container in order to avoid spilling oil. 2. Remove socket bolts (1) (4 used). Remove seat (2).
l : 6 mm
Removal
W3-7-2-1
Group 7 Pilot Valve
1
WACDA0-03-07-004
3. Remove bolts, washers (2, 3) (2 used for each).

Remove cover (1).
j : 13 mm
W3-7-2-2
Group 7 Pilot Valve
6 3
WACG90-03-07-001 WACDA0-03-07-005
5
4. Disconnect connectors (1) (4 used).

Remove the cover (6) assembly.
j : 13 mm
W3-7-2-3
Group 7 Pilot Valve
1
WACG90-03-07-002 WACC50-03-07-016
6. Remove socket bolts (1) (2 used). Remove armrest 7

(2).
l : 5 mm
7. Raise boot (4). Loosen lock nut (5). Remove clip
bands (7) (2 used) from the shaft mounting part of
the pilot valve. Disconnect connector (6).
8. Remove the lever (3) assembly and boot (4) from
the pilot valve.
j : 22 mm
WACC50-03-07-017
W3-7-2-4
Group 7 Pilot Valve
11
1 2 11
12
1 3
2 4
2 13, 16
10
10 13, 16
2 5 5
14
9 8 6
7
WABAA0-03-07-008 WACC50-03-07-007
15 15
9. Remove caps (2) (4 used) from covers (3, 9).

10. Remove bolts, washers (1) (2 used) and screw (4).
Remove cover (3).
j : 10 mm
11. Remove bolts, washers (10) (2 used) and screws (8)
(2 used). Remove cover (9) and plates (5) (2 used).
j : 10 mm
12. Remove clip band (6) and glass wool (7).

(Refer to W1-4-1.)
13. Disconnect hoses (15) (6 used) from pilot valve (14).
j : 17 mm
14. Put the matching marks on frame (12) and pilot
valve (14). Remove socket bolts (13) (4 used) and
washers (16) (4 used) from frame (12). Remove
brackets (11) (2 used) and pilot valve (14) from
frame (12).
l : 5 mm
15. Remove the adapters with pilot valve (14) attached
if necessary.
W3-7-2-5
Group 7 Pilot Valve
11
11 1 2
12
1 3
2 4
13, 16 2
10
13, 16 10
2 A 5 5
14
9 8 6
7
WACC50-03-07-007 WABAA0-03-07-008
15 15
IMPORTANT: Check the angles to connect the hose 5. Install cover (9) and plates (5) (2 used) with bolts,
and to install the adapter. (Refer to W1-7-1.) washers (10) (2 used) and screws (8) (2 used).
j : 10 mm
Installation
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)
1. Install all removed adapters to pilot valve (14).
2. Fit the matching marks on frame (12) and pilot valve
(14). Install pilot valve (14) and brackets (11) (2 used)
to frame (12) with washers (16) (4 used) and socket 6. Install cover (3) with bolts, washers (1) (2 used) and
bolts (13) (4 used). screw (4).
l : 5 mm j : 10 mm
m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft) m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)
3. Connect hoses (15) (6 used) to pilot valve (14). 7. Install caps (2) (4 used) to covers (3, 9).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

4. Secure glass wool (7) to pilot valve (14) with clip
band (6).
W3-7-2-6
Group 7 Pilot Valve
7
3
WACC50-03-07-017 WACC50-03-07-016
2
8. Install boot (4) and the lever (3) assembly to the
pilot valve. Secure the lever (3) assembly with lock
nut (5).
j : 22 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)

9. Connect connector (6). Secure the wire harness to
the shaft mounting part of the pilot valve with clip
band (7).
10. Install arm rest (2) with socket bolts (1) (2 used).
l : 5 mm
m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)
1
WACG90-03-07-002
W3-7-2-7
Group 7 Pilot Valve
6 3
WACG90-03-07-001 WACDA0-03-07-005
5
11. Install the cover (6) assembly with bolts, washers (3,
5) (2 used for each).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

12. Connect connectors (1) (4 used).
W3-7-2-8
Group 7 Pilot Valve
1
WACDA0-03-07-004
each).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-7-2-9
Group 7 Pilot Valve
1
2
WACC50-03-07-001

l : 6 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-7-2-10
Group 7 Pilot Valve
Removal and Installation of Travel Pilot Valve
1, 2
6, 7 WACDA0-04-03-001 WACC50-03-05-001
5 4

Removal
2. Remove bolt (6) and washer (7). Remove floor mat
(1) and plate (2).
j : 13 mm
Remove cover (5).
j : 17 mm
W3-7-3-1
Group 7 Pilot Valve
1
3 4
WACC90-03-07-002
WACDA0-03-07-003 6 4 4
2

(2).
j : 13 mm

(Refer to W1-4-1.)
5. Disconnect connector (6) and hoses (4) (15 used)
from pilot valve (3).
j : 17 mm
W3-7-3-2
Group 7 Pilot Valve
1
9
10
2
11
3
4
2 8
7
6
WACC50-03-07-014

lever (1, 9) assemblies.
j : 17 mm
7. Remove unions (5) (3 used).
j : 19 mm
8. Remove the filter (6) assembly.
j : 19 mm
9. Remove the adapter (4) assembly, adapter (7), and
elbow (8).
j : 19 mm
10. Remove socket bolts (10) (2 used) and washers (11)
(2 used). Remove pilot valve (3) from the floor.
l : 8 mm
necessary.
W3-7-3-3
Group 7 Pilot Valve
1
9
10
2
11
3
4
2 8
7
6
WACC50-03-07-014
IMPORTANT: Check the angles to connect the hose 4. Install the filter (6) assembly.
j : 19 mm
Installation m : 30 N·m (3 kgf·m, 22 lbf·ft)
1. Install all adapters which have been removed in 5. Install unions (5) (3 used).
step 11 for removal to pilot valve (3).
j : 19 mm
2. Install pilot valve (3) to the floor with washers (11) (2
used) and socket bolts (10) (2 used). m : 30 N·m (3 kgf·m, 22 lbf·ft)
l : 8 mm 6. Install the lever (1, 9) assemblies with bolts, washers
(2) (4 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
3. Install the adapter (4) assembly, adapter (7), and
elbow (8). m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-7-3-4
Group 7 Pilot Valve
1
3 4
WACC90-03-07-002
6 4 4 WACDA0-03-07-003
2
7. Connect hoses (4) (15 used) and connector (6) to

pilot valve (3).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-7-3-5
Group 7 Pilot Valve
1, 2
6, 7 WACDA0-04-03-001
5 4 WACC50-03-05-001

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

and bolt (6).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-7-3-6
Group 7 Pilot Valve
Removal and Installation of Blade Pilot Valve
WACC50-03-07-009

Removal
(2).
j : 13 mm
W3-7-4-1
Group 7 Pilot Valve
7 3 6
3
6
4
WACC50-03-07-011

lever (7) assembly. dCAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.)
j : 13 mm 4. Disconnect hoses (5) (4 used) from pilot valve (4).
j : 17 mm
5. Remove bolts, washers (6) (2 used). Remove pilot
valve (4) from bracket (8).
j : 13 mm
necessary.
W3-7-4-2
Group 7 Pilot Valve
7 3 6
3
6
4
WACC50-03-07-011
Installation
1. Install all removed adapters to pilot valve (4). 4. Install the lever (7) assembly with bolts, washers (3)
(2 used).
2. Install pilot valve (4) to bracket (8) with bolts,
washers (6) (2 used). j : 13 mm
j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
m : 10 N·m (1 kgf·m, 7.4 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the
3. Connect hoses (5) (4 used) to pilot valve (4).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
W3-7-4-3
Group 7 Pilot Valve
WACC50-03-07-009
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-7-4-4
Group 7 Pilot Valve
Removal and Installation of Boom Swing

Pilot Valve
4
1, 2
5
WACG90-04-03-001
7, 8 WACC50-03-07-008
a- Front Side
IMPORTANT: The hoses and pipes contain hydraulic 3. Disconnect hoses (3) (2 used) from pilot valve (4).
oil with a container in order to avoid spilling oil. j : 17 mm
IMPORTANT: Cap the open ends in case the hoses 4. Disconnect hoses (5) (2 used) from pilot valve (4).
5. Remove adapters (6) (4 used) from pilot valve (4).
hoses, and pipes for assembling. If the clips which j : 19 mm
Removal

(Refer to W1-4-1.)
2. Remove bolt (7) and washer (8). Remove floor mat
(1) and plate (2).
j : 13 mm
W3-7-5-1
Group 7 Pilot Valve
8
7
6 1
2
5
WACC50-03-07-015
6. Remove bolts, washers (2) (2 used). Remove pedal

(8) from bracket (6).
j : 13 mm
7. Remove socket bolts (7) (2 used) and spring washers
(1) (2 used). Remove bracket (6) from pilot valve (4).
l : 6 mm
8. Remove bolts, washers (3) (2 used). Remove pilot
valve (4) and cover (5) from the floor.
j : 13 mm
W3-7-5-2
Group 7 Pilot Valve
8
7
6 1
2
5
WACC50-03-07-015

Installation
1. Install cover (5) and pilot valve (4) to the floor with
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

2. Install bracket (6) to pilot valve (4) with socket bolts
(7) (2 used) and spring washers (1) (2 used).
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Install pedal (8) to pilot valve (4) with bolts, washers
(2) (2 used).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-7-5-3
Group 7 Pilot Valve
4 3, 4
5 WACG90-04-03-001
5, 6
WACC50-03-07-008
4. Install adapters (6) (4 used) to pilot valve (4). IMPORTANT: Check the hydraulic oil level. Start the
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft) and bolt (5).
5. Connect hoses (5) (2 used) to pilot valve (4). j : 13 mm
6. Connect hoses (3) (2 used) to pilot valve (4). m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
W3-7-5-4
Group 7 Pilot Valve
Disassembly of Pilot Valves (Right and Left)
17
16
5
4 3
20
3
2
15
19
14
18
11
12
13
8
7
7
8
WACB50-03-07-001
2- Washer (4 Used) 8- Spring Seat (2 Used) 14- Plate 19- Spool (4 Used)
3- Spring (2 Used) 9- Push Red (4 Used) 15- Joint 20- Bellows
4- Spring (2 Used) 11- Seal (4 Used) 16- Plate
5- Spring (4 Used) 12- Plug (4 Used) 17- Nut
7- Spring Seat (2 Used) 13- O-Ring (4 Used) 18- Casing
W3-7-6-1
Group 7 Pilot Valve
Disassembly of Pilot Valves (Right and Left)

4. Attach a spanner onto the upper part of joint (15).
IMPORTANT: Casing (18) is made of aluminium.
Remove universal joint (15).
Strong force deforms it. Handle it with care.
IMPORTANT: Spool (19) has been selected to match j : 22 mm
the hole on casing (18). The dimensions of springs
5. Remove plate (14).
(3, 4) and spring seat (7, 8) are different. Arrange
the disassembled parts together with the port in IMPORTANT: Do not damage plug (12). Insert a soft
order not to confuse. The port number is stamped rubber between plug (12) and a tool.
on the outer surface of casing (18). 6. Remove plug (12) (4 used) upward by using a pair of
1. Remove bellows (20). pliers. Remove O-rings (13) (4 used) and seals (11) (4
used) from sleeves (12) (4 used).
IMPORTANT: Do not secure casing (18) in a vise when
removing not (17). 7. Remove push rod (9) (2 used) from casing (18).
2. Secure nut (17) in a vise. Turn plate (16) by using a
spanner. Remove nut (17).
j : 22 mm, 32 mm
fNOTE: LOCTITE #262 has been applied on joint (15).

3. Secure the flat surface of casing (18) in a vise.
Remove plate (16) from joint (15).
j : 32 mm
fNOTE: LOCTITE #262 has been applied on joint (15).
W3-7-6-2
Group 7 Pilot Valve
IMPORTANT: The quantity of washer (2) has been

determined for each port during the performance
testing. Do not lose washer (2). Keep washer (2)
carefully in order to install shim (2) to the original
port when assembling.
8. Remove spring seat (7, 8) (2 used for each), springs
(5) (4 used), and springs (3, 4) (2 used for each) from
spools (19) (4 used).
9. 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.
10. Slowly turn and remove spools (19) (4 used) from
casing (18).
W3-7-6-3
Group 7 Pilot Valve
Assembly of Pilot Valves (Right and Left)
17
20
15
16
9
11
12
13
7, 8
3, 4 5
19
18
WACB50-03-07-002
2- Washer (4 Used) 8- Spring Seat (2 Used) 14- Plate 19- Spool (4 Used)
3- Spring (2 Used) 9- Push Red (4 Used) 15- Joint 20- Bellows
4- Spring (2 Used) 11- Seal (4 Used) 16- Plate
5- Spring (4 Used) 12- Plug (4 Used) 17- Nut
7- Spring Seat (2 Used) 13- O-Ring (4 Used) 18- Casing
W3-7-6-4
Group 7 Pilot Valve
Assembly of Pilot Valves (Right and Left)

IMPORTANT: Refer to the table in the left in order to
assemble the parts correctly.
2. Install washer (2), and spring (3) to spool (19). Install
IMPORTANT: The pilot valve is the susceptible
spring (5) to casing (18).
hydraulic component to contamination. Keep the
parts clean when assembling. 3. Install spring seat (7) to spring (5) with the
protrusion up.
fNOTE: The table below shows the relations between
each port and the parts. Do not confuse them when 4. Install other spools (19) (3 used) in the same way as
assembling. step 1 to step 3.
Port No. Spool Shim Push Rod (9)
(19) (2)
1 Same to the Same to the Same to the
2 former one former one former one
3
4
Port No. Springs (5) Springs (3, 4)

1 Same to the Short
2 former one Long
3 Short
4 Long
1. Check the port hole number and insert same spool

(19) before disassembling.
fNOTE: Spool (19) has been selected to match the port

hole. Spool (19) and casing (18) should be replaced as an
assembly.
W3-7-6-5
Group 7 Pilot Valve
IMPORTANT: Check the position to install push rod MPORTANT: Fit the bolt hole on plate (14) to the
(9). screw hole on casing (18).
5. Install push rods (9). 12. Place plate (14) on casing (18). Install joint (15).
After pushing push rods (9) several times by hand,
remove it. Check if spring (3) is located correctly. j : 22 mm
Install push rods (9) to casing (18) after checking.
m : 47.1±2.9 N·m (4.8±0.3 kgf·m, 3.5±2.1 lbf·ft)
6. Install other push rods (9) in the same way as step.
IMPORTANT: Check the tightness of plate (16).
7. Apply grease onto the ball part at the ends of push 13. Apply LOCTITE #262 onto joint (15). Install plate (16)
rods (9) (4 used). to joint (15).
8. Apply grease onto the joint part of joint (15). 14. Apply LOCTITE #262 onto joint (15). Secure plate
9. Apply grease onto the inner surface of seals (11) (4 (16) by using a spanner. Tighten nut (17) by using a
used). spanner.
10. Install seals (11) (4 used) and O-rings (13) (4 used) to j : 22 mm, 32 mm
plug (12) (4 used). Push the plug (12) assemblies (4
used) by hand until O-ring (13) is inserted into the m : 68.6±4.9 N·m (7±0.5 kgf·m, 51±3.6 lbf·ft)
hole on casing (18). 15. Install bellows (20).
11. Secure casing (18) in a vise lightly.
W3-7-6-6
Group 7 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
20
21 22
WADB-03-08-004
1- Bolt, Washer (2 Used) 10- Spring Pin (2 Used) 19- O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring (4 Used) 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool (4 Used) 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (4 Used) 26- Spacer (4 Used) 35- Pin (2 Used)
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used)
W3-7-7-1
Group 7 Pilot Valve
Disassembly of Travel Pilot Valve

IMPORTANT: Casing (23) is made of aluminium.
the hole of casing (23). Spool (24) and casing (23)
Strong force deforms it. Handle it with care.
should be replaced as an assembly.
IMPORTANT: Put the mark on spools (24) (4 used)
the hole on casing (23). Arrange the disassembled
when keeping in order to easily install spools (24)
parts together with each port in order not to
(4 used) to the original hole.
confuse. The port number is stamped on the outer
surface of casing (23). 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
(2) from holder (7).
with spool (24) together.
j : 10 mm IMPORTANT: The quantity of shim (27) has been
2. Remove socket bolts (30) (2 used) and spring determined during the performance testing at the
washers (29) (2 used). Remove the holder (7) factory. When keeping, pair shim (27) with each
assembly from casing (23). spool.
6. Compress balance spring (18). Remove spring guide
l : 8 mm (17), balance spring (18), shims (27) (3 used), and
3. Remove the pusher (16) assemblies (4 used) from spacer (26) from spool (24).
casing (23). 7. Remove spring (25) from casing (23).
4. Remove pushers (16) (4 used) from bushings (15) 8. Remove other spools (24) in the same way as step 5
(4 used). Remove oil seals (28) (4 used) and O-rings to step 7.
(14) (4 used) from bushings (15) (4 used) by using a
bamboo spatula.
W3-7-7-2
Group 7 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, 12. Remove other bracket (11) in the same way as step
such as goggles, helmets, etc in order to prevent 9 to step 11.
personal injury. 13. Place holder (7) with the casing (23) mounting
IMPORTANT: Place a stand under bracket (11) and surface up.
receive a reaction force. If holder (7) bears the
reaction force, strong force acts on pin (35). dCAUTION: Metal fragments may fly off when
Therefore, pin (35) may be deformed.
9. Place stand (b) under bracket (11). The inner
personal injury.
surfaces of the spring pins (12, 13) holes on bracket
(11) are stepped-shape. The spring pin can only be 14. The holes of spring pins (3, 4) (2 used for each) in
removed in one direction. Tap and remove spring cam (5) are stepped-shape. Tap the bottom of cam
pins (12, 13) from bracket (11) at the same time by (5) and remove spring pins (3, 4) (2 used for each)
using the special tool (ST 1237). Remove bracket from cams (5) (2 used) at the same time by using the
(11) from pin (35). Do not remove spring pin (10) special tool (ST 1237). As the holes of spring pins (3,
with bracket (11) attached unless necessary. The 4) (2 used for each) are crimped, spring pins (3, 4)
hole end of spring pin (10) has been crimped. 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
W3-7-7-3
Group 7 Pilot Valve

personal injury.
15. Remove pins (35) (2 used) by using a bar and a
hammer. At the same time, cams (5) (2 used) are
removed. Do not remove bushings (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
W3-7-7-4
Group 7 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
19, 20 14
25
21, 22 27
16
26
24
23
WADB-03-08-005
1- Bolt, Washer (2 Used) 10- Spring Pin (2 Used) 19- O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring (4 Used) 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool (4 Used) 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (4 Used) 26- Spacer (4 Used) 35- Pin (2 Used)
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used)
W3-7-7-5
Group 7 Pilot Valve
Assembly of Travel Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil dCAUTION: Metal fragments may fly off when
IMPORTANT: The pilot valve is the susceptible
personal injury.
hydraulic component to contamination. Keep the
parts clean when assembling. fNOTE: Bushings (6) (4 used) are identical.
1. Insert spacer (26), shims (27) (3 used), and balance  Insert bushings (6) (4 used) into the special tool
spring (18) into spool (24) in sequence. Install shim (ST 7256). Tap the special tool (ST 7256) by using a
(27) as the same condition before disassembling. hammer and install bushing (6) to the end of hole on
holder (7). Stop tapping when the bushing (6) end is
IMPORTANT: Check the direction to install spring
flush with the hole end.
guide (17).
2. Compress balance spring (18) by hand. Install spring 7 ST 7256
guide (17) to spool (24) with the stepped part down.
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.
W3-7-7-6
Group 7 Pilot Valve
 Install bushing (6) in the same way. 12. Install O-rings (33) (2 used) to pins (35) (2 used).
Apply grease onto O-rings (33) (2 used). Install pins
6
(35) (2 used) and cams (5) (2 used) to holder (7).
ST 7256 7
personal injury.
IMPORTANT: Check the direction to install spring
W178-02-11-311 pins (3, 4).
13. Install spring pins (3, 4) to cam (5) by using the
 Install bushing (6) as illustrated. Stop tapping when special tool (ST 1237). Secure cam (5) and pin (35).
the bushing (6) end is flush with the outside of At this time, slits (b) of spring pins (3, 4) should be
holder (7). positioned 90° away each other. Tap and install
spring pins (3, 4) until spring pins (3, 4) come in
contact with the stepped part in the hole.
6 7
ST 7256 3 b b
a
4 W178-02-07-050
W178-02-11-312
b - Slit
a- Outside of Holder
 Install bushing (6) as illustrated.

14. Crimp the hole end of cam (5) where spring pins (3,
4) are inserted by using a punch.
15. Install other cam (5) in the same way as step 13 to
6 step 14.
ST 7256
W178-02-11-313
7
W3-7-7-7
Group 7 Pilot Valve
16. Place holder (7) on the casing (23) assembly. Install 21. As for the direction to install bracket (11), refer to
holder (7) to casing (23) with socket bolts (30) (2 the figure in Disassembly of Travel Pilot Valve on
used) and spring washers (29) (2 used). Check the W3-8-7-1. Install bracket (11) to pin (35). Fit the
mark direction and install holder (7). holes to insert spring pins (12, 13).
l : 8 mm IMPORTANT: Place stand (b) under bracket (11)

and receive a reaction force. If holder (7) bears
m : 50 N·m (5 kgf·m, 37 lbf·ft) the reaction force, strong force acts on pin (35).
Therefore, pin (35) may be deformed.
17. Install rubber seats (31) (2 used) to pins (35) (2
used). 22. Place stand (b) under bracket (11). Install spring pins
(12, 13) to bracket (11) until they come in contact
IMPORTANT: Check the direction of damper (32). with the stepped part by using the special tool (ST
The inner surface of damper (32) is edged-shape. 1237). The slits of spring pins (2 used) should be
If damper (32) is pried when installing, O-ring (33) positioned 90° away each other.
may be damaged.
18. Install dampers (32) (2 used) to pins (35) (2 used)
with the lever up. a a
19. Secure dampers (32) (2 used) and rubber seats (31)

(2 used) to holder (7) with socket bolts (9) (4 used) 11 35
and spring washers (8) (4 used).
l : 5 mm
12, 13
m : 7 N·m (0.7 kgf·m, 5 lbf·ft) b
20. Apply grease onto O-rings (34) (2 used). Push
O-rings (34) (2 used) to the end of pins (35) (2 used).
W176-02-07-011
a - Crimped Position
b - Stand
W3-7-7-8
Group 7 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).
Install plugs (20) (2 used) to casing (23).
j : 5 mm
m : 10 N·m (1 kgf·m, 7.5 lbf·ft)

Install plugs (21) (2 used) to casing (23).
j : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-7-7-9
Group 7 Pilot Valve
(Blank)
W3-7-7-10
Group 7 Pilot Valve
Disassembly of Pilot Valves for Boom Swing,

Blade, Auxiliary (Optional)
11
09
05
10
10 07
06
08
07
B
B
A
A 04
04 C
C
D
D 03
03
02
02
01
01 00
00
16
16
15
B WADB-03-08-001
00- Spacer (2 Used) 04B- Oil Seal (2 Used) 07- Bushing (2 Used) 15A- Casing
01- Shim (6 Used) 04C- O-Ring (2 Used) 08- Pin 15B- Spool (2 Used)
02- Balance Spring (2 Used) 04D- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04A- Bushing (2 Used) 06- Holder 11- Boot
W3-7-8-1
Group 7 Pilot Valve
Disassembly of Pilot Valve

IMPORTANT: Casing (15A) is made of aluminium. IMPORTANT: When removing holder (06), the pusher
Strong force deforms it. Handle it with care. (04D) assembly may fly out.
IMPORTANT: Spool (15B) has been selected to 5. Put the matching marks on casing (15A) and holder
match the hole on casing (15A). Arrange the (06). Loosen and remove socket bolts (10) (2 used)
disassembled parts together with each port in alternately. Remove holder (06) from casing (15A).
order not to confuse. The port number is stamped
on the outer surface of casing (15A). l : 5 mm
1. Secure the pilot valve in a vise. Remove boot (11) 6. Remove the pusher (04D) assemblies (2 used) from
from holder (06). casing (15A).
2. Remove set screw (09) from cam (05). IMPORTANT: Do not damage bushing (04A).
7. Remove pushers (04D) (2 used), O-rings (04C) (2
l : 2.5 mm
used), and oil seals (04B) (2 used) from bushings
fNOTE: LOCTITE #262 has been applied on set screw (04A) (2 used).
(09).
3. Remove pin (08). Remove cam (05) from holder (06).

personal injury.
IMPORTANT: Do not remove bushing (07) unless
necessary.
IMPORTANT: Bushing (07) cannot be reused.
4. Remove bushings (07) (2 used) from holder (06) by
using a hammer and the special tool (ST7690).
W3-7-8-2
Group 7 Pilot Valve
IMPORTANT: Casing (15A) has been selected to

match the hole of spool (15B). Replace spool (15B)
and casing (15A) as an assembly.
IMPORTANT: Put the mars on spools (15B) (2 used)
when keeping in order to easily install spools
(15B) (2 used) to the original hole.
8. Remove the spool (15B) assembly from casing (15A)
by rotating.
IMPORTANT: The quantity of shims (01) has been
determined during the performance testing at the
factory. When keeping, pair shim (01) with each
spool.
9. Compress balance spring (02). Remove spring guide
(03), balance spring (02), shims (01) (3 used), and
spacer (00) from spool (15B).
10. Remove return spring (16) from casing (15A).
11. Remove other spools (15B) in the same way as step
8 to step 11.
W3-7-8-3
Group 7 Pilot Valve
Assembly of Pilot Valves for Boom Swing,

Blade, Auxiliary (Optional)
07 08 09
05
11
04D
04B 10
06
03
04C
16
04A
E
15B
02
01
00
15A
Detail E WADB-03-08-006
00- Spacer (2 Used) 04B- Oil Seal (2 Used) 07- Bushing (2 Used) 15A- Casing
01- Shim (6 Used) 04C- O-Ring (2 Used) 08- Pin 15B- Spool (2 Used)
02- Balance Spring (2 Used) 04D- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04A- Bushing (2 Used) 06- Holder 11- Boot
W3-7-8-4
Group 7 Pilot Valve
Assembly of Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not deform and damage the sliding
onto parts in order to prevent them from seizing. surface when installing oil seal (04B).
IMPORTANT: The pilot valve is the susceptible IMPORTANT: Check the direction to install oil seal
hydraulic component to contamination. Keep the (04B).
parts clean when assembling. 5. Apply grease onto oil seal (04B). Install oil seal (04B)
IMPORTANT: Install shim (01) as the same quantity to bushing (04A).
before disassembling.
1. Install spacer (00), shims (01) (3 used), and balance 04B
spring (02) to spool (15B) in sequnce.
IMPORTANT: Install spring guide (03) with the
stepped part down.
04A
2. Compress balance spring (02) by hand. Install spring
guide (03) to spool (15B).
WDAD-03-11-003
IMPORTANT: When installing the parts to holder (06)
and casing (15A), apply hydraulic oil.
3. Secure casing (15A) in a vise. Install return spring 6. Apply grease onto the bushing (04A) sliding surface
(16) to casing (15A). and O-ring (04C). Install O-ring (04C) and pusher
(04D) to bushing (04A).
IMPORTANT: Install the spool (15B) assembly to the
original port before disassembling. 7. Install the pusher (04D) assembly to cashing (15A).
4. Install the spool (15B) assembly to casing (15A) by 8. Install other spool (15B) and pusher (04D) in the
rotating. same way as step 1 to step 7.
W3-7-8-5
Group 7 Pilot Valve

personal injury.
9. Install bushings (07) (2 used) to holder (06) by using
a hammer and the special tool (ST7690).
and install holder (06) to casing (15A) by tightening
socket bolts (10) (2 used) alternately.
l : 5 mm
m : 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)

11. Apply grease onto A part of pushers (04D) (2 used).
Install cam (05) to holder (06) with pin (08).
A
04D
WDAD-03-11-004
12. Apply LOCTITE #262 onto set screw (09). Install set
screw (09) to cam (05).
l : 2.5 mm
m : 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)

13. Install boot (11) to holder (06).
W3-7-8-6
Removal and Installation of 2-Spool Solenoid

Valve
1 4 7 5
3 2
WACG90-03-05-004
6 WACG90-03-05-007
IMPORTANT: The hoses and pipes contain hydraulic 3. Remove bolts, washers (5) (3 used). Remove cover
oil. When removing the hoses and pipes, receive (7).
j : 17 mm
and pipes have been disconnected. In addition, 4. Remove bolt, washer (6). Remove cover (4).
hoses, and pipes for assembling. If the clips which j : 17 mm
Removal

(Refer to W1-4-1.)
Remove cover (3).
j : 17 mm
W3-8-1-1
1 2 3 6 7
WACC50-03-08-002
5 4 7 8 7
WACG90-03-05-006
9
5. Remove bolts, washers (4) (4 used). Remove support
(3).
j : 19 mm
7. Remove bolt, washer (2). Remove horn (1).
j : 13 mm
8. Remove clip bands (6, 12).
9. Disconnect hoses (7) (6 used) from 2-spool solenoid
valve (8).
j : 17 mm, 22 mm
11. Remove socket bolts (9) (2 used). Remove 2-spool
solenoid valve (8) from plate (11). WACC50-03-08-004
7 8 12 10 11
l : 6 mm
12. Remove the adapters with 2-spool solenoid valve
(8) attached if necessary.
W3-8-1-2
9 6 7
WACC50-03-08-004 WACC50-03-08-002
7 8 12 10 11 7 8 7

Installation
1. Install all removed adapters to 2-spool solenoid
valve (8).
2. Install 2-spool solenoid valve (8) to plate (11) with
socket bolts (9) (2 used).
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

4. Connect hoses (7) (6 used) to 2-spool solenoid valve
(8).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
j : 22 mm
m : 40 N·m (4 kgf·m, 30 lbf·ft)

5. Install clip bands (6, 12).
W3-8-1-3
9 10 11
4 7 5
13 12 WACG90-03-05-006 6 WACG90-03-05-007
1
6. Install horn (9) with bolt, washer (10).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

8. Install support (11) with bolts, washers (12) (4 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

9. Install cover (4) with bolt, washer (6).
j : 17 mm 3 2
WACG90-03-05-004
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft) 11. Install cover (3) with bolts, washers (1, 2) (2 used for
each).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-8-1-4
Disassembly of 2-Spool Solenoid Valve
7 7
2
4 2 4
12
6 12 6
5 5
9 13 9
13
8
8
9 9
3 3
1 11 1
14
15
17
16
18
10
10
WADB-03-09-001
1- Piston (2 Used) 6- Wave Washer (2 Used) 11- Body 16- Adjuster

2- Pin (2 Used) 7- Lock Nut (2 Used) 12- Spool (2 Used) 17- O-Ring
3- Plate (2 Used) 8- Solenoid (2 Used) 13- Spring (2 Used) 18- Lock Nut
4- Casing (2 Used) 9- O-Ring (4 Used) 14- Check Valve
5- Plate (2 Used) 10- O-Ring (2 Used) 15- Spring
W3-8-2-1
Disassembly of 2-Spool Solenoid Valve

IMPORTANT: Arrange the disassembled parts
together with each port in order not to confuse.
1. Remove lock nut (7) from the piston (1) assembly.
Remove casing (4) from body (11).
j : 17 mm
2. Remove wave washer (6), plates (5, 3), O-rings (9) (2
used), and solenoid (8) from piston (1).
IMPORTANT: When removing piston (1), pin (2) may
fall off. Do not lose pin (2).
3. Remove the piston (1) assembly from body (11).
Remove pin (2) and O-ring (10) from the piston (1)
assembly.
4. Remove spool (12) and spring (13) from body (11)
by using a magnet.
5. Remove the other piston (1) assembly in the same
way as step 1 to step 4.
IMPORTANT: If turning lock nut (18) and adjuster
(16), the setting changes. When they have been
turned, adjust the pressure. should be adjusted.
(Refer to T4-5 in the separated volume, T/M.)
6. Loosen lock nut (18).
j : 17 mm
7. Remove the adjuster (16) assembly from body (11).
Remove O-ring (17) from the adjuster (16) assembly.
l : 6 mm
8. Remove spring (15) and check valve (14) from body
(11) by using a magnet.
W3-8-2-2
Assembly of 2-Spool Solenoid Valve
4 7 6 5
9
1
8
2
9
3
11 14
10
12
15
13
TADB-03-06-001 WADB-03-09-002
11 18 16 17
1- Piston (2 Used) 6- Wave Washer (2 Used) 11- Body 16- Adjuster

2- Pin (2 Used) 7- Lock Nut (2 Used) 12- Spool (2 Used) 17- O-Ring
3- Plate (2 Used) 8- Solenoid (2 Used) 13- Spring (2 Used) 18- Lock Nut
4- Casing (2 Used) 9- O-Ring (4 Used) 14- Check Valve
5- Plate (2 Used) 10- O-Ring (2 Used) 15- Spring
W3-8-2-3
Assembly of 2-Spool Solenoid Valve

IMPORTANT: When adjuster (16) and lock nut (18)
have been disassembled, adjust the pressure.
(Refer to T4-5 in the separated volume, T/M.)
1. Install check valve (14) and spring (15) to body (11).
2. Install O-ring (17) to the adjuster (16) assembly.
Install the adjuster (16) assembly to body (11).
l : 6 mm
3. Tighten lock nut (18).
j : 17 mm
m : 15 to 20 N·m (1.5 to 2 kgf·m, 11 to 15 lbf·ft)

4. Install spring (13) and spool (12) to body (11).
5. Install pin (2) and O-ring (10) to piston (1). Install
piston (1) to body (11).
6. Install plates (3, 5), solenoid (8), O-rings (9) (2 used),
and wave washer (6) to piston (1).
7. Install casing (4) to the piston (1) assembly. Install
the piston (1) assembly to body (11) with lock nut
(7).
j : 17 mm
m : 15 to 20 N·m (1.5 to 2 kgf·m, 11 to 15 lbf·ft)

8. Install the other piston (1) assembly in the same way
as step 4 to step 7.
W3-8-2-4
MEMO
MEMO
SECTION 4
UNDERCARRIAGE
CONTENTS
Removal and Installation of Swing Bearing..........W4-1-1-1
Removal and Installation of Travel Device.............W4-2-1-1
Disassembly of Travel Reduction Gear....................W4-2-2-1
Assembly of Travel Reduction Gear..........................W4-2-2-4
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
Group 4 Track Adjuster
Removal and Installation of Track Adjuster...........W4-4-1-1
Disassembly of Track Adjuster....................................W4-4-2-1
Assembly of Track Adjuster.........................................W4-4-2-6
Group 5 Front Idler
Removal and Installation of Front Idler...................W4-5-1-1
Disassembly of Front Idler...........................................W4-5-2-1
Assembly of Front Idler.................................................W4-5-2-4
Group 6 Upper and Lower Rollers
Removal and Installation of Lower Roller..............W4-6-1-1
Group 7 Track
Removal and Installation of Track.............................W4-7-1-1
Removal and Installation of Blade Cylinder..........W4-8-1-1
Disassembly of Blade Cylinder...................................W4-8-2-1
Assembly of Blade Cylinder.........................................W4-8-2-4
ACG90W-4-1
(Blank)
ACG90W-4-2
Removal and Installation of Swing Bearing
3
4
5
5
b
ST 0052
3 a 2
W1M9-03-01-002 1
W110-03-01-004
a- Matching Mark
b- Outer Race Mounting Bolt
Before removing and installing the swing bearing, the

upperstructure must be removed first. dCAUTION: Swing bearing (1) weight: 36 kg (80 lb)
Therefore, the procedure starts on the premise that the 4. Install special tools (ST 0052) (3 used) to swing
upperstructure has already been removed here. bearing (1) with the swing bearing (1) outer race
mounting bolts (b) (3 used) and nuts (3 used).
Removal Attach wile ropes onto the special tools (ST 0052)
(3 used). Hoist swing bearing (1). Remove swing
1. Put matching marks (a) on inner race (2) of swing
bearing (1).
bearing (1) and track frame (3).
2. Remove knock pins (5) (2 used). j : 19 mm
3. Remove bolts (4) (16 used).
j : 19 mm
W4-1-1-1
f
5
5
ST 0052
1 W110-03-01-004
3 a 2 f- Outer Race Mounting Bolt
W1M9-03-01-002
a- Matching Mark
b
d
c
e
WACG90-04-01-001
WACG90-04-01-002
b- Soft Zone Marking Position e- THREEBOND application surface at the track frame (3) side.
c- Front Side
d- Position for Knock Pin
Installation
1. Clean the mounting surfaces of track frame (3) and 4. Fit matching marks (a) on track frame (3) and inner
swing bearing (1). race (2) of swing bearing (1) so that the position of
"S" (soft zone) stamp (b) is as illustrated.
2. Apply THREEBOND #1102 or equivalent onto the
swing bearing (1) mounting surface of track frame 5. Install swing bearing (1) with bolts (4) (16 used).
(3).
j : 19 mm
d CAUTION: Swing bearing (1) weight: 36 kg (80 lb)
m : 110 N·m (11 kgf·m, 81 lbf·ft)
3. Install special tools (ST 0052) (3 used) to swing
bearing (1) with the swing bearing (1) outer race
mounting bolts (f ) (3 used) and nuts (3 used). Attach
wire ropes onto the special tools (ST 0052) (3 used).
Hoist swing bearing (1).
j : 19 mm
W4-1-1-2
a b 1
5
5
5 mm
2 W175-03-01-002
W1M9-03-01-002 a- Swing Bearing b- Grease Level
IMPORTANT: Check the direction to install knock pin 7. After installing swing bearing (a), add grease
(5). (Alvania EP2 or equivalent) to the gear part of swing
6. Install knock pins (5) (2 used) by using a plastic bearing (a). Add grease (Alvania EP2 or equivalent)
hammer. to grease bath (2) until the pinion (1) of swing
device is 5 mm (0.2 in) under grease.
c
fNOTE: Amount of grease: 3 to 3.3 L (3.17 to 3.49 US qt)
d
5
WDEA-03-10-018
c- Taper Part
d- Up
W4-1-1-3
(Blank)
W4-1-1-4
Removal and Installation of Travel Device 1

Removal 2
maintenance. (Refer to W1-6-1.) 3, 4 W1NG-03-02-001
2. Remove the track. (Refer to W4-7-1.)

(Refer to W1-4-1.)
8

Remove cover (2) from track frame (1).
j : 17 mm
4. Disconnect hoses (8) (4 used) from travel device (7). 9
j : 17 mm, 22 mm
5. Disconnect adapters (9) (4 used) from travel device
(7).
j : 17 mm, 22 mm
7 5, 6 WACG90-04-02-008
dCAUTION: Travel device (7) weight: 33 kg (73 lb)
6. Attach nylon slings onto travel device (7). Hoist and
hold travel device (7). Remove socket bolts (5) (12
used) and spring washers (6) (12 used). Hoist and
remove travel device (7).
l : 8 mm
fNOTE: LOCTITE #263 or equivalent has been applied on

socket bolt (5).
7. Remove other travel device in the same way as step
1 to step 6.
W4-2-1-1
Installation
8
d CAUTION: Travel device (7) weight: 33 kg (73 lb)
1. Apply LOCTITE #263 or equivalent onto socket bolts
(5) (12 used). Attach nylon slings onto travel device
(7). Hoist travel device (7). Install travel device (7)
with spring washers (6) (12 used) and socket bolts
(5) (12 used).
9
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

2. Install adapters (9) (4 used) to travel device (7).
j : 17 mm
7 5, 6 WACG90-04-02-008
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
j : 22 mm
1
m : 40 N·m (4 kgf·m, 30 lbf·ft)
3. Connect hoses (8) (4 used) to travel device (7).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
j : 22 mm
m : 40 N·m (4 kgf·m, 30 lbf·ft)

4. Install the track. (Refer to W4-7-1.)
5. Install other travel device in the same way as step 1 2
to step 4.
6. Bleed air from the hydraulic system. (Refer to W1-4- 3, 4 W1NG-03-02-001
1.)
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
7. Install cover (2) to track frame (1) with bolts (3) (3

used) and washers (4) (3 used).
j : 17 mm
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

8. Install other cover in the same way as step 7.
W4-2-1-2
Disassembly of Travel Reduction Gear
9
8
7
6
5
4
3
2
10 1
11
12
13
30 14 33
29
28
27 15
26
16
17
25 18
24
23
22
21 34
35
20
19
32
WACG90-04-02-001
1- Plug (2 Used) 10- Spring Pin (3 Used) 18- Stopper Ring 26- Ring Gear
2- O-Ring (2 Used) 11- Pin (3 Used) 19- Retaining Ring (4 Used) 27- Ball Bearing
3- Cover 12- Thrust Washer (3 Used) 20- Thrust Plate 28- Retaining Ring
4- O-Ring 13- First Stage Planetary Gear (3 21- Second Stage Planetary Gear 29- Ball Bearing
5- Thrust Plate Used) (4 Used) 30- Floating Seal
6- Drive Gear 14- Needle (45 Used) 22- Needle (92 Used) 32- Travel Motor
7- Retaining Ring 15- Retaining Ring (3 Used) 23- Inner Race (4 Used) 33- Sprocket
8- Carrier 16- O-Ring 24- Thrust Washer (4 Used) 34- Spring Washer (12 Used)
9- Sun Gear 17- Plug 25- Retaining Ring 35- Socket Bolt (12 Used)
W4-2-2-1
Disassembly of Travel Reduction Gear

 These are the procedures before Disassembly of
dCAUTION: The travel device may move without
securing it when removing sprocket (33). Receive
Travel Motor (W4-2-3) and before Disassembly of a reaction force in order not to move the travel
Brake Valve (W4-2-4). device when disassembling.
d CAUTION: There may be pressure accumulated
inside of the travel device. Loosen the air bleed
3. Remove socket bolts (35) (12 used) and spring
washers (34) (12 used). Remove sprocket (33) from
plug slowly. Release any remaining pressure ring gear (26).
completely. Remove the drain plug and drain gear
oil. If the air bleed plug is loosened suddenly, the l : 8 mm
plug may be fly out and gear oil may gush out.
Keep body and face away from plug. fNOTE: THREEBOND #2446 has been applied on socket
bolt (35).
1. Remove plugs (1) (2 used) and O-rings (2) (2 used)
from cover (3). Drain gear oil from the travel device. 4. Remove plug (17) and O-ring (16) from cover (3).
l : 8 mm l : 5 mm
5. Remove stopper ring (18) from cover (3) by using a
fNOTE: Amount of oil: 0.33 L (0.348 US qt)
screwdriver. Remove cover (3) from ring gear (26).
dCAUTION: Travel device weight: 24 kg (53 lb)
6. Remove O-ring (4) from ring gear (26).
3 IMPORTANT: Replace the carrier (8) as the carrier (8)
assembly (parts No. 5 to 15).
33 7. Remove the carrier (8) assembly from ring gear (26).
WADB-04-02-002
2. Attach nylon slings onto the travel device. Hoist

the travel device. Place the travel device onto a
workbench with the cover (3) side up.
W4-2-2-2
IMPORTANT: Spring pin (10) and pin (11) cannot 11. Install a C-clamp to the flange parts in travel
be removed as they have been press-fitted into motor (32) and ring gear (26). Tighten the C-clamp.
carrier (8). Remove retaining ring (25) from travel motor (32).
8. Remove retaining rings (15) (3 used), thrust plate
(5), drive gear (6), first stage planetary gears (13) (3
used), needles (14) (45 used), and thrust washers 26
(12) (3 used) from carrier (8).
9. Remove retaining ring (7) and sun gear (9) from
carrier (8).
10. Remove retaining rings (19) (4 used), thrust plate a
(20), second stage planetary gears (21) (4 used), a
needles (22) (92 used), thrust washers (24) (4 used)
and inner races (23) (4 used) from travel motor (32).
32
W571-03-02-006
a- C-Clamp
IMPORTANT: Do not remove ball bearings (27, 29)

unless necessary. When they have been removed,
replace them with the new ones.
12. Remove the ring gear (26) assembly from travel
motor (32).
IMPORTANT: Handle floating seals (30) with care.
(Refer to W4-2-5.)
13. Remove floating seal (30) from ring gear (26) and
travel motor (32).
W4-2-2-3
Assembly of Travel Reduction Gear
32 30 29 26 28 27 25 9 7
8
5
3
6
16
17
20
11
15
2
14
13
18
24 23 21 22 19 10 12 4
33 34 35
WACG90-04-02-002
1- Plug (2 Used) 10- Spring Pin (3 Used) 18- Stopper Ring 26- Ring Gear
2- O-Ring (2 Used) 11- Pin (3 Used) 19- Retaining Ring (4 Used) 27- Ball Bearing
3- Cover 12- Thrust Washer (3 Used) 20- Thrust Plate 28- Retaining Ring
4- O-Ring 13- First Stage Planetary Gear (3 21- Second Stage Planetary Gear 29- Ball Bearing
5- Thrust Plate Used) (4 Used) 30- Floating Seal
6- Drive Gear 14- Needle (45 Used) 22- Needle (92 Used) 32- Travel Motor
7- Retaining Ring 15- Retaining Ring (3 Used) 23- Inner Race (4 Used) 33- Sprocket
8- Carrier 16- O-Ring 24- Thrust Washer (4 Used) 34- Spring Washer (12 Used)
9- Sun Gear 17- Plug 25- Retaining Ring 35- Socket Bolt (12 Used)
W4-2-2-4
Assembly of Travel Reduction Gear IMPORTANT: Handle floating seal (30) with care.
(Refer to W4-2-5.)
 These are the procedures after Assembly of Brake
Valve (W4-2-4) and after Assembly of Travel Motor 5. Apply grease onto the entire circumference of the
(W4-2-3). O-ring of floating seal (30). Install floating seal (30)
IMPORTANT: Before assembling, apply hydraulic oil to travel motor (32) and ring gear (26).
onto parts in order to prevent them from seizing. 6. Fit ring gear (26) to travel motor (32). Evenly tap and
1. Place ring gear (26) with the travel motor (32) side install ring gear (26) to travel motor (32) by using a
up. plastic hammer.

7. Install a C-clamp to the flange parts in travel motor
(32) and ring gear (26). Tighten the C-clamp. Install
such as goggles, hard hat, etc. in order to prevent retaining ring (25) to travel motor (32).
personal injury.
2. Evenly tap and install ball bearing (27) to ring gear
fNOTE: Check if ring gear (26) can turn. If not,
disassemble ball bearings (27, 29) and floating seal (30)
(26) by using a bar and a hammer. At this time, and assemble them again.
install ball bearing (27) with the thinner inner race
side facing to the retaining ring (28) side.
3. Install retaining ring (28) to ring gear (26). 26

such as goggles, hard hat, etc. in order to prevent
personal injury. a
4. Evenly tap and install ball bearing (29) to ring gear a
(26) by using a bar and a hammer. At this time,
install ball bearing (29) with the thinner inner race
side facing to the retaining ring (28) side.
32
W571-03-02-006
a- C-Clamp
W4-2-2-5
8. Install inner races (23) (4 used), thrust washers 14. Fit the plug (1) hole of cover (3) to the notch of ring
(24) (4 used), second stage planetary gears (21) (4 gear (26). Install the cover (3) assembly and stopper
used), needles (22) (92 used), thrust plate (20), and ring (18) to ring gear (26).
retaining rings (19) (4 used) to travel motor (32).
IMPORTANT: Replace the carrier (8) as the carrier (8)
fNOTE: Attach a screwdriver onto the end of stopper
ring (18). Tap the circumference of it by using a hammer
assembly (parts No. 5 to 15). and install cover (3).
9. Install sun gear (9) to carrier (8) with retaining ring 15. Install O-rings (2) (2 used) to plugs (1) (2 used).
(7). Install plugs (1) (2 used) to cover (3).
10. Install the carrier (8) assembly and drive gear (6) to
l : 8 mm
ring gear (26).
11. Install thrust washers (12) (3 used), first stage m : 46 to 51 N·m (4.7 to 5.2 kgf·m, 34 to 38
planetary gears (13) (3 used), needles (14) (45 used), lbf·ft)
thrust plate (5), and retaining rings (15) (3 used) to 16. Install O-ring (16) to plug (17). Install plug (17) to
pins (11) (3 used). cover (3).
12. Apply grease onto O-ring (4).
l : 5 mm
Install O-ring (4) to ring gear (26).
m : 12 to 18 N·m (1.2 to 1.8 kgf·m, 8.9 to 13.5
13. Add gear oil (IDEMITSU APOLLO OIL DIESEL MOTIVE lbf·ft)
S-330 or SAE#30CD) to ring gear (26).
fNOTE: Amount of oil: 0.33 L (0.348 US qt)

dCAUTION: The travel device may move without
securing it when installing sprocket (33). Receive
a reaction force in order not to move the travel
device when installing.
IMPORTANT: Fit the chamfered side of sprocket (33)
to the ring gear (26) side.
17. Degrease the socket bolt (35) holes of ring gear (26)
and socket bolts (35) (12 used). Apply LOCTITE #263
or equivalent onto socket bolts (35) (12 used). Install
sprocket (33) to ring gear (26) with spring washers
(34) (12 used) and socket bolts (35) (12 used).
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W4-2-2-6
Disassembly of Travel Motor

7
6
5
4
3
2
1
8
9
10
11
12
13
14
15
16
17
16
18
19
20
21
22
21
22
21
23
24
25
29
28
27
26
WACG90-04-02-003
30 31 32 31
1- Housing 9- Valve Plate 17- Spring 25- Plunger (7 Used)

2- Piston 10- Backup Ring 18- Cylinder Block 26- Bearing
3- Oil Seal 11- O-Ring 19- Pin (3 Used) 27- Spring Pin
4- Bearing 12- Brake Piston 20- Holder 28- Brake Valve
5- Shaft 13- O-Ring 21- Plate (3 Used) 29- Socket Bolt (7 Used)
6- Ball (2 Used) 14- Backup Ring 22- Friction Plate (2 Used) 30- Spring (8 Used)
7- Swash Plate 15- Retaining Ring 23- Spacer 31- O-Ring (2 Used)
8- O-Ring 16- Washer (2 Used) 24- Holder 32- Pin
W4-2-3-1
Disassembly of Travel Motor

 These are the procedures after Disassembly of Travel
dCAUTION: When removing brake piston (12) by
using air, hold brake piston (12) with a cloth in
Reduction Gear (W4-2-2). order not to fly out.
IMPORTANT: Valve plate (9) and spring (30) may be
4. Apply air 1.2 MPa (12 kgf/cm2) or less air pressure to
removed with brake valve (28) together when
the parking brake releasing oil passage. Raise and
removing brake valve (28) from housing (1). Do
remove brake piston (12).
not drop valve plate (9) and spring (30).
IMPORTANT: The open end of brake valve (28) is the 5. Remove backup rings (10, 14) and O-rings (11, 13)
seat surface for pressure oil when releasing the from brake piston (12).
parking brake. Take care not to damage the seat 6. Remove plate (21) from housing (1).
surface when placing it with the open end down.
1. Place the travel motor with the brake valve (28) side
up. Remove socket bolts (29) (7 used). Remove the
brake valve (28) assembly from housing (1).
l : 6 mm
28
a WADB-04-02-005
a- Seat Surface
2. Remove valve plate (9) and springs (30) (8 used)

from housing (1).
IMPORTANT: Do not remove bearing (26) and spring
pin (27).
3. Remove O-ring (8) and O-rings (31) (2 used) from
brake valve (28).
W4-2-3-2
7. Place housing (1) horizontally with the parking 10. Remove plate (21), spacer (23), and swash plate (7)
brake releasing oil passage (a) side up. Remove the from housing (1).
cylinder block (18) assembly from housing (1).
11. Remove balls (6) (2 used) and piston (2) from
housing (1) by using a magnet.
1 12. Remove the shaft (5) assembly from housing (1) by

a using a bar and a plastic hammer.
IMPORTANT: Do not remove bearing (4) unless
necessary.
18
13. Remove bearing (4) from shaft (5) by using a press.
14. Remove oil seal (3) from the shaft (5) mounting hole
side of housing (1) by using a screwdriver.
fNOTE: Adhesive has been applied on the outer

circumference of oil seal (3). Oil seal (3) cannot be reused.
15. Remove pin (32) from housing (1).
a- Parking Brake Releasing Oil Passage WACG90-04-02-005
IMPORTANT: Replace cylinder block (18) as the

assembly (9, 15 to 20, 24, 25).
8. Remove plungers (25) (7 used), holders (24, 20), pins
(19) (3 used), friction plates (22) (2 used), and plate
(21) from cylinder block (18).
dCAUTION: When removing retaining ring (15),

use a press in order to prevent washer (16) and
spring (17) from flying out.
9. Remove retaining ring (15), washers (16) (2 used),
and spring (17) from cylinder block (18).
W4-2-3-3
Assembly of Travel Motor
3
4
2
6
24 7
20 19
18 16
23 17
21 1
22 25
13
14
11
10
8
12 30 9 26 5 15 28 27 29
WACG90-04-02-004
1- Housing 9- Valve Plate 17- Spring 25- Plunger (7 Used)

2- Piston 10- Backup Ring 18- Cylinder Block 26- Bearing
3- Oil Seal 11- O-Ring 19- Pin (3 Used) 27- Spring Pin
4- Bearing 12- Brake Piston 20- Holder 28- Brake Valve
5- Shaft 13- O-Ring 21- Plate (3 Used) 29- Socket Bolt (7 Used)
6- Ball (2 Used) 14- Backup Ring 22- Friction Plate (2 Used) 30- Spring (8 Used)
7- Swash Plate 15- Retaining Ring 23- Spacer 31- *O-Ring (2 Used)
8- O-Ring 16- Washer (2 Used) 24- Holder 32- *Pin
fNOTE: As for the item with mark *, refer to W4-2-3-1.
W4-2-3-4
Assembly of Travel Motor 7. Apply grease onto swash plate (7). Fit the hollows
(2 places) on the back side of swash plate (7) to the
 These are the procedures before Assembly of Travel
ball (6) position. Install swash plate (7) to housing
Reduction Gear (W4-2-4).
(1).
onto parts in order to prevent them from seizing. 8. Place housing (1) horizontally with the parking
1. Place housing (1) with the brake valve (28) brake releasing oil passage (a) side up. At this time,
mounting side up. check if swash plate (7) is located correctly.
2. Install pin (32) to housing (1). fNOTE: If housing (1) is placed with parking brake
releasing oil passage (a) downside, the thick part of
IMPORTANT: Replace oil seal (3) with the new one.
swash plate (7) becomes topside and swash plate (7)
3. Clean the oil seal (3) mounting part of housing (1). may be located off the center.
Install oil seal (3) to housing (1) by using the special
tool (ST 8140). Be sure not to deform oil seal (3).
Apply OCEAN grease #7 onto the inner surface of oil
seal (3) after installing. 1
a
IMPORTANT: The lip contacting surface of oil seal
(3) is located on the bearing (4) mounting side of
shaft (5). Do not damage it.
4. Install bearing (4) to shaft (5) by using a press.
5. Tap and install the shaft (5) assembly to housing (1)
by using a plastic hammer.
IMPORTANT: Install piston (2) to the piston (2) hole
with the stepped part down.
6. Apply grease onto balls (6) (2 used). Install piston (2)
and balls (6) (2 used) to housing (1).
a- Parking Brake Releasing Oil Passage WACG90-04-02-005
W4-2-3-5
IMPORTANT: Brake piston (12) keeps floating

d CAUTION: When installing retaining ring (15) to
cylinder block (18), use a press in order to prevent
due to O-rings and backup rings in the outer
circumference. Evenly push brake piston (12) by
washer (16) and spring (17) from flying out. hands. Do not push brake piston (12) by using a
7. Install washers (16) (2 used), spring (17), and hammer excessively.
retaining ring (15) to cylinder block (18) by using a 15. Install O-rings (11, 13) and backup rings (10, 14)
press. to brake piston (12). Install brake piston (12) to
8. Apply grease onto pins (19) (3 used) in order to housing (1).
prevent them from falling off from cylinder block
(18). Install pins (19) (3 used) to cylinder block (18). 12 a
Install holder (20) on pins (19) (3 used).

IMPORTANT: Alternately install friction plates (22)
and plates (21).
9. Install friction plates (22) (2 used) and plate (21) to
cylinder block (18).
10. Install holder (24) and plungers (25) (7 used) to
cylinder block (18).
11. Install spacer (23) and plate (21) to housing (1).
12. Fit the splines of shaft (5) and cylinder block (18).
Install the cylinder block (18) assembly to shaft (5).
13. Place housing (1) with the brake valve (28) 2
mounting side up. a- Oil Passage in Piston (27)
WACG90-04-02-006
14. Install plate (21) to housing (1).
16. Add hydraulic oil to housing (1).
fNOTE: Oil amount: 0.1 L (0.106 US qt)
W4-2-3-6
IMPORTANT: Bearing (26) and spring pin (27) have

been installed to brake valve (28).
IMPORTANT: Install valve plate (9) with the thrust
surface of brass up.
IMPORTANT: Apply grease onto the back of valve
plate (9) and spring (30) in order not to fall off.
17. Install valve plate (9) to brake valve (28) by fitting
the position of spring pin (27).
18. Apply grease to O-rings (8, 31). Install springs (30) (8
used), O-ring (8), and O-rings (31) (2 used) to brake
valve (28).
IMPORTANT: Do not drop valve plate (9). If valve

plate (9) is damaged, oil leakage may occur.
19. Place housing (1) horizontally with the parking
brake releasing oil passage (a) side up. Install
brake valve (28) by fitting the socket bolt (29) hole
position of housing (1). At this time, as brake piston
(12) is not completely pushed in housing (1), the
clearance between brake valve (28) and housing (1)
is approx. 10 mm. Evenly tighten and install brake
valve (28) to housing (1) with socket bolts (29) (7
used).
l : 6 mm
m : 28.4 to 30.4 N·m (2.8 to 3.0 kgf·m, 21 to 22.5

lbf·ft)
1
a
WACG90-04-02-005
a- Parking Brake Releasing Oil Passage
W4-2-3-7
(Blank)
W4-2-3-8
Disassembly of Brake Valve
4
3
6 12
7
11
8
10
9 13
2
3
4
WACG90-04-02-007
5
1- Body 5- Plug (2 Used) 9- Plug (2 Used) 13- Counterbalance Valve

2- Plate (2 Used) 6- Shuttle 10- O-Ring (2 Used)
3- Spring (2 Used) 7- Pin (2 Used) 11- Spring
4- O-Ring (2 Used) 8- Plug (2 Used) 12- Spool
W4-2-4-1
Disassembly of Brake Valve

IMPORTANT: Replace the brake valve as an assembly.
(except O-rings (4, 10) (2 used for each))
1. Remove plugs (5) (2 used) from body (1). Remove
O-rings (4) (2 used) from plugs (5) (2 used).
j : 27 mm
IMPORTANT: Do not disassemble counterbalance
valve (13).
2. Remove springs (3) (2 used), plates (2) (2 used), and
counterbalance valve (13) from body (1).
3. Remove plugs (9) (2 used) from body (1). Remove
O-rings (10) (2 used) from plugs (9) (2 used).
l : 8 mm
IMPORTANT: When removing spool (12), do not drop
spring (11).
4. Remove spring (11) and spool (12) from body (1).
5. Remove plugs (8) (2 used) from body (1).
l : 4 mm
6. Remove pins (7) (2 used) and shuttle (6) from body
(1).
W4-2-4-2
Assembly of Brake Valve
13 1
3
2
12 11 10
W1MW-03-02-007
6 7 8
Section A-A
1- Body 5- Plug (2 Used) 9- Plug (2 Used) 13- Counterbalance Valve

2- Plate (2 Used) 6- Shuttle 10- O-Ring (2 Used)
3- Spring (2 Used) 7- Pin (2 Used) 11- Spring
4- O-Ring (2 Used) 8- Plug (2 Used) 12- Spool
W4-2-4-3
Assembly of Brake Valve

1. Install shuttle (6) and pins (7) (2 used) to body (1).
2. Install a seal tape onto plugs (8) (2 used). Install
plugs (8) (2 used) to body (1).
l : 4 mm
m : 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

3. Install spool (12) and spring (11) to body (1).
Install plugs (9) (2 used) to body (1).
l : 8 mm
m : 46 to 51 N·m (4.7 to 5.3 kgf·m, 34 to 38

lbf·ft)
5. Install counterbalance valve (13), plates (2) (2 used),
and springs (3) (2 used) to body (1).
Install plugs (5) (2 used) to body (1).
l : 27 mm
m : 127 to 167 N·m (13 to 17 kgf·m, 94 to 123

lbf·ft)
W4-2-4-4
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
(Blank)
W4-2-5-2
Removal and Installation of Center Joint
2 1
3, 4
WACDA0-04-03-001
5, 6
WACC50-03-06-004
IMPORTANT: The hoses and pipes contain hydraulic 5. Remove bolt (5) and washer (6). Remove floor mat
oil. When removing the hoses and pipes, receive (3) and plate (4).
j : 13 mm
Removal

(Refer to W1-4-1.)
3. Slide seat (1).

4. Remove socket bolts (2) (4 used). Remove seat (1).
l : 6 mm
W4-3-1-1
3 4
6 5
WACC50-03-07-009

(4).
j : 13 mm
7. Remove bolts, washers (7, 5). Remove cover (6).
j : 17 mm
(1).
j : 17 mm
W4-3-1-2
2 2 4 3 5
2 WACC50-04-03-001
WACC50-04-03-004
9. Remove the swing device. (Refer to W3-6-1.)

10. Disconnect hoses (2) (8 used) from center joint (1).
j : 17 mm, 19 mm, 22 mm
11. Remove bolts, washers (4) (2 used) from main frame
(5). Remove stopper (3).
j : 19 mm

bolt, washer (4).
W4-3-1-3
3 3
2, 4
3
WACC50-04-03-002
12. Disconnect hoses (3) (10 used) from center joint (1). 13. Remove bolts (2) (4 used) and washers (4) (4 used).
Remove center joint (1) from the track frame.
j : 17 mm, 19 mm, 22 mm
j : 17 mm

bolt (2).
14. Remove the adapters with center joint (1) attached
if necessary.
W4-3-1-4
3 3
2, 4
3
WACC50-04-03-002
IMPORTANT: Check the angles to connect the hose 3. Connect hoses (3) (10 used) to center joint (1).
j : 17 mm
Installation m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
1. Install all removed adapters to center joint (1).
j : 19 mm
2. Apply LOCTITE #263 or equivalent onto bolts (2) (4
used). Install center joint (1) to the track frame with m : 30 N·m (3 kgf·m, 22 lbf·ft)
bolts (2) (4 used) and washers (4) (4 used). j : 22 mm
j : 17 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
W4-3-1-5
4 3 5 2 2
WACC50-04-03-004 2 WACC50-04-03-001
4. Apply LOCTITE #263 or equivalent to bolts, washers 7. Bleed air from the hydraulic system. (Refer to W1-4-
(4) (2 used). Install stopper (3) to main frame (5) with 1.)
j : 19 mm engine and check for any oil leaks.
m : 90 N·m (9 kgf·m, 66 lbf·ft)

5. Connect hoses (2) (8 used) to center joint (1).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
j : 22 mm
m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

6. Install the swing device. (Refer to W3-6-1.)
W4-3-1-6
3 4
6 5
WACC50-03-07-009
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

9. Install cover (6) with bolts, washers (5, 7).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W4-3-1-7
2 1
3, 4
WACDA0-04-03-001
5, 6
WACC50-03-06-004
and bolt (5). dCAUTION: Seat (1) weight: 24 kg (53 lb)
j : 13 mm
l : 6 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
m : 20 N·m (2 kgf·m, 15 lbf·ft)
13. Slide seat (1).
W4-3-1-8
Disassembly of Center Joint
1 8
3 7
10
4
11
12
5
13
14
W577-03-03-001
1- Spindle 5- O-Ring 9- Thrust Ring 13- Spring Washer (4 Used)

2- Pin 6- Oil Seal (7 Used) 10- Retaining Ring 14- Bolt (4 Used)
3- Dust Seal 7- Plug (3 Used) 11- O-Ring
4- Backup Ring 8- Body 12- Flange
W4-3-2-1
Disassembly of Center Joint

IMPORTANT: For easy removal of oil seal (6), use the
IMPORTANT: Do not disassemble pin (2) and plug (7).
pins (2 used). Do not damage the seal groove.
1. Put the matching marks on body (8) and flange (12).
5. Remove oil seals (6) (7 used), O-ring (5), backup ring
Remove bolts (14) (4 used) and spring washers (13)
(4), and dust seal (3) from body (8).
(4 used). Remove flange (12) from body (8).
j : 13 mm
2. Remove O-ring (11), retaining ring (10), and thrust
ring (9) from body (8).
3. Install the special tool (ST 1467) to the bolt (14)
holes (2 places) in diagonal position with the bolts
(M8) (2 used).
b
a ST 1467
W178-02-11-240
W1MP-03-03-002
a- Bolt (M8)
b- Bolt (M16)
IMPORTANT: Do not damage the seal sliding surface
of spindle (1).
4. Remove spindle (1) from body (8).
W4-3-2-2
Assembly of Center Joint
8 5
12 9
11
13 14 7 10 T577-03-07-001
1- Spindle 5- O-Ring 9- Thrust Ring 13- Spring Washer (4 Used)

2- Pin 6- Oil Seal (7 Used) 10- Retaining Ring 14- Bolt (4 Used)
3- Dust Seal 7- Plug (3 Used) 11- O-Ring
4- Backup Ring 8- Body 12- Flange
W4-3-2-3
Assembly of Center Joint

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: The clearance between body (8) and
onto parts in order to prevent them from seizing. spindle (1) is approximately 0.1 mm. Insert body
IMPORTANT: When assembling the seals, apply (8) along the axis straight and slowly. Do not
grease (Apolloil Autorex C) and install the seals to damage the seal.
each groove. IMPORTANT: Do not make a step on thrust ring (9)
IMPORTANT: Check the direction to install dust seal mounting part (b).
(3) and oil seal (6). 4. Place spindle (1) with the pin (2) mounting side
1. Place body (8) with the dust seal (3) mounting side down on a workbench. Evenly tap and install body
up. Install oil seals (6) (7 used) to body (8). (8) to spindle (1) by using a plastic hammer.
b
2. Install O-ring (5) and backup ring (4) to body (8). 1
3. Install dust seal (3) to spindle (1) with lip part (a) 8
facing to the body (8) side.
WABA50-04-03-004
b- Thrust Ring (9) Mounting Part
3
a
4
5
WABA50-04-03-003
a- Lip Part
W4-3-2-4
5. Install thrust ring (9) and retaining ring (10) to body

(8). Check if retaining ring (10) turns in the groove.
10 9
WABA50-04-03-005
6. Install O-ring (11) to body (8).

7. Fit the matching marks on body (8) and flange
(12). Install flange (12) to body (8) with bolts (14) (4
used).
j : 13 mm
m : 24.5 to 27.5 N·m (2.5 to 2.8 kgf·m, 18 to 20.5

lbf·ft)
W4-3-2-5
(Blank)
W4-3-2-6
Removal and Installation of Track Adjuster

2
b a
2 1
d c
W1M9-03-04-001
a- Nut c- Thread Part

b- Spring d- Rod
WADB-04-04-004
Before removing and installing the track adjuster, the

tracks and front idler must be removed first. (Refer to W4-
5-1 and W4-7-1.) Therefore, the procedure starts on the
premise that the tracks and front idler have already been
removed here.
Removal
dCAUTION: Track adjuster (1) may fly out due

to the spring (b) force when removing track
adjuster (1). Do not stand in the same direction to
remove track adjuster (1) or where it may fly out.
Particularly, the spring (b) load is always applied
to thread part (c) of the rod. If the rod and/or
thread part (c) are damaged, metal fragments may
fly out due to the spring (b) force.
1. Pry and remove track adjuster (1) from track frame
(2) by using a pry bar.
W4-4-1-1
2 1 2
3 4
W1M9-03-04-001
WADB-04-04-004
Installation
IMPORTANT: The left and right sides of track
adjuster (1) are different according to the
direction of grease nipple (4). Install track adjuster
(1) with the lubrication port of grease nipple (4)
facing to the hole (5) side of track frame (2).
1. Install track adjuster (1) to track frame (2). At this
time, check that bracket (3) of track adjuster (1)
comes in contact with the surface of plate (6).
2. Install the front idler. (Refer to W4-5-1.)
3. Connect the track. (Refer to W4-7-1.)
W4-4-1-2
Disassembly of Track Adjuster
04
09
03
00A
10
00B 01
08
07
06
05
13
12
WACB-04-04-001
11
00A- Cylinder 04- Plug 08- Retaining Ring 12- Socket Bolt (3 Used)
00B- Rod 05- Piston Rod 09- Valve 13- Flange
01- Spring 06- Wear Ring 10- Washer
03- Nut 07- U-Packing 11- Dust Seal
W4-4-2-1
Disassembly of Track Adjuster

dCAUTION: Special tool (ST 4140) weight: 36 kg
d CAUTION: Special tool (ST 4943) weight: 225 kg
(500 lb)
(80 lb)
2. Remove nuts (a) (4 used) from the special tool (ST
dCAUTION: The spring force is extremely large.
Carry out the disassembly and assembly work
4943). Attach nylon slings onto the eyebolts (2
used) of the special tool (ST 4140). Hoist the special
carefully. In addition, inspect the special tool for tool (ST 4140). Remove the special tool (ST 4140)
any damage thoroughly in order to perform the from the special tool (ST 4943).
work safely.
j : 46 mm
1. Place oil jack (c) (30 tons (66200 lb)) between holder
(b) and base (d) of the special tool (ST 4943).
ST 4140
a
b
ST 4943
WDCD-04-04-010
d
W105-03-04-006
a- Nut c- Oil Jack

b- Holder d- Base
W4-4-2-2
3. Install track adjuster (a) to holder (b) of the special 4. Install the special tool (ST 4140) to the special
tool (ST 4943). tool (ST 4943) in order to cover track adjuster (a).
Operate the oil jack. Raise until nut (03) comes out
from the center hole of the special tool (ST 4140).
ST 4140
a
03
b WDAD-04-04-003
a
a- Track Adjuster
WDAD-04-04-002
a- Track Adjuster b- Holder
W4-4-2-3
dCAUTION: As spring (01) is compressed, a strong

force is applied. Check if track adjuster (a) is
dCAUTION: There may be pressure accumulated
inside of cylinder (00A). As valve (09) may fly out
installed correctly when raised. and the high-pressure grease may spout out, do
5. Install nuts (b) (4 used) of the special tool (ST 4943). not loosen valve (09) quickly. Keep body parts and
Secure track adjuster (a). Slowly operate the oil face away from valve (09) and loosen it gradually.
jack. Compress track adjuster (a) until the clearance 6. Remove valve (09) from rod (00B).
between washer (10) and nut (03) becomes approx.
10 mm (0.4 in). j : 19 mm
7. Remove plug (04) from nut (03).
j : 46 mm
l : 5 mm
fNOTE: Spring (01) compressed length:
8. Remove nut (03) from rod (00B).
Spring free length (255 mm (10 in)) - Spring set length
(191 mm (7.5 in)) = Spring compressed length (64 mm j : 41 mm
(2.5 in))
dCAUTION: Lower the oil jack before removing
nut (b) and the special tool (ST 4140). Prevent
washer (10) and spring (01) from flying out due to
the spring (01) force.
9. Slowly lower the oil jack until spring (01) reaches
the free length.
fNOTE: Spring (01) free length: 255 mm (10 in)

b
W105-03-04-012
b- Nut
W4-4-2-4
dCAUTION:
(80 lb)
Special tool (ST 4140) weight: 36 kg
10. Attach nylon slings onto the eyebolts (2 used) of

the special tool (ST 4140). Hoist and hold the special
tool (ST 4140). Remove nuts (b) (4 used) from the
special tool (ST 4943). Hoist and remove the special
tool (ST 4140) from the special tool (ST 4943).
j : 46 mm
ST 4140
WDAD-04-04-004
11. Remove washer (10) from spring (01).

12. Remove the spring (01) assembly from the special
tool (ST 4943). Place it horizontally.
13. Remove spring (01) from cylinder (00A).
14. Remove socket bolts (12) (3 used) from flange (13).
Remove flange (13) from cylinder (00A). Remove
dust seal (11) from flange (13).
l : 6 mm
15. Remove piston rod (05) from cylinder (00A).
16. Remove retaining ring (08), U-packing (07), and
wear ring (06) from piston rod (05).
W4-4-2-5
Assembly of Track Adjuster
09 03 10 00B 01 12 05
WACB-04-04-002
04 08 07 06 00A 13 11
00A- Cylinder 04- Plug 08- Retaining Ring 12- Socket Bolt (3 Used)
00B- Rod 05- Piston Rod 09- Valve 13- Flange
01- Spring 06- Wear Ring 10- Washer
03- Nut 07- U-Packing 11- Dust Seal
W4-4-2-6
Assembly of Track Adjuster

IMPORTANT: Before assembling, apply hydraulic oil 5. Install spring (01) to cylinder (00A). Place the spring
onto parts in order to prevent them from seizing. (01) assembly on the special tool (ST 4943).
1. Apply grease onto the inner surface of cylinder 6. Install washer (10) to spring (01).
(00A). Fill grease in portion A at the bottom of
cylinder (00A). dCAUTION:
(80 lb)
00A A 7. Attach nylon slings onto the eyebolts (2 used) of

the special tool (ST 4140). Hoist the special tool (ST
4140). Install the special tool (ST 4140) to the special
tool (ST 4943).
WADB-04-04-003
ST 4140
2. Install wear ring (06), U-packing (07), and retaining

ring (08) to piston rod (05).
3. Install piston rod (05) to cylinder (00A). Bleed air
ST 4943
from cylinder (00A).
4. Install dust seal (11) to flange (13). Install flange (13)
to cylinder (00A) with socket bolts (12) (3 used).
l : 6 mm
WDAD-04-04-004
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W4-4-2-7
8. Install nuts (a) (4 used) of the special tool (ST 4943). 13. Lower the oil jack.
Secure the spring (01) assembly.
j : 46 mm
dCAUTION:
(80 lb)
14. Attach nylon slings onto the eyebolts (2 used) of

the special tool (ST 4140). Hoist and hold the special
tool (ST 4140). Remove nuts (a) (4 used) from the
special tool (ST 4943). Hoist and remove the special
tool (ST 4140) from the special tool (ST 4943).
j : 46 mm
a 15. Remove track adjuster (b) from the special tool (ST
4943).
W105-03-04-012
a- Nut
b
9. Operate an oil jack. Compress spring (01) to the
specified length.
fNOTE: Specified spring length: 191 mm

10. Install nut (03) to rod (00B). Fit the plug (04)
mounting holes of nut (03) and rod (00B).
j : 41 mm
11. Install plug (04) to nut (03). ST 4943
l : 5 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft) WDAD-04-04-002
12. Install valve (09) to rod (00B). b- Track Adjuster
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W4-4-2-8
Group 5 Front Idler
Removal and Installation of Front Idler
1 1
a
3
b
2 WACC50-04-05-001
a- Nylon Sling b- Wooden Block WABAA0-04-05-003
Removal
Before removing the front idler, the tracks should be 3. When keeping front idler (1) temporarily, place front
removed first. (Refer to 4-7-1.) Therefore, the procedure idler (1) on wooden blocks (b) as illustrated.
starts on the premise that the tracks have already been
removed here.
d CAUTION: Front idler (1) weight: 22 kg (49 lb)
dCAUTION: Front idler (1) may fly out due to the

spring force when removing front idler (1). Do not
stand in the same direction to remove front idler
(1) or where front idler (1) may fly out.
1. Attach nylon slings (a) onto front idler (1). Hoist and
hold front idler (1).
2. Hoist and remove front idler (1) with yoke (2)
together from side frame (3) by using a pry bar.
W4-5-1-1
Group 5 Front Idler
1
b 3
WACC50-04-05-001 WAEA-04-05-001
2
c- Sliding Part
a- Sliding Part b- Nylon Sling
Installation
IMPORTANT: Clean sliding part (a) of yoke (2) and
sliding part (c) of side frame (3). Apply grease.
1. Install front idler (1) in the reverse way of removal.
W4-5-1-2
Group 5 Front Idler
Disassembly of Front Idler
05
00A 03
02
00B
04
01
00B
02
03
05
08
10 07
08
09
WACB-04-05-001
00A- Idler 02- O-Ring (2 Used) 05- Pin (2 Used) 09- Yoke
00B- Bushing (2 Used) 03- Floating Seal (2 Used) 07- Plate 10- Plug
01- Axle 04- Yoke 08- Bolt, Washer (4 Used)
W4-5-2-1
Group 5 Front Idler
Disassembly of Front Idler
dCAUTION:
kg
The idler (00A) assembly weight: 22 5. Put the matching marks onto yoke (04) and axle
(01). Remove the axle (01) assembly from idler (00A)
by using a press.
1. Attach nylon slings onto the idler (00A) assembly.
Hoist the idler (00A) assembly. Place the idler (00A)
assembly horizontally on wooden blocks. 04 01
fNOTE: Wooden Block: 85 mm or more square

00A
2. Remove bolts, washers (08) (4 used). Remove plate
(07) from yokes (04, 09).
j : 19 mm

W105-03-05-008
personal injury.
3. Remove pin (05) from yoke (04) at the upper side by IMPORTANT: Handle floating seal (03) with care.
using a round bar and a hammer. (Refer to W4-5-3.)
fNOTE: Diameter of round bar: 8 mm 6. Remove yoke (04) from idler (00A). Remove floating
seals (03) (2 used) from idler (00A) and yokes (04,
dCAUTION:
kg (45 lb)
The idler (00A) assembly weight: 20
09). Drain off engine oil from idler (00A).
4. Attach nylon slings onto the idler (00A) assembly. fNOTE: Amount of oil: 0.03 L (0.032 US qt)
Hoist the idler (00A) assembly. Set the idler (00A)
assembly with the side where pin (05) has been
removed up. 04
03
00A
03
02
01
09
W105-03-05-009
W4-5-2-2
Group 5 Front Idler
8. Remove O-rings (02) (2 used) from axle (01).

d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, IMPORTANT: Do not remove bushing (00B) unless
such as goggles, hard hat, etc. in order to prevent necessary.
personal injury. 9. When replacing bushing (00B), remove bushings
IMPORTANT: Place wooden blocks (a) under yoke (00B) (2 used) from idler (00A) by using the special
(09) in order not to damage yoke (09). tool (ST 1965) and a press.
7. Place yoke (09) onto wooden blocks (a). Remove
pin (05) from yoke (09) by using a round bar and a
hammer. Put the matching marks onto yoke (09)
and axle (01). Remove axle (01) from yoke (09) by 00A
using a press.
ST 1965
fNOTE: Diameter of round bar: 8 mm
05 00B
02
09
a
W105-03-05-011
01 10. Remove plug (10) from yoke (09).
l : 4 mm
02
a- Wooden Block W105-03-05-010
W4-5-2-3
Group 5 Front Idler
Assembly of Front Idler
00B 00A 05 10
01
02
03
04
WACB-04-05-002
09 07 08
00A- Idler 02- O-Ring (2 Used) 05- Pin (2 Used) 09- Yoke
00B- Bushing (2 Used) 03- Floating Seal (2 Used) 07- Plate 10- Plug
01- Axle 04- Yoke 08- Bolt, Washer (4 Used)
W4-5-2-4
Group 5 Front Idler
Assembly of Front Idler IMPORTANT: Handle floating seal (03) with care.
(Refer to W4-5-3.)
IMPORTANT: Before assembling, apply engine oil
onto parts in order to prevent them from seizing. 5. Apply engine oil onto the sliding surface of floating
seal (03) and the outer surface of O-ring. Install
1. Install bushings (00B) (2 used) to idler (00A) by using
floating seal (03) to idler (00A) and yoke (04).
a press.
6. Install the axle (01) assembly to idler (00A) from the
2. Attach nylon slings onto idler (00A). Hoist idler
side where floating seal (03) has been installed.
(00A). Place idler (00A) horizontally on wooden
blocks.
fNOTE: Wooden Block: 85 mm or more square

3. Install O-ring (02) to axle (01).

personal injury.
IMPORTANT: Check the direction to install pin (05).
and install yoke (04) to axle (01) with pin (05) by
using a hammer. At this time, install pin (05) with
the slit (a) side facing to the shaft at the axle (01)
side.
01 04 02
WACB-04-05-004
View A
a
05
WACB-04-05-005
a- Slit
W4-5-2-5
Group 5 Front Idler
7. Attach nylon slings onto the idler (00A) assembly.

Hoist the idler (00A) assembly. Turn over and place dCAUTION: Metal fragments may fly off when
the idler (00A) assembly on wooden blocks.
8. Add engine oil (API CD class, SAE #30) to part (B) of personal injury.
idler (00A).
IMPORTANT: Check the direction to install pin (05).
fNOTE: Amount of oil: 0.03 L (0.032 US qt) 10. Fit the matching marks made when disassembling
and install yoke (09) to axle (01) with pin (05) by
B 00A using a hammer. At this time, install pin (05) with
the slit (a) side facing to the shaft at the axle (01)
side.
11. Install plate (07) to yokes (04, 09) with bolts, washers
(08) (4 used).
j : 19 mm
WADB-04-05-007
m : 90 N·m (9 kgf·m, 66 lbf·ft)
12. Install plug (10) to yoke (09).
IMPORTANT: Handle floating seal (03) with care.
(Refer to W4-5-3.) l : 4 mm
9. Install other O-ring (02) to axle (01). Apply engine
oil onto the sliding surface of floating seal (03) and
the outer surface of O-ring. Install other floating seal
(03) to idler (00A) and yoke (04).
09
03
02
01 00A
04
WADB-04-05-005
W4-5-2-6
Removal and Installation of Lower Roller

IMPORTANT: The lower roller cannot be
disassembled. Replace it as an assembly.
Removal
dCAUTION: Securely support the raised machine

by using blocks. b
1. Raise the machine off the ground by using the front
attachment. Place the blocks under the track frame
and support the machine.
dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (1) may fly out and
b- 90 to 110° M1M7-04-006
the high-pressure grease may spout out from the

grease outlet (a), do not loosen valve (1) quickly 2 1 a
and/or excessively. Keep body parts and face away
from valve (1) and loosen it gradually. Do not
loosen grease fitting (2).
IMPORTANT: Loosening valve (1) by 1 to 1.5 turns is
enough. Do not loosen it over those turns.
IMPORTANT: When gravel or mud is packed between a- Grease Outlet W1NC-03-06-001
sprockets and track links, remove them before
loosening.
2. Loosen valve (1) in the track adjuster gradually.
Drain grease until the clearance in the track is
enough to remove lower roller (4).
j : 19 mm
3. Tighten valve (1) clockwise to the original condition.
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

3, 6
Remove lower roller (4).
j : 22 mm

4
bolt (3). M588-07-052
W4-6-1-1
Installation 5
 The procedure starts on the premise that the track
has been raised off the ground.
1. Set lower roller (4) below track frame (5). Fit lower
2
roller (4) to the mounting holes of track frame (5).
used). Install lower roller (4) with bolts (3) (2 used)
and washers (6) (2 used).
j : 22 mm
m : 220 N·m (22 kgf·m, 162 lbf·ft)

3, 6
3. Apply grease through grease fitting (2) and adjust
the track tension.
fNOTE: Joint part (b) of the track (rubber crawler (c))

should be in the center when measuring the track 4
(rubber crawler (c)) tension. At this time, turn the track in M588-07-052
reverse direction so that the track sag should be located
down.
Track Sag Specification (A): 10 to 15 mm (rubber crawler
(c))
Side (a)
4
c- Rubber Crawler W567-03-07-007

M503-05-050
b c
attachment. Remove the blocks under track frame
(5).
M102-07-075
b
b- Joint Part c- Rubber Crawler
W4-6-1-2
When adding engine oil, perform step 5 to step 7 after

removing the lower roller from the track frame.
5. Add engine oil (API CD class, SAE #30) through the 1 2
plug (2) hole of cover (1).
fNOTE: Amount of oil: 65±10 ml (0.069±0.011 US qt)

6. Apply LOCTITE #503 onto plug (2).
7. Install plug (2).
l : 4 mm
m : 10 to 18 N·m (1 to 1.8 kgf·m, 7.4 to 13.5

lbf·ft)
WADB-04-06-003
W4-6-1-3
(Blank)
W4-6-1-4
Group 7 Track
Removal and Installation of Track

Removal
d CAUTION: Rubber crawler weight: 78 kg (175 lb)

dbyCAUTION: Securely support the raised machine
using blocks.
b

attachment.
dtrack
CAUTION: The pressure inside cylinder of the
adjuster is high. As valve (1) may fly out and
b- 90 to 110° M1M7-04-006
the high-pressure grease may spout out from the

grease outlet (c), do not loosen valve (1) quickly 2 1 c
and/or excessively. Keep body parts and face away
from valve (1) and loosen it gradually. Do not
loosen grease fitting (2).
IMPORTANT: Loosening valve (1) by 1 to 1.5 turns is
enough. Do not loosen it over those turns.
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before c- Grease Outlet W1NC-03-06-001
loosening.
2. Loosen valve (1) in the track adjuster slowly and
drain grease.
j : 19 mm
fNOTE: If rotating the track in forward and reverse

direction with valve (1) loosened, the track can be
removed and installed easily.
3. Insert steel pipes (3) into the track. Rotate the
sprocket in reverse direction. After the front idler is
floated by steel pipes (3), slide and remove the track
transversely.
3
a- Rotating Direction M503-07-062
W4-7-1-1
Group 7 Track
Installation
d CAUTION: Rubber crawler weight: 78 kg (175 lb)

dbyCAUTION: Securely support the raised machine
using blocks. b
attachment.
2. Mesh the track with the sprocket. Attach the track
onto the front idler. Rotate the sprocket in reverse
direction and push the track.
3. Tighten valve (1).
b- Rotating Direction WAFA-04-07-001
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

4. Apply grease through grease fitting (2) and adjust
the track tension. 1
2
fNOTE: Joint endless mark (c) of the track (rubber
crawler (e)) should be in the center when measuring the
track (rubber crawler (e)) tension. At this time, turn the
track in reverse direction so that the track sag should be
located down.
Track Sag Specification (A): 10 to 15 mm (Rubber crawler
(e))
M588-07-052
Side (a)
e
M503-05-050 WACG90-04-07-001
c e
d- Lower Roller e- Rubber Crawler
c
c- Endless Mark e- Rubber Crawler
M102-07-075
W4-7-1-2
Removal and Installation of Blade Cylinder

1 2 3
secure the hoses have been removed, install the 4
Removal
1. Swing the upperstructure by 90 degrees and park
the machine on a solid and level surface. Lower the 8
blade top onto the ground.
(2) from blade cylinder (3).
7 6 5
j : 17 mm WACG90-04-08-007

personal injury.
3. Remove bolts (7) (2 used), washers (6) (2 used), and
lock (5). Remove pin (8) from track frame (4) by
j : 19 mm

bolt (7).
4. Start the engine. Operate the blade control lever
and retract the cylinder rod to the stroke end. In
order not to extend the cylinder rod, pass wires
through the boss of cylinder rod and secure it. Stop
the engine.
W4-8-1-1

(Refer to W1-4-1.)
10 11 1 4
5. Remove bolt, washer (10) and clip (11) from blade
cylinder (1).
j : 17 mm 9
6. Disconnect hoses (4) (2 used) from blade cylinder 6
(1). 8
j : 19 mm 7

personal injury.
7. Remove bolts (7) (2 used), washers (8) (2 used), and
lock (6). Remove pin (5) from blade (9) by using a WACG90-04-08-007
bar and a hammer. Remove blade cylinder (1) from
blade (9).
j : 19 mm

bolt (7).
W4-8-1-2
Installation
1. Apply grease to the bushing inside of blade cylinder
(1), the lip part of the dust seal (both bottom and 10 11 1 4
rod sides), and the boss side.
2. Apply grease to pin (5). Fit the pin (5) holes of blade
cylinder (1) and blade (9).

9
such as goggles, hard hat, etc. in order to prevent 6
personal injury. 8
3. Install blade cylinder (1) to blade (9) with pin (5) by 7
using a hammer. Apply LOCTITE #263 or equivalent
to bolt (7). Secure pin (5) with lock (6), bolts (7) (2
used), and washers (8) (2 used).
5
j : 19 mm
m : 110 N·m (11 kgf·m, 81 lbf·ft)

4. Connect hoses (4) (2 used) to blade cylinder (1). WACG90-04-08-007
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

5. Install clip (11) to blade cylinder (1) with bolt,
washer (10).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W4-8-1-3
6. Remove the wires from the blade cylinder (3) rod

side.
1 2 3
7. Start the engine. Operate the blade control lever
and extend the cylinder rod slowly. Fit the pin (8)
holes of blade cylinder (3) and track frame (4).

personal injury.
8. Apply grease onto pin (8). Install blade cylinder (3)
to track frame (4) with pin (8) by using a hammer.
8
used). Secure pin (8) to track frame (4) with lock (5),
bolts (7) (2 used), and washers (6) (2 used).
7 6 5
j : 19 mm WACG90-04-08-007
m : 110 N·m (11 kgf·m, 81 lbf·ft)

10. Install cover (2) to blade cylinder (3) with bolts,
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

IMPORTANT: After completing the work, operate the
blade cylinder to the stroke end several times and
bleed air from the circuit.
W4-8-1-4
Disassembly of Blade Cylinder
13
12
11
10
8 9
6 7
5
4
2 3
14
WACG90-04-08-001
1- Cylinder Rod 5- O-Ring 9- Packing 13- Piston Nut

2- Dust Seal 6- Backup Ring 10- Seal Ring 14- Cylinder Tube
3- Bushing 7- O-Ring 11- Piston
4- Cylinder Head 8- Backup Ring 12- Wear Ring
W4-8-2-1
Disassembly of Blade Cylinder

IMPORTANT: The seals cannot be reused. Replace 3. Loosen cylinder head (4) by using hook wrench (b).
them with the new ones. Remove cylinder rod (1) from cylinder tube (14).
 The procedure starts on the premise that the pipes and Diameter of cylinder head (4): 78 mm
the bands securing the pipes have been removed.
1. Secure the cylinder on a workbench horizontally.
Drain off hydraulic oil from the cylinder.
b
14
W102-04-02-027
IMPORTANT: The lock washer in cylinder head (4) 1 4

forms an integral part with cylinder tube (14). Do W506-04-02-004
not damage cylinder tube (14) and cylinder head b- Hook Wrench
(4) when bending and extending the lock washer.
2. Pull out cylinder rod (1) about 100 mm (3.94 in).
Install a protective cover to cylinder rod (1). Extend
lock washer (a) in cylinder head (4).
1 4
W506-04-02-003
a- Lock Washer
W4-8-2-2
IMPORTANT: Piston nut (13) cannot be reused. 8. Remove packing (9) and dust seal (2) from cylinder
Replace it with the new one. head (4).
4. Secure the cylinder rod (1) on a workbench 9. Remove O-rings (5, 7) and backup rings (6, 8) from
horizontally. Remove piston nut (13) from cylinder cylinder head (4).
rod (1).
IMPORTANT: When bushing (3) has been removed,
j : 36 mm replace it with the new one when assembling.
5. Remove piston (11) by using the special tool (ST 10. Remove bushing (3) from cylinder head (4).
3444).
fNOTE: Bushing (3) cannot be tapped and removed from
Special Tool for Piston: ST 3444: 65 mm cylinder head (4). Cut off bushing (3) by using a lathe.
Insert a screwdriver strongly and remove bushing (3).
6. Install the protective tape onto the thread part
of cylinder rod (1) in order to protect the seal of
cylinder head (4). Remove cylinder head (4) from
cylinder rod (1).
7. Secure piston (11) in a vise. Remove wear ring (12)
and seal ring (10) from piston (11).
W4-8-2-3
Assembly of Blade Cylinder
13 12 10 11 14 1 9 8 7 6 5 4 2
WACG90-04-08-002
3
1- Cylinder Rod 5- O-Ring 9- Packing 13- Piston Nut

2- Dust Seal 6- Backup Ring 10- Seal Ring 14- Cylinder Tube
3- Bushing 7- O-Ring 11- Piston
4- Cylinder Head 8- Backup Ring 12- Wear Ring
W4-8-2-4
Assembly of Blade Cylinder

IMPORTANT: Before assembling, apply hydraulic oil 2. Install O-rings (5, 7) and backup rings (6, 8) to
onto parts in order to prevent them from seizing. cylinder head (4).
1. Install bushing (3) to cylinder head (4) by using the IMPORTANT: Check the direction to install packing
special tool (ST 8155). (9).
3. Install packing (9) to the inside of cylinder head (4).
ST 8155
4
3
9
4
WACG90-04-08-004
W1LD-04-02-004
3
4. Install dust seal (2) to cylinder head (4).
4
a b
WACG90-04-08-003
a- Check that bushing (3) reaches the contacting surface.

b- Check that bushing (3) is not out.
W4-8-2-5
5. Install wear ring (12) to piston (11). Install seal ring 7. Install the cylinder head (4) assembly to cylinder rod
(10b). Install seal ring (10a) by using the special tool (1) by turning.
(ST 8157).
Special Tool for Cylinder Head (Rod Outer Diameter):
ST 8156: 35mm
ST 8157
8. Install the piston (11) assembly to cylinder rod (1).
10a
Special Tool for Piston: ST 3444: 65mm
10b
m : 491±49 N·m (50±5.0 kgf·m, 360±36 lbf·ft)
IMPORTANT: Piston nut (13) cannot be reused.
12
11
Replace it with the new one.
9. Secure cylinder rod (1) on a workbench horizontally.
WACG90-04-08-005 Install piston nut (13) to cylinder head (1) by using
the special tool (ST 5908).
10a- Seal Ring 10b- Square Ring j : 36 mm
m : 510 to 550 N·m (51 to 55 kgf·m, 380 to 410

IMPORTANT: If not adjusting wear ring (12) and lbf·ft)
seal ring (10), piston (11) cannot be installed to
cylinder tube (14).
6. Install the special tool (ST 8157) onto piston (11).
Adjust wear ring (12) and seal ring (10a).
12
10a
ST 8157
WACG90-04-08-006
W4-8-2-6
10. Secure cylinder tube (14) on a workbench

horizontally. Insert the cylinder rod (1) assembly
into cylinder tube (14) straight by using the special
tool (ST 7984) in order not to damage the cylinder
rod (1) assembly.
Special Tool for Cylinder Rod (Tube Inner Diameter):
ST 7984: 65mm
11. Tighten cylinder head (4) to cylinder tube (14) by
using hook wrench (a). Bend the lock washer in
order not to loosen.
Diameter of cylinder head (4): 78 mm
m : 215.5 to 235.2 N·m (21.5 to 23.5 kgf·m, 159

to 175 lbf·ft)
14
W506-04-02-019
a- Hook Wrench
W4-8-2-7
(Blank)
W4-8-2-8
MEMO
MEMO
SECTION 5
FRONT ATTACHMENT
CONTENTS
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
Cylinder.........................................................................W5-2-4-1
Disassembly of Boom Cylinder..................................W5-2-5-1
Assembly of Boom Cylinder........................................W5-2-5-4
Disassembly of Arm, Bucket, and Boom Swing
Cylinders.......................................................................W5-2-6-1
Assembly of Arm, Bucket, and Boom Swing
Cylinders.......................................................................W5-2-6-7
ACG90W-5-1
(Blank)
ACG90W-5-2
Removal and Installation of Front

Attachment
Removal
1. Park the machine on a solid and level surface. Fully
extend the arm cylinder and the bucket cylinder
and lower the boom. Place the arm end on the
ground.
2. Remove bolts (7) (2 used), spring washers (8) (2
used), and washers (9) (2 used). Remove cover (6) WABA50-05-02-011
from boom cylinder (5). Remove caps (11) (2 used).
j : 17 mm
dCAUTION: Boom cylinder (5) weight: 24 kg (53 lb)

personal injury.
3. Attach nylon slings onto boom cylinder (5). Hoist
and hold boom cylinder (5). Remove bolt (1), spring
washer (2), and bushing (3) from the boom. Remove 10
pin (4) from the boom by using a bar and a hammer.
Remove shims (12) between the boom and boom
cylinder (5).
j : 19 mm
4. Start the engine. Operate the boom control lever
and retract cylinder rod (10). Pass wires through the
cylinder rod (10) hole and secure cylinder rod (10) in
order not to extend.
5. Place the cylinder rod (10) side of boom cylinder (5)
onto the stand.
W554-02-03-007
W5-1-1-1

(Refer to W1-4-1.)

6. Disconnect the connector (2) of boom light. 9 2
Remove clips (9) (2 used). Loosen clips (1) (3 used)
which secure pipe of boom back and the wire
harness of the boom light. Remove the wire harness
from clips (1) (3 used).
1
dCAUTION:
lb)
Front attachment weight: 250 kg (555
7. Attach nylon slings onto the boom. Reduce slack

of the nylon slings. Hoist and hold the boom at the
center of gravity.
j : 22 mm
9. Remove nuts (6) (2 used). Remove bolt (4) from the 9
swing post. WACC50-05-01-002
j : 17 mm

nut (6).

personal injury. 3
10. Remove boom foot pin (5) from the swing post by
11. Hoist and remove the front attachment. Remove 4
shims (7) from the right and left sides of the boom
foot pin (5) part.
5, 7
6
WACC50-05-01-001
W5-1-1-2
Installation
dCAUTION:
lb)
Front attachment weight: 250 kg (555
1. Hoist the front attachment. Fit the boom foot part

to the mounting hole of the swing post. Insert
shims (7) to both right and left of the boom foot
parts and adjust the right and left clearances within
0.5 mm (0.02 in) respectively. 1

personal injury.
2. Install boom foot pin (3) by using a hammer. 3, 7
IMPORTANT: Install nut (4) so that the clearance
between nut (4) and the swing post boss should
be 2 to 3 mm.
4
3. Apply LOCTITE #263 or equivalent to nuts (4) (2 WACC50-05-01-001
used). Install bolt (2) and nuts (4) (2 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

4. Apply grease to the grease fitting (a) of boom foot.
5. Connect hoses (1) (4 used). a
j : 22 mm
m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

MABC-07-005
a- Grease Fitting at the Boom Foot
W5-1-1-3
6. Remove the wires from the boom cylinder (5) rod

side.

7. Hoist boom cylinder (5). Start the engine with the
cylinder rod of boom cylinder (5) retracted to the
stroke end. Extend boom cylinder (5) slowly. Fit the
pin (4) holes of the boom cylinder (5) cylinder rod
side and the boom.

personal injury.
8. Install shims (12) to both sides of the cylinder rod
boss. Adjust total clearance of left and right within
0.5 mm. Install pin (4) by using a hammer. Secure
pin (4) to the boom with bolt (1), spring washer (2),
and bushing (3).
WABA50-05-02-011
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft) 14 13
fNOTE: Shim (12) thickness: 0.5 mm (0.02 in), 1.0 mm

(0.039 in)
9. Apply grease to grease fitting (a) at the cylinder rod.
10. Install caps (11) (2 used). Apply LOCTITE #263 or
equivalent to bolt (7). Install cover (6) to boom
cylinder (5) with bolts (7) (2 used), spring washers 10
(8) (2 used), and washers (9) (2 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

11. Pass the wire harness of boom light through clips
(10) (3 used). Connect connector (13). Secure the
wire harness of boom light and the boom pipes
with clips (10) (3 used). Install clips (14) (2 used).
14
IMPORTANT: After completing the work, add
WACC50-05-01-002
hydraulic oil to the specified level. Operate each
cylinder to the stroke end several times and bleed
air in the circuit. Check for any oil leak of each
hose connection.
M1M7-07-020
a- Grease Fitting at the Cylinder Rod
W5-1-1-4
Group 2 Cylinder
Removal and Installation of Boom Cylinder

Removal
Retract the arm cylinder and bucket cylinder and
lower the arm top onto the ground.
2. Remove bolts (7) (2 used), spring washers (8) (2
used), and washers (9) (2 used). Remove cover (6)
from boom cylinder (5). Remove caps (11) (2 used).
WABA50-05-02-011
j : 17 mm

bolt (7).

personal injury.
3. Attach nylon slings onto boom cylinder (5). Hoist
and hold boom cylinder (5). Remove bolt (1), spring
washer (2), and bushing (3). Remove pin (4) by using
a bar and a hammer.
j : 19 mm
4. Remove shims (12) from both sides of the cylinder
rod (10) boss. Start the engine. Retract cylinder
rod (10) to the stroke end. In order not to extend
cylinder rod (10), pass wires through the boss of
cylinder rod (10) and secure it.
W554-02-03-007
5. Place boom cylinder (5) onto a stand.

(Refer to W1-4-1.)

W5-2-1-1
Group 2 Cylinder
6. Disconnect hoses (8) (2 used) from boom cylinder

(7).
8
j : 22 mm
7. Remove bolt (2) and nuts (4) (2 used) from swing
7
post (6).
j : 17 mm

bolt (2) and nut (4).

WABA50-05-02-012

personal injury.
8. Remove pin (1) by using a bar and a hammer. 1, 5 2 6 7
Remove shims (5) from both sides of the cylinder
tube boss.
fNOTE: Put the matching marks on swing post (6) and

pin (1) for assembling.
9. Hoist and remove boom cylinder (7) from swing
post (6).
4 WAEB-05-01-002
W5-2-1-2
Group 2 Cylinder
Installation
1. Apply grease to the lip part of dust seal for boom
cylinder (7), the boss side, and the bushing inside 1, 5 2 6 7
(both bottom side and rod side).

IMPORTANT: Use one or more shims (5) respectively
at the right and left sides.
2. Apply grease to pin (1). Attach nylon slings onto
boom cylinder (7). Hoist boom cylinder (7). Fit the
pin (1) holes of boom cylinder (7) and swing post
(6). Install shims (5) to both sides of the cylinder
tube boss. Adjust total clearance of right and left
within 0.5 mm (0.02 in).
fNOTE: Shim (5) thickness: 0.5 mm (0.02 in)

personal injury. 4 WAEB-05-01-002
3. Install pin (1) by using a hammer.
4. Apply grease to grease fitting (a) at the cylinder
bottom side.
IMPORTANT: Install nut (4) so that the clearance
between nut (4) and the swing post (6) boss
should be 2 to 3 mm.
5. Apply LOCTITE #263 or equivalent to bolt (2) and
nuts (4) (2 used). Install bolt (2) and nuts (4) (2 used)
to swing post (6).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

a M1M7-07-021
6. Connect hoses (8) (2 used) to boom cylinder (7).
a- Grease Fitting at the Cylinder Bottom
j : 22 mm
m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

8
WABA50-05-02-012
W5-2-1-3
Group 2 Cylinder

7. Remove the wires from the boom cylinder (5) rod
side.
8. Hoist boom cylinder (5). Start the engine with the
cylinder rod retracted to the stroke end. Slowly
extend the cylinder rod. Fit the pin (4) holes of
boom cylinder (5) and the boom.

personal injury.
9. Install shims (12) to both sides of the cylinder rod
boss. Adjust total clearance of right and left within
0.5 mm. Install pin (4) by using a hammer. Secure
pin (4) to the boom with bolt (1), spring washer (2),
and bushing (3).
WABA50-05-02-011
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

(0.039 in) a
10. Apply grease to grease fitting (a) at the cylinder rod
side.
11. Apply LOCTITE #263 or equivalent to bolts (7) (2
used). Install caps (11) (2 used) to boom cylinder (5).
Install cover (6) to boom cylinder (5) with bolts (7) (2
used), spring washers (8) (2 used), and washers (9) (2
used).
M1M7-07-020
j : 17 mm a- Grease Fitting at the Cylinder Rod
m : 50 N·m (5 kgf·m, 37 lbf·ft)

boom cylinder to the stroke end several times and
bleed air from the circuit.
W5-2-1-4
Group 2 Cylinder
Removal and Installation of Arm Cylinder 1
IMPORTANT: The hoses and pipes contain hydraulic 12

4, 6, 13
Removal
1. Park the machine on a solid and level surface. 7 3 2
Retract the arm cylinder and bucket cylinder and WABAA0-05-02-006
lower the arm top onto the ground.
2. Set wooden block (3) between arm cylinder (1) and
boom (2). Support arm cylinder (1).

5
personal injury.
3. Remove bolt (4), spring washer (13), and bushing W577-04-02-008
(6). Remove pin (7) by using a bar and a hammer.
Remove shims (12) from both sides of the cylinder
rod boss. 1 9, 10, 11
j : 19 mm
fNOTE: If pin (7) can not be removed, raise boom (2) a

little and remove pin (7).
4. In order not to extend cylinder rod (5), pass wires
through the boss of cylinder rod (5) and secure it.

(Refer to W1-4-1.) WDEG-05-02-098
8
5. Remove bolt, washer (9). Remove clamp (10) and
bushing (11) from arm cylinder (1). Disconnect
hoses (8) (2 used).
j : 13 mm
j : 22 mm
W5-2-2-1
Group 2 Cylinder
6. Attach nylon slings onto arm cylinder (1). Hold arm

cylinder (1).
1
A
personal injury.
7. Remove bolt (3), spring washer (6), and bushing (4).
Remove pin (2) from arm cylinder (1) by using a bar
and a hammer. Remove shims (5) from both sides of
the cylinder tube boss.
j : 19 mm 3, 4, 6
8. Remove arm cylinder (1) from boom (7). 2

7
WAYE-04-02-004
Detail A 5
2 3, 4, 6
WDEG-05-02-099
W5-2-2-2
Group 2 Cylinder
Installation
Detail A
1. Apply grease onto the lip part of the dust seal for 7 3
arm cylinder (2), the boss side, and the bushing
inside (both bottom side and rod side). 2

2. Attach nylon slings onto arm cylinder (2). Hoist arm
cylinder (2). Fit the pin (4) holes of arm cylinder (2)
and boom (3). Install shims (7) to both sides of the
cylinder tube boss. Adjust total clearance of right
and left within 0.5 mm (0.02 in).
fNOTE: Shim (7) thickness: 0.5 mm (0.02 in), 1.0 mm 4 5, 6, 8

(0.039 in)
WDEG-05-02-099
personal injury.
3. Install pin (4) by using a hammer. Secure pin (4) a
to boom (3) with bolt (5), spring washer (8), and
bushing (6).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

4. Apply grease onto grease fitting (a) at the cylinder
bottom side.
5. Connect hoses (1) (2 used) to arm cylinder (2).
j : 22 mm M585-07-046
m : 40 N·m (4 kgf·m, 29.5 lbf·ft) a- Grease Fitting at the Cylinder Bottom
6. Secure hose (1) of rod side, bushing (11), and clamp

(10) to the arm cylinder (2) rod side with bolt,
2 9, 10, 11 A
washer (9).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
WDEG-05-02-098
1
W5-2-2-3
Group 2 Cylinder

7. Remove the wires from the arm cylinder (1) rod side. 1
8. Start the engine with the cylinder rod retracted to 7

the stroke end. Slowly extend the cylinder rod. Fit 2, 6, 8
the pin (3) holes of arm cylinder (1) and arm (4). 4
fNOTE: If it is difficult to fit the pin (3) holes, raise boom

(5) a little and fit the pin (3) holes.
9. Install shims (7) to the right and left sides of the
cylinder rod. Adjust total clearance of right and left
within 0.5 mm (0.02 in).
3 5
fNOTE: Shim (7) thickness: 0.5 mm (0.02 in), 1.0 mm WABAA0-05-02-006
(0.039 in)

a hammer is used. Wear necessary protection, a
personal injury.
10. Install pin (3) by using a hammer. Secure pin (3) to
arm (4) with bolt (2), spring washer (8), and bushing
(6).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

11. Apply grease to grease fitting (a) at the cylinder rod
side.
M571-07-006
IMPORTANT: After completing the work, operate
arm cylinder (1) to the stroke end several times
and bleed air from the circuit.
W5-2-2-4
Group 2 Cylinder
Removal and Installation of Bucket Cylinder

oil. When removing the hoses and pipes, receive 1
3
hoses, and pipes for assembling. If the clips which 2
3
Removal
W554-04-02-006
Retract the arm cylinder and bucket cylinder (1) and
lower the end part of arm (2) onto the ground.
5 9
2. Set wooden blocks (3) under the arm (2) top and
between bucket cylinder (1) and arm (2).
dCAUTION: Before removing pin (6), secure the

link by using wires in order not to fall off.

4

personal injury.
3. Remove nuts (5) (2 used) and bolt (4). Remove pin 6
(6) by using a bar and a hammer. Remove shims (9). WLAA-05-02-002
j : 24 mm

nut (5).
4. Start the engine. Operate the bucket control lever 7 1
and retract bucket cylinder (1). In order not to
extend rod (7), pass wires (8) through the rod hole
and secure rod (7) to the bucket cylinder (1) tube.
Stop the engine.
8
W102-04-02-005
W5-2-3-1
Group 2 Cylinder

(Refer to W1-4-1.) 2 3, 4, 5
8
5. Disconnect hoses (7) (2 used) from bucket cylinder 1
(1).
j : 22 mm

personal injury.
6. Attach nylon slings onto bucket cylinder (1). Hoist
and hold bucket cylinder (1). Remove bolt (3), spring
washer (4), and bushing (5) from arm (6). Remove
pin (2) by using a bar and a hammer. Remove shims
(8) from both sides of the cylinder tube boss.
j : 19 mm 7 6
7. Remove bucket cylinder (1) from arm (6). WACC50-05-02-005
W5-2-3-2
Group 2 Cylinder
Installation
2 3, 4, 5
1. Apply grease to the lip part of the dust seal for 13
bucket cylinder (1), the boss side, and the bushing
inside (both bottom and rod sides).
1
2. Fit the hole on the cylinder bottom side to the
cylinder mounting holes on arm (6).
3. Install shims (13) to the right and left sides of the
cylinder bottom side. Adjust total clearance of left
and right within 0.5 mm (0.02 in).

(0.039 in)

personal injury. 7 6 WACC50-05-02-005
4. Install pin (2) by using a hammer. Secure pin (2) with
bolt (3), spring washer (4), and bushing (5).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

5. Apply grease to grease fitting (a) at the cylinder
bottom side.
a
6. Connect hoses (7) (2 used) to bucket cylinder (1).
j : 22 mm
m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

engine and check for any oil leaks. M571-07-006
7. Remove wires (9) from rod (8) of bucket cylinder (1).

a- Grease Fitting at the Cylinder Bottom
8 1
9
W102-04-02-005
W5-2-3-3
Group 2 Cylinder
8. Start the engine with the cylinder rod retracted to

the stroke end. Slowly extend the cylinder rod. Fit 11 2 13
the pin (3) holes of bucket cylinder (1), link A (11),
and links B (9) (2 used).
9. Install shims (13) to the right and left sides of the 1
cylinder rod side. Adjust total clearance of left and
right within 0.5 mm (0.02 in).
fNOTE: Shim (13) thickness: 0.5 mm (0.02 in), 1.0 mm 9

(0.039 in) 3

WLAA-05-02-002

personal injury.
IMPORTANT: Adjust the clearance between the boss
of link B (9) and nut (2) is 2 to 3 mm. Install nut (2).
10. Remove the wires which secure link B (9). Install pin
(3) by using a hammer. a
11. Install bolt (1) to link B (9) and pin (3) with nuts (2) (2
used).
j : 24 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft) WACG90-05-02-013
12. Apply grease to grease fitting (a) at the cylinder rod a- Grease Fitting at the Cylinder Rod
(3 locations).
IMPORTANT: When link B (9) is removed from the
arm, be sure to insert shim (13) at installing it. 13 13
bucket cylinder to the stroke end several times
and bleed air from the circuit.
9 9
W178-02-11-289
W5-2-3-4
Group 2 Cylinder

Cylinder
1 2 3
7
10
5 4 WACC50-05-02-004
WACC50-05-02-003 6
IMPORTANT: The hoses and pipes contain hydraulic 3. Start the engine. Retract the cylinder rod to the
oil. When removing the hoses and pipes, receive stroke end. In order not to extend the cylinder rod,
oil with a container in order to avoid spilling oil. pass wires through the boss of cylinder rod and
IMPORTANT: Cap the open ends in case the hoses secure it.
and pipes have been disconnected. In addition, 4. Remove bolts, washers (7, 9) (2 used for each).
attach identification tags onto the connectors, Remove cover (10).
secure the hoses have been removed, install the j : 17 mm
(8).
Removal
j : 17 mm
 The procedure starts on the premise that the front
attachment has swung to the left.
1. Park the machine on a solid and level surface. Fully
retract the arm cylinder and the bucket cylinder and
lower the boom. Place the arm end on the ground.
2. Remove nuts (3) (2 used). Remove bolt (1) from pin
(2). Remove pin (2) from the swing post.
j : 17 mm

bolt (1).
fNOTE: When removing bolt (1), pin (2) may fall off. Put
the matching marks on the boss of swing post and pin
(2) for assembling.
W5-2-4-1
Group 2 Cylinder
5
1
1 6
WACC50-05-02-001
7
WACC50-05-02-002
7. Set wooden blocks between boom swing cylinder

(Refer to W1-4-1.)
(2) and main frame (8). Support boom swing
cylinder (2). Remove bolt (7) and bushing (6).
6. Disconnect hoses (1) (2 used) from boom swing Remove pin (5).
cylinder (2).
j : 19 mm
j : 17 mm
bolt (7).
dCAUTION:
(47 lb)
Boom swing cylinder (4) weight: 21 kg
8. Hoist and remove boom swing cylinder (2) from

main frame (8).
W5-2-4-2
Group 2 Cylinder
8
1
1
7 WACC50-05-02-001
6
WACC50-05-02-002
Installation
1. Apply grease onto the dust seal lip part of boom 4. Connect hoses (1) (2 used).
swing cylinder (5).
j : 17 mm
dCAUTION: Boom swing cylinder (5) weight: 21 kg
(47 lb) m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
2. Attach nylon slings onto boom swing cylinder (5).
Hoist boom swing cylinder (5). Place the boss of
boom swing cylinder (5) tube onto main frame (9).
Set wooden blocks between boom swing cylinder
(5) and main frame (9). Support boom swing
cylinder (5).
3. Apply grease to pin (8). Fit the pin (8) holes of main
frame (9) and boom swing cylinder (5). Install pin
(8) by using a plastic hammer. Apply LOCTITE #263
or equivalent to bolt (6). Secure pin (8) with bolt (6)
and bushing (7).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W5-2-4-3
Group 2 Cylinder
1 2 3
10
5 a 4 WACC50-05-02-003
6 WACC50-05-02-004
5. Remove the wires from the boom swing cylinder (4) 10. Install cover (8) with bolts, washers (6) (5 used).
rod side.
j : 17 mm
engine and check for any oil leaks. m : 50 N·m (5 kgf·m, 37 lbf·ft)
6. Start the engine with the boom swing cylinder (4) 11. Install cover (10) with bolts, washers (7, 9) (2 used
rod retracted to the stroke end. Slowly extend the for each).
boom swing cylinder (4) rod. Fit the pin (2) holes of
boom swing cylinder (4) and the swing post. j : 17 mm
7. Apply grease to pin (2). Fit the bolt (1) holes of the m : 50 N·m (5 kgf·m, 37 lbf·ft)
swing post and pin (2). Install pin (2).
IMPORTANT: After completing the work, operate
IMPORTANT: Install nut (3) so that the clearance boom swing cylinder (4) to the stroke end several
between the boss of swing post and nut (3) should times and bleed air from the circuit.
be 2 to 3 mm.
8. Apply LOCTITE #263 or equivalent to bolt (1). Install
bolt (1). Install nuts (3) (2 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

9. Apply grease to grease fitting (a) at the cylinder rod.
W5-2-4-4
Group 2 Cylinder
Disassembly of Boom Cylinder
21 18
22
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
23
WACG90-05-02-001
1- Cylinder Rod 7- Bushing 13- Cushion Ring 19- Piston

2- Wiper Ring 8- U-Ring 14- Spacer 20- Steel Ball
3- Cylinder Head 9- Connector 15- Stopper 21- Set Screw
4- O-Ring 10- Stopper 16- Retainer 22- Seal Ring
5- Backup Ring 11- O-Ring 17- Cushion Bearing 23- Cylinder Tube
6- O-Ring 12- Backup Ring 18- Slide Ring (2 Used)
W5-2-5-1
Group 2 Cylinder
Disassembly of Boom Cylinder

 The procedure starts on the premise that the 3. Loosen cylinder head (3) by using hook wrench
pipes and the bands securing the pipes have been (b) with the protective cover on cylinder rod (1).
removed. Remove the cylinder rod (1) assembly from cylinder
d CAUTION: Boom cylinder weight: 24 kg (53 lb) tube (23).
IMPORTANT: The seals cannot be reused. Replace Diameter of cylinder head (3): 85 mm
them with the new ones.
1. Hoist the cylinder and secure it on a workbench
horizontally. Drain off hydraulic oil from the b
cylinder.
23
W102-04-02-027
1 3
IMPORTANT: The lock washer (a) in cylinder head (3)
W506-04-02-004
forms an integral part with cylinder tube (23). Do b- Hook Wrench
not damage cylinder tube (23) and cylinder head
(3) when bending and extending lock washer (a).
2. Pull out cylinder rod (1) about 100 mm (3.94 in).
1 3
W506-04-02-003
a- Lock Washer
W5-2-5-2
Group 2 Cylinder
4. Cut away the crimped part by using a hand drill. 9. Remove O-ring (11) from retainer (16) by using a
Remove set screw (21). Remove steel ball (20). spatula.
fNOTE: Set screw (21) has been crimped by using a 10. Remove backup ring (12) from retainer (16) by using
a screwdriver.
punch at two places after installing.
l : 4 mm 11. Remove stopper (15), spacer (14), and cushion ring
(13) from retainer (16).
Remove piston (19) and cushion bearing (17) by 12. Remove wiper ring (2) and U-ring (8) from cylinder
using the special tool (ST 3450). head (3) by using a screwdriver.
Special Tool for Piston: ST 3450: 50 mm 13. Remove O-rings (4, 6) from cylinder head (3) by
using a spatula. Remove backup ring (5) by using a
6. Remove stopper (10) from connector (9). Remove screwdriver.
connector (9).
IMPORTANT: Bushing (7) cannot be reused. When
7. Install the protective tape onto the thread part bushing (7) has been removed, replace it with the
of cylinder rod (1) in order to protect the seal new one when assembling.
of cylinder head (3). Remove the retainer (16)
14. Remove bushing (7) from cylinder head (3) by using
assembly, stopper (10), and cylinder head (3) from
a press and the special tool (ST 8158).
cylinder rod (1).
IMPORTANT: When removing the seals, do not
damage parts.
8. Secure piston (19) in a vise. Remove slide rings
(18) (2 used) from piston (19). Cut and remove seal
ring (22a) from piston (19) by using a screwdriver.
Remove O-ring (22b) by using a spatula.
ST
18 22a 18 19 3
22b WACB-05-02-003
22a- Seal Ring

22b- O-Ring
W1MP-04-02-016
W5-2-5-3
Group 2 Cylinder
Assembly of Boom Cylinder
21 18 22 18 17 1 23 15 11 12 6 5 8 7 4 3 2
WACG90-05-02-002
20 19 16 14 13 10 9
1- Cylinder Rod 7- Bushing 13- Cushion Ring 19- Piston

2- Wiper Ring 8- U-Ring 14- Spacer 20- Steel Ball
3- Cylinder Head 9- Connector 15- Stopper 21- Set Screw
4- O-Ring 10- Stopper 16- Retainer 22- Seal Ring
5- Backup Ring 11- O-Ring 17- Cushion Bearing 23- Cylinder Tube
6- O-Ring 12- Backup Ring 18- Slide Ring (2 Used)
W5-2-5-4
Group 2 Cylinder
Assembly of Boom Cylinder

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not damage U-ring (8).
onto parts in order to prevent them from seizing. IMPORTANT: Check the direction to install U-ring (8).
IMPORTANT: The seals cannot be reused. Replace 4. Install U-ring (8) to cylinder head (3) by using a
them with the new ones. spatula.
1. Install cushion ring (13), spacer (14), and stopper
(15) to retainer (16).
2. Install backup ring (12) and O-ring (11) to retainer
(16).
3. Install bushing (7) to cylinder head (3) by using
special tool (ST 8158). 8
3
WACG90-05-02-004
5. Install wiper ring (2) to cylinder head (3) by using

special tool (ST 8045).
7
ST 8045
WACG90-05-02-003 2
WACG90-05-02-005
6. Install O-rings (4, 6) and backup ring (5) to cylinder

head (3).
3 4 5 6
WACG90-05-02-006
W5-2-5-5
Group 2 Cylinder
IMPORTANT: Check that O-ring (22b) is not twisted. IMPORTANT: If not adjusting seal ring (22a), piston
7. Install O-ring (22b) to piston (19). Install seal ring (19) cannot be installed to cylinder tube (23).
(22a) to piston (19) by using special tools (ST 2622, 8. Pass piston (19) in special tool (ST 2626). Adjust seal
ST 2624). ring (22a).
22a
ST 2624
17
22a
ST 2626
ST 2622
22b
19 W566-04-02-011
22a- Seal Ring
9. Install slide rings (18) (2 used) to piston (19) in order

not to fit their split positions.
W566-04-02-010
22a- Seal Ring
10. Secure cylinder rod (1) in a vise. Install cylinder head
22b- O-Ring (3) and the retainer (16) assembly to cylinder rod (1).
Special Tool for Cylinder Head: Rod Outer Diameter
ST 7979: 40 mm
11. Install the retainer (16) assembly to cylinder head
(3) with connector (9) and stopper (10).
W5-2-5-6
Group 2 Cylinder
IMPORTANT: Check the direction to install cushion IMPORTANT: When inserting the cylinder rod (1)
bearing (17). assembly, do not drop slide ring (18) from piston
12. Secure the cylinder on a workbench horizontally. (19).
Install cushion bearing (17) and the piston (19) 14. Secure cylinder tube (23) on a workbench
assembly to cylinder rod (1) by using special tool (ST horizontally. Insert the cylinder rod (1) assembly
3450). into cylinder tube (23) by using special tool (ST
7985).
Special Tool for Piston: ST 3450: 50 mm
Special Tool for Cylinder Rod: Tube Inner Diameter
m : 687 N·m (68.7 kgf·m, 510 lbf·ft)
ST 7985: 70 mm
13. Install steel ball (20) to piston (19). Install set screw
(21). Crimp set screw (21) by using a punch (2 15. Tighten cylinder head (3) to cylinder tube (23) by
places). using hook wrench (a). Bend the lock washer in
order not to loosen.
l : 4 mm
Diameter of cylinder head (3): 85 mm
m : 16.2 N·m (1.6 kgf·m, 12 lbf·ft)
m : 304 N·m (30.4 kgf·m, 225 lbf·ft)
23
W506-04-02-019
a- Hook Wrench
W5-2-5-7
Group 2 Cylinder
(Blank)
W5-2-5-8
Group 2 Cylinder
Disassembly of Arm, Bucket, and Boom

Swing Cylinders
Arm Cylinder
18
17
16
19
9
14
12
11
10
9
22
21
8
7
6
5
4
3
2
15
WACG90-05-02-007
1- Cylinder Rod 6- O-Ring 11- Steel Ball 17- Cushion Seal

2- Wiper Ring 7- Bushing 12- Set Screw 18- Stopper (2 Used)
3- Cylinder Head 8- U-Ring 14- Seal Ring 19- Retaining Ring
4- O-Ring 9- Slide Ring (2 Used) 15- Cylinder Tube 21- Packing Head
5- Backup Ring 10- Piston 16- Cushion Bearing 22- Retaining Ring
W5-2-6-1
Group 2 Cylinder
Bucket Cylinder
9
14
12
11
10
9
7
8
20
6
5
4
3
2
15
WACG90-05-02-008
1- Cylinder Rod 5- Backup Ring 9- Slide Ring (2 Used) 14- Seal Ring
2- Wiper Ring 6- O-Ring 10- Piston 15- Cylinder Tube
3- Cylinder Head 7- Bushing 11- Steel Ball 20- Backup Ring
4- O-Ring 8- U-Ring 12- Set Screw
W5-2-6-2
Group 2 Cylinder
Boom Swing Cylinder
9
14
12
11
10
9
22
21
8
7
6
5
4
3
15
WACG90-05-02-009
1- Cylinder Rod 5- Backup Ring 9- Slide Ring (2 Used) 14- Seal Ring
2- Wiper Ring 6- O-Ring 10- Piston 15- Cylinder Tube
3- Cylinder Head 7- Bushing 11- Steel Ball 21- Packing Head
4- O-Ring 8- U-Ring 12- Set Screw 22- Retaining Ring
W5-2-6-3
Group 2 Cylinder
Disassembly of Arm, Bucket, and Boom Swing

Cylinders
3. Loosen cylinder head (3) by using hook wrench
 The procedure starts on the premise that the (b) with the protective cover on cylinder rod (1).
pipes and the bands securing the pipes have been Remove the cylinder rod (1) assembly from cylinder
removed. tube (15).
d CAUTION: Boom swing cylinder weight: 21 kg
(47 lb)
Diameter of cylinder head (3):
Arm Cylinder: 85 mm
IMPORTANT: The seals cannot be reused. Replace
them with the new ones. Bucket Cylinder: 68 mm
1. Hoist the cylinder and secure it on a workbench Boom Swing Cylinder: 78 mm
horizontally. Drain off hydraulic oil from the
cylinder.
b
15
W102-04-02-027
IMPORTANT: The lock washer (a) in cylinder head (3)

forms an integral part with cylinder tube (15). Do
not damage cylinder tube (15) and cylinder head
(3) when bending and extending lock washer (a). 1 3 W506-04-02-004
2. Pull out cylinder rod (1) about 200 mm (7.87 in). b- Hook Wrench
3
1
W506-04-02-003
a- Lock Washer
W5-2-6-4
Group 2 Cylinder
4. Cut away the crimped part by using a hand drill. IMPORTANT: When removing the seals, do not
Remove set screw (12). Remove steel ball (11). damage parts.
8. Secure piston (10) in a vise. Remove slide rings
fNOTE: Set screw (12) has been crimped by using a
(9) (2 used) from piston (10). Cut and remove seal
punch (2 place) after installing.
ring (14a) from piston (10) by using a screwdriver.
l : 4 mm (Arm Cylinder) Remove O-ring (14b) by using a spatula.
l : 3 mm (Bucket Cylinder, Boom Swing 9 14a 9 10
Cylinder)
Remove piston (10) by using the special tool for
piston.
Special Tool for Piston:
ST 3422: 41 mm (Bucket Cylinder, Boom Swing
14b WACB-05-02-003
Cylinder)
14a- Seal Ring
ST 3450: 50 mm (Arm Cylinder) 14b- O-Ring
6. Install a protective tape onto the thread part of

9. (only Arm, Boom Swing Cylinders)
cylinder rod (1) in order to protect the seal of
cylinder head (3). Remove cylinder head (3) from Remove retaining ring (22) and packing head (21)
cylinder rod (1). from cylinder head (3).
IMPORTANT: When removing the seals, do not 10. Remove wiper ring (2), U-ring (8), and backup ring
damage parts. (20) from cylinder head (3) by using a screwdriver.
7. (only Arm Cylinder) 11. (only bucket cylinder)
Remove retaining ring (19), stoppers (18) (2 used), Remove backup ring (20) by using a screwdriver.
cushion bearing (16), and cushion seal (17) from
cylinder rod (1). 12. Remove O-rings (4, 6) from cylinder head (3) by
using a spatula. Remove backup ring (5) by using a
screwdriver.
W5-2-6-5
Group 2 Cylinder
IMPORTANT: Bushing (7) cannot be reused. When

bushing (7) has been removed, replace it with the
new one when assembling.
13. Remove bushing (7) from cylinder head (3) by using
a press and special tool (a).
Special Tool for Bushing: Rod Outer Diameter
Cylinder)
ST 8158: 40 mm (Arm Cylinder)
W1MP-04-02-016
a- Special Tool for Bushing
W5-2-6-6
Group 2 Cylinder
Assembly of Arm, Bucket, and Boom Swing

Cylinders
Arm Cylinder
16 19 12 9 14 9 10 15 1 6 5 4 3 2
17
18 11 22 21 8 7 WACG90-05-02-010
Bucket Cylinder
12 9 14 9 10 15 1 6 5 4 3 2
WACG90-05-02-011
11 7 8 20
Boom Swing Cylinder
12 9 14 9 10 15 1 6 5 4 3 2
WACG90-05-02-012
11 22 21 8 7
1- Cylinder Rod 9- Slide Ring (2 Used) 17- Cushion Seal (only Arm 21- Packing Head (only Arm, Boom
2- Wiper Ring 10- Piston Cylinder) Swing Cylinders)
3- Cylinder Head 11- Steel Ball 18- Stopper (2 Used) (only Arm 22- Retaining Ring (only Arm,
4- O-Ring 12- Set Screw Cylinder) Boom Swing Cylinders)
5- Backup Ring 14- Seal Ring 19- Retaining Ring (only Arm
6- O-Ring 15- Cylinder Tube Cylinder)
7- Bushing 16- Cushion Bearing (only Arm 20- Backup Ring (only Bucket
8- U-Ring Cylinder) Cylinder)
W5-2-6-7
Group 2 Cylinder
Assembly of Arm, Bucket, and Boom Swing 4. Install wiper ring (2) to cylinder head (3) by using
Cylinders the special tool.
IMPORTANT: Before assembling, apply hydraulic oil Special Tool for Wiper Ring: Rod Outer Diameter
IMPORTANT: The seals cannot be reused. Replace Cylinder)
them with the new ones.
1. Install bushing (7) to cylinder head (3) by using the
special tool.
Special Tool for Bushing: Rod Outer Diameter
Cylinder)
ST 8158: 40 mm (Arm Cylinder) 2
a
WACG90-05-02-005
5. (only Arm, Boom Swing Cylinders)

7
Install packing head (21) and retaining ring (22) to
3
cylinder head (3).
6. Install O-rings (4, 6) and backup ring (5) to cylinder
head (3).
WACG90-05-02-003
a- Special Tool for Bushing
IMPORTANT: Do not damage U-ring (8).

3 4 5 6
IMPORTANT: Check the direction to install U-ring (8).
2. Install U-ring (8) to cylinder head (3).
3. (only bucket cylinder)
Install backup ring (20) to cylinder head (3).
WACG90-05-02-006
8
3
WACG90-05-02-004
W5-2-6-8
Group 2 Cylinder
IMPORTANT: Check that O-ring (14b) is not twisted. IMPORTANT: If not adjusting seal ring (14a), piston
7. Install O-ring (14b) to piston (10). Install seal ring (10) cannot be installed to cylinder tube (15).
(14a) to piston (10) by using the special tool. 8. Pass piston (10) into the special tool. Adjust seal ring
(14a).
Special Tool (a) for Seal Ring: Tube Inner Diameter
Special Tool for Seal Ring: Tube Inner Diameter
ST 4192: 55 mm (Bucket Cylinder)
ST 4190: 65 mm (Boom Swing Cylinder)
ST 2483: 65 mm (Boom Swing Cylinder)
Special Tool (b) for Seal Ring: Tube Inner Diameter
ST 4191: 65 mm (Boom Swing Cylinder) 14a
10
e
b
14a
W566-04-02-011
14a- Seal Ring e- Special Tool for Seal Ring
a 14b
10 9. Install slide rings (9) (2 used) to piston (10) in order

not to fit their split positions.
10. Install the cylinder head (3) assembly to cylinder rod
W566-04-02-010 (1) by using the special tool.
14a- Seal Ring a- Special Tool for Seal Ring Special Tool for Cylinder Head: Rod Outer Diameter
14b- O-Ring b- Special Tool for Seal Ring
Cylinder)
IMPORTANT: Face the slit in cushion seal (17) to the
piston side.
11. (only Arm Cylinder)
Install cushion seal (17) to cylinder rod (1). Install
cushion bearing (16) as illustrated. Install stoppers
(18) (2 used) and retaining ring (19).
19 17 16 18
WACG90-05-02-013
W5-2-6-9
Group 2 Cylinder
12. Secure the cylinder on a workbench horizontally. IMPORTANT: When inserting the cylinder rod (1)
Install the piston (10) assembly to cylinder rod (1) by assembly, do not drop slide ring (9) from piston
using the special tool. (10).
Special Tool for Piston: 14. Secure cylinder tube (15) on a workbench
horizontally. Insert the cylinder rod (1) assembly
ST 3450: 50 mm (Arm Cylinder) into cylinder tube (15) by using the special tool.
m : 687 N·m (68.7 kgf·m, 510 lbf·ft) Special Tool for Cylinder Rod: Tube Inner Diameter
ST 3422: 41 mm (Bucket Cylinder) ST 7985: 70 mm (Arm Cylinder)
m : 343 N·m (34.3 kgf·m, 255 lbf·ft) ST 8133: 55 mm (Bucket Cylinder)
ST 3450: 41 mm (Boom Swing Cylinder) ST 7984: 65 mm (Boom Swing Cylinder)
15. Tighten cylinder head (3) to cylinder tube (15) by
m : 441 N·m (44.1 kgf·m, 330 lbf·ft)
using a hook wrench. Bend the lock washer in order
13. Install steel ball (11) to piston (10). Install set screw not to loosen.
(12). Crimp set screw (12) by using a punch (2
Diameter of cylinder head (3):
places).
(Arm Cylinder): 85 mm
Arm Cylinder
m : 304 N·m (30.4 kgf·m, 225 lbf·ft)
l : 4 mm
(Bucket Cylinder): 68 mm
m : 16.2 N·m (1.7 kgf·m, 12 lbf·ft)
m : 294 N·m (29.4 kgf·m, 215 lbf·ft)
Bucket Cylinder, Boom Swing Cylinder
(Boom Swing Cylinder): 78 mm
l : 3 mm
m : 294 N·m (29.4 kgf·m, 215 lbf·ft)
m : 6.8 N·m (0.7 kgf·m, 5 lbf·ft)
15
W506-04-02-019
a- Hook Wrench
W5-2-6-10
MEMO
MEMO
Hitachi Construction Machinery Co., Ltd. Hitachi Ref. No.
Attn: Technical Information Center
Tel: 81-29-832-7084
Fax: 81-29-831-1162
E-mail: HCM-TIC-GES@hitachi-kenki.com
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
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DATE: PAGE NO.:
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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:
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PART NO.

Service Manual consists of the following separate Part No.

Quantity To Convert From Into Multiply By

fNOTE: The numerical value in this manual might be

Symbol / Name Explanation

Recognize Safety Information

Understand Signal Words

 CAUTION also calls attention to safety message in this

 fNOTE: indicates an additional explanation for an

Follow Safety Instructions

Prepare for Emergencies

Wear Protective Clothing

You may need:

Protect Against Noise

Use Handrails and Steps

Adjust the Operator's Seat

Fasten Your Seat Belt

Move and Operate Machine Safely

Operate Only from Operator's Seat

Keep Riders off Machine

Precautions for Operations

Investigate Job Site Beforehand

Install OPG Guard

ROPS: Roll Over Protective Structure

Restriction of Attachment Installation

Provide Signals for Jobs Involving Multiple

Confirm Direction of Machine to Be Driven

Drive Machine Safely

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

Avoid Injury from Rollaway Accidents

Avoid Injury from Back-Over and Swing

Keep Person Clear from Working Area

Never Position Bucket Over Anyone

 Be careful when working on frozen ground.

Never Undercut a High Bank

Dig with Caution

Operate with Caution

Avoid Power Lines

Precautions for Lightning

If lightning comes close, immediately stop the operation,

If lightning strikes the machine or near the machine,

Protect Against Flying Debris

Park Machine Safely

Handle Fluids Safely−Avoid Fires

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

Be sure to further follow the details described in the

Practice Safe Maintenance

Before servicing the machine:

7. Attach a “Do Not Operate” tag on the control lever.

 If a maintenance procedure must be performed with the

Warn Others of Service Work

Support Machine Properly

Stay Clear of Moving Parts

Prevent Parts from Flying

 Travel reduction gears are under pressure.

Avoid Injury from Attachment Falling Accident

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

Hot fluids and surfaces:

Replace Rubber Hoses Periodically

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

Avoid High-Pressure Fluids

Check Key Switch:

Check Heat Shields: