WDC390 en 00

PART NO.
WDC390-EN-00
ZX210LCN-G
HYDRAULIC EXCAVATOR
Workshop Manual
ZX210LCN-G
WORKSHOP MANUAL
Hydraulic Excavator
URL:http://www.hitachi-c-m.com WDC390-EN-00
Service Manual consists of the following separate Part No.

Technical Manual (Operational Principle) : Vol. No.TODC390-EN
Technical Manual (Troubleshooting) : Vol. No.TTDC390-EN
Workshop Manual : Vol. No.WDC390-EN
PRINTED IN JAPAN (K) 2014, 10 Engine Manual : Vol. No.EDCD-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).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECF Engine Controller Engine controller. ECF controls EC motor according to the
machine operating condition.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
SY-1
SYMBOL AND ABBREVIATION
(Blank)
SY-2
SAFETY
Recognize Safety Information

 These are the SAFETY ALERT SYMBOLS.
 When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
 Follow recommended precautions and safe operating
practices.
SA-688
Understand Signal Words

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

of information.
SA-1
SAFETY
Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in 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.
 Never attempt to modify or disassemble the inlet/exhaust
parts and the muffler filter. Avoid giving shocks on the
muffler filter by striking elements with other objects or
dropping the elements. Failure to do so may affect the
exhaust gas purifying device, possibly damaging it or
lowering its performance.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.
SA-2
SAFETY
Prepare for Emergencies

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

 Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing SA-438
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
 Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
 Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
SA-3
SAFETY
Protect Against Noise

 Prolonged exposure to loud noise can cause impairment or
loss of hearing.
 Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
SA-434
Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
 In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.
SA-435
SA-4
SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not leave parts and/or tools lying around the
operator’s seat. Store them in their specified locations.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
 Keep all flammable objects and/or explosives away from
the machine.
 After using the ashtray, always cover it to extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
SA-5
SAFETY
Use Handholds and Steps

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

 A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
 The seat should be adjusted whenever changing the
operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror SA-378
is broken, immediately replace it with a new one.
SA-6
SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with
a control lever and/or pedal, possibly resulting in serious
personal injury or death.
 Before leaving the machine, be sure to first lower the front
attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF
to stop the engine.
 Before leaving the machine, close all windows, doors, and
access covers and lock them up.
Fasten Your Seat Belt

 If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
 Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
 Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to SA-237
minimize the chance of injury from an accident.
 We recommend that the seat belt be replaced every three
years regardless of its apparent condition.
SA-7
SAFETY
Move and Operate Machine Safely

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

 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
 Start the engine only when seated in the operator's seat.
 NEVER start the engine while standing on the track or on
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders. SA-444
SA-8
SAFETY
Jump Starting
 Battery gas can explode, resulting in serious injury.
 If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
 The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
 Never use a frozen battery.
 Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
Keep Riders off Machine

 Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
 Only the operator should be on the machine. Keep riders
off.
 Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-379
SA-9
SAFETY
Precautions for Operations

 Investigate the work site before starting operations.
 Be sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
 Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
 When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M178-05-007
SA-10
SAFETY
Investigate Job Site Beforehand

 When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
 Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles or banks
from collapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
 When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
SA-11
SAFETY
 Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
 If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
 Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
 Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent M104-05-016
machine tipping over from occurring. When operating on
rough terrain or on slopes:
 Reduce the engine speed.
 Select slow travel speed mode.
 Operate the machine slowly and be cautious with
machine movements.
Install OPG Guard

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

OPG: Operator Protective Guard
SA-490
SA-12
SAFETY
Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.
SA-481
Confirm Direction of Machine to Be Driven

 Incorrect travel pedal/lever operation may result in serious
injury or death.
 Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when travel pedals/levers are
operated to the front.
SA-491
SA-13
SAFETY
Drive Machine Safely

 Before driving the machine, always confirm that the travel
levers/pedals direction corresponds to the direction you
wish to drive.
 Be sure to detour around any obstructions.
 Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do A
not allow personnel to stay around the machine while
traveling.
 Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.
 Never attempt to ascend or descend 35 degrees or
steeper slopes.
 Be sure to fasten the seat belt.
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 0.2 to 0.3 m (A)
above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If A SA-658
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.
SA-441
WRONG
SA-590
SA-14
SAFETY
 Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
 Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
 Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
 Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
 Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
 Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
 When crossing train tracks, use wood plates in order not
to damage them.
 Do not make contact with electric wires or bridges.
 When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
 When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
 Avoid operations that may damage the track and
undercarriage components.
 During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.
SA-15
SAFETY
Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
 Select level ground when possible to park the machine.
 Do not park the machine on a grade.
 Lower the bucket and/or other work tools to the ground.
 Turn the auto-idle switch OFF and the power mode switch
E or P.
 Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
 Stop the engine and remove the key from the key switch.
SA-391
 Pull the pilot control shut-off lever to LOCK position.
 Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.
SA-2273
SA-16
SAFETY
Avoid Injury from Back-Over and Swing

Accidents
 If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
 Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
 Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
 USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW. SA-383
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
 No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
 Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
 Keep windows, mirrors, and lights clean and in good
condition.
 Dust, heavy rain, fog, etc., can reduce visibility. As visibility
decreases, reduce speed and use proper lighting.
 Read and understand all operating instructions in the SA-384
operator’s manual.
SA-17
SAFETY
Keep Person Clear from Working Area

 A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or death.
 Keep all persons clear from the area of operation and
machine movement.
 Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to prevent
anyone from entering the work area.
SA-386
Never Position Bucket Over Anyone

 Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
SA-487
SA-18
SAFETY
Avoid Undercutting
 In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage
perpendicular to the edge of the excavation with the travel
motors at the rear.
 If the footing starts to collapse and if retreat is not
possible, do not panic. Often, the machine can be secured
by lowering the front attachment, in such cases.
SA-488
Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE
--- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
 The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
 Be extra careful before operating on a grade.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the SA-012
machine.
 Reduce operating speeds to avoid tipping or slipping.
 Avoid changing direction when traveling on grades.
 NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
 Reduce swing speed as necessary when swinging loads.
 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become
soft and make ground travel unstable.
SA-440
SA-19
SAFETY
Never Undercut a High Bank

 The edges could collapse or a land slide could occur causing
SA-489
Dig with Caution

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

 If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
 Take care to avoid hitting overhead obstacles with the
boom or arm.
SA-389
SA-20
SAFETY
Avoid Power Lines

 Serious injury or death can result if the machine or front
attachments are not kept a safe distance from electric lines.
 When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
 Check and comply with any local regulations that may
apply.
 Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381
Precautions for Lightning

 The machine is vulnerable to lightning strikes.
 In the event of an electrical storm, immediately stop
operation, and lower the bucket to the ground. Evacuate
to a safe place far away from the machine.
 After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only after
repairing them.
SA-1088
SA-21
SAFETY
Object Handling
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
resulting in serious injury or death.
 When using the machine for craning operations, be sure
to comply with all local regulations.
 Do not use damaged chains or frayed cables, sables,
slings, or ropes.
 Before craning, position the upperstructure with the
travel motors at the rear.
 Move the load slowly and carefully. Never move it
suddenly.
 Keep all persons well away from the load.
 Never move a load over a person’s head.
 Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
 Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
SA-014
Protect Against Flying Debris

 If flying debris hit eyes or any other part of the body, serious
injury may result.
 Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
 Keep bystanders away from the working area before
striking any object.
 Always close the front windows, doors, door windows and
the overhead window when operating the machine.
SA-432
SA-22
SAFETY
Park Machine Safely

To avoid accidents:
 Park machine on a firm, level surface.
 Lower bucket to the ground.
 Turn auto-idle switch OFF and power mode switch E or P.
 Run engine at slow idle speed without load for 5 minutes.
 Turn key switch to OFF to stop engine.
 Remove the key from the key switch.
 Pull the pilot control shut-off lever to the LOCK position.
 Close windows, roof vent, and cab door.
 Lock all access doors and compartments.
SA-390
Handle Fluids Safely−Avoid Fires

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

 Store flammable fluids well away from fire hazards.
 Do not incinerate or puncture pressurized containers. SA-018
 Do not store oily rags; they can ignite and burn
spontaneously.
 Securely tighten the fuel and oil filler cap.
SA-019
SA-23
SAFETY
Transport Safely
 Take care the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
 Observe the related regulations and rules for safe
transportation.
 Select an appropriate truck or trailer for the machine to
be transported.
 Be sure to use a signal person.
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight. SA-395
3. Turn auto-idle switch OFF and turn mode switch to PWR

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

TRANSPORTING section in the operator’s manual.
SA-24
SAFETY
Practice Safe Maintenance

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

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

8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
 If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
 If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support any
machine elements that must be raised for service work.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter in the operator’s manual. SA-527
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
SA-25
SAFETY
 Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
 Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
Warn Others of Service Work

 Unexpected machine movement can cause serious injury.
 Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS3076175 SS2045102
Support Machine Properly

 Never attempt to work on the machine without securing
the machine first.
 Always lower the attachment to the ground before you
work on the machine.
 If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
SA-527
SA-26
SAFETY
Stay Clear of Moving Parts

 Entanglement in moving parts can cause serious injury.
 To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
SA-026
SA-2294
Prevent Parts from Flying

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

 As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
 GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
SA-27
SAFETY
Store Attachments Safely

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.
SA-034
Prevent Burns
Hot spraying fluids:
 After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
 To avoid possible injury from hot spraying water. DO
NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to SA-039
release all pressure before removing the cap.
Hot fluids and surfaces:
 Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
 Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
SA-28
SAFETY
Replace Rubber Hoses Periodically

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

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

 Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
 Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
SA-044
SA-29
SAFETY
Prevent Fires
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to fires.
 Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
 Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
 Do not bend or strike high-pressure lines.
 Never install bent or damaged lines, pipes, or hoses.
 Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
SA-019
Check for Shorts:
 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
 Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.
SA-30
SAFETY
Clean up Flammables:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammables immediately. Check and clean high
temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammables away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammables such as
dead leaves from entering. However, flammables which
have passed through the wire screen may cause fires.
Check and clean the machine every day and immediately
remove accumulated flammables.
Check Key Switch:

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

 Damaged or missing heat shields may lead to fires.
 Damaged or missing heat shields must be repaired or

replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as mufflers may cause fire. Always close the engine cover
while operating the machine.
SA-31
SAFETY
Evacuating in Case of Fire

 If a fire breaks out, evacuate the machine in the following
way:
 Stop the engine by turning the key switch to the OFF
position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method in the operator’s manual.
SS-1510
Beware of Exhaust Fumes

 Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
 If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
SA-016
SA-32
SAFETY
Precautions for Welding and Grinding
 Welding may generate gas and/or small fires.
 Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe place
before starting welding.
 Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
 Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
 After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818
SA-33
SAFETY
Avoid Heating Near Pressurized Fluid Lines

 Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
 Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
 Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc..
SA-030
Avoid Applying Heat to Lines Containing

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

Damper
High-pressure nitrogen gas is sealed in the accumulator and
the gas damper. Inappropriate handling may cause explosion,
possibly resulting in serious injury or death.
Strictly comply with the following items:

 Do not disassemble the unit.
 Keep the units away from open flames and fire.
 Do not bore a hole, do not cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing the unit, sealed gas must be released.
Consult your nearest Hitachi dealer.
SA-34
SAFETY
Remove Paint Before Welding or Heating

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

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silicon dust or other contamination
may cause sickness.
 Depending on the work site conditions, the risk
of inhaling asbestos fiber, silicon dust or other
contamination may exist. Spray water to prevent asbestos
fibers, silicon dust or other contamination from becoming
airborne. Do not use compressed air.
 When operating the machine in a work site where
asbestos fibers, silicon dust or other contamination SA-029
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contamination.
 Keep bystanders out of the work site during operation.
 Asbestos fibers might be present in imitation parts. Use
only genuine Hitachi Parts.
SA-35
SAFETY
Prevent Battery Explosions

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

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

 If spilled onto skin, refrigerant may cause a cold contact
burn.
 Refer to the instructions described on the container for
proper use when handling the refrigerant.
 Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
 Never touch the refrigerant.
SA-405
SA-36
SAFETY
Handle Chemical Products Safely

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

 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
 Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
 Do not pour waste onto the ground, down a drain, or into
any water source.
 Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations SA-226
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
 Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
SA-37
SAFETY
Never Ride Attachment

Never allow anyone to ride attachments or load. This is an
extremely dangerous practice.
Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.
SA-38
SAFETY
Precaution for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which is
situated at the back of the driver's seat. There is a possibility
that a medical device, including an implantable device
such as a cardiac pacemaker, would be affected and would
malfunction by the electrical waves emitted from the
communication terminal equipment.
Any person affixed with a medical device such as the above SA-2302
should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.662 inches) apart at
all times. If such condition cannot be met, please contact our
company's nearest dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.
Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipments:
E-GSM900 0.573 W/Kg (914.80 MHz)
DCS-1800 0.130 W/Kg (1710.20 MHz)
WCDMA Band I 0.271 W/Kg (1950.00 MHz)
*This data was measured by having each type of

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

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).
In EU Member nation: *Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).
SA-39
SAFETY
Before Returning the Machine to the Customer
 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced.
SA-435
SA-40
SECTION AND GROUP SECTION 1 GENERAL INFORMATION
CONTENTS Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Pressure Release Procedure
WORKSHOP MANUAL Group 6 Preparation
SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure
Group 2 Undercarriage
Group 3 Front Attachment
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 8 Pump Device
Group 9 Control Valve
Group 10 Swing Device
Group 11 Pilot Valve
Group 12 Solenoid Valve
Group 13 Signal Control 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 Upper and Lower Rollers
reserved to make changes at any time
without notice. Group 6 Track
SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder
COPYRIGHT(C)2014
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle) TECHNICAL MANUAL (Troubleshooting)
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specification Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Excavator Test
Group 1 Control System Group 5 Component Test
Group 2 Hydraulic System Group 6 Adjustment
Group 3 Electrical System SECTION 5 TROUBLESHOOTING
SECTION 3 COMPONENT OPERATION Group 1 Introduction
Group 1 Pump Device Group 2 Component Layout
Group 2 Swing Device Group 3 Troubleshooting A
Group 3 Control Valve Group 4 Troubleshooting B
Group 4 Pilot Valve Group 5 Troubleshooting C
Group 5 Travel Device Group 6 Electrical System Inspection
Group 6 Signal Control Valve Group 7 ICX
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
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..........................................W1-4-1-5
Hydraulic Circuit Pressure Release Procedure......W1-5-1-1
Group 6 Preparation
Preparation before Inspection and
Maintenance...............................................................W1-6-1-1
DC390W-1-1
(Blank)
DC390W-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.
fNOTE:
 Apply lubricant (e.g. white zinc B dissolved into spindle
oil) to bolts and nuts to reduce friction coefficient of
them.
 Make sure bolt and nut threads are clean before WDAA-01-02-001
installing.
Bolt Types
Tighten the nuts or bolts correctly to the torque
specifications.
As the different types and grades of bolt are used,
use and tighten the correct bolts correctly when
assembling the machine or components.
Specified Tightening Torque Chart
Hexagon
Wrench
Bolt Dia. Wrench WDAA-01-02-002 WDAA-01-02-003 WDAA-01-02-004
Size
Size
Socket Bolt
N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft)
M6 10 5 3 to 4 (0.3 to 0.4) (2.2 to 3)
M8 13 6 30 (3) (22) 20 (2) (15) 10 (1) (7.4)
M10 17 8 65 (6.5) (48) 50 (5) (37) 20 (2) (15)
M12 19 10 110 (11) (81) 90 (9) (66) 35 (3.5) (26)
M14 22 12 180 (18) (133) 140 (14) (103) 55 (5.5) (41)
M16 24 14 270 (27) (200) 210 (21) (155) 80 (8) (59)
M18 27 14 400 (40) (300) 300 (30) (220) 120 (12) (89)
M20 30 17 550 (55) (410) 400 (40) (300) 170 (17) (125)
M22 32 750 (75) (550) 550 (55) (410) 220 (22) (162)
M24 36 950 (95) (700) 700 (70) (520) 280 (28) (205)
M27 41 1400 (140) (1030) 1050 (105) (770) 400 (40) (300)
M30 46 1950 (195) (1440) 1450 (145) (1070) 550 (55) (410)
M33 50 2600 (260) (1920) 1950 (195) (1440) 750 (75) (550)
M36 55 3200 (320) (2360) 2450 (245) (1810) 950 (95) (700)
W1-2-1-1
SECTION 1 GENERAL
Group 2 Tightening
IMPORTANT: The following items are applied to both

fine and coarse pitch threads.
 Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it)
 Torque tolerance is ±10 %.
 Use the bolts of correct length. The bolts that
are too long cannot be tightened as the bolt tip
comes into contact with the bottom of bolt hole.
Also the bolts that are too short cannot develop
sufficient tightening force.
 The torque given in the chart on the previous
page are for general use only, however,
a different torque is given for a specific
application. Use the specified torque.
 Clean the nut and bolt threads and remove dirt
or corrosion before installing.
Tightening Order
When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.
a b c
1 12 9 4 1 6 7 14
1.4 6 3
4 5
2 13 8 5 2 3 10 11
2.3
W105-01-01-003
a- Equally tighten upper and b- Tighten diagonally c- Tighten from center

lower alternately diagonally
W1-2-1-2
SECTION 1 GENERAL
Group 2 Tightening
Precautions for Spilt Flange

IMPORTANT:
 Clean the sealing surfaces. Check if there are
any scratches and roughness on the surface of
the seal that cause oil leaks and damage to the
WDAA-01-02-005
O-ring.
 Use only specified O-rings. Inspect O-rings for
any damage. Do not file the O-ring surfaces. Incorrect
When installing O-ring into a groove, use grease
in order to hold O-ring in place.
 While tightening the bolt by hand, check that
flange is installed to the port correctly. Do not
pinch the O-ring.
 Tighten the bolts up and down, left and right
alternately, in order to ensure even tightening
WDAA-01-02-006
to the specified torque.
 Do not use air wrenches. Using an impact
wrench often causes tightening of one bolt fully
before tighten the others, resulting in damage
to O-rings or uneven tightening of bolts.
Nut and Bolt Locking

 Lock Plate
W105-01-01-008
IMPORTANT: Do not reuse the lock plates. Do not try
to bend the same point twice.
Correct Incorrect
 Split Pin
IMPORTANT: Do not turn in the loosening direction
in order to align the grooves and holes on the nut.
a b
Always turn in the tightening direction. Do not
reuse the split pins.
Correct Correct Incorrect
 Wire
IMPORTANT: Attach wire to bolts in the bolt-
tightening direction. Do not reuse the wire.
a
WDAA-01-02-007
a- Bend along edge sharply b- Do not bend it round
Correct Correct
Incorrect
Correct d Incorrect
c
WDAA-01-02-008
c- Tighten d- Loosen
W1-2-1-3
SECTION 1 GENERAL
Group 2 Tightening
Piping Joint
IMPORTANT: The torque given in table below are for
general use only, however, a different torque is
given for a specific application. Use the specified
1 4 3 5 2
torque.
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
a- Joint Body WDAA-01-02-009
IMPORTANT: a
 Do not over-tighten union nut (3). Excessive

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

Description
Union Nut N·m (kgf·m) (lbf·ft)
30° male 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 270 (27) (200)
55 380 (38) (280)
60 380 (38) (280)
37° female 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
fNOTE: Tightening torque of 37° male coupling without

union is similar to tightening torque of 37° female.
W1-2-1-4
SECTION 1 GENERAL
Group 2 Tightening
Pipe Joint
Pipe connection (metal joint)
(Union Nut Wrench Size: 17, 19, 22, 27)
Metal (3) of adapter (1) and pipe (2) seals pressure oil.
 Precautions for use

Do not damage sealing surfaces (4) and (5) when
disassembling and assembling. 1 4 5 3 2
Tightening Torque
Use the specified tightening torque in the table below.
Wrench Size (mm) 17 19 22 27
N·m 25 30 40 80
Tightening
(kgf·m) (2.5) (3) (4) (8) M1M7-07-005
Torque
(lbf·ft) (18) (22) (30) (59)
O-ring Seal Joint

O-ring (6) is installed against the end surface of adapter
(7) and seals pressure oil.
IMPORTANT:
7 6 9
 Replace O-ring (6) with a new one when
reinstalling.
 Before tightening union nut (9), confirm that
O-ring (6) is seated correctly in O-ring groove
(8). Tightening union nut (9) with O-ring (6)
displaced will damage O-ring (6), resulting in oil
leakage.
 Do not damage O-ring groove (8) of adapter (7) 8 10 a
WDAA-01-02-011
or sealing surface (10) on the hose side. Damage a- Joint Body
to O-ring (6) may cause oil leakage.
 If union nut (9) is found to be loose, causing
oil leakage, do not tighten it to stop the leak. Wrench Size mm Tightening Torque
Instead, replace O-ring (6) with a new one, then Union Nut N·m (kgf·m) (lbf·ft)
tighten union nut (9) after confirming that 19 30 (3) (22)
O-ring (6) is securely seated in O-ring groove (8). 22 70 (7) (52)
27 95 (9.5) (70)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 350 (35) (260)
W1-2-1-5
SECTION 1 GENERAL
Group 2 Tightening
Quick Coupling
3 1
1. Coupling procedure
 Push socket ring (1) into plug (3) by rotating it fully
counterclockwise and then pulling it toward you.
 Release socket ring (1). Check that socket ring (1)
is returned by the spring force and the coupling is
locked completely by ball (2). At this time, check if
socket ring (1) is returned to the original position (to
M1M7-07-006
the rightmost direction). 2
2. Separating procedure
 Remove the hose by rotating socket ring (1) fully
counterclockwise and then pulling it. Because no
check function is attached inside, be careful that oil
flows out.
 Cap the removed hoses using special plug.
dCAUTION:
 When disconnecting, do not damage joint
surface.
 When disconnecting, clean the joint part and
thoroughly wipe off the cleaning solution to
prevent any foreign material from entering.
 Complete the joint disconnecting / connecting
procedure. Check enough if oil leaks especially
after installation.
 After installation, check if socket ring (1)
is returned to the original position (to the
rightmost direction).
W1-2-1-6
SECTION 1 GENERAL
Group 2 Tightening
Screw-In Connection R G
30°
Depending on types of screw and sealing, different
types of screw-in connection are used.
IMPORTANT: Check that the thread pitch and thread

type (tapered or straight) are the correct type
before using any screw-in connection. (In general, a b
the screw-in connection of male tapered thread is a- Male Tapered Thread b- Male Straight Thread
used except for measurement purpose.) W105-01-01-018
Wrench Size mm Tightening Torque

Joint Body FC material SS material
19 15 (1.5, 11) 35 (3.5, 26)
22 30 (3, 22) 50 (5, 37)
27 50 (5, 37) 95 (9.5, 70)
36 70 (7, 52) 160 (16, 118)
Seal Tape Application 41 110 (11, 81) 200 (20, 148)
Seal tape is used in order to seal clearances between 50 160 (16, 118) 330 (33, 245)
male and female threads so that any leaks between 60 200 (20, 148)
threads may be prevented. Therefore, apply just
enough seal tape to fill up thread clearances. Do not
overwrap.
fNOTE: Unit: N·m (kgf·m, lbf·ft)
 Application Procedure
Check that the thread surface is clean and, free of dirt c
or damage. Apply the seal tape around threads in order
to leave one to two pitch threads uncovered. Wrap the
seal tape in the same direction as the threads.
d e
W105-01-01-019
c- Internal Thread e- Clearance
d- External Thread
Low-Pressure-Hose Clamp Tightening f
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
T-Bolt Type Band Clamp:

4.5 N·m (0.45 kgf·m, 3.3 lbf·ft)
Worm Gear Type Band Clamp:

6 to 7 N·m (0.6 to 0.7 kgf·m, 4.4 to 5.2 lbf·ft)
f- Leave one to two pitch

M114-07-041
threads uncovered
g h
WDAA-01-02-012 M114-07-043
g- T-Bolt Type Band Clamp h- Worm Gear Type Band Clamp
W1-2-1-7
SECTION 1 GENERAL
Group 2 Tightening
Connecting Hose
dCAUTION: When replacing the hoses, use only

genuine Hitachi service parts. Using hoses other
Incorrect Correct
than genuine Hitachi hoses may cause oil leaks,

hose rupture or separation of fitting, possibly
resulting in a fire on the machine. Do not install
hoses kinked. Application of high oil pressure,
vibration, or an impact to a kinked hose may
result in oil leaks, hose rupture or separation of
fitting. Utilize the print marks on hoses when W105-01-01-011
installing in order to prevent hose from being
kinked. Take necessary measures to protect hoses
from rubbing against each other. If the hoses rub Incorrect a Correct
against each other, wear to the hoses may result
and lead to hose rupture. Take care so that the
hoses do not come into contact with the moving
parts or sharp objects.
W105-01-01-012
a- Rubbing Against Each Other
Incorrect Correct
b b
W105-01-01-013
a- Rubbing Against Each Other b- Clamp
Incorrect Correct
a
b
W105-01-01-014
a- Rubbing Against Each Other b- Clamp
W1-2-1-8
SECTION 1 GENERAL
Group 3 Painting
Painting
Painting specification
Surfaces to Be Painted Painting Colour
Main surface of upperstructure (except cab) YR-01 [TAXI yellow]
Main frame HG Beige Deep
Inner Gray
Front YR-01 [TAXI yellow]
Track (including swing bearing) N1.0 [Black]
Floor plate M/F Cation (allowed)
Final painted color

Inside and outside surface of cab HG Beige Deep
Shaded area on cab (Only the left side) Shining Silver
Right window beam KANSAI PAINT CO, LTD. LF-113-230B
Seat stand [N2.0 (Black)]
Lever (Travel, pilot shut-off ) [N2.0 (Black)]
Engine cover High Grade Black
Tool box, Tool box cover High Grade Black
Step High Grade Black
Handrail on upperstructure right side High Grade Black
Mirror stay High Grade Black
Nonslip cover KANSAI PAINT CO., LTD. 1400 (Deep Black)
W1-3-1-1
SECTION 1 GENERAL
Group 3 Painting
185
720
W178-01-03-003
a- Paint all circumference in the lower hinge swing position shining

silver
b- Paint all circumference in the door catch cover YR-01 (TAXI Yellow)
1- Cab Shaded Area
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 1 2 3
hydraulic oil level.
2. Stop the engine. Push air bleed button (1) of

hydraulic oil tank (3) and bleed air from hydraulic oil
tank (3).
3. Remove cap (2) of hydraulic oil tank (3).
W1R7-01-04-001
4. Install vacuum pump (a) to the position where cap

(2) has been removed. Operate vacuum pump (a) a
and maintain negative pressure in hydraulic oil tank
(3).
b
fNOTE: Operate vacuum pump (a) continuously while
working. c
W1R7-01-04-002
a- Vacuum Pump
b- Hose
c- Adapter
W1-4-1-1
SECTION 1 GENERAL
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 plugs 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 plugs. 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 plugs and bleed air from the (never fully stroke the cylinders during initial
pump until hydraulic oil comes out from the gap. operation stage).
 After bleeding all air, securely tighten the plugs.  As the pilot circuit has an air bleed device, air in the
pilot circuit will be bled while performing the above
IMPORTANT: If air is accumulated inside of the motor operation for approx. 5 minutes.
and if the engine starts in lacking of hydraulic oil,  Reset the front attachment in position for checking
the motor may be damaged. hydraulic oil level.
 Bleeding Air from Travel Motor, Swing Motor  Stop the engine. Check hydraulic oil level. Replenish
 Remove the air bleed plug (top) from the travel hydraulic oil if necessary.
motor and swing motor. Fill the motor case with
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,
cleaning the fuel solenoid pump strainer or running
the fuel tank dry, be sure to bleed the air from the fuel
system.
Air Bleeding Procedures

This machine is equipped with a fuel solenoid pump.
d CAUTION: Fuel leaks may lead to fires.
1
1. Check that fuel cock (1) on bottom of the fuel tank is
opened.
2. Set the key switch to the ON position and hold it in
that position for approx. three minutes. Therefore,
the fuel solenoid pump operates and starts to bleed
air.
M1U1-07-015
3. While holding the key switch in the ON position,
reciprocate fuel main filter priming pump (2). After
air is bled from the main filter, return priming pump
(2) to the original position. 2
4. After the main filter is filled with fuel, hold the key
switch in the ON position for 30 seconds.
5. Start the engine. Check the fuel system for fuel
leaks.
IMPORTANT: Even if air is not thoroughly bled,
do not hold the key switch in the ON position
for more than five minutes. In case air is not
thoroughly bled, first return the key switch to the
OFF position. Then, after waiting for more than
30 seconds, set the key switch to the ON position
again. Failure to do so may cause damage to
the fuel solenoid pump and/or discharging the
batteries.
M81U-07-030
W1-4-1-3
SECTION 1 GENERAL
Air Bleeding by Priming Pump

In case air is not bled due to malfunction of the fuel
solenoid pump, operating the priming pump only can
1
bleed air.
1. Check that fuel cock (1) on bottom of the fuel tank is
opened.
2. Loosen air bleed plug (4) on the fuel main filter.
j : 10 mm
3. Supply fuel by reciprocating priming pump (2). After M1U1-07-015
no air bubbles are spouted through air bleed plug
(4), tighten air bleed plug (4).
j : 10 mm
4. After tightening air bleed plug (4), reciprocate
priming pump (2) approx. 150 strokes. 3
5. Wipe off any spilled fuel.

6. Start the engine. Check that no fuel leaks are
present. If the engine does not start, repeat the
above procedures from step 1.
4
Air Bleeding by Cranking
M1GR-07-010
Bleed air from the fuel system after changing the
common rail.
1. Bleed air until the engine supply pump entrance
enough according to the above-mentioned 2
procedures.
2. Operate the starter motor for long cranking within
20 seconds. If the engine falls to start, return the key
switch to the OFF position. Wait more than about 60
seconds, then try again.
M81U-07-030
W1-4-1-4
SECTION 1 GENERAL
Bleeding Air from Radiator
dCAUTION: Do not loosen the radiator cap until

the system has cooled. Hot steam may spout out
and cause severe burns. Wait until coolant cools
and loosen the cap slowly. Release all pressure
and remove the cap.
Preparation
1. Park the machine on a solid and level surface.
Set the front attachment in position for checking
hydraulic oil level.
2. Stop the engine. Remove the radiator cap.
W1-4-1-5
SECTION 1 GENERAL
(Blank)
W1-4-1-6
SECTION 1 GENERAL
Hydraulic Circuit Pressure Release Procedure

Release any remaining pressure as follows before
removing/installing the front attachment.
1. Set pilot shut-off lever (1) to the UNLOCK position.

2. Turn engine stop switch (2) ON.
fNOTE: Perform step 1 and step 2, and set the key switch
to the START position. Although the starter rotates, the
engine does not start.
IMPORTANT: Battery will deplete. Operate the key
switch for short period.
3. With the key switch set in the START position, 1 2
operate the control lever in order to release any M1U1-01-029
pressure in the hydraulic circuit 4 to 5 times.
4. Return pilot shut-off lever (1) to the LOCK position.
5. Turn engine stop switch (2) OFF.
W1-5-1-1
SECTION 1 GENERAL
(Blank)
W1-5-1-2
SECTION 1 GENERAL
Group 6 Preparation
Preparation before Inspection and

Maintenance
Before performing the maintenance procedures given in
the following chapters, park the machine as described
below, unless otherwise specified.
1. Park the machine on a level surface.

2. Lower the bucket to the ground. M104-07-021
3. Turn the auto-idle switch OFF.

4. Set the engine control dial to the slow idle position.
1
Run the engine at slow idle speed without load for
five minutes.
5. Set the key switch to the OFF position. Stop the
engine. Remove the key from the key switch. If
maintenance should be performed with the engine
running, do not leave the machine unattended.
6. Set pilot shut-off lever (1) to the LOCK position.
7. Before performing any work on the machine, attach
tag (2) on the door or control lever.
WDAA-01-06-001
W1-6-1-1
SECTION 1 GENERAL
Group 6 Preparation
(Blank)
W1-6-1-2
MEMO
MEMO
SECTION 2
MAINTENANCE STANDARD
CONTENTS
Pump Device....................................................................W2-1-1-1
Swing Motor.....................................................................W2-1-2-1
Travel Motor......................................................................W2-2-1-1
Sprocket.............................................................................W2-2-1-3
Front Idler..........................................................................W2-2-2-1
Upper Roller......................................................................W2-2-3-1
Lower Roller......................................................................W2-2-3-2
Track.....................................................................................W2-2-4-1
Pin and Bushing...............................................................W2-3-1-1
Side Cutter (2014503, 2014504)................................W2-3-1-3
Point (4427919)...............................................................W2-3-1-4
Standard Dimensions for Arm and Bucket
Connection..................................................................W2-3-1-5
Standard Dimensions for Arm and Boom
Connection..................................................................W2-3-1-6
Cylinder..............................................................................W2-3-2-1
DC390W-2-1
(Blank)
DC390W-2-2
Pump Device
1 2 1
4 5 4
WDAD-03-08-001
1- Servo Piston (6 Used) 3- Shaft 5- Rotor (2 Used)

2- Pump Casing 4- Plunger (18 Used)
W2-1-1-1
1. Outer diameter (A) of shaft (3)

3
Unit: mm (in) A
Standard Allowable Limit
A 35 (1.38) 34.8 (1.37)
W176-02-04-019
2. The plunger (4) assembly: Shoe thickness (B) B

4
Unit: mm (in)
B 5.5 (0.22) 5.2 (0.21)
W176-02-04-020
3. Clearance (C) between shoe and plunger of the

plunger (4) assembly C
4
Unit: mm (in)
C 0.15 (0.006) 0.4 (0.016)
W176-02-04-020
4. Clearance between outer diameter (a) of plunger (4) 5

and inner diameter (D) of rotor (5) 4
Unit: mm (in)
Standard Allowable Limit D
(D-a) 0.033 (0.001) 0.07 (0.003)
W176-02-04-021
5. Clearance between inner diameter (E) of pump

2
casing (2) and outer diameter (b) of servo piston (1) b
Unit: mm (in)
(E-b) 0.06 (0.002) 0.12 (0.005) E
W176-02-04-022
W2-1-1-2
Swing Motor
2 3
W178-02-11-153
1- Rotor 2- Plunger (9 Used) 3- Friction Plate (3 Used)
W2-1-2-1
1. Clearance between outer diameter (d) of plunger (2)

and inner diameter (D) of rotor (1)
Unit: mm (in)
Standard Allowable Limit 2
D-d 0.027 (0.001) 0.052 (0.002)

d
W178-02-11-155
D D
W178-02-11-156
2. Clearance (δ) between plunger (2) and shoe (a)

bottom 2
Unit: mm (in)
a
0 (0) 0.3 (0.012) δ
a- Shoe
W107-02-06-140
W2-1-2-2
3. Shoe (a) thickness (t)

Unit: mm (in)
5.5 (0.22) 5.3 (0.21) a
a- Shoe
W178-02-11-157
4. Friction plate (3) thickness (t) 3
Unit: mm (in)
Standard Allowable Limit t
2.0 (0.08) 1.8 (0.07)
W178-02-11-158
W2-1-2-3
(Blank)
W2-1-2-4
Travel Motor
1 2
WDCD-04-02-004
1- Rotor 2- Plunger (9 Used)
W2-2-1-1
1. Clearance (ε) between shoe (a) and plunger (2)

bottom a
Unit: mm (in)
0.10 to 0.25 (0.004 to 0.5 (0.02)
0.010)
ε
2
a- Shoe
W1V1-03-02-005
2. Clearance between outer diameter (d) of plunger (2) D

and inner diameter (D) of rotor (1)
Unit: mm (in)
0.03 (0.001) 0.08 (0.003)
D-d≤0.08 mm (0.003 in)
W105-02-06-134
W105-02-06-135
3. Shoe (a) thickness (t) a
Unit: mm (in)
6.0 (0.236) 5.6 (0.220)
t
2
a- Shoe
W1V1-03-02-005
W2-2-1-2
Sprocket
C'
B
C
D
A
W178-02-11-235 W178-02-11-236
Unit: mm (in)
A 70 (2.8) [62 (2.4)] Build up
B 80.3 (3.2) 75.3 (3.0) welding and
C 119.7 (4.7) 114.7 (4.5) hand finishing
C' 644.6 (25.4) -
D 190.0 (7.5) -
fNOTE: Values in [ ] are just for reference.
W2-2-1-3
(Blank)
W2-2-1-4
Front Idler
C D
W166-03-05-001
A
Unit: mm (in)
Standard Allowable Remedy
Limit
A 84 (3.31) [68 (2.67)] Build up
B 159 (6.26) - welding and
C 500 (19.7) [488 (19.2)] hand finishing
D 538 (21.2) -
E 19 (0.75) 25 (0.98)
Axle and Bushing

Unit: mm (in)
Limit
Axle Outer 75.0 (2.95) [74.2 (2.93)] Replace
Diameter
Bushing Inner 75.0 (2.95) [76 (2.99)]
Diameter
Flange 2 (0.08) [1.2 (0.05)]
Thickness
W2-2-2-1
(Blank)
W2-2-2-2
Upper Roller
A
B
WDDE-02-02-001
Unit: mm (in)
Limit
A 84 (3.3) - Replace
B 165 (6.5) -
C 120 (4.7) [110 (4.3)]
W2-2-3-1
Lower Roller
W157-03-06-003
Roller
Unit: mm (in)
Limit
A 169.0 (6.7) [187 (7.4)] Build up
B 218.0 (8.6) - welding and
C 24.5 (1.0) [15.5 (0.6)] hand finishing
D 150.0 (5.9) 132 (5.2) or replace
Axle and Bushing

Unit: mm (in)
Limit
Axle Outer 65 (2.6) [64.2 (2.5)] Replace
Diameter
Bushing Inner 65 (2.6) [66.0 (2.6)]
Diameter
Flange 2 (0.08) [1.2 (0.05)]
Thickness
W2-2-3-2
Track
Link
Measure the length of four links.
 Do not measure the part included the master pin.
 Measure the length with tension on the track.
A
W155-03-07-001
Unit: mm (in)
Limit
A 762 (30.0) [786 (30.9)] Build up
B 105 (4.1) [98 (3.9)] welding and
hand finishing
or replace
Grouser Shoe
W105-03-07-024
Unit: mm (in)
Shoe Size 600 mm Grouser
Limit
A 219 (8.6) - Build up
B 10 (0.39) - welding or
C 26 (1.02) [18 (0.71)] replace
W2-2-4-1
Master Bushing
W105-03-07-023
Unit: mm (in)
Limit
A 129.2 (5.08) - Replace
B 38.7 (1.52) [41.7 (1.64)]
C 59 (2.32) [54 (2.13)]
Master Pin
W105-03-07-021
Unit: mm (in)
Limit
A 203 (7.99) - Replace
B 38.4 (1.51) [35.4 (1.39)]
W2-2-4-2
Pin
W142-03-07-004
A
Unit: mm (in)
Limit
A 212 (8.35) - Replace
B 38 (1.50) [35 (1.4)]
Bushing
W105-03-07-023
Unit: mm (in)
Limit
A 137.5 (5.41) - Replace
B 38.7 (1.52) [39.7 (1.56)]
C 59 (2.32) [54 (2.13)]
W2-2-4-3
(Blank)
W2-2-4-4
Pin and Bushing
C F
E
A G
H
J
B I K
W1V1-04-01-012
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Pin 90 (3.54) 89.0 (3.50) Replace
Boss (Main Frame) 90 (3.54) 91.5 (3.60)
Bushing (Boom) 90 (3.54) 91.5 (3.60)
B Pin 80 (3.15) 79.0 (3.11)
Boss (Main Frame) 80 (3.15) 81.5 (3.21)
Bushing (Boom Cylinder) 80 (3.15) 81.5 (3.21)
C Pin 90 (3.54) 89.0 (3.50)
Bushing (Boom Cylinder) 90 (3.54) 91.5 (3.60)
Boss (Boom) 90 (3.54) 91.5 (3.60)
D Pin 90 (3.54) 89.0 (3.50)
Boss (Boom) 90 (3.54) 91.5 (3.60)
Bushing (Arm) 90 (3.54) 91.5 (3.60)
E Pin 80 (3.15) 79.0 (3.11)
Boss (Arm) 80 (3.15) 81.5 (3.21)
Bushing (Arm Cylinder) 80 (3.15) 81.5 (3.21)
F Pin 80 (3.15) 79.0 (3.11)
Boss (Boom) 80 (3.15) 81.5 (3.21)
Bushing (Arm Cylinder) 80 (3.15) 81.5 (3.21)
W2-3-1-1
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
G Pin 71 (2.80) 70.0 (2.76) Replace
Boss (Arm) 71 (2.80) 72.5 (2.85)
Bushing (Bucket Cylinder) 71 (2.80) 72.5 (2.85)
H Pin 80 (3.15) 79.0 (3.11)
Boss (Link B) 80 (3.15) 81.5 (3.21)
Bushing (Link A) 80 (3.15) 81.5 (3.21)
Bushing (Bucket Cylinder) 80 (3.15) 81.5 (3.21)
I Pin 71 (2.80) 70.0 (2.76)
Boss (Link B) 71 (2.80) 72.5 (2.85)
Bushing (Arm) 71 (2.80) 72.5 (2.85)
J Pin 80 (3.15) 79.0 (3.11)
Boss (Bucket) 80 (3.15) 81.5 (3.21)
Bushing (Link A) 80 (3.15) 81.5 (3.21)
K Pin 80 (3.15) 79.0 (3.11)
Boss (Bucket) 80 (3.15) 81.5 (3.21)
Bushing (Arm) 80 (3.15) 81.5 (3.21)
IMPORTANT: When replacing HN bushing for the
front attachment, install it by using a press.
W2-3-1-2
Side Cutter (2014503, 2014504)
C
D
W155-04-01-002
Unit: mm (in)
Limit
A 278 (10.9) 181 (7.1) Replace
B 295 (11.6) -
C 433 (17.0) -
D 135 (5.3) -
W2-3-1-3
Point (4427919)
B C
W105-04-01-020
Unit: mm (in)
Limit
A 215 (8.5) 107.5 (4.2) Replace
B 95 (3.7) -
C 108 (4.3) -
D 95 (3.7) -
W2-3-1-4
Standard Dimensions for Arm and Bucket

Connection
IMPORTANT: If the front attachment of a previous
model machine is used, use the grease intervals
for previous model machine.
WDCD-02-03-005
Section A Section B
WDCD-02-03-003
Unit: mm (in)
ZX210LCN-G ZX200-3 Class
a 450 (17.7) 
b 10 (0.39) 
c 604 (23.8) 
d 580 (22.8) 
e 476 (18.7) 
f 1471 (57.9) 
g 433 (17.0) 
h 326 (12.8) 305 (12.00)
i 80 (3.15) 
j 475 (18.7) 
k 31 (1.2) 
l 433 (17.0) 
m 307 (12.1) 
n 80 (3.1) 
o 15 ° -3.7 °
p 15 ° 3.7 °
q 449 (17.7) 
W2-3-1-5
Standard Dimensions for Arm and Boom

Connection
WDCD-02-03-001
Section C
Unit: mm (in)
ZX210LCN-G ZX200-3 Class
s 90 (3.54) 
t 352 (13.85) 
u 490 (19.3) 
IMPORTANT: If the front attachment of a previous

model machine is used, use the grease intervals
for previous model machine.
WDCD-02-03-004
s- Pin Hole Inner Diameter
W2-3-1-6
Cylinder
Rod Rod Bend and Run Out
b
a
A
W166-04-02-022
c d
W105-04-02-094 a- Cylinder Rod c- V Block
b- Dial Gauge d- 1 m (39.4 in)
Unit: mm (in) Unit: mm (in)

Cylinder Name Recommended Size After Re- Bend Run Out Remedy
manufacturing (A) 0.5 (0.020) 1.0 (0.039) Repair
Boom 85+0.027-0.057 (3.35+0.001-0.006) 1.0 (0.039) 2.0 (0.079) Replace
Arm 95+0.027-0.057 (3.74+0.001-0.006)
Bucket 80+0.027-0.057 (3.15+0.001-0.006)
W2-3-2-1
(Blank)
W2-3-2-2
MEMO
MEMO
SECTION 3
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Group 12 Pilot Shut-Off Valve
Removal and Installation of Cab...............................W3-1-1-1 Removal and Installation of Pilot Shut-Off
Dimensions of The Cab Glass......................................W3-1-2-1 Valve............................................................................ W3-12-1-1
Removal and Installation of 3-Spool Solenoid
Group 2 Counterweight Valve Unit.................................................................. W3-12-2-1
Removal and Installation of Counterweight.........W3-2-1-1
Group 3 Main Frame Removal and Installation of Signal Control
Removal and Installation of Main Frame................W3-3-1-1 Valve............................................................................ W3-13-1-1
Group 8 Pump Device
Removal and Installation of Pump Device.............W3-8-1-1
Disassembly of Pump Device.....................................W3-8-2-1
Assembly of Pump Device...........................................W3-8-2-8
Disassembly of Regulator............................................W3-8-3-1
Assembly of Regulator..................................................W3-8-3-3
Disassembly of Solenoid Valve...................................W3-8-4-1
Assembly of Solenoid Valve........................................W3-8-4-3
Structure of Pilot Pump................................................W3-8-5-1
Removal and Installation Control Valve..................W3-9-1-1
Disassembly of Housing...............................................W3-9-2-1
Assembly of Housing.....................................................W3-9-2-3
Disassembly of Control Valve (4-Spool Side)........W3-9-3-1
Assembly of Control Valve (4-Spool Side)........... W3-9-3-10
Disassembly of Control Valve (5-Spool Side)........W3-9-4-1
Assembly of Control Valve (5-Spool Side)........... W3-9-4-10
Removal and Installation of Swing Device......... W3-10-1-1
Disassembly of Swing Device.................................. W3-10-2-1
Assembly of Swing Device....................................... W3-10-2-6
Removal and Installation of Pilot Valve (Left).... W3-11-1-1
Removal and Installation of Pilot Valve
(Right)......................................................................... W3-11-2-1
Removal and Installation of Travel Pilot
Valve............................................................................ W3-11-3-1
Disassembly of Pilot Valves (Right and Left)...... W3-11-4-1
Assembly of Pilot Valves (Right and Left)............ W3-11-4-4
Disassembly of Travel Pilot Valve............................ W3-11-5-1
Assembly of Travel Pilot Valve................................. W3-11-5-5
DC390W-3-1
(Blank)
DC390W-3-2
Group 1 Cab
Removal and Installation of Cab
6 2
5 4 1 WDAA-03-01-023
3 WDAA-03-01-047
IMPORTANT: Cap the open ends in case the hoses 4. Remove floor mat (4).
and pipes have been disconnected. In addition,
5. Remove bolts, washers (5) (4 used). Remove travel
attach an identification tag onto the connectors,
control levers (6) (2 used).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which j : 17 mm
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Open door (1).
dCAUTION: Seat (2) weight: 21 kg (47 lb)

3. Remove bolts, washers (3) (4 used). Remove seat (2).
j : 17 mm
W3-1-1-1
Group 1 Cab
4
12 7
5
10
13 9
W178-02-01-012 W178-02-01-013
6. Remove bolts, washers (4) (2 used). Remove rear 8. Remove screws (7) (6 used). Remove duct (9).
box (3).
9. Remove air filter (6).
j : 17 mm 10. Remove screws (13) (6 used). Remove duct (10).
7. Remove duct (5). 11. Remove clip (12) (2 used). Remove duct (8).
W3-1-1-2
Group 1 Cab
10
11
14
12
13
W178-02-01-014 W178-02-01-015
12. Disconnect connectors (10, 11, 12, 13). Disconnect 13. Disconnect washer hose (14).
ground (9).
W3-1-1-3
Group 1 Cab
16
17
18
15
19
20
21
W178-02-01-016 W178-02-01-017
14. Remove cap (15) (5 used) and screw (16) (5 used). 15. Remove screw (18) (2 used) and bolts, washers (21).
Remove cover (17). Remove ducts (19, 20).
j : 17 mm
W3-1-1-4
Group 1 Cab
a
a
a
4
2
3
6
1
5 4
4
6
a- Lifting Bracket
W178-02-01-018 WDC390-03-01-001
17. Remove socket bolts (2) (2 used) and washers (3) (2

dCAUTION:
(640 lb)
The cab (1) assembly weight: 290 kg used).
16. Attach nylon slings onto lifting brackets (a) (4 l : 8 mm

places) of cab (1). Hoist and hold the cab (1) 18. Remove bolts, washers (4) (7 used).
assembly.
j : 17 mm
19. Remove nuts (6) (4 used) and washers (5) (4 used).
Remove the cab (1).
j : 24 mm
W3-1-1-5
Group 1 Cab
a
a
a
4
2
3
6
1
5 4
4
6
a- Lifting Bracket
W178-02-01-018 WDC390-03-01-001
Installation
dCAUTION:
(640 lb)
The cab (1) assembly weight: 290 kg
1. Attach nylon slings onto lifting brackets (a) (4

places) of cab (1). Hoist the cab (1).
2. Install the cab (1) with washers (5) (4 used) and nuts
(6) (4 used).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)

3. Install bolts, washers (4) (7 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

4. Install washers (3) (2 used) and socket bolts (2) (2
used).
j : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-6
Group 1 Cab
16
17
18 Mating Surface
15
19
20
21
W178-02-01-017 W178-02-01-016
5. Install ducts (19, 20) with screw (18) (2 used) and 6. Install cover (17) with screw (16) (5 used). Install cap
bolts, washers (21). (15) (5 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-7
Group 1 Cab
10
11
14
12
13
W178-02-01-015 W178-02-01-014
7. Connect washer hose (14). 8. Connect ground (9). Connect connertors (10, 11, 12,
13).
W3-1-1-8
Group 1 Cab
4
12 7 5
10
13 9
W178-02-01-013 W178-02-01-012
9. Install duct (8) with clip (12) (2 used). 13. Install duct (5).
10. Install duct (10) with screw (13) (6 used). 14. Install rear box (3) with bolts, washers (4) (2 used).
11. Install air filter (6). j : 17 mm
12. Install duct (9) with screw (7) (6 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-9
Group 1 Cab
6 2
5 4 1 WDAA-03-01-023
3 WDAA-03-01-047
15. Install travel control levers (6) (2 used) with bolts,

washers (5) (4 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

16. Install floor mat (4).

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

18. Close door (1).
W3-1-1-10
Group 1 Cab
Dimensions of The Cab Glass

Unit: mm A
a
R2
67 303.5
11
R35
R98
Section A W178-02-01-019 4-φ130-1
30 R3018
405
Polish Chamfer
Both Sides 375
51 612
238
R118
(5 mm)
343.5
148.5
196
100
W178-02-01-002
50
c1 c1 R70
370.5
a- Chamfer Here
W178-02-01-006
B
(60.3) 261.6±1
Section C W178-02-01-019 (9.4)
C R42
R72
14
733
366
R58 R2992
R58
546±1
R11508
R92
(4 mm)
R1808
882.5 997 170.6
(4 mm)
70
50
R308 R1898 R42
R258 321.9±1
W178-02-01-024
100
150
943
W178-02-01-007
Section B W178-02-01-019
W3-1-2-1
Group 1 Cab
Unit: mm
a
a
85.4
a
343.3 213
R105
R72 R10
R105
(4 mm)
39.5
D
733
733
C R2465 2-φ12.2+0.5
-0
(4 mm) Section C and D

40 6.754
W178-02-01-019
Polish Chamfer
Both Sides
289.5
3-R4 50
2-R4
86.9 50 50
556.3
50
a- Chamfer Here W178-02-01-011
423
a- Chamfer Here
W178-02-01-008
366.1 104.5
R12 R95
W178-02-01-004 (5 mm)
982.7
872
R2002
R5 for 3 Places
R123
R2475
38.2 R14
364.7 (5 mm) 51
470.6
R115
W178-02-01-009
888.58
W178-02-01-010
W3-1-2-2
Group 1 Cab
W178-02-01-005
A
753
R63
R63
490
610.5 (4 mm)
R115
R115
R167
50
50
512.5
R167
W178-02-01-025
Section A
W178-02-01-019
W3-1-2-3
Group 1 Cab
Remove Cab Glass

Procedures to remove left-hand cab glass, lower glass of Mounting Rubber Section
the door and upper front glass
dCAUTION: When removing broken or cracked

glass beware of the danger of glass shards that a b
may cause serious injury.

Before removing, gummed tape or something like
should be used to paste the broken or cracked
glass ready to reinforce them so as to prevent hurt
from occurring. Be sure to remove glass pieces
away.
d
Take protective measures before removing. c
Reinforce broken or cracked glass with gummed
tape to assist in safe removal.
W178-02-01-022
a- Mounting Rubber c- Seal Rubber W178-02-01-004

b- Glass d- Cab
1. Insert bamboo spatula into position A in mount-

A
ing rubber (a) to pry the mounting rubber (a) apart
along all periphery. It is easier to remove glass
when air is entered between cab (d) and mounting
rubber. b
a
2. Tap glass from the side in cab (d) by palm of the
hand to take the glass (b) off. Two men are required
to do the work.
IMPORTANT: Be sure to install the cab glass and
mounting rubber using the special bonding agent.
The cab glass may fall if the special bonding
agent is not used. The cab glass assembly can’t be d
replaced individually. Be sure to change the cab c
glass as an assembly.
The upper front glass is arched-fringed. If
this glass needs to be replaced, contact with
the nearest HITACHI Office to replace it as an
assembly. a- Mounting Rubber c- Seal Rubber W178-02-01-022
b- Glass d- Cab
W3-1-2-4
Group 1 Cab
Procedures to Remove Right-Hand Cab Glass

Mounting Rubber Section
1. Insert a bamboo spatula into position A in
a
mounting rubber to pry the mounting rubber apart b
along all periphery. It is easier to remove the glass
when air is entered between cab and mounting A
rubber.
2. Tap glass from the side in cab by palm of the hand c
to take the glass off. Two men are required to do the
work.
W216-02-01-005
a- Glass c- Cab W178-02-01-002

b- Mounting Rubber
Method to remove rear side cab glass

1. Remove stopper (groove rubber) (d) with a minus
screwdriver. a
2. Insert a bamboo spatula into position A in b

mounting rubber (b) to pry the mounting rubber (b)
apart along all periphery.
d
3. Tap glass from the side in cab by palm of the hand
to take the glass off. Two men are required to do the
work. A A
c w216-02-01-003
W178-02-01-005
a- Glass c- Cab
b- Mounting Rubber d- Stopper (Groove Rubber)
W3-1-2-5
Group 1 Cab
Cab Glass Installation Procedure Left-Hand Cab Glass

Procedure for installing left-hand cab glass, lower glass of
the door and upper front glass
a A
1. Install the seal rubber (b) on the left-hand cab glass
and lower glass of the door.
Section A
b
W178-02-01-021
c
a- CSE Braid c- Put Connect End in Center of
b- Seal Rubber Glass Edge and Then adhere It
Lower Glass Of Door
50
A
W178-02-01-023 a
b
2. When the mounting rubber is already on the glass,

pull and fasten the mounting rubber onto the 10 10
mounting face of cab. a- CSE Braid
b- Seal Rubber
IMPORTANT: Be sure to install the cab glass and W178-02-01-020
mounting rubber using the special bonding agent. Mounting Rubber Section
agent is not used. The cab glass assembly can’t be
replaced individually. Be sure to change the cab
d
glass as an assembly. e
The upper front glass is archedfringed. If this glass
needs to be replaced, replaced it as an assembly.
W178-02-01-022
b- Seal Rubber
d- Mounting Rubber
e- Glass
f- Cab W178-02-01-004
W3-1-2-6
Group 1 Cab
Spacer a (4458466) Spacer b (4458469) Spacer c (4458470)

20 20 20
5
R7 R6
10.9 9.3 10.5
8.7 0.5 Flat 7
5 5
0.5
1 3.6 a 3.6 a a
b c 1
6 6
8.5 8.5
W178-02-11-051 W178-02-11-053 W178-02-11-055
a- Apply Adhesive to Both Sides a- Apply Adhesive to Both Sides a- Apply Adhesive to
b- Concave c- Convex Both Sides
Left-Hand Glass Left-Hand Glass D Lower Door Glass

B D
B
400 3 286
700
3 225
2
3
30
c 4 160 650
305 1 62
1
c
A 85 2
110 290 445
52 450
A 60
1- Spacer a 1- Spacer a 123
W178-02-11-052
2- Spacer b 3- Spacer c 2- Spacer b
W178-02-11-054 W178-02-11-056
3- Spacer c 3- Spacer c
4- Sucker Lifter
Section A-A Section B-B Section C-C
e
f 2
3
1- Spacer a 1
d- Glass d e g
e- Bonding Agent 2- Spacer b e
f- Install Spacer with Its 3- Spacer c
W1SE-02-01-023 d- Glass W178-02-11-057
Concave Side Facing e- Bonding Agent e- Bonding Agent
Bonding Agent g- Install spacer with Its 18
convex Side Facing W178-02-11-058
Section D-D
Bonding Agent
3- Spacer c
e- Bonding 18 W178-02-11-059
Agent
W3-1-2-7
Group 1 Cab
a g
8~9 mm
h
9.0
13~15 mm
i
5.5 5.0 b
e
5.5~5.9
4.9 3.6 j W1SE-02-01-027

W1SE-02-01-043
12.0 f
b- Cut nozzle end into V-shaped.
e- Apply bead so that bead triangle may be
even.
W178-02-11-060 f- Panel
a- Apply Bead Here

g- Glass 4 to 5 mm
h- Spacer a or b
i- Apply Adhesive to Both Side
j- Cab
c- Remove the seal. W1SE-02-01-028

d- Adhesive Cartridge
13. The required amount (just for reference) of bonding agent and primer
Bonding Agent: Sunrise MSI SR Seal U90 Primer: Sunrise MSI

(4463876) Prime 24 (for painting)
Glass
320 cm3 Cartridge Primer 35 (for glass)
150 cm3 for each bin
Right-Hand Glass (1 used) 1 Used 1/10 Used for each
Rear Left-Hand Glass (1 used) 1/2 Used 1/20 Used for each
Lower Door Glass (1 used) 1/3 Used 1/50 Used for each
W3-1-2-8
Group 1 Cab
Method for Installing Right-Hand Cab Glass

1. Install the mounting rubber into the surrounding of
a
cab glass. Bond the connectors of mounting rubber b
with the bonding agent (Cemedine 366 Standard or
equivalent).
fNOTE: Rubber aging will cause the contraction of

rubber, be sure to leave a little extra, install by pressing c
with hands.
a- Glass
2. Put and fasten the mounting rubber on the b- Mounting Rubber
mounting face of cab after installing rubber. c- Cab
W216-02-01-005
W178-02-01-002
Procedures for Installing Rear Cab Glass

1. Insert mounting rubber around the cab glass.
a
Install the connectors or mounting rubber with
the bonding agent (Cemedine 366 Standard or b
equivalent).
fNOTE: Rubber aging will cause the contraction of d

rubber, be sure to leave a little extra, install by pressing
with hands.
2. After installing the glass assembly on the cab, insert
the stopper into rubber.
IMPORTANT: The rear side glass is arched-fringed.
If this glass needs to be replaced, contact with c w216-02-01-003
the nearest HITACHI Office to replace it as an
assembly.
a- Glass c- Cab W178-02-01-005

b- Mounting Rubber d- Stopper
W3-1-2-9
Group 1 Cab
Procedures to Install Upper Front Glass

1. Mounting rubber is stuck on glass. Be sure to install
Position for Mounting Rubber
the glass with the mounting rubber contacting the (All around the Glass) Frame
cab mounting face, then secure them. (All around
the glass)
2. Stick seal (1) to the lower side of the front upper
glass with POS seal.
Stick both right and left ends (the thicker part) of
seal (1) to the glass and secure it with bonding
agent POS seal.
Upper Glass
Stick the end of middle lip in seal (1) with POS seal.
Be sure no visible undulation or boss can be found.
fNOTE: POS seal:

POS seal (black) of TOSHIBA silicon
Glue-state bonding agent, tubed
1
IMPORTANT: Be sure to install the cab glass and Lower Glass
mounting rubber using the special bonding agent.
agent is not used. The cab glass assembly can’t be
replaced individually. Be sure to change the cab
glass as an assembly. Upper Glass
The upper front glass is arched-fringed. If this
glass needs to be replaced, contact the nearest
HITACHI Office to replace it as an assembly. Slick POS
POS Seal
Seal Here
1 1
Lower Glass
Lower Glass
W178-02-11-065
W3-1-2-10
Removal and Installation of Counterweight
WDC390-03-02-001 WDC390-03-02-002
4
Removal
2. Open the engine cover.
dCAUTION:
(11800 lb)
Counterweight (4) weight: 5310kg
3. Remove caps (5) (2 used). Install the Freno-Linkbolts

(A-42, M42, Pitch 4.5 mm) (2 used) to the cap (5)
mounting holes (2 places). Attach wire ropes onto
the Freno-Linkbolts. Hoist and hold counterweight
(4).
4. Remove bolts (6) (4 used) and washers (7) (4 used).
Remove counterweight (4).
j : 55 mm
W3-2-1-1
WDC390-03-02-001 WDC390-03-02-002
4
Installation
dCAUTION:
(11800 lb)
Counterweight (4) weight: 5310 kg
1. Install the Freno-Linkbolts (A-42, M42, Pitch 4.5 mm)

(2 used) to the cap (5) mounting holes (2 places).
Attach wire ropes onto the Freno-Linkbolts. Hoist
counterweight (4).
2. Install counterweight (4) with washers (7) (4 used)
and bolts (6) (4 used).
j : 55 mm
m : 2900 N·m (290 kgf·m, 2140 lbf·ft)

3. Remove the the Freno-Linkbolts (2 used) from the
cap (5) mounting holes (2 places). Install caps (5) (2
used).
4. Close the engine cover.
W3-2-1-2
Group 3 Main Frame
Removal and Installation of Main Frame
3 4 1
WDCD-03-03-001
IMPORTANT: The hose and pipe contain hydraulic

oil. When removing the hose and pipe, receive oils
with a container in order to avoid spilling oils.
IMPORTANT: Cap the open ends in case the hoses
attach identification tags onto the connectors,
hoses and install the clips in case the clips which
Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)
dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove counterweight (2). (Refer to W3-2-1.)
3. Remove front attachment (3). (Refer to W5-1-1.)
4. Remove boom cylinder (4). (Refer to W5-2-1.)
5. Remove cab (1). (Refer to W3-1-1.)
W3-3-1-1
Group 3 Main Frame
a
6
12
8 b
5 11 9, 10
WDC390-03-03-001 WDC390-03-03-002
a- Counterweight Mounting b- Boom Mounting Bracket Hole

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

hoses (6) (4 used). dCAUTION:
(10400 lb)
Main frame (12) weight: 4680 kg
j : 36 mm 10. Attach wire ropes onto counterweight mounting

7. Disconnect hose (7). part (a) (2 places) of the main frame (12) rear side
and boom mounting bracket hole (b) (2 places).
j : 27 mm
8. Disconnect hose (8).
j : 17 mm
9. Remove bolts (9) (2 used) and spring washers (10) (2
used). Remove stopper (11).
j : 22 mm
W3-3-1-2
Group 3 Main Frame
12 13
14
WDAB-03-03-003
11. Reduce slack of wire ropes by using a chain block.

Put the matching marks onto main frame (12) and
outer race (13) of the swing bearing.
12. Remove bolts (14) (32 used).
j : 30 mm
13. Adjust the chain block in order to level main frame
(12). Hoist and remove main frame (12).
W3-3-1-3
Group 3 Main Frame
12 13
12
b
14
WDC390-03-03-002 WDAB-03-03-003
a- Counterweight Mounting b- Boom Mounting Bracket Hole

Part
Installation 3. Fit the matching marks made when disassembling

and install main frame (12) to outer race (13) of the
dCAUTION:
(10400 lb)
Main frame (12) weight: 4680 kg swing bearing. Install bolts (14) (32 used).
1. Attach wire ropes onto counterweight mounting j : 30 mm

part (a) (2 places) of the main frame (12) rear side
m : 510 N·m (51 kgf·m, 380 lbf·ft)
and boom mounting bracket hole (b) (2 places).
2. Adjust the chain block in order to level main frame
(12).
W3-3-1-4
Group 3 Main Frame
5 11 9, 10
WDC390-03-03-001
4. Install stopper (11) with spring washers (10) (2 used)

j : 22 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)

5. Connect hose (8).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

j : 27 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)

7. Connect hoses (6) (4 used).
j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-3-1-5
Group 3 Main Frame
3 4 1
WDCD-03-03-001
8. Install boom cylinder (4). (Refer to W5-2-1.)

9. Install front attachment (3). (Refer to W5-1-1.)
10. Install counterweight (2). (Refer to W3-2-1.)
11. Install cab (1). (Refer to W3-1-1.)
12. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
W3-3-1-6
Group 8 Pump Device
Removal and Installation of Pump Device

6
3, 4
WDC390-03-08-004
1

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

(Refer to W1-4-1.)
2. Remove bolts, washers (2) (6 used). Remove the
cover (3) assembly and O-ring (4) from the top of
hydraulic oil tank (1).
j : 17 mm
3. Drain off hydraulic oil by using an oil feed pump.
fNOTE: Total oil amount of hydraulic oil tank (1): 130 L

(34.4 US gal)
4. Open cover (5) and engine cover (6).
W3-8-1-1
Group 8 Pump Device
1, 2
5
WDC390-03-08-005
6
WDC390-03-08-006
7. Remove bolts, washers (5) (4 used). Remove cover

dCAUTION: Engine cover (3) weight: 37 kg (82 lb) (6).
5. Hoist and hold engine cover (3). Remove washers (1)
(2 used) and lock pins (2) (2 used). j : 17 mm
6. Remove bolts, washers (4) (4 used). Remove engine

cover (3).
j : 17 mm
W3-8-1-2
Group 8 Pump Device
1 4 5
3 2
WDC390-03-08-007 WDC390-03-08-008
8. Remove bolts, washers (2) (3 used) and bolts, 9. Remove bolts, washers (5) (3 used). Remove cover
washers (3) (4 used). Remove cover (1). (4).
j : 17 mm j : 17 mm
W3-8-1-3
Group 8 Pump Device
WDC390-03-08-010
WDC390-03-08-009
10. Remove bolts, washers (15) (3 used). 15. Disconnect hose (28).
j : 10 mm j : 27 mm
11. Disconnect connectors (16) (7 used). 16. Remove clamps (21) (4 used). Disconnect rubber
hose (22).
12. Place containers under pump device (17) and pipe
(24). Disconnect hose (18). 17. Remove socket bolts (23) (4 used). Disconnect pipe
(24). Remove O-ring (30).
j : 36 mm
l : 10 mm
13. Disconnect hoses (19) (2 used).
18. Remove socket bolts (25) (8 used) and flanges (26)
j : 19 mm (4 used). Disconnect hoses (27) (2 used). Remove
14. Disconnect hose (20). O-rings (29) (2 used).
j : 17 mm l : 10 mm
W3-8-1-4
Group 8 Pump Device
29, 30, 31, 32 33

36, 37 38
WDC390-03-08-011
17
34 WDCD-03-08-012
19. Remove bolts (29) (2 used) and nuts (30) (2 used).

Remove clamp (31) and gasket (32). dCAUTION:
lb)
Pump device (17) weight: 170 kg (375
j : 17 mm 22. Remove bolts (36) (3 used) and washers (37) (3

used). Install eyebolts (M12, Pitch 1.75 mm) (3 used)
dCAUTION:
25kg (56 lb)
The muffler (33) assembly weight:
to the bolt (36) holes (3 places). Attach nylon slings
onto eyebolts. Hoist and hold pump device (17).
20. Attach nylon slings onto muffler (33). Hoist and hold
the muffler (33) assembly. j : 19 mm
21. Remove bolts, washers (34) (3 used). Remove the 23. Remove bolts, washers (38) (5 used). Remove pump
muffler (33) assembly. device (17).
j : 17 mm j : 17 mm
24. Remove the adapters with pump device (17)
attached if necessary.
W3-8-1-5
Group 8 Pump Device
29, 30, 31, 32 40 33 36, 37 38
WDC390-03-08-011
34 WDCD-03-08-012 17
Installation 6. Install the muffler (33) assembly with bolts, washers

(34) (3 used).
1. Install all removed adapters to pump device (17).
j : 17 mm
dCAUTION:
lb)
Pump device (17) weight: 170 kg (375
m : 50 N·m (5 kgf·m, 37 lbf·ft)
2. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to the
IMPORTANT: Replace gasket (32) with the new one.
bolt (36) holes (3 places). Attach nylon slings onto
eyebolts. Hoist pump device (17). 7. Install gasket (32) and clamp (31) to muffler (33) and
exhaust pipe (40) with nuts (30) (2 used) and bolts
3. Install pump device (17) with bolts, washers (38) (5 (29) (2 used).
used).
j : 17 mm
j : 17 mm
m : 7 to 10 N·m (0.7 to 1 kgf·m, 5.2 to 7.4 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
4. Remove eyebolts (3 used) from the bolt (36) holes (3
places). Install washers (37) (3 used) and bolts (36) (3
used).
j : 19 mm
dCAUTION:
kg (37 lb)
The muffler (33) assembly weight: 25
5. Attach nylon slings onto muffler (33). Hoist the

muffler (33) assembly.
W3-8-1-6
Group 8 Pump Device
WDC390-03-08-012 WDC390-03-08-013
8. Install O-rings (29) (2 used). Connect hoses (27) (2 13. Connect hoses (19) (2 used).
used) with flanges (26) (4 used) and socket bolts
(25) (8 used). j : 19 mm
l : 10 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

m : 110 N·m (11 kgf·m, 81 lbf·ft)
9. Connect rubber hose (22) with clamps (21) (4 used). j : 36 mm
m : 6 N·m (0.6 kgf·m, 4.4 lbf·ft) m : 180 N·m (18 kgf·m, 133 lbf·ft)
10. Install O-ring (30). Connect pipe (24) with socket 15. Connect connectors (16) (7 used).
bolts (23) (4 used). 16. Install clamps (41) (3 used) with bolts, washers (15)
(3 used).
l : 10 mm
j : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
11. Connect hose (28). m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 0.2 to 0.3 lbf·ft)
j : 27 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)

j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
W3-8-1-7
Group 8 Pump Device
4 5 1
3 2
WDC390-03-08-008 WDC390-03-08-007
17. Install cover (4) with bolts, washers (5) (3 used). 18. Install cover (1) with bolts, washers (2) (3 used) and
bolts, washers (3) (4 used).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-8-1-8
Group 8 Pump Device
7 1, 2
5
WDC390-03-08-005
6
WDC390-03-08-006
19. Install cover (6) with bolts, washers (5) (4 used).
j : 17 mm
dCAUTION: Engine cover (3) weight: 37 kg (82 lb)
20. Hoist engine cover (3). Install engine cover (3) with
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

21. Install stay (7) to engine cover (3) with washers (1) (2
used) and lock pins (2) (2 used).
W3-8-1-9
Group 8 Pump Device
3, 4
WDC390-03-08-004
1
22. Fill hydraulic oil to hydraulic oil tank (1).
fNOTE: Total oil amount of hydraulic oil tank (1): 130 L

23. Install O-ring (4).
24. Install the cover (3) assembly to the top of hydraulic
oil tank (1) with bolts, washers (2) (6 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

1.)
26. Close engine cover (6) and cover (5).
W3-8-1-10
Group 8 Pump Device
Disassembly of Pump Device
4
2 3
5
1
17
16 18
15
14
6
13
11 12
10
56 7 9
55
54 17
8
15 14 16
19
51
49 12
50 20
27 11 68
10
9 67 69
26
66 70
67
80
64 71
21 63
49 65
50 21 22
60 22 23
26 29 58 61 24
62 81
61
58 60
74 72
59 58
60
57 91 61
77 73
58 61
58 60 75
59 76
78 91
68
57 58
58
78
WDCD-03-08-019
W3-8-2-1
Group 8 Pump Device
79
53
52
90
89
88
87 28
86
85
25
84
48
47
35
33
34 36
37
38
32
31 30
39
46
45 40
41
42
43
44
42 WDC390-03-08-001
1- Socket Bolt (4 Used) 24- Plug 47- Gear Casing 70- O-Ring (2 Used)
2- Regulator 25- Plug 48- Spring Pin (2 Used) 71- Socket Bolt (12 Used)
3- Socket Bolt (2 Used) 26- Retaining Ring (2 Used) 49- Oil Seal (2 Used) 72- Set Screw (2 Used)
4- Socket Bolt (2 Used) 27- Gear 50- Retaining Ring (2 Used) 73- Servo Piston (2 Used)
5- Socket Bolt (2 Used) 28- Gasket 51- Pump Casing 74- Pin (2 Used)
6- Regulator 29- Gear 52- Spring Washer (6 Used) 75- O-Ring (2 Used)
7- O-Ring (4 Used) 30- Plug 53- Bolt (6 Used) 76- Stopper L (2 Used)
8- O-Ring (6 Used) 31- O-Ring 54- Spring Pin (4 Used) 77- Valve Plate
9- Bearing Nut (2 Used) 32- Gasket 55- O-Ring (10 Used) 78- Link (2 Used)
10- Bearing (2 Used) 33- Socket Bolt (2 Used) 56- O-Ring (2 Used) 79- Pipe
11- Ring (2 Used) 34- Pipe 57- Pin (2 Used) 80- Pump 1 Delivery Pressure
12- Bearing (2 Used) 35- Level Gauge 58- Retaining Ring (12 Used) Sensor
13- Shaft 36- Socket Bolt (2 Used) 59- Pin (2 Used) 81- Pump 2 Delivery Pressure
14- Pin (2 Used) 37- Spring Washer (2 Used) 60- Lever (4 Used) Sensor
15- Center Shaft (2 Used) 38- Washer (2 Used) 61- Pin (4 Used) 84- O-Ring
16- Spring (2 Used) 39- Pilot Pump 62- Valve Plate 85- N Sensor
17- Plunger (14 Used) 40- Retaining Ring 63- Backup Ring 86- Washer
18- Rotor (2 Used) 41- Retaining Ring 64- O-Ring 87- Socket Bolt
19- Shaft 42- Ball Bearing (2 Used) 65- Spring Pin (2 Used) 88- Bracket
20- Thrust Ring 43- Gear 66- Selector Head 89- Spring Washer
21- O-Ring (2 Used) 44- Gear Shaft 67- O-Ring (4 Used) 90- Socket Bolt
22- Plug (2 Used) 45- Retaining Ring 68- Socket Bolt (16 Used) 91- Pin (4 Used)
23- O-Ring 46- Oil Seal 69- Stopper S (2 Used)
W3-8-2-2
Group 8 Pump Device
Disassembly of Pump Device

7. Remove socket bolts (3, 5) (2 used for each). Raise
1. Disconnect the both ends of pipe (79) from
regulator (6) to the direction of selector head (66).
regulators (2, 6).
Remove regulator (6) from pump casing (51). Do not
j : 17 mm remove socket bolt (4).
2. Remove pump 1 delivery pressure sensor (80) and l : 8 mm
pump 2 delivery pressure sensor (81) from selector
8. Remove O-rings (56) (2 used), O-rings (55) (10 used),
head (66).
O-rings (7) (4 used), and spring pins (54) (4 used)
j : 27 mm from pump casing (51).
3. Remove socket bolts (87, 90), washer (86), and
spring washer (89). Remove N sensor (85), O-ring
dCAUTION: Pump device weight: 160 kg (355 lb)
(84), and bracket (88) from pump casing (51). dCAUTION: When hoisting the pump device, do
not take pump casing (51) off the ground but turn
l : 5 mm to the gear casing (47) side.
4. Remove plug (25) from gear casing (47).
socket bolt (1, 3) holes of pump casing (51). Hoist
j : 17 mm the pump device. Place the pump device with gear
casing (47) down. Place a wooden block (80 mm or
5. Remove plug (30) from gear casing (47). Drain off more square) under gear casing (47).
engine oil.
10. Remove socket bolts (33) (2 used) from gear casing
j : 22 mm (47). Remove level gauge (35), pipe (34), and gasket
(32).
fNOTE: Amount of oil: 1 L (1.06 US qt)
6. Remove socket bolts (1) (4 used). Raise regulator l : 6 mm
(2) to the direction of selector head (66). Remove
regulator (2) from pump casing (51).
l : 8 mm
W3-8-2-3
Group 8 Pump Device
11. Remove socket bolts (36) (2 used), spring washers 12. Remove socket bolts (68) (16 used) from selector
(37) (2 used), and washers (38) (2 used) from gear head (66). Remove stoppers S (69) (2 used) and
casing (47). While tapping the flange part of pilot stoppers L (76) (2 used) from selector head (66).
pump (39) by using a plastic hammer, remove pilot
pump (39) from gear casing (47). l : 6 mm
l : 8 mm fNOTE: O-rings (70, 75) are installed on stopper S (69)

and stopper L (76). If it is difficult to remove stopper (c),
fNOTE: THREEBOND has been applied onto the tap the outer periphery of stopper (c) by using a plastic
mounting surface of pilot pump (39). hammer. Turn stopper (c) until the half of socket bolt (68)
hole can be seen. Insert a screwdriver into the socket bolt
(68) hole. Remove stopper (c).
W178-02-11-082
c- Stopper
W3-8-2-4
Group 8 Pump Device
13. Remove socket bolts (71) (12 used) from selector 18. Both valve plates (62, 77) are very similar and their
head (66). Measure and record the clearance installing directions are determined. Record the
between pump casing (51) and selector head (66). position and the direction to install valve plates (62,
77) before removing. Remove retaining rings (58) (8
l : 10 mm used) from pins (61) (4 used) and pins (91) (4 used).
Remove valve plates (62, 77) from links (78) (2 used).
fNOTE: When loosening socket bolts (71) (12 used),
Do not remove pins (61) (4 used) unless necessary.
selector head (66) will be pushed out due to the force of
spring (16). 19. Remove rotors (18) (2 used), springs (16) (2 used),
center shafts (15) (2 used), and plungers (17) (14
dCAUTION: The selector head (66) assembly
weight: 29 kg (64 lb)
used) from pump casing (51) in sequence. Remove
pins (14) (2 used) from center shafts (15) (2 used).
screw holes (a) (2 places) of selector head (66). Hoist fNOTE: Remove plunger (17) with it tilted inside.
and remove the selector head (66) assembly from IMPORTANT: As the pump performance is changed,
pump casing (51). do not deform link (78).
20. Remove the link (78) assemblies (2 used) from
a
pump casing (51). Do not disassemble the link (78)
66 assembly unless necessary.
fNOTE: If it is difficult to remove the link (78) assembly,

use a screwdriver.
21. Remove bolts (53) (6 used) and spring washers (52)
(6 used) from pump casing (51).
j : 24 mm
WDBE-03-08-006
a- Screw Hole
15. Warm up set screw (72) by using a drier. Remove set

screw (72) from servo piston (73). Remove pins (74)
(2 used).
l : 6 mm
16. Remove servo pistons (73) (2 used) from selector
head (66).
17. Remove backup ring (63), O-ring (64), and O-rings
(8) (6 used) from pump casing (51).
W3-8-2-5
Group 8 Pump Device
dCAUTION: The pump casing (51) assembly

22. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the 26. Attach nylon slings onto pump casing (51). Hoist
socket bolt (71) holes (2 places) of pump casing (51). and place the pump casing (51) assembly with the
Attach nylon slings onto the eyebolts. Hoist and selector head (66) mounting side down.
remove the pump casing (51) assembly from gear
27. Remove plug (24) from pump casing (51). Remove
casing (47). Shafts (13, 19) and gears (27, 29) are
O-ring (23) from plug (24).
removed with pump casing (51) together.
Place pump casing (51) with the regulator mounting j : 19 mm
surface up.
23. Remove spring pins (48) (2 used) and gasket (28)
from gear casing (47). 28. Attach nylon slings onto pump casing (51). Hoist
24. Put the matching marks on the meshed position and place the pump casing (51) assembly on a
of the splines on shafts (13, 19) and gears (27, 29). wooden block with the pump transmission side
Put the matching marks on the meshed position of down. Use the wooden block (100 mm or more
gears (27, 29). square).
29. Remove the shaft (13, 19) assembly from pump
27 29 casing (51) by using the special tools (ST 1470, ST
1471). Bearings (10, 12) are removed with shafts (13,
19) together.
ST 1470
19 ST 1471
13
W137-02-04-007
13
25. Remove retaining rings (26) (2 used) from shafts (13,
19). Remove gears (27, 29) from shafts (13, 19). 19
51
W178-02-04-054
W3-8-2-6
Group 8 Pump Device
30. Remove thrust ring (20) from pump casing (51). 36. Remove retaining ring (40) from gear casing (47).
Remove retaining ring (41) from gear shaft (44).
31. Remove bearing nut (9) from shaft (13) by using the
special tools (ST 3058, ST 5000). 37. Remove ball bearing (42) at the upper side and gear
shaft (44) from gear casing (47) by using the special
ST 3058, ST 5000 tool (ST 1393).
44
42
W137-02-04-023
32. Remove bearings (10, 12) and ring (11) from shaft
(13) by using a press.
33. Remove bearing nut (9), bearings (10, 12), and ring W178-02-11-085
(11) from shaft (19) in the same way as step 33 and
38. Remove gear (43) and ball bearing (42) from gear
step 34.
casing (47).
dCAUTION: Pump casing (51) weight: 42 kg (93 lb) 39. Install shackles to the outer bolt holes of gear
34. Attach nylon slings onto pump casing (51). Hoist casing (47). Hoist and turn over gear casing (47) by
and place pump casing (51) with the regulator using nylon slings.
mounting side up.
40. Remove retaining ring (45) and oil seal (46) from
35. Remove retaining rings (50) (2 used) and oil seals gear casing (47).
(49) (2 used) from pump casing (51).
W3-8-2-7
Group 8 Pump Device
Assembly of Pump Device

77 64 63 91 18 16 15 17 12 20 11 10 9 49 29
26
19
50
13
26
27
62 58, 61 60 18 91 16 15 17 12 11 10 9 49
68 69 67 70 8 7 54 55 59 58 57 56 51
66
73
72
74
75
76
W178-02-11-086
68 65 22 21 78 14 24 23
W3-8-2-8
Group 8 Pump Device
39 40 43
30, 31 36, 37, 38 32, 33, 34 41
42
6 5 4 35 3
25 44
81
45
48 46
71 79
84, 85
80
86, 87
WDC390-03-08-002
2 1 88, 89, 90 52, 53 28 47
WDC390-03-08-003
1- Socket Bolt (4 Used) 24- Plug 47- Gear Casing 70- O-Ring (2 Used)
2- Regulator 25- Plug 48- Spring Pin (2 Used) 71- Socket Bolt (12 Used)
3- Socket Bolt (2 Used) 26- Retaining Ring (2 Used) 49- Oil Seal (2 Used) 72- Set Screw (2 Used)
4- Socket Bolt (2 Used) 27- Gear 50- Retaining Ring (2 Used) 73- Servo Piston (2 Used)
5- Socket Bolt (2 Used) 28- Gasket 51- Pump Casing 74- Pin (2 Used)
6- Regulator 29- Gear 52- Spring Washer (6 Used) 75- O-Ring (2 Used)
7- O-Ring (4 Used) 30- Plug 53- Bolt (6 Used) 76- Stopper L (2 Used)
8- O-Ring (6 Used) 31- O-Ring 54- Spring Pin (4 Used) 77- Valve Plate
9- Bearing Nut (2 Used) 32- Gasket 55- O-Ring (10 Used) 78- Link (2 Used)
10- Bearing (2 Used) 33- Socket Bolt (2 Used) 56- O-Ring (2 Used) 79- Pipe
11- Ring (2 Used) 34- Pipe 57- Pin (2 Used) 80- Pump 1 Delivery Pressure
12- Bearing (2 Used) 35- Level Gauge 58- Retaining Ring (12 Used) Sensor
13- Shaft 36- Socket Bolt (2 Used) 59- Pin (2 Used) 81- Pump 2 Delivery Pressure
14- Pin (2 Used) 37- Spring Washer (2 Used) 60- Lever (4 Used) Sensor
15- Center Shaft (2 Used) 38- Washer (2 Used) 61- Pin (4 Used) 84- O-Ring
16- Spring (2 Used) 39- Pilot Pump 62- Valve Plate 85- N Sensor
17- Plunger (14 Used) 40- Retaining Ring 63- Backup Ring 86- Washer
18- Rotor (2 Used) 41- Retaining Ring 64- O-Ring 87- Socket Bolt
19- Shaft 42- Ball Bearing (2 Used) 65- Spring Pin (2 Used) 88- Bracket
20- Thrust Ring 43- Gear 66- Selector Head 89- Spring Washer
21- O-Ring (2 Used) 44- Gear Shaft 67- O-Ring (4 Used) 90- Socket Bolt
22- Plug (2 Used) 45- Retaining Ring 68- Socket Bolt (16 Used) 91- Pin (4 Used)
23- O-Ring 46- Oil Seal 69- Stopper S (2 Used)
W3-8-2-9
Group 8 Pump Device
Assembly of Pump Device

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

facing to the engine side.
4. Install retaining ring (40) to gear casing (47). Install
retaining ring (41) to gear shaft (44).
5. Install O-ring (31) to plug (30). Install plug (30) to
gear casing (47).
j : 22 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-8-2-10
Group 8 Pump Device
11. Set the preload of bearings (10, 12) (2 used for 12. Set the preload of bearings (10, 12) with shaft (19)
each) with shafts (13, 19) attached according to the attached in the same way as step 11.
following procedures.
13. Install thrust ring (20) to the side to insert shaft (19)
 Apply hydraulic oil onto the thread part of bearing in pump casing (51).
nut (9). Tighten bearing nut (9) until it comes in
contact with bearing (10) by using the special tools
(ST 3058, ST 5000).
ST 3058, ST 5000
9
10
W178-02-11-090
 Install the special tool (ST 3070) to bearing (10). After

rotating 2 to 3 turns, measure the starting torque.
ST 3070
10
W178-02-11-091
 Adjust bearing nut (9) until the starting torque

reaches the specification.
m : 2±0.5 N·m (0.2±0.05 kgf·m, 1.5±0.4 lbf·ft)
fNOTE: If the starting torque is higher than the limit of

specified torque, loosen bearing nut (9). Tap the shaft
end and release the load of bearing (10).
W3-8-2-11
Group 8 Pump Device
14. Warm up pump casing (51) to 50 to 80 °C (122 to 19. Install the special tools (ST 2649, ST 2650) over the
176 °F). spline parts of shafts (13, 19).
dCAUTION: Take care as pump casing (51) is too fNOTE: If the special tools are not available, install a
hot. vinyl tape onto the spline part of the shaft in order not to
15. Apply hydraulic oil onto bearings (10, 12) (2 used for damage oil seal (49).
each) with shafts (13, 19) attached. Install shafts (13,
19) to pump casing (51) by using special tool (a).
If it is difficult to insert shafts (13, 19), tap them by
using a bar. ST 2650
a
49
51
19
ST 2649 W178-02-11-094
c 20. Apply grease onto the inside of oil seals (49) (2

c used). Evenly tap and install oil seals (49) (2 used) to
shafts (13, 19).
W178-02-11-093 21. Remove the special tools (ST 2649, ST 2650) from
shafts (13, 19).
a- Special Tool c- Wooden Block
b- M8, Pitch 1.25 mm 22. Install retaining rings (50) (2 used) to pump casing
(51).
16. Allow pump casing (51) to cool until its temperature
becomes lower than 40 °C (104 °F).
17. Install O-ring (23) to plug (24). Install plug (24) to
pump casing (51).
j : 19 mm
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

18. Attach nylon slings onto pump casing (51). Hoist
and place the pump casing (51) assembly with the
regulator mounting side up.
W3-8-2-12
Group 8 Pump Device
23. Fit the matching marks on shafts (13, 19) and 24. Install spring pins (48) (2 used) to gear casing (47).
gears (27, 29). Install retaining rings (26) (2 used) Install gasket (28).
to shafts (13, 19). When replacing the shaft and the
gear, install the gear according to the following dCAUTION: The pump casing (51) assembly
procedures.
25. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
 Secure the special tool (ST 7934) to the plunger (17)
the socket bolt (71) holes (2 places) of pump casing
mounting side of shafts (13, 19) with the socket bolt
(51). Hoist the pump casing (51) assembly. While
(M8, Pitch 1.25 mm).
engaging gear (43) with gear (29), install the pump
19 casing (51) assembly to gear casing (47) with bolts
(53) (6 used) and spring washers (52) (6 used).
ST 7934 13
j : 24 mm
m : 150 N·m (15 kgf·m, 111 lbf·ft)
a W178-02-11-097
a- M8, Pitch 1.25 mm
 Turn shafts (13, 19) clockwise, viewed from the gear

(27, 29) mounting side, until shafts (13, 19) come
in contact with the special tool. (Remove a play in
periphery direction.)
 Install gear (27) and retaining ring (26) to the spline
of shaft (13).
 Install gear (29) to the spline of shaft (19) and engage
it with gear (27). If gear (29) does not engage, adjust
shaft (19) within a play of the special tool by turning.
 Install retaining ring (26) to the spline of shaft (19).
 Remove the special tool (ST 7934).
W3-8-2-13
Group 8 Pump Device
26. Apply THREEBOND #1215 onto the mounting 30. Insert plungers (17) (7 used for each) into shafts (13,
surface of pilot pump (39). Install pilot pump (39) 19).
to gear casing (47) with socket bolts (36) (2 used),
31. Apply grease onto pins (14) (2 used). Install pins (14)
spring washers (37) (2 used), and washers (38) (2
(2 used) to center shafts (15) (2 used).
used).
32. Apply grease onto the spherical surface of center
l : 8 mm shafts (15) (2 used). Install center shafts (15) (2 used)
to shafts (13, 19).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
27. Install gasket (32) and pipe (34) to gear casing (47)
with socket bolts (33) (2 used).
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

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

lever (60) facing to the selector head (66) side. Fit parallel
surface (a) of pin (57) to the groove.
59 57
78 51
a a W178-02-11-098
a- Parallel Surface
29. Apply hydraulic oil onto the plunger (17) mounting

surface of shafts (13, 19).
W3-8-2-14
Group 8 Pump Device
33. Install springs (16) (2 used) to center shafts (15) (2 39. Install regulator (2) to pump casing (51) according
used). to the following procedures.
34. Insert center shafts (15) (2 used) and plungers (17)  Adjust sleeves (b) (2 used) in regulator (2) so that the
(14 used) into rotors (18) (2 used). grooves of pin (59) are in a line.
 Place regulator (2) onto pump casing (51). Insert
35. Insert a grip of a file into the center hole of center
pin (59) of link (79) into the grooves of sleeves (b) (2
shafts (15) (2 used). While turning center shafts (15)
used).
(2 used), insert pin (14) into the grooves of rotors
 Move regulator (2) while fitting to spring pin (54) in
(18) (2 used).
pump casing (51).
fNOTE: If pins (14) (2 used) do not enter the grooves  Install regulator (2) to pump casing (51) with socket
bolts (1) (4 used).
of rotors (18) (2 used), selector head (66) cannot be
installed to pump casing (51). l : 8 mm
IMPORTANT: Check the direction to install valve
m : 50 N·m (5 kgf·m, 37 lbf·ft)
plate (62).
36. Insert pins (61) (2 used) and pins (91) (2 used) of 59
valve plate (62) into the hole of levers (60) (2 used) b
at the regulator (2) side. Install retaining rings (58) (4 2
used).
77 62
a
51
W178-02-11-101
78 54
b- Sleeve
W178-02-11-100
40. Install regulator (6) to pump casing (51) with socket
a- Upward bolts (3, 5) (2 used for each) in the same way as step
39.
l : 8 mm
IMPORTANT: Check the direction to install valve
plate (77). m : 50 N·m (5 kgf·m, 37 lbf·ft)
37. Insert pins (61) (2 used) and pins (91) (2 used) of 41. Install backup ring (63), O-rings (64), and O-rings (8)
valve plate (77) into the hole of levers (60) (2 used) (6 used) to pump casing (51).
at the regulator (6) side. Install retaining rings (58) (4
42. Insert servo piston (73) (2 used) into selector head
used).
(66).
38. Install O-rings (56) (2 used), O-rings (55) (10 used),
O-rings (7) (4 used), and spring pins (54) (4 used) to
pump casing (51).
W3-8-2-15
Group 8 Pump Device
43. Apply LOCTITE LI829 onto set screw (72). Install pins 47. Install O-rings (67) (4 used) to selector head (66).
(74) (2 used) to servo pistons (73) (2 used) with set
48. Install O-rings (70) (2 used) to stoppers S (69) (2
screws (72) (2 used).
used). Install stoppers S (69) (2 used) to selector
l : 6 mm head (66) with socket bolts (68) (8 used).
m : 35 N·m (3.5 kgf·m, 26 lbf·ft) l : 6 mm
44. Install spring pins (65) (2 used) to selector head (66). m : 20 N·m (2 kgf·m, 15 lbf·ft)
dCAUTION: The selector head (66) assembly

49. Install O-rings (75) (2 used) to stoppers L (76) (2
used). Install stoppers L (76) (2 used) to selector
head (66) with socket bolts (68) (8 used).
screw holes (a) (2 places) of selector head (66). Hoist l : 6 mm
the selector head (66) assembly. Place selector head
(66) onto pump casing (51) while fitting to spring m : 20 N·m (2 kgf·m, 15 lbf·ft)
pin (65).
dCAUTION: Pump device weight: 160 kg (355 lb)
f NOTE: Check the clearance between selector head 50. Hoist and place the selector head (66) assembly
(66) and pump casing (51) in order to compare with the with the regulator mounting side up.
clearance before disassembling. When the clearance is
larger, pins (14) (2 used) may not be inserted into the
grooves of rotors (18) (2 used), or pins (74) (2 used) may
not be inserted into the holes of valve plates (62, 77).
66
WDBE-03-08-006
a- Screw Hole
46. Install selector head (66) to pump casing (51) with

socket bolts (71) (12 used).
l : 10 mm
m : 110 N·m (11 kgf·m, 81 lbf·ft)
W3-8-2-16
Group 8 Pump Device
51. Insert the special tool (ST 2650) into shaft (19). 54. Install a seal tape onto plug (25). Install plug (25) to
Apply grease onto oil seal (46). Install oil seal (46) to gear casing (47).
shaft (19). Remove the special tool (ST 2650). Install
oil seal (46). j : 17 mm
m : 40 N·m (4 kgf·m, 30 lbf·ft)

fNOTE: If the special tool (ST 2650) is not available,
install a vinyl tape onto the spline part of shaft (19) in 55. Install bracket (88), O-ring (84), and N sensor (85) to
order to protect. Install oil seal (46). pump casing (51) with spring washer (89), washer
(86), and socket bolts (90, 87).
ST 2650
j : 5 mm
46 m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

56. Install pump 2 delivery pressure sensor (81) and
pump 1 delivery pressure sensor (80) to selector
head (66).
j : 27 mm
m : 100 N·m (10 kgf·m, 74 lbf·ft)

W178-02-11-103
57. Connect the both ends of pipe (79) to regulators (2,
52. Install retaining ring (45) to gear casing (47). 6).
53. Install a seal tape onto elbow (83). Install elbow j : 17 mm

(83) to gear casing (47). Add engine oil (NISSEKI
MITSUBISHI DIESEL DH-1 15W-40 or DH-2 15W-40 or m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
equivalent) through the elbow (83) hole. 58. Insert level gauge (35) into pipe (34).
fNOTE: Amount of oil: 1 L (1.06 US qt)
W3-8-2-17
Group 8 Pump Device
(Blank)
W3-8-2-18
Group 8 Pump Device
Disassembly of Regulator
Pump 1 Regulator Pump 2 Regulator
1 2 3
6 7 8 9 10 11 12 13 14 15
5
4 16
17
18
19
33
32 W176-02-04-001
31 30 29 28 27 26 25 24 23 22 21 20
1- Pipe 10- Spool 19- Lock Nut 28- Cylinder

2- Socket Bolt (2 Used) 11- Sleeve 20- Socket Bolt (4 Used) 29- O-Ring
3- Solenoid Valve 12- Piston 21- Stopper Assembly 30- Backup Ring
4- Lock Nut 13- Cylinder 22- O-Ring 31- O-Ring
5- Lock Nut 14- O-Ring 23- Spring 32- Socket Bolt (4 Used)
6- Stopper Assembly 15- Cover 24- Spring 33- Cover
7- O-Ring 16- Set Bolt 25- Sleeve
8- Spring 17- Lock Nut 26- Spool
9- Casing 18- Lock Nut 27- Piston
W3-8-3-1
Group 8 Pump Device
Disassembly of Regulator
6. Remove O-ring (7) from stopper assembly (6).
 The regulators are used for pump 1 and pump 2. The
inner structure in the regulator is fully identical, and 7. Remove springs (23, 24) from casing (9).
the difference is only in its accessories. The regulator
8. Insert a round bar into the hole of casing (9). Push
for pump 2 is explained here.
the spool (26) end. Remove cylinder (28), sleeve
(25), and spool (26) from casing (9). At this time,
IMPORTANT: As the setting changes, do not
piston (27) is removed with cylinder (28) together.
disassemble regulator adjusting screw parts (4, 5,
16, 17, 18, 19). When it should be disassembled, 9. Remove piston (27), O-rings (29, 31), and backup
adjust according to the procedures of ring (30) from cylinder (28).
performance test after assembling.
10. Remove spring (8) from casing (9).
1. Disconnect pipe (1) from casing (9). 11. Insert a round bar into the hole of casing (9). Push
the spool (10) end. Remove cylinder (13), sleeve
j : 17 mm (11), and spool (10) from casing (9). At this time,
piston (12) is removed with cylinder (13) together.
2. Remove socket bolts (2) (2 used). Remove solenoid
valve (3) from casing (9). 12. Remove piston (12) and O-ring (14) from cylinder
(13).
l : 8 mm
IMPORTANT: Do not turn set bolt (16) and lock nuts

(17, 18, 19). If turning, the setting changes.
3. Remove socket bolts (20) (4 used) from cover (15).
Remove the cover (15) assembly from casing (9). At
this time, set bolt (16) and stopper assembly (21) are
removed with the cover (15) assembly together.
l : 6 mm
4. Remove O-ring (22) from stopper assembly (21).
IMPORTANT: Do not turn lock nuts (4, 5). If turning,

the setting changes.
5. Remove socket bolts (32) (4 used) from cover (33).
Remove the cover (33) assembly from casing (9). At
this time, stopper assembly (6) is removed with the
cover (33) assembly together.
l : 6 mm
W3-8-3-2
Group 8 Pump Device
Assembly of Regulator
Pump 1 Regulator Pump 2 Regulator
1 2 3
6 7 8 9 10 11 12 13 14 15
5
4 16
17
18
19
33
32 W176-02-04-001
31 30 29 28 27 26 25 24 23 22 21 20
1- Pipe 10- Spool 19- Lock Nut 28- Cylinder

2- Socket Bolt (2 Used) 11- Sleeve 20- Socket Bolt (4 Used) 29- O-Ring
3- Solenoid Valve 12- Piston 21- Stopper Assembly 30- Backup Ring
4- Lock Nut 13- Cylinder 22- O-Ring 31- O-Ring
5- Lock Nut 14- O-Ring 23- Spring 32- Socket Bolt (4 Used)
6- Stopper Assembly 15- Cover 24- Spring 33- Cover
7- O-Ring 16- Set Bolt 25- Sleeve
8- Spring 17- Lock Nut 26- Spool
9- Casing 18- Lock Nut 27- Piston
W3-8-3-3
Group 8 Pump Device
Assembly of Regulator
7. Install O-ring (7) and spring (8) to stopper assembly
IMPORTANT: The sleeve (11, 25) holes of casing (9)
(6) with cover (33) attached. Install the cover (33)
are the same bores. The shapes of various parts
assembly to casing (9) with socket bolts (32) (4
are very similar. Assemble it while checking the
used).
illustration in order not to confuse.
IMPORTANT: Before assembling, apply hydraulic oil l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
IMPORTANT: Check the direction to install sleeve
(11), spool (10), and piston (12). 8. Install O-ring (22) and springs (23, 24) to stopper
assembly (21) with cover (15) attached. Install the
1. Insert spool (10) into sleeve (11). Install sleeve (11) cover (15) assembly to casing (9) with socket bolts
to the center of casing (9) by using a round bar. (20) (4 used).
2. Install O-ring (14) to cylinder (13). l : 6 mm

3. Insert piston (12) into cylinder (13). Install cylinder m : 20 N·m (2 kgf·m, 15 lbf·ft)
(13) to casing (9).
9. Install solenoid valve (3) to casing (9) with socket
bolts (2) (2 used).
IMPORTANT: Check the direction to install sleeve
(25) and spool (26). l : 8 mm
4. Insert spool (26) into sleeve (25). Install sleeve (25) m : 50 N·m (5 kgf·m, 37 lbf·ft)
to the center of casing (9) by using a round bar.
10. Apply grease onto the thread part of pipe (1).
5. Install O-rings (29, 31) and backup ring (30) to Connect pipe (1) to casing (9).
cylinder (28).
6. Insert piston (27) into cylinder (28). Install cylinder j : 17 mm
(28) to casing (9). m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
W3-8-3-4
Group 8 Pump Device
Disassembly of Solenoid Valve
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
W178-02-04-050
1- Socket Bolt 7- Spring 13- Orifice 19- O-Ring

2- Solenoid 8- O-Ring 14- Plate 20- Filter
3- Spring 9- O-Ring 15- Wave Washer 21- O-Ring
4- O-Ring 10- O-Ring 16- Filter
5- Diaphragm 11- Sleeve 17- Body
6- Retaining Ring 12- Spool 18- O-Ring
W3-8-4-1
Group 8 Pump Device
Disassembly of Solenoid Valve

4. Remove filters (16) (2 used), filter (20), and O-rings
 Take care not to damage the mounting surface for
(18, 19, 21) from body (17).
the regulator.
 When replacing the parts, replace them as an l : 6 mm
assembly.
 Take care not to hit the solenoid part. fNOTE: When cleaning filter (10), blow it from the both
 When disconnecting the connector, do not pry it, but surfaces by using air. Finally blow it from the outside
disconnect it straight. (screw side) by using air.
5. Disassemble another solenoid (2) in the same way
1. Remove socket bolts (1) (2 used). Remove solenoid as step 1 to step 4.
(2) and O-ring (4).
l : 4 mm
IMPORTANT: Do not drop plate (14) and wave

washer (15).
2. Remove plate (14) and wave washer (15) from body
(14).
ST2953
W178-02-04-052
3. Remove O-rings (8, 9, 10) from sleeve (3).
W3-8-4-2
Group 8 Pump Device
Assembly of Solenoid Valve
2 1 5 6 7 11 12 13 14 15 17 16
21 20
3 4 8 9 10
19
18
W178-02-04-051
1- Socket Bolt 7- Spring 13- Orifice 19- O-Ring

2- Solenoid 8- O-Ring 14- Plate 20- Filter
3- Spring 9- O-Ring 15- Wave Washer 21- O-Ring
4- O-Ring 10- O-Ring 16- Filter
5- Diaphragm 11- Sleeve 17- Body
6- Retaining Ring 12- Spool 18- O-Ring
W3-8-4-3
Group 8 Pump Device
Assembly of Solenoid Valve 5. Install O-ring (4) to body (17).

1. Install O-rings (18, 19, 21), filters (16) (2 used), and 6. Install solenoid (2) to body (17) with socket bolts (1)
filter (20) to body (17). (2 used).
l : 6 mm l : 4 mm
m : 10+3 N·m (1+0.3 kgf·m, 7.4+2.2 lbf·ft) m : 5+2 N·m (0.5+0.2 kgf·m, 3.7+1.5 lbf·ft)
2. Install wave washer (15) and plate (14) to body (17). 7. Assemble another solenoid (2) in the same way as
step 1 to step 6.
fNOTE: When assembling body (17) in a horizontal
position, apply grease onto wave washer (15) and plate
(14) in order not to fall off. After assembling, check that
plate (14) is installed straight.
3. Install O-rings (8, 9, 10) to sleeve (11).

IMPORTANT: When installing sleeve (11), keep the
sleeve end and body (17) end in the same position.
In addition, when installing the sleeve, be sure not
to pry and cause damage to O-ring.
4. Using special tool (ST 2953), install sleeve (11)
assembly to body (17).
fNOTE: When there is no special tool (ST 2953) available,

tighten solenoid (2) alternately with socket bolts (1) (2
used). Then sleeve (11) end and body (17) end should be
placed in the same position. Install the solenoid.
ST2953
W178-02-04-052
W3-8-4-4
Group 8 Pump Device
Structure of Pilot Pump

6
14
15
1
15
2 10
3
4
6
3
2
8
9
13
12
11 W137-02-04-034
10
W3-8-5-1
Group 8 Pump Device
IMPORTANT: The housing is made of aluminum. Take

care not to damage the housing. Take extreme
care in order to control the tightening torque.
No. Part Name Q’ty Wrench Size Tightening Torque Remark
(mm) N·m (kgf·m) (lbf·ft)
1 Housing 1
2 Backup Ring 2 Apply grease when
installing
3 Seal 2 Apply grease when
installing
4 Bushing 2 Apply hydraulic oil when
installing
5 Gear 1
6 Bushing 2 Apply hydraulic oil when
installing
7 Flange 1
8 Oil Seal 1 Apply grease onto the lip
part when installing
9 Retaining Ring 1
10 O-Ring 2 Apply grease when
installing
11 Cover 1
12 Washer 4
13 Bolt 4 j : 17 35+5 3.5+0.5 2.6+3.7
14 Gear 1
15 Key 2
W3-8-5-2
Removal and Installation Control Valve
1 4
5
3
6 7
WDC390-03-09-004 WDC390-03-09-005
IMPORTANT: The hose and pipe contain hydraulic 3. Remove bolts, washers (2) (2 used). Remove cover
oil. When removing the hose and pipe, receive oils (3).
j : 17 mm
and pipes have been disconnected. In addition, 4. Remove bolts, washers (4) (4 used). Remove cover
attach an identification tag onto the connectors, (5).
secure the hoses have been removed. 5. Open door (6, 7).
Removal

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

circuit. (Refer to W1-5-1.)
2. Open engine cover (1).
W3-9-1-1
9 10 11
8, 77 11
WDCD-03-09-012 WDCD-03-09-002
6. Remove bolts, washers (8) and clamps (77).
j : 17 mm
7. Remove 3-spool solenoid valve unit (9). (Refer to
W3-12-2.)
8. Disconnect the connectors and hoses connected to
signal control valve (10). (Refer to W3-13-1.)
9. Disconnect connectors (11) (2 used).
W3-9-1-2
16
18
24, 25 19 24, 25 20
WDC390-03-09-006 WDC390-03-09-007
10. Disconnect hoses (12) (2 used). 15. Place a container under the disconnecting part of
pipe (19). Remove coupling (20). Disconnect the oil
j : 27 mm cooler side of pipe (19).
j : 13 mm
j : 19 mm 16. Remove socket bolts (21) (2 used). Disconnect the
12. Remove bolts, washers (14) and clamps (15) (2 control valve (22) side of pipe (19). Remove O-ring
used). (23).
j : 19 mm l : 8 mm
13. Remove bolts, washers (24) (2 used) and clamps (25)
(2 used).
j : 19 mm
14. Place a container under the disconnecting part of
pipe (16). Remove couplings (17, 18). Disconnect
the both ends of pipe (16).
j : 13 mm
W3-9-1-3
a- Eyebolt Mounting Hole

WDC390-03-09-008 WDC390-03-09-009
17. Disconnect all hoses and pipes. 20. Remove bolts (6) (3 used), spring washers (9) (3
used) and washers (7) (3 used). Remove the signal
j : 17 mm, 19 mm, 36 mm control valve (8) assembly.
l : 8 mm j : 22 mm
dCAUTION: The control valve (22) assembly

eyebolt mounting holes (a) (2 places) of control
valve (5). Attach nylon slings onto the eyebolts.
Hoist and hold the control valve (5) assembly.
19. Remove bolts (1) (2 used), bolts (3) (2 used), washers
(2) (2 used), and washers (4) (2 used). Place the
control valve (5) assembly on a workbench.
j : 24 mm
W3-9-1-4
1, 2
1, 2
5
WDC390-03-09-010
dCAUTION:
lb)
Control valve (3) weight: 190 kg (420

eyebolt mounting holes (2 places) of control valve
(3). Attach nylon slings onto the eyebolts. Hoist and
hold control valve (3).
used). Remove control valve (3) from brackets (4, 5).
j : 24 mm
23. Remove the adapter with control valve (3) attached
if necessary.
W3-9-1-5
1, 2
1, 2
5
WDC390-03-09-010
Installation
1. Install all removed adapters to control valve (3).
dCAUTION:
lb)
Control valve (3) weight: 190 kg (420

eyebolt mounting holes (2 places) of control valve
(3). Attach nylon slings onto the eyebolts. Hoist and
hold control valve (3).
3. Install control valve (3) to brackets (4, 5) with
washers (2) (4 used) and bolts (1) (4 used).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
W3-9-1-6
a- Eyebolt Mounting Hole

WDC390-03-09-009 WDC390-03-09-008
4. Install the signal control valve (8) assembly with 7. Connect all hoses and pipes.
washers (7) (3 used), spring washers (9) (3 used) and
bolts (6) (3 used). j : 17 mm
j : 22 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
m : 140 N·m (14 kgf·m, 103 lbf·ft) j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

dCAUTION: The control valve (3) assembly weight:
210 kg (465 lb)
j : 36 mm
eyebolt mounting holes (a) (2 places) of control m : 180 N·m (18 kgf·m, 133 lbf·ft)
valve (3). Attach nylon slings onto the eyebolts.
Hoist the control valve (3) assembly. l : 8 mm
6. Install the control valve (3) assembly with washers m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
(2) (2 used), washers (4) (2 used), bolts (1) (2 used),
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
W3-9-1-7
16
18
24, 25 19 24, 25 20
WDC390-03-09-006 WDC390-03-09-007
8. Install O-ring (23). Connect the control valve (22) 12. Install clamp (15) (2 used) with bolts, washers (14).
side of pipe (19) with socket bolts (21) (2 used).
j : 19 mm
l : 8 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
9. Connect the oil cooler side of pipe (19) with
coupling (20). j : 19 mm
j : 13 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft)
10. Connect pipe (16) with couplings (18, 17). j : 27 mm
j : 13 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)
m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft)

11. Install clamp (25) (2 used) with bolts, washers (24) (2
used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-9-1-8
9 10 11
8, 77 11
WDCD-03-09-012 WDCD-03-09-002
15. Connect connectors (11) (2 used).

16. Connect all removed connectors and hoses to signal
control valve (10). (Refer to W3-13-1.)
17. Install 3-spool solenoid valve unit (9). (Refer to W3-
12-2.)
18. Install clamps (77) with bolts, washers (8).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-9-1-9
1 4
5
3
6 7
WDC390-03-09-004 WDC390-03-09-005

1.)
20. Shut door (6, 7).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

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

23. Shut engine cover (1).
W3-9-1-10
Disassembly of Housing
4
5 4 5
4 4
4 4
4
2
4
4
5
4
5
4
4
WDC390-03-09-001
1- Housing (5-Spool Side) 3- Socket Bolt (8 Used) 5- O-Ring (10 Used)

2- Housing (4-Spool Side) 4- O-Ring (16 Used)
W3-9-2-1
Disassembly of Housing
dCAUTION:
kg (170 lb)
The housing (1) assembly weight: 76
The housing (2) assembly weight: 79 kg (175 lb)
1. Remove socket bolts (3) (8 used).
l : 14 mm
2. Remove housing (2) from housing (1).
3. Remove O-rings (4) (16 used) and O-rings (5) (10
used) from housing (1) or housing (2).
W3-9-2-2
Assembly of Housing
4
5 4 5
4 4
4 4
4
2
4
4
5
4
5
4
4
WDC390-03-09-001
1- Housing (5-Spool Side) 3- Socket Bolt (8 Used) 5- O-Ring (10 Used)

2- Housing (4-Spool Side) 4- O-Ring (16 Used)
W3-9-2-3
Assembly of Housing

1. Install O-rings (4) (16 used) and O-rings (5) (10 used)
to the mounting surface of housing (2).
dCAUTION:
kg (170 lb)
The housing (2) assembly weight: 79 kg (175 lb)

2. Install housing (1) to housing (2) with socket bolts
(3) (9 used).
l : 14 mm
m : 210 to 220 N·m(21 to 22 kgf·m, 155 to 162

lbf·ft)
W3-9-2-4
Disassembly of Control Valve (4-Spool Side)
8
10
3 4
5 11
2
39 6
7
13
12 14
1 15
40
16
17
18
19
20
55 21
22
19
52 23
29 24
53 35 25
52 30
43 36 26
51 37 31 27
43 3 28
5 38 32
6
5 43
5 33
49 41
48 5
7
WDC390-03-09-002
W3-9-3-1
56
56 56 56
57
57 57 88
89
58
58 58
90
57
57 57
64 64
91
65 65
59 66 66
89
88
60 61
62
70 70
71 71
66 66
65 65
64 64
WDC390-03-09-003
W3-9-3-2
102
103
104
105
106
107 108
100
99
98 122
97 109 121 128
96 120
95 110
119 100
94 118
117 126
116
125
101
101
101
100
112
111
122
144
123 143
124
1
122
128
100
126
125
122
138
137
136
135
142
141
140
W178-02-05-011
W3-9-3-3
283
293
285
286
296
38 34
37
36
297
283 298
284
285
286
287
289
288
W178-02-11-114
W3-9-3-4
1- Housing 30- Spacer 70- Poppet (2 used) 120- Nut

2- Overload Relief Valve 31- Backup Ring 71- Spring (2 used) 121- Nut
3- O-Ring (8 used) 32- O-Ring 88- Spring Seat (2 used) 122- Socket Bolt (14 used)
4- Cap 33- Spool 89- Spring Seat (2 used) 123- O-Ring
5- Socket Bolt (14 used) 34- Poppet 90- Spring 124- Plug
6- O-Ring (2 used) 35- Poppet 91- Spring 125- Poppet (2 used)
7- Overload Relief Valve (3 used) 36- Spring (2 used) 94- Poppet 126- Spring (2 used)
8- Spool Assembly (Travel Right) 37- O-Ring (2 used) 95- Poppet 128- Flange (2 used)
9- Spool Assembly (Bucket) 38- Plug (2 used) 96- Spring 135- Spool
10- Spool Assembly (Boom 1) 39- O-Ring 97- Plug 136- Spring
11- Spool Assembly (Arm 2) 40- O-Ring 98- Spring 137- O-Ring
12- Socket Bolt (4 used) 41- Cap 99- Spacer 138- Flange
13- Plug 43- Cap (3 used) 100- O-Ring (4 used) 140- O-Ring
14- O-Ring 48- Socket Bolt (2 used) 101- O-Ring (5 used) 141- Flange
15- Piston 49- Cap 102- Plug 142- Socket Bolt (4 used)
16- Spring 51- Bolt 103- O-Ring 143- O-Ring
17- Body 52- Spring Seat (2 used) 104- Spring Seat 144- Plug
18- O-Ring 53- Spring 105- Spring 283- Socket Bolt (4 used)
19- O-Ring (3 used) 55- Spool 106- Spool 284- Flange
20- Sleeve 56- Bolt (4 used) 107- Body 285- O-Ring (2 used)
21- Backup Ring 57- Spring Seat (6 used) 108- Socket Bolt (4 used) 286- Spring (2 used)
22- O-Ring 58- Spring (3 used) 109- O-Ring 287- Popper
23- O-Ring 59- Spool 110- Plug 288- Plug
24- Backup Ring 60- Spool 111- Poppet 289- O-Ring
25- Spool 61- Spool 112- Spring 291- Poppet
26- Poppet 62- Spool 116- Body 293- Flange
27- Spring Seat 64- Plug (4 used) 117- O-Ring 296- Poppet
28- Spring 65- Backup Ring (4 used) 118- Screw 297- Plug
29- Spring 66- O-Ring (4 used) 119- O-Ring 298- O-Ring
W3-9-3-5
 Disassembly of Spool  Disassembly of Overload Relief Valve (2, 7)

1. Remove socket bolts (5) (6 used). Remove cap (4), IMPORTANT: Do not disassemble the overload
O-rings (3) (4 used), and O-rings (6) from housing relief valve. If the overload relief valve has been
(1). disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING/Operational Performance
l : 8 mm Test in the separated volume, T/M.)
IMPORTANT: Do not disassemble the spool (33) 7. Remove overload relief valves (2), overload relief
assembly unless necessary. valve (7) (3 used), O-ring (39) and O-ring (40) from
2. Put the matching marks on the spool (8, 9, 10, 11, housing (1).
33) assemblies and housing (1). Remove the spool
j : 32 mm
(8, 9, 10, 11, 33) assemblies and spring (29) from
housing (1).
 Disassembly of Check Valve
8. Remove plug (38) (2 used), O-ring (37), spring (36) (2
 Disassembly of Boom Anti-Drift Valve (Selector Valve)
used), and poppet (34, 35) from housing (1).
3. Remove plug (13) and O-ring (14) from body (17).
l : 10 mm
j : 38 mm
9. Remove socket bolts (6) (2 used). Remove flange
4. Remove socket bolts (12) (4 used). Remove the body
(284), O-ring (285), spring (286), and poppet (287)
(17) assembly, O-rings (19) (3 used), and O-ring (18)
from housing (1).
from housing (1).
l : 8 mm
l : 8 mm
10. Remove socket bolts (283) (2 used).
5. Remove piston (15) and spring (16) from body (17).
Remove flange (293), O-ring (285), spring (286), and
6. Remove the sleeve (20) assembly, spring seat (27),
poppet (296) from housing (1).
and spring (28) from housing (1). Remove backup
rings (21, 24), O-rings (22, 23), poppet (26), and l : 8 mm
spool (25) from sleeve (20).
11. Remove plugs (297) and O-rings (298) from housing
(1).
l : 10 mm
12. Remove plugs (288) and O-rings (289) from housing
(1).
l : 6 mm
W3-9-3-6
 Disassembly of Travel (Right) Spool (59)  Disassembly of Boom 1 Spool (61)

13. Secure spool (59) in a vise by using wooden pieces. 17. Secure spool (61) in a vise by using wooden pieces.
Remove bolt (56), spring seats (57) (2 used), and Remove bolt (56), spring seats (57) (2 used), and
spring (58) from spool (59). spring (58) from spool (61).
l : 8 mm l : 8 mm
18. Warm the plug (64) part of spool (61) by using a
 Disassembly of Bucket Spool (60) drier. Remove plug (64) by using the special tool
14. Secure spool (60) in a vise by using wooden pieces. (ST 5909). Remove O-ring (66) and backup ring (65)
Remove bolt (56), spring seats (57) (2 used), and from plug (64).
spring (58) from spool (60).
19. Remove spring (71) and poppet (70) from spool (61).
l : 8 mm
15. Warm the plug (64) part of spool (60) by using a  Disassembly of Arm 2 Spool (62)
drier. Remove plug (64) by using the special tool 20. Secure spool (62) in a vise by using wooden pieces.
(ST 5909). Remove O-ring (66) and backup ring (65) Remove bolt (56), spring seats (88, 89) (2 used for
from plug (64). each), and springs (90, 91) from spool (62).
ST 5909 l : 8 mm
 Disassembly of Arm Regenerative Valve

21. Secure spool (33) in a vise by using wooden pieces.
Remove spool (30) from spool (33). Remove backup
W157-02-05-049
ring (31) and O-ring (32) from spool (30).
16. Remove spring (71) and poppet (70) from spool (60).
W3-9-3-7
22. Remove socket bolts (5) (8 used). Remove caps (43)  Disassembly of Load Check Valve
(3 used), cap (41), and O-rings (3) (4 used) from 27. Remove socket bolt (129). Remove flange (128) (2
housing (1). used), O-ring (100) (2 used), spring (126) (2 used)
and poppet (125) (2 used) from housing (1).
l : 8 mm
l : 8 mm
 Disassembly of Flow Combiner Valve
23. Remove socket bolts (48) (2 used). Remove cap
(49), O-ring (6), and the spool (55) assembly from
housing (1). Remove bolt (51), spring seats (52) (2
used), and spring (53) from spool (55).
l : 5 mm
 Disassembly of Bucket Flow Rate Control Valve

24. Remove socket bolts (108) (4 used). Remove the
body (107) assembly and O-rings (100, 101) from
housing (1).
l : 8 mm
25. Remove plug (102), O-ring (103), spring seat (104),
spring (105), and spool (106) from body (107).
Remove plug (110) and O-ring (109) from body
(107).
j : 27 mm
26. Remove sleeve (99), springs (96, 98), plug (97), and
poppets (95, 94) from housing (1).
W3-9-3-8
 Disassembly of Boom Anti-Drift Valve (Check Valve)

28. Remove socket bolts (122) (4 used). Remove body
(116), O-rings (101) (4 used), and O-rings (100) from
housing (1).
l : 8 mm
29. Remove plugs (124) and O-rings (123) from body
(116).
IMPORTANT: Do not disassemble the nut (120, 121)
and plag (118) unless necessary.
30. Remove spring (112) and poppet (111) from
housing (1).
 Disassembly of Bypass Shut-Out Valve

(138) and O-ring (137) from housing (1).
l : 8 mm
32. Remove spring (136) and spool (135) from housing
(1).
(141) and O-ring (140) from housing (1).
l : 8 mm
W3-9-3-9
Assembly of Control Valve (4-Spool Side)
3, 4, 5 13
12
7, 40 2, 39
138
122
283
142
141
293, 285, 286, 296
297, 298
122
283
128
38, 37, 36, 34 284, 285, 286, 287

TDC390-03-03-003
288, 289
3, 41
3, 43 7 TDC390-03-03-004
W3-9-3-10
56 56 56 56
88 57 57 57
89
91 58 58 58
90
89
88 57 57 57
64 64
65 65
66 66
62 61 60 59
70 70
71 71
66 66
65 65
64 64
W178-02-05-023
6 3 62 3 61 3 60 3 59
29
30
33
31, 32
T178-03-03-018 W178-02-11-121
W3-9-3-11
101
101
120
121
B 118
A
C 119
122 117
116
122 123
124
111 112 100 W178-02-05-022
D
135 136 137 138
A Section
108
1
W178-02-11-115
B Section C Section
W178-02-11-117
125
126
D Section
100 99 98 97 96 95 94
102
128
122
103
128 100 105
122 126 104

125 106
109
W178-02-11-116
110 107 101 100

T178-03-03-013
W3-9-3-12
12
E Section
E
G
55
52
53
6
52
1 48
49 51
W178-02-11-118 W178-02-11-119
G Section
13
14
17
15
25
16
20
18 26
19
21
22
23
24
27
28
W178-02-05-021
W3-9-3-13
1- Housing 30- Spacer 70- Poppet (2 used) 120- Nut

2- Overload Relief Valve 31- Backup Ring 71- Spring (2 used) 121- Nut
3- O-Ring (8 used) 32- O-Ring 88- Spring Seat (2 used) 122- Socket Bolt (14 used)
4- Cap 33- Spool 89- Spring Seat (2 used) 123- O-Ring
5- Socket Bolt (14 used) 34- Poppet 90- Spring 124- Plug
6- O-Ring (2 used) 35- Poppet 91- Spring 125- Poppet (2 used)
7- Overload Relief Valve (3 used) 36- Spring (2 used) 94- Poppet 126- Spring (2 used)
8- Spool Assembly (Travel Right) 37- O-Ring (2 used) 95- Poppet 128- Flange (2 used)
9- Spool Assembly (Bucket) 38- Plug (2 used) 96- Spring 135- Spool
10- Spool Assembly (Boom 1) 39- O-Ring 97- Plug 136- Spring
11- Spool Assembly (Arm 2) 40- O-Ring 98- Spring 137- O-Ring
12- Socket Bolt (4 used) 41- Cap 99- Spacer 138- Flange
13- Plug 43- Cap (3 used) 100- O-Ring (4 used) 140- O-Ring
14- O-Ring 48- Socket Bolt (2 used) 101- O-Ring (5 used) 141- Flange
15- Piston 49- Cap 102- Plug 142- Socket Bolt (4 used)
16- Spring 51- Bolt 103- O-Ring 143- O-Ring
17- Body 52- Spring Seat (2 used) 104- Spring Seat 144- Plug
18- O-Ring 53- Spring 105- Spring 283- Socket Bolt (4 used)
19- O-Ring (3 used) 55- Spool 106- Spool 284- Flange
20- Sleeve 56- Bolt (4 used) 107- Body 285- O-Ring (2 used)
21- Backup Ring 57- Spring Seat (6 used) 108- Socket Bolt (4 used) 286- Spring (2 used)
22- O-Ring 58- Spring (3 used) 109- O-Ring 287- Popper
23- O-Ring 59- Spool 110- Plug 288- Plug
24- Backup Ring 60- Spool 111- Poppet 289- O-Ring
25- Spool 61- Spool 112- Spring 291- Poppet
26- Poppet 62- Spool 116- Body 293- Flange
27- Spring Seat 64- Plug (4 used) 117- O-Ring 296- Poppet
28- Spring 65- Backup Ring (4 used) 118- Screw 297- Plug
29- Spring 66- O-Ring (4 used) 119- O-Ring 298- O-Ring
W3-9-3-14
Assembly of Control Valve (4-Spool Side)  Assembly of Boom 1 Spool (61)

Install poppet (49) and spring (45) to the bottom of
spool (50).
 Assembly of Travel (Right) Spool (59) 9. Install O-ring (44) and backup ring (43) to plug (48).
1. Secure spool (59) in a vise by using wooden pieces. Apply LOCTITE #271 onto the thread part of plug
Install spring seats (57) (2 used), spring (58), and (48).
bolt (56) to spool (59). 10. Install plug (48) to spool (50) by using the special
tool (ST 5909).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
11. Tum over spool (61), then damp it in a vise. Install
O-ring (66) and backup ring (65) to plug (64). Apply
 Assembly of Bucket Spool (60)
LOCTITE #271 onto the thread part of plug (64).
Install poppet (70) and spring (71) to the bottom of 12. Install plug (64) to spool (61) by using the special
spool (60). tool (ST 5909).
3. Install O-ring (66) and backup ring (65) to plug (64). m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
Apply LOCTITE #271 onto the thread part of plug
(64). 13. Install spring seats (38) (2 used), spring (39), and
bolt (41) to the top of spool (50).
4. Install plug (64) to spool (60) by using the special
tool (ST 5909). l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft) m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
ST 5909
 Assembly of Arm 2 Spool (62)
Install spring seats (88, 89) (2 used for each), springs
(90, 91), and bolt (56) to spool (62).
W157-02-05-049 l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

5. Tum over spool (60), then clamp it in a vise. Install
O-ring (66) and backup ring (65) plug (64). Apply 15. Install O-rings (3) (4 used) to housing (1). Install caps
LOCTITE #271 onto the thread part of plug (64). (43) (3 used) and cap (41) to housing (1) with socket
bolts (5) (8 used).
6. Install plug (64) to spool (60) by using the special
tool (ST 5909).
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

7. Install spring seats (57) (2 used), spring (58), and
bolt (56) to the top of spool (60).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
W3-9-3-15
 Assembly of Arm Regenerative Valve

Install O-ring (32) and backup ring (31) to spool (30).
Install spool (30) to spool (33). Install the spool (33)
assembly and spring (29) to housing (1).
 Assembly of Spool
17. Install the spool (59, 60, 61, 62) assemblies, O-rings
(3) (4 used), and O-ring (6) to housing (1). Install cap
(4) to housing (1) with socket bolts (5) (6 used).
l : 8 mm
m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft)
W3-9-3-16
 Assembly of Bucket Flow Rate Control Valve  Assembly of Bypass Shut-Out Valve
18. Install O-rings (103, 109) to plugs (102, 110). 25. Install O-ring (143) to plug (144).
19. Install spring (105), spool (106), spring seat (104), 26. Install spool (105), spring (106), and O-ring (4) to
and plug (102) to body (107). housing (1). Install flange (107) to housing (1) with
j : 27 mm
l : 8 mm
20. Install plug (110) to body (107).
21. Install poppets (94, 95), springs (96, 98), plug (97), m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
and spacer (99) to housing (1). 27. Install plug (144) to flange (138).
22. Install O-rings (100, 101) to housing (1). Install body
(107) to housing (1) with socket bolts (108) (4 used).  Assembly of Overload Relief Valves (2, 7)
IMPORTANT: If the overload relief valve has been
l : 8 mm
disassembled, pressure should be adjusted.
m : 62 N·m (6.2 kgf·m, 46 lbf·ft) (Refer to TROUBLESHOOTING/Operational
Performance Test in the separated volume, T/M.)
 Assembly of Flow Combiner Valve 28. Install O-rings (39, 40) to overload relief valves (2, 7).
23. Install spring seats (52) (2 used) and spring (53) to Install overload relief valves (2, 7) to housing (1).
bolt (51). Install bolt (51) to spool (55).
j : 32 mm
24. Install spool (55) and O-ring (6) to housing (1).
Install cap (49) to housing (1) with socket bolts (48) m : 85 N·m (8.5 kgf·m, 63 lbf·ft)
(2 used).
l : 5 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-9-3-17
 Assembly of Check Valve  Assembly of Boom Anti-Drift Valve (Selector Valve)

29. Install O-rings (289) to plugs (288). Install plugs 37. Install backup rings (21, 24) and O-rings (22, 23) to
(288) to housing (1). sleeve (20).
l : 6 mm 38. Apply grease onto spring seat (27) and spring (28)
in order to prevent from falling off. Face the hole
30. Install O-rings (298) to plugs (297). Install plugs on spool (25) to the poppet (26) side. Install spool
(297) to housing (1). (25), poppet (26), spring seat (27), and spring (28)
to sleeve (20). Install the sleeve (20) assembly to
l : 10 mm
housing (1).
31. Install O-ring (37) to plug (38). Install poppet (34),
39. Install O-ring (14) to plug (13). Install spring (16),
spring (36), and plug (38) to housing (1).
piston (15), O-ring (18), and plug (13) to body (17).
l : 10 mm 40. Install O-rings (19) (3 used) to housing (1). Install the
32. Install poppets (287, 296), springs (286) (2 used), body (17) assembly with socket bolts (12) (4 used).
and O-rings (285) (2 used) to housing (1).
l : 8 mm
33. Install flanges (284, 293) to housing (1) with socket
bolts (283) (4 used). m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
41. Tighten plug (13).
l : 8 mm
j : 38 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
34. Install O-ring (140) to housing (1). Install flange
 Assembly of Boom Anti-Drift Valve (Check Valve)
42. Install O-rings (123) to plugs (124).
l : 8 mm 43. Install poppet (111), spring (112), O-rings (100), and
m : 62 N·m (6.2 kgf·m, 46 lbf·ft) O-rings (101) (4 used) to housing (1).
 Assembly of Load Cheak Valve 44. Install body (16) to housing (1) with socket bolts
35. Install poppet (125) (2 used), spring (126) (2 used), (122) (4 used).
and O-ring (100) (2 used) to housing (1). l : 8 mm
36. Install flange (128) (2 used) to housing (1) with
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
45. Tighten plugs (124).
l : 8 mm
m : 60 N·m (6 kgf·m, 44 lbf·ft)
W3-9-3-18
8
6
5
9
4
10
11
2
13
14
1 12
15
16
17
18
19
20
4 5 34 21
19
22
38 35 23
24
29
45 25
4 30 26
38
31 27
4
44 39 32 28
43 4 33
38
42 4 36
38
41 37
40
W178-02-05-012
W3-9-4-1
51 51 51 51 51
52 52 52 52 52
53 53 53 53 53
52 52 52 52 52
46 47 48 49 50
W178-02-05-015
W3-9-4-2
60
59
58
57
54
56
55
54
61
62 145
66
65
64
63
54
85
84
67 83
82
68 89
69 58
76
70
89
71 81
72 80 89
73 79
78
77 56
74
67 55
75
88 54
68
87
69 88
58 58
70 76 87
86 58
71
54 86
72 81
80 54
73
79
78
74 77
75
W178-02-05-010
W3-9-4-3
91 92 93 96
90
91 97
92 93
94
95
99
98
96
97
W178-02-11-114
W3-9-4-4
1- Housing 24- Backup Ring 47- Spool (Auxiliary) 70- Spring (2 used)
2- O-Ring 25- Spool 48- Spool (Boom 2) 71- Spool (2 used)
3- Main Relief Valve 26- Poppet 49- Spool (Arm 1) 72- Body (2 used)
4- Socket Bolt (16 Used) 27- Spring Seat 50- Spool (Swing) 73- Socket Bolt (8 used)
5- O-Ring (10 Used) 28- Spring 51- Bolt (5 used) 74- O-Ring (2 used)
6- Cap 29- Spacer 52- Spring Seat (10 used) 75- Plug (2 used)
7- Spool (Travel Left) 30- Backup Ring 53- Spring (5 used) 76- Spacer (2 used)
8- Spool (Auxiliary) 31- O-Ring 54- Socket Bolt (22 used) 77- Spring (2 used)
9- Spool (Boom 2) 32- Spring 55- Cap (2 used) 78- Plug (2 used)
10- Spool (Arm 1) 33- Poppet 56- O-Ring (2 used) 79- Spring (2 used)
11- Spool (Swing) 34- Overload Relief Valve 57- Body 80- Poppet (2 used)
12- Socket Bolt (4 used) 35- O-Ring 58- O-Ring (5 used) 81- Poppet (2 used)
13- Plug 36- O-Ring 59- Spring 82- Plug
14- O-Ring 37- Overload Relief Valve 60- Poppet 83- O-Ring
15- Piston 38- Cap (4 used) 61- O-Ring 84- Spring
16- Spring 39- Cap 62- Plug 85- Poppet
17- Body 40- Socket Bolt (2 used) 63- Flange 86- Flange (2 used)
18- O-Ring 41- Cap 64- O-Ring 87- Spring (2 used)
19- O-Ring (3 used) 42- O-Ring 65- Spring 88- Poppet (2 used)
20- Sleeve 43- Washer 66- Poppet 89- O-Ring (6 used)
21- Backup Ring 44- Spring 67- Plug (2 used)
22- O-Ring 45- Spool 68- O-Ring (2 used)
23- O-Ring 46- Spool (Travel Left) 69- Spring Seat (2 used)
W3-9-4-5
Disassembly of Control Valve (5-Spool Side)  Disassembly of Overload Relief Valve (34)
IMPORTANT: Do not disassemble the overload
relief valve. If the overload relief valve has been
 Disassembly of Spool
disassembled, pressure should be adjusted. (Refer
1. Remove socket bolts (4) (6 used). Remove cap (6),
O-rings (5) (5 used), and O-rings (90) from housing
Test in the separated volume, T/M.)
(1).
7. Remove overload relief valve (34) and O-ring (35)
l : 8 mm from housing (1).
2. Put the matching marks on spools (7, 8, 9, 10, 11) j : 32 mm
and housing (1). Remove the spool (7, 8, 9, 10, 11)
assemblies from housing (1).
 Disassembly of Main Relief Valve (3)
IMPORTANT: Do not disassemble the main
 Disassembly of Arm Anti-Drift Valve relief valve. If the main relief valve has been
3. Remove plug (13) and O-ring (14) from body (17). disassembled, pressure should be adjusted. (Refer
j : 38 mm
4. Remove socket bolts (12) (3 used). Remove the body 8. Remove main relief valve (3), and O-ring (2) from
(17) assembly, O-rings (18), and O-rings (19) (3 used) housing (1).
from housing (1).
j : 32 mm
l : 8 mm
5. Remove piston (15) and spring (16) from body (17).  Disassembly of Check Valve (Orifice) (Parallel Circuit in
4-Spool Section)
6. Remove spool (25), sleeve (20), poppet (26), spring 9. Remove spacer (29), spring (32), and poppet (33)
seat (27), and spring (28) from housing (1). from housing (1). Remove backup ring (30) and
O-ring (31) from spacer (29).
Remove backup rings (21, 24) and O-rings (22, 23)
from sleeve (20). 10. Remove socket bolts (91) (2 used). Remove flange
(92), O-ring (93), spring (98), and poppet (99) from
housing (1).
l : 8 mm
housing (1).
l : 8 mm
W3-9-4-6
12. Remove plugs (96) (3 used) and O-rings (97) (3 used)  Disassembly of Arm 1 Spool (49)
from housing (1). 16. Secure spool (49) in a vise by using wooden pieces.
Remove bolt (51), spring seats (52) (2 used for each),
l : 8 mm and springs (53) from spool (49).
l : 8 mm
 Disassembly of Travel (Left) Spool (46)
Remove bolt (51), spring seats (52) (2 used), and  Disassembly of Swing Spool (50)
spring (53) from spool (46). 17. Secure spool (50) in a vise by using wooden pieces.
Remove bolt (51), spring seats (52) (2 used), and
l : 8 mm spring (53) from spool (50).
l : 8 mm
 Disassembly of Auxiliary Spool (47)
l : 8 mm
 Disassembly of Boom 2 Spool (48)

l : 8 mm
W3-9-4-7
18. Remove socket bolts (4) (10 used). Remove caps  Disassembly of Arm Anti-Drift Valve
(38) (4 used), cap (39), and O-rings (5) (5 used) from 22. Remove socket bolts (54) (4 used). Remove flange
housing (1). (57), O-rings (89) (4 used), spring (59), and poppet
(60) from housing (1). Remove plug (62) and O-ring
l : 8 mm (61) from flange (57).
l : 8 mm
 Disassembly of Auxiliary Flow Combiner Valve
19. Remove socket bolts (40) (2 used). Remove cap (41),
O-ring (42), washer (43), springs (44), and spools  Disassembly of Arm 1 Flow Rate Control Valve and
(45) from housing (1). Auxiliary Flow Rate Control Valve
23. Loosen plugs (67, 75) (2 used for each) from bodies
l : 5 mm (72) (2 used).
24. Remove socket bolts (73) (8 used). Remove the body
 Disassembly of Overload Relief Valve (37) (72) assemblies (2 used) and O-rings (58, 59) (2 used
IMPORTANT: Do not disassemble the overload for each) from housing (1).
relief valve. If the overload relief valve has been
disassembled, pressure should be adjusted. (Refer l : 8 mm
25. Remove plugs (67) (2 used), O-rings (68) (2 used),
spring seats (69) (2 used), springs (70), and spools
20. Remove overload relief valve (37) and O-ring (36) (71) from bodies (72) (2 used). Remove plugs (75) (2
from housing (1). used) and O-rings (74) (2 used) from bodies (72) (2
used).
j : 32 mm
26. Remove sleeves (76) (2 used), springs (77, 79), plugs
(78), and poppets (80, 81) from housing (1).
 Disassembly of Check Valve (Auxiliary Flow Combiner
Circuit)
housing (1).
l : 8 mm
W3-9-4-8
 Disassembly of Load Check Valve (Boom 2 Parallel

Circuit, Swing Circuit)
27. Remove socket bolts (8) (8 used) from housing (1).
Remove flanges (75) (2 used), O-rings (13) (2 used),
springs (12) (2 used), and poppets (76) (2 used).
l : 8 mm
28. Remove socket bolts (8) (8 used). Remove covers
(84) (2 used) and O-rings (85) (2 used) from housing
(1).
l : 8 mm
 Disassembly of Load Check Valve (Travel (Left) Parallel

Circuit)
29. Remove plug (10), O-ring (9), spring (38), and
poppet (86) from housing (1).
l : 8 mm
84 85
82
W1V1-02-05-016
W3-9-4-9
Assembly of Control Valve (5-Spool Side)
A Section B Section
54 1
73
73
60
59
A
B 58
57
W178-02-05-018
W178-02-05-027
76 77 78 79 80 81
67
68
70
69
71
74
75 72 89 58
T178-03-03-013
W3-9-4-10
C Section
1
54
54
54 C
D 88
E
87
58
W178-02-05-018
E Section D Section
54
86
W178-02-05-028
88
85
87 84 F Section
58 83
66
65
64
82
54
86
T178-03-03-044
63
W178-02-05-026
W3-9-4-11
E Section
40
W178-02-05-018
45
42
44
41
43 W178-02-05-026
G Section
51 51 51 51 51
52 52 52 52 52
53 53 53 53 53
52 52 52 52 52
46 47 48 49 50
W178-02-05-024
W3-9-4-12
34 4
6 37
4
4 4
4
4
12
I
G
38
38
39
38 38 W178-02-05-018
M178-05-003
G Section
5 7 5 8 5 9 5 10 11 5 H Section
13
14
17
15
25
20 16
26 18
19
30, 31 21
29
32 22
23
33
24
27
28
W178-02-05-029
T178-03-03-041
5 5 5 5 5
W3-9-4-13
1- Housing 24- Backup Ring 47- Spool (Auxiliary) 70- Spring (2 used)
2- O-Ring 25- Spool 48- Spool (Boom 2) 71- Spool (2 used)
3- Main Relief Valve 26- Poppet 49- Spool (Arm 1) 72- Body (2 used)
4- Socket Bolt (16 Used) 27- Spring Seat 50- Spool (Swing) 73- Socket Bolt (8 used)
5- O-Ring (10 Used) 28- Spring 51- Bolt (5 used) 74- O-Ring (2 used)
6- Cap 29- Spacer 52- Spring Seat (10 used) 75- Plug (2 used)
7- Spool (Travel Left) 30- Backup Ring 53- Spring (5 used) 76- Spacer (2 used)
8- Spool (Auxiliary) 31- O-Ring 54- Socket Bolt (22 used) 77- Spring (2 used)
9- Spool (Boom 2) 32- Spring 55- Cap (2 used) 78- Plug (2 used)
10- Spool (Arm 1) 33- Poppet 56- O-Ring (2 used) 79- Spring (2 used)
11- Spool (Swing) 34- Overload Relief Valve 57- Body 80- Poppet (2 used)
12- Socket Bolt (4 used) 35- O-Ring 58- O-Ring (5 used) 81- Poppet (2 used)
13- Plug 36- O-Ring 59- Spring 82- Plug
14- O-Ring 37- Overload Relief Valve 60- Poppet 83- O-Ring
15- Piston 38- Cap (4 used) 61- O-Ring 84- Spring
16- Spring 39- Cap 62- Plug 85- Poppet
17- Body 40- Socket Bolt (2 used) 63- Flange 86- Flange (2 used)
18- O-Ring 41- Cap 64- O-Ring 87- Spring (2 used)
19- O-Ring (3 used) 42- O-Ring 65- Spring 88- Poppet (2 used)
20- Sleeve 43- Washer 66- Poppet 89- O-Ring (6 used)
21- Backup Ring 44- Spring 67- Plug (2 used)
22- O-Ring 45- Spool 68- O-Ring (2 used)
23- O-Ring 46- Spool (Travel Left) 69- Spring Seat (2 used)
W3-9-4-14
Assembly of Control Valve (5-Spool Side) 6. Install O-rings (5) (5 used) to housing (1). Install
cap (39) and caps (38) (4 used) to housing (1) with
onto parts in order to prevent them from seizing. l : 8 mm
 Assembly of Travel (Left) Spool (46)
1. Secure spool (46) in a vise by using wooden pieces. m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft)
Install spring seats (52) (2 used), spring (53), and 7. Install the spool (46, 47, 48, 49, 50) assemblies to
bolt (51) to spool (46). housing (1).
l : 8 mm 8. Install O-rings (5) (5 used) and O-ring (90) to
housing (1). Install cap (6) to housing (1) with socket
m : 15 N·m (1.5 kgf·m, 11 lbf·ft) bolts (4) (6 used).
l : 8 mm
 Assembly of Auxiliary Spool (47)
2. Secure spool (47) in a vise by using wooden pieces. m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft)
Install spring seats (52) (2 used), spring (53), and
bolt (51) to spool (47).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
 Assembly of Boom 2 Spool (48)

l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
 Assembly of Arm 1 Spool (49)

Install spring seats (52) (2 used), springs (53), and
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
 Assembly of Swing Spool (50)

l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
W3-9-4-15
 Assembly of Auxiliary Flow Rate Control Valve  Assembly of Load Check Valve
9. Install O-rings (74, 68) to plugs (67, 75). 16. Install poppets (88) (2 used), springs (87) (2 used),
and O-rings (58) (2 used) to housing (1).
10. Install spring (70), spool (71), spring seat (69), and
plug (67) to body (72). 17. Install flanges (86) (2 used) to housing (1) with
11. Install plug (75) to body (72).
12. Install poppets (80, 81), springs (77, 79), plug (78), l : 8 mm
and sleeve (76) to housing (1).
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
13. Install O-rings (58, 89) to housing (1). Install body
18. Install O-rings (56) (2 used) to housing (1). Install
cap (55) (2 used) to housing (1) with socket bolts
l : 8 mm (54) (8 used).
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

 Assembly of Check Valve (Auxiliary Flow Combiner
Circuit)
14. Install poppet (66), spring (65), and O-ring (64) to
housing (1). Install flange (63) to housing (1) with
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
 Assembly of Auxiliary Flow Combiner Valve

15. Install spool (45), springs (44), O-rings (42) (2 used),
and spring seats (43) (2 used) to housing (1). Install
cap (41) to housing (1) with socket bolts (40) (4
used).
l : 5 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-9-4-16
19. Install O-ring (83) to plug (82). Install poppet (85),  Assembly of Arm 1 Flow Rate Control Valve
spring (84), and plug (82) to housing (1). 26. Install O-rings (68, 74) to plugs (67, 75).
l : 8 mm 27. Install spring (70), spool (71), spring seat (69), and
plug (67) to body (72).
 Assembly of Arm Anti-Drift Valve 28. Install plug (67) to body (72).
20. Install backup rings (21, 24) and O-rings (22, 23) to 29. Install poppets (80, 81), springs (77, 79), plug (78),
sleeve (20). and sleeve (76) to housing (1).
21. Apply grease onto spring seat (27) and spring (28) in 30. Install O-rings (58, 59) to housing (1). Install body
order to prevent from falling off. (72) to housing (1) with socket bolts (73) (4 used).
22. Face the hole on spool (25) to the poppet (26) side.
l : 8 mm
Install spool (25), poppet (26), seat (27), and spring
(28) to sleeve (20). Install the sleeve (20) assembly to m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
housing (1).
23. Install O-ring (14) to plug (13). Install spring (16),
piston (15), O-ring (18), and plug (13) to body (17).
j : 38 mm
24. Install O-rings (19) (3 used) and O-ring (18) to
housing (1). Install the body (17) assembly to
housing (1) with socket bolts (12) (3 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

j : 38 mm
W3-9-4-17
 Assembly of Arm Anti-Drift Valve  Assembly of Check Valve (Orifice) (Parallel Circuit 4
31. Install O-ring (61) to plug (62). Install plug (70) to Spool Section)
flange (57). 35. Install poppet (99), spring (98), and O-ring (93) to
32. Install flange (57), O-rings (89) (4 used), spring (59),
and poppet (60) to housing (1) with socket bolts (8)
(4 used). l : 8 mm
l : 8 mm m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
m : 62 N·m (6.2 kgf·m, 46 lbf·ft) 36. Install poppet (95), spring (94), and O-ring (93) to
 Assembly of Overload Relief Valves (34, 37)
IMPORTANT: If the overload relief valve has been l : 8 mm
to TROUBLESHOOTING/Operational Performance m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
37. Install backup ring (30) and O-ring (31) to spacer
33. Install O-rings (35, 36) to overload relief valves (34, (29). Install spacer (29), spring (32), and poppet (33)
37). Install overload relief valves (34, 37) to housing to housing (1).
(1).
38. Install O-rings (97) (3 used) to plugs (96) (3 used).
j : 32 mm Install plugs (96) (3 used) to housing (1).
 Assembly of Main Relief Valve

IMPORTANT: If the main relief valve has been
34. Install main relief valve to housing (1).
j : 32 mm
m : 60 N·m (6 kgf·m, 44 lbf·ft)
W3-9-4-18
Removal and Installation of Swing Device

1 4
5 WDC390-03-09-004
3
IMPORTANT: The hose and pipe contain hydraulic oil.

When removing the hose and pipe, receive oil with
a container in order to avoid spilling oil.
Removal

(Refer to W1-4-1.)
(3).
j : 17 mm
(5).
j : 17 mm
W3-10-1-1
1 2
WDC390-03-10-002
5. Disconnect connector (4). 11. Remove plug (1) (2 used).

6. Disconnect hose (6). j : 30 mm
j : 36 mm 12. Install the bolt (M20, Pitch 2.5 mm) to the hole
where plug (1) have been removed.
13. Turn the bolt and raise swing device (5) from the
j : 19 mm main frame. Hoist and remove swing device (5) from
8. Remove socket bolts (8) (8 used) and flanges (9) the main frame.
(4 used). Disconnect hoses (10) (2 used). Remove
j : 30 mm
O-rings (11) (2 used).
l : 8 mm fNOTE: THREEBOND #1102 has been applied on the

main frame mounting surface of swing device (5).
dCAUTION:
lb)
Swing device (5) weight: 220 kg (490 14. Remove knock pin (2) (2 used).
9. Attach the nylon slings onto the body of swing fNOTE: THREEBOND #1102 has been applied on knock
pin (2).
motor. Hoist and hold swing device (5).
15. Remove the adapters with swing device (5)
10. Put the matching marks (a) onto housing of swing attached if necessary.
device (5) and the main frame. Remove bolts (12)
(12 used) and washers (13) (12 used).
j : 30 mm
W3-10-1-2
1 2
WDC390-03-10-002
Installation
1. Install all removed adapters to swing device (5). 7. Install O-rings (11) (2 used). Connect hoses (10) (2
used) with flanges (9) (4 used) and socket bolts (8)
dCAUTION:
lb)
Swing device (5) weight: 220 kg (490 (8 used).
2. Apply THREEBOND #1102 onto the main frame l : 8 mm

mounting surface of swing device (5). Attach a
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
nylon sling onto the body of swing motor. Hoist
swing device (5). 8. Connect hoses (7) (2 used).
3. Fit the matching marks (a) and the position of knock j : 19 mm
pin (2). Install swing device (5) to the main frame.
m : 30 N·m (3 kgf·m, 22 lbf·ft)
4. Apply THREEBOND #1102 onto knock pins (2) (2
used), and plugs (1) (2 used). Tap and install knock 9. Connect hose (6).
pins (2) (2 used), and plugs (1) (2 used) to the main
frame. j : 36 mm
5. Install plug (1). m : 180 N·m (18 kgf·m, 133 lbf·ft)
j : 30 mm 10. Connect connector (4).
6. Install swing device (5) with washers (13) (12 used)

j : 30 mm
m : 500 N·m (50 kgf·m, 370 lbf·ft)
W3-10-1-3
1 4
5 WDC390-03-09-004
3

1.)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

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

14. Shut engine cover (1).
W3-10-1-4
Disassembly of Swing Device
23
24
1
25
2
34
26 3
33
21 4
32 5
34
20 6
27 7
19
8
28 9
18
29 10
17 13
16 11
30
15 12
31
14
WDC390-03-10-001
1- Motor 10- Spring Pin (3 Used) 19- Thrust Plate 29- Sleeve
2- First Stage Sun Gear 11- Needle Bearing (6 Used) 20- Second Stage Sun Gear 30- O-Ring
3- Thrust Plate 12- Planetary Gear (3 Used) 21- First Stage Carrier 31- Shaft
4- Pin (3 Used) 13- Thrust Plate (6 Used) 23- Socket Bolt (8 Used) 32- Drain Plug
5- Spring Pin (3 Used) 14- Roller Bearing 24- Socket Bolt (12 Used) 33- Pipe
6- Needle Bearing (3 Used) 15- Bearing Nut 25- Ring Gear 34- Plug (2 Used)
7- Planetary Gear (3 Used) 16- Lock Plate 26- Housing
8- Thrust Plate (3 Used) 17- Bolt (2 Used) 27- Roller Bearing
9- Pin (3 Used) 18- Second Stage Carrier 28- Oil Seal
W3-10-2-1
Disassembly of Swing Device

2. Place swing device (b) onto the special tool (ST
d CAUTION:
lb)
Swing device (b) weight: 220 kg (490 5097). Secure swing device (b) with bolts (M20,
Pitch 2.5 mm) (2 used) so that stopper (c) at the
dCAUTION: When hoisting swing device (b), do
not sling the rope suddenly.
bottom of special tool (ST 5097) should be inserted
into the clearance between teeth of the pinion gear
in shaft (31). Secure the special tool (ST 5097) on a
workbench in order to receive the reaction force.
eyebolt mounting positions (a) (2 places) of swing
device (b). Hoist swing device (b). j : 30 mm
b
a
b c
ST 5097
W178-02-11-134
b- Swing Device
c- Stopper
3. Remove drain plug (32). Drain off oil from swing

device (b).
W178-02-06-005 l : 8 mm
a- Eyebolt Mounting Position fNOTE: Amount of oil: 6.7 L (1.8 US gal)

b- Swing Device 4. Disconnect pipe (33) from housing (26).
j : 18 mm
5. Put the matching marks at the jointed part between
motor (1) and ring gear (25), between ring gear (25)
and housing (26).
W3-10-2-2
IMPORTANT: The hole for spring pin (5) located on

d CAUTION: Motor (1) weight: 47 kg (105 lb) first stage carrier (21) is not a through one. Check
6. Remove socket bolts (23) (8 used). Insert a the tapping-in distance of spring pin (5).
screwdriver into the gap around jointed part. Hoist 13. Install spring pin (5) with the first stage carrier (21)
and remove motor (1) from ring gear (25). assembly attached to pin (4) by using the special
tool (ST 1462). Stop tapping when spring pin (5)
l : 10 mm
reaches the middle of pin (4) hole and do not tap
fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been spring pin (5) to the end.
applied onto the mating surface. 14. Remove pins (4) (3 used), planetary gears (7) (3
7. Remove first stage sun gear (2) from first stage used), needle bearings (6) (3 used), and thrust plates
carrier (21). (8) (3 used) from first stage carrier (21).
8. Remove the first stage carrier (21) assembly from 15. Remove thrust plate (3) from first stage carrier (21).
ring gear (25).
IMPORTANT: Do not damage the rotating surface for
9. Remove socket bolts (24) (12 used). needle bearing of pin (4) except for the both ends.
l : 14 mm 16. Secure the end of pin (4) opposite the spring pin
(5) hole in a vise. Remove spring pins (5) (3 used) by
dCAUTION: Ring gear (25) weight: 23 kg (51 lb) using the special tool (ST 1462).
10. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the IMPORTANT: Do not damage the rotating surface for
motor (1) mounting screw part of ring gear (25). needle bearing of pin (9) except for the both ends.
Insert a screwdriver into the gap around jointed 17. Disassemble the second stage carrier (18) assembly
part. Hoist and remove ring gear (25) from housing in the same way as the first stage carrier (21)
(26). assembly. Remove planetary gears (12) (3 used),
needle bearings (11) (6 used), and thrust plates (13)
fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been
(6 used). Remove spring pins (10) (3 used) from pins
applied onto the mating surface.
(9) (3 used) by using the special tool (ST 1463).
11. Remove second stage sun gear (20) from second
stage carrier (18). 18. Remove thrust plate (19) from second stage carrier
(18).
12. Remove the second stage carrier (18) assembly from
shaft (31). 19. Remove bolts (17) (2 used). Remove lock plate (16)
from bearing nut (15).
j : 17 mm
W3-10-2-3
20. Remove bearing nut (15) from shaft (31) by using 23. Push the spline side of shaft (31) by using press
the special tool (ST 2926). (a). Remove the shaft (31) assembly and the inner
race of roller bearing (14) from housing (26). The
inner race of roller bearing (27) and sleeve (29) are
15 removed with shaft (31) together.
24. Place the special tool (ST 1460) onto the stepped
part of special tool (ST 1461).
ST 1460
ST 2926
ST 1461
W178-02-11-135
dCAUTION: The housing (26) assembly weight:

110 kg (245 lb)
W178-02-11-137
bolt (24) holes (2 places) of housing (26). Remove
bolts (M20, Pitch 2.5 mm) which secure housing (26)
and the special tool (ST 5097). Hoist the housing
(26) assembly and remove the special tool (ST 5097).
j : 30 mm
22. Install the special tool (ST 1464) to housing (26).
Place housing (26) on press (a).
j : 30 mm
26
ST 1464
W178-02-11-136
a- Press
W3-10-2-4
dCAUTION:
(100 lb)
The shaft (31) assembly weight: 45 kg dCAUTION: Metal fragments may fly off when
25. Insert the pinion gear of the shaft (31) assembly into such as goggles, hard hat, etc. in order to prevent
the tooth-hole on the special tool (ST 1460). Place personal injury.
the pinion gear of shaft (31) to press (a). 28. Insert a round bar into the oil passage in housing
(26). Remove outer race (a) of roller bearing (27) by
using a round bar and a hammer.
a
b
a
31
27
29 W178-02-11-139
ST 1460
a- Outer Race b- Hole for Round Bar
ST 1461
dCAUTION:
kg (145 lb)
29. Attach nylon slings onto the body of the housing

W178-02-11-138
(26) assembly. Hoist and turn over the housing (26)
assembly.
a- Press
30. Insert a screwdriver into the notch on housing (26)
where oil seal (28) is mounted. Remove oil seal (28)
26. Push the spline side of shaft (31) by using press (a). from housing (26).
Remove the inner race of roller bearing (27) and
sleeve (29). fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been
applied onto the outer surface of oil seal (28). Oil seal
27. Remove O-ring (30) from sleeve (29). (28) cannot be reused.

such as goggles, hard hat, etc. in order to prevent
personal injury.
31. Remove the outer race of roller bearing (14) from
housing (26) by using a bar and a hammer.
W3-10-2-5
Assembly of Swing Device
1
2 4
3 5
23
21
6
20 7
18
8
25
19 10
13
24
12
17 11
16 13
9
15
33
14
27
26
28 32
30
29
31
WDCR-03-01-002
1- Motor 10- Spring Pin (3 Used) 19- Thrust Plate 29- Sleeve
2- First Stage Sun Gear 11- Needle Bearing (6 Used) 20- Second Stage Sun Gear 30- O-Ring
3- Thrust Plate 12- Planetary Gear (3 Used) 21- First Stage Carrier 31- Shaft
4- Pin (3 Used) 13- Thrust Plate (6 Used) 23- Socket Bolt (8 Used) 32- Drain Plug
5- Spring Pin (3 Used) 14- Roller Bearing 24- Socket Bolt (12 Used) 33- Pipe
6- Needle Bearing (3 Used) 15- Bearing Nut 25- Ring Gear 34- Plug (2 Used)
7- Planetary Gear (3 Used) 16- Lock Plate 26- Housing
8- Thrust Plate (3 Used) 17- Bolt (2 Used) 27- Roller Bearing
9- Pin (3 Used) 18- Second Stage Carrier 28- Oil Seal
W3-10-2-6
Assembly of Swing Device

IMPORTANT: Before assembling, apply gear oil onto dCAUTION: Metal fragments may fly off when
parts in order to prevent them from seizing.
1. Install O-ring (30) to sleeve (29).
personal injury.
dCAUTION:
(89 lb)
The shaft (31) assembly weight: 40 kg 4. Evenly tap and install the outer race of roller bearing
(27) to housing (26) by using a bar and a hammer.
2. Install sleeve (29) and the inner race of roller Tap and listen to ring in order to check if the
bearing (27) to shaft (31) by using the special tool installation is completed.
(ST 4149) and press (a).
f NOTE: The press-in distance of the inner race can be a hammer is used. Wear necessary protection,
assured by using the special tool.
personal injury.
5. Apply THREEBOND #1215 onto the outer surface of
oil seal (28). Place oil seal (28) flat on housing (26)
and push it by hand in gently. Place the special tool
a
(ST 2550) on oil seal (28). Install the special tool (ST
2550) by using a hammer straightly.
fNOTE: Oil seal (28) can be replaced by using the special

ST 4149 tool (ST 2550) without removing sleeve (29).
27
29 ST 2550
28
31
26
W178-02-06-013
a- Press
dCAUTION: Housing (26) weight: 60 kg (135 lb) W178-02-11-144

3. Attach nylon slings onto the body of housing (26).
Hoist and place housing (26) with the sleeve (29) 6. Apply grease onto the inner surface of oil seal (28).
mounting side up. Apply grease onto the outer surface of sleeve (29)
with shaft (31) attached. Apply grease carefully
when installing shaft (31) in order not to curl the lip.
W3-10-2-7
11. Tighten bearing nut (15) to shaft (31) by hand in

d CAUTION: The housing (26) assembly weight: 64
kg (145 lb)
order not to drop shaft (31).
7. Attach nylon slings onto the body of the housing dCAUTION: The housing (26) assembly weight:
110 kg (245 lb)
(26) assembly. Hoist and place the housing (26)
assembly with the ring gear (25) side up. 12. Install eyebolts (M16, Pitch 2.0 mm) to the ring gear
(25) mounting screw part of housing (26). Hoist and
place housing (26) on a press.
such as goggles, hard hat, etc. in order to prevent 13. Remove bearing nut (15) from shaft (31).
personal injury. 14. Place the special tool (ST 2924) onto the inner race
8. Install the outer race of roller bearing (14) to of roller bearing (14). Install the inner race by using
housing (26) by using a bar and a hammer. Tap and a press.
listen to ring in order to check if the installation is
completed. fNOTE: The specified press-in distance of the inner race
can be assured by using the special tool (ST 2924).
dCAUTION:
kg (145 lb)
ST 2924
bolt (24) holes of housing (26). Hoist housing (26). 14
Slowly place and install housing (26) to shaft (31).
Check and fit carefully in order not to curl the lip of
oil seal (28).

personal injury. W178-02-11-145
10. Install the inner race of roller bearing (14) to shaft
(31) by using a bar and a hammer. Tap the inner
race until the upper end on the inner race of roller
bearing (14) reaches two threads for bearing nut
(15) in shaft (31).
fNOTE: The fitting between the inner race of roller

bearing (14) and shaft (31) is tight.
W3-10-2-8
18. Remove the bolts (M20, Pitch 2.5 mm) (2 used)

d CAUTION: The housing (26) assembly weight:
110 kg (245 lb)
which secure housing (26) and the special tool (ST
5097).
IMPORTANT: Check that the flange surface of
housing (26) does not touch the special tool (ST j : 30 mm
5097). 19. Turn housing (26) to both sides five times. Tap
15. Hoist and place the housing (26) assembly on housing (26) several times by using a plastic
the special tool (ST 5097). Install the housing (26) hammer.
assembly with bolts (M20, Pitch 2.5 mm) (2 used)
20. Install housing (26) to the special tool (ST 5097) with
so that the stopper at the bottom of special tool
bolts (M20, Pitch 2.5 mm) (2 used).
(ST 5097) should be inserted into the clearance
between teeth of the pinion gear in shaft (31). j : 30 mm
Secure the special tool (ST 5097) on a workbench in
order to receive the reaction force. 21. Tighten bearing nut (15) by using the special tool
(ST 2926).
j : 30 mm
26 m : 500 N·m (50 kgf·m, 370 lbf·ft)
22. Repeat step 18 and step 21 two to three times so
that bearings of bearing nut (15) and roller bearings
a (14, 27) can fit.
ST 5097
23. Remove the bolts (M20, Pitch 2.5 mm) (2 used)
which secure housing (26) and the special tool (ST
5097).
j : 30 mm
W178-02-11-134
a- Stopper
dCAUTION:
110 kg
The housing (26) assembly weight:
24. Hoist and place the housing (26) assembly on a flat

IMPORTANT: Check the direction to install bearing stand. When the housing (26) assembly is placed,
nut (15). check that the contacting position of oil seal (28)
on the sleeve (29) outer surface does not move. In
16. Apply grease onto the thread part of bearing nut
case the contacting position of oil seal (28) moves,
(15). Place the thread part of bearing nut (15) onto
bearing nut (15) is tightened insufficiently. Perform
shaft (31). At this time, face the stepped side of
step 17 to step 23 again.
bearing nut (15) to the roller bearing (14) side.
25. Install housing (26) to the special tool (ST 5097) with
17. Tighten bearing nut (15) by using the special tool
(ST 2926).
j : 30 mm
m : 500 N·m (50 kgf·m, 370 lbf·ft)
15
ST 2926
W178-02-11-146
W3-10-2-9
26. Fit the spline part of lock plate (16) to that of shaft 33. Install planetary gears (12) (2 used), needle bearings
(31). Tighten bearing nut (15) further until the bolt (11) (4 used), thrust plates (13) (4 used), pins (9) (2
(17) hole of bearing nut (15) fit to that of lock plate used), and spring pins (10) (2 used) to second stage
(16). carrier (18) in the same way as step 30 to step 32.
27. Remove the bolts (M20, Pitch 2.5 mm) (2 used) IMPORTANT: Check the direction to install thrust
which secure housing (26) and the special tool (ST plate (3).
5097). 34. Install thrust plate (3) to the first stage carrier (21)
assembly with the oil groove facing outside.
j : 30 mm
35. Install needle bearing (6) to planetary gear (7).
28. Install lock plate (16) to bearing nut (15) with bolts
Install thrust plate (8) and the planetary gear (7)
(17) (2 used).
assembly to first stage carrier (21). At this time,
j : 17 mm install thrust plate (8) to the housing (26) side of the
planetary gear (7) assembly.
m : 50 N·m (5 kgf·m, 37 lbf·ft)
36. Install pin (4) to the position where planetary gear
IMPORTANT: Check the direction to install thrust (7) of first stage carrier (21) has been installed with
plate (19). the spring pin hole facing the near side. The spring
29. Install thrust plate (19) to second stage carrier (18) pin holes of both first stage carrier (21) and pin (4)
with the oil groove facing outside. should be in line.
30. Install needle bearings (11) (2 used) to planetary IMPORTANT: Check the direction of spring pin (5).
gear (12). Install thrust plates (13) (2 used) and the 37. Install spring pin (5) to first stage carrier (21) with
planetary gear (12) assembly to second stage carrier slit (a) of spring pin (5) facing to the end of pin (4) by
(18). using the special tool (ST 1462).
31. Install pin (9) to the position where planetary gear
(12) of second stage carrier (18) has been installed
5
with the spring pin hole facing the near side. The
spring pin holes of both second stage carrier (18) 4
and pin (9) should be in line.
a
IMPORTANT: Check the direction of spring pin (10).
32. Install spring pin (10) to second stage carrier (18) by W178-02-11-147
using the special tool (ST 1463) with slit (a) of spring a- Slit
pin (10) facing to the end of pin (9).
10
9
W178-02-11-147
a- Slit
W3-10-2-10
IMPORTANT: Check the mounting position of thrust IMPORTANT: Check the direction to install first stage
plate (8). sun gear (2).
38. Install planetary gears (7) (2 used), needle bearings 44. Install first stage sun gear (2) to the first stage carrier
(6) (2 used), thrust plates (8) (2 used), pins (4) (2 (21) assembly with the stepped part down.
used), spring pins (5) (2 used), and thrust plate (3) to
45. Install a seal tape onto the thread part of pipe (33).
first stage carrier (21) in the same way as step 35 to
Install pipe (33) to housing (26). Face pipe (33)
step 37.
down.
39. Fit the spline and install the second stage carrier
(18) assembly to shaft (31). j : 18 mm
40. Install second stage sun gear (20) to the second 46. Install a seal tape onto drain plug (32). Install drain
stage carrier (18) assembly with the small diameter plug (32) to pipe (33).
part up.
l : 8 mm
41. Apply THREEBOND #1215 (or LOCTITE #5020) onto
the ring gear (25) mounting surface of housing (26). m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
47. Add gear oil to ring gear (25) until gear oil reaches
dCAUTION: Ring gear (25) weight: 23 kg (51 lb)
the middle part of first stage sun gear (2).
motor (1) mounting screw part of ring gear (25). Oil amount: 6.7 L (1.82 US gal)
Hoist ring gear (25). Fit the matching marks. Install 48. Apply THREEBOND #1212 (or LOCTITE #5020) onto
ring gear (25) to housing (26) with socket bolts (24) the motor (1) mounting surface of ring gear (25).
(12 used).
l : 14 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)

43. Fit the spline and install the first stage carrier (21)
assembly to second stage sun gear (20).
W3-10-2-11
dCAUTION: Motor (1) weight: 47 kg (105 lb)

motor (1). Hoist motor (1). Fit the matching marks.
Install motor (1) to ring gear (25) with socket bolts
(23) (8 used).
l : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W178-02-06-005
a- Eyebolt Mounting Position
W3-10-2-12
Removal and Installation of Pilot Valve (Left)

5
1 WDAA-03-01-023
6
WDC390-03-11-003

oil. When removing the hose and pipe, receive oils dCAUTION: Seat (5) weight: 21 kg (47 lb)
with a container in order to avoid spilling oils. 3. Remove socket bolts (6) (4 used). Remove seat (5).
l : 6 mm
Removal

(Refer to W1-4-1.)
2. Open door (1).
W3-11-1-1
13
12 3
2
11
4
10
5
6
8
9
7
WDC390-03-11-004
4. Remove screws (2) (4 used). Remove cover (3). Raise

boot (1).
5. Remove screws (4) (4 used). Remove cover (5).
6. Remove cap (13). Remove screws (9, 11) and, bolt,
washer (10). Remove cover (12).
j : 10 mm
7. Remove screw (6, 8). Remove cover (7).
W3-11-1-2
25
35 27
31
26
32
24
33, 34
30
29
28
W178-02-07-004
WDC390-03-11-006
8. Remove clip bands (24, 25). Disconnect connector

(35).
9. Loosen lock nut (26). Remove the lever (27)
assembly.
j : 19 mm, 22 mm
j : 19 mm
11. Remove bolts, washers (30) (3 used), spring pin
(31), bolt (32), spring washer (33), and washer (34),
Remove pilot valve (29).
j : 13 mm
12. Remove the adapter with pilot valve (29) attached if
necessary.
W3-11-1-3
25
35 27
31
26
32
24
33, 34
30
29
28
W178-02-07-004
WDC390-03-11-006
Installation
1. Install all removed adapters to pilot valve (29).
2. Install pilot valve (29) with washer (34), spring
washer (33), bolt (32), spring pin (31), and bolts,
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

4. Tighten lock nut (26) and install the lever (27)
assembly.
j : 19 mm, 22 mm
m : 55 N·m (5.5 kgf·m, 40 lbf·ft)

5. Install clip bands (25, 24). Connect connector (35).
W3-11-1-4
13
12 3
2
11
4
10
5
6
8
9
7
WDC390-03-11-004

1.)
7. Install cover (7) with screw (6, 8).
8. Install cover (12) with bolt, washer (10), and screw
(9, 11). Install cap (13).
j : 10 mm
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

9. Install cover (5) with screw (4) (4 used).
10. Install cover (3) and boot (1) with screws (2) (4 used).
W3-11-1-5
1 WDAA-03-01-023
6
WDC390-03-11-003

11. Install seat (5) with socket bolts (6) (4 used).
l : 6 mm
m : 8 N·m (0.8 kgf·m, 5.9 lbf·ft)

12. Shut door (1).
W3-11-1-6
Removal and Installation of Pilot Valve

(Right) 5
1 WDAA-03-01-023
6
WDC390-03-11-003

oil.When removing the hose and pipe, receive oils dCAUTION: Seat (5) weight: 21 kg (47 lb)
with a container in order to avoid spilling oils. 3. Remove socket bolts (6) (4 used). Remove seat (5).
l : 6 mm
Removal

(Refer to W1-4-1.)
2. Open door (1).
W3-11-2-1
14
1
13
12
2
11
10 3
4
9
8 5
WDC390-03-11-005
7 6
4. Remove screw (13) (4 used). Remove cover (12). 8. Remove bolts, washers (1) (2 used). Remove switch
Raise boot (14). box (2).
5. Remove screw (3) (4 used). Remove cover (11). j : 13 mm
6. Remove cap (4). Remove screw (9, 10). Remove
cover (8).
7. Remove screw (5, 6). Remove cover (7).
W3-11-2-2
20
19
17 18
22, 23
24 27
21
25, 26
28
W178-02-11-160
W178-02-11-159
9. Remove clip bands (17, 18). Disconnect connector 12. Remove bolts, washers (21) (3 used), spring pin
(27). (22), bolt (23), spring washer (25), and washer (26).
Remove pilot valve (24).
10. Loosen lock nut (19). Remove the lever (20)
assembly. j : 13 mm
j : 19 mm, 22 mm 13. Remove the adapter with pilot valve (24) attached if
necessary.
j : 19 mm
W3-11-2-3
20
19
17 18
22, 23
24 27
21
25, 26
28
W178-02-11-160
W178-02-11-159
Installation 3. Connect hoses (28) (6 used).

1. Install all removed adapters to pilot valve (24). j : 19 mm
2. Install pilot valve (24) with washer (26), spring
m : 30 N·m (3 kgf·m, 22 lbf·ft)
washer (25), bolt (23), spring pin (22), and bolts,
washer (21) (3 used). 4. Tighten lock nut (19) and install the lever (20)
assembly.
j : 13 mm
j : 19 mm, 22 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
m : 55 N·m (5.5 kgf·m, 40 lbf·ft)
5. Install clip bands (18, 17). connect connector (27).
W3-11-2-4
14
1
13
12
2
11
10 3
4
9
8 5
WDC390-03-11-005
7 6
6. Bleed air from the hydraulic system. (Refer to W1-4- 11. Install switch box (2) with bolts, washers (1) (2 used).
1.)
j : 13 mm
engine and check for any oil leaks. m : 20 N·m (2 kgf·m, 15 lbf·ft)
7. Install cover (7) with screws (5, 6).
8. Install cover (8) with screws (9, 10). Install cap (4).
9. Install cover (11) with screws (3) (4 used).
10. Install cover (12), and boot (14) with screws (13) (4
used).
W3-11-2-5
1 WDAA-03-01-023
6
WDC390-03-11-003

12. Install seat (5) with socket bolts (6) (4 used).
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

13. Shut door (1).
W3-11-2-6
Removal and Installation of Travel Pilot Valve
4
3 2 WDAD-03-11-005 WDAD-03-11-008

oil. When removing the hose and pipe, receive oils dCAUTION: Remove cover (3) while holding it. Do
not drop cover (3).
IMPORTANT: Cap the open ends in case the hoses 4. Remove bolts, washers (2) (6 used). Remove cover
and pipes have been disconnected. In addition, (3).
j : 17 mm
hoses and install the clips in case the clips which 5. Disconnect hoses (5) (4 used).
j : 19 mm
Removal
6. Disconnect pipes (6) (2 used).
1. Swing the upperstructure by 90 degrees and set the
machine for inspection and maintenance. (Refer to j : 17 mm
W1-6-1.)

(Refer to W1-4-1.)
2. Open door (1).
3. Remove the floor mat.
W3-11-3-1
2
4
1
5, 6, 7
WDAD-03-11-009 WDAD-03-11-010
7. Remove bolts, washers (3) (4 used). Remove levers

(1) (2 used) and pedals (2) (2 used).
j : 17 mm
8. Remove socket bolts (5) (2 used), spring washers
(7) (2 used) and washers (6) (2 used). Remove pilot
valve (4).
l : 8 mm
9. Remove the adapters with pilot valve (4) attached if
necessary.
W3-11-3-2
2
4
1
5, 6, 7
WDAD-03-11-010 WDAD-03-11-009
Installation
1. Install all removed adapters to pilot valve (4).
2. Install pilot valve (4) with washers (6) (2 used),
spring washers (7) (2 used) and socket bolts (5) (2
used).
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Install pedals (2) (2 used) and levers (1) (2 used) with
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-11-3-3
4
WDAD-03-11-008 3 2 WDAD-03-11-005
4. Connect pipes (6) (2 used).
j : 17 mm
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

1.)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

8. Install the floor mat.
9. Close door (1).
W3-11-3-4
Disassembly of Pilot Valves (Right and Left)
17
16
15
14
13
12
11
10
18
9 9
8 10
7
6 19
5 5 20
4 6 21
22
3 3
2
4
1
WDC390-03-11-001
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing
W3-11-4-1
Disassembly of Pilot Valves (Right and Left)

IMPORTANT: Casing (18) is made of aluminium. 3. Attach a spanner onto the upper part of universal
Strong force deforms it. Handle it with care. joint (15). Remove universal joint (15).
IMPORTANT: Spool (19) has been selected to match
j : 17 mm
the hole on casing (18). The dimensions of balance
springs (3, 4) and return springs (5, 6) as well as
those of pushers (9, 10) are different. Arrange
fNOTE: Universal joint (15) has been secured on casing
(18) by using LOCTITE #262.
the disassembled parts together with the port in
4. Remove plate (14).
order not to confuse. The port number is stamped
on the outer surface of casing (18). IMPORTANT: Do not damage sleeve (12). Insert a soft
IMPORTANT: Do not remove screw joint (17) while rubber between sleeve (12) and a tool. Oil seal (11)
securing casing (18) in a vise. The strong torque cannot be removed from sleeve (12).
may act on screw joint (17). Sleeve (12) and oil seal (11) should be replaced as
1. Secure screw joint (17) in a vise. Turn cam (16) by an assembly.
using a spanner. Remove screw joint (17). 5. Remove sleeves (12) (4 used) upward by using a pair
of pliers. Remove O-rings (13) (4 used) from sleeves
j : 19 mm, 30 mm (12) (4 used).
2. Secure the flat surface of casing (18) in a vise. IMPORTANT: The dimensions of pushers (9, 10) for
Remove cam (16) from universal joint (15). ports (1, 3) and for ports (2, 4) are different. Keep
the disassembled parts together by the port
j : 30 mm
number in order not to confuse.
6. Remove pushers (9, 10) (2 used for each) from
casing (18).
W3-11-4-2
7. When compressing the spring, do not lower spool IMPORTANT: The quantity of shims (2) has been
(19). Install the special tool (ST 4145) to the port determined for each port during the performance
hole on casing (18) as illustrated. testing. Do not lose shim (2). Keep shim (2)
carefully in order to install shim (2) to the original
l : 6 mm port when assembling.
9. Remove the special tool (ST 4146). Remove spring
guides (7) (4 used), return springs (5, 6) (2 used for
each), and balance springs (3, 4) (2 used for each)
from spools (19) (4 used).
18 10. Remove shim (2) and spacers (1) (4 used) from
spools (19) (4 used).
19 IMPORTANT: Spool (19) has been selected to match
the hole on casing (18). Spool (19) and casing (18)
should be replaced as an assembly.
11. Remove the special tool (ST 4145) from casing (18).
Slowly turn and remove spool (19) from casing (18).
W178-02-07-048
ST 4145 IMPORTANT: Retaining ring (22) may come off while
disassembling. Do not drop retaining ring (22)
8. Install the special tool (ST 4146) to the pusher hole inside casing (18). If retaining ring (22) falls inside
on casing (18). Push the special tool (ST 4146) and casing (18), remove retaining ring (22) completely.
compress the spring. Tighten the special tool (ST Retaining ring (22) cannot be reused.
4146) by using the socket bolt (M14, Pitch 2.0 mm). 12. Remove retaining ring (22) from casing (18) by
Remove retaining rings (8) (4 used) from spools (19) using a screwdriver. Install a bolt (M8, Pitch 1.25
(4 used) by using a screwdriver. mm) to plug (21). Remove plug (21) from casing
(18). Remove O-ring (20) from plug (21).
l : 12 mm
j : 13 mm
ST 4146
18
W178-02-07-048
W3-11-4-3
Assembly of Pilot Valves (Right and Left)
17
15
16
11
14 9, 10
13
12
8
7
3, 4
5, 6
2
21 1
20
18 19
22
W178-02-11-298
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing
W3-11-4-4
Assembly of Pilot Valves (Right and Left)

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Refer to the table in the left in order to
onto parts in order to prevent them from seizing. assemble the parts correctly.
IMPORTANT: The pilot valve is the susceptible 3. Install spacer (1), shim (2), and balance spring (3) to
hydraulic component to contamination. Keep the spool (19). Install return spring (5) to casing (18).
parts clean when assembling.
4. Install spring guide (7) to return spring (5) with the
protrusion up.
fNOTE: The table below shows the relations between 5. Install other spools (19) (3 used) in the same way as
each port and the parts. Do not confuse them when step 1 to step 4.
assembling.
6. Install the special tool (ST 4146) to the pusher (9, 10)
Spool Shim holes on casing (18). Push the special tool (ST 4146)
Port No. Pushers (9, 10)
(19) (2) and compress the spring. Tighten the special tool
1 One outer groove (ST 4146) by using a bolt (M14, Pitch 2.0 mm).
Two outer
2 l : 12 mm
Same to the Same to the grooves
3 former one former one One outer groove
Two outer ST 4146
4
grooves
ST 4144
Return Springs Balance Springs
Port No.
(5, 6) (3, 4)
1 Short Short
2 Long Long
3 Short Short
4 Long Long
1. Check the port hole number and insert same spool

(19) before disassembling. Install the thinner end W178-02-07-049
of spool (19) into the port hole on casing (18) by ST 4145
turning slowly.
fNOTE: Spool (19) has been selected to match the port

7. Install retaining ring (8) to the ring holder (ST 4144).
hole. Spool (19) and casing (18) should be replaced as an
assembly.
2. Install the special tool (ST 4145) to the port hole on
casing (18) in order not to lower spool (19) when
the spring is compressed.
j : 6 mm
W3-11-4-5
8. Install retaining ring (8) to the groove on the head IMPORTANT: Fit the bolt hole on plate (14) to the
of spool (21) extending from the special tool (ST screw hole on casing (18).
4146). 16. Apply LOCTITE #262 onto the thread part of
IMPORTANT: Check the position to install pusher (9). universal joint (15). Place plate (14) on casing (18).
Install universal joint (15).
9. Install pusher (9).
After pushing pusher (9) several times by hand, j : 17 mm
remove it. Check if retaining ring (8) comes off or
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
balance spring (3) is located correctly.
IMPORTANT: Check the tightness of cam (16).
Install pusher (9) to casing (18) after checking.
17. Install cam (16) to universal joint (15). The clearance
10. Install other pushers (9, 10) in the same way as step between cam (16) and pushers (9, 10) (2 used for
8 to step 9. each) should be 0 to 0.2 mm.
11. Apply grease onto the ball part at the ends of 18. Secure cam (16) by using a spanner. Tighten screw
pushers (9, 10) (2 used for each). joint (17) by using a spanner.
12. Apply grease onto the joint part of universal joint
j : 19 mm, 30 mm
(15).
13. Apply grease onto the inner surface of oil seals (11) m : 70 N·m (7 kgf·m, 52 lbf·ft)
(4 used).
fNOTE: Sleeve (12) and oil seal (11) should be replaced

as an assembly.
14. Install oil seals (11) (4 used) to sleeves (12) (4 used).
Install O-rings (13) (4 used) to the sleeve (12)
assemblies (4 used). Push the sleeve (12) assemblies
(4 used) by hand until O-ring (13) is inserted into the
hole on casing (18).
15. Secure casing (18) in a vise lightly.
W3-11-4-6
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
WDC390-03-11-002
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 (2 Used)
W3-11-5-1
Disassembly of Travel Pilot Valve

IMPORTANT: Casing (23) is made of aluminium. IMPORTANT: Spool (24) has been selected to match
Strong force deforms it. Handle it with care. the hole of casing (23). Spool (24) and casing (23)
IMPORTANT: Spool (24) has been selected to match should be replaced as an assembly.
the hole on casing (23). IMPORTANT: Put the mark on spools (24) (4 used)
Arrange the disassembled parts together with when keeping in order to easily install spools (24)
each port in order not to confuse. (4 used) to the original hole.
The port number is stamped on the outer surface 5. Remove the spool (24) assembly from casing (23) by
of casing (23). rotating.
1. Remove bolts, washers (1) (2 used). Remove cover Spring guide (17), balance spring (18), shims
(2) from holder (7). (27), and spacer (26) are removed with spool (24)
together.
j : 10 mm
IMPORTANT: The quantity of shims (27) have 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.
l : 8 mm 6. Compress balance spring (18). Remove spring guide
(17), balance spring (18), shims (27), and spacer (26)
3. Remove the pusher (16) assemblies (4 used) from are removed from spool (24).
casing (23).
7. Remove spring (25) from casing (23).
4. Remove pushers (16) (4 used) from bushings (15)
(4 used). Remove oil seals (28) (4 used) and O-rings 8. Remove other spools (24) in the same way as step 5
(14) (4 used) from bushings (15) (4 used) by using a to step 7.
bamboo spatula.
W3-11-5-2
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, hard hat, 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).
with bracket (11) attached unless necessary. The As the holes of spring pins (3, 4) (2 used for each)
hole end of spring pin (10) has been crimped. are crimped, spring pins (3, 4) may feel tight when
removing.
12, 13
11
35
10
a- Crimped Position W176-02-07-019

b- Stand
10. Remove socket bolts (9) (2 used) and spring washers

(8) (2 used). Remove damper (32) and rubber seat
(31) from pin (35). O-ring (34) is removed together.
l : 5 mm
W3-11-5-3

personal injury.
15. Remove pin (35) by using a bar and a hammer. At
the same time, cams (5) (2 used) are removed.
Do not remove bushings (6) (4 used) with holder
(7) attached unless necessary. If removing, tap and
remove bushings (6) (4 used) by using the special
tool (ST 7256).
16. Remove plugs (20) (2 used) from casing (23).
Remove O-rings (19) (2 used) from plugs (20) (2
used).
l : 5 mm
17. Remove plugs (21) (2 used) from casing (23).
Remove O-rings (22) (2 used) from plugs (21) (2
used).
l : 6 mm
W3-11-5-4
Assembly of Travel Pilot Valve
11 32 31 1 2 35 6 12 10 13 7 5 3, 4 30
29
34 15
9
33
8 17
28
18
14
25
27
16
26
24
23
W178-02-11-180
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 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 (2 Used)
fNOTE: As for the parts with mark *, refer to W3-11-5-1.
W3-11-5-5
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), and balance spring  Insert bushings (6) (4 used) into the special tool
(18) into spool (24) in sequence. Install shim (27) as (ST 7256). Tap the special tool (ST 7256) by using a
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.
W3-11-5-6
 Install bushing (6) on the opposite side in the same 12. Install O-ring (33) to pin (35). Apply grease onto
way. O-ring (33). Install pin (35) and cam (5) to holder (7).
6
ST 7256 7
personal injury.
IMPORTANT: Check the direction to install spring
pins (3, 4).
13. Install spring pins (3, 4) to cam (5) by using the
W178-02-11-311
special tool (ST 1237). Secure cam (5) and pin (35).
At this time, the slits (a) of spring pins (3, 4) should
 Install bushing (6) in the near side as illustrated. Stop be positioned 90SDgr away each other. Tap and
tapping when the bushing (6) end is flush with the install spring pins (3, 4) until spring pins (3, 4) come
outside of holder (7). in contact with the stepped part in the hole.
6
7 ST 7256 3 b b
a
b- Slit 4 W178-02-07-050
a- Outside of Holder W178-02-11-312
14. Crimp the hole end (2 places) of cam (5) where

 Install bushing (6) in the near and opposite side as spring pins (3, 4) are inserted by using a punch.
illustrated.
15. Install other cam (5) in the same way as step 12 to
6 step 14.
ST 7256 7
W178-02-11-313
W3-11-5-7
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). W3-11-5-1. Install bracket (11) to pin (35). Fit the
holes to insert spring pins (12, 13).
Check the mark direction and install holder (7).
IMPORTANT: Place a stand under bracket (11) and
l : 8 mm receive a reaction force. If holder (7) bears the
reaction force, strong force acts on pin (35).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
Therefore, pin (35) may be deformed.
17. Install rubber seat (31) to pin (35). 22. Place stand (b) under bracket (11). Install spring pins
IMPORTANT: Check the direction of damper (32). (12, 13) to bracket (11) until they come in contact
The inner surface of damper (32) is edged-shape. with the stepped part by using the special tool (ST
If damper (32) is pried when installing, O-ring (33) 1237). The slits of spring pins (2 used) should be
may be damaged. positioned 90SDgr away each other.
18. Install damper (32) to pin (35) with the lever up.
19. Secure damper (32) and rubber seat (31) to holder a a
(7) with socket bolts (9) (2 used) and spring washers
(8) (2 used).
11 35
l : 5 mm
m : 7 N·m (0.7 kgf·m, 5.2 lbf·ft)

20. Apply grease onto O-ring (34). Push O-ring (34) to b 12, 13
the end of pin (35).
a- Crimped Position W176-02-07-011

b- Stand
W3-11-5-8
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 17
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, 3.7 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).
l : 5 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

Install plugs (21) (2 used) to casing (23).
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-11-5-9
(Blank)
W3-11-5-10
Group 12 Pilot Shut-Off Valve
Removal and Installation of Pilot Shut-Off

Valve
3
2
W178-02-11-026
WDC390-03-12-001

oil. When removing the hose and pipe, receive oils dCAUTION: Remove cover (3) while holding it. Do
with a container in order to avoid spilling oil. not drop cover (3).
IMPORTANT: Cap the open ends in case the hoses 4. Remove bolts, washers (2) (6 used). Remove cover
and pipes have been disconnected. In addition, (3).
j : 17 mm
Removal
machine for inspection and maintenance. (Refer to
W1-6-1.)

(Refer to W1-4-1.)
2. Open door (1).
3. Remove the floor mat.
W3-12-1-1
8
6
2
1 3
5
3
6
4
W178-02-11-181 6 7
W178-02-08-002
5. Remove spring (4). 9. Remove spring pin (5). Remove lever (1).
6. Disconnect hoses (6) (7 used). 10. Remove bolts, washers (2) (2 used). Remove pilot
shut-off valve (3).
j : 19 mm
j : 17 mm
11. Remove the adapters with pilot shut-off valve (3)
j : 17 mm attached if nesessary.
j : 17 mm
W3-12-1-2
8
6
2
3 1
5
3
6
4
6 7 W178-02-11-181
W178-02-08-002
Installation 4. Connect pipes (8) (2used).

1. Install all removed adapters to pilot shut-off valve j : 17 mm
(3).
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
2. Install pilot shut-off valve (3) with bolts, washers (2)
(2 used). 5. Connect hose (7).
j : 17 mm j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

3. Install lever (1) with spring pin (5). 6. Connect hoses (6) (7 used).
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

7. Install spring (4).
W3-12-1-3
3
2
W178-02-11-026
WDC390-03-12-001

1.)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

10. Install the floor mat.
11. Close door (1).
W3-12-1-4
Removal and Installation of 3-Spool Solenoid

Valve Unit
3 1
2 WDC390-03-09-004
5
IMPORTANT: The hose and pipe contain hydraulic oil. 2. Open engine cover (3).
(5).
IMPORTANT: Cap the open ends in case the hoses j : 17 mm

and pipes have been disconnected. In addition, 4. Remove bolts, washers (1) (4 used). Remove cover
attach identification tags onto the connectors, (2).
Removal

(Refer to W1-4-1.)
W3-12-2-1
4 5
5
2 2
3 2
1 WDC390-03-13-001 6 4 WDC390-03-13-002
5. Disconnect connectors (1) (3 used).

j : 17 mm
j : 19 mm
j : 17 mm
9. Remove socket bolts (6) (2 used). Remove 3-spool
solenoid valve unit (5).
l : 8 mm
10. Remove the adapters with 3-spool solenoid valve
unit (5) attached if necessary.
W3-12-2-2
5 4
5
2 2
2 3
6 4 WDC390-03-13-002 1 WDC390-03-13-001

1. Install all removed adapters to 3-spool solenoid j : 17 mm
valve unit (5).
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
2. Install 3-spool solenoid valve unit (5) with socket
bolts (6) (2 used). 5. Connect pipes (2) (4 used).
l : 8 mm j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

3. Connect hoses (3) (3 used). 6. Connect connectors (1) (3 used).
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-12-2-3
3 1
2 WDC390-03-09-004
5

1.)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

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

10. Close engine cover (3).
W3-12-2-4
Removal and Installation of Signal Control

Valve
5 3
7, 8
1
6 2 WDC390-03-09-004 WDC390-03-13-003
IMPORTANT: The hose and pipe contain hydraulic oil. 4. Remove bolts, washers (3) (4 used). Remove cover
When removing the hose and pipe, receive oil with (6).
j : 17 mm
and pipes have been disconnected. In addition, 5. Disconnect connectors (4) (2 used).
6. Disconnect all hoses and pipes.
hoses and install the clips in case the clips which j : 17 mm, 19 mm
7. Remove socket bolts (7) (4 used) and washers (8) (4
used). Remove signal control valve (9).
Removal
l : 8 mm
maintenance. (Refer to W1-6-1.) 8. Remove the adapters with signal control valve (9)
attached if necessary.
(Refer to W1-4-1.)
(2).
j : 17 mm
W3-13-1-1
5 3
7, 8
1
WDC390-03-13-003 4 2 WDC390-03-09-004
Installation 4. Connect connectors (4) (2 used).

1. Install all removed adapters to signal control valve 5. Bleed air from the hydraulic system. (Refer to W1-4-
(9). 1.)
2. Install signal control valve (9) with washers (8) (4 IMPORTANT: Check the hydraulic oil level. Start the
used) and socket bolts (7) (4 used). engine and check for any oil leaks.
l : 8 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
3. Connect all hoses and pipes. m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 19 mm
8. Close engine cover (5).
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-13-1-2
MEMO
MEMO
SECTION 4
UNDERCARRIAGE
CONTENTS
Removal and Installation of Swing Bearing..........W4-1-1-1
Disassembly of Swing Bearing...................................W4-1-2-1
Assembly of Swing Bearing.........................................W4-1-2-4
Removal and Installation of Travel Device.............W4-2-1-1
Disassembly of Travel Device......................................W4-2-2-1
Assembly of Travel Device...........................................W4-2-2-5
Disassembly of 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
Disassembly of Center Joint........................................W4-3-2-1
Assembly of Center Joint.............................................W4-3-2-3
Replacement of Body and Spindle...........................W4-3-2-6
Group 4 Track Adjuster
Removal and Installation of Track Adjuster...........W4-4-1-1
Disassembly of Front Idler...........................................W4-4-2-1
Assembly of Front Idler.................................................W4-4-2-4
Disassembly of Track Adjuster....................................W4-4-3-1
Assembly of Track Adjuster.........................................W4-4-3-5
Group 5 Upper and Lower Rollers
Removal and Installation of Upper Roller..............W4-5-1-1
Removal and Installation of Lower Roller..............W4-5-2-1
Disassembly of Lower Roller.......................................W4-5-3-1
Assembly of Lower Roller.............................................W4-5-3-3
Group 6 Track
Removal and Installation of Track.............................W4-6-1-1
DC390W-4-1
(Blank)
DC390W-4-2
Removal and Installation of Swing Bearing
2 1
4, 5
ST 0050
a 3
a- Matching Mark
1
WDAA-04-01-001 W110-03-01-004
Before removing and installing the swing bearing, the

upperstructure must be removed first. (Refer to W3-3-1.) dCAUTION:
lb)
Swing bearing (1) weight: 220 kg (490
Therefore, the procedure starts on the premise that the
upperstructure has already been removed here. 3. Install the special tools (ST 0050) (3 used) to swing
bearing (1). Attach nylon slings onto the special
Removal tools (ST 0050) (3 used). Hoist swing bearing (1).
Remove swing bearing (1).
1. Put matching marks (a) on inner race (2) of swing
bearing (1) and track frame (3).
2. Remove bolts (4) (36 used) and spring washers (5)
(36 used).
j : 30 mm
W4-1-1-1
2 1
ST 0050
1 W110-03-01-004
d
a
a 3
a- Matching Mark
c
WDAA-04-01-001
e
a
WDC390-04-01-001
a- Position for Grease Fitting

b- Soft Zone Marking Position
c- Position for Plug
d- Front Side
e- Hole Position for Knock Pin
Installation IMPORTANT: If matching marks (a) do not fit, the soft

zone position of the inner race will be dislocated.
1. Clean the mounting surfaces of track frame (3) and
swing bearing (1). 4. Fit matching marks (a) on track frame (3) and inner
race (2) of swing bearing (1).
2. Apply THREEBOND #1102 onto the swing bearing
(1) mounting surface on track frame (3). At this time,
apply THREEBOND #1102 onto the center of swing
bearing (1) mounting bolt holes.
dCAUTION:
lb)
Swing bearing (1) weight: 220 kg (490
3. Install the special tools (ST 0050) (3 used) to swing

bearing (1). Attach nylon slings onto the special
tools (ST 0050) (3 used). Hoist swing bearing (1).
W4-1-1-2
1
4, 5
a b 7
5 mm
WDAA-04-01-001 W175-03-01-002
a- Gera Part of Swing Bearing

b- Grease Level
5. Install swing bearing (1) with spring washers (5) (36

used) and bolts (4) (36 used).
j : 30 mm
m : 500 N·m (50 kgf·m, 370 lbf·ft)

6. After installing swing bearing (1), add grease
(Alvania EP2 or equivalent) to gear part (a) of
the swing bearing. Add grease (Alvania EP2 or
equivalent) to grease bath (6) until pinion (7) of the
swing device is 5 mm (0.2 in) under grease.
fNOTE: Amount of grease: 14±1 L (3.7±0.3 US gal)
W4-1-1-3
(Blank)
W4-1-1-4
Disassembly of Swing Bearing

1 2 3
8 7 6 5
W178-02-11-193
7 8
W178-02-11-194
1- Outer Race 5- Seal 9- Grease Fitting (2 Used)

2- Seal 6- Ball (121 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (121 Used)
W4-1-2-1
Disassembly of Swing Bearing 3. Install bolt (b) to the screw hole (M10, Pitch 1.5
mm) of plug (4). Tap or pull bolt (b) and remove
plug (4) from outer race (1).

personal injury.
1. Grind off the crimped part of pin (3) by using a
1
grinder. Tap the bottom side of pin (3) of plug (4) by
using a bar and a hammer. Remove pin (3) of plug
(4).
3
4
b W178-02-11-196
b- Bolt
W178-02-11-195 dCAUTION: Swing bearing weight: 210 kg (465 lb)

4. Place inner race (7) of the swing bearing on a
wooden block by using the special tools (ST 0050)
(3 used). Hoist outer race (1) horizontally. Hold outer
2. Thread hole (a) of plug (4) by using a tap (M10, Pitch
race (1).
1.5 mm).
WJAA-04-01-002
a- Hole
W4-1-2-2
5. Remove balls (6) (121 used) and supports (8) (121

used) from the plug (4) hole while rotating outer
race (1).
1
2
a 7
6 5
W178-02-11-197
a- Magnet
8
W178-02-11-198
b- Wire
fNOTE: Remove ball (6) by using magnet (a). Use wire (b)
and remove support (8).
6. Remove seals (2, 5) from outer race (1) and inner
race (7) by using a scrapper.
W4-1-2-3
Assembly of Swing Bearing

1 2 3
8 7 6 5
W178-02-11-193
7 8
W178-02-11-194
1- Outer Race 5- Seal 9- Grease Fitting (2 Used)

2- Seal 6- Ball (121 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (121 Used)
W4-1-2-4
Assembly of Swing Bearing
dCAUTION: Swing bearing weight: 210 kg (465 lb) dCAUTION: Metal fragments may fly off when
1. Install special tools (ST 0050) (3 used) to outer race
(1). Attach wire ropes onto special tools (ST 0050) such as goggles, helmets, etc in order to prevent
(3 used). Hoist the swing bearing horizontally. Align personal injury.
outer race (1) and inner race (7) coaxially. 2. Install plug (4) to outer race (1) by using a hammer.
Secure plug (4) to outer race (1) with pin (3).
Apply grease onto balls (6) (121 used) and supports
(8) (121 used). Crimp the head of pin (3) by using a punch.
Install balls (6) (121 used) and supports (8) (121
used) alternately from the plug (4) hole by using a
round bar while turning outer race (1).
3
1
2
6 W178-02-11-201
3. Degrease the groove part for seals (2, 5) completely.

5
W178-02-11-199
Apply THREEBOND #1530D onto seals (2,5). Install
seals (2, 5) to outer race (1) and inner race (7).
4. Add grease (Alvania EP2 or equivalent) to the swing
bearing through grease fittings (9) (2 used). At this
time, add grease while turning outer race (1).
fNOTE: Grease amount: 0.5 L (0.53 US qt)
W178-02-11-200
W4-1-2-5
(Blank)
W4-1-2-6
Removal and Installation of Travel Device
WDAA-04-02-001 WDAA-04-02-002
Before removing the travel device, the tracks should be

removed first. (Refer to W4-6-1.) Therefore, the procedure
starts on the premise that the tracks have already been
removed here.
with a container in order to avoid spilling oils. j : 27 mm
attach identification tags onto the connectors, j : 17 mm
dCAUTION:
lb)
Travel device (5) weight: 330 kg (730
6. Attach nylon slings onto travel device (5). Hoist and

Removal hold travel device (5). Remove bolts (9) (14 used)
and washers (10) (14 used). Hoist and remove travel
1. Set the machine position for inspection and device (5).
j : 30 mm
(Refer to W1-4-1.) 7. Remove the adapters with travel device (5) attached
2. Remove bolts (2) (6 used) and washers (3) (6 used). if necessary.
Remove cover (4). 8. Remove other travel device in the same way as step
1 to step 6.
j : 22 mm
3. Place a container under travel device (5). Disconnect
hoses (6) (2 used).
j : 36 mm
W4-2-1-1
WDAA-04-02-002
Installation
1. Install all removed adapters to travel device (5).
dCAUTION:
lb)
Travel device (5) weight: 330 kg (730
2. Attach nylon slings onto travel device (5). Hoist

travel device (5). Install travel device (5) with
washers (10) (14 used) and bolts (9) (14 used).
j : 30 mm
m : 630 N·m (63 kgf·m, 460 lbf·ft)

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

j : 27 mm
m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
W4-2-1-2
WDAA-04-02-001
6. Connect track (1). (Refer to 4-6-1.)

7. Install other travel device in the same way as step 1
to step 6.
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
9. Install cover (4) with washers (3) (6 used) and bolts
(2) (6 used).
j : 22 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)

10. Install other cover in the same way as step 9.
W4-2-1-3
(Blank)
W4-2-1-4
Disassembly of Travel Device
WDBE-04-02-004
00- Travel Motor 12- Third Stage Carrier 25- Planetary Gear (3 Used) 35- Needle Bearing (3 Used)
02- Floating Seal 13- Planetary Gear (3 Used) 26- Needle Bearing (3 Used) 36- Thrust Plate (6 Used)
03- Roller Bearing (2 Used) 15- Thrust Plate (6 Used) 27- Thrust Plate (6 Used) 37- Pin (3 Used)
04- Drum 16- Pin (3 Used) 28- Pin (3 Used) 38- Spring Pin (3 Used)
05- Sprocket 17- Spring Pin (3 Used) 29- Spring Pin (3 Used) 39- Shaft
06- Bolt (18 Used) 18- Sun Gear 30- Sun Gear 41- Cover
07- Spring Washer (18 Used) 20- Ring Gear 32- First Stage Carrier 42- Stopper
09- Bearing Nut 21- Bolt (20 Used) 33- Spacer 43- Bolt, Washer (16 Used)
10- Knock Pin 23- Second Stage Carrier 34- Planetary Gear (3 Used) 44- Plug (3 Used)
11- Needle Bearing (6 Used) 24- Spacer 48- O-Ring
W4-2-2-1
Disassembly of Travel Device

IMPORTANT: Do not remove stopper (42) unless
dCAUTION: There may be pressure accumulated
inside of the travel device. Loosen the air bleed damage and wear are found.
plug slowly. Release any remaining pressure 4. Remove bolts, washers (43) (16 used). Remove cover
completely. Remove the drain plug and drain gear (41) from ring gear (20).
oil. If the air bleed plug is loosened suddenly, the
plug may be fly out and gear oil may gush out. j : 19 mm
Keep body and face away from plug.
fNOTE: THREEBOND #1215 (or LOCTITE #5020) has been
applied between cover (41) and ring gear (20). For easy
dCAUTION: Travel Device weight: 330 kg (730 lb) removal, insert and tap a chisel between cover (41) and
ring gear (20).
1. Attach a nylon sling onto the body of travel device.
Hoist the travel device. Place the travel device on a 5. Remove shaft (39) and the first stage carrier (32)
workbench with the travel motor (00) side up. Install assembly from second stage carrier (23).
the special tool (ST 5090) to the travel device with
6. Remove sun gear (30) from second stage carrier
(23).
j : 30 mm 7. Remove the second stage carrier (23) assembly from
ring gear (20).
ST 5090
00
W105-03-02-007
dCAUTION: Travel device weight: 330 kg (730 lb)

2. Attach a nylon sling onto the body of travel device.
Hoist the travel device. Place the travel device on a
workbench with the travel motor (00) side down.
fNOTE: Secure the spacer to the workbench tightly in

order to receive a reaction force when disassembling.
3. Remove plugs (44) (3 used).
l : 10 mm
W4-2-2-2
8. Remove sun gear (18) from third stage carrier (12).

dCAUTION: Ring gear (20) + sprocket (05) + drum
d CAUTION: The third stage carrier (12) assembly
(04) weight: 140 kg (310 lb)
IMPORTANT: The travel motor (00) side of drum (04)
9. Attach claws (a) of the special tool (ST 0916) onto is the seal sliding surface for travel motor (00).
the outer surface of third stage carrier (12). Hoist the Place it on a wooden block in order not to damage.
third stage carrier (12) assembly from drum (04). 11. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the bolt, washer (43) holes (2 places) of ring gear
ST 0916
(20). Attach nylon slings onto the eyebolts. Hoist
a
and remove the ring gear (20) assembly from travel
motor (00).
fNOTE: If it is difficult to remove, rotate sprocket (05).

IMPORTANT: Handle floating seal (02) with care.
(Refer to W4-2-5.)
12. Remove one side of floating seal (02) from travel
motor (00).
W178-02-11-203 13. Remove the inner race of roller bearing (03) from
drum (04).
a- Claw
IMPORTANT: Do not remove knock pin (10) unless

necessary.
10. Remove bearing nut (09) from travel motor (00) by
using the special tools (ST 7248, ST 7249).
ST 7248
ST 7249
09
W178-03-02-013
W4-2-2-3
18. Remove O-ring (48) from ring gear (20).

d CAUTION: Sprocket (05) weight: 46 kg (105 lb)
dCAUTION: When removing sprocket (05), dCAUTION: Metal fragments may fly off when
gather up the nylon sling and hoist sprocket (05)
horizontally. Do not drop sprocket (05).
personal injury.
14. Remove bolts (06) (18 used) and spring washers
IMPORTANT: Do not remove roller bearing (03)
(07) (18 used). Attach a nylon sling onto sprocket
unless necessary.
(05). Hoist sprocket (05). Remove sprocket (05) from
drum (04). 19. Remove the outer races of roller bearings (03) (2
used) from drum (04) by using a bar and a hammer.
j : 30 mm
20. Remove spring pins (38) (3 used) from first stage
fNOTE: LOCTITE #262 (or THREEBOND #1386) has been carrier (32) by using the special tool (ST 1391).
applied on bolt (06). 21. Remove pins (37) (3 used), thrust plates (36) (6
d CAUTION: Ring gear (20) + drum (04) weight: 89
kg (200 lb)
used), planetary gears (34) (3 used), needle bearings
(35) (3 used), and spacer (33) from first stage carrier
(32).
bolt (06) holes (2 used) on drum (04). Attach nylon 22. Remove spring pins (29) (3 used) from second stage
slings onto the eyebolts. Hoist the ring gear (20) carrier (23) by using the special tool (ST 1391).
assembly. Place the ring gear (20) assembly with the
23. Remove pins (28) (3 used), thrust plates (27) (6
drum (04) side up.
used), planetary gears (25) (3 used), needle bearings
IMPORTANT: Handle floating seal (02) with care. (26) (3 used), and spacer (24) from second stage
(Refer to W4-2-5.) carrier (23).
16. Remove one side of floating seal (02) from drum 24. Remove spring pins (17) (3 used) from third stage
(04). carrier (12) by using the special tool (ST 1463).
dCAUTION: Drum (04) weight: 40 kg (89 lb) 25. Remove pins (16) (3 used), thrust plates (15) (6
used), planetary gears (13) (3 used), and needle
bolt (06) holes (2 places) on drum (04). Attach nylon bearings (11) (6 used) from third stage carrier (12).
slings onto the eyebolts. Hoist and hold drum (04).
Remove bolts (21) (20 used). Remove drum (04)
from ring gear (20).
j : 24 mm
W4-2-2-4
Assembly of Travel Device
21 04 48
09 10 12 18 20 24 23 30 33 32
44
41
39
42
34
36
35
37
38
02 03 03 43
00
13 11 16 15 17 25 26 28 27 29
05 07 06
WDBE-04-02-001
00- Travel Motor 12- Third Stage Carrier 25- Planetary Gear (3 Used) 35- Needle Bearing (3 Used)
02- Floating Seal 13- Planetary Gear (3 Used) 26- Needle Bearing (3 Used) 36- Thrust Plate (6 Used)
03- Roller Bearing (2 Used) 15- Thrust Plate (6 Used) 27- Thrust Plate (6 Used) 37- Pin (3 Used)
04- Drum 16- Pin (3 Used) 28- Pin (3 Used) 38- Spring Pin (3 Used)
05- Sprocket 17- Spring Pin (3 Used) 29- Spring Pin (3 Used) 39- Shaft
06- Bolt (18 Used) 18- Sun Gear 30- Sun Gear 41- Cover
07- Spring Washer (18 Used) 20- Ring Gear 32- First Stage Carrier 42- Stopper
09- Bearing Nut 21- Bolt (20 Used) 33- Spacer 43- Bolt, Washer (16 Used)
10- Knock Pin 23- Second Stage Carrier 34- Planetary Gear (3 Used) 44- Plug (3 Used)
11- Needle Bearing (6 Used) 24- Spacer 48- O-Ring
W4-2-2-5
Assembly of Travel Device

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Handle floating seal (02) with care.
onto parts in order to prevent them from seizing. (Refer to W4-2-5.)
2. Apply gear oil onto O-ring of one side of floating
seal (02). Install one side of floating seal (02) to
travel motor (00). Apply gear oil onto the whole
sliding surface on floating seal (02).
personal injury. fNOTE: If it is difficult to install O-ring of floating seal
d CAUTION: Be careful as roller bearing (03) is too
hot.
(02), push O-ring to the periphery direction by using a
bamboo spatula.
IMPORTANT: When roller bearing (03) has been
removed, follow the procedure as steps 1, 3, 5, and
12. such as goggles, helmets, etc in order to prevent
1. Warm up the inner race of roller bearing (03) of the personal injury.
travel motor (00) side to 50 to 70 °C (122 to 158 IMPORTANT: Do not tap except for the outer race of
°F) by using a heater. Install the inner race of roller roller bearing (03).
bearing (03) of the travel motor (00) side to travel 3. Install the outer race of roller bearing (03) of the
motor (00). After roller bearing (03) of the travel cover (41) side to drum (04) by using a bar and a
motor (00) side cools, install roller bearing (03) of hammer.
the travel motor (00) side to travel motor (00) by
using a bar and a hammer. fNOTE: Check that the outer race of roller bearing (03)
on the cover (41) side is installed completely.
fNOTE: Check that the inner race of roller bearing (03)
on the travel motor side is installed completely.
03
04
03
WDBE-04-02-002
00
WDBE-04-02-002
W4-2-2-6

d CAUTION: Drum (04) weight: 40 kg (89 lb) bolt (06) (2 places) holes on drum (04). Attach nylon
4. Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the slings onto the eyebolts. Hoist drum (04) assembly.
bolt (06) holes (2 places) on drum (04). Attach nylon Place drum (04) assembly with the travel motor (00)
slings onto the eyebolts. Hoist drum (04). Place side down.
drum (04) with the ring gear (20) side down.
dCAUTION: Sprocket (05) weight: 46 kg (105 lb)
a hammer is used. Wear necessary protection, dCAUTION: When installing sprocket (05),
gather up the nylon sling and hoist sprocket (05)
horizontally. Do not drop sprocket (05).
personal injury.
IMPORTANT: Fit the chamfered side of sprocket (05)
IMPORTANT: Do not tap except for the outer race of
to the drum (04) side.
roller bearing (03).
7. Attach a nylon sling onto sprocket (05). Hoist
5. Install the outer race of roller bearing (03) of the
sprocket (05). Place sprocket (05) onto drum (04).
travel motor (00) side to drum (04) by using a bar
and a hammer. 8. Degrease the bolt (06) holes on drum (04) and bolts
(06) (18 used). Apply LOCTITE #262 or THREEBOND
fNOTE: Check that the outer race of roller bearing (03) #1386B onto bolts (06) (18 used). Install sprocket
on the travel motor (00) side is installed completely. (05) to drum (04) with spring washers (07) (18 used)
00
04 03 j : 30 mm
m : 485 N·m (48.5 kgf·m, 360 lbf·ft)
WDBE-04-02-003
W4-2-2-7
dCAUTION: Ring gear (20) weight: 49 kg (110 lb) dCAUTION: Ring gear (20) + sprocket (05) + drum
(04) weight: 140 kg (310 lb)
bolt (21) holes (2 places) on ring gear (20). Attach IMPORTANT: The travel motor (00) side of drum (04)
nylon slings onto the eyebolts. Hoist ring gear (20). is the seal sliding surface for travel motor (00).
Place ring gear (20) with the cover (41) side down. Place it on a wooden block in order not to damage.
10. Install O-ring (48) to ring gear (20). 14. Attach nylon slings onto the ring gear (20)
assembly. Hoist the ring gear (20) assembly. Place
dCAUTION:
kg (190 lb)
Sprocket (05) + drum (04) weight: 86 the ring gear (20) assembly with the cover (41) side
up.
11. Attach nylon slings onto the sprocket (05) assembly.
Hoist the sprocket (05) assembly. Place the sprocket dCAUTION: Ring gear (20) + sprocket (05) + drum
(04) weight: 140 kg (310 lb)
(05) assembly onto ring gear (20).
15. Install eyebolts (M12, Pitch 1.75 mm) to the bolt,
12. Apply LOCTITE #262 or THREEBOND #1386B washer (43) hole (2 places) of ring gear (20). Attach
onto bolts (21) (20 used). Install the sprocket (05) nylon slings onto the eyebolts. Hoist the ring gear
assembly to ring gear (20) with bolts (21) (20 used). (20) assembly. Place the ring gear (20) assembly
straight on travel motor (00). At this time, check that
j : 24 mm
the clearance between travel motor (00) and drum
m : 270 N·m (27 kgf·m, 200lbf·ft) (04) is even all around.
IMPORTANT: Handle floating seal (02) with care. 16. Push the ring gear (20) assembly into travel motor
(Refer to W4-2-5.) (00) straight by shaking.
13. Apply gear oil onto O-ring of other side of floating
seal (02). Install one side of floating seal (02) to
drum (04).
fNOTE: If it is difficult to install O-ring of floating seal

(02), push O-ring to the periphery direction by using a
bamboo spatula.
W4-2-2-8
IMPORTANT: Check the direction to install bearing

nut (09).
18. Apply grease onto the thread part of bearing nut
(09). Install bearing nut (09) to travel motor (00) with
personal injury.
the machining surface facing to roller bearing (03)
dCAUTION:
hot.
Be careful as roller bearing (03) is too on the cover (41) side. Tighten bearing nut (09) by
hand.
17. Warm up the inner race of roller bearing (03) of 19. Install bearing nut (09) by using special tools (ST
the cover (41) side to 50 to 70 °C (122 to 158 °F) by 7248, ST 7249) and a torque wrench.
using a heater. Install the inner race of roller bearing
(03) of the cover (41) side to travel motor (00). After m : 500 N·m (50 kgf·m, 370 lbf·ft)
roller bearing (03) of the cover (00) side cools, install
roller bearing (03) of the cover (00) side to travel
motor (00) by using a bar and a hammer.
ST 7248
fNOTE: Install roller bearing (03) until the inner race side
of roller bearing (03) reaches three threads for bearing
ST 7249
nut (09).
fNOTE: Check that the inner race of roller bearing (03)
on the cover (41) side is installed completely. 09
00
03 W178-03-02-013
20. After installing bearing nut (09), tap the sprocket

(05) end by using a plastic hammer and reduce
a play. Rotate sprocket (05) both clockwise and
counterclockwise 4 to 5 turns.
21. Repeat steps 19, 20.
22. Tighten bearing nut in the same way as step 19.
WDBE-04-02-003 m : 500 N·m (50 kgf·m, 370 lbf·ft)
W4-2-2-9
IMPORTANT: When knock pin (10) has been 28. Install other planetary gears (13) (2 used) to third
removed, follow the procedure as step 23. stage carrier (12) in the same way as steps 19 to 22.
23. Fit the phases of the spline center in travel motor
(00) and the knock pin (10) center. If the center dCAUTION: The third stage carrier (12) assembly
phases are not fitted, rotate bearing nut (09) in
tightening direction until both center phases are
fitted.
dCAUTION: Third stage carrier (12) falls at the
moment when knock pin (10) is inserted into third
stage carrier (12). Do not catch fingers.
09 10
29. Attach claws (a) of the special tool (ST 0916) onto
the outer surface of third stage carrier (12). Hoist
00 the third stage carrier (12) assembly. Install the third
stage carrier (12) assembly to the spline in travel
motor (00).
ST 0916
W178-02-11-208
a
IMPORTANT: There is an identification groove on

one side of planetary gear (13). Install planetary
gear (13) with the identification groove side facing
to the spring pin (17) hole.
24. Install needle bearings (11) (2 used) to planetary
gear (13).
W178-02-11-203
25. Secure planetary gear (13) between thrust plates a- Claw
(15) (2 used). Install them to third stage carrier (12).
26. Install pin (16) to third stage carrier (12). At this time,
fit the spring pin (17) hole of third stage carrier (12)
and the pin (16) hole.
27. Install spring pin (17) to third stage carrier (12) with
the slit (b) side facing to the second stage carrier
(23) side.
17
16
b
W178-02-11-210
b- Slit
W4-2-2-10
30. Install sun gear (18) to third stage carrier (12) with 37. Install the second stage carrier (23) assembly to ring
the thinner diameter part up. gear (20).
31. Install spacer (24) to second stage carrier (23). 38. Install sun gear (30) to second stage carrier (23) with
the thinner diameter part up.
32. Install needle bearing (26) to planetary gear (25).
39. Install spacer (33) to first stage carrier (32).
33. Secure planetary gear (25) between thrust plates
(27) (2 used). Install them to second stage carrier 40. Install needle bearing (35) to planetary gear (34).
(23).
41. Secure planetary gear (34) between thrust plates
34. Install pin (28) to second stage carrier (23). At this (36) (2 used). Install them to first stage carrier (32).
time, fit the spring pin (29) hole of second stage
42. Install pin (37) to first stage carrier (32). At this time,
carrier (23) and the pin (28) hole.
fit the spring pin (38) hole of first stage carrier (32)
35. Install spring pin (29) to second stage carrier (23) and the pin (37) hole.
with the slit (a) side facing to the cover (41) side.
43. Install spring pin (38) to first stage carrier (32) with
29 the slit (b) side facing to the cover (41) side.
28
a
38
37
b
W178-02-11-210
a- Slit
W178-02-11-210
36. Install other planetary gears (25) (2 used) to second b- Slit
stage carrier (23) in the same way as steps 32 to 35.
44. Install other planetary gears (34) (2 used) to first
stage carrier (32) in the same way as steps 40 to 43.
W4-2-2-11
45. Insert the spline side of shaft (39) into the center of
sun gear (30). Rotate sprocket (05) slowly by hand.
Engage travel motor (00) and planetary gear (34)
with shaft (39), and install them.
46. Install the first stage carrier (32) assembly to ring
gear (20).
47. Fill ring gear (20) with gear oil (SAE#90(GL-4)).
fNOTE: Oil amount 6.8 L (1.8 US gal)

48. Clean the mating surfaces of ring gear (20) and
cover (41), and apply THREEBOND #1215 or LOCTITE
#5020. Install cover (41) to ring gear (20) with bolts,
j : 19 mm
m : 110 N·m (11 kgf·m, 81 lbf·ft)

49. Install a seal tape onto plugs (44) (3 used). Install
plugs (44) (3 used) to cover (41).
l : 10 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W4-2-2-12
Disassembly of Brake Valve
WDAA-04-02-009
01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug

01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring
01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug
02- Stopper (2 Used) 10- Spring (2 Used) 16- Spring 22A- O-Ring
03- Spring (2 Used)
W4-2-4-1
Disassembly of Brake Valve IMPORTANT: As the setting changes, do not

disassemble relief valve (15).
1. Remove plugs (05) (2 used) from casing (01A).
Remove O-rings (07) (2 used) from plugs (05) (2 IMPORTANT: Do not move piston (a) with the outer
used). surface of relief valve (15) attached. O-ring may be
damaged.
j : 36 mm 7. Remove relief valves (15) (2 used) from casing (01A).
2. Remove springs (03) (2 used) and stoppers (02) (2
j : 36 mm
used) from casing (01A) by using a magnet.
15
3. Remove spool (01B) from casing (01A) by using a
magnet.
IMPORTANT: Do not remove plug (22) unless
necessary.
4. Remove plug (22) from casing (01A). Remove O-ring
(22A) from plug (22).
l : 6 mm
a
5. Remove seat (13) from casing (01A).
W1V1-03-02-008
a- Piston
l : 5 mm
6. Remove ball (11) by using a magnet.
8. Remove springs (10) (2 used) and poppet (08) (2
used) from casing (01A) by using a magnet.
9. Remove plug (17) from casing (01A). Remove O-ring
(17A) from plug (17).
l : 6 mm
10. Remove spring (16) and spool (01C) from casing
(01A) by using a magnet.
W4-2-4-2
Assembly of Brake Valve
01B 01A
02
03
07
05
05
22
01C
16
22A 17A 17
08
10
15 11 13 15
WDAA-04-02-010
01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug

01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring
01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug
02- Stopper (2 Used) 10- Spring (2 Used) 16- Spring 22A- O-Ring
03- Spring (2 Used)
W4-2-4-3
Assembly of Brake Valve 8. Install springs (10) (2 used) to poppets (08) (2 used).
Install poppets (08) (2 used) to the hole of casing
(01A) completely.
9. Install relief valves (15) (2 used) to casing (01A)
1. Install spool (01B) into the center of casing (01A). while pushing poppets (2) (2 used).
2. Install O-ring (07), spring (03) and stopper (02) to j : 36 mm

plug (05). Install the plug (05) assembly to casing
(01A) with one thread tighten. m : 450 N·m (45 kgf·m, 330 lbf·ft)
IMPORTANT: Check the direction to install spool
fNOTE: If plug (05) is fully tightened, it is difficult to
(01C).
install other plug (05) as spool (01B) is pushed.
10. Install spool (01C) to casing (01A) with the hole side
3. Install O-ring (07), spring (03) and stopper (02) to
facing the near side.
other plug (05). Install the plug (05) assembly to
casing (01A) and tighten by hand. 11. Install spring (16) to casing (01A).
4. Tighten plugs (05) (2 used). 12. Install O-ring (17A) to plug (17). Install plug (17) to
casing (01A).
j : 36 mm
l : 6 mm
m : 450 N·m (45 kgf·m, 330 lbf·ft)
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
5. Install ball (11) to casing (01A).
6. Install seat (13) to casing (01A).
l : 5 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

7. Install O-ring (22A) to plug (22). Install plug (22) to
casing (01A).
l : 6 mm
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
W4-2-4-4

these procedures:
ring (1) surfaces together. Apply oil onto sliding W178-02-11-001
surface (e) of seal ring (1). 2
hardening.

trouble.
 Clean the floating seal and seal mounting bores with a
cleaning solvent.
Check the bore surface for scuffing or scoring by d
 After installing the floating seal, check that O-ring (2) W178-02-11-002
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
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

W4-2-5-1
(Blank)
W4-2-5-2
12 1 6
9 8 10
2
4, 14
3, 13
2 11 5
W178-02-11-237 W178-02-11-238
IMPORTANT: The hose and pipe contain hydraulic 7. Disconnect hoses (5) (2 used).
with a container in order to avoid spilling oils. j : 27 mm
IMPORTANT: Cap the open ends in case the hoses 8. Disconnect hoses (6) (4 used).
attach identification tags onto the connectors, j : 36 mm
hoses, and pipes for assembling. Connect the 9. Disconnect hoses (7) (2 used).
secure the hoses have been removed. j : 17 mm
Removal used). Remove stopper (10).
1. Set the machine position for inspection and j : 22 mm
11. Remove rubber (11).
d CAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.) dCAUTION: Center joint (1) weight: 27 kg (60 lb)
2. Disconnect hoses (2) (4 used). 12. Install eyebolts (M14, Pitch 2.0 mm) to the bolt (8)
holes (2 places) of center joint (1). Attach nylon
j : 36 mm slings onto eyebolts. Hoist and hold center joint (1).
3. Disconnect hose (3). 13. Remove bolts, washers (12) (4 used). Remove center
joint (1).
j : 27 mm
4. Remove adapter (13). j : 19 mm
14. Remove the adapters with center joint (1) attached
j : 22 mm if necessary.
j : 17 mm
6. Remove adapter (14).
j : 19 mm
W4-3-1-1
12 1 6
9 8 10
2
4, 14
3, 13
5 2 11
W178-02-11-238 W178-02-11-237

1. Install all removed adapters which have been j : 36 mm
removed in step 14 when removing to center joint
(1) . m : 180 N·m (18 kgf·m, 133 lbf·ft)
dCAUTION: Center joint (1) weight: 27 kg (60 lb)
2. Install eyebolts (M14, Pitch 2.0 mm) to the bolt (8) j : 27 mm
holes (2 places) of center joint (1). Attach nylon
slings onto eyebolts. Hoist center joint (1). m : 95 N·m (9.5 kgf·m, 70 lbf·ft)
3. Install center joint (1) with bolts, washers (12) (4 9. Install adapter (14).
used).
j : 19 mm
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft) 10. Connect hose (4).
4. Install rubber (11).
j : 17 mm
5. Install stopper (10) with spring washers (9) (2 used)
and bolts (8) (2 used). m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
j : 22 mm 11. Install adapter (13).
m : 140 N·m (14 kgf·m, 103 lbf·ft) j : 22 mm
6. Connect hoses (7) (2 used). m : 70 N·m (7 kgf·m, 52 lbf·ft)
j : 17 mm 12. Connect hose (3).
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)

j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)

1.)
W4-3-1-2
Disassembly of Center Joint
WDAA-04-03-003
00A- Spindle 03- O-Ring 06- Ring 09- Cover

00B- Plug (with Ball Attached) 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body 05- Bushing 08- O-Ring
02- Dust Seal
W4-3-2-1
Disassembly of Center Joint

IMPORTANT: For easy removal of oil seal (04), use the
d CAUTION: Center joint weight: 27 kg (60 lb) pins (2 used). Do not damage the seal groove.
1. Remove bolts, washers (10) (2 used) diagonally. 6. Remove oil seals (04) (6 used), O-ring (03), and dust
Install an eyebolt (M10, Pitch 1.5 mm) to the bolt seal (02) from body (01).
(10) hole (2 places) of body (01). Attach a nylon sling
onto an eyebolt. Hoist the center joint. Secure the
center joint on a workbench.
j : 17 mm
2. Put the matching marks on body (01) and spindle
(00A). Remove other bolts, washers (10) (2 used).
Remove cover (09) from body (01).
j : 17 mm
3. Remove O-ring (08), retaining ring (07), and ring (06)
from body (01).
4. Install the special tools (ST 1033, ST 1020) to body
(01) with bolts, washers (10) (2 used).
W178-02-11-240
j : 17 mm
IMPORTANT: Do not damage the seal groove.
7. When replacing bushing (05), weld four places on
10 the bushing (05) bore by using a welding bar. Shrink
and remove bushing (05).
01
W506-03-03-002
IMPORTANT: Do not damage the seal sliding surface

of spindle (00A).
5. Remove spindle (00A) from body (01).
W4-3-2-2
Assembly of Center Joint
00B
00A
02
03
05
04
01
06
07
08
09
10
W178-03-03-001
00A- Spindle 03- O-Ring 06- Ring 09- Cover

00B- Plug (with Ball Attached) 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body 05- Bushing 08- O-Ring
02- Dust Seal
W4-3-2-3
Assembly of Center Joint

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not damage bushing (05).
onto parts in order to prevent them from seizing. IMPORTANT: The clearance between body (01) and
IMPORTANT: When assembling the seals, apply spindle (00A) is approximately 0.1 mm. Insert
grease (Apolloil Autorex C) and install seals to body (01) along axis straight and slowly. Do not
each groove. damage the seal.
IMPORTANT: If bushing (05) has been removed, IMPORTANT: Do not make a step on ring (06)
install bushing (05) first. (Refer to W4-3-2-6.) mounting part (b).
1. Install dust seal (02) to spindle (00A) with lip part (a) 3. Place spindle (00A) on a workbench. Fit the
of dust seal (02) facing to body (01) side. matching marks made when disassembling and
install body (01) to spindle (00A).
02 b 00A
01
01
W178-03-03-002
a- Lip Part W800-03-03-002
b- Ring (06) Mounting Part
2. Install O-ring (03) and oil seals (04) (6 used) to body

(01).
W4-3-2-4
IMPORTANT: Install ring (06) with the chamfered

side facing to the spindle (00A) side.
4. Install ring (06) and O-ring (08) to body (01).
00A
01
06
08
WDAA-04-03-004
5. Install retaining ring (07) to spindle (00A).

6. Install cover (09) to body (01) with bolts, washers
(10) (4 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W4-3-2-5
Replacement of Body and Spindle

ST 2558
IMPORTANT: When replacing body (01) or spindle
(00A) with the new one, the following procedures
are required. 01
In case of Body (01)

1. Clean body (01) and bushing (05).
05
2. Install bushing (05) to body (01) by using the special
tool (ST 2558) and a press.
fNOTE: Pushing force: 0.5 to 1.5 t (1110 to 3310 lb)
W178-02-11-242
In case of spindle (00A)
00B C
1. Clean spindle (00A).
00A
2. Install plug (00B) to spindle (00A) by using the
special tool (ST 2559).
3. Install ball (a) of plug (00B) so that the top of each
ball is 0.4 mm (0.02 in) or more lower than the
respective sleeve (c) edge as illustrated in detail C.
WDAA-04-03-005
ST 2559 Detail C
b
c
WDAA-04-03-006 WDAA-04-03-007
a- Ball b- 0.4 mm (0.02 in) or more

c- Sleeve
W4-3-2-6
Removal and Installation of Track Adjuster
c a 1
ST 1650
7 2
WDCD-04-04-002
a- Hoisting Position
c- Hoisting Position
Before removing and installing the track adjuster, the 3. Attach a weight onto part (b) of the special tool
tracks must be removed first. (Refer to W4-6-1.) (ST 1650). Set the track adjuster (7) assembly
Therefore, the procedure starts on the premise that the horizontally.
tracks have already been removed here.
4. Pull out the track adjuster (7) assembly until nylon
slings can be attached onto hoisting position (c) of
Removal
track adjuster (7).
dCAUTION:
(120 lb)
Special tool (ST 1650) weight: 53 kg 5. Attach nylon slings onto hoisting position (c) of
track adjuster (7). Hoist and hold the track adjuster
1. Install the special tool (ST 1650) to the yoke (2) part (7) assembly.
of front idler (1).
6. Remove the special tool (ST 1650) from the yoke (2)
dCAUTION: The track adjuster (7) assembly
part of front idler (1). Remove the track adjuster (7)
assembly.
2. Attach a vise onto hoisting position (a) of front idler
(1). Hoist and hold the track adjuster (7) assembly.
W4-4-1-1
7 3, 4
a 5, 6 a
WDCD-04-04-004 WDCD-04-04-003
a- Block
6. Place track adjuster (7) onto blocks (a) (4 used).

j : 24 mm

8. Turn over the track adjuster (7) assembly.
dCAUTION:
adjuster (7).
Take care not to turn over track
dCAUTION: Front idler (1) weight: 110 kg (245 lb)

Remove front idler (1).
j : 24 mm
W4-4-1-2
7 5, 6
a 3, 4 a
WDCD-04-04-004 WDCD-04-04-003
a- Block
Installation 4. Install washers (4) (2 used) and bolts (3) (2 used).
dCAUTION:
adjuster (7).
Take care not to turn over track j : 24 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft)

dCAUTION: Front idler (1) weight: 110 kg (245 lb)
Track adjuster (7) weight: 140 kg (310 lb)
1. Place track adjuster (7) and front idler (1) onto
blocks (a) (4 used) with the bolt (5) hole side up.
2. Install front idler (1) with washers (6) (2 used) and
bolts (5) (2 used).
j : 24 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft)

3. Turn over the track adjuster (7) assembly.
W4-4-1-3
c a 1
ST 1650
7 2
WDCD-04-04-002
a- Hoisting Position
c- Hoisting Position

dCAUTION: The track adjuster (7) assembly +
Special tool (ST 1650) weight: 310 kg (685 lb)
5. Attach nylon slings onto hoisting position (c) 9. Hoist and hold the track adjuster (7) assembly.
of track adjuster (7). Attach a vise onto hoisting Attach a weight onto part (b) of the special tool
position (a) of front idler (1). Hoist the track adjuster (ST 1650). Set the track adjuster (7) assembly
(7) assembly. horizontally.
6. Install the track adjuster (7) assembly to the track 10. Install the track adjuster (7) assembly to the track
frame until it reaches where nylon slings can be frame.
removed.
7. Remove nylon slings.
dCAUTION:
(120 lb)
Special tool (ST 1650) weight: 53 kg
8. Install the special tool (ST 1650) to the yoke (2) part
of front idler (1).
W4-4-1-4
Disassembly of Front Idler
WDCD-04-04-006
00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used)
01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used)
W4-4-2-1
Disassembly of Front Idler

IMPORTANT: Handle floating seals with care. (Refer
dCAUTION:
kg (245 lb)
The idler (03A) assembly weight: 110
to W4-4-4.)
1. Place the idler (03A) assembly horizontally. Remove 4. Remove bearing (00) from the upper side of idler
plug (06) from bearing (00) at the lower side. Drain (03A). Remove floating seals (05) (2 used) from idler
off engine oil from the idler (03A) assembly. Remove (03A) and bearing (00).
plug (06) from bearing (00) at the upper side.
l : 6 mm
fNOTE: Oil amount: 0.27 L (0.29 US qt)

a hammer is used. Wear necessary protection, 00
such as goggles, helmets, etc in order to prevent 05
personal injury.
2. Remove pin (04) from bearing (00) on the upper
03A
side by using a round bar and a hammer.
fNOTE: Diameter of round bar: 16 mm

05
dCAUTION:
(56 lb)
The axle (01) assembly weight: 25 kg
02
3. Put the matching marks on bearing (00) and axle
(01). Remove the axle (01) assembly from the idler
(03A) assembly by using a press. 01
00
00 01
W105-03-05-009
03A
W105-03-05-008
W4-4-2-2
dCAUTION:
(56 lb)
The axle (01) assembly weight: 25 kg dCAUTION: Idler (03A) weight: 70 kg (155 lb)
IMPORTANT: Do not remove bushing (03B) unless
IMPORTANT: Place wooden blocks under bearing necessary.
(00) in order not to damage bearing (00). 9. When replacing bushing (03B), remove it by the
5. Attach nylon slings onto the axle (01) assembly. special tool (ST 1425) and a press.
Hoist the axle (01) assembly. Place the bearing (00)
part of the axle (01) assembly onto wooden blocks.

personal injury.
6. Remove pin (04) by using a bar and a hammer.
03A ST 1425
fNOTE: Diameter of round bar: 16 mm
7. Put the matching marks on bearing (00) and axle
(01). Remove axle (01) from bearing (00) by using a
press.
8. Remove O-rings (02) (2 used) from axle (01).
03B
W105-03-05-011
04 02
00
a
01
02
W105-03-05-010
a- Wooden Block
W4-4-2-3
Assembly of Front Idler
03A
03B 04 00
06
01 05 02
WDCD-04-04-005
00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used)
01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used)
W4-4-2-4
Assembly of Front Idler

dCAUTION: Idler (03A) weight: 70 kg (155 lb)
(Refer to W4-4-4.)
1. Install bushings (03B) (2 used) to idler (03A).
5. Apply engine oil onto the O-ring of floating seal
2. Place axle (01) vertically. Install O-ring (02) to the (05). Install floating seal (05) to idler (03A) and
upper side of axle (01). bearing (00).
3. Fit the matching marks on axle (01) and bearing
(00). Evenly tap and install bearing (00) to axle (01) dCAUTION:
(56 lb)
The axle (01) assembly weight: 25 kg
by using a plastic hammer.
6. Attach nylon slings onto bearing (00) of the axle (01)
assembly. Hoist the axle (01) assembly. Install the
axle (01) assembly to idler (03A) on the side where
such as goggles, helmets, etc in order to prevent floating seal (05) has already been installed.
personal injury.
4. Install pin (04) by using a bar and a hammer.
05 00
04
01
00
01
03A
W157-03-05-006
02
W105-03-05-014 7. Install a seal tape onto the thread part of plug (06).
Install to bearing (00).
l : 6 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
W4-4-2-5
dCAUTION:
kg (210 lb)
The idler (03A) assembly weight: 95 dCAUTION: Metal fragments may fly off when
8. Attach nylon slings onto the idler (03A) assembly. such as goggles, helmets, etc in order to prevent
Hoist the idler (03A) assembly. Turn over the idler personal injury.
(03A) assembly. 12. Install pin (04) by using a bar and a hammer.
9. Install O-ring (02) to axle (01). 13. Add engine oil (API CD class, SAE #30) through the
plug (06) hole of bearing (00).
(Refer to W4-4-4.) fNOTE: Oil amount: 0.27 L (0.29 US qt)
10. Apply engine oil onto the O-ring of floating seal 14. Install a seal tape onto the thread part of plug (06).
(05). Install floating seal (05) to idler (03A) and Install plug (06) to bearing (00).
bearing (00).
l : 6 mm
00 05 02 03A m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
00
01
W157-03-05-005
11. Fit the matching marks on axle (01) and bearing

(00). Evenly tap and install bearing (00) to axle (01)
by using a plastic hammer.
W4-4-2-6
Disassembly of Track Adjuster
WDCD-04-04-007
00A- Cylinder 03- Yoke 08- Bracket 15- Valve

00B- Rod 04- Seal 09- Bolt 16- Bracket
01- Spacer 05- Dust Seal 10- Washer
02- Spring 07- Nut 14- Piston Rod
W4-4-3-1
Disassembly of Track Adjuster

dCAUTION:
(71 lb)
dCAUTION: The spring force is extremely large.

Carry out the disassembly and assembly work
5. Remove nuts (d) (4 used) from the special tool (ST
4950). Attach nylon slings onto the eyebolts (2
carefully. In addition, inspect the special tool for used) of the special tool (ST 4052). Hoist the special
any damage thoroughly in order to perform the tool (ST4052). Remove the special tool (ST 4052).
work safely.
1. Remove bolt (09) and washer (10) from bracket (16). j : 46 mm
j : 17 mm
2. Remove valve (15) and bracket (16) from piston rod
(14).
j : 24 mm
ST 4052
3. Remove piston rod (14) from cylinder (00A).
dCAUTION: Check the surfaces of the special tool

(ST 4953). Check the direction to install.
4. Place an oil jack (30 tons) between holder (a) and
base (b) of the special tool (ST 4950).
d
WDCD-04-04-010
dCAUTION:
kg (265 lb)
The spring (02) assembly weight: 120
ST 4953 6. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and

a nuts (2 used) to the bolt holes (2 places) of yoke (03)
diagonally. Attach nylon slings onto the eyebolts.
Hoist the spring (02) assembly.
c
7. Place the spring (02) assembly on holder (a) of the
special tool (ST 4950).
b
WDCD-04-04-009
a- Holder c- Oil Jack

b- Base d- Nut
W4-4-3-2
8. Install the special tool (ST 4052) in order to cover 11. Remove nut (07) from rod (00B).
the spring (02) assembly. Install washers (J222016)
(4 used) and bolts (J921650) (4 used) to the bolt j : 75 mm
holes (4 places) of yoke (03). Secure the special tool 12. Lower the oil jack slowly.
(ST 4052) and the spring (02) assembly with them.
13. Remove nuts (a) (4 used) of the special tool (ST
j : 24 mm 4950).
j : 46 mm
a
J921650,
J222016
dCAUTION:
(71 lb)
14. Attach nylon slings onto the eyebolts (2 used) of

the special tool (ST 4052). Hoist and hold the special
tool (ST4052). Remove bolts (J921650) (4 used) and
washers (J222016) (4 used). Remove the special tool
(ST4052).
ST 4052
WDCD-04-04-013
a- Nut
dCAUTION: As spring (02) is compressed, a strong

force is applied. Check if the spring (02) assembly
is installed correctly with compressing spring (02)
by using the oil jack.
9. Tighten nuts (a) (4 used) of the special tool (ST 4950)
and secure the spring (02) assembly. Operate the oil WDCD-04-04-012
jack. Compress spring (02) to the position where nut
(07) is loose.
fNOTE: Spring (02) compressed length:

Spring free length (560 mm (22 in)) - Spring set length
(460 mm (18.1 in)) = Spring compressed length (100 mm
(3.94 in))
10. Remove bolt (09) and washer (10) from bracket (08).
Remove bracket (08) from nut (07).
j : 17 mm
W4-4-3-3
dCAUTION: Yoke (03) weight: 21 kg (47 lb)

15. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and
nuts (2 used) to the bolt holes (2 places) of yoke (03)
Hoist yoke (03).
16. Remove yoke (03) from the spring (02) assembly.
dCAUTION:
kg (205 lb)
17. Install eyebolts (M10, Pitch 1.5 mm) to rod (00B).

Attach nylon slings onto the eyebolts. Hoist the
spring (02) assembly.
18. Remove the spring (02) assembly from the special
tool (ST 4950).
dCAUTION: Spring (02) weight: 61 kg (135 lb)

19. Remove spring (02) from the rod (00B) assembly.
20. Remove spacer (01) from rod (00B).
IMPORTANT: Rod (06) has been installed in cylinder
(00A).
21. Remove rod (06) from cylinder (00A).
IMPORTANT: Do not damage seal (04) and dust seal
(05).
22. Remove seal (04) and dust seal (05) from cylinder
(00A).
W4-4-3-4
Assembly of Track Adjuster
08 07 02 00B 00A 04 05 14
WDCD-04-04-008
09 10 03 01
Detail A
15
WDCD-04-04-011
09 10 16
00A- Cylinder 03- Yoke 08- Bracket 15- Valve

00B- Rod 04- Seal 09- Bolt 16- Bracket
01- Spacer 05- Dust Seal 10- Washer
02- Spring 07- Nut 14- Piston Rod
W4-4-3-5
Assembly of Track Adjuster 6. Remove the eyebolts from rod (00B).
dCAUTION: Cylinder (00A) weight: 20 kg (45 lb) dCAUTION: Yoke (03) weight: 21 kg (47 lb)
dCAUTION:
29 kg (64 lb)
The cylinder (00A) assembly weight: 7. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and
1. Install rod (00B) to cylinder (00A).
Hoist the yoke (03).
2. Apply grease onto seal (04) and dust seal (05). Install
8. Place yoke (03) on spring (02). Remove eyebolts (2
seal (04) and dust seal (05) to cylinder (00A).
used) and nuts (2 used) from yoke (03). Install the
3. Install spacer (01) to rod (00B). special tool (ST4052). Install bolts (J921650) (4 used)
and washers (J222016) (4 used) to the bolt holes
dCAUTION: Spring (02) weight: 61 kg (135 lb) (4 places) of yoke (03). Secure the special tool (ST
4. Install spring (02) to rod (00B). 4052) and yoke (03) with them.
dCAUTION:
kg (210 lb)
The spring (02) assembly weight: 93 j : 24 mm
5. Install eyebolts (M10, Pitch 1.5 mm) to the bolt (09)

holes of rod (00B). Attach nylon slings onto the a
J921650,
eyebolts. Hoist the spring (02) assembly. Place the J222016
spring (02) assembly on the special tool (ST 4950).
WDCD-04-04-013
a- Nut
W4-4-3-6
9. Tighten nuts (a) (4 used) of the special tool (ST 4950) 12. Install bracket (08) to nut (07) with washer (10) and
and secure the spring (02) assembly. bolt (09).
j : 46 mm j : 17 mm
m : 60 N·m (6 kgf·m, 44 lbf·ft)

a 13. Lower the oil jack.
14. Remove nuts (a) (4 used) of the special tool (ST
4950).
dCAUTION:
(71 lb)
15. Attach nylon slings onto the eyebolts (2 used) of

the special tool (ST 4052). Hoist and hold the special
tool (ST4052). Remove bolts (J921650) (4 used) and
washers (J222016) (4 used). Remove the special tool
(ST4052).
WDCD-04-04-013
dCAUTION:
kg (265 lb)
a- Nut
16. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and
10. Operate the oil jack. Compress spring (02) to the diagonally. Attach nylon slings onto the eyebolts.
specified length. Hoist the spring (02) assembly.
fNOTE: Specified spring length: 460 mm (18.1 in) 17. Remove the spring (02) assembly from the special
tool (ST 4950).
11. Install nut (07) to rod (00B).
j : 75 mm
W4-4-3-7
18. Fill part A of cylinder (00A) with grease.
A 00A
WDCD-04-04-014
19. Install piston rod (14) to cylinder (00A).

20. Bleed air from part A of cylinder (00A) and cylinder
(00A).
21. Install bracket (16) and valve (15) to piston rod (14).
j : 24 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

22. Install washer (10) and bolt (09) to bracket (16).
j : 17 mm
m : 60 N·m (6 kgf·m, 44 lbf·ft)
W4-4-3-8

these procedures:
hardening.

trouble.
cleaning solvent.
ring (1).
f
A A
B B
A=B A≠B
W178-02-11-003

W4-4-4-1
(Blank)
W4-4-4-2
Removal and Installation of Upper Roller
1 2
W105-03-06-001 TDAA-03-08-002
dCAUTION: The pressure inside the track adjuster

cylinder is high. Do not loosen valve (1) quickly or
too much as valve (1) may fly out or high-pressure
grease in the adjuster cylinder may gush out.
Keep body parts and face away from valve (1) and
loosen valve (1) carefully. Do not loosen grease
fitting (2).
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
IMPORTANT: Loosening valve (1) by 1 to 1.5 turns is
enough. Do not loosen valve (1) over those turns.
Removal
2. Loosen valve (1) in the track adjuster. Drain grease
from the cylinder.
j : 24 mm
W4-5-1-1
6
b a 5
4
W1V7-03-06-001
3 c 4
4
W105-03-06-003
a- Oil Jack
b- Nonskid Cloth
c- Wooden Block
3
W105-03-06-005
dCAUTION: Use nonskid cloth (b) between track

frame (3) and oil jack (a) in order not to slip.
3. Raise the track in order to get clearance between
upper roller (4) and track (5).
4. Place wooden block (c) between track (5) and track
frame (3).
5. Loosen bolts (6) (4 used) of upper roller (4). Remove
upper roller (4).
j : 24 mm
W4-5-1-2
b a 5
W1V7-03-06-001
3 c 4
W105-03-06-003
a- Oil Jack
b- Nonskid Cloth
c- Wooden Block
1 2
a
WXXX-03-07-001
a- Track sag specification
TDAA-03-08-002
Installation
1. Install upper roller (4) with bolts (6) (4 used). 5. Apply grease through grease fitting (2) and adjust
the track tension.
j : 24 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft)

fNOTE: Track sag specification (a): 300 to 335 mm (11.8
to 13.2 in)
2. Remove wooden block (c), oil jack (a), and nonskid
cloth (b) between track (5) and track frame (3).
3. Tighten valve (1) in the track adjuster.
j : 24 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION: Securely support the raised machine

by using blocks.
4. Raise the track to be adjusted. Rotate the track in
the reverse direction a little.
W4-5-1-3
W158-03-06-001
6. Lower the track.

IMPORTANT: Upper roller (4) cannot be
disassembled. Replace it as an assembly.
7. Add engine oil (API CD class, SAE #30) through the
plug (8) hole of cover (7).
fNOTE: Amount of oil: 65 mL (0.069 US qt)

8. Apply THREEBOND #2353 onto plug (8).
l : 6 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W4-5-1-4
Removal and Installation of Lower Roller
3, 4, 5 2 3, 4, 5
90° to 110°
1 a WDAA-04-05-001 b M104-07-067
a- Wooden Block b- Stand
Removal
2. Put the matching marks on track guard (1) and track
frame (2).
dCAUTION: When removing bolt (3) without

holding track guard (1), track guard (1) will fall
down.
3. Place wooden blocks (a) under track guard (1).
4. Remove bolts (3) (4 used), spring washers (4) (4
used), and washers (5) (4 used).
j : 27 mm
angle between boom and arm to 90 degrees to 110
degrees. Lower the boom with the round bottom
of the bucket contacting with the ground. Raise the
track frame off the ground. At this time, place stand
(b) under the track frame and support the machine.
W4-5-2-1
1 2
TDAA-03-08-002
W105-03-06-001
WDCN-04-05-001
3
dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (1) may fly out and
the high-pressure grease may spout out, do not
loosen valve (1) quickly and/or excessively. Keep
body parts and face away from valve (1), and
loosen it carefully. Do not loosen grease fitting (2).
IMPORTANT: Loosening valve (1) by 1 to 1.5 turns is
enough. Do not loosen it over those turns.
loosening.
6. Loosen valve (1) in the track adjuster. Drain grease
and loosen the track tension until the clearance in
the track is enough to remove track guard (3).
j : 24 mm
dCAUTION: Track guard (3) weight: 22 kg (49 lb)

7. Remove track guard (3) by using a forklift.
W4-5-2-2
1 2
WDCN-04-05-002
3 a
a- Wooden Block
8. Put the matching marks on lower roller (1) and track

frame (2). dCAUTION: Lower roller (1) weight: 35 kg (78 lb)
11. Remove lower roller (1) by using a forklift.
dCAUTION: When removing bolt (3) without
holding lower roller (1), lower roller (1) will fall
down.
9. Place wooden block (a) under lower roller (1).
10. Remove bolts (3) (4 used).
j : 27 mm
W4-5-2-3
1 2
1
WDCN-04-05-002
WDCN-04-05-003 3 a
4
a- Wooden Block
Installation
dCAUTION: Lower roller (1) weight: 35 kg (78 lb)

1. Set lower roller (1) on track link (4) by using a
forklift.
2. Raise lower roller (1) in order to adjust its mounting
position by using a forklift and place wooden block
(a) under it.
3. Fit the bolt (3) holes of track frame (2) and lower
roller (1) and fit the matching marks made when
removing. Install lower roller (1) with bolts (3) (4
used).
j : 27 mm
m : 460 N·m (46 kgf·m, 340 lbf·ft)
W4-5-2-4
3, 4, 5 6 3, 4, 5
1 2
WDCN-04-05-001 WDAA-04-05-003
4. Set track guard (1) on track link (2) by using a

forklift.

by using blocks.
5. Lower the machine in order to adjust the track
guard (1) mounting position.
dCAUTION: Track guard (1) weight: 22 kg (49 lb)

6. Fit the bolt (3) holes of track frame (6) and track
guard (1) and fit the matching marks made when
removing by using a pry bar. Install track guard
(1) with washers (5) (4 used), spring washers (4) (4
used), and bolts (3) (4 used).
j : 27 mm
m : 500 N·m (50 kgf·m, 370 lbf·ft)
W4-5-2-5
1 2
TDAA-03-08-002 WXXX-03-07-001
a- Track Sag Specification
7. Tighten valve (1) in the track adjuster.
j : 24 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

by using blocks.
8. Raise the track to be adjusted off the ground. Rotate
the track in the reverse direction a little.
9. Apply grease through grease fitting (2) and adjust
the track tension.
fNOTE: Track sag specification (a): 300 to 335 mm (11.8

to 13.2 in)
W4-5-2-6
Disassembly of Lower Roller
3
2
4 1
5
7
6
5
4
3
2
1
W157-03-06-004
1- Plug (2 Used) 3- Pin (2 Used) 5- Floating Seal (2 Used) 7- Roller

2- Collar (2 Used) 4- O-Ring (2 Used) 6- Bushing (2 Used) 8- Axle
W4-5-3-1
Disassembly of Lower Roller 4. Remove pin (3) from the axle (8) assembly. Remove
axle (8) from collar (2) by using a press.
dCAUTION: Lower roller weight: 35 kg (78 lb)
1. Remove plug (1) from the end of collar (2). Drain oil
from roller (7). 4 3 2
l : 6 mm

such as goggles, helmets, etc. in order to prevent 8
personal injury.
2. Put the matching marks on collar (2) and axle (8).
Remove pin (3) from collar (2) at one side by using a
round bar and a hammer. Remove axle (8) from the
side of roller (7), where pin (3) has been removed,
by using a press. At this time, pin (3) and collar (2)
W178-02-11-268
on the opposite side are removed with axle (8)
together.
5. Remove O-rings (4) (2 used) from axle (8).
fNOTE: Diameter of round bar: 14 mm (0.55 in)
dCAUTION: Roller (7) weight: 21 kg (47 lb)
2 5 7 5 IMPORTANT: Do not remove bushing (6) unless
necessary.
6. Remove bushing (6) by using the special tool (ST
1955) and a press.
5
2
ST 1955
8
W105-03-06-026
6
(Refer to W4-5-4.) 7
3. Remove floating seals (5) (2 used) from both sides of
roller (7) and collars (2) (2 used).
W178-02-11-269
W4-5-3-2
Assembly of Lower Roller
2 7 6 5 4 3 1
W105-03-06-023
1- Plug (2 Used) 3- Pin (2 Used) 5- Floating Seal (2 Used) 7- Roller

2- Collar (2 Used) 4- O-Ring (2 Used) 6- Bushing (2 Used) 8- Axle
W4-5-3-3
Assembly of Lower Roller

IMPORTANT: Do not dent the flange surface of 5. Install the axle (8) assembly to roller (7).
bushing (6).
6. Apply grease onto O-ring (4) at the other side. Install
1. Install bushings (6) (2 used) to roller (7) by using a O-ring (4) to the roller (7) assembly.
press.
2. Apply grease onto O-ring (4) at one side. Install (Refer to W4-5-4.)
O-ring (4) to axle (8).
7. Install floating seal (5) to roller (7) and collar (2) at
IMPORTANT: Do not damage O-ring (4). the other side.
3. Fit the pin (3) hole and install collar (2) to one side of IMPORTANT: Do not damage O-ring (4).
axle (8) with pin (3).
8. Fit the pin (3) hole and install collar (2) to axle (8)
with pin (3).
8 3 9. Apply THREEBOND #2353 onto plug (1). Add engine
oil (API CD class, SAE #30) through the plug (1) hole
of collar (2). Tighten plug (1).
l : 6 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
2
fNOTE: Amount of oil: 0.26 L (0.27 US qt)
W105-03-06-031

(Refer to W4-5-4.)
4. Install floating seal (5) to roller (7) and collar (2).
7 5
5 2
W157-03-06-008
W4-5-3-4
Group 5 Upper and Lower Roller

these procedures:
hardening.

trouble.
cleaning solvent.
ring (1).
f
A A
B B
A=B A≠B
W178-02-11-003

W4-5-4-1
Group 5 Upper and Lower Roller
(Blank)
W4-5-4-2
Group 6 Track
Removal and Installation of Track
3
4 5
2
a
W105-03-07-006 WDCD-04-06-001
a- Wooden Block
Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)
2. Rotate the track so that master pin (1) is positioned
over front idler (2). Place wooden block (a) under
shoe (3) and support shoe (3).
dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (4) may fly out
and the high-pressure grease may spout out, do
not loosen valve (4) quickly and/or excessively.
Keep body parts and face away from valve (4) and
loosen valve (4) carefully. Do not loosen grease
fitting (5).
IMPORTANT: Loosening valve (4) 1 to 1.5 turns is
enough. Do not loosen valve (4) over those turns.
loosening.
3. Loosen valve (4). Drain grease and loosen the track.
j : 24 mm
W4-6-1-1
Group 6 Track
7
6
1 1 7
a- Direction to Remove
W105-03-07-010
6
ST 1970
W105-03-07-009
W1V1-03-07-001
4. Remove snap ring (6) from master pin (1).
fNOTE: If snap ring (6) interferes with master link (7),

dCAUTION: The track adjuster may fly out due
to the spring force when removing the track. Do
push master pin (1) to the installing direction in order to not stand in the same direction to remove the
make clearance between snap ring (6) and master pin track adjuster or where it may fly out. Particularly,
(1). Then, remove master pin (1). strong force is always applied to the thread
part of the rod. If the rod and/or the threads are
damaged, metal fragments may fly out due to the
spring force .

personal injury.
IMPORTANT: Master pin (1) can be removed to only
one direction. Check direction (a) to remove
master pin (1).
5. Remove master pin (1) by using the special tool (ST
1970) and a hammer.
W4-6-1-2
Group 6 Track
90˚~110˚
a
a- Stand
M104-07-067 W105-03-07-011
6. Set the angle between boom and arm to 90˚ to

110˚. Lower the boom with the round bottom of the
bucket contacting with the ground. Raise the track
frame and pull out the track. Place stand (a) under
the track frame and support the machine at this
time.
dCAUTION:
(2830 lb)
The track assembly weight: 1280 kg
7. Slowly operate a travel control lever on the side to

be removed the track to the reverse position and
extend the track.
W4-6-1-3
Group 6 Track
a b
W105-03-07-014
W105-03-07-013
a- Front Idler Side

b- Sprocket (8) Side
W105-03-07-015
Installation
1. Raise the machine. Set the track under the machine 3. Slowly operate a travel control lever on the side to
so that sprocket (8) meshes with the track end. install the track in the forward direction with the
Check the direction of the track at this time. machine raised off the ground. Wind the track while
rotating travel device (9).
dCAUTION:
(2830 lb)
The track assembly weight: 1280 kg
2. Hoist and mesh the track with the claws of sprocket

(8).
W4-6-1-4
Group 6 Track
6
1 7
b- Direction to Install
W105-03-07-010
7
3
a
6
W105-03-07-016
a- Wooden Block
W105-03-07-009
4. Wind the track link until the connection part of the

track link reaches the front idler (2) side. Lower the
machine. Place wooden block (a) under shoe (3) and
support shoe (3).
IMPORTANT: Master pin (1) can be installed to only
one direction. Check direction (b) to install master
pin (1).
5. Install master pin (1) to the track.
IMPORTANT: Replace snap ring (6) with the new one.
6. Install snap ring (6). Snap ring (6) has the direction
to install. Install snap ring (6) to the groove of
master link (7) with the flat surface of a pair of pliers
hole facing the near side.
W4-6-1-5
Group 6 Track
4 5
11
13
12
10
WDCD-04-06-001
c b c
W197-03-07-001
13
b- Apply grease.
c- Do not apply grease.
WXXX-03-07-001
a- Track Sag Specification
IMPORTANT: If link (10) has been disassembled, fill 10. Install pin (12) to link (10) and bushing (11) while
grease (Daphne Epones SR) into the clearance holding them in order not to move due to grease.
between bushing (11) and pin (12).
11. Wipe off excess grease after installing pin (12).
IMPORTANT: If link (10) has been disassembled,
perform step 7 to step 11. 12. Tighten valve (4). Apply grease through grease
fitting (5) and adjust the track tension.
IMPORTANT: Check the direction to install seal (13).
7. Install seal (13) to link (10). j : 24 mm
8. Apply grease onto the bushing (11) end. Fit the pin m : 90 N·m (9 kgf·m, 66 lbf·ft)
(12) holes on link (10) and bushing (11). Stand them
on a flat plate. fNOTE: Track sag specification (a): 300 to 335 mm (11.8
to 13.2 in)
d CAUTION: Take care not to come off link (10).
9. Fill the bushing (11) inside with grease.
W4-6-1-6
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
Disassembly of Boom, Arm Cylinder........................W5-2-4-1
Assembly of Boom, Arm Cylinder.............................W5-2-4-5
Disassembly of Bucket Cylinder................................W5-2-5-1
Assembly of Bucket Cylinder......................................W5-2-5-4
DC390W-5-1
(Blank)
DC390W-5-2
Removal and Installation of Front

Attachment
Removal
1. Park the machine on a solid and level surface. Fully
retract the arm cylinder and bucket cylinder and
lower the arm top onto the ground.
2. Stop the engine. Remove the boom cylinder at the
left and right sides. (Refer to W5-2-1.)

(Refer to W1-4-1.)
W105-04-02-001

3. Disconnect hoses (1, 2) (2 used for each) of the
bucket cylinder and the arm cylinder.
1 2
j : 36 mm, 41 mm
W1V1-04-01-001
W5-1-1-1
4. Remove bolt (3), washer (2), plate (4), and block (5) 1
from plate (a) of boom foot pin (1).
j : 27 mm
dCAUTION: Front attachment assembly (d)

weight: 3820 kg (8430 lb) a
5. Attach wire ropes onto the boom. Reduce the slack 5

of wire ropes.
4
3
2
a- Plate
W178-02-11-280
6. Insert a pry bar between plate (a) of boom foot pin

(1) and bracket (c). Slightly pull out plate (a).
dCAUTION:
lb)
Boom foot pin (1) weight: 45 kg (100
7. Turn plate (a) upward by hand. Turn it to left and

right and pull out boom foot pin (1). (Adjust the
position by using the lifting ropes for the front
W178-02-11-281
attachment.)
8. Hoist front attachment assembly (d) and move the 1
machine backward.
9. Place wooden blocks. Place front attachment
assembly (d) onto the wooden blocks.
a b
a- Plate c- Bracket
b- Insert a pry bar
W178-02-11-280
d- Front Attachment Assembly
W178-02-11-282
W5-1-1-2
Installation a
dCAUTION: Front attachment assembly (a) weight:

3820 kg (8430 lb)
IMPORTANT: Use one or more thrust plates
respectively at the right and left sides.
1. Attach wire ropes onto front attachment assembly
(a). Hoist front attachment assembly (a). Move
the machine forward and fit the boom foot to the
a- Front Attachment Assembly
mounting hole on the frame. Install thrust plates
to the right and left sides of the boom. Adjust total W178-02-11-282
clearance of right and left within 1 mm.
1
fNOTE: Thrust plate thickness: 1 mm (0.039 in), 1.5 mm
(0.059 in), 2 mm (0.079 in)
dCAUTION:
lb)
Boom foot pin (1) weight: 45 kg (100

personal injury. 4
2. Install boom foot pin (1) by using a hammer. Install 3
bolt (3), washer (2), plate (4), and block (5). 2
j : 27 mm W178-02-11-280
m : 400 N·m (40 kgf·m, 300 lbf·ft)
W5-1-1-3
3. Connect hoses (1, 2) (2 used for each) of the bucket

cylinder and arm cylinder.
j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft) 1 2
j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)
W1V1-04-01-001
4. Install the boom cylinder at the right and left sides.

(Refer to W5-2-1.)

1.)
6. Apply grease onto grease fitting (a) of the boom

foot.
a- Grease Fitting of Boom Foot
W1V1-04-01-001
W5-1-1-4
IMPORTANT: When the arm has been removed from 1

the boom, perform the following steps when
installing.
IMPORTANT: Use one or more thrust plates
7. Install thrust plates (2) to the left and right sides of
the arm. Adjust the total clearance of left and right 2 2
within 1 mm (0.039 in).
fNOTE: Thrust plate (2) thickness: 1 mm (0.039 in), 1.5

mm (0.059 in), 2 mm (0.079 in)
8. Install the arm cylinder rod side to the arm. Apply
3 3
grease onto grease fittings (1, 3) on the boom
connecting boss of arm and the arm cylinder rod
side.
IMPORTANT: For handling of HN bushing for the
front attachment, check the followings.
Precautions when installing the bushing
If a hammer is used, the bushing may be damaged. Use a
W178-02-11-285
press.
Special tool when installing bushing (bushing inner

diameter)
(ST 1454): 71 mm
Precautions when reinforcing the arm

The heat when welding in order to reinforce the arm may
cause oil leakage and decrease lubrication performance.
When lubrication oil leaks, replace the bushing.
W5-1-1-5
(Blank)
W5-1-1-6
Group 2 Cylinder
Removal and Installation of Boom Cylinder

Removal
2. Stop the engine. Disconnect hoses (1) (2 used) from
boom cylinder (2).
j : 17 mm W105-04-02-001
dCAUTION:
lb)
Boom cylinder (2) weight: 170 kg (375
1
3. Attach the nylon sling onto boom cylinder (2). Hoist
and hold boom cylinder (2).

personal injury.
4. Remove nuts (5) (2 used), bolt (7), and stopper
(6) from the boom cylinder (2) rod side. Push pin
2
(4) into the boom by using a bar and a hammer.
Remove thrust plates (3), and thrust plates (8).
j : 30 mm W105-04-02-032
6
5 3 4 8 2
W158-04-02-013
W5-2-1-1
Group 2 Cylinder
5. Place boom cylinder (1) on a stand.

6. Remove other boom cylinder (1) in the same way as
step 3 to step 5.
7. Start the engine. Operate the boom control lever
and retract boom cylinder (1). Pass the wires
through the rod hole and secure the rod to the
cylinder tube.
8. Stop the engine.

W105-04-02-035
9. Disconnect hoses (5) (4 used) at the cylinder side 6 1 2
from boom cylinders (1) (2 used).
j : 36 mm

personal injury. 3
10. Remove nuts (4) (2 used) and bolt (2) from the
4
cylinder bottom side. Remove pin (3) by using a bar
and a hammer. Remove thrust plates (6). 3
5 4
j : 24 mm
WLBA-05-02-012
dCAUTION:
lb)
11. Hoist and remove boom cylinder (1).

12. Remove other boom cylinder (1) in the same way as
step 10 to step 11.
1
W105-04-02-040
W5-2-1-2
Group 2 Cylinder
Installation
dCAUTION:
lb)
1. Attach the nylon sling onto boom cylinder (1).

Hoist boom cylinder (1). Fit the hole at the cylinder
bottom side to the mounting hole on the main
flame.
IMPORTANT: Use one or more thrust plates (6)
2. Install thrust plates (6) to the right and left sides of
the cylinder bottom side. Adjust total clearance of
right and left within 1 mm (0.039 in). At this time,
install thrust plate (6) (thickness: 1 mm (0.039 in))
1
on the opposite side of the cab and adjust the
W105-04-02-040
clearance at the cab side.
fNOTE: Thrust plate (6) thickness: 1 mm (0.039 in), 2 mm

(0.079 in) 6 1 2
personal injury.
3. Install pin (3) by using a hammer. Install bolt (2) to
pin (3) with nuts (4) (2 used).
j : 24 mm 3
m : 270 N·m (27 kgf·m, 200 lbf·ft) 4

3
4. Install other boom cylinder (1) in the same way as
5 4
step 1 to step 3.
WLBA-05-02-012
5. Connect hoses (5) (4 used) to boom cylinders (1) (2
used).
j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
W5-2-1-3
Group 2 Cylinder

6. Remove wires from the boom cylinder (2) rod
side. Start the engine. Operate the boom control
lever and fit the holes at cylinder rod side to the
mounting holes on boom.

personal injury.
7. Fit thrust plates (3), thrust plates (8), and pin (4) 7
to the mounting holes on boom. Install pin (4) by
using a bar and a hammer.
8. Install bolt (7) to pin (4) and stopper (6) with nuts (5)
(2 used).
j : 30 mm
6
m : 550 N·m (55 kgf·m, 410 lbf·ft) 5 3 4 8 2
9. Install other boom cylinder (2) in the same way as W158-04-02-013
step 6 to step 8.
10. Connect hoses (1) (2 used) to boom cylinder (2). 1
Apply grease.
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

IMPORTANT: After completing the work, operate the
boom cylinder several times to the stroke end and
bleed air from the circuit.
2
W105-04-02-032
W5-2-1-4
Group 2 Cylinder
Removal and Installation of Arm Cylinder

Removal
2. Place wooden block (3) between arm cylinder (1)
and boom (2). Stop the engine.
3. Remove nuts (6) (2 used) and bolt (8) from stopper W105-04-02-001
(7) and pin (5) at the rod side.
j : 30 mm 1

personal injury.
4. Remove pin (5) by using a bar and a hammer. 2
Remove thrust plates (4).
W187-04-02-005
4
8 5
1
6
W187-04-02-006
W5-2-2-1
Group 2 Cylinder
5. Start the engine. Operate the arm control lever and 1 2

retract arm cylinder (2). In order not to extend rod
(1), pass wires (3) through the rod hole and secure
rod (1) to the arm cylinder (2) tube.
6. Stop the engine.


circuit. (Refer to W1-5-1.) W187-04-02-010
7. Disconnect hoses (4) (2 used) and hose (5) from arm

cylinder (2). 2 4 5
j : 36 mm, 41 mm
WDC390-05-02-001
d CAUTION: Arm cylinder (2) weight: 260 kg (575

lb)
8. Attach the nylon sling onto arm cylinder (2). Hoist 2
and hold arm cylinder (2).
W102-04-02-016
W5-2-2-2
Group 2 Cylinder
9. Remove nuts (5) (2 used) and bolt (2) from stopper

(6) and pin (4) at the bottom side.
j : 30 mm
2
3
4
personal injury.
10. Remove pin (4) by using a bar and a hammer.
Remove thrust plates (3).
6
5
11. Hoist and remove arm cylinder (1).
W187-04-02-007
W5-2-2-3
Group 2 Cylinder
Installation
dCAUTION:
lb)
Arm cylinder (1) weight: 260 kg (575
1
1. Attach the nylon slings onto arm cylinder (1).

Hoist arm cylinder (1). Fit the holes on the cylinder
bottom side to the cylinder mounting holes on
boom.
respectively at the left and right sides.
right and left within 1.5 mm (0.059 in). W102-04-02-016

(0.079 in)

personal injury.
3. Install pin (4) by using a bar and a hammer.
2 3
4. Install bolt (2) to pin (4) and stopper (6) with nuts (5) 4
1
(2 used).
j : 30 mm
m : 550 N·m (55 kgf·m, 410 lbf·ft)

6
5
W187-04-02-007
W5-2-2-4
Group 2 Cylinder
5. Connect hose (3) to arm cylinder (1). Apply grease. 1 2 3
j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)

6. Connect hoses (2) (2 used) to arm cylinder (1).
j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)

7. Remove wires (5) from rod (4) of arm cylinder (1). WDC390-05-02-001
Start the engine. Operate the arm control lever and
fit the hole at cylinder rod side to the mounting
hole on arm (6). 4 1
8. Install thrust plates (7) to the right and left sides of 6
the cylinder rod side. Adjust total clearance of right
and left within 1 mm (0.039 in).
5
(0.079 in)
W187-04-02-010
personal injury.
9. Install pin (8) by using a hammer.
10. Install bolt (12) to pin (8) and stopper (11) with nuts
(9) (2 used).
7
12 8
j : 30 mm 11
m : 280 N·m (28 kgf·m, 205 lbf·ft)
arm cylinder several times to the stroke end and
bleed air from the circuit. 10
W187-04-02-006
W5-2-2-5
Group 2 Cylinder
(Blank)
W5-2-2-6
Group 2 Cylinder
Removal and Installation of Bucket Cylinder

Removal
2. Place wooden blocks (3) (2 used) under the arm (2)
top and between bucket cylinder (1) and arm (2).
Stop the engine.
W105-04-02-001
d CAUTION: Before removing pin (7), secure the
link by using wires in order not to fall off.

personal injury.
3. Remove nuts (6) (2 used) and bolt (4). Remove pin
(7) by using a bar and a hammer. Remove thrust
plates (5) (4 used). 3
2
j : 30 mm
3
W178-02-11-287
6 5
7 4
WLAA-05-02-002
W5-2-3-1
Group 2 Cylinder
4. Start the engine. Operate the bucket control lever 1 2

and retract bucket cylinder (2). In order not to
extend rod (1), pass wires (3) through the rod hole
and secure rod (1) to the bucket cylinder (2) tube.
5. Stop the engine.

(Refer to W1-4-1.)

3 W102-04-02-005
6. Disconnect hoses (4) (2 used) from bucket cylinder
(2).
2 4
j : 36 mm
dCAUTION:
(355 lb)
Bucket cylinder (2) weight: 160 kg

personal injury.
7. Attach the nylon sling onto bucket cylinder (2).

Hoist and hold bucket cylinder (2). Remove nuts (6)
(2 used) and bolt (8). Remove pin (7) by using a bar
and a hammer. Remove thrust plates (5).
WDAD-05-02-009
j : 24 mm
8. Hoist and remove bucket cylinder (2).
2
5
6 7
WDCA-05-02-005
W5-2-3-2
Group 2 Cylinder
Installation 1
2
dCAUTION:
(355 lb)
Bucket cylinder (1) weight: 160 kg
1. Attach the nylon sling onto bucket cylinder (1). 3 4

Hoist bucket cylinder (1). Fit the holes the cylinder
bottom side to the cylinder mounting hole on the
arm. 5
right and left within 1 mm (0.039 in). 6

(0.079 in)

personal injury.
WDCA-05-02-005
4. Install bolt (5) to stopper (6) of the arm and pin (4)
with nuts (3) (2 used).
1 7
j : 24 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)

5. Connect hoses (7) (2 used) to bucket cylinder (1).
j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
WDAD-05-02-009
W5-2-3-3
Group 2 Cylinder
IMPORTANT: Check the hydraulic oil level. Start the 1 2

6. Remove wires (3) from rod (1) of bucket cylinder (2).
Start the engine. Operate the bucket control lever.
Fit the holes at cylinder rod side to the holes of link
A (4) and link B (9). Fit thrust plates (7) (4 used) and
pin (10) to the holes of link A (4) and link B (9).
daCAUTION: Metal fragments may fly off when

hammer is used. Wear necessary protection,
3 W102-04-02-005
personal injury.
8. Install bolt (5) to stopper (6) and pin (10) with nuts
4 8 7
(8) (2 used).
j : 30 mm
m : 280 N·m (28 kgf·m, 205 lbf·ft)

IMPORTANT: In case link B (9) has been removed 6
from the arm, insert thrust plates (11) (2 used)
when installing.
bucket cylinder several times to the stroke end 10 9 5
and bleed air from the circuit.
WLAA-05-02-002
11 11
W178-02-11-289
9 9
W5-2-3-4
Group 2 Cylinder
Disassembly of Boom, Arm Cylinder
Boom Cylinder
11 1 2 3 4 7 5 6 9 10
14 13 19 16 20 21 22 12 8
20 16 15 17 18 19 24 23
W158-04-02-016
Arm Cylinder
11 1 2 3 4 7 5 6 9 10
14 13 15 16 25 26 28 22 12
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
W5-2-4-1
Group 2 Cylinder
1- Wiper Ring 9- Backup Ring 17- Seal Ring 25- Snap Ring (Only Arm Cylinder)
2- Backup Ring 10- O-Ring 18- O-Ring 26- Cushion Seal (Only Arm
3- U-Ring 11- Cylinder Rod 19- Slide Ring (2 Used) Cylinder)
4- Buffer Ring 12- Cylinder Tube 20- Slide Ring (2 Used) 27- Cushion Bearing (Only Arm
5- Bushing 13- Cushion Bearing 21- Shim Cylinder)
6- Snap Ring 14- Cushion Seal 22- Set Screw 28- Stopper (2 Used) (Only Arm
7- Cylinder Head 15- Piston 23- Steel Ball Cylinder)
8- Socket Bolt (12 Used) 16- Backup Ring (2 Used) 24- Nut
W5-2-4-2
Group 2 Cylinder
Disassembly of Boom, Arm Cylinder

 The procedure starts on the premise that the
pipes and the bands securing the pipes have been
removed.
IMPORTANT: Pull out cylinder rod (11) straightly in
dCAUTION: Boom cylinder weight: 170 kg (375 lb)
order not to damage the sliding surface.
Arm cylinder weight: 260 kg (575 lb)
3. Tap and remove cylinder head (7) with cylinder rod
1. Hoist the cylinder. Secure the cylinder horizontally (11) together from cylinder tube (12) by using a
on a workbench. Drain hydraulic oil from the plastic hammer.
cylinder.
4. Secure cylinder rod (11) on special tool (ST 5908).
Put the matching marks on cylinder rod (11) and the
end of nut (24) (arm cylinder: cushion bearing (27)).
ST 5908
W102-04-02-027
2. Fully extend and support cylinder rod (11). Remove

socket bolts (8) (12 used) from cylinder head (7). W158-04-02-022
l : 14 mm
W5-2-4-3
Group 2 Cylinder
5. Cut away the crimped part by using a hand drill. 7. Remove slide rings (19) (2 used), slide rings (20),
Remove set screw (22). Remove steel ball (23). backup rings (16) (2 used), O-ring (18), and seal ring
(17) from piston (15).
fNOTE: Set screw (22) has been caulked by using a
8. Remove cylinder head (7) from cylinder rod (11).
punch at two places after installing.
l : 10 mm 9. Remove O-ring (10) and backup rings (9, 2) from
cylinder head (7). Remove wiper ring (1), U-ring (3),
6. Remove nut (24) by using special tool (ST 5908) and buffer ring (4), snap ring (6), and bushing (5).
special tool for nut (24). Remove piston (15), shims
(21), cushion bearing (13) and cushion seal (14) from Special tool when removing bushing (rod outer
cylinder rod (11). diameter):
Special Tool for Piston Nut: ST 8020: 85 mm (Boom Cylinder)
ST 3263: 90 mm (Boom Cylinder) ST 8021: 95 mm (Arm Cylinder)
ST 3264: 100 mm (Arm Cylinder) 10. (Arm cylinder only)

Remove stoppers (28) (2 used) from cylinder rod
ST 5908
(11) by using a screwdriver. Remove cushion
bearing (27), cushion seal (26), and snap ring (25).
W158-04-02-022
W5-2-4-4
Group 2 Cylinder
Assembly of Boom, Arm Cylinder
Boom Cylinder
Face the slit to the piston.
Hole (1 Place)
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20
21
22, 23
24
Check the direction of oil groove W178-04-02-003

when installing.
Arm Cylinder
Face the slit to the piston.
Hole (1 Place)
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20 21
22, 23
24 26
25
27
28
Check the direction of oil groove

when installing.
W178-04-02-005
W5-2-4-5
Group 2 Cylinder
1- Wiper Ring 9- Backup Ring 17- Seal Ring 25- Snap Ring (Only Arm Cylinder)
2- Backup Ring 10- O-Ring 18- O-Ring 26- Cushion Seal (Only Arm
3- U-Ring 11- Cylinder Rod 19- Slide Ring (2 Used) Cylinder)
4- Buffer Ring 12- Cylinder Tube 20- Slide Ring (2 Used) 27- Cushion Bearing (Only Arm
5- Bushing 13- Cushion Bearing 21- Shim Cylinder)
6- Snap Ring 14- Cushion Seal 22- Set Screw 28- Stopper (2 Used) (Only Arm
7- Cylinder Head 15- Piston 23- Steel Ball Cylinder)
8- Socket Bolt (12 Used) 16- Backup Ring (2 Used) 24- Nut
W5-2-4-6
Group 2 Cylinder
Assembly of Boom, Arm Cylinder

IMPORTANT: Before assembling, apply hydraulic oil 5. Install O-ring (18) and seal ring (17) to piston (15)
onto parts in order to prevent them from seizing. by using the special tool A. After installing seal ring
1. Install bushing (5) to cylinder head (7). (17), adjust seal ring (17) by using the special tool B.
Special tool when installing bushing (rod outer Special tool A, Special tool B (tube inner diameter):
diameter): ST 2964, ST 2208: 120 mm (Boom Cylinder)
ST 8020: 85 mm (Boom Cylinder) ST 2978, ST 2535: 135 mm (Arm Cylinder)
ST 8021: 95 mm (Arm Cylinder) 6. Install backup rings (16) (2 used), slide rings (19) (2
IMPORTANT: Check the direction to install. used), and slide rings (20) (2 used) to piston (15).
2. Install U-ring (3), backup ring (2), buffer ring (4), and 7. Install the cylinder head (7) assembly to cylinder rod
snap ring (6) to cylinder head (7). (11).
3. Install wiper ring (1) to cylinder head (7) by using a Special tool when installing cylinder head (rod outer
plastic hammer. diameter):
Special tool when installing wiper ring (rod outer ST 8020: 85 mm (Boom Cylinder)
diameter):
ST 8021: 95 mm (Arm Cylinder)
ST 8020: 85 mm (Boom Cylinder)
IMPORTANT: Face the slit in cushion seal (26) to the
ST 8021: 95 mm (Arm Cylinder) piston side. Check the direction of oil groove in
cushion bearing (27).
4. Install O-ring (10) and backup ring (9) to cylinder
head (7). 8. (Arm cylinder only)
Install snap ring (25) and cushion seal (26) to
cylinder rod (11). Install cushion bearing (27) and
stoppers (28) (2 used).
W5-2-4-7
Group 2 Cylinder
IMPORTANT: Face the slit in cushion seal (14) to the 11. Install steel ball (23) to cylinder rod (1) and tighten
piston side. Check the direction of oil groove in with set screw (22). Crimp set screw (22) by using a
cushion bearing (13). punch (2 places).
9. Install cushion seal (14) and cushion bearing (13) to
l : 10 mm
cylinder rod (11).
10. Fit the matching marks before disassembling and m : 56.9±10.7 N·m (5.7±1.1 kgf·m, 42 lbf·ft)
tighten piston (24) by using special tool (ST 5908).
Special tool when turning piston nut:
dCAUTION: Fit the cylinder rod (11) assembly with
the center of cylinder tube (12) and install in order
not to damage the rings.
ST 3263: 90 mm (Boom Cylinder)
12. Secure cylinder tube (12) on a workbench
m : 4780 N·m (478 kgf·m, 3530 lbf·ft) horizontally. Insert the cylinder rod (11) assembly to
cylinder tube (12).
ST 3264: 100 mm (Arm Cylinder)
13. Install cylinder head (7) to cylinder tube (12) with
m : 10200 N·m (1020 kgf·m, 7520 lbf·ft) socket bolts (6) (12 used).
l : 14 mm
ST 5908
Boom Cylinder
m : 270 N·m (27 kgf·m, 200 lbf·ft)

Arm Cylinder
m : 370 N·m (37 kgf·m, 275 lbf·ft)
W158-04-02-022
W5-2-4-8
Group 2 Cylinder
Disassembly of Bucket Cylinder

1 2 3 4 5 6 7 8 9 10 11
22 19 18 12
23
W1V1-04-02-009
17 18 24 19 21 20 17
1- Cylinder Rod 6- Socket Bolt (10 Used) 11- O-Ring 20- O-Ring
2- Wiper Ring 7- Cylinder Head 12- Cylinder Tube 21- Seal Ring
3- Backup Ring 8- Bushing 17- Slide Ring (2 Used) 22- Set Screw
4- U-Ring 9- Snap Ring 18- Slide Ring (2 Used) 23- Steel Ball
5- Buffer Ring 10- Backup Ring 19- Backup Ring (2 Used) 24- Piston Nut
W5-2-5-1
Group 2 Cylinder
Disassembly of Bucket Cylinder

 The procedure starts on the premise that the
pipes and the bands securing the pipes have been
removed.
IMPORTANT: Pull out cylinder rod (1) straightly in
f NOTE: The arm cylinder is explained here. order not to damage the sliding surface.
dCAUTION:
lb)
Bucket cylinder weight: 160 kg (355 3. Tap and remove cylinder head (7) with cylinder
rod (1) together from cylinder tube (12) by using a
1. Hoist the cylinder. Secure the cylinder horizontally plastic hammer.
on a workbench. Drain hydraulic oil from the 4. Secure cylinder rod (1) on special tool (ST 5908). Put
cylinder. the matching marks on cylinder rod (1) and the end
of piston nut (24).
ST 5908
W102-04-02-027
W158-04-02-022
2. Fully extend and support cylinder rod (1). Remove
socket bolts (6) (10 used) from cylinder head (7).
l : 14 mm
W5-2-5-2
Group 2 Cylinder
5. Cut away the crimped part by using a hand drill. 7. Remove slide rings (17) (2 used), slide rings (18) (2
Remove set screw (22). Remove steel ball (23). used), backup rings (19) (2 used), O-ring (20), and
seal ring (21) from piston nut (24).
fNOTE: Set screw (22) has been caulked by using a
8. Remove cylinder head (7) from cylinder rod (1).
punch at two places after installing.
l : 6 mm 9. Remove O-ring (11) and backup rings (10, 3) from
cylinder head (7). Remove wiper ring (2), U-ring (4),
6. Remove piston nut (24) by using special tool (ST buffer ring (5), snap ring (9), and bushing (8).
5908) and special tool for piston nut (24).
Special tool when removing bushing (rod outer
Special Tool for Piston Nut: diameter):
ST 3263: 90 mm ST 8019: 80 mm
ST 5908
W158-04-02-022
W5-2-5-3
Group 2 Cylinder
Assembly of Bucket Cylinder
1 2 4 5 6 7 12 17 18 19 18 17
22
3 8 9 10, 11 24 20, 21 23
W1V1-04-02-001
1- Cylinder Rod 6- Socket Bolt (10 Used) 11- O-Ring 20- O-Ring
2- Wiper Ring 7- Cylinder Head 12- Cylinder Tube 21- Seal Ring
3- Backup Ring 8- Bushing 17- Slide Ring (2 Used) 22- Set Screw
4- U-Ring 9- Snap Ring 18- Slide Ring (2 Used) 23- Steel Ball
5- Buffer Ring 10- Backup Ring 19- Backup Ring (2 Used) 24- Piston Nut
W5-2-5-4
Group 2 Cylinder
Assembly of Bucket Cylinder

IMPORTANT: Before assembling, apply hydraulic oil 5. Install O-ring (20) and seal ring (21) to piston nut
onto parts in order to prevent them from seizing. (24) by using the special tool A. After installing seal
1. Install bushing (8) to cylinder head (7). ring (21), adjust seal ring (21) by using the special
tool B.
Special tool when installing bushing (rod outer
diameter): Special tool A, Special tool B (tube inner diameter):
ST 8019: 80 mm ST 2963, ST 2207: 115 mm
IMPORTANT: Check the direction to install. 6. Install backup rings (19) (2 used), slide rings (17) (2
used), and slide rings (18) (2 used) to piston nut (24).
2. Install U-ring (4), backup ring (3), buffer ring (5), and
snap ring (9) to cylinder head (7). 7. Install the cylinder head (7) assembly to cylinder rod
(1).
3. Install wiper ring (2) to cylinder head (7) by using a
plastic hammer. Special tool when installing cylinder head (rod outer
diameter):
Special tool when installing wiper ring (rod outer
diameter): ST 8019: 80 mm
ST 8019: 80 mm IMPORTANT: Face the slit in cushion seal (15) to the
piston side. Check the direction of oil groove in
4. Install O-ring (11) and backup ring (10) to cylinder
cushion bearing (14).
head (7).
W5-2-5-5
Group 2 Cylinder
8. Fit the matching marks before disassembling and 9. Install steel ball (23) to cylinder rod (1) and tighten
tighten piston nut (24) by using special tool (ST with set screw (22). Crimp set screw (22) by using a
5908). punch (2 places).
Special tool when turning piston nut: l : 6 mm
ST 3263: 90 mm
m : 58 N·m (5.8 kgf·m, 43 lbf·ft)
m : 5660 N·m (566 kgf·m, 4170 lbf·ft)
dCAUTION: Fit the cylinder rod (1) assembly with
the center of cylinder tube (12) and install in order
not to damage the rings.
ST 5908
10. Secure cylinder tube (12) on a workbench
horizontally. Insert the cylinder rod (1) assembly to
cylinder tube (12).
11. Install cylinder head (7) to cylinder tube (12) with
l : 14 mm
W158-04-02-022
Bucket Cylinder
m : 270 N·m (27 kgf·m, 200 lbf·ft)
W5-2-5-6
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.:
YOUR NAME: (Located at the left top corner in the cover page)
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

 NOTE indicates an additional explanation for an element

Follow Safety Instructions

Prepare for Emergencies

Wear Protective Clothing

You may need:

Protect Against Noise

Use Handholds 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

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 SA-657

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

Protect Against Flying Debris

Park Machine Safely

Handle Fluids Safely−Avoid Fires

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

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

Be sure to further follow the details described in the

Practice Safe Maintenance

Before servicing the machine:

7. Remove the key from the key switch.

 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.

Store Attachments Safely

 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:

 Damaged or missing heat shields must be repaired or

Evacuating in Case of Fire