INTRODUCTION

TO THE READER

• This manual is written for an experienced technician
to provide technical information needed to maint ain
and repair this machine.
• Be sure to thoroughly read this manual for cor-
rect product information and service procedures.
• If you have any questions or comments, at if you
found any errors regarding the content s of this
manual, please cont act using “Service Manual
Revision Request Form” at the end of this man-
ual.
(Note: Do not tear of f the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
• This manual contains the revision information
to the 11, July 2008.

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 and the
Workshop Manual.
• Information included in the Technical Manual:
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems, operational performance test s, and
troubleshooting procedures.
• Information included in the Workshop Manual:
technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
standards, and removal/inst allation and assem-
ble/disassemble procedures.

PAGE NUMBER

• Each page has a number , located on the center

lower part of the p age, and each number cont ains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W : Workshop Manual

W18K-E-00(20181019) IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS

In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting
heavy parts.
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
• IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
• NOTE:
Indicates supplementary technical information or
know-how.

UNITS USED

• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

W18K-E-00(20181019) IN-02
 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 in-
jury.
• Follow recommended precautions and safe operating
practices.

SA-688

001-E01A-0001

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 situa-

tion which, if not avoided, will result in death or seri-
ous 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 don’t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine. SA-1223

• CAUTION also calls attention to safety messages in this

manual.

• 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.

002-E01A-1223

W18K-E-00(20181019) SA-1
 SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine

and all safety messages in the operator’s manual.

• Safety signs should be installed, maintained and re-

placed when necessary.

• If a safety sign or this manual is damaged or missing,

order a replacement from your authorized dealer in
the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering). SA-003

• Learn how to operate the machine and its controls cor-

rectly and safely.

• Allow only trained, qualified, authorized personnel to

operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may im-

pair its function and/or safety and affect machine life.

• The safety messages in this SAFETY chapter are in-

tended 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 operat-
ing or performing maintenance work on the machine.
003-E01B-0003

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.
SA-437
• 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.

004-E01A-0437

W18K-E-00(20181019) SA-2
 SAFETY
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment appro-

priate to the job.

You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438

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.
005-E01A-0438

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
006-E01A-0434

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 “PRE-START INSPECTION”
chapter in the operator’s manual.

SA-435
007-E01A-0435

W18K-E-00(20181019) SA-3
 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 re-
sulting in a personal accident.
• Do not leave parts and/or tools lying around the op-
erator’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, possi-
bly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
• Keep all flammable objects and/or explosives away
from the machine.
• After using the ashtray, always cover it to extinguish
the match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may ex-
plode.

524-E01A-0000

W18K-E-00(20181019) SA-4
 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 handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps,
SA-439
and handrails when leaving the machine.

008-E01A-0439

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 ped-
als and to correctly operate the control levers with his
back against the seat back.
• If not, move the seat forward or backward, and check SA-378

again.

009-E01A-0378

W18K-E-00(20181019) SA-5
 SAFETY
FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning ma-
chine, 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 compo-
nent before operating the machine.
• Be sure to remain seated with the seat belt securely SA-237
fastened at all times when the machine is in operation
to minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every
three years regardless of its apparent condition.
010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, swinging,
or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or oper-
ating the machine in congested areas. Coordinate
hand signals before starting the machine. SA-426

011-E01A-0426

HANDLE STARTING AIDS SAFELY

Starting fluid:

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and ca-
bles.
• Remove container from machine if engine does not
need starting fluid.
• To prevent accidental discharge when storing a pres-
surized container, keep the cap on the container, and
store it in a cool, well-protected location. SA-293

• Do not incinerate or puncture a starting fluid con-

tainer.
036-E01A-0293-3

W18K-E-00(20181019) SA-6
 SAFETY
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 from the operator’s seat.

• NEVER start the engine while standing on the track or
on ground.
• Do not start engine by shorting across starter termi-
nals.
SA-444

• Before starting the engine, confirm that all control lev-

ers are in neutral.

012-E01B-0444

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 EN-
GINE” 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.
SA-032

• Failure to follow correct jump starting procedures

could result in a battery explosion or a runaway ma-
chine.

S013-E01A-0032

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the ma-
chine.

• Only allow the operator 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

014-E01B-0379

W18K-E-00(20181019) SA-7
 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.
SA-380
• Reinforce ground, edges, and road shoulders as nec-
essary. Keep the machine well back from the edges
of excavations and road shoulders.
• When working on an incline or on a road shoulder,
employ a signal person as required.
• Confirm that your machine is equipped 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 ma-
chine near flammable objects such as dry grass.
015-E01A-0380

PROTECT AGAINST FALLING STONES AND

DEBRIS

• Confirm that your machine is FOPS cab equipped

before working in areas where the possibility of falling
stones or debris exist.

SA-490

015-E01A-0380

W18K-E-00(20181019) SA-8
 SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES

• For jobs involving multiple numbers of machines, pro-

vide 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.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO BE

DRIVEN

• Incorrect travel pedal/lever operation may result in seri-

ous injury 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 ped-
als/levers are operated to the front.

SA-491
017-E01A-0491

W18K-E-00(20181019) SA-9
 SAFETY
DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the direc-
tion 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 not allow personnel to stay around the
machine while traveling.
SA-387

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

overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 0.5 to 1.0
m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.

SA-388

SA-441

• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure
sage operation.

SA-589

019-E01C-0492

W18K-E-00(20181019) SA-10
 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 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 and the H/P mode switch off. SA-391

• Run the engine at slow idle speed without load for 5

minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must
park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E02A-0493

W18K-E-00(20181019) SA-11
 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 BY-
STANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383
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.
Use hand signals, which conform to your local regula-
tions, when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator. SA-384

• Learn the meanings of all flags, signs, and markings

used on the job and confirm who has the responsibil-
ity 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
operator’s manual.

021-E01A-0494

W18K-E-00(20181019) SA-12
 SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA

• A person may be hit severely by the swinging front at-

tachment 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 pre-
vent anyone from entering the work area.

SA-386
022-E01A-0386

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
023-E01A-0487

AVOID UNDERCUTTING

• In order to retreat from the edge of an excavation if the

footing should collapse, always position the undercar-
riage 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
024-E01A-0488

W18K-E-00(20181019) SA-13
 SAFETY
AVOID TIPPING

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE --- SERIOUS OR FATAL CRUSHING INJU-
RIES 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: SA-012

• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• 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. SA-440

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to be-
come soft and make ground travel unstable.
025-E01B-0495

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur

causing serious injury or death.

SA-489

026-E01A-0489

W18K-E-00(20181019) SA-14
 SAFETY
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 seri-
SA-382
ous eye injury.
• Contact your local “diggers hot line” if available in
your area , and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382

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
028-E01A-0389

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

029-E01A-0381

W18K-E-00(20181019) SA-15
 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.
SA-014

• Move the load slowly and carefully. Never move it

suddenly.
• Keep all persons will 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.

030-E01A-0014

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body, se-
rious injury may result.

• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.

SA-432
031-E01A-0432

W18K-E-00(20181019) SA-16
 SAFETY
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a level surface.
• Lower bucket to the ground.
• Turn auto-idle switch and H/P mode switch off.
• Run engine at slow idle speed without load for 5 min-
utes.
• 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 posi- SA-390

tion.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.

033-E08B-0390

HANDLE FLUIDS SAFELY－AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel ig-

nites, an explosion and/or a fire may occur, possibly re-
sulting in serious injury or death.

• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are flam- SA-018
mable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spon-
taneously.
• Securely tighten the fuel and oil filler cap.

SA-019

034-E01A-0496

W18K-E-00(20181019) SA-17
 SAFETY
PRACTICE SAFE MAINTENANCE

To avoid accidents:
• Understand service procedures before doing 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. SA-028

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 mov-
ing the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK posi-
tion.
10. Allow the engine to cool.

• If a maintenance procedure must be performed with

the engine running, do not leave 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 SA-527

work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or replace
as necessary. Refer to the section discussing that
part in the “MAINTENANCE” chapter of the operator’s
manual.
• Keep all parts in good condition and properly in-
stalled.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable de-
tergent 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 perform-
ing welding on the machine.
500-E02B-0497

W18K-E-00(20181019) SA-18
 SAFETY
• Sufficiently illuminate the work site. Use a mainte-
nance 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, anti-
freeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious in-

jury.

• 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.

501-E01A-0287
SA-287

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 SA-527
a jack.
519-E01A-0527

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 be-
come entangled when working around rotating parts.

502-E01A-0026

SA-026

W18K-E-00(20181019) SA-19
 SAFETY
PREVENT PARTS FROM FLYING

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in se-
rious injury, blindness, or death.

• Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and face
away from valve.

• Travel reduction gears are under pressure. SA-344

• 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.

503-E01B-0344

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic ham-

mers, and blades can fall and cause serious injury or
death.

• Securely store attachments and implements to pre-

vent falling. Keep children and bystanders away from
storage areas.

SA-034

504-E01A-0034

W18K-E-00(20181019) SA-20
 SAFETY
PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under pres-

sure. Hot water or steam is contained in the engine, ra-
diator 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 SA-039

all pressure to be released before removing the cap.

• The hydraulic oil tank is pressurized. Again, be sure
to release all pressure before removing the cap.

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.
SA-225
• Wait for the oil and components to cool before starting
any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under pres-

sure 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 inspec-
tion alone.

• Periodically replace the rubber hoses. (See the page

of “Periodic replacement of parts” in the operator’s
manual).

SA-019
• Failure to periodically replace rubber hoses may cause
a fire, fluid injection into skin, or the front attachment to
fall on a person nearby, which may result in severe
burns, gangrene, or otherwise serious injury or death.

S506-E01A-0019

W18K-E-00(20181019) SA-21
 SAFETY
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 dis-

connecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care SA-031

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
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044
507-E03A-0499

W18K-E-00(20181019) SA-22
 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 dam-
aged clamps, lines, hoses, oil-cooler and oil-cooler
flange bolts.
• Do not bend or strike high-pressure lines. SA-019

• Never install bent or damaged lines, pipes or hoses.

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..

Clean up Flammables:
• Spilled fuel, oil, antifreeze fluid and window washer fluid,
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 spilled or accumulated flam-
mables immediately.

Check Key Switch:

• If fire breaks out, failure to stop the engine will escalate
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.

508-E02B-0019

W18K-E-00(20181019) SA-23
 SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air in-
side the hydraulic tank will escalate fire, hampering fire
fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pressur-
ized air inside the hydraulic oil tank is released (a
hissing sound should be heard).
• If any abnormalities are found, be sure to repair them
before operating the machine.

Check Heat Shields:

• Damaged or missing heat shield may lead to fires.
• Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the follow-

ing 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 cannot
be opened, break the front or rear window panes with SA-393

the emergency evacuation hammer to escape from the

cab. Refer the explanation pages on the Emergency
Evacuation Method in the operator’s manual.
518-E02B-0393

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 ex-
tension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the
area.
SA-016
509-E01A-0016

W18K-E-00(20181019) SA-24
 SAFETY
PRECAUTIONS FOR WELDING AND GRIND-
ING

• 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 grind-
ing.
• After finishing welding and grinding, recheck that there SA-818

are no abnormalities such as the area surrounding the

welded area still smoldering.

523-E01A-0818

AVOID HEATING NEAR PRESSURIZED FLUID

LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to your-
self and bystanders.

• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable mate-
rials.
• Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install tem-
porary fire-resistant guards to protect hoses or other
materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CON- SA-030

TAINING 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.

510-E01B-0030

W18K-E-00(20181019) SA-25
 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. SA-029

Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove solvent
or paint stripper containers and other flammable ma-
terial from area. Allow fumes to disperse at least 15
minutes before welding or heating.
511-E01A-0029

BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung
cancer.
• Depending on the wok site conditions, the risk of in-
haling asbestos fiber may exist. Spray water to pre-
vent asbestos from becoming airborne. Do not use
compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask rated
to prevent the inhalation of asbestos.
• Keep bystanders out of the work site during opera- SA-029

tion.
• Asbestos might be present in imitation parts. Use only
genuine Hitachi Parts.

W18K-E-00(20181019) SA-26
 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
SA-032
electrolyte level is lower than specified. Explosion of
the battery may result.
• Loose terminals may produce sparks. Securely
tighten all terminals.

• 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 elec-

trolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM

SAFELY

• If spilled onto skin, refrigerant may cause a cold contact

burn.

• Refer to the freon container for proper use when ser-

vicing the air conditioning system.
• Use a recovery and recycling system to avoid venting
freon into the atmosphere.
• Never let the freon stream make contact with the skin.

SA-405

513-E01A-0405

W18K-E-00(20181019) SA-27
 SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause se-

rious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides spe-

cific 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 SA-309
what the risks are and how to do the job safely. Then
follow procedures and use recommended equipment.
• See your authorized dealer for MSDS’s (available
only in English) on chemical products used with your
machine.

515-E01A-0309

DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the envi-

ronment 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 regula- SA-226

tions 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 cen-
ter, or from your authorized dealer.

516-E01A-0226

W18K-E-00(20181019) SA-28
 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

S517-E01A-0435

W18K-E-00(20181019) SA-29
 SAFETY
(Blank)

W18K-E-00(20181019) SA-30
 SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic
Oil Tank
SECTION 2 UPPERSTRUCTURE
WORKSHOP MANUAL
Group 1 Cab
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 DQR Valve
Group 7 Shuttle Valve
Group 8 EHC Valve
Group 9 Oil Cooler Fan Motor
Group 10 Compressor Drive Motor
Group 11 Air Conditioner
Group 12 Grease Pump
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Travel Brake Valve
Group 4 Center Joint
Group 5 Adjuster Cylinder
Group 6 Front Idler
Group 7 Upper and Lower Rollers
All information, illustrations and speci-
fications in this manual are based on Group 8 Track
the latest product information available Group 9 Accumulator
at the time of publication. The right is
reserved to make changes at any time Group 10 Welding Repair Procedure
without notice.
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
Group 3 Bushing and Point
COPYRIGHT(C)2007
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved

W18K-E-00(20181019)
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Control Equipment
Group 1 Controller Group 5 DQR Valve
Group 2 Control System Group 6 Travel Device
Group 3 ELU System Group 7 Others(Upperstructure)
Group 4 Hydraulic System Group 8 Others(Undercarriage)
Group 5 Electrical System
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Cross Reference Table
Group 2 Standard Group 3 Component Layout
Group 3 Engine Test Group 4 Troubleshooting A
Group 4 Excavator Test Group 5 Troubleshooting B
Group 5 Component Test Group 6 Troubleshooting C
Group 7 Electrical System Inspection

W18K-E-00(20181019)
 SECTION 1
GENERAL

CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Maintenance Standard Terminology......... W1-1-7

Group 2 Tightening
Tightening Torque Specification ............... W1-2-1
Torque Chart............................................ W1-2-3
Piping Joint.............................................. W1-2-6
Periodic Replacement of Parts .............. W1-2-10

Group 3 Painting
Painting ................................................... W1-3-1

Group 4 Bleeding Air from Hydraulic Oil

Tank
Bleeding Air from Hydraulic Oil Tank........ W1-4-1

W18K-E-00(20181019) 18KW-1-1
(Blank)

W18K-E-00(20181019) 18KW-1-2
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop
may cause machine components to be
contaminated during disassembling/assembling,
resulting in damage to machine components, as
well as decreased efficiency in service work.
• Inspect the Machine
Be sure to thoroughly understand all
disassem-bling/assembling procedures beforehand,
to help avoid incorrect disassembling of
components as well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
• The machine model, machine serial number, and
hour meter reading.
• Reason for disassembly (symptoms, failed parts,
and causes).
• Clogging of filters and oil, water or air leaks, if
any.
• Capacities and condition of lubricants.
• Loose or damaged parts.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the
area for disassembling work.
W18K-E-00(20181019) W1-1-1
• Precautions for Disassembling
• To prevent dirt from entering, cap or plug the
removed pipes.
• Before disassembling, clean the exterior of the
components and place on a work bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
• If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
tag them as necessary.
• Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
• Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
• Measure and record the degree of wear and
clearances.
 GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling
• Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace part.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
remove the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
W18K-E-00(20181019) W1-1-2
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and in-
stallation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the mo-
tor may result.
If the cylinder is operated with air
trapped in the cylinder tube, dam-
age to the cylinder may result.
Be sure to bleed air before starting
the engine.
• Bleeding Air from Hydraulic Pump
• Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.
 GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes. W18K-01-04-001

• Reposition the front attachment to check hydrau-

lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

W18K-E-00(20181019) W1-1-3
 GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:

(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.

(2) Check the slide surface on seal ring (A) for

scuffing, scoring, corrosion, deformation or B W105-03-05-019

uneven wear.

(3) Check O-ring (B) for tears, breaks,

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting

bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect

(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.

(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal a a
mating face (C) by measuring the distances
A
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating. B

b b

a=b a≠b
W110-03-05-004

W18K-E-00(20181019) W1-1-4
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
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.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016

lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
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 with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008

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 they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

W18K-E-00(20181019) W1-1-5
 GENERAL / Precautions for Disassembling and Assembling

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.

W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples 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. W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Separation of W162-01-01-006
Scoring
Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W18K-E-00(20181019) W1-1-6
 GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY

“Standard”
1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies

adjusted to specification.

“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.

W18K-E-00(20181019) W1-1-7
 GENERAL / Precautions for Disassembling and Assembling
(Blank)

W18K-E-00(20181019) W1-1-8
 GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION

No. Descriptions Bolt Dia Q’ty Wrench Torque

mm Size (mm) Nxm (kgfxm) (lbfxft)
1 Engine cushion rubber mounting bolt 36 6 55 3200 (320) (230)
2 Engine bracket mounting bolt a 20 6 30 550 (55) (40)
b 3/4  28.6 440 (44) (320)
c 27  41 1050 (105) (70)
3 Hydraulic oil tank mounting bolt 30 8 46 1450 (145) (100)
4 Fuel tank mounting bolt 30 15 46 1450 (145) (100)
5 Pump transmission mounting bolt 1/2 16 19.1 120 (12) ()
6 Pump device mounting bolt 20 12 30 550 (55) (40)
7 Fan drive pump mounting socket bolt 20 4 17 400 ( 40) ()
8 Gear pump mounting bolt 12 4 19 90 (9) (6)
9 Control valve mounting nut 16 12 24 270 (27) ()
10 Swing device mounting bolt 33 48 50 2600 (260) (10)
11 Swing motor mounting nut 20 8 30 400 (40) (29)
12 Battery mounting bolt 10 16 17  ( ) ()
13 Cab mounting bolt 18 10 27 300 (30) (2)
14 Cab bed mounting bolt 16 42 24 270 (27) ()
Swing bearing mounting bolt 45 58 70 4700 (470) (340)
15
45 60 70 4700 (470) (3400)
16 Counterweight mounting nut 45 6 70 3920 (39) (280)
17 Engine bed mounting bolt 30 20 30 1450 (145) (100)
18 Oil cooler mounting nut 27 4 41 1400 (140) (100)
19 Radiator mounting nut 27 4 41 1400 (140) (100)
20 Fan motor mounting bolt 16 4 24 210 (21) (15)
21 Fan motor bracket mounting bolt 12 6 19 90 (9) (6)
22 Travel device mounting bolt a 22 32 32 750 (75) (50)
b 33 64 50 2600 (260) (10)
c 30 60 46 1950 (195) (140)
23 Sprocket mounting bolt 30 30 46 1950 (195) (140)
24 Travel motor mounting bolt 20 8 30 400 (40) (29)
25 Upper roller mounting bolt 20 24 30 400 (40) (29)
26 Lower roller mounting bolt 30 64 46 1950 (195) (140)
27 Track guard mounting bolt 30 24 46 1950 (195) (140)
28 Track shoe bolt 33 392 50 3190 (3) (230)
29 Side frame mounting bolt 45 68 70 40 (4) (30)
30 Loader Front pin-retaining bolt a 20 2 30 400 (40) (295)
b  4  0 () (0)
c 24 4 36 700 (0) (50)
d  4  0 () ()
31 Backhoe Front pin-retaining bolt a 20 24 30 400 (40) (295)
b 16 12 24 210 (21) (155)

W18K-E-00(20181019) W1-2-1
 GENERAL / Tightening

NOTE 1.Apply lubricant (e.g. white zinc B dis-

solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.

W18K-E-00(20181019) W1-2-2
 GENERAL / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them SA-040

correctly when assembling the machine or compo-

nents.

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225

Socket Bolt
Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft)
M8 13 6 30 (3.0) (22) 20 (2.0) (15) 10 (1.0) (7.4)
M10 17 8 65 (6.5) (48) 50 (5.0) (37) 20 (2.0) (15)
M12 19 10 110 (11) (81) 90 (9) (66) 35 (3.5) (26)
M14 22 12 180 (18) (135) 140 (14) (103) 55 (5.5) (41)
M16 24 14 270 (27) (200) 210 (21) (155) 80 (8.0) (59)
M18 27 14 400 (40) (295) 300 (30) (220) 120 (12) (89)
M20 30 17 550 (55) (410) 400 (40) (295) 170 (17) (125)
M22 32 17 750 (75) (550) 550 (55) (410) 220 (22) (160)
M24 36 19 950 (95) (700) 700 (70) (520) 280 (28) (205)
M27 41 19 1400 (140) (1030) 1050 (105) (770) 400 (40) (295)
M30 46 22 1950 (195) (1440) 1450 (145) (1070) 550 (55) (410)
M33 50 24 2600 (260) (1920) 1950 (195) (1440) 750 (75) (550)
M36 55 27 3200 (320) (2360) 2450 (245) (1810) 950 (95) (700)

W18K-E-00(20181019) W1-2-3
 GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.

Bolt Tightening Order

When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.
Tighten from center and diagonally
Equally tighten upper and lower alternately Tighten diagonally

1 12 9 4 1 6 7 14
6 3
1st to 4th

4 5
2 13 8 5 2 3 10 11

2nd to 3rd
W105-01-01-003

W18K-E-00(20181019) W1-2-4
 GENERAL / Tightening
Service Recommendations for Spilt Flange

IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
Incorrect
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
W105-01-01-016
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008

an air wrench often causes tight- Correct Incorrect

ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply

Nut and Bolt Locking Correct Correct Incorrect

• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.

• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009

Correct Correct Incorrect

ening, not while loosening.

• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen Incorrect
Correct

Tighten

W105-01-01-010

W18K-E-00(20181019) W1-2-5
 GENERAL / Tightening
PIPING JOINT 1 4 3 5 2

IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
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. 37°

30°
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017

2. Scratches or other damage to

sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.

Wrench Size Wrench Size mm Tightening

Description mm Torque
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,22)
22 22 39 (4.0,29)
27 27 78 (8.0,58)
32 32 137 (14,101)
36 36 175 (18,129)
41 41 205 (21,151)
37°female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,22)
22 19 39 (4.0,29)
27 22 78 (8.0,58)
32 27 137 (14,101)
36 32 175 (18,129)
41 36 205 (21,151)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.

W18K-E-00(20181019) W1-2-6
 GENERAL / Tightening
O-ring Seal Joint 9
7 6

O-ring (6) seats against the end face of adapter (7) to

seal pressure oil.

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

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 1
in O-ring groove (e). Tightening M104-07-033

nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (e) or sealing surface mm mm
(10). Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
Damage to O-ring (6) will cause 19 17 29.5 (3.0,21.5)
oil leakage. 22 19 69 (7.0,51)
4. If nut (9) is loose and oil is leak- 27 22 93 (9.5,69)
ing, do not re-tighten nut (9). Re- 32 27 137 (14,101)
place O-ring (6) with a new one 36 30,32 175 (18,129)
and check that O-ring (6) is cor- 41 36 205 (21,151)
rectly seated in place, tighten nut 46 41 205 (21,151)
(9).

W18K-E-00(20181019) W1-2-7
 GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, dif ferent 30°
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018

Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.

• Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

Confirm that the thread su rface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. W rap seal
tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque dif fers

depending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)

M114-07-043 M1 14-07-042

W18K-E-00(20181019) W1-2-8
 GENERAL / Tightening
Connecting Hose
Incorrect Correct
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation
of fitting, possibly resulting in a fire on the
machine.

Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print Incorrect Correct
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other

If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012

Incorrect Correct
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp

Rubbing Against
Each Other

W105-01-01-013

Incorrect Correct

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

W18K-E-00(20181019) W1-2-9
 GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS

To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Pump to High Pressure Filter
High Pressure Filter to Control Valve
Control Valve to Front
Oil cooler to Hydraulic Oil Tank
Hydraulic hoses Transmission Oil Cooler Hose
Loading Shovel Main Frame to
Every 2 years, or
Front Hoses Boom
8000 hours
Backhoe Front Main Frame to
Hoses Boom
Fuel Tank to Water Separator Filter
Water Separator to Cooler
Fuel Hoses
Engine to Fuel Cooler
Fuel Cooler to Fuel Tank

NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.

W18K-E-00(20181019) W1-2-10
 GENERAL / Painting
PAINTING

Painting Specification
Surfaces to be Painted Painting Colour
• Upper Structure (Outside) YR-01 [TAXI Yellow]
Side fenders (left and right), Counterweight, Counter-
weight side and front step, Handrail of counterweight,
HG Beige Deep
Fuel tank side step, Handrail of upper side fenders (left
and right)
Handrail and step of upper side control valve support,
Handrail and step around the cab, Engine cover upper
HG Black
handrail and step, Handrail and step of fuel and hydraulic
tank upper, Handrail and step of battery cover upper.
Inside N-40 [Gray]
Muffler M/F Beige Deep
Air Cleaner HG Beige Deep
• Front Attachment YR-01 [TAXI Yellow]
• Track N-10 [Black]

Final Painting Colour

• Outside surface of cab
Around cab window for the front, left and right side N-30 [Gray]
Other outside HG Beige Deep
• Inside surface HG Beige Deep
• Inside surface of cab bed N-40 [Gray]

Masking Specification
• Engine number plate • Pilot Accumulator
• Each hydraulic moter number plate • Door, Catchs, Handles
• Each pump number plate • Ground line disconnection switch box
• Each valve number plate • Wring connector, Mark band
• Each reduction gear number plate • Escape equipment
• Control valve number plate • Handrail chain
• Back mirror

W18K-E-00(20181019) W1-3-1
 GENERAL / Painting
Machine Front Side Machine Rear Side

1 1 3 2

1
2

W18K-01-03-001 W18K-01-03-002

W18K-01-03-005

Surfaces to be Painted Painting Colour

1- Upper handrail on the fuel tank, Handrail of engine cover, Step on the
engine cover rear, Handrail and step around the cab, Handrail on the HG Black
hydraulic oil tank upper, Upper handrail on the battery box
2- Sliding fold-in ladder, Sliding fold-in ladder front step, Right side fender,
Handrail of right side fenders, Upper handrail and step on the counter- HG Beige Deep
weight, Counterweight side handrail and step
3- Water tank, Upper and rear side of frame YR-01 [TAXI Yellow]

W18K-E-00(20181019) W1-3-2
 GENERAL / Painting
Machine Right Side Machine Left Side

1 2 1 2 1

3
3

4 4

4 3

3
4

1 1 1
W18K-01-03-003 W18K-01-03-004
4 4

Surfaces to be Painted Painting Colour

1- Muffler, Muffler Cover, Right side of engine bed cover, Cover under the
fender, Left fender, Counterweight, Counterweight front side step, M/F Beige Deep
Counterweight side step
2- Side ladder on the hydraulic oil tank, Hand rail and step between the
hydraulic tank and engine cover, Hand rail and step between the fuel HG Black
tank and engine cover
3- Radiator grill, Oil cooler grill, Stay N-10 [Black]
4- Compressor cover, Upper fuel filter on the left fender, Condenser cover,
YR-01 [TAXI Yellow]
Upper fender cover, Grill

W18K-E-00(20181019) W1-3-3
 GENERAL / Painting
Machine Right Side Machine Left Side

W18K-01-03-003 W18K-01-03-004

Fuel Tank
Shaded Area Shaded Area （Out Side）
YR-01 TAXI Yellow YR-01 TAXI Yellow YR-01 TAXI Yellow
(Gray for the parts other (Gray for the parts other (Inside)
than the shaded area) than the shaded area) N-40 Gray（Lacquer）

Side Surface of
Center Step、
Side Surface of
Ladder Mounting
Bracket
HG Beige Deep

W18K-01-03-006
A W18K-01-03-007

Side Surface of Ladder Mounting Bracket

HG Beige Deep

View B View A
W18K-01-03-008

W18K-E-00(20181019) W1-3-4
 GENERAL / Painting
Engine Unit Front Side

N-40 Gray（Lacquer） YR-01 TAXI Yellow N-40 Gray（Lacquer）

W18K-01-03-009

Main Frame

View D Shaded Area

D YR-01 TAXI Yellow
(Gray for the parts
other than the shaded
area)

C E

W18K-01-03-010
Shaded Area W18K-01-03-011

YR-01 TAXI Yellow

(Gray for the parts other
than the shaded area)

Shaded Area
YR-01 TAXI Yellow
(Gray for the parts other
than the shaded area)
View C View E

W18K-01-03-012

W18K-E-00(20181019) W1-3-5
 GENERAL / Painting
(Blank)

W18K-E-00(20181019) W1-3-6
 GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and
eyes, causing serious injury.
Avoid this hazard by relieving
pressure before disconnecting
hydraulic or other lines.
2. Hydraulic oil may be hot just
after operation. Hot hydraulic
oil may spurt, possibly causing
severe burns. Be sure to wait
for oil to cool before starting
maintenance / repair.
3. Do not loosen air breather cap
on hydraulic oil tank quickly. Air
breather cap may fly off due to
internal pressure. Always turn
the air breather cap slowly to
release any remaining pressure
before removing it.

Preparation

1. Park the machine on a level solid surface. Lower

the front attachment to the ground.

W18K-01-04-001

2. Stop the engine. Loosen the lock of the air

breather cap (1) on the hydraulic oil tank with a
hexagon wrench. Turn air breather cap (1) ap-
proximately 30° counterclockwise to release any
remaining pressure.
: 4 mm

Hexagon Wrench
W118-02-03-018

W18K-E-00(20181019) W1-4-1
 GENERAL / Bleeding Air from Hydraulic Oil Tank

3. Remove socket bolt (2) of air breather cap (1) at 2

one side to remove air breather cap (1). Remove 3
filter (3). Wind an adhesive tape around bayonet 1
assembly (4) approx. one and half turns so that Port
the port is plugged. Reinstall filter (3) and air
breather cap (1) to the original position.
: 4 mm 4

4. Remove other side air breather cap (1). Connect

a vacuum pump. Operate the vacuum pump con-
tinuously to create negative pressure in the hy-
draulic oil tank. Run the vacuum pump continu-
ously while maintenance / repair period.

5. After completing the maintenance / repair, be

sure to remove the adhesive tape from bayonet
assembly (4).

W118-02-05-001

W18K-E-00(20181019) W1-4-2
 MEMO

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W18K-E-00(20181019)
 MEMO

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W18K-E-00(20181019)

UPPERSTRUCTURE
CONTENTS
Group 1 Cab
Removal and Installation of Cab ........... W2-1-1
Dimensions of the Cab Glass ............... W2-1-4
Group 2 Counterweight
Removal and Installation of
Counterweight .................................... W2-2-1
Group 3 Pump Device
Removal and Installation of
Pump Device ...................................... W2-3-1
Disassembly of Pump Transmission ... W2-3-22
Assembly of Pump Transmission ........ W2-3-26
Disassembly of Main Pump ................ W2-3-30
Assembly of Main Pump ..................... W2-3-38
Maintenance Standard ........................ W2-3-46
Disassembly of Regulator for
Main Pump ....................................... W2-3-48
Assembly of Regulator for
Main Pump ....................................... W2-3-54
Structure of 4-Spool Pump .................. W2-3-61
Disassembly of Oil Cooler
Fan Drive Pump ................................ W2-3-62
Assembly of Oil Cooler
Fan Drive Pump ................................ W2-3-66
Maintenance Standard ........................ W2-3-72
Disassembly of Regulator for
Oil Cooler Fan Drive Pump .................. 2-3-74
Assembly of Regulator for
Oil Cooler Fan Drive Pump ............... W2-3-80
Disassembly of Air Conditioner
Compressor Drive Pump and
Pilot Pump ........................................ W2-3-86
Assembly of Air Conditioner
Compressor Drive Pump
and Pilot Pump ................................. W2-3-92
W18K-E-00(20181019) 18KW-2-1
SECTION 2
Maintenance Standard ........................ W2-3-96
Disassembly of Pump Transmission
Oil Lubrication Pump ......................... W2-3-98
Assembly of Pump Transmission
Oil Lubrication Pump ....................... W2-3-100
Maintenance Standard ...................... W2-3-102
Group 4 Control Valve
Removal and Installation of
Control Valve ...................................... W2-4-1
Disassembly of Control Valve ............... W2-4-6
Assembly of Control Valve .................. W2-4-14
Disassembly and Assembly of
Main Relief Valve and
Overload Relief Valve ....................... W2-4-18
Structure of Make-Up Valve ................ W2-4-20
Group 5 Swing Device
Removal and Installation of
Swing Device ...................................... W2-5-1
Disassembly of Swing Device ............... W2-5-8
Assembly of Swing Device .................. W2-5-16
Disassembly of Swing Motor ............... W2-5-28
Assembly of Swing Motor ................... W2-5-32
Maintenance Standard ........................ W2-5-36
Disassembly and Assembly of
Valve Unit .......................................... W2-5-38
Group 6 DQR Valve
Removal and Installation DQR Valve .... W2-6-1
Structure of DQR Valve ......................... W2-6-4
Group 7 Shuttle Valve
Removal and Installation of
Shuttle Valve ...................................... W2-7-1
Structure of Shuttle Valve ..................... W2-7-3

Group 8 EHC Valve

Removal and Installation of
EHC Valve ....................................... W2-8-1
Structure of EHC Valve ......................... W2-8-7
Disassembly and Assembly of
Proportional Solenoid Valve ................ W2-8-8
Structure of Solenoid .......................... W2-8-10

Group 9 Oil Cooler Fan Motor

Removal and Installation of
Oil Cooler Fan Motor .......................... W2-9-1
Disassembly of Oil Cooler Fan Motor ... W2-9-6
Assembly of Oil Cooler Fan Motor ........ W2-9-8
Maintenance Standard ........................ W2-9-10

Group 10 Compressor Drive Motor

Removal and Installation of
Compressor Drive Motor ................... W2-10-1
Disassembly of Compressor
Drive Motor ....................................... W2-10-4
Assembly of Compressor
Drive Motor ....................................... W2-10-6

Group 11 Air Conditioner

Work after Replacing Component ....... W2-11-1
Charge Air Conditioner
with Refrigerant ................................ W2-11-2

Group 12 Grease Pump

Grease Pump Construction ................ W2-12-1

W18K-E-00(20181019) 18KW-2-2
 UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION OF CAB

Removal

CAUTION: Cab (1) weight: 1210 kg (2668 lb)

Lifting Bracket 1 Lifting Bracket
1. Attach a nylon sling to the lifting bracket (4 places)
in cab (1). Hoist and hold cab (1).

W18M-02-01-003

W18K-E-00(20181019) W2-1-1
 UPPERSTRUCTURE / Cab
2. Remove U-nuts (4) (10 used) and washers (5) (10 2 3 1
used) from cushions (2) (10 used).
: 27 mm

3. Remove sems bolts (3) (18 used) from cab (1).

: 19 mm

4, 5
W18M-02-01-009
2

4, 5

4, 5
W18M-02-01-008

Door 2 3

4, 5
W18M-02-01-010

4. Remove all connectors and plugs from cab (1). Lifting Bracket 1 Lifting Bracket

CAUTION: Cab (1) weight: 1210 kg (2668 lb)

5. Remove cab (1) from the cab bed.

W18M-02-01-003

W18K-E-00(20181019) W2-1-2
 UPPERSTRUCTURE / Cab
Installation Lifting Bracket 1 Lifting Bracket

CAUTION: Cab (1) weight: 1210 kg (2668 lb)

1. Hoist and align cab (1) with the mounting hole on

cab bed.

W18M-02-01-003

Door 2 3
2. Install cab (1) to cushion (2) with U-nuts (4) (10
used) and washers (5) (10 used).
: 27 mm
: 300 Nm (30.5 kgfm, 221 lbfft)
1

4, 5
W18M-02-01-010
2
3. Install cab (1) to the cab bed with sems bolts (3)
(18 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)

4. Install all connectors and plugs.

4, 5

4, 5
W18M-02-01-008

2 3 1

4, 5
W18M-02-01-009

W18K-E-00(20181019) W2-1-3
 UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS

NOTE: Material: JISR3211 or equivalent

Rubber Rubber
Bushing Bushing

Sems Bolt
1
A
Plate

W18M-02-01-002
B

Unit: mm

2.5 3.2
4.5

Wiper Motor
Shaft Core

Rubber C

35
35 8 12
17.5
10
6
77.5 60 12
36.5
Rubber A Adhesive
Rubber E
Rubber D
3.2 6
8 10 6
24 10 (Glass)
(Glass)
4.5 8
6 36.5 W18M-02-01-005
(Glass)
Rubber E
17.5 60
Rubber B 8 10 6
Rubber D
Adhesive F
6 77.5
12

36.5 6
Section A 60 35
77.5

17.5

Rubber C

24 3.2
4.5

Section B-B W18M-02-01-006

W18K-E-00(20181019) W2-1-4
 UPPERSTRUCTURE / Cab

Unit: mm
Chamfer the Corner
(4 Places)
80

80

Mark Position
(Outside)

1
Laminated Glass
17021
Color: Clear
Thichkness: 10.8 mm
Chamfer along the
Periphery

W18G-02-01-004
17341

W18K-E-00(20181019) W2-1-5
 UPPERSTRUCTURE / Cab

Stopper Spacer

2 3

Connected
Position

Handrail
Connected
Position
W18M-02-01-003

Unit: mm

1355.81

4-R61

4-R61

2 3
10851

Tempered Glass
Tempered Glass
Color: Green 7691.0 Color: Green
Thickness: 5 mm
Thickness: 5 mm
Chamfer along the Periphery
Chamfer along the
Mark Position Periphery
NUB34413
50

W18G-02-01-005
50

1222.61

W117-02-01-004
4331.0

W18K-E-00(20181019) W2-1-6
 UPPERSTRUCTURE / Cab
Rubber
Bushing

4 5

Connected Connected
Position Position

W18M-02-01-004

Unit: mm
129.7

5-R61 4-R61
129.7

4 5
Tempered Glass Tempered Glass
Color: Green Color: Green
Thickness: 5 mm Thickness: 5 mm 7691.0
962 Chamfer along the Chamfer along the
Periphery Periphery

50 Mark Position
NUB34413
Outside

50

W18M-02-01-018
710.2 4331.0 W18M-02-01-007

W18K-E-00(20181019) W2-1-7
 UPPERSTRUCTURE / Cab

Connected
Position
Guide Pipe

W18M-02-01-001

Connected
Position

Unit: mm

1355.81
4781

4-R61 4-R61
6
Tempered Glass
3241 Color: Green
2 Thickness: 5 mm
10851

Chamfer along the

Tempered Glass Periphery
Color: Green
Thickness: 5 mm Mark Position
50 NUB34413
Chamfer along the Periphery

Mark Position W18G-02-01-006

50 NUB34413 50

438.21

W18G-02-01-005
50

1222.61

W18K-E-00(20181019) W2-1-8
 UPPERSTRUCTURE / Cab
Rubber A Rubber B Rubber C

+5 +5
1738 -0 1740 -0 1718 -0
+5

A A
A
6 8
6

24 +0-1
+0
36 -1
C5 24 -1
+0
W18M-02-01-012

Section A Section A
W18M-02-01-013
C5
W18M-02-01-011
Section A

Rubber D Rubber E Adhesive F

+5
1718 -0 1800 +100
1300 -0

A A

8 12 A
10
6
36 +0-1
W18M-02-01-015
Section A +2
10 -0
W18M-02-01-016
Section A
W18M-02-01-014
Section A

W18K-E-00(20181019) W2-1-9
 UPPERSTRUCTURE / Cab
(Blank)

W18K-E-00(20181019) W2-1-10
 UPPERSTRUCTURE / Counterweight
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT

CAUTION: Park the machine on a solid and

level surface. Lower the bucket to the ground
steady before doing any work.
Do not operate the machine or the front
attachment without the counterweight.
Otherwise the machine may tip over.

Removal

1. Park the machine on a solid and level surface. Set

the front attachment as illustrated.

T142-05-03-007

T142-05-03-008

2. Remove bolts (1) (8 used). Remove covers (2) (2

used) from the counterweight. Counterweight
: 17 mm

2 1

W18C-02-02-004

W18K-E-00(20181019) W2-2-1
 UPPERSTRUCTURE / Counterweight

CAUTION: Counterweight weight: 25300 kg

(55800 lb)

3. Install a shackle and a wire into a hole on the

upper side of the counterweight. (2 places)
Hoist and hold the counterweight. A Counterweight

W18K-02-02-001

View A
4. Remove U-nuts (5) (6 used) and washers (6) (6
used).
: 70 mm
Lifting
NOTE: When removing U-nut (5) from bolt (3), Hole
washer (6) falls. Catch washer (6) with a 3, 4
tray.

5. Push up bolt (3) and washer (4) by hand. Wind a

nylon sling onto the neck of bolt (3). Hoist and
remove bolt (3) from the counterweight. (6 places)

W18C-02-02-003

5, 6
6. Hoist and remove the counterweight from the
main frame.

Counterweight

Main Frame W141-02-02-003

W18K-E-00(20181019) W2-2-2
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight weight: 25300 kg

(55800 lb)
Counterweight

1. Install a shackle and a wire into a hole on the

upper side of the counterweight. (2 places)
Hoist the counterweight.

2. Place the counterweight onto the main frame

while aligning the bolt holes on the counterweight Main Frame W141-02-02-003

and the main frame.

IMPORTANT: Apply lubricant onto bolt (3).

Install washer (4) to bolt (3) with the
chamfered side inside washer (4)
facing to the bolt (3) head.
3. Install washer (4) to bolt (3). Wind a nylon sling
onto the neck of bolt (3). Hoist and insert bolt (3) A Counterweight
in to the bolt hole. (6 places)

IMPORTANT: Install washer (6) to bolt (3) with the

groove surface facing downward.
4. Temporarily tighten washers (6) (6 used) and A
U-nuts (5) (6 used) to bolts (3) (6 used).
W18K-02-02-001
5. Tighten bolts (3) (6 used).
: 70 mm
: 3920 N⋅m (400 kgf⋅m, 2900 lbf⋅ft)
View A

Lifting
Hole
3, 4

W18C-02-02-003

5, 6

W18K-E-00(20181019) W2-2-3
 UPPERSTRUCTURE / Counterweight
6. Install covers (2) (2 used) to the counterweight
with bolts (1) (8 used). Counterweight
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2 1

W18C-02-02-004

W18K-E-00(20181019) W2-2-4
 UPPERSTRUCTURE / Pump Device
REMOVAL AND INSTALLATION OF PUMP
DEVICE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

W18K-E-00(20181019) W2-3-1
 UPPERSTRUCTURE / Pump Device
Removal of Pump Device

W18K-02-03-001

6 7 8
9
Machine
Front B
3 10

4 11
22
12
21
20
19
18 13
14, 15
17
16
5
View A (Engine Unit Upper Side)
W18K-02-03-002

1 W18C-02-03-001

Section B (Shield Plate Pump Side)

1- Pump Device 7- Cover 13 - Bracket 18 - Bracket

2- Engine 8- Cover 14 - Bolt (92 Used) 19 - Cover
3- Bolt (26 Used) 9- Bracket 15 - Washer (92 Used) 20 - Cover
4- Cover (3 Used) 10 - Cover 16 - Cover 21 - Cover
5- Cover (3 Used) 11 - Cover 17 - Cover 22 - Bracket
6- Cover 12 - Cover

W18K-E-00(20181019) W2-3-2
 UPPERSTRUCTURE / Pump Device
Removal

1. Prepare a container. Remove the drain plug from

the lower side of the pump transmission. Open
the drain cock and drain oil.
Container volume: 30 L (7.9 US gal)

Drain Plug Drain Cock W18C-02-04-017

IMPORTANT: Attach an identification tag onto the

disconnected hose, piping and
harness for assembling.
2. Disconnect all hoses, pipings and connectors
from pump device (1). Install a plug or a cap onto
the open ends of the disconnected hoses and
pipings.

(Hose)
: 19 mm, 22 mm, 27 mm, 36 mm
(Piping)
: 17 mm
(Bolt)
: 17 mm, 19 mm
(Socket Bolt)
: 8 mm, 14 mm

W18K-E-00(20181019) W2-3-3
 UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B 6 7 8
3 9

10
4

11
22
12
21
20
19
5 18 13
14, 15
View A (Engine Unit Upper Side) 17
W18K-02-03-002 16

1 W18C-02-03-001

Section B (Shield Plate Pump Side)

W18K-E-00(20181019) W2-3-4
 UPPERSTRUCTURE / Pump Device
7. Remove bolts (27) (16 used) and washers (28)
CAUTION: Cover (4) weight: 18 kg (40 lb) (16 used). Remove brackets (23, 26) from
Cover (5) weight: 23 kg (55 lb) bracket (9).
: 24 mm
3. Remove bolts (3) (29 used). Hoist and remove
covers (4, 5) (3 used for each) from the upper
side of the engine unit. CAUTION: Bracket (9) weight: 43 kg (95 lb)
: 19 mm
8. Attach a nylon sling onto bracket (9). Hoist and
4. Remove bolts (14) (92 used) and washers (15) hold bracket (9). Remove bolts (30) (8 used) and
(92 used). Remove covers (6 to 8), (10 to 12), (16, washers (31) (8 used). Hoist and remove bracket
17), (19 to 21) and brackets (13, 18, 22) from the (9) from the upper side of the engine unit.
upper side of pump device (1). : 19 mm
: 17 mm Nylon Sling
9

5. Remove bolts (24) (3 used). Disconnect the

connector of maintenance lamp (29).
: 17 mm

9 24 25 Connector 30, 31
W18B-02-04-024

23 26

27, 28
29

Shield Plate Engine Side W18C-02-03-006

6. Remove bolts (25) (4 used). Remove

maintenance lamp (29) from bracket (9).
: 17 mm

W18K-E-00(20181019) W2-3-5
 UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B

View A (Engine Unit Upper Side)

W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W18K-E-00(20181019) W2-3-6
 UPPERSTRUCTURE / Pump Device
9. Remove the oil cooler fan motor. (Refer to 12. Install the special tool (ST 7326) to engine (2)
REMOVAL AND INSTALLATION OF OIL with bolts (34) (2 used). (2 places)
COOLER FAN MOTOR on W2-9-1.)
CAUTION: Bracket (32) weight: 49 kg (110 lb)
CAUTION: Pump device (1) weight: 1540 kg
(3400 lb) 13. Remove bolts (36) (6 used), (38) (2 used),
washers (37) (6 used) and (39) (2 used).
10. Install a shackle and a wire to the lifting bracket Attach a wire and a shackle to the bolt (36) hole
(2 places) on the pump transmission. Attach a on bracket (32). Hoist and remove bracket (32)
nylon sling onto the bodies of the main pumps (2 from the frame. (2 places)
used). Install a lever block. Hoist and hold pump : 41 mm, 55 mm
device (1).
At this time, do not touch the lifting sling with the 32 36, 37
hoses.
Wire
Lever Block
Lifting
Bracket
Nylon Sling

Main Pump

38, 39 W18C-02-03-009

W146-02-03-033

11. Remove bolts (34) (6 used) and spring washers

(35) (4 used). Remove bracket (33) between
engine (2) and bracket (32). (2 places)
: 29 mm

32
2

33
34, 35

W18C-02-03-009

W18K-E-00(20181019) W2-3-7
 UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B

View A (Engine Unit Upper Side)

W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W18K-E-00(20181019) W2-3-8
 UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the piping from the lower
CAUTION: Pump device (1) weight: 1540 kg side of pump device (1).
(3400 lb) 15. Place pump device (1) on the stable place by
using wooden blocks (approx 220 mm (8.7 in)
IMPORTANT: If shaft (42) is installed to the pump height).
device (1) side, the clearance is too 1
small to remove pump device (1).
When removing pump device (1)
from engine (2), push shaft (42) to
the engine (2) side by hand.
14. Remove bolts (40) (16 used) and spring washers
(41) (16 used).
Adjust the lever block and align the center of
pump device (1). Pull out pump device (1)
straightly from engine (2). Hoist and remove Wooden
pump device (1) from engine (2). Block
: 19 mm 40
W18C-02-04-015
41

16. Attach a nylon sling onto the body of shaft (42).

42 2 Hoist and remove shaft (42) from engine (2).

Nylon Sling

2
42

1
W18C-02-03-007

Lever Block

W146-02-03-018

W146-02-03-033

W18K-E-00(20181019) W2-3-9
 UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B

View A (Engine Unit Upper Side)

W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W18K-E-00(20181019) W2-3-10
 UPPERSTRUCTURE / Pump Device

CAUTION: Main pump (45) weight: Each

192 kg (430 lb) (for each)
Fan motor drive pump (46) weight: 96 kg (220
lb)

17. Install eyebolts (M12, Pitch 1.75 mm) (6 used) to

the bodies of main pumps (45) (3 used). Attach a
wire onto eyebolts (6 used). Hoist and hold main
pump (45).
Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
the body of fan motor drive pump (46). Attach a
wire onto eyebolts (2 used). Hoist and hold fan
motor drive pump (46).

18. Remove bolts (43) (12 used), socket bolts (47) (4

used), spring washers (44) (12 used) and (48) (4
used). Hoist and remove main pumps (45) (3
used) and fan motor drive pump (46) from the
pump transmission.
: 30 mm
: 17 mm
Pump
Transmission

45
43, 44

47, 48

46 W18C-02-03-011

W18K-E-00(20181019) W2-3-11
 UPPERSTRUCTURE / Pump Device
Installation of Pump Device

W18K-02-03-001

Machine
Front B
6 7 8
3 9

10
4

11
22
12
21
20
19
5 13
18
14, 15
View A (Engine Unit Upper Side) 17
W18K-02-03-002
16

1 W18C-02-03-001

Section B (Shield Plate Pump Side)

1- Pump Device 7- Cover 13 - Bracket 18 - Bracket

2- Engine 8- Cover 14 - Bolt (92 Used) 19 - Cover
3- Bolt (26 Used) 9- Bracket 15 - Washer (92 Used) 20 - Cover
4- Cover (3 Used) 10 - Cover 16 - Cover 21 - Cover
5- Cover (3 Used) 11 - Cover 17 - Cover 22 - Bracket
6- Cover 12 - Cover

W18K-E-00(20181019) W2-3-12
 UPPERSTRUCTURE / Pump Device
Installation
IMPORTANT: Install shaft (42) with the screw hole
of the end facing to the pump device
CAUTION: Main pump (45) weight: Each (1) side. Apply hydraulic oil onto
192 kg (430 lb) (for each) shaft (42).
Fan motor drive pump (46) weight: 96 kg (220 2. Hoist shaft (42). Install shaft (42) to engine (2).
lb)
Nylon Sling
IMPORTANT: Apply THREEBOND #1215 onto the
pump transmission mounting 2
surface on each pump. 42
1. Hoist and install main pumps (45) (3 used) and
fan motor drive pump (46) to the pump
transmission with bolts (43) (12 used), socket
bolts (47) (4 used), spring washers (44) (12
used) and (48) (4 used).
: 30 mm W146-02-03-018

: 550 N⋅m (55 kgf⋅m, 410 lbf⋅ft)

3. Install special tools (ST 7304, ST 7305) to the
: 17 mm
shaft (42) mounting position on pump device (1).
: 400 N⋅m (40 kgf⋅m, 2 95 lbf⋅ft)
At this time, insert the special tool (ST 7304) into
the pump transmission while aligning the splines
Pump
Transmission
of the gear.
ST 7304 ST 7305

45
43, 44

47, 48

W18B-02-04-031

Pump
Transmission

46 W18C-02-03-011 ST7304,
ST7305

W18B-02-04-033

W18K-E-00(20181019) W2-3-13
 UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B
3

5
View A (Engine Unit Upper Side)
W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W18K-E-00(20181019) W2-3-14
 UPPERSTRUCTURE / Pump Device
8. Install pump device (1) to engine (2) with bolts
CAUTION: Pump device (1) weight: 1540 kg
(40) (16 used) and spring washers (41) (16
(3400 lb)
used).
: 19 mm
4. Hoist pump device (1). Align the spline on shaft : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
(42) with that of the special tool (ST 7305). Insert
shaft (42) into the special tool (ST 7305). 40
41
1
ST 7305

42 2

W18C-02-03-007

CAUTION: Bracket (32) weight: 49 kg (110

lb)

W18B-02-04-032
9. Hoist bracket (32). Install bracket (32) to the
frame with bolts (36) (6 used), (38) (2 used),
IMPORTANT: Do not drop special tools (ST 7304,
washers (37) (6 used) and (39) (2 used). (2
ST 7305) and shaft (42) when
places)
removing pump device (1).
: 41 mm
5. Remove pump device (1) first. At this time, face
: 10 50 N⋅m (105 kgf⋅m, 7 70 lbf⋅ft)
shaft (42) to the engine (2) side and special tools
: 55 mm
(ST 7304, ST 7305) to the pump transmission
: 3 200 N⋅m (320 kgf⋅m, 23 60 lbf⋅ft)
side.

6. Remove special tools (ST 7304, ST 7294) from 32 36, 37

pump device (1).

IMPORTANT: Apply THREEBOND #1215 onto the

engine mounting surface of pump
device (1).
7. Hoist pump device (1). Align the spline of shaft
(42).

38, 39 W18C-02-03-009

W18K-E-00(20181019) W2-3-15
 UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B 6 7 8
3 9

10
4

11
22
12
21
20
19
5 18 13
14, 15
View A (Engine Unit Upper Side) 17
W18K-02-03-002 16

1 W18C-02-03-001

Section B (Shield Plate Pump Side)

W18K-E-00(20181019) W2-3-16
 UPPERSTRUCTURE / Pump Device
10. Remove bolts (34) (2 used). Remove the special 14. Install brackets (23, 26) to bracket (9) with bolts
tool (ST 7326) from engine (2). (27) (16 used) and washers (28) (16 used).
: 27 mm : 24 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)
11. Install bracket (33) between engine (2) and
bracket (32) with bolts (34) (6 used) and spring 9 24 25 Connector
washers (35) (4 used). (2 places)
: 29 mm
: 440 N⋅m (4 4 kgf⋅m, 3 20 lbf⋅ft)
32 23 26

27, 28
29

33 Shield Plate Engine W18C-02-03-006

34, 35
15. Install maintenance lamp (29) to bracket (9) with
bolts (25) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, .37 lbf⋅ft)
W18C-02-03-009

16. Connect the connectors to maintenance lamp

12. Install the oil cooler fan motor. (Refer to (29) and secure with bolts (24) (3 used).
REMOVAL AND INSTALLATION OF OIL
COOLER FAN MOTOR on W2-9-1.) 17. Install covers (6 to 8), (10 to 12), (16, 17), (19 to
21) and brackets (13, 18, 22) to the upper side of
pump device (1) with bolts (14) (92 used) and
CAUTION: Bracket (9) weight: 43 kg (95 lb)
washers (15) (92 used).
: 17 mm
13. Hoist bracket (9). Install bracket (9) to the upper
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
side of the engine unit with bolts (30) (8 used)
and washers (31) (8 used).
18. Install covers (4, 5) (3 used for each) to the upper
: 19 mm
side of the engine unit with bolts (3) (29 used).
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
: 19 mm
9 : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft))

30, 31
W18B-02-04-024

W18K-E-00(20181019) W2-3-17
 UPPERSTRUCTURE / Pump Device

W18K-02-03-001

Machine
Front B

View A (Engine Unit Upper Side)

W18K-02-03-002

W18C-02-03-001

Section B (Shield Plate Pump Side)

W18K-E-00(20181019) W2-3-18
 UPPERSTRUCTURE / Pump Device
19. Connect all hoses, pipings and connectors to
pump device (1).

(Hose)
: 19 mm
: 30 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 40 N⋅m (4.0 kgf⋅m, 30 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.3 kgf⋅m, 69 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
(Piping)
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
(Bolt)
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
(Socket bolt)
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
: 14 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

IMPORTANT: After installing pump device (1) and

before starting the engine, add oil to
the pump transmission (Refer to
Adding Oil to Pump Transmission
on W2-3-20) and bleed air from the
pump (Refer to Bleeding Air from
Pump on W2-3-21).

W18K-E-00(20181019) W2-3-19
 UPPERSTRUCTURE / Pump Device
Adding Oil to Pump Transmission Nozzle

IMPORTANT: In case the pump transmission has 1

been disassembled and assembled
and after starting the engine, it will
take time to lubricate each part
inside the pump transmission with
oil. Finally it may cause a fault.
In order to protect each part of the
pump transmission, lubricate each
part before starting the engine.

1. Remove a nozzle of oil feed pump (1). Install the

special tool (ST 6651).

2. Disconnect hose (10) from pump transmission oil

lubrication pump (7). Oil Feed Pump W146-02-03-019
: 27 mm

3. Install oil feed pump (1) to hose (10) at the

delivery side of pump transmission oil lubrication 2 3 4 5 6
pump (7). Add approx. 10 liters (2.6 US gal) of oil.
Oil: Apollo oil diesel motive S-330 Hose Oil Feed
Side Pump
Side
4. Remove the special tool (ST 6651) from hose
(10). Connect hose (10) to pump transmission oil
lubrication pump (7). W146-02-03-020
ST 6651
: 27 mm
: 93 N⋅m (9.3 kgf⋅m, 69 lbf⋅ft) 2- Adapter : (R 3/4)
3- Quick Coupling : (R 3/4)
5. Remove level gauge (8). Add oil to the specified 4- Quick Coupling : (R 3/4)
level through pipe (9). 5- Adapter : (R 1/4)
6- Adapter : (R 1/4)
Oil: Apollo oil diesel motive S-330
NOTE: Total oil amount: 26 L (6.9 US gal.)
NOTE: Add oil while checking the oil level with
level gauge (8).

10

W18C-02-03-010

W18K-E-00(20181019) W2-3-20
 UPPERSTRUCTURE / Pump Device
Bleeding Air from Hydraulic Pump

IMPORTANT: As air is accumulated inside of the

pump and if the engine is start in
lacking of hydraulic oil, the pump
will be damaged. Bleed air from the
pump.
IMPORTANT: If hose opening clamps (1, 2) are
removed, hydraulic oil may spurt
out. Do not remove hose opening 2
clamps (1, 2).
1. Loosen hose opening clamp (1) (12 places) of
the main pump and hose opening clamp (2) of
the fan drive pump by 2 to 3 turns.
1
: 19 mm, 27 mm

2. Start and run the engine at the slow idle. Bleed

air until only hydraulic oil flows from the tread part
of the hose opening clamp.

3. Stop the engine. Tighten all hose opening

clamps.
: 19 mm W18C-02-04-018
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm
: 93 N⋅m (9.3 kgf⋅m, 69 lbf⋅ft)

IMPORTANT: After completing the work, check

the hydraulic oil level. Start and run
the engine at idling speed for 20
minutes. Check for any oil leaks.

W18K-E-00(20181019) W2-3-21
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF PUMP TRANSMISSION

1
2
3
4
5
6
7

8
9
10
11
12
13
20
19
18
17
16
15 Pump Side

14

33 31, 32 30

38 21
22
39, 40
23
24
34 25
29 26
27, 28
Lifting
Holes Pulling-Out Hole
W18C-02-04-003

Engine
Side
W18C-02-04-004

35 36, 37

1- O-Ring 11 - Washer (10 Used) 21 - O-Ring (3 Used) 31 - Bolt (16 Used)

2- Spacer 12 - Bolt (10 Used) 22 - Ball Bearing (3 Used) 32 - Spring Washer (16 Used)
3- Disc Spring 13 - Oil Seal 23 - Gear (3 Used) 33 - Cover (3 Used)
4- Spacer 14 - Case 24 - Spacer (3 Used) 34 - Cover
5- Roller Bearing 15 - Ball Bearing 25 - Retaining Ring (3 Used) 35 - Pipe Assembly
6- Retaining Ring 16 - Retaining Ring 26 - Ball Bearing (3 Used) 36 - Bolt (4 Used)
7- Stopper 17 - Spacer 27 - Bolt (2 Used) 37 - Spring Washer (4 Used)
8- Gear 18 - Gear 28 - Washer (2 Used) 38 - Hook (2 Used)
9- Roller Bearing 19 - Ball Bearing 29 - Cover 39 - Bolt (4 Used)
10 - Cover 20 - O-Ring 30 - Cork (8 Used) 40 - Spring Washer (4 Used)

W18K-E-00(20181019) W2-3-22
 UPPERSTRUCTURE / Pump Device
Disassembly of Pump Transmission
CAUTION: Pump transmission weight:
780 kg (1720 lb)
1. Place the pump transmission on the stable stand
with the pump side facing upward.
2. Remove bolts (36) (4 used) and washers (37) (4
used). Disconnect pipe assembly (35) from case
(14).
3. Remove bolts (39) (4 used) and spring washers
(40) (4 used). Remove hooks (38) (2 used) from
case (14).
10. Remove O-ring (1), O-rings (21) (3 used) and
O-ring (20) from cover (29), covers (33) (3 used)
and cover (34).
11. Install an eyebolt (M10, Pitch 1.5 mm) to the
lifting hole (2 places for each) on gear (18) and
gears (23) (3 used).
CAUTION: The gear (18) assembly weight:
22 kg (50 lb)
The gear (23) assembly weight: 31 kg (70 lb)
12. Hoist and remove the gear (18) assembly and the
gear (23) assemblies (3 used) from case (14).

4. Remove bolts (31) (16 used) and spring washers 13. Remove retaining ring (16), retaining rings (25) (3
(32) (16 used). used), spacer (17) and spacers (24) (3 used)
: 17 mm from gear (18) and gears (23) (3 used).

5. Remove corks (30) (8 used) from covers (33) (3 IMPORTANT: Put the matching mark onto gears
used) and cover (34). (18, 23) and ball bearings (15, 19),
(22) (3 used) and (26) (3 used).
14. Warm up the gear (18) assembly and the gear
CAUTION: Cover (33) weight: 38 kg (84 lb)
(23) assemblies (3 used) to 90 °C (194 °F) in an
Cover (34) weight: 37 kg (82 lb)
oil tank. Remove ball bearings (15, 19), (22) (3
used) and (26) (3 used) from gears (18) and
6. Install a bolt (M20, Pitch 2.5 mm) to the
gears (23) (3 used).
pulling-out hole (2 places for each) on covers
(33) (3 used) and cover (34) and float from case
(14).
: 30 mm

7. Install an eyebolt (M20, Pitch 2.5 mm) to the

lifting hole (2 places for each) on covers (33) (3
used) and cover (34).

8. Hoist and remove covers (33) (3 used) and cover

(34) from case (14).

9. Remove bolts (27) (2 used) and washers (28) (2

used). Remove cover (29) from case (14).
: 19 mm

W18K-E-00(20181019) W2-3-23
 UPPERSTRUCTURE / Pump Device

2
3
4
5
6
7

8
9
10
11
12
13

Pump Side

14

Bolt Hole

W18C-02-04-003

Engine
Side
W18C-02-04-004

W18K-E-00(20181019) W2-3-24
 UPPERSTRUCTURE / Pump Device
15. Install an eyebolt (M27, Pitch 3.0 mm) to the bolt 23. Hoist and remove the gear (8) assembly from
hole (2 places) on the side of case (14). case (14). At this time, the inner race of roller
bearing (5) is removed with gear (8) together.
CAUTION: The case (14) assembly weight:
24. Remove the outer race of roller bearing (5),
500 kg (1110 lb)
spacer (4), disc spring (3) and spacer (2) from
case (14).
16. Hoist and turn over the case (14) assembly.
25. Remove retaining ring (6) and stopper (7) from
17. Remove oil seal (13) from cover (10).
the gear (8) assembly.
18. Remove bolts (12) (10 used) and washers (11)
IMPORTANT: Put the matching marks onto gear
(10 used).
(8) and the inner races of roller
: 19 mm
bearings (5, 9).
26. Warm up the gear (8) assembly to approx. 90 °C
CAUTION: Cover (10) weight: 31 kg (70 lb) (194 °F) in an oil tank. Remove the inner races of
roller bearings (5, 9) from gear (8).
19. Insert a bolt (M12, Pitch 1.75 mm) to the
pulling-out hole (2 places) on cover (10). Float
cover (10) from case (14).
: 19 mm

20. Install an eyebolt (M12, Pitch 1.75 mm) to the

pulling-out hole (2 places) on cover (10).

21. Hoist and remove cover (10) from case (14). At

this time, the outer race of roller bearing (9) is
removed with cover (10) together.

CAUTION: The gear (8) assembly weight: 50

kg (110 lb)

22. Install an eyebolt (M10, Pitch 1.5 mm) to the

lifting hole (2 places) on gear (8).

W18K-E-00(20181019) W2-3-25
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF PUMP TRANSMISSION

Pump Side 21 23 26 Engine Side

33 31, 32 30

38
25
39, 40
22

34
29 24
27, 28
11, 12
8
4 10
3
13

W18C-02-04-004
1
35 36, 37 2
6
7

9
5

18

17
16
19
15

20
14

W18C-02-04-005

1- O-Ring 11 - Washer (10 Used) 21 - O-Ring (3 Used) 31 - Bolt (16 Used)

2- Spacer 12 - Bolt (10 Used) 22 - Ball Bearing (3 Used) 32 - Spring Washer (16 Used)
3- Disc Spring 13 - Oil Seal 23 - Gear (3 Used) 33 - Cover (3 Used)
4- Spacer 14 - Case 24 - Spacer (3 Used) 34 - Cover
5- Roller Bearing 15 - Ball Bearing 25 - Retaining Ring (3 Used) 35 - Pipe Assembly
6- Retaining Ring 16 - Retaining Ring 26 - Ball Bearing (3 Used) 36 - Bolt (4 Used)
7- Stopper 17 - Spacer 27 - Bolt (2 Used) 37 - Spring Washer (4 Used)
8- Gear 18 - Gear 28 - Washer (2 Used) 38 - Hook (2 Used)
9- Roller Bearing 19 - Ball Bearing 29 - Cover 39 - Bolt (4 Used)
10 - Cover 20 - O-Ring 30 - Cork (8 Used) 40 - Spring Washer (4 Used)

W18K-E-00(20181019) W2-3-26
 UPPERSTRUCTURE / Pump Device
Assembly of Pump Transmission
• As for the method to hoist the parts and the
position of the lifting hole, refer to Removal.
1. Warm up ball bearings (15, 19), (22) (3 used) and
(26) (3 used) to approx. 90 °C (194 °F) by using
a bearing heater.
IMPORTANT: Install ball bearings (15, 19) while
aligning the matching marks made
when disassembling.
2. Install spacer (17), retaining ring (16) and ball
bearings (15, 19) to gear (18).
CAUTION: Gear (23) weight: 25 kg (60 lb)
IMPORTANT: Install ball bearings (22, 26) while
aligning the matching marks made
when disassembling.
3. Install spacers (24) (3 used), retaining rings (25)
(3 used), ball bearings (22) (3 used) and (26) (3
used) to gears (23) (3 used).
4. Heat the inner races of roller bearings (5, 9) to
approx. 90°C by using a bearing heater.
CAUTION: Gear (8) weight: 42 kg (93 lb)
IMPORTANT: Install the inner races of roller
bearings (5, 9) while aligning the
matching marks made when
disassembling.
5. Install stopper (7), retaining ring (6) and the inner
races of roller bearings (5, 9) to gear (8).
W18K-E-00(20181019) W2-3-27
CAUTION: Case (14) weight: 420 kg (930 lb)
6. Hoist and place case (14) with the engine side
facing upward.
7. Install spacer (2), disc spring (3), spacer (4) and
the outer race of roller bearing (5) to case (14).
CAUTION: The gear (8) assembly weight: 50
kg (110 lb)
8. Hoist and install gear (8) to case (14).
9. Install oil seal (13) to cover (10) by using a plate
and a hammer.
CAUTION: Cover (10) weight: 31 kg (70 lb)
IMPORTANT: Apply THREEBOND #1215 onto the
case (14) mounting surface of cover
(10).
Apply LOCTITE #243 onto the thread
part of bolt (12).
10. Hoist cover (10). Install cover (10) to case (14)
with bolts (12) (10 used) and washers (11) (10
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
CAUTION: The case (14) assembly weight:
500 kg (1110 lb)
11. Hoist and turn over the case (14) assembly.
 UPPERSTRUCTURE / Pump Device

Lubrication Pump Side 21 23 Engine Side

33 31, 32 30 Port

38
39, 40

34
29
Lubrication 27, 28
Port
Lubrication
Port

W18C-02-04-004

35 36, 37 1

18

20
14

W18C-02-04-005

W18K-E-00(20181019) W2-3-28
 UPPERSTRUCTURE / Pump Device
CAUTION: The gear (18) assembly weight:
22 kg (55 lb)
The gear (23) assembly weight: 31 kg (70 lb)
12. Hoist and install the gear (18) assembly and the
gear (23) assemblies (3 used) to case (14).
13. Install O-ring (1), O-rings (21) (3 used) and
O-ring (20) to cover (29), covers (33) (3 used)
and cover (34).
CAUTION: Cover (33) weight: 38 kg (84 lb)
Cover (34) weight: 37 kg (82 lb)
15. Install cover (29) to case (14) with bolts (27) (2
used) and washers (28) (2 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
16. Install hooks (38) (2 used) to case (14) with bolts
(39) (4 used) and spring washers (40) (4 used).
IMPORTANT: Apply THREEBOND #1215 onto the
pipe assembly (35) mounting
surface of case (14).
17. Connect pipe assembly (35) to case (14) with
bolts (36) (4 used) and spring washers (37) (4
used).

IMPORTANT: Install covers (33) (3 used) and 18. Install corks (30) (8 used) to covers (33) (3 used)
cover (34) with the lubrication port and cover (34).
on the side facing to the position as
illustrated on W2-3-28.
14. Hoist covers (33) (3 used) and cover (34). Install
covers (33) (3 used) and cover (34) to case (14)
with bolts (31) (16 used) and spring washers (32)
(16 used).
: 17 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf⋅ft)

W18K-E-00(20181019) W2-3-29
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF MAIN PUMP
• The components of casing (26) are same as
those of casing (74). 16
15

14
13 17
18
12 19
11 20
9 10
8 21

22
23

7 25
24
26
5
6 27
5 28
4
29 47
3 46
30 45
2 44
1 43
42
49
41 48
40
39
38

36 37
51 50 66
35 52
67 68
34
33
32
31
65
64
63
62 69
70
60 71
59
58 61 72
56
55 73
54 74
75
57
76
53 77

78
79
80
82 81
84 83 W18C-02-04-006

W18K-E-00(20181019) W2-3-30
 UPPERSTRUCTURE / Pump Device

1- Socket Bolt (4 Used) 22 - O-Ring (4 Used) 43 - Plug 64 - O-Ring

2- Seal Cover 23 - Plug (4 Used) 44 - Seat 65 - O-Ring (6 Used)
3- O-Ring 24 - Plug (4 Used) 45 - Steel Ball 66 - Regulator
4- Retaining Ring (2 Used) 25 - Screw (4 Used) 46 - Stopper 67 - Socket Bolt (4 Used)
5- Spacer (3 Used) 26 - Casing 47 - O-Ring 68 - Socket Bolt (4 Used)
6- Bearing (2 Used) 27 - O-Ring (4 Used) 48 - Adjusting Screw 69 - Seal Cover
7- Shaft 28 - O-Ring (2 Used) 49 - Lock Nut 70 - Oil Seal
8- Lock Nut (2 Used) 29 - Support 50 - Valve Cover 71 - O-Ring
9- Adjusting Screw (2 Used) 30 - Socket Bolt (4 Used) 51 - Spring Pin (2 Used) 72 - Shaft
10 - Spring Pin 31 - Swash Plate (2 Used) 52 - Pin 73 - Support
11 - Stopper (2 Used) 32 - Bushing (2 Used) 53 - O-Ring 74 - Casing
12 - Backup Ring (2 Used) 33 - Shoe Plate (2 Used) 54 - Stopper 75 - Socket Bolt (4 Used)
13 - O-Ring (2 Used) 34 - Plunger (18 Used) 55 - Steel Ball 76 - Pin
14 - Tilt Pin (2 Used) 35 - Retainer (2 Used) 56 - Seat 77 - Spring Pin
15 - Regulator 36 - Spherical Bushing (2 Used) 57 - O-Ring 78 - Valve Cover
16 - Socket Bolt (4 Used) 37 - Spring (18 Used) 58 - O-Ring (4 Used) 79 - O-Ring
17 - Stopper (2 Used) 38 - Cylinder Block (2 Used) 59 - Lock Nut 80 - Plug
18 - Backup Ring (2 Used) 39 - Valve Plate 60 - Adjusting Screw 81 - O-Ring
19 - O-Ring (2 Used) 40 - Needle Bearing 61 - Needle Bearing 82 - O-Ring
20 - Servo Piston (2 Used) 41 - O-Ring (2 Used) 62 - Socket Bolt (8 Used) 83 - Booster
21 - Set Screw (8 Used) 42 - O-Ring 63 - Valve Plate 84 - Coupling

W18K-E-00(20181019) W2-3-31
 UPPERSTRUCTURE / Pump Device

16
15

9
8 21

22
23

26

29
30

49
41 48

39

50 66
52
67

64
63
62

60
59
58 61
73
74
75
57 76

78

82 81
84 83 W18C-02-04-006

W18K-E-00(20181019) W2-3-32
 UPPERSTRUCTURE / Pump Device
Disassembly of Main Pump
IMPORTANT: Do not disassemble lock nuts (8) (2
used), (49, 59), adjusting screws (9)
(2 used) and (48, 60) as the set flow
rate may change.
1. Remove plugs (23) (4 used) and O-rings (22) (4
used) from casing (26, 74). Drain hydraulic oil
from the main pump.
: 36 mm
2. Remove socket bolts (16) (4 used). Remove
regulator (15) from casing (26). At this time,
check that O-ring with the regulator (15) side at-
tached does not fall off.
: 6 mm
3. Remove socket bolts (67) (4 used). Remove
regulator (66) from casing (74). At this time,
check that O-ring with the regulator (66) side at-
tached does not fall off.
: 6 mm
4. Remove set screws (21) (8 used) from casings
(26, 74).
CAUTION: Main pump weight: 195 kg (430
lb)
5. Hoist and turn over the main pump with the regu-
lator mounting surface facing downward. At this
time, do not damage the regulator mounting sur-
face.
NOTE: Install a shackle to the hole on the flange
of support (29, 73). Turn over the main
pump.
W18K-E-00(20181019) W2-3-33
IMPORTANT: Do not drop valve plate (63).
6. Remove socket bolts (75) (4 used). Separate
casing (74) from valve cover (78).
: 17 mm
7. Remove socket bolts (62) (8 used). Separate
valve cover (50) from valve cover (78).
: 10 mm
8. Remove O-ring (57), O-rings (58) (4 used) and
(81, 82) from valve cover (78).
9. Remove coupling (84) and booster (83) from
shaft (7).
IMPORTANT: Do not drop valve plate (39).
10. Remove socket bolts (30) (4 used). Separate
casing (26) from valve cover (50).
: 17 mm
11. Remove O-rings (41, 64) from valve covers (50,
78).
IMPORTANT: Valve plate (39) and valve plate (63)
are similar. Do not confuse valve
plates (39) and (63) when handling
them.
12. Remove valve plates (39, 63) and pins (52, 76)
from valve covers (50, 78).
 UPPERSTRUCTURE / Pump Device

10

26
5
6
5 28
4
29 47
3 46
45
2 44
1

40

38

36 37
51 50
35
34
33

31

61
56
55
54

53 77

78

W18C-02-04-006

W18K-E-00(20181019) W2-3-34
 UPPERSTRUCTURE / Pump Device
13. Remove spring pins (51) (2 used) and spring pin
(77) from valve covers (50, 78).
IMPORTANT: Do not remove needle bearings (40,
61) unless necessary.
14. Remove needle bearings (40, 61) from valve
covers (50, 78).
IMPORTANT: Do not remove seats (44, 56).
Check the flow of air through seats
(44, 56) with valve covers (50, 78)
attached from the stoppers (46, 54)
side. If the air cannot flow freely,
there may be dirt on seats (44, 56).
15. Remove O-rings (47, 53), stoppers (46, 54) and
steel balls (45, 55) from valve covers (50, 78).
IMPORTANT: Wind vinyl tape onto the rotating
surface of needle bearing (40) on
shaft (7) in order to protect the sur-
face.
16. Remove cylinder block (38) from casing (26). At
this time, springs (37) (9 used), spherical bushing
(36), retainer (35) and plungers (34) (9 used) are
removed with cylinder block (38) together.
NOTE: Grasp and slowly remove cylinder block
(38) by hands while lightly turning cylinder
block (38) to left and right.
W18K-E-00(20181019) W2-3-35
17. Remove retainer (35) from the cylinder block (38)
assembly. At this time, plungers (34) (9 used) are
removed with retainer (35) together.
18. Remove plungers (34) (9 used) from retainer
(35).
19. Remove spherical bushing (36) from cylinder
block (38). Remove springs (37) (9 used).
20. Remove socket bolts (1) (4 used). Remove seal
cover (2) and O-ring (3) from support (29).
: 6 mm
NOTE: There are pulling-out holes on seal cover
(2). Remove seal cover (2) by using a bolt
(M8, Pitch 1.25 mm).
21. Lightly tap and remove support (29) from the cas-
ing (26) side by using a plastic hammer.
22. Remove spring pin (10) and O-ring (28) from
support (29).
23. Remove swash plate (31) and shoe plate (33)
from casing (26).
24. Tap the flange part of the casing (26) side of shaft
(7) by using a plastic hammer and remove shaft
(7) from support (29). At this time, bearing (6) is
removed with shaft (7) together.
25. Remove retaining ring (4) from shaft (7). Remove
spacer (5) and bearing (6).
 UPPERSTRUCTURE / Pump Device

14
13 17
18
12 19
11 20

25
24
26

68

65

69
70
71

73
74

W18C-02-04-006

W18K-E-00(20181019) W2-3-36
 UPPERSTRUCTURE / Pump Device
26. Remove stoppers (11, 17) from casing (26). IMPORTANT: The components of casing (26) are
NOTE: Install a bolt (M6, Pitch 1.0 mm) to the same as those of casing (74).
center hole of the stopper and remove the 33. Disassemble the casing (74) assembly in the
stopper. same way as steps 16 to 27.
NOTE: Spacer (5) in the seal cover (69) side is not
IMPORTANT: As LOCTITE has been applied onto equipped for casing (74).
the contacting part between servo
piston (20) and tilt pin (14). Do not
disassemble them unless neces-
sary.
27. Warm up tilt pin (14) by using a drier. Secure
servo piston (20) in order not to damage by using
a pair of pliers. Turn and remove tilt pin (14).
Remove servo piston (20) from casing (26).

28. Remove O-rings (13, 19) and backup rings (12,

18) from stoppers (11, 17).

29. Remove plugs (24) (4 used) and screws (25) (4

used) from casings (26, 74).
: 4 mm, 5 mm

30. Remove socket bolts (68) (4 used). Remove seal

cover (69) and O-ring (71) from support (73).
: 6 mm
NOTE: There are pulling-out holes on seal cover
(69). Remove seal cover (69) by using a
bolt (M8, Pitch 1.25 mm).

31. Remove oil seal (70) from seal cover (69).

32. Remove O-rings (65) (6 used) from casing (74).

W18K-E-00(20181019) W2-3-37
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF MAIN PUMP

29 36 31 33 35 32 26 41 50 49 48 82 64 65 18, 19 17 20 14 11 12, 13 73
60
8 59

9
10
1 68
71
6
69
5

7
2
72
4 A A 70
3 75

30
A 77 A
W18C-02-04-007
28 34 37 38 76
39 51 52 40 84 83 78 61 63 74
79, 80

Section of Check Valve

Section A-A 44 46
45 47

W18B-02-04-040
25

24
W18C-02-04-008

53 54 55 56

W18K-E-00(20181019) W2-3-38
 UPPERSTRUCTURE / Pump Device

1- Socket Bolt (4 Used) 22 - *O-Ring (4 Used) 43 - *Plug 64 - O-Ring

2- Seal Cover 23 - *Plug (4 Used) 44 - Seat 65 - O-Ring (6 Used)
3- O-Ring 24 - Plug (4 Used) 45 - Steel Ball 66 - *Regulator
4- Retaining Ring (2 Used) 25 - Screw (4 Used) 46 - Stopper 67 - *Socket Bolt (4 Used)
5- Spacer (3 Used) 26 - Casing 47 - O-Ring 68 - Socket Bolt (4 Used)
6- Bearing (2 Used) 27 - *O-Ring (4 Used) 48 - Adjusting Screw 69 - Seal Cover
7- Shaft 28 - O-Ring (2 Used) 49 - Lock Nut 70 - Oil Seal
8- Lock Nut (2 Used) 29 - Support 50 - Valve Cover 71 - O-Ring
9- Adjusting Screw (2 Used) 30 - Socket Bolt (4 Used) 51 - Spring Pin (2 Used) 72 - Shaft
10 - Spring Pin 31 - Swash Plate (2 Used) 52 - Pin 73 - Support
11 - Stopper (2 Used) 32 - Bushing (2 Used) 53 - O-Ring 74 - Casing
12 - Backup Ring (2 Used) 33 - Shoe Plate (2 Used) 54 - Stopper 75 - Socket Bolt (4 Used)
13 - O-Ring (2 Used) 34 - Plunger (18 Used) 55 - Steel Ball 76 - Pin
14 - Tilt Pin (2 Used) 35 - Retainer (2 Used) 56 - Seat 77 - Spring Pin
15 - *Regulator 36 - Spherical Bushing (2 Used) 57 - *O-Ring 78 - Valve Cover
16 - *Socket Bolt (4 Used) 37 - Spring (18 Used) 58 - *O-Ring (4 Used) 79 - O-Ring
17 - Stopper (2 Used) 38 - Cylinder Block (2 Used) 59 - Lock Nut 80 - Plug
18 - Backup Ring (2 Used) 39 - Valve Plate 60 - Adjusting Screw 81 - *O-Ring
19 - O-Ring (2 Used) 40 - Needle Bearing 61 - Needle Bearing 82 - O-Ring
20 - Servo Piston (2 Used) 41 - O-Ring (2 Used) 62 - *Socket Bolt (8 Used) 83 - Booster
21 - *Set Screw (8 Used) 42 - *O-Ring 63 - Valve Plate 84 - Coupling

NOTE: As for the parts with mark *, refer to W2-3-30.

W18K-E-00(20181019) W2-3-39
 UPPERSTRUCTURE / Pump Device

65
29 31 33 26 50 18, 19 17 20 14 11 12, 13 73

10

6
69
5

72
4 A A

A A
W18C-02-04-007
28
78 74

Section of Check Valve

Section A-A

W18B-02-04-040
25

24
W18C-02-04-008

W18K-E-00(20181019) W2-3-40
 UPPERSTRUCTURE / Pump Device
Assembly of Main Pump
IMPORTANT: Apply LOCTITE #1305N onto the
thread part of servo piston (20).
1. Install tilt pins (14) (2 used) and servo pistons
(20) (2 used) to casings (26, 74).
2. Install O-rings (13) (2 used), (19) (2 used),
backup rings (12) (2 used) and (18) (2 used) to
stoppers (11) (2 used) and (17) (2 used).
3. Install the stopper (11) assembly and the stopper
(17) assembly to casings (26, 74).
4. Install spacers (5) (3 used), bearings (6) (2 used)
and retaining rings (4) (2 used) to shafts (7, 72).
NOTE: Spacer (5) in the seal cover (69) side is not
equipped for shaft (72).
5. Install screws (25) (4 used) and plugs (24) (4
used) to casings (26, 74).
: 4 mm
: 9 N⋅m (0.9 kgf⋅m, 7 lbf⋅ft)
: 5 mm
: 10 N⋅m (0.9 kgf⋅m, 7 lbf⋅ft)
IMPORTANT: Do not tap shafts (7, 72) by using a
hammer.
6. Install shafts (7, 72) to supports (29, 73), At this
time, lightly tap the outer race of bearing (6) by
using a plastic hammer. Tap the outer race into
the most inside by using a bar and a hammer.
W18K-E-00(20181019) W2-3-41
IMPORTANT: Apply grease onto the mating sur-
faces between swash plate (31) and
shoe plate (33). After installing
swash plate (31), check that swash
plate (31) can move smoothly by
hand.
7. Attach a nylon sling onto the bodies of casings
(26, 74). Hoist and place casings (26, 74) with
the regulator mounting surface facing downward.
Install swash plates (31) (2 used) with shoe
plates (33) (2 used) attached to tilt pins (14) (2
used).
NOTE: Install shoe plate (33) with the chamfered
side facing to the swash plate (31) side.
8. Install spring pins (10) (2 used) and O-rings (28)
(2 used) to supports (29, 73). Install O-rings (27)
(4 used) to casings (26, 74).
9. Install O-ring (57), O-rings (58) (4 used), (65) (6
used) and O-ring (81) among valve covers (50,
78) and casing (74) respectively.
10. Align the support (29) assembly and the support
(73) assembly with casings (26, 74).
 UPPERSTRUCTURE / Pump Device

36 35 26 41 50 82 64

72
A A

30
A 77 A
W18C-02-04-007
34 37 38 76
39 51 52 40 84 83 78 61 63 74

Section of Check Valve

Section A-A 46
45 47

W18B-02-04-040

W18C-02-04-008

53 54 55

W18K-E-00(20181019) W2-3-42
 UPPERSTRUCTURE / Pump Device
11. Install springs (37) (18 used), spherical bushings 17. Install valve cover (50) to the casing (26) assem-
(36) (2 used), retainers (35) (2 used) and plung- bly with socket bolts (30) (4 used).
ers (34) (18 used) to cylinder blocks (38) (2 used) : 17 mm
in this order. : 430 N⋅m (44 kgf⋅m, 320 lbf⋅ft)

12. Install the cylinder block (38) assemblies (2 used)
to casings (26, 74).
NOTE: For easy installation, align shafts (7, 72)
with the spline grooves in cylinder block
(38) and spherical bushing (36) before in-
stalling.
18. Install set screws (21) (4 used) to casing (26).
: 4 mm
: 12 N⋅m (1.2 kgf⋅m, 9 lbf⋅ft)
19. Install steel ball (45), stopper (46) and O-ring (47)
to valve cover (50).

13. Install needle bearings (40, 61) to valve covers 20. Install steel ball (55), stopper (54) and O-ring (53)
(50, 78). to valve cover (78).

14. Install spring pins (51) (2 used), pin (52) and 21. Install coupling (84) and booster (83) onto shaft
O-ring (41) to valve cover (50). (7).

15. Install spring pin (77), pin (76) and O-rings (64,
82) to valve cover (78).

IMPORTANT: Apply grease onto the mounting

surfaces before installing valve
plates (39, 63). Install valve plates
(39, 63) with the spherical side fac-
ing to the cylinder block (38) side.
16. Install vale plates (39, 63) to valve covers (50,
78).

W18K-E-00(20181019) W2-3-43
 UPPERSTRUCTURE / Pump Device

29 26 50 73

1 68
71
69

2
A A 70
3 75

A A
W18C-02-04-007

78 74
79, 80

Section of Check Valve

Section A-A

W18B-02-04-040

W18C-02-04-008

W18K-E-00(20181019) W2-3-44
 UPPERSTRUCTURE / Pump Device
22. Install valve cover (78) to the valve cover (50) 28. Install seal cover (69) to support (73) with socket
assembly with socket bolts (62) (8 used). bolts (68) (4 used).
: 17 mm : 6 mm
: 430 N⋅m (44 kgf⋅m, 320 lbf⋅ft) : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

23. Install the valve cover (78) assembly to the cas-

ing (74) assembly with bolts (75) (4 used).
24. Install set screws (21) (4 used) to the casing (74)
assembly.
: 4 mm
: 12 N⋅m (1.2 kgf⋅m, 9 lbf⋅ft)
25. Install plugs (23) (4 used), O-rings (22) (4 used),
plugs (43, 80) and O-rings (42, 79) to the casing
(26) assembly and the casing (74) assembly.
: 19 mm
: 36 N⋅m (3.7 kgf⋅m, 27 lbf⋅ft)
: 36 mm
: 170 N⋅m (17.5 kgf⋅m, 125 lbf⋅ft)
CAUTION: Main pump weight: 195 kg (430
lb)
29. Hoist and place the pump assembly with the
regulator mounting surface facing upward.
NOTE: Install a shackle to the hole on the flange
part of supports (29, 73) before hoisting.
30. Install regulators (15, 66) with socket bolts (16) (4
used) and (67) (4 used).
: 6 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

26. Install O-ring (3) to seal cover (2). Install seal

cover (2) to support (29) with socket bolts (1) (4
used).
: 6 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

27. Install oil seal (70) and O-ring (71) to seal cover
(69).

W18K-E-00(20181019) W2-3-45
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD

1. Clearance between plunger (34) outer diameter

(d) and cylinder block (38) bore (D)

D-d Unit: mm (in)

Standard Allowable Limit
d D
0.038 (0.001) 0.078 (0.003)

W117-02-02-009

2. Spring (37) free length (L)

Unit: mm (in)
Standard Allowable Limit
40.9 (1.6) 40.1 (1.6)

W117-02-02-010

3. Clearance (e) between plunger (34) and the

crimped part of the shoe, and shoe thickness (t)
e Unit: mm (in)
Standard Allowable Limit
0 to 0.1 0.35
(0 to 0.004) (0.014)
t Unit: mm (in)
Standard Allowable Limit e
5.4 (0.2) 5.0 (0.2) t

W117-02-02-011

Stand
4. Distance between retainer (35) bottom and
spherical bushing (36) top
H
H-h Unit: mm (in) h
Standard Allowable Limit
23.8 (0.9) 22.8 (0.9) W117-02-02-012

W18K-E-00(20181019) W2-3-46
 UPPERSTRUCTURE / Pump Device
(Blank)

W18K-E-00(20181019) W2-3-47
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF REGULATOR FOR
MAIN PUMP
12
11
10
9
8

7 66
6 13
15
5 16
4 17
3
19
2
1 14
20

21
22
26 18 23
24
27 25 46
28
29
31 30
32
45
47

44
43
42
37 39 41
34
40
33 48
49
35
36
38

63
51
64 52
53

57
65
50
62 61
56
60
58 55
54
59
W18C-02-04-009

W18K-E-00(20181019) W2-3-48
 UPPERSTRUCTURE / Pump Device

1- Pin 18 - Pin 35 - O-Ring 51 - Supporting Plug

2- Sleeve 19 - Lever 36 - O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring (2 Used) 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - Socket Bolt (4 Used) 62 - O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (4 Used)
16 - Feedback Lever 33 - Socket Bolt (4 Used) 50 - Pin 66 - Piston
17 - Pin 34 - Cover

W18K-E-00(20181019) W2-3-49
 UPPERSTRUCTURE / Pump Device

12
11
10
9
8

3
2
1

26

27 46
28
29
31 30
32
45
47

44
43
42
37 39 41
34

33 48
49
35
36
38

63
51
64
53

57
65
50
62 61
56
60
58 54
59
W18C-02-04-009

W18K-E-00(20181019) W2-3-50
 UPPERSTRUCTURE / Pump Device
Disassembly of Regulator for Main Pump

1. Remove socket bolts (37) (2 used) and (39) (2
used). Remove the regulator from the pump body.
Remove pins (57) (2 used) and O-rings (58, 59)
from casing (38).
: 6 mm
8. Remove retaining ring (32) from spool (26). Re-
move spring seat (31), spring (30) and sleeve
(27) from spool (26).
9. Remove retaining ring (28) from sleeve (27).

2. Remove socket bolts (33) (4 used). Remove 10. Remove pin (1), sleeve (2) and O-ring (3) from
cover (34), O-rings (35) and O-rings (36) (3 used) casing (38).
from casing (38).
: 5 mm 11. Remove lock rings (53, 54) from casing (38).

IMPORTANT: Do not disassemble lock nuts (43,
48, 47) and adjusting screws (42, 49,
41) as the set flow rate changes.
When removing cover (45), prevent
springs (9, 10) inside from flying
out.
3. Remove socket bolts (46) (4 used). Remove the
cover (45) assembly and O-ring (44) from casing
(38).
: 5 mm
IMPORTANT: Supporting plugs (51, 56) look quite
similar. Put the matching marks in
order to install correctly.
12. Insert a bolt (M6, Pitch 1.0 mm) into the center
hole of supporting plugs (51, 56). Remove sup-
porting plugs (51, 56) from casing (38).
At this time, pin (50) is removed with supporting
plug (51) together.
13. Remove pin (50) from supporting plug (56).

4. Remove springs (9, 10) and spring seat (8) from

casing (38).

5. Remove stopper (11) and O-ring (12) from the

cover (45) assembly.

6. Remove socket bolts (65) (4 used). Remove

cover (64) from casing (38).
: 5 mm

7. Remove O-rings (60, 61, 62, 63) and spring (29)

from casing (38).

W18K-E-00(20181019) W2-3-51
 UPPERSTRUCTURE / Pump Device

7 66
6
15
5 16
4 17
19

14
20

21
22
26 23
24
25

41

38

51
52

56
55

W18C-02-04-009

W18K-E-00(20181019) W2-3-52
 UPPERSTRUCTURE / Pump Device
14. Remove O-rings (52, 55) from supporting plugs
(51, 56).

IMPORTANT: Do not remove pin (20) from lever

(19).
15. Remove lever (19) from casing (38) by using a
pair of pincers.

16. Remove pin (17) and feedback lever (16) by us-

ing a round bar (4 mm).

IMPORTANT: Do not remove pin (14) from lever

(15).
17. Remove lever (15) from casing (38).

18. Remove pilot piston (25) from casing (38).

19. Insert a round bar (Dia. 4 mm (0.2 in)) into the

pilot piston (25) side. Remove spring seat (24),
spring (23) and stopper (22) from casing (38).

20. Remove O-ring (21) from stopper (22).

21. Insert a round bar (Dia. 4 mm (0.2 in)) into the

adjusting screw (41) side. Remove compensating
rod (7) and the sleeve (5) assembly from casing
(38).

22. Remove compensating rod (7), compensating

piston (6) and O-ring (4) from sleeve (5).

23. Remove spool (26) from casing (38).

W18K-E-00(20181019) W2-3-53
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF REGULATOR FOR MAIN
PUMP A 34 33

B C W117-02-02-016

Section A-B
64 38 25 18 19 20 23 22 21

61 48

49
65

37 24 39
W18C-02-04-010

Section A-C
63 29 30 28 27 26 17 15 8 40
D 45
9 44 47
10 66 43
32
42
31

3
4 5 6 7 14 57 11 12 41
58 16 50
D W117-02-02-007

13 51 52 53
Section D-D

14 56 55 54 W18B-02-04-043

W18K-E-00(20181019) W2-3-54
 UPPERSTRUCTURE / Pump Device

1- Pin 18 - Pin 35 - *O-Ring 51 - Supporting Plug

2- Sleeve 19 - Lever 36 - *O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring (2 Used) 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - *O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - *O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - *Socket Bolt (4 Used) 62 - *O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (4 Used)
16 - Feedback Lever 33 - Socket Bolt (4 Used) 50 - Pin
17 - Pin 34 - Cover
NOTE: As for the parts with mark *, refer to W2-3-48.

W18K-E-00(20181019) W2-3-55
 UPPERSTRUCTURE / Pump Device

B C W117-02-02-016

Section A-B
38 25 19 20

W18C-02-04-010

Section A-C
29 30 28 27 26 17 15
D

32

31

7 14
16 50
D W117-02-02-007

51 52 53
Section D-D

56 55 54 W18B-02-04-043

W18K-E-00(20181019) W2-3-56
 UPPERSTRUCTURE / Pump Device
Assembly of Regulator for Main Pump
IMPORTANT: Check the direction to install com-
pensating rod (7) as illustrated.
1. Insert compensating rod (7) into casing (38).
2. Install pin (14) to lever (15). Insert lever (15) into
casing (38). Install pin (14) while aligning with the
groove in compensating rod (7).
3. Install retaining ring (28) to sleeve (27).
IMPORTANT: After inserting, check that spool (26)
moves smoothly.
4. Insert sleeve (27) and spool (26) into casing (38).
IMPORTANT: Check the direction to install feed-
back lever (16).
5. Align the pin hole (the hole in the upper side) on
feedback lever (16) with the pin hole on spool
(26). Install pin (17).
Compensating Lever (26) Side
Rod (7) Side
W18B-02-04-018
W18K-E-00(20181019)
IMPORTANT: After inserting, check that pilot pis-
ton (25) moves smoothly.
6. Insert pilot piston (25) into casing (38).
7. Install O-rings (52, 55) to supporting plugs (51,
56).
IMPORTANT: Supporting plugs (51, 56) look quite
similar.
Install plugs (51, 56) while aligning
the matching marks made when
disassembling in order to install
correctly.
8. Align the groove on pilot piston (25) with pin (20)
on lever (19). Install lever (19).
9. Install pin (50) to supporting plug (56). Align pin
(50) with the hole on lever (19). Install supporting
plug (56) to lever (19).
10. Install lock ring (54) to supporting plug (56).
11. Install supporting plug (51) to casing (38). Install
lock ring (53).
12. Install spring (30) and spring seat (31) to spool
(26). Install retaining ring (32).
13. Install spring (29) to casing (38).
W2-3-57
 UPPERSTRUCTURE / Pump Device

A 34 33

B C W117-02-02-016

Section A-B
64 38 23 22 21

61

65

37 24 39
W18C-02-04-010

Section A-C

63 8
D 45
9 44
10

3
4 5 6 7 57 11 12
58
D W117-02-02-007

Section D-D

W18B-02-04-043

W18K-E-00(20181019) W2-3-58
 UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the direction to install com- 25. Install pins (57) (2 used) and O-rings (58, 59) to
pensating piston (6) as illustrated. casing (38).
14. Install O-ring (4) and compensating piston (6) to
sleeve (5). 26. Install the regulator to the pump body with socket
bolts (37) (2 used) and (39) (2 used).
15. Install sleeve (5), O-ring (3), sleeve (2) and pin : 6 mm
(1) to casing (38). : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

16. Install O-rings (60, 62, 61 and 63) to casing (38).

17. Install cover (64) to casing (38) with socket bolts

(65) (4 used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8 lbf⋅ft)

18. Install O-ring (35) and O-rings (36) (3 used) to

cover (34).

19. Install cover (34) to casing (38) with socket bolts

(33) (4 used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8 lbf⋅ft)

20. Install O-ring (21) to stopper (22).

21. Install spring seat (24), spring (23) and stopper

(22) to casing (38).

22. Install O-ring (12) to stopper (11).

23. Install spring seat (8) and springs (9, 10) to cas-
ing (38).

24. Install stopper (11) and O-ring (44) to the cover

(45) assembly. Install the cover (45) assembly to
casing (38) with socket bolts (46) (4 used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8 lbf⋅ft)

W18K-E-00(20181019) W2-3-59
 UPPERSTRUCTURE / Pump Device
(Blank)

W18K-E-00(20181019) W2-3-60
 UPPERSTRUCTURE / Pump Device
STRUCTURE OF 4-SPOOL PUMP

A B C D

T117-02-01-017

A - Oil Cooler Fan Motor Drive Pump (Plunger Pump) C - Compressor Motor Drive Pump (End Side Tandem Gear Pump)
B - Pilot Pump (Pump Transmission Side Tandem Gear) D - Pump Transmission Oil Lubrication Pump (Gear Pump)

W18K-E-00(20181019) W2-3-61
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF OIL COOLER FAN
DRIVE PUMP 17
18

16 20 21 22

19
15 23
14
13
12
11
10 24 25
26
27

9 28
8
7
6
5 29
30
4 31
3 32 51
2
1 50
49
48

47
44 46
45
43
42
39 52
53
54
40 41
55

37 38 62
35
34 63 59 58
36 66 65 64 61 57 56
60
33

W18C-02-04-012

1- Socket Bolt (4 Used) 18 - Socket Bolt (4 Used) 35 - Shoe Plate 51 - Socket Bolt (4 Used)
2- Cover 19 - Servo Piston 36 - Plunger (9 Used) 52 - Plug
3- O-Ring 20 - O-Ring 37 - Retainer 53 - O-Ring
4- Oil Seal 21 - Backup Ring 38 - Spherical Bushing 54 - Casing
5- Shaft 22 - Stopper 39 - Retaining Ring 55 - Socket Bolt (3 Used)
6- Spacer 23 - O-Ring 40 - Spring (9 Used) 56 - O-Ring (4 Used)
7- Bearing 24 - O-Ring 41 - Cylinder Block 57 - Seat
8- Spacer 25 - Plug 42 - Stopper 58 - Steel Ball
9- Retaining Ring 26 - Lock Nut 43 - Steel Ball 59 - Stopper
10 - Lock Nut 27 - Eyebolt 44 - Seat 60 - Plug
11 - Adjusting Screw 28 - Housing 45 - Valve Cover 61 - O-Ring
12 - Spring Pin 29 - O-Ring (2 Used) 46 - Adjusting Screw 62 - Spring Pin
13 - Stopper 30 - O-Ring 47 - Lock Nut 63 - Pin
14 - Backup Ring 31 - Cover 48 - Coupling 64 - O-Ring
15 - O-Ring 32 - Socket Bolt (4 Used) 49 - O-Ring 65 - Needle Bearing
16 - Tilt Pin 33 - Swash Plate 50 - Plate 66 - Valve Plate
17 - Regulator 34 - Bushing

W18K-E-00(20181019) W2-3-62
 UPPERSTRUCTURE / Pump Device
Disassembly of Oil Cooler Fan Drive Pump
IMPORTANT: Do not disassemble adjusting screw
(11), lock nut (10), adjusting screw
(46) and lock nut (47) as the set flow
rate changes.
1. Remove plug (60). Drain hydraulic oil from the
pump.
: 19 mm
2. Remove socket bolts (18) (4 used). Remove
regulator (17).
: 6 mm
CAUTION: Pump weight: 62 kg (140 lb)
IMPORTANT: Do not damage the regulator
mounting surface on housing (28).
3. Attach a nylon sling onto the body of housing (28).
Hoist and place housing (28) with the regulator
mounting surface facing downward. Remove
socket bolts (51) (4 used). Remove socket bolts
(51) (4 used). Remove plate (50), O-ring (49) and
coupling (48) from valve cover (45).
: 10 mm
4. Remove retaining ring (39) from coupling (48).
IMPORTANT: At this time, do not remove cover
(31) from housing (28).
Do not drop valve plate (66).
5. Remove socket bolts (32) (4 used). Remove
valve cover (45) from housing (28).
: 17 mm
W18K-E-00(20181019) W2-3-63
IMPORTANT: Do not remove needle bearing (65)
unless necessary.
6. Remove valve plate (66) and O-ring (64) from
valve cover (45).
7. Remove socket bolts (55) (3 used). Remove
casing (54) and O-rings (56) (4 used) from valve
cover (45).
: 5 mm
8. Remove plug (52) and O-ring (53) from casing
(54).
: 19 mm
IMPORTANT: Do not remove seats (44, 57).
Check the flow of air through seats
(44, 57) with valve cover (45) at-
tached from the stoppers (42, 59)
side. If the air can not flow freely,
there may be dirt on seats (44, 57).
Clean seats (44, 57) by using a com-
pressor.
9. Remove stoppers (42, 59) and steel balls (43,
58) from valve cover (45).
IMPORTANT: Wind vinyl tape onto the rotating
surface of needle bearing (65) on
shaft (5) in order to protect the sur-
face.
10. Remove cylinder block (41) from housing (28). At
this time, springs (40) (9 used), spherical bushing
(38), retainer (37) and plungers (36) (9 used) are
removed with cylinder block (41) together.
NOTE: Remove cylinder block (41) while lightly
turning cylinder block (41) to left and right
by hands slowly.
 UPPERSTRUCTURE / Pump Device

16 20 21 22

19
14 15
13

9 28
8
7
6
5

4 31
3
2
1

45

40 41

37 38
35
34 36

33

W18C-02-04-012

W18K-E-00(20181019) W2-3-64
 UPPERSTRUCTURE / Pump Device
11. Remove retainer (37) from the cylinder block (41) 21. Attach a nylon sling onto the body of housing (28).
assembly. At this time, plungers (36) (9 used) are Hoist and place housing (28) with the regulator
removed with retainer (37) together. mounting surface facing upward.

12. Remove plungers (36) (9 used) from retainer (37).
13. Remove spherical bushing (38) from cylinder
block (41). Remove springs (40) (9 used).
14. Remove socket bolts (1) (4 used) from cover (31).
Remove cover (2).
: 6 mm
NOTE: Remove cover (2) by installing a bolt (M8,
Pitch 1.25 mm) into the pulling-out hole.
22. Install a bolt (M5, Pitch 0.75 mm) to the center of
stoppers (13, 22). Remove stoppers (13, 22)
from housing (28).
IMPORTANT: LOCTITE has been applied onto the
joint part between servo piston (19)
and tilt pin (16). Do not remove them
unless necessary.
23. Remove backup rings (14, 21) and O-rings (15,
20) from stoppers (13, 22).

15. Remove O-ring (3) and oil seal (4) from cover (2).
16. Lightly tap the flange part of cover (31) at the
housing (28) side. Separate cover (31) from
housing (28).
24. Warm up tilt pin (16) by using a drier. Secure
servo piston (19) in order not to damage by using
a pair of pliers. Turn and remove tilt pin (16).
Remove servo piston (19) from housing (28).

IMPORTANT: Do not remove bushing (34) unless

necessary.
17. Remove swash plate (33) and shoe plate (35)
from the inside of housing (28).

18. Lightly tap shaft (5) at the valve cover (45) side
by using a plastic hammer. Remove shaft (5)
from cover (31).

19. Remove retaining ring (9) from shaft (5). Remove

spacer (8) and the inner ring plate and the outer
race of bearing (7).

20. Remove the inner race of bearing (7) and spacer

(6) from shaft (5).

W18K-E-00(20181019) W2-3-65
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF OIL COOLER FAN DRIVE
PUMP

31 14, 15 13 35 19 33 16 28 34 22 20, 21 64 66 47 46 50
10

11
12

30
51
1

6
49

39

5
48

32

7 8 9 37 36 38 40 41 62 60, 61 63 65 45
W18C-02-04-013

42 43

44
23

57

58

54 59

W18B-02-04-044

52, 53 56 55

W18K-E-00(20181019) W2-3-66
 UPPERSTRUCTURE / Pump Device

1- Socket Bolt (4 Used) 18 - *Socket Bolt (4 Used) 35 - Shoe Plate 51 - Socket Bolt (4 Used)
2- Cover 19 - Servo Piston 36 - Plunger (9 Used) 52 - Plug
3- O-Ring 20 - O-Ring 37 - Retainer 53 - O-Ring
4- Oil Seal 21 - Backup Ring 38 - Spherical Bushing 54 - Casing
5- Shaft 22 - Stopper 39 - Retaining Ring 55 - Socket Bolt (3 Used)
6- Spacer 23 - O-Ring 40 - Spring (9 Used) 56 - O-Ring (4 Used)
7- Bearing 24 - *O-Ring 41 - Cylinder Block 57 - Seat
8- Spacer 25 - *Plug 42 - Stopper 58 - Steel Ball
9- Retaining Ring 26 - *Lock Nut 43 - Steel Ball 59 - Stopper
10 - Lock Nut 27 - *Eyebolt 44 - Seat 60 - Plug
11 - Adjusting Screw 28 - Housing 45 - Valve Cover 61 - O-Ring
12 - Spring Pin 29 - *O-Ring (2 Used) 46 - Adjusting Screw 62 - Spring Pin
13 - Stopper 30 - *O-Ring 47 - Lock Nut 63 - Pin
14 - Backup Ring 31 - Cover 48 - Coupling 64 - O-Ring
15 - O-Ring 32 - Socket Bolt (4 Used) 49 - O-Ring 65 - Needle Bearing
16 - Tilt Pin 33 - Swash Plate 50 - Plate 66 - Valve Plate
17 - *Regulator 34 - Bushing
NOTE: As for the parts with mark *, refer to W2-3-62.

W18K-E-00(20181019) W2-3-67
 UPPERSTRUCTURE / Pump Device

31 14, 15 13 35 19 33 16 28 34 22 20, 21

12

30

3 W18C-02-04-013

7 8 9

W18B-02-04-044

W18K-E-00(20181019) W2-3-68
 UPPERSTRUCTURE / Pump Device
Assembly of Oil Cooler Fan Drive Pump

IMPORTANT: Apply LOCTITE #1303B onto the
thread part of servo piston (19).
1. Insert servo piston (19) into housing (28). Install
tilt pin (16) to servo piston (19).
2. Install O-ring (15) and backup ring (14) to stopper
(13).
Install O-ring (20) and backup ring (21) to stopper
(22).
3. Install stoppers (13, 22) to housing (28).
IMPORTANT: Apply grease onto the mounting
surface. Install with the chamfered
side of shoe plate (35) to swash
plate (33).
4. Install shoe plate (35) to swash plate (33).
5. Attach a nylon sling onto the body of housing (28).
Hoist and place housing (28) with the mounting
regulator surface facing downward.
6. Insert swash plate (33) into housing (28). Insert
tilt pin (16) into bushing (34) of swash plate (33).
IMPORTANT: After installing cover (31), check
that swash plate (33) moves
smoothly.
7. Install spring pin (12) and O-ring (30) to cover
(31).
9. Install spacer (6) and the inner race of bearing (7)
to shaft (5).
IMPORTANT: Install the outer race and the inner
ring plate of bearing (7) with the
stamped marks facing to the hous-
ing (28) side.
10. Install the outer race, the inner ring plate of bear-
ing (7), spacer (8) and retaining ring (9) to shaft
(5) in this order.
IMPORTANT: Do not tap shaft (5) by using a
hammer.
11. Install shaft (5) to cover (31).
At this time, lightly tap and install the outer race
of bearing (7) by using a plastic hammer. Tap the
outer race into the most inside by using a bar and
a hammer.
12. Install O-ring (3) and oil seal (4) to cover (2).
13. Install cover (2) to cover (31) with socket bolts (1)
(4 used).
: 6 mm
: 29.4 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

IMPORTANT: Check that swash plate (33) is in-

serted in the sliding surface of
cover (31). Check that swash plate
(33) is inserted in tilt pin (16).
8. Install housing (28) to cover (31).

W18K-E-00(20181019) W2-3-69
 UPPERSTRUCTURE / Pump Device

28 64 66 50

51

49

39

5
48

32 37 36 38 40 41 62 60, 61 63 65 45
W18C-02-04-013

42 43

44

57

58

54 59

W18B-02-04-044

52, 53 56 55

W18K-E-00(20181019) W2-3-70
 UPPERSTRUCTURE / Pump Device
14. Install springs (40) (9 used), spherical bushing 22. Install O-ring (49) to plate (50).
(38), retainer (37) and plungers (36) (9 used) to
cylinder block (41) in this order. 23. Install retaining ring (39) to coupling (48).

IMPORTANT: For easy installation, align the
spline in cylinder block (41) with the
spline in spherical bushing (38) be-
fore installing.
15. Install the cylinder block (41) assembly to shaft
(5).
24. Install coupling (48) to the end of shaft (5).
25. Install plate (50) to valve plate (45) and tighten
with socket bolts (51) (4 used).
: 10 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

16. Install seat (44), steel ball (43) and stopper (42)
to valve cover (45).
17. Install seat (57), steel ball (58) and stopper (59)
to valve cover (45).
18. Install O-rings (61, 64) and plug (60) to valve
cover (45).
: 19 mm
: 36.3 N⋅m (3.7 kgf⋅m, 27 lbf⋅ft)
19. Install needle bearing (65) to valve cover (45).
NOTE: For easy insertion of the shaft (5) end, ap-
ply grease onto the needle part of needle
bearing (65).
26. Install O-ring (53) and plug (52) to casing (54).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
27. Install O-rings (56) (4 used) to valve cover (45).
Tighten casing (54) with socket bolts (55) (3
used).
: 5 mm
: 11.8 N⋅m (1.2 kgf⋅m, 9 lbf⋅ft)
28. Install regulator (17) to valve cover (45) with
socket bolts (18) (4 used).
: 6 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

IMPORTANT: Apply grease onto the flat side of

valve plate (66) in order not to fall
off.
20. Install spring pin (62) and pin (63) to valve cover
(45). Install valve plate (66).

21. Install the valve cover (45) assembly to housing

(28) and tighten with socket bolts (32) (4 used).
: 17 mm
: 431.2 N⋅m (44 kgf⋅m, 320 lbf⋅ft)

W18K-E-00(20181019) W2-3-71
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD

1. Clearance between plunger (36) outer diameter

(d) and cylinder block (41) bore (D)

D-d Unit: mm (in)

Standard Allowable Limit
d D
0.039 (0.002) 0.067 (0.003)

W117-02-02-009

2. Spring (40) free length (L)

Unit: mm (in)
Standard Allowable Limit
41.1 (1.6) 40.3 (1.6)

W117-02-02-010

3. Clearance (e) between plunger (36) and the

crimped part of the shoe, and shoe thickness (t)

e Unit: mm (in)
Standard Allowable Limit
0 to 0.1 0.3
(0 to 0.004) (0.012) e
t Unit: mm (in) t
Standard Allowable Limit
4.9 (0.2) 4.7 (0.2) W117-02-02-011

Stand
4. Distance between retainer (37) bottom and
spherical bushing (38) top
H
h
H-h Unit: mm (in)
Standard Allowable Limit W18C-02-04-019

23.0 (0.9) 22.0 (0.2)

W18K-E-00(20181019) W2-3-72
 UPPERSTRUCTURE / Pump Device
(Blank)

W18K-E-00(20181019) W2-3-73
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF REGULATOR FOR OIL
COOLER FAN DRIVE PUMP

12
11
10
9
8

7
6 13
5 15
4 16
3 17
2 18
1
14 19
20

21
22
26 23
24
27
28 25
29
30 46
31 47
32
45
44
43
42
37 39 41
34
40
33
48
35 49
36
38

50
63
51
52
53
64

65
66
57
62 61 56
60 58
55
59 54

W18C-02-04-014

W18K-E-00(20181019) W2-3-74
 UPPERSTRUCTURE / Pump Device

1- Pin 18 - Pin 35 - O-Ring 51 - Supporting Plug

2- Sleeve 19 - Lever 36 - O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - Socket Bolt (4 Used) 62 - O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (2 Used)
16 - Feedback Lever 33 - Socket Bolt (4 Used) 50 - Pin 66 - Socket Bolt (2 Used)
17 - Pin 34 - Cover

W18K-E-00(20181019) W2-3-75
 UPPERSTRUCTURE / Pump Device

12
11
10
9
8

3
2
1

26

27
28
29
30 46
31 47
32
45
44
43
42
37 39 41
34
33
48
35 49
36
38

50
63
51

53
64

65
66
57
62 61 56
60 58
59 54

W18C-02-04-014

W18K-E-00(20181019) W2-3-76
 UPPERSTRUCTURE / Pump Device
Disassembly of Regulator for Oil Cooler Fan
Drive Pump
1. Remove socket bolts (37) (2 used) and (39) (2
used). Remove the regulator from the pump body.
Remove pins (57) (2 used) and O-rings (58, 59)
from casing (38).
: 6 mm
2. Remove socket bolts (33) (4 used). Remove
cover (34), O-ring (35) and O-rings (36) (3 used)
from casing (38).
: 5 mm
IMPORTANT: Do not disassemble lock nuts (43,
48, 47) and adjusting screws (41, 42,
49) as the set flow rate changes.
When removing cover (45), prevent
springs (9, 10) inside from flying
out.
3. Remove socket bolts (46) (4 used). Remove the
cover (45) assembly and O-ring (44) from casing
(38).
: 5 mm
8. Remove retaining ring (32) from spool (26).
Remove spring seat (31), spring (30) and sleeve
(27).
9. Remove retaining ring (28) from sleeve (27).
10. Remove pin (1), sleeve (2) and O-ring (3) from
casing (38).
11. Remove lock rings (53, 54) from casing (38).
IMPORTANT: Supporting plugs (51, 56) look quite
similar. Put the matching marks in
order to install correctly.
12. Insert a bolt (M6, Pitch 1.0 mm) into the center
hole of supporting plugs (51, 56). Remove
supporting plugs (51, 56) from casing (38).
At this time, pin (50) is removed with supporting
plug (56) together.
13. Remove pin (50) from supporting plug (56).

4. Remove springs (9, 10) and spring seat (8) from

casing (38).

5. Remove stopper (11) and O-ring (12) from the

cover (45) assembly.

6. Remove socket bolts (65) (2 used) and (66) (2

used). Remove cover (64) from casing (38).
: 5 mm

7. Remove O-rings (60, 61, 62, 63) and spring (29)

from casing (38).

W18K-E-00(20181019) W2-3-77
 UPPERSTRUCTURE / Pump Device

7
6
5 15
4 16
17
19
14
20

21
22
26 23
24

25

41

38

51
52

56
55

W18C-02-04-014

W18K-E-00(20181019) W2-3-78
 UPPERSTRUCTURE / Pump Device
14. Remove O-rings (52, 55) from supporting plugs
(51, 56).

IMPORTANT: Do not remove pin (20) from lever

(19).
15. Remove lever (19) from casing (38) by using a
pair of pincers.

16. Remove pin (17) and feedback lever (16) by

using a round bar (4 mm).

IMPORTANT: Do not remove pin (14) from lever

(15).
17. Remove lever (15) from casing (38).

18. Remove pilot piston (25) from casing (38).

19. Insert a round bar (4 mm) from the pilot piston

(25) side into casing (38). Remove spring seat
(24), spring (23) and stopper (22) from casing
(38).

20. Remove O-ring (21) from stopper (22).

21. Insert a round bar (4 mm) from the adjusting

screw (41) side into casing (38). Remove
compensating rod (7) and the sleeve (5)
assembly from casing (38).

22. Remove compensating rod (7), compensating

piston (6) and O-ring (4) from sleeve (5).

23. Remove spool (26) from casing (38).

W18K-E-00(20181019) W2-3-79
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF REGULATOR FOR OIL
COOLER FAN DRIVE PUMP A 34 33

B C W117-02-02-016

Section A-B
64 38 25 18 19 20 23 22 21

65

61 48

49
66

37 24 39
W117-02-02-006

D Section A-C
63 29 30 28 27 26 17 15 8 9 10 44 40 45 47
31

32
3 41
1 43
2
42

4 6 5 7 D 16 14 50 58 57 11 12
W117-02-02-017

Section D-D
13 51 52 53

54

14 56 55 W18B-02-04-043

W18K-E-00(20181019) W2-3-80
 UPPERSTRUCTURE / Pump Device

1- Pin 18 - Pin 35 - *O-Ring 51 - Supporting Plug

2- Sleeve 19 - Lever 36 - *O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - *O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - *O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - *Socket Bolt (4 Used) 62 - *O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (2 Used)
16 - Feedback Lever 33 - Socket Bolt (4 Used) 50 - Pin 66 - Socket Bolt (2 Used)
17 - Pin 34 - Cover
NOTE: As for the parts with mark *, refer to W2-3-74.

W18K-E-00(20181019) W2-3-81
 UPPERSTRUCTURE / Pump Device

B C W117-02-02-016

Section A-B
38 25 19 20

W117-02-02-006

D Section A-C
29 30 28 27 26 17 15
31

32

7 D 16 14 50
W117-02-02-017

Section D-D
51 52 53

54

56 55 W18B-02-04-043

W18K-E-00(20181019) W2-3-82
 UPPERSTRUCTURE / Pump Device
Assembly of Regulator for Oil Cooler Fan Drive
Pump
IMPORTANT: Check the direction to install
compensating rod (7) as illustrated.
1. Insert compensating rod (7) into casing (38).
2. Install pin (14) to lever (15). Insert lever (15) into
casing (38). Install pin (14) while aligning with the
groove in compensating rod (7).
3. Install retaining ring (28) to sleeve (27).
IMPORTANT: After inserting, check that spool (26)
moves smoothly.
4. Insert sleeve (27) and spool (26) into casing (38).
IMPORTANT: Check the direction to install
feedback lever (16).
5. Align the pin hole (the hole in upper side) on
feedback lever (16) with the pin hole on spool
(26). Install pin (17).
Compensating Lever (16) Side
Rod (7) Side
W18B-02-04-018
W18K-E-00(20181019)
IMPORTANT: After inserting, check that pilot
piston (25) moves smoothly.
6. Insert pilot piston (25) into casing (38).
7. Install O-rings (52, 55) to supporting plugs (51,
56).
IMPORTANT: Supporting plugs (51, 56) look quite
similar.
Install plugs (51, 56) while aligning
the matching marks made when
disassembling in order to install
correctly.
8. Align the groove on pilot piston (25) with pin (20)
on lever (19). Install lever (19).
9. Install pin (50) to supporting plug (56). Align pin
(50) with the hole on lever (19). Install supporting
plug (56) to lever (19).
10. Install lock ring (54) to supporting plug (56).
11. Install supporting plug (51) to casing (54). Install
lock ring (53)
12. Install spring (30) and spring seat (31) to spool
(26). Install retaining ring (32).
13. Install spring (29) to casing (38).
W2-3-83
 UPPERSTRUCTURE / Pump Device

A 34 33

B C W117-02-02-016

Section A-B
64 38 23 22 21

65

61

66

37 24 39
W117-02-02-006
D Section A-C
63 8 9 10 44 45

3
1
2

4 6 5 D 58 57 11 12
W117-02-02-017

Section D-D

W18B-02-04-043

W18K-E-00(20181019) W2-3-84
 UPPERSTRUCTURE / Pump Device
IMPORTANT: Check the direction to install 25. Install pins (57) (2 used) and O-rings (58, 59) to
compensating piston (6) as casing (38).
illustrated.
14. Install O-ring (4) and compensating piston (6) to 26. Install the regulator to the pump body with socket
sleeve (5). bolts (37) (2 used) and (39) (2 used).
: 6 mm
15. Install sleeve (5), O-ring (3), sleeve (2) and pin : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
(1) to casing (38).

16. Install O-rings (60, 62, 61 and 63) to casing (38).

17. Install cover (64) to casing (38) with socket bolts

(65) (2 used) and (66) (2 used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8 lbf⋅ft)

18. Install O-ring (35) and O-rings (36) (3 used) to

cover (34).

19. Install cover (34) to casing (38) with socket bolts

(33) (4 used)
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8 lbf⋅ft)

20. Install O-ring (21) to stopper (22).

21. Install spring seat (24), spring (23) and stopper

(22) to casing (38).

22. Install O-ring (12) to stopper (11).

23. Install spring seat (8) and springs (9, 10) to

casing (38).

24. Install stopper (11) and O-ring (44) to the cover

(45) assembly. Install the cover (45) assembly to
casing (38) with socket bolts (46) (4 used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8 lbf⋅ft)

W18K-E-00(20181019) W2-3-85
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF AIR CONDITIONER
COMPRESSOR DRIVE PUMP AND PILOT
PUMP

16
15

14
13

12
10
9
8
7 30
11 29
5 6
28
4 27
3 26

2
1 25

24 44
23 43
22 42
21
20
41
17 40
18
39
38
37
19
36
35

34
33

31

32
45

W18B-02-04-015

W18K-E-00(20181019) W2-3-86
 UPPERSTRUCTURE / Pump Device

1- Coupling 13 - O-Ring 24 - Coupling 35 - Plate

2- O-Ring 14 - Knock Pin (2 Used) 25 - O-Ring 36 - Knock Pin (2 Used)
3- Nut (4 Used) 15 - Plate 26 - Center Plate 37 - Pressure Plate
4- Spring Washer (4 Used) 16 - Knock Pin (2 Used) 27 - Backup Ring 38 - Seal Plate
5- Stud Bolt (4 Used) 17 - O-Ring 28 - Seal Plate 39 - Isolation Plate
6- Cover 18 - Cover 29 - Isolation Plate 40 - Backup Ring
7- Backup Ring 19 - Socket Bolt (2 Used) 30 - Pressure Plate 41 - O-Ring
8- Seal Plate 20 - Pressure Plate 31 - Driven Gear 42 - Flange
9- Isolation Plate 21 - Seal Plate 32 - Drive Gear 43 - Oil Seal
10 - Pressure Plate 22 - Isolation Plate 33 - O-Ring 44 - Snap Ring
11 - Drive Gear 23 - Backup Ring 34 - Knock Pin (2 Used) 45 - Stabilizer (4 Used)
12 - Driven Gear

W18K-E-00(20181019) W2-3-87
 UPPERSTRUCTURE / Pump Device

15

14
13

12
10
9
8
7 30
11 29
6
28
4 27
3 26

2
1 25

24
23
22
21
20
17
18

19

35

33

31

32
45

W18B-02-04-015

W18K-E-00(20181019) W2-3-88
 UPPERSTRUCTURE / Pump Device
Disassembly of Air Conditioner Compressor
Drive Pump and Pilot Pump
CAUTION: Pilot pump weight: 27 kg (60 lb)
8. Remove plate (15) from center plate (26).
NOTE: Lightly tap and remove the outer race of
cover (6) by using a plastic hammer.

1. Remove O-ring (2) from cover (6). Remove
coupling (1) from drive gear (11).
2. Remove socket bolts (19) (2 used) from cover (6).
Remove cover (18) and O-ring (17) from cover
(6).
: 8 mm
9. Remove backup ring (23), insulation plate (22),
seal plate (21) and pressure plate (20) from plate
(15).
10. Remove O-ring (25) from center plate (26).
11. Remove center plate (26) from plate (35).

3. Remove nuts (3) (4 used) and spring washers (4) 12. Remove coupling (24) from center plate (26).
(4 used) from cover (6).
: 22 mm 13. Remove stabilizers (45) (2 used) and O-ring (33)
from plate (35).
4. Remove cover (6) from plate (15).
14. Remove backup ring (27), seal plate (28) and
NOTE: Cover (6) has been secured with knock
isolation plate (29) from plate (35) by using a
pins (14) (2 used). Lightly tap and remove
bamboo spatula.
the outer race of cover (6) by using a
plastic hammer.
IMPORTANT: Remove driven gear (31) and drive
gear (32) at the same time.
5. Remove backup ring (7), seal plate (8) and
15. Remove driven gear (31) and drive gear (32)
isolation plate (9) from plate (15) by using a
from plate (35). At this time, pressure plate (30) is
bamboo spatula.
also removed.
IMPORTANT: Do not confuse driven gears (12, 31)
when storing them.
Remove driven gear (12) and drive
gear (11) at the same time.
6. Remove driven gear (12) and drive gear (11)
from plate (15). At this time, pressure plate (10) is
also removed.

IMPORTANT: Do not remove knock pin (14)

unless necessary.
7. Remove O-ring (13) and stabilizers (45) (2 used)
from plate (15).

W18K-E-00(20181019) W2-3-89
 UPPERSTRUCTURE / Pump Device

44
43
42

41
40
39
38
37
36
35

W18B-02-04-015

W18K-E-00(20181019) W2-3-90
 UPPERSTRUCTURE / Pump Device
16. Remove plate (35) from flange (42).

IMPORTANT: Do not remove knock pin (36)

unless necessary.
17. Remove backup ring (40), isolation plate (39),
seal plate (38) and pressure plate (37) from plate
(35).

18. Remove O-ring (41) from flange (42).

19. Remove snap ring (44) and oil seal (43) from
flange (42).
NOTE: Stud bolt (5) is still left in flange (42). Do
not remove stud bolt (5) unless necessary.

W18K-E-00(20181019) W2-3-91
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF AIR CONDITIONER
COMPRESSOR DRIVE PUMP AND PILOT
PUMP

B C B C

5 6 14 13 12 15 25 16 26 34 33 35 31 41 36 42
3
4

2 1 10 11 20 24 30 32 37 43 44
B C B C
38 40
19 17 45 39

18

View A 9

7
8
Section B Section C W18B-02-04-050

1- Coupling 13 - O-Ring 24 - Coupling 35 - Plate

2- O-Ring 14 - Knock Pin (2 Used) 25 - O-Ring 36 - Knock Pin (2 Used)
3- Nut (4 Used) 15 - Plate 26 - Center Plate 37 - Pressure Plate
4- Spring Washer (4 Used) 16 - Knock Pin (2 Used) 27 - *Backup Ring 38 - Seal Plate
5- Stud Bolt (4 Used) 17 - O-Ring 28 - *Seal Plate 39 - Isolation Plate
6- Cover 18 - Cover 29 - *Isolation Plate 40 - Backup Ring
7- Backup Ring 19 - Socket Bolt (2 Used) 30 - Pressure Plate 41 - O-Ring
8- Seal Plate 20 - Pressure Plate 31 - Driven Gear 42 - Flange
9- Isolation Plate 21 - *Seal Plate 32 - Drive Gear 43 - Oil Seal
10 - Pressure Plate 22 - *Isolation Plate 33 - O-Ring 44 - Snap Ring
11 - Drive Gear 23 - *Backup Ring 34 - Knock Pin (2 Used) 45 - Stabilizer (4 Used)
12 - Driven Gear

NOTE: As for the parts with mark *, refer to

W2-3-86.

W18K-E-00(20181019) W2-3-92
 UPPERSTRUCTURE / Pump Device
Assembly of Air Conditioner Compressor Drive
Pump and Pilot Pump
1. Install oil seal (43) and snap ring (44) to flange
(42).
2. Install O-ring (41) and knock pins (36) (2 used) to
flange (42).
3. Align plate (35) with center plate (26).
Temporarily place plate (35).
NOTE: Temporarily install plate (35) to center
plate (26) in order to prevent backup ring
(27) from coming out and to prevent
backup ring (27) from falling off due to the
gear movement during installation.
4. Install driven gear (31) and drive gear (32) to
plate (35).
5. Install pressure plate (37) to plate (35) with the
groove side of pressure plate (37) facing to the
flange (42) side.
6. Install seal plate (38), isolation plate (39) and
backup ring (40) to pressure plate (37).
7. Install flange (42) to the plate (35) assembly.
8. Remove center plate (26) from the plate (35)
assembly. Secure the plate (35) assembly in a
vise with the oil seal (43) side facing downward.
9. Lightly tap and install plate (35) to flange (42) by
using a plastic hammer lightly.
W18K-E-00(20181019) W2-3-93
10. Install pressure plate (30), isolation plate (29),
seal plate (28) and backup ring (27) to plate (35)
through the center plate (26) side.
11. Install O-ring (33), knock pins (34) (2 used) and
stabilizers (45) (2 used) to plate (35).
IMPORTANT: Check that the mating surfaces of
plate (35) and center plate (26) are
matched closely.
12. Install center plate (26) to the plate (35) assembly.
Install coupling (24) to center plate (26).
13. Install O-ring (25) and knock pins (16) (2 used) to
center plate (26).
14. Align plate (15) with cover (6). Temporarily place
plate (15).
NOTE: Temporarily install plate (15) to cover (6) in
order to prevent backup ring (7) from
coming out and to prevent backup ring (7)
from falling off due to the gear movement
during installation.
15. Install driven gear (12) and drive gear (11) to
plate (15).
16. Install pressure plate (20) to plate (15) with the
groove side of pressure plate (20) facing to the
cover (6) side.
17. Install seal plate (21), isolation plate (22) and
backup ring (23) to pressure plate (20).
18. Install the center plate (26) assembly to the plate
(15) assembly.
 UPPERSTRUCTURE / Pump Device

B C B C

5 6 14 13 15
3
4

2 1 10 11
B C B C

19 17 45

18

View A 9

7
8
Section B Section C W18B-02-04-050

W18K-E-00(20181019) W2-3-94
 UPPERSTRUCTURE / Pump Device
19. Remove cover (6) from the plate (15) assembly.

20. Install O-ring (13), knock pins (14) (2 used) and

stabilizers (45) (2 used) to plate (15).

21. Install pressure plate (10), isolation plate (9), seal

plate (8) and backup ring (7) to plate (15).

22. Install cover (6) to plate (15). Tighten with stud

bolts (5) (4 used), spring washers (4) (4 used)
and nuts (3) (4 used).
: 22 mm
: 26 N⋅m (2.6 kgf⋅m, 19 lbf⋅ft)

23. Install O-ring (17) to cover (6).

24. Install cover (18) to cover (6). Tighten with socket

bolts (19) (2 used).
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft)

25. Install coupling (1) to drive gear (11).

26. Install O-ring (2) to cover (6).

W18K-E-00(20181019) W2-3-95
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD

Drive Gears (11, 32), Driven Gears (12, 31)

Plates (15, 35) øb<ø27.48 mm (ø1.1 in)
a≥0.15 mm (0.006 in)
a b

W117-02-02-022

W117-02-02-021

W18K-E-00(20181019) W2-3-96
 UPPERSTRUCTURE / Pump Device
(Blank)

W18K-E-00(20181019) W2-3-97
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF PUMP TRANSMISSION
OIL LUBRICATION PUMP 14
12 13

11
10
9
6 8
7

1 5
4
3
2

15

W18B-02-04-014

1- Bolt (4 Used) 5- Driven Gear 9- Gasket A 13 - Oil Seal

2- Cover 6- Knock Pin 10 - Gasket B 14 - Snap Ring
3- O-Ring 7- Plate 11 - Balance Seal 15 - Drive Gear
4- Side Plate B 8- Side Plate A 12 - Flange

W18K-E-00(20181019) W2-3-98
 UPPERSTRUCTURE / Pump Device
Disassembly of Pump Transmission Oil
Lubrication Pump

IMPORTANT: If securing flange (12) in a vise by

too strong force, flange (12) may be
deformed.
1. Secure flange (12) in a vise. Remove bolts (1) (4
used). Remove cover (2) from plate (7).
: 14 mm
NOTE: Cover (2) is secured on plate (7) with
knock pin (6). Remove cover (2) while
tapping cover (2) by using a plastic
hammer.

2. Remove O-ring (3) from cover (2).

3. Remove side plate B (4) from driven gear (5) and

drive gear (15).

IMPORTANT: Remove driven gear (5) and drive

gear (15) by rotating slowly.
4. Remove driven gear (5) and drive gear (15) from
plate (7).

IMPORTANT: Do not remove knock pin (6) unless

necessary.
5. Remove plate (7) from flange (12).

6. Remove side plate A (8), gasket A (9), gasket B

(10) and balance seal (11) from flange (12).
NOTE: Use a bamboo spatula when removing
gasket A (9), gasket B (10) and balance
seal (11).

7. Remove snap ring (14) and oil seal (13) from

flange (12).

W18K-E-00(20181019) W2-3-99
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF PUMP TRANSMISSION
OIL LUBRICATION PUMP
1 2 5 6 7 12
C

View D
15 3 4 8 13 14

Detail C

9 10 11

Section B-B Section A-A W117-02-02-020

1- Bolt (4 Used) 5- Driven Gear 9- Gasket A 13 - Oil Seal

2- Cover 6- Knock Pin 10 - Gasket B 14 - Snap Ring
3- O-Ring 7- Plate 11 - Balance Seal 15 - Drive Gear
4- Side Plate B 8- Side Plate A 12 - Flange

W18K-E-00(20181019) W2-3-100
 UPPERSTRUCTURE / Pump Device
Assembly of Pump Transmission Oil Lubrication
Pump

1. Install oil seal (13) and snap ring (14) to flange

(12).

2. Apply grease onto the groove for balance seal

(11) on flange (12). Install balance seal (11),
gasket B (10), gasket A (9) and side plate A (8) to
flange (12).

3. Install plate (7) to flange (12).

4. Apply grease onto the inner surface of plate (7).

IMPORTANT: Install drive gear (15) by rotating

slowly.
5. Install drive gear (15) to flange (12).

6. Install driven gear (5) to flange (12).

7. Install O-ring (3) to cover (2).

IMPORTANT: Tighten bolt (1) evenly. Drive gear

(15) may not rotate.
8. Install cover (2) to plate (7) and tighten with bolts
(1) (4 used).
: 17 mm
: 34 to 39 N⋅m
(3.5 to 4.0 kgf⋅m, 25 to 29 lbf⋅ft)

IMPORTANT: Check that drive gear (15) rotates

smoothly after installation.

W18K-E-00(20181019) W2-3-101
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD

Plate (7) Drive Gear (15), Driven Gear (5)

a≥0.15 mm (0.006 in) øb<ø14.96 mm (ø0.6 in) b
a

W117-02-02-022

W117-02-02-021

W18K-E-00(20181019) W2-3-102
 UPPERSTRUCTURE / Control Valve
REMOVAL AND INSTALLATION OF
CONTROL VALVE

Removal

CAUTION: Bleed air from the hydraulic oil 3 4, 5 3

tank before doing any work. (Refer to BLEED 2
AIR FROM HYDRAULIC OIL TANK on 4, 5
W1-4-1.)
1
6
1. Remove bolts (4) (18 used). Remove clamps (5)
(9 used) from control valve bracket (2).
: 17 mm

2. Remove socket bolts (1) (12 used). Disconnect

pipings (6) (5 used) from control valves (3) (3
used). Cap the disconnected pipings.
: 10 mm 6
W18K-02-04-001

3. Remove bolts (8) (18 used). Remove clamps (9) 3

(9 used) from control valve bracket (2).
: 17 mm 2

4. Disconnect pipings (7) (24 used) from control 7

valves (3) (3 used). Install plugs or caps onto the
open ends. Attach an identification tag onto the 7 8, 9
disconnected pipings for assembling.
: 19 mm 7

W18K-02-04-002

W18K-E-00(20181019) W2-4-1
 UPPERSTRUCTURE / Control Valve
5. Remove socket bolts (13) (4 used) from the
control valve (3) side. Remove flanges (14) (2 3 13, 14 3 15, 16
used). Disconnect hose (17). Install plugs or caps
onto the disconnected hose.
: 14 mm
2

11, 12
CAUTION: Piping (10) weight: 16 kg (40 lb) 3

6. Attach a nylon sling onto piping (10). Hold piping 17

(10). Remove socket bolts (11) (4 used) and 10
flanges (12) (2 used) from piping (10) on the 10
control valve (3) side.
: 14 mm
W18C-02-07-042

Main Frame
7. Disconnect piping (10) from the control valve (3)
side. Place piping (10) on the main frame slowly.

8. Disconnect other pipings (10) (24 used) from

control valves (3) (3 used) in the same way as
steps 6 to 7.

CAUTION: Control valve (3) weight: 260 kg

(580 lb)

9. Attach a nylon sling onto the body of control

valve (3). Hoist and hold control valve (3).

10. Remove bolts (15) (4 used) and U-nuts (16) (4

used). Hoist and remove control valve (3) from
control valve bracket (2).
: 24 mm

11. Remove other control valves (3) (2 used) from

control valve bracket (2) in the same way as
steps 8 to 9.

W18K-E-00(20181019) W2-4-2
 UPPERSTRUCTURE / Control Valve
Installation

CAUTION: Control valve (3) weight: 260 kg

(580 lb) 3 13, 14 3 15, 16

1. Attach a nylon sling onto the body of control

valve (3). Hoist and hold control valve (3). 2

2. Install control valve (3) to control valve bracket 11, 12

3
(2) with bolts (15) (4 used) and U-nuts (16) (4
used).
: 24 mm 17
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) 10

10
3. Install other control valves (3) (2 used) to control
valve bracket (2) in the same way as steps 1 to 2. W18C-02-07-042

CAUTION: Piping (10) weight: 16 kg (40 lb)

4. Attach a nylon sling onto piping (10). Hold piping

(10). Connect piping (10) to control valve (3) with
socket bolts (11) (4 used) and flanges (12) (2
used).
: 14 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

5. Connect other pipings (10) (24 used) to control

valves (3) (3 used) in the same way as step 4.

6. Connect hose (17) to control valve (3) with

socket bolts (13) (4 used) and flanges (14) (2
used).
: 14 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

W18K-E-00(20181019) W2-4-3
 UPPERSTRUCTURE / Control Valve
7. Connect pipings (7) (24 used) to control valves 3
(3) (3 used).
: 14 mm 2
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)
7
8. Install clamps (9) (9 used) to control valve
bracket (2) with bolts (8) (18 used). 7 8, 9
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 7

9. Connect pipings (6) (5 used) to control valves (3)

(3 used) with socket bolts (1) (12 used).
: 10 mm W18K-02-04-002
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

10. Install clamps (5) (9 used) to control valve 3 4, 5 3

bracket (2) with bolts (4) (18 used). 2
4, 5
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 1
6
IMPORTANT: After completing the work, check
hydraulic oil level and any oil
leakage.

6
W18K-02-04-001

W18K-E-00(20181019) W2-4-4
 UPPERSTRUCTURE / Control Valve
(Blank)

W18K-E-00(20181019) W2-4-5
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE

2 3 4

T18C-01-02-005

1 - Control Valve Bracket 2 - Control Valve 3 - Control Valve 4 - Control Valve

W18K-E-00(20181019) W2-4-6
 UPPERSTRUCTURE / Control Valve
Control Valve 4

10
9
8 11
7 12
6
2 5
4
3

13
14
15 22
16
17
20 18
1
19
25 22
23
21
26
27
22
24
22

23
23
22 28

42 23 32
41 43 33
29
40 23 34
37
38 35
39 23
30
31
36

W18C-02-05-005

1 - Outlet Section 12 - O-Ring (4 Used) 23 - Overload Relief Valve 34 - O-Ring

(6 Used)
2- Nut (4 Used) 13 - Spring Seat (4 Used) 24 - Housing (Arm) 35 - Inlet Section
3- Tie Rod (4 Used) 14 - Spool (4 Used) 25 - Socket Bolt (4 Used) 36 - Nut (4 Used)
4- Spring (4 Used) 15 - Socket Bolt (16 Used) 26 - Flange 37 - O-Ring (4 Used)
5- Spring (4 Used) 16 - Plate (4 Used) 27 - O-Ring 38 - Spacer (4 Used)
6- Spring Seat (4 Used) 17 - O-Ring (4 Used) 28 - Housing (Boom) 39 - Cap (4 Used)
7- Spool End (4 Used) 18 - Spring (3 Used) 29 - Housing (Bucket) 40 - Socket Bolt (8 Used)
8- O-Ring (4 Used) 19 - Poppet (3 Used) 30 - Housing (Left Travel) 41 - O-Ring (4 Used)
9- Cap (4 Used) 20 - O-Ring (10 Used) 31 - Main Relief Valve 42 - Plug (4 Used)
10 - Socket Bolt (8 Used) 21 - O-Ring (5 Used) 32 - Socket Bolt (4 Used) 43 - Plug
11 - Plug (4 Used) 22 - Make-Up Valve (5 Used) 33 - Flange

W18K-E-00(20181019) W2-4-7
 UPPERSTRUCTURE / Control Valve
Control Valve 3

2 42
41
3
40
39
38
37
15 22
16
17
20 18
1
19
23 22
21

22
44
22

23
23
22 45

23 32
14 33
13 46
23 34
4 35
5 23
6 47
10 7 31
36
8
9
12
11 W18C-02-05-006

1 - Outlet Section 11 - Plug (4 Used) 21 - O-Ring (5 Used) 38 - Spacer (4 Used)

2 - Nut (4 Used) 12 - O-Ring (4 Used) 22 - Make-Up Valve (5 Used) 39 - Cap (4 Used)
3 - Tie Rod (4 Used) 13 - Spring Seat (4 Used) 23 - Overload Relief Valve 40 - Socket Bolt (8 Used)
(6 Used)
4- Spring (4 Used) 14 - Spool (4 Used) 31 - Main Relief Valve 41 - O-Ring (4 Used)
5- Spring (4 Used) 15 - Socket Bolt (16 Used) 32 - Socket Bolt (4 Used) 42 - Plug (4 Used)
6- Spring Seat (4 Used) 16 - Plate (4 Used) 33 - Flange 44 - Housing (Bucket)
7- Spool End (4 Used) 17 - O-Ring (4 Used) 34 - O-Ring 45 - Housing (Arm)
8- O-Ring (4 Used) 18 - Spring (3 Used) 35 - Inlet Section 46 - Housing (Boom)
9- Cap (4 Used) 19 - Poppet (3 Used) 36 - Nut (4 Used) 47 - Housing (Right Travel)
10 - Socket Bolt (8 Used) 20 - O-Ring (10 Used) 37 - O-Ring (4 Used)

W18K-E-00(20181019) W2-4-8
 UPPERSTRUCTURE / Control Valve
Control Valve 2
10
9
8 11
7 12
6
2 5
4
3

13
14
15 22
16
17
20 18
1
19
25 22
23
21
26
27
22
48
22

23
23
22 49

23
42
41 22
50
40 23
37 23
38 35
39 23
51
31
36

23
W18C-02-05-007

1 - Outlet Section 11 - Plug (4 Used) 21 - O-Ring (5 Used) 38 - Spacer (4 Used)

2 - Nut (4 Used) 12 - O-Ring (4 Used) 22 - Make-Up Valve (6 Used) 39 - Cap (4 Used)
3 - Tie Rod (4 Used) 13 - Spring Seat (4 Used) 23 - Overload Relief Valve 40 - Socket Bolt (8 Used)
(8 Used)
4- Spring (4 Used) 14 - Spool (4 Used) 25 - Socket Bolt (4 Used) 41 - O-Ring (4 Used)
5- Spring (4 Used) 15 - Socket Bolt (16 Used) 26 - Flange 42 - Plug (4 Used)
6- Spring Seat (4 Used) 16 - Plate (4 Used) 27 - O-Ring 48 - Housing (Boom)
7- Spool End (4 Used) 17 - O-Ring (4 Used) 31 - Main Relief Valve 49 - Housing (Bucket)
8- O-Ring (4 Used) 18 - Spring (4 Used) 35 - Inlet Section 50 - Housing (Arm)
9- Cap (4 Used) 19 - Poppet (4 Used) 36 - Nut (4 Used) 51 - Housing (Swing)
10 - Socket Bolt (8 Used) 20 - O-Ring (10 Used) 37 - O-Ring (4 Used)

W18K-E-00(20181019) W2-4-9
 UPPERSTRUCTURE / Control Valve
Control Valve 4
10
9
8 11
7 12
6
2 5
4
3

13
14
15 22
16
17
20 18
1
19
25 22
23
21
26
27
22
24
22

23
23
22 28

23 32
42
41 43 33
29
40 23 34
37
38 35
39 23
30
31
36

W18C-02-05-005

1 - Outlet Section 12 - O-Ring (4 Used) 23 - Overload Relief Valve 34 - O-Ring

(6 Used)
2- Nut (4 Used) 13 - Spring Seat (4 Used) 24 - Housing (Arm) 35 - Inlet Section
3- Tie Rod (4 Used) 14 - Spool (4 Used) 25 - Socket Bolt (4 Used) 36 - Nut (4 Used)
4- Spring (4 Used) 15 - Socket Bolt (16 Used) 26 - Flange 37 - O-Ring (4 Used)
5- Spring (4 Used) 16 - Plate (4 Used) 27 - O-Ring 38 - Spacer (4 Used)
6- Spring Seat (4 Used) 17 - O-Ring (4 Used) 28 - Housing (Boom) 39 - Cap (4 Used)
7- Spool End (4 Used) 18 - Spring (3 Used) 29 - Housing (Bucket) 40 - Socket Bolt (8 Used)
8- O-Ring (4 Used) 19 - Poppet (3 Used) 30 - Housing (Left Travel) 41 - O-Ring (4 Used)
9- Cap (4 Used) 20 - O-Ring (10 Used) 31 - Main Relief Valve 42 - Plug (4 Used)
10 - Socket Bolt (8 Used) 21 - O-Ring (5 Used) 32 - Socket Bolt (4 Used) 43 - Plug
11 - Plug (4 Used) 22 - Make-Up Valve (5 Used) 33 - Flange

W18K-E-00(20181019) W2-4-10
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve
(Control Valve 4)
• The procedure to disassemble and assemble
control valve 4 is explained here. As for other
control valves, their basic structure are similar
except the shape of the spool.
IMPORTANT: As many components of the control
valve are in similar shape and the
direction to install many
components is determined,
disassemble the control valve while
putting the mark as for the direction
and the position to install for
assembling.
CAUTION: Control valve weight: 260 kg (580
lb)
1. Place the control valve assembly on a clean
workbench.
IMPORTANT: Do not disassemble overload relief
valve (23). When adjusting the
overload relief valve, use the special
tester. In addition, attach a spanner
onto the body side when removing
overload relief valve (23) and main
relief valve (31).
2. Remove overload relief valves (23) (6 used),
make-up valves (22) (5 used) and plug (43) from
housings (24, 28, 29).
Remove main relief valve (31) from inlet section
(35).
: 38 mm
W18K-E-00(20181019) W2-4-11
CAUTION: Inlet section (35) weight: 62 kg
(140 lb)
Outlet section (1) weight: 23 kg (55 lb)
Housings (24, 28, 29, 30) weight: 59 kg (130
lb)
3. Loosen socket bolts (15) (16 used). Remove
plates (16) (4 used) and O-rings (17) (4 used)
from housings (24, 28, 29, 30).
: 10 mm
4. Remove springs (18) (3 used) and poppets (19)
(3 used) from housings (24, 28, 29).
5. Remove socket bolts (25) (4 used) and (32) (4
used). Remove flanges (26, 33) and O-rings (27,
34) from housing (28) and inlet section (35).
: 10 mm, 14 mm
6. Loosen nuts (2) (4 used) and remove tie rods (3)
(4 used).
: 30 mm
IMPORTANT: When hoisting each section and
each housing of the control valve,
install an eyebolt (M16, Pitch 2.0
mm) into the bolt hole for the piping,
and hoist each section and each
housing of the control valve. At this
time, do not drop O-ring.
7. Separate inlet section (35), housings (24, 28, 29,
30) and outlet section (1) individually.
 UPPERSTRUCTURE / Control Valve

10
9
8 11
7 12
6
5
4

13
14

20

21

24

28

42
41
29
40
37
38 35
39
30

W18C-02-05-005

W18K-E-00(20181019) W2-4-12
 UPPERSTRUCTURE / Control Valve
8. Remove O-rings (20) (10 used) and (21) (5 used)
from inlet section (35) and housings (24, 28, 29,
30).

IMPORTANT: LOCTITE has been applied onto

plug (11). Do not remove plug (11)
unless necessary.
9. Loosen socket bolts (10) (8 used). Remove caps
(9) (4 used) and O-rings (8) (4 used) from
housings (24, 28, 29, 30).
: 10 mm

IMPORTANT: Rotate and remove spool (14)

slowly.
10. Remove spool (14) from housings (24, 28, 29,
30).

IMPORTANT: LOCTITE has been applied onto

plug (42). Do not remove plug (42)
unless necessary.
11. Loosen socket bolts (40) (8 used). Remove caps
(39) (4 used) and O-rings (37) (4 used) from
housings (24, 28, 29, 30). Remove spacers (38)
(4 used) from caps (39) (4 used).
: 10 mm

12. Secure spool (14) in a vise by using wooden

pieces. Warm up the outside at the spool end (7)
side of spool (14) up to 200 to 250°C (392 to
482°F). Attach a spanner onto spool end (7) and
rotate spool end (7). Remove spool end (7) from
spool (14). (4 places)
: 30 mm

13. Remove spring seats (6, 13) and springs (4, 5)

from spool end (7). (4 places)

W18K-E-00(20181019) W2-4-13
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE
(Control Valve 4)

1 2 3 22
40
39 9
41, 42 11, 12

24
10
25
26
28

29
A

30

31
W18C-02-05-008
35 36 33 32

29 17 15 16 18 19
Section A

38 37 8 13 6 7

4 5
14 W18C-02-05-009

1 - Outlet Section 12 - O-Ring (4 Used) 23 - Overload Relief Valve 34 - O-Ring

(6 Used)
2- Nut (4 Used) 13 - Spring Seat (4 Used) 24 - Housing (Arm) 35 - Inlet Section
3- Tie Rod (4 Used) 14 - Spool (4 Used) 25 - Socket Bolt (4 Used) 36 - Nut (4 Used)
4- Spring (4 Used) 15 - Socket Bolt (16 Used) 26 - Flange 37 - O-Ring (4 Used)
5- Spring (4 Used) 16 - Plate (4 Used) 27 - O-Ring 38 - Spacer (4 Used)
6- Spring Seat (4 Used) 17 - O-Ring (4 Used) 28 - Housing (Boom) 39 - Cap (4 Used)
7- Spool End (4 Used) 18 - Spring (3 Used) 29 - Housing (Bucket) 40 - Socket Bolt (8 Used)
8- O-Ring (4 Used) 19 - Poppet (3 Used) 30 - Housing (Left Travel) 41 - O-Ring (4 Used)
9- Cap (4 Used) 20 - O-Ring (10 Used) 31 - Main Relief Valve 42 - Plug (4 Used)
10 - Socket Bolt (8 Used) 21 - O-Ring (5 Used) 32 - Socket Bolt (4 Used) 43 - Plug
11 - Plug (4 Used) 22 - Make-Up Valve (5 Used) 33 - Flange

W18K-E-00(20181019) W2-4-14
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve
(Control Valve 4)
IMPORTANT: Align the marks made when
disassembling.
IMPORTANT: Apply grease onto O-rings in order
to prevent O-rings (20, 21) from
falling off.
1. Install O-rings (20) (10 used) and (21) (5 used) to
housings (24, 28, 29, 30) and inlet section (35).
CAUTION: Inlet section (35) weight: 62 kg
(140 lb)
Outlet section (1) weight: 23 kg (55 lb)
Housings (24, 28, 29, 30) weight: 59 kg (130
lb)
IMPORTANT: Check and arrange the housings
and the sections in the correct order
and direction.
IMPORTANT: Perform the work while checking
O-ring in order not to fall off or
come out.
2. Hoist and place each section and housing in
order.
NOTE: When hoisting each section and housing,
install an eyebolt (M16, Pitch 2.0 mm) into
the bolt hole for the piping.
4. When removing spool end (7), assemble spool
end (7) as follows.
• Secure spool (14) in a vise by using wooden
pieces.
• Apply LOCTITE #271 onto the thread part of
spool end (7).
• Install spring seats (6, 13) and springs (4, 5) to
spool end (7).
• Install spool end (7) to spool (14).
: 30 mm
: 27±1.5 N⋅m (2.8±0.15 kgf⋅m, 20±1 lbf⋅ft)
5. Install spacers (38) (4 used) to caps (39) (4 used).
Install O-rings (37) (4 used) and caps (39) (4
used) to housings (24, 28, 29, 30) with socket
bolts (40) (8 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
IMPORTANT: Slowly rotate and insert spool (14)
into each housing.
6. Install the spool (14) assemblies (4 used) to
housings (24, 28, 29, 30).

3. Pass tie rods (3) (4 used) through each section

and housing, and tighten with nuts (2) (4 used)
and (36) (4 used).
: 30 mm
: 414.5±20.6 N⋅m
(42.3±2.1 kgf⋅m, 306 to 15 lbf⋅ft)

W18K-E-00(20181019) W2-4-15
 UPPERSTRUCTURE / Control Valve

22
40
9
39

24
10
25
26 28

29
A

30

31
W18C-02-05-008
35 33 32

29 17 15 16 18 19
Section A

38 37 8

W18C-02-05-009

W18K-E-00(20181019) W2-4-16
 UPPERSTRUCTURE / Control Valve
7. Install O-rings (8) (4 used) and caps (9) (4 used)
to housings (24, 28, 29, 30) with socket bolts (10)
(8 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

8. Install poppets (19) (3 used) and springs (18) (3

used) to housings (24, 28, 29, 30). Install O-rings
(17) (4 used) and plates (16) (4 used) to
housings (24, 28, 29, 30) with socket bolts (15)
(16 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

9. Install O-rings (27, 34) and flanges (26, 33) to

housing (28) and inlet section (35) with socket
bolts (25) (4 used) and (32) (4 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
: 14 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

10. Install overload relief valves (23) (6 used) to

housings (24, 28, 29). Install main relief valve
(31) to inlet section (35).
: 38 mm
: 93 to 108 N⋅m
(9.5 to 11 kgf⋅m, 69 to 80 lbf⋅ft)

11. Install make-up valves (22) (5 used) and plug

(43) to housings (24, 28, 29).
: 38 mm
: 147 to 167 N⋅m
(15 to 17 kgf⋅m, 108 to 123 lbf⋅ft)

W18K-E-00(20181019) W2-4-17
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY AND ASSEMBLY OF MAIN
RELIEF VALVE AND OVERLOAD RELIEF
VALVE

3 4 7 11 12 5 1 11 2

14
13

15

W18B-02-04-009

17 16 9 10 6 8

1- Cap 6- Pilot Poppet 11 - O-Ring 16 - O-Ring

2- Plug 7- Spring 12 - Name Plate 17 - Backup Ring
3- Sleeve 8- Pilot Spring 13 - Lock Nut
4- Main Poppet 9- O-Ring 14 - O-Ring
5- Pilot Seat 10 - Backup Ring 15 - Adjusting Screw

W18K-E-00(20181019) W2-4-18
 UPPERSTRUCTURE / Control Valve
Disassembly and Assembly of Main Relief Valve
and Overload Relief Valve
IMPORTANT: It is necessary to test the
performance of the overload relief
valve itself and adjust it. Do not
disassemble the overload relief
valve unless any problem occurs.
Disassembly
1. Put the matching marks onto plug (2) and
adjusting screw (15).
2. Attach a spanner onto plug (2). Loosen lock nut
(13) and remove adjusting screw (15). At this
time, do not drop pilot spring (8) and pilot poppet
(6).
: 17 mm, 38 mm
: 6 mm
IMPORTANT: As pilot seat (5) is secured to plug
(2), pilot seat (5) cannot be
disassembled.
3. Secure cap (1) in a vise. Loosen plug (2).
Remove plug (2) from cap (1). At this time, pilot
seat (5) is removed with plug (2) together.
: 38 mm
4. Remove spring (7) and sleeve (3) from cap (1).
5. Remove O-ring (9) and backup ring (10) from
pilot seat (5).
6. Remove main poppet (4) from sleeve (3).
7. Remove O-ring (16) and backup ring (17) from
main poppet (4).
W18K-E-00(20181019) W2-4-19
Assembly
1. Install O-ring (16) and backup ring (17) to main
poppet (4).
2. Install main poppet (4) to sleeve (3).
3. Install O-ring (9) and backup ring (10) to pilot
seat (5).
4. Install spring (7) to sleeve (3).
5. Install plug (2) to sleeve (3).
NOTE: Install plug (2) to sleeve (3) with sleeve (3)
vertical.
IMPORTANT: When installing pilot poppet (6),
check that pilot poppet (6) is
installed in pilot seat (5) securely.
6. Install pilot poppet (6) and pilot spring (8) to plug
(2). Align the matching marks made when
disassembling and install adjusting screw (15) to
plug (2). Secure with lock nut (13).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
7. Install O-ring (1) to plug (2). Install plug (2) to cap
(1).
: 38 mm
: 150 N⋅m (15 kgf⋅m, 111 lbf⋅ft)
IMPORTANT: After assembling, check that main
poppet (4) moves.
 UPPERSTRUCTURE / Control Valve
STRUCTURE OF MAKE-UP VALVE

3 7 8 2 6 9 1

W18B-02-04-008
4 5

Torque
Part Name Q’ty Remark
N⋅m (kgf⋅m) (lbf⋅ft)
1- Plug 1 100 (10) (72) : 38 mm
2- Sleeve 1
3- Poppet 1
4- Washer 1
5- Lock Nut 1
6- Spring 1
7- O-ring 1
8- Backup Ring 1
9- O-ring 1

W18K-E-00(20181019) W2-4-20
 UPPERSTRUCTURE / Swing Device
REMOVAL AND INSTALLATION OF
SWING DEVICE
1
CAUTION: Bleed air from the hydraulic oil 8
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
A 2
Removal 3 3

4 4
(Control valve side)
7
IMPORTANT: Attach identification tags onto the 5
disconnected hoses for reassem-
6
bling.

1. Disconnect pipings (4) (6 used) and hose (2)

from control valve (1). Install a plug or a cap to
the disconnected piping and hose.
W18K-02-05-001
: 14 mm

2. Remove bolts (9) (4 used), washes (10) (8 used) 1

and nuts (11) (4 used) from control bracket (8). View A
Remove brackets (3) (2 used). 8
: 24 mm

3. Disconnect the hoses (9 used) and the connector

from swing device (5). Install a plug or a cap to
the disconnected hose 3
3
(Hose)
: 19 mm, 22 mm, 36 mm, 41 mm
(Bolt)
9, 10, 11 9, 10, 11
: 19 mm W18K-02-05-002

W18K-E-00(20181019) W2-5-1
 UPPERSTRUCTURE / Swing Device

CAUTION: Be careful to avoid getting your

hand caught by reaction force bar on the hy-
draulic wrench.

4. Remove bolts (7) (24 used) by using a hydraulic

wrench.
: 50 mm
5
5. Remove a cork from the pulling-out hole (2
places) on swing device (5).
7
CAUTION: Swing device (5) weight: 1420 kg
(3140 lb)
6
6. Install a bolt (M24, Pitch 3.0 mm) to the pull-
ing-out hole (2 places) on swing device (5). Float
swing device (5) from frame (6).
W18C-02-05-001

7. Install an eyebolt (M24, Pitch 3.0 mm) to the lift-

ing hole (2 places) on swing device (5). Lifting Hole
Pulling-Out
Hole
8. Hoist and hold swing device (5). Hoist and re-
move swing device (5) from frame (6).

Pulling-Out
Hole

W18C-02-05-002
Lifting Hole

W18K-E-00(20181019) W2-5-2
 UPPERSTRUCTURE / Swing Device
(Front side)

1. Disconnect front hose (5). (backhoe: 10 used, 1

loading shovel: 12 used) Install a plug or a cap to
the disconnected hose.
: 17 mm 2

2. Disconnect hoses (3) (7 used) and the connector

from swing device (1). Install a plug or a cap to
the disconnected hose.
(Hose)
: 19 mm, 22 mm, 36 mm, 41 mm
(Bolt)
: 19 mm

5 4 3 W18K-02-05-003
3. Put the matching marks on swing device (1) and
frame (2).

CAUTION: Be careful to avoid getting your

hand caught by reaction force bar on the hy-
draulic wrench.

4. Remove bolts (4) (24 used) by using a hydraulic

wrench. 1
: 50 mm

5. Remove a cork from the pulling-out hole (2

places) on swing device (1). 4

CAUTION: Swing device (1) weight: 1420 kg

(3140 lb) 2

6. Install a bolt (M24, Pitch 3.0 mm) to the pull-

ing-out hole (2 places) on swing device (1). Float
W18C-02-05-001
swing device (1) from frame (2).

7. Install an eyebolt (M24, Pitch 3.0 mm) to the lift- Lifting

ing hole (2 places) on swing device (1). Hole
Pulling-Out
8. Hoist and hold swing device (1). Hoist and re- Hole
move swing device (1) from frame (2).

Pulling-Out
Hole

W18C-02-05-002
Lifting
Hole

W18K-E-00(20181019) W2-5-3
 UPPERSTRUCTURE / Swing Device
Installation

(Control valve side)

1. Install an eyebolt (M24, Pitch 3.0 mm) to the lift-

ing hole (2 places) on swing device (5).

5
CAUTION: Swing device (5) weight: 1420 kg
(3140 lb)
CAUTION: Be careful to avoid getting your
7
hand caught by reaction force bar on the hy-
draulic wrench.

2. Hoist swing device (5). Install swing device (5) to

6
frame (6) with bolts (7) (24 used) by using a hy-
draulic wrench.
: 50 mm
: 2 600 N⋅m (260 kgf⋅m, 1920 lbf⋅ft) W18C-02-05-001

3. Install a cork to the pulling-out hole (2 places) on

Lifting
swing device (5). Hole
Pulling-Out
4. When removing the knock pin, install the knock Hole
pin to the knock hole (2 places) on swing device
(5) by using a hammer.

Pulling-Out
Hole

W18C-02-05-002
Lifting
Hole

W18K-E-00(20181019) W2-5-4
 UPPERSTRUCTURE / Swing Device
5. Connect the hoses (9 used) and the connector to
swing device (5).
(Hose) 1
: 19 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft) 8
: 22 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
: 36 mm
A 2
: 235 N⋅m (24 kgf⋅m, 175 lbf⋅ft)
: 41 mm 3 3
: 295 N⋅m (30 kgf⋅m, 220 lbf⋅ft) 4 4
(Bolt)
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 5

6. Install brackets (3) (2 used) to control bracket (8)

with bolts (9) (4 used), washers (10) (8 used) and
nuts (11) (4 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft) W18K-02-05-001

7. Connect pipings (4) (6 used) and hose (2) to con-

trol valve (1).
: 14 mm View A
8
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

3
3

9, 10, 11 9, 10, 11
W18K-02-05-002

W18K-E-00(20181019) W2-5-5
 UPPERSTRUCTURE / Swing Device
(Front side)

CAUTION: Swing device (1) weight: 1420 kg 1

(3140 lb)
2
1. Install an eyebolt (M24, Pitch 3.0 mm) to the lift-
ing hole (2 places) on swing device (1). Hoist
swing device (1).

CAUTION: Be careful to avoid getting your

hand caught by reaction force bar on the hy-
draulic wrench.

2. Install swing device (1) to frame (2) with bolts (4) 4 3

5 W18K-02-05-003
(24 used) by using a hydraulic wrench.
: 50 mm
: 2 600 N⋅m (260 kgf⋅m, 192 0 lbf⋅ft)

3. Install a cork to the pulling-out hole (2 places) on

swing device (1).

4. When removing the knock pin, install the knock

pin to the knock hole (2 places) on swing device
(1) by using a hammer. 1

5. Connect hoses (3) (7 used) and the connector to

swing device (1). 4
(Hose)
: 19 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
: 22 mm 2
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
: 36 mm
: 235 N⋅m (24 kgf⋅m, 175 lbf⋅ft)
: 41 mm W18C-02-05-001

: 295 N⋅m (30 kgf⋅m, 200 lbf⋅ft)

(Bolt) Lifting
: 19 mm Hole
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) Pulling-Out
Hole
6. Connect front hose (5). (backhoe: 10 used, load-
ing shovel: 12 used)
: 17 mm
: 400 N⋅m (40 kgf⋅m, 295 lbf⋅ft)
1

Pulling-Out
Hole

W18C-02-05-002
Lifting
Hole

W18K-E-00(20181019) W2-5-6
 UPPERSTRUCTURE / Swing Device
(Blank)

W18K-E-00(20181019) W2-5-7
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING DEVICE

2 15
16
17

60
18
19 44
20
21 43
22

23

24
25
3
26
4 45
2
28
6
29

7 30
31 46
32
8
33 47
9 34
48
10 32
31 49
50
11
35 51
36
37 52
38 53
12
36
54
13 35
39 55
14 40
41 56
42
57

58

59

W18C-02-05-003

W18K-E-00(20181019) W2-5-8
 UPPERSTRUCTURE / Swing Device

1 - Valve Unit 17 - Stud Bolt (4 Used) 32 - Spacer (6 Used) 47 - Spherical Bearing

2 - Swing Motor 18 - Bolt (18 Used) 33 - First Stage Planetary Gear 48 - O-Ring
(3 Used)
3- First Stage Sun Gear 19 - Washer (18 Used) 34 - Retaining Ring (3 Used) 49 - Retainer
4- Thrust Plate 20 - Cover 35 - Spherical Bearing (8 Used) 50 - O-Ring
6- Retaining Ring 21 - Cork (2 Used) 36 - Spacer (8 Used) 51 - Oil Seal
7- First Stage Carrier 22 - First Stage Ring Gear 37 - Retaining Ring (4 Used) 52 - Cover
8- Second Stage Sun Gear 23 - Bolt (24 Used) 38 - Second Stage Planetary 53 - Lock Washer (6 Used)
Gear (4 Used)
9- Bolt (4 Used) 24 - Washer (24 Used) 39 - Pin (4 Used) 54 - Bolt (12 Used)
10 - Thrust Washer 25 - Cork (2 Used) 40 - Lock Plate (4 Used) 55 - Pinion Gear
11 - Second Stage Carrier 26 - Case 41 - Lock Washer (4 Used) 56 - Plate
12 - Retaining Ring 27 - Pin (3 Used) 42 - Bolt (8 Used) 57 - Washer (4 Used)
13 - Roller Bearing 28 - Bolt (6 Used) 43 - Cork (2 Used) 58 - Bolt (4 Used)
14 - Second Stage Ring Gear 29 - Lock Washer (3 Used) 44 - Housing 59 - Wire (2 Used)
15 - Nut (4 Used) 30 - Lock Plate (3 Used) 45 - Shaft 60 - O-Ring
16 - Spring Washer (4 Used) 31 - Spherical Bearing (6 Used) 46 - Deflector

W18K-E-00(20181019) W2-5-9
 UPPERSTRUCTURE / Swing Device

Bolt

2 15
16
17

18
19
20
21
22

23

24
25
3
26
4

11

14

W18C-02-05-003

W18K-E-00(20181019) W2-5-10
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Device
1. Remove the bolts (2 used) of swing motor (2) di-
agonally. Install an eyebolt (M16, Pitch 2.0 mm).
: 24 mm
CAUTION: Swing motor (2) weight: 230 kg
(510 lb)
IMPORTANT: Do not remove stud bolt (17) unless
necessary.
2. Remove nuts (15) (4 used) and spring washers
(16) (4 used). Hoist swing motor (2). Remove
swing motor (2) from cover (20).
: 30 mm
3. Remove bolts (18) (18 used) and washers (19)
(18 used).
: 24 mm
4. Remove corks (21) (2 used) from cover (20).
CAUTION: Cover (20) weight: 34 kg (75 lb)
5. Install the bolts (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on cover (20). Float cover
(20) from first stage ring gear (22).
: 24 mm
6. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on cover (20).
7. Hoist cover (20). Remove cover (20) from first
stage ring gear (22).
CAUTION: First stage ring gear (22) weight:
43 kg (95 lb)
8. Install a bolt (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on first stage sun gear
(22). Float first stage ring gear (22) from case
(26).
: 24 mm
W18K-E-00(20181019) W2-5-11
9. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on first stage ring gear
(22).
10. Hoist first stage ring gear (22). Remove first
stage ring gear (22) from case (26).
11. Remove first stage sun gear (3) and thrust plate
(4) from first stage carrier (7).
12. Install an eyebolt (M16, Pitch 2.0 mm) to the lift-
ing hole (3 places) on first stage carrier (7).
CAUTION: The first stage carrier (7) assem-
bly weight: 100 kg (220 lb)
13. Hoist the first stage carrier (7) assembly. Remove
first stage carrier (7) from second stage carrier
(11). At this time, second stage sun gear (8) is
removed with first stage carrier (7) together.
14. Remove bolts (23) (24 used) and washers (24)
(24 used).
: 36 mm
15. Remove corks (25) (2 used) from case (26).
CAUTION: Case (26) weight: 45 kg (100 lb)
16. Install a bolt (M24, Pitch 3.0 mm) to the pull-
ing-out hole (2 places) on case (26). Float case
(26) from second stage ring gear (14).
: 36 mm
 UPPERSTRUCTURE / Swing Device

44

43

26
45

9
10

50
11

52

53
12
54
39 55
14
56
57

58

59

W18C-02-05-003

W18K-E-00(20181019) W2-5-12
 UPPERSTRUCTURE / Swing Device
17. Install an eyebolt (M16, Pitch 3.0 mm) to the pull-
ing-out hole (2 places) on case (26).
18. Hoist case (26). Remove case (26) from second
stage ring gear (14)
CAUTION: Second stage ring gear (14)
weight: 85 kg (190 lb)
19. Install a bolt (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on second stage ring gear
(14). Float second stage ring gear (14) from
housing (44).
: 24 mm
20. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on second stage ring gear
(14).
21. Hoist second stage ring gear (14). Remove sec-
ond stage ring gear (14) from housing (44).
22. Remove bolts (9) (4 used). Remove thrust
washer (10) from shaft (45).
: 30 mm
23. Install an eyebolt (M16, Pitch 2.0 mm) to the lift-
ing hole on pins (39) (2 used).
CAUTION: The second stage carrier (11) as-
sembly
weight: 150 kg (330 lb)
24. Hoist the second stage carrier (11) assembly.
Remove the second stage carrier (11) assembly
from shaft (45).
25. Remove retaining ring (12) from housing (44).
W18K-E-00(20181019) W2-5-13
26. Remove corks (43) (2 used) from housing (44).
27. Install an eyebolt (M24, Pitch 3.0 mm) to the pull-
ing-out hole (2 places) on housing (44).
CAUTION: The housing (44) assembly
weight: 700 kg (1550 lb)
IMPORTANT: When turning over housing (44), do
not drop roller bearing (13).
28. Hoist and turn over housing (44).
29. Cut wires (59) (2 used). Remove wires (59) (2
used) from bolts (58) (4 used).
30. Remove bolts (58) (4 used) and washers (57) (4
used). Remove plate (56) from shaft (45).
: 41 mm
31. Install an eyebolt (M12, Pitch 1.75 mm) to the lift-
ing hole (2 places) on piston gear (55).
CAUTION: Pinion gear (55) weight: 96 kg
(230 lb)
32. Hoist pinion gear (55). Remove pinion gear (55)
from shaft (45).
CAUTION: Cover (52) weight: 20 kg (44 lb)
33. Remove bolts (54) (12 used) and lock washers
(53) (6 used). Remove cover (52) and O-ring (50)
from housing (44).
: 27 mm
 UPPERSTRUCTURE / Swing Device

44

45
27
28
6
29

7 30
31 46
32
8
33 47
34
48
32
31 49

11
35 51
36
37
52
38
36
13 35
39
40
41
42

W18C-02-05-003

W18K-E-00(20181019) W2-5-14
 UPPERSTRUCTURE / Swing Device
34. Install an eyebolt (M27, Pitch 3.0 mm) to the bolt
(58) hole (2 places) on shaft (45).
CAUTION: The shaft (45) assembly weight:
230 kg (510 lb)
35. Hoist the shaft (45) assembly. Remove the shaft
(45) assembly from housing (44). At this time, the
inner races of spherical bearing (47) and roller
bearing (13) are removed with shaft (45) to-
gether.
36. Remove deflector (46) from housing (44) by tap-
ping by using a hammer.
37. Remove oil seal (51), retainer (49) and O-ring
(48) from cover (52). Remove spherical bearing
(47) by using a press.
38. Remove the outer race of roller bearing (13) from
housing (44) by using a hammer.
CAUTION: The first stage carrier (7) assem-
bly weight: 100 kg (220 lb)
39. Extend lock washers (29) (3 used). Remove bolts
(28) (6 used). Remove lock washers (29) (3
used), lock plates (30) (3 used), pins (27) (3
used) and the first stage planetary gear (33) as-
semblies (3 used) from the first stage carrier (7)
assembly.
: 24 mm
W18K-E-00(20181019) W2-5-15
CAUTION: First stage carrier (7) weight: 54
kg (120 lb)
40. Remove retaining ring (6). Hoist and hold first
stage carrier (7). Remove first stage carrier (7)
from second stage sun gear (8).
IMPORTANT: Spherical bearings (31) (2 used)
with a pair have been installed. If
spherical bearing (31) is removed,
put the mark onto each bearing for
assembling.
41. Remove spherical bearings (31) (6 used), spac-
ers (32) (6 used) and retaining rings (34) (3 used)
from first stage planetary gears (33) (3 used).
CAUTION: The second stage carrier (11) as-
sembly weight: 150 kg (330 lb)
42. Extend lock washers (41) (4 used). Remove bolts
(42) (8 used). Remove lock washers (41) (4
used), lock plates (40) (4 used), pins (39) (4
used) and the second stage planetary gear (38)
assemblies (4 used) from the second stage car-
rier (11) assembly.
: 24 mm
IMPORTANT: Spherical bearings (35) (2 used)
with a pair have been installed. If
spherical bearing (35) is removed,
put the mark onto each bearing for
assembling.
43. Remove spherical bearings (35) (8 used), spac-
ers (36) (8 used) and retaining rings (37) (4 used)
from second stage planetary gears (38) (4 used).
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING DEVICE

60
2
27
20 28
3 29, 30
4 18
19
6 31
22 32
7 34
8 33
26 23
14 24
9 35
10 37

11 36
38
12
40, 41
13
42
44
39

48 45

50 46

52 47

51

49 53

54

57
58

59 56 55

W144-02-06-022

W18K-E-00(20181019) W2-5-16
 UPPERSTRUCTURE / Swing Device

1 - *Valve Unit 17 - *Stud Bolt (4 Used) 32 - Spacer (6 Used) 47 - Spherical Bearing

2 - Swing Motor 18 - Bolt (18 Used) 33 - First Stage Planetary Gear 48 - O-Ring
(3 Used)
3- First Stage Sun Gear 19 - Washer (18 Used) 34 - Retaining Ring (3 Used) 49 - Retainer
4- Thrust Plate 20 - Cover 35 - Spherical Bearing (8 Used) 50 - O-Ring
6- Retaining Ring 21 - *Cork (2 Used) 36 - Spacer (8 Used) 51 - Oil Seal
7- First Stage Carrier 22 - First Stage Ring Gear 37 - Retaining Ring (4 Used) 52 - Cover
8- Second Stage Sun Gear 23 - Bolt (24 Used) 38 - Second Stage Planetary 53 - Lock Washer (6 Used)
Gear (4 Used)
9- Bolt (4 Used) 24 - Washer (24 Used) 39 - Pin (4 Used) 54 - Bolt (12 Used)
10 - Thrust Washer 25 - *Cork (2 Used) 40 - Lock Plate (4 Used) 55 - Pinion Gear
11 - Second Stage Carrier 26 - Case 41 - Lock Washer (4 Used) 56 - Plate
12 - Retaining Ring 27 - Pin (3 Used) 42 - Bolt (8 Used) 57 - Washer (4 Used)
13 - Roller Bearing 28 - Bolt (6 Used) 43 - *Cork (2 Used) 58 - Bolt (4 Used)
14 - Second Stage Ring Gear 29 - Lock Washer (3 Used) 44 - Housing 59 - Wire (2 Used)
15 - *Nut (4 Used) 30 - Lock Plate (3 Used) 45 - Shaft 60 - O-Ring
16 - *Spring Washer (4 Used) 31 - Spherical Bearing 46 - Deflector
(6 Used)

NOTE: As for the parts with mark *, refer to W2-5-8.

W18K-E-00(20181019) W2-5-17
 UPPERSTRUCTURE / Swing Device

27
20 28
3 29, 30
4
31
32
6

34
7
8 33

35
10 37

11 36
38
40, 41
42

39
45

W144-02-06-022

W18K-E-00(20181019) W2-5-18
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Device
IMPORTANT: When installing spherical bearing
(31) to first stage planetary gear (33),
apply molybdenum disulphide onto
the outer periphery of the outer race
of spherical bearing (31). Install
spherical bearing (31) with the
stamped mark of aligning code “A”
facing inside.
In addition, spherical bearings (31)
(2 used) are a pair. When replacing
spherical bearing (31), replace with
a pair (2 used).
1. Install retaining rings (34) (3 used), spacers (32)
(6 used) and spherical bearings (31) (6 used) to
first stage planetary gears (33) (3 used).
2. Install an eyebolt (M16, Pitch 2.0 mm) to the lift-
ing hole (3 places) on first stage carrier (7).
CAUTION: First stage carrier (7) weight: 54
kg (120 lb)
3. Hoist first stage carrier (7). Install first stage car-
rier (7) to second stage sun gear (8) with retain-
ing ring (6).
IMPORTANT: Face the detaching prevention
groove for pin (27) outside.
4. Install the first stage planetary gear (33) assem-
blies (3 used) to first stage carrier (7) with pins
(27) (3 used).
IMPORTANT: Do not reuse lock washer (29).
5. Install lock plates (30) (3 used) and lock washers
(29) (3 used) to pins (27) (3 used) with bolts (28)
(6 used). Bend lock washers (29) (3 used) along
the bolt end.
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
W18K-E-00(20181019) W2-5-19
IMPORTANT: Install thrust plate (4) with the oil
groove facing to the shaft (45) side.
6. Install thrust plate (4) to first stage sun gear (3).
Install first stage sun gear (3) to first stage carrier
(7).
IMPORTANT: When installing spherical bearing
(35) to second stage planetary gear
(38), apply molybdenum disulphide
onto the outer periphery of the outer
race of spherical bearing (35). Install
spherical bearing (35) with the
stamped mark of aligning code “A”
facing inside.
In addition, spherical bearings (35)
(2 used) are a pair. When replacing
spherical bearing (35), replace with
a pair (2 used).
7. Install retaining rings (37) (4 used), spacers (36)
(8 used) and spherical bearings (35) (8 used) to
second stage planetary gears (38) (4 used).
IMPORTANT: Install thrust plate (10) with the oil
groove facing to the cover (20) side.
8. Install thrust plate (10) to second stage carrier
(11).
IMPORTANT: Face the detaching prevention
groove for pin (39) outside.
9. Install the second stage planetary gear (38) as-
semblies (4 used) to second stage carrier (11)
with pins (39) (4 used).
IMPORTANT: Do not reuse lock washer (41).
10. Install lock plates (40) (4 used) and lock washers
(41) (4 used) to pins (39) (4 used) with bolts (42)
(8 used). Bend lock washers (41) (4 used) along
the bolt end.
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
 UPPERSTRUCTURE / Swing Device

44

48 45

50 46

52 47

51

49

58

W144-02-06-022

W18K-E-00(20181019) W2-5-20
 UPPERSTRUCTURE / Swing Device
11. Warm up spherical bearing (47) to approx. 90°C
by using a bearing heater. CAUTION: The shaft (45) assembly weight:
230 kg (510 lb)

CAUTION: Spherical bearing (47) weight: 16. Hoist the shaft (45) assembly. Install the shaft
58 kg (130 lb) (45) assembly to housing (44).

IMPORTANT: Apply molybdenum disulphide onto
the outer periphery of spherical
bearing (47). In addition, the inner
race is pushed by spherical bearing
(47). If the outer race is pushed,
spherical bearing (47) may be dam-
aged.
12. Install spherical bearing (47) to shaft (45) with the
stamped mark facing upward by using a press.
IMPORTANT: Install oil seal (51) with the lip part
facing to the spherical bearing (47)
side. In addition, apply molybdenum
disulphide onto the outer periphery
of oil seal (51).
17. Install oil seal (51) to cover (52) by using the spe-
cial tool (ST 2646). Apply grease onto the ring
groove of cover (52). Install O-ring (50).

IMPORTANT: As for retainer (49), face the O-ring ST 2646

(48) groove side to the spherical
bearing (47) side.
13. Apply grease onto the ring groove of retainer (49). 51
Install O-ring (48). Install retainer (49) to shaft
50
(45).
52

45
49
W114-02-06-012
48
47

W114-02-06-011

14. Install deflector (46) to housing (44) by using a

bar and a hammer.
NOTE: Insert deflector (46) until deflector (46)
comes into contact with the end of housing
(44).

15. Install an eyebolt (M27, Pitch 3.0 mm) to the bolt

(58) hole (2 places) on shaft (45).

W18K-E-00(20181019) W2-5-21
 UPPERSTRUCTURE / Swing Device

9
10

11
12
13
44
39
45

52

53

54

57
58

59 56 55

W144-02-06-022

W18K-E-00(20181019) W2-5-22
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Do not reuse the lock washer (53).
18. Install the cover (52) assembly to housing (44)
with lock washers (53) (6 used) and bolts (54)
(12 used). Bend lock washer (53) in order to se-
cure.
: 27 mm
: 300 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
19. Install an eyebolt (M12, Pitch 1.75 mm) to the lift-
ing hole (2 places) on pinion gear (55).
CAUTION: Pinion gear (55) weight: 96 kg
20. Hoist pinion gear (55). Install plate (56) to shaft
(45) with washers (57) (4 used) and bolts (58) (4
used).
At this time, check that the clearance between
pinion gear (55) and plate (56) is 0.3 to 1.1 mm.
: 41 mm
: 1400 N⋅m (140 kgf⋅m, 1030 lbf⋅ft)
21. Install wires (59) (2 used) to bolts (58) (4 used).
22. Install an eyebolt (M24, Pitch 3.0 mm) to the pull-
ing-out hole (2 places) on housing (44).
CAUTION: The housing (44) assembly
weight: 700 kg (1550 lb)
23. Hoist and turn over the housing (44) assembly.
W18K-E-00(20181019) W2-5-23
IMPORTANT: Apply molybdenum disulphide onto
the roller bearing (13) mounting part
of housing (44).
24. Install the outer race of roller bearing (13) to
housing (44) by using a bar and a hammer.
25. Install retaining ring (12) to housing (44).
26. Install an eyebolt (M16, Pitch 2.0 mm) to pins
(39) (2 used).
CAUTION: The second stage carrier (11) as-
sembly weight: 150 kg (330 lb)
IMPORTANT: Apply LOCTITE #243 onto the thread
part of bolt (9).
27. Hoist the second stage carrier (11) assembly. In-
stall the second stage carrier (11) assembly to
shaft (45) while aligning the splines.
28. Install thrust washer (10) to shaft (45) with bolts
(9) (4 used).
: 30 mm
: 550 N⋅m (55 kgf⋅m, 410 lbf⋅ft)
 UPPERSTRUCTURE / Swing Device

60
2

20
3
18
19

22
7

26 23
14 24

11

44

W144-02-06-022

W18K-E-00(20181019) W2-5-24
 UPPERSTRUCTURE / Swing Device
29. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on second stage ring gear CAUTION: First stage ring gear (22) weight:
(14). 43 kg (95 lb)

IMPORTANT: Apply THREEBOND #1215 onto the

CAUTION: Second stage ring gear (14)
weight: 85 kg (190 lb)
IMPORTANT: Apply THREEBOND #1215 onto the
mating surfaces of housing (44) and
second stage ring gear (14).
30. Hoist second stage ring gear (14). Install second
stage ring gear (14) to housing (44) while align-
ing the splines of the gear.
mating surfaces of case (26) and
first stage ring gear (22).
35. Hoist first stage ring gear (22). Install first stage
ring gear (22) to case (26) while aligning the
splines of the gear.
36. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-
ing-out hole (2 places) on cover (20).

31. Install an eyebolt (M16, Pitch 3.0 mm) to the pull-
ing-out hole (2 places) on case (26).
CAUTION: Case (26) weight: 45 kg (100 lb)
IMPORTANT: Apply THREEBOND #1215 onto the
mating surfaces of second stage
ring gear (14) and case (26).
32. Hoist case (26). Install case (26) to second stage
ring gear (14) with bolts (23) (24 used) and
washers (24) (24 used).
: 36 mm
: 700 N⋅m (71.5 kgf⋅m, 520 lbf⋅ft)
CAUTION: The first stage carrier (7) assem-
bly weight: 100 kg (220 lb)
37. Install O-ring (60) to cover (20).
CAUTION: Cover (20) weight: 34 kg (75 lb)
IMPORTANT: Apply THREEBOND #1215 onto the
mating surfaces of first stage ring
gear (22) and cover (20).
38. Hoist cover (20). Install cover (20) to first stage
ring gear (22) with bolts (18) (18 used) and
washers (19) (18 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
NOTE: Check that first stage sun gear (3) rotates
smoothly by hands.

33. Hoist the first stage carrier (7) assembly. Install

the first stage carrier (7) assembly to second
stage carrier (11) while aligning the splines of the
gear.

34. Install an eyebolt (M16, Pitch 2.0 mm) to the pull-

ing-out hole (2 places) on first stage ring gear
(22).

W18K-E-00(20181019) W2-5-25
 UPPERSTRUCTURE / Swing Device

W144-02-06-022

W18K-E-00(20181019) W2-5-26
 UPPERSTRUCTURE / Swing Device
39. Install corks (21) (2 used), (25) (2 used) and (43)
(2 used) to each pulling-out hole on the swing
reduction gear by using a hammer.

CAUTION: Swing motor (2) weight: 178 kg

(395 lb)

40. Install swing motor (2) to the swing reduction

gear with nuts (15) (4 used) and spring washers
(16) (4 used). Add gear oil.
Gear oil: SP90
(Gear Lube)
Oil amount: 60 L (15.9 US gal)
: 30 mm
: 400 N⋅m (40 kgf⋅m, 2 9 5 lbf⋅ft)

W18K-E-00(20181019) W2-5-27
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING MOTOR
10
9 11

5
6
7
6
5 12
4 13
3
14
2 16 15
1

17 14
18
19
20
21
22
23 32

24
28 25
26 31
27

30

33
34
29
35
36
37
38
39
38

W118-02-04-002
39
38
1- Socket Bolt (6 Used) 11 - O-Ring (2 Used) 21 - Guide Ring 31 - Bolt (12 Used)
2- Cover 12 - Shim 22 - Valve Plate 32 - Socket Bolt (9 Used)
3- O-Ring 13 - Spacer 23 - Rotor 33 - Cover
4- Oil Seal 14 - Retaining Ring (2 Used) 24 - Disc Spring (4 Used) 34 - O-Ring
5- Retaining Ring (2 Used) 15 - Coupling 25 - Shim 35 - Piston
6- Spacer (2 Used) 16 - Socket Bolt (3 Used) 26 - Holder 36 - Piston Ring
7- Bearing 17 - Cover 27 - Retainer 37 - Piston Ring
8- Shaft 18 - Pin 28 - Plunger (9 Used) 38 - Plate (9 Used)
9- Casing 19 - O-Ring 29 - Shoe Plate 39 - Friction Plate (8 Used)
10 - Plug (2 Used) 20 - Bearing 30 - Spring (12 Used)

W18K-E-00(20181019) W2-5-28
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Motor 7. Remove piston rings (36, 37) from piston (35).

8. Remove retaining ring (14) and coupling (15)

CAUTION: Swing motor weight: 195 kg (430
from shaft (8).
lb)
9. Remove plates (38) (9 used), friction plates (39)
1. Hoist and place the swing motor on a workbench.
(8 used), shim (12) and spacer (13) from cover
Remove plug (10) from casing (9). Drain hydrau-
(17).
lic oil.
: 36 mm
10. Remove retaining ring (14) from shaft (8).
2. Remove bolts (31) (2 used) diagonally. Install an
IMPORTANT: When removing cover (17), valve
eyebolt (M16, Pitch 2.0 mm).
plate (22) may be removed with
Hoist and place the swing motor on wooden
cover (17) together. Remove cover
blocks (2 used) vertically.
(17) carefully in order to prevent
: 24 mm
valve plate (22) from falling off.
11. Remove socket bolts (16) (3 used) and (32) (9
used) from cover (17). Install an eyebolt (M16,
Swing Motor Pitch 2.0 mm) to the bolt (31) hole on cover (17).
Hoist cover (17). Remove cover (17) from casing
(9).
: 14 mm

Wooden 12. Remove valve plate (22), guide ring (21) and
Block
O-ring (19) from cover (17).
W18B-02-05-004 NOTE: Do not remove bearing (20) unless nec-
essary.
3. Put the matching marks on casing (9) and covers
(17, 33).

4. Loosen other bolts (31) (10 used) evenly. Re-

move cover (33) from cover (17). Remove O-ring
(34) from cover (33).
: 24 mm

5. Remove springs (30) (12 used) from cover (17).

6. Install an eyebolt (M16, Pitch 2.0 mm) to the cen-

ter hole on piston (35). Hoist piston (35). Remove
piston (35) from cover (17).

W18K-E-00(20181019) W2-5-29
 UPPERSTRUCTURE / Swing Device

5
6
7
6
5
4
3
2
1

20

23

24
28 25
26
27

33

29

W118-02-04-002

W18K-E-00(20181019) W2-5-30
 UPPERSTRUCTURE / Swing Device
13. Place casing (9) on a workbench horizontally with 21. Push shaft (8) by using a press and remove the
the main piping mounting surface facing upward. inner race of bearing (7).

22. Tap shoe plate (29) by using a copper bar. Re-

CAUTION: The rotor (23) assembly weight:
move shoe plate (29) from casing (9).
41 kg (90 lb)
23. Tap the outer race of bearing (7) by using a cop-
14. Wind a nylon sling onto the body of rotor (23).
per bar. Remove bearing (7) from casing (9).
Remove rotor (23) from casing (9). At this time,
plunger (28), holder (26) and retainer (27) are
removed with rotor (23) together.

15. Wind vinyl tape around the inner race of bearing

(20) in order to protect.

16. Remove plungers (28) (9 used), retainer (27),

holder (26), disc spring (24) and shim (25) from
rotor (23).

17. Remove socket bolts (1) (6 used). Remove cover

(2) from casing (9).
: 8 mm

18. Remove oil seal (4) and O-ring (3) from cover (2).

19. Remove shaft (8) from casing (9) by tapping by

using a plastic hammer from the cover (33) side.

20. Remove retaining rings (5) (2 used) from shaft (8).

Remove spacers (6) (2 used).

W18K-E-00(20181019) W2-5-31
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING MOTOR

16 34 30 14 35 33 15 31

36

Dimension A
37

38
39
17 32

12
13

19
20
18
21 22

9
23
11
10
10
11 24

25
26
28
5
6
27

29 1 2 4 8 5 6 3 W117-02-04-005

1- Socket Bolt (6 Used) 11 - O-Ring (2 Used) 21 - Guide Ring 31 - Bolt (12 Used)
2- Cover 12 - Shim 22 - Valve Plate 32 - Socket Bolt (9 Used)
3- O-Ring 13 - Spacer 23 - Rotor 33 - Cover
4- Oil Seal 14 - Retaining Ring (2 Used) 24 - Disc Spring (4 Used) 34 - O-Ring
5- Retaining Ring (2 Used) 15 - Coupling 25 - Shim 35 - Piston
6- Spacer (2 Used) 16 - Socket Bolt (3 Used) 26 - Holder 36 - Piston Ring
7- Bearing 17 - Cover 27 - Retainer 37 - Piston Ring
8- Shaft 18 - Pin 28 - Plunger (9 Used) 38 - Plate (9 Used)
9- Casing 19 - O-Ring 29 - Shoe Plate 39 - Friction Plate (8 Used)
10 - Plug (2 Used) 20 - Bearing 30 - Spring (12 Used)

W18K-E-00(20181019) W2-5-32
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Motor
1. Install retaining ring (5) and spacer (6) to the ro-
tor side of shaft (8).
2. Assemble the inner race and the inner ring plate
of bearing (7). Warm up them to approx. 60 °C
(140 °F) by using a heater or an oil bath.
3. Install bearing (7) to shaft (8) with the inner ring
plate facing inside by using a press.
4. Install spacer (6) and retaining ring (5) to shaft
(8).
5. Lightly tap the outer race of bearing (7) by using
a copper bar and install shaft (8) to casing (9).
6. Install oil seal (4) to cover (2). Install O-ring (3).
7. Install cover (2) to casing (9) with socket bolts (1)
(6 used)
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft)
IMPORTANT: Install shoe plate (29) with the
chamfered surface facing inside.
IMPORTANT: After installing shoe plate (29), ro-
tate shoe plate (29) by hand. If shoe
plate (29) cannot be rotated, reas-
semble shoe plate (29) as it may be
seized.
8. Apply grease onto the chamfered surface and the
outer periphery of shoe plate (29).
Install shoe plate (29) to casing (9).
W18K-E-00(20181019)
IMPORTANT: The smooth surface of rotor (23) is
the sliding surface for the valve
plate. Do not damage the sliding
surface.
9. Assemble rotor (23) into an assembly in the fol-
lowing procedures.
• Place rotor (23) with the smooth surface facing
downward.
• Assemble disc springs (24) (4 used) so that the
outer surface is matching with the outer surface
and the inner surface is matching with the inner
surface. Place disc spring (24) on the projection
part of top in rotor (23).
Place shim (25) on them and cover them with
holder (26). At this time, align holder (26) with the
spline in rotor (23).
25
24
26
23
W18B-02-04-010
• Place retainer (27) on holder (26) with the cham-
fered surface facing downward.
27
Chamfered
26 Surface
W176-02-06-016
• Align the plunger hole on retainer (27) with that
on rotor (23). Insert plungers (28) (9 used).
CAUTION: The rotor (23) assembly weight:
41 kg (90 lb)
10. Install the rotor (23) assembly into shaft (8).
W2-5-33
 UPPERSTRUCTURE / Swing Device

16 34 30 14 35 33 15 31

36
37

38
39
17 32

12
13

19
18
21 22

11
10
10
11

8 W117-02-04-005

W18K-E-00(20181019) W2-5-34
 UPPERSTRUCTURE / Swing Device
11. Install guide ring (21) and O-ring (19) to cover
(17).
12. Apply grease onto the flat surface of valve plate
(22). Install valve plate (22) to cover (17) while
aligning with pin (18).
IMPORTANT: Align the notches on plates (38) (9
used) and friction plates (39) (8
used). In addition, adjust shim (12)
so that dimension A between the
stepped surface of cover (17) and
top of plate (38) is 3.3 mm (0.1 in).

17
CAUTION: The casing (9) assembly weight:
120 kg (270 lb)
A
13. Install an eyebolt (M16, Pitch 2.0 mm) to the
cover mounting bolt (32) hole on casing (9).
Hoist and place casing (9) on a wooden block 38
vertically.

W18B-02-04-013

9
Wooden Block 17. Install plates (38) (9 used) and friction plates (39)
(Height: 200 mm)
(8 used) alternately in this order to cover (17) and
coupling (15).

18. Install piston rings (36, 37) to piston (35).

19. Install piston (35) to cover (17).

20. Install springs (30) (12 used) to piston (35).

W18B-02-04-011

21. Install O-ring (34) to cover (33). Install cover (33)

IMPORTANT: Do not drop valve plate (22) from
to cover (17) with bolts (31) (12 used).
cover (17).
: 24 mm
14. Install cover (17) to casing (9) with socket bolts
: 235 N⋅m (24 kgf⋅m, 173 lbf⋅ft)
(16) (3 used) and (32) (9 used).
: 14 mm
22. Install O-rings (11) (2 used) to plugs (10) (2 used).
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
Install plugs (10) (2 used) to casing (9).
: 36 mm
15. Install retaining ring (14), coupling (15) and re-
: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)
taining ring (14) to shaft (8).

16. Install spacer (13) and shim (12) to cover (17).

W18K-E-00(20181019) W2-5-35
 UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD Dial Gauge

1. Clamp the plunger in a vise. Install a dial gauge

to the shoe. Measure clearance (A) between the
plunger spherical part and the shoe bottom while
moving the shoe up and down. A
If clearance (A) exceeds the allowable limit, re-
place the plunger and the shoe as an assembly. Guide

Unit: mm (in)
Standard Allowable Limit
0 0.3 (0.01)

2. Measure plunger diameter (B) around top, middle Vise

Plate
W115-02-04-062

and skirt part in both vertically and horizontally by

using a micrometer.
Measure rotor bore (C) at two places (vertically
and horizontally) by using a cylinder gauge. (B) (B) (B)

(C)-(B) Unit: mm (in)

Standard Allowable Limit W115-02-04-065

0.026 (0.001) 0.056 (0.002)

3. Measure flange thickness (D) of the shoe by us-

ing a micrometer. (C) (C)

Unit: mm (in)
(C) (C)
Standard Allowable Limit
10.0 (0.4) 9.8 (0.4)

W115-02-04-066

4. Measure height H and h.

E=H-h

Unit: mm (in)
Standard Allowable Limit
E 35.6 (1.4) 34.8 (1.4) (D)

W115-02-04-068

26 27

H
h

W115-02-04-069

W18K-E-00(20181019) W2-5-36
 UPPERSTRUCTURE / Swing Device
5. Measure dimension (A).
17
Unit: mm (in)
A
Standard Allowable Limit
3.3 (0.1) 4.3 (0.2)

Remedy: Adjust by using the shims. 38

6. Measure the disc spring thickness.

I-i Unit: mm (in)

W18B-02-04-013
Standard Allowable Limit
7.8 (0.3) 7.4 (0.3)
Cover

Casing
Valve Plate
i

W117-02-04-006

7. Measure the brake spring length.

Unit: mm (in)
Standard Allowable Limit
54 (2.1) 53.6 (2.1)

Remedy: Replace the spring.

8. Measure thickness of the plate and the friction

plate.(17 used)

Unit: mm (in)
Standard Allowable Limit
36.8 (1.4) 36.2 (1.4)

Remedy: Replace the plate and the friction plate.

W18K-E-00(20181019) W2-5-37
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY AND ASSEMBLY OF
VALVE UNIT

1 2 3 4 5 4 3 2

6 6

W118-02-04-003
11 10

1 - Plug (2 Used) 4 - Poppet (2 Used) 7 - O-Ring (2 Used) 10 - O-Ring (2 Used)

2 - O-Ring (2 Used) 5 - Housing 8 - Relief Valve (2 Used) 11 - Backup Ring (4 Used)
3 - Spring (2 Used) 6 - Plug (2 Used) 9 - Plug (2 Used)

W18K-E-00(20181019) W2-5-38
 UPPERSTRUCTURE / Swing Device
Disassembly of Valve Unit
CAUTION: Valve unit weight: 31kg (68 lb)
1. Loosen plugs (1) (2 used). Remove springs (3) (2
used) and poppets (4) (2 used).
: 14 mm
2. Remove plugs (6) (2 used).
: 6 mm
3. Remove plugs (9) (2 used).
: 41 mm
IMPORTANT: Do not disassemble the relief valve
(8) assembly.
4. Attach a spanner onto the body of the relief valve
(8) assembly. Remove the relief valve (8) assem-
bly from housing (5). (2 places)
: 41 mm
W18K-E-00(20181019) W2-5-39
Assemble Valve Unit
1. Install the relief valve (8) assemblies (2 used).
: 41 mm
: 176 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
2. Install plugs (9) (2 used).
: 41 mm
: 176 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
3. Install plugs (6) (2 used).
: 6 mm
: 36 N⋅m (3.7 kgf⋅m, 27 lbf⋅ft)
4. Install spring (3) to poppet (4). Insert poppet (4)
into housing (5). (2 places)
Install plugs (1) (2 used) to housing (5).
: 14 mm
: 334 N⋅m (34 kgf⋅m, 246 lbf⋅ft)
 UPPERSTRUCTURE / Swing Device
(Blank)

W18K-E-00(20181019) W2-5-40
 UPPERSTRUCTURE / DQR Valve
REMOVAL AND INSTALLATION DQR EHC Valve
VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

(Pilot Panel Side) 1

3
Removal

1. Disconnect hoses (6) (15 used) from DQR valve Frame

2
(2). Cap the open ends. Attach an identification W18K-02-08-001

tag onto the disconnected hoses for assembling.

: 17 mm, 19 mm, 27 mm

2 6
CAUTION: DQR valve (2) weight: 28 kg (65 Ib)
5
2. Remove socket bolts (5) (4 used) from DQR valve
(2). Remove DQR valve (2) from pilot panel (1).
: 8 mm

3. Disconnect hoses (8) (15 used) from DQR valve

(3). Cap the open ends. Attach an identification 6 1
tag onto the disconnected hoses for assembling.
: 17 mm, 19 mm, 27 mm
6

CAUTION: DQR valve (3) weight: 28 kg (65 Ib)

W18L-02-06-001
4. Remove socket bolts (7) (4 used) from DQR valve
(3). Remove DQR valve (3) from pilot panel (4).
: 8 mm

3 7 8

8 4

8 W18L-02-06-002

W18K-E-00(20181019) W2-6-1
 UPPERSTRUCTURE / DQR Valve
Installation
3 7 8

CAUTION: DQR valve (3) weight: 28 kg (65 Ib)

1. Install DQR valve (3) to pilot panel (4) with socket

bolts (7) (4 used). 8 4
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft)

2. Connect hoses (8) (15 used) to DQR valve (3).

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
8 W18L-02-06-002
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 70 Ibf⋅ft)
2 6
CAUTION: DQR valve (2) weight: 28 kg (65 Ib)
5
3. Install DQR valve (2) to pilot panel (1) with socket
bolts (5) (4 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft)
6 1
4. Connect hoses (6) (15 used) to DQR valve (2).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) 6
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 70 Ibf⋅ft) W18L-02-06-001

EHC Valve

2 Frame W18K-02-08-001

W18K-E-00(20181019) W2-6-2
 UPPERSTRUCTURE / DQR Valve
(Blank)

W18K-E-00(20181019) W2-6-3
 UPPERSTRUCTURE / DQR Valve
STRUCTURE OF DQR VALVE

8
3
9

W18G-02-06-010

W18K-E-00(20181019) W2-6-4
 UPPERSTRUCTURE / DQR Valve

A A A A A A A

A A A A A A A
W18G-02-06-008

9
8
2
3

4
5

6
W18G-02-06-009
7 Section A-A

Wrench Size Tightening Torque

Item Part Name Q’ty Remarks
(mm) N⋅m (kgf⋅m) Ibf⋅ft
1 Adapter 7 : 22 50 (5.0) 37 PF 3/8
2 O-Ring 7
3 Body 1
4 Spool 6
5 Spring 6
6 O-Ring 6
7 Plug 6 :5 50 (5.0) 37 PF 3/8
8 Plug 14 :5 10 (1.0) 7 PF 1/8
9 O-Ring 14

W18K-E-00(20181019) W2-6-5
 UPPERSTRUCTURE / DQR Valve
(Blank)

W18K-E-00(20181019) W2-6-6
 UPPERSTRUCTURE / Shuttle Valve
REMOVAL AND INSTALLATION OF SHUT-
TLE VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on Pilot Panel Control Valve
W1-4-1.)

Removal

IMPORTANT: Attach an identification tag onto the

disconnected pipings and hose for
assembling.
1. Disconnect pipings (3) (16 used) and hoses (6)
(12 used) from shuttle valves (2) (4 used).
(Piping)
: 19 mm
(Hose)
: 22 mm

2. Remove pressure sensor (7) from shuttle valve W18K-02-07-001

(2).
3 2 1
3. Remove bolts (5) (8 used) from bracket (1). Re-
move the shuttle valve (2) assemblies (4 used).
: 10 mm, 17 mm 3
2 2

4. Remove bolts (7) (4 used for each) from brackets 4

(4) (4 used). Remove shuttle valves (2) (4 used) 4
from brackets (4) (4 used). 5
: 13 mm, 17 mm 5
6

W18K-02-07-002
7

W18K-E-00(20181019) W2-7-1
 UPPERSTRUCTURE / Shuttle Valve
Installation
2 2
1. Install shuttle valves (2) (4 used) to brackets (4) 3
(4 used) with bolts (7) (4 used for each).
: 13 mm 4
4
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
: 17 mm 5
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 5
6

2. Install the shuttle valve (2) assemblies (4 used) to

bracket (1) with bolts (5) (2 used for each).
: 10 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft) W18K-02-07-002
7
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Install pressure sensor (7) to shuttle valve (2). Pilot Panel Control Valve

4. Connect pipings (3) (16 used) and hoses (6) (12

used) to shuttle valves (2) (4 used).
(Piping)
: 19 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
(Hose)
: 22 mm
: 40 N⋅m (4 kgf⋅m, 30 lbf⋅ft)

W18K-02-07-001

3 2 1

W18K-E-00(20181019) W2-7-2
 UPPERSTRUCTURE / Shuttle Valve
STRUCTURE OF SHUTTLE VALVE

4
3
2
1

4
4 3
3 2
2 1
1 W18B-02-10-001
8

Wrench Size Tightening Torque

Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1- Plug 3 :6 20 (2.0) (15)
2- O-ring 3
3- Plug 3 :5
4- Steel ball 3 8
5- Seal 1
6- Steel ball 3
7- Body 1
8- Seal 1 -

W18K-E-00(20181019) W2-7-3
 UPPERSTRUCTURE / Shuttle Valve
(Blank)

W18K-E-00(20181019) W2-7-4
 UPPERSTRUCTURE / EHC Valve
REMOVAL AND INSTALLATION OF EHC
VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal

1. Remove bolts (3) (3 used). Remove the clips (3

used).
: 17 mm
1
2. Remove bolts (5) (2 used). Remove bracket (4)
from pilot panel (1).
: 17 mm

3. Disconnect hoses (6) (8 used), piping (7) and 2 Frame

W18K-02-08-001

connectors (9) (15 used) from EHC valve (2). Cap

the open ends of the hose and the piping. Attach
3 Clip 4, 5 6
an identification tag onto the disconnected hoses
and pipings for assembling.
: 17 mm, 19 mm, 22 mm 1

4. Remove bolts (8) (4 used). Remove EHC valve (2)

from pilot panel (1).
: 17 mm
2

9 7

6 9 8 W18L-02-08-002

W18K-E-00(20181019) W2-8-1
 UPPERSTRUCTURE / EHC Valve
5. Remove bolts (12) (4 used). Remove the clips (4
used). Remove bolts (15) (2 used). Remove
bracket (14) from pilot panel (10).
11
: 17 mm

6. Disconnect hoses (13) (7 used), piping (16) and

connectors (18) (14 used) from EHC valve (11). 10
Cap the open ends of the hose and piping. Attach
an identification tag onto the disconnected hoses
and pipings for assembling.
: 17 mm, 19 mm, 22 mm
W18K-02-08-001
7. Remove bolts (17) (4 used). Remove EHC valve
Clip 12 13 14, 15
(11) from pilot panel (10).
: 17 mm

10

11

16

13

18 17 W18L-02-08-003

W18K-E-00(20181019) W2-8-2
 UPPERSTRUCTURE / EHC Valve
Installation
3 Clip 4, 5 6
1. Install EHC valve (2) to pilot panel (1) with bolts
(8) (4 used). 1
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft)

2. Connect hoses (6) (8 used), piping (7) and

connectors (9) (15 used) to EHC valve (2).
: 17 mm 2
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm 9 7
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 30 Ibf⋅ft)
6 9 8 W18L-02-08-002

3. Install bracket (4) to pilot panel (1) with bolts (5) (2

used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft)

4. Install the clips (3 used) to bracket (4) with bolts

(3) (3 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft) 1

W18K-02-08-001
2 Frame

W18K-E-00(20181019) W2-8-3
 UPPERSTRUCTURE / EHC Valve
5. Install EHC valve (11) to pilot panel (10) with bolts Clip 12 13 14, 15
(17) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft)
10
6. Connect hoses (13) (7 used), piping (16) and
connectors (18) (14 used) to EHC valve (11). 11
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) 16
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 30 Ibf⋅ft)
13

7. Install bracket (14) to pilot panel (10) with bolts 18 17 W18L-02-08-003

(15) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft)

8. Install the clips (4 used) to bracket (14) with bolts

(12) (4 used). 11
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft) 10

Frame
W18K-02-08-001

W18K-E-00(20181019) W2-8-4
 UPPERSTRUCTURE / EHC Valve
Engine Bed Side (Pump Space)
2 3 4, 5 6
Removal Clip

1. Remove bolts (6) (5 used) from bracket (4). 1

Remove the clips (5 used).
: 17 mm

2. Remove bolts (5) (2 used). Remove bracket (4)

from pilot panel (1).
: 17 mm

3. Disconnect connectors (7) (11 used), pipings (9)

(6 used) and hose (8) from EHC valve (2).
: 17 mm, 19 mm
9 8 7 W18L-02-08-004

4. Remove bolts (3) (4 used). Remove EHC valve (2)

from pilot panel (1).
: 17 mm

W18K-E-00(20181019) W2-8-5
 UPPERSTRUCTURE / EHC Valve
Installation
2 3 4, 5 6
1. Install EHC valve (2) to pilot panel (1) with bolts Clip
(3) (4 used).
: 17 mm 1
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft)

2. Connect connectors (7) (11 used), pipings (9) (6

used) and hose (8) to EHC valve (2).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

3. Install bracket (4) to pilot panel (1) with bolts (5) (2

used). 7 W18L-02-08-004
9 8
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft)

4. Secure the clips (5 used) to bracket (4) with bolts

(6) (5 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 Ibf⋅ft)

W18K-E-00(20181019) W2-8-6
 UPPERSTRUCTURE / EHC Valve
STRUCTURE OF EHC VALVE

Section B

Proportional Plug
W18G-02-08-009
Solenoid Valve

W18G-02-08-010
Plug
Proportional Solenoid Valve

Section A W18G-02-08-011

W18K-E-00(20181019) W2-8-7
 UPPERSTRUCTURE / EHC Valve
DISASSEMBLY AND ASSEMBLY OF PROPORTIONAL SOLENOID VALVE

1
2
3
4
5

7
8
9
12
13 14
10 15
11 16

17
18
19

W18G-02-08-012

4 2 3, 5 6 1 8 12 13 17 10 18

19
W18G-02-08-013

7 9 14 15 16 11

1- Socket Bolt (4 Used) 6- Solenoid 11 - Orifice 16 - O-Ring

2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
4- Adjusting Bolt 9- Diaphragm 14 - O-Ring 19 - Wave Spring
5- Spring 10 - Spool 15 - O-Ring

W18K-E-00(20181019) W2-8-8
 UPPERSTRUCTURE / EHC Valve
Disassembly of Proportional Solenoid Valve
IMPORTANT: Do not lose spring (7) inside
solenoid (6) when removing
solenoid (6).
Do not disassemble lock nut (2) and
adjusting bolt (4) for pressure
adjustment.
1. Remove socket bolts (1) (4 used). Remove
solenoid (6). Remove O-ring (8).
: 3 mm
2. Remove spool (10) from sleeve (17). Remove
diaphragm (9), washer (12) and spring (13).
3. Remove sleeve (17) from the housing. Remove
plate (18) and wave spring (19).
IMPORTANT: Do not remove orifice (11) from
sleeve (17).
4. Remove O-rings (14, 15, 16) from sleeve (17).
W18K-E-00(20181019) W2-8-9
Assembly of Proportional Solenoid Valve
1. Install wave spring (19) and plate (18) to the
housing.
IMPORTANT: Align the hole on sleeve (17) with
that on the housing when inserting
sleeve (17) into the housing.
2. Install O-rings (14, 15, 16) to sleeve (17). Insert
sleeve (17) into the housing.
IMPORTANT: Do not damage the edge inside of
sleeve (17) when inserting spool (10)
into sleeve (17).
After inserting spool (10), push
about 3 to 5 mm (0.1 to 0.2 in) by
fingers. Check that spool (10) moves
smoothly.
3. Install diaphragm (9), washer (12) and spring (13)
to spool (10). Insert spool (10) into sleeve (17).
IMPORTANT: When installing solenoid (6), do not
drop spring (7).
4. Install spring (7) to solenoid (6). Install O-ring (8)
to the housing. Install solenoid (6) with socket bolt
(1).
: 3 mm
: 2.9 N⋅m (0.3 kgf⋅m, 2.1 lbf⋅ft)
 UPPERSTRUCTURE / EHC Valve
STRUCTURE OF SOLENOID 1

W18G-02-09-006

10 9 8 7 6 5 4 3 2

Wrench Size Tightening Torque

Item Part Name Q’ ty Remark
(mm) N⋅m (kgf⋅m) (Ibf⋅ft)
1 Socket bolt 4 :4 7 (0.7) (5)
2 Plug 1 : 27 50 (5.0) (37)
3 O-Ring 2
4 Spring 2
5 Square Ring 4
6 Spool 1
7 Casing 1
8 Spring Seat 2
9 Solenoid 1
10 Nut 1 4 (0.4) (3)

W18K-E-00(20181019) W2-8-10
 UPPERSTRUCTURE / Oil Cooler Fan Motor
REMOVAL AND INSTALLATION OF OIL
COOLER FAN MOTOR

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal
Engine Unit Front Side

CAUTION: Cover (1) weight: 27 kg (60 lb)

Cover (2) weight: 18 kg (40 lb)

1. Remove bolts (3) (26 used) from covers (1) (3

used) and (2) (3 used) on the engine unit. Hoist 1 2
and remove covers (1) (3 used) and (2) (3 used)
from the engine unit.
: 19 mm

3 W18K-02-09-001

2. Remove bolt (11). Remove clamp (12) from the

oil cooler. 4 5 6 7, 8
: 17 mm

3. Remove bolts (7) (4 used) and clamps (8) (4

used) from piping (4) and bracket (10). 9
: 17 mm
10
4. Remove socket bolts (6) (4 used). Disconnect
piping (9) from piping (4).
: 10 mm
Oil Cooler
11, 12 W18K-02-09-002

5. Disconnect hose (5) and hoses (13) (2 used) Oil Cooler 5 13

from fan motor (14). Cap the disconnected
hoses.
: 27 mm, 36 mm 14

W18K-02-09-003
13

W18K-E-00(20181019) W2-9-1
 UPPERSTRUCTURE / Oil Cooler Fan Motor
6. Remove bolts (16) (23 used). Remove nets (17) Bolt Hole for
15 Piping Clamp
(2 used) and plates (18) (4 used).
: 19 mm

CAUTION: The bracket (10) assembly 10

weight: 191 kg (421 lb)

7. Install eyebolts (M10, Pitch 1.5 mm) and (M12, 14

Pitch 1.75 mm) to the bolt hole (2 places) for the
piping clamp on bracket (10). Hoist and hold 16
bracket (10). Remove bolts (15) (6 used). Hoist
and remove the bracket (10) assembly.
: 19 mm
17

CAUTION: The fan (19) assembly weight: 68 18

kg (150 lb)

8. Attach a nylon sling onto fan (19). Hoist and hold W18C-02-09-001

fan (19). Remove socket bolts (20) (6 used) and

bolt (21). Remove the fan (19) assembly from fan
motor (14).
: 24 mm 19
: 10 mm

9. Remove coupling (22) from fan motor (14).

CAUTION: Fan motor (14) weight: 58 kg (130

A A
lb)

10. Attach a nylon sling onto the body of fan motor

(14). Hoist and hold fan motor (14).
14
11. Remove bolts (23) (4 used). Hoist and remove
fan motor (14) from bracket (10).
: 24 mm W18K-02-09-004

Section A 20

19

14

21

10 W18K-02-09-005
23 22

W18K-E-00(20181019) W2-9-2
 UPPERSTRUCTURE / Oil Cooler Fan Motor
Installation
Section A 20
CAUTION: Fan motor (14) weight: 58 kg (130 19
lb)
14
1. Install fan motor (14) to bracket (10) with bolts
(23) (4 used). 21
: 24 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

2. Install coupling (22) to fan motor (14).

CAUTION: The fan (19) assembly weight: 68 10 W18K-02-09-005

kg (150 lb) 23 22

IMPORTANT: Apply LOCTITE #24 3 onto VRFNHW

EROW( 20) .
19
3. Attach a nylon sling onto fan (19). Hoist the fan
(19) assembly. Install the fan (19) assembly to
fan motor (14) with socket bolts (20) (6 used) and
bolt (21).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft) A A
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

CAUTION: The bracket (10) assembly

14
weight: 191 kg (421 lb)

4. Install eyebolts (M10, Pitch 1.5 mm) and (M12,

Pitch 1.75 mm) to the bolt hole (2 places) for the W18K-02-09-004

piping clamp on bracket (10). Hoist the bracket

(10) assembly. Install the bracket (10) assembly
to the oil cooler with bolts (15) (6 used). Bolt Hole for
: 19 mm 15 Piping Clamp
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
Oil Cooler

5. Install plates (18) (4 used) and nets (17) (2 used)

to the oil cooler with bolts (16) (23 used). 10
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
14

16

17

18

W18C-02-09-001

W18K-E-00(20181019) W2-9-3
 UPPERSTRUCTURE / Oil Cooler Fan Motor
6. Connect piping (9) to piping (4) and secure with
socket bolts (6) (4 used). Oil Cooler 5 13
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
14
7. Secure piping (9) to piping (4) and bracket (10)
with clamps (8) (4 used) and bolts (7) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

8. Connect hose (5) and hoses (13) (2 used) to fan

motor (14).
: 27 mm
W18K-02-09-003
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft) 13
: 36 mm
: 240 N⋅m (24 kgf⋅m, 175 lbf⋅ft)
4 5 6 7, 8
9. Secure hose (5) to the oil cooler with clamp (12)
and bolt (11).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 9

CAUTION: Cover (1) weight: 27 kg (60 lb) 10

Cover (2) weight: 18 kg (40 lb)

10. Hoist covers (1) (3 used) and (2) (3 used). Install

covers (1) (3 used) and (2) (3 used) to the engine Oil Cooler
unit with bolts (3) (26 used). 11, 12 W18K-02-09-002

: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

11. Start the engine. Loosen the drain hose a little.

Bleed air until only hydraulic oil comes out.
Engine Unit Front Side

1 2

3 W18K-02-09-001

W18K-E-00(20181019) W2-9-4
 UPPERSTRUCTURE / Oil Cooler Fan Motor
(Blank)

W18K-E-00(20181019) W2-9-5
 UPPERSTRUCTURE / Oil Cooler Fan Motor
DISASSEMBLY OF OIL COOLER FAN
MOTOR

1
2

5
6

7
8
9
16
17

10

11
12
13
14
18
15 19
20
21
22

23
24

25
26

27
28
29
30
W18B-02-11-005
31

1- Housing 9- Socket Bolt (6 Used) 17 - Plunger (7 Used) 25 - Bearing

2- O-Ring 10 - Valve Plate 18 - Socket Bolt (7 Used) 26 - Bearing Nut
3- Cover 11 - Cylinder Block 19 - Plate 27 - Shim (Several)
4- Valve Block 12 - Shim 20 - Shim 28 - O-Ring
5- Plug 13 - Spring Seat 21 - Shaft 29 - Oil Seal
6- Knock Pin 14 - Disc Spring (4 Used) 22 - Key 30 - Seal Case
7- Washer (6 Used) 15 - Center Pin 23 - Bearing 31 - Retaining Ring
8- Socket Bolt (6 Used) 16 - Piston Ring (14 Used) 24 - Case

W18K-E-00(20181019) W2-9-6
 UPPERSTRUCTURE / Oil Cooler Fan Motor
Disassembly of Oil Cooler Fan Motor
IMPORTANT: Do not remove bearings (25, 23)
1. Remove plug (5). Drain hydraulic oil from the unless necessary. If removing
motor. bearings (25, 23), replace the motor
: 10 mm assembly with the new one.
6. Remove socket bolts (18) (7 used). Remove
2. Remove key (22) from shaft (21). Remove socket plate (19), center pin (15), plunger (17) and
bolts (9) (6 used). Remove valve block (4) from cylinder block (11) from shaft (21).
cover (3). : 6 mm
: 10 mm
IMPORTANT: Do not remove piston ring (16)
IMPORTANT: Do not drop valve plate (10) when unless necessary.
removing cover (3). Knock pin (6) is 7. Remove shim (12), spring seat (13) and disc
installed in cover (3). Do not remove spring (14) from cylinder block (11).
cover (3) unless necessary.
3. Remove socket bolts (8) (6 used) and washers
(7) (6 used). Remove cover (3), O-ring (2) and
valve plate (10) from housing (1).
: 14 mm

CAUTION: The shaft (21) assembly weight:

Approx. 25 kg (55 lb)

4. Remove retaining ring (31). Remove the shaft

(21) assembly from housing (1) by using a puller.

5. Remove seal case (30), oil seal (29), O-ring (28)

and shim (27) from the shaft (21) assembly.

W18K-E-00(20181019) W2-9-7
 UPPERSTRUCTURE / Oil Cooler Fan Motor
ASSEMBLY OF OIL COOLER FAN MOTOR

30 26 28 25 24 23 20 19 15 17

21 22
1

29 4

9
31 27 5

11

6
7, 8
10
W18B-02-11-004

1- Housing 9- Socket Bolt (6 Used) 17 - Plunger (7 Used) 25 - Bearing

2- O-Ring 10 - Valve Plate 18 - Socket Bolt (7 Used) 26 - Bearing Nut
3- Cover 11 - Cylinder Block 19 - Plate 27 - Shim (Several)
4- Valve Block 12 - Shim 20 - Shim 28 - O-Ring
5- Plug 13 - Spring Seat 21 - Shaft 29 - Oil Seal
6- Knock Pin 14 - Disc Spring (4 Used) 22 - Key 30 - Seal Case
7- Washer (6 Used) 15 - Center Pin 23 - Bearing 31 - Retaining Ring
8- Socket Bolt (6 Used) 16 - Piston Ring (14 Used) 24 - Case

W18K-E-00(20181019) W2-9-8
 UPPERSTRUCTURE / Oil Cooler Fan Motor
Assembly of Oil Cooler Fan Motor
NOTE: As for parts 12, 13, 14, 16 and 18, refer to 8. Install plug (5) to housing (1).
the illustration when disassembling on : 10 mm
W2-9-6. : 59 to 76 N⋅m
(6 to 7.8 kgf⋅m, 44 to 56 lbf⋅ft)
1. Install shim (12), spring seat (13) and disc
springs (14) (4 used) to cylinder block (11). Pass
and install center pin (15) and plungers (17) (7
used) to cylinder block (11) through plate (19).

2. Install shim (20) and plate (19) to shaft (21) with

socket bolts (18) (7 used).
: 6 mm

CAUTION: The shaft (21) assembly weight:

Approx. 25 kg (55 lb)

3. Install the shaft (21) assembly to housing (1).

4. Install O-ring (28) and oil seal (29) to seal case

(30).

5. Install shim (27) and seal case (30) to housing

(1) with retaining ring (31).

6. Install valve plate (10) and O-ring (2) to cover (3).

Install cover (3) to housing (1) with socket bolts
(8) (6 used).
: 14 mm
: 230 to 270 N⋅m
(23 to 28 kgf⋅m, 170 to 200 lbf⋅ft)

7. Install key (22) to shaft (21). Install valve block

(4) to cover (3) with socket bolts (9) (6 used).
: 10 mm
: 98 to 123 N⋅m
(10 to 12.5 kgf⋅m, 72 to 91 lbf⋅ft)

W18K-E-00(20181019) W2-9-9
 UPPERSTRUCTURE / Oil Cooler Fan Motor
MAINTENANCE STANDARD

1. Clearance between outer diameter (d) of center

pin (15) and bore (D) of cylinder block (11)
Clearance between outer diameter (d′) of piston
(17) and bore (D′) of cylinder block (11)
d D
D-d Unit: mm (in)
Standard Allowable Limit
0.004 to 0.022 0.05
(0.0002 to 0.001) (0.002)
W117-02-02-009

D′-d′ Unit: mm (in)

Standard Allowable Limit
0.005 to 0.029 0.05
(0.0002 to 0.001) (0.002)

W18K-E-00(20181019) W2-9-10
 UPPERSTRUCTURE / Compressor Drive Motor
REMOVAL AND INSTALLATION OF
COMPRESSOR DRIVE MOTOR
1 2 3

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal Adjusting Adjusting

Bolt Bolt
1. Remove bolts (4) (14 used). Remove guard cover
(5).
: 17 mm

2. Disconnect hoses (1) (3 used) from compressor

drive motor (2). W18C-02-11-002
: 27 mm, 36 mm
5 4
3. Loosen the adjusting bolts (3 used). Remove
V-belts (10) (6 used) from pulley (9).
: 13 mm 6 7 8 9 10

4. Remove center bolt (8), bolts (6) (3 used) and

plate (7). Remove pulley (9) from compressor
drive motor (2).
: 10 mm, 13 mm

5. Remove bolts (3) (4 used). Remove compressor

drive motor (2).
: 19 mm
W18C-02-11-001

W18K-E-00(20181019) W2-10-1
 UPPERSTRUCTURE / Compressor Drive Motor
Installation

IMPORTANT: Do not tap pulley (9) by using a

6 7 8 9
hammer when installing pulley (9) to
compressor drive motor (2).
Warm up the inner surface of pulley
(9) by using a heater before installing
pulley (9).
1. Install a key to the shaft of compressor drive motor
(2). Install pulley (9) to the shaft.

2. Install plate (7), center bolt (8) and bolts (6) (3

used) to pulley (9). W18C-02-11-001
: 10 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.4 to 3.0 lbf⋅ft)
: 13 mm
: 10 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)

W18K-E-00(20181019) W2-10-2
 UPPERSTRUCTURE / Compressor Drive Motor
3. Install the compressor drive motor (2) assembly
1 2 3
with bolts (3) (4 used).

4. Attach V-belts (10) (6 used) onto pulley (9). Adjust

tension of V-belt (10) with the adjusting bolt (3
places).
NOTE: V-belt (10) tension adjustment procedure Adjusting
Push the V-belt at center (A) by fingers with Bolt Adjusting
Bolt
98 N (10 kgf, 72 Ibf) and adjust sag
dimension B to 13 to 14 mm (0.51 to 0.55
in).

5. Connect hoses (1) (3 used) to compressor drive 10

motor (2).
: 27 mm W18C-02-11-002

: 95 N⋅m (9.5 kgf⋅m, 70 lbf⋅ft) 10 5 4

: 36 mm
: 180 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
A
6. Install guard cover (5) with bolts (4) (14 used).
: 17 mm B
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W18B-02-13-003

W18K-E-00(20181019) W2-10-3
 UPPERSTRUCTURE / Compressor Drive Motor
DISASSEMBLY OF COMPRESSOR DRIVE MOTOR
9
8
7
6

4
3

21
20
2
1 12 19

18
11
10 17

16
22
15
14
13

23
24 31
30
29
28

27

26

25 W118-02-10-001

1- Plug (2 Used) 9- Spring Guide 17 - Plunger (9 Used) 25 - O-Ring

2- O-Ring (2 Used) 10 - Socket Bolt (4 Used) 18 - Swash Plate 26 - Pin (2 Used)
3- Cover 11 - Washer (4 Used) 19 - Shaft 27 - Housing
4- Needle Bearing 12 - Pin (2 Used) 20 - Key 28 - Spacer
5- Valve Plate 13 - Rotor 21 - Bearing 29 - Retaining Ring
6- Retaining Ring 14 - Pin (3 Used) 22 - Pin 30 - Oil Seal
7- Spring Guide 15 - Spherical Bushing 23 - Plug 31 - Retaining Ring
8- Spring 16 - Retainer 24 - O-Ring

W18K-E-00(20181019) W2-10-4
 UPPERSTRUCTURE / Compressor Drive Motor
Disassembly

1. Remove plug (23) from housing (27). Drain oil 8. Remove retaining ring (29) and spacer (28) from
from housing (27). shaft (19). Remove bearing (21) from shaft (19).

IMPORTANT: When removing cover (3), valve
plate (5) is removed with cover (3)
together. Do not drop valve plate (5).
2. Remove socket bolts (10) (4 used) and washers
(11) (4 used). Remove cover (3) from housing
(27).
: 10 mm
9. Remove bearing (21) from shaft (19) by using a
bar and a hammer.
IMPORTANT: In case oil seal (30) is removed,
replace oil seal (30) with a new one.
10. Remove retaining ring (31) from housing (27).
Remove oil seal (30).

3. Remove valve plate (5), needle bearing (4) and

pins (12) (2 used) from cover (3).

IMPORTANT: The end of shaft (19) is the inner

race of needle bearing (4). Wind a
vinyl tape in order to protect.
4. Remove O-ring (25), rotor (13), spherical bushing
(15), retainer (16) and plungers (17) (9 used) from
housing (27).

IMPORTANT: Do not remove spring (8) unless

necessary.
5. Remove pins (14) (3 used) from rotor (13).

6. Remove key (20) from shaft (19).

7. Remove shaft (19) from the key (20) mounting

side by tapping by using a plastic hammer. At this
time, swash plate (18), pin (22) and bearing (21)
are removed with shaft (19) together from housing
(27).

W18K-E-00(20181019) W2-10-5
 UPPERSTRUCTURE / Compressor Drive Motor
ASSEMBLY OF COMPRESSOR DRIVE MOTOR

10 1 23 24 15 17 16 18

28
29
20

1 2 4 3 12 26 25 5 6 7 19 13 8 9 14 27 21 22 30 31

W118-02-10-002

1- Plug (2 Used) 9- Spring Guide 17 - Plunger (9 Used) 25 - O-Ring

2- O-Ring (2 Used) 10 - Socket Bolt (4 Used) 18 - Swash Plate 26 - Pin (2 Used)
3- Cover 11 - Washer (4 Used) 19 - Shaft 27 - Housing
4- Needle Bearing 12 - Pin (2 Used) 20 - Key 28 - Spacer
5- Valve Plate 13 - Rotor 21 - Bearing 29 - Retaining Ring
6- Retaining Ring 14 - Pin (3 Used) 22 - Pin 30 - Oil Seal
7- Spring Guide 15 - Spherical Bushing 23 - Plug 31 - Retaining Ring
8- Spring 16 - Retainer 24 - O-Ring

W18K-E-00(20181019) W2-10-6
 UPPERSTRUCTURE / Compressor Drive Motor
Assembly
IMPORTANT: Install oil seal (30) with the seal lip
facing to the inside of housing (27).
1. Apply grease onto oil seal (30). Install oil seal (30)
to housing (27).
2. Install retaining ring (31) to housing (27).
IMPORTANT: The key groove on shaft (19) and the
outer surface on the opposite side of
shaft (19) are the inner race of
needle bearing (4). Do not damage
them.
3. Install bearing (21) to shaft (19).
4. Install spacer (28) and retaining ring (29) to shaft
(19).
5. Place housing (27) with the cover (3) side facing
upward.
6. Install pin (22) to housing (27).
7. Install the shaft (19) assembly to housing (27).
8. Place housing (27) horizontally.
9. Install swash plate (18) to housing (27) by using a
bar and a hammer.
IMPORTANT: Install swash plate (18) until its
bottom surface comes in contact
with housing (27) completely. Check
that shaft (19) is 18.5 mm (0.73 in)
out from the upper surface of
housing (27).
10. Install spring guide (9), spring (8), spring guide (7)
and retaining ring (6) to rotor (13).
NOTE: As the force of spring (8) is too strong to
install retaining ring (6), install retaining ring
(6) by using a press.
W18K-E-00(20181019)
11. Install plungers (17) (9 used) to retainer (16).
12. Apply grease onto pins (14) (3 used). Install pins
(14) (3 used) to rotor (13).
13. Install spherical bushing (15) and plungers (17) (9
used) to rotor (13).
14. Install the rotor (13) assembly to shaft (19) by
turning shaft (19).
15. Place the housing (27) assembly with the cover
(3) mounting surface facing upward.
16. Apply grease into the needle part of needle
bearing (4) with cover (3) attached. Push the
needle to the outer surface direction.
17. Install pins (12) (2 used) to cover (3).
IMPORTANT: Apply grease onto the cover (3) side
of valve plate (5) in order not to drop
valve plate (5).
18. Install valve plate (5) to cover (3).
19. Install O-ring (25) and pins (26) (2 used) to
housing (27).
20. Install cover (3) to housing (27) with socket bolts
(10) (4 used) and washers (11) (4 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 67 lbf⋅ft)
21. Install key (20) to shaft (19).
W2-10-7
 UPPERSTRUCTURE / Compressor Drive Motor
(Blank)

W18K-E-00(20181019) W2-10-8
 UPPERSTRUCTURE / Air Conditioner
WORK AFTER REPLACING COMPONENT

The following work is required after replacing

compressor, high pressure hose, low pressure hose,
condenser, receiver tank, liquid hose, and air
conditioner unit.
The same work is required when gas leakage is
found.

1. Add compressor oil

2. Charge air conditioner with refrigerant

・ Purging
・ Charge air conditioner with refrigerant
・ Warm up operation
・ Inspection

ADD COMPRESSOR OIL

Compressor oil quantity to be added after component

replacement:
・ 220 cm3 (0.23 US qt) :
After replacement of the compressor, high
pressure hose, condenser, receiver tank, liquid
hose, or air conditioner unit.
・ 100 cm3 (0.11 US qt) :
After replacement of the low pressure hose.

W18K-E-00(20181019) W2-11-1
 UPPERSTRUCTURE / Air Conditioner
CHARGE AIR CONDITIONER WITH
REFRIGERANT

Necessity of Purging
Be sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit.

1. Pressure rise in the high pressure side

Air
If air remains in the air conditioner circuit, this
disturbs the heat exchange between refrigerant
and air in the condenser, causing pressure to rise
in the high pressure side (compressor side).
Usually, refrigerant gas is easily liquefied;
however, air cannot be liquefied and remains as
a gas in the condenser because the temperature
at which air liquefies is low. That is, liquidation of
the refrigerant gas in the condenser decreases
by the amount of air in the circuit, and the gas Pressure increases if air
W115-02-10-001
pressure in the high pressure side increases remains in the air
conditioner circuit
accordingly.

2. Metal corrosion

If air remains in the air conditioner circuit, a

chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.

Hydrochloric acid Hydrochloric acid W115-02-10-002

corrodes metals if
moisture exists

Metal corrosion

3. Plugging of the expansion valve by moisture

When high pressure refrigerant gas passes

through the expansion valve, gas pressure
decreases and temperature drops. Moisture
included in high pressure refrigerant gas in the
air conditioner circuit freezes at the expansion
valve orifice, plugging refrigerant flow. Operation Plugged refrigerant
of the air conditioner becomes unstable and flow
Ice produced at the
cooling efficiency lowers. expansion valve disturbs
W115-02-10-003
refrigerant flow, lowering
cooling efficiency
Low cooling
efficiency

W18K-E-00(20181019) W2-11-2
 UPPERSTRUCTURE / Air Conditioner
Purging Procedure Gauge Manifold

IMPORTANT: Never mistake the charge hose Low Pressure

connections. Valve
1. Close the high and low pressure valves on the Low Pressure
Charge Hose High Pressure
gauge manifold (Parts Number 4360564).
Valve
Connect the high-pressure-side charge hose and
the low-pressure-side charge hoses to the High Pressure
high-pressure-side charge valve (“D” marked) Charge Hose
and to the low-pressure-side charge valve (“S” Center Pressure
marked) located on the compressor, respectively. Charge Hose
Vacuum Pump
Connect the charge hose located on the center of
the manifold bottom to the vacuum pump (Parts
Number 4360565).
NOTE: Vacuum Pump Joint Adapter (Parts
Number 4360566).

W115-02-10-005

Low Pressure
Side S
Compressor
D
High Pressure
Side
T142-02-05-018

Fully Open
2. Open the high pressure and low pressure valves
in the gauge manifold. Perform purging for 10
minutes or more by operating the vacuum pump. Fully Open

In Operation

W115-02-10-005

W18K-E-00(20181019) W2-11-3
 UPPERSTRUCTURE / Air Conditioner
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again. Close
3. When the low pressure gauge reading falls
below-755 mmHg, stop the vacuum pump and Close
close the high and low pressure valves. Wait for
approximately five minutes and confirm that the
pointer does not return to 0.

In Operation

W115-02-10-005

4. With the high pressure and low pressure valves

of the gauge manifold closed, connect the charge
hose to the refrigerant container (Parts Number
4347644).

Refrigerant Container

W115-02-10-007

5. Loosen the charge hose connection to the gauge

manifold and open the refrigerant container valve
to purge air in the charge hose with the
refrigerant pressure. Loosen

Open

W115-02-10-007

W18K-E-00(20181019) W2-11-4
 UPPERSTRUCTURE / Air Conditioner
IMPORTANT: Always stop the engine when
High
charging the air conditioner with Pressure
refrigerant. Never position the Gauge
refrigerant container upside down Tighten
during charging operation. When
changing the refrigerant container
during charging operation, be sure Open
to purge air from the charge hose,
as shown in step 10.
6. Fully tighten the charge hose connection to the
gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with Open
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
2
reading reaches 98 kPa (1 kgf/cm , 14 psi).
NOTE: Use warm water of 40 °C (104 °F) or less
to warm the refrigerant container to aid in
charging operation.
W115-02-10-007

IMPORTANT: Use the leak tester for R134a.

7. After charging, check the line connections for gas
leaks using leak tester (Parts Number 4360567). W115-02-10-008

W18K-E-00(20181019) W2-11-5
 UPPERSTRUCTURE / Air Conditioner
8. Confirm that the high pressure and low pressure
valves in the gauge manifold and the refrigerant
container valve are closed.
Start the engine and operate the air conditioner.

Operating Conditions of the Air Conditioner:

Engine Speed : Slow Idle
Cab Window : Fully Open
Air Conditioner Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum

IMPORTANT: Never open the high pressure valve

in the gauge manifold.
9. Open the low pressure valve in the gauge Open
manifold and the refrigerant container valve to
charge with refrigerant until the bubbles seen in
the receiver tank sight glass disappear.
NOTE: The required refrigerant quantity is 1400
g±50 g (3±0.01 lb).

Open

W115-02-10-007

10. If the refrigerant container becomes empty during

the charging work, replace it with a new Close
refrigerant container as follows:
(1) Close the high pressure and low pressure
valves on the manifold gauge.
(2) Replace the empty container with a new
one.
(3) Tighten, then slightly loosen the refrigerant
container joint.
(4) Slightly open the low pressure valve on the
manifold gauge. Close
(5) When the refrigerant container joint starts to
leak, immediately tighten the refrigerant
container joint and close the low pressure
valve on the manifold gauge.

11. After charging, close the low pressure valve in

the gauge manifold and the refrigerant container
valve, and stop the engine.
W115-02-10-007

W18K-E-00(20181019) W2-11-6
 UPPERSTRUCTURE / Air Conditioner
IMPORTANT: If the air conditioner is operated
with very low refrigerant, the
compressor may be damaged. If the
air conditioner is overcharged with
refrigerant, cooling efficiency will
lower and abnormal high pressure
will arise in the air conditioner Sight Glass
circuit.
12. Start the engine and operate the air conditioner
again.
Observe the sight glass of the receiver tank to
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Receiver Tank
Cab Window : Fully Open
Air Conditioner Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
NOTE: As the bubbles in the sight glass vary
W115-02-10-009
depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .

Checking procedures: Stop the air conditioner and

wait until refrigerant returns to the balanced pressure.
Then, start the air conditioner again.
Relation between Refrigerant Quantity and
Refrigerant Flow in Sight Glass:
Refrigerant Flow in Sight Glass
Refrigerant
(approx. 1 min. after air conditioner Explanation for Refrigerant Flow in Sight Glass
Quantity
switch is turned ON)
(immediately after) (approx. 1 mm after) Immediately after the air conditioner is turned ON,
Adequate few bubbles are seen. Then the flow becomes trans-
parent and shows thin milk white color.
W115-02-10-016

No bubbles are seen after the air conditioner is

Overcharged turned ON.
W115-02-10-017

Bubbles are seen continuously after the air condi-

Not Enough tioner is turned ON.
W115-02-10-018

CAUTION: Wait until the high-pressure-side

W115-02-10-019
pressure drops to less than 980 kPa (10
Bubbles exist: Bubbles are seen in refrigerant flow
kgf/cm2, 142 psi) before attempting to dis-
as both liquid refrigerant and refrigerant gas exist,
connect the high-pressure-side charge hose.
being mixed.
Otherwise refrigerant and compressor oil
may gush out.
W115-02-10-020

Transparent: Refrigerant flow is transparent as only

liquid refrigerant exists. 13. After checking refrigerant quantity, disconnect the
low-pressure-side charge hose first. Wait for the
high-pressure-side pressure to drop to less than
980 kPa (10 kgf/cm2, 142 psi). Disconnect the
115-02-10-021
high-pressure-side charge hose.
Milk white: Refrigerant flow shows thin milk white
as oil and refrigerant are separated.

W18K-E-00(20181019) W2-11-7
 UPPERSTRUCTURE / Air Conditioner
Warm-Up Operation
After charging the air conditioner, carry out warm-up
operation for five minutes to lubricate system with
compressor oil.

Operating Conditions of the Air Conditioner

Engine Speed : Slow Idle
Cab Window : Fully Open
Air Conditioner Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum

Inspection
After warm-up operation, carry out gas leak check
and performance check.

CAUTION: Refrigerant will produce Leak Tester

poisonous material if exposed to heat of
1000 °C (1800 °F) or more. Never bring
refrigerant close to a fire.

1. Check the air conditioner for gas leaks using a

leak tester.
(1) Perform checking under well-ventilated
conditions.
(2) Thoroughly wipe off dust from the charge
hose connections of the compressor.
(3) Pay special attention to check the line
W115-02-10-013
connections.
(4) If any gas leaks are found, retighten the line
connections.

2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner
component.
Retighten Line
(1) Check each component for abnormalities. Connection
(2) Carry out ON-OFF check of the compressor
clutch.
(3) Check compressor fan belt tension.
(4) Check the coolant level in the radiator.
(5) Operate the air conditioner and check the
performance. W115-02-10-014

W18K-E-00(20181019) W2-11-8
 UPPERSTRUCTURE / Air Conditioner
3. The checklist before the summer season is as
follows:
(1) Check each air conditioner component for
abnormalities.
(2) Check the line connections for oil leaks.
(3) Check refrigerant quantity.
(4) Check the engine cooling circuit.
(5) Check the V-belt for wear. Replace if
necessary.

4. Off-Season Maintenance
(1) During off-season, operate the idler pulley
and compressor at least once a month for a
short time to check for any abnormal
sounds.
(2) Do not remove the compressor belts during
off-season. Operate the compressor
occasionally at slow speed for 5 to 10
minutes with the belt slightly loosened in
order to lubricate the machine parts.

W18K-E-00(20181019) W2-11-9
 UPPERSTRUCTURE / Air Conditioner
(Blank)

W18K-E-00(20181019) W2-11-10
 UPPERSTRUCTURE / Grease Pump
GREASE PUMP CONSTRUCTION

• As for check grease level and supply method,

refer to “Operator’s Manual (Auto-Lubrication
System)”.

W18K-E-00(20181019) W2-12-1
 UPPERSTRUCTURE / Grease Pump
Grease Pump Construction

1
2
3
4
29 5
6
30 7
32 8
34 33 6
31 4 9
3
58 2 10
35 1 11
36 60
37 12
39
59
13
38 14
45
61 46 15
40 16
47
41 48 49
42
17
43
51 50
44 52
53
54 18

19
20

55

21

56
57 22
23
24
25
26
27
28

W18C-02-14-001

W18K-E-00(20181019) W2-12-2
 UPPERSTRUCTURE / Grease Pump

1- Screw 17 - Rod 33 - Screw 48 - O-Ring

2- Weight 18 - Spring 34 - Cartridge 49 - O-Ring
3- Weight 19 - Ball 35 - Coil 50 - Nut
4- Retaining Ring 20 - Plunger 36 - Connector 51 - Bearing
5- Rod 21 - Tube 37 - Manifold 52 - O-Ring
6- Retaining Ring 22 - Seal 38 - Reducing Valve 53 - Washer
7- Rod 23 - O-Ring 39 - Flow Control Valve 54 - O-Ring
8- Ball Bearing 24 - Cylinder 40 - O-Ring 55 - Tube
9- Pin 25 - Cage 41 - Gasket 56 - Plug
10 - O-Ring 26 - Ball 42 - Oil Motor 57 - Retaining Ring
11 - Tube 27 - O-Ring 43 - Washer 58 - Seal Kit
12 - Screw 28 - Check Seat 44 - Screw 59 - Seal Kit
13 - Bushing 29 - Screw 45 - Plug 60 - Seal Kit
14 - Anchor 30 - Cover 46 - Housing 61 - Fitting
15 - Washer 31 - Gasket 47 - Ring
16 - Seal 32 - Gauge

W18K-E-00(20181019) W2-12-3
 UPPERSTRUCTURE / Grease Pump
(Blank)

W18K-E-00(20181019) W2-12-4
 MEMO

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W18K-E-00(20181019)
 MEMO

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W18K-E-00(20181019)

UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
Removal and Installation of
Swing Bearing ....................................... W3-1-1
Group 2 Travel Device
Removal and Installation of
Travel Device......................................... W3-2-1
Disassembly of Travel Device................ W3-2-10
Assembly of Travel Device .................... W3-2-24
Disassembly of Travel Motor ................. W3-2-36
Assembly of Travel Motor ...................... W3-2-42
Maintenance Standard........................... W3-2-48
Disassembly and Assembly of
Travel Mode Selection Valve................ W3-2-50
Group 3 Travel Brake Valve
Removal and Installation of
Travel Brake Valve................................. W3-3-1
Disassembly of Travel Brake Valve.......... W3-3-6
Assembly of Travel Brake Valve .............. W3-3-8
Group 4 Center Joint
Removal and Installation of Center Joint . W3-4-1
Disassembly of Center Joint .................... W3-4-8
Assembly of Center Joint....................... W3-4-10
Group 5 Adjuster Cylinder
Removal and Installation of
Adjuster Cylinder ................................... W3-5-1
Disassembly of Adjuster Cylinder ............ W3-5-8
Assembly of Adjuster Cylinder ............... W3-5-10
W18K-E-00(20181019) 18KW-3-1
SECTION 3
Group 6 Front Idler
Removal and Installation of Front Idler .... W3-6-1
Disassembly of Front Idler ....................... W3-6-6
Assembly Front Idler ................................ W3-6-8
Maintenance Standard ........................... W3-6-10
Group 7 Upper and Lower Rollers
Removal and Installation of
Upper/ Lower Rollers ............................. W3-7-1
Disassembly of Upper Roller ................... W3-7-8
Assembly of Upper Roller ...................... W3-7-10
Disassembly of Lower Roller ................. W3-7-12
Assembly of Lower Roller ...................... W3-7-14
Maintenance Standard ........................... W3-7-16
Group 8 Track
Removal and Installation of Track ............ W3-8-1
Structure of Track..................................... W3-8-5
Maintenance Standard ............................. W3-8-6
Group 9 Accumulator
Removal and Installation of
Accumulator ........................................... W3-9-1
Disassembly of Accumulator .................... W3-9-4
Assembly of Accumulator......................... W3-9-6
Group 10 Welding Repair Procedure
Welding Repair Procedure ..................... W3-10-1
Welding Rod Specification ..................... W3-10-2
Repair Track Shoe (Shoe Lug)............... W3-10-3
Repair Front Idler................................... W3-10-6
Repair Sprocket ..................................... W3-10-8
(Blank)

W18K-E-00(20181019) 18KW-3-2
 UNDERCARRIAGE / Swing Bearing
REMOVAL AND INSTALLATION OF SWING
BEARING
5
Removal

1. Remove the front attachment, the counterweight

and the main frame. (Refer to REMOVAL AND
INSTALLATION OF FRONT ATTACHMENT on
W4-1-1, REMOVAL AND INSTALLATION OF 3
COUNTERWEIGHT on W2-2-1 and REMOVAL 1, 2, 3, 4 W18K-03-01-001

AND INSTALLATION OF FRAME on W2-3-1.)

2. Remove sems bolts (2) (8 used) from clamps (1) 8

(8 used). Remove clamps (1) (8 used), rubbers Track Frame
(3) (16 used) and spacers (4) (8 used) from lu-
brication pipings (5) (6 used). Remove lubrication 6, 7
pipings (5) (6 used) from swing bearing (8).
: 17 mm

CAUTION: Be careful to avoid getting yore

hand caught by reaction force bar on the hy-
draulic wrench.

3. Remove bolts (6) (60 used) and washers (7) (60 W18B-03-01-005

used) from swing bearing (8) by using a hydraulic Sling Belt

wrench.
: 75 mm

4. Put the matching marks between the inner race

and the outer race on swing bearing (8) and be-
tween the outer race and the track frame.

5. Pass the eye of the sling belt through the outer

bolt holes on the outer race of swing bearing (8).
Pass a steel rib through the eye. Steel Rib W18B-03-01-002

CAUTION: Swing bearing (8) weight: 4190 kg

(9240 lb)

6. Hoist and remove swing bearing (8) from the

track frame.

W141-03-01-001

W18K-E-00(20181019) W3-1-1
 UNDERCARRIAGE / Swing Bearing
Installation

CAUTION: Swing bearing (2) weight: 4190 kg

(9240 lb)

IMPORTANT: Install swing bearing (8) with mark

(S) on the inner ring facing to the 8
right side of the machine.
1. Hoist swing bearing (8). Align the inner race with
knock pin (9) (2 places) while aligning the match-
ing marks before removal. Place swing bearing
(8) onto the track frame.
NOTE: As for details about hoisting swing bearing
(8), refer to Removal.

W141-03-01-001

8 9

CAUTION: Be careful to avoid getting your

hand caught by reaction force bar on the hy-
draulic wrench.

2. Apply lubricant onto the thread part of bolts (6) W141-03-01-002

(60 used). Install swing bearing (8) to the track 8

frame with bolts (6) (60 used) and washers (7) Track Frame
(60 used) by using a hydraulic wrench.
: 70 mm 6, 7
: 4700 N⋅m (480 kgf⋅m, 3470 Ibf⋅ft)

3. Install Iubrication pipings (5) (6 used) to swing

bearing (8). Secure lubrication pipings (5) (6
used) with sems bolts (2) (8 used), clamps (1) (8
used), rubbers (3) (16 used) and spacers (4) (8
used).
: 17 mm W18B-03-01-005

: 20 N⋅m (2 kgf⋅m, 15 Ibf⋅ft)

4. Install the main frame, the counterweight and the 5

front attachment. (Refer to REMOVAL AND IN-
STALLATION OF FRONT ATTACHMENT on
W4-1-1, REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1 and REMOVAL
AND INSTALLATION OF FRAME on W2-3-1.)

1, 2, 3, 4 W18K-03-01-001

W18K-E-00(20181019) W3-1-2
 UNDERCARRIAGE / Travel Device
REMOVAL AND INSTALLATION OF
TRAVEL DEVICE

Remove the track shoe on the sprocket side before

removing and installing the reduction gear at the
sprocket side. (Refer to REMOVAL AND
INSTALLATION OF TRACK on W3-8-1.)

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal

1. Remove sems bolts (6) (8 used) from step (1). 1 2 3 4 5

Remove step (1) from cover (2).
: 19 mm

6 W18K-03-03-002

7 2, 5
2. Remove bolts (9) (6 used) and washers (10) (6
used) from clamps (7) (4 used). Remove clamps 8
(7) (4 used) and disconnect hoses (8) (4 used)
from covers (2, 5).
: 17 mm

9, 10 W18K-03-02-002

W18K-E-00(20181019) W3-2-1
 UNDERCARRIAGE / Travel Device

2 3 4 5 11, 12, 13, 14

CAUTION: Cover (2) weight: 78 kg (175 lb)
Cover (3) weight: 31 kg (70 lb)
Cover (4) weight: 31 kg (70 lb)
Cover (5) weight: 71 kg (160 lb)

3. Attach a nylon sling onto covers (2, 3, 4 and 5).

Hoist and hold covers (2, 3, 4 and 5) by using a
forklift.
16 15 W18K-03-03-002
4. Remove sems bolts (15) (26 used) from covers
(2, 3, 4 and 5). Remove covers (2, 3, 4 and 5)
from track frame (16) and support (17).
: 19 mm
15 5

CAUTION: Support (17) weight: 78 kg (175

lb)

5. Attach a nylon sling onto support (17). Hoist and

hold support (17) by using a forklift.
15 4 W18K-03-03-003

6. Remove bolts (11) (4 used), spring washers (12)

(4 used) and washers (13) (4 used) from support
(17). Remove support (17) from brackets (14) (2
used). 8
: 24 mm

7. Disconnect hoses (8) (2 used) from travel motor

(18). Cap the open ends.
: 17 mm, 36 mm

17

18

W18K-03-02-001

W18K-E-00(20181019) W3-2-2
 UNDERCARRIAGE / Travel Device
8. Remove socket bolts (19) (8 used) and split 19 20
flanges (21) (4 used) from hoses (20) (2 used).
Disconnect hoses (20) (2 used) from travel motor
(18). Cap the open ends.
: 14 mm

21

9. Remove drain plugs (22, 25) and level plug (24)

on the travel motor (18) side and the sprocket
side from cover (23) and the travel reduction gear.
Drain gear oil from cover (23). 18
: 14 mm, 17 mm, 22 mm
NOTE: Gear oil amount: 90 L (23.8 US gal.) W18K-03-02-001

18

23

22

Travel Motor Side W18K-03-02-003

24

25

Sprocket Side W144-03-01-005

CAUTION: Travel motor (18) weight: 260 kg

(580 lb)

10. Attach a nylon sling onto the body of travel motor

(18). Hoist and hold travel motor (18). Remove
bolts (26) (4 used) and washers (27) (4 used)
from travel motor (18). Remove travel motor (18) 26, 27
from cover (23).
: 30 mm

18

23 W18K-03-02-001

W18K-E-00(20181019) W3-2-3
 UNDERCARRIAGE / Travel Device
11. Install an eyebolt (M20, Pitch 2.5 mm) to the bolt Eyebolt Mounting Position
(26) hole. Install an eyebolt (M22, Pitch 2.5 mm)
to the pulling-out hole on cover (23).
NOTE: Refer to the illustration in the right as for 26
the eyebolt mounting position.
18

CAUTION: Travel reduction gear at travel 23

motor (18) side weight: 310 kg (690 lb)
28, 29

12. Hoist and hold the travel reduction gear at the

travel motor (18) side. 30, 31

13. Remove bolts (28) (16 used) and washers (29)

(16 used). Hoist and remove the travel reduction
gear at travel motor (18) side from the travel
reduction gear at the sprocket side.
: 32 mm W18K-03-02-003

CAUTION: Travel reduction gear at sprocket

side weight: 2800 kg (6180 lb)
Side Frame

14. Hold the travel reduction gear at the sprocket

side by using a fork lift.

15. Remove bolts (30) (32 used) and spring washers

(31) (32 used). Remove the travel reduction gear
at the sprocket side from the side frame.
: 50 mm
28, 29
30, 31

W18C-03-02-002

W18K-E-00(20181019) W3-2-4
 UNDERCARRIAGE / Travel Device
Installation Eyebolt Mounting Position

CAUTION: Travel reduction gear at sprocket

side weight: 2800 kg (6180 lb) 26, 27

18
1. Hold the travel reduction gear at the sprocket
side by using a fork lift. Install the travel reduction 23
gear at the sprocket side to the side frame with
28, 29
bolts (30) (32 used) and spring washers (31) (32
used).
: 50 mm 30, 31
: 2600 N⋅m ( 260 kgf⋅m, 1920 lbf⋅ft)

2. Install an eyebolt (M20, Pitch 2.5 mm) to the bolt

(26) hole. Install an eyebolt (M22, Pitch 2.5 mm)
to the pulling-out hole on cover (23).
NOTE: Refer to the illustration in the right as for W18K-03-02-003

the eyebolt mounting position.

CAUTION: Travel reduction gear at travel

Side Frame
motor (18) side weight: 310 kg (690 lb)

3. Hoist and install the travel reduction gear at the

travel motor (18) side to the travel reduction gear
at the sprocket side with bolts (28) (16 used) and
washers (29) (16 used).
: 32 mm
: 750 N⋅m (75 kgf⋅m, 5 50 lbf⋅ft)
28, 29
CAUTION: Travel motor (18) weight: 260 kg
30, 31
(580 lb)

4. Attach a nylon sling onto the body of travel motor

(18). Hoist and hold travel motor (18). W18C-03-02-002

5. Install travel motor (18) to cover (23) with bolts

(26) (4 used) and washers (27) (4 used).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 295 lbf⋅ft)

W18K-E-00(20181019) W3-2-5
 UNDERCARRIAGE / Travel Device
6. Wind the seal tape onto drain plugs (22, 25).
Install drain plugs (22, 25) to cover (23) and the
travel reduction gear.
: 14 mm
18
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
: 17 mm
23
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)

22

Travel Motor Side W18K-03-02-003

25

Sprocket Side W144-03-01-005

7. Connect hoses (20) (2 used) to travel motor (18) 8 19 20

with socket bolts (19) (8 used) and split flanges
(21) (4 used).
: 14 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

8. Connect hoses (8) (2 used) to travel motor (18).

: 17 mm 21
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 36 mm
: 175 N⋅m (17.5 kgf⋅m, 129 lbf⋅ft)

18

W18K-03-02-001

W18K-E-00(20181019) W3-2-6
 UNDERCARRIAGE / Travel Device
9. Wind the seal tape onto level plug (24) and filler
plug (32). Add gear oil through level plug (24)
and filler plug (32). After adding, install level plug
(24) and filler plug (32) to cover (23) and the
travel reduction gear.
: 14 mm 23
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
: 22 mm
: 195 N⋅m (20 kgf⋅m, 144 lbf⋅ft)
NOTE: Gear oil amount: 90 L (23.8 US gal.)
32
IMPORTANT: After installing the travel motor, fill
hydraulic oil in the travel motor.
Perform break-in operation after
installing the travel motor or the
travel device in order to prevent the Travel Motor Side W18K-03-02-003

travel motor from seizuring.

Condition: 1. Fuel control lever:
Slow idle
2. Travel mode: Slow
3. Operation duration: 24
More than 2 min.

CAUTION: Support (17) weight: 78 kg (175

lb)

10. Attach a nylon sling onto support (17). Hoist and

Sprocket Side W144-03-01-005
align support (17) with the mounting hole on
brackets (14) (2 used).
Install support (17) to bracket (14) with bolts (11)
(4 used), spring washers (12) (4 used) and
washers (13) (4 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

17

W18K-03-02-001

11, 12, 13, 14

W18K-03-03-002

W18K-E-00(20181019) W3-2-7
 UNDERCARRIAGE / Travel Device
2 3 4 5
CAUTION: Cover (2) weight: 78 kg (175 lb)
Cover (3) weight: 31 kg (70 lb)
Cover (4) weight: 31 kg (70 lb)
Cover (5) weight: 71 kg (160 lb)

11. Attach a nylon sling onto covers (2, 3, 4 and 5).

Hoist covers (2, 3, 4 and 5) by using a forklift.
Align covers (2, 3, 4 and 5) with the mounting
hole on track frame (16) and support (17). 16 15 W18K-03-03-002

12. Install covers (2, 3, 4 and 5) to track frame (16)

and support (17) with sems bolts (15) (26 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 15 5

15 4 W18K-03-03-003

17

W18K-03-02-001

13. Secure hoses (8) (2 used) to covers (2, 5) with 7 2, 5

bolts (9) (6 used), washers (10) (6 used) and
clamps (7) (4 used). 8
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

9, 10 W18K-03-02-002

W18K-E-00(20181019) W3-2-8
 UNDERCARRIAGE / Travel Device
14. Install step (1) to cover (2) with sems bolts (6) (8 1 2
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

6 W18K-03-03-002

W18K-E-00(20181019) W3-2-9
 UNDERCARRIAGE / Travel Device
DISASSEMBLY OF TRAVEL DEVICE

14
13
12
11
10
9
7
8
6
5
4
3 15
2 16
17
1

34
33

19 32
22 20
23 21
24
23
25
27
28
29

35
36
37
38
30 39 40 36
41 35
42
43 57
31
26
58
44
45 56
46 55
54
53
47
52

48
51
60
49 63 61
50 62
59

64
68 65
66
67
65 W18C-03-02-004
64

W18K-E-00(20181019) W3-2-10
 UNDERCARRIAGE / Travel Device

1 - Retaining Ring 19 - Lock Plate 36 - Spacer (8 Used) 53 - Retaining Ring

2 - Bolt (10 Used) 20 - Lock Washer 37 - Retaining Ring (4 Used) 54 - First Stage Sun Gear
3 - Spring Washer (10 Used) 21 - Bolt (2 Used) 38 - Second Stage Planetary 55 - Retaining Ring
Gear (4 Used)
4- Roller Bearing 22 - Knock Pin (2 Used) 39 - Pin (4 Used) 56 - Stopper Pin
5- Gear 23 - Ball Bearing (2 Used) 40 - Lock Plate (4 Used) 57 - Cork (2 Used)
6- Roller Bearing 24 - Gear 41 - Lock Washer (4 Used) 58 - Ball Bearing
7- Housing 25 - Cork (2 Used) 42 - Bolt (8 Used) 59 - Retaining Ring
8- O-Ring 26 - Roller Bearing 43 - Ring Gear 60 - Bolt (20 Used)
9- Bearing Nut 27 - Cover 44 - Roller Bearing 61 - Spring Washer (20 Used)
10 - Spindle 28 - Spring Washer (16 Used) 45 - Bolt (30 Used) 62 - Cover
11 - Support 29 - Bolt (16 Used) 46 - Washer (30 Used) 63 - Pin (3 Used)
12 - Cork (2 Used) 30 - Cork (3 Used) 47 - Sprocket 64 - Roller Bearing (6 Used)
13 - Floating Seal 31 - Cork (2 Used) 48 - Drum 65 - Spacer (6 Used)
14 - Cork (2 Used) 32 - Second Stage Carrier 49 - Washer (28 Used) 66 - Retaining Ring (3 Used)
15 - Support 33 - Spacer 50 - Bolt (28 Used) 67 - First Stage Planetary Gear
(3 Used)
16 - Socket Bolt (12 Used) 34 - Second Stage Sun Gear 51 - Shaft 68 - Retaining Ring (3 Used)
17 - Socket Bolt (12 Used) 35 - Spherical Bearing (8 Used) 52 - First Stage Carrier

W18K-E-00(20181019) W3-2-11
 UNDERCARRIAGE / Travel Device

10

19
20
21

30

43 57

47

48
51
60
61
62

W18C-03-02-004

W18K-E-00(20181019) W3-2-12
 UNDERCARRIAGE / Travel Device
Disassembly of Travel Device IMPORTANT: Loosen bearing nut (9) without
removing.
Travel Reduction Gear at Sprocket Side 5. Loosen bearing nut (9) by using the special tool
(ST 3931).
IMPORTANT: Before disassembling, put the Details of ST 3931: ST 3147, ST 3148, ST 3149
matching marks onto the mating
part of sprocket (47), drum (48), ring
ST3148
gear (43) and cover (62).

1. Remove corks (30) (3 used) from drum (48). ST3147

2. Install an eyebolt (M16, Pitch 2.0 mm) to the

lifting hole (3 places) on drum (48). 9
ST3149

CAUTION: Travel reduction gear at sprocket

(47) side weight: 2800 kg (6180 lb)

3. Hoist and place the travel reduction gear at the W144-03-01-003

sprocket (47) side with cover (62) facing

downward. 6. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (3 places) on drum (48).
4. Remove bolts (21) (2 used) from lock plate (19).
Remove lock washer (20) and lock plate (19) 7. Hoist and turn over the travel reduction gear at
from spindle (10). the sprocket (47) side. Place shaft (51) on the
: 30 mm wooden blocks in order not to contact with the
ground.
NOTE: Height of wooden block: 230 mm (9.1 in)

51

W18C-03-02-003
Wooden Block

8. Remove bolts (60) (20 used) and spring washers

(61) (20 used) from cover (62).
: 24 mm

9. Remove corks (57) (2 used) from cover (62).

W18K-E-00(20181019) W3-2-13
 UNDERCARRIAGE / Travel Device

32

43

58
56
55
54
47
52

51
63
62
59

68

W18C-03-02-004

W18K-E-00(20181019) W3-2-14
 UNDERCARRIAGE / Travel Device
CAUTION: Cover (62) weight: 120 kg (265 lb)
10. Install a bolt (M16, Pitch 2.0 mm) to the
pulling-out hole (2 places) on cover (62). Float
cover (62) from ring gear (43).
: 24 mm
11. Install an eyebolt (M16, Pitch 2.0 mm) to the
pulling-out hole (2 places) on cover (62).
12. Hoist and remove cover (62) from ring gear (43).
13. Remove retaining ring (59) from cover (62).
Remove stopper pin (56) and ball bearing (58)
from cover (62) by using a puller.
14. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole on the shaft (51) end.
W18K-E-00(20181019) W3-2-15
CAUTION: The shaft (51) assembly weight:
57 kg (130 lb)
15. Hoist and remove shaft (51) from the travel
reduction gear at the sprocket (47) side. At this
time, first stage sun gear (54) is removed with
shaft (51) together.
CAUTION: Shaft (51) weight: 48 kg (110 lb)
IMPORTANT: Put the matching marks onto shaft
(51) and first stage sun gear (54).
16. Remove retaining ring (55) from shaft (51).
Remove first stage sun gear (54) from shaft (51).
17. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (3 places) on first stage carrier (52).
CAUTION: The first stage carrier (52)
assembly weight: 280 kg (620 lb)
18. Hoist and remove the first stage carrier (52)
assembly from second stage carrier (32).
19. Remove retaining rings (68) (3 used) from pins
(63) (3 used).
20. Remove pins (63) (3 used) from first stage carrier
(52).
 UNDERCARRIAGE / Travel Device

34
33
32

45
46
53
47
52

48

63

64
65
66
67
65 W18C-03-02-004
64

W18K-E-00(20181019) W3-2-16
 UNDERCARRIAGE / Travel Device

CAUTION: The first stage planetary gear (67) CAUTION: First stage carrier (52) weight:
assembly weight: 35 kg (80 lb) 130 kg (290 lb)

IMPORTANT: Put the matching marks onto first
stage planetary gear (67) and first
stage carrier (52) as a pair for
assembling.
21. Install an eyebolt (M10, Pitch 1.5 mm) to the
lifting hole (2 places) while removing first stage
planetary gears (67) (3 used).
22. Hoist and remove the first stage planetary gear
(67) assemblies (3 used) from first stage carrier
(52).
CAUTION: First stage planetary gear (67)
weight: 26 kg (60 lb)
IMPORTANT: Put the matching marks onto first
stage planetary gear (67) and roller
bearing (64) as a pair for
assembling.
23. Remove roller bearings (64) (6 used), spacers
(65) (6 used) and retaining rings (66) (3 used)
from first stage planetary gears (67) (3 used).
26. Hoist and remove first stage carrier (52) from
second stage sun gear (34).
27. Remove spacer (33) from second stage carrier
(32).
28. Remove bolts (45) (30 used) and washers (46)
(30 used) from sprocket (47).
: 46 mm
CAUTION: Sprocket (47) weight: 300 kg (660
lb)
29. Install a bolt (M30, Pitch 3.0 mm) to the
pulling-out hole (2 places) on sprocket (47). Float
sprocket (47) from drum (48).
: 46 mm
30. Install an eyebolt (M30, Pitch 3.0 mm) to the
pulling-out hole (2 places) on sprocket (47).
31. Hoist and remove sprocket (47) from drum (48).

24. Remove retaining ring (53) from second stage

sun gear (34).

25. Attach a nylon sling onto the pin (63) holes (3

places) on first stage carrier (52).

W18K-E-00(20181019) W3-2-17
 UNDERCARRIAGE / Travel Device

10

15

32

35
36
37
38
39 40 36
41 35
42
43
26
44
45

48
60

W18C-03-02-004

W18K-E-00(20181019) W3-2-18
 UNDERCARRIAGE / Travel Device
CAUTION: The second stage carrier (32)
assembly weight: 510 kg (1130 lb)
32. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (2 places) on second stage carrier (32).
Hoist and hold second stage carrier (32).
33. Remove bearing nut (9) from second stage
carrier (32).
34. Hoist and remove the second stage carrier (32)
assembly from ring gear (43).
35. Remove bolts (42) (8 used), lock washers (41) (4
used) and lock plates (40) (4 used) from second
stage carrier (32). Remove pins (39) (4 used)
from second stage carrier (32).
: 30 mm
36. Remove second stage planetary gears (38) (4
used) from second stage carrier (32).
IMPORTANT: Put the matching marks onto
second stage planetary gear (38)
and spherical bearing (35) as a pair
for assembling.
37. Remove spherical bearings (35) (8 used),
spacers (36) (8 used) and retaining rings (37) (4
used) from second stage planetary gears (38) (4
used).
38. Install an eyebolt (M16, Pitch 2.0 mm) to the bolt
(60) hole (2 places) on ring gear (43).
W18K-E-00(20181019) W3-2-19
CAUTION: Ring gear (43) + drum (48) +
others weight: 1010 kg (2230 lb)
39. Attach a plate (Dia. 375 mm ( )) onto the ring
gear (43) side of spindle (10). Hoist and remove
ring gear (43), the drum (48) assembly and the
inner race of roller bearing (26) from spindle (10)
by tapping by using a hammer. At this time, the
outer races of roller bearing (26, 44) are removed
with drum (48) together.
CAUTION: Inner race of roller bearing (26)
weight: 30 kg (70 lb)
40. Raise the inner race of roller bearing (26) by
hand. Make clearance between the inner race
and the outer race. Pass a nylon sling through
the clearance. Hoist and remove the inner race of
roller bearing (26) from drum (48).
CAUTION: Ring gear (43) + drum (48) +
others weight: 990 kg (2190 lb)
41. Install an eyebolt (M30, Pitch 3.0 mm) to the bolt
(45) hole on drum (48). Hoist and place ring gear
(43) and the drum (48) assembly with support
(15) facing upward.
 UNDERCARRIAGE / Travel Device

13
10
11

3 15
2 16
17
1

22

24
25
27

31 43

48

49
50

W18C-03-02-004

W18K-E-00(20181019) W3-2-20
 UNDERCARRIAGE / Travel Device
42. Remove one side of floating seal (13) from Travel Reduction Gear at Travel Motor Side
support (15).
50. Remove retaining ring (1) from cover (27).
43. Remove corks (31) (2 used) from drum (48).
51. Remove bolts (2) (10 used) with mark H and
44. Install a bolt (M30, Pitch 3.0 mm) to the washers (3) (10 used) from cover (27).
pulling-out hole (2 places) on drum (48). Float : 32 mm
drum (48) from ring gear (43).

45. Remove socket bolts (16) (12 used) from support

(15). Remove support (15) from drum (48).
: 14 mm
2, 3
46. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (3 places) on drum (48). 27

CAUTION: Drum (48) weight: 510 kg (1130

lb)

47. Remove bolts (50) (28 used) and washers (49)

(28 used) from drum (48). Hoist and remove W18C-03-02-005

drum (48) from ring gear (43).

: 46 mm 52. Remove corks (25) (2 used) from cover (27).

48. Remove one side of floating seal (13) from

CAUTION: Cover (27) weight: 86 kg (190 lb)
support (11).
53. Install a bolt (M22, Pitch 2.5 mm) to the
49. Remove socket bolts (17) (12 used) from support
pulling-out hole (2 places) on cover (27). Float
(11). Remove support (11) from spindle (10).
cover (27) from housing (7).
: 14 mm
: 32 mm

IMPORTANT: Do not remove knock pin (22) unless

necessary.
54. Install an eyebolt (M22, Pitch 2.5 mm) to the
pulling-out hole (2 places) on cover (27). Hoist
and remove cover (27) from housing (7).

55. Install an eyebolt (M16, Pitch 2.0 mm) to the

lifting hole (2 places) on gear (24).

W18K-E-00(20181019) W3-2-21
 UNDERCARRIAGE / Travel Device

7
6
5
4

23
24
23

W18C-03-02-004

W18K-E-00(20181019) W3-2-22
 UNDERCARRIAGE / Travel Device

CAUTION: The gear (24) assembly weight:

80 kg (180 lb)

IMPORTANT: Put the matching marks onto gear

(24) in order not to confuse the
direction when assembling.
56. Hoist and remove gear (24) from housing (7). At
this time, ball bearings (23) (2 used) are removed
with gear (24) together.

IMPORTANT: Put the matching marks onto gear

(5) in order not to confuse the
direction when assembling.
57. Remove gear (5) from housing (7) by using a
puller. At this time, roller bearings (4, 6) are
removed with gear (5) together.

IMPORTANT: Put the matching marks onto roller

bearings (4, 6).
58. Warm up the gear (5) assembly to approx. 90 °C
(194 °F) in an oil bath. Remove roller bearings (4,
6) from gear (5).

CAUTION: Gear (24) weight: 74 kg (165 lb)

IMPORTANT: Put the matching marks onto gear

(24) and ball bearing (23).
59. Warm up the gear (24) assembly to approx.
90 °C (194 °F) in an oil bath. Remove ball
bearings (23) (2 used) from gear (24).

W18K-E-00(20181019) W3-2-23
 UNDERCARRIAGE / Travel Device
ASSEMBLY OF TRAVEL DEVICE

2, 3 7 8 10 11 15 44 26 32 34 43 68

4
62
6 52
53
13
54
9 58
56
33
55
51 59
23 39

24 40, 41

27
21
63
28
64

67

60, 61

W18C-03-02-008

19, 20 17 16 49, 50 47 45, 46 48 42 36, 37 35 38 65, 66

W18K-E-00(20181019) W3-2-24
 UNDERCARRIAGE / Travel Device

1 - Retaining Ring 19 - Lock Plate 36 - Spacer (8 Used) 53 - Retaining Ring

2 - Bolt (10 Used) 20 - Lock Washer 37 - Retaining Ring (4 Used) 54 - First Stage Sun Gear
3 - Spring Washer (10 Used) 21 - Bolt (2 Used) 38 - Second Stage Planetary 55 - Retaining Ring
Gear (4 Used)
4- Roller Bearing 22 - *Knock Pin (2 Used) 39 - Pin (4 Used) 56 - Stopper Pin
5- Gear 23 - Ball Bearing (2 Used) 40 - Lock Plate (4 Used) 57 - *Cork (2 Used)
6- Roller Bearing 24 - Gear 41 - Lock Washer (4 Used) 58 - Ball Bearing
7- Housing 25 - *Cork (2 Used) 42 - Bolt (8 Used) 59 - Retaining Ring
8- O-Ring 26 - Roller Bearing 43 - Ring Gear 60 - Bolt (20 Used)
9- Bearing Nut 27 - Cover 44 - Roller Bearing 61 - Spring Washer (20 Used)
10 - Spindle 28 - Spring Washer (16 Used) 45 - Bolt (30 Used) 62 - Cover
11 - Support 29 - Bolt (16 Used) 46 - Washer (30 Used) 63 - Pin (3 Used)
12 - *Cork (2 Used) 30 - *Cork (3 Used) 47 - Sprocket 64 - Roller Bearing (6 Used)
13 - Floating Seal 31 - *Cork (2 Used) 48 - Drum 65 - Spacer (6 Used)
14 - *Cork (2 Used) 32 - Second Stage Carrier 49 - Washer (28 Used) 66 - Retaining Ring (3 Used)
15 - Support 33 - Spacer 50 - Bolt (28 Used) 67 - First Stage Planetary Gear
(3 Used)
16 - Socket Bolt (12 Used) 34 - Second Stage Sun Gear 51 - Shaft 68 - Retaining Ring (3 Used)
17 - Socket Bolt (12 Used) 35 - Spherical Bearing (8 Used) 52 - First Stage Carrier

NOTE: As for the parts with mark *, refer to W3-2-10.

W18K-E-00(20181019) W3-2-25
 UNDERCARRIAGE / Travel Device

2, 3 7 10

23

24

27

W18C-03-02-008

NOTE: As for cork (25), refer to W3-2-10.

W18K-E-00(20181019) W3-2-26
 UNDERCARRIAGE / Travel Device
Assembly of Travel Device IMPORTANT: Apply THREEBOND #1215 onto the
mounting surfaces of housing (7)
Travel Reduction Gear at Travel Motor Side and cover (27).
7. Hoist and install cover (27) to housing (7) with
bolts (2) (10 used) with mark H and washers (3)
CAUTION: Gear (24) weight: 74 kg (165 lb) (10 used).
: 32 mm
IMPORTANT: Install ball bearings (23) while : 550 N⋅m (5 5 kgf⋅m, 410 lbf⋅ft)
aligning the matching marks made
when disassembling.
1. Warm up ball bearings (23) (2 used) to approx.
90 °C (194 °F) by using a bearing heater. Install
ball bearings (23) (2 used) to gear (24).
2, 3
IMPORTANT: Install roller bearings (4, 6) while
aligning the matching marks made 27
when disassembling.
2. Warm up roller bearings (4, 6) to approx. 90 °C
(194 °F) by using a bearing heater. Install roller
bearings (4, 6) to gear (5).
W18C-03-02-005
IMPORTANT: Install the gear (5) assembly while
aligning the matching marks made
8. Install corks (25) (2 used) to cover (27) by using a
when disassembling.
plastic hammer.
3. Install the gear (5) assembly to housing (7).
9. Install retaining ring (1) to cover (27).
4. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (2 places) on gear (24).
Travel Reduction Gear at Sprocket Side
CAUTION: The gear (24) assembly weight:
80 kg (180 lb) 10. Install an eyebolt (M33, Pitch 3.0 mm) to the
outmost bolt hole (2 places) on spindle (10). Hoist
IMPORTANT: Install the gear (24) assembly while and place spindle (10) on the wooden blocks as
aligning the matching marks made illustrated below.
when disassembling. NOTE: Height of wooden block: 230 mm (9.1 in)
5. Hoist and install the gear (24) assembly to
housing (7).
10
CAUTION: Cover (27) weight: 86 kg (190 lb)

6. Install an eyebolt (M22, Pitch 2.5 mm) to the

pulling-out hole (2 places) on cover (27).

W18C-03-02-006
Wooden Block

W18K-E-00(20181019) W3-2-27
 UNDERCARRIAGE / Travel Device

10 11 15 26 43

13

60

W18C-03-02-008

17 16 49, 50 45 48

W18K-E-00(20181019) W3-2-28
 UNDERCARRIAGE / Travel Device
IMPORTANT: Apply LOCTITE #243 onto socket
bolt (17).
11. Install support (11) to spindle (10) with socket
bolts (17) (12 used).
: 14 mm
: 21 0 N⋅m (21 kgf⋅m, 155 lbf⋅ft)
IMPORTANT: Apply grease onto O-ring and the
seal ring part of floating seal (13),
and the sliding surface of support
(11).
12. Install one side of floating seal (13) to support
(11) by using a bamboo spatula.
13. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (3 places) on drum (48).
CAUTION: Drum (48) weight: 510 kg (1130
lb)
IMPORTANT: Apply THREEBOND #1215 onto the
mounting surfaces of drum (48) and
ring gear (43). Apply LOCTITE #24 3
onto bolt (50).
Install drum (48) while aligning the
matching marks made when
disassembling.
14. Hoist and install drum (48) to ring gear (43) with
bolts (50) (28 used) and washers (49) (28 used).
: 46 mm
: 1950 N⋅m (200 kgf⋅m, 1440 lbf⋅ft)
IMPORTANT: Apply LOCTITE #243 onto socket
bolt (16).
15. Install support (15) to drum (48) with socket bolts
(16) (12 used).
: 14 mm
: 21 0 N⋅m (21 kgf⋅m, 155 lbf⋅ft)
W18K-E-00(20181019) W3-2-29
16. Install corks (31) (2 used) to drum (48) by using a
plastic hammer.
IMPORTANT: Apply grease onto O-ring and the
seal ring part of floating seal (13),
and the sliding surface of support
(15).
17. Install one side of floating seal (13) to support
(15) by using a bamboo spatula.
18. Install an eyebolt (M30, Pitch 3.0 mm) to the bolt
(45) hole (2 places) on drum (48).
CAUTION: Ring gear (43) + drum (48) +
others weight: 990 kg (2190 lb)
19. Hoist and place ring gear (43) and the drum (48)
assembly on the wooden blocks with support (15)
facing downward.
NOTE: Height of wooden block: 230 mm (9.1 in)
43
48
15
Wooden Block W18C-03-02-007
CAUTION: Inner race of roller bearing (26)
weight: 30 kg (70 lb)
20. Attach a nylon sling onto the inner race of roller
bearing (26).
21. Hoist and install the inner race of roller bearing
(26) to drum (48).
22. Install an eyebolt (M16, Pitch 2.0 mm) to the bolt
(60) hole (2 places) on ring gear (43).
 UNDERCARRIAGE / Travel Device

10 32 34 43

33

39

40, 41

64

67

W18C-03-02-008

19, 20 17 16 49, 50 47 45, 46 48 42 36, 37 35 38 65, 66

W18K-E-00(20181019) W3-2-30
 UNDERCARRIAGE / Travel Device
CAUTION: Ring gear (43) + drum (48) +
others weight: 1010 kg (2230 lb)
23. Hoist and install ring gear (43) and the drum (48)
assembly to spindle (10).
IMPORTANT: Install spherical bearing (35) while
aligning the matching marks made
when disassembling.
24. Install retaining rings (37) (4 used), spacers (36)
(8 used) and spherical bearings (35) (8 used) to
second stage planetary gears (38) (4 used).
25. Install the second stage planetary gear (38)
assemblies (4 used) to second stage carrier (32)
with pins (39) (4 used).
IMPORTANT: Do not reuse the lock washer.
26. Install lock plates (40) (4 used) and lock washers
(41) (4 used) to pins (39) (4 used) with bolts (42)
(8 used).
: 30 mm
: 550 N⋅m (5 5 kgf⋅m, 410 lbf⋅ft)
27. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (2 places) on second stage carrier
(32).
CAUTION: The second stage carrier (32)
assembly weight: 510 kg (1130 lb)
28. Hoist and install the second stage carrier (32)
assembly to ring gear (43) while aligning the
splines of the gear.
W18K-E-00(20181019) W3-2-31
IMPORTANT: Tighten bearing nut (9) by hand as
much as possible
29. Tighten bearing nut (9) to second stage carrier
(32).
30. Install an eyebolt (M30, Pitch 3.0 mm) to the
pulling-out hole (2 places) on sprocket (47).
CAUTION: Sprocket (47) weight: 300 kg (660
lb)
IMPORTANT: Apply LOCTITE #24 3 onto bolt (45).
Install sprocket (47) while aligning
the matching marks made when
disassembling.
31. Hoist and install sprocket (47) to drum (48) with
bolts (45) (30 used) and washers (46) (30 used).
: 46 mm
: 1950 N⋅m (195 kgf⋅m, 1440 lbf⋅ft)
32. Install spacer (33) and second stage sun gear
(34) to second stage carrier (32).
IMPORTANT: Install roller bearing (64) while
aligning the matching marks made
when disassembling.
33. Install retaining rings (66) (3 used) and spacers
(65) (6 used) to first stage planetary gears (67) (3
used). Install roller bearings (64) (6 used) to first
stage planetary gears (67) (3 used).
34. Install an eyebolt (M10, Pitch 1.5 mm) to the
lifting hole (2 places) on first stage planetary gear
(67).
 UNDERCARRIAGE / Travel Device

34 43 68

62
52
53
54
58
56
55
51 59

63

67

60, 61

W18C-03-02-008

47 48

NOTE: As for cork (57), refer to W3-2-10.

W18K-E-00(20181019) W3-2-32
 UNDERCARRIAGE / Travel Device
CAUTION: The first stage planetary gear (67)
assembly weight: 35 kg (80 lb)
IMPORTANT: Install the first stage planetary gear
(67) assembly while aligning the
matching marks made when
disassembling.
35. Hoist and install the first stage planetary gear
(67) assembly to first stage carrier (52) with pins
(63) (3 used).
36. Install retaining rings (68) (3 used) to pins (63) (3
used).
37. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole (3 places) on first stage carrier (52).
Attach a nylon sling onto the eyebolts (3 used).
CAUTION: The first stage carrier (52)
assembly weight: 280 kg (620 lb)
38. Hoist and install the first stage carrier (52)
assembly to second stage sun gear (34).
39. Install retaining ring (53) to second stage sun
gear (34).
CAUTION: Shaft (51) weight: 48 kg (110 lb)
IMPORTANT: Install first stage sun gear (54) while
aligning the matching marks made
when disassembling.
40. Install first stage sun gear (54) to shaft (51).
Secure first stage sun gear (54) to shaft (51) with
retaining ring (55).
41. Install an eyebolt (M16, Pitch 2.0 mm) to the
lifting hole on the shaft (51) end.
W18K-E-00(20181019) W3-2-33
CAUTION: The shaft (51) assembly weight:
57 kg (130 lb)
42. Hoist and install the shaft (51) assembly to the
travel reduction gear at the sprocket (47) side
while aligning the splines of the gear.
43. Install ball bearing (58), stopper pin (56) and
retaining ring (59) to cover (62).
44. Install an eyebolt (M16, Pitch 2.0 mm) to the
pulling-out hole (2 places) on cover (62).
CAUTION: Cover (62) weight: 120 kg (265 lb)
IMPORTANT: Apply THREEBOND #1215 onto the
mating surfaces of cover (62) and
ring gear (43).
Install cover (62) while aligning the
matching marks made when
disassembling.
45. Hoist and install cover (62) to ring gear (43) with
bolts (60) (20 used) and spring washers (61) (20
used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)
46. Install corks (57) (2 used) to cover (62) by using a
plastic hammer.
47. Install an eyebolt (M16, Pitch 2.0 mm) to the
pulling-out hole (3 places) on drum (48).
CAUTION: Travel reduction gear at sprocket
(47) side weight: 2800 kg (6180 lb)
48. Hoist and turn over the travel reduction gear at
the sprocket (47) side.
 UNDERCARRIAGE / Travel Device

10

21

W18C-03-02-008

19, 20 48

NOTE: As for cork (30), refer to W3-2-10.

W18K-E-00(20181019) W3-2-34
 UNDERCARRIAGE / Travel Device
49. Tighten bearing nut (9) by using the special tool
(ST 3931).
Details of ST 3931: ST 3147, ST 3148, ST 3149
: 5880±588 N⋅m
(600±60 kgf⋅m, 4340± 440 lbf⋅ft)

ST3148

ST3147

9
ST3149

W144-03-01-003

IMPORTANT: Do not reuse lock washer (20).

50. Secure bearing nut (9) to spindle (10) with lock
plate (19), lock washer (20) and bolts (21) (2
used).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 295 lbf⋅ft)

51. Install corks (30) (3 used) to drum (48) by using a

plastic hammer.

W18K-E-00(20181019) W3-2-35
 UNDERCARRIAGE / Travel Device
DISASSEMBLY OF TRAVEL MOTOR

10

9
8
7
6
5 11
4 12
3 13
2 19 14
1 18 15
17 16
17
16
15
14
13
12
11
21

22
20
38

37 39

23 36
35
34 40
24 33
41
32
25
26 31 43
30 42
29 61
28 44 60

45
59
27
58

46

57
56
55
54
53

52

51
50
49 W146-03-02-001
48
47

W18K-E-00(20181019) W3-2-36
 UNDERCARRIAGE / Travel Device

1- Socket Bolt (6 Used) 17 - Piston (2 Used) 32 - Rotor 47 - Retaining Ring

2- Cover 18 - O-Ring (3 Used) 33 - Valve Plate 48 - Coupling
3- Oil Seal 19 - Plug (3 Used) 34 - Guide Ring 49 - Retaining Ring
4- O-Ring 20 - O-Ring 35 - Bearing 50 - Spacer
5- Retaining Ring 21 - Plate 36 - O-Ring 51 - Shim
6- Spacer 22 - Swash Plate 37 - Valve Cover 52 - Separator Plate (7 Used)
7- Roller Bearing 23 - Casing 38 - Socket Bolt (3 Used) 53 - Piston Ring
8- Spacer 24 - Screw (2 Used) 39 - Socket Bolt (9 Used) 54 - Piston Ring
9- Retaining Ring 25 - Front Casing 40 - O-Ring 55 - Piston
10 - Shaft 26 - Socket Bolt (14 Used) 41 - Plug 56 - O-Ring
11 - Socket Bolt (8 Used) 27 - Piston (9 Used) 42 - Plug 57 - Cover
12 - Cover (2 Used) 28 - Retainer 43 - O-Ring 58 - O-Ring
13 - Stopper (2 Used) 29 - Bushing 44 - Pin 59 - Plug
14 - O-Ring (2 Used) 30 - Shim 45 - Spring (12 Used) 60 - Plug
15 - Spring (2 Used) 31 - Disc Spring (4 Used) 46 - Friction Plate (6 Used) 61 - Socket Bolt (12 Used)
16 - Backup Ring (2 Used)

W18K-E-00(20181019) W3-2-37
 UNDERCARRIAGE / Travel Device

10

19

20
38

37 39

23 36

34
33

25

61

45

46

57
56
55
54
53

52

51
50
49
W146-03-02-001
48
47

W18K-E-00(20181019) W3-2-38
 UNDERCARRIAGE / Travel Device
Disassembly of Travel Motor 7. Remove piston rings (53, 54) from piston (55).

8. Remove retaining ring (49) and coupling (48)

CAUTION: Travel motor weight: 260 kg (195
from shaft (10).
lb)
9. Remove separator plates (52) (7 used), friction
1. Place the travel motor on a workbench. Remove
plates (46) (6 used), shim (51) and spacer (50)
plugs (19) (2 used) from casing (23). Drain
from valve cover (37).
hydraulic oil from casing (23).
: 36 mm
10. Remove retaining ring (47) from shaft (10).
2. Remove socket bolts (61) (2 used) diagonally
IMPORTANT: When removing valve cover (37),
from cover (57). Install an eyebolt (M16, Pitch 2.0
valve plate (33) may be removed
mm).
with cover (37) together. Remove
Hoist and place the travel motor on wooden
valve cover (37) carefully in order to
blocks (2 used) vertically.
prevent valve plate (33) from falling
: 24 mm
off.
11. Remove socket bolts (38) (3 used) and (39) (9
used) from valve cover (37). Install an eyebolt
(M16, Pitch 2.0 mm) to the bolt (61) hole on valve
cover (37). Hoist and remove valve cover (37)
from casing (23).
: 14 mm

IMPORTANT: Do not remove bearing (35) unless

W18B-02-05-004
necessary.
3. Put the matching marks onto front casing (25), 12. Remove valve plate (33), guide ring (34) and
casing (23), valve cover (37) and cover (57). O-ring (36) from valve cover (37).

4. Evenly loosen and remove other bolts (61) (10
used) from cover (57). Remove cover (57) from
valve cover (37). Remove O-ring (56) from cover
(57).
: 24 mm
13. Attach a nylon sling onto the body of casing (23).
Place casing (23) on a workbench horizontally
with the main piping mounting surface facing
upward.

5. Remove springs (45) (12 used) from piston (55).

6. Install an eyebolt (M16, Pitch 2.0 mm) to the

center hole on piston (55). Hoist and remove
piston (55) from valve cover (37).

W18K-E-00(20181019) W3-2-39
 UNDERCARRIAGE / Travel Device

10

9
8
7
6
5 11
4 12
3 13
2 14
1 15
17 16
16 17
15
14
13
12
11
21

22
20

23
35

24
32
25
26 31
30
29
28

27

57

W146-03-02-001

W18K-E-00(20181019) W3-2-40
 UNDERCARRIAGE / Travel Device
CAUTION: Rotor (32) weight: 37 kg (82 lb)
14. Attach a nylon sling onto the body of rotor (32).
Remove rotor (32) from casing (23). At this time,
pistons (27) (9 used), retainer (28) and bushing
(29) are removed with rotor (23) together.
15. Wind the vinyl tape around the inner race of
bearing (35) in order to protect.
16. Remove pistons (27) (9 used), retainer (28),
bushing (29), shim (30) and disc springs (31) (4
used) from rotor (32).
17. Remove socket bolts (1) (6 used) from cover (2).
Remove cover (2) from casing (23).
: 8 mm
18. Remove oil seal (3) and O-ring (4) from cover (2).
19. Remove shaft (10) from casing (23) by tapping by
using a plastic hammer from the cover (57) side.
20. Remove retaining rings (5, 9) from shaft (10).
Remove spacers (6, 8) from shaft (10).
21. Remove the inner ring plate and the outer race of
roller bearing (7) from shaft (10).
22. Push shaft (10) by using a press. Remove the
inner race of roller bearing (7) from shaft (10).
23. Install a shackle to the flange hole (2 places) on
front casing (25).
W18K-E-00(20181019) W3-2-41
CAUTION: Front casing (25) weight: 37 kg
(82 lb)
Casing (23) weight: 51 kg (115 lb)
24. Remove socket bolts (26) (14 used) from front
casing (25). Hoist and remove front casing (25)
from casing (23).
: 12 mm
25. Remove O-rings (20) and screws (24) (2 used)
from front casing (25).
26. Remove socket bolts (11) (8 used) from covers
(12) (2 used). Remove covers (12) (2 used) from
casing (23).
: 14 mm
IMPORTANT: Keep stopper (13) in order to install
to the original position.
27. Remove stoppers (13) (2 used), springs (15) (2
used) and pitons (17) (2 used) from casing (23).
NOTE: Remove stopper (13) and piston (17) from
casing (23) by pushing with the fingers.
28. Remove O-rings (14) (2 used) from stoppers (13)
(2 used).
29. Remove backup rings (16) (2 used) from pistons
(17) (2 used).
30. Remove swash plate (22) from casing (23). At
this time, plate (21) is removed with swash plate
(22) together.
31. Remove plate (21) from swash plate (22).
 UNDERCARRIAGE / Travel Device
ASSEMBLY OF TRAVEL MOTOR

13 12 14 15 17 21 19 18 16 11 33 36 35 37 53 54

25
38
9
8
46
2 52
6 47
5
49
55
10
59
48
57
3
7
4
1
45

20 61
26

22 30 28 31 29 27 32 23 44 34 39 50 51 56

W145-03-02-005

1- Socket Bolt (6 Used) 17 - Piston (2 Used) 32 - Rotor 47 - Retaining Ring

2- Cover 18 - O-Ring (3 Used) 33 - Valve Plate 48 - Coupling
3- Oil Seal 19 - Plug (3 Used) 34 - Guide Ring 49 - Retaining Ring
4- O-Ring 20 - O-Ring 35 - Bearing 50 - Spacer
5- Retaining Ring 21 - Plate 36 - O-Ring 51 - Shim
6- Spacer 22 - Swash Plate 37 - Valve Cover 52 - Separator Plate (7 Used)
7- Roller Bearing 23 - Casing 38 - Socket Bolt (3 Used) 53 - Piston Ring
8- Spacer 24 - *Screw (2 Used) 39 - Socket Bolt (9 Used) 54 - Piston Ring
9- Retaining Ring 25 - Front Casing 40 - *O-Ring 55 - Piston
10 - Shaft 26 - Socket Bolt (14 Used) 41 - *Plug 56 - O-Ring
11 - Socket Bolt (8 Used) 27 - Piston (9 Used) 42 - *Plug 57 - Cover
12 - Cover (2 Used) 28 - Retainer 43 - *O-Ring 58 - *O-Ring
13 - Stopper (2 Used) 29 - Bushing 44 - Pin 59 - Plug
14 - O-Ring (2 Used) 30 - Shim 45 - Spring (12 Used) 60 - *Plug
15 - Spring (2 Used) 31 - Disc Spring (4 Used) 46 - Friction Plate (6 Used) 61 - Socket Bolt (12 Used)
16 - Backup Ring (2 Used)

NOTE: As for the parts with mark *, refer to W3-2-36.

W18K-E-00(20181019) W3-2-42
 UNDERCARRIAGE / Travel Device
Assembly of Travel Motor
CAUTION: Casing (23) weight: 51 kg (115 lb)
1. Place casing (23) horizontally with plug (19)
facing sideways.
2. Apply grease onto the joint surfaces of swash
plate (22) and plate (21). Install plate (21) to
swash plate (22).
3. Install swash plate (22) to casing (23).
CAUTION: Front casing (25) weight: 37 kg
(82 lb)
4. Install O-ring (20) and screws (24) (2 used) to
front casing (25).
5. Install front casing (25) to casing (23) with socket
bolts (26) (14 used) while aligning the matching
marks made when disassembling.
: 12 mm
: 180 N⋅m (18.5 kgf⋅m, 133 lbf⋅ft)
6. Install O-rings (14) (2 used) to stoppers (13) (2
used).
7. Install backup rings (16) (2 used) to pistons (17)
(2 used).
IMPORTANT: Check that swash plate (22) moves
in stopper (13). If swash plate (22)
cannot move, go back to step 2 and
assemble again.
8. Install piston (17), spring (15), stopper (13) and
cover (12) to the valve cover (37) side. Secure
cover (12) with socket bolts (11) (4 used).
: 14 mm
: 235±35 N⋅m (24±3.6 kgf⋅m, 175±26 lbf⋅ft)
W18K-E-00(20181019) W3-2-43
9. Install piston (17), spring (15), stopper (13) and
cover (12) to the front casing (25) side. Secure
cover (12) with socket bolts (11) (4 used).
: 14 mm
: 235±35 N⋅m (24±3.6 kgf⋅m, 175±26 lbf⋅ft)
10. Install spacer (8) and retaining ring (9) to the rotor
side of shaft (10).
11. Assemble and warm up the inner race and the
inner ring plate of roller bearing (7) to approx. 60°
(140°F) by using a heater or an oil bath.
12. Install roller bearing (7) to shaft (10) with the
inner ring plate facing inside by using a press.
13. Install the outer race of roller bearing (7) to shaft
(10).
14. Install spacer (6) and retaining ring (5) to shaft
(10).
15. Install shaft (10) to front casing (25) while tapping
the outer race of roller bearing (7) by using a
copper bar lightly.
16. Install oil seal (3) to cover (2) by using a plate
and a hammer. Install O-ring (4) to cover (2).
17. Install cover (2) to front casing (25) with socket
bolts (1) (6 used).
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft)
 UNDERCARRIAGE / Travel Device

33 36 37

38

47
49

10
48

61

30 28 31 29 27 32 23 44 34

W145-03-02-005

W18K-E-00(20181019) W3-2-44
 UNDERCARRIAGE / Travel Device
IMPORTANT: The smooth surface of rotor (32) is
the sliding surface for the valve
plate. Do not damage the sliding
surface.
18. Assemble rotor (32) into an assembly in the
following procedures.
• Place rotor (32) with the smooth surface facing
downward.
• Assemble disc springs (31) (4 used) so that the
outer race is matching with the outer race and
the inner race is matching with the inner race.
Place disc springs (31) (4 used) on the projection
part in rotor (32).
Place shim (30) on them. Cover them with
bushing (29). At this time, align bushing (29) with
the spline in rotor (32).
30 31
29
32
CAUTION: Rotor (32) weight: 37 kg (82 lb)
19. Install the rotor (32) assembly to shaft (10).
20. Install guide ring (34), O-ring (36) and pin (44) to
valve cover (37).
21. Apply grease onto the flat surface of valve plate
(33). Align the pin (44) positions and install valve
plate (33) to valve cover (37).
CAUTION: The casing (23) assembly weight:
51 kg (115 lb)
22. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
the bolt (61) hole on casing (23).
Hoist and place casing (23) on a wooden block
vertically.
23
Wooden Block
(Height: 200 mm)
(7.9 in)

W18B-02-04-010

• Place retainer (28) on bushing (29) with the

chamfered surface facing downward. W18B-02-04-011

28

Chamfered
Surface
W176-02-06-016

29

• Align the plunger hole on retainer (28) with that of

rotor (32). Insert pistons (27) (9 used).

W18K-E-00(20181019) W3-2-45
 UNDERCARRIAGE / Travel Device

19 18 33 37 53 54

38

46
52
47
49
55
10
48
57

45

61

23 39 50 51 56

W145-03-02-005

W18K-E-00(20181019) W3-2-46
 UNDERCARRIAGE / Travel Device
IMPORTANT: Do not drop valve plate (33) from 27. Install piston rings (53, 54) to piston (55).
valve cover (37).
23. Install valve cover (37) to casing (23) with socket 28. Install piston (55) to valve cover (37).
bolts (38) (3 used) and (39) (9 used).
: 14 mm 29. Install springs (45) (12 used) to piston (55).
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
30. Install O-ring (56) to cover (57). Install cover (57)
24. Install retaining ring (47), coupling (48) and to valve plate (37) with socket bolts (61) (12
retaining ring (49) to shaft (10). used).
: 24 mm
25. Install spacer (50) and shim (51) to valve cover : 235 N⋅m (24 kgf⋅m, 175 lbf⋅ft)
(37).
31. Install O-rings (18) (3 used) to plugs (19) (3
IMPORTANT: Align the notches on separator used). Install plugs (19) (3 used) to casing (23).
plates (52) (7 used) and friction : 36 mm
plates (46) (6 used). Adjust shim (51) : 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)
so that dimension A between the
stepped surface of valve cover (37)
and top of separator plate (52) is 3.3
mm (0.1 in).

37
A

52

W18B-02-04-013

26. Install separator plates (52) (7 used) and friction

plates (46) (6 used) alternately to valve cover
(37) and coupling (48).

W18K-E-00(20181019) W3-2-47
 UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARD
Dial Gauge

1. Clamp the plunger with a shoe in a vise. Shoe

Install a dial gauge to the shoe. Measure
spherical clearance between the plunger and the
shoe while moving the shoe up and down.
If the clearance exceeds the allowable limit,
replace the plunger and the shoe as an
assembly.
Guide
Unit: mm (in)
Standard Allowable Limit
0 0.3 (0.01)

W115-02-04-062
Vise
Plate Plunger

Plunger

2. Measure outer diameter d of the plunger at 3

places of upper, middle and skirt in cross
direction by using a micro meter. (d) (d) (d)
Measure inner diameter D of the rotor at 2 places
in cross direction by using a cylinder gauge.
W115-02-04-065

Unit: mm (in)
Standard D-d Allowable Limit
Rotor
0.059 (0.002) 0.118 (0.005)

(D) (D)

(D) (D)

W115-02-04-066

W18K-E-00(20181019) W3-2-48
 UNDERCARRIAGE / Travel Device
3. Measure flange thickness B of the shoe by using Shoe Plunger
a micro meter.

Unit: mm (in)
Standard Allowable Limit
B 10.0 (0.4) 9.8 (0.4)
B

W115-02-04-068

4. Measure height E and h of retainer (28) and

28 29
bushing (29).
C=H-h Stand

Unit: mm (in)
Standard Allowable Limit H
h
C 35.6 (1.4) 34.8 (1.4)

5. Measure the free length of spring (45). W115-02-04-069

Unit: mm (in)
Standard Allowable Limit
Free Length 54.0 (2.1) 53.6 (2.1)

6. Measure height D of separator plates (52) (7

used) and friction plates (46) (6 used).

Unit: mm (in)
Standard Allowable Limit
D 27.9 (1.1) 27.3 (1.1)

7. Measure height E between the end of valve cover

(37) and separator plate (52).

Unit: mm (in)
Standard Allowable Limit
E 51.5 (2.0) 50.5 (2.0) E

W115-03-07-029

W18K-E-00(20181019) W3-2-49
 UNDERCARRIAGE / Travel Device
DISASSEMBLY AND ASSEMBLY OF
TRAVEL MODE SELECTION VALVE

1 2 3 4 5 6 18 7 8 9 10 11

Screw Hole

17 16 15 14 13 12
W117-03-02-005

1- Plug 6- Valve Casing 11 - O-Ring (6 Used) 15 - Spacer (2 Used)

2- O-Ring 7- Piston 12 - O-Ring (3 Used) 16 - O-Ring (3 Used)
3- Spring 8- Plug 13 - Plug (3 Used) 17 - Plug (3 Used)
4- Spring Seat 9- Socket Bolt (4 Used) 14 - Piston 18 - O-Ring
5- Spool 10 - Orifice (2 Used)

W18K-E-00(20181019) W3-2-50
 UNDERCARRIAGE / Travel Device
Disassembly of Travel Mode Selection Valve
1. Remove socket bolts (9) (4 used) from the travel
mode selection valve. Remove the travel mode
selection valve from the travel motor.
: 6 mm
2. Remove O-rings (11) (6 used) from valve casing
(6).
3. Remove orifices (10) (2 used) from valve casing
(6).
: 2.5 mm
4. Remove plugs (17) (3 used) and plugs (1, 8) from
valve casing (6). Remove O-rings (16) (3 used)
and O-rings (2, 18) from each plug.
: 6 mm, 8 mm
: 24 mm
5. Remove piston (7) from plug (8).
6. Remove spring (3), spring seat (4) and spool (5)
from valve casing (6).
7. Remove spacers (15) (2 used) from valve casing
(6) through a screw hole (M5, Pitch 0.8 mm).
Remove piston (14).
8. Remove plugs (13) (3 used) from valve casing
(6). Remove O-rings (12) (3 used) from plugs
(13) (3 used).
W18K-E-00(20181019) W3-2-51
Assembly of Travel Mode Selection Valve
1. Install O-rings (12) (3 used) to plugs (13) (3
used). Install valve casing (6).
2. Insert piston (14) and spacers (15) (2 used) to
valve casing (6).
3. Install O-rings (16) (3 used) to plugs (17) (3
used). Install plugs (17) (3 used) to valve casing
(6).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
4. Install spring seat (4) and spring (3) to spool (5).
Insert the spool (5) assembly into valve casing
(6).
5. Install O-ring (2) to plug (1). Install plug (1) to
valve casing (6).
: 8 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
6. Install piston (7) and O-ring (18) to plug (8).
Install the plug (8) assembly to valve casing (6).
: 24 mm
: 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
7. Install orifices (10) (2 used) to valve casing (6).
: 2.5 mm
: 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)
8. Install O-rings (11) (6 used) to valve casing (6).
9. Install valve casing (6) to the travel motor with
socket bolts (9) (4 used).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
 UNDERCARRIAGE / Travel Device
(Blank)

W18K-E-00(20181019) W3-2-52
 UNDERCARRIAGE / Travel Brake Valve
REMOVAL AND INSTALLATION OF
TRAVEL BRAKE VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal
1
1. Remove clamps (2) (2 used), bolts (4) (3 used)
and washers (5) (3 used) from cover (1) and
hoses (3) (2 used).
: 17 mm

W18K-03-03-002
2 1

4, 5 W18K-03-02-002

CAUTION: Cover (1) weight: 71 kg (160 lb)

6 7 1
2. Attach a nylon sling onto cover (1). Hoist and
hold cover (1) by using a forklift.

3. Remove sems bolts (7) (8 used) from cover (1).

Remove cover (1) from track frame (6) and
support (8).
: 19 mm W18K-03-03-003

3 1

W18K-03-02-001

W18K-E-00(20181019) W3-3-1
 UNDERCARRIAGE / Travel Brake Valve
4. Remove socket bolts (11) (8 used) and split
flanges (12) (4 used) from travel brake valve (9). 9 10 11 10
Disconnect hoses (10) (2 used) from travel brake
valve (9). Cap the open ends.
: 14 mm

12

W18L-03-03-005

5. Remove bolts (15) (4 used) and washers (16) (4 13 6 14 15, 16

used) from clamps (14) (4 used). Remove clamps
(14) (4 used) from pipings (13) (2 used).
: 19 mm

W18K-03-03-002

6. Remove socket bolts (18) (8 used) and split

9 17 13 18
flanges (17) (4 used) from travel brake valve (9).
Disconnect pipings (13) (2 used) from travel
brake valve (9). Cap the open ends.
: 14 mm
17

CAUTION: Travel brake valve (9) weight: 55

kg (125 lb)

7. Support travel brake valve (9) by using a forklift.

8. Remove bolts (19) (4 used) and washers (20) (4 21 19, 20 W18L-03-03-006

used) from travel brake valve (9). Remove travel

brake valve (9) from bracket (21).
: 24 mm

W18K-E-00(20181019) W3-3-2
 UNDERCARRIAGE / Travel Brake Valve
Installation

CAUTION: Travel brake valve (9) weight: 55

kg (125 lb) 9 17 13 18

1. Align travel brake valve (9) with the mounting

hole on bracket (21) by using a forklift. Install
travel brake valve (9) to bracket (21) with bolts 17
(19) (4 used) and washers (20) (4 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft)

2. Connect pipings (13) (2 used) to travel brake

valve (9) with socket bolts (18) (8 used) and split
flanges (17) (4 used). 21 19, 20 W18L-03-03-006

: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft)

3. Secure pipings (13) (2 used) to track frame (6) 13 6 14 15, 16

with clamps (14) (4 used), bolts (15) (4 used) and
washers (16) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf·ft)

W18K-03-03-002

4. Connect hoses (10) (2 used) to travel brake valve

9 10 11 10
(9) with socket bolts (11) (8 used) and split
flanges (12) (4 used).
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft)

12

W18L-03-03-005

W18K-E-00(20181019) W3-3-3
 UNDERCARRIAGE / Travel Brake Valve

CAUTION: Cover (1) weight: 71 kg (160 lb)

1
5. Attach a nylon sling onto cover (1). Hoist and
align cover (1) with the mounting hole on track
frame (6) and support (8).

6 W18K-03-03-002

6. Install cover (1) to support (8) with sems bolts (7) 3

(4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf·ft)

W18K-03-02-001

7. Install cover (1) to track frame (6) with sems bolts 6 7 1

(7) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf·ft)

W18K-03-03-003

W18K-E-00(20181019) W3-3-4
 UNDERCARRIAGE / Travel Brake Valve
1

W18K-03-03-002

8. Secure hoses (3) (2 used) to cover (1) with 2 1

clamps (2) (2 used), bolts (4) (3 used) and 3
washers (5) (3 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf·ft)

4, 5 W18K-03-02-002

W18K-E-00(20181019) W3-3-5
 UNDERCARRIAGE / Travel Brake Valve
DISASSEMBLY OF TRAVEL BRAKE
VALVE

1 2

13
12 2
11
10
9
1
8 7

5
6
14
15 4

16
17

18

17
16 8
9
10
26
11
25 12
24 13
23
22
21
20
15 19

14

W18B-03-03-002

1- Socket Bolt (8 Used) 8- Spring Seat (2 Used) 15 - Cap Assembly (2 Used) 22 - Spring (4 Used)
2- Relief Valve (2 Used) 9- Spring (2 Used) 16 - Spring (2 Used) 23 - Steel Ball (4 Used)
3- Body 10 - Spring Seat (2 Used) 17 - Check Valve (2 Used) 24 - Cap (2 Used)
4- Orifice 11 - O-Ring (2 Used) 18 - Plunger 25 - Backup Ring (2 Used)
5- O-Ring (3 Used) 12 - Backup Ring (2 Used) 19 - Plug (4 Used) 26 - O-Ring (2 Used)
6- Plug (3 Used) 13 - Plug (2 Used) 20 - O-Ring (4 Used)
7- Orifice 14 - Socket Bolt (8 Used) 21 - Spring Guide (4 Used)

W18K-E-00(20181019) W3-3-6
 UNDERCARRIAGE / Travel Brake Valve
Disassembly
1. Remove socket bolts (14) (8 used) from body (3).
: 14 mm
IMPORTANT: Do not damage body (3) and cap
assembly (15).
2. Lightly pry and remove cap assemblies (15) (2
used) from both sides of body (3) by using a
screwdriver.
IMPORTANT: When removing plug (13), plug (13)
flies out a little by the reaction force
of spring (9). Do not drop plug (13),
spring seat (10) and spring (9).
3. Loosen plugs (13) (2 used) at both sides of
plunger (18) at the same time. Remove plug (13)
at one side only. Remove spring seat (10) and
spring (9) from body (3).
: 36 mm
4. Remove spring (16) and check valve (17) from
plunger (18) at the side without plug (13).
5. Slowly turn and remove the plunger (18)
assembly from the side with plug (13) attached.
Remove spring seat (8) from body (3) at the
opposite side.
6. Secure plug (13) in plunger (18) in a vise.
7. Pass a bar through a cross hole on plunger (18).
Turn the bar. Loosen plug (13) without removing.
W18K-E-00(20181019) W3-3-7
8. Remove the plunger (18) assembly from the vise.
IMPORTANT: When removing plug (13), plug (13)
flies out a little by the reaction force
of spring (9). Do not drop plug (13),
spring seat (10) and spring (9).
9. Remove plug (13) from plunger (18) by hand.
Remove spring seat (10) and spring (9).
10. Remove O-rings (11) (2 used) and backup rings
(12) (2 used) from plugs (13) (2 used).
11. Remove spring (16), check valve (17) and spring
seat (8) from plunger (18).
12. Remove O-rings (26) (2 used) and backup rings
(25) (2 used) from caps (24) (2 used).
13. Remove plugs (19) (4 used) from caps (24) (2
used). Remove O-rings (20) (4 used) from plugs
(19) (4 used).
: 14 mm
14. Remove spring guides (21) (4 used), springs (22)
(4 used) and steel balls (23) (4 used) from caps
(24) (2 used).
15. Remove socket bolts (1) (8 used) from body (3).
: 10 mm
IMPORTANT: Do not disassemble relief valve (2)
as the set flow rate changes.
16. Remove relief valves (2) (2 used) from body (3).
 UNDERCARRIAGE / Travel Brake Valve
ASSEMBLY OF TRAVEL BRAKE VALVE

19 24 10 14 9 25 4 8 17 16 18 3 7 11 12 23 22 21

20

13 2

1
26
T144-03-05-002

1- Socket Bolt (8 Used) 8- Spring Seat (2 Used) 15 - Cap Assembly (2 Used) 22 - Spring (4 Used)
2- Relief Valve (2 Used) 9- Spring (2 Used) 16 - Spring (2 Used) 23 - Steel Ball (4 Used)
3- Body 10 - Spring Seat (2 Used) 17 - Check Valve (2 Used) 24 - Cap (2 Used)
4- Orifice 11 - O-Ring (2 Used) 18 - Plunger 25 - Backup Ring (2 Used)
5- O-Ring (3 Used) 12 - Backup Ring (2 Used) 19 - Plug (4 Used) 26 - O-Ring (2 Used)
6- Plug (3 Used) 13 - Plug (2 Used) 20 - O-Ring (4 Used)
7- Orifice 14 - Socket Bolt (8 Used) 21 - Spring Guide (4 Used)

W18K-E-00(20181019) W3-3-8
 UNDERCARRIAGE / Travel Brake Valve
Assembly
1. Install relief valves (2) (2 used) to body (3) with
socket bolts (1) (8 used).
: 10 mm
: 98 to 108 N⋅m
(10 to 11 kgf⋅m, 72 to 80 lbf·ft)
2. Install steel balls (23) (4 used), springs (22) (4
used) and spring guides (21) (4 used) to caps
(24) (2 used).
3. Install O-rings (20) (4 used) to plugs (19) (4 used).
Install plugs (19) (4 used) to caps (24) (2 used).
: 14 mm
: 14.7 to 16.7 N⋅m
(1.5 to 1.7 kgf⋅m, 11 to 12 lbf·ft)
4. Install backup rings (25) (2 used) and O-rings
(26) (2 used) to caps (24) (2 used).
IMPORTANT: Install spring seat (8) with the larger
chamfered side facing to the
plunger (18) side.
5. Secure plunger (18) in a vise. Install check valve
(17), spring (16), spring seat (8) and spring (9) to
the one side of plunger (18).
6. Install backup rings (12) (2 used) and O-rings
(11) (2 used) to plugs (13) (2 used).
IMPORTANT: Install spring seat (10) with the
chamfered side facing to the
plunger (13) side.
7. Slowly turn and install spring seat (10) to plugs
(13).
W18K-E-00(20181019) W3-3-9
IMPORTANT: Install plug (13) by pushing against
the reaction force from spring (9).
8. Install plug (13) to plunger (18) by hand.
9. Slowly turn and insert the plunger (18) assembly
into body (3) from the side without plug (13).
IMPORTANT: Install spring seat (8) with the larger
chamfered side facing to the
plunger (18) side.
10. Install check valve (17), spring (16), spring seat
(8) and spring (9) to inserted plunger (18) at the
opposite side.
IMPORTANT: Install spring seat (10) with the
chamfered side facing to the
plunger (13) side.
11. Slowly turn and install spring seat (10) to plug
(13).
IMPORTANT: Install plug (13) by pushing against
the reaction force from spring (9).
12. Install plug (13) to plunger (18) by hand.
13. Tighten plugs (13) at both sides at the same time.
: 36 mm
: 255 to 274 N⋅m
(26 to 28 kgf⋅m, 188 to 202 lbf·ft)
14. Install cap assemblies (15) (2 used) to body (3)
with socket bolts (14) (8 used).
: 14 mm
: 196 to 216 N⋅m
(20 to 22 kgf⋅m, 145 to 159 lbf·ft)
 UNDERCARRIAGE / Travel Brake Valve
(Blank)

W18K-E-00(20181019) W3-3-10
 UNDERCARRIAGE / Center Joint
REMOVAL AND INSTALLATION OF
CENTER JOINT

Removal

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

1. Remove socket bolts (3) (16 used) and split 2 3 4 3

flanges (1) (8 used) from hoses (2) (4 used).
Disconnect hoses (2) (4 used) from center joint
2
(4). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 14 mm
5
2. Disconnect hoses (5) (7 used) from center joint
(4). Cap the open ends. Attach an identification 1
tag onto the disconnected hoses for assembling.
: 17 mm, 19 mm, 22 mm, 36 mm

5
W18K-03-04-002
2

3. Remove bolts (6) (3 used) and washers (7) (3

4
used) from stopper (8). Remove stopper (8) from
center joint (4).
: 32 mm

6, 7

6, 7 8 W18K-03-04-002

W18K-E-00(20181019) W3-4-1
 UNDERCARRIAGE / Center Joint
4. Disconnect hoses (9) (2 used) from center joint 9 10 4 9
(4). Cap the open ends.
: 17 mm, 36 mm

5. Disconnect connectors (10) (2 used) from center 11

joint (4).
12
6. Remove sems bolts (11) (4 used) from clamps
(12) (4 used). Remove clamps (12) (4 used) and 13
harness (16) from bracket (13).
: 17 mm 14

7. Remove sems bolts (14) (2 used) from bracket

(13). Remove bracket (13) from bracket (15). 16 15 W18K-03-04-001

: 17 mm

8. Remove socket bolts (18) (16 used) and split

flanges (19) (8 used) from hoses (17) (4 used). 18 19 17
Disconnect hoses (17) (4 used) and blocks (20)
(4 used) from center joint (4). Cap the open ends.
: 17 mm

17

18

20 4 20 19 W18K-03-04-001

W18K-E-00(20181019) W3-4-2
 UNDERCARRIAGE / Center Joint

CAUTION: Center joint (4) weight: 261 kg Pulling-Out Hole

(580 lb)

9. Install an eyebolt (M16, Pitch 2.0 mm) to the

pulling-out hole (2 places) on the upper part of 4
center joint (4). Attach a nylon sling onto the
eyebolt. Hoist and hold center joint (4).

W146-03-05-005

IMPORTANT: Put the matching marks onto the

body of center joint (4) and bracket
(15).
10. Remove bolts (21) (4 used) and washers (22) (4
used) from center joint (4). Remove center joint
(4) from bracket (15).
: 30 mm
21, 22

W18K-03-04-001
15 4

21, 22

15

W145-03-04-001

W18K-E-00(20181019) W3-4-3
 UNDERCARRIAGE / Center Joint
Installation
Pulling-Out Hole

CAUTION: Center joint (4) weight: 261 kg

(580 lb)
4
1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
center joint (4). Attach a nylon sling onto the
eyebolt. Hoist and align center joint (4) with the
matching mark on bracket (15). Install center joint
(4) to bracket (15) with bolts (21) (4 used) and
washers (22) (4 used).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 406 lbf·ft)
W146-03-05-005

21, 22

15

W145-03-04-001

21, 22

W18K-03-04-001
15 4

W18K-E-00(20181019) W3-4-4
 UNDERCARRIAGE / Center Joint
2. Install stopper (8) to center joint (4) with bolts (6) 4
(3 used) and washers (7) (3 used).
: 32 mm
: 750 N⋅m (76.5 kgf⋅m, 553 lbf·ft)

6, 7

6, 7 8 W18K-03-04-002

3. Connect hoses (5) (7 used) to center joint (4).

2 3 4 3
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft)
: 19 mm 2
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf·ft)
: 36 mm 5
: 175 N⋅m (18 kgf⋅m, 129 lbf·ft)
1
4. Connect hoses (2) (4 used) to center joint (4)
with socket bolts (3) (16 used) and split flanges
(1) (8 used). 5
: 14 mm
W18K-03-04-002
: 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft) 2

W18K-E-00(20181019) W3-4-5
 UNDERCARRIAGE / Center Joint
5. Install blocks (20) (4 used) and connect hoses 18 19 17
(17) (4 used) to center joint (4) with socket bolts
(18) (16 used) and split flanges (19) (8 used).
: 17 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf·ft)

17

18

20 4 20 19 W18K-03-04-001

6. Install bracket (13) to bracket (15) with sems

bolts (14) (2 used). 9 10 4 9
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf·ft)

7. Connect connectors (10) (2 used) to center joint 11

(4).
12
8. Secure clamps (12) (4 used) and harness (16) to
bracket (13) with sems bolts (11) (4 used). 13
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf·ft) 14

9. Connect hoses (9) (2 used) to center joint (4).

: 17 mm 16 15 W18K-03-04-001

: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft)

: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf·ft)

W18K-E-00(20181019) W3-4-6
 UNDERCARRIAGE / Center Joint
(Blank)

W18K-E-00(20181019) W3-4-7
 UNDERCARRIAGE / Center Joint
DISASSEMBLY OF CENTER JOINT

13
1 14

12 15

11
16

2 17

18

19
3

10
W146-03-05-002

1- Body 6- Spindle 11 - Spring Washer (8 Used) 16 - O-Ring

2- Seal (5 Used) 7- O-Ring (4 Used) 12 - Bolt (8 Used) 17 - Plate
3- O-Ring 8- Plug (4 Used) 13 - Bolt (6 Used) 18 - O-Ring
4- Ball (39 Used) 9- O-Ring (3 Used) 14 - Spring Washer (6 Used) 19 - Ball (36 Used)
5- Ring Plate 10 - Plug (3 Used) 15 - Cover

W18K-E-00(20181019) W3-4-8
 UNDERCARRIAGE / Center Joint
Disassembly of Center Joint
CAUTION: Body (1) weight: 140 kg (310 lb)
IMPORTANT: Put the matching marks onto body Spindle (6) weight: 100 kg (220 lb)
(1) and spindle (6).
1. Remove bolts (13) (6 used) and spring washers IMPORTANT: When removing spindle (6) from
(14) (6 used) from cover (15). Install bolts (13) (2 body (1), ball (4) may fall off from
used) to the pulling-out hole (2 places) on cover spindle (6). Do not damage ball (4).
(15). Tighten the bolt. Raise and remove cover 3. Install special tool (A) to spindle (6) and body (1).
(15) from body (1). Remove spindle (6) from body (1).
: 24 mm
Details of special tool (A): ST 2440, ST 2441, ST
2917
ST 2443, ST 2444
Pulling-Out Hole
J901232, J901650
ST 2440

ST 2917 ST 2441
J 901232 ST 2444
ST 2443

J 901650

W146-03-05-005

2. Remove bolts (12) (8 used), spring washers (11) W146-03-05-003

(8 used) and plate (17) from body (1). Remove

4. Remove seals (2) (5 used) and O-ring (3) from
balls (19) (36 used) from body (1).
body (1).
: 19 mm
5. Remove balls (4) (39 used) and ring plate (5)
from spindle (6).

6. Remove plugs (8) (4 used) from spindle (6).

: 41 mm

W18K-E-00(20181019) W3-4-9
 UNDERCARRIAGE / Center Joint
ASSEMBLY OF CENTER JOINT

13 16 12 11

14

15
17
18

19

4
5

10 9

T145-03-02-001

1- Body 6- Spindle 11 - Spring Washer (8 Used) 16 - O-Ring

2- Seal (5 Used) 7- O-Ring (4 Used) 12 - Bolt (8 Used) 17 - Plate
3- O-Ring 8- Plug (4 Used) 13 - Bolt (6 Used) 18 - O-Ring
4- Ball (39 Used) 9- O-Ring (3 Used) 14 - Spring Washer (6 Used) 19 - Ball (36 Used)
5- Ring Plate 10 - Plug (3 Used) 15 - Cover

W18K-E-00(20181019) W3-4-10
 UNDERCARRIAGE / Center Joint
Assembly of Center Joint

1. Apply grease onto ring plate (5) and balls (4) (39
used). Install ring plate (5) and balls (4) (39 used)
to spindle (6).
2. Install seals (2) (5 used) and O-ring (3) to body
(1).
6. Install cover (15) to O-rings (16, 18). Install cover
(15) to body (1) with spring washers (14) (6 used)
and bolts (13) (6 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft)

CAUTION: Body (1) weight: 140 kg (310 lb)

Spindle (6) weight: 100 kg (220 lb)

3. Install body (1) to spindle (6) by using special tool

(A).

Details of Special tool (A): ST 2440, ST 2441, ST

2917
ST 2443, ST 2444
J901232, J901650
ST 2440

ST 2917 ST 2441
J 901232 ST 2444
ST 2443

J 901650

W146-03-05-003

4. Apply grease onto balls (19) (36 used). Insert

balls (19) (36 used) into the groove on spindle (6)
and body (1).

5. Place plate (17) onto balls (19) (36 used).

Tighten spring washers (11) (8 used) and bolts
(12) (8 used). Push balls (19) (36 used) into the
groove.
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf·ft)

W18K-E-00(20181019) W3-4-11
 UNDERCARRIAGE / Center Joint
(Blank)

W18K-E-00(20181019) W3-4-12
 UNDERCARRIAGE / Adjuster Cylinder
REMOVAL AND INSTALLATION OF
ADJUSTER CYLINDER

IMPORTANT: Bleed air from the hydraulic oil tank

before doing any work. (Refer to
BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Removal 1
CAUTION: Grease pressure in the adjuster
cylinder is high. Do not loosen valve (1)
quickly or too much as valve (1) may fly off
or high-pressure grease in the cylinder may
gush out. It is enough to loosen valve (1) by
1 turn.
Keep body parts and face away from valve
(1) and loosen valve (1) carefully. Do not 2
loosen grease fitting (2). W18C-03-05-001

1. Loosen valve (1) in the adjuster cylinder. Drain

grease and loosen the track tension.
: 24 mm

2. Place a container for hydraulic oil under stop

valve (6) of accumulator (3).
6
3. Remove plug (5) from stop valve (6) of 3
accumulator (3). 4
: 9 mm

CAUTION: Do not open handle (4) quickly as

high-pressure hydraulic oil in accumulator
(3) may gush out. Keep body parts and face 5 W18C-03-05-002

away from stop valve (6) and open handle (4)

carefully.

4. Open handle (4) and drain hydraulic oil from

accumulator (3).

W18K-E-00(20181019) W3-5-1
 UNDERCARRIAGE / Adjuster Cylinder
5. Remove of the track. (Refer to REMOVAL AND 7
INSTALLATION OF TRACK on W3-8-1.)

6. Disconnect hoses (8) (2 used) from adjuster

cylinder (7). Cap the open ends.
: 19 mm, 27 mm
8

W18K-03-05-002

CAUTION: Front idler (10) weight: 860 kg

A
9 10
(1900 lb)

7. Remove front idler (10) from side frame (9).

(Refer to REMOVAL AND INSTALLATION OF
FRONT IDLER on W3-6-1.)

CAUTION: The yoke (11) assembly weight:

520 kg (1150 lb)

8. Attach a wire onto yoke (11). Pull out yoke (11) to

the position where yoke (11) can be removed 7 11 W18K-03-06-001
from adjuster cylinder (7).

13 14 15 16 17
9. Remove sems bolts (18) (2 used) from plate (19).
Remove plate (19) from brackets (17) (2 used).
: 17 mm
18
10. Remove bolts (14) (4 used) and spring washers
(13) (4 used) from brackets (17) (2 used). 19
Remove brackets (17) (2 used) from lock plates 12 20
(12) (2 used).
: 24 mm

W18K-03-06-002
View A

W18K-E-00(20181019) W3-5-2
 UNDERCARRIAGE / Adjuster Cylinder
11. Remove valve (20) from piston rod (21). 21 A
20
: 24 mm

11 W18K-03-06-001

15 16
12. Remove bolts (16) (4 used) from lock washers
(15) (2 used). Remove lock washers (15) (2
used) and lock plates (12) (2 used) from yoke
(11).
: 30 mm

CAUTION: Yoke (11) weight: 175 kg (390 lb) 12 20

13. Hoist and remove yoke (11) from piston rod (21).

W18K-03-06-002
View A
CAUTION: Adjuster cylinder (7) weight: 350
kg (780 lb)

14. Attach a nylon sling onto the groove part on

7 9
piston rod (21). Pull out adjuster cylinder (7)
partway from side frame (9). Groove Part

15. Attach a nylon sling onto the body of adjuster

cylinder (7).

16. Hoist and remove adjuster cylinder (7) from side

frame (9).

21 W18K-03-05-002

W18K-E-00(20181019) W3-5-3
 UNDERCARRIAGE / Adjuster Cylinder
Installation
• As for the method to hoist the parts and the 7 9
position of the lifting holes, refer to Removal.
11 Groove Part

CAUTION: Adjuster cylinder (7) weight: 350

kg (780 lb)

1. Hoist and insert adjuster cylinder (7) into the

position where the groove part on piston rod (21)
comes out from side frame (9).

21 W18K-03-05-002

CAUTION: Yoke (11) weight: 175 kg (390 lb)

21 A
2. Attach a nylon sling onto yoke (11). Hoist and
align yoke (11) with the mounting surface on
piston rod (21).

11 W18K-03-06-001

3. Install lock plates (12) (2 used) to the groove on

piston rod (21). Secure lock plates (12) (2 used)
to yoke (11) with bolts (16) (4 used) and lock 13 14 15 16 17
washers (15) (2 used).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 406 lbf⋅ft)
18
4. Install valve (20) to piston rod (21). 19
: 24 mm
12 20
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
21

W18K-03-06-002
View A

W18K-E-00(20181019) W3-5-4
 UNDERCARRIAGE / Adjuster Cylinder

7 11 W18K-03-06-001

13 14 17
5. Install brackets (17) (2 used) to lock plates (12)
(2 used) with bolts (14) (4 used) and spring
washers (13) (4 used).
: 24 mm 18
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
19
6. Install plate (19) to brackets (17) (2 used) with 12
sems bolts (18) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W18K-03-06-002
View A
CAUTION: The adjuster cylinder (7)
assembly weight: 52 kg (115 lb)

7. Push adjuster cylinder (7) with yoke (11) attached

into side frame (9).

CAUTION: Front idler (10) weight: 860 kg

(1900 lb) 10 11

8. Install front idler (10) to side frame (9). (Refer to

REMOVAL AND INSTALLATION OF FRONT
IDLER on W3-6-1.)

9 7 W18K-03-05-003

W18K-E-00(20181019) W3-5-5
 UNDERCARRIAGE / Adjuster Cylinder
9. Connect hoses (8) (2 used) to adjuster cylinder 7
(7).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
8

W18K-03-05-002

10. Close handle (4) and install plug (5).

: 9 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

11. Start the engine. Operate the travel control lever

in the forward direction slowly. Fill the adjuster 4
cylinder with hydraulic oil. At this time, a load is
applied so that the pressure of 12.7 MPa (130
kgf/cm2, 1850 psi) or more occurs in a travel
circuit.
W18C-03-05-002
5

1
12. Add grease through grease fitting (2) and adjust
the track tension. (Refer to REMOVAL AND
INSTALLATION OF TRACK on W3-8-1.)

2 W18C-03-05-001

W18K-E-00(20181019) W3-5-6
 UNDERCARRIAGE / Adjuster Cylinder
(Blank)

W18K-E-00(20181019) W3-5-7
 UNDERCARRIAGE / Adjuster Cylinder
DISASSEMBLY OF ADJUSTER CYLINDER

6
20
19 7
18
Cushion Side

17
Front Idler
Side
16

15
22 14
21 13
12
11
10
9
8

W144-03-03-002

1- Base Cylinder 7- Cylinder 13 - Plate 18 - Plug

2- Wear Ring (2 Used) 8- Flange 14 - U-Ring 19 - Flange
3- Backup Ring 9- Spring Washer (20 Used) 15 - Backup Ring 20 - O-Ring
4- U-Ring 10 - Bolt (20 Used) 16 - Wear Ring (2 Used) 21 - Spring Washer (8 Used)
5- Plate 11 - O-Ring 17 - Piston Rod 22 - Bolt (8 Used)
6- Retaining Ring 12 - Retaining Ring

W18K-E-00(20181019) W3-5-8
 UNDERCARRIAGE / Adjuster Cylinder
Disassembly of Adjuster Cylinder
CAUTION: Adjuster cylinder weight: 345 kg
(760 lb)
1. Place the adjuster cylinder vertically with the
cushion side facing downward.
2. Remove bolts (22) (8 used) and spring washers
(21) (8 used) from flange (19). Remove flange
(19) from base cylinder (1).
: 27 mm
CAUTION: Rod (17) weight: 67 kg (150 lb)
3. Attach a nylon sling onto the groove on piston rod
(17). Hoist and remove piston rod (17) from base
cylinder (1).
4. Remove retaining ring (12), plate (13), U-ring
(14), backup ring (15) and wear rings (16) (2
used) from piston rod (17).
W18K-E-00(20181019) W3-5-9
CAUTION: Flange (8) weight: 32 kg (71 lb)
5. Remove bolts (10) (20 used) and spring washers
(9) (20 used) from flange (8). Attach a nylon sling
onto flange (8). Hoist and remove flange (8) from
cylinder (7).
: 30 mm
CAUTION: Base cylinder (1) weight: 107 kg
(240 lb)
6. Install an eyebolt (M18, Pitch 2.5 mm) to the bolt
(22) hole (2 places) on base cylinder (1). Hoist
and remove base cylinder (1) from cylinder (7).
7. Remove retaining ring (6), plate (5), backup ring
(3), U-ring (4) and wear rings (2) (2 used) from
base cylinder (1).
 UNDERCARRIAGE / Adjuster Cylinder
ASSEMBLY OF ADJUSTER CYLINDER

20 22 21 1 11 16 15 14 13 5 6

12

17 19

10 9 8 2 3 4

Hose Valve, Hose

Mounting Hole Mounting Hole
17 18 7
8

Grease Fitting Valve

Mounting Hole
(M16, Pitch 1.5 mm)
W18K-03-06-001

1- Base Cylinder 7- Cylinder 13 - Plate 18 - Plug

2- Wear Ring (2 Used) 8- Flange 14 - U-Ring 19 - Flange
3- Backup Ring 9- Spring Washer (20 Used) 15 - Backup Ring 20 - O-Ring
4- U-Ring 10 - Bolt (20 Used) 16 - Wear Ring (2 Used) 21 - Spring Washer (8 Used)
5- Plate 11 - O-Ring 17 - Piston Rod 22 - Bolt (8 Used)
6- Retaining Ring 12 - Retaining Ring

W18K-E-00(20181019) W3-5-10
 UNDERCARRIAGE / Adjuster Cylinder
Assembly of Adjuster Cylinder 5. Install wear rings (16) (2 used), backup ring (15),
• As for the method to hoist the parts and the U-ring (14), plate (13) and retaining ring (12) to
position of the lifting holes, refer to Removal. piston rod (17).

IMPORTANT: Assemble the adjuster cylinder so

that the position of the grease fitting CAUTION: Piston rod (17) weight: 67 kg (150
valve mounting hole on right and lb)
left piston rods (17) and that of the
hose mounting hole on cylinder (7) IMPORTANT: Fill the chamber in base cylinder (1)
are located on the outside of the with grease. Push piston rod (17)
side frame. into base cylinder (1) and
IMPORTANT: Do not expose backup ring (15) to completely bleed air from base
air until the moment just before cylinder (1).
assembly due to its moisture 6. Hoist and install piston rod (17) to base cylinder
absorbability. (1).

1. Install backup ring (3), U-ring (4) and plate (5)
and retaining ring (6) to base cylinder (1).
2. Install wear rings (2) (2 used) to base cylinder
(1).
7. Install O-ring (20) to flange (19). Fill the groove
on the inner diameter of flange (19) with grease.
Install flange (19) to base cylinder (1) with bolts
(22) (8 used) and spring washers (21) (8 used).
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)

CAUTION: Base cylinder (1) weight: 107 kg

(240 lb)

3. Hoist and install base cylinder (1) to cylinder (7).

CAUTION: Flange (8) weight: 32 kg (71 lb)

4. Install O-ring (11) to flange (8). Fill the groove on

the inner diameter of flange (8) with grease.
Install flange (8) to cylinder (7) with bolts (10) (20
used) and spring washers (9) (20 used).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 406 lbf⋅ft)

W18K-E-00(20181019) W3-5-11
 UNDERCARRIAGE / Adjuster Cylinder
(Blank)

W18K-E-00(20181019) W3-5-12
 UNDERCARRIAGE / Front Idler
REMOVAL AND INSTALLATION OF FRONT
IDLER

CAUTION: Bleed air from the hydraulic oil 1

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
CAUTION: The pressure inside the adjuster
cylinder is high. As valve (1) may fly out and
the highly pressurized grease may spout out,
do not loosen valve (1) quickly and/or
2
excessively. It is enough to loosen valve (1) W18C-03-05-001

by 1 to 1.5 turns. Keep body parts and face

away from valve (1), and loosen valve (1)
carefully. Do not loosen grease fitting (2).

1. Loosen valve (1) in the adjuster cylinder and drain 6

3
grease. Loose the track.
: 24 mm 4

2. Place a container for hydraulic oil under stop valve

(6) of accumulator (3).

3. Remove plug (5) from stop valve (6) of 5 W18C-03-05-002

accumulator (3).
: 9 mm

CAUTION: Do not open handle (4) quickly as

high-pressure hydraulic oil in accumulator (3)
may gush out. Keep body parts and face away
from handle (4), and open handle (4) carefully.

4. Open handle (4) and drain hydraulic oil from

accumulator (3).

W18K-E-00(20181019) W3-6-1
 UNDERCARRIAGE / Front Idler
5. Remove the track. (Refer to REMOVAL AND
INSTALLATION OF TRACK on W3-8-1.) 7

6. Disconnect hoses (8) (2 used) from adjuster

cylinder (7).
: 19 mm, 27 mm

W18K-03-05-002

7. Attach a wire onto the hole on front idler (12).

9 10, 11 12

CAUTION: The front idler (12) assembly

weight: 1400 kg (3090 lb)

8. Hoist front idler (12). Pull out front idler (12) to the
position when bolt (10) of yoke (13) comes out
from side frame (9).

CAUTION: Front idler (12) weight: 860 kg

(1900 lb)
13 W18K-03-06-001

9. Remove bolts (10) (4 used) and washers (11) (4

used) from yoke (13). Remove front idler (12) from
yoke (13).
: 46 mm

W18K-E-00(20181019) W3-6-2
 UNDERCARRIAGE / Front Idler
Installation
1. Attach a wire onto yoke (13). Pull out half of yoke
9 10, 11 12
(13) from side frame (9) by using a forklift.

2. Attach a wire onto the hole on front idler (12).

CAUTION: Front idler (12) weight: 860 kg

(1900 lb)

3. Hoist front idler (12). Install front idler (12) to yoke

(13) with bolts (10) (4 used) and washers (11) (4
used). Push front idler (12) and adjuster cylinder
(7) to side frame (9) by using a forklift. 7 13 W18K-03-06-001

4. Connect hoses (8) (2 used) to adjuster cylinder

(7).
: 19 mm 7
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm
: 80 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

5. Install the track. (Refer to REMOVAL AND

INSTALLATION OF TRACK on W3-8-1.)
8

W18K-03-05-002

W18K-E-00(20181019) W3-6-3
 UNDERCARRIAGE / Front Idler
6. Close handle (4). Install plug (5).
: 9 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

7. Tighten valve (1) of adjuster cylinder (7). 4

: 24 mm
: 150 N⋅m (15 kgf⋅m, 111 lbf⋅ft)

8. Start the engine. Operate the travel lever in the

forward direction and fill adjuster cylinder (7) with W18C-03-05-002
5
hydraulic oil.
Add grease through grease fitting (2) and adjust
the track tension. (Refer to REMOVAL AND
INSTALLATION OF TRACK on W3-8-1.) 1

2 W18C-03-05-001

W18K-E-00(20181019) W3-6-4
 UNDERCARRIAGE / Front Idler
(Blank)

W18K-E-00(20181019) W3-6-5
 UNDERCARRIAGE / Front Idler
DISASSEMBLY OF FRONT IDLER

2
3
4
5
6

7
1

6
5
4
3
2

W144-03-04-003

1 - Pin (2 Used) 3 - Pedestal (2 Used) 5 - O-Ring (2 Used) 7 - Idler

2 - Plug (2 Used) 4 - Floating Seal (2 Used) 6 - Bushing (2 Used) 8 - Axle

W18K-E-00(20181019) W3-6-6
 UNDERCARRIAGE / Front Idler
Disassembly of Front Idler
CAUTION: The axle (8) assembly weight:
140 kg (310 Ib)
CAUTION: Front idler weight: 860 kg
(1900 Ib) 6. Remove axle (8) from idler (7) by using a press.
Pedestal (3) at the opposite side is removed with
1. Secure the front idler in a stable condition. axle (8) together.
Press
2. Remove plugs (2) (2 used) from pedestal (3).
Drain oil from pedestals (3) (2 used).
8
： 6 mm

CAUTION: Pedestal (3) weight: 42 kg (93 Ib)

7
3. Remove pin (1) by using a bar and a hammer by
tapping. Attach a nylon sling onto pedestal (3).
Remove pedestal (3) from axle (8). (One side
only)
3
4. Remove O-ring (5) from axle (8). (One side only) W146-03-07-003

5. Remove floating seal (4) from idler (7) and 7. Remove pin (1) from axle (8) by using a bar and
pedestal (3). (One side only) a hammer by tapping. Remove pedestal (3) at the
opposite side.

8. Remove O-ring (5) from axle (8).

9. Remove floating seal (4) from idler (7) and

pedestal (3).

CAUTION: Idler (7) weight: 670 kg (1480 Ib)

10. When replacing bushing (6), weld four places, 90°

apart from each others on the bushing (6) bore.
Shrink and remove bushing (6) from idler (7).

90°

90°

W105-03-05-012

W18K-E-00(20181019) W3-6-7
 UNDERCARRIAGE / Front Idler
ASSEMBLY OF FRONT IDLER

3 2
1 5 4 6

W144-03-04-001

W144-03-04-002

1 - Pin (2 Used) 3 - Pedestal (2 Used) 5 - O-Ring (2 Used) 7 - Idler

2 - Plug (2 Used) 4 - Floating Seal (2 Used) 6 - Bushing (2 Used) 8 - Axle

W18K-E-00(20181019) W3-6-8
 UNDERCARRIAGE / Front Idler
Assembly of Front Idler

IMPORTANT: Apply lubricant onto the inner 6. Install O-ring (5) and pedestal (3) on the opposite
diameter part of idler (7). side to axle (8). Align the holes on pedestal (3)
and axle (8). Install pin (1) by tapping.
1. Install bushings (6) (2 used) to idler (7) by using a
press. 3 4 5 7

2. Install O-ring (5) to axle (8). Install floating seal (4)

to idler (7) and pedestal (3). (One side only)

CAUTION: Pedestal (3) weight: 42 kg (93 Ib)

Axle (8) weight: 96kg (220 Ib)

3. Install pedestal (3) to axle (8) on the side where 8

O-Ring (5) has been installed. Align the holes on
pedestal (3) and axle (8). Install pin (1) by tapping.
(One side only) W157-03-05-005

8 7. Add engine oil through the hole on plugs (2) (2

used) of pedestals (3) (2 used).
1
Engine oil: 1.3 L (0.34 US gal,) (API class CD、
SAE30)
3
8. Install plugs (2) (2 used) to pedestals (3) (2 used).
: 6 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.2 to 2.9 Ibf·ft)
W105-03-05-014

CAUTION: The axle (8) assembly weight:

140 kg (310 Ib)

4. Attach a nylon sling onto the body of axle (8).

Hoist and install the axle (8) assembly to dler (7)
by using a press.

5. Install floating seal (4) to idler (7) and pedestal (3)

on the opposite side.

W18K-E-00(20181019) W3-6-9
 UNDERCARRIAGE / Front Idler
MAITENANCE STANDARD

D
E F

B A
C

W18C-03-06-001
W144-03-04-002

Unit: mm (1 mm = 0.03937 in)

Item Standard Allowable Limit Remedy
A : Idler Outer Dia 1045 (1015) Repair or Replace
B : Axle Outer Dia 160-0.085-0.125 (159.2) Replace
B’ : Bushing Inner Dia 160+0.480+0.420 (161) Replace
C : Bushing Flange Thickness 15-0.1-0.2 (13.5) Replace
D : Idler Outer Thickness 304 (280) Repair or Replace
E : Tread Width 144 (115) Repair or Replace
F : Flange Height 27.5 37.5 Repair or Replace
G : Reference 379.5 - -

NOTE: If welding is required for repair, refer to

Welding Repair Procedure on W3-10-1 and
the pattern drawings attached in the back
of this book.
The values in ( ) are just for reference.

W18K-E-00(20181019) W3-6-10
 UNDERCARRIAGE / Upper and Lower Rollers
REMOVAL AND INSTALLATION OF UP-
PER/LOWER ROLLERS
1
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal of Upper Roller

CAUTION: The pressure inside the adjuster

2
cylinder is high. As valve (1) may fly out and W18C-03-05-001

the highly pressurized grease may spout out,

do not loosen valve (1) quickly and/or exces-
sively. It is enough to loosen valve (1) by 1 to
1.5 turns. Keep body parts and face away
from valve (1), and loosen valve (1) carefully.
Do not loosen grease fitting (2). 6
3

1. Loosen valve (1) in the adjuster cylinder and 4

drain grease. Loose the track.
: 24 mm

2. Place a container for hydraulic oil under stop

valve (6) of accumulator (3). 5 W18C-03-05-002

3. Remove plug (5) from stop valve (6) of accumu-

lator (3).
: 9 mm

CAUTION: Do not open handle (4) quickly as

high-pressure hydraulic oil in accumulator
(3) may gush out. Keep body parts and face
away from handle (4), and open handle (4)
carefully.

4. Open handle (4) and drain hydraulic oil from ac-

cumulator (3).

W18K-E-00(20181019) W3-7-1
 UNDERCARRIAGE / Upper and Lower Rollers
5. Hoist the track as illustrated and make a gap
between the track and upper roller (8) so that Protector
upper roller (8) can be removed.
Wire rope: 36 mm × 8 m (1.4 in × 26 ft)

CAUTION: When using a power wrench, do

not injure hands by the reaction bar.

6. Remove bolts (7) (4 used) from pedestals (9) (2

used) by using a power wrench.
: 30 mm

W118-03-07-002
CAUTION: Upper roller (8) weight: 51 kg
(120 lb)
7
7. Remove upper roller (8) and pedestals (9)
(2used) from the side frame by using a forklift. 8

Side Frame

W18C-03-07-001

Installation of Upper Roller

7

CAUTION: Upper roller (8) weight: 51 kg 8

(120 lb)

1. Install pedestals (9) (2 used) to upper roller (8). 9

Install upper roller (8) to the side frame by using
a forklift or other tools.
Side Frame

CAUTION: When using a power wrench, do

not injure hands by the reaction bar.

2. Secure upper roller (8) to the side frame with

bolts (7) (4 used) by using a power wrench.
: 30 mm W18C-03-07-001

: 400 N⋅m (40 kgf⋅m, 29 5 Ibf·ft)

W18K-E-00(20181019) W3-7-2
 UNDERCARRIAGE / Upper and Lower Rollers
3. Close handle (4). Install plug (5).
: 9 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf·ft)

4. Tighten valve (1) on the adjuster cylinder.

: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 Ibf·ft)
4

5. Start the engine. Operate the travel lever in the

forward direction and fill the adjuster cylinder with
hydraulic oil. At this time, a load is applied so that
pressure of 12.7 MPa (110 kgf/cm2) or higher W18C-03-05-002
occurs in a travel circuit. 5

1
6. Apply grease through grease fitting (2) and adjust
the track sag. (Refer to REMOVAL AND IN-
STALLATION OF TRACK on W3-8-1.)

2 W18C-03-05-001

W18K-E-00(20181019) W3-7-3
 UNDERCARRIAGE / Upper and Lower Rollers

CAUTION: The pressure inside the adjuster

cylinder is high. As valve (1) may fly out and 1
the highly pressurized grease may spout out,
do not loosen valve (1) quickly and/or exces-
sively. It is enough to loosen valve (1) by 1 to
1.5 turns. Keep body parts and face away
from valve (1), and loosen valve (1) carefully.
Do not loosen grease fitting (2).

7. Loosen valve (1) in the adjuster cylinder and

drain grease. Loose the track. 2 W18C-03-05-001
: 24 mm

8. Place a container for hydraulic oil under stop

valve (6) of accumulator (3).
6
9. Remove plug (5) from stop valve (6) of accumu- 3
lator (3). 4
: 9 mm

CAUTION: Do not open handle (4) quickly as

high-pressure hydraulic oil in accumulator
(3) may gush out. Keep body parts and face 5 W18C-03-05-002

away from handle (4), and open handle (4)

carefully.

10. Open handle (4) and drain hydraulic oil from ac-
cumulator (3).

W18K-E-00(20181019) W3-7-4
 UNDERCARRIAGE / Upper and Lower Rollers
Removal of Lower Roller

1. Raise the machine as illustrated. Set a block un-

der the track frame.
90 to 110°
CAUTION: Lower roller (10) weight: 320 kg
(710 Ib)

2. Hold lower roller (10) by using a forklift. W18K-03-07-001

CAUTION: When using a power wrench, do

not injure hands by the reaction bar.

3. Remove bolts (11) (4 used) by using a power

wrench.
: 46 mm

Side Frame

10

11
W117-03-07-004

W18K-E-00(20181019) W3-7-5
 UNDERCARRIAGE / Upper and Lower Rollers
Installation of Lower Roller

CAUTION: Lower roller (10) weight: 320 kg

(710 Ib)
90 to 110°

1. Align and hold lower roller (10) with the mounting

hole on the side frame by using a forklift.

2. Temporally tighten lower roller (10) with bolts (11) W18K-03-07-001

(4 used).
: 46 mm

3. Remove the forklift.

CAUTION: When using a power wrench, do

not injure hands by the reaction bar.

4. Secure lower roller (10) to the side frame with Side Frame
bolts (11) (4 used) by using a power wrench.
： 46 mm
： 19 50 N⋅m (195 kgf⋅m, 14 40 Ibf·ft) 10

11
W117-03-07-004

W18K-E-00(20181019) W3-7-6
 UNDERCARRIAGE / Upper and Lower Rollers
5. Close handle (4). Install plug (5).
: 9 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf·ft)

6. Tighten valve (1) on the adjuster cylinder. 4

: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 Ibf·ft)

7. Start the engine. Operate the travel lever in the

W18C-03-05-002
forward direction and fill the adjuster cylinder with 5
hydraulic oil. At this time, a load is applied so that
pressure of 12.7 MPa (110 kgf/cm2) or higher 1
occurs in a travel circuit.

8. Apply grease through grease fitting (2) and adjust

the track sag. (Refer to REMOVAL AND IN-
STALLATION OF TRACK on W3-8-1.)

2 W18C-03-05-001

W18K-E-00(20181019) W3-7-7
 UNDERCARRIAGE / Upper and Lower Rollers
DISASSEMBLY OF UPPER ROLLER
7

5
4
3
2
1

1
8
2
3
4
5

9
W18C-03-07-002

3 4 5 6 7 9 2

A
B

C
W18C-03-07-003

1 - Cap (4 Used) 4 - Floating Seal (2 Used) 6 - Roller 8 - Set Screw (2 Used)

2 - Retainer (2 Used) 5 - Roller Bearing (2 Used) 7 - Plug 9 - Axle
3 - O-Ring (2 Used)

W18K-E-00(20181019) W3-7-8
 UNDERCARRIAGE / Upper and Lower Rollers
Disassembly of Upper Roller

7. Remove retainer (2) at another side in the same

CAUTION: Upper roller weight: 51 kg (120
way as steps 2 to 4. Remove O-ring (3) and
lb)
floating seal (4).
1. Remove plug (7) from roller (6). Drain engine oil
8. Remove the inner race of roller bearing (5) inside
from upper roller (6).
axle (9) by using a bar and a hammer.
: 6 mm
9. Remove the outer race of roller bearing (5) from
2. Remove cap (1) and set screw (8) from retainer
roller (6) by using a bar and a hammer.
(2). (One side only)

3. Install a bolt (M10, Pitch 1.25 mm) to the hole on

cap (1). (One side only)

4. Remove retainer (2) and O-ring (3) from axle (9)

by tapping and rotating the bolt counterclockwise
by using a plastic hammer. Remove floating seal
(4) from retainer (2). (One side only)

CAUTION: Roller (6) weight: 37 kg (82 lb)

5. Attach a nylon sling onto the body of upper roller

(6). Hoist and place roller (6) with the side with-
out retainer (2) facing upward.

6. Remove axle (9) from roller (6) by tapping the

axle (9) end by using a plastic hammer. At this
time, the inner race of roller bearing (5), retainer
(2) and floating seal (4) are removed with axle (9)
together. At the same time, the inner race of roller
bearing (5) at another side is removed from axle
(9).

W18K-E-00(20181019) W3-7-9
 UNDERCARRIAGE / Upper and Lower Rollers
ASSEMBLY OF UPPER ROLLER
7

5
4
3
2
1

1
8
2
3
4
5

9
W18C-03-07-002

3 4 5 6 7 9 2

A
B

C
W18C-03-07-003

1 - Cap (4 Used) 4 - Floating Seal (2 Used) 6 - Roller 8 - Set Screw (2 Used)

2 - Retainer (2 Used) 5 - Roller Bearing (2 Used) 7 - Plug 9 - Axle
3 - O-Ring (2 Used)

W18K-E-00(20181019) W3-7-10
 UNDERCARRIAGE / Upper and Lower Rollers
Assembly of Upper Lower
1. Install the outer races (2 used) of roller bearing
(5) to roller (6) by using a bar and a hammer.
2. Install floating seals (4) (2 used) to roller (6) and
retainers (2) (2 used).
3. Install the inner race of roller bearing (5) to axle
(9) by using a bar and a hammer. (One side only)
IMPORTANT: Tighten retainer (2) until surface (B)
of retainer (2) is flush with surface
(A) of axle (9).
4. Install O-ring (3) to axle (9). Install retainer (2) to
axle (9) by rotating clockwise. (One side only)
CAUTION: Roller (6) weight: 37 kg (82 lb)
5. Install axle (9) to roller (6) by using a press.
6. Install the inner race of roller bearing (5) at an-
other side to axle (9) by using a bar and a ham-
mer.
W18K-E-00(20181019) W3-7-11
IMPORTANT: Tighten retainer (2) until surface (B)
of retainer (2) is flush with surface
(A) of axle (9).
7. Install O-ring (3) to axle (9). Install retainer (2)
at another side to axle (9) by rotating clockwise.
8. Install set screws (8) (2 used) to retainers (2) (2
used).
9. Add engine oil through the plug (7) hole on roller
(6).
Engine oil : API class CD SAE30
Oil amount : 700 mL (0.18 US gal.)
10. Wind a seal tape onto plug (7). Install plug (7) to
roller (6).
: 6 mm
: 34 N⋅m (3.5 kgf⋅m, 25.5 lbf･ft)
 UNDERCARRIAGE / Upper and Lower Rollers
DISASSEMBLY OF LOWER ROLLER

3
4
5
7
8
2
7
1
6
5
4
W117-03-07-002
3

4 7 6 8 7 2 3 1 8 3

5 6 2
W118-03-07-004

1 - Plug (2 Used) 3 - Collar (2 Used) 5 - O-Ring (2 Used) 7 - Bushing (2 Used)

2 - Pin (2 Used) 4 - Floating Seal (2 Used) 6 - Axle 8 - Roller

W18K-E-00(20181019) W3-7-12
 UNDERCARRIAGE / Upper and Lower Rollers
Disassembly of Lower Roller

9. Remove O-rings (5) (2 used) from axle (6).

CAUTION: Lower roller weight: 320 kg (710
lb)
IMPORTANT: Do not damage roller (8) when cut-
ting bushing (7) by using gas.
1. Remove plugs (1) (2 used) from roller (8). Drain
10. If replacing bushing (7), weld four places, 90°
engine oil from roller (8).
apart from each other on the bushing (7) bore by
: 6 mm
using a welding rod. Shrink and remove bushing
(7) from roller (8). Cut and remove bushing (7) by
2. Tap and remove pin (2) from collar (3) and axle
using gas.
(6) at one side by using a bar and a hammer.
90°
NOTE: In case pin (2) cannot be removed, use a
press.
90°
CAUTION: Axle (6) + collar (3) weight: 110
kg (250 lb)

3. Remove axle (6) from roller (8) by using a press. W105-03-05-012

At this time, collar (3) at another side is removed

with axle (6) together.

4. Remove collar (3) from roller (8).

5. Remove floating seal (4) from roller (8) and collar

(3).

6. Tap and remove pin (2) from collar (3) by using a

bar and a hammer.
NOTE: In case pin (2) cannot be removed, use a
press.

CAUTION: Axle (6) weight: 83 kg (190 lb)

7. Remove collar (3) at another side from axle (6)

by using a press.

8. Remove floating seal (4) from roller (8) and col-

lar (3).

W18K-E-00(20181019) W3-7-13
 UNDERCARRIAGE / Upper and Lower Rollers
ASSEMBLY OF LOWER ROLLER

3
4
5
7
8
2
7
1
6
5
4
W117-03-07-002
3

4 7 6 8 7 2 3 1 8 3

5 6 2
W118-03-07-004

1 - Plug (2 Used) 3 - Collar (2 Used) 5 - O-Ring (2 Used) 7 - Bushing (2 Used)

2 - Pin (2 Used) 4 - Floating Seal (2 Used) 6 - Axle 8 - Roller

W18K-E-00(20181019) W3-7-14
 UNDERCARRIAGE / Upper and Lower Rollers
Assembly of Lower Roller
9. Install collar (3) to axle (6). Align the pin (2) hole.
Tap and install pin (2) by using a hammer.
CAUTION: Roller (8) weight: 175 kg (390 Ib)
10. Add engine oil through the plug (1) hole on collar
1. Install bushings (7) (2 used) into roller (8) by us-
(3).
ing a press.
Engine oil : API class CD SAE30
Oil amount : 0.9 L (0.24 US gal.)
CAUTION: Axle (6) weight: 83 kg (190 Ib)
11. Wind a seal tape onto plugs (1) (2 used). Install
2. Apply grease onto O-ring (5). Install O-ring (5) to plugs (1) (2 used) to collars (3) (2 used).
only one side of axle (6). : 6 mm
: 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf·ft)
3. Install collar (3) to axle (6) at the side with O-ring
(5) attached. Align the pin (2) hole. Tap and install
pin (2) by using a hammer.

4. Install floating seal (4) to roller (8) and collar (3)

at the side where axle (6) will be inserted.

CAUTION: Axle (6) + collar (3) weight: 110

kg (250 Ib)

5. Install the axle (6) assembly to roller (8) by using

a press.

CAUTION: The roller (8) assembly weight:

300 kg (670 Ib)

6. Attach a nylon sling onto the body of the roller (8)

assembly. Hoist and turn over the roller (8) as-
sembly.

7. Apply grease onto O-ring (5). Install O-ring (5) to

axle (6).

8. Install floating seal (4) to roller (8) and collar (3).

W18K-E-00(20181019) W3-7-15
 UNDERCARRIAGE / Upper and Lower Rollers
MAINTENANCE STANDARD

Upper Roller

296

148

A B

W144-03-05-002

Unit: mm (1 mm = 0.03937 in)

Item Standard Allowable Limit Remedy
A: Roller (Outer Dia.) 200 180 Replace
B: Tread (Outer Dia.) 236 (214) Replace
C: Tread Width 21 (10) Replace
NOTE: The values in ( ) are for reference only.

W18K-E-00(20181019) W3-7-16
 UNDERCARRIAGE / Upper and Lower Rollers
Lower Roller

426

C A 390

W144-03-05-004

Unit: mm (1 mm = 0.03937 in)

Item Standard Allowable Limit Remedy
A: Roller (Outer Dia.) 330 300 Replace
B: Tread Interval (Outer Dia.) 316 (350) Replace
-0.085
C: Axle (Outer Dia.) 145 -0.125 (144.2) Replace
D: Bushing (Flange Thickness) 15-0.1-0.2 (13.5) Replace
NOTE: The values in ( ) are for reference only.

W18K-E-00(20181019) W3-7-17
 UNDERCARRIAGE / Upper and Lower Roller
(Blank)

W18K-E-00(20181019) W3-7-18
 UNDERCARRIAGE / Track
REMOVAL AND INSTALLATION OF TRACK
Track Wooden Block Side Frame
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Set a wooden block between the side frame and W146-03-09-006

the track.
NOTE: Size of wooden block (Reference)
L 600 mm (23.6 in), W 300 mm (11.8 in), H
430 mm (16.9 in)
1
CAUTION: The pressure inside the adjuster
cylinder is high. As valve (1) may fly out and
the highly pressurized grease may spout out,
do not loosen valve (1) quickly and/or
excessively. It is enough to loosen valve (1)
by 1 to 1.5 turns.
Keep body parts and face away from valve (1),
and loosen valve (1) carefully. Do not loosen
grease fitting (2). 2 W18C-03-05-001

2. Loosen valve (1) in the adjuster cylinder. Drain

grease and loosen the track.
: 24 mm
NOTE: Operate the machine in reverse with valve 6
3
(1) loosened and loosen the track more.
4
3. Place a container for hydraulic oil under stop valve
(6) of accumulator (3).

4. Remove plug (5) from stop valve (6) of

accumulator (3). 5 W18C-03-05-002

: 9 mm

W18K-E-00(20181019) W3-8-1
 UNDERCARRIAGE / Track

CAUTION: Do not open handle (4) quickly as

high-pressure hydraulic oil in accumulator (3)
6
may gush out. Keep body parts and face away 3
from handle (4) and open handle (4) carefully.
4

W18C-03-05-002

5. Open handle (4) and drain hydraulic oil from

accumulator (3). 8
7
6. Close handle (4).
NOTE: If starting the engine and operating the
travel lever with handle (4) open, hydraulic 9
oil gushes out from stop valve (6).

W142-03-07-001

7. Extend lock pin (9). Remove lock pin (9) from

master pin (7).
: 46 mm

8. Remove master pin (7) from track link (8) by using

a bar and a hammer. Remove track link (8).

9. Raise the machine. Place a stand under the track

frame and support the machine. W18K-03-07-001

CAUTION: Track weight: 8640 kg (19100 lb) Wooden Block Side Frame
Front
10. Remove the track from the bottom of the side
frame.
Front Idler

W146-03-09-003

W18K-E-00(20181019) W3-8-2
 UNDERCARRIAGE / Track
Installation
CAUTION: Track weight: 8640 kg (19100 lb) Side Frame Wooden Block 10

IMPORTANT: Check the direction of the track. Front

Face the casting number of the shoe
to the inside of the side frame.
1. Set a wooden blocks on the side frame. Raise the
machine.
NOTE: Size of wooden block (Reference)
L 600 mm (23.6 in), W 300 mm (11.8 in), H W146-03-09-004

430 mm (16.9 in)

10
Forward

2. Set the track under the side frame. Lower the Front
machine on the track. Hoist the travel device (10)
side of the track. Mesh the claws of the track with
travel device(10).

3. Start the engine and slowly operate the travel

W146-03-09-005
lever forward. Wind the track while rotating travel
device (10).
11 8
4. Install and tighten chain blocks (11, 12) to the joint
part of the track. Tighten them at the opposite side
in the same way.

CAUTION: When aligning the master pin (7) 7

hole on track link (8), do not insert the fingers
into the hole.

5. Align the master pin (7) hole on track link (8) while
adjusting chain blocks (11, 12). Install master pin
(7) by using a bar and a hammer. 12 W18C-03-08-001

W18K-E-00(20181019) W3-8-3
 UNDERCARRIAGE / Track
6. Install lock pin (9) master pin (7) by using a
hammer.
Bend and secure lock pin (9). 7 8

W142-03-07-001

7. Install plug (5) to stop valve (6).

: 9 mm 6
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

5 W18C-03-05-002

1
8. Tighten valve (1) of the adjuster cylinder.
: 24 mm
: 147 N⋅m (15 kgf⋅m, 111 lbf⋅ft)

9. Raise the machine. Turn the track forward and

reverse by two turns.

2 W18C-03-05-001
10. Turn the track reverse by 1/4 turn.
NOTE: Turn the track in reverse direction so that
the track sag faces downward.

11. Add grease through grease fitting (2) and adjust

the track tension.
Track sag specifications (A): 570 to 640 mm (22.4
to 25.2 in)
NOTE: Clean the side frame and the track before
measuring the track tension.
A

W18K-03-08-001

W18K-E-00(20181019) W3-8-4
 UNDERCARRIAGE / Track
STRUCTURE OF TRACK

1 2 3

7 6 5 4

8 9 5 4

W18K-03-08-002

12 11 10

1 - Track Link 4 - Lock Pin 7 - Master Bushing 10 - Bolt

2 - Master Track Link 5 - Master Pin 8 - Nut 11 - Washer
3 - Bushing 6 - Collar 9 - Shoe 12 - Pin

W18K-E-00(20181019) W3-8-5
 UNDERCARRIAGE / Track
MAINTENANCE STANDARD

D
E
F

W18K-03-08-003
350

Unit: mm (1 mm = 0.03937 in)

Item Standard Allowable Limit Remedy
A: Shoe Height 20 0 Replace
B: Link Height 197 186.6 Replace
C: Link Thickness 84 (70) Replace
+0.05
D: Link Pin Outer Diameter 70.51 0 (64) Replace
+0.03
E: Master Pin Outer Diameter 70 0 (66) Replace
F: Bushing Outer Diameter 110+0.50 100.3 Replace
F’: Bushing Inner Diameter 71.2+0.50 (82) Replace
G: Link Pitch *1270 *1296.5 Replace
*: The dimension of four links.
NOTE: The values in ( ) are for reference.

W18K-E-00(20181019) W3-8-6
 UNDERCARRIAGE / Accumulator
REMOVAL AND INSTALLATION OF AC-
CUMULATOR

IMPORTANT: Bleed air from the hydraulic oil tank 1

before doing any work. (Refer to
BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

Removal
CAUTION: The pressure Inside of adjuster
cylinder is high. As valve (1) may fly out and
the highly pressurized grease may spout out, 2 W18C-03-05-001
do not loosen valve (1) quickly and/or exces-
sively. It is enough to loosen valve (1) by only
one turn.
Keep body parts and face away from valve
(1) and loosen valve (1) carefully. Do not
loosen grease fitting (2). 6
3
1. Loosen valve (1) in the adjuster cylinder and 4
drain grease. Loose track as well.
: 24 mm

2. Place a container for hydraulic oil under stop

valve (6) of accumulator (3).
W18C-03-05-002
5
3. Remove plug (5) from stop valve (6) of accumu-
lator (3).
: 9 mm

CAUTION: Do not open handle (4) quickly as

high-pressure hydraulic oil in accumulator
(3) may gush out. Keep body parts and face
away from stop valve (6) and open stop valve
(4) carefully.

4. Open handle (4) and drain hydraulic oil from ac-

cumulator (3).

W18K-E-00(20181019) W3-9-1
 UNDERCARRIAGE / Accumulator
5. Disconnect hose (7) from accumulator (3). Cap 7
the open ends. Attach an identification tag onto
the hose for assembling.
: 36 mm

CAUTION: Accumulator (3) weight:

95 kg (210 lb) 8

6. Hold accumulator (3) by using a chain block. 9

Remove nuts (9) (8 used) and U-bolts (8) (2 10
used) from accumulator (3). Remove accumula-
tor (3) from bracket (10).
: 24 mm
3
M144-07-109

W18K-E-00(20181019) W3-9-2
 UNDERCARRIAGE / Accumulator
Installation 7
CAUTION: Accumulator (3) weight:
95 kg (210 lb)
1. Hoist accumulator (3) by chain block. Install ac-
cumulator (3) to bracket (10) with U-bolts (8) (2
used) and nuts (9) (8 used).
: 24 mm 8
: 210 Nm (21.5 kgfm, 156 lbfft)
9
2. Connect hose (7) to accumulator (3). 10
: 36 mm
: 175 Nm (18 kgfm, 129 lbf ft)

3. Close handle (4). Install plug (5). 3

M144-07-109
: 9 mm
: 30 Nm (3 kgfm, 21.5 Ibf·ft)

4. Tighten valve (1) in the adjuster cylinder.

: 24 mm
4
: 147 Nm (15 kgfm, 108 Ibf·ft)

5. Start the engine. Operate the travel lever in the

forward direction. Fill the adjuster cylinder with
hydraulic oil. At this time, a load is applied so that W18C-03-05-002
the pressure of 12.7 MPa (130 kgf/cm2, 1850 psi) 5
or more occurs in a travel circuit.
1
6. Add grease through grease fitting (2) and adjust
the track sag. (Refer to REMOVE AND INSTAL-
LATION OF TRACK on W3-8-1.)

2 W18C-03-05-001

W18K-E-00(20181019) W3-9-3
 UNDERCARRIAGE / Accumulator
DISASSEMBLY OF ACCUMULATOR

26

25

24
23

22

21
1

20

19

18

17
16
2
15

3
14
4

13 7

10

11

12

W118-03-08-003

1 - Shell 8- Backup Ring 15 - O-Ring 22 - O-Ring

2 - Oil Port Assembly 9- Spacer 16 - Gas Plug 23 - Gas Valve
3 - Gasket 10 - Lock Nut 17 - Retaining Ring 24 - Cap
4 - Bleed Plug 11 - O-Ring 18 - Washer 25 - Wire
5 - Retaining Ring 12 - Bushing 19 - O-Ring 26 - Valve Guard
6 - Washer 13 - Bladder 20 - Backup Ring
7 - O-Ring 14 - Valve Stem 21 - Ring

W18K-E-00(20181019) W3-9-4
 UNDERCARRIAGE / Accumulator
Disassembly of Accumulator
CAUTION: As the accumulator is charged
with high pressure gas, do not weld or torch-
cut it, nor expose the accumulator to the
flame.
1. Before disassembling, clean the outer surface of
the accumulator. Cut and remove wire (25). Re-
move valve guard (26) from valve stem (14).
2. Remove cap (24) from valve stem (14) of bladder
(13).
IMPORTANT: Before installing the charge valve,
turn handle (A) counterclockwise
and handle (B) clockwise.
3. Install the charge valve (Parts Number: 4032854)
to valve stem (14). Turn handle (A) clockwise.
Carefully turn handle (B) counterclockwise and
release nitrogen gas from bladder (13) until the
gauge shows zero pressure.
A
B
7. Remove backup ring (20), O-ring (19) and wash-
er (18) from gas plug (16).
8. Turn over shell (1). (Face the oil port assembly
(2) side upward.)
9. Remove bleed plug (4) from oil port assembly (2).
Remove lock nut (10) from oil port assembly (2)
by using a hooked wrench.
10. Remove spacer (9) from oil port assembly (2).
11. Remove backup ring (8), O-ring (7) and washer
(6) from oil port assembly (2).
12. Put the fingers in shell (1). Pick up and remove
retaining ring (5) from shell (1) by fingers.
13. Remove oil port assembly (2) from shell (1).
14. Put the fingers in shell (1) through the hole on the
oil port assembly (2) side and pick up bladder
(13) by fingers. Remove bladder (13) from shell
(1).
15. Remove retaining ring (17), gas plug (16) and
O-ring (15) from valve stem (14).

Charge Valve

Accumulator W115-03-08-029

4. Remove the charge valve from valve stem (14).

5. Carefully loosen gas valve (23) and remove gas

valve (23) from valve stem (14).

6. Remove ring (21) from valve stem (14) by using

a hooked wrench.

W18K-E-00(20181019) W3-9-5
 UNDERCARRIAGE / Accumulator
ASSEMBLY OF ACCUMULATOR

12 11 2 10 9 5 13 1 17 16 21 14 25 26

3 4 8 7 6 15 18 19 20 22 23 24
W118-03-08-002

1 - Shell 8- Backup Ring 15 - O-Ring 22 - O-Ring

2 - Oil Port Assembly 9- Spacer 16 - Gas Plug 23 - Gas Valve
3 - Gasket 10 - Lock Nut 17 - Retaining Ring 24 - Cap
4 - Bleed Plug 11 - O-Ring 18 - Washer 25 - Wire
5 - Retaining Ring 12 - Bushing 19 - O-Ring 26 - Valve Guard
6 - Washer 13 - Bladder 20 - Backup Ring
7 - O-Ring 14 - Valve Stem 21 - Ring

W18K-E-00(20181019) W3-9-6
 UNDERCARRIAGE / Accumulator
Assembly of Accumulator
1. Install O-ring (15), gas plug (16) and retaining
ring (17) to valve stem (14).
2. Insert the head of pulling rod special tool (NOK
special tool No.: TAT150-10/B) into shell (1)
through the hole on the valve stem (14) side. Pull
out the head of pulling rod special tool from the
opposite side. Install the head of pulling rod spe-
cial tool (NOK special tool No.: TAT150-10/B) to
valve stem (14). Insert bladder (13) and valve
stem (14) into shell (1).
12. Install gasket (3) and bleed plug (4) to oil port
assembly (2).
13. Turn over shell (1). (Face the valve stem (14)
side upward.)
IMPORTANT: After charging with nitrogen gas,
smear gas valve (23) with soap
bubble and check gas leakage.
14. Install gas valve (23) with O-ring (22) attached to
valve stem (14). Charge bladder (13) with nitro-
gen gas by using a charge valve. (Refer to
Charging Nitrogen Gas on W3-9-10.)

Head

Pulling Rod Charge Valve

W18N-03-10-012

3. Pull out valve stem (14) from shell (1) by using

pulling rod special tool (NOK special tool No.: Nitrogen Gas
Accumulator Cylinder
TAT150-10/B). W18B-03-10-001

4. Install washer (18), O-ring (19) and backup ring
(20) to gas plug (16).
5. Tighten ring (21) to gas plug (16) by using a
hooked wrench.
6. Turn over shell (1). (Face the oil port assembly
(2) mounting side upward.)
15. Install cap (24) to gas valve (23).
16. Install valve guard (26) to valve stem (14). Tight-
en valve guard (26).
17. Connect wire (25) to valve guard (26) and ring
(21).

7. Install oil port assembly (2) to shell (1).

8. Pick up and insert retaining ring (5) into shell (1)

by fingers.

9. Remove oil port assembly (2). Align oil port as-

sembly (2) with retaining ring (5).

10. Install washer (6), O-ring (7) and backup ring (8)
to the groove on oil port assembly (2).

11. Install spacer (9) and lock nut (10) to oil port as-
sembly (2).
Tighten lock nut (10) by using a hooked wrench.

W18K-E-00(20181019) W3-9-7
 UNDERCARRIAGE / Accumulator
Maintenance

IMPORTANT: Perform the check of gas pressure

once a year for function mainte-
nance of accumulator.
The accumulator bladder has been charged with
high-pressure nitrogen gas of 9.8 MPa (100 kgf/cm2,
1420 psi).
Accumulator malfunctions are mainly caused by
damage in the bladder. If the following symptoms are
found, disassemble the accumulator and check the
bladder. If the bladder is damaged, replace the blad-
der with a new one and recharge the bladder with ni-
trogen gas.

・ Gas leaks from the bleed plug when the plug is

loosened.
・ Mixture of gas and oil gushes from the stop valve
when draining hydraulic oil from the accumulator.
・ The gas pressure in bladder is extremely low.
・ The pressure gauge reading of the charged gas
pressure in bladder is 0 MPa (0 kgf/cm2, 0 psi).
・ Oil mist gushes from the charge valve assembly
port when discharging gas.

Use the charge valve and hose assembly when

checking gas pressure in the bladder and charging
the bladder with nitrogen gas.

1-1
Number Charge Valve Assembly
1 2-2
1-2 1 Charge Valve
2-1 1-1 Pressure Gauge
1-2 Plug
2 1-3 Joint
2-3 2 Hose Assembly
2-1 Hose
1-3 2-2 Joint
2-3 Connector

Parts No. 4032854

Nitrogen Gas Tank

Accumulator

W115-03-08-032

W18K-E-00(20181019) W3-9-8
 UNDERCARRIAGE / Accumulator
Check of Gas Pressure

1. Bleed air from the hydraulic oil tank.

Remove the plug. Slowly open the stop valve and Accumulator
drain hydraulic oil from the accumulator
: 19 mm
: 29.5 Nm (3 kgfm, 21.5 lbfft)

2. Disconnect wire (25). Remove valve guard (26)

and cap (24) from the accumulator.
Before installing the charge valve, turn handle (A)
counterclockwise and handle (B) clockwise.
Stop
Install the charge valve onto valve stem (14) of Valve
the accumulator. Plug
W118-03-08-001

3. Slowly turn handle (A) clockwise and open gas

valve (23) of the accumulator. Wait one minute A
and read the pressure value shown on the pres-
sure gauge
Specified pressure value: Pressure
9.80.5 MPa (1005 kgf/cm2, 142071 psi) at 20 Gauge
B
C (68 F).
Charge Valve
4. If the gas pressure is less than 8.3 MPa (85
kgf/cm2, 1210 psi), charge nitrogen gas into Valve Stem
bladder (13) according to Charging Nitrogen Gas
on W3-9-10.
Accumulator
5. After checking, turn handle (A) counterclockwise
and close gas valve (23). Turn handle (B) coun- W115-03-08-028

terclockwise and release the residual gas in the A

charge valve.
B
6. Remove the charge valve from the accumulator.
Check gas valve (23) for gas leaks. Install cap Charge Valve
(24), valve guard (26) and connect wire (25) to
the accumulator.

7. Close the stop valve and install the plug.

: 19 mm
: 29.5 Nm (3 kgfm, 21.5 lbfft)

W115-03-08-029

13 14 25 26

23 24

W118-03-08-002

W18K-E-00(20181019) W3-9-9
 UNDERCARRIAGE / Accumulator
Charge Nitrogen Gas

1. Remove the valve guard and he cap from the

accumulator. Before installing the charge valve, A C
turn handle (A) counterclockwise and handle (B)
B
clockwise. Then, install the charge valve to valve
stem (14) of the accumulator.

2. Connect the hose assembly to the charge valve

and the nitrogen gas tank. Install handle (C) to
the gas tank valve.

3. Lightly turn handle (C) and open the nitrogen gas

tank valve.
Lightly turn handle (B) counterclockwise and re-
lease the residual gas in the hose assembly.
Close handle (B). Nitrogen Gas Tank

Accumulator W18B-03-10-001
4. Turn handle (A) clockwise and charge the blad-
der with nitrogen gas.
Gas Pressure
Check the charged gas by opening or closing 2
(kgf/cm )
handle (C) by a reasonable amount. Close han-
dle (C) when the charged gas pressure reaches
11.8 MPa (123 kgf/cm2, 1710 psi). 110 2
107 kgf/cm
NOTE: Accumulator N2 gas capacity: 18.2 L (4.8
US gal). 2
100 kgf/cm
100
2
93 kgf/cm

90
5. Carefully turn handle (B) counterclockwise and
release gas pressure in the bladder until it
reaches 9.80.5 MPa (1005 kgf/cm2, 142071
psi ). Close handle (B). 0 10 20 30 40
W115-03-08-033
Temperature (C)

CAUTION: The charged gas pressure in the

bladder varies depending on the temperature
as shown in right diagram. Temperature Gas Pressure

6. Turn handle (A) counterclockwise. Close the gas (°C) (°F) kpa (psi)
valve. Check the gas valve for gas leakage. Re- (kgf/cm2)
move the charge valve from the accumulator. A 0 0 93 1322
B 20 68 100 1422
C 40 104 107 1522

W18K-E-00(20181019) W3-9-10
 UNDERCARRIAGE / Welding Repair Procedure
WELDING REPAIR PROCEDURE

Preparation
Equipment Required
Welder and Accessories ×1 unit
Welding Rods ×1 set
Standard Tools ×1 set
Grinder ×1 unit
Gas Torch ×1 set
Touch Up Paint ×1 unit
Thermal Chalks (Thermocrayon) ×1 set

Precautions for Welding:

1. Attach the ground cable as near as possible to
the welding area. If the ground cable is far from
the welding area, the electrical equipment or
other components may be damaged.
2. Be careful not to produce welding defects such
as under cuts when welding.
3. Be careful not to damage other components by
spattering during welding.
4. Be sure to make welding beads smooth and flat
with a grinder.
5. Before performing grinder work, be sure to wear
safety glasses or goggles.

Thermal Chalks
For correct welding, use thermal chalk
(thermocrayon) to measure the temperature of the
components to be welded before and after the
welding.

Thermal Chalk Specification: M-300 (250 to 300 °C,

482 to 572 °F)

How to use thermal chalks:

Mark the preheated components with thermal chalk. Thermal Chalk
If the chalk mark is melted, the temperature of the
component is higher than the regulated temperature.
Do not use thermal chalk while heating the
components.

W115-03-11-001

W18K-E-00(20181019) W3-10-1
 UNDERCARRIAGE / Welding Repair Procedure
WELDING ROD SPECIFICATION

IMPORTANT: In order to dry the welding rods, NOTE: 1 °C=1.8 °C+32

heat them to 300 to 350 °C for one 1 mm=0.03937 in
hour before using.

Welding Rods for Underlaying: JIS Z 3211 D4316

Shinko Make LB26×4 mm dia. or equivalent to AWS
7016, BSE 614 H

Example of Chemical Composition(%) of Deposited Metal

C Si Mn P S
0.08 0.44 0.97 0.013 0.009

Example of Mechanical Properties of Deposited Metal

Yield Point Breaking Strength Elongation Absorption Energy Heat
N / mm2 (kgf / mm2) N / mm2 (kgf / mm2) % J (kgf⋅m) Treatment
470 (48) 540 (55) 33 220 (22) As Welded
410 (42) 500 (51) 34 240 (24) 620 °C×1 hr

Dimensions and Current Range (AC or DC ⊕)

Rod Diameter (mm) 2.0 2.6 3.2 4.0 5.0 6.0 7.0 8.0
Rod Length (mm) 300 350 350 400 450 450 450 450
Flat Welding 35 to 60 55 to 85 100 to 140 140 to 190 190 to 250 260 to 320 300 to 380 340 to 440
Current
Vertical
Range (A)
Overhead 30 to 55 50 to 80 90 to 130 120 to 180 160 to 210 - - -
Welding

Welding Rods for Overlaying:

JIS DF 2A-450-B Shinko Make HF-450×5 mm dia.
or Philip 450 or Acrossdiamond 500

Example of Chemical Composition (%) of Deposited Metal

C Si Mn P S Cr Mo V
0.20 1.21 0.39 0.011 0.008 2.54 0.57 0.30

Example of Hardness of Deposited Metal (Vickers Hardness)

As Welded Heat Treatment
Pre-Heat Temperature / Pre-Heat Temperature /
Temperature between Temperature between 550 °C×6 hrs 625 °C×6 hrs
Welding Paths (150 °C) Welding Paths (300 °C)
452 408 443 348

Dimensions and Current Range (AC or DC⊕)

Rod Diameter (mm) 4.0 5.0 6.0
Rod Length (mm) 400 400 450
Current Range (A) Flat welding 140 to 180 190 to 240 220 to 300
Rod End Color: Red
Derivative Color: Pink

W18K-E-00(20181019) W3-10-2
 UNDERCARRIAGE / Welding Repair Procedure
REPAIR TRACK SHOE (SHOE LUG)
Unit: mm
1. Refer to the drawing on the right for new shoe
dimensions. New Shoe Dimension

120

35

120
W144-03-08-006

NOTE: 1 mm=0.03937 in

2. When the shoe has worn to the dimension as Allowable Limit of Shoe Dimension
shown in the drawing, repair the shoe by
following steps 3 to 7. Welding Area

100

Welding Area

W144-03-08-007
100

NOTE: 1 mm=0.03937 in

W18K-E-00(20181019) W3-10-3
 UNDERCARRIAGE / Welding Repair Procedure
3. Prepare reinforcement materials. Prepare one
piece of reinforcement (1) and two pieces of Unit: mm
30
reinforcement (2, 3, and 4) conforming to the C15
dimensions as shown to the right. 26

Material: SMn 443H (JIS G4052, SAE 154H) or

Equivalent
26

Section A W144-03-08-001

NOTE: 1 mm=0.03937 in
1

C15
A
680

W144-03-08-002

A
180

W144-03-08-003

A
150

W144-03-08-004

A
120

W144-03-08-004

W18K-E-00(20181019) W3-10-4
 UNDERCARRIAGE / Welding Repair Procedure
4. Preheat the shoe to 150 to 250 °C (302 to 482
°F) with a gas burner . Measure preheating
temperature with thermal chalk.
5. Weld the reinforcement materials. Perform
cladding by welding with HF-260 electrodes
Hardsurfacing (JIS: Z3251 DF2A-300-B) or
equivalent.

NOTE: Current conforming to the electrode di- Precautions for Repair welding
ameter: • Make as a small weld bead as possible.
4.0 mm dia. Electrode: 14 to 180 (284 to • Remove slag on the weld beads by t apping with a
356 °F) ampere hammer.
• Maintain the base metal temperature at 300 °C (572
5.0 mm dia. Electrode: 190 to 240 (374 to
°F) or lower between welding paths.
464 °F) ampere
• Prevent cracks by tapping the weld bead.

Unit: mm
NOTE: 1 mm = 0.03937 in

Finish the toe of weld smoothly.

680

Finish the toe of weld smoothly. 120 130 150

Weld
26

100

Section A Section B
Reinforcement Material (1)
26

Reinforcement Material (3) Reinforcement Reinforcement Material (4)

Material (2) W144-03-08-008

6. Immediately after cladding by welding, heat to

500 to 550 °C (932 to 1022 °F). Then, leave it to
cool at room temperature.
7. Check if any cracks ex ist on the welded sections Hammering
by liquid penetrant inspection.

W144-03-08-009

W18K-E-00(20181019) W3-10-5
 UNDERCARRIAGE / Welding Repair Procedure
REPAIR FRONT IDLER

1. Clean the front idler and remove rust, dust, soil,

or surface roughness with a grinder before doing
any repair welding.

W144-03-08-010

IMPORTANT: Correctly measure prehearting tem-

perature with thermal chalk.

2. Preheat the front idler to 200 to 250 °C (392 to

482 °F) with a gas burner.

W144-03-08-011

IMPORTANT: Check if any cracks exist on the

weld beads by visual inspection.
Even if the wear amount is 5 to 6 Thermal Chalk
mm (0.19 to 0.24 in) or less, place 2
to 3 layers of underlay welding by
minimum 5 to 6 mm (0.19 to 0.24 in)
thick.
During welding, maintain the base
metal temperature at 200 and 250 °C
(392 to 482 °F) between welding
paths.
W144-03-08-013
3. Perform underlay welding first with LB26
electrodes or equivalent.

W144-03-08-012

W18K-E-00(20181019) W3-10-6
 UNDERCARRIAGE / Welding Repair Procedure
IMPORTANT: During welding, maintain the base
metal temperature at 200 and 250 °C
(392 to 482 °F) between welding
paths.

4. Perform cladding by welding with HF-450

electrodes or equivalent.

W144-03-08-014

Glass Wool

5. After heat treatment, avoid cooling the front idler

quickly. Use glass wool. Always allow the base
metal to cool slowly.

W144-03-08-015

6. After 24 hours, remove glass wool. Check if any

cracks exist on the welded sections by liquid
penetrant inspection.

7. Finish the front idler surface in the correct form

using a grinder. Use the attached paper pattern
to check the contour.

W144-03-08-016

W18K-E-00(20181019) W3-10-7
 UNDERCARRIAGE / Welding Repair Procedure
REPAIR SPROCKET

1. Clean the sprocket and remove rust, dust, soil, or

surface roughness before doing any repair
welding.

W144-03-08-018

IMPORTANT: Correctly measure prehearting

temperature with thermal chalk.

2. Pre-heat the sprocket to 200 to 250 °C (392 to

482 °F) with a gas burner.

W144-03-08-019

Thermal Chalk

W144-03-08-021

IMPORTANT: During welding, maintain the base

metal temperature at 200 and 250 °C
(392 to 482 °F) between welding
paths.

3. Perform the underlay welding first with LB26

electrodes or equivalent.

W144-03-08-020

W18K-E-00(20181019) W3-10-8
 UNDERCARRIAGE / Welding Repair Procedure
IMPORTANT: During welding, maintain the base
metal temperature at 200 and 250 °C
(392 to 482 °F) between welding
paths.

4. Perform cladding by welding with HF-450

electrodes or equivalent.

W144-03-08-022

5. After heat treatment, avoid cooling the sprocket

Glass Wool
quickly. Use glass wool. Always allow the base
metal to cool slowly.

W144-03-08-023

6. After 24 hours, remove glass wool. Check if any

cracks exist on the welded sections by liquid
penetrant inspection.

W144-03-08-024

7. Finish the sprocket surface in the correct form

using a grinder. Use the attached paper patterns
A and B to check the contour.

W144-03-08-025

W18K-E-00(20181019) W3-10-9
 UNDERCARRIAGE / Welding Repair Procedure
(Blank)

W18K-E-00(20181019) W3-10-10
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W18K-E-00(20181019)
 MEMO

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W18K-E-00(20181019)
 SECTION 4
FRONT ATTACHMENT

CONTENTS
Group 1 Front Attachment
Removal and Installation of
Front Attachment ................................... W4-1-1

Group 2 Cylinder
Removal and Installation of Cylinder ....... W4-2-1
Disassembly of Cylinder ........................ W4-2-35
Assembly of Cylinder ............................. W4-2-44
Main Points to Bleed Air ........................ W4-2-50
Maintenance Standard........................... W4-2-52

Group 3 Bushing and Point

Removal and Installation of Bushing........ W4-3-1
Maintenance Standard............................. W4-3-4

W18K-E-00(20181019) 18KW-4-1
(Blank)

W18K-E-00(20181019) 18KW-4-2
 FRONT ATTACHMENT/ Front Attachment
REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT Hydraulic
Hose
Lubrication
CAUTION: Bleed air from the hydraulic oil Hose
tank. Stop the engine. Operate the control
lever several times and release any
remaining pressure in the circuit. (Refer to
BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal of Front Attachment (Loading Shovel)

1. Disconnect the hydraulic hoses (8 used) and the

lubrication hoses (7 used) between the arm and
the bucket from the arm side. Install the plated W18B-04-01-015
plug to the open end.
: 36 mm
: 14 mm
Boom
2. Disconnect the lubrication hose between the
Lubrication
boom and the arm. Hose
: 36 mm

Arm

W18B-04-01-022

3. Disconnect the lubrication hoses (2 used) at the Level Cylinder Lubrication

arm cylinder rod pin part and the level cylinder Hose
rod side from the cylinder rod side.
: 19 mm

Arm Cylinder
W18C-04-01-001

W18K-E-00(20181019) W4-1-1
 FRONT ATTACHMENT/ Front Attachment
4. Remove the bucket cylinders (2 used). (Refer to
REMOVAL AND INSTALLATION OF BUCKET
Bucket
CYLINDER on W4-2-16.) Cylinder

W18B-04-01-017

110 mm (4.3 in)

5. Remove O-rings (2 used) at the end of the arm Bolt

from the bucket boss part. (M5, Pitch: 0.8 mm)

NOTE: O-ring cannot be re-used. When installing, Double Nut and

replace O-ring with the new one. Washer on Both
Right and Left

O-Ring (1A)

Detail of O-Ring W18G-04-01-014

CAUTION: Bucket weight: 15100 kg (33300

lb)

6. Install a shackle, a wire and a chain block to the

lifting bracket (2 places) for the bucket. Hold the
bucket. Lifting
Bracket

Bucket

W18B-04-01-018

W18K-E-00(20181019) W4-1-2
 FRONT ATTACHMENT/ Front Attachment

Arm

Bucket

W18B-04-01-076
7. Remove bolts (2) (8 used) and spring washers Arm
(3) (8 used) from stoppers (4) (2 used) for the Bucket
arm end pin. Remove stoppers (4) (2 used) from
the bucket.
: 30 mm 2, 3

1
CAUTION: Pin (1) weight: 91 kg (210 lb)

8. Pull out pins (1) (2 used) to the position where

the arm can be removed from the bucket. Wind a
nylon sling onto the bodies of pins (1) (2 used). 4
Hoist and remove pins (1) (2 used) from the
bucket.

9. Hoist and remove the bucket from the arm.

Remove shims (5) (4 used) from the pin hole. 5
W141-04-01-002

10. Start the engine. Place the arm end on the

wooden block.
Arm

Wooden W18C-04-01-002
Block

W18K-E-00(20181019) W4-1-3
 FRONT ATTACHMENT/ Front Attachment
11. Bleed air from the hydraulic oil tank. Stop the
engine. Operate the control lever several times
and release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
6, 7, 8, 9, 10
TANK on W1-4-1.)

12. Remove nuts (9) (16 used) from bolts (6) (8 used).
Remove plates (10) (2 used), clamps (8) (8 used),
washers (7) (8 used) and bolts (6) (8 used) from
the hoses (6 used).
: 19 mm

13. Disconnect the hoses (6 used) between the

boom and the arm from the arm side. Install the
plated plug to the open end.
: 14 mm W18C-04-01-003

CAUTION: Arm weight: 6700 kg (14800 lb) Machine

Body Side
Lifting
14. Install a shackle, a wire and a chain block to the Bracket
lifting bracket (2 places) for the arm. Hoist and
hold the arm.

W141-04-01-006

W18K-E-00(20181019) W4-1-4
 FRONT ATTACHMENT/ Front Attachment

CAUTION: Level cylinder weight: 1370 kg Lifting Bracket

(3020 lb) Level Cylinder
Arm cylinder weight: 1660 kg (3660 lb)

15. Attach a chain block between the lifting bracket

for the boom bottom plate and the rod side of the
cylinder tube. Hold the level cylinder and the arm
cylinder.

16. Pull out the pin of the level cylinder rod end to the
position where the cylinder rod can be removed.
Arm Cylinder
At this time, leave the pin inside the arm without W18B-04-01-028

removing.

17. Start the engine and retract the lever cylinder.

Secure the rod part to the cylinder tube by using
a wire in order not to come out.
Arm
18. Pull out the pin of the arm cylinder rod end to the
position where the cylinder rod can be removed.
At this time, leave the pin inside the arm without
removing.

19. Start the engine and retract the arm cylinder. W18B-04-01-026
Secure the rod part to the cylinder tube by using
a wire in order not to come out. Arm
Boom
20. Remove bolts (12) (4 used) and spring washers
12, 13
(13) (4 used) from plates (14) (2 used). Remove
plates (14) (2 used) from the boom.
: 36 mm
11 14

CAUTION: Pin (11) weight: 150 kg (340 lb)

21. Pull out pins (11) (2 used) to the position where

the arm can be removed from the boom. Wind a 15
nylon sling onto the bodies of pins (11) (2 used).
Hoist and remove pins (11) (2 used) from the W141-04-01-004
boom.

22. Hoist and remove the arm from the boom.

Remove shims (15) (4 used) from the pin hole.

W18B-04-01-030

W18K-E-00(20181019) W4-1-5
 FRONT ATTACHMENT/ Front Attachment
23. Place the arm on the wooden block.
NOTE: Dimension of wooden block
Length 800 mm (31.5 in), Width 900 mm
(35.4 in), Height 800 mm (31.5 in)

W141-04-01-005
Wooden
Block

Level Cylinder
24. Wind the chain block which is holding the level
cylinder and the arm cylinder as much as
possible, and secure the chain block to the boom.

Chain Block Arm Cylinder

W18B-04-01-037

25. Disconnect the lubrication hoses (2 used)

between the boom cylinder rod side and the main
frame side from the rod side.
: 19 mm Lubrication
Hose

M144-07-004

26. Disconnect the lubrication hose between the

boom and the main frame from the boom bottom
plate side.
: 36 mm

Boom Lubrication W18B-04-01-036

Hose

W18K-E-00(20181019) W4-1-6
 FRONT ATTACHMENT/ Front Attachment

CAUTION: The boom assembly weight:

17800 kg (39300 lb) Lifting Bracket

27. Install a shackle and a wire to the lifting bracket

(2 places) for the boom. Hoist and hold the boom.

CAUTION: Boom cylinder weight: 2280 kg

(5030 lb)

28. Install a wire and a chain block to the rod side on

W18B-04-01-039
the tube on the boom cylinders (2 used). Hoist
and hold the boom cylinder rod by using the lifting Lifting Bracket
bracket on the boom bulkhead and the chain
block.
Boom
29. Remove the rod end pins (2 used) of the boom
cylinders (2 used). (Refer to REMOVAL AND
Pin
INSTALLATION OF BOOM CYLINDER on
W4-2-2.)

30. Start the engine and retract the cylinder. Secure

the rod part to the cylinder tube by using a wire in
order not to come out. W18B-04-01-041

Boom Cylinder
31. Stop the engine. Bleed air from the hydraulic oil
tank. Operate the control lever several times and
release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

W18K-E-00(20181019) W4-1-7
 FRONT ATTACHMENT/ Front Attachment
32. Remove nuts (18) (32 used) from bolts (16) (16 16, 17, 18, 19, 20
used). Remove plates (20) (2 used), clamps (19)
(24 used) and washers (17) (16 used) from the Hydraulic
Hose
hydraulic hoses (8 used).
: 19 mm

CAUTION: Do not disconnect the hydraulic

hose suddenly in order to prevent pressure
oil from spouting out by pressure. Slowly
loosen and remove the socket bolt. Boom

33. Disconnect the hydraulic hoses (8 used) between

the boom and the main frame from the main W141-04-01-009

Main Frame
frame side. Install the plated plug to the open
end.
NOTE: In case the hydraulic hose is disconnected,
much pressure oil may flow out. Provide a
larger container in order to collect pressure
oil.
: 30 mm
: 14 mm

CAUTION: The boom assembly weight: Lifting Bracket

17800 kg (39300 lb)

34. Install a shackle, a wire and a chain block to

another lifting bracket (1 place) for the boom.
Hoist and hold the boom.

35. Wind up the chain block which is holding the

boom cylinders (2 used) as much as possible and
secure the chain block to the boom. Chain Block

Boom Cylinder
W141-04-01-007

W18K-E-00(20181019) W4-1-8
 FRONT ATTACHMENT/ Front Attachment
36. Remove bolts (22) (4 used) and spring washers Boom
(23) (4 used) from plates (24) (2 used). Remove Main Frame
plates (24) (2 used) from the main frame.
: 30 mm 22, 23

21 24

25

W141-04-01-004
CAUTION: Pin (21) weight: 105 kg (240 lb)

37. Pull out pins (21) (2 used) to the position where

the boom can be removed from the main frame.
Attach a nylon sling onto the bodies of pins (21)
(2 used). Hoist and remove pins (21) (2 used)
from the main frame.

38. Hoist and remove the boom assembly from the

main frame. W18B-04-01-030

Remove shims (25) (4 used) from the pin hole.

CAUTION: The boom assembly weight:

17800 kg (39250 lb)

39. Place the boom assembly on the wooden block.

NOTE: Dimension of the wooden block
Length 800 mm (31.5 in), Width 900 mm
(35.4 in), Height 1200 mm (47.2 in)
W18B-04-01-047
Wooden
Block
CAUTION: In case the boom is removed (the
counterweight is still attached on), do not
perform the travel and the swing operations.
The machine can turn over according to the
road conditions.

W18K-E-00(20181019) W4-1-9
 FRONT ATTACHMENT/ Front Attachment
Installation of Front Attachment (Loading Shovel)
• As for the method to hoist the parts and the
position of the lifting hole, refer to Removal.

CAUTION: The boom assembly weight:

17800 kg (39250 lb)

1. Hoist the boom assembly and align the pin holes

on the connected parts of the boom and the main
frame. Install shims (25) (4 used) to the pin hole.

CAUTION: Pin (21) weight: 105 kg (240 lb)

W18B-04-01-044

Boom
2. Attach a nylon sling onto the bodies of pins (21) Main Frame
(2 used). Hoist pins (21) (2 used). Install pins
(21) (2 used) to the boom foot pin hole. Install 22, 23
plates (24) (2 used) to the main frame with spring
washers (23) (4 used) and bolts (22) (4 used).
: 30 mm 21 24
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)

25

W141-04-01-004

W18K-E-00(20181019) W4-1-10
 FRONT ATTACHMENT/ Front Attachment
3. Bleed air from the hydraulic oil tank. Operate the
control lever several times and release any
remaining pressure in the circuit. (Refer to
BLEED AIR FROM HYDRAULIC OIL TANK on 16, 17, 18, 19, 20
W1-4-1.)
Hydraulic
Hose
4. Connect the hydraulic hoses (8 used) between
the boom and the main frame.
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

5. Secure the hydraulic hoses (8 used) with bolts Boom

(16) (16 used), washers (17) (16 used), clamps
(19) (24 used), plates (20) (2 used) and nuts (18) W141-04-01-009

(32 used). Main Frame

: 19 mm
: 35 N⋅m (3.5 kgf⋅m, 26 lbf⋅ft)

6. Remove the wire which secures the rod parts of

the boom cylinders (2 used).

CAUTION: Boom cylinder weight: 2280 kg

(5030 lb)

7. Start the engine and extend the boom cylinder

rod. Align the pin holes on the end of the boom
cylinder rod and the main frame. Install the pins
(2 used) to the pin hole. (Refer to REMOVAL Boom Cylinder
AND INSTALLATION OF BOOM CYLINDER on
W4-2-2.) W18B-04-01-039

8. Connect the lubrication hose between the boom

and the main frame.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)

Boom Lubrication W18B-04-01-036

Hose

W18K-E-00(20181019) W4-1-11
 FRONT ATTACHMENT/ Front Attachment
9. Connect the lubrication hoses (2 used) between
the rod sides of the boom cylinders (2 used) and
the main frame.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
Lubrication
Hose

M144-07-004
CAUTION: Arm weight: 6700 kg (14800 lb)

10. Hoist the arm and align the arm with the pin hole
on the end of the boom.
Install shims (15) (4 used) to the pin hole.

CAUTION: Pin (11) weight: 196 kg (440 lb)

11. Attach a nylon sling onto the bodies of pins (11)

(2 used). Hoist pins (11) (2 used). Insert pins (11)
(2 used) into the pin hole on the end of the boom.
Secure plates (14) (2 used) to the boom with W18B-04-01-030
spring washers (13) (4 used) and bolts (12) (4 Arm
used). Boom
: 36 mm
: 700 N⋅m (71.5 kgf⋅m, 520 lbf⋅ft) 12, 13

11 14

15

W141-04-01-004

W18K-E-00(20181019) W4-1-12
 FRONT ATTACHMENT/ Front Attachment
12. Remove the wire which secures the arm cylinder
rod part.

13. Start the engine and extend the arm cylinder rod.
Align the pin holes on the end of the arm cylinder
rod. Install the pin into the hole.

14. Remove the wire which secures the level cylinder

rod part.

15. Start the engine and extend the level cylinder rod.
Align the pin holes on the end of the level cylinder W18B-04-01-026
rod. Install the pin into the hole.

16. Place the arm end on the wooden block.

Arm

W18B-04-01-021
Wooden
Block

17. Bleed air from the hydraulic oil tank. Operate the 6, 7, 8, 9, 10
control lever several times and release any
remaining pressure in the circuit. (Refer to
BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

18. Connect the hydraulic hoses (6 used) between

the boom and the arm.
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

19. Secure the hydraulic hoses (6 used) with bolts (6) W18C-04-01-003

(8 used), washers (7) (8 used), clamps (8) (16

used), plates (10) (2 used) and nuts (9) (16
used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

W18K-E-00(20181019) W4-1-13
 FRONT ATTACHMENT/ Front Attachment

CAUTION: Bucket weight: 15100 kg (33290

lb) Arm

20. Hoist the bucket. Start the engine and raise the
arm. Align the pin holes on the end of the arm
and the bucket. Bucket
Install shims (5) (4 used) to the pin hole.

Arm W18B-04-01-076

CAUTION: Pin (1) weight: 91 kg (210 lb) Bucket

21. Attach a nylon sling onto the bodies of pins (1) (2

used). Hoist pins (1) (2 used). Insert pins (1) (2
used) into the pin hole. Install stoppers (4) (2 2、3
1
used) to the bucket with spring washers (3) (8
used) and bolts (2) (8 used).
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
4

5
W141-04-01-002

O-Ring Arm
22. Install the bucket cylinders (2 used). (Refer to
REMOVAL AND INSTALLATION OF BUCKET
CYLINDER on W4-2-16.)
Bucket
23. Install O-rings (2 used) to the end of the arm.

W18G-04-01-050

110 mm (4.3 in)

Bolt
(M5, Pitch 0.8 mm)

Double Nut and

Washer on Both
Right and Left

O-Ring (1A)

Detail of O-Ring W18G-04-01-014

W18K-E-00(20181019) W4-1-14
 FRONT ATTACHMENT/ Front Attachment
24. Connect the lubrication hose at the rod pin part of
Level Cylinder Lubrication
the arm cylinder and the level cylinder rod side. Hose
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

Arm Cylinder
W18C-04-01-001

25. Connect the lubrication hose between the boom

Boom
and the arm.
: 36 mm Lubrication
Hose
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)

Arm

W18B-04-01-022

Hydraulic
26. Stop the engine. Bleed air from the hydraulic oil Hose
Lubrication
tank. Operate the control lever several times and Hose
release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

27. Connect the hydraulic hoses (8 used) and the

lubrication hoses (7 used) to between the arm
and the bucket.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft) W18B-04-01-015

W18K-E-00(20181019) W4-1-15
 FRONT ATTACHMENT/ Front Attachment
28. Apply grease through the grease fitting after
installing the bucket, the arm and the boom. (As
for the lubrication positions, refer to the
Lubrication section in the Operator's Manual.)

IMPORTANT: After completing the work, add

hydraulic oil to the specified level.
Bleed air from each cylinder. (Refer
to Main Point to Bleed Air on
W4-2-50.)

W18K-E-00(20181019) W4-1-16
 FRONT ATTACHMENT/ Front Attachment
Removal of Front Attachment (Backhoe)
Bolt
(M5, Pitch 0.8 mm)
1. Remove O-rings (4 used) from the bucket
connecting part of link A and the end of the arm. Double Nut and
Washer on Both
NOTE: O-ring cannot be re-used. When installing, Right and Left
replace O-ring with the new one.

O-Ring (1A)

Detail of O-Ring W18G-04-01-014

Arm
2. Start the engine. Position the front attachment as Boom
illustrated to the right.
NOTE: If the angle between the boom and the arm
is 120 to 140°, the removal procedures Link A
below are easier.
120° to 140°
3. Remove bolts (2) (4 used) and spring washers
(3) (4 used) from link A and stopper (4) for the
bucket connecting pin. Remove stoppers (4) (2
used) from the bucket.
: 24 mm
W18B-04-01-049

Bucket
CAUTION: Pin (1) weight: 60 kg (140 lb)
2, 3
4. Pull out pins (1) (2 used) to the position where
link A can be removed from the bucket. Attach a
nylon sling onto the bodies of pins (1) (2 used).
Wind a nylon sling onto the bodies of pins (1) (2
4
used). Hoist and remove pins (1) (2 used) from
the bucket.
1

Link A
W146-04-01-001

Bucket Cylinder
5. Retract the bucket cylinders (2 used). Secure the
rod part to the cylinder tube by using a wire in
order not to come out.

W18B-04-01-050

W18K-E-00(20181019) W4-1-17
 FRONT ATTACHMENT/ Front Attachment

CAUTION: Bucket weight: 13200 kg (29200

lb)

6. Install a shackle, a wire and a chain block to the

lifting bracket (2 places) for the bucket. Hoist and
hold the bucket.

Lifting
Hole

W18B-04-01-051

Arm
Bucket
CAUTION: Cover (7) weight: 20 kg (44 lb)
5, 6
8
7. Remove bolts (5) (24 used) and spring washers
(6) (24 used) from covers (7) (4 used) for the pin
at the arm end. Remove covers (7) (4 used) from
the bucket. 9
NOTE: There are some lifting holes on cover (7).
Install an eyebolt (M10, Pitch 1.5 mm). 7
Hoist and remove cover (7).
: 24 mm W141-04-01-010

Arm
8. Remove O-rings (9) (4 used) from covers (7) (4
used).

CAUTION: Pin (8) weight: 85 kg (190 lb)

Bucket

9. Pull out pins (8) (2 used) to the position where

the arm can be removed from the bucket. Wind a
nylon sling onto the bodies of pins (8) (2 used).
Hoist and remove pins (8) (2 used) from the
bucket.
W18B-04-01-052
10. Hoist and remove the bucket from the arm.

W18K-E-00(20181019) W4-1-18
 FRONT ATTACHMENT/ Front Attachment
11. Place the arm end on the wooden block. Arm

Wooden Block W18B-04-01-053

Hydraulic
12. Stop the engine. Bleed air from the hydraulic oil Hose
tank. Operate the control lever several times and
Bucket
release any remaining pressure in the circuit. Cylinder
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

13. Disconnect the hydraulic hoses (4 used) from the

bucket cylinders (2 used). Install the plated plug Boom
to the open end. A
: 14 mm

Arm

W18B-04-01-054

Lubrication
14. Disconnect the lubrication hose between the Hose
boom and the arm.
: 19 mm

View A W18C-04-01-006

Lubrication
Hose
15. Disconnect the lubrication hoses (2 used) and the
lubrication pipings (2 used) between the boom
and the arm and the rod sides of the arm
cylinders (2 used) from the arm side.
: 19 mm

W18C-04-01-007

W18K-E-00(20181019) W4-1-19
 FRONT ATTACHMENT/ Front Attachment

Arm Cylinder
CAUTION: Arm cylinder weight: 1550 kg
(3420 lb)

16. Attach a nylon sling onto the bodies of the arm

cylinders (2 used). Hoist and hold the arm
cylinders (2 used).

17. Remove the pins (2 used) from the rod ends of

Wooden
the arm cylinders (2 used). (Refer to REMOVAL Block
AND INSTALLATION OF ARM CYLINDER on
W4-2-8.)

18. Set a wooden block between the arm cylinders (2 W18B-04-01-057

used) and the boom.

19. Start the engine and retract the arm cylinders (2

used). Place the rod sides of the arm cylinders (2
used) on the wooden block.

20. Secure the rod parts of the arm cylinders (2 used)

to the cylinder tube by using a wire in order not to
come out.

21. Install a shackle, a wire and a chain block to the

lifting bracket (2 places) for the arm.

Lifting
Bracket

Arm
W18B-04-01-059

W18K-E-00(20181019) W4-1-20
 FRONT ATTACHMENT/ Front Attachment

CAUTION: The arm assembly weight: 9700

kg (21400 lb)
Boom
22. Hoist and hold the arm.

23. Remove bolts (11) (6 used) and spring washers Arm

(12) (6 used) from plate (13). Remove plate (13)
from the boom.
: 30 mm

CAUTION: Pin (10) weight: 550 kg (1220 lb)

W18B-04-01-060

24. Pull out pin (10) to the position where the boom
Arm Boom
can be removed from the arm. Attach a nylon
sling onto the body of pin (10). Hoist pin (10). 11, 12
Remove pin (10) from the boom. 10

25. Remove the arm assembly from the boom.

13
26. Remove shims (14) (4 used) from the pin hole.
W18C-04-01-008
14

Arm Assembly

27. Place the arm assembly on the wooden block.

Wooden
Block
W18B-04-01-062

28. Place the boom end on the wooden block. Boom

W18B-04-01-063
Wooden
Block

W18K-E-00(20181019) W4-1-21
 FRONT ATTACHMENT/ Front Attachment
29. Disconnect the lubrication hoses (2 used)
between the rod sides of the boom cylinders (2
used) and the main frame from the rod side.
: 19 mm

Lubrication
Hose

30. Disconnect the lubrication hose between the M144-07-004

boom and the main frame from the boom side.

: 36 mm

Boom Lubrication W18B-04-01-036

Hose

CAUTION: The boom assembly weight:

22200 kg (49000 lb)

31. Install a shackle, a wire and a chain block to the Lifting

Bracket
lifting bracket (2 places) for the boom. Hold the
boom.

W18C-04-01-009

CAUTION: Boom cylinder weight: 2270 kg

(5010 lb) Lifting
Bracket

32. Install a wire and a chain block to the tube rod

sides of the boom cylinders (2 used). Hold the
rod sides of the boom cylinders (2 used) by using
the lifting bracket on the boom bulkhead and the
chain block.
Boom

W18B-04-01-067
Boom Cylinder

W18K-E-00(20181019) W4-1-22
 FRONT ATTACHMENT/ Front Attachment
33. Remove the pins (2 used) from the rod ends of
the boom cylinders (2 used). (Refer to REMOVAL
AND INSTALLATION OF BOOM CYLINDER on
W4-2-2.)

34. Start the engine and retract the boom cylinders (2

used). Secure the rod parts of the boom cylinders
(2 used) to the cylinder tube by using a wire in
order not to come out.

Boom Cylinder W18B-04-01-068

15, 16, 17, 18, 19

35. Stop the engine. Bleed air from the hydraulic oil Hydraulic
tank. Operate the control lever several times and Hose
release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

36. Remove nuts (19) (48 used) from bolts (15) (24
used). Remove plates (18) (2 used), clamps (17)
(36 used) and washers (16) (24 used) from the Boom
hydraulic hoses (10 used).
: 19 mm W141-04-01-013

Main Frame
CAUTION: Do not disconnect the hydraulic
hose suddenly in order to prevent pressure
oil from spouting out by pressure. Slowly
loosen and remove the socket bolt.
37. Disconnect the hydraulic hose (10 used) between
the boom and the main frame from the boom side.
Install the plated plug to the open end. (Refer to
BLEED AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)
: 17 mm
NOTE: In case the hydraulic hose is disconnected,
much pressure oil may flow out. Provide a
larger container in order to collect pressure
oil.

W18K-E-00(20181019) W4-1-23
 FRONT ATTACHMENT/ Front Attachment
38. Wind up the chain block which is holding the
boom cylinders (2 used) as much as possible and
secure the chain block to the boom. Chain Block

39. Remove bolts (18) (4 used) and spring washers Boom

(22) (4 used) from plates (23) (2 used). Remove
plates (23) (2 used) from the main frame.
: 30 mm

Boom Cylinder

W18B-04-01-071

Boom
CAUTION: Pin (20) weight: 105 kg (240 lb) Main Frame

40. Pull out pins (20) (2 used) to the position where 21, 22
the boom can be removed from the main frame.
Attach a nylon sling onto the bodies of pins (20) 20
(2 used). Hoist and remove pins (20) (2 used) 23
from the main frame.

41. Hoist and remove the boom assembly from the

main frame.
Remove shims (24) (4 used) from the pin hole.
24
42. Place the boom assembly on the wooden block. W141-04-01-008

NOTE: Dimension of wooden block

Length 800 mm (31.5 in), Width 900 mm Boom Assembly
(39.4 in), Height 1100 mm (43.3 in)

Wooden
Block

W18B-04-01-072

W18K-E-00(20181019) W4-1-24
 FRONT ATTACHMENT/ Front Attachment
Installation of Front Attachment (Backhoe)
• As for the method to hoist the parts and the
position of lifting hole, refer to Removal.

Boom
CAUTION: The boom assembly weight:
22200 kg (49000 lb)

1. Hoist the boom and align the pin holes on the

connected parts of the boom and the main frame.
Install shims (24) (4 used) to the pin hole.

CAUTION: Pin (20) weight: 105 kg (240 lb)

2. Attach a nylon sling onto the bodies of pins (20) W18B-04-01-071

(2 used). Hoist pins (20) (2 used). Insert pins (20) Boom Main Frame
(2 used) into the pin hole. Install plates (23) (2
used) to the main frame with spring washers (21) 21, 22
(4 used) and bolts (22) (4 used).
: 36 mm 20
: 700 N⋅m (71.5 kgf⋅m, 520 lbf･ft) 23

3. Start the engine. Lower the boom and place the

end of the boom on the wooden block.

24

W141-04-01-008

W18K-E-00(20181019) W4-1-25
 FRONT ATTACHMENT/ Front Attachment
4. Bleed air from the hydraulic oil tank. Operate the 15, 16, 17, 18, 19
control lever several times and release any
remaining pressure in the circuit. (Refer to Hydraulic
BLEED AIR FROM HYDRAULIC OIL TANK on Hose
W1-4-1.)

CAUTION: Do not disconnect the plated

plug at the end of the hose suddenly in order
to prevent pressure oil from spouting out by
pressure. Slowly loosen and remove the
Boom
socket bolt.
W141-04-01-013
5. Connect the hydraulic hoses (10 used) between
Main Frame
the boom and the main frame.
: 17 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf･ft)

6. Secure the hydraulic hoses (10 used) with bolts

(15) (24 used), washers (16) (24 used), clamps
(17) (36 used), plates (18) (2 used) and nuts (19)
(48 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 67 lbf･ft)

7. Remove the wire which secures the rod parts of

the boom cylinders (2 used).

CAUTION: Boom cylinder weight: 2270 kg

(5010 lb)

8. Start the engine and extend the boom cylinder

rod. Align the pin holes on the end of the boom Boom Cylinder W18B-04-01-068

cylinder rod and the main frame. Install the pins

(2 used) to the pin hole. (Refer to REMOVAL
AND INSTALLATION OF BOOM CYLINDER on
W4-2-2.)

9. Connect the lubrication hose between the boom

and the main frame.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf･ft) Boom Lubrication W18B-04-01-036

Hose

W18K-E-00(20181019) W4-1-26
 FRONT ATTACHMENT/ Front Attachment
10. Connect the lubrication hoses (2 used) at the rod
sides of the boom cylinders (2 used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf･ft)

Lubrication
Hose

CAUTION: The arm assembly weight: 9700

kg (21400 lb)
M144-07-004

11. Hoist the arm and align the pin holes on the arm
and the end of the boom.
Boom
12. Install shims (14) (4 used) to the pin hole.
Arm
CAUTION: Pin (10) weight: 550 kg (1220 lb)

13. Attach a nylon sling onto the body of pin (10).

Hoist pin (10). Insert pin (10) into the pin hole.
Install plate (13) to the arm with spring washers
(12) (6 used) and bolts (11) (6 used).
: 30 mm W18B-04-01-060

: 400 N⋅m (41 kgf⋅m, 295 lbf･ft)

Arm Boom

11, 12
10

13

W18C-04-01-008
14

W18K-E-00(20181019) W4-1-27
 FRONT ATTACHMENT/ Front Attachment
14. Place the arm end on the wooden block. Arm Cylinder

15. Remove the wire which secures the rod parts of

the arm cylinders (2 used).

CAUTION: Arm cylinder weight: 1550 kg

(3420 lb)

16. Hoist the rod sides of the arm cylinders (2 used).

Start the engine and extend the rods of the arm
cylinders (2 used). Align the pin holes on the end
of the arm cylinder rod.
W18B-04-01-057
Wooden
17. Install the pins (2 used) to the rod ends of the Block
arm cylinders (2 used). (Refer to REMOVAL AND
INSTALLATION OF ARM CYLINDER on W4-2-8.) Hydraulic
Hose
18. Stop the engine. Bleed air from the hydraulic oil
tank. Operate the control lever several times and Bucket
release any remaining pressure in the circuit. Cylinder
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

19. Connect the hydraulic hoses (4 used) to the

Boom
bucket cylinder.
: 14 mm A
: 210 N⋅m (21.5 kgf⋅m, 155 lbf･ft)
Arm
20. Connect the lubrication hose between the boom
and the arm.
: 19 mm W18B-04-01-054

: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf･ft)

Lubrication
Hose

View A W18C-04-01-006

W18K-E-00(20181019) W4-1-28
 FRONT ATTACHMENT/ Front Attachment
21. Connect the lubrication hoses (2 used) and the Lubrication
lubrication pipings (2 used) between the boom Hose
and the arm and the rod sides of the arm
cylinders (2 used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf･ft)

W18C-04-01-007
22. Start the engine and raise the arm.
NOTE: If the angle between the boom and the arm Arm
is 120 to 140°, the installation procedures Boom
below are easier.

CAUTION: Bucket weight: 13200 kg (29200 Bucket

lb)
120° to 140°
23. Hoist the bucket and align the pin hole on the arm
end.

24. Install O-rings (9) (4 used) to covers (7) (4 used).

W18B-04-01-052

CAUTION: Pin (8) weight: 85 kg (190 lb) Arm

Cover (7) weight: 20 kg (44 lb) Bucket

5, 6
IMPORTANT: When installing covers (7) (4 used), 8
check the direction of the guard
mounting bolt.
25. Attach a nylon sling onto the bodies of pins (8) (2
used). Hoist pins (8) (2 used). Insert pins (8) (2 9
used) into the pin hole. Install covers (7) (4 used)
to the bucket with bolts (5) (24 used) and spring 7
washers (6) (24 used).
NOTE: There are four lifting holes on covers (7) (4 W141-04-01-010

used). Install an eyebolt (M10, Pitch 1.5

mm). Hoist and install covers (7) (4 used)
to the bucket. Bolt Hole for
: 24 mm Guard
Mounting
: 210 N⋅m (21.5 kgf⋅m, 155 lbf･ft)

7 W18C-04-01-010

W18K-E-00(20181019) W4-1-29
 FRONT ATTACHMENT/ Front Attachment
26. Remove the wire which secures the rod parts of
Arm
the bucket cylinders (2 used).

27. Start the engine and extend the rod of the bucket
cylinder.Align the pin holes on links A (2 used)
and the bucket connecting part. Link A

CAUTION: Pin (1) weight: 60 kg (140 lb)

W18B-04-01-049

28. Attach a nylon sling onto the bodies of pins (1) (2

Bucket
used). Hoist pins (1) (2 used). Insert pins (1) (2
used) into the pin hole. Install stoppers (4) (2 2, 3
used) to the bucket with spring washers (3) (6
used) and bolts (2) (6 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf･ft)
4

Link A
W146-04-01-001

W18K-E-00(20181019) W4-1-30
 FRONT ATTACHMENT/ Front Attachment
29. Install O-rings (4 used) to links A (2 used) and the
bucket connecting part. O-Ring Link A

Bucket

W18G-04-01-050

90 mm (3.5 in)

Bolt
(M5, Pitch 0.8 mm)

Double Nut and

Washer on Both
Right and Left

O-Ring (1A)

Detail of O-Ring W18G-04-01-014

30. Install O-rings (4 used) to the arm and the bucket O-Ring
Arm
connecting part.

31. Apply grease through the grease fitting after

Bucket
installing the bucket, the arm and the boom. (As
for the lubrication positions, refer to the
Lubrication section in the Operator's Manual.)

IMPORTANT: After completing the work, add

hydraulic oil to the specified level.
Bleed air from each cylinder. (Refer W18G-04-01-050

to Main Point to Bleed Air on 145 mm (5.7 in)

W4-2-50.)
Bolt
(M5, Pitch 0.8 mm)

Double Nut and

Washer on Both
Right and Left

O-Ring (1A)

Detail of O-Ring W18G-04-01-014

W18K-E-00(20181019) W4-1-31
 FRONT ATTACHMENT/ Front Attachment
(Blank)

W18K-E-00(20181019) W4-1-32
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF
CYLINDER

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

W18K-E-00(20181019) W4-2-1
 FRONT ATTACHMENT / Cylinder
Removal and Installation of Boom Cylinder
Hydraulic Hose
(Loading shovel)

Boom Cylinder

A
B

W18B-04-01-017

Hydraulic Hose
(Backhoe)

Boom Cylinder

B
A

W18B-04-02-004

Boom Boom Cylinder 2 Boom Cylinder

1 Main Frame
6
3
7
4 9
8

W141-04-02-002 Section B W141-04-02-001

Section A

1 - Spacer 4 - Spring Washer (2 Used) 7 - Bolt (2 Used) 9 - Pin

2 - Plate 5 - Pin 8 - Spring Washer (2 Used)
3 - Bolt (2 Used) 6 - Plate

W18K-E-00(20181019) W4-2-2
 FRONT ATTACHMENT / Cylinder
Removal

1. Disconnect the lubrication hoses (4 used) from 5. Start the engine and retract the boom cylinder
the boom cylinders (2 used) at the boom cylinder rods (2 used). Secure the rods (2 used) to the
side. cylinder tube by using a wire in order not to
: 19 mm extend the rods (2 used) by its own weight.

6. Stop the engine. Bleed air from the hydraulic oil

CAUTION: Boom cylinder weight: 2280 kg
tank. Operate the control lever several times and
(5030 lb)
release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
2. Attach a nylon sling onto the boom cylinders (2
TANK on W1-4-1.)
used). Hoist and hold the boom cylinders.
7. Disconnect the hydraulic hoses (4 used) from the
3. Remove bolts (7) (4 used) and spring washers
boom cylinders (2 used) at the boom cylinder
(8) (4 used) from plates (6) (2 used) in the rod
side. Install a plated plug to the open end.
side. Remove plates (6) (2 used) from the main : 30 mm
frame. : 14mm, 17 mm
: 30 mm

CAUTION: Pin (9) weight: 110 kg (250 lb)

4. Push out pins (9) (2 used) to the position where

the boom cylinders (2 used) can be removed
from the main frame. Attach a nylon sling onto
the body of pins (9) (2 used). Hoist and remove
pins (9) (2 used) from the main frame.

W18K-E-00(20181019) W4-2-3
 FRONT ATTACHMENT / Cylinder
(Loading shovel)
Hydraulic Hose

Boom Cylinder

A
B

W18B-04-01-017

Hydraulic Hose
(Backhoe)

Boom Cylinder

B
A

W18B-04-02-004

Boom Boom Cylinder 2 Boom Cylinder

1 Main Frame

W141-04-02-002 Section B W141-04-02-001

Section A

W18K-E-00(20181019) W4-2-4
 FRONT ATTACHMENT / Cylinder
8. Remove bolts (3) (4 used) and spring washers
(4) (4 used) from plates (2) (4 used) in the bottom
side. Remove plates (2) (2 used) from the boom.
: 30 mm

CAUTION: Pin (5) weight: 110 kg (250 lb)

9. Push out pins (5) (2 used) to the position where

the boom cylinders (2 used) can be removed
from the boom. Attach a nylon sling onto the body
of pins (5) (2 used). Hoist and remove pins (5) (2
used) from the boom.

10. Hoist and remove the boom cylinders (2 used).

Remove spacers (1) (2 used) from the pin hole.

W18K-E-00(20181019) W4-2-5
 FRONT ATTACHMENT / Cylinder
(Loading shovel)
Hydraulic Hose

Boom Cylinder

A
B

W18B-04-01-017

Hydraulic Hose
(Backhoe)

Boom Cylinder

B
A

W18B-04-02-004

Boom Boom Cylinder 2 Boom Cylinder

1 Main Frame
6
3
7
4 9
8

W141-04-02-002 Section B W141-04-02-001

Section A

1 - Spacer 4 - Spring Washer (2 Used) 7 - Bolt (2 Used) 9 - Pin

2 - Plate 5 - Pin 8 - Spring Washer (2 Used)
3 - Bolt (2 Used) 6 - Plate

W18K-E-00(20181019) W4-2-6
 FRONT ATTACHMENT / Cylinder
Installation

CAUTION: Boom cylinder weight: 2280 kg CAUTION: Pin (9) weight: 110 kg (250 lb)
(5030 lb)
7. Attach a nylon sling onto the body of pins (9) (2
1. Attach a nylon sling onto the boom cylinders (2 used). Hoist and insert pins (9) (2 used) into the
used). Hoist the boom cylinders. pin hole. Install plates (6) (2 used) to the main
frame with bolts (7) (4 used) and spring washers
2. Align the pin holes on the bottom side of the (8) (4 used).
boom cylinders (2 used) and the boom. : 30 mm
Install spacers (1) (2 used) to the pin hole. : 400 Nm (41 kgfm, 295 lbfft)

8. Connect the lubrication hoses (4 used) to the

CAUTION: Pin (5) weight: 110 kg (250 lb)
3. Attach a nylon sling onto the body of pins (5) (2
used). Hoist and insert pins (5) (2 used) into the
pin hole. Install plates (2) (2 used) to the boom
with bolts (3) (4 used) and spring washers (4) (4
used).
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)
boom cylinder.
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
9. Loosen the air breather on the cylinders (2 used)
and bleed air from the cylinders. (Refer to MAIN
POINTS TO BLEED AIR on W4-2-54.)

4. Connect the hydraulic hoses (2 used) to the

boom cylinders (2 used).
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)
: 14 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

5. Remove the wire which secures the boom

cylinder rods (2 used).

6. Start the engine. While hoisting the boom cylinder

rod side, extend the boom cylinder rod and align
the pin holes on the main frame and the boom
cylinders (2 used) rod side.

W18K-E-00(20181019) W4-2-7
 FRONT ATTACHMENT / Cylinder
Removal and Installation of Arm Cylinder

(Loading shovel)

A B

Hydraulic Hose
C

Hydraulic Hose W18B-04-01-017

(Backhoe)

B
A

W18B-04-02-004

6 Arm Cylinder
3, 4

3, 4 Boom

2 2
5 1

Section A

Section B
W18C-04-02-001
Boom Arm Cylinder W141-04-02-003

Arm Cylinder
Lifting Bracket Boom

W18B-04-02-007
View C (Loading Shovel)

1 - Pin 3 - Bolt (2 Used) 5 - Pin 6 - Plate (Backhoe only)

2 - Plate 4 - Spring Washer (2 Used)

W18K-E-00(20181019) W4-2-8
 FRONT ATTACHMENT / Cylinder
Removal
1. Disconnect all lubrication hoses from the arm
cylinder at the arm cylinder side.
Loading shovel lubrication hose: 2 used
Backhoe lubrication hose: 4 used
: 19 mm
CAUTION: Arm cylinder weight:
1660 kg (3660 lb) (Loading shovel)
1550 kg (3420 lb) (Backhoe)
2. (Loading shovel)
Attach a chain block onto the arm cylinder and
the lifting bracket on the boom bottom plate. Hold
the arm cylinder.
Lifting Bracket
Arm Cylinder
W18B-04-02-005
(Backhoe)
Attach a nylon sling onto the arm cylinders (2
used). Hoist and hold the arm cylinders.
3. Remove bolts (3) (2 used) and spring washers
(4) (2 used) from plate (2) in the rod side.
Remove plate (2) from the arm.
: 30 mm
4. Push out pin (5) to the position where the arm
cylinder can be removed from the arm.
W18K-E-00(20181019)
CAUTION: Pin (5) weight: 90 kg (200 lb)
5. (Loading shovel)
Hold and remove pin (5) by using a forklift.
(Backhoe)
Attach a nylon sling onto the body of pins (5) (2
used). Hoist and remove pins (5) (2 used) from
the boom.
6. Start the engine and retract the arm cylinder rod.
Secure the rod part to the cylinder tube by using
a wire in order not to extend the rod by its own
weight.
(Backhoe only)
Remove plates (6) (2 used) from the pin hole.
7. Stop the engine. Bleed air from the hydraulic oil
tank. Operate the control lever several times and
release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)
8. Disconnect all hydraulic hoses from the arm
cylinder at the cylinder side. Install a plated plug
to the open end.
Loading shovel hydraulic hose: 2 used
Backhoe hydraulic hose: 4 used
: 30 mm
: 14 mm
9. Remove bolts (3) (2 used) and spring washers
(4) (2 used) from plate (2) in the bottom side.
Remove plate (2) from the boom.
: 30 mm
10. Push out pin (1) to the position where the arm
cylinder can be removed from the boom.
W4-2-9
 FRONT ATTACHMENT / Cylinder
(Loading shovel)

A B

Hydraulic Hose
C

W18B-04-01-017

Hydraulic Hose
(Backhoe)

B
A

W18B-04-02-004

6 Arm Cylinder
3, 4
3, 4
Boom

2
2
5
1

Section A

W18C-04-02-001 Section B
Boom Arm Cylinder W141-04-02-003

Arm Cylinder
Lifting Bracket Boom

W18B-04-02-007
View C (Loading Shovel)

W18K-E-00(20181019) W4-2-10
 FRONT ATTACHMENT / Cylinder

CAUTION: Pin (1) weight: 90 kg (200 lb)

11. (Loading shovel)

Hold pin (1) by using a forklift. Remove pin (1)
from the boom.
(Backhoe)
Attach a nylon sling onto the body of pins (1) (2
used). Hoist and remove pins (1) (2 used) from
the boom.

12. (Loading shovel)

Hold and remove the arm cylinder by using a
chain block.
(Backhoe)
Hoist and remove the arm cylinders (2 used).

W18K-E-00(20181019) W4-2-11
 FRONT ATTACHMENT / Cylinder
(Loading shovel)

A B

Hydraulic Hose
C

W18B-04-01-017

Hydraulic Hose
(Backhoe)

B
A

W18B-04-02-004

6 Arm Cylinder
3, 4
3, 4
Boom

2
2
5
1

Section A

W18C-04-02-001 Section B
Boom Arm Cylinder W141-04-02-003

Arm Cylinder
Lifting Bracket Boom

W18B-04-02-007
View C (Loading Shovel)

1 - Pin 3 - Bolt (2 Used) 5 - Pin 6 - Plate (Backhoe only)

2 - Plate 4 - Spring Washer (2 Used)

W18K-E-00(20181019) W4-2-12
 FRONT ATTACHMENT / Cylinder
Installation
• As for the method to hoist the parts and the
position of the lifting holes, refer to Removal.
NOTE: (Loading shovel only)
In case the level cylinder has been
removed, install the level cylinder at first.
(Refer to Removal and Installation of Level
Cylinder on W4-2-26.)
5. Connect the hydraulic hose to the arm cylinder.
Loading shovel hydraulic hose: 2 used
Backhoe hydraulic hose: 4 used
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)
: 14 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
6. Remove the wire which secures the rod.

CAUTION: Arm cylinder weight:

1660 kg (3660 lb) (Loading shovel)
1550 kg (3420 lb) (Backhoe)

1. (Loading shovel)
Hoist the arm cylinder by using a chain block.
(Backhoe)
Hoist arm cylinders (2 used).

2. Align the pin holes on the arm cylinder bottom

side and the boom.

CAUTION: Pin (1) weight: 90 kg (200 lb)

3. (Loading shovel)
Hoist pin (1) by using a forklift.
(Backhoe)
Attach a nylon sling onto the body of pins (1) (2
used). Hoist pins (1) (2 used).

4. Insert pin (1) into the pin hole. Install plate (2) to
the boom with bolts (3) (2 used) and spring
washers (4) (2 used).
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)

W18K-E-00(20181019) W4-2-13
 FRONT ATTACHMENT / Cylinder
(Loading shovel)

A B

C Hydraulic Hose

W18B-04-01-017

Hydraulic Hose
(Backhoe)

B
A

W18B-04-02-004

Arm Cylinder
6
3, 4
3, 4
Boom

2
2
5
1

Section A

W18C-04-02-001 Section B
Boom Arm Cylinder W141-04-02-003

Arm Cylinder
Lifting Bracket Boom

W18B-04-02-007
View C (Loading Shovel)

W18K-E-00(20181019) W4-2-14
 FRONT ATTACHMENT / Cylinder
7. (Loading shovel)
Start the engine. While hoisting the arm cylinder
rod side by using a chain block, extend the arm
cylinder rod and align the pin holes on the arm
cylinder rod side and the arm.
(Backhoe)
Start the engine. While hoisting the arm cylinders
(2 used) rod side, extend the arm cylinder rod
and align the pin holes on the arm cylinders (2
used) rod side and the arm. Install plates (6) (2
used) to the pin hole.

CAUTION: Pin (5) weight: 90 kg (200 lb)

8. (Loading shovel)
Hoist pin (5) by using a forklift.
(Backhoe)
Attach a nylon sling onto the body of pins (5) (2
used). Hoist pins (5) (2 used).

9. Insert pin (5) into the pin hole. Install plate (2) to
the arm with bolts (3) (2 used) and spring
washers (4) (2 used).
: 30 mm
: 400 Nm (41 kgfm)

10. Connect the lubrication hose to the arm cylinder.

Loading shovel lubrication hose: 2 used
Backhoe lubrication hose: 4 used
: 19 mm
: 29.5 Nm (3 kgfm)

11. Loosen the air breather of the cylinder and

bleed air from the cylinder. (Refer to MAIN
POINTS TO BLEED AIR on W4-2-54.)

W18K-E-00(20181019) W4-2-15
 FRONT ATTACHMENT / Cylinder
Removal and Installation of Bucket Cylinder
(Loading Shovel)

Hydraulic Hose

C
A

W18B-04-01-017

Bucket Cylinder Bucket Cylinder

Bucket Boom

6, 7
5
2, 3 8

1 9

Section A Section B W18C-04-02-003

W18C-04-02-002

Bucket Cylinder
Lifting Bracket Arm

W18B-04-02-020
View C

1 - Stopper 4 - Pin 6 - Bolt (2 Used) 8 - Plate

2 - Bolt (3 Used) 5 - Spacer 7 - Spring Washer (2 Used) 9 - Pin
3 - Spring Washer (3 Used)

W18K-E-00(20181019) W4-2-16
 FRONT ATTACHMENT / Cylinder
Removal
1. Disconnect the lubrication hoses (4 used) from
the bucket cylinder at the bucket cylinder side.
: 19 mm
CAUTION: Bucket cylinder weight: 1370 kg
(3020 lb)
2. Attach a nylon sling onto the bottom side of the
bucket cylinders (2 used) tube. Attach a chain
block onto the nylon sling and the lifting bracket
on the arm bottom plate. Hold the bottom side of
the bucket cylinders (2 used) tube.
3. Remove bolts (2) (6 used) and spring washers
(3) (6 used) from stopper (1). Remove stoppers
(1) (2 used) from the bucket.
: 30 mm
CAUTION: Pin (4) weight: 80 kg (180 lb)
4. Push out pins (4) (2 used) to the position where
the bucket cylinders (2 used) can be removed
from the bucket. Attach a nylon sling onto the
body of pins (4) (2 used). Hoist and remove pins
(4) (2 used).
5. Loosen the chain block and remove the bottom
side of the bucket cylinders (2 used).
W18K-E-00(20181019) W4-2-17
IMPORTANT: Attach a soft waste on the arm boss
in order not to damage the arm by a
wire.
6. Attach a wire onto the rod side of the bucket
cylinders (2 used) tube. Pass the wire through
the outside and the inside of the arm boss. Hold
the rod side of the bucket cylinders (2 used) tube.
Pass a wire through
outside and inside.
Arm Boss
Bucket
Cylinder
W141-04-02-013
7. Remove bolts (6) (4 used) and spring washers
(7) (4 used) from plates (8) (2 used). Remove
plates (8) (2 used) from the boom.
: 30 mm
CAUTION: Pin (9) weight: 80 kg (180 lb)
8. Push out pins (9) (2 used) to the position where
the bucket cylinders (2 used) can be removed
from the boom. Attach a nylon sling onto the body
of pins (9) (2 used). Hoist and remove pins (9) (2
used).
9. While holding the bucket cylinders (2 used), start
the engine and retract the bucket cylinder rod.
Remove spacers (5) (2 used) from the pin hole at
the cylinder rod side.
 FRONT ATTACHMENT / Cylinder

Hydraulic Hose

C
A

W18B-04-01-017

Bucket Cylinder Bucket Cylinder

Boom
Bucket

Section A Section B W18C-04-02-003

W18C-04-02-002

Bucket Cylinder
Lifting Bracket Arm

W18B-04-02-020
View C

W18K-E-00(20181019) W4-2-18
 FRONT ATTACHMENT / Cylinder
10. Stop the engine. Bleed air from hydraulic oil tank.
Operate the control lever several times and
release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)

11. Disconnect the hydraulic hoses (4 used) from the

bucket cylinders (2 used) at the bucket cylinder
side. Install a plated plug to the open end.
: 14 mm

IMPORTANT: Place a wooden block on the place

where the bucket cylinder will be
lowered down.
12. Hold and remove the bucket cylinders (2 used)
from the bucket.

13. Secure the rod of the bucket cylinders (2 used)

to the cylinder tube by using a wire in order not to
extend the rod by its own weight.

W18K-E-00(20181019) W4-2-19
 FRONT ATTACHMENT / Cylinder

Hydraulic Hose

C
A

W18B-04-01-017

Bucket Cylinder Bucket Cylinder

Bucket Boom

6, 7
5
2, 3 8

1 9

Section A Section B W18C-04-02-003

W18C-04-02-002

Bucket Cylinder
Lifting Bracket Arm

W18B-04-02-020
View C

1 - Stopper 4 - Pin 6 - Bolt (2 Used) 8 - Plate

2 - Bolt (3 Used) 5 - Spacer 7 - Spring Washer (2 Used) 9 - Pin
3 - Spring Washer (3 Used)

W18K-E-00(20181019) W4-2-20
 FRONT ATTACHMENT / Cylinder
Installation
• As for the method to hoist the parts and the
position of the lifting holes, refer to Removal.
1. Remove the wire which secures the rod (2 used).
CAUTION: Bucket cylinder weight: 1370 kg
(3020 lb)
IMPORTANT: Attach a soft waste on the arm boss
in order not to damage the arm by a
wire.
2. Attach a wire onto the rod side of the bucket
cylinders (2 used) tube. Pass the wire through
the outside and the inside of the arm boss. Hoist
the rod side of the bucket cylinders (2 used) tube.
3. While holding the bucket cylinders (2 used),
connect the hydraulic hoses (4 used) to the
bucket cylinders (2 used).
: 14 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
4. Start the engine. While hoisting the rod side of
the bucket cylinders (2 used), extend the bucket
cylinder rod.
IMPORTANT: Install spacer (5) with the chamfered
side facing to the cylinder side.
5. Install spacers (5) (2 used) to the pin hole at the
cylinder rod side. Align the pin holes on the boom
and the rod side of the bucket cylinders (2 used).
W18K-E-00(20181019) W4-2-21
CAUTION: Pin (9) weight: 80 kg (180 lb)
6. Attach a nylon sling onto the body of pins (9) (2
used). Hoist and insert pins (9) (2 used) into the
pin hole. Install plates (8) (2 used) to the boom
with bolts (6) (4 used) and spring washers (7) (4
used).
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)
7. Attach a nylon sling onto the bottom side of the
bucket cylinders (2 used) tube. Attach a chain
block onto the nylon sling and the lifting bracket
on the arm bottom plate. Align the pin holes on
the bucket and the bottom side of the bucket
cylinders (2 used).
CAUTION: Pin (4) weight: 80 kg (180 lb)
8. Attach a nylon sling onto the body of pins (4) (2
used). Hoist and insert pins (4) (2 used) into the
pin hole. Install stoppers (1) (2 used) to the
bucket with bolts (2) (8 used) and spring washers
(3) (8 used).
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)
9. Connect the lubrication hoses (4 used) to the
bucket cylinders (2 used).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
10. Loosen the air breather of the cylinder and bleed
air from the cylinder. (Refer to MAIN POINTS TO
BLEED AIR on W4-2-54.)
 FRONT ATTACHMENT / Cylinder
Removal and Installation of Bucket Cylinder
(Backhoe)

Hydraulic Hose

Link A

Link B W18B-04-02-004

Bucket Cylinder Link A Bucket Bucket Cylinder

Link B Arm
8
1 2, 3
6, 7

4 5

Section A W118-04-01-021
Section B W141-04-02-003

Lubrication Port

Link A

Link B

W18C-04-02-004

1 - Pin 3 - Spring Washer (4 Used) 5 - Pin 7 - Spring Washer (2 Used)

2 - Bolt (4 Used) 4 - Stopper 6 - Bolt (2 Used) 8 - Plate

W18K-E-00(20181019) W4-2-22
 FRONT ATTACHMENT / Cylinder
Removal

1. Disconnect the lubrication hoses (6 used) from
the bucket cylinder at the bucket cylinder side.
: 19 mm, 22 mm
2. Set the front attachment as illustrated below.
Insert a wooden block between link A, link B and
the arm.
Link B
Link A
7. Stop the engine. Bleed air from the hydraulic oil
tank. Operate the control lever several times and
release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)
8. Disconnect the hydraulic hoses (4 used) from the
bucket cylinders (2 used) at the bucket cylinder
side. Install a plated plug to the open end.
: 14 mm

9. Remove bolts (6) (4 used) and spring washers

(7) (4 used) from plates (8) (2 used). Remove
plates (8) (2 used) from the arm.
: 30 mm

W18B-04-02-008
Wooden Block
CAUTION: Pin (5) weight: 40 kg (90 lb)
CAUTION: Bucket cylinder weight: 890 kg
10. Push out pins (5) (2 used) to the position where
(1970 lb)
the bucket cylinders (2 used) can be removed
from the arm. Attach a nylon sling onto the body
3. Attach a nylon sling onto the bucket cylinders (2
of pins (5) (2 used). Hoist and remove pins (5) (2
used). Hold the bucket cylinders (2 used).
used).
4. Remove bolts (2) (8 used) and spring washers
11. Hoist and remove the bucket cylinders (2 used)
(3) (8 used) from stopper (4). Remove stoppers
from the arm.
(4) (2 used) from link B.
: 30 mm

CAUTION: Pin (1) weight: 80 kg (180 lb)

5. Push out pins (1) (2 used) to the position where

the rod of the bucket cylinders (2 used) can be
removed from link A. Attach a nylon sling onto the
body of pins (1) (2 used). Hoist and remove pins
(1) (2 used).

6. Start the engine and retract the bucket cylinder rod.

Secure the rod to the cylinder tube by using a
wire in order not to extend the rod by its own
weight.

W18K-E-00(20181019) W4-2-23
 FRONT ATTACHMENT / Cylinder

Hydraulic Hose

Link A

Link B W18B-04-02-004

Bucket Cylinder Link A Bucket Bucket Cylinder

Link B Arm
8
1 2, 3
6, 7

4 5

Section A W118-04-01-021
Section B W141-04-02-003

Lubrication
Port

Link A

Link B

W18C-04-02-004

1 - Pin 3 - Spring Washer (4 Used) 5 - Pin 7 - Spring Washer (2 Used)

2 - Bolt (4 Used) 4 - Stopper 6 - Bolt (2 Used) 8 - Plate

W18K-E-00(20181019) W4-2-24
 FRONT ATTACHMENT / Cylinder
Installation

CAUTION: Bucket cylinder weight: 890 kg
(1970 lb)
IMPORTANT: Check
1. Attach a nylon sling onto the bucket cylinders (2
used). Hoist the bucket cylinders (2 used).
2. Align the pin holes on the arm and the bottom
side of the bucket cylinders (2 used).
CAUTION: Pin (5) weight: 40 kg (90 lb)
3. Attach a nylon sling onto the body of pins (5) (2
used). Hoist and insert pins (5) (2 used) into the
pin hole. Install plates (8) (2 used) to the arm with
bolts (6) (4 used) and spring washers (7) (4
used).
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)
4. Connect the hydraulic hoses (4 used) to the
bucket cylinders (2 used).
: 14 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
CAUTION: Pin (1) weight: 80 kg (180 lb)
the direction of the
lubrication port and install stopper
(4).
7. Attach a nylon sling onto the body of pin (1).
Hoist and insert pins (1) (2 used) into the pin hole.
Install stoppers (4) (2 used) to link B with bolts (2)
(8 used) and spring washers (3) (8 used).
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)
8. Connect the lubrication hoses (6 used) to the
bucket cylinders (2 used).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
9. Loosen the air breather of the cylinder and bleed
air from the cylinder. (Refer to MAIN POINTS TO
BLEED AIR on W4-2-54.)

5. Remove the wire which secures the rod of the

bucket cylinder.

6. Start the engine. Hoist the rod side of the bucket

cylinders (2 used) tube. Extend the bucket
cylinder rod. Align the pin holes on link B, link A
and the rod side of the bucket cylinders (2 used).

W18K-E-00(20181019) W4-2-25
 FRONT ATTACHMENT / Cylinder
Removal and Installation of Level Cylinder
(Loading Shovel Only)

Hydraulic Hose

A
A

W18B-04-01-017

Level Cylinder
Boom or Arm
4
2, 3

Section A
W18C-04-02-005

1 - Pin 2 - Bolt (2 Used) 3 - Spring Washer (2 Used) 4 - Plate

W18K-E-00(20181019) W4-2-26
 FRONT ATTACHMENT / Cylinder
Removal

IMPORTANT: Check that arm cylinder is equipped

when removing the level cylinder. CAUTION: Pin (1) weight: 90 kg

IMPORTANT: Set the bucket assembly onto the 4. Move pin (1) to the position where the level
ground. cylinder can be removed from the arm. Wind the
nylon slings onto the body of pin (1). Lower and
remove it from the arm.
1. Disconnect the lubrication hoses (2 used) from
the level cylinder.
Cap the open ends.
: 19 mm

CAUTION: Level cylinder weight: 1370 kg

2. Attach nylon slings onto the rod side and bottom

side of level cylinder. Hold the level cylinder.

Nylon Sling

W18J-04-02-006
Level Cylinder

3. Remove bolts (2) (2 used) and spring washers

(3) (2 used) from pin (1) at the rod side. Remove
plate (4) from the arm.
: 30 mm

W18K-E-00(20181019) W4-2-27
 FRONT ATTACHMENT / Cylinder

DANGER: The hydraulic circuits of the level CAUTION: Pin (1) weight: 90 kg
cylinder and boom cylinder are connected.
When the rod of level cylinder is extended,
the boom cylinders are retracted, At the 10. Move pin (1) to the position where the level
same time, the boom is lowered. Take care cylinder can be removed from the boom.
the boom movement. Wind the nylon slings onto the body of pin (1).
Provide signals commonly known by all Lower and remove pin (1) from the boom.
personnel involved. Also, appoint a signal
person to coordinate the job site. 11. Lower the level cylinder by using the chain blocks
and the nylon slings. Remove it.
5. Start the engine and lower the boom. Retract the
rod of level cylinder. Secure the rod part by using
the wires in order not to extend the level cylinder.

6. Stop the engine. Bleed air from the hydraulic oil

tank. Operate the control lever several times and
release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.). If the remaining pressure is
left, release the remaining pressure by loosening
the air bleed valve of the cylinder. (Refer to
BLEED AIR FROM CYLINDER on W4-2-54.)

7. Disconnect the hydraulic hoses (3 used) from the

level cylinder. Install a plate plug to the open end.
: 14 mm

8. Remove the arm cylinder. (Refer to W4-2-9.)

9. Remove bolts (2) (2 used) and spring washers

(3) (2 used) from pin (1) at the bottom side.
Remove plate (4) from the boom.
: 30 mm

W18K-E-00(20181019) W4-2-28
 FRONT ATTACHMENT / Cylinder
(Blank)

W18K-E-00(20181019) W4-2-29
 FRONT ATTACHMENT / Cylinder

Hydraulic Hose

A
A

W18B-04-01-017

Level Cylinder
Boom or Arm
4
2, 3

Section A
W18C-04-02-005

1 - Pin 2 - Bolt (2 Used) 3 - Spring Washer (2 Used) 4 - Plate

W18K-E-00(20181019) W4-2-30
 FRONT ATTACHMENT / Cylinder
Installation

 As for the method to hoist the parts and the position 7. Connect the hydraulic hoses (2 used) to the level
of the lifting holes, refer to REMOVAL on W4-2-27. cylinder.
: 14 mm
: 210 Nm (21 kgfm)
CAUTION: Level cylinder weight: 1370 kg
8. Remove the wires which secures the rod part.
1. Secure the rod part by using the wires in order
not to extend the level cylinder.

2. Hoist the level cylinder by using the chain blocks

and the nylon slings.

3. Fit the pin holes of the level cylinder bottom side

and the boom.

CAUTION: Pin (5) weight: 90 kg

4. Wind the nylon slings onto the body of pin (1).

Hoist it.
5. Install pin (1) to the pin hole. Install plate (4) to
the boom with bolts (2) (2 used) and spring
washers (3) (2 used).
: 30 mm
: 400 Nm (40 kgfm)

6. Install the arm cylinder. (Refer to W4-2-13.)

W18K-E-00(20181019) W4-2-31
 FRONT ATTACHMENT / Cylinder

DANGER: The hydraulic circuits of the level

cylinder and boom cylinder are connected.
When the rod of level cylinder is extended,
the boom cylinders are retracted, At the
same time, the boom is lowered. Take care
the boom movement.
Provide signals commonly known by all
personnel involved. Also, appoint a signal
person to coordinate the job site.

9. Start the engine. Raise the boom. Extend the rod

of level cylinder. Fit the pin holes of the rod and
the arm by using the chain blocks.

CAUTION: Pin (1) weight: 90 kg

10. Wind the nylon slings onto the body of pin (1).
Hoist it.

11. Install pin (1) to the pin hole. Install plate (4) to
the arm with bolts (2) (2 used) and spring
washers (3) (2 used).
: 30 mm
: 400 Nm (40 kgfm)

12. Connect the lubrication hoses (2 used) to the

level cylinder.
: 19 mm
: 30 Nm (3 kgfm)

13. Remove the air bleed plug of cylinder. Bleed air

from the cylinder. (Refer to W4-2-54.)

W18K-E-00(20181019) W4-2-32
 FRONT ATTACHMENT / Cylinder
(Blank)

W18K-E-00(20181019) W4-2-33
 FRONT ATTACHMENT / Cylinder
Removal and Installation of Dump Cylinder
(Loading Shovel Only)

W18B-04-01-001

Bucket Dump Cylinder Bucket Dump Cylinder

8
4

5, 6
9

3 7

2
Section B W144-04-01-010

Section A W118-04-02-007

1 - Lock Plate 4 - Plate 6 - Spring Washer (2 Used) 8 - Spacer (2 Used)

2 - Socket Bolt (4 Used) 5 - Bolt (2 Used) 7 - Grease Fitting 9 - Pin
3 - Pin

W18K-E-00(20181019) W4-2-34
 FRONT ATTACHMENT / Cylinder
Removal
1. Remove bolts (12) (24 used) from covers (10, 11)
(2 used for each). Remove covers (10, 11) (2
used for each) from the side of the bucket.
: 19 mm
Cover (10)
Bolt (12)
Cover (11)
W18C-04-02-006
Side of Bucket
2. Disconnect the lubrication hose from the dump
cylinder.
: 19 mm
CAUTION: Dump cylinder weight: 300 kg
(670 lb)
3. Attach a nylon sling onto the dump cylinders (2
used). Hold the dump cylinders (2 used).
4. Remove socket bolts (2) (4 used) from lock
plates (1) (2 used) at the dump cylinder rod side.
Remove lock plates (1) (2 used) from the bucket.
: 19 mm
CAUTION: Pin (3) weight: 21 kg (50 lb)
5. Push out pins (3) (2 used) to the position where
the dump cylinders (2 used) can be removed
from the bucket. Attach a nylon sling onto the
body of pins (3) (2 used). Hoist and remove pins
(3) (2 used).
6. Start the engine and retract the dump cylinder rod.
Secure the rod to the cylinder tube by using a
wire in order not to extend the rod by its own
weight.
W18K-E-00(20181019)
7. Stop the engine. Bleed air from the hydraulic oil
tank. Operate the control lever several times and
release any remaining pressure in the circuit.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)
8. Disconnect the hydraulic hoses (4 used) from the
dump cylinders (2 used) at the dump cylinder
side. Install a plated plug to the open end.
: 10 mm
9. Remove grease fittings (7) (2 used) from pins (9)
(2 used).
: 14 mm
10. Remove bolts (5) (4 used) and spring washers
(6) (4 used) from plate (4) of the bottom side.
Remove plates (4) (2 used) from the bucket.
: 24 mm
CAUTION: Pin (9) weight: 32 kg (71 lb)
11. Push out pins (9) (2 used) to the position where
the dump cylinders (2 used) can be removed
from the bucket. Attach a nylon sling onto the
body of pins (9) (2 used). Hoist and remove pins
(9) (2 used).
12. Hoist and remove the dump cylinder from the
bucket. Remove spacers (8) (4 used) from the
pin hole.
W4-2-35
 FRONT ATTACHMENT / Cylinder

W18B-04-01-001

Bucket Dump Cylinder Bucket Dump Cylinder

8
4

5, 6
9

3 7

2
Section B W144-04-01-010

Section A W118-04-02-007

1 - Lock Plate 4 - Plate 6 - Spring Washer (2 Used) 8 - Spacer (2 Used)

2 - Socket Bolt (4 Used) 5 - Bolt (2 Used) 7 - Grease Fitting 9 - Pin
3 - Pin

W18K-E-00(20181019) W4-2-36
 FRONT ATTACHMENT / Cylinder
Installation
• As for the method to hoist the parts and the
position of the lifting holes, refer to Removal. CAUTION: Pin (3) weight: 21 kg (50 lb)

8. Attach a nylon sling onto the body of pins (3) (2

CAUTION: Dump cylinder weight: 300 kg
(670 lb)
1. Attach a nylon sling onto the dump cylinders (2
used). Hoist the dump cylinders (2 used).
2. Align the pin hole on the bucket and the bottom
side of the dump cylinders (2 used). Install
spacers (8) (4 used) to the pin hole.
CAUTION: Pin (9) weight: 32 kg (71 lb)
3. Attach a nylon sling onto the body of pins (9) (2
used). Hoist and insert pins (9) (2 used) into the
pin hole. Install plates (4) (2 used) to the bucket
with bolts (5) (4 used) and spring washers (6) (4
used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
used). Hoist and insert pins (3) (2 used) into the
pin hole. Install lock plates (1) (2 used) to the
bucket while aligning the groove on pins (3) (2
used). Install lock plates (1) (2 used) to the
bucket with socket bolts (2) (8 used).
: 19 mm
: 1030 Nm (105 kgfm, 760 lbfft)
9. Install covers (10, 11) (2 used for each) to the
side of the bucket with bolts (12) (24 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)
Cover (10)
Bolt (12)
Cover (11)

4. Install grease fittings (7) (2 used) to pins (9) (2

used). W18C-04-02-006

: 14 mm Side of Bucket

10. Connect the lubrication hoses (6 used) to the

5. Connect the hydraulic hoses (4 used) to the dump cylinders (2 used).
dump cylinders (2 used). : 19 mm
: 10 mm : 29.5 Nm (3 kgfm, 22 lbfft)
: 110 Nm (11 kgfm, 81 lbfft)
11. Loosen the air breather of the cylinder and bleed
6. Remove the wire which secures the rod of the air from the cylinder. (Refer to MAIN POINTS TO
dump cylinder. BLEED AIR on W4-2-50.)
7. Start the engine. Hoist the rod side of the dump
cylinders (2 used) tube. Extend the dump
cylinder rod and align the pin holes on the bucket
and the dump cylinder rod side.

W18K-E-00(20181019) W4-2-37
 FRONT ATTACHMENT / Cylinder
(Blank)

W18K-E-00(20181019) W4-2-38
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF CYLINDER

Boom Cylinder (Loading Shovel, Backhoe), Arm

Cylinder (Backhoe)

27
26
25
24
23 1
22
21

20
19
18
17
16
28 2
29
3
4
5
13
15 6
7

9
10
11
12

14
W18B-04-02-016

1- Piston Rod 9- Bushing 17 - Slide Ring 25 - Slide Ring

2- Wiper Ring 10 - Retaining Ring 18 - Slide Ring 26 - Slide Ring
3- Slide Ring 11 - Backup Ring 19 - Seal Ring 27 - Cushion Bearing
4- Backup Ring 12 - O-Ring 20 - Seal Ring 28 - Steel Ball
5- U-Ring Packing 13 - Socket Bolt 21 - Piston 29 - Set Screw
(Boom: 11 Used)
(Arm: 10 Used)
6 - Ring 14 - Air Breather 22 - Backup Ring
7 - Air Breather 15 - Cylinder Tube 23 - O-Ring
8 - Cylinder Head 16 - Nut 24 - Backup Ring

W18K-E-00(20181019) W4-2-39
 FRONT ATTACHMENT / Cylinder
Arm Cylinder (Loading Shovel), Bucket Cylinder
(Backhoe)

Air breather (13) is not 23

provided for the arm 22
cylinder. 21
1

20

19
18
17
16
24
15 25
2
3
4
13 5
14 6
7

9
10
11
12

26

W18C-04-02-007

1- Piston Rod 8- Cylinder Head 15 - Nut 22 - Slide Ring

2- Wiper Ring 9- Bushing 16 - Slide Ring 23 - Cushion Bearing
3- Ring 10 - Retaining Ring 17 - Slide Ring 24 - Steel Ball
4- Backup Ring 11 - Backup Ring 18 - Seal Ring 25 - Set Screw
5- U-Ring Packing 12 - O-Ring 19 - Seal Ring 26 - Air Breather
(Arm: 1 Used)
(Bucket: 2 Used)
6 - Ring 13 - Air Breather 20 - Piston
7 - Socket Bolt 14 - Cylinder Tube 21 - Slide Ring
(Arm: 10 Used)
(Bucket: 8 Used)

W18K-E-00(20181019) W4-2-40
 FRONT ATTACHMENT / Cylinder
Bucket Cylinder (Loading Shovel)

26
25
24
23
22 1
21
20

19
18
17
16
15
2
27

3
4
12
14 5
6

8
9
10
11

13
W18C-04-02-008

1- Piston Rod 8- Bushing 15 - Nut 22 - O-Ring

2- Wiper Ring 9- Retaining Ring 16 - Slide Ring 23 - Backup Ring
3- Backup Ring 10 - Backup Ring 17 - Slide Ring 24 - Slide Ring
4- U-Ring Packing 11 - O-Ring 18 - Seal Ring 25 - Slide Ring
5- Ring 12 - Socket Bolt (8 Used) 19 - Seal Ring 26 - Cushion Bearing
6- Air Breather 13 - Air Breather 20 - Piston 27 - Set Screw
7- Cylinder Head 14 - Cylinder Tube 21 - Backup Ring

W18K-E-00(20181019) W4-2-41
 FRONT ATTACHMENT / Cylinder
Level Cylinder
(Loading Shovel)

25
24
23
22
21 1
20
19
18
17
16
15 26
27

2
3
4
14 5
6
13 7

9
10
11
12

28

W18C-04-02-009

1- Piston Rod 8- Cylinder Head 15 - Nut 22 - O-Ring

2- Wiper Ring 9- Bushing 16 - Slide Ring 23 - Backup Ring
3- Ring 10 - Retaining Ring 17 - Slide Ring 24 - Slide Ring
4- Backup Ring 11 - Backup Ring 18 - Seal Ring 25 - Slide Ring
5- U-Ring Packing 12 - O-Ring 19 - Seal Ring 26 - Steel Ball
6- Ring 13 - Air Breather 20 - Piston 27 - Set Screw
7- Socket Bolt (11 Used) 14 - Cylinder Tube 21 - Backup Ring 28 - Air Breather

W18K-E-00(20181019) W4-2-42
 FRONT ATTACHMENT / Cylinder
Dump Cylinder
(Loading Shovel)

21

20
19
1

18

17
16
15
14
22
13
23
2

3
4
12 5
6

8
9
10
11

W18C-04-02-010

1- Piston Rod 7- Cylinder Head 13 - Nut 19 - Slide Ring

2- Wiper Ring 8- Bushing 14 - Slide Ring 20 - Slide Ring
3- Backup Ring 9- Retaining Ring 15 - Slide Ring 21 - Cushion Bearing
4- U-Ring Packing 10 - Backup Ring 16 - Seal Ring 22 - Steel Ball
5- Ring 11 - O-Ring 17 - Seal Ring 23 - Set Screw
6- Socket Bolt (8 Used) 12 - Cylinder Tube 18 - Piston

W18K-E-00(20181019) W4-2-43
 FRONT ATTACHMENT / Cylinder

Backup rings (22, 24) and

O-ring (23) are not provided
for the arm (LD), bucket 27
(BH) and dump cylinders. 26
Slide ring (3) is not provided 25
for the bucket (LD) and 24
23 1
dump cylinders.
Steel ball (28) is not 22
provided for the bucket 21
cylinder (LD).
Cushion bearing (27) is not 20
provided for the level 19
cylinder. Air breathers (7, 18
14) are not provided for the 17
dump cylinder. 16
28 2
29
3
4
5
13
15 6
7

9
10
11
12

14
W18B-04-02-016

1- Piston Rod 9- Bushing 17 - Slide Ring 24 - Backup Ring

2- Wiper Ring 10 - Retaining Ring 18 - Slide Ring 25 - Slide Ring
3- Slide Ring 11 - Backup Ring 19 - Seal Ring 26 - Slide Ring
4- Backup Ring 12 - O-Ring 20 - Seal Ring 27 - Cushion Bearing
5- U-Ring Packing 13 - Socket Bolt 21 - Piston 28 - Steel Ball
(Boom, Level: 11 Used),
(Arm: 10 Used),
(Bucket, Dump: 8 Used)
6 - Ring 14 - Air Breather 22 - Backup Ring 29 - Set Screw
7 - Air Breather 15 - Cylinder Tube 23 - O-Ring
8 - Cylinder Head 16 - Nut

NOTE: LD: Loading shovel

BH: Backhoe

W18K-E-00(20181019) W4-2-44
 FRONT ATTACHMENT / Cylinder
Disassembly of Cylinder

1. Disconnect the pipe from cylinder tube (15). 3. Remove set screw (29) and steel ball (28) from
: Arm, bucket: 14 mm nut (16). Remove nut (16) from piston rod (1).
NOTE: Set screw (29) has been crimped by using
CAUTION: The piston rod (1) assembly a punch at two places after installing. Cut
weight: away the crimped position by using a hand
drill and remove set screw (29).
Loading shovel Backhoe Bucket:
Boom 1180 kg (2610 lb) 1180 kg (2610 lb) : 10 mm
Arm 840 kg (1860 lb) 830 kg (1830 lb) Except the bucket:
Bucket 670 kg (1480 lb) 500 kg (1110 lb) : 14 mm
Level 740 kg (1640 lb) - Boom, level:
Dump 180 kg (400 lb) - : 220 mm
Arm:
IMPORTANT: Remove the piston rod (1) assembly : 200 mm
straight in order not to damage the Bucket (loading shovel):
sliding surface. : 180 mm
2. Remove socket bolt (13) from cylinder head (8). Bucket (backhoe):
Hoist and remove the piston rod (1) assembly : 165 mm
from cylinder tube (15). Dump:
Boom, level: : 130 mm
: 27 mm
Arm, bucket 4. Remove piston (21) and cushion bearing (27)
(loading shovel): from piston rod (1).
: 24 mm NOTE: Cushion bearing (27) is not equipped for
Bucket (backhoe), dump: the level cylinder.
: 22 mm

W18K-E-00(20181019) W4-2-45
 FRONT ATTACHMENT / Cylinder

27
26
25
24
23 1
22

21
20
19
18
17

3
4
5
6

9
10

18B-04-02-016

W18K-E-00(20181019) W4-2-46
 FRONT ATTACHMENT / Cylinder
IMPORTANT: When removing the seals, do not
CAUTION: Piston rod (1) weight: damage the parts.
Loading shovel Backhoe 6. Remove O-ring (23), backup rings (22, 24), slide
Boom 910 kg (2010 lb) 910 kg (2010 lb) rings (17, 18, 25, 26) and seal rings (19, 20) from
Arm 670 kg (1480 lb) 610 kg (1350 lb) piston (21).
Bucket 560 kg (1240 lb) 400 kg (890 lb)
Level 490 kg (1080 lb) - 7. Remove wiper ring (2), slide ring (3), U-ring
Dump 110 kg (250 lb) - packing (5), backup ring (4), ring (6), bushing (9)
and retaining ring (10) from cylinder head (8).

CAUTION: The cylinder head (8) assembly

weight:
Loading shovel Backhoe
Boom 150 kg (340 lb) 150 kg (340 lb)
Arm 130 kg (290 lb) 90 kg (200 lb)
Bucket 70 kg (160 lb) 50 kg (110 lb)
Level 150 kg (340 lb) -
Dump 50 kg (110 lb) -

5. Attach a nylon sling onto cylinder head (8). Hoist

and hold cylinder head (8). Wind a vinyl tape onto
the thread part of piston rod (1) in order to protect
the seal of cylinder head (8). Remove the
cylinder head (8) assembly from piston rod (1).

W18K-E-00(20181019) W4-2-47
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF CYLINDER

Backup rings (22, 24) and

O-ring (23) are not provided
for the arm (LD), bucket
(BH) and dump cylinders.
2
Slide ring (3) is not provided 8 3
for the bucket (LD) and
13 4, 5
dump cylinders.
6
Steel ball (28) is not
provided for the bucket 9
cylinder (LD). 10
Cushion bearing (27) is not
provided for the level 11, 12
cylinder. Air breathers (7,
14) are not provided for the 1
dump cylinder.
15

27
22, 23, 24
26
21 25
19, 20
18
17
16
29
28

W118-04-01-012

1- Piston Rod 9- Bushing 17 - Slide Ring 24 - Backup Ring

2- Wiper Ring 10 - Retaining Ring 18 - Slide Ring 25 - Slide Ring
3- Slide Ring 11 - Backup Ring 19 - Seal Ring 26 - Slide Ring
4- Backup Ring 12 - O-Ring 20 - Seal Ring 27 - Cushion Bearing
5- U-Ring Packing 13 - Socket Bolt 21 - Piston 28 - Steel Ball
(Boom, Level: 11 Used),
(Arm: 10 Used),
(Bucket, Dump: 8 Used)
6 - Ring 14 - Air Breather 22 - Backup Ring 29 - Set Screw
7 - Air Breather 15 - Cylinder Tube 23 - O-Ring
8 - Cylinder Head 16 - Nut

W18K-E-00(20181019) W4-2-48
 FRONT ATTACHMENT / Cylinder
Assembly of Cylinder
NOTE: Degrease, clean and dry the disassembled CAUTION: The cylinder head (8) assembly
parts before assembling. Warm up the seal weight:
parts to 80°C (176°F) before assembling.
Loading shovel Backhoe
IMPORTANT: Install backup ring (4) to the pin Boom 150 kg (340 lb) 150 kg (340 lb)
hole side of piston rod (1). Install Arm 130 kg (290 lb) 90 kg (200 lb)
U-ring packing (5) to the piston (21) Bucket 70 kg (160 lb) 50 kg (110 lb)
side. Face the lip part of U-ring Level 150 kg (340 lb) -
packing (5) to the piston (21) side. Dump 50 kg (110 lb) -
Install ring (6) with the lip part
facing to the piston (21) side.
CAUTION: Piston rod (1) weight:
1. Install retaining ring (10), bushing (9), ring (6),
U-ring packing (5), backup ring (4), slide ring (3) Loading shovel Backhoe
and wiper ring (2) to cylinder head (8). Boom 910 kg (2010 lb) 910 kg (2010 lb)
Arm 670 kg (1480 lb) 610 kg (1350 lb)
IMPORTANT: Install backup ring (11) to the pin Bucket 560 kg (1240 lb) 400 kg (890 lb)
hole side of piston rod (1). Install Level 490 kg (1080 lb) -
O-ring (12) to the piston (21) side. Dump 110 kg (250 lb) -
2. Install backup ring (11) and O-ring (12) to cylinder
head (8). 3. Wind the vinyl tape onto the thread part of piston
rod (1). Install the cylinder head (8) assembly to
piston rod (1) by turning.

W18K-E-00(20181019) W4-2-49
 FRONT ATTACHMENT / Cylinder

27
22, 23, 24 26
21
25
19, 20
18
17
16

W118-04-01-012

W18K-E-00(20181019) W4-2-50
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Clean the thread part of piston rod IMPORTANT: Clean both ends of piston (21). This
(1) and cushion bearing (27). This can affect to the tightening torque
can affect to the tightening torque of nut (16).
of nut (16). 8. Clean both ends of piston (21). Install piston (21)
IMPORTANT: Install cushion bearing (27) with the to cylinder rod (1). At this time, face the step
larger groove side facing to the surface to the nut (16) side.
cylinder head (8) side.
4. Clean piston rod (1) and cushion bearing (27). IMPORTANT: Clean nut (16). This can affect to the
Install cushion bearing (27) to piston rod (1). tightening torque.
NOTE: Check the outer diameter of cushion 9. Clean nut (16).
bearing (27) before assembling. (Refer to Install nut (16) to piston rod (1). Tighten nut (16)
W4-2-52.) to the specified torque.
NOTE: Cushion bearing (27) is not equipped for NOTE: If the parts are not degreased thoroughly,
the level cylinder. cushion bearing (27) may expand as the
parts are tightened too much due to the oil
27
slip.
Groove
Boom
: 220 mm
: 54700±2750 Nm
(5570±280 kgfm, 40400±2030 lbfft)
W18B-04-02-011
Arm (loading shovel)
: 200 mm
5. Install O-ring (23) and backup rings (22, 24) to : 44400±2210 Nm
the inner side of piston (21). (4520±225 kgfm, 32800±1630 lbfft)
NOTE: O-ring (23) and backup rings (22, 24) are Arm (backhoe)
not equipped for the dump cylinder. : 200 mm
: 53100±2650 Nm
6. Install sealing rings (19, 20) to the outer side of (5410±270 kgfm, 39200±1960 lbfft)
piston (21). At this time, install seal rings (19, 20) Bucket (loading shovel)
by using a bamboo spatula in order to prevent : 180 mm
from inserting into the other ring grooves. : 33000±1670 Nm
(3350±170 kgfm, 24400±1240 lbfft)
IMPORTANT: Install rings (17, 18, 25, 26) in order Bucket (backhoe)
not to align their split positions at : 165 mm
the same place. : 29000±1430 Nm
7. Install rings (17, 18, 25, 26) to the outer surface (2930±146 kgfm, 21400±1060 lbfft)
of piston (21). Level
: 220 mm
: 55000±2750 Nm
(5570±280 kgfm, 40600±2030 lbfft)
Dump
: 130 mm
: 15000±2700 Nm
(1475±275 kgfm, 11100±2000 lbfft)

W18K-E-00(20181019) W4-2-51
 FRONT ATTACHMENT / Cylinder

13

15

27

16
29
28

W118-04-01-012

W18K-E-00(20181019) W4-2-52
 FRONT ATTACHMENT / Cylinder
IMPORTANT: The outer diameter dimensions of
cushion bearing (27) are not same CAUTION: The piston rod (1) assembly
before and after nut (16) are weight:
tightened. Measure the outer Loading shovel Backhoe
diameter after it is tightened and Boom 1180 kg (2600 lb) 1180 kg (2600 lb)
check if the dimension is within the Arm 840 kg (1860 lb) 830 kg (1830 lb)
specification. Bucket 670 kg (1480 lb) 500 kg (1110 lb)
10. Measure the outer diameter of cushion bearing Level 740 kg (1630 lb) -
(27) at 4 places (A), (B), (C) and (D) after Dump 180 kg (400 lb) -
tightening nut (16).
If the measured values are not within the IMPORTANT: Align with the center of cylinder
specification, repeat the work from step 4. tube (15) and insert the piston rod
(1) assembly straight in order not to
A B C D damage the rings.
12. Insert the piston rod (1) assembly into cylinder
tube (15). Install cylinder head (8) to cylinder tube
(15) with socket bolt (13).

Boom, level
: 27 mm
: 2460±460 Nm
(251±47 kgfm, 1820±340 lbfft)
Arm, bucket (loading shovel)
W18B-04-02-014
: 24 mm
: 1910±353 Nm
Standard Unit: mm (in) (195±36 kgfm, 1410±260 lbfft)
Cylinder After tightening Bucket (backhoe)
: 22 mm
-0.195 -0.001
Boom Dia.218-0.224 (Dia.8.6 ) : 1590±295 Nm
-0.009
(162±30 kgfm, 1180±220 lbfft)
-0.140 -0.006
Arm (loading shovel) Dia.188 (Dia.7.4 ) Dump
-0.169 -0.007
±0.015 ±0.001
: 22 mm
Arm (backhoe) Dia.187.71 (Dia.7.4 ) : 1410±265 Nm
Bucket -0.140 -0.006 (144±27 kgfm, 1040±195 lbfft)
Dia.178 (Dia.7 )
(loading shovel) -0.165 -0.006
-0.195 -0.008 13. Install the pipe to cylinder tube (15) with the
Bucket (backhoe) Dia.158 (Dia.6.2-0.009 )
-0.220 socket bolt.
-0.290 -0.011 : Arm (loading shovel)
Dump Dia.126 (Dia.5 )
-0.315 -0.012 : 14 mm
: 443±82.4 Nm
IMPORTANT: Crimp set screw (29) at 2 places (45.1±8.4 kgfm, 330±61 lbfft)
diagonally by using a punch after : Arm (backhoe), bucket: 14 mm
tightening set screw (29). : 225±42.2 Nm
11. Install steel ball (28) and set screw (29) to nut (22.9±4.3 kgfm, 170±31 lbfft)
(16).

Wrench
Tightening Torque
Cylinder Size
Nm (kgfm)
(mm)
96±19
Dump 14
(9.8±1.9, 71±14 lbfft)
Boom, arm, level 138±26
14
(14.1±2.6, 102±19 lbfft)
Bucket 57±11
10
(5.8±1.1, 42±8 lbfft)

W18K-E-00(20181019) W4-2-53
 FRONT ATTACHMENT / Cylinder
MAIN POINTS TO BLEED AIR
Boom Cylinder
Bottom Side
Position of Air Breather Arm Cylinder
(Loading Shovel) Bottom Side

Bucket Cylinder
Rod Side

Level Cylinder
Rod Side
Level Cylinder
Bottom Side Boom Cylinder
Rod Side
Bucket Cylinder
Bottom Side

W18B-04-01-001

Position of Air Breather

(Backhoe) Arm Cylinder Arm Cylinder
Rod Side Bottom Side
Bucket Cylinder
Bottom Side
(2 Used) Boom Cylinder
Bottom Side

Boom Cylinder
Rod Side

Bucket Cylinder
Rod Side

W118-04-02-011

W18K-E-00(20181019) W4-2-54
 FRONT ATTACHMENT / Cylinder
Main Points to Bleed Air
• Main points to bleed air in each cylinder are 6. Remove the rubber cap at the cylinder bottom
same. Refer to the following procedures and side. Loosen the air breather.
bleed air from in each cylinder. : 8 mm

7. Operate the control lever slowly and retract the

CAUTION: Escaping fluid under pressure
may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing the hydraulic pipings or other
equipment.
Hot hydraulic oil just after operation may
spout and cause severe burns. Wait for oil in
order to cool before starting any work.
cylinder as much as possible. Bleed air until only
oil comes out from the air breather.
8. Tighten the air breather at the cylinder bottom
side. Install the rubber cap to the air breather.
: 8 mm
: 5.0±1.0 N·m (0.5±0.1 kgf·m, 3.7±0.7 lbf·ft)

1. Set the engine to the slow speed before bleeding

air. Operate the cylinder slowly to the stroke end
5 to 6 times.

2. Set the front attachment as illustrated on

W4-2-50.

3. Remove a rubber cap at the cylinder rod side.

Loosen a air breather.
NOTE: As the hydraulic hoses of the boom
cylinder and the level cylinder for the
loading shovel are connected, bleed air at
the same time.

4. Operate the control lever slowly and extend the

cylinder as much as possible. Bleed air until only
oil comes out from the air breather.
: 8 mm

5. Tighten the air breather at the cylinder rod side.

Install the rubber cap to the air breather.
: 8 mm
: 5.0±1.0 N·m (0.5±0.1 kgf·m, 3.7±0.7 lbf·ft)

W18K-E-00(20181019) W4-2-55
 FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
a b
Cylinder Tube
1. Tube (a)
• Check the inside and outside for any damage.

2. Pin, bushing (b) A

• Check the inside for any damage.

W145-04-01-015

Piston Rod
1. Rod (c) d c
• Place V blocks (2 used) onto the flat ground at 1
meter away between the V blocks. Place the
cylinder rod onto the V blocks. Install a dial
gauge. The rod should be repaired if the run-out C
is over 1.0 mm when operating the cylinder rod
by 1 turn.
If the run-out is over 2.0 mm, the rod should be
replaced. W166-04-02-023

• Check whether the wear on the outer diameter

surface is 0.02 mm or more at length of 200 mm Dial Gauge
for specified dimension (c). Piston Rod
• Check the surface for any damage.
• Check the plated part for any rust.
• Check the cushion part for any damage.

2. Pin, bushing (d)

W166-04-02-022
• Check the inside for any damage.
1m
V Block

Recommended Dimension Unit: mm

Loading Shovel Backhoe
Boom Level Stick Bucket Dump Boom Stick Bucket
0 0 0 0 0 0 0 0
Cylinder Tube Inner Dia. (A) 280 280 240 225 190 280 250 200
-0.081 -0.081 -0.072 -0.072 -0.072 -0.081 -0.081 -0.072

Rod Recommended Dimension -0.015 -0.015 -0.014 -0.014 -0.012 -0.015 -0.014 -0.014
200 200 180 170 110 200 170 150
(C) After Recovery -0.035 -0.035 -0.032 -0.032 -0.027 -0.035 -0.032 -0.032

NOTE: 1 mm = 0.03937 in

W18K-E-00(20181019) W4-2-56
 FRONT ATTACHMENT / Cylinder
Standard of Cushion Bearing
Unit: mm (in) A B C D
Cylinder Standard
-0.235 -0.009
Boom Dia.218-0.264 (Dia.8.6 )
-0.01

-0.170 -0.007
Arm (loading shovel) Dia.188 (Dia.7.4 )
-0.199 -0.008
±0.015 ±0.001
Arm (backhoe) Dia.187.67 (Dia.7.4 )
Bucket Dia.178
-0.170
(Dia.7
-0.007
)
(loading shovel) -0.195 -0.008 W18B-04-02-014
-0.235 -0.009
Bucket (backhoe) Dia.158 (Dia.6.2-0.01 )
-0.260

-0.320 -0.013
Dump Dia.126 (Dia.5 ) e f
-0.345 -0.014
e f

Piping
1. Piping (e)
• Check for any damage in depth more than 0.1
mm.
• Check for any deformation and damage. g
g
2. Socket bolt (f)
• Check for any heavy rust.
T182-05-02-004
• Check the thread part for any damage.

3. Ring (g)
• Replace O-ring when disassembling.

Piston/cylinder head
• Check the inside and outside for any damage.
• Check the groove for any damage.
• When the internal leakage is found, check the
seals for damage.
• Replace when the base metal of the bushing
sliding surface can be seen.

W18K-E-00(20181019) W4-2-57
 FRONT ATTACHMENT / Cylinder
(Blank)

W18K-E-00(20181019) W4-2-58
 FRONT ATTACHMENT / Bushing and Point
REMOVAL AND INSTALLATION OF
BUSHING

Removal Installation
1. Remove dust seal (1). 1. Cool bushing (2) by using dry ice.

2. Built up weld at four places, 90° apart from each 2. Install bushing (2) and dust seal (1).
others on the bushing (2) bore by using a welding
rod. Shrink and remove bushing (2).

NOTE: If bushing (2) cannot be removed, burn off

bushing (2).

Loading Shovel

1 3 2 2 W144-04-02-001
2 3

1
2
1

W144-04-02-006
W144-04-02-004
W144-04-02-003

Section of Part A Section of Part B Section of Part B Section of Part C

(Arm Side) (Boom Side) (Boom Side)
W144-04-02-005

1 - Dust Seal 2 - Bushing 3 - Spacer

W18K-E-00(20181019) W4-3-1
 FRONT ATTACHMENT / Bushing and Point
Backhoe

W145-04-02-005
1 2 3

Section of Part A
Section of Part A
(Bucket Side)
W144-04-02-011 (Arm Side)
W144-04-02-010
2
2 2

1 1

Section of Part B
(Boom Side)
Section of Part C
Section of Part B (Boom Side)
(Arm Side) W144-04-02-009 W144-04-02-008 W144-04-02-007

1 - Dust Seal 2 - Bushing 3 - Spacer

W18K-E-00(20181019) W4-3-2
 FRONT ATTACHMENT / Bushing and Point
(Blank)

W18K-E-00(20181019) W4-3-3
 FRONT ATTACHMENT / Bushing and Point
MAINTENANCE STANDARD

Pin and Bushing (Loading Shovel)

G
B
A

C C

F F

W118-04-01-003

W18K-E-00(20181019) W4-3-4
 FRONT ATTACHMENT / Bushing and Point

Unit: mm
Allowable
Position Item Standard
Limit
Pin Outer Dia. 200−0.1−0.2 196
Bushing Inner Dia. (Boom Side) 200+0.50+0.40 202
A : Boom and Arm Bushing Outer Dia. 230+0.48+0.43 −
Bushing Inner Dia. (Arm Side) 200+0.60+0.50 202
Bushing Outer Dia. 230+0.48+0.43 −
Pin Outer Dia. 160−0.1−0.2 156
B : Bucket Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 160+0.10 −
Bearing Inner Dia. (Cylinder Side) 160+0.006−0.071 161.5
Pin Outer Dia. 180−0.4−0.3 176
Pin Hole Inner Dia. (Boom Side) 180+0.10 −
C : Level Cylinder, Boom and Arm Pin Hole Inner Dia. (Arm Side) 180+0.10 −
Bearing Inner Dia. (Cylinder Rod Side) 180+0.20−0.07 182
(Cylinder Bottom Side) 180+0.006−0.071 182
Pin Outer Dia. 160−0.1−0.2 156
Bushing Inner Dia. (Arm Side) 160+0.40+0.30 162
D : Arm and Bucket Bushing Outer Dia. 190+0.33+0.28 −
Bushing Inner Dia. (Bucket Side) 160+0.40+0.36 162
Bushing Outer Dia. 190+0.33+0.28 −
Pin Outer Dia. 160−0.1−0.2 156
Bushing Inner Dia. (Bucket Side) 160+0.40+0.30 162
E : Bucket Cylinder and Bucket
Bushing Outer Dia. 190+0.33+0.28 −
Bearing Inner Dia. (Cylinder Side) 160+0.006−0.071 161.5
Pin Outer Dia. 180−0.4−0.3 176
F : Arm Cylinder, Boom and Arm Pin Hole Inner Dia. (Boom/Arm Sides) 180+0.10 −
Bearing Inner Dia. (Cylinder Side) 180+0.006−0.071 182
Pin Outer Dia. 180−0.1−0.2 176
G : Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 180+0.10 −
Bearing Inner Dia. (Cylinder Side) 180+0.006−0.071 182

NOTE: 1 mm=0.03937 in

W18K-E-00(20181019) W4-3-5
 FRONT ATTACHMENT / Bushing and Point

W118-04-01-003

W18K-E-00(20181019) W4-3-6
 FRONT ATTACHMENT / Bushing and Point

Unit: mm
Allowable
Position Item Standard
Limit
Pin Outer Dia. 110−0.1−0.2 106
H : Bucket Open / Close Cylinder and
Pin Hole Inner Dia. (Bucket Side) 110+0.35+0.25 112
Front Bucket
Bearing Inner Dia. (Cylinder Side) 110+0.25+0.05 111.5
Pin Outer Dia. 140−0.1−0.2 136
Bushing Inner Dia. (Rear Side) 140+0.45+0.35 142
I : Rear Bucket and Front Bucket Bushing Outer Dia. 165+0.32+0.28 −
Bushing Inner Dia. (Front Side) 140+0.45+0.35 142
Bushing Outer Dia. 165+0.32+0.28 −
Pin Outer Dia. 110−0.1−0.2 106
J : Bucket Open / Close Cylinder and
Pin Hole Inner Dia. (Bucket Side) 110 −
Rear Bucket
Bearing Inner Dia. (Cylinder Side) 110+0.25+0.05 111.5
Pin Outer Dia. 180−0.1−0.2 176
Bushing Inner Dia. (Boom Side) 180+0.50+0.40 182
K : Boom and Main Frame Bushing Outer Dia. 210+0.35+0.30 −
Bushing Inner Diameter (Frame Side) 180+0.40+0.30 182
Bushing Outer Dia. 210+0.35+0.30 −
Pin Outer Dia. 180−0.1−0.2 176
Bushing Inner Dia. (Frame Side) 180+0.40+0.30 184
L : Boom Cylinder and Main Frame
Bushing Outer Dia. 210+0.35+0.30 −
Bearing Inner Dia. (Cylinder Side) 180+0.006−0.071 182

NOTE: 1 mm=0.03937 in

W18K-E-00(20181019) W4-3-7
 FRONT ATTACHMENT / Bushing and Point
Pin and Bushing (Backhoe)

F D

E C

A W118-04-02-011

W18K-E-00(20181019) W4-3-8
 FRONT ATTACHMENT / Bushing and Point

Unit: mm
Allowable
Position Item Standard
Limit
Pin Outer Dia. 180−0.10−0.20 176
Bushing Inner Dia. (Frame Side) 180+0.40+0.30 184
A: Boom Cylinder and Main Frame
Bushing Outer Dia. 210+0.35+0.30 −
Bearing Inner Dia. (Cylinder Side) 180+0.006−0.071 182
Pin Outer Dia. 180−0.10−0.20 176
Bushing Inner Dia. (Frame Side) 180+0.40+0.30 182
B: Boom and Main Frame Bushing Outer Dia. 210+0.35+0.30 −
Bushing Inner Dia. (Boom Side) 180+0.50+0.40 182
Bushing Outer Dia. 210+0.35+0.30 －
Pin Outer Dia. 180−0.10−0.20 176
C: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 180+0.100 −
Bearing Inner Dia. (Cylinder Side) 180+0.006−0.071 182
Pin Outer Dia. 180−0.10−0.20 176
Bushing Inner Dia. (Boom Side) 180+0.40+0.30 184
D: Boom and Arm Cylinder
Bushing Outer Dia. 210+0.35+0.30 −
Bearing Inner Dia. (Cylinder Side) 180+0.006−0.071 182
Pin Outer Dia. 220−0.2−0.3 216
Bushing Inner Dia. (Boom Side) 220+0.29+0.24 222
E: Boom and Arm Bushing Outer Dia. 250+0.25+0.22 −
Bushing Inner Dia. (Arm Side) 220+0.37+0.32 222
Bushing Outer Dia. 250+0.35+0.32 −
Pin Outer Dia. 180−0.10−0.20 176
Bearing Inner Dia. (Cylinder Side) 180+0.006−0.071 182
F: Arm Cylinder and Arm
Bushing Inner Dia. (Arm Side) 180+0.40+0.30 184
Bushing Outer Dia. 210+0.35+0.30 −
Pin Outer Dia. 130−0.10−0.20 126
G: Arm and Bucket Cylinder Bearing Inner Dia. (Cylinder Side) 130+0.006−0.071 131.5
Pin Hole Inner Dia. (Arm Side) 130+0.100 −

NOTE: 1 mm=0.03937 in

W18K-E-00(20181019) W4-3-9
 FRONT ATTACHMENT / Bushing and Point

H
I

J K

W118-04-02-011

W18K-E-00(20181019) W4-3-10
 FRONT ATTACHMENT / Bushing and Point

Unit: mm
Allowable
Position Item Standard
Limit
Pin Outer Dia. 150−0.10−0.20 146
Bushing Inner Dia. (Link A Side) 150+0.45+0.35 152
Bushing Outer Dia 180+0.36+0.32 −
Bushing Inner Dia. (Link B Side: Outside) 150+0.45+0.35 152
H: Bucket Cylinder and Link
Bushing Outer Dia. 180+0.36+0.32 −
Bushing Inner Dia. (Link B Side: Inside) 150+0.45+0.35 152
Bushing Outer Dia. 180+0.36+0.32 −
Bearing Inner Dia. (Cylinder Side) 150+0.006−0.071 151.5
Pin Outer Dia. 130−0.10−0.20 126
Bushing Inner Dia. (Link A Side) 130+0.40+0.30 132
I: Link and Bucket Bushing Outer Dia. 155+0.32+0.28 −
Bushing Inner Dia. (Bucket Side) 130+0.23+0.13 132
Bushing Outer Dia. 155+0.32+0.28 −
Pin Outer Dia. 150−0.10−0.20 146
Bushing Inner Dia. (Arm Side) 150+0.45+0.35 152
J: Arm and Bucket Bushing Outer Dia. 180+0.36+0.32 −
Bushing Inner Dia. (Bucket Side) 150+0.45+0.35 152
Bushing Outer Dia. 180+0.36+0.32 −
Pin Outer Dia. 110−0.10−0.20 106
Bushing Inner Dia. (Arm Side) 110+0.35+0.25 112
Bushing Outer Dia. 130+0.26+0.22 −
K: Arm and Link Bushing Inner Dia. (Link B Side: Outside) 110+0.35+0.25 112
Bushing Outer Dia. 130+0.305+0.265 −
Bushing Inner Dia. (Link B Side: Inside) 110+0.35+0.25 112
Bushing Outer Dia. 130+0.305+0.265 −

NOTE: 1 mm=0.03937 in

W18K-E-00(20181019) W4-3-11
 FRONT ATTACHMENT / Bushing and Point
Point

M104-07-056

Unit: mm
Item Standard Allowable Limit Remedy
PCSA 10.5 m3 (13.7 yd3)
469 (285) Replace
Loading Shovel Bucket
A : Tooth Point
PCSA 9.6 m3 (12 .6 yd3),
335 (180) Replace
CECE 8.4 m3 Backhoe Bucket

NOTE: 1 mm=0.03937 in
The values in ( ) are just for reference.

W18K-E-00(20181019) W4-3-12
 MEMO

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W18K-E-00(20181019)
 MEMO

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W18K-E-00(20181019)
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162

SERVICE MANUAL REVISION REQUEST FORM

NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)

DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)

YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)

W18K-E-00(20181019)
 THE ATTACHED PATTERN LIST

The following patterns are attached to this manual.

1. Sprocket (A).

2. Sprocket (B).

3. Front Idler.

W18K-E-00(20181019)