PART NO.

WAFF50-EN-00

ZX65USB-6
HYDRAULIC EXCAVATOR
Workshop Manual

ZX65USB-6

WORKSHOP MANUAL
Hydraulic Excavator

URL:http://www.hitachi-c-m.com
WAFF50-EN-00

Service Manual consists of the following separate Part No.

Technical Manual : Vol. No.TAFF50-EN
Workshop Manual : Vol. No.WAFF50-EN
PRINTED IN JAPAN (K) 2019, 05 Engine Manual : Vol. No.ETDEP-EN,EWDEP-EN
 INTRODUCTION

To The Reader

This manual is written for an experienced technician to provide technical information needed to maintain and repair this
machine.
The machine specification and description according to destination may be explained on this manual.
● Be sure to thoroughly read this manual for correct product information and service procedures.
● If you have any questions or comments, at if you found any errors regarding the contents of this manual, please
contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy
this form for usage.)
• PS Information Center (PSI) Hitachi Construction Machinery Co., Ltd.
• TEL: 81-29-832-7084
• FAX: 81-29-831-1162
• E-mail: HCM-TIC-GES@hitachi-kenki.com

Additional References

Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training
material etc.) in addition to this manual.

Manual Composition

This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
● Information included in the Technical Manual: Technical information needed for redelivery and delivery
• Operation and activation of all devices and systems, operational performance tests, and troubleshooting
procedures.
● Information included in the Workshop Manual: Technical information needed for maintenance and repair of the
machine
• Tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and
assemble / disassemble procedures
● Information included in the Engine Manual: Technical information needed for redelivery and delivery and
maintenance and repair of the machine
• Operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures

Page Number

Each page has a number, located on the center lower part of the page. Each number contains the following information:
● Technical Manual: T 1-3-5

T Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
● Workshop Manual: W 1-3-2-5

W Workshop Manual
1 Section Number
3 Group Number
2 Sub Group Number

WAFF50-EN-00(07/05/2019) IN-1
 INTRODUCTION

5 Consecutive Page Number for Each Group

WAFF50-EN-00(07/05/2019) IN-2
 INTRODUCTION

Safety Alert Symbol and Headline Notations

In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal
injury of machine damage.

WARNING

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow
the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw
attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and
equipment when lifting heavy parts.

CAUTION

Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death. This is also
provided before the indication of mass to draw attention to safety during handling of the machine.
IMPORTANT

Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. This header is
given to matters that are important in terms of operation and management.

NOTE

Indicates supplementary technical information or know-how.

Units Used

SI Units (International System of Units) are used in this manual.

A table for conversion from SI units to other system units is shown below for reference purposes.
Quantity To Convert From Into Multiply By
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3 yd3 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm2 10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min-1 rpm 1.0

WAFF50-EN-00(07/05/2019) IN-3
 INTRODUCTION

Quantity To Convert From Into Multiply By

Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0

WAFF50-EN-00(07/05/2019) IN-4
 SYMBOL AND ABBREVIATION

Symbols and abbreviations

Symbols/ Name Meaning

abbrevia­
tions
TO Technical manual (Operational princi­ Technical manual (Operational principle).
ple)
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Mounting/dismounting, disassembly and as­
sembly of devices).
MC Main Controller Main Controller. MC controls the engine, pumps, and valves ac­
cording to the machine operation condition.
ECU Engine Control Unit Engine Controller. ECU controls the fuel injection amount and oth­
ers according to the machine operation condition.
ECM Engine Control Module Engine Controller. ECM controls the fuel injection amount and oth­
ers according to the machine operation condition.
E-ECU Engine Controller Engine Controller. E-ECU controls the fuel injection amount and
others according to the machine operation condition.
VGS Variable Geometry System controller Variable Geometry System controller. VGS is a system for efficiently
supercharging even when the engine speed is low and the ex­
haust energy is low. Through adjustment of the nozzle opening of
the turbine housing, the turbine rotation speed is optimized, the
low-speed torque and acceleration are improved, and the power
consumption and PM are reduced.
GSM Global System for Mobile communica­ Communication Controller. GSM is one of wireless communication
tions controller methods and is used in over 100 countries centering around Eu­
rope and Asia, which serves as the de facto global standard for
mobile phones.
GPS Global Positioning System Global Positioning System.
CAN Controller Area Network CAN communication. CAN is ISO Standards of the serial communi­
cation protocol (rules).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional item.
MPDr. Maintenance Pro Dr. MPDr. is software for conducting troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-Idle.
WU Warming-Up Warming up.
Li Low (Slow) Idle Minimum Engine Speed.
ATT Attachment Attachment. In this document, it refers to an optional part such as
breaker, pulverizer, and crusher.
HI, Hi High Travel fast speed position.
LO, Lo Low Travel slow speed position.
DPF Diesel Particulate Filter DPF (Diesel Particulate Filter) is a filter to remove fine particles in­
cluding harmful substances in the exhaust gas of the diesel en­
gine. Exhaust fine particle removing device.

WAFF50-EN-00(07/05/2019) SY-1
 SYMBOL AND ABBREVIATION

Symbols/ Name Meaning

abbrevia­
tions
DPD Diesel Particulate Diffuser DPD (Diesel Particulate Diffuser) is an exhaust gas purifying device
(one type of DPF) that removes PM (particulate matter) in the ex­
haust gas of the diesel engine. DPD collects and filters PM in the
exhaust gas using a ceramic filter and, when the PM accumulation
amount has become large, incinerates the accumulated PM at
once, and regenerates the filter.
DOC Diesel Oxidation Catalyst Oxidation catalyst for diesel. DOC oxidizes the unburnt fuel and
raises the exhaust temperature.
CSF Catalyzed Soot Filter Filter. The filter collects PM, and removes it by burning it by means
of high-temperature exhaust gas whose temperature has been
raised by oxidation catalyst. The catalyst is also applied on the fil­
ter, thus accelerating burning of PM.
SF Soot Filter Filter. The filter collects PM, and removes it by burning it by means
of high-temperature exhaust gas whose temperature has been
raised by oxidation catalyst.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation The EGR re-circulates a part of exhaust gas into intake manifold
and mixes it with intake-air to lower the burn temperature and
suppress the generation of NOx (nitrogen oxide).
CSD Cold Start Device Cold start device. When coolant temperature decreases down to
less than 5゜C, the cold-start device advances the fuel injection
timing and also slightly increases the fuel injection amount. There­
fore, the engine start-up performance at low temperatures is im­
proved.

WAFF50-EN-00(07/05/2019) SY-2
 CONTRASTING LIST OF PART NAME

Contrasting List of Part Name between Technical Manual and Parts Catalog

Part name in technical manual Part name in parts catalog Part No.
Fuel Sensor (float) FLOAT YD00011791
EGR Temperature Sensor SENSOR, EGR GAS TEMP YD00009156
Cam Angle Sensor SENSOR, GEAR REV YD00009160
Crank Speed Sensor SENSOR, FLYWHEEL REV YD00009159
Coolant Temperature Sensor SENSOR;THERMO 4677180
Intake Air Temperature Sensor SENSOR, AIR TEMP YD00009154
EGR Differential Pressure Sensor SENSOR, PRESSURE YD00009256
DOC Exhaust Temperature Sensor SENSOR, EXH. TEMP YD00006475
CSF Exhaust Temperature Sensor SENSOR, EXH. TEMP YD00006476
Differential Pressure Sensor SENSOR;PRESSURE YD00009257
Auto-Idle Pressure Sensor SENSOR;PRESSURE 4436535

WAFF50-EN-00(07/05/2019) CO-1
 CONTRASTING LIST OF PART NAME

MEMO

WAFF50-EN-00(07/05/2019) CO-2
 SAFETY

Recognize Safety Information

● These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in

this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe operating
practices.

SA-2644 ja

Understand Signal Words

● On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or
CAUTION are used with the safety alert symbol.
• DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death or
serious injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury.
• DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
• Some safety signs are occasionally used on this
machine that do not use any of the designated signal
words mentioned above after the safety alert symbol.
• CAUTION also calls attention to safety message in
this manual.
● To avoid confusing machine protection with personal SA-632 en_GB
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 a piece of information.

WAFF50-EN-00(07/05/2019) 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
replaced when necessary.
• If a safety sign or operator's manual is damaged or
missing, order a replacement from your authorized
dealer in the same way you order other replacement
parts (be sure to state machine model and serial
number when ordering).
● Learn how to operate the machine and its controls
correctly and safely.
SA-003 ja
● Allow only trained, qualified, authorized personnel to
operate the machine.
● Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization. Failure to do so may deteriorate the safety, function, and/
or service life of the part. In addition, personal accident, machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty Policy.
• Never attempt to modify the air intake or exhaust parts or disassemble the muffler filter. Avoid shocking the
muffler filter by striking it or dropping it. Doing so may negatively affect the exhaust gas purifying device, possibly
damaging it or lowering its performance.
• Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will
void Hitachi Warranty Policy.
● The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it
is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/ or your authorized dealer before operating or performing
maintenance work on the machine.

WAFF50-EN-00(07/05/2019) SA-2
 SAFETY

Prepare for Emergencies

● Be prepared for a fire or an accident.

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

Wear Protective Clothing

● Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

• A hard hat
• Safety belt
• Safety shoes
• Safety glasses, goggles, or face shield
• Heavy gloves
• Hearing protection
• Reflective clothing SA-438 ja

• Wet weather gear

• Respirator or filter mask
Be sure to wear the correct equipment and clothing for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.
● Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while
operating the machine.

WAFF50-EN-00(07/05/2019) SA-3
 SAFETY

Protect Against Noise

● Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.

SA-434 ja

Inspect Machine

● Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.
• In the walk-around inspection be sure to cover all
points described in the "Inspect Machine Daily Before
Starting" section in the operator's manual.

SA-435 ja

WAFF50-EN-00(07/05/2019) SA-4
 SAFETY

General Precautions for the Cab

● Always keep inside the cab clean by observing instructions below, to prevent any personal accidents from occurring.
• Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones from the soles of
your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator's
work boots, the operator's foot may slip off the pedal, possibly resulting in a personal accident.
• Do not mess up around the operator's seat with parts, tools, soil, stones, obstacles that may fold up or turn over,
cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the travel levers/
pedals, pilot control shut-off lever or control levers, which may result in serious injury or death.
• Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly starting a fire.
• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating
the machine.
• Keep all flammable materials and/or explosives away from the machine.
• After using the ashtray, always cover it to extinguish the match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.
• Correctly lay the floor mat specific to the machine. If another floor mat is used, it may be displaced and contact
with the travel pedals during operation, resulting in serious injury or death.

Use Handholds and Steps

● Falling is one of the major causes of personal injury.

• When you get on and off the machine, always use the
crawler instead of the step for safety. Also get on and
off from the position of the crawler that can secure
your feet space enough.
• When you get on and off the machine, always face
the machine.
• Maintain a three-point contact with the steps and
handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or SA-439 ja
dismount a moving machine.
• In case adhered slippery material such as oil, grease, or mud is present on steps, handrails, or platforms, thoroughly
remove such material.

WAFF50-EN-00(07/05/2019) SA-5
 SAFETY

Adjust the Operator's Seat

● A seat which is poorly adjusted for the individual

operator, or the work to be undertaken, may quickly
fatigue the operator leading to misoperation.
• The seat should be adjusted whenever the operator
of the machine changes.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the rear view mirror position so that the best SA-378 ja
rear visibility is obtained from the operator's seat. If
the mirror is broken, immediately replace it with a new one.

Ensure Safety Before Rising from or Leaving Operator's Seat

● Before rising from the operator's seat to open/close either side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a
control lever and/or pedal, possibly resulting in serious personal injury or death.
● Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.
● Before leaving the machine, close all windows, doors, and access covers and lock them.

Fasten Your Seat Belt

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

SA-237 ja

WAFF50-EN-00(07/05/2019) SA-6
 SAFETY

Move and Operate Machine Safely

● Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm
the location of bystanders before moving, swinging,
or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the machine.
SA-1291 ja
• Use appropriate illumination. Check that all lights are
operable before operating the machine. If any faulty illumination is present, immediately repair it.
• Ensure the cab door, windows, doors and covers are securely locked.
• Check the mirrors in the cab for problems.
If there is, replace the problem part (s) or clean the mirror.

Operate Only from Operator's Seat

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

SA-444 ja

WAFF50-EN-00(07/05/2019) SA-7
 SAFETY

Jump Starting

● Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to follow
the instructions shown in the "OPERATING THE
ENGINE" chapter in the operator's manual.
• The operator must be in the operator's seat so that
the machine will be under control when the engine
starts. Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
SA-032 ja

Checking Battery Level and Supplementary Charging

Never short across the battery terminals, including to check the remaining battery power. Doing so will result in sparks
and may cause an explosion or fire.
Use a hydrometer to check remaining battery power.

Keep Riders off Machine

● Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the
machine.
• Only the operator should be on the machine. Keep
riders off.
• Riders also obstruct the operator's view, resulting in
the machine being operated in an unsafe manner.

SA-1292 ja

WAFF50-EN-00(07/05/2019) SA-8
 SAFETY

Precautions for Operations

● Investigate the work site before starting operations.

• Be sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
• Keep bystanders and obstacles clear of the area of
machine operation.
Keep persons other than the operator away from
areas where there is danger, such as from flying
objects.
Always be aware of the surroundings while operating.
When working in a small area surrounded by
obstacles, take care not to hit the upperstructure
against obstacles. M586-12-012 ja
• When loading onto trucks, bring the bucket over the
truck beds from the rear side. Take care not to swing the bucket over the cab or over any person.

WAFF50-EN-00(07/05/2019) SA-9
 SAFETY

Investigate Job Site Beforehand

● When working at the edge of an excavation or on a road

shoulder, the machine could tip over, possibly resulting
in serious injury or death.
• Investigate the configuration and ground conditions
of the job site beforehand to prevent the machine
from falling and to prevent the ground, stockpiles or
banks from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder,
employ a signal person as required.
SA-1293 ja
• Never allow bystanders to enter the working area
such as swing radius or traveling range.
• When the ground footing is weak, reinforce the ground before starting work.
• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and
slippery.
• Beware the possibility of fire when operating the machine near flammable materials such as dry grass.
• Make sure the worksite has sufficient strength to
firmly support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks
positioned perpendicular to the cliff face with travel
motors at the rear, so that the machine can more
easily evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is
required, be sure to investigate the area first and
confirm that no danger of the cliff or bank collapsing
exists. If any possibility of cliff or bank collapsing
exists, do not work on the area.
• Soft ground may collapse when the machine is
M586-05-021 ja
operated on it, possibly causing the machine to tip
over. When working on soft ground is required, be sure to reinforce the ground first using steel plates strong and
firm enough to easily support the machine.
• Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes.
Prevent machine tipping over from occurring. When operating on rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with machine movements.

WAFF50-EN-00(07/05/2019) SA-10
 SAFETY

Install OPG Guard

● In case the machine is operated in areas where the

possibility of falling stones or debris exists, equip
genuine Hitachi OPG guard. Contact your nearest Hitachi
dealer for installation method of the OPG guard.
Depending on the specifications applied to your
machine, modification of the machine to meet ROPS
standards will be possible.
● To maintain unimpaired operator protection and
manufacture's protective structure.
• Damaged ROPS, OPG guard must be replaced, not
repaired or revised.
• Any alternation to the ROPS or OPG guard must be
approved by the manufacturer.

ROPS : Roll Over Protective Structure

OPG : Operator Protective Guard
SA-490 ja

Restriction of Attachment Installation

Do not install an attachment which exceeds the specified weight for the machine structure.

Provide Signals for Jobs Involving Multiple Machines

● In case more than one machine is operated in the same

job site, accidental collision between machines may
cause serious injury or death.
● For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person's
directions.

SA-481 ja

WAFF50-EN-00(07/05/2019) SA-11
 SAFETY

Confirm Direction of Machine to Be Driven

● Incorrect travel pedal/lever operation may result in serious injury or death.

• Before driving the machine, confirm the position of
the undercarriage in relation to the operator's
position. If the travel motors are located in front of
the cab, the machine will move in reverse when travel
pedals/levers are operated facing forwards.

SA-1294 ja

WAFF50-EN-00(07/05/2019) SA-12
 SAFETY

Drive Machine Safely

● Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the
direction you wish to drive.
• Be sure to detour around any obstructions.
• Avoid traveling over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Do not allow personnel to stay around the
machine while traveling.
● Driving on a slope may cause the machine to slip or
overturn, possibly resulting in serious injury or death.
SA-1295-1 ja
• Never attempt to ascend or descend 30 degrees or
steeper slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 200 to
300 mm (see A on the right) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.
• Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If
the direction must be changed, move the machine to
SA-1296-1 ja
level ground, then, change the direction to ensure
safe operation.
● Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
● If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to
neutral. Then, restart the engine.
● Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be SA-441 ja
obtained.
● Use a signal person when moving, swinging or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.

MZX5-04-002 ja

WAFF50-EN-00(07/05/2019) SA-13
 SAFETY

● When the machine descends a slope at high speed,

machine weight accelerates descending speed. It may
cause collision accident due to misjudging of braking
distance or machine turnover due to running on an
unexpected obstacle. Always ensure that travel mode
display (1) on the monitor is , and then reduce the
1
engine speed before descending a slope.
● Driving in narrow areas, such as on the shoulder of a
road, presents the risk of the machine falling, turning
over or having a serious accident, so use someone to
provide guidance.
● Before moving the machine, check the direction of the MADR-00-001-1 ja
undercarriage (position of the travel motor) and then
operate the travel lever or pedal.
● Select a travel route that is as flat as possible. Steer the
machine as straight as possible, making small gradual
changes in direction.
● Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary. M
● Use wood plates in order not to damage the road
surface. Be careful of steering when operating on asphalt
roads in summer.
● When crossing train tracks, use wood plates in order not M104-05-008-2 ja
to damage them.
● Do not make contact with electric wires or bridges.
● When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
track shoe surface.
● When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
● Avoid operations that may damage the track and
undercarriage components.
● During freezing weather, always clean snow and ice from SA-673 ja
track shoes before loading and unloading the machine,
to prevent the machine from slipping.

M586-05-002 ja

WAFF50-EN-00(07/05/2019) SA-14
 SAFETY

Avoid Injury from Rollaway Accidents

● Death or serious injury may result if you attempt to

mount or try to bodily stop a moving machine.
● Park the machine in compliance with the safe parking
procedures described on page "Park Machine Safely" to
prevent the machine from running away.
• Block both tracks and lower the bucket to the ground,
thrust the bucket teeth into the ground if you must
park on a grade.
• Park at a reasonable distance from other machines.

SA-1297 ja

WAFF50-EN-00(07/05/2019) SA-15
 SAFETY

Avoid Injury from Back-Over and Swing Accidents

● If any person is present near the machine when backing

or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
• Always look around BEFORE YOU BACK UP AND
SWING THE MACHINE. BE SURE THAT ALL
BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO
THE WORK AREA. USE THE HORN OR OTHER SIGNAL
TO WARN BYSTANDERS BEFORE MOVING MACHINE. SA-383 ja

• 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
regulations, when work conditions require a signal
person.
• No machine motions shall be made unless signals are
clearly understood by both signal person and
operator.
• Learn the meanings of all flags, signs, and markings SA-384 ja
used on the job and confirm who has the
responsibility for signaling.
• Keep windows, mirrors, and lights clean and in good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.
• Read and understand all operating instructions in the operator's manual.

WAFF50-EN-00(07/05/2019) SA-16
 SAFETY

Keep People Clear from Working Area

● People around the operating machine may be hit severely by the swinging front attachment or counterweight, be
caught in other objects, and/or be struck by flying objects, resulting in serious injury or death.
• Set up barriers and/or put a "NO ADMISSION" sign at
the machine operating site and areas exposed by
flying objects to prevent anyone from entering the
work area.
• Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to
prevent anyone from entering the work area.

SA-667 ja

Never Position the Bucket Over Anyone

● Never lift, move, or swing the bucket above anyone or

above the truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.

SA-668 ja

WAFF50-EN-00(07/05/2019) SA-17
 SAFETY

Avoid Undercutting

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

footing should collapse, always position the
undercarriage perpendicular to the edge of the
excavation with the travel motors at the rear.
• If the footing starts to collapse and if retreat is not
possible, do not raise the front attachment in a panic.
Lowering the front attachment may be safer in most
cases.

SA-1300 ja

Avoid Tipping

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE

--- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE
FASTEN YOUR SEAT BELT
● The danger of tipping is always present when operating
on a grade, possibly resulting in serious injury or death.
To avoid tipping:
● Be extra careful before operating on a gradient.
• 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-1301 ja
● Be careful when working on frozen ground.
• Temperature increases will cause the ground to become soft and make ground travel unstable.

WAFF50-EN-00(07/05/2019) SA-18
 SAFETY

Never Undercut a High Bank

● The edges could collapse or a land slide could occur

causing serious injury or death.

SA-1302 ja

Dig with Caution

● Accidental severing of underground cables or gas lines

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

Operate with Caution

● If the front attachment or any other part of the machine

hits against an overhead obstacle, such as a bridge, both
the machine and the overhead obstacle will be
damaged, and personal injury may result as well.
• Take care to avoid hitting overhead obstacles with
the boom or arm.

SA-673 ja

WAFF50-EN-00(07/05/2019) SA-19
 SAFETY

Avoid Power Lines

● Serious injury or death can result if the machine or front

attachments are not kept a safe distance from electric
lines.
• When operating near an electric line, never move any
part of the machine or load to within 3 m plus twice
the line insulator length of overhead wires.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site. SA-1305 ja

Precautions for Lightning

● Lightning may strike the machine.

If lightning comes close, immediately stop the operation,
and take the following action.
• When you are around the machine or operating
cabless machine, evacuate to a safe place far away
from the machine.
• When you are in the cab, stay in the cab until
lightning has passed and safety is assured. Close the
cab doors and windows. Lower the bucket to the
ground, and stop the engine. Put your hands on your
lap to avoid contact with any metal surfaces. Never
go out of the cab.
If lightning strikes the machine or near the machine, check
all of the machine safety devices for any failure after
lightning has passed and safety is assured. If any trouble is SA-2744 ja
found, operate the machine only after repairing it.

WAFF50-EN-00(07/05/2019) SA-20
 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, slings,
or ropes.
• Before craning, position the upperstructure with the
travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is
SA-014 ja
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.

Protect Against Flying Debris

● If flying debris hit eyes or any other part of the body, serious injury may result.
• Guard against injury from flying pieces of metal or
debris exist, or when removing or installing pins
using a hammer; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.

SA-432 ja

WAFF50-EN-00(07/05/2019) SA-21
 SAFETY

Park Machine Safely

• To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket and/or blade to the ground.
• Pull the pilot control shut-off lever to the LOCK
position.
• Turn the auto-idle switch OFF. Failure to do so may
create a hazardous condition as the engine speed
may unexpectedly increase.
• Run engine at slow idle speed without load for 5
minutes.
M1M7-05-024 ja
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Close windows, roof vent and cab door.
• Lock all access doors and compartments.

Handle Fluids Safely−Avoid Fires

● Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in
serious injury or death.
• Do not refuel the machine while smoking or when
near open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
● All fuels, most lubricants, and some coolants are
flammable.
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
SA-018 ja
• Securely tighten the fuel and oil filler caps.
• When removing, inspecting and servicing parts of the
fuel system (such as replacing the fuel filter), place a
special container under the opening and take care
not to spill fuel on the ground.
• Do not use a piece of cloth instead of a container. Fuel
evaporating from the cloth may catch on fire.
Immediately wipe up any fuel spills.

SA-019 ja

Transport Safely

WAFF50-EN-00(07/05/2019) SA-22
 SAFETY

• Take care the machine may turn over when loading or

unloading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe
transportation.
• Select an appropriate truck or trailer for the machine SA-1307 ja
to be transported.
• Be sure to use a signal person.
• Always follow the following precautions for loading 3
or unloading:
1. Select solid and level ground.
2. Be sure to use a loading dock or ramp strong enough to
support the machine weight.
3. Ramps must be sufficient in width, length, and strength.
Be sure that the incline of the ramp is less than 15 2
degrees.
4. Loading docks must be sufficient in width and strength 1
MADR-00-001-2 ja
to support the machine and have a gradient of less than
15 degrees.
5. Push auto-idle switch (1) to turn A/I display (2) OFF.
6. Select the slow travel mode for loading or unloading the machine. Always ensure that travel mode display (3) on the
monitor is , before traveling the machine.
7. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up
or down the ramp.
8. Never steer the machine while on the ramp. If the traveling direction must be changed while on the ramp, unload the
machine from the ramp, reposition the machine on the ground, then try loading again.
9. At the top end of the ramp where it meets the flatbed, there is a sudden bump. Take care when traveling over it.
10. Place blocks in front of and behind the tires. Securely fasten the machine to the truck or trailer deck with wire ropes.
11. Do not operate any levers besides the travel levers when driving up or down the ramp.
12. Prevent possible injury from machine tipping while the upperstructure is rotating.
13. Keep the arm tucked under and rotate the upperstructure slowly for best stability.
Be sure to further follow the details described in the "TRANSPORTING" section in the operator’s manual.

Practice Safe Maintenance

● To avoid accidents:
• Understand service procedures before starting work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Do not use a high pressure washer on electrical parts
of the engine or the ECU (engine control unit).
Doing so may damage the electrical parts if water
gets inside, and prevent the machine from operating
properly.
• Keep hands, feet and clothing away from power-
driven parts.
SA-028 ja
Before servicing the machine:
1. Park the machine on a level surface.

WAFF50-EN-00(07/05/2019) SA-23
 SAFETY

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5 minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving the control levers several times.
7. Remove the key from the key switch.
8. Attach a "Do Not Operate" tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
● If a maintenance procedure must be performed with the
engine running, do not leave the machine unattended.
● If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support any
machine elements that must be raised for service work.
● Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
"MAINTENANCE" chapter of this manual.
● Keep all parts in good condition and properly installed.
● Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris. SA-527 ja
● When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.
● Turn the battery disconnect switch to OFF before adjusting the electrical systems or performing welding on the
machine.
● Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
● Always use a work light protected with a guard. If the
light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
● When the floor tilt mechanism check and/or
maintenance is conducted, the operator’s station is tilted
upward. Before conducting maintenance work, refer to
"Cab Tilting Mechanism" in operator’s manual for the
detailed operation procedures and correctly operate the SA-037 ja
machine.
● When required to work under the floor, support the
raised operator’s station with the fall prevention bars (red
color) to ensure safety.
● When the inspection/maintenance work is complete, tilt
the operator’s station downward after housing the fall
prevention bars. Be sure to slowly lower the operator’s
station at the time.
● Be careful not to allow the operator’s station to tilt down
without first stowing the fall prevention bars. Damage to
the tilt mechanism may result.

M1MW-07-031 ja

Warn Others of Service Work

● Unexpected machine movement can cause serious injury.

WAFF50-EN-00(07/05/2019) SA-24
 SAFETY

• 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.
• Never attempt to operate the machine with a “Do Not
Operate” tag attached.
• Make it a rule for the inspection/service person to
hold the engine start key during inspection/service
work.

SS2045102-4 ja

WAFF50-EN-00(07/05/2019) SA-25
 SAFETY

Support Machine Properly

● Never attempt to work on the machine without securing the machine first.
• Always lower the attachment to the ground before you work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do
not work under a machine that is supported solely by
a jack.

SA-527 ja

Stay Clear of Moving Parts

● Entanglement in moving parts can cause serious injury.

• To prevent accidents, care should be taken to ensure
that hands, feet, clothing, jewelry and hair do not
become entangled when working around rotating
parts.
• Stop the engine before performing any engine
inspections.
• Do not inspect the engine with the key in the key
switch.
Someone may fail to notice the machine is being
inspected and accidentally start the engine.
SA-026 ja

SA-2294 ja

WAFF50-EN-00(07/05/2019) SA-26
 SAFETY

Prevent Parts from Flying

● Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or VALVE
ASSEMBLY.
• As pieces may fly off, be sure to keep body and face
away from valve.
• Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster may
cause the parts such as a spring to fly off, possibly
resulting in severe personal injury or death.
SA-344 ja
● Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

Avoid Injury from Attachment Falling Accident

● Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.
• To avoid possible personal injury from attachment
falling accident, use a platform when replacing an
attachment.
• Securely store attachments such as a bucket, blade,
breaker and other parts to prevent falling.
• Keep children and bystanders away from attachment
storage areas.

SA-034 ja

WAFF50-EN-00(07/05/2019) SA-27
 SAFETY

Prevent Burns

Hot spraying fluids:

● After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the engine,
radiator and heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
• Avoid possible injury from hot spraying water. DO
NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow
all pressure to be released before removing the cap.
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.
• Close the radiator cap securely after the inspection. SA-039 ja
If not fully closed, coolant may spurt out while
operating the machine.
• If engine oil needs to be drained while the engine is still hot, keep away from the engine while doing so to avoid
getting burned by the hot engine oil. Be sure to wear eye protection.
Hot Fluids and Surfaces
● Fluids such as engine oil, gear oil, coolant and hydraulic
oil get hot during operation.
Parts of the machine also get hot, such as the engine,
muffler, hoses, hydraulic lines.
● Perform maintenance only after the fluids and parts have
cooled down.

SA-225 ja

Replace Rubber Hoses Periodically

● Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the page of "Periodic replacement of parts" in the operator's manual.)
● Failure to periodically replace rubber hoses may cause a
fire, fluid injection into skin, or the front attachment to
fall on a person nearby, which may result in severe burns,
gangrene, or otherwise serious injury or death.

SA-019 ja

WAFF50-EN-00(07/05/2019) SA-28
 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
disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care
to protect hands and body from high-pressure fluids.
Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031 ja
skin must be surgically removed within a few hours or
gangrene may result.
● The engine uses a high pressure common rail system.
• The fuel is injected at very high pressure. Never
disassemble parts of the fuel system.
• Never loosen high pressure fuel lines while the
engine is running. Doing so is dangerous as high
pressure fuel will spray out.
• Have your authorized dealer handle inspection,
disassembly and repairs of parts in the engine’s fuel
system.
SA-292 ja

SA-044 ja

WAFF50-EN-00(07/05/2019) SA-29
 SAFETY

Prevent Fires

Check for Oil Leaks:

● Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each
other, damage to the oil cooler, and loose oil cooler
flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil cooler and oil
cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or hoses.
• Replace fuel hoses and hydraulic hoses periodically
even if there is no abnormality in their external SA-019 ja
appearance.
• Make sure there are no fuel leaks before starting the engine.
• Do not remove the fuel cap while the engine is running.
• Do not fill the fuel tank above the designated level.
Check for Shorts:
● Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical
cables and wires.
• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.
• Never attempt to modify electric wirings.
• Never start the engine in any way except using the key switch.
• Do not start the engine by shorting the starter circuit. Doing so will result in sparks and may cause an explosion or
fire.
Clean up Flammable Materials:
● Spilled fuel and oil, trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires.
• Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated
flammable materials immediately. Check and clean high temperature parts such as the exhaust outlet and muffler
earlier than the normal interval.
• Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents.
• Do not store oily cloths as they are vulnerable to catching fire.
• Keep flammable materials away from open flames.
• Do not ignite or crush a pressurized or sealed container.
• Do not use fuel as a cleaner.
• Wire screens may be provided on openings on the engine compartment covers to prevent flammable materials
such as dead leaves from entering. However, flammable materials which have passed through the wire screen may
cause fires. Check and clean the machine every day and immediately remove accumulated flammable materials.

WAFF50-EN-00(07/05/2019) SA-30
 SAFETY

Check Key Switch:

● If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.
• Always check key switch function before operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that the engine stops.
• If any abnormalities are found, be sure to repair them before operating the machine.
Check Heat Shield Covers around Engine Compartment
● If the engine compartment heat shield cover becomes broken or lost, fire may break out.
• If the engine compartment heat shield cover becomes broken or lost, repair or replace it before operating the
machine.

Evacuating in Case of Fire

● If a fire breaks out, evacuate the machine in the following

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

SS-1510 ja

Beware of Exhaust Fumes

● Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
• If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air into
the area.
• After servicing the exhaust system, make sure all
connections are tightened as specified.
• White smoke may be generated from burning PM
(particulate matter) during muffler filter regeneration.
Do not attempt to perform a manual regeneration of SA-016 ja
the muffler filter in a poorly ventilated area.

WAFF50-EN-00(07/05/2019) SA-31
 SAFETY

Precautions for Welding and Grinding

● Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and
prepared area. Store flammable materials in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Turn the battery disconnect switch to the OFF
position before performing welding on the machine.
● Grinding on the machine may create fire hazards. Store
flammable materials in a safe place before starting
SA-818 ja
grinding.
● After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded
area still smoldering.

Avoid Heating Near Pressurized Fluid Lines

● Flammable spray can be generated by heating near

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

Avoid Applying Heat to Lines Containing Flammable Fluids

● Do not weld or flame cut pipes or tubes that contain flammable fluids.
● Clean pipes and tubes thoroughly with non-flammable solvent before welding or flame cutting.

WAFF50-EN-00(07/05/2019) SA-32
 SAFETY

Precautions for Handling Accumulator and Gas Damper

High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause
explosion, possibly resulting in serious injury or death.
Strictly comply with the following items:
● Do not disassemble the unit.
● Keep the units away from open flames and fire.
● Do not bore a hole, do not cut by torch.
● Avoid giving shocks by hitting or rolling the unit.
● Before disposing of the unit, sealed gas must be released. Consult your authorized dealer.

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.
• Remove paint before welding or heating.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
• Allow fumes to disperse at least 15 minutes after
welding or heating.
• Use attention to the following points when removing
paint. SA-029 ja
1. If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or
paint stripper containers and other flammable materials from area.

WAFF50-EN-00(07/05/2019) SA-33
 SAFETY

Beware of Asbestos and Silicon Dust and Other Contamination

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

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

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 first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of
the battery may result.
• Loose terminals may produce sparks. Securely tighten SA-032 ja
all terminals.
• Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.
● Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly
resulting in blindness. If electrolyte is splashed into eyes, flush your eyes continuously with water for about 15
minutes. Seek medical attention immediately.
• Be sure to wear eye protection when checking electrolyte specific gravity.

WAFF50-EN-00(07/05/2019) SA-34
 SAFETY

Service Air Conditioning System Safely

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

burn.
• Refer to the instructions described on the container
for proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.

SA-405 ja

WAFF50-EN-00(07/05/2019) SA-35
 SAFETY

Handle Chemical Products Safely

● Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants,
electrolyte coolants, paints, and adhesives.
• Safety Data Sheet (SDS) provides specific details on
chemical products: physical and health hazards,
safety procedures, and emergency response
techniques.
• Check the SDS before you start any job using a
hazardous chemical. That way you will know exactly
what the risks are and how to do the job safely. Then
follow procedures and use recommended SA-2579 ja
equipment.
• See your authorized dealer for SDS's (available only in English) on chemical products used with your machine.

Dispose of Waste Properly

● Improperly disposing of waste can threaten the

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

WAFF50-EN-00(07/05/2019) SA-36
 SAFETY

Never Ride Attachment

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

Warnings about the Muffler Filter

Muffler Filter

The muffler filter removes particulate matter (PM) in the exhaust gas. PM accumulates in the muffler filter and when a
certain amount has been deposited the muffler filter regenerates (burns the PM) automatically. Follow the instructions
below to prevent the muffler filter from being damaged.
Post injection is used in auto-regeneration, so fuel is burned directly inside the muffler filter (burns in a chemical
reaction with the oxidation catalyst). This heat regenerates the filter (burns the PM), but this combustion raises
the temperature of the exhaust gas to almost 600 ℃.
Take care not to touch it accidentally. Be careful to avoid burns and stay safe.
Pay attention to whether anyone or anything flammable is near the exhaust.
Fuel consumption may suffer slightly due to post injection.
Although dilution of engine oil with fuel from post injection is kept to a minimum, when operated under low load
(low exhaust temperature), there is a possibility of it being diluted slightly.
Be sure to perform the regular check of engine oil level daily.
Even if regeneration of the muffler filter is performed, the PM may not be regenerated if operating conditions
such as idling or operating under low loads occur frequently.
At such times, if the ECU (engine control unit) determines manual regeneration needs to be performed, it lights
the muffler filter regeneration request lamp. If the muffler filter regeneration request lamp lights, perform a
manual regeneration right away. Continuing to operate the machine with the muffler filter regeneration request
lamp lit, results in the accumulation of excessive PM, which may cause the PM to burn abnormally, and potentially
damage the muffler filter and/or start a fire.
• White smoke may be generated from burning PM (particulate matter) during muffler filter regeneration.
Do not attempt to perform a manual regeneration in a poorly ventilated area.
• Due to the risk of carbon monoxide poisoning, never perform regeneration in a poorly ventilated location.
• The temperature of the exhaust gas gets very hot, so to avoid fire, make sure nothing that can burn easily is anywhere
near the exhaust outlet.
• The temperature of the exhaust gas gets very hot, so to avoid injury, take care not to touch the exhaust pipe, even
accidentally. In addition, keep everyone away from the exhaust outlet.
• Do not touch the water that comes out of the muffler filter. The water is slightly acidic due to the effect of the
oxidation catalyst built into the muffler filter. Wash it off thoroughly with lots of water if it comes in contact with skin.

Warnings about the ECU (Engine Control Unit)

ECU (Engine Control Unit)

Never do things like using an ECU other than the specified one, writing data other than designated to the ECU, leaving it
in an out of order condition, or using it with sensors or actuators removed, as doing so may be considered a violation of
laws on exhaust gas regulations.
The Hitachi Warranty is invalidated if used improperly.
The ECU must only be used in combination with an engine of the specified model and engine serial number.
When injectors are replaced, it is necessary to rewrite the ECU with injection quantity correction data for the new
injectors.
Your authorized dealer must rewrite the data.
If the ECU is replaced, your authorized dealer must write the data from the old ECU to the new ECU.

WAFF50-EN-00(07/05/2019) SA-37
 SAFETY

Precautions for Communication Terminal

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

Precautions for the Communications Terminal (Optional)

This machine is equipped with a communications terminal

(optional) that emits radio waves from inside the cover
under the operator's seat or from inside the monitor cover at
the front-right of the operator’s seat. While this
communications terminal is operating, it may affect medical
equipment and cause them to malfunction (general medical
equipment, including devices implanted inside the body,
such as pacemakers).
People who use such medical equipment should adjust the
position of the operator's seat so they can ensure a distance
of at least 22 cm from the cover where the communications
terminal is installed and their medical device.
If the condition above cannot be fulfilled, consult your
authorized dealer and do not use the machine until the MAEP-00-004-1 ja
representative makes sure the communications terminal will
not emit electrical waves.
● Specific absorption rate (SAR: measured in units of 10 g) from the communications terminal:

E-GSM900 0.12 W/Kg (897.6 MHz)

DCS-1800 0.06 W/Kg (1748.0 MHz)
WCDMA Band I 0.05 W/Kg (1950.0 MHz)
WCDMA Band Ⅷ 0.10 W/Kg (892.60 MHz)

* The measurement results above are based on a distance of 3 cm between a person's body and the communications
terminal installed in the machine.
* The term specific absorption rate (SAR) is used in the evaluation of the affect of radio waves emitted by wireless
devices, such as cell phones, when used close to the human body.
In Japan: *Under the Japanese Radio Act and other regulations governing wireless equipment, the SAR is limited to 2
W/kg or less (as of March 2012).
In Europe: the SAR is limited to 2 W/kg or less according to "Council Recommendation 1999/519/EC 12 July 1999."
● Do not disassemble, repair, modify or move communication equipment, antennas or cables. Doing so may damage
the machine itself or the communication equipment, and/or cause a fire. (Consult your authorized dealer for the
removal or installation of communication equipment.)
● Do not pinch, bind or pull on cables, cords or connectors with excessive force, as doing so will damage them. A short
circuit or break in wiring may damage the machine itself or the communication equipment, and/or cause a fire.

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 SAFETY

Precautions about Operator’s Seat Protections when Overturned (4-pillar Canopy or Cab
Models)

The cab (canopy) has a mechanism (Roll-Over Protective

Structure) for absorbing the impact energy and protecting
the operator if the machine rolls. Please note however that it
cannot fulfill its function if the maximum machine operating
weight noted in the ROPS certificate is exceeded due to
modifications or mounting of a special attachment; doing so
may lead to serious injury or death.
In addition, comply with the following points to ensure the
performance of the protective structure.
● Welding or drilling the cab (canopy) may weaken the
structure, so consult your authorized dealer.
● Always fasten the seat belt when operating the machine.
If the seat belt is not fastened and the machine rolls over,
the cab (canopy) itself may be protected by the structure,
but the operator may hit things inside the cab (canopy)
and/or be thrown outside the cab (canopy) and end up 4 Pillar Canopy
under the machine. MADB-00-029-2 ja

The Roll-Over Protective Structure (ROPS) certificate is valid

under the following conditions.
● Must be under the maximum operating weight noted on
the certificate.
● The protective structure must be mounted correctly.
● The protective structure must not be modified.
● The protective structure must not be damaged.

Cab
MADB-00-030-4 ja

A: Maximum machine operating weight guaranteed by the

protective structure
B: Applicable model
MAEP-00-005-1 ja

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 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 ja

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SECTION AND GROUP SECTION1 GENERAL
CONTENTS Group1 Precautions
Group2 Tightening
Group3 Painting
Group4 Bleeding Air
Group5 Preparation
WORKSHOP MANUAL
SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure
Group2 Undercarriage
Group3 Front Attachment

SECTION3 UPPERSTRUCTURE
Group1 Cab
Group2 Counterweight
Group3 Pump Device
Group4 Control Valve
Group5 Swing Device
Group6 Pilot Valve
Group7 Solenoid Valve
Group8 Revolution Sensing Valve
Group9 Muffler Filter

SECTION4 UNDERCARRIAGE
Group1 Swing Bearing
Group2 Travel Device
Group3 Center Joint
Group4 Track Adjuster
Group5 Front Idler
Group6 Upper and Lower Rollers
Group7 Track
Group8 Blade Cylinder
MEMO

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SECTION AND GROUP SECTION5 FRONT ATTACHMENT
CONTENTS Group1 Front Attachment
Group2 Cylinder
Group3 Hose Rupture Valve

WORKSHOP MANUAL
MEMO

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1

GENERAL

Precautions .......................................... W1-1-1-1

Precautions for Disassembling and Assembling .W1-1-1-1
Precautions for Using Floating Seal .........................W1-1-2-1
Precautions for Using Nylon Sling ............................W1-1-3-1
Maintenance Standard Terminology .......................W1-1-4-1
Tightening............................................ W1-2-1-1
Tightening Bolts and Nuts...........................................W1-2-1-1
Bolt Types ..........................................................................W1-2-2-1
Specified Tightening Torque Chart ..........................W1-2-3-1
Tightening Order ............................................................W1-2-4-1
Precautions for Spilt Flange ........................................W1-2-5-1
Nut and Bolt Locking.....................................................W1-2-6-1
Tightening Piping Joint ................................................W1-2-7-1
Union Joint........................................................................W1-2-8-1
Pipe Joint ...........................................................................W1-2-9-1
O-Ring Face Seal Joint................................................ W1-2-10-1
Quick Coupling............................................................. W1-2-11-1
Screw-In Connection .................................................. W1-2-12-1
Seal Tape Application................................................. W1-2-13-1
Low-Pressure-Hose Clamp Tightening ................ W1-2-14-1
Connecting Hose ......................................................... W1-2-15-1
Painting ................................................ W1-3-1-1
Painting ..............................................................................W1-3-1-1
Bleeding Air ......................................... W1-4-1-1
Bleeding Air from Hydraulic System ........................W1-4-1-1
Bleeding Air from Pump...............................................W1-4-2-1
Bleeding Air from Travel Motor, Swing Motor......W1-4-3-1
Bleeding Air from Hydraulic Circuit..........................W1-4-4-1
Bleeding Air from Fuel System...................................W1-4-5-1
Bleeding Air from Radiator..........................................W1-4-6-1
Preparation .......................................... W1-5-1-1
Preparation before Inspection and Maintenance ...
..........................................................................................W1-5-1-1
Hydraulic Circuit Pressure Release Procedure ......W1-5-2-1
Pressure Release from Hydraulic Oil Tank ..............W1-5-3-1

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2

MAINTENANCE STANDARD

Upperstructure .................................... W2-1-1-1

Maintenance Standard for Pump Device ...............W2-1-1-1
Maintenance Standard for Swing Motor ................W2-1-2-1
Undercarriage...................................... W2-2-1-1
Maintenance Standard for Travel Motor.................W2-2-1-1
Maintenance Standard for Sprocket ........................W2-2-2-1
Maintenance Standard for Front Idler .....................W2-2-3-1
Maintenance Standard for Upper Roller.................W2-2-4-1
Maintenance Standard for Lower Roller.................W2-2-5-1
Maintenance Standard for Track (Rubber Crawler)
..........................................................................................W2-2-6-1
Maintenance Standard for Track (Steel Crawler) .W2-2-7-1
Front Attachment ................................ W2-3-1-1
Maintenance Standard for Pin and Bushing .........W2-3-1-1
Maintenance Standard for Side Cutter (3066997,
3066998).......................................................................W2-3-2-1
Maintenance Standard for Point (4080730) ..........W2-3-3-1
Standard Dimensions for Arm and Bucket
Connection ..................................................................W2-3-4-1
Maintenance Standard for Cylinder .........................W2-3-5-1

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3

UPPERSTRUCTURE

Cab ........................................................ W3-1-1-1 Assembly of Swing Motor............................................W3-5-6-1

Removal of Cab................................................................W3-1-1-1 Pilot Valve ............................................ W3-6-1-1
Installation of Cab...........................................................W3-1-2-1
Removal of Pilot Valve (Left) .......................................W3-6-1-1
Dimensions of Cab Glass..............................................W3-1-3-1
Installation of Pilot Valve (Left) ..................................W3-6-2-1
Procedure to Remove Cab Glass and Overhead
Removal of Pilot Valve (Right) ....................................W3-6-3-1
Window.........................................................................W3-1-4-1
Installation of Pilot Valve (Right) ...............................W3-6-4-1
Procedure to Install Cab Glass....................................W3-1-5-1
Disassembly of Pilot Valves (Left and Right) .........W3-6-5-1
Procedure to Install Overhead Window..................W3-1-6-1
Assembly of Pilot Valves (Left and Right)...............W3-6-6-1
Procedure to Install Front Window Pane................W3-1-7-1
Removal of Travel Pilot Valve......................................W3-6-7-1
Counterweight..................................... W3-2-1-1 Installation of Travel Pilot Valve.................................W3-6-8-1
Disassembly of Travel Pilot Valve ..............................W3-6-9-1
Removal of Counterweight .........................................W3-2-1-1
Assembly of Travel Pilot Valve................................. W3-6-10-1
Installation of Counterweight ....................................W3-2-2-1
Removal of Boom Swing Pilot Valve ..................... W3-6-11-1
Pump Device ........................................ W3-3-1-1 Installation of Boom Swing Pilot Valve ................ W3-6-12-1
Removal of Pump Device.............................................W3-3-1-1 Disassembly of Boom Swing Pilot Valve.............. W3-6-13-1
Installation of Pump Device........................................W3-3-2-1 Assembly of Boom Swing Pilot Valve ................... W3-6-14-1
Disassembly of Pump Device .....................................W3-3-3-1 Removal of Blade Pilot Valve ................................... W3-6-15-1
Assembly of Pump Device...........................................W3-3-4-1 Installation of Blade Pilot Valve............................... W3-6-16-1
Disassembly of Regulator ............................................W3-3-5-1 Disassembly of Blade Pilot Valve............................ W3-6-17-1
Assembly of Regulator..................................................W3-3-6-1 Assembly of Blade Pilot Valve.................................. W3-6-18-1
Removal of Auxiliary Pilot Valve ............................. W3-6-19-1
Control Valve........................................ W3-4-1-1 Installation of Auxiliary Pilot Valve ........................ W3-6-20-1
Removal of Control Valve.............................................W3-4-1-1 Disassembly of Auxiliary Pilot Valve...................... W3-6-21-1
Installation of Control Valve........................................W3-4-2-1 Assembly of Auxiliary Pilot Valve ........................... W3-6-22-1
Structure of Control Valve............................................W3-4-3-1 Solenoid Valve ..................................... W3-7-1-1
Disassembly of Body......................................................W3-4-4-1
Assembly of Body ...........................................................W3-4-5-1 Removal of 2-Spool Solenoid Valve .........................W3-7-1-1
Disassembly of Unload Section .................................W3-4-6-1 Installation of 2-Spool Solenoid Valve ....................W3-7-2-1
Assembly of Unload Section.......................................W3-4-7-1 Disassembly of 2-Spool Solenoid Valve..................W3-7-3-1
Disassembly of Boom Anti-Drift Valve ....................W3-4-8-1 Assembly of 2-Spool Solenoid Valve .......................W3-7-4-1
Assembly of Boom Anti-Drift Valve ..........................W3-4-9-1 Removal of LS Cut Solenoid Valve ............................W3-7-5-1
Disassembly of Spool ................................................. W3-4-10-1 Installation of LS Cut Solenoid Valve .......................W3-7-6-1
Assembly of Spool....................................................... W3-4-11-1 Disassembly of LS Cut Solenoid Valve.....................W3-7-7-1
Disassembly of Shuttle Valve and Pressure Assembly of LS Cut Solenoid Valve ..........................W3-7-8-1
Compensator ........................................................... W3-4-12-1 Revolution Sensing Valve ................... W3-8-1-1
Assembly of Shuttle Valve and Pressure
Removal of Revolution Sensing Valve.....................W3-8-1-1
Compensator ........................................................... W3-4-13-1
Installation of Revolution Sensing Valve ................W3-8-2-1
Swing Device........................................ W3-5-1-1 Disassembly of Revolution Sensing Valve .............W3-8-3-1
Removal of Swing Device ............................................W3-5-1-1 Assembly of Revolution Sensing Valve ...................W3-8-4-1
Installation of Swing Device .......................................W3-5-2-1 Muffler Filter ........................................ W3-9-1-1
Disassembly of Swing Reduction Gear ...................W3-5-3-1
Removal of Muffler Filter..............................................W3-9-1-1
Assembly of Swing Reduction Gear.........................W3-5-4-1
Installation of Muffler Filter.........................................W3-9-2-1
Disassembly of Swing Motor ......................................W3-5-5-1
Disassembly of Muffler Filter ......................................W3-9-3-1

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 Assembly of Muffler Filter............................................W3-9-4-1

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4

UNDERCARRIAGE

Swing Bearing...................................... W4-1-1-1 Assembly of Blade Cylinder.........................................W4-8-4-1

Removal of Swing Bearing...........................................W4-1-1-1
Installation of Swing Bearing......................................W4-1-2-1
Travel Device........................................ W4-2-1-1
Removal of Travel Device.............................................W4-2-1-1
Installation of Travel Device........................................W4-2-2-1
Disassembly of Travel Device .....................................W4-2-3-1
Assembly of Travel Device...........................................W4-2-4-1
Disassembly of Brake Valve.........................................W4-2-5-1
Assembly of Brake Valve...............................................W4-2-6-1
Center Joint.......................................... W4-3-1-1
Removal of Center Joint ...............................................W4-3-1-1
Installation of Center Joint ..........................................W4-3-2-1
Disassembly of Center Joint........................................W4-3-3-1
Assembly of Center Joint .............................................W4-3-4-1
Track Adjuster...................................... W4-4-1-1
Removal of Track Adjuster ...........................................W4-4-1-1
Installation of Track Adjuster ......................................W4-4-2-1
Disassembly of Track Adjuster ...................................W4-4-3-1
Assembly of Track Adjuster .........................................W4-4-4-1
Front Idler............................................. W4-5-1-1
Removal of Front Idler...................................................W4-5-1-1
Installation of Front Idler..............................................W4-5-2-1
Disassembly of Front Idler ...........................................W4-5-3-1
Assembly of Front Idler.................................................W4-5-4-1
Upper and Lower Rollers..................... W4-6-1-1
Removal of Upper Roller ..............................................W4-6-1-1
Installation of Upper Roller .........................................W4-6-2-1
Removal of Lower Roller...............................................W4-6-3-1
Installation of Lower Roller..........................................W4-6-4-1
Track ..................................................... W4-7-1-1
Removal of Track (Rubber Crawler) ..........................W4-7-1-1
Installation of Track (Rubber Crawler) .....................W4-7-2-1
Removal of Track (Steel Crawler)...............................W4-7-3-1
Installation of Track (Steel Crawler)..........................W4-7-4-1
Blade Cylinder...................................... W4-8-1-1
Removal of Blade Cylinder...........................................W4-8-1-1
Installation of Blade Cylinder......................................W4-8-2-1
Disassembly of Blade Cylinder...................................W4-8-3-1

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5

FRONT ATTACHMENT

Front Attachment ................................ W5-1-1-1

Removal of Front Attachment....................................W5-1-1-1
Installation of Front Attachment...............................W5-1-2-1
Cylinder ................................................ W5-2-1-1
Removal of Boom Cylinder..........................................W5-2-1-1
Installation of Boom Cylinder.....................................W5-2-2-1
Disassembly of Boom Cylinder ..................................W5-2-3-1
Assembly of Boom Cylinder........................................W5-2-4-1
Removal of Arm Cylinder .............................................W5-2-5-1
Installation of Arm Cylinder ........................................W5-2-6-1
Disassembly of Arm Cylinder......................................W5-2-7-1
Assembly of Arm Cylinder ...........................................W5-2-8-1
Removal of Bucket Cylinder ........................................W5-2-9-1
Installation of Bucket Cylinder ................................ W5-2-10-1
Disassembly of Bucket Cylinder ............................. W5-2-11-1
Assembly of Bucket Cylinder ................................... W5-2-12-1
Removal of Boom Swing Cylinder ......................... W5-2-13-1
Installation of Boom Swing Cylinder .................... W5-2-14-1
Disassembly of Boom Swing Cylinder.................. W5-2-15-1
Assembly of Boom Swing Cylinder ....................... W5-2-16-1
Hose Rupture Valve ............................. W5-3-1-1
Removal of Hose Rupture Valve for Boom Cylinder
..........................................................................................W5-3-1-1
Installation of Hose Rupture Valve for Boom
Cylinder.........................................................................W5-3-2-1
Structure of Hose Rupture Valve for Boom
Cylinder.........................................................................W5-3-3-1
Removal of Hose Rupture Valve for Arm Cylinder ..
..........................................................................................W5-3-4-1
Installation of Hose Rupture Valve for Arm
Cylinder.........................................................................W5-3-5-1
Structure of Hose Rupture Valve for Arm Cylinder .
..........................................................................................W5-3-6-1

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1

GENERAL

Precautions .......................................... W1-1-1-1

Precautions for Disassembling and Assembling .W1-1-1-1
Precautions for Using Floating Seal .........................W1-1-2-1
Precautions for Using Nylon Sling ............................W1-1-3-1
Maintenance Standard Terminology .......................W1-1-4-1
Tightening............................................ W1-2-1-1
Tightening Bolts and Nuts...........................................W1-2-1-1
Bolt Types ..........................................................................W1-2-2-1
Specified Tightening Torque Chart ..........................W1-2-3-1
Tightening Order ............................................................W1-2-4-1
Precautions for Spilt Flange ........................................W1-2-5-1
Nut and Bolt Locking.....................................................W1-2-6-1
Tightening Piping Joint ................................................W1-2-7-1
Union Joint........................................................................W1-2-8-1
Pipe Joint ...........................................................................W1-2-9-1
O-Ring Face Seal Joint................................................ W1-2-10-1
Quick Coupling............................................................. W1-2-11-1
Screw-In Connection .................................................. W1-2-12-1
Seal Tape Application................................................. W1-2-13-1
Low-Pressure-Hose Clamp Tightening ................ W1-2-14-1
Connecting Hose ......................................................... W1-2-15-1
Painting ................................................ W1-3-1-1
Painting ..............................................................................W1-3-1-1
Bleeding Air ......................................... W1-4-1-1
Bleeding Air from Hydraulic System ........................W1-4-1-1
Bleeding Air from Pump...............................................W1-4-2-1
Bleeding Air from Travel Motor, Swing Motor......W1-4-3-1
Bleeding Air from Hydraulic Circuit..........................W1-4-4-1
Bleeding Air from Fuel System...................................W1-4-5-1
Bleeding Air from Radiator..........................................W1-4-6-1
Preparation .......................................... W1-5-1-1
Preparation before Inspection and Maintenance ...
..........................................................................................W1-5-1-1
Hydraulic Circuit Pressure Release Procedure ......W1-5-2-1
Pressure Release from Hydraulic Oil Tank ..............W1-5-3-1

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 SECTION1 GENERAL
Group1 Precautions

Precautions for Disassembling and Assembling

Precautions for Disassembling

• 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 disassembling / assembling procedures. This helps prevent
incorrect disassembling and unnecessary purchase of parts.
Check and record the following items. 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. Then thoroughly clean them.
Precautions for Disassembling and Assembling
• Precautions for Disassembling:
• Cap the open ends in case the hoses and pipes have been disconnected. In addition, install identification tags onto
the connectors, hoses, and pipes for assembling.
• Before disassembling, clean the exterior of the components and place on a workbench.
• Drain hydraulic oil and gear oil from the hydraulic components and reduction gear.
• Be sure to provide appropriate containers for draining fluids.
• Use matching marks for easier reassembling if necessary.
• Be sure to use the specified special tools when instructed.
• 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), and then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and tag them if 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.
• 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.
• Apply appropriate lubricant oil to parts in order to prevent them from seizing.
• Be sure to replace O-rings, backup rings, oil seals, and floating seals with new ones once they have been
disassembled. Apply 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.
• Fit the matching marks made when disassembling and assemble them.
• 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 completed, count the
number of tools so as to make sure that no forgotten tools remain in the assembled machine.

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 SECTION1 GENERAL
Group1 Precautions

MEMO

WAFF50-EN-00(07/05/2019) W1-1-1-2
 SECTION1 GENERAL
Group1 Precautions

Precautions for Using Floating Seal

1. In general, replace the floating seal with a new one after disassembling.
If the floating seal is required to be reused, follow these procedures:
• Keep seal rings together as a matched set with seal ring (1) surfaces together. Apply oil onto sliding surface (e) of
seal ring (1).
• Check sliding surface (e) of seal ring (1) for scuffing, scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
• Check O-ring (2) for tears, breaks, deformation, or hardening.
2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following to prevent trouble.
• Clean the floating seal and seal mounting bores with cleaning solvent.
Use a wire brush to remove mud, rust, or dirt from seal mounting bores. After cleaning, thoroughly dry parts with
compressed air.
• Clean seal ring (1) and O-ring (2) mounting bores. Check the bore surface for scuffing or scoring. (by touching the
surface with finger)
• After installing the floating seal, check that O-ring (2) is not twisted, and that it is installed correctly on seal ring (1).
• After installing the floating seal, check that O-ring (2) and seal ring sliding surface (e) is parallel with seal mating
surface (f ) by measuring the distances (e) and (f ) at point (A) and (B), as illustrated. If these distances differ, correct
O-ring (2) seating.
1

2
f

a A b A

c
b
d B B

A=B A≠B
WDDQ-04-02-001-1 ja

a- Correct c- Twist of O-ring e- Sliding Surface

b- Incorrect d- Bend of O-ring f- Seal Mating Surface

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Group1 Precautions

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WAFF50-EN-00(07/05/2019) W1-1-2-2
 SECTION1 GENERAL
Group1 Precautions

Precautions for Using Nylon Sling

1. Follow the following precautions to use nylon slings safely.

• Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the
corners. This will prevent the nylon sling from being damaged and the lifted load from slipping.
• Lower the temperature of the lifted load to lower than 100 °C (212 °F). If the temperature of the lifted load is over
100 °C (212 °F), do not lift the load.
• 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 lifted load
balanced.
• When lifting a load using an eyehole (a), be sure to eliminate any gaps between the sling and load. Reduce the
load weight so that it is less than 80 % of the sling breaking force.
a b

WDDQ-01-01-001-1 ja

a- Correct Eyehole Lifting Method b- Incorrect Eyehole Lifting Method

• Avoid using twisted, bound, connected, or hitched slings.
• Do not place any object on twisted or bent slings (c).

c
W162-01-01-009-1 ja

c- Bent of Sling
• When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with
protrusions.
• Avoid dragging slings on the ground, throwing slings, or pushing slings with a metal object.
• When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling
is not damaged.
• Store the nylon slings indoors so that they won’t deteriorate with heat, sun light, or chemicals.

2. CAUTION
If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the
nylon sling for any damage before using.

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 SECTION1 GENERAL
Group1 Precautions

Before using a nylon sling, visually check the nylon sling for any damage corresponding to following examples. If any
damage is found, cut and discard the sling. If any damage is found, cut and discard the sling.
Even if no damage is found, do not use slings older than 7 years.
Damaged Appearance
a a

b f

c
c g

WDDQ-01-01-002-1 ja

a- Broken Sewing Thread c- Fuzz e- Separation of Belt g- Broken Warp

b- Scuffing d- Broken Sewing Thread f- Scoring

WAFF50-EN-00(07/05/2019) W1-1-3-2
 SECTION1 GENERAL
Group1 Precautions

Maintenance Standard Terminology

• "Standard dimension" is the dimension under the conditions below. Allowable errors will be indicated if necessary.
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies adjusted to specification
• “Allowable Limit” is the dimension under the conditions below. Therefore, in consideration of operation efficiency and
maintenance expense, proper maintenance shall be carried out before reaching the "Allowable Limit".
1. Normal machine performance cannot be accomplished after exceeding this limit.
2. Repair or adjustment is difficult after exceeding this limit.
3. Repair or adjustment is impossible after exceeding this limit.

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Group1 Precautions

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WAFF50-EN-00(07/05/2019) W1-1-4-2
 SECTION1 GENERAL
Group2 Tightening 　

Tightening Bolts and Nuts

CAUTION
Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For
loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially
causing personal injure.

WDAA-01-02-001-1 ja

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 SECTION1 GENERAL
Group2 Tightening

MEMO

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 SECTION1 GENERAL
Group2 Tightening

Bolt Types

Tighten the nuts or bolts correctly to the torque specifications.

As the different types and grades of bolt are used, use and tighten the correct bolts correctly when assembling the
machine or components.

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Group2 Tightening

MEMO

WAFF50-EN-00(07/05/2019) W1-2-2-2
 SECTION1 GENERAL
Group2 Tightening

Specified Tightening Torque Chart

2013/09
Bolt Hexagon Head Bolt Socket Bolt
Dia. Wrench Socket Bolt Wrench
mm Size mm Size mm
WDAA-01-02-002 ja WDAA-01-02-003 ja
WDAA-01-02-004 ja

N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft) N·m (lbf·ft)

6 3 to 4 (2.2 to 3) 10 5
8 30 (22) 20 (15) 10 (7.4) 13 20 (15) 6
10 65 (48) 50 (37) 20 (15) 17 50 (37) 8
12 110 (81) 90 (66) 35 (26) 19 90 (66) 10
14 180 (133) 140 (103) 55 (41) 22 140 (103) 12
16 270 (200) 210 (155) 80 (59) 24 210 (155) 14
18 400 (300) 300 (220) 120 (89) 27 300 (220) 14
20 550 (410) 400 (300) 170 (125) 30 400 (300) 17
22 750 (550) 550 (410) 220 (162) 32
24 950 (700) 700 (520) 280 (205) 36
27 1400 (1030) 1050 (770) 400 (300) 41
30 1950 (1440) 1450 (1070) 550 (410) 46
33 2600 (1920) 1950 (1440) 750 (550) 50
36 3200 (2360) 2450 (1810) 950 (700) 55

IMPORTANT
The following items are applied to both fine and coarse pitch threads.
• Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil
with white zinc B dissolved in it)
• Torque tolerance is ±10 %.
• Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into
contact with the bottom of bolt hole. Also the bolts that are too short cannot develop sufficient tightening
force.
• The torque given in the previous table are for general use only, however, a different torque is given for a
specific application. Use the specified torque.
• Clean the nut and bolt threads and remove dirt or corrosion before installing.

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Group2 Tightening

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Group2 Tightening

Tightening Order

When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
a b c

1 12 9 4 1 6 7 14
1, 4 6 3

4 5
2 13 8 5 2 3 10 11
2, 3
W105-01-01-003-1 ja

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

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Group2 Tightening

MEMO

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 SECTION1 GENERAL
Group2 Tightening

Precautions for Spilt Flange

IMPORTANT
• Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause
oil leaks and damage to the O-ring.

WDAA-01-02-005-1 ja
• Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces. When installing O-
ring into a groove, use grease in order to hold O-ring in place.
• While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring.

WDAA-01-02-006-1 ja
• Tighten the bolts up and down, right and left alternately, in order to ensure even tightening to the specified
torque.

W105-01-01-008-1 ja
• Do not use an impact wrench. It is difficult to evenly tighten the bolts by using an impact wrench. Using an
impact wrench often causes uneven tightening of bolts or damage to O-rings.

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Group2 Tightening

MEMO

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 SECTION1 GENERAL
Group2 Tightening

Nut and Bolt Locking

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

 Í

a b

  Í

a
WDAA-01-02-007-1 ja

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

● Split Pin
IMPORTANT
Do not turn in the loosening direction (d) in order to align the grooves and holes on the nut. Always turn in the
tightening direction (c). Do not reuse the split pins.

● Wire
IMPORTANT
Attach wires to bolts in the bolt-tightening direction (c). Do not reuse the wires.

  Í

 d Í
c

WDAA-01-02-008-1 ja

c- Tighten Direction d- Loosen Direction

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Group2 Tightening

MEMO

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 SECTION1 GENERAL
Group2 Tightening

Tightening Piping Joint

IMPORTANT
• The torque given in the following table are for general use only, however, a different torque is given for a
specific application. Use the specified torque.
• Apply lubricant, such as the Grease Spray to the bolts and nuts in order to reduce friction coefficient of them.
• Torque tolerance is ±10 %.
• Slightly apply lubricant onto the threads first by using the Grease Spray.

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 SECTION1 GENERAL
Group2 Tightening

MEMO

WAFF50-EN-00(07/05/2019) W1-2-7-2
 SECTION1 GENERAL
Group2 Tightening

Union Joint

Metal sealing surfaces (4, 5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-
diameter lines.
IMPORTANT
• Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly
cracking the adapter. Tighten union nut (3) to the specifications.
• Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to
damage them when connecting / disconnecting.
1 4 3 5 2

37 º
30 º

b c

a
WDDQ-01-02-001-1 ja

a- Joint Body b- Male Union Joint c- Female Union Joint

2013/09
Description Wrench Size (mm) Tightening Torque
Union Nut N·m (lbf·ft)
30° male 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)
55 380 (280)
60 380 (280)
37° female 17 25 (18.5)
19 30 (22)
22 40 (29.5)
27 80 (59)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)

NOTE
Tightening torque of 37° male coupling without union is similar to tightening torque of 37° female.

WAFF50-EN-00(07/05/2019) W1-2-8-1
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Group2 Tightening

MEMO

WAFF50-EN-00(07/05/2019) W1-2-8-2
 SECTION1 GENERAL
Group2 Tightening

Pipe Joint

Pipe Connection (Metal Joint) (Union Nut Wrench Size: 17, 19, 22, 27): Metal (3) of adapter (1) and pipe (2) seals pressure
oil.
● Precautions for use: Do not damage sealing surfaces (4) and (5) when disassembling and assembling.

1 4 5 3 2

M1M7-07-005-1 ja
● Tightening Torque: Use the specified tightening torque in the following table.

2013/09
Wrench Size (mm) 17 19 22 27
Tightening Torque N·m 25 30 40 80
(lbf·ft) (18.5) (22) (29.5) (59)

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 SECTION1 GENERAL
Group2 Tightening

MEMO

WAFF50-EN-00(07/05/2019) W1-2-9-2
 SECTION1 GENERAL
Group2 Tightening

O-Ring Face Seal Joint

O-ring (6) is installed against the end surface of adapter (7) and seals pressure oil.
IMPORTANT
• Replace O-ring (6) with the new one when reinstalling.
• Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening
union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.
• Do not damage O-ring groove (8) of adapter (7) or sealing surface (10) on the hose side. Damage to O-ring (6)
may cause oil leakage.
• If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-
ring (6) with the new one, and then tighten union nut (9) after confirming that O-ring (6) is securely seated in
O-ring groove (8).
7 6 9

8 10 a
WDAA-01-02-011-1 ja

a- Joint Body

2013/09
Wrench Size (mm) Tightening Torque
Union Nut N·m (lbf·ft)
19 30 (22)
22 70 (52)
27 95 (70)
32 140 (103)
36 180 (133)
41 210 (155)
50 350 (260)

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 SECTION1 GENERAL
Group2 Tightening

MEMO

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 SECTION1 GENERAL
Group2 Tightening

Quick Coupling

1. Coupling procedure
• Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you.
• Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked
completely by ball (2). At this time, check if socket ring (1) is returned to the original position (to the rightmost
direction).
2. Separating procedure
• Remove the hose by rotating socket ring (1) fully counterclockwise and then pulling it. Because no check function
is attached inside, be careful that oil flows out.
• Cap the removed hoses using special plug.

M1M7-07-006-1 ja

CAUTION
• When disconnecting, do not damage joint surface.
• When disconnecting, clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign
material from entering.
• Complete the joint disconnecting / connecting procedure. Check enough if oil leaks especially after
installation.
• After installation, check if socket ring (1) is returned to the original position (to the rightmost direction).

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Group2 Tightening

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 SECTION1 GENERAL
Group2 Tightening

Screw-In Connection

Depending on types of screw and sealing, different types of screw-in connection are used.
IMPORTANT
Check that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in
connection.

R(PTᲣ G(PF)

a b

W105-01-01-018-1 ja

a- Male Tapered Thread b- Male Straight Thread

2013/09
Wrench Size (mm) Tightening Torque (N･m (lbf･ft))
Joint Body Cast iron Structural rolled steel
19 15 (11) 35 (26)
22 30 (22) 50 (37)
27 50 (37) 95 (70)
36 70 (52) 160 (118)
41 110 (81) 200 (148)
50 160 (118) 330 (245)
60 200 (148)

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 SECTION1 GENERAL
Group2 Tightening

MEMO

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 SECTION1 GENERAL
Group2 Tightening

Seal Tape Application

Seal tape is used in order to seal clearances (e) between male (d) and female (c) threads so that any leaks between threads
may be prevented. Therefore, apply just enough seal tape to fill up thread clearances (e). Do not overwrap.
c

d e
W105-01-01-019-1 ja

c- Internal Thread d- External Thread e- Clearance

Application Procedure
Check that the thread surface is clean and, free of dirt or damage. Apply the seal tape around threads in order to leave
one to two pitch threads uncovered. Wrap the seal tape in the same direction as the threads.
f

M114-07-041-1 ja

f- Leave one to two pitch threads uncovered

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 SECTION1 GENERAL
Group2 Tightening

MEMO

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 SECTION1 GENERAL
Group2 Tightening

Low-Pressure-Hose Clamp Tightening

Low-pressure-hose clamp tightening torque differs depending on the type of clamp. Tighten them according to each
step.
● T-Bolt Type Band Clamp (g)
g

WDAA-01-02-012-1 ja
● Worm Gear Type Band Clamp (h)
h

M114-07-043-1 ja

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 SECTION1 GENERAL
Group2 Tightening

MEMO

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 SECTION1 GENERAL
Group2 Tightening

Connecting Hose

CAUTION
When replacing the hoses, use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses
may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install
kinked hoses. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks,
hose rupture or separation of fitting. Utilize the print marks on hoses when installing in order to prevent hose
from being kinked. Take necessary measures to protect hoses from rubbing against each other. If the hoses rub
against each other, wear to the hoses may result and lead to hose rupture. Take care so that the hoses do not come
into contact with the moving parts or sharp objects.

Í 

Í a 

Í 
b b

Í 

a
b
WDDQ-01-02-002-1 ja

a- Rubbing Against Each Other b- Clamp

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Group2 Tightening

MEMO

WAFF50-EN-00(07/05/2019) W1-2-15-2
 SECTION1 GENERAL
Group3 Painting 　
　
Painting

Surfaces to Be Painted Painting Color

Main surface of upperstructure (Except the resin covers) PB5-01 (SP-424) [Dark Gray]
Swing post, Boom swing cylinder
Cab
Seat base, Floor plate (Except the resin covers)
Cylinder (Boom, Arm, Bucket)
Track, Blade, Bucket, Blade Cylinder
Counterweight
Front (without the bucket), Upperstructure cover part YR1-01 [TAXI yellow]
Lever (Travel, Blade) N-10 [Black]

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 SECTION1 GENERAL
Group3 Painting

MEMO

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 SECTION1 GENERAL
Group4 Bleeding Air 　
　
Bleeding Air from Hydraulic System
　
Bleed air from the hydraulic system when hydraulic oil has been drawn, the suction filter and suction pipe have been
replaced, or the pump device, swing motor, travel motor, cylinders have been removed/installed.

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Group4 Bleeding Air

MEMO

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 SECTION1 GENERAL
Group4 Bleeding Air

Bleeding Air from Pump

IMPORTANT
If air is accumulated inside of the pump and the engine starts in lacking of hydraulic oil, the pump may be
damaged.

1. Remove the air bleed plug on top of the pump. Add hydraulic oil to the pump.
2. After the pump is filled with hydraulic oil, temporarily tighten air bleed plug on each pump.Then, start the engine and
run it at slow idle speed.
3. Slightly loosen the plug and bleed air from the pump until hydraulic oil comes out from the gap. After bleeding all air,
securely tighten the plug.
: 30 to 40 N·m

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 SECTION1 GENERAL
Group4 Bleeding Air

MEMO

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 SECTION1 GENERAL
Group4 Bleeding Air

Bleeding Air from Travel Motor, Swing Motor

IMPORTANT
If air is accumulated inside of the motor and the motor starts in lacking of hydraulic oil, the motor may be
damaged.

1. Remove the air bleed plug (top) from the travel motor or swing motor.Fill the motor case with hydraulic oil.

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Group4 Bleeding Air

MEMO

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 SECTION1 GENERAL
Group4 Bleeding Air

Bleeding Air from Hydraulic Circuit

IMPORTANT
If air is accumulated inside of the cylinder and the cylinder is operated suddenly in lacking of hydraulic oil, the
seal may be damaged or the cylinder may seize.

1. After refilling hydraulic oil, start the engine.While operating each cylinder, swing motor, or travel motors evenly,
operate the machine under light loads for about 10 to 15 minutes. Slowly start each operation at first.
2. As the pilot circuit has an air bleed device, air in the pilot circuit will be bled while performing the step 1 operation for
approx. 5 minutes.
3. Return the position to check hydraulic oil level.
4. Stop the engine. Check hydraulic oil level. Add hydraulic oil if necessary.

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Group4 Bleeding Air

MEMO

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 SECTION1 GENERAL
Group4 Bleeding Air

Bleeding Air from Fuel System

Air in the fuel system may make the engine hard to start or make it run irregularly.
After draining water and sediment from the fuel filter, replacing the fuel filter, or running the fuel tank dry, be sure to
bleed the air from the fuel system.
Air Bleeding Procedures
This machine is equipped with an automatic air bleed device.
1. Check that fuel level is over half of the fuel tank. If fuel is lack, add fuel.
2. Set the key switch to the ON position and hold it in that position for about 10 to 15 seconds.
3. Start the engine and check the fuel system for fuel leaks.

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 SECTION1 GENERAL
Group4 Bleeding Air

MEMO

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 SECTION1 GENERAL
Group4 Bleeding Air

Bleeding Air from Radiator

CAUTION
Do not loosen cap when the coolant temperature of radiator is too high. Hot steam may spout out and cause
severe burns. Wait until coolant cools and loosen the cap slowly. Release all pressure and remove the cap.

Preparation
1. Park the machine on a solid and level surface. Set the front attachment in position for checking hydraulic oil level.
2. Stop the engine. Remove the radiator cap.

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Group4 Bleeding Air

MEMO

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 SECTION1 GENERAL
Group5 Preparation 　
　
Preparation before Inspection and Maintenance
　
CAUTION 　
Components, hydraulic oil, lubricant, and coolant just after operation are too hot. Wait until they cool. Then, start
the work.

Securing Work Spaces and Personnel

Before starting the work, select wide and solid footing and keep bystanders away from machine moving area. Slowly
operate the front attachment. Secure co-workers according to the work. When working with co-workers, thoroughly
check hand signals and sufficiently pay attention.
Machine Position for Inspection and Maintenance
Before performing the maintenance procedures given in the following items, park the machine as described below,
unless otherwise specified.
1. Park the machine on a solid and level surface.
2. Lower the bucket to the ground.

M1M7-05-024 ja
3. Turn OFF the auto-idle switch.
4. Set the engine control dial to the slow idle position and run the engine for 5 minutes in order to cool the engine.
5. Set the key switch to the OFF position and stop the engine. Remove the key.
6. Set pilot shut-off lever (1) to the LOCK position.
7. Before performing any work on the machine, attach tag (2) in a highly visible place such as the door or control lever.
1

WDAA-01-06-001-1 ja

CAUTION
Never attempt to maintain the machine when the engine is running in order to prevent the accident. If
maintenance work while engine running is unavoidable, strictly comply with the following items.

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 SECTION1 GENERAL
Group5 Preparation

• One person should take the operator's seat to be ready to stop the engine any time while communicating
with other workers.
• When working around the moving parts is unavoidable, do not approach hands, feet, and clothes which are
easy to be entangled.
• If parts or tools are dropped or inserted into the fan or the belt, they may fly off or be cut off. Do not drop or
insert parts and tools into the moving parts.
• Set pilot shut-off lever (1) to the LOCK position so that the front attachment will not move.
• Never touch the control levers and pedals. If operating the control levers or pedals is unavoidable, give the
hand signals to co-workers and evacuate them to the safer place.

WDDQ-01-05-001 ja

WAFF50-EN-00(07/05/2019) W1-5-1-2
 SECTION1 GENERAL
Group5 Preparation

Hydraulic Circuit Pressure Release Procedure

Release any remaining pressure as follows before removing/installing the front attachment.
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1)

2. Tilt up the floor. (Refer to the operator's manual.)

CAUTION
Each attachment may move rapidly in case the overload relief valve is loosened rapidly. Check that the
machine has been set in the position for inspection and maintenance, then loosen it slowly. Do not loosen it
more than 3/4 turns as hydraulic oil may spout.

5 4
6 1

3 2

WAFF-01-05-001-1 ja
1- Overload Relief Valve (Arm 3- Overload Relief Valve (Buck­ 5- Overload Relief Valve (Boom
Roll-Out) et Roll-In) Raise)
2- Overload Relief Valve (Buck­ 4- Overload Relief Valve (Boom 6- Overload Relief Valve (Arm
et Roll-Out) Lower) Roll-In)

IMPORTANT
Do not turn lock nut (9) and adjusting screw (8). Failure to do so can change the setting.

3. Slowly loosen body (7) of the overload relief valve in which any remaining pressure to be released.
: 24 mm
: 70 to 80 N·m

WAFF50-EN-00(07/05/2019) W1-5-2-1
 SECTION1 GENERAL
Group5 Preparation

7 9
8

TAEA-03-04-013-5 ja
7- Body 8- Adjusting Screw 9- Lock Nut

WAFF50-EN-00(07/05/2019) W1-5-2-2
 SECTION1 GENERAL
Group5 Preparation

Pressure Release from Hydraulic Oil Tank

CAUTION
Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release pressure before
disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may
spout out and cause severe burns. Allow oil to cool before starting any work. Do not turn cap (2) of hydraulic oil
tank (3) quickly. Cap (2) may fly off by internal pressure. Release any remaining pressure before removing cap (2).

Preparation
1. Park the machine on a solid and level surface. Set the front attachment in position for checking hydraulic oil level.
2. Stop the engine. Slowly loosen cap (2) of hydraulic oil tank (3) and bleed air from hydraulic oil tank (3).
3. Remove cap (2) of hydraulic oil tank (3).

NOTE
Hydraulic oil tank (3) becomes negative pressure by installing vacuum pump (a) to the position where cap (2) is
removed and operating vacuum pump (a). This operation prevents hydraulic oil from draining when disconnecting
hoses. Operate vacuum pump (a) continuously while working.

3 2
b

WABA-01-05-003-1 ja

a- Vacuum Pump b- Hose c- Adapter

WAFF50-EN-00(07/05/2019) W1-5-3-1
 SECTION1 GENERAL
Group5 Preparation

MEMO

WAFF50-EN-00(07/05/2019) W1-5-3-2
2

MAINTENANCE STANDARD

Upperstructure .................................... W2-1-1-1

Maintenance Standard for Pump Device ...............W2-1-1-1
Maintenance Standard for Swing Motor ................W2-1-2-1
Undercarriage...................................... W2-2-1-1
Maintenance Standard for Travel Motor.................W2-2-1-1
Maintenance Standard for Sprocket ........................W2-2-2-1
Maintenance Standard for Front Idler .....................W2-2-3-1
Maintenance Standard for Upper Roller.................W2-2-4-1
Maintenance Standard for Lower Roller.................W2-2-5-1
Maintenance Standard for Track (Rubber Crawler)
..........................................................................................W2-2-6-1
Maintenance Standard for Track (Steel Crawler) .W2-2-7-1
Front Attachment ................................ W2-3-1-1
Maintenance Standard for Pin and Bushing .........W2-3-1-1
Maintenance Standard for Side Cutter (3066997,
3066998).......................................................................W2-3-2-1
Maintenance Standard for Point (4080730) ..........W2-3-3-1
Standard Dimensions for Arm and Bucket
Connection ..................................................................W2-3-4-1
Maintenance Standard for Cylinder .........................W2-3-5-1

WAFF50-EN-00(07/05/2019)
MEMO

WAFF50-EN-00(07/05/2019)
 SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure
　
Maintenance Standard for Pump Device
　
　
　
　

1 2
WAFF-02-01-001-1 ja
1- Cylinder Block 2- Plunger (11 Used)
1. Clearance between outer diameter (d) of plunger (2) and inner diameter (D) of cylinder block (1)

Allowable Limit (mm) 0.05

D-d≤0.05 mm

D d

1 2

W507-02-04-009-2 ja
2. Clearance (ε) between plunger (2) and shoe (a) bottom

Allowable Limit (mm) 0.2

ε≤0.2 mm

WAFF50-EN-00(07/05/2019) W2-1-1-1
 SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure

ε
2
W1V1-03-02-005-1 ja

a- Shoe
3. Wear amount of oil seal mounting surface
Check that there are no damage and/or abnormal wear.

Standard (mm) Allowable Limit (mm)

0 0.025
D0-D1≤0.025 mm

D0 D1

WAEJ-02-01-101-1 ja

WAFF50-EN-00(07/05/2019) W2-1-1-2
 SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure

Maintenance Standard for Swing Motor

WAEJ-02-01-102-1 ja
1- Rotor 2- Plunger (9 Used)
1. Clearance between outer diameter (d) of plunger (2) and cylinder inner diameter (D) of rotor (1)

Allowable Limit (mm) 0.04

D-d≤0.04 mm

D d

1 2

W507-02-04-009-2 ja
2. Clearance (ε) between plunger (2) and shoe (a) bottom

WAFF50-EN-00(07/05/2019) W2-1-2-1
 SECTION2 MAINTENANCE STANDARD
Group1 Upperstructure

Allowable Limit (mm) 0.4

ε≤0.4 mm

ε
a

WAEJ-02-01-103-1 ja

a- Shoe

WAFF50-EN-00(07/05/2019) W2-1-2-2
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage
　
Maintenance Standard for Travel Motor
　
　
2 3 　
　
　

WAEJ-02-02-100-1 ja
1- Valve Plate 2- Rotor 3- Plunger (9 Used)
1. Clearance between outer diameter (d) of plunger (3) and inner diameter (D) of rotor (2)

Standard (mm) Allowable Limit (mm)

0.02 0.04
(D-d)≤0.04 mm

D d

2 3

W507-02-04-009-1 ja
2. Clearance (ε) between shoe (a) and plunger (3) bottom

WAFF50-EN-00(07/05/2019) W2-2-1-1
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

Standard (mm) Allowable Limit (mm)

0.15 0.4
ε≤0.4 mm

ε
3

W1V1-03-02-005-3 ja

a- Shoe
3. Wear amount of sliding surface against valve plate of rotor (2)
Check that there are no damage, abnormal wear, and/or seizure.
Damage and/or wear: 0.02 mm (0.001 in) or less
4. Wear amount of sliding surface against rotor (2) of valve plate
Check that there are no damage, abnormal wear, and/or seizure.
Damage and/or wear: 0.02 mm (0.001 in) or less

WAFF50-EN-00(07/05/2019) W2-2-1-2
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

Maintenance Standard for Sprocket

D C B

W503-03-02-004-1 ja

Standard (mm) Allowable Limit (mm) Remedy

A 47.6 41.6 Replace parts.
B 377.3 371.3
C 415.8 -
D 423.2 417.2
E 135 -

WAFF50-EN-00(07/05/2019) W2-2-2-1
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

MEMO

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 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

Maintenance Standard for Front Idler

C D F

A
B

W503-03-05-001-1 ja

Standard (mm) Allowable Limit (mm) Remedy

A 53 47 Replace
B 92 -
C 49 -
D 335 309
E 10 -
F 379 -

Axle and Bushing

Standard (mm) Allowable Limit (mm) Remedy

Axle Outer Diam­ 45 44.2 Replace
eter
Bushing Inner Diame­ 45 45.5
ter
Flange Thick­ 2.0 1.5
ness

Lubrication Oil
Engine Oil (SAE #30, CD class)
Amount of engine oil: 70 mL (70 cm3)

WAFF50-EN-00(07/05/2019) W2-2-3-1
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

MEMO

WAFF50-EN-00(07/05/2019) W2-2-3-2
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

Maintenance Standard for Upper Roller

WAEJ-02-02-101-1 ja

Standard (mm) Allowable Limit (mm) Remedy

A 110 - Replace
B 80 74

Lubrication Oil
Engine Oil (API CD class, SAE #30)
Amount of engine oil: 80 mL (80 cm3)

WAFF50-EN-00(07/05/2019) W2-2-4-1
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

MEMO

WAFF50-EN-00(07/05/2019) W2-2-4-2
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

Maintenance Standard for Lower Roller

B

C D E

WAFF-02-02-001-1 ja

Standard (mm) Allowable Limit (mm) Remedy

A 53 45 Replace
B 142 -
C 44 -
D 110 102
E 137 -

Axle and Bushing

Standard (mm) Allowable Limit (mm) Remedy

Axle Outer Diam­ 40 39.2 Replace
eter
Bushing Inner Diame­ 40 40.5
ter
Flange Thick­ 2.0 1.5
ness

Lubrication Oil
Gear Oil (SAE #30, CD class)
Oil amount: 120 mL (120 cm3)

WAFF50-EN-00(07/05/2019) W2-2-5-1
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

MEMO

WAFF50-EN-00(07/05/2019) W2-2-5-2
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

Maintenance Standard for Track (Rubber Crawler)

Rubber Crawler Crack

1. Outside of Rubber Crawler
If there is a crack on lug base (1) with depth of 3 mm (0.12 in) or more, repair the track.
If there is a crack between lugs (2) with depth of 3 mm (0.12 in) or more, repair the track.
If there is a crack on lugs (3) or between lugs (2) and it reaches steel code (5) or steel core (4) with length of 30 mm
(1.18 in) or more, immediately repair the track.

1 4

5
2

W190-03-07-001-1 ja
2. Inside of Rubber Crawler (Roller (6) Side)
If there is a crack that reaches steel code (5) or steel core (4), immediately repair the track.

4 6

WABA-02-02-003-1 ja

Lug Wear
1. If height (A) of lug (8) is less than 5 mm (0.2 in), replace rubber crawler (7) as an assembly.

W190-03-07-003-1 ja
2. If any part of steel code (5) appeared on the track, replace the worn rubber crawler as an assembly.

WAFF50-EN-00(07/05/2019) W2-2-6-1
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

W190-03-07-004-1 ja

A
A

A-A 2

W1LA-03-07-001-2 ja

Standard (mm) Allowable Limit (mm) Remedy

1 25 5 Replace
2 54 67
3 25 29

Rubber Crawler and Steel Code Cutting

1. When either of the two rows of steel code (5) has cut, replace the rubber crawler as an assembly.

W190-03-07-005-1 ja

Steel Core Separation

1. When any part of steel core (4) has separated, replace the rubber crawler as an assembly.

WAFF50-EN-00(07/05/2019) W2-2-6-2
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

W190-03-07-006-1 ja

WAFF50-EN-00(07/05/2019) W2-2-6-3
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

MEMO

WAFF50-EN-00(07/05/2019) W2-2-6-4
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

Maintenance Standard for Track (Steel Crawler)

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

A
W155-03-07-001-1 ja

Standard (mm) Allowable Limit (mm) Remedy

A 540 556 Build up welding and hand fin­
B 67 60 ishing or replace

Grouser shoe

W105-03-07-024-2 ja

Shoe width 400 mm grouser

Standard (mm) Allowable Limit (mm) Remedy
C 154 - Build up welding and hand
D 6 - finishing or replace
E 14 7

Master pin

J P

I
WADR-02-02-101-1 ja

Standard (mm) Allowable Limit (mm) Remedy

I 140 - Replace
J 22.15 19.5
P 21.8 -

WAFF50-EN-00(07/05/2019) W2-2-7-1
 SECTION2 MAINTENANCE STANDARD
Group2 Undercarriage

Pin

L
B

AK
W142-03-07-004-2 ja

Standard (mm) Allowable Limit (mm) Remedy

K 140 - Replace
L 22.3 20.5

Bushing

N O

M
WDDQ-02-02-002-1 ja

Standard (mm) Allowable Limit (mm) Remedy

M 79.8 - Replace
N 22.5 23.5
O 35 33

WAFF50-EN-00(07/05/2019) W2-2-7-2
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment
　
Maintenance Standard for Pin and Bushing
　
Q
R 　
B P 　
A
　
　
　

D
A
E
B
U
F

L M
H N AA T

WAFF-02-03-001-1 ja

WAFF50-EN-00(07/05/2019) W2-3-1-1
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

Name Standard (mm) Allowable Limit (mm) Remedy

A Pin 60 59 Replace
Bushing (Boom) 60 61.5
B Pin 60 59
Bushing (Boom Cylinder) 60 61.5
D Pin 60 59
Bushing (Boom Cylinder) 60 61.5
E Pin 60 59
Bushing (Arm) 60 61.5
F Pin 55 54
Bushing (Arm Cylinder) 55 56.5
G Pin 55 54
Bushing (Arm Cylinder) 55 56.5
H Pin 45 44
Bushing (Bucket Cylinder) 45 46.5
J Pin 50 49
Bushing (Bucket Cylinder) 50 51.5
Bushing (Link A) 50 51.5
Link B 50 51.5
L Pin 45 44
Bushing (Arm) 45 46.5
Link B 45 46.5
M Pin 45 44
Bushing (Link A) 45 46.5
N Pin 45 44
Bushing (Arm) 45 46.5
P Pin 110 109
Bushing (Main Frame) 110 111.5
Bushing (Swing Post) 110 111.5
Q Pin 55 54
Bushing (Boom Swing Cylinder) 55 56.5
R Pin 55 54
Bushing (Boom Swing Cylinder) 55 56.5
T Pin 50 49
Bushing (Blade) 50 51.5
U Pin 71 70
Bushing (Blade Cylinder) 71 72.5

WAFF50-EN-00(07/05/2019) W2-3-1-2
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

Name Standard (mm) Allowable Limit (mm) Remedy

AA Pin 65 64
Bushing (Blade Cylinder) 65 66.5

IMPORTANT
When replacing HN bushing for the front attachment, install it by using a press.

WAFF50-EN-00(07/05/2019) W2-3-1-3
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

MEMO

WAFF50-EN-00(07/05/2019) W2-3-1-4
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

Maintenance Standard for Side Cutter (3066997, 3066998)

D
A

W1MH-04-01-001-1 ja

Standard (mm) Allowable Limit (mm) Remedy

A 142 92 Replace
B 175 -
C 235 -
D 110 -

WAFF50-EN-00(07/05/2019) W2-3-2-1
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

MEMO

WAFF50-EN-00(07/05/2019) W2-3-2-2
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

Maintenance Standard for Point (4080730)

B C

WAEQ-02-03-001-1 ja

Standard Dimension (mm) Allowable Limit (mm) Remedy

A 135 67.5 Replace
B 56 -
C 62 -
D 50 -

WAFF50-EN-00(07/05/2019) W2-3-3-1
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

MEMO

WAFF50-EN-00(07/05/2019) W2-3-3-2
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

Standard Dimensions for Arm and Bucket Connection

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

B
A
A h p
n
A B

i m

k
j

WAEQ-02-03-002-1 ja

ZX65USB-6 (mm) ZX65USB-5 (mm)

a 208 ←
b 10 ←
c 325 ←
d 296 ←
e 245 ←
f 906 ←
g 274.5 ←
h 172.5 ←
i 45 ←
j 243.1 ←
k 30 ←
m 45 ←
n -45° ←
p 90° ←

NOTE
Dimensions n: -45°, p: 90° means the angle for the bolt hole.

WAFF50-EN-00(07/05/2019) W2-3-4-1
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

MEMO

WAFF50-EN-00(07/05/2019) W2-3-4-2
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

Maintenance Standard for Cylinder

Rod

W105-04-02-094-1 ja

Cylinder Name Recommended Size After Re-manufacturing (A) (mm)

Boom 60-0.030 -0.076
Arm 55-0.030-0.076
Bucket 50-0.030-0.076
Boom Swing 55-0.030-0.076
Blade 70-0.010-0.050

Rod Bend and Run Out

b
a

c d
W166-04-02-022-1 ja

a- Cylinder Rod b- Dial Gauge c- V Block d- 1 m

Bend (mm) Run Out (mm) Remedy

0.5 1.0 Repair
1.0 2.0 Replace

WAFF50-EN-00(07/05/2019) W2-3-5-1
 SECTION2 MAINTENANCE STANDARD
Group3 Front Attachment

MEMO

WAFF50-EN-00(07/05/2019) W2-3-5-2
3

UPPERSTRUCTURE

Cab ........................................................ W3-1-1-1 Assembly of Swing Motor............................................W3-5-6-1

Removal of Cab................................................................W3-1-1-1 Pilot Valve ............................................ W3-6-1-1
Installation of Cab...........................................................W3-1-2-1
Removal of Pilot Valve (Left) .......................................W3-6-1-1
Dimensions of Cab Glass..............................................W3-1-3-1
Installation of Pilot Valve (Left) ..................................W3-6-2-1
Procedure to Remove Cab Glass and Overhead
Removal of Pilot Valve (Right) ....................................W3-6-3-1
Window.........................................................................W3-1-4-1
Installation of Pilot Valve (Right) ...............................W3-6-4-1
Procedure to Install Cab Glass....................................W3-1-5-1
Disassembly of Pilot Valves (Left and Right) .........W3-6-5-1
Procedure to Install Overhead Window..................W3-1-6-1
Assembly of Pilot Valves (Left and Right)...............W3-6-6-1
Procedure to Install Front Window Pane................W3-1-7-1
Removal of Travel Pilot Valve......................................W3-6-7-1
Counterweight..................................... W3-2-1-1 Installation of Travel Pilot Valve.................................W3-6-8-1
Disassembly of Travel Pilot Valve ..............................W3-6-9-1
Removal of Counterweight .........................................W3-2-1-1
Assembly of Travel Pilot Valve................................. W3-6-10-1
Installation of Counterweight ....................................W3-2-2-1
Removal of Boom Swing Pilot Valve ..................... W3-6-11-1
Pump Device ........................................ W3-3-1-1 Installation of Boom Swing Pilot Valve ................ W3-6-12-1
Removal of Pump Device.............................................W3-3-1-1 Disassembly of Boom Swing Pilot Valve.............. W3-6-13-1
Installation of Pump Device........................................W3-3-2-1 Assembly of Boom Swing Pilot Valve ................... W3-6-14-1
Disassembly of Pump Device .....................................W3-3-3-1 Removal of Blade Pilot Valve ................................... W3-6-15-1
Assembly of Pump Device...........................................W3-3-4-1 Installation of Blade Pilot Valve............................... W3-6-16-1
Disassembly of Regulator ............................................W3-3-5-1 Disassembly of Blade Pilot Valve............................ W3-6-17-1
Assembly of Regulator..................................................W3-3-6-1 Assembly of Blade Pilot Valve.................................. W3-6-18-1
Removal of Auxiliary Pilot Valve ............................. W3-6-19-1
Control Valve........................................ W3-4-1-1 Installation of Auxiliary Pilot Valve ........................ W3-6-20-1
Removal of Control Valve.............................................W3-4-1-1 Disassembly of Auxiliary Pilot Valve...................... W3-6-21-1
Installation of Control Valve........................................W3-4-2-1 Assembly of Auxiliary Pilot Valve ........................... W3-6-22-1
Structure of Control Valve............................................W3-4-3-1 Solenoid Valve ..................................... W3-7-1-1
Disassembly of Body......................................................W3-4-4-1
Assembly of Body ...........................................................W3-4-5-1 Removal of 2-Spool Solenoid Valve .........................W3-7-1-1
Disassembly of Unload Section .................................W3-4-6-1 Installation of 2-Spool Solenoid Valve ....................W3-7-2-1
Assembly of Unload Section.......................................W3-4-7-1 Disassembly of 2-Spool Solenoid Valve..................W3-7-3-1
Disassembly of Boom Anti-Drift Valve ....................W3-4-8-1 Assembly of 2-Spool Solenoid Valve .......................W3-7-4-1
Assembly of Boom Anti-Drift Valve ..........................W3-4-9-1 Removal of LS Cut Solenoid Valve ............................W3-7-5-1
Disassembly of Spool ................................................. W3-4-10-1 Installation of LS Cut Solenoid Valve .......................W3-7-6-1
Assembly of Spool....................................................... W3-4-11-1 Disassembly of LS Cut Solenoid Valve.....................W3-7-7-1
Disassembly of Shuttle Valve and Pressure Assembly of LS Cut Solenoid Valve ..........................W3-7-8-1
Compensator ........................................................... W3-4-12-1 Revolution Sensing Valve ................... W3-8-1-1
Assembly of Shuttle Valve and Pressure
Removal of Revolution Sensing Valve.....................W3-8-1-1
Compensator ........................................................... W3-4-13-1
Installation of Revolution Sensing Valve ................W3-8-2-1
Swing Device........................................ W3-5-1-1 Disassembly of Revolution Sensing Valve .............W3-8-3-1
Removal of Swing Device ............................................W3-5-1-1 Assembly of Revolution Sensing Valve ...................W3-8-4-1
Installation of Swing Device .......................................W3-5-2-1 Muffler Filter ........................................ W3-9-1-1
Disassembly of Swing Reduction Gear ...................W3-5-3-1
Removal of Muffler Filter..............................................W3-9-1-1
Assembly of Swing Reduction Gear.........................W3-5-4-1
Installation of Muffler Filter.........................................W3-9-2-1
Disassembly of Swing Motor ......................................W3-5-5-1
Disassembly of Muffler Filter ......................................W3-9-3-1

WAFF50-EN-00(07/05/2019)
 Assembly of Muffler Filter............................................W3-9-4-1

WAFF50-EN-00(07/05/2019)
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Removal of Cab
　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, 　
install the clips after connecting the hoses.
　
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.) 　
2. Open door (1).
3. Remove floor mats (2, 3). 　
　
　

3 2

WAEJ-03-01-100-1 ja
4. Disconnect connector (9).

CAUTION
The cab (4) assembly weight: 220 kg

5. Install the shackles (4 used) to cab (4). Attach the nylon slings onto the shackles (4 used). Hoist and hold cab (4).
6. Remove caps (5) (2 used), bolts (6, 11) (2 used for each), bolt (7), bolts (10) (3 used), bolts (12) (4 used), and washers (8)
(12 used) from cab (4).
: 19 mm

WAFF50-EN-00(07/05/2019) W3-1-1-1
 SECTION3 UPPERSTRUCTURE
Group1 Cab

7. Hoist and remove the cab (4) assembly from the floor.
a 4

12

5
6

8
11 9
10

WAFF-03-01-101-1 ja

a- Shackle Mounting Position

WAFF50-EN-00(07/05/2019) W3-1-1-2
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Installation of Cab

CAUTION
The cab (4) assembly weight: 220 kg

1. Install the shackles (4 used) to cab (4). Attach nylon slings onto the shackles (4 used). Hoist the cab (4) assembly.
2. Fit the cab (4) assembly to the floor mounting hole.
3. Install cab (4) to the floor with washers (8) (12 used), bolts (6, 11) (2 used for each), bolt (7), bolts (10) (3 used), bolts
(12) (4 used), and caps (5) (2 used).
: 19 mm
: 110 N·m
4. Connect connector (9).
a 4

12

5
6

8
11 9
10

WAFF-03-01-101-1 ja

a- Shackle Mounting Position

5. Install floor mats (2, 3).

WAFF50-EN-00(07/05/2019) W3-1-2-1
 SECTION3 UPPERSTRUCTURE
Group1 Cab

6. Close door (1).

3 2

WAEJ-03-01-100-1 ja

WAFF50-EN-00(07/05/2019) W3-1-2-2
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Dimensions of Cab Glass

CAUTION
Use the genuine parts for the glasses

WAFF50-EN-00(07/05/2019) W3-1-3-1
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Unit: mm

WAFF-03-01-102-1 ja

a- Marking Stamped Position b- Black Ceramic Coated Surface

WAFF50-EN-00(07/05/2019) W3-1-3-2
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Unit: mm

WAFF-03-01-103-1 ja

a- Marking Stamped Position b- Black Ceramic Coated Surface

WAFF50-EN-00(07/05/2019) W3-1-3-3
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Unit: mm

WAFF-03-01-104-1 ja

c- Silk-Screen Coated Surface

WAFF50-EN-00(07/05/2019) W3-1-3-4
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Unit: mm

WAFF-03-01-105-1 ja

a- Marking Stamped Position b- Black Ceramic Coated Surface

WAFF50-EN-00(07/05/2019) W3-1-3-5
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Unit: mm

WAFF-03-01-106-1 ja

a- Marking Stamped Position b- Black Ceramic Coated Surface

WAFF50-EN-00(07/05/2019) W3-1-3-6
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Unit: mm

WAFF-03-01-107-1 ja

a- Marking Stamped Position b- Black Ceramic Coated Surface

WAFF50-EN-00(07/05/2019) W3-1-3-7
 SECTION3 UPPERSTRUCTURE
Group1 Cab

MEMO

WAFF50-EN-00(07/05/2019) W3-1-3-8
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Procedure to Remove Cab Glass and Overhead Window

Removal Procedures of Overhead Window (1), Lower Right-Hand Glass (6), Upper Right-Hand Glass (9), Rear Left-Hand
Glass (3), Upper Door Glass (5), Lower Door Glass (4), and Rear Glass (2)

CAUTION
When removing the broken or cracked glass, the glass shards may cause serious injury. Before removing, use the
duct tape or equivalent in order to paste the broken or cracked glass and reinforce them. Remove the glass pieces
away.

1. Remove the resin panel, garnish, and spacer around the glass.
1

2
5

3 9
6
4
WAFF-03-01-108-1 ja
2. Prick a through hole in adhesive (b) by using awl (a) (or a knife).
7
8
a

b
W1SE-02-01-033-1 ja
7- Cab 8- Glass

a- Awl b- Adhesive
3. Pass piano wire (c) (or a metal wire) through the through hole.

W1SE-02-01-034-1 ja

c- Piano Wire

WAFF50-EN-00(07/05/2019) W3-1-4-1
 SECTION3 UPPERSTRUCTURE
Group1 Cab

IMPORTANT
The piano wire is easily broken if a part of the piano wire turns hot. Change the position and cut the adhesive.

4. Wind the both ends of the piano wire onto the screw driver. Draw the wire back and forth in order to cut adhesive (b)
between cab (7) and glass (8). Remove glass (8) from cab (7).

NOTE
Cut off the middle of adhesive between glass and cab.

7 d

e
f

W1SE-02-01-035-1 ja

d- Cab Outside e- Adhesive f- Cab Inside

WAFF50-EN-00(07/05/2019) W3-1-4-2
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Procedure to Install Cab Glass

Installation Procedures of Lower Right-Hand Glass (6), Upper Right-Hand Glass (9), Rear Left-Hand Glass (3), Upper Door
Glass (5), Lower Door Glass (4), and Rear Glass (2)

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

NOTE
Do not damage the cab (7) paint.

2. Clean the cut surface of adhesive at the cab (7) side by using white gasoline.

b
5 2
9
6
3
4
WAFF-03-01-109-1 ja

a- Knife b- 1 to 2 mm

IMPORTANT
Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer,
apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the
contents should be used within 180 days (or 2 hours with the cap off).

3. Apply Primer for paint surfaces to the cut surface of adhesive at the cab (7) side by using a brush. Wait for about 15
minutes in order to let it dry by itself.
7
c

W1SE-02-01-038-1 ja

c- brush d- Cut surface of adhesive at cab side

4. Clean the mating edge of the new glass by using clean rag and white gasoline.

IMPORTANT
Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer,
apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the
contents should be used within 180 days (or 2 hours with the cap off).

5. Apply Primer for glass to the adhesive applying position on the glass by using a brush. Wait for about 15 minutes in
order to let it dry by itself.

WAFF50-EN-00(07/05/2019) W3-1-5-1
 SECTION3 UPPERSTRUCTURE
Group1 Cab

6. Put dam rubber (10) onto the cab (7) side.

7 10
WAEQ-03-01-100-1 ja
7. Cut off the nozzle end of adhesive cartridge (Sikaflex 250 -2) into V-shaped by using a knife.

8 mm

12 mm
e

W1SE-02-01-027-3 ja

e- V-shaped
8. Remove the seal of the adhesive cartridge end. Install the V-shaped nozzle.
9. Install the adhesive cartridge to the manual coking gun.
10. Evenly apply adhesive (h) to the cut surface of the residual adhesive at the cab (7) side.

h
f

g
7

WAEJ-03-01-109-2 ja

f- Seal g- Adhesive Cartridge h- Adhesive

11. Raise the glass by using the suction lifter (rubber sucker 4355282), and adhere it to cab (7).

NOTE
Remove all adhesive except the mounting surface, before solidifying by using white gasoline.

12. Secure the glass by using the duct tape until the adhesive becomes solid in order to prevent it from being
mispositioned or coming off.

NOTE
Time for adhesive (Sikaflex 250 -2) to become solid: 12 hours in spring, 24 hours in winter (just for reference)

WAFF50-EN-00(07/05/2019) W3-1-5-2
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Procedure to Install Overhead Window

1. Cut off the residual adhesive from the cab (7) side so that the adhesive still remains approx. 1 to 2 mm in thickness by
using a knife or similar.

NOTE
Do not damage the cab (7) paint.

WAFF-03-01-110-1 ja

a- Knife b- 1 to 2 mm
2. Clean the cut surface of adhesive at the cab (7) side by using white gasoline.

IMPORTANT
Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer,
apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the
contents should be used within 180 days (or 2 hours with the cap off).

3. Apply Primer (SUNSTAR #580) for paint surfaces to the cut surface of adhesive at the cab (7) side by using a brush and
let it dry by itself (for 5 or more minutes or 24 and less hours).

NOTE
Apply sufficient amount of Primer without residual Primer and faint portions.

7
c

W1SE-02-01-038-1 ja

c- brush d- Cut surface of adhesive at cab side

4. Clean the contacting surface of new overhead window (1) by using clean rag and white gasoline.

WAFF50-EN-00(07/05/2019) W3-1-6-1
 SECTION3 UPPERSTRUCTURE
Group1 Cab

IMPORTANT
Primer should be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer,
apply Primer as quickly as possible and close the cap immediately after using. After opening Primer, all the
contents should be used within 180 days (or 2 hours with the cap off).

5. Apply Primer (SUNSTAR #435-41) for overhead window to the adhesive applying position of the overhead window (1)
by using a brush and let it dry by itself (for 5 or more minutes or 24 and less hours).
6. Evenly apply adhesive (SUNSTAR Penguin Seal #560) to the cut surface of the residual adhesive at the cab (7) side.
7. Raise overhead window (1) by using the suction lifter (rubber sucker 4355282), and adhere it to cab (7) within 5
minutes.

NOTE
Remove all adhesive except the mounting surface, before solidifying by using white gasoline.

WAFF50-EN-00(07/05/2019) W3-1-6-2
 SECTION3 UPPERSTRUCTURE
Group1 Cab

8. Secure overhead window (1) by using the duct tape until the adhesive becomes solid in order to prevent it from being
mispositioned or coming off.

D
7 1
D

B B
C C
E

B-B C-C
39 mm

42 mm

D-D E-E

4 mm 21 mm

Dimension of Clearance between CAB and Overhead Window

WAEJ-03-01-112-2 ja

WAFF50-EN-00(07/05/2019) W3-1-6-3
 SECTION3 UPPERSTRUCTURE
Group1 Cab

MEMO

WAFF50-EN-00(07/05/2019) W3-1-6-4
 SECTION3 UPPERSTRUCTURE
Group1 Cab

Procedure to Install Front Window Pane

1. Stick seal (11) to the lower side C part of the front window pane by using adhesive. Secure both the right and left ends
(the thicker part) of seal (11) to the glass by using adhesive. Stick seal (11) by using adhesive so that no visible
undulation or extruded glue can be found on the contacting surface B part of seal (11) and front window pane (a).

A-A
a

B C

11
A

WAFF-03-01-111-1 ja

a- Front Window Pane

WAFF50-EN-00(07/05/2019) W3-1-7-1
 SECTION3 UPPERSTRUCTURE
Group1 Cab

MEMO

WAFF50-EN-00(07/05/2019) W3-1-7-2
 SECTION3 UPPERSTRUCTURE
Group2 Counterweight

Removal of Counterweight
　
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.) 　
2. Tilt up the floor. (Refer to the operator's manual.)
3. Remove bolts, washers (4) (3 used) and bolts, washers (6) (2 used). Remove cover (5). 　
: 17 mm
　
4. Open cover (3).
5. Remove bolts, washers (1) (5 used) Remove the cover (2) assembly. 　
: 17 mm
1 2 　
　
　
　

6 5 4
WAFF-03-02-001-1 ja
6. Remove bolts (8) (2 used) and washers (9) (2 used).
: 24 mm
8, 9

WAFF-03-02-002-1 ja

CAUTION
Counterweight (16) weight : 750 kg

7. Remove caps (15) (2 used). Install Freno-Linkbolts (A-20, M20, pitch 2.5 mm) (2 used) to cap (15) mounting holes (2
places). Hoist and hold counterweight (16).
8. Remove bolts (17) (3 used) and washers (18) (3 used) from counterweight (16).
: 36 mm

WAFF50-EN-00(07/05/2019) W3-2-1-1
 SECTION3 UPPERSTRUCTURE
Group2 Counterweight

9. Raise counterweight (16) a little. Slide counterweight (18) to the rear side. Remove counterweight (16) from main
frame (19).
19 15 16

18 17
WAFF-03-02-003-1 ja

WAFF50-EN-00(07/05/2019) W3-2-1-2
 SECTION3 UPPERSTRUCTURE
Group2 Counterweight

Installation of Counterweight

CAUTION
Counterweight (16) weight : 750 kg

1. Install Freno-Linkbolts (A-20, M20, pitch 2.5 mm) (2 used) to cap (15) mounting holes (2 places). Hoist counterweight
(16). Place counterweight (16) onto main frame (19). Slide counterweight (18) to the front side.
2. Install counterweight (16) to main frame (19) with bolts (17) (3 used) and washers (18) (3 used).
: 36 mm
: 930 N·m
3. Remove Freno-Linkbolts (2 used) from the cap (15) mounting holes (2 places). Install caps (15) (2 used).
19 15 16

18 17
WAFF-03-02-003-1 ja
4. Install washers (9) (2 used) and bolts (8) (2 used).
: 24 mm
: 210 N·m
8, 9

WAFF-03-02-002-1 ja
5. Install the cover (2) assembly with bolts, washers (1) (5 used).
: 17 mm
: 50 N·m
6. Close cover (3).

WAFF50-EN-00(07/05/2019) W3-2-2-1
 SECTION3 UPPERSTRUCTURE
Group2 Counterweight

7. Install cover (5) with bolts, washers (4) (3 used) and bolts, washers (6) (2 used).
: 17 mm
: 50 N·m
1 2

6 5 4
WAFF-03-02-001-1 ja
8. Tilt down the floor. (Refer to the operator's manual.)

WAFF50-EN-00(07/05/2019) W3-2-2-2
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

Removal of Pump Device

　
CAUTION 　
Escaping fluid under pressure may penetrate the skin and eyes and cause serious injury. Release the pressure
before disconnecting the hydraulic piping or removing other equipment. Hot hydraulic oil just after operation 　
may spout out and cause severe burns. Wait until oil cools before starting any work.
　
IMPORTANT
　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil. 　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, 　
install the clips after connecting the hoses.
　
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.) 　
2. Open cover (1).

CAUTION
Release any pressure from hydraulic oil tank (2). (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

3. Remove bolts, washers (3) (6 used) Remove cover (4) and O-ring (5).
: 17 mm
1

2
4, 5

3
WAFF-03-03-101-1 ja
4. Place a container. Drain any hydraulic oil by using an oil feed pump.

NOTE
Total oil amount of hydraulic oil tank: 79.8 L

WAFF50-EN-00(07/05/2019) W3-3-1-1
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

5. Remove bolts, washers (6) (4 used) and bolts, washers (7) (2 used). Remove cover (8).
6
A
A 8

8
6
WAFF-03-03-102-1 ja
6. Tilt up the floor. (Refer to the operator's manual.)
7. Remove muffler filter (9). (Refer to "Removal of Muffler Filter"W3-9-1-1.)
9

WAFF-03-03-103-1 ja
8. Disconnect hoses (15) (3 used) from pump device (11).
: 17 mm, 19 mm
9. Disconnect hose (16) from pump device (11).
: 41 mm
10. Remove socket bolts (14) (4 used). Disconnect suction pipe (12) from pump device (11). Remove O-ring (13).
: 10 mm

CAUTION
Pump device (11) weight: 40 kg

11. Attach nylon slings onto the center of gravity of pump device (11). Hoist and hold pump device (11).
12. Remove bolts, washers (10) (4 used) Hoist and remove pump device (11) from engine (17).
: 19 mm

WAFF50-EN-00(07/05/2019) W3-3-1-2
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

13. Remove the adapters attached to pump device (11) if necessary.

17 10 11

16 15 15 14 12, 13
WAFF-03-03-104-1 ja

WAFF50-EN-00(07/05/2019) W3-3-1-3
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

MEMO

WAFF50-EN-00(07/05/2019) W3-3-1-4
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

Installation of Pump Device

1. Install all removed adapters to pump device (11).

CAUTION
Pump device (11) weight: 40 kg

2. Install pump device (11) to engine (17) with bolts, washers (10) (4 used).
: 19 mm
: 90 N·m

IMPORTANT
Apply grease onto O-ring (13).

3. Install O-ring (13) to the groove of the suction pipe (12) flange part. Install suction pipe (12) to pump device (11) with
socket bolts (14) (4 used).
: 10 mm
: 90 N·m
4. Connect hose (16) to pump device (11).
: 41 mm
: 200 N·m
5. Connect hoses (15) (3 used) to pump device (11).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
17 10 11

16 15 15 14 12, 13
WAFF-03-03-104-1 ja

WAFF50-EN-00(07/05/2019) W3-3-2-1
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

6. Install muffler filter (9). (Refer to "Installation of Muffler Filter"W3-9-2-1.)

9

WAFF-03-03-103-1 ja
7. Fill hydraulic oil tank (2) with hydraulic oil.

NOTE
Total oil amount of hydraulic oil tank: 79.8 L

8. Install O-ring (5). Install cover (4) with bolts, washers (3) (6 used).
: 17 mm
: 50 N·m
9. Bleed air from the hydraulic system. (Refer to "Bleeding Air from Hydraulic System"W1-4-1-1.)
・ Pump Air Bleed Plug
: 6 mm
: 30 to 35 N·m

WAFF50-EN-00(07/05/2019) W3-3-2-2
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

10. Close cover (1).

1

2
4, 5

3
WAFF-03-03-101-1 ja
11. Tilt down the floor. (Refer to the operator's manual.)
12. Install cover (8) with bolts, washers (6) (4 used) and bolts, washers (7) (2 used).
: 17 mm
: 50 N·m
6
A
A 8

8
6
WAFF-03-03-102-1 ja

WAFF50-EN-00(07/05/2019) W3-3-2-3
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

MEMO

WAFF50-EN-00(07/05/2019) W3-3-2-4
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

Disassembly of Pump Device

1 2 12
3

4
5 13
6 7
8
9 14

10

11
26 15
25

16
24
23
22
21
27 17
28 18
29
30
29
31 19
20
32
33
34
35
36 38
37 39
40

41
42

54 43
41
44

45
46
53 47
48
49
52
50
51

W1N0-02-03-051-1 ja

WAFF50-EN-00(07/05/2019) W3-3-3-1
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

1- Bolt (2 Used) 15- Casing 29- Retainer (2 Used) 43- Orifice

2- Washer (2 Used) 16- O-Ring 30- Spring 44- Shaft
3- Pilot Pump 17- Pin 31- Cylinder Block 45- Retaining Ring
4- O-Ring 18- Pin 32- Needle (3 Used) 46- Bearing
5- Collar 19- Needle Bearing 33- Holder 47- Retaining Ring
6- Coupling 20- O-Ring 34- Retainer 48- Oil Seal
7- Plug 21- Plug 35- Plunger (11 Used) 49- O-Ring
8- O-Ring 22- O-Ring 36- Shoe Plate 50- Seal Holder
9- Control Piston 23- Spring 37- Pin 51- Retaining Ring
10- Pin (2 Used) 24- Coin Filter 38- Swash Plate 52- Socket Bolt (8 Used)
11- O-Ring (2 Used) 25- O-Ring 39- Spring Holder 53- Cover
12- Socket Bolt (4 Used) 26- O-Ring 40- Spring 54- O-Ring
13- Regulator 27- Valve Plate 41- Thrust Bushing (2 Used)
14- O-Ring 28- Retaining Ring 42- Screw

IMPORTANT
When replacing casing (15) and cover (53), replace them as an assembly.

1. Remove socket bolts (12) (4 used) from regulator (13). Remove regulator (13) from casing (15).
: 6 mm
2. Remove pins (10) (2 used), O-rings (11) (2 used), and O-ring (14) from casing (15).
3. Remove bolts (1) (2 used) and washers (2) (2 used) from pilot pump (3). Remove pilot pump (3) from casing (15).
: 13 mm
4. Remove O-ring (4), collar (5), coupling (6), and O-rings (25, 26) from casing (15).

CAUTION
The pump system weight: 40 kg

5. Hoist the pump device and place it with the cover (53) side up.
6. Remove socket bolts (52) (8 used) from cover (53). Record the clearance between casing (15) and cover (53). Remove
the cover (53) assembly from casing (15).
: 8 mm
7. Remove retaining ring (51) from cover (53). Tap the rear end of the shaft (44) assembly by using a plastic hammer and
remove the shaft (44) assembly from cover (53).
8. Remove the seal holder (50) assembly, retaining ring (47), bearing (46), and retaining ring (45) from shaft (44).
9. Remove O-ring (49) and oil seal (48) from seal holder (50).
10. Remove O-ring (54) from cover (53).
11. Remove screw (42) and orifice (43). Remove thrust bushings (41) (2 used) from cover (53).

NOTE
LOTITE #262 has been applied onto screw (42) and orifice (43).

12. Remove O-rings (16, 20) and pin (17) from casing (15).
13. Remove spring (40) and spring holder (39) from swash plate (38).
14. Remove swash plate (38) and shoe plate (36) from casing (15). Remove pin (37) from swash plate (38).

IMPORTANT
When replacing inner parts (28 to 35) of the cylinder block (31) assembly and valve plate (27), replace them as an
assembly.

15. Remove the cylinder block (31) assembly from casing (15).
16. Remove plungers (35) (11 used), retainer (34), holder (33), and needles (32) (3 used) from cylinder block (31).
17. Remove retaining ring (28), retainers (29) (2 used), and spring (30) from cylinder block (31).

WAFF50-EN-00(07/05/2019) W3-3-3-2
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

18. Remove valve plate (27) and pin (18) from casing (15).

IMPORTANT
Do not remove needle bearing (19) unless necessary.

19. Remove needle bearing (19) from casing (15).

20. Remove plug (7), O-ring (8), and control piston (9) from casing (15).
: 46 mm

IMPORTANT
Do not remove coin filter (24) unless it is necessary.

21. Remove plug (21), O-ring (22), spring (23), and coin filter (24) from casing (15).

WAFF50-EN-00(07/05/2019) W3-3-3-3
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

MEMO

WAFF50-EN-00(07/05/2019) W3-3-3-4
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

Assembly of Pump Device

8 9 13 12 11 30 32 14 37 39 40 15 16 53

38
A 54

41
7
45
47

44

48

6 3 1 2 5 19 28 27 31 29 35 33 34 36 46 50 49 51

B 52

A
10 24 23 22

21

WAFF-03-03-105-1 ja

WAFF50-EN-00(07/05/2019) W3-3-4-1
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

1- Bolt (2 Used) 15- Casing 28- Retaining Ring 42- *1Screw

2- Washer (2 Used) 16- O-Ring 29- Retainer (2 Used)
43- *1 Orifice
3- Pilot Pump 17- *1Pin 30- Spring
44- Shaft
4- *1O-ring 18- Pin 31- Cylinder Block
45- Retaining Ring
5- Collar 19- Needle Bearing 32- Needle (3 Used)
46- Bearing
6- Coupling *1O-ring 33- Holder
20- 47- Retaining Ring
7- Plug 34- Retainer
21- Plug 48- Oil Seal
8- O-Ring 35- Plunger (11 Used)
22- O-Ring 49- O-Ring
9- Control Piston 36- Shoe Plate
23- Spring 50- Seal Holder
10- Pin (2 Used) 37- Pin
24- Coin Filter 51- Retaining Ring
11- O-Ring (2 Used) 38- Swash Plate
25- *1O-ring 52- Socket Bolt (8 Used)
12- Socket Bolt (4 Used) 39- Spring Holder
*1O-ring 53- Cover
13- Regulator 26- 40- Spring
54- O-Ring
14- O-Ring 27- Valve Plate 41- Thrust Bushing (2 Used)

As for the item with mark *1, refer to "Disassembly of Pump Device"W3-3-3-1.

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

1. Install coin filter (24), spring (23), O-ring (22), and plug (21) to casing (15).

IMPORTANT
Install control piston (9) with the groove part (a) side up.

2. Install control piston (9), O-ring (8), and plug (7) to casing (15).
: 46 mm
: 500 to 600 N·m (50 to 60 kgf·m)
9
a

15

W1N0-02-03-053-1 ja

a- Groove Part
3. Install needle bearing (19) to casing (15).
4. Place casing (15) with the cover (53) mounting side up.

WAFF50-EN-00(07/05/2019) W3-3-4-2
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

IMPORTANT
When replacing valve plate (27) and inner parts (28 to 35) of the cylinder block (31) assembly, replace them as an
assembly.

5. Install pin (18) to casing (15). Fit the groove part (b) of valve plate (27) to pin (18) of casing (15) and install it.
27

18

15

W1N0-02-03-054-1 ja

b- Groove Part
6. Install retainers (29) (2 used), spring (30), and retaining ring (28) to cylinder block (31).
7. Install needles (32) (3 used), holder (33), retainer (34), and plungers (35) (11 used) to cylinder block (31).
8. Install the cylinder block (31) assembly to casing (15).
9. Install pin (37) to swash plate (38).

IMPORTANT
Fit the groove positions of swash plate (38) and shoe plate (36) and install it.

10. Apply grease onto the shoe plate (36) mounting surface of swash plate (38). Install shoe plate (36) to swash plate (38).

IMPORTANT
Check that the control piston (9) end is inserted into the swash plate (38) groove.

11. Install the swash plate (38) assembly to casing (15).

IMPORTANT
Check that the spring holder (39) protrusion part is inserted into the swash plate (38) countersinking part.

12. Install spring holder (39) and spring (40) to swash plate (38).
13. Install O-ring (16), pin (17), and O-ring (20) to casing (15).

WAFF50-EN-00(07/05/2019) W3-3-4-3
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

IMPORTANT
Check the positions to install orifice (43) and screw (42).

14. Apply LOTITE #262 onto screw (42) and orifice (43). Install thrust bushings (41) (2 used) to cover (53) with screw (42)
and orifice (43).
: 5 to 7 N·m (0.5 to 0.7 kgf·m)

41
53

42 43

W1N0-02-03-055-1 ja
15. Install O-ring (54) to cover (53).
16. Install oil seal (48) and O-ring (49) to seal holder (50).
17. Install retaining ring (45), bearing (46), and retaining ring (47) to shaft (44).
18. Install the shaft (44) assembly to cover (53) by using a plastic hammer.
19. Apply grease onto O-ring (49) and the lip part of oil seal (48). Install the seal holder (50) assembly to shaft (44). Install
the seal holder (50) assembly to cover (53) by using special tool (ST 7694) and a plastic hammer.
Unit: mm

90

67

φ51
φ71

Special tool when installing seal holder: ST 7694

W1N0-02-03-056-1 ja
20. Install retaining ring (51) to cover (53).
21. Install the cover (53) assembly to casing (15) with socket bolts (52) (8 used).
: 8 mm
: 51 to 65 N·m (5.1 to 6.5 kgf·m)

NOTE
Check the clearance between casing (15) and cover (53) which is recorded before disassembling. If the clearance is
larger, the inner parts may not be installed correctly, such as pin (18) not being inserted into the groove of valve plate
(27).

22. Install O-rings (25, 26), coupling (6), collar (5), and O-ring (4) to casing (15).

WAFF50-EN-00(07/05/2019) W3-3-4-4
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

23. Install pilot pump (3) to casing (15) with washers (2) (2 used) and bolts (1) (2 used).
: 13 mm
: 19.5 to 23.5 N·m (2 to 2.4 kgf·m)
24. Install O-ring (14), O-rings (11) (2 used), and pins (10) (2 used) to casing (15).

IMPORTANT
Install regulator (13) so that lever (c) of regulator (13) is inserted into groove (d) of control piston (9).

25. Install regulator (13) to casing (15) with socket bolts (12) (4 used).
: 6 mm
: 19.5 to 23.5 N·m (2 to 2.4 kgf·m)
9 13

d c
W1N0-02-03-057-1 ja

c- Lever d- Groove Part

WAFF50-EN-00(07/05/2019) W3-3-4-5
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

MEMO

WAFF50-EN-00(07/05/2019) W3-3-4-6
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

Disassembly of Regulator
1

2
3
43 4
44 5
45
46 6
47 7
8
9
48 8

49 10
30
50 11
31
32 51
52
33 53
34 54
55
56
35
36
37
38 12 12
29 39 13 13
40 14 15
41
42
16

28
27
26
25
24 18
23 19
20 17
21
22
W1N0-02-03-061-1 ja
1- Spool 15- Orifice 29- Socket Bolt (2 Used) 43- Adjusting Screw Kit
2- Sleeve 16- Valve Body 30- Nut 44- O-Ring
3- Connector 17- Lever 31- Adjusting Screw 45- Spring Seat
4- Spring 18- Retainer 32- Nut 46- Spring
5- Needle Roller 19- Spring Washer 33- Adjusting Screw 47- Spool
6- Retainer 20- Socket Bolt 34- Cover 48- Sleeve
7- O-Ring 21- O-Ring 35- O-Ring 49- O-Ring
8- Backup Ring (2 Used) 22- Plug 36- Spring Guide 50- O-Ring (2 Used)
9- O-Ring (2 Used) 23- Plug 37- O-Ring 51- Backup Ring
10- Plug 24- O-Ring 38- Spring Guide 52- O-Ring
11- Retaining Ring 25- Stopper 39- Spring 53- O-Ring
12- Plug (2 Used) 26- Spring 40- Spring 54- Backup Ring
13- O-Ring (2 Used) 27- Steel Ball 41- Spring Seat 55- Spring
14- Orifice 28- Valve Seat 42- O-Ring 56- Spring Seat

IMPORTANT
Do not disassemble adjusting screws (31, 33) and nuts (30, 32) of regulator, since the setting value changes.

WAFF50-EN-00(07/05/2019) W3-3-5-1
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

IMPORTANT
Parts (1 to 6, 10, 14 to 18, 25 to 28, 33 to 34, 38 to 41) and valve body (16) should be replaced as an assembly. The
LS valve assembly (43 to 56) should be replaced as an assembly.

1. Remove the LS valve assembly (43 to 56) from valve body (16).
: 24 mm
2. Remove plug (22) and O-ring (21) from valve body (16).
: 8 mm
3. Remove socket bolt (20) and spring washer (19). Remove lever (17) from retainer (18).
4. Remove retainer (18) from valve body (16).
IMPORTANT
Take care that the inner parts do not fly out.

5. Remove retaining ring (11) from valve body (16). Remove the plug (10) assembly from valve body (16).
6. Remove spring (4), needle roller (5), retainer (6), backup rings (8) (2 used), O-ring (7), and O-rings (9) (2 used) from plug
(10).
IMPORTANT
Take care that the inner parts do not fly out.

7. Remove socket bolts (29) (2 used). Remove the cover (34) assembly and O-ring (42) from valve body (16).
: 5 mm
8. Remove spring seat (41), springs (39, 40), spring guides (36, 38), and O-rings (35, 37) from cover (34).
9. Remove the sleeve (2) assembly from valve body (16).
10. Remove connector (3) and spool (1) from sleeve (2).
11. Remove plugs (12) (2 used), O-rings (13) (2 used), and orifices (14, 15) from valve body (16).
12. Remove plug (23), O-ring (24), stopper (25), spring (26), steel ball (27), and valve seat (28) from valve body (16).

WAFF50-EN-00(07/05/2019) W3-3-5-2
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

Assembly of Regulator
31 30 43 44 48 49 45 46 47 55 56 12 13 14 17

28
27
26
25
24 18
19
20
21
23 33 32 34 29 50 51 52 53 54 16 22

36 35 39 41 42 12 2 1 3 5 6 7

11
10

37 38 40 13 15 4 8 9 8
W1N0-02-03-062-1 ja
1- Spool 15- Orifice 29- Socket Bolt (2 Used) 43- Adjusting Screw Kit
2- Sleeve 16- Valve Body 30- Nut 44- O-Ring
3- Connector 17- Lever 31- Adjusting Screw 45- Spring Seat
4- Spring 18- Retainer 32- Nut 46- Spring
5- Needle Roller 19- Spring Washer 33- Adjusting Screw 47- Spool
6- Retainer 20- Socket Bolt 34- Cover 48- Sleeve
7- O-Ring 21- O-Ring 35- O-Ring 49- O-Ring
8- Backup Ring (2 Used) 22- Plug 36- Spring Guide 50- O-Ring (2 Used)
9- O-Ring (2 Used) 23- Plug 37- O-Ring 51- Backup Ring
10- Plug 24- O-Ring 38- Spring Guide 52- O-Ring
11- Retaining Ring 25- Stopper 39- Spring 53- O-Ring
12- Plug (2 Used) 26- Spring 40- Spring 54- Backup Ring
13- O-Ring (2 Used) 27- Steel Ball 41- Spring Seat 55- Spring
14- Orifice 28- Valve Seat 42- O-Ring 56- Spring Seat
1. Install valve seat (28), steel ball (27), spring (26), stopper (25), O-ring (24), and plug (23) to valve body (16).
2. Install orifices (14, 15), O-rings (3) (2 used), and plugs (12) (2 used) to valve body (16).
IMPORTANT
Install spool (1) with the countersinking part on the cover (34) side.

3. Install spool (1) and connector (3) to sleeve (2).

4. Install the sleeve (2) assembly to valve body (16).
IMPORTANT
Install so that the ball part of spring seat (41) is inserted into the countersinking part of spool (1).

WAFF50-EN-00(07/05/2019) W3-3-6-1
 SECTION3 UPPERSTRUCTURE
Group3 Pump Device

5. Install O-rings (35, 37), spring guides (36, 38), springs (39, 40), and spring seat (41) to cover (34).
6. Install O-ring (42) and the cover (34) assembly to valve body (16) with socket bolts (29) (2 used).
: 5 mm
: 10 to 13 N·m
IMPORTANT
Install retainer (18) so that hole (a) is in a vertical position.

7. Install retainer (18) to valve body (16).

16

18
W1N0-02-03-063-1 ja

a- Retainer (18) Hole

IMPORTANT
Install lever (17) so that ball part end (b) is inserted into groove part (c) of connector (3).

8. Install lever (17) to retainer (18) with spring washer (19) and socket bolt (20).
: 4 mm
: 5 to 7 N·m

3 b

17

W1N0-02-03-064-1 ja

b- Ball Part End c- Groove Part

9. Install plug (22) and O-ring (21) to valve body (16).
: 8 mm
: 49 to 54 N·m
10. Install O-rings (9) (2 used), O-ring (7), backup rings (8) (2 used), retainer (6), needle roller (5), and spring (4) to plug (10).
11. Install the plug (10) assembly to valve body (16). Install retaining ring (11) to valve body (16).
12. Install the LS valve assembly (43 to 56) to valve body (16).
: 24 mm
: 59 to 69 N·m

WAFF50-EN-00(07/05/2019) W3-3-6-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Removal of Control Valve

　
IMPORTANT 　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil. 　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, 　
install the clips after connecting the hoses.
　
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.) 　
CAUTION 　
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
　
CAUTION 　
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)
　
2. Tilt up the floor. (Refer to the operator's manual.)
3. Remove bolts, washers (12) (4 used) and washers (22) (2 used) from cover (13). Remove cover (13) from frame (14).
: 17 mm

14

22

12
13
12
WAFF-03-04-001-1 ja
4. Disconnect connector (18) from pressure sensor (17).
5. Disconnect hoses (15) (49 used) from control valve (19).
: 17 mm, 19 mm, 22 mm, 27 mm, 41 mm, 50 mm
6. Remove the back pressure valve (16) assembly.
: 60 mm

CAUTION
Control valve (19) weight: 68 kg

7. Attach nylon slings onto control valve (19), then hoist and hold it.
8. Remove bolts, washers (20) (4 used) from plate (21). Remove control valve (19) from plate (21).
: 17 mm

WAFF50-EN-00(07/05/2019) W3-4-1-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

9. Remove pressure sensor (17) from control valve (19).

: 24 mm
10. Remove the adapters attached to control valve (19) if necessary.
15 16 17, 18

20

21

19
WAFF-03-04-002-1 ja

WAFF50-EN-00(07/05/2019) W3-4-1-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Installation of Control Valve

1. Install all removed adapters to control valve (19).

2. Install pressure sensor (17) to control valve (19).
: 24 mm
: 16 N·m

CAUTION
Control valve (19) weight: 68 kg

3. Attach nylon slings onto control valve (19), then hoist and hold it. Install control valve (19) to plate (21) with bolts,
washers (20) (4 used).
: 17 mm
: 50 N·m
4. Install the back pressure valve (16) assembly.
: 60 mm
: 350 N·m
5. Connect hoses (15) (49 used) to control valve (19).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 22 mm
: 40 N·m
: 27 mm
: 80 N·m
: 41 mm
: 210 N·m
: 50 mm
: 350 N·m

WAFF50-EN-00(07/05/2019) W3-4-2-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

6. Connect connector (18) to pressure sensor (17).

15 16 17, 18

20

21

19
WAFF-03-04-002-1 ja
7. Tilt down the floor. (Refer to the operator's manual.)
8. Bleed air from the hydraulic system. (Refer to "Bleeding Air from Hydraulic System"W1-4-1-1.)

IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)

9. Install cover (13) to frame (14) with bolts, washers (12) (4 used), and washers (22) (2 used).
: 17 mm
: 50 N·m

14

22

12
13
12
WAFF-03-04-001-1 ja

WAFF50-EN-00(07/05/2019) W3-4-2-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Structure of Control Valve

86
87

88

a
b
c

d
e
f
g 175
31
h

i
j
k
89
m
87
n 86

37
56
WAFF-03-06-101-1 ja

a- Unload Section b- Piping Port Section c- Swing Section d- Blade Section

e- Travel (Left) Section f- Travel (Right) Section g- Boom Swing Section h- Boom 2 Section
i- Boom 1 Section j- Arm 1 Section k- Arm 2 Section m- Bucket Section
n- Auxiliary Section
31- O-Ring (27 Used) 56- Plug (21 Used) 87- Washer (8 Used) 89- Block
37- O-Ring (26 Used) 86- Nut (8 Used) 88- Tie Rod (4 Used) 175- Plug

WAFF50-EN-00(07/05/2019) W3-4-3-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

a
21
20 47
18 48 23
146

56
17 37
16
26
37 29 27
56 28 b
12 30 56
10 20 37
31
149 31
10 29
29 45
3 173
4 174 30 46
c
31 20 29 44
6 21
7 43
8 30 31 40
172 171 150 41
147 47 40
29 48
49 39
52 50
29
151 56
37
29 59 58
44 30
45
31
54 29 60
61
45 31
84 29 141
30 147 44 45
36 43
115
37 116
47 38 115
48
49 91
50
d 52 29
56
37
29 99
44 100
30
45 31
29 60
54
61
152
45 30 29 31
37
56
WAFF-03-06-102-1 ja

a- Unload Section b- Piping Port Section c- Swing Section d- Blade Section

WAFF50-EN-00(07/05/2019) W3-4-3-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

3- Spring Seat 27- Spring 47- Plug (14 Used) 115- Retainer (2 Used)
4- Spring 28- Spool 48- O-Ring (14 Used) 116- Spring
6- Retainer 29- O-Ring (73 Used) 49- Seat (10 Used) 141- Cover
7- O-Ring 30- O-Ring (26 Used) 50- Backup Ring (10 Used) 146- Orifice
8- Adjuster 31- O-Ring (27 Used) 52- Steel Ball (10 Used) 147- O-Ring (2 Used)
10- Differential Reducing Valve 36- Spring 54- Cover (7 Used) 149- Body (Unload)
11- Plug 37- O-Ring (26 Used) 56- Plug (21 Used) 150- Body (Piping Port)
12- Orifice 38- Plug (5 Used) 58- Piston 151- Body (Swing)
16- Spring 39- Spool 59- Spool 152- Body (Blade)
17- Strainer 40- Retainer (2 Used) 60- Check Valve (9 Used) 171- Orifice
18- Orifice 41- Spring 61- Spring (9 Used) 172- Orifice
20- O-Ring (3 Used) 43- Bolt (9 Used) 84- Orifice 173- Strainer
21- Plug (2 Used) 44- O-Ring (23 Used) 91- Spool 174- Spring
23- Main Relief Valve 45- Socket Bolt (40 Used) 99- Piston
26- Piston 46- Cover (6 Used) 100- Spool

WAFF50-EN-00(07/05/2019) W3-4-3-3
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

45
e 46
44
43
118
47 119
48 118
49
50
29 92
52
56
37
101
29 102
44
45 30
31
54 29 45
f
153 46
30 44
45 85 29 43
31 118
47 119
38 139 118
48
37 49
50
29 92
52 56
37
101
29 102
44 g 45
45 30 46
31 44
54 43
29 124
78 125
154 47
30 48 124
45 85 29 49
31 50
38 139 29
52 94
37 56
37
105
29 106
44
45 30
31
54 29

155 30
45 29
31 60 61

37
56

WAEJ-03-06-104-5 ja

e- Travel (Left) Section f- Travel (Right) Section g- Boom Swing Section

29- O-Ring (73 Used) 47- Plug (12 Used) 78- Make-Up Valve 119- Spring (2 Used)
30- O-Ring (26 Used) 48- O-Ring (12 Used) 85- Orifice (2 Used) 124- Retainer (2 Used)
31- O-Ring (27 Used) 49- Seat (10 Used) 92- Spool (2 Used) 125- Spring
37- O-Ring (26 Used) 50- Backup Ring (10 Used) 94- Spool 139- Spring (2 Used)
38- Plug (5 Used) 52- Steel Ball (10 Used) 101- Piston (2 Used) 153- Body (Travel (Left))
43- Bolt (9 Used) 54- Cover (7 Used) 102- Spool (2 Used) 154- Body (Travel (Right))
44- O-Ring (23 Used) 56- Plug (21 Used) 105- Piston 155- Body (Boom Swing)
45- Socket Bolt (40 Used) 60- Check Valve (9 Used) 106- Spool
46- Cover (6 Used) 61- Spring (9 Used) 118- Retainer (4 Used)

WAFF50-EN-00(07/05/2019) W3-4-3-4
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

45
h 162
44
43
127
47 128
48 127
49 163
50
79 29
52
56
168 37
75 29 164
166 167 165 30
44 31 i 45
77
65 29 60 46
61
64 160 43 44
63
30 29 31 127
140 47 128
37 77 48 127
38 49
83 95
50
29
52
76 56
74 75 37
80 148 29 107
73 108 30
72 31
71 29 60
44 61
62
63 156
140 30 29 31
65 70 j
30 37
68 38 169
64
44 44
45
77 43
83 130
131
47
48 130
49 96
50
77 29
52
56
37
109
24 110
44 30
45 31
170 29
45
157
30 29 31
60
61
37
56
WAFF-03-06-104-1 ja

h- Boom 2 Section i- Boom 1 Section j- Arm 1 Section

WAFF50-EN-00(07/05/2019) W3-4-3-5
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

29- O-Ring (73 Used) 62- Cover 96- Spool 156- Body (Boom 1)
30- O-Ring (26 Used) 63- Orifice (2 Used) 97- Spool 157- Body (Arm 1)
31- O-Ring (27 Used) 64- Socket Bolt (4 Used) 98- Spool 158- Body (Bucket)
37- O-Ring (26 Used) 65- Socket Bolt (4 Used) 107- Piston 159- Body (Auxiliary)
38- Plug (5 Used) 68- Piston 108- Spool 160- Body (Boom 2)
43- Bolt (9 Used) 70- Sleeve 109- Piston 162- Cover
44- O-Ring (23 Used) 71- Backup Ring 110- Spool 163- Spool
45- Socket Bolt (40 Used) 72- O-Ring 111- Piston 164- Piston
46- Cover (6 Used) 73- Steel Ball 112- Spool 165- Spool
47- Plug (14 Used) 74- Orifice 113- Piston 166- Cover
48- O-Ring (14 Used) 75- Spring (2 Used) 114- Spool 167- Sleeve
49- Seat (10 Used) 76- Poppet 127- Retainer (4 Used) 168- Poppet
50- Backup Ring (10 Used) 77- Overload Relief Valve (6 Used) 128- Spring (2 Used) 169- Cover (2 Used)
52- Steel Ball (10 Used) 79- Plug (3 Used) 130- Retainer (2 Used) 170- Cover (2 Used)
56- Plug (21 Used) 80- Spring Guide 131- Spring
60- Check Valve (9 Used) 83- Orifice (2 Used) 140- Spring (2 Used)
61- Spring (9 Used) 95- Spool 148- Spring

WAFF50-EN-00(07/05/2019) W3-4-3-6
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

169
k 44 45
43
130
131
47
48 130
49 96
50
29
52
56
29 37
109
110
44 30
45 31
29 60
170
61 77
45 m
161 46
30 31
29 44
43 45
37 133
134
50 47
77 48 133
49 97
50
29
52
56
37
24 111
112 30
44
45 31
29 60 70 n
54 46
61
45 44
158
30 29 31 136
43
45
137
37 79 136
56 98
47
48
56
37
24 113
114
44 30
45 31
29
54
30
45 159 29
31
60 61
37
56
WAFF-03-06-105-1 ja

k- Arm 2 Section m- Bucket Section n- Auxiliary Section

WAFF50-EN-00(07/05/2019) W3-4-3-7
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

29- O-Ring (73 Used) 49- Seat (10 Used) 98- Spool 136- Retainer (2 Used)
30- O-Ring (26 Used) 50- Backup Ring (10 Used) 109- Piston (2 Used) 137- Spring
31- O-Ring (27 Used) 52- Steel Ball (10 Used) 110- Spool (2 Used) 148- Spring
37- O-Ring (26 Used) 54- Cover (7 Used) 111- Piston 158- Body (Bucket)
38- Plug (5 Used) 56- Plug (21 Used) 112- Spool 159- Body (Auxiliary)
43- Bolt (9 Used) 60- Check Valve (9 Used) 113- Piston 161- Body (Arm 2)
44- O-Ring (23 Used) 61- Spring (9 Used) 114- Spool 169- Cover (2 Used)
45- Socket Bolt (40 Used) 77- Overload Relief Valve (6 Used) 130- Retainer (4 Used) 170- Cover (2 Used)
46- Cover (6 Used) 79- Plug (3 Used) 131- Spring (2 Used)
47- Plug (14 Used) 96- Spool 133- Retainer (2 Used)
48- O-Ring (14 Used) 97- Spool 134- Spring

WAFF50-EN-00(07/05/2019) W3-4-3-8
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Disassembly of Body
86 87
a
88

29

30 b

149 20
31
29 29
30

150 30 29 c
147 31
29

29
30
31
29
60
61
151 30
147 29 31

29
30
31
29
60
152 30 61
29
31
WAFF-03-06-111-1 ja

a- Unload Section b- Piping Port Section c- Swing Section d- Blade Section

20- O-Ring (3 Used) 60- Check Valve (9 Used) 88- Tie Rod (4 Used) 151- Body (Swing)
29- O-Ring (73 Used) 61- Spring (9 Used) 147- O-Ring (2 Used) 152- Body (Blade)
30- O-Ring (26 Used) 86- Nut (8 Used) 149- Body (Unload)
31- O-Ring (26 Used) 87- Washer (8 Used) 150- Body (Piping Port)

WAFF50-EN-00(07/05/2019) W3-4-4-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

29
30
31
29
153
30
29
31 f

29
30
31
29 g
78
154
30
29
31

29
30
31
29

155 30
29
31 60 61

WAEJ-03-06-104-4 ja

e- Travel (Left) Section f- Travel (Right) Section g- Boom Swing Section

29- O-Ring (73 Used) 60- Check Valve (9 Used) 153- Body (Travel (Left))
30- O-Ring (26 Used) 61- Spring (9 Used) 154- Body (Travel (Right))
31- O-Ring (26 Used) 78- Make-Up Valve 155- Body (Boom Swing)

WAFF50-EN-00(07/05/2019) W3-4-4-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

79

29 30
31 i
29 77
60
31
160 30
29 31
77

29 30
31
29
60
61
156
30 31
29

77 j

77

29 30
31
29
60
61
157
30 31
29

WAFF-03-06-113-1 ja

h- Boom 2 Section i- Boom 1 Section j- Arm 1 Section

29- O-Ring (73 Used) 60- Check Valve (9 Used) 79- Plug (3 Used) 157- Body (Arm 1)
30- O-Ring (26 Used) 61- Spring (9 Used) 89- Block 160- Body (Boom 2)
31- O-Ring (26 Used) 77- Overload Relief Valve (6 Used) 156- Body (Boom 1)

WAFF50-EN-00(07/05/2019) W3-4-4-3
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

29 30
31
29
60
61 77
161
30
29 31 m

77

29 30
31
29
60 79 n
61
158
30 31
29

79
89

29 30 87
31 86
29
60
61
159
30 31
29
WAFF-03-06-114-1 ja

k- Arm 2 Section m- Bucket Section n- Auxiliary Section

29- O-Ring (73 Used) 60- Check Valve (9 Used) 79- Plug (3 Used) 89- Block
30- O-Ring (26 Used) 61- Spring (9 Used) 86- Nut (8 Used) 159- Body (Auxiliary)
31- O-Ring (26 Used) 77- Overload Relief Valve (6 Used) 87- Washer (8 Used) 161- Body (Arm 2)

CAUTION
Control valve weight: 68 kg

IMPORTANT
Do not disassemble overload relief valve (77).

1. Remove overload relief valves (77) (6 used) and make-up valve (78) from sections (g, i, j, m)
: 26 mm
2. Remove plugs (79) (3 used) from sections (h, n).
: 21 mm

WAFF50-EN-00(07/05/2019) W3-4-4-4
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

IMPORTANT
Do not drop O-rings (20, 29, 30, 31, 147), check valve (60), and spring (61) when removing tie rod (88).

3. Remove nuts (86) (8 used), washers (87) (8 used), tie rods (88) (4 used), and block (89) from the body. Divide the
control valves into each section.
: 17 mm
4. Remove O-rings (20) (3 used), O-rings (29) (73 used), O-rings (147) (2 used), O-rings (30) (26 used), and O-rings (31) (26
used) from each section.
5. Remove springs (61) (9 used) and check valves (60) (9 used) from sections (c, d, g, h, i, j, k, m, n).

WAFF50-EN-00(07/05/2019) W3-4-4-5
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-4-4-6
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Assembly of Body

A A

B B
D D

88 86, 87 89
N
A-A B-B

149
151
a
N
c

N-N
N

D-D

60
61
152

N
d

WAFF-03-06-115-1 ja

a- Unload Section c- Swing Section d- Blade Section

60- Check Valve (9 Used) 87- Washer (8 Used) 149- Body (Unload)
61- Spring (9 Used) 88- Tie Rod (4 Used) 151- Body (Swing)
86- Nut (8 Used) 89- Block 152- Body (Blade)

WAFF50-EN-00(07/05/2019) W3-4-5-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

E E
F F
G G
H H

N 78
88 86, 87 89

E-E G-G
F-F

153, 154 155

e, f
N
g
H-H
N-N
79
N

60
61

160

N
h

WAFF-03-06-116-1 ja

e- Travel (Left) Section f- Travel (Right) Section g- Boom Swing Section h- Boom 2 Section
60- Check Valve (9 Used) 79- Plug (3 Used) 88- Tie Rod (4 Used) 154- Body (Travel (Right))
61- Spring (9 Used) 86- Nut (8 Used) 89- Block 155- Body (Boom Swing)
78- Make-Up Valve 87- Washer (8 Used) 153- Body (Travel (Left)) 160- Body (Boom 2)

WAFF50-EN-00(07/05/2019) W3-4-5-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

J J
L L
M M

77 89 N 77
88 86, 87 77
N 77
J-J L-L

157
156 N
i N j
M-M
N-N
N

60
61

161

WAFF-03-06-117-1 ja

i- Boom 1 Section j- Arm 1 Section k- Arm 2 Section

60- Check Valve (9 Used) 86- Nut (8 Used) 89- Block 161- Body (Arm 2)
61- Spring (9 Used) 87- Washer (8 Used) 156- Body (Boom 1)
77- Overload Relief Valve (6 Used) 88- Tie Rod (4 Used) 157- Body (Arm 1)

WAFF50-EN-00(07/05/2019) W3-4-5-3
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

N N
P P

N 77 89 N
77 88 86, 87 79
79
N-N P-P

159
158

N N
l m

N-N

60
61

WAFF-03-06-118-1 ja

m- Bucket Section n- Auxiliary Section

60- Check Valve (9 Used) 79- Plug (3 Used) 88- Tie Rod (4 Used) 159- Body (Auxiliary)
61- Spring (9 Used) 86- Nut (8 Used) 89- Block
77- Overload Relief Valve (6 Used) 87- Washer (8 Used) 158- Body (Bucket)

WAFF50-EN-00(07/05/2019) W3-4-5-4
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

1. Install check valves (61) (9 used) and springs (60) (9 used) to sections (c, d, g, h, i, j, k, m, n).
2. Install O-rings (20) (3 used), O-rings (29) (73 used), O-rings (147) (2 used), O-rings (30) (26 used), and O-rings (31) (26
used) to each section.
3. Arrange bodies (149 to 161) of each section in the same order of before disassembling. Assemble bodies (149 to 161)
with tie rods (88) (4 used), block (89), washers (87) (8 used), and nuts (86) (8 used).
: 17 mm
: 67 to 72 N·m
4. Install plugs (79) (3 used) to sections (h, n).
: 21 mm
: 65 to 69 N·m
5. Install overload relief valves (77) (6 used) to sections (i, j, m).
: 26 mm
: 60 to 64 N·m
6. Install make-up valve (78) to section (g).
: 26 mm
: 60 to 64 N·m

WAFF50-EN-00(07/05/2019) W3-4-5-5
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-4-5-6
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Disassembly of Unload Section

21 47
20 48
18 146

23

56
37
17 26
16 27
37 28
56

10

149

3
4
31
6
7
8

WAEJ-03-06-110-2 ja
3- Spring Seat 16- Spring 26- Piston 48- O-Ring
4- Spring 17- Strainer 27- Spring 56- Plug (2 Used)
6- Retainer 18- Orifice 28- Spool 146- Orifice
7- O-Ring 20- O-Ring 31- O-Ring 149- Body (Unload)
8- Adjuster 21- Plug 37- O-Ring (2 Used)
10- Differential Reducing Valve 23- Main Relief Valve 47- Plug

IMPORTANT
Do not loosen the lock nut of main relief valve (23). If turning, the setting changes.

1. Remove main relief valve (23) from body (149).

: 27 mm

WAFF50-EN-00(07/05/2019) W3-4-6-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

IMPORTANT
Do not disassemble the steel ball knocked in spring seat (3). Do not drop spring (4) and spring seat (3) when
removing retainer (6) from body (149).

IMPORTANT
Do not loosen the lock nut of adjuster (8). If turning, the setting changes.

2. Remove retainer (6) from body (149). Remove O-ring (31) from retainer (6). Remove spring (4) and spring seat (3) from
body (149) by using a magnet.
: 24 mm

IMPORTANT
Do not drop spring (27) when removing piston (26) from body (149).

IMPORTANT
Replace piston (26), spool (28), and body (149) as an assembly.

3. Remove plug (56) from body (149). Remove piston (26), spring (27), and spool (28) from body (149) by using a magnet.
: 8 mm

IMPORTANT
Do not loosen the lock nut of differential reducing valve (10). If turning, the setting changes.

4. Remove differential reducing valve (10) from body (149). Remove piston (a) and spring (c) from body (149) by using a
magnet or other tools.
: 24 mm

b c

10 23

a 149

WAEJ-03-06-111-2 ja

a- Piston b- Guide c- Spring

5. Install a bolt (M8, Pitch 1.25 mm) to the pulling-out hole of guide (b). Remove guide (b) from body (149).
6. Remove plug (56) from body (149). Remove O-ring (37), spring (16), and strainer (17) from body (149).
: 8 mm
IMPORTANT
Orifices (18, 146) cannot be disassembled.

WAFF50-EN-00(07/05/2019) W3-4-6-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Assembly of Unload Section

B D D B

A
10
A

8 23

56
7 6 31 4 3 149 28 27 26 37

A-A B-B D-D

16 17 48 47 20 21

37 146 18

56

WAEJ-03-06-112-2 ja

a- Unload Valve
3- Spring Seat 16- Spring 26- Piston 48- O-Ring
4- Spring 17- Strainer 27- Spring 56- Plug (2 Used)
6- Retainer 18- Orifice 28- Spool 146- Orifice
7- O-Ring 20- O-Ring 31- O-Ring 149- Body (Unload)
8- Adjuster 21- Plug 37- O-Ring (2 Used)
10- Differential Reducing Valve 23- Main Relief Valve 47- Plug

WAFF50-EN-00(07/05/2019) W3-4-7-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
Apply grease on the seals.

1. Install O-ring (37) to plug (56). Install strainer (17), spring (16) and plug (56) to the side of body (149).
: 8 mm
: 55 to 59 N·m
2. Install guide(b), piston (a), and spring (c) to differential reducing valve (10). Install differential reducing valve (10) to
body (149) with taking care not to drop guide (b), piston (a), and spring (c).
: 24 mm
: 81 to 85 N·m

b c

10 23

a 149

WAEJ-03-06-111-2 ja

a- Piston b- Guide c- Spring

IMPORTANT
Replace piston (26), spool (28), and body (149) as an assembly.

3. Install spring (27) to piston (26). Install the piston (26) assembly to spool (28) with taking care not to drop spring (27).
Install the spool (28) assembly to body (149).
4. Install O-ring (37) to plug (56). Install plug (56) to body (149).
: 8 mm
: 60 to 70 N·m
5. Install O-ring (31) to retainer (6). Insert spring (4) into retainer (6) until it comes in contact with adjuster (8). Install
spring seat (3) to spring (4).
6. Install the retainer (6) assembly to body (149) with taking care not to drop spring seat (3) and spring (4).
: 24 mm
: 55 to 60 N·m
7. Install main relief valve (23) to body (149).
: 27 mm
: 70 to 80 N·m

WAFF50-EN-00(07/05/2019) W3-4-7-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Disassembly of Boom Anti-Drift Valve

76
75
74
148
80
72
71
70
30
68
44
73

65
65
44

64

83
62

64

156

WAEJ-03-06-113-2 ja
30- O-Ring 68- Piston 74- Orifice 148- Spring
44- O-Ring (2 Used) 70- Sleeve 75- Spring 156- Body (Boom)
62- Cover 71- Backup Ring 76- Poppet
64- Socket Bolt (2 Used) 72- O-Ring 80- Spring Guide
65- Socket Bolt (2 Used) 73- Steel Ball 83- Orifice

WAFF50-EN-00(07/05/2019) W3-4-8-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

IMPORTANT
Orifice (74) cannot be disassembled.

IMPORTANT
Remove cover (62) and piston (68) at the same time. Do not drop piston (68).

1. Remove socket bolts (64, 65) (2 used for each) from body (156). Remove cover (62) and piston (68) from body (156).
Remove O-rings (44) (2 used) from cover (62).
: 5 mm

IMPORTANT
Replace the sleeve (70) assembly, piston (68), poppet (76), cover (62), and body (156) as an assembly.

2. Install a bolt (M12, Pitch 1.75 mm) to the pulling-out hole of sleeve (70). Pull the sleeve (70) assembly out from body
(156).

NOTE
The sleeve (70) assembly means sleeve (70) assembled with steel ball (73), orifice (74), spring (148), and spring guide
(80).

3. Remove spring (75) and poppet (76) from body (156) by using a magnet.
4. Remove O-rings (30, 72) and backup ring (71) from sleeve (70).

WAFF50-EN-00(07/05/2019) W3-4-8-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Assembly of Boom Anti-Drift Valve

70 44 30 71 72 75 76

65
68

62 73 80 148 74 156

WAEJ-03-06-114-2 ja
30- O-Ring 68- Piston 74- Orifice 148- Spring
44- O-Ring 70- Sleeve 75- Spring 156- Body (Boom)
62- Cover 71- Backup Ring 76- Poppet
64- *1 Socket Bolt (2 Used) 72- O-Ring 80- Spring Guide
65- Socket Bolt (2 Used) 73- Steel Ball 83- *1 Orifice
As for the item with mark *1, refer to "Disassembly of Boom Anti-Drift Valve"W3-4-8-1.

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
Replace the sleeve (70) assembly, piston (68), poppet (76), cover (62), and body (156) as an assembly.

1. Install poppet (76) to body (156). Insert spring (75) into the poppet hole.
2. Install O-rings (30, 72) and backup ring (71) to sleeve (70). Install the sleeve (70) assembly to body (156).
3. Install piston (68) and O-rings (44) (2 used) to cover (62).
4. Install the cover (62) assembly to body (156) with socket bolts (64, 65) (2 used for each), taking care not to drop piston
(68).
: 5 mm
: 10 to 12 N·m

WAFF50-EN-00(07/05/2019) W3-4-9-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-4-9-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Disassembly of Spool

NOTE
The illustration shows the swing section.

45

46

44

45

41
40

39
43
40

45 54

151
44

45

WAEJ-03-06-115-3 ja
39- Spool 43- Bolt 46- Cover
40- Retainer (2 Used) 44- O-Ring (2 Used) 54- Cover
41- Spring 45- Socket Bolt (4 Used) 151- Body (Swing)

NOTE
The swing spool is explained here.

WAFF50-EN-00(07/05/2019) W3-4-10-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

1. Remove socket bolts (45) (2 used) from body (151). Remove cover (46) and O-ring (44) from body (151).
: 5 mm

IMPORTANT
Each body applies different spools. Arrange the disassembled parts together with each body, in order not to
confuse.

IMPORTANT
Replace the spool (39) assembly and body (151) as an assembly.

2. Pull the spool (39) assembly out from body (151).

NOTE
The spool (39) assembly means spool (39) assembled with bolt (43), retainers (40) (2 used), and spring (41).

3. Remove socket bolts (45) (2 used) from body (151). Remove cover (54) and O-ring (44) from body (151).
: 5 mm

WAFF50-EN-00(07/05/2019) W3-4-10-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Assembly of Spool

NOTE
The illustration shows the swing section.

45 39 40 41 46

54 44 151 44 45 40 43

WAEJ-03-06-116-3 ja
39- Spool 43- Bolt 46- Cover
40- Retainer (2 Used) 44- O-Ring (2 Used) 54- Cover
41- Spring 45- Socket Bolt (4 Used) 151- Body (Swing)

NOTE
The swing spool is explained here.

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
Replace the spool (39) assembly and body (151) as an assembly.

1. Install the spool (39) assembly to body (151).

2. Install O-ring (44) to cover (54). Install cover (54) to body (151) with socket bolts (45) (2 used).
: 5 mm
: 10 to 12 N·m
3. Install O-ring (44) to the other side cover (46) in the same way. Install cover (46) to body (151) with socket bolts (45) (2
used).
: 5 mm
: 10 to 12 N·m

WAFF50-EN-00(07/05/2019) W3-4-11-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-4-11-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Disassembly of Shuttle Valve and Pressure Compensator

NOTE
The illustration shows the swing section.

47
48
49
50
29
52

56
37
58
59

151

36
37
38

WAEJ-03-06-115-4 ja
29- O-Ring 47- Plug 52- Steel Ball 151- Body (Swing)
36- Spring 48- O-Ring 56- Plug
37- O-Ring (2 Used) 49- Seat 58- Piston
38- Plug 50- Backup Ring 59- Spool

NOTE
As an example, the swing section is explained here.

WAFF50-EN-00(07/05/2019) W3-4-12-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

1. Remove plug (47) from body (151). Remove O-ring (48) from plug (47).
: 6 mm

IMPORTANT
When removing seat (49), do not drop steel ball (52).

2. Remove the seat (49) assembly and steal ball (52) from body (151) by using slip joint pliers.
3. Remove O-ring (29) and backup ring (50) from seat (49).
4. Remove plug (38) from body (151). Remove O-ring (37) from plug (38). Remove spring (36) from body (151) by using a
magnet.
: 8 mm

NOTE
Spring (36) is only assembled in the swing, boom, travel (right) and travel (left) sections.

IMPORTANT
When removing the spool (59) assembly, do not drop piston (58).

IMPORTANT
Each body applies different spools and pistons. Arrange the disassembled parts together with each body, in order
not to confuse.

5. Remove plug (56) from body (151). Remove O-ring (37) from plug (56). Remove the spool (59) assembly from body
(151).
: 8 mm

IMPORTANT
Replace spool (59), piston (58), and body (151) as an assembly.

6. Remove piston (58) from spool (59).

WAFF50-EN-00(07/05/2019) W3-4-12-2
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

Assembly of Shuttle Valve and Pressure Compensator

NOTE
The illustration shows the swing section.

52 49 47 48 50 29 151

38
56
37 36 59 58 37

WAEJ-03-06-116-4 ja
29- O-Ring 47- Plug 52- Steel Ball 151- Body (Swing)
36- Spring 48- O-Ring 56- Plug
37- O-Ring (2 Used) 49- Seat 58- Piston
38- Plug 50- Backup Ring 59- Spool

NOTE
As an example, the swing section is explained here.

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
Replace spool (59), piston (58), and body (151) as an assembly.

1. Install piston (58) to spool (59). Insert spring (36) into the spring (36) hole of spool (59).

NOTE
Spring (36) is only assembled in the swing, boom, travel (right) and travel (left) sections.

IMPORTANT
Do not drop piston (58) from the spool (59) assembly.

2. Install the spool (59) assembly to body (151).

3. Install O-ring (37) to plug (56). Install plug (56) to body (151).
: 8 mm
: 60 to 70 N·m

WAFF50-EN-00(07/05/2019) W3-4-13-1
 SECTION3 UPPERSTRUCTURE
Group4 Control Valve

4. Install O-ring (37) to plug (38). Install plug (38) to body (151).
: 8 mm
: 60 to 70 N·m
5. Install backup ring (50), O-ring (29) and steel ball (52) to seat (49).
6. Install the seat (49) assembly to body (151).
7. Install O-ring (48) to plug (47). Install plug (47) to body (151).
: 6 mm
: 31 to 35 N·m

WAFF50-EN-00(07/05/2019) W3-4-13-2
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

Removal of Swing Device

　
IMPORTANT 　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil. 　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, 　
install the clips after connecting the hoses.
　
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.) 　
CAUTION 　
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
　
2. Tilt up the floor. (Refer to the operator's manual.)
3. Disconnect hoses (1) (6 used).
　
: 17 mm, 19 mm, 22 mm 　
CAUTION 　
The swing device (2) weight: 45 kg

4. Remove bolts (4) (8 used) and washers (5) (8 used). Remove swing device (2) from main frame (8).
: 24 mm
5. Remove the adapters attached to swing device (2) if necessary.
2

1 4, 5 1
WAFF-03-05-001-1 ja

WAFF50-EN-00(07/05/2019) W3-5-1-1
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

MEMO

WAFF50-EN-00(07/05/2019) W3-5-1-2
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

Installation of Swing Device

1. Install all removed adapters to swing device (2).

CAUTION
The swing device (2) weight: 45 kg

2. Install swing device (2) to main frame (8) with bolts (4) (8 used) and washers (5) (8 used).
: 24 mm
: 270 N·m
3. Connect hoses (1) (6 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 22 mm
: 40 N·m
4. Tilt down the floor. (Refer to the operator's manual.)
IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)

1 4, 5 1
WAFF-03-05-001-1 ja

WAFF50-EN-00(07/05/2019) W3-5-2-1
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

MEMO

WAFF50-EN-00(07/05/2019) W3-5-2-2
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

Disassembly of Swing Reduction Gear

8
11
17 12

16
15
14

13 2
4
7

20
22
21
19
5
10

24
4
7
3
23
25
26
6

WAEJ-03-07-101-1 ja
1- Swing Motor 8- Washer 16- Roller Bearing 23- First Stage Planetary Gear (3
2- Second Stage Sun Gear 10- Ring Gear 17- Housing Used)
3- First Stage Sun Gear 11- Roller Bearing 19- Second Stage Carrier 24- O-Ring
4- Bolt (7 Used) 12- Oil Seal 20- Second Stage Planetary Gear 25- Needle Bearing (3 Used)
5- Socket Bolt (13 Used) 13- Shaft (4 Used) 26- Inner Race (3 Used)
6- First Stage Carrier 14- Spacer 21- Inner Race (4 Used)
7- Plate (2 Used) 15- Spring Plate 22- Needle Bearing (4 Used)

WAFF50-EN-00(07/05/2019) W3-5-3-1
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

CAUTION
Swing device weight: 44 kg

1. Drain hydraulic oil from drain port (a).

NOTE
Oil amount: 0.6 L

WAEJ-03-07-102-1 ja

a- Drain Port
2. Remove socket bolts (5) (2 used) from swing motor (1). Remove swing motor (1) and O-ring (24) from ring gear (10).
: 10 mm

IMPORTANT
Replace the first stage carrier (6) assembly (3, 4, 6, 7, 23, 25, 26) and the second stage carrier (19) assembly (4, 7,
19, 20, 21, 22) as an assembly respectively. Bolts (4) have been locked in order not to loosen. When removing
them, the locking effect is lost.

3. Remove the first stage carrier (6) assembly, second stage sun gear (2), and the second stage carrier (19) assembly from
ring gear (10).
4. Remove socket bolts (5) (11 used) from ring gear (10). Remove ring gear (10) from housing (17).
: 10 mm
5. Remove washer (8) from shaft (13).
6. Remove shaft (13) from housing (17) by using a plastic hammer.
7. Remove the inner race of roller bearing (16), spring plate (15), and spacer (14) from shaft (13) by using a press.

IMPORTANT
Do not remove the outer races of roller bearings (16, 11) from housing (17). Failure to follow these instructions
will shorten service life of the roller bearings (16, 11) as press-fit force of roller bearings (16, 11) outer races is
reduced. When they have been removed, replace housing (17) with the new one.

8. Remove oil seal (12) from housing (17).

WAFF50-EN-00(07/05/2019) W3-5-3-2
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

Assembly of Swing Reduction Gear

7 4 1 2 3

5
26
25
6
24
7
23
22
21 8
20
19
10
5
11

17
12

16

15
14

13

WAEJ-03-07-103-1 ja
1- Swing Motor 8- Washer 16- Roller Bearing 23- First Stage Planetary Gear (3
2- Second Stage Sun Gear 10- Ring Gear 17- Housing Used)
3- First Stage Sun Gear 11- Roller Bearing 19- Second Stage Carrier 24- O-Ring
4- Bolt (7 Used) 12- Oil Seal 20- Second Stage Planetary Gear 25- Needle Bearing (3 Used)
5- Socket Bolt (13 Used) 13- Shaft (4 Used) 26- Inner Race (3 Used)
6- First Stage Carrier 14- Spacer 21- Inner Race (4 Used)
7- Plate (2 Used) 15- Spring Plate 22- Needle Bearing (4 Used)

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
Install oil seal (12) with the metal surface facing to the swing motor side.

1. Apply grease onto the lip part of oil seal (12). Install oil seal (12) to housing (17).

WAFF50-EN-00(07/05/2019) W3-5-4-1
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

IMPORTANT
When the outer races of roller bearings (16, 11) have been removed, replace housing (17) with the new one.

2. When roller bearings (16, 11) have been removed and they including housing (17) are replaced with the new ones,
install the outer races of roller bearings (16, 11) to housing (17) by using a press.
3. Install spacer (14), spring plate (15), and the inner race of roller bearing (16) to shaft (13) by using a press.
4. Apply grease onto roller bearing (16).

NOTE
Amount of grease: 60 g

IMPORTANT
Do not damage oil seal (12) with the spline part of shaft (13).

5. Install the shaft (13) assembly to housing (17).

6. Install the inner race of roller bearing (11).
7. Adjust the preload of roller bearing.
8. Push roller bearing (11) by using the special tool (ST 4147).

ST 4147

WAEJ-03-07-104-1 ja
9. Rotate housing (17) over 10 turns with the pushing force (3500 N (350 kgf, 790 lbf )) by using the special tool (ST 4147).

3500 N
ST 4147

17

11

12 13

WAEJ-03-07-105-1 ja

WAFF50-EN-00(07/05/2019) W3-5-4-2
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

10. Measure clearance A between roller bearing (11) and shaft (13).

WAEJ-03-07-106-1 ja
11. Check the table and select washer (8) according to clearance A.

Measured value of clearance A (mm) Thickness of washer (8) (mm) Parts No.
6.54 to 6.65 6.70 4613141
6.66 to 6.80 6.85 4613142
6.81 to 6.95 7.00 4613143
6.96 to 7.10 7.15 4613144
7.11 to 7.25 7.30 4613145
7.26 to 7.40 7.45 4613146
12. Push roller bearing (11) with the pushing force (16500 N (1650 kgf, 3710 lbf )) further and install washer (8).
13. Apply THREEBOND #1215 or equivalent onto the ring gear (10) mating surface of housing (17). Install ring gear (10) to
housing (17) with socket bolts (5) (11 used).
: 10 mm
: 110 N·m
14. Install the second stage carrier (19) assembly, second stage sun gear (2), and the first stage carrier (6) assembly to the
housing (17) assembly.
15. Install O-ring (24) to ring gear (10).
16. Add hydraulic oil to the swing reduction gear.

NOTE
Oil amount: 0.6 L

17. Install swing motor (1) to ring gear (10) with socket bolts (5) (2 used).
: 10 mm
: 110 N·m

WAFF50-EN-00(07/05/2019) W3-5-4-3
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

MEMO

WAFF50-EN-00(07/05/2019) W3-5-4-4
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

Disassembly of Swing Motor

WAEJ-03-07-107-1 ja
1- Casing 11- Holder 21- Cover 40- Spring (2 Used)
2- Ball Bearing 12- Retainer 22- Ball Bearing 41- Plug (2 Used)
3- Shaft 13- Plunger (9 Used) 23- Pin 42- O-Ring (2 Used)
4- Swash Plate 14- Disc Plate 24- Valve Plate 43- Plug (2 Used)
5- Rotor 15- Brake Piston 25- Pin (2 Used) 44- O-Ring (2 Used)
6- Collar 16- O-Ring 26- O-Ring (2 Used) 45- Plug
7- Spring 17- O-Ring 27- Socket Bolt (5 Used) 46- O-Ring
8- Washer 18- Spring Seat (2 Used) 28- Orifice 47- Retaining Ring
9- Retaining Ring 19- Disc Spring (2 Used) 38- Relief Valve (2 Used)
10- Pin (3 Used) 20- O-Ring 39- Check Valve (2 Used)

WAFF50-EN-00(07/05/2019) W3-5-5-1
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

IMPORTANT
As the setting changes, do not disassemble relief valve (38).

1. Remove relief valves (38) (2 used) from casing (1).

: 32 mm
2. Remove plugs (41) (2 used) from casing (1). Remove O-rings (42) (2 used) from plugs (41) (2 used).
: 8 mm
3. Remove springs (40) (2 used) and check valves (39) (2 used) from casing (1).
4. Remove orifice (28) from casing (1).
: 2.5 mm
5. Remove plug (45) from casing (1). Remove O-ring (46) from plug (45).
: 6 mm
6. Remove plugs (43) (2 used) from cover (21). Remove O-rings (44) (2 used) from plugs (43) (2 used).
: 5 mm
7. Remove socket bolts (27) (5 used) from casing (1).
: 10 mm

IMPORTANT
Do not remove ball bearing (22) unless necessary.

IMPORTANT
Do not drop valve plate (24) while removing cover (21).

8. Remove cover (21) and O-ring (20) from casing (1).

IMPORTANT
Do not damage the mating surfaces when separating valve plate (24) from cover (21) or rotor (5) by using a
screwdriver.

9. Remove valve plate (24) from rotor (5).

IMPORTANT
Do not remove pin (23) and pins (25) (2 used) unless necessary.

10. Remove O-rings (26) (2 used) from cover (21).

11. Remove disc springs (19) (2 used) and spring seats (18) (2 used) from casing (1).

WAFF50-EN-00(07/05/2019) W3-5-5-2
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

CAUTION
When removing brake piston (15), hold brake piston (15) with a cloth in order not to fly out.

12. Put the matching marks on casing (1) and brake piston (15). Apply air through parking brake port (a) of casing (1).
Raise and remove brake piston (15).

WAEJ-03-07-108-1 ja

a- Parking Brake Port

13. Remove O-rings (16, 17) from brake piston (15).

IMPORTANT
Do not damage the sliding surfaces of rotor (5) and plunger (13).

14. Remove the rotor (5) assembly from shaft (3).

IMPORTANT
Replace rotor (5) and plunger (13) as an assembly.

15. Remove plungers (13) (9 used), retainer (12), holder (11), and pins (10) (3 used) from rotor (5).

CAUTION
When removing retaining ring (9), push washer (8) and spring (7) by using a press in order not to fly out.

16. Remove retaining ring (9), washer (8), spring (7), and collar (6) from rotor (5) by using a press.

IMPORTANT
Do not damage the sliding surface of swash plate (4).

17. Remove disc plate (14) and swash plate (4) from casing (1).
18. Place the casing (1) assembly horizontally with the orifice (28) mounting side down. Tap the ball bearing (2) mounting
side by using a plastic hammer and remove the shaft (3) assembly from casing (1).
19. Remove ball bearing (2) from shaft (3) by using a press.
20. Remove retaining ring (47) from ball bearing (2).

WAFF50-EN-00(07/05/2019) W3-5-5-3
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

MEMO

WAFF50-EN-00(07/05/2019) W3-5-5-4
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

Assembly of Swing Motor

20 27 15 18 24 8 3 22 9 23 19 25

44 21
43
5
26
7 17
16
28
14
6 13
12
1

4
10 47
11
2

45
46

38

41
42

39 40
WAFF-03-05-101-1 ja
1- Casing 11- Holder 21- Cover 40- Spring (2 Used)
2- Ball Bearing 12- Retainer 22- Ball Bearing 41- Plug (2 Used)
3- Shaft 13- Plunger (9 Used) 23- Pin 42- O-Ring (2 Used)
4- Swash Plate 14- Disc Plate 24- Valve Plate 43- Plug (2 Used)
5- Rotor 15- Brake Piston 25- Pin (2 Used) 44- O-Ring (2 Used)
6- Collar 16- O-Ring 26- O-Ring (2 Used) 45- Plug
7- Spring 17- O-Ring 27- Socket Bolt (5 Used) 46- O-Ring
8- Washer 18- Spring Seat (2 Used) 28- Orifice 47- Retaining Ring
9- Retaining Ring 19- Disc Spring (2 Used) 38- Relief Valve (2 Used)
10- Pin (3 Used) 20- O-Ring 39- Check Valve (2 Used)

WAFF50-EN-00(07/05/2019) W3-5-6-1
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
Install bearing (2) with the attached retaining ring (47) side up as shown in Figure A.

1. Install ball bearing (2) to shaft (3) by using a press.

3 47

A
WAEJ-03-07-110-1 ja
2. Install retaining ring (47) to ball bearing (2).

IMPORTANT
Install shaft (3) until retaining ring (47) of ball bearing (2) comes into contact with casing (1). When shaft (3) is
installed further, retaining ring (47) is deformed.

3. Tap the cover (21) mounting side by using a plastic hammer and install the shaft (3) assembly to casing (1).

IMPORTANT
Install swash plate (4) with the chamfered side facing to the casing (1) side.

4. Apply grease onto the chamfered side of swash plate (4). Install swash plate (4) to casing (1).

IMPORTANT
Install collar (6) with the chamfered side facing to the casing (1) side.

5. Install collar (6), spring (7), and washer (8) to rotor (5).

CAUTION
When installing retaining ring (9) to rotor (5), push washer (8) and spring (7) by using a press to prevent them
from jumping out.

6. Push washer (8) and spring (7) by using a press. Install retaining ring (9) to rotor (5). Turn over rotor (5).
7. Apply grease to pins (10) (3 used). Install pins (10) (3 used) to rotor (5). Install holder (11) onto pin (10).
8. Install retainer (12) and plungers (13) (9 used) to rotor (5).
9. Place the casing (1) assembly horizontally with the orifice (28) mounting surface side down. While turning shaft (3),
install the rotor (5) assembly to casing (1). Place casing (1) with the cover (21) mounting side up.
10. Install disc plate (14) to casing (1).

WAFF50-EN-00(07/05/2019) W3-5-6-2
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

11. Install O-rings (16, 17) to brake piston (15). Fit the matching marks made when disassembling and install brake piston
(15) to casing (1).

NOTE
If it is not easy to install brake piston (15) to casing (1) due to the friction from O-rings (16, 17), evenly tap and install
brake piston (15) by using a plastic hammer.

12. Install spring seats (18) (2 used) and disc springs (19) (2 used) to brake piston (15) as illustrated in Figure B.

18

19

18

B
WAEJ-03-07-111-1 ja
13. Install pin (23), pins (25) (2 used) to cover (21).
14. Apply grease onto valve plate (24) with care not to drop valve plate (24) from cover (21).

IMPORTANT
Check the direction to install valve plate (24).

15. Fit pin (23) and install valve plate (24) to cover (21).

IMPORTANT
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

16. Evenly tap and install ball bearing (22) to cover (21) by using a bar and a hammer.
17. Install O-rings (26) (2 used) to cover (21).
18. Install O-ring (20) to casing (1).
19. Install cover (21) to casing (1).
20. Install cover (21) to casing (1) with socket bolts (27) (5 used).
: 10 mm
: 130 ± 7 N·m
21. Install O-rings (44) (2 used) to plugs (43) (2 used). Install plugs (43) (2 used) to cover (21).
: 5 mm
: 16 N·m
22. Install O-ring (46) to plug (45). Install plug (45) to casing (1).
: 6 mm
: 23 ± 1 N·m
23. Install orifice (28) to casing (1).
: 2.5 mm
: 2.5 ± 0.5 N·m

WAFF50-EN-00(07/05/2019) W3-5-6-3
 SECTION3 UPPERSTRUCTURE
Group5 Swing Device

24. Install check valves (39) (2 used) and springs (40) (2 used) to casing (1). Install O-rings (42) (2 used) to plugs (41) (2
used). Install plugs (41) (2 used) onto casing (1).
: 8 mm
: 40 ± 2 N·m
25. Install relief valves (38) (2 used) to casing (1).
: 32 mm
: 160 ± 10 N·m

WAFF50-EN-00(07/05/2019) W3-5-6-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Removal of Pilot Valve (Left)

　
IMPORTANT 　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil. 　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, 　
install the clips after connecting the hoses.
　
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.) 　
CAUTION 　
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
　
2. Remove bolts (7) (3 used), bolts (14), and washers (6) (4 used). Remove cover (8).
: 10 mm 　
3. Remove bolts and washers (15) (3 used). Remove cover (1). 　
: 10 mm
4. Raise boot (4). Loosen lock nut (13). Remove the lever (3) assembly and boot (4). 　
: 19 mm
5. Disconnect hoses (12) (6 used).
　
: 17 mm
6. Put the matching marks on frame (5) and pilot valve (9). Remove bolts and washers (2) (4 used). Remove pilot valve (9)
from frame (5).
: 13 mm
7. Remove clip band (10) and glass wool (11).
8. Remove the adapters attached to pilot valve (9) if necessary.

3 7
6

4
8

5
14
2
9 13
10
11

12
1
15

WAEJ-03-08-100-1 ja

WAFF50-EN-00(07/05/2019) W3-6-1-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-1-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Installation of Pilot Valve (Left)

1. Install all removed adapters to pilot valve (9).

2. Secure glass wool (11) with clip band (10).
3. Fit the matching marks on frame (5) and pilot valve (9). Install pilot valve (9) to frame (5) with bolts, washers (2) (4
used).
: 13 mm
: 10 N·m
4. Connect hoses (12) (6 used).
: 17 mm
: 25 N·m

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

5. Install the lever (3) assembly and boot (4). Holding up boot (4) and install the lever (3) assembly with lock nut (13).
: 19 mm
: 90 N·m
6. Install cover (1) with bolts, washers (15) (3 used).
: 10 mm
: 5 N·m
7. Install covers (8) with bolts (7) (3 used), bolts (14), and washers (6) (4 used).
: 10 mm
: 5 N·m

3 7
6

4
8

5
14
2
9 13
10
11

12
1
15

WAEJ-03-08-100-1 ja

WAFF50-EN-00(07/05/2019) W3-6-2-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-2-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Removal of Pilot Valve (Right)

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

2. Raise boot (3). Loosen lock nut (5). Remove clip band (6) from the shaft mounting part of pilot valve (4). Disconnect
connector (2).
3. Remove the lever (1) assembly and boot (3) from pilot valve (4).

6
2
5

WAEJ-03-08-101-1 ja
4. Remove bolts, washer (7), screws (9) (4 used), and washers (10) (4 used).
: 13 mm
: 5 mm

WAFF50-EN-00(07/05/2019) W3-6-3-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

5. Raise cover (8). Disconnect all connectors (11). Remove cover (8).

9 10

11

WAEJ-03-08-102-1 ja
6. Disconnect hoses (19) (6 used).
: 17 mm
7. Put the matching marks on bracket (15) and pilot valve (4). Remove spring pin (18), bolt (12), washer (17), and bolts,
washers (16) (3 used). Remove pilot valve (4) from bracket (15).
: 13 mm
8. Remove clip band (13) and glass wool (14).
9. Remove the adapters attached to pilot valve (4) if necessary.

18 12
17 19
4

13

16

15 14

WAEJ-03-08-103-1 ja

WAFF50-EN-00(07/05/2019) W3-6-3-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Installation of Pilot Valve (Right)

1. Install all removed adapters to pilot valve (4).

2. Secure glass wool (14) with clip band (13).
3. Fit the matching marks on bracket (15) and pilot valve (4). Install pilot valve (4) to bracket (15) with bolts, washers (16)
(3 used), washer (17), bolt (12), and spring pin (18).
: 13 mm
: 10 N·m
4. Connect hoses (19) (6 used).
: 17 mm
: 25 N·m

18 12
17 19
4

13

16

15 14

WAEJ-03-08-103-1 ja

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

5. Install cover (8).

6. Raise cover (8). Connect all connectors (11).

WAFF50-EN-00(07/05/2019) W3-6-4-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

7. Install cover (8) with washers (10) (4 used), bolts (9) (4 used), and bolts, washer (7).
: 13 mm
: 10 N·m
: 5 mm
: 10 N·m

9 10

11

WAEJ-03-08-102-1 ja
8. Secure harness to the shaft mounting part of pilot valve (4) with clip band (6).
9. Install boot (3) and the lever (1) assembly to pilot valve (4). Connect connector (2). Holding up boot (3), install the lever
(1) assembly with locknut (5).

6
2
5

WAEJ-03-08-101-1 ja

WAFF50-EN-00(07/05/2019) W3-6-4-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Disassembly of Pilot Valves (Left and Right)

17

16

15

14

13

12

11

10
18
9

7
6 19
5 20
4 21
22
3

WAEQ-03-06-001-1 ja
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing

WAFF50-EN-00(07/05/2019) W3-6-5-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Casing (18) is made of aluminium. A strong force deforms it. Handle with care.

IMPORTANT
Spool (19) has been selected to match the hole on casing (18). The dimensions of balance springs (3, 4) and return
springs (5, 6) as well as those of pushers (9, 10) are different. Arrange the disassembled parts together by the port
number in order not to confuse. The port number is stamped on the outer surface of casing (18).

IMPORTANT
Do not remove screw joint (17) while securing casing (18) in a vice. The strong torque may act on screw joint (17).

1. Secure screw joint (17) in a vice. Turn cam (16) by using a spanner. Remove screw joint (17).
: 19 mm, 32 mm
2. Lightly secure the flat surface of casing (18) in a vice. Remove cam (16) from universal joint (15).
: 32 mm
3. Attach a spanner onto the upper part of universal joint (15). Remove universal joint (15).
: 17 mm

NOTE
LOCTITE #262 has been applied onto universal joint (15).

4. Remove plate (14).

IMPORTANT
Do not damage the sleeve (12) surface. Insert a soft rubber between sleeve (12) and a tool. Oil seal (11) cannot be
removed from sleeve (12). Sleeve (12) and oil seal (11) should be replaced as an assembly.

5. Remove sleeves (12) (4 used) upward by using a pair of pliers. Remove O-rings (13) (4 used) from sleeves (12) (4 used).

IMPORTANT
The dimensions of pushers (9, 10) for ports (1, 3) and for ports (2, 4) are different. Arrange the disassembled parts
together by the port number in order not to confuse.

6. Remove pushers (9, 10) (2 used for each) from casing (18).
7. When compressing the spring, do not lower spool (19). Install special tool (ST 4145) to the port hole on casing (18) as
illustrated in Figure A.
: 6 mm

WAFF50-EN-00(07/05/2019) W3-6-5-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

18

ST 4145
A
W178-02-07-048-1 ja

8. Install special tool (ST 4146) to the pusher hole on casing (18). Push special tool (ST 4146) and compress the spring.
Tighten special tool (ST 4146) by using a socket bolt (M14, Pitch 2.0 mm). Remove retaining rings (8) (4 used) from
spools (19) (4 used) by using a screw driver.
: 12 mm

ST 4146

18

W178-02-07-048-2 ja

IMPORTANT
The quantity of shims (2) has been determined for each port. Arrange them by the port number.

9. Remove special tool (ST 4146). Remove spring guides (7) (4 used), return springs (5, 6) (2 used for each), and balance
springs (3, 4) (2 used for each) from spools (19) (4 used).
10. Remove shim (2) and spacers (1) (4 used) from spools (19) (4 used).

IMPORTANT
Spool (19) has been selected to match the hole on casing (18). Spool (19) and casing (18) should be replaced as an
assembly.

11. Remove special tool (ST 4145) from casing (18). Slowly turn and remove spool (19) from casing (18).

WAFF50-EN-00(07/05/2019) W3-6-5-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Retaining ring (22) may come off while disassembling. Do not drop retaining ring (22) inside casing (18). If
retaining ring (22) falls inside casing (18), remove retaining ring (22) completely. Removed retaining ring (22)
cannot be reused.

12. Remove retaining ring (22) from casing (18) by using a screw driver. Install a bolt (M8, Pitch 1.25 mm) to plug (21).
Remove plug (21) from casing (18). Remove O-ring (20) from plug (21).
: 13 mm

WAFF50-EN-00(07/05/2019) W3-6-5-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Assembly of Pilot Valves (Left and Right)

17

16 15
9, 10
11 12
14
13 8
7
3, 4
5, 6
2

1
20
21

22 19
18
W178-02-06-055-1 ja
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing

NOTE
The following table shows the relations between each port and the parts. Do not confuse them when assembling.

Port No. Spool (19) Shim (2) Pushers (9, 10)

1 One outer groove
2 Two outer grooves
Same to the former one Same to the former one
3 One outer groove
4 Two outer grooves

Port No. Return Springs (5, 6) Balance Springs (3, 4)

1 Short Short
2 Long Long
3 Short Short
4 Long Long
IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.

1. Check the port hole number and insert same spools (19) (4 used) before disassembling. Install the thinner ends of
spools (19) (4 used) into the port hole on casing (18) by rotating them slowly.

NOTE
Spools (19) (4 used) has been selected to match the port hole. Spools (19) (4 used) and casing (18) should be replaced
as an assembly.

WAFF50-EN-00(07/05/2019) W3-6-6-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

2. Install special tool (ST 4145) to the port hole on casing (18) in order not to lower spools (19) (4 used) when the spring
is compressed.
: 6 mm

IMPORTANT
Refer to the table in order to assemble the parts correctly.

3. Install spacers (1) (4 used), shim (2), and balance springs (3, 4) (2 used for each) to spools (19) (4 used). Install return
springs (5, 6) (2 used for each) to casing (18).
4. Install spring guides (7) (4 used) onto return springs (5, 6) (2 used for each) with the protrusion side up.
5. Install special tool (ST 4146) to the pusher (9, 10) holes on casing (18). Push special tool (ST 4146) and compress the
spring. Tighten special tool (ST 4146) by using a bolt (M14, Pitch 2.0 mm).
: 12 mm
6. Install retaining ring (8) to special tool (ST 4144).
7. Install retaining rings (8) (4 used) to the grooves on the heads of spools (19) (4 used) extending from special tool (ST
4146).
ST 4146

ST 4144

ST 4145
W178-02-07-049-1 ja

IMPORTANT
Check the position to install pushers (9, 10).

8. Install pushers (9, 10) (2 used for each). After pushing pushers (9, 10) (2 used) several times by hand, remove them.
Check if retaining rings (8) (4 used) come off or balance springs (3, 4) (2 used for each) are located correctly. After
checking, install pushers (9, 10) (2 used for each) to casing (18).
9. Apply grease onto the ball part at the ends of pushers (9, 10) (2 used for each).
10. Apply grease onto the joint part of universal joint (15).
11. Apply grease onto the inner surface of oil seals (11) (4 used).

NOTE
Sleeve (12) and oil seal (11) should be replaced as an assembly.

12. Install oil seals (11) (4 used) and O-rings (13) (4 used) to sleeves (12) (4 used). Push the sleeve (12) assemblies (4 used)
by hand until O-rings (13) (4 used) are inserted into the holes on casing (18).
13. Secure casing (18) in a vise lightly.

WAFF50-EN-00(07/05/2019) W3-6-6-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Fit the bolt hole on plate (14) to the screw hole on casing (18).

14. Apply LOCTITE #262 onto the thread part of universal joint (15). Place plate (14) on casing (18). Install universal joint
(15).
: 17 mm
: 25 N·m

IMPORTANT
Check the tighting amount of cam (16).

15. Install cam (16) to universal joint (15). The clearance between cam (16) and pushers (9, 10) (2 used for each) should be
0 to 0.2 mm.
16. Secure cam (16) by using a spanner. Tighten screw joint (17) by using a spanner.
: 19 mm, 30 mm
: 70 N·m
17. Install O-ring (20) to plug (21). Install plug (21) and retaining ring (22) to casing (18).

WAFF50-EN-00(07/05/2019) W3-6-6-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-6-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Removal of Travel Pilot Valve

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

2. Remove floor mats (1, 2, 3, 4).

1

4 3 2
WAEQ-03-06-002-1 ja

WAFF50-EN-00(07/05/2019) W3-6-7-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

3. Remove bolts, washers (8) (4 used) Remove the pedal (6) assemblies (2 used) and the lever (5) assemblies (2 used)
from pilot valve (7).
: 17 mm

8 7

WAEJ-03-08-105-1 ja
4. Tilt up the floor. (Refer to the operator's manual.)

WAEJ-03-08-106 ja

WAFF50-EN-00(07/05/2019) W3-6-7-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

5. Disconnect hoses (10) (9 used) from pilot valve (9).

: 17 mm, 19 mm
9

10

10

10
WAFF-03-06-001-1 ja
6. Tilt down the floor. (Refer to the operator's manual.)
7. Remove socket bolts (12) (2 used) and washers (13) (2 used). Remove pilot valve (9) from floor (11).
: 8 mm
8. Remove the adapters attached to pilot valve (9) if necessary.

12, 13
9

11

WAEJ-03-08-108-1 ja

WAFF50-EN-00(07/05/2019) W3-6-7-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-7-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Installation of Travel Pilot Valve

1. Install all removed adapters to pilot valve (9).

2. Install pilot valve (9) to floor (11) with socket bolts (12) (2 used) and washers (13) (2 used).
: 8 mm
: 50 N·m

12, 13
9

11

WAEJ-03-08-108-1 ja
3. Tilt up the floor. (Refer to the operator's manual.)
4. Connect hoses (10) (9 used) to pilot valve (9).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
9

10

10

10
WAFF-03-06-001-1 ja

WAFF50-EN-00(07/05/2019) W3-6-8-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

5. Tilt down the floor. (Refer to the operator's manual.)

WAEJ-03-08-106 ja

IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)

6. Install the lever (5) assemblies (2 used) and the pedal (6) assemblies (2 used) to pilot valve (7) with bolts, washers (8) (4
used).
: 17 mm
: 50 N·m

8 7

WAEJ-03-08-105-1 ja

WAFF50-EN-00(07/05/2019) W3-6-8-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

7. Install floor mats (1, 2, 3, 4).

1

4 3 2
WAEQ-03-06-002-1 ja

WAFF50-EN-00(07/05/2019) W3-6-8-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-8-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Disassembly of Travel Pilot Valve

1

3
4

7 35
34
33
32
8 31
9
30
10 29
11

28

14
27
12
15 26
13

25
16

17 24

18

19 23
20
36
22 37
21 19
20
36
37
19
20
WAFA-03-08-001-1 ja
1- Bolt, Washer (2 Used) 8- Spring Washer (4 Used) 18- Balance Spring (4 Used) 28- Oil Seal (4 Used)
2- Cover 9- Socket Bolt (4 Used) 19- O-Ring (5 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 10- Spring Pin (2 Used) 20- Plug (5 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 11- Bracket (2 Used) 21- Plug (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 12- Spring Pin (2 Used) 22- O-Ring (2 Used) 32- Damper (2 Used)
6a- Bushing 13- Spring Pin (2 Used) 23- Casing 33- O-Ring (2 Used)
6b- Bushing 14- O-Ring (4 Used) 24- Spool (4 Used) 34- O-Ring (2 Used)
6c- Bushing 15- Bushing (4 Used) 25- Spring (4 Used) 35- Pin (2 Used)
6d- Bushing 16- Pusher (4 Used) 26- Spacer (4 Used) 36- Steel Ball (3 Used)
7- Holder 17- Spring Guide (4 Used) 27- Shim (12 Used) 37- Sleeve (3 Used)

WAFF50-EN-00(07/05/2019) W3-6-9-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Casing (23) is made of aluminium. A strong force deforms it. Handle with care.

IMPORTANT
Spool (24) has been selected to match the hole on casing (23). Arrange the disassembled parts together by the
port number in order not to confuse. The port number is stamped on the outer surface of casing (23).

1. Remove bolts, washers (1) (2 used) Remove cover (2) from holder (7).
: 10 mm
2. Remove socket bolts (30) (2 used) and spring washers (29) (2 used). Remove the holder (7) assembly from casing (23).
: 8 mm
3. Remove the pusher (16) assemblies (4 used) from casing (23).
4. Remove pushers (16) (4 used) from bushings (15) (4 used). Remove oil seals (28) (4 used) and O-rings (14) (4 used) from
bushings (15) (4 used) by using a spatula.

IMPORTANT
Spool (24) has been selected to match the hole of casing (23). Spool (24) and casing (23) should be replaced as an
assembly.

IMPORTANT
Put the mark on spools (24) (4 used) when keeping in order to easily install spools (24) (4 used) to the original
hole.

5. Turn and remove the spool (24) assemblies (4 used) from casing (23). Spring guides (17) (4 used), balance springs (18)
(4 used), shims (27) (12 used), and spacers (26) (4 used) are removed with spools (24) (4 used) together.

IMPORTANT
The quantity of shims (27) has been determined for each port. Arrange them by the port number.

6. Compress balance springs (18) (4 used). Remove spring guides (17) (4 used), balance springs (18) (4 used), shims (27)
(12 used), and spacers (26) (4 used) from spools (24) (4 used).
7. Remove springs (25) (4 used) from casing (23).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Place a stand under bracket (11) and receive a reaction force. If holder (7) bears the reaction force, strong force
acts on pin (35). Therefore, pin (35) may be deformed.

8. Place stand (b) under brackets (11) (2 used). The inner diameter parts of the spring pin (12, 13) holes on brackets (11)
(2 used) are stepped-shape. The spring pin can only be removed in one direction. Tap and remove spring pins (12, 13)
(2 used for each) together from brackets (11) (2 used) by using special tool (ST 1237) and a hammer. Remove brackets
(11) (2 used) from pins (35) (2 used). Do not remove spring pins (10) (2 used) installed into brackets (11) (2 used) unless
necessary. The hole end of spring pin (10) has been crimped.

WAFF50-EN-00(07/05/2019) W3-6-9-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

12, 13
11
35
10

W176-02-07-019-1 ja

a- Crimped Position b- Stand

9. Remove socket bolts (9) (4 used) and spring washers (8) (4 used). Remove dampers (32) (2 used) and rubber seats (31)
(2 used) from pins (35) (2 used). O-rings (34) (2 used) are removed together.
: 5 mm
10. Remove O-rings (33) (2 used) from pins (35) (2 used).
11. Place holder (7) with the casing (23) mounting surface up.

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

12. The holes of spring pins (3, 4) in cams (5) (2 used) are stepped-shape. Tap the bottom of cam (5) and remove spring
pins (3, 4) (2 used for each) together from cams (5) (2 used) by using special tool (ST 1237) and a hammer. As the holes
of spring pins (3, 4) are crimped, spring pins (3, 4) may feel tight when removing.

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

13. Remove pin (35) by using a bar and a hammer. At the same time, cams (5) (2 used) are removed. Do not remove
bushings (6a, 6b, 6c, 6d) installed to holder (7) unless necessary. If necessary, tap and remove bushings (6a, 6b, 6c, 6d)
by using special tool (ST 7256) and a hammer.
14. Remove plugs (20) (5 used) from casing (23). Remove O-rings (19) (5 used) from plugs (20) (5 used).
: 5 mm
15. Remove plugs (21) (2 used) from casing (23). Remove O-rings (22) (2 used) from plugs (21) (2 used).
: 6 mm
16. Remove sleeves (37) (3 used) and steel balls (36) (3 used) from casing (23).
: 4 mm

WAFF50-EN-00(07/05/2019) W3-6-9-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-9-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Assembly of Travel Pilot Valve

11 32 31 1 2 35 6 12 10 13 7 5 3, 4

34 15
9
33
8 17
28
18
19, 20
14
25
21, 22
27
16
26
19, 20, 36, 37
24
23

19, 20, 36, 37

WAFA-03-08-002-1 ja
1- Bolt, Washer (2 Used) 9- Socket Bolt (4 Used) 20- Plug (5 Used) 30- *1Socket Bolt (2 Used)
2- Cover 10- Spring Pin (2 Used) 21- Plug (2 Used) 31- Rubber Seat (2 Used)
3- Spring Pin (2 Used) 11- Bracket (2 Used) 22- O-Ring (2 Used) 32- Damper (2 Used)
4- Spring Pin (2 Used) 12- Spring Pin (2 Used) 23- Casing 33- O-Ring (2 Used)
5- Cam (2 Used) 13- Spring Pin (2 Used) 24- Spool (4 Used) 34- O-Ring (2 Used)
6a- Bushing 14- O-Ring (4 Used) 25- Spring (4 Used) 35- Pin (2 Used)
6b- Bushing 15- Bushing (4 Used) 26- Spacer (4 Used) 36- Steel Ball (3 Used)
6c- Bushing 16- Pusher (4 Used) 27- Shim (12 Used) 37- Sleeve (3 Used)
6d- Bushing 17- Spring Guide (4 Used) 28- Oil Seal (4 Used)
7- Holder 18- Balance Spring (4 Used) 29- *1Spring Washer (2 Used)
8- Spring Washer (4 Used) 19- O-Ring (5 Used)
*1Refer to "Disassembly of Travel Pilot Valve"W3-6-9-1.

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.

1. Install spacers (26) (4 used), shims (27) (12 used), and balance springs (18) (4 used) into spools (24) (4 used) in
sequence. Install shim (27) as the same condition before disassembling.

IMPORTANT
Check the direction to install spring guide (17).

2. Compress balance springs (18) (4 used) by hand. Install spring guides (17) (4 used) to spools (24) (4 used) with the
stepped part down.

WAFF50-EN-00(07/05/2019) W3-6-10-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Before inserting the parts into holder (7) and casing (23), apply hydraulic oil.

3. Install springs (25) (4 used) into casing (23).

4. Install the spool (24) assemblies (4 used) into the original port before disassembling. Install the spool (24) assemblies
(4 used) to casing (23) by turning.
5. Install oil seals (28) (4 used) to bushings (15) (4 used).
6. Apply grease onto the inner surface of oil seals (28) (4 used).
7. Install O-rings (14) (4 used) and pushers (16) (4 used) to bushings (15) (4 used).
8. Apply grease onto the head of pushers (16) (4 used).
9. Install the pusher (16) assemblies (4 used) into casing (23).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

10. When bushings (6a, 6b, 6c, 6d) have been removed from holder (7), install bushings (6a, 6b, 6c, 6d) to holder (7) by
using special tool (ST 7256) and a hammer.
11. Install bushing (6c) to special tool (ST 7256). Tap special tool (ST 7256) by using a hammer and install bushing (6c) to
the end of hole on holder (7). Stop tapping when the bushing (6c) end is flush with the hole end.
7 ST 7256

6c
W178-02-11-310-2 ja

12. Install bushing (6b) as illustrated in Figure D.

6b 6c
ST 7256 7

D
W178-02-11-311-2 ja

13. Install bushing (6d) as illustrated in Figure A. Stop tapping when the bushing (6d) end is flush with the outside of
holder (7).
6b 6c 6d
7 ST 7256

A
W178-02-11-312-3 ja

c- Outside of Holder

WAFF50-EN-00(07/05/2019) W3-6-10-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

14. Install bushing (6a) as illustrated in Figure B.

6a 6b 6c 6d

ST 7256 7

B
W178-02-11-313-2 ja

NOTE
Bushings (6a, 6b, 6c, 6d) are identical.

15. Install O-rings (33) (2 used) to pins (35) (2 used). Apply grease onto O-rings (33) (2 used). Install pins (35) (2 used) and
cams (5) (2 used) to holder (7).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Check the direction to install spring pins (3, 4).

16. Install spring pins (3,4) (2 used for each) to cams (5) (2 used) and pins (35) (2 used) by using special tool (ST 1237) and a
hammer. At this time, slits (d) of spring pins (3, 4) (2 used for each) should be positioned 90° away each other. Tap and
install spring pins (3, 4) (2 used for each) until spring pins (3, 4) come in contact with the stepped part in the hole.
3 b d

4
W178-02-07-050-3 ja

d- Slit

17. Crimp the outer circumferences of the cams’ (5) (2 used) holes where spring pins (3, 4) are inserted by using a punch.
18. Place holder (7) on the casing (23) assembly. Install holder (7) to casing (23) with socket bolts (30) (2 used) and spring
washers (29) (2 used). Check the mark direction and install holder (7).
: 8 mm
: 50 N·m
19. Install rubber seats (31) (2 used) to pins (35) (2 used).

IMPORTANT
Check the direction of damper (32). The inner surface of damper (32) is edged-shape. If damper (32) is pried when
installing, O-ring (33) may be damaged.

20. Install dampers (32) (2 used) to pins (35) (2 used) with the lever up.

WAFF50-EN-00(07/05/2019) W3-6-10-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

21. Secure dampers (32) (2 used) and rubber seats (31) (2 used) to holder (7) with socket bolts (9) (4 used) and spring
washers (8) (4 used).
: 5 mm
: 7 N·m
22. Apply grease onto O-rings (34) (2 used). Install O-rings (34) (2 used) to the end of pins (35) (2 used).
23. As for the installing direction of brackets (11) (2 used), refer to the figure of travel pilot valve disassembling. (Refer to
"Disassembly of Travel Pilot Valve"W3-6-9-1.) Install brackets (11) (2 used) to pins (35) (2 used). Fit the holes to insert
spring pins (12, 13).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Place a stand under bracket (11) and receive a reaction force. If holder (7) bears the reaction force, strong force
acts on pin (35). Therefore, pin (35) may be deformed.

24. Place stand (f ) under brackets (11) (2 used). Install spring pins (12,13) (2 used for each) to brackets (11) (2 used) and
pins (35) (2 used) until they come in contact with the stepped part by using special tool (ST 1237) and a hammer. The
slits of spring pins (12, 13) (2 used for each) should be positioned 90° away each other.
e e

11 35

f
12, 13

W176-02-07-011-2 ja

e- Crimped Position f- Stand

25. Crimp the outer circumferences of the brackets’ (11) (2 used) holes where spring pins (12, 13) are inserted by using a
punch.
26. Install cover (2) to holder (7) with bolts, washers (1) (2 used).
: 10 mm
: 5 N·m
27. Apply grease onto the spring pin (10) contact part of dampers (32) (2 used).
28. Install steel balls (36) (3 used) and sleeves (37) (3 used) to casing (23).
: 4 mm
: 8.3 N·m
29. Install O-rings (19) (5 used) to plugs (20) (5 used). Install plugs (20) (5 used) onto casing (23).
: 5 mm
: 10 N·m
30. Install O-rings (22) (2 used) to plugs (21) (2 used). Install plugs (21) (2 used) onto casing (23).
: 6 mm
: 20 N·m

WAFF50-EN-00(07/05/2019) W3-6-10-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Removal of Boom Swing Pilot Valve

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

2. Remove floor mats (11, 12).

11 12
WAEQ-03-06-002-2 ja
3. Remove bolts and washers (2) (2 used). Remove pedal (3).
: 13 mm

WAFF50-EN-00(07/05/2019) W3-6-11-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

4. Remove socket bolts (4) (2 used) and spring washers (5) (2 used). Remove Bracket (6).
: 6 mm

2 3

4, 5

WAEJ-03-08-111-3 ja
5. Tilt up the floor. (Refer to the operator's manual.)

WAEJ-03-08-106 ja

WAFF50-EN-00(07/05/2019) W3-6-11-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

6. Disconnect hoses (7) (4 used) from pilot valve (1).

: 17 mm, 19 mm

7 1

WAEJ-03-08-110-1 ja
7. Remove the adapters attached to pilot valve (1) if necessary.
8. Remove bolts and washers (8) (2 used). Remove pilot valve (1) and cover (9) from floor (10).
: 13 mm

10 9 8

WAEJ-03-08-111-1 ja

WAFF50-EN-00(07/05/2019) W3-6-11-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-11-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Installation of Boom Swing Pilot Valve

1. Install cover (9) and pilot valve (1) to floor (10) with bolts, washers (8) (2 used).
: 13 mm
: 10 N·m

10 9 8

WAEJ-03-08-111-1 ja
2. Install all removed adapters to pilot valve (1).
3. Connect hoses (7) (4 used) to pilot valve (1).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m

7 1

WAEJ-03-08-110-1 ja

WAFF50-EN-00(07/05/2019) W3-6-12-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

4. Tilt down the floor. (Refer to the operator's manual.)

WAEJ-03-08-106 ja

IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)

5. Install bracket (6) with socket bolts (4) (2 used) and spring washers (5) (2 used).
: 6 mm
: 20 N·m
6. Install pedal (3) with bolts, washers (2) (2 used).
: 13 mm
: 10 N·m

2 3

4, 5

WAEJ-03-08-111-3 ja

WAFF50-EN-00(07/05/2019) W3-6-12-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

7. Install floor mats (11, 12).

11 12
WAEQ-03-06-002-2 ja

WAFF50-EN-00(07/05/2019) W3-6-12-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-12-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Disassembly of Boom Swing Pilot Valve

11

09

05

10

10 07
06

08
07

b
b
a
a 04
04 c
c
d
d 03
03
02
02
01
01 00
00
16
16

15

WABA-03-07-104-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot

WAFF50-EN-00(07/05/2019) W3-6-13-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Casing (15a) is made of aluminium. A strong force deforms it. Handle it with care.

IMPORTANT
Spool (15b) has been selected to match the hole on casing (15a). Arrange the disassembled parts together by the
port number in order not to confuse. The port number is stamped on the outer surface of casing (15a).

1. Secure the pilot valve in a vise. Remove boot (11) from holder (06).
2. Remove set screw (09) from cam (05).
: 2.5 mm

NOTE
LOCTITE #262 has been applied onto set screw (09).

3. Remove pin (08). Remove cam (05) from holder (06).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Do not remove bushing (07) unless necessary.

IMPORTANT
Bushing (07) cannot be reused.

4. Remove bushings (07) (2 used) from holder (06) by using a hammer and special tool (ST 7690).

IMPORTANT
The pusher (04d) assembly may fly out when removing holder (06).

5. Put the matching marks on casing (15a) and holder (06). Loosen and remove socket bolts (10) (2 used) alternately.
Remove holder (06) from casing (15a).
: 5 mm
6. Remove the pusher (04d) assemblies (2 used) from casing (15a).

IMPORTANT
Do not damage bushing (04a).

7. Remove pushers (04d) (2 used), O-rings (04c) (2 used), and oil seals (04b) (2 used) from bushings (04a) (2 used).

IMPORTANT
Spool (15b) has been selected to match the hole of casing (15a). Spool (15b) and casing (15a) should be replaced
as an assembly.

IMPORTANT
Put the mark on spools (15b) (2 used) when keeping in order to easily install spools (15b) (2 used) to the original
hole.

8. Turn and remove the spool (15b) assemblies (2 used) from casing (15a).

WAFF50-EN-00(07/05/2019) W3-6-13-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
The quantity of shims (01) has been determined for each port. Arrange them by the port number.

9. Compress balance springs (02) (2 used). Remove spring guides (03) (2 used), balance springs (02) (2 used), shims (01)
(6 used), and spacers (00) (2 used) from spools (15b) (2 used).
10. Remove return springs (16) (2 used) from casing (15a).

WAFF50-EN-00(07/05/2019) W3-6-13-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-13-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Assembly of Boom Swing Pilot Valve

07 08 09

05

11
04d

04b 10

06

03

04c
16

04a
E

15b

02
01
00

15a

WABA-03-07-105-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.

IMPORTANT
Install shims (01) as the same condition before disassembling.

1. Install spacers (00) (2 used), shims (01) (6 used), and balance springs (02) (2 used) to spools (15b) (2 used) in sequence.
2. Compress balance springs (02) (2 used) by hand. Install spring guides (03) (2 used) to spools (15b) (2 used) with the
stepped part down.
3. Secure casing (15a) in a vise. Install return springs (16) (2 used) to casing (15a).

WAFF50-EN-00(07/05/2019) W3-6-14-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Install the spool (15b) assembly into the original port before disassembling.

4. Turn and install the spool (15b) assemblies (2 used) to casing (15a).

IMPORTANT
Do not deform and damage the sliding surface when installing oil seal (04b).

IMPORTANT
Check the direction to install oil seal (04b).

5. Apply grease onto oil seals (04b) (2 used). Install oil seals (04b) (2 used) to bushings (04a) (2 used).
04b

04a

WDAD-03-11-003-2 ja
6. Apply grease onto the sliding surfaces of bushings (04a) (2 used) and O-rings (04c) (2 used). Install O-rings (04c) (2
used) and pushers (04d) (2 used) to bushings (04a) (2 used).
7. Install the pusher (04d) assemblies (2 used) into casing (15a).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

8. Install bushings (07) (2 used) to holder (06) by using a hammer and special tool (ST 7690).
9. Fit the matching marks made when disassembling and install holder (06) to casing (15a) by tightening socket bolts
(10) (2 used) alternately.
: 5 mm
: 7.0 N·m
10. Apply grease onto A part of pushers (04d) (2 used). Install cam (05) to holder (06) with pin (08).
A

04d

WDAD-03-11-004-2 ja
11. Apply LOCTITE #262 onto set screw (09). Install set screw (09) to cam (05).
: 2.5 mm
: 7 N·m
12. Install boot (11) to holder (06).

WAFF50-EN-00(07/05/2019) W3-6-14-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Removal of Blade Pilot Valve

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

IMPORTANT
The stopper has been installed to the screw (2) tip in order to prevent it from coming off. Do not loosen screw (2)
excessively.

2. Loosen screw (2). Remove cover (3).

3. Remove bolts, washers (5) (6 used) Remove plate (14) and covers (1, 4).
1

5
2

14 4
WAFF-03-06-021-1 ja
4. Remove bolts, washers (13) (2 used) Remove the lever (12) assembly.
: 13 mm
5. Disconnect hoses (8) (6 used).
: 17 mm, 19 mm
6. Remove bolts, washers (11) (2 used) Remove pilot valve (10) from bracket (9).
: 13 mm
7. Remove clip bands (6) (2 used) and glass wool (7) from pilot valve (10).

WAFF50-EN-00(07/05/2019) W3-6-15-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

8. Remove the adapters attached to pilot valve (10) if necessary.

A

10 A 11

9 6

7
13

8
12
8

6 11
WAEQ-03-06-005-1 ja

WAFF50-EN-00(07/05/2019) W3-6-15-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Installation of Blade Pilot Valve

1. Install all removed adapters to pilot valve (10).

2. Secure glass wool (7) to pilot valve (10) with clip bands (6) (2 used).
3. Install pilot valve (10) to bracket (9) with bolts, washers (11) (2 used).
: 13 mm
: 10 N·m
4. Connect hoses (8) (6 used) to pilot valve (10).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

5. Install the lever (12) assembly with bolts, washers (13) (2 used).
: 13 mm
: 10 N·m
A

10 A 11

9 6

7
13
8
12
8

6 11
WAEQ-03-06-005-1 ja
6. Install covers (1, 4) and plate (14) with bolts, washers (5) (6 used).

WAFF50-EN-00(07/05/2019) W3-6-16-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

7. Install cover (3) with screw (2).

1

5
2

14 4
WAFF-03-06-021-1 ja

WAFF50-EN-00(07/05/2019) W3-6-16-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Disassembly of Blade Pilot Valve

11

09

05

10

10 07
06

08
07

b
b
a
a 04
04 c
c
d
d 03
03
02
02
01
01 00
00
16
16

15

WABA-03-07-104-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot

WAFF50-EN-00(07/05/2019) W3-6-17-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Casing (15a) is made of aluminium. A strong force deforms it. Handle it with care.

IMPORTANT
Spool (15b) has been selected to match the hole on casing (15a). Arrange the disassembled parts together by the
port number in order not to confuse. The port number is stamped on the outer surface of casing (15a).

1. Secure the pilot valve in a vise. Remove boot (11) from holder (06).
2. Remove set screw (09) from cam (05).
: 2.5 mm

NOTE
LOCTITE #262 has been applied onto set screw (09).

3. Remove pin (08). Remove cam (05) from holder (06).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Do not remove bushing (07) unless necessary.

IMPORTANT
Bushing (07) cannot be reused.

4. Remove bushings (07) (2 used) from holder (06) by using a hammer and special tool (ST 7690).

IMPORTANT
The pusher (04d) assembly may fly out when removing holder (06).

5. Put the matching marks on casing (15a) and holder (06). Loosen and remove socket bolts (10) (2 used) alternately.
Remove holder (06) from casing (15a).
: 5 mm
6. Remove the pusher (04d) assemblies (2 used) from casing (15a).

IMPORTANT
Do not damage bushing (04a).

7. Remove pushers (04d) (2 used), O-rings (04c) (2 used), and oil seals (04b) (2 used) from bushings (04a) (2 used).

IMPORTANT
Spool (15b) has been selected to match the hole of casing (15a). Spool (15b) and casing (15a) should be replaced
as an assembly.

IMPORTANT
Put the mark on spools (15b) (2 used) when keeping in order to easily install spools (15b) (2 used) to the original
hole.

8. Turn and remove the spool (15b) assemblies (2 used) from casing (15a).

WAFF50-EN-00(07/05/2019) W3-6-17-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
The quantity of shims (01) has been determined for each port. Arrange them by the port number.

9. Compress balance springs (02) (2 used). Remove spring guides (03) (2 used), balance springs (02) (2 used), shims (01)
(6 used), and spacers (00) (2 used) from spools (15b) (2 used).
10. Remove return springs (16) (2 used) from casing (15a).

WAFF50-EN-00(07/05/2019) W3-6-17-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-17-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Assembly of Blade Pilot Valve

07 08 09

05

11
04d

04b 10

06

03

04c
16

04a
E

15b

02
01
00

15a

WABA-03-07-105-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.

IMPORTANT
Install shims (01) as the same condition before disassembling.

1. Install spacers (00) (2 used), shims (01) (6 used), and balance springs (02) (2 used) to spools (15b) (2 used) in sequence.
2. Compress balance springs (02) (2 used) by hand. Install spring guides (03) (2 used) to spools (15b) (2 used) with the
stepped part down.
3. Secure casing (15a) in a vise. Install return springs (16) (2 used) to casing (15a).

WAFF50-EN-00(07/05/2019) W3-6-18-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Install the spool (15b) assembly into the original port before disassembling.

4. Turn and install the spool (15b) assemblies (2 used) to casing (15a).

IMPORTANT
Do not deform and damage the sliding surface when installing oil seal (04b).

IMPORTANT
Check the direction to install oil seal (04b).

5. Apply grease onto oil seals (04b) (2 used). Install oil seals (04b) (2 used) to bushings (04a) (2 used).
04b

04a

WDAD-03-11-003-2 ja
6. Apply grease onto the sliding surfaces of bushings (04a) (2 used) and O-rings (04c) (2 used). Install O-rings (04c) (2
used) and pushers (04d) (2 used) to bushings (04a) (2 used).
7. Install the pusher (04d) assemblies (2 used) into casing (15a).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

8. Install bushings (07) (2 used) to holder (06) by using a hammer and special tool (ST 7690).
9. Fit the matching marks made when disassembling and install holder (06) to casing (15a) by tightening socket bolts
(10) (2 used) alternately.
: 5 mm
: 7.0 N·m
10. Apply grease onto A part of pushers (04d) (2 used). Install cam (05) to holder (06) with pin (08).
A

04d

WDAD-03-11-004-2 ja
11. Apply LOCTITE #262 onto set screw (09). Install set screw (09) to cam (05).
: 2.5 mm
: 7 N·m
12. Install boot (11) to holder (06).

WAFF50-EN-00(07/05/2019) W3-6-18-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Removal of Auxiliary Pilot Valve

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

2. Remove floor mats (11, 12).

11 12
WAEQ-03-06-002-2 ja

WAFF50-EN-00(07/05/2019) W3-6-19-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

3. Remove socket bolts (1) (2 used) and spring washers (2) (2 used). Remove pedal (3).
: 6 mm
1, 2

WAEQ-03-06-006-1 ja
4. Tilt up the floor. (Refer to the operator's manual.)

WAEJ-03-08-106 ja

WAFF50-EN-00(07/05/2019) W3-6-19-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

5. Disconnect hoses (4) (5 used).

: 17 mm, 19 mm
4

WAFF-03-06-031-1 ja
6. Remove the adapters attached to pilot valve (5) if necessary.
7. Remove bolts, washers (6) (2 used) Remove pilot valve (5) from floor (7).
: 13 mm

6
WAEQ-03-06-008-1 ja

WAFF50-EN-00(07/05/2019) W3-6-19-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-19-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Installation of Auxiliary Pilot Valve

1. Install pilot valve (5) to floor (7) with bolts, washers (6) (2 used).
: 13 mm
: 10 N·m
2. Install all removed adapters to pilot valve (5).

6
WAEQ-03-06-008-1 ja
3. Connect hoses (4) (5 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
4

WAFF-03-06-031-1 ja

WAFF50-EN-00(07/05/2019) W3-6-20-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

4. Tilt down the floor. (Refer to the operator's manual.)

WAEJ-03-08-106 ja

IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)

5. Install pedal (3) with socket bolts (1) (2 used) and spring washers (2) (2 used).
: 6 mm
: 20 N·m
1, 2

WAEQ-03-06-006-1 ja

WAFF50-EN-00(07/05/2019) W3-6-20-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

6. Install floor mats (11, 12).

11 12
WAEQ-03-06-002-2 ja

WAFF50-EN-00(07/05/2019) W3-6-20-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-20-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Disassembly of Auxiliary Pilot Valve

11

09

05

10

10 07
06

08
07

b
b
a
a 04
04 c
c
d
d 03
03
02
02
01
01 00
00
16
16

15

WABA-03-07-104-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot

WAFF50-EN-00(07/05/2019) W3-6-21-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Casing (15a) is made of aluminium. A strong force deforms it. Handle it with care.

IMPORTANT
Spool (15b) has been selected to match the hole on casing (15a). Arrange the disassembled parts together by the
port number in order not to confuse. The port number is stamped on the outer surface of casing (15a).

1. Secure the pilot valve in a vise. Remove boot (11) from holder (06).
2. Remove set screw (09) from cam (05).
: 2.5 mm

NOTE
LOCTITE #262 has been applied onto set screw (09).

3. Remove pin (08). Remove cam (05) from holder (06).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Do not remove bushing (07) unless necessary.

IMPORTANT
Bushing (07) cannot be reused.

4. Remove bushings (07) (2 used) from holder (06) by using a hammer and special tool (ST 7690).

IMPORTANT
The pusher (04d) assembly may fly out when removing holder (06).

5. Put the matching marks on casing (15a) and holder (06). Loosen and remove socket bolts (10) (2 used) alternately.
Remove holder (06) from casing (15a).
: 5 mm
6. Remove the pusher (04d) assemblies (2 used) from casing (15a).

IMPORTANT
Do not damage bushing (04a).

7. Remove pushers (04d) (2 used), O-rings (04c) (2 used), and oil seals (04b) (2 used) from bushings (04a) (2 used).

IMPORTANT
Spool (15b) has been selected to match the hole of casing (15a). Spool (15b) and casing (15a) should be replaced
as an assembly.

IMPORTANT
Put the mark on spools (15b) (2 used) when keeping in order to easily install spools (15b) (2 used) to the original
hole.

8. Turn and remove the spool (15b) assembly from casing (15a).

WAFF50-EN-00(07/05/2019) W3-6-21-2
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
The quantity of shims (01) has been determined for each port. Arrange them by the port number.

9. Compress balance springs (02) (2 used). Remove spring guides (03) (2 used), balance springs (02) (2 used), shims (01)
(6 used), and spacers (00) (2 used) from spools (15b) (2 used).
10. Remove return springs (16) (2 used) from casing (15a).

WAFF50-EN-00(07/05/2019) W3-6-21-3
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-6-21-4
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

Assembly of Auxiliary Pilot Valve

07 08 09

05

11
04d

04b 10

06

03

04c
16

04a
E

15b

02
01
00

15a

WABA-03-07-105-2 ja
00- Spacer (2 Used) 04b- Oil Seal (2 Used) 07- Bushing (2 Used) 15a- Casing
01- Shim (6 Used) 04c- O-Ring (2 Used) 08- Pin 15b- Spool (2 Used)
02- Balance Spring (2 Used) 04d- Pusher (2 Used) 09- Set Screw 16- Return Spring (2 Used)
03- Spring Guide (2 Used) 05- Cam 10- Socket Bolt (2 Used)
04a- Bushing (2 Used) 06- Holder 11- Boot

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.

IMPORTANT
Install shims (01) as the same condition before disassembling.

1. Install spacers (00) (2 used), shims (01) (6 used), and balance springs (02) (2 used) to spools (15b) (2 used) in sequence.
2. Compress balance springs (02) (2 used) by hand. Install spring guides (03) (2 used) to spools (15b) (2 used) with the
stepped part down.
3. Secure casing (15a) in a vise. Install return springs (16) (2 used) to casing (15a).

WAFF50-EN-00(07/05/2019) W3-6-22-1
 SECTION3 UPPERSTRUCTURE
Group6 Pilot Valve

IMPORTANT
Install the spool (15b) assembly into the original port before disassembling.

4. Turn and install the spool (15b) assemblies (2 used) to casing (15a).

IMPORTANT
Do not deform and damage the sliding surface when installing oil seal (04b).

IMPORTANT
Check the direction to install oil seal (04b).

5. Apply grease onto oil seals (04b) (2 used). Install oil seals (04b) (2 used) to bushings (04a) (2 used).
04b

04a

WDAD-03-11-003-2 ja
6. Apply grease onto the sliding surfaces of bushings (04a) (2 used) and O-rings (04c) (2 used). Install O-rings (04c) (2
used) and pushers (04d) (2 used) to bushings (04a) (2 used).
7. Install the pusher (04d) assemblies (2 used) into casing (15a).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

8. Install bushings (07) (2 used) to holder (06) by using a hammer and special tool (ST 7690).
9. Fit the matching marks made when disassembling and install holder (06) to casing (15a) by tightening socket bolts
(10) (2 used) alternately.
: 5 mm
: 7.0 N·m
10. Apply grease onto A part of pushers (04d) (2 used). Install cam (05) to holder (06) with pin (08).
A

04d

WDAD-03-11-004-2 ja
11. Apply LOCTITE #262 onto set screw (09). Install set screw (09) to cam (05).
: 2.5 mm
: 7 N·m
12. Install boot (11) to holder (06).

WAFF50-EN-00(07/05/2019) W3-6-22-2
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

Removal of 2-Spool Solenoid Valve

　
IMPORTANT 　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil. 　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, 　
install the clips after connecting the hoses.
　
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.) 　
CAUTION 　
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)
　
2. Tilt up the floor. (Refer to the operator's manual.)
　
　
　
　
　

WAEJ-03-08-106 ja
3. Remove clip band (4). Disconnect connectors (5) (2 used).
4. Disconnect hoses (3) (6 used).
: 17 mm, 19 mm, 22 mm
5. Remove socket bolts (2) (2 used). Remove 2-spool solenoid valve (1) from bracket (6).
: 6 mm

WAFF50-EN-00(07/05/2019) W3-7-1-1
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

6. Remove the adapters attached to 2-spool solenoid valve (1) if necessary.

1

5 2

2
WAFF-03-07-001-1 ja

WAFF50-EN-00(07/05/2019) W3-7-1-2
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

Installation of 2-Spool Solenoid Valve

1. Install all removed adapters to 2-spool solenoid valve (1).

2. Install 2-spool solenoid valve (1) to bracket (6) with socket bolts (2) (2 used).
: 6 mm
: 20 N·m
3. Connect hoses (3) (6 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 22 mm
: 40 N·m
4. Connect connectors (5) (2 used). Install clip band (4).
1

5 2

2
WAFF-03-07-001-1 ja
5. Tilt down the floor. (Refer to the operator's manual.)

WAEJ-03-08-106 ja

WAFF50-EN-00(07/05/2019) W3-7-2-1
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)

WAFF50-EN-00(07/05/2019) W3-7-2-2
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

Disassembly of 2-Spool Solenoid Valve

7 7

2
4 2 4

12
6 12 6
5 5
9 13 9
13

8
8

9 9
3 3

1 11 1

14
15
17
16
18
10
10

WABA-03-08-100-1 ja
1- Piston (2 Used) 6- Wave Washer (2 Used) 11- Body 16- Adjuster
2- Pin (2 Used) 7- Lock Nut (2 Used) 12- Spool (2 Used) 17- O-Ring
3- Plate (2 Used) 8- Solenoid (2 Used) 13- Spring (2 Used) 18- Lock Nut
4- Casing (2 Used) 9- O-Ring (4 Used) 14- Check Valve
5- Plate (2 Used) 10- O-Ring (2 Used) 15- Spring

IMPORTANT
Arrange the disassembled parts together by the port number in order not to confuse.

1. Remove lock nuts (7) (2 used) from the piston (1) assemblies (2 used). Remove casing (4) (2 used) from body (11).
: 17 mm
2. Remove wave washers (6) (2 used), plates (5, 3) (2 used for each), O-rings (9) (4 used), and solenoids (8) (2 used) from
pistons (1) (2 used).

IMPORTANT
When removing piston (1), pin (2) may fall off. Do not lose pin (2).

3. Remove the piston (1) assemblies (2 used) from body (11). Remove pins (2) (2 used) and O-rings (10) (2 used) from the
piston (1) assemblies (2 used).
4. Remove spools (12) (2 used) and springs (13) (2 used) from body (11) by using a magnet.

WAFF50-EN-00(07/05/2019) W3-7-3-1
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

IMPORTANT
Do not disassemble lock nut (18) and adjuster (16).

5. Loosen lock nut (18).

: 17 mm
6. Remove the adjuster (16) assembly from body (11). Remove O-ring (17) from the adjuster (16) assembly.
: 6 mm
7. Remove spring (15) and check valve (14) from body (11) by using a magnet.

WAFF50-EN-00(07/05/2019) W3-7-3-2
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

Assembly of 2-Spool Solenoid Valve

4 7 6 5

9
1
8
2
9

3
11
10
14
12
13
15

17
11 18
16

WABA-03-08-101-1 ja
1- Piston (2 Used) 6- Wave Washer (2 Used) 11- Body 16- Adjuster
2- Pin (2 Used) 7- Lock Nut (2 Used) 12- Spool (2 Used) 17- O-Ring
3- Plate (2 Used) 8- Solenoid (2 Used) 13- Spring (2 Used) 18- Lock Nut
4- Casing (2 Used) 9- O-Ring (4 Used) 14- Check Valve
5- Plate (2 Used) 10- O-Ring (2 Used) 15- Spring

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
Do not disassemble adjuster (16) and lock nut (18).

1. Install check valve (14) and spring (15) to body (11).

2. Install O-ring (17) to the adjuster (16) assembly. Install the adjuster (16) assembly to body (11).
: 6 mm
3. Tighten lock nut (18).
: 17 mm
: 15 to 20 N·m
4. Install springs (13) (2 used) and spools (12) (2 used) to body (11).
5. Install pin (2) (2 used) and O-rings (10) (2 used) to pistons (1) (2 used). Install pistons (1) (2 used) to body (11).
6. Install plates (3, 5) (2 used for each), solenoids (8) (2 used), O-rings (9) (4 used), and wave washers (6) (2 used) to
pistons (1) (2 used).

WAFF50-EN-00(07/05/2019) W3-7-4-1
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

7. Install casings (4) (2 used) to the piston (1) assemblies (2 used). Install the piston (1) assemblies (2 used) to body(11)
with lock nuts (7) (2 used).
: 17 mm
: 15 to 20 N·m

WAFF50-EN-00(07/05/2019) W3-7-4-2
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

Removal of LS Cut Solenoid Valve

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

CAUTION
Remove cover (5) while holding cover (5). Do not drop cover (5).

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

: 17 mm

4
5
WAFF-03-07-011-1 ja
3. Disconnect hoses (14) (3 used) and connector (15).
: 17 mm
4. Remove bolts, washers (16) (2 used) Remove LS cut solenoid valve (13) from frame (12).
: 13 mm

WAFF50-EN-00(07/05/2019) W3-7-5-1
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

5. Remove the adapters attached to LS cut solenoid valve (13) if necessary.

16

13

12 15 14
WAFF-03-07-012-1 ja

WAFF50-EN-00(07/05/2019) W3-7-5-2
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

Installation of LS Cut Solenoid Valve

1. Install all removed adapters to LS cut solenoid valve (13).

2. Install LS cut solenoid valve (13) to frame (12) with bolts, washers (16) (2 used).
: 13 mm
: 10 N·m
3. Connect hoses (14) (3 used) and connector (15).
: 17 mm
: 25 N·m
16

13

12 15 14
WAFF-03-07-012-1 ja

IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)

4. Install cover (5) with bolts, washers (4) (4 used).

: 17 mm
: 50 N·m

4
5
WAFF-03-07-011-1 ja

WAFF50-EN-00(07/05/2019) W3-7-6-1
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-7-6-2
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

Disassembly of LS Cut Solenoid Valve

7
10

12 4

13
6

5
11
9

WAEJ-03-09-101-1 ja
1- Piston 5- Plate 9- O-Ring (2 Used) 13- Spring
2- Pin 6- Wave Washer 10- O-Ring
3- Plate 7- Lock Nut 11- Body
4- Casing 8- Solenoid 12- Spool
1. Remove lock nut (7) from the piston (1) assembly. Remove casing (4) from body (11).
: 17 mm
2. Remove wave washer (6), plates (5, 3), O-rings (9) (2 used), and solenoid (8) from piston (1).

IMPORTANT
When removing piston (1), pin (2) may fall off. Do not lose pin (2).

3. Remove the piston (1) assembly from body (11). Remove pin (2) and O-ring (10) from piston (1).
4. Remove spool (12) and spring (13) from body (11) by using a magnet.

WAFF50-EN-00(07/05/2019) W3-7-7-1
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-7-7-2
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

Assembly of LS Cut Solenoid Valve

B B-B 6 7

5
4

9
9
1
2 8
10
3

11

12

13
B

WAEJ-03-09-102-1 ja
1- Piston 5- Plate 9- O-Ring (2 Used) 13- Spring
2- Pin 6- Wave Washer 10- O-Ring
3- Plate 7- Lock Nut 11- Body
4- Casing 8- Solenoid 12- Spool

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

1. Install spring (13) and spool (12) to body (11).

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

WAFF50-EN-00(07/05/2019) W3-7-8-1
 SECTION3 UPPERSTRUCTURE
Group7 Solenoid Valve

MEMO

WAFF50-EN-00(07/05/2019) W3-7-8-2
 SECTION3 UPPERSTRUCTURE
Group8 Revolution Sensing Valve

Removal of Revolution Sensing Valve

　
IMPORTANT 　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil. 　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, 　
install the clips after connecting the hoses.
　
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.) 　
　
CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.) 　

CAUTION 　
Remove cover (2) while holding cover (2). Do not drop cover (2). 　
2. Remove bolts, washers (1) (4 used) Remove cover (2).
　
: 17 mm
　
　
　

1
2
WAFF-03-07-011-2 ja
3. Disconnect hoses (3) (6 used).
: 17 mm, 19 mm
4. Remove bolts, washers (4) (2 used) Remove revolution sensing valve (5) from frame (6).
: 13 mm

WAFF50-EN-00(07/05/2019) W3-8-1-1
 SECTION3 UPPERSTRUCTURE
Group8 Revolution Sensing Valve

5. Remove the adapters attached to revolution sensing valve (5) if necessary.

6 3 5 4
WAFF-03-08-001-1 ja

WAFF50-EN-00(07/05/2019) W3-8-1-2
 SECTION3 UPPERSTRUCTURE
Group8 Revolution Sensing Valve

Installation of Revolution Sensing Valve

1. Install all removed adapters to revolution sensing valve (5).

2. Install revolution sensing valve (5) to frame (6) with bolts, washers (4) (2 used).
: 13 mm
: 10 N·m
3. Connect hoses (3) (6 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m

6 3 5 4
WAFF-03-08-001-1 ja

WAFF50-EN-00(07/05/2019) W3-8-2-1
 SECTION3 UPPERSTRUCTURE
Group8 Revolution Sensing Valve

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

4. Install cover (2) with bolts, washers (1) (4 used).

: 17 mm
: 50 N·m

1
2
WAFF-03-07-011-2 ja

WAFF50-EN-00(07/05/2019) W3-8-2-2
 SECTION3 UPPERSTRUCTURE
Group8 Revolution Sensing Valve

Disassembly of Revolution Sensing Valve

13
12
14
11

24
25
26
27
28

3 16
17
15
18
2 32

20
21
8
9
10

23
22
29
30
31
28

WAEQ-03-08-002-1 ja
1- Body 12- Spring 20- Spool 27- Washer
2- Differential Reducing Valve 13- Spool 21- Spring 28- Lock Nut (2 Used)
3- Variable Metering Valve 14- O-Ring 22- Spring Seat 29- O-Ring
8- O-Ring 15- Spring 23- Cartridge 30- Plug
9- O-Ring 16- O-Ring 24- Cartridge 31- Washer
10- O-Ring 17- Guide 25- O-Ring 32- Ball
11- O-Ring 18- Piston 26- Plug

WAFF50-EN-00(07/05/2019) W3-8-3-1
 SECTION3 UPPERSTRUCTURE
Group8 Revolution Sensing Valve

IMPORTANT
Replace differential reducing valve (2) as an assembly excluding O-rings (8, 9, 16). Replace variable metering valve
(3) as an assembly excluding O-ring (14).

IMPORTANT
Do not turn lock nuts (b) of differential reducing valve (2) and variable metering valve (3).

1. Remove differential reducing valve (2) from body (1). Remove piston (18) and spring (15) from body (1) by using a
magnet.
: 24 mm

a b

WAEJ-03-10-102-1 ja

a- Cartridge b- Lock Nut

2. Install bolt (M8, Pitch 1.25 mm) to the pulling-out hole of guide (17). Remove guide (17) from body (1).

CAUTION
Spool (13) and spring (12) may be left in body (1) when removing cartridge (24) from body (1). Remove spool (13)
and spring (12) by using a magnet.

3. Remove variable metering valve (3), spring (12), and spool (13) from body (1).
: 24 mm

WAFF50-EN-00(07/05/2019) W3-8-3-2
 SECTION3 UPPERSTRUCTURE
Group8 Revolution Sensing Valve

Assembly of Revolution Sensing Valve

25 24 11 12 13 14

26

27
28

31
30
29 15

23 22 10 21 1 20 9 8 18 17 16

WAEJ-03-10-104-2 ja
1- Body 12- Spring 20- Spool 27- Washer
2- *1Differential Reducing Valve 13- Spool 21- Spring 28- Lock Nut (2 Used)
*1Variable Metering Valve 14- O-Ring 22- Spring Seat 29- O-Ring
3-
15- Spring 23- Cartridge 30- Plug
8- O-Ring
16- O-Ring 24- Cartridge 31- Washer
9- O-Ring
17- Guide 25- O-Ring 32- *1Ball
10- O-Ring
18- Piston 26- Plug
11- O-Ring
As for the item with mark *1, refer to "Disassembly of Revolution Sensing Valve"W3-8-3-1.

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

1. Install spring (12) and spool (13) to cartridge (24).

IMPORTANT
Install cartridge (24) with the spool (13) and spring (12) mounting side up. In case cartridge (24) cannot be
installed to body (1) by hand, spool (13) may have come off. Remove cartridge (24) from body (1) and check if the
spool sliding surface is damaged.

2. Install cartridge (24) to body (1) and turn it by one to two turns by hand. Tighten cartridge (24).
: 24 mm
: 55 to 61 N·m
3. Apply grease onto spring (15). Install piston (18) and spring (15) to guide (17). Install the guide (17) assembly to
cartridge (23).

WAFF50-EN-00(07/05/2019) W3-8-4-1
 SECTION3 UPPERSTRUCTURE
Group8 Revolution Sensing Valve

IMPORTANT
Install cartridge (23) with the piston (15) mounting side up. In case cartridge (23) cannot be installed to body (1)
by hand, the guide (17) assembly may have come off cartridge (23). Remove cartridge (23) from body (1) and
check if the sliding surfaces of piston (18) and guide (17) are damaged.

4. Install cartridge (23) to body (1) and turn it by one to two turns by hand. Tighten cartridge (23).
: 24 mm
: 85 to 94 N·m
IMPORTANT
Do not turn lock nuts of differential reducing valve (2) and variable metering valve (3).

WAFF50-EN-00(07/05/2019) W3-8-4-2
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

Removal of Muffler Filter

　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, 　
install the clips after connecting the hoses.
　
1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.) 　
2. Tilt up the floor. (Refer to the operator's manual.)
3. Remove bolts, washers (1) (2 used) Remove pipe (2). 　
: 17 mm
　
4. Remove bolts, washers (4) (5 used) Remove cover (3).
: 17 mm 　
5. Remove bolts, washers (5) (3 used) and bolts, washers (6) (2 used). Remove cover (7).
: 17 mm 　
1 2 4 3 4
　
　
4
　

5
　
　
　
　
7

5
WAFF-03-09-001-1 ja

WAFF50-EN-00(07/05/2019) W3-9-1-1
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

6. Remove bolts, washers (19) (2 used), washer (20), and clip (21).
: 17 mm
19 20, 21

WAFF-03-09-002-1 ja
7. Remove bolts, washers (23) (2 used) and washer (25). Remove cover (24).
: 17 mm

CAUTION
Support (28) weight: 22 kg

8. Attach a nylon sling onto support (28), then hoist and hold it.
9. Remove bolts, washers (30) (4 used) Remove the plate (29) assembly.
: 19 mm
10. Remove bolts, washers (31) (4 used) Remove plate (32).
: 19 mm

WAFF50-EN-00(07/05/2019) W3-9-1-2
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

11. Remove bolts (27) (2 used), washers (26) (2 used) and bolts, washers (37) (2 used). Remove support (28).
: 19 mm, 24 mm
23 24 25

26 27

28
37

32 31 30 29
WAFF-03-09-003-1 ja
12. Remove bolt (33), nut (35), spring washer (36), and washers (34) (2 used).
: 17 mm
13. Remove pipe (17) and clamp (16).
14. Remove clip band (18).

IMPORTANT
After disconnecting connector (9) from muffler filter (11), cap connector (9)

15. Disconnect connectors (9) (3 used).

WAFF50-EN-00(07/05/2019) W3-9-1-3
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

16. Remove nuts (10) (4 used).

: 12 mm
9 34, 35, 36 17 33, 34

16
18

11

10
WAFF-03-09-004-1 ja

CAUTION
Muffler filter (11) assembly weight: 23 kg

17. Install shackles (2 used) to lifting brackets (a) (2 places) of muffler filter (11). Attach nylon slings onto the shackles (2
used), then hoist and hold the muffler filter (11) assembly.

IMPORTANT
Take care not to break pipe (13).

18. Remove bolts, washers (12) (4 used) Remove the muffler filter (11) assembly.
: 14 mm

WAFF50-EN-00(07/05/2019) W3-9-1-4
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

IMPORTANT
Gasket (14) cannot be reused.

19. Remove gasket (14).

a

11

12
13

12

14
WAFF-03-09-005-1 ja
a- Lifting Bracket

WAFF50-EN-00(07/05/2019) W3-9-1-5
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

MEMO

WAFF50-EN-00(07/05/2019) W3-9-1-6
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

Installation of Muffler Filter

CAUTION
Muffler filter (11) assembly weight: 23 kg

1. Loosen bolts (15) (2 used).

: 14 mm
2. Install shackles (2 used) to lifting brackets (a) (2 places) of muffler filter (11). Attach nylon slings onto the shackles (2
used). Hoist the muffler filter (11) assembly.

IMPORTANT
Check the direction to install the muffler filter (11) assembly.

IMPORTANT
Take care not to break pipe (13).

3. Install the muffler filter (11) assembly while fitting to pipe (13).
4. Temporarily install bolts, washers (12) (4 used).
: 14 mm
a
15

11

12
13

12

WAFF-03-09-005-3 ja
a- Lifting Bracket

IMPORTANT
Replace gasket (14) with the new one.

5. Temporarily install exhaust pipe (8) and gasket (14) with nuts (10a to 10d).
: 12 mm
6. Tighten nuts (10a to 10d) in order of 10a to 10d.
: 12 mm
: 32 ± 3 N·m
7. Tighten bolts, washers (12a to 12d) in order of 12a to 12d.
: 14 mm
: 49 ± 5 N·m

WAFF50-EN-00(07/05/2019) W3-9-2-1
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

8. Tighten bolts (15a to 15b) in order of 15a to 15b.

: 14 mm
: 49 ± 5 N·m
9. Remove the caps (3 used) from connectors (9) (3 used). Connect connectors (9) (3 used).
10. Install clip band (18).
11. Install clamp (16) and pipe (17) with bolt (33), nut (35), spring washer (36), and washers (34) (2 used).
: 17 mm
: 50 N·m
9 34, 35, 36 17 33, 34

16
15b 18

10c

15a
10a

12b
12d
11

10b
14

12a 12c 10d 8 14 10

WAFF-03-09-006-1 ja
12. Install plate (32) with bolts, washers (31) (2 used).
: 19 mm
: 90 N·m
13. Install the plate (29) assembly with bolts, washers (30) (2 used).
: 19 mm
: 90 N·m

CAUTION
Support (28) weight: 22 kg

14. Attach a nylon sling onto support (28), then hoist it.
15. Install support (28) with bolts, washers (37, 38, 39) (2 used for each), washers (26) (2 used), and bolts (27) (2 used).
: 19 mm
: 90 N·m
: 24 mm
: 210 N·m

WAFF50-EN-00(07/05/2019) W3-9-2-2
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

16. Install cover (24) with bolts, washers (23) (3 used) and bolt, washer (25).
: 17 mm
: 50 N·m
23 24 25

26 27

28
37

32 31 39 38 30 29
WAFF-03-09-003-2 ja
17. Install bolts, washers (19) (2 used). Install clip (21) with bolt, washer (20).
: 17 mm
: 50 N·m
19 20, 21

WAFF-03-09-002-1 ja
18. Install cover (7) with bolts, washers (5) (3 used) and bolts, washers (6) (2 used).
: 17 mm
: 50 N·m

WAFF50-EN-00(07/05/2019) W3-9-2-3
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

19. Install cover (3) with bolts, washers (4) (5 used).

: 17 mm
: 50 N·m
20. Install pipe (2) with bolts, washers (1) (2 used).
: 17 mm
: 50 N·m
1 2 4 3 4

5
WAFF-03-09-001-1 ja
21. Tilt down the floor. (Refer to the operator's manual.)

WAFF50-EN-00(07/05/2019) W3-9-2-4
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

Disassembly of Muffler Filter

WAEJ-03-12-001-1 ja

WAFF50-EN-00(07/05/2019) W3-9-3-1
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

1- Clip (2 Used) 9- Flange (5 Used) 17- Flange 25- Hose

2- Clip 10- Gasket (2 Used) 18- Filter 26- Clip (2 Used)
3- Band 11- Stay 19- Diesel Oxidation Catalyst 27- Hose
4- Sensor 12- Flange 20- Bolt (2 Used) 28- Pipe
5- Sensor 13- Bolt (2 Used) 21- Bolt (2 Used) 29- Bracket
6- Bracket 14- Nut (20 Used) 22- Gasket (4 Used) 30- Sensor
7- Bolt (2 Used) 15- Muffler 23- Pipe 31- Bolt (2 Used)
8- Bolt (20 Used) 16- Flange 24- Clip (2 Used)

IMPORTANT
Cap the open ends in case the connectors, hoses, and pipes have been disconnected. In addition, attach
identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have
been removed, install the clips after connecting the hoses.

1. Remove band (3) from sensors (4, 5).

2. Remove sensor (4) from the diesel oxidation catalyst (19) assembly.
: 17 mm
3. Remove sensor (5) from the diesel oxidation catalyst (19) assembly.
: 13 mm
4. Remove clip (2) and clips (1) (2 used) from bracket (29). Remove the connectors of sensors (4, 5) from bracket (29).
5. Remove bolts (21) (2 used). Remove gaskets (22) (4 used). Disconnect pipes (23, 18) from the diesel oxidation catalyst
(19) assembly and the filter (18) assembly.
: 21 mm
6. Remove clips (24, 26) (2 used for each). Disconnect the both ends of hoses (25, 27).
7. Remove bolts (31) (2 used). Remove sensor (30) from bracket (29).
: 10 mm
8. Remove bolts (20) (2 used). Remove bracket (29) from flange (16).
: 12 mm
9. Remove bolts (13) (2 used). Remove stay (11) from flange (12).
: 14 mm
10. Put the matching marks between filter (18) and muffler (15), between muffler (15) and flanges (9, 16), and between
filter (18) and flanges (12, 17). Remove bolts (8) (10 used) and nuts (14) (10 used). Remove muffler (15), flanges (9, 12,
16, 17), and gasket (10) from the filter (18) assembly.
: 12 mm
11. Put the matching marks between filter (18) and diesel oxidation catalyst (19), between filter (18) and flanges (9) (2
used), and between diesel oxidation catalyst (19) and flanges (9) (2 used). Remove bolts (8) (10 used) and nuts (14) (10
used). Remove filter (18), flanges (9) (4 used), and gasket (10) from the diesel oxidation catalyst (19) assembly.
: 12 mm
12. Remove bolts (7) (2 used) and bracket (6) from diesel oxidation catalyst (19).
: 12 mm

WAFF50-EN-00(07/05/2019) W3-9-3-2
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

Assembly of Muffler Filter

WAEJ-03-12-001-1 ja

WAFF50-EN-00(07/05/2019) W3-9-4-1
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

1- Clip (2 Used) 9- Flange (5 Used) 17- Flange 25- Hose

2- Clip 10- Gasket (2 Used) 18- Filter 26- Clip (2 Used)
3- Band 11- Stay 19- Diesel Oxidation Catalyst 27- Hose
4- Sensor 12- Flange 20- Bolt (2 Used) 28- Pipe
5- Sensor 13- Bolt (2 Used) 21- Bolt (2 Used) 29- Bracket
6- Bracket 14- Nut (20 Used) 22- Gasket (4 Used) 30- Sensor
7- Bolt (2 Used) 15- Muffler 23- Pipe 31- Bolt (2 Used)
8- Bolt (20 Used) 16- Flange 24- Clip (2 Used)

IMPORTANT
Replace gasket (10) with the new one.

IMPORTANT
Replace bolt (8) and nut (14) with the new ones.

1. Install gasket (10) to diesel oxidation catalyst (19). Fit the matching marks made when disassembling and install filter
(18) to the diesel oxidation catalyst (19) assembly with flanges (9) (4 used), nuts (14) (10 used), and bolts (8) (10 used).
: 12 mm
: 25.5 ± 2.9 N·m

IMPORTANT
Replace gasket (10) with the new one.

IMPORTANT
Replace bolt (8) and nut (14) with the new ones.

2. Install gasket (10) to the filter (18) assembly. Fit the matching marks made when disassembling and install muffler (15)
to the filter (18) assembly with flanges (9, 12, 16, 17), nuts (14) (10 used), and bolts (8) (10 used).
: 12 mm
: 25.5 ± 2.9 N·m

CAUTION
Tighten bolt (13) when installing the muffler filter to the engine.

3. Temporarily install stay (11) to flange (12) with bolts (13) (2 used).
: 14 mm
4. Install bracket (29) to flange (16) with bolts (20) (2 used).
: 12 mm
: 25.5 ± 2.9 N·m
5. Install sensor (30) to bracket (29) with bolts (31) (2 used).
: 10 mm
: 7 ± 1.4 N·m

IMPORTANT
Replace hoses (25, 27) with the new ones.

6. Connect the sensor (30) side of hoses (25, 27) with clips (24, 26). At this time, face hoses (25, 27) toward sensor (30)
without slack.
7. Connect the hose (25, 27) sides of pipes (23, 28) with clips (24, 26).

WAFF50-EN-00(07/05/2019) W3-9-4-2
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

IMPORTANT
Replace bolt (21) with the new one.

IMPORTANT
Replace gaskets (22) (4 used) with the new ones.

8. Apply anti-seize onto the thread parts of bolts (21) (2 used). Connect gaskets (22) (4 used) and pipes (23, 28) to the
diesel oxidation catalyst (19) assembly and the filter (18) assembly with bolts (21) (2 used). At this time, face hoses (25,
27) toward sensor (30) without slack.
: 21 mm
: 29.4 ± 4.9 N·m
9. Install the connectors of sensors (4, 5) to bracket (29) with clip (2) and clips (1) (2 used).
10. Install sensor (5) to the diesel oxidation catalyst (19) assembly.
: 13 mm
: 40 ± 5 N·m
11. Install sensor (4) to the diesel oxidation catalyst (19) assembly.
: 17 mm
: 40 ± 5 N·m
12. Install band (3) to sensors (4, 5).
13. Install bracket (6) to diesel oxidation catalyst (19) with bolts (7) (2 used).
: 12 mm
: 25.5 ± 2.9 N·m

WAFF50-EN-00(07/05/2019) W3-9-4-3
 SECTION3 UPPERSTRUCTURE
Group9 Muffler Filter

MEMO

WAFF50-EN-00(07/05/2019) W3-9-4-4
4

UNDERCARRIAGE

Swing Bearing...................................... W4-1-1-1 Assembly of Blade Cylinder.........................................W4-8-4-1

Removal of Swing Bearing...........................................W4-1-1-1
Installation of Swing Bearing......................................W4-1-2-1
Travel Device........................................ W4-2-1-1
Removal of Travel Device.............................................W4-2-1-1
Installation of Travel Device........................................W4-2-2-1
Disassembly of Travel Device .....................................W4-2-3-1
Assembly of Travel Device...........................................W4-2-4-1
Disassembly of Brake Valve.........................................W4-2-5-1
Assembly of Brake Valve...............................................W4-2-6-1
Center Joint.......................................... W4-3-1-1
Removal of Center Joint ...............................................W4-3-1-1
Installation of Center Joint ..........................................W4-3-2-1
Disassembly of Center Joint........................................W4-3-3-1
Assembly of Center Joint .............................................W4-3-4-1
Track Adjuster...................................... W4-4-1-1
Removal of Track Adjuster ...........................................W4-4-1-1
Installation of Track Adjuster ......................................W4-4-2-1
Disassembly of Track Adjuster ...................................W4-4-3-1
Assembly of Track Adjuster .........................................W4-4-4-1
Front Idler............................................. W4-5-1-1
Removal of Front Idler...................................................W4-5-1-1
Installation of Front Idler..............................................W4-5-2-1
Disassembly of Front Idler ...........................................W4-5-3-1
Assembly of Front Idler.................................................W4-5-4-1
Upper and Lower Rollers..................... W4-6-1-1
Removal of Upper Roller ..............................................W4-6-1-1
Installation of Upper Roller .........................................W4-6-2-1
Removal of Lower Roller...............................................W4-6-3-1
Installation of Lower Roller..........................................W4-6-4-1
Track ..................................................... W4-7-1-1
Removal of Track (Rubber Crawler) ..........................W4-7-1-1
Installation of Track (Rubber Crawler) .....................W4-7-2-1
Removal of Track (Steel Crawler)...............................W4-7-3-1
Installation of Track (Steel Crawler)..........................W4-7-4-1
Blade Cylinder...................................... W4-8-1-1
Removal of Blade Cylinder...........................................W4-8-1-1
Installation of Blade Cylinder......................................W4-8-2-1
Disassembly of Blade Cylinder...................................W4-8-3-1

WAFF50-EN-00(07/05/2019)
MEMO

WAFF50-EN-00(07/05/2019)
 SECTION4 UNDERCARRIAGE
Group1 Swing Bearing

Removal of Swing Bearing

Before removing and installing the swing bearing, the upperstructure must be removed first.
Therefore, the procedure starts on the premise that the upperstructure has already been removed here.
1. Put matching marks (a) on inner race (3) of swing bearing (1) and track frame (4).
2. Remove knock pins (2) (2 used).

NOTE
THREEBOND #1102 has been applied onto knock pin (2).

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

: 22 mm

2
2

4 a 3

WABA-04-01-100-1 ja

a- Matching Mark

WAFF50-EN-00(07/05/2019) W4-1-1-1
 SECTION4 UNDERCARRIAGE
Group1 Swing Bearing

CAUTION
Swing bearing (1) weight: 71 kg

4. Install special tools (ST 0052) (3 used) to swing bearing (1). Attach wire ropes onto special tools (ST 0052) (3 used).
Hoist swing bearing (1). Remove swing bearing (1) from track frame (4).

NOTE
THREEBOND #1102 has been applied onto the contacting surface.

ST 0052

WABA-04-01-101-1 ja

WAFF50-EN-00(07/05/2019) W4-1-1-2
 SECTION4 UNDERCARRIAGE
Group1 Swing Bearing

Installation of Swing Bearing

1. Clean the mounting surfaces of track frame (4) and swing bearing (1).
2. Apply THREEBOND #1102 onto the swing bearing (1) mounting surface of track frame (4).

CAUTION
Swing bearing (1) weight: 71 kg

3. Install special tools (ST 0052) (3 used) to swing bearing (1). Attach wire ropes onto special tools (ST 0052) (3 used).
Hoist swing bearing (1).

ST 0052

WABA-04-01-101-1 ja

IMPORTANT
If matching marks (a) do not fit, soft zone position (b) of the inner race will be dislocated.

4. Fit matching marks (a) made when disassembling on track frame (4) and inner race (3) of swing bearing (1).
5. Install swing bearing (1) with bolts (5) (24 used).
: 22 mm
: 180 N·m

WAFF50-EN-00(07/05/2019) W4-1-2-1
 SECTION4 UNDERCARRIAGE
Group1 Swing Bearing

IMPORTANT
Check the position to install knock pin (2).

6. Apply THREEBOND #1102 onto knock pin (2). Install knock pins (2) (2 used) by using a plastic hammer.

d
5

2 c

(6°)
2 e
7.5°
d

4 a 3

b b
WAFF-04-01-001-1 ja

a- Matching Mark b- Soft Zone Marking Posi­ c- Machine Front Side d- Position for Knock Pin
tion
e- Oil Supplying Part

WAFF50-EN-00(07/05/2019) W4-1-2-2
 SECTION4 UNDERCARRIAGE
Group2 Travel Device 　

Removal of Travel Device

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

The procedure starts on the premise that the track links have been removed. (Refer to "Removal of Track (Rubber
Crawler)"W4-7-1-1 / "Removal of Track (Steel Crawler)"W4-7-3-1.)

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

2. Remove bolts (3) (3 used) and washers (4) (3 used). Remove cover (2) from track frame (1).
: 19 mm

3, 4

WAEJ-04-02-100-1 ja
3. Disconnect hoses (8) (4 used) from travel device (7).
: 17 mm, 27 mm

CAUTION
Travel device (7) weight: 77 kg

4. Attach nylon slings onto travel device (7), then hoist and hold it. Remove bolts (5) (12 used) and washers (6) (12 used).
Hoist and remove travel device (7).
: 22 mm

NOTE
LOCTITE #262 has been applied onto bolt (5).

WAFF50-EN-00(07/05/2019) W4-2-1-1
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

5. Remove the adapters attached to travel device (7) if necessary.

7 5, 6

WAEJ-04-02-101-1 ja
6. Remove other travel device in the same way.

WAFF50-EN-00(07/05/2019) W4-2-1-2
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

Installation of Travel Device

1. Install all removed adapters to travel device (7).

CAUTION
Travel device (7) weight: 77 kg

2. Apply LOCTITE #262 onto bolt (5). Attach nylon slings onto travel device (7) and hoist it. Install travel device (7) with
washers (6) (12 used) and bolts (5) (12 used).
: 22 mm
: 220 N·m
3. Connect hoses (8) (4 used) to travel device (7).
: 17 mm
: 25 N·m
: 27 mm
: 80 N·m

7 5, 6

WAEJ-04-02-101-1 ja
4. Connect the track link. (Refer to "Installation of Track (Rubber Crawler)"W4-7-2-1 / "Installation of Track (Steel
Crawler)"W4-7-4-1.)
5. Install other travel device in the same way.
6. Bleed air from the hydraulic system. (Refer to "Bleeding Air from Hydraulic System"W1-4-1-1.)

WAFF50-EN-00(07/05/2019) W4-2-2-1
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage. In order to prevent the
travel motor from seizing, perform the break-in operation after installing.

Condition: 1. Engine speed: Slow idle speed

2. Travel mode switch: Slow speed
3. Operation duration: Over 2 minutes

7. Install cover (2) to track frame (1) with bolts (3) (3 used) and washers (4) (3 used).
: 19 mm
: 110 N·m

3, 4

WAEJ-04-02-100-1 ja
8. Install other cover in the same way.

WAFF50-EN-00(07/05/2019) W4-2-2-2
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

Disassembly of Travel Device

11
10
9
8
7
6

5
4
3 27
2 26b
1 26a

25

24

23
22
20

19
18
17
16
15
14
13
12
41
40
39
38
37
36
35
21
34
33

32
31
30
29
28
53
52
51 54
42 50
49
43 48
47

46
45
63
44
65 64

WAEJ-04-02-102-2 ja

WAFF50-EN-00(07/05/2019) W4-2-3-1
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

1- Plug (3 Used) 15- Thrust Plate 28- Oil Seal 43- Spring (2 Used)
2- O-Ring (3 Used) 16- Second Stage Planetary Gear 29- Ball Bearing 44- Valve Plate
3- Cover (4 Used) 30- Shaft 45- Ball Bearing
4- O-Ring 17- Needle Bearing (4 Used) 31- Steel Ball (2 Used) 46- O-Ring
5- Wire 18- Inner Race (4 Used) 32- Swash Plate 47- Disc Plate
6- Thrust Plate 19- Thrust Washer (4 Used) 33- Plunger (9 Used) 48- O-Ring
7- First Stage Planetary Gear (3 20- Ring Gear 34- Retainer Plate 49- O-Ring
Used) 21- Plug (2 Used) 35- Holder 50- Brake Piston
8- Needle Bearing (3 Used) 22- Plug (2 Used) 36- Pin (3 Used) 51- Spring (4 Used)
9- Inner Race (3 Used) 23- Bearing Nut 37- Rotor 52- Spring (8 Used)
10- Thrust Washer (3 Used) 24- Bearing 38- Collar 53- Brake Valve
11- First Stage Carrier 25- Steel Ball (99 Used) 39- Spring 54- Socket Bolt (6 Used)
12- Drive Gear 26a- Floating Seal 40- Washer 63- O-Ring (4 Used)
13- Sun Gear 26b- Floating Seal 41- Retaining Ring 64- Pin (4 Used)
14- Screw (4 Used) 27- Body 42- Piston (2 Used) 65- Pin

CAUTION
The travel device weight: 60 kg

1. Remove plugs (1) (3 used) and O-rings (2) (3 used) from cover (3). Drain gear oil from the travel device.
: 6 mm

NOTE
Oil amount: 0.9 L

IMPORTANT
Do not drop valve plate (44) while removing brake valve (53).

2. Hoist the travel device and place it with the motor side up. Remove socket bolts (54) (6 used). Record the clearance
between brake valve (53) and body (27). Remove brake valve (53) and valve plate (44).
: 10 mm
3. Remove pins (64) (4 used), pin (65), O-rings (63) (4 used), and O-ring (46) from brake valve (53).

IMPORTANT
Replace disc plate (47), brake piston (50), and springs (51, 52) as an assembly.

4. Remove springs (51) (4 used) and springs (52) (8 used) from brake piston (50).

CAUTION
When removing brake piston (50) by applying air to body (27), hold brake piston (50) with a cloth to prevent it
from jumping out.

5. Put the matching marks on brake piston (50) and body (27). Apply air to the brake releasing oil passage of body (27).
Raise and remove brake piston (50).
6. Remove O-rings (48, 49) from brake piston (50).
7. Remove disc plate (47) from body (27).

IMPORTANT
Replace body (27) and piston (42) as an assembly.

8. Remove the rotor (37) assembly, ball bearing (45), swash plate (32), steel balls (31) (2 used), pistons (42) (2 used), and
springs (43) (2 used) from body (27).

WAFF50-EN-00(07/05/2019) W4-2-3-2
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

IMPORTANT
Replace plunger (33), retainer plate (34), holder (35), pin (36), rotor (37), collar (38), spring (39), washer (40), and
retaining ring (41) as an assembly.

9. Remove plungers (33) (9 used), retainer plate (34), holder (35), and pins (36) (3 used) from rotor (37).

CAUTION
When removing retaining ring (41), push washer (40) and spring (39) by using a press to prevent them from
jumping out.

10. Push washer (40) and spring (39) by using a press and remove retaining ring (41). Remove washer (40), spring (39), and
collar (38) from rotor (37).

CAUTION
The ring gear (20) assembly weight: 35 kg

IMPORTANT
Replace ring gear (20) as an assembly.

11. Install eyebolt (M12, Pitch 1.75 mm) to the socket bolt (54) mounting hole of body (27). Hoist body (27) and place it
with the body (27) side down onto wooden blocks (50×400 mm, 1.97×15.7 in).
12. Remove plug (21) at the cover (3) side from ring gear (20).
: 5 mm
13. Install eyebolt (G1/4) (2 used) to the plug (1) mounting hole of cover (3). Insert a steel pipe (16) into the eyebolt hole.
14. Turn cover (3) by using a steel pipe until wire (5) can be seen through the hole for plug (21). When wire (5) can be seen
through the plug (21) mounting hole at the cover (3) mounting side, remove wire (5) through the hole by using a
screw driver.
15. Attach the wire ropes onto the eyebolts of cover (3). Hoist and remove cover (3) from ring gear (20).
16. Remove O-ring (4) from cover (3).
17. Remove thrust plate (6), drive gear (12), the first stage carrier (11) assembly, and sun gear (13) from ring gear (20).
18. Remove first stage planetary gears (7) (3 used), needle bearings (8) (3 used), inner races (9) (3 used), and thrust
washers (10) (3 used) from first stage carrier (11).
19. Remove screws (14) (4 used), thrust plate (15), second stage planetary gears (16) (4 used), needle bearings (17) (4
used), inner races (18) (4 used), and thrust washers (19) (4 used) from body (27).
: 5 mm

NOTE
LOCTITE #262 has been applied onto screw (14).

20. Remove plug (21) at the body (27) side from ring gear (20). Remove steel balls (25) (99 used) from the mounting hole
at the plug (21) side.
: 5 mm

WAFF50-EN-00(07/05/2019) W4-2-3-3
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

21. Install socket bolts (M14, Pitch 2.0 mm, Length: 40 mm or more) (3 used) to the sprocket mounting holes. Tighten the
bolts evenly. Remove ring gear (20) from body (27).
: 12 mm

20

27
a a

WAEJ-04-02-103-1 ja

a- Wooden Block b- Plate

22. Remove plugs (22) (2 used) from bearing nut (23).

NOTE
Plug (22) has been crimped by using a punch at two places after installing.

: 8 mm

IMPORTANT
Bearing nut (23) cannot be reused.

23. Remove bearing nut (23) from body (27) by using special tool (ST 3349).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

24. Remove bearing (24) from body (27) by using a bar and a hammer.
IMPORTANT
Handle floating seals (26a, 26b) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)

25. Remove floating seals (26a, 26b) from body (27) and ring gear (20) by using a screw driver.
26. Remove the shaft (30) assembly from body (27) by using a bar and a plastic hammer.

IMPORTANT
Oil seal (28) cannot be reused.

27. Remove oil seal (28) from the shaft (30) hole of body (27) by using a screw driver.

WAFF50-EN-00(07/05/2019) W4-2-3-4
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

28. Secure the inner race part of ball bearing (29) which is remained in shaft (30) in a vise. Remove ball bearing (29) from
shaft (30) by using a bar and a plastic hammer.

29

30

WAEJ-04-02-104-1 ja

c- Bar

WAFF50-EN-00(07/05/2019) W4-2-3-5
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

MEMO

WAFF50-EN-00(07/05/2019) W4-2-3-6
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

Assembly of Travel Device

33 63 49 34 32 27 26b 26a 21 25 24 23 22 20 28 11 7 21

37
4
64
2
40
1
41
45 3

9
8
10

12
13
30
6
53 44
39 14
65
38
51
52

54 46 50 48 47 36 35 29 42 43 19 16 17 18 15 5

WAEJ-04-02-105-2 ja
1- Plug (3 Used) 15- Thrust Plate 28- Oil Seal 43- Spring (2 Used)
2- O-Ring (3 Used) 16- Second Stage Planetary Gear 29- Ball Bearing 44- Valve Plate
3- Cover (4 Used) 30- Shaft 45- Ball Bearing
4- O-Ring 17- Needle Bearing (4 Used) 31- *1Steel Ball (2 Used) 46- O-Ring
5- Wire 18- Inner Race (4 Used) 32- Swash Plate 47- Disc Plate
6- Thrust Plate 19- Thrust Washer (4 Used) 33- Plunger (9 Used) 48- O-Ring
7- First Stage Planetary Gear (3 20- Ring Gear 34- Retainer Plate 49- O-Ring
Used) 21- Plug (2 Used) 35- Holder 50- Brake Piston
8- Needle Bearing (3 Used) 22- Plug (2 Used) 36- Pin (3 Used) 51- Spring (4 Used)
9- Inner Race (3 Used) 23- Bearing Nut 37- Rotor 52- Spring (8 Used)
10- Thrust Washer (3 Used) 24- Bearing 38- Collar 53- Brake Valve
11- First Stage Carrier 25- Steel Ball (99 Used) 39- Spring 54- Socket Bolt (6 Used)
12- Drive Gear 26a- Floating Seal 40- Washer 63- O-Ring (4 Used)
13- Sun Gear 26b- Floating Seal 41- Retaining Ring 64- Pin (4 Used)
14- Screw (4 Used) 27- Body 42- Piston (2 Used) 65- Pin

As for the item with mark *1, refer to "Disassembly of Travel Device"W4-2-3-1.

WAFF50-EN-00(07/05/2019) W4-2-4-1
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

1. Place body (27) with the brake valve (53) mounting surface up. Clean the oil seal (28) mating surface of body (27).
Install oil seal (28) to body (27) by using special tool (ST 2726).

ST 2726

27 28

WAEJ-04-02-106-1 ja
2. Install ball bearing (29) to shaft (30) by using special tool (ST 2727) and a plastic hammer.

30

29

ST 2727

W178-02-11-230-3 ja

IMPORTANT
Handle floating seals (26a, 26b) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)

3. Install floating seals (26a, 26b) to body (27) and ring gear (20) by using special tool (ST 2728).

IMPORTANT
Replace bearing nut (23) with the new one.

4. Install bearing (24) to ring gear (20) by using special tool (ST 2729).
5. Install body (27) to ring gear (20).
6. Install bearing nut (23) to body (27) by using special tool (ST 3349).
: 240 ± 10 N·m
7. Install plugs (22) (2 used) to bearing nut (23).
: 8 mm
: 35 ± 5 N·m
8. Crimp plug (22) by using a punch at two places.

WAFF50-EN-00(07/05/2019) W4-2-4-2
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

9. Install a seal tape onto plug (21). Install steel balls (25) (99 used) through the plug (21) mounting hole at the body (27)
side. Install plug (21).
: 5 mm
: 8 ± 1 N·m
10. Apply LOCTITE #262 onto screw (14). Install thrust washers (19) (4 used), inner races (18) (4 used), needle bearings (17)
(4 used), second stage planetary gears (16) (4 used), thrust plate (15), and screws (14) (4 used) to body (27) in
sequence.
: 5 mm
: 25 ± 5 N·m
11. Install sun gear (13) to ring gear (20).
12. Install first stage carrier (11) to sun gear (13).
13. Install thrust washers (10) (3 used), inner races (9) (3 used), needle bearings (8) (3 used), and first stage planetary gears
(7) (3 used) to first stage carrier (11).
14. Install drive gear (12) to ring gear (20).
15. Install thrust plate (6) to first stage carrier (11).
16. Install O-ring (4) to cover (3).
17. Install cover (3) to ring gear (20).
18. Install eyebolt (G1/4) (2 used) to the plug (1) mounting hole of cover (3). Insert a steel pipe (16) into the eyebolt hole.
19. Bend the end of wire (5) approx. 6mm and around 90 degrees. Insert wire (5) into the plug (21) mounting hole. Wind
wire (5) by turning cover (3) by using a steel pipe.
20. Install a seal tape onto plug (21). Install plug (21) to ring gear (20).
: 5 mm
: 8 ± 1 N·m
21. Apply grease onto the sliding part and the side surface of oil seal (28). Install the shaft (30) assembly to body (27) by
using a plastic hammer.
22. Install steel balls (31) (2 used), springs (43) (2 used), pistons (42) (2 used), and swash plate (32) to body (27).
23. Install collar (38), spring (39), and washer (40) to rotor (37) in sequence.

CAUTION
When installing retaining ring (41) to rotor (37), push washer (40) and spring (39) by using a press in order not to
fly out.

24. Push washer (40) and spring (39) by using a press and install retaining ring (41) to rotor (37).
25. Install pins (36) (3 used) to rotor (37). Place holder (35) onto pin (36).
26. Install plungers (33) (9 used) and retainer plate (34) to rotor (37).
27. Install the rotor (37) assembly to body (27).
28. Install disc plate (47) to body (27).
29. Install O-rings (48, 49) to brake piston (50).
30. Fit the matching marks on brake piston (50) and body (27). Install the brake piston (50) assembly to body (27) by
tapping it evenly by using a plastic hammer.
31. Install O-ring (46) to body (27).
32. Place springs (51) (4 used) and springs (52) (8 used) onto brake piston (50).
33. Install ball bearing (45) to brake valve (53) by using special tool (ST 2730).

WAFF50-EN-00(07/05/2019) W4-2-4-3
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

IMPORTANT
Check the direction to install valve plate (44).

34. Apply grease onto the contacting surfaces of brake valve (53) and valve plate (44). Install O-rings (63) (4 used), pins
(64) (4 used), and valve plate (44) to brake valve (53).

IMPORTANT
Check the clearance between body (27) and brake valve (53). If the clearance is larger, the component parts may
not be installed correctly.

35. Install brake valve (53) to body (27) with socket bolts (54) (6 used).
: 10 mm
: 129 ± 7 N·m
36. Add gear oil through the plug (1) mounting hole of cover (3). Install O-rings (2) (3 used) to plugs (1) (3 used). Install
plugs (1) (3 used) to cover (3).
: 6 mm
: 23 ± 1 N·m

NOTE
Oil amount: 0.9 L

WAFF50-EN-00(07/05/2019) W4-2-4-4
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

Disassembly of Brake Valve

WAEJ-04-02-107-1 ja
1- Spool 7- Spool 13- Check Valve (2 Used) 58- Spring Seat (2 Used)
2- Spring Seat (2 Used) 8- Spool 14- Plug (2 Used) 59- Spool
3- Spring (2 Used) 9- Body 15- O-Ring (2 Used) 60- Valve Body
4- Plug 10- Cap (2 Used) 55- Plug (2 Used) 61- Socket Bolt (3 Used)
5- O-Ring 11- O-Ring (2 Used) 56- O-Ring (2 Used) 62- O-Ring (3 Used)
6- Spring 12- Spring (2 Used) 57- Spring (2 Used) 63- Spring Seat

WAFF50-EN-00(07/05/2019) W4-2-5-1
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

IMPORTANT
Replace spring (57), spring seat (58), spool (59), and valve body (60) as an assembly.

1. Remove plugs (55) (2 used), O-rings (56) (2 used), springs (57) (2 used), spring seats (58) (2 used), and spool (59) from
valve body (60).
: 8 mm
2. Remove socket bolts (61) (3 used). Remove valve body (60) and O-rings (62) (3 used) from body (9).
: 6 mm

IMPORTANT
Replace spools (1, 7, 8), body (9), spring (12), check valve (13), and plug (14) as an assembly.

3. Remove plug (4), spring seat (63), spring (6), O-ring (5), and spools (7, 8) from body (9).
: 8 mm
4. Remove caps (10) (2 used), springs (3) (2 used), O-rings (11) (2 used), and spring seats (2) (2 used) from body (9).
: 36 mm

IMPORTANT
Do not damage the spool (1) assembly when pulling it out.

5. Remove the spool (1) assembly by rotating it slowly.

6. Insert a round bar (diameter: 5 mm, length: 30 mm (1.18 in)) into the through hole of spool (1) and secure it in a vise.
Remove plugs (14) (2 used) from spool (1). Remove O-rings (15) (2 used) from plugs (14) (2 used).
: 6 mm

IMPORTANT
Check the combination of check valves (13) at the left and right. Keep the parts so that they can be assembled as
the original condition before disassembling.

7. Remove springs (12) (2 used) and check valves (13) (2 used) from spool (1).

WAFF50-EN-00(07/05/2019) W4-2-5-2
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

Assembly of Brake Valve

12 13 1
2
11
3

14,15

63

10
4

5
6
9 8 7

55

56

61 60 59 58 57

WAEJ-04-02-108-1 ja
1- Spool 7- Spool 13- Check Valve (2 Used) 58- Spring Seat (2 Used)
2- Spring Seat (2 Used) 8- Spool 14- Plug (2 Used) 59- Spool
3- Spring (2 Used) 9- Body 15- O-Ring (2 Used) 60- Valve Body
4- Plug 10- Cap (2 Used) 55- Plug (2 Used) 61- Socket Bolt (3 Used)
5- O-Ring 11- O-Ring (2 Used) 56- O-Ring (2 Used) 62- *1O-Ring (3 Used)
6- Spring 12- Spring (2 Used) 57- Spring (2 Used) 63- Spring Seat
As for the item with mark *1, refer to "Disassembly of Brake Valve"W4-2-5-1.

WAFF50-EN-00(07/05/2019) W4-2-6-1
 SECTION4 UNDERCARRIAGE
Group2 Travel Device

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
Check the combination of check valves (13) at the left and right. Install them in the same combination before
disassembling.

1. Install springs (12) (2 used) and check valves (13) (2 used) to spool (1).
2. Insert a round bar (diameter: 5 mm, length: 30 mm (1.18 in)) into the through hole of spool (1) and secure it in a vise.
Install O-rings (15) (2 used) to plugs (14) (2 used). Install plugs (14) (2 used) to spool (1).
: 6 mm
: 32 ± 2.5 N·m
3. Install the spool (1) assembly, spring seats (2) (2 used), and springs (3) (2 used) to body (9).
4. Install O-rings (11) (2 used) to caps (10) (2 used). Install caps (10) (2 used) to body (9).
: 36 mm
: 245 ± 5 N·m
5. Install spools (8, 7), spring (6), and spring seat (63) to body (9).
6. Install O-ring (5) to plug (4). Install plug (4) to body (9).
: 8 mm
: 55 ± 5 N·m
7. Install O-rings (62) (3 used) and valve body (60) to body (9) with socket bolts (61) (3 used).
: 6 mm
: 38 ± 2 N·m
8. Install spool (59), spring seats (58) (2 used), and springs (57) (2 used) to valve body (60).
9. Install O-rings (56) (2 used) to plugs (55) (2 used). Install plugs (55) (2 used) to valve body (60).
: 8 mm
: 55 ± 5 N·m

WAFF50-EN-00(07/05/2019) W4-2-6-2
 SECTION4 UNDERCARRIAGE
Group3 Center Joint 　
　
Removal of Center Joint

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

2. Tilt up the floor. (Refer to the operator's manual.)

3. Disconnect hoses (1) (8 used).
: 17 mm, 22 mm, 27 mm
4. Remove bolts (4) (2 used) and washers (5) (2 used). Remove stopper (3).
: 19 mm

NOTE
LOCTITE #262 has been applied onto bolt (4).

4, 5

1
WAFF-04-03-001-1 ja

WAFF50-EN-00(07/05/2019) W4-3-1-1
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

CAUTION
Remove cover (6) while holding cover (6). Do not drop cover (6).

5. Remove bolts (7) (4 used), collars (8) (4 used) and washers (9) (4 used) from track frame (10). Remove cover (6) from
track frame (10).
: 17 mm

10

7, 8, 9

WAEJ-04-03-101-1 ja
6. Disconnect hoses (11) (10 used) from center joint (2).
: 17 mm, 22 mm, 27 mm

CAUTION
Center joint (2) weight: 22 kg

7. Install special tool (ST 0261) to adapter (14) of center joint (2). Attach nylon slings onto special tool (ST 0261). Hoist and
hold center joint (2).
8. Remove bolts (12) (4 used) and washers (13) (4 used). Lower and remove center joint (2).
: 22 mm

NOTE
LOCTITE #262 has been applied onto bolt (12).

WAFF50-EN-00(07/05/2019) W4-3-1-2
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

9. Remove the adapter attached to center joint (2) if necessary.

11 14

12, 13

11 2
WAFF-04-03-002-1 ja

WAFF50-EN-00(07/05/2019) W4-3-1-3
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

MEMO

WAFF50-EN-00(07/05/2019) W4-3-1-4
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

Installation of Center Joint

1. Install all removed adapters to center joint (2).

CAUTION
Center joint (2) weight: 22 kg

2. Install special tool (ST 0261) to adapter (14) of center joint (2). Attach nylon slings onto special tool (ST 0261). Hoist
center joint (2).
3. Apply LOCTITE #262 to bolt (12). Install center joint (2) to the track frame with bolts (12) (4 used) and washers (13) (4
used).
: 22 mm
: 140 N·m
4. Connect hoses (11) (10 used) to center joint (2).
: 17 mm
: 25 N·m
: 22 mm
: 40 N·m
: 27 mm
: 80 N·m
11 14

12, 13

11 2
WAFF-04-03-002-1 ja
5. Apply LOCTITE #262 to bolt (4). Install stopper (3) with bolts (4) (2 used) and washers (5) (2 used).
: 19 mm
: 90 N·m

WAFF50-EN-00(07/05/2019) W4-3-2-1
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

6. Connect hoses (1) (8 used).

: 17 mm
: 25 N·m
: 22 mm
: 40 N·m
: 27 mm
: 80 N·m
1

4, 5

1
WAFF-04-03-001-1 ja
7. Tilt down the floor. (Refer to the operator's manual.)

IMPORTANT
Check the hydraulic oil level and start the engine. Tilt up the floor and check each part for any oil leakage. After
checking, tilt down the floor. (Refer to the operator's manual.)

8. Install cover (6) to track frame (10) with washers (9) (4 used), collars (8) (4 used), and bolts (7) (4 used).
: 17 mm
: 65 N·m

10

7, 8, 9

WAEJ-04-03-101-1 ja

WAFF50-EN-00(07/05/2019) W4-3-2-2
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

Disassembly of Center Joint

1
2

12

13
11 8

10
7

3
17

15

6 14

WAEJ-04-03-103-1 ja
1- Spindle 5- Pin 9- O-Ring 13- Plug (3 Used)
2- Body 6- Oil Seal (4 Used) 10- Backup Ring 14- Bolt (4 Used)
3- Flange 7- O-Ring 11- Dust Seal 15- Spring Washer (4 Used)
4- Ring 8- O-Ring 12- Retaining Ring 17- Oil Seal (3 Used)

WAFF50-EN-00(07/05/2019) W4-3-3-1
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

CAUTION
Center joint weight: 22 kg

IMPORTANT
Do not disassemble pin (5) and plug (13).

1. Remove bolts (14) (2 used) and spring washers (15) (2 used) diagonally. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
the bolt (14) holes (2 places) of body (2). Attach nylon slings onto the eyebolts. Hoist the center joint. Secure the
center joint on a workbench.
: 17 mm
2. Put the matching marks on body (2) and spindle (1). Remove bolts (14) (4 used) and spring washers (15) (4 used).
Remove flange (3) from body (2).
: 17 mm
3. Remove O-ring (8), retaining ring (12), and ring (4) from body (2).
4. Install special tool (ST 1033) and special tool (ST 1020) to body (2) with bolts (14) (2 used) and spring washers (15) (2
used).
: 17 mm

ST 1020

14, 15
ST 1033

W506-03-03-002-2 ja

IMPORTANT
Do not damage the seal sliding surface of spindle (1).

5. Remove spindle (1) from body (2).

WAFF50-EN-00(07/05/2019) W4-3-3-2
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

IMPORTANT
For easy removal of oil seals (6, 17), use the pins (2 used). Do not damage the seal groove.

6. Remove oil seals (6) (4 used), oil seals (17) (3 used), O-rings (7, 9), backup ring (10), and dust seal (11) from body (2).

W178-02-11-240-1 ja

WAFF50-EN-00(07/05/2019) W4-3-3-3
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

MEMO

WAFF50-EN-00(07/05/2019) W4-3-3-4
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

Assembly of Center Joint

11
7 9

10

17

15 14 3 13 12 8

WAEJ-04-03-104-1 ja
1- Spindle 5- Pin 9- O-Ring 13- Plug (3 Used)
2- Body 6- Oil Seal (4 Used) 10- Backup Ring 14- Bolt (4 Used)
3- Flange 7- O-Ring 11- Dust Seal 15- Spring Washer (4 Used)
4- Ring 8- O-Ring 12- Retaining Ring 17- Oil Seal (3 Used)

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
When assembling the seals, lightly apply grease (Apolloil Autolex C) to the seals. Install the seals to the grooves.

1. Place body (2) with the dust seal (11) mounting side up. Install oil seals (6) (4 used) and oil seals (17) (3 used) to body
(2).
2. Install O-rings (7, 9) and backup ring (10) to body (2).

WAFF50-EN-00(07/05/2019) W4-3-4-1
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

3. Install dust seal (11) to spindle (1) with lip part (a) facing to the body (2) side.

11
a
2

WAEJ-04-03-105-1 ja

a- Lip Part

IMPORTANT
The clearance between body (2) and spindle (1) is approximately 0.1 mm. Install straight and slowly. Do not
damage the seals.

IMPORTANT
Do not make a step on ring (4) mounting part (b).

4. Place spindle (1) with the pin (5) mounting side down on a workbench. Fit the matching marks made when
disassembling. Evenly tap and install body (2) to spindle (1) by using a plastic hammer.

1
b
2

WAEJ-04-03-106-1 ja

b- Ring (4) Mounting Part

WAFF50-EN-00(07/05/2019) W4-3-4-2
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

IMPORTANT
Install ring (4) with chamfered surface (c) facing to the flange (3) side.

5. Install ring (4) and retaining ring (12) to body (2).

c 3 12 4

WAEJ-04-03-107-1 ja

c- Chamfered Side
6. Install O-ring (8) to body (2).
7. Install flange (3) to body (2) with bolts (14) (4 used) and spring washers (15) (4 used).
: 17 mm
: 55 N·m

WAFF50-EN-00(07/05/2019) W4-3-4-3
 SECTION4 UNDERCARRIAGE
Group3 Center Joint

MEMO

WAFF50-EN-00(07/05/2019) W4-3-4-4
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster 　
　
Removal of Track Adjuster
　
Before removing and installing the track adjuster, the track links and front idler must be removed first. (Refer to "Removal
of Track (Rubber Crawler)"W4-7-1-1 / "Removal of Track (Steel Crawler)"W4-7-3-1, "Removal of Front
Idler"W4-5-1-1) Therefore, the procedure starts on the premise that the track links and front idler have already been
removed here.

CAUTION
Track adjuster (1) may fly out due to the spring (b) force when removing track adjuster (1). Do not stand in the
same direction to remove track adjuster (1) or where it may fly out. Thread part (c) of rod (d) is always under a load
of spring (b). When rod (d) or thread part (c) is broken, the load of spring (b) could fly the broken parts out;
especially pay attention to it.

1. Pry and remove track adjuster (1) from track frame (2) by using a bar.

2 1 2
b a

d c

WAEJ-04-04-100-1 ja

a- Nut b- Spring c- Thread Part d- Rod

WAFF50-EN-00(07/05/2019) W4-4-1-1
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

MEMO

WAFF50-EN-00(07/05/2019) W4-4-1-2
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

Installation of Track Adjuster

CAUTION
Install track adjuster (1) with the oil supplying part of grease fitting (4) facing to the hole (5) side of side frame (2).

1. Install track adjuster (1) to track frame (2). At this time, check bracket (3) of track adjuster (1) touches the plate surface.
2. Install the front idler. (Refer to "Installation of Front Idler"W4-5-2-1.)
3. Connect the track. (Refer to "Installation of Track (Rubber Crawler)"W4-7-2-1 / "Installation of Track (Steel
Crawler)"W4-7-4-1.)

2 1 2
3
4

WAEJ-04-04-100-2 ja

WAFF50-EN-00(07/05/2019) W4-4-2-1
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

MEMO

WAFF50-EN-00(07/05/2019) W4-4-2-2
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

Disassembly of Track Adjuster

WAEJ-04-04-101-1 ja
00- Cylinder 04- Plug 07- Dust Seal 10- Washer
01- Spring 05- Piston Rod 08- Valve
03- Nut 06- Seal 09- Grease Fitting

WAFF50-EN-00(07/05/2019) W4-4-3-1
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

CAUTION
Special tool (ST 4943) weight: 225 kg

CAUTION
The spring force is extremely large. Carry out the disassembly and assembly work carefully. In addition, inspect
the special tool for any damage thoroughly in order to perform the work safely.

1. Place hydraulic jack (c) (30 tons (66200 lb)) between holder (b) and base (d) of special tool (ST 4943).

CAUTION
Special tool (ST 4140) weight: 36 kg

2. Remove nuts (a) (4 used) from special tool (ST 4943). Attach nylon slings onto the eyebolts (2 used) of special tool (ST
4140). Hoist special tool (ST 4140). Remove special tool (ST 4140) from special tool (ST 4943).
: 46 mm

ST 4140

c
ST 4943

d
WABA-04-04-102-1 ja

a- Nut b- Holder c- Hydraulic Jack d- Base

3. Attach nylon slings onto track adjuster (e). Hoist track adjuster (e). Install track adjuster (e) to holder (b) of special tool
(ST 4943).

WAFF50-EN-00(07/05/2019) W4-4-3-2
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

4. Install special tool (ST 4140) to special tool (ST 4943) in order to cover track adjuster (e). Operate the hydraulic jack.
Jack up until nut (03) comes out from the center hole of special tool (ST 4140).

ST 4140
e

03

b
e

WABA-04-04-103-1 ja

b- Holder e- Track Adjuster

CAUTION
As spring (01) is compressed, a strong force is applied. Check if track adjuster (e) is installed correctly when jacked
up.

5. Install nuts (a) (4 used) of special tool (ST 4943). Secure track adjuster (e). Slowly operate the hydraulic jack. Compress
track adjuster (e) until the clearance between washer (10) and nut (03) becomes approx. 10 mm.
: 46 mm

NOTE
Spring (01) compressed length:

Spring free length Spring set length Spring compressed length

(mm) (mm) (Spring free length - Spring set length) (mm)
Rubber Crawler 321.3 234.5 86.8
Steel Crawler 321.3 256 65.3

CAUTION
Sometimes, cylinder (00) is under an internal pressure. As valve (08) may fly out and the high-pressure grease may
spout out, do not loosen valve (08) quickly. Keep body parts and face away from valve (08) and loosen it gradually.
Do not loosen grease fitting (09).

6. Remove valve (08) from cylinder (00).

: 19 mm
7. Remove plug (04) from nut (03).
: 5 mm
8. Remove nut (03) from cylinder (00).
: 46 mm

WAFF50-EN-00(07/05/2019) W4-4-3-3
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

CAUTION
Before removing nut (a) and special tool (ST 4140), lower the hydraulic jack and then remove it. Prevent washer
(10) and spring (01) from flying out due to the spring (01) force.

9. Slowly lower the hydraulic jack until spring (01) reaches the free length.

NOTE
Spring (01) free length: 321.3 mm

WABA-04-04-104-1 ja

a- Nut e- Track Adjuster

CAUTION
Special tool (ST 4140) weight: 36 kg

10. Attach nylon slings onto the eyebolts (2 used) of special tool (ST 4140). Hoist and hold special tool (ST 4140). Remove
nuts (a) (4 used) from special tool (ST 4943). Hoist and remove special tool (ST 4140) from special tool (ST 4943).
: 46 mm

ST 4140

WABA-04-04-105-1 ja
11. Remove washer (10) from spring (01).
12. Install eyebolts (M16, Pitch 1.5 mm) to the valve (08) hole of cylinder (00). Attach nylon slings onto the eyebolts. Hoist
the spring (01) assembly.
13. Remove the spring (01) assembly from special tool (ST 4943). Place it horizontally.
14. Remove spring (01) from cylinder (00).
15. Remove piston rod (05) from the cylinder (00) assembly.

WAFF50-EN-00(07/05/2019) W4-4-3-4
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

IMPORTANT
Do not damage seal (06) and dust seal (07).

16. Remove dust seal (07) and seal (06) from cylinder (00).

WAFF50-EN-00(07/05/2019) W4-4-3-5
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

MEMO

WAFF50-EN-00(07/05/2019) W4-4-3-6
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

Assembly of Track Adjuster

05 07 06 00 01 10 04 03 08 09

WAEJ-04-04-102-1 ja
00- Cylinder 04- Plug 07- Dust Seal 10- Washer
01- Spring 05- Piston Rod 08- Valve
03- Nut 06- Seal 09- Grease Fitting

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

1. Apply grease onto the inner circumference of seal (06) and dust seal (07). Install seal (06) and dust seal (07) to cylinder
(00).
2. Apply grease to the inner surface of cylinder (00) thinly. Fill grease in entire A part of the bottom surface of cylinder
(00).

00 A

WABA-04-04-107-2 ja
3. Install piston rod (05) to the cylinder (00) assembly. Bleed air from the inside of cylinder (00).
4. Install spring (01) to cylinder (00).
5. Install eyebolts (M16, Pitch 1.5 mm) to the valve (08) hole of cylinder (00). Attach nylon slings onto the eyebolts. Hoist
the spring (01) assembly. Place the spring (01) assembly onto special tool (ST 4943).
6. Remove eyebolts from cylinder (00).
7. Install washer (10) to spring (01).

WAFF50-EN-00(07/05/2019) W4-4-4-1
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

CAUTION
Special tool (ST 4140) weight: 36 kg

8. Attach nylon slings onto eyebolts (2 used) of special tool (ST 4140) and hoist it. Install special tool (ST 4140) to special
tool (ST 4943).

ST 4140

ST 4943

WABA-04-04-105-2 ja
9. Install nuts (a) (4 used) of special tool (ST 4943). Secure the spring (01) assembly.
: 46 mm

WABA-04-04-104-2 ja

a- Nut
10. Operate the hydraulic jack. Compress spring (01) to the specified length.

NOTE

Specified spring length (mm)

Rubber Crawler 234.5
Steel Crawler 256

11. Install nut (03) to cylinder (00).

: 46 mm
12. Install plug (04) to nut (03).
: 5 mm
: 15 N·m
13. Install valve (08) to cylinder (00).
: 19 mm
: 90 N·m

WAFF50-EN-00(07/05/2019) W4-4-4-2
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

14. Lower the hydraulic jack.

CAUTION
Special tool (ST 4140) weight: 36 kg

15. Attach nylon slings onto the eyebolts (2 used) of special tool (ST 4140). Hoist and hold special tool (ST 4140). Remove
nuts (a) (4 used) from special tool (ST 4943). Hoist and remove special tool (ST 4140) from special tool (ST 4943).
: 46 mm
16. Attach nylon slings onto track adjuster (e). Hoist track adjuster (e). Remove track adjuster (e) from special tool (ST
4943).

ST 4943

WABA-04-04-108-1 ja

a- Nut e- Track Adjuster

WAFF50-EN-00(07/05/2019) W4-4-4-3
 SECTION4 UNDERCARRIAGE
Group4 Track Adjuster

MEMO

WAFF50-EN-00(07/05/2019) W4-4-4-4
 SECTION4 UNDERCARRIAGE
Group5 Front Idler 　
　
Removal of Front Idler
　
Before removing and installing the front idler, the track links must be removed first. (Refer to "Removal of Track (Rubber
Crawler)"W4-7-1-1 / "Removal of Track (Steel Crawler)"W4-7-3-1) Therefore, the procedure starts on the premise that 　
the track links have already been removed here.

CAUTION
Front idler (1) weight: 45 kg

CAUTION
Front idler (1) may fly out due to the spring force when removing front idler (1). Do not stand in the same direction
to remove front idler (1) or where it may fly out.

1. Attach nylon sling (A) onto front idler (1), then hoist and hold it.
2. Hoist and remove front idler (1) with yoke (2) together from track frame (3) by using a bar.

A 1

3 2

WAEJ-04-05-100-1 ja
3. When keeping front idler (1) temporarily, place front idler (1) on wooden block (a) as illustrated in figure B.

B
WAEJ-04-05-101-1 ja

a- Wooden Block

WAFF50-EN-00(07/05/2019) W4-5-1-1
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

MEMO

WAFF50-EN-00(07/05/2019) W4-5-1-2
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

Installation of Front Idler

CAUTION
Front idler (1) weight: 45 kg

IMPORTANT
Clean track frame (3) and sliding part (b) of yoke (2) thoroughly. Then apply grease.

1. Install front idler (1) in an opposite way of removing it.

3
A 1

3 2

WAEJ-04-05-102-1 ja

b- Sliding Part

WAFF50-EN-00(07/05/2019) W4-5-2-1
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

MEMO

WAFF50-EN-00(07/05/2019) W4-5-2-2
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

Disassembly of Front Idler

05

00a
03
02 04
00b

03a
03b
00b

01 08

05 03 02

03c
07
03d
08

04
WAFF-04-05-001-1 ja
00a- Idler 02- O-Ring (2 Used) 03c- Floating Seal 05- Pin (2 Used)
00b- Bushing (2 Used) 03a- Floating Seal 03d- Floating Seal 07- Plate
01- Axle 03b- Floating Seal 04- Yoke (2 Used) 08- Bolt, Washer (4 Used)

CAUTION
The idler (00a) assembly weight: 45 kg

1. Attach nylon slings onto the idler (00a) assembly and hoist it. Place the idler (00a) assembly on the wooden block
horizontally.

NOTE
Wooden Block: 85 mm or more square

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

NOTE
LOCTITE #262 has been applied onto bolts and washer (08).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

3. Remove pin (05) from yoke (04) at the upper side by using a round bar and a hammer.

NOTE
Diameter of round bar: 9 mm

WAFF50-EN-00(07/05/2019) W4-5-3-1
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

CAUTION
The idler (00a) assembly weight: 40 kg

4. Attach nylon slings onto the idler (00a) assembly and hoist it. Set the idler (00a) assembly on a press with the side
where pin (5) has been removed up.
5. Put the matching marks on yoke (04) and axle (01). Remove the axle (01) assembly from idler (00a) by using a press.

04 01

00a

W105-03-05-008-3 ja

IMPORTANT
Handle floating seals (03a to 03d) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)

6. Remove yoke (04) from idler (00a). Remove floating seals (03a to 03d) from idler (03A) and yokes (04) (2 used). Drain
off engine oil from idler (00a)

NOTE
Oil amount: 70 mL

04

03a
03b

00a

03c
03d 02

01

04

W105-03-05-009-4 ja

WAFF50-EN-00(07/05/2019) W4-5-3-2
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Place wooden block (a) under the bearing in order not to damage yoke (04).

7. Place yoke (04) on wooden block (a). Remove pin (05) from yoke (04) at the other side by using a round bar and a
hammer. Put the matching marks on yoke (04) and axle (01). Remove axle (01) from yoke (04) by using a press.

NOTE
Diameter of round bar: 9 mm

05
02
04

01

02

WAFF-04-05-002-1 ja

a- Wooden Block
8. Remove O-rings (02) (2 used) from axle (01).

WAFF50-EN-00(07/05/2019) W4-5-3-3
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

CAUTION
Idler (00a) weight: 30 kg

IMPORTANT
Do not remove bushing (00b) unless necessary.

9. When replacing bushing (00b), remove bushings (00b) (2 used) from idler (00a) by using special tool (ST 1966) and a
press.

00a b

00b

W105-03-05-011-6 ja

b- Special Tool (ST 1966)

WAFF50-EN-00(07/05/2019) W4-5-3-4
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

Assembly of Front Idler

00b 00a 04 02

07
08
01

03a 03d
03b 03c

05
WAFF-04-05-003-1 ja
00a- Idler 02- O-Ring (2 Used) 03c- Floating Seal 05- Pin (2 Used)
00b- Bushing (2 Used) 03a- Floating Seal 03d- Floating Seal 07- Plate
01- Axle 03b- Floating Seal 04- Yoke (2 Used) 08- Bolt, Washer (4 Used)

IMPORTANT
Before assembly, apply engine oil onto parts in order to prevent them from seizing.

1. Install bushings (00b) (2 used) to idler (00a) by using a press.

CAUTION
Idler (00a) weight: 30 kg

2. Attach nylon slings onto idler (00a) and hoist it. Place idler (00a) on the wooden block horizontally.

NOTE
Wooden Block: 85 mm or more square

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

WAFF50-EN-00(07/05/2019) W4-5-4-1
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Check the direction to install pin (05).

4. Fit the matching marks made when disassembling and install yoke (04) to axle (01) with pin (05) by using a hammer.
At this time, put the slit (c) side of pin (05) in the axial direction of axle (01).

01 04 02

05

e
WAFF-04-05-004-1 ja

e- Slit

IMPORTANT
Handle floating seals (03a, 03b) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)

5. Apply engine oil to the sliding surface of floating seals (03a, 03b) and the outer surface of the O-ring. Install floating
seals (03a, 03b) to idler (00a) and yoke (04).
6. Install the axle (01) assembly to idler (00a) from the side where floating seal (03) has been installed by using a press.

CAUTION
The idler (00a) assembly weight: 36 kg

7. Attach nylon slings onto the idler (00a) assembly and hoist it. Turn over and place the idler (00a) assembly on the
wooden block.
8. Add engine oil (SAE #30, CD class) to the B part of idler (00a).

NOTE
Oil amount: 70 mL
B 00a

WABA-04-05-104-2 ja

WAFF50-EN-00(07/05/2019) W4-5-4-2
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

IMPORTANT
Handle floating seals (03c to 03d) with care. (Refer to "Precautions for Using Floating Seal"W1-1-2-1.)

9. Install other O-ring (02) to axle (01). Apply engine oil to the sliding surface of floating seals (03c, 03d) and the outer
surface of the O-ring. Install floating seals (03c, 03d) to idler (00a) and other yoke (04).
04

03d 02
03c
01 00a

04

WABA-04-05-105-3 ja

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Check the direction to install pin (05).

10. Fit the matching marks made when disassembling and install yoke (04) to axle (01) with pin (05) by using a hammer.
At this time, put the slit (c) side of pin (05) in the axial direction of axle (01).
11. Apply LOCTITE # 262 onto bolts and washers (08) (4 used). Install plate (07) to yokes (04) (2 used) with bolts, washers
(08) (4 used).
: 19 mm
: 88 N·m

WAFF50-EN-00(07/05/2019) W4-5-4-3
 SECTION4 UNDERCARRIAGE
Group5 Front Idler

MEMO

WAFF50-EN-00(07/05/2019) W4-5-4-4
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers 　
　
Removal of Upper Roller
　
IMPORTANT 　
The upper roller cannot be disassembled. Replace it as an assembly.
　
CAUTION
Pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or too much as valve (1)
may fly out or high-pressure grease may spout out. Keep body parts and face away from valve (1) and loosen it
gradually. Do not loosen grease fitting (2).

IMPORTANT
Loosening valve (1) by 1 to 1.5 turns is enough. Do not loosen it over those turns.

IMPORTANT
When gravel or mud is packed between the sprocket, remove it before loosening.

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
2. Loosen valve (1) in the track adjuster. Drain grease and loosen the track tension.
: 19 mm

2 1 a 1

WAEJ-04-06-100-1 ja

a- Grease Outlet

IMPORTANT
Use the cushion pad between track frame (3) and hydraulic jack (4) to prevent them from slipping.

3. Jack up track link (6) in order to get clearance between upper roller (5) and track link (6) by using hydraulic jack (4).
Place wooden block (10) between track link (6) and track frame (3).

WAFF50-EN-00(07/05/2019) W4-6-1-1
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers

4. Remove bolt (7), nut (9), and spring washer (8). Remove upper roller (5).
: 24 mm

NOTE
LOCTITE #262 has been applied onto bolt (7).

6 10 5 7, 8, 9 3

WAEJ-04-06-101-1 ja

WAFF50-EN-00(07/05/2019) W4-6-1-2
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers

Installation of Upper Roller

1. Apply LOCTITE #262 onto bolt (7). Install upper roller (5) to track frame (3) with bolt (7), nut (9), and spring washer (8).
: 24 mm
: 210 N·m
2. Remove wooden block (10).
3. Lower hydraulic jack (4). Remove hydraulic jack (4) and the cushion pad from track frame (3).

6 10 5 7, 8, 9 3

WAEJ-04-06-101-1 ja
4. Tighten valve (1) of the track adjuster.
: 19 mm
: 90 N·m

WAEJ-04-06-102-1 ja

CAUTION
Support the raised machine surely by blocks.

5. Jack up the track link to be adjusted. Rotate the track link in the reverse direction a little.

WAFF50-EN-00(07/05/2019) W4-6-2-1
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers

6. Supply grease to the grease fitting and adjust the track tension.

NOTE
Joint part (b) of the track link (rubber crawler (d)) should be in the center when measuring the track link (rubber
crawler (d)) tension. At this time, turn the track in reverse direction so that the track sag should be located down.
Track Sag Specification (Y): 10 to 15 mm (rubber crawler (d)) (A): 140 to 160 mm (steel crawler (e))

X c

b d
Y

b
d

A
e
WAFF-04-06-001-1 ja

b- Joint Part c- Lower Roller d- Rubber Crawler e- Steel Crawler

7. Lower the track link.

WAFF50-EN-00(07/05/2019) W4-6-2-2
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers

Removal of Lower Roller

IMPORTANT
The lower roller cannot be disassembled. Replace it as an assembly.

CAUTION
Securely support the raised machine by using the blocks.

1. Raise the machine off the ground by using the front attachment. Place the blocks under the track frame and support
the machine.

WABA-04-06-100-1 ja

a- 90 to 110 °

CAUTION
Pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or too much as valve (1)
may fly out or high-pressure grease may spout out. Keep body parts and face away from valve (1) and loosen it
gradually. Do not loosen grease fitting (2).

IMPORTANT
Loosening valve (1) by 1 to 1.5 turns is enough. Do not loosen it over those turns.

IMPORTANT
When gravel or mud is packed between the sprocket, remove it before loosening.

2. Loosen valve (1) in the track adjuster carefully. Drain grease until the clearance in the track link is enough to remove
lower roller (4).
: 19 mm
3. Tighten valve (1) clockwise to the original condition.
: 19 mm
: 90 N·m

WAFF50-EN-00(07/05/2019) W4-6-3-1
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers

4. Remove bolts (3) (2 used) and spacers (6) (2 used). Remove lower roller (4).
: 30 mm
(Lower Roller (4) in Part (A) at Right and Left Sides)
Remove bolts (3) (2 used), spacer (6), and washer (7). Remove lower roller (4).
: 30 mm

NOTE
LOTITE #262 has been applied onto bolt (3).

2 1 b

3, 6

WAEJ-04-06-104-1 ja

b- Grease Outlet

3 7 d 6 3

e f

WAFF-04-06-002-1 ja

d- Lower Roller (4) in Part (A) e- Inside f- Outside g- Front Side

at Right and Left Sides

WAFF50-EN-00(07/05/2019) W4-6-3-2
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers

Installation of Lower Roller

• The following procedures are to be performed with the machine jacked up.

1. Set lower roller (4) under the lower surface of track frame (5). Fit lower roller (4) to the mounting hole of track frame
(5).

WAFF50-EN-00(07/05/2019) W4-6-4-1
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers

2. Apply LOCTITE #262 to bolts (3) (2 used). Install lower roller (4) with washers (6) (2 used) and bolts (3) (2 used).
: 30 mm
: 620 N·m
(Lower Roller (4) in Part (A) at Right and Left Sides)
Apply LOCTITE #262 to bolts (3) (2 used). Install lower roller (4) with washer (7), spacer (6), and bolts (3) (2 used).
: 30 mm
: 620 N·m

3, 6

WAEJ-04-06-105-1 ja

3 7 d 6 3

e f

WAFF-04-06-002-1 ja

d- Lower Roller (4) in Part (A) e- Inside f- Outside g- Front Side

at Right and Left Sides

WAFF50-EN-00(07/05/2019) W4-6-4-2
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers

3. Supply grease to the grease fitting and adjust the track tension.

NOTE
Joint part (h) of the track (rubber crawler (i)) should be in the center when measuring the track link (rubber crawler (i))
tension. At this time, turn the track in reverse direction so that the track sag should be located down.
Track Sag Specification (Y): 10 to 15 mm (rubber crawler (i)) (A): 140 to 160 mm (steel crawler (j))

X 4

h i
Y

h
i

A
j
WAFF-04-06-001-2 ja

h- Joint Part i- Rubber Crawler j- Steel Crawler

WAFF50-EN-00(07/05/2019) W4-6-4-3
 SECTION4 UNDERCARRIAGE
Group6 Upper and Lower Rollers

4. Jack up the front of the base machine. Remove the block from the lower part of track frame (5).

WAEQ-04-06-100-1 ja
5. Add engine oil (SAE #30, API-CD class) through the plug (9) hole of cover (8).

NOTE
Before adding engine oil, remove the lower roller from track frame.
Oil amount: 120±15 mL

6. Apply LOCTITE #503 onto plug (9).

7. Install plug (9).
: 5 mm
: 15 ± 1.5 N·m
8 9

WAFF-04-06-003-1 ja

WAFF50-EN-00(07/05/2019) W4-6-4-4
 SECTION4 UNDERCARRIAGE
Group7 Track 　
　
Removal of Track (Rubber Crawler)
　
　
CAUTION
Rubber crawler weight: 250 kg 　
CAUTION 　
Securely support the raised machine by using the blocks.

1. Raise the machine off the ground by using the front attachment.

WABA-04-06-100-1 ja

a- 90 to 110°

WAFF50-EN-00(07/05/2019) W4-7-1-1
 SECTION4 UNDERCARRIAGE
Group7 Track

CAUTION
Pressure inside the cylinder of the track adjuster is high. Do not loosen valve (1) quickly or too much as valve (1)
may fly out or high-pressure grease may spout out. Keep body parts and face away from valve (1) and loosen it
gradually. Do not loosen grease fitting (2).

IMPORTANT
Loosening valve (1) by 1 to 1.5 turns is enough. Do not loosen it over those turns.

IMPORTANT
When gravel or mud is packed between the sprocket, remove it before loosening.

2. Loosen valve (1) in the track adjuster slowly and drain grease.
: 19 mm

NOTE
If rotating the track in forward and reverse direction with valve (1) loosened, the track can be removed and installed
easily.

2 1 b

WABA-04-07-100-1 ja

b- Grease Outlet

CAUTION
Rubber crawler weight: 250 kg

3. Insert steel pipe (3) into the track link. Rotate the sprocket in the reverse direction. When the track link comes off from
the front idler by steel pipe (3), slide and remove it in the transverse direction.

3
WABA-04-07-101-1 ja

c- Rotating Direction

WAFF50-EN-00(07/05/2019) W4-7-1-2
 SECTION4 UNDERCARRIAGE
Group7 Track

Installation of Track (Rubber Crawler)

CAUTION
Securely support the raised machine by using the blocks.

1. Raise the machine off the ground by using the front attachment.

CAUTION
Rubber crawler weight: 250 kg

2. Mesh the track with the sprocket. Attach the track onto the front idler. Rotate the sprocket in reverse direction and
push the track.
3. Insert steel pipe (3) into the track link. Rotate the sprocket in reverse direction. Attach the track link onto the front
idler. Check that the track is securely engaged with the sprocket and the front idler.

WABA-04-07-102-1 ja

c- Rotating Direction
4. Tighten valve (1).
: 19 mm
: 90 N·m

WAFF50-EN-00(07/05/2019) W4-7-2-1
 SECTION4 UNDERCARRIAGE
Group7 Track

5. Apply grease through grease fitting (2) and adjust the track tension.

1
2

WABA-04-07-001-1 ja

NOTE
Joint part (f) of the track (rubber crawler (d)) should be in the center when measuring the track link (rubber crawler
(d)) tension. At this time, turn the track in reverse direction so that the track sag should be located down.
Track Sag Specification (Y): 10 to 15 mm (Rubber crawler (d))

X e

f d
Y

f
d

WAEJ-04-06-103-3 ja

d- Rubber Crawler e- Lower Roller f- Joint Part

WAFF50-EN-00(07/05/2019) W4-7-2-2
 SECTION4 UNDERCARRIAGE
Group7 Track

Removal of Track (Steel Crawler)

CAUTION
Steel crawler weight: 285 kg

1. Set the machine position for inspection and maintenance. (Refer to "Preparation before Inspection and
Maintenance"W1-5-1-1.)
2. Rotate the track so that master pin (3) is positioned over front idler (2). Place wooden block (a) under shoe (1) to
support shoe (1).

CAUTION
The pressure inside cylinder of track adjuster (4) is high. Do not loosen valve (6) quickly or too much as valve (6)
may fly out or high-pressure grease may spout out. Keep body parts and face away from valve (6) and loosen it
gradually. Do not loosen grease fitting (5).

IMPORTANT
Loosening valve (6) by 1 to 1.5 turns is enough. Do not loosen it over those turns.

IMPORTANT
When gravel or mud is packed between the sprocket, remove it before loosening.

3. Loosen valve (6). Drain grease and loosen the track links.
: 19 mm
1

2
5 6 b

3 4

a
WAFF-04-07-001-1 ja

a- Wooden Block b- Grease Outlet

IMPORTANT
Pin (7) cannot be reused.

4. Remove pin (7) from master pin (3).

WAFF50-EN-00(07/05/2019) W4-7-3-1
 SECTION4 UNDERCARRIAGE
Group7 Track

CAUTION
The front idler part may fly out due to the spring force when removing the track. Do not stand in the same
direction to remove the front idler or where it may fly out. Particularly, strong force is always applied to the thread
part of the rod of the track adjuster. If the rod and/or the threads are damaged, metal fragments may fly out due
to the spring force.

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Master pin (3) can be installed/removed to only one direction. Check direction (d) to remove master pin (3).

5. Put the matching marks onto master pin (3) and master link (e). Remove master pin (3) by using special tool (ST 1970)
and a hammer.

c d

7
3 e 7

ST 1970

WAFF-04-07-002-1 ja

c- Direction to Install d- Direction to Remove e- Master Link

6. Set angle (g) between the boom and arm to 90 to 110 degrees. Lower the boom with the round bottom of the bucket
contacting with the ground.Raise the track frame and pull out the track. At this time, place stand (f ) under the track
frame and support the machine.

WAFF50-EN-00(07/05/2019) W4-7-3-2
 SECTION4 UNDERCARRIAGE
Group7 Track

CAUTION
Steel crawler weight: 285 kg

7. Slowly operate the travel control lever for the track link to be removed to the reverse position and extend the track
link.

f
WAFF-04-07-003-1 ja

f- Stand g- 90 to 100°

WAFF50-EN-00(07/05/2019) W4-7-3-3
 SECTION4 UNDERCARRIAGE
Group7 Track

MEMO

WAFF50-EN-00(07/05/2019) W4-7-3-4
 SECTION4 UNDERCARRIAGE
Group7 Track

Installation of Track (Steel Crawler)

1. Jack up the machine. Set the track under the machine so that sprocket (8) meshes with the track end. Check the
direction of the tracks.

CAUTION
Steel crawler weight: 285 kg

2. Hoist and mesh the track link with the claws of sprocket (8).
3. Slowly operate a travel control lever on the side to install the track link in the forward direction with the machine
jacked up. Wind the track link while rotating travel device (9).

h i 8

WAFF-04-07-004-1 ja

h- Front Idler Side i- Sprocket (8) Side

4. Wind the track link until connection part (10) of the track link reaches front idler (2). Lower the machine. Place wooden
block (a) under shoe (1) and support shoe (1).

IMPORTANT
Master pin (3) can be installed/removed to only one direction. Check direction (c) to install master pin (3).

5. Fit the matching marks made when removing. Install master pin (3) to the track link.

WAFF50-EN-00(07/05/2019) W4-7-4-1
 SECTION4 UNDERCARRIAGE
Group7 Track

IMPORTANT
Replace pin (7) with the new one.

6. Install pin (7) to master pin (3). Bend the end of pin (7) to prevent it from coming off.
2

c d

10
10 3 7
1

3 7
WAFF-04-07-005-1 ja

a- Wooden Block c- Direction to Install d- Direction to Remove

IMPORTANT
If master link (e) has been disassembled, fill grease (Daphne Eponex SR) into the clearance between bushing (11)
and master pin (3) when assembling.

IMPORTANT
Perform procedure 7 to procedure 10 when master link (e) has been disassembled.

7. Apply grease to the bushing (11) end. Fit the master pin (3) holes on master link (e) and bushing (11). Stand them on a
flat plate.

CAUTION
Do not drop master link (e).

8. Fill the bushing (11) inside with grease.

9. Install master pin (3) to master link (e) and bushing (11) while holding them to prevent them from moving due to
grease.
10. Wipe off excess grease after installing master pin (3).

WAFF50-EN-00(07/05/2019) W4-7-4-2
 SECTION4 UNDERCARRIAGE
Group7 Track

11. Tighten valve (6) of track adjuster (4). Apply grease through grease fitting (5) and adjust the track tension.
: 19 mm
: 90 N·m

NOTE
Track sag specification (j): 140 to 160 mm

5 6
11

c d

e 3 e 4

WAFF-04-07-006-1 ja

c- Direction to Install d- Direction to Remove e- Master Link j- Track Sag Specification

WAFF50-EN-00(07/05/2019) W4-7-4-3
 SECTION4 UNDERCARRIAGE
Group7 Track

MEMO

WAFF50-EN-00(07/05/2019) W4-7-4-4
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder 　
　
Removal of Blade Cylinder
　
IMPORTANT 　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.
　

IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags 　
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Park the machine on a solid and level surface. Make the machine swing to the right by 90 degrees. Lower the end of
blade onto the ground.
2. Remove bolts, washers (1) (2 used) Remove cover (2).
: 17 mm

CAUTION
Blade cylinder (3) weight: 46 kg

3. Attach nylon slings onto blade cylinder (3), then hoist and hold it.

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

4. Remove bolts (7) (2 used) and washers (6) (2 used). Remove lock (5). Remove pin (8) from track frame (4) by using a bar
and a hammer.
: 19 mm

NOTE
LOCTITE #262 has been applied onto bolt (7).

1 2

7 6 5 8
WAFF-04-08-001-1 ja
5. Start the engine. Operate the blade control lever and retract blade cylinder (3). In order not to extend the rod, pass
wires through the rod hole and secure the rod to the cylinder tube. Stop the engine.

WAFF50-EN-00(07/05/2019) W4-8-1-1
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)

6. Disconnect hoses (9) (2 used).

: 22 mm

CAUTION
Blade cylinder (3) weight: 46 kg

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

7. Remove bolts (10) (2 used) and washers (11) (2 used). Remove lock (12). Remove pin (13) by using a bar and a hammer.
Hoist and remove blade cylinder (3) from blade (14).
: 19 mm

NOTE
LOCTITE #262 has been applied onto bolt (10).

9
3

14

11

10

12 13
WAFF-04-08-001-2 ja

WAFF50-EN-00(07/05/2019) W4-8-1-2
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

Installation of Blade Cylinder

1. Apply grease onto the bushing inside and the lip part of the dust seal for blade cylinder (3) (both bottom and rod
sides).

CAUTION
Blade cylinder (3) weight: 46 kg

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

2. Apply grease to the surface of pin (13). Install pin (13) by using a hammer. Apply LOCTITE #262 to bolt (10). Install lock
(12) with bolts (10) (2 used) and washers (11) (2 used).
: 19 mm
: 110 N·m
3

14

11

10

12 13
WAFF-04-08-001-3 ja
3. Apply grease to grease fitting (a) at the cylinder bottom side.

a
WAEQ-04-08-100-1 ja

a- Grease Fitting of the Cylinder Bottom Side

WAFF50-EN-00(07/05/2019) W4-8-2-1
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

4. Connect hoses (9) (2 used).

: 22 mm
: 40 N·m
9

WAFF-04-08-001-4 ja

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

5. Remove the wire from the blade cylinder (3) rod.

6. Start the engine. Operate the blade control lever and extend blade cylinder (3) slowly. Fit the hole on the cylinder rod
side to the cylinder mounting hole on track frame (4).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

7. Apply grease to the surface of pin (8). Install pin (8) by using a hammer.
8. Apply LOCTITE #262 to bolt (7). Install lock (5) with bolts (7) (2 used) and washers (6) (2 used).
: 19 mm
: 110 N·m
9. Install cover (2) with washers (16) (2 used) and bolts (1) (2 used).
: 17 mm
: 50 N·m
1 2

7 6 5 8
WAFF-04-08-001-1 ja

WAFF50-EN-00(07/05/2019) W4-8-2-2
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

10. Apply grease to grease fitting (b) of the blade cylinder rod side.
b

WAEQ-04-08-100-2 ja

b- Grease Fitting of the Cylinder Rod Side

IMPORTANT
After completing all the work, operate the blade cylinder to the stroke end several times and bleed air from the
circuit.

WAFF50-EN-00(07/05/2019) W4-8-2-3
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

MEMO

WAFF50-EN-00(07/05/2019) W4-8-2-4
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

Disassembly of Blade Cylinder

15

14

22

13

1
17

16 18
19
17

10
3
11
12

7
21
8

20

WAFF-04-08-002-1 ja
1- Cylinder Tube 8- Backup Ring 13- Piston 18- Steel Ball
3- Cylinder Rod 9- Wiper Ring 14- Seal Ring 19- Set Screw
5- Cylinder Head 10- O-Ring 15- Wear Ring 20- Retaining Ring
6- Bushing 11- Backup Ring 16- O-Ring 21- Rod Seal
7- U-Ring 12- O-Ring 17- Backup Ring (2 Used) 22- Dust Ring
• The procedure starts on the premise that the pipes and bands securing the pipes have been removed.

WAFF50-EN-00(07/05/2019) W4-8-3-1
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

CAUTION
Blade cylinder weight: 46 kg

1. Hoist the cylinder and secure it on a workbench horizontally. Drain off hydraulic oil from the cylinder.

W102-04-02-027-1 ja

IMPORTANT
The lock washer of cylinder head (5) is integrated with cylinder tube (1). Do not damage cylinder tube (1) and
cylinder head (5) when the lock washer is bended and extended.

2. Pull out cylinder rod (3) about 200 mm. Install a protective cover to cylinder rod (3). Extend lock washer (a) of cylinder
head (5).

3 5

WABA-04-09-103-1 ja

a- Lock Washer

WAFF50-EN-00(07/05/2019) W4-8-3-2
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

IMPORTANT
Remove cylinder rod (3) straight in order not to damage the sliding surface.

3. Loosen cylinder head (5) by using hook wrench (b) with the protective cover on cylinder rod (3). Remove the cylinder
rod (3) assembly from cylinder tube (1). Remove a protective cover from cylinder rod (3).
Cylinder head (5) diameter: 180 mm

5
3

WABA-04-09-104-1 ja

b- Hook Wrench
4. Cut away the crimped parts by using a hand drill. Remove set screw (19). Remove steel ball (18).

NOTE
Set screw (19) has been crimped at two places by using a punch after installing.

: 6 mm
5. Secure cylinder rod (3) horizontally. Remove piston (13) from cylinder rod (3) by using the special tool.
Special tool when turning piston (ST 3365): 85 mm
6. Install a protective tape onto the thread of cylinder rod (3). Remove cylinder head (5) from cylinder rod (3).
7. Secure piston (13) in a vice. Remove dust ring (22) and wear ring (15) from piston (13).

IMPORTANT
Do not damage piston (13) when removing seals.

8. Cut and remove seal ring (14) from piston (13) by using a screwdriver.

13

14

WAFF-05-02-022-2 ja

WAFF50-EN-00(07/05/2019) W4-8-3-3
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

9. Remove O-ring (16) and backup rings (17) (2 used) from piston (13).
10. Remove backup ring (11) and O-rings (10, 12) from cylinder head (5).
11. Remove retaining ring (20) and wiper ring (9) from cylinder head (5).
12. Remove backup ring (8), rod seal (21), and U-ring (7) from cylinder head (5).

IMPORTANT
Bushing (9) cannot be reused. If bushing (9) has been removed, replace it with the new one when assembling.

13. Remove bushing (6) from cylinder head (5) by using special tool (ST 8016).

ST8016

WAFF-05-02-023-2 ja

WAFF50-EN-00(07/05/2019) W4-8-3-4
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

Assembly of Blade Cylinder

9, 20 5 12 21, 8 7 10, 11 6 3 1 13 22 14 15 16, 17 18, 19

WAFF-04-08-003-1 ja
1- Cylinder Tube 8- Backup Ring 13- Piston 18- Steel Ball
3- Cylinder Rod 9- Wiper Ring 14- Seal Ring 19- Set Screw
5- Cylinder Head 10- O-Ring 15- Wear Ring 20- Retaining Ring
6- Bushing 11- Backup Ring 16- O-Ring 21- Rod Seal
7- U-Ring 12- O-Ring 17- Backup Ring (2 Used) 22- Dust Ring

IMPORTANT
Check the direction to install rod seal (6) and U-ring (8).

1. Install U-ring (7), rod seal (21), and backup ring (8) to cylinder head (5).
12 11 10

20
9
8 21 7 6
WAFF-05-02-038-2 ja
2. Apply hydraulic oil onto the inner diameter of cylinder head (5). Install bushing (6) to cylinder head (5) by using special
tool (ST 8016).

ST8016

6
5

WAFF-05-02-025-2 ja

WAFF50-EN-00(07/05/2019) W4-8-4-1
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

3. Install wiper ring (9) and retaining ring (20) to cylinder head (5) by using special tool (ST 8051).

ST8051
5

9
WAFF-05-02-026-2 ja
4. Install O-rings (10, 12) and backup ring (11) to cylinder head (5).
5. Install O-ring (16) and backup rings (17) (2 used) to piston (13).
6. Install dust ring (22), wear ring (15), and seal ring (14) to piston (13) by using special tool (ST 2964).

f
15

13

W566-04-02-010-5 ja

f- Special Tool (ST 2964)

IMPORTANT
Piston (13) cannot be installed to cylinder tube (1) without adjusting dust ring (22), wear ring (15), and seal ring
(14).

7. Set piston (13) through special tool (ST 2208) to adjust dust ring (22), wear ring (15), and seal ring (14).

16

15

W566-04-02-011-4 ja

g- Special Tool (ST 2208)

8. Install a protective tape onto the thread of cylinder rod (3). Turn and install the cylinder head (5) assembly to cylinder
rod (3).

WAFF50-EN-00(07/05/2019) W4-8-4-2
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

9. Secure cylinder rod (3) on special tool (ST 5908). Install the piston (13) assembly to cylinder rod (3) by using the special
tool.
Special tool when turning piston (ST 3365): 85 mm
: 1500 ± 150 N·m
ST 5908

W158-04-02-022-1 ja
10. Install steel ball (18) to cylinder rod (3) and tighten with set screw (19). Crimp set screw (19) at two places by using a
punch.
: 6 mm
: 20 ± 2 N·m

IMPORTANT
When installing the cylinder rod (3) assembly, be careful not to drop dust ring (22), wear ring (15), and seal ring
(14) from piston (13).

11. Apply hydraulic oil on to the packings. Secure cylinder tube (1) in a vise horizontally. Install the cylinder rod (3)
assembly to cylinder tube (1).
12. Tighten cylinder head (5) to cylinder tube (1) by using hook wrench (b). Bend the lock washer in order to prevent it
from loosening.
Cylinder head (5) diameter: 180 mm
: 1000 ± 100 N·m

WABA-04-09-107-1 ja

b- Hook Wrench

WAFF50-EN-00(07/05/2019) W4-8-4-3
 SECTION4 UNDERCARRIAGE
Group8 Blade Cylinder

MEMO

WAFF50-EN-00(07/05/2019) W4-8-4-4
5

FRONT ATTACHMENT

Front Attachment ................................ W5-1-1-1

Removal of Front Attachment....................................W5-1-1-1
Installation of Front Attachment...............................W5-1-2-1
Cylinder ................................................ W5-2-1-1
Removal of Boom Cylinder..........................................W5-2-1-1
Installation of Boom Cylinder.....................................W5-2-2-1
Disassembly of Boom Cylinder ..................................W5-2-3-1
Assembly of Boom Cylinder........................................W5-2-4-1
Removal of Arm Cylinder .............................................W5-2-5-1
Installation of Arm Cylinder ........................................W5-2-6-1
Disassembly of Arm Cylinder......................................W5-2-7-1
Assembly of Arm Cylinder ...........................................W5-2-8-1
Removal of Bucket Cylinder ........................................W5-2-9-1
Installation of Bucket Cylinder ................................ W5-2-10-1
Disassembly of Bucket Cylinder ............................. W5-2-11-1
Assembly of Bucket Cylinder ................................... W5-2-12-1
Removal of Boom Swing Cylinder ......................... W5-2-13-1
Installation of Boom Swing Cylinder .................... W5-2-14-1
Disassembly of Boom Swing Cylinder.................. W5-2-15-1
Assembly of Boom Swing Cylinder ....................... W5-2-16-1
Hose Rupture Valve ............................. W5-3-1-1
Removal of Hose Rupture Valve for Boom Cylinder
..........................................................................................W5-3-1-1
Installation of Hose Rupture Valve for Boom
Cylinder.........................................................................W5-3-2-1
Structure of Hose Rupture Valve for Boom
Cylinder.........................................................................W5-3-3-1
Removal of Hose Rupture Valve for Arm Cylinder ..
..........................................................................................W5-3-4-1
Installation of Hose Rupture Valve for Arm
Cylinder.........................................................................W5-3-5-1
Structure of Hose Rupture Valve for Arm Cylinder .
..........................................................................................W5-3-6-1

WAFF50-EN-00(07/05/2019)
MEMO

WAFF50-EN-00(07/05/2019)
 SECTION5 FRONT ATTACHMENT
Group1 Front Attachment
　
Removal of Front Attachment
　
IMPORTANT 　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil. 　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
　
install the clips after connecting the hoses.
　
1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder extended to
the maximum. Lower the end of arm to the ground. 　
2. Stop the engine. Remove the rod side of the boom cylinder. (Refer to "Removal of Boom Cylinder"W5-2-1-1.)

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)

3. Remove clip band (14). Disconnect bullet connectors (15) (2 used).

4. Remove clip bands (13) (4 used). Remove wire harness (16).

13

16

14, 15

WAEJ-05-01-101-2 ja

CAUTION
Front attachment weight: 805 kg

5. Attach nylon slings onto the boom. Reduce slack of the nylon slings. Hoist and hold the boom at the center of gravity.

WAFF50-EN-00(07/05/2019) W5-1-1-1
 SECTION5 FRONT ATTACHMENT
Group1 Front Attachment

6. Remove clip bands (17) (6 used) and clips band (18). Disconnect hoses (19) (8 used).
: 17 mm, 19 mm, 22 mm, 27 mm
17

19 18
WAFF-05-01-001-1 ja
7. Remove nuts (22) (2 used) and bolt (20).
: 24 mm

NOTE
LOCTITE #262 has been applied onto bolt (20).

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

8. Put the matching marks on the boss of the swing post and boom foot pin (21). Remove boom foot pin (21) by using a
bar and a hammer.
9. Hoist and remove the front attachment from the swing post. Remove the shim.
20

21

22

WAEQ-05-01-002-2 ja

WAFF50-EN-00(07/05/2019) W5-1-1-2
 SECTION5 FRONT ATTACHMENT
Group1 Front Attachment

Installation of Front Attachment

CAUTION
Front attachment weight: 805 kg

1. Attach nylon slings onto the boom. Hoist the front attachment. Fit the boom foot to the boom mounting hole on the
swing post. Fit shims to the right and left sides of the boom foot. Make each of the right and left clearances between
the boom and the swing post 1 mm or less.

NOTE
Shim thickness: 0.5 mm, 1.0 mm

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

2. Fit the matching marks on the boss of the swing post and boom foot pin (21). Install boom foot pin (21) by using a
hammer.

IMPORTANT
Install nut (22) with a clearance of 2 to 3 mm between nut (22) and the boss of the swing post.

3. Apply LOCTITE #262 to bolt (20). Install bolt (20) and nuts (22) (2 used). Apply grease to grease fitting (a) of the boom
foot.
: 24 mm
: 270 N·m
20

21

22

WAEQ-05-01-002-1 ja

a- Grease Fitting of Boom Foot

WAFF50-EN-00(07/05/2019) W5-1-2-1
 SECTION5 FRONT ATTACHMENT
Group1 Front Attachment

4. Connect hoses (19) (8 used). Install clip bands (17) (6 used) and clip band (18).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 22 mm
: 40 N·m
: 27 mm
: 80 N·m
17

19 18
WAFF-05-01-001-1 ja
5. Connect bullet connectors (15) (2 used). Install clip band (14).
6. Install harness (16) with clip bands (13) (4 used).

13

16

14, 15

WAEJ-05-01-101-2 ja
7. Install the rod side of the boom cylinder. (Refer to "Installation of Boom Cylinder"W5-2-2-1.)
IMPORTANT
After completing all the work, add hydraulic oil to the specified level. Operate each cylinder to the stroke end
several times and bleed air in the circuit. Check for any oil leak of each hose connection.

WAFF50-EN-00(07/05/2019) W5-1-2-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder
　
Removal of Boom Cylinder
　
IMPORTANT 　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil. 　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
　
install the clips after connecting the hoses.
　
1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder retracted to
the minimum. Lower the end of arm to the ground. 　
2. Remove bolts (7) (2 used), spring washers (8) (2 used), and washers (9) (2 used). Remove cover (6) from boom cylinder
(5).
　
: 17 mm

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

CAUTION
Boom cylinder (5) weight: 78 kg

3. Attach nylon slings onto boom cylinder (5), then hoist and hold it. Remove bolt (1), spring washer (2), and bushing (3).
Remove pin (4) by using a bar and a hammer. Remove shim (12).
: 24 mm

NOTE
LOCTITE #262 has been applied onto bolt (1).

4. Place boom cylinder (5) on a stand.

WAFF50-EN-00(07/05/2019) W5-2-1-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

5. Start the engine. Operate the boom control lever and retract boom cylinder (5). In order not to extend rod (10), pass
wires through the rod (10) hole and secure the rod to the cylinder tube.

1, 2, 3

4 10

12
5

7, 8, 9

WAEJ-05-01-100-1 ja

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)

6. Remove bolts, washers (18) (2 used) Remove cover (19).

: 17 mm
18

19
WAFF-05-02-001-1 ja
7. Remove clip band (22). Disconnect connector (23).

WAFF50-EN-00(07/05/2019) W5-2-1-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

8. Remove clip bands (20) (2 used). Disconnect hoses (21) (3 used).

: 17 mm, 19 mm, 27 mm

22
20

23

20 21
WAFF-05-02-002-1 ja
9. Remove clip band (24). Disconnect hose (25).
: 27 mm

24

25

WAFF-05-02-003-1 ja

CAUTION
Boom cylinder (5) weight: 78 kg

10. Remove bolt (15) and nuts (17) (2 used).

: 24 mm

NOTE
LOCTITE #262 has been applied onto bolt (15).

WAFF50-EN-00(07/05/2019) W5-2-1-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

11. Put the matching marks on swing post (16) and pin (14). Remove pin (14) by using a bar and a hammer. Remove shim
(26).
12. Hoist and remove boom cylinder (5) from swing post (16).

14, 26 15 16 5

17

WABA-05-02-100-3 ja

WAFF50-EN-00(07/05/2019) W5-2-1-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Installation of Boom Cylinder

1. Apply grease to the lip part of the dust seal, the side of the boss, and the inner surface of the bushing (both the
bottom and rod sides) of boom cylinder (5).

CAUTION
Boom cylinder (5) weight: 78 kg

IMPORTANT
Use one or more shims (26) respectively at the right and left sides.

2. Attach nylon slings onto boom cylinder (5) and hoist it. Fit the hole on the cylinder bottom side to the cylinder
mounting hole on swing post (16). Fit shims (26) to the right and left sides of the hole of the cylinder bottom side.
Make the total of the left and right clearances up to 0.5 mm.

NOTE
Shim (26) thickness: 0.5 mm, 0.8 mm

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

3. Apply grease to the surface of pin (14). Fit the matching marks on swing post (16) and pin (14). Install pin (14) by using
a hammer.

IMPORTANT
Install nut (17) with a clearance of 2 to 3 mm between nut (17) and the boss of swing post (16) .

4. Apply LOCTITE #262 to bolt (15). Install bolt (15) and nuts (17) (2 used).
: 24 mm
: 270 N·m

14, 26 15 16 5

17

WABA-05-02-100-3 ja

WAFF50-EN-00(07/05/2019) W5-2-2-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

5. Apply grease to grease fittings (a) at the boom cylinder bottom side.

WABK-05-02-100-1 ja

a- Grease Fitting of the Cylinder Bottom Side

6. Connect hose (25). Install clip band (24).
: 27 mm
: 80 N·m

24

25

WAFF-05-02-003-1 ja
7. Connect hoses (21) (3 used). Install clip bands (20) (2 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 27 mm
: 80 N·m

WAFF50-EN-00(07/05/2019) W5-2-2-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

8. Connect connector (23). Install clip band (22).

22
20

23

20 21
WAFF-05-02-002-1 ja
9. Install cover (19) with bolts, washers (18) (2 used).
: 17 mm
: 50 N·m
18

19
WAFF-05-02-001-1 ja

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

10. Remove the wire from the boom cylinder (5) rod.
11. Start the engine. Operate the boom control lever and extend boom cylinder (5) slowly. Fit the hole on the cylinder rod
side to the cylinder mounting holes on the boom.

NOTE
When the work is finished, air in the cylinder has been released.

WAFF50-EN-00(07/05/2019) W5-2-2-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Use one or more shims (12) respectively at the right and left sides.

12. Fit shims (12) to the right and left sides of the hole of the cylinder rod side. Make the total of the left and right
clearances up to 0.5 mm. Install pin (4) by using a hammer. Apply LOCTITE #262 to bolt (1). Install bolt (1), spring
washer (2), and bushing (3).
: 24 mm
: 210 N·m

NOTE
Shim (12) thickness: 0.5 mm, 1 mm

13. Install cover (6) to boom cylinder (5) with bolts (7) (2 used), spring washers (8) (2 used), and washers (9) (2 used).
: 17 mm
: 65 N·m
1, 2, 3

12
5

7, 8, 9

WAEQ-05-02-007-1 ja
14. Apply grease to grease fitting (b) of the boom cylinder rod side.

WABK-05-02-101-1 ja

b- Grease Fitting of the Cylinder Rod Side

IMPORTANT
After completing all the work, operate the boom cylinder to the stroke end several times and bleed air from the
circuit.

WAFF50-EN-00(07/05/2019) W5-2-2-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Disassembly of Boom Cylinder

7
10
25
9
3 8
6
13
5
24
14
23
20 12
19
11
20 12
18
16
15 21 1
17

22

WAFF-05-02-021-1 ja
1- Cylinder Tube 9- U-Packing 15- Piston 21- Steel Ball
3- Cylinder Rod 10- Dust Wiper 16- Piston Seal 22- Set Screw
5- Cylinder Head 11- O-Ring 17- Wear Ring 23- O-Ring
6- Bushing 12- Backup Ring (2 Used) 18- Dust Ring 24- Backup Ring
7- Retaining Ring 13- O-Ring 19- O-Ring 25- Backup Ring
8- Buffer Seal 14- Cushion Ring 20- Backup Ring (2 Used)
• The procedure starts on the premise that the pipes and bands securing the pipes have been removed.

WAFF50-EN-00(07/05/2019) W5-2-3-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

CAUTION
Boom cylinder weight: 78 kg

IMPORTANT
The seals cannot be reused. Replace them with the new ones.

1. Hoist the cylinder and secure it on a workbench horizontally. Drain off hydraulic oil from the cylinder.

W102-04-02-027-1 ja

IMPORTANT
Lock washer (a) of cylinder head (5) is integrated with cylinder tube (1). Do not damage cylinder tube (1) and
cylinder head (5) when lock washer (a) is bended and extended.

2. Pull out cylinder rod (3) about 200 mm. Install a protective cover to cylinder rod (3). Extend lock washer (a) of cylinder
head (5).

3 5

WABA-04-09-103-1 ja

a- Lock Washer

WAFF50-EN-00(07/05/2019) W5-2-3-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Remove cylinder rod (3) straight in order not to damage the sliding surface.

3. Loosen cylinder head (5) by using hook wrench (b) with the protective cover on cylinder rod (3). Remove the cylinder
rod (3) assembly from cylinder tube (1). Remove a protective cover from cylinder rod (3).
Cylinder head (5) diameter: 129 mm

5
3

WABA-04-09-104-1 ja

b- Hook Wrench
4. Secure the cylinder rod (3) assembly to special tool (ST 5908).
ST 5908

W158-04-02-022-1 ja
5. Cut away the crimped parts by using a hand drill. Remove set screw (22). Remove steel ball (21).

NOTE
Set screw (22) has been crimped at two places by using a punch after installing.

: 6 mm
6. Remove the piston (15) assembly by using special tools (ST 5908) and (ST 3362). Remove cushion ring (14) from
cylinder rod (3).
Special Tool: ST 3362 (Wrench Size:75 mm)
ST 5908

W158-04-02-022-1 ja

WAFF50-EN-00(07/05/2019) W5-2-3-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Do not damage piston (15) when removing seals.

7. Remove piston seal (16) from piston (15) by using a screwdriver.

15

16

WAFF-05-02-022-1 ja
8. Remove dust ring (18), wear ring (17), backup rings (20) (2 used), and O-ring (19) from piston (15).
9. Install a protective tape onto the thread of cylinder rod (3). Remove the cylinder head (5) assembly from cylinder rod
(3).
10. Remove retaining ring (7), dust wiper (10), backup ring (25), U-packing (9), buffer seal (8), O-ring (13), backup rings (12)
(2 used), backup ring (24), and O-rings (11, 23) from cylinder head (5).

IMPORTANT
Bushing (6) cannot be reused. If bushing (6) has been removed, replace it with the new one when assembling.

11. Remove bushing (6) from cylinder head (5) by using special tool (ST 8012).

WAFF-05-02-023-1 ja

c- Special Tool (ST 8012)

WAFF50-EN-00(07/05/2019) W5-2-3-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Assembly of Boom Cylinder

A 1 3 14 B

A B
18 16 15 17
13 5 24 23 12 11 12 22

21

10 25 9 8 6 20 19 20

WAFF-05-02-024-1 ja
1- Cylinder Tube 9- U-Packing 15- Piston 21- Steel Ball
3- Cylinder Rod 10- Dust Wiper 16- Piston Seal 22- Set Screw
5- Cylinder Head 11- O-Ring 17- Wear Ring 23- O-Ring
6- Bushing 12- Backup Ring (2 Used) 18- Dust Ring 24- Backup Ring
7- Retaining Ring 13- O-Ring 19- O-Ring 25- Backup Ring
8- Buffer Seal 14- Cushion Ring 20- Backup Ring (2 Used)

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
The seals cannot be reused. Replace them with the new ones.

1. Install bushing (6) to cylinder head (5) by using special tool (ST 8012).
Special Tool: ST 8012 ( Rod Outer Diameter: 60 mm)

6
5

WAFF-05-02-025-1 ja

d- Special Tool (ST 8012)

WAFF50-EN-00(07/05/2019) W5-2-4-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Check the direction to install U-packing (9) and buffer seal (8).

2. Install U-packing (9), buffer seal (8), and backup ring (25) to cylinder head (5).
3. Install dust wiper (10) and retaining ring (7) to cylinder head (5) by using a plastic hammer and special tool (ST 8049).
Special Tool: ST 8049 ( Rod Outer Diameter: 60 mm)

10
WAFF-05-02-026-1 ja

e- Special Tool (ST 8049)

4. Install O-rings (11, 13, 23), backup rings (12) (2 used), and backup ring (24) to cylinder head (5).
13 5 24 23 12 11 12

10 25 9 8 6
WAFF-05-02-027-1 ja
5. Install piston seal (16) to piston (15) by using special tool (ST 2962).
Special Tool: ST 2962 (Tube Inner Diameter: 110 mm)

f
16

15

W566-04-02-010-3 ja

f- Special Tool (ST 2962)

WAFF50-EN-00(07/05/2019) W5-2-4-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
If not adjusting piston seal (16), piston (15) cannot be installed to cylinder tube (1).

6. Adjust piston seal (16) by using special tool (ST 2962).

Special Tool: ST 2962 (Tube Inner Diameter: 110 mm)

16

15

W566-04-02-011-3 ja

f- Special Tool (ST 2962)

IMPORTANT
Install dust ring (18) and wear ring (17) with their respective cut sections 180 degrees apart.

7. Install dust ring (18), wear ring (17), O-ring (19), and backup rings (20) (2 used) to piston (15).
8. Install a protective tape onto the thread of cylinder rod (3). Turn and install the cylinder head (5) assembly to cylinder
rod (3).

IMPORTANT
Check the direction of the oil groove on cushion ring (14).

9. Install cushion ring (14) and the piston (15) assembly to cylinder rod (3) by using special tool (ST 5908) and special tool
(ST 3362).
Special Tool: ST 3362 (Wrench Size:75 mm)
: 11000-110 N·m
ST 5908

W158-04-02-022-1 ja

IMPORTANT
When cushion ring (14) is stuck, install cushion ring (14) and the piston (15) assembly again.

10. Check that cushion ring (14) is not stuck.

11. Tighten steel ball (21) and set screw (22) to piston (15). Crimp set screw (22) at two places by using a punch.
: 6 mm
: 20 ± 2 N·m

WAFF50-EN-00(07/05/2019) W5-2-4-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
When installing the cylinder rod (3) assembly, be careful not to drop dust ring (18) and wear ring (17) from piston
(15).

CAUTION
Fit the cylinder rod (3) assembly with the center of cylinder tube (1) and install straight in order not to damage the
rings.

12. Secure cylinder tube (1) to a workbench horizontally. Install the cylinder rod (3) assembly to cylinder tube (1).
13. Tighten cylinder head (5) to cylinder tube (1) by using hook wrench (b). Bend the lock washer in order to prevent it
from loosening.
Cylinder head (5) diameter: 129 mm
: 950 ± 95 N·m

WABA-04-09-107-1 ja

b- Hook Wrench

WAFF50-EN-00(07/05/2019) W5-2-4-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Removal of Arm Cylinder

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder retracted to
the minimum. Lower the end of arm to the ground.
2. Place wooden block (3) between arm cylinder (1) and boom (2). Stop the engine.

3 2

WAEJ-05-02-106-1 ja

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

3. Remove bolt (4), spring washer (5), and bushing (6). Remove pin (7) by using a bar and a hammer. Remove shim (20).
: 22 mm

NOTE
LOCTITE #262 has been applied onto bolt (4).

NOTE
If pin (7) is hard to be removed, raise boom (2) a little then remove pin (7).

4. Start the engine. Operate the arm control lever and retract arm cylinder (1). In order not to extend rod (12), pass wire
(17) through the rod (12) hole and secure the rod to the cylinder tube. Stop the engine.

WAFF50-EN-00(07/05/2019) W5-2-5-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

5. Remove bolts, washers (19) (2 used) Remove cover (18).

: 17 mm
20
7
4, 5, 6

1 17

12

18
2

19
WAEQ-05-02-004-1 ja

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)

6. Remove clip bands (21) (4 used). Disconnect hoses (8) (4 used).

: 17 mm, 19 mm, 36 mm
A

21
8

21
A

8
WAEQ-05-02-005-1 ja

WAFF50-EN-00(07/05/2019) W5-2-5-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

CAUTION
Arm cylinder (1) weight: 63 kg

7. Attach nylon slings onto arm cylinder (1), then hoist and hold it.

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

8. Remove bolt (14), spring washer (15), and bushing (16). Remove pin (13) by using a bar and a hammer. Remove shim
(23).
: 22 mm

NOTE
LOCTITE #262 has been applied onto bolt (14).

9. Hoist and remove arm cylinder (1) from boom (2).

1 13, 23 14, 15, 16

WAEJ-05-02-108-2 ja

WAFF50-EN-00(07/05/2019) W5-2-5-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

MEMO

WAFF50-EN-00(07/05/2019) W5-2-5-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Installation of Arm Cylinder

1. Apply grease to the lip part of the dust seal, the side of the boss, and the inner surface of the bushing (both the
bottom and rod sides) of arm cylinder (1).

CAUTION
Arm cylinder (1) weight: 63 kg

IMPORTANT
Use one or more shims (23) respectively at the right and left sides.

2. Attach nylon slings onto arm cylinder (1) and hoist it. Fit the hole on the cylinder bottom side to the cylinder
mounting holes on boom (2). Fit shims (23) to the right and left sides of the hole of the cylinder bottom side. Make the
total of the right and left clearances between boom (2) and arm cylinder (1) 0.5 mm or less.

NOTE
Shim (23) thickness: 0.5 mm, 1 mm

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

3. Apply LOCTITE #262 to bolt (14). Install pin (13) by using a hammer. Install bolt (14), spring washer (15), and bushing
(16).
: 22 mm
: 140 N·m

1 13, 23 14, 15, 16

WAEJ-05-02-108-2 ja

WAFF50-EN-00(07/05/2019) W5-2-6-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

4. Apply grease to grease fitting (a) of the arm cylinder bottom side.
a

WABK-05-02-102-1 ja

a- Grease Fitting of the Cylinder Bottom Side

5. Connect hoses (8) (4 used). Install clip bands (21) (4 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 36 mm
: 180 N·m
A

21
8

21
A

8
WAEQ-05-02-005-1 ja

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

6. Install cover (18) with bolts, washers (19) (2 used).

: 17 mm
: 50 N·m
7. Remove wire (17) from rod (12) of arm cylinder (1).

WAFF50-EN-00(07/05/2019) W5-2-6-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

8. Start the engine. Operate the arm control lever and extend arm cylinder (1) slowly. Fit the hole on the cylinder rod side
to the cylinder mounting holes on arm (24).

NOTE
When the work is finished, air in the cylinder has been released.

NOTE
When the mounting holes do not fit, raise boom (2) a little and fit the mounting holes.

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Use one or more shims (20) respectively at the right and left sides.

9. Fit shims (20) to the right and left sides of the hole of the cylinder rod side. Make the total of the right and left
clearances between arm (24) and arm cylinder (1) 0.5 mm or less. Install pin (7) by using a hammer. Apply LOCTITE
#262 to bolt (4). Install bolt (4), spring washer (5), and bushing (6).
: 22 mm
: 140 N·m

NOTE
Shim (20) thickness: 0.5 mm, 1.0 mm

20
7
4, 5, 6

24

1 17

12

18
2

19
WAEQ-05-02-004-2 ja

WAFF50-EN-00(07/05/2019) W5-2-6-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

10. Apply grease to grease fitting (b) of the arm cylinder rod side.
b

WABK-05-02-103-1 ja

b- Grease Fitting of the Cylinder Rod Side

IMPORTANT
After completing all the work, operate the arm cylinder to the stroke end several times and bleed air from the
circuit.

WAFF50-EN-00(07/05/2019) W5-2-6-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Disassembly of Arm Cylinder

22
21
3
14
20
19
20
15
18
16
17

7
10
23
9
8
6 1
5
13
12
11
12
11
12

WAFF-05-02-031-1 ja
1- Cylinder Tube 9- U-Packing 15- Piston 21- Set Screw
3- Cylinder Rod 10- Dust Wiper 16- Piston Seal 22- Steel Ball
5- Cylinder Head 11- O-Ring (2 Used) 17- Wear Ring 23- Backup Ring
6- Bushing 12- Backup Ring (3 Used) 18- Dust Ring
7- Retaining Ring 13- O-Ring 19- O-Ring
8- Buffer Seal 14- Cushion Ring 20- Backup Ring (2 Used)
• The procedure starts on the premise that the pipes and bands securing the pipes have been removed.

WAFF50-EN-00(07/05/2019) W5-2-7-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

CAUTION
Arm cylinder weight: 63 kg

IMPORTANT
The seals cannot be reused. Replace them with the new ones.

1. Hoist the cylinder and secure it on a workbench horizontally. Drain off hydraulic oil from the cylinder.

W102-04-02-027-1 ja

IMPORTANT
Lock washer (a) of cylinder head (5) is integrated with cylinder tube (1). Do not damage cylinder tube (1) and
cylinder head (5) when lock washer (a) is bended and extended.

2. Pull out cylinder rod (3) about 200 mm. Install a protective cover to cylinder rod (3). Extend lock washer (a) of cylinder
head (5).

3 5

WABA-04-09-103-1 ja

a- Lock Washer

WAFF50-EN-00(07/05/2019) W5-2-7-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Remove cylinder rod (3) straight in order not to damage the sliding surface.

3. Loosen cylinder head (5) by using hook wrench (b) with the protective cover on cylinder rod (3). Remove the cylinder
rod (3) assembly from cylinder tube (1). Remove a protective cover from cylinder rod (3).
Cylinder head (5) diameter: 108 mm

5
3

WABA-04-09-104-1 ja

b- Hook Wrench
4. Secure the cylinder rod (3) assembly to special tool (ST 5908).
ST 5908

W158-04-02-022-1 ja
5. Cut away the crimped part by using a hand drill. Remove set screws (21) (2 used). Remove steel ball (22).

NOTE
Set screw (21) has been crimped at two places by using a punch after installing.

: 6 mm
6. Remove the piston (15) assembly by using special tools (ST 5908) and (ST 3364). Remove cushion ring (14) from
cylinder rod (3).
Special Tool: ST 3364 (Wrench Size:70 mm)
ST 5908

W158-04-02-022-1 ja

WAFF50-EN-00(07/05/2019) W5-2-7-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Do not damage piston (15) when removing seals.

7. Remove piston seal (16) from piston (15) by using a screwdriver.

15

16

WAFF-05-02-022-1 ja
8. Remove dust ring (18), wear ring (17), backup rings (20) (2 used), and O-ring (19) from piston (15).
9. Install a protective tape onto the thread of cylinder rod (3). Remove the cylinder head (5) assembly from cylinder rod
(3).
10. Remove retaining ring (7), dust wiper (10), backup ring (23), U-packing (9), buffer seal (8), O-ring (13), backup rings (12)
(3 used), and O-rings (11) (2 used) from cylinder head (5).

IMPORTANT
Bushing (6) cannot be reused. If bushing (6) has been removed, replace it with the new one when assembling.

11. Remove bushing (6) from cylinder head (5) by using special tool (ST 8011).
Special Tool: ST 8011 ( Rod Outer Diameter: 55 mm)

WAFF-05-02-023-1 ja

c- Special Tool (ST 8011)

WAFF50-EN-00(07/05/2019) W5-2-7-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Assembly of Arm Cylinder

A 1 3 14 B

A B
18 16 15 17
13 12
21
5 22

7
10

23 9 8 6 11 20 19 20

WAFF-05-02-032-1 ja
1- Cylinder Tube 9- U-Packing 15- Piston 21- Set Screw (2 Used)
3- Cylinder Rod 10- Dust Wiper 16- Piston Seal 22- Steel Ball
5- Cylinder Head 11- O-Ring (2 Used) 17- Wear Ring 23- Backup Ring
6- Bushing 12- Backup Ring (3 Used) 18- Dust Ring
7- Retaining Ring 13- O-Ring 19- O-Ring
8- Buffer Seal 14- Cushion Ring 20- Backup Ring (2 Used)

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
The seals cannot be reused. Replace them with the new ones.

1. Install bushing (6) to cylinder head (5) by using special tool (ST 8011).
Special Tool: ST 8011 ( Rod Outer Diameter: 55 mm)

6
5

WAFF-05-02-033-1 ja

d- Special Tool (ST 8011)

WAFF50-EN-00(07/05/2019) W5-2-8-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Check the direction to install U-packing (9) and buffer seal (8).

2. Install U-packing (9), buffer seal (8), and backup ring (23) to cylinder head (5).
3. Install dust wiper (10) and retaining ring (7) to cylinder head (5) by using a plastic hammer and special tool (ST 8048).
Special Tool: ST 8048 ( Rod Outer Diameter: 55 mm)

10
WAFF-05-02-026-1 ja

e- Special Tool (ST 8048)

4. Install O-ring (13), O-rings (11) (2 used), and backup rings (12) (3 used) to cylinder head (5).
13 12
5

7
10

23 9 8 6 11
WAFF-05-02-034-1 ja
5. Install piston seal (16) to piston (15) by using special tool (ST 2943).
Special Tool: ST 2943 (Tube Inner Diameter: 90 mm)

f
16

15

W566-04-02-010-3 ja

f- Special Tool (ST 2943)

WAFF50-EN-00(07/05/2019) W5-2-8-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
If not adjusting piston seal (16), piston (15) cannot be installed to cylinder tube (1).

6. Adjust piston seal (16) by using special tool (ST 2598).

Special Tool: ST 2598 (Tube Inner Diameter: 90 mm)

16

15

W566-04-02-011-4 ja

g- Special Tool (ST 2598)

IMPORTANT
Install dust ring (18) and wear ring (17) with their respective cut sections 180 degrees apart.

7. Install dust ring (18), wear ring (17), O-ring (19), and backup rings (20) (2 used) to piston (15).
8. Install a protective tape onto the thread of cylinder rod (3). Turn and install the cylinder head (5) assembly to cylinder
rod (3).

IMPORTANT
Check the direction of the oil groove on cushion ring (14).

9. Install cushion ring (14) and the piston (15) assembly to cylinder rod (3) by using special tool (ST 5908) and special tool
(ST 3364).
Special Tool: ST 3364 (Wrench Size:70 mm)
: 10000-10 N·m
ST 5908

W158-04-02-022-1 ja

IMPORTANT
When cushion ring (14) is stuck, install cushion ring (14) and the piston (15) assembly again.

10. Check that cushion ring (14) is not stuck.

11. Tighten steel ball (22) and set screw (21) to piston (15). Crimp set screw (21) at two places by using a punch.
: 6 mm
: 20 ± 2 N·m

WAFF50-EN-00(07/05/2019) W5-2-8-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
When installing the cylinder rod (3) assembly, be careful not to drop dust ring (18) and wear ring (17) from piston
(15).

CAUTION
Fit the cylinder rod (3) assembly with the center of cylinder tube (1) and install straight in order not to damage the
rings.

12. Secure cylinder tube (1) to a workbench horizontally. Insert the cylinder rod (3) assembly into cylinder tube (1).
13. Tighten cylinder head (5) to cylinder tube (7) by using hook wrench (b). Bend the lock washer in order to prevent it
from loosening.
Cylinder head (5) diameter: 108 mm
: 800 ± 80 N·m

WABA-04-09-107-1 ja

b- Hook Wrench

WAFF50-EN-00(07/05/2019) W5-2-8-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Removal of Bucket Cylinder

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Place the machine on a firm level ground and lower the boom with the arm cylinder and bucket cylinder (1) retracted
to the minimum. Lower the end of arm (2) to the ground.
2. Insert wooden block (a) between the end of arm (2) and the ground and between bucket cylinder (1) and arm (2).

a
2
a

W178-02-11-287-1 ja

a- Wooden Block

WAFF50-EN-00(07/05/2019) W5-2-9-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

CAUTION
Before removing pin (7), secure the links using wires to prevent them from falling off.

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

3. Put the matching marks on link B (17) and pin (7). Remove nuts (6) (2 used) and stopper pin (4). Remove pin (7) by
using a bar and a hammer. Remove shim (5).
: 24 mm

NOTE
LOCTITE #262 has been applied onto stopper pin (4).

4 5

7 17

WABA-05-02-109-4 ja
4. Start the engine. Operate the bucket control lever and retract bucket cylinder (1). In order not to extend rod (8), pass
wire (3) through the rod (8) hole and secure the rod to the cylinder tube. Stop the engine.
8 1

3
W102-04-02-005-2 ja

WAFF50-EN-00(07/05/2019) W5-2-9-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)

5. Disconnect hoses (14) (2 used).

: 27 mm

14

WAEJ-05-02-112-3 ja

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

CAUTION
Bucket cylinder (1) weight: 36 kg

6. Attach nylon slings onto bucket cylinder (1), then hoist and hold it. Remove bolt (10), spring washer (11), and bushing
(12). Remove pin (9) by using a bar and a hammer. Remove shim (15).
: 22 mm

NOTE
LOCTITE #262 has been applied onto bolt (10).

WAFF50-EN-00(07/05/2019) W5-2-9-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

7. Hoist and remove bucket cylinder (1) from arm (2).

10, 11, 12
15
9

WAEJ-05-02-112-2 ja

WAFF50-EN-00(07/05/2019) W5-2-9-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Installation of Bucket Cylinder

1. Apply grease to the lip part of the dust seal, the side of the boss, and the inner surface of the bushing (both the
bottom and rod sides) of bucket cylinder (1).

CAUTION
Bucket cylinder (1) weight: 36 kg

IMPORTANT
Use one or more shims (15) respectively at the right and left sides.

2. Attach nylon slings onto bucket cylinder (1) and hoist it. Fit the hole at the cylinder bottom side to the cylinder
mounting holes of arm (2). Fit shims (15) to the right and left sides of the hole of the cylinder bottom side. Make the
total of the right and left clearances between arm (2) and arm cylinder (1) 0.5 mm or less.

NOTE
Shim (15) thickness: 0.5 mm, 1 mm

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

3. Apply LOCTITE #262 to bolt (10). Install pin (9) by using a hammer. Install bolt (10), spring washer (11), and bushing
(12).
: 22 mm
: 140 N·m

10, 11, 12
15
9

WAEJ-05-02-112-2 ja

WAFF50-EN-00(07/05/2019) W5-2-10-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

4. Apply grease to grease fitting (b) at the bucket cylinder bottom side.

WABK-05-02-103-2 ja

b- Grease Fitting of the Cylinder Bottom Side

5. Connect hoses (14) (2 used).
: 27 mm
: 80 N·m

14

WAEJ-05-02-112-3 ja

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

6. Remove wire (3) from rod (8) of bucket cylinder (1).

8 1

3
W102-04-02-005-2 ja

WAFF50-EN-00(07/05/2019) W5-2-10-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

7. Start the engine. Operate the bucket control lever and extend bucket cylinder (1) slowly. Fit the hole on the cylinder
rod side to the cylinder mounting holes on link A (16) and links B (17) (2 used).

NOTE
When the work is finished, air in the cylinder has been released.

CAUTION
Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in
order to prevent personal injury.

IMPORTANT
Use one or more shims (5) respectively at the right and left sides.

8. Fit shims (5) to the right and left sides of the link A (16) hole. Make the total of the right and left clearances between
bucket cylinder (1) and link A (16) 0.5 mm or less.

NOTE
Shim (5) thickness: 0.5 mm, 1 mm

9. Remove the wires which secure link B (17). Fit the matching marks on link B (17) and pin (7). Install pin (7) by using a
hammer.
10. Apply LOTITE #262 to stopper pin (4). Install stopper pin (4) to link B (17) and pin (7) with nuts (6) (2 used).
: 24 mm
: 270 N·m

16 4 5 1

7 17

WABA-05-02-109-5 ja

WAFF50-EN-00(07/05/2019) W5-2-10-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

11. Apply grease to grease fittings (c) (2 places) at the bucket cylinder rod side.
c

WABK-05-02-104-1 ja

c- Grease Fitting of the Cylinder Rod Side

IMPORTANT
After completing all the work, operate the bucket cylinder to the stroke end several times and bleed air from the
circuit.

WAFF50-EN-00(07/05/2019) W5-2-10-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Disassembly of Bucket Cylinder

17
16
18

15

20 1

19
21 22
20

11
12
13

6
8
9
25
10
7

WAFF-05-02-035-1 ja
1- Cylinder Tube 8- Buffer Seal 13- O-Ring 19- O-Ring
3- Cylinder Rod 9- U-Packing 15- Piston 20- Backup Ring (2 Used)
5- Cylinder Head 10- Dust Wiper 16- Piston Seal 21- Steel Ball
6- Bushing 11- O-Ring 17- Wear Ring 22- Set Screw
7- Retaining Ring 12- Backup Ring 18- Dust Ring (2 Used) 23- Backup Ring

WAFF50-EN-00(07/05/2019) W5-2-11-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

• The procedure starts on the premise that the pipes and bands securing the pipes have been removed.

CAUTION
Bucket cylinder weight: 36 kg

IMPORTANT
The seals cannot be reused. Replace them with the new ones.

1. Hoist the cylinder and secure it on a workbench horizontally. Drain off hydraulic oil from the cylinder.

W102-04-02-027-1 ja

IMPORTANT
Lock washer (a) of cylinder head (5) is integrated with cylinder tube (1). Do not damage cylinder tube (1) and
cylinder head (5) when lock washer (a) is bended and extended.

2. Pull out cylinder rod (3) about 200 mm. Install a protective cover to cylinder rod (3). Extend lock washer (a) of cylinder
head (5).

3 5

WABA-04-09-103-1 ja

a- Lock Washer

WAFF50-EN-00(07/05/2019) W5-2-11-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Remove cylinder rod (3) straight in order not to damage the sliding surface.

3. Loosen cylinder head (5) by using hook wrench (b) with the protective cover on cylinder rod (3). Remove the cylinder
rod (3) assembly from cylinder tube (1). Remove a protective cover from cylinder rod (3).
Cylinder head (5) diameter: 98 mm

5
3

WABA-04-09-104-1 ja

b- Hook Wrench
4. Secure the cylinder rod (3) assembly to special tool (ST 5908).
ST 5908

W158-04-02-022-1 ja
5. Cut away the crimped parts by using a hand drill. Remove set screw (22). Remove steel ball (21).
: 4 mm

NOTE
Set screw (22) has been crimped at two places by using a punch after installing.

6. Remove the piston (15) assembly by using special tools (ST 5908) and (ST 3363).
Special Tool: ST 3363 (Wrench Size:65 mm)
ST 5908

W158-04-02-022-1 ja
7. Remove dust ring (18), wear ring (17), backup rings (20) (2 used), and O-ring (19) from piston (15).

WAFF50-EN-00(07/05/2019) W5-2-11-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Do not damage piston (15) when removing seals.

8. Remove piston seal (16) from piston (15) by using a screwdriver.

15

16

WAFF-05-02-022-1 ja
9. Install a protective tape onto the thread of cylinder rod (3). Remove the cylinder head (5) assembly from cylinder rod
(3).
10. Remove dust wiper (10), U-packing (9), buffer seal (8), retaining ring (7), O-ring (13), backup ring (12), and O-ring (11)
from cylinder head (5).

IMPORTANT
Bushing (6) cannot be reused. If bushing (6) has been removed, replace it with the new one when assembling.

11. Remove bushing (6) from cylinder head (5) by using special tool (ST 8040).
Special Tool: ST 8040 (Rod Outer Diameter: 50 mm)

WAFF-05-02-023-1 ja

c- Special Tool (ST 8040)

WAFF50-EN-00(07/05/2019) W5-2-11-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Assembly of Bucket Cylinder

A 1 3 B

A B 18 16 15 17
13 12 11 22

5
21

7
10
25 9 8 6 20 19 20

WAFF-05-02-036-1 ja
1- Cylinder Tube 8- Buffer Seal 13- O-Ring 19- O-Ring
3- Cylinder Rod 9- U-Packing 15- Piston 20- Backup Ring (2 Used)
5- Cylinder Head 10- Dust Wiper 16- Piston Seal 21- Steel Ball
6- Bushing 11- O-Ring 17- Wear Ring 22- Set Screw
7- Retaining Ring 12- Backup Ring 18- Dust Ring (2 Used) 23- Backup Ring

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
The seals cannot be reused. Replace them with the new ones.

IMPORTANT
Check the direction to install U-packing (9) and buffer seal (8).

1. Install U-packing (9), buffer seal (8), and backup ring (23) to cylinder head (5).
2. Install bushing (6) to cylinder head (5) by using special tool (ST 8040).
Special Tool: ST 8040 ( Rod Outer Diameter: 50 mm)

6
5

WAFF-05-02-025-1 ja

d- Special Tool (ST 8040)

WAFF50-EN-00(07/05/2019) W5-2-12-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

3. Install dust wiper (10) to cylinder head (5) by using a plastic hammer and special tool (ST 8047).
Special Tool: ST 8047 ( Rod Outer Diameter: 50 mm)

10
WAFF-05-02-026-1 ja

e- Special Tool (ST 8047)

4. Install O-rings (13, 11) and backup ring (12) to cylinder head (5).
13 12 11

7
10
25 9 8 6
WAFF-05-02-038-1 ja
5. Install piston seal (16) to piston (15) by using special tools (ST 2623) and (ST 2625).
Special Tool: ST 2623 (Tube Inner Diameter: 80 mm)
Special Tool: ST 2625 (Tube Inner Diameter: 80 mm)

f
16

15

W566-04-02-010-6 ja

f- Special Tool (ST 2625) g- Special Tool (ST 2623)

WAFF50-EN-00(07/05/2019) W5-2-12-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
If not adjusting piston seal (16), piston (15) cannot be installed to cylinder tube (1).

6. Adjust piston seal (16) by using special tool (ST 2627).

Special Tool: ST 2627 (Tube Inner Diameter: 80 mm)

16

15

W566-04-02-011-5 ja

h- Special Tool (ST 2627)

IMPORTANT
Install dust ring (18) and wear ring (17) with their respective cut sections 180 degrees apart.

7. Install dust rings (18) (2 used), wear ring (17), O-ring (19), and backup rings (20) (2 used) to piston (15).
8. Install a protective tape onto the thread of cylinder rod (3). Turn and install the cylinder head (5) assembly to cylinder
rod (3).
9. Install the piston (15) assembly to cylinder rod (3) by using special tool (ST 5908) and special tool (ST 3363).
Special Tool: ST 3363 (Wrench Size:65 mm)
: 10000-100 N·m
ST 5908

W158-04-02-022-1 ja
10. Tighten steel ball (21) and set screw (22) to piston (15). Crimp set screw (22) at two places by using a punch.
: 6 mm
: 20 ± 2 N·m

CAUTION
Fit the cylinder rod (3) assembly with the center of cylinder tube (1) and install straight in order not to damage the
rings.

IMPORTANT
When installing the cylinder rod (3) assembly, be careful not to drop dust ring (18) and wear ring (17) from piston
(15).

11. Secure cylinder tube (1) in a vise horizontally. Install washer (23) and the cylinder rod (3) assembly to cylinder tube (1).

WAFF50-EN-00(07/05/2019) W5-2-12-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

12. Tighten cylinder head (5) to cylinder tube (1) by using hook wrench (b). Bend the lock washer in order to prevent it
from loosening.
Cylinder head (5) diameter: 98 mm
: 700 ± 70 N·m

WABA-04-09-107-1 ja

b- Hook Wrench

WAFF50-EN-00(07/05/2019) W5-2-12-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Removal of Boom Swing Cylinder

• The following procedures start after the front swings to the left.

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Park the machine on a solid and level surface. Make the machine swing to the right by 90 degrees. Lower the boom
with the arm cylinder and bucket cylinder retracted to the maximum. Lower the end of arm to the ground.

CAUTION
Boom swing cylinder (4) weight: 45 kg

2. Insert a wooden block between boom swing cylinder (4) and main frame (5). Put the matching marks on the boss of
the swing post and pin (2). Remove nuts (3) (2 used) and bolt (1). Remove pin (2).
: 22 mm

NOTE
LOCTITE #262 has been applied onto bolt (1).

NOTE
Removing bolt (1) could lead to pin (2) dropping.

5 4

WAEJ-05-02-115-1 ja
3. Start the engine. Operate the boom swing pedal and retract boom swing cylinder (4). In order not to extend the rod,
pass wires through the rod hole and secure the rod to the cylinder tube.

WAFF50-EN-00(07/05/2019) W5-2-13-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

CAUTION
Remove cover (6) while holding cover (6). Do not drop cover (6).

4. Remove bolts, washers (7) (4 used) Remove cover (6).

: 17 mm

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)

5. Disconnect hose (13) of the cylinder bottom side.

: 22 mm

CAUTION
Remove cover (9) while holding cover (9). Do not drop cover (9).

6. Remove bolts, washers (8) (4 used) Remove cover (9).

: 17 mm
7. Disconnect hose (14) of the cylinder rod side.
: 22 mm
8. Remove bolt (10), spring washer (11), and bushing (15). Remove pin (12) from the main frame (the lower side).
: 22 mm

WAFF50-EN-00(07/05/2019) W5-2-13-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

9. Hoist and remove boom swing cylinder (4) from the main frame.

7
8

9 6

4 10, 11, 15

12

13
4 14
WAFF-05-02-061-1 ja

WAFF50-EN-00(07/05/2019) W5-2-13-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

MEMO

WAFF50-EN-00(07/05/2019) W5-2-13-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Installation of Boom Swing Cylinder

1. Apply grease to the lip part of the dust seal of boom swing cylinder (4).

CAUTION
Boom swing cylinder (4) weight: 45 kg

2. Place a wooden block on the main frame. Attach nylon slings onto boom swing cylinder (4) and hoist it. Place boom
swing cylinder (4) on the wooden block.
3. Fit the hole on the cylinder bottom side to the cylinder mounting hole on the main frame. Apply grease to the surface
of pin (12). Install pin (12) by using a plastic hammer. Install bolt (10), spring washer (11), and bushing (15).
: 22 mm
: 140 N·m
4. Connect hose (13) to the bottom side of boom swing cylinder (4). Connect hose (14) to the cylinder rod side.
: 22 mm
: 40 N·m
4 10, 11, 15

12

13
4 14
WAFF-05-02-062-1 ja

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

5. Remove the wire from the rod of boom swing cylinder (4).
6. Start the engine. Operate the boom swing pedal and extend boom swing cylinder (4) slowly. Fit the hole on the
cylinder rod side to the cylinder mounting hole on the swing post.

NOTE
When the work is finished, air in the cylinder has been released.

7. Apply grease to the surface of pin (2). Fit the matching marks on the boss of the swing post and pin (2). Install pin (2).

WAFF50-EN-00(07/05/2019) W5-2-14-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Install nut (3) with a clearance of 2 to 3 mm between nut (3) and the boss of the swing post.

8. Apply LOCTITE #262 to bolt (1). Install bolt (1) to the swing post and the pin with nuts (3) (2 used).
: 22 mm
: 180 N·m

WAEJ-05-02-115-2 ja
9. Install cover (9) with bolts, washers (8) (4 used).
: 17 mm
: 50 N·m
10. Install cover (6) with bolts, washers (7) (4 used).
: 17 mm
: 50 N·m

7
8

9 6
WAFF-05-02-063-1 ja

WAFF50-EN-00(07/05/2019) W5-2-14-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

11. Apply grease to grease fitting (a) at the rod side of the boom swing cylinder.

a
WABK-05-02-105-1 ja

a- Grease Fitting at Cylinder Rod Side

IMPORTANT
After completing all the work, operate the boom swing cylinder to the stroke end several times and bleed air from
the circuit.

WAFF50-EN-00(07/05/2019) W5-2-14-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

MEMO

WAFF50-EN-00(07/05/2019) W5-2-14-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Disassembly of Boom Swing Cylinder

17
16
18

15

20
19
21 22
20 1

3
11
12
13
5

6
8
9
25
10
7

WAFF-05-02-071-1 ja
1- Cylinder Tube 8- Buffer Seal 13- O-Ring 19- O-Ring
3- Cylinder Rod 9- U-Packing 15- Piston 20- Backup Ring (2 Used)
5- Cylinder Head 10- Dust Wiper 16- Piston Seal 21- Steel Ball
6- Bushing 11- O-Ring 17- Wear Ring 22- Set Screw
7- Retaining Ring 12- Backup Ring 18- Dust Ring 24- Backup Ring

WAFF50-EN-00(07/05/2019) W5-2-15-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

• The procedure starts on the premise that the pipes and bands securing the pipes have been removed.

CAUTION
Boom swing cylinder weight: 45 kg

IMPORTANT
The seals cannot be reused. Replace them with the new ones.

1. Hoist the cylinder and secure it on a workbench horizontally. Drain off hydraulic oil from the cylinder.

W102-04-02-027-1 ja

IMPORTANT
Lock washer (a) of cylinder head (5) is integrated with cylinder tube (1). Do not damage cylinder tube (1) and
cylinder head (5) when lock washer (a) is bended and extended.

2. Pull out cylinder rod (3) about 200 mm. Install a protective cover to cylinder rod (3). Extend lock washer (a) of cylinder
head (5).

3 5

WABA-04-09-103-1 ja

a- Lock Washer

WAFF50-EN-00(07/05/2019) W5-2-15-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Remove cylinder rod (3) straight in order not to damage the sliding surface.

3. Loosen cylinder head (5) by using hook wrench (b) with the protective cover on cylinder rod (3). Remove the cylinder
rod (3) assembly from cylinder tube (1). Remove a protective cover from cylinder rod (3).
Cylinder head (5) diameter: 113 mm

5
3

WABA-04-09-104-1 ja

b- Hook Wrench
4. Secure the cylinder rod (3) assembly to special tool (ST 5908).
ST 5908

W158-04-02-022-1 ja
5. Cut away the crimped parts by using a hand drill. Remove set screw (22). Remove steel ball (21).
: 6 mm

NOTE
Set screw (22) has been crimped at two places by using a punch after installing.

6. Remove the piston (15) assembly by using special tools (ST 5908) and (ST 3364).
Special Tool: ST 3364 (Wrench Size:70 mm)
ST 5908

W158-04-02-022-1 ja
7. Secure piston (15) in a vice. Remove dust ring (18), wear ring (17), backup rings (20) (2 used), and O-ring (19) from
piston (15).

WAFF50-EN-00(07/05/2019) W5-2-15-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Do not damage piston (15) when removing seals.

8. Remove piston seal (16) from piston (15) by using a screwdriver.

15

16

WAFF-05-02-022-1 ja
9. Install a protective tape onto the thread of cylinder rod (3). Remove the cylinder head (5) assembly from cylinder rod
(3).
10. Remove retaining ring (7), dust wiper (10), U-packing (9), buffer seal (8), O-ring (13), backup ring (12), and O-ring (11)
from cylinder head (5).
11. Remove backup ring (24) from cylinder head (5).

IMPORTANT
Bushing (6) cannot be reused. If bushing (6) has been removed, replace it with the new one when assembling.

12. Remove bushing (6) from cylinder head (5) by using special tool (ST 8011).
Special Tool: ST 8011 (Rod Outer Diameter: 55 mm)

WAFF-05-02-023-1 ja

c- Special Tool (ST 8011)

WAFF50-EN-00(07/05/2019) W5-2-15-4
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

Assembly of Boom Swing Cylinder

10 13 11,12 5 1 15 18 19 22

6 9,24 3 16 17 20 21

WAEJ-05-02-120-1 ja
1- Cylinder Tube 8- Buffer Seal 13- O-Ring 19- O-Ring
3- Cylinder Rod 9- U-Packing 15- Piston 20- Backup Ring (2 Used)
5- Cylinder Head 10- Dust Wiper 16- Piston Seal 21- Steel Ball
6- Bushing 11- O-Ring 17- Wear Ring 22- Set Screw
7- Retaining Ring 12- Backup Ring 18- Dust Ring 24- Backup Ring

IMPORTANT
Before assembly, apply hydraulic oil onto the parts in order to prevent them from seizing.

IMPORTANT
The seals cannot be reused. Replace them with the new ones.

IMPORTANT
Check the direction to install U-packing (9) and buffer seal (8).

1. Install backup ring (24), U-packing (9), and buffer seal (8) to cylinder head (5).
2. Install bushing (6) to cylinder head (5) by using special tool (ST 8011).
Special Tool: ST 8011 ( Rod Outer Diameter: 55 mm)

6
5

WAFF-05-02-025-1 ja

d- Special Tool (ST 8011)

WAFF50-EN-00(07/05/2019) W5-2-16-1
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

3. Install dust wiper (10) and retaining ring (7) to cylinder head (5) by using a plastic hammer and special tool (ST 8048).
Special Tool: ST 8048 ( Rod Outer Diameter: 55 mm)

10
WAFF-05-02-026-1 ja

e- Special Tool (ST 8048)

4. Install O-ring (13), O-rings (11, 13), and backup ring (12) to cylinder head (5).
5. Install piston seal (16) to piston (15) by using special tool (ST 2976).
Special Tool: ST 2976 (Tube Inner Diameter: 95 mm)

f
16

15

W566-04-02-010-3 ja

f- Special Tool (ST 2976)

IMPORTANT
If not adjusting piston seal (16), piston (15) cannot be installed to cylinder tube (1).

6. Pass special tool (ST 2976) through piston (15). Adjust piston seal (16).
Special Tool: ST 2976 (Tube Inner Diameter: 95 mm)

16

15

W566-04-02-011-3 ja

f- Special Tool (ST 2976)

WAFF50-EN-00(07/05/2019) W5-2-16-2
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

IMPORTANT
Install dust ring (18) and wear ring (17) with their respective cut sections 180 degrees apart.

7. Install dust rings (18) (2 used), wear ring (17), O-ring (19), and backup rings (20) (2 used) to piston (15).
8. Install a protective tape onto the thread of cylinder rod (3). Turn and install the cylinder head (5) assembly to cylinder
rod (3).
9. Install the piston (15) assembly to cylinder rod (3) by using special tool (ST 5908) and special tool (ST 3364).
Special Tool: ST 3364 (Wrench Size:70 mm)
: 12000-120 N·m
ST 5908

W158-04-02-022-1 ja
10. Tighten steel ball (21) and set screw (22) to piston (15). Crimp set screw (22) at two places by using a punch.
: 6 mm
: 20 ± 2 N·m

CAUTION
Fit the cylinder rod (3) assembly with the center of cylinder tube (1) and install straight in order not to damage the
rings.

IMPORTANT
When installing the cylinder rod (3) assembly, be careful not to drop dust ring (18) and wear ring (17) from piston
(15).

11. Secure cylinder tube (1) in a vise horizontally. Install the cylinder rod (3) assembly to cylinder tube (1).
12. Tighten cylinder head (5) to cylinder tube (1) by using hook wrench (b). Bend the lock washer in order to prevent it
from loosening.
Cylinder head (5) diameter: 113 mm
: 980 ± 98 N·m

WABA-04-09-107-1 ja

b- Hook Wrench

WAFF50-EN-00(07/05/2019) W5-2-16-3
 SECTION5 FRONT ATTACHMENT
Group2 Cylinder

MEMO

WAFF50-EN-00(07/05/2019) W5-2-16-4
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve
　
Removal of Hose Rupture Valve for Boom Cylinder
　
IMPORTANT 　
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil. 　
IMPORTANT 　
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
　
install the clips after connecting the hoses.
　
1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder retracted to
the minimum. Lower the end of arm to the ground. 　
CAUTION 　
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.) 　
CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)

2. Remove bolts, washers (18) (2 used) Remove cover (19).

: 17 mm

18

19

WAFF-05-03-001-1 ja
3. Remove clip band (22). Disconnect connector (23).

WAFF50-EN-00(07/05/2019) W5-3-1-1
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

4. Remove clip bands (20) (2 used). Disconnect hoses (21) (3 used).

: 17 mm, 19 mm, 27 mm
20

21

22 23 20
WAFF-05-03-002-1 ja
5. Remove adapter (35).
: 27 mm
6. Remove bolts (24) (2 used), spring washers (25) (2 used), and washers (38) (2 used). Remove the hose rupture valve
(26) assembly from the boom cylinder.
: 17 mm
24, 25, 38

26

35

WAFF-05-03-003-1 ja
7. Remove nuts (33) (2 used), washers (34) (2 used), bolts (30) (2 used), spring washers (31) (2 used), and washers (32) (2
used). Remove shim (36) and hose rupture valve (26) from bracket (37).
: 17 mm

WAFF50-EN-00(07/05/2019) W5-3-1-2
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

8. Remove the adapters from hose rupture valve (26) if necessary.

A

37
33, 34

26
30, 31, 32

36

WAFF-05-03-004-1 ja

WAFF50-EN-00(07/05/2019) W5-3-1-3
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

MEMO

WAFF50-EN-00(07/05/2019) W5-3-1-4
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

Installation of Hose Rupture Valve for Boom Cylinder

1. Install all removed adapters to hose rupture valve (26).

2. Install hose rupture valve (26) and shim (36) to bracket (37) with washers (32) (2 used), spring washers (31) (2 used),
bolts (30) (2 used), washers (34) (2 used), and nuts (33) (2 used).
: 17 mm
: 50 N·m
A

37
33, 34

26
30, 31, 32

36

WAFF-05-03-004-1 ja
3. Install the hose rupture valve (26) assembly to the boom cylinder with bolts (24) (2 used), spring washers (25) (2 used),
and washers (38) (2 used).
: 17 mm
: 50 N·m

WAFF50-EN-00(07/05/2019) W5-3-2-1
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

4. Install adapter (35).

: 27 mm
: 80 N·m
24, 25, 38

26

35

WAFF-05-03-003-1 ja
5. Connect hoses (21) (3 used). Install clip bands (20) (2 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 27 mm
: 80 N·m
6. Connect connector (23). Install clip band (22).
20

21

22 23 20
WAFF-05-03-002-1 ja

WAFF50-EN-00(07/05/2019) W5-3-2-2
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

7. Install cover (19) with bolts, washers (18) (2 used).

: 17 mm
: 50 N·m

18

19

WAFF-05-03-001-1 ja

WAFF50-EN-00(07/05/2019) W5-3-2-3
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

MEMO

WAFF50-EN-00(07/05/2019) W5-3-2-4
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

Structure of Hose Rupture Valve for Boom Cylinder

4 1
A

A-A 5
6 6

WAEQ-05-02-013-2 ja

Wrench Size Specified Torque

No. Part Name Q'ty Remarks
mm N·m
1 Hose Rupture Valve 1
4 Plug 2 :6 35
5 O-Ring 2
6 O-Ring 2
7 O-Ring 2

WAFF50-EN-00(07/05/2019) W5-3-3-1
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

MEMO

WAFF50-EN-00(07/05/2019) W5-3-3-2
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

Removal of Hose Rupture Valve for Arm Cylinder

IMPORTANT
The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in
order to avoid spilling oil.

IMPORTANT
Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags
onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed,
install the clips after connecting the hoses.

1. Park the machine on a solid and level ground. Lower the boom with the arm cylinder and bucket cylinder retracted to
the minimum. Lower the end of arm to the ground.
2. Remove bolts, washers (19) (2 used) Remove cover (18).
: 17 mm

18

19
WAEQ-05-02-010-1 ja

WAFF50-EN-00(07/05/2019) W5-3-4-1
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

CAUTION
Release any pressure in hydraulic oil tank. (Refer to "Pressure Release from Hydraulic Oil Tank"W1-5-3-1.)

CAUTION
Release any pressure from the hydraulic circuit. (Refer to "Hydraulic Circuit Pressure Release Procedure"W1-5-2-1.)

3. Remove clip bands (21) (3 used). Disconnect hoses (8) (3 used).

: 17 mm, 19 mm, 36 mm

21

WAEQ-05-02-011-1 ja
4. Disconnect pipe (32).
: 27 mm
5. Remove socket bolts (26) (2 used), spring washers (27) (2 used), and washers (28) (2 used). Remove the hose rupture
valve (30) assembly from the arm cylinder.
: 8 mm
6. Remove nuts (29) (2 used), washers (33) (2 used), bolts (23) (2 used), spring washers (24) (2 used), and washers (25) (2
used). Remove hose rupture valve (30) from bracket (31).
: 17 mm

WAFF50-EN-00(07/05/2019) W5-3-4-2
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

NOTE
THREEBOND #1324 has been applied onto bolt (23).

7. Remove the adapters from hose rupture valve (30) if necessary.

A
26, 27, 28
A

32

31

30

29, 33 23, 24, 25

26, 27, 28

WAFF-05-03-005-1 ja

WAFF50-EN-00(07/05/2019) W5-3-4-3
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

MEMO

WAFF50-EN-00(07/05/2019) W5-3-4-4
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

Installation of Hose Rupture Valve for Arm Cylinder

1. Install all removed adapters to hose rupture valve (30).

2. Apply THREEBOND #1324 onto bolt (23). Install hose rupture valve (30) temporarily to bracket (31) with washers (25) (2
used), spring washers (24) (2 used), bolts (23) (2 used), washers (33) (2 used), and nuts (29) (2 used).
: 17 mm
3. Install the hose rupture valve (30) assembly temporarily to the arm cylinder with washers (28) (2 used), spring washers
(27) (2 used), and socket bolts (26) (2 used).
: 8 mm
4. Install pipe (32) temporarily.
: 27 mm
5. Tighten socket bolts (26) (2 used).
: 8 mm
: 50 N·m
6. Tighten nuts (29) (2 used).
: 17 mm
: 50 N·m
7. Loosen socket bolts (26) (2 used).
: 8 mm
8. Tighten pipe (32).
: 27 mm
: 120 N·m
9. Tighten socket bolts (26) (2 used).
: 8 mm
: 50 N·m

A
26, 27, 28
A

32

31

30

29, 33 23, 24, 25

26, 27, 28

WAFF-05-03-005-1 ja

WAFF50-EN-00(07/05/2019) W5-3-5-1
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

10. Connect hoses (8) (3 used). Install clip bands (21) (3 used).
: 17 mm
: 25 N·m
: 19 mm
: 30 N·m
: 36 mm
: 180 N·m

21

WAEQ-05-02-011-1 ja

IMPORTANT
Check the hydraulic oil level. Start the engine and check each part for any oil leakage.

11. Install cover (18) with bolts, washers (19) (2 used).

: 17 mm
: 50 N·m

18

19
WAEQ-05-02-010-1 ja

WAFF50-EN-00(07/05/2019) W5-3-5-2
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

Structure of Hose Rupture Valve for Arm Cylinder

4 1
A

A-A 5
6 6

WAEQ-05-02-013-2 ja

Wrench Size Specified Torque

No. Part Name Q'ty Remarks
mm N·m
1 Hose Rupture Valve 1
4 Plug 2 :6 35
5 O-Ring 2
6 O-Ring 2
7 O-Ring 2

WAFF50-EN-00(07/05/2019) W5-3-6-1
 SECTION5 FRONT ATTACHMENT
Group3 Hose Rupture Valve

MEMO

WAFF50-EN-00(07/05/2019) W5-3-6-2
Hitachi Construction Machinery Co., Ltd. Hitachi ref. No.
Attn: PS Information Center
Tel: 029-832-7084
Fax: 029-831-1162
E-mail: HCM-TIC-GES@hitachi-kenki.com

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