INTRODUCTION

TO THE READER

• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for usage.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

MANUAL COMPOSITION

• This manual consists of two portions:

the Technical Manual and the Workshop Manual.
Use the manuals according to purpose.

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

PAGE NUMBER

• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

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

IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS

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

signal words are used to alert the reader to the Indicated potentially hazardous situation which could,
potential for personal injury of machine damage. if not avoided, result in personal injury or death.

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

UNITS USED

• SI Units (International System of Units) are used in 2

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

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
°C °F °C×1.8+32
3 3
m yd 1.308 Temperature
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

IN-02
 SAFETY
RECOGNIZE SAFETY INFORMATION

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

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

001-E01A-0688 SA-688

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING,
or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death
or serious injury.

• WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.

• CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor
or moderate injury.

• DANGER or WARNING safety signs are located

near specific hazards. General precautions are
listed on CAUTION safety signs.

• Some safety signs don’t use any of the SA-1223

designated signal words above after the safety
alert symbol are occasionally used on this
machine.

• CAUTION also calls attention to safety messages in

this manual.

• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could
result in damage to the machine.

• NOTE indicates an additional explanation for an

element of information.

002-E01C-1223

SA-1
 SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the ma-

chine and all safety messages in this manual.

• Safety signs should be installed, maintained and re-

placed when necessary.

• If a safety sign or this manual is damaged or miss-

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

• Learn how to operate the machine and its controls

correctly and safely.

• Allow only trained, qualified, authorized personnel to

operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.

• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of ma-
chines. 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.
003-E01B-0003

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label at-
tached 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, ambu- SA-437

lance service, hospital, and fire department

posted near your telephone.

004-E01A-0437

SA-2
 SAFETY
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.

• Operating equipment safely requires the full

attention of the operator. Do not wear radio or music
headphones while operating the machine.

005-E01A-0438

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

impairment or loss of hearing.

• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.

006-E01A-0434 SA-434

INSPECT MACHINE

• Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.

• In the walk-around inspection be sure to cover all

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

S007-E01A-0435
SA-435

SA-3
 SAFETY
GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the operator’s work
boots the operator’s foot may slip off the pedal,
possibly resulting in a personal accident.

• Don’t leave parts and/or tools lying around the op-

erator’s seat. Store them in their specified loca-
tions.

• Avoid storing transparent bottles in the cab. Don’t

attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.

• Refrain from listening to the radio, or using music

headphones or mobile telephones in the cab while
operating the machine.

• Keep all flammable objects and/or explosives

away from the machine.

• After using the ashtray, always cover it to extin-

guish the match and/or tobacco.

• Don’t leave cigarette lighters in the cab. When the

temperature in the cab increases, the lighter may
explode.

524-E01A-0000

SA-4
 SAFETY
USE HANDHOLDS AND STEPS

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

• When you mounting and dismounting the ma-

chine, always face the machine and maintain a
three-point contact with the steps and handrails.

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or

dismount a moving machine.
SA-439
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.

008-E01B-0439

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator
leading to misoperations.

• The seat should be adjusted whenever changing

the operator for the machine.
• The operator should be able to fully depress the
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. SA-378

009-E01A-0378

SA-5
 SAFETY
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 SA-237
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 be replaced
every three years regardless of its apparent
condition.

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders.

Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-366
machine.

011-E01A-0426

SA-6
 SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT

• Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious
injury or death.

• Start the engine only when seated in the

operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals. SA-444
• Before starting the engine, confirm that all control
levers are in neutral.

012-E01B-0444

JUMP STARTING

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to

follow the instructions shown in the “OPERATING
THE 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 SA-032
could result in a battery explosion or a runaway
machine.

S013-E01A-0032

SA-7
 SAFETY
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-370

014-E01B-0379

PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES

• For jobs involving multiple numbers of 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.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN

• Incorrect travel pedal/lever operation may result in

serious injury death.

• Before driving the machine, confirm the position of

the undercarriage in relation to the operator’s po-
sition. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.

SA-500
017-E01A-0491

SA-8
 SAFETY
DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the di-
rection 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. Don’t allow personnel to stay around
the machine while traveling.
SA-367

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

overturn, possibly resulting in serious injury or death.

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

facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.

SA-368

• 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 ma-
chine to level ground, then, change the direction
SA-441
to ensure sage operation.

019-E01D-0492

SA-589

SA-9
 SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS

• Death or serious injury may result if you attempt to

mount or stop a moving machine.

To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade. SA-364

• Position the machine to prevent rolling.

• Park a reasonable distance from other machines.

020-E08A-0493

SA-10
 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.
SA-383
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.

• USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person. SA-384

• No machine motions shall be made unless signals

are clearly understood by both signalman and
operator.

• Learn the meanings of all flags, signs, and

markings used on the job and confirm who has
the responsibility for signaling.

• Keep windows, mirrors, and lights clean and in

good condition.

• Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper
lighting.

• Read and understand all operating instructions in

the operator’s manual.

S021-E01A-0494

SA-11
 SAFETY
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. SA-373

To avoid tipping:
• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is
unavoidable.
• Reduce swing speed as necessary when swinging
loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to

become soft and make ground travel unstable.

S025-E01B-0495

SA-12
 SAFETY
AVOID POWER LINES

• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.

• When operating near an electric line, NEVER

move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
SA-374
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.

029-E01A-0381

OBJECT HANDLING

• If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.

• When using the machine for craning operations,

be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is
SA-014
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.

032-E01A-0014

SA-13
 SAFETY
PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,

serious injury may result.

• Guard against injury from flying pieces of metal or

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

SA-432
031-E01A-0432

PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK SA-375

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

033-E09B-0390

SA-14
 SAFETY
ҥAVOID FIRES
HANDLE FLUIDS SAFELYҥ

• 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 SA-018

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.
• Securely tighten the fuel and oil filler cap.

034-E01A-0496
SA-019

SA-15
 SAFETY
SAFETY TRANSPORTING

• The danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
SA-376
• Be sure to observe local regulations when
transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.

Take the following precautions when loading /

unloading the machine:
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation of
a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.

S035-E08A-0395

SA-16
 SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:

• Understand service procedures before doing

work.
• Keep work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from power-
driven parts.

• Before servicing the machine:

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes. SA-028
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 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 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.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or SA-527

replace as necessary. Refer to the section

discussing that part in the “MAINTENANCE”
chapter in the operator’s 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.
• When cleaning parts, always use nonflammable
detergent oil. Never use highly frammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.

S500-E02B-0497

SA-17
 SAFETY
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
• Always use a work light protected with a guard. In SA-037

case the light bulb is broken, spilled fuel, oil

antifreeze fluid, or window washer fluid may catch
fire.
S500-E02B-0497

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.

• Before performing any work on the machine,

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

S501-E01A-0287

SA-287

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without

securing the machine first.

• Always lower the attachment to the ground before

you work on the machine.
• If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a
SA-527
machine that is supported solely by a jack.
519-E01A-0527

STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious

injury.

• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.

502-E01A-0026
SA-026

SA-18
 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.

• Travel reduction gears are under pressure.

SA-344
• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.

503-E01B-0344

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

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

• Securely store attachments and implements to

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

SA-034

504-E01A-0034

USE TOOLS PROPERLY

• Use tools appropriate for the work to be done.

• Makeshift tools, parts, and procedures can create
safety hazards.
• For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
• Use only recommended replacement parts.
(See the parts catalog.)

SA-040
S522-E01A-0040

SA-19
 SAFETY
PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.

• To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the SA-039
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.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225

• Wait for the oil and components to cool before

starting any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES

PERIODICALLY

• Rubber hoses that contain flammable fluids under

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

S506-E01A-0019

SA-20
 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
SA-031
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 skin must be surgically removed within a
few hours or gangrene may result.

SA-292

507-E03A-0499

SA-044

SA-21
 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- SA-019
cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
• Check before starting work for missing or
damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..

Clean up Flammables:

• Spilled fuel and oil, and trash, grease, debris,

accumulated coal dust, and other flammables may
cause fires.

• Prevent fires by inspecting and cleaning the

machine daily and by removing spilled or
accumulated flammables immediately.

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.
S508-E02B-0019

SA-22
 SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
• If any abnormalities are found, be sure to repair
them before operating the machine.

Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be
repaired or replaced before operating the
machine.

S508-E02B-0019

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.

SA-393
• In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.

518-E02B-0393

SS-1510

SA-23
 SAFETY
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.

509-E01A-0016
SA-016

PRECAUTIONS FOR WELDING AND

GRINDING

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before start-
ing grinding.
• After finishing welding and grinding, recheck that SA-818

there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
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
SA-030
hoses or other materials before engaging in
welding, soldering, etc..

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that

contain flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030

SA-24
 SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING

• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.

• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the SA-029
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 material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.

511-E01A-0029

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 ob-
ject across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion SA-032
of the battery may result.
• Loose terminals may produce sparks. Securely
tighten all terminals.

• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into
eyes, possibly resulting in blindness.

• Be sure to wear eye protection when checking

electrolyte specific gravity.

512-E01C-0032

SA-25
 SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY

• If spilled onto skin, refrigerant may cause a cold

contact burn.

• Refer to the freon container for proper use when

servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405

513-E01A-0405

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause

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

• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.

• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.

S515-E01A-0309

SA-26
 SAFETY
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 SA-226
can damage the Earth’s atmosphere.
Government regulations may require a certified air
conditioning service center to recover and recycle
used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.

S516-E01A-0226

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

S517-E01A-0435 SA-435

SA-27
 SAFETY
(Blank)

SA-28
 SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Bleeding Air
Group 4 Painting
SECTION 2 UPPERSTRUCTURE
Group 1 Canopy
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 Pilot Valve
Group 7 Solenoid Valve
Group 8 Revolution Sensing Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
All information, illustrations and speci-
fications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.

COPYRIGHT(C)2002
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specification Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Excavator Test
Group 1 Hydraulic System Group 5 Component Test
Group 2 Electrical System SECTION 5 TROUBLESHOOTING
SECTION 3 COMPONENT OPERATION Group 1 Diagnosing Procedure
Group 1 Pump Device Group 2 Troubleshooting A
Group 2 Revolution Sensing Valve Group 3 Troubleshooting B
Group 3 Swing Device Group 4 Electrical System Inspection
Group 4 Control Valve
Group 5 Pilot Valve
Group 6 Travel Device
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
 SECTION 1
GENERAL INFORMATION

CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1

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

Group 3 Bleeding Air

Bleed Air from Hydraulic Oil Tank ............ W1-3-1

Group 4 Painting
Painting ................................................... W1-4-1

1LDW-1-1
（Blank）

1LDW-1-2
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling

• Clean the Machine • Precautions for Disassembling

Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem- instructed.
bling/assembling procedures beforehand, to help • If a part or component cannot be removed after
avoid incorrect disassembling of components as removing its securing nuts and bolts, do not
well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.

• Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the

area for disassembling work.

W1-1-1
 GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling Bleeding Air from Hydraulic System

• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and instal-
replace part. lation of the pump, swing motor, travel motor or cylin-
• Dirt or debris on the contact or sliding surfaces der is done, bleed air from the hydraulic system in
may shorten the service life of the machine. Take the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic mo-
clean and dry.
tor housing, damage to the motor
• If an anti-corrosive agent has been used on a
may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, damage
• Be sure to use the designated tools to assemble to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor / Swing Motor

• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.

W1-1-2
 GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary. T570-06-03-011

W1-1-3
 GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions A

1. In general, replace the floating seal with a new

one after disassembling.
If the floating seal is to be reused, follow these
procedures:

(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
B W105-03-05-019
(2) Check the slide surface on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear.

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

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

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

(1) Clean the floating seal and seal mounting

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

(2) Clean the floating seal and seal mounting

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

(3) Check that the O-ring is not twisted, and that it W105-03-05-020

is installed correctly on the seal ring. Correct

D Incorrect

a a
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating C
face (C) by measuring the distances (A) and
(C) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.

b b

a=b a≠b

W110-03-05-004

W1-1-4
 GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of
Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016

lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or hitched
slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.
• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

W1-1-5
 GENERAL / Precautions for Disassembling and Assembling

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

W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Separation of W162-01-01-006
Scoring
Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W1-1-6
 GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies

adjusted to specification.

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

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

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

W1-1-7
 GENERAL / Precautions for Disassembling and Assembling
(Blank)

W1-1-8
 GENERAL / Tightening

TIGHTENING TORQUE SPECIFICATIONS

Bolt Dia Wrench Torque

No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
Engine cushion rubber mounting nut 14 4 22 137 (14) (101)
1
Engine cushion rubber mounting bolt 12 2 19 88 (9) (65)
Engine bracket mounting bolt (Front) 10 8 17 49 (5) (36)
2
Engine bracket mounting bolt (Rear) 10 8 17 49 (5) (36)
3 Hydraulic oil tank mounting bolt 12 4 19 88 (9) (65)
4 Fuel tank mounting bolt 10 2 17 20 (2) (15)
5 PF 1/8 19 29.5 (3) (22)
ORS fittings for hydraulic hoses and piping PF 3/8 22 39 (4) (29)
PF 1/2 27 64 (6.5) (47)
6 Pump mounting bolt 12 2 10 108 (11) (80)
7 Pump cover mounting bolt 10 6 17 49 (5) (36)
Control valve mounting bolt 10 4 17 49 (5) (36)
8
Control valve base mounting bolt 10 4 17 49 (5) (36)
9 Swing device mounting bolt 16 4 24 205 (21) (152)
Battery mounting nut 6 2 10 5 (0.5) (3.5)
10
Battery mounting bolt 10 2 17 49 (5) (36)
11 Canopy mounting bolt 16 4 24 205 (21) (152)
12 Cab mounting bolt 16 4 24 205 (21) (152)
Swing bearing mounting bolt to upperstructure 14 22 22 175 (18) (130)
13
Swing bearing mounting bolt to undercarriage 12 20 19 108 (11) (80)
14 Travel device mounting bolt 12 26 19 128 (13) (94)
15 Sprocket mounting bolt 12 24 19 128 (13) (94)
16 Upper roller mounting bolt 14 2 22 137 (14) (101)
17 Lower roller mounting bolt 18 8 27 451 (46) (332)
18 Cover mounting bolt 6 10 5 (0.5) (3.5)
8 13 10 (1) (7)
10 17 49 (5) (36)
19 Counterweight mounting bolt 20 3 30 390 (40) (290)

W1-2-1
 GENERAL / Tightening

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

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

W1-2-2
 GENERAL / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

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

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

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

correctly when assembling the machine or compo-

nents.

Specified Tightening Torque Chart

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

Socket Bolt
Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.1)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.0) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)

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

Bolt Tightening Order

When tightening two or more bolts, tighten them alter-

nately, as shown, to ensure even tightening.

Equally tighten upper and lower Tighten from center and diagonally
alternately Tighten diagonally

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

4 5
2 13 8 5 2 3 10 11

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

W1-2-4
 GENERAL / Tightening
Service Recommendations for Spilt Flange

IMPORTANT: 1. Be sure to clean and Inspect seal-

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

ening of one bolt fully before RIGHT WRONG

tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.

Bend along edge sharply Do not bend it round

Nut and Bolt Locking

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

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

RIGHT RIGHT WRONG

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

Tighten

W105-01-01-010

W1-2-5
 GENERAL / Tightening
PIPING JOINT 1 4 3 5 2

IMPORTANT: The torques given in the chart are

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

Metal sealing surfaces (4) and (5) of adapter (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37°

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

2. Scratches or other damage to

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

Wrench Size Wrench Size Tightening Torque

Description mm mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,22)
22 22 39 (4.0,28.5)
27 27 93 (9.5,69)
32 32 137 (14,101)
36 36 175 (18,129)
41 41 205 (21,151)
37°female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,22)
22 19 39 (4.0,28.5)
27 22 93 (9.5,69)
32 27 137 (14,101)
36 32 175 (18,129)
41 36 205 (21,151)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.

W1-2-6
 GENERAL / Tightening
O-ring Seal Joint 7 6 9

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

seal pressure oil.

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

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 10
in O-ring groove (e). Tightening M104-07-033

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

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (8) or sealing surface mm mm
(10). Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
Damage to O-ring (6) will cause 19 17 29.5 (3.0,22)
oil leakage. 22 19 69 (7.0,51)
4. If nut (9) is loose and oil is leak- 27 22 93 (9.5,69)
ing, do not re-tighten nut (9). Re- 32 27 137 (14,101)
place O-ring (6) with a new one 36 30,32 175 (18,129)
and check that O-ring (6) is cor- 41 36 205 (21,151)
rectly seated in place, tighten nut 46 41 205 (21,151)
(9).

W1-2-7
 GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread

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

Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application

Seal tape is used to seal clearances between male Internal Thread

and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread
clearances. Do not overwrap. External Thread
Clearance

• Application Procedure
W105-01-01-019

Confirm that the thread surface is clean and, free of Leave one to two pitch threads uncovered
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs

depending on the type of clamp.
T-Bolt Type Band Clamp: M114-07-041

4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )

Worm Gear Type Band Clamp:
T-Bolt Type Worm Gear Type
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)

M114-07-043 M114-07-042

W1-2-8
 GENERAL / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.

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

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

If hoses rub against each other, wear to the

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

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

Rubbing Against
Each Other

W105-01-01-013

WRONG RIGHT

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

W1-2-9
 GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS

To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deteriora-
tion, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace if
necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, if necessary.
Consult your authorized dealer for correct replace-
ment.

Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years or Every 6000 hours
Engine Fuel hose (Fuel tank to injection pump) Every 2 years or Every 6000 hours
Heater hose (Heater to engine) Every 2 years or Every 6000 hours
Pump suction hose Every 2 years or Every 6000 hours
Basic Machine
Pump delivery hose Every 2 years or Every 6000 hours
Hydraulic Swing hose Every 2 years or Every 6000 hours
System Boom cylinder line hose Every 2 years or Every 6000 hours
Front-End Arm cylinder line hose Every 2 years or Every 6000 hours
Attachment Bucket cylinder line hose Every 2 years or Every 6000 hours
Pilot hose Every 2 years or Every 6000 hours

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

and gaskets, when replacing hoses.

W1-2-10
 GENERAL / Bleeding Air
BLEED AIR FROM HYDRAULIC OIL TANK

CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if re-
moved without releasing internal pressure
first. Loosen the hydraulic oil tank cap to re-
lease any remaining pressure.

Preparation M570-07-005

1. Place the machine on a firm, level surface and

lower the bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank (2) 1

cap (1) to release any remaining pressure.

3. Remove hydraulic oil tank (2) cap (1). 2

4. Connect a vacuum pump with the hole removed

cap (1) to maintain negative pressure in the hy-
draulic oil tank.
NOTE: Be sure to run the vacuum pump continu-
ously while working.

W1LD-01-03-001

Vacuum Pump

Hose

Adapter

W1LD-01-03-002

W1-3-1
 GENERAL / Bleeding Air
(Blank)

W1-3-2
 GENERAL / Painting
PAINTING
Section Surfaces to Be Painted Painting Color
• Upperstructure Outer cover (Right, Left, Rear, Top) YR1-01[TAXI yellow]
Skirt (Front, Right, Left) SP-424[Dark gray]
Main frame SP-424[Dark gray]
Inner face (Oil tank, Fuel tank) SP-424[Dark gray]
Canopy (Pole) SP-424[Dark gray]
Stay (Front, Right, Left) SP-424[Dark gray]
Lever (Travel, Blade, Fuel, Lock) SP-424[Dark gray]
Pedal (Travel, Boom swing) SP-424[Dark gray]
Floor plate, Seat base SP-424[Dark gray]
Console (Right, Left) SP-424[Dark gray]
Counterweight SP-424[Dark gray]
• Undercarriage Track frame (Including idler, upper roller and SP-424[Dark gray]
lower roller)
Swing bearing SP-424[Dark gray]
Blade (Including cylinder) SP-424[Dark gray]
• Front attachment Boom, Arm, Bucket and Link (Including cyl- YR1-01[TAXI yellow]
inder)
Swing post (Including cylinder) SP-424[Dark gray]

Front Attachment Outer Cover

Canopy (Pole)

Lever
Stay (Front) Skirt (Left)

Swing Skirt (Right)

Post

Swing Bearing
Blade

Counterweight W1LD-01-04-001

Track Frame

W1-4-1
 GENERAL / Painting
(Blank)

W1-4-2
 MEMO

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 MEMO

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 SECTION 2
UPPERSTRUCTURE

CONTENTS
Group 1 Canopy Group 6 Pilot Valve
Remove and Install Canopy ............... W2-1-1 Remove and Install Front Pilot Valve ....W2-6-1
Remove and Install Travel Pilot Valve...W2-6-3
Group 2 Counterweight Remove and Install Blade Pilot Valve ...W2-6-5
Remove and Install Remove and Install Boom Swing
Counterweight .................................. W2-2-1 Pilot Valve ...........................................W2-6-7
Disassemble Front Pilot Valve ............W2-6-10
Group 3 Pump Device Assemble Front Pilot Valve .................W2-6-14
Remove and Install Disassemble Travel Pilot Valve ...........W2-6-18
Pump Device .................................... W2-3-1 Assemble Travel Pilot Valve................W2-6-22
Disassemble Pump Device................. W2-3-4 Disassemble Blade and Boom Swing
Assemble Pump Device ..................... W2-3-6 Pilot Valve .........................................W2-6-26
Maintenance Standard ..................... W2-3-10 Assemble Blade and Boom Swing
Pilot Valve .........................................W2-6-28
Group 4 Control Valve
Remove and Install Group 7 Solenoid Valve
Control Valve .................................... W2-4-1 Disassemble and Assemble
Disassemble And Assemble Solenoid Valve ....................................... W2-7-1
Control Valve .................................... W2-4-6

Group 5 Swing Device Group 8 Revolution Sensing Valve

Remove and Install Remove and Install Revolution
Swing Device.................................... W2-5-1 Sensing Valve ........................................ W2-8-1
Disassemble Swing Disassemble Revolution Sensing Valve ... W2-8-6
Reduction Gear ................................ W2-5-4 Assemble Revolution Sensing Valve ........ W2-8-8
Assemble Swing
Reduction Gear ................................ W2-5-6
Disassemble Swing Motor ................ W2-5-12
Assemble Swing Motor ..................... W2-5-14
Maintenance Standards.................... W2-5-18

1LDW-2-1
（Blank）

1LDW-2-2
 UPPERSTRUCTURE / Canopy
REMOVE AND INSTALL CANOPY
Removal 2
1
1. Attach sling belt (2) to canopy (1) and hold it.

2. Remove screws (3) (4 used) to remove cover (4).

W1LD-02-01-001

CAUTION: Canopy weight : 32 kg (71 lb)

3. Remove bolts (5) (4 used) from the frame. Lift
canopy (1) by crane to remove it from the frame.
: 24 mm
3 W1LD-02-01-002

W1LD-02-01-003

W2-1-1
 UPPERSTRUCTURE / Canopy
Installation
CAUTION: Canopy weight : 32 kg (71 lb)
2
1. Attach sling belt (2) to canopy (1). Lift the canopy 1
(1) by crane and put it on the frame.

2. Install canopy (1) to the frame with bolts (5) (4 W1LD-02-01-001

used) . 1
: 24 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

W1LD-02-01-003
3. Install cover (4) to canopy (1) with screw (3) (4
used).

3 W1LD-02-01-002

W2-1-2
 UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT

Removal

CAUTION: Counterweight weight:

370 kg (820 lb) (ZX40U)
600 kg (1320 lb) (ZX50U)
1
1. Remove the canopy from the frame.
NOTE: Refer to "REMOVE AND INSTALL
CANOPY".

2. Loosen bolts (1) (4 used) and remove engine

cover (2). 2

: 13 mm

SS-2304

4
3. Open tank cover (3) until lock (4) is locked.
3
: 13 mm

M1LD-07-014

4. Install eyebolts (M16, Pitch 2.0) (2 used) onto

counterweight (5).
Attach the wire ropes to the eyebolts.
Hold the counterweight by crane.

W571-02-02-003

W2-2-1
 UPPERSTRUCTURE / Counterweight

5. Remove counterweight (5) mounting bolts (6) (3

used).
6
: 30 mm (ZX40U, ZX50U)

W571-02-02-004

6. Lift counterweight (5) and slide it backward to

remove it from the frame by crane.

W571-02-02-003

W2-2-2
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight weight:

370 kg (820 lb) (ZX40U)
600 kg (1320 lb) (ZX50U)

1. Install eyebolts (M16, pitch 2.0) (2 used) to

counterweight (5).
Attach the wire ropes to the eyebolts. 5
Lift and move counterweight (5) forward to install
it onto the frame by crane.

W571-02-02-003

2. Tighten bolts (6) (3 used) to hold counter weight

(5) in position. 6

: 30 mm (ZX40U, ZX50U)
5
: 392 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

W571-02-02-004

3. Unlock lock (4). Shut tank cover (3). 4

3

M1LD-07-014
1

4. Install engine cover (2) with bolts (1) (4 used).

: 13 mm
: 9.8 N⋅m (1 kgf⋅m , 7.2 lbf⋅ft)

5. Install the canopy onto the frame.

NOTE: Refer to "REMOVE AND INSTALL
CANOPY".

SS-2304

W2-2-3
 UPPERSTRUCTURE / Counterweight
（Blank）

W2-2-4
 UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

Removal 1
IMPORTANT: Bleed air from the hydraulic oil tank 5
before any work. (Refer to W1-3-1.)
2

1. Remove canopy (1), engine cover (2), and

counterweight (3) from the frame.
3
NOTE: As for removal of the canopy, engine cover ,
and counterweight, refer to the section of
canopy and counterweight.

2. Remove bolts (6) (6 used) and (7) (4 used) to

remove covers (4 and 5) from the frame.
: 13 mm
4 M1LD-05-001

3. Disconnect all the hoses from pump device (9).

Cap the removed hoses.
: 19 mm , 22 mm , 36 mm
: 8 mm

W571-02-03-001

CAUTION: Pump device weight : 19 kg (42

lb)

4.Remove bolts (8) (2 used) to lift and remove pump

device (9) by crane.
: 10 mm

W566-02-03-003

W2-3-1
 UPPERSTRUCTURE / Pump Device
Installation

CAUTION: Pump device weight : 19 kg (42

lb)

1. Install pump device (9) onto the engine flywheel

housing with blots (8) (2 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m)

2. Connect all the hoses onto pump device (9).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
8
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 36 mm
: 235 N⋅m (24 kgf⋅m, 175 lbf⋅ft)
: 8 mm
: 65 N⋅m (6.6 kgf⋅m, 48 lbf⋅ft) 9

3. Install covers (4 and 5) onto the frame with W566-02-03-003

bolts(6) (6 used) and (7) (4 used). 7

: 13 mm
: 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)
6

4. Install counterweight(3), engine cover(2), and

canopy(1) onto the frame.

NOTE: As for installation of the counterweight,

engine cover , and canopy, refer to the
section of counterweight and canopy.

IMPORTANT: Bleed air from the pump. (Refer to

W1-1-2)
When the installation is completed, W571-02-03-001

check the oil level. Start the engine

and check for any oil leaks. 1
5

4 M1LD-05-001

W2-3-2
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-3-3
 UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE
28
7
27 6
26
25
24 5
23
22
21
20
19 4 3
18
17 2
1
16
15
14
13
11
12
10
8
9

49
48 47
46
45

40
39
38
37

31
43
42 30
41 29

44

35
34
36 33
32
W1LD-02-03-001
1- Retaining Ring 14 - Stopper Pin 26 - Retaining Ring 38 - Seal Washer
2- O-Ring 15 - Ceramic Ball (2 Used) 27 - Valve Plate 39 - Bolt
3- Seal Holder 16 - Swash Plate 28 - Needle Bearing 40 - Nut
4- Oil Seal 17 - Plunger (11 Used) 29 - Spring Holder 41 - Choke
5- Shaft 18 - Retainer 30 - Spring 42 - O-Ring
6- Ball Bearing 19 - Holder 31 - Spring Guide 43 - Plug
7- Retaining Ring 20 - Retainer 32 - Control Piston 44 - Socket Bolt (7 Used)
8- Plug 21 - Needle (3 Used) 33 - Sleeve 45 - Coupling
9- O-Ring 22 - Cylinder Block 34 - O-Ring 46 - Collar (2 Used)
10 - Body S 23 - Retainer 35 - Spring Pin 47 - Gear Pump
11 - Gasket 24 - Spring 36 - LS Valve 48 - Washer (4 Used)
12 - Pin (2 Used) 25 - Retainer 37 - Body H 49 - Socket Bolt 4 Used)
13 - Spring

W2-3-4
 UPPERSTRUCTURE / Pump Device
Disassemble Pump Device
10. Remove spring guide (31) from body H (37).
• Be sure to thoroughly read “Precautions for Remove spring (30), spring holder (29), and
Disassembling and Assembling” on page W1-1-1 cylinder block (22) assembly from body S (10).
before starting the disassembly work.
11. Remove plungers(17) (11 used), retainer (18),
1. Remove socket bolts (49) (4 used) to remove holder (19), retainer (20), and needles (21) (3
gear pump (47) from body H (37). used) from cylinder block (22).
: 6 mm
CAUTION: When removing retaining ring
2. Remove collars (46) (2 used) from gear pump (26), push spring (24) with a press. By failing
(47) and coupling (45) from body H (37). to use a press, the spring tends to fly off.

IMPORTANT: Never loosen the lock nut (40) and 12. Remove retaining ring (26) from cylinder block
bolt (39). If loosened, the set values (22) to remove retainer (25), spring (24), retainer
will be changed. (23).
3. Remove valve (36) from body H (37).
: 24 mm 13. Remove swash plate (16) from body S (10) to
remove ceramic balls (15) (2 used). Remove
stopper pin (14) and spring (13) from body S (10).
CAUTION: To remove body H (37) from body
S (10), 2 temporary bolts (M10, length 60 mm IIMPORTANT: Do not remove ball bearing (6)
(2.4 in)) can be used. By failing to use the unless replacing it.
temporary bolts, spring (30) tends to fly off.
Take care not to let spring (30) fly off.
4. Remove socket bolts (44) (2 used) on spring (30) 14. Remove retaining ring (1) from body S (10). Tap
side. Install temporary bolts (M10, length 60 mm) the body H (37) side on shaft assembly (5) with a
in the holes instead. plastic hammer lightly to remove it. Remove seal
: 8 mm holder (3), retaining ring (7), and ball bearing (6)
from the shaft assembly. Remove oil seal (4) and
5. Remove other socket bolts (44) (5 used). O-ring (2) from seal holder (3).
: 8 mm

6. Loosen and remove temporary bolts (2 used)

from body H (37) alternately.

IMPORTANT: When removing body H (37) from

body S (10), take care not to drop
valve plate (27) and spring pin (35).
Do not remove needle bearing (28)
unless replacing it.
7. Remove body H (37) from body S (10) to remove
gasket (11), pins (12) (2 used), and valve plate
(27) in this order.

8. Remove control piston (32) and sleeve (33) from

body H (37).
: 35 mm

9. Remove plug (43) and choke (41) from body H

(37).
: 5 mm, 4 mm

W2-3-5
 UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE
2 3 6 7 29 30 19 20 23 24 25 11 26 27 28 31 38 40 39
1

45

5 46
47
48

49

10

43
13 14 15 16 21 18 17 22 32 33 34 35 37 41 42
W1LD-02-03-002

44

48、49

36

W1LD-02-03-003
1- Retaining Ring 14 - Stopper Pin 26 - Retaining Ring 38 - Seal Washer
2- O-Ring 15 - Ceramic Ball (2 Used) 27 - Valve Plate 39 - Bolt
3- Seal Holder 16 - Swash Plate 28 - Needle Bearing 40 - Nut
4- Oil Seal 17 - Plunger (11 Used) 29 - Spring Holder 41 - Choke
5- Shaft 18 - Retainer 30 - Spring 42 - O-Ring
6- Ball Bearing 19 - Holder 31 - Spring Guide 43 - Plug
7- Retaining Ring 20 - Retainer 32 - Control Piston 44 - Socket Bolt (7 Used)
8- *Plug 21 - Needle (3 Used) 33 - Sleeve 45 - Coupling
9- *O-Ring 22 - Cylinder Block 34 - O-Ring 46 - Collar (2 Used)
10 - Body S 23 - Retainer 35 - Spring Pin 47 - Gear Pump
11 - Gasket 24 - Spring 36 - LS Valve 48 - Washer (4 Used)
12 - *Pin (2 Used) 25 - Retainer 37 - Body H 49 - Socket Bolt 4 Used)
13 - Spring
NOTE: As for items with “∗”, refer to W2-3-4.

W2-3-6
 UPPERSTRUCTURE / Pump Device
Assemble Pump Device
11. Install cylinder block (22) assembly to body S (10).
• Be sure to thoroughly read “Precautions for Install coupling (45) onto the end of shaft (5).
Disassembly and Assembly Work” on page W1-
1-1 before starting the assembly work. 12. Install O-ring (42) onto plug (43). Install choke
(41) and plug (43) into body H (37).
IMPORTANT: When replacing ball bearing (6), : 4 mm (choke)
press the ball bearing down onto : 6 to 9 N⋅m (0.6 to 0.9 kgf⋅m, 4.4 to 6.6
shaft (5) first and install retaining lbf⋅ft)
ring (7) onto the shaft. : 5 mm(plug)
1. Press ball bearing (6) onto shaft (5) to install : 15 to 20 N⋅m (1.5 to 2 kgf⋅m, 11 to 14.5
retaining ring (7). Insert the shaft assembly into lbf⋅ft)
body S (10).
13. Install O-ring (34) onto sleeve (33). Install the
IMPORTANT: Apply grease onto O-ring(2) on the sleeve into body H (37). Install control piston (32)
outer diameter on seal holder(3) and into the sleeve.
oil seal(4) lip part. : 35 mm(sleeve)
2. Install oil seal (4) and O-ring (2) onto seal holder : 50 to 60 N⋅m (5.1 to 6.1 kgf⋅m, 37 to 44
(3). Install seal holder (3) onto shaft (5) using lbf⋅ft)
special tool (ST 7274) to install retaining ring (1).
14. Install spring pin (35) for valve plate (27), valve
3. Install O-ring (9) onto plug (8). Install plug (8) into plate (27), spring guide (31), pins (12) (2 used),
body S (10). and gasket(11) into body h(37).
: 6 mm NOTE: Refer to W2-3-4 as for pin (12).
NOTE: Refer to W2-3-4 as for plug (8) and O-ring
(9).

4. Install spring (13) and stopper pin (14) to body S

(10).

IMPORTANT: Apply grease onto ceramic balls (15)

(2 used) and swash plate (16) slide
surface.
5. Install ceramic balls (15) (2 used) into body S (10)
to install swash plate (16).

6. Install retainer (23), spring (24), and retainer (25)

to cylinder block (22) in this order.

7. Push retainer (25) and spring (24) with a press to

install retaining ring (26).

8. Turn cylinder block (22) upside down to install

needles (21) (3 used), retainer (20), and holder
(19).

9. Install plungers (17) (11 used) and retainer (18)

into cylinder block (22).

10. Align the hole in swash plate (16) on body S (10)

with the spherical part of spring holder (29), then
install the spring holder and spring (30).

W2-3-7
 UPPERSTRUCTURE / Pump Device

30

46
48
49

47

10

37 W1LD-02-03-002

44

48、49

36

W1LD-02-03-003

W2-3-8
 UPPERSTRUCTURE / Pump Device
15. Cover body S (10) with body H (37) aligning pins
(12) (2 used) position. Install and tighten
temporary bolts (M10, length 60 mm) (2 used)
into the socket bolt (44) holes on spring (30) side.
: 8 mm

16. Tighten socket bolts (44) (5 used) into other

socket bolt (44) holes in body H (37) slightly.
: 8 mm

17. Remove one of temporary bolts (M10, length 60

mm) to install socket bolt (44). Remove the other
temporary bolt to install socket bolt (44). Tighten
socket bolts slightly.
: 8 mm

18. Tighten socket bolts (44) (7 used).

: 8 mm
: 51 to 65 N⋅m (5.2 to 6.6 kgf⋅m, 38 to 48
lbf⋅ft)

19. Install LS valve (36) into body H (37).

: 24 mm
: 59 to 69 N⋅m (6 to 7 kgf⋅m, 44 to 51 lbf⋅ft)

20. Install collars (46) (2 used) into gear pump (47).

Install the gear pump to body H (37) with socket
bolts (49) (4 used) and washers (48) (4 used).
: 6 mm
: 24.5 to 27.5 N⋅m (2.5 to 2.8 kgf⋅m, 18 to
20 lbf⋅ft)

W2-3-9
 UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARDS

1. Clearance between the cylinder block bore and

plunger
Cylinder
Block
(D-d): 0.05 mm (0.002 in) or less.

D d

W507-02-04-009
Plunger

2. Clearance between the plunger tip and shoe

bottom

δ: 0.2 mm (0.008 in) or less.

W107-02-06-140

3. Oil Seal Lip Surface Wear: 0.025 mm (0.001 in) or

less
Make sure that there is no damage.

W2-3-10
 UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE 1

Removal

IMPORTANT: Bleed air from the hydraulic oil tank

before any work. (Refer to W1-3-1.)

1. Remove covers (1 ,2, and 3) from the main frame.

: 13 mm

IMPORTANT: Cap all disconnected hose ends and

attach tags to the hoses to aid in re-
assembly. 2
2. Disconnect all the hoses and pipes from the con-
trol valve.
: 19 mm, 22 mm, 27 mm, 36 mm, 41 mm
M1LD-05-007

Control Valve
CAUTION: Plate weight: 8 kg 3
Control valve weight: 60 kg
3. Remove bolts (4) (4 used) to remove plate (5)
from main frame (6).
: 17 mm

W1LD-02-04-002
8 7 6

W2-4-1
 UPPERSTRUCTURE / Control Valve
4. Attach the nylon slings to the caps of control
Nylon 4
valve. Lift control valve (8) with plate (5) and re- Sling
move from the main frame by crane.

Nylon
Sling

Nylon
Sling

5
Nylon 8
Sling
W1LD-02-04-001

5. Remove bolts (7) (4 used) to remove control

valve (8) from plate (5).
: 17 mm 5

W1LD-02-04-002
8 7

W2-4-2
 UPPERSTRUCTURE / Control Valve
Installation 4

CAUTION: Control valve weight: 60 kg

Plate weight: 8 kg 5
1. Install plate (5) to control valve (8) with bolts (7) (4
used).
: 17 mm W1LD-02-04-002

: 49 N⋅m (5 kgf⋅m) 8 7
Nylon
Sling
4
2. Attach the nylon slings to the caps of control
valve. Lift control valve (8) with plate (5) by crane.
Install the control valve onto the main frame with Nylon
bolts (4) (4 used). Sling
: 17 mm
: 49 N⋅m (5 kgf⋅m)

3. Connect all the hoses onto control valve (8).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m)
Nylon
: 22 mm Sling
: 39 N⋅m (4 kgf⋅m)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m)
: 36 mm
: 175 N⋅m (18 kgf⋅m) 5
Nylon
: 41 mm Sling 8
: 205 N⋅m (21 kgf⋅m) W1LD-02-04-001

W2-4-3
 UPPERSTRUCTURE / Control Valve
4. Install covers (3, 2, and 1) onto the main frame. 1
: 13 mm
: 10 N⋅m (1.0 kgf⋅m)

IMPORTANT: After connecting the hoses, check

the hydraulic oil level. Start the en-
gine and check the hoses for any oil
leaks.

M1LD-05-007

Control Valve
3

W2-4-4
 UPPERSTRUCTURE / Control Valve

(Blank)

W2-4-5
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE CONTROL VALVE
21 14
20 22
13
18
18
19 23
18
24
14 13
17 25
16 26
27
15 28
29
30
12
11 29
33
10 35
9 31 34
29 32
2
3 1-a
4 29
5
6
7 9 30
8
31
21
30
47 20 1-b 29
48
55
49 54
50 53
51
52
56
57
58
59 47 77
39 48
49 55
40 60 50 54
41 61
42 51 53
43
44 52
1-c 77 56
45 57
46 36 58 47 77
37 76 59 48
75 55
38 74 49
73 54
72 50
71 51 53
70
69
68 52
67 39
66 1-d 77 56
57
65 37 58
40 38 59
41
42
43
44
62
9 1-e
63
64 39
40 37
38
41
42
43
44
45 W1LD-02-04-003
46

W2-4-6
 UPPERSTRUCTURE / Control Valve

1a - Body (Unload) 14 - Plug (2 Used) 36 - Spring (4 Used) 58 - Piston (9 Used)

1b - Body (Piping Port) 15 - Plug 37 - O-Ring (9 Used) 59 - Spool (9 Used)
1c - Body (Swing) 16 - Spring 38 - Plug (9 Used) 60 - Check Valve (7 Used)
1d - Body (Boom) 17 - Strainer 39 - Spool (9 Used) 61 - Spring (7 Used)
1e - Body (Arm) 18 - Choke (3 Used) 40 - Retainer (9 Used) 62 - Cover
1f - Body (Bucket) 19 - Stocking Plug 41 - Spring (9 Used) 63 - Choke
1g - Body (Offset) 20 - O-Ring (2 Used) 42 - Retainer (9 Used) 64 - Socket Bolt (2 Used)
1h - Body (Auxiliary) 21 - Plug (2 Used) 43 - Bolt (9 Used) 65 - Socket Bolt (2 Used)
1i - Body (Travel Right) 22 - Relief Cut Valve 44 - O-Ring (9 Used) 66 - Plug
1j - Body (Travel Left) 23 - Main Relief Valve 45 - Socket Bolt (16 Used) 67 - O-Ring
1k - Body (Blade) 24 - Plug 46 - Cover (8 Used) 68 - Piston
2- Steel Ball 25 - O-Ring 47 - Plug (9 Used) 69 - O-Ring
3- Spring Seat 26 - Piston 48 - O-Ring (9 Used) 70 - Sleeve
4- Spring 27 - Spring 49 - Seat (8 Used) 71 - Backup Ring
5- O-Ring 28 - Spool 50 - Backup Ring (8 Used) 72 - O-Ring
6- Retainer 29 - O-Ring (55 Used) 51 - O-Ring (8 Used) 73 - Steel Ball
7- O-Ring 30 - O-Ring (21 Used) 52 - Steel Ball (8 Used) 74 - Stopper
8- Adjuster 31 - O-Ring (11 Used) 53 - O-Ring (9 Used) 75 - Spring
9- Metal Plug (24 Used) 32 - O-Ring (10 Used) 54 - Cover (9 Used) 76 - Poppet
10 - Differential Pressure 33 - Plug 55 - Socket Bolt (18 Used) 77 - Overload Relief Valve (7 Used)
Reducing Valve
11 - Stocking Plug 34 - O-Ring 56 - Plug (9 Used) 78 - Make-Up Valve
12 - Choke 35 - Safety Lock Valve 57 - O-Ring (9 Used) 79 - Plug (2 Used)
13 - O-Ring (2 Used)

W2-4-7
 UPPERSTRUCTURE / Control Valve

47 77
55
48 54
49 53
50
51 56
77
52 57
58 47 78
59 48 55
49 54
50 53
51
52
56
39 57
40 1-f 58
41 59
37
42 38 39
43 40
44 41 37
46 42
45 43 38 1-g 79
45 44
47 55
46 48 54
49 53
50
51 56
52 57
79 58 47
59 48 55
49 54
50 53
51
52
56
1-h 57
39 58
40 37 59
41 38 39
42
40
43 41
44 42 36
46 37 1-i
43 38
45 44
47 55
48 54
49 53
50
46 51
45 52 56 77
57
58
39 59 55
40 47 54
41
42 48 53
43 36
44 37 1-j
38 56
57
58
39 59
40
41
42
43
46
44 1-k
45
37
38

46 W1LD-02-04-004

45

W2-4-8
 UPPERSTRUCTURE / Control Valve

1a - Body (Unload) 14 - Plug (2 Used) 36 - Spring (4 Used) 58 - Piston (9 Used)

1b - Body (Piping Port) 15 - Plug 37 - O-Ring (9 Used) 59 - Spool (9 Used)
1c - Body (Swing) 16 - Spring 38 - Plug (9 Used) 60 - Check Valve (7 Used)
1d - Body (Boom) 17 - Strainer 39 - Spool (9 Used) 61 - Spring (7 Used)
1e - Body (Arm) 18 - Choke (3 Used) 40 - Retainer (9 Used) 62 - Cover
1f - Body (Bucket) 19 - Stocking Plug 41 - Spring (9 Used) 63 - Choke
1g - Body (Offset) 20 - O-Ring (2 Used) 42 - Retainer (9 Used) 64 - Socket Bolt (2 Used)
1h - Body (Auxiliary) 21 - Plug (2 Used) 43 - Bolt (9 Used) 65 - Socket Bolt (2 Used)
1i - Body (Travel Right) 22 - Relief Cut Valve 44 - O-Ring (9 Used) 66 - Plug
1j - Body (Travel Left) 23 - Main Relief Valve 45 - Socket Bolt (16 Used) 67 - O-Ring
1k - Body (Blade) 24 - Plug 46 - Cover (8 Used) 68 - Piston
2- Steel Ball 25 - O-Ring 47 - Plug (9 Used) 69 - O-Ring
3- Spring Seat 26 - Piston 48 - O-Ring (9 Used) 70 - Sleeve
4- Spring 27 - Spring 49 - Seat (8 Used) 71 - Backup Ring
5- O-Ring 28 - Spool 50 - Backup Ring (8 Used) 72 - O-Ring
6- Retainer 29 - O-Ring (55 Used) 51 - O-Ring (8 Used) 73 - Steel Ball
7- O-Ring 30 - O-Ring (21 Used) 52 - Steel Ball (8 Used) 74 - Stopper
8- Adjuster 31 - O-Ring (11 Used) 53 - O-Ring (9 Used) 75 - Spring
9- Metal Plug (24 Used) 32 - O-Ring (10 Used) 54 - Cover (9 Used) 76 - Poppet
10 - Differential Pressure 33 - Plug 55 - Socket Bolt (18 Used) 77 - Overload Relief Valve (7 Used)
Reducing Valve
11 - Stocking Plug 34 - O-Ring 56 - Plug (9 Used) 78 - Make-Up Valve
12 - Choke 35 - Safety Lock Valve 57 - O-Ring (9 Used) 79 - Plug (2 Used)
13 - O-Ring (2 Used)

W2-4-9
 UPPERSTRUCTURE / Control Valve
Remove and Install Relief Valve and Make-up Valve

22

23

10 35

77
77

78

79

79

77

T1LD-03-04-001

10 - Differential Pressure 23 - Main Relief Valve 77 - Overload Relief Valve (7 Used) 79 - Plug (2 Used)
Reducing Valve
22 - Relief Cut Valve 35 - Safety Lock Valve 78 - Make-Up Valve

W2-4-10
 UPPERSTRUCTURE / Control Valve
Removal Installation

• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before in-
Removing. stalling.

1. Remove differential pressure reducing valve (10). 1. Install plugs (79) (2 used).
: 24 mm : 21 mm
: 64 to 68 N⋅m (6.5 to 6.9 kgf⋅m, 47 to 50
2. Remove relief cut valve (22). lbf⋅ft)
: 27 mm
2. Install make-up valve (78).
3. Remove main relief valve (23). : 26 mm
: 26 mm : 59 to 63 N⋅m (6.0 to 6.4 kgf⋅m, 44 to 46
lbf⋅ft)
4. Remove safety lock valve (35).
: 24 mm 3. Install overload relief valves (77) (7 used).
: 26 mm
5. Remove overload relief valves (77) (7 used). : 59 to 63 N⋅m (6.0 to 6.4 kgf⋅m, 44 to 46
: 26 mm lbf⋅ft)

6. Remove make-up valve (78). 4. Install safety lock valve (35).

: 26 mm : 24 mm
: 54 to 59 N⋅m (5.5 to 6.0 kgf⋅m, 40 to 44
7. Remove plugs (79) (2 used). lbf⋅ft)
: 21 mm
5. Install main relief valve (23).
: 26 mm
: 69 to 78 N⋅m (7.0 to 8.0 kgf⋅m, 51 to 58
lbf⋅ft)

6. Install relief cut valve (22).

: 27 mm
: 69 to 78 N⋅m (7.0 to 8.0 kgf⋅m, 51 to 58
lbf⋅ft)

7. Install differential pressure reducing valve (10).

: 24 mm
: 79 to 83 N⋅m (8.1 to 8.5 kgf⋅m, 58 to 61
lbf⋅ft)

W2-4-11
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE BODY
Tie Rod Nut
Unload Section
Washer

Piping Port Section

B B
1 mm

Function
Section

T1LD-03-04-001

NOTE: The illustration shows the swing section.

W1LD-02-04-006

29
A

60

61

32

1 A
Cross Section A-A
T566-03-03-009 Cross Section B-B
W566-02-04-005

1 - Body 30 - *O-Ring 32 - O-Ring 61 - Spring

29 - O-Ring 31 - *O-Ring 60 - Check Valve

NOTE: As for items with “*”, refer to W2-4-6 to 8.

W2-4-12
 UPPERSTRUCTURE / Control Valve
Disassemble Assemble

• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before as-
disassembling. sembling.

IMPORTANT: Take care not to drop off O-rings 1. Install check valve (60), O-rings (29,30,31,and
(29,30,31, and 32). 32) into each section. Install spring (61) into the
bore of check valve (60).
NOTE: As for O-rings (30 and 31), refer to W2-4-6
1. Remove the nuts (4 used). Remove the washers
to 8.
(4 used) and tie rods (4 used) to divide the control
valve into each section.
: 17 mm IMPORTANT: Pay attention to the direction of tie
rod. Install the tie rod with its longer
2. Remove O-rings (29,30,31,and 32) from each thread side facing unload section.
section. Remove spring (61) and check valve (60) IMPORTANT: When installing the function sec-
from each section with a magnet. tions, install them 1mm away from
NOTE: As for O-rings (30 and 31), refer to W2-4-6 the unload section and piping port
to 8. section. Assemble it putting a metal
plate( thickness : 1mm) beneath the
function sections.

W1LD-02-04-005
Metal Plate: thickness: 1 mm

2. Put a metal plate(thickness: 1 mm) beneath the

function sections(9 used). Put bodies (1) in each
section as before disassembling. Attach the tie
rods and tighten them with washers (4 used) and
nuts (4 used).
: 17 mm
: 54 to 58 N⋅m (5.5 to 5.9 kgf⋅m, 40 to 43
lbf⋅ft)

W2-4-13
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE UNLOAD SECTION

B C C B

9 18 19 12 22

11
A 10

23

8
24

7 6 5 4 3 2 1 28 27 26 25

16 17 13 14 20 21

15 18 18

Cross Section A-A Cross Section B-B Cross Section C-C

W566-02-04-001

1 - Body 8 - Adjuster 15 - Plug 22 - Relief Cut Valve

2 - Steel Ball 9 - Metal Plug (15 Used) 16 - Spring 23 - Main Relief Valve
3 - spring Seat 10 - Differential Pressure Re- 17 - Strainer 24 - Plug
ducing Valve
4- Spring 11 - Stocking Plug 18 - Choke (3 Used) 25 - O-Ring
5- O-Ring 12 - Choke 19 - Stocking Plug 26 - Piston
6- retainer 13 - O-Ring (2 Used) 20 - O-Ring 27 - Spring
7- O-Ring 14 - Plug (2 Used) 21 - Plug 28 - Spool

W2-4-14
 UPPERSTRUCTURE / Control Valve
Disassemble Unload Section IMPORTANT: Never loosen the lock nut of relief
cut valve (22). If loosened, the set
• Read PRECAUTIONS FOR DISASSEMBLING pressure may be changed.
AND ASSEMBLING (W1-1-1) carefully before 4. Remove relief cut valve (22) from body (1).
disassembling. : 27 mm

IMPORTANT: Never turn the lock nut of relief valve. IMPORTANT: Never loosen the lock nut of differ-
If turned, the set pressure may be ential pressure reducing valve (10).
changed. If loosened, the set pressure may be
1. Remove main relief valve (23) from body (1). changed.
: 26 mm 5. Remove differential pressure reducing valve (10)
from body (1). Remove the piston and spring from
IMPORTANT: Do not remove steel ball (2) from body (1) with a magnet.
spring seat (3). When replacing : 24 mm
these parts, replace them as an as-
sembly. When removing retainer (6) Guide Spring
from body (1), spring (4) and spring
seat (3) tend to come off together
with retainer (6). When removing re- 10
tainer (6), take care not to drop
spring (4) and spring seat (3).
IMPORTANT: Never loosen adjuster (8) and the
nut of retainer (6). If loosened, the
set pressure may be changed.
2. Remove retainer (6) from body (1). Remove
spring (4) and spring seat (3) from body (1) with a
magnet.
: 24 mm
Piston 1 T566-03-03-005
IMPORTANT: When removing piston (26) from
body (1), spring (27) is removed to-
gether with the piston. When remov- 6. Install the bolt (M8, pitch 1.25) into the guide hole
ing piston (26), take care not to drop to pull the guide out of body (1).
off spring (27).
3. Remove plug (24) from body (1). Remove piston 7. Remove plug (15) from body (1). Remove spring
(26) and spring (27) from body (1) with a magnet. (16) and strainer (17) from body (1).
: 8 mm : 8 mm

IMPORTANT: Metal plug (9) and choke (18) cannot

be removed.

W2-4-15
 UPPERSTRUCTURE / Control Valve
ASSEMBLE UNLOAD SECTION

B C C B

9 18 19 12 22

11
A 10

23

8
24

7 6 5 4 3 2 1 28 27 26 25

16 17 13 14 20 21

15 18 18

Cross Section A-A Cross Section B-B Cross Section C-C

W566-02-04-001

1 - Body 8 - Adjuster 15 - Plug 22 - Relief Cut Valve

2 - Steel Ball 9 - Metal Plug (15 Used) 16 - Spring 23 - Main Relief Valve
3 - spring Seat 10 - Differential Pressure Re- 17 - Strainer 24 - Plug
ducing Valve
4- Spring 11 - Stocking Plug 18 - Choke (3 Used) 25 - O-Ring
5- O-Ring 12 - Choke 19 - Stocking Plug 26 - Piston
6- retainer 13 - O-Ring (2 Used) 20 - O-Ring 27 - Spring
7- O-Ring 14 - Plug (2 Used) 21 - Plug 28 - Spool

W2-4-16
 UPPERSTRUCTURE / Control Valve
Assemble Unload Section 5. Install plug (24) into body (1).
: 8 mm
• Read PRECAUTIONS FOR DISASSEMBLING : 59 to 69 N⋅m (6 to 7 kgf⋅m, 44 to 51 lbf⋅ft)
AND ASSEMBLING (W1-1-1) carefully before as-
sembling. 6. Insert spring (4) into retainer (6) until spring (4)
comes in contact with adjuster (8) to install spring
・ Apply grease onto the seals. seat (3) to spring (4).

1. Install strainer (17) , spring (16) , and plug (15) 7. Install the retainer (6) assembly to body (1) while
wound with a seal tape to body(1). taking care not to drop off spring seat (3) and
: 8 mm spring (4).
: 54 to 58 N⋅m (5.5 to 5.9 kgf⋅m, 40 to 43 : 24 mm
lbf⋅ft) : 54 to 59 N⋅m (5.5 to 6.0 kgf⋅m, 40 to 44
lbf⋅ft)
2. Install the guide, piston, and spring to differential 8. 8.Install main relief valve (23) into body (1).
pressure reducing valve (10). Install differential : 26 mm
pressure reducing valve (10) to body (1) while tak- : 69 to 78 N⋅m (7.0 to 8.0 kgf⋅m, 51 to 58
ing care not to drop off the guide, piston, and lbf⋅ft)
spring.
: 24 mm
: 79 to 83 N⋅m (8.1 to 8.5 kgf⋅m, 58 to 61
lbf⋅ft)

Guide Spring

10

Piston 1 T566-03-03-005

3. install relief cut valve (22) to body (1).

: 27 mm
: 69 to 78 N⋅m (7.0 to 8.0 kgf⋅m, 51 to 58
lbf⋅ft)

4. Install spring (27) into piston (26) in the unload

valve. Install the piston (26) assembly into spool
(28) while taking care not to drop off the spring.

W2-4-17
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE SPOOL

NOTE: The illustration shows the swing section.

39

46 45 41 40
53 54

55
43 42 44

1
W566-02-04-005

1 - Body 41 - Spring 44 - O-Ring 53 - O-Ring

39 - Spool 42 - Retainer 45 - Socket Bolt (2 Used) 54 - Cover
40 - Retainer 43 - Bolt 46 - Cover 55 - Socket Bolt (2 Used)

W2-4-18
 UPPERSTRUCTURE / Control Valve
Disassemble Assemble

• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before as-
disassembling. sembling.

1. Remove socket bolts (45) (2 used) from body (1). 1. Install the spool (39) assembly into body (1).
Remove cover (46) and O-ring( 44) from body (1).
: 5 mm 2. 2.Install O-ring (53) onto cover (54). Install the
cover onto body (1) with socket bolts (55) (2
2. Pull spool (39) as am assembly out of body (1). used).
NOTE: The spool (39) assembly consists of spool : 5 mm
(39), bolt (43), retainer (42),spring (41), : 10 to 12 N⋅m (1.0 to 1.2 kgf⋅m, 7.4 to 8.9
and retainer (40). lbf⋅ft)
NOTE: Do not remove bolt (43), retainer (42),
spring (41) and retainer (40) from spool 3. Install O-ring (44) onto cover (46). Install the
(39). cover onto body (1) with socket bolts (45) (2
When replacing these parts, replace them used).
as an assembly. : 5 mm
: 10 to 12 N⋅m (1.0 to 1.2 kgf⋅m, 7.4 to 8.9
3. Remove socket bolts (55) (2 used) from body (1) lbf⋅ft)
to remove cover (54) and O-ring (53).
: 5 mm

W2-4-19
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE BOOM SECTION

66 67 70 69 71 72

65

68

63 62 73 74 75 76

1
T566-03-03-010

1- Body 65 - Socket Bolt (2 Used) 69 - O-Ring 73 - Steel Ball

62 - Cover 66 - Plug 70 - Sleeve 74 - Set Screw
63 - Choke 67 - O-Ring 71 - Backup Ring 75 - spring
64 - *Socket Bolt (2 Used) 68 - Piston 72 - O-Ring 76 - Poppet

NOTE: As for items with “*”, refer to W2-4-6.

W2-4-20
 UPPERSTRUCTURE / Control Valve
Disassemble Assemble

• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before as-
disassembling. sembling.

IMPORTANT: Do not remove choke (63), plug (66), 1. Install poppet (76) into body (1). Install spring (75)
and set screw (74). into the poppet (76) hole.
IMPORTANT: When removing cover (62) from
body (1), piston (68) tends to come IMPORTANT: Apply grease onto O-rings (69 and
off together with cover (62). Take 72). Install sleeve (70) so that spring
care not to drop piston (68). (75) can be aligned with the spring
1. Remove socket bolts (64) (2 used) and (65) (2 mounting position in sleeve (70).
used) from body (1) to remove cover (62) and pis- 2. Install O-rings (69,72) and backup ring (71) onto
ton (68). sleeve (70). Install the sleeve (70) assembly into
: 5 mm body (1).
3. Install piston (68) and O-ring (67) into cover (62).
2. Install the bolt (M12, pitch 1.75) into the sleeve
(70) hole to pull the sleeve (70)assembly out of 4. Install the cover (62) assembly to body (1) with
body (1). socket bolts (65) (2 used) and (64) (2 used) while
taking care not to drop off piston (68).
NOTE: The sleeve (70)assembly consists of : 5 mm
sleeve (70), steel ball (73), and set screw : 10 to 12 N⋅m
(74). (1.0 to 1.2 kgf⋅m, 7.4 to 8.9 lbf⋅ft)
IMPORTANT: Check if spring (75) stays in body
(1).
3. Remove spring (75) and poppet (76) from body
(1) with a magnet.

W2-4-21
 UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE SHUT-
TLE VALVE AND PRESSURE COMPEN-
SATION VALVE

NOTE: The illustration shows the swing section.

52 48 47 49 50 51

38 37 36 59 58 57 56
W566-02-04-005

1- Body 47 - Plug 51 - O-Ring 57 - O-Ring

36 - Spring 48 - O-Ring 52 - Steel Ball 58 - Piston
37 - O-Ring 49 - Seat 56 - Plug 59 - Spool
38 - Plug 50 - Backup Ring

W2-4-22
 UPPERSTRUCTURE / Control Valve
Disassemble Assemble

• Read PRECAUTIONS FOR DISASSEMBLING ・ Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before
disassembling. AND ASSEMBLING (W1-1-1) carefully before as-
sembling.
1. Remove plug (47) from body (1).
: 6 mm 1. Install piston (58) into spool (59). Insert spring
(36) into the spring hole in spool (59) completely.
IMPORTANT: When removing seat (49) from body NOTE: Spring (36) is provided for the swing, boom,
(1), steel ball (52) tends to come off right travel, and left travel.
together with seat (49). Take care
not to drop steel ball (52). 2. Install the spool (59) assembly into body (1). At
2. Remove seat (49) and steel ball (52) from body this time take care not to drop off piston (58).
(1) with a pliers.
3. Install O-ring (57) to plug (56) and O-ring (37) to
3. Remove O-Ring (51) and backup ring (50) from plug (38). Install plugs (56 and 38) to body (1) in
seat (49). this order.
: 8 mm
4. Remove plug (38) from body (1) to remove spring : 59 to 69 N⋅m (6 to 7 kgf⋅m, 44 to 51 lbf⋅ft)
(36) with a magnet.
: 8 mm IMPORTANT: Apply grease onto O-ring (51).
NOTE: Spring (36) is provided for the swing, boom, 4. Install backup ring (50), O-ring (51),and steel ball
right travel, and left travel. (52) onto seat (49).

IMPORTANT: When removing the spool (59) as- 5. Install the seat(49) assembly into body (1).
sembly, take care not to drop piston
(58). 6. Install plug (47) into body (1).
5. Remove plug (56). Push the spool (59) assembly : 6 mm
with piston (58) out from plug (38) side by finger : 30 to 34 N⋅m (3.1 to 3.5 kgf⋅m, 22 to 25
and remove the spool (59) assembly with piston lbf⋅ft)
(58) from body (1).

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

W2-4-23
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-4-24
 UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
Removal

IMPORTANT: Bleed air from the hydraulic oil tank

before any work. (Refer to W1-3-1)

1. Remove the canopy.

1
NOTE: Refer to “REMOVE AND INSTALL
CANOPY”.

2. Remove covers (1, 2) from the frame.

: 13 mm

3. Disconnect all the pilot hoses at the quick coupler 2

part. Disconnect all the connectors.

M1LD-01-001

CAUTION: Floor plate with seat and pilot

valve weight: 105 kg 12 3
11 4
4. Remove bolts (3 to 11). Install eyebolts (M8, pitch
1.25) (4 used). Lift floor plate (12) with the seat
and pilot valve to remove from the frame by crane.
: 13 mm, 17 mm, 24 mm 5

5. Disconnect all the hoses from swing device (13). 6

Cap the removed hoses.
: 19 mm, 22 mm

Eyebolt
7
Eyebolt

W1LD-02-05-002
10 9 8

CAUTION: Swing device weight: 50 kg 13

6. Remove bolts (14) (8 used) to lift and remove
swing device (13) from the frame by crane.
: 24 mm

W1LD-02-05-003
14

W2-5-1
 UPPERSTRUCTURE / Swing Device
Installation

13
CAUTION: Swing device weight: 50 kg
1. Install swing device (13) to the frame with bolts
(14) (8 used).
: 24 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

2. Connect all the hoses to swing device (13).

: 19 mm
W1LD-02-05-003
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 14
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) 12 3
11 4

CAUTION: Floor plate with seat and pilot

valve weight: 105 kg 5
3. Install eyebolts (M8, pitch 1.25) (4 used) to floor
plate (12) with the seat and valve plate. 6
Lift and install it onto the frame with bolts (3 to 11)
by crane.
: 13 mm
: 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)
Eyebolt
: 17 mm 7
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) Eyebolt
: 24 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

4. Connect all the pilot hoses at the quick coupler

part. Connect all the connectors.
W1LD-02-05-002
10 9 8

5. Install covers (1, 2) to the frame with the bolts (17

used).
: 13 mm
: 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)

6. Install the canopy.

NOTE: Refer to “REMOVE AND INSTALL
CANOPY”. 1

IMPORTANT: When the installation is completed,

check the oil level. Start the engine
and check for any oil leaks.

M1LD-01-001

W2-5-2
 UPPERSTRUCTURE / Swing Device
(Blank)

W2-5-3
 UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING REDUCTION
GEAR

20

21
1 Swing Motor
22

23 2

4
29
24 5

25 6
7
26
8

9
27
10
11
28 12
13
14

15
19
16

17

18

W571-02-05-005

1- Socket Bolt (4 Used) 9- Retaining Ring 17 - Socket Bolt (9 Used) 25 - Spring Plate
2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin (4 Used) 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing

W2-5-4
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Reduction Gear 9. Remove shaft (28) from housing (23) with a
press.
• Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before 10. Remove the inner race of roller bearing (24),
disassembling. spring plate (25), thrust plate (26) and plate (27)
from shaft (28) with a press.
CAUTION: Swing motor weight: 13 kg IMPORTANT: Do not remove the outer races of
roller bearings (21) and (24) from
1. Remove socket bolts (1) (4 used) from the swing housing (23). Failure to follow these
motor, then remove the swing motor. instructions will shorten service life
: 6 mm of the bearings as press-fit force of
roller bearing (21 and 24) outer
2. Remove socket bolts (17) (9 used) from ring gear races is reduced. Always replace
(18). housing (23) with a new one if the
: 8 mm bearings are removed.
11. Remove oil seal (22) from housing (23).
3. Remove ring gear (18), first stage carrier (8)
assembly, second stage sun gear (10) and
second stage carrier (13) assembly from housing
(23).
Remove retaining ring (9) from second stage sun
gear (10).

4. Remove retaining rings (3) (3 used), plate (4), first

stage sun gear (5), first stage planetary gears (6)
(3 used) and needle bearings (7) (3 used) from
first stage carrier (8) asembly.

5. Drive spring pins (19) (4 used) at second stage

carrier (13) assembly into pin (12) with a round
bar (length: 100 mm or more, diameter: 5 mm).

6. Remove pins (12) (4 used), second stage

planetary gears (14) (4 used), needle bearings
(15) (4 used), thrust plates (16) (4 used) and plate
(11) from second stage carrier (13) assembly.

7. Securely hold shaft (28). Remove nut (20) from

shaft (28) using a special tool (ST 7313).

(ST 7313)
W1LD-02-05-001

8. Remove plug (29) from housing (23).

: 5 mm

W2-5-5
 UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING REDUCTION GEAR

30

2
3
17
6
4
7
5
8
18
15
9
14
10
12 11
16 13
19 20
23 21

22 29

25 24
26
27
28

W571-02-05-004

1- Socket Bolt (4 Used) 9- Retaining Ring 17 - Socket Bolt (9 Used) 25 - Spring Plate
2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin (4 Used) 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal 30 - Swing Motor
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing

W2-5-6
 UPPERSTRUCTURE / Swing Device
Assemble Swing Reduction Gear

• Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before
assembling.

IMPORTANT: Install oil seal (22) with the lip of the

oil seal facing upward (motor side).

1. Install oil seal (22) into housing (23).

2. If roller bearings (21 and 24) are replaced with

new ones together with housing (23), press the
outer race of roller bearings (21) and (24) into
housing (23).

3. Press plate (27), thrust plate (26), spring plate

(25) and the inner race of roller bearing (24) onto
shaft (28).

IMPORTANT: Be careful not to damage oil seal

(22) by shaft (28) during installation.
Also, make sure that plug (29) has
been removed. If plug (29) is not
removed, distortion of oil seal (22)
may result.

4. Install shaft (28) assembly into housing (23).

IMPORTANT: Install nut (20) with the grooved face

upward (motor side).

5. Install the inner race of roller bearing (21) into

shaft (28), and temporarily tighten nut (20).

6. Install plug (29).

: 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)

W2-5-7
 UPPERSTRUCTURE / Swing Device

3
17
6
4
7
5
8
18
15

14 10
12
11
16
13
20
23

28

W571-02-05-004

W2-5-8
 UPPERSTRUCTURE / Swing Device
7. Adjust the roller bearing pre-load. 5) Tighten nut (20) onto shaft (28) using a special
tool (ST 7313).
Starting Torque
: 152 N⋅m (15.5 kgf⋅m, 112 lbf⋅ft)

(ST7313)
17 W1LD-02-05-001

6) After turning housing (23) in both directions

several times, measure rotation starting torque
20 (B) of housing (23) at socket bolt (17).
23

7) Confirm that the measured torque value is within

standards.
(If not, repeat procedure from 1).
＊
Torpue difference Standard value
B-A +1.0 to +3.3 kgf

IMPORTANT: Install retaining ring (3) with the

chamfered corner facing toward
plate (4).
28
8. Install needle bearings (7) (3 used), first stage
W571-02-05-008
planetary gears (6) (3 used), first stage sun gear
1) Securely hold shaft (28), then loosen nut (20).
(5), plate (4) and retaining ring (3) onto first stage
carrier (8).
2) Tap the outer diameter of housing (23) (shown
with * to the illustration) 3 to 4 turns with a plastic
9. Install thrust plates (11), (16) (4 used), needle
hammer.
bearings (15) (4 used), second stage planetary
gears (14) (4 used) and pins (12) (4 used) onto
3) Install one socket bolt (17) into housing (23).
second stage carrier (13).
4) After turning housing (23) to both directions
several times, measure rotation starting torque
(A) of housing (23) at socket bolt (17).

W2-5-9
 UPPERSTRUCTURE / Swing Device

30

2
17
8

18

12 10

13

19 20
23

28

W571-02-05-004

W2-5-10
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Drive in spring pins (19) (4 used) IMPORTANT: Install retaining ring (9) with its
with its slit facing upward (motor chamfered corner facing upwards.
side).
12. Install retaining ring (9) onto second stage sun
10. Align pin holes on second stage carrier (13) and gear (10). Install second stage sun gear (10) into
pins (12) (4 used), then drive spring pins (19) (4 second stage carrier (13).
used) into the carrier.
13. Install first stage carrier (8) assembly into second
stage carrier (13) assembly.

14. Apply THREEBOND #1215 to the counter bore

on the housing (23). Install ring gear (18) into
12 housing (23), and tighten it with socket bolts (17)
(9 used).

19 : 8 mm
W571-02-05-007
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
IMPORTANT: Install second stage carrier (13)
aligning splines so that the pin on 15. Add approx. 0.7 litter (0.185 US gal) of hydraulic
second stage carrier (13) is inserted oil into the swing reduction gear.
into the hole of nut (20). Confirm
dimension A shown in the 16. Install O-ring (2) onto swing motor (30). Install the
illustration is approx. 18.5 mm. If swing motor onto ring gear (18). Tighten socket
dimension A is approx. 27.5 mm, it bolts (1) (4 used).
indicates that pin is not inserted into
the hole on nut (20) properly. : 6 mm
: 29 N⋅m (3 kgf⋅m, 21 lbf⋅ft)
13
Pin
Ａ

20

W571-02-05-006

11. Install second stage carrier (13) assembly onto

shaft (28) aligning the holes on nut (20) with the
pin.

W2-5-11
 UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING MOTOR 8

6
5
4

13
14

15

16
17
18
19
20
21

22

11
10
9
30
29
28
27
26
25
24

23 W1LD-02-05-005
1- Friction Plate (2 Used) 9- Collar 17 - Rotor 24 - Cover
2- Disc Plate (2 Used) 10 - O-Ring 18 - Collar 25 - Pin
3- Swash Plate 11 - O-Ring 19 - Spring 26 - Bearing
4- Shaft 13 - Plunger (9 Used) 20 - Washer 27 - Valve Plate
5- Bearing 14 - Retainer 21 - Retaining Ring 28 - Spring (22 Used)
6- O-Ring 15 - Holder 22 - Pin 29 - Brake Piston
7- Case 16 - Pin (3 Used) 23 - Socket Bolt (3 Used) 30 - O-Ring
8- O-Ring

W2-5-12
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor
CAUTION: Always use a special tool on
• Read PRECAUTIONS FOR DISASSEMBLING washer (20) to press spring (19) when
AND ASSEMBLING (W1-1-1) carefully before removing retaining ring (21). If retaining ring
disassembling. (21) is removed without pressing, washer
(20) and spring (19) may fly out, possibly
IMPORTANT: Be careful not to allow valve plate causing serious injury.
(27) to fall when removing cover
(24). 7. Press washer (20) and spring (19) using a special
tool (ST 7314). Remove retaining ring (21) to
1. Put matching marks on cover (24) and case (7). remove washer (20), spring (19) and collar (18)
Loosen socket bolts (23) (3 used). Remove cover from rotor (17).
(24) and valve plate (27) in this order.
: 12 mm
(ST7314)
2. Remove springs (28) (22 used) and O-ring (6)
from case (7).

21
CAUTION: When removing brake piston (29)
using compressed air, be sure to cover the
brake piston with rags to prevent the piston 20
from flying out. 19
3. Remove brake piston (29) and O-ring (30) from
18
case (7) by applying compressed air into the pilot
port on case (7).

4. Remove collar (9), and O-rings (10),(11).

W1LD-02-05-004
5. Remove rotor (17) assemblies (13 to 21), swash 8. Remove shaft (4) from case (7) by tapping shaft
plate (3), friction plates (1) (2 used) and disc (4) with a plastic hammer.
plates (2) (2 used) .
9. Remove O-ring (8) from case (7).
NOTE: Take care not to damage the sliding
surface of swash plate (3).

6. Remove plungers (13) (9 used), retainer (14),

holder (15) and pins (16) (3 used) from rotor
assemblies (13 to 21).

W2-5-13
 UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR

22 23 28 27 21 20 26 24

25

30

29

17
10
11
19 9
18
1
16
2
7
13
8

W555-02-05-003

15 5 4 3 14

1- Friction Plate (2 Used) 9- Collar 17 - Rotor 24 - Cover

2- Disc Plate (2 Used) 10 - O-Ring 18 - Collar 25 - Pin
3- Swash Plate 11 - O-Ring 19 - Spring 26 - Bearing
4- Shaft 13 - Plunger (9 Used) 20 - Washer 27 - Valve Plate
5- Bearing 14 - Retainer 21 - Retaining Ring 28 - Spring (22 Used)
6- O-Ring 15 - Holder 22 - Pin 29 - Brake Piston
7- Case 16 - Pin (3 Used) 23 - Socket Bolt (3 Used) 30 - O-Ring
8- O-Ring

W2-5-14
 UPPERSTRUCTURE / Swing Device
Assemble Swing Motor
8. Install friction plates (1) (2 used) and disc plates
• Read PRECAUTIONS FOR DISASSEMBLING (2) (2 used) to rotor (17) one by one alternately in
AND ASSEMBLING (W1-1-1) carefully before place.
assembling.
IMPORTANT: Do not tap collar (9) with a plastic
IMPORTANT: If ball bearing (5) has been removed, hammer or similar instrument to
press bearing (5) onto shaft (4) install collar (9). Collar (9) and / or
beforehand. case (7) may be damaged. Use a
Press ball bearing (5) until the end of press to install collar (9) into case
ball bearing (5) is flush with the end (7).
surface of case (7).
9. Install O-rings (10) and (11) onto collar (9), and
1. Press shaft (4) and ball bearing (5) assembly into press them into case (7).
case (7).

2. Install collar (18), spring (19) and washer (20) into

rotor (17).

3. While depressing washer (20) and spring (19)

using a special tool (ST 7314), install retaining
ring (21) into rotor (17).

(ST7314)

21

20
19

17

W1LD-02-05-004

4. Install pins (16) (3 used) into rotor (17). Put holder

(15) onto pins (16).

5. Install plungers (13) (9 used) and retainer (14)

into rotor (17).

6. Install swash plate (3) into case (7).

7. Install rotor (17) assemblies (13 to 21) into case

(7).

W2-5-15
 UPPERSTRUCTURE / Swing Device

23 28 27 24

30

29

W555-02-05-003

W2-5-16
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Do not tap brake piston (29) with a
plastic hammer or similar
instrument to install brake piston 29
(29). Brake piston (29) and / or case
(7) may be damaged. Use a press to
install brake piston (29) into case (7)
as the illustration.

10. Install O-ring (30) onto brake piston (29). Press

brake piston (29) into case (7).

11. Install springs (28) (22 used) and O-ring (6) into
case (7).

12. Attach valve plate (27) to cover (24). Install cover

M6 Threaded Hole
(24) on case (7) while aligning the matching
marks on cover (24) and case (7). Tighten socket
W527-02-05-003
bolts (23) (3 used).

: 12 mm
: 177±10 N⋅m (18±1 kgf⋅m, 131±7.4 lbf⋅ft)

NOTE: Apply grease to valve plate (27) before

attaching it to cover (24) in order to prevent
it from falling.

W2-5-17
 UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARDS

1. The clearance between the plunger diameter and

the rotor bore diameter
Rotor
(D-d): 0.40 mm or less.

D d

W507-02-04-009

2. The clearance between the plunger and the shoe

δ: 0.4 mm or less.

W107-02-06-140

3. The wear amount of the oil seal mounting

surfaces no damage and / or wear is allowed. D0 D1

(D0 - D1): 0.25 mm or less.

W509-02-04-010

W2-5-18
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL FRONT PILOT 4
VALVE
Removal

IMPORTANT: Bleed air from the hydraulic oil tank

before any work. (Refer to W1-3-1.)
1. Remove screws(1) (6 used) from the lever stand
to remove covers (2, 3).

2. Remove clip band (10) and plug (11) from pilot

valve (13) on the left stand only.

3. Raise boots (4) (2 used) to remove screws (16) (8

used) and plates (15) (4 used). 2 1 3
Fast Speed Travel Pedal M1LA-01-006
4. Raise boot (4) on the left lever to remove clip
band (9).
5
5. Raise boots (4) (2 used) and loosen lock nuts (8)
(2 used) to remove levers (7) (2 used) with grip 6
(5) together.
: 22 mm 7
Pilot Shut-off
Lever 8
6. Remove boot (4) (2 used). 9
10
11
IMPORTANT: Attach identification tags on the 16
disconnected hoses to aid in 15
reassembly.
7. Remove hoses (12) (12 used) from pilot valves
(13) (2 used).
: 19 mm 14

IMPORTANT: Put the mating marks on pilot valve 13

(13) and the lever stand to aid in Left Stand Pilot
Shut-off Switch 12 T532-02-06-002

reassembly.
8. Remove bolts (14) (8 used) to remove pilot valves
(13) ( 2used) from the lever stand.
: 13 mm

W2-6-1
 UPPERSTRUCTURE / Pilot Valve
Installation

5
1. Insert pilot valves (13) (2 used) into the lever
stand and align the matching marks made when
6
disassembling.

7
2. Install pilot valves (13) (2 used) to the lever stand Pilot Shut-off
with bolts (14) (8 used). Lever 8
: 13 mm 9
10
: 10 N⋅m (1 kgf⋅m, 7.4 Ibf⋅ft)
11
16
3. Connect hoses (12) (12 used) to pilot valves (13) 15
(2 used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 Ibf⋅ft)
14
4. Insert levers (7) (2 used) (with grip (5)) into boots
13
(4) (2 used). Install levers (7) (2 used) into pilot
valves (13) (2 used). When installing, lever (7) Left Stand Pilot
Shut-off Switch 12 T532-02-06-002

with horn button should be installed on left side.

5. Secure levers (7) (2 used) to pilot valves (13) (2

used) with lock nuts (8) (2 used).
4
: 22 mm
: 140 N⋅m (14 kgf⋅m, 103 Ibf⋅ft)

6. Raise boot (4) to install clip band (9).

7. Install clip band (10) and plug (11) to pilot valve

(13) on the left lever stand only.

8. Install boot (4) (2 used) with plates (15) (4 used)

and screws (16) (8 used).

9. Install covers (2 and 3) with screws (1) (6 used)

on the stands. 2 1 3
Fast Speed Travel Pedal M1LA-01-006
IMPORTANT: After the complete work, check the
oil level. Start the engine and check
the connection for oil leaks.

W2-6-2
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INASTALL TRAVEL PILOT
VALVE
Removal

IMPORTANT: Bleed air from the hydraulic oil tank 1

before any work. (Refer to W1-3-1.)
1. Remove bolts (2) (4 used) and wing bolt (3) to
remove cover (1) from the main frame.
: 13 mm

2. Remove bolts (6) (4 used) from pilot valve (10) to

remove pedals (5) (2 used) and levers (4) (2 2
used).
: 6 mm
3 W1LA-02-05-006

IMPORTANT: Attach identification tags onto the

disconnected hoses to aid in
reassembly. 4
3. Disconnect pilot hoses (9) (6 used) from pilot
valve (10). Attach a cap onto the open ends. 5
6

4. Loosen bolts (7) (4 used) for pilot valve (10).

: 13 mm
11
5. Remove bolts (11) (4 used) to remove the cover
(8) assembly from the floor. 7
: 13 mm 8

6. Remove bolts (7) (4 used) to remove pilot valve

(10) from cover (8). W1LA-02-06-004
: 13 mm 10 9

W2-6-3
 UPPERSTRUCTURE / Pilot Valve
Installation

1. Install pilot valve (10) to cover (8) with bolts (7) (4

used) temporarily.
: 13 mm

4
2. Install the cover (8) assembly to the floor with
bolts (11) (4 used). 5
: 13 mm 6
: 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)

3. Connect hoses (9) (6 used) onto pilot valve (10).

11
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
7
8
4. Tighten bolts (7) (4 used) for pilot valve (10).
: 13 mm
: 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)
W1LA-02-06-004

5. Install levers (4) (2 used) and pedals (5) (2 used) 10 9

to pilot valve (10) with socket bolts (6) (4 used).
: 6 mm
: 30 N⋅m (3.1 kgf⋅m, 22 lbf⋅ft)

6. Install cover (1) to the floor in the main frame with 1

bolts (2) (4 used) and wing bolt (3).
: 13 mm
: 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)

IMPORTANT: After connecting the hoses and

connectors, check the hydraulic oil
level. Start the engine and check the
2
connections for oil leaks.

W1LA-02-05-006

W2-6-4
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BLADE PILOT
VALVE
Removal 4

IMPORTANT: Bleed air from the hydraulic oil tank

before any work. (Refer to W1-3-1.)
1. Remove bolts (2) (4 used) to remove cover (1).
: 13 mm

2. Remove bolts (3) (2 used) to remove lever (4)

from pilot valve (6).
: 13 mm

1、2 M1LA-05-004

3. Loosen bolts (5) (2 used). 4

3
: 13 mm

4. Remove bolts (8) (2 used) to remove the bracket 5

(9) assembly from the floor. 9
6
: 17 mm

IMPORTANT: Attach identification tags onto the

disconnected hoses to aid in
ressembly.
5. Disconnect hoses (7) (4 used) from pilot valve (6).
Attach a cap onto the open ends. W1LA-02-06-005

: 19 mm
7
NOTE: Hold hoses (7) (4 used) with a wire to
prevent them from falling down.

6. Remove bolts (5) (2 used) to remove pilot valve

(6).
: 13 mm

W2-6-5
 UPPERSTRUCTURE / Pilot Valve
Installation
3 4
1. Install pilot valve (6) to bracket (9) with bolts (5) (2
used). 5
: 13 mm 9
: 10 N⋅m(1 kgf⋅m, 7.4 lbf⋅ft) 6

2. Connect hoses (7) (4 used) onto pilot valve (6).

: 19 mm
: 29.5 N⋅m(3 kgf⋅m, 22 lbf⋅ft)
8
3. Install the bracket (9) assembly to the floor with
bolts (8) (2 used).
: 17 mm
: 50 N⋅m(5.1 kgf⋅m, 37 lbf⋅ft)

W1LA-02-06-005

7
4. Install lever (4) with bolts (3) (2 used).
: 13 mm
: 10 N⋅m(1 kgf⋅m, 7.4 lbf⋅ft)
4

5. Install cover (1) with bolts (2) (4 used).

: 13 mm
: 10 N⋅m(1 kgf⋅m, 7.4 lbf⋅ft)

IMPORTANT: After connecting the hoses and

connectors, check the hydraulic oil 1、2 M1LA-05-004

level. Start the engine and check the

connections for oil leaks.

W2-6-6
 UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BOOM SWING
PILOT VALVE
Removal
1
Floor
IMPORTANT: Bleed air from the hydraulic oil tank
before any work. (Refer to W1-3-1.)
1. Remove bolts (2) (4 used) and wing bolt (3) to
remove cover (1) from the main frame.
: 13 mm

2. Open cover (5). 2

W1LA-02-05-006
3
3. Remove socket bolts (13) (2 used) to remove
pedal (6) from pilot valve (7).
: 6 mm
4
4. Remove bolts (12) (2 used) from pilot valve (7).
: 13 mm
13
5
5. Remove bolts (11) (2 used) in plate (9).
: 13 mm
6
IMPORTANT: Attach identification tags onto the 12
disconnected hoses to aid in 11
reassembly.
6. Disconnect hoses (10) (4 used) from pilot valve 7
(7). Attach a cap onto the open ends.
: 19 mm 8

7. Remove pilot valve (7) from plate (9).

9

10
10

W1LD-02-06-001

W2-6-7
 UPPERSTRUCTURE / Pilot Valve
Installation

1. Install pilot valve (7) to bracket (8) with bolts (12)

(2 used). 4
: 13 mm
: 10 N⋅m(1 kgf⋅m, 7.4 lbf⋅ft) 13
5
2. Connect hoses (10) (4 used) onto pilot valve (7).
: 19 mm
: 29.5 N⋅m(3 kgf⋅m, 22 lbf⋅ft) 6

12
11
3. Install pilot valve (7) assembly to the floor with
bolts (11) (2 used). 7
: 13 mm
: 10 N⋅m(1 kgf⋅m, 7.4 lbf⋅ft)
8

4. Install pedal (6) to pilot valve (7) with socket bolts

(13) (2 used).
: 6 mm 9
: 20 N⋅m(2 kgf⋅m, 15 lbf⋅ft)

5. Shut cover (5). 10

10

6. Install cover (1) onto the floor in the main frame

with bolts (2) (4 used) and wing bolt (3).
: 13 mm W1LD-02-06-001
: 10 N⋅m(1 kgf⋅m, 7.4 lbf⋅ft)
IMPORTANT: After connecting the hoses and
connectors, check the hydraulic oil
level. Start the engine and check the
connections for oil leaks. 1
Floor

W1LA-02-05-006
3

W2-6-8
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-6-9
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE FRONT PILOT VALVE

13

12

14

11
15

11
10

8
8
7
9
21
6
20
16 21
5
20
4 5
19
3 6

3 18
2
4
1

17

W567-02-06-002

1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)

W2-6-10
 UPPERSTRUCTURE / Pilot Valve
Disassemble Front Pilot Valve

IMPORTANT: Block (10) and housing (18) are IMPORTANT: Two kinds of push rods are used.
made of aluminium. Too strong a They must be handled in order of
force can deform, or damage them. port number after removing.
Therefore, handle with care.
4. Pull push rods (8) (2 used) and (9) (2 used) out of
IMPORTANT: As spool (17) has been selected to block (10).
match the hole of housing (18), they
must be replaced as a set. In 5. Remove oil seals (15) (4 used) from block (10)
addition, the dimensions of balance with a bamboo spatula.
springs A (3), B (4) and return NOTE: If a metal bar is used, the mating part of oil
springs A (5), B (6) as well as those seal may be damaged.
of push rods A (8), B (9) are different.
For this reason, be sure to indicate IMPORTANT: Retaining ring (7) may come off
the port number from which each is while disassembling. Take care not
removed. Port numbers are stamped to drop it.
on housing (18). 6. Press springs with special tool (ST 7257) from the
top of spring guide (16). Retaining ring (7) will
IMPORTANT: Do not clamp housing (18) in a vise appear. Remove it with a screwdriver or similar
to remove the screw joint (13) tool. (4 places)
because the screw joint may be
damaged. 7
1. Clamp screw joint (13) in a vise. Then turn cam
(12) with a spanner to remove the screw joint.
: 32 mm

2. Clamp the flat surface of housing (18) in a vise

slightly. Remove cam (12) from universal joint
(14). 16
: 32 mm
ST 7257
NOTE: Universal joint (14) has been secured on
block (10) with LOCTITE. Don’t remove it
unless necessary.

3. Remove socket bolts (11) (2 used) to remove

block (10). At this time, push rods (8) (2 used) W176-02-07-005

and (9) (2 used) are still on the block side.

: 6 mm IMPORTANT: The number of shims (2) has been
determined for each port during the
performance testing at the factory.
Take care not to lose them. Keep
them carefully so as to install them
to each former port when
reassembly.
7. Remove spring guide (16) (4 used), balance
springs (3) (2 used) and (4) (2 used), return
springs (5) (2 used) and (6) (2 used), shim (2)
and spacer (1) (4 used) from spool (17) (4 used).

W2-6-11
UPPERSTRUCTURE / Pilot Valve

21
20
21

20

19

18

17

W567-02-06-002

W2-6-12
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: As the spool (17) has been selected
to match the hole of the housing (18),
keep them carefully so as to install
them to the former port when
reassembling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it slowly.
NOTE: The spool and the housing must be
replaced as an assembly.

9. Remove O-rings (19) and (21) (2 used) from

housing (18). Don’t remove dowel pin (20) (2
used) unless necessary.

W2-6-13
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE FRONT PILOT VALVE

13
14
12

10

11 15 8, 9

16
3, 4
21 5, 6
2

19

20 1

17

W567-02-06-001

18

1- Spacer (4 Used) 7- Retaining Ring (4 Used) 12 - Cam 17 - Spool (4 Used)

2- Shim (Several) 8- Push Rod A (2 Used) 13 - Screw Joint 18 - Housing
3- Balance Spring A (2 Used) 9- Push Rod B (2 Used) 14 - Universal Joint 19 - O-Ring
4- Balance Spring B (2 Used) 10 - Block 15 - Oil Seal (4 Used) 20 - Dowel Pin (2 Used)
5- Return Spring A (2 Used) 11 - Socket Bolt (2 Used) 16 - Spring Guide (4 Used) 21 - O-Ring (2 Used)
6- Return Spring B (2 Used)

W2-6-14
 UPPERSTRUCTURE / Pilot Valve
Assemble Front Pilot Valve

IMPORTANT: The pilot valve is susceptible to IMPORTANT: Install spring guide (16), with the
contamination. Keep parts clean protrusion facing upward.
when assembling. 3. Install spring guides (16) (4 used) onto return
springs (3) (2 used) or (4) (2 used).
NOTE: Table below shows the relations between
each port and the components. Take care 4. Install retaining ring (7) onto ring holder (ST
not to confuse them when assembling. 7255).
ST 7255
7
Port Spool Shim Push rods
No. (17) (2) (8), (9)
1 with outer
Same to Same to groove
2 the former the former without outer W176-02-07-008

one one groove

3 with outer 5. Insert the spool (17) head into the hole of spring
groove special tool (ST 7257) to press the spring from
4 without outer the top of spring guide (16). Install retaining ring
groove (7) with the ring holder (ST 7255) onto the head of
the spool.
Port Return Springs Blance Springs 7
No. (5), (6) (3), (4) ST 7257 ST 7255

1 short short
2 long long 17
3 short short
4 long long
Packing Material
IMPORTANT: Make sure of the port hole number 16
and insert the spool (17) to the
former port. W176-02-07-009

1. Insert the thinner end of spools (17) (4 used) to NOTE: Put approx. dia.8 mm, length 10 mm of
housing (18), then push the spool in rotating it. packing material into the port hole so as to
NOTE: The spool has been selected to match the not only make the work easy to do, but also
hole of the housing. The spool and housing prevent the spool from lowering to the
must be replaced as an assembly. bottom when compressing the spring.

IMPORTANT: Refer to the table above to assemble 6. Assemble remained spools (17) (3 used) into
them correctly. housing (18) in the same procedures as step 2 to
2. Install the spacers (1) (4 used), shim (2), balance 5.
springs (3) (2 used) or (4) (2 used), return springs
(5) (2 used) or (6) (2 used) onto spool (17) 7. Install O-rings (19) and (21) (2 used) onto
installed in housing (18). housing (18).

W2-6-15
 UPPERSTRUCTURE / Pilot Valve

13
14
12

10

11 15 8, 9

20

W567-02-06-001

18

W2-6-16
 UPPERSTRUCTURE / Pilot Valve
8. Apply grease to the inner faces of oil seals (15) (4 IMPORTANT: Make sure of the tighteness of cam.
used), then install the oil seals (4 used) into block 13. Clamp housing (18) carefully in a vise and then
(10) with a bamboo spatula. install cam (12) to universal joint (14).
NOTE: As shown bellow, insert push rods (8) and Tighten the universal joint so that the clearance
(9) first, then install oil seal (15). This between the cam and push rods (8) (2 used) and
prevents the oil seal from entering into the (9) (2 used) becomes 0 to 0.2 mm.
hole. : 32 mm

Oil Seal IMPORTANT: Do not clamp housing (18) in a vise

Mounting Hole
because screw joint (13) may be
damaged.
10 14. Clamp screw joint (13) in a vise to tighten
8, 9
universal joint (14). Tighten cam (12) with a
spanner.
: 32 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)

W176-02-07-007

IMPORTANT: Make sure of the position to install

the push rod.
9. Install push rods (8) (2 used) and (9) (2 used) to
block (10). When installing the push rods, install
the push rods with groove to ports # 1 and # 3,
the ones without groove to ports # 2 and # 4,
respectively.

10. Apply grease to the ball at the ends of push rods

(8) (2 used) and (9) (2 used).

11. Apply grease to the joint part of universal joint

(14).

12. Align the position of dowel pins (20) (2 used),

install the block (10) assembly to housing (18)
with socket bolts (11) (2 used).
: 6mm
: 20 N⋅m (2 kgf⋅m, 15 Ibf⋅ft)

W2-6-17
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE TRAVEL PILOT VALVE

18 19

20
19
21
7 8 17 20 22
9 21
10 22 23
11 18
16
5 23
17
6 15
7 24
14
16 24 25
5 35
15
12 25
4
14
3 34
4 13
2 3
2 33
1 32
1

26
27
28
29
30
31
W585-02-06-006

1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (4 Used) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)

W2-6-18
 UPPERSTRUCTURE / Pilot Valve
Disassemble Travel Pilot Valve
IMPORTANT: As the spool (23) assemblies (4
• Thoroughly read PRECAUTIONS FOR used) are adjusted by the pressure
DISASEMBLING AND ASSEMBLING (W1-1-1) of shim (21), they should not be
prior to disassembling. disassembled. If disassembling the
• Spool (23) has been selected to match the hole of spool (23) assemblies, record the
casing (34). number and thickness of shim (21).
The spool and casing must be replaced as an 7. Remove spool (23) assemblies (2 used), O-rings
assembly. (25) (4 used) and (35) (2 used), and springs (24)
• Put identification tags on the disassembled parts (4 used) from casing (34).
by port to aid when re-assembling.
• 8. Remove spring guides (19) (4 used), springs (20)
(4 used), shims (21) (4 used), and washers (22)
IMPORTANT: Put the mating marks onto cam (10), (4 used) from spool (23) assemblies (4 used).
pin (11) and cover (12), casings (13,
34) before disassembling.
1. Clamp the pilot valve in a vise to remove boot (8)
from cover (12).

2. Remove set screw( 9) from cam (10). Pull pin (11)

out to remove cam (10) from cover (12).
: 2 mm
NOTE: ・LOCTITE is applied onto the set screw.
・Steel ball (6) can not be removed from
cam (10).

3. Loosen and remove socket bolts (7) (2 used)

alternately. Remove covers (12) (2 used) and
casing (13) assembly from casing (34).
: 6 mm

IMPORTANT: Put identification tags on the

disassembled parts by port.
4. Remove grease cups (4) (4 used), push rods (18)
(4 used), and bushing (2) assemblies (4 used)
from casing (13) assembly.

5. Remove pistons (17) (4 used), springs (16) (4

used), spring seats (15) (4 used), and steel balls
(14) (12 used) from casing (13).

6. Remove packings (3) (4 used) and O-rings (1) (4

used) from bushing (2) assemblies (4 used).

W2-6-19
 UPPERSTRUCTURE / Pilot Valve

5
12

34

26
27
28
29
30
31
W585-02-06-006

W2-6-20
 UPPERSTRUCTURE / Pilot Valve
9. 9.Remove plugs (31) (2 used) and O-rings (30) (2
used) from casing (34).
: 6 mm

10. Remove seats (29) (2 used), steel balls (28) (2

used), bushings (27) (2 used) and seats (26) (2
used) from casing (34) with a magnet.

IMPORTANT: Be sure not to remove busing (5)

from cover (12) unless bushing (5) is
damaged.
11. Pull bushings (5) (4 used) out of covers (12) (2
used).

W2-6-21
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL PILOT VALVE

9
8 11 5
6 10
18 4
3
2
7
12
1
17
16
35
15 13
19
14
31
25
30
20
21
24
22
32
33
23 C C
34
27
29 28 W585-02-06-008

26

Cross SectionC-C

W585-02-06-007

1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (4 Used) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)

W2-6-22
 UPPERSTRUCTURE / Pilot Valve
Assemble Travel Pilot Valve
7. Install push rods (18) (4 used) and bushing (2)
• Thoroughly read PRECAUTIONS FOR assemblies (4 used) to casing (13).
DISASEMBLING AND ASSEMBLING (W1-1-1)
prior to assembling. 8. Install bushings (5)(4 used) to covers (12) (2
• Clean the parts and put them by port for used).
assembling.

9. Clamp casing (34) in a vise. Install casing (13)

1. Install seats (26) (2 used), bushings (27) (2 used), assembly and cover (12) to casing (34) with
steel balls (28) (2 used) and seats (29) (2 used) socket bolts (7) (4 used).
to casing (34). : 6 mm
: 23.5 N⋅m (2.4 kgf⋅m, 17.5 lbf⋅ft)
2. Install O-rings (30) (2 used) to plugs (31) (2 used).
Install them to casing (34).

IMPORTANT: Be sure to install shim (21) to the

original condition.
3. Install washers (22) (4 used), shims (21) (4 used),
springs (20) (4 used), and spring guides (19) (4
used) to spools (23) (4 used) in this order.

IMPORTANT: Be sure to install spool (23)

assembly into the original hole when
dissembling.
4. Install springs (24) (4 used), spool (23)
assemblies (4 used), and O-rings (25) (4
used)and (35) (2 used) to casing (34).

5. Install steel balls (14) (12 used), spring seats (15)

(4 used), springs (16) (4 used) and pistons (17) (4
used) to casing (13).

6. Install O-rings (1) (4 used) and packings (3) (4

used) to bushings (2) (4 used).
3

W585-02-06-005
Lip Part

W2-6-23
 UPPERSTRUCTURE / Pilot Valve

9
11
8 10
18 4

12

C C

W585-02-06-008

Cross Section C-C

W585-02-06-007

W2-6-24
 UPPERSTRUCTURE / Pilot Valve
10. Install grease cups (4) (4 used) to push rods (18)
(4 used).

11. Install cams (10) (2 used) to cover (12) with pins

(11) (2 used).

12. Apply LOCTITE #241 onto set screws (9) (2

used). Secure cams (10) (2 used) and pin (11) (2
used) with set screws (9) (2 used).
: 2 mm
: 5 N⋅m (0.5 kgf⋅m, 3.7 lbf⋅ft)

13. Install boots (8) (2 used) to covers (12) (2 used).

W2-6-25
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE BLADE AND BOOM
SWING PILOT VALVE

20

7 20

8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15

15
4
11 14

14
3

3 12
13
2
2

21
1
1

W1LA-02-06-001

1 - O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2 - Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3 - Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4 - Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5 - Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6 - Socket Bolt (2 Used)

W2-6-26
 UPPERSTRUCTURE / Pilot Valve
Disassemble Blade and Boom Swing Pilot Valve
7. Remove spring guides (19) (2 used), springs (18)
• Read PRECAUTIONS FOR DISASEMBLING (2 used), washers (16) (2 used), and shims (17)
AND ASSEMBLING (W1-1-1) carefully before (2 used) from spool (15) assemblies (2 used).
disassembling.
• Spool (15) has been selected to match the hole of IMPORTANT: As the spool (15) assemblies (2
casing (21). used) are adjusted by the pressure
The spool and casing must be replaced as an of shim (17), they should not be
assembly. disassembled. If disassembling the
• Discriminate between the disassembled parts by spool (15) assemblies, record the
port No. where the parts are located in order to quantity and thickness of shim (17).
avoid confusion. IMPORTANT: Do not remove bushing (4) from
cover (11) unless bushing (4) is
IMPORTANT: Put the mating marks onto cam (9), damaged.
pin (10), cover (11), and casing (21) 8. Pull bushings (4) (2 used) out of cover (11).
before disassembling.
1. Clamp the pilot valve in a vise to remove boot (7)
from cover (11).

2. Remove set screw (8) from cam (9). Pull pin (10)
out to remove cam (9) from cover (11).
: 2 mm
NOTE: LOCTITE is applied onto the set screw.
NOTE: Steel ball (5) cannot be disassembled from
cam (9).

3. Loosen and remove socket bolts (6) (2 used)

alternately. Remove cover (11) from casing (21).
: 6 mm

4. Remove pusher (20) assemblies (2 used) from

casing (21).

5. Remove bushings (2) (2 used) from pusher (20)

assembly. Remove O-rings (1) (2 used) and
packings (3) (2 used) from bushings (2) (2 used).

IMPORTANT: Put identification tags on the

disassembled parts by port in order
to avoid confusion.
6. Remove spool (15) assemblies (2 used) and
springs (14) (2 used) from casing (21).

W2-6-27
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLE BLADE AND BOOM SWING
PILOT VALVE
8 10
7
9
5

20

3
6
2

11

19

18

14

17

16

12

13

15 W1LA-02-06-002

21

1 - O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2 - Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3 - Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4 - *Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5 - Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6 - Socket Bolt (2 Used)

NOTE: As for the items with a mark “*”, refer to

W2-6-26.

W2-6-28
 UPPERSTRUCTURE / Pilot Valve
Assemble Blade and Boom Swing Pilot Valve
8. Apply LOCTITE #241 onto set screw (8). Secure
• Read PRECAUTIONS FOR DISASEMBLING cam (9) and pin (10) with set screws (8).
AND ASSEMBLING (W1-1-1) carefully before : 2 mm
assembling. : 5 N⋅m (0.5 kgf⋅m, 3.7 lbf⋅ft)
• Clean the parts and put them by port for
assembling. 9. Install boot (7) to cover (11).

1. Install bushings (4) (2 used) to cover (11).

IMPORTANT: Be sure to install shim (17) to the

original condition.
2. Install washers (16) (2 used), shims (17) (2 used),
springs (18) (2 used), and spring guides(19) (2
used) to spools (15) (2 used) in this order.

IMPORTANT: Be sure to install spool (15)

assembly into the original hole when
disassembling.
3. Install springs (14) (2 used) and spool(15)
assemblies (2 used) to casing (21).

4. Install O-rings (1) (2 used) and packings (3) (2

used) to bushings (2) (2 used).
3

W585-02-06-005
Lip Part

5. Install pushers (20) (2 used) to bushing (2)

assemblies (2 used). Install them to casing (21).

6. Clamp casing (21) in a vise. Install cover (11) to

casing (21) with socket bolts (6) (2 used).
: 6 mm
: 23.5 N⋅m (2.4 kgf⋅m, 17.5 lbf⋅ft)

7. Install cam (9) to cover (11) with pin (10).

W2-6-29
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-6-30
 UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE AND ASSEMBLE SOLENOID VALVE

1 3 2

W574-02-07-001

1 - ON-OFF Solenoid Valve 2 - ON-OFF Solenoid Valve 3 - Relief Valve 4 - Housing

(Pilot Control (Travel Speed Selector)
Shut-Off Lever )

W2-7-1
 UPPERSTRUCTURE / Solenoid Valve

7
1

8
3

6
9

10

11

12

13

W574-02-07-002

1 - Guide 5 - Washer 8 - Solenoid 11 - Spool

2 - O-Ring 6 - Spool 9 - Tube 12 - Spring
3 - Washer 7 - Nut 10 - O-Ring 13 - Housing
4 - Spring

W2-7-2
 UPPERSTRUCTURE / Solenoid Valve
Disassemble Solenoid Valve Assemble Solenoid Valve

• Read PRECAUTIONS FOR DISASSEMBLING • Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before AND ASSEMBLING (W1-1-1) carefully before
disassembling. assembling.

1. Loosen nut (7), then remove solenoid (8). 1. Install spool (6), washer (5), spring (4) and
washer (3) into housing (13).
: 19 mm

2. Install guide (1) with O-ring (2) into housing (13).

2. Remove tube (9), O-ring (10), spool (11) and
spring (12) from housing (13). : 24 mm
: 74 to 88 N⋅m
: 21 mm (7.5 to 9.0 kgf⋅m, 55 to 65 lbf⋅ft)

3. Remove guide (1) from housing (13). 3. Install spring (12) and spool (11) into housing
(13).
: 24 mm

4. Install tube (9) with O-ring (10) into housing (13).

4. Remove washer (3), spring (4), washer (5) and
spool (6) from housing (13). : 21 mm
: 47 to 74 N⋅m
(4.8 to 7.5 kgf⋅m, 35 to 55 lbf⋅ft)

5. Install solenoid (8) and nut (7) onto tube (9).

: 19 mm
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)

W2-7-3
 UPPERSTRUCTURE / Solenoid Valve
（Blank）

W2-7-4
 UPPERSTRUCTURE / Revolution Sensing Valve
REMOVE AND INSTALL REVOLUTION 1 2
SENSING VALVE

Removal
IMPORTANT: Bleed air from the hydraulic oil tank
before any work. (Refer to W1-3-1)

3
1. Open engine cover (1). Insert rod (3) into hole (2)
for the lock to lock engine cove (1).

2. Push latch (4) on tank cover (5) upward to unlock.

4 SS-2304

M1LD-07-017

3. Open tank cover (5) until lock (6) is locked. 5

M1LD-07-013

M1LD-07-014

W2-8-1
 UPPERSTRUCTURE / Revolution Sensing Valve
4. Disconnect all hoses from revolution sensing 7
valve (8). Cap all the disconnected hoses. Attach 8
tags onto them to aid reassembly.
: 19 mm, 22 mm

5. Remove bolts (7) (2 used) to remove revolution

sensing valve (8).
: 13 mm

M1LD-07-007

W2-8-2
 UPPERSTRUCTURE / Revolution Sensing Valve
Installation 7
8
1. Install revolution sensing valve (8) with bolts (7)
(2 used).
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

2. Connect all the hoses onto revolution sensing

valve (8).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

3. Push lock (6) upward by right hand to unlock.

M1LD-07-007
6

4. Shut tank cover (5).

M1LD-07-015

M1LD-07-013

W2-8-3
 UPPERSTRUCTURE / Revolution Sensing Valve
5. Align the mating mark on tank cover (5) with that 5
on cover (9).

9 M1LD-07-010
6. Push tank cover (5) downward until tank cover (5)
is locked.

7. Remove rod (3) from hole (2) for the lock. Shut
engine cover (1).

M1LD-07-012
3 2

SS-2304

W2-8-4
 UPPERSTRUCTURE / Revolution Sensing Valve
(Blank)

W2-8-5
 UPPERSTRUCTURE / Revolution Sensing Valve
DISASSEMBLE REVOLUTION SENSING
VALVE

5
4
4

4 6

2
W566-02-08-001

3 11 12 13 4 14 4

15

2 10 1 9 8 18 17 7 16
W566-02-08-002

1- Body 6- Choke 11 - O-Ring 15 - Spring

2- Differential Reducing Vlave 7- Plug 12 - Spring 16 - O-Ring
3- Variable Orifice Valve 8- O-Ring 13 - Spool 17 - Guide
4- Plug (3 Used) 9- O-Ring 14 - O-Ring 18 - Piston
5- Plug 10 - O-Ring

W2-8-6
 UPPERSTRUCTURE / Revolution Sensing Valve
Disassemble Revolution Sensing Valve

• Read PRECAUTIONS FOR DISASSEMBLING

AND ASSEMBLING (W1-1-1) carefully before
disassembling.

IMPORTANT: Do not remove plugs (5 and 7).

IMPORTANT: Never turn the lock nuts of differen-

tial reducing valve(2) and variable
orifice valve(3). If turned, the set
pressure may be changed.
Lock Nut
Cartridge

W176-02-06-017

1. Remove differential reducing valve (2) from body

(1). Remove piston (18) and spring (15) from
body (1) with a magnet.
: 24 mm

2. Install the bolt (M8) into the hole on guide (17) to

remove guide (17) from body (1).

IMPORTANT: When removing variable orifice

valve (3) from body (1), spool (13)
and spring (12) may be left inside
the body. In this case, remove spool
(13) and spring (12) with a magnet.
3. Remove variable orifice valve (3), spring (12),
and spool (13) from body (1).
: 24 mm

4. Remove plugs (4) (3 used) and choke (6) from

body (1).
: 6 mm, 5 mm

W2-8-7
 UPPERSTRUCTURE / Revolution Sensing Valve
ASSEMBLE REVOLUTION SENSING
VALVE

5
4
4

4 6

2
W566-02-08-001

3 11 12 13 4 14 4

15

2 10 1 9 8 18 17 7 16
W566-02-08-002

1- Body 6- Choke 11 - O-Ring 15 - Spring

2- Differential Reducing Vlave 7- Plug 12 - Spring 16 - O-Ring
3- Variable Orifice Valve 8- O-Ring 13 - Spool 17 - Guide
4- Plug (3 Used) 9- O-Ring 14 - O-Ring 18 - Piston
5- Plug 10 - O-Ring

W2-8-8
 UPPERSTRUCTURE / Revolution Sensing Valve
Assemble Revolution Sensing Valve IMPORTANT: Install differential reducing valve (2)
into body (1) with guide (17) assem-
• Read PRECAUTIONS FOR DISASSEMBLING bly facing upward. In case differen-
AND ASSEMBLING (W1-1-1) carefully before as- tial reducing valve (2) cannot be in-
sembling. stalled to body (1) by hand, guide
(17) assembly may be off. At this
time check if the sliding surfaces of
1.Install choke (6) and plugs (4) (3 used) to body (1). piston (18) and guide (17) are dam-
: 5 mm aged after pulling differential reduc-
: 9.8 to 11.0 N⋅m ing valve (2) out of body (1).
(1.0 to 1.2 kgf⋅m, 7.2 to 8.1 lbf⋅ft)
: 6 mm
: 30.5 to 34.0 N⋅m
(3.1 to 3.5 kgf⋅m, 22.5 to 25 lbf⋅ft) 5. Install differential reducing valve (2) to body (1)
turning it I to 2 times by hand. Tighten it.
: 24 mm
IMPORTANT: Apply grease onto O-Rings (14, 11). : 79 to 83 N⋅m
2. Install spring (12), spool (13), and O-rings (11, 14) (8.1 to 8.5 kgf⋅m, 58 to 61 lbf⋅ft)
to variable orifice valve (3).

IMPORTANT: Install variable orifice valve (3) into

body (1) with O-ring (14) facing up-
ward. In case variable orifice valve
(3) cannot be installed to body (1) by
hand, spool (13) may be off. At this
time check if the spool (13) sliding
surface is damaged after pulling
variable orifice valve (3) out of body
(1).
3. Install variable orifice valve (3) to body (1) turning
it 1 to 2 times by hand. Tighten it.
: 24 mm
: 54 to 59 N⋅m
(5.5 to 6.0 kgf⋅m, 40 to 44 lbf⋅ft)

IMPORTANT: Apply grease onto O-rings (10, 9, 8,

16) and spring (15).
4. Install piston (18), spring (15) and O-ring (16) to
guide (17). Install O-rings (10, 9, 8) and guide
(17) assembly to differential reducing valve (2).

W2-8-9
 UPPERSTRUCTURE / Revolution Sensing Valve
(Blank)

W2-8-10
 MEMO

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 MEMO

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 SECTION 3
UNDERCARRIAGE

CONTENTS
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing .......... W3-1-1 Remove and Install Upper Roller ............. W3-6-1
Remove and Install Lower Roller ............. W3-6-3
Group 2 Travel Device Disassemble and Assemble
Remove and Install Travel Device ........... W3-2-1 Lower Roller........................................... W3-6-6
Disassemble Travel Device ..................... W3-2-2 Maintenance Standards ........................... W3-6-8
Assemble Travel Device .......................... W3-2-6
Maintenance Standards......................... W3-2-16 Group 7 Track
Remove and Install Rubber Crawler ........ W3-7-1
Group 3 Center Joint Maintenance Standards ........................... W3-7-3
Remove and Install Center Joint.............. W3-3-1
Disassemble Center Joint........................ W3-3-4
Assemble Center Joint ............................ W3-3-6

Group 4 Track Adjuster

Remove and Install Track Adjuster .......... W3-4-1
Disassemble Track Adjuster .................... W3-4-2
Assemble Track Adjuster ......................... W3-4-8

Group 5 Front Idler

Remove and Install Front Idler................. W3-5-1
Disassemble and Assemble Front Idler ... W3-5-2
Maintenance Standards........................... W3-5-4

1LDW-3-1
（Blank）

1LDW-3-2
 UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING

The procedures described below starts after removing

the upper structure.

Removal
1. Put matching marks on inner race (1) of the swing
bearing and track frame (2). Matching Mark

2. Remove mounting bolts (3) (20 used) of the swing

bearing inner race. 1 2 W105-03-01-001

: 19 mm

W507-02-03-002
CAUTION: Swing bearing weight: 55 kg
(121 lb)
3. Attach lifting tools (ST 0052) to swing bearing (4)
outer race, lift swing bearing (4) by crane and
remove it.

ST 0052

W507-03-01-001

W3-1-1
 UNDERCARRIAGE / Swing Bearing
Installation
Clean the mating surfaces of the track frame and
swing bearing.

1. Apply THREEBOND #1102 to the mating

surfaces of the swing bearing and the track
frame.

Front Side
CAUTION: Swing bearing weight: 55 kg Position for
(121 lb) "S" (Soft Zone) Grease Fitting
Marking Position
IMPORTANT: Failure to align the marks may result
in misalignment of the inner race
soft zone. 25°

2. Lift the swing bearing by crane. Align the

alignment marks both on the track frame and
swing bearing.
9°

16°

Position for
Grease Fitting

W1LD-03-01-001

3
3. Install mounting bolts (3) (20 used) to the inner
race of the swing bearing and tighten to
specification.
: 19 mm
: 108 N⋅m (11 kgf⋅m 80 lbf⋅ft)

W507-02-03-002

W3-1-2
 UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE

Removal
IMPORTANT: Bleed air from the hydraulic oil tank
before any work. (Refer to W1-3-1)

1. Remove bolts (1) (3 used) to remove cover (2).

: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2
2. Disconnect all hoses from the travel device.
Cap all disconnected hose ends and put tags on
all disconnected hoses to aid in ressambly.
: 19 mm 1
W507-03-02-001
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

CAUTION: Travel device weight: 65 kg

(143 lb)

3. Remove travel device mounting bolts (3) (13

used). Lift and remove the travel device by crane.
: 19 mm
: 128 N⋅m (13 kgf⋅m, 94 lbf⋅ft)

Installation 3
W554-03-02-005
NOTE: Refer to "Removal" section for wrench size
and tightening torque.

1. Lift the travel device by crane. Install the travel

device to the track frame with mounting bolts (3)
(13 used).
2. Connect all hoses to the travel device.
3. Install the travel motor cover (2) onto the track
frame with bolts (1) (3 used).

IMPORTANT: After connecting the hoses, check

the hydraulic oil level. Start the en-
gine and check the hoses for oil
leaks.
To prevent the travel motor from
seizing, be sure to perform break-in
operation after installation.

Break-in operation conditions

1.Engine speed: Slow idle speed
2.Travel pedal : Slow speed range
3.Operation duration: 2 minutes or
more

W3-2-1
 UNDERCARRIAGE / Travel Device
1 2
DISASSEMBLE TRAVEL DEVICE 3

29 4
30 5
30
29 6
27 7
28 8
27 9
15 10
18 11
17
26 16
15
25 14
24
23
22
21 13
12
20
19

37 36
W571-03-02-004
55 35
54
53 58 52
51 50 34
49 33
48 32
47 31
46
45
43
44
71 43
42
70 41
40
59 39
57
60 38
61 56
62
63
66 64
67 65
68
50
49 69
52
51 W571-03-02-005
1 - Sun Gear 19 - Retaining Ring (4 Used) 37 - Swash Plate 55 - Socket Bolt (4 Used)
2 - Thrust Collar 20 - Thrust Washer (4 Used) 38 - Plunger (9 Used) 56 - O-Ring
3 - First Stage Carrier 21 - Second Stage Planetary Gear 39 - Holder 57 - Choke
(4 Used)
4- Retaining Ring 22 - Needle Bearing (4 Used) 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring (4 Used) 41 - Pin (3 Used) 59 - Ball (2 Used)
6- Slide Ring 24 - Thrust Washer (4 Used) 42 - Rotor 60 - Spring (2 Used)
7- O-Ring 25 - Retaining Ring 43 - Retainer (2 Used) 61 - Spring Guide (2 Used)
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring (2 Used)
9- Stopper Ring 27 - Bearing (2 Used) 45 - Retaining Ring 63 - Plug (2 Used)
10 - O-Ring (2 Used) 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug (2 Used) 29 - O-Ring (2 Used) 47 - O-Ring 65 - Spool
12 - Plug 30 - Seal Ring (2 Used) 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug (2 Used) 67 - O-Ring (2 Used)
14 - Retaining Ring (3 Used) 32 - Control Piston 50 - O-Ring (2 Used) 68 - Plug (2 Used)
15 - Thrust Washer (6 Used) 33 - Oil Seal 51 - Spring (2 Used) 69 - Spool
16 - Pin (3 Used) 34 - Bearing 52 - Ring (2 Used) 70 - O-Ring (2 Used)
17 - Needle Bearing (3 Used) 35 - Shaft 53 - Socket Bolt (7 Used) 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball (2 Used) 54 - Relief Valve Assembly
(3 Used)

W3-2-2
 UNDERCARRIAGE / Travel Device
Disassemble Travel Device
• Read PRECAUTIONS FOR DISASSEMBLING 9. Remove plungers (38) (9 used), holder (39), bar-
AND ASSEMBLING (W1-1-1) carefully before rel holder (40) and pins (41) (3 used) from rotor
disassembling. (42).
1. Remove plugs (63) (2 used), spring guides (61)
(2 used), springs (60) (2 used) and balls (59) (2 CAUTION: Always hold retainer (43) and
used) from body (58). Remove O-rings (62) (2 spring (44) with a press when removing re-
used) from plugs (63) (2 used). taining ring (45). If retaining ring (45) is re-
moved without holding retainer (43) and
2. Remove plugs (49) (2 used), springs (51) (2 spring (44), retainer (43) and spring (44) may
used), Rings (52) (2 used) and spool (69) from fly out potentially causing serious injury.
body (58). Remove O-rings (50) (2 used) from
plugs (49) (2 used). 10. Remove retaining ring (45) from rotor (42), then
remove retainer (43), spring (44) and retainer
3. Remove plugs (68) (2 used), spacer (66), spool (43).
(65) and spring (64) from body (58). Remove O-
rings (67) (2 used) from plugs (68) (2 used). 11. Remove plug (12), O-ring (13), plugs (11) (2
used) and O-rings (10) (2 used) from cover (8).
4. Remove socket bolts (55) (4 used), relief valve : 5 mm, 8 mm
assembly (54), O-rings (70) (2 used) and (71)
from body (58).
: 6 mm 12. Remove stopper ring (9) from cover (8) using a
screwdriver, then remove cover (8) from ring gear
(26).
CAUTION: Valve plate (46) may stick to body
(58). Take care not to drop valve plate (46)
when removing body (58).

5. Removes socket bolts (53) (7 used) to remove

body (58) and valve plate (46) from body (31).
: 10 mm

6. Remove O-ring (56), bearing (48) and choke (57)

from body (58).

7. Remove O-ring (47) from body (31).

8. Remove rotor (42) assembly, swash plate (37),

balls (36) (2 used), and control piston (32) from
body (31).

W3-2-3
UNDERCARRIAGE / Travel Device

1
2
3
4
29
30 5
30
29 6
7
27
28 8
27
15
18
17
26 16
15
25
24 14
23
22
21
20
19

W571-03-02-004
35

34
33
32
31

W571-03-02-005

W3-2-4
 UNDERCARRIAGE / Travel Device
13. Remove O-ring (7) and slide ring (6) from cover
(8).

14. Remove drive gear (5), first stage carrier (3) as-
sembly, retaining ring (4) and sun gear (1) from
ring gear (26).

15. Remove retaining rings (14) (3 used), thrust

washers (15) (3 used), first stage planetary gears
(18) (3 used), needle bearings (17) (3 used),
thrust washers (15) (3 used) and pins (16) (3
used) from first stage carrier (3).

16. Remove thrust collar (2), retaining rings (19) (4

used), thrust washers (20) (4 used), second stage
planetary gears (21) (4 used), needle bearings
(22) (4 used), rings (23) (4 used) and thrust
washers (24) (4 used) from body (31).

CAUTION: Attach a bar to shaft (35) assem-

bly. While tapping the end of the bar with a
hammer, remove shaft (35) assembly from
body (31). Do not remove bearing (34) unless
replacement is necessary.
17. Remove shaft (35) from body (31).

18. Remove retaining ring (25) from body (31).

19. Remove body (31) from ring gear (26).

IMPORTANT: Attach a bar to bearing (27). While

tapping the end of the bar with a
hammer, remove bearing (27) from
ring gear (26). Replace bearing (27)
with a new one if removed.

20. Remove seal ring (30), O-ring (29), bearing (27),

retaining ring (28) and bearing (27) from ring gear
(26).

21. Remove O-ring (29) and seal ring (30) from body
(31).

22. Remove oil seal (33) from body (31).

W3-2-5
 UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL DEVICE

18 17 15 19 20 21 22 24 25 33 28 34 29 37 36 40 41 47 53 44 48
58

15

16

23
14

55

13 54
12
6
8

10

11

9 7 4 3 2 1 5 26 32 27 39 30 38 42 43 31 56 35 57 45 46

T571-03-05-001

1 - Sun Gear 19 - Retaining Ring (4 Used) 37 - Swash Plate 55 - Socket Bolt (4 Used)
2 - Thrust Collar 20 - Thrust Washer (4 Used) 38 - Plunger (9 Used) 56 - O-Ring
3 - First Stage Carrier 21 - Second Stage Planetary 39 - Holder 57 - Choke
Gear (4 Used)
4- Retaining Ring 22 - Needle Bearing (4 Used) 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring (4 Used) 41 - Pin (3 Used) 59 - Ball (2 Used)
6- Slide Ring 24 - Thrust Washer (4 Used) 42 - Rotor 60 - Spring (2 Used)
7- O-Ring 25 - Retaining Ring 43 - Retainer (2 Used) 61 - Spring Guide (2 Used)
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring (2 Used)
9- Stopper Ring 27 - Bearing (2 Used) 45 - Retaining Ring 63 - Plug (2 Used)
10 - O-Ring (2 Used) 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug (2 Used) 29 - O-Ring (2 Used) 47 - O-Ring 65 - Spool
12 - Plug 30 - Seal Ring (2 Used) 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug (2 Used) 67 - O-Ring (2 Used)
14 - Retaining Ring (3 Used) 32 - Control Piston 50 - O-Ring (2 Used) 68 - Plug (2 Used)
15 - Thrust Washer (6 Used) 33 - Oil Seal 51 - Spring (2 Used) 69 - Spool
16 - Pin (3 Used) 34 - Bearing 52 - Ring (2 Used) 70 - O-Ring (2 Used)
17 - Needle Bearing (3 Used) 35 - Shaft 53 - Socket Bolt (7 Used) 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball (2 Used) 54 - Relief Valve Assembly
(3 Used)

W3-2-6
UNDERCARRIAGE / Travel Device

69 69

52

49

51

50 68

59

60

61

64 62 63 65 66 67

W571-03-02-001

W3-2-7
 UNDERCARRIAGE / Travel Device

19 20 21 22 24 25 33 28 29 30

23

2 26 27 31

T571-03-05-001

W3-2-8
 UNDERCARRIAGE / Travel Device
Assemble Travel Device
• Read PRECAUTIONS FOR DISASSEMBLING 5. Install rings (23) (4 used), thrust washers (24) (4
AND ASSEMBLING (W1-1-1) carefully before as- used), second stage planetary gears (21) (4
sembling. used), needle bearings (22) (4 used) and thrust
washers (20) (4 used) onto body (31) in this order.
1. Install oil seal (33) into body (31). Secure them with retaining rings (19) (4 used),
then install thrust collar (2).
2. Install O-ring (29) onto seal ring (30), then install
them into the body (31).

3. Install bearing (27), retaining ring (28), bearing

(27) and the assembly of seal ring (30) and O-ring
(29) into ring gear (26) in this order.

NOTE: Apply grease to O-ring (29) for easy as-

sembling. Degrease the seating surface of
seal ring (30).

4. Install ring gear (26) into body (31), tapping

around the circumference of ring gear (26) evenly
with a plastic hammer. Install retaining ring (25)
while depressing clearance between the flanges
of body (31) and ring gear (26) using screw
clamps.

26

Screw Clamp

31

W571-03-02-006

W3-2-9
 UNDERCARRIAGE / Travel Device

18 17 15

15
16
14

13
12
6
8

10

11

9 7 4 3 1 5 26

T571-03-05-001

W3-2-10
 UNDERCARRIAGE / Travel Device
6. Install pins (16) (3 used) onto first stage carrier
(3). Install sun gear (1) and secure it with retain-
ing ring (4).

7. Install thrust washers (15) (3 used), first stage

planetary gears (18) (3 used), needle bearings
(17) (3 used) and thrust washers (15) (3 used)
onto first stage carrier (3) in this order, then install
retaining rings (14) (3 used).

8. Install first stage carrier (3) assembly onto ring

gear (26), then install drive gear (5) into first stage
carrier (3) assembly.

9. Install O-ring (7) onto ring gear (26). Add 0.6 litter
(0.159 US gal) of lubrication oil into ring gear (26).

CAUTION: Apply grease to cover (8) and

slide ring (6) to hold them. Apply grease to
O-ring (7), then install it horizontally with
care to avoid damage. Install cover (8) so that
its plug hole aligns with the notch on ring
gear (26).

10. Install the assembly of cover (8) and slide ring (6)
onto ring gear (26), then secure them using stop-
per ring (9).

11. Install plug (11), O-ring (10), plug (12) and O-ring
(13) onto cover (8).
: 5 mm
: 12 to 13 N⋅m
(1.2 to 1.3 kgf⋅m, 8.9 to 9.6 lbf⋅ft)
: 8 mm
: 46 to 51 N⋅m
(4.7 to 5.2 kgf⋅m, 34 to 38 lbf⋅ft)

W3-2-11
UNDERCARRIAGE / Travel Device

34 37 36 40 41 47 53 44 43 48

58

71

55
54

70

32 39 38 43 42 31 56 35 57 45 46

T571-03-05-001

W3-2-12
 UNDERCARRIAGE / Travel Device
IMPORTANT: Do not remove bearing (34) on shaft
(35) assembly unless replacing it.

12. Install control piston (32), shaft (35) assembly,

balls (36) (2 used) and swash plate (37) into body
(31) in this order.

13. Install retainer (43), spring (44) and retainer (43)

into rotor (42) in this order.

14. Depress retainer (43) and spring (44) downward

with a press, and install retaining ring (45).

15. Install pins (41) (3 used) and barrel holder (40)

into rotor (42).

16. Install plungers (38) (9 used) and holder (39) onto

rotor (42).

17. Install rotor (42) assembly into body (31). Add 0.2
litter (0.053 US gal) of hydraulic oil into body (31).

18. Install bearing (48), O-ring (47) and valve plate

(46) onto body (58) in this order. Install choke (57)
and O-ring (56).

19. Install body (58) onto body (31), and tighten using
socket bolts (53) (7 used).
: 10 mm
: 51 to 65 N⋅m
(5.2 to 6.6 kgf⋅m, 38 to 48 lbf⋅ft)

20. Install O-ring (70), O-ring (71), relief valve (54)

and socket bolt (55) onto body (58).
: 6 mm
: 25 to 32 N⋅m
(2.6 to 3.3 kgf⋅m, 18.5 to 24 lbf⋅ft)

W3-2-13
UNDERCARRIAGE / Travel Device

69 58 69

52

49

51

50 68

59

60

61

64 63 62 65 66 67

W571-03-02-001

W3-2-14
 UNDERCARRIAGE / Travel Device
21. Install O-rings (67) (2 used) onto plugs (68) (2
used). Install spring (64), spool (65) and spacer
(66) into body (58), then install plugs (68) (2
used).
: 8 mm
: 46 to 51 N⋅m
(4.7 to 5.2 kgf⋅m, 34 to 38 lbf⋅ft)

22. Install O-rings (50) (2 used) onto plugs (49) (2

used). Install spool (69), rings (52) (2 used),
springs (51) (2 used) into body (58), then install
plugs (49) (2 used).
: 36 mm
: 196 to 245 N⋅m
(20 to 25 kgf⋅m, 145 to 180 lbf⋅ft)

23. Install O-rings (62) (2 used) onto plugs (63) (2

used). Install balls (59) (2 used), springs (60) (2
used), spring guides (61) (2 used), plugs (63) (2
used) into body (58) in this order.
: 6 mm
: 5.9 N⋅m (0.6 kgf⋅m, 4.4 lbf⋅ft)

W3-2-15
 UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARDS

Sprocket

C B

D
A
W1SE-03-02-001 W105-03-07-040

Unit: mm
Dimension Standard Allowable Limit Remedy
A 47.6 (42.6)
B 73.1 70.6
Cladding by
C 96.05 93.55 welding and
finishing
C’ PCD92.35 -
D 135.0 -
NOTE: The value in the parenthesis is the refer-
ence value.

W3-2-16
 UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT

Removal

IMPORTANT: Bleed air from the hydraulic oil tank

before any work. (Refer to W1-3-1)

1. Remove floor plate.

1
NOTE: Refer to "REMOVE AND INSTALL SWING
DEVICE" for removing floor plate.

2. Attach tags to all hoses connected to center joint

(1), to identify for reassembling in the same posi-
tions.
W507-03-03-001
Remove all body side hoses from center joint (1). 1
Cap all disconnected hose ends. 2
: 19 mm, 22 mm, 27 mm
3

3. Remove bolts (3) (2 used) to remove lock plate

(2) from the frame.
: 19 mm
W1LD-03-03-001
4

4. Remove bolts (4) (3 used) to remove undercover

(5) from the frame. 5
: 19 mm

W554-03-03-002

5. Disconnect all spindle side hoses from center

joint (1). Cap all disconnected hose ends.
: 19 mm, 22 mm, 27 mm

CAUTION: Center joint weight: 19 kg (42 lb)

6. Remove bolts (6) (4 used). Lift and remove center
joint (1) from the frame by crane.
: 17 mm 1
W507-03-03-004

1
6

W571-03-03-001

W3-3-1
 UNDERCARRIAGE / Center Joint
Installation
1
6
CAUTION: Center joint weight: 19 kg (42 lb)
1. Install center joint (1) onto the frame with bolts (6)
(4 used).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W571-03-03-001

2. Connect all spindle side hoses to center joint (1).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

1
W507-03-03-004
4
3. Install undercover (5) onto the frame with bolts (4)
(3 used).
: 19 mm 5
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

4. Install lock plate (2) onto the frame with bolts (3)
(2 used).
: 19 mm W554-03-03-002
1
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
2
3
5. Connect all body side hoses to center joint (1).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) W1LD-03-03-001

: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

6. Install the floor plate.

NOTE: Refer to "REMOVE AND INSTALL SWING
DEVICE" for installing the floor plate. 1

IMPORTANT: After connecting the hoses, fill the

hydraulic oil tank to the correct level.
Start the engine and check the hose
connections for oil leaks.
W507-03-03-001

W3-3-2
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-3
 UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT

11

10

12 13

W555-03-03-001
1- Bolt (4 Used) 5 - Thrust Washer 8 - O-Ring 11 - Spindle
2- Cover 6 - Body 9 - Backup Ring 12 - Plug (4 Used)
3- Retaining Ring 7 - Oil Seal (7 Used) 10 - Dust Seal 13 - Plug (3 Used)
4- O-ring

W3-3-4
 UNDERCARRIAGE / Center Joint
Disassemble Center Joint IMPORTANT: For easy removal, two pins can be
• Read PRECAUTIONS FOR DISASSEMBLING used to pry out oil seals (7). Take
AND ASSEMBLING (W1-1-1) carefully before care not to damage the seal groove
disassembling. with the pins.

1. Clamp the center joint horizontally in a vise.

2. Remove bolt (1) (4 used), to remove cover (2)

from body (6). Pin
: 13 mm

3. Remove O-ring (4), retaining ring (3) and thrust

washer (5) from body (6).
7
4. Attach the special tool (ST 1995) to body (6) with
bolts (1) (2 used).
: 13 mm
W105-03-03-015

ST 1995
6. Remove oil seals (7) (7 used) from body (6).
1
7. Remove dust seal (10), backup ring (9) and O-
ring (8) from body (6).
6

W506-03-03-002

IMPORTANT: Take care not to damage the seal

sliding surface of spindle (11), when
removing spindle (8). When laying
spindle (8) horizontally on the
ground, take extra care not to dam-
age or contaminate the spindle sur-
faces with rough materials such as
sand. Put alignment marks on body
(6) and spindle (11).
5. Screw ST 1995 to remove spindle (11) from body
(6).
: 13 ㎜

W3-3-5
 UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT

5 2

4
6

8
9
10

11

W555-03-03-002
12 13

1- Bolt (4 Used) 5 - Thrust Washer 8 - O-Ring 11 - Spindle

2- Cover 6 - Body 9 - Backup Ring 12 - Plug (4 Used)
3- Retaining Ring 7 - Oil Seal (7 Used) 10 - Dust Seal 13 - Plug (3 Used)
4- O-ring

W3-3-6
 UNDERCARRIAGE / Center Joint
Assemble Center Joint
• Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before as-
sembling.

IMPORTANT: Before installing various seals into

the seating grooves, coat the seals
with grease or hydraulic oil. After
installing O-ring (8), dust seal (10),
and oil seals (7), coat the lips of
them with grease.

1. Install O-ring (8), backup ring (9), dust seal (10)

and oil seals (7) (7 used) onto body (6).

IMPORTANT: Align the alignment marks when in-

stalling body (6). If body (6) is rap-
idly pushed downward, the seal may
be damaged. Install body (6) onto
spindle (11) while pushing and turn-
ing body (6) slowly.

2. Place spindle (11) on a work bench, then install

body (6) onto spindle (11).

3. Install body (6) until body (6) comes into contact

with spindle (11) flange while tapping the outside
of body (6) with a plastic hammer.

4. Install thrust washer (5) and O-ring (4) onto body

(6).

IMPORTANT: Install retaining ring (3) with the

chamfered side facing cover (2).
Confirm that retaining ring (3) is cor-
rectly seated.

5. Install retaining ring (3) onto spindle (11).

6. Secure cover (2) to body (6) with bolts (1) (4

used).
: 13 mm
: 10.8 N⋅m (1.1 kgf⋅m, 8.0 lbf⋅ft)

W3-3-7
 UNDERCARRIAGE / Center Joint
（Blank）

W3-3-8
 UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER

Before removing or installing the track adjuster, the

rubber crawler and front idler must be removed or
installed beforehand. Refer to the corresponding
sections for the removal and installation of the rubber
crawler and front idler
The procedures described below start after the rubber
crawler and front idler are removed.

Removal

CAUTION: Truck adjuster weight:

14 kg (30 lb)

1. After removing the front idler assembly, remove

track adjuster (1) from the track frame.

2
Installation W507-03-04-001

IMPORTANT: Make sure that the track adjuster (1)

is not hung on spring guide (3) on
track frame (2) and correctly seated
on the plate (4).

1. Insert track adjuster (1) into track frame (2) as

illustrated.

W507-03-04-001
3 3

W507-03-04-003
W507-03-04-002

W3-4-1
 UNDERCARRIAGE / Track Adjuster
DISASSEMBLE TRACK ADJUSTER
1 2
3

5
6
7

10

16

15 13

12

11
14

W1LD-03-04-001

1- Socket Bolt (3 Used) 5- Wear Ring 9- Cylinder 13 - Plug

2- Dust Seal 6- U-Ring 10 - O-Ring 14 - Washer
3- Flange 7- Retaining Ring 11 - Valve 15 - Spring
4- Piston Rod 8- Rod 12 - Nut 16 - Spacer

W3-4-2
 UNDERCARRIAGE / Track Adjuster
Disassemble Track Adjuster
• Be sure to read “Precautions for Disassembly and CAUTION: Track adjuster weight:
Assembly” thoroughly on page W1-1-1 before 14 kg (31 lb)
starting any repair work. 3. Attach the wire rope to the track adjuster. Lift the
track adjuster by crane and put the track adjuster
on cradle of special tool.
CAUTION: Special tool weight: 161 kg
(350 lb)
Track Adjuster

CAUTION: Be sure to use special tool (ST

4943) for assembly / disassembly of the track
adjuster.
The spring force is extremely large, so
disassembly and assembly work must be
carried out carefully. It is necessary to
Cradle of
inspect the special tool for any damage Special tool
thoroughly to ensure safety.
1. Place an oil jack (30 ton) between the cradle and
the base of special tool (ST 4943).

W105-03-04-009
Nut
CAUTION: Plate (ST 4140) weight: 36 kg
(79 lb)
4. Install plate (ST 4140) onto special tool (ST 4943)
so that plate (ST 4140) overlies the track adjuster.
Cradle
Remove valve (11) from rod (8).
Oil Jack
Plate
(ST 4140)

Base
W105-03-04-006
Track
Adjuster

CAUTION: Plate (ST 4140) weight: 36 kg

(79 lb) (ST 4943)
2. Loosen the nuts (4 used) to remove plate (ST
4140).
: 46 mm W105-03-04-011

5. Operate the oil jack to jack up the cradle by the

specified amount 82.1 mm (3.2 in)
Plate (ST 4140)
NOTE: 82.1 mm=(Free length: 305.1 mm)-(Set
length 223 mm)
Cradle

Oil Jack

W105-03-04-007

W105-03-04-013

W3-4-3
 UNDERCARRIAGE / Track Adjuster

15 13

12

11
14

W1LD-03-04-001

W3-4-4
 UNDERCARRIAGE / Track Adjuster
6. Tighten the nuts onto plate (ST 4140) to secure
the track adjuster. CAUTION: Plate (ST 4140) weight:
Operate the oil jack to compress the track 36 kg (79 lb)
adjuster approximately 10 mm (0.4 in) until a When removing the nut and plate (ST 4140),
clearance is observed between washer (14) and be sure to remove it after loosening the oil
nut (12). jack. Not loosening the oil jack poses a
: 46 mm danger of washer (14) and spring (15) flying
off under the reaction of the spring.
8. Lower the oil jack to release the spring force.
Loosen the nuts to remove plate (ST 4140).
Remove washer (14) from rod (8).
Nut
Plate (ST4140)
Plate
(ST 4140)

14

W105-03-04-012
15

7. Remove plug (13) from nut (12). Remove the nut

(12) from rod (8).
: 5 mm
: 46 mm W105-03-04-016

CAUTION: Spring assembly weight:

13 kg (28.5 lb)

12 8 13 9. Install eyebolt (M14, pitch 1.5) to the rod (8). Lift

and remove the spring (15) assembly from the
special tool by crane.

Eyebolt

15

W105-03-04-014

W105-03-04-017

CAUTION: Spring weight: 7 kg (15.5 lb)

10. Remove spring (15) from rod (8) after removing
the eyebolt.

W3-4-5
 UNDERCARRIAGE / Track Adjuster

1 2
3

5
6
7

10

16

W1LD-03-04-001

W3-4-6
 UNDERCARRIAGE / Track Adjuster
11. Remove spacer (16) from rod (8).

12. Remove socket bolts (1) (3 used) from cylinder

(9) to remove flange (3) and dust seal (2).
: 6 mm

13. Remove piston rod (4) from cylinder (9).

14. Remove retaining ring (7), U-ring (6) and wear

ring (5) from piston rod (4).

15. Remove rod (8) and O-ring (10) from cylinder (9).

W3-4-7
 UNDERCARRIAGE / Track Adjuster
ASSEMBLE TRACK ADJUSTER

4 5 6 7 9 10 14
1 3

12 13 8 11

W1LD-03-04-002
A 15 B 16

1- Socket Bolt (3 Used) 5- Wear Ring 9- Cylinder 13 - Plug

2- Dust Seal 6- U-Ring 10 - O-Ring 14 - Washer
3- Flange 7- Retaining Ring 11 - Valve 15 - Spring
4- Piston Rod 8- Rod 12 - Nut 16 - Spacer

W3-4-8
 UNDERCARRIAGE / Track Adjuster
Assemble Track Adjuster
CAUTION: Spring assembly weight:
13 kg (28.5 lb)
• Be sure to read “Precautions for Disassembly and 6. Install spring (15) onto cylinder (9). Install eyebolt
Assembly” thoroughly on page W1-1-1 before (M14, pitch 1.5) to the cylinder. Lift the spring
starting any repair work. assembly by crane. Then set them on special tool
(ST 4943).
1. Install O-ring (10) and rod (8) into cylinder (9). Eyebolt

9
IMPORTANT: Install U-ring (6) with the lip facing
retaining ring (7).
Apply the hydraulic oil to wear ring
(5) and the U-ring (6).
2. Install wear ring (5), U-ring (6) and retaining ring
(7) onto piston rod (4). ST 4943

IMPORTANT: Fill chamber (B) in cylinder (9) with

grease. Insert piston rod (4) into the
cylinder to completely bleed air 15
remaining in the cylinder.
3. Apply grease onto piston rod (4) assembly, and
insert it into cylinder (9).

IMPORTANT: Fill groove (A) on flange (3) with W105-03-04-017

7. Install washer (14) onto rod (8).

grease.
4. Install dust seal (2) into flange (3). Secure the
flange assembly to cylinder (9) with socket bolts
CAUTION: Plate (ST 4140) weight: 36 kg
(1) (3 used).
(79 lb)
: 6 mm
8. Lift and Install plate (ST 4140) onto the spring.
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
Tighten the nuts of the special tool to secure the
spring assembly.
5. Install spacer (16) onto rod (8). : 46 mm

Plate
(ST 4140)

Nut

ST 4943

W105-03-04-012

W3-4-9
UNDERCARRIAGE / Track Adjuster

12 13 8 11

W1LD-03-04-002
15

W3-4-10
 UNDERCARRIAGE / Track Adjuster
9. Operate the oil jack to compress spring (15) until
the specified length (223 mm) (8.8 in) is obtained. CAUTION: Track adjuster weight:
14 kg (30 lb)
12. Attach the wire rope to the track adjuster. Lift the
track adjuster by crane and remove them from the
special tool.
15

Track Adjuster
Oil Jack

Special Tool
W105-03-04-026

10. Install nut (12) and valve (11) to rod (8). Install
plug (13) to the nut. W105-03-04-009
: 46 mm
: 5 mm
: 14.5 N⋅m (1.5 kgf⋅m, 10.5 lbf⋅ft) CAUTION: Special tool (ST 4944) weight:
: 19 mm 64 kg (141 lb)
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft) IMPORTANT: If only the track adjuster is to be
transported, be sure to use special
12 8 13 tool (ST 4944) to avoid personal
injury.
: 30 mm

Track Adjuster

W105-03-04-014

CAUTION: Plate (ST 4140) weight:

36 kg (79 lb)
11. Lower the oil jack to remove the nuts and plate Special Tool
W105-03-04-028

(ST 4140). (ST 4944)

: 46 mm

Plate (ST 4140)

W105-03-04-011

W3-4-11
 UNDERCARRIAGE / Track Adjuster
(Blank)

W3-4-12
 UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER

Before removing or installing the front idler, the rubber

crawler must be removed or installed beforehand.
Refer to "REMOVE AND INSTALL RUBBER
CRAWLER".
The procedures described below start after the rubber
crawler is removed.

Removal

CAUTION: Front idler weight: 41 kg (90 lb)

The front idler may fly out due to the strong
spring force from the track adjuster spring
when removing it. Give yourself ample clear-
ance, staying clear of the front idler’s line. W507-03-05-001

1. Remove the idler assembly from the track frame. Idler Assembly
Remove the front idler and yoke assembly from Track Frame
the track frame using a crowbar.

CAUTION: When storing the front idler, lay

the front idler on wooden blocks to keep bal-
ance.

W562-03-05-001

Installation

1. To install the front idler, simply perform the re-

moval procedures in reverse. Take care on follow-
ing points:

• Apply grease to the sliding surfaces of the track

frame and bearing after cleaning them.
Sliding
Surfaces

Track
Frame

W507-03-04-003

W3-5-1
 UNDERCARRIAGE / Front Idler
DISASSEMBLE AND ASSEMBLE FRONT
IDLER

4 5

6 7
2
8
1

9 W1LD-03-05-001

1 - Axle 4 - Bushing (2 Used) 6 - Yoke (2 Used) 8 - Bolt (4 Used)

2 - Floating Seal (2 Used) 5 - O-Ring (2 Used) 7 - Plate 9 - Spring Pin (2 Used)
3 - Idler

W3-5-2
 UNDERCARRIAGE / Front Idler
Disassemble Front Idler Assemble Front Idler
• Be sure to read “Precautions for Disassembly and • Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before Assembly” thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.

1. Remove bolts (8) (4 used) to remove plate (7) 1. Install bushings (4) (2 used) into idler (3) with a
from yoke (6) (2 used). press.
: 19 mm
2. Install axle (1) into idler (3).
2. Remove spring pin (9) (2 used) from yoke (6) (2
used). 3. Install O-ring (5) (2 used) onto axle (1).
8 mm
IMPORTANT: For handling of floating seal (2), re-
IMPORTANT: For handling of floating seal (2), re- fer to the section “Floating Seal Pre-
fer to the section “Floating Seal Pre- cautions” on page W1-1-4.
cautions” on page W1-1-4. 4. Install floating seal (2) (2 used) and yoke (6) (2
3. Remove yoke (6) (2 used) and floating seals (2) used) into idler (3).
(2 used) from idler (3).
5. Tap spring pin (9) (2 used) into yoke (6) (2 used).
4. Remove O-ring (5) (2 used) from axle (1).
6. Secure plate (7) to yoke (6) (2 used) with bolts (8)
5. Remove axle (1) from idler (3). (4 used).
: 19 mm
IMPORTANT: Do not remove bushings (4) (2 used) : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
unless necessary.
6. When replacing bushing (4) (2 used), build-up
weld at 4 places in its inner diameter with welding
rod, shrink bushing (4) to pull it out.

90°

90°

W105-03-05-012

W3-5-3
 UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD

C D F

A
B

W503-03-05-001

Unit: mm (in)

Standard Allowable Limit Remedy

A 53 (2.1) −

B 92 (3.6) −

C 44 (1.7) − Build-up weld

D 300 (11.8) − and finishing

E 10 (0.4) −

F 344 (13.5) −

Axle and Bushing Unit: mm (in)

Standard Allowable Limit Remedy

Axle Outside Dia. 40 (1.6) −

Inside Dia. 40 (1.6) − Replace

Bushing
Flange Thickness 2 (0.08) −

NOTE: Lubrication Oil

Engine Oil Grade: API Class CD, SAE30
Oil Capacity: 60 cm3 (0.063 US qt)

W3-5-4
 UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
1

CAUTION: Grease pressure in the track ad-

juster is high. Do not loosen valve (1) quickly
or loosen it too much. Valve (1) may fly out or
high pressure grease in the track adjuster
may spout out. Loosen carefully, keeping
body parts and face away from valve (1).
Never loosen grease fitting (2). W105-03-07-002

1 2
IMPORTANT: Clean off gravel or mud packed
between the sprockets and tracks
before loosening valve (1).
It’s enough to turn valve (1) by only
one turn. Do not loosen it over one
turn.
Grease Outlet

W1F1-03-07-001

1. Slowly loosen track adjuster valve (1) to loosen

the track tension.
: 19 mm

IMPORTANT: Place pads between track frame (3)

and oil jack (4) when jacking up to
prevent the jack from slipping.

2. Jack up track (6) until the clearance between

track (6) and upper roller (5) is wide enough to
remove upper roller (5). Then place wooden
blocks on track frame (3) to support track (6).
W507-03-06-001

6 Wooden Blocks 5 7
3. Loosen bolt (7) and remove upper roller (5). 3
: 22 mm

W507-03-06-003

W3-6-1
 UNDERCARRIAGE / Upper and Lower Roller
Installation
1. Install upper roller (5) onto track frame (3) with
6 Wooden Blocks 5 7
bolt (7). 3
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

2. Remove wooden blocks.

4
3. Lower oil jack (4) to lower the track (6).
Remove oil jack (4).
W507-03-06-003

4. Tighten track adjuster valve (1).

: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
１ 2

CAUTION: Securely support the raised ma-

chine with wooden blocks.
5. Jack up the track at the side being adjusted and
rotate slightly in reverse direction.

6. Supply grease via grease fitting (2) to adjust the

track tension.

Track sag specifications (A):

10 to 15 mm (0.4 to 0.6 in) (Rubber Cralwer)

Roller W507-03-06-005

Rubber Cralwer
M503-05-050 90～110º

7. Jack up the one side track using the front attach-

ment and remove wooden blocks.
M570-07-001

W3-6-2
 UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL LOWER ROLLER
Removal

CAUTION: Support the raised track securely

using wooden blocks.

1. Raise the one side track off the ground using the
90～110º
front attachment. Then place a block under track
frame to support the machine.

M570-07-001

CAUTION: Grease pressure in the track ad-

juster is high. Do not loosen valve (1) quickly 1
or loosen it too much. Valve (1) may fly out or
high pressure grease in the track adjuster
may spout. Loosen carefully, keeping body
parts and face well away from valve (1).
Never loosen grease fitting (2).

W105-03-07-002
IMPORTANT: Clean off gravel or mud packed
between the sprockets and tracks
before loosening valve (1). 1 2
It’s enough to turn valve (1) by only
one turn. Do not loosen it over one
turn.
2. Loosen track adjuster valve (1) slowly to let
grease flow out until the clearance between the
track frame and crawler is wide enough to remove
lower roller (3). Grease Outlet
: 19 mm
W1F1-03-07-001
3. Loosen bolt (4) and remove lower roller (3).
: 27 mm
1

3
4

W507-03-06-005

W3-6-3
 UNDERCARRIAGE / Upper and Lower Roller
Installation
1 2
CAUTION: Securely support the raised ma-
chine with wooden blocks.
1. Install lower roller (3) to the underside of the track 3
frame, aligning the bolt holes. 4

2. Apply LOCTITE #262 to bolt (4) threads and

tighten to specifications.

: 27 mm
: 450 N⋅m (46 kgf⋅m, 330 lbf⋅ft)

W507-03-06-005

3. Tighten track adjuster valve (1). 1

: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

4. Rotate slightly in reverse direction the track at the

side being adjusted.

5. Supply grease via grease fitting (2) to adjust the

track tension.
W105-03-07-002

Track sag specifications (A):

10 to 15 mm (0.4 to 0.6 in ) (Rubber Cralwer) 1 2

Roller

A Grease Outlet

W1F1-03-07-001

Rubber Crawler
M503-05-050

6. Jack up the one side track using the front attach-

ment and remove wooden blocks.

90～110º

M570-07-001

W3-6-4
 UNDERCARRIAGE / Upper and Lower Roller
(Blank)

W3-6-5
 UNDERCARRIAGE / Upper and Lower Roller
DISASSENBLE AND ASEMBLE LOWER
ROLLER

1 2 3 4 5 6 7

10

W577-03-06-001

1 - Floating Seal 4 - Axle 7 - O-Ring 9 - Stopper Ring

2 - Roller 5 - Floating Seal 8 - Plug 10 - Collar
3 - Busing (2 Used) 6 - Collar

W3-6-6
 UNDERCARRIAGE / Upper and Lower Roller
Disassemble Lower Roller Assemble Lower Roller

• Be sure to read “Precautions for Disassembly and • Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before Assembly” thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.

1. Remove plug (8) from collar (6) to drain engine oil IMPORTANT: For handling of floating seal (1) and
from the roller. (5), refer to the section “Precautions
: 4 mm for Floating Seal Handling “ on page
W1-1-4.
IMPORTANT: Axle (4) and collar (10) unable to be 1. Install floating seal (1) to roller (2) and collar (10).
disassembled. In case the axle must Press axle (4) with collar (10) into roller (2).
be replaced, replace axle (4) assem-
bly. 2. Install floating seal (5) to roller (2) and collar (6).
2. Remove stopper ring (9) from collar (6). Push out NOTE: When disassembling, O-ring (7) may be
axle (4) assembly from the collar (6) side in roller damaged. Replace it with the new one.
(2) with a press.
3. Install O-ring (7) to axle (4).
IMPORTANT: For handling of floating seal (1) and Aligning the grooves on axle (4) and collar (6) for
(5), refer to the section “Precautions stopper ring (9), install collar (6) and stopper ring
for Floating Seal Handling “ on page (9) onto axle (4).
W1-1-4.
IMPORTANT: Apply LOCTITE #503 onto plug (8).
3. Remove collar (6) from roller (2). Remove floating 4. Refill engine oil (SAE #30, API class CD) (45 cm3
seal (1) and (5) from both sides of roller (2). (0.047 US qt)) through the plug hole on collar (6).
Install plug (8) to the collar.
4. Remove O-ring (7) from axle (4). : 4 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
IMPORTANT: Do not remove bushings (3) (2 used)
from roller (2). In case the bushing
must be replaced, replace the roller
(2) assembly.

W3-6-7
 UNDERCARRIAGE / Upper and Lower Roller
MAINTENANCE STANDARDS

Upper Roller

W566-03-06-001

Unit: mm

Standard Allowable Limit Remedy

A 110 (4.33) -
Replace
B 80 (3.15) -

IMPORTANT: Do not disassemble the upper roller.

Replace it as an assembly.
Lubrication oil: Engine oil API CD Class SAE30
Quantity: 60 mL (0.016 US gal)

W3-6-8
 UNDERCARRIAGE / Upper and Lower Roller

Lower Roller

C D E

B
W577-03-06-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 53 (2.09) -
B 142 (5.59) -
Build-up weld
C 39 (1.54) - and finishing or
D 95 (3.74) - replace

E 122 (4.80) -

Unit: mm (in)
Axle and Bushing

Standard Allowable Limit Remedy

Outside
Axle 35 (1.39) -
Dia
Inside
35 (1.39) - Replace
Dia
Bushing
Flange
2 (0.08) -
Thickness

Lubrication Oil
Engine Oil Grade: API Class CD, SAE30
Oil Capacity: 45 cm3 (0.048 US qt)

W3-6-9
 UNDERCARRIAGE / Upper and Lower Roller
(Blank)

W3-6-10
 UNDERCARRIAGE / Track
REMOVE AND INSTALL RUBBER CRAWLER
Removal
1 2

CAUTION: Grease pressure in the track

adjuster is high. Do not loosen valve (1)
quickly or loosen it too much. Valve (1) may
fly out or high pressure grease in the track
adjuster may spout. Loosen carefully,
keeping body parts and face well away from
Grease Outlet
valve (1). Never loosen grease fitting (2).
If the rod and/or the threads are damaged,
W1F1-03-07-001
metal fragments may fly off when track
adjuster is removed. Take necessary
precautions to prevent any personal injury
from occurring.
1. Operate the boom and arm so shat the angle
between them is 90° to 110°, Lower the boom
with the bucket rolled-in to jack up the machine.
Then place a block under track frame to support
the machine. 90～110º

M570-07-001

IMPORTANT: Clean off gravel or mud packed

between the sprockets and tracks
before loosening valve (1).
It’s enough to turn valve (1) by only
one turn. Do not loosen it over one
turn.

1
2. Slowly loosen track adjuster valve (1) to allow
grease to escape.
: 19 mm

W190-03-06-001

Rotate Direction

3. Insert steel pipes into the gaps between the

rubber crawler and track frame.
Then, rotate the sprocket in reverse direction.
After the rubber crawler is raised off the front idler
with the steel pipes, slide the rubber track away Steel pipe
M503-07-062
from the track frame and remove it.

W3-7-1
 UNDERCARRIAGE / Track
Installation

CAUTION: Support the raised track securely

using wooden blocks.

1. Using the front attachment, raise the one side

track of the machine off the ground, and place
wooden blocks under the track frame to securely
90～110º
support the machine.

2. Reinstall the rubber crawler on the sprocket and

hang the other end of the rubber track over the
front idler.
M570-07-001
Rotate the sprocket in the reverse direction to
sufficiently remesh the rubber crawler back onto
the sprocket.
Rotate Direction
IMPORTANT: Check that the rubber crawler is
securely engaged onto both the
sprocket and front idler.

3. After inserting a steel pipe into the gap between

the rubber crawler and track frame, rotate the Steel pipe
sprocket again. Then, completely install the M503-07-063

１ 2
rubber track onto the front idler.

4. Tighten the track adjuster valve (1). Add grease

into the adjuster cylinder via the grease fitting to
adjust track sag.

Track Sag Specification (A)

Rubber Crawler: 10 to 15 mm (0.4 to 0.6 in)

NOTE: With the joint section of the rubber track W507-03-06-005

placed just under the lower roller, measure
track sag at the lower center roller as
illustrated.
Roller

Joint

Track (Rubber Crawler)

M503-05-050

Joint M102-07-070

M102-07-075

W3-7-2
 UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Outside of Rubber Crawler
1. If there is a crack on lug base (1) with depth of 6
mm (0.2 in) or more, repair crawler. 1
4
If there is a crack between lugs (2) with depth of 6
mm (0.2 in) or more, repair crawler. 5
2
If there is a crack on rugs (3) or between lugs (2)
that reaches to steel code (5) or steel core (4)
with length of 30 mm (1.2 in) or more,
immediately repair crawler. 3

2. Inside of Rubber Crawler (Roller Side)

If there is a crack that reaches to steel code (5) or
steel core (4), immediately repair crawler.
W190-03-07-001

5 W190-03-07-002

Lower Roller

Lug Wear
1. If the lug height (A) is less than 5 mm, replace the Rubber Track
rubber crawler as an assembly.

Lug W190-03-07-003

2. If any portion of steel code (5) appeared on

crawler, replace worn rubber crawler as an
assembly.

5
W190-03-07-004

W3-7-3
 UNDERCARRIAGE / Track
Rubber Crawler and Steel Cord Cutting
1. When either of the two rows of the steel cord (5)
has cut, replace rubber crawler as an assembly.

5
W190-03-07-005

Steel Core Separation

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

W190-03-07-006

W3-7-4
 MEMO

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 MEMO

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 SECTION 4
FRONT ATTACHMENT

CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment...... W4-1-1
Maintenance Standards........................... W4-1-6

Group 2 Cylinder
Remove and Install Cylinders .................. W4-2-1
Disassemble Boom Cylinder.................... W4-2-8
Assemble Boom Cylinder ...................... W4-2-12
Disassemble Arm Cylinder .................... W4-2-16
Assemble Arm Cylinder ......................... W4-2-20
Disassemble Bucket Cylinder ................ W4-2-26
Assemble Bucket Cylinder..................... W4-2-30
Disassemble Boom Swing Cylinder
and Blade Cylinder .............................. W4-2-34
Assemble Boom Swing Cylinder
and Blade Cylinder .............................. W4-2-38
Maintenance Standards......................... W4-2-44

1LDW-4-1
（Blank）

1LDW-4-2
 FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT

Removal
IMPORTANT: Bleed air from the hydraulic oil tank
before any work. (Refer to W1-3-1)
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinder and lower the
bucket onto the ground. Lay wooden block under
the arm tip.

2. Loosen bolt (5) to remove cover (3). W1LD-04-01-003

: 19 mm

CAUTION: Boom cylinder weight:

1
51 kg (112 lb) (ZX40U)
55 kg (121 lb) (ZX50U)
2

IMPORTANT: As for the handling of the nylon

slings, refer to “Precautions for the
Handling of Nylon Slings” on page
W1-1-5.
3. Connect boom cylinder (2) to a crane with sling
belts. Remove bolt (1) and pin (4) while slightly
lifting the boom cylinder.
: 22 mm
5 4 3
W1LD-04-01-002

4. Start the engine, slightly operate the boom lever

to retract boom cylinder (2).

5. Place the boom cylinder (2) on a bench. Use a

wire to secure the boom cylinder rod as illus-
trated.
Stop the engine.
2
NOTE: Bench Height: 700 mm (28 in) or more.

6. Remove boom cylinder.

Refer to “Remove Boom Cylinder” (W4-2-5). Wire

W554-02-03-007

W4-1-1
 FRONT ATTACHMENT / Front Attachment
7. Loosen bolt (7) (2 used) to remove cover (6).
: 13 mm

8. Disconnect all hoses. Cap each disconnected

hose end. 6
: 22 mm, 27 mm

W1LD-04-01-001
9. Loosen nut (10) (2 used) for stopper bolt (8) on
boom foot pin (9), then remove stopper bolt (8).
: 22 mm

CAUTION: Front attachment weight:

490 kg (1080 lb) (ZX40U)
W527-04-01-004
513 kg (1130 lb) (ZX50U) 10 9
10. Attach a wire rope around the boom at the boom
foot side as in illustration. Take up slack of the
wire rope.

W1LD-04-01-004

W4-1-2
 FRONT ATTACHMENT / Front Attachment
11. Remove boom foot pin (9).

9 W527-04-01-004

12. After hoisting the front attachment, move the ma-

chine backward. Place the front attachment on
wooden blocks.

W1LD-04-01-005

W4-1-3
 FRONT ATTACHMENT / Front Attachment
Installation

CAUTION: Front attachment weight:

490 kg (1080 lb) (ZX40U)
513 kg (1130 lb) (ZX50U)
1. Attach a wire rope around the boom.
Lift the boom to the boom foot pin pinhole position
by crane. Move the machine forward.

W1LD-04-01-005

2. Drive in boom foot pin (9) while aligning the boom

foot with the pin holes on the frame bracket.

IMPORTANT: Apply LOCKTITE #262 to nuts (10 (2

used), and adjust the clearance be-
tween the frame and nut within 2 to
3 mm, when tightening the nuts. 8
3. Install stopper bolt (8) into boom foot pin (9).
Tighten stopper bolt (8) with nut (10) (2 used).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbt⋅ft)

4. Uncap the ends of hoses routed on the machine. 10 9 W527-04-01-004

Connect all hoses.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbt⋅ft)
: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47, lbt⋅ft)

5. Install cover (6) with bolts (7) (2 used).

6
: 13 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbt⋅ft)

W1LD-04-01-001

W4-1-4
 FRONT ATTACHMENT / Front Attachment

CAUTION: Boom cylinder weight:

51 kg (112 lb) (ZX40U)
55 kg (121 lb) (ZX50U)
6. Install boom cylinder.
Refer to “Install Boom Cylinder” (W4-2-6).

IMPORTANT: After filling hydraulic oil to specified

level, start the engine, check the
connections for any oil leakage.

IMPORTANT: After all work is completed, run each

cylinder several times to stroke end
to bleed air from the circuit.

W4-1-5
 FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARDS

Pin Bushing

M N

H A
C

B
E D P
I K Q
J
O
G
H
W571-04-01-004
W533-04-01-002

Unit: mm (in)

Key Letter Part Name Standard Allowable Limit Remedy

Pin 50 (1.97) 49.0 (1.93)
A
Bushing (Boom) 50 (1.97) 51.5 (2.03)
Pin 50 (1.97) 49.0 (1.93)
B
Bushing (Boom Cylinder) 50 (1.97) 51.5 (2.03)
Pin 50 (1.97) 49.0 (1.93)
C
Bushing (Boom Cylinder) 50 (1.97) 51.5 (2.03)
Pin 50 (1.97) 49.0 (1.93)
D Replace
Bushing (Arm) 50 (1.97) 51.5 (2.03)
Pin 45 (1.77) 44.0 (1.73)
E
Bushing (Arm Cylinder) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
F
Bushing (Arm Cylinder) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
G
Bushing (Bucket Cylinder) 45 (1.77) 46.5 (1.83)

W4-1-6
 FRONT ATTACHMENT / Front Attachment

Unit: mm (in)

Key Letter Part Name Standard Allowable Limit Remedy

Pin 45 (1.77) 44.0 (1.73)
Bushing (Bucket Cylinder) 45 (1.77) 46.5 (1.83)
H
Bushing (Link A) 45 (1.77) 46.5 (1.83)
Bushing (Link B) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
I Bushing (Arm) 45 (1.77) 46.5 (1.83)
Link B 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
J
Bushing (Link A) 45 (1.77) 46.5 (1.83)
Pin 45 (1.77) 44.0 (1.73)
K
Bushing (Arm) 45 (1.77) 46.5 (1.83)
Pin 90 (3.54) 89.0 (3.50)
L
Bushing (Main Frame) 90 (3.54) 91.5 (3.60) Replace
Pin 50 (1.97) 49.0 (1.93)
M Bushing
50 (1.97) 51.5 (2.03)
(Boom Swing Cylinder)
Pin 50 (1.97) 49.0 (1.93)
N Bushing
50 (1.97) 51.5 (2.03)
(Boom Swing Cylinder)
Pin 45 (1.77) 44.0 (1.73)
O
Bushing (Blade) 45 (1.77) 46.5 (1.83)
Pin 55 (2.17) 54.0 (2.13)
P
Bushing (Blade Cylinder) 55 (2.17) 56.5 (2.22)
Pin 55 (2.17) 54.0 (2.13)
Q
Bushing (Blade Cylinder) 55 (2.17) 56.5 (2.22)

W4-1-7
 FRONT ATTACHMENT / Front Attachment
Side Cutter

D
A

W505-04-01-001

Unit: mm (in)

Standard Allowable Limit Remedy

A 127 (5.00) 85 (3.35)
B 163 (6.42) -
Replace
C 223 (8.78) -
D 130 (5.12) -

Point

B C

W554-04-01-003
Unit: mm (in)

Standard Allowable Limit Remedy

A 128 (5.04) 65 (2.56)
B 56 (2.21) -
Replace
C 62 (2.44) -
D 51 (2.01) -

W4-1-8
 FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER

Remove Bucket Cylinder

1
IMPORTANT: Bleed air from the hydraulic oil tank
before any work. (Refer to W1-3-1)
1. Lay wooden blocks (3) under the arm (2) tip and
in the clearance between the arm (2) top surface 3
and bucket cylinder (1).
2
3

IMPORTANT: Secure the link using a wire to W554-04-02-006

prevent the link from falling before

4 5
removing pin (7).
2. Remove ring (4) and stopper pin (6) from the link,
then remove pin (7).

3. Secure cylinder rod (5) using a wire to prevent 6

rod (5) from extending.
Link

7
W527-04-02-002
Link

CAUTION: Bucket cylinder weight:

28 kg (62 lb) (ZX40U)
33 kg (73 lb) (ZX50U) 1
4. Attach bucket cylinder (1) to crane using sling belt
and hold it.

5. Remove bolt (9). Remove pin (8) to remove

cylinder (1).
: 22 mm
W571-04-02-002

6. Disconnect hoses (10) (2 used) from bucket

cylinder (1) at the cylinder bottom. Close all 9
1 8
openings with cap.
: 22 mm

7. Lift and remove bucket cylinder (1) by crane.

10
W571-04-02-003

W4-2-1
 FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder

CAUTION: Bucket cylinder weight: 9

28 kg (62 lb) (ZX40U) 1 8
33 kg (73 lb) (ZX50U)
1. Lift bucket cylinder (1) by crane. Connect hoses
(10) (2 used) to bucket cylinder (1).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

2. Align the pin holes on cylinder (1) tube and arm.

Insert pin (8), and secure it with bolt (9).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 10
W571-04-02-003
3. Start the engine, and extend bucket cylinder rod
(5). Align the rod hole of bucket cylinder rod (5)
7
with the link hole, then insert pin (7).

5
4. Insert stopper pin (6) into link and pin (7) to install
ring (4). W507-04-02-004

4
IMPORTANT: After installation, bleed air from the
hydraulic system by moving the
bucket cylinder full stroke several
times.

Link

W527-04-02-002
Link

W4-2-2
 FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder
4 5 1
1. Insert a wooden block (3) between arm cylinder
(1) and boom (2).

2. Remove bolt (4), then remove pin (5).

: 22 mm

3. Secure the cylinder rod with a wire to prevent the

rod from extending.

4. Disconnect cylinder hoses (6) (2 used) from arm 3 2

W571-04-02-004
cylinder (1), and close all openings with cap.
: 27 mm
1

CAUTION: Arm cylinder weight:

41 kg (90 lb) (ZX40U)
42 kg (93 lb) (ZX50U)
5. Attach a sling belt onto arm cylinder (1), and hold
it by crane. 6
W527-04-02-006

W571-04-02-006

6. Remove bolt (7), then remove pin (8).

: 22 mm 1

7. Lift and remove arm cylinder (1) by crane.

8 7 W527-04-02-008

W4-2-3
 FRONT ATTACHMENT / Cylinder
Install Arm Cylinder

CAUTION: Arm cylinder weight: 1

41 kg (90 lb) (ZX40U)
42 kg (93 lb) (ZX50U)
1. Lift arm cylinder (1) by crane. Align the pin holes
on the cylinder tube side and arm.

2. Insert pin (8) and secure it with bolt (7).

: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 7
8

3. Connect hoses (6) (2 used) to arm cylinder (1). W527-04-02-008

: 27 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft) 1

6
W527-04-02-006

4. Start the engine and extend arm cylinder (1) so

that the rod hole on arm cylinder (1) is aligned 1
with the hole on the arm. 4 5

5. Insert pin (5) and secure it with bolt (4).

: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

IMPORTANT: After installation, bleed air from the

hydraulic system by moving the
bucket cylinder full stroke several
times.

3 2
W571-04-02-004

W4-2-4
 FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder

1. Loosen bolt (5) to remove cover (3). 1

: 19 mm
2

2. Attach a sling belt to boom cylinder (2). While

holding boom cylinder (2) by crane, remove bolt
(1) and pin (4).
: 22 mm

CAUTION: Boom cylinder weight: 5 4

3
51 kg (112 lb) (ZX40U) W1LD-04-01-002
55 kg (121 lb) (ZX50U)
3. Place a support under the end of boom cylinder
(2) tube. Operate the boom control lever to fully
retract the rod. Thread a piece of wire through the
rod hole, and tie it to the boom cylinder (2) tube to
2
prevent the cylinder rod from extending.

Wire

W554-02-03-007
4. Disconnect hose (6) (2 used) from boom cylinder
(2). Close all openings with cap.
: 27 mm 6

5. Loosen nut (8) (2 used), and remove bolt (7). W1LD-04-02-001

Pull out pin (9). 2

: 22 mm

6. Lift and remove boom cylinder (2) by crane.

7
9
8 W1LD-04-02-002

W4-2-5
 FRONT ATTACHMENT / Cylinder
Install Boom Cylinder

CAUTION: Boom cylinder weight:

51 kg (112 lb) (ZX40U)
55 kg (121 lb) (ZX50U)
1. Lift boom cylinder (2) by crane. Align the pin 2
holes on the cylinder tube side and swing post.

IMPORTANT: Apply LOCKTITE #262 to nuts (10) (2

used), and adjust the clearance
between the frame and nut within 2
to 3 mm, when tightening the nuts.
2. Insert pin (9) and secure it with bolt (7) and nut (8)
7
(2 used).
9
: 22 mm 8 W1LD-04-02-002
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
6

3. Connect hoses (6) (2 used) to boom cylinder (2).

: 27 mm 2
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

W1LD-04-02-001

4. Lift boom cylinder (2) by crane. Start engine and

extend boom cylinder (2) until mounting holes are 1
aligned.
2
5. Insert pin (4) and secure it with bolt (1).
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

6. Install cover (3) onto boom cylinder with bolt (5).

: 19 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

IMPORTANT: After installation, bleed air from the 5 4

3
hydraulic system by moving the
boom cylinder full stroke several W1LD-04-01-002

times.

W4-2-6
 FRONT ATTACHMENT / Cylinder
(Blank)

W4-2-7
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE BOOM CYLINDER

26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2

27 Clevis Part

W1LD-04-02-003
1- Piston Rod 8- Backup Ring 15 - Cushion Ring 22 - Steel Ball
2- Wiper Ring 9- U-Ring 16 - Spacer 23 - Set Screw
3- Cylinder Head 10 - Connector 17 - Stopper 24 - Seal Ring
4- O-Ring 11 - Stopper 18 - Cushion Bearing 25 - O-Ring
5- Backup Ring 12 - Retainer 19 - Shim 26 - Slide Ring
6- O-Ring 13 - Backup Ring 20 - Slide Ring 27 - Cylinder Tube
7- Bushing 14 - O-Ring 21 - Piston

W4-2-8
 FRONT ATTACHMENT / Cylinder
Disassemble Boom Cylinder 3. Loosen cylinder head (3) with a hook wrench and
pull piston rod (1) (with protective cover on it) out
• Read PRECAUTIONS FOR DISASSEMBLING of cylinder tube (27).
AND ASSEMBLING (W1-1-1) carefully before Cylinder head (3) diameter: 105 mm (4.13 in)
disassembling.
• Start the following procedures after disconnecting
Hook Wrench
the lines.

CAUTION: Boom cylinder weight:

51 kg (112 lb) (ZX40U)
55 kg (121 lb) (ZX50U) 27

IMPORTANT: When draining off hydraulic oil from

the cylinder, piston rod (1) shall be
moved slowly in order to prevent the 3
oil from splashing.
1. Clamp the pin mounting part (clevis part) of
cylinder tube (27) and hold it horizontally in a vise Protective Cover
1
to drain hydraulic oil from the cylinder. W506-04-02-004

IMPORTANT: As set screw (23) head is

IMPORTANT: Be careful not to damage cylinder
mushroomed after being installed,
tube (27) when locking or unlocking
cut the mushroomed part with a
cylinder head.
hand drill before loosening set
2. Pull out piston rod (1) approximately 200 mm (7.9
screw (23).
in). Place a protective cover onto the piston rod,
4. Secure piston rod (1) horizontally. Remove set
extend the detent.
screw (23) and steel ball (22) from piston (21).
: 4 mm

Detent 5. Remove piston (21), shim (19) and cushion

bearing (18) from piston rod (1).
: 65 mm

6. Wrap piston rod (1) screw thread with protective

tape to protect wiper ring (2) of cylinder head (3)
and then remove cylinder head (3) from piston
rod (1).

1 3
IMPORTANT: Do not reuse slide rings (20) and (26).
W506-04-02-003
When disassembling boom cylinder,
replace them with new ones.
7. Clamp piston (21) and hold it horizontally in a vice
to remove slide ring (20) and (26) from piston
(21).

W4-2-9
 FRONT ATTACHMENT / Cylinder

25
24

21

17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2

W1LD-04-02-003

W4-2-10
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (21 IMPORTANT: Do not reuse bushing (7).
when removing seals. Replace it with new one when
8. Insert a screwdriver into the clearance between disassembling the cylinder.
piston (21) and seal ring (24). Raise seal ring (24) 14. Remove bushing (7) from the inside of cylinder
with screwdriver. Cut off seal ring (24) with cutting head (3) with a special tool.
pliers to remove seal ring (24) from piston (21). NOTE: As bushing (7) is installed into cylinder
Remove O-ring (25) in the same procedure. head (3) with a press, it can not be
removed with a hammer. After cutting off
the inner surface of bushing (7) with a lathe,
scrape off thinned bushing (7) from
21 cylinder head (3) with a special tool
24, 25 (copper spatula).

W506-04-02-007

9. Remove stopper (11), connector (10) and retainer

(12) from cylinder head (3).

10. Remove backup ring (13) and O-ring (14) from

the outside of retainer (12).

11. Remove stopper (17), spacer (16) and cushion

bearing (15) from the inside of retainer (12).

12. Remove wiper ring (2), U-ring (9) and backup ring
(8) from the inside of cylinder head (3).

13. Remove O-ring (4), backup ring (5) and O-ring (6)
from the outside of cylinder head (3).

W4-2-11
 FRONT ATTACHMENT / Cylinder
ASSEMBLE BOOM CYLINDER

3 4 7 5 6 13 14 27 18 19 21 20 26 23 22

W571-04-02-009
2 8 9 10 11 12 15 16 17 1 25 24

1- Piston Rod 8- Backup Ring 15 - Cushion Ring 22 - Steel Ball

2- Wiper Ring 9- U-Ring 16 - Spacer 23 - Set Screw
3- Cylinder Head 10 - Connector 17 - Stopper 24 - Seal Ring
4- O-Ring 11 - Stopper 18 - Cushion Bearing 25 - O-Ring
5- Backup Ring 12 - Retainer 19 - Shim 26 - Slide Ring
6- O-Ring 13 - Backup Ring 20 - Slide Ring 27 - Cylinder Tube
7- Bushing 14 - O-Ring 21 - Piston

W4-2-12
 FRONT ATTACHMENT / Cylinder
Assemble Boom Cylinder IMPORTANT: Take care of the mounting direction
• Read PRECAUTIONS FOR DISASSEMBLING of U-ring (9).
AND ASSEMBLING (W1-1-1) carefully before 2. Install backup ring (8) and U-ring (9) to cylinder
assembling. head (3).
3

CAUTION: Boom cylinder weight:

51 kg (112 lb) (ZX40U) 9
55 kg (121 lb) (ZX50U)
IMPORTANT: Apply hydraulic oil to the inner side
of cylinder head (3).
Press bushing (7) until the end of
bushing (7) is flush with the end
surface of cylinder head (3). If not
flushing, backup ring (8) will be
damaged when installing backup
ring (8). W1LD-04-02-004

3. Install wiper ring (2) to cylinder head (3) with

special tool (ST 8048).
7
3

ST 8048
Flush the
surface
3

W577-04-02-007

2
W506-04-02-012
1. Press bushing (7) into cylinder head (3) with 4. Install O-ring (4), backup ring (5) and O-ring (6) to
special tool (ST 7275). the outside of cylinder head (3).

5. Install cushion ring (15), spacer (16) and stopper

(17) to the inside of retainer (12).
ST 7275 Install O-ring (14) and backup ring (13) to the
outside of retainer (12).
7
3 6. Install retainer (12) assembly, connector (10) and
stopper (11) to cylinder head (3).

W506-04-02-010

W4-2-13
 FRONT ATTACHMENT / Cylinder

3 27 18 19 21 20 26 23 22

W571-04-02-009
1 25 24

W4-2-14
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Make sure that o-ring (25) is not IMPORTANT: When the work of installing set
twisted after installing it. screw (23) is finished, crimp it at two
7. Install o-ring (25) to piston (21), and then install places with a punch in order to
seal ring (24) with special tool (ST 2594, ST2335) prevent it from loosening.
and (ST 2590, ST 2334). 12. Install steel ball (22) into piston (21) and then
install set screw (23) on it.
ST 2594(ZX40U)
ST 2335(ZX50U) : 4 mm
: 16.5 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft)
24
ST 2590(ZX40U) IMPORTANT: Take care not to let slide rings (20)
ST 2334(ZX50U) and (26) drop from piston (21) when
25 inserting the piston rod (1) assembly.
In addition, care should be taken not
to damage the piston rod assembly
21
and insert the piston rod assembly
straightly. Apply the hydraulic oil to
the packing parts.
W566-04-02-010 13. Lay cylinder tube (27) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
IMPORTANT: Adjust seal ring (24). If not adjusting, tube.
piston (21) can not be installed to
cylinder tube (27). IMPORTANT: Apply the hydraulic oil to the
8. Adjust seal ring (24) with special tool (ST 2598, packing parts.
ST 2336). 14. Tighten cylinder head (3) to cylinder tube (27)
with a hook wrench. Bend the detent to prevent it
from loosening.
Cylinder head (3) diameter: 105 mm
: 360 N⋅m (37 kgf⋅m, 265 lbf⋅ft)
24
Hook Wrench

ST 2598(ZX40U)
ST 2336(ZX50U)

W566-04-02-011

IMPORTANT: When installing slide ring (20) and

(26), do not align their split portion.
27
9. Install slide rings (20) and (26) to piston (21).
W506-04-02-019

10.Wrap the piston rod (1) screw thread with

protective tape and then install the cylinder head
(3) assembly to the piston rod while rotating the
former one.

IMPORTANT: Take care not to install cushion

bearing (18) in wrong direction.
11. Install cushion bearing (18), shim (19) and the
piston (21) assembly to piston rod (1).
: 65 mm
: 1740 N⋅m (175 kgf⋅m, 1280 lbf⋅ft)

W4-2-15
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE ARM CYLINDER

1 30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2

Clevis Part

31

W1LD-04-02-006
1- Piston Rod 9- U-Ring 17 - Stopper 25 - O-Ring
2- Wiper Ring 10 - Connector 18 - Cushion Bearing 26 - Slide Ring
3- Cylinder Head 11 - Stopper 19 - Backup Ring 27 - Cushion Seal
4- O-Ring 12 - Retainer 20 - Slide Ring 28 - Retaining Ring
5- Backup Ring 13 - Backup Ring 21 - Piston 29 - Cushion Bearing
6- O-Ring 14 - O-Ring 22 - Steel Ball 30 - Stopper
7- Bushing 15 - Cushion Ring 23 - Set Screw 31 - Cylinder Tube
8- Backup Ring 16 - Spacer 24 - Seal Ring

W4-2-16
 FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
• Read PRECAUTIONS FOR DISASEMBLING IMPORTANT: Set screw (23) was crimped with a
AND ASEMBLING (W1-1-1) carefully before punch in two places after it was
disassembling. tightened. Before loosening set
• Start the following procedures after disconnecting screw, cut away the crimped
the lines. portions.
4. Secure piston rod (1) horizontally and remove set
screw (23) and steel ball (22) from piston (21).
CAUTION: Arm cylinder weight: : 4 mm
41 kg (90 lb) (ZX40U)
42 kg (93 lb) (ZX50U) 5. Remove piston (21), backup ring (19) and cushin
IMPORTANT: When draining off hydraulic oil from bearing (18) from piston rod (1).
the cylinder, piston rod (1) shall be : 60 mm
moved slowly in order to prevent the
oil from splashing. 6. Remove retaining ring (28) from piston rod (1).
1. Clamp the cylinder tube (31) pin at its mounting
portion (clevis part) in a vise and secure it
horizontally to drain off hydraulic oil from the 7. Slide cushion bearing (29) toward piston rod (1)
cylinder. screw thread to remove stoppers (30).

IMPORTANT: The detent is provided on cylinder 8. Remove cushion bearing (29) and cushion seal
tube (29) to form an integral part. (27) from piston rod (1).
Take care not to damage the cylinder
tube and cylinder head (30) when 9. Wrap piston rod (1) screw thread with protective
bending and extending the detent. tape to protect wiper ring (2) of cylinder head (3)
2. Pull piston rod (1) approx. 200 mm (7.9 in) out to and then remove cylinder head (3) from piston
install a protective cover on the piston rod and rod (1).
then extend the detent at cylinder head (3).
IMPORTANT: Do not reuse slide rings (20) and (26).
Detent
When disassembling boom cylinder,
replace them with new ones.
10. Clamp piston (21) and hold it horizontally in a vice
to remove slide ring (20) and (26) from piston
(21).

1 3
W506-04-02-003

3. Loosen cylinder head (3) with a hook wrench and

pull piston rod (1) (with protective cover on it) out
of cylinder tube (31).
Arm cylinder head diameter: 95 mm (3.7 in)
Hook Wrench

31

1
W506-04-02-004

W4-2-17
 FRONT ATTACHMENT / Cylinder

25
24

21

17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2

W1LD-04-02-006

W4-2-18
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (21) IMPORTANT: Do not reuse bushing (7).
when removing seals. Replace it with new one when
11. Insert a screwdriver into the clearance between disassembling the cylinder.
piston (21) and seal ring (24). Raise seal ring (24) 17. Remove bushing (7) from the inside of cylinder
with screwdriver. Cut off seal ring (24) with cutting head (3) with a special tool.
pliers to remove seal ring (24) from piston (21). NOTE: As bushing (7) is installed into cylinder
Remove o-ring (25) in the same procedure. head (3) with a press, it can not be
removed with a hammer. After cutting off
the inner surface of bushing (7) with a lathe,
scrape off thinned bushing (7) from
21 cylinder head (3) with a special tool
24、25 (copper spatula).

W506-04-02-007

12. Remove stopper (11), connector (10) and retainer

(12) from cylinder head (3).

13. Remove backup ring (13) and O-ring (14) from

the outside of retainer (12).

14. Remove stopper (17), spacer (16) and cushion

bearing (15) from the inside of retainer (12).

15. Remove wiper ring (2), U-ring (9) and backup ring
(8) from the inside of cylinder head (3).

16. Remove O-ring (4), backup ring (5) and O-ring (6)
from the outside of cylinder head (3).

W4-2-19
 FRONT ATTACHMENT / Cylinder
ASSEMBLE ARM CYLINDER

3 4 5 6 15 16 17 31 18 19 20 26 23 22

28 27

W1LD-04-02-007
2 7 8 9 10 11 12 13 14 1 21 25 24 29 30

1- Piston Rod 9- U-Ring 17 - Stopper 25 - O-Ring

2- Wiper Ring 10 - Connector 18 - Cushion Bearing 26 - Slide Ring
3- Cylinder Head 11 - Stopper 19 - Backup Ring 27 - Cushion Seal
4- O-Ring 12 - Retainer 20 - Slide Ring 28 - Retaining Ring
5- Backup Ring 13 - Backup Ring 21 - Piston 29 - Cushion Bearing
6- O-Ring 14 - O-Ring 22 - Steel Ball 30 - Stopper
7- Bushing 15 - Cushion Ring 23 - Set Screw 31 - Cylinder Tube
8- Backup Ring 16 - Spacer 24 - Seal Ring

W4-2-20
 FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder IMPORTANT: Take care of the mounting direction
• Read PRECAUTIONS FOR DISASSEMBLING of U-ring (9).
AND ASSEMBLING (W1-1-1) carefully before 2. Install backup ring (8) and U-ring (9) to cylinder
assembling. head (3).

3
CAUTION: Arm cylinder weight:
41 kg (90 lb) (ZX40U) 9
42 kg (93 lb) (ZX50U)
IMPORTANT: Apply hydraulic oil to the inner side
of cylinder head (3).
Press bushing (7) until the end of
bushing (7) is flush with the end
surface of cylinder head (3).
If not flushing, backup ring (8) will
be damaged when installing backup
ring (8). W1LD-04-02-004

3. Install wiper ring (2) to cylinder head (3) with

special tool (ST 8047).
7
3

ST 8047
Flush the
surface
3

W577-04-02-007

2
W506-04-02-012
1. Press bushing (7) into cylinder head (3) with 4. Install O-ring (4), backup ring (5) and O-ring (6) to
special tool (ST 7325). the outside of cylinder head (3).

5. Install cushion ring (15), spacer (16) and stopper

(17) to the inside of retainer (12).
ST 7325 Install O-ring (14) and backup ring (13) to the
outside of retainer (12).
7
3 6. Install retainer (12) assembly, connector (10) and
stopper (11) to cylinder head (3).

W506-04-02-010

W4-2-21
 FRONT ATTACHMENT / Cylinder

3 31 18 19 20 26 23 22

28 27

W1LD-04-02-007
1 21 25 24 29 30

W4-2-22
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Make sure that O-ring (25) is not IMPORTANT: Take care not to install cushion
twisted after installing it. bearing (18) in wrong direction.
7. Install O-ring (25) to piston (21), and then install 13. Install cushion bearing (18), backup ring (19) and
seal ring (24) with special tool (ST 2625) and (ST piston (21) assembly to piston rod (1).
2623). : 60 mm
: 1270 N⋅m (130 kgf⋅m, 940 lbf⋅ft)
ST 2625

IMPORTANT: When the work of installing set

24 screw (23) is finished, crimp it at two
ST 2623 places with a punch in order to
prevent it from loosening.
25 14. Install steel ball (22) into piston (21) and then
install set screw (23) on it.
: 4 mm
21
: 16.5 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft)

IMPORTANT: Take care not to let slide rings (20)

W566-04-02-010 and (26) drop from piston (21) when
inserting the piston rod (1) assembly.
IMPORTANT: Adjust seal ring (24). If not adjusting, In addition, care should be taken not
piston (21) can not be installed to to damage the piston rod assembly
cylinder tube (21). and insert the piston rod assembly
8. Adjust seal ring (24) with special tool (ST 2627). straightly. Apply the hydraulic oil to
the packing parts.
15. Lay cylinder tube (31) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
tube.
24

ST 2627

W566-04-02-011

IMPORTANT: When installing slide ring (20) and

(26), do not align their split portion.
9. Install slide rings (20) and (26) to piston (21).

10. Wrap the piston rod (1) screw thread with

protective tape and then install the cylinder head
(3) assembly to the piston rod while rotating the
former one.

11. Install cushion seal (27) and cushion bearing (29)

to piston rod (1).

12. Install stopper (30) and retaining ring (28) to

piston rod (1).

W4-2-23
 FRONT ATTACHMENT / Cylinder

3 31

W1LD-04-02-007

W4-2-24
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply the hydraulic oil to the
packing parts.
16. Tighten cylinder head (3) to cylinder tube (31)
with a hook wrench. Bend the detent to prevent it
from loosening.
Cylinder head (3) diameter: 95 mm
: 330 N⋅m (34 kgf⋅m, 245 lbf⋅ft)

Hool Wrench

31
W506-04-02-019

W4-2-25
 FRONT ATTACHMENT / Cylinder
DISASEMBLE BUCKET CYLINDER

16
15
14

13
12
11
10

9
8
7
6
5
4
3
2

Clevis Part

17

W1LD-04-02-005

1- Piston Rod 6- O-Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 7- Backup Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- U-Ring 12 - Steel Ball 16 - Slide Ring
4- O-Ring 9- Bushing 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring

W4-2-26
 FRONT ATTACHMENT / Cylinder
Disassemble Bucket Cylinder 3. Loosen cylinder head (3) with a hook wrench and
pull piston rod (1) (with protective cover on it) out
• Read PRECAUTIONS FOR DISASSEMBLING of cylinder tube (17).
AND ASSEMBLING (W1-1-1) carefully before Cylinder head (3) diameter: 85 mm (3.35 in)
disassembling. Hook Wrench
• Start the following procedures after disconnecting
the lines.

CAUTION: Bucket cylinder weight: 17

28 kg (62 lb) (ZX40U)
33kg (73 lb) (ZX50U)

IMPORTANT: When draining off hydraulic oil from 3

the cylinder, piston rod (1) shall be
moved slowly in order to prevent the
oil from splashing. Protective Cover
1
1. Clamp the pin mounting part (clevis part) of W506-04-02-004

cylinder tube (17) and hold it horizontally in a vise

to drain hydraulic oil from the cylinder. IMPORTANT: As set screw (13) head is
mushroomed after being installed,
IMPORTANT: The detent in cylinder head (3) is cut the mushroomed part with a
provided on cylinder tube (17) to hand drill before loosening set
form an integral part. Take care not screw (13).
to damage the cylinder tube and 4. Secure piston rod (1) horizontally.
cylinder head (3) when bending and Remove set screw (13) and steel ball (12) from
extending the detent. piston (11).
2. Pull out piston rod (1) approximately 200 mm (7.9 : 3 mm
in). Place a protective cover onto the piston rod,
extend the detent. 5. Remove piston (11) from piston rod (1).
: 50 mm (ZX40U)
Detent 55 mm (ZX50U)

6. Wrap piston rod (1) screw thread with protective

tape to protect wiper ring (2) of cylinder head (3)
and then remove cylinder head (3) from piston
rod (1).

IMPORTANT: Do not reuse slide rings (10) and (16).

When dissembling bucket cylinder,
1 3 replace them with new ones.
W506-04-02-003 7. Clamp piston (11) and hold it horizontally in a vice
to remove slide ring (10) and (16) from piston
(11).

W4-2-27
 FRONT ATTACHMENT / Cylinder

15
14

11

9
8
7
6
5
4
3
2

W1LD-04-02-005

W4-2-28
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (11)
when removing seals.
8. Insert a screwdriver into the clearance between
piston (11) and seal ring (14). Raise seal ring (14)
with screwdriver. Cut off seal ring (14) with cutting
pliers to remove seal ring (14) from piston (11).
Remove O-ring (15) in the same procedure.

11

14, 15

W506-04-02-007

9. Remove wiper ring (2), U-ring (8) and backup ring

(7) from the inner side of cylinder head (3).

10. Remove O-ring (4), backup ring (5) and O-ring (6)
from the outer side of cylinder head (3).

IMPORTANT: Do not reuse bushing (9).

Replace it with new one when
disassembling the cylinder.
11. Remove bushing (9) from the inner side of
cylinder head (3) with a special tool.
NOTE: As bushing (9) is installed into cylinder
head (3) with a press, it can not be
removed with a hammer. After cutting off
the inner surface of bushing (9) with a lathe,
scrape off thinned bushing (9) from
cylinder head (3) with a special tool
(copper spatula).

W4-2-29
 FRONT ATTACHMENT / Cylinder
ASSEMBLE BUCKET CYLINDER

3 4 5 6 17 10 16 13 12

W571-04-02-011
2 7 8 9 1 11 14 15

1- Piston Rod 6- O-Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 7- Backup Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- U-Ring 12 - Steel Ball 16 - Slide Ring
4- O-Ring 9- Bushing 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring

W4-2-30
 FRONT ATTACHMENT / Cylinder
Assemble Bucket Cylinder 3. Install wiper ring (2) to cylinder head (3) with
• Read PRECAUTIONS FOR DISASSEMBLING special tool (ST 8045, ST 8046).
AND ASSEMBLING (W1-1-1) carefully before
assembling.

ST 8045 (ZX40U)
CAUTION: Bucket cylinder weight: ST 8046 (ZX50U)
28 kg (62 lb) (ZX40U)
3
33kg (73 lb) (ZX50U)
1. Press bushing (9) into cylinder head (3) with
special tool (ST 7277, ST 7276).

ST 7277 (ZX40U)
ST 7276 (ZX50U)
2
9
W506-04-02-012

3
4. Install O-ring (4), backup ring (5) and O-ring (6) to
the outside of cylinder head (3).

IMPORTANT: Make sure that O-ring (15) is not

twisted after installing it.
5. Install O-ring (15) to piston (11), and then install
W506-04-02-010
seal ring (14) with special tool (ST 2624, ST
2596) and (ST 2622, ST2592).
IMPORTANT: Take care of the mounting direction ST 2624 (ZX40U)
of U-ring (8). ST 2596 (ZX50U)
2. Install backup ring (7) and U-ring (8) to cylinder 14
head (3). ST 2622 (ZX40U)
3 ST 2592 (ZX50U)
15

8
11

W566-04-02-010

W1LD-04-02-004

W4-2-31
 FRONT ATTACHMENT / Cylinder

3 17 10 16 13 12

W571-04-02-011
1 11 14

W4-2-32
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Adjust seal ring (14). If not adjusted, IMPORTANT: Take care not to let slide rings (10)
piston (11) can not be installed to and (16) drop from piston (11) when
cylinder tube (17). inserting the piston rod (1) assembly.
6. Adjust seal ring (14) with special tool (ST 2626, In addition, care should be taken not
ST 2600). to damage the piston rod assembly
straightly. Apply the hydraulic oil to
the packing parts.
11. Lay cylinder tube (17) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
14 tube.

ST 2626 (ZX40U)
ST 2600 (ZX50U) IMPORTANT: Apply the hydraulic oil to the
packing parts.
12. Tighten cylinder head (3) to cylinder tube (17)
with a hook wrench. Bend the detent to prevent it
from loosening.
Cylinder head (3) diameter: 85 mm (ZX40U)
W566-04-02-011
90 mm (ZX50U)
: 320 N⋅m (32.5 kgf⋅m, 235 lbf⋅ft)
IMPORTANT: When installing slide ring (10) and (ZX40U、ZX50U)
(16), do not align their split portion.
7. Install slide rings (10) and (16) to piston (11). Hook Wrench

8. Wrap the piston rod (1) screw thread with

protective tape and then install the cylinder head
(3) assembly to the piston rod while rotating the
former one.

9. Install piston (11) assembly to piston rod (1).

: 50 mm (ZX40U)
: 830 N⋅m (85 kgf⋅m, 610 lbf⋅ft)
: 55 mm (ZX50U) 17
: 1030 N⋅m (105 kgf⋅m, 760 lbf⋅ft)
W506-04-02-019

IMPORTANT: When the work of installing set

screw (13) is finished, crimp it at two
places with a punch in order to
prevent it from loosening.
10. Install steel ball (12) into piston (11) and then
install set screw (13) on it.
: 3 mm (ZX40U)
: 6.8 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)
: 4 mm (ZX50U)
: 16.5 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft)

W4-2-33
 FRONT ATTACHMENT / Cylinder
DISASSEMBLE BOOM SWING CYLINDER
AND BLADE CYLINDER

16
15
14
13
12
11
10
9
8
7
6
5
4

3
2

Clevis Part

17

W1LD-04-02-008
1- Piston Rod 6- U-Ring 10 - Slide Ring 14 - Seal Ring
2- Wiper Ring 7- O-Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- Backup Ring 12 - Steel Ball 16 - Slide Ring
4- Bushing 9- O-Ring 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring

W4-2-34
 FRONT ATTACHMENT / Cylinder
Disassemble Boom Swing Cylinder and Blade 3. Loosen cylinder head (3) with a hook wrench and
Cylinder pull piston rod (1) (with protective cover on it) out
of cylinder tube (17).
• Read PRECAUTIONS FOR DISASSEMBLING Cylinder head (3) diameter: 115 mm (4.53 in)
AND ASSEMBLING (W1-1-1) carefully before (Boom swing cylinder, Blade cylinder)
disassembling. Hook Wrench
• Start the following procedures after disconnecting
the lines.

CAUTION: Cylinder weight: 17

Boom swing cylinder: 48 kg (106 lb)
Blade cylinder: 30 kg (66 lb)

IMPORTANT: When draining off hydraulic oil from 3

the cylinder, piston rod (1) shall be
moved slowly in order to prevent the
oil from splashing. Protective Cover
1
1. Clamp the pin mounting part (clevis part) of W506-04-02-004

cylinder tube (17) and hold it horizontally in a vise

to drain hydraulic oil from the cylinder. IMPORTANT: As set screw (13) head is
mushroomed after being installed,
IMPORTANT: The detent in cylinder head (3) is cut the mushroomed part with a
provided on cylinder tube (17) to hand drill before loosening set
form an integral part. Take care not screw (13).
to damage the cylinder tube and 4. Secure piston rod (1) horizontally.
cylinder head (3) when bending and Remove set screw (13) and steel ball (12) from
extending the detent. piston (11).
2. Pull out piston rod (1) approximately 200 mm (7.9 : 4 mm
in). Place a protective cover onto the piston rod,
extend the detent. 5. Remove piston (11) from piston rod (1).
: 60 mm
Detent (Boom swing cylinder, Blade cylinder)

6. Wrap piston rod (1) screw thread with protective

tape to protect wiper ring (2) of cylinder head (3)
and then remove cylinder head (3) from piston
rod (1).

IMPORTANT: Do not reuse slide rings (10) and (16).

When dissembling the cylinder,
1 3 replace them with new ones.
W506-04-02-003 7. Clamp piston (11) and hold it horizontally in a vise
to remove slide ring (10) and (16) from piston
(11).

W4-2-35
 FRONT ATTACHMENT / Cylinder

15
14

11

9
8
7
6
5
4

3
2

W1LD-04-02-008

W4-2-36
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (11)
when removing seals.
8. Insert a screwdriver into the clearance between
piston (11) and seal ring (14). Raise seal ring (14)
with screwdriver. Cut off seal ring (14) with cutting
pliers to remove seal ring (14) from piston (11).
Remove O-ring (15) in the same procedure.

11

14, 15

W506-04-02-007

9. Remove wiper ring (2), U-ring (6) and backup ring

(5) from the inner side of cylinder head (3).

10. Remove O-ring (7), backup ring (8) and O-ring (9)
from the outer side of cylinder head (3).

IMPORTANT: Do not reuse bushing (4).

Replace it with new one when
disassembling the cylinder.
11. Remove bushing (4) from the inner side of
cylinder head (3) with a special tool.
NOTE: As bushing (4) is installed into cylinder
head (3) with a press, it can not be
removed with a hammer. After cutting off
the inner surface of bushing (4) with a lathe,
scrape off thinned bushing (4) from
cylinder head (3) with a special tool
(copper spatula).

W4-2-37
 FRONT ATTACHMENT / Cylinder
ASSEMBLE BOOM SWING CYLINDER
AND BLADE CYLINDER

NOTE: The cross section of boom swing cylinder

and the cross section of blade cylinder are
the same.

3 7 8 9 17 11 10 16 13 12

W1LD-04-02-009

2 7 5 6 1 14 15

1- Piston Rod 6- U-Ring 10 - Slide Ring 14 - Seal Ring

2- Wiper Ring 7- O-Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- Backup Ring 12 - Steel Ball 16 - Slide Ring
4- Bushing 9- O-Ring 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring

W4-2-38
 FRONT ATTACHMENT / Cylinder
Assemble Boom Swing Cylinder and Blade IMPORTANT: Take care of the mounting direction
Cylinder of U-ring (6).
• Read PRECAUTIONS FOR DISASSEMBLING 2. Install backup ring (5) and U-ring (6) to cylinder
AND ASSEMBLING (W1-1-1) carefully before head (3).
assembling. 3

CAUTION: Cylinder weight:

Boom swing cylinder: 48 kg (106 lb) 6
Blade cylinder: 30 kg (66 lb)
IMPORTANT: Apply hydraulic oil to the inner side
of cylinder head (3). Press bushing
(4) until the end of bushing (4) is
flush with the end surface of
cylinder head (3). If not flush,
backup ring (5) will be damaged
when installing backup ring (5.) W1LD-04-02-004

3. Install wiper ring (2) to cylinder head (3) with

4 special tool.
3 Boom swing cylinder: ST 8047
Blade cylinder: ST 8048
Flush the
surface

ST 8047
ST 8048

3
W577-04-02-007

1. Press bushing (4) into cylinder head (3) with

special tool.
Boom swing cylinder: ST 7325 2
Blade cylinder: ST 7275 W506-04-02-012

4. Install O-ring (7), backup ring (8) and O-ring (9) to

ST 7325
the outer side of cylinder head (3).
ST 7275

4
3

W506-04-02-010

W4-2-39
 FRONT ATTACHMENT / Cylinder

3 17 11 10 16 13 12

W1LD-04-02-009

1 14 15

W4-2-40
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Make sure that O-ring (15) is not 8. Wrap the piston rod (1) screw thread with
twisted after installing it. protective tape and then install the cylinder head
5. Install O-ring (15) to piston (11), and then install (3) assembly to the piston rod while rotating the
seal ring (14) with special tool. former one.
Boom swing cylinder and blade cylinder:
ST 2597, ST 2593 9. Install piston (11) assembly to piston rod (1).
: 60 mm
ST 2597
: 1960 N⋅m (200 kgf⋅m, 1450 lbf⋅ft)

14 IMPORTANT: When the work of installing set

screw (13) is finished, crimp it at two
ST 2593
places with a punch in order to
prevent it from loosening.
15 10. Install steel ball (12) into piston (11) and then
install set screw (13) on it.
11 : 4 mm
: 16.5 N⋅m (1.7 kgf⋅m, 12 lbf⋅ft)

W566-04-02-010
IMPORTANT: Take care not to let slide rings (10)
and (16) drop from piston (11) when
inserting the piston rod (1) assembly.
IMPORTANT: Adjust seal ring (14). If not adjusted,
In addition, care should be taken not
piston (11) can not be installed to
to damage the piston rod assembly
cylinder tube (17).
and insert the piston rod assembly
6. Adjust seal ring (14) with special tool.
straightly. Apply the hydraulic oil to
Boom swing cylinder and blade cylinder: ST 2601
the packing parts.
11. Lay cylinder tube (17) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
tube.
14

ST 2601

W566-04-02-011

IMPORTANT: When installing slide ring (10) and

(16), do not align their split portion.
7. Install slide rings (10) and (16) to piston (11).

W4-2-41
 FRONT ATTACHMENT / Cylinder

3 17

W1LD-04-02-009

W4-2-42
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply the hydraulic oil to the
packing parts.
12. Tighten cylinder head (3) to cylinder tube (17)
with a hook wrench. Bend the detent to prevent it
from loosening.
Cylinder head (3) diameter: 115 mm
: 390 N⋅m (40 kgf⋅m, 290 lbf⋅ft)

Hook Wrench

17
W506-04-02-019

W4-2-43
 FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD

Rod Rod Bend and Run Out

A Dial Gauge
Cylinder Rod

W105-04-02-094 W166-04-02-022
ZX40U unit: mm (in)
1m
Recommended Size After
Cylinder Name V Block
Re-manufacturing (A)
+0.023 (2.1 +0.0009 unit: mm (in)
Boom 55 ) Bend Run out Remedy
-0.043 7 −0.0017
+0.023 (1.9 +0.0009 Allowable limit 0.5 (0.020) 1.0 (0.039) Repair
Arm 50 ) Allowable limit 1.0 (0.039) 2.0 (0.079) Replace
-0.043 7 −0.0017
+0.023 (1.5 +0.0009
Bucket 40 )
-0.043 8 −0.0017
+0.023 (1.9 +0.0009
Boom Swing 50 )
-0.043 7 −0.0017
+0.023 (2.1 +0.0009
Blade 55 )
-0.043 7 −0.0017

ZX50 unit: mm (in)

Recommended Size After
Cylinder Name
Re-manufacturing (A)
+0.023 (2.1 +0.0009
Boom 55 )
-0.043 7 −0.0017
+0.023 (1.9 +0.0009
Arm 50 )
-0.043 7 −0.0017
+0.023 (1.7 +0.0009
Bucket 45 )
-0.043 7 −0.0017
+0.023 (1.9 +0.0009
Boom Swing 50 )
-0.043 7 −0.0017
+0.023 (2.1 +0.0009
Blade 55 )
-0.043 7 −0.0017

Wear to The Inner Diameter of Rod Bushing

ZX40U,ZX50U unit: mm (in)
Cylinder Remedy
Standard inner Diameter (C) Allowable Limit
Name
-0.21 +0.008
) +0.3
Boom 50 (1.97 Replace
-0.16 +0.006 (0.012)
-0.16 +0.006
) +0.3
Arm 45 (1.77 Replace C
-0.11 +0.004 (0.012)
-0.16 +0.006
) +0.3
Bucket 45 (1.77 Replace
-0.11 +0.004 (0.012)
-0.21 +0.008
) +0.3
Boom Swing 50 (1.97 Replace
-0.16 +0.006 (0.012)
-0.21 +0.008 ) +0.3
Blade 55 (2.17 Replace
-0.16 +0.006 (0.012)

W4-2-44
 MEMO

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 SECTION 5
ENGINE

CONTENTS
SECTION 1 General Information SECTION 5 Fuel System
GENERAL REPAIR INSTRUCTION................... 2 FUEL CIRCULATION SYSTEM DIAGRAM ......88
NOTES ON THE FORMAT GOVERNOR ....................................................89
OF THIS MANUAL ........................................... 2 NOZZLE HOLDER ASSEMBLY .......................97
APPEARANCE .................................................. 5
MAIN DATA AND SPECIFICATIONS ................. 6 SECTION 6 Troubleshooting
TIGHTENING TORQUE SPECIFICATIONS....... 7
ANGULAR NUT AND BOLT SECTION 7 Special Tool
TIGHTENING METHOD .................................. 9
TIGHTENING TORQUE ON SECTION 8 Service Standard
MAJOR COMPONENTS ................................ 11
GASKET LOCATION ....................................... 17 SECTION 9 Conversion Table
MAINTENANCE............................................... 20 LENGTH ........................................................109
RECOMENDED LUBRICATION OIL................ 25 AREA ............................................................. 111
VOLUME........................................................ 111
SECTION 2 Engine MASS ............................................................ 113
DISASSEMBLY................................................ 28 PRESSURE ................................................... 114
INSPECTION AND REPAIR ............................ 41 TORQUE ....................................................... 115
REASSEMBLY................................................. 55 TEMPERATURE ............................................ 116

SECTION 3 Lubrication System

LUBRICATION OIL CIRCULATION
SYSTEM DIAGRAM....................................... 78
OIL PUMP ....................................................... 79

SECTION 4 Cooling System

COOLING WATER CIRCULATION
SYSTEM DIAGRAM....................................... 82
WATER PUMP................................................. 83
THERMOSTAT ................................................ 86

1LDW-5-1
（Blank）

1LDW-5-2
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162

SERVICE MANUAL REVISION REQUEST FORM

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