PART NO.

WJAA-EN-01

ZX470-5B • 470LC-5B • 470H-5B • 470LCH-5B • 470R-5B • 470LCR-5B HYDRAULIC EXCAVATOR WORKSHOP MANUAL
Workshop Manual

ZX
470-5B
470LC-5B
470H-5B
470LCH-5B
URL:http://www.hitachi-c-m.com 470R-5B
470LCR-5B
Hydraulic Excavator
Service Manual consists of the following separate Part No.
WJAA-EN-01

Technical Manual (Operational Principle) : Vol. No.TOJAA-EN

Technical Manual (Troubleshooting) : Vol. No.TTJAA-EN
Workshop Manual : Vol. No.WJAA-EN
PRINTED IN JAPAN (K) 2015, 04 Engine Manual : Vol. No.ETJAA-EN, EWJAA-EN
 INTRODUCTION
To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
Form” at the end of this manual. (Note: Do not tear off
 Be sure to thoroughly read this manual for correct the form. Copy it for usage.):
product information and service procedures.  Publications Marketing & Product Support Hitachi
Construction Machinery Co. Ltd.
 TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: dc@hitachi-kenki.com

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

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

Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:

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

IN-01
 INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential d CAUTION:
Indicated potentially hazardous situation which could, if
for personal injury of machine damage.
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
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. f NOTE:
Indicates supplementary technical information or know-
To avoid injury and damage, be sure to use appropriate
how.
lifting techniques and equipment when lifting heavy
parts.

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

Quantity To Convert From Into Multiply By

Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3 yd3 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm 2
10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min -1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0

fNOTE: The numerical value in this manual might be

different from the above-mentioned table.

IN-02
 SYMBOL AND ABBREVIATION

Symbol / Name Explanation

Abbreviation
TO Technical manual (Operational principle)Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
VGS Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged
system to supercharge the exhaust energy while running
the engine at slow idle speed. VGS optimizes the turbine
rotation, improves the performance at slow-speed torque
and the acceleration, reduces fuel consumption, and reduces
particulate matter (PM) by adjusting the nozzle opening of
turbine housing.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.

SY-1
 SYMBOL AND ABBREVIATION

Symbol / Name Explanation

Abbreviation
DPF Diesel Particulate Filter DPF is a filter which removes particulate matter (PM)
including the toxic substance of exhaust gas of the diesel
engine. Exhaust particulate removal equipment.
DPD Diesel Particulate Diffuser DPD is an exhaust emission control system, a type of DPF,
which cleans up particulate matter (PM) of diesel engine
exhaust gas. DPD is a ceramic filter which traps and filters
PM of exhaust gas. DPD burns up accumulated PM when PM
increases and regenerates the filter.
DOC Diesel Oxidation Catalyst Oxidation catalyst for the diesel engine. Diesel oxidation
catalyst oxidizes unburnt fuel and raises exhaust
temperature.
CSF Catalyzed Soot Filter Filter. The filter traps, burns, and remove particulate matter
(PM) by using high-temperature-exhaust gas with diesel
oxidation catalyst. Catalyst is applied onto the filter. This
advances PM burning.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the
intake manifold and combines it with intake-air. Therefore,
combustion temperature is lowered and generation of oxide
of nitrogen (NOx) is controlled.

SY-2
 SAFETY

Recognize Safety Information

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

SA-688

Understand Signal Words

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

SA-1223
 To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.

 NOTE: indicates an additional explanation for an

element of information.

SA-1
 SAFETY

Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
 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. SA-003
 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Never attempt to modify or disassemble the inlet/exhaust
parts and the muffler filter. Avoid giving shocks on the
muffler filter by striking elements with other objects or
dropping the elements. Failure to do so may affect the
exhaust gas purifying device, possibly damaging it or
lowering its performance.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.

SA-2
 SAFETY
Prepare for Emergencies
 Be prepared if a fire starts or if an accident occurs.
 Keep a first aid kit and fire extinguisher on hand.
 Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
 To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
 Establish emergency procedure guidelines to cope with
fires and accidents.
 Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone.
SA-437

Wear Protective Clothing

 Wear close fitting clothing and safety equipment
appropriate to the job.

You may need:

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

SA-3
 SAFETY

Protect Against Noise

 Prolonged exposure to loud noise can cause impairment or
loss of hearing.
 Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.

SA-434

Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
 In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.

SA-435

SA-4
 SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not leave parts and/or tools lying around the
operator’s seat. Store them in their specified locations.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
 Keep all flammable objects and/or explosives away from
the machine.
 After using the ashtray, always cover it to extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.

SA-5
 SAFETY

Use Handholds and Steps

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

Adjust the Operator's Seat

 A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
 The seat should be adjusted whenever changing the
operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror SA-378
is broken, immediately replace it with a new one.

SA-6
 SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with
a control lever and/or pedal, possibly resulting in serious
personal injury or death.
 Before leaving the machine, be sure to first lower the front
attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF
to stop the engine.
 Before leaving the machine, close all windows, doors, and
access covers and lock them up.

Fasten Your Seat Belt

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

SA-7
 SAFETY

Move and Operate Machine Safely

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

Operate Only from Operator's Seat

 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
 Start the engine only when seated in the operator's seat.
 NEVER start the engine while standing on the track or on
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders. SA-444

SA-8
 SAFETY

Jump Starting
 Battery gas can explode, resulting in serious injury.
 If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
 The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
 Never use a frozen battery.
 Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032

Keep Riders off Machine

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

SA-379

SA-9
 SAFETY

Precautions for Operations

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

M178-05-007

SA-10
 SAFETY

Investigate Job Site Beforehand

 When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
 Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles or banks
from collapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
 When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.

SA-11
 SAFETY
 Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
 If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
 Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
 Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent M104-05-016
machine tipping over from occurring. When operating on
rough terrain or on slopes:
 Reduce the engine speed.
 Select slow travel speed mode.
 Operate the machine slowly and be cautious with
machine movements.

Install OPG Guard

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

ROPS: Roll Over Protective Structure

OPG: Operator Protective Guard

SA-490

SA-12
 SAFETY

Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.

SA-481

Confirm Direction of Machine to Be Driven

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

SA-491

SA-13
 SAFETY

Drive Machine Safely

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

 Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.
 Never attempt to ascend or descend 35 degrees or
steeper slopes.
 Be sure to fasten the seat belt.
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 0.2 to 0.3 m (A)
above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If A SA-658
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.

SA-441

WRONG

SA-590

SA-14
 SAFETY
 Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
 Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
 Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
 Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
 Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
 Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
 When crossing train tracks, use wood plates in order not
to damage them.
 Do not make contact with electric wires or bridges.
 When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
 When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
 Avoid operations that may damage the track and
undercarriage components.
 During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.

SA-15
 SAFETY

Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.

To avoid rollaways:
 Select level ground when possible to park the machine.
 Do not park the machine on a grade.
 Lower the bucket and/or other work tools to the ground.
 Turn the auto-idle switch OFF and the power mode switch
ECO.
 Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
 Stop the engine and remove the key from the key switch.
SA-391
 Pull the pilot control shut-off lever to LOCK position.
 Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.

SA-2273

SA-16
 SAFETY

Avoid Injury from Back-Over and Swing

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

SA-17
 SAFETY

Keep Person Clear from Working Area

 A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or death.
 Keep all persons clear from the area of operation and
machine movement.
 Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to prevent
anyone from entering the work area.

SA-386

Never Position Bucket Over Anyone

 Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.

SA-487

SA-18
 SAFETY
Avoid Undercutting
 In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage
perpendicular to the edge of the excavation with the travel
motors at the rear.
 If the footing starts to collapse and if retreat is not
possible, do not panic. Often, the machine can be secured
by lowering the front attachment, in such cases.

SA-488

Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE
--- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
 The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
 Be extra careful before operating on a grade.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the SA-012
machine.
 Reduce operating speeds to avoid tipping or slipping.
 Avoid changing direction when traveling on grades.
 NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
 Reduce swing speed as necessary when swinging loads.

 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become
soft and make ground travel unstable.

SA-440

SA-19
 SAFETY

Never Undercut a High Bank

 The edges could collapse or a land slide could occur causing
serious injury or death.

SA-489

Dig with Caution

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

Operate with Caution

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

SA-389

SA-20
 SAFETY

Avoid Power Lines

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

SA-381

Precautions for Lightning

 The machine is vulnerable to lightning strikes.
 In the event of an electrical storm, immediately stop
operation, and lower the bucket to the ground. Evacuate
to a safe place far away from the machine.
 After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only after
repairing them.

SA-1088

SA-21
 SAFETY

Object Handling
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
resulting in serious injury or death.
 When using the machine for craning operations, be sure
to comply with all local regulations.
 Do not use damaged chains or frayed cables, sables,
slings, or ropes.
 Before craning, position the upperstructure with the
travel motors at the rear.
 Move the load slowly and carefully. Never move it
suddenly.
 Keep all persons well away from the load.
 Never move a load over a person’s head.
 Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
 Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.

SA-014

Protect Against Flying Debris

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

SA-432

SA-22
 SAFETY

Park Machine Safely

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

SA-390

Handle Fluids Safely−Avoid Fires

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

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

 Store flammable fluids well away from fire hazards.
 Do not incinerate or puncture pressurized containers. SA-018
 Do not store oily rags; they can ignite and burn
spontaneously.
 Securely tighten the fuel and oil filler cap.

SA-019

SA-23
 SAFETY

Transport Safely
 Take care the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
 Observe the related regulations and rules for safe
transportation.
 Select an appropriate truck or trailer for the machine to
be transported.
 Be sure to use a signal person.
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight. SA-395

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

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

Be sure to further follow the details described in the

TRANSPORTING section.

SA-24
 SAFETY

Practice Safe Maintenance

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

Before servicing the machine:

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

7. Remove the key from the key switch.

8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.

 If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
 If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support any
machine elements that must be raised for service work.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter of this manual. SA-527
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.

SA-25
 SAFETY
 Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
 Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.

SA-037

Warn Others of Service Work

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

SS2045102

Support Machine Properly

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

SA-26
 SAFETY

Stay Clear of Moving Parts

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

SA-026

SA-2294

Prevent Parts from Flying

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

 Travel reduction gears are under pressure.

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

SA-27
 SAFETY

Store Attachments Safely

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.

SA-034

Prevent Burns
Hot spraying fluids:

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

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
 To avoid possible injury from hot spraying water. DO
NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to SA-039
release all pressure before removing the cap.

Hot fluids and surfaces:

 Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
 Wait for the oil and components to cool before starting
any maintenance or inspection work.

SA-225

SA-28
 SAFETY

Replace Rubber Hoses Periodically

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

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

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

Avoid High-Pressure Fluids

 Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
 Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044

SA-29
 SAFETY

Prevent Fires
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to fires.
 Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
 Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
 Do not bend or strike high-pressure lines.
 Never install bent or damaged lines, pipes, or hoses.
 Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
SA-019
Check for Shorts:
 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
 Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.

SA-30
 SAFETY
Clean up Flammables:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammables immediately. Check and clean high
temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammables away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammables such as
dead leaves from entering. However, flammables which
have passed through the wire screen may cause fires.
Check and clean the machine every day and immediately
remove accumulated flammables.

Check Key Switch:

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

Check Heat Shields:

 Damaged or missing heat shields may lead to fires.

 Damaged or missing heat shields must be repaired or

replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as mufflers may cause fire. Always close the engine cover
while operating the machine.

SA-31
 SAFETY

Evacuating in Case of Fire

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

SS-1510

Beware of Exhaust Fumes

 Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
 If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
 PM (Particle Matter) combustion may generate white
smoke during muffler filter regeneration. Do not attempt
to do muffler filter manual regeneration in a badly
ventilated indoors.

SA-016

SA-32
 SAFETY
Precautions for Welding and Grinding
 Welding may generate gas and/or small fires.
 Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe place
before starting welding.
 Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
 Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
 After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818

SA-33
 SAFETY

Avoid Heating Near Pressurized Fluid Lines

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

SA-030

Avoid Applying Heat to Lines Containing

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

Precautions for Handling Accumulator and Gas

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

Strictly comply with the following items: Do not disassemble

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

SA-34
 SAFETY

Remove Paint Before Welding or Heating

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

Beware of Asbestos and Silicon Dust and Other

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

SA-35
 SAFETY

Prevent Battery Explosions

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

 Battery electrolyte is poisonous. If the battery should

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

Service Air Conditioning System Safely

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

SA-405

SA-36
 SAFETY

Handle Chemical Products Safely

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

Dispose of Waste Properly

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

SA-37
 SAFETY

Never Ride Attachment

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

Notes for Muffler Filter

Muffler Filter
The muffler filter removes particle matters (PM) in
the exhaust gas. The muffler filter traps PM, and it is
automatically regenerated by burning PM when the set
amount of PM is accumulated in the filter. Follow the
instructions below to prevent the muffler filter from being
damaged.

dWARNING: Exhaust gas from the muffler filter, muffler

and exhaust piping becomes hot during and right
after engine running and filter regeneration (burning
PM). Keep away from the direction of the exhaust
piping and its vicinity during the filter regeneration.
Be careful not to let your skin contact with any hot gas
from the exhaust piping. It may cause severe burns.

Do not directly touch water coming out of the muffler filter.

The water is mildly-acidic by oxidation catalyst mounted
in the muffler filter. If filter water spills on your skin,
immediately flush it out with clean water.

Precautions for Communication Terminal

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

SA-38
 SAFETY
Precaution for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which is
situated at the back of the driver's seat. There is a possibility
that a medical device, including an implantable device
such as a cardiac pacemaker, would be affected and would
malfunction by the electrical waves emitted from the
communication terminal equipment.

Any person affixed with a medical device such as the above SA-2302
should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.662 inches) apart at
all times. If such condition cannot be met, please contact our
company's nearest dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.

Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipment:
E-GSM900 0.573 W/Kg (914.80 MHz)
DCS-1800 0.130 W/Kg (1710.20 MHz)
WCDMA Band I 0.271 W/Kg (1950.00 MHz)

*This data was measured by having each type of

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

In Japan: *Under the Japanese Radio Act and other relevant

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).

In EU Member nation: *Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).

SA-39
 SAFETY

Before Returning The Machine To The Customer

 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced

SA-435

SA-40
 SECTION 1 GENERAL INFORMATION
SECTION AND GROUP Group 1 Precautions for Disassembling and Assembling
CONTENTS Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil Tank
Group 5 Hydraulic Circuit Pressure Release Procedure
Group 6 Preparation
SECTION 2 MAINTENANCE STANDARD
WORKSHOP MANUAL Group 1 Upperstructure
Group 2 Undercarriage
Group 3 Attachment
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Engine
Group 5 Radiator
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Swing Device
Group 11 Pilot Valve
Group 12 Solenoid Valve
Group 13 Signal Control Valve
Group 14 Shockless Valve
Group 15 Fan Valve
Group 16 Fan Motor
Group 17 Muffler Filter
All information, illustrations and SECTION 4 UNDERCARRIAGE
specifications in this manual are based on Group 1 Swing Bearing
the latest product information available
at the time of publication. The right is Group 2 Travel Device
reserved to make changes at any time Group 3 Center Joint
without notice.
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 5 ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
COPYRIGHT(C)2015
Hitachi Construction Machinery Co., Ltd. Group 3 Hose Rupture Valve
Tokyo, Japan
All rights reserved
SECTION 6 COUNTERWEIGHT REMOVAL/
INSTALLATION DEVICE
Group 1 Cylinder
TECHNICAL MANUAL (Operational Principle) TECHNICAL MANUAL (Troubleshooting)
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specification Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Excavator Test
Group 1 Controller Group 5 Component Test
Group 2 Control System Group 6 Adjustment
Group 3 ECM System SECTION 5 TROUBLESHOOTING
Group 4 Hydraulic System Group 1 Diagnosing Procedure
Group 5 Electrical System Group 2 Monitor
SECTION 3 COMPONENT OPERATION Group 3 e-Service
Group 1 Pump Device Group 4 Component Layout
Group 2 Swing Device Group 5 Troubleshooting A
Group 3 Control Valve Group 6 Troubleshooting B
Group 4 Pilot Valve Group 7 Air Conditioner
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
SECTION 1

GENERAL
CONTENTS
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling
and Assembling.........................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Painting Specification...................................................W1-3-1-1
Final Painted Color.........................................................W1-3-1-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1
Bleeding Air from Hydraulic System........................W1-4-1-2
Bleeding Air from Fuel System...................................W1-4-1-3
Group 5 Pressure Release Procedure
Hydraulic Circuit Pressure Release Procedure......W1-5-1-1
Group 6 Preparation
Preparation before Inspection
and Maintenance.......................................................W1-6-1-1

JAAW-1-1
(Blank)

JAAW-1-2
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Disassembling and  If a part or component cannot be removed after

Assembling removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), then take the
Precautions for Disassembling appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and tag
 Clean the Machine
them if necessary.
Thoroughly wash the machine before bringing it
 Store common parts, such as bolts and nuts with
into the shop. Bringing a dirty machine into the shop
reference to where they are to be used and in a
may cause machine components to be contaminated
manner that will prevent loss.
during disassembling / assembling, resulting in
 Inspect the contact or sliding surfaces of
damage to machine components, as well as decreased
disassembled parts for abnormal wear, sticking, or
efficiency in service work.
other damage.
 Measure and record the degree of wear and
 Inspect the Machine
clearances.
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
 Precautions for Assembling
incorrect disassembling of components as well as
 Be sure to clean all parts and inspect them for any
personal injury.
damage. If any damage is found, repair or replace
Check and record the items listed below to prevent
part.
problems from occurring in the future.
 Dirt or debris on the contact or sliding surfaces may
 The machine model, machine serial number, and
shorten the service life of the machine. Take care not
hour meter reading.
to contaminate any contact or sliding surfaces.
 Reason for disassembly (symptoms, failed parts, and
 Apply appropriate lubricant oil onto parts in order to
causes).
prevent them from seizing.
 Clogging of filters and oil, water or air leaks, if any.
 Be sure to replace O-rings, backup rings, oil seals, and
Capacities and condition of lubricants.
floating seals with new ones once they have been
 Loose or damaged parts.
disassembled. Apply grease before installing
 Be sure that liquid-gasket-applied surfaces are clean
 Prepare and Clean Tools and Disassembly Area
and dry.
Prepare the necessary tools to be used and the area for
 If an anti-corrosive agent has been used on a new
disassembling work.
part, be sure to thoroughly clean the part to remove
the agent.
Precautions for Disassembling and Assembling
 Fit the matching marks made when disassembling
 Precautions for Disassembling and assemble them.
 Cap the open ends in case the hoses and pipes  Be sure to use the designated tools to assemble
have been disconnected. In addition, attach an bearings, bushings, and oil seals.
identification tag onto the connectors, hoses, and  Keep a record of the number of tools used for
pipes for assembling. disassembly / assembly. After assembling is
 Before disassembling, clean the exterior of the completed, count the number of tools so as to make
components and place on a workbench. sure that no forgotten tools remain in the assembled
 Drain hydraulic oil and gear oil from the hydraulic machine.
components and reduction gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling if
necessary.
 Be sure to use the specified special tools when
instructed.

W1-1-1-1
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Using Floating Seal 1

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

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding
surface (e) of seal ring (1). W178-02-11-001
2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) for tears, breaks, deformation, or
hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following to prevent
trouble.
 Clean the floating seal and seal mounting bores with
cleaning solvent. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a- Correct c- Twist of O-Ring
 After installing the floating seal, check that O-ring b- Incorrect d- Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
(e) and (f ) at point (A) and (B), as illustrated. If these
distances differ, correct O-ring (2) seating. a A b A

B B

A=B A≠B

W178-02-11-003

a- Correct e- Sliding Surface

b- Incorrect f- Seal Mating Surface

W1-1-1-2
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings a
safely.
 Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
 Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load with
a temperature of 100 °C (212 °F) or more, reduce the
load weight.
 Do not lift acid or alkali chemicals. W102-04-02-016
 Take care not to allow the sling to become wet. The
a- Correct Eyehole Lifting
load may slip.
Method
 When required to use more than one sling, use slings
with the same width and length to keep the lifted b
load balanced.
 When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
 Avoid using twisted, bound, connected, or hitched
slings.
 Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
 When removing the slings from under the load, take
care not to damage the nylon slings. Avoid contact W105-04-01-008
with protrusions.
 Avoid dragging slings on the ground, throwing b- Incorrect Eyehole Lifting
Method
slings, or pushing slings with a metal object.
 When using with other types of slings (wire rope) or
accessories (shackle), protect the joint so that the
nylon sling is not damaged.
 Store the nylon slings indoors so that they won’t
deteriorate with heat, sun light, or chemicals.

c W162-01-01-009

c- Bent of Sling

W1-1-1-3
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

dCAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may result.
Be sure to visually check the nylon sling for any
damage before using.

2. Before using a nylon sling, visually check the nylon

sling for any damage corresponding to examples
shown to the right. If any damage is found, cut and
discard the sling.
Even if no damage is found, do not use slings older
than 7 years.

Damaged Appearance a
a

W162-01-01-002 W162-01-01-006
e
a- Broken Sewing Thread a- Broken Sewing Thread e- Separation of Belt

b f

W162-01-01-003 W162-01-01-007
b
b- Scuffing b- Scuffing f- Scoring

c
c g

W162-01-01-004
W162-01-01-008
c- Fuzz d- Broken Sewing Thread
c- Fuzz g- Broken Warp

W162-01-01-005

a- Broken Sewing Thread

W1-1-1-4
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

Maintenance Standard Terminology

“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification. Allowable errors will be
indicated if necessary.

“Allowable Limit”
1. Normal machine performance cannot be
accomplished after exceeding this limit.
2. Repair or adjustment is difficult after exceeding this
limit.
3. Repair or adjustment is impossible after exceeding
this limit.
Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.

W1-1-1-5
 SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling

(Blank)

W1-1-1-6
 SECTION 1 GENERAL
Group 2 Tightening

Tightening Bolts and Nuts

dCAUTION: Use tools appropriate for the work

to be done. Makeshift tools and procedures
can create safety hazards. For loosening and
tightening nuts and bolts, use correct size tools.
Otherwise, tightening tools may slip, potentially
causing personal injure.
fNOTE:
 Apply lubricant (e.g. white zinc B dissolved into spindle
oil) to bolts and nuts to reduce friction coefficient of
them.
 Make sure bolt and nut threads are clean before WDAA-01-02-001
installing.

Bolt Types
Tighten the nuts or bolts correctly to the torque
specifications.
As the different types and grades of bolt are used,
use and tighten the correct bolts correctly when
assembling the machine or components.

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench WDAA-01-02-002 WDAA-01-02-003 WDAA-01-02-004
Size
Size
Socket Bolt
N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft)
M6 10 5 3 to 4 (0.3 to 0.4) (2.2 to 3)
M8 13 6 30 (3) (22) 20 (2) (15) 10 (1) (7.4)
M10 17 8 65 (6.5) (48) 50 (5) (37) 20 (2) (15)
M12 19 10 110 (11) (81) 90 (9) (66) 35 (3.5) (26)
M14 22 12 180 (18) (133) 140 (14) (103) 55 (5.5) (41)
M16 24 14 270 (27) (200) 210 (21) (155) 80 (8) (59)
M18 27 14 400 (40) (300) 300 (30) (220) 120 (12) (89)
M20 30 17 550 (55) (410) 400 (40) (300) 170 (17) (125)
M22 32 750 (75) (550) 550 (55) (410) 220 (22) (162)
M24 36 950 (95) (700) 700 (70) (520) 280 (28) (205)
M27 41 1400 (140) (1030) 1050 (105) (770) 400 (40) (300)
M30 46 1950 (195) (1440) 1450 (145) (1070) 550 (55) (410)
M33 50 2600 (260) (1920) 1950 (195) (1440) 750 (75) (550)
M36 55 3200 (320) (2360) 2450 (245) (1810) 950 (95) (700)

W1-2-1-1
 SECTION 1 GENERAL
Group 2 Tightening

IMPORTANT: The following items are applied to both

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

Tightening Order
When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.

a b c

1 12 9 4 1 6 7 14
1.4 6 3

4 5
2 13 8 5 2 3 10 11
2.3

W105-01-01-003

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

lower alternately diagonally

W1-2-1-2
 SECTION 1 GENERAL
Group 2 Tightening

Precautions for Spilt Flange

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

Nut and Bolt Locking

 Lock Plate
W105-01-01-008
IMPORTANT: Do not reuse the lock plates. Do not try
to bend the same point twice.
Correct Incorrect
 Split Pin
IMPORTANT: Do not turn in the loosening direction
in order to align the grooves and holes on the nut.
a b
Always turn in the tightening direction. Do not
reuse the split pins.
Correct Correct Incorrect

 Wire
IMPORTANT: Attach wire to bolts in the bolt-
tightening direction. Do not reuse the wire.

a
WDAA-01-02-007

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

Correct Correct
Incorrect

Correct d Incorrect
c

WDAA-01-02-008

c- Tighten d- Loosen

W1-2-1-3
 SECTION 1 GENERAL
Group 2 Tightening

Piping Joint
IMPORTANT: The torque given in table below are for
general use only, however, a different torque is
given for a specific application. Use the specified
1 4 3 5 2
torque.

Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
a- Joint Body WDAA-01-02-009
IMPORTANT: a

 Do not over-tighten union nut (3). Excessive

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

Wrench Size mm Tightening Torque

Description
Union Nut N·m (kgf·m) (lbf·ft)
30° male 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 270 (27) (200)
55 380 (38) (280)
60 380 (38) (280)
37° female 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)

fNOTE: Tightening torque of 37° male coupling without

union is similar to tightening torque of 37° female.

W1-2-1-4
 SECTION 1 GENERAL
Group 2 Tightening

Pipe Joint
Pipe connection (metal joint)
(Union Nut Wrench Size: 17, 19, 22, 27)

Metal (3) of adapter (1) and pipe (2) seals pressure oil.

 Precautions for use

Do not damage sealing surfaces (4) and (5) when
disassembling and assembling. 1 4 5 3 2

Tightening Torque
Use the specified tightening torque in the table below.
Wrench Size (mm) 17 19 22 27
N·m 25 30 40 80
Tightening
(kgf·m) (2.5) (3) (4) (8) M1M7-07-005
Torque
(lbf·ft) (18) (22) (30) (59)

O-ring Seal Joint

O-ring (6) is installed against the end surface of adapter
(7) and seals pressure oil.

IMPORTANT:
7 6 9
 Replace O-ring (6) with a new one when
reinstalling.
 Before tightening union nut (9), confirm that
O-ring (6) is seated correctly in O-ring groove
(8). Tightening union nut (9) with O-ring (6)
displaced will damage O-ring (6), resulting in oil
leakage.
 Do not damage O-ring groove (8) of adapter (7) 8 10 a
WDAA-01-02-011
or sealing surface (10) on the hose side. Damage a- Joint Body
to O-ring (6) may cause oil leakage.
 If union nut (9) is found to be loose, causing
oil leakage, do not tighten it to stop the leak. Wrench Size mm Tightening Torque
Instead, replace O-ring (6) with a new one, then Union Nut N·m (kgf·m) (lbf·ft)
tighten union nut (9) after confirming that 19 30 (3) (22)
O-ring (6) is securely seated in O-ring groove (8). 22 70 (7) (52)
27 95 (9.5) (70)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 350 (35) (260)

W1-2-1-5
 SECTION 1 GENERAL
Group 2 Tightening

Quick Coupling
3 1
1. Coupling procedure
 Push socket ring (1) into plug (3) by rotating it fully
counterclockwise and then pulling it toward you.
 Release socket ring (1). Check that socket ring (1)
is returned by the spring force and the coupling is
locked completely by ball (2). At this time, check if
socket ring (1) is returned to the original position (to
M1M7-07-006
the rightmost direction). 2

2. Separating procedure
 Remove the hose by rotating socket ring (1) fully
counterclockwise and then pulling it. Because no
check function is attached inside, be careful that oil
flows out.
 Cap the removed hoses using special plug.

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

W1-2-1-6
 SECTION 1 GENERAL
Group 2 Tightening

Screw-In Connection R G
30°
Depending on types of screw and sealing, different
types of screw-in connection are used.

IMPORTANT: Check that the thread pitch and thread

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

Wrench Size mm Tightening Torque

Joint Body FC material SS material
19 15 (1.5, 11) 35 (3.5, 26)
22 30 (3, 22) 50 (5, 37)
27 50 (5, 37) 95 (9.5, 70)
36 70 (7, 52) 160 (16, 118)
Seal Tape Application 41 110 (11, 81) 200 (20, 148)
Seal tape is used in order to seal clearances between 50 160 (16, 118) 330 (33, 245)
male and female threads so that any leaks between 60 200 (20, 148)
threads may be prevented. Therefore, apply just
enough seal tape to fill up thread clearances. Do not
overwrap.
fNOTE: Unit: N·m (kgf·m, lbf·ft)

 Application Procedure
Check that the thread surface is clean and, free of dirt c
or damage. Apply the seal tape around threads in order
to leave one to two pitch threads uncovered. Wrap the
seal tape in the same direction as the threads.
d e
W105-01-01-019
c- Internal Thread e- Clearance
d- External Thread
Low-Pressure-Hose Clamp Tightening f
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.

T-Bolt Type Band Clamp:

4.5 N·m (0.45 kgf·m, 3.3 lbf·ft)

Worm Gear Type Band Clamp:

6 to 7 N·m (0.6 to 0.7 kgf·m, 4.4 to 5.2 lbf·ft)

f- Leave one to two pitch

M114-07-041
threads uncovered
g h

WDAA-01-02-012 M114-07-043
g- T-Bolt Type Band Clamp h- Worm Gear Type Band Clamp

W1-2-1-7
 SECTION 1 GENERAL
Group 2 Tightening

Connecting Hose

dCAUTION: When replacing the hoses, use only

genuine Hitachi service parts. Using hoses other
Incorrect Correct

than genuine Hitachi hoses may cause oil leaks,

hose rupture or separation of fitting, possibly
resulting in a fire on the machine. Do not install
hoses kinked. Application of high oil pressure,
vibration, or an impact to a kinked hose may
result in oil leaks, hose rupture or separation of
fitting. Utilize the print marks on hoses when W105-01-01-011
installing in order to prevent hose from being
kinked. Take necessary measures to protect hoses
from rubbing against each other. If the hoses rub Incorrect a Correct
against each other, wear to the hoses may result
and lead to hose rupture. Take care so that the
hoses do not come into contact with the moving
parts or sharp objects.
W105-01-01-012

a- Rubbing Against Each Other

Incorrect Correct
b b

W105-01-01-013
a- Rubbing Against Each Other b- Clamp

Incorrect Correct

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

W1-2-1-8
 SECTION 1 GENERAL
Group 3 Painting

Painting Specification

Surfaces to Be Painted Painting Colour

Main surface of upperstructure (except cab) YR-01 [TAXI yellow]
Main frame P1-01 [High Grade Black]
Inner HK1 Coat Primer gray
Step High Grade Black
Counterweight YR-01 [TAXI yellow]
Front attachment YR-01 [TAXI yellow]
Track N-1.0 [Black]
Floor plate M/F Cation (allowed)

Final Painted Color

Inside and outside surface of cab High Grade Black

Shaded area on cab (Only the left side) Shining Silver
Suspension lifter N2.0 [Black]
Lever (Travel, pilot shut-off, foot rest) High Grade Black
Eruption plate Deep Black
Ladder, Handrail High Grade Black
Mirror stay High Grade Black
Muffler exhaust pipe B701K (Black heat-resistant painting)

W1-3-1-1
 SECTION 1 GENERAL
Group 3 Painting

1 4

WJAA-01-03-003
WJAA-01-03-001
2

WJAA-01-03-002
A

WJBA-01-03-004
a

Section A

10 mm W1J1-01-03-005

WJAA-01-03-004

a- Paint all circumference in the lower hinge swing position shining

silver.
1- Ladder 3- Main Frame 5- Shaded Area on Cab
2- Step (Front, Rear) 4- Handrail 6- Cover [High Grade Black]

W1-3-1-2
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Hydraulic Oil Tank

dCAUTION: Escaping fluid under pressure may

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

Preparation
1. Park the machine on a solid and level surface.
Set the front attachment in position for checking 1 2 3
hydraulic oil level.

2. Stop the engine. Push air bleed button (1) of

hydraulic oil tank (3) and bleed air from hydraulic oil
tank (3).

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

W1R7-01-04-001

4. Install vacuum pump (a) to the position where cap

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

W1R7-01-04-002

a- Vacuum Pump
b- Hose
c- Adapter

W1-4-1-1
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Hydraulic System

Bleed air from the hydraulic system as follows when
hydraulic oil has been drawn, the suction filter and
suction pipe have been replaced, or the pump device,
swing motor, travel motor, cylinders have been removed/
installed.

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

W1-4-1-2
 SECTION 1 GENERAL
Group 4 Bleeding Air

Bleeding Air from Fuel System

Air in the fuel system may make the engine hard to
start or make it run irregularly.
After draining water and sediment from the fuel filter,
replacing the fuel filter, cleaning the fuel solenoid
pump strainer or running the fuel tank dry, be sure to
bleed the air from the fuel system.

Air Bleeding Procedures

This machine is equipped with a fuel solenoid pump.
d CAUTION: Fuel leaks may lead to fires.
1. Fill the fuel tank with fuel.
2. Check that fuel cock (1) near the fuel prefilter is
opened. 1
3. Set the key switch to the ON position and hold it in
MJAA-07-103
that position for approx. three minutes. Therefore,
the electrical fuel pump operates and starts to
bleed air.

dCAUTION:
time.
Bleed air in one fuel main filter (3) at a

4. While holding the key switch in the ON position,

loosen air bleed plug (4) of fuel main filter (3) and
reciprocate priming pump (2). After air is bled from 3
fuel main filter (3), tighten air bleed plug (4) and
return priming pump (2) to the original position.
5. Wipe off any spilled fuel.
6. After fuel main filter (3) is filled with fuel, hold the 2
key switch in the ON position for 30 seconds.
4
7. Start the engine. Check the fuel system for fuel M1GR-07-010
leaks. If the engine does not start, repeat the above
procedures from step 1.
IMPORTANT: Even if air is not thoroughly bled,
do not hold the key switch in the ON position
for more than five minutes. In case air is not
thoroughly bled, first return the key switch to the
OFF position. Then, after waiting for more than
30 seconds, set the key switch to the ON position
again. Failure to do so may cause damage to the
electrical pump and/or discharging the batteries.

W1-4-1-3
 SECTION 1 GENERAL
Group 4 Bleeding Air

Air Bleeding by Priming Pump

In case air is not bled due to malfunction of the fuel
solenoid pump, operating the priming pump only can
bleed air.
1. Fill the fuel tank with fuel.
2. Check that fuel cock (1) near the fuel prefilter is
opened.
3. Loosen air bleed plug (4) on fuel main filter (3).

j : 10 mm
4. Supply fuel by reciprocating priming pump (2). After
no air bubbles are spouted through air bleed plug 1
(4), tighten air bleed plug (4).
MJAA-07-103
j : 10 mm
5. After tightening air bleed plug (4), reciprocate
priming pump (2) approx. 150 strokes.
6. Wipe off any spilled fuel.
7. Start the engine. Check that no fuel leaks are
present. If the engine does not start, repeat the 3
above procedures from step 1.

Air Bleeding by Cranking

Bleed air from the fuel system after changing the 2
common rail.
1. Bleed air until the engine supply pump entrance
4
enough according to the above-mentioned M1GR-07-010
procedures.
2. Operate the starter motor for long cranking within
20 seconds. If the engine falls to start, return the key
switch to the OFF position. Wait more than about 60
seconds, then try again.

W1-4-1-4
 SECTION 1 GENERAL
Group 5 Pressure Release Procedure

Hydraulic Circuit Pressure Release Procedure

Release any remaining pressure as follows before
removing/installing the front attachment.

1. Set pilot shut-off lever (1) to the UNLOCK position.

2. Turn engine stop switch (2) ON.

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

W1-5-1-1
 SECTION 1 GENERAL
Group 5 Pressure Release Procedure

(Blank)

W1-5-1-2
 SECTION 1 GENERAL
Group 6 Preparation

Preparation before Inspection and

Maintenance
Before performing the maintenance procedures given in
the following chapters, park the machine as described
below, unless otherwise specified.

1. Park the machine on a level surface.

2. Lower the bucket to the ground. M104-07-021

3. Turn the auto-idle switch OFF.

4. Set the engine control dial to the slow idle position.
1
Run the engine at slow idle speed without load for
five minutes.
5. Set the key switch to the OFF position. Stop the
engine. Remove the key from the key switch. If
maintenance should be performed with the engine
running, do not leave the machine unattended.
6. Set pilot shut-off lever (1) to the LOCK position.
7. Before performing any work on the machine, attach
tag (2) on the door or control lever.

WDAA-01-06-001

W1-6-1-1
 SECTION 1 GENERAL
Group 6 Preparation

(Blank)

W1-6-1-2
MEMO
MEMO
SECTION 2

MAINTENANCE STANDARD
CONTENTS
Group 1 Upperstructure
Main Pump........................................................................W2-1-1-1
Fan Pump...........................................................................W2-1-1-2
Swing Motor.....................................................................W2-1-2-1
Group 2 Undercarriage
Travel Motor......................................................................W2-2-1-1
Sprocket.............................................................................W2-2-1-2
Center Joint.......................................................................W2-2-2-1
Front Idler..........................................................................W2-2-3-1
Upper Roller......................................................................W2-2-4-1
Lower Roller......................................................................W2-2-4-2
Track.....................................................................................W2-2-5-1
Group 3 Front Attachment
Remove and Install Bushing.......................................W2-3-1-1
Pin and Bushing...............................................................W2-3-1-3
Side Cutter.........................................................................W2-3-1-5
Point.....................................................................................W2-3-1-5
Standard Dimensions for Arm and Bucket
Connection..................................................................W2-3-1-6
Standard Dimensions for Arm and Boom
Connection..................................................................W2-3-1-8
Cylinder..............................................................................W2-3-2-1

JAAW-2-1
(Blank)

JAAW-2-2
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Main Pump
1. Clearance between plunger (32) outer diameter (A)
and cylinder block (27) bore diameter (B).
A B

B-A Unit: mm (in)

Standard Allowable Limit
0.038 (0.001) 0.078 (0.003)
W117-02-02-009

2. Free length (C) of cylinder spring (28)

C Unit: mm (in)
Standard Allowable Limit
41.8 (1.65) 41.0 (1.61)

3. Clearance (D) between plunger (32) and shoe

C
bottom and shoe thickness (E)
W117-02-02-010
D Unit: mm (in)
Standard Allowable Limit
0 to 0.1 (0 to 0.004) 0.35 (0.014)

E Unit: mm (in)
Standard Allowable Limit
D
5.4 (0.21) 5.0 (0.20) E

W117-02-02-011
4. The difference between the surface of retainer (30)
to the top of spherical bushing (29)

F-G Unit: mm (in) a

Standard Allowable Limit

23.8 (0.94) 22.8 (0.90) G F

W117-02-02-012

a- Base

W2-1-1-1
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Fan Pump
1. Clearance between plunger (6) outer diameter (A)
and cylinder block (4) bore diameter (B).
A B

B-A Unit: mm (in)

Standard Allowable Limit
0.02 (0.001) 0.05 (0.002)
W117-02-02-009

2. Free length (C) of spring (15)

C Unit: mm (in)
Standard Allowable Limit
34.5 (1.4) 33.2 (1.3)

3. Clearance (D) between plunger (6) and shoe bottom

C
and shoe thickness (E)
W117-02-02-010
D Unit: mm (in)
Standard Allowable Limit
0.1 (0.004) 0.2 (0.008)

E Unit: mm (in)
Standard Allowable Limit
D
4.0 (0.16) 3.9 (0.15) E

W117-02-02-011
4. The difference between the surface of retainer (8) to
the top of holder (9)

F-G Unit: mm (in) a

Standard Allowable Limit

4.0 (0.16) 3.6 (0.14) G F

W117-02-02-012

a- Base

W2-1-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

Swing Motor
1. Clearance between plunger outer diameter (A) and
rotor inner bore (B)
A
B-A Unit: mm (in)
Standard Allowable Limit
0.027 (0.0011) 0.052 (0.0020)

W107-02-06-138

B B

2. Clearance (C) between plunger (6) and shoe bottom

C Unit: mm (in)
W107-02-06-139
Standard Allowable Limit
0 (0) 0.3 (0.0118)

W107-02-06-140

W107-02-06-141

W2-1-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure

3. Shoe thickness (D)

D Unit: mm (in)
Standard Allowable Limit
5.5 (0.22) 5.3 (0.21)
D

W107-02-06-142

4. Friction plate (11) thickness (E)

E

E Unit: mm (in)
Standard Allowable Limit
2.0 (0.08) 1.8 (0.07) W107-02-06-143

W2-1-2-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Travel Motor
1. Clearance between inner diameter (A) of rotor (14)
and outer diameter (B) of plunger (10):

A-B: 0.06 mm (0.002 in) or less

A B

W507-02-04-009
2. Clearance between plunger (10) and shoe engaging
(C):

C: 0.4 mm (0.016 in) or less

3. Clearance between inner diameter (D) and outer

diameter (E) at the mounting position (4) of housing
(1) and piston (4): W107-02-06-140

D-E: 0.03 mm (0.001 in) or less

4. Wear amount on the sliding surfaces of rotor (14)

and valve plate (15):
Check there is no abnormal scratch, wear or score.
D
Damage and wear amount within 0.02 mm (0.001
in) or less.

W162-03-02-005

W2-2-1-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Sprocket

B
C
D

E
A

W105-03-07-042

Unit: mm (in)
Standard Allowable Limit Remedy
A 92 (3.6) [82 (3.2)]
B 131.6 (5.2) 126.6 (4.9)
C 167.6 (6.6) - Build up and finishing
D 177.5 (7.0) 172.5 (6.8)
E 215.9 (8.5) -

fNOTE: Value in [ ] is just for reference.

W2-2-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Center Joint

Item Allowable Limit (basis of judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Seizure and abnormal wear Replace
3. Uneven wear within 180 ˚
Wear Area Within
Half Range
Bushing
Replace

T157-01-01-040
Sliding surface
Heavily damaged one by seizure or foreign matter Replace
with seals
Sliding surface 1 Excessively worn one by seizure or foreign matter, or one
between body Replace
having the score of 0.1 mm (0.004 in) or more
and spindle other
than sliding Repair the surface
surfaces with 2 One having the score of less than 0.1 mm (0.004 in) smooth by using
seals an oil stone
Body, Spindle
1 One that has worn 0.5 mm (0.02 in) or more, or excessively
Replace
worn
Repair the surface
Sliding surface 2 One that has worn 0.5 mm (0.02 in) or less
smooth
with ring
3 One that has scores due to seizure or foreign matter but
Repair the surface
the damage is less than the allowable wear limit 0.5 mm
smooth
(0.02 in) and is repairable
1 One that has worn 0.5 mm (0.02 in) or more Replace
Repair the surface
Sliding surface 2 One that has worn less than 0.5 mm (0.02 in)
Cover smooth
with ring
3 One that has scores due to seizure or foreign matter but
Repair the surface
the damage is less than the allowable wear limit 0.5 mm
smooth
(0.02 in) and is repairable

W2-2-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

(Blank)

W2-2-2-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Front Idler

C
D

E
A
W166-03-05-001
B

Unit: mm (in)
Standard Allowable Limit Remedy
A 102 (4.0) [82.3 (3.2)]
B 200 (7.9) -
Cladding by welding and
C 630 (24.8) [591.6 (23.3)]
finish or replace
D 675 (26.6) -
E 45 (1.8) -

Axle and Bushing

Standard Allowable Limit Remedy

Axle Outside Dia. 110 (4.33) [109.2 (4.30)]
Inside Dia. 110 (4.33) [111 (4.37)] Replace
Bushing
Flange Thickness 6 (0.24) [5.2 (0.21)]

fNOTE: Values in [ ] are just for reference.

W2-2-3-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

(Blank)

W2-2-3-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Upper Roller
Roller

W157-03-06-003

Unit: mm (in)
Standard Allowable Limit Remedy
A 103 (4.1) -
B 210 (8.3) - Replace
C 170 (6.7) [160 (6.3)]

Axle and Bushing

Unit: mm (in)
Standard Allowable Limit Remedy
Axle Outside Dia. 60 (2.4) [59.2 (2.3)]
Inside Dia. 60 (2.4) [61 (2.4)] Replace
Bushing
Flange Thickness 4.5 (0.2) [3.7 (0.1)]

fNOTE: The values in [ ] are just for reference.

W2-2-4-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Lower Roller
Roller

W157-03-06-003

Unit: mm (in)
Standard Allowable Limit Remedy
A 214 (8.4) [249 (9.8)]
B 284 (11.2) - Cladding by welding and
C 35 (1.4) [17.5 (0.7)] finish or replace
D 200 (7.9) [182 (7.2)]

Axle and Bushing

Unit: mm (in)
Standard Allowable Limit Remedy
Axle Outside Dia. 85 (3.3) [84.2 (3.3)]
Inside Dia. 85 (3.3) [86 (3.4)] Replace
Bushing
Flange Thickness 6 (0.2) [5.2 (0.2)]

fNOTE: The values in [ ] are just for reference.

W2-2-4-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Track
Link
Measure the length of four links.
1. Do not measure the part included the master pin.
2. Measure the length with tension on the track.

W155-03-07-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 863.6 (34) [905.3 (35.6)] Cladding by welding and
B 129 (5.1) [122 (4.8)] finish or replace

Master Pin

C B C

A W800-03-07-028

Unit: mm (in)
Standard Allowable Limit Remedy
A 254 (10) -
B 47.3 (1.86) [44.3 (1.74)] Replace
C 47.57 (1.87) -

fNOTE: The values in [ ] are just for reference.

W2-2-5-1
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Master Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Limit Remedy
A 160.8 (6.3) -
B 47.9 (1.89) [59.9 (2.36)] Replace
C 71.35 (2.81) [66.4 (2.61)]

Grouser Shoe

W105-03-07-024

Unit: mm (in)
Standard Allowable Limit Remedy
A 247 (9.7) -
B 15 (0.6) - Replace
C 36 (1.4) 24 (0.9)

fNOTE: The values in [ ] are just for reference.

W2-2-5-2
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Limit Remedy
A 169 (6.7) -
B 48.4 (1.91) [49.4 (1.95)] Replace
C 71.35 (2.81) [66.4 (2.61)]

Pin

A W142-03-07-004

Unit: mm (in)
Standard Allowable Limit Remedy
A 254 (10) - Cladding by welding and
B 47.6 (1.87) [44.6 (1.76)] finish or replace

fNOTE: The values in [ ] are just for reference.

W2-2-5-3
 SECTION 2 MAINTENANCE STANDARD
Group 2 Undercarriage

(Blank)

W2-2-5-4
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Remove and Install Bushing

D
C

W166-04-02-005

1 2 1 2 1 2 1 2 3

2
A: Bucket and Link A
W166-04-02-012

1 2 3

B: Link A C: Boom and Arm

W166-04-02-013 W166-04-02-014

1 2 3 2 1 2 3

D: Boom and Main Frame E: Arm and Link B F: Arm and Bucket
W166-04-02-010 W166-04-02-015 W166-04-02-016

1- Dust Seal 2- Bushing 3- Spacer

W2-3-1-1
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Removal
1. Remove dust seal (1) and bushing (2).

fNOTE: If bushing (2) cannot be removed, burn off

bushing (2).

Installation
1. Cool bushing (2) by using dry ice.
2. Install bushing (2) and dust seal (1).
Install bushing (2) by using the following plate.

Plate when installing bushing

A: Bucket side ............................................ ST 2881
Link A side ............................................. ST 2873
B: Link A ...................................................... ST 2873
C: Arm ......................................................... ST 2877
D: Boom side ............................................. ST 2877
Main frame side .................................. ST 2886
E: Arm .......................................................... ST 2882
F: Bucket side ............................................ ST 2881
Arm side .................................................. ST 2873

W2-3-1-2
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Pin and Bushing

D F
C G

H
B I

E
A
K
J

W105-04-01-018

Unit: mm (in)
Position Item Standard Allowable Limit
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Frame Side) 110 (4.33) 111.5 (4.39)
A: Boom Cylinder and Main Frame Bushing Outer Dia. 130 (5.12) -
Bearing Inner Dia. (Cylinder Side) 110 (4.33) 111.5 (4.39)
Pin Outer Dia. 120 (4.72) 119 (4.69)
Bushing Inner Dia. (Frame Side) 120 (4.72) 121.5 (4.78)
B: Boom and Main Frame Bushing Outer Dia. 140 (5.51) -
Bushing Inner Dia. (Boom Side) 120 (4.72) 121.5 (4.78)
Bushing Outer Dia. 140 (5.51) -
Pin Outer Dia. 120 (4.72) 119 (4.69)
C: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 120 (4.72) -
Bearing Inner Dia. (Cylinder Side) 120 (4.72) 121.5 (4.78)

W2-3-1-3
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Unit: mm (in)
Position Item Standard Allowable Limit
Pin Outer Dia. 110 (4.33) 109 (4.29)
D: Boom and Arm Cylinder Pin Hole Inner Dia. (Boom Side) 110 (4.33) -
Bearing Inner Dia. (Cylinder Side) 110 (4.33) 111.5 (4.39)
Pin Outer Dia. 120 (4.72) 119 (4.29)
Bushing Inner Dia. (Boom Side) 120 (4.72) 121.5 (4.78
E: Boom and Arm Bushing Outer Dia. 140 (5.51) -
Bushing Inner Dia. (Arm Side) 120 (4.72) 121.5 (4.78)
Bushing Outer Dia. 140 (5.51) -
Pin Outer Dia. 110 (4.33) 109 (4.29)
F: Arm Cylinder and Arm Pin Hole Inner Dia. (Arm Side) 110 (4.33) -
Bearing Inner Dia. (Cylinder Side) 110 (4.33) 111.5 (4.39)
Pin Outer Dia. 100 (3.94) 99 (3.90)
G: Arm and Bucket Cylinder Pin Hole Inner Dia. (Arm Side) 100 (3.94) -
Bearing Inner Dia. (Cylinder Side) 100 (3.94) 101.5 (4.00)
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Link A Side) 110 (4.33) 111.5 (4.39)
H: Bucket Cylinder and Link Bushing Outer Dia. 130 (5.12) -
Bearing Inner Dia. (Cylinder Side) 110 (4.33) 111.5 (4.39)
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Link A Side) 110 (4.33) 111.5 (4.39)
I: Link and Bucket Bushing Outer Dia. 130 (5.12) -
Bushing Inner Dia. (Bucket Side) 110 (4.33) 109 (4.29)
Bushing Outer Dia. 130 (5.12) -
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Arm Side) 110 (4.33) 111.5 (4.39)
J: Arm and Bucket Bushing Outer Dia. 130 (5.12) -
Bushing Inner Dia. (Bucket Side) 110 (4.33) 111.5 (4.39)
Bushing Outer Dia. 130 (5.12) -
Pin Outer Dia. 100 (3.94) 99 (3.90)
K: Arm and Link Bushing Inner Dia. (Arm Side) 100 (3.94) 101.5 (4.00)
Bushing Outer Dia. 115 (4.53) -

IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a press.

W2-3-1-4
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Side Cutter

B A

W166-04-01-011

Unit: mm (in)
Standard Allowable Limit Remedy
A 305 (12.0) 200 (7.9)
Replace
B 40 (1.6) -

Point

B C

A
W1J1-04-01-002

Unit: mm (in)
Standard Allowable Limit Remedy
A 254 (10.0) 127 (5.0)
B 140 (5.5) -
Replace
C 137 (5.4) -
D 129 (5.1) -

W2-3-1-5
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Standard Dimensions for Arm and Bucket

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

Section A Section B

WJAA-02-03-001

W2-3-1-6
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Unit: mm (in)
Model ZX470-5B ZX450-3/500LC-3 ZX450 ZX400-5
a 520 (20.47)   
b 10 (0.39)   
c 750 (29.53)   
d 710 (27.95)   
e - - - -
f 1911 (75.24)  1896 (74.65) 
g -  643 (25.32) 
470.5 to 471.0
h   
(18.52 to 18.54)
i 130 (5.12)   
j 558 (21.97)   
k 106 (4.17)   
l 648 (25.51)  643 (25.32) 
m 471 (18.54)   
n 130 (5.12)   
o 45 °   
p 45 °   
q 680 (26.77)   

fNOTE: Dimension h: 470.5 to 471.0 mm (18.52 to 18.54

in) includes the clearance for shims to adjust bucket
clearance.
Dimensions o and p: 45 ° means the angle for the bolt
hole.

W2-3-1-7
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Standard Dimensions for Arm and Boom

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

Section C

WJAA-02-03-002

Unit: mm (in)
Model ZX470-5B ZX450-3/500LC-3 ZX450 EX400-5
s 140 (5.51)   
t 471 (18.54)   
u 632 (24.88)   

W2-3-1-8
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

Cylinder
Rod Rod Bend and Run Out
a b
A

1m
W105-04-02-094 c W166-04-02-022

a- Cylinder Rod c- V Block

b- Dial Gauge
Unit: mm (in) Unit: mm (in)
Recommended Size After Bend Run Out Remedy
Cylinder Name
Re-manufacturing (A) 0.5 (0.02) 1.0 (0.04) Repair
Boom 115-0.012-0.027 (4.5-0.0005-0.0011) 1.0 (0.04) 2.0 (0.08) Replace
Arm 130+0.031-0.061 (5.1+0.0012-0.0024)
Bucket 120+0.027-0.057 (4.7+0.0011-0.0022)

W2-3-2-1
 SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment

(Blank)

W2-3-2-2
MEMO
MEMO
SECTION 3

UPPERSTRUCTURE
CONTENTS
Group 1 Cab Group 11 Pilot Valve
Removal and Installation of Cab...............................W3-1-1-1 Removal and Installation of Pilot Valve (Left).... W3-11-1-1
Dimensions of Cab Glass (Standard Cab)...............W3-1-2-1 Removal and Installation of Pilot Valve
Dimensions of Cab Glass (H Cab)........................... W3-1-2-20 (Right)......................................................................... W3-11-2-1
Removal and Installation of Travel Pilot
Group 2 Counterweight Valve............................................................................ W3-11-3-1
Removal and Installation of Counterweight.........W3-2-1-1 Disassembly of Pilot Valves (Right and Left)...... W3-11-4-1
Group 3 Main Frame Assembly of Pilot Valves (Right and Left)............ W3-11-4-4
Removal and Installation of Main Frame................W3-3-1-1 Disassembly of Travel Pilot Valve............................ W3-11-5-1
Assembly of Travel Pilot Valve................................. W3-11-5-5
Group 4 Engine
Removal and Installation of Engine.........................W3-4-1-1 Group 12 Solenoid Valve
Removal and Installation of Pilot Shut-Off
Group 5 Radiator Solenoid Valve......................................................... W3-12-1-1
Removal and Installation of Radiator......................W3-5-1-1 Removal and Installation of 4-Spool Solenoid
Group 6 Hydraulic Oil Tank Valve Unit ................................................................. W3-12-2-1
Removal and Installation of Hydraulic Oil Removal and Installation of 2-Spool Solenoid
Tank................................................................................W3-6-1-1 Valve Unit ................................................................. W3-12-3-1
Removal and Installation of Fan Pump
Group 7 Fuel Tank Control Solenoid Valve......................................... W3-12-4-1
Removal and Installation of Fuel Tank.....................W3-7-1-1 Disassembly of Pilot Shut-Off Solenoid
Valve............................................................................ W3-12-5-1
Group 8 Pump Device Assembly of Pilot Shut-Off Solenoid Valve......... W3-12-5-3
Removal and Installation of Pump Device.............W3-8-1-1
Structure of 4-Spool Solenoid Valve Unit............ W3-12-6-1
Disassembly of Main Pump.........................................W3-8-2-1
Structure of 2-Spool Solenoid Valve Unit............ W3-12-7-1
Assembly of Main Pump...............................................W3-8-2-6
Structure of Fan Pump Solenoid Valve................. W3-12-8-1
Disassembly of Regulator for Main Pump..............W3-8-3-1
Assembly of Regulator for Main Pump...................W3-8-3-3 Group 13 Signal Control Valve
Disassembly of Fan Pump............................................W3-8-4-1 Removal and Installation of Signal Control
Assembly of Fan Pump.................................................W3-8-4-5 Valve............................................................................ W3-13-1-1
Structure of Pilot Pump................................................W3-8-5-1 Structure of Signal Control Valve........................... W3-13-2-1
Group 9 Control Valve Group 14 Shockless Valve
Removal and Installation of Control Valve.............W3-9-1-1 Removal and Installation of Shockless Valve..... W3-14-1-1
Disassembly and Assembly of Valve Unit...............W3-9-2-1 Structure of Shockless Valve.................................... W3-14-2-1
Disassembly of Control Valve (4-Spool Side)........W3-9-3-1
Assembly of Control Valve (4-Spool Side)..............W3-9-3-9 Group 15 Fan Valve
Disassembly of Control Valve (5-Spool Side)........W3-9-4-1 Removal and Installation of Fan Valve.................. W3-15-1-1
Assembly of Control Valve (5-Spool Side)..............W3-9-4-8 Structure of Fan Valve................................................. W3-15-2-1

Group 10 Swing Device Group 16 Fan Motor

Removal and Installation of Swing Device......... W3-10-1-1 Removal and Installation of Fan Motor................ W3-16-1-1
Disassembly of Swing Device.................................. W3-10-2-1 Structure of Fan Motor............................................... W3-16-2-1
Assembly of Swing Device....................................... W3-10-2-7 Group 17 Muffler Filter
Disassembly of Swing Motor................................... W3-10-3-1 Removal and Installation of Muffler Filter........... W3-17-1-1
Assembly of Swing Motor......................................... W3-10-3-4 Disassembly of Muffler Filter................................... W3-17-2-1
Assembly of Muffler Filter......................................... W3-17-2-5

JAAW-3-1
(Blank)

JAAW-3-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Removal and Installation of Cab

6 3 2

5 4 1 WDAA-03-01-023 WJAA-03-01-013

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition, d CAUTION: Seat (2) weight: 46 kg (105 lb)
attach an identification tag onto the connectors, 3. Remove socket bolts (3) (4 used). Remove seat (2).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which l : 6 mm
secure the hoses have been removed. 4. Remove floor mat (4).
5. Remove bolts, washers (5) (4 used). Remove travel
Removal control levers (6) (2 used).
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.) j : 17 mm

2. Open door (1).

W3-1-1-1
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

9
B

WDAA-03-01-048

Detail A 7
14 12 WDAA-03-01-050

11 10 11
Detail B

8 7 WDAA-03-01-049
13 WDAA-03-01-051

6. Remove bolts, washers (7) (3 used). Remove bracket

(8).

j : 19 mm
7. Remove cover (9).
8. Disconnect plug (10) and connectors (11) (2 used).
9. Remove bolt, washer (12) and screw (13). Remove
cover (14).

j : 13 mm

W3-1-1-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

15 29 26, 28 68 69 33 31

A B

25

20, 21

20, 21 22, 23, 24

WDAA-03-01-052
WDAA-03-01-053
32 30
18
71 70
Detail A Detail B

WDAA-03-01-062 WDAA-03-01-065
19 16, 17, 18

10. Open cover (15). 14. Remove caps (26) (2 used). Remove screws (28) (2
used). Remove cover (29) and duct (33).
11. Remove caps (16) (2 used). Remove seals (17) (2
used) and screws (18) (3 used). Remove cover (19). 15. Remove bolts, washers (30) (2 used).
12. Remove bolts, washers (20) (2 used) and washers j : 17 mm
(21) (2 used).
16. Remove bolt, washer (31). Remove cover (32).
j : 13 mm
j : 13 mm
13. Remove caps (22) (3 used). Remove seals (23) (3
used) and screws (24) (3 used). Remove cover (25). 17. Remove screws (68) (2 used). Remove duct (69).
18. Remove bolt, washer (70). Remove duct (71).

j : 13 mm

W3-1-1-3
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

A B

WDAA-03-01-063 WDAA-03-01-064

34
Detail A Detail B

34 35 34 WDAA-03-01-054 37 36 37 WDAA-03-01-055

19. Remove clip (35).

20. Disconnect connectors (34) (7 used).
21. Remove clip (36).
22. Disconnect connectors (37) (4 used).

W3-1-1-4
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

1 41 A

43
44

WJAA-03-01-015
42

Detail A 46 45

38 40 39
WDAA-03-01-056

48 47
TDAA-05-08-006

23. Shut door (1). 29. Remove bolt (45). Disconnect connector (46).
24. Open cover (38). j : 13 mm
25. Remove filter (39). 30. Push the lock and shift lever (47). Disconnect
26. Remove screws (40) (6 used). Remove filter case (41). connector (48).

27. Open cover (42). 31. Open door (1).

28. Remove bolts, washers (43) (4 used). Remove cover

(44).

j : 17 mm

W3-1-1-5
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

49

WJAA-03-01-016
73 72

WJAA-03-01-014

a- Lifting Bracket

d CAUTION: The cab (49) assembly weight:

Standard machine: 450 kg (995 lb)
H spec. machine: 550 kg (1220 lb)

32. Attach nylon slings onto lifting bracket (a) (4 places)

of cab (49). Hoist and hold the cab (49) assembly.

dDo
CAUTION: Remove cover (72) while holding it.
not drop cover (72).
33. Remove bolts, washers (73) (6 used). Remove cover
(72).

j : 19 mm

W3-1-1-6
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

55, 56 54 55, 56 52, 53

74, 75, 76

WJAA-03-01-017

54 52, 53 54 55, 56 50, 51 55, 56

WJAA-03-01-018

34. Remove bolt (74), washer (75), and spacer (76). 37. Remove bolts, washers (54) (5 used).

j : 32 mm j : 17 mm
35. Remove socket bolts (50) (2 used) and washers (51) 38. Remove nuts (55) (4 used) and washers (56) (4 used).
(2 used). Remove the cab (49) assembly.

l : 8 mm j : 24 mm
36. Remove socket bolts (52) (5 used) and washers (53)
(5 used).

l : 8 mm

W3-1-1-7
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

57 60 61 62 63 Detail A 66

66

64

59 62

WDAA-03-01-061
58 65

64

57 60 77 62 WDAA-03-01-060

67
WDAA-03-01-067

39. Disconnect connectors (57) (5 used). 44. Remove bolts, washers (64) (4 used). Remove MC
(65).
40. Remove screws (58) (4 used). Remove monitor
controller (59). j : 13 mm
41. Remove bolt, washer (77).
d(64
CAUTION:
lb)
Bracket assembly (67) weight: 29 kg
j : 17 mm
45. Remove bolts, washers (66) (6 used). Remove
42. Remove screws (60) (4 used). Disconnect connector
bracket assembly (67).
(61).
43. Remove screws (62) (5 used). Remove cover (63). j : 17 mm

W3-1-1-8
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

57 60 61 62 63 Detail A 66

66

64

59
62
WDAA-03-01-061
58 65

64

57 60 77, 78 62 WDAA-03-01-060

67
WDAA-03-01-067

Installation 4. Connect connector (61) with screws (60) (4 used).

d(64
CAUTION:
lb)
Bracket assembly (67) weight: 29 kg 5. Install clamp (78) with bolt, washer (77).

j : 17 mm
1. Install bracket assembly (67) with bolts, washers (66)
(6 used). m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm 6. Install monitor controller (59) with screws (58) (4

used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
7. Connect connectors (57) (5 used).
2. Install MC (65) with bolts, washers (64) (4 used).

j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Install cover (63) with screws (62) (5 used).

W3-1-1-9
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

a 55, 56 54 55, 56 52, 53

49

WJAA-03-01-014
54 52, 53 54 55, 56 50, 51 55, 56
a- Lifting Bracket WJAA-03-01-018

11. Install washers (53) (5 used) and socket bolts (52) (5

d CAUTION: The cab (49) assembly weight: used).
Standard machine: 450 kg (995 lb)
j : 8 mm
H spec. machine: 550 kg (1220 lb)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
8. Attach nylon slings onto lifting bracket (a) (4 places)
of cab (49). Hoist the cab (49) assembly. 12. Install washers (51) (2 used) and socket bolts (50) (2
used).
9. Install the cab (49) assembly with washers (56) (4
used) and nuts (55) (4 used). j : 8 mm
j : 24 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 210 N·m (21 kgf·m, 155 lbf·ft)
10. Install bolts, washers (54) (5 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-10
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

74, 75, 76

WJAA-03-01-017 WJAA-03-01-016
73 72

13. Install spacer (76), washer (75), and bolt (74).

j : 32 mm

m : 400 N·m (40 kgf·m, 300 lbf·ft)

14. Install cover (72) with bolts, washers (73) (6 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-1-1-11
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

1 41
A

43
44

WJAA-03-01-015
42

Detail A 46 45

38 40 39
WDAA-03-01-056

48 47
TDAA-05-08-006

15. Open cover (42). 19. Open cover (38).

16. Connect connector (48). Shift lever (47) and lock it. 20. Install filter case (41) with screws (40) (6 used).
IMPORTANT: Do not use an impact wrench when 21. Install filter (39).
tightening bolt (45). Using an impact wrench may
22. Shut cover (38).
result in damage to the cover.
17. Connect connector (46) with bolt (45). 23. Open door (1).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

18. Install cover (44) with bolts, washers (43) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-12
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

A B

WDAA-03-01-063 WDAA-03-01-064

34
Detail A Detail B

34 35 34 WDAA-03-01-054 37 36 37 WDAA-03-01-055

24. Connect connectors (37) (4 used).

25. Install clip (36).
26. Connect connectors (34) (7 used).
27. Install clip (35).

W3-1-1-13
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

15 29 26, 28 68 69 33 31

A B

25

20, 21

20, 21 22, 23, 24

WDAA-03-01-052
WDAA-03-01-053
32 30
18
71 70
Detail A Detail B

WDAA-03-01-062 WDAA-03-01-065
19 16, 17, 18

28. Install duct (71) with bolt, washer (70). 33. Install cover (25) with screws (24) (3 used). Install
seals (23) (3 used) and caps (22) (3 used).
j : 13 mm
34. Install washers (21) (2 used) and bolts, washers (20)
m : 20 N·m (2 kgf·m, 15 lbf·ft) (2 used).
29. Install duct (69) with screws (68) (2 used). j : 13 mm
30. Install cover (32) with bolt, washer (31).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
j : 13 mm 35. Open cover (15).
m : 20 N·m (2 kgf·m, 15 lbf·ft) 36. Install cover (19) with screws (18) (3 used). Install
seals (17) (2 used) and caps (16) (2 used).
31. Install bolts, washers (30) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

32. Install duct (33) and cover (29) with screws (28) (3
used). Install caps (26) (2 used).

W3-1-1-14
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

9
B

WDAA-03-01-048

Detail A 7
14 12 WDAA-03-01-050

11 10 11
Detail B

8 7 WDAA-03-01-049
13 WDAA-03-01-051

37. Install cover (14) with screw (13) and bolt, washer
(12).

j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

38. Connect connectors (11) (2 used) and plug (10).
39. Install cover (9).
40. Install bracket (8) with bolts, washers (7) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-1-1-15
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

6 3 2

5 4 1 WDAA-03-01-023 WJAA-03-01-013

41. Install travel control levers (6) (2 used) with bolts,

washers (5) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

42. Install floor mat (4).

d CAUTION: Seat (2) weight: 46 kg (105 lb)

43. Install seat (2) with socket bolts (3) (4 used).

j : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-1-1-16
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Dimensions of Cab Glass (Standard Cab)

Unit: mm Section A

WDAA-03-01-036

WDAA-03-01-030

a- Black Ceramic Painted b- Black Ceramic Painted Range WDAA-03-01-001

Surface

Section B Detail C

a- Black Ceramic Painted

WDAA-03-01-002
Surface WDAA-03-01-035

W3-1-2-1
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

WDAA-03-01-030

a- Black Ceramic Painted WDAA-03-01-034

Surface

Section A

a- Black Ceramic Painted WDAA-03-01-037

Surface

W3-1-2-2
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Section A

WDAA-03-01-004

WDAA-03-01-031

a- Chamfer along the Periphery WDAA-03-01-003

W3-1-2-3
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Section A

WDAA-03-01-006

WDAA-03-01-031

a- Chamfer along the Periphery WDAA-03-01-005

W3-1-2-4
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm Section A

WDAA-03-01-038
WDAA-03-01-031 a- Black Ceramic Painted d- Shaded Paint along the
Surface Periphery Here

a- Black Ceramic Painted c- Chamfer here. WDAA-03-01-007

Surface
b- Black Ceramic Painted Range

Section B Section C

WDAA-03-01-008 WDAA-03-01-009

W3-1-2-5
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

WDAA-03-01-031

a- Black Ceramic Painted b- Black Ceramic Painted Range WDAA-03-01-010

Surface

Section A Detail B

WDAA-03-01-038 WDAA-03-01-011

a- Black Ceramic Painted d- Shaded Paint along the

Surface Periphery Here

W3-1-2-6
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

WDAA-03-01-031

a- Black Ceramic Painted WDAA-03-01-012

Surface
b- Black Ceramic Painted Range
c- Chamfer here.

Section A Section B

a- Black Ceramic Painted WDAA-03-01-038 WDAA-03-01-008

Surface
d- Dotted edge along the
Periphery Here

W3-1-2-7
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm Section A

a- Black Ceramic Painted WDAA-03-01-038

WDAA-03-01-030 Surface
d- Shaded Paint along the
Periphery Here

WDAA-03-01-013
a- Black Ceramic Painted b- Black Ceramic Painted Range
Surface

W3-1-2-8
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedure to Remove Cab Glass

Procedures to Remove Right-Hand Glass (1), Rear Left- 1

Hand Glass (2), Lower Door Glass (3), and Rear Glass (4)

dCAUTION: When removing the broken or cracked

glass, the glass shards may cause serious injury.
Before removing, use the duct tape or equivalent
in order to paste the broken or cracked glass and
reinforce them. Remove the glass pieces away.
WDAA-03-01-030
1. Remove resin panel (5), garnish (6), and the spacer
around the glass.

6
2

6
2. Prick a hole in adhesive (b) by using awl (a) (or a
knife). 3
5 WDAA-03-01-031

7
8
a

3. Pass piano wire (c) (or a metal wire) through the b

hole. W1SE-02-01-033

7- Cab a- Awl
8- Glass b- Adhesive

c- Piano Wire W1SE-02-01-034

W3-1-2-9
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

IMPORTANT: The piano wire is easily broken if a part

of the piano wire turns hot. Change the position 7 a
and cut the adhesive.
4. Wind the both ends of the piano wire onto the 8
screwdriver. Draw the wire back and forth in order
to cut adhesive (b) between cab (7) and glass (8).
Remove glass (8) from cab (7).

fNOTE: Cut off the middle of adhesive between glass

and cab. b
c

a- Cab Outside W1SE-02-01-035

b- Adhesive
c- Cab Inside

W3-1-2-10
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedure to Install Cab Glass

Procedures to Install Right-Hand Glass (1), Rear Left-Hand 1

Glass (2), Lower Door Glass (3), and Rear Glass (4)

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

fNOTE: Do not damage the cab (7) paint.

WDAA-03-01-030

3
2 WDAA-03-01-031
2. Clean the cutting edge of adhesive at cab (7) side by
using white spirit. 7

W1SE-02-01-036
IMPORTANT: Primer should be shaken for about 1
minute and mix thoroughly before opening the a- Knife b- Cut off adhesive by 1 to 2 mm
cap. After opening Primer, apply Primer as quickly deep.
as possible and close the cap immediately after
using. After opening Primer, all the contents
should be used within 180 days (or 2 hours with
the cap off). 7
3. Apply Primer for paint (Sika Aktivator DM-1) to the c
cutting edge of adhesive at cab (7) side by using a
brush. Wait for about 15 minutes in order to let it d
dry by itself.

W1SE-02-01-038

c- Apply Primer by using a d- Cutting edge of adhesive at

brush. cab (7) side

W3-1-2-11
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

4. Clean the mating edge of the new glass by using

clean rag and ethyl alcohol.

IMPORTANT: Primer (Sika Primer 206G+P) should

be shaken for about 1 minute and mix thoroughly
before opening the cap. After opening Primer,
apply Primer as quickly as possible and close
the cap immediately after using. After opening
Primer, all the contents should be used within 180
days (or 2 hours with the cap off).
5. Apply Primer for glass (Sika Primer 206G+P) to the
cutting edge of adhesive at cab side by using a
brush. Wait for about 15 minutes in order to let it
dry by itself.
6. Install the spacer with facing to the glass surface by
using the instant adhesive. (As for the positions to
install spacers A, B, and C dam rubber, refer to W3-1-
2-14 to W3-1-2-16.)
7. Cut off the nozzle of adhesive cartridge (Sika Tack
Go!) into V-shaped by using a knife. (As for the
cutting procedure of nozzle, refer to W3-1-2-17.)
8. Remove the seal of the cartridge end. Install the
V-shaped nozzle.
9. Install the cartridge to the manual manual caulking
gun.
10. Apply adhesive to the adhesive position at cab side
so that the bead triangle may be even. (As for the
position to apply adhesive, refer to W3-1-2-17.)
11. Raise the glass by using the suction lifter (rubber
sucker 4355282), and adhere it to the cab within 5
minutes.

fNOTE: Install the glass while fitting the spacer position

on the glass. Remove all adhesive except the mounting
surface, before solidifying by using white spirit.
12. Secure the glass by using the duct tape until the
adhesive becomes solid in order to prevent them
from being mispositioned or coming off. (Refer to
W3-1-2-13.)

fNOTE: Time for adhesive (Sika Tack Go!) to become

solid: 8 hours (just for reference)

W3-1-2-12
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Rear Glass Right-Hand Glass

WDAA-03-01-039

Rear Left-Hand Glass

WDAA-03-01-040

Lower Door Glass

WDAA-03-01-041 WDAA-03-01-042

Spacer A Spacer B Spacer C

WDAA-03-01-043 WDAA-03-01-044 WDAA-03-01-045

a- Two-Side Adhesive Tape a- Two-Side Adhesive Tape

Dam Rubber

WDAA-03-01-046

W3-1-2-13
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Left-Hand Glass

1- Spacer A a- From Radius Curve End

WDAA-03-01-014
2- Dam Rubber b- Glass External Form Line
3- Stopper c- Adhesive Range

Section A Section B Section C

WDAA-03-01-017 WDAA-03-01-018 WDAA-03-01-019

d- Clearance between glass and panel: 6 mm e- Glass e- Glass
e- Glass

Section D Detail E

WDAA-03-01-020 WDAA-03-01-024
e- Glass f- Apply Super X.

W3-1-2-14
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Right-Hand Glass

1- Spacer A a- From Radius Curve End WDAA-03-01-016

2- Spacer C b- Glass External Form Line
3- Dam Rubber c- Adhesive Range

Section A Section B Section C

WDAA-03-01-022 WDAA-03-01-027 WDAA-03-01-028

e- Glass d- Glass and panel: Clearance OR-02: 8 mm a- From Radius Curve End
e- Glass e- Glass

W3-1-2-15
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Unit: mm

Rear Glass

Section A

WDAA-03-01-021

a- From Radius Curve End

e- Glass

WDAA-03-01-015

1- Spacer B b- Glass External Form Line

a- From Radius Curve End c- Adhesive Range

Section B Section C

WDAA-03-01-025 WDAA-03-01-026

d- Glass and panel: Clearance e- Glass

OR-02: 8 mm
e- Glass

W3-1-2-16
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

8 to 9 mm

a
13 to 15 mm
b

W1SE-02-01-027
12
W1SE-02-01-043
b- Cut nozzle end into V-shaped. f
W1JB-02-01-031
a- Apply adhesive (bead) here. e- Apply bead so that bead triangle may be
even.
f- Panel

W1SE-02-01-028

c- Remove the seal.

d- Adhesive Cartridge

13. The required amount (just for reference) of adhesive and primer

Painted Surface or Glass Surface

Adhesive Surface
Adhesive Primer Primer
Sika Tack Go! Sika Aktivator DM-1 Sika Primer 206G+P

310 ml Cartridge 250 ml Can 30 ml Bottle

Lower Door Glass 170 ml 0.6 ml 0.5 ml
Rear Left-Hand Glass 220 ml 0.55 ml 0.5 ml
Rear Right-Hand Glass 105 ml 1 ml 0.9 ml
Rear Glass 205 ml 0.5 ml 0.45 ml

W3-1-2-17
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedures to Install Upper Door Glass

1. Before installing the glass, remove garnish (2) 1
around sash assembly (1) from the cab inside for
easy removal. Push sash assembly (1) by hands and
remove the sash outside.
2

2. Install glass A (3) and glass B (4) into the sash

grooves.

3 4
WDAA-03-01-031
3. Install sash assembly (1) onto the door from the
outside of cab. Secure sash assembly (1) at the
inside of cab by using garnish (2).

W3-1-2-18
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedures to Install Upper Front Glass

1. Stick the seal to the lower side of the front upper

glass by using Cemedine Super X.
Stick and secure both right and left ends (the thicker
part) of the seal to the glass by using adhesive.
Stick the mating surface of seal (1) and the glass
by using Cemedine Super X so that no visible
undulation or boss can be found.

fNOTE: Cemedine Super X No. 8008

Glue-state adhesive, tubed
Cemedine 366 Deluxe

IMPORTANT: The front glass is arched-fringed. When

replacing the glass, contact with the nearest
HITACHI Office and replace it as an assembly.

WDAA-03-01-029

Detail A (Inside) Detail A (Outside)

WDAA-03-01-032 WDAA-03-01-033

a- Cemedine Super X No. 8008 a- Cemedine Super X No. 8008

b- Cemedine 366 Deluxe b- Cemedine 366 Deluxe
c- Fill seal for the inside of installation point here. e- No gap between drainage and wedge
d- Do not apply seal to this groove.

W3-1-2-19
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Dimensions of Cab Glass (H Cab)

fNOTE: The glasses are same to those of the standard

cab except for the front glass.

Unit: mm

WJAA-03-01-001

WJAA-03-01-002

W3-1-2-20
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

Procedures to Install Front Glass (H Cab)

Upper Front Glass Lower Front Glass

4
a a

b
b
WJAA-03-01-005

2
3

WJAA-03-01-004

1. Install Z rubber (2) around glass (1). WJAA-03-01-007

2. Install only A part (4) of wedge (3) into the groove 1- Glass 3- Wedge
on Z rubber (2). 2- Z Rubber 4- A Part
a- Connecting Position b- Drainage Hole Position

W3-1-2-21
 SECTION 3 UPPERSTRUCTURE
Group 1 Cab

2
5

WJAA-03-01-006
c
1
WJAA-03-01-012
2
1
2
5 5
6

WJAA-03-01-009 WJAA-03-01-010

1
3. Install cord (5) around the inside of Z rubber (2). 2
Apply soapy water onto the cord (5) part.
3
4. Install Z rubber (2) to cab (6) from the lower side of
glass (1) while pulling cord (5).
6
IMPORTANT: Use a tool, which the edge of
screwdriver is rounded, in order not to damage Z
rubber (2). WJAA-03-01-011
5. Install wedge (3) into the groove on Z rubber (2).
1- Glass 5- Cord
2- Z Rubber 6- Cab
3- Wedge
a- Connecting Position c- Get cord (5) long enough to
b- Drainage Hole Position remove.

W3-1-2-22
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

Removal and Installation of Counterweight

3 1
Detail A

4 2

5
WJAA-03-02-002
WJAA-03-02-001

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Remove cover (2) while holding it. Do

not drop cover (2).
2. Remove bolts, washers (1) (5 used). Remove cover
(2).

j : 19 mm

dCAUTION: Remove cover (4) while holding it.Do

not drop cover (4).
3. Remove bolts, washers (3) (5 used). Remove cover
(4).

j : 19 mm
4. Disconnect connector (5).

W3-2-1-1
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

13
14
15
16
17 10
13 9
14 11
15 12
16
17 6
10
9 11
11

7
a 9
8
15
8 13,14
7
16,17
a- Bracket W1J1-02-02-003
12
WJAA-03-02-003

dCAUTION:
(20100 lb)
Counterweight (6) weight: 9100 kg

5. Attach a wire rope onto lifting bracket (a) (2 places)

of counterweight (6). Hoist and hold counterweight
(6).
6. Remove bolts (7) (2 used), washers (8) (2 used), nuts
(9) (2 used), shim (10), and washers (11) (2 used).

j : 65 mm

fNOTE: Shim (10) is installed to the clearance between

nut (9) and main frame (12).
7. Remove bolts (13) (4 used), lock washers (14)
(2 used), plates (15) (2 used), and shims (16, 17)
(several). Remove counterweight (6).

j : 36 mm

W3-2-1-2
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

13
14
15
16
17 10
13 9
14 11
15 12
16
17 6
10
9 11
11

a 9

15

8 13,14
7
16,17
a- Bracket W1J1-02-02-003
12

WJAA-03-02-003

Installation

dCAUTION:
(20100 lb)
Counterweight (6) weight: 9100 kg

1. Attach a wire rope onto lifting bracket (a) (2 places)

of counterweight (6). Hoist counterweight (6).
2. Install counterweight (6) with bolts (7) (2 used),
washers (8) (2 used), washers (11) (2 used), nuts (9)
(2 used), and shim (10).

j : 65 mm

m : 2350 N·m (235 kgf·m, 1730 lbf·ft)

3. Install shims (16, 17) (several), plates (15) (2 used),
lock washers (14) (2 used), and bolts (13) (4 used).

j : 36 mm

m : 440 N·m (44 kgf·m, 320 lbf·ft)

fNOTE: Adjust shims (16, 17) so that there is no

clearance between main frame (12) and plate (15).

W3-2-1-3
 SECTION 3 UPPERSTRUCTURE
Group 2 Counterweight

3 1
Detail A

4 2

5
WJAA-03-02-002
WJAA-03-02-001

4. Connect connector (5).

5. Install cover (4) with bolts, washers (3) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

6. Install cover (2) with bolts, washers (1) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-2-1-4
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

Removal and Installation of Main Frame

3
1

WJAA-03-03-001

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove cab (1). (Refer to W3-1-1.)
3. Remove counterweight (2). (Refer to W3-2-1.)
4. Remove front attachment (3). (Refer to W5-1-1.)
5. Remove boom cylinder (4). (Refer to W5-2-1.)

W3-3-1-1
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

11

9, 10

8 6 7 WJAA-03-03-002

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

hoses (6) (4 used).

j : 41 mm
7. Disconnect hose (7).

j : 27 mm
8. Disconnect hose (8).

j : 17 mm
9. Remove bolts (9) (2 used) and washers (10) (4 used).
Remove stopper (11).

j : 22 mm

W3-3-1-2
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

d
12
ST0247 ST0246
b, c b, c

W1J1-02-03-002

WJAA-03-03-003 ST0246, ST0247

c b
a- Counterweight Mounting c- Nut
Part d- Boom Mounting Bracket Hole
b- Bolt

W166-02-03-010

dCAUTION:
(23810 lb)
Main frame (12) weight: 10800 kg

Special tools (ST0246, ST0247) weight: 100 kg

(225lb) each
10. Install special tools (ST0246, ST0247) to
counterweight mounting part (a) (2 places) of the
main frame (12) rear side with bolts (b) (M39) (2
used) and nuts (c) (2 used).

j : 60 mm
11. Attach wire ropes onto special tools (ST0246,
ST0247) and boom mounting bracket hole (d) (2
places).

W3-3-1-3
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

12 15 14

13 14, 15 15 WJAA-03-03-005
WJAA-03-03-004

e- Front Attachment Side

12. Reduce slack of the wire rope by using a chain

block. Put the matching marks onto main frame (12)
and outer race (13) of the swing bearing.
13. Remove bolts (14) (29 used) and bolts (15) (7 used).

j : 46 mm
14. Adjust the chain block in order to level main frame
(12). Hoist and remove main frame (12).

W3-3-1-4
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

d
12
ST0247 ST0246
b, c b, c

W1J1-02-03-002

WJAA-03-03-003 ST0246, ST0247

c b
a- Counterweight Mounting c- Nut
Part d- Boom Mounting Bracket Hole
b- Bolt

W166-02-03-010

Installation

dCAUTION:
(23810 lb)
Main frame (12) weight: 10800 kg

Special tools (ST0246, ST0247) weight: 100 kg

(225 lb) each
1. Install special tools (ST0246, ST0247) to
counterweight mounting part (a) (2 places) of the
main frame (12) rear side with bolts (b) (M39) (2
used) and nuts (c) (2 used).

j : 60 mm
2. Attach wire ropes onto special tools (ST0246,
ST0247) and boom mounting bracket hole (d) (2
places).
3. Adjust the chain block in order to level main frame
(12).

W3-3-1-5
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

12 15 14

13 WJAA-03-03-004 15 WJAA-03-03-005

4. Fit the matching marks made when disassembling

and install main frame (12) to outer race (13) of the
swing bearing. Install bolts (15) (7 used) and bolts
(14) (29 used).

j : 46 mm

m : 1950 N·m (195 kgf·m, 1440 lbf·ft)

W3-3-1-6
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

11

9, 10

8 6 7 WJAA-03-03-002

5. Install stopper (11) with washers (10) (4 used) and

bolts (9) (2 used).

j : 22 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

6. Connect hose (8).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

7. Connect hose (7).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

8. Connect hoses (6) (4 used).

j : 41 mm

m : 200 N·m (20 kgf·m, 148 lbf·ft)

W3-3-1-7
 SECTION 3 UPPERSTRUCTURE
Group 3 Main Frame

3
1

WJAA-03-03-001

9. Install boom cylinder (4). (Refer to W5-2-1.)

10. Install front attachment (3). (Refer to W5-1-1.)
11. Install counterweight (2). (Refer to W3-2-1.)
12. Install cab (1). (Refer to W3-1-1.)
13. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.

W3-3-1-8
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

Removal and Installation of Engine

1 4

2, 3

WJAA-03-04-001 WJAA-03-04-002

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal 5
1. Set the machine position for inspection and
maintenance. Close the fuel cock. (Refer to W1-6-1.)
2. Open cover (1).
3. Remove wing nuts (2) (4 used) and washers (3) (4
used). Remove cover (4).
WJAA-03-04-003
4. Disconnect ground (5).

W3-4-1-1
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

9
13

10 14 7, 8 11, 12 14
6 WJAA-03-04-004 WJAA-03-04-005

5. Open engine cover (6).

6. Remove pin (7) and washer (8). Remove the support
(10) side of cylinder (9).
7. Remove pin (11) and washers (12) (2 used). Remove
the support (10) side of stopper (13).
8. Remove bolts, washers (14) (4 used) from the inside
of engine cover (6). Remove engine cover (6).

j : 17 mm

W3-4-1-2
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

19 20 21 22

15
16

17
18

WJAA-03-04-006

9. Remove bolts, washers (15) (7 used). Remove cover

(16).

j : 19 mm
10. Remove bolts, washers (17) (7 used). Remove cover
(18).

j : 19 mm
11. Remove bolts, washers (19) (6 used). Remove cover
(20).

j : 19 mm
12. Remove bolts, washers (21) (2 used). Remove the
cover (22) assembly.

j : 19 mm

W3-4-1-3
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

129 130
122

124 123 121 125 126 131 127 128 132

WJAA-03-06-001 WJAA-03-06-002

13. Remove bolts, washers (121) (4 used). Remove pipe

(122).

j : 19 mm
14. Remove bolts, washers (123) (12 used). Remove
cover (124).

j : 19 mm
15. Remove bolts, washers (125) (13 used). Remove
cover (126).

j : 19 mm
16. Remove bolts, washers (127) (7 used). Remove
bracket (128).

j : 19 mm
17. Remove bolts, washers (129) (3 used). Remove
bracket (130).

j : 19 mm
18. Open covers (131, 132).

W3-4-1-4
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

148 143 144 38 39, 40 41 42

147

WJAA-03-09-013
WJAA-03-02-001

19. Remove bolts, washers (147) (2 used). Open the

bracket (148) assembly. dCAUTION: Remove cover (143) while holding it.
Do not drop cover (143).
j : 19 mm 20. Remove bolts, washers (144) (5 used). Remove cover
(143).

j : 19 mm

dCAUTION: Remove cover (38) while holding it.

Do not drop cover (38).
21. Remove bolts, washers (39) (6 used) and washers
(40) (6 used). Remove cover (38).

j : 19 mm

dCAUTION: Remove cover (41) while holding it.

Do not drop cover (41).
22. Remove bolts, washers (42) (5 used). Remove cover
(41).

j : 19 mm

W3-4-1-5
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

141

142 WJAA-03-07-001

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
23. Remove bolts, washers (141) (6 used). Remove cover
(142).

j : 17 mm
24. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Oil amount: 310 L (81.9 US gal)

W3-4-1-6
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

WJAA-03-04-022 WJAA-03-04-023

25. Disconnect hose (150). 28. Disconnect hose (156).

j : 36 mm j : 36 mm
26. Disconnect hose (151). 29. Remove socket bolts (157) (4 used). Disconnect pipe
(158). Remove O-ring (159).
j : 27 mm
l : 14 mm
27. Remove socket bolts (152) (8 used) and flanges
(153) (4 used). Disconnect hoses (154) (2 used). 30. Remove socket bolts (160) (4 used). Disconnect pipe
Remove O-rings (155) (2 used). (161). Remove O-ring (162).

l : 12 mm l : 8 mm
31. Disconnect hose (163).

j : 17 mm
32. Disconnect hoses (164) (2 used).

j : 41 mm
33. Disconnect hose (165).

j : 41 mm

W3-4-1-7
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

168 173 171 172

166, 167

168 169, 170 171 169, 170 WJAA-03-09-017

WJAA-03-09-016

34. Remove bolts, washers (166) (3 used) and clips (167) 36. Remove bolts, washers (169) (4 used) and clips (170)
(3 used). (4 used).

j : 17 mm j : 17 mm
35. Disconnect connectors (168) (3 used). 37. Disconnect connectors (171) (3 used).
38. Disconnect both ends of hose (172).

j : 17 mm
39. Disconnect hose (173).

j : 17 mm

W3-4-1-8
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

177 174, 175, 176

184 182

181

180
183

178, 179
WJAA-03-09-018

40. Remove bolts (174) (8 used), spring washers (175) 44. Remove bolts (174) (3 used), spring washers (175)
(8 used), and washers (176) (8 used). Remove cover (3 used), and washers (176) (3 used). Remove cover
(177). (182).

j : 19 mm j : 19 mm
41. Remove bolt, washer (178) and clip (179). 45. Remove bolts (174) (3 used), spring washers (175)
(3 used), and washers (176) (3 used). Remove cover
j : 17 mm (183).
42. Remove hose (181) upward.
j : 19 mm
43. Remove bolts (174) (4 used), spring washers (175)
46. Remove bolts (174) (2 used), spring washers (175)
(4 used), and washers (176) (4 used). Remove cover
(2 used), and washers (176) (2 used). Remove cover
(180).
(184).
j : 19 mm
j : 19 mm

W3-4-1-9
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

185 188

186 WJAA-03-04-024 187

WJAA-03-09-019

47. Remove bolt, washer (185). 49. Remove bolts, washers (187) (3 used).

j : 19 mm j : 19 mm
48. Remove bolts, washers (186) (5 used). 50. Remove the cover (188) assembly.

j : 19 mm

W3-4-1-10
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

191

189 190
WJAA-03-09-022

51. Remove bolts, washers (189) (2 used).

j : 19 mm
52. Remove bolts, washers (190) (3 used). Remove the
bracket (191) assembly.

j : 19 mm

W3-4-1-11
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

135 133, 134 137 136 139 138

135

WJAA-03-06-011 WJAA-03-06-012

53. Remove bolt, washer (133) and clip (134).

j : 17 mm
54. Disconnect connectors (135) (3 used).
IMPORTANT: Do not loosen screws (136) (4 used).
If screw (136) has been loosened, differential
pressure sensor (137) should be replaced.
55. Remove bolts, washers (138) (2 used). Remove the
bracket (139) assembly.

j : 13 mm

W3-4-1-12
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

32 33 30 31
24, 25 26, 27

37

36 35 34 WJAA-03-04-026
28, 29 WJAA-03-04-025

56. Remove bolt, washer (24) and clip (25). 59. Remove bolts, washers (30) (4 used). Remove
support (31).
j : 17 mm
j : 19 mm
57. Remove bolts, washers (26) (2 used) and clips (27) (2
used). 60. Remove bolts, washers (32) (4 used). Remove
support (33).
j : 17 mm
j : 19 mm
58. Remove bolts, washers (28) (2 used) and clips (29) (2
used). 61. Remove bolts, washers (34) (4 used). Remove
support (35).
j : 17 mm
j : 19 mm
62. Remove bolts, washers (36) (4 used). Remove
support (37).

j : 19 mm

W3-4-1-13
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

48

49

50

43
WJAA-03-05-016 WJAA-03-04-009
44, 45 46,47

63. Place a container under cock (43). Open cock (43). 64. Remove bolt, washer (44) and clip (45).
Drain off coolant. Close cock (43).
j : 17 mm
f NOTE: Coolant amount: 52 L (13.7 US gal)
65. Remove bolt, washer (46) and clip (47).

j : 17 mm
66. Disconnect connector (48).
67. Remove clamps (49) (2 used). Disconnect hose (50).

W3-4-1-14
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

51, 52 54 56 55

60
55
57

53 62 59
61
58

WJAA-03-04-010 WJAA-03-04-011

68. Remove bolts, washers (51) (2 used) and clips (52) (2 70. Disconnect plugs (54) (2 used).
used).
71. Remove clamps (55) (2 used). Disconnect hose (56).
j : 17 mm 72. Remove clamps (57, 58) (2 used for each).
69. Disconnect connectors (53) (5 used). Disconnect hose (59).
73. Remove clamps (60, 61) (2 used for each).
Disconnect hose (62).

W3-4-1-15
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

65 66

WJAA-03-04-027 WJAA-03-04-013

74. Remove clamps (65) (2 used). Disconnect hose (66). 75. Disconnect connector (67).
76. Remove caps (68) (2 used), screw (69), and nut (70).
Disconnect terminals (71) (2 used).

j : 12 mm
77. Disconnect connector (72).
78. Release the belt tension by moving pulley (74) back
and forth by using adjusting bolt (73).
IMPORTANT: Do not disconnect hoses (2 used) of
compressor (78).
79. Remove socket bolts (75) (4 used), spring washers
(76) (4 used), and washers (77) (4 used). Place the
compressor (78) assembly horizontally.

l : 6 mm
80. Disconnect hoses (79) (2 used).

j : 41 mm

W3-4-1-16
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

WJAA-03-04-028 83 84 WJAA-03-04-016

81. Remove clamps (80) (3 used). Disconnect hoses (81) 83. Remove clamp (83). Disconnect hose (84).
(3 used).
82. Disconnect hoses (82) (2 used).

j : 36 mm

W3-4-1-17
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

86 85 WJAA-03-04-017 WJAA-03-04-029

84. Remove clamp (85). Disconnect hose (86).

85. Remove nut (102). Disconnect terminal (103).

j : 17 mm
86. Remove bolt (104). Disconnect terminal (105).

j : 8 mm 101

IMPORTANT: The circuit may be shorted when doing 100

the work with the battery ground connected.
87. Remove nut (100). Disconnect ground (101). WJAA-03-04-030

j : 22 mm

W3-4-1-18
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

Detail A

87 a
91

88 92
97, 98
89 99
94, 95 b 111
96
110
a 109

A
107 108
106 92
89 93
90
WJAA-03-04-031
WJAA-03-04-020

a- Lifting Bracket b- Lifting Hole

dCAUTION: The engine (87) assembly weight:

1500 kg (3310 lb)
dCAUTION: Bracket (96) weight: 22 kg (49 lb)
96. Install eyebolts (M10, Pitch 1.5 mm) to lifting hole
88. Install shackles to lifting bracket (a) (4 places) of (b) of bracket (96). Attach nylon slings onto the
engine (87). Attach nylon slings onto the shackles (4 eyebolts. Hoist and hold bracket (96). Remove bolts
used). Hoist and hold the engine (87) assembly. (94) (4 used) and washers (95) (4 used). Remove
bracket (96).
89. Remove bolt (88), nut (90), washers (89) (2 used),
plate (106), and cushion (107). fNOTE: LOCTITE #262 has been applied on bolts (94) (4
used).
j : 41 mm
j : 24 mm
90. Remove bolt (91), nut (93), washers (92) (2 used),
plate (108), and cushion (109). 97. Remove bolts (97) (4 used) and washers (98) (4
used). Remove bracket (99).
j : 32 mm
91. Remove bolts (88, 91) at the front attachment side fNOTE: LOCTITE #262 has been applied on bolts (97) (4
used).
in the same way as step 89 to step 90.
j : 19 mm
92. Hoist engine (87) by 15 mm.
98. Remove brackets (96, 99) at the front attachment
93. Move engine (87) to the pump device side by 50
side in the same way as step 96 to step 97.
mm. Remove engine (87).
99. Remove the adapter with engine (87) attached if
94. Place engine (87) on wooden blocks.
necessary.
95. Remove cushions (110, 111) (2 used for each) at the
counterweight and front attachment sides.

W3-4-1-19
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

192

193

WJAA-03-04-021

100. Remove muffler filter (192). (Refer to W3-17-1.)

101. Remove pump device (193). (Refer to W3-8-1.)

W3-4-1-20
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

192

193

WJAA-03-04-021

Installation
1. Install pump device (193). (Refer to W3-8-1.)
2. Install muffler filter (192). (Refer to W3-17-1.)

W3-4-1-21
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

Detail A

87 a
91

88 92
97, 98
89 99
94, 95 b 111
96
110
a 109

A
107 108
106 92
89 93
90
WJAA-03-04-031
WJAA-03-04-020

a- Lifting Bracket b- Lifting Hole

3. Install all removed adapters to engine (87).

4. Apply LOCTITE #262 onto bolts (97) (4 used). Install
dCAUTION: The engine (87) assembly weight:
1500 kg (3310 lb)
bracket (99) with washers (98) (4 used) and bolts
8. Install shackles to lifting bracket (a) (4 places) of
(97) (4 used).
engine (87). Attach nylon slings onto the shackles (4
j : 19 mm used). Hoist the engine (87) assembly.
9. Install engine (87) with cushion (109), plate (108),
m : 110 N·m (11 kgf·m, 81 lbf·ft)
washers (92) (2 used), nut (93), and bolt (91).
dCAUTION: Bracket (96) weight: 22 kg (49 lb)
j : 32 mm
5. Install eyebolts (M10, Pitch 1.5 mm) to lifting hole
(b) of bracket (96). Attach nylon slings onto the m : 750 N·m (75 kgf·m, 550 lbf·ft)
eyebolts. Hoist bracket (96). Apply LOCTITE #262
10. Install engine (87) with cushion (107), plate (106),
onto bolts (94) (4 used). Install bracket (96) with
washers (89) (2 used), nut (90), and bolt (88).
washers (95) (4 used) and bolts (94) (4 used).
j : 41 mm
j : 24 mm
m : 1400 N·m (140 kgf·m, 1030 lbf·ft)
m : 270 N·m (27 kgf·m, 200 lbf·ft)
11. Install bolts (88, 91) at the front attachment side in
6. Install brackets (96, 99) at the front attachment side
the same way as step 9 to step 10.
in the same way as step 4 to step 5.
7. Install cushions (110, 111) (2 used for each) at the
counterweight and front attachment sides.

W3-4-1-22
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

WJAA-03-04-029
86 85 WJAA-03-04-017

IMPORTANT: The circuit may be shorted when doing

the work with the battery ground connected.
12. Connect ground (101) with nut (100).

j : 22 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft) 101

13. Connect terminal (105) with bolt (104). 100
j : 8 mm
WJAA-03-04-030
m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
14. Connect terminal (103) with nut (102).

j : 17 mm

m : 16 N·m (1.6 kgf·m, 12 lbf·ft)

15. Connect hose (86) with clamp (85).

W3-4-1-23
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

WJAA-03-04-028 83 84 WJAA-03-04-016

16. Connect hose (84) with clamp (83). 17. Connect hoses (82) (2 used).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

18. Connect hoses (81) (3 used) with clamps (80) (3
used).

W3-4-1-24
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

65 66

WJAA-03-04-027
WJAA-03-04-013

19. Connect hoses (79) (2 used). 23. Connect terminals (71) (2 used) with nut (70) and
screw (69). Install caps (68) (2 used).
j : 41 mm
j : 12 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)
m : 20 N·m (2 kgf·m, 15 lbf·ft)
20. Install the compressor (78) assembly with washers
(77) (4 used), spring washers (76) (4 used), and 24. Connect connector (67).
socket bolts (75) (4 used).
25. Connect hose (66) with clamps (65) (2 used).
j : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

IMPORTANT: The belt does not fit when replacing
with a new one. Therefore, adjust the belt tension
again after running the engine at slow idle for 3 to
5 minutes.
21. Adjust the belt tension by moving pulley (74) back
and forth by using adjusting bolt (73).
22. Connect connector (72).

W3-4-1-25
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

51, 52 54 56 55

60
55
57

53 62 59
61
58

WJAA-03-04-010 WJAA-03-04-011

26. Connect hose (62) with clamps (60, 61) (2 used for
each).
27. Connect hose (59) with clamps (57, 58) (2 used for
each).
28. Connect hose (56) with clamps (55) (2 used).
29. Connect plugs (54) (2 used).
30. Connect connectors (53) (5 used).
31. Install clips (52) (2 used) and bolts, washers (51) (2
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-26
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

48

49

50

44, 45 46, 47 WJAA-03-04-009

32. Connect hose (50) with clamps (49) (2 used).

33. Connect connector (48).
34. Install clip (47) and bolt, washer (46).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

35. Install clip (45) and bolt, washer (44).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-27
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

32 33 30 31
24, 25 26, 27

37

WJAA-03-04-025 36 35 34 WJAA-03-04-026
28, 29

36. Install support (37) with bolts, washers (36) (4 used). 40. Install clips (29) (2 used) with bolts, washers (28) (2
used).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
37. Install support (35) with bolts, washers (34) (4 used).
41. Install clips (27) (2 used) with bolts, washers (26) (2
j : 19 mm used).
m : 90 N·m (9 kgf·m, 66 lbf·ft) j : 17 mm
38. Install support (33) with bolts, washers (32) (4 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 19 mm 42. Install clip (25) with bolt, washer (24).
m : 90 N·m (9 kgf·m, 66 lbf·ft) j : 17 mm
39. Install support (31) with bolts, washers (30) (4 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-4-1-28
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

135 133, 134 137 136 139 138

135

WJAA-03-06-011 WJAA-03-06-012

43. Install the bracket (139) assembly with bolts,

washers (138) (2 used).

j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

44. Connect connectors (135) (3 used).
45. Install clip (134) with bolt, washer (133).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-29
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

191

189 190 WJAA-03-09-022

46. Install the bracket (191) assembly with bolts,

washers (190) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

47. Install bolts, washers (189) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-4-1-30
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

185 188

186 WJAA-03-04-024
187
WJAA-03-09-019

48. Install the cover (188) assembly with bolts, washers

(187) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

49. Install bolts, washers (186) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

50. Install bolt, washer (185).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-4-1-31
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

177 174, 175, 176

184 182

181

180
183

178, 179
WJAA-03-09-018

51. Install cover (184) with washers (176) (2 used), 55. Pass hose (181) through cover (182).
spring washers (175) (2 used), and bolts (174) (2
56. Install clip (179) and bolt, washer (178).
used).
j : 17 mm
j : 19 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
57. Install cover (177) with washers (176) (8 used),
52. Install cover (183) with washers (176) (3 used),
spring washers (175) (8 used), and bolts (174) (8
spring washers (175) (3 used), and bolts (174) (3
used).
used).
j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
53. Install cover (182) with washers (176) (3 used),
spring washers (175) (3 used), and bolts (174) (3
used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

54. Install cover (180) with washers (176) (4 used),
spring washers (175) (4 used), and bolts (174) (4
used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-4-1-32
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

168 173 171 172

166, 167

168 169, 170 171 169, 170 WJAA-03-09-017

WJAA-03-09-016

58. Connect hose (173).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

59. Connect both ends of hose (172).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

60. Connect connectors (171) (3 used).
61. Install clips (170) (4 used) and bolts, washers (169) (4
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

62. Connect connectors (168) (3 used).
63. Install clips (167) (3 used) and bolts, washers (166) (3
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-33
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

WJAA-03-04-022 WJAA-03-04-023

64. Connect hose (165). 69. Connect hose (156).

j : 41 mm j : 36 mm

m : 200 N·m (20 kgf·m, 148 lbf·ft) m : 180 N·m (18 kgf·m, 133 lbf·ft)
65. Connect hoses (164) (2 used). 70. Install O-rings (155) (2 used) to hoses (154) (2 used).
Connect hoses (154) (2 used) with flanges (153) (4
j : 41 mm used) and socket bolts (152) (8 used).
m : 200 N·m (20 kgf·m, 148 lbf·ft) l : 12 mm
66. Connect hose (163).
m : 140 N·m (14 kgf·m, 103 lbf·ft)
j : 17 mm 71. Connect hose (151).
m : 25 N·m (2.5 kgf·m, 18 lbf·ft) j : 27 mm
67. Install O-ring (162) to pipe (161). Connect pipe (161)
m : 80 N·m (8 kgf·m, 59 lbf·ft)
with socket bolts (160) (4 used).
72. Connect hose (150).
l : 8 mm
j : 36 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
68. Install O-ring (159) to pipe (158). Connect pipe (158)
with socket bolts (157) (4 used).

l : 14 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-4-1-34
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

141

142 WJAA-03-07-001

73. Add coolant to the radiator.

fNOTE: Coolant amount: 52 L (13.7 US gal)

74. Fill hydraulic oil to the hydraulic oil tank.

fNOTE: Oil amount: 310 L (81.9 US gal)

75. Install cover (142) with bolts, washers (141) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

76. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
77. Bleed air from the fuel system. (Refer to W1-4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.

W3-4-1-35
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

148 143 144 38 39, 40 41 42

147

WJAA-03-09-013
WJAA-03-02-001

78. Install cover (41) with bolts, washers (42) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

79. Install cover (38) with washers (40) (6 used) and
bolts, washers (39) (6 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

80. Install cover (143) with bolts, washers (144) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

81. Close the bracket (148) assembly. Install bolts,
washers (147) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-4-1-36
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

194 192

129 130
122

124 123 121 125 126 131 127 128 132

WJAA-03-06-001 WJAA-03-06-002

82. Open covers (131, 132). 86. Install cover (124) with bolts, washers (123) (12
used).
83. Install bracket (130) with bolts, washers (129) (3
used). j : 19 mm
j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft) 87. Install pipe (122) with bolts, washers (121) (4 used).
Fit the center positions of exhaust pipe (194) of
84. Install bracket (128) with bolts, washers (127) (7
muffler filter (192) and pipe (122).
used).
j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
85. Install cover (126) with bolts, washers (125) (13
used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-4-1-37
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

19 20 21 22

15
16

17
18

WJAA-03-04-006

88. Install the cover (22) assembly with bolts, washers

(21) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

89. Install cover (20) with bolts, washers (19) (6 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

90. Install cover (18) with bolts, washers (17) (7 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

91. Install cover (16) with bolts, washers (15) (7 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-4-1-38
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

9
13

10 14 7, 8 11, 12 14
6 WJAA-03-04-004 WJAA-03-04-005

92. Install engine cover (6) with bolts, washers (14) (4

used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

93. Install the support (10) side of stopper (13) with
washers (12) (2 used) and pin (11).
94. Install the support (10) side of cylinder (9) with
washer (8) and pin (7).
95. Close engine cover (6).

W3-4-1-39
 SECTION 3 UPPERSTRUCTURE
Group 4 Engine

1 4

2, 3

WJAA-03-04-001 WJAA-03-04-002

96. Connect ground (5).

97. Install cover (4) with washers (3) (4 used) and wing
nuts (2) (4 used).
98. Close cover (1).

WJAA-03-04-003

W3-4-1-40
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

Removal and Installation of Radiator

2 1 WJAA-03-07-001

dCAUTION: Bleed air from the hydraulic oil tank

before doing any work. (Refer to W1-4-1.)
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Remove bolts, washers (1) (6 used). Remove cover
(2).

j : 17 mm
3. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Oil amount: 310 L (81.9 US gal)

W3-5-1-1
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

3
5

6 7
WJAA-03-02-001 WJAA-03-05-016

dCAUTION: Remove cover (3) while holding it. Do

not drop cover (3).
4. Remove bolts, washers (4) (5 used). Remove cover
(3).

j : 19 mm

dCAUTION: Remove cover (5) while holding it. Do

not drop cover (5).
5. Remove bolts, washers (6) (5 used). Remove cover
(5).

j : 19 mm
6. Place a container under cock (7). Open cock (7).
Drain off coolant. Close cock (7).

fNOTE: Coolant amount: 52 L (13.7 US gal)

W3-5-1-2
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

13

15

16

8 13 14 10, 11, 12 15
WJAA-03-05-001 WJAA-03-05-002

7. Remove bolts, washers (8) (4 used). Remove cap

assembly (9).

j : 17 mm
8. Remove bolts (10) (2 used), spring washers (11) (2
used), and washers (12) (2 used). Remove bolts,
washers (13) (9 used). Remove cover (14).

j : 19 mm
9. Remove bolts, washers (15) (3 used). Remove
bracket (16).

j : 19 mm

W3-5-1-3
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

22

23

17, 18, 19 21 20 22 24 25 24
WJAA-03-05-003 WJAA-03-05-004

10. Remove bolts (17) (2 used), spring washers (18) (2

used), and washers (19) (2 used). Remove bolts,
washers (20) (7 used). Remove cover (21).

j : 19 mm
11. Remove bolts, washers (22) (3 used). Remove
bracket (23).

j : 19 mm
12. Remove bolts, washers (24) (2 used). Remove
bracket (25).

j : 19 mm

W3-5-1-4
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

26 27 29 31 30 32

33
28

WJAA-03-05-006 WJAA-03-05-007

13. Remove bolts, washers (26) (7 used). Remove cover

(27).

j : 19 mm
14. Remove bolts, washers (28) (6 used). Remove cover
(29).

j : 19 mm
15. Remove bolts, washers (30) (4 used). Remove
bracket (31).

j : 19 mm
16. Open cover (32).
17. Remove bolts, washers (33) (2 used). Remove the
cover (32) assembly.

j : 19 mm

W3-5-1-5
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

41 39 42 40 43 39 44 34 49 48 47 50 49

43
41

34 35 37 36 38 45, 46
WJAA-03-05-008 WJAA-03-05-009

18. Remove bolts, washers (34) (3 used). Remove 24. Remove clamp (45). Disconnect hose (46).
bracket (35).
25. Remove bolts, washers (47) (4 used). Remove air
j : 19 mm cleaner duct (48).

19. Disconnect plugs (36) (2 used). j : 19 mm

20. Remove clamp (37). Disconnect hose (38). 26. Remove bolts, washers (49) (9 used). Remove
bracket (50).
21. Remove bolts, washers (39) (8 used). Remove
clamps (40) (4 used). j : 19 mm
j : 17 mm
22. Remove clamps (41) (4 used). Disconnect pipe (42).

j : 11 mm
23. Remove clamps (43) (4 used). Disconnect pipe (44).

j : 11 mm

W3-5-1-6
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

54 55 57 58

59

56 53 52 51 59 60
WJAA-03-05-010 WJAA-03-05-011

27. Remove bolt, washer (51). Remove clamp (52).

j : 19 mm
28. Remove coupling (53). Remove bolts, washers (54)
(2 used). Disconnect pipe (55). Remove O-ring (56).

j : 19 mm
29. Remove clamps (57) (2 used). Disconnect hose (58).

j : 11 mm
30. Remove clamps (59) (4 used). Disconnect hose (60).

j : 11 mm

W3-5-1-7
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

61 62 64, 65 63

WJAA-03-08-004 WJAA-03-08-005

31. Open cover (61).

32. Remove clamp (62). Disconnect hose (63).

j : 7 mm
33. Remove bolt, washer (64). Remove clip (65).

j : 17 mm

W3-5-1-8
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

68, 69 70

70

73
71

66, 67
73

72
WJAA-03-05-012 WJAA-03-05-013

34. Remove bolts (66) (2 used) and washers (67) (2

used).

j : 19 mm
35. Remove bolts (68) (2 used) and washers (69) (2
used).

j : 19 mm
36. Open duct (70).
37. Remove bolts, washers (71) (12 used). Remove nets
(72) (2 used).

j : 10 mm

dCAUTION:
(115 lb)
The duct (70) assembly weight: 50 kg

38. Attach nylon slings onto duct (70). Hoist and hold
the duct (70) assembly.
39. Remove bolts, washers (73) (4 used).

j : 19 mm
40. Remove the duct (70) assembly.

W3-5-1-9
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

86 85 80, 81 a 88

87

79

76
84

83 75 74 77, 78 82 77, 78 a- Lifting Hole

WJAA-03-05-014 WJAA-03-05-015

41. Remove bolts, washers (74) (4 used). Remove cover

(75). dCAUTION: Radiator (87) and air cleaner (88)
weight: 360 kg (795 lb)
j : 19 mm 46. Install shackles (2 used) to lifting hole (a) (2 places)
42. Disconnect connector (76). on radiator (87). Attach nylon slings onto shackles (2
used). Hoist and hold radiator (87).
43. Remove bolts, washers (77) (2 used). Remove clips
(78) (2 used).

j : 17 mm
IMPORTANT: Take care not to disconnect hose (79).
44. Remove bolts, washers (80) (4 used) and bushings
(81) (4 used). Place air conditioner condenser (82)
onto main frame (83).

j : 13 mm
IMPORTANT: Take care not to disconnect hose (84).
45. Remove bolts, washers (85) (4 used). Place fuel
cooler (86) onto main frame (83).

j : 13 mm

W3-5-1-10
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

104, 105, 106 107 108 109

104

100

100, 101, 102 103 110

WJAA-03-05-019 WJAA-03-05-018

47. Remove bolts, washers (100) (2 used), spacer (101),

and rubber (102). Remove cover (103).

j : 19 mm
48. Remove bolts, washers (104) (4 used), spacers (105)
(2 used), and rubbers (106) (2 used). Remove cover
(107).

j : 19 mm
49. Disconnect hose (108).

j : 36 mm
50. Disconnect hose (109).

j : 27 mm
51. Remove hose band (110).

W3-5-1-11
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

Detail A

111

A
WJAA-03-05-020

WJAA-03-02-001

52. Disconnect hose (111).

j : 36 mm

W3-5-1-12
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

95, 96 87 93, 94

90 89 91 92 95, 96
WJAA-03-05-016 WJAA-03-05-017

53. Remove clamps (89) (2 used). Disconnect hose (90).

j : 11 mm
54. Remove socket bolts (91) (4 used) and flanges (92)
(2 used). Disconnect hose (93). Remove O-ring (94).

j : 10 mm
55. Remove bolts (95) (4 used) and washers (96) (4
used).

j : 30 mm
56. Remove the radiator (87) assembly.

W3-5-1-13
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

95, 96 87 93, 94

90 89 91 92 95, 96
WJAA-03-05-016 WJAA-03-05-017

a 88
Installation 87

dCAUTION: Radiator (87) and air cleaner (88)

weight: 360 kg (795 lb)
1. Install shackles (2 used) to lifting hole (a) (2 places)
on radiator (87). Attach nylon slings onto shackles (2
used). Hoist radiator (87).
2. Install radiator (87) with washers (96) (4 used) and
bolts (95) (4 used).

j : 30 mm

m : 550 N·m (50 kgf·m, 410 lbf·ft)

3. Install O-ring (94) to hose (93). Connect hose (93)
a- Lifting Hole
with flanges (92) (2 used) and socket bolts (91) (4
WJAA-03-05-015
used).

l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

4. Connect hose (90) with clamps (89) (2 used).

j : 11 mm

W3-5-1-14
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

Detail A

111

A
WJAA-03-05-020

WJAA-03-02-001

5. Connect hose (111).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

W3-5-1-15
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

104, 105, 106 107 108 109

104

100

100, 101, 102 103 110

WJAA-03-05-019 WJAA-03-05-018

6. Install hose band (110).

7. Connect hose (109).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

8. Connect hose (108).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

9. Install cover (107) with rubbers (106) (2 used),
spacers (105) (2 used), and bolts, washers (104) (4
used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

10. Install cover (103) with rubber (102), spacer (101),
and bolts, washers (100) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-5-1-16
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

86 85 80, 81

79

76
84

83 75 74 77, 78 82 77, 78
WJAA-03-05-014

11. Install fuel cooler (86) with bolts, washers (85) (4

used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

12. Install air conditioner condenser (82) with bushings
(81) (4 used) and bolts, washers (80) (4 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

13. Install clips (78) (2 used) with bolts, washers (77) (2
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

14. Connect connector (76).
15. Install cover (75) with bolts, washers (74) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-5-1-17
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

68, 69 70

70

73
71

66, 67
73

72
WJAA-03-05-012 WJAA-03-05-013

20. Install washers (69) (2 used) and bolts (68) (2 used).

dCAUTION:
(115 lb)
The duct (70) assembly weight: 50 kg
j : 19 mm
16. Attach nylon slings onto duct (70). Hoist the duct
m : 110 N·m (11 kgf·m, 81 lbf·ft)
(70) assembly.
21. Install washers (67) (2 used) and bolts (66) (2 used).
17. Install the duct (70) assembly with bolts, washers
(73) (4 used). j : 19 mm
j : 19 mm m : 110 N·m (11 kgf·m, 81 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
18. Install nets (72) (2 used) to duct (70) with bolts,
washers (71) (12 used).

j : 10 mm

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3.0 lbf·ft)

19. Close duct (70).

W3-5-1-18
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

61 62 64, 65 63

WJAA-03-08-004 WJAA-03-08-005

22. Open cover (61).

23. Install clip (65) with bolt, washer (64).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

24. Connect hose (63) with clamp (62).

j : 7 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-19
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

54 55 57 58

59

56 53 52 51 59 60
WJAA-03-05-010 WJAA-03-05-011

25. Connect hose (60) with clamps (59) (4 used).

j : 11 mm
26. Connect hose (58) with clamps (57) (2 used).

j : 11 mm
27. Install O-ring (56) to pipe (55). Connect pipe (55)
with bolts, washers (54) (2 used) and coupling (53).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

28. Install clamp (52) with bolt, washer (51).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-5-1-20
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

41 39 42 40 43 39 44 34 49 48 47 50 49

43
41

34 35 37 36 38 45, 46
WJAA-03-05-008 WJAA-03-05-009

29. Install bracket (50) with bolts, washers (49) (9 used). 34. Install clamps (40) (4 used) with bolts, washers (39)
(8 used).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
30. Install air cleaner duct (48) with bolts, washers (47)
(4 used). 35. Connect hose (38) with clamp (37).

j : 19 mm 36. Connect plugs (36) (2 used).

37. Install bracket (35) with bolts, washers (34) (3 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
31. Connect hose (46) with clamp (45). j : 19 mm

32. Connect pipe (44) with clamps (43) (4 used). m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 11 mm
33. Connect pipe (42) with clamps (41) (4 used).

j : 11 mm

W3-5-1-21
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

26 27 29 31 30 32

33
28

WJAA-03-05-006 WJAA-03-05-007

38. Install the cover (32) assembly with bolts, washers

(33) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

39. Close cover (32).
40. Install bracket (31) with bolts, washers (30) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

41. Install cover (29) with bolts, washers (28) (6 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

42. Install cover (27) with bolts, washers (26) (7 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-5-1-22
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

22

23

17, 18, 19 21 20 22 24 25 24
WJAA-03-05-003 WJAA-03-05-004

43. Install bracket (25) with bolts, washers (24) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

44. Install bracket (23) with bolts, washers (22) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

45. Install cover (21) with bolts, washers (20) (7 used),
washers (19) (2 used), spring washers (18) (2 used),
and bolts (17) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-5-1-23
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

13

15

16

8 13 14 10, 11, 12 15
WJAA-03-05-001 WJAA-03-05-002

46. Install bracket (16) with bolts, washers (15) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

47. Install cover (14) with bolts, washers (13) (9 used),
washers (12) (2 used), spring washers (11) (2 used),
and bolts (10) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

48. Install cap assembly (9) with bolts, washers (8) (4
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-24
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

97

98
b- Cover on Radiator M1J1-07-078

87

2 1 WJAA-03-07-001

99

M1J1-07-039

49. Remove bolts, washers (97) (2 used). Remove cover 54. Bleed air from the cooling system.
(98).
55. Bleed air from the hydraulic system. (Refer to W1-
j : 19 mm 4-1.)

50. Remove cap (99). Add coolant to radiator (87). Install IMPORTANT: Check the coolant level and the
cap (99). hydraulic oil level. Start the engine and check for
any oil leaks.
fNOTE: Coolant amount: 52 L (13.7 US gal) 56. Install cover (98) with bolts, washers (97) (2 used).
51. Remove bolts, washers (1) (6 used). Remove cover
(2). j : 19 mm

j : 17 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

52. Add hydraulic oil.

fNOTE: Oil amount: 310 L (81.9 US gal)

53. Install cover (2) with bolts, washers (1) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-25
 SECTION 3 UPPERSTRUCTURE
Group 5 Radiator

3
5

6
WJAA-03-02-001

57. Install cover (5) with bolts, washers (6) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

58. Install cover (3) with bolts, washers (4) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-5-1-26
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

Removal and Installation of Hydraulic Oil

Tank

76 1 4 6

2 3 5
WJAA-03-07-001 WJAA-03-07-002

dCAUTION: Bleed air from the hydraulic oil tank

before doing any work. (Refer to W1-4-1.)
dCAUTION: Remove cover (4) while holding it. Do
not drop cover (4).
IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts, washers (3) (7 used). Remove cover
and pipes have been disconnected. In addition, (4).
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the j : 19 mm
hoses and install the clips in case the clips which
secure the hoses have been removed. dCAUTION: Remove cover (6) while holding it. Do
not drop cover (6).
Removal
6. Remove bolts, washers (5) (5 used). Remove cover
1. Set the machine position for inspection and (6).
maintenance. (Refer to W1-6-1.)
j : 19 mm
2. Push air bleed valve (76) and bleed air from the
hydraulic oil tank.
3. Remove bolts, washers (1) (6 used). Remove cover
(2).

j : 17 mm
4. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Amount of oil: 310 L (81.9 US gal)

W3-6-1-1
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

10 1

7 8 2

WJAA-03-07-003 WJAA-03-07-001

7. Remove plug (7).

8. Place a container under hydraulic oil tank (8).
9. Slowly open drain cock (9) and drain off remaining
hydraulic oil.
10. Close drain cock (9).
11. Install plug (7) to the original position.
12. Remove bolts, washers (10) (2 used).

j : 19 mm
13. Install cover (2) with bolts, washers (1) (6 used).

W3-6-1-2
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

22 22
15 12, 13, 14 16, 17, 18 11 19

23

12 16 20 24 22 22 21
WJAA-03-07-001 WJAA-03-07-004

14. Open cover (11). 17. Open cover (20).

15. Remove bolts, washers (12) (2 used), spacer (13),
and rubber (14). Remove cover (15).
dCAUTION: Handrail (21) weight: 24 kg (53 lb)
18. Attach nylon slings onto handrail (21). Hoist and
j : 19 mm hold handrail (21).

16. Remove bolts, washers (16) (4 used), spacers (17) (2 19. Remove bolts, washers (22) (8 used). Remove
used), and rubbers (18) (2 used). Remove cover (19). handrail (21).

j : 19 mm j : 19 mm
20. Remove bolts, washers (23) (3 used). Remove cover
(24).

j : 19 mm

W3-6-1-3
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

31 32
36
36

33 34 35 37

WJAA-03-07-006 WJAA-03-07-007

21. Remove bolts, washers (31) (3 used). Remove cover

(32).

j : 19 mm
22. Remove bolts, washers (33) (2 used). Remove
bracket (34).

j : 19 mm
23. Loosen bolts, washers (35) (2 used).

j : 19 mm
24. Remove bolts, washers (36) (9 used). Remove cover
(37). Remove bolts, washers (35) (2 used).

j : 19 mm

W3-6-1-4
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

79

77 76 78

WJAA-03-07-013 WJAA-03-07-014

25. Open covers (76, 77).

26. Remove bolts, washers (78) (2 used). Open bracket
assembly (79).

j : 19 mm

W3-6-1-5
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

48 47 46 38, 39 42 40, 41

50 49 44, 45 43

WJAA-03-07-008

27. Remove bolt, washer (38). Remove clip (39). 31. Remove bolts, washers (44) (2 used). Remove clips
(45) (2 used).
j : 17 mm
j : 17 mm
28. Remove bolt, washer (40). Remove clip (41).
32. Disconnect hoses (46) (2 used).
j : 17 mm
j : 27 mm
29. Disconnect hoses (42) (3 used).
33. Remove coupling (47). Disconnect pipe (48).
j : 19 mm
34. Remove coupling (49). Disconnect pipe (50).
30. Disconnect hoses (43) (3 used).

j : 22 mm

W3-6-1-6
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

53 54 55 51, 52 80 59 60

60

56 62 60 57, 58 61
WJAA-03-07-009 WJAA-03-07-016

35. Disconnect hose (80). 41. Remove bolt, washer (57). Remove clip (58).

j : 27 mm j : 17 mm
36. Remove bolt, washer (51). Remove clip (52). 42. Disconnect hose (59).

j : 17 mm j : 19 mm
37. Disconnect hose (53). 43. Disconnect hoses (60) (10 used).

j : 41 mm j : 19 mm
38. Disconnect hose (54). 44. Disconnect connectors (61) (4 used).

j : 19 mm 45. Disconnect connector (62).

39. Disconnect hose (55).

j : 22 mm
40. Disconnect hoses (56) (2 used).

j : 27 mm

W3-6-1-7
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

74, 75 72 74, 75

a- Screw Hole

74, 75 69 67, 68 70, 71 73 74, 75

WJAA-03-07-011 WJAA-03-07-012

50. Remove hose clamps (72) (2 used). Disconnect hose

d CAUTION: Hydraulic oil tank (8) weight: 290 kg
(640 lb)
(73).

46. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to j : 11 mm

screw holes (a) (2 places) of hydraulic oil tank (8). 51. Remove bolts (74) (8 used) and spacers (75) (8 used).
Attach wire ropes onto the eyebolts. Hoist and hold
hydraulic oil tank (8). j : 24 mm
47. Remove bolt, washer (67). Remove clip (68). 52. Remove hydraulic oil tank (8).

j : 17 mm
48. Disconnect connector (69).

j : 17 mm
49. Remove bolt, washer (70). Remove clip (71).

j : 17 mm

W3-6-1-8
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

74, 75 72 74, 75

a- Screw Hole

74, 75 69 67, 68 70, 71 73 74, 75

WJAA-03-07-011 WJAA-03-07-012

Installation 4. Install clip (71) with bolt, washer (70).

dCAUTION:
(640 lb)
Hydraulic oil tank (8) weight: 290 kg j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
screw holes (a) (2 places) of hydraulic oil tank (8). 5. Connect connector (69).
Attach wire ropes onto the eyebolts. Hoist hydraulic
6. Install clip (68) with bolt, washer (67).
oil tank (8).
2. Connect hose (73) with hose clamps (72) (2 used). j : 17 mm

j : 11 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Install hydraulic oil tank (8) with spacers (75) (8

used) and bolts (74) (8 used).

j : 24 mm

m : 270 N·m (27 kgf·m, 200 lbf·ft)

W3-6-1-9
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

53 54 55 51,52 80 59 60

60

56 62 60 57, 58 61
WJAA-03-07-009 WJAA-03-07-016

7. Connect connector (62). 13. Connect hose (55).

8. Connect connectors (61) (4 used). j : 22 mm
9. Connect hoses (60) (10 used).
m : 40 N·m (4 kgf·m, 30 lbf·ft)
j : 19 mm 14. Connect hose (54).
m : 30 N·m (3 kgf·m, 22 lbf·ft) j : 19 mm
10. Connect hose (59).
m : 30 N·m (3 kgf·m, 22 lbf·ft)
j : 19 mm 15. Connect hose (53).
m : 30 N·m (3 kgf·m, 22 lbf·ft) j : 41 mm
11. Install clip (58) with bolt, washer (57).
m : 200 N·m (20 kgf·m, 148 lbf·ft)
j : 17 mm 16. Install clip (52) with bolt, washer (51).
m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 17 mm
12. Connect hoses (56) (2 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 27 mm 17. Connect hose (80).
m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-6-1-10
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

48 47 46 38, 39 42 40, 41

50 49 44, 45 43

WJAA-03-07-008

18. Connect pipe (50) with coupling (49). 23. Connect hoses (42) (3 used).
19. Connect pipe (48) with coupling (47). j : 19 mm
20. Connect hoses (46) (2 used).
m : 30 N·m (3 kgf·m, 22 lbf·ft)
j : 27 mm 24. Install clip (41) with bolt, washer (40).
m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 17 mm
21. Install clips (45) (2 used) with bolts, washers (44) (2
m : 50 N·m (5 kgf·m, 37 lbf·ft)
used).
25. Install clip (39) with bolt, washer (38).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
22. Connect hoses (43) (3 used).

j : 22 mm

m : 40 N·m (4 kgf·m, 30 lbf·ft)

W3-6-1-11
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

79

77 76 78

WJAA-03-07-013 WJAA-03-07-014

26. Close bracket assembly (79). Install bolts, washers

(78) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

27. Shut covers (76, 77).

W3-6-1-12
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

31 32 36
36

33 34 35 37

WJAA-03-07-006 WJAA-03-07-007

28. Install cover (37) with bolts, washers (35) (2 used)

and bolts, washers (36) (9 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

29. Install bracket (34) with bolts, washers (33) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

30. Install cover (32) with bolts, washers (31) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-6-1-13
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

22 22
15 12, 13, 14 16, 17, 18 11 19

23

20 24 22 22 21 12 16

WJAA-03-07-004 WJAA-03-07-001

31. Install cover (24) with bolts, washers (23) (3 used). 35. Install cover (19) with rubbers (18) (2 used), spacers
(17) (2 used), and bolts, washers (16) (4 used).
j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION: Handrail (21) weight: 24 kg (53 lb)
36. Install cover (15) with rubber (14), spacer (13), and
32. Attach nylon slings onto handrail (21). Hoist
bolts, washers (12) (2 used).
handrail (21).
33. Install handrail (21) with bolts, washers (22) (8 used). j : 19 mm

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

37. Shut cover (11).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
34. Shut cover (20).

W3-6-1-14
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

10

WJAA-03-07-003

38. Install bolts, washers (10) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-6-1-15
 SECTION 3 UPPERSTRUCTURE
Group 6 Hydraulic Oil Tank

76 1 4 6

2 3 5

WJAA-03-07-001 WJAA-03-07-002

39. Install cover (6) with bolts, washers (5) (5 used). IMPORTANT: Take care not to contaminate the
hydraulic oil tank with dust, water, or sand when
j : 19 mm replacing it.
m : 90 N·m (9 kgf·m, 66 lbf·ft) 42. Refill the hydraulic oil.
40. Install cover (4) with bolts, washers (3) (7 used). fNOTE: Amount of oil: 310 L (81.9 US gal)
43. Install cover (2) with bolts, washers (1) (6 used).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
41. Remove bolts, washers (1) (6 used). Remove cover m : 50 N·m (5 kgf·m, 37 lbf·ft)
(2). 44. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
j : 17 mm

W3-6-1-16
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

Removal and Installation of Fuel Tank

1 6 3, 4, 5 7, 8, 9 2 10

WJAA-03-08-001 WJAA-03-07-001
3 7

dCAUTION: Fuel is highly flammable. Never bring

a fire close to fuel.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Installation
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Remove cap (1).
3. Place a container. Drain off fuel by using an oil feed
pump.

fNOTE: Amount of oil: 725 L (192 US gal)

4. Open cover (2).
5. Remove bolts, washers (3) (2 used), spacer (4), and
rubber (5). Remove cover (6).

j : 19 mm
6. Remove bolts, washers (7) (4 used), spacers (8) (2
used) and rubbers (9) (2 used). Remove cover (10).

j : 19 mm

W3-7-1-1
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

11
16 22 17 18 23

12

47, 48

15

11

WJAA-03-08-009
13, 14 19, 20, 21 WJAA-03-08-002

7. Remove bolts, washers (11) (4 used), bolts (47) (2

used), and washers (48) (2 used). Remove handrail
(12).

j : 19 mm
8. Remove bolts (13) (2 used) and washers (14) (2
used). Remove bolts, washers (15) (4 used). Remove
handrail (16).

j : 19 mm
9. Remove bolts, washers (17) (4 used). Remove cap
assembly (18).

j : 17 mm
10. Remove bolts (19) (2 used), spring washers (20) (2
used), and washers (21) (2 used). Remove bolts,
washers (22) (9 used). Remove cover (23).

j : 19 mm

W3-7-1-2
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

25 24 26

24 WJAA-03-08-003 WJAA-03-08-004

28 27 28 29, 30

11. Remove bolts, washers (24) (3 used). Remove

bracket (25).

j : 19 mm
12. Open cover (26).
13. Loosen hose clamps (27) (2 used). Disconnect hoses
(28) (2 used).

j : 7 mm
14. Remove bolt, washer (29). Remove clip (30).

j : 17 mm
15. Disconnect plugs (32) (2 used). WJAA-03-08-005
33 34, 35 32
16. Disconnect connector (33).
17. Remove bolt, washer (34). Remove clip (35).

j : 17 mm

W3-7-1-3
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

37 39 41

36 38 40 WJAA-03-08-006

dCAUTION: Remove cover (36) while holding it.

Do not drop cover (36).
18. Remove bolts, washers (37) (5 used). Remove cover
(36).

j : 19 mm

dCAUTION: Remove cover (38) while holding it.

Do not drop cover (38).
19. Remove bolts, washers (39) (5 used). Remove cover
(38).

j : 19 mm

dCAUTION: Remove cover (40) while holding it.

Do not drop cover (40).
20. Remove bolts, washers (41) (6 used). Remove cover
(40).

j : 19 mm

W3-7-1-4
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

49 a 42
45, 46 44 45, 46

45, 46 45, 46
a
WJAA-03-08-007
WJAA-03-08-010
a- Screw Hole

dCAUTION: Fuel Tank (42) weight: 300 kg (665 lb)

21. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to the
screw holes (a) (3 places) on fuel tank (42). Attach a
nylon sling onto the eyebolts. Hoist and hold fuel
tank (42).
22. Place a container under hose (44) (2 used). Remove
hose clamps (43) (2 used). Disconnect hoses (44) (2
used). Drain fuel completely.

j : 7 mm
23. Remove bolts (45) (8 used) and spacers (46) (8 used).

j : 24 mm
24. Hoist and move fuel tank (42) to outside of the
machine. Do not make fuel tank (42) contact with
bracket (49) at this time. Remove fuel tank (42).

W3-7-1-5
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

49 a 42
45, 46 44 45, 46

a
45, 46 45, 46
WJAA-03-08-007
a WJAA-03-08-010
a- Screw Hole

Installation

dCAUTION: Fuel Tank (42) weight: 300 kg (665 lb)

1. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to the
thread parts (a) (3 places) on hydraulic oil tank (42).
Attach a nylon sling onto the eyebolts. Hoist fuel
tank (42).Hoist and move fuel tank (42) to outside
of the machine. Do not make fuel tank (42) contact
with bracket (49) at this time.
2. Connect hoses (44) (2 used) with hose clamps (43)
(2 used).

j : 7 mm
3. Apply LOCTITE #262 onto bolts (45) (8 used). Install
spacers (46) (8 used) and bolts (45) (8 used).

j : 24 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-7-1-6
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

37 39 41

36 38 40 WJAA-03-08-006

4. Install cover (40) with bolts, washers (41) (6 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

5. Install cover (38) with bolts, washers (39) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

6. Install cover (36) with bolts, washers (37) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-7-1-7
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

25 24 26

24 WJAA-03-08-003 WJAA-03-08-004

28 27 28 29, 30

7. Install clip (35) with bolt, washer (34).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

8. Connect connector (33).
9. Connect plugs (32) (2 used).
10. Install clip (30) with bolt, washer (29).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

11. Open cover (26). WJAA-03-08-005
33 34, 35 32
12. Connect hoses (28) (2 used) with hose clamps (27)
(2 used).

j : 7 mm
13. Install bracket (25) with bolts, washers (24) (3 used).

W3-7-1-8
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

16 22 17 18 23
11

12

47, 48

15

11
13, 14 19, 20, 21 WJAA-03-08-002
WJAA-03-08-009

14. Install cover (23) with bolts, washers (22) (9 used),

washers (21) (2 used), spring washers (20) (2 used),
and bolts (19) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

15. Install cap assembly (18) with bolts, washers (17) (4
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

16. Install handrail (16) with bolts, washers (15) (4 used),
washers (14) (2 used), and bolts (13) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

17. Install handrail (12) with washers (48) (2 used), bolts
(47) (2 used), and bolts, washers (11) (4 used).

W3-7-1-9
 SECTION 3 UPPERSTRUCTURE
Group 7 Fuel Tank

6 3, 4, 5 7, 8, 9 2 10

42
WJAA-03-08-001 WJAA-03-07-001
3 7

18. Open cover (2).

19. Install cover (10) with rubbers (9) (2 used), spacers
(8) (2 used), and bolts, washers (7) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

20. Install cover (6) with rubber (5), spacer (4), and bolts,
washers (3) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

21. Fill fuel tank (42) with fuel.

fNOTE: Amount of oil: 725 L (192 US gal)

IMPORTANT: Take care not to contaminate fuel tank
(42) with dust, water, or sand when refilling fuel.
22. Bleed air from the fuel system. (Refer to W1-4-1.)

W3-7-1-10
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Removal and Installation of Pump Device

1

73

72

WJAA-03-07-001 WJAA-03-09-012
2 5 6

IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts, washers (72) (3 used). Remove
and pipes have been disconnected. In addition, bracket (73).
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the j : 19 mm
hoses and install the clips in case the clips which 6. Open covers (5, 6).
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

d(Refer
CAUTION: Bleed air from the hydraulic oil tank.
to W1-4-1.)
2. Remove bolts, washers (1) (6 used). Remove cover
(2).

j : 17 mm
3. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Oil amount: 310 L (81.9 US gal)

4. Remove the muffler filter. (Refer to W3-17-1.)

W3-8-1-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

8 4

WJAA-03-09-013 3 WJAA-03-02-001

7. Remove bolts, washers (7) (2 used). Open the

bracket (8) assembly. dnot
CAUTION: Remove cover (3) while holding it. Do
drop cover (3).
j : 19 mm 8. Remove bolts, washers (4) (5 used). Remove cover
(3).

j : 19 mm

W3-8-1-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

WJAA-03-09-014 WJAA-03-09-015

9. Disconnect hose (10). 12. Disconnect hose (16).

j : 36 mm j : 36 mm
10. Disconnect hose (11). 13. Remove socket bolts (17) (4 used). Disconnect pipe
(18). Remove O-ring (19).
j : 27 mm
l : 14 mm
11. Remove socket bolts (12) (8 used) and flanges (13)
(4 used). Disconnect hoses (14) (2 used). Remove 14. Remove socket bolts (20) (4 used). Disconnect pipe
O-rings (15) (2 used). (21). Remove O-ring (22).

l : 12 mm l : 8 mm
15. Disconnect hose (23).

j : 17 mm
16. Disconnect hoses (24) (2 used).

j : 41 mm
17. Disconnect hose (25).

j : 41 mm

W3-8-1-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

28 33 31 32

26, 27

28 WJAA-03-09-016 29, 30 31 29, 30 WJAA-03-09-017

18. Remove bolts, washers (26) (3 used) and clips (27) (3 20. Remove bolts, washers (29) (4 used) and clips (30) (4
used). used).

j : 17 mm j : 17 mm
19. Disconnect connectors (28) (3 used). 21. Disconnect connectors (31) (3 used).
22. Disconnect the both ends of hose (32).

j : 17 mm
23. Disconnect hose (33).

j : 17 mm

W3-8-1-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

37 34, 35, 36

44 42

41

40
43

38, 39 WJAA-03-09-018

24. Remove bolts (34) (8 used), spring washers (35) (8 28. Remove bolts (34) (3 used), spring washers (35) (3
used), and washers (36) (8 used). Remove cover (37). used), and washers (36) (3 used). Remove cover (42).

j : 19 mm j : 19 mm
25. Remove bolts, washer (38) and clip (39). 29. Remove bolts (34) (3 used), spring washers (35) (3
used), and washers (36) (3 used). Remove cover (43).
j : 17 mm
j : 19 mm
26. Remove hose (41) upward.
30 Remove bolts (34) (2 used), spring washers (35) (2
27. Remove bolts (34) (4 used), spring washers (35) (4
used), and washers (36) (2 used). Remove cover (44).
used), and washers (36) (4 used). Remove cover (40).
j : 19 mm
j : 19 mm

W3-8-1-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

45 48

46 WJAA-03-09-020 47 WJAA-03-09-019

31. Remove bolt, washer (45). 33. Remove bolts, washers (47) (3 used).

j : 19 mm j : 19 mm
32. Remove bolts, washers (46) (5 used). 34. Remove the cover (48) assembly.

j : 19 mm

W3-8-1-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

51 52

49 50 WJAA-03-09-022 53 WJAA-03-09-024

a- Lifting Hole

35. Remove bolts, washers (49) (2 used).

j : 19 mm
dkgCAUTION:
(67 lb)
The bracket (52) assembly weight: 30

36. Remove bolts, washers (50) (3 used). Remove the 37. Install shackles (2 used) to lifting hole (a) (2 places)
bracket (51) assembly. of bracket (52). Attach nylon slings onto shackles (2
used). Hoist and hold the bracket (52) assembly.
j : 19 mm
38. Remove bolts, washers (53) (2 used).

j : 19 mm

W3-8-1-7
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

52
52

54

WJAA-03-09-023 WJAA-03-09-021
55, 56, 57

39. Remove bolts, washers (54) (2 used). 40. Remove bolts (55) (3 used), spring washers (56)
(3 used), and washers (57) (3 used). Remove the
j : 19 mm bracket (52) assembly.

fNOTE: LOCTITE #262 has been applied onto bolts (55) (3

used).
j : 19 mm

W3-8-1-8
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

58 58

59, 60, 61 62 WJAA-03-09-025 63, 64, 65 WJAA-03-09-026

b- Eyebolt (M12, Pitch 1.75 mm)

43. Remove bolts (63) (7 used), spring washers (64) (7

dlb)
CAUTION: Pump device (58) weight: 320 kg (710 used), and washers (65) (7 used). Move pump device
(58) 50 mm in parallel. Remove pump device (58).
41. Install eyebolts (b) (2used) to pump device (58).
Attach nylon slings onto eyebolts (b) (2 used). Hoist fNOTE: LOCTITE #262 has been applied onto bolts (63) (7
and hold pump device (58). used).

42. Remove bolts (59) (2 used), spring washers (60) j : 19 mm

(2 used), and washers (61) (2 used). Remove the 44. Remove the adapter with pump device (58)
bracket (62) assembly. attached if necessary.
fNOTE: LOCTITE #262 has been applied onto bolts (59) (2
used).
j : 19 mm

W3-8-1-9
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

66 67 WJAA-03-09-027 68 69, 70 WJAA-03-09-028

IMPORTANT: Coupling (67) cannot be reused. IMPORTANT: Coupling flange (68) cannot be reused.
45. Remove socket bolts (66) (2 used). Remove coupling 46. Remove socket bolts (69) (16 used) and washers (70)
(67). (16 used). Remove coupling flange (68).

l : 8 mm fNOTE: LOCTITE #262 has been applied onto socket

bolts (69) (16 used).
l : 8 mm

W3-8-1-10
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

66 67 WJAA-03-09-027 68 69, 70 WJAA-03-09-028

Installation
1. Apply LOCTITE #262 onto socket bolts (69) (16
used).
IMPORTANT: Replace coupling flange (68) with the
new one.
2. Face the casting number on coupling flange (68) to
the pump device side. Install coupling flange (68)
with washers (70) (16 used) and socket bolts (69) (16
used).

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

IMPORTANT: Replace coupling (67) with the new
one.
3. Install coupling (67) with socket bolts (66) (2 used).

l : 8 mm

m : 130 N·m (13 kgf·m, 96 lbf·ft)

W3-8-1-11
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

58 58

59, 60, 61 62 WJAA-03-09-025 63, 64, 65 WJAA-03-09-026

b- Eyebolt (M12, Pitch 1.75 mm)

4. Install all removed adapters to pump device (58). 8. Apply LOCTITE #262 onto bolts (59) (2 used).

dlb)
CAUTION: Pump device (58) weight: 320 kg (710 9. Install the bracket (62) assembly with washers (61)
(2 used), spring washers (60) (2 used), and bolts (59)
(2 used).
5. Install eyebolts (b) (2used) to pump device (58).
Attach nylon slings onto eyebolts (b) (2 used). Hoist j : 19 mm
pump device (58).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
6. Apply LOCTITE #262 onto bolts (63) (7 used).
7. Install pump device (58) with washers (65) (7 used),
spring washers (64) (7 used), and bolts (63) (7 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-8-1-12
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

52
a

54

WJAA-03-09-023 WJAA-03-09-021
52 55, 56, 57
a- Lifting Hole

dkgCAUTION:
(67 lb)
The bracket (52) assembly weight: 30

10. Install shackles (2 used) to lifting hole (a) (2 places)

of bracket (52). Attach nylon slings onto shackles (2
used). Hoist the bracket (52) assembly.
11. Apply LOCTITE #262 onto bolts (55) (3 used).
12. Install the bracket (52) assembly with washers (57)
(3 used), spring washers (56) (3 used), and bolts (55)
(3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

13. Install bolts, washers (54) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, lbf·ft)

W3-8-1-13
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

51 52

49 50 WJAA-03-09-022 53 WJAA-03-09-024

14. Install bolts, washers (53) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

15. Install the bracket (51) assembly with bolts, washers
(50) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

16. Install bolts, washers (49) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-8-1-14
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

45 48

46 WJAA-03-09-020 47 WJAA-03-09-019

17. Install the cover (48) assembly with bolts, washers

(47) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

18. Install bolts, washers (46) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

19. Install bolt, washer (45).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-8-1-15
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

37 34, 35, 36

44 42

41

40
43

38, 39 WJAA-03-09-018

20. Install cover (44) with washers (36) (2 used), spring 24. Pass hose (41) through cover (42).
washers (35) (2 used), and bolts (34) (2 used).
25. Install clip (39) and bolt, washer (38).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
21. Install cover (43) with washers (36) (3 used), spring
26. Install cover (37) with washers (36) (8 used), spring
washers (35) (3 used), and bolts (34) (3 used).
washers (35) (8 used), and bolts (34) (8 used).
j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
22. Install cover (42) with washers (36) (3 used), spring
washers (35) (3 used), and bolts (34) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

23. Install cover (40) with washers (36) (4 used), spring
washers (35) (4 used), and bolts (34) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-8-1-16
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

28 33 31 32

26, 27

28 WJAA-03-09-016 29, 30 31 29, 30 WJAA-03-09-017

27. Connect hose (33).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

28. Connect the both ends of hose (32).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

29. Connect connectors (31) (3 used).
30. Install clips (30) (4 used) and bolts, washers (29) (4
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

31. Connect connectors (28) (3 used).
32. Install clips (27) (3 used) and bolts, washers (26) (3
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-8-1-17
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

WJAA-03-09-014 WJAA-03-09-015

33. Connect hose (25). 38. Connect hose (16).

j : 41 mm j : 36 mm

m : 200 N·m (20 kgf·m, 148 lbf·ft) m : 180 N·m (18 kgf·m, 133 lbf·ft)
34. Connect hoses (24) (2 used). 39. Install O-rings (15) (2 used) to hoses (14) (2 used).
Connect hoses (14) (2 used) with flanges (13) (4
j : 41 mm used) and socket bolts (12) (8 used).
m : 200 N·m (20 kgf·m, 148 lbf·ft) l : 12 mm
35. Connect hose (23).
m : 140 N·m (14 kgf·m, 103 lbf·ft)
j : 17 mm 40. Connect hose (11).
m : 25 N·m (2.5 kgf·m, 18 lbf·ft) j : 27 mm
36. Install O-ring (22) to pipe (21). Connect pipe (21)
m : 80 N·m (8 kgf·m, 59 lbf·ft)
with socket bolts (20) (4 used).
41. Connect hose (10).
l : 8 mm
j : 36 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
37. Install O-ring (19) to pipe (18). Connect pipe (18)
with socket bolts (17) (4 used).

l : 14 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-8-1-18
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

8 4

WJAA-03-09-013 3 WJAA-03-02-001

42. Install cover (3) with bolts, washers (4) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

43. Close the bracket (8) assembly. Install bolts, washers
(7) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-8-1-19
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

73

72

WJAA-03-07-001 WJAA-03-09-012
2 5 6

44. Shut covers (5, 6).

45. Install bracket (73) with bolts, washers (72) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

46. Install the muffler filter. (Refer to W3-17-1.)
47. Fill hydraulic oil to the hydraulic oil tank.

fNOTE: Oil amount: 310 L (81.9 US gal)

48. Install cover (2) with bolts, washers (1) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

49. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.

W3-8-1-20
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Main Pump

56 57
63 63 15
64 D
64 58 A
67 59
68 57 E
69 B
55
60
61

65 19
66
84 56
19
73 57
57 62
76 74 16
75 64
83
63
18 62
70
71 16
26
77 72 27
78 71
79 70 37 G
80 C 29
30
38
D 32 25
33 27
93 36
94 H
28
81 39 38
92 37 C
32
E
45
34
36 29 28 50

41 30 52
41
42 40 33 54
31 49 48
42 34
41 44 51
46 39 C
47
42 40 53
47 46 43 3 4
2
A 35 22 7 8
21
20 6
B
1 5
23

19 11
87 82
24 10
9

18
12
17
13
16
86 15
G 24 14
H 85 90
91

WJAA-03-09-004

W3-8-2-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

1- Valve Cover 25- Valve Plate R 49- O-Ring (2 Used) 72- Drive Gear
2- Nut (2 Used) 26- Valve Plate L 50- Stopper S (2 Used) 73- Driven Gear
3- Set Screw (2 Used) 27- Cylinder Block (2 Used) 51- Servo Piston (2 Used) 74- Spacer
4- Socket Bolt 28- Cylinder Spring (18 Used) 52- Stopper L (2 Used) 75- Retaining Ring
5- Booster 29- Spherical Bushing (2 Used) 53- O-Ring (2 Used) 76- Front Casing
6- O-Ring 30- Retainer (2 Used) 54- Backup Ring (2 Used) 77- O-Ring
7- Booster Cover 31- Roller Bearing 55- Pump Casing 78- Oil Seal
8- Socket Bolt (5 Used) 32- Plunger (18 Used) 56- Eyebolt (2 Used) 79- Front Cover
9- O-Ring 33- Shoe Plate (2 Used) 57- Plug (20 Used) 80- Retaining Ring
10- Cover 34- Swash Plate (2 Used) 58- O-Ring (5 Used) 81- Socket Bolt (11 Used)
11- Socket Bolt (2 Used) 35- Pin 59- O-Ring (2 Used) 82- Coupling
12- Socket Bolt (2 Used) 36- Tilt Bushing (2 Used) 60- Name Plate 83- Pin (4 Used)
13- Socket Bolt (9 Used) 37- Tilt Pin (2 Used) 61- Rivet (2 Used) 84- Pin
14- Plug (2 Used) 38- Feedback Pin (2 Used) 62- Tapered Screw with Orifice (4 85- Inner Spacer
15- O-Ring (2 Used) 39- Swash Plate Stand (2 Used) Used) 86- Stop Ring
16- Plug (12 Used) 40- Pin (2 Used) 63- Plug (3 Used) 87- Pin (4 Used)
17- Valve Plate Pin (2 Used) 41- Retaining Ring (3 Used) 64- O-Ring (3 Used) 90- O-Ring (2 Used)
18- Seat Packing (2 Used) 42- Bearing Spacer (2 Used) 65- Socket Bolt (8 Used) 91- Plug (2 Used)
19- Pin (4 Used) 43- Roller Bearing 66- Socket Bolt (8 Used) 92- Cover
20- Stopper (2 Used) 44- Drive Shaft 67- Servo Cover (2 Used) 93- Socket Bolt (8 Used)
21- Steel Ball (2 Used) 45- Driven Shaft 68- Nut (2 Used) 94- O-Ring
22- Seat (2 Used) 46- Bearing Spacer (2 Used) 69- Set Screw (2 Used)
23- Plug (2 Used) 47- Retaining Ring (2 Used) 70- Retaining Ring (2 Used)
24- Needle Bearing (2 Used) 48- Backup Ring (2 Used) 71- Spacer (2 Used)

W3-8-2-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Main Pump

dCAUTION:
(600 lb)
The pump assembly weight: 270 kg

1. Remove plug (63). Drain oil from pump casing (55).

IMPORTANT: Put the mark on the removed regulator
when keeping in order not to confuse.
2. Remove two regulators of pump 1 and pump 2 from
pump casing (55). (Refer to W3-8-3.)
3. Remove the fan pump from cover (10). (Refer to W3-
8-4.)
4. Remove the pilot pump from booster cover (7).
(Refer to W3-8-5.)
5. Remove socket bolts (93) (8 used). Remove cover
(92) and O-ring (94) from front casing (76).

l : 10 mm
6. Remove socket bolts (8) (5 used). Remove booster
cover (7) and O-ring (6) from valve cover (1).

l : 6 mm
7. Remove booster (5) from driven shaft (45).
8. Remove socket bolts (11) (2 used). Remove cover
(10), coupling (82), and O-ring (9) from valve cover
(1).

l : 8 mm

dCAUTION: Valve cover (1) weight: 60 kg (135 lb)

9. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the
bolt holes of valve cover (1). Attach a nylon sling
onto the eyebolt. Hoist and hold valve cover (1).
10. Remove socket bolt (4), socket bolts (12) (2 used),
and socket bolts (13) (9 used) from valve cover (1).
Tap and remove valve cover (1) from pump casing
(55) by using a plastic hammer.

l : 17 mm
11. Remove seat packing (18) from pump casing (55).

W3-8-2-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

IMPORTANT: Do not remove needle bearing (24)

unless necessary.
12. Remove stop ring (86), inner spacer (85), and valve
plate (25) from drive shaft (44). Remove valve plate
(26) from driven shaft (45).

dCAUTION: The pump casing (55) assembly

weight: 210 kg (465 lb)
13. Place the pump casing (55) assembly horizontally.
14. Remove the cylinder block (27) assemblies (2 used)
from drive shaft (44) and driven shaft (45) of pump
casing (55).
15. Remove plungers (32) (18 used), retainers (30) (2
used), spherical bushings (29) (2 used), and cylinder
springs (28) (18 used) from cylinder blocks (27) (2
used).
16. Remove the swash plate (34) assemblies (2 used)
from pump casing (55).
17. Remove shoe plates (33) (2 used) from swash plates
(34) (2 used).
IMPORTANT: THREEBOND #1305N has been applied
on the contacting part between tilt pin (37) and
servo piston (51). Do not disassemble tilt pin (37)
and servo piston (51) unless necessary. As the
setting changes, do not turn nuts (2, 68) and set
screws (3, 69).
18. Remove socket bolts (66) (8 used). Remove servo
covers (67) (2 used), stoppers L (52) (2 used), servo
pistons (51) (2 used), stoppers S (50) (2 used), and
tilt pins (37) (2 used) from pump casing (55).

l : 10 mm
19. Remove backup rings (54) (2 used) and O-rings (53)
(2 used) from stoppers L (52) (2 used).
20. Remove backup rings (48) (2 used) and O-rings (49)
(2 used) from stoppers S (50) (2 used).
21. Remove retaining ring (80) and front cover (79) from
front casing (76).
22. Remove oil seal (78) from front cover (79).

W3-8-2-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

dCAUTION: Front casing (76) weight: 32 kg (75 lb)

23. Install a lifting tool to the engine mounting bolt
hole of front casing (76). Attach a nylon sling onto
the lifting tool. Hoist and hold front casing (76).
Remove socket bolts (81) (11 used) from front
casing (76). Remove front casing (76) from pump
casing (55).

l : 10 mm

fNOTE: Pins (19) (2 used), pin (83), and pin (84) are
located between front casing (76) and pump casing (55).
When the contacting part of front casing (76) and pump
casing (55) is secured tight, tap and remove front casing
(76) by using a plastic hammer.
24. Remove retaining rings (70) (2 used), bearing
spacers (71) (2 used), and drive gear (72) from drive
shaft (44).
25. Remove retaining ring (75), bearing spacer (74), and
driven gear (73) from driven shaft (45).
26. Remove retaining rings (47) (2 used) and bearing
spacers (46) (2 used) from pump casing (55).
Remove retaining ring (41) and bearing spacer (42)
from driven shaft (45).
27. Tap the shaft end by using a plastic hammer and
remove drive shaft (44) and driven shaft (45) from
pump casing (55).
IMPORTANT: Do not remove roller bearings (43, 31)
unless necessary. Attach a plate onto the outer
ring of roller bearings (43, 31) and push out them
by using a press.
28. When replacing roller bearings (43, 31) in drive shaft
(44) and driven shaft (45), remove retaining ring
(41), bearing spacer (42), and roller bearings (43, 31).
29. Remove socket bolts (65) (8 used). Remove swash
plate stands (39) (2 used) from pump casing (55).

l : 6 mm

W3-8-2-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Main Pump

56

54,53 51 38 37 55 49,48 2 3 17 4 1
52
66
68
69 20 21
67
81 22
15
65 58
11
82 59

9 Section X-X
34
36 10

76
16

58
40 39 57 29 33 28 3130 15 14 27 32 18 13 23 16
62

41 73 47 46 42 31 42 41 45 26 5 6 8

74 7

75

47 B
B

71

19
78

44

86
35
70
70
24
79
25
80
77 12 Section B-B
72 18 46 43 42 41 85
91 90
93 94 92
Section A-A

WJAA-03-09-005

W3-8-2-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

1- Valve Cover 25- Valve Plate R 49- O-Ring (2 Used) 72- Drive Gear
2- Nut (2 Used) 26- Valve Plate L 50- Stopper S (2 Used) 73- Driven Gear
3- Set Screw (2 Used) 27- Cylinder Block (2 Used) 51- Servo Piston (2 Used) 74- Spacer
4- Socket Bolt 28- Cylinder Spring (18 Used) 52- Stopper L (2 Used) 75- Retaining Ring
5- Booster 29- Spherical Bushing (2 Used) 53- O-Ring (2 Used) 76- Front Casing
6- O-Ring 30- Retainer (2 Used) 54- Backup Ring (2 Used) 77- O-Ring
7- Booster Cover 31- Roller Bearing 55- Pump Casing 78- Oil Seal
8- Socket Bolt (5 Used) 32- Plunger (18 Used) 56- Eyebolt (2 Used) 79- Front Cover
9- O-Ring 33- Shoe Plate (2 Used) 57- Plug (20 Used) 80- Retaining Ring
10- Cover 34- Swash Plate (2 Used) 58- O-Ring (5 Used) 81- Socket Bolt (11 Used)
11- Socket Bolt (2 Used) 35- Pin 59- O-Ring (2 Used) 82- Coupling
12- Socket Bolt (2 Used) 36- Tilt Bushing (2 Used) 60- Name Plate 83- Pin (4 Used)
13- Socket Bolt (9 Used) 37- Tilt Pin (2 Used) 61- Rivet (2 Used) 84- Pin
14- Plug (2 Used) 38- Feedback Pin (2 Used) 62- Tapered Screw with Orifice (4 85- Inner Spacer
15- O-Ring (2 Used) 39- Swash Plate Stand (2 Used) Used) 86- Stop Ring
16- Plug (12 Used) 40- Pin (2 Used) 63- Plug (3 Used) 87- Pin (4 Used)
17- Valve Plate Pin (2 Used) 41- Retaining Ring (3 Used) 64- O-Ring (3 Used) 90- O-Ring (2 Used)
18- Seat Packing (2 Used) 42- Bearing Spacer (2 Used) 65- Socket Bolt (8 Used) 91- Plug (2 Used)
19- Pin (4 Used) 43- Roller Bearing 66- Socket Bolt (8 Used) 92- Cover
20- Stopper (2 Used) 44- Drive Shaft 67- Servo Cover (2 Used) 93- Socket Bolt (8 Used)
21- Steel Ball (2 Used) 45- Driven Shaft 68- Nut (2 Used) 94- O-Ring
22- Seat (2 Used) 46- Bearing Spacer (2 Used) 69- Set Screw (2 Used)
23- Plug (2 Used) 47- Retaining Ring (2 Used) 70- Retaining Ring (2 Used)
24- Needle Bearing (2 Used) 48- Backup Ring (2 Used) 71- Spacer (2 Used)

W3-8-2-7
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Main Pump

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
1. Apply THREEBOND #1305N onto the thread part of
socket bolts (65) (8 used).
2. Install swash plate stands (39) (2 used) to pump
casing (55) with socket bolts (65) (8 used).

l : 6 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

3. Install roller bearing (43), bearing spacer (42), and
retaining ring (41) to drive shaft (44).
4. Install drive shaft (44) to pump casing (55) by using
a plastic hammer. Install bearing spacer (46) and
retaining ring (47) to pump casing (55).
5. Install retaining ring (70), spacer (71), drive gear
(72), spacer (71), and retaining ring (70) to drive
shaft (44).
6. Install retaining ring (41), bearing spacer (42), roller
bearing (31), bearing spacer (42), and retaining ring
(41) to driven shaft (45).
7. Install driven shaft (45) to pump casing (55) by using
a plastic hammer.
8. Install pin (35) to pump casing (55).
9. Install bearing spacer (46) and retaining ring (47) to
pump casing (55).
10. Install driven gear (73), spacer (74), and retaining
ring (75) to driven shaft (45).
11. Install pins (19) (2 used), pin (83), and pin (84) to
pump casing (55).
12. Apply grease onto the seat packing (18) mounting
surface of pump casing (55). Install seat packing (18)
to pump casing (55).

W3-8-2-8
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

13. Install O-ring (94) and cover (92) to front casing (76) 22. Install servo covers (67) (2 used) to pump casing (55)
with socket bolts (93) (8 used). with socket bolts (66) (8 used).

l : 10 mm l : 10 mm

m : 100 N·m (10 kgf·m, 74 lbf·ft) m : 100 N·m (10 kgf·m, 74 lbf·ft)

dCAUTION: Front casing (76) weight: 32 kg (75 lb) 23. Fit tilt bushing (36) of swash plate (34) to tilt pin
(37). Install swash plate (34) to swash plate stand
14. Install front casing (76) to pump casing (55) with
(39). Check if swash plate (34) moves smoothly.
socket bolts (81) (11 used).

l : 10 mm

m : 100 N·m (10 kgf·m, 74 lbf·ft)

15. Apply grease onto the lip part in oil seal (78). Install
oil seal (78) to front cover (79) with the lip part
facing to the front cover (79) side.
16. Install O-ring (77), front cover (79), and retaining
ring (80) to front casing (76).
17. Install O-rings (49) (2 used) and backup rings (48) (2
used) to stoppers S (50) (2 used).
18. Install O-rings (53) (2 used) and backup rings (54) (2
used) to stoppers L (52) (2 used).
19. Apply THREEBOND #1305N onto the thread part of
servo pistons (51) (2 used).
20. Apply THREEBOND #1305N onto the tilt pin (37)
mounting position in servo pistons (51) (2 used).
21. Install servo pistons (51) (2 used), tilt pins (37) (2
used), stoppers L (52) (2 used), and stoppers S (50)
(2 used) to pump casing (55).
a

50
37 51
52
36
39

34
WJAA-03-09-011

a- Tilt Pin Mounting Position

W3-8-2-9
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

24. Install cylinder springs (28) (18 used), spherical

bushings (29) (2 used), retainers (30) (2 used), and,
plungers (32) (18 used) to cylinder blocks (27) (2
used).
25. Fit the splines and install the cylinder block (27)
assemblies (2 used) to drive shaft (44) and driven
shaft (45).
IMPORTANT: The shapes of valve plates (25, 26) are
different.
26. Fit the valve plate pin (17) positions and install valve
plates (25, 26) to valve cover (1).

fNOTE: Install valve plate (25) to the drive shaft (44) side.
Install valve plate (26) to the driven shaft (45) side.

a a

25 26

W16J-02-04-015
a- Notch

27. Install seats (22) (2 used), steel balls (21) (2 used),

and stoppers (20) (2 used) to valve cover (1).
28. Install needle bearings (24) (2 used) to valve cover
(1).
29. Install O-rings (15, 58, and 59) and seat packing (18)
to pump casing (55).

W3-8-2-10
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

34. Install coupling (82) to drive shaft (44). Install O-ring

d CAUTION: Valve cover (1) weight: 60 kg (135 lb) (9) to cover (10). Install cover (10) to valve cover (1)
30. Install the special tool to the end of drive shaft (44) with socket bolts (11) (2 used).
and driven shaft (45).
l : 8 mm
148 mm m : 60 N·m (6 kgf·m, 44 lbf·ft)
130.7 mm 35. Install two regulators of pump 1 and pump 2 to
φ387

φ34.5

97.7 mm pump casing (55) with the socket bolts (6 used).

-0.075
0

Install feedback pin (38) of tilt pin (37) to the

+0.05
+0.15

feedback lever of the regulator at this time. (Refer to

R30
W3-8-3.)

R2
l : 6 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

R10
30 °

151 mm

133.7 mm
φ387

φ32

43.9 mm
+0.05
+0.15
-0.075
0

R30

R1

R10
30 °
W16J-02-04-009

31. Install pins (19) (2 used) to valve cover (1). Tap and
install valve cover (1) to pump casing (55) by using a
plastic hammer.
32. Install valve cover (1) to pump casing (55) with
socket bolt (4), socket bolts (12) (2 used), and socket
bolts (13) (9 used).

l : 17 mm

m : 630 N·m (63 kgf·m, 460 lbf·ft)

33. Install booster (5) to driven shaft (45). Install O-ring
(6) to booster cover (7). Install booster cover (7) to
valve cover (1) with socket bolts (8) (5 used).

l : 8 mm

m : 60 N·m (6 kgf·m, 44 lbf·ft)

W3-8-2-11
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

36. Install the pilot pump to booster cover (7) with the
spring washers (2 used) and socket bolts (2 used).
(Refer to W3-8-5.)

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

dCAUTION: Fan pump weight: 23 kg (51 lb)

37. Install the fan pump to cover (10) with the washers
(2 used) and socket bolts (2 used). (Refer to W3-8-4.)

l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-8-2-12
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Regulator for Main Pump

7
6

5
4 8
3 9
2
34 26
1

33
28 32
31
30
11

10
27 13
26 29 30
5 14
18 15
19 16
25 20
17
21
22

12
24 23 WJAA-03-09-006

1- Casing 10- Support Plug 19- Sleeve 28- Pump Control Solenoid Valve
2- Spring Seat 11- O-Ring 20- Pilot Piston 29- Socket Bolt (2 Used)
3- Pilot Spring 12- O-Ring 21- Sleeve 30- O-Ring (2 Used)
4- Adjusting Disc 13- Pin 22- O-Ring 31- Seat
5- O-Ring (2 Used) 14- O-Ring (5 Used) 23- Plug 32- Steel Ball
6- Cover 15- O-Ring 24- Socket Bolt (4 Used) 33- Stopper
7- Socket Bolt (4 Used) 16- Pin 25- Socket Bolt 34- Socket Bolt (6 Used)
8- Nut 17- Feedback Lever 26- Plug (9 Used)
9- Adjusting Screw 18- Spool 27- Valve Casing

W3-8-3-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Regulator for Main Pump

10. Remove adjusting disc (4) from casing (1) by using a
IMPORTANT: The same type of regulators are
bolt (M4). Remove O-ring (5) from adjusting disc (4).
installed to pump 1 and pump 2. Do not confuse
them as the characteristics are different. The 11. Remove pilot spring (3) and spring seat (2) from
pump 1 regulator is explained here. casing (1).
1. Remove socket bolts (34) (6 used). Remove the 12. Remove O-ring (30), seat (31), steel ball (32), and
regulator from the main pump. stopper (33) from casing (1).
l : 6 mm
IMPORTANT: Do not remove pin (13) unless
necessary.
2. Remove O-rings (5, 14, 15, and 30) from casing (1).
3. Remove socket bolts (29) (2 used). Remove pump
control solenoid valve (28) from valve casing (27).

l : 4 mm
4. Remove plug (23) from valve casing (27). Remove
O-ring (12) from plug (23).

l : 8 mm
5. Remove socket bolt (25) and socket bolts (24) (4
used). Remove valve casing (27) from casing (1).

l : 6 mm
IMPORTANT: As the setting changes, do not turn nut
(8) and adjusting screw (9).
6. Remove socket bolts (7) (4 used). Remove cover (6)
from casing (1).

l : 5 mm
7. Remove support plug (10) from casing (1). Remove
O-ring (11) from support plug (10).

l : 6 mm
IMPORTANT: Do not remove pin (16) unless
necessary.
8. Remove feedback lever (17) from casing (1).
9. Remove O-ring (22), sleeve (21), pilot piston (20),
spool (18), and sleeve (19) from casing (1).

W3-8-3-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Regulator for Main Pump

29

34
16

11
26
10 1
15
30

17

WJAA-03-09-007

26 31 32 33 28

27

30 2 3 4 5

25

12, 23 7
8
24 9

WJAA-03-09-008
21 22 5 20 19 18 13 14

W3-8-3-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

1- Casing 10- Support Plug 19- Sleeve 28- Pump Control Solenoid Valve
2- Spring Seat 11- O-Ring 20- Pilot Piston 29- Socket Bolt (2 Used)
3- Pilot Spring 12- O-Ring 21- Sleeve 30- O-Ring (2 Used)
4- adjusting disc 13- Pin 22- O-Ring 31- Seat
5- O-Ring (2 Used) 14- O-Ring (5 Used) 23- Plug 32- Steel Ball
6- Cover 15- O-Ring 24- Socket Bolt (4 Used) 33- Stopper
7- Socket Bolt (4 Used) 16- Pin 25- Socket Bolt 34- Socket Bolt (6 Used)
8- Nut 17- Feedback Lever 26- Plug (9 Used)
9- Adjusting Screw 18- Spool 27- Valve Casing

W3-8-3-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Regulator for Main Pump 10. Install valve casing (27) to casing (1) with socket bolt
(25) and socket bolts (24) (4 used).
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing. l : 5 mm
1. Install sleeve (19) and spool (18) to casing (1).
m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)
2. Fit and install pin (16) of feedback lever (17) to the
pin (16) hole on sleeve (19). 11. Install O-ring (12) to plug (23).

3. Install O-ring (11) to support plug (10). 12. Install plug (23) to valve casing (27).

4. Move feedback lever (17) so that the support plug l : 8 mm

(10) hole on feedback lever (17) can be seen from
the mounting hole on support plug (10). Install m : 31 N·m (3.1 kgf·m, 23 lbf·ft)
support plug (10) to casing (1) while fitting support
plug (10) to the support plug (10) hole on feedback 13. Install pump control solenoid valve (28) to valve
lever (17). casing (27) with socket bolts (29) (2 used).
l : 6 mm l : 4 mm
m : 36 N·m (3.7 kgf·m, 27 lbf·ft) m : 7 N·m (0.7 kgf·m, 5.2 lbf·ft)
5. Install O-ring (5) to adjusting disc (4). 14. Install O-rings (5, 14, 15, and 30) to casing (1).
6. Install spring seat (2), pilot spring (3), and adjusting 15. Install the regulator to the main pump with socket
disc (4) to casing (1). bolts (34) (6 used).
7. Install cover (6) to casing (1) with socket bolts (7) (4 l : 6 mm
used).
m : 29 N·m (2.9 kgf·m, 21 lbf·ft)
l : 5 mm

m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)

8. Install stopper (33), steel ball (32), seat (31), and
O-ring (30) to casing (1).
9. Install sleeve (21), pilot piston (20), and O-ring (22)
to casing (1).

W3-8-3-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

(Blank)

W3-8-3-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of Fan Pump

WJAA-03-09-009

W3-8-4-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

1- Body S 13- Gasket 24- Control Piston 35- Plug (2 Used)

2- Body H 14- Ball (2 Used) 25- Spool 38- Socket Bolt (7 Used)
3- Shaft 15- Spring 26- Block 39- Socket Bolt (4 Used)
4- Cylinder Block 16- Spring 27- Piston 40- O-Ring
5- Valve Plate 17- Sleeve 28- Oil Seal 41- O-Ring (2 Used)
6- Plunger (11 Used) 18- Control Piston 29- Roller Bearing 42- O-Ring
8- Retainer 19- Washer (3 Used) 30- Needle Bearing 43- O-Ring
9- Holder 20- Seal Holder 31- Retaining Ring 44- O-Ring
10- Swash Plate 21- Spring Guide 32- Retaining Ring
11- Needle (3 Used) 22- Spring 33- Retaining Ring
12- Pin (4 Used) 23- Sleeve 34- Plug

W3-8-4-2
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Disassembly of fan pump

10. Remove the cylinder block (4) assembly from shaft
d CAUTION: Fan pump weight: 23 kg (51 lb) (3).
1. Remove plugs (35) (2 used) from body S (1) and
11. Remove plunger (6) (11 used), retainer (8), holder
body H (2). Drain oil from the fan pump.
(9), washer (19), and needle (11) (3 used) from
l : 6 mm cylinder block (4).
2. Remove O-rings (41) (2 used) from plugs (35) (2 12. Remove retaining ring (32), washer (19), spring (15),
used). and washer (19) from cylinder block (4).
3. Remove socket bolts (39) (2 used). Remove block
(26) from body H (2).

l : 4 mm
4. Remove O-ring (43), plug (34), and piston (27) from
block (26).

l : 5 mm
5. Remove O-ring (40) from plug (34).
IMPORTANT: Evenly loosen socket bolts (38) (7
used). When loosening socket bolt (38), body H
(2) is floated from body S (1) by the reaction force
of springs (15, 16, 22). At this time, record the
clearance between body S (1) and body H (2).
IMPORTANT: Do not remove pin (12) and needle
bearing (30) unless necessary. Do not drop valve
plate (5).
6. Remove socket bolts (38) (7 used). Remove body H
(2) and gasket (13) from body S (1). Remove valve
plate (5) from body H (2).

l : 8 mm
7. Remove control piston (18), spring (16), and sleeve
(17) from body H (2).
8. Remove O-ring (42) from sleeve (17).
9. Remove socket bolts (39) (2 used). Remove control
piston (24), spring (22), sleeve (23), spring guide
(21), and spool (25) from body H (2).

l : 4 mm

W3-8-4-3
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

13. Remove swash plate (10) and balls (14) (2 used)

from body S (1).
14. Remove retaining ring (31) from body S (1).
15. Tap and remove the shaft (3) assembly from body S
(1) by using a plastic hammer.
16. Remove the seal holder (20) assembly from shaft (3).
17. Remove oil seal (28) and O-ring (44) from seal
holder (20).
IMPORTANT: Do not remove roller bearing (29)
unless necessary.
18. Remove retaining ring (33) and roller bearing (29)
from shaft (3).

W3-8-4-4
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Fan Pump

4 18 16 17 19 1 13 42 2

10
12

31 5
20 32
28 30
14
15
3
12

33 43
29
26
44 34
40

39

9 19 11 6 24 23 39 22 21 35 41 38 25 27

WJAA-03-09-010

W3-8-4-5
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

1- Body S 13- Gasket 24- Control Piston 35- Plug (2 Used)

2- Body H 14- Ball (2 Used) 25- Spool 38- Socket Bolt (7 Used)
3- Shaft 15- Spring 26- Block 39- Socket Bolt (4 Used)
4- Cylinder Block 16- Spring 27- Piston 40- O-Ring
5- Valve Plate 17- Sleeve 28- Oil Seal 41- O-Ring (2 Used)
6- Plunger (11 Used) 18- Control Piston 29- Roller Bearing 42- O-Ring
8- Retainer 19- Washer (3 Used) 30- Needle Bearing 43- O-Ring
9- Holder 20- Seal Holder 31- Retaining Ring 44- O-Ring
10- Swash Plate 21- Spring Guide 32- Retaining Ring
11- Needle (3 Used) 22- Spring 33- Retaining Ring
12- Pin (4 Used) 23- Sleeve 34- Plug

W3-8-4-6
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Assembly of Fan Pump 12. Install needle bearing (30) to body H (2).
IMPORTANT: Before assembling, apply hydraulic oil 13. Install spring guide (21) and sleeve (23) to body H
onto parts in order to prevent them from seizing. (2) with socket bolts (39) (2 used).
1. Install roller bearing (29) and retaining ring (33) to
l : 4 mm
shaft (3).
2. Install oil seal (28) and O-ring (44) to seal holder m : 4 N·m (0.4 kgf·m, 3.0 lbf·ft)
(20). 14. Install spring (22) and control piston (24) to sleeve
3. Install the seal holder (20) assembly and retaining (23).
ring (31) to body S (1). 15. Install O-ring (42) to sleeve (17).
IMPORTANT: Do not damage oil seal (28). 16. Install sleeve (17), spring (16), and control piston
4. Wind a duct tape onto the gear of shaft (3). Tap and (18) to body H (2).
install the shaft (3) assembly to body S (1) by using a
17. Install valve plate (5) to body H (2).
plastic hammer.
5. Install retaining ring (31) to body S (1).
6. Install balls (14) (2 used) and swash plate (10) to
body S (1).
7. Install washer (19), spring (15), washer (19), and
retaining ring (32) to cylinder block (4).
8. Install needles (11) (3 used), washer (19), and holder
(9) to cylinder block (4).
9. Install plungers (6) (11 used) to retainer (8).
10. Install the retainer (8) assembly to cylinder block (4).
11. Install the cylinder block (4) assembly to shaft (3).

W3-8-4-7
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

IMPORTANT: Check that a clearance between

body S (1) and body H (2) is equal to that
before disassembling. If the dimension differs,
disassemble and assemble again.
18. Install gasket (13) and body H (2) to body S (1) with
socket bolts (38) (7 used).

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

19. Install O-ring (40) to plug (34).
20. Install plug (34), piston (27), and O-ring (43) to block
(26).

l : 5 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

21. Install spool (25) and the block (26) assembly to
body H (2) with socket bolts (39) (2 used).

l : 4 mm

m : 4 N·m (0.4 kgf·m, 3.0 lbf·ft)

22. Install O-rings (41) (2 used) to plugs (35) (2 used).
23. Install plugs (35) (2 used) to body S (1) and body H
(2).

l : 6 mm

m : 27 N·m (2.7 kgf·m, 20 lbf·ft)

W3-8-4-8
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Structure of Pilot Pump

1
2

3
4

13
5 6
10
11
3

12

1 8
11
10
9

8
7

14

15
6
W137-02-04-034

W3-8-5-1
 SECTION 3 UPPERSTRUCTURE
Group 8 Pump Device

Tightening
Wrench Size Torque
No. Part Name Q’ty Remark
(mm) (kgf·m,
N·m
lbf·ft)
Apply a film of hydraulic oil to bushing when
1 Bushing 4
installing
2 Gear 1
Apply a film of hydraulic oil to bushing when
3 Bushing 4
installing
4 Knock Pin 2
5 Key 2
6 O-Ring 2 Apply grease to O-ring when installing
7 Retaining Ring 1
Apply grease onto the lip part in oil seal when
8 Oil Seal 1
installing
9 Flange 1
10 Backup Ring 2 Apply grease to backup ring when installing
11 Seal 2 Apply grease to seal when installing
12 Gear 1
13 Housing 1
14 Bolt 2 j : 17 35 (3.5, 26)
15 Cover 1

W3-8-5-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Removal and Installation of Control Valve

5 2, 3, 4 6, 7, 8 1 9 10

2 6 WJAA-03-07-001 11 WJAA-03-10-023

IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts, washers (10) (4 used). Remove the
and pipes have been disconnected. In addition, bracket (11) assembly.
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the j : 19 mm
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

d(Refer
CAUTION: Bleed air from the hydraulic oil tank.
to W1-4-1.)
2. Open cover (1).
3. Remove bolts, washers (2) (2 used), spacer (3), and
rubber (4). Remove cover (5).

j : 19 mm
4. Remove bolts, washers (6) (4 used), spacers (7) (2
used), and rubbers (8) (2 used). Remove cover (9).

j : 19 mm

W3-9-1-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WJAA-03-10-022 WJAA-03-10-024

6. Remove bolts, washers (12) (2 used). Remove 11. Remove signal control valve (19). (Refer to W3-13-1.)
bracket (13).
12. Remove 2-spool solenoid valve unit (20). (Refer to
j : 17 mm W3-12-3.)

7. Remove bolts, washers (14) (2 used). Remove 13. Remove socket bolts (21) (4 used). Disconnect pipe
bracket (15). (22). Remove O-ring (23).

j : 17 mm l : 10 mm

8. Disconnect the both ends of hoses (16) (2 used). 14. Remove socket bolts (24) (4 used). Disconnect pipe
(25). Remove O-ring (26).
j : 19 mm
l : 10 mm
9. Disconnect hoses (17) (10 used).

j : 19 mm
10. Disconnect hoses (18) (5 used).

j : 17 mm

W3-9-1-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

41 38, 39

WJAA-03-10-025 40 WJAA-03-10-026

15. Remove bolt, washer (27). Remove clip (28). 21. Remove bolt, washer (38). Remove clip (39).

j : 17 mm j : 17 mm
16. Remove bolt, washer (29). Remove clip (30). 22. Remove bolts, washers (40) (2 used). Place the
bracket (41) assembly outside the working area.
j : 17 mm
j : 19 mm
17. Disconnect connectors (31) (3 used).
18. Remove socket bolts (32) (4 used) and flanges (33)
(2 used). Disconnect hose (34). Remove O-ring (35).

l : 12 mm
19. Disconnect hoses (36) (2 used).

j : 36 mm
20. Disconnect hoses (37) (4 used).

j : 17 mm

W3-9-1-3
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

53

55
56

WJAA-03-10-027 54 57 WJAA-03-10-028

23. Remove socket bolts (42) (24 used) and flanges (43) 27. Remove bolts, washers (53, 54) (2 used for each).
(12 used). Disconnect hoses (44) (6 used). Remove Place the bracket (55) assembly outside the working
O-rings (45) (6 used). area.

l : 12 mm j : 19 mm
24. Remove bolt (46), spring washer (47), and nut (48). 28. Remove bolts, washers (56) (2 used). Remove
Remove clamps (49) (2 used). bracket (57).

j : 19 mm j : 19 mm
25. Remove socket bolts (42) (8 used). Disconnect the
pipe (50, 51) assemblies. Remove O-rings (45) (2
used).

l : 12 mm
26. Disconnect hose (52).

j : 17 mm

W3-9-1-4
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WJAA-03-10-029 WJAA-03-10-030

29. Remove socket bolts (58) (24 used) and flanges (59)
(12 used). Disconnect hoses (60) (6 used). Remove a
O-rings (61) (6 used).

l : 12 mm
30. Disconnect hoses (62) (6 used).

j : 17 mm
31. Disconnect hose (63).

j : 19 mm
64
dlb)
CAUTION: Control valve (64) weight: 430 kg (950

32. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to

lifting holes (a) (2 places) of control valve (64).
Attach nylon slings onto the eyebolts (2 used). Hoist WJAA-03-10-032
and hold control valve (64).
a- Lifting Hole

W3-9-1-5
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

72, 74 73, 74

75

WJAA-03-10-031 64 71 WJAA-03-10-033

33. Disconnect hose (65). 39. Remove bolts, washers (71) (8 used). Disconnect
the pipe (72, 73) assemblies. Remove O-rings (74) (2
j : 17 mm used).
34. Disconnect the both ends of hoses (66) (2 used).
j : 19 mm
j : 19 mm 40. Disconnect hoses (75) (2 used).
35. Disconnect the both ends of hose (67).
j : 17 mm
j : 17 mm 41. Remove the adapter with control valve (64)
36. Disconnect hoses (68) (8 used). attached if necessary.

j : 19 mm
37. Disconnect connectors (69) (3 used).
38. Remove bolts (70) (4 used). Remove control valve
(64).

j : 30 mm

W3-9-1-6
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

72, 74 73, 74
a

64
75

64 71 WJAA-03-10-033 WJAA-03-10-032

a- Lifting Hole
Installation
1. Install all removed adapters to control valve (64).
2. Connect hoses (75) (2 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

3. Install O-rings (74) (2 used) to the pipe (72, 73)
assemblies. Connect the pipe (72, 73) assemblies
with bolts, washers (71) (8 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

dlb)
CAUTION: Control valve (64) weight: 430 kg (950

4. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to

lifting holes (a) (2 places) of control valve (64).
Attach nylon slings onto the eyebolts (2 used). Hoist
control valve (64).

W3-9-1-7
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WJAA-03-10-031

5. Install control valve (64) with bolts (70) (4 used). 8. Connect the both ends of hose (67).

j : 30 mm j : 17 mm

m : 550 N·m (55 kgf·m, 410 lbf·ft) m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
6. Connect connectors (69) (3 used). 9. Connect the both ends of hoses (66) (2 used).
7. Connect hoses (68) (8 used). j : 19 mm
j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)
m : 30 N·m (3 kgf·m, 22 lbf·ft) 10. Connect hose (65).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

W3-9-1-8
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WJAA-03-10-029 WJAA-03-10-030

11. Connect hose (63).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

12. Connect hoses (62) (6 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

13. Install O-rings (61) (6 used) to hoses (60) (6 used).
Connect hoses (60) (6 used) with flanges (59) (12
used) and socket bolts (58) (24 used).

l : 12 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

W3-9-1-9
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

53

55
56

WJAA-03-10-027 54 57 WJAA-03-10-028

14. Install bracket (57) with bolts, washers (56) (2 used). 18. Install clamps (49) (2 used) with nut (48), spring
washer (47), and bolt (46).
j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
15. Install the bracket (55) assembly with bolts, washers
(53, 54) (2 used for each). 19. Install O-rings (45) (6 used) to hoses (44) (6 used).
Connect hoses (44) (6 used) with flanges (43) (12
j : 19 mm used) and socket bolts (42) (24 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft) l : 12 mm
16. Connect hose (52).
m : 140 N·m (14 kgf·m, 103 lbf·ft)
j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

17. Install O-rings (45) (2 used) to the pipe (50, 51)
assemblies. Connect the pipe (50, 51) assemblies
with socket bolts (42) (8 used).

l : 12 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

W3-9-1-10
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

41 38, 39

WJAA-03-10-025 40 WJAA-03-10-026

20. Install the bracket (41) assembly with bolts, washers 25. Connect connectors (31) (3 used).
(40) (2 used).
26. Install clip (30) with bolt, washer (29).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
21. Install clip (39) with bolt, washer (38).
27. Install clip (28) with bolt, washer (27).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
22. Connect hoses (37) (4 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

23. Connect hoses (36) (2 used).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

24. Install O-ring (35) to hose (34). Connect hose (34)
with flanges (33) (2 used) and socket bolts (32) (4
used).

l : 12 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

W3-9-1-11
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WJAA-03-10-022 WJAA-03-10-024

28. Install O-ring (26) to pipe (25). Install pipe (25) with 34. Connect the both ends of hoses (16) (2 used).
socket bolts (24) (4 used).
j : 19 mm
l : 10 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
35. Install bracket (15) with bolts, washers (14) (2 used).
29. Install O-ring (23) to pipe (22). Install pipe (22) with
socket bolts (21) (4 used). j : 17 mm

l : 10 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

36. Install bracket (13) with bolts, washers (12) (2 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
30. Install 2-spool solenoid valve unit (20). (Refer to W3- j : 17 mm
12-3.)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
31. Install signal control valve (19). (Refer to W3-13-1.)
32. Connect hoses (18) (5 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

33. Connect hoses (17) (10 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-9-1-12
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

5 2, 3, 4 6, 7, 8 1 9 10

2 6 WJAA-03-07-001 11 WJAA-03-10-023

37. Bleed air from the hydraulic system. (Refer to W1- 40. Install cover (5) with rubber (4), spacer (3), and bolts,
4-1.) washers (2) (2 used).
IMPORTANT: Check the hydraulic oil level. Start the j : 19 mm
engine and check for any oil leaks.
38. Install the bracket (11) assembly with bolts, washers m : 90 N·m (9 kgf·m, 66 lbf·ft)
(10) (4 used). 41. Shut cover (1).
j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

39. Install cover (9) with rubbers (8) (2 used), spacers (7)
(2 used), and bolts, washers (6) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-9-1-13
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

(Blank)

W3-9-1-14
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly and Assembly of Valve Unit

WJAA-03-10-020

W3-9-2-1
SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

13

WJAA-03-10-021

W3-9-2-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

View A
54

55
55

56

56

53

56

55

55

WJAA-03-10-019
54 41

W3-9-2-3
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

1- Housing 33- Plug (4 Used) 65- Cap (2 Used) 96- Flow Rate Control Valve (2
2- Spool 34- Cover (2 Used) 66- Cap (2 Used) Used)
3- Spool 35- Socket Bolt (4 Used) 67- O-Ring (5 Used) 97- Socket Bolt (12 Used)
4- Spool 36- Flange (5 Used) 68- Spring (2 Used) 98- Spring (3 Used)
5- Spool 37- O-Ring (5 Used) 69- Spool (2 Used) 99- Piston (3 Used)
6- Spool (2 Used) 38- Socket Bolt (20 Used) 70- Cap 100- Check Valve (3 Used)
7- Cap (2 Used) 39- Check Valve 71- Cap 101- Poppet
8- Backup Ring (2 Used) 40- Overload Relief Valve (6 Used) 72- Check Valve (2 Used) 102- Poppet
9- O-Ring (2 Used) 41- O-Ring (14 Used) 73- Cap (2 Used) 103- Check Valve
10- Spacer (2 Used) 42- Backup Ring (10 Used) 74- Check Valve (2 Used) 104- Piston
11- Spring (2 Used) 43- O-Ring (10 Used) 75- Cap 105- Cap
12- Check Valve (2 Used) 44- Cap (2 Used) 76- Sleeve (2 Used) 106- Backup Ring
13- Housing 45- O-Ring (4 Used) 77- Piston (2 Used) 107- O-Ring
14- Spool 46- Cap (2 Used) 78- O-Ring (2 Used) 108- Check Valve
15- Spool 47- Backup Ring (7 Used) 79- Backup Ring (2 Used) 109- Spring
16- Spool 48- Spring (10 Used) 80- Spool (2 Used) 110- Check Valve
17- Cap 49- Check Valve (7 Used) 81- Spring 111- Arm Rod Anti-Drift Valve
18- Spring 50- Socket Bolt (8 Used) 82- O-Ring (3 Used) 112- Flow Rate Control Valve
19- O-Ring (13 Used) 51- Washer (14 Used) 83- Spring Guide (2 Used) Assembly
20- Spacer 52- Socket Bolt (6 Used) 84- Sleeve 113- Socket Bolt (6 Used)
21- Spool 53- O-Ring 85- O-Ring (2 Used) 114- Piston
22- Main Relief Valve 54- O-Ring (2 Used) 86- Cap (2 Used) 115- Cap
23- Cover 55- O-Ring (5 Used) 87- Boom 2 Anti-Drift Valve 116- Backup Ring
24- O-Ring (18 Used) 56- O-Ring (6 Used) 88- Socket Bolt (5 Used) 117- O-Ring
25- Spring Guide (18 Used) 57- Boom Overload Relief Valve 89- Spring (3 Used) 118- Spring
26- Spring (9 Used) 58- Cap (2 Used) 90- Poppet (3 Used) 119- Check Valve
27- Cap (9 Used) 59- Cap (2 Used) 91- O-Ring (2 Used) 120- Poppet
28- Cover 60- O-Ring (12 Used) 92- Spring 121- Spring
29- Cover 61- O-Ring (4 Used) 93- Sleeve 122- Cap
30- Cap (8 Used) 62- Backup Ring (5 Used) 94- O-Ring (3 Used) 123- Cap
31- O-Ring (11 Used) 63- Cap 95- Flow Rate Control Valve 124- Spool
32- Socket Bolt (26 Used) 64- Piston (2 Used) 125- Auxiliary Flow Combiner Valve

a Load Check Valve f Check Valve k Load Check Valve p Load Check Valve
b Arm Regeneration Cut Valve g Bypass Shut-Out Valve l Check Valve q Bypass Shut-Out Valve
c Bucket Regeneration Cut Valve h Load Check Valve m Check Valve
d Check Valve i Load Check Valve n Check Valve
e Flow Combiner Valve j Boost Check Valve o Load Check Valve

W3-9-2-4
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Housing Assembly of Housing

1. Remove socket bolt (50) and washer (51) from IMPORTANT: Before assembling, apply hydraulic oil
housing (1). onto parts in order to prevent them from seizing.
1. Install O-rings (41) (2 used), O-ring (53), O-rings (54)
l : 14 mm
(2 used), O-rings (55) (5 used), and O-rings (56) (6
2. Remove socket bolts (50) (7 used), socket bolts (52) used) to housing (1).
(6 used), and washers (51) (13 used) from housing
2. Install housing (13) to housing (1) with socket bolts
(13).
(50) (7 used), socket bolts (52) (6 used), and washers
l : 14 mm (51) (13 used).
3. Remove housing (13) from housing (1). l : 14 mm
4. Remove O-rings (41) (2 used), O-ring (53), O-rings m : 250 N·m (25 kgf·m, 185 lbf·ft)
(54) (2 used), O-rings (55) (5 used), and O-rings (56)
(6 used) from housing (1). 3. Install washer (51) and socket bolt (50) to housing
(1).

l : 14 mm

m : 250 N·m (25 kgf·m, 185 lbf·ft)

W3-9-2-5
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

(Blank)

W3-9-2-6
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Control Valve (4-Spool Side)

e d
c

WJAA-03-10-003

W3-9-3-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

13

WJAA-03-10-004

W3-9-3-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

1- Housing 33- Plug (4 Used) 65- Cap (2 Used) 96- Flow Rate Control Valve (2
2- Spool 34- Cover (2 Used) 66- Cap (2 Used) Used)
3- Spool 35- Socket Bolt (4 Used) 67- O-Ring (5 Used) 97- Socket Bolt (12 Used)
4- Spool 36- flange (5 Used) 68- Spring (2 Used) 98- Spring (3 Used)
5- Spool 37- O-Ring (5 Used) 69- Spool (2 Used) 99- Piston (3 Used)
6- Spool (2 Used) 38- Socket Bolt (20 Used) 70- Cap 100- Check Valve (3 Used)
7- Cap (2 Used) 39- Check Valve 71- Cap 101- Poppet
8- Backup Ring (2 Used) 40- Overload Relief Valve (6 Used) 72- Check Valve (2 Used) 102- Poppet
9- O-Ring (2 Used) 41- O-Ring (14 Used) 73- Cap (2 Used) 103- Check Valve
10- Spacer (2 Used) 42- Backup Ring (10 Used) 74- Check Valve (2 Used) 104- Piston
11- Spring (2 Used) 43- O-Ring (10 Used) 75- Cap 105- Cap
12- Check Valve (2 Used) 44- Cap (2 Used) 76- Sleeve (2 Used) 106- Backup Ring
13- Housing 45- O-Ring (4 Used) 77- Piston (2 Used) 107- O-Ring
14- Spool 46- Cap (2 Used) 78- O-Ring (2 Used) 108- Check Valve
15- Spool 47- Backup Ring (7 Used) 79- Backup Ring (2 Used) 109- Spring
16- Spool 48- Spring (10 Used) 80- Spool (2 Used) 110- Check Valve
17- Cap 49- Check Valve (7 Used) 81- Spring 111- Arm Rod Anti-Drift Valve
18- Spring 50- Socket Bolt (8 Used) 82- O-Ring (3 Used) 112- Flow Rate Control Valve
19- O-Ring (13 Used) 51- Washer (14 Used) 83- Spring Guide (2 Used) Assembly
20- Spacer 52- Socket Bolt (6 Used) 84- Sleeve 113- Socket Bolt (6 Used)
21- Spool 53- O-Ring 85- O-Ring (2 Used) 114- Piston
22- Main Relief Valve 54- O-Ring (2 Used) 86- Cap (2 Used) 115- Cap
23- Cover 55- O-Ring (5 Used) 87- Boom 2 Anti-Drift Valve 116- Backup Ring
24- O-Ring (18 Used) 56- O-Ring (6 Used) 88- Socket Bolt (5 Used) 117- O-Ring
25- Spring Guide (18 Used) 57- Boom Overload Relief Valve 89- Spring (3 Used) 118- Spring
26- Spring (9 Used) 58- Cap (2 Used) 90- Poppet (3 Used) 119- Check Valve
27- Cap (9 Used) 59- Cap (2 Used) 91- O-Ring (2 Used) 120- Poppet
28- Cover 60- O-Ring (12 Used) 92- Spring 121- Spring
29- Cover 61- O-Ring (4 Used) 93- Sleeve 122- Cap
30- Cap (8 Used) 62- Backup Ring (5 Used) 94- O-Ring (3 Used) 123- Cap
31- O-Ring (11 Used) 63- Cap 95- Flow Rate Control Valve 124- Spool
32- Socket Bolt (26 Used) 64- Piston (2 Used) 125- Auxiliary Flow Combiner Valve

a Load Check Valve f Check Valve k Load Check Valve p Load Check Valve
b Arm Regeneration Cut Valve g Bypass Shut-Out Valve l Check Valve q Bypass Shut-Out Valve
c Bucket Regeneration Cut Valve h Load Check Valve m Check Valve
d Check Valve i Load Check Valve n Check Valve
e Flow Combiner Valve j Boost Check Valve o Load Check Valve

W3-9-3-3
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Control Valve (4-Spool Side) Disassembly of Check Valve (39)

Disassembly of Spools (6, 14, 15, and 16) IMPORTANT: Do not disassemble check valve (39)
unless necessary.
1. Remove socket bolts (32) (6 used). Remove cover
(28) and O-rings (24) (4 used) from housing (13). 8. Remove check valve (39) from housing (13).

l : 10 mm j : 41 mm

2. Remove socket bolts (32) (3 used) and socket bolts 9. Remove O-rings (41, 43) and backup ring (42) from
(35) (2 used). Remove cover (34) and O-rings (24) (3 check valve (39).
used) from housing (13). Disassembly of Main Relief Valve (22)
l : 10 mm IMPORTANT: As the setting changes, do not
disassemble the relief valve. If the relief valve is
3. Remove socket bolts (32) (2 used). Remove cover
disassembled, pressure should be adjusted. (Refer
(23) and O-ring (24) from housing (13).
to TROUBLESHOOTING / Operational Performance
l : 10 mm Test in the separated volume, T/M.)
10. Remove main relief valve (22) from housing (13).
4. Put the matching marks on housing (13) and spools
(6, 14, 15, and 16). j : 41 mm
IMPORTANT: Do not disassemble spools (6, 14, 15, 11. Remove O-ring (19) from main relief valve (22).
and 16) unless necessary.
5. Remove spools (6, 14, 15, and 16) from housing (13).
Disassembly of Boom Overload Relief Valve (57)
IMPORTANT: As the setting changes, do not
disassemble the relief valve. If the relief valve is
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
6. Remove boom overload relief valve (57) from
housing (13).

j : 41 mm
7. Remove O-rings (41, 43), and backup ring (42) from
boom overload relief valve (57).

W3-9-3-4
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Overload Relief Valve (40) Disassembly of Bucket Regeneration Cut Valve (c)
IMPORTANT: As the setting changes, do not 22. Remove sleeve (84) from housing (13).
disassemble the relief valve. If the relief valve is
disassembled, pressure should be adjusted. (Refer j : 36 mm
to TROUBLESHOOTING / Operational Performance 23. Remove sleeve (76), spool (80), spring (81), and
Test in the separated volume, T/M.) spring guide (83) from housing (13).
12. Remove overload relief valves (40) (3 used) from
24. Remove piston (77), backup ring (79), and O-ring
housing (13).
(78) from sleeve (76).
j : 41 mm 25. Remove O-ring (82) and cap (86) from sleeve (84).
13. Remove O-rings (41, 43) (3 used for each) and
l : 12 mm
backup rings (42) (3 used) from overload relief
valves (40) (3 used). 26. Remove O-ring (85) from cap (86).
Disassembly of Load Check Valve (a)
14. Remove cap (123) from housing (13).

l : 14 mm
15. Remove spring (48) and check valve (49) from
housing (13).
16. Remove O-rings (61, 19) and backup ring (62) from
cap (123).
Disassembly of Arm Regeneration Cut Valve (b)
17. Remove sleeve (93) from housing (13).

j : 36 mm
18. Remove sleeve (76), spool (80), spring (92), and
spring guide (83) from housing (13).
19. Remove piston (77), backup ring (79), and O-ring
(78) from sleeve (76).
20. Remove O-ring (82) and cap (86) from sleeve (93).

l : 12 mm
21. Remove O-ring (85) from cap (86).

W3-9-3-5
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Check Valve (d)

27. Remove cap (63) from housing (13).

j : 14 mm
28. Remove check valve (49) and spring (48) from
housing (13).
29. Remove O-rings (61, 19) and backup ring (62) from
cap (63).
Disassembly of Flow Combiner Valve (e)
30. Remove cap (17) from housing (13).

j : 46 mm
31. Remove spring (18) spacer (20), and spool (21) from
housing (13).
32. Remove O-ring (19) from cap (17).

Disassembly of Check Valve (f)

33. Remove cap (46) from housing (13).

l : 14 mm
34. Remove spring (48) and check valve (49) from
housing (13).
35. Remove O-ring (19) and backup ring (47) from cap
(46).
36. Remove cap (58) from housing (13).

l : 17 mm
37. Remove O-ring (45) from cap (58).

W3-9-3-6
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Flow Rate Control Valve (95) Disassembly of Bypass Shut-Out Valve (g)
IMPORTANT: Do not disassemble flow rate control 45. Remove cap (65) from housing (13).
valve (95) unless necessary.
j : 46 mm
38. Remove socket bolts (97) (4 used). Remove flow rate
control valve (95) from housing (13). 46. Remove spool (69) and spring (68) from housing
(13).
l : 12 mm
47. Remove piston (64), cap (66), and O-ring (67) from
39. Remove piston (99), spring (98), check valve (100), cap (65).
and poppet (101) from housing (13).
j : 46 mm
40. Remove O-rings (60, 94) from flow rate control valve
(95). 48. Remove O-ring (67) from cap (66).
Disassembly of Flow Rate Control Valve Assembly
(112) Disassembly of Load Check Valve (h)
IMPORTANT: Do not disassemble flow rate control 49. Remove cap (73) from housing (13).
valve assembly (112) unless necessary.
l : 14 mm
41. Remove socket bolts (113) (6 used). Remove flow
rate control valve assembly (112) from housing (13). 50. Remove spring (48) and check valve (74) from
housing (13).
l : 12 mm
51. Remove O-ring (19) and backup ring (47) from cap
42. Remove spring (89) and poppet (90) from housing (73).
(13).
43. Remove piston (99), spring (98), check valve (100),
and piston (114) from housing (13).
44. Remove O-rings (60) (4 used) and O-rings (91, 94)
from flow rate control valve assembly (112).

W3-9-3-7
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

52. Remove cap (70) from housing (13).

l : 14 mm
53. Remove O-ring (19) and backup ring (47) from cap
(70).
54. Remove socket bolts (38) (8 used).

l : 12 mm
55. Remove flanges (36) (2 used) from housing (13).
56. Remove O-rings (37) (2 used) from flanges (36) (2
used).
57. Remove cap (44) from housing (13).

j : 46 mm
58. Remove O-ring (45) from cap (44).

W3-9-3-8
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Control Valve (4-Spool Side)

13 A 97 113 35 32

B
C

32 32
TJAA-03-03-006

Section A Section C
13 24 28
40
H
41
42,43 b
14
94
15
95 101
34 16
24 49
6 61,62

23 99 48
24
98 19

100
TJAA-03-03-041 a 23 WJAA-03-10-006

Section B Section D
39
60 89 90

41
36 42,43
38 91
37
112 114
66 g 94
67
42,43
99
41
98

65 67 64 68 69 WJAA-03-10-005 100
57

WJAA-03-10-007

W3-9-3-9
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Section E Section H (Arm Regeneration Cut Valve (b))

40
I 86 85
41
42,43 c

74
93 83
48
92
73 82

h 80
47,19
77 78,79
76
42,43
41
WJAA-03-10-009
40
WJAA-03-10-008

Section F Section I (Bucket Regeneration Cut Valve (c))

86 85

84 83
70 81
82

80

77 78, 79
47,19 76

WJAA-03-10-010 WJAA-03-10-009
58 45

Section G
19 63 d 22
19

48
62,61
49

44 21
45
49 20
48 19
47,19 18

WJAA-03-10-011
46 f 17 e

W3-9-3-10
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

1- Housing 33- Plug (4 Used) 65- Cap (2 Used) 96- Flow Rate Control Valve (2
2- Spool 34- Cover (2 Used) 66- Cap (2 Used) Used)
3- Spool 35- Socket Bolt (4 Used) 67- O-Ring (5 Used) 97- Socket Bolt (12 Used)
4- Spool 36- Flange (5 Used) 68- Spring (2 Used) 98- Spring (3 Used)
5- Spool 37- O-Ring (5 Used) 69- Spool (2 Used) 99- Piston (3 Used)
6- Spool (2 Used) 38- Socket Bolt (20 Used) 70- Cap 100- Check Valve (3 Used)
7- Cap (2 Used) 39- Check Valve 71- Cap 101- Poppet
8- Backup Ring (2 Used) 40- Overload Relief Valve (6 Used) 72- Check Valve (2 Used) 102- Poppet
9- O-Ring (2 Used) 41- O-Ring (14 Used) 73- Cap (2 Used) 103- Check Valve
10- Spacer (2 Used) 42- Backup Ring (10 Used) 74- Check Valve (2 Used) 104- Piston
11- Spring (2 Used) 43- O-Ring (10 Used) 75- Cap 105- Cap
12- Check Valve (2 Used) 44- Cap (2 Used) 76- Sleeve (2 Used) 106- Backup Ring
13- Housing 45- O-Ring (4 Used) 77- Piston (2 Used) 107- O-Ring
14- Spool 46- Cap (2 Used) 78- O-Ring (2 Used) 108- Check Valve
15- Spool 47- Backup Ring (7 Used) 79- Backup Ring (2 Used) 109- Spring
16- Spool 48- Spring (10 Used) 80- Spool (2 Used) 110- Check Valve
17- Cap 49- Check Valve (7 Used) 81- Spring 111- Arm Rod Anti-Drift Valve
18- Spring 50- Socket Bolt (8 Used) 82- O-Ring (3 Used) 112- Flow Rate Control Valve
19- O-Ring (13 Used) 51- Washer (14 Used) 83- Spring Guide (2 Used) Assembly
20- Spacer 52- Socket Bolt (6 Used) 84- Sleeve 113- Socket Bolt (6 Used)
21- Spool 53- O-Ring 85- O-Ring (2 Used) 114- Piston
22- Main Relief Valve 54- O-Ring (2 Used) 86- Cap (2 Used) 115- Cap
23- Cover 55- O-Ring (5 Used) 87- Boom 2 Anti-Drift Valve 116- Backup Ring
24- O-Ring (18 Used) 56- O-Ring (6 Used) 88- Socket Bolt (5 Used) 117- O-Ring
25- Spring Guide (18 Used) 57- Boom Overload Relief Valve 89- Spring (3 Used) 118- Spring
26- Spring (9 Used) 58- Cap (2 Used) 90- Poppet (3 Used) 119- Check Valve
27- Cap (9 Used) 59- Cap (2 Used) 91- O-Ring (2 Used) 120- Poppet
28- Cover 60- O-Ring (12 Used) 92- Spring 121- Spring
29- Cover 61- O-Ring (4 Used) 93- Sleeve 122- Cap
30- Cap (8 Used) 62- Backup Ring (5 Used) 94- O-Ring (3 Used) 123- Cap
31- O-Ring (11 Used) 63- Cap 95- Flow Rate Control Valve 124- Spool
32- Socket Bolt (26 Used) 64- Piston (2 Used) 125- Auxiliary Flow Combiner Valve

a Load Check Valve f Check Valve k Load Check Valve p Load Check Valve
b Arm Regeneration Cut Valve g Bypass Shut-Out Valve l Check Valve q Bypass Shut-Out Valve
c Bucket Regeneration Cut Valve h Load Check Valve m Check Valve
d Check Valve i Load Check Valve n Check Valve
e Flow Combiner Valve j Boost Check Valve o Load Check Valve

W3-9-3-11
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Control Valve (4-Spool Side) Assembly of Bypass Shut-Out Valve (g)
IMPORTANT: Before assembling, apply hydraulic oil 9. Install O-ring (67) to cap (66).
onto parts in order to prevent them from seizing.
10. Install O-ring (67), cap (66), and piston (64) to cap
1. Install O-ring (45) to cap (44). (65).
Install cap (44) to housing (13).
j : 46 mm
j : 46 mm
m : 250 N·m (25 kgf·m, 185 lbf·ft)
m : 250 N·m (25 kgf·m, 185 lbf·ft)
11. Install spring (68) and spool (69) to housing (13).
2. Install O-rings (37) (2 used) to flanges (36) (2 used).
12. Install cap (65) to housing (13).
3. Install flanges (36) (2 used) to housing (13) with
socket bolts (38) (8 used). j : 46 mm

l : 12 mm m : 250 N·m (25 kgf·m, 185 lbf·ft)

m : 140 N·m (14 kgf·m, 103 lbf·ft)

Assembly of Flow Rate Control Valve Assembly
4. Install backup ring (47) and O-ring (19) to cap (70). (112)
5. Install cap (70) to housing (13). 13. Install O-rings (91, 94) and O-rings (60) (4 used) to
flow rate control valve assembly (112).
l : 14 mm
14. Install piston (114), check valve (100), spring (98),
m : 350 N·m (35 kgf·m, 260 lbf·ft) and piston (99) to housing (13).
15. Install poppet (90) and spring (89) to housing (13).
Assembly of Load Check Valve (h)
16. Install flow rate control valve assembly (112) to
6. Install backup ring (47) and O-ring (19) to cap (73). housing (13) with socket bolts (113) (6 used).
7. Install check valve (74) and spring (48) to housing
(13).
8. Install cap (73) to housing (13).

l : 14 mm

m : 350 N·m (35 kgf·m, 260 lbf·ft)

W3-9-3-12
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Flow Rate Control Valve (95) Assembly of Check Valve (d)
17. Install O-rings (60, 94) to flow rate control valve (95). 28. Install backup ring (62) and O-rings (61, 19) to cap
(63).
18. Install poppet (101), check valve (100), spring (98),
and piston (99) to housing (13). 29. Install spring (48) and check valve (49) to housing
(13).
19. Install flow rate control valve (95) to housing (13)
with socket bolts (97) (4 used). 30. Install cap (63) to housing (13).

l : 12 mm l : 14 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft) m : 350 N·m (35 kgf·m, 260 lbf·ft)
20. Install O-ring (45) to cap (58).
Assembly of Bucket Regeneration Cut Valve (c)
21. Install cap (58) to housing (13).
31. Install O-ring (85) to cap (86).
l : 17 mm
32. Install cap (86) and O-ring (82) to sleeve (84).
m : 400 N·m (40 kgf·m, 300 lbf·ft)
l : 12 mm

Assembly of Check Valve (f) m : 180 N·m (18 kgf·m, 133 lbf·ft)
22. Install backup ring (47) and O-ring (19) to cap (46). 33. Install O-ring (78), backup ring (79), and piston (77)
to sleeve (76).
23. Install check valve (49) and spring (48) to housing
(13). 34. Install spring guide (83), spring (81), spool (80), and
sleeve (76) to sleeve (84).
24. Install cap (46) to housing (13).
35. Install sleeve (84) to housing (13).
l : 14 mm
j : 36 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
Assembly of Flow Combiner Valve (e)
25. Install O-ring (19) to cap (17).
26. Install spool (21), spacer (20), and spring (18) to
housing (13).
27. Install cap (17) to housing (13).

j : 46 mm

m : 250 N·m (25 kgf·m, 185 lbf·ft)

W3-9-3-13
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Arm Regeneration Cut Valve (b) Assembly of Overload Relief Valve (40)
36. Install O-ring (85) to cap (86). IMPORTANT: As the setting changes, do not
disassemble the relief valve. If the relief valve is
37. Install cap (86) and O-ring (82) to sleeve (93).
disassembled, pressure should be adjusted. (Refer
l : 12 mm to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
m : 180 N·m (18 kgf·m, 133 lbf·ft) 44. Install backup rings (42) (3 used) and O-rings (41,
38. Install O-ring (78), backup ring (79), and piston (77) 43) (3 used for each) to overload relief valves (40) (3
to sleeve (76). used).
39. Install spring guide (83), spring (92), spool (80), and 45. Install overload relief valves (40) (3 used) to housing
sleeve (76) to sleeve (93). (13).
40. Install sleeve (93) to housing (13). j : 41 mm
j : 36 mm m : 100 N·m (10 kgf·m, 74 lbf·ft)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
Assembly of Main Relief Valve (22)
Assembly of Load Check Valve (a) IMPORTANT: As the setting changes, do not
disassemble the relief valve. If the relief valve is
41. Install backup ring (62) and O-rings (61, 19) to cap disassembled, pressure should be adjusted. (Refer
(123). to TROUBLESHOOTING / Operational Performance
42. Install check valve (49) and spring (48) to housing Test in the separated volume, T/M.)
(13). 46. Install O-ring (19) to main relief valve (22).
43. Install cap (123) to housing (13). 47. Install main relief valve (22) to housing (13).
l : 14 mm j : 41 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft) m : 100 N·m (10 kgf·m, 74 lbf·ft)

W3-9-3-14
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Check Valve (39) Assembly of Spools (6, 14, 15, and 16)
48. Install backup ring (42) and O-rings (41, 43) to check 52. Fit the matching marks made when disassembling
valve (39). and install spools (6, 14, 15, and 16) to housing (13).
49. Install check valve (39) to housing (13). 53. Install O-ring (24) and cover (23) to housing (13)
with socket bolts (32) (2 used).
j : 41 mm
l : 10 mm
m : 100 N·m (10 kgf·m, 74 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
Assembly of Boom Overload Relief Valve (57)
54. Install O-rings (24) (3 used) and cover (34) to
IMPORTANT: As the setting changes, do not
housing (13) with socket bolts (32) (3 used) and
disassemble the relief valve. If the relief valve is
socket bolts (35) (2 used).
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance l : 10 mm
Test in the separated volume, T/M.)
50. Install backup ring (42) and O-rings (41, 43) to boom m : 90 N·m (9 kgf·m, 66 lbf·ft)
overload relief valve (57). 55. Install O-rings (24) (4 used) and cover (28) to
51. Install boom overload relief valve (57) to housing housing (13) with socket bolts (32) (6 used).
(13).
l : 10 mm
j : 41 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 100 N·m (10 kgf·m, 74 lbf·ft)

W3-9-3-15
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

(Blank)

W3-9-3-16
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Control Valve (5-Spool Side)

i j k

WJAA-03-10-001

W3-9-4-1
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

WJAA-03-10-002

W3-9-4-2
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

1- Housing 33- Plug (4 Used) 65- Cap (2 Used) 96- Flow Rate Control Valve (2
2- Spool 34- Cover (2 Used) 66- Cap (2 Used) Used)
3- Spool 35- Socket Bolt (4 Used) 67- O-Ring (5 Used) 97- Socket Bolt (12 Used)
4- Spool 36- Flange (5 Used) 68- Spring (2 Used) 98- Spring (3 Used)
5- Spool 37- O-Ring (5 Used) 69- Spool (2 Used) 99- Piston (3 Used)
6- Spool (2 Used) 38- Socket Bolt (20 Used) 70- Cap 100- Check Valve (3 Used)
7- Cap (2 Used) 39- Check Valve 71- Cap 101- Poppet
8- Backup Ring (2 Used) 40- Overload Relief Valve (6 Used) 72- Check Valve (2 Used) 102- Poppet
9- O-Ring (2 Used) 41- O-Ring (14 Used) 73- Cap (2 Used) 103- Check Valve
10- Spacer (2 Used) 42- Backup Ring (10 Used) 74- Check Valve (2 Used) 104- Piston
11- Spring (2 Used) 43- O-Ring (10 Used) 75- Cap 105- Cap
12- Check Valve (2 Used) 44- Cap (2 Used) 76- Sleeve (2 Used) 106- Backup Ring
13- Housing 45- O-Ring (4 Used) 77- Piston (2 Used) 107- O-Ring
14- Spool 46- Cap (2 Used) 78- O-Ring (2 Used) 108- Check Valve
15- Spool 47- Backup Ring (7 Used) 79- Backup Ring (2 Used) 109- Spring
16- Spool 48- Spring (10 Used) 80- Spool (2 Used) 110- Check Valve
17- Cap 49- Check Valve (7 Used) 81- Spring 111- Arm Rod Anti-Drift Valve
18- Spring 50- Socket Bolt (8 Used) 82- O-Ring (3 Used) 112- Flow Rate Control Valve
19- O-Ring (13 Used) 51- Washer (14 Used) 83- Spring Guide (2 Used) Assembly
20- Spacer 52- Socket Bolt (6 Used) 84- Sleeve 113- Socket Bolt (6 Used)
21- Spool 53- O-Ring 85- O-Ring (2 Used) 114- Piston
22- Main Relief Valve 54- O-Ring (2 Used) 86- Cap (2 Used) 115- Cap
23- Cover 55- O-Ring (5 Used) 87- Boom 2 Anti-Drift Valve 116- Backup Ring
24- O-Ring (18 Used) 56- O-Ring (6 Used) 88- Socket Bolt (5 Used) 117- O-Ring
25- Spring Guide (18 Used) 57- Boom Overload Relief Valve 89- Spring (3 Used) 118- Spring
26- Spring (9 Used) 58- Cap (2 Used) 90- Poppet (3 Used) 119- Check Valve
27- Cap (9 Used) 59- Cap (2 Used) 91- O-Ring (2 Used) 120- Poppet
28- Cover 60- O-Ring (12 Used) 92- Spring 121- Spring
29- Cover 61- O-Ring (4 Used) 93- Sleeve 122- Cap
30- Cap (8 Used) 62- Backup Ring (5 Used) 94- O-Ring (3 Used) 123- Cap
31- O-Ring (11 Used) 63- Cap 95- Flow Rate Control Valve 124- Spool
32- Socket Bolt (26 Used) 64- Piston (2 Used) 125- Auxiliary Flow Combiner Valve

a Load Check Valve f Check Valve k Load Check Valve p Load Check Valve
b Arm Regeneration Cut Valve g Bypass Shut-Out Valve l Check Valve q Bypass Shut-Out Valve
c Bucket Regeneration Cut Valve h Load Check Valve m Check Valve
d Check Valve i Load Check Valve n Check Valve
e Flow Combiner Valve j Boost Check Valve o Load Check Valve

W3-9-4-3
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Control Valve (5-Spool Side) Disassembly of Auxiliary Flow Combiner Valve (125)
Disassembly of Spools (2, 3, 4, 5, and 6) 8. Remove auxiliary flow combiner valve (125) from
housing (1).
1. Remove socket bolts (32) (6 used). Remove cover
(29) and O-rings (24) (5 used) from housing (1). j : 32 mm
l : 10 mm 9. Remove O-ring (19) from auxiliary flow combiner
valve (125).
2. Remove socket bolts (32) (3 used) and socket bolts
(35) (2 used). Remove cover (34) and O-rings (24) (3
used) from housing (1). Disassembly of Boom 2 Anti-Drift Valve (87)

l : 10 mm IMPORTANT: Do not disassemble boom 2 anti-drift

valve (87) unless necessary.
3. Remove socket bolts (32) (4 used). Remove covers
10. Remove socket bolts (88) (4 used). Remove boom 2
(23) (2 used) and O-rings (24) (2 used) from housing
anti-drift valve (87) from housing (1).
(1).
l : 12 mm
l : 10 mm
11. Remove spring (89) and poppet (90) from housing
4. Put the matching marks on housing (1) and spools
(1).
(2, 3, 4, 5, and 6).
12. Remove O-ring (91) and O-rings (60) (2 used) from
IMPORTANT: Do not disassemble spools (2, 3, 4, 5,
boom 2 anti-drift valve (87).
and 6) unless necessary.
5. Remove spools (2, 3, 4, 5, and 6) from housing (1).

Disassembly of Overload Relief Valve (40)

IMPORTANT: As the setting changes, do not
disassemble the relief valve. If the relief valve is
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
6. Remove overload relief valves (40) (5 used) from
housing (1).

j : 41 mm
7. Remove O-rings (41, 43) (5 used for each) and
backup rings (42) (5 used) from overload relief
valves (40) (5 used).

W3-9-4-4
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Load Check Valve (i) Disassembly of Check Valve (l)

13. Remove cap (105) from housing (1). 22. Remove cap (115) from housing (1).

l : 14 mm l : 10 mm
14. Remove check valve (108), spring (109), and check 23. Remove spring (118) and check valve (119) from
valve (110) from housing (1). housing (1).
15. Remove backup ring (62), O-ring (61), backup ring 24. Remove O-ring (117) and backup ring (116) from
(62), O-ring (107), backup ring (106), and O-ring (82) cap (115).
from cap (105).
Disassembly of Check Valve (m)
Disassembly of Boost Check Valve (j)
25. Remove cap (46) from housing (1).
16. Remove cap (122) from housing (1).
l : 14 mm
j : 36 mm
26. Remove spring (48) and check valve (49) from
17. Remove spring (121) and poppet (120) from housing (1).
housing (1).
27. Remove O-ring (19) and backup ring (47) from cap
18. Remove O-ring (67) from cap (122). (46).
28. Remove cap (58) from housing (1).
Disassembly of Load Check Valve (k)
l : 17 mm
19. Remove cap (124) from housing (1).
29. Remove O-ring (45) from cap (58).
l : 14 mm
20. Remove spring (48) and check valve (49) from
housing (1).
21. Remove O-rings (61, 19) and backup ring (62) from
cap (124).

W3-9-4-5
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Arm Rod Anti-Drift Valve (111) Disassembly of Flow Rate Control Valve (96b)
IMPORTANT: Do not disassemble arm rod anti-drift IMPORTANT: Do not disassemble flow rate control
valve (111) unless necessary. valve (96b) unless necessary.
30. Remove socket bolts (88) (4 used). Remove arm rod 36. Remove socket bolts (97) (4 used). Remove another
anti-drift valve (111) from housing (1). flow rate control valve (96b) from housing (1).

l : 12 mm l : 12 mm
31. Remove spring (89) and poppet (90) from housing 37. Remove piston (99), spring (98), check valve (100),
(1). and poppet (102) from housing (1).
32. Remove O-ring (91) and O-rings (60) (3 used) from 38. Remove O-rings (60, 94) from flow rate control valve
arm rod anti-drift valve (111). (96b).

Disassembly of Flow Rate Control Valve (96a) Disassembly of Check Valve (n)
IMPORTANT: Do not disassemble flow rate control 39. Remove cap (73) from housing (1).
valve (96a) unless necessary.
l : 14 mm
33. Remove socket bolts (97) (4 used). Remove flow rate
control valve (96a) from housing (1). 40. Remove spring (48) and check valve (74) from
housing (1).
l : 12 mm
41. Remove O-ring (19) and backup ring (47) from cap
34. Remove piston (104), spring (48), and check valve (73).
(103) from housing (1).
35. Remove O-rings (60, 94) from flow rate control valve Disassembly of Load Check Valve (o)
(96a).
42. Remove cap (75) from housing (1).

l : 14 mm
43. Remove check valve (72), spring (48), and check
valve (49) from housing (1).
44. Remove O-ring (19) and backup ring (47) from cap
(75).

W3-9-4-6
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Disassembly of Load Check Valve (p)

45. Remove cap (71) from housing (1).

l : 14 mm
46. Remove check valve (72), spring (48), and check
valve (49) from housing (1).
47. Remove O-ring (19) and backup ring (47) from cap
(71).

Disassembly of Bypass Shut-Out Valve (q)

48. Remove cap (65) from housing (1).

j : 46 mm
49. Remove spool (69) and spring (68) from housing (1).
50. Remove piston (64), cap (66), and O-ring (67) from
cap (65).

j : 46 mm
51. Remove O-ring (67) from cap (66).
52. Remove cap (44) from housing (1).

j : 46 mm
53. Remove O-ring (45) from cap (44).
54. Remove socket bolts (38) (12 used).

l : 12 mm
55. Remove flanges (36) (3 used) from housing (1).
Remove O-rings (37) (3 used) from flanges (36) (3
used).

W3-9-4-7
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Control Valve (5-Spool Side)

32 J 1 88 44,45 97 45,58

N
O
P

88 TJAA-03-03-007

Section J Section L
29 24 1
89

24
2 23 60
111
24
91
3 94
34 90 60
4 96b

5 102
100
24 99
19
6 23
125
42,43
41
98 40 WJAA-03-10-013

TJAA-03-03-010

Section K Section M
j 122 60 87
k 40
67
41 121
19 42,43 120
n 91
124 74 89
90
61,62 94 73
19,47
96a l
48 119 38
49 118
116,117 37
60 36
42,43
41
103 48 104 WJAA-03-10-012 115 48 40 WJAA-03-10-014

W3-9-4-8
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Section N
40
41
42,43
37
48 36
Q
38
o 19,47
75

38

37
49
36
42,43
41 TJAA-03-03-017

72 40 WJAA-03-10-015

Section O Section Q
i
19

82 107,106 m
105 62,61,62
46
108
19,47
109 71
110
47 48 49 T450-03-03-008
p

49 48 72 WJAA-03-10-016

Section P

q 67
66

64

69 68 67 65 WJAA-03-10-017

W3-9-4-9
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

1- Housing 33- Plug (4 Used) 65- Cap (2 Used) 96- Flow Rate Control Valve (2
2- Spool 34- Cover (2 Used) 66- Cap (2 Used) Used)
3- Spool 35- Socket Bolt (4 Used) 67- O-Ring (5 Used) 97- Socket Bolt (12 Used)
4- Spool 36- Flange (5 Used) 68- Spring (2 Used) 98- Spring (3 Used)
5- Spool 37- O-Ring (5 Used) 69- Spool (2 Used) 99- Piston (3 Used)
6- Spool (2 Used) 38- Socket Bolt (20 Used) 70- Cap 100- Check Valve (3 Used)
7- Cap (2 Used) 39- Check Valve 71- Cap 101- Poppet
8- Backup Ring (2 Used) 40- Overload Relief Valve (6 Used) 72- Check Valve (2 Used) 102- Poppet
9- O-Ring (2 Used) 41- O-Ring (14 Used) 73- Cap (2 Used) 103- Check Valve
10- Spacer (2 Used) 42- Backup Ring (10 Used) 74- Check Valve (2 Used) 104- Piston
11- Spring (2 Used) 43- O-Ring (10 Used) 75- Cap 105- Cap
12- Check Valve (2 Used) 44- Cap (2 Used) 76- Sleeve (2 Used) 106- Backup Ring
13- Housing 45- O-Ring (4 Used) 77- Piston (2 Used) 107- O-Ring
14- Spool 46- Cap (2 Used) 78- O-Ring (2 Used) 108- Check Valve
15- Spool 47- Backup Ring (7 Used) 79- Backup Ring (2 Used) 109- Spring
16- Spool 48- Spring (10 Used) 80- Spool (2 Used) 110- Check Valve
17- Cap 49- Check Valve (7 Used) 81- Spring 111- Arm Rod Anti-Drift Valve
18- Spring 50- Socket Bolt (8 Used) 82- O-Ring (3 Used) 112- Flow Rate Control Valve
19- O-Ring (13 Used) 51- Washer (14 Used) 83- Spring Guide (2 Used) Assembly
20- Spacer 52- Socket Bolt (6 Used) 84- Sleeve 113- Socket Bolt (6 Used)
21- Spool 53- O-Ring 85- O-Ring (2 Used) 114- Piston
22- Main Relief Valve 54- O-Ring (2 Used) 86- Cap (2 Used) 115- Cap
23- Cover 55- O-Ring (5 Used) 87- Boom 2 Anti-Drift Valve 116- Backup Ring
24- O-Ring (18 Used) 56- O-Ring (6 Used) 88- Socket Bolt (5 Used) 117- O-Ring
25- Spring Guide (18 Used) 57- Boom Overload Relief Valve 89- Spring (3 Used) 118- Spring
26- Spring (9 Used) 58- Cap (2 Used) 90- Poppet (3 Used) 119- Check Valve
27- Cap (9 Used) 59- Cap (2 Used) 91- O-Ring (2 Used) 120- Poppet
28- Cover 60- O-Ring (12 Used) 92- Spring 121- Spring
29- Cover 61- O-Ring (4 Used) 93- Sleeve 122- Cap
30- Cap (8 Used) 62- Backup Ring (5 Used) 94- O-Ring (3 Used) 123- Cap
31- O-Ring (11 Used) 63- Cap 95- Flow Rate Control Valve 124- Spool
32- Socket Bolt (26 Used) 64- Piston (2 Used) 125- Auxiliary Flow Combiner Valve

a Load Check Valve f Check Valve k Load Check Valve p Load Check Valve
b Arm Regeneration Cut Valve g Bypass Shut-Out Valve l Check Valve q Bypass Shut-Out Valve
c Bucket Regeneration Cut Valve h Load Check Valve m Check Valve
d Check Valve i Load Check Valve n Check Valve
e Flow Combiner Valve j Boost Check Valve o Load Check Valve

W3-9-4-10
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Control Valve (5-Spool Side) Assembly of Load Check Valve (o)
IMPORTANT: Before assembling, apply hydraulic oil 12. Install backup ring (47) and O-ring (19) to cap (75).
onto parts in order to prevent them from seizing.
13. Install check valve (49), spring (48), and check valve
1. Install O-rings (37) (3 used) to flanges (36) (3 used). (72) to housing (1).
2. Install flanges (36) (3 used) to housing (1) with 14. Install cap (75) to housing (1).
socket bolts (38) (12 used).
l : 14 mm
l : 12 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
m : 140 N·m (14 kgf·m, 103 lbf·ft)
3. Install O-ring (45) to cap (44). Assembly of Check Valve (n)
4. Install cap (44) to housing (1). 15. Install backup ring (47) and O-ring (19) to cap (73).
j : 46 mm 16. Install check valve (74) and spring (48) to housing
(1).
m : 250 N·m (25 kgf·m, 185 lbf·ft)
17. Install cap (73) to housing (1).

Assembly of Bypass Shut-Out Valve (q) l : 14 mm

5. Install O-ring (67) to cap (66). m : 350 N·m (35 kgf·m, 260 lbf·ft)
6. Install O-ring (67), cap (66), and piston (64) to cap
(65).
7. Install spring (68) and spool (69) to housing (1).
8. Install cap (65) to housing (1).

j : 46 mm

m : 250 N·m (25 kgf·m, 185 lbf·ft)

Assembly of Load Check Valve (p)

9. Install backup ring (47) and O-ring (19) to cap (71).
10. Install check valve (49), spring (48), and check valve
(72) to housing (1).
11. Install cap (71) to housing (1).

l : 14 mm

m : 350 N·m (35 kgf·m, 260 lbf·ft)

W3-9-4-11
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Flow Rate Control Valve (96b) 27. Install O-ring (45) to cap (58).
18. Install O-rings (60, 94) to flow rate control valve 28. Install cap (58) to housing (1).
(96b).
l : 17 mm
19. Install poppet (102), check valve (100), spring (98),
and piston (99) to housing (1). m : 400 N·m (40 kgf·m, 300 lbf·ft)
20. Install flow rate control valve (96b) to housing (1)
with socket bolts (97) (4 used). Assembly of Check Valve (m)

l : 12 mm 29. Install backup ring (47) and O-ring (19) to cap (46).
30. Install check valve (49) and spring (48) to housing
m : 140 N·m (14 kgf·m, 103 lbf·ft)
(1).
31. Install cap (46) to housing (1).
Assembly of Flow Rate Control Valve (96a)
21. Install O-rings (60, 94) to another flow rate control l : 14 mm
valve (96a).
m : 350 N·m (35 kgf·m, 260 lbf·ft)
22. Install check valve (103), spring (48), and piston
(104) to housing (1).
Assembly of Check Valve (l)
23. Install flow rate control valve (96a) to housing (1)
32. Install backup ring (116) and O-ring (117) to cap
with socket bolts (97) (4 used).
(115).
l : 12 mm 33. Install check valve (119) and spring (118) to housing
(1).
m : 140 N·m (14 kgf·m, 103 lbf·ft)
34. Install cap (115) to housing (1).
Assembly of Arm Rod Anti-Drift Valve (111) l : 10 mm
24. Install O-ring (91) and O-rings (60) (3 used) to arm
m : 80 N·m (8 kgf·m, 59 lbf·ft)
rod anti-drift valve (111).
25. Install poppet (90) and spring (89) to housing (1).
26. Install arm rod anti-drift valve (111) to housing (1)
with socket bolts (88) (4 used).

l : 12 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

W3-9-4-12
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Load Check Valve (k) Assembly of Boom 2 Anti-Drift Valve (87)
35. Install backup ring (62) and O-rings (61, 19) to cap 44. Install O-ring (91) and O-rings (60) (2 used) to boom
(124). 2 anti-drift valve (87).
36. Install check valve (49) and spring (48) to housing 45. Install poppet (90) and spring (89) to housing (1).
(1).
46. Install boom 2 anti-drift valve (87) to housing (1)
37. Install cap (124) to housing (1). with socket bolts (88) (4 used).

l : 14 mm l : 12 mm

m : 350 N·m (35 kgf·m, 260 lbf·ft) m : 140 N·m (14 kgf·m, 103 lbf·ft)
Assembly of Boost Check Valve (j)
Assembly of Auxiliary Flow Combiner Valve (125)
38. Install O-ring (67) to cap (122).
47. Install O-ring (19) to auxiliary flow combiner valve
39. Install poppet (120) and spring (121) to housing (1).
(125).
40. Install cap (122) to housing (1).
48. Install auxiliary f low combiner valve (125) to
j : 36 mm housing (1).

m : 180 N·m (18 kgf·m, 133 lbf·ft) j : 32 mm

m : 83 N·m (8.3 kgf·m, 61 lbf·ft)

Assembly of Load Check Valve (i)
41. Install O-ring (82), backup ring (106), O-ring (107),
backup ring (62), O-ring (61), and backup ring (62)
to cap (105).
42. Install check valve (110), spring (109), and check
valve (108) to housing (1).
43. Install cap (105) to housing (1).

l : 14 mm

m : 350 N·m (35 kgf·m, 260 lbf·ft)

W3-9-4-13
 SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve

Assembly of Overload Relief Valve (40)

IMPORTANT: As the setting changes, do not
disassemble the relief valve. If the relief valve is
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
48. Install backup rings (42) (5 used) and O-rings (41,
43) (5 used for each) to overload relief valves (40) (5
used).
49. Install overload relief valves (40) (5 used) to housing
(1).

j : 41 mm

m : 100 N·m (10 kgf·m, 74 lbf·ft)

Assembly of Spools (2, 3, 4, 5, and 6)

50. Fit the matching marks made when disassembling
and install spools (2, 3, 4, 5, and 6) to housing (1).
51. Install O-rings (24) (2 used) and covers (23) (2 used)
to housing (1) with socket bolts (32) (4 used).

l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

52. Install O-rings (24) (3 used) and cover (34) to
housing (1) with socket bolts (32) (3 used) and
socket bolts (35) (2 used).

l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

53. Install O-rings (24) (5 used) and cover (29) to
housing (1) with socket bolts (32) (6 used).

l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-9-4-14
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Removal and Installation of Swing Device

4 1, 2, 3

1 WJAA-03-07-001

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove bolts, washers (1) (2 used), spacer (2), and
rubber (3). Remove cover (4).

j : 17 mm

W3-10-1-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

WJAA-03-11-010

3. Place a container under swing device (5). Remove

hose (6). dCAUTION:
lb) each
Swing device (5) weight: 230 kg (510

j : 27 mm 10. Attach a nylon sling onto the body of swing motor.

4. Disconnect hose (7). Hoist and hold swing device (5).
11. Remove bolts (17) (26 used), washers (18) (22 used),
j : 27 mm
and spacers (19) (4 used). Remove swing devices (5)
5. Disconnect hoses (8) (2 used). (2 used).
j : 36 mm j : 32 mm
6. Remove socket bolts (9) (16 used) and flanges (10) 12. Remove the adapter with swing device (5) attached
(8 used). Disconnect hoses (11) (4 used). Remove if necessary.
O-rings (12) (4 used).

l : 8 mm
7. Remove hose (13).

j : 19 mm
8. Disconnect hose (14).

j : 19 mm
9. Remove clips (15) (2 used). Disconnect hoses (16) (2
used).

W3-10-1-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

WJAA-03-11-010

Installation 6. Connect hose (14).

1. Install all removed adapters to swing device (5). j : 19 mm

dCAUTION:
lb) each
Swing device (5) weight: 230 kg (510 m : 30 N·m (3 kgf·m, 22 lbf·ft)
7. Install hose (13).
2. Apply THREEBOND #1215 onto the main frame
mounting surface of swing device (5). Attach a j : 19 mm
nylon sling onto the body of swing motor. Hoist
swing device (5). m : 30 N·m (3 kgf·m, 22 lbf·ft)
3. Install swing device (5) with spacers (19) (4 used), 8. Connect hoses (8) (2 used).
washers (18) (4 used), and bolts (17) (26 used).
j : 36 mm
j : 32 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
m : 750 N·m (75 kgf·m, 550 lbf·ft) 9. Connect hose (7).
4. Install O-rings (12) (4 used). Connect hoses (11) (4
used) with flanges (10) (8 used) and socket bolts (9) j : 27 mm
(16 used). m : 80 N·m (8 kgf·m, 59 lbf·ft)
l : 8 mm 10. Install hose (6).
m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 27 mm
5. Connect hoses (16) (2 used) with clips (15) (2 used). m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-10-1-3
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

4 1, 2, 3

1 WJAA-03-07-001

11. Bleed air from the hydraulic system. (Refer to W1-

4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
12. Install cover (4) with rubber (3), spacer (2), and bolts,
washers (1) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-10-1-4
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Disassembly of Swing Device

1

24 3

25
28 27
26
4
23
22 5
21

20 6

19
7

18
8
29
17
16
9
15
30
16
31
14 10
32
33 11

12
34

13
35

WJAA-03-11-008

1- Motor 10- Bolt (2 Used) 19- Thrust Plate (3 Used) 28- Cork (2 Used)
2- Socket Bolt (8 Used) 11- Lock Plate 20- Planetary Gear (3 Used) 29- Oil Seal
3- Ring Gear 12- Bearing Nut 21- Needle Bearing (3 Used) 30- Roller Bearing
4- First Stage Sun Gear 13- Roller Bearing 22- Spring Pin (3 Used) 31- Screw (4 Used)
5- Thrust Plate 14- Thrust Plate (3 Used) 23- Pin (3 Used) 32- Magnet (4 Used)
6- First Stage Carrier 15- Planetary Gear (3 Used) 24- Socket Bolt (12 Used) 33- Sleeve
7- Second Stage Sun Gear 16- Needle Bearing (6 Used) 25- Drain Plug 34- O-Ring
8- Thrust Plate 17- Spring Pin (3 Used) 26- Cock 35- Shaft
9- Second Stage Carrier 18- Pin (3 Used) 27- Housing

W3-10-2-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Disassembly of Swing Device

dCAUTION: Swing device (b) weight: 230 kg (510 dCAUTION: Motor (1) weight: 50 kg (115 lb)
lb) 4. Put the matching marks on the jointed part of
motor (1) and ring gear (3), and ring gear (3) and
1. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
housing (27). Remove socket bolts (2) (8 used). Hoist
swing device (b). Hoist the swing device.
and remove motor (1).
a
l : 10 mm

fNOTE: Insert a screwdriver into the clearance between

motor (1) and ring gear (3), and float up motor (1) in
b
order to remove easily.
5. Remove first stage sun gear (4). Remove the first
stage carrier (6) assembly from ring gear (3).

W16J-02-06-003
a- Eyebolt Mounting Position b- Swing Device

2. Place swing device (b) on bracket (ST 5101). Secure

swing device (b) on a bracket with bolts (M22,
Pitch 2.5 mm) (2 used). Secure the bracket on a
workbench in order to receive the reaction force.

j : 32 mm
b

ST 5101

W1V7-02-06-001
b- Swing Device

3. Remove drain plug (25). Turn cock (26). Drain oil

from swing device (b). Remove cock (26) from
housing (27).

j : 26 mm

fNOTE: Drain Plug: R1/2

W3-10-2-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

11. Place block (a) on a press. Place the housing (27)

d CAUTION: Ring gear (3) weight: 23 kg (51 lb) assembly on block (a).
6. Remove socket bolts (24) (12 used). Install eyebolts
(M12, Pitch 1.75 mm) to the motor mounting screw
part of ring gear (3). Hoist ring gear (3). Remove ring
27
gear (3) from housing (27).

l : 14 mm

fNOTE: TREEBOND has been applied onto the mating

surface of housing (27) and ring gear (3). Insert a
screwdriver into the notch between jointed parts and
separate the surface in order to remove easily.

dCAUTION: The second stage carrier (9) assembly

weight: 23 kg (51 lb)
7. Remove second stage sun gear (7) and the second
stage carrier (9) assembly from housing (27). a W1HH-02-06-012

8. Remove bolts (10) (2 used). Remove lock plate (11) a- Block

from bearing nut (12).

j : 17 mm
9. Remove bearing nut (12) from shaft (35) by using
the special tool (ST 2926).

35

ST 2926

W178-02-06-008

dCAUTION: The housing (27) assembly weight:

120 kg (265 lb)
10. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
the bolt (24) hole of housing (27). Remove bolts
(M22, Pitch 2.5 mm) (2 used) which secure housing
(27) and bracket (ST 5101). Hoist the housing (27)
assembly and remove the bracket.

j : 32 mm

W3-10-2-3
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

dCAUTION: If pushing shaft (35) by using a press

(c), provide a protection cover (b) (outer diameter:
290 mm (11.4 in), inner diameter: 90 mm (3.5 in),
thickness: 25 to 30 mm (1.0 to 1.2 in)). Housing
(27) and roller bearing (13) are broken and flown
off. The metal fragments may result in personal
injury. Press at 30 ton or less.Degrease the
housing inside before heating roller bearing (13).
Failure to degrease may cause a fire.
12. Cover housing (27) with protection cover (b) and
remove shaft (35) by using press (c). At this time, the
inner race of roller bearing (30) and sleeve (33) are
removed with shaft (35) together.

35 14
27

W157-02-06-010
b- Protection Cover

W1V7-02-06-002
b- Protection Cover
c- Press

W3-10-2-4
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

13. Remove outer race of roller bearing (13) from

housing (27). dCAUTION: Push shaft (35) inside the guide by
using a press.
dCAUTION:
(135 lb)
The shaft (35) assembly weight: 60 kg 15. Install shaft (35) with a special tool attached to a
press (e). Remove the inner race of roller bearing
14. Set a special tool to the shaft (35) assembly. (30).

fNOTE: Use the following parts as a special tool when 16. Remove sleeve (33) from shaft (35). Remove the
O-ring (34), screws (31) (4 used) and magnets (32) (4
removing roller bearing (30).
used) from sleeve (33).
 Shaft (b) or bolt: lengh: 270 mm (10.6 in), diameter:
19 mm (0.75 in) (8 used) (All shoud be identical in
lengh with no wear and deformation on both ends.) e
Material: S35C
 Hose clamp (c): standard diameter: 8-1/2inch 35
(applicable diameter: 185 to 215 mm (7.3 to 8.5 in) (2
used) 30
 Guide (d): height: 230 mm (9.1 in), outer diameter: 230 33
mm (9.1 in), inner diameter: 210 mm (8.3 in)
a
b d
c

W157-02-06-014
d- Guide
e- Press

W157-02-06-012

35
30
33
c

b
d

W157-02-06-013
a- Special tool when removing c- Hose Clamp
roller bearing (30) d- Guide
b- Shaft

W3-10-2-5
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

17. Insert a round bar into housing (27). Tap and

remove the outer race of roller bearing (30).

dCAUTION: Housing (27) weight: 70 kg (155 lb)

18. Attach a nylon sling onto the body of housing
(27). Hoist nad turn over the housing (27). Insert a
screwdriver into the notch on housing (27) where
oil seal (29) is mounted. Remove oil seal (29).

fNOTE: THREEBOND has been applied onto the outer

surface of oil seal (29). Therefore, the oil seal cannot be
reused.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
19. Tap the outer race of roller bearing (13) by using
a bar and a hammer. Remove the outer race from
housing (27).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
20. Remove spring pins (22) (3 used) from first stage
carrier (6) by using a round bar and hammer.
21. Remove pins (23) (3 used), first stage planetary
gears (20) (3 used), thrust plates (19) (3 used), and
needle bearings (21) (3 used) from first stage carrier
(6).
22. Remove thrust plate (5) from first stage carrier (6).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
23. Remove spring pins (17) (3 used) from second stage
carrier (9) by using a round bar and hammer.
24. Remove pins (18) (3 used), second stage planetary
gears (15) (3 used), thrust plates (14) (3 used), and
needle bearings (16) (6 used) from second stage
carrier (9).
25. Remove thrust plate (8) from second stage carrier
(9).

W3-10-2-6
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Assembly of Swing Device

22 23 20 4 5 1

2
21
19 6
17 3
15 7
9
16
24
8
18
10
11
14
12
27 13
26

25

32
30

29

31 33
34

35

WJAA-03-11-009

1- Motor 10- Bolt (2 Used) 19- Thrust Plate (3 Used) 28- Cork (2 Used)
2- Socket Bolt (8 Used) 11- Lock Plate 20- Planetary Gear (3 Used) 29- Oil Seal
3- Ring Gear 12- Bearing Nut 21- Needle Bearing (3 Used) 30- Roller Bearing
4- First Stage Sun Gear 13- Roller Bearing 22- Spring Pin (3 Used) 31- Screw (4 Used)
5- Thrust Plate 14- Thrust Plate (3 Used) 23- Pin (3 Used) 32- Magnet (4 Used)
6- First Stage Carrier 15- Planetary Gear (3 Used) 24- Socket Bolt (12 Used) 33- Sleeve
7- Second Stage Sun Gear 16- Needle Bearing (6 Used) 25- Drain Plug 34- O-Ring
8- Thrust Plate 17- Spring Pin (3 Used) 26- Cock 35- Shaft
9- Second Stage Carrier 18- Pin (3 Used) 27- Housing

W3-10-2-7
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Assembly of Swing Device

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
dCAUTION: Shaft (35) weight: 36 kg (80 lb)
8. Install sleeve (33) and the inner race of roller
1. Install needle bearings (21) (3 used) to first stage bearing (30) to shaft (35). Install the inner race of
planetary gears (20) (3 used). roller bearing (30) to sleeve (33) by using special
2. Install thrust plate (5) to first stage carrier (6) with tool (ST 7295) and press (b).
the oil groove up.
fNOTE: The press-in distance of the inner race of roller
3. Install first stage planetary gears (20) (3 used) and bearing (30) can be assured by using the special tool
thrust plates (19) (3 used) to first stage carrier (6). when installing.
4. Fit pin (23) to the spring pin (22) holes on first stage
carrier (6). Install pins (23) (3 used) by using a plastic
hammer.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection, b
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Check the direction of spring pin (22). ST 7295 30
5. Install spring pin (22) to first stage carrier (6) with
the slit (a) of spring pin (22) facing to the end of pin 33
(23) by using hammer.
35

22 W1V7-02-06-004
b- Press
23

W1V7-02-06-003
a- Slit

6. Assemble second stage carrier (9) in the same way

as steps 1 to 5. Assemble thrust plate (8), second
planetary gears (15) (3 used), needle bearings (16) (6
used), thrust plates (14) (3 used), pins (18) (3 used),
and spring pins (17) (3 used).
7. Install O-ring (34), magnets (32) (4 used) and screws
(31) (4 used) to sleeve (33).

W3-10-2-8
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

dCAUTION: Housing (27) weight: 70 kg (155 lb) dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
9. Attach a nylon sling onto the body of housing (27).
Hoist and place housing (27) with the sleeve (33) such as goggles, helmets, etc in order to prevent
mounting side up. personal injury.
14. Evenly tap and install the outer race of roller bearing
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
(13) to housing (27) evenly by using a bar and a
hammer. Tap and listen to ring in order to check if
such as goggles, helmets, etc in order to prevent the installation is completed.
personal injury.
10. Evenly tap and install the outer race of roller bearing dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
(30) to housing (27) evenly by using a bar and a
hammer. Tap and listen to ring in order to check if such as goggles, helmets, etc in order to prevent
the installation is completed. personal injury.
15. Install the inner race of roller bearing (13) to shaft
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
(35) by using a bar and a hammer. Tap the inner
race until the upper end on the inner race of roller
such as goggles, helmets, etc in order to prevent bearing (14) reaches two threads for bearing nut
personal injury. (12) in shaft.
11. Apply THREEBOND #1215 onto the outer surface of
oil seal (29). Place oil seal (29) flat on housing (27)
and push by hands in gently. Place the special tool
of seal (ST 7300) on oil seal (29). Tap it in by using a
hammer straight.

ST 7300 29

27

WIHH-02-06-010

12. Apply grease onto the inner surface of oil seal (29).
Therefore, apply grease onto the outer surface of
sleeve (33) with shaft (35) attached.
13. Turn over a housing (27). Install eyebolts (M16, Pitch
2.0 mm) (2 used) to the bolt (24) hole of housing
(27). Hoist housing (27). Slowly place and install
housing (27) to shaft (35). At this time, Check and fit
carefully in order not to curl the lip of oil seal (29).

W3-10-2-9
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

16. Install bearing nut (12) to shaft (35) and tighten by

hand.

fNOTE: Prevent shaft (35) from falling off when hoisting

housing (27).

dCAUTION: The housing (27) assembly weight:

130 kg (290 lb)
17. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
the bolt (24) hole of housing (27). Hoist and place
housing (27) on a press.
18. Remove bearing nut (12) from shaft (35).
19. Place inner race special tool (ST 2924) onto the roller
bearing (13) inner race. Install the inner race by
using a press.

fNOTE: The specified press-in distance of the inner race

can be assured by using the special tool when installing.

13 ST 2924

WIHH-02-06-009

20. Hoist and place the housing (27) assembly on

bracket (ST 5101). Install the housing (27) assembly
with bolts (M22, Pitch 2.5 mm) (2 used). At this time,
insert the stopper (a) at the bottom of the bracket
between teeth of the pinion gear. Secure bracket on
a workbench in order to receive the reaction force.

j : 32 mm

27

ST 5101
a

W1V7-02-06-001
a- Stopper

W3-10-2-10
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

IMPORTANT: Check the direction to install bearing

nut (12). dCAUTION:
(51 lb)
Second stage carrier (9) weight: 23 kg
21. Apply grease onto the thread part of bearing nut
(12). Install the thread part of bearing nut (12) to IMPORTANT: Check the direction to install second
shaft (35).At this time, face the step side of bearing stage carrier (9).
nut (12) to the roller bearing (13) side. Tighten 23. Install the second stage carrier (9) assembly to the
bearing nut (13) by using special tool (ST 2926) to spline in shaft (35).
the specified torque.
9
m : 490 N·m (49 kgf·m, 360 lbf·ft)
35
fNOTE: Apply grease for keeping correct tightening
torque.

12
W1V7-02-06-005

24. Install second stage sun gear (7) to the second stage
carrier (9) assembly.
25. Apply THREEBOND #1215 onto the ring gear (3)
mounting surface of housing (27). Clean off old
ST 2926 adhesive in advance.

W178-02-06-008

22. Install lock plate (11) to bearing nut (12) with bolts
(10) (2 used). In case the spline of lock plate (11) and
that of shaft (35) are not aligned, tighten bearing
nut (12) in tightening direction until both splines
are aligned.

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-10-2-11
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

dCAUTION: Ring gear (3) weight: 23 kg (51 lb)

26. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the motor mounting screw part of ring gear (3)
before hoisting. Fit the matching marks made when
disassembling and install ring gear (3) to housing
(27). Tighten socket bolts (24) (12 used).

l: 14 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft)

27. Fit the spline and install the first stage carrier (6)
assembly to second stage sun gear (7).
IMPORTANT: Check the direction to install first stage
sun gear (4).
28. Install first stage sun gear (4) to the first stage carrier
(6) assembly with the step part down.
29. Install cock (26) to housing (27). Install a seal tape
onto drain plug (25). Install drain plug (25) to cock
(26).

j : 26 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

fNOTE: Drain Plug: R1/2

30. Add gear oil (6.7 L (1.77 US gal)) to housing (27).
31. Apply liquid packing (THREEBOND #1215) onto the
motor (1) mounting surface of ring gear (3).

dCAUTION: Motor (1) weight: 50 kg (115 lb)

32. Hoist motor (1). Fit the matching marks made when
diassembling. Install motor (1) to ring gear (3) with
socket bolts (2) (8 used).

l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-10-2-12
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Disassembly of Swing Motor

11

9
8
7
6

5 10
4

3
2
24
25 29
26
1 27 30
28

23 27
26
25
24

12
13
14
15 22
21 31
16 20
19
18
17
WJAA-03-11-007

1- Casing 9- Rotor 17- O-Ring 25- O-Ring (2 Used)

2- Oil Seal 10- Plate (4 Used) 18- O-Ring 26- Spring (2 Used)
3- Bearing 11- Friction Plate (3 Used) 19- Brake Piston 27- Poppet (2 Used)
4- Shaft 12- O-Ring 20- Spring (24 Used) 28- Valve Casing
5- Shoe Plate 13- Piston 21- Valve Plate 29- Socket Bolt (4 Used)
6- Plunger (9 Used) 14- Spring 22- Bearing 30- Plug (2 Used)
7- Plate 15- Ball 23- O-Ring 31- Relief Valve (2 Used)
8- Retainer 16- Plug (2 Used) 24- Plug (2 Used)

W3-10-3-1
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Disassembly of Swing Motor

dCAUTION:
kg (110 lb)
The swing motor assembly weight: 48 8. Put the matching marks on casing (1) and brake
piston (19). Attach a claw of the special tool (ST
1468) onto brake piston (19) groove. Remove brake
piston (19) from casing (1) by using the special tool
IMPORTANT: As the setting changes, do not
(ST 1468).
disassemble relief valve (32).
1. Remove relief valves (31) (2 used) from valve casing
(28).

j : 41 mm ST 1468
2. Remove plug (24) from valve casing (28). Remove 19
O-ring (25) from plug (24).

l : 14 mm 1

3. Remove spring (26) and poppet (27) from valve

casing (28).
4. Remove another poppet (27) in the same way as
step 2 to step 3. W1HH-02-06-006
5. Put the matching marks on valve casing (28) and
9. Remove O-rings (17, 18) from casing (1).
casing (1). Remove socket bolts (29) (4 used). At this
time, record the clearance between valve casing
(28) and casing (1).

l : 17 mm
IMPORTANT: Do not remove bearing (22) unless
necessary.
6. Remove valve casing (28) from casing (1). As valve
plate (21) may be removed with valve casing (28)
together, do not drop valve plate (21). Remove
O-ring (23) from valve casing (28).
IMPORTANT: Do not damage the mating surfaces
when separating valve plate (21) from valve
casing (28) or rotor (9) by using a screwdriver.
7. If valve plate (21) is still attached on rotor (9) side
in step 6, remove valve plate (21) from the rotor (9).
Remove springs (20) (24 used) from brake piston
(19).

W3-10-3-2
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

IMPORTANT: Do not damage the sliding surfaces of

rotor (9) and plunger (6).
10. Place casing (1) horizontally. Remove rotor (9),
retainer (8), plate (7), and plungers (6) (9 used) from
shaft (4).
11. Remove plates (10) (4 used) and friction plates (11)
(3 used) from casing (1).
IMPORTANT: Do not damage the sliding surface of
shoe plate (5).
12. Remove shoe plate (5) from casing (1).
13. Tap and remove shaft (4) from casing (1) by using a
plastic hammer.
14. Remove the inner race of bearing (3) from shaft (4)
by using a press.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
15. Remove the outer race of bearing (3) from casing (1)
by using a bar and a hammer.
16. Remove oil seal (2) from casing (1).
IMPORTANT: The filter and orifice are installed inside
piston (13). Do not disassemble piston (13) unless
they are clogged or deformed. If the inner parts of
piston (13) are replaced, replace piston (13) as an
assembly.
17. Remove piston (13) from casing (1) by using a pair
of pliers.
18. Remove O-ring (12) from piston (13).
19. Remove spring (14) and ball (15) from casing (1).
20. Remove plugs (16) (2 used) from casing (1).

l : 6 mm

W3-10-3-3
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Assembly of Swing Motor

27 26

12
25
13
24 14

15

16
29

WJAA-03-11-001 WJAA-03-11-003

31

21 30 22 28

23 20

18 19
9
17
11
6
10
7

1 8

4 2 3 5
WJAA-03-11-002

W3-10-3-4
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

1- Casing 9- Rotor 17- O-Ring 25- O-Ring (2 Used)

2- Oil Seal 10- Plate (4 Used) 18- O-Ring 26- Spring (2 Used)
3- Bearing 11- Friction Plate (3 Used) 19- Brake Piston 27- Poppet (2 Used)
4- Shaft 12- O-Ring 20- Spring (24 Used) 28- Valve Casing
5- Shoe Plate 13- Piston 21- Valve Plate 29- Socket Bolt (4 Used)
6- Plunger (9 Used) 14- Spring 22- Bearing 30- Plug (2 Used)
7- Plate 15- Ball 23- O-Ring 31- Relief Valve (2 Used)
8- Retainer 16- Plug (2 Used) 24- Plug (2 Used)

W3-10-3-5
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

Assembly of Swing Motor

IMPORTANT: Before assembling, apply hydraulic oil 11. Install the rotor (9) assembly to shaft (4).
onto parts in order to prevent them from seizing.
IMPORTANT: There are 4 notches on the outer side of
1. Install plugs (16) (2 used) to casing (1). plate (10). There are 4 notches on the inner side of
friction plate (11).
l : 6 mm
12. Place casing (1) vertically. Alternately install plates
m : 35 N·m (3.5 kgf·m, 26 lbf·ft) (10) (4 used) and friction plates (11) (3 used) and
align each notch at the same place.
2. Install O-ring (12) to piston (13).
13. Install O-rings (17, 18) to casing (1).
IMPORTANT: If the inner parts of piston (13) are 14. Fit the matching marks and install brake piston (19)
replaced, replace piston (13) as an assembly. to casing (1).
3. Install ball (15), spring (14), and piston (13) to casing
(1) in order to fit the end of piston (13) to that of fNOTE: If it is not easy to install O-rings (17, 18) into
brake piston (27) due to the resistant force from O-rings
casing (1).
(17, 18), tap brake piston (19).
4. Install oil seal (2) to casing (1) by using a plate with 15. Install springs (20) (24 used) to brake piston (19).
the lip part up.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.

5. Install the outer race of bearing (3) to casing (1) by

using a bar and a hammer.
6. Install the inner race of bearings (3, 22) to shaft (4)
with the flange facing to the step side of shaft (4) by
using a press.
7. Wind the tape onto the spline at the end of shaft (4)
in order not to damage oil seal (2). Place casing (1)
with the plug (16) side up. Install shaft (4) to casing
(1).
8. Install shoe plate (5) to casing (1) with the
chamfered surface facing inside.
9. Fit the notches on plate (7) and retainer (8). Install
plungers (6) (9 used) to the plate (7) assembly.
Install retainer (8) to plunger (6) with the notch
facing to the shoe plate (5) side.
10. Install the plunger (6) assembly into rotor (9).

W3-10-3-6
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

16. Tap and install the outer race, the bearing type
indicated surface of bearing (22) to valve casing (28)
by using a plastic hammer.
IMPORTANT: Check the surfaces of valve plate (21).
17. Install O-ring (23) to valve casing (28). Apply grease
onto valve plate (21) in order to prevent from falling
off from valve casing (28). Install valve plate (21) to
valve casing (28) with the notch in the port facing to
rotor (9).
18. Apply grease onto the needle part of bearing (22) in
order to install shaft (4) to bearing (22) easily.
19. Fit the matching marks on casing (1) and valve
casing (28). Place valve casing (28) on to casing.
Check that a clearance between valve casing (28)
and casing (1) is equal to that before disassembling.
If the clearance is larger than that before
disassembling, repeat the procedures from step 8.
20. Install valve casing (28) to casing (1) with socket
bolts (29) (4 used).

l : 17 mm

ml : 440 N·m (44 kgf·m, 320 lbf·ft)

21. Install poppet (27) and spring (26) to valve casing
(28). Install O-ring (25) to plug (24). Install plug (24)
to valve casing (28).

l : 14 mm

m : 340 N·m (34 kgf·m, 251 lbf·ft)

22. Install another poppet (27) in the same way as step
21.
23. Install relief valves (32) (2 used) to valve casing (28).

j : 41 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

W3-10-3-7
 SECTION 3 UPPERSTRUCTURE
Group 10 Swing Device

(Blank)

W3-10-3-8
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Removal and Installation of Pilot Valve (Left)

3 2

1 WDAA-03-01-023 WJAA-03-01-013

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition, dCAUTION: Seat (2) weight: 46 kg (105 lb)
attach an identification tag onto the connectors, 3. Remove socket bolts (3) (4 used). Remove seat (2).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which l : 6 mm
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).

W3-11-1-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Detail B
14
13
14

21 23 22

15

B
17

10
16
WDAA-03-12-002
9

7, 8 12 11 WDAA-03-12-001
20 18 19

4. Remove socket bolts (7) (2 used) and washers (8) (2

used). Remove lever (9).

l : 6 mm
5. Remove socket bolts (10) (2 used) and washers (11)
(2 used). Remove armrest (12).

l : 6 mm
6. Raise boot (13) and remove screws (14) (3 used).
7. Raise cover (15). Disconnect connector (16). Remove
cover (15).
8. Remove screw (17), bolt, washer (18), and washer
(19). Remove cover (20).

j : 10 mm
9. Remove screws (21, 22) (2 used for each). Remove
cover (23).

W3-11-1-2
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

25 27 26 30, 31

WDAA-03-12-023 WDAA-03-12-019
28 24 29 32

10. Remove clip bands (24, 25).

11. Loosen lock nut (26). Remove the lever (27)
assembly.

j : 19 mm, 22 mm
12. Disconnect hoses (28) (6 used).

j : 19 mm
13. Remove socket bolts (30) (4 used) and washers (31)
(4 used). Remove pilot valve (29) and boot (32).

l : 6 mm
14. Remove the adapter with pilot valve (29) attached if
necessary.

W3-11-1-3
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

25 27 26 30, 31

WDAA-03-12-023 WDAA-03-12-019
28 24 29 32

Installation
1. Install all removed adapters to pilot valve (29).
2. Install pilot valve (29) and boot (32) with washers
(31) (4 used) and socket bolts (30) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Connect hoses (28) (6 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

4. Tighten lock nut (26) and install the lever (27)
assembly.

j : 19 mm, 22 mm

m : 55 N·m (5.5 kgf·m, 41 lbf·ft)

5. Install clip bands (25, 24).

W3-11-1-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Detail B
14
13
14

21 23 22

15

B
17

10
16
WDAA-03-12-002
9

7, 8 12 11 WDAA-03-12-001
20 18 19

6. Install cover (23) with screws (22, 21) (2 used for 13. Install lever (9) with washers (8) (2 used) and socket
each). bolts (7) (2 used).
7. Install cover (20) with washer (19), bolt, washer (18), l : 6 mm
and screw (17).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
j : 10 mm

m : 3.3 to 4.2 N·m (0.3 to 0.4 kgf·m, 2.2 to 3

lbf·ft)
8. Install cover (15).
9. Raise cover (15). Connect connector (16).
10. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
11. Install screws (14) (3 used). Lower boot (13).
12. Install armrest (12) with washers (11) (2 used) and
socket bolts (10) (2 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-11-1-5
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

3 2

1 WDAA-03-01-023 WJAA-03-01-013

dCAUTION: Seat (2) weight: 46 kg (105 lb)

14. Install seat (2) with socket bolts (3) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

15. Shut door (1).

W3-11-1-6
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Removal and Installation of Pilot Valve

(Right)
3 2

1 WDAA-03-01-023 WJAA-03-01-013

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition, dCAUTION: Seat (2) weight: 46 kg (105 lb)
attach an identification tag onto the connectors, 3. Remove socket bolts (3) (4 used). Remove seat (2).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which l : 6 mm
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).

W3-11-2-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Detail A
14
13
15 11
10 12

16

WDAA-03-12-006

9 11
7 8
WDAA-03-12-005

4. Remove socket bolts (7) (2 used) and washers (8) (2

used). Remove armrest (9).

l : 6 mm
5. Remove tray (10). Remove screws (11) (3 used).
6. Raise cover (12). Disconnect connectors (13) (2
used). Remove cover (12).
7. Raise boot (14). Remove screws (15) (2 used).
Remove cover (16).

W3-11-2-2
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

19 20 17 18 20 24

23
24

WDAA-03-12-007
21 22 25 24

WDAA-03-12-005

8. Remove clip bands (17, 18).

9. Loosen lock nut (19). Remove the lever (20)
assembly.

j : 19 mm, 22 mm
10. Remove bolts, washers (21) (3 used). Tilt the bracket
(22) assembly with the cover (23) side up.

j : 17 mm
11. Remove screws (24) (3 used) and washer (25).
Remove cover (23).

W3-11-2-3
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

A Detail A
28, 29

30

WDAA-03-12-008
26

27 26 WDAA-03-12-020

12. Disconnect hoses (26) (6 used).

j : 19 mm
13. Remove socket bolts (28) (4 used) and washers (29)
(4 used). Remove pilot valve (27) and boot (30).

l : 6 mm
14. Remove the adapter with pilot valve (27) attached if
necessary.

W3-11-2-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

A Detail A
28, 29

30

WDAA-03-12-008
26

27 26 WDAA-03-12-020

Installation
1. Install all removed adapters to pilot valve (27).
2. Install pilot valve (27) and boot (30) with washers
(29) (4 used) and socket bolts (28) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Connect hoses (26) (6 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-11-2-5
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

19 20 17 18 20 24

23
24

WDAA-03-12-007
21 22 25 24

WDAA-03-12-005

4. Install cover (23) with washer (25) and screws (24) (3

used).
5. Install bracket (22) with bolts, washers (21) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

6. Tighten lock nut (19) and install the lever (20)
assembly.

j : 19 mm, 22 mm

m : 55 N·m (5.5 kgf·m, 41 lbf·ft)

7. Install clip bands (18, 17).

W3-11-2-6
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Detail A
14
13
15 11
10 12

16

WDAA-03-12-006

9 11
7 8
WDAA-03-12-005

8. Install cover (16) with screws (15) (2 used).

9. Install cover (12).
10. Raise cover (12). Connect connectors (13) (2 used).
11. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
12. Install boot (14).
13. Install screws (11) (3 used). Install tray (10).
14. Install armrest (9) with washers (8) (2 used) and
socket bolts (7) (2 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-11-2-7
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

3 2

1 WDAA-03-01-023 WJAA-03-01-013

dCAUTION: Seat (2) weight: 46 kg (105 lb)

15. Install seat (2) with socket bolts (3) (4 used).

l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

16. Shut door (1).

W3-11-2-8
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Removal and Installation of Travel Pilot Valve

2 3 12, 13
WJAA-03-01-016 4 5 WJAA-03-12-001

IMPORTANT: Cap the open ends in case the hoses 5. Place a container under pilot valve (4). Disconnect
and pipes have been disconnected. In addition, hoses (5) (6 used).
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the j : 19 mm
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Swing the upperstructure by 90 degrees and set the
machine for inspection and maintenance. (Refer to
W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Remove the floor mat.

dCAUTION: Remove cover (3) while holding it. Do

not drop cover (3).
4. Remove bolts, washers (2) (4 used), bolts (12) (3
used), and washers (13) (3 used). Remove cover (3).

j : 17 mm

W3-11-3-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

WDAA-03-12-017 WDAA-03-12-018

6. Remove bolts, washers (7) (4 used). Remove levers

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

j : 17 mm
7. Remove socket bolts (10) (2 used) and washers (11)
(2 used). Remove pilot valve (4).

l : 8 mm
8. Remove the adapter with pilot valve (4) attached if
necessary.

W3-11-3-2
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

WDAA-03-12-017 WDAA-03-12-018

Installation
1. Install all removed adapters to pilot valve (4).
2. Install pilot valve (4) with washers (11) (2 used) and
socket bolts (10) (2 used).

l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Install pedals (9) (2 used) and levers (8) (2 used) with
bolts, washers (7) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-11-3-3
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

2 3 12, 13
WJAA-03-01-016 4 5 WJAA-03-12-001

4. Connect hoses (5) (6 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

5. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
6. Install cover (3) with washers (13) (3 used), bolts (12)
(3 used), and bolts, washers (2) (4 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

7. Install the floor mat.
8. Shut door (1).

W3-11-3-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Disassembly of Pilot Valves (Right and Left)

17

16

15

14

13

12

11

10
18
9

7
6 19
23
5 20
4 21
22
3

WDAA-03-12-021

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing

W3-11-4-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Disassembly of Pilot Valves (Right and Left)

3. Attach a spanner onto the upper part of universal
IMPORTANT: Casing (18) is made of aluminium.
joint (15). Remove universal joint (15).
Strong force deforms it. Handle it with care.
IMPORTANT: Spool (19) has been selected to match j : 17 mm
the hole on casing (18). The dimensions of balance
springs (3, 4) and return springs (5, 6) as well as fNOTE: Universal joint (15) has been secured on casing
those of pushers (9, 10) are different. Arrange (18) by using LOCTITE #262.
the disassembled parts together with the port in 4. Remove plate (14).
order not to confuse. The port number is stamped
IMPORTANT: Do not damage sleeve (12). Insert a soft
on the outer surface of casing (18).
rubber between sleeve (12) and a tool. Oil seal (11)
IMPORTANT: Do not remove screw joint (17) while cannot be removed from sleeve (12).
securing casing (18) in a vise. The strong torque
Sleeve (12) and oil seal (11) should be replaced as
may act on screw joint (17).
an assembly.
1. Secure screw joint (17) in a vise. Turn cam (16) by
5. Remove sleeves (12) (4 used) upward by using a pair
using a spanner. Remove screw joint (17).
of pliers. Remove O-rings (19) (4 used) from sleeves
j : 19 mm, 32 mm (12) (4 used).
IMPORTANT: The dimensions of pushers (9, 10) for
2. Secure the flat surface of casing (18) in a vise. ports (1, 3) and for ports (2, 4) are different. Keep
Remove cam (16) from universal joint (15). the disassembled parts together by the port
number in order not to confuse.
j : 32 mm 6. Remove pushers (9, 10) (2 used for each) from
casing (18).

W3-11-4-2
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

7. When compressing the spring, do not lower spool IMPORTANT: The quantity of shims (2) has been
(19). Install the special tool (ST 4145) to the port determined for each port during the performance
hole on casing (18) as illustrated. testing. Do not lose shim (2). Keep shim (2)
carefully in order to install shim (2) to the original
l : 6 mm port when assembling.
9. Remove the special tool (ST4146). Remove spring
guides (7) (4 used), return springs (5, 6) (2 used for
each), and balance springs (3, 4) (2 used for each)
from spools (19) (4 used).
18 10. Remove shim (2) and spacers (1) (4 used) from
spools (19) (4 used).
IMPORTANT: Spool (19) has been selected to match
the hole on casing (18). Spool (19) and casing (18)
should be replaced as an assembly.
11. Remove the special tool (ST 4145) from casing (18).
Slowly turn and remove spool (19) from casing (18).
W178-02-07-048
ST 4145 IMPORTANT: Retaining ring (22) may come off while
disassembling. Do not drop retaining ring (22)
8. Install the special tool (ST 4146) to the pusher hole inside casing (18). If retaining ring (22) falls inside
on casing (18). Push the special tool (ST 4146) and casing (18), remove retaining ring (22) completely.
compress the spring. Tighten the special tool (ST Retaining ring (22) cannot be reused.
4146) by using the socket bolt (M14, Pitch 2.0 mm). 12. Remove retaining ring (22) from casing (18) by
Remove retaining rings (8) (4 used) from spools (19) using a screwdriver. Install a bolt (M8, Pitch 1.25
(4 used) by using a screwdriver. mm) to plug (21). Remove plug (21) from casing
(18). Remove O-ring (20) from plug (21).
l : 12 mm
j : 13 mm

ST 4146
13. Remove filter (23) from casing (18).

j : 10 mm

18

W178-02-07-048

W3-11-4-3
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Assembly of Pilot Valves (Right and Left)

17

15
16

11
14 9, 10
13
12
8
7
3, 4
5, 6
2

1
21
20

23 18 19

22

WDAA-03-12-022

1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing

W3-11-4-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Assembly of Pilot Valves (Right and Left)

IMPORTANT: Refer to the table in the left in order to
IMPORTANT: Before assembling, apply hydraulic oil
assemble the parts correctly.
onto parts in order to prevent them from seizing.
3. Install spacer (1), shim (2), and balance spring (3) to
IMPORTANT: The pilot valve is the susceptible
spool (19). Install return spring (5) to casing (18).
hydraulic component to contamination. Keep the
parts clean when assembling. 4. Install spring guide (7) to return spring (5) with the
protrusion up.

fNOTE: The table below shows the relations between 5. Install other spools (19) (3 used) in the same way as
step 1 to step 4.
each port and the parts. Do not confuse them when
assembling. 6. Install the special tool (ST 4146) to the pusher (9, 10)
Spool Shim holes on casing (18). Push the special tool (ST 4146)
Port No. Pushers (9, 10) and compress the spring. Tighten the special tool
(19) (2)
1 One outer groove (ST 4146) by using a bolt (M14, Pitch 2.0 mm).
Two outer l : 12 mm
2
Same to the Same to the grooves
3 former one former one One outer groove ST 4146
Two outer
4
grooves
ST 4144
Return Springs Balance Springs
Port No.
(5, 6) (3, 4)
1 Short Short
2 Long Long
3 Short Short
4 Long Long

1. Check the port hole number and insert same spool

(19) before disassembling. Install the thinner end W178-02-07-049
of spool (19) into the port hole on casing (18) by ST 4145
turning slowly.
7. Install retaining ring (8) to the ring holder (ST 4144).
fNOTE: Spool (19) has been selected to match the port
hole. Spool (19) and casing (18) should be replaced as an
assembly.
2. Install the special tool (ST 4145) to the port hole on
casing (18) in order not to lower spool (19) when
the spring is compressed.

j : 6 mm

W3-11-4-5
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

8. Install retaining ring (8) to the groove on the head IMPORTANT: Fit the bolt hole on plate (14) to the
of spool (21) extending from the special tool (ST screw hole on casing (18).
4146). 16. Apply LOCTITE #262 onto the screw part of
IMPORTANT: Check the position to install pusher (9). universal joint (15). Place plate (14) on casing (18).
Install universal joint (15).
9. Install pusher (9).
After pushing pusher (9) several times by hand, j : 17 mm
remove it. Check if retaining ring (8) comes off or
balance spring (3) is located correctly. m : 25 N·m (2.5 kgf·m, 19 lbf·ft)
Install pusher (9) to casing (18) after checking.
IMPORTANT: Check the tightness of cam (16).
10. Install other pushers (9, 10) in the same way as step 17. Install cam (16) to universal joint (15). The clearance
8 to step 9. between cam (16) and pushers (9, 10) (2 used for
11. Apply grease onto the ball part at the ends of each) should be 0 to 0.2 mm.
pushers (9, 10) (2 used for each). 18. Secure cam (16) by using a spanner. Tighten screw
12. Apply grease onto the joint part of universal joint joint (17) by using a spanner.
(15).
j : 19 mm, 32 mm
13. Apply grease onto the inner surface of oil seals (11)
(4 used). m : 70 N·m (7 kgf·m, 51 lbf·ft)
19. Install plug (23) to casing (18).
fNOTE: Sleeve (12) and oil seal (11) should be replaced
as an assembly. l : 10 mm
14. Install oil seals (11) (4 used) to sleeves (12) (4 used).
Push the sleeve (12) assemblies (4 used) by hand m : 20 N·m (2 kgf·m, 15 lbf·ft)
until O-ring (13) is inserted into the hole on sleeves
(12) (4 used).
15. Secure casing (18) in a vise lightly.

W3-11-4-6
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Disassembly of Travel Pilot Valve

3
4

7 35
34
33
32
8 31
9
30
10 29
11

28

14
27
12
15 26
13

25
16

17 24

18

19 23
36
20
21 22
WDAA-03-12-024

1- Bolt, Washer (2 Used) 10- Spring Pin 19- O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring (4 Used) 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (16 Used) 26- Spacer (4 Used) 35- Pin
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used) 36- Plug

W3-11-5-1
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Disassembly of Travel Pilot Valve

IMPORTANT: Spool (24) has been selected to match
IMPORTANT: Casing (23) is made of aluminium.
the hole of casing (23). Spool (24) and casing (23)
Strong force deforms it. Handle it with care.
should be replaced as an assembly.
IMPORTANT: Spool (24) has been selected to match
IMPORTANT: Put the mark on spools (24) (4 used)
the hole on casing (23).
when keeping in order to easily install spools (24)
Arrange the disassembled parts together with (4 used) to the original hole.
each port in order not to confuse.
5. Remove the spool (24) assembly from casing (23) by
The port number is stamped on the outer surface rotating.
of casing (23). Spring guide (17), balance spring (18), shims (27) (3
1. Secure casing (23) in a vise. Remove bolts, washers used), and spacer (26) are removed with spool (24)
(1) (2 used). Remove cover (2) from holder (7). together.
j : 10 mm IMPORTANT: The quantity of shims (27) have been
determined during the performance testing at the
2. Remove socket bolts (30) (2 used) and spring factory. When keeping, pair shim (27) with each
washers (29) (2 used). Remove the holder (7) spool.
assembly from casing (23).
6. Compress balance spring (18). Remove spring guide
l : 8 mm (17), balance spring (18), shims (27) (3 used), and
spacer (26) from spool (24).
3. Remove the pusher (16) assemblies (4 used) from
casing (23). 7. Remove spring (25) from casing (23).
4. Remove pushers (16) (4 used) from bushings (15) 8. Remove other spools (24) in the same way as step 5
(4 used). Remove oil seals (28) (4 used) and O-rings to step 7.
(14) (4 used) from bushings (15) (4 used) by using a
bamboo spatula.

W3-11-5-2
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

11. Remove O-ring (33) from pin (35).

d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, 12. Remove other bracket (11) in the same way as step
such as goggles, helmets, etc in order to prevent 9 to step 11.
personal injury. 13. Place holder (7) with the casing (23) mounting
IMPORTANT: Place a stand under bracket (11) and surface up.
receive a reaction force. If holder (7) bears the
reaction force, strong force acts on pin (35). dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
Therefore, pin (35) may be deformed.
such as goggles, helmets, etc in order to prevent
9. Place a stand under bracket (11).
personal injury.
The inner surfaces of the spring pins (12, 13) holes
on bracket (11) are stepped-shape. The spring pin 14. The holes of spring pins (3, 4) (2 used for each) in
can only be removed in one direction. cam (5) are stepped-shape. Tap the bottom of cam
Tap and remove spring pins (12, 13) from bracket (5) and remove spring pins (3, 4) (2 used for each)
(11) at the same time by using the special tool (ST from cams (5) (2 used) at the same time by using the
1237). Remove bracket (11) from pin (35). special tool (ST 1237).
Do not remove spring pin (10) with bracket (11) As the holes of spring pins (3, 4) (2 used for each)
attached unless necessary. are crimped, spring pins (3, 4) may feel tight when
The hole end of spring pin (10) has been crimped. removing.

12, 13
11
35
10

W176-02-07-019
a- Crimped Position
b- Stand

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

(8) (2 used). Remove damper (32) and rubber seat
(31) from pin (35). O-ring (34) is removed together.

l : 5 mm

W3-11-5-3
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
15. Remove pin (35) by using a bar and a hammer. At
the same time, cams (5) (2 used) are removed.
Do not remove bushings (6) (4 used) with holder
(7) attached unless necessary. If removing, remove
bushings (6) (4 used) by tapping by using the
special tool (ST 7256).
16. Remove plugs (20) (2 used) from casing (23).
Remove O-rings (19) (2 used) from plugs (20) (2
used).

l : 5 mm
17. Remove plugs (21) (2 used) from casing (23).
Remove O-rings (22) (2 used) from plugs (21) (2
used).

l : 6 mm

W3-11-5-4
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Assembly of Travel Pilot Valve

11 32 31 1 2 35 6 12 10 13 7 5 3, 4 30

29
34 15
9
33
8 17
28
18
14
25
27
16
26

24
23
36

WDAA-03-12-025

1- Bolt, Washer (2 Used) 10- Spring Pin 19- *O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- *Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- *Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- *O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool (4 Used) 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (16 Used) 26- Spacer (4 Used) 35- Pin
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used) 36- Plug

fNOTE: As for the parts with mark *, refer to W3-11-5-1.

W3-11-5-5
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

Assembly of Travel Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
onto parts in order to prevent them from seizing.
such as goggles, helmets, etc in order to prevent
IMPORTANT: The pilot valve is the susceptible
personal injury.
hydraulic component to contamination. Keep the
parts clean when assembling. fNOTE: Bushings (6) (4 used) are identical.
1. Insert spacer (26), shims (27) (3 used), and balance  Insert bushings (6) (4 used) into the special tool
spring (18) into spool (24) in sequence. Install shim (ST 7256). Tap the special tool (ST 7256) by using a
(27) as the same condition before disassembling. hammer and install bushing (6) to the end of hole on
holder (7).
IMPORTANT: Check the direction to install spring
Stop tapping when the bushing (6) end is flush with
guide (17).
the hole end.
2. Compress balance spring (18) by hand. Install spring
guide (17) to spool (24) with the stepped part down. 7 ST 7256

IMPORTANT: Before inserting the parts into holder

(7) and casing (23), apply hydraulic oil.
3. Insert spring (25) into casing (23).
6
4. Insert the spool (24) assembly into the original port W178-02-11-310
before disassembling. Insert the spool (24) assembly
into casing (23) by rotating.
5. Install oil seal (28) to bushing (15).
6. Apply grease onto the inner surface of oil seal (28).
7. Install O-ring (14) and pusher (16) to bushing (15).
8. Apply grease onto the head of pusher (16).
9. Insert the pusher (16) assembly into casing (23).
10. Install other spools (24) in the same way as step 1 to
step 9.
11. When bushing (6) has been removed from holder
(7), install bushings (6) (4 used) to holder (7) by
using the special tool (ST 7256) in the following
procedures.

W3-11-5-6
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

 Install bushing (6) on the opposite side in the same 12. Install O-rings (33) (2 used) to pin (35). Apply grease
way. onto O-rings (33) (2 used). Install pin (35) and cams
6 (5) (2 used) to holder (7).
ST 7256 7
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Check the direction to install spring
pins (3, 4).
W178-02-11-311
13. Install spring pins (3, 4) to cam (5) by using the
special tool (ST 1237). Secure cam (5) and pin (35).
 Install bushing (6) in the near side as illustrated. Stop At this time, the slits of spring pins (3, 4) should be
tapping when the bushing (6) end is flush with the positioned 90SDgr away each other.
outside of holder (7). Tap and install spring pins (3, 4) until spring pins
(3, 4) come in contact with the stepped part in the
6
hole.
7 ST 7256

3 a b

W178-02-11-312
a- Outside of Holder 4 W178-02-07-050
a- Slit
b- Slit
 Install bushing (6) in the near and opposite side as
illustrated. 14. Crimp the hole end of cam (5) where spring pins (3,
4) are inserted by using a punch.
6
15. Install other cam (5) in the same way as step 13 to
ST 7256 7 step 14.

W178-02-11-313

W3-11-5-7
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

16. Place holder (7) on the casing (23) assembly. Install 21. As for the direction to install bracket (11), refer to
holder (7) to casing (23) with socket bolts (30) (2 the figure in Disassembly of Travel Pilot Valve on
used) and spring washers (29) (2 used). W3-11-5-1. Install bracket (11) to pin (35). Fit the
Check the mark direction and install holder (7). holes to insert spring pins (12, 13).

l : 8 mm IMPORTANT: Place a stand under bracket (11) and

receive a reaction force. If holder (7) bears the
m : 50 N·m (5 kgf·m, 37 lbf·ft) reaction force, strong force acts on pin (35).
Therefore, pin (35) may be deformed.
17. Install rubber seats (31) (2 used) to pin (35).
22. Place a stand under bracket (11).
IMPORTANT: Check the direction of damper (32). Install spring pins (12, 13) to bracket (11) until they
The inner surface of damper (32) is edged-shape. come in contact with the stepped part by using
If damper (32) is pried when installing, O-ring (33) the special tool (ST 1237). The slits of spring pins (2
may be damaged. used) should be positioned 90° away each other.
18. Install dampers (32) (2 used) to pin (35) with the
lever up.
19. Secure damper (32) and rubber seat (31) to holder b c
(7) with socket bolts (9) (4 used) and spring washers
(8) (4 used). 11 35
l : 5 mm

m : 7 N·m (0.7 kgf·m, 5 lbf·ft)

12, 13
20. Apply grease onto O-ring (34). Push O-rings (34) (2 a
used) to the end of pin (35).

W176-02-07-011
a- Stand
b- Crimped Position
c- Crimped Position

W3-11-5-8
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

23. Crimp the hole edge of bracket (11) where spring

pins (12, 13) are inserted by using a punch.
24. Install other bracket (11) in the same way as step 22
to step 23.
25. Install cover (2) to holder (7) with bolts, washers (1)
(2 used).

j : 10 mm

m : 5 N·m (0.5 kgf·m, 3.5 lbf·ft)

26. Apply grease onto the spring pin (10) contact part
of dampers (32) (2 used).
27. Install O-rings (19) (2 used) to plugs (20) (2 used).
Install plugs (20) (2 used) to casing (23).

j : 5 mm

m : 10 N·m (1 kgf·m, 7.5 lbf·ft)

28. Install O-rings (22) (2 used) to plugs (21) (2 used).
Install plugs (21) (2 used) to casing (23).

j : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-11-5-9
 SECTION 3 UPPERSTRUCTURE
Group 11 Pilot Valve

(Blank)

W3-11-5-10
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Removal and Installation of Pilot Shut-Off

Solenoid Valve

4 2, 3 WJAA-03-01-016

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Swing the upperstructure by 90 degrees and set the
machine for inspection and maintenance. (Refer to
W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open door (1).
3. Remove a floor mat.

dCAUTION: Remove cover (4) while holding it. Do

not drop cover (4).
4. Remove bolts, washers (2) (7 used) and washers (3)
(3 used). Remove cover (4).

j : 19 mm

W3-12-1-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

6
8

WJAA-03-13-007 WDAA-03-13-007
7

5. Disconnect connector (5).

6. Place a container under pilot shut-off solenoid valve
(6). Disconnect hoses (7) (10 used).

j : 19 mm
7. Remove bolts, washers (8) (2 used). Remove pilot
shut-off solenoid valve (6).

j : 17 mm
8. Remove the adapter with pilot shut-off solenoid
valve (6) attached if necessary.

W3-12-1-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

6
8

WJAA-03-13-007 WDAA-03-13-007
7

Installation
1. Install all removed adapters to pilot shut-off
solenoid valve (6).
2. Install pilot shut-off solenoid valve (6) with bolts,
washers (8) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Connect hoses (7) (10 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

4. Connect connector (5).

W3-12-1-3
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

4 2, 3 WJAA-03-01-016

5. Bleed air from the hydraulic system. (Refer to W1-

4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
6. Install cover (4) with washers (3) (3 used) and bolts,
washers (2) (7 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

7. Install a floor mat.
8. Shut door (1).

W3-12-1-4
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Removal and Installation of 4-Spool Solenoid

Valve Unit

2 3 4
WJAA-03-07-002 WJAA-03-07-013

IMPORTANT: Cap the open ends in case the hoses 3. Open covers (3, 4).
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

d(Refer
CAUTION: Bleed air from the hydraulic oil tank.
to W1-4-1.)

dnot
CAUTION: Remove cover (1) while holding it. Do
drop cover (1).
2. Remove bolts, washers (2) (5 used). Remove cover
(1).

j : 19 mm

W3-12-2-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

6 12 9

9
10

5
8 11 9 7
WJAA-03-07-014 WJAA-03-13-009

4. Remove bolts, washers (5) (2 used). Open bracket 9. Remove bolts, washers (11) (2 used). Remove
assembly (6). 4-spool solenoid valve unit (12).

j : 19 mm j : 17 mm
5. Disconnect connectors (7) (4 used). 10. Remove the adapter with 4-spool solenoid valve
unit (12) attached if necessary.
6. Disconnect hose (8).

j : 27 mm
7. Disconnect hoses (9) (10 used).

j : 17 mm
8. Disconnect hose (10).

j : 19 mm

W3-12-2-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

6 12 9

9
10

5 8 11 9 7
WJAA-03-13-009
WJAA-03-07-014

Installation 6. Connect connectors (7) (4 used).

1. Install all removed adapters to 4-spool solenoid 7. Close bracket assembly (6). Install bolts, washers (5)
valve unit (12). (2 used).
2. Install 4-spool solenoid valve unit (12) with bolts, j : 19 mm
washers (11) (2 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Connect hose (10).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

4. Connect hoses (9) (10 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

5. Connect hose (8).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-12-2-3
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

2 3 4
WJAA-03-07-002 WJAA-03-07-013

8. Shut covers (3, 4).

9. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
10. Install cover (1) with bolts, washers (2) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-12-2-4
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Removal and Installation of 2-Spool Solenoid

Valve Unit
5 2, 3, 4 6, 7, 8 1 9

2 6
WJAA-03-07-001

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Open cover (1).
3. Remove bolts, washers (2) (2 used), spacer (3), and
rubber (4). Remove cover (5).

j : 19 mm
4. Remove bolts, washers (6) (4 used), spacers (7) (2
used), and rubbers (8) (2 used). Remove cover (9).

j : 19 mm

W3-12-3-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

WJAA-03-13-008

5. Disconnect connectors (10) (2 used).

6. Place a container under 2-spool solenoid valve unit
(11). Disconnect hoses (12) (9 used).

j : 19 mm
7. Remove bolts, washers (13) (2 used). Remove
2-spool solenoid valve unit (11).

j : 17 mm
8. Remove the adapter with 2-spool solenoid valve
unit (11) attached if necessary.

W3-12-3-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

WJAA-03-13-008

Installation
1. Install all removed adapters to 2-spool solenoid
valve unit (11).
2. Install 2-spool solenoid valve unit (11) with bolts,
washers (13) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Connect hoses (12) (9 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

4. Connect connectors (10) (2 used).

W3-12-3-3
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

5 2, 3, 4 6, 7, 8 1 9

2 6
WJAA-03-07-001

5. Bleed air from the hydraulic system. (Refer to W1-

4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
6. Install cover (9) with rubbers (8) (2 used), spacers (7)
(2 used), and bolts, washers (6) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

7. Install cover (5) with rubber (4), spacer (3), and bolts,
washers (2) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

8. Shut cover (1).

W3-12-3-4
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Removal and Installation of Fan Pump

Control Solenoid Valve

2 3 4
WJAA-03-07-002 WJAA-03-07-013

IMPORTANT: Cap the open ends in case the hoses 3. Open covers (3, 4).
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

d(Refer
CAUTION: Bleed air from the hydraulic oil tank.
to W1-4-1.)

dnot
CAUTION: Remove cover (1) while holding it. Do
drop cover (1).
2. Remove bolts, washers (2) (5 used). Remove cover
(1).

j : 19 mm

W3-12-4-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

6
8 10

5 7 8

WJAA-03-07-014 WJAA-03-13-010

4. Remove bolts, washers (5) (2 used). Open bracket 7. Remove bolts, washers (9) (2 used). Remove fan
assembly (6). pump control solenoid valve (10).

j : 19 mm j : 13 mm
5. Disconnect connector (7). 8. Remove the adapter with fan pump control
solenoid valve (10) attached if necessary.
6. Disconnect hoses (8) (3 used).

j : 17 mm

W3-12-4-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

6 8 10

7 8
5
WJAA-03-13-010
WJAA-03-07-014

Installation 4. Connect connector (7).

1. Install all removed adapters to fan pump control 5. Close bracket assembly (6). Install bolts, washers (5)
solenoid valve (10). (2 used).
2. Install fan pump control solenoid valve (10) with j : 19 mm
bolts, washers (9) (2 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Connect hoses (8) (3 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

W3-12-4-3
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

2 3 4
WJAA-03-07-002 WJAA-03-07-013

6. Shut covers (3, 4).

7. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
8. Install cover (1) with bolts, washers (2) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-12-4-4
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Disassembly of Pilot Shut-Off Solenoid Valve

WDAA-03-13-014

1- Socket Bolt (2 Used) 4- Body 7- O-Ring

2- Solenoid 5- Spool 8- Plug
3- O-Ring 6- Spring 9- Filter

W3-12-5-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Disassembly of Pilot Shut-Off Solenoid Valve

IMPORTANT: Filter (9) cannot be removed.
1. Put the matching marks on body (4) and solenoid
(2). Secure body (4) in a vise. Remove socket bolts
(1) (2 used) from body (4). Remove solenoid (2) and
O-ring (3) from body (4).

l : 4 mm
2. Remove plug (8) from body (4). Remove O-ring (7)
from plug (8).

l : 6 mm
3. Remove spring (6) and spool (5) from body (4).

W3-12-5-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Assembly of Pilot Shut-Off Solenoid Valve

2
1
3

T1V1-03-07-012

1- Socket Bolt (2 Used) 4- Body 7- O-Ring

2- Solenoid 5- Spool 8- Plug
3- O-Ring 6- Spring 9- Filter

W3-12-5-3
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Assembly of Pilot Shut-Off Solenoid Valve

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
1. Secure body (4) in a vise. Insert spool (5) and spring
(6) into body (4).
2. Install O-ring (7) to plug (8). Install plug (8) to body
(4).

l : 6 mm

m : 27 N·m (2.7 kgf·m, 20 lbf·ft)

IMPORTANT: When solenoid (2) is installed after
installing O-ring (3) to body (4), O-ring (3) may be
damaged.
3. Install O-ring (3) to solenoid (2). Fit the matching
marks and install solenoid (2) to body (4).
4. Install solenoid (2) to body (4) with socket bolts (1)
(2 used).

l : 4 mm

m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

W3-12-5-4
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Structure of 4-Spool Solenoid Valve Unit

2 3

WJAA-03-13-001
4

3 6 7 8 9 10

11

15 14 13 12

WJAA-03-13-002

W3-12-6-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Wrench Size Tightening Torque

No. Part Name Q’ty (mm) Remark
N·m (kgf·m, lbf·ft)
1 Body 1
2 Socket Bolt 8 l:4 5 (0.5, 3.7)
3 Solenoid 4
4 Plug (Filter) 4 l:6 10 (1, 7.4)
5 Plug (Filter) 1 l : 10 20 (2, 15)
6 Washer 4
7 Spring 4
8 Spool 4
9 Sleeve 4
10 Plate 4
11 Wave Spring 4
12 O-Ring 4
13 O-Ring 4
14 O-Ring 4
15 O-Ring 4

W3-12-6-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Structure of 2-Spool Solenoid Valve Unit

1
5

4 WJAA-03-13-003

3 6 7 8 9 10

11

15 14 13 12

WJAA-03-13-004

W3-12-7-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Wrench Size Tightening Torque

No. Part Name Q’ty (mm) Remark
N·m (kgf·m, lbf·ft)
1 Body 1
2 Socket Bolt 4 l:4 5 (0.5, 3.7)
3 Solenoid 2
4 Plug (Filter) 2 l:6 10 (1, 7.4)
5 Plug (Filter) 1 l : 10 20 (2, 15)
6 Washer 2
7 Spring 2
8 Spool 2
9 Sleeve 2
10 Plate 2
11 Wave Spring 2
12 O-Ring 2
13 O-Ring 2
14 O-Ring 2
15 O-Ring 2

W3-12-7-2
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Structure of Fan Pump Solenoid Valve

WJAA-03-13-005

3 5 6 7 8 9

10

14 13 12 11

WJAA-03-13-006

W3-12-8-1
 SECTION 3 UPPERSTRUCTURE
Group 12 Solenoid Valve

Wrench Size Tightening Torque

No. Part Name Q’ty (mm) Remark
N·m (kgf·m, lbf·ft)
1 Body 1
2 Socket Bolt 2 l:4 5 (0.5, 3.7)
3 Solenoid 1 l:6 10 (1, 7.4)
4 Plug (Filter) 2
5 Washer 1
6 Spring 1
7 Spool 1
8 Sleeve 1
9 Plate 1
10 Wave Spring 1
11 O-Ring 1
12 O-Ring 1
13 O-Ring 1
14 O-Ring 1

W3-12-8-2
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

Removal and Installation of Signal Control

Valve
1, 2, 3 4 5, 6, 7 8

1 5 WJAA-03-07-001

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove bolts, washers (1) (2 used), spacer (2), and
rubber (3). Remove cover (4).

j : 19 mm
3. Remove bolts, washers (5) (4 used), spacers (6) (2
used), and rubbers (7) (2 used). Remove cover (8).

j : 19 mm

W3-13-1-1
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

Pilot Valve Side

15

15
15

14

a WJAA-03-14-001

a- Pilot Valve Side b- Control Valve Side 15 WJAA-03-14-002

4. Place a container under signal control valve (14).

Disconnect hoses (15) (16 used).

j : 19 mm

W3-13-1-2
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

Control Valve Side

10 11 9

b
9
10
9

10
14

12, 13

a WJAA-03-14-001

a- Pilot Valve Side b- Control Valve Side 10 11 9 WJAA-03-14-003

5. Disconnect hoses (9) (12 used).

j : 19 mm
6. Disconnect hoses (10) (4 used).

j : 17 mm
7. Disconnect connectors (11) (2 used).
8. Remove socket bolts (12) (4 used) and washers (13)
(4 used). Remove signal control valve (14).

l : 8 mm
9. Remove the adapter with signal control valve (14)
attached if necessary.

W3-13-1-3
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

Control Valve Side

10 11 9

b
9
10
9

10
14

12, 13

a WJAA-03-14-001

a- Pilot Valve Side b- Control Valve Side 10 11 9 WJAA-03-14-003

Installation
1. Install all removed adapters to signal control valve
(14).
2. Install signal control valve (14) with washers (13) (4
used) and socket bolts (12) (4 used).

l : 8 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Connect connectors (11) (2 used).
4. Connect hoses (10) (4 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

5. Connect hoses (9) (12 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-13-1-4
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

Pilot Valve Side

15

15
15

14

a WJAA-03-14-001

a- Pilot Valve Side b- Control Valve Side 15 WJAA-03-14-002

6. Connect hoses (15) (16 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-13-1-5
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

1, 2, 3 4 5, 6, 7 8

1 5 WJAA-03-07-001

7. Bleed air from the hydraulic system. (Refer to W1-

4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
8. Install cover (8) with rubbers (7) (2 used), spacers (6)
(2 used), and bolts, washers (5) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

9. Install cover (4) with rubber (3), spacer (2), and bolts,
washers (1) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-13-1-6
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

Structure of Signal Control Valve

13

12 4

11

4 10

7 8
7
7

4 4

W1JB-02-10-002

W3-13-2-1
 SECTION 3 UPPERSTRUCTURE
Group 13 Signal Control Valve

15
16
17
18
19
14 16
17 20
21
19
16 20
17
18
19
20

14

22
23
24
25
26
27
19
28
17
16
29
20
19 14
5 18
17
16
20 19
21
17
16
20
19
18
17
16

W1JB-02-10-003

1- Bolt (3 Used) 9- Body 3 17- O-Ring (7 Used) 25- O-Ring

2- Body 1 10- Gasket 18- Spring (4 Used) 26- Spring
3- Gasket 11- Body 4 19- Spring Guide (7 Used) 27- Spool
4- Filter (17 Used) 12- Gasket 20- Spool (6 Used) 28- Spring
5- Body 2 13- Body 5 21- Spring (2 Used) 29- Plate
6- Gasket 14- Socket Bolt (11 Used) 22- Plate
7- Shuttle Valve (2 Used) 15- Plate 23- O-Ring
8- Spring (4 Used) 16- Plug (7 Used) 24- Shuttle Valve

W3-13-2-2
 SECTION 3 UPPERSTRUCTURE
Group 14 Shockless Valve

Removal and Installation of Shockless Valve

Detail A
3 1 2

WJAA-03-15-001

A
WJAA-03-02-001

IMPORTANT: Cap the open ends in case the hoses 2. Disconnect hoses (1) (2 used).
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors, j : 22 mm
hoses, and pipes for assembling. Connect the 3. Remove bolts, washers (2) (2 used). Remove
hoses and install the clips in case the clips which shockless valve (3).
secure the hoses have been removed.
Removal j : 13 mm

1. Set the machine position for inspection and 4. Remove the adapter with shockless valve (3)
maintenance. (Refer to W1-6-1.) attached if necessary.

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

W3-14-1-1
 SECTION 3 UPPERSTRUCTURE
Group 14 Shockless Valve

Detail A
3 1 2

WJAA-03-15-001

A
WJAA-03-02-001

Installation 4. Bleed air from the hydraulic system. (Refer to W1-

4-1.)
1. Install all removed adapters to shockless valve (3).
IMPORTANT: Check the hydraulic oil level. Start the
2. Install shockless valve (3) with bolts, washers (2) (2
engine and check for any oil leaks.
used).

j : 13 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Connect hoses (1) (2 used).

j : 22 mm

m : 40 N·m (4 kgf·m, 30 lbf·ft)

W3-14-1-2
 SECTION 3 UPPERSTRUCTURE
Group 14 Shockless Valve

Structure of Shockless Valve

4 5 6 7

T183-03-07-008

Wrench Size Tightening Torque

No. Part Name Q’ty (mm) Remark
N·m (kgf·m, lbf·ft)
1 Plug 2 l:8 40 (4, 30)
2 O-Ring 2
3 Body 1
4 Spring 2
5 Plunger 1
6 Ring 1
7 Orifice 1

W3-14-2-1
 SECTION 3 UPPERSTRUCTURE
Group 14 Shockless Valve

(Blank)

W3-14-2-2
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

Removal and Installation of Fan Valve

2 1 WJAA-03-07-001

dCAUTION: Bleed air from the hydraulic oil tank

before doing any work. (Refer to W1-4-1.)
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Remove bolts, washers (1) (6 used). Remove cover
(2).

j : 17 mm
3. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Oil amount: 310 L (81.9 US gal)

W3-15-1-1
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

3
5

6 7
WJAA-03-02-001 WJAA-03-05-016

dCAUTION: Remove cover (3) while holding it. Do

not drop cover (3).
4. Remove bolts, washers (4) (5 used). Remove cover
(3).

j : 19 mm

dCAUTION: Remove cover (5) while holding it. Do

not drop cover (5).
5. Remove bolts, washers (6) (5 used). Remove cover
(5).

j : 19 mm
6. Place a container under cock (7). Open cock (7).
Drain off coolant. Close cock (7).

fNOTE: Coolant amount: 52 L (13.7 US gal)

W3-15-1-2
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

13

15

16

8 13 14 10, 11, 12 15
WJAA-03-05-001 WJAA-03-05-002

7. Remove bolts, washers (8) (4 used). Remove cap

assembly (9).

j : 17 mm
8. Remove bolts (10) (2 used), spring washers (11) (2
used), and washers (12) (2 used). Remove bolts,
washers (13) (9 used). Remove cover (14).

j : 19 mm
9. Remove bolts, washers (15) (3 used). Remove
bracket (16).

j : 19 mm

W3-15-1-3
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

22

23

17, 18, 19 21 20 22 24 25 24
WJAA-03-05-003 WJAA-03-05-004

10. Remove bolts (17) (2 used), spring washers (18) (2

used), and washers (19) (2 used). Remove bolts,
washers (20) (7 used). Remove cover (21).

j : 19 mm
11. Remove bolts, washers (22) (3 used). Remove
bracket (23).

j : 19 mm
12. Remove bolts, washers (24) (2 used). Remove
bracket (25).

j : 19 mm

W3-15-1-4
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

26 27 29 31 30 32

33
28

WJAA-03-05-006 WJAA-03-05-007

13. Remove bolts, washers (26) (7 used). Remove cover

(27).

j : 19 mm
14. Remove bolts, washers (28) (6 used). Remove cover
(29).

j : 19 mm
15. Remove bolts, washers (30) (4 used). Remove
bracket (31).

j : 19 mm
16. Open cover (32).
17. Remove bolts, washers (33) (2 used). Remove the
cover (32) assembly.

j : 19 mm

W3-15-1-5
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

41 39 42 40 43 39 44 34 49 48 47 50 49

43
41

34 35 37 36 38 45, 46
WJAA-03-05-008 WJAA-03-05-009

18. Remove bolts, washers (34) (3 used). Remove 24. Remove clamp (45). Disconnect hose (46).
bracket (35).
25. Remove bolts, washers (47) (4 used). Remove air
j : 19 mm cleaner duct (48).

19. Disconnect plugs (36) (2 used). j : 19 mm

20. Remove clamp (37). Disconnect hose (38). 26. Remove bolts, washers (49) (9 used). Remove
bracket (50).
21. Remove bolts, washers (39) (8 used). Remove
clamps (40) (4 used). j : 19 mm
j : 17 mm
22. Remove clamps (41) (4 used). Disconnect pipe (42).

j : 11 mm
23. Remove clamps (43) (4 used). Disconnect pipe (44).

j : 11 mm

W3-15-1-6
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

54 55 57 58

59

56 53 52 51 59 60
WJAA-03-05-010 WJAA-03-05-011

27. Remove bolt, washer (51). Remove clamp (52).

j : 19 mm
28. Remove coupling (53). Remove bolts, washers (54)
(2 used). Disconnect pipe (55). Remove O-ring (56).

j : 19 mm
29. Remove clamps (57) (2 used). Disconnect hose (58).

j : 11 mm
30. Remove clamps (59) (4 used). Disconnect hose (60).

j : 11 mm

W3-15-1-7
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

61 62 64, 65 63

WJAA-03-08-004 WJAA-03-08-005

31. Open cover (61).

32. Remove clamp (62). Disconnect hose (63).

j : 7 mm
33. Remove bolt, washer (64). Remove clip (65).

j : 17 mm

W3-15-1-8
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

68, 69 70

70

73
71

66, 67
73

72
WJAA-03-05-012 WJAA-03-05-013

34. Remove bolts (66) (2 used) and washers (67) (2

used).

j : 19 mm
35. Remove bolts (68) (2 used) and washers (69) (2
used).

j : 19 mm
36. Open duct (70).
37. Remove bolts, washers (71) (12 used). Remove nets
(72) (2 used).

j : 10 mm

dCAUTION:
(115 lb)
The duct (70) assembly weight: 50 kg

38. Attach nylon slings onto duct (70). Hoist and hold
the duct (70) assembly.
39. Remove bolts, washers (73) (4 used).

j : 19 mm
40. Remove the duct (70) assembly.

W3-15-1-9
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

86 85 80, 81 a 88

87

79

76
84

83 75 74 77, 78 82 77, 78 a- Lifting Hole

WJAA-03-05-014 WJAA-03-05-015

41. Remove bolts, washers (74) (4 used). Remove cover

(75). dCAUTION: Radiator (87) and air cleaner (88)
weight: 360 kg (795 lb)
j : 19 mm 46. Install shackles (2 used) to lifting hole (a) (2 places)
42. Disconnect connector (76). on radiator (87). Attach nylon slings onto shackles (2
used). Hoist and hold radiator (87).
43. Remove bolts, washers (77) (2 used). Remove clips
(78) (2 used).

j : 17 mm
IMPORTANT: Take care not to disconnect hose (79).
44. Remove bolts, washers (80) (4 used) and bushings
(81) (4 used). Place air conditioner condenser (82)
onto main frame (83).

j : 13 mm
IMPORTANT: Take care not to disconnect hose (84).
45. Remove bolts, washers (85) (4 used). Place fuel
cooler (86) onto main frame (83).

j : 13 mm

W3-15-1-10
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

104, 105, 106 107 108 109

104

100

100, 101, 102 103 110

WJAA-03-05-019 WJAA-03-05-018

47. Remove bolts, washers (100) (2 used), spacer (101),

and rubber (102). Remove cover (103).

j : 19 mm
48. Remove bolts, washers (104) (4 used), spacers (105)
(2 used), and rubbers (106) (2 used). Remove cover
(107).

j : 19 mm
49. Disconnect hose (108).

j : 36 mm
50. Disconnect hose (109).

j : 27 mm
51. Remove hose band (110).

W3-15-1-11
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

Detail A

111

A
WJAA-03-05-020

WJAA-03-02-001

52. Disconnect hose (111).

j : 36 mm

W3-15-1-12
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

95, 96 87 93, 94

90 89 91 92 95, 96
WJAA-03-05-016 WJAA-03-05-017

53. Remove clamps (89) (2 used). Disconnect hose (90).

j : 11 mm
54. Remove socket bolts (91) (4 used) and flanges (92)
(2 used). Disconnect hose (93). Remove O-ring (94).

j : 10 mm
55. Remove bolts (95) (4 used) and washers (96) (4
used).

j : 30 mm
56. Remove the radiator (87) assembly.

W3-15-1-13
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

119

117
116

118 122 120, 121

WJAA-03-05-023 WJAA-03-05-025

57. Remove bolts, washers (116) (5 used). Remove cover

(117).

j : 19 mm
58. Disconnect hose (118).

j : 41 mm
59. Disconnect hoses (119) (3 used).

j : 36 mm
60. Remove bolts (120) (2 used) and washers (121) (2
used). Remove fan valve (122).

j : 17 mm

W3-15-1-14
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

119

117
116

118 122 120, 121

WJAA-03-05-023 WJAA-03-05-025

Installation
1. Install fan valve (122) with washers (121) (2 used)
and bolts (120) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

2. Connect hoses (119) (3 used).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

3. Connect hose (118).

j : 41 mm

m : 200 N·m (20 kgf·m, 148 lbf·ft)

W3-15-1-15
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

95, 96 87 93, 94

90 89 91 92 95, 96
WJAA-03-05-016 WJAA-03-05-017

a 88

87
dCAUTION: Radiator (87) and air cleaner (88)
weight: 360 kg (795 lb)
4. Install shackles (2 used) to lifting hole (a) (2 places)
on radiator (87). Attach nylon slings onto shackles (2
used). Hoist radiator (87).
5. Install radiator (87) with washers (96) (4 used) and
bolts (95) (4 used).

j : 30 mm

m : 550 N·m (55 kgf·m, 410 lbf·ft)

6. Install O-ring (94) to hose (93). Connect hose (93)
with flanges (92) (2 used) and socket bolts (91) (4
a- Lifting Hole
used).
WJAA-03-05-015
l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

7. Connect hose (90) with clamps (89) (2 used).

j : 11 mm

W3-15-1-16
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

Detail A

111

A
WJAA-03-05-020

WJAA-03-02-001

8. Connect hose (111).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

W3-15-1-17
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

104, 105, 106 107 108 109

104

100

100, 101, 102 103 110

WJAA-03-05-019 WJAA-03-05-018

9. Install hose band (110).

10. Connect hose (109).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

11. Connect hose (108).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

12. Install cover (107) with rubbers (106) (2 used),
spacers (105) (2 used), and bolts, washers (104) (4
used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

13. Install cover (103) with rubber (102), spacer (101),
and bolts, washers (100) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-15-1-18
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

86 85 80, 81

79

76
84

83 75 74 77, 78 82 77, 78
WJAA-03-05-014

14. Install fuel cooler (86) with bolts, washers (85) (4

used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

15. Install air conditioner condenser (82) with bushings
(81) (4 used) and bolts, washers (80) (4 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

16. Install clips (78) (2 used) with bolts, washers (77) (2
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

17. Connect connector (76).
18. Install cover (75) with bolts, washers (74) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-15-1-19
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

68, 69 70

70

73
71

66, 67
73

72
WJAA-03-05-012 WJAA-03-05-013

23. Install washers (69) (2 used) and bolts (68) (2 used).

dCAUTION:
(115 lb)
The duct (70) assembly weight: 50 kg
j : 19 mm
19. Attach nylon slings onto duct (70). Hoist the duct
m : 110 N·m (11 kgf·m, 81 lbf·ft)
(70) assembly.
24. Install washers (67) (2 used) and bolts (66) (2 used).
20. Install the duct (70) assembly with bolts, washers
(73) (4 used). j : 19 mm
j : 19 mm m : 110 N·m (11 kgf·m 81 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
21. Install nets (72) (2 used) to duct (70) with bolts,
washers (71) (12 used).

j : 10 mm

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3.0 lbf·ft)

22. Close duct (70).

W3-15-1-20
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

61 62 64, 65 63

WJAA-03-08-004 WJAA-03-08-005

25. Open cover (61).

26. Install clip (65) with bolt, washer (64).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

27. Connect hose (63) with clamp (62).

j : 7 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft )

W3-15-1-21
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

54 55 57 58

59

56 53 52 51 59 60
WJAA-03-05-010 WJAA-03-05-011

28. Connect hose (60) with clamps (59) (4 used).

j : 11 mm
29. Connect hose (58) with clamps (57) (2 used).

j : 11 mm
30. Install O-ring (56) to pipe (55). Connect pipe (55)
with bolts, washers (54) (2 used) and coupling (53).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

31. Install clamp (52) with bolt, washer (51).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-15-1-22
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

41 39 42 40 43 39 44 34 49 48 47 50 49

43
41

34 35 37 36 38 45, 46
WJAA-03-05-008 WJAA-03-05-009

32. Install bracket (50) with bolts, washers (49) (9 used). 37. Install clamps (40) (4 used) with bolts, washers (39)
(8 used).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
33. Install air cleaner duct (48) with bolts, washers (47)
(4 used). 38. Connect hose (38) with clamp (37).

j : 19 mm 39. Connect plugs (36) (2 used).

40. Install bracket (35) with bolts, washers (34) (3 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
34. Connect hose (46) with clamp (45). j : 19 mm

35. Connect pipe (44) with clamps (43) (4 used). m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 11 mm
36. Connect pipe (42) with clamps (41) (4 used).

j : 11 mm

W3-15-1-23
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

26 27 29 31 30 32

33
28

WJAA-03-05-006 WJAA-03-05-007

41. Install the cover (32) assembly with bolts, washers

(33) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

42. Close cover (32).
43. Install bracket (31) with bolts, washers (30) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

44. Install cover (29) with bolts, washers (28) (6 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

45. Install cover (27) with bolts, washers (26) (7 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-15-1-24
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

22

23

17, 18, 19 21 20 22 24 25 24
WJAA-03-05-003 WJAA-03-05-004

46. Install bracket (25) with bolts, washers (24) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

47. Install bracket (23) with bolts, washers (22) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

48. Install cover (21) with bolts, washers (20) (7 used),
washers (19) (2 used), spring washers (18) (2 used),
and bolts (17) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-15-1-25
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

13

15

16

8 13 14 10, 11, 12 15
WJAA-03-05-001 WJAA-03-05-002

49. Install bracket (16) with bolts, washers (15) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

50. Install cover (14) with bolts, washers (13) (9 used),
washers (12) (2 used), spring washers (11) (2 used),
and bolts (10) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

51. Install cap assembly (9) with bolts, washers (8) (4
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-15-1-26
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

97

98
b- Cover on Radiator M1J1-07-078

87

2 1 WJAA-03-07-001

99

M1J1-07-039

52. Remove bolts, washers (97) (2 used). Remove cover 57. Bleed air from the cooling system.
(98).
58. Bleed air from the hydraulic system. (Refer to W1-
j : 19 mm 4-1.)

53. Remove cap (99). Add coolant to radiator (87). Install IMPORTANT: Check the coolant level and the
cap (99). hydraulic oil level. Start the engine and check for
any oil leaks.
fNOTE: Coolant amount: 52 L (13.7 US gal) 59. Install cover (98) with bolts, washers (97) (2 used).
54. Remove bolts, washers (1) (6 used). Remove cover
(2). j : 19 mm

j : 17 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

55. Add hydraulic oil.

fNOTE: Oil amount: 310 L (81.9 US gal)

56. Install cover (2) with bolts, washers (1) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-15-1-27
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

3
5

6
WJAA-03-02-001

60. Install cover (5) with bolts, washers (6) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

61. Install cover (3) with bolts, washers (4) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-15-1-28
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

Structure of Fan Valve

View A

A W1JB-02-13-002 W1JB-02-13-003

Section B
1 2 3 4 5 6

7 8 9 10 11 12 13

14

18 17 16 15

W1JB-02-13-001

W3-15-2-1
 SECTION 3 UPPERSTRUCTURE
Group 15 Fan Valve

Wrench Size No. Part Name Q’ty Wrench Size

No. Part Name Q’ty
(mm) (mm)
1 Pin 2 10 O-Ring 1
2 Poppet 2 11 Spring 1
3 Poppet 1 12 O-Ring 1
4 Backup Ring 2 13 Lock Nut 1 j : 19
5 O-Ring 1 14 Screw 1
6 O-Ring 1 15 Body 1 j : 32
7 Spring 1 16 Poppet 1
8 O-Ring 1 17 Adaptor 1 j : 32
9 Spring 1 18 Backup Ring 2

W3-15-2-2
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

Removal and Installation of Fan Motor

2 1 WJAA-03-07-001

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove bolts, washers (1) (6 used). Remove cover
(2).

j : 17 mm
3. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Oil amount: 310 L (81.9 US gal)

W3-16-1-1
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

3
5

6 7
WJAA-03-02-001 WJAA-03-05-016

dCAUTION: Remove cover (3) while holding it. Do

not drop cover (3).
4. Remove bolts, washers (4) (5 used). Remove cover
(3).

j : 19 mm

dCAUTION: Remove cover (5) while holding it. Do

not drop cover (5).
5. Remove bolts, washers (6) (5 used). Remove cover
(5).

j : 19 mm
6. Place a container under cock (7). Open cock (7).
Drain off coolant. Close cock (7).

fNOTE: Coolant amount: 52 L (13.7 US gal)

W3-16-1-2
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

13

15

16

8 13 14 10, 11, 12 15
WJAA-03-05-001 WJAA-03-05-002

7. Remove bolts, washers (8) (4 used). Remove cap

assembly (9).

j : 17 mm
8. Remove bolts (10) (2 used), spring washers (11) (2
used), and washers (12) (2 used). Remove bolts,
washers (13) (9 used). Remove cover (14).

j : 19 mm
9. Remove bolts, washers (15) (3 used). Remove
bracket (16).

j : 19 mm

W3-16-1-3
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

22

23

17, 18, 19 21 20 22 24 25 24
WJAA-03-05-003 WJAA-03-05-004

10. Remove bolts (17) (2 used), spring washers (18) (2

used), and washers (19) (2 used). Remove bolts,
washers (20) (7 used). Remove cover (21).

j : 19 mm
11. Remove bolts, washers (22) (3 used). Remove
bracket (23).

j : 19 mm
12. Remove bolts, washers (24) (2 used). Remove
bracket (25).

j : 19 mm

W3-16-1-4
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

26 27 29 31 30 32

33
28

WJAA-03-05-006 WJAA-03-05-007

13. Remove bolts, washers (26) (7 used). Remove cover

(27).

j : 19 mm
14. Remove bolts, washers (28) (6 used). Remove cover
(29).

j : 19 mm
15. Remove bolts, washers (30) (4 used). Remove
bracket (31).

j : 19 mm
16. Open cover (32).
17. Remove bolts, washers (33) (2 used). Remove the
cover (32) assembly.

j : 19 mm

W3-16-1-5
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

41 39 42 40 43 39 44 34 49 48 47 50 49

43
41

34 35 37 36 38 45, 46
WJAA-03-05-008 WJAA-03-05-009

18. Remove bolts, washers (34) (3 used). Remove 24. Remove clamp (45). Disconnect hose (46).
bracket (35).
25. Remove bolts, washers (47) (4 used). Remove air
j : 19 mm cleaner duct (48).

19. Disconnect plugs (36) (2 used). j : 19 mm

20. Remove clamp (37). Disconnect hose (38). 26. Remove bolts, washers (49) (9 used). Remove
bracket (50).
21. Remove bolts, washers (39) (8 used). Remove
clamps (40) (4 used). j : 19 mm
j : 17 mm
22. Remove clamps (41) (4 used). Disconnect pipe (42).

j : 11 mm
23. Remove clamps (43) (4 used). Disconnect pipe (44).

j : 11 mm

W3-16-1-6
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

54 55 57 58

59

56 53 52 51 59 60
WJAA-03-05-010 WJAA-03-05-011

27. Remove bolt, washer (51). Remove clamp (52).

j : 19 mm
28. Remove coupling (53). Remove bolts, washers (54)
(2 used). Disconnect pipe (55). Remove O-ring (56).

j : 19 mm
29. Remove clamps (57) (2 used). Disconnect hose (58).

j : 11 mm
30. Remove clamps (59) (4 used). Disconnect hose (60).

j : 11 mm

W3-16-1-7
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

61 62 64, 65 63

WJAA-03-08-004 WJAA-03-08-005

31. Open cover (61).

32. Remove clamp (62). Disconnect hose (63).

j : 7 mm
33. Remove bolt, washer (64). Remove clip (65).

j : 17 mm

W3-16-1-8
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

68, 69 70

70

73
71

66, 67
73

72
WJAA-03-05-012 WJAA-03-05-013

34. Remove bolts (66) (2 used) and washers (67) (2

used).

j : 19 mm
35. Remove bolts (68) (2 used) and washers (69) (2
used).

j : 19 mm
36. Open duct (70).
37. Remove bolts, washers (71) (12 used). Remove nets
(72) (2 used).

j : 10 mm

dCAUTION:
(115 lb)
The duct (70) assembly weight: 50 kg

38. Attach nylon slings onto duct (70). Hoist and hold
duct (70) assembly.
39. Remove bolts, washers (73) (4 used).

j : 19 mm
40. Remove the duct (70) assembly.

W3-16-1-9
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

86 85 80, 81 a 88

87

79

76
84

83 75 74 77, 78 82 77, 78 a- Lifting Hole

WJAA-03-05-014 WJAA-03-05-015

41. Remove bolts, washers (74) (4 used). Remove cover

(75). dCAUTION: Radiator (87) and air cleaner (88)
weight: 360 kg (795 lb)
j : 19 mm 46. Install shackles (2 used) to lifting hole (a) (2 places)
42. Disconnect connector (76). on radiator (87). Attach nylon slings onto shackles (2
used). Hoist and hold radiator (87).
43. Remove bolts, washers (77) (2 used). Remove clips
(78) (2 used).

j : 17 mm
IMPORTANT: Take care not to disconnect hose (79).
44. Remove bolts, washers (80) (4 used) and bushings
(81) (4 used). Place air conditioner condenser (82)
onto main frame (83).

j : 13 mm
IMPORTANT: Take care not to disconnect hose (84).
45. Remove bolts, washers (85) (4 used). Place fuel
cooler (86) onto main frame (83).

j : 13 mm

W3-16-1-10
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

104, 105, 106 107 108 109

104

100

100, 101, 102 103 110

WJAA-03-05-019 WJAA-03-05-018

47. Remove bolts, washers (100) (2 used), spacer (101),

and rubber (102). Remove cover (103).

j : 19 mm
48. Remove bolts, washers (104) (4 used), spacers (105)
(2 used), and rubbers (106) (2 used). Remove cover
(107).

j : 19 mm
49. Disconnect hose (108).

j : 36 mm
50. Disconnect hose (109).

j : 27 mm
51. Remove hose band (110).

W3-16-1-11
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

Detail A

111

A
WJAA-03-05-020

WJAA-03-02-001

52. Disconnect hose (111).

j : 36 mm

W3-16-1-12
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

95, 96 87 93, 94

90 89 91 92 95, 96
WJAA-03-05-016 WJAA-03-05-017

53. Remove clamps (89) (2 used). Disconnect hose (90).

j : 11 mm
54. Remove socket bolts (91) (4 used) and flanges (92)
(2 used). Disconnect hose (93). Remove O-ring (94).

j : 10 mm
55. Remove bolts (95) (4 used) and washers (96) (4
used).

j : 30 mm
56. Remove the radiator (87) assembly.

W3-16-1-13
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

88 114

113

112 112 115

WJAA-03-05-022 WJAA-03-05-021

dCAUTION:
30 kg (67 lb)
The air cleaner (88) assembly weight:

57. Attach nylon slings onto the air cleaner (88)

assembly. Hoist and hold the air cleaner (88)
assembly.
58. Remove bolts, washers (112) (4 used).

j : 19 mm
59. Remove bolts, washers (113) (2 used). Remove the
air cleaner (88) assembly.

j : 19 mm
60. Remove bolts, washers (114) (2 used). Remove
bracket (115).

j : 19 mm

W3-16-1-14
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

118 118 121 119

120

117
116

118 118
WJAA-03-05-023 WJAA-03-05-025

61. Remove bolts, washers (116) (5 used). Remove cover

(117).

j : 19 mm
62. Remove bolts, washers (118) (8 used).

j : 19 mm

dCAUTION:
kg (155 lb)
The bracket (119) assembly weight: 70

63. Attach nylon slings onto bracket (119). Hoist and

hold the bracket (119) assembly.
64. Remove bolts, washers (120) (6 used). Remove the
bracket (119) assembly. Place the bracket (119)
assembly with the fan motor (121) side down.

j : 19 mm

W3-16-1-15
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

122 126 124 133 131, 132, 134 135 130 121
125

123
127

128 119

121

129 136, 137, 138 130 129

W1J1-02-13-010 WJAA-03-05-024

65. Remove socket bolts (122) (6 used). Remove fan 70. Remove bolts, washers (129) (4 used). Remove fan
(123). guards (130) (2 used).

l : 10 mm j : 19 mm
66. Remove lock pin (124). 71. Remove socket bolts (131) (8 used) and flanges
(132) (4 used). Disconnect hoses (133) (2 used).
67. Remove nut (125) and washer (126).
Remove O-rings (134) (2 used).
j : 24 mm
l : 8 mm
68. Remove coupling (127) and key (128).
72. Disconnect hose (135).
69. Place the bracket (119) assembly with the fan motor
(121) side up. j : 27 mm
73. Remove nuts (136) (2 used), washers (137) (4 used),
and bolts (138) (2 used). Remove fan motor (121).

j : 19 mm

W3-16-1-16
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

122 126 124 133 131, 132, 134 135 130 121
125

123
127

128 119

121

129 136, 137, 138 130 129

W1J1-02-13-010 WJAA-03-05-024

Installation 5. Install fan guards (130) (2 used) with bolts, washers

(129) (4 used).
dCAUTION:
40kg (89 lb)
The bracket (119) assembly weight:
j : 19 mm
1. Attach nylon slings onto the bracket (119) assembly.
m : 90 N·m (9 kgf·m, 66 lbf·ft)
Hoist the bracket (119) assembly. Place the bracket
(119) assembly with the fan motor (121) side up. 6. Place the bracket (119) assembly with the fan motor
(121) side down.
2. Install fan motor (121) with bolts (138) (2 used),
washers (137) (4 used), and nuts (136) (2 used). 7. Install key (128) and coupling (127).

j : 19 mm 8. Apply LOCTITE #262 onto nut (125). Install washer

(126) and nut (125).
m : 110 N·m (11 kgf·m, 81 lbf·ft)
j : 24 mm
3. Connect hose (135).
m : 100 N·m (10 kgf·m, 74 lbf·ft)
j : 27 mm
9. Install lock pin (124).
m : 80 N·m (8 kgf·m, 59 lbf·ft)
10. Apply LOCTITE #262 onto socket bolts (122) (6
4. Install O-rings (134) (2 used) to hoses (133) (2 used). used). Install fan (123) with socket bolts (122) (6
Connect hoses (133) (2 used) with flanges (132) (4 used).
used) and socket bolts (131) (8 used).
l : 10 mm
l : 8 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-16-1-17
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

118 118 121 119

120

117
116

118 118
WJAA-03-05-023 WJAA-03-05-025

11. Install the bracket (119) assembly with bolts,

washers (120) (6 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

12. Install bolts, washers (118) (8 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

13. Install cover (117) with bolts, washers (116) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-1-18
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

88 114

113

112 112 115

WJAA-03-05-022 WJAA-03-05-021

14. Install bracket (115) with bolts, washers (114) (2

used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

dCAUTION:
30 kg (67 lb)
The air cleaner (88) assembly weight:

15. Attach nylon slings onto the air cleaner (88)

assembly. Hoist the air cleaner (88) assembly.
16. Install the air cleaner (88) assembly with bolts,
washers (113) (2 used) and bolts, washers (112) (4
used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-1-19
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

95, 96 87 93, 94

90 89 91 92 95, 96
WJAA-03-05-016 WJAA-03-05-017

a 88

87
dCAUTION: Radiator (87) and air cleaner (88)
weight: 360 kg (795 lb)
17. Install shackles (2 used) to lifting hole (a) (2 places)
on radiator (87). Attach nylon slings onto shackles (2
used). Hoist radiator (87).
18. Install radiator (87) with washers (96) (4 used) and
bolts (95) (4 used).

j : 30 mm

m : 550 N·m (55 kgf·m, 410 lbf·ft)

19. Install O-ring (94) to hose (93). Connect hose (93)
with flanges (92) (2 used) and socket bolts (91) (4
a- Lifting Hole
used).
WJAA-03-05-015
l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

20. Connect hose (90) with clamps (89) (2 used).

j : 11 mm

W3-16-1-20
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

Detail A

111

A
WJAA-03-05-020

WJAA-03-02-001

21. Connect hose (111).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

W3-16-1-21
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

104, 105, 106 107 108 109

104

100

100, 101, 102 103 110

WJAA-03-05-019 WJAA-03-05-018

22. Install hose band (110).

23. Connect hose (109).

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

24. Connect hose (108).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

25. Install cover (107) with rubbers (106) (2 used),
spacers (105) (2 used), and bolts, washers (104) (4
used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

26. Install cover (103) with rubber (102), spacer (101),
and bolts, washers (100) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-1-22
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

86 85 80, 81

79

76
84

83 75 74 77, 78 82 77, 78
WJAA-03-05-014

27. Install fuel cooler (86) with bolts, washers (85) (4

used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

28. Install air conditioner condenser (82) with bushings
(81) (4 used) and bolts, washers (80) (4 used).

j : 13 mm

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

29. Install clips (78) (2 used) with bolts, washers (77) (2
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

30. Connect connector (76).
31. Install cover (75) with bolts, washers (74) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-1-23
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

68, 69 70

70

73
71

66, 67
73

72
WJAA-03-05-012 WJAA-03-05-013

36. Install washers (69) (2 used) and bolts (68) (2 used).

dCAUTION:
(115 lb)
The duct (70) assembly weight: 50 kg
j : 19 mm
32. Attach nylon slings onto duct (70). Hoist the duct
m : 110 N·m (11 kgf·m, 81 lbf·ft)
(70) assembly.
37. Install washers (67) (2 used) and bolts (66) (2 used).
33. Install the duct (70) assembly with bolts, washers
(73) (4 used). j : 19 mm
j : 19 mm m : 110 N·m (11 kgf·m, 81 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
34. Install nets (72) (2 used) to duct (70) with bolts,
washers (71) (12 used).

j : 10 mm

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3.0 lbf·ft)

35. Close duct (70).

W3-16-1-24
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

61 62 64, 65 63

WJAA-03-08-004 WJAA-03-08-005

38. Open cover (61).

39. Install clip (65) with bolt, washer (64).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

40. Connect hose (63) with clamp (62).

j : 7 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-16-1-25
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

54 55 57 58

59

56 53 52 51 59 60
WJAA-03-05-010 WJAA-03-05-011

41. Connect hose (60) with clamps (59) (4 used).

j : 11 mm
42. Connect hose (58) with clamps (57) (2 used).

j : 11 mm
43. Install O-ring (56) to pipe (55). Connect pipe (55)
with bolts, washers (54) (2 used) and coupling (53).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

44. Install clamp (52) with bolt, washer (51).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-1-26
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

41 39 42 40 43 39 44 34 49 48 47 50 49

43
41

34 35 37 36 38 45, 46
WJAA-03-05-008 WJAA-03-05-009

45. Install bracket (50) with bolts, washers (49) (9 used). 50. Install clamps (40) (4 used) with bolts, washers (39)
(8 used).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
46. Install air cleaner duct (48) with bolts, washers (47)
(4 used). 51. Connect hose (38) with clamp (37).

j : 19 mm 52. Connect plugs (36) (2 used).

53. Install bracket (35) with bolts, washers (34) (3 used).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
47. Connect hose (46) with clamp (45). j : 19 mm

48. Connect pipe (44) with clamps (43) (4 used). m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 11 mm
49. Connect pipe (42) with clamps (41) (4 used).

j : 11 mm

W3-16-1-27
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

26 27 29 31 30 32

33
28

WJAA-03-05-006 WJAA-03-05-007

54. Install the cover (32) assembly with bolts, washers

(33) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

55. Close cover (32).
56. Install bracket (31) with bolts, washers (30) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

57. Install cover (29) with bolts, washers (28) (6 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

58. Install cover (27) with bolts, washers (26) (7 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-1-28
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

22

23

17, 18, 19 21 20 22 24 25 24
WJAA-03-05-003 WJAA-03-05-004

59. Install bracket (25) with bolts, washers (24) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

60. Install bracket (23) with bolts, washers (22) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

61. Install cover (21) with bolts, washers (20) (7 used),
washers (19) (2 used), spring washers (18) (2 used),
and bolts (17) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-1-29
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

13

15

16

8 13 14 10, 11, 12 15
WJAA-03-05-001 WJAA-03-05-002

62. Install bracket (16) with bolts, washers (15) (3 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

63. Install cover (14) with bolts, washers (13) (9 used),
washers (12) (2 used), spring washers (11) (2 used),
and bolts (10) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

64. Install cap assembly (9) with bolts, washers (8) (4
used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-16-1-30
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

97

98
b- Cover on Radiator M1J1-07-078

87

2 1 WJAA-03-07-001

99

M1J1-07-039

65. Remove bolts, washers (97) (2 used). Remove cover 70. Bleed air from the cooling system.
(98).
71. Bleed air from the hydraulic system. (Refer to W1-
j : 19 mm 4-1.)

66. Remove cap (99). Add coolant to radiator (87).Install IMPORTANT: Check the coolant level and the
cap (99). hydraulic oil level. Start the engine and check for
any oil leaks.
fNOTE: Coolant amount: 52 L (13.7 US gal) 72. Install cover (98) with bolts, washers (97) (2 used).
67. Remove bolts, washers (1) (6 used). Remove cover
(2). j : 19 mm

j : 17 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

68. Add hydraulic oil.

fNOTE: Oil amount: 310 L (81.9 US gal)

69. Install cover (2) with bolts, washers (1) (6 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-16-1-31
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

3
5

6
WJAA-03-02-001

73. Install cover (5) with bolts, washers (6) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

74. Install cover (3) with bolts, washers (4) (5 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-1-32
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

Structure of Fan Motor

21
22

23

W1JB-02-12-002

1 2 3 4 5 6 7 8 9 10 11

W1JB-02-12-001
20 19 18 17 16 15 14 13 12

W3-16-2-1
 SECTION 3 UPPERSTRUCTURE
Group 16 Fan Motor

Tightening Tightening
Torque Torque
No. Part Name Q’ty No. Part Name Q’ty
(kgf·m, (kgf·m,
N·m N·m
lbf·ft) lbf·ft)
1 End Cap 1 13 Retaining Ring 1
2 Rotor Insert Assembly 1 14 Retaining Ring 1
3 Vane Spring 24 15 Seal 1
4 Mount 12 16 Seal 1
5 Vane 12 17 Pin 2
6 Cam Ring 1 18 Seal 1
7 Port Plate Pressure 1 19 Needle Bearing 1
8 O-Ring 1 20 Socket Bolt 4 100 (10, 74)
9 Housing 1 21 Bolt 1
10 Ball Bearing 1 22 Valve 1
11 Key 1 23 Screw 1 12 (1.2, 8.9)
12 Shaft 1

W3-16-2-2
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

Removal and Installation of Muffler Filter

4 3 1 5 6 WJAA-03-06-001 7 8 WJAA-03-06-002

IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Remove bolts, washers (1) (4 used). Remove pipe (2).

j : 19 mm
3. Remove bolts, washers (3) (12 used). Remove cover
(4).

j : 19 mm
4. Remove bolts, washers (5) (13 used). Remove cover
(6).

j : 19 mm
5. Remove bolts, washers (7) (7 used). Remove bracket
(8).

j : 19 mm

W3-17-1-1
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

15 13 12

11

WJAA-03-06-011 WJAA-03-06-012
14

6. Disconnect connectors (11) (2 used).

IMPORTANT: Do not loosen screws (12) (4 used).
If screw (12) has been loosened, differential
pressure sensor (13) should be replaced.
7. Remove clips (14) (2 used). Disconnect hoses (15) (2
used).

W3-17-1-2
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

19
23, 24

16, 17, 18 22 20, 21 WJAA-03-06-005

WJAA-03-06-013

8. Remove bolts (16) (4 used), nuts (17) (4 used), and

washers (18) (4 used). dCAUTION:
lb)
Muffler filter (19) weight: 50 kg (115

j : 17 mm 10. Attach nylon slings onto the body of muffler filter

9. Disconnect exhaust pipe (23). Remove gasket (24). (19). Hoist and hold muffler filter (19).
11. Remove bolts (20) (4 used) and washers (21) (4
used).

j : 22 mm
IMPORTANT: Take care not to break pipe (22).
12. Remove muffler filter (19).

W3-17-1-3
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

19

23, 24

22 20, 21 16, 17, 18

WJAA-03-06-005 WJAA-03-06-013

Installation 4. Install gasket (24). Connect exhaust pipe (23) with

washers (18) (4 used), nuts (17) (4 used), and bolts
dCAUTION:
lb)
Muffler filter (19) weight: 50 kg (115 (16) (4 used).

1. Attach nylon slings onto the body of muffler filter j : 17 mm

(19). Hoist and hold muffler filter (19).
m : 85 N·m (8.5 kgf·m, 63 lbf·ft)
IMPORTANT: Take care not to break pipe (22).
2. Fit muffler filter (19) to pipe (22). Install muffler filter
(19).
3. Install washers (21) (4 used) and bolts (20) (4 used).

j : 22 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

W3-17-1-4
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

15 13 12

11

WJAA-03-06-011 WJAA-03-06-012
14

IMPORTANT: Replace clip (14) and hose (15) with the

new ones.
5. Connect hoses (15) (2 used) with clips (14) (2 used).
Face hoses (15) (2 used) toward differential pressure
sensor (13) without the sag at this time.
6. Connect connectors (11) (2 used).

W3-17-1-5
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

23 19 10

4 3 1 5 6 7 8 9
WJAA-03-06-001
WJAA-03-06-002

7. Install bracket (8) with bolts, washers (7) (7 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

8. Install cover (6) with bolts, washers (5) (13 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

9. Install cover (4) with bolts, washers (3) (12 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

10. Install pipe (2) with bolts, washers (1) (4 used). Fit
the center of pipe (2) to that of exhaust pipe (23) of
muffler filter (19) at this time.

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-17-1-6
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

Disassembly of Muffler Filter

3, 4 1 2 12, 13 6, 7

9 8 16 15 WJAA-03-06-009

20 21 22 10 26 30
29
23
19
24

25 27 28

31

18

19
11
10 32
36
26

34 39
35

38
WJAA-03-06-007

W3-17-2-1
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

1- Harness 10- Washer (12 Used) 22- Bracket 32- Nut (12 Used)
2- Harness 11- Washer (12 Used) 23- Bolt (2 Used) 34- Bolt (4 Used)
3- Bolt 12- Bolt 24- Bolt (2 Used) 35- Bolt (4 Used)
4- Clip 13- Clip 25- Gasket 36- Bolt (12 Used)
6- Bolt (4 Used) 15- Pipe 26- Bolt (12 Used) 38- Bracket
7- Clip (4 Used) 16- Pipe 27- Filter 39- Bracket
8- CSF Exhaust Temperature 18- Diesel Oxidation Catalyst 28- Gasket
Sensor 19- Nut (12 Used) 29- Bolt (2 Used)
9- DOC Exhaust Temperature 20- Bracket 30- Bracket
Sensor 21- Bracket 31- Muffler

W3-17-2-2
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

Disassembly of Muffler Filter 8. Disconnect pipes (15, 16) from the diesel oxidation
catalyst (18) assembly and the muffler (31)
IMPORTANT: Cap the open ends in case the hoses
assembly.
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors, j : 14 mm
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which 9. Remove bolts (26) (2 used), washers (10) (2 used),
secure the hoses have been removed. and nuts (19) (2 used). Remove bracket (20).
1. Put the matching marks on the diesel oxidation j : 12 mm
catalyst (18) assembly and DOC exhaust
temperature sensor (9). Put the matching marks on 10. Remove bolts (23) (2 used). Remove bracket (21).
the diesel oxidation catalyst (18) assembly and CSF j : 17 mm
exhaust temperature sensor (8).
11. Remove bolts (24) (2 used). Remove bracket (22).
2. Remove bolt (3) and clip (4) from bracket (20).
Remove harness (1). j : 12 mm
j : 10 mm
3. Remove bolt (12) and clip (13) from bracket (21).
Remove harnesses (1, 2).

j : 17 mm
4. Disconnect harness (1) from DOC exhaust
temperature sensor (9).
5. Disconnect harness (2) from CSF exhaust
temperature sensor (8).
6. Remove DOC exhaust temperature sensor (9) and
CSF exhaust temperature sensor (8) from the diesel
oxidation catalyst (18) assembly.

j : 14 mm
7. Remove bolts (6) (2 used) and clips (7) (4 used) from
brackets (22, 30).

j : 10 mm

W3-17-2-3
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

12. Remove bolts (35) (4 used). Remove bracket (38).

j : 14 mm
13. Remove other bolts (26) (10 used), washers (10) (10
used), and nuts (19) (10 used).

j : 12 mm
14. Remove the diesel oxidation catalyst (18) assembly
and gasket (25) from the filter (27) assembly.
15. Remove bolts (29) (2 used). Remove bracket (30).

j : 12 mm
16. Remove bolts (34) (4 used). Remove bracket (39).

j : 14 mm
17. Remove bolts (36) (12 used), washers (11) (12 used),
and nuts (32) (12 used).

j : 12 mm
18. Remove the filter (27) assembly and gasket (28)
from the muffler (31) assembly.

W3-17-2-4
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

Assembly of Muffler Filter

3, 4 1 2 12, 13 6, 7

9 8 16 15 WJAA-03-06-009

20 21 22 10 26 30
29
23
19
24

25 27 28

31

18

19
11
10 32
36
26

34 39
35

38
WJAA-03-06-007

W3-17-2-5
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

1- Harness 10- Washer (12 Used) 22- Bracket 32- Nut (12 Used)
2- Harness 11- Washer (12 Used) 23- Bolt (2 Used) 34- Bolt (4 Used)
3- Bolt 12- Bolt 24- Bolt (2 Used) 35- Bolt (4 Used)
4- Clip 13- Clip 25- Gasket 36- Bolt (12 Used)
6- Bolt (4 Used) 15- Pipe 26- Bolt (12 Used) 38- Bracket
7- Clip (4 Used) 16- Pipe 27- Filter 39- Bracket
8- CSF Exhaust Temperature 18- Diesel Oxidation Catalyst 28- Gasket
Sensor 19- Nut (12 Used) 29- Bolt (2 Used)
9- DOC Exhaust Temperature 20- Bracket 30- Bracket
Sensor 21- Bracket 31- Muffler

W3-17-2-6
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

Assembly of Muffler Filter 6. Place the filter (27) assembly on the flat and level
surface to keep mounting surface of brackets (38,
1. Temporarily tighten gasket (28), filter (27), and
39) horizontally.
bracket (39) to the muffler (31) assembly with bolts
(34) (4 used). 7. Tighten bolts (34) (4 used) and bolts (35) (4 used).

j : 14 mm j : 14 mm
2. Temporarily tighten gasket (25), the diesel oxidation m : 51 N·m (5.1 kgf·m, 38 lbf·ft)
catalyst (18) assembly and bracket (38) to the filter
(27) assembly with bolts (35) (4 used). 8. Tighten bolts (26, 36) (12 used for each) and nuts
(19, 32) (12 used for each).
j : 14 mm
j : 12 mm
3. Temporarily tighten bracket (20) to the diesel
oxidation catalyst (18) assembly with bolts (26) (2 m : 30 N·m (3 kgf·m, 22 lbf·ft)
used), washers (10) (2 used) and nuts (19) (2 used).
9. Install bracket (30) to the muffler (31) assembly with
j : 12 mm bolts (29) (2 used).

4. Temporarily tighten bolts (36) (12 used), washers j : 12 mm

(11) (12 used), and nuts (32) (12 used).
m : 30 N·m (3 kgf·m, 22 lbf·ft)
j : 12 mm
10. Install bracket (22) to the diesel oxidation catalyst
5. Temporarily tighten other bolts (26) (10 used), (18) assembly with bolts (24) (2 used).
washers (10) (10 used) and nuts (19) (10 used).
j : 12 mm
j : 12 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
11. Install bracket (21) to the diesel oxidation catalyst
(18) assembly with bolts (23) (2 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-17-2-7
 SECTION 3 UPPERSTRUCTURE
Group 17 Muffler Filter

12. Connect pipes (15, 16) to the diesel oxidation 16. Connect harness (2) to CSF exhaust temperature
catalyst (18) assembly and the muffler (31) sensor (8).
assembly.
17. Connect harness (1) to DOC exhaust temperature
j : 14 mm sensor (9).
18. Install harnesses (1, 2) to bracket (21) with bolt (12)
m : 30 N·m (3 kgf·m, 22 lbf·ft)
and clip (13).
13. Install pipes (15, 16) to brackets (22, 30) with bolts
(6) (4 used) and clips (7) (4 used). j : 17 mm

j : 10 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

19. Install harness (1) to bracket (20) with bolt (3) and
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
clip (4).
14. Apply anti-seize onto the thread part of sensors (8,
9). j : 10 mm

15. Fit the matching marks made when disassembling m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
and install DOC exhaust temperature sensor (9) and
CSF exhaust temperature sensor (8) to the diesel
oxidation catalyst (18) assembly.

j : 14 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-17-2-8
MEMO
MEMO
SECTION 4

UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
Removal and Installation of Swing Bearing..........W4-1-1-1
Disassembly of Swing Bearing...................................W4-1-2-1
Assembly of Swing Bearing.........................................W4-1-2-4
Group 2 Travel Device
Removal and Installation of Travel Device.............W4-2-1-1
Disassembly of Travel Device......................................W4-2-2-1
Assembly of Travel Device...........................................W4-2-2-8
Disassembly of Travel Motor.......................................W4-2-3-1
Assembly of Travel Motor............................................W4-2-3-5
Disassembly of Brake Valve.........................................W4-2-4-1
Assembly of Brake Valve...............................................W4-2-4-4
Group 3 Center Joint
Removal and Installation of Center Joint...............W4-3-1-1
Disassembly of Center Joint........................................W4-3-2-1
Assembly of Center Joint.............................................W4-3-2-3
Replacement of Body and Spindle...........................W4-3-2-6
Group 4 Track Adjuster
Removal and Installation of Track Adjuster...........W4-4-1-1
Disassembly of Track Adjuster....................................W4-4-2-1
Assembly of Track Adjuster.........................................W4-4-2-6
Group 5 Front Idler
Removal and Installation of Front Idler...................W4-5-1-1
Disassembly of Front Idler...........................................W4-5-2-1
Assembly of Front Idler.................................................W4-5-2-4
Group 6 Upper and Lower Rollers
Removal and Installation of Upper Roller..............W4-6-1-1
Removal and Installation of Lower Roller..............W4-6-2-1
Disassembly of Lower Roller.......................................W4-6-3-1
Assembly of Lower Roller.............................................W4-6-3-3
Group 7 Track
Removal and Installation of Track.............................W4-7-1-1

JAAW-4-1
(Blank)

JAAW-4-2
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Removal and Installation of Swing Bearing

1 4

a 1

W105-03-01-002

2 3

a- Matching Mark 3
W142-03-01-001

ST 0051

1
W110-03-01-004

Before removing and installing the swing bearing, the

upperstructure must be removed first. (Refer to W3-3-1.) dCAUTION:
(1440 lb)
Swing bearing (1) weight: 650 kg
Therefore, the procedure starts on the premise that the
upperstructure has already been removed here. 3. Install special tools (ST 0051) (3 used) to swing
bearing (1). Attach wire ropes onto special tools
Removal (ST 0051) (3 used). Hoist swing bearing (1). Remove
swing bearing (1).
1. Put matching mark (a) on inner race (2) of swing
bearing (1) and track frame (3). fNOTE: THREEBOND #1102 has been applied between
2. Remove bolts (4) (40 used). swing bearing (1) and track frame (3).

j : 41 mm

W4-1-1-1
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

a 1 ST 0051

1 W110-03-01-004

e b
2 3

a- Matching Mark
W142-03-01-001
c

WJAA-04-01-003
b- Position for Grease Fitting
c- Soft Zone Marking Position
d- Position for Plug
e- Front Side

Installation IMPORTANT: If matching marks (a) do not fit, the soft

zone position of inner race will be dislocated.
1. Clean the mounting surfaces of track frame (3) and
swing bearing (1). 4. Fit matching marks (a) on track frame (3) and inner
race (2) of swing bearing (1).
2. Apply THREEBOND #1102 onto the swing bearing
(1) mounting surface of track frame (3).

dCAUTION:
(1440 lb)
Swing bearing (1) weight: 650 kg

3. Install special tools (ST 0051) (3 used) to swing

bearing (1). Attach wire ropes onto special tools (ST
0051) (3 used). Hoist swing bearing (1).

W4-1-1-2
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

1 4
1 f 7

5mm

W105-03-01-002 6

W175-03-01-002

f- Grease Level

5. Install swing bearing (1) with bolts (4) (40 used).

j : 41 mm

m : 1400 N·m (140 kgf·m, 1030 lbf·ft)

6. After installing swing bearing (1), add grease
(Alvania EP2 or equivalent) to grease bath (6) until
pinion (7) of the swing device is 5 mm (0.2 in) under
grease.

fNOTE: Grease amount: 17 L (4.5 US gal)

W4-1-1-3
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

(Blank)

W4-1-1-4
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Disassembly of Swing Bearing

1 2 3

7 6
5
8

W1J1-03-01-001

9
1

WJAA-04-01-001

1- Outer Race 5- Seal 9- Grease Fitting

2- Seal 6- Ball (86 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (86 Used)

W4-1-2-1
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Disassembly of Swing Bearing 3. Install bolt (10) to the screw hole (M10, Pitch 1.5
mm) of plug (4). Tap from within or pull bolt (10)
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
and remove plug (4) from outer race (1).

such as goggles, helmets, etc in order to prevent

personal injury.
1. Grind off the crimped part of pin (3) by using a
grinder. Tap the bottom side of pin (3) of plug (4) by 1
using a bar and a hammer. Remove pin (3) of plug
(4).
3
4

W178-02-11-196
10

W178-02-11-195
dCAUTION:
lb)
Swing Bearing weight: 650 kg (1440

4. Place inner race (7) of swing bearing on a wooden

2. Thread hole (a) of plug (4) by using a tap (M10, Pitch
block by using the special tool (ST 0051). Hoist outer
1.5 mm).
race (1) horizontally. Hold outer race (1).

a- Hole

W4-1-2-2
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

5. Remove balls (6) (86 used) and supports (8) (86

used) from the plug (4) hole while rotating outer
race (1).

1
2

11 7

6 5
W178-02-11-197

12

8
W178-02-11-198

fNOTE: Remove ball (6) by using magnet (11). Use wire

(12) and remove support (8).
6. Remove seals (2, 5) from outer race (1) and inner
race (7) by using a scrapper.

W4-1-2-3
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Assembly of Swing Bearing

1 2 3

8 7 6 5

W178-02-11-193

9
1

WJAA-04-01-001

1- Outer Race 5- Seal 9- Grease Fitting

2- Seal 6- Ball (86 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (86 Used)

W4-1-2-4
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

Assembly of Swing Bearing

dCAUTION:
lb)
Swing Bearing weight: 650 kg (1440 dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
1. Install special tools (ST 0051) (3 used) to outer race such as goggles, helmets, etc in order to prevent
(1). Attach a wire rope onto special tools (ST 0051) personal injury.
(3 used). Hoist the swing bearing horizontally. Align 2. Install plug (4) to outer race (1) by using a hammer.
outer race (1) and inner race (7) coaxially. Apply Secure plug (4) to outer race (1) with pin (3). Crimp
grease onto balls (6) (86 used) and supports (8) (86 the pin (3) hole of outer race (1) by using a punch (2
used). Install balls (6) (86 used) and supports (8) (86 places).
used) alternately from the plug (4) hole by using a
round bar while turning outer race (1).

1
2

6
W178-02-11-201

5
W178-02-11-199

W178-02-11-200

W4-1-2-5
 SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing

3. Degrease the groove part for seals (2, 5) completely.

Apply THREEBOND #1530D onto seals (2,5).Install
seals (2, 5) to outer race (1) and inner race (7).
4. Add grease (Alvania EP2 or equivalent) to the swing
bearing through grease fitting (9). At this time, add
grease while turning outer race (1).

fNOTE: Grease amount: 1.2 L (0.3 US gal)

W4-1-2-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Removal and Installation of Travel Device

WJAA-04-02-013

Removal
IMPORTANT: Cap the open ends in case the hoses
d CAUTION: Cover (4) weight: 32 kg (71 lb)
4. Install eyebolts (M16, Pitch 2 mm) to the bolt (2)
and pipes have been disconnected. In addition,
hole. Attach nylon slings onto the eyebolts. Hoist
attach an identification tag onto the connectors,
and hold cover (4).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which 5. Remove bolts (11) (5 used) and spring washers (12)
secure the hoses have been removed. (5 used). Remove cover (4).

j : 24 mm
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Disconnect track (1). (Refer to W4-6-1.)
3. Remove bolt (2) and washers (3) (2 used).

j : 24 mm

W4-2-1-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

WJAA-04-02-014

6. Place a container under travel device (5). Remove

socket bolts (13) (8 used) and flanges (14) (4 used). dlb)
CAUTION: Travel device (5) weight: 680 kg (1500
Disconnect hoses (6) (2 used).
9. Attach nylon slings onto travel device (5). Hoist and
l : 10 mm hold travel device (5). Remove bolts (9) (20 used)
7. Disconnect hose (7). and washers (10) (20 used). Hoist and remove travel
device (5).
j : 27 mm
j : 32 mm
8. Disconnect hose (8).
10. Remove the adapter with travel device (5) attached
j : 19 mm if necessary.
11. Remove another travel device in the same way as
step 1 to step 10.

W4-2-1-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

WJAA-04-02-014

Installation 4. Connect hose (7).

1. Install all removed adapters to travel device (5). j : 27 mm

dlb)
CAUTION: Travel device (5) weight: 680 kg (1500 m : 80 N·m (8 kgf·m, 59 lbf·ft)
5. Connect hoses (6) (2 used) with flanges (14) (4 used)
2. Attach nylon slings onto travel device (5). Hoist
and socket bolts (13) (8 used).
travel device (5). Install travel device (5) with
washers (10) (20 used) and bolts (9) (20 used). l : 10 mm
j : 32 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 750 N·m (75 kgf·m, 550 lbf·ft)
3. Connect hose (8).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W4-2-1-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

WJAA-04-02-013

6. Connect track (1). (Refer to W4-6-1.)

7. Install another travel device in the same way as step
d CAUTION: Cover (4) weight: 32 kg (71 lb)
9. Install eyebolts (M16, Pitch 2 mm) to the bolt (2)
1 to step 6.
hole. Attach nylon slings onto the eyebolts. Hoist
8. Bleed air from the hydraulic system. (Refer to W1- cover (4).
4-1.)
10. Install cover (4) with spring washers (12) (5 used)
IMPORTANT: Check the hydraulic oil level. Start the and bolts (11) (5 used).
engine and check for any oil leaks. In order to
prevent the travel motor from seizing, perform j : 24 mm
the break-in operation after installing.
m : 210 N·m (21 kgf·m, 155 lbf·ft)
11. Install washers (3) (2 used) and bolt (2).
Condition: 1. Engine speed: Slow idle speed
2. Travel mode switch: Slow speed j : 24 mm
3. Operation duration: Over 2 minutes m : 210 N·m (21 kgf·m, 155 lbf·ft)
12. Install another cover (4) in the same way as step 9 to
step 11.

W4-2-1-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Device

10

9
8

7
6
5

4
3
2 24 25 26
23
22
21
1 20
19 27
18

17
28
16
15 29

30
14
31
32
11 12 13 33
34
35
36 51
37

39 38
40
42 41

50

49
48
47
46
45
43 44 W1J1-03-02-006

1- Travel Motor 15- Washer (24 Used) 28- Spacer 40- Needle Bearing (4 Used)
2- Bolt (4 Used) 16- Bolt (24 Used) 29- First Stage Carrier 41- Needle Bearing (4 Used)
3- Spring Washer (4 Used) 17- Third Stage Carrier 30- Thrust Plate (3 Used) 42- Thrust Plate (4 Used)
4- O-Ring 18- Third Stage Sun Gear 31- Spring Pin (3 Used) 43- Shaft
5- Housing 19- Second Stage Carrier 32- Second Stage Planetary Gear 44- Ring Gear
6- Floating Seal 20- Spacer (3 Used) 45- Bolt (30 Used)
7- Roller Bearing 21- Second Stage Sun Gear 33- Pin (3 Used) 46- Retaining Ring
8- Drum 22- Thrust Plate (3 Used) 34- Needle Bearing (3 Used) 47- Stopper Pin
9- Roller Bearing 23- Needle Bearing (3 Used) 35- Thrust Plate (3 Used) 48- Ball Bearing
10- O-Ring 24- Pin (3 Used) 36- Thrust Plate (4 Used) 49- Cover
11- Bearing Nut 25- First Stage Planetary Gear (3 37- Third Stage Planetary Gear (4 50- Bolt (16 Used)
12- Lock Plate Used) Used) 51- Plug (3 Used)
13- Bolt (2 Used) 26- Thrust Plate (3 Used) 38- Spring Pin (4 Used)
14- Sprocket 27- Spring Pin (3 Used) 39- Pin (4 Used)

W4-2-2-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Device

dCAUTION: There may be pressure accumulated dCAUTION:

lb)
Travel motor (1) weight: 134 kg (300
inside of the travel device. Loosen the air bleed
plug slowly. Release any remaining pressure 2. Put the matching marks on travel motor (1) and
completely. Remove the drain plug and drain gear housing (5). Install an eyebolt (M12, Pitch 1.75 mm)
oil. If the air bleed plug is loosened suddenly, the to lifting hole (c) ( 2 places) of travel motor (1).
plug may be fly out and gear oil may gush out. Attach a nylon sling onto the eyebolt. Hoist and
Keep body and face away from plug. hold travel motor (1). Remove bolts (2) (4 used) and
spring washers (3) (4 used) from travel motor (1).
dCAUTION: Travel Device weight: 671 kg (1480 lb) Remove travel motor (1) from housing (5). Remove
1. Attach a nylon sling onto the body of travel device. O-ring (4) from travel motor (1).
Hoist and hold the travel device. Place a container
under the travel device. Loosen plug (51a) by 2 to l : 27 mm
3 turns. Remove plug (51b). Drain gear oil from
the travel device. Place the travel device on a
workbench with the travel motor (1) side up. 2, 3

fNOTE: Amount of oil: 11.0 L (2.9 US gal) 5

j : 14 mm

51a
c

c- Lifting Hole
W16J-03-02-002

51b
WJAA-04-02-004

W4-2-2-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

7. Remove shaft (43) from first stage carrier (29).

d CAUTION: Travel reduction gear weight: 540 kg
(1200 lb)
Remove the first stage carrier (29) assembly and
second stage sun gear (21) from second stage
3. Attach a nylon sling onto the body of drum and carrier (19).
ring gear (44). Hoist the travel reduction gear. Place
the travel reduction gear on a workbench with the dCAUTION: The second stage carrier (19)
assembly weight: 25 kg (60 lb)
cover (49) side up.
8. Attach two nylon slings onto second stage carrier
dCAUTION: Cover (49) weight: 22 kg (49 lb) (19). Hoist second stage carrier (19). Remove the
4. Put the matching marks on cover (49) and ring gear second stage carrier (19) assembly and third stage
(44). Install an eyebolt (R3/4) to the plug (51) hole (2 sun gear (18) from third stage carrier (17).
places) of cover (49). Attach a nylon sling onto the
eyebolt. Hoist and hold cover (49). Remove bolts
(50) (16 used) from cover (49). Remove cover (49)
from ring gear (44).

j : 22 mm

fNOTE: THREEBOND #1389B has been applied between

ring gear (44) and cover (49). If it is difficult to remove,
pry it out by using a screwdriver.

dCAUTION: Ring gear (44) weight: 70 kg (155 lb)

5. Put the matching marks on ring gear (44) and drum
(8). Install an eyebolt (M14, Pitch 2.0 mm) to the bolt
(50) hole (2 places) of ring gear (44). Attach a nylon
sling onto the eyebolt. Hoist and hold ring gear (44).
6. Remove bolts (45) (30 used) from ring gear (44).
Remove ring gear (44) from drum (8). Remove
O-ring (10) from drum (8).

j : 27 mm

W4-2-2-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

dCAUTION: The third stage carrier (17) assembly

weight: 70 kg (155 lb)
9. Attach two nylon slings onto third stage carrier (17).
Hoist third stage carrier (17). Remove the third stage
carrier (17) assembly from drum (8).
10. Remove bolts (13) (2 used) from lock plate (12).
Remove lock plate (12) from bearing nut (11).

j : 19 mm
11. Install the special tool (ST 3136) to bearing nut (11).
Remove bearing nut (11) from housing (5).

ST 3136

W1JB-03-02-003

W4-2-2-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

16. Put the matching marks on sprocket (14) and drum

d CAUTION: Drum (8) + sprocket (14) + others
weight: 180 kg (400 lb)
(8).

IMPORTANT: The housing (5) side of drum (8) is the dCAUTION: Sprocket (14) weight: 85 kg (190 lb)
seal sliding surface for housing (5). Place it on a
wooden block after removing.
dCAUTION: When removing sprocket (14),
gather up the nylon sling and hoist sprocket (14)
12. Put the matching marks on drum (8) and housing horizontally. Do not drop sprocket (14).
(5). Install an eyebolt (M18, Pitch 2.5 mm) to the bolt 17. Remove bolts (16) (24 used) and washers (15) (24
(45) hole (2 places) of drum (8). Attach a nylon sling used) from sprocket (14). Attach a nylon sling onto
onto the eyebolt. Hoist and hold drum (8). sprocket (14). Hoist sprocket (14). Remove sprocket
13. Remove the drum (8) assembly from housing (5). (14) from drum (8).
Remove the inner race of roller bearing (9) from
j : 32 mm
drum (8).
IMPORTANT: Handle floating seal (6) with care. fNOTE: LOCTITE #262 has been applied on bolt (16).
(Refer to W4-2-5.)
14. Remove one side of floating seal (6) from housing
(5).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Do not remove the inner race of roller
bearing (7) unless necessary. When it has been
removed, replace it with the new one.
15. Remove the inner race of roller bearing (7) from
housing (5) by using a bar and a hammer.

W4-2-2-5
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent such as goggles, helmets, etc in order to prevent
personal injury. personal injury.
IMPORTANT: Do not remove the outer race of roller IMPORTANT: Do not remove the outer race of roller
bearing (7) unless necessary. When it has been bearing (9) unless necessary. When it has been
removed, replace it with the new one. removed, replace it with the new one.
18. Remove the outer race of roller bearing (7) from 21. Remove the outer race of roller bearing (9) from
drum (8) by using a bar and a hammer. drum (8) by using a bar and a hammer.

dCAUTION:
lb)
Drum (8) + others weight: 100 kg (225 22. Remove spring pin (38) from third stage carrier
(17) by using a round bar (diameter: 8 mm, 0.3 in).
Remove pin (39), third stage planetary gear (37),
19. Install an eyebolt (M22, Pitch 2.5 mm) to the bolt
and thrust plates (36, 42) from third stage carrier
(16) hole (2 places) of drum (8) through the motor
(17). Remove needle bearings (40, 41) from third
(1) side. Attach a nylon sling onto the eyebolt. Hoist
stage planetary gear (37).
and turn over drum (8).
IMPORTANT: Handle floating seal (6) with care.
(Refer to W4-2-5.)
20. Remove one side of floating seal (6) from drum (8).

W4-2-2-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

23. Remove spring pins (38) (3 used), pins (39) (3

used), third stage planetary gears (37) (3 used),
thrust plates (36, 42) (3 used for each), and needle
bearings (40, 41) (3 used for each) from third stage
carrier (17) in the same way as step 22.
24. Disassemble the first stage carrier (29) assembly and
the second stage carrier (19) assembly in the same
way as step 22 and step 23.
Spring pin (27)
Diameter of round bar: 4 mm (0.16 in)
Spring pin (31)
Diameter of round bar: 5 mm (0.20 in)
25. Remove spacer (28) from first stage carrier (29).
Remove spacer (20) from second stage carrier (19).

W4-2-2-7
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Device

14 15 16

1 2 3 4 5 6 8 7 9 11 10 45 44 17 18 20 19 21 28 29

51

49

46

48

47

43

25
26
27
24
23
22
50

36 38 35 32 34 33 30 31

12 13 42 37 41 40 39

T16J-03-05-001

1- Travel Motor 15- Washer (24 Used) 28- Spacer 40- Needle Bearing (4 Used)
2- Bolt (4 Used) 16- Bolt (24 Used) 29- First Stage Carrier 41- Needle Bearing (4 Used)
3- Spring Washer (4 Used) 17- Third Stage Carrier 30- Thrust Plate (3 Used) 42- Thrust Plate (4 Used)
4- O-Ring 18- Third Stage Sun Gear 31- Spring Pin (3 Used) 43- Shaft
5- Housing 19- Second Stage Carrier 32- Second Stage Planetary Gear 44- Ring Gear
6- Floating Seal 20- Spacer (3 Used) 45- Bolt (30 Used)
7- Roller Bearing 21- Second Stage Sun Gear 33- Pin (3 Used) 46- Retaining Ring
8- Drum 22- Thrust Plate (3 Used) 34- Needle Bearing (3 Used) 47- Stopper Pin
9- Roller Bearing 23- Needle Bearing (3 Used) 35- Thrust Plate (3 Used) 48- Ball Bearing
10- O-Ring 24- Pin (3 Used) 36- Thrust Plate (4 Used) 49- Cover
11- Bearing Nut 25- First Stage Planetary Gear (3 37- Third Stage Planetary Gear (4 50- Bolt (16 Used)
12- Lock Plate Used) Used) 51- Plug (3 Used)
13- Bolt (2 Used) 26- Thrust Plate (3 Used) 38- Spring Pin (4 Used)
14- Sprocket 27- Spring Pin (3 Used) 39- Pin (4 Used)

W4-2-2-8
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Device

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
dCAUTION: Drum (8) weight: 100 kg (225 lb)
dCAUTION: Housing (5) weight: 90 kg (200 lb)
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
1. Attach a nylon sling onto the body of housing (5). such as goggles, helmets, etc in order to prevent
Hoist housing (5). Place housing (5) with the motor personal injury.
(1) side down. IMPORTANT: Do not tap except for the outer race of
IMPORTANT: Handle floating seal (6) with care. roller bearing (7).
(Refer to W4-2-5.) 4. Install an eyebolt (M22, Pitch 2.5 mm) to the bolt
2. Apply grease onto O-ring of one side of floating seal (16) hole (2 places) of drum (8) through the motor
(6). Install one side of floating seal (6) to housing (1) side. Attach a nylon sling onto the eyebolt. Hoist
(5). Apply gear oil onto the whole sliding surface on drum (8). Place drum (8) with the ring gear (44)
floating seal (6). side down. Evenly tap and install the outer race of
roller bearing (7) to drum (8) by using a bar and a
fNOTE: If it is difficult to install O-ring of floating seal hammer.
(6), push O-ring to the periphery direction by using a
bamboo spatula. fNOTE: Check that the outer race of roller bearing (7) is
installed completely.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.

dCAUTION:
hot.
Be careful as roller bearing (7) is too

3. Warm up the inner race of roller bearing (7) to 50

to 70 °C (122 to 158 °F) by using a heater. Install
the inner race of roller bearing (7) to housing (5) by
using a bar and a hammer.

fNOTE: Check that the inner race of roller bearing (7) is

installed completely.

W4-2-2-9
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: Handle floating seal (6) with care.

(Refer to W4-2-5.) dCAUTION: Sprocket (14) weight: 85 kg (190 lb)
5. Apply grease onto O-ring of other side of floating
seal (6). Install one side of floating seal (6) to drum
dCAUTION: When installing sprocket (14),
gather up the nylon sling and hoist sprocket (14)
(8). horizontally. Do not drop cover (14).
IMPORTANT: Fit the chamfered side of sprocket (14)
fNOTE: If it is difficult to install O-ring of floating seal
to the drum (8) side.
(6), push O-ring to the periphery direction by using a
bamboo spatula. 8. Attach two nylon slings onto sprocket (14). Hoist
sprocket (14). Place sprocket (14) onto drum (8).
6. Install an eyebolt (M18, Pitch 2.5 mm) to the bolt
(45) hole (2 places) of drum (8) through the ring 9. Degrease the bolt (16) holes on drum (8) and bolts
gear (44) side. Attach a nylon sling onto the eyebolt. (16) (24 used). Apply LOCTITE #262 onto bolts (16)
Hoist drum (8). Place drum (8) with the ring gear (24 used). Install sprocket (14) to drum (8) with bolts
(44) side up. (16) (24 used) and spring washers (15) (24 used).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
j : 32 mm

such as goggles, helmets, etc in order to prevent m : 750 N·m (75 kgf·m, 550 lbf·ft)
personal injury.
IMPORTANT: Do not tap except for the outer race of
roller bearing (9).
7. Evenly tap and install the outer race of roller bearing
(9) to drum (8) by using a bar and a hammer.

fNOTE: Check that the outer race of roller bearing (9) is

installed completely.

W4-2-2-10
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

dCAUTION: Drum (8) + sprocket (14) + others

weight: 180 kg (400 lb)
10. Hoist the drum (8) assembly. Fit the matching marks
made when disassembling and place the drum (8)
assembly straight on housing (5). At this time, check
that the clearance between housing (5) and drum
(8) is even all around.
11. While applying the weight and shaking drum (8),
push drum (8) into housing (5) straight.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.

dCAUTION:
hot.
Be careful as roller bearing (9) is too

12. Warm up the inner race of roller bearing (9) to 50

to 70 °C (122 to 158 °F) by using a heater. Install
the inner race of roller bearing (9) to housing (5) by
using a bar and a hammer.

fNOTE: Check that the inner race of roller bearing (9) is

installed completely.
IMPORTANT: Check the direction to install bearing
nut (11).
13. Apply grease onto the thread part of bearing nut
(11). Install bearing nut (11) to housing (5) with the
machine surface facing to the roller bearing (9) side.
Tighten bearing nut (11) by hand.

W4-2-2-11
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

14. Install bearing nut (11) by using the special tool (ST IMPORTANT: There is an identification groove on one
3136) and a torque wrench. side of third stage planetary gear (37). Install third
stage planetary gear (37) with the identification
m : 500 N·m (50 kgf·m, 370 lbf·ft) groove side facing to the cover (49) side.
ST 3136 19. Install needle bearings (40, 41) to third stage
planetary gear (37).
20. Secure third stage planetary gear (37) between
thrust plates (36, 42). Install them to third stage
carrier (17).
21. Install pin (39) to third stage carrier (17). At this time,
fit the spring pin (38) holes of third stage carrier (17)
and pin (39).
22. Install spring pin (38) to third stage carrier (17) with
W1JB-03-02-003 the slit (a) side facing to the second stage carrier
(19) side.
15. After installing bearing nut (11), tap the sprocket 38
(14) end by using a hammer and reduce play. Rotate 39
a
sprocket (14) both clockwise and counterclockwise
by 4 to 5 turns.
16. Repeat step 14 and step 15.
a- Slit W178-02-11-210
17. Tighten bearing nut (11) in the same way as step 14
again. 23. Install other third stage planetary gears (37) (3 used)
to third stage carrier (17) in the same way as step 19
m : 500 N·m (50 kgf·m, 370 lbf·ft) to step 22.
IMPORTANT: In case the spline of lock plate (12) and
that of housing (5) do not fit, tighten bearing nut
(11) in tightening direction until both splines fit.
18. Degrease the bolt (13) holes on bearing nut (11) and
bolts (13) (2 used). Apply LOCTITE #262 onto bolts
(13) (2 used). Install lock plate (12) to bearing nut
(11) with bolts (13) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W4-2-2-12
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

36. Secure first stage planetary gear (25) between

d CAUTION: The third stage carrier (17) assembly
weight: 70 kg (155 lb)
thrust plates (22, 26). Install them to first stage
carrier (29).
24. Attach two nylon slings onto the third stage
37. Install pin (24) to first stage carrier (29). At this time,
carrier (17) assembly. Hoist the third stage carrier
fit the spring pin (27) holes of first stage carrier (29)
(17) assembly. Install the third stage carrier (17)
and pin (24).
assembly to housing (5).
38. Install spring pin (27) to first stage carrier (29) with
25. Install third stage sun gear (18) to third stage carrier
the slit (b) side facing to the cover (49) side.
(17) with the small outer diameter side up.
24 27
26. Install spacer (20) to second stage carrier (19). b

27. Install needle bearing (34) to second stage

planetary gear (32).
28. Secure second stage planetary gear (32) between b- Slit W178-02-11-210
thrust plates (30, 35). Install them to second stage
39. Install other first stage planetary gears (25) (2 used)
carrier (19).
to first stage carrier (29) in the same way as step 35
29. Install pin (33) to second stage carrier (19). At this to step 38.
time, fit the spring pin (31) holes of second stage
40. Install the first stage carrier (29) assembly to second
carrier (19) and pin (33).
stage carrier (19).
30. Install spring pin (31) to second stage carrier (19)
with the slit (a) side facing to the cover (49) side.
33 31
a

a- Slit W178-02-11-210

31. Install other second stage planetary gears (32) (2

used) to second stage carrier (19) in the same way
as step 27 to step 30.

dCAUTION: The second stage carrier (19)

assembly weight: 25 kg (56 lb)
32. Attach two nylon slings onto the second stage
carrier (19) assembly. Hoist the second stage carrier
(19) assembly. Install the second stage carrier (19)
assembly to third stage sun gear (18).
33. Install second stage sun gear (21) to second stage
carrier (19) with the small outer diameter side up.
34. Install spacer (28) to first stage carrier (29).
35. Install needle bearing (23) to first stage planetary
gear (25).

W4-2-2-13
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

41. Insert the spline side of shaft (43) into the center 50. Degrease the bolt (50) holes on ring gear (44) and
of second stage sun gear (21). Rotate sprocket (14) bolts (50) (16 used). Apply LOCTITE #262 onto bolts
slowly by hand. Engage travel motor (1) and first (50) (16 used). Install cover (49) to ring gear (44)
stage planetary gears (25) (3 used) with shaft (43), with bolts (50) (16 used).
and install them.
j : 22 mm
42. Install O-ring (10) to drum (8).
m : 180 N·m (18 kgf·m, 133 lbf·ft)
dCAUTION: Ring gear (44) weight: 70 kg (155 lb)
51. Install a seal tape onto plugs (51) (3 used). Install
43. Install an eyebolt (M14, Pitch 2.0 mm) to the bolt
plugs (51) (3 used) to cover (49).
(50) hole of ring gear (44). Attach a nylon sling onto
the eyebolt. Hoist ring gear (44). Fit the matching l : 14 mm
marks made when disassembling and place ring
gear (44) onto drum (8). m : 70 N·m (7 kgf·m, 52 lbf·ft)
44. Degrease the bolt (45) holes on drum (8) and bolts
(45) (30 used). Apply LOCTITE #262 onto bolts (45)
(30 used). Install ring gear (44) to drum (8) with
socket bolts (45) (30 used).

j : 27 mm

m : 400 N·m (41 kgf·m, 300 lbf·ft)

45. Attach a tube bar onto ball bearing (48). Tap a tube
bar by using a hammer and install ball bearing (48)
to cover (49).

fNOTE: Ball bearing (48) inner diameter: 45mm (1.8 in),

outer diameter: 68 mm (2.7 in)

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
46. Attach a tube bar onto stopper pin (47). Tap a tube
bar by using a hammer and install stopper pin (47)
to ball bearing (48).

fNOTE: Stopper pin (47) inner diameter: 26 mm (1.0 in),

outer diameter: 52 mm (2.0 in)
IMPORTANT: Install retaining ring (46) with the
chamfered surface facing to the cover (49) side.
47. Install retaining ring (46) to cover (49).

dCAUTION: Cover (49) weight: 22 kg (49 lb)

48. Clean the mating surfaces of ring gear (44) and
cover (49). Apply THREEBOND #1389B.
49. Install an eyebolt (PT3/4) to the plug (51) hole (2
places) of cover (49). Attach a nylon sling onto the
eyebolt. Hoist cover (49). Place cover (49) onto ring
gear (44).

W4-2-2-14
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

dCAUTION:
(1200 lb)
Travel reduction gear weight: 540 kg

52. Install an eyebolt (M18, Pitch 2.5 mm) to the bolt

hole (2 places) of the flange part in housing (5).
Attach a nylon sling onto the eyebolt. Hoist and
turn over the travel reduction gear.
53. Fill gear oil to the travel reduction gear.

fNOTE: Amount of oil: 11.0 L (2.9 US gal)

54. Install O-ring (4) to motor (1).

dCAUTION: Motor (1) weight: 134 kg (300 lb)

55. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
lifting hole (c) of motor (1). Attach a nylon sling onto
the eyebolts. Hoist motor (1). Fit the splines of shaft
(43) and motor (1). Install motor (1) to housing (5)
and driven shaft (45).

2, 3 5

c- Lifting Hole
W16J-03-02-002

56. Install motor (1) to housing (5) with bolts (2) (4

used) and spring washers (3) (4 used).

j : 27 mm

m : 300 N·m (31 kgf·m, 220 lbf·ft)

W4-2-2-15
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

(Blank)

W4-2-2-16
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Motor

1 2 3 4

7
6
5
2

17
16
15
14

13
12
11

10 25
9
24
8
23
22
21
20

18

30
29
28
27
19
26

W1J1-03-02-002

1- Housing 9- Swash Plate 17- Roller Bearing 25- O-Ring

2- O-Ring (4 Used) 10- Plunger (9 Used) 18- Plate (5 Used) 26- Spring (10 Used)
3- Spring (2 Used) 11- Retainer 19- Friction Plate (4 Used) 27- Pin
4- Piston (2 Used) 12- Bushing 20- Backup Ring 28- Pin (4 Used)
5- Oil Seal 13- Spring (9 Used) 21- O-Ring 29- Brake Valve
6- Roller Bearing 14- Rotor 22- O-Ring 30- Socket Bolt (9 Used)
7- Shaft 15- Valve Plate 23- Backup Ring
8- Steel Ball (2 Used) 16- Collar 24- Brake Piston

W4-2-3-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Travel Motor IMPORTANT: Do not remove roller bearing (17)

unless necessary. Remove roller bearing (17) by
dCAUTION:
lb)
The travel motor weight: 134 kg (300 using a small puller if necessary. As the outer race
is deformed, roller bearing (17) cannot be reused.
1. Attach a nylon sling onto the travel motor. Hoist the IMPORTANT: Do not damage valve plate (15).
travel motor. Place the travel motor with the brake
3. Remove valve plate (15), pin (27), and pins (28) (4
valve (29) side up.
used) from brake valve (29).
dCAUTION: Brake valve (29) weight: 39 kg (86 lb) 4. Wrap the tape on the thrust surface of shaft (7) for
IMPORTANT: Evenly loosen socket bolts (30) (9 used). roller bearing (17) in order to protect.
When loosening socket bolt (30), valve housing
5. Remove springs (26) (10 used) from housing (1).
(29) is floated from case (1) by the reaction force of
springs (13, 26). At this time, record the clearance 6. Remove O-ring (25) and O-rings (2) (4 used) from
between case (1) and valve housing (29). housing (1).
IMPORTANT: When removing the brake valve (29)
assembly, do not drop valve plate (15). dCAUTION: When removing brake piston (24),
cover with a cloth in order not to fly out brake
2. Remove socket bolts (30) (9 used). Install an eyebolt piston (24).
(M12, Pitch 1.75 mm) to the lifting hole (a) of brake
7. Apply air 100 to 300 kPa (1.0 to 3.0 kgf/cm2, 15 to 44
valve (29). Attach a nylon sling onto the eyebolt.
psi) to the brake releasing oil passage in housing (1).
Hoist brake valve (29). Remove brake valve (29) from
Float and remove brake piston (24).
housing (1).

l : 14 mm

1 29 30

W16J-03-02-002
a- Lifting Hole

W4-2-3-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

8. Remove O-rings (21, 22), and backup rings (20, 23)

from brake piston (24). dCAUTION: When removing swash plate (9), cover
with a cloth in order not to fly out piston (4).
9. Remove plates (18) (5 used) and friction plates (19)
IMPORTANT: When swash plate (9) cannot be
(4 used) from housing (1).
removed, apply air 100 to 300 kPa (1.0 to 3.0 kgf/
10. Remove rotor (14), springs (13) (9 used), bushing cm2, 15 to 44 psi) through the piston oil passage
(12), retainer (11), and plungers (10) (9 used) from hole. Swash plate (9) and piston (4) are removed.
housing (1). 12. Remove swash plate (9) from housing (1).

dCAUTION:
kg (145 lb)
The housing (1) assembly weight: 65 13. Remove balls (8) (2 used), pistons (4) (2 used), and
springs (3) (2 used) from housing (1) by using a
11. Attach a nylon sling onto housing (1). Hoist magnet.
the housing (1) assembly. Place the housing (1) 14. Attach a bar onto the bottom the spline hole of
assembly horizontally with the brake releasing oil shaft (1). Tap and remove shaft (1) and roller bearing
passage (a) down. (6) from housing (1) by using a bar and a plastic
hammer.
fNOTE: When facing the brake releasing oil passage (a)
upward, the thicker part of swash plate (9) faces upward.
When placing the housing (1) assembly horizontally,
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
swash plate (9) suddenly may come out. such as goggles, helmets, etc in order to prevent
personal injury.
15. Remove the outer race of roller bearing (6) from
housing (1) by using a bar and a hammer.
1

a WJAA-04-02-008
a- Brake Releasing Oil Passage

W4-2-3-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: Oil seal (5) cannot be reused.

16. Remove oil seal (5) from housing (1) by using a
screwdriver.

fNOTE: THREEBOND #1104 or #1215 has been applied

onto the outer surface of the oil seal.
IMPORTANT: When removing shaft (7) from roller
bearing (6), do not drop shaft (7).
17. Secure the inner race of roller bearing (6) remained
on shaft (7) in a vise. Remove shaft (7) from roller
bearing (6) by using a bar and a plastic hammer.

WJAA-04-02-007

W4-2-3-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Motor

27 30 26 22,23 24 20,21 7 4 3

16

29 8

17

15

28

25
2

14 10 18 19 11 12 9 6 5
W1J1-03-02-003

1- Housing 9- Swash Plate 17- Roller Bearing 25- O-Ring

2- O-Ring (4 Used) 10- Plunger (9 Used) 18- Plate (5 Used) 26- Spring (10 Used)
3- Spring (2 Used) 11- Retainer 19- Friction Plate (4 Used) 27- Pin
4- Piston (2 Used) 12- Bushing 20- Backup Ring 28- Pin (4 Used)
5- Oil Seal 13- Spring (9 Used) 21- O-Ring 29- Brake Valve
6- Roller Bearing 14- Rotor 22- O-Ring 30- Socket Bolt (9 Used)
7- Shaft 15- Valve Plate 23- Backup Ring
8- Steel Ball (2 Used) 16- Collar 24- Brake Piston

W4-2-3-5
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Travel Motor

IMPORTANT: Before assembling, apply hydraulic oil dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
onto parts in order to prevent them from seizing.
such as goggles, helmets, etc in order to prevent
dCAUTION: Housing (1) weight: 60 kg (135 lb) personal injury.
1. Attach a nylon sling onto housing (1). Hoist housing 6. Install the inner race to shaft (7) with the flange part
(1). Place housing (1) with the brake valve (29) side facing to the stepped part of shaft (7) by using a bar
up. and a hammer.
2. Apply OCEAN grease #7 onto the inner surface of oil 7. Install springs (3) (2 used) and pistons (4) (2 used) to
seal (5). housing.
3. Apply THREEBOND #1104 or #1215 onto the outer IMPORTANT: The small diameter side of shaft (7) is
surface of oil seal (5). matched with the inner race on roller bearing (17).
4. Clean the oil seal (5) mating part of housing (1). Do not damage the inner race of roller bearing
Install oil seal (5) to housing (1) by using a plate, a (17).
bar, and a plastic hammer. 8. Install shaft (7) to housing (1) by using a plastic
hammer.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, fNOTE: Shaft (7) can be inserted without tapping when
such as goggles, helmets, etc in order to prevent aligning them correctly.
personal injury.
5. Install the outer race of roller bearing (6) to housing
(1) by using a bar and a hammer.

W4-2-3-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

9. Install balls (8) (2 used) to housing (1). IMPORTANT: Install retainer (11) with the chamfered
surface (b) facing to the bushing (12) side.
10. Apply grease onto the ball (8) hole on swash plate
(9). Align the position of balls (8) (2 used) and install 12. Install springs (13) (9 used), bushing (12), retainer
swash plate (9) to housing (1). (11), and plungers (10) (9 used) to rotor (14).

dCAUTION:
kg (145 lb)
The housing (1) assembly weight: 65 11

11. Attach a nylon sling onto housing (1). Hoist

the housing (1) assembly. Place the housing (1)
b 12
assembly horizontally with the brake releasing oil
passage (a) down.
W178-02-11-225
fNOTE: When facing the brake releasing oil passage (a) b- Chamfered Surface Side
upward, the thicker part of swash plate (9) faces upward.
13. Install the rotor (14) assembly to housing (1).
When placing the housing (1) assembly horizontally,
swash plate (9) suddenly may come out.
dCAUTION:
kg (190 lb)
The housing (1) assembly weight: 85

1 14. Attach a nylon sling onto housing (1). Hoist

the housing (1) assembly. Place the housing (1)
assembly with the brake valve (29) mounting
surface side up.
IMPORTANT: Check the order to install friction plate
(19) and plate (18).
15. Install friction plates (19) (4 used) and plates (18) (5
used) to housing.
16. Apply grease onto O-rings (21, 22) and backup rings
(20, 23). Install O-rings (21, 22) and backup rings (20,
23) to brake piston (24).

a WJAA-04-02-008
a- Brake Releasing Oil Passage

W4-2-3-7
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

IMPORTANT: Check the direction to install brake IMPORTANT: The spring (26) mounting holes
piston (24). Install brake piston (24) with the notch (12 places) on brake piston (24) are located
vertical corresponding to the pin (28) mounting corresponding to springs (26) (10 used). Check the
hole on housing (1). position to install springs (26).
17. Install brake piston (24) to housing (1) by using a 18. Install springs (26) (10 used) to brake piston (24).
plastic hammer.
24
f NOTE: As O-ring (22) is positioned around brake piston
(24), brake piston (24) cannot be fully inserted. When
installing brake valve (29), tighten brake piston (24) with
socket bolt (30).
b
26

26
1
b

W16J-03-02-003
24 b- Not used
19. Install O-rings (2) (4 used) and O-ring (25) to
a
housing (1).
20. Add hydraulic oil into housing (1) until plate (18) is
submerged.

28 W16J-03-02-003

a- Notch

W4-2-3-8
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

21. Install pin (27) to brake valve (29). 25. Install collar (16) to shaft (7).
IMPORTANT: Check the direction to install pin (28).
22. Install pins (28) (4 used) to brake valve (29) with the
dCAUTION: Brake valve (29) weight: 39 kg (29 lb)
IMPORTANT: When installing valve housing (29)
large diameter side facing to brake valve (29). to housing (1), check that a clearance between
housing (1) and valve housing (29) is equal to that
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
before disassembling. If the dimension differs,
disassemble and assemble again.
such as goggles, helmets, etc in order to prevent
personal injury. IMPORTANT: Do not drop valve plate (15).If valve
plate (15) is damaged, oil leakage will occur.
IMPORTANT: Check the direction to install the outer
race of roller bearing (17). 26. Install brake valve (29) to housing (1) with socket
bolts (30) (9 used).
23. Install the outer race of roller bearing (17) to brake
valve (29) with the stamped mark facing outside by l : 14 mm
using a bar and a hammer.
m : 300 N·m (30 kgf·m, 221 lbf·ft)
24. Apply grease onto the flat surface of valve plate
(15). Fit the valve plate (15) with the pin (27)
position and install valve plate (15) to brake valve
(29).

fNOTE: Valve plate (15) is secured to brake valve (29)

tightly in order not to drop brake valve (15) when turning
over.

W4-2-3-9
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

(Blank)

W4-2-3-10
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Brake Valve

1
2
5 6
3 7 9
4 8 10
11

12
35
36
37
38
39
40
41
42
43
44
48

47 49
10 46
9

13
16
17 14
18 15
19
20
21
51 22
24
4 26
3 27
28
2 23 30 31
1 25 32
45 33
29 34
44
43
50 42 5
41 36
40
39 35
38
37

WJAA-04-02-012

1- Plug (2 Used) 14- O-Ring 27- Spring (2 Used) 40- Spring Seat (2 Used)
2- O-Ring (2 Used) 15- Plug 28- Spring Guide (2 Used) 41- Plug (2 Used)
3- Spring (2 Used) 16- Poppet Seat (2 Used) 29- O-Ring (2 Used) 42- O-Ring (2 Used)
4- Check Valve (2 Used) 17- Backup Ring (2 Used) 30- Backup Ring (2 Used) 43- Spring (2 Used)
5- Relief Valve 18- O-Ring (2 Used) 31- O-Ring (2 Used) 44- Check Valve (2 Used)
6- Plug 19- Backup Ring (2 Used) 32- Plug (2 Used) 45- Spool
7- O-Ring 20- Poppet (2 Used) 33- Nut (2 Used) 46- Valve Housing
8- Spring 21- Relief Housing (2 Used) 34- Set Screw (2 Used) 47- Pin (4 Used)
9- Plug (6 Used) 22- Piston (2 Used) 35- Socket Bolt (8 Used) 48- Pin
10- O-Ring (6 Used) 23- Backup Ring (2 Used) 36- Cap (2 Used) 49- Orifice
11- Orifice (2 Used) 24- O-Ring (2 Used) 37- O-Ring (2 Used) 50- Spool Assembly
12- Socket Bolt (9 Used) 25- Backup Ring (2 Used) 38- Spring Seat (2 Used) 51- Orifice (2 Used)
13- Valve Assembly 26- Spring Seat (2 Used) 39- Spring (2 Used)

W4-2-4-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Disassembly of Brake Valve

IMPORTANT: As the setting changes, do not
IMPORTANT: Spool assembly (50), valve assembly
disassemble relief valves (5) (2 used). As the
(13), orifices (11, 49, and 51), and the plug should
setting changes, do not turn set screws (34) (2
be replaced as the valve housing (46) assembly.
used). Attach an identification tag onto relief
dCAUTION: The brake valve weight: 39 kg (86 lb) valves (5) (2 used) for assembling.
1. Secure the brake valve on a workbench. IMPORTANT: Do not move piston (22) attached on
the outer surface of relief valve (5). O-ring (24)
2. Remove plug (6) from valve housing (46). Remove
may be damaged.
O-ring (7) from plug (6). Remove spring (8) from
valve housing (46) by using a magnet. 6. Remove relief valves (5) (2 used) from valve housing
(46).
l : 10 mm
j : 36 mm
3. Remove plug (15) from valve housing (46). Remove
O-ring (14) from plug (15).
22 24 5
l : 10 mm
IMPORTANT: Remove valve housing assembly 34
(13) by rotating. If they stick even a little, try
again instead of pulling them roughly. Do not
disassemble valve assembly (13).
4. Remove valve assembly (13) from valve housing WJAA-04-02-010
(46). 7. Hold one cap (36). Evenly loosen and remove socket
5. Remove plugs (1) (2 used) from valve housing (46). bolts (35) (4 used) from cap (36). Remove cap (36)
Remove O-rings (2) (2 used) from plugs (1) (2 used). from valve housing (46).
Remove springs (3) (2 used) and check valves (4) (2
used) from valve housing (46) by using a magnet. l : 10 mm

l : 14 mm fNOTE: If cap (36) cannot be removed, tap by using

a plastic hammer. Tap cap (36) with socket bolt (35)
attached (loosened).

W4-2-4-2
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

8. Remove socket bolts (35) (4 used) from another cap

(36). Remove cap (36) from valve housing (46).

l : 10 mm
9. Remove spring seats (38) (2 used), springs (39) (2
used), and spring seats (40) (2 used) from valve
housing (46).
IMPORTANT: Remove spool assembly (50) by
rotating. If they stick even a little, try again
instead of pulling them roughly.
10. Remove spool assembly (50) from valve housing
(46).
11. Secure spool assembly (50) by using wooden pieces
in a vise.
12. Remove plugs (41) (2 used) from spool (45). Remove
O-rings (42) (2 used) from plugs (41) (2 used).
Remove springs (43) (2 used) and check valves (44)
(2 used) from spool (45).

W4-2-4-3
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Brake Valve

Relief Valve (5)

18 26 24 27 31 29 32 33

17,19 20 22 23,25 28 30

10 11 6 7 36 38 41
37
39
51
42
35 40
43
44
A A A 45

9
49
8
50
13

14
48 47

12

15

46 5 2 1 3 4
WJAA-04-02-011

W4-2-4-4
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

1- Plug (2 Used) 14- O-Ring 27- Spring (2 Used) 40- Spring Seat (2 Used)
2- O-Ring (2 Used) 15- Plug 28- Spring Guide (2 Used) 41- Plug (2 Used)
3- Spring (2 Used) 16- Poppet Seat (2 Used) 29- O-Ring (2 Used) 42- O-Ring (2 Used)
4- Check Valve (2 Used) 17- Backup Ring (2 Used) 30- Backup Ring (2 Used) 43- Spring (2 Used)
5- Relief Valve 18- O-Ring (2 Used) 31- O-Ring (2 Used) 44- Check Valve (2 Used)
6- Plug 19- Backup Ring (2 Used) 32- Plug (2 Used) 45- Spool
7- O-Ring 20- Poppet (2 Used) 33- Nut (2 Used) 46- Valve Housing
8- Spring 21- Relief Housing (2 Used) 34- Set Screw (2 Used) 47- Pin (4 Used)
9- Plug (6 Used) 22- Piston (2 Used) 35- Socket Bolt (8 Used) 48- Pin
10- O-Ring (6 Used) 23- Backup Ring (2 Used) 36- Cap (2 Used) 49- Orifice
11- Orifice (2 Used) 24- O-Ring (2 Used) 37- O-Ring (2 Used) 50- Spool Assembly
12- Socket Bolt (9 Used) 25- Backup Ring (2 Used) 38- Spring Seat (2 Used) 51- Orifice (2 Used)
13- Valve Assembly 26- Spring Seat (2 Used) 39- Spring (2 Used)

W4-2-4-5
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Assembly of Brake Valve 6. Install the spool (45) assembly approximately half
way into valve housing (46).
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing. 7. Install O-rings (37) (2 used) to caps (36) (2 used).
IMPORTANT: Check the direction to install valve 8. Install spring seat (40), spring (39), and spring seat
assembly (13). (38) to valve housing (46). Install cap (36) with
1. Install O-rings (7, 14) to plugs (6, 15). Install valve socket bolts (35) (4 used).
assembly (13), spring (8), and plugs (6, 15) to valve
housing (46). l : 10 mm

l : 10 mm m : 110 N·m (11 kgf·m, 81 lbf·ft)

9. Install another cap (36) in the same way as step 8.
m : 65 N·m (6.5 kgf·m, 48lbf·ft)
2. Install O-rings (2) (2 used) to plugs (1) (2 used).
Install check valves (4) (2 used), springs (3) (2 used),
and plugs (1) (2 used) to valve housing (46).

l : 14 mm

m : 420 N·m (42 kgf·m, 310 lbf·ft)

IMPORTANT: Install relief valve (5) to the original
position before disassembly.
3. Install relief valves (5) (2 used) to valve housing (46).

j : 36 mm

m : 420 N·m (42 kgf·m, 310 lbf·ft)

4. Install O-rings (42) (2 used) to plugs (41) (2 used).
5. Install check valves (44) (2 used), springs (43) (2
used), and plugs (41) (2 used) to spool (45).

W4-2-4-6
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

Precautions for Using Floating Seal 1

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

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding
surface (e) of seal ring (1). W178-02-11-001
2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) for tears, breaks, deformation, or
hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following to prevent
trouble.
 Clean the floating seal and seal mounting bores with
cleaning solvent. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a- Correct c- Twist of O-Ring
 After installing the floating seal, check that O-ring b- Incorrect d- Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
(e) and (f ) at point (A) and (B), as illustrated. If these
distances differ, correct O-ring (2) seating. a A b A

B B

A=B A≠B

W178-02-11-003

a- Correct e- Sliding Surface

b- Incorrect f- Seal Mating Surface

W4-2-5-1
 SECTION 4 UNDERCARRIAGE
Group 2 Travel Device

(Blank)

W4-2-5-2
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Removal and Installation of Center Joint

6 5 WJAA-04-03-001

IMPORTANT: Cap the open ends in case the hoses 4. Disconnect hose (4).
and pipes have been disconnected. In addition,
attach an identification tag onto the connectors, j : 17 mm
hoses, and pipes for assembling. Connect the 5. Remove bolts (8) (2 used) and washers (9) (2 used).
hoses and install the clips in case the clips which Remove stopper (10). Remove washers (14) (2 used)
secure the hoses have been removed. between stopper (10) and center joint (1) at this
time.
Removal
j : 22 mm
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.) 6. Remove adapters (6) (2 used).
7. Remove rubber cover (5).
dCAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.)
2. Place a container under center joint (1). Disconnect
hoses (2) (4 used).

j : 41 mm
3. Disconnect hose (3).

j : 27 mm

W4-3-1-1
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

WJAA-04-03-002

8. Remove adapters (15) (4 used). 12. Disconnect hoses (7) (2 used).

j : 41 mm j : 19 mm

dCAUTION: Center joint (1) weight: 52 kg (115 lb) 13. Remove bolts (12) (4 used) and washers (13) (4
used). Remove center joint (1).
9. Install eyebolts (G1) to the plug (15) hole (2 places
in diagonal position) of center joint (1). Attach nylon j : 24 mm
slings onto the eyebolts. Hoist and hold center joint
(1). 14. Remove the adapter with center joint (1) attached if
necessary.
10. Disconnect hoses (5) (2 used).

j : 27 mm
11. Disconnect hoses (6) (4 used).

j : 41 mm

W4-3-1-2
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

WJAA-04-03-002

Installation 5. Connect hoses (6) (4 used).

1. Install all removed adapters to center joint (1). j : 41 mm

dCAUTION: Center joint (1) weight: 52 kg (115 lb) m : 200 N·m (20 kgf·m, 148 lbf·ft)
2. Install eyebolts (G1) to the plug (15) hole (2 places
6. Connect hoses (5) (2 used).
in diagonal position) of center joint (1). Attach nylon
slings onto the eyebolts. Hoist center joint (1). j : 27 mm
3. Install center joint (1) with washers (13) (4 used) and
m : 80 N·m (8 kgf·m, 59 lbf·ft)
bolts (12) (4 used).
7. Install adapters (15) (4 used).
j : 24 mm
j : 41 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
m : 210 N·m (21 kgf·m, 155 lbf·ft)
4. Connect hoses (7) (2 used).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W4-3-1-3
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

6 5 WJAA-04-03-001

8. Install rubber cover (5). 12. Connect hose (3).

9. Install adapters (6) (2 used). j : 27 mm
10. Install washers (14) (2 used) between stopper (10)
m : 80 N·m (8 kgf·m, 59 lbf·ft)
and center joint (1). Install stopper (10) with washers
(9) (2 used) and bolts (8) (2 used). 13. Connect hoses (2) (4 used).

j : 22 mm j : 41 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft) m : 200 N·m (20 kgf·m, 148 lbf·ft)
11. Connect hose (4). 14. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
j : 17 mm
IMPORTANT: Check the hydraulic oil level. Start the
m : 25 N·m (2.5 kgf·m, 18 lbf·ft) engine and check for any oil leaks.

W4-3-1-4
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Disassembly of Center Joint

00B

00A

01

02
03

05

06

07

08
04

09

10

W16J-03-03-001

00A- Spindle 02- Dust Seal 05- Bushing 08- O-Ring

00B- Plug (With Ball) 03- O-Ring 06- Ring 09- Cover
01- Body 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)

W4-3-2-1
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Disassembly of Center Joint IMPORTANT: For easy removal of oil seal (04), use the
pins (2 used). Do not damage the seal groove.
dCAUTION: Center joint weight: 52 kg (115 lb)
6. Remove oil seals (04) (6 used), O-ring (03), and dust
1. Remove bolts, washers (10) (2 used) diagonally. seal (02) from body (01).
Install an eyebolt (M12, Pitch 1.75 mm) to the bolt
(10) hole (2 places) of body (01). Attach a nylon sling
onto the eyebolt. Hoist the center joint. Secure the
center joint on a workbench.

j : 17 mm
2. Put the matching marks on body (01) and spindle
(00A). Remove other bolts, washers (10) (2 used).
Remove cover (09) from body (01).

j : 17 mm
3. Remove O-ring (08), retaining ring (07), and ring (06)
from body (01).
4. Install the special tools (ST 1033, ST 1020) to body
(01) with bolts, washers (10) (2 used).

j : 17 mm
W178-02-11-240

IMPORTANT: Do not damage the seal surface.

ST 1020 7. When replacing bushing (05), build-up weld at 4
places in its inner diameter by using a welding rod.
ST 1033
10 Shrink and remove bushing (05).

01

W183-03-03-004

IMPORTANT: Do not damage the the seal sliding

surface of spindle (00A).
5. Remove spindle (00A) from body (01).

W4-3-2-2
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Assembly of Center Joint

00A

02
03

05

04

01

06
08
10

07
09
W183-03-08-001

00A- Spindle 02- Dust Seal 05- Bushing 08- O-Ring

03- O-Ring 06- Ring 09- Cover
00B- *Plug (With Ball)
04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body

fNOTE: As for the parts with mark *, refer to W4-3-2-1.

W4-3-2-3
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Assembly of Center Joint

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not damage bushing (05).
onto parts in order to prevent them from seizing. IMPORTANT: The clearance between body (01) and
IMPORTANT: When assembling the seals, apply spindle (00A) should be 0.1 mm (0.004 in). Insert
grease (Apolloil Autorex C) and install seals to body (01) along axis straight and slowly. Do not
each groove. damage the seal.
IMPORTANT: If bushing (05) has been removed, IMPORTANT: Install body (01) so that the ring (06)
install bushing (05) first. (Refer to W4-3-2-6.) mounting part (b) is flat.
1. Apply grease onto the mounting part for dust seal 3. Apply grease onto the oil seal (04) inside, the
(02) on body (01). Install dust seal (02) to body (01) bushing (05) inside, and the dust seal (02) sliding
with the metal part (a) facing to the body (01) side. surface of spindle (00A). Place spindle (00A) on a
workbench. Fit the matching marks made when
disassembling and install body (01) to spindle (00A).

a 02

b 00A

W800-03-03-001 01
01
a- Metal Part
2. Install O-ring (03) and oil seals (04) (6 used) to body
(01).

W800-03-03-002
b- Ring (06) Mounting Part

W4-3-2-4
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

IMPORTANT: Install ring (06) with the chamfered

surface facing to the spindle (00A) side.
4. Install ring (06) and O-ring (08) to body (01).
5. Install retaining ring (07) to spindle (00A).
6. Install cover (09) to body (01) with bolts, washers
(10) (4 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W4-3-2-5
 SECTION 4 UNDERCARRIAGE
Group 3 Center Joint

Replacement of Body and Spindle

ST 2670
IMPORTANT: When replacing body (01) or spindle
(00A) with the new one, the following procedures
are required. 01

In case of Body (01)

1. Clean body (01) and bushing (05).
05
2. Apply grease onto the bushing (05) mounting part
on body (01).
3. Install bushing (05) to body (01) by using the special
tool (ST 2670).

fNOTE: Pushing force: 0.5 to 1.5 t (1100 to 3310 lb)

W178-02-11-242

In case of spindle (00A) 00B C

1. Clean spindle (00A). 00A
2. Install plug (00B) to spindle (00A) by using the
special tool (ST 2560).
3. Install ball (a) of plug (00B) so that the top of each
ball is 0.4 mm (0.02 in) or more lower than the
respective sleeve (c) edge as illustrated in detail C.

WDAA-04-03-005

ST 2560 Detail C

b
c

WDAA-04-03-006 WDAA-04-03-007

a- Ball b- 0.4 mm or more

c- Sleeve

W4-3-2-6
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Removal and Installation of Track Adjuster

W142-03-04-002

Before removing and installing the track adjuster, the

tracks and front idler must be removed first. (Refer to W4-
7-1 and W4-5-1.)
Therefore, the procedure starts on the premise that the
tracks and front idler have already been removed here.

Removal

dlb)
CAUTION: Track adjuster (1) weight: 240 kg (530

dthe
CAUTION: Track adjuster (1) may fly out due to
spring force when removing track adjuster
(1). Do not stand in the same direction to remove
track adjuster (1) or where it may fly out.
1. Attach nylon slings onto track adjuster (1). Hoist and
hold track adjuster (1). Remove track adjuster (1).

fNOTE: If it is difficult to remove it, pry it out by using a

pry bar.

W4-4-1-1
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

W142-03-04-002
W16J-03-04-002
2

Installation

dlb)
CAUTION: Track adjuster (1) weight: 240 kg (530

1. Attach nylon slings onto track adjuster (1). Hoist

track adjuster (1).
2. Install track adjuster (1) with the grease outlet (2)
side down.

W4-4-1-2
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Disassembly of Track Adjuster

2
3
4

5
6
7
1
8

9
10

11

12
13
14
15
W1J1-03-04-002
16

1- Socket Bolt (4 Used) 5- Wear Ring 9- O-Ring 13- Nut

2- O-Ring 6- U-Ring 10- Spacer 14- Bolt
3- Guide 7- Retaining Ring 11- Spring 15- Rod
4- Piston Rod 8- Cylinder 12- Bracket 16- Valve

W4-4-2-1
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Disassembly of Track Adjuster 2. Check that valve (16) is loose. Compress spring (11)
of the track adjuster by using the special tool (ST
 Use a pump unit which has the maximum pressure
4932) so that clearance (h) between bracket (12)
of 69 MPa (700 kgf/cm2, 9950 psi) and the flow rate
and nut (13) is 10 mm (0.4 in).
of 8 to 10 liters (2.1 to 2.6 US gal). Set the main relief
pressure to 49 MPa (500 kgf/cm2, 7110 psi), the
propelling power to 80 t (176000 lb) or lower.
d CAUTION: The spring (11) force is extremely
large. Carry out the disassembly and assembly
h

work carefully. Inspect the special tool for any

damage thoroughly in order to perform the work
safely.
12
dCAUTION: Track adjuster weight: 240 kg (530 lb)
13
15
1. Attach a nylon sling onto the track adjuster. Hoist
the track adjuster. Install the track adjuster to holder
(e) of the special tool (ST 4932). 14

ST 4932 16
W142-03-04-020

h- Clearance

W142-03-04-019

e- Holder

W4-4-2-2
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

3. Put the matching marks on rod (15) and nut (13). 9. Install an eyebolt (M16, Pitch 2.0 mm) to piston
rod (4). Attach a nylon sling onto spring (11). Pass a
4. Remove valve (16) from rod (15).
nylon sling through the eyebolt on piston rod (4).
j : 24 mm Hoist and place the spring (11) assembly on holder
(e).
5. Remove bolt (14) from nut (13).

j : 17 mm
6. Remove nut (13) from rod (15).

j : 100 mm 4
7. Retract the cylinder of the special tool (ST 4932)
slowly and extend spring (11) to the free length.

fNOTE: Spring (11) free length: 782 mm (30.8 in)

11
dCAUTION:
kg (530 lb)
The spring (11) assembly weight: 240

8. Secure bracket (12) and spring (11) by using wire

(g). Attach a nylon sling onto spring (11). Hoist
the spring (11) assembly. Remove the spring (11)
assembly from the special tool (ST 4932).
e

W142-03-04-006

e- Holder

11 ST 4932

12

W142-03-04-005

g- Wire

W4-4-2-3
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

13. Remove socket bolts (1) (4 used) from guide (3).

d CAUTION: The cylinder (8) assembly weight: 75
kg (170 lb)
Remove guide (3) from piston rod (4).

10. Remove the cylinder (8) assembly from spring (11). l : 12 mm

2 3
1

15
11

W142-03-04-010

14. Remove piston rod (4) from cylinder (8).

15. Remove O-ring (2) from guide (3).

W142-03-04-007

dCAUTION: Spring (11) weight: 122 kg (270 lb)

11. Remove wire (g) which secure spring (11) and
bracket (12). Attach a nylon sling onto spring (11).
Hoist spring (11). Remove spring (11) from holder
(e).

dCAUTION: Bracket (12) weight: 22 kg (49 lb)

12. Remove spacer (10) and bracket (12) from holder
(e).

W4-4-2-4
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

dCAUTION: Cylinder (8) weight: 39 kg (86 lb)

Rod (15) weight: 21 kg (47 lb)
16. Install an eyebolt (M16, Pitch 1.5 mm) to rod (15).
Attach a nylon sling onto the eyebolt. Hoist cylinder
(8). Remove rod (15) from cylinder (8).
17. Remove O-ring (9) from cylinder (8).
18. Remove retaining ring (7), U-ring (6), and wear ring
(5) from piston rod (4).

W4-4-2-5
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Assembly of Track Adjuster

16 13 12 11 9 6 5 8 3 4

14 15 10 a 7 1 2 b

W1J1-03-04-001

a- Grease Chamber b- Grease Groove c- Lifting Hole f- Grease Outlet

1- Socket Bolt (4 Used) 5- Wear Ring 9- O-Ring 13- Nut

2- O-Ring 6- U-Ring 10- Spacer 14- Bolt
3- Guide 7- Retaining Ring 11- Spring 15- Rod
4- Piston Rod 8- Cylinder 12- Bracket 16- Valve

W4-4-2-6
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

Assembly of Track Adjuster

IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing.
1. Apply grease onto wear ring (5) and U-ring (6).
2. Install wear ring (5) to piston rod (4).
3. Install U-ring (6) to piston rod (4) with the lip part
facing to the rod (15) side.
4. Install retaining ring (7) to piston rod (4).

dCAUTION: Rod (15) weight: 21 kg (47 lb)

5. Apply grease onto O-ring (9). Install O-ring (9) to
cylinder (8). Install an eyebolt (M16, Pitch 1.5 mm) to
the rod (15) lifting hole (d). Attach a nylon sling onto
the eyebolt. Hoist the rod. Install rod (15) to cylinder
(8).
6. Fill grease chamber (a) with grease.
7. Apply hydraulic oil onto piston rod (4).
d
9

15
8

WJAA-04-04-001

W4-4-2-7
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

8. Install an eyebolt (M16, Pitch 2.0 mm) to piston

rod (4). Attach a nylon sling onto the eyebolt. Hoist dCAUTION: Bracket (12) weight: 22 kg (49 lb)
Spring (11) weight: 122 kg (270 lb)
the rod. Insert piston rod (4) to cylinder (8) and
completely bleed air from grease chamber (a) and 12. Attach a nylon sling onto bracket (12). Hoist bracket
rod (15). (12). Place bracket (12) and spacer (10) onto holder
(e). Attach a nylon sling onto spring (11). Hoist
9. Fill grease groove (b) with grease.
spring (11). Place spring (11) onto bracket (12).
10. Apply grease onto O-ring (2). Apply LOCTITE #262 Secure bracket (12) and spring (11) by using a wire.
onto socket bolts (1) (4 used).
11. Install O-ring (2) to guide (3). Install guide (3) to
cylinder (8) with socket bolts (1) (4 used).

l : 12 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft) 8

3 1

10

11

12 e

W142-03-04-018
W142-03-04-007

e- Holder

dCAUTION:
kg (170 lb)
The cylinder (8) assembly weight: 75

13. Fit the cylinder (8) assembly with spacer (10) and
bracket (12), and install the cylinder (8) assembly to
the bracket (12) assembly.

W4-4-2-8
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

IMPORTANT: Slowly compress spring (11) while

d CAUTION: The spring (11) assembly weight: 240
kg (530 lb)
fitting the center of rod (15) with that of bracket
(12) by using a pry bar. Do not damage the threads
14. Attach a nylon sling onto spring (11). Pass a nylon on rod (15).
sling through the eyebolt on piston rod (4). Hoist 16. Operate the cylinder of the special tool (ST 4932)
and place the spring (11) assembly slowly and and remove wire (g). Compress spring (11) to the
horizontally. specified spring (11) length.

fNOTE: Specified spring length: 620 mm (24.4 in)

ST 4932
11

11
12

W142-03-04-006

15. Install the spring (11) assembly to the special tool

(ST 4932) with grease outlet (f ) on rod (15) facing W142-03-04-015
down.Remove the eyebolt from piston rod (4).
g- Wire

ST 4932

W142-03-04-005

W4-4-2-9
 SECTION 4 UNDERCARRIAGE
Group 4 Track Adjuster

IMPORTANT: Check that the grease outlet of rod (15)

is fitting with that of nut (13).
17. Fit the matching marks made when disassembling
and install nut (13) to rod (15). Secure nut (13) to rod
(15) with bolt (14).

j : 100 mm

j : 17 mm

m : 40 N·m (4 kgf·m, 30 lbf·ft)

13

15

14
16
W142-03-04-020

18. Install valve (16) to rod (15).

j : 24 mm

m : 150 N·m (15 kgf·m, 111 lbf·ft)

19. Retract the cylinder of special tool (ST 4932).

dCAUTION: Track adjuster weight: 240 kg (530 lb)

20. Attach a nylon sling onto the track adjuster. Hoist
the track adjuster. Remove the track adjuster from
special tool (ST4932).

dCAUTION: If only the spring assembly is

transported, use a firm steel box and take any
other precautions in order to carry the track
adjuster safely.

W4-4-2-10
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Removal and Installation of Front Idler

1 1

3 2 a
W17P-03-05-001 W105-03-05-003

a- Wooden Block

Before removing and installing the front idler, the tracks 2. Attach nylon slings onto yoke (2) and bearing (3).
must be removed first. (Refer to W4-7-1.) Hoist and hold front idler (1). Remove front idler (1).
Therefore, the procedure starts on the premise that the
3. Place front idler (1) on wooden blocks (a) (2 used).
tracks have already been removed here.

Removal

dCAUTION: Front idler (1) weight: 290 kg (640 lb)

dCAUTION: Front idler (1) may fly out due to the
spring force when removing front idler (1). Do not
stand in the same direction to remove front idler
(1) or where front idler (1) may fly out.
1. Pull out front idler (1) to the position where nylon
slings can be attached onto yoke (2).

fNOTE: If it is difficult to remove it, use a pry bar.

W4-5-1-1
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

3 2 W17P-03-05-001

Installation

dCAUTION: Front idler (1) weight: 290 kg (640 lb)

1. Attach nylon slings onto yoke (2) and bearing (3).
Hoist front idler (1).
2. Install front idler (1) to the track frame, the position
where nylon slings can be removed.
3. Remove the nylon slings.
4. Install front idler (1).

W4-5-1-2
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Disassembly of Front Idler

2
1
3 8
5
6
7

10
11
6 9
5

3 12
2
1

14
13

W1J1-03-05-001

1- Bearing (2 Used) 5- Floating Seal (2 Used) 9- Guard 13- Bolt (4 Used)

2- Pin (2 Used) 6- Bushing (2 Used) 10- Bolt (3 Used) 14- Spring Washer (4 Used)
3- O-Ring (2 Used) 7- Idler 11- Spring Washer (3 Used)
4- Axle 8- Plug (2 Used) 12- Yoke

W4-5-2-1
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Disassembly of Front Idler

1. Remove bolts (10) (3 used) and spring washers (11)
dCAUTION:
(515 lb)
The idler (7) assembly weight: 232 kg

(3 used) from guard (9). Remove guard (9) from yoke

(12). Axle (4) weight: 28 kg (62 lb)
Bearing (1) weight: 27 kg (60 lb)
j : 19 mm
5. Put the matching marks on bearing (1) and axle (4).
dCAUTION: Yoke (12) weight: 44 kg (98 lb) Remove the axle (4) assembly from idler (7) by using
a press.
2. Attach a nylon sling onto yoke (12). Hoist and hold
yoke (12). Remove bolts (13) (4 used) and spring
washers (14) (4 used). Remove yoke (12) from 1 4
bearings (1) (2 used).

j : 30 mm 7

3. Remove plug (8) from bearing (1). Drain off oil.

l : 6 mm

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury. W105-03-05-008
4. Remove pin (2) from bearing (1) by using a bar and
a hammer. IMPORTANT: Handle floating seal (5) with care.
(Refer to W4-5-3.)
6. Remove bearing (1) from the upper side of idler (7).
Remove floating seals (5) (2 used) from idler (7) and
bearings (1) (2 used).

W105-03-05-009

W4-5-2-2
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

IMPORTANT: Do not remove bushing (6) unless

d CAUTION: The axle (4) assembly weight: 54 kg
(120 lb)
necessary.
10. When replacing bushing (6), remove bushings (6)
IMPORTANT: Place wooden block (a) under bearing (2 used) from idler (7) by using the special tool (ST
(1) in order not to damage bearing (1). 1973) and a press.
7. Attach a nylon sling onto the axle (4) assembly.
Hoist the axle (4) assembly. Place bearing (1) onto
wooden block (a).

ST 1973
2

1
a
6

W105-03-05-011

W105-03-05-010

a- Wooden Block

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
8. Remove pin (2) from bearing (1) at the other side by
using a bar and a hammer. Put the matching marks
on bearing (1) and axle (4). Remove axle (4) from
bearing (1) by using a press.
9. Remove O-rings (3) (2 used) from axle (4).

W4-5-2-3
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Assembly of Front Idler

1 2 5 7 4 6 3 7 8 9 10 11

3 5 2 1 14 13 12
W1J1-03-05-002

1- Bearing (2 Used) 5- Floating Seal (2 Used) 9- Guard 13- Bolt (4 Used)

2- Pin (2 Used) 6- Bushing (2 Used) 10- Bolt (3 Used) 14- Spring Washer (4 Used)
3- O-Ring (2 Used) 7- Idler 11- Spring Washer (3 Used)
4- Axle 8- Plug (2 Used) 12- Yoke

W4-5-2-4
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Assembly of Front Idler IMPORTANT: Handle floating seal (5) with care.
(Refer to W4-5-3.)
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing. 4. Apply grease onto O-ring of floating seal (5). Install
floating seal (5) to idler (7) and bearing (1).
dCAUTION: Idler (7) weight: 150 kg (335 lb)
1. Install bushings (6) (2 used) to idler (7) by using the dCAUTION:
(120 lb)
The axle (4) assembly weight: 54 kg
special tool (ST 1973) and a press.
5. Attach a nylon sling onto bearing (1) of the axle (4)
assembly. Hoist the axle (4) assembly. Install the axle
(4) assembly to idler (7) from the side where floating
seal (5) has already been installed.

ST 1973

W105-03-05-011

dCAUTION: Axle (4) weight: 28 kg (62 lb)

Bearing (1) weight: 27 kg (60 lb)
2. Attach a nylon sling onto axle (4). Hoist axle (4).
Place axle (4) vertically. Install O-ring (3) to the
upper side of axle (4).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
3. Fit the matching marks made when disassembling
and install bearing (1) to axle (4) by using a plastic
hammer. Install pin (2) to bearing (1) by using a bar
and a hammer.

2
4
1

3 W105-03-05-014

W4-5-2-5
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

6. Apply LOCTITE #503 onto plug (8). Install plug (8) to

bearing (1). dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
l : 6 mm such as goggles, helmets, etc in order to prevent
personal injury.
m : 20 N·m (2 kgf·m, 15 lbf·ft)
9. Fit the matching marks made when disassembling
dCAUTION:
(405 lb)
The idler (7) assembly weight: 183 kg and install bearing (1) to axle (4) by using a plastic
hammer. Install pin (2) to bearing (1) by using a bar
7. Attach a nylon sling onto the idler (7) assembly. and a hammer.
Hoist the idler (7) assembly. Turn over the idler (7) 10. Add engine oil (API CD class, SAE #30) through the
assembly. plug (8) hole of bearing (1).
IMPORTANT: Handle floating seal (5) with care.
(Refer to W4-5-3.)
fNOTE: Amount of oil: 0.45 L (0.12 US gal)
11. Apply LOCTITE #503 onto plug (8). Install plug (8) to
8. Install other O-ring (3) to axle (4). Apply grease onto bearing (1).
O-ring of floating seal (5). Install other floating seal
(5) to idler (7) and bearing (1). l : 6 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft)

1 5 3 7
dCAUTION: Yoke (12) weight: 44 kg (98 lb)
12. Attach a nylon sling onto yoke (12). Hoist yoke (12).
1
Fit the bolt (13) holes of bearing (1) and yoke (12).
13. Install yoke (12) to bearings (1) (2 used) with bolts
(13) (4 used) and spring washers (14) (4 used).

l : 30 mm
4 m : 400 N·m (40 kgf·m, 300 lbf·ft)
W157-03-05-005 14. Install guard (9) to yoke (12) with bolts (10) (3 used)
and spring washers (11) (3 used).

l : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W4-5-2-6
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

Precautions for Using Floating Seal 1

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

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding
surface (e) of seal ring (1). W178-02-11-001
2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) for tears, breaks, deformation, or
hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following to prevent
trouble.
 Clean the floating seal and seal mounting bores with
cleaning solvent. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a- Correct c- Twist of O-Ring
 After installing the floating seal, check that O-ring b- Incorrect d- Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
(e) and (f ) at point (A) and (B), as illustrated. If these
distances differ, correct O-ring (2) seating. a A b A

B B

A=B A≠B

W178-02-11-003

a- Correct e- Sliding Surface

b- Incorrect f- Seal Mating Surface

W4-5-3-1
 SECTION 4 UNDERCARRIAGE
Group 5 Front Idler

(Blank)

W4-5-3-2
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Removal and Installation of Upper Roller

2 1

W105-03-06-001 W800-03-07-002

dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (1) may fly out
and the high-pressure grease may spout out, do
not loosen valve (1) quickly and/or excessively.
Keep body parts and face away from valve (1) and
loosen valve (1) carefully. Do not loosen grease
fitting (2).
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
IMPORTANT: Loosening valve (1) 1 to 1.5 turns is
enough. Do not loosen valve (1) over those turns.

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Loosen valve (1) of the track adjuster. Drain grease
from the cylinder.

j : 24 mm

W4-6-1-1
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

4 3

6, 7 5 b W116-03-06-002 3 W116-03-06-003

a- Oil Jack
b- Wooden Block

3. Raise track (4) until enough clearance is observed

between upper roller (3) and track (4) by using the
oil jack.
4. Insert wooden blocks (b) between upper roller (3)
and track frame (5).
5. Remove bolts (6) (4 used) and washers (7) (4 used)
from upper roller (3).

j : 27 mm

dCAUTION: Upper roller (3) weight: 39 kg (86 lb)

6. Attach nylon slings onto the body of upper roller
(3). Hoist upper roller (3). Remove upper roller (3).

W4-6-1-2
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

4 3

6, 7 5 b W116-03-06-002 3 W116-03-06-003

a- Oil Jack
b- Wooden Block

2 1

Wxxx-03-07-001

a- Track Sag Specification

W800-03-07-002

Installation 5. Raise the track to be adjusted. Rotate the track in

the reverse direction a little.
dCAUTION: Upper roller (3) weight: 39 kg (86 lb)
6. Apply grease through grease fitting (2) and adjust
1. Attach nylon slings onto the body of upper roller
the track (4) tension.
(3). Hoist upper roller (3).
2. Install upper roller (3) with washers (7) (4 used) and fNOTE: Track sag specification (c):
bolts (6) (4 used).  ZX470-5B, 470H-5B, 470R-5B : 380 to 430 mm (15.0 to
16.9 in)
j : 27 mm
 ZX470LC-5B, 470LCH-5B, 470LCR-5B : 390 to 440 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft) (15.4 to 17.3 in)
3. Remove wooden blocks (b) and oil jack (a) between
track (4) and track frame (5).
4. Tighten valve (1) of the track adjuster.

j : 24 mm

m : 150 N·m (15 kgf·m, 111 lbf·ft)

dCAUTION: Securely support the raised machine

by using the blocks.

W4-6-1-3
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

W158-03-06-001

7. Lower the track.

IMPORTANT: The upper roller cannot be
disassembled. Replace it as an assembly.
8. Add engine oil (API CD class, SAE #30) through the
plug (9) hole of cover (8).

fNOTE: Amount of oil: 120 mL (0.13 US qt)

9. Apply LOCTITE #503 onto plug (9).
10. Install plug (9).

l : 6 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W4-6-1-4
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Removal and Installation of Lower Roller

3, 4 6

90˚~110˚

2 1 a WJAA-04-06-001 b M104-07-067

a- Wooden Block b- Stand

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Put the matching marks on track guard (1) and track
frame (2).

dCAUTION: If removing bolt (3) without holding

track guard (1), track guard (1) falls off.
3. Insert wooden blocks (a) under track guard (1).
4. Remove bolts (3) (4 used) and spacers (4) (4 used).

j : 32 mm
5. Remove bolts (6) (4 used).

j : 32 mm
6. Swing the upperstructure by 90 degrees so that
the angle between boom and arm should be 90 °
to 110°. Lower the boom with the round bottom
contacting with the ground. Raise the track frame.
Place stand (b) under the track frame and support
the machine at this time.

W4-6-2-1
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

W800-03-07-002

1 9

W105-03-06-001

WJAA-04-06-002

dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (7) may fly out
and the high-pressure grease may spout out, do
not loosen valve (7) quickly and/or excessively.
Keep body parts and face away from valve (7) and
loosen valve (7) carefully. Do not loosen grease
fitting (8).
IMPORTANT: Loosening valve (7) 1 to 1.5 turns is
enough. Do not loosen valve (7) over those turns.
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
7. Loosen valve (7). Drain grease. Loosen the
track until the clearance enough to remove track
guard (1) and lower roller (9) is obtained.

j : 24 mm

dCAUTION: Track guard (1) weight: 40 kg (89 lb)

Lower roller (9) weight: 80 kg (180 lb)
8. Remove track guard (1) and lower roller (9) by using
a forklift.

W4-6-2-2
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

1 9 3, 4 6

2 1 a WJAA-04-06-001
WJAA-04-06-002
10

Installation

dCAUTION: Track guard (1) weight: 40 kg (89 lb)

Lower roller (9) weight: 80 kg (180 lb)
1. Set track guard (1) and lower roller (9) on track link
(10) by using a forklift while fitting the matching
marks made when removing.
2. Lower the machine so that the position to install
lower roller (9) can be adjusted.
3. Fit the bolt (6) holes of track frame (2) and lower
roller (9). Apply LOCTITE #262 onto bolts (6) (4
used). Install lower roller (9) with bolts (6) (4 used).

j : 32 mm

m : 750 N·m (75 kgf·m, 550 lbf·ft)

4. Apply LOCTITE #262 onto bolts (3) (4 used). Install
track guard (1) with spacers (4) (4 used) and bolts (3)
(4 used) by using a pry bar.

j : 32 mm

m : 750 N·m (75 kgf·m, 550 lbf·ft)

W4-6-2-3
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

W800-03-07-002 Wxxx-03-07-001

a- Track Sag Specification

5. Tighten valve (7).

j : 24 mm

m : 150 N·m (15 kgf·m, 111 lbf·ft)

dCAUTION: Securely support the raised machine

by using the blocks.
6. Raise the track to be adjusted. Rotate the track in
the reverse direction a little.
7. Apply grease through grease fitting (8) and adjust
the track tension.

fNOTE: Track sag specification (a)

 ZX470-5B, 470H-5B, 470R-5B : 380 to 430 mm (15.0 to
16.9 in)
 ZX470LC-5B, 470LCH-5B, 470LCR-5B : 390 to 440 mm
(15.4 to 17.3 in)

W4-6-2-4
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Disassembly of Lower Roller

5
6
4

6
1
3

W166-03-06-006

1- Floating Seal (2 Used) 3- O-Ring (2 Used) 5- Pin (2 Used) 7- Bushing (2 Used)

2- Axle 4- Collar (2 Used) 6- Plug (2 Used) 8- Roller

W4-6-3-1
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Disassembly of Lower Roller 4. Remove pin (5) from the axle (2) assembly. Remove
axle (2) from collar (4) by using a press.
dCAUTION: Lower roller weight: 80 kg (180 lb)
3 4
1. Remove plug (6) from the end of collar (4). Drain oil
from roller (8).

l : 6 mm

dCAUTION:
lb)
Axle (2) + collar (4) weight: 25 kg (56
2

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
2. Put the matching marks on collar (4) and axle (2).
Remove pin (5) from collar (4) at one side by using W178-02-11-268
a round bar and a hammer. Remove axle (2) from
roller (8), from the side where pin (5) was removed 5. Remove O-rings (3) (2 used) from axle (2).
by using a press. At this time, pin (5) and collar (4)
on the opposite side are removed with axle (2)
together.
dCAUTION: Roller (8) weight: 47 kg (105 lb)
IMPORTANT: Do not remove bushing (7) unless
necessary.
fNOTE: Diameter of round bar: 25 mm (1.0 in)
6. Remove bushing (7) by using the special tool (ST
4 1 8 1 1955) and a press.

ST 1955
1
4

2 8

W105-03-06-026

W178-02-11-269
IMPORTANT: Handle floating seal (1) with care.
(Refer to W4-6-4.)
3. Remove floating seals (1) (2 used) from both sides of
roller (8) and collars (4) (2 used).

W4-6-3-2
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Assembly of Lower Roller

4 5 6

8 2 7 1 3 W162-03-06-002

1- Floating Seal (2 Used) 3- O-Ring (2 Used) 5- Pin (2 Used) 7- Bushing (2 Used)

2- Axle 4- Collar (2 Used) 6- Plug (2 Used) 8- Roller

W4-6-3-3
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Assembly of Lower Roller

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

dCAUTION: Roller (8) weight: 47 kg (105 lb)

IMPORTANT: Do not damage bushing (7).
1. Install bushings (7) (2 used) to roller (8) by using a
press.

dCAUTION: Axle (2) weight: 20 kg (45 lb)

2. Apply grease onto O-ring (3) at one side. Install
O-ring (3) to axle (2).
IMPORTANT: Do not damage O-ring (3).
3. Fit the pin (5) hole and install collar (4) to one side of
axle (2) with pin (5).

2 5

4
W105-03-06-031

IMPORTANT: Handle floating seal (1) with care.

(Refer to W4-6-4.)
4. Install floating seal (1) to roller (8) and collar (4).
8 1

1 4

W157-03-06-008

W4-6-3-4
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

dCAUTION:
(180 lb)
The roller (8) assembly weight: 80 kg

The axle (2) assembly weight: 25 kg (56 lb)

5. Install the axle (2) assembly to the roller (8)
assembly.
6. Apply grease onto O-ring (3) at the other side. Install
O-ring (3) to the roller (8) assembly.
IMPORTANT: Handle floating seal (1) with care.
(Refer to W4-6-4.)
7. Install floating seal (1) to roller (8) and collar (4) at
the other side.
IMPORTANT: Do not damage O-ring (3).
8. Fit the pin (5) hole and install collar (4) to axle (2)
with pin (5).
9. Install a seal tape onto plug (6).
10. Add engine oil (API CD class, SAE #30) through the
plug (6) hole of collar (4). Tighten plug (6).

l : 6 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

fNOTE: Amount of oil: 1.0 L (0.26 US gal)

W4-6-3-5
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

(Blank)

W4-6-3-6
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

Precautions for Using Floating Seal 1

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

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil onto sliding
surface (e) of seal ring (1). W178-02-11-001
2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) for tears, breaks, deformation, or
hardening.

2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following to prevent
trouble.
 Clean the floating seal and seal mounting bores with
cleaning solvent. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a- Correct c- Twist of O-Ring
 After installing the floating seal, check that O-ring b- Incorrect d- Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
(e) and (f ) at point (A) and (B), as illustrated. If these
distances differ, correct O-ring (2) seating. a A b A

B B

A=B A≠B

W178-02-11-003

a- Correct e- Sliding Surface

b- Incorrect f- Seal Mating Surface

W4-6-4-1
 SECTION 4 UNDERCARRIAGE
Group 6 Upper and Lower Rollers

(Blank)

W4-6-4-2
 SECTION 4 UNDERCARRIAGE
Group 7 Track

Removal and Installation of Track

3
5 4
2

1 W800-03-07-027

b- Grease Outlet

a
W105-03-07-006

a- Wooden Block

Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Rotate the tracks so that master pin (1) is positioned
over the front idler (2) side of the track adjuster.
Insert wooden blocks (a) under shoe (3) and
support it.

dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (4) may fly out
and the high-pressure grease may spout out, do
not loosen valve (4) quickly and/or excessively.
Keep body parts and face away from valve (4) and
loosen valve (4) carefully. Do not loosen grease
fitting (5).
IMPORTANT: Loosening valve (4) 1 to 1.5 turns is
enough. Do not loosen valve (4) over those turns.
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
3. Loosen valve (4). Drain grease and loosen the tracks.

j : 24 mm

W4-7-1-1
 SECTION 4 UNDERCARRIAGE
Group 7 Track

3
6, 7 3
1

3
6, 7

c
W105-03-07-006

W1J7-03-07-002

c- Chain Block
dCAUTION: Shoe (3) weight:
600 mm: 29 kg (64 lb)
750 mm: 36 kg (80 lb)
900 mm: 43 kg (95 lb)
4. Remove bolts (6) (8 used) and nuts (7) (8 used) from
shoes (3) (2 used) at the front and rear of master pin
(1). Remove shoes (3) (2 used).

j : 32 mm
5. Secure shoes (3) (2 used) at the front and rear of
master pin (1) by using chain blocks (c).

W4-7-1-2
 SECTION 4 UNDERCARRIAGE
Group 7 Track

Assembly of Special Tool (ST 1532) for Removal /

Installation of Master Pin

12
11

10
9

1
8

10
15

19

18
11 12
17
16
15
10
9

10 16
9
W1J7-03-07-001

8- Hydraulic Cylinder (ST 1512) 12 - Pusher (ST 1521) 15 - Extension (3 Kinds) 18 - Guide (ST 1525)
9- Screw (2 Used) (ST 1516) 13 - Handling Screw (ST 1514) 19 - Guide Pin (ST 1529)
10 - Nut (2 Used) (ST 1515) (ST 1530) 16 - Nut (2 Used) (ST 1515)
11 - Frame (ST 1513) 14 - Adapter (ST 1518) 17 - Pilot (ST 1517)

W4-7-1-3
 SECTION 4 UNDERCARRIAGE
Group 7 Track

Assembly of Special Tool (ST 1532) for Removal / 12. Install hoses (d) (2 used) of electric pump (ST 1531)
Installation of Master Pin to hydraulic cylinder (8).
The procedures for assembly of special tool (ST 1532) for
10
removal / installation of master pin are explained. Theses
are not unnecessary in case the special tool (ST 1532) 9
for removal / installation of master pin has already been
assembled.
8
IMPORTANT: Screws (9) (2 used) should be installed
to the hole of hydraulic cylinder (8) surely. In case
screws (9) (2 used) are not installed surely, they
may come off from hydraulic cylinder (8) when
removing and installing master pin (1).
6. Install screws (9) (2 used) to hydraulic cylinder (8). A

IMPORTANT: In case dimensions (A) of nuts (10) (2

used) are different, screw (9) may be deformed
when removing and installing master pin (1).
Install nuts (10) (2 used) so that dimensions (A)
from hydraulic cylinder (8) should be same.
7. Install nuts (10) (2 used) to screws (9) (2 used) so
that dimensions (A) from hydraulic cylinder (8) d
should be same.
W1J7-03-07-005

d CAUTION: Frame (11) weight: 74 kg (165 lb)

d- Hose
8. Install frame (11) to the nut (10) position of screws
(9) (2 used). Install nut (16).
9. Install extension (15) to hydraulic cylinder (8).

fNOTE: There are three kinds of extension (15). Their

dimensions are different. In case the stroke of hydraulic
cylinder (8) is insufficient when removing and installing
master pin (1), add other extensions (15).
10. Install pilot (17) and pusher (12) to extension (15).
11. Install adapter (14) to frame (11) with handling
screw (13).

W4-7-1-4
 SECTION 4 UNDERCARRIAGE
Group 7 Track

14
12

ST 1532

W1J7-03-07-004

ST 1532
9
W1J7-03-07-003
e- Nylon Sling

dCAUTION: Special tool (ST 1532) for removal /

installation of master pin weight: 150 kg (335 lb)
13. Attach nylon slings (e) onto screw (9) (2 places) of
special tool (ST 1532) for removal / installation of
master pin. Hoist special tool (ST 1532) for removal
/ installation of master pin. Move special tool (ST
1532) for removal / installation of master pin to
the master pin (1) mounting position. Adjust nylon
slings (e) so that the height of adapter (14) and
pusher (12) in special tool (ST 1532) for removal /
installation of master pin should be aligned with
that of master pin (1).

W4-7-1-5
 SECTION 4 UNDERCARRIAGE
Group 7 Track

16
10
14 9
12
8

1 17

15
ST 1532

W1J7-03-07-004

W1J7-03-07-005

IMPORTANT: Align the center of adapter (14) 15. Extend hydraulic cylinder (8) and push out master
and pusher (12) with that of master pin (1). pin (1).
When removing master pin (1) with the centers
misaligned, special tool (ST 1532) for removal / fNOTE: In case the stroke of hydraulic cylinder (8) is
installation of master pin may be deformed and insufficient, retract it once and add shorter extensions
damaged. (15) between extension (15) and pilot (17). In case the
stroke of hydraulic cylinder (8) is insufficient in spite
14. Fit the end of master pin (1) to the adapter (14) hole
of using extensions (15) (3 used), move the mounting
of special tool (ST 1532) for removal / installation of
position of nuts (10, 16) (2 used for each) to the hydraulic
master pin. Adjust hydraulic cylinder (8) and push
cylinder (8) side.
pusher (12) to the end of master pin (1). Check the
mounting condition of master pin (1) and special
tool (ST 1532) for removal / installation of master
pin.

W4-7-1-6
 SECTION 4 UNDERCARRIAGE
Group 7 Track

90˚ to 110˚

f
f- Stand
ST 1532
9
M104-07-067
W1J7-03-07-003
c- Chain Block

16. Remove special tool (ST 1532) for removal /

installation of master pin and chain blocks (c).
17. Set the angle between boom and arm to 90˚ to
110˚. Lower the boom with the round bottom
contacting with the ground. Raise the track frame.
Place stand (f ) under the track frame and support
the machine at this time.
W105-03-07-011
dCAUTION: The track assembly weight:
600 mm: 2640 kg (5830 lb)
750 mm: 3030 kg (6680 lb)
900 mm: 3370 kg (7430 lb)
18. Slowly operate the travel control lever for the track
to be removed to the reverse position and extend
the track.

W4-7-1-7
 SECTION 4 UNDERCARRIAGE
Group 7 Track

20

a b

W105-03-07-014

21

W105-03-07-013

a- Front Idler Side

b- Sprocket (20) Side

W105-03-07-015

Installation
1. Raise the machine. Set the track under the machine
so that sprocket (20) should mesh with the track
end.Check the direction of the track at this time.

dCAUTION: The track assembly weight:

600 mm: 2640 kg (5830 lb)
750 mm: 3030 kg (6680 lb)
900 mm: 3370 kg (7430 lb)
2. Hoist and mesh the track with the claws of sprocket
(20)
3. With the machine raised, slowly operate the travel
control lever for the track to be installed in the
forward direction. Wind the track while rotating
travel device (21).

W4-7-1-8
 SECTION 4 UNDERCARRIAGE
Group 7 Track

c
W1J7-03-07-007

W1J7-03-07-002

4. Wind track link (22) until the connection part of c- Chain Block
track link (22) reaches the front idler (2) side.
IMPORTANT: The taper part of guide pin (19) should
19
be inserted first.
5. Secure shoes (3) (2 used) by using chain blocks (c). 12 18
Fit the master pin (1) mounting hole of track link 17 22
(22) by using chain blocks (c). Install guide pin (19) 15
to the master pin (1) mounting hole.

1
ST 1532
W1J7-03-07-006

6. Install extension (15), pilot (17), pusher (12), and

master pin (1) to special tool (ST 1532) for removal /
installation of master pin.

fNOTE: Master pin (1) is symmetrical. The installing

direction is not specified.
7. Install guide (18) to master pin (1).

W4-7-1-9
 SECTION 4 UNDERCARRIAGE
Group 7 Track

19
e 14

22

W1J7-03-07-006
ST 1532
9
W1J7-03-07-003
e- Nylon Sling

dCAUTION: Special tool (ST 1532) for removal /

installation of master pin weight: 150 kg (335 lb)
8. Attach nylon slings (e) onto screw (9) (2 places) of
special tool (ST 1532) for removal / installation of
master pin. Hoist special tool (ST 1532) for removal
/ installation of master pin. Move special tool (ST
1532) for removal / installation of master pin to the
master pin (1) mounting position of track link (22).
Adjust nylon slings (e) so that the hole height of
adapter (14) in special tool (ST 1532) for removal /
installation of master pin should be aligned with the
master pin (1) mounting hole of track link (22).

W4-7-1-10
 SECTION 4 UNDERCARRIAGE
Group 7 Track

16
10
19 9
14

17
22
15
1

W1J7-03-07-006

W1J7-03-07-005

IMPORTANT: Align the center of adapter (14) and 10. Extend hydraulic cylinder (8) and insert master pin
master pin (1) with that of the master pin (1) (1) until guide pin (19) is pushed out.
mounting hole. When installing master pin (1)
with the centers misaligned, special tool (ST 1532) fNOTE: In case the stroke of hydraulic cylinder (8) is
for removal / installation of master pin may be insufficient, retract it once and add shorter extensions
deformed and damaged. (15) between extension (15) and pilot (17). In case the
stroke of hydraulic cylinder (8) is insufficient in spite
9. Fit the end of guide pin (19) to the adapter (14) hole
of using extensions (15) (3 used), move the mounting
of special tool (ST 1532) for removal / installation of
position of nuts (10, 16) (2 used for each) to the hydraulic
master pin. Adjust hydraulic cylinder (8) and push
cylinder (8) side.
master pin (1) until it comes in contact with guide
pin (19). Check the mounting condition of guide
pin (19) and special tool (ST 1532) for removal /
installation of master pin.

W4-7-1-11
 SECTION 4 UNDERCARRIAGE
Group 7 Track

3
6, 7

c
6, 7
3

ST 1532
22
W1J7-03-07-003 W105-03-07-006
c- Chain Block

11. Remove special tool (ST 1532) for removal /

installation of master pin and chain blocks (c) from
track link (22).

dCAUTION: Shoe (3) weight:

600 mm: 29 kg (64 lb)
750 mm: 36 kg (80 lb)
900 mm: 43 kg (95 lb)
12. Install shoes (3) (2 used) with nuts (7) (8 used) and
bolts (6) (8 used).

j : 32 mm

m : 1370 N·m (137 kgf·m, 1010 lbf·ft)

W4-7-1-12
 SECTION 4 UNDERCARRIAGE
Group 7 Track

5 4

W800-03-07-027

WXXX-03-07-001

a- Track Sag Specification

13. Tighten valve (4). Apply grease through grease

fitting (5) and adjust the track tension.

j : 24 mm

m : 150 N·m (15 kgf·m, 111 lbf·ft)

fNOTE: Track sag specification (A)

 ZX470-5B, 470H-5B: 380 to 430 mm (15.0 to 16.9 in)
 ZX470LC-5B, 470LCH-5B, 470LCR-5B: 390 to 440 mm
(15.4 to 17.3 in)

W4-7-1-13
 SECTION 4 UNDERCARRIAGE
Group 7 Track

10
9
19

12 18
17
8
15

10
9

W1J7-03-07-006

14. Remove extension (15), pilot (17), pusher (12), and W1J7-03-07-005
d
guide (18) from special tool (ST 1532) for removal /
installation of master pin. d- Hose

15. Remove hoses (d) (2 used) of electric pump (ST

1531) from hydraulic cylinder (8). Disassemble
special tool (ST 1532) for removal / installation
of master pin in the reverse way as assembly
procedures on W4-7-1-4 when disassembling and
keeping it.

fNOTE: Put the matching marks on screw (9) and nut

(10) for assembly before removing nuts (10) (2 used)
from screws (9) (2 used).

W4-7-1-14
MEMO
MEMO
SECTION 5

FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Removal and Installation of Front
Attachment..................................................................W5-1-1-1
Removal and Installation of Bushing.......................W5-1-2-1
Group 2 Cylinder
Removal and Installation of Boom Cylinder..........W5-2-1-1
Removal and Installation of Arm Cylinder.............W5-2-2-1
Removal and Installation of Bucket Cylinder........W5-2-3-1
Disassembly of Boom Cylinder..................................W5-2-4-1
Assembly of Boom Cylinder........................................W5-2-4-4
Disassembly of Arm Cylinder......................................W5-2-5-1
Assembly of Arm Cylinder...........................................W5-2-5-4
Disassembly of Bucket Cylinder................................W5-2-6-1
Assembly of Bucket Cylinder......................................W5-2-6-4
Group 3 Hose Rupture Valve
Removal and Installation of Hose Rupture Valve for
Boom Cylinder............................................................W5-3-1-1
Removal and Installation of Hose Rupture Valve for
Arm Cylinder...............................................................W5-3-2-1
Structure of Hose Rupture Valve for
Boom Cylinder............................................................W5-3-3-1
Structure of Hose Rupture Valve for Arm Cylinder
(Bottom Side)..............................................................W5-3-3-3
Structure of Hose Rupture Valve for Arm Cylinder
(Rod Side).....................................................................W5-3-3-5

JAAW-5-1
(Blank)

JAAW-5-2
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

Removal and Installation of Front

Attachment
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected.In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
W1J1-04-01-001
1. Park the machine on a solid and level surface. Fully
retract the arm and bucket cylinders and lower the
2
front attachment onto the ground.
2. Disconnect plugs of the boom light between front
attachment and main frame.
3. Disconnect lubrication hose (2) from the rod side of
boom cylinder (1). (2 places at right and left) 1

j : 19 mm
4. Remove bolts (5) (4 used), washer (3), and stopper
(4). (2 places at right and left)
W105-04-01-002
j : 30 mm

dCAUTION: Boom cylinder weight: 430 kg (950 lb)

dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
1

such as goggles, helmets, etc in order to prevent 3

personal injury. 4

5. Hoist and hold boom cylinder (1). Push out pin (6) to 5
the position where the cylinder rod can be removed
by tapping by using a bar and a hammer.

fNOTE: When pin (6) cannot be removed, start the

6
engine, operate the boom control lever, and adjust the
rod end pin (6) hole on boom cylinder (1).

W166-04-01-005

W5-1-1-1
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

6. Insert plate (a) between boom cylinder (1) and the

main frame. Lower boom cylinder (1). 1

7. Remove another boom cylinder (1) in the same way

as step 5 to step 6.
8. Start the engine. Operate the boom control lever
and retract the rod of boom cylinder (1). In order
not to extend the rod, pass a wire through the rod
hole and secure the rod to the cylinder tube. Stop
the engine.

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
a
dCAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.) a- Plate W157-04-01-005
9. Remove socket bolts (12) (16 used). Disconnect
hoses (11) (4 used).

l : 12 mm
10. Remove bolts (13) (2 used) and plate (14) from
boom foot pin (15).

j : 30 mm

12
11

11 M1J1-07-049

13

14
15
W105-04-01-007

W5-1-1-2
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

dCAUTION: Front attachment (standard) weight:

8000 kg (17700 lb)
11. Attach wire ropes onto the boom. Hoist and hold
the front attachment.
12. Screw threaded rod (b) of the special tool (ST 1975)
into the hole on boom foot pin (15). Screw nut (c)
and remove boom foot pin (15).

j : 36 mm
13. Hoist the front attachment and the machine
backward.
14. Place wooden blocks under the front attachment. W105-04-01-008
Lower the front attachment.

15

ST 1975

b- Threaded Rod c- Nut

W105-04-01-022

W157-04-01-004

W5-1-1-3
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

Installation

dCAUTION: Front attachment (standard) weight:

8000 kg (17700 lb)
1. Hoist the front attachment and fit the boom foot
pin (15) holes on the main frame and boom. Insert
shims into left and right sides of the boom foot.
Adjust the clearance within 1.5 mm.

fNOTE: Shim Thickness: 3.2 mm, 2.3 mm, 1.0 mm

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury. W157-04-01-004
2. Install boom foot pin (15) by using a hammer. Install
plate (14) with bolts (13) (2 used).

j : 30 mm

m : 400 N·m (40 kgf·m, 300 lbf·ft)

3. Connect hoses (11) (4 used) with socket bolts (12) 13
(16 used).

l : 12 mm
14
m : 140 N·m (14 kgf·m, 103 lbf·ft)
15
W105-04-01-007

12
11

11 M1J1-07-049

W5-1-1-4
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

dCAUTION: Boom cylinder weight: 430 kg (950 lb)

IMPORTANT: Add hydraulic oil to the specified level.
Start the engine and check the hose connections
for any oil leaks.
1
4. Hoist boom cylinder (1). Start the engine.Extend
boom cylinder (1) and fit the pin (6) holes on the
boom and boom cylinder (1).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
5. Install pin (6) by using a hammer. Install boom
cylinder (1) on both sides. W157-04-01-006

6. Install washer (3) and stopper (4) with bolts (5) (4

used). (2 places at right and left) 1
j : 30 mm
3
m : 400 N·m (40 kgf·m, 300 lbf·ft) 4

7. Connect lubrication hose (2) to the rod side of 5

boom cylinder (1).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft) 6

8. Connect plugs of the boom light.

W166-04-01-005

W105-04-01-002

W5-1-1-5
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

9. Apply grease to boom foot side (e) and boom

cylinder rod side (d). d
e
10. After completing the work, add hydraulic oil to the
specified level.
11. Operate each cylinder to the stroke end several
times and bleed air from the circuit. Check for any
oil leaks of the hose connections.

d- Boom Cylinder Rod Side e- Boom Foot Side

W166-04-01-102

W5-1-1-6
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

IMPORTANT: When the arm has been removed from g 14 f

the boom, perform the following procedures
when installing the arm.
12. Install plate (14) to the right and left of arm (f ).
13. Insert shims between arm (f ) and plate (4). Adjust
the clearance within 1.5 mm.

fNOTE: Shim Thickness: 1.0 mm, 2.0 mm

14. Apply grease onto the joint pins of boom and arm
and the arm cylinder rod side by using a grease gun
after installing the arm.
IMPORTANT: As for handling of HN bushing for the
front attachment, check the followings.
Precautions when installing the bushing f- Arm g- Boom
When installing the bushing by using a hammer, the
W166-04-01-100
bushing may be damaged.Install the bushing by using a
press.

Precautions when reinforcing the arm h i

The heat when welding in order to reinforce the arm
may cause oil leakage from the bushing and decrease
lubrication performance.
When welding heat causes oil leakage of the bushing,
replace it.

h- Joint Pins of Boom and Arm

i- Arm Cylinder Rod Side
WJAA-05-01-002

W5-1-1-7
 SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment

(Blank)

W5-1-1-8
 SECTION 5 FRONT ATTACHMENT
Group1 Front Attachment

Removal and Installation of Bushing

d
c

b
a

W166-04-02-005
f

1 2 2 1 2 3

1 2 1

2
a W166-04-02-012

1 2 3

b
W166-04-02-013 c
W166-04-02-014

1 2 3 2 1 2 3

d W166-04-02-010
e W166-04-02-015 f W166-04-02-016

a- Bucket and Link A c- Boom and Arm e- Arm and Link B

b- Link A d- Boom and Main Frame f- Arm and Bucket

1- Dust Seal 2- Bushing 3- Spacer

W5-1-2-1
 SECTION 5 FRONT ATTACHMENT
Group1 Front Attachment

Removal
1. Remove dust seal (1) and bushing (2).

fNOTE: In case bushing (2) cannot be removed, burn off

it.

Installation
1. Cool bushing (2) by using dry ice.
2. Install bushing (2) and dust seal (1).

fNOTE: Install bushing (2) by using the tools below.

Tool for Bushing

a: Bucket Side..................................................... ST 2881

Link A Side...................................................... ST 2873

b: Link A................................................................ ST 2873

c: Arm.................................................................... ST 2877

d: Boom Side....................................................... ST 2877

Main Frame Side........................................... ST 2886

e: Arm.................................................................... ST 2882

f: Bucket Side..................................................... ST 2881

Arm Side.......................................................... ST 2873

W5-1-2-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Boom Cylinder

7 2
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected.In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the 1
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Disconnect hose (2) from boom cylinder (1).
8
6
j : 19 mm 5
4
dCAUTION:
lb)
Boom cylinder (1) weight: 430 kg (950 3 W166-04-01-003

2. Attach nylon slings onto boom cylinder (1). Hoist

and hold boom cylinder (1).

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
3. Remove bolts (3) (4 used), spring washers (4) (4
used), stopper (5), and washers (6) from the boom
cylinder (1) rod side. Push pin (8) in boom (7) by
using a hammer.

j : 30 mm
4. Place boom cylinder (1) on stand (a). Remove
another boom cylinder (1) in the same way.
5. Starts the engine. Operate the boom control lever
and retract boom cylinder (1). In order not to extend
the rod, pass a wire through the rod hole and secure
the rod to the cylinder tube.

a
1
a- Stand W105-04-02-035

W5-2-1-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

6. Stop the engine.

9
dCAUTION: Release any pressure in the hydraulic
circuit. (Refer to W1-5-1.)

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
7. Disconnect hoses (9) (4 used) from boom cylinders
(1) (2 used).

j : 41 mm

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
1 A

such as goggles, helmets, etc in order to prevent

W166-04-01-002
personal injury.
8. Remove bolt (10), spring washer (11), and washer
(12) from the cylinder bottom side. Remove pin (13). Section A
Remove spacer (14) and shims (15) (several).

j : 30 mm 13

dCAUTION:
lb)
Boom cylinder (1) weight: 430 kg (950

9. Remove boom cylinder (1). 10, 11, 12

10. Remove the other boom cylinder in the same way.

15 1 14 W162-04-01-025

1
W105-04-02-040

W5-2-1-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation
IMPORTANT: If a hammer is used to install the 9
bushing, the bushing may be damaged.Install the
bushing by using a press.

dCAUTION:
lb)
Boom cylinder (1) weight: 430 kg (950

1. Hoist boom cylinder (1). Fit the hole at boom

cylinder tube side to the mounting hole on the
main frame.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
1 A

such as goggles, helmets, etc in order to prevent

W166-04-01-002
personal injury.
2. Install shims (15) (several), spacer (14), and pin (13).
Install washer (12), spring washer (11), and bolt (10). Section A

j : 30 mm
13
m : 400 N·m (40 kgf·m, 300 lbf·ft)
3. Install the other boom cylinder in the same way.
4. Connect hoses (9) (4 used) to boom cylinders (1) (2 10, 11, 12
used).

j : 41 mm

m : 200 N·m (20 kgf·m, 148 lbf·ft)

15 1 14 W162-04-01-025

1
W105-04-02-040

W5-2-1-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

IMPORTANT: Check the hydraulic oil level. Start the

engine and check for any oil leaks. 7 2
5. Remove the wires from the boom cylinder (1) rod
side. Starts the engine. Operate the boom control
lever and fit the hole at cylinder rod side to the
mounting hole on boom. 1

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
6. Install pin (8). 8
6
7. Install washer (6), stopper (5), spring washers (4) (4 5
used), and bolts (3) (4 used). 4
3 W166-04-01-003

j : 30 mm

m : 400 N·m (40 kgf·m, 300 lbf·ft)

8. Connect hose (2) to boom cylinder (1).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

9. Install another boom cylinder (1) in the same way.
IMPORTANT: After completing the work, operate
boom cylinder (1) several times to the stroke end
and bleed air from the circuit.

a
1
a- Stand W105-04-02-035

W5-2-1-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Arm Cylinder

IMPORTANT: Cap the open ends in case the hoses 1
and pipes have been disconnected.In addition,
attach an identification tag onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Disconnect hose (8) from arm cylinder (1).
3
j : 19 mm 2
2. Place wooden block (3) between arm cylinder (1) W162-04-01-008
and boom (2).
3. Remove nuts (4) (2 used), bolt (5), and stopper (6)
from the arm cylinder (1) rod side. 8

j : 30 mm

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
7

such as goggles, helmets, etc in order to prevent

personal injury.
4. Remove pin (7).
1
5
5. Starts the engine.Operate the arm control lever and
retract arm cylinder (1). In order not to extend the
6
rod, pass a wire through the rod hole and secure the
rod to the cylinder tube.
4

W166-04-01-004

W5-2-2-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

6. Stop the engine.

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
1 9, 10 11, 12

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
7. Remove socket bolts (9) (8 used) and flanges (10) 13
(4 used). Disconnect hoses (11) (2 used) from arm
cylinder (1). Remove O-rings (12) (2 used) from
hoses (11) (2 used).

l : 12 mm
8. Disconnect hose (13) from arm cylinder (1).
W162-04-01-008
j : 19 mm

dCAUTION:
lb)
Arm cylinder (1) weight: 660 kg (1460

9. Attach nylon slings onto arm cylinder (1). Hoist and 1

hold arm cylinder (1).
15

d CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
16
such as goggles, helmets, etc in order to prevent
personal injury. 17
10. Remove nuts (14) (2 used), bolt (15), and stopper
(16) from the arm cylinder (1) bottom side. 14

j : 30 mm
11. Remove pin (17).
W166-04-01-006
12. Remove arm cylinder (1).

W5-2-2-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation
IMPORTANT: If a hammer is used to install the
1 9, 10 11, 12
bushing, the bushing may be damaged.Install the
bushing by using a press.

dCAUTION:
lb)
Arm cylinder (1) weight: 660 kg (1460
13
1. Hoist arm cylinder (1). Fit the hole at the cylinder
bottom side to the pin (17) mounting hole on the
boom.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury. W162-04-01-008

2. Install pin (17).

3. Install stopper (16), bolt (15), and nuts (14) (2 used)
to pin (17).
1
j : 30 mm
15
m : 400 N·m (40 kgf·m, 300 lbf·ft)
4. Connect hose (13) to arm cylinder (1). 16

j : 19 mm 17

m : 30 N·m (3 kgf·m, 22 lbf·ft) 14

5. Install O-rings (12) (2 used) to hoses (11) (2 used).
Connect hoses (11) (2 used) to arm cylinder (1) with
flanges (10) (4 used) and socket bolts (9) (8 used).
W166-04-01-006
l : 12 mm

m : 140 N·m (14 kgf·m 103 lbf·ft)

W5-2-2-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

dCAUTION:
lb)
Arm cylinder (1) weight: 460 kg (1020
1

IMPORTANT: Add hydraulic oil. Start the engine and

check for any oil leaks.
6. Remove the wires from the arm cylinder (1) rod side.
Hoist arm cylinder (1). Start the engine.Operate the
arm control lever and fit the hole at cylinder rod
side to the pin (7) mounting hole on arm.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
3
2
such as goggles, helmets, etc in order to prevent
W162-04-01-008
personal injury.
7. Install pin (7).
8. Install stopper (6), bolt (5), and nuts (4) (2 used) to
pin (7). 8

j : 30 mm
7
m : 400 N·m (40 kgf·m, 300 lbf·ft)
9. Connect hose (8) to arm cylinder (1).

j : 19 mm
1
m : 30 N·m (3 kgf·m 22 lbf·ft) 5

IMPORTANT: After completing the work, operate

6
arm cylinder (1) several times to the stroke end
and bleed air from the circuit.
4

W166-04-01-004

W5-2-2-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Removal and Installation of Bucket Cylinder

IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected.In addition,
attach an identification tag onto the connectors, 1
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

3
Removal
2
1. Insert wooden blocks (3) (2 used) under the arm (2) 3
top and between arm (2) and bucket cylinder (1).
W178-02-11-287
dCAUTION: Before removing pin (7), secure the
link by using a wire in order not to fall off.
4 5
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
2. Remove nuts (6) (2 used) and bolt (4). Remove pin
(7). Remove shims (5) (several). 6

j : 30 mm

W158-04-02-006
3. Starts the engine. Operate the bucket control lever
and retract bucket cylinder (1). In order not to
1
extend the rod, pass a wire through the rod hole
and secure the rod to the cylinder tube.

W102-04-02-005

W5-2-3-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

4. Stop the engine.

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
10,11 8 9 12

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

5. Remove socket bolts (8) (8 used) and flanges (9) (4 1

used). Disconnect hoses (10) (2 used) from bucket
cylinder (1). Remove O-rings (11) (2 used) from
hoses (10) (2 used).

l : 10 mm
6. Disconnect hose (12) from bucket cylinder (1). W166-04-01-009

j: 19 mm
1
d CAUTION:
(905 lb)
Bucket cylinder (1) weight: 410 kg

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
14

such as goggles, helmets, etc in order to prevent 16

personal injury.
7. Hoist bucket cylinder (1). Remove nuts (13) (2 used),
bolt (14), and stopper (15). Remove pin (16). 15
13
j : 30 mm
8. Remove bucket cylinder (1). W166-04-01-006

W5-2-3-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Installation
IMPORTANT: If a hammer is used to install the 10,11 8 9 12
bushing, the bushing may be damaged. Install the
bushing by using a press.

dCAUTION:
(905 lb)
Bucket cylinder (1) weight: 410 kg

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection, 1
such as goggles, helmets, etc in order to prevent
personal injury.
1. Hoist bucket cylinder (1). Fit the hole at cylinder
bottom side to the cylinder mounting hole on arm.
Install pin (16). W166-04-01-009
2. Install stopper (15), bolt (14), and nuts (13) (2 used)
to pin (16). 1
j : 30 mm

m : 400 N·m (40 kgf·m, 300 lbf·ft) 14

3. Connect hose (12) to bucket cylinder (1).
16
j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

15
4. Install O-rings (11) (2 used) to hoses (10) (2 used). 13
Connect hoses (10) (2 used) to bucket cylinder (1)
with flanges (9) (4 used) and socket bolts (8) (8
used). W166-04-01-006

l: 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W5-2-3-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

5. Remove the wires from the bucket cylinder (1) rod

side.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection, 1
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
3
6. Starts the engine. Operate the bucket control lever
and fit the hole at cylinder rod side to the holes of 2
link A (17) and link B (18). Install shims (5) (several) 3
and pin (7).
W178-02-11-287
7. Install bolt (4) and nuts (6) (2 used) to pin (7).

j : 30 mm 17 4 5

m : 400 N·m (40 kgf·m, 300 lbf·ft)

IMPORTANT: After completing the work, operate the
bucket cylinder several times to the stroke end
and and bleed air from the circuit.
6

7 18

W158-04-02-006

W102-04-02-005

W5-2-3-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Boom Cylinder

12

13

14
15
16
22
15
14

17

18
19
20

21
2

5
6

7
8
9
10

11

W1J1-04-02-020

1- Cylinder Rod 7- Backup Ring 13- Cushion Bearing 19- Steel Ball
2- Wiper Ring 8- U-Ring 14- Slide Ring (2 Used) 20- Set Screw
3- Socket Bolt (8 Used) 9- Ring 15- Slide Ring (2 Used) 21- Cylinder Tube
4- Cylinder Head 10- Bushing 16- Seal Ring 22- O-Ring
5- Backup Ring 11- Retaining Ring 17- Piston
6- O-Ring 12- Cushion Seal 18- Nut

W5-2-4-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Boom Cylinder 4. Install cylinder rod (1) to the special tool (ST 5908).
Put the matching marks on cylinder rod (1) and nut
 The procedure starts on the premise that the piping
(18).
and the bands securing the piping have been
ST 5908
removed.
d CAUTION: Boom cylinder weight: 430 kg (950 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.

W158-04-02-022

5. Cut away the crimped part (2 places) of set screw

(20) by using a hand drill. Remove set screw (20) and
steel ball (19).

l : 6 mm

W102-04-02-027 6. Remove nut (18) from cylinder rod (1) by using the
special tools (ST 5908, ST 3268). Remove piston (17)
2. Fully extend cylinder rod (1). Remove socket bolts from cylinder rod (1).
(3) (8 used) from cylinder head (4).
j : 125 mm
l : 19 mm
IMPORTANT: Slide rings (14, 15) cannot be reused.
IMPORTANT: Do not damage the sliding surface of Replace them with new ones when assembling.
cylinder rod (1).
7. Remove slide rings (14, 15) (2 used for each), seal
3. Tap and remove cylinder head (4) with cylinder ring (16), and O-ring (22) from piston (17).
rod (1) together from cylinder tube (21) by using a
plastic hammer.

W5-2-4-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

8. Remove cushion bearing (13), cushion seal (12), and

cylinder head (4) from cylinder rod (1).
9. Remove O-ring (6), backup ring (5), wiper ring (2),
retaining ring (11), ring (9), U-ring (8), and backup
ring (7) from cylinder head (4).
10. Remove bushing (10) from cylinder head (4) by
using the special tool (ST 2671).

fNOTE: Cylinder rod (1) outer diameter: 115 mm (4.5 in)

W5-2-4-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Boom Cylinder

2 8 9 3 4 6 21 1 13 14 15 16 15 14 18 20

17 22 19
12

7 10 11 5
a
W1J7-04-02-005

a- Slit

1- Cylinder Rod 7- Backup Ring 13- Cushion Bearing 19- Steel Ball
2- Wiper Ring 8- U-Ring 14- Slide Ring (2 Used) 20- Set Screw
3- Socket Bolt (8 Used) 9- Ring 15- Slide Ring (2 Used) 21- Cylinder Tube
4- Cylinder Head 10- Bushing 16- Seal Ring 22- O-Ring
5- Backup Ring 11- Retaining Ring 17- Piston
6- O-Ring 12- Cushion Seal 18- Nut

W5-2-4-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Boom Cylinder 5. Install U-ring (8) to cylinder head (4) with the lip
part facing to the bushing (10) side.
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing. 6. Install wiper ring (2) to cylinder head (4) by using
1. Install bushing (10) to cylinder head (4) by using the the special tool (ST 2671) and a plastic hammer.
special tool (ST 2671). 7. Install O-ring (6) and backup ring (5) to cylinder
head (4).
fNOTE: Cylinder rod (1) outer diameter: 115 mm (4.5 in)
2. Install retaining ring (11) to cylinder head (4). 8. Install O-ring (22) and seal ring (16) to piston (17) by
using the special tool (ST 2970). After installing seal
3. Install ring (9) to cylinder head (4) with the lip part ring (16), adjust seal ring (16) by using the special
facing to the bushing (10) side. tool (ST 2970).
4. Install backup ring (7) to cylinder head (4).
fNOTE: Cylinder tube (21) inner bore: 170 mm (6.7 in)

W5-2-4-5
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

9. Install slide rings (14, 15) (2 used for each) with their 15. Install ball (19) and set screw (20) to nut (18).Crimp
slits positioned 180° away facing to the opposite set screw (20) by using a punch (2 places).
each other.
l : 6 mm
10. Install the cylinder head (4) assembly to cylinder rod
(1) by using the special tool (ST 2671). m : 64 N·m (6.4 kgf·m, 47 lbf·ft)
11. Install cushion seal (12) to cylinder rod (1) with slit 16. Secure cylinder tube (21) on a workbench
(a) facing to the piston (17) side. horizontally.
12. Install cushion bearing (13) to cylinder rod (1) with IMPORTANT: Do not damage the rings.
the chamfered surface facing of cushion bearing 17. Fit to the center of cylinder tube (21) and insert the
(13) to the cylinder head (4) side. cylinder rod (1) assembly straight.
13. Install the piston (17) assembly to cylinder rod (1). 18. Install cylinder head (4) to cylinder tube (21) with
14. Fit the matching marks made when disassembling socket bolts (3) (8 used).
and install nut (18) to cylinder rod (1) by using the
j : 19 mm
special tools (ST 5908, ST 3268).
m : 1230 N·m (123 kgf·m, 910 lbf·ft)
j : 125 mm

m : 14200 N·m (1420 kgf·m, 10500 lbf·ft)

ST 5908

W158-04-02-022

W5-2-4-6
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Arm Cylinder

12
13

17

14
15
16
22
15
14

19 20 1
18

21

7
8
9
10
11
5
6

W1J1-04-02-021

1- Cylinder Rod 7- Backup Ring 13- Cushion Bearing 19- Steel Ball
2- Wiper Ring 8- U-Ring 14- Slide Ring (2 Used) 20- Set Screw
3- Socket Bolt (8 Used) 9- Ring 15- Slide Ring (2 Used) 21- Cylinder Tube
4- Cylinder Head 10- Bushing 16- Seal Ring 22- O-Ring
5- Backup Ring 11- Retaining Ring 17- Piston
6- O-Ring 12- Cushion Seal 18- Nut

W5-2-5-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Arm Cylinder 4. Install cylinder rod (1) to the special tool (ST 5908).
Put the matching marks on cylinder rod (1) and nut
 The procedure starts on the premise that the piping
(18).
and the bands securing the piping have been ST 5908
removed.
d CAUTION: Arm cylinder weight: 660 kg (1460 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.

W158-04-02-022

5. Cut away the crimped part (2 places) of set screw

(20) by using a hand drill. Remove set screw (20) and
steel ball (19).

l : 8 mm

W102-04-02-027 6. Remove nut (18) from cylinder rod (1) by using the
special tools (ST 3283, ST 5908). Remove piston (17)
2. Fully extend cylinder rod (1). Remove socket bolts from cylinder rod (1).
(3) (8 used) from cylinder head (4).
j : 135 mm
l : 22 mm
IMPORTANT: Slide rings (14, 15) cannot be reused.
IMPORTANT: Do not damage the sliding surface of Replace them with new ones when assembling.
cylinder rod (1).
7. Remove slide rings (14, 15) (2 used for each), seal
3. Tap and remove cylinder head (4) with cylinder ring (16), and O-ring (22) from piston (17).
rod (1) together from cylinder tube (21) by using a
plastic hammer.

W5-2-5-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

8. Remove cushion bearing (13), cushion seal (12), and

cylinder head (4) from cylinder rod (1).
9. Remove O-ring (6), backup ring (5), wiper ring (2),
retaining ring (11), ring (9), U-ring (8), and backup
ring (7) from cylinder head (4).
10. Remove bushing (10) from cylinder head (4) by
using the special tool (ST 8023).

fNOTE: Cylinder rod (1) outer diameter: 130 mm (5.1 in)

W5-2-5-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Arm Cylinder

2 8 9 3 4 6 21 1 13 14 15 16 15 14 18 20

17 22 19
12

7 10 11 5
a
W1J7-04-02-005

a- Slit

1- Cylinder Rod 7- Backup Ring 13- Cushion Bearing 19- Steel Ball
2- Wiper Ring 8- U-Ring 14- Slide Ring (2 Used) 20- Set Screw
3- Socket Bolt (8 Used) 9- Ring 15- Slide Ring (2 Used) 21- Cylinder Tube
4- Cylinder Head 10- Bushing 16- Seal Ring 22- O-Ring
5- Backup Ring 11- Retaining Ring 17- Piston
6- O-Ring 12- Cushion Seal 18- Nut

W5-2-5-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Arm Cylinder 5. Install U-ring (8) to cylinder head (4) with the lip
part facing to the bushing (10) side.
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing. 6. Install wiper ring (2) to cylinder head (4) by using
1. Install bushing (10) to cylinder head (4) by using the the special tool (ST 8023) and a plastic hammer.
special tool (ST 8023). 7. Install O-ring (6) and backup ring (5) to cylinder
head (4).
fNOTE: Cylinder rod (1) outer diameter: 130 mm (5.1 in)
2. Install retaining ring (11) to cylinder head (4). 8. Install O-ring (22) and seal ring (16) to piston (17) by
using the special tool (ST 2971). After installing seal
3. Install ring (9) to cylinder head (4) with the lip part ring (16), adjust seal ring (16) by using the special
facing to the bushing (10) side. tool (ST 2971).
4. Install backup ring (7) to cylinder head (4).
fNOTE: Cylinder tube (21) inner bore: 190 mm (7.5 in)

W5-2-5-5
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

9. Install slide rings (14, 15) (2 used for each) with their 15. Install ball (19) and set screw (20) to nut (18).Crimp
slits positioned 180° away facing to the opposite set screw (20) by using a punch (2 places).
each other.
l : 8 mm
10. Install the cylinder head (4) assembly to cylinder rod
(1) by using the special tool (ST 8023). m : 100 N·m (10 kgf·m, 74 lbf·ft)
11. Install cushion seal (12) to cylinder rod (1) with slit 16. Secure cylinder tube (21) on a workbench
(a) facing to the piston (17) side. horizontally.
12. Install cushion bearing (13) to cylinder rod (1) with IMPORTANT: Do not damage the rings.
the chamfered surface facing of cushion bearing 17. Fit to the center of cylinder tube (21) and insert the
(13) to the cylinder head (4) side. cylinder rod (1) assembly straight.
13. Install the piston (17) assembly to cylinder rod (1). 18. Install cylinder head (4) to cylinder tube (21) with
14. Fit the matching marks made when disassembling socket bolts (3) (8 used).
and install nut (18) to cylinder rod (1) by using the
j : 22 mm
special tools (ST 5908, ST 3283).
m : 1560 N·m (156 kgf·m, 1150 lbf·ft)
j : 135 mm

m : 27300 N·m (2730 kgf·m, 20100 lbf·ft)

ST 5908

W158-04-02-022

W5-2-5-6
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Bucket Cylinder

13

17

14
15
16
1
22
15
14

18 19 20

21

7
8
9
10
11
5
6

W1J1-04-02-022

1- Cylinder Rod 7- Backup Ring 14- Slide Ring (2 Used) 20- Set Screw
2- Wiper Ring 8- U-Ring 15- Slide Ring (2 Used) 21- Cylinder Tube
3- Socket Bolt (8 Used) 9- Ring 16- Seal Ring 22- O-Ring
4- Cylinder Head 10- Bushing 17- Piston
5- Backup Ring 11- Retaining Ring 18- Nut
6- O-Ring 13- Cushion Bearing 19- Steel Ball

W5-2-6-1
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Disassembly of Bucket Cylinder 4. Install cylinder rod (1) to the special tool (ST 5908).
Put the matching marks on cylinder rod (1) and nut
 The procedure starts on the premise that the piping
(18).
and the bands securing the piping have been
ST 5908
removed.
d CAUTION: Bucket cylinder weight: 410 kg (905
lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.

W158-04-02-022

5. Cut away the crimped part (2 places) of set screw

(20) by using a hand drill. Remove set screw (20) and
steel ball (19).

l : 8 mm
W102-04-02-027
6. Remove nut (18) from cylinder rod (1) by using the
special tools (ST 3276, ST 5908). Remove piston (17)
2. Fully extend cylinder rod (1). Remove socket bolts from cylinder rod (1).
(3) (8 used) from cylinder head (4).
j : 130 mm
l : 19 mm
IMPORTANT: Slide rings (14, 15) cannot be reused.
IMPORTANT: Do not damage the sliding surface of Replace them with new ones when assembling.
cylinder rod (1).
7. Remove slide rings (14, 15) (2 used for each), seal
3. Tap and remove cylinder head (4) with cylinder ring (16), and O-ring (22) from piston (17).
rod (1) together from cylinder tube (21) by using a
plastic hammer.

W5-2-6-2
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

8. Remove cushion bearing (13) and cylinder head (4)

from cylinder rod (1).
9. Remove O-ring (6), backup ring (5), wiper ring (2),
retaining ring (11), ring (9), U-ring (8), and backup
ring (7) from cylinder head (4).
10. Remove bushing (10) from cylinder head (4) by
using the special tool (ST 8036).

fNOTE: Cylinder rod (1) outer diameter: 120 mm (4.7 in)

W5-2-6-3
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Bucket Cylinder

2 8 9 3 4 6 21 1 13 14 15 16 15 14 18 20

17 22 19

7 10 11 5

W1J7-04-02-007

1- Cylinder Rod 7- Backup Ring 14- Slide Ring (2 Used) 20- Set Screw
2- Wiper Ring 8- U-Ring 15- Slide Ring (2 Used) 21- Cylinder Tube
3- Socket Bolt (8 Used) 9- Ring 16- Seal Ring 22- O-Ring
4- Cylinder Head 10- Bushing 17- Piston
5- Backup Ring 11- Retaining Ring 18- Nut
6- O-Ring 13- Cushion Bearing 19- Steel Ball

W5-2-6-4
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

Assembly of Bucket Cylinder 5. Install U-ring (8) to cylinder head (4) with the lip
part facing to the bushing (10) side.
IMPORTANT: Before assembling, apply hydraulic oil
onto parts in order to prevent them from seizing. 6. Install wiper ring (2) to cylinder head (4) by using
1. Install bushing (10) to cylinder head (4) by using the the special tool (ST 8036) and a plastic hammer.
special tool (ST8036). 7. Install O-ring (6) and backup ring (5) to cylinder
head (4).
fNOTE: Cylinder rod (1) outer diameter: 120 mm (4.7 in)
2. Install retaining ring (11) to cylinder head (4). 8. Install O-ring (22) and seal ring (16) to piston (17) by
using the special tool (ST 2970). After installing seal
3. Install ring (9) to cylinder head (4) with the lip part ring (16), adjust seal ring (16) by using the special
facing to the bushing (10) side. tool (ST 2970).
4. Install backup ring (7) to cylinder head (4).
fNOTE: Cylinder tube (21) inner bore: 170 mm (6.7 in)

W5-2-6-5
 SECTION 5 FRONT ATTACHMENT
Group 2 Cylinder

9. Install slide rings (14, 15) (2 used for each) with their 15. Secure cylinder tube (21) on a workbench
slits positioned 180° away facing to the opposite horizontally.
each other.
IMPORTANT: Do not damage the rings.
10. Install the cylinder head (4) assembly to cylinder rod 16. Fit to the center of cylinder tube (21) and insert the
(1) by using the special tool (ST 2810). cylinder rod (1) assembly straight.
11. Install cushion bearing (13) to cylinder rod (1) with 17. Install cylinder head (4) to cylinder tube (21) with
the chamfered surface facing of cushion bearing socket bolts (3) (8 used).
(13) to the cylinder head (4) side.
l : 19 mm
12. Install the piston (17) assembly to cylinder rod (1).
13. Fit the matching marks made when disassembling m : 1140 N·m (114 kgf·m, 840 lbf·ft)
and install nut (18) to cylinder rod (1) by using the
special tools (ST 5908, ST 3276).

j : 130 mm

m : 20900 N·m (2090 kgf·m, 15400 lbf·ft)

ST 5908

W158-04-02-022

14. Install ball (19) and set screw (20) to nut (18).Crimp
set screw (20) by using a punch (2 places).

l : 8 mm

m : 100 N·m (10 kgf·m, 74 lbf·ft)

W5-2-6-6
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

Removal and Installation of Hose Rupture

Valve for Boom Cylinder
IMPORTANT: The hose and pipe contain hydraulic oil.
When removing the hose and pipe, receive oil with
a container in order to avoid spilling oil.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach identification tags onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Park the machine on a solid and level surface. Fully
retract the arm and bucket cylinders. Lower the
bucket to the ground.
2. Stop the engine.

W1J1-04-01-001

W5-3-1-1
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
1 13
3. Disconnect hoses (11) (2 used) from hose rupture
valves (3, 10).
4
2
j : 36 mm
4. Disconnect hoses (12) (6 used) from hose rupture 5 3
valves (3, 10). 6
7
j : 19 mm
5. Remove socket bolts (9) (4 used). Remove O-ring (8)
and pipe (13) from hose rupture valve (3).

l : 10 mm
6. Remove socket bolts (7) (4 used) and washers (6) (4 10 6 5 4
used). Remove cover (5), O-rings (4) (2 used), and 8 9 8 7
hose rupture valve (3) from boom cylinder (2). WJAA-05-03-001

l : 10 mm
7. Remove other hose rupture valve (10) and pipe (1) 11
in the same way as step 5 to step 6.
12
8. Remove the adapters with hose rupture valves (3,
10) attached if necessary. 12

WJAA-05-03-002

W5-3-1-2
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

Installation
1. Install all removed adapters to hose rupture valves
(3, 10).
2. Install O-rings (4) (2 used), hose rupture valve (3),
and cover (5) to boom cylinder (2) with washers (6) 1 13
(4 used) and socket bolts (7) (4 used).
4
l : 10 mm 2

m : 110 N·m (11 kgf·m, 81 lbf·ft) 5 3

6
3. Install O-ring (8) and pipe (13) with socket bolts (9)
(4 used). 7

l : 10 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

4. Install other hose rupture valve (10) and pipe (1) in
the same way as step 2 to step 3. 10 4
6 5
8 9 8 7
5. Connect hoses (12) (6 used) to hose rupture valves
(3, 10). WJAA-05-03-001

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft) 11

12
6. Connect hoses (11) (2 used) to hose rupture valves
(3, 10).
12
j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
7. Bleed air from the pilot pipings.

WJAA-05-03-002

W5-3-1-3
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

(Blank)

W5-3-1-4
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

Removal and Installation of Hose Rupture

Valve for Arm Cylinder
IMPORTANT: The hose and pipe contain hydraulic oil.
When removing the hose and pipe, receive oil with
a container in order to avoid spilling oil.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach identification tags onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal
1. Park the machine on a solid and level surface. Fully
retract the arm and bucket cylinders. Lower the
bucket to the ground.
2. Stop the engine.

W1J1-04-01-001

W5-3-2-1
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

1 2 3
d CAUTION: Bleed air from the hydraulic oil tank.
(Refer to W1-4-1.)

dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
12
11
3. Disconnect hoses (17, 18).
10
j : 19 mm 9
4. Disconnect the both ends of hoses (16, 14).

j : 27 mm
5. Disconnect the both ends of hoses (15, 13).

j : 36 mm
6. Remove socket bolts (4, 12) (4 used for each). 19
Remove O-rings (6, 10) and pipes (5, 11) from hose
rupture valves (3, 2).

l : 12 mm
7. Remove socket bolts (7, 1) (4 used for each). Remove
O-rings (8, 9) and hose rupture valves (3, 2) from 8 7 6 5 4
arm cylinder (19). WJAA-05-03-003

l : 12 mm 13 14 15 16 17
8. Remove the adapters with hose rupture valves (2, 3)
attached if necessary.

18 14 13 WJAA-05-03-004

W5-3-2-2
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

Installation 1 2 3

1. Install all removed adapters to hose rupture valves

(2, 3).
12
2. Install O-rings (8, 9) and hose rupture valves (3, 2) to
11
arm cylinder (19) with socket bolts (7, 1) (4 used for
each). 10
9
l : 12 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)

3. Install O-rings (6, 10) and pipes (5, 11) to hose
rupture valves (3, 2) with socket bolts (4, 12) (4 used
for each).

l : 12 mm 19

m : 140 N·m (14 kgf·m, 103 lbf·ft)

4. Connect the both ends of hoses (15, 13).

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft) 8 7 6 5 4

WJAA-05-03-003
5. Connect the both ends of hoses (16, 14).

j : 27 mm 13 14 15 16 17

m : 80 N·m (8 kgf·m, 59 lbf·ft)

6. Connect hoses (17, 18).

j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
7. Bleed air from the pilot pipings.

18 14 13 WJAA-05-03-004

W5-3-2-3
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

(Blank)

W5-3-2-4
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

Structure of Hose Rupture Valve for Boom

Cylinder

1 2 3 4 5 6

17 7
16 8
9
15 14 13 12 11 10
WJAA-05-03-005

W5-3-3-1
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

No. Part Name Q’ty Wrench Size Tightening Torque Remark

N·m (kgf·m)
1 Plunger 1
2 Spring 1
3 Plug 3
4 O-Ring 3
5 Spring 1
6 Plunger 1
7 Cover 1
8 Spring 1
9 Spring 1
10 Socket Bolt 4
11 O-Ring 1
12 Spacer 1
13 Spring Holder 1
14 Spool 1
15 Body 1
16 O-Ring 3
17 Plug 3

W5-3-3-2
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

Structure of Hose Rupture Valve for Arm

Cylinder (Bottom Side)

1 2 3

4
5
20
19

18
17
16
6
15
7
8

14 13 12 11 10 9
WJAA-05-03-006

W5-3-3-3
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

No. Part Name Q’ty Wrench Size Tightening Torque Remark

N·m (kgf·m)
1 Cover 2
2 O-Ring 2
3 Socket Bolt 12
4 Spring 1
5 Plunger 1
6 Spring 1
7 Spring 1
8 Cover 1
9 Socket Bolt 4
10 O-Ring 1
11 Spacer 1
12 Spring Holder 1
13 Spool 1
14 Body 1
15 Cover 1
16 O-Ring 1
17 O-Ring 1
18 Plug 1
19 Plunger 1
20 Spring 1

W5-3-3-4
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

Structure of Hose Rupture Valve for Arm

Cylinder (Rod Side)

1 2 3

4
5
20
19

18
17
16
6
15
7
8

14 13 12 11 10 9
WJAA-05-03-007

W5-3-3-5
 SECTION 5 FRONT ATTACHMENT
Group 3 Hose Rupture Valve

No. Part Name Q’ty Wrench Size Tightening Torque Remark

N·m (kgf·m)
1 Cover 2
2 O-Ring 2
3 Socket Bolt 12
4 Spring 1
5 Plunger 1
6 Spring 1
7 Spring 1
8 Cover 1
9 Socket Bolt 4
10 O-Ring 1
11 Spacer 1
12 Spring Holder 1
13 Spool 1
14 Body 1
15 Cover 1
16 O-Ring 1
17 O-Ring 1
18 Plug 1
19 Plunger 1
20 Spring 1

W5-3-3-6
MEMO
MEMO
SECTION 6

COUNTERWEIGHT REMOVAL/INSTALLATION DEVICE

CONTENTS
Group 1 Cylinder
Removal and Installation of Counterweight
Removal/Installation Cylinder..............................W6-1-1-1
Disassembly of Counterweight Removal / Installation
Cylinder . ......................................................................W6-1-2-1
Assembly of Counterweight Removal / Installation
Cylinder.........................................................................W6-1-2-4

JAAW-6-1
(Blank)

JAAW-6-2
 SECTION 6 COUNTERWEIGHT REMOVAL/INSTALLATION DEVICE
Group 1 Cylinder

Removal and Installation of Counterweight

Removal/Installation Cylinder

M116-06-019

IMPORTANT: The hose and pipe contain hydraulic oil.

When removing the hose and pipe, receive oil with
a container in order to avoid spilling oil.
IMPORTANT: Cap the open ends in case the hoses
and pipes have been disconnected. In addition,
attach identification tags onto the connectors,
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which
secure the hoses have been removed.

Removal

dCAUTION: Do not perform the work under the

counterweight.
1. Swing the upperstructure by 90 degrees and set the
machine position for inspection and maintenance.
(Refer to W1-6-1.)
2. Lower the counterweight. (Refer to Operator's
Manual.)

W6-1-1-1
 SECTION 6 COUNTERWEIGHT REMOVAL/INSTALLATION DEVICE
Group 1 Cylinder

1 2 3 4

5
11

10 9 WJAA-06-01-006

8 7 6 WJAA-06-01-008

dCAUTION: Counterweight removal/installation

cylinder (5) weight: 95 kg (210 Ib)
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
3. Attach nylon slings onto counterweight such as goggles, hard hat, etc. in order to prevent
removal/installation cylinder (5). Hoist and hold personal injury.
counterweight removal/installation cylinder (5). 10. Remove ring (6) and pin (7). Remove pin (8) by using
a bar and a hammer.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, 11. Remove counterweight removal/installation
such as goggles, hard hat, etc. in order to prevent cylinder (5).
personal injury. 12. Remove the adapters with counterweight removal/
4. Remove bolts (4) (2 used), lock plate (3), and retainer installation cylinder (5) attached if necessary.
(2). Remove pin (1) by using a bar and a hammer.

j : 19 mm
5. Set the pilot shut-off lever to the LOCK position.
6. Operate the counterweight pilot valve control lever
and fully retract counterweight removal/installation
cylinder (5). Stop the engine.
7. Secure the cylinder rod to the cylinder tube by
using wires.
8. Bleed air from the hydraulic oil tank. (Refer to W1-4-
1.)
9. Disconnect hoses (10, 11) and connector (9).

j : 27 mm

W6-1-1-2
 SECTION 6 COUNTERWEIGHT REMOVAL/INSTALLATION DEVICE
Group 1 Cylinder

1 2 3 4

5
11

10 9 WJAA-06-01-006

8 7 6 WJAA-06-01-008

Installation
1. Install all removed adapters to counterweight
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
removal/installation cylinder (5). such as goggles, hard hat, etc. in order to prevent
personal injury.
dCAUTION: Counterweight removal/installation
cylinder (5) weight: 95 kg (210 Ib) 8. Install pin (1) by using a hammer. Install retainer (2),
lock plate (3), and bolts (4) (2 used). Stop the engine.
2. Attach nylon slings onto counterweight removal/
installation cylinder (5). Hoist counterweight j : 19 mm
removal/installation cylinder (5).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, 9. Raise the counterweight. (Refer to Operator's
such as goggles, hard hat, etc. in order to prevent Manual.)
personal injury.
3. Install pin (8) by using a hammer. Install pin (7) and
ring (6).
4. Connect hoses (10, 11) and connector (9).

j : 27 mm

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

5. Remove the wires from the cylinder rod.
6. Start the engine. Set the engine control dial to the
slow idle position.
7. Operate the counterweight pilot valve control lever.
Fit the pin (1) holes of counterweight removal/
installation cylinder (5).

W6-1-1-3
 SECTION 6 COUNTERWEIGHT REMOVAL/INSTALLATION DEVICE
Group 1 Cylinder
(Blank)

W6-1-1-4
 SECTION 6 Counterweight Removal / Installation Device
Group 1 Cylinder

Disassembly of Counterweight Removal /

Installation Cylinder

15
2
14

15
17
16
17
4

1 12

7
6
8

11

10

13

18 19

WJBA-06-02-001

1- Cylinder Tube 6- Seal Ring 11- Backup Ring 16- O-Ring

2- Cylinder Rod 7- Backup Ring 12- O-Ring 17- Backup Ring (2 Used)
3- Cylinder Head 8- Ring 13- Piston 18- Steel Ball
4- Wiper Ring 9- Bushing 14- Seal Ring 19- Set Screw
5- Retaining Ring 10- O-Ring 15- Slide Ring (2 Used)

W6-1-2-1
 SECTION 6 Counterweight Removal / Installation Device
Group 1 Cylinder

Disassembly of Counterweight Removal / IMPORTANT: Pull out cylinder rod (2) straight in
Installation Cylinder order not to damage the sliding surface.
 The procedure starts on the premise that the piping 3. Loosen cylinder head (3) by using hook wrench
and the bands securing the piping have been (b) with the protective cover on cylinder rod (2).
removed. Remove the cylinder rod (2) assembly from cylinder
tube (1).
d CAUTION: Counterweight removal / installation
cylinder weight: 100 kg (ZX470-5B), 120 kg Diameter of cylinder head (3): 160 mm
(ZX670LC-5B)
1. Secure the pin mounting part (clevis part) of b
cylinder tube (1) in a vise horizontally. Drain off
hydraulic oil from the cylinder.
IMPORTANT: Lock washer (a) in cylinder head (3)
1
forms an integral part with cylinder tube (1). Do
not damage cylinder tube (1) and cylinder head
(3) when bending and extending lock washer (a).
2. Pull out cylinder rod (2) about 200 mm from
cylinder tube (1). Install a protective cover to
cylinder rod (2). Extend lock washer (a) in cylinder
head (3) by using a chisel and a hammer.
2 3
W506-04-02-004
b- Hook Wrench

4. Secure cylinder rod (2) on the special tool (ST 5908).

a

ST 5908

2 3
W158-04-02-022
W506-04-02-003

5. Cut away the crimped part by using a hand drill.

a- Lock Washer Remove set screw (19). Remove steel ball (18).

fNOTE: Set screw (19) has been crimped by using a

punch (2 places) after installing.
l : 6 mm

W6-1-2-2
 SECTION 6 Counterweight Removal / Installation Device
Group 1 Cylinder

6. Remove the piston (13) assembly from cylinder rod

(2).
7. Remove cylinder head (3) from cylinder rod (2).
8. Remove O-ring (10), retaining ring (5), wiper ring (4),
ring (8), seal ring (6), backup ring (7), and O-ring (12)
from cylinder head (3).
9. Remove bushing (9) from cylinder head (3) by using
the special tool (ST 8020).

fNOTE: Outer diameter of cylinder rod (1): 85 mm

W6-1-2-3
 SECTION 6 Counterweight Removal / Installation Device
Group 1 Cylinder

Assembly of Counterweight Removal /

Installation Cylinder

3 12 6 8 11 10 9 2 1 13 15 14 17 19
4
5

7 16 18

WJBA-06-02-002

1- Cylinder Tube 6- Seal Ring 11- Backup Ring 16- O-Ring

2- Cylinder Rod 7- Backup Ring 12- O-Ring 17- Backup Ring (2 Used)
3- Cylinder Head 8- Ring 13- Piston 18- Steel Ball
4- Wiper Ring 9- Bushing 14- Seal Ring 19- Set Screw
5- Retaining Ring 10- O-Ring 15- Slide Ring (2 Used)

W6-1-2-4
 SECTION 6 Counterweight Removal / Installation Device
Group 1 Cylinder

Assembly of Counterweight Removal / Installation 4. Install seal ring (6) to cylinder head (3) with the lip
Cylinder part of seal ring (6) facing to the bushing (9) side.
IMPORTANT: Before assembling, apply hydraulic oil 5. Install wiper ring (4) and retaining ring (5) to
onto parts in order to prevent them from seizing. cylinder head (3) by using the special tool (ST 8020)
1. Install bushing (9) to cylinder head (3) by using the and a plastic hammer.
special tool (ST 8020). 6. Install O-ring (10) and backup ring (11) to cylinder
head (3).
fNOTE: Outer diameter of cylinder rod (2): 85 mm
2. Install ring (8) to cylinder head (3) with the lip part 7. Install O-ring (12) to cylinder head (3).
of ring (8) facing to the bushing (9) side. 8. Install seal ring (14) to piston (13) by using the
3. Install backup ring (7) to cylinder head (3). special tool (ST 2970). After installing seal ring (14),
adjust seal ring (14) by using the special tool (ST
2970).

fNOTE: Inner diameter of cylinder tube (1): 130 mm

W6-1-2-5
 SECTION 6 Counterweight Removal / Installation Device
Group 1 Cylinder

9. Install slide rings (15) (2 used) to piston (13). At this 15. Secure cylinder tube (1) on a workbench
time, the slits of slide rings (15) (2 used) should be horizontally.
positioned 180 ° away each other.
IMPORTANT: Do not damage the rings.
10. Install O-ring (16) and backup ring (17) to piston 16. Fit the cylinder rod (2) assembly to the center of
(13). cylinder tube (1) and install it straight.
11. Install the cylinder head (3) assembly to cylinder rod 17. Secure cylinder tube (1) in a vise horizontally. Install
(2) by using the special tool (ST 2810). the cylinder rod (2) assembly to cylinder tube (1).
12. Install the piston (13) assembly to cylinder rod (2). 18. Tighten cylinder head (3) to cylinder tube (1) by
13. Install cylinder rod (2) to the special tool (ST 5908). using hook wrench (a). Bend the lock washer in
order not to loosen.
14. Install steel ball (18) and set screw (19) to piston
(13). Crimp set screw (19) by using a punch (2 Diameter of cylinder head (3): 160 mm
places).

l : 6 mm

m : 19.6±2 N·m (2±0.2 kgf·m)

a

ST 5908

1
W506-04-02-019
W158-04-02-022 a- Hook Wrench

W6-1-2-6
MEMO
MEMO
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com

SERVICE MANUAL REVISION REQUEST FORM

COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:
FAX: (Located at the bottom center in the page. If two or more revisions
are requested, use the comment column)
E-mail:

YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.

REPLY:

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