INTRODUCTION

TO THE READER

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

ADDITIONAL REFERENCES

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

MANUAL COMPOSITION

• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.

• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER

• Each page has a number, located on the center

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

Example : T 1-3-5

Consecutive Page Number for Each Group

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

IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS

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

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

UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

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

IN-02
 SAFETY
RECOGNIZE SAFETY INFORMATION

• 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.

001-E01A-0688 SA-688

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the

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

• DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious
injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
• Some safety signs don’t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine. SA-1223

• CAUTION also calls attention to safety messages in this

manual.

• To avoid confusing machine protection with personal

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

• NOTE indicates an additional explanation for an

element of information.

002-E01C-1223

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). SA-003

• Learn how to operate the machine and its controls

correctly and safely.

• Allow only trained, qualified, authorized personnel to

operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair

its function and/or safety and affect machine life.

• 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.
003-E01C-0003

PREPARE FOR EMERGENCIES

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

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

• Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
• Be sure to check and service the fire extinguisher at
regular intervals following instructions in the fire extin-
guisher operation manual to maintain it in good operat-
ing condition.
SA-437
• Establish emergency procedure guidelines to cope
with fires and accidents.
• Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone.
004-E01B-0437

SA-2
 SAFETY
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment

appropriate to the job.

You may need:

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

• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
005-E01B-0438

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment

or loss of hearing.

• Wear a suitable hearing protective device such as

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

SA-434
006-E01A-0434

INSPECT MACHINE

• Inspect your machine carefully each day or shift by

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

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

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

007-E01A-0435 SA-435

SA-3
 SAFETY
SAFETY OPERATOR’S STATION

• Clean mud or grease from your shoes before getting

on the machine. Failure to do so may result in the pos-
sibility of your shoes slipping off the pedals, causing a
safety hazard.
• Don’t leave parts and/or tools lying around the opera-
tor’s seat. Always store them in their proper place.
• Never attach any thing such as a window hanger close
to the windowpane. Never place the bottle in the op-
erator’s station. They may cause a fire and impede
visibility.
• Don’t listen to music headphone or the radio, and don’t
use a cellular telephone in the operator’s station while
driving or operating the machine.
• Keep inflammable and/or explosive away from the op-
erator’s station.
• Be sure to put a cover on the ashtray to completely ex-
tinguish match and tobacco.
• Don’t leave a lighter anywhere in the operator’s station.
The lighter may explode when temperature in the op-
erator’s station increases.
524-E01A-0000

SA-4
 SAFETY
USE HANDHOLDS AND STEPS

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

• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps,
SA-439
and handrails when leaving the machine.

008-E01A-0439

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for the

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

• The seat should be adjusted whenever changing the

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

again.

009-E01A-0378

SA-5
 SAFETY
FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may

become injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning machine,
resulting in serious injury or death.

• Prior to operating the machine, thoroughly examine

webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
• Be sure to remain seated with the seat belt securely SA-237
fastened at all times when the machine is in operation
to minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every
three years regardless of its apparent condition.
010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm

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

hand signals before starting the machine.

011-E01A-0426

SA-6
 SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the

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

• Start the engine only when seated in the operator's

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

012-E01B-0444

JUMP STARTING

• Battery gas can explode, resulting in serious injury.

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

the instructions shown in the “OPERATING THE
ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
SA-032

• Failure to follow correct jump starting procedures

could result in a battery explosion or a runaway
machine.

013-E01A-0032

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being
struck by foreign objects and being thrown off the
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

014-E01B-0379

SA-7
 SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES

• For jobs involving multiple numbers of machines, provide

signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s direc-
tions.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO BE

DRIVEN

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

ous injury death.

• Before driving the machine, confirm the position of the

undercarriage in relation to the operator’s position. If
the travel motors are located in front of the cab, the
machine will move in reverse when travel ped-
als/levers are operated to the front.
017-E01A-0491 SA-491

SA-8
 SAFETY
DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the direc-
tion you wish to drive.

• Be sure to detour around any obstructions.

• Avoid crossing over obstacles. Scattered soil, and

broken pieces of rocks and/or metal in the vicinity
around the machine may be present. Keep people
away from the machine. SA-387

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

turn, possibly resulting in serious injury or death.

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

ing the direction of travel, approximately 200 to 300
mm (approximately 8 to 12 in) (A) above the ground.
• If the machine starts to skid or becomes unstable, im-
mediately lower the bucket to the ground and stop.

SA-388

SA-441

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

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

SA-589

019-E01C-0492

SA-9
 SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS

• Death or serious injury may result if you attempt to mount

or stop a moving machine.

To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch and the H/P mode switch off. SA-391

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

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

020-E02A-0493

SA-10
 SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS

• If any person is present near the machine when backing

or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP AND
SWING THE MACHINE. BE SURE THAT ALL
BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
• No machine motions shall be made unless signals are SA-384

clearly understood by both signalman and operator.

• Learn the meanings of all flags, signs, and markings
used on the job and confirm who has the responsibility
for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.

021-E01A-0494

SA-11
 SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN
JUMP FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when operating
on a grade, possibly resulting in serious injury or death.
SA-012
To avoid tipping:
• Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the
machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable.
SA-440
• 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.
025-E01B-0495

AVOID POWER LINES

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

attachments are not kept a safe distance from electric
lines.

• When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m (10 ft)
plus twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381

029-E01A-0381

SA-12
 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.
SA-014
• 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.

032-E01A-0014

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.

031-E01A-0432
SA-432

SA-13
 SAFETY
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle switch and H/P mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK SA-390

position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E08B-0390

HANDLE FLUIDS SAFELYҥ

ҥAVOID 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 SA-018

flammable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten all fuel and oil filler caps.

034-E01A-0496

SA-019

SA-14
 SAFETY
SAFETY TRANSPORTING

• The danger of tipping is present when loading/unloading

the machine onto/from a truck or trailer bed.

• Be sure to observe local regulations when transporting

the machine on public roads.
• Provide an appropriate truck or trailer for transporting
the machine.

Take the following precautions when loading / unloading

the machine: SA-395

1) Select firm level ground.

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

S035-E08A-0395

SA-15
 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. SA-028

3. Turn the auto-idle switch off.

4. Run the engine at slow idle speed without load for 5
minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by
moving the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK
position.
10. Allow the engine to cool.

• If a maintenance procedure must be performed with SA-527

the engine running, do not leave machine unattended.
• If the machine must be raised, maintain a 90 to 110°
angle between the boom and arm. Securely support
any machine elements that must be raised for service
work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or replace
as necessary. Refer to the section discussing that part
in the “MAINTENANCE” chapter of this manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
• Don’t operate the machine with a broken windowpane.
Failure to do so may cause personal injury. Be sure to
repair any broken windowpane before operating the
machine.
500-E02B-0497

SA-16
 SAFETY
• Be sure to use incombustible detergent oils to clean
parts. Never use flammable materials such as gaso-
line when cleaning the machine and/or parts.
• Illuminate your work area adequately but safety.
• Use a portable safety light for working inside or under
the machine
• Make sure that the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ig-
nite spilled fuel or oil.
SA-037
500-E02B-0497

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injuly.

• Before performing any work on the machine, attach a

“Do Not Operate” tag on the on the control lever

SA-287
S501-E01A-0287

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 SA-527
jack.
519-E01A-0527

SA-17
 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.

502-E01A-0026 SA-026

SA-18
 SAFETY
PREVENT PARTS FROM FLYING

• Grease in the track adjuster is under high pressure.

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

• Do not attempt to remove GREASE FITTING or

VALVE ASSEMBRY.
• As pieces may fly off, be sure to keep body and face
away from valve.
• Travel reduction gears are under pressure.
SA-344

• As pieces may fly off, be sure to keep body and face

away from AIR RELEASE PLUG to avoid injury. GEAR
OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen AIR
RELEASE PLUG to release pressure.

503-E01B-0344

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent

falling. Keep children and bystanders away from
storage areas.

504-E01A-0034 SA-034

USE TOOLS PROPERLY

• Use tools appropriate for the work to be done.

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

S522-E01A-0040

SA-040

SA-19
 SAFETY
PREVENT BURNS

Hot spraying fluids:

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

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

• To avoid possible injury from hot spraying water. DO

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

all pressure to be released before removing the cap.

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

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
SA-225
• Wait for the oil and components to cool before starting
any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and abrasion.
It is very difficult to gauge the extent of deterioration due
to aging, fatigue, and abrasion of rubber hoses by
inspection alone.

• Periodically replace the rubber hoses. (See the page

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

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

S506-E01A-0019

SA-20
 SAFETY
AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure

can penetrate the skin or eyes causing serious injury,
blindness or death.

• Avoid this hazard by relieving pressure before

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

to protect hands and body from high-pressure fluids.

Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.

SA-292

SA-044
507-E03A-0499

SA-21
 SAFETY
PREVENT FIRES

Check for Oil Leaks:

• Fuel, hydraulic oil and lubricant leaks can lead to fires.

• Check for oil leaks due to missing or loose clamps,

kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose oil-cooler
flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
• Do not bend or strike high-pressure lines. SA-019

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

Check for Shorts:

• Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight(8) to ten(10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
• Check before each shift or after eight(8) to ten(10)
hours operation for missing or damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc..

Clean up Flammables:
• Spilled fuel and oil, air conditioning refrigerant,
windshield washer and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.

• Prevent fires by inspecting and cleaning the machine

daily and by removing spilled or accumulated
flammables immediately.

Check Key Switch:

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

• Always check key switch function before operating the

machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
• If any abnormalities are found, be sure to repair them
before operating the machine.
508-E02B-0019

SA-22
 SAFETY
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.

508-E02A-0393

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 SA-393

be opened, break the front or rear window panes with the
emergency evacuation hammer to escape from the cab.
Refer the explanation pages on the Emergency Evacua-
tion Method.

518-E02A-0393 SS-1510

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

• If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
exten-sion to remove the exhaust fumes or open
doors and windows to bring enough outside air into the
area.

509-E01A-0016

SA-016

SA-23
 SAFETY
PRECAUTIONS FOR WELDING AND REPAIR
WORK WITH GRINDER

• Welding may generate gas and/or cause a fire danger.

• Perform welding in an open well-equipped location.

Keep flammable in a safe place.
• Have a qualified only person perform welding. Never
allow unqualified personnel to perform welding.
• Grinding may cause a fire danger. Keep flammable in a
safe place.

• After completing welding and/or grinding work, be sure to SA-818

check that no signs of fire such as a wisp of smoke are
present in or around the job site.
523-E01A-0818

AVOID HEATING NEAR PRESSURIZED FLUID

LINES

• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.

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

near pressurized fluid lines or other flammable
materials.
• Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install
temporary fire-resistant guards to protect hoses or SA-030
other materials before engaging in welding, soldering,
etc..

AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.

510-E01B-0030

SA-24
 SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING

• Hazardous fumes can be generated when paint is

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

• Avoid potentially toxic fumes and dust.

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

SA-029
• 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 soap and water before welding. Remove solvent
or paint stripper containers and other flammable
material from area. Allow fumes to disperse at least
15 minutes before welding or heating.

511-E01A-0029

SA-25
 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 operate the machine with the battery electrolyte
SA-032
level lower than the lowest allowable limit. Failure to do
so may cause the batteries to explode.

• Battery electrolyte is poisonous. If the battery should

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

• Be sure to wear eye protection when checking

electrolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM

SAFELY

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

burn.

• Refer to the freon container for proper use when

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

SA-405

513-E01A-0405

SA-26
 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 SA-309
what the risks are and how to do the job safely. Then
follow procedures and use recommended equipment.
• See your authorized dealer for MSDS’s (available only
in English) on chemical products used with your
machine.

515-E01A-0309

DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the

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 SA-226

damage the Earth’s atmosphere. Government regula-

tions may require a certified air conditioning service
center to recover and recycle used air conditioning re-
frigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center, or from your authorized dealer.

516-E01A-0226

SA-27
 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 re-
placed.
S517-E01A-0435

SA-4.35

SA-28
 SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
WORKSHOP MANUAL Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Shockless Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
TECHNICAL MANUAL (Operational Principle)
All information, illustrations and speci- SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
fications in this manual are based on Group 1 Specification Group 1 Pump Device
the latest product information available Group 2 Component Layout Group 2 Swing Device
at the time of publication. The right is SECTION 2 SYSTEM Group 3 Control Valve
reserved to make changes at any time Group 1 Control System Group 4 Pilot Valve
without notice. Group 2 Hydraulic System Group 5 Travel Device
Group 3 Electrical System Group 6 Others(Upperstructure)
Group 7 Others(Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
COPYRIGHT(C)1999
Group 1 Introduction Group 2 Component Layout
Hitachi Construction Machinery Co., Ltd.
Group 2 Engine Test Group 3 Troubleshooting A
Tokyo, Japan
Group 3 Excavator Test Group 4 Troubleshooting B
All rights reserved
Group 4 Hydraulic Component Test Group 5 Troubleshooting C
Group 5 Standard Group 6 Electrical System Inspection

←これ以下
記載しない
 SECTION 1
GENERAL INFORMATION

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

Group 2 Tightening Torque

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

183W-1-1
(Blank)

183W-1-2
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling

• Clean the Machine • Precautions for Disassembling

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

Prepare the necessary tools to be used and the area

for disassembling work.

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

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

• Bleeding Air from Travel Motor / Swing Motor

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

motor removed, fill the motor case with hydraulic
oil.

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

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes. W183-04-02-003
• Reposition the front attachment to check hydraulic
oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

W183-04-02-002

ᓡᒉ

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

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

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

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

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

uneven wear.

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

or hardening.

2. If incorrectly assembled, oil leakage or damage

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

(1) Clean the floating seal and seal mounting

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

(2) Clean the floating seal and seal mounting

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

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

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

b b

a=b aҐb
W110-03-05-004

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

1. Follow the precautions below to use nylon slings

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

lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or hitched
slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008

slings or pushing slings with a metal object.

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009

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

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

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

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Separation of W162-01-01-006
Scoring
Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

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

2. Dimension of new components or assemblies

adjusted to specification.

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

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

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

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

W1-1-8
 GENERAL / Tightening

TIGHTENING TORQUE SPECIFICATIONS

Bolt Dia. Wrench Torque

Descriptions Q’ty
(mm) Size mm N⋅m (kgf⋅m) (lbf⋅ft)
Engine cushion rubber mounting bolt(Fan side) 22 2 32 740 (75) (540)
(Pump side) 33 2 50 2550 (260) (1880)
Engine bracket mounting bolt 27 12 41 1030 (105) (760)
Radiator mounting bolt 27 4 30 1030 (105) (760)
Hydraulic oil tank mounting bolt 20 8 30 540 (55) (400)
Fuel tank mounting bolt 20 8 41 540 (55) (400)
ORS fittings for hydraulic hoses and piping 1-7/16-
12UNF 4 41 205 (21) (152)
1-11/16-
12UNF 4 50 340 (35) (251)
Pump mission mounting bolt 1/2-13UNF 16 19 118 (12) (87)
Pump device mounting bolt(Hexagon wrench) 20 12 17 390 (40) (290)
Pump mounting bolt(Hexagon wrench) 16 4 14 205 (21) (152)
Gear pump mounting bolt 27 2 22 137 (14) (102)
Control valve mounting bolt 20 8 30 390 (40) (290)
Swing control valve mounting bolt 16 3 17 49 (5) (36)
Swing device mounting bolt 27 32 41 1370 (140) (1010)
Swing motor mounting bolt 12 24 19 88 (9) (65)
Battery mounting nut 12 2 19 34 (3.5) (26)
Cab mounting bolt 16 8 24 265 (27) (195)
Cab bed mounting bolt 16 58 24 205 (21) (152)
Swing bearing mounting bolt(Upperstructure) 36 52 55 2750 (280) (2030)
(Undercarriage) 36 50 55 2750 (280) (2030)
Travel device mounting bolt 27 52 41 1370 (140) (1010)
Travel motor mounting bolt 18 8 27 295 (30) (215)
Sprocket mounting bolt 27 60 41 1370 (140) (1010)
Upper roller mounting bolt 20 24 30 540 (55) (400)
Lower roller mounting bolt 27 64 41 1370 (140) (1010)
Shoe mounting bolt 30 416 46 2840 (290) (2100)
Track guard mounting bolt 27 28 41 1370 (140) (1010)
Side frame mounting bolt 42 52 65 3920 (400) (2900)
Counterweight mounting bolt 45 6 63 3920 (400) (2900)
Oil cooler mounting bolt 24 4 36 930 (95) (690)
Front pin-retaining(Backhoe)
Stopper bolt A 20 12 30 390 (40) (290)
Stopper bolt B 20 12 30 390 (40) (290)
Front pin-retaining(Loading shovel)
Stopper bolt A 20 14 30 390 (40) (290)
Stopper bolt B 20 4 17 540 (55) (400)
Stopper bolt C 16 18 24 265 (27) (195)
Stopper bolt D 12 6 19 88 (9) (65)
Side cutter mounting bolt 33 12 50 2550 (260) (1880)

W1-2-1
 GENERAL / Tightening

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

dissolved into spindle oil) to bolts and
nuts to reduce friction coefficient of them.
2. Make sure bolt and nut threads are clean
before installing.
3. Apply LOCTITE to threads before
installilng and tightening swing bearing
mounting bolts and lower roller mounting
bolts.

W1-2-2
 GENERAL / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

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

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

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

correctly when assembling the machine or compo-

nents.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart

Hexagon T Bolt H Bolt, Socket bolt M Bolt
Bolt Wrench
Wrench
Dia. Size N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
Size
M 8 13 6 29.5 (3) (22) 19.5 (2) (14.5) 9.8 (1) (7.2)
M 10 17 8 64 (6.5) (47) 49 (5) (36) 19.5 (2) (14.5)
M 12 19 10 108 (11) (80) 88 (9) (65) 34 (3.5) (25.5)
M 14 22 12 175 (18) (130) 137 (14) (101) 54 (5.5) (40)
M 16 24 14 265 (27) (195) 205 (21) (152) 78 (8) (58)
M 18 27 14 390 (40) (290) 295 (30) (220) 118 (12) (87)
M 20 30 17 540 (55) (400) 390 (40) (290) 167 (17) (123)
M 22 32 17 740 (75) (540) 540 (55) (400) 215 (22) (159)
M 24 36 19 930 (95) (690) 690 (70) (505) 275 (28) (205)
M 27 41 19 1370 (140) (1010) 1030 (105) (760) 390 (40) (290)
M 30 46 22 1910 (195) (1410) 1420 (145) (1050) 540 (55) (400)
M 33 50 24 2550 (260) (1880) 1910 (195) (1410) 740 (75) (540)
M 36 55 27 3140 (320) (2310) 2400 (245) (1770) 930 (95) (690)

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

Bolt Tightening Order

When tightening two or more bolts, tighten them alter-

nately, as shown, to ensure even tightening.
Tighten from center and diago-
Equally tighten upper and lower alter- Tighten diagonally

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

4 5
2 13 8 5 2 3 10 11

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

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

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

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

ening of one bolt fully before RIGHT WRONG

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

Bend along edge sharply Do not bend it round

Nut and Bolt Locking

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

• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tight- Bend along edge sharply
W105-01-01-009
ening, not while loosening.
RIGHT RIGHT WRONG
• Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
Loosen WRONG
RIGHT

Tighten

W105-01-01-010

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

IMPORTANT: The torques given in the chart are for

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

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

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

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

2. Scratches or other damage to

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

Wrench Size Wrench Size mm Tightening Torque

Description mm
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30ѯmale 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,21.5)
22 22 39 (4.0,28.5)
27 27 93 (9.5,69)
32 32 137 (14.0,101)
36 36 175 (18.0,129)
41 41 205 (21.0,151)
37ѯfemale 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,21.5)
22 19 39 (4.0,28.5)
27 22 93 (9.5,69)
32 27 137 (14.0,101)
36 32 175 (18.0,129)
41 36 205 (21.0,151)
NOTE: Tightening torque of 37ѯmale coupling without union is similar
to tightening torque of 37ѯfemale.

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

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

seal pressure oil.

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

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

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

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (e) or sealing surface (10). mm mm
Damage to O-ring (6) will cause Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
oil leakage. 19 17 29.5 (3.0,21.5)
4. If nut (9) is loose and oil is leak- 22 19 69 (7.0,51)
ing, do not re-tighten nut (9). Re- 27 22 93 (9.5,69)
place O-ring (6) with a new one 32 27 137 (14.0,101)
and check that O-ring (6) is cor- 36 30,32 175 (18.0,129)
rectly seated in place, tighten nut 41 36 205 (21.0,151)
(9). 46 41 205 (21.0,151)

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

IMPORTANT: Be sure to confirm that the thread

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

Male Tapered Thread

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

• Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

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

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs de-

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

M114-07-043 M114-07-042

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

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

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

If hoses rub against each other, wear to the

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

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

Rubbing Against
Each Other

W105-01-01-013

WRONG RIGHT

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

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

To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deteriora-
tion, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regardless
of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Base Machine
Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Front Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years

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

and
gaskets, when replacing hoses.

W1-2-10
 SECTION 2
UPPERSTRUCTURE

CONTENTS
Group 1 Cab Disassemble Main Control Valve 2
Remove and Install Cab ...................... W2-1-1 (5-Spool Section) ............................. W2-4-16
Dimensions of the Cab Glass ............ W2-1-15 Assemble Main Control Valve 2
(5-Spool Section) ............................. W2-4-18
Group 2 Counterweight Disassemble Main Control Valve 1
Remove and Install Counterweight ...... W2-2-1 (4-Spool Section) ............................. W2-4-20
Assemble Main Control Valve 1
Group 3 Pump Device (4-Spool Section) ............................. W2-4-28
Remove and Install Pump Device ........ W2-3-1 Disassemble Main Control Valve 2
Disassemble Pump Transmission........ W2-3-4 (4-Spool Section) ............................. W2-4-34
Assemble Pump Transmission ............ W2-3-6 Assemble Main Control Valve 2
Disassemble Main Pump ..................... W2-3-8 (4-Spool Section) ............................. W2-4-36
Assemble Main Pump........................ W2-3-12 Disassemble Manifold ....................... W2-4-38
Maintenance Standard ...................... W2-3-14 Assemble Manifold ............................ W2-4-40
Disassemble Regulator(Main Pump) . W2-3-16 Disassemble Swing Control Valve 1... W2-4-42
Assemble Regulator(Main Pump) ...... W2-3-20 Assemble Swing Control Valve 1 ....... W2-4-48
Disassemble Pump of Disassemble Swing Control Valve 2... W2-4-52
Oil Cooler Fan Motor ....................... W2-3-26 Assemble Swing Control Valve 2 ....... W2-4-54
Assemble Pump of
Oil Cooler Fan Motor ....................... W2-3-30 Group 5 Swing Device
Maintenance Standard ...................... W2-3-32 Remove and Install Swing Device........ W2-5-1
Disassemble Regulator(Pump for Disassemble Swing Reduction Gear .... W2-5-6
Driving Oil Cooler Fan Motor) .......... W2-3-34 Assemble Swing Reduction Gear....... W2-5-12
Assemble Regulator(Pump for Disassemble Swing Motor ................. W2-5-16
Driving Oil Cooler Fan Motor) .......... W2-3-38 Assemble Swing Motor ...................... W2-5-20
Configuration of Pilot Pump ............... W2-3-44 Disassemble and Assemble Swing
Configuration of Pump for Parking Brake Releasing Valve ........ W2-5-24
Lubricating Pump Transmission ....... W2-3-46 Maintenance Standard....................... W2-5-26

Group 4 Control Valve

Remove and Install Control Valve ........ W2-4-1
Disassemble Main Control Valve 1
(5-Spool Section)............................... W2-4-6
Assemble Main Control Valve 1
(5-Spool Section)............................. W2-4-10

183W-2-1
Group 6 Pilot Valve Group 11 Oil Cooler Fan Motor
Remove and Install Right Pilot Valve ... W2-6-1 Remove and Install Oil Cooler
Remove and Install Left Pilot Valve ..... W2-6-5 Fan Motor ........................................ W2-11-1
Remove and Install Travel Pilot Valve. Disassemble Oil Cooler Fan Motor .... W2-11-4
Remove and Install Bucket Pilot Assemble Oil Cooler Fan Motor ......... W2-11-6
Valve(for Loading Shovel Only) .......... W2-6-9
Disassemble Front Pilot Valve ........... W2-6-14
Assemble Front Pilot Valve................ W2-6-18
Disassemble Travel Pilot Valve.......... W2-6-22
Assemble Travel Pilot Valve .............. W2-6-26
Disassemble Pilot Valve for
Bucket Opening / Closing ................ W2-6-32
Assemble Pilot Valve for
Bucket Opening / Closing ................ W2-6-34

Group 7 Pilot Shut-Off Valve

Remove and Install
Pilot Shut-off Valve ............................ W2-7-1
Disassemble Pilot Shut-off Valve ......... W2-7-4
Assemble Pilot Shut-off Valve.............. W2-7-6

Group 8 Shockless Valve

Remove and Install Front Attachment
Shockeless Valve .............................. W2-8-1
Disassemble and Assemble the
Shockless Valve ................................ W2-8-3

Group 9 Solenoid Valve

Remove and Install Solenoid Valve...... W2-9-1
Disassemble 2-Spool EHC Valve
(Boost Solenoid Valve, Control
Solenoid Valve for Oil Cooler Fan) ..... W2-9-4
Assemble 2-Spool EHC Valve
(Boost Solenoid Valve, Control
Solenoid Valve for Oil Cooler Fan) ..... W2-9-6
Configuration of Solenoid Valve ........... W2-9-8

Group 10 Signal Control Valve

Remove and Install Signal
Control Valve ................................... W2-10-1
Pilot Port ........................................... W2-10-3

183W-2-2
 UPPERSTRUCTURE / Cab

REMOVE AND INSTALL CAB

Removal

CAUTION: Seat (1) weight: 40 kg (90 Ib)

1

1. Remove seat mounting socket bolts (2) (4 used)

to remove seat (1). 2
ϖ 6 mm

W183-02-01-040

2. Remove bolts (8) (2 used) from rear side of the

cab. Remove bolts (3) (3 used) inside of rear box
(7).
ϖ 13 mm
4
5
7

8 6
3. Disconnect cigarette lighter connector (4), buzzer
cancel switch connector (5) and troubleshooting 9
switch connector (6), from inside of rear box (7).
Then remove rear box (7).

4. Remove duct (9) with facing up.

W183-02-01-002

W2-1-1
 UPPERSTRUCTURE / Cab
5. Remove caps (12) (5 used) from duct cover (11)
with a screwdriver. Remove screws (10) (5 used) 10
with a screwdriver to remove duct cover (11).
11

12

W183-02-01-039

IMPORTANT: If connector (13) of ECM wiring is

removed, the engine will fail to be
started. After cab has been removed,
remove ECM from the cab and
secure it on floor. Be sure to connect
connector (13).

6. Disconnect wiring connectors (13, 14 and 15) 13

from the right side in the cab. ECM

14

15

W183-02-01-018

16 17 18
7. Remove bolts (19) (4 used) and press duct (17)
into duct (18) to remove duct (17) from the duct
(16) side.
ϖ 17 mm

W183-02-01-003
19

W2-1-2
 UPPERSTRUCTURE / Cab
8. Remove bolts (25) (7 used) to remove bracket
(24). (2 places both left and right)
20
ϖ 17 mm
21 22

9. Disconnect DC-DC converter connector (27),

radio antenna connector (30) and step light
23
connector (31) from rear side of the cab.

10. Remove bolts (32) (4 used) to remove wiper

motor cover (33). 33
Disconnect wiper motor connector (22) and head 24
light connector (23). 32
25
ϖ 13 mm
26

11. Remove joint (21) from vinyl hose (20) for the
window washer. 27

NOTE: If joint (21) is not installed to vinyl hose (20),

it should be cut off with a cutter, etc.
Therefore, joint (part No. 4254237) should 31 30 29 28
be used when reassambling.
W183-02-01-035

Joint (21)

W183-02-01-036

12. Remove screws (28) (8 used) with a

screwdriver to remove covers (26 and 29).

W2-1-3
 UPPERSTRUCTURE / Cab
13. Remove bolts (34) (2 used) to remove the mirror.
Remove the chain.
ϖ 13 mm Mirror

34

Chain

CAUTION: Cab weight: 630 kg (1390 Ib)

M183-01-033

14. Attach wire ropes to the top of the cab.

15. Remove nuts (35) (10 used) and cab mounting W183-02-01-029

bolts (36) (6 used), lift and remove the cab by a

crane.
ϖ 17 mm
35
ϖ 24 mm
36

16. Remove screws (37) (8 used) with a screwdriver W183-02-01-001

to remove ECM from the cab. Secure the

removed ECM on floor and connect connector
(13).

13
ECM
37

W183-02-01-018

W2-1-4
 UPPERSTRUCTURE / Cab

Installation
1. Remove ECM connector which is secured on floor.
Install ECM on the cab with screws (37) (8 used).

13
ECM
37

CAUTION: Cab weight: 630 kg (1390 Ib)

W183-02-01-018

2. Attach wire rope to the top of the cab. Hoist and

install the cab by a crane.

W183-02-01-029

3. Secure the cab with nuts (35) (10 used) and

mounting bolts (36) (6 used).
ϖ 17 mm 35
ϖ 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
ϖ 24 mm 36
ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)

W183-02-01-001

4. Install the mirror with bolts (34) (2 used).

Attach the chain.
ϖ 13 mm Mirror
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
34

Chain

M183-01-033

W2-1-5
 UPPERSTRUCTURE / Cab
5. Install covers (26 and 29) with screws (28) (8
used).
20

21 22

6. Connect joint (21) to window washer vinyl hose

(20) in wiper motor cover (33). Connect harness
23
of wiper motor (22) and head light (23).

7. Install wiper motor cover (33) with bolts (32) (4

used). 33
ϖ 13 mm 24
32
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) 25
26
8. Connect DC-DC converter connector (27) radio
antenna connector (30) and step light connector
27
(31) at the rear side of the cab.

9. Install bracket (24) with bolts (25) (7 used). (2 places

both right and left)
31 30 29 28
ϖ 17 mm
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) W183-02-01-035

W2-1-6
 UPPERSTRUCTURE / Cab
10. Press duct (17) into duct (18) and insert duct (17)
into duct (16). Then tighten it with bolts (19) (4 used). 16 17 18
ϖ 17 mm
ϖ 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

W183-02-01-003
19

11. Connect cable connectors (13, 14 and 15) at right

in the cab.

13
ECM

14

15

W183-02-01-018

12. Install duct cover (11) with screws (10) (5 used).

Install caps (12) (5 used).
10

11

12

W183-02-01-039

W2-1-7
 UPPERSTRUCTURE / Cab

13. Install duct (9) at rear inside of the cab.

3

14. Connect the harness of cigarette lighter (4),

buzzer cancel switch (5) and troubleshooting
switch (6) in rear box (7). 4
5
7

15. Install rear box (7) with bolts (3) (3 used) and
8 6
(8) (2 used).
ϖ 13 mm
9
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W183-02-01-002

CAUTION: Seat (1) weight: 40 kg ( 90 Ib)

16. Install seat (1) with socket bolts (2) (4 used).

ϖ 6 mm
ϖ 20 N⋅m (2 kgf⋅m 14.5 Ibf⋅ft) 1

W183-02-01-040

W2-1-8
 UPPERSTRUCTURE / Cab

Remove cab bed

(only for loading shovel)
1. Remove pilot valve.
( Refer to Remove and Install Pilot Valve section
on page W2-6-1)
ϖ 13 mm, 17 mm, 19 mm, 22 mm

W178-02-07-002

2. Remove pilot shut-off valve.

(See Remove and Install Pilot Shut-Off Valve on
page W2-7-1)
ϖ 17 mm, 19 mm

W178-02-08-001

CAUTION: The floor plate (1) assembly weight:

200 kg (440 Ib)

3. Install eyebolts (M10, Pitch 1.5) into the bolt holes

in floor plate (1) (3 places). Pass wire ropes
through them and hoist by a crane to remove the 1 Eyebolt
floor plate (1) assembly.

NOTE: It is easy to adjust the wire ropes length and

level the frame if a chain block is used.

W183-02-01-024

W2-1-9
 UPPERSTRUCTURE / Cab
IMPORTANT: Attach identification tags to pipes to
aid reassembling. Upper Side

4. Disconnect all pipes and connectors from cab

bed.
ϖ 19 mm, 22 mm, 27 mm

NOTE: Cap all disconnected pipes.

Cab
Bed

W183-02-01-019

2,3,4,5
5. Remove bolts (2) (8 used), washers (3) (8 used)
and spring washers (4) (8 used) to remove plates
(5) (4 used).
ϖ 19 mm

6. Attach wire at the top corners (2 places) of the

fender assembly (6). Put two iron bars under the
fender, then secure the iron bars with wire.
6
7. Do the same work as procedure 6 at the opposite
side for hoisting fender assembly. 7

CAUTION: The fender assembly (6) weight:

180 kg (400 Ib) Cab Bed W183-02-01-020

8. Remove bolts (7) (6 used) to remove the fender

assembly (6) from cab bed.
ϖ 24 mm

CAUTION: The fender assembly (8) weight:

150 kg (330 Ib)
Iron Bar
9. Remove the fender assembly (8) from cab bed by
same method as in procedure 6 to 8.

6
W183-02-01-032

W2-1-10
 UPPERSTRUCTURE / Cab
10. Remove bolts (10) (4 used) from cab bed to
remove bracket (9) and cushion rubber (11). (10 Cab Bed
places)
Section
ϖ 19 mm

CAUTION: Cab bed weight: 590 kg (1300 Ib)

11. Install eyebolts (M12, Pitch 1.75) into the screw

holes for cab bed bolts (10) (4 places). Remove 9 10 11 W183-02-01-027

cab bed mounting bolts (12) (28 used) and hoist

by a crane to remove cab bed from the frame.
ϖ 19 mm

Eyebolt

Cab Bed

Frame
12

W183-02-01-026

W2-1-11
 UPPERSTRUCTURE / Cab

Install Cab Bed

(only for loading shovel)

CAUTION: Cab bed weight: 590 kg (1300 Ib)

Eyebolt

1. Hoist cab bed by a crane and install it onto the

Cab Bed
frame with bolts (12) (28 used).
ϖ 19 mm
Frame
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) 12

W183-02-01-026

2. Install bracket (9) and cushion rubber (11) onto

cab bed with bolts (10) (4 used). (10 places) Section
ϖ 19 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

9 10 11 W183-02-01-027

2,3,4,5
Handrail

CAUTION: The fender assembly (8) weight:

150 kg (330 Ib)

3. Hoist the fender assembly (8) by a crane and

install it to the cab bed with bolts (7) (6 used).
ϖ 24 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)
6

CAUTION: The fender assembly (6) weight: 7

180 kg (400 Ib)

4. Install the fender assembly (6) onto cab bed by

Cab Bed W183-02-01-020
same method as in procedure 3.
8
5. Install plates (5) (4 used) onto handrail with spring
washers (4) (8 used), washers (3) (8 used) and
bolts (2) (8 used).
ϖ 19 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

W2-1-12
 UPPERSTRUCTURE / Cab

6. Connect all pipes and connectors into cab bed. Upper Side
Pilot hose (Except cooler hose)
ϖ 22 mm
ϖ 40 N⋅m (4.1 kgf⋅m, 30.0 Ibf⋅ft)
ϖ 27 mm
ϖ 95 N⋅m (9.7 kgf⋅m, 70 Ibf⋅ft)
Cooler hose
ϖ 19 mm
Cab
ϖ 120 N⋅m (12 kgf⋅m, 87 Ibf⋅ft) Bed
ϖ 24 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)
ϖ 27 mm
ϖ 300 N⋅m (30.5 kgf⋅m, 220 Ibf⋅ft)

CAUTION: The floor plate (1) assembly weight:

200 kg (440 Ib) W183-02-01-019

1 Screw Part
7. Hoist the floor plate (1) assembly by a crane and
place it while aligning the cushion rubber screw
part of cab bed with the bolt hole in floor plate (1).

1
8. Install pilot shut-off valve.
(Refer to Remove and Install Shut-off Valve
section on page W2-7-1)
ϖ 17 mm Cushion Rubber
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
ϖ 19 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) W183-02-01-028

W178-02-08-001

W2-1-13
 UPPERSTRUCTURE / Cab
9. Install pilot valve.
(Refer to Remove and Install Pilot Valve section
on page W2-6-1)
ϖ 13 mm
ϖ 10 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
ϖ 17 mm
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
ϖ 19 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
ϖ 22 mm
ϖ 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)

W178-02-07-002

W2-1-14
 UPPERSTRUCTURE / Cab

Dimensions of the Cab Glass

Unit: mm Chamfer along

the Periphery
NOTE: 1 mm=0.03937 in 4-R61
561.5

(5 mm)
843

382

1026±1

Chamfer along
the Periphery
2-R61

(5 mm)
907±1

R241
R191
NOTE: Material: JIS R3211, R3212 or equivalent

1088.5±1

Chamfer along
the Periphery
4-R91

(8.8 mm) 1530 +1.5 -0.5

887 +1.5 -0.5

W183-02-01-033

W2-1-15
 UPPERSTRUCTURE / Cab

Unit: mm
NOTE: 1 mm=0.03937 in
NOTE: Material: JIS R3211, R3212 or equivalent

Chamfer
398±1 Here 346±1
51 51
Chamfer
Here
Chamfer Here Chamfer Here
2-R79 2-R5 2-R5 2-R79

Chamfer Slightly Chamfer Slightly

Unless Polish Unless Polish
Chamfered 2-φ12.2±1 2-φ12.2±1 Chamfered
756±1 756±1
40 (4 mm) (4 mm) 40

39.5 +0 -1
+0
39.5 -1
291.5 291.5

398±1 397±1
51

582±1

Chamfer along 4-R61

the Periphery

(5 mm) 738±1

748.5±1

Chamfer 3-R61
along the
Periphery (5 mm)
406±1
R141

778.5±1

W183-02-01-034

W2-1-16
 UPPERSTRUCTURE / Cab

Unit: mm
NOTE: 1 mm=0.03937 in
NOTE: Material: JIS R3211, R3212 or equivalemt
Chamfer
along the
Periphery

(5 mm) 582±1

4-R61

902±1

W183-02-01-010

W2-1-17
 UPPERSTRUCTURE / Cab

Cab Glass Installation Method

1. Install mounting rubber along the glass periphery. Mounting Rubber Section
Apply bonding agent (cemedine 366 standard)
onto the rubber connecting ends to stick together. Mounting Rubber Glass

NOTE: Rubber aging will cause the contraction of

rubber, be sure to leave a little extra, install Stopper
by pressing and sticking.

2. After installing glass assembly on the cab, insert

the stopper into rubber. Cab

W216-02-01-003

W2-1-18
 UPPERSTRUCTURE / Counterweight

REMOVE AND INSTALL COUNTERWEIGHT

Removal

CAUTION: Counterweight weight: 17500 kg

(38580 Ib)

1. Install lifting accessories and wire ropes to sling

brackets on the top of the counterweight. Set
the wire rope taut by a crane.

Frame

W183-02-02-002

CAUTION: Watch out for the power-wrench

reaction bar’s movement. Take
care not to be hit by the reaction
bar.

2. With a power wrench, remove bolts (1) (8 used)

and washers (2) (8 used).
ϖ 65 mm

W183-02-02-001

1 2
3. Remove the counterweight by a crane.

W2-2-1
 UPPERSTRUCTURE / Counterweight

Installation

ӸCAUTION: Counterweight weight: 17500 kg

(38580 Ib)

1. Install lifting accessories and wire ropes to sling

brackets on the top of the counterweight. Then,
lift the counterweight by a crane.

2. Align the bolt hole in the counterweight with the

hole in the frame and place the counterweight
onto the frame.

Frame

W183-02-02-002

CAUTION: Watch out for the power-wrench

reaction bar’s movement. Take
care not to be hit the reaction
bar.

IMPORTANT: Apply lubricant to bolts (1) before

installing.

3. Install bolts (1) (8 used), and washers (2) (8

used). With a power wrench, tighten bolts (1) (8
used)
ϖ 65 mm
ϖ 2350 N⋅m (240 kgf⋅m, 1730 Ibf⋅ft)
W183-02-02-001

1 2

4. Remove lifting accessories from the

counterweight.

W2-2-2
 UPPERSTRUCTURE / Pump Device

REMOVE AND INSTALL PUMP DEVICE

Cap
CAUTION: 1. Escaping fluid under pressure
can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release W183-01-01-001

any remaining pressure

before removing it.

Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap W183-04-02-003
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2.
: 4 mm

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil W183-04-02-002

tank. Wooden Blocks

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W2-3-1
 UPPERSTRUCTURE / Pump Device

Removal
Eyebolt Pump Transmission
1. Disconnect all hydraulic lines and electric cables
from the pump and pump transmission.
4
ϖ 13 mm, 17 mm, 19 mm, 22 mm, 27 mm,
Main Pump
36 mm, 41 mm 3
ϖ 8 mm, 10 mm

NOTE: Cap the disconnected pipes.

CAUTION: Main pump weight: 160 kg (350 Ib)

1
2. Install eyebolt (M12) into the hoisting holes (2
places) in the main pump. Attach a wire to the two
eyebolts and hoist by a crane.

3. Remove socket bolts (1) (4 used) to remove the 3-Tandem Pump 2

main pump.
ϖ 17 mm

4. Remove the other two pumps in accordance with W183-02-04-011

the procedure 2 to 3.

CAUTION: 3-tandem pump weight: 55 kg Tightening Torque

Tool Size Remarks
(120 Ib) N⋅m (kgf⋅m) Ibf⋅ft
: 13 mm 20 (2) 14.5 Bolt
5. Install eyebolt (M8) into the hoisting holes (2
: 17 mm 50 (5.1) 37 Bolt
places ) in the 3-tandem pump. Attach a wire to
the two eyebolts and hoist by a crane. : 19 mm 29.5 (3) 21.5 Hose
ϖ 22 mm 69 (7) 51 Hose
6. Remove socket bolts (2) (4 used) to remove the
: 27 mm 93 (9.5) 69 Hose
3-tandem pump.
: 36 mm 175 (18) 130 Hose
ϖ 14 mm
: 41 mm 205 (21) 152 Hose
Socket
CAUTION: Pump transmission weight: ϖ 8 mm 50 (5.1) 37
Bolt
530 kg (1170 Ib)
Socket
: 10 mm 108 (11) 80
7. Attach a wire to both left and right parts of bracket Bolt
(3) for the pump transmission and hoist by a
crane.

8. Remove the mounting bolts (4) (16 used) from the

pump transmission. Then remove the pump
transmission.
ϖ 19 mm

W2-3-2
 UPPERSTRUCTURE / Pump Device

Installation
IMPORTANT: After installing the pump, be sure to
NOTE: As for wrench size and tightening torque,
perform break-in operation to
refer to Removal.
prevent burning.

1. Hoist the pump transmission by a crane.

BREAK-IN OPERATION PROCEDURE:
1. Fill hydraulic oil into the pump casing.
2. Install the pump transmission onto the engine with 2. Start the engine and run at slow idle
bolts (4) (16 used). speed for 20 minutes, check for oil
ϖ 19 mm leaks while running at slow idle.
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) 3. Increase the engine speed to the fast
idle speed. Raise and lower the boom
3. Hoist the 3-tandem pump by a crane. Install the for 20 minutes repeatedly. (Do not
3-tandem pump onto the pump transmission with operate the control levers quickly.
socket bolts (2) (4 used). Slowly move the levers to full stroke.)
ϖ 14 mm
Eyebolt Pump Transmission
ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)
Air Bleeding
Position
4. Hoist the main pump by a crane or hoist. Install
the main pump onto the pump transmission with Main Pump 4
socket bolts (1) (4 used).
ϖ 17 mm 3
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

5. Install the other two main pump in accordance

with the procedure 4.

6. Connect all hydraulic lines and electric cables to 1

the pumps and pump transmission.
Air Bleeding
7. Bleed air trapped inside of the pumps. (Refer to Position

page W1-1-2)
2
3-Tandem
Pump

W183-02-03-001

W2-3-3
 UPPERSTRUCTURE / Pump Device

DISASSEMBLE PUMP TRANSMISSION

1 2
3
4
5
6
7
8
9

10

15
19 16
20 17
21 18
22
30 31,32 23 Pump Side
24

11

33

25

26
27
28
29

14
13
11 36 34,35 12
Engine Side
W183-02-04-008

W183-02-04-010

1- Bolt (3 Used) 10 - Roller Bearing 19 - O-Ring 28 - Retaining Ring (3 Used)

2- Spring Washer (3 Used) 11 - Casing 20 - Ball Bearing 29 - Ball Bearing (3 Used)
3- Cover 12 - Oil Seal 21 - Gear 30 - Cover (3 Used)
4- O-Ring 13 - Bolt (10 Used) 22 - Spacer 31 - Socket Bolt (12 Used)
5- Disc Spring 14 - Cover 23 - Retaining Ring 32 - Spring Washer (12 Used)
6- Roller Bearing 15 - Air Breather 24 - Ball Bearing 33 - O-Ring (3 Used)
7- Retaining Ring 16 - Reducer 25 - Ball Bearing (3 Used) 34 - Bolt (4 Used)
8- Stopper 17 - Pipe 26 - Gear (3 Used) 35 - Spring Washer (4 Used)
9- Gear 18 - Elbow 27 - Spacer (3 Used) 36 - Cover

W2-3-4
 UPPERSTRUCTURE / Pump Device

Disassemble Pump Transmission

• Be sure to thoroughly read “Precautions for 6. Remove retaining rings (23 and 28) and spacers
Disassembly and Assembly Work” on page (22 and 27) from gears (21 and 26) to remove ball
W1-1-1 before starting the disassembly work. bearings (20, 24, 25 and 29) with puller res-
pectively.

CAUTION: The pump transmission weight:

530 kg (1170 Ib) CAUTION: Casing (11) weight: 300 kg (660 Ib)

1. Place the pump transmission with the pump side 7. Place casing (11) with its engine side facing up.
facing up. Ȁ
Ȁ 8. Remove bolts (13) (10 used) from casing (11) to
2. Remove socket bolts (31) (12 used) and spring remove cover (14).
washers (32) (12 used) from casing (11) to ϖ 19 mm
remove cover (30) (3 used) and O-ring (33) (3
used).
9. Remove oil seal (12) from cover (14).
ϖ 17 mm

3. Remove bolts (34) (4 used) and spring washers CAUTION: The gear (9) assembly weight:
(35) (4 used) from casing (11) to remove cover
40 kg (90 Ib)
(36) and O-ring (19).
ϖ 24 mm
10 Install eyebolts (M10, Pitch 1.5) into the two
hoisting holes of the gear (9) assembly. Remove
4. Remove bolts (1) (3 used) and spring washers (2) the gear (9) assembly from casing (11) and disc
(3 used) from casing (11) to remove cover (3) and spring (5).
O-ring (4).
ϖ 22 mm 11. Remove retaining ring (7) and stopper (8) from
gear (9). Remove the inner race of roller bearings
(6 and 10) with puller.
CAUTION: The gear (21) assembly weightϖ
ϖ
20 kg (40 Ib)
The gear (26) assembly weight:
30 kg (70 Ib)

5. Install eyebolts (M10, Pitch 1.5) into the two hoisting

holes in the gears (21 and 26) assembly to
remove the gears (21 and 26) assembly from
casing (11).

W2-3-5
 UPPERSTRUCTURE / Pump Device

ASSEMBLE PUMP TRANSMISSION

Pump Side Engine Side
25 26 29

33 28

27

13
14
15 16
17 6
30 31,32 18

A 4
7
8
9

1,2 5
3 10 12

34,35
19

20

22
W183-02-04-010 21
36 A
23

24
11

W183-02-04-009

Section A-A

1- Bolt (3 Used) 10 - Roller Bearing 19 - O-Ring 28 - Retaining Ring (3 Used)

2- Spring Washer (3 Used) 11 - Casing 20 - Ball Bearing 29 - Ball Bearing (3 Used)
3- Cover 12 - Oil Seal 21 - Gear 30 - Cover (3 Used)
4- O-Ring 13 - Bolt (10 Used) 22 - Spacer 31 - Socket Bolt (12 Used)
5- Disc Spring 14 - Cover 23 - Retaining Ring 32 - Spring Washer (12 Used)
6- Roller Bearing 15 - Air Breather 24 - Ball Bearing 33 - O-Ring (3 Used)
7- Retaining Ring 16 - Reducer 25 - Ball Bearing (3 Used) 34 - Bolt (4 Used)
8- Stopper 17 - Pipe 26 - Gear (3 Used) 35 - Spring Washer (4 Used)
9- Gear 18 - Elbow 27 - Spacer (3 Used) 36 - Cover

W2-3-6
 UPPERSTRUCTURE / Pump Device

Assemble Pump Transmission

8. Press in ball bearings (29) (3 used) at the engine
CAUTION: Gear (9) weight: 31 kg (70 Ib) side of gears (26) (3 used), and install spacers
(27) and retaining rings (28) (3 used for each).

1. Install stopper (8) and retaining ring (7) to gear (9).

Press in the inner race of roller bearing (10) to the CAUTION: The gear (21) assembly weight:
engine side and press in the inner race of roller 20 kg (40 Ib)
bearing (6) to the pump side. The gear (26) assembly weight:
30 kg (70 Ib)
CAUTION: Casing (11) weight: 300 kg (660 Ib)
9. Install the gears (21 and 26) assembly into casing
(11).
2. Place casing (11) with the engine side facing up.
10. Press ball bearing (20) into the gear (21)
assembly.
CAUTION: The gear (9) assembly weight:
40 kg (90 Ib) 11. Press ball bearings (25) (3 used) into the gear
(26) assemblies (3 used).
3. Place disc spring (5) and the outer race of roller
bearing (6) into casing (11), and install the gear 12. Install O-ring (4) to cover (3). Install cover (3) to
(9) assembly. casing (11) with bolts (1) (3 used) and spring
washers (2) (3 used).
IMPORTANT: Apply grease on the inner diameter
ϖ 22 mm
and THREEBOND on the outer
diameter of oil seal (12). ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

4. Install oil seal (12) into cover (14) and press in the 13. Install O-ring (19) to cover (36). Install cover (36)
outer race of roller bearing (10). to casing (11) with bolts (34) (4 used) and spring
washers (35) (4 used).
5. Install cover (14) to casing (11) with bolts (13) (10 ϖ 24 mm
used). ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)
ϖ 19 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) 14. Install O-rings (33) (3 used) to covers (30) (3
used). Install covers (30) (3 used) to casing (11)
with socket bolts (31) (12 used) and spring
CAUTION: Casing (11) weight: 300 kg (660 Ib) washers (32) (12 used).
ϖ 17 mm
6. Place casing (11) with the engine side facing ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
down.

7. Press in ball bearing (24) at the engine side of

gear (21), and install spacer (22) and retaining
ring (23).

W2-3-7
 UPPERSTRUCTURE / Pump Device

DISASSEMBLE MAIN PUMP

17 18

16 19
15
14 20
13
12
11 21
22
10

9 23

24
7 8
6

5
25
4 26
3 27
2 28
1 48
29 47
46
45
44
43
42
41
40
39
38
37
36
35
34
32 33 40

31 49
50
30

51

52
53
W183-02-04-001

1- Socket Bolt (4 used) 15 - Housing 29 - Socket Bolt (4 Used) 43 - Nut

2- Cover 16 - Tilt Pin 30 - Swash Plate 44 - Booster
3- O-Ring 17 - Regulator 31 - Bushing 45 - O-Ring
4- Oil Seal 18 - Socket Bolt (4 Used) 32 - Plunger (9 Used) 46 - O-Ring
5- Shaft 19 - Stopper 33 - Retainer Plate 47 - Cover
6- Bearing 20 - Backup Ring 34 - Spherical Bushing 48 - Socket Bolt (6 Used)
7- Spacer 21 - O-Ring 35 - Spacer 49 - Spring Pin (2 Used)
8- Retaining Ring 22 - Servo Piston 36 - Cylinder Block 50 - Pin
9- Nut 23 - O-Ring (2 Used) 37 - Valve Plate 51 - Spring (9 Used)
10 - Adjusting Screw 24 - Plug (2 Used) 38 - Bearing 52 - Shoe (9 Used)
11 - Spring Pin (2 Used) 25 - O-Ring (2 Used) 39 - O-Ring 53 - Shoe Plate
12 - Stopper 26 - O-Ring 40 - O-Ring (10 Used)
13 - Backup Ring 27 - Cover 41 - Cover
14 - O-Ring 28 - Washer (4 Used) 42 - Adjusting Screw

W2-3-8
 UPPERSTRUCTURE / Pump Device

Disassemble Main Pump

• Be sure to thoroughly read “Precautions for 5. Take out cylinder block (36) from housing (15).
Disassembly and Assembly Work” on page Now you can see plungers (32) (9 used), shoes
W1-1-1 Before starting the disassembly work. (52) (9 used), spherical bushing (34) and retainer
plate (33) all connected together on cylinder block
IMPORTANT: Do not remove adjusting bolts (10 (36).
and 42) and nuts (9 and 43), the oil
flow rate setting may change as a NOTE: Grasp cylinder (36) with two hands and
consequence. slowly take it out while turning it to left and
right lightly.
1. Remove plugs (24) (2 used) and O-rings (23) (2
used) to bleed hydraulic oil in the pump. 6. Remove retainer plate (33) from the cylinder block
ϖ 36 mm (36) assembly. At this time, plungers (32) (9 used)
and shoes (52) (9 used) are still connecting with
retainer plate (33).
2. Remove socket bolts (18) (4 used) to remove
regulator (17).
7. Remove plungers (32) (9 used) and shoes (52)
ϖ 6 mm (9 used) from retainer plate (33).

3. Remove socket bolts (48) (6 used) to remove 8. Remove spherical bushing (34) from cylinder
cover (47), booster (44) and O-rings (45 and 46). block (36) to remove spacer (35) and springs (51)
ϖ 8 mm (9 used).

IMPORTANT: As for oil seal (4), do not remove it

IMPORTANT: Be careful as valve plate (37) may
unless necessary; replace with a new
come off together with cover (41)
one when removed.
when removing the cover.
As for bearing (38), do not remove
unless necessary; replace with a new 9. Remove socket bolts (1) (4 used) to remove cover
one when removed. (2) and O-ring (3).
ϖ 6 mm
4. Remove socket bolts (29) (4 used) to remove
cover (41), O-rings (39) and (40) (10 used), spring 10. Remove cover (27) from housing (15) by tapping
pins (49) (2 used), valve plate (37) and pin (50). with a plastic hammer. At this moment, remove
ϖ 17 mm O-rings (26), (25) (2 used) and spring pins (11) (2
used).

11. Remove swash plate (30) and shoe plate (53)

from housing (15).

12. Remove shaft (5) from cover (27) by tapping with

a plastic hammer.

W2-3-9
UPPERSTRUCTURE / Pump Device

16 19
15

12
22

7 8
6

W183-02-04-001

W2-3-10
 UPPERSTRUCTURE / Pump Device

IMPORTANT: Servo piston (22) is connected to tilt

pin (16) with LOCTITE. Take care not
to damage servo piston (22) when
disassembling.

13. Remove stoppers (12 and 19), servo piston (22),

and tilt pin (16) from housing (15).

14. Remove retaining ring (8) from shaft (5) and

remove spacer (7) and bearing (6).

W2-3-11
 UPPERSTRUCTURE / Pump Device

ASSEMBLE MAIN PUMP

10 9 27 11 12 13,14 26 7 8 22 16 15 31 19 20,21 40 39 38 43 42 47

48
2
5
46
4

23,24
3

1
29

6 28 25 30 53 52 33 34 32 35 51 36 37 49 50 41 45 44

W183-02-04-002

1- Socket Bolt (4 Used) 15 - Housing 29 - Socket Bolt (4 Used) 43 - Nut

2- Cover 16 - Tilt Pin 30 - Swash Plate 44 - Booster
3- O-Ring 17 - Regulator 31 - Bushing 45 - O-Ring
4- Oil Seal 18 - Socket Bolt (4 Used) 32 - Plunger (9 Used) 46 - O-Ring
5- Shaft 19 - Stopper 33 - Retainer Plate 47 - Cover
6- Bearing 20 - Backup Ring 34 - Spherical Bushing 48 - Socket Bolt (6 Used)
7- Spacer 21 - O-Ring 35 - Spacer 49 - Spring Pin (2 Used)
8- Retaining Ring 22 - Servo Piston 36 - Cylinder Block 50 - Pin
9- Nut 23 - O-Ring (2 Used) 37 - Valve Plate 51 - Spring (9 Used)
10 - Adjusting Screw 24 - Plug (2 Used) 38 - Bearing 52 - Shoe (9 Used)
11 - Spring Pin (2 Used) 25 - O-Ring (2 Used) 39 - O-Ring 53 - Shoe Plate
12 - Stopper 26 - O-Ring 40 - O-Ring (10 Used)
13 - Backup Ring 27 - Cover 41 - Cover
14 - O-Ring 28 - Washer (4 Used) 42 - Adjusting Screw

W2-3-12
 UPPERSTRUCTURE / Pump Device

Assemble Main Pump

IMPORTANT: Apply LOCKTITE (Medium strength) IMPORTANT: Apply grease on valve plate (37).
on the interface of servo piston (22)
and tilt pin (16). 10. Install spring pins (49) (2 used), pin (50) and
O-rings (40) (10 used) to cover (41), then install
1. Install tilt pin (16), servo piston (22) and stoppers valve plate (37) on it.
(12) and (19) into housing (15).
NOTE: Install valve plate (37) while aligning the pin
2. Install bearing (6), spacer (7) and retaining ring (8) hole in the plate with pin (50).
onto shaft (5).
11. Install the housing (15) assembly to cover (41)
3. Assemble spring pins (11) (2 used). O-rings (25) with socket bolts (29) (4 used) and washers (28) (4
(2 used) and (26) onto cover (27), and install used).
cover (27) into housing (15). ϖ 17 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
4. Align swash plate (30) which is connected with
shoe plate (53) with tilt pin (16), and install them to 12. Align booster (44) with shaft (5) spline, and install
housing (15). it onto shaft (5).

NOTE: Check the swash plate by hand to ensure 13. Install O-rings (45 and 46) to cover (47). Then
that it moves smoothly after installing install cover (47) to cover (41) with socket bolts
swash plate (30). (48) (6 used).
ϖ 8 mm
5. Install oil seal (4) and O-ring (3) onto cover (2). ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

6. Press shaft (5) into cover (27) and install cover (2) 14. Align the feedback lever of regulator (17) with tilt
with socket bolt (1) to cover (27). pin (16) and install regulator (17) with socket bolts
ϖ 6 mm (18) (4 used) (Refer to W2-3-8).
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) ϖ 6 mm
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
7. Install springs (51) (9 used), spacer (35) and
spherical bushing (34) to cylinder block (36). 15. Install O-rings (23) (2 used) and plugs (24) (2 used).
8. Assemble plungers (32) (9 used) and shoes (52) ϖ 36 mm
(9 used) to retainer plate (33) which is to be ϖ 147 N⋅m (15 kgf⋅m 108 Ibf⋅ft)
installed to cylinder block (36).

9. Install the cylinder block (36) assembly onto shaft

(5).

W2-3-13
 UPPERSTRUCTURE / Pump Device

MAINTENANCE STANDARD

1. Clearance between plunger (32) outer diameter

(d) and cylinder block (36) bore diameter (D).
d D

DПd Unit: mm (in)

Standard Allowable Limit
0.047 (0.002) 0.094 (0.004)
W117-02-02-009

2. Free length (L) of spring (51)

L Unit: mm (in)
Standard Allowable Limit
49.5 (1.95) 48.0 (1.89)

W117-02-02-010
3. Clearance (e) between plunger (32) and shoe (52)
and thickness (t) of shoe (52)

e Unit: mm (in)
Standard Allowable Limit
0ϡ0.1 (0~0.004) 0.35 (0.014)

t Unit: mm (in)
Standard Allowable Limit e
t
6.5 (0.26) 6.3 (0.25)
W117-02-02-011

4. Height from the reverse face of retainer plate (33)

to the top of spherical bushing (34)
Stand
H-h Unit: mm (in)
Standard Allowable Limit h H
16.5 (0.65) 15.5 (0.61)
W117-02-02-012

W2-3-14
 UPPERSTRUCTURE / Pump Device

(Blank)

W2-3-15
 UPPERSTRUCTURE / Pump Device

DISASSEMBLE REGULATOR
(MAIN PUMP) 13
12
11
10
9
8

7
6 22
5 23
4 24
3 25
2 26
1 21 27
20
32
19 31
18
17 30
16 53
15 29
14 54
28 55
56
52
51
33 50
45 46 49
34 48
39 47
40
57

35 62
36 61
37
38 44
60
66 59
43 58

42 67
68
74 65
41 73 69 64
70 63
71
72
W183-02-04-014

W2-3-16
 UPPERSTRUCTURE / Pump Device

1- Pin 20 - Spool 39 - Cover 58 - Retaining Ring

2- Sleeve 21 - Pin 40 - O-Ring 59 - O-Ring
3- O-Ring 22 - Lever 41 - Socket Bolt (2 Used) 60 - Supporting Plug
4- O-Ring 23 - Feedback Lever 42 - Socket Bolt (2 Used) 61 - Pin
5- Sleeve 24 - Pin 43 - Cover 62 - Housing
6- Compensating Piston 25 - Pin 44 - O-Ring 63 - Retaining Ring
7- Compensating Rod 26 - Lever 45 - Socket Bolt (2 Used) 64 - O-Ring
8- Spring Seat 27 - Pin 46 - Socket Bolt (2 Used) 65 - Supporting Plug
9- Spring 28 - Pilot Piston 47 - O-Ring 66 - Pin
10 - Spring 29 - Spring Seat 48 - O-Ring 67 - Pin
11 - Piston 30 - Spring 49 - Adjusting Screw 68 - O-Ring
12 - Stopper 31 - Stopper 50 - Adjusting Screw 69 - Stopper
13 - O-Ring 32 - O-Ring 51 - Nut 70 - Ball
14 - Retaining Ring 33 - Socket Bolt (4 Used) 52 - O-Ring 71 - Seat
15 - Spring Seat 34 - Cover 53 - Cover 72 - O-Ring
16 - Spring 35 - O-Ring 54 - Nut 73 - O-Ring
17 - Spring 36 - Seat (2 Used) 55 - Nut 74 - O-Ring
18 - Retaining Ring 37 - Ball (2 Used) 56 - Adjusting Screw
19 - Sleeve 38 - Stopper (2 Used) 57 - Socket Bolt (4 Used)

W2-3-17
 UPPERSTRUCTURE / Pump Device

12
11
10
9
8

7
6 22
5 23
4 24
3
2 26
1 21 27
20

19 31
17 30
16
15 29
14 53 54
28 55
56

51
33 50
45 46 49
34
39

40
57

35 62
36 61
37
38 44
60
66
43 58

42 67
68
74 65
41 73 69
70 63
71
72
W183-02-04-014

W2-3-18
 UPPERSTRUCTURE / Pump Device

Disassemble Regulator
(Main Pump)
• Be sure to thoroughly read “Precautions for 9. Remove bolts (57) (4 used) to remove cover (53),
Disassembly and Assembly Work” on page stopper (12), piston (11), springs (10 and 9),
W1-1-1 before starting the disassembly work. spring sheet (8), stopper (31), spring (30) and
spring seat (29).
1. Remove socket bolts (45) (2 used) and (46) (2 ϖ 5 mm
used) to remove the regulator from main pump.
ϖ 6 mm IMPORTANT: Do not remove pin (66) from su-
pporting plug (65) and put marks on
IMPORTANT: Do not remove adjusting bolts (49, 50 supporting plugs (60 and 65) to
and 56) and nuts (51, 54 and 55), the prevent confusing them.
oil flow rate setting of the pump will
change as a consequence. 10. Remove retaining rings (58 and 63) from housing
(62) to remove supporting plugs (60 and 65) using
2. Remove socket bolts (33) (4 used) to remove bolts (M6).
covers (34 and 39).
ϖ 5 mm IMPORTANT: Do not remove pin (27) from lever
(26).
3. Remove O-ring (35) from cover (34).
11. Remove lever (26) from housing (62) with a
pincers etc. to remove pilot piston (28).
4. Remove O-ring (40), seat (36), ball (37) and
stopper (38) from cover (39).
12. Remove pin (24) from feedback lever (23) with a
5. Remove O-rings (68 and 72), seat (71), ball (70), copper bar from the supporting plug (60) hole to
stopper (69) and pin (67) from housing (62). remove feadback lever (23), sleeve (19) and
spool (20).
6. Remove socket bolts (42) (2 used) and (41) (2 ϖ 4 mm
used) to remove cover (43) and O-rings (44, 73
and 74). IMPORTANT: Do not remove pins (21 and 61) from
ϖ 5 mm lever (22).

7. Remove pin (1), sleeve (2), O-rings (3 and 4), 13. Remove lever (22) with a pincers etc. from
sleeve (5) and compensating piston (6) from housing (62) to remove compensating rod (7).
housing (62).

8. Remove retaining ring (14) from housing (62) to

remove spring seat (15) and springs (16 and 17).

W2-3-19
 UPPERSTRUCTURE / Pump Device

ASSEMBLE REGULATOR
(MAIN PUMP)
A 60 59 58
62 40 38 37 36 35 34
B 33

A B 65 64 63 W117-02-02-023
W183-02-04-006
57 69 70 72 71 39

Section A-A 17 44 15 16 18 20 19 25 24 26 28 29 30 31 62 32

43

42 55

56

41
53

14 74 73 45 68 66 23 27 46 67
W183-02-04-015
Section B-B
3 5 6 7 62 61 22 8 9 10 11 52 47 12 48 13 54 49

51

50

1 2 4 21 53 W183-02-04-005

W2-3-20
 UPPERSTRUCTURE / Pump Device

1- Pin 20 - Spool 39 - Cover 58 - Retaining Ring

2- Sleeve 21 - Pin 40 - O-Ring 59 - O-Ring
3- O-Ring 22 - Lever 41 - Socket Bolt (2 Used) 60 - Supporting Plug
4- O-Ring 23 - Feedback Lever 42 - Socket Bolt (2 Used) 61 - Pin
5- Sleeve 24 - Pin 43 - Cover 62 - Housing
6- Compensating Piston 25 - Pin 44 - O-Ring 63 - Retaining Ring
7- Compensating Rod 26 - Lever 45 - Socket Bolt (2 Used) 64 - O-Ring
8- Spring Seat 27 - Pin 46 - Socket Bolt (2 Used) 65 - Supporting Plug
9- Spring 28 - Pilot Piston 47 - O-Ring 66 - Pin
10 - Spring 29 - Spring Seat 48 - O-Ring 67 - Pin
11 - Piston 30 - Spring 49 - Adjusting Screw 68 - O-Ring
12 - Stopper 31 - Stopper 50 - Adjusting Screw 69 - Stopper
13 - O-Ring 32 - O-Ring 51 - Nut 70 - Ball
14 - Retaining Ring 33 - Socket Bolt (4 Used) 52 - O-Ring 71 - Seat
15 - Spring Seat 34 - Cover 53 - Cover 72 - O-Ring
16 - Spring 35 - O-Ring 54 - Nut 73 - O-Ring
17 - Spring 36 - Seat (2 Used) 55 - Nut 74 - O-Ring
18 - Retaining Ring 37 - Ball (2 Used) 56 - Adjusting Screw
19 - Sleeve 38 - Stopper (2 Used) 57 - Socket Bolt (4 Used)

W2-3-21
 UPPERSTRUCTURE / Pump Device

A
62 40 38 37 36
60 59 58
B

A B
W183-02-04-006
57 39
65 64 63 W117-02-02-023

Section A-A 17 44 15 16 18 20 19 24 26 28 29 30 31 62 32

43

42

41
53

14 74 73 66 23 27
W183-02-04-015
Section B-B
3 5 6 7 62 61 22 8 9 10 11 52 12

1 2 4 21 53 W183-02-04-005

W2-3-22
 UPPERSTRUCTURE / Pump Device

Assemble Regulator
1. Insert compensating rod (7) and lever (22) into 9. Insert supporting plug (60) into housing (62) and
housing (62). install retaining ring (58).

2. Align pin (61) of lever (22) with the pin hole in 10. Install O-ring (32) onto stopper (31).
housing (62) inside. Align pin (21) with stepped
joint portion of compensating rod (7) to install
lever (22) into housing (62). 11. Install spring seat (29), spring (30) and stopper
(31) to housing (62).

3. Assemble retaining ring (18) to sleeve (19) and

insert sleeve (19) and spool (20) into housing 12. Install O-ring (13) onto stopper (12).
(62).
13. Place O-ring (52) in housing (62) where spring
IMPORTANT: Check spool (20) that it should move seat (8), springs (9 and 10), piston (11) and
smoothly before installing feedback stopper (12) should be inserted. Install cover (53)
lever (23). Be sure to install spool to housing (62) with socket bolts (57) (4 used).
(20) and feedback lever (23) in ϖ 5 mm
correct direction. Do not make any ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
mistakes while doing this.
14. Install spring (16), spring seat (15) and retaining
4. Align the pin hole in feedback lever (23) with the ring (14) onto spool (20).
pin hole in spool (20), and install pin (24) from the
mounting hole of supporting plug (60).
15. Place O-ring (4) to sleeve (5) and install sleeve (5),
compensating piston (6), O-ring (3), sleeve (2)
5. Insert pilot piston (28) and lever (26) into housing and pin (1) into housing (62).
(62).

16. Assemble spring (17), O-rings (44, 73 and 74) into

IMPORTANT: Check pilot piston (28) that it should housing (62) and install cover (43) with socket
move smoothly before installing bolts (42) (2 used) and (41) (2 used).
lever (26).
ϖ 5 mm
ϖ 12 N⋅m (1.2 kgfcm, 8.7 Ibf⋅ft)
6. Align pin (27) of lever (26) with stepped joint
portion of pilot piston (28) to install lever (26).
17. Place O-ring (40) to cover (39) and then install
7. Install O-rings (59 and 64) to supporting plugs (60 stopper (38), ball (37) and seat (36).
and 65) respectively.

8. Align pin (66) of supporting plug (65) with the pin

hole of lever (26) to insert the pin and install
retaining ring (63).

W2-3-23
 UPPERSTRUCTURE / Pump Device

A
62 35 34
B 33

A B W117-02-02-023
W183-02-04-006
69 70 72 71 39

Section A-A 62

45 68 46
W183-02-04-015
Section B-B
62

W183-02-04-005

W2-3-24
 UPPERSTRUCTURE / Pump Device
18. Place O-ring (35) to cover (34) and install covers
(39 and 34) into housing (62) with socket bolts
(33) (4 used).
ϖ 5 mm
ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)

19. Install stopper (69), ball (70), seat (71) and O-ring
(72) into housing (62).

20. Install O-ring (68) to housing (62).

21. Install the regulator onto the pump with socket

bolts (45) (2 used) and (46) (2 used).
ϖ 6 mm
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W2-3-25
 UPPERSTRUCTURE / Pump Device

DISASSEMBLE PUMP OF OIL COOLER

FAN MOTOR
17 18

16 19
15
14
13
12 20
11 21
10 22
9
23
24
8
7
6
7
5 25
26 51
4 27 50
3
2 49
1 28 48
47
46
45
44
43
42
41
40 52
39
38
37
36
35
34
33
32 41

30 31 53
54
29

W183-02-04-016

1- Socket Bolt (4 Used) 15 - Housing 29 - Swash Plate 43 - Adjusting Screw

2- Cover 16 - Tilt Pin 30 - Bushing 44 - Nut
3- O-Ring 17 - Regulator 31 - Shoe Plate 45 - O-Ring
4- Oil Seal 18 - Socket Bolt (4 Used) 32 - Shoe (9 Used) 46 - Retaining Ring
5- Shaft 19 - Stopper 33 - Plunger (9 Used) 47 - Coupling
6- Bearing 20 - Backup Ring 34 - Retainer Plate 48 - Sub Plate
7- Spacer (2 Used) 21 - O-Ring 35 - Spherical Bushing 49 - Socket Bolt (4 Used)
8- Retaining Ring 22 - Servo Piston 36 - Spring (9 Used) 50 - Sub Plate
9- Nut 23 - O-Ring (2 Used) 37 - Cylinder Block 51 - Socket Bolt (4 Used)
10 - Adjusting Screw 24 - Plug (2 Used) 38 - Valve Plate 52 - O-Ring
11 - Spring Pin 25 - O-Ring (2 Used) 39 - Bearing 53 - Spring Pin (2 Used)
12 - Stopper 26 - O-Ring 40 - O-Ring 54 - Pin
13 - Backup Ring 27 - Cover 41 - O-Ring (10 Used)
14 - O-Ring 28 - Socket Bolt (4 Used) 42 - Cover

W2-3-26
 UPPERSTRUCTURE / Pump Device
Disassemble Pump of Oil Cooler Fan Motor
• Be sure to thoroughly read “Precautions for 6. Remove cylinder block (37) from housing (15) with
Disassembly and Assembly Work” on page plugers (33) (9 used), shoes (32) (9 used),
W1-1-1 before starting the disassembly work. spherical bushing (35) and retainer plate (34) still
attached on the cylinder block.
IMPORTANT: Do not remove adjusting bolts (10
and 43) and nuts (9 and 44), the oil NOTE: Hold cylinder block (37) with two hands and
flow rate setting may change as a slowly take it out while turning it lightly to left
consequence. and right.

1. Remove plugs (24) (2 used) and O-ring (23) (2 7. Remove retainer plate (34) from the cylinder block
used) to drain hydraulic oil in the pump. (37) assembly, with plungers (33) (9 used) and
ϖ 36 mm shoes (32) (9 used) still attached on retainer plate
(34).
2. Remove socket bolts (18) (4 used) to remove
8. Remove plungers (33) (9 used) and shoes (32)
regulator (17) from housing (15).
(9 used) from retainer plate (34).
ϖ 6 mm
9. Remove spherical bushing (35) from cylinder
3. Remove socket bolts (51) (4 used) to remove sub block (37) to remove springs (36) (9 used).
plate (50) and O-ring (52) from sub plate (48).
ϖ 10 mm IMPORTANT: Do not remove oil seal (4) unless
necessary; replace with a new one
when removed.
4. Remove socket bolts (49) (4 used) to remove sub
plate (48), O-ring (45), retaining ring (46) and
coupling (47) from cover (42). 10. Remove socket bolts (1) (4 used) to remove cover
ϖ 8 mm (2) and O-ring (3).
ϖ 6 mm
IMPORTANT: Be careful as valve plate (38) may
come off together with cover (42) 11. Remove cover (27) from housing (15) by tapping
when removing cover (42). with a plastic hammer. At this moment, remove
Do not remove bearing (39) unless O-rings (25) (2 used), (26) and spring pins (11)
necessary; replace with a new one (2 used).
when removed.
12. Remove swash plate (29) and shoe plate (31)
from housing (15).
5. Remove socket bolts (28) (4 used) to remove
cover (42), O-rings (40), (41) (10 used), spring
13. Remove shaft (5) from cover (27) by tapping with
pins (53) (2 used), valve plate (38) and pin (54)
a plastic hammer.
from housing (15).
ϖ 17 mm

W2-3-27
 UPPERSTRUCTURE / Pump Device

16 19
15

12
22

8
7
6
7
5

W183-02-04-016

W2-3-28
 UPPERSTRUCTURE / Pump Device

IMPORTANT: Be careful not to damage the surface

of servo piston (22) while dis-
assembling it since LOCTITE is
applied on the joint portion between
servo piston (22) and tilt pin (16).

14. Remove stoppers (12 and 19) from housing (15)

to remove servo piston (22) and tilt pin (16).

15. Remove retaining ring (8) from shaft (5) to remove

spacers (7) (2 used) and bearing (6).

W2-3-29
 UPPERSTRUCTURE / Pump Device

ASSEMBLE PUMP OF OIL COOLER FAN

MOTOR

27 12 13,14 22 32 16 15 30 20,21 19 41 44 43

9
10 40
49
11
26
2 47
5 4

23,24

46
7
3 52

1 45

28 51

6 25 29 31 34 35 33 36 37 38 53 54 39 42 48 50

W183-02-04-017

1- Socket Bolt (4 Used) 15 - Housing 29 - Swash Plate 43 - Adjusting Screw

2- Cover 16 - Tilt Pin 30 - Bushing 44 - Nut
3- O-Ring 17 - Regulator 31 - Shoe Plate 45 - O-Ring
4- Oil Seal 18 - Socket Bolt (4 Used) 32 - Shoe (9 Used) 46 - Retaining Ring
5- Shaft 19 - Stopper 33 - Plunger (9 Used) 47 - Coupling
6- Bearing 20 - Backup Ring 34 - Retainer Plate 48 - Sub Plate
7- Spacer (2 Used) 21 - O-Ring 35 - Spherical Bushing 49 - Socket Bolt (4 Used)
8- Retaining Ring 22 - Servo Piston 36 - Spring (9 Used) 50 - Sub Plate
9- Nut 23 - O-Ring (2 Used) 37 - Cylinder Block 51 - Socket Bolt (4 Used)
10 - Adjusting Screw 24 - Plug (2 Used) 38 - Valve Plate 52 - O-Ring
11 - Spring Pin 25 - O-Ring (2 Used) 39 - Bearing 53 - Spring Pin (2 Used)
12 - Stopper 26 - O-Ring 40 - O-Ring 54 - Pin
13 - Backup Ring 27 - Cover 41 - O-Ring (10 Used)
14 - O-Ring 28 - Socket Bolt (4 Used) 42 - Cover

W2-3-30
 UPPERSTRUCTURE / Pump Device
Assemble Pump of Oil Cooler Fan Motor
IMPORTANT: Apply grease on valve plate (38).
IMPORTANT: Apply LOCTITE (medium strength) on
the joint portion between servo 10. Install spring pins (53) (2 used), pin (54), valve
piston (22) and tilt pin (16). plate (38) and O-rings (41) (10 used) to cover
(42).
1. Install tilt pin (16), servo piston (22) and stoppers
(12 and 19) into housing (15). NOTE: Install valve plate (38) while aligning the pin
hole in valve plate (38) with pin (54).
2. Install spacer (7), bearing (6), spacer (7) and
retaining ring (8) onto shaft (5). 11. Install the housing (15) assembly with socket bolts
(28) (4 used) to cover (42).
3. Assemble spring pin (11), O-rings (25) (2 used) ϖ 17 mm
and (26) to cover (27). Install cover (27) to ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
housing (15).
12. Install coupling (47) to the housing (15) assembly.
4. Align swash plate (29) with tilt pin (16) when shoe
plate (31) has been installed to swash plate (29).
13. Place O-ring (45) onto sub plate (48). Install sub
Install the swash plate into housing (15).
plate (48) to cover (42) with socket bolts (49) (4
used).
NOTE: Check the swash plate (29) by hand to ϖ 8 mm
ensure it moves smoothly after being ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
installed.
14. Place O-ring (52) onto sub plate (50). Install sub
5. Install oil seal (4) and O-ring (3) to cover (2). plate (50) to sub plate (48) with socket bolts (51)
(4 used).
6. Press shaft (5) into cover (27). And install cover ϖ 10 mm
(2) to cover (27) with socket bolts (1) (4 used). ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
ϖ 6 mm
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) 15. Align the feedback lever of regulator (17) with tilt
pin (16) to install regulator (17) with socket bolts
7. Install springs (36) (9 used) and spherical bushing (18) (4 used) (Refer to W2-3-26).
(35) into cylinder block (37). ϖ 6 mm
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
8. Assemble plungers (33) (9 used) and shoes (32)
(9 used) to retainer plate (34). Install retainer plate 16. Install O-rings (23) (2 used) and plugs (24) (2
(34) to cylinder block (37). used).
ϖ 36 mm
9. Install the cylinder block (37) assembly onto shaft ϖ 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
(5).

W2-3-31
 UPPERSTRUCTURE / Pump Device

MAINTENANCE STANDARD

1. Clearance between plunger (33) outer diameter

(d) and bore inner diameter (D) of cylinder block
(37) d D

DПd Unit: mm (in)

Standard Allowable Limit
W117-02-02-009
0.047 (0.002) 0.094 (0.004)

2. Free lenghth (L) of spring (36)

L Unit: mm (in)
Standard Allowable Limit
49.5 (1.95) 48.0 (1.89)

W117-02-02-010

3. Clearance (e) between plunger (33) and caulking

part of shoe(32) and the thickness (t) of the shoe

e Unit: mm (in)
Standard Allowable Limit
0 to 0.1 (0 to 0.004) 0.35 (0.014)

t Unit: mm (in) e
t
Standard Allowable Limit
6.5 (0.26) 6.3 (0.25)
W117-02-02-011

4. Height from the reverse face of retainer plate (34)

to the top of spherical bushing (35) Block

H-h Unit: mm (in)

h H
Standard Allowable Limit
16.5 (0.65) 15.5 (0.61) W117-02-02-012

W2-3-32
 UPPERSTRUCTURE / Pump Device

(Blank)

W2-3-33
 UPPERSTRUCTURE / Pump Device

DISASSEMBLE REGULATOR
ϑPump for Driving Oil Cooler Fan Motor ϒ

12
11
10
9
8

7
6
21
5 22
4 23
3 24
2
1 25
26
20
19 31
30
18
17
16 29
15 28
14
13 44
27
43

42
41
32 40
36 37 45
39 46
33
38
34
47

48
35
49

50
51
52
62 53
54
61
57 55
60
58 56
59
63

64
W183-02-04-018

W2-3-34
 UPPERSTRUCTURE / Pump Device

1- Pin 17 - Retaining Ring 33 - Cover 49 - Pin

2- Sleeve 18 - Sleeve 34 - O-Ring 50 - Pin
3- O-Ring 19 - Spool 35 - O-Ring (3 Used) 51 - Supporting Plug
4- O-Ring 20 - Pin 36 - Socket Bolt 52 - O-Ring
5- Sleeve 21 - Lever 37 - Socket Bolt 53 - Retaining Ring
6- Compensating Piston 22 - Feedback Lever 38 - O-Ring 54 - Supporting Plug
7- Compensating Rod 23 - Pin 39 - Adjusting Screw 55 - O-Ring
8- Spring Seat 24 - Pin 40 - Adjusting Screw 56 - Retaining Ring
9- Spring 25 - Lever 41 - Nut 57 - Pin
10 - Spring 26 - Pin 42 - O-Ring 58 - O-Ring
11 - Stopper 27 - Pilot Piston 43 - Cover 59 - O-Ring
12 - O-Ring 28 - Spring Seat 44 - Nut 60 - O-Ring
13 - Retaining Ring 29 - Spring 45 - Nut 61 - O-Ring
14 - Spring Seat 30 - Stopper 46 - Adjusting Screw 62 - Cover
15 - Spring 31 - O-Ring 47 - Socket Bolt (4 Used) 63 - Socket Bolt (2 Used)
16 - Spring 32 - Socket Bolt (4 Used) 48 - Housing 64 - Socket Bolt (2 Used)

W2-3-35
 UPPERSTRUCTURE / Pump Device

12
11
10
9
8

7
6
21
5 22
4 23
3 24
2
1 25
26
20
19 31
30
18
17
16 29
15 28
14
13 44
27
43

42
41
32 40
36 37 45
39 46
33
38
34
47

48
35
49

50
51
52
62 53
54
61
57 55
60
58 56
59
63

64
W183-02-04-018

W2-3-36
 UPPERSTRUCTURE / Pump Device

Disassemble Regulator
IMPORTANT: Do not remove pin (50) from su-
ϑ Pump to drive Oil Cooler Fan Motorϒ ϒ pporting plug (51) and put marks on
• Be sure to thoroughly read “Precautions for supporting plugs (51 and 54) to
Disassembly and Assembly Work” on page prevent confusing them.
W1-1-1 before starting the disassembly work.

9. Remove retaining rings (53 and 56) from housing

1. Remove socket bolts (36) (2 used) and (37) (2 (48) to remove supporting plugs (51 and 54) by
used) to remove the regulator from the pump. using bolt (M6) respectively.
ϖ 6 mm
IMPORTANT: Do not remove pin (26) from lever
IMPORTANT: Do not remove adjusting bolts (39, 40 (25).
and 46) and nuts (41, 44, and 45), the
oil flow rate setting will change as a
consequence. 10. Remove lever (25) with a pincers, etc. from
housing (48) and pilot piston (27).

2. Remove socket bolts (32) (4 used) to remove

cover (33). 11. Remove pin (23) from feedback lever (22) with a
copper bar through the hole of supporting plug
ϖ 5 mm (51) to remove feedback lever (22), sleeve (18)
and spool (19).
3. Remove O-rings (34) and (35) (3 used) from cover
ϖ 4 mm
(33).

4. Remove socket bolts (63) (2 used) and (64) (2 IMPORTANT: Do not remove pins (20 and 49) from
used) to remove cover (62) and O-rings (59, 60 lever (21).
and 61).
ϖ 5 mm 12. Remove lever (21) from housing (48) with a
pincers, etc. to remove compensating rod (7).

5. Remove O-ring (58) and pin (57) from housing

(48).

6. Remove pin (1), sleeve (2), O-rings (3 and 4),

sleeve (5) and compensating piston (6) from
housing (48).

7. Remove retaining ring (13) from housing (48) to

remove spring seat (14) and springs (15 and 16).

8. Remove socket bolts (47) (4 used) to remove

cover (43), stopper (11), springs (10 and 9),
spring seat (8), stopper (30), spring (29) and
spring seat (28).
ϖ 5 mm

W2-3-37
 UPPERSTRUCTURE / Pump Device

ASSEMBLE REGULATOR
(Pump for Driving Oil Cooler Fan Motor)
A 48 51 52 53
48 34 33
B

32

47

35

A B W183-02-04-012
54 55 56
W183-02-04-013

Section A-A 16 61 14 15 17 19 18 48 24 23 50 25 26 27 28 29 30 31 43

62

63 45

46

64

13 60 59 36 58 22 37 57
W183-02-04-004
Section B-B
49 21 8 9 10 42 38 43 44 39

41

2 40

4 6 5 7 22 20 11 12 W117-02-02-017

W2-3-38
 UPPERSTRUCTURE / Pump Device

1- Pin 17 - Retaining Ring 33 - Cover 49 - Pin

2- Sleeve 18 - Sleeve 34 - O-Ring 50 - Pin
3- O-Ring 19 - Spool 35 - O-Ring (3 Used) 51 - Supporting Plug
4- O-Ring 20 - Pin 36 - Socket Bolt 52 - O-Ring
5- Sleeve 21 - Lever 37 - Socket Bolt 53 - Retaining Ring
6- Compensating Piston 22 - Feedback Lever 38 - O-Ring 54 - Supporting Plug
7- Compensating Rod 23 - Pin 39 - Adjusting Screw 55 - O-Ring
8- Spring Seat 24 - Pin 40 - Adjusting Screw 56 - Retaining Ring
9- Spring 25 - Lever 41 - Nut 57 - Pin
10 - Spring 26 - Pin 42 - O-Ring 58 - O-Ring
11 - Stopper 27 - Pilot Piston 43 - Cover 59 - O-Ring
12 - O-Ring 28 - Spring Seat 44 - Nut 60 - O-Ring
13 - Retaining Ring 29 - Spring 45 - Nut 61 - O-Ring
14 - Spring Seat 30 - Stopper 46 - Adjusting Screw 62 - Cover
15 - Spring 31 - O-Ring 47 - Socket Bolt (4 Used) 63 - Socket Bolt (2 Used)
16 - Spring 32 - Socket Bolt (4 Used) 48 - Housing 64 - Socket Bolt (2 Used)

W2-3-39
 UPPERSTRUCTURE / Pump Device

A 48 51 52 53
48 34 33
B

47

35

A B W183-02-04-012
54 55 56
W183-02-04-013

Section A-A 16 61 14 15 17 19 18 48 23 50 25 26 27 28 29 30 31

62

63

64

13 60 59 22
W183-02-04-004
Section B-B
49 21 8 9 10 42 43

4 6 5 7 20 11 12 W117-02-02-017

W2-3-40
 UPPERSTRUCTURE / Pump Device

Assemble Regulator
1. Insert compensating rod (7) and lever (21) into 9. Insert supporting plug (54) into housing (48) and
housing (48). install retaining ring (56).

2. Align pins (49) of lever (21) with the pin hole in 10. Install O-ring (31) onto stopper (30).
housing (48) inside. Align pin (20) with the
stepped part of compensating rod (7) and install
lever (21) into housing (48). 11. Install spring seat (28), spring (29) and stopper
(30) into housing (48).

3. Place retaining ring (17) onto sleeve (18). Insert

sleeve (18) and spool (19) into housing (48). 12. Install O-ring (12) onto stopper (11).

IMPORTANT: Check spool (19) to ensure it moves 13. Place O-ring (42) into housing (48) and insert
smoothly before installing feedback spring seat (8), spring (9 and 10) and stopper (11).
lever (22) and do not make any Install cover (43) to housing (48) with socket bolts
mistake about the facing of spool (47) (4 used).
(19) and feadback lever (22). ϖ 5 mm
ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
4. Align the pin hole in feedback lever (22) with the
pin hole in spool (19) and install pin (23) from the 14. Install spring (15), spring sheet (14) and retaining
mounting hole in supporting plug (51). ring (13) onto spool (19).

5. Insert pilot piston (27) and lever (25) into housing 15. Place O-ring (4) onto sleeve (5) with which com-
(48). pensating piston (6), O-ring (3), sleeve (2) and pin
(1) can be installed into housing (48).
IMPORTANT: Check pilot piston (27) to ensure it
moves smoothly before installing 16. Assemble spring (16), O-rings (59, 60 and 61) into
lever (25). housing (48) to which cover (62) can be installed
with socket bolts (63) (2 used) and (64) (2 used).
6. Align pin (26) of lever (25) with the stepped part of ϖ 5 mm
pilot piston (27) and install lever (25). ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)

7. Install O-rings (52 and 55) onto supporting plugs

(51 and 54) respectively. 17. Install O-rings (34) and (35) (3 used) to cover (33).

8. Align pin (50) of supporting plug (51) with the pin

hole in lever (25) and insert it, and install retaining
ring (53).

W2-3-41
 UPPERSTRUCTURE / Pump Device

A 48
48
B 33

32

A B W183-02-04-012 W183-02-04-013

Section A-A 48

36 37
W183-02-04-004
Section B-B

W117-02-02-017

W2-3-42
 UPPERSTRUCTURE / Pump Device
18. Install cover (33) to housing (48) with socket bolts
(32) (4 used).
ϖ 5 mm
ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)

19. Install the regulator onto the pump with socket

bolts (36) (2 used) and (37) (2 used).
ϖ 6 mm
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W2-3-43
 UPPERSTRUCTURE / Pump Device

CONFIGURATION OF PILOT PUMP

C 6 7
1 2 3 4 5

A B

W183-02-04-007

15 14 13 12 11 10 C 9 8

16 17

17 16 16 17

Part A Part B

Section C-C

W183-02-04-019

W2-3-44
 UPPERSTRUCTURE / Pump Device

Wrench Size Tightening Torque

Item Part Name Q’ty Remarks
(mm) (in) N⋅m (kgf⋅m) (Ibf⋅ft)
1 Socket Bolt 4 12 (0.47) 34 to 39 (3.5 to 4.0) (25.5 to 29)
2 Washer 4
3 Plate 1
4 Pressure Plate 2
5 Gear Plate 1
6 Gear 1
7 Flange 1
8 Retaining Ring 1
9 Oil Seal 1 When installing, apply a film
of grease to the lip
10 Gear 1
11 Coupling 1
12 Dowel Pin 1
13 O-Ring 1 When installing, apply grease
14 Plate 1
15 O-Ring 1 When installing, apply grease
16 Backup Ring 2 When installing, apply grease
17 Seal Plate 2 When installing, apply grease

W2-3-45
 UPPERSTRUCTURE / Pump Device

CONFIGURATION OF PUMP FOR LUBRICATING PUMP TRANSMISSION

2 3 4 5 6
1
C

View D 12 11 10 9 8 7

Detali C

13 14 15

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

W2-3-46
 UPPERSTRUCTURE / Pump Device

Wrench Size Tightening Toruqe

Item Part Name Q’ty Remarks
(mm) (in) N⋅m (kgf⋅m) (Ibf⋅ft)
1 Bolt 4 17 0.67 34 to 39 (3.5 to 4.0) (25.5 to 29)
2 Cover 1
3 Driven Gear 1
4 Dowel Pin 2
5 Plate 1
6 Flange 1
7 Retaining Ring 1
8 Oil Seal 1
9 Side Plate A 1
10 Side Plate B 1
11 O-Ring 1
12 Drive Gear 1
13 Gasket A 1
14 Gasket B 1
15 Balance Seal 1

MAITENANCE STANDARD

Plate (5) Drive gear (12), Drive gear (3)

㈰ғ0.15 mm a ̨ b>̨ 14.96 mm (0.59 in)
(0.006 in) b

W117-02-02-022

W117-02-02-021

W2-3-47
 UPPERSTRUCTURE / Pump Device

(Blank)

W2-3-48
 UPPERSTRUCTURE / Control Valve

REMOVE AND INSTALL CONTROL VALVE

Cap
CAUTION: 1. Escaping fluid under pressure
can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release W183-01-01-001

any remaining pressure

before removing it.

Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap W183-04-02-003
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2.
: 4 mm

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil W183-04-02-002

tank. Wooden Blocks

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W2-4-1
 UPPERSTRUCTURE / Control Valve

Remove and Install Control Valve

NOTE: BH: Backhoe

LD: Loading shovel

Main Control Valve

Front Side Travel Right (Forward)

Bucket 1 (Roll-Out)
Bucket 1 (Roll-In)
Boom (Lower) Travel Right (Reverse)
Travel Left (Forward) Boom 1 (Raise)
Front Side
BH: Arm 2 (Roll-Out)
LD: Arm 2 (Roll-In)

Bucket 2
(Roll-Out) Boom 2
(Raise)

BH: Arm 2 (Roll-In)

Boom 2 LD: Arm 2 (Roll-Out)
(Lower)

Travel Left
(Reverse)
BH: Arm 1 (Roll-Out) BH: Auxiliary
LD: Bucket (Close) Bucket 2 (Roll-In)
LD: Arm 1 (Roll-In) BH: Auxiliary W183-02-05-020 W183-02-05-021
LD: Bucket (Open) BH: Arm 1 (Roll-In)
LD: Arm 1 (Roll-Out)

Swing Control Valve

Front Side

Boom 3 (Raise)

Swing (Right)
Boom 3 (Lower)

Swing (Left) Front Side

BH: Arm 3 (Roll-Out) Bucket 3 (Roll-Out) W183-02-05-023
LD: Arm 3 (Roll-In) BH: Arm 3 (Roll-In)
W183-02-05-022
Bucket 3 (Roll-In) LD: Arm 3 (Roll- Out)

W183-02-05-022

W2-4-2
 UPPERSTRUCTURE / Control Valve

Removal Main Control

IMPORTANT: Attach identification tags to hoses to Valve
aid reassembling.

1. Disconnect all hoses, pipes and connectors from Swing Control

Valve
control valve.
ϖ 19 mm
ϖ 19 mm
ϖ 41 mm
ϖ 12 mm
1

M183-07-031
NOTE: Cap all disconnected hose and pipe ends. 2
Main Control Valve
CAUTION: Main control valve weight:
390 kg (860 Ib)
Swing control valve weight:
150 kg (330 Ib)

2. Remove bolts (1) (4 used) and (2) (3 used).

ϖ 30 mm
3
3. Install eyebolts (M12, Pitch 1.75) to the bolt holes 3
(3) (3 places) and install eyebolts (M14, pitch 2) to
the holes (4) (4 places). Hoist by a crane, remove
main control valve and swing control valve.

T183-03-03-002

Swing Control Valve 4

T183-03-03-030

W2-4-3
 UPPERSTRUCTURE / Control Valve

NOTE: BH: Backhoe

LD: Loading shovel

Main Control Valve

Front Side Travel Right (Forward)

Bucket 1 (Roll-Out)
Bucket 1 (Roll-In))
Boom 1 (Lower) Travel Right (Reverse)
Travel Left (Forward) Boom 1 (Raise)
Front Side
BH: Arm 2 (Roll-Out)
LD: Arm 2 (Roll-In)

Bucket 2
(Roll-Out) Boom 2
(Raise)

BH: Arm 2 (Roll-In)

Boom 2 LD: Arm 2 (Roll-Out)
(Lower)

Travel Left
(Reverse)

BH: Arm 1 (Roll-Out) BH: Auxiliary

LD: Bucket (Close) Bucket 2 (Roll-In)
LD: Arm 1 (Roll-In) BH: Auxiliary W183-02-05-020 W183-02-05-021
LD: Bucket (Open) BH: Arm 1 (Roll-In)
LD: Arm 1 (Roll-Out)

Swing Control Valve

Front Side

Boom 3 (Raise)

Swing (Right)
Boom 3 (Lower)

Swing (Left) Front Side

BH: Arm 3 (Roll-Out) Bucket 3 (Roll-Out) W183-02-05-023
LD: Arm 3 (Roll -In) BH: Arm 3 (Roll-In)
W183-02-05-022
Bucket 3 (Roll-In) LD: Arm 3 (Roll-Out)

W2-4-4
 UPPERSTRUCTURE / Control Valve

Installation
1. Install eyebolts (M12, Pitch 1.75) into bolt holes
(3) (3 places) and install eyebolts (M14, pitch 2) Main Control Valve
into bolt holes (4) (4 places).

CAUTION: Main control valve weight:

390 kg (860 Ib)
Swing control valve weight:
150 kg (330 Ib)

2. Hoist main control valve and swing control valve 3

by a crane. Install them with bolts (1) (4 used) and 3
(2) (3 used).
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
Ȁ
3. Connect all hoses, pipe and connector onto
control valve.
ϖ 19 mm
T183-03-03-002
ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft)
ϖ 19 mm
ϖ 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft) Swing Control Valve 4
ϖ 41 mm
ϖ 295 N⋅m (30 kgf⋅m, 215 Ibf⋅ft)
ϖ 12 mm
ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

IMPORTANT: Be sure to check the hydraulic oil

level after assembling. Start engine
to check each part for any oil
leakage.
4

T183-03-03-030

Main Control
Valve

Swing Control
Valve

M183-07-031
2

W2-4-5
 UPPERSTRUCTURE / Control Valve

DISASSEMBLE MAIN CONTROL VLAVE 1

(5-SPOOL SECTION) 8 9 10

11
7

Overload
Relief Valve

6 24
6 6 6
5 26
5
5 5 25
4
4 20 4 27
4 28
3 3 31
3 29
2 2 3 21 2 33 30
32
2
1 34
17 23
35
16 19 22 36
15 16
14 37
14
13 13 38
12 18 39
40
41

48

47 45 43 42

Check Valve

46 44

W183-02-05-001

NOTE: BH: Backhoe

LD: Loading Shovel
1 - Spool (BH: Auxiliary/ 13 - Backup Ring (2 Used) 25 - Adjusting Screw 37 - Sleeve (6 Used)
LD: Bucket Open and Close) (6 Used)
2 - Spring Guide (5 Used) 14 - O-Ring (2 Used) 26 - O-Ring (6 Used) 38 - O-Ring (6 Used)
3 - Sleeve (5 Used) 15 - Spacer 27 - Spring (6 Used) 39 - Backup Ring (6 Used)
4 - Spring (5 Used) 16 - Spring (2 Used) 28 - Poppet (6 Used) 40 - O-Ring (6 Used)
5 - Spring Guide (5 Used) 17 - Check Valve 29 - Seat (6 Used) 41 - Overload Relief Valve (6 Used)
6 - Cap (5 Used) 18 - Cap 30 - O-Ring (6 Used) 42 - Cap
7 - O-Ring (5 Used) 19 - Check Valve 31 - Backup Ring (12 Used) 43 - Chip
8 - Socket Bolt (10 Used) 20 - Spool (Arm 1) 32 - O-Ring (6 Used) 44 - Backup Ring
9 - O-Ring (2 Used) 21 - Spool (Boom 2) 33 - Spring (6 Used) 45 - O-Ring
10 - Cap (2 Used) 22 - Spool (Bucket 2) 34 - Spring (6 Used) 46 - Spring
11 - Cover 23 - Spool (Travel Left) 35 - Piston (6 Used) 47 - Check Valve
12 - Cap 24 - Lock Nut (6 Used) 36 - Poppet (6 Used) 48 - Housing

W2-4-6
 UPPERSTRUCTURE / Control Valve
Disassemble Main Control Valve 1 (5-spool
section) Overload Relief Valve

• Be sure to thoroughly read “Precautions for IMPORTANT: Do not disassemble the overload
Disassembly and Assembly Work” on page relief valves unless necessary,
W1-1-1 before starting the disassembly work. because the adjustment on the test
• Attach tags to the spools and the places where bench should be carried out, keep
the spools inserted, in order to prevent overload relief valve with tag
misplacement when assembling. attached in order to set it to its
original position before being
Spool removed.

1. Remove socket bolts (8) (10 used) to remove

cover (11) from housing (48). 8. Remove overload relief valves (41) (6 used) (3 for
upper and 3 for lower) from housing (48).
ϖ 10 mm
ϖ 41 mm

2. Slowly take out the spool (1 and 20 to 23) assem-

blies (5 used) from housing (48) while comfirming 9. Loosen and remove seat (29). Remove springs
their corresponding position in housing (48). (33 and 34), piston (35) and poppet (36) from
sleeve (37).

3. Remove O-rings (7) (5 used) from housing (48). ϖ 36 mm

4. Clamp the spool (1) assembly in a vise with wooden IMPORTANT: Put matching marks on adjusting
spatulas inserted at both sides to hold it. bolts (25) and seat (29) and take a
note of the turning amount of
adjusting bolt (25).
5. Loosen cap (6) while holding spring guide (5) by
hand, and remove spring guide (2), sleeve (3),
spring (4) and spring guide (5). 10. Remove lock nut (24) to remove adjusting bolt
(25), spring (27) and poppet (28) from seat (29).
ϖ 10 mm
ϖ 19 mm
ϖ 6 mm
6. Disassemble the spool (20 to 23) assemblies (4
used) in accordance with the procedures 4 to 5.
Check Valve
11. Loosen and remove cap (42) from housing (48).
7. Remove caps (12 and 18) of the opposite spools
(20 and 21) to remove spacer (15), spring (16) ϖ 14 mm
and check valves (17 and 19) respectively.
ϖ 8 mm, 10 mm 12. Remove spring (46) and check valve (47) from
housing (48).
NOTE: Spacer (15) is no use on spool (21).

W2-4-7
 UPPERSTRUCTURE / Control Valve

48

49

50
51
52

53
54
55
56
41 57
58
59
85 61
82 62
84 82 63
64
83 81 65
72 66
80 73 67
80 74 68
69
75 70
76 71
77
78
Overload Relief Valve
79 (Boom Motor Selector)

Overload Relief Valve

W183-02-04-020

41 - Overload Relief Valve (6 Used) 57 - Backup Ring 68 - Backup Ring 77 - O-Ring

48 - Housing 58 - O-Ring 69 - Seat 78 - Backup Ring
49 - Overload Relief Valve 59 - Sleeve 70 - Spring 79 - O-Ring
(Boom Motor Selector)
50 - Cap 61 - O-Ring 71 - Spring 80 - Socket Bolt (10 Used)
51 - O-Ring 62 - Poppet 72 - Piston 81 - Cover (3 Used)
52 - Piston 63 - Spring 73 - O-Ring 82 - O-Ring (5 Used)
53 - Sleeve 64 - Spring Guide 74 - Backup Ring (2 Used) 83 - Cover (2 Used)
54 - Backup Ring 65 - Spring 75 - Poppet 84 - O-Ring (2 Used)
55 - O-Ring 66 - Poppet 76 - Sleeve 85 - Plug (2 Used)
56 - Lock Nut 67 - O-Ring

W2-4-8
 UPPERSTRUCTURE / Control Valve
13. Remove socket bolts (80) (10 used) from the
lower side of the main control valve to remove
covers (81) (3 used) and (83) (2 used) from
housing (48).
ϖ 10 mm

Overload Relief Valve

(Boom Motor Selector)
IMPORTANT: As for overload relief valve, do not
disassemble it unless necessary
because its adjustment should be
carried out on the test bench if it is
removed. Keep overload relief valve
with tag attached in order to set it to
its original position.

14. Loosen sleeve (76) to remove overload relief valve

(49) from housing (48).
ϖ 41 mm

15. Remove sleeve (59) from sleeve (76) to remove

poppet (75), piston (72), springs (70 and 71), seat
(69), poppet (66), spring (65), spring guide (64)
and spring (63).
ϖ 36 mm
ϖ 3 mm

NOTE: Take poppet (75) out from the housing (48)

side of sleeve (76) by pushing lightly with a
round bar.

IMPORTANT: Attach matching marks on sleeves

(53 and 59) and lock nut (56) and
take a note of turning amount of
sleeve (53).

16. Loosen lock nut (56) to remove sleeve (53) from

sleeve (59).
ϖ 30 mm, 36 mm

17. Remove cap (50) to remove piston (52) and

poppet (62) from sleeve (53).
ϖ 27 mm

W2-4-9
 UPPERSTRUCTURE / Control Valve

ASSEMBLE MAIN CONTROL VALVE 1

(5-SPOOL SECTION)
Check Valve
Overload Relief Valve (49) 42
(Boom Motor Selector) 45
44

46
Manifold 43

47

Check Valve

W183-02-05-024

48

Front Side

T183-03-03-029
Overload Relief Valve
(Boom Motor Selector)

72 78 74 73 70 66 68 64 54 63 62 57 52 53 51 50

W183-02-05-003

79 75 71 77 69 67 65 76 61 55 59 58 56

42 - Cap 52 - Piston 62 - Poppet 71 - Spring

43 - Chip 53 - Sleeve 63 - Spring 72 - Piston
44 - Backup Ring 54 - Backup Ring 64 - Spring Guide 73 - O-Ring
45 - O-Ring 55 - O-Ring 65 - Spring 74 - Backup Ring (2 Used)
46 - Spring 56 - Locknut 66 - Poppet 75 - Poppet
47 - Check Valve 57 - Backup Ring 67 - O-Ring 76 - Sleeve
48 - Housing 58 - O-Ring 68 - Backup Ring 77 - O-Ring
49 - Overload Relief Valve 59 - Sleeve 69 - Seat 78 - Backup Ring
(Boom Motor Selector)
50 - Cap 61 - O-Ring 70 - Spring 79 - O-Ring
51 - O-Ring

W2-4-10
 UPPERSTRUCTURE / Control Valve

Assemble Main Control Valve 1 (5-Spool Section)

1. Place housing (48) on the work bench with the 8. Install sleeve (59) into sleeve (76).
manifold side facing down. ϖ 36 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
NOTE: Place a soft rag or shop cloth on the work ϖ 41 mm
bench. ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

Overload Relief Valve IMPORTANT: Install overload relief valve (49) to its
(Boom Motor Selector) position where it was removed.
Be sure to perform adjustment to the
2. Place O-ring (51) onto cap (50) and install poppet valve on test bench.
(62), piston (52) and cap (50) to sleeve (53). (Refer to Performance Test and
Adjustment for Overload Relief Valve
ϖ 27 mm
chapter in Technical Manual)
ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
9. Install overload relief valve (49) into housing (48).
3. Install lock nut (56) to sleeve (53) and assemble
backup rings (54 and 57) and O-rings (55 and 58). ϖ 41 mm
ϖ 78 N⋅m (8 kgf⋅m, 58 Ibf⋅ft)
IMPORTANT: As for sleeve (53), it should be
screwed in only by the same amount Check Valve
to removal, so that the matching 10. Install check valve (47) and spring (46) into housing
marks can be aligned precisely. (48).

4. Install sleeve (53) into sleeve (59) and secure with IMPORTANT: Chip (43) prevents cap (42) from
lock nut (56). being pulled, and looseness.
Chip (43) will be damaged on cap (42)
5. Install spring (63), spring guide (64), spring (65) being removed because it is made of
and poppet (66) into sleeve (59). nylon.
Be sure to replace chip (43) with a
new one and install cap (42).
6. Install backup rings (74) (2 used) and O-ring (73)
onto poppet (75) and install backup ring (68) and
O-ring (67) onto seat (69). 11. Assemble chip (43), backup ring (44) and O-ring
(45) into cap (42) and install cap (42) onto housing
(48).
7. Assemble backup ring (78) and O-rings (77 and
79) onto sleeve (76), and install poppet (75), ϖ 14 mm
piston (72), springs (70 and 71) and seat (69). ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft)

W2-4-11
 UPPERSTRUCTURE / Control Valve

A Overload Relief Valve (41)

Front Side 40 35 36 38 37 33 27 29 26

39 34 32 31 28 30 25 24
W162-02-04-022

Overload Relief
Valve (41) 5-Spool Section
48 T183-03-03-028
6
9,10 5
Upper Side 11 4
8 3
7 2
Front Side
21
22 1
23 20

17
16

19 15
16

82 80

81 83 13,14 18 12 13,14

T183-03-03-027
W183-02-05-002

Overload Relief
Valve (41)

NOTE: BH: Backhoe

LD: Loading Shovel
1 - Spool (BH: Auxiliary / 13 - Backup Ring (2 Used) 25 - Adjusting Bolt (6 Used) 37 - Sleeve (6 Used)
LD: Bucket- Open / Close)
2 - Spring Guide (5 Used) 14 - O-Ring (2 Used) 26 - O-Ring (6 Used) 38 - O-Ring (6 Used)
3 - Sleeve (5 Used) 15 - Spacer 27 - Spring (6 Used) 39 - Backup Ring (6 Used)
4 - Spring (5 Used) 16 - Spring (2 Used) 28 - Poppet (6 Used) 40 - O-Ring (6 Used)
5 - Spring Guide (5 Used) 17 - Check Valve 29 - Seat (6 Used) 41 - Overload Relief Valve (6
Used)
6- Cap (5 Used) 18 - Cap 30 - O-Ring (6 Used) 48 - Housing
7- O-Ring (5 Used) 19 - Check Valve 31 - Backup Ring (12 Used) 80 - Socket Bolt (10 Used)
8- Socket Bolt (10 Used) 20 - Spool (Arm 1) 32 - O-Ring (6 Used) 81 - Cover (3 Used)
9- O-Ring (2 Used) 21 - Spool (Boom 2) 33 - Spring (6 Used) 82 - O-Ring (5 Used)
10 - Cap (2 Used) 22 - Spool (Bucket 2) 34 - Spring (6 Used) 83 - Cover (2 Used)
11 - Cover 23 - Spool (Travel Left) 35 - Piston (6 Used)
12 - Cap 24 - Lock Nut (6 Used) 36 - Poppet (6 Used)

W2-4-12
 UPPERSTRUCTURE / Control Valve

Overload Relief Valve Spool

12. Install backup rings (31)(2 used) and O-rings (30 18. Place O-rings (82) (5 used) to the lower side of
and 32) onto seat (29) and O-ring (26) onto housing (48) and install covers (81) (3 used) and
adjusting bolt (25). (83) (2 used) with socket bolts (80) (10 used).
ϖ 10 mm
IMPORTANT: As for adjusting bolt (25), it should be ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
screwed in only by the same amount
to removal, so that the matching 19. Clamp and hold spool (1) in a vise with wooden
marks can be aligned precisely. spatulas inserted. Assemble spring guide (5),
spring (4), sleeve (3) and spring guide (2) into cap
13. Assemble poppet (28), spring (27), adjusting bolt (6) and install cap (6) to spool (1).
(25) and lock nut (24) onto seat (29). ϖ 10 mm
ϖ 19 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
ϖ 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf⋅ft)
ϖ 6 mm
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) 20. Assemble four spools (20 to 23) in accordance
with the procedure 19.
14. Install poppet (36), piston (35) and springs (33 and
21. Assemble check valves (17 and 19), spring (16)
34) into sleeve (37). and spacer (15) to spools (20 and 21)
respectively.
15. Install seat (29) into sleeve (37).
ϖ 36 mm NOTE: Spacer (15) is not used in spool (21).
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

16. Install backup ring (39) and O-rings (40 and 38) to 22. Place backup ring (13) and O-ring (14) into cap
sleeve (37). (12 and 18). Install caps (12 and 18) to spools (20
and 21) respectively.
ϖ 8 mm
IMPORTANT: Install overload relief valve (41) to its
position where it was removed. ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft)
Be sure to perform an adjustment to ϖ 10 mm
the valve on test bench. ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
(Refer to Performance Test and
Adjustment for Overload Relief Valve 23. Assemble O-rings (7) (5 used) into housing (48).
in Technical manual)

17. Install overload relief valves (41) (6 used), 3 for

upper and 3 for lower into housing (48).
ϖ 41 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-13
 UPPERSTRUCTURE / Control Valve

A Overload Relief Valve (41)

Front Side 40 35 36 38 37 33 27 29 26

39 34 32 31 28 30 25 24
W162-02-04-022

Overload Relief
Valve (41) 5-Spool Section
48 T183-03-03-028
6
5
Upper Side 11 4
8 3
7 2
Front Side
21
22 1
23 20

17
16

19 15
16

82 80

81 83 13,14 18 12 13,14

T183-03-03-027
W183-02-05-002

Overload Relief
Valve (41)

W2-4-14
 UPPERSTRUCTURE / Control Valve
IMPORTANT: Install the spool (1 and 20 to 23)
assemblies (5 used) to the positions
where they were removed. Insert
spools (20 and 22) so that splined
plug (85) of cover (83) can enter the
slot of spool.

83

85

Spool
W183-02-05-031

24. Hold the spring parts of the spools (1 and 20 to 23)

assemblies and insert them into housing (48)
while turning them slowly.

25. Install cover (11) to housing (48) with socket bolts

(8) (10 used).
ϖ 10 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-15
 UPPERSTRUCTURE / Control Valve

DISASSEMBLE MAIN CONTROL VALVE 2

(5-SPOOL SECTION)

3
2 10 Load Check
6 Valve
1 5
4
9
8 12
6
5
7 4
6 11
5 9
39 8
4 13
14
15
16
17 22
18 23

3
19
2 20 24
21 25
1 31
32
33
34 28
30 29 27
26
Holding Valve

35
36

37
38
W183-02-05-004

1- O-Ring (2 Used) 11 - Check Valve (4 Used) 21 - Backup Ring 31 - Backup Ring

2- Flange (2 Used) 12 - Cap (4 Used) 22 - Cap 32 - O-Ring
3- Socket Bolt (8 Used) 13 - Cap 23 - O-Ring 33 - Spring
4- O-Ring (6 Used) 14 - O-Ring 24 - Socket Bolt (4 Used) 34 - Poppet
5- Backup Ring (6 Used) 15 - Spring 25 - Washer (4 Used) 35 - Cap
6- Chip (6 Used) 16 - Poppet 26 - Cap 36 - O-Ring
7- Cap 17 - Sleeve 27 - O-Ring 37 - Socket Bolt (4 Used)
8- Check Valve (5 Used) 18 - Backup Ring 28 - Piston 38 - Washer (4 Used)
9- Spring (5 Used) 19 - O-Ring 29 - Cover 39 - Housing
10 - Cap 20 - O-Ring 30 - O-Ring

W2-4-16
 UPPERSTRUCTURE / Control Valve
Disassemble Main Control Valve 2 (5-Spool
Section) Load Check Valve

• Be sure to thoroughly read “Precautions for 6. Loosen and remove cap (10) and (12) (4 used)
Disassembly and Assembly Work” on page from housing (39).
W1-1-1 before starting the disassembly work. ϖ 14 mm

Holding Valve 7. Pull out check valves (8) (5 used), springs (9) (5
1. Remove socket bolts (24) (4 used) and washers used) and check valves (11) (4 used) from
(25) (4 used) to remove cover (29) from housing housing (39).
(39).
ϖ 12 mm NOTE: Check valve (11) is not used in cap (10).

2. Remove spring (33) and poppet (34) from housing

(39).

IMPORTANT: In case poppet (16) can not be pulled

out from sleeve (17) after long term
operation, for the seat surface being
deformed, replace sleeve (17) and
poppet (16).

3. Remove cap (13) to remove spring (15) and

poppet (16) from cover (29).
ϖ 10 mm

4. Remove cap (26) to remove piston (28).

ϖ 10 mm

5. With a pipe (inner dia 10 mm (0.39 in), outer dia

14 mm (0.55 in)), push out sleeve (17) by tapping
it lightly from cap (26) side.

W2-4-17
 UPPERSTRUCTURE / Control Valve

ASSEMBLE MAIN CONTROL VALVE 2

(5-SPOOL SECTION)

Front Side
Load Check Valve

A B

10 4 9 8 12 4 9 6 8

W183-02-05-027
5 6 5 11 W183-02-05-028
Manifold
Load Check
Valve (B)
Load Check
Valve (A)

Holding Valve 39
7
W183-02-05-026
2 3

Holding Valve

29 27 26 30 31,32 33 34

28

20,21

18,19

16
15

23 22 14 13 17 24,25 W183-02-05-029

1- O-Ring (2 Used) 11 - Check Valve (4 Used) 21 - Backup Ring 31 - Backup Ring

2- Flange (2 Used) 12 - Cap (4 Used) 22 - Cap 32 - O-Ring
3- Socket Bolt (8 Used) 13 - Cap 23 - O-Ring 33 - Spring
4- O-Ring (6 Used) 14 - O-Ring 24 - Socket Bolt (4 Used) 34 - Poppet
5- Backup Ring 15 - Spring 25 - Washer (4 Used) 35 - Cap
6- Chip (6 Used) 16 - Poppet 26 - Cap 36 - O-Ring
7- Cap 17 - Sleeve 27 - O-Ring 37 - Socket Bolt (4 Used)
8- Check Valve (5 Used) 18 - Backup Ring 28 - Piston 38 - Washer (4 Used)
9- Spring (5 Used) 19 - O-Ring 29 - Cover 39 - Housing
10 - Cap 20 - O-Ring 30 - O-Ring

W2-4-18
 UPPERSTRUCTURE / Control Valve

Assemble Main Control Valve 2 (5-Spool

Section)
7. Assemble O-rings (14 and 27) onto caps (13 and
1. Place housing (39) on work bench with the mani- 26) respectively. Then install these caps into cover
fold side down. (29).
ϖ 10 mm
ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
NOTE: Place a soft rag or shop cloth on the work
bench.
8. Install backup ring (31) and O-rings (30 and 32) to
Load Check Valve cover (29).
2. Assemble check valves (8) (5 used), springs (9)
(5 used) and check valves (11) (4 used) into housing 9. Install cover (29) to housing (39) with socket bolts
(39). (24) (4 used) and washers (25) (4 used).
ϖ 12 mm
ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
NOTE: Check valve (11) is not used in cap (10)
part.

IMPORTANT: Chips (6) prevent caps (7, 10 and 12)

from being pulled, and looseness.
Chips (6) are made of nylon and will
be damaged on caps (7, 10 and 12)
being removed.
Be sure to replace chips (6) with new
ones and install caps (7, 10 and 12).

3. Assemble chips (6), backup ring (5) and O-rings

(4) onto caps (10) and (12) (4 used), and install
caps (10) and (12) (4 used) into housing (39).
ϖ 14 mm
ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft)

Holding Valve
4. Place poppet (34) and spring (33) into housing
(39).

5. Assemble backup rings (18 and 21) and O-rings

(19 and 20) onto sleeve (17).

6. Assemble piston (28), sleeve (17), poppet (16)

and spring (15) into cover (29).

W2-4-19
 UPPERSTRUCTURE / Control Valve

DISASSEMBLE MAIN CONTROL VALVE 1

(4-SPOOL SECTION)
23

22
24
Main Relief Overload Re-
Valve lief Valve

43 61

18 42
12 18
41 60
Make-Up
Valve 17 17 40 59
11
39 58
10 16 16 57
38
9 37 56
8 15 15 36 55
7 54
14 35 53
14
6 34 52
5 33 51
13 32 50
4 49 62
19 20 21 31
3 48 63
30
47 64
2 29
1 46 65
26 28 45
25 27 44 66
67
68
69
70
Shuttle Valve

88

W183-02-05-005

W2-4-20
 UPPERSTRUCTURE / Control Valve

1- O-Ring (2 Used) 19 - Spool (Boom 1) 37 - O-Ring 55 - Seat (4 Used)

2- Backup Ring (2 Used) 20 - Spool (Bucket 1) 38 - Sleeve 56 - Poppet (4 Used)
3- O-Ring (2 Used) 21 - Spool (Travel Right) 39 - Piston 57 - Spring (4 Used)
4- Sleeve (2 Used) 22 - O-Ring (4 Used) 40 - Lock Nut 58 - O-Ring (4 Used)
5- Poppet (2 Used) 23 - Socket Bolt (8 Used) 41 - O-Ring 59 - Adjusting Bolt (4 Used)
6- Backup Ring (4 Used) 24 - Cover 42 - Adjusting Bolt 60 - Lock Nut (4 Used)
7- O-Ring (2 Used) 25 - Sleeve 43 - Main Relief Valve 61 - Overload Relief Valve (4 Used)
8- Spring (2 Used) 26 - Poppet 44 - O-Ring (4 Used) 62 - Seat
9- O-Ring (2 Used) 27 - Spring 45 - Backup Ring (4 Used) 63 - O-Ring
10 - Backup Ring (2 Used) 28 - O-Ring 46 - O-Ring (4 Used) 64 - Ball
11 - Cap (2 Used) 29 - Backup Ring 47 - Sleeve (4 Used) 65 - Cap
12 - Make-Up Valve (2 Used) 30 - Seat 48 - Poppet (4 Used) 66 - O-Ring
13 - Spool (Arm 2) 31 - Poppet 49 - Piston (4 Used) 67 - Backup Ring
14 - Spring Guide (4 Used) 32 - Spring 50 - Spring (4 Used) 68 - O-Ring
15 - Sleeve (4 Used) 33 - O-Ring 51 - Spring (4 Used) 69 - Spring
16 - Spring (4 Used) 34 - Cap 52 - O-Ring (4 Used) 70 - Check Valve
17 - Spring Guide (4 Used) 35 - Lock Nut 53 - Backup Ring (8 Used) 88 - Housing
18 - Cap (4 Used) 36 - O-Ring 54 - O-Ring (4 Used)

W2-4-21
 UPPERSTRUCTURE / Control Valve

23

22
24
Main Relief Overload Relief
Valve Valve

61

12 18 18
Make-Up 60
Valve 17 17 59
11
58
10 16 16 57
9 56
8 15 15 55
7 54
14 14 53
6 52
5 51
13 50
4 49
19 20 21
3 48
2 47
1 46
45
44

Shuttle Valve

88

W183-02-05-005

W2-4-22
 UPPERSTRUCTURE / Control Valve
Disassemble Main Control Valve 1 (4-Spool
Section) Overload Relief Valve

• Be sure to thoroughly read “Precaution for IMPORTANT: Do not disassemble the overload
Disassembly and Assembly Work” on page relief valve unless necessary. As
W1-1-1 before starting the disassembly work. adjustment on the test bench should
• Attach a tag to each spool that should be installed be carried out if it is disassembled
into the corresponding position on the housing in keep a tag attaching to the valve to
order to prevent misplacement. ensure that it can be reassembled to
the position where it was removed.

Spool
7. Remove overload relief valves (61) (4 used) (2 for
1. Remove socket bolts (23) (8 used) to remove cover upper and 2 for lower) from housing (88).
(24) from housing (88).
ϖ 41 mm
ϖ 10 mm

8. Loosen and remove seat (55) to remove springs

2. Slowly pull out the spool (13, 19 to 21) assemblies (50 and 51), piston (49) and poppet (48) from
(4 used) from housing (88) while confirming the sleeve (47).
corresponding position on housing (88).
ϖ 36 mm

3. Remove O-rings (22) (4 used) from housing (88).

IMPORTANT: Put matching marks on adjusting bolt
(59) and seat (55) and take a note of
4. Clamp and hold the spool (13) assembly in a vise the amount to turn adjusting bolt (59).
with wooden spatulas inserted at both sides.

9. Remove lock nut (60) to remove adjusting bolt (59),

5. Loosen and remove cap (18) while holding spring spring (57) and poppet (56) from seat (55).
guide (17) by a hand to remove spring guide (14),
spool (15), spring (16) and spring guide (17). ϖ 19 mm
ϖ 6 mm
ϖ 10 mm

Make-Up Valve
6. Disassemble the spools (19 to 21) assemblies (3
used) in accordance with the procedure 4 to 5. 10. Loosen sleeve (4) to remove make-up valves (12)
(2 used) (1 for upper and 1 for lower) from housing
(88).
ϖ 41 mm

11. Remove cap (11) to remove spring (8) and poppet

(5) from sleeve (4).
ϖ 36 mm

W2-4-23
 UPPERSTRUCTURE / Control Valve

Main Relief Overload Relief

Valve Valve

43

42
41
Make-Up
Valve 40
39
38
37
36
35
34
33
32
62
31
63
30 64
29
65
26 28
25 27 66
67
68
69
70
Shuttle Valve

88

W183-02-05-005

W2-4-24
 UPPERSTRUCTURE / Control Valve

Main Relief Valve

IMPORTANT: Do not disassemble the main relief
valve unless necessary.

12. Loosen cap (34) to remove main relief valve (43)

from housing (88).
ϖ 41 mm

13. Loosen lock nuts (35 and 40).

ϖ 30 mm, 41 mm

IMPORTANT: Seat (30) is being pressed in cap (34).

Do not remove it.

14. Remove sleeve (25) from cap (34) to remove

spring (27) and poppet (26).

IMPORTANT: Put matching marks on adjusting bolt

(42) and sleeve (38) and take a note of
the amount to turn adjusting bolt
(42).

15. Remove adjusting bolt (42) from sleeve (38) to

remove piston (39), spring (32) and poppet (31).
ϖ 22 mm

IMPORTANT: Put matching marks on sleeve (38)

and cap (34) and take a note of the
amount to turn sleeve (38).

16. Remove sleeve (38) from cap (34).

ϖ 27mm

Shuttle Valve
17. Loosen cap (65) to the remove shuttle valve from
housing (88).
ϖ 41 mm

18. Remove spring (69) and check valve (70) from

housing (88).

19. Remove seat (62) to remove ball (64) cap (65).

ϖ 27 mm

W2-4-25
 UPPERSTRUCTURE / Control Valve

88

87
86
84
81 76
75
80
74
83
79 73
85 78 72
Overload Relief
72 71 Valve
82
77 Check
Make-Up Valve
Valve
Flow-Combining W183-02-05-018
Valve

71 - Cap 76 - Check Valve 81 - Spool 86 - O-Ring (3 Used)

72 - Chip (2 Used) 77 - Cap 82 - Socket Bolt (8 Used) 87 - Plug (3 Used)
73 - Backup Ring 78 - O-Ring 83 - Cover 88 - Housing
74 - O-Ring 79 - Spring 84 - O-Ring (4 Used)
75 - Spring 80 - Spacer 85 - Cover (3 Used)

W2-4-26
 UPPERSTRUCTURE / Control Valve
20. Remove socket bolts (82) (8 used) to remove
covers (83), (85) (3 used) and O-rings (84) (4 used)
from housing (88).

Flow-combining Valve
21. Remove cap (77) to remove spring (79), spacer
(80) and spool (81) from housing (88).
ϖ 46 mm

Check Valve
22. Remove cap (71) to remove spring (75) and check
valve (76) from housing (88).
ϖ 14 mm

W2-4-27
 UPPERSTRUCTURE / Control Valve

ASSEMBLE MAIN CONTROL VALVE 1

(4-SPOOL SECTION)

Shuttle Valve
Shuttle Valve
70 67 65 64 63 62

Manifold

W162-02-04-023
69 68 66

Check Valve
71
73
74
Front Side
88

72
T183-03-03-029
75
Upper Side 76
88

Front Side
W183-02-05-024

Flow-Combining Valve
81 72 79 77

Check Valve

Flow-Combining Valve W162-02-04-024

80 78

T183-03-03-027

62 - Seat 68 - O-Ring 73 - Backup Ring 78 - O-Ring

63 - O-Ring 69 - Spring 74 - O-Ring 79 - Spring
64 - Ball 70 - Check Valve 75 - Spring 80 - Spacer
65 - Cap 71 - Cap 76 - Check Valve 81 - Spool
66 - O-Ring 72 - Chip (2 Used) 77 - Cap 88 - Housing
67 - Backup Ring

W2-4-28
 UPPERSTRUCTURE / Control Valve

Assemble Main Control Valve 1 (4-Spool Section)

Shuttle Valve
1. Place housing (88) on the work bench with the 6. Install backup ring (67) and O-rings (66 and 68)
manifold side down. onto cap (65) and O-ring (63) to seat (62).

7. Insert ball (64) into cap (65) and install seat (62).
NOTE: Place a soft rag or shop cloth on the work
bench. ϖ 27 mm
ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft)
Check Valve
2. Install check valve (76) and spring (75) into 8. Assemble check valve (70) and spring (69) into
housing (88). housing (88) and install cap (65).
ϖ 41 mm
IMPORTANT: Chips (72) prevent caps (71 and 77) ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
from being pulled, and looseness.
Chips (72) will be damaged if caps
(71 and 77) are removed because
they are made of nylon.
Be sure to replace chips (72) with
new ones and install caps (71 and
77).

3. Assemble backup ring (73), O-ring (74) and chip

(72) onto cap (71) and install cap (71) into housing
(88).
ϖ 14 mm
ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft)

Flow-Combining Valve
4. Place O-ring (78) and chip (72) onto cap (77) and
install spring (79).

5. Insert spool (81) and spacer (80) into housing (88)

and install cap (77).
ϖ 46 mm
ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

W2-4-29
 UPPERSTRUCTURE / Control Valve

Main Relief Valve (43)

Main Relief
Valve 26 25 28 30 32 33 34 35 38 40 42

27 29 31 36 37 39 41
W183-02-05-007

Front Side
88
Make-Up Valve (12)
Make-Up
Valve 1 5 6 3 8 4 9 11
T183-03-03-029

88
Front Side

W162-02-04-028

2 7 10

Make-Up T183-03-03-027
Valve

1- O-Ring (2 Used) 9- O-Ring (2 Used) 29 - Backup Ring 37 - O-Ring

2- Backup Ring (2 Used) 10 - Backup Ring (2 Used) 30 - Seat 38 - Sleeve
3- O-Ring (2 Used) 11 - Cap (2 Used) 31 - Poppet 39 - Piston
4- Sleeve (2 Used) 12 - Make-Up Valve (2 Used) 32 - Spring 40 - Lock Nut
5- Poppet (2 Used) 25 - Sleeve 33 - O-Ring 41 - O-Ring
6- Backup Ring (4 Used) 26 - Poppet 34 - Cap 42 - Adjusting Bolt
7- O-Ring (2 Used) 27 - Spring 35 - Lock Nut 43 - Main Relief Valve
8- Spring (2 Used) 28 - O-Ring 36 - O-Ring 88 - Housing

W2-4-30
 UPPERSTRUCTURE / Control Valve

Main Relief Valve Make-Up Valve

IMPORTANT: Sleeve (38) can be screwed in only by 15. Assemble backup rings (6) (2 used) and O-ring (7)
same amount to that of removal so as onto poppet (5) and install backup ring (10) and
to align with the matching marks. O-ring (9) onto cap (11). Then install poppet (5) to
cap (11).

9. Assemble lock nut (35) and O-rings (36 and 37)

onto sleeve (38) and install sleeve (38) to cap 16. Assemble poppet (5), spring (8) and cap (11) into
(34). sleeve (4).
ϖ 41 mm ϖ 36 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

17. Assemble backup ring (2) and O-rings (1 and 3)

10. Install poppet (31), spring (32) and piston (39) into onto sleeve (4) and install make-up valve (12) into
cap (34). housing (88).
ϖ 41 mm
IMPORTANT: Adjusting bolt (42) should be ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
screwed in only by same amount to
that of removal so as to align with the
matching marks.

11. Install lock nut (40) and O-ring (41) onto adjusting
bolt (42) and install adjusting bolt (42) into sleeve
(38).
ϖ 22 mm
ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft)
ϖ 30 mm
ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft)

12. Install backup ring (29) and O-ring (28) into seat
(30).

13. Place poppet (26) and spring (27) into sleeve (25)
and install sleeve (25) to cap (34).

IMPORTANT: Be sure to perform the adjustment to

the main relief valve. (Refer to
Adjustment of the Main Relief Valve
in chapter of Performance Test,
Techical Manual)

14. Install main relief valve (43) into housing (88).

ϖ 41 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-31
 UPPERSTRUCTURE / Control Valve

A Overload Relief Valve (61)

44 49 48 46 47 51 57 55 58

45 50 52 53 56 54 59 60
W162-02-04-022

Overload Re- Front Side

lief Valve 4-Spool Section

24
18
T183-03-03-029
17
16
Upper Side 88 23 15
Overload Re- 22
lief Valve 14

Front Side
19
21

20

13

84 85 83 82
W183-02-05-025

T183-03-03-027

13 - Spool (Arm 2) 22 - O-Ring (4 Used) 50 - Spring (4 Used) 59 - Adjusting Bolt (4 Used)

14 - Spring Guide (4 Used) 23 - Socket Bolt (8 Used) 51 - Spring (4 Used) 60 - Lock Nut (4 Used)
15 - Sleeve (4 Used) 24 - Cover 52 - O-Ring (4 Used) 61 - Overload Relief Valve (4 Used)
16 - Spring (4 Used) 44 - O-Ring (4 Used) 53 - Backup Ring (8 Used) 82 - Socket Bolt (8 Used)
17 - Spring Guide (4 Used) 45 - Backup Ring (4 Used) 54 - O-Ring (4 Used) 83 - Cover
18 - Cap (4 Used) 46 - O-Ring (4 Used) 55 - Seat (4 Used) 84 - O-Ring (4 Used)
19 - Spool (Boom 1) 47 - Sleeve (4 Used) 56 - Poppet (4 Used) 85 - Cover (3 Used)
20 - Spool (Bucket 1) 48 - Poppet (4 Used) 57 - Spring (4 Used) 88 - Housing
21 - Spool (Travel Right) 49 - Piston (4 Used) 58 - O-Ring (4 Used)

W2-4-32
 UPPERSTRUCTURE / Control Valve

Overload Relief Valve Spool

18. Assemble backup rings (53) (2 used) and O-rings 24. Place O-rings (84) (4 used) to the lower side of
(52 and 54) onto seat (55) and install O-ring (58) housing (88) where cover (83) and (85) (3 used)
onto adjusting bolt (59). should be installed with socket bolts (82) (8 used).
ϖ 10 mm
IMPORTANT: Adjusting bolt (59) should be ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
screwed in only by same amount to
that of removal so as to align with the
matching marks. 25. Clamp and hold spool (13) in a vise with wooden
spatulas inserted at both sides.Assemble spring
guide (17), sleeve (15), spring (16) and spring
19. Assemble poppet (56), spring (57), adjusting bolt guide (14) onto cap (18) and install cap (18) into
(59) and lock nut (60) into seat (55). spool (13).
ϖ 19 mm ϖ 10 mm
ϖ 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf⋅ft)
ϖ 6 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
26. Assemble 3 spools (19 to 21) in accordance with
20. Install poppet (48), piston (49) and springs (50 and the procedure 25.
51) into sleeve (47).
27. Place O-rings (22) (4 used) to housing (88).
21. Install seat (55) into sleeve (47).
ϖ 36 mm IMPORTANT: Install the 4 spool (13 and 19 to 21)
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) assemblies to their positions where
they were disassembled. Insert
22. Install backup ring (45) and O-rings (44 and 46) spools (13 and 19 to 21) so that
onto sleeve (47). splined plug (87) of cover (85) can
enter the spool’s slot.

IMPORTANT: Install overload relief valve (61) into

its position where it was removed.
85
Be sure to perform the adjustment to
the valve on test bench. 87
(Refer to the Adjustment of Overload
Relief Valve in chapter of Spool
Performance Test, Technical Manual) W183-02-05-031

23. Install overload relief valves (61) (4 used) (2 for 28. Hold the spring part of each spool (13 and 19 to
upper and 2 for lower) into housing (88). 21) assemblies to insert it into housing (88) while
ϖ 41 mm turning slowly.
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
29. Install cover (24) to housing (88) with socket bolts
(23) (8 used).
ϖ 10 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-33
 UPPERSTRUCTURE / Control Valve

DISASSEMBLE MAIN CONTROL VALVE 2

(4-SPOOL SECTION)

43 44
42

Load Check
Valve 39
38
41
30
29
28
40 2
39 1
38
30
29 30
28 29
37
28 3
36

35 4
34
26 12 33
32 5
31 30 6
29
28 7
27 8
25 19 9
18 Slow Return Valve
17
16 10
2
22 1
24 21
23 15
20 14
13
12 W183-02-05-008
11
Holding Valve

1- Socket Bolt (7 Used) 12 - O-Ring (2 Used) 23 - Socket Bolt (4 Used) 34 - Spring

2- Washer (7 Used) 13 - Spring 24 - Washer (4 Used) 35 - Poppet
3- O-Ring 14 - Poppet 25 - Piston 36 - Cap
4- Manifold 15 - Sleeve 26 - Cap 37 - Cap (2 Used)
5- Poppet 16 - Backup Ring 27 - Cap 38 - Spring (3 Used)
6- Spring 17 - O-Ring 28 - Chip (5 Used) 39 - Check Valve (3 Used)
7- O-Ring 18 - O-Ring 29 - Backup Ring (5 Used) 40 - Cap
8- Backup Ring 19 - Backup Ring 30 - O-Ring (5 Used) 41 - Check Valve
9- Flange 20 - Cap 31 - O-Ring 42 - Cap (2 Used)
10 - Socket Bolt (4 Used) 21 - O-Ring 32 - Backup Ring 43 - O-Ring (2 Used)
11 - Cap 22 - Cover 33 - O-Ring 44 - Housing

W2-4-34
 UPPERSTRUCTURE / Control Valve
Disassemble Main Control Valve 2 (4-Spool
Section) Slow Return Valve

• Be sure to thoroughly read “Precautions for 8. Remove socket bolts (10) (4 used) to remove the
Disassembly and Assembly Work” on page manifold (4) assembly from housing (44).
W1-1-1 before starting the disassembly work. ϖ 12 mm

9. Remove flange (9) to remove spring (6) and

Holding Valve poppet (5) from manifold (4).
1. Remove socket bolts (23) (4 used) and washers
(24) (4 used) to remove the cover (22) assembly
from housing (44).
ϖ 12 mm

2. Remove spring (34) and poppet (35) from housing

(44).

IMPORTANT: After long term operation poppet (14)

can not be pulled out from sleeve (15)
for the seat surface being deformed,
replace sleeve (15) and poppet (14).

3. Remove cap (11) to remove spring (13) and

poppet (14) from cover (22).
ϖ 10 mm

4. Remove cap (26) to remove piston (25).

ϖ 10 mm

5. Push out sleeve (15) from cap (26) side with a

pipe (inner dia 10 mm (0.39 in), outer dia 14 mm
(0.55 in)) while tapping it slightly.

Load Check Valve

6. Loosen and remove caps (37) (2 used) and (40)
from housing (44).
ϖ 14 mm

7. Pull out check valves (39) (3 used), springs (38)

(3 used) and check valve (41) from housing (44).

NOTE: Check valve (41) is not used in cap (37)

part.

W2-4-35
 UPPERSTRUCTURE / Control Valve

ASSEMBLE MAIN CONTROL VALVE 2

(4-SPOOL SECTION)

Slow Return Load Check Valve

Valve 37 40
A B

29 30

41
29 30
38 28
38 28

39
Load Check 39
Valve (B)
W162-02-04-029
W162-02-04-034
Front Side
Load Check
Valve (A)
Holding Valve T183-03-03-029
44

Holding Valve Slow Return Valve

10
12 11 15 23,24

13
7
9
14
8

16,17 6

5
18,19

25
4

22 12 26 31 32,33 34 35 3
W183-02-05-030

W183-02-05-009

1- Socket Bolt (7 Used) 12 - O-Ring (2 Used) 23 - Socket Bolt (4 Used) 34 - Spring

2- Washer (7 Used) 13 - Spring 24 - Washer (4 Used) 35 - Poppet
3- O-Ring 14 - Poppet 25 - Piston 36 - Cap
4- Manifold 15 - Sleeve 26 - Cap 37 - Cap (2 Used)
5- Poppet 16 - Backup Ring 27 - Cap 38 - Spring (3 Used)
6- Spring 17 - O-Ring 28 - Chip (5 Used) 39 - Check Valve (3 Used)
7- O-Ring 18 - O-Ring 29 - Backup Ring (5 Used) 40 - Cap
8- Backup Ring 19 - Backup Ring 30 - O-Ring (5 Used) 41 - Check Valve
9- Flange 20 - Cap 31 - O-Ring 42 - Cap (2 Used)
10 - Socket Bolt (4 Used) 21 - O-Ring 32 - Backup Ring 43 - O-Ring (2 Used)
11 - Cap 22 - Cover 33 - O-Ring 44 - Housing

W2-4-36
 UPPERSTRUCTURE / Control Valve
Assemble Main Control Valve 2 (4-Spool Section)
7. Place O-rings (12) onto caps (11 and 26) res-
Load Check Valve pectively and into caps (11 and 26) to cover (22).

1. Install check valves (39) (3 used), springs (38) ϖ 10 mm

(3 used) and check valve (41) into housing (44). ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

NOTE: Check valve (41) is not used in cap (37) 8. Install cover (22) to housing (44) with socket bolts
part. (23) (4 used) and washers (24) (4 used).
ϖ 12 mm
IMPORTANT: Chips (28) prevents caps (27, 36, 37 ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
and 40) from being pulled, and
looseness.
Slow Return Valve
Chips (28) will be damaged when
caps (27, 36, 37, 40) are removed 9. Install O-ring (3) to manifold (4) and install backup
because they are made of nylon. ring (8) and O-ring (7) onto flange (9).
Be sure to replace chips (28) with new
ones and install caps (27, 36, 37 and 10. Insert poppet (5) and spring (6) into manifold (4) to
40). which flange (9) is to be installed.

2. Assemble O-ring (30), backup ring (29) and chips 11. Install the manifold (4) assmebly to housing (44)
(28) onto caps (37) (2 used) and (40). Install caps with socket bolts (10) (4 used).
(37) (2 used) and (40) into housing (44). ϖ 12 mm
ϖ 14 mm ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft)

Holding Valve
3. Place poppet (35) and spring (34) into housing
(44).

4. Assemble backup rings (16 and 19) and O-rings

(17 and 18) onto sleeve (15).

5. Assemble piston (25), sleeve (15), poppet (14)

and spring (13) into cover (22).

6. Install backcup ring (32) and O-rings (31 and 33)

into cover (22).

W2-4-37
 UPPERSTRUCTURE / Control Valve

DISASSEMBLE MANIFOLD

5-Spool Section 1

6
5
28
25
24
23 2
22 3
6 3
5

1
27 1 4
26

1 7
5 8
6
9
10
11
22 12
23 13
24 14
25
3 27 Arm Regeneration
26 Valve
4

15
16
17

4-Spool Section 18
19
20
21
1

W183-02-05-010

1- O-Ring (8 Used) 8- Spring 15 - O-Ring 22 - O-Ring (2 Used)

2- O-Ring (2 Used) 9- Sleeve 16 - Backup Ring 23 - Backup Ring (2 Used)
3- O-Ring (11 Used) 10 - O-Ring 17 - O-Ring 24 - Chip (2 Used)
4- O-Ring (2 Used) 11 - Backup Ring 18 - Sleeve 25 - Cap (2 Used)
5- Washer (7 Used) 12 - Piston 19 - Spring Guide 26 - Socket Bolt (14 Used)
6- Socket Bolt (7 Used) 13 - Spool 20 - O-Ring 27 - Washer (14 Used)
7- Check Valve 14 - Spring 21 - Cap 28 - Manifold

W2-4-38
 UPPERSTRUCTURE / Control Valve

Disassemble Manifold
• Be sure to thoroughly read “Precautions for 6. Screw jig (ST 1469) on to sleeve (9) to pull it out,
Disassembly and Assembly Work” on page in case it remains in manifold (28).
W1-1-1 before starting the disassembly work. 9

Manifold
NOTE: When placing 4-spool and 5-spool sections
or manifold on work bench,lay a rag or shop
cloth to prevent scratching the mounting
surface. ST 1469
W183-02-05-015

1. Remove socket bolts (6) (6 used) and the socket 7. Remove piston (12), spring (8) and check valve (7)
bolts (7 used) from 4-spool section housing to from sleeve (9).
remove 4-spool section housing from manifold
(28). 8. Remove cap (21) to remove spring guide (19).
ϖ 14 mm ϖ 12 mm

2. Remove O-rings (1) (4 used), (3) (5 used) and (4)

(1 used) from manifold (28).

3. Remove socket bolts (6) (1 used), (26) (14 used)

and the housing bolts (4 used) of 5-spool section
to remove 5-spool section housing from manifold
(28).
ϖ 14 mm

4. Remove O-rings (1) (4 used), (2) (2 used), (3) (6

used) and (4) (1 used) from manifold (28).

Arm Regeneration Valve

CAUTION: When removing sleeve (18), it will

be sprung out due to the action
force from spring (14); sleeve (18)
should be removed while pressing
it.

5. Remove sleeve (18) to remove spring (14) and

spool (13) from manifold (28).
ϖ 46 mm

W2-4-39
 UPPERSTRUCTURE / Control Valve

ASSEMBLE MANIFOLD
Arm Regeneration Valve
Arm Regeneration Valve
20 18 14 13 11,10 15 9

21 19 17 16 12 8 7

W183-02-05-012
Front Side

T183-03-03-029

26,27
Manifold
28
4-spool Section 5-Spool Section
26,27

1 1
26,27 1
1 2
Arm Regen-
eration Valve

26,27
5,6
3
5,6
3 3

26,27 26,27
4

1
1
1
1
26,27
W183-02-05-011

1- O-Ring (8 Used) 8- Spring 15 - O-Ring 22 - O-Ring (2 Used)

2- O-Ring (2 Used) 9- Sleeve 16 - Backup Ring 23 - Backup Ring (2 Used)
3- O-Ring (11 Used) 10 - O-Ring 17 - O-Ring 24 - Chip (2 Used)
4- O-Ring (2 Used) 11 - Backup Ring 18 - Sleeve 25 - Cap (2 Used)
5- Washer (7 Used) 12 - Piston 19 - Spring Guide 26 - Socket Bolt (14 Used)
6- Socket Bolt (7 Used) 13 - Spool 20 - O-Ring 27 - Washer (14 Used)
7- Check Valve 14 - Spring 21 - Cap 28 - Manifold

W2-4-40
 UPPERSTRUCTURE / Control Valve

Assemble Manifold Manifold

1. Place the manifold (28) housing on work bench 7. Assemble O-rings (1) (4 used), (2) (2 used), (3)
with the mounting side of 5-spool section facing (6 used) and (4) onto 5-spool section housing
up. interface of manifold (28).

8. Install manifold (28) to 5-spool section housing

NOTE: Lay a rag or shop cloth on the work bench
with socket bolts (6), (26) (14 used), washers (5)
first in order to avoid damaging the
and (27) (14 used). Secure socket bolts (4 used)
mounting surface, when placing the
for 5-spool section housing.
manifold.
ϖ 14 mm
ϖ 245 N⋅m (25 kgf⋅m, 180 Ibf⋅ft)
IMPORTANT: Chip (24) prevents cap (25) from
being pulled, and looseness.
9. Assemble O-rings (1) (4 used), (3) (5 used) and
Chip (24) will be damaged if cap (25)
(4) (1 used) onto 4-spool section housing interface
is removed because it is made of
of manifold (28).
nylon.
Be sure to replace chip (24) with a
10. Install 4-spool section housing to manifold (28)
new one and install cap (25).
with socket bolts (6) (6 used) and washers (5) (6
used). Secure socket bolts (7 used) for 4-spool
Arm Regeneration Valve
section housing.
2. Assemble backup ring (16) and O-rings (15 and
ϖ 14 mm
17) onto sleeve (18).
ϖ 245 N⋅m (25 kgf⋅m, 180 Ibf⋅ft)
3. Assemble piston (12), backup ring (11) and O-ring
(10) to sleeve (9) and install sleeve (9) into sleeve
(18).

4. Assemble spring (8) and check valve (7) into

sleeve (9) and install sleeve (18) into manifold
(28).
ϖ 46 mm
ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

5. Assemble spool (13), spring (14) and spring guide

(19) into sleeve (18).

6. Place O-ring (20) onto cap (21) and install it to

sleeve (18).
ϖ 12 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-41
 UPPERSTRUCTURE / Control Valve

DISASSEMBLE SWING CONTROL VALVE 1

49 50 51

48 52

47 1
46
45
Main Relief
Valve
44 25 25
43
42
24 24
41
40 23 23
39 2
38 22 22 3
4
37 5
21 21
36 6
35 7
34 8
33 9
32
10
31 27
28 26 20 11
30
29 12
13
14 Overload Re-
15 lief Valve
16
17
18

19

W183-02-05-013
1- Overload Relief Valve (2 Used) 14 - Poppet (2 Used) 27 - Spool (Swing) 40 - O-Ring
2- Lock Nut (2 Used) 15 - Sleeve (2 Used) 28 - Spool (Boom 3) 41 - O-Ring
3- Adjusting Bolt (2 Used) 16 - O-Ring (2 Used) 29 - Sleeve 42 - Sleeve
4- O-Ring (2 Used) 17 - Backup Ring (2 Used) 30 - Poppet 43 - Piston
5- Spring (2 Used) 18 - O-Ring (2 Used) 31 - Spring 44 - Lock Nut
6- Poppet (2 Used) 19 - Housing 32 - O-Ring 45 - O-Ring
7- Seat (2 Used) 20 - Spool (Arm 3) 33 - Backup Ring 46 - Adjusting Bolt
8- O-Ring (2 Used) 21 - Spring Guide (4 Used) 34 - Seat 47 - Main Relief Valve
9- Backup Ring (4 Used) 22 - Spring (4 Used) 35 - Poppet 48 - O-Ring (4 Used)
10 - O-Ring (2 Used) 23 - Sleeve (4 Used) 36 - Spring 49 - Socket Bolt (8 Used)
11 - Spring (2 Used) 24 - Spring Guide (4 Used) 37 - O-Ring 50 - Cap (2 Used)
12 - Spring (2 Used) 25 - Cap (4 Used) 38 - Cap 51 - O-Ring (2 Used)
13 - Piston (2 Used) 26 - Spool (Bucket 3) 39 - Lock Nut 52 - Cover

W2-4-42
 UPPERSTRUCTURE / Control Valve

Disassemble Swing Control Valve 1

Overload Relief Valve
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly Work” on page IMPORTANT: Do not disassemble overload relief
W1-1-1 before starting the disassembly work. valve unless necessary. As
• Attach a tag to each spool to mark the position adjustment should be carried out on
where it was in order to prevent them from being test bench if it is disassembled, keep
misplaced. a tag attaching to the valve to ensure
that it can be reassembled to the
Spool position where it was removed.

1. Remove socket bolts (49) (8 used) to remove

cover (52) from housing (19). 7. Remove overload relief valves (1) (2 used) (1 for
upper and 1 for lower) from housing (19).
ϖ 10 mm
ϖ 41 mm
2. Slowly pull out the spool (20 and 26 to 28) assemblies
(4 used) from housing (19) while confirming the 8. Loosen and remove seat (7) to remove springs (11
corresponding position on housing (19). and 12), piston (13) and poppet (14) from sleeve
(15).
3. Remove O-rings (48) (4 used) from housing (19). ϖ 36 mm

4. Clamp and hold the spool (20) assembly in a vise IMPORTANT: Put matching marks on adjusting bolt
with wooden spatulas inserted at both sides. (3) and seat (7) and take a note of the
amount that the bolt has been turned.
5. Loosen and remove cap (25) while holding spring
guide (24) with a hand. Remove spring guide (24), 9. Remove lock nut (2) to remove adjusting bolt (3),
sleeve (23), spring (22) and spring guide (21). spring (5) and poppet (6) from seat (7).
ϖ 10 mm ϖ 19 mm
ϖ 6 mm
6. Disassemble 3 spools (26 to 28) in accordance
with the procedure 4 to 5. Main Relief Valve
IMPORTANT: Do not disassemble the main relief
valve unless necessary.

10. Remove cap (38) to remove main relief valve (47)

from housing (19).
ϖ 41 mm

W2-4-43
 UPPERSTRUCTURE / Control Valve

46
Main Relief
Valve
44
43
42

39
38

36
35
34

31
30
29

Overload Relief
Valve

W183-02-05-013

W2-4-44
 UPPERSTRUCTURE / Control Valve
IMPORTANT: Seat (34) has been pressed in cap
(38). Do not disassemble it.

11. Loosen lock nuts (39 and 44) and remove sleeve
(29) from cap (38) to remove spring (31) and
poppet (30).
ϖ 30 mm, 41 mm

IMPORTANT: Put matching marks on adjusting bolt

(46) and sleeve (42) and take a note of
the amount to turn the bolt.

12. Remove adjusting bolt (46) from sleeve (42).

Remove piston (43), spring (36) and poppet (35).
ϖ 22 mm

IMPORTANT: Put matching marks between

sleeve (42) and cap (38) and take a
note of the amount that the sleeve
has been turned.

13. Remove sleeve (42) from cap (38).

ϖ 27 mm

W2-4-45
 UPPERSTURCTURE / Control Valve

19

Overload Re-
lief Valve
53
67 54
70 67 55
69 56
66
68 57
58

59
65 60
Make-Up Valve
61
62
63
64

W183-02-05-019

19 - Housing 57 - Poppet 62 - Backup Ring 67 - O-Ring (4 Used)

53 - O-Ring 58 - Backup Ring (2 Used) 63 - Cap 68 - Cover
54 - Backup Ring 59 - O-Ring 64 - Make-Up Valve 69 - O-Ring
55 - O-Ring 60 - Spring 65 - Socket Bolt (8 Used) 70 - Plug
56 - Sleeve 61 - O-Ring 66 - Cover (3 Used)

W2-4-46
 UPPERSTURCTURE / Control Valve

Make-Up Valve
14. Remove socket bolts (65) (8 used) to remove
covers (68), (66) (3 used) and O-rings (67) (4 used)
from housing (19).
ϖ 10 mm

15. Loosen sleeve (56) to remove make-up valve (64)

from housing (19).
ϖ 41 mm

16. Remove cap (63) to remove spring (60) and

poppet (57) from sleeve (56).
ϖ 36 mm

W2-4-47
 UPPERSTURCTURE / Control Valve

ASSEMBLE SWING CONTROL VALVE 1

Front Side Main Relief Valve (47)

Main Relief 29 30 32 34 35 36 43 38 39 42 44 46
Valve

19
31 33 40 37 41 45
Overload
Relief Valve
W183-02-05-007
T183-03-03-030

19 Overload Relief Valve (1)

18 14 13 16 9 6 5 7 4 2

17 12 10 11 15 8 3
Overload Relief
T183-03-03-031
Valve Front Side
W162-02-04-022

1- Overload Relief Valve (2 Used) 11 - Spring (2 Used) 30 - Poppet 39 - Lock Nut

2- Lock Nut (2 Used) 12 - Spring (2 Used) 31 - Spring 40 - O-Ring
3- Adjusting Bolt (2 Used) 13 - Piston (2 Used) 32 - O-Ring 41 - O-Ring
4- O-Ring (2 Used) 14 - Poppet (2 Used) 33 - Backup Ring 42 - Sleeve
5- Spring (2 Used) 15 - Sleeve (2 Used) 34 - Seat 43 - Piston
6- Poppet (2 Used) 16 - O-Ring (2 Used) 35 - Poppet 44 - Lock Nut
7- Seat (2 Used) 17 - Backup Ring (2 Used) 36 - Spring 45 - O-Ring
8- O-Ring (2 Used) 18 - O-Ring (2 Used) 37 - O-Ring 46 - Adjusting Bolt
9- Backup Ring (4 Used) 19 - Housing 38 - Cap 47 - Main Relief Valve
10 - O-Ring (2 Used) 29 - Sleeve

W2-4-48
 UPPERSTURCTURE / Control Valve

Assemble Swing Control Valve 1

Overload Relief Valve
7. Assemble O-rings (8 and 10) and backup ring (9)
Main Relief valve onto seat (7). Place O-ring (4) onto adjusting bolt
IMPORTANT: Sleeve (42) should be screwed on (3).
only by the same amount to that of
removal so as to align the matching IMPORTANT: Adjusting bolt (3) should be screwed
marks. on only by the same amount to that
of removal so as to align the
1. Assemble lock nut (39) and O-rings (40 and 41) matching marks.
onto sleeve (42) and install sleeve (42) into cap
(38). 8. Assemble poppet (6), spring (5), adjusting bolt (3)
ϖ 41 mm and lock nut (2) onto seat (7).
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) ϖ 19 mm
ϖ 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf⋅ft)
2. Assemble poppet (35), spring (36) and piston (43) ϖ 6 mm
into cap (38). ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

IMPORTANT: Adjusting bolt (46) should be 9. Assemble poppet (14), piston (13) and springs (11
screwed on only by the same amount and 12) into sleeve (15).
to that of removal so as to align the
matching marks. 10. Assemble backup ring (17) and O-rings (16 and
18) onto sleeve (15) and install seat (7) into
3. Place lock nut (44) and O-ring (45) onto adjusting sleeve (15).
bolt (46) and install adjusting bolt (46) into sleeve ϖ 36 mm
(42). ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
ϖ 22 mm
ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft) IMPORTANT: Install overload relief valve (1) into its
position where it was removed.
4. Place O-ring (32) and backup ring (33) onto seat Be sure to perform the adjustment to
(34). the valve on a test bench.
(Refer to the Adjustment of Overload
5. Place poppet (30) and spring (31) into sleeve (29) Relief Valve Performance in chapter
and install sleeve (29) into cap (38). of Technical Manual)

IMPORTANT: Be sure to perform adjustment to 11. Install overload relief valve (1) (2 used) into
main relief valve. (Refer to the housing (19).
Adjustment of Main Relief Valve in ϖ 41 mm
chapter of Performance Test, ϖ 98 N⋅m (10 kgf⋅m 72 Ibf⋅ft)
Technical Manual)

6. Install main relief valve (47) into housing (19).

ϖ 41 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-49
 UPPERSTURCTURE / Control Valve

Front Side Make-Up Valve (64)

53 57 58 55 60 56 62 63

19 54 59 61 W162-02-04-028
A

T183-03-03-030 Spool

52
Make-Up 25
Valve

24
48 23
22
49
27 21

20
19
19
T183-03-03-031
Front Side 28
26

65

67 66 68 66
W183-02-05-006

19 - Housing 26 - Spool (Bucket 3) 56 - Sleeve 63 - Cap

20 - Spool (Arm 3) 48 - O-Ring (4 Used) 57 - Poppet 64 - Make-Up Valve
21 - Spring Guide (4 Used) 49 - Socket Bolt (8 Used) 58 - Backup Ring (2 Used) 65 - Socket Bolt (8 Used)
22 - Spring (4 Used) 52 - Cover 59 - O-Ring 66 - Cover (3 Used)
23 - Sleeve (4 Used) 53 - O-Ring 60 - Spring 67 - O-Ring (4 Used)
24 - Spring Guide (4 Used) 54 - Backup Ring 61 - O-Ring 68 - Cover
25 - Cap (4 Used) 55 - O-Ring 62 - Backup Ring

W2-4-50
 UPPERSTURCTURE / Control Valve

Make-Up Valve IMPORTANT: Install the 4 spools (20 and 26 to 28)

12. Assemble O-ring (59) and backup rings (58) (2 assemblies into their positions
used) onto poppet (57) and install O-ring (61) and where they were disassembled.
backup ring (62) onto cap (63).
Insert spools (20, 26 and 28) so that

13. Assemble poppet (57), spring (60) and cap (63) splined plug (70) of cover (66) can
into sleeve (56). enter into the spool’s slot.
ϖ 36 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
66

14. Assemble O-rings (53 and 55) and backup ring 70

(54) onto sleeve (56) and assemble make-up
valve (64) into housing (19). Spool

ϖ 41 mm W183-02-05-031

ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

19. Hold the spring part of each spool (20 and 26 to
Spool 28) assemblies and insert it into housing (19) while
turning it slowly.
15. Assemble O-rings (67) (4 used) onto the lower
side of housing (19). Install covers (68) and (66)
(3 used) to housing (19) with socket bolts (65) (8 20. Install cover (52) to housing (19) with socket bolts
used). (49) (8 used).
ϖ 10 mm ϖ 10 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

16. Clamp and hold spool (20) in a vise with wooden

spatulas inserted at both sides. Assemble spring
guide (24), sleeve (23), spring (22) and spring
guide (21) onto cap (25). Install cap (25) to spool
(20).
ϖ 10 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

17. Assemble 3 spools (26 to 28) in accordance with

the procedure 16.

18. Assemble O-rings (48) (4 used) to housing (19).

W2-4-51
 UPPERSTURCTURE / Control Valve

DISASSEMBLE SWING CONTROL VALVE 2

1
2
41
3
4
5
42 8

5
6 1
2
3
4
Load Check 1
Valve
2
3
4
27 5
28
29 7 39
30 38
31 37
32 36
33
34
35
9
40
26 10
25 21 11
20 12
19
13
23 22 14
24 15
Holding Valve 16
Check Valve
17
18

W183-02-05-014

1- Check Valve (4 Used) 12 - Poppet 23 - Washer (4 Used) 33 - O-Ring

2- Spring (4 Used) 13 - Spring 24 - Socket Bolt (4 Used) 34 - O-Ring
3- O-Ring (4 Used) 14 - O-Ring 25 - O-Ring 35 - Backup Ring
4- Backup Ring (4 Used) 15 - Backup Ring 26 - Cap 36 - Backup Ring
5- Chip (4 Used) 16 - Cover 27 - Cap 37 - O-Ring
6- Cap 17 - Washer (4 Used) 28 - O-Ring 38 - Spring
7- Cap (2 Used) 18 - Socket Bolt (4 Used) 29 - Spring 39 - Poppet
8- Housing 19 - Cap 30 - Poppet 40 - O-Ring
9- O-Ring 20 - O-Ring 31 - Sleeve 41 - Check Valve
10 - Flange 21 - Piston 32 - Backup Ring 42 - Cap
11 - Socket Bolt (4 Used) 22 - Cover

W2-4-52
 UPPERSTURCTURE / Control Valve

Disassemble Swing Control Valve 2

Check Valve
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly Work” on page 8. Remove socket bolts (18) (4 used) to remove cover
W1-1-1 before starting the disassembly work. (16) from housing (8).
ϖ 12 mm
Holding Valve
1. Remove socket bolts (24) (4 used) and washers 9. Remove spring (13) and poppet (12) from housing
(23) (4 used) to remove the cover (22) assembly (8).
from housing (8).
ϖ 12 mm

2. Remove spring (38) and poppet (39) from housing

(8).

IMPORTANT: In case poppet (30) can not be pulled

out from sleeve (31) after long term
operation, because of seat surface
being deformed, replace sleeve (31)
and poppet (30).

3. Remove cap (27) to remove spring (29) and

poppet (30) from cover (22).

4. Remove cap (19) to remove piston (21).

ϖ 10 mm

5. Lightly tap sleeve (31) to push it out with a pipe

(inner dia 10 mm (0.39 in), outer dia 14 mm (0.55
in)) from cap (19) side.

Load Check Valve

6. Loosen and remove caps (6), (7) (2 used) and (42)
from housing (8).
ϖ 14 mm

7. Pull out check valves (1), (41) and spring (2) from
housing (8).

NOTE: Check valve (41) is not used in caps (6 and

7) part.

W2-4-53
 UPPERSTURCTURE / Control Valve

ASSEMBLE SWING CONTROL VALVE 2

Check Valve

Front Side Holding Valve

18

Check Valve 16
8

15 14

13
12

Load Check Valve (C) W183-02-05-016

Load Check
Valve (A) T183-03-03-030
Load Check Valve (B)

Load Check Valve Holding Valve

42
A B C 21 34,35 32,33 30 29
7 6
3 3
22
4 3 4 28
4
20
5
2 5 19
41
40 27
5 2 1
2 1 1
31
36,37 23,24
W162-02-04-034
W183-02-05-024
W162-02-04-029
38
39

W162-02-04-037

1- Check Valve (4 Used) 12 - Poppet 23 - Washer (4 Used) 33 - O-Ring

2- Spring (4 Used) 13 - Spring 24 - Socket Bolt (4 Used) 34 - O-Ring
3- O-Ring (4 Used) 14 - O-Ring 25 - O-Ring 35 - Backup Ring
4- Backup Ring (4 Used) 15 - Backup Ring 26 - Cap 36 - Backup Ring
5- Chip (4 Used) 16 - Cover 27 - Cap 37 - O-Ring
6- Cap 17 - Washer (4 Used) 28 - O-Ring 38 - Spring
7- Cap (2 Used) 18 - Socket Bolt (4 Used) 29 - Spring 39 - Poppet
8- Housing 19 - Cap 30 - Poppet 40 - O-Ring
9- O-Ring 20 - O-Ring 31 - Sleeve 41 - Check Valve
10 - Flange 21 - Piston 32 - Backup Ring 42 - Cap
11 - Socket Bolt (4 Used) 22 - Cover

W2-4-54
 UPPERSTURCTURE / Control Valve

Assemble Swing Control Valve 2

Check Valve Holding Valve

1. Install poppet (12) and spring (13) into housing (8). 5. Place poppet (39) and spring (38) into housing (8).

2. Place backup ring (15) and O-ring (14) onto cover 6. Assemble O-rings (33 and 34) and backup rings
(16) and install cover (16) into housing (8) with (32 and 35) onto sleeve (31).
socket bolts (18) (4 used).
ϖ 12 mm 7. Assemble piston (21), sleeve (31), poppet (30)
ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) and spring (29) into cover (22).

IMPORTANT: Chips (5) prevents caps (6, 7 and 42) 8. Assemble backup ring (36) and O-rings (37 and
from being pulled, and looseness. 40) onto cover (22).
Chips will be damaged because they
are made of nylon when the caps is 9. Assemble O-rings (20 and 28) onto caps (19 and
removed. 27) respectively. Then install caps (19 and 27) into
Be sure to replace chips (5) with new cover (22).
ones and install caps (6, 7 and 42). ϖ 10 mm
ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
Load Check Valve
3. Assemble check valves (1) (4 used), springs (2) (4 10. Install cover (22) to housing (8) with socket bolts
used) and check valve (41) into housing (8). (24) (4 used) and washers (23) (4 used).
ϖ 12 mm
NOTE: Check valve (41) is not used in caps (6 and 7). ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

4. Assemble O-rings (3), backup rings (4) and chips

(5) onto caps (6), (7) (2 used) and (42) respectively.
Then install the caps into housing (8).
ϖ 14 mm
ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft)

W2-4-55
 UPPERSTURCTURE / Control Valve

(Blank)

W2-4-56
 UPPERSTRUCTURE / Swing Device

REMOVE AND INSTALL SWING DEVICE

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation
1. Park the machine on a level solid surface. Lower W183-04-02-003
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2. W183-04-02-002

ϖ 4 mm Wooden Blocks

3. Remove the hydraulic oil tank cap. Connect a Cap

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W2-5-1
 UPPERSTRUCTURE / Swing Device
1
Removal
17
16 2
NOTE: Attach identification tags to the hoses for 14 3
15
easier distinguishing when assembling.
13
1. Drain oil out through the drain cock, then
disconnect hoses (1 to 3, 6 to 17). 4
ϖ 41 mm
ϖ 295 N⋅m (30 kgf⋅m, 215 Ibf⋅ft)
ϖ 36 mm
ϖ 235 N⋅m (24 kgf⋅m, 175 Ibf⋅ft)
12
ϖ 27 mm
ϖ118 N⋅m (12 kgf⋅m, 87 Ibf⋅ft) 7 6
ϖ19 mm 8
ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft) 9
ϖ 8 mm
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) Front Side 11 10

NOTE: Cap the disconnected hose ends. W183-02-06-003

2. Remove bolts (4) (16 used).

ϖ 41 mm

3. Remove corks (18) (2 used) with a screw driver,

and clean bolt holes with a tap (M27, Pitch 3.0) 4 18

19

W183-02-06-006

W2-5-2
 UPPERSTRUCTURE / Swing Device
4. Install bolt (M27, Pitch 3.0) (2 used) to the hole
mentioned in step 3. Attach nylon sling to motor Swing Device (Front) Bolt Hole
(20) to get ready to hoist the swing device by a 19
crane.
Nylon sling (eye type at both ends): 2 used
Front Side
ϖ 41 mm

CAUTION: Swing device weight: 688 kg

(1520 Ib) Bolt Hole 19
W183-02-06-004

5. Catch hold of nylon sling tightly and tighten the Swing Device (Rear) Bolt Hole
bolt to raise the swing device slowly until knock 19
pins (19) (2 used) are removed from the swing
frame.
Front Side

6. Hoist the swing device by a crane to remove the

bolt. Then pull knock pins (19) (2 used) out from
the bottom.
ϖ 41 mm Bolt Hole 19
W183-02-06-005

7. Remove the other swing device following the

same procedure. Nylon Sling

20

W155-02-06-012

W2-5-3
 UPPERSTRUCTURE / Swing Device

Installation
4 18

NOTE: Refer to “Removal” section for wrench

sizes and tightening torque. 19

1. Clean the interfaces of swing reduction gear and

swing frame.

W183-02-06-006

CAUTION: Swing device assembly weight:

Swing Device (Front) Bolt Hole
688 kg (1520 Ib)
19

2. Align the swing gear tooth with the holes of

Front Side
knock pin (19) (2 used) and place the swing
device to its mouting surface. Tap knock pins
(19) (2 used) in, then remove nylon sling.

3. Install bolts (4) (16 used). 19

Bolt Hole
Tap new corks (18) (2 used) into bolt holes.
W183-02-06-004
ϖ 41 mm
ϖ 1370 N⋅m (140 kgf⋅m, 1010 Ibf⋅ft)
Swing Device (Rear) Bolt Hole
4. Install the other swing device assembly following 19
the same procedure.

5. Connect hoses (1 to 3 and 6 to 17). Front Side

IMPORTANT: Be sure to fill the swing motor with

hydraulic oil after installing it. Bolt Hole 19
Check the oil level. Check for any
oil leaks after starting the engine. W183-02-06-005

1
17
16 2
14 3
15
13

12

7 6
8
9
Front Side 11 10

W183-02-06-003

W2-5-4
 UPPERSTRUCTURE / Swing Device

(Blank)

W2-5-5
 UPPERSTRUCTURE / Swing Device

Disassemble Swing Reduction Gear

24 2

23
3

4
25
26
5
27
6
7
28
8

22
9
10

29 11

30 9
12
31
32 13
14
39 33
15
38
16

34 17
35
18
36

17

37 21

19
20

W142-02-06-002
1- Motor 11 - First Stage Planetary Gear (3 Used) 21 - Spring Pin (3 Used) 31 - Cover
2- Bolt (16 Used) 12 - Ring Gear 22 - First Stage Carrier 32 - Screw (4 Used)
3- Washer (16 Used) 13 - Second Stage Sun Gear 23 - Spacer (12 Used) 33 - Magnet (4 Used)
4- Cover 14 - Thrust Plate 24 - Sems Bolt (12 Used) 34 - Sleeve
5- First Stage Sun Gear 15 - Pin (3 Used) 25 - Retaining Ring 35 - O-Ring
6- Thrust Plate 16 - Second Stage Carrier 26 - Spacer 36 - Oil Seal (2 Used)
7- Pin (3 Used) 17 - Thrust Plate (6 Used) 27 - Bearing 37 - Shaft
8- Spring Pin (3 Used) 18 - Second Stage Planetary Gear (3 Used) 28 - Housing 38 - Bolt (10 Used)
9- Thrust Plate (6 Used) 19 - Ring Gear 29 - Bearing 39 - Spring Washer (10 Used)
10 - Needle Bearing (3 Used) 20 - Knock Pin (2 Used) 30 - O-Ring

W2-5-6
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Reduction Gear
CAUTION: The second stage carrier (16)
• Be sure to thoroughly read “Precautions for assembly weight: 80 kg (180 Ib)
Disassembly and Assembly” on page W1-1-1
before starting the disassembly work.
7. Remove second stage sun gear (13) from the
second stage carrier (16) assembly.
CAUTION: Motor weight: 71 kg (160 Ib)
8. Install eyebolts (M12, Pitch 1.75) into the three
1. Drain out gear oil out from the swing device. holes in the second stage carrier (16) assembly.
Make matching marks on all interfaces of motor Hoist by a crane and remove it from ring gear
(1), cover (4), ring gears (12) and (19) and (19).
housing (28). Then loosen and remove bolts
(24) (12 used). CAUTION: Ring gear (19) weight: 60 kg
ϖ 19 mm (130 Ib)

2. Install an eyebolt (M22, pitch 1.5) onto motor (1). 9. Install eyebolts (M12, Pitch 1.75) into the two
Hoist by a crane and remove motor (1) from holes in ring gear (19).Hoist by a crane and
cover (4). remove it from housing (28)

NOTE: Insert a flat head screw driver into the NOTE: Insert a flat head screw driver between
clearance between motor (1) and cover ring gear (19) and housing (28) to drive
(4) to drive the motor out. It is easy to ring gear (19) out. It is easy to remove in
remove in this way. this way.

3. Loosen and remove bolt (2). Then remove cover 10. Tap knock pins (20) (2 used) out from housing
(4). (28).
ϖ 32 mm
11. Remove retaining ring (25), spacer (26) from
4. Remove first stage sun gear (5) from the first shaft (37).
stage carrier (22) assembly.

CAUTION: Housing (28) + shaft (37) + others

CAUTION: The first stage carrier (22) assembly weight: 340 kg (750 Ib)
weight: 40 kg (90 Ib)
12. Sling the housing (28) body with nylon sling.
5. Install eyebolts (M12, pitch 1.75) into the three Hoist by a crane and reverse it.
hoisting holes in the first stage carrier (22)
assembly. Hoist by a crane and remove it. 13. Remove bolt (38) to remove cover (31) from
housing (28).
ϖ 24 mm
CAUTION: Ring gear (12) weight: 60 kg
(130 Ib) 14. Remove O-ring (30), oil seals (36) (2 used) from
cover (31).
6. Install eyebolts (M12, Pitch 1.75) into the two
hoisting holes in ring gear (12). Hoist by a crane
and remove it from ring gear (19).

NOTE: Insert a flat head screw driver between

ring gears (12) and (19) to drive ring gear
(12) out. It is easy to remove in this way.

W2-5-7
UPPERSTRUCTURE / Swing Device

28

29

32
33

34
35

37

W142-02-06-002

W2-5-8
 UPPERSTRUCTURE / Swing Device
16. Remove shaft (37) from housing (28) with a
CAUTION: Housing (28) + shaft (37) + others
press.
weight: 340 kg (750 Ib) Press

15. Sling the housing (28) body with a nylon sling

and hoist by a crane to reverse it.

Protection Cover
CAUTION: Before pressing shaft (37), provide
a protection cover (outer dia-
merter: 520 mm (20.5 in), inner 28
diameter: 130 mm (5.1 in), thickness:
25 to 30 mm (1.0 to 1.2 in)). Then
use the press to remove shaft (37)
while covering housing (28) and
bearing (27) with the protection W157-02-06-011
cover. Failure to use the
protection cover may result in
personal injury due to flying CAUTION: Shaft (37) + bearing (29) weight:
metal fragments if housing (28) 130 kg (290 Ib)
and / or bearing (27) is / are
broken. Use a press with the
17. Put shaft (37) onto special mounting tool
capacity less than 30 tons (66000
(ST5082).
Ib). Be sure to degrease the
housing inside before heating
bearing (27). Failure to degrease
may cause a fire.
37
28 37 27
29
34

ST 5082
Protection Cover

W142-02-06-006

W157-02-06-010

W2-5-9
UPPERSTRUCTURE / Swing Device

27
6
7
28
8

22
9
10

29 11

32
33
15
16

34 17
35
18

17

21

W142-02-06-002

W2-5-10
 UPPERSTRUCTURE / Swing Device
25. Disassemble the second stage carrier (16)
18. Put special tool (ST 5082) into the guide. assembly in steps 23 to 24.

NOTE: The dimensions of the guide to pull bearing NOTE: No needle bearing is used on second
(29) out are as follows: stage planetary gear (18).
Height: 290 mm (11.5 in)
Outer diameter: 360 mm (14.5 in)
Inner diameter: 340 mm (13.5 in)

CAUTION: When pressing shaft (37) with a

press, the work should be carried
out in the guide.

19. Put shaft (37) on the press. Pull bearing (29) and
sleeve (34) out from shaft (37).
Press
37

29
34

ST 5082

Guide

W183-02-06-002

20. Remove O-ring (35), screws (32) (4 used) and

magnets (33) (4 used) from sleeve (34).

CAUTION: Housing + others weight: 190 kg

(420 Ib)

21. Sling the housing (28) body with a nylon sling.

Hoist by a crane to reverse it.

22. Put the thrust plate to bearing (27) and pull

bearing (27) out of housing (28) with a press.

23. Push spring pins (8) (3 used) out of first stage

carrier (22) with a round bar and by tapping with
a hammer.
(Diameter: 5.0 mm, Length: 50 mm or more)

24. Remove pins (7) (3 used), first stage planetary

gears (11) (3 used), thrust plates (9) (6 used),
needle bearings (10) (3 used) and thrust plate
(6) from first stage carrier(22).
Ȁ

W2-5-11
 UPPERSTRUCTURE / Swing Device

Assemble Swing Reduction Gear

6 5 1 24

23
8
2 9
3 4
22 7
12 10
19 11
21
18
20
13
16

17
15
14
25
26
27
29

28

31
39

30

32

33 35 37 34 36 38

W142-02-06-003

1- Motor 11 - First Stage Planetary Gear (3 Used) 21 - Spring Pin (3 Used) 31 - Cover
2- Bolt (16 Used) 12 - Ring Gear 22 - First Stage Carrier 32 - Screw (4 Used)
3- Washer (16 Used) 13 - Second Stage Sun Gear 23 - Spacer (12 Used) 33 - Magnet (4 Used)
4- Cover 14 - Thrust Plate 24 - Sems Bolt (12 Used) 34 - Sleeve
5- First Stage Sun Gear 15 - Pin (3 Used) 25 - Retaining Ring 35 - O-Ring
6- Thrust Plate 16 - Second Stage Carrier 26 - Spacer 36 - Oil Seal (2 Used)
7- Pin (3 Used) 17 - Thrust Plate (6 Used) 27 - Bearing 37 - Shaft
8- Spring Pin (3 Used) 18 - Second Stage Planetary (3 Used) 28 - Housing 38 - Bolt (10 Used)
9- Thrust Plate (6 Used) 19 - Ring Gear 29 - Bearing 39 - Spring Washer (10 Used)
10 - Needle Bearing (3 Used) 20 - Knock Pin (2 Used) 30 - O-Ring

W2-5-12
 UPPERSTRUCTURE / Swing Device
Assemble Reduction Gear
10. Install O-ring (30) onto cover (31).
1. Install needle bearings (10) one after another
onto first stage planetary gears (11) (3 used). 11. Install sleeve (34) onto shaft (37).

IMPORTANT: Install thrust plate (6) with the oil 12. Heat bearing (29) in an oil pan to the temperature
slit side facing upward. of 110 °C (230 °F) and press shaft (37) using
special tool (ST 5082) and a press.
2. Install thrust plate (6) onto first stage carrier (22).
Press in
IMPORTANT: Install thrust plate (9) with the oil
slit side facing planetary gear (11). ST 5082

3. Install first stage planetary gears (11) (3 used),

thrust plates (9) (6 used) onto first stage carrier
29
(22).
34

4. Align pins (7) (3 used) with the spring pin holes in 37

first stage carrier (22), then assemble them.

IMPORTANT: Tap spring pin (8) in with the slit

facing the end of pin (7).
W183-02-06-001

5. Tap spring pins (8) (3 used) into first stage carrier

(22) and pin (7). CAUTION: Housing (28) weight: 180 kg (400 Ib)

7 13. Lay housing (28) onto a press bench with the

Slit
motor side facing downward. Then install the
8
shaft (37) assembly onto housing (28) with a
press.

14. Align cover (31) with the bolt hole in housing (28)
6. Assemble second stage carrier (16) according and tighten it with bolt (38) and spring washer (39)
to steps 2 to 5. temporarily.
ϖ 24 mm
NOTE: There is no needle bearing on second ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
stage carrier (16).

IMPORTANT: Apply LOCTITE #262 on screw (32). CAUTION: Housing (28) + shaft (37) + others
weight: 340 kg (750 Ib)
7. Install magnets (33) (4 used) onto sleeve (34)
with screws (32) (4 used). 15. Reverse the housing (28) assembly and put on
the press bench.
8. Apply grease on O-ring (35) and assemble it onto
sleeve (34). IMPORTANT: When presssing bearing (27) onto
shaft (37), apply grease both on
IMPORTANT: Apply THREEBOND #1215 on the its inner and outer faces.
matching surfaces of oil seal (36)
for cover (31). 16. Heat bearing (27) in an oil pan to the temperature
of 80 to 100 °C ( 176 to 212 °F ) and press it
9. Install oil seals (36) (2 used) to cover (31) after onto shaft (37) with a press.
applying grease to the inner race of oil seal.

W2-5-13
 UPPERSTRUCTURE / Swing Device

1 24

23

2
3 4
22
12
19

20
13
16

25
26
27

28

31
39

37 38

W142-02-06-003

W2-5-14
 UPPERSTRUCTURE / Swing Device
17. Install spacer (26), retaining ring (25) onto shaft
CAUTION: First stage carrier (22) assembly
(37).
weight: 40 kg (90 Ib)
NOTE: If shaft (37) is not installed into housing 25. Install the first stage carrier (22) assembly onto
(28) completely, retaining ring (25) can’t second stage sun gear (13).
be installed.
IMPORTANT: When installing first stage sun gear
18. Turn housing (28) inversely and tighten bolts (5), its stepped end should be face
(38) (10 used). downward.
ϖ 24 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) 26. Install first stage sun gear (5) onto first stage
carrier (22).
19. Apply THREEBOND #1215 on the mounting
surface of ring gear (19) for housing (28). 27. Apply THREEBOND #1215 on the mounting
surface of cover (4) for ring gear (12) and install
CAUTION: Ring gear (19) weight: about 60 kg cover (4) onto ring gear (12) via washer (3),
(130 Ib) bolts (2) (16 used).
ϖ 32 mm
20. Align the matching mark made when disassem- ϖ 540 N⋅m (55 kgf⋅m, 400 Ibf⋅ft)
bling on ring gear (19), install ring gear (19) onto
housing (28). Then tap knock pins (20) (2 used) 28. Bond the drain plug round with seal tape and
in. then fill gear oil in after installing into housing
(28).
CAUTION: The second stage carrier (16) ϖ 30 mm
assembly weight: 80 kg (180 Ib) Gear oil : 24 L (6.3 US gal, 5.3 UK gal)

21. Install eyebolts (M12, Pitch 1.75) into the three CAUTION: Motor (1) weight: 80 kg (180 Ib)
hoisting holes in the second stage carrier (16)
assembly. Hoist by a crane and assemble into
29. Apply THREEBOND #1215 on the mounting
housing (28).
surface of motor (1) for cover (4).
Ȁ
22. Install second stage sun gear (13) onto second
30. Remove the adapter of hose 1 on motor (1). Then
stage carrier (16).
install eyebolt (ST 0006). (Refer to W2-5-4)
Ȁ
23. Apply THREEBOND #1215 on the mounting
31. Hoist motor (1) by a crane and install cover (4),
surface of ring gear (12) for ring gear (19).
spacer (23) and sems bolts (24) (12 used) on to
the motor.
CAUTION: Ring gear (12) weight: 60 kg (130 Ib) ϖ 19 mm
ϖ 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
24. Install eyebolt (M12, Pitch 1.75) into the two
hoisting holes in the ring gear (12). Hoist by a
crane. Align the matching mark made when
disassembling and install onto ring gear (19).

W2-5-15
 UPPERSTRUCTURE / Swing Device

DISASSEMBLE SWING MOTOR

4
9
3 10
5
6 11
7
2 8 12

1 13

14

15 17
16
18
28 19 30
20
21
22 31

23 32
24
25
26
27
33
29 34
35
36
35
37
38
39
40
41 42

43

W142-02-06-004
1- Roller Bearing 12 - O-Ring 23 - Rotor 34 - Retaining Ring
2- O-Ring 13 - Friction Plate (2 Used) 24 - Push Rod (12 Used) 35 - Spacer (2 Used)
3- Valve Casing 14 - Relief Valve (2 Used) 25 - Spacer 36 - Roller Bearing
4- Socket Bolt (4 Used) 15 - Pin (2 Used) 26 - Holder 37 - Retaining Ring
5- Poppet (2 Used) 16 - Retaining Ring 27 - Retainer Plate 38 - O-Ring
6- Spring (2 Used) 17 - O-Ring 28 - Plunger (9 Used) 39 - Oil Seal
7- O-Ring (2 Used) 18 - Plate (3 Used) 29 - Thrust Plate 40 - Seal Cover
8- Plug (2 Used) 19 - Retaining Ring 30 - Plug 41 - Retaining Ring
9- Valve Plate 20 - Spacer 31 - O-Ring 42 - Swing Parking Brake Re-
leasing Valve
10 - Spring (24 Used) 21 - Spring 32 - Casing 43 - Bolt (3 Used)
11 - Brake Piston 22 - Spacer 33 - Shaft

W2-5-16
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor
О Be sure to thoroughly read “Precautions for 7. Remove springs (10) (24 used) from casing (32).
Disassembling and Assembling” on page W1-1-1
before starting the disassembly work. 8. Install a bolt into screw hole (M8, pitch 1.25) on
brake piston (11). Then, remove brake piston
(11) from casing (32).
CAUTION: Swing motor weight: 80 kg (180 Ib)
9. Remove O-rings (12 and 17) from casing (32).
1. Remove plug (30) from casing (32) to drain
hydraulic oil.
ϖ 30 mm

Relief Valve

IMPORTANT: Do not disassemble relief valve (14).

Don’t turn the adjusting screw either.

2. Remove relief valves (14) from valve casing (3).

ϖ 27 mm

Make-Up Valve

3. Remove plugs (8) (2 used).

ϖ 14 mm

4. Remove springs (6) (2 used) and poppets (5) (2

used).

5. Put matching marks on the mating section

between valve casing (3) and casing (32).
ϖ 17 mm

6. Loosen socket bolts (4) (4 used) to remove

valve casing (3) from casing (32).

NOTE: Note that valve casing (3) will be raised

by spring (10) force.
Valve plate (9) may come off together with
valve casing (3).Take care not to drop
valve plate (9).

W2-5-17
 UPPERSTRUCTURE / Swing Device

9
3

1 13

15
16
18
28 19
20
21
22

23 32
24
25
26
27
33
29 34
35
36
35
37

39
40
41 42

43

W142-02-06-004

W2-5-18
 UPPERSTRUCTURE / Swing Device
21. Remove plungers (28) (9 used), retainer plate
CAUTION: Casing (32) + shaft (33) + rotor (23)
(27), holder (26), spacer (25) and push rods
assembly weight: 50 kg (110 Ib) (24) (12 used) from rotor (23).

10. Lay casing (32) horizontally and pull rotor (23)

CAUTION: When removing retaining ring
with plunger (28), retainer plate (27) and etc.
out from shaft (33) (19), be sure to hold spacer (20)
Ȁ with a press or a similar tool.
11. Remove plates (18) (3 used) and friction plates Otherwise, retaining ring (19)
(13) (2 used) from casing (32). and spacer (20) will fly off,
causing personal injury.
12. Remove thrust plate (29).
Ȁ 22. Holding spacer (20) with a press, remove retaining
13. Remove retaining ring (41) and seal cover (40) ring (19).
from casing (32).
23. Remove spacers (20), (22) and spring (21).
14. Remove shaft (33) from casing (32) by tapping
the valve casing (3) mouting side of shaft (33) 24. Loosen bolts (43) (3 used) and remove swing
with a plastic hammer. parking brake releasing valve (42) from casing
(32).
15. Remove oil seal (39) from seal cover (40). ϖ 10 mm

16. Remove valve plate (9), pins (15) (2 used) and

O-ring (2) from valve casing (3).

17. With a puller, remove the outer race of roller

bearing (1) from valve casing (3).

18. With a press, remove retaining ring (16) and the

inner race of roller bearing (1) from shaft (33).

19. Remove retaining rings (34 and 37) and spacers

(35) (2 used) from shaft (33). Take care not to
damage the outer surface of oil seal (39) on the
shaft.

20. With a press, remove the inner race of roller

bearing (36) from shaft (33).

W2-5-19
 UPPERSTRUCTURE / Swing Device
Assemble Swing Motor
4 3 7 8 6 5 14

19

1 20
30
15 16 10
31 Section A-A 2 9 43
11 42
13
18

34 12
17 21
35 24 23
25
36 26 28
22
27
29

Inner Race
Plate W183-02-06-007 W142-02-06-008
35 37
33 39 40 41 38 32

1- Roller Bearing 12 - O-Ring 23 - Rotor 34 - Retaining Ring

2- O-Ring 13 - Friction Plate (2 Used) 24 - Push Rod (12 Used) 35 - Spacer (2 Used)
3- Valve Casing 14 - Relief Valve (2 Used) 25 - Spacer 36 - Roller Bearing
4- Socket Bolt (4 Used) 15 - Pin (2 Used) 26 - Holder 37 - Retaining Ring
5- Poppet (2 Used) 16 - Retaining Ring 27 - Retainer Plate 38 - O-Ring
6- Spring (2 Used) 17 - O-Ring 28 - Plunger (9 Used) 39 - Oil Seal
7- O-Ring (2 Used) 18 - Plate (3 Used) 29 - Thrust Plate 40 - Seal Cover
8- Plug (2 Used) 19 - Retaining Ring 30 - Plug 41 - Retaining Ring
9- Valve Plate 20 - Spacer 31 - O-Ring 42 - Swing Parking Brake Re-
leasing Valve
10 - Spring (24 Used) 21 - Spring 32 - Casing 43 - Bolt (3 Used)
11 - Brake Piston 22 - Spacer 33 - Shaft

W2-5-20
 UPPERSTRUCTURE / Swing Device
Assemble Swing Motor
9. Apply gease to the inner of thrust plate (29) and
IMPORTANT: When installing the roller bearing install it into casing (32).
(36) inner race to shaft (33), the
inner race plate should be facing 10. Install spacer (22), spring (21), spacer (20) in
inward. that order into rotor (23).

11. With a press to push spacer (20) until retaining

1. Install retaining ring (34) and one spacer (35) on ring (19) is installed. Install retaining ring (19).
shaft (33). Press the inner race of roller bearing
(36) onto shaft (33). 12. Install push rods (24) (12 used) in rotor (23).
Install spacer (25) and holder (26) in rotor (23)
2. After installing another spacer (35) on shaft (33), in that order.
install retaining ring (37).
IMPORTANT: Plungers (28) (9 used) should be
IMPORTANT: When installing the roller bearing installed at the center projecting part
(1) inner race to shaft (33), the of retainer plate (27).
surface of the inner race with mark
should be facing inward.
13. After installing plungers (28) (9 used) to retainer
plate (27), apply a film of hydraulic oil to the
3. Press the inner race of roller bearing (1) onto plunger holes in rotor (23). Then, insert plungers
shaft (33). Install retaining ring (16). (28) into rotor (23).

IMPORTANT: When tapping the outer race of

roller bearing (36) into casing (32), CAUTION: Casing (32) + shaft (33) + rotor (23)
the surface with mark shall be assembly weight: 50 kg(110 Ib)
used as the outer surface.
14. Lay casing (32). Install the rotor (23) assembly
4. With a metal extension bar and a hammer, onto shaft (33).
install the outer race of roller bearing (36) into
casing (32). IMPORTANT: Plate (18) has notches on the outer
diameter. Friction plate (13) has
IMPORTANT: Apply grease to the inner of oil seal notches on the spline teeth. Install
(39) inner race. plate (18) and friction plate (13) so
that notched positions on both
5. Install oil seal (39) into seal cover (40) with a parts are aligned with each other.
protection plate and a press.
15. Stand casing (32) upright. Install plates (18) (3
6. Install O-ring (38) in casing (32). used) and friction plates (13) (2 used) one by
one alternately.
7. Tap shaft (33) into casing (32) with a plastic
hammer. 16. Install O-rings (17 and 12) in casing (32).

8. Place seal cover (40) onto casing (32) and

secure it with retaining ring (41).

W2-5-21
 UPPERSTRUCTURE / Swing Device

4 3 7 8 6 5 14

1
15 10
Section A-A 2 9 43
11 42

12
17

W183-02-06-007 W142-02-06-008
32

W2-5-22
 UPPERSTRUCTURE / Swing Device
IMPROTANT: Align the brake piston (11) slit as IMPORTANT: While taking care not to allow valve
shown bellow. plate (9) to drop off, align the
32 matching marks (made during dis-
assembly).
Slit
21. Install valve casing (3) to casing (32).
Tighten valve casing (3) with socket bolts (4) (4
11 used).
ϖ 17 mm
ϖ 430 N⋅m (44 kgf⋅m, 320 Ibf⋅ft)

22. Install parking brake releasing valve (42) into

W142-02-06-011
casing (32) via bolts (43) (3 used).
17. Install brake piston (11) into casing (32). If ϖ 10 mm
brake piston (11) is difficult to install because of ϖ 10 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
the resistance force from O-rings (12) and (17),
tap it evenly with a plastic hammer. Make-up Valve
23. Install poppets (5) (2 used) and springs (6) (2
18. Install springs (10) (24 used) in brake piston used) in valve casing (3). Tighten two plugs (8)
(11). with O-rings (7).
ϖ 14 mm
IMPORTANT: When installing roller bearing (1),
ϖ 330 N⋅m (34 kgf⋅m, 245 Ibf⋅ft)
tap the side where the bearing type
is marked with a plastic hammer.
Relief Valve
24. Install relief valves (14) (2 used) to valve casing
19. Drive the outer race of roller bearing (1) into (3).
valve casing (3) with a plastic hammer. ϖ 27 mm
ϖ 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
IMPORTANT: Install valve plate (9) with the
spherical face facing upward.

20. Install O-ring (2), pins (15) (2 used) and valve

plate (9) to valve casing (3).

NOTE: Apply a film of grease to valve plate (9) to

prevent valve plate (9) from coming out of
valve casing (3).

W2-5-23
 UPPERSTRUCTURE / Swing Device
DISASSEMBLE AND ASSEMBLE SWING
PARKING BRAKE RELEASING VALVE

42 44 45 46 47 48

55 49

54 50
53
52

51

W142-02-06-010

43

42 - Swing Parking Brake 46 - Spring 50 - Spool 53 - Spacer

Releasing Valve
43 - Bolt (3 Used) 47 - O-Ring 51 - Bushing 54 - Orifice
44 - O-Ring 48 - Spring 52 - Filter 55 - Poppet
45 - O-Ring 49 - Steel Ball

W2-5-24
 UPPERSTRUCTURE / Swing Device
Disassemble Swing Parking Brake Releasing
Valve

1. Remove O-rings (44), (45) and (47) from swing

parking brake releasing valve (42).

2. Remove springs (46) and (48) from swing parking

brake releasing valve (42).

3. Remove spool (50) from swing parking brake

releasing valve (42).

4. Remove poppet (55) from swing parking brake

releasing valve (42).

5. Remove bushing (51), filter (52), spacer (53)

and orifice (54) from poppet (55).

Assemble Swing Parking Brake Releasing

Valve

1. Install orifice (54), spacer (53), filter (52),

bushing (51) onto poppet (55).

2. Install the poppet (55) assembly onto swing

parking brake releasing valve (42).

3. Install spool (50) onto swing parking brake

releasing valve (42).

4. Install spring (46) onto poppet (55) and install

spring (48) onto spool (50).

5. Install O-rings (44), (45) and (47) onto swing

parking brake releasing valve (42).

W2-5-25
 UPPERSTRUCTURE / Swing Device

MAINTENANCE STANDARD

Swing Motor

1. Clearance between plunger and rotor bore.

d
D-d
Standard Clearance Allowable Limit
0.032 mm (0.0013 in) 0.062 mm (0.0024 in)

W107-02-06-138

D D

W107-02-06-139

2. Clearance between plunger top and shoe

bottom (δ)

Standard Clearance Allowable Limit

0 0.3 mm (0.0118 in) δ

W107-02-06-140

W2-5-26
 UPPERSTRUCTURE / Swing Device

3. Shoe Thickness (t)

Standard Clearance Allowable Limit
6.0 mm (0.236 in) 5.8 mm (0.228 in)

W107-02-06-142

4. Friction Plate Thickness

Standard Clearance Allowable Limit
4.0 mm (0.157 in) 3.6 mm (0.142 in) W107-02-06-143

2
1

5. Holder (2) Height from Retainer Plate (1)

Bottom Face H-h

Standard Clearance Allowable Limit h H

7.0 mm (0.276 in) 6.5 mm (0.256 in) W107-02-06-146

If dimension H-h is reduced to below 6.5 mm

(0.256 in), replace retainer plate (1) and holder
(2).

W2-5-27
 UPPERSTRUCTURE / Swing Device

(Blank)

W2-5-28
 UPPERSTRUCTURE / Pilot Valve

REMOVE AND INSTALL RIGHT PILOT

VALVE

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil W183-04-02-003
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release W183-04-02-002
any remaining pressure befor
Wooden Blocks
removing it.

Cap
Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2.
ϖ 4 mm

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continously to W183-01-01-001
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

Removal
1. Remove seat mounting socket bolts (2) (4 used) 2
to remove seat (1).
ϖ 6 mm
W183-02-01-040

W2-6-1
 UPPERSTRUCTURE / Pilot Valve
2. Remove screw (23), cover (22) to move boot (28)
up.
ϖ 17 mm 29

3
28
3. Remove screws (20) and (16) to move cover (17) 4
up. Disconnect each harness connectors for key 27
switch (19), air controller (18) and grip (3), then 26 5
remove cover (17). Remove screws (21), (15) and 25 6
(13) to remove cover (14). 24 7
8
9
4. Remove the connector and bolt (11) for switch box 23 10
(12) to remove switch box (12). 11
22 12
ϖ 13 mm
20
19
IMPORTANT: Attach identification tags on all 18 21
disconnected hoses to aid in 17
reassembling.

5. Disconnect hoses (30 to 35).

16
ϖ 19 mm

NOTE: Attach caps to all disconnected hose ends.

15
6. Loosen nut (4) to remove clips (5) and (26).
Disconnect connector (6) to remove grip (3) (with 14 13
harness).
W178-02-07-001
Loosen nut (27) to remove lever (29), washers
(24), (25) and boot (28).
ϖ 22 mm
ϖ 19 mm 30
35
34 31
7. Remove bolts (9) and (8) (with pin (7)) to remove 32
valve (10).
33
ϖ 13 mm

Installation
1. Secure valve (10) with bolts (9) and (8) (with pin W178-02-07-002
(7)).
ϖ 13 mm 30 - Hose A3: (To the pilot shut-off valve)
ϖ 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft) 31 - Hose C1: (To the signal control valve port B for bucket roll-in)
32 - Hose S26: (To the signal control valve port H for boom lower)
33 - Hose T3: (To the pilot shut-off valve)
34 - Hose S25: (To the signal control valve port B for bucket roll-
out)
35 - Hose C2: (To the signal control valve port A, D for boom
raise)

NOTE: Piping location shows that of JIS pattern.

W2-6-2
 UPPERSTRUCTURE / Pilot Valve

2. Connect hoses (30 to 35).

ϖ 19 mm
ϖ 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
30
IMPORTANT: If the harness is arranged to the 35
34 31
inside of spring pin (7), it may make
contact with the moving part of the 32
pilot valve which may damage it. Be 33
sure to arrange the harness to the
outside of spring pin (7).

3. Temporarily tighten nut (27) to lever (29), then

install washers (24), (25). Install lever (29) onto
valve (10) with nut (27). Install boot (28). W178-02-07-002

Temporarily tighten nut (4) to lever (29), then 29

install grip (3) with nut (4). 3
Pass the harness of grip (3) through the upper 28
hole of boot (28), then connect it to lever (29), via 4
27
clips (5) and (26). Arrange the harness to the 26 5
outside of spring pin (7) over bolt (8) head.
Connect connector (6). 25 6
24 7
ϖ 22 mm 8
ϖ 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 9
ϖ 19 mm 23 10
11
ϖ 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 22 12
20
4. Install switch box (12) with bolt (11), then connect 19
the connector. 18 21
ϖ 13 mm 17
ϖ 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)

5. Connect each harness of key switch (19) and air

16
controller (18).

6. Install cover (14) with bolts (21), (15) and (13).

Install cover (17) with bolts (20 and 16).
15
7. Install cover (22) with bolt (23). 14 13

W178-02-07-001

W2-6-3
 UPPERSTRUCTURE / Pilot Valve

8. Install seat (1) with socket bolts (2) (4 used).

ϖ 6 mm
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

IMPORTANT: Be sure to check the hydraulic oil 1

level after assembling. Start engine
to check each part for any oil
leakage. 2

W183-02-01-040

W2-6-4
 UPPERSTRUCTURE / Pilot Valve

REMOVE AND INSTALL LEFT PILOT

VALVE

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
W183-04-02-003
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may W183-04-02-002
fly off if removed without
Wooden Blocks
releasing internal pressure Cap
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.
2. After stopping the engine, move the control levers
several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
W183-01-01-001
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2.
ϖ 4 mm
3. Remove the hydraulic oil tank cap. Connect a
vacuum pump and operate it continously to 1
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.
2
9 Radio
Removal 3
8
1. Remove screw (2) and cover (3) to move boot (1) 4
up. At this time, the console is at the most front
position.
ϖ 17 mm

2. Remove screws (7), (8) to remove cover (9). 7

Remove screws (4), (5) to move cover (6) up to 6
5
disconnect the radio connector, then remove W178-02-07-003
cover (6).

W2-6-5
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Attach identification tags on all
disconnected hoses to aid in
reassembling.

3. Disconnect hoses (10 to 15).

ϖ 19 mm 10
15
14 11
12
NOTE: Attach caps on each disconnected hose
ends. 13

4. Loosen nut (17) to remove clips (28) and (20).

Disconnect connector (27) to remove grip (16)
(with harness).
Loosen nut (19) to remove lever (18), washers
(24), (25) and boot (1).
ϖ 22 mm W178-02-07-004
ϖ 19 mm 10 - Hose A2: (To the pilot shut-off valve)
11 - Hose C5: (To the signal control valve port C, F for boom
lower)
5. Remove bolts (23) and (22) (with pin (21)) to 12 - Hose S15: (To the signal control valve for right swing)
remove valve (26). 13 - Hose T2: (To the pilot shut-off valve)
14 - Hose C3: (To the signal control valve port G for arm roll-in)
ϖ 13 mm 15 - Hose S16: (To the signal control valve for left swing)

NOTE: Piping location shows that of JIS pattern.

16

Installation
1. Install valve (26) with bolts (23) and (22) (with pin 28
(21)). 17
ϖ 13 mm 18
27
ϖ 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)
1
19
2. Connect hoses (10 to 15). 20
21
ϖ 19 mm 22
ϖ 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 23
24
25
26

W178-02-07-003

W2-6-6
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: If the harness is arranged to the
inside of spring pin (21), it may make
contact with the moving part of the
pilot valve which may damage it. Be 16
sure to arrange harness to the
outside of spring pin (21).
28
3. Temporarily tighten nut (19) to lever (18), then 17
install washers (24), (25). Install lever (18) onto 18
valve (26) with nut (19). Install boot (1). 27
Temporarily tighten nut (17) to lever (18), then 1
install grip (16) with nut (17). 19
20
Pass the harness of grip (16) through the upper
21
hole of boot (1), then connect it to lever (18), via
22
clips (28) and (20). Arrange the harness to the
outside of spring pin (21) over bolt (22) head. 24
Connect connector (27). 25
ϖ 22 mm 26
ϖ 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 9 Radio 2
ϖ 19 mm 8 3
ϖ 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 4

4. Connect the connector of the radio and install

cover (6) with screws (4) and (5).
Install cover (9) with screws (7), (8). 7
6
5
5. Install cover (3) with screws (2).
W178-02-07-003

IMPORTANT: Be sure to check the hydraulic oil

level after assembling. Start engine
to check each part for any oil
leakage.

W2-6-7
 UPPERSTRUCTURE / Pilot Valve

(Blank)

W2-6-8
 UPPERSTRUCTURE / Pilot Valve

REMOVE AND INSTALL TRAVEL PILOT

VALVE. REMOVE AND INSTALL BUCKET
PILOT VALVE (FOR LOADING SHOVEL
ONLY)

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it. W183-04-02-003

Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap W183-04-02-002

approx. 30° counterclockwise using a hexagon Wooden Blocks

wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic Cap
System on page W1-1-2.
ϖ 4 mm

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W2-6-9
 UPPERSTRUCTURE / Pilot Valve

Removal
1. Loosen bolts (2) (2 used) at the lower side of the
frame.
Front Side 1
NOTE: Do not remove bolt (2).
ϖ 19 mm
3

2
2. Remove bolts (1) (3 used) while holding under
cover (3) by hand. Move under cover (3) to the
front side a bit and remove it out.
ϖ 19 mm

W183-02-06-008

3. Loosen bolts (31) (4 used) to remove pedals (33)

(2 used) and levers (32) (2 used).
ϖ 17 mm 4

32
33 5
4. ϑFor loading shovel onlyϒ
Loosen bolts (4) (3 used) to remove cover (5).
6
Loosen bolts (6) (2 used) to remove pedal (7). (2
31 7
places both left and right)
8
ϖ 17 mm
9
10

30 11
29 12
28 13
14
27 15
16
22
21 17
20
26 25 24 23 19
18

W183-02-07-005

W2-6-10
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Attach identification tags to pipes
and hoses to clarify correct 11 - Hose SRT: (To pilot valve port T for travel)
reassembly. 12 - Hose RLT: (From pilot valve port T for left side bucket opening
/ closing)
13 - Hose 14: (To signal control valve port N)
5. Remove hoses (11 to 26) under the cab. 14 - Hose RLP: (From pilot valve port P for left side bucket open-
ing / closing)
ϖ 19 mm 15 - Hose SLP: (To pilot valve port P for left side bucket opening /
closing)
16 - Hose T4: (To lock valve)
NOTE: Cap the disconnected pipes and hoses. 17 - Hose P1: (From lock valve)
Hoses (11 to 15, 18 and 23 to 26) are not 18 - Hose SRT: (From pilot valve port T for right side bucket
used in backhoe machine. opening / closing)
19 - Hose C7: (To signal control valve port L)
20 - Hose C6: (To signal control valve port K)
6. Remove socket bolts (30) (2 used), spring washers 21 - Hose C8: (To signal control valve port I)
(29) (2 used) and plane washers (28) (2 used) to 22 - Hose C9: (To signal control valve port J)
remove pilot valve (27). 23 - Hose SLP: (From pilot valve port P for travel)
24 - Hose RLP: (To pilot valve port P for right side bucket opening
ϖ 8 mm / closing)
25 - Hose 13: (To signal control valve port M)
26 - Hose RLT: (To pilot valve port T for right side bucket opening /
7. (For loading shovel only) closing)
Remove socket bolts (8) (2 used) and spring
washers (9) (2 used) to remove pilot valve (10)
which is used to open / close bucket.(2 places
both left and right)
ϖ 8 mm

W2-6-11
 UPPERSTRUCTURE / Pilot Valve

Installation
1. Install pilot valve (27) with socket bolts (30) (2
used), spring washers (29) (2 used) and plane
washers (28) (2 used).
ϖ 8 mm 4
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
32
33 5
2. (For loading shovel only)
Install pilot valve (10) for bucket opening / closing 6
with socket bolts (8) (2 used) and spring washers 31 7
(9) (2 used). (2 places both left and right) 8
ϖ 8 mm 9
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 10

30 11
3. Connect hoses (11 to 26) under the cab.
29 12
ϖ 19 mm
28 13
ϖ 30 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
14
27 15
NOTE: Hoses (11 to 15, 18 and 23 to 26) are not
used in the backhoe machine. 16
22
4. Install pedals (33) (2 used) and lever (32) to pilot 21 17
valve (27) with bolts (31) (4 used). 20
26 25 24 23 19
ϖ 17 mm 18
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W183-02-07-005
5. (For loading shovel only)
Install pedal (7) to pilot valve (10) for bucket
opening / closing with bolts (6) (2 used). Install
cover (5) with bolts (4) (3 used).
ϖ 17 mm 11 - Hose SRT: (To pilot valve port T for travel)
12 - Hose RLT: (From pilot valve port T for left side bucket open-
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
ing / closing)
13 - Hose 14: (To signal control valve port N)
IMPORTANT: Be sure to check the hydraulic oil 14 - Hose RLP: (From pilot valve port P for left side bucket
level after assembling. Start engine opening / closing)
15 - Hose SLP: (To pilot valve port P for left side bucket opening /
to check each part for any oil closing)
leakage. 16 - Hose T4: (To lock valve)
17 - Hose P1: (From lock valve)
18 - Hose SRT: (From pilot valve port T for right side bucket
opening / closing)
19 - Hose C7: (To signal control valve port L)
20 - Hose C6: (To signal control valve port K)
21 - Hose C8: (To signal control valve port I)
22 - Hose C9: (To signal control valve port J)
23 - Hose SLP: (From pilot valve port P for travel)
24 - Hose RLP: (To pilot valve port P for right side bucket opening
/ closing)
25 - Hose 13: (To signal control valve port M)
26 - Hose RLT: (To pilot valve port T for right side bucket opening
/ closing)

W2-6-12
 UPPERSTRUCTURE / Pilot Valve
6. Insert under cover (3) to bolts (2) (2 used) from
front side.

7. Install bolts (1) (3 used) while holding under cover Front Side 1
(3) by hand and secure bolts (2) (2 used).
ϖ 19 mm
ϖ 90 N]m (9.2 kgf]m, 67 Ibf⋅ft)
3

W183-02-06-008

W2-6-13
 UPPERSTRUCTURE / Pilot Valve

DISASSEMBLE FRONT PILOT VALVES

13

12

14

11
15

11
10

8
8
7
9

21
6
16 20
21
5
20
4 5
19
3 6

3 18
2
4

17

W176-02-07-001

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

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

W2-6-14
 UPPERSTRUCTURE / Pilot Valve

Disassemble Front Pilot Valves

IMPORTANT: Two kinds of push rods are used.

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

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

slightly. Remove cam (12) from universal joint
(14). 16
ϖ 32 mm ST 7257

NOTE: The universal joint has been secured on

block (10) with LOCTITE. Don’t remove it
unless necessary.
W176-02-07-005

3. Remove socket bolt (11) to remove block (10). At

this time, push rods (8) and (9) are still on the IMPORTANT: The number of shims has been
block side. determined for each port during the
ϖ 6 mm performance testing at the factory.
Take care not to lose them. Keep
them carefully so as to install them
to each former port when
reassembly.

7. Remove spring guide (16), balance springs (3),

(4), return springs (5), (6), shim (2), spacer (1)
from spool (17).

W2-6-15
UPPERSTRUCTURE / Pilot Valve

21

20
21
20

19

18

17

W176-02-07-001

W2-6-16
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: As the spool has been selected to
match the hole of the housing, keep
them carefully so as to install them
to the former port when
reassembling.

8. Remove spool (17) from housing (18). Pull it out

while turning it slowly.

NOTE: The spool and housing must be replaced as

assembly.

9. Remove O-rings (19), (21) from housing (18).

Don’t remove dowel pin (20) unless necessary.

W2-6-17
 UPPERSTRUCTURE / Pilot Valve

ASSEMBLE FRONT PILOT VALVES

13 14
10
12
15
11

8, 9

7
16

3, 4

5, 6

19

17

W176-02-07-006

21 20 18

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

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

W2-6-18
 UPPERSTRUCTURE / Pilot Valve

Assemble Front Pilot Valves

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

3 With outer
5. Insert the spool (17) head into the hole of spring
groove special tool (ST 7257) to press the spring from the
4 Without outer top of spring guide (16). Install retaining ring (7)
with the ring holder (ST 7255) onto the head of the
groove
spool.

Port Return Springs Balance Springs

ST 7257 ST 7255
No. (5), (6) (3), (4)
1 Short Short 17
2 Long Long
3 Short Short
Packing Material
4 Long Long

IMPORTANT: Make sure of the port hole number, W176-02-07-009

and insert the spool to the former NOTE: Put approx. dia. 8 mm, length 10 mm of
port. packing material into the port hole so as to
not only make the work easy to do, but also
prevent the spool from lowering to the
1. Insert the thinner end of spool (17) into housing
bottom when compressing the spring.
(18), then slowly push the spool in while rotating it.
6. Assemble the remaining spools (17) (3 used) into
NOTE: The spool has been selected to match the housing (18) with the same procedures in step 2
hole of the housing. The spool and housing to 5.
must be replaced as assembly.
7. Install O-rings (19) and (21) (2 used) on to
IMPORTANT: Refer to the table above to assemble
housing (18).
them correctly.

2. Install spacer (1), shim (2), balance spring (3) or

(4), return spring (5) or (6) onto spool (17)
installed in housing (18).

W2-6-19
 UPPERSTRUCTURE / Pilot Valve

13 14
10
12
15
11

8, 9

W176-02-07-006

20 18

W2-6-20
 UPPERSTRUCTURE / Pilot Valve
8. Apply grease to the inner face of oil seals (15) (4 IMPORTANT: Make sure of the tighteness of cam.
used), then install the oil seals (4 used) into block
(10) with a bamboo spatula.
13. Clamp housing (18) carefully in a vise and then
install cam (12) to universal joint (14).
NOTE: As shown bellow, inserting push rods (8), Tighten the universal joint so that the clearance
(9) first, then installing the oil seal. It will between the cam and push rod (8), (9) becomes 0
prevent the oil seal from entering into the to 0.2 mm (0 to 0.008 in).
hole.
ϖ 32 mm
­§îºіî
⃾֞Ƴἤ

IMPORTANT: Don’t clamp housing (18) in a vise

10
because the strong torque may act
on the screw joint.

14. Clamp screw joint (13) in a vise to tighten

universal joint (14). Tighten cam (12) with a
W176-02-07-007
spanner.
ϖ 32 mm
IMPORTANT: Make sure of the position to install ϖ 88.2 N]m (9 kgf]m, 65 Ibf]ft)
the push rod.

9. Install push rods (8), (9) to block (10). When

installing the push rods, install the push rods with
groove to ports # 1 and # 3, the ones without
groove to ports # 2 and # 4, respectively.

10. Apply grease to the ball at the front end of push

rods (8), (9).

11. Apply grease to the joint part of universal joint (14)

12. Align the position of dowel pin (20), install the

block (10) assembly to housing (18) with socket
bolts (11) (2 used).
ϖ 6 mm
ϖ 19.6 N]m (2 kgf]m, 14.5 Ibf]ft)

W2-6-21
 UPPERSTRUCTURE / Pilot Valve

DISASSEMBLE TRAVEL PILOT VALVE

35 2

34
33
32
31
30

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

12
25 13
24 23

22

21

20

19

18
14

17
15

16

W176-02-07-002

1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjusting Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)

W2-6-22
 UPPERSTRUCTURE / Pilot Valve

Disassemble Travel Pilot Valve

1. Clamp casing (14) in vise. Loosen bolt (1) to 7. Remove spring (18) from casing (14). (4 places)
remove cover (2) from holder (10).
ϖ 10 mm IMPORTANT: Put a stand under bracket (26). If
holder (10) bears the reaction force,
2. Remove socket bolts (8) (2 places) to remove a strong force acts on pin (3) and the
holder (10) from casing (14). pin may deform its shape.
ϖ 8 mm
IMPORTANT: The inside of spring pins (24), (25)
3. Pull out pusher (23) from casing (14) (4 places). hole in the bracket is in stepped
Bushing (13) and oil seal (11) are removed with shape. Therefore the spring pin can
the pusher. only be pulled out from one
direction.

4. Pull out pusher (23) from bushing (13) with a

bamboo spatula to remove oil seal (11). (4 places) 8. Put a stand under bracket (26).
Push out both spring pins (24), (25) from bracket
(26) at the same time using special tool (ST 1237).
IMPORTANT: Make mark on spools so as to easily Remove the bracket from pin (3). (2 places)
install them to their former position.
NOTE: The outside end of the spring pin has been
5. Pull out the spool (17) assembly from casing (14) caulked.
while turning the spool. (4 places)
Spring guide (22), balance spring (21), shim (20)
and spacer (19) are removed with the spool. 24,25

NOTE: The spool has been selected to match the 26

3 27
hole in the casing. The spool and casing
must be replaced as assembly. Caulked Here

IMPORTANT: The number of shims has been Stand

determined during the performance
testing at the factory. They must be
kept together with their spool.
W176-02-07-019
6. Compress balance spring (21). Remove spring
guide (22), balance spring (21), shim (20) and
spacer (19) from spool (17). (4 places)
9. Remove socket bolts (28) (2 used) to remove
damper (6) and rubber seat (7) from pin (3). O-
ring (4) is removed with them. (2 places)
ϖ 5 mm

W2-6-23
 UPPERSTRUCTURE / Pilot Valve

35
34
33
32
31
30

10

14

W176-02-07-002

W2-6-24
 UPPERSTRUCTURE / Pilot Valve

10. Remove O-ring (5) from pin (3). (2 places)

11. Place holder (10) with the casing (14) mating

surface facing up.

IMPORTANT: The holes for spring pins (34), (35) of

cam (32) are in stepped-shape.
Therefore tap the pins from the
bottom of the cam.

12. Push out both spring pins (34), (35) from cam (32)
at the same time using special tool (ST 1237). (2
places)

NOTE: The spring pin is a double-pin.

NOTE: The spring pin is caulked in its hole, so it

may feel tight when removing.

13. Remove pin (3) with a round bar and a hammer.

At this time, cam (32) is also removed. (2 places)

NOTE: Don’t remove bushings (31) (4 used) left on

holder (10) unless necessary. When
removal is necessary, the bushing special
tool (ST 7256) should be used to tap it out.

14. Remove lock nuts (33) (2 used) from cam (32) to

remove adjusting bolts (30) (2 used). (2 places)
ϖ 13 mm
ϖ 4 mm

W2-6-25
 UPPERSTRUCTURE / Pilot Valve

ASSEMBLE TRAVEL PILOT VALVE

26 6 7 1 2 3 31 25 27 24 10 32 30 33 34, 35 8 9

13
22
4
28
5 11 21
29 12 18
23
20

19

17
14

W176-02-07-010

15, 16

1- Bolt (2 Used) 10 - Holder 19 - Spacer (4 Used) 28 - Socket Bolt (4 Used)

2- Cover 11 - Oil Seal (4 Used) 20 - Shim (Several) 29 - Spring Washer (4 Used)
3- Pin (2 Used) 12 - O-Ring (4 Used) 21 - Balance Spring (4 Used) 30 - Adjusting Bolt (4 Used)
4- O-Ring (2 Used) 13 - Bushing (4 Used) 22 - Spring Guide (4 Used) 31 - Bushing (4 Used)
5- O-Ring (2 Used) 14 - Casing 23 - Pusher (4 Used) 32 - Cam (2 Used)
6- Damper (2 Used) 15 - O-Ring 24 - Spring Pin (2 Used) 33 - Lock Nut (4 Used)
7- Rubber Seat (2 Used) 16 - Plug 25 - Spring Pin (2 Used) 34 - Spring Pin (2 Used)
8- Socket Bolt (2 Used) 17 - Spool (4 Used) 26 - Bracket (2 Used) 35 - Spring Pin (2 Used)
9- Spring Washer (2 Used) 18 - Spring (4 Used) 27 - Spring Pin (2 Used)

W2-6-26
 UPPERSTRUCTURE / Pilot Valve

Assemble Travel Pilot Valve

IMPORTANT: Pay attention to the mounting dir- 6. If bushing (31) has been removed from holder
ection of spring guide (22). (10), it shall be installed on the holder using
special tool (ST 7256) in the following procedures.
IMPORTANT: Install the former number of shims.
NOTE: The bushings (4 used) are indentical.
ОInsert the bushing into special tool (ST 7256),
1. Assemble spool (17) into assembly. (4 used) then tap on the special tool (ST 7256) to install
ОȀInsert spacer (19), shim (20), balance spring the bushing into the hole of holder.
(21) into the spool in order. Stop tapping when the bushing end is flush
ОȀPress balance spring (21) by hand. Install with the inside wall.
spring guide (22) to the spool with the stepped- ST 7256
10
end facing down.

2. Insert spring (18) to casing (14). (4 places)

31
W176-02-07-016

IMPORTANT: Insert the spool (17) assembly into ОInstall the bushing on the opposite side using
the former port. the same procedure. 31
10
ST 7256
3. Turn and install the spool (17) assembly into
casing (14). (4 places)

W176-02-07-015
4. Assemble pusher (23) (4 used).
ОȀInstall oil seal (11) onto bushing (13). О Install the bushing in near side as shown
ОȀApply grease to the inner face of oil seal. bellow. Stop tapping when the bushing end is
ОȀInstall O-ring (12) to the bushing. flush with the outside of holder.
ОȀInsert pusher (23) to the bushing.
ОȀApply grease to the pusher head section. 31
10 ST 7256

5. Insert the pusher (23) assembly to holder (10). (4

places). Holder Outside

W176-02-07-014

ОȀInstall the bushing on the opposite side as

shown below. 31
10
ST 7256

W176-02-07-013

W2-6-27
UPPERSTRUCTURE / Pilot Valve

3 10 32 30 33 34, 35 8 9

23

14
W176-02-07-010

W2-6-28
 UPPERSTRUCTURE / Pilot Valve
7. Place adjusting bolt (30) to cam (32). Tighten the IMPORTANT: Don’t adjust the adjusting bolt (30)
bolt by hand, and then lightly secure it temporarily while pressing the pusher (23) head
with lock nut (33). (2 places) with the adjusting bolt. The standard
clearance between the adjusting bolt
and pusher must be 0 to 0.2 mm (0 to
NOTE: Adjust the dimensions later.
0.008 in).

8. Apply grease on the head (mating surface for 13. Adjust bolt (30) by the following procedures. (2
pusher (23)) of adjusting bolts (30). (2 places) places)
Ȁ ϖ 13 mm
9. Install O-ring (5) to pin (3), then assemble the pin ϖ 4 mm
to holder (10) with cam (32). (2 places) ОȀLoosen lock nut (33).
ОȀMove cam (32) to check whether there is play, if
IMPORTANT: Take care of the inserting direction of none, turn adjusting bolt to adjust.
the spring pin. ОȀTurn both adjusting bolts on the left and right
alternatively to keep the cam horizontal.
IMPORTANT: Tap the spring pin in until it makes ОȀMeasure sizes A and B from both left and right
contact with the stepped part in hole. caves on the cam to holder (10). Fine adjust the
adjusting bolt to get same distance for both left
and right.
10. Install spring pins (34), (35) to cam (32) using ОȀSecure the adjusting bolt with a hexagon-
special tool (ST 1237), then secure the cam and headed wrench. Tighten the lock nut to
pin (3). The spring pins shall be displaced with specified torque fist for securing the adjusting
their slits in 90°. (2 places) bolt.
ОȀW hen adjustment is finished, move cam to
34 35 Slit Slit check that there is a little play. If there is no play,
the pusher may be in compressed condition,
and adjustment should be carried out again.
ϖ 9.8 N]m (1 kgf]m, 7.2 Ibf]ft)

30 33 32 10

W176-02-07-017 A B

11. Caulk the hole edge of cam (32), where spring

pins (34), (35) are inserted, with a punch. (2
places)

12. Place holder (10) on the casing (14) assembly

and install it with socket bolts (8) (2 used), spring
washers (9) (2 used).
W176-02-07-003
ϖ 8 mm
ϖ 49 N]m (5 kgf]m, 36 Ibf]ft)

W2-6-29
 UPPERSTRUCTURE / Pilot Valve

26 6 7 1 2 3 25 27 24 10

4
28
5
29

W176-02-07-010

W2-6-30
 UPPERSTRUCTURE / Pilot Valve

14. Install rubber seat (7) to pin (3). (2 places) IMPORTANT: Place a stand under the bracket. If
holder (10) bears the reaction force,
a strong force acts on pin (3) and the
pin may deform.
15. Apply grease to O-ring (5). (2 places)
IMPORTANT: The inside of the spring pin hole in
the bracket is stepped-shape. Make
sure of the direction to insert the
IMPORTANT: Pay attention to the direction of spring pin.
damper (6).

IMPORTANT: Make sure of the facing direction of

IMPORTANT: The inner bore of damper (6) is the spring pin.
edged-shape. If the damper is pried
upward, O-ring (5) will be damaged.
20. Put a stand under the bracket (26).
Tap spring pins (24), (25) into the bracket until
16. With the lever upward, install damper (6) to pin (3) the spring pin comes to the stepped end using
straight without prying. (2 places) special tool (ST 1237). The spring pins shall be
displaced with their slits in 90°.

17. Secure damper (6) to holder (10) with socket bolts

(28) (2 used) and spring washers (29) (2 used). (2
places) Caulked Here Caulked Here
ϖ 8 mm
ϖ 7 N]m (0.7kgf]m, 5.1 Ibf]ft) 26 3

18. Apply grease to O-ring (4), then press it to the Stand 24, 25
end-most of pin (3). (2 places)

W176-02-07-011

IMPORTANT: As for the direction to install the

bracket, refer to the figure in the
disassemble section. Take care not 21. Caulk the hole edge of bracket (26), where spring
to misassemble it. pins (24), (25) are inserted, with a punch. (2
places)
19. Install pin (3) into bracket (26), then align the (Refer to the figure above.)
inserting holes of spring pin (24), (25) to fix the
pin on bracket. 22. Install pin (3) on other bracket (26) as same in
steps 19 to 21.

23. Install cover (2) to holder (10) with bolts (1) (2

used).
ϖ 10 mm
ϖ 5 N]m (0.5 kgf]m, 3.6 Ibf]ft)

24. Apply grease to the spring pin (27) contact part of

damper (6). (2 places)

W2-6-31
 UPPERSTRUCTURE / Pilot Valve

DISASSEMBLE PILOT VALVE FOR

BUCKET OPENING / CLOSING

1
18
2

17

10

11

12

13

14

15

16
W183-02-07-004

1- Set Screw 6- O-Ring (2 Used) 11 - Shim (Several) 16 - Cap (4 Used)

2- Cam 7- Bushing (2 Used) 12 - Spacer (2 Used) 17 - Pin
3- Bushing (2 Used) 8- Pusher (2 Used) 13 - Spring (2 Used) 18 - Socket Bolt (2 Used)
4- Holder 9- Spring Guide (2 Used) 14 - Spool (2 Used)
5- Oil Seal (2 Used) 10 - Balance Spring (2 Used) 15 - Casing

W2-6-32
 UPPERSTRUCTURE / Pilot Valve
Disassemble Pilot valve for Bucket Opening /
Closing

1. With a vice hold casing (15), remove set screw (1). 8. Remove spring (13) from casing (15). (2 places)
ϖ 5 mm

2. With an adapter bar and a hammer, pull out pin

(17) and remove cam (2) at the same time.

3. Remove socket bolts (18) (2 used) to remove

holder (4) from casing (15).
ϖ 6 mm

4. Pull out pusher (8) from casing (15) (2 places). At

this moment, bushing (7) and oil seal (5) are on
the pusher.

5. Pull out pusher (8) from bushing (7) and remove

oil seal (5) with a bamboo spatula. (2 places)

IMPORTANT: Keep the two spools with marks on,

so that they will be installed easily to
the holes where they were.

6. Pull out the spool (14) assembly from casing (15)

while turning it. (2 places)
Spring guide (9), balance spring (10), shim (11)
and spacer (12) are all on the spool.

NOTE: As the casing and the spool are precision

parts specially made to fit each other, they
must be replaced as a set.

IMPORTANT: The number of shims is determined

during the performance test before
delivered, therefore keep the shims
together with each spool.

7. Compress balance spring (10) to remove spring

guide (9), balance spring (10), shim (11) and
spacer (12) from spool (14). (2 places)

W2-6-33
 UPPERSTRUCTURE / Pilot Valve

ASSEMBLE PILOT VALVE FOR BUCKET

OPENING / CLOSING

2
1
8
3

18 5
17
7

4
9
6
10
15
13
14
11,12
16

W183-02-07-001

1- Set Screw 6- O-Ring (2 Used) 11 - Shim (Several) 16 - Cap (4 Used)

2- Cam 7- Bushing (2 Used) 12 - Spacer (2 Used) 17 - Pin
3- Bushing (2 Used) 8- Pusher (2 Used) 13 - Spring (2 Used) 18 - Socket Bolt (2 Used)
4- Holder 9- Spring Guide (2 Used) 14 - Spool (2 Used)
5- Oil Seal (2 Used) 10 - Balance Spring (2 Used) 15 - Casing

W2-6-34
 UPPERSTRUCTURE / Pilot Valve
Assemble Pilot Valve for Bucket Opening /
Closing

IMPORTANT: Install spring guide (9) with the 8. In case bushings (3) (2 used) were removed from
stepped part facing the spring. holder (4). Install the bushings into the holder as
follows using special tool (ST 7131).

IMPORTANT: Place shims by same number that

NOTE: Both bushings are same parts.
they were disassembled.
ОInsert bushing into special tool (ST 7131) and
place special tool (ST 7131) into holder (4)
1. Insert spacers (12) (2 used), shim (11) and balance while tapping with a hammer.
springs (10) (2 used) in order onto spools (14) (2 Stop tapping as the bottom of the bushing is
used). flush with the top surface of holder (4).
ST 7131
2. Install spring guides (9) (2 used) onto spools (14)
(2 used) with the stepped part facing the spring 4
while compressing the balance spring by hand.

3
3. Insert spring (13) into casing (15). (2 places)
W183-02-07-003

IMPORTANT: Insert the spool (14) assembly into О Install bushing on the opposite by same way.
the port where it was removed.

4. Insert the spool (14) assembly into casing (15)

while turning it. (2 places) 9. Install holder (4) on the casing (15) assembly and
secure it with socket bolts (18) (2 used)
ϖ 6 mm
5. Place oil seals (5) (2 used) to bushings (7) (2
used) with their inner periphery being applied with ϖ 20 N]m(2 kgf]m, 14.5 Ibf]ft)
grease. Ȁ
10. Align the pin holes in cam (2) and holder (4) and
6. Place O-ring (6) onto bushings (7) (2 used) and install pin (17) while tapping it with a hammer.
insert pushers (8) (2 used) with the head of the
pusher being applied with grease. 11. Install set screw (1).
ϖ 5 mm
7. Insert the pusher (8) assembly into holder (4). (2 ϖ 12 N]m(1.2 kgf]m, 8.7 Ibf]ft)
places)

W2-6-35
 UPPERSTRUCTURE / Pilot Valve

(Blank)

W2-6-36
 UPPERSTRUCTURE / Pilot Shut-off Valve

REMOVE AND INSTALL PILOT SHUT-OFF

VALVE

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation W183-04-02-003
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic W183-04-02-002

System on page W1-1-2. Wooden Blocks

ϖ 4 mm
Cap

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W2-7-1
 UPPERSTRUCTURE / Pilot Shut-off Valve
Removal
1. Remove spring (3).

IMPORTANT: Attach tags to hoses to aid in

assembly.
1

2. Disconnect hoses (6 to 13) and pipes (14,15).

ϖ19 mm 2
3
5
3. Remove spring pin (5) to remove lever (1).
4
4. Remove bolt (2) to remove pilot shut-off valve
(4).
ϖ17 mm
W178-02-08-001

13 14 2
Installation 12 15
1. Install pilot shut-off valve (4) with bolt (2). 11

2. Install lever (1) with spring pin (5).

3. Connect hoses (6 to 13) and pipes (14,15). 6

10
4. Install spring (3).

Wrench Size Tightening Torqne

Remark
(mm) N⋅m (kgf⋅m) Ibf⋅ft
ϖ 17 49 (5) 36 Bolt 7
ϖ 19 29 (3) 21.5 Hose, Pilot
8

9 W183-02-07-007

6- Hose T4 : (To the oil tank)

7- Hose A4 : (To the signal control valve)
8- Hose A5 : (To the signal control valve)
9- Hose P : (To 3-pool solenoid valve)
10 - Hose T3 : (To the right pilot valve)
11 - Hose A3 : (To the right pilot valve)
12 - Hose P1 : (To the travel pilot valve)
13 - Hose T2 : (To the left pilot valve)
14 - Hose T4 : (To the left pilot valve)
15 - Hose T1 : (To the travel pilot valve)

W2-7-2
 UPPERSTRUCTURE / Pilot Shut-off Valve

(Blank)

W2-7-3
 UPPERSTRUCTURE / Pilot Shut-off Valve

DISASSEMBLE PILOT SHUT-OFF VALVE

3
6
2 7
1
8
9

13 10

11

12

W178-02-08-005

1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin

W2-7-4
 UPPERSTRUCTURE / Pilot Shut-off Valve
Disassemble Pilot Shut-Off Valve

• Be sure to thoroughly read “Precautions for

Disassembly and Assembly Work” on page
W1-1-1 before starting any repair work.

1. Make matching marks on body (4) and bracket

(11). Remove retaining ring (6), washer (7),
backup ring (8) and O-ring (9) from body (4) to
remove the spool (10) assembly.

2. Remove washer (1), backup ring (2) and O-ring

(3) from body (4).

3. Clamp the spool (10) with wooden spatula in a

vise. Remove socket bolt (13) and bracket (11).
ϖ 4 mm

NOTE: Don’t remove pin (12) unless necessary.

4. Remove socket bolt (5) from body (4).

ϖ 8 mm

W2-7-5
 UPPERSTRUCTURE / Pilot Shut-off Valve

ASSEMBLE PILOT SHUT-OFF VALVE

12 13 11 4 5 Z

Section Z-Z W178-02-08-006

10 6 7 8 9 4 3 2 1 11

13

T178-03-07-002

1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin

W2-7-6
 UPPERSTRUCTURE / Pilot Shut-off Valve
Assemble Pilot Shut-Off Valve

1. Apply LOCTITE # 262 on socket bolt (5) and

install it to body (4).
ϖ8 mm
ϖ29.4 N⋅m (3.0 kgf⋅m, 21.5 Ibf ⋅ft)

2. Clamp spool (10) with wooden spatula in a vise.

Apply LOCTITE # 262 on socket bolt (13), then
install bracket (11) on to spool (10).
ϖ4 mm
ϖ3.9 N⋅m (0.4 kgf⋅m, 2.9 Ibf ⋅ft)

3. Install O-ring (3), backup ring (2) and washer

(1) on to body (4).

4. Apply hydraulic oil to spool (10) and install it to

body (4).

5. Install O-ring (9), backup ring (8) and washer

(7) to body (4), and install retaining ring (6) to
spool (10).

W2-7-7
 UPPERSTRUCTURE / Pilot Shut-off Valve

(Blank)

W2-7-8
 UPPERSTRUCTURE / Shockless Valve

REMOVE AND INSTALL FRONT ATTACH-

MENT SHOCKLESSӸ
ӸVALVE

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation W183-04-02-003

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

the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining in
the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic W183-04-02-002
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2. Wooden Blocks

ϖ 4 mm
Cap

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W2-8-1
 UPPERSTRUCTURE / Shockless Valve

Removal

IMPORTANT: Attach identification tags to hoses to

aid reassembly. For the Boom Lower Pilot Operation Circuit
1
5
1. Disconnect hoses (1 to 4)
ϖ 19 mm Front Side

2. Remove bolts (5) (2 used) to remove the shackless

valve. 2
ϖ 13 mm
W183-02-09-001
Installation
For Pi Pressure Circuit of Pump 2 Regulator
1. Install the shackless valve with bolts (5) (2 used).
ϖ 13 mm 3
4
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) Front Side

2. Connect hoses (1 to 4). 5

ϖ 19 mm
ϖ 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

T183-05-04-026

1- Hose F80 :(To the boom lower spool and holding valve selector valve)
2- Hose F90 :(From the pilot valve)
3- Hose DH :(To the pi port of pump 2 regulator)
4- Hose PA :(From the pilot valve)

W2-8-2
 UPPERSTRUCTURE / Shockless Valve

DISASSEMBLE AND ASSEMBLE THE

SHOCKLESS VALVE
(For the Boom Lower Pilot Operation Circuit and
Pi Pressure Circuit of Pump 2 Regulator)

4 5 6 7

T183-03-07-008

Wrench Size Tightening Torque

Item Part Name Q’ty Remarks
(mm) N⋅⋅ m (kgf⋅⋅ m) (Ibf⋅⋅ ft)
1 Plug 2 : 8 39 (4) (29)
2 O-Ring 2
3 Body 1
4 Spring 2
5 Plunger 1
6 Ring 1
7 Orifice 1

W2-8-3
 UPPERSTRUCTURE / Shockless Valve

(Blank)

W2-8-4
 UPPERSTRUCTURE / Solenoid Valve

REMOVE AND INSTALL SOLENOID VALVE

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation
1. Park the machine on a level solid surface. Lower W183-04-02-003
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2. W183-04-02-002

ϖ 4 mm Wooden Blocks

3. Remove the hydraulic oil tank cap. Connect a Cap

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W2-9-1
 UPPERSTRUCTURE / Solenoid Valve

12
Solenoid
Valve Unit 11
10 2 2-Spool EHC
3 Valve

4
7

5
W183-02-10-001

1 - Bolt (2 Used) 4 - Bolt (2 Used) 7 - Solenoid valve for Heavy 10 - Power Decreasing Sole-
Lift noid Valve (SA)
2 - Booster Solenoid Valve 5 - Bolt (4 Used) 8 - Solenoid Valve Flow Rate 11 - Power Decreasing Sole-
(ST) Reducing noid Valve (SB)
3 - Control Solenoid Valve for 6 - Solenoid Valve for Switch- 9 - Socket Bolt (4 Used) 12 - Solenoid Valve for Boom
Oil Cooler Fan (SF) ing 2-Speed Travel Mode Selector (SC)

W2-9-2
 UPPERSTRUCTURE / Solenoid Valve

Removal
IMPORTANT: Attach tags to the disconnected
pipes and hoses for easier
reassembly.

1. Disconnect all pipes and electrical cables from

each solenoid valve.

Tightening Torque Remarks

Wrench Size (mm)
N]m (kgf]m) Ibf]ft

: 19 29.5 (3) 21.5 Hose

: 22 39 (4) 29 Hose
: 27 59 (6) 43 Hose

2. Remove bolts (1) (2 used), (4) (2 used), (5) (4 used)

and socket bolts (9) (4 used) to remove each
solenoid valves.
ϖ 13 mm
ϖ 20 N]m(2 kgf]m, 14.5 Ibf]ft)
ϖ 17 mm
ϖ 50 N]m(5.1 kgf]m, 37 Ibf]ft)
ϖ 4 mm
ϖ 7 N]m(0.7 kgf]m, 5.1 Ibf]ft)

Installation
NOTE: As for the wrench sizes and tightening torque,
refer to Removal Section.

1. Install each solenoid valves with bolts (1) (2 used),

(4) (2 used), (5) (4 used) and socket bolts (9) (4
used).
Ȁ
2. Connect all pipes and electrical cables to each
valve.

W2-9-3
 UPPERSTRUCTURE / Solenoid Valve

DISASSEMBLE 2-SPOOL EHC VALVE

(BOOST SOLENOID VALVE, CONTROL SOLENOID VALVE FOR OIL COOLER FAN)

1
3
2

4
5

7
8
9
10
11 14
12
13 15
16

17
18

19

W157-02-11-016

1- Socket Bolt (2 Used) 6- Solenoid 11 - Orifice 16 - O-Ring

2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 19 - Washer
5- Spring 10 - Spool 15 - O-Ring

W2-9-4
 UPPERSTRUCTURE / Solenoid Valve
Disassemble 2-Spool EHC Valve
(Boost Solenoid Valve, Control Solenoid Valve
for Oil Cooler Fan)

IMPORTANT: Take care not lose spring (7)

provided in the groove of
solenoid (6) when removing
solenoid (6).
Don’t turn lock nut (2) and
adjusting screw (4).

1. Loosen socket bolts (1) to remove solenoid (6).

ϖ 3 mm

IMPORTANT: Don’t disassemble orifice (11)

provided on spool (10).

2. Pull out spool (10) and remove diaphragm (9),

washer (12) and spring (13).

3. Pull sleeve (17) out and remove O-rings (14, 15,

16), washer (19) and plate (18).

4. Disassemble the other solenoid valve according

to procedures 1 to 3.

W2-9-5
 UPPERSTRUCTURE / Solenoid Valve
ASSEMBLE 2-SPOOL EHC VALVE
(BOOST SOLENOID VALVE, CONTROL SOLENOID VALVE FOR OIL COOLER FAN)

4 2 3 6 1 8 17 14 15 10 16 11 19

9 7 12 13 18

W157-02-11-001

1- Socket Bolt (2 Used) 6- Solenoid 11 - Orifice 16 - O-Ring

2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 19 - Washer
5- Spring 10 - Spool 15 - O-Ring

W2-9-6
 UPPERSTRUCTURE / Solenoid Valve
Assemble 2-spool EHC valve
(Boost Solenoid Valve, Control Solenoid Valve
for Oil Cooler Fan) 17
16
IMPOTRANT: Apply grease to O-rings (14, 15 and 15
16) and apply a film of hydraulic oil to 14
sleeve (17).

1. Install washer (19), plate (18) into the housing.

Install O-rings (14, 15, 16) on sleeve (17), then
insert it into the housing. Housing

W157-02-11-005

10

IMPORTANT: Take care not to damage the edge

portion in the bore of sleeve (17),
then insert it into the housing. 9
After inserting spool, check that
spool (10) slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in). Apply hydraulic 17
oil to the spool. 13
12
Housing

W157-02-11-009

2. Install diaphragm (9), washer (12), spring (13) to

spool (10). Install spool (10) into sleeve (17).

10

IMPORTANT: Lock nut (2), adjusting screw (4),

spring (5), O-ring (3) are not W157-02-11-010
separated, so no need to assemble
them. 6
When assembling solenoid (6), take
care not to drop spring (7).

3. Install solenoid (6) with bolt (1).

ϖ 3 mm 7
ϖ 2.9 N]m (0.3 kgf]m, 2.2 Ibf]ft)

W157-02-11-011

CONFIGURATION OF SOLENOID VLAVE

W2-9-7
 UPPERSTRUCTURE / Solenoid Valve

Solenoid Valve Unit

Boom Mode Power Power

Selector Sole- Decreasing Decreasing
noid Valve Valve Valve

20 21 22 23 24

19
Pilot Relief
18 Valve
17 1
16 2

3
15 4

5
14
6
13

12
7

11 10 9
T183-03-07-003

Wrench Tightening Torque Wrench Tightening Torque

Item Parts Name Q’ty Size Item Parts Name Q’ty Size
(mm) Nxm (kgfxm) Ibfxft (mm) Nxm (kgfxm) Ibfxft

1 Plug 1 22 49 (5) 36 13 O-Ring 3

2 Shim 1 14 Rod 3
3 Spring 1 15 O-Ring 3
4 O-Ring 1 16 Stopper 3
5 Valve Assembly 1 17 Plunger 3
6 Gasket 1 18 Screw 3 32 29.5 (3) 21.5

7 Spool 1 19 Coil Assembly 3

8 Casing 1 20 Spring 3
9 Spool Assembly 3 21 Spring Seat 3
10 Spring 3 22 Pipe 3
11 O-Ring 3 23 Housing 3
12 O-Ring 3 24 Spacer 3
NOTE: Shim (2) is used to adjust pressure.

W2-9-8
 UPPERSTRUCTURE / Solenoid Valve

Flow Rate Reducing Solenoid Valve

W117-02-07-004
2 3 4 5 6 7 8 9

Tightening Torque
Parts Name Q’ty Wrench Size
NĊm (kgfĊm) (Ibfxft)
1- Socket Bolt 4 Ѕ 4 mm 7 (0.7) (5.1)
2- Plug 1 49 (5) (36)
3- O-Ring 2
4- Spring 2
5- Cam Ring 4
6- Spool 1
7- Casing 1
8- Spring Seat 2
9- Solenoid 1

W2-9-9
 UPPERSTRUCTURE / Solenoid Valve
Heavy Lift Solenoid. 2- Speed Shift Solenoid for
Travel

18
1
17
16
2
15
3

14
4
13
5
12
6
11
7
10
8

W140-02-11-002

Tightening Torque
Part Name Q’ty Wrench Size
NĊm (kgfĊm) Ibfxft
1- Screw 1 Ѕ32 mm 34.3 (3.5) 25.5
2- Coil 1
3- Spacer 1
4- Housing 1
5- O-Ring 1
6- Pipe 1
7- Seat 1
8- Spring 1
9- Housing 1
10- Spring 1
11- O-Ring 1
12- O-Ring 1
13- O-Ring 1
14- Body 1
15- Spool 1
16- Rod 1
17- Stopper 1
18- Plunger 1

W2-9-10
 UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL
CONTROL VALVE

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation
W183-04-02-003
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic W183-04-02-002

System on page W1-1-2.

Wooden Blocks
ϖ 4 mm
Cap
3. Remove the hydraulic oil tank cap. Connect a
vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W2-10-1
 UPPERSTRUCTURE / Signal Control Valve
Removal
IMPORTANT: Attach tags to hoses and pipes to
aid in assembly.

NOTE: When removing pipe of signal control valve, Pilot Valve Side
PH
if a SNAP-ON TOOL (GAN850812B: tool A
size: 19.05 mm) is used, it may be easier to C M
remove the pipe.
E B

1. Disconnect all hoses and pipes from each port. D SB

H G
F
2. Remove the pressure sensors (swing, travel). N
PI
3. Remove bolt (20) to remove the signal control
valve. Pilot Valve
I
Side
: 17 mm J
K
DF
Installation SH
1. Apply LOCTITE to bolt (20) and install the signal
control valve.
SA L 20
W183-02-11-001

2. Connect all hoses and pipes to each port. Control Valve Side
SM
3
3. Install the pressure sensors (swing, travel). 1 5
13
Wrench size Tightening Torque 2 4
Remark
(mm) N]
]m (kgf]
]m) (Ibf]
]ft) SK SE
: 17 25 2.5 (18) Hose, pipe 7 8
: 17 50 5.1 (37) Bolt 14
6
: 19 29.5 3 (21.5) Hose Pressure Sensor
(Swing)
: 24 16 1.6 (11.5) Pressure sensor 9
Control Valve SN
Section
10 11

SL

Pressure
Sensor (Travel) 20 12 SP W183-02-11-002

W2-10-2
 UPPERSTRUCTURE / Signal Control Valve
PILOT PORT
Pilot Valve Side

NOTE: BH: Backhoe

LD: Loading Shovel
Port Name Connected To Remark
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower, Bucket Roll-Out Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure (BH)
Arm Roll-In Pilot Pressure (LD)
Port D Right Pilot Valve Boom Raise Pilot Pressure
Port E Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port F Left Pilot Valve Arm Roll-Out Pilot Pressure (BH)
Arm Roll-In Pilot Pressure (LD)
Port G Left Pilot Valve Arm Roll-In Pilot Pressure (BH)
Arm Roll-Out Pilot Pressure (LD)
Port H Right Pilot Valve Bucket Roll-In Pilot Pressure
Port I Travel Pilot Valve Left Travel Forward Pilot Pressure
Port J Travel Pilot Valve Left Travel Forward Pilot Pressure
Port K Travel Pilot Valve Right Travel Forward Pilot Pressure
Port L Travel Pilot Valve Right Travel Forward Pilot Pressure
Port M Auxiliary Pilot Valve (BH) Auxiliary Pilot Valve (BH)
Bucket Close Pilot Valve (LD) Bucket Close Pilot Valve (LD)
Port N Auxiliary Pilot Valve (BH) Auxiliary Pilot Valve (BH)
Bucket Open Pilot Valve (LD) Bucket Open Pilot Valve (LD)
Port SA Pump 1 and 2 Regulator Pump 1 and 2 Control Pressure
Port SB − Plug
Port PI Pilot Shut-Off Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heat Circuit)
Port SH − Plug
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank

W2-10-3
 UPPERSTRUCTURE / Signal Control Valve
Control Valve Side

Control Valve Side

SM
3
1 5
13
2 4
SK SE
7 8
14
6
Pressure Sensor
(Swing)
9
Control Valve SN
Section
10 11

SL

Pressure
Sensor (Travel) 20 12 SP W183-02-11-002

NOTE: BH: Backhoe

LD: Loading Shovel
Port Name Connected To Remark
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 − Plug
Port 3 − Plug
Port 4 − Plug
Port 5 − Plug
Port 6 Control Valve Arm Roll-Out Pilot Pressure (BH)
Arm Roll-In Pilot Pressure (LD)
Port 7 Control Valve Arm Roll-In Pilot Pressure (BH)
Arm Roll-Out Pilot Pressure (LD)
Port 8 Control Valve Bucket Roll-In Pilot Pressure
Port 9 Control Valve Left Travel Forward Pilot Pressure
Port 10 Control Valve Left Travel Reverse Pilot Pressure
Port 11 Control Valve Right Travel Forward Pilot Pressure
Port 12 Control Valve Right Travel Reverse Pilot Pressure
Port 13 Control Valve Auxiliary Close Pilot Pressure (BH)
Bucket Close Pilot Pressure (LD)
Port 14 Control Valve Auxiliary Open Pilot Pressure (BH)
Bucket Open Pilot Pressure (LD)
Port SE Shuttle Valve Boom Raise Priority Pilot Pressure
Port SM Shuttle Valve Auxiliary
Port SN Shuttle Valve Swing Brake Release
Port SP Shuttle Valve Swing Brake Release
Port SL Control Valve Combiner Valve Shifting Pressure
Port SK − Plug

W2-10-4
 UPPERSTRUCTURE / Oil Cooler Fan Motor

REMOVE AND INSTALL OIL COOLER FAN

MOTOR

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation W183-04-02-003
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic W183-04-02-002

System on page W1-1-2. Wooden Blocks

ϖ 4 mm
Cap

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W2-11-1
 UPPERSTRUCTURE / Oil Cooler Fan Motor

Removal

1. Disconnect all hoses (1, 2, and 3) from oil cooler

fan motor (4).

Wrench Size Tightening Torque 1

Remarks
(mm) N⋅m (kgf⋅m) Ibf⋅ft 4
ϖ 27 mm 118 (12) 87 Hose (1)
ϖ 8 mm 50 (5.1) 37 Hose(2, 3) 2

CAUTION: Fan weight: 22 kg (50 Ib)

3

2. Remove bolt (7) to remove fan (6) from oil cooler

fan motor (4).
ϖ 19 mm
ϖ 90 N]m (9.2 kgf]m, 67 Ibf]ft)
W183-02-11-003

CAUTION: Oil cooler fan motor weight:

24 kg (50 Ib)

3. Remove oil cooler fan motor mounting bolts (5) to

remove oil cooler fan motor (4) from bracket (8).
ϖ 19 mm
ϖ 90 N]m (9.2 kgf]m, 67 Ibf]ft)
A A

Installation
4
NOTE: Refer to the Removal section for wrench
size and tightening torque.

1. Install oil cooler fan motor (4) to bracket (8) with W183-02-11-004

mounting bolts (5) (4 used).

2. Install fan (6) to oil cooler fan motor (4) with bolt
4 5 6
(7).

3. Reconnect hoses (2 and 3) to oil cooler fan motor

(4). 7

4. Fill hydraulic oil in via the hole of hose (1).

Connect hose (1).

5. Start the engine and slowly loosen hose (1). Bleed

the air until only hydraulic oil comes out.
8
W183-02-11-005
Section A-A

W2-11-2
 UPPERSTRUCTURE / Oil Cooler Fan Motor

(Blank)

W2-11-3
 UPPERSTRUCTURE / Oil Cooler Fan Motor

DISASSEMBLE OIL COOLER FAN MOTOR

1
2

4
5

6
7

8
9

16
17

10

11
12
13
14
15 18
19
20
21
22

23

24
25
26
27
28
29
30
W118-02-09-001
31

1- Housing 9- Socket Bolt (6 Used) 17 - Plunger (7 Used) 25 - Bearing

2- O-Ring 10 - Plate 18 - Screw (7 Used) 26 - Nut
3- Cover 11 - Cylinder Block 19 - Plate 27 - Shim (2 Used)
4- Valve Block 12 - Shim 20 - Shim 28 - O-Ring
5- Socket Bolt (6 Used) 13 - Spring Seat 21 - Shaft 29 - Oil Seal
6- Plug 14 - Disc Spring (4 Used) 22 - Key 30 - Seal Case
7- Knock Pin 15 - Center Pin 23 - Bearing 31 - Retaining Ring
8- Washer (6 Used) 16 - Piston Ring (14 Used) 24 - Case

W2-11-4
 UPPERSTRUCTURE / Oil Cooler Fan Motor
Disassemble Oil Cooler Fan Motor

• Be sure to thoroughly read “Precautions for 7. Remove piston rings (16) (14 used) from plungers
Disassembly and Assembly Work” on page W1- (17) (7 used). Remove shim (12), spring seat (13)
1-1 before starting the disassmbly work. and disc springs (14) (4 used) from cylinder block
(11).
1. Remove plug (6) to drain hydraulic oil from the
motor.
ϖ10 mm

2. Remove key (22) from shaft (21). Remove socket

bolts (5) (6 used) to remove valve block (4) from
cover (3).
ϖ5 mm

IMPORTANT: Take care not to drop plate (10) when

removing cover (3).

3. Remove socket bolts (9) (6 used) to remove cover

(3), knock pin (7), O-ring (2) and plate (10).
ϖ5 mm

4. Remove retaining ring (31) from housing (1).

Remove the shaft (21) assembly from housing (1)
with a puller.

5. Remove seal case (30), oil seal (29), O-ring (28)

and shims (27) from the shaft (21) assembly.

IMPORTANT: Do not remove bearings (25 and 23)

unless necessary.
They must be replaced with new
ones if they are removed.

6. Remove screws (18) (7 used) to remove plate

(19), center pin (15), plungers (17) (7 used) and
cylinder block (11) from shaft (21).

W2-11-5
 UPPERSTRUCTURE / Oil Cooler Fan Motor

ASSEMBLE OIL COOLER FAN MOTOR

30 26 28 25 24 23 20 19 15 17

21 22
1

2
3

29 31 27 6

11 8, 9 7 10
W183-02-11-006

1- Housing 9- Socket Bolt (6 Used) 17 - Plunger (7 Used) 25 - Bearing

2- O-Ring 10 - Plate 18 - Screw (7 Used) 26 - Nut
3- Cover 11 - Cylinder Block 19 - Plate 27 - Shim (2 Used)
4- Valve Block 12 - Shim 20 - Shim 28 - O-Ring
5- Socket Bolt (6 Used) 13 - Spring Seat 21 - Shaft 29 - Oil Seal
6- Plug 14 - Disc Spring (4 Used) 22 - Key 30 - Seal Case
7- Knock Pin 15 - Center Pin 23 - Bearing 31 - Retaining Ring
8- Washer (6 Used) 16 - Piston Ring (14 Used) 24 - Case

W2-11-6
 UPPERSTRUCTURE / Oil Cooler Fan Motor

Assembling Oil Cooler Fan Motor

NOTE: Refer to the illustration for parts (4, 5, 12 to 8. Install plug (6) into housing (1).
14, 16 and 18). ϖ 10 mm
ϖ 59 to 76 N]m
1. Install piston rings (16) (14 used) onto plungers (6 to 7.8 kgf]m, 43 to 56 Ibf]ft)
(17) (7 used). Install shim (12), spring seat (13)
and disc springs (14) (4 used) into cylinder block
(11). After inserting center pin (15) and plungers
(17) (7 used) into plate (19), install them into
cylinder block (11).

2. Install shim (20) and plate (19) to shaft (21) with

screws (18) (7 used).

3. Install the shaft (21) assembly in housing (1).

4. Install shims (27), O-ring (28), oil seal (29), seal

case (30) and retaining ring (31) onto shaft (21).

5. Install key (22) on shaft (21).

6. Install plate (10), knock pin (7), and O-ring (2) to

cover (3). Secure cover (3) with socket bolts (9)
(6 used).
ϖ 5 mm
ϖ12 N]m (1.2 kgf]m, 8.7 Ibf]ft)

7. Install valve block (4) to cover (3) with socket bolts

(5) (6 used).
ϖ 5 mm
ϖ12 N]m (1.2 kgf]m, 8.7 Ibf]ft)

W2-11-7
 UPPERSTRUCTURE / Oil Cooler Fan Motor

(Blank)

W2-11-8
 SECTION 3
UNDERCARRIAGE

CONTENTS
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing ......... W3-1-1 Remove and Install Upper Roller ............ W3-6-1
Disassemble Swing Bearing ................... W3-1-4 Remove and Install Lower Roller ............ W3-6-3
Assemble Swing Bearing ........................ W3-1-6 Disassemble Upper Roller ...................... W3-6-6
Assemble Upper Roller........................... W3-6-8
Group 2 Travel Device Disassemble Lower Roller .................... W3-6-10
Remove and Install Travel Device .......... W3-2-1 Assemble Lower Roller......................... W3-6-12
Disassemble Travel Reducer.................. W3-2-4 Maintenance Standard ......................... W3-6-14
Assemble Travel Reducer .................... W3-2-10
Disassemble Travel Motor .................... W3-2-18 Group 7 Track
Assemble Travel Motor......................... W3-2-22 Remove and Install Tracks ..................... W3-7-1
Disassemble Travel Brake Valve .......... W3-2-26 Maintenance Standard ........................... W3-7-7
Assemble Travel Brake Valve ............... W3-2-30
Maintenance Standard ......................... W3-2-32

Group 3 Center Joint

Remove and Install Center Joint............. W3-3-1
Disassemble Center Joint....................... W3-3-4
Assemble Center Joint ........................... W3-3-6
Maintenance Standard ......................... W3-3-10

Group 4 Track Adjuster

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

Group 5 Front Idler

Remove and Install Front Idler................ W3-5-1
Disassemble Front Idler ......................... W3-5-2
Assemble Front Idler .............................. W3-5-6
Maintenance Standard ........................... W3-5-8

183W-3-1
(Blank)

183W-3-2
 UNDERCARRIAGE / Swing Bearing

REMOVE AND INSTALL SWING BEARING

Before removing the swing bearing, the uppersturcture
must be removed first. For removal and installation of
Matching Marks
the upperstructure, refer to “Remove and Install Front
Attachment” section and “Remove and Install
Counterweight” section.
In this section, the procedure starts on the premise that
the upperstructure has already been removed.

1 2
Removal
1. Put matching marks on swing bearing inner race W142-03-01-001

(1) and track frame (2).

3
2. Disconnect all lubrication hoses (4 used) to the
swing bearing.
ϖ 17 mm

3. Remove swing bearing inner race mounting bolts

(3) (50 used).
ϖ 55 mm

W105-03-01-002
CAUTION: Swing bearing weight:
1710 kg (3770 Ib)
ST 9050
4. Attach lifting tool (ST 9050) to the 3 lift holes in
swing bearing (4) to hoist and remove swing
bearing (4).

4 W105-03-01-003

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

1. Apply THREEBOND #1102 to the swing bearing

mounting surface on the track frame.

CAUTION: Swing bearing weight:

1710 kg (3770 Ib)

IMPORTANT: Be sure to align the matching marks.

Otherwise, the inner race soft zone 4 W105-03-01-003
will be in the incorrect position.
Front Side

2. Install special tool (ST 9050) to swing bearing (4)

and hoist the swing bearing by a crane. Align the Soft Zone Position
swing bearing with the track frame using the (Inner Race)
matching marks during disassembly.

Plug Position
Soft Zone Position
(Outer Race)

Greasing Hole Positions

3. Tighten swing bearing mounting bolts (3) (50 used). (4 Places) W105-03-01-005

ϖ 55 mm
ϖ 2450 N⋅m (250 kgf⋅m, 1810 Ibf⋅ft) 3

4. Re-connect lubrication hoses (4 used) to the swing

bearing.
ϖ 17 mm
ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

W105-03-01-002

W3-1-2
 UNDERCARRIAGE / Swing Bearing
(Blank)

W3-1-3
 UNDERCARRIAGE / Swing Bearing

DISASSEMBLE SWING BEARING

1 2 3

10,11 8 7 6 5 W166-03-01-001

6
7
8

10

11

W111-03-01-008

1 - Outer Race 4 - Plug 7 - Inner Race 10 - Turn Buckle (3 Used)

2 - Seal 5 - Seal 8 - Support (81 Used) 11 - Rod (3 Used)
3 - Pin 6 - Ball (81 Used) 9 - Bolt (50 Used)

W3-1-4
 UNDERCARRIAGE / Swing Bearing
Disassemble Swing Bearing
• Be sure to thoroughly read “Precautions for
Disassembly and Assembly Work” on page W1-
1-1 before starting the disassembly work. 3

1. Remove pin (3) located in plug (4) section by

driving from the bottom side of the swing bearing.

NOTE: Pin (3) head is crimped. Grind off the

crimped part.

W105-03-01-007

2. Remove plug (4).

NOTE: Screw bolt (M10, pitch 1.5) in the threaded 4

hole in plug (4). Tap the bolt head from the
bottom side or pull the bolt to remove the
plug.

W105-03-01-008

1
CAUTION: Swing bearing weight:
1710 kg (3770 Ib) 2

3. Lift swing bearing outer race (1) horizontally

slightly by a crane.
Remove rods (11) (3 used) and turn buckles (10) A
(3 used) which fasten seal (5) to remove seals (2 7
and 5).

4. Place swing inner race (7) onto a wooden block.

Hoist outer race (1) by a crane to strain the sling. 6 5 W105-03-01-009

5. While rotating outer race (1), remove balls (6) (81 B

used) and supports (8) (81 used) from the plug
hole.
Use bar magnet (A) to take out balls. Use bent
wire (B) to remove supports (8).
8 W105-03-01-010

W3-1-5
 UNDERCARRIAGE / Swing Bearing

ASSEMBLE SWING BEARING

1 2 3

10,11 8 7 6 5 W166-03-01-001

6
7
8

10

11

W111-03-01-008

1 - Outer Race 4 - Plug 7 - Inner Race 10 - Turn Buckle (3 Used)

2 - Seal 5 - Seal 8 - Support (81 Used) 11 - Rod (3 Used)
3 - Pin 6 - Ball (81 Used) 9 - Bolt (50 Used)

W3-1-6
 UNDERCARRIAGE / Swing Bearing
Assemble Swing Bearing

CAUTION: Swing bearing weight:

1710 kg (3770 Ib)

1. Before assembling the swing bearing inner race

and outer race, completely remove any oil on the
groove surfaces of seal (2). Then, apply
THREEBOND #1735 to the groove and install
seal (2). 2
Install seal (5) in the groove on the inner race and
fasten the seal with rods (11) and turn buckles
(10). (tighten each turn buckle 10 to 15 turns
evenly.) 6
5
IMPORTANT: Apply grease to balls (6) (81 used) W142-03-01-005

and supports (8) (81 used).

After installing all balls (6) and
supports (8), confirm that the
clearance between the ball and the
±10 mm (1.57±
support is 40± ±0.39 in).
40±10 mm
(1.57±0.39 in)

W142-03-01-006

W142-03-01-004
Ȁ
2. Lift the outer race (1) by a crane horizontally and
match it with the inner race coaxilally. Rotating 3
the outer race, insert balls (6) (81 used), supports
(8) (81 used) into the plug hole alternatively with a
round bar.
1
3. Install plug (4) and pin (3) into outer race (1).
Crimp the head of pin (3) with a punch.
Sufficiently lubricate the swing bearing with grease
(Alvania EP2 or equivalent).

W142-03-01-007

W3-1-7
 UNDERCARRIAGE / Swing Bearing
(Blank)

W3-1-8
 UNDERCARRIAGE / Travel Device

REMOVE AND INSTALL TRAVEL DEVICE

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation
1. Park the machine on a level solid surface. Lower W183-04-02-003
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2. W183-04-02-002

ϖ 4 mm Wooden Blocks

3. Remove the hydraulic oil tank cap. Connect a Cap

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W3-2-1
 UNDERCARRIAGE / Travel Device

Removal
The removal procedure starts on the premise that 3 2 1
the tracks have been removed. Refer to page
W3-7-1 for removal and installation of the track.

1. Remove bolts (7) (8 used) to remove cover (6).

Disconnect hoses (2 to 5).
Ȁ Bolt (7)
ϖ 24 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)
Ȁ Hose (2 to 5)
ϖ 22 mm
ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft)
ϖ 27 mm 4 5
ϖ 118 N⋅m (12 kgf⋅m, 87 Ibf⋅ft)
ϖ 10 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

NOTE: Cap the disconnected hoses and pipes.

2. Attach a wire rope to the travel device hoisting.

6

CAUTION: Travel device weight: 1720 kg

(3790 Ib) 7 W183-03-02-014

3. Remove bolts (1) (26 used) to remove the travel

device by a crane.
ϖ 41 mm
ϖ 1050 N⋅m (107 kgf⋅m, 770 Ibf⋅ft)

Installation
NOTE: As for the wrench sizes and tightening
torque, refer to Removal Section.

1. Install travel device with bolts (1) (26 used).

2. Connect hoses (2 to 5).
3. Install cover (6) with bolts (7) (8 used).
W111-03-02-002
IMPORTANT: Fill travel motor full of hydraulic oil
after installation. In addition, be sure
to perform a break-in operation in
order to prevent the travel motor
from burning out.
Break-in Operation Conditions
1. Engine control dial: Min. speed
2. Travel motor switch: Low speed
3. Operation duration: Above 2
minutes

W3-2-2
 UNDERCARRIAGE / Travel Device

(Blank)

W3-2-3
 UNDERCARRIAGE / Travel Device

DISASSEMBLE TRAVEL REDUCER 51

15 16

14
8 13
10
9
8
6
3
5
4
3 11
2 12 17
1 18

7 19

20
21
22
23
24
25
26
33 27
28 40
32
39

29 52
30
31
29
38
37
41
42
36 43
44

35
34
45

46
47
48

49 W183-03-02-001
50

1- 3-Stage Carrier 14 - Ring Gear 27 - Spacer 40 - Bolt (30 Used)

2- 3-Stage Sun Gear 15 - Cover 28 - 2-Stage Carrier 41 - Bolt (2 Used)
3- Thrust Plate (8 Used) 16 - Plug (3 Used) 29 - Roller Bearing (8 Used) 42 - Lock Plate
4- Needle Bearing (4 Used) 17 - Bolts (26 Used) 30 - 3-Stage Planetary Gear (4 Used) 43 - Bearing Nut
5- 2-Stage Planetary Gear (4 18 - Spring Washer (26 Used) 31 - Retaining Ring (4 Used) 44 - Roller Bearing
Used)
6- Spring Pin (4 Used) 19 - Socket Bolt (36 Used) 32 - Spring Pin (4 Used) 45 - Sprocket
7- Pin (4 Used) 20 - Bearing 33 - Pin (4 Used) 46 - Drum
8- Thrust Plate (6 Used) 21 - Retaining Ring 34 - Bolt (4 Used) 47 - Socket Bolt (18 Used)
9- Needle Bearing (3 Used) 22 - Seat 35 - Spring Washer (4 Used) 48 - Floating Seal
10 - 1-Stage Planetary Gear (3 23 - Propeller Shaft 36 - Housing 49 - O-Ring
Used)
11 - Spring Pin (3 Used) 24 - Spacer 37 - Support 50 - Motor
12 - Pin (3 Used) 25 - 1-Stage carrier 38 - Roller Bearing 51 - Dummy Plug (2 Used)
13 - O-Ring 26 - 2-Stage Sun Gear 39 - Spring Washer (30 Used) 52 - Dummy Plug

W3-2-4
 UNDERCARRIAGE / Travel Device

Disassemble Travel Reducer

• Be sure to thoroughly read “Precautions for
Disassembly and Assembly Work” on page CAUTION: Travel device weight (Excluding
W1-1-1 before starting the disassembly work. the motor):1590 kg (3510 Ib)

4. Hoist the travel device by a crane and place it on

CAUTION: When the pressure is trapped the work bench with cover (15) facing up.
inside the travel device, slowly
loosen the air bleeding plug. Do
not remove the drain plug to CAUTION: Cover (15) weight: 76 kg (170 Ib)
bleed the gear oil until the inside
pressure has been completely
5. Remove dummy plugs (51) (2 used) and bolts
released.
(17) (26 used) to install the eyebolts (M14, Pitch
Procede to loosen plug slowly as
2) into the two sling holes in cover (15). Hoist
both plug and gear oil can cause
cover (15) and remove it from ring gear (14).
injury by flying off,or spurting out.
Be sure to keep your body and ϖ 22 mm
face away from the front of the
plug. 6. Remove socket bolts (19) (36 used) from ring
gear (14).
ϖ 17 mm
CAUTION: Travel device weight: 1720 kg
(3790 Ib)
CAUTION: Ring gear (14) weight: 240 kg
1. Loosen the air bleeding plug (16-A) by 2 to 3 turns (530 Ib)
and remove drain plug (16-B) to bleed the gear oil
from the travel device. Place travel device on the
7. Install eyebolts (M14, Pitch 2) into the holes for
work bench with motor (50) side facing up.
bolt (17) of ring gear (14) and hoist ring gear by a
ϖ 17 mm crane to remove it.

8. Remove O-ring (13) and propeller shaft (23) from

16-A
drum (46).

CAUTION: 1-Stage carrier (25) assmebly

weight: 90 kg (200 Ib)

16-B
9. Install eyebolts (M12, Pitch 1.75) into the three
sling holes in the 1-stage carrier (25) assembly.
W111-03-02-006 Hoist the assembly and remove it from 2-stage
carrier (28).
2. Install eyebolts (M12, Pitch 1.75) into the three
sling holes in motor (50) and attach a wire. 10. Remove 2-stage sun gear (26) from 2-stage
carrier (28).

CAUTION: Motor (50) weight: 130 kg (290 Ib)

3. Remove bolts (34) (4 used) to hoist motor (50) by

a crane for removal. Remove O-ring (49) from
motor (50).
ϖ 27 mm

W3-2-5
 UNDERCARRIAGE / Travel Device

2
1

19

28 40

52

38
37
41
42
36 43
44

45

46
47
48

W183-03-02-001

W3-2-6
 UNDERCARRIAGE / Travel Device

CAUTION: 2-Stage carrier (28) assembly CAUTION: Drum (46) + sprocket (45) + the
weight: 95 kg (210 Ib) others weight: 560 kg (1230 Ib)

11. Install eyebolts (M12, Pitch 1.75) into the two sling
16. Install eyebolts (M22, Pitch 2.5) into the holes for
holes in the 2-stage carrier (28) assembly. Hoist
socket bolts (19) of drum (46). Hoist drum (46) to
the assembly to remove it from 3-stage carrier (1).
remove it from housing (36). At this moment, the
drum section is connected with the outer race of
roller bearing (38) and roller bearing (44).
CAUTION: 3-Stage carrier (2) weight: 30 kg
(70 Ib) 17. Remove floating seal (48) from housing (36) and
support (37) respectively.
12. Attach a nylon sling to the gear part of 3-stage sun
gear (2) (2 places). Hoist the gear to remove it 18. Remove the inner race of roller bearing (44) from
from 3-stage carrier (1). drum (46).

19. Remove dummy plugs (52) (2 used) from sprocket

CAUTION: 3-Stage carrier (1) assembly weight: (45). Remove bolts (40) (30 used) from sprocket
210 kg (460 Ib) (45).

13. Install eyebolts (M12, Pitch 1.75) into the two sling
holes in the 3-stage carrier (1) assembly. Hoist the CAUTION: Sprocket (45) weight: 210 kg
assembly to remove it. (460 Ib)

14. Remove bolts (41) (2 used) to remove lock plate

20. Screw puller bolts (M27, Pitch 3, L 70 mm ) into
(42) from bearing nut (43).
the two pulling holes in sprocket (45) and make
ϖ 22 mm sprocket (45) separate from drum (46) slowly.

15. Install jig (ST 3142) to bearing nut (43). Loosen NOTE: Apply adhesive on the interface of sprocket
and remove bearing nut (43) from housing (36). and drum.
ST 3142 43 ϖ 41 mm

21. Install eyebolts (M27, Pitch 3) into the two sling

holes in sprocket (45). Hoist sprocket (45) to
remove it from drum (46).
ϖ 41 mm

CAUTION: Drum (46)+the others weight:

290 kg (640 Ib)

22. Hoist drum (46) to reverse it.

W111-03-02-018

23. Remove socket bolts (47) (18 used) to remove

support (37) from drum (46).
ϖ 10 mm

W3-2-7
 UNDERCARRIAGE / Travel Device

8
10
9
8
6
3
5
4
3 11
12
1

24
25

33 27
28
32

29
30
31
29
38

44

46

W183-03-02-001

W3-2-8
 UNDERCARRIAGE / Travel Device

24. Remove the outer race of roller bearing (38) from

drum (46). CAUTION: 1-Stage carrier (25) assembly weight:
90 kg (200 Ib)
25. Remove spacers (24 and 27) from 1-stage carrier
(25) and 2-stage carrier (28) respectively. 33. Pull out pins (12) (3 used) from 1-stage carrier
(25) to remove 1-stage planetary gears (10) (3
26. Push out spring pins (32) (4 used) with a round used).
bar from 3-stage carrier (1).
: 8 mm 34. Remove thrust plates (8) (6 used) needle bearings
(9) (3 used) from 1-stage planetary gears (10) (3
used) respectively.
CAUTION: 3-Stage carrier (1) assembly weight:
210 kg (460 Ib)

27. Pull out pin (33) (4 used) from 3-stage carrier (1)
to remove 3-stage planetary gears (30) (4 used).

28. Remove roller bearings (29) (8 used) and retaining

rings (31) (4 used) from 3-stage planetary gears
(30) (4 used) respectively.

29. Push out spring pins (6) (4 used) from 2-stage

carrier (28) with a round bar.
: 6 mm

CAUTION: 2-Stage carrier (28) assembly weight:

95 kg (210 Ib)

30. Pull out pins (7) (4 used) from 2-stage carrier (28)
to remove 2-stage planetary gears (5) (4 used).

31. Remove thrust plates (3) (8 used) and needle

bearings (4) (4 used) from 2-stage planetary
gears (5) (4 used) respectively.

32. Push out spring pins (11) (3 used) from 1-stage

carrier (25) with a round bar.
: 5 mm

W3-2-9
 UNDERCARRIAGE / Travel Device

ASSEMBLE TRAVEL REDUCER

44 43 45 39 40

50 48 36 47 37 38 46 13 19 1 14 28

51
16

25
27
2
24
26
23
20
34 22

35 21
10
12
49
11
15

17
18

42 41 33 8 9
W183-03-02-002

29 31 52 30 32 5 7 4 3 6

1- 3-Stage Carrier 14 - Ring Gear 27 - Spacer 40 - Bolt (30 Used)

2- 3-Stage Sun Gear 15 - Cover 28 - 2-Stage Carrier 41 - Bolt (2 Used)
3- Thrust Plate (8 Used) 16 - Plug (3 Used) 29 - Roller Bearing (8 Used) 42 - Lock Plate
4- Needle Bearing (4 Used) 17 - Bolt (26 Used) 30 - 3-Stage Planetary Gear (4 43 - Bearing Nut
Used)
5 - 2-Stage Planetary Gear (4 18 - Spring Washer (26 Used) 31 - Retaining Ring (4 Used) 44 - Roller Bearing
Used)
6 - Spring Pin (4 Used) 19 - Socket Bolt (36 Used) 32 - Spring Pin (4 Used) 45 - Sprocket
7 - Pin (4 Used) 20 - Bearing 33 - Pin (4 Used) 46 - Drum
8 - Thrust Plate (6 Used) 21 - Retaining Ring 34 - Bolt (4 Used) 47 - Socket Bolt (18 Used)
9 - Needle Bearing (3 Used) 22 - Seat 35 - Spring Washer (4 Used) 48 - Floating Seal
10 - 1-Stage Planetary Gear (3 23 - Propeller Shaft 36 - Housing 49 - O-Ring
Used)
11 - Spring Pin (3 Used) 24 - Spacer 37 - Support 50 - Motor
12 - Pin (3 Used) 25 - 1-Stage carrier 38 - Roller Bearing 51 - Dummy Plug (2 Used)
13 - O-Ring 26 - 2-Stage Sun Gear 39 - Spring Washer (30 Used) 52 - Dummy Plug

W3-2-10
 UNDERCARRIAGE / Travel Device

Assemble Travel Reducer

8. Tap spring pins (6) (4 used) into pins (7) (4 used)
1. Assemble retaining rings (31) (4 used) and roller on 2-stage carrier (28).
bearings (29)(8 used) to 3-stage planetary gears
(30) (4 used). NOTE: Be sure that the slit part of spring pin (6)
Ȁ faces upwards in relation to end of pin (7)
and tap it in.
2. Assemble 3-stage planetary gears (30) (4 used)
into 3-stage carrier (1). 7
Ȁ
6
3. Align spring pin (32) of 3-stage carrier (1) with its Slit
mounting holes in pins (33) (4 used) and install it.
Ȁ
4. Tap spring pins (32) (4 used) into pins (33) (4
9. Install needle bearings (9) (3 used) into 1-stage
used) on 3-stage carrier (1).
carriers (10) (3 used).

NOTE: Be sure to make the slit part of spring pin

(32) face the upper part of pin (33) and tap it 10. Align thrust plates (8) (6 used) with pin (12)
in. mounting holes in both ends of 1-stage planetary
gear (10). Install 1-stage planetary gears (10) (3
33 used) into 1-stage carrier (25).
32 Slit
11. Align with spring pin (11) mounting holes in 1-
stage carrier (25) to install pins (12) (3 used).

5. Install needle bearings (4) (4 used) into 2-stage 12. Tap spring pins (11) (3 used) into pins (12) (3 used)
planetary gears (5) (4 used). on 1-stage carrier (25).

NOTE: Be sure that the slit part of spring pin (11)

6. Align thrust plates (3) (8 used) with pin (7) mounting
holes in both ends of 2-stage planetary gear (5). faces upwards in relation to the end of pin
(12) and tap it in.
Install 2-stage planetary gears (5) (4 used) into 2-
stage carrier (28). 12
11
7. Align with spring pin (6) mounting hole in 2-stage Slit
carrier (28) to install pin (7) (4 used).

13. Press outer race of roller bearing (38) into drum

(46).

W3-2-11
 UNDERCARRIAGE / Travel Device

44 43 45 39 40

48 36 47 37 46

W183-03-02-002

52

W3-2-12
 UNDERCARRIAGE / Travel Device

14. Install support (37) to drum (46) with socket bolts 20. Hoist drum (46) to place it into housing (36) with
(47) (18 used). equal clearance around drum (46) to housing
ϖ 10 mm (36).
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
21. Tap the inner race of roller bearing (44) into
housing (36) with a hammer and adapter bar.
CAUTION: Drum (46) weight: 290 kg (640 Ib)
22. Install bearing nut (43) to housing (36) and screw
on it by hand.
15. Hoist drum (46) and reverse it.

23. Install jig (ST 3142) into bearing nut (43) and
16. Install the inner race of roller bearing (44) into secure it with a torque wrench.
drum (46).
ϖ 41 mm
ϖ 590 N⋅m (60 kgf⋅m, 430 Ibf⋅ft)
CAUTION: Sprocket (45) weight: 210 kg
(460 Ib)
ST 3142
43

IMPORTANT: Install sprocket (45) with the

chamfered facing drum (46).

17. Install sprocket (45) to drum (46) with bolts (40)

(30 used) and spring washers (39) (30 used).
Install dummy plugs (52) (2 used) into the two
holes for pulling out sprocket (45).

NOTE: Apply LOCTITE #262 on bolt (40).

ϖ 41 mm
ϖ 1050 N⋅m (107 kgf⋅m, 770 Ibf⋅ft) W111-03-02-018

24. Tap the up side of sprocket (45) with a plastic

CAUTION: Drum (46)+sprocket (45)+the others hammer after securing bearing nut (43). Then turn
weight: 560 kg (1230 Ib) drum (46) clockwise and counterclockwise three
times respectively.
IMPORTANT: As for the handling of floating seal,
refer to the Handling of Floating Seal
on page w1-1-4.

18. Hoist drum (46) to reverse it. Install floating seal

(48) onto support (37) in housing (36) with
bamboo spatula, etc.

CAUTION: Drum (46)+sprocket (45)+the others

weight: 560 kg (1230 Ib)

19. Hoist drum (46) to reverse it.

W3-2-13
UNDERCARRIAGE / Travel Device

43

36 46 13 1 28

25
27
2
24
26
23

10

42 41
W183-03-02-002

W3-2-14
 UNDERCARRIAGE / Travel Device

25. Again, do the same work as procedure 24 and

screw on bearing nut (43) to the specified torque. CAUTION: 2-Stage carrier (28) assembly
ϖ 41 mm weight: 95 kg (210 Ib)
ϖ 590 N]m (60 kgf]m, 430 Ibf]ft)
30. Install eyebolts (M12, Pitch 1.75) into the two sling
26. Insert the detent part of lock plate (42) into the slit holes of the 2-stage carrier (28) assembly and
of housing (36). Align the hole of lock plate (42) hoist it by a crane to install it to 3-stage carrier (1).
with the bolt hole of bearing nut (43) and screw on Ȁ
housing nut (43) in securing direction. 31. Place spacer (27) into the 2-stage carrier (28)
assembly.
27. Install lock plate (42) to bearing nut (43) with bolts Ȁ
(41) (2 used). 32. Install 2-stage sun gear (26) into 2-stage carrier
(28) with the low part of the teeth facing upward.
NOTE: Apply LOCTITE #262 on bolt (41). Upper Side
ϖ 22 mm
ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf]ft)

CAUTION: 3-Stage carrier (1) assembly weight:

26 W166-03-02-002
210 kg (460 Ib)

28. Install eyebolts (M12, Pitch 1.75) into the two sling CAUTION: 1-Stage carrier (25) assembly
holes of the 3-stage carrier (1) assembly and hoist weight: 85 kg (190 Ib)
it by a crane to install it to housing (36).
33. Install eyebolts (M12, Pitch 1.75) into the three
sling holes of the 1-stage carrier (25) assembly
and hoist it by a crane to install it to 2-stage carrier
29. Attach a nylon sling to the gear part of 3-stage sun
(28).
gear (2) and hoist it by a crane to install it to the
3-stage carrier (1) assembly with the low part of Ȁ
the teeth facing up. 34. Place spacer (24) into 1-stage carrier (25).
Ȁ
Upper Side
35. Insert propeller shaft (23) to the center of the
carrier, while meshing propeller shaft (23) with 1-
stage planetary gear (10).

36. Install O-ring (13) onto drum (46).

2 W166-03-02-002
Ȁ

W3-2-15
 UNDERCARRIAGE / Travel Device

Ȁ
Ȁ

50 36 46 19 14

51
16

23
20
34 22

35 21

49

15

17
18

W183-03-02-002

Ȁ
Ȁ
Ȁ

W3-2-16
 UNDERCARRIAGE / Travel Device

Ȁ
44. Wind sealing-type tape on plug (16) and install it
CAUTION: Ring gear (14) weight: 240 kg into cover (15).
(530 Ib) ϖ 17 mm
ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
37. Install eyebolt (M14, Pitch 2) into ring gear (14)
and hoist it by a crane to install it to drum (46).
Ȁ CAUTION: Travel device weight (Excluding
38. Apply LOCTITE#262 on socket bolts (19) (36 Motor): 1590 kg (3510 Ib)
used) and then screw on them.
ϖ 17 mm 45. Hoist the travel device to reverse it.
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf]ft)
Ȁ
Ȁ 46. Fill the gear oil.
39. If bearing (20) and seat (22) were removed, install Gear oil: about 43 L (11.36 Us gallon)
them into cover (15).
Ȁ
NOTE: Install the bearing with the punched mark 47. Install O-ring (49) onto motor (50).
side facing up.

40. Install retaining ring (21) onto cover (15). CAUTION: Motor (50) weight: 130 kg (290 Ib)
Ȁ
41. Apply THREEBOND #1215 on the mounting face 48. Hoist motor (50) and install it into housing (36)
of ring gear (14) and cover (15). while aligning the spline part of propeller shaft
(23) with that of motor (50) shaft.
Ȁ
CAUTION: Cover (15) weight: 76 kg (170 Ib) 49. Put spring washers (35) (4 used) on bolts (34) (4
used) and screw them on.
42. Install eyebolt (M14, Pitch 2) into the sling hole of ϖ 27 mm
cover (15) and hoist it by a crane. Install cover ϖ 300 N⋅m (30.5 kgf⋅m, 220 Ibf⋅ft)
(15) to ring gear (14) with bolts (17) (26 used) and
spring washers (18) (26 used).

NOTE: Apply LOCTITE #262 on bolt (17).

ϖ 22 mm
ϖ 140 N⋅m (14 kgf⋅m,101 Ibf]ft)

43. Install dummy plugs (51) (2 used) into the two

sling holes in cover (15).

W3-2-17
 UNDERCARRIAGE / Travel Device

DISASSEMBLE TRAVEL MOTOR

6
5
3 4
2

1
7
8
10 9
22
21
11 20
12
19

18
17
16

15
28
14 29
13
30
31
32
33

34
23

35 24

25

27
34

26
36

W183-03-02-013

1- Case 10 - O-Ring (4 Used) 19 - Cylinder Block 28 - O-Ring

2- O-Ring (2 Used) 11 - Plug (2 Used) 20 - Valve Plate 29 - Brake Piston
3- Plug (2 Used) 12 - O-Ring (2 Used) 21 - Collar 30 - Backup Ring
4- O-Ring (4 Used) 13 - Steel Ball (2 Used) 22 - Roller Bearing 31 - O-Ring
5- Spring (2 Used) 14 - Swash Plate 23 - Socket Bolt (9 Used) 32 - O-Ring
6- Piston (2 Used) 15 - Plunger Assembly (9 Used) 24 - Travel Brake Valve 33 - Backup Ring
7- Shaft 16 - Retainer Plate 25 - Pin 34 - Friction Plate (3 Used)
8- Roller Bearing 17 - Retainer Holder 26 - Pin (4 Used) 35 - Friction Plate (4 Used)
9- Oil Seal 18 - Spring (9 Used) 27 - Spring (12 Used) 36 - Disc Plate (5 Used)

W3-2-18
 UNDERCARRIAGE / Travel Device

Disassemble Travel Motor

6. Remove friction plates (34) (3 used), (35) (4 used)
• Be sure to thoroughly read “Precautions for and disc plates (36) (5 used) from case (1).
Disassembly and Assembly Work” on page
W1-1-1 before starting the disassembly work.
CAUTION: Cylinder block (19) assembly weight:
CAUTION: Travel brake valve (24) assembly 20 kg (40 Ib)
weight: 39 kg (90 Ib)
7. Remove the cylinder block (19) assembly from
IMPORTANT: Since valve plate (20) will come out case (1). At this moment, plunger assemblies (15)
with the travel brake valve (24) (9 used), retainer holder (17), retainer plate (16)
assembly if the assembly is removed, and springs (18) (9 used) are all connecting with
do not let the plate come off. cylinder block (19).

NOTE: Hold cylinder block (19) and turning it left

1. Remove socket bolts (23) (9 used) from case (1)
to remove the travel brake valve (24) assembly. At and right lightly, with two hands to take it out
slowly.
this moment, the outer race of roller bearing (22)
is connected with the travel brake valve (24)
assembly. 8. Remove retainer plate (16) from cylinder block
ϖ 14 mm (19). At this moment, plunger assemblies (15) (9
used) are connecting with retainer plate (16).
Ȁ
IMPORTANT: As cylinder block (19) and valve plate
9. Remove plunger assemblies (15) (9 used) from
(20) are easy to damage, please
retainer plate (16).
handle with care.
10.Remove retainer holder (17) and springs (18) (9
2. Remove collar (21) and valve plate (20) from used) from cylinder block (19).
cylinder block (19).
Ȁ IMPORTANT: Do not damage friction face of swash
3. Remove O-ring (28) from case (1) and springs plate (14). In addition, piston (6) and
(27) (12 used) from brake piston (29) respectively. steel ball (13) may come out with
swash plate (14), in such event keep
piston (6) and steel ball (13) from
CAUTION: Case (1) should be fixed firmly. dropping.
Otherwise, case (1) will move
about, injury will occur and the
11. Remove swash plate (14) from case (1).
motor parts may be damaged
during the removal of brake
piston (29).

4. Install eyebolts (M10) into the two sling holes of

brake piston (29) and hoist it by a crane to remove
it from case (1).

5. Remove O-rings (31 and 32) and backup rings (30

and 33) from brake piston (29).

W3-2-19
 UNDERCARRIAGE / Travel Device

6
5

1
7
8
9

13

W183-03-02-013

W3-2-20
 UNDERCARRIAGE / Travel Device
12. Remove pistons (6) (2 used), springs (5) (2 used)
and steel balls (13) (2 used) from case (1).

NOTE: If it is difficult to remove steel ball (13), that

means the ball has been set in case (1), so
use some kerosene or thinner, etc. to clean
grease first, and then with a magnet to take
it out from case (1).

IMPORTANT: Do not damage the spline part of

shaft (7) and contact part of oil seal
(9), because oil leakage will occur if
they are damaged.

13. Remove shaft (7) from case (1). At this moment,

the inner race of roller bearing (8) is connecting
with the shaft.

14. Press the inner race of roller bearing (8) to

remove it from shaft (7).

15. Remove oil seal (9) from case (1).

W3-2-21
 UNDERCARRIAGE / Travel Device

ASSEMBLE TRAVEL MOTOR

23 20 29 36 19 15 16 14 6 5

27

25
24
7

22

9
8

T183-03-05-003
21 26 28 30, 31 32, 33 35 34 18 17 13

1- Case 10 - O-Ring (4 Used) 19 - Cylinder Block 28 - O-Ring

2- O-Ring (2 Used) 11 - Plug (2 Used) 20 - Valve Plate 29 - Brake Piston
3- Plug (2 Used) 12 - O-Ring (2 Used) 21 - Collar 30 - Backup Ring
4- O-Ring (4 Used) 13 - Steel Ball (2 Used) 22 - Roller Bearing 31 - O-Ring
5- Spring (2 Used) 14 - Swash Plate 23 - Socket Bolt (9 Used) 32 - O-Ring
6- Piston (2 Used) 15 - Plunger Assembly (9 Used) 24 - Travel Brake Valve 33 - Backup Ring
7- Shaft 16 - Retainer Plate 25 - Pin 34 - Friction Plate (3 Used)
8- Roller Bearing 17 - Retainer Holder 26 - Pin (4 Used) 35 - Friction Plate (4 Used)
9- Oil Seal 18 - Spring (9 Used) 27 - Spring (12 Used) 36 - Disc Plate (5 Used)

W3-2-22
 UNDERCARRIAGE / Travel Device

Assemble Travel Motor

CAUTION: Case (1) assembly weight: 54 kg
IMPORTANT: Apply grease on inside periphery of (120 Ib)
the oil seal for case (1) at the Cylinder block (19) assembly
pressed-in part and outside weight: 20 kg (40 Ib)
periphery of the oil seal.
IMPORTANT: Apply hydraulic oil on the contact
1. Press oil seal (9) into case (1). parts of swash plate (14) and plunger
assembly (15).
The inner race of roller bearing (22)
2. Assemble springs (5) (2 used), pistons (6) (2 is on the front end of shaft (7) and be
used) and steel balls (13) (2 used) into case (1) careful not to damage it.
while applying grease on steel ball (13).
8. Put case (1) horizontally and install the cylinder
3. Press the inner race of roller bearing (8) into shaft block (19) assembly to shaft (7).
(7). Press shaft (7) to install it into case (1).
9. With travel brake valve (24) facing upward, place
the case (1) assembly vertically.
CAUTION: Case (1) assembly weight: 54 kg
(120 Ib)
10. Install friction plates (34) (3 used), (35) (4 used)
and disc plates (36) (5 used) into case (1).
4. Place the case (1) assembly horizontally with the
oil pipe for brake releasing facing down. NOTE: First, place two friction plates (34), and then
place each of disc plate (36) and friction
IMPORTANT: Install swash plate (14) with its plate (35) alternately, and finally place one
spherical pit aligning with steel ball piece of friction plate (34).
(13).
IMPORTANT: Apply grease on the outside of brake
5. Install swash plate (14) to case (1). Now, apply piston (29) and the internal diameter
more grease on the interfaces of swash plate (14) of case (1).
and case (1).
11. Assemble backup rings (30 and 33) and O-rings
6. Install springs (18) (9 used) and retainer holder (31 and 32) onto brake piston (29) and install it
(17) into cylinder block (19). into case (1).

IMPORTANT: Apply hydraulic oil in plunger 12. Align pin (25) of travel brake valve (24) with the
assembly (15) mounting hole of pin hole in valve plate (20) and install collar (21)
cylinder block (19). and valve plate (20) to travel brake valve (24).

7. Assemble plunger assemblies (15) (9 used) with 13. Install springs (27) (12 used) into brake piston
retainer plate (16) and install to cylinder block (29).
(19).

W3-2-23
 UNDERCARRIAGE / Travel Device

23 29

24

T183-03-05-003
26 28

W3-2-24
 UNDERCARRIAGE / Travel Device

CAUTION: Travel brake valve (24) weight:

39 kg (90 Ib)

14. Place O-ring (28) to case (1) and align pin (26) of
travel brake valve (24) with the pin holes in case
(1) and brake piston (29). Install travel brake valve
(24) to case (1) with socket bolts (23)(9 used).

W3-2-25
 UNDERCARRIAGE / Travel Device

DISASSEMBLE TRAVEL BRAKE VALVE

6
1 7
2 8
3 5
4 9
10
11

10 9
35

12

36 13
37 14
38 16 15
39 18
40 20
21
48
17 22
19
24
26 5
47
49
46 28 23
10 30 25
9
41 32
27 33
42 34
43 29
44 31
4
45 3
2
1
44
43
36 42
41
50
40
39
35
38
37

W183-03-02-010

1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 40 - Spring Seat (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 41 - Plug (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 42 - O-Ring (2 Used)
5- Overload Relief Valve (2 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 43 - Spring (2 Used)
Used)
6 - Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 44 - Check Valve (2 Used)
7 - O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 45 - Spool
8 - Spring 21 - Relief Valve Housing (2 34 - Set Screw (2 Used) 46 - Valve Housing
Used)
9- Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 47 - Pin (4 Used)
10 - O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 48 - Pin
11 - Orifice 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 49 - Set Screw
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 50 - Spool Assembly
13 - Valve Assembly 26 - Spring Seat (2 Used)

W3-2-26
 UNDERCARRIAGE / Travel Device

Disassemble Travel Brake Valve

IMPORTANT: Put matching marks on set screw (34)
and plug (32) and take a note of the
CAUTION: Valve housing (46) assembly weight: turning amount that set screw (34)
39 kg (90 Ib) has been screwed.

1. Fix the valve housing (46) assembly on a firm 6. Remove nut (33) from plug (32) to remove set
work bench. screw (34).
ϖ 19 mm
2. Remove plugs (6 and 15) and O-rings (7 and 14) ϖ 6 mm
respectively, and remove spring (8).
ϖ 10 mm 7. Remove poppet seat (16), poppet (20), relief valve
housing (21), piston (22), spring seat (26), spring
IMPORTANT: Remove valve assembly (13) while (27) and spring guide (28) from plug (32).
turning it. In case there is a little
resistance to turning do not try to Spool
pull it out forcedly. Insert it back and
try to pull it out again. 8. Equally loosen socket bolts (35) (4 used) while
Do not disassemble valve assembly holding cap (36) to remove cap (36) from valve
(13) unless necessary. housing (46). (2 places both left and right)
ϖ 10 mm
3. Lightly push valve assembly (13) out. Then pull it
out from valve housing (46) while turning it by NOTE: Tap cap (36) off with a plastic hammer if it
hand. can not be removed. Socket bolt (35)
loosened should be in its position while
4. Remove plug (1) to remove O-ring (2), spring (3) tapping cap (36).
and check valve (4). (2 places both left and right)
ϖ 14 mm 9. Remove spring seat (38), spring (39) and spring
seat (40) from valve housing (46). (2 places both
left and right)
Overload Relief Valve
IMPORTANT: Do not disassemble the overload IMPORTANT: Pull out spool assembly (50) while
relief valve unless necessary. Attach turning it. In case there is a little
tags to the valve and keep carefully resistance to turning, do not try to
so that it can be reset to the position pull it out forcedly. Insert it back and
where it was removed. try to pull it again.

5. Loosen plug (32) to remove overload relief valve 10. Lightly push spool assembly (50) out. Then pull it
(5) from valve housing (46). (2 places both left and out from valve housing (46) while turning it by
right) hand.
ϖ 36 mm

W3-2-27
UNDERCARRIAGE / Travel Device

41
43
44

45

41
50

W183-03-02-010

W3-2-28
 UNDERCARRIAGE / Travel Device
11. Clamp spool assembly (50) and hold it by the vise
with wooden spatula inserted at both sides.

12. Remove plugs (41) (2 used) to remove springs

(43) (2 used) and check valves (44) (2 used) from
spool (45).

W3-2-29
 UNDERCARRIAGE / Travel Device

ASSEMBLE TRAVEL BRAKE VALVE

Overload Relief Valve (5)

16 18 21 26 24 27 31 29 32 33
34

17я
я 19 20 22 23я
я 25 28 30

36 38

41
6
37

35 39
42
A A A 7
40
43
8
44
45
13
50

14

48 47
12
15

46
5 2 1 3 4
Section A-A-A W183-03-02-016

1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 39 - Spring (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 40 - Spring Seat (2 Used)v
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 41 - Plug (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 42 - O-Ring (2 Used)
5- Overload Relief Valve (2 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 43 - Spring (2 Used)
Used)
6 - Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 44 - Check Valve (2 Used)
7 - O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 45 - Spool
8 - Spring 21 - Relief Valve Housing (2 34 - Set Screw (2 Used) 46 - Valve Housing
Used)
9- Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 47 - Pin (4 Used)
10 - O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 48 - Pin
11 - Orifice 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 49 - Set Screw
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 50 - Spool Assembly
13 - Valve Assembly 26 - Spring Seat (2 Used)

W3-2-30
 UNDERCARRIAGE / Travel Device

Assemble Travel Brake Valve

IMPORTANT: Set screw (34) should be screwed on
1. Assemble O-rings (7 and 14) onto plugs (6 and only by the same amount to removal
15) respectively. Install valve assembly (13) and while aligning the matching marks.
plugs (6 and 15) into valve housing (46).
ϖ 10 mm 6. Install set screw (34) into plug (32) and screw on
ϖ 64 N⋅m (6.5 kgf⋅m, 47 Ibf⋅ft) nut (33).
ϖ 19 mm
2. Place O-ring (2) onto plug (1). Install check valve ϖ 65 N⋅m (6.6 kgf⋅m, 48 Ibf⋅ft)
(4), spring (3) and plug (1) into valve housing (46). ϖ 6 mm
(left and right, 2 places) ϖ 16 N⋅m (1.6 kgf⋅m, 11.5 Ibf⋅ft)
ϖ 14 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) IMPORTANT: Install overload relief valve (41) into
its position where it was
disassembled and be sure to perform
Overload Relief Valve the adjustment to the valve on the
3. Assemble O-ring (31) onto plug (32) and test bench. (Refer to the Adjustment
assemble backup ring (30) and O-ring (29) onto of Overload Relief Valve in
spring guide (28). Performance Test chapter, Technical
Manual)
4. Assemble backup rings (23 and 25) and O-ring
(24) onto piston (22) and assemble backup rings 7. Install overload relief valves (5) (2 used) into valve
(17 and 19) and O-ring (18) onto poppet seat (16). housing (46).
ϖ 36 mm
5. Assemble spring guide (28), spring (27), spring ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
seat (26), piston (22), relief housing (21), poppet
(20) and poppet seat (16) into plug (32).
Spool
8. Place O-rings (42) onto plugs (41) (2 used). Install
check valves (44) (2 used), springs (43) (2 used)
and plugs (41) (2 used) into spool (45).

9. Insert spool assembly (50) into valve housing (46)

while slowly turning it.
Ȁ
10. Install O-ring (37) onto cap (36). (left and right, 2
places)
Ȁ
11. Assemble spring seat (40), spring (39) and spring
seat (38) into valve housing (46) and install cap
(36) to it with socket bolts (35) (4 used). (left and
right, 2 places)
ϖ 10 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

W3-2-31
 UNDERCARRIAGE / Travel Device

MAITENANCE STANDARD

1. Move the plunger of travel motor up and down to

measure the play between plunger and shoe.

Unit: mm (in)
Standard Size Allowable Limit Size
MAX 0.15 (0.0059) 0.4 (0.0157)

W111-03-02-106

2. Clearance between the plunger of travel motor

and the rotor.

Measure the outer dia of the plunger and the inner

dia of the rotor and calculate the clearance.

Unit: mm (in) W111-03-02-107

Standard Size Allowable Limit Size

MAX 0.045 (0.0018) 0.06 (0.0024)

Check the outer periphery of the plunger visually.

Replace it when scratch is found.

3. Measure the outer dia of piston of travel motor

W111-03-02-108
and the bore dia for piston operating in casing and
calculate the clearance.

Unit: mm (in)
Standard Size Allowable Limit Size
MAX 0.018 (0.0007) 0.03 (0.0012)

Check the outer periphery of the piston visually

and replace it when scratch is found.

W162-03-02-005

W3-2-32
 UNDERCARRIAGE / Travel Device
4. Move the piston of the travel motor up and down
and measure the clearance between the steel ball
and the shoe attached to the piston.

Unit: mm (in)
Standard Size Allowable Limit Size
MAX 0.5 (0.0197) 0.7 (0.028)

W107-02-06-140

Valve
5. Check the tilt selector valve of the travel motor.

Measure the clearance between the valve and the

bore dia. for valve body.

Unit: mm (in)
Standard Size Allowable Limit Size
MAX 0.018 (0.0007) 0.04 (0.016)

W111-03-02-109
Body

W3-2-33
 UNDERCARRIAGE / Travel Device

Sprocket

C
D

E
A

W105-03-02-241

Unit: mm (in)
Allowable Limit
Standard Size Measurements
Size
A 114 (4.49) 104 (4.09)
B 1038 (40.87) 1028 (40.47)
Clad by welding
C 1128.9 (44.44) -
and finishing
D 1480 (58.27) 1470 (57.87)
E 260.4 (10.25) -

W3-2-34
 UNDERCARRIAGE / Center Joint

REMOVE AND INSTALL CENTER JONT

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation
1. Park the machine on a level solid surface. Lower W183-04-02-003
the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2. W183-04-02-002

ϖ 4 mm Wooden Blocks

3. Remove the hydraulic oil tank cap. Connect a Cap

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W3-3-1
 UNDERCARRIAGE / Center Joint
Removal
1. Attach tags to all hoses connected to the center
joint to aid reconnection. Disconnect hoses (1 to 4 2
and 7 to 15) and remove adapters.
1
ϖ 22 mm 5
3
ϖ 39 N⋅m (4.0 kgf⋅m, 29 Ibf⋅ft)
ϖ 27 mm 4
8
ϖ 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
ϖ 41 mm
ϖ 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)
ϖ 50 mm
ϖ 340 N⋅m (35 kgf⋅m, 255 Ibf⋅ft)
6

NOTE: Cap all disconnected hose and pipe ends.

W142-03-03-002
2. Remove bolts (6) (2 used) to remove stopper (5). 7
ϖ 22 mm
ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)
17
3. Install eyebolts (PF1) to the holes (2 places) where
hoses (1 to 4) were removed to lift the center joint
with a wire rope.
16
9
CAUTION: The center joint assembly weight:
52 kg (110 Ib) 15

4. Remove bolts (17) (4 used). Then, remove the 10

center joint assembly while holding the center joint
by a crane.
ϖ 24 mm 14
ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) 11

Installation
NOTE: Refer to “Removal” section above for
wrench sizes and tightening torque.

CAUTION: The center joint assembly weight:

13 12
52 kg (110 Ib)

1. Hoist the center joint assembly and install it onto

track frame with bolts (17) (4 used).
W183-03-03-002

2. Connect hoses (1 to 4 and 7 to 16) and adapters.

3. Install stopper (5) with bolts (6) (2 used).

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

W3-3-3
 UNDERCARRIAGE / Center Joint

DISASSEMBLE CENTER JOINT

2
3
4

10

11

W183-03-03-001

1 - Spindle 4 - Bushing 7 - Ring 10 - Cover

2 - Dust Seal 5 - Oil Seal (6 Used) 8 - Retaining Ring 11 - Bolt (4 Used)
3 - O-Ring 6 - Body 9 - O-Ring

W3-3-4
 UNDERCARRIAGE / Center Joint
Disassemble Center Joint
• Be sure to thoroughly read “Precautions for 4. Install removal special tool for center joint (ST
Disassembly and Assembly Work” on page 1930) to body (6) with cover (10) mounting bolts
W1-1-1 before starting the disassembly work. (11) (2 used).
ϖ 19 mm
ST 1020
CAUTION: Center joint weight: 52 kg (110 Ib)
ST 1930

1. Remove bolts (11) (2 used) in diagonal position

from cover (10). Install eyebolts (M12, Pitch 1.75)
into the holes where bolts (11) were removed.
Pass wire through eyebolts and hoist the center
joint. Place the center joint on work bench (ST
5099).
ϖ 19 mm

Eyebolt W183-03-03-004

10 5. Turn bolt (ST 1020) on special tool (ST 1930) to

press spindle (1) down to remove it out from body
11
(6).

IMPORTANT: Take care not to damage the sliding

ST 5099 surface of the spindle (1) seal.
It is easy to remove seals with 2 pins.
Don’t damage the seal grooves by
W183-03-03-003 pins.

2. Loosen bolts (11) (2 used) to remove cover (10)

from body (6). 6. Remove oil seals (5) (6 used) from body (6).
ϖ 19 mm

3. Remove O-ring (9), retaining ring (8) and ring (7)

from body (6).

IMPORTANT: Put matching marks on body (6) and

spindle (1). 6

1
5

Matching Mark W105-03-03-015

7. Remove dust seal (2) and O-ring (3) from body
(6).
6

W142-03-03-004

W3-3-5
 UNDERCARRIAGE / Center Joint

ASSEMBLE CENTER JOINT

7 6
8

9
11
10
W183-03-08-001

1 - Spindle 4 - Bushing 7 - Ring 10 - Cover

2 - Dust Seal 5 - Oil Seal (6 Used) 8 - O-Ring 11 - Bolt (4 Used)
3 - O-Ring 6 - Body 9 - Retaining Ring

W3-3-6
 UNDERCARRIAGE / Center Joint
Assemble Center Joint
1. If bushing (4) is removed, be sure to press IMPORTANT: When installing ring (7), its cham-
bushing (4) into body (6). fered face shall face inside.

2. Install O-ring (3) and dust seal (2) into body (6). 6. Install ring (7) to body (6).

3. Install oil seals (5) (6 used) into body (6). IMPORTANT: Install retaining ring (9) with the
chamfered edge facing the spindle.
4. Aligning the matching marks put when disassembling,
install spindle (1) into body (6). 7. Install retaining ring (9) onto spindle (1).

IMPORTANT: Be sure to slowly push spindle (1) 8. Secure cover (10) to body (6) with bolts (11) (4 used).
into body. Failure to do so may ϖ 19 mm
damage seals. Moreover, the ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
clearance between body (6) and
spindle (1) is approx 0.05 mm (0.004
in) so that the center of body (6) and
spindle (1) can be aligned during
installation. In addition, no step is
allowed to form at portion A (where
ring (7) is installed) shown bellow
when assembling.
1
0.05 mm (0.002 in)
A

W105-03-03-024

5. Tap body (6) with a plastic hammer slightly and

evenly. Insert spindle (1) with no step forming at
the mounting position between body (6) and ring
(7) of spindle (1).

W3-3-7
 UNDERCARRIAGE / Center Joint

7 6
8

9
11
10
W183-03-08-001

W3-3-8
 UNDERCARRIAGE / Center Joint
IMPORTANT: Check for oil leaks while applying oil
2
at pressure of 0.5 Mpa (5 kgf/cm , 71
Psi) to the main port and drain port
respectively.

Frame Upper Part

3

1
4
6
2

W142-03-03-002
5
Frame Lower Part

7
13

12
8

11 9

10

W183-03-03-002

1- Hose : (main port 1) 8- Hose : (main port 4)

2- Hose : (main port 2) 9- Hose : (main port 3)
3- Hose : (main port 3) 10 - Hose : (drain port)
4- Hose : (main port 4) 11 - Hose : (main port 1)
5- Hose : (drain port) 12 - Hose : (main port 2)
6- Hose : (pilot port) 13 - Hose : (pilot port)
7- Hose : (pilot port)

W3-3-9
 UNDERCARRIAGE / Center Joint

MAINTENANCE STANDARD

Item Allowable Limit (basis of judgment) Remedy

Wear less than 0.2 mm (0.008 in) Replace
Scored, abnormal wear Replace
Uneven wear (Wear range is less than Replace
180°)
Wear Area
Bushing

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

W3-3-10
 UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER

Before removing the track adjuster, the tracks and the

front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to
applicable removal/installation sections. In this section,
the procedure starts on the premise that the tracks and
the front idler have already been removed.

2
CAUTION: When removing track adjuster (1),
1
track adjuster (1) may fly off by
spring force. Don’t stand in the
removal direction of track adjuster
(1) or in places where track
adjuster (1) may fly out.
The rod screw is loaded by spring
force. Be alert that if the rod or W142-03-04-002
screw section is broken, the
broken pieces may fly out by
spring force, causing personal 3 2
injury and/or death.

Removal

CAUTION: Track adjuster weight:

650 kg (1430 Ib)

1. Remove track adjuster (1) from track frame (2) by

prying it with a crowbar.
W166-03-04-002

3 4
Installation
1. Install track adjuster (1) into spring guide (3) on
track frame (2).
Check that the end face of track adjuster (1)
comes into contact with the face of plate (4).

W183-03-04-002

W3-4-1
 UNDERCARRIAGE / Track Adjuster

DISASSEMBLE TRACK ADJUSTER

1
3

5
6
2 7
8
9

10

12

11

14

13

15

16

18

W167-03-04-004

17

1- O-Ring 6- Backup Ring 11 - O-Ring 16 - Nut

2- Socket Bolt (4 Used) 7- U-Ring 12 - Cylinder 17 - Bolt
3- Guide 8- Plate 13 - Spring 18 - Valve
4- Piston Rod 9- Retaining Ring 14 - Spacer
5- Wear Ring (2 Used) 10 - Rod 15 - Bracket

W3-4-2
 UNDERCARRIAGE / Track Adjuster
Disassemble Track Adjuster
IMPORTANT: Compress spring until the clearance
• Be sure to thoroughly read “Precautions for between bracket (15) and nut (16) is
Disassembly and Assembly Work” on page approx. 10 mm (0.39 in).
W1-1-1 before disassembling work.
Use a pump unit which has the maximum 2. Loosen valve (18). Compress track adjuster spring
2
pressure of 69 MPa (700 kgf/cm , 9 950 psi) and (13) with special tool (ST 4932).
the flow rate of 8 to 10 liters (2.1 to 2.6 US gal.).
Clearance 10 mm (0.39 in)
Be sure to set the main relief pressure to 49 MPa
2
(500 kgf/cm , 7 110 psi) (80 tons) or lower.

Be sure to use special tool (ST 4932) for

assembly/disassembly of the track adjuster.
15
16
CAUTION: Prevent personal injury. The 17
spring force of the track adjuster 18
is extremely strong. Thoroughly
inspect the special tool for any
damage. Carefully perform
W142-03-04-020
assembly work referring to the
procedure below.

3. Remove valve (18) and bolt (17) to remove nut

CAUTION: Track adjuster assembly weight: (16).
650 kg (1430 Ib)
ϖ 30 mm, 150 mm
1. Position the track adjuster on the rest of special
tool (ST 4932) by a crane.

ST 4932

Rest

W142-03-04-019

W3-4-3
 UNDERCARRIAGE / Track Adjuster

12

14

13

15

W167-03-04-004

W3-4-4
 UNDERCARRIAGE / Track Adjuster
4. Slowly return the piston of special tool (ST 4932)
until spring (13) extends to its free length. CAUTION: The cylinder (12) assembly weight:
280 kg (620 Ib)

7. Lift and remove the cylinder (12) assembly from

13 ST 4932
spring (13).
Eyebolt

15 12

13

W142-03-04-005

Rest
CAUTION: Track adjuster weight (Nut exclud-
ed): 640 kg (1410 Ib)

5. Tie bracket (15) and spring (13) together with wire. W142-03-04-007
Fasten a sling belt to spring (13). Lift bracket (15)
and spring (13) together out of special tool (ST
4932) by a crane. CAUTION: Spring weight: 350 kg (770 Ib)

8. Remove the wire fastening spring (13) and bracket

(15). Lift and remove spring (13) by a crane.
6. Install eye bolt (M16, Pitch 2) onto piston rod (4).
Fasten a sling belt around spring (13) and through
eyebolt (M16, Pitch 2). Lift and position the CAUTION: Bracket weight: 45 kg (100 Ib)
assembly on the rest by a crane, as illustrated.
9. Remove spacer (14) and bracket (15) out of the
rest.
Eyebolt

13

Rest

W142-03-04-006

W3-4-5
 UNDERCARRIAGE / Track Adjuster

1
3

5
6
2 7
8
9

10

12

11

W167-03-04-004

W3-4-6
 UNDERCARRIAGE / Track Adjuster

10. Remove socket bolts (2) (4 used) and guide (3).

ϖ14 mm

CAUTION: Piston rod weight: 35 kg (80 Ib)

11. Pull out piston rod (4) from cylinder (12).

12. Remove O-ring (1) from guide (3).

CAUTION: Cylinder (12) weight: 110 kg (240 Ib)

Rod (10) weight: 60 kg (130 Ib)

13. Remove rod (10) and O-ring (11) from cylinder

(12).

14. Remove wear rings (5) (2 used), retaining ring (9),

plate (8), U-ring (7), backup ring (6) from piston
rod (4).

5
6
7
9

W142-03-04-008

W3-4-7
 UNDERCARRIAGE / Track Adjuster

ASSEMBLE TRACK ADJUSTER

18 17 16 15 14 11 10 7 6 5 4 2 3

Chamber B
9 8 13 12 1

W142-03-04-016

1- O-Ring 6- Backup Ring 11 - O-Ring 16 - Nut

2- Socket Bolt (4 Used) 7- U-Ring 12 - Cylinder 17 - Bolt
3- Guide 8- Plate 13 - Spring 18 - Valve
4- Piston Rod 9- Retaining Ring 14 - Spacer
5- Wear Ring (2 Used) 10 - Rod 15 - Bracket

W3-4-8
 UNDERCARRIAGE / Track Adjuster
Assemble Track Adjuster
1. Clean all parts. Install wear rings (5) (2 used), IMPORTANT: Fill chamber (B) in cylinder (12) with
backup ring (6), U-ring (7), plate (8) and retaining grease and insert piston rod (4) to
ring (9) to piston rod (4). completely bleed air from chamber
4
(B) and from the inside of rod (10).

4. Install O-ring (1) on guide (3). Install guide (3) on

5
piston rod (4). Apply LOCTITE #262 to socket
6 bolts (2) (4 used) and tighten the socket bolts.
7
8
9 ϖ 14 mm
ϖ 210 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

1
3
2

W142-03-04-008 4

2. Apply a film of grease to O-ring (11) and install it

into cylinder (12). Install rod (10) into cylinder (12).
11

10
12
W142-03-04-018

W142-03-04-012

3. Apply grease to U-ring (7), wear rings (5) (2 used),

cylinder (12) and piston rod (4). Install piston rod
(4) into cylinder (12).

W3-4-9
 UNDERCARRIAGE / Track Adjuster

15 14 4

13 12

W142-03-04-016

W3-4-10
 UNDERCARRIAGE / Track Adjuster

CAUTION: Bracket (15) weight: 45 kg (100 Ib) CAUTION: Track adjuster weight (excluding
Spring (13) weight: 350 kg (770 Ib) nut): 640 kg (1410 Ib)

5. Place bracket (15) and spacer (14) on the rest. Lift 7. Fasten a sling belt around spring (13) through the
and place spring (13) onto the rest. Tie spring (13) eyebolt in piston rod (4). Lift and lay the assembly
and bracket (15) together with pieces of wire. on a clean, secured level surface by a crane.
Eyebolt

4
12

13

14

13 W142-03-04-006

8. Attach a sling belt through the spring part of the

Rest assembly. Lift and position the track adjuster
15
assembly on special tool (ST 4932) while
balancing it horizontally. Remove the eyebolt.

W142-03-04-007

CAUTION: Cylinder (12) assembly weight: ST 4932

280 kg (620 Ib)

6. Install eyebolt (M16, Pitch 2) onto piston rod (4).

Lift and position the cylinder (12) assembly in
place onto spacer (14) and bracket (15) by a
crane.

W142-03-04-005

W3-4-11
 UNDERCARRIAGE / Track Adjuster

18 17 16 15 10

13

W142-03-04-016

W3-4-12
 UNDERCARRIAGE / Track Adjuster
IMPORTANT: Be sure to slowly compress spring 11. Tighten valve (18).
(13) while aligning the center of rod ϖ 24 mm
(10) with the center of bracket (15) ϖ 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
using a crowbar.
Take care not to damage the threads 12. Retract the cylinder of special tool (ST 4932).
on rod (10).

9. Remove wire from spring (13). Compress spring CAUTION: Track adjuster weight:
(13) by operating the cylinder of special tool (ST 650 kg (1430 Ib)
4932) until the specified spring length is obtained.
(Specified spring length: 800 mm (31.5 in)) 13. Securely fasten a sling belt to the track adjuster.
13 Lift and remove the track adjuster by a crane.
ST 4932
14. If the spring assembly must be transported, take
care not to damage it. Use a firm steel box for
transportation of the spring assembly and take all
15 other precautions to insure safe transportation.

Wire

W142-03-04-015

10. Install nut (16) and bolt (17) to rod (10).

ϖ 150 mm
ϖ 24 mm
ϖ 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)

16

10

17
18

W142-03-04-020

W3-4-13
 UNDERCARRIAGE / Track Adjuster
(Blank)

W3-4-14
 UNDERCARRIAGE / Front Idler

REMOVE AND INSTALL FRONT IDLER

Removal
Before removing the front idler, the tracks must be
removed first. For removal and installation of the
tracks, refer to “Remove and Install Tracks” section.
In this section, the procedure starts on the premise
that the tracks have already been removed.

CAUTION: Front idler weight: Approx.

760 kg (1680 Ib)
W142-03-05-002

CAUTION: When removing the front idler, the

front idler may come out
explosively by spring force. Don’t
4
stand in the removal direction of 3
the front idler or in a place where
the front idler may come out.

1. Slide the front idler forward, with a crowbar.

1
2 5
W142-03-05-003
2. Attach sling belts to bearing (1) and yoke (2)
sections. Remove the front idler assembly from
track frame (3) by a crane.

3. Remove bolts (5) (4 used) to remove guard (4)

from yoke (2).
ϖ 24 mm

Wooden Blocks
W105-03-05-003

4. When storing the front idler, place it on blocks as

shown.
3

Installation
1. To install the front idler, simply perform the
removal procedures in the reverse order.
Apply a film of grease to the sliding surface
between track frame (3) and bearing (1) after 1
cleaning.
W142-03-05-005

W3-5-1
 UNDERCARRIAGE / Front Idler

DISASSEMBLE FRONT IDLER

2
1
3
4
6

6 8

4
3
2

13

14

8
12

W142-03-05-001

11 10 9

1- Bearing (2 Used) 5- Axle 9 - Yoke 12 - Guard

2- Pin (2 Used) 6- Bushing (2 Used) 10 - Bolt (4 Used) 13 - Bolt (4 Used)
3- O-Ring (2 Used) 7- Idler 11 - Spring Washer (4 Used) 14 - Spring Washer (4 Used)
4- Floating Seal (2 Used) 8- Plug (2 Used)

W3-5-2
 UNDERCARRIAGE / Front Idler
Disassemble Front Idler
• Be sure to thoroughly read “Precautions for IMPORTANT: For handling of floating seal, refer to
Disassembly and Assembly Work” on page the section “Precautions for Floating
W1-1-1 before starting the disassembly work. Seal Handling” on page W1-1-4.

5. Remove floating seals (4) (2 used) from bearing

CAUTION: Guard (12) weight: 13 kg (30 Ib) (1) and idler (7).

1. Loosen bolts (13) (4 used) to remove guard (12)

from yoke (9).
ϖ 24 mm

CAUTION: Yoke (9) weight: 13 kg (30 Ib)

2. Loosen bolts (10) (4 used) to remove yoke (9)

from bearing (1).
Remove plug (8) from bearing (1) to drain oil into a
container.
ϖ 36 mm
ϖ 6 mm

3. Remove pin (2) from bearings (1) (2 used).

CAUTION: Idler assembly weight:

Approx. 740 kg (1630 Ib)
Axle (5) weight:
Approx. 60 kg (130 Ib)
Bearing (1) weight:
Approx. 40 kg (90 Ib)

4. Push axle (5) out of bearing (1) with a press.

Bearing (1) in opposite side shall be pushed out
with its axle (5).
Press

1 5

W105-03-05-008

W3-5-3
 UNDERCARRIAGE / Front Idler

W142-03-05-001

W3-5-4
 UNDERCARRIAGE / Front Idler

CAUTION: Axle (5) weight: 60 kg (130 Ib)

6. Press out axle (5) to remove bearing (1) and O-

ring (3) (2 used).

Press
3

W183-03-05-001

7. In case of replacing bushing (6), remove the bushing

with a press and special tool (ST 1915).

Press

ST 1915

Front Idler

W105-03-05-011

W3-5-5
 UNDERCARRIAGE / Front Idler

ASSEMBLE FRONT IDLER

1 2 3 4 5 6 8

9 10 11
12

13, 14

W142-03-05-004

1- Bearing (2 Used) 5- Axle 9 - Yoke 12 - Guard

2- Pin (2 Used) 6- Bushing (2 Used) 10 - Bolt (4 Used) 13 - Bolt (4 Used)
3- O-Ring (2 Used) 7- Idler 11 - Spring Washer (4 Used) 14 - Spring Washer (4 Used)
4- Floating Seal (2 Used) 8- Plug (2 Used)

W3-5-6
 UNDERCARRIAGE / Front Idler
Assemble Front Idler

CAUTION: Idler weight: 510 kg (1120 Ib) CAUTION: The axle (5) assembly weight:
75 kg (170 Ib)
1. Install bushing (6) (2 used) into idler (7) with a
press. 4. Insert axle (5) into idler (7). Install O-ring (3) onto
axle (5).

CAUTION: Axle (5) weight: 60 kg (130 Ib) 1 4 3 7

Bearing (1) weight: 40 kg (90 Ib)
1
2. Install O-ring (3) (1 used) to axle (5). Aligning the
pin holes, install axle (5) into bearing (1) and
secure with pin (2). Take care not to damage O-
ring (3).
5

2 W157-03-05-005
5 5. Install the other floating seals (4) (one pair) into
idler (7) and into the other bearing (1).
1
6. Install bearing (1) onto axle (5), aligning the pin
holes, secure them with pin (2).

7. Add engine oil via plug (8) hole on bearing (1).

Apply sealant (LOCTITE #503 or equivalent) to
3 W105-03-05-014 plug (8). Tighten plug (8).
IMPORTANT: For handling of floating seal, refer to ϖ 6 mm
the section “Precautions for Floating ϖ 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
Seal Handling” on page W1-1-4. Engine oil: APl CD class SAE30
Quantity: 0.6 L, 0.16 Us gallon
3. Install floating seals (4) (one pair) into idler (7) and
into bearing (1).
CAUTIN: Idler (7) weight: 740 kg (1630 Ib)
7 Yoke (9) weight: 13 kg (30 Ib)
4 1
8. Install yoke (9) to bearing (1) and tighten bolts (10)
(4 used) with spring washers (11) (4 used).
ϖ 36 mm
ϖ 390 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)
5
CAUTION: Guard (12) weight: 13 kg (30 Ib)
W157-03-05-006
9. Install guard (12) to yoke (9) with spring washers
(14) (4 used) and bolts (13) (4 used).
ϖ 24 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)

W3-5-7
 UNDERCARRIAGE / Front Idler

MAINTENANCE STANDARD

C D

A W166-03-05-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 123 (4.84) [85.8 (3.38)]
B 277 (10.9) - Clad by welding
C 934 (36.77) 914 (35.98) and finish or
D 980 (38.58) - replace
E 23 (0.91) 33 (1.3)

Axle and Bushing

Unit: mm (in)
Allowable Limit Allowable Limit Remedy
Axle Outer Dia. 130 (5.12) [129.2 (5.09)]
Inner Dia. 130 (5.12) [131 (5.16)] Replace
Bushing
Flange Thickness 6 (0.24) [5.2 (0.20)]

NOTE: Values in [ ] are just for reference.

W3-5-8
 UNDERCARRIAGE / Upper And Lower Roller

REMOVE AND INSTALL UPPER ROLLER

Removal

CAUTION: Grease pressure in the adjuster

cylinder is high. Do not loosen
valve (1) quickly or loosen it too
much as valve (1) may fly off or
high-pressure grease in the
adjusting cylinder may spurt out.
Loosen carefully, keeping body
parts and face away from valve
(1). W105-03-06-001

Never loosen grease fitting (2).

1

1. Loosen valve (1) of adjustor to drain grease.

ϖ 24 mm

Grease Outlet
M104-07-119

3
IMPORTANT: Use a nonskid cloth between track
frame (5) and jack to prevent
slipping.

2. Jack tracks (3) up high enough to permit upper

roller (4) removal. Insert a wooden block between
tracks (3) and track frame (5).
Wooden Block
5 4

W105-03-06-003

CAUTION: Upper roller weight: 60 kg (430 Ib)

3. Lift upper roller (4) by a crane. Remove bolts (6) (4

used) to remove upper roller (4) from track frame
(5). 4
ϖ 30 mm

6 5
W105-03-06-005

W3-6-1
 UNDERCARRIAGE / Upper And Lower Roller
Installation
1. Lift upper roller (4) by a crane. Install upper roller
(4) onto track frame (5) with bolts (6) (4 used).
ϖ 30 mm
ϖ 550 N⋅m (56 kgf⋅m, 400 Ibf⋅ft) 4

2. Remove the wooden block and jack. 6 5

W105-03-06-005

Wooden Block
5 4

W105-03-06-003

3. Apply grease from grease fitting (2) of adjustor to

adjust tracks tension. 2
Track sag specifications (A): 485 to 515 mm
(19.09 to 20.28 in)

NOTE: Check track sag after thoroughly removing

soil stuck on the track area.

Grease Outlet
M104-07-119

W157-03-06-002

W3-6-2
 UNDERCARRIAGE / Upper And Lower Roller

REMOVE AND INSTALL LOWER ROLLER

5
Removal
1. Remove the track guard and bolts (1) (4 used) to
remove lower roller (5).
ϖ 41 mm
1

W105-03-06-008

IMPORTANT: The adjuster cylinder is under high

pressure. Be sure to support the
raised body with wooden block, etc.

2. Lift one side of the track frame height enough to

remove the lower roller.
Insert wooden blocks under track frame (2).
2

W105-03-06-009

CAUTION: The adjuster cylinder is under

high pressure. Do not loosen
valve (3) quickly or loosen it too
much as high-pressure grease in
the adjusting cylinder may spurt
out. Do not loosen it over 1.5
turns.
Loosen carefully, keeping body
parts and face away from valve
(3). W105-03-06-001

Never loosen grease fitting (4).

3. Loosen track adjuster valve (3) slowly. Discharge

the grease till the space is enough for removing
the lower roller (5) from the track frame.
ϖ 24 mm

4
Grease Outlet
CAUTION: Lower roller weight: 200 kg (440 Ib) M104-07-119

4. Remove lower roller (5) by a fork lift.

W3-6-3
 UNDERCARRIAGE / Upper And Lower Roller
Installation

CAUTION: Lower roller weight: 200 kg (440 Ib)

1. Put lower rollers (5) on the tracks frame (2) as per

illustration by a fork lift.

5 W105-03-06-011

2. Lower the track frame (2) until the clearance

between the track frame and collar (6) for lower
roller (5) is very close.

W105-03-06-012
6 5

3. Install lower roller (5) onto track frame (2) with

bolts (1) (4 used).
ϖ 41 mm 5
ϖ 1050 N⋅m (107 kgf⋅m, 770 Ibf)

W105-03-06-008

W3-6-4
 UNDERCARRIAGE / Upper And Lower Roller
4. Supply grease through grease fitting (4) to adjust
tracks tension. 4
Track sag specifications (A): 485 to 515 mm
ϑ19.1 to 20.3 inϒ

Grease Outlet
M104-07-119

W157-03-06-002

W3-6-5
 UNDERCARRIAGE / Upper And Lower Roller

DISASSEMBLE UPPER ROLLER

11

10
9

6
5
4
3
2
1

12
W166-03-06-005

1 - Socket Bolt (3 Used) 4 - O-Ring 7 - Roller 10 - Axle

2 - Plug 5 - Thrust Plate 8 - Bushing 11 - Bracket
3 - Cover 6 - Bushing 9 - Floating Seal 12 - Socket Bolt (3 Used)

W3-6-6
 UNDERCARRIAGE / Upper And Lower Roller
Disassemble Upper Roller
• Be sure to thoroughly read “Precautions for 6. When replacing bushings (6) and (8), remove the
Disassembly and Assembly Work” on page bushing from the roller using press and special
W1-1-1 before starting the disassembly work. tool (ST 1967).

1. Remove plug (2) to drain oil. NOTE: Bushings can also be removed by cladding
ϖ 6 mm four weld beads on the inside of bushing at
90° intervals.
Bushing will shrink enough to permit
2. Remove socket bolts (1) (3 used) and cover (3).
removal with a hammer.
ϖ 17 mm
Press
3. Remove socket bolt (12) (3 used) and thrust plate
(5). ST 1967
ϖ 8 mm
7
4. Remove axle (10) from roller (7). 6

5. Remove floating seal (9) from roller (7) and

bracket (11). 8

NOTE: Floating seal (9) can be reused if it is not

worn. Keep the floating seal in a matched
set and put cardboard between seals to
protect the sealing face.

W142-03-06-005

7. Pull out axle (10) from bracket (11) with a press.

W3-6-7
 UNDERCARRIAGE / Upper And Lower Roller

ASSEMBLE UPPER ROLLER

11 10 9 7

2
12

8 6 4
W166-03-06-008

1 - Socket Bolt (3 Used) 4 - O-Ring 7 - Roller 10 - Axle

2 - Plug 5 - Thrust Plate 8 - Bushing 11 - Bracket
3 - Cover 6 - Bushing 9 - Floating Seal 12 - Socket Bolt (3 Used)

W3-6-8
 UNDERCARRIAGE / Upper And Lower Roller
Assemble Upper Roller
• Before assembly, clean all parts. 8. Add engine oil via plug (2) hole on cover (3).
Engine oil: API CD class SAE30
• Remove all scratches and roughness on the parts Quantity: 0.2 L (0.05 Us gallon)
with an oil stone.
9. Apply LOCTITE #503 or equivalent to plug (2).
• Replace all O-rings and seals with new ones. Tighten plug (2) to cover (3).
ϖ 6 mm
1. When necessary to replace bushings, press bu- ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
shings (6) and (8) in roller (7) with a press.

NOTE: Pressure to press in bushings (6) and (8):

20 ton

2. Install axle (10) bracket (11) with a press.

IMPORTANT: Apply a coat of grease to the O-ring

part of floating seal (9) and a film of
hydraulic oil to the steel ring part.
For handling of floating seal (9), refer
to the section “Precautions for
Floating Seal Handling” on page W1-
1-4.

3. Install floating seal (9) to roller (7) and to bracket

(11).

4. Insert axle (10) into roller (7).

5. Install thrust plate (5) to axle (10), tighten socket

bolts (12) (3 used).
ϖ 8 mm
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

6. Apply grease to O-ring (4) and install it to cover

(3).
Ȁ
7. Install cover (3) to roller (7), and tighten socket
bolts (1) (3 used).
ϖ 17 mm
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W3-6-9
 UNDERCARRIAGE / Upper And Lower Roller

DISASSEMBLE LOWER ROLLER

4 6

7
6

3
4

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

W3-6-10
 UNDERCARRIAGE / Upper And Lower Roller
Disassemble Lower Roller
• Be sure to thoroughly read “Precautions for 6. In case of replacing bushings (7), remove the
Disassembly and Assembly Work” on page bushings using press and special tool (ST 1921).
W1-1-1 before starting the disassembly work.

Press
CAUTION: Lower roller weight:
200 kg (440 Ib)

1. Remove plugs (6) from collars (4) (2 used) and ST 1921

drain oil. Push out pins (5) (2 used) from collars Roller
(4) (2 used) with an adapter bar and hammer.
ϖ 6 mm
7

2. Press down axle (2) until O-ring (3) comes out of

collar (4).
Remove collar (4) from axle (2).

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

Remove axle (2) from roller (8).
W105-03-06-028

4. Remove floating seal (1) from roller (8) and collar

(4).

5. Press out axle (2), and remove collar (4) and O-

ring (3) from axle (2).
Press

3 4

W105-03-06-027

W3-6-11
 UNDERCARRIAGE / Upper And Lower Roller

ASSEMBLE LOWER ROLLER

4 5 6

W162-03-06-002
8 2 7 1 3

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

W3-6-12
 UNDERCARRIAGE / Upper And Lower Roller
Assemble Lower Roller

CAUTION: Lower roller weight: 120 kg (260 Ib) 4. Insert axle (2) into roller (8). Install O-ring (3) and
the other collar (4). Secure them with pin (5).
1. Install bushings (7) (2 used) onto roller (8) with a
press. 4 1 2 8
Take care not to dent the flange surface of
bushings (7).
Apply a coat of grease to O-ring (3) and install it
onto axle (2).

2. Press collar (4) onto axle (2) while aligning the pin 3
W157-03-06-009
(5) holes both in axle (2) and collar (4). Secure
them with pin (5). 5. Add engine oil via plug (6) hole on collars (4) (2
Take care not to damage O-ring (3). used).
Engine oil: API CD class SAE30
2 5 Quantity: 1.5 L (0.4 Us gallon)

6. Apply sealant LOCTITE #503 or equivalent to

plugs (6) (2 used). Install plugs (6) (2 used) into
collar (4).
ϖ 6 mm
ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
4 3
W166-03-06-009

IMPORTANT: Coat grease on O-ring of floating seal

and then install it. For handling of
floating seal, refer to the section
“Precautions for Handling Floating
Seal” on page W1-1-4.

3. Install floating seal (1) to roller (8) and to collar (4).

8 1

1 4

W157-03-06-008

W3-6-13
 UNDERCARRIAGE / Upper And Lower Roller

MAINTENANCE STANDARD
Upper Roller

A
B
W166-03-06-007

Unit: mm (in)
Standard Allowable Limit Remedy
A 118 (4.65) − Clad by welding
B 240 (9.45) − and finish or
C 200 (7.87) 190 (7.48) replace

Axle and Bushing

Unit: mm (in)
Standard Allowable Limit Remedy
Axle Outer Dia. 75 (2.95) [74.2 (2.92)]
Inner Dia. 75.2 (2.96) [76.2 (3)] Replace
Bushing
Flange Thickness 4.5 (0.18) [3.7 (0.15)]

NOTE: Values in [ ] are just for reference.

W3-6-14
 UNDERCARRIAGE / Upper And Lower Roller

Lower Roller

C C

W157-03-06-003

Unit: mm (in)
Standard Allowable Limit Remedy
A 290 (11.42) [328 (12.91)]
B 366 (14.4) - Clad by welding and
C 38 (1.5) - finish or replace
D 280 (11.02) 262 (10.31)

Axle and Bushing

Unit: mm (in)
Standard Allowable Limit Remedy
Axle Outer Dia. 120 (4.72) [119.2 (4.69)]
Inner Dia. 120 (4.72) [121 (4.76)] Replace
Bushing
Flange Thickness 6 (0.24) [5.2 (0.20)]

NOTE: Values in [ ] are just for reference.

W3-6-15
 UNDERCARRIAGE / Upper And Lower Roller
(Blank)

W3-6-16
 UNDERCARRIAGE / Track

REMOVE AND INSTALL TRACKS

Removal

CAUTION: The adjusting cylinder is highly

pressurized. Loosening valve (1)
quickly or excessively may cause
valve (1) to fly off and the highly
pressurized grease to spurt out,
possibly resulting in personal
injury. Do not loosen the valve
over 1.5 turns.
Be sure to loosen vlave (1) slowly
and gradually, keeping face and W105-03-07-001
body parts away from valve (1). In
addition, never attempt to loosen 5
grease fitting (2).

1. Rotate the tracks so that master pin (3) is 4

positioned over front idler (4).
Put a wooden block under track shoes (5) as
shown.

Wooden Block W105-03-07-006

1
2. Loosen the track tension.

NOTE: Slowly turn valve (1) counterclockwise one

turn, grease will be released via grease
outlet.
ϖ 24 mm
W105-03-07-002

Grease Outlet M104-07-119

W3-7-1
 UNDERCARRIAGE / Track
3. Remove pin (6), which is used to secure master
pin (3). If it is difficult to remove pin (6) from 7
master link (7), tap in master pin (3) in the 3
inserting direction to make clearance between pin
(6) and master pin (3) before attempting to pull out
pin (6). 6

CAUTION: The front idler may jump out of

position due to strong spring
force when the track is W142-03-07-001

disconnected. Never stand in

front of the front idler.
Moreover, if the rod or the rod
screw is damaged, the damaged
part may fly off since strong
spring force is always applied to
the rod screw. Take necessary
precautions to prevent personal
injury.

W105-03-07-005

W3-7-2
 UNDERCARRIAGE / Track
ST 1970
4. Remove master pin (3) using special tool (ST
1970).

IMPORTANT: The direction of removing master pin

is as illustrated. Be sure to strike the
pin correctly.

3
W105-03-07-008

Pin

Remove
master pin in
this direction

Master Pin W166-03-07-002

Boom
5. Raise the machine as illustrated with the angle
between the boom and the arm held at 90° to 110° Arm
and the bucket round bottom section placed on 90° to 110°
the ground.
Put wooden blocks under the track frame to safely
support the raised machine.

W105-03-07-012

6. Slowly operate the raised side travel lever in the

reverse direction to remove the tracks from the
machine.

W105-03-07-011

W3-7-3
 UNDERCARRIAGE / Track
Installation
1. Raise the machine with the front attachment and
put the track under the lower roller so that the
sprocket teeth align with the end of the track. Be
sure to position the track in the correct direction,
as illustrated. Sprocket
Idler Side
Side

W105-03-07-013

CAUTION: Track link assembly weight:

5310 kg (11710 Ib)

2. Lift the track, and place it on sprocket (1).

W105-03-07-014

3. With the machine kept raised, slowly turn the

raised side sprocket in forward direction to wind
the track around the raised track frame (2).
2

W105-03-07-015

4. Turn sprocket until the end of track (5) comes on

front idler (4).
Lower the machine and put a wooden block as
illustrated.

5
W105-03-07-016

Wooden Block

W3-7-4
 UNDERCARRIAGE / Track
5. Install master pin (3), with a hammer and special ST 1970
tool (ST 1971). 3

IMPORTANT: Master pin (3) is directional. Be sure

to install it in correct direction.

W105-03-07-017

Pin

Direction for
installing the
master pin

W166-03-07-002
Master Pin

6. Install pin (6).

IMPORTANT: Old pin (6) can’t be reused. Replace it 6

with a new one for its easy
deformation.

W142-03-07-001

W3-7-5
 UNDERCARRIAGE / Track
7. Charge grease to the cylinder through grease
fitting to adjust the track tension.
ϖ 24 mm

Track sag specifications (A): 485 to 515 mm

(19.09 to 20.28 in)

NOTE: Check track sag after thoroughly removing

soil stuck on the track area.

W105-03-07-018

W157-03-06-002

W3-7-6
 UNDERCARRIAGE / Track

MAINTENANCE STANDARD
Link Pin and Track Bushing
Measure the length of four links:

• Do not measure the master-pin-included part of

the track.

• The work shall be done with the tension on the

track.

A
W155-03-07-001

Unit: mm (in)
Standard Allowable Limit Remedy
A 1041.4 (41.0) 1061.8 (41.8) Clad by welding and
B 155 (6.1) [148 (5.83)] finish or replace

Master Pin

A W142-03-07-003

Unit: mm (in)
Standard Allowable Limit Remedy
A 301 (11.85) -
Replace
B 57.8 (2.28) [54.8 (2.16)]

NOTE: Values in [ ] are just for reference.

W3-7-7
 UNDERCARRIAGE / Track
Master Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Limit Remedy
A 204 (8.03) -
B 58.65 (2.31) [61.7 (2.43)] Replace
C 90 (3.54) [85 (3.35)]

Grouser Shoe

W105-03-07-024

Unit: mm (in)
Shoe 600 mm Grouser
Standard Allowable Limit Remedy
A 302 (11.89) −
B 25 (0.98) [26 (1.02)] Replace
C 50 (1.97) [45 (1.77)]

NOTE: Values in [ ] are just for reference.

W3-7-8
 UNDERCARRIAGE / Track
Bushing

W105-03-07-023

Unit: mm (in)
Standard Allowable Limit Remedy
A 222.1 (8.74) -
B 59.15 (2.33) [60.2 (2.37)] Replace
C 90 (3.54) 85 (3.35)

Pin

W105-03-07-020

Unit: mm (in)
Standard Allowable Limit Remedy
A 319.5 (12.58) -
Peplace
B 58.15 (2.29) [55.2 (2.17)]

NOTE: Values in [ ] are just for reference.

W3-7-9
 UNDERCARRIAGE / Track
(Blank)

W3-7-10
 SECTION 4
FRONT ATTACHMENT

CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment..... W4-1-1
Remove and Install Bucket and Arm
(Backhoe)............................................. W4-1-2
Remove and Install Bucket and Arm
(Loading Shovel) ................................ W4-1-10
Remove and Install Boom
(Backhoe, Loading Shovel) ................. W4-1-14
Greasing(Backhoe) .............................. W4-1-18
Greasing(Loading Shovel) .................... W4-1-19

Group 2 Cylinder
Remove and Install Cylinder ................... W4-2-1
Disassemble Cylinder ........................... W4-2-35
Assemble Cylinder ............................... W4-2-42
Air Bleeding Procedure......................... W4-2-50
Maintenance Standard ......................... W4-2-51

Group 3 Bushing and Point

Remove and Install Bushing ................... W4-3-1
Maintenance Standard ........................... W4-3-6

183W-4-1
(Blank)

183W-4-2
 FRONT ATTACHMENT / Front Attachment

REMOVE AND INSTALL FRONT ATTACH-

MENT

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Always turn the air
breather cap slowly to release
any remaining pressure befor
removing it.

Preparation W183-04-02-003

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

the front attachment to the ground.

2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system. Rotate the hydraulic oil tank cap
approx. 30° counterclockwise using a hexagon
wrench to release the trapped air in the hydraulic W183-04-02-002
oil tank. Refer to Bleeding Air from Hydraulic
System on page W1-1-2. Wooden Blocks

ϖ 4 mm
Cap

3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continously to
maintain negative pressure in the hydraulic oil
tank.

NOTE: Run the vacuum pump continously while

working on the hydraulic system.

W183-01-01-001

W4-1-1
 FRONT ATTACHMENT / Front Attachment

REMOVE AND INSTALL BUCKET AND

ARM (BACKHOE)
2

Link A

Link B

B
C
W183-04-02-003
21, 22

11
10
3 5, 4

6 9, 8

Section B W142-04-01-013

W183-04-01-006
12
Section A

21, 22
18,19
15, 14
13 20
16
17
16

Section C Section D W118-04-01-011

W183-04-01-003

1- Bucket Cylinder 7- Pin 13 - Pin 18 - Bolt (2 Used)

2- Arm Cylinder 8- Bolt (3 Used) 14 - Bolt (10 Used) 19 - Spring Washer (2 Used)
3- Pin 9- Spring Washer (3 Used) 15 - Spring Washer (10 Used) 20 - Plate
4- Bolt (3 Used) 10 - Stopper 16 - Cover (2 Used) 21 - O-Ring (4 Used)
5- Spring Washer (3 Used) 11 - Spacer 17 - Pin 22 - Ring (4 Used)
6- Stopper 12 - O-Ring (2 Used)

W4-1-2
 FRONT ATTACHMENT / Front Attachment
Remove Bucket and Arm
(Backhoe)

CAUTION: When driving the pin with a CAUTION: Pin (7) weight: 95 kg (210 Ib)
hammer, metal debris may fly,
causing personal injury. 4. Remove bolts (8) (3 used), spring washers (9)
Be sure to use proper safety (3 used) and stopper (10), which are used on
equipment. pin (7) to mount link B and arm. Then pull pin
(7) out. When pin (7) is pulled out half way, hoist
1. Remove ring (22) at the linkage part of the it by a crane to remove pin (7).
bucket and link A. Move O-ring to the bucket
side. (4 places at left and right) ϖ 30 mm

21, 22
CAUTION: Link A assembly + link B weight:
660 kg (1460 Ib)

Bucket 5. Hoist link A and link B by a crane and remove

from the arm.

CAUTION: Spacer (11) weight: 30 kg (70 Ib)

Moving of the W183-04-01-001
O-Ring and Ring
6. Remove spacer (11) from link A and remove O-
rings (12) (2 used) from spacer (11).

CAUTION: Cover (16) weight: 25 kg (60 Ib)

Link A
Bucket 7. Remove bolts (14) (5 used), spring washers
(15) (5 used) and cover (16) from pin (13) to
W183-04-01-002
mount bucket and arm. (2 places at left and
right).
2. Remove bucket cylinder (1). (Refer to W4-2-14)
ϖ 32 mm

CAUTION: Link A assembly + link B weight:

660 kg (1460 Ib) CAUTION: Pin (13) weight: 150 kg (330 Ib)
Pin (3) weight: 110 kg (240 Ib)
8. Remove pin (13) out of the pin hole.
3. Holding link A and link B by a crane, remove bolts
(4) (3 used), spring washers (5) (3 used) and CAUTION: Bucket weight: 4490 kg (9900 Ib)
stopper (6) , which are used on pin (3) to mount 3
(Standard bucket capacity 5.0 m )
bucket and link A.Then pull pin (3) out. BE bucket weight: 5990 kg
ϖ 30 mm (13210 Ib)
3
(BE bucket capacity 7.1 m )

9. Hoist the bucket by a crane and remove it.

10. Remove arm cylinder (2). (Refer to W4-2-6)

W4-1-3
 FRONT ATTACHMENT / Front Attachment

Link A

Link B

B
C
W183-04-02-003

Section B W142-04-01-013

W183-04-01-006

Section A

18,19

20

17

Section C Section D W118-04-01-011

W183-04-01-003

W4-1-4
 FRONT ATTACHMENT / Front Attachment
11. Remove the greasing hoses (4 used) from the
mounting part of the boom and arm. (2 places at
left and right )
ϖ 19 mm

Greasing Hose

M142-07-082

CAUTION: Arm weight: 3570 kg (7870 Ib)

Pin (17) weight: 180 kg (400 Ib)

12. Hoist arm by a crane to remove bolts (18) (2 used),

spring washers (19) (2 used) and plate (20) from
pin (17) to link boom and arm .Then remove pin
(17).
ϖ 30 mm

13. Hoist the arm by a crane to remove it. Lay down

wooden blocks and put the boom on the wooden
blocks.

W4-1-5
 FRONT ATTACHMENT / Front Attachment

Link A

Link B

B
C
W183-04-02-003
21, 22

11
10
3 5, 4

6 9, 8

Section B W142-04-01-013

W183-04-01-006
12
Section A

21, 22
18,19
15, 14
13 20
16
17
16

Section C Section D W118-04-01-011

W183-04-01-003

1- Bucket Cylinder 7- Pin 13 - Pin 18 - Bolt (2 Used)

2- Arm Cylinder 8- Bolt (3 Used) 14 - Bolt (10 Used) 19 - Spring Washer (2 Used)
3- Pin 9- Spring Washer (3 Used) 15 - Spring Washer (10 Used) 20 - Plate
4- Bolt (3 Used) 10 - Stopper 16 - Cover (2 Used) 21 - O-Ring (4 Used)
5- Spring Washer (3 Used) 11 - Spacer 17 - Pin 22 - Ring (4 Used)
6- Stopper 12 - O-Ring (2 Used)

W4-1-6
 FRONT ATTACHMENT / Front Attachment
Install Bucket and Arm
(Backhoe)

CAUTION: When driving the pin with a CAUTION: Link B weight: 120 kg (260 Ib)
hammer, metal debris may fly,
causing personal injury. 7. Hoist link B by a crane to align the pin holes of
Be sure to use proper safety the arm and link B.
equipment.

CAUTION: Pin (7) weight: 95 kg (210 Ib)

CAUTION: Arm weight: 3570 kg (7870 Ib)

8. Hoist pin (7) by a crane and insert it into the pin

1. Start the engine. Raise the boom and hoist the hole.
arm by a crane to align the pin hole of the boom
with that of the arm.
CAUTION: Link B weight: 120 kg (260 Ib)
CAUTION: Pin (17) weight: 180 kg (400 Ib)
9. Hoist the other link B by a crane and install it
into pin (7). Install bolts (8) (3 used), spring
2. Insert pin (17) into the pin hole. Install bolts (18) washers (9) (3 used) and stopper (10).
(2 used), spring washers (19) (2 used) and plate
(20). ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
CAUTION: Spacer (11) weight: 30 kg (70 Ib)
3. Install arm cylinder (2). (Refer to W4-2-6) Link A weight: 200 kg (440 Ib)

CAUTION: Bucket weight: 4490 kg (9900 Ib) 10. Install O-rings (12) (2 used) onto spacer (11).
(Standard bucket capacity 5.0 m )
3 Then install link A (2 used) to spacer (11).
BE bucket weight: 5990 kg (13210 Ib)
3
(BE bucket capacity 7.1 m ) CAUTION: Link A + spacer (11) weight:
430 kg (950 Ib)
4. Start the engine. Raise the arm and align the pin
hole of the arm with that of the bucket. 11. Pass a metal bar through the pin hole in link A
and attach a wire on it. Hoist link A and spacer
CAUTION: Pin (13) weight: 150 kg (330 Ib) (11) by a crane.

5. Insert pin (13) into the pin hole. CAUTION: Pin (3) weight: 110 kg (240 Ib)

CAUTION: Cover (16) weight: 25 kg (60 Ib) 12. Align the pin holes of the bucket, link A and
spacer (11) and insert pin (3) to install bolts (4)
(3 used), spring washers (5) (3 used) and
6. Install bolts (14) (5 used), spring washers (15) stopper (6).
(5 used) and covers (16). (2 places at left and
right). ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
ϖ 32 mm
ϖ 550 N⋅m (56 kgf⋅m, 400 Ibf⋅ft)

W4-1-7
 FRONT ATTACHMENT / Front Attachment

Link A

Link B

B
C
W183-04-02-003
21, 22

Section B W142-04-01-013

W183-04-01-006

Section A

21, 22

Section D W118-04-01-011
Section C W183-04-01-003

W4-1-8
 FRONT ATTACHMENT / Front Attachment
13. Move bucket O-ring (21) back to its position to
install ring (22). (4 places at right and left)
21, 22

Bucket

W183-04-01-001

Moving of the O-Ring and Ring

Link A

Bucket
W183-04-01-004

14. Install bucket cylinder (1). (Refer to W4-2-14)

15. Attach the hose to the mounting part of the boom

and arm. (2 places at right and left)
ϖ 19 mm
ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

Greasing Hose

M142-07-082

W4-1-9
 FRONT ATTACHMENT / Front Attachment

REMOVE AND INSTALL BUCKET AND

ARM (LOADING SHOVEL)
B

3 4

W183-04-02-002

Wooden Blocks
Hydraulic Hose Greasing Hose

W183-04-02-027

W183-04-02-023
W183-04-02-010

Wooden Blocks

13
9 12

8 11 14

7, 6

W183-04-01-007
10
Section A
Section B W166-04-01-015

1- Dump Cylinder (2 Used) 5- Pin (2 Used) 9 - Shim (Several) 12 - Bolt (4 Used)

2- Bucket Cylinder (2 Used) 6- Bolt (6 Used) 10 - O-Ring (2 Used) 13 - Spring Washer (4 Used)
3- Arm Cylinder 7- Spring Washer (6 Used) 11 - Pin (2 Used) 14 - Plate (2 Used)
4- Level Cylinder 8- Stopper (2 Used)

W4-1-10
 FRONT ATTACHMENT / Front Attachment
Remove Bucket and Arm
(Loading Shovel)

CAUTION: When driving the pin with a CAUTION: Bucket + dump cylinder weight:
hammer, metal debris may fly, 9520 kg (20990 Ib)
causing personal injury.
Be sure to use proper safety 5. Hoist the bucket by a crane and remove it. Put
equipment.
the arm on wooden blocks.

1. Move the O-ring on the mounting part of the 6. Remove arm cylinder (3). Then remove level
bucket and arm to the bucket side. (2 places at cylinder (4). (Refer to W4-2-10 Remove and
right and left) Install the arm cylinder and refer to W4-2-22
Remove and Install the Level Cylinder)
Moving of the O-ring

CAUTION: If the air breather cap on the

hydraulic oil tank is turned
quickly, the air breather cap may
fly off due to pressure remaining
Arm
inside. Slowly turn the air
Bucket breather cap to relieve pressure.

W183-04-01-002
2. Remove bucket cylinder (2). (Refer to W4-2-18) 7. Stop the engine. Operate the lever several times
to release the remaining pressure from
hydraulic circuit. Then drain the air out from the
CAUTION: If the air breather cap on the hydraulic oil tank. Disconnect the hydraulic
hydraulic oil tank is turned hoses (6 used) and greasing hoses (2 used)
quickly, the air breather cap from the mounting part of the arm and boom.
may fly off due to pressure
ϖ 12 mm
remaining inside. Slowly turn
ϖ 19 mm
the air breather cap to relieve
pressure.
CAUTION: Arm weight: 4200 kg (9260 Ib)
3. Stop the engine and operate the lever several Pin (11) weight: 80 kg (180 Ib)
times to release the remaining pressure in the
hydraulic circuit. Then drain the air out from the 8. Hoist arm by a crane to remove bolts (12) (2
hydraulic oil tank.Disconnect the hydraulic used), spring washers (13) (2 used) and plate
hoses (2 used) and greasing hose from the (14) from pin (11) to mount arm and boom. Pull
mounting part of the arm and bucket. pin (11) out. (2 places at right and left)
ϖ 12 mm ϖ 30 mm
ϖ 19 mm
9. Hoist arm by a crane and remove it. Place boom
CAUTION: Pin (5) weight: 65 kg (140 Ib) onto wooden blocks.

4. Start the engine to hold the arm in position.

Remove bolts (6) ( 3 used), spring washers (7)
(3 used) and stopper (8) from pin (5) of the
bucket and arm. Push pins (5) out and remove
shims (9).(2 places at right and left)
ϖ 24 mm

W4-1-11
 FRONT ATTACHMENT / Front Attachment

3 4

W183-04-02-002

Wooden Blocks
Hydraulic Hose Greasing Hose

W183-04-02-027

W183-04-02-023
W183-04-02-010

Wooden Blocks

13
9 12

8 11 14

7, 6

W183-04-01-007
10
Section A
Section B W166-04-01-015

W4-1-12
 FRONT ATTACHMENT / Front Attachment
Install Bucket and Arm
(Loading Shovel)

3
CAUTION: When driving the pin with a CAUTION: Bucket (6.5 m ) + dump cylinder
hammer, metal debris may fly, weight: 9520 kg (20990 Ib)
causing personal injury.
Be sure to use proper safety 5. Start the engine. Raise the arm and align the pin
equipment. hole of the arm with that of the bucket to install
shim (9).
CAUTION: Arm weight: 4200 kg (9260 Ib)
CAUTION: Pin (5) weight: 65 kg (140 Ib)
1. Start the engine. Raise the boom up and hoist
the arm by a crane. Align the pin hole of the 6. Insert pin (5) into the pin hole. Install bolts (6) (3
boom with that of the arm. used), spring washers (7) (3 used) and stopper
(8). (2 places at right and left)
CAUTION: Pin (11) weight: 80 kg (180 Ib) ϖ 24 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
2. Insert pin (11) into the pin hole. Install bolts (12)
(2 used), spring washers (13) (2 used) and CAUTION: If the air breather cap on the
plate (14). (2 places at right and left) hydraulic oil tank is turned
ϖ 30 mm quickly, the air breather cap may
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) fly off due to pressure
remaining inside. Slowly turn
the air breather cap and remove
CAUTION: If the air breather cap on the
after completely releasing any
hydraulic oil tank is turned remaining pressure.
quickly, the air breather cap may
fly off due to pressure
remaining inside. Slowly turn 7. Stop the engine. Operate the lever several times
the air breather cap and remove to release the remaining pressure in the
after completely releasing any hydraulic circuit. Then drain the air out from the
remaining pressure. hydraulic oil tank. Install hydraulic hoses (2
used) and the greasing hose to the mounting
part of the arm and bucket.
3. Stop the engine. Operate the lever several times
to release the remaining pressure from the ϖ 12 mm
hydraulic circuit. Then drain the air out from the ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)
hydraulic oil tank. Install hydraulic hoses (6 ϖ 19 mm
used) and greasing hoses (2 used) to the ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)
mounting part of the boom and arm.
8. Move O-ring (10) having been moved to the
ϖ 12 mm
bucket side back to its original position and
ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)
install it. (2 places at right and left)
ϖ 19 mm
ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft) Moving of the O-ring

4. Install level cylinder (4) and then install arm

cylinder (3). (Refer to W4-2-22 Remove and
Install Level Cylinder and refer to W4-2-10
Remove and Install Arm Cylinder.)
Arm
Bucket

W183-04-01-004
9. Install bucket cylinder (2). (Refer to W4-2-18)

W4-1-13
 FRONT ATTACHMENT / Front Attachment

REMOVE AND INSTALL BOOM

(BACKHOE, LOADING SHOVEL)

W183-04-02-003
A

W183-04-02-002

Hydraulic Hoses

Hydraulic Hoses Greasing Hose

Greasing Hose

Backhoe Loading Shovel W183-04-02-025

W183-04-02-024

6 4
Section A 5
W162-04-01-025
1 - Boom Cylinder (2 Used) 3 - Bolt (4 Used) 5 - Plate (2 Used) 6 - Shim (2 Used)
2 - Pin (2 Used) 4 - Spring Washer (4 Used)

W4-1-14
 FRONT ATTACHMENT / Front Attachment

Remove Boom

CAUTION: When driving the pin with a

hammer, metal debris may fly,
causing personal injury. Be
sure to use proper safety
equipment.

1. Remove the bucket and arm. (Refer to W4-1-2

Backhoe and W4-1-10 Loading Shovel)

2. Remove boom cylinder (1). (Refer to W4-2-2)

CAUTION: If the air breather cap on the

hydraulic oil tank is turned
quickly, the air breather cap may
fly off due to the pressure
remaining inside. Slowly turn
the air breather cap and remove
after completely releasing any
remaining pressure.

3. Stop the engine. Operate the lever several times

to release the remaining pressure in the
hydraulic circuit. Then drain the air out from the
hydraulic oil tank. Disconnect the hydraulic
hoses (11 used) from the main frame side.
ϖ 12 mmЕ14 mm

CAUTION: Boom weight

Backhoe: 8860 kg (19530 Ib)
BE backhoe: 8580 kg (18920 Ib)
Loading shovel: 5690 kg
(12540 Ib)
Pin (2) weight: 70 kg (150 Ib)

4. Hoist the boom by a crane. Remove bolts (3) (2

used),spring washers (4) (2 used) and plate (5)
from pin (2) by which the boom and main frame
being installed together. Then remove shims (6).
(2 places at right and left)
ϖ 30 mm

5. Hoist the boom by a crane and remove the

boom.

W4-1-15
FRONT ATTACHMENT / Front Attachment

W183-04-02-003
A

W183-04-02-002

Hydraulic
Hoses

Hydraulic Hoses Greasing Hose

Greasing Hose

Backhoe Loading Shovel W183-04-02-025

W183-04-02-024

6 4
Section A 5
W162-04-01-025

W4-1-16
 FRONT ATTACHMENT / Front Attachment
Install Boom
IMPORTANT: When finishing the installing of
bucket, arm and boom, carry out
CAUTION: Boom weight
the following work.
Backhoe: 8860 kg (19530 Ib)
Be Backhoe: 8580 kg (18920 Ib)
Loading Shovel: 5690 kg (12540 Ib) 6. When finishing the installing of bucket, arm and
boom, apply grease to all grease fittings shown
1. Hoist the boom by a crane to align the pin holes in the figure. (Refer to W4-1-18)
of the boom and main frame. Install shims (6).
(2 places at right and left) NOTE: In order to protect the grease fittings
around the bucket, a cap is installed.
Before greasing, the cap should be
CAUTION: Pin (2) weight: 70 kg (150 Ib)
removed with a screw driver first. Then
carry out greasing.
2. Insert pin (2) into the pin hole. Install bolts (3) (2
used), spring washers (4) (2 used) and plate (5).
(2 places at right and left)
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m,295 Ibf⋅ft)
CAUTION: If the air breather cap on the
hydraulic oil tank is turned
quickly, the air breather cap may
fly off due to pressure remaining
inside. Slowly turn the air
breather cap and remove after
completely releasing any
remaining pressure.

3. Stop the engine. Operate the lever several times

to release the remaining pressure in the
hydraulic circuit. Then drain the air out from the
hydraulic oil tank. Lay down wooden blocks and
place the boom on them. Install the hydraulic
hoses (11 used) to the main frame side.
ϖ 12 mm
ϖ 140 N⋅m (14 kgf⋅m,101 Ibf⋅ft)
ϖ 14 mm
ϖ 210 N⋅m (21.5 kgf⋅m,155 Ibf⋅ft)

4. Install boom cylinder (1). (Refer to W4-2-2)

5. Install the bucket and arm (Refer to W4-1-2

Backhoe paragraph and W4-1-10 Loading
Shovel paragraph)

W4-1-17
 FRONT ATTACHMENT / Front Attachment

GREASING
(BACKHOE)

Bucket and Link

Joint Pin

A
Bucket and Arm Arm and Link
Joint Pin Joint Pin

W183-04-01-005
Boom Foot Arm Side

Boom Cylinder
Bottom Side

Arm Cylinder
Bottom Side
Bucket Cylinder
Bottom Side

Arm Cylinder
Rod Side
Boom Cylin-
der Rod Side
Boom Cylinder
Rod Side
Development A M142-07-046 Development B M142-07-049
Boom Foot
Body Side

Bucket Cylinder
Rod Side

Development C
M142-07-045

W4-1-18
 FRONT ATTACHMENT / Front Attachment

GREASING
(LOADING SHOVEL)

E
A

Arm Foot Arm Foot M183-01-058

Bucket Side Boom Side
Arm Cylinder
Bottom Pin Bucket Cylinder
Arm Foot
Rod Side
Level Cylinder Bucket Side
Bottom Side

Boom Foot Boom Cylinder M142-07-047 M142-07-048

Bottom Side Bucket Cylinder Level Cylinder Arm Cylinder
Bottom Side Rod Side Rod Pin
Development D
Development E

Dump Cylinder
Rod Pin

Bucket
Joint Pin

M142-07-042
Dump Cylinder
M113-07-012
Bottom Pin

W4-1-19
 FRONT ATTACHMENT / Front Attachment

(Blank)

W4-1-20
 FRONT ATTACHMENT / Cylinder

REMOVE AND INSTALL CYLINDER

CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and eyes,
causing serious injury. Avoid
this hazard by relieving
pressure before disconnecting
hydraulic lines.
2. Hydraulic oil may be hot after
operation. Hot hydraulic oil
may spurt out, possibly
causing severe burns. Be sure
to wait for oil to cool before
starting any repair work.
3. The hydraulic oil tank cap may
fly off if removed without
releasing internal pressure
first. Push the air release
valve on top of the hydraulic
oil tank to release any
remaining pressure.

Preparation
1. Park the machine on a solid and level surface with
the front attachment positioned as illustrated
below.

Wooden Blocks W183-04-02-003

W183-04-02-002

Wooden Blocks

W4-2-1
 FRONT ATTACHMENT / Cylinder

Remove and Install Boom Cylinder B

Backhoe

B W183-04-02-003

Loading Shovel

W183-04-02-002

A: Cylinder Rod Side Greasing Hose B: Cylinder Bottom Side

1 6

Hydraulic Hose

Greasing Hose
Hydraulic Hose

10
W183-04-02-013

3 W183-04-02-004

9
1 5
2
7
4
8

10

10
Section A W166-04-01-015 Section B W183-04-02-014

1 - Pin (2 Used) 4 - Plate (2 Used) 7 - Bolt (㈐ Used) 9 - Plate (2 Used)

2 - Spacer (2 Used) 5 - Bolt (㈐ Used) 8 - Spring Washer (4 Used) 10 - Boom Cylinder (2 Used)
3 - Spring Washer (4 Used) 6 - Pin (2 Used)

W4-2-2
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a

CAUTION: Pin (6) weight: 70 kg (150 Ib)
hammer, metal debris may fly,
causing personal injury.
Be sure to use proper safety 6. Remove bolts (7) (2 used), spring washers (8) (2
equipment. used) and plate (9) on the cylinder bottom side to
remove pin (6).
Removal
1. Disconnect greasing hoses (2 used for each one) 7. Hoist boom cylinder (10) by a crane to remove it.
from boom cylinders (10) (2 used). Then remove spacer (2).
ϖ 19 mm ϖ 30 mm

8. Remove boom cylinder (10) on the other side by

CAUTION: Boom cylinder weight: 1170 kg the same procedures.
(2580 Ibϒ
ϒ
Pin (1) weight: 70 kgϑ
ϑ150 Ibϒ
ϒ

2. While holding boom cylinder (10) by a crane,

remove bolts (5) (2 used), spring washers (3) (2
used), and plate (4) on the cylinder rod side. Drive
pin (1) in until pin (1) comes out of the cylinder rod
hole.
ϖ 30 mm

3. Remove pin (1) of boom cylinder (10) on the other

side by the same procedure.

4. Start the engine. Fully retract boom cylinder (10).

Secure the rod with a wire wound through the rod
hole so that boom cylinder (10) will not extend.

CAUTION: If the air breather cap on the

hydraulic oil tank is turned
quickly, the air breather cap may
fly off due to pressure remaining
inside. Slowly turn the air
breather cap and remove after
completely releasing any remai-
ning pressure.

5. Stop the engine. Operate the lever several times

to release the remaining pressure from the hy-
draulic circuit. Drain the air out from the hydraulic
oil tank and remove the hydraulic hoses (2 used)
from each boom cylinders (10) (2 Used).
Ӹ ϖ12 mm, 14 mm

W4-2-3
 FRONT ATTACHMENT / Cylinder

Backhoe

B W183-04-02-003

Loading Shovel

W183-04-02-002

A: Cylinder Rod Side Greasing Hose B: Cylinder Bottom Side

1 6

Hydraulic Hose

Greasing Hose
Hydraulic Hose

10
W183-04-02-013

3 W183-04-02-004

1 9
5
2
7
4
8

10

10
Section A W166-04-01-015 Section B W183-04-02-014

W4-2-4
 FRONT ATTACHMENT / Cylinder
Installation
8. Connect the greasing hoses (2 used for each side).
CAUTION: Boom cylinder weight: 1170kg ϖ 19 mm
(2580 Ib) ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)
Pin (6) weight: 70 kg (150 Ib)
9. Release any air remaining in the cylinder. (Refer
to page W4-2-50.)
1. While hoisting boom cylinder (10) by a crane,
align the cylinder bottom side pin hole with the
boom pin hole. Then, install spacer (2).

2. Install pin (6) and secure it with bolts (7) (2 used),

spring washers (8) (2 used), and plate (9).
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

3. Install the other side boom cylinder (10) by the

same procedure.

4. Connect the hydraulic hoses (2 used for each

side). Remove the wire securing the cylinder rod.
ϖ 12 mm
ϖ 140 N⋅m (14 kgf⋅m,101 Ibf⋅ft)
ϖ 14 mm
ϖ 210 N⋅m (21.5 kgf⋅m,155 Ibf⋅ft)

5. Hoist the cylinder rod by a crane and extend the

rod so that cylinder rod hole aligns with the main
frame hole.

CAUTION: Pin (1) weight: 70 kg (150 Ib)

6. Insert pin (1) into the pin hole at the cylinder rod
side and install bolts (5) (2 used), spring washers
(3) (2 used) and plate (4).
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

7. Install the other side boom cylinder (10) by the

same procedure.

W4-2-5
 FRONT ATTACHMENT / Cylinder
Remove and Install Arm Cylinder
(Backhoe)
B

W183-04-02-003

A: Cylinder Rod Side B: Cylinder Bottom Side

2 Hydraulic Hose

Greasing Hose Greasing Hose

W183-04-02-016

Greasing Hose
W166-04-01-020
1
W183-04-02-001

4
2

3
5

Section A and B W142-04-01-015

1 - Pin (2 Used) 3 - Bolt (4 Used) 4 - Spring Washer (4 Used) 5 - Plate (2 Used)

2 - Arm Cylinder

W4-2-6
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a CAUTION: Pin weight: 80 kg (180 Ib)
hammer, metal debris may fly,
causing personal injury. 5. Remove bolts (3) (2 used) on the arm cylinder bottom
Be sure to use proper safety side, spring washers (4) (2 used) and plate (5), to
equipment. remove pin (1).
ϖ 30 mm
Removal
1. Disconnect the greasing hose from the arm 6. Remove arm cylinder (2) by a crane.
cylinder (2) rod side.
ϖ 19 mm

CAUTION: Arm cylinder weight: 1450 kg

(3200 Ib)
Pin weight: 80 kg (180 Ib)

2. While holding arm cylinder (2) by a crane, remove

bolts (3) (2 used) on the cylinder rod side, spring
washers (4) (2 used) and plate (5) to remove pin
(1).
ϖ 30 mm

3. Start the engine. Fully retract the arm cylinder (2).

Secure the rod with a wire wound through the rod
hole so that the arm cylinder will not extend.
Ȁ
CAUTION: If the air breather cap on the
hydraulic oil tank is turned quickly,
the air breather cap may fly off
due to pressure remaining inside.
Slowly turn the air breather cap
and remove after completely
releasing any remaining pressure.

4. Stop the engine. Operate the lever several times

to release the remaining pressure from the
hydraulic circuit. Then drain the air out from the
hydraulic oil tank. Loosen the hydraulic hoses (3
used) and greasing hose at bottom side. Then
remove them.
ϖ 12 mm, 14 mm
ϖ 19 mm

W4-2-7
 FRONT ATTACHMENT / Cylinder

W183-04-02-003

A: Cylinder Rod Side B: Cylinder Bottom Side

2 Hydraulic Hose

Greasing Hose Greasing Hose

W183-04-02-016

Greasing Hose
W166-04-01-020
1
W183-04-02-001

4
2

3
5

Section A and B W142-04-01-015

W4-2-8
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a 7. Connect the greasing hose to side pin (1) for arm
hammer, metal debris may fly, cylinder rod end.
causing personal injury. ϖ 19 mm
Be sure to use proper safety ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)
equipment.
8. Release any air remaining in arm cylinder (2).
Installation (Refer to W4-2-50.)

CAUTION: Arm cylinder weight: 1450 kg

(3200 Ib)
1. While hoisting arm cylinder (2) by a crane, align
the cylinder bottom side pin hole with the boom
bracket hole.

CAUTION: Pin weight: 80 kg (180 Ib)

2. Hoist and insert pin (1) into the cylinder bottom

side pin hole. Install bolts (3) (2 used), spring
washers (4) (2 used) and plate (5).
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

3. Reconnect the hydraulic hoses (3 used) and

greasing hose on the arm cylinder bottom.
ϖ 12 mm
ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)
ϖ 14 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
ϖ 19 mm
ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

4. While hoisting the cylinder rod by a crane, remove

the wire securing the cylinder rod.
Ȁ
5. Start the engine. Adjust the height while extending
the cylinder rod. Align the pin hole in the cylinder
rod side with that of the arm.

CAUTION: Pin weight: 80kg (180 Ib)

6. Insert pin (1) into the cylinder rod side pin hole.
Install bolts (3) (2 used), spring washers (4) (2 used)
and plate (5).
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

W4-2-9
 FRONT ATTACHMENT / Cylinder

Remove and Install Arm Cylinder

(Loading Shovel)

B
A

W183-04-02-002

A: Cylinder Rod Side B: Cylinder Bottom Side

Greasing Hose Hydraulic Hose
1 Greasing Hose

1
W183-04-02-017 1 W183-04-02-018

2
1
W183-04-02-008

4
2
5

W118-04-01-005
Section A and B

1 - Pin (2 Used) 3 - Spring Washer (4 Used) 5 - Plate (2 Used) 6 - Dust Seal (4 Used)
2 - Arm Cylinder 4 - Bolt (4 Used)

W4-2-10
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a CAUTION: Pin weight: 50 kg (110 Ib)
hammer, metal debris may fly,
causing personal injury. 6. Remove bolt (4) (2 used), spring washers (3) (2
Be sure to use proper safety used) and plate (5) on the arm cylinder bottom
equipment. side, then remove pin (1).
Removal ϖ 30 mm

7. Remove dust seals (6) (2 used). Remove arm

1. Disconnect the greasing hose from arm cylinder cylinder (2) by a crane.
(2) rod.
ϖ 19 mm

CAUTION: Arm cylinder weight: 980 kg

(2160 Ib)
Pin weight: 50 kg (110 Ib)

2. While holding arm cylinder (2) with a chainblock,

remove bolts (4) (2 used), spring washers (3) (2
used) and plate (5) on the cylinder rod side, and
remove pin (1).
ϖ 30 mm

3. Remove dust seals (6) (2 used).

4. Start the engine. Fully retract the arm cylinder (2).

Secure the rod with a wire wound through the rod
hole so that the arm cylinder will not extend.

CAUTION: If the air breather cap on the

hydraulic oil tank is turned
quickly, the air breather cap may
fly off due to pressure remaining
inside. Slowly turn the air
breather cap and remove after
completely releasing any
remaining pressure.

5. Stop the engine. Operate the lever several times

to release the remaining pressure from the
hydraulic circuit. Then drain the air out from the
hydraulic oil tank. Loosen and remove the
hydraulic hoses (3 used).
ϖ 12 mm, 14 mm
ϖ 19 mm

W4-2-11
 FRONT ATTACHMENT / Cylinder

B
A

W183-04-02-002

A: Cylinder Rod Side B: Cylinder Bottom Side

Greasing Hose Hydraulic Hose
Greasing
1

1
W183-04-02-017 1 W183-04-02-018

2
1
W183-04-02-008

4
2
5

W118-04-01-005
Section A and B

W4-2-12
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a CAUTION: Pin weight: 50 kg (110 Ib)
hammer, metal debris may fly,
causing personal injury. Be sure 6. Insert pin (1) into the cylinder rod side pin hole.
to use proper safety equipment. Install plate (5), spring washers (3) (2 used), and
bolts (4) (2 used).
Installation
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
CAUTION: Arm cylinder weight: 980 kg
(2160 Ib) 7. Connect the greasing hose to arm cylinder (2) rod
end side pin (1).
1. While hoisting arm cylinder (2) with a chainblock, ϖ 19 mm
install dust seals (6) (2 used) into the cylinder ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)
bottom side pin hole, align the cylinder bottom
side pin hole with the boom bracket hole.
8. Release any air remaining in arm cylinder (2).

CAUTION: Pin weight: 50 kg (110 Ib) (Refer to page W4-2-50)

2. Hoist and insert pin (1) into the cylinder bottom

side pin hole. Install plate (5), spring washers (3)
(2 used), and bolts (4) (2 used).
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

3. Reconnect the hydraulic hoses (3 used) and

greasing hose on the arm cylinder bottom.
ϖ 12 mm
ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)
ϖ 14 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
ϖ 19 mm
ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

4. While hoisting the cylinder rod with a chainblock,

remove the wire securing the cylinder rod.
Ȁ
5. Install dust seals (6) (2 used) into the cylinder rod
hole.
Start the engine. Extend the rod so that cylinder
rod hole aligns with the arm cylinder pin hole.

W4-2-13
 FRONT ATTACHMENT / Cylinder

Remove and Install Bucket Cylinder

(Backhoe)

W183-04-02-003

A: Cylinder Rod Side B: Cylinder Bottom Side

Hydraulic Hose
9 10
10 Greasing Hose

5
Wooden Block

11 W166-04-01-008

1
W166-04-01-009

10
9 11 6
5 10
7

2, 3
1 8

Section A W118-04-01-021 Section B

W166-04-01-015

1 - Pin 4 - Stopper 7 - Bolt (2 Used) 10 - Bucket Cylinder

2 - Spring Washer (3 Used) 5 - Pin 8 - Plate 11 - Link B (2 Used)
3 - Bolt (3 Used) 6 - Spring Washer (2 Used) 9 - Link A

W4-2-14
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a CAUTION: Pin (5) weight: 60 kg (130 Ib)
hammer, metal debris may fly,
causing personal injury. 6. While holding bucket cylinder (10) by a crane,
Be sure to use proper safety remove bolts (7) (2 used) on the cylinder bottom
equipment. side, spring washers (6) (2 used) and plate (8) to
remove pin (5).
Removal
ϖ 30 mm
1. Disconnect the greasing hose from bucket
cylinder (10) bottom. 7. Remove bucket cylinder (10) by a crane.
ϖ 19 mm

2. Lay a wooden block between the arm and bucket

cylinder (10). Then, fasten link A (9) and links B
(11) (2 used) with a wire and chainblock so that
links B (11) (2 used) does not fall when pin (1) is
removed.

CAUTION: Bucket cylinder weight: 960 kg

(2120 Ib)
Pin (1) weight: 140 kg (310 Ib)

3. While holding bucket cylinder (10) by a crane,

remove bolts (3) (3 used) on the cylinder rod side,
spring washers (2) (3 used) and stopper (4) to
remove pin (1). When the pin is pulling out half
way, hoist by a crane to remove pin (1).
ϖ 30 mm

4. Start the engine. Fully retract bucket cylinder (10).

Fasten the rod with a wire wound through the rod
hole so that bucket cylinder (10) will not extend.

CAUTION: If the air breather cap on the

hydraulic oil tank is turned
quickly, the air breather cap may
fly off due to pressure remaining
inside. Slowly turn the air
breather cap and remove after
completely releasing any
remaining pressure.

5. Stop the engine. Operate the lever several times

to release the remaining pressure from the
hydraulic circuit. Then drain the air out from the
hydraulic oil tank. Remove the hydraulic hoses (3
used) at the cylinder bottom side.
ϖ 12 mmЕ14 mm

W4-2-15
 FRONT ATTACHMENT / Cylinder

W183-04-02-003

A: Cylinder Rod Side B: Cylinder Bottom Side

Hydraulic Hose
9 10
10 Greasing Hose

5
Wooden Block

11 W166-04-01-008

1
W166-04-01-009

10
9 11 6
5 10
7

2, 3
8
1

Section A W118-04-01-021 Section B

W166-04-01-015

W4-2-16
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a 6. Remove the wire and chainblock which fastening
hammer, metal debris may fly, links A and B to prevent links B (11) (2 used) from
causing personal injury. dropping. Start the engine and remove the
Be sure to use proper safety wooden block laid between arm and bucket
equipment. cylinder (10).

Installation 7. Release any air remaining in bucket cylinder (10).

(Refer to W4-2-50 ).

CAUTION: Bucket cylinder weight: 960 kg

(2120 Ib)

1. While hoisting bucket cylinder (10) by a crane,

align the cylinder bottom side pin hole with the
bucket cylinder bracket hole.

CAUTION: Pin (5) weight: 60 kg (130 Ib)

2. Insert pin (5) into the cylinder bottom side pin hole.
Install bolts (7) (2 used), spring washers (6) (2
used) and plate (8).
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

3. Reconnect the hydraulic hoses (3 used) and

greasing hose on to bucket cylinder (10) bottom
side.
ϖ 12 mm
ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)
ϖ 14 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
ϖ 19 mm
ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

4. Remove the wire fastening the cylinder rod. Start

the engine. Extend the rod. Hoist link A and link B
by a crane so that cylinder rod hole aligns with link
A and B pin holes.

CAUTION: Pin (1) weight: 140 kg (310 Ib)

5. Hoist and insert pin (1) into the cylinder rod side
pin hole. Install bolts (3) (3 used), spring washers
(2) (3 used) and stopper (4).
ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

W4-2-17
 FRONT ATTACHMENT / Cylinder

Remove and Install Bucket Cylinder

(Loading Shovel)

W183-04-02-002
A: Cylinder Rod Side B: Cylinder Bottom Side

Greasing Hose Hydraulic Hose

Greasing Hose

9
W183-04-02-018 9
1 2 W183-04-02-007 W183-04-02-020

10
6 2
7

3
8
9 1

4, 5

Section B
Section A W183-04-02-014
W142-04-01-013

1 - Pin (2 Used) 4 - Bolt (6 Used) 7 - Bolt ( 4 Used) 9 - Pin (2 Used)

2 - Bucket Cylinder (2 Used) 5 - Spring Washer (6 Used) 8 - Spring Washer (4 Used) 10 - Spacer (2 Used)
3 - Stopper (2 Used) 6 - Plate (2 Used)

W4-2-18
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a CAUTION: Pin (1) weight: 70 kg (150 Ib)
hammer, metal debris may fly,
causing personal injury.
6. While holding bucket cylinder (2) by a crane,
Be sure to use proper safety
remove bolts (4) (3 used), spring washers (5)
equipment.
(3 used) and stopper (3) on the cylinder bottom
side to remove pin (1).
Removal
1. Disconnect the greasing hose from bucket ϖ 24 mm
cylinder (2) rod.
7. Remove bucket cylinder (2) by a crane.
ϖ 19 mm
8. Remove cylinder on the other side by the same
CAUTION: Bucket cylinder weight: 920 kg procedure.
(2030 Ib)
Pin (9) weight: 50 kg (110 Ib)

2. While holding bucket cylinder (2) by a crane,

remove bolts (7) (2 used), spring washers (8) (2
used) and plate (6) on the cylinder rod side to
remove pin (9). Then, remove spacer (10).
ϖ 30 mm

3. Remove cylinder on the other side by the same

procedure.

4. Start the engine. Fully retract bucket cylinder (2).

Fasten the rod with a wire wound through the rod
hole so that bucket cylinder (2) will not extend.

CAUTION: If the air breather cap on the

hydraulic oil tank is turned
quickly, the air breather cap may
fly off due to pressure remaining
inside. Slowly turn the air
breather cap and remove after
completely releasing any remain-
ing pressure.

5. Stop the engine. Release any remaining air from

the hydraulic lines and oil tank.
Disconnect hydraulic hoses (4 used) from the
cylinder bottom side.
ϖ 12 mmЕ14 mmЕ17 mm

W4-2-19
 FRONT ATTACHMENT / Cylinder

W183-04-02-002
A: Cylinder Rod Side B: Cylinder Bottom Side

Greasing Hose Hydraulic Hose

Greasing Hose

9
W183-04-02-018 9 W183-04-02-020

1 2

W183-04-02-007

10
6 2
7

3
8
9 1

4, 5

Section B
W183-04-02-014
Section A W142-04-01-013

W4-2-20
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a CAUTION: Pin (9) weight: 50 kg (110 Ib)
hammer, metal debris may fly,
causing personal injury. 6. Insert pin (9) into the cylinder rod side pin hole.
Be sure to use proper safety Install bolts (7) (2 used), spring washers (8) (2
equipment. used) and plate (6).
Installation ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
CAUTION: Bucket cylinder weight: 920 kg 7. Install bucket cylinder (2) on the other side by the
(2030 Ib) same procedure.

1. While hoisting bucket cylinder (2) by a crane, align 8. Release any air remaining in bucket cylinder (2).
the cylinder bottom side pin hole. (Refer to W4-2-50.)

CAUTION: Pin (1) weight: 70 kg (150 Ib)

2. Insert pin (1) into pin hole, install bolts (4) (3 used),
spring washers (5) (3 used) and stopper (3).
ϖ 24 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)

3. Reconnect the hydraulic hoses (2 used for each

side) and greasing hose on the bucket cylinder.
ϖ 12 mm
ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)
ϖ 14 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
ϖ 17 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

4. While hoisting the cylinder rod by a crane, remove

the wire fastening the cylinder rod.

5. Install spacer (10) into the cylinder rod hole. Start

the engine. Extend the rod so that cylinder rod
hole aligns with boom pin hole.

W4-2-21
 FRONT ATTACHMENT / Cylinder

Remove and Install Level Cylinder

(Loading Shovel only)

B
A

W183-04-02-002

A: Cylinder Rod Side 1 B: Cylinder Bottom Side

Hydraulic Hose
Greasing Hose

2
W166-04-01-021
Greasing Hose
W166-04-01-024
W183-04-02-009

3
1 2 4

A and B Section W166-04-01-015

1 - Pin (2 Used) 3 - Spring Washer (4 Used) 5 - Plate (2 Used) 6 - Dust Seal (4 Used)
2 - Level Cylinder 4 - Bolt (4 Used)

W4-2-22
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a CAUTION: If the air breather cap on the
hammer, metal debris may fly, hydraulic oil tank is turned
causing personal injury. quickly, the air breather cap may
Be sure to use proper safety fly off due to pressure remaining
equipment. inside. Slowly turn the air
breather cap and remove after
Removal completely releasing any remain-
ing pressure.
IMPORTANT: Remove the arm cylinder before
removing level cylinder (2). (Refer to
W4-2-10 Remove and Install Arm 6. Stop the engine. Release any pressure remaining
Cylinder.) in the hydraulic lines and bleed air trapped in the
hydraulic oil tank.

1. Disconnect the greasing hoses (2 used) from level 7. Remove hydraulic hoses from boom cylinder bottom
cylinder (2). side (2 places at right and left), level cylinder (2)
ϖ 19 mm rod side and bottom side. (Refer to W4-2-2
Remove and Install Boom Cylinder.)
CAUTION: If the air breather cap on the ϖ 10 mm, 12 mm
hydraulic oil tank is turned
quickly, the air breather cap may CAUTION: Pin (1) weight: 50 kg (110 Ib )
fly off due to pressure remaining
inside. Slowly turn the air
breather cap and remove after 8. Remove bolts (4) (2 used), spring washers (3) (2
completely releasing any used) and plate (5) on level cylinder (2) bottom
remaining pressure. side, to remove pin (1).
ϖ 30 mm
2. Stop the engine. Operate the lever several times
to release the remaining pressure in the hydraulic 9. Remove dust seals (6) (2 used) from bottom side.
circuit. Then drain the air out from the hydraulic oil Remove level cylinder (2) by a crane.
tank.

3. Remove the hydraulic hoses from the bottom

cylinder rod side (2 places at right and left).
(Refer to W4-2-2 Remove and Install Boom
Cylinder.)
ϖ 12 m, 14 mm

CAUTION: Level cylinder (2) weight: 710 kg

(1570 Ib)
Pin (1) weight: 50 kg (110 Ib)

4. Hold level cylinder (2) with a chain block. Remove

bolts (4) (2 used), spring washers (3) (2 used),
and plate (5) from the rod side, and remove pin
(1).
ϖ 30 mm

5. Remove dust seals (6) (2 used) from rod side.

Start the engine and retract the cylinder. Secure
the rod with wire wound through the rod hole so
that the cylinder will not extend.

W4-2-23
 FRONT ATTACHMENT / Cylinder

B
A

W183-04-02-002

A: Cylinder Rod Side 1 B: Cylinder Bottom Side

Hydraulic Hose
Greasing Hose

2
W166-04-01-021
Greasing Hose
W166-04-01-024
W183-04-02-009

3
1 2 4

Section A and B W166-04-01-015

W4-2-24
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a CAUTION: Pin (1) weight: 50 kg (110 Ib)
hammer, metal debris may fly,
causing personal injury. 6. Install pin (1) on the cylinder rod side. Then, install
Be sure to use proper safety bolts (4) (2 used), spring washers (3) (2 used) and
equipment. plate (5).
Installation ϖ 30 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

CAUTION: Level cylinder weight: 710 kg 7. Connect the hydraulic hoses to the boom cylinder
(1570 Ib) rod sides (2 places at right and left). (Refer to
Pin (1) weight: 50 kg (110 Ib) W4-2-2 Remove and Install Boom Cylinder.)
ϖ 10 mm
1. Lift level cylinder (2) with a chain block, install dust ϖ 108 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)
seals (6) (2 used) into the cylinder bottom side pin ϖ 12 mm
hole and align the pin hole in the bottom side. ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

2. Install pin (1) into the cylinder bottom side and 8. Connect the greasing hoses (2 used) to level
install bolts (4) (2 used), spring washers (3) (2 cylinder (2).
used) and plate (5). ϖ 19 mm
ϖ 30 mm ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
9. Remove the air bleed plug from the cylinder to
3. Connect the hydraulic hoses to the boom cylinder bleed any air remaining in the cylinder. (Refer to
bottom sides (2 places at right and left), level W4-2-50.)
cylinder (2) rod side and cylinder bottom side.
(Refer to W4-2-2 Remove and Install Boom
Cylinder.)
ϖ 10 mm
ϖ 108 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)
ϖ 12 mm
ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

4. Remove the wire securing the cylinder rod. Install

dust seals (6) (2 used) into the cylinder rod side
pin hole.
ϖ 10 mm
ϖ 108 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)

5. Start the engine. Extend the rod so that cylinder

rod hole aligns with arm pin holes.

W4-2-25
 FRONT ATTACHMENT / Cylinder

Remove and Install Dump Cylinder

(Loading Shovel only)

Hydraulic Hose
1

W183-04-02-005 B

W183-04-02-010

Wooden Block

A: Cylinder Rod Side B: Cylinder Bottom Side

1 2
1

3
6

10 7

9
8
5
11
W183-04-02-011

Section A Section B

W166-04-01-028

1 - Dump Cylinder (2 Used) 4 - Socket Bolt (4 Used) 7 - Pin (2 Used) 10 - Grease Fitting (2 Used)
2 - Pin (2 Used) 5 - Lock Plate (2 Used) 8 - Stopper (2 Used) 11 - Spacer (4 Used)
3 - Grease Fitting (2 Used) 6 - Adapter (2 Used) 9 - Sems Bolt (6 Used)

W4-2-26
 FRONT ATTACHMENT / Cylinder

Removal

CAUTION: When driving the pin with a

hammer, metal debris may fly,
causing personal injury.
Dump Cylinder Front Cover
Be sure to use proper safety
equipment.

1. Lay a wooden block under the bucket.

Ȁ
2. Remove the front cover and side cover on the
bucket.
ϖ 17, 24 mm

3. Remove grease fitting (3) from pin (2) at dump

cylinder (1) rod side. W166-04-01-029
Front
ϖ 10 mm

CAUTION: Dump cylinder weight: 160 kg

(350 Ib)
Pin (2) weight: 20 kg (40 Ib)

4. Hold dump cylinder (1) with a chain block. Remove

socket bolts (4) (2 used), and lock plate (5) on the
rod side, and remove pin (2).
Side Cover
ϖ 17 mm

5. Start the engine and retract dump cylinder (1).

Secure the rod with a wire wound through the rod
hole so that the cylinder will not extend.

CAUTION: If the air breather cap on the

hydraulic oil tank is turned
quickly, the air breather cap may
fly off due to pressure remaining
inside. Slowly turn the air side
breather cap and remove after
completely releasing any remain- M113-07-012
ing pressure.

W4-2-27
 FRONT ATTACHMENT / Cylinder

Hydraulic Hose
1

W183-04-02-005
B

W183-04-02-010
Wooden
Block

A: Cylinder Rod Side B: Cylinder Bottom Side

1
1

10 7

9
8

11
W183-04-02-011

Section A Section B
W166-04-01-028

W4-2-28
 FRONT ATTACHMENT / Cylinder
6. Stop the engine. Release any pressure remain-
ing in the hydraulic lines and bleed air trapped
in the hydraulic oil tank. Disconnect the
hydraulic hoses (2 used) from the cylinder.
ϖ 8 mm

CAUTIONϖPin (7) weight: 20 kg (40 Ib)

7. Remove adapter (6) and grease fitting (10) from

pin (7) at the dump cylinder (1) bottom side.
ϖ 19 mm

8. While holding dump cylinder (1) by a crane,

remove sems bolts (9) (3 used), and stopper (8)
from the cylinder bottom. Remove pin (7)
completely. Remove dump cylinder (1) by a crane.
ϖ 19 mm

9. Remove spacers (11) (2 used) from the dump

cylinder (1) bottom side.

10. Remove dump cylinder (1) on the other side by

the same procedure.

W4-2-29
 FRONT ATTACHMENT / Cylinder

Hydraulic Hose
1

W183-04-02-005
B

W183-04-02-010
Wooden
Block

A: Cylinder Rod Side B: Cylinder Bottom Side

1 2
1

6
10 7
4
9

5 8
11
W183-04-02-011
Section A Section B

W166-04-01-028

1 - Dump Cylinder (2 Used) 4 - Socket Bolt (4 Used) 7 - Pin (2 Used) 10 - Grease Fitting (2 Used)
2 - Pin (2 Used) 5 - Lock Plate (2 Used) 8 - Stopper (2 Used) 11 - Spacer (4 Used)
3 - Grease Fitting (2 Used) 6 - Adapter (2 Used) 9 - Sems Bolt (6 Used)

W4-2-30
 FRONT ATTACHMENT / Cylinder

CAUTION: When driving the pin with a

hammer, metal debris may fly,
causing personal injury.
Be sure to use proper safety
equiment.

Installation

CAUTION: Dump cylinder weight: 160 kg

(350 Ib)
Pin (7) weight: 20 kg (40 Ib)

1. While lifting dump cylinder (1) by a chain block,

align the pin holes at the bottom side. Install
spacers (11) (2 used) into the cylinder bottom
side.

2. Install pin (7) into the cylinder bottom side.

Install sems bolts (9) (3 used) and stopper (8).
ϖ 19 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)

3. Install adapter (6) and grease fitting (10) onto

pin (7) at dump cylinder (1) bottom side.
ϖ 19 mm
ϖ 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)

4. Connect the hydraulic hoses (2 used) to dump

cylinder (1).
ϖ 8 mm
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

5. Hoist the rod side of dump cylinder (1) by a

chain block. Then remove the wire to be
secured the rod. Start the engine and extend
the rod. Align the pin hole in cylinder rod side.

W4-2-31
 FRONT ATTACHMENT / Cylinder

Hydraulic Hose
1

W183-04-02-005
B

W183-04-02-010

Wooden Block

A: Cylinder Rod Side B: Cylinder Bottom Side

1 2

5
W183-04-02-011

Section B
Section A
W166-04-01-028

W4-2-32
 FRONT ATTACHMENT / Cylinder

Front Cover
CAUTIONϖ
ϖ Pin (2) weight: 20 kg (40 Ib)

6. Install pin (2) into the cylinder (1) rod side. Then,
install socket bolts (4) (2 used) and lock plate
(5).
ϖ 17 mm
ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

7. Install grease fitting (3) to the end face of pin (2)

on the cylinder rod side.
ϖ 10 mm
ϖ 5.9 N⋅m (0.6 kgf⋅m, 4.3 Ibf⋅ft)
W166-04-01-029
Front
8. Install dump cylinder (1) on the other side by the
same procedures.

9. Start the engine and remove the wooden block

laid under the bucket.

10. Remove the air bleed plug from the cylinder to

bleed air remaining in the cylinder. (Refer to Front cover
W4-2-50.)

11. Install the front cover and side cover on the

cylinder rod side.
ϖ 17 mm
ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
ϖ 24 mm
ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)

Side

M113-07-012

W4-2-33
 FRONT ATTACHMENT / Cylinder
(Blank)

W4-2-34
 FRONT ATTACHMENT / Cylinder

DISASSEMBLE CYLINDER
Boom Cylinder

Arm Cylinder 19
15
Bucket Cylinder
16
(Loading Shovel Only)
17 1
20
Dump Cylinder
(Loading Shovel Only) 17
16

21
22 14
13

23

2
3

4
7
8
9
10
11
12
5
6

W183-04-02-029

1- Cylinder Rod 7- Slide Ring 13 - Set Screw 19 - Cushion Bearing

2- Wiper Ring 8- Backup Ring 14 - Steel Ball 20 - Seal Ring
3- Socket Bolt (8 Used) 9- U-Ring 15 - Piston 21 - Shim
4- Cylinder Head 10 - Buffer Ring 16 - Slide Ring (2 Used) 22 - Nut
5- Backup Ring 11 - Bushing 17 - Slide Ring (2 Used) 23 - Cylinder Tube
6- O-Ring 12 - Retaining Ring

W4-2-35
 FRONT ATTACHMENT / Cylinder
Bucket Cylinder
(Backhoe)

19
15

16

17 1
20

17
16

22
14
13

23

2
3

4
7
8
9
10
11
12
5
6

W183-04-02-021

1- Cylinder Rod 7- Slide Ring 12 - Retaining Ring 17 - Slide Ring (2 Used)

2- Wiper Ring 8- Backup Ring 13 - Set Screw 19 - Cushion Bearing
3- Socket Bolt (8 Used) 9- U-Ring 14 - Steel Ball 20 - Seal Ring
4- Cylinder Head 10 - Buffer Ring 15 - Piston 22 - Nut
5- Backup Ring 11 - Bushing 16 - Slide Ring (2 Used) 23 - Cylinder Tube
6- O-Ring

W4-2-36
 FRONT ATTACHMENT / Cylinder
Level Cylinder
(Loading Shovel)

16

17

20 17

16 1
15

14
21
13
22

23

2
3

5
6

8
9
10

11

12

W183-04-02-022
1- Cylinder Rod 7- Slide Ring 12 - Retaining Ring 17 - Slide Ring (2 Used)
2- Wiper Ring 8- Backup Ring 13 - Set Screw 20 - Seal Ring
3- Socket Bolt (8 Used) 9- U-Ring 14 - Steel Ball 21 - Shim
4- Cylinder Head 10 - Buffer Ring 15 - Piston 22 - Nut
5- Backup Ring 11 - Bushing 16 - Slide Ring (2 Used) 23 - Cylinder Tube
6- O-Ring

W4-2-37
 FRONT ATTACHMENT / Cylinder
Disassemble Cylinder

Boom Cylinder

19
15

16

17 1
20

17

16

21
22 14
13

23

2
3

4
7
8
9
10
11
12
5
6

W183-04-02-029

1- Cylinder Rod 7- Slide Ring 13 - Set Screw 19 - Cushion Bearing

2- Wiper Ring 8- Backup Ring 14 - Steel Ball 20 - Seal Ring
3- Socket Bolt (8 Used) 9- U-Ring 15 - Piston 21 - Shim
4- Cylinder Head 10 - Buffer Ring 16 - Slide Ring (2 Used) 22 - Nut
5- Backup Ring 11 - Bushing 17 - Slide Ring (2 Used) 23 - Cylinder Tube
6- O-Ring 12 - Retaining Ring

W4-2-38
 FRONT ATTACHMENT / Cylinder
Disassemble Cylinder

CAUTION: Cylinder rod (1) weight:

• Be sure to thoroughly read all “Precautions for
Disassembly and Assembly” on page W1-1-1 Loading Shovel Backhoe
before starting the disassembly work. Boom: 650 kg 660 kg
(1430 Ib) (1460 Ib)
• The cylinder structure are similar, so the boom Arm: 540 kg 800 kg
cylinder disassembly procedure is described as (1190 Ib) (1760 Ib)
an example for all cylinders. Bucket: 520 kg 610 kg
(1150 Ib) (1340 Ib)
The disassembly procedure below starts on the 640 kg(BE)
premise that the hydraulic lines and the line (1410 Ib)
securing bands have been removed. Level: 390 kg (860 Ib)
Dump: 100 kg (220 Ib)

CAUTION: Cylinder weight: 2. Fully extend cylinder rod (1). Secure the rod end
Loading Shovel Backhoe by a crane. Remove socket bolts (3) from
Boom cylinder: 1170 kg 1170 kg cylinder head (4).
(2580 Ib) (2580 Ib)
Arm cylinder: 980 kg 1450 kg Ȁ Loading Shovel
(2160 Ib) (3200 Ib) ϖ Boom, Level 27 mm
Bucket cylinder:920 kg 1090 kg ϖ Arm 24 mm
(2030 Ib) (2400 Ib) ϖ Bucket 22 mm
1170 kg(BE)
ϖ Dump 17 mm
(2580 Ib)
Ȁ Backhoe
ϖ Boom, Bucket 27 mm
Level cylinder: 710 kg (1570 Ib)
Dump cylinder: 160 kg (350 Ib) ϖ Arm 24 mm

1. Hoist and horizontally secure the cylinder on a IMPORTANT: When removing cylinder rod (1), be
work bench by a crane. Then, drain the sure to pull cylinder rod (1) straight
hydraulic oil from the cylinder. out so as not to damage the sliding
surface.

3. While tapping cylinder head (4) with a plastic

hammer, remove cylinder head (4) along with
cylinder rod (1) from cylinder tube (23).

4. Secure cylinder rod (1) on special tool (ST 5908).

W102-04-02-027 Put matching marks on the end faces of cylinder
rod (1) and nut (22).
ST 5908

W158-04-02-022

W4-2-39
 FRONT ATTACHMENT / Cylinder

19
15

16

17 1
20

17

16

21
22 14
13

4
7
8
9
10
11
12
5
6

W183-04-02-029

W4-2-40
 FRONT ATTACHMENT / Cylinder
5. Remove set screw (13), steel ball (14). 8. Remove cushion bearing (19) and cylinder head
(4) from cylinder rod (1).
NOTE: After set screw (13) was installed, two
places were crimped. Remove the NOTE: There is no cushion bearing (19) in level
crimped places with a grinder to loosen cylinder (Loading shovel).
set screw (13).
9. Remove wiper ring (2), slide ring (7), backup
Loading Shovel ring (8), U-ring (9) and buffer ring (10) from
ϖ Boom, Level 17 mm cylinder head (4).
ϖ Arm, Bucket 14 mm
ϖ Dump 10 mm

Backhoe 10. Remove retaining ring (12) and bushing (11)

from cylinder head (4).
ϖ Boom, Arm, Bucket 17 mm

6. Using special tool (ST 5908) for disassembling

and assembling cylinder, remove nut (22) and 11. Remove O-ring (6) and backup ring (5) from
piston (15). cylinder head (4).
Remove nut (22), then remove shim (21) from
cylinder rod (1).
Ȁ
Ȁ Nut turning tool:
Loading Shovel Backhoe
Boom: 180 mm (7.1 in) 180 mm (7.1 in)
(ST 3278) (ST 3278)
Arm: 155 mm (6.1 in) 200 mm (7.9 in)
(ST 3285) (ST 3279)
Bucket: 155 mm (6.1 in) 180 mm (7.1 in)
(ST 3285) (ST 3278)

Level: 180 mm (7.1 in) (ST 3278)

Dump: 95 mm (3.7 in) (ST 3075)

NOTE: There is no shim (21) in bucket cylinder

(Backhoe).
ST 5908

W158-04-02-022

7. Remove slide rings (16 and 17) (2 used each

one) and seal ring (20) from piston (15).

W4-2-41
 FRONT ATTACHMENT / Cylinder

ASSEMBLE CYLINDER
Boom Cylinder
2
1
Arm Cylinder 7
10
8
Bucket Cylinder 11

(Loading shovel only) 9

12
3
Dump Cylinder 5, 6
(Loading shovel only) 4

23

19

16

17
15
20
17
21 16
14 22
13

W166-04-02-020
1- Cylinder Rod 7- Slide Ring 13 - Set Screw 19 - Cushion Bearing
2- Wiper Ring 8- Backup Ring 14 - Steel Ball 20 - Seal Ring
3- Socket Bolt (8 Used) 9- U-Ring 15 - Piston 21 - Shim
4- Cylinder Head 10 - Buffer Ring 16 - Slide Ring (2 Used) 22 - Nut
5- Backup Ring 11 - Bushing 17 - Slide Ring (2 Used) 23 - Cylinder Tube
6- O-Ring 12 - Retaining Ring

W4-2-42
 FRONT ATTACHMENT / Cylinder
Level Cylinder Bucket Cylinder
(Loading Shovel) (Backhoe)

2
2 1
1 7
7 10
8
10 11
8
11 9
9 12
12 3
3 5, 6
5, 6
4
4

23
23

19

16

16 17
15
17 20

15 20 17
16
17 14
21 22
16
13
14 22
13

W166-04-02-019
W166-04-02-020
1- Cylinder Rod 7- Slide Ring 13 - Set Screw 19 - Cushion Bearing
2- Wiper Ring 8- Backup Ring 14 - Steel Ball 20 - Seal Ring
3- Socket Bolt (8 Used) 9- U-Ring 15 - Piston 21 - Shim
4- Cylinder Head 10 - Buffer Ring 16 - Slide Ring (2 Used) 22 - Nut
5- Backup Ring 11 - Bushing 17 - Slide Ring (2 Used) 23 - Cylinder Tube
6- O-Ring 12 - Retaining Ring

W4-2-43
 FRONT ATTACHMENT / Cylinder

Assemble Cylinder
Boom Cylinder

2
1
7
10
8
11
9
12
3

5, 6
4

23

19

16

17
15
20
17
21
16
14 22
13

W166-04-02-020
1- Cylinder Rod 7- Slide Ring 13 - Set Screw 19 - Cushion Bearing
2- Wiper Ring 8- Backup Ring 14 - Steel Ball 20 - Seal Ring
3- Socket Bolt (8 Used) 9- U-Ring 15 - Piston 21 - Shim
4- Cylinder Head 10 - Buffer Ring 16 - Slide Ring (2 Used) 22 - Nut
5- Backup Ring 11 - Bushing 17 - Slide Ring (2 Used) 23 - Cylinder Tube
6- O-Ring 12 - Retaining Ring

W4-2-44
 FRONT ATTACHMENT / Cylinder
Assemble Cylinder

CAUTION: Cylinder rod (1) weight:

1. Press bushing (11) into cylinder head (4) using
the special tool. Install retaining ring (12) in Loading Shovel Backhoe
cylinder head (4). Boom: 650 kg 660 kg
(1430 Ib) (1460 Ib)
Bushing pressing tool: Arm: 540 kg 800 kg
Dump (loading shovel only): (1190 Ib) (1760 Ib)
85 mm(ST 8020) Bucket: 520 kg 610 kg
(1150 Ib) (1340 Ib)
IMPORTANT: Install buffer ring (10) with the lip 640 kg(BE)
facing the cylinder bottom. (1410 Ib)
Level: 390 kg (860 Ib)
2. Install buffer ring (10) into cylinder head (4). Dump: 100 kg (220 Ib)

IMPORTANT: Install U-ring (9) with the lip facing 9. Secure cylinder rod (1) on special tool (ST 5908).
the cylinder bottom. Ȁ ST5908

3. After installing backup ring (8) into cylinder head

(4), install U-ring (9).

4. Install slide ring (7) in cylinder head (4).

IMPORTANT: Install wiper ring (2) with the lip

facing outward. W158-04-02-022

10. Wrap the threaded part on cylinder rod (1) with

5. Press wiper ring (2) into cylinder head (4) using protecting tape.Rotate and install the cylinder
the special Tool. head (4) assembly onto cylinder rod (1).
Ȁ
Ȁ Wiper ring pressing tool IMPORTANT: Install cushion bearing (19) with the
Ȁ Dump (loading shovel only) slit facing the cylinder head (4).
85 mm(ST 8020)
11. Install cushion bearing (19) onto cylinder rod (1).
6. Install O-ring (6) and backup ring (5) around
cylinder head (4).
NOTE: There is no cushion bearing (19) in level
7. In order to prevent the seal ring from going into cylinder (loading shovel).
other slit, install seal ring (20) around piston 19
(15) with a bamboo spatula as a special tool.

IMPORTANT: Install slide rings (16 and 17) with Slit

their slits positioned in 180°°
W183-04-02-012
opposite each other.
12. Install piston (15) onto cylinder rod (1).
8. Install slide ring (16) (2 used) and (17) (2 used)
onto piston (15).

W4-2-45
FRONT ATTACHMENT / Cylinder

19

15

21

22

W166-04-02-020

W4-2-46
 FRONT ATTACHMENT / Cylinder
13. Install shim (21) and nut (22) onto cylinder rod
CAUTION: If they haven’t been thoroughly
(1).
degreased, nut (22) will be over
tightened because there is oil for
NOTE: Shim (21) is not installed on bucket lubricating, causing cushion
cylinder (backhoe). bearing (19) expanding.

14. Tighten nut (22). (3) After tightening nut (22) to the specified torque,
Nut turning tool: measure the contour dimensions of cushion
Backhoe bearing (19) at 4 places of A, B, C and D as
Boom 180 mm (ST3278) shown in figure E. Make sure the dimensions
ϖ38000 N⋅m (3880 kgf⋅m, 27940 Ibf⋅ft) are within the specified range.
Arm 200 mm (ST3279)
ϖ68650 N⋅m (7000 kgf⋅m, 50400 Ibf⋅ft) IMPORTANT: If any dimensions are out of the
Bucket 180 mm (ST3278) specified range, disassemble it
ϖ43050 N⋅m (4390 kgf⋅m, 31610 Ibf⋅ft) again and then assemble from step
Loading Shovel 1.
Boom 180 mm (ST3278)
ϖ 38000 N⋅m (3880 kgf⋅m, 27940 Ibf⋅ft) Figure E
Arm 155 mm (ST3285)
ϖ 40300 N⋅m (4110 kgf⋅m, 29590 Ibf⋅ft) A B C D
Bucket 155 mm (ST3285)
ϖ 26200 N⋅m (2670 kgf⋅m, 19220 Ibf⋅ft)
Level 180 mm (ST3278)
ϖ 38000 N⋅m (3880 kgf⋅m, 27940 Ibf⋅ft)
Dump 95 mm (ST3075)
ϖ 9800 N⋅m (1000 kgf⋅m, 7200 Ibf⋅ft)

Precautions for tightening nut (22)

IMPORTANT: The contour dimensions of cushion

bearing (19) may be different before W115-04-01-093

and after tightening the nut.

Therefore, when tightening nut (22),
Standard Dimensions Unit: mm (in)
be sure to check that the contour Cylinder Before Tightening After Tightened
dimensions are in the specified Boom -0.235 -0.009 -0.193 -0.008
Φ168 (6.6 ) Φ168 (6.6 )
range. (Loading Shovel) -0.260 -0.010 -0.218 -0.009
Arm -0.340 -0.013 -0.284 -0.011
Φ198 (7.8 ) Φ198 (7.8 )
(Backhoe) -0.369 -0.015 -0.313 -0.012
(1) Measure the contour dimensions of cushion
Arm -0.235 -0.009 -0.188 -0.007
bearing (19) only at 4 places of A, B, C and D. (Loading Shovel)
Φ158
-0.260
(6.2
-0.010
) Φ158
-0.213
(6.2
-0.008
)
Make sure that the dimensions are in the Bucket -0.270 -0.011 -0.227 -0.009
Φ178 (7.0 ) Φ178 (7.0 )
specified range and no deformation on them. (BE Backhoe) -0.295 -0.012 -0.252 -0.010
Bucket -0.170 -0.007 -0.140 -0.005
Φ158 (6.2 ) Φ158 (6.2 )
(Loading Shovel) -0.195 -0.008 -0.165 -0.006
IMPORTANT: The parts out of specified range or
Bucket -0.270 -0.011 -0.226 -0.009
deformed should be replaced with (STD Backhoe)
Φ168
-0.295
(6.6
-0.012
) Φ168
-0.251
(6.6
-0.010
)
new ones. Dump -0.170 -0.007 -0.135 -0.005
Φ91 (3.6 ) Φ91 (3.6 )
(Loading Shovel) -0.192 -0.008 -0.157 -0.006

(2) Piston rod (1), nut (22), piston (15) and

cushion bearing (19) should be thoroughly
cleaned and thoroughly degreased in
kerosene or diluent.

W4-2-47
FRONT ATTACHMENT / Cylinder

23

14 22
13

W166-04-02-020

W4-2-48
 FRONT ATTACHMENT / Cylinder
15. Install steel ball (14) into nut (22) and secure the 19. Install cylinder head (4) into cylinder tube (23).
ball with set screw (13). Tighten socket bolts (3) (8 used).

ϖ 17 mm Backhoe
ϖ 180 N⋅m (18.4 kgf⋅m, 132 Ibf⋅ft) ϖ 27 mm (Boom, Bucket)
ϖ 14 mm ϖ 2460 N⋅m (251 kgf⋅m, 1810 Ibf⋅ft)
ϖ 97 N⋅m (9.89 kgf⋅m, 71 Ibf⋅ft) ϖ 24 mm (Arm)
ϖ 10 mm ϖ 1910 N⋅m (195 kgf⋅m, 1410 Ibf⋅ft)
ϖ 57 N⋅m (5.8 kgf⋅m, 42 Ibf⋅ft)
Loading Shovel
16. Crimp two places around set screw (13) top ϖ 27 mm (Boom, Level)
fringe to prevent set screw (13) from loosening. ϖ 2460 N⋅m (251 kgf⋅m, 1810 Ibf⋅ft)
ϖ 24 mm (Arm)
ϖ 1910 N⋅m (195 kgf⋅m, 1410 Ibf⋅ft)
CAUTION: Cylinder tube (23) weight: ϖ 22 mm (Bucket)
Loading Shovel Backhoe ϖ 1590 N⋅m (162 kgf⋅m, 1170 Ibf⋅ft)
Boom: 520 kg 520 kg ϖ 17 mm (Dump)
(1150 Ib) (1150 Ib)
ϖ 640 N⋅m (65.26 kgf⋅m, 470 Ibf⋅ft)
Arm: 440 kg 650 kg
(970 Ib) (1430 Ib)
Bucket: 400 kg 480 kg
(880 Ib) (1060 Ib)
530 kg(BE)
(1170 Ib)
Level: 320 kg (710 Ib)
Dump: 60 kg (130 Ib)

17. Horizontally secure cylinder tube (23) on a work

bench.

CAUTION: Cylinder rod (1) weight:

Loading Shovel Backhoe
Boom: 650 kg 660 kg
(1430 Ib) (1460 Ib)
Arm: 540 kg 800 kg
(1190 Ib) (1760 Ib)
Bucket: 520 kg 610 kg
(1150 Ib) (1340 Ib)
640 kg(BE)
(1410 Ib)
Level: 390 kg (860 Ib)
Dump: 100 kg (220 Ib)

IMPORTANT: When installing cylinder rod (1)

into cylinder tube (23), take care to
correctly align them and install the
rod staight so as not to damage
rings.

18. Insert cylinder rod (1) into cylinder tube (23).

W4-2-49
 FRONT ATTACHMENT / Cylinder

AIR BLEEDING PROCEDURE

3. Remove the rubber cap. Then remove the air
NOTE: The methods to bleed air from loading
bleeding plug.
shovel front are similar.
ϖ 19 mm
CAUTION: Hydraulic fluid under pressure
4. Bleed air till oil seeps out from the hole.
can penetrate the skin or eyes
causing serious injury. Avoid 5. Install the air bleeding plug. Then install the
this hazard by relieving rubber cap.
pressure before disconnecting ϖ 19 mm
any hydraulic lines. ϖ 44±2.9 N⋅m
Hydraulic oil becomes hot
(4.5±0.3 kgf⋅m, 32.5±2.2 Ibf⋅ft)
during operation. Disconnecting
hydraulic lines soon after
operation can result in severe
burns. Wait for the oil and
components to cool before
starting any repair work.

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

the bucket to the ground.

2. Stop the engine. Move all control levers to

release pressure remaining in the system.
Air Bleeding Plug Air Bleeding Plug
(Arm Cylinder) (Boom Cylinder)

Air Bleeding Plug

(Bucket Cylinder)

Air Bleeding Plug Air Bleeding Plug

(Boom Cylinder) (Level Cylinder) W183-04-02-003

Air Bleeding Plug

(Boom Cylinder)
Air Bleeding Plug
(Bucket Cylinder)

Air Bleeding Plug

(Dump Cylinder)

Air Bleeding Plug

(Arm Cylinder)

W183-04-02-006

W4-2-50
 FRONT ATTACHMENT / Cylinder

MAINTENANCE STANDARD

Cylinder Tube
1. Tube Section (a) a b

• Check if any score is present on both outer and

inner tube surfaces.

2. Pin and Bushing Section (b) A B

• Check if bore dia. (B) wear is 0.5 mm or more

than specification.
• Check if any score is present on the bore W145-04-01-015
surfaces.
d c Piston
IMPORTANT: Take extra care to check the tube
bore as it is very difficult.

Piston Rod
1. Rod Section (c) D C
• Place two V-blocks 1 m apart on level ground.
Lay the cylinder rod across the V-blocks. Rotate
the rod one turn and measure the rod deflection
using a dial gauge. Measure the deflection in W166-04-02-023

three positions. If one measured deflection is Dial Gauge

0.5 mm or more, replace the rod. Cylinder Rod
Check if the rod is bent 0.5 mm or more at
length of per 1 m.
• Check if the outer diameter (C) wear is 0.02 mm
or more at length of per 200 mm.
• Check if any score is present on the surface.
• Check if the surface is rusting. W166-04-02-022

• Check if the cushion installing section is

1m
damaged.
V Block
2. Pin Bushing Bore Section (d)
• Check if the bushing bore (D) wear is 0.2 mm or
more than specification.
• Check if the bore is scored.

W4-2-51
 FRONT ATTACHMENT / Cylinder
Hydraulic Pipe e f
1. Pipe (e) e f
• Check if 0.1 mm or deeper score is present on
the contact surface.
• Check if the pipe is deformed or damaged.

2. Socket Bolt (f)

• Check if the bolt is rusting.
• Check if the threads are damaged. g
g
3. O-Ring (g)
• Be sure to replace with new one after T182-05-02-004
disassembling.

Piston and Cylinder Head

• Check if the exterior and/or interior is scored.
• Check if the groove is scored.
• Check if seals are damaged and if internal oil
leakage exists.
• Replace bushing if the base metal is exposed
on the slide surface.

Standard Dimension List

Unit: mm (in)
Loading Shovel Backhoe
Boom Level Arm Bucket Dump Boom Arm Bucket
Cylinder Tube Inner 230 +0.072 230 +0.072
215
+0.072
200
+0.072
140
+0.063
230
+0.072
260
+0.081
230
+0.072
(BE)
0 0 0 0 0 0 0 0
Dia.(A) +0.003
(9.1 0 )
+0.003 +0.003 +0.003 +0.003 +0.002 +0.003 +0.003 +0.072
(9.1 0 ) (9.1 0 ) (8.5 0 ) (7.9 0 ) (5.5 0 ) (9.10 ) (10.2 0 ) 240 0
+0.003
(9.4 0 )
Cylinder Tube Bushing 160 +0.006
150
+0.25
150
+0.25
130
+0.25
90
+0.25
160
+0.006
170
+0.25
150
+0.25
-0.071 +0.05 +0.05 +0.05 +0.05 -0.071 +0.05 +0.05 (BE)
Bore Dia. (B) +0.0098
(5.9 +0.0020 )
+0.0002 +0.0098 +0.0098 +0.0098 +0.0098 +0.0002 +0.0098 +0.25
(6.3 -0.0028 ) (5.9 +0.0020 ) (5.9 +0.0020 ) (5.1
+0.0020 ) (3.5 +0.0020 ) (6.3 -0.0028 ) (6.7 +0.0020 ) 150 +0.05
+0.0098
(5.9 ) +0.0020
Rod Dia. (C) 160 -0.014 160 -0.014 150 -0.014 150 -0.014 85 -0.012 160 -0.014 180 -0.014 160 -0.014
-0.032 -0.032 -0.032 -0.032 -0.032 -0.032 -0.032 -0.032 (BE)
Recommended -0.0006
O.D size after Re-plating (7.1 -0.0013 )
-0.0006 -0.0006 -0.0006 -0.0006 -0.0005 -0.0006 -0.0006 -0.014
(6.3 -0.0013 ) (6.3 -0.0013 ) (5.9 -0.0013 ) (5.9 -0.0013 ) (3.3 -0.0013 ) (6.3 -0.0013 ) (7.1-0.0013 ) 170 -0.032
-0.0006
(6.7 -0.0013 )
Pistion Rod Bushing Bore 160 +0.25
150
+0.25
150
+0.25
130
+0.006
90
+0.25
160
+0.25
170
+0.25
160
+0.25
(BE)
+0.05 +0.05 +0.05 -0.071 +0.05 +0.05 +0.05 +0.05
Dia. (D) +0.0098
(6.3 +0.0020 )
+0.0098 +0.0098 +0.0098 +0.0002 +0.0098 +0.0098 +0.0098 +0.25
(6.3 +0.0020 ) (5.9 +0.0020 ) (5.9 +0.0020 ) (5.1
-0.0028 ) (3.5 +0.0020 ) (6.3 +0.0020 ) (6.7 +0.0020 ) 160 +0.05
+0.0098
(6.3 +0.0020 )

W4-2-52
 FRONT ATTACHMENT / Bushing and Point

REMOVE AND INSTALL BUSHING

Backhoe
d

a W142-04-01-024
Bucket
Link A
Arm 2 1 2
1 2

Bucket

a: Bucket and Arm W166-04-02-012

b: Link A and Bucket W166-04-02-016
Arm
1 2
Boom
Arm
2

2
Arm Cylinder

ʆ: Arm
W166-04-02-009

c: Arm and Boom W166-04-02-014

1 - Dust Seal 2 - Bushing

W4-3-1
 FRONT ATTACHMENT / Bushing and Point

e W142-04-01-024

1 2
2 1 2
Link B

Link B

2
Arm Link A
W166-04-02-015
W166-04-02-016
e: Arm and Link B f: Link A and Link B
1 2
Main Frame Main Frame

2
2
Boom Cylinder
Boom

g: Main Frame W166-04-02-009 h: Boom and Main Frame

W166-04-02-009

W4-3-2
 FRONT ATTACHMENT / Bushing and Point
Loading Shovel

b
c

d
W142-04-01-023

1 2

Rear Bucket Bucket

2
2
Dump Cylinder
Front Bucket
b: Bucket
a: Front Bucket and Rear Bucket W166-04-02-009 W166-04-02-009

1 2

Bucket Bucket

2 2
Arm

W166-04-02-018
Bucket Cylinder

C: Bucket and Arm d: Bucket W166-04-02-009

1 - Dust Seal 2 - Bushing

W4-3-3
 FRONT ATTACHMENT / Bushing and Point

W142-04-01-023

Arm 1 2
1 2
Main Frame
Boom

Boom
2

f: Boom and Main Frame

W166-04-02-009

e: Arm and Boom W166-04-02-014

Main Frame

Boom Cylinder
W166-04-02-009

g: Main Frame

W4-3-4
 FRONT ATTACHMENT / Bushing and Point
Removal
1. Remove dust seal (1) and bushing (2).

NOTE: In case the bushing is difficult to remove,

use a torch to remove it.

Installation
1. Cool bushing (2) in dry ice.

2. Install bushing (2) and dust seal (1).

Install bushing (2) using install tools.

Bushing Install Tools

Backhoe
Loading Shovel
a: Bucket Side .................................. ST 2842
a: Bucket (Front) Side ....................... ST 2840
Arm Side....................................... ST 2843
Bucket (Rear )Side........................ ST 2829
b: Link A Side ................................... ST 2836
b: Bucket .......................................... ST 2831
Bucket Side .................................. ST 2838
c: Bucket Side .................................. ST 2833
c: Arm Side....................................... ST 2841
Arm Side....................................... ST 2834
Boom Side .................................... ST 2839
d: Bucket .......................................... ST 2829
d: Arm............................................... ST 2839
e: Arm Side....................................... ST 2843
e: Arm Side....................................... ST 2840
Boom Side .................................... ST 2832
Link B Side ................................... ST 2837
f: Boom Side .................................... ST 2843
f: Link A Side ................................... ST 2843
Main Frame Side........................... ST 2832
Link B Side ................................... ST 2842
g: Main Frame................................... ST 2832
g: Main Frame .................................. ST 2832
h: Main Frame Side .......................... ST 2832
Boom Side .................................... ST 2843

W4-3-5
 FRONT ATTACHMENT / Bushing and Point

MAINTENANCE STANDARD
Pin and Bushing (Backhoe)

c e
a g
f

h
i

b d

k W142-04-01-024
j

W4-3-6
 FRONT ATTACHMENT / Bushing and Point

Unit: mm ( in)
Allowable
Part Name Location Specification
Limit
Pin Dia. 160 (6.3) 158. 5 (6.2)
Bushing Inner Dia. (Frame Side) 160 (6.3) 161.5 (6.4)
a: Boom and Main Frame Bushing Outer Dia. 180 (7.1) -
Bushing Inner Dia. (Boom Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Frame Side) 160 (6.3) 161.5 (6.4)
b: Boom Cylinder and Main Frame Bushing Outer Dia. 180 (7.1) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 161.5 (6.4)
Pin Dia. 160 (6.3) 158. 5 (6.2)
c: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 160 (6.3) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 161.5 (6.4)
Pin Dia. 170 (6.7) 168. 5 (6.6)
Bushing Inner Dia. (Boom Side) 170 (6.7) 171.5 (6.8)
d: Boom and Arm Bushing Outer Dia. 200 (7.9) -
Bushing Inner Dia. (Arm Side) 170 (6.7) 171.5 (6.8)
Bushing Outer Dia. 200 (7.9) -
Pin Dia. 170 (6.7) 168. 5 (6.6)
e: Arm and Cylinder Boom Pin Hole Inner Dia. (Boom Side) 170 (6.7) -
Bearing Inner Dia. (Cylinder Side) 170 (6.7) 171.5 (6.8)
Pin Dia. 170 (6.7) 168.5 (6.6)
Bushing Inner Dia. (Arm Side) 170 (6.7) 171.5 (6.8)
f: Arm Cylinder and Arm Bushing Outer Dia. 195 (7.7) -
Bearing Inner Dia. (Cylinder Side) 170 (6.7) 171.5 (6.8)
Pin Dia. 150 (5.9) 148.5 (5.8)
g: Arm and Bucket Cylinder Pin Hole Inner Dia. (Arm Side) 150 (5.9) -
Bearing Inner Dia. (Cylinder Side) 150 (5.9) 151.5 (6.0)

W4-3-7
 FRONT ATTACHMENT / Bushing and Point

Unit: mm (in)
Allowable
Part Name Location Specification
Limit
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Link A Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
h: Bucket Cylinder and Link
Bushing Inner Dia (Link B Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 161.5 (6.4)
Pin Dia. 140 (5.5) 138.5 (5.5)
Bushing Inner Dia.( Link A Side) 140 (5.5) 141.5 (5.6)
i: Link and Bucket Bushing Outer Dia. 170 (6.7) -
Bushing Inner Dia. (Bucket Side) 140 (5.5) 141.5 (5.6)
Bushing Outer Dia. 170 (6.7) -
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Arm Side) 160 (6.3) 161.5 (6.4)
j: Arm and Bucket Bushing Outer Dia. 190 (7.5) -
Bushing Inner Dia. (Bucket Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
Pin Dia. 130 (5.1) 128.5 (5.1)
Bushing Inner Dia. (Arm Side) 130 (5.1) 131.5 (5.2)
k: Arm and Link Bushing Outer Dia. 155 (6.1) -
Bushing Inner Dia. (Link B Side) 130 (5.1) -
Bushing Outer Dia. 155 (6.1) -

W4-3-8
 FRONT ATTACHMENT / Bushing and Point
(Blank)

W4-3-9
 FRONT ATTACHMENT / Bushing and Point
Pin and Bushing (Loading Shovel)

e f
d
a c

h
g

i
c
b

k j W142-04-01-023

W4-3-10
 FRONT ATTACHMENT / Bushing and Point

Unit: mm (in)
Allowable
Part Name Location Specification
Limit
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Boom Side) 160 (6.3) 161.5 (6.4)
a: Boom and Main Frame Bushing Outer Dia. 190 (7.5) -
Bushing Inner Dia. (Frame Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 180 (7.1) -
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Frame Side) 160 (6.3) 161.5 (6.4)
b: Boom Cylinder and Main Frame Bushing Outer Dia. 180 (7.1) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 111.5 (4.4)
Pin Dia. 150 (5.9) 148.5 (5.8)
Pin Hole Inner Dia. (Boom Side) 150 (5.9) -
c: Level Cylinder and Boom and Arm Pin Hole Inner Dia. (Arm Side) 150 (5.9) -
Arm Cylinder and Boom and Arm
Bearing Inner Dia. ( Cylinder Rod Side) 150 (5.9) 151.5 (6.0)
( Cylinger Bottom Side) 150 (5.9) 151.5 (6.0)
Pin Dia. 160 (6.3) 158.5 (6.2)
d: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 160 (6.3) -
Bearing Inner Dia. (Cylinder Side) 160 (6.3) 161.5 (6.4)
Pin Dia. 130 (5.1) 128.5 (5.1)
e: Bucket Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 130 (5.1) -
Bearing Inner Dia. (Cylinder Side) 130 (5.1) 131.5 (5.2)
Pin Dia. 160 (6.3) 158.5 (6.2)
Bushing Inner Dia. (Arm Side) 160 (6.3) 161.5 (6.4)
f: Arm and Boom Bushing Outer Dia. 190 (7.5) -
Bushing Inner Dia. (Boom Side) 160 (6.3) 161.5 (6.4)
Bushing Outer Dia. 190 (7.5) -
Pin Dia. 140 (5.5) 138.5 (5.5)
Bushing Inner Dia. (Bucket Side) 140 (5.5) 139.5 (5.5)
g: Bucket and Arm Bushing Outer Dia. 165 (6.5) -
Bushing Inner Dia. (Arm Side) 140 (5.5) 141.5 (5.6)
Bushing Outer Dia. 165 (6.5) -

W4-3-11
 FRONT ATTACHMENT / Bushing and Point

Unit: mm (in)
Allowable
Part Name Location Specification
Limit
Pin Dia. 90 (3.5) 88.5 (3.5)
Bushing Inner Dia. (Bucket Side) 90 (3.5) 91.5 (3.6)
h: Dump Cylinder and Front Bucket Bushing Outer Dia. 110 (4.3) -
Bearing Inner Dia. (Cylinder Side) 90 (3.5) 91.5 (3.6)
Pin Dia. 130 (5.1) 128.5 (5.1)
Bushing Inner Dia. (Rear Side) 130 (5.1) 131.5 (5.2)
i: Rear Bucket and Front Bucket Bushing Outer Dia. 155 (6.1) -
Bushing Inner Dia. (Front Side) 130 (5.1) 131.5 (5.2)
Bushing Outer Dia. 155 (6.1) -
Pin Dia. 90 (3.5) 88.5 (3.5)
j: Rear Bucket and Dump Cylinder Pin Hole Inner Dia. (Bucket Side) 90 (3.5) -
Bearing Inner Dia. (Cylinder Side) 90 (3.5) 91.5 (3.6)
Pin Dia. 130 (5.1) 128.5 (5.1)
Bushing Inner Dia. (Bucket Side) 130 (5.1) 131.5 (5.2)
k: Bucket Cylinder and Rear Bucket 155 (6.1) -
Bushing Outer Dia.
Bearing Inner Dia. (Cylinder Side) 130 (5.1) 131.5 (5.2)

W4-3-12
 FRONT ATTACHMENT / Bushing and Point
Side Cutter

Section A

W142-04-01-020

Unit: mm (in)
Standard Allowable Limit Remedy
B 450 (18.0) 280 (11.0)
Replace
C 145 (6.0) 90 (3.5)

Point (Backhoe)

B C

W142-04-01-021

Unit: mm (in)
Standard Allowable Limit Remedy
A 315 (12.5) 153 (6.0)
B 154 (6.1) −
Replace
C 172 (6.8) −
D 172 (6.8) −

W4-3-13
 FRONT ATTACHMENT / Bushing and Point
Point (Loading Shovel)

B C

W142-04-01-022

Unit: mm (in)
Standard Allowable Limit Remedy
A 329 (13.0) 206 (8.1)
B 159 (6.3) −
Replace
C 204 (8.0) −
D 204 (8.0) −

W4-3-14
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162

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