160W Workshop Manuel PDF
160W Workshop Manuel PDF
160W Workshop Manuel PDF
: KM-CBBE
Vol. No. : WCBBE-00
160W
Workshop Manual
Service Manual (Manual No. KM-CBBE) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TOCBBE
Technical Manual (Troubleshooting) : Vol. No. TTCBBE
Workshop Manual : Vol. No. WCBBE
• 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 cor- ual.
rect 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 redelivery 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
Example : T 1-3-5
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.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0688
SA-688
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
SA-2
SAFETY
PREPARE FOR EMERGENCIES
004-E01A-0437
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
• In the walk-around inspection be sure to cover all
points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
SA-5
SAFETY
USE HANDHOLDS AND STEPS
008-E01B-0439
009-E01A-0378
SA-6
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
• Start the engine only when seated in the
operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control
levers are in neutral.
SA-084
012-E01B-0444
JUMP STARTING
machine.
S013-E01A-0032
SA-8
SAFETY
KEEP RIDERS OFF MACHINE
014-E01B-0379
SA-091
018-E01A-0481
SA-481
017-E01A-0491
SA-092
SA-9
SAFETY
DRIVE MACHINE SAFELY (WORK SITE)
SA-288
019-E05B-0090
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCI-DENTS
• 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 ma-
chine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Place the shift lever in neutral, and put the brake
switch in the P (parking brake) position.
• Turn the auto-idle switch and the H/P mode
switch off.
• Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK posi-
SA-278
tion.
• Block both tires 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.
020-E01A-0270
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
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 clearly understood by both signalman SA-384
and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
• Read and understand all operating instructions in
the operator’s manual.
S021-E01A-0494
SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
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 5 degrees if crossing the grade is
unavoidable. SA-562
S025-E01B-0495
SA-13
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-14
SAFETY
PROTECT AGAINST FLYING DEBRIS
031-E01A-0432
SA-432
033-E07B-0093
SA-15
SAFETY
HANDLE FLUIDS SAFELY-AVOID FIRES
034-E01A-0496
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
035-E06A-0395
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-18
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
SS2045102
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING
503-E03A-0344
SA-344
SA-034
504-E01A-0034
521-E02A-0249
SA-21
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 all pressure to be released before
removing the cap. SA-039
505-E01B-0498 SA-225
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E03A-0499
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019
hoses.
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
SA-24
SAFETY
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
• Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
S508-E02B-0019
SA-25
SAFETY
EVACUATING IN CASE OF FIRE
518-E02B-0393
SS-1510
509-E01A-0016
SA-016
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that SA-818
SA-27
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.
511-E01A-0029
512-E01C-0032
SA-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when
servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
S515-E01A-0309
SA-29
SAFETY
DISPOSE OF WASTE PROPERLY
S516-E01A-0226
S517-E01A-0435 SA-435
SA-30
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling and
Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil Tank
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Signal Control Valve
Group 10 Travel Shockless Valve
Group 11 Solenoid Valve
Group 12 Pilot Relief Valve
Group 13 Steering Valve
Group 14 Brake Valve
Group 15 Accumulator Charging Valve
Group 16 Transmission Control Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Motor
All information, illustrations and speci- Group 3 Center Joint
fications in this manual are based on
the latest product information available Group 4 Transmission
at the time of publication. The right is
reserved to make changes at any time
Group 5 Axle
without notice. Group 6 Axle Lock Cylinder
Group 7 Operate-Check Valve
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
COPYRIGHT(C)2003 Group 2 Cylinder
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan Group 3 Hose-Rupture Safety Valve
All rights reserved
Group 4 Operate-Check Valve
SECTION 5 ENGINE
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Signal Control Valve
Group 3 Electrical System Group 7 Steering Valve
Group 8 Brake Valve
Group 9 Transmission Control Valve
Group 10 Others (Upperstructure)
Group 11 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Component Layout
Group 2 Standard Group 3 Troubleshooting A
Group 3 Engine Test Group 4 Troubleshooting B
Group 4 Excavator Test Group 5 Troubleshooting C
Group 5 Component Test Group 6 Electrical System Inspection
Group 6 Adjustment Group 7 ICX
SECTION 1
GENERAL
— CONTENTS —
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling.................................................W1-1-1
Maintenance Standard Terminology.......... W1-1-7
Group 3 Painting
Painting.................................................... W1-3-1
CBBW-1-1
(Blank)
CBBW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
W1-1-1
GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and in-
replace part. stallation of the pump, swing motor, travel motor or
• Dirt or debris on the contact or sliding surfaces cylinder is done, bleed air from the hydraulic system
may shorten the service life of the machine. Take in the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
• Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic mo-
clean and dry.
tor housing, damage to the motor
• If an anti-corrosive agent has been used on a
may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, dam-
• Be sure to use the designated tools to assemble age 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.
W1-1-2
GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit
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:
uneven wear.
b b
a=b a≠b
W110-03-05-004
W1-1-4
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling
slings with the same width and length to keep the Incorrect Eyehole
lifted load balanced. Lifting Method
• When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions. W105-04-01-008
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
2. Before using a nylon sling, visually check the ny- Scuffing
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.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
Bolt Dia Wrench Torque
No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
Engine cushion rubber mounting nut 14 4 22 140 (14.0) (103)
1
Engine cushion rubber mounting bolt 16 2 24 235 (24) (175)
Engine bracket mounting bolt 10 7 17 50 (5.1) (37)
2
Engine bracket mounting nut 10 1 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
17 24.5 (2.5) (18)
19 30 (3.1) (22)
22 40 (4.1) (30)
ORS and metal face seal fittings for hydraulic hoses and
5 27 95 (9.7) (70)
piping
32 140 (14.3) (105)
36 175 (17.8) (130)
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 14 4 22 140 (14.0) (103)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 12 30 500 (51) (370)
12
10 Swing motor mounting bolt (Hex. 8 10 90 (9.2) (67)
Wrench)
11 Battery mounting nut 10 2 17 50 (5.1) (37)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 20 31 30 510 (52) (375)
13
Swing bearing mounting bolt to chassis 20 36 30 490 (50) (360)
14 * Center joint lock mounting bolts 16 5 24 270 (27.5) (200)
15 * Transmission mounting bolts 20 3 30 550 (56.0) (410)
16
16 * Travel motor mounting bolts (Hex. 4 14 270 (27.5) (200)
Wrench)
17 * Propel shaft mounting nuts 10 32 14 76 (8) (60)
19 * Rear axle mounting bolts 20 8 30 550 (56.0) (410)
20 Wheel pin nuts 22 40 30 600 (61) (440)
6 - 10 10 (1) (7.4)
21 Cover mounting bolt 10 - 17 50 (5.1) (37)
12 - 19 90 (9.2) (66)
8 4 pairs 13 10.3 to (1.05 to (7.59 to
22 Flexible master coupling of piping
12.4 1.26) 9.11)
23 T-bolt clamp of low pressure piping - 11 6.0 (0.6) (4.3)
* : Apply LOCTITE to the threads.
W1-2-1
GENERAL / Tightening
TORQUE CHART
Bolt Types
W162-01-01-001
W1-2-2
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
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
W1-2-3
GENERAL / Tightening
Service Recommendations for Split Flange
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009
• 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
W1-2-4
GENERAL / Tightening
PIPING JOINT
IMPORTANT: The torques given in the chart are 1 4 3 5 2
for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
Union Joint
M202-07-051
Joint Body
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.
W1-2-5
GENERAL / Tightening
O-ring Seal Joint 9
7 6
W1-2-6
GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.
M114-07-043 M114-07-042
W1-2-7
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
machine.
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
W1-2-8
GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Engine
Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Brake valve seals (Rubber parts) Every 2 years
Upperstructure Brake hose Every 2 years
Brakes Stop light switch Every 2 years
Center joint seals (Rubber parts) Every 2 years
Undercarriage
Brake hose Every 1 years
Steering hose Every 2 years
Steering Mechanism Steering cylinder seals (Rubber parts) Every 2 years
Steering valve seals (Rubber parts) Every 2 years
Pump suction hose Every 2 years
Base Machine Pump delivery hose Every 2 years
Swing hose Every 2 years
Hydraulic
Boom cylinder line hose Every 2 years
System
Arm cylinder line hose Every 2 years
Front Attachment
Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
W1-2-9
GENERAL / Tightening
(Blank)
W1-2-10
GENERAL / Painting
PAINTING
W1F3-01-03-001
W1-3-1
GENERAL / Painting
A
YR-01
(TAXI Yellow) Out Surface of Hinge Swing
Portion YR-01 (TAXI Yellow)
185
720
W178-01-03-003
5
Section A Section B
Mask Garnished Portion
Door
YR-01(TAXI Yellow) Panel Behind the
Door
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
Front Attachment
Antislip Cover
YR-01 (TAXI Yellow)
KASAI PAINT
Amilack 1400
Deep Black
Upper Side
of Frame
W178-01-03-007
W1-3-2
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK
Preparation
1. Place the machine on a firm, level surface and
lower the bucket to the ground.
W1F3-01-04-001
W1F3-01-04-002
Vacuum Pump
Hose
4. Connect a vacuum pump with the hole removed
cap (2) to maintain negative pressure in the
hydraulic oil tank (3). Adapter
NOTE: Be sure to run the vacuum pump
continuously while working.
W562-02-03-008
W1-4-1
GENERAL / Bleeding Air from Hydraulic Oil Tank
(Blank)
W1-4-2
MEMO
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SECTION 2
UPPERSTRUCTURE
— CONTENTS —
Group 1 Cab Group 5 Control Valve
Remove and Install Cab .........................W2-1-1 Remove and Install Control Valve.......... W2-5-1
Dimensions of the Cab Glass.................W2-1-7 Disassemble Control Valve
(4-Spool Section) ................................. W2-5-2
Group 2 Counterweight Disassemble Control Valve
Remove and Install Counterweight ........W2-2-1
(5-Spool Section) ................................. W2-5-8
Group 3 Main Frame Disassemble and Assemble
Remove and Install Main Frame ............W2-3-1 4-Spool and 5-Spool Sections............ W2-5-14
Assemble Control Valve
Group 4 Pump Device (4-Spool Section) ............................... W2-5-16
Remove and Install Pump Device ..........W2-4-1 Assemble Control Valve
Disassemble Pump Device ....................W2-4-4 (5-Spool Section) ............................... W2-5-24
Assemble Pump Device .......................W2-4-12 Remove and Install
Disassemble Regulator ........................W2-4-24 Auxiliary Control Valve ....................... W2-5-33
Assemble Regulator .............................W2-4-26 Disassemble Auxiliary Control Valve ... W2-5-34
Disassemble Solenoid Valve ................W2-4-28 Assemble Auxiliary Control Valve ........ W2-5-36
Assemble Solenoid Valve.....................W2-4-30
Disassemble and Assemble Group 6 Swing Device
Pilot Pump ..........................................W2-4-32 Remove and Install Swing Device ......... W2-6-1
Maintenance Standard .........................W2-4-34 Disassemble Swing Reduction Gear ..... W2-6-4
Assemble Swing Reduction Gear ........ W2-6-10
Disassemble Swing Motor ................. W2-6-18
Assemble Swing Motor ........................ W2-6-22
Maintenance Standard ......................... W2-6-26
CBBW-2-1
Group 7 Pilot Valve Group 12 Pilot Relief Valve
Remove and Install Pilot Valve...............W2-7-1 Remove and Install Pilot Relief Valve .. W2-12-1
Disassemble Front/Swing Pilot Valve.....W2-7-6 Construction of Pilot Relief Valve......... W2-12-2
Assemble Front/Swing Pilot Valve........W2-7-10
Disassemble Travel,
Group 13 Steering Valve
Remove and Install Steering Valve ...... W2-13-1
Positioning/Auxiliary
Disassemble Steering Valve ................ W2-13-2
Blade/Stabilizer Pilot Valve .................W2-7-14
Assemble Steering Valve ..................... W2-13-6
Assemble Travel,
Positioning/Auxiliary Group 14 Brake Valve
Blade/Stabilizer Pilot Valve .................W2-7-16 Remove and Install Brake Valve .......... W2-14-1
Disassemble Brake Valve .................... W2-14-2
Group 8 Pilot Shut-Off Valve
Assemble Brake Valve ......................... W2-14-6
Remove and Install
Pilot Shut-Off Valve...............................W2-8-1 Group 15 Accumulator Charging Valve
Disassemble Pilot Shut-Off Valve...........W2-8-2 Remove and Install
Assemble Pilot Shut-Off Valve ...............W2-8-4 Accumulator Charging Valve.............. W2-15-1
Construction of
Group 9 Signal Control Valve
Accumulator Charging Valve.............. W2-15-2
Remove and Install Signal
Control Valve ........................................W2-9-1 Group 16 Transmission Control Valve
Remove and Install
Group 10 Travel Shockless Valve
Transmission Control Valve ............. W2-16-1
Remove and Install
Construction of
Travel Shockless Valve.......................W2-10-1
Transmission Control Valve ............. W2-16-2
Construction of
Travel Shockless Valve.......................W2-10-2
CBBW-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Removal
1. Remove seat mounting nuts (2) (4 used) to re-
move seat (1).
: 17 mm
2
1
W1F3-02-01-001
4
3. Raise duct (5) to remove it. 5
W1F3-02-01-002
W2-1-1
UPPERSTRUCTURE / Cab
5. Disconnect cable connectors (10, 11, 12, 13) on
the right side in the cab and ground (9) at rear
side in the cab.
: 13 mm
10
11
12
13
14
W178-02-01-015
16
7. Remove cap (15) from duct cover (17) with a
screwdriver. Remove screw (16) with a screw- 17
driver then remove duct cover (17).
15
W178-02-01-016
W178-02-01-017
20 21
W2-1-2
UPPERSTRUCTURE / Cab
W178-02-01-018
23
24
W157-02-01-010
W157-02-01-001
W2-1-3
UPPERSTRUCTURE / Cab
Installation
W157-02-01-001
W157-02-01-010
6
3. Install duct (8) to the rear console of the cab with
clips (7) (2 used). Install filter (6) into duct (8).
7
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft)
W1F3-02-01-002
10
11
12
13
W178-02-01-014
W2-1-4
UPPERSTRUCTURE / Cab
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
4
5
W178-02-01-012
8. Install duct (20) with bolt (21). Install duct (19) into
duct (20) and secure them with bolts (18).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
18
Mating Surface
19
W178-02-01-017
20 21
W2-1-5
UPPERSTRUCTURE / Cab
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17).
16
17
15
W178-02-01-016
2
1
W1F3-02-01-001
W2-1-6
UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
Chamfer
A
Unit: mm Here
R2
67 303.5 Chamfer along the
11 Periphery unless
Otherwise Specified
R98 R35
4-φ13 0 -1
Section A R3018
W178-02-01-019
405 30 Chamfer Both
Sides
375
238 51 612
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
W178-02-01-006
B
Along the Along the W178-02-01-002
Periphery Periphery
c1 c1
14
733
R58
R58
R11508
Section B W178-02-01-019
R1808
882.5 997
(4 mm)
R308 R1898
R258
100
150
943
W178-02-01-007
W2-1-7
UPPERSTRUCTURE / Cab
Unit: mm
Chamfer Here
Chamfer Here
85.4
Charmfer Slightly
343.3 213 unless the periphery
Polish Chamfered
R105
R72 R10
R105
(4 mm)
Chamfer Slightly unless the
Periphery Polish Chamfered 39.5 D
733
733
C R2465
2-φ12.2 +0.5-0
W178-02-01-019
Polish Chamfer
Both Sides
289.5
3-R4 50
2-R4
86.9 50 50
556.3
W178-02-01-011 50
423
W178-02-01-008
366.1 104.5
R12 R95
R2002
872
R123
R115
888.58
W178-02-01-010
W2-1-8
UPPERSTRUCTURE / Cab
Remove Cab Glass
Procedures to remove left-hand cab glass, lower
glass of the door and upper front glass
Mounting Rubber Section
W178-02-01-004
W2-1-9
UPPERSTRUCTURE / Cab
Procedure to Remove Right-Hand Cab Glass Mounting Rubber Section
Cab Inside
1. Insert a bamboo spatula into position A in Glass
Mounting Rubber
mounting rubber to pry the mounting rubber apart
along all periphery. It is easier to remove the glass
A
when air is entered between cab and mounting
rubber.
Cab
W178-02-01-002
Glass
Mounting Rubber
W178-02-01-005
W2-1-10
UPPERSTRUCTURE / Cab
Left-Hand Cab Glass
Cab Glass Installation Procedure
Procedure for installing left-hand cab glass, lower
glass of the door and upper front glass
A
1. Install the seal rubber on the left-hand cab glass CSE Braid
and lower glass of the door.
Section A
Seal Rubber
5
W178-02-01-023 A
CSE Braid
Seal Rubber
10 10
pull and fasten the mounting rubber onto the Mounting Rubber Section
mounting face of cab.
W178-02-01-022
W178-02-01-004
W2-1-11
UPPERSTRUCTURE / Cab
Procedure for Installing Right-Hand Cab Glass Mounting Rubber Section
W178-02-01-002
W178-02-01-005
W2-1-12
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
Removal
FLENO LINKBOLT 1
CAUTION: Counterweight Weight: Mounting Holes
3770 kg (8320 lb) 2
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight Weight:
3770 kg (8320 lb)
Toque Wrench
Power Wrench W178-02-02-004
W178-02-02-001
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
Removal
weight:
Monoblock boom: 2680 kg (5910 Ib) Monoblock Boom
2-Piece boom: 3220 kg (7100 Ib)
W1F3-04-01-002
2-Piece Boom
W1F3-04-01-001
W2-3-1
UPPERSTRUCTURE / Main Frame
W1F3-03-03-003
Front
5. Put mating marks on the upperstructure and the W105-02-03-005
outer race of the swing bearing.
Loosen the mounting bolt of the swing bearing
and remove it.
: 27 mm
NOTE: Chain block shall be used to adjust and
level the frame, then lift it slightly off the
undercarriage.
W1F3-03-01-002
Bolt
W2-3-2
UPPERSTRUCTURE / Main Frame
Installation
W178-02-02-003
W2-3-3
UPPERSTRUCTURE / Main Frame
W1F3-04-01-001
W2-3-4
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
W2-4-1
UPPERSTRUCTURE / Pump Device
Installation
W2-4-2
UPPERSTRUCTURE / Pump Device
(Blank)
W2-4-3
UPPERSTRUCTURE / Pump Device
DISASSEMBLE MAIN PUMP
22
21
18 20
19
17
16
15
14
13
12
11
23
10 24
9
8
7
6
5
4 25
3
39
2
1 26 38
37
36
27
35
40
34 41
33 42
30 32 43
29 31 44
28 45
46
47
51
52 50 48
53
63
54 49
62
61
60
64
55
56 59
65
57 66
58 67
68
69
71 70
W1F3-02-04-001
W2-4-4
UPPERSTRUCTURE / Pump Device
1- Socket Bolt (2 Used) 19 - Servo Piston (2 Used) 37 - Needle Bearing 55 - Spring Pin
2- Steering Pump 20 - O-Ring (2 Used) 38 - Gear 56 - Pin
3- Cover 21 - Backup Ring (2 Used) 39 - O-Ring 57 - O-Ring (2 Used)
4- O-Ring 22 - Stopper (2 Used) 40 - Socket Bolt (4 Used) 58 - Plug (2 Used)
5- Retaining Ring (2 Used) 23 - O-Ring (2 Used) 41 - Cover 59 - O-Ring
6- Spacer (2 Used) 24 - Plug (2 Used) 42 - Oil Seal 60 - Spring Pin (2 Used)
7- Bearing (2 Used) 25 - O-Ring (2 Used) 43 - O-Ring 61 - Pin
8- Spacer (2 Used) 26 - Plug (8 Used) 44 - Shaft 62 - Socket Bolt (4 Used)
9- Shaft 27 - Socket Bolt (4 Used) 45 - Housing 63 - Cover
10 - Cover 28 - Swash Plate (2 Used) 46 - O-Ring (18 Used) 64 - Socket Bolt (2 Used)
11 - Nut (2 Used) 29 - Bushing (2 Used) 47 - O-Ring (2 Used) 65 - Cover
12 - Adjusting Screw (2 Used) 30 - Shoe Plate (2 Used) 48 - Valve Plate 66 - O-Ring
13 - Spring Pin (2 Used) 31 - Plunger (18 Used) 49 - Needle Bearing 67 - PTO Gear Case
14 - Stopper (2 Used) 32 - Retainer (2 Used) 50 - Eye Bolt 68 - Socket Bolt (4 Used)
15 - Backup Ring (2 Used) 33 - Spherical Bushing (2 Used) 51 - Nut (2 Used) 69 - O-Ring
16 - O-Ring (2 Used) 34 - Spring (18 Used) 52 - Adjusting Screw (2 Used) 70 - Pilot Pump
17 - Housing 35 - Cylinder Block (2 Used) 53 - Plug (8 Used) 71 - Socket Bolt (2 Used)
18 - Tilt Pin (2 Used) 36 - Valve Plate 54 - Valve Cover
W2-4-5
UPPERSTRUCTURE / Pump Device
22
21
18 20
19
17
16
15
14
13
12
11
23
10 24
9
8
7
6
5
4 25
3
39
2
1 26 38
37
36
27
35
40
34 41
33 42
30 32 43
29 31 44
28 45
46
47
51
52 50 48
53
63
54 49
62
61
60
64
55
56 59
65
57 66
58 67
68
69
71 70
W1F3-02-04-001
W2-4-6
UPPERSTRUCTURE / Pump Device
Disassemble Main Pump
• Be sure to read “Precautions for Disassembly and IMPORTANT: Take care that valve plate (36) and
Assembly Work” thoroughly on page W1-1-1 (48) may come off when parts
before starting the disassembly work. separated. Do not remove needle
• For removal of the regulator, refer to “Remove bearings (37) and (49) unless
Regulator”section. necessary. In case they are removed,
replace them with new ones.
IMPORTANT: Do not disassemble nut (11), 6. Separate housing (17), valve cover (54) and the
adjusting screw (12), nut (51) and housing (45) assemblies. Be sure to remove
adjusting screw (52) of main pump 1 O-rings (25) (2 used), (39), (43), (46) (18 used), spring
and 2. The set flow rate may be pins (55) (2 used) and (60) (2 used) when
changed. separating these assemblies.
1. Remove plugs (24) (2 used) and O-rings (23) (2
used) to drain hydraulic oil from the main pump. 7. Remove valve plate (36) and pin (56) from valve
: 36 mm cover (54).
2. Remove socket bolts (68) (4 used), remove the 8. Remove cylinder block (35) from housing (17) and
PTO gear case (67) assembly and o-ring (59) the housing (45) assembly. Springs (34) (9 used),
housing from valve cover (54). spherical bushing (33), retainer (32) and plungers
: 8 mm (31) (9 used) will be removed together with
cylinder block (35).
3. Remove socket bolts (1) (2 used), remove NOTE: Slowly remove cylinder block (35) while
steering pump (2), cover (3) and O-ring (4) from turning it to left and right softly by both
cover (10). hands.
: 8 mm
9. Remove retainer (32) from the cylinder block (35)
4. Remove eye bolt (50) from valve cover (54). assembly. Plungers (31) (9 used) will be removed
together with retainer (32).
CAUTION: Pump Device Weighet:
95 kg (210 lb) 10. Remove plungers (31) (9 used) from retainer (32).
IMPORTANT: Take care not to dent or scratch the
contact surface of regulator. 11. Remove spherical bushing (33) from cylinder
After installing swash plate (28), block (35), then remove springs (34) (9 used).
check if it moves smoothly.
5. Attach a nylon sling to the main pump. Turn the 12. Tap cover (10) with a plastic hammer to remove it.
main pump over with the regulator mounting side Remove O-rings (46) (2 used) and spring pin (13)
facing downward. Remove socket bolts (27) (4 as well.
used) and (62) (4 used).
: 14 mm 13. Remove swash plate (28) and shoe plate (30)
from housing (17).
W2-4-7
UPPERSTRUCTURE / Pump Device
22
21
18 20
19
17
16
15
14
10
9
8
7
6
5
45
48
54
61
W1F3-02-04-001
W2-4-8
UPPERSTRUCTURE / Pump Device
IMPORTANT: As LOCTITE (middle strength) has
been applied on the contacting part
between servo piston (19) and tilt
pin (18), do not disassemble them
unless required. When
disassembling them, do not damage
servo piston (19).
14. Remove stoppers (14), (22), backup rings (15),
(21), O-rings (16) and (20) from housing (17) to
remove servo piston (19) and tilt pin (18).
18. Remove valve plate (48) and pin (61) from valve
cover (54).
W2-4-9
UPPERSTRUCTURE / Pump Device
ASSEMBLE MAIN PUMP
63 33 45 28 30 29 39 46 52 51 22 21 20 17 18 19 14 16 15 10 11
12
13
4
3
40
1
43 5
44 42
9
41
27
62
47 32 31 34 35 36 56 55 37 38 54 49 61 47 60 48 8 25 7 6
T1F3-03-01-003
1- Socket Bolt (2 Used) 19 - Servo Piston (2 Used) 37 - Needle Bearing 55 - Spring Pin
2- *Steering Pump 20 - O-Ring (2 Used) 38 - Gear 56 - Pin
3- Cover 21 - Backup Ring (2 Used) 39 - O-Ring 57 - *O-Ring (2 Used)
4- O-Ring 22 - Stopper (2 Used) 40 - Socket Bolt (4 Used) 58 - *Plug (2 Used)
5- Retaining Ring (2 Used) 23 - *O-Ring (2 Used) 41 - Cover 59 - *O-Ring
6- Spacer (2 Used) 24 - *Plug (2 Used) 42 - Oil Seal 60 - Spring Pin (2 Used)
7- Bearing (2 Used) 25 - O-Ring (2 Used) 43 - O-Ring 61 - Pin
8- Spacer (2 Used) 26 - *Plug (8 Used) 44 - Shaft 62 - Socket Bolt (4 Used)
9- Shaft 27 - Socket Bolt (4 Used) 45 - Housing 63 - Cover
10 - Cover 28 - Swash Plate (2 Used) 46 - O-Ring (18 Used) 64 - *Socket Bolt (2 Used)
11 - Nut (2 Used) 29 - Bushing (2 Used) 47 - O-Ring (2 Used) 65 - *Cover
12 - Adjusting Screw (2 Used) 30 - Shoe Plate (2 Used) 48 - Valve Plate 66 - *O-Ring
13 - Spring Pin (2 Used) 31 - Plunger (18 Used) 49 - Needle Bearing 67 - *PTO Gear Case
14 - Stopper (2 Used) 32 - Retainer (2 Used) 50 - *Eye Bolt 68 - *Socket Bolt (4 Used)
15 - Backup Ring (2 Used) 33 - Spherical Bushing (2 Used) 51 - Nut (2 Used) 69 - *O-Ring
16 - O-Ring (2 Used) 34 - Spring (18 Used) 52 - Adjusting Screw (2 Used) 70 - *Pilot Pump
17 - Housing 35 - Cylinder Block (2 Used) 53 - Plug (8 Used) 71 - *Socket Bolt (2 Used)
18 - Tilt Pin (2 Used) 36 - Valve Plate 54 - Valve Cover
W2-4-10
UPPERSTRUCTURE / Pump Device
Assemble Main Pump
IMPORTANT: Apply LOCTITE (middle strength) to 8. Install O-ring (43) and oil seal (42) onto cover (41).
the matching part between servo Install cover (41) onto cover (63) with socket bolts
piston (19) and tilt pin (18). (40) (4 used).
1. Install tilt pin (18), servo piston (19), O-rings (16), : 5 mm
(20), backup rings (15), (21), stopper (14) and : 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
(22) into both housing (17) and housing (45).
9. Install springs (34) (9 used) and spherical bushing
2. Install spring pin (13) and O-ring (25) onto covers
(33) into cylinder block (35).
(10) and (63). Install them onto housings (17) and
(45).
10. Install plungers (31) (9 used) into retainer (32),
and install retainer (32) into cylinder block (35).
3. Tap the covers (10) and (63) with a plastic
hammer onto housings (17) and (45).
11. Aligning the splines, then install the cylinder block
(35) assembly onto both shaft (9) and shaft (44).
IMPORTANT: Take care not to dent or scratch the
contact surface of regulator.
After installing swash plate (28), IMPORTANT: Apply grease to the back of valve
check if it moves smoothly. plate (48) to prevent it from coming
4. Place housings (17) and (45) on a workbench off.
with their regulator mounting side facing down. 12. Install pin (61), valve plate (48), O-rings (46) (6
Install swash plate (28) with shoe plate (30) onto used), O-ring (47) and spring pin (60) onto valve
tilt pin (18). cover (54). Install valve cover (54) onto housing
(17) with socket bolts (27) (4 used).
5. Install spacer (8) onto shaft (9) and (44), then Temporarily secure socket bolts (27) (4 used) so
install bearing (7) with a press. that shaft (44) can be turned by hand.
: 14 mm
6. Install spacer (6) and retaining ring (5) onto each
shaft (9) and shaft (44). Install each shaft (9) and
(44) into covers (10) and (63) with a press.
W2-4-11
UPPERSTRUCTURE / Pump Device
45 39 46 17 18
44
9
27
62
38 54
T1F3-03-01-003
W2-4-12
UPPERSTRUCTURE / Pump Device
13. Install gear (38) into shaft (9).
16. Install O-ring (59) and the PTO gear case (67)
assembly with socket bolts (68) (4 used) onto
valve cover (54).
: 8 mm
: 33 N⋅m (3.5 kgf⋅m, 24.5 Ibf⋅ft)
W2-4-13
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD
31 35
1. Clearance between plunger (31) diameter (d) and
cylinder block (35) bore (D).
W117-02-02-009
34
L
W117-02-02-010
W117-02-02-011
Stand 32 33
4. Distance between retainer (32) bottom and
spherical bushing (33) top.
H-h Unit: mm (in) h H
Standard Allowable Limit
19.0 (0.75) 18.2 (0.72) W117-02-02-012
W2-4-14
UPPERSTRUCTURE / Pump Device
(Blank)
W2-4-15
UPPERSTRUCTURE / Pump Device
DISASSEMBLE REGULATOR
(MAIN PUMP 2 SIDE)
12
11
10
9
8
7
D
6 B 21
5 F 22
23
4 24
3
2 25
1 20 26
19 A 31
G 30
18 E
C 29
17
16 28
15
14
13 27
32
34
33
47
46
35
36 45
37
44
43 48
42
39 41 49
40
38
D 50
E
67
51
66
52
53
64 59 54
65
A 58
B 57
C 62 56
63 55
60 W1F3-02-04-006
61
W2-4-16
UPPERSTRUCTURE / Pump Device
W2-4-17
UPPERSTRUCTURE / Pump Device
12
11
10
9
8
7
D
6 B 21
5 F 22
23
4 24
3
2 25
1 20 26
19 A 31
G 30
18 E
C 29
17
16 28
15
14
13 27
32
34
33
47
46
35
36 45
37
44
43 48
42
39 41 49
40
38
D 50
E
67
51
66
52
F
G 53
59 54
64
65
A 58
B 57
C 62 56
63 55
60 W1F3-02-04-006
61
W2-4-18
UPPERSTRUCTURE / Pump Device
Disassemble Regulator
(Main Pump 2 Side)
• Be sure to read “Precautions for Disassembly and 9. Remove socket bolts (46) (5 used) from cover
Assembly Work” thoroughly on page W1-1-1 (45) to remove cover (45), stopper (11), springs
before starting the disassembly work. (10) and (9), spring seat (8), stopper (30), spring
(29) and spring seat (28).
1. Remove socket bolts (38) (2 used) and (39) (2 : 5 mm
used) to remove the regulator from the main
pump. IMPORTANT: Do not remove pin (58) from
: 6 mm supporting plug (57). Make matching
marks between support plugs (52),
2. Remove solenoid valve (34) from housing (50). (57) and housing (50) to prevent
: 32 mm them from confusion.
10. Remove retaining rings (54) and (55) from
IMPORTANT: Do not remove adjusting screws (41), housing (50) to remove supporting plugs (52) and
(42), (49) and nuts (43), (47), (48). The (57) using puller bolts (M6).
flow rate setting of the pump will
change after removing. IMPORTANT: Do not remove pin (26) from lever
3. Remove socket bolts (32) (4 used) from cover (25).
(33), remove cover (33) from housing (50). 11. Remove lever (25) from housing (50) with a pairs
: 5 mm or tweezers etc. to remove pilot piston (27).
4. Remove O-ring (35), (36) and (37) (2 used) from IMPORTANT: In case pin (23) cannot be removed,
cover (33). remove sleeve (18) first to remove
pin (23) with making play for spool
5. Remove O-rings (60), (61) (7 used) and pin (59) (19).
from housing (50). 12. Insert a copper bar into the supporting plug (52)
hole to remove pin (23) from feedback lever (22).
6. Remove socket bolts (65) (2 used) and (66) (2 used) After that, remove feedback lever (22), sleeve (18),
from cover (67) to remove cover (67), spring (16) retaining ring (17) and spool (19).
and O-ring (63), (64) and (62) (2 used).
: 5 mm IMPORTANT: Do not remove pins (20) and (51)
from lever (21).
7. Remove pin (1), sleeve (2), O-rings (3) and (4), 13. Remove lever (21) with a pairs of tweezers etc.
sleeve (5) and compensating piston (6) from from housing (50) to remove compensating rod
housing (50). (7).
W2-4-19
UPPERSTRUCTURE / Pump Device
ASSEMBLE REGULATOR A
(MAIN PUMP 2 SIDE) B
52 53
54
51
55
56
57
A
50 24 23 25 27 28 29 30 45 T1F3-03-01-006
Section B-B
46
48
49
63 38 60 58 22 26 39 31
T1F3-03-01-007
Section A-A 67 16 64 14 15 17 19 18 21 8 9 10 44 45 47
13
41
66
43
3 42
65
1 2 4 5 6 7 20 59 40 12 11
T1F3-03-01-008
W2-4-20
UPPERSTRUCTURE / Pump Device
W2-4-21
UPPERSTRUCTURE / Pump Device
ASSEMBLE REGULATOR A
(MAIN PUMP 2 SIDE) B
52 53
54
51
55
56
57
A
50 24 23 25 27 28 29 30 45 T1F3-03-01-006
Section B-B
46
48
49
63 38 60 58 22 26 39 31
T1F3-03-01-007
Section A-A 67 16 64 14 15 17 19 18 21 8 9 10 44 45 47
13
41
66
43
3 42
65
1 2 4 5 6 7 20 59 40 12 11
T1F3-03-01-008
W2-4-22
UPPERSTRUCTURE / Pump Device
Assemble Regulator
(Main Pump 2 Side)
1. Insert compensating rod (7) and lever (21) into IMPORTANT: Supporting plug (57) and (52) can be
housing (50). installed in either hole. Be sure to
install them according to the
2. Align pin (51) of lever (21) with the pin hole in matching mark made when
housing (50) inside. Align pin (20) with stepped disassembling and never confuse
joint portion of compensating rod (7) to install them, otherwise the pump control
lever (21) into housing (50). will be out of order.
8. Align pin (58) of supporting plug (57) with the pin
3. Install retaining ring (17) to sleeve (18) and insert hole of lever (25) to insert pin (58) and install
sleeve (18) and spool (19) into housing (50). retaining ring (55).
IMPORTANT: Check spool (19) if it should move 9. Insert supporting plug (52) into housing (50) and
smoothly before installing feedback install retaining ring (54).
lever (22). Be sure to install spool
(19) and feedback lever (22) in the 10. Install O-ring (31) onto stopper (30).
correct direction. Do not make any
mistake while doing this procedure. 11. Install spring seat (28), spring (29) and stopper
4. Align the pin hole in feedback lever (22) with the (30) to housing (50).
pin hole in spool (19), and tap pin (23) from the
mounting hole of supporting plug (52) with a 12. Install O-ring (12) onto stopper (11).
plastic hammer.
13. Place O-ring (44) in housing (50). After that, insert
spring seat (8), springs (9) and (10) and stopper
5. Insert pilot piston (27) and lever (25) into housing (11) into housing (50). Install cover (45) to housing
(50). (50) with socket bolts (46) (4 used).
: 5 mm
IMPORTANT: Check pilot piston (27) if it should : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft)
move smoothly before installing
lever (25). 14. Install spring (15), spring seat (14) and retaining
6. Align pin (26) of lever (25) with stepped joint ring (13) onto spool (19).
portion of pilot piston (27) to install lever (25).
15. Place ring (4) to sleeve (5) and install sleeve (5),
7. Install O-rings (53) and (56) to supporting plugs compensating piston (6), O-ring (3), sleeve (2)
(52) and (57) respectively. and pin (1) into housing (50).
W2-4-23
UPPERSTRUCTURE / Pump Device
T1F3-03-01-006
50
Section B-B
63 38 60 39
T1F3-03-01-007
Section A-A
66
65
T1F3-03-01-008
W2-4-24
UPPERSTRUCTURE / Pump Device
16. Install spring (16), O-rings (64), (63) and (62) (2
used) into housing (50) and install cover (67) to
housing (50) with socket bolts (66) (2 used) and
(65) (2 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft)
W2-4-25
UPPERSTRUCTURE / Pump Device
DISASSEMBLE REGULATOR 12
(MAIN PUMP 1 SIDE) 11
10
9
8
7
6 D 21
B
5 22
F 23
4
3 24
2 25
1 20
19 26
A 31
18 G 30
E
17 C 29
16
15 28
14
27
13
32
33
34
58
57
38
39
40 56
41 35
42 36
43 37 55
44 54
53
52 59
50 60
51
49
46
45 47
48
61
D
E
62
63
F
75 G 64
69 65
A
68
B 67
C
73 70 66
74 71
W1F3-02-04-007
72
W2-4-26
UPPERSTRUCTURE / Pump Device
W2-4-27
UPPERSTRUCTURE / Pump Device
12
11
10
9
8
7
6 D 21
B
5 22
4
F 23
3 24
2 25
1 20
19 26
A 31
18 G 30
E
17 C 29
16
15 28
14 27
13
32
33
34
58
57
38
39
40 56
41 35
42 36
43 37 55
44 54
53
52 59
50 60
51
49
46
45 47
48
61
D
E
62
63
F
75 G 64
69 65
A
68
B 67
C
73 70 66
74 71
W1F3-02-04-007
72
W2-4-28
UPPERSTRUCTURE / Pump Device
Disassemble Regulator
(Main Pump 1 Side)
• Be sure to read “Precautions for Disassembly and 9. Remove pin (1), sleeve (2), O-rings (3) and (4),
Assembly Work” thoroughly on page W1-1-1 sleeve (5) and compensating piston (6) from
before starting the disassembly work. housing (61).
1. Remove socket bolts (49) (2 used) and (50) (2 10. Remove retaining ring (13) from housing (61) to
used) to remove the regulator from the main remove spring seat (14) and spring (15).
pump.
: 6 mm 11. Remove socket bolts (57) (4 used) from cover
(56) to remove cover (56), stopper (11), springs
IMPORTANT: Do not remove adjusting screws (52), (10) and (9), spring seat (8), stopper (30), spring
(53), (60) and nuts (54), (58), (59). The (29) and spring seat (28).
flow rate setting of the pump will : 5 mm
change after removing.
2. Remove socket bolts (45) (4 used) from cover IMPORTANT: Do not remove pin (69) from
(46) to remove covers (46). supporting plug (68). Make matching
: 5 mm marks between support plugs (63),
(68) and housing (61) to prevent
3. Remove O-ring (47) (3 used) and (48) from cover them from confusion.
(46). 12. Remove retaining rings (65) and (66) from
housing (61) to remove supporting plugs (63) and
4. Remove O-rings (71), (72) (7 used) and pin (70) (68) using forcing bolts (M6).
from housing (61).
IMPORTANT: Do not remove pin (26) from lever
5. Remove socket bolts (34) (2 used) and (33) (2 (25).
used) from block (32) to remove block (32), spring 13. Remove lever (25) from housing (61) with a pairs
(16) and O-ring (75), (74) and (73) (2 used). of tweezers etc. to remove pilot piston (27).
: 5 mm
IMPORTANT: In case pin (23) cannot be removed,
6. Remove socket bolts (42) (2 used) to remove remove sleeve (18) first to remove
cover (43) from block (32). pin (23) with making play for spool
: 5 mm (19).
14. Insert a copper bar into the supporting plug (63)
7. Press piston 1 (36) from block (32) and hole to remove pin (23) from feedback lever (22).
compensating rods (7) side to remove the stopper After that, remove feedback lever (22), sleeve
2 (39) assembly, piston (39) and stopper (35). (18), retaining ring (17) and spool (19).
W2-4-29
UPPERSTRUCTURE / Pump Device
7
D 21
B
F
20
A
G
E
C
61
D
E
62
F
G
A
B
C
W1F3-02-04-007
W2-4-30
UPPERSTRUCTURE / Pump Device
W2-4-31
UPPERSTRUCTURE / Pump Device
ASSEMBLE REGULATOR A
(MAIN PUMP 1 SIDE) B
63 64
65
66
67
68
A
41 38 32 35 61 24 23 25 27 28 29 30 T1F3-03-01-006
Section B-B
56
57
42
59
60
40
44
T1F3-03-01-004
43 39 37 36 74 49 71 69 22 26 50 31
Section A-A 16 75 14 15 17 19 18 21 8 9 10 55 51 56 58
62
13
52
3
54
34
53
33 1 2 4 5 6 7 20 70 12 11 T1F3-03-01-005
W2-4-32
UPPERSTRUCTURE / Pump Device
W2-4-33
UPPERSTRUCTURE / Pump Device
A
B
63 64
65
66
67
68
A
41 38 32 35 61 24 23 25 27 28 29 30 T1F3-03-01-006
Section B-B
56
57
42
59
60
40
44
T1F3-03-01-004
43 39 37 36 74 49 71 69 22 26 50 31
Section A-A 16 75 14 15 17 19 18 21 8 9 10 55 51 56 58
13 62
52
3
54
34
53
33 1 2 4 5 6 7 20 70 12 11 T1F3-03-01-005
W2-4-34
UPPERSTRUCTURE / Pump Device
Assemble Regulator
(Main Pump 1 Side)
1. Insert compensating rod (7) and lever (21) into IMPORTANT: Supporting plugs (68) and (63) can
housing (61). be installed in either hole. Be sure to
install them according to the
2. Align pin (62) of lever (21) with the pin hole in the matching mark made when
housing (61) inside. Align pin (20) with stepped disassembling and never confuse
joint portion of compensating rod (7) to install them, otherwise the pump control
lever (21) into housing (61). will be out of order.
8. Align pin (69) of supporting plug (68) with the pin
3. Install Assemble retaining ring (17) to sleeve (18) (69) hole of lever (25) to insert the pin and install
and insert sleeve (18) and spool (19) into housing retaining ring (66).
(61).
9. Insert supporting plug (63) into housing (61) and
IMPORTANT: Check spool (19) if it should move install retaining ring (65).
smoothly before installing feedback
lever (22). Be sure to install spool 10. Install O-ring (31) onto stopper (30).
(19) and feedback lever (22) in the
correct direction. Do not make any 11. Install spring seat (28), spring (29) and stopper
mistake while doing this procedure. (30) to housing (61).
4. Align the pin hole in feedback lever (22) with the
pin hole in spool (19), and tap pin (23) from the 12. Install O-ring (12) onto stopper (11).
mounting hole of supporting plug (63) with a
plastic hammer. 13. Place O-ring (55) in housing (61). After that, insert
spring seat (8), springs (9) and (10) and stopper
(11) into housing (50).
5. Insert pilot piston (27) and lever (25) into housing Install cover (56) to housing (61) with socket bolts
(61). (57) (5 used).
: 5 mm
IMPORTANT: Check pilot piston (27) if it should : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft)
move smoothly before installing
lever (25). 14. Install spring (15), spring seat (14) and retaining
6. Align pin (26) of lever (25) with stepped joint ring (13) onto spool (19).
portion of pilot piston (27) to install lever (25).
15. Install O-ring (4) to sleeve (5) and install sleeve
7. Install O-rings (64) and (67) to supporting plugs (5), compensating piston (6), O-ring (3), sleeve (2)
(63) and (68) respectively. and pin (1) into housing (61).
W2-4-35
UPPERSTRUCTURE / Pump Device
A
B
T1F3-03-01-006
41 38 32 35 61
Section B-B
42
T1F3-03-01-004
43 39 37 36 74 49 71 69 50
Section A-A 16 75
34
33 11 T1F3-03-01-005
W2-4-36
UPPERSTRUCTURE / Pump Device
16. Install O-rings (38), (41) and piston (37) to
stopper 2 (39)
W2-4-37
UPPERSTRUCTURE / Pump Device
DISASSEMBLE PTO GEAR BOX
1
4
3
2 7
1
8
6
5
10
9
11
12
13
12 W1F3-02-04-002
14
W2-4-38
UPPERSTRUCTURE / Pump Device
Disassemble PTO Gear Box
W2-4-39
UPPERSTRUCTURE / Pump Device
ASSEMBLE PTO GEAR BOX
12 9 9
14 10
13
11
8
2 8
1
Gear Casing
6 7
4
3
5 4 5
W1F3-02-04-004
W1F3-02-04-003
3 2
W2-4-40
UPPERSTRUCTURE / Pump Device
Assemble PTO Gear Box
4. Install O-ring (10) and plug (9) into gear case (11).
W2-4-41
UPPERSTRUCTURE / Pump Device
DISASSEMBLE AND ASSEMBLE PILOT
PUMP AND STEERING PUMP
27
13
26
10
10
12
1
9
6
26
14
27
6
9
2
3
5
16
15
7
12
W137-02-04-034
W2-4-42
UPPERSTRUCTURE / Pump Device
Tightening Torque
Wrench Size
No. Part Name Q’ty (kgf⋅m) Remarks
mm N⋅m
(Ibf·ft)
1 Housing 1
2 Flange 1
3 Oil Seal 1 Apply grease to the lip of seal when assembling
5 Retaining Ring 1
6 Seal 2 Apply grease when assembling
7 Cover 1
9 Backup Ring 2 Apply grease when assembling
10 Key 2
12 O-Ring 2 Apply grease when assembling
13 Gear 1
14 Gear 1
15 Washer 2
(4 to 4.5)
16 Bolt 2 : 17 39 to44
(29 to 32.5)
26 Bushing 4 Apply a film of hydraulic oil when installing
27 Bushing 4 Apply a film of hydraulic oil when installing
W2-4-43
UPPERSTRUCTURE / Pump Device
(Blank)
W2-4-44
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
Removal
W2-5-1
UPPERSTRUCTURE / Control Valve
Installation
NOTE: Refer to “Removal” section above for
wrench sizes and tightening torques.
5
CAUTION: Control valve weight: 130 kg
(290 lb)
W1F3-02-05-001
W1F1-02-05-003
W2-5-2
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-3
UPPERSTRUCTURE / Control Valve
DISASSEMBLE 4-SPOOL CONTROL
VALVE
41
X
1
2
42
3 29
23 43 47
4
5 30
44 48
6 24
7 31
Arm Re-
8generative 45
25 49
9Valve
(Switch 32
10 Valve) 26 50
Boom
Anti- 36 33 46
Drift 11 51
Valve
27
12 34
13 28
14 37 52
Check Valve
15 35 (Main Relief
38
16 Circuit)
17
39
18
40
W
60 62
61 63
64
65
W
58
66
59
67
72
X W1F1-02-05-004
W2-5-4
UPPERSTRUCTURE / Control Valve
Disassemble 4-Spool Control Valve Upper Sec-
tion
• Be sure to read “Precautions for Disassembly IMPORTANT: Put mating marks on main spools
and Assembly” thoroughly on page W1-1-1 be- (28, 36, 46, 52) and housing (72) in
fore starting the disassembly work. order to avoid confusion during re-
• Attach identification tags to the spool and mount- assembling.
ing positions in the housing in order to avoid 7. Clamp main spools (28, 36, 46, 52) in a vise with
misassembling. padded wooden pieces, then remove bolts (24,
32, 42, 48), spring seats (25, 33, 43, 49), springs
1. Remove socket bolts (67) (11 used) from housing (26, 34, 44, 50) and spring seats (27, 35, 45 and
(72), and then remove pilot housing (66). 51).
: 8 mm : 17 mm
2. Remove boom anti-drift valve assembly (5 to 16), 8. Remove plug (40), O-ring (39), spring (38) and
O-ring (4) and backup ring (3) from pilot housing poppet (37) from spool (36).
(66). : 17 mm
NOTE: Pry the boom anti-drift valve assembly by
hand and remove it from pilot housing (66). 10. Remove spring (17) and poppet (18) from hous-
ing (72).
3. Remove plug (16), O-ring (15), backup ring (14),
spring (13), washer (12) and spool (11) from
sleeve (10).
W2-5-5
UPPERSTRUCTURE / Control Valve
Arm Re-
generative
Valve
Boom (Switch
Anti- Valve)
Drift 19
Valve
20
21 53
54 Check Valve
55 (Main Relief
22 Circuit)
56
57
W
69
70
71 W
68
72
X W1F1-02-05-004
W2-5-6
UPPERSTRUCTURE / Control Valve
11. Remove spring (19), washer (20), O-ring (21)
and spool (22) from housing (72).
Lock Nut
Cartridge
W176-02-06-017
W2-5-7
UPPERSTRUCTURE / Control Valve
72
79
78
77 83
76 82
81
Check Valve 80
75 Orifice (Arm 1 87
74 Load Check 86
Parallel 85
73 (Arm 2
Circuit)
Tandem 84
98
Circuit) 97
96
95
94
93 Bucket Flow
92 Rate Control
91 Valve (Poppet
90 Valve)
89
99 88 108
109
107
102
103
100 104
101 105
W176-02-05-012
106
W2-5-8
UPPERSTRUCTURE / Control Valve
Disassemble 4-Spool Control Valve Side Section
15. Remove plug (106), then spring (104), washer
(103), spool (102) and O-ring (105).
: 36 mm
W2-5-9
UPPERSTRUCTURE / Control Valve
72
115
110
116 119
111 117
118
112
Check Valve (Flow
113 Combiner Circuit) 120
114
Auxiliary Flow
Rate Control
Valve
121
122
W1F1-02-05-005
W2-5-10
UPPERSTRUCTURE / Control Valve
Disassemble 4-Spool Control Valve Lower Sec-
tion
IMPORTANT: Never turn the lock nut. If turned,
the set pressure may be changed.
22. Turn the cartridge of overload relief valve (119)
and remove it from housing (72).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017
W2-5-11
UPPERSTRUCTURE / Control Valve
DISASSEMBLE 5-SPOOL CONTROL
VALVE
184
183
185
123
124
125 155
156
126 149
127 186
128 157
129 150
130 158
165
131 151
144 159
171
132 152
134 145 166
Arm Anti-Drift 177
Valve
135 133 146 153 160 167 172
136
143 147
137
141 168 173
138 178
148 154
139 169 174 179
140 161
142 175 180
162
163 170
181
164 176
182
187
W176-02-05-011
W2-5-12
UPPERSTRUCTURE / Control Valve
123 -Backup Ring 140 -Poppet 157 -Spring Seat 174 -Spring
124 -O-Ring 141 -Backup Ring 158 -Spring 175 -Spring Seat
125 -Plug 142 -O-Ring 159 -Spring Seat 176 -Main Spool
126 -O-Ring 143 -Overload Relief Valve 160 -Main Spool 177 -O-Ring
127 -O-Ring 144 -Plug 161 -Poppet 178 -Bolt
128 -O-Ring 145 -O-Ring 162 -Spring 179 -Spring Seat
129 -Backup Ring 146 -Backup Ring 163 -O-Ring 180 -Spring
130 -Backup Ring 147 -O-Ring 164 -Plug 181 -Spring Seat
131 -O-Ring 148 -Main Relief Valve 165 -O-Ring 182 -Main Spool
132 -Sleeve 149 -O-Ring 166 -Bolt 183 -Socket Bolt
133 -Spool 150 -Bolt 167 -Spring Seat 184 -Plug
134 -Washer 151 -Spring Seat 168 -Spring 185 -O-Ring
135 -Spring 152 -Spring 169 -Spring Seat 186 -Pilot Housing
136 -Backup Ring 153 -Spring Seat 170 -Main Spool 187 -Housing
137 -O-Ring 154 -Main Spool 171 -O-Ring
138 -Plug 155 -O-Ring 172 -Bolt
139 -Spring 156 -Bolt 173 -Spring Seat
W2-5-13
UPPERSTRUCTURE / Control Valve
183
123
124
125 155
156
126 149
127 186
128 157
129 150
130 158
165
131 151
159
171
132 152 166
134
Arm Anti-Drift 177
Valve
135 133
153 160 167 172
136
143
137
141 168 173
138 178
148 154
139 169 174
179
140 161
175 180
142
162
170
163
181
164 176
182
187
W176-02-05-011
W2-5-14
UPPERSTRUCTURE / Control Valve
Disassemble 5-Spool Control Valve Upper Sec-
tion
1. Remove socket bolts (183) (10 used) from hous- 7. Remove plug (164), O-ring (163), spring (162)
ing (187) to remove pilot housing (186). and poppet (161) from main spool (160).
: 8 mm : 17 mm
2. Remove arm anti-drift valve assembly (125 to 8. Remove spring (139), poppet (140), backup ring
138) and O-ring (124), backup ring (123) from (141), and O-ring (142) from housing (187).
pilot housing (186).
NOTE: Pry out the arm anti-drift valve assembly IMPORTANT: Never turn the lock nut. If turned,
by hand while removing pilot housing the set pressure may be changed.
(186). 9. Turn the cartridges of overload relief valve (143)
and main relief valve (148) to remove them from
3. Remove plug (138), O-ring (137), backup ring housing (187).
(136), spring (135), washer (134) and spool (133) : 27 mm
from sleeve (132).
Lock Nut
4. Remove plug (125), O-rings (126, 127, 128, 131) Cartridge
and backup rings (129, 130) from sleeve (132).
W2-5-15
UPPERSTRUCTURE / Control Valve
Load Check
Valve (Arm 1 Load Check Valve
Parallel Circuit) 213 (Arm 2 Parallel
Aux. Flow Rate Control 197 Circuit)
Valve (Poppet Valve) 214
198 215
199 208
209 216
200
201 210
Load Check 202 211
191 Valve (Travel 203 212
Parallel Cir- 193 204
192 cuit) 194 205
195 206
196 207
188
189
190
187
223
224
221
220
219
218 W176-02-05-013
217
W2-5-16
UPPERSTRUCTURE / Control Valve
W2-5-17
UPPERSTRUCTURE / Control Valve
Load Check
Valve (Arm 1 Load Check Valve
Parallel Circuit) 213 (Arm 2 Parallel
Aux. Flow Rate Control 197 Circuit)
Valve (Poppet Valve) 214
198 215
199 208
209 216
200
201 210
Load Check 202 211
191 Valve (Travel 203 212
Parallel Cir- 193 204
192 cuit) 194 205
195 206
196 207
187
223
224
221
220
219
218 W176-02-05-013
217
W2-5-18
UPPERSTRUCTURE / Control Valve
Disassemble 5-Spool Control Valve Side Section
10. Remove plug (217), then remove O-ring (218),
spring (219), washer (220) and spool (221).
: 36 mm
W2-5-19
UPPERSTRUCTURE / Control Valve
187
244
235 243 245
236 246
227
228 237
247
229
238
230
248
239
231
232 254
233
234
Auxiliary Flow
Combiner
249 252
Valve
250 253
251
W1F3-02-05-007
187 - Housing 233 - Spring 243 - Overload Relief Valve 249 - Socket Bolt
227 - Plug 234 - Bolt 244 - O-Ring 250 - O-Ring
228 - Spring 235 - Plug 245 - Backup Ring 251 - Plug
229 - Poppet 236 - Spring 246 - O-Ring 252 - O-Ring
230 - Spool 237 - Poppet 247 - Plug 253 - Plug
231 - O-Ring 238 - Spool 248 - O-Ring 254 - Pilot Housing
232 - Washer 239 - O-Ring
W2-5-20
UPPERSTRUCTURE / Control Valve
Disassemble 5-Spool Control Valve Lower Sec-
tion
IMPORTANT: Never turn the lock nut. If turned,
the set pressure may be changed.
19. Turn the cartridge of overload relief valve (243) to
remove it from housing (187).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017
W2-5-21
UPPERSTRUCTURE / Control Valve
SEPARATE AND COMBINE 4-SPOOL AND
5-SPOOL CONTROL VALVES
187
262
261
256
257
259
258
72 260
263
264
265
255 266 267
268
269
270
271
272
273 277
274 275 276
W176-02-05-015
W2-5-22
UPPERSTRUCTURE / Control Valve
Separate Combine
1. Install O-rings (256 to 258, 260, 261, 263, 265,
CAUTION: Housing (72) weight: 266, 268 to 272, 274, 276) and backup rings (259,
45 kg (100 Ib) 262, 264, 267, 273, 275, 277) into housing (187).
Housing (187) weight: 50 kg (110 Ib)
1. Remove socket bolts (255) (9 used), then sepa- CAUTION: Housing (72) weight:
rate housing (72) and housing (187). 45 kg (100 Ib)
: 12 mm Housing (187) weight: 50 kg (110 Ib)
2. Remove O-rings (256 to 258, 260, 261, 263, 265, 2. Connect housing (72) and housing (187) with
266, 268 to 272, 274, 276) and backup rings (259, socket bolt (255).
262, 264, 267, 273, 275, 277) from housing : 12 mm
(187). : 108+9.8 N⋅m (11+1 kgf⋅m, 80+7 lbf⋅ft)
W2-5-23
UPPERSTRUCTURE / Control Valve
ASSEMBLE 4-SPOOL CONTROL VALVE
37
38
52 39
28 36 46 W1F1-02-05-007 40
Boom Anti-Drift Valve W176-02-05-024
Section A Boom 1
5
63, 64
10
62 6
65 11
66
29
7
30 8
58
14 9
59
1 12
2 15 13
16
Boom
Anti-Drift 17
Valve 18
W176-02-05-025
3 4 W176-02-05-022
W2-5-24
UPPERSTRUCTURE / Control Valve
W2-5-25
UPPERSTRUCTURE / Control Valve
37
38
52 39
40
28 36 46 W1F1-02-05-007
Section A 5
63, 64 10
62 6
65 11
66
29 7
30 8
58 14 9
59
12
1
15 13
2
16
Boom 17
Anti-Drift
Valve 18
W176-02-05-025
3 4 W176-02-05-022
W2-5-26
UPPERSTRUCTURE / Control Valve
Assemble 4-Spool Control Valve Upper Section
1. Clamp main spool (36) with wood pieces in a vise, IMPORTANT: When replacing sleeve (10) or spool
then install poppet (37), spring (38), O-ring (39) (11), replace them together.
and plug (40). 6. Assemble O-ring (15), backup ring (14), spring
: 17 mm (13), washer (12), and spool (11) onto plug (16),
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) then install them onto sleeve (10).
NOTE: When assembling washer (12), the cham-
2. Install spring seats (27, 35, 45, 51), springs (26, fer side shall be facing to the spring side.
34, 44, 50), spring seats (25, 33, 43, 49) and
bolts (24, 32, 42, 48) onto spools (28, 36, 46, 52) 7. Install boom anti-drift valve assembly (5 to 16)
respectively. onto pilot housing (66).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) IMPORTANT: When replacing housing (72) or
poppet (18), tap poppet (18) with a
3. Install screw (30) and O-ring (29) onto pilot steel bar.
housing (66), then install nut (65), shim (64), re- 8. Install poppet (18) and spring (17) into housing
taining ring (63) and cap (62) into screw (30). (72).
: 4 mm
: 17 mm 9. Install spool (22), O-ring (21), washer (20) and
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) spring (19) into housing (72).
NOTE: When assembling washer (20), the cham-
4. Install screw (2) and O-ring (1) onto pilot housing
fer side shall be facing to the spring side.
(66), then install nut (59) and cap (58) onto screw
(2).
10. Install poppet (57), spring (56), O-ring (55),
: 4 mm
backup ring (54) and plug (53) into housing (72).
: 17 mm
: 14 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)
5. Install backup rings (7, 8) and O-rings (5, 6, 9)
11. Install main spool assemblies (28, 36, 46, 52),
onto sleeve (10).
O-rings (4, 23, 31, 41, 47, 71) and backup rings
NOTE: Check the assembling location of backup (3, 70) into housing (72) respectively.
rings (7, 8) and O-rings (6, 9).
9 8 7 6
W176-02-05-023
W2-5-27
UPPERSTRUCTURE / Control Valve
A
B Arm 2 Arm 1
66 C
Section B
72 69
Load Check Valve (Arm
69 2 Tandem Circuit)
68
86 87
99
D
67
101 72
100
T176-03-03-038
Section D 106 105 104 103 102
Bucket Flow Rate 80 81 82 83
Control Valve Check Valve Orifice
(Switch Valve) (Arm 1 Parallel Cir-
cuit)
T176-03-03-006
94
88
93
89 Section C Boom 1
90 95
Boom 2
91 96
92
97
98 Bucket Flow Rate Con-
trol Valve (Poppet Valve)
W176-02-05-026
Section A Swing
84, 85
86
75
87
74 Load Check Valve
(Boom 1 Parallel Cir-
73
cuit)
T176-03-03-005
76 77 78 79
Bypass Shut-Out Valve T176-03-03-007
W2-5-28
UPPERSTRUCTURE / Control Valve
W2-5-29
UPPERSTRUCTURE / Control Valve
A Arm 2 Arm 1
B Section B
66 C
69
72
Load Check Valve (Arm
2 Tandem Circuit)
69
86 87
68
99
D
67
101 72
100
T176-03-03-038
80 81 82 83
Section D 106 105 104 103 102 Check Valve Orifice
(Arm 1 Parallel Cir-
Bucket Flow Rate cuit)
Control Valve T176-03-03-006
(Switch Valve)
Section C Boom 1
88
93
89 Boom 2
90 95
91 96
92
97
98 Bucket Flow Rate Con-
trol Valve (Poppet Valve)
W176-02-05-026
Section A Swing
84, 85
86
87
Load Check Valve
75 (Boom 1 Parallel Cir-
cuit)
T176-03-03-005
76 77 78 79
Bypass Shut-Out Valve T176-03-03-007
W2-5-30
UPPERSTRUCTURE / Control Valve
IMPORTANT: Never turn the lock nut. If turned, 19. Install O-rings (107, 108) and backup ring (109)
the set pressure may be changed. into housing (72). Install pilot plate (99) with
12. Install pilot housing (66) onto housing (72) with socket bolts (100) (7 used) and (101) (3 used).
socket bolts (67) (11 used). Turn the cartridges of : 6 mm
overload relief valves (68, 69) to install them into : 25 N⋅m (2.5 kgf・m, 18 Ibf⋅ft)
housing (72). : 8 mm
: 8 mm : 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 27 mm 20. Tighten plug (106) which has been temporarily
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 Ibf⋅ft) tightened in step 13.
: 36 mm
: 200 N⋅m (20 kgf⋅m, 145 Ibf⋅ft)
Lock Nut
Cartridge 21. Install spool (79), seat (78), spring (77), O-ring
(76) and plug (75) into housing (72).
: 27 mm
: 180+3 N⋅m (18+0.3 kgf⋅m, 130.2+2.2
Ibf⋅ft)
W176-02-06-017
NOTE: Apply grease onto O-rings of overload re- NOTE: Install seat (78) with the chamfered side
lief valves (68, 69). (In order to protect facing the spring.
O-rings from breakage).
15. Install O-rings (88, 92) and backup rings (89, 91)
onto bushing (90).
W2-5-31
UPPERSTRUCTURE / Control Valve
Section A
72
121
122
B 119 T176-03-03-036
W176-02-05-020
120 120 120 120
Section B
115
110
111
112, 113
117
114
W2-5-32
UPPERSTRUCTURE / Control Valve
Assemble 4-Spool Control Valve Lower Section
22. Install O-ring (120) onto housing (72), then install
pilot housing (121) with socket bolts (122) (5
used).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
Lock Nut
Cartridge
W176-02-06-017
W2-5-33
UPPERSTRUCTURE / Control Valve
ASSEMBLE 5-SPOOL CONTROL VALVE
Main Spool Main Spool (160)
(154, 170, 176, 182)
177 171 165 155 149
Section A
151, 167,
157
173, 179
158
152, 168,
174, 180
156
150, 166,
172, 178
159
153, 169,
175, 181
160
154, 170,
176, 182
161
182 176 170 160 154 162
W176-02-05-021
163
Arm Anti-Drift Valve
B 184 185 164
A
Arm Anti-Drift Valve
143 W176-02-05-024
136
134
137
135
138
139
140
W176-02-05-027
T176-03-03-038
W2-5-34
UPPERSTRUCTURE / Control Valve
123 -*Backup Ring 140 -Poppet 157 -Spring Seat 174 -Spring
124 -*O-Ring 141 -*Backup Ring 158 -Spring 175 -Spring Seat
125 -Plug 142 -*O-Ring 159 -Spring Seat 176 -Main Spool
126 -O-Ring 143 -Overload Relief Valve 160 -Main Spool 177 -O-Ring
127 -O-Ring 144 -*Plug 161 -Poppet 178 -Bolt
128 -O-Ring 145 -*O-Ring 162 -Spring 179 -Spring Seat
129 -Backup Ring 146 -*Backup Ring 163 -O-Ring 180 -Spring
130 -Backup Ring 147 -*O-Ring 164 -Plug 181 -Spring Seat
131 -O-Ring 148 -Main Relief Valve 165 -O-Ring 182 -Main Spool
132 -Sleeve 149 -O-Ring 166 -Bolt 183 -Socket Bolt
133 -Spool 150 -Bolt 167 -Spring Seat 184 -Plug
134 -Washer 151 -Spring Seat 168 -Spring 185 -O-Ring
135 -Spring 152 -Spring 169 -Spring Seat 186 -Pilot Housing
136 -Backup Ring 153 -Spring Seat 170 -Main Spool 187 -Housing
137 -O-Ring 154 -Main Spool 171 -O-Ring
138 -Plug 155 -O-Ring 172 -Bolt
139 -Spring 156 -Bolt 173 -Spring Seat
W2-5-35
UPPERSTRUCTURE / Control Valve
161
162
182 176 170 160 154
Arm Anti-Drift Valve W176-02-05-021
163
B
A 164
143 Arm Anti-Drift Valve
W176-02-05-024
131
136
134
137
135
138
139
140
T176-03-03-038 W176-02-05-027
W2-5-36
UPPERSTRUCTURE / Control Valve
Assemble 5-Spool Control Valve Upper Section
1. Clamp main spool (160) with wood pieces in a 5. Install arm anti-drift valve assembly (125 to 138)
vise. Install poppet (161), spring (162), O-ring onto pilot housing (186).
(163) and plug (164).
: 17 mm IMPORTANT: Tap poppet (140) with a steel bar
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) when replacing housing (187) or
poppet (140).
2. Install spring seats (153, 159, 169, 175, 181), 6. Install poppet (140) and spring (139), O-ring
springs (152, 158, 168, 174, 180), spring seats (142) and backup ring (141) onto housing (187).
(151, 157, 167, 173, 179), and bolts (150, 156,
166, 172, 178) onto main spools (154, 160, 170, 7. Install main spool assemblies (154, 160, 170, 176,
176, 182) respectively. 182), O-rings (124, 149, 155, 165, 171, 177) and
: 17 mm backup ring (123) into housing (187).
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
IMPORTANT: Never turn the lock nut. If turned,
3. Install backup rings (129, 130) and O-rings (126, the set pressure may be changed.
127, 128, 131) and plug (125) onto sleeve (132). 8. Install pilot housing (186) onto housing (187) with
NOTE: Check the mounting location of backup socket bolts (183) (10 used). Turn the cartridges
rings (129, 130) and O-rings (128, 131). of overload relief valve (143) and main relief
valve (148) to install them into housing (187).
: 8 mm
131 130 129 128
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 lbf⋅ft)
Lock Nut
Cartridge
W176-02-05-023
W2-5-37
UPPERSTRUCTURE / Control Valve
Boom 2
191 Section B Positioning Section C
192 187
223
222
224 Load Check Valve
(Positioning
Tandem Circuit)
F
E
D 216
C 215 216
Aux. Flow B 215
Rate A 213, 214
Control Load
Valve 193, Check
194 Valve
T176-03-03-036
217 218 219 220 221 (Boom 2
Section F Parallel
Aux. Flow Rate Circuit) 2
195
Control Valve
(Switch Valve) 196
Load
Check
203 Valve
197 (Positioning
202 Section D W176-02-05-029
Parallel Circuit)
198 Arm 1 Swing Section E
199 204
200 205
201 Load
206
Load Check Check
207 Aux. Flow Rate Control Valve (Arm 1 Valve
Valve (Poppet Valve) Parallel Circuit) (Swing
Circuit)
W176-02-05-026
Section A
216 216
216
215 215
215 208,
213,
209
213, 214 214
210
Check Valve
(Main Circuit)
210
208,
209
211
212
Load Check
Valve (Arm 1
Tandem Circuit)
W176-02-05-030
W176-02-05-028
W2-5-38
UPPERSTRUCTURE / Control Valve
W2-5-39
UPPERSTRUCTURE / Control Valve
F E
D 216
C
215 216
B
215
A
213, 214
Aux. Flow Rate Load
193, Check
Control Valve
T176-03-03-036 194 Valve
(Boom 2
Parallel
Circuit) 2
217 218 219 220 221 195
Section F 196
Aux. Flow Rate
Control Valve Load
(Switch Valve) Check
Valve
Section D (Positioning
203 Parallel Circuit) W176-02-05-029
W176-02-05-026
Section A 216 216
215 215
208,
216 213,
209
214
215 210
213, 214
Check Valve 210
(Main Circuit) 208,
209
211
212
Load Check
Valve (Arm 1
Tandem Circuit)
W176-02-05-030
W176-02-05-028
W2-5-40
UPPERSTRUCTURE / Control Valve
Assemble 5-Spool Control Valve Side Section
9. Install spool (221), washer (220), spring (219)
and O-ring (218) into pilot plate (224), then install
plug (217) (temporarily).
: 36 mm
NOTE: Tighten plug (217) after installing pilot plate
(224) on housing (187). Check the length
of the threaded portion because the thread
length of plug (217) and plug (106) is dif-
ferent.
W2-5-41
UPPERSTRUCTURE / Control Valve
Section B
187
247
249
254
A
243
T176-03-03-036
W176-02-05-021
248 248 248 248 248
Section A
227
235
236 228
237
229 Aux. Flow
Combiner
238 Valve
230
239, 240 231, 232
233
234
W1F3-02-05-002
187 - Housing 233 - Spring 243 - Overload Relief Valve 249 - Socket Bolt
227 - Plug 234 - Bolt 244 - *O-Ring 250 - *O-Ring
228 - Spring 235 - Plug 245 - *Backup Ring 251 - *Plug
229 - Poppet 236 - Spring 246 - *O-Ring 252 - *O-Ring
230 - Spool 237 - Poppet 247 - *Plug 253 - *Plug
231 - O-Ring 238 - Spool 248 - O-Ring 254 - Pilot Housing
232 - Washer 239 - O-Ring
NOTE: As for mark *, refer to W2-5-20.
W2-5-42
UPPERSTRUCTURE / Control Valve
Assemble 5-Spool Control Valve Lower Section IMPORTANT: Never turn the lock nut. If turned,
IMPORTANT: Overall dimensions of spool (230) the set pressure may be changed.
have been determined. When dis- 24. Turn the cartridge of overload relief valve (243) to
assembling or replacing poppet install it into housing (187).
(229), spring (228), plug (227), re- : 27 mm
place them as an assembly. : 78+3 N⋅m (8+0.3 kgf⋅m, 57.9+2.2 lbf⋅ft)
20. Clamp spool (230) with wood pieces in a vise,
then install washer (232), spring (233) and bolt Lock Nut
(234).
Cartridge
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
NOTE: Assemble washer (232) with the cham-
fered side facing the spring.
W176-02-06-017
IMPORTANT: Overall dimensions of spool (238) NOTE: Apply grease on the O-ring of overload re-
have been determined. When dis- lief valve (243). (In order to protect the
assembling or replacing poppet O-ring from breakage.)
(237), spring (236), plug (235), re-
place them as an assembly.
21. Clamp spool (238) with wood pieces in a vise,
then install washer (240), spring (241) and bolt
(242).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
NOTE: Assemble washer (240) with the cham-
fered side facing the spring.
W2-5-43
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-44
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL AUXILIARY
CONTROL VALVE
Removal 3
W1F3-02-05-005
Installation 4
W2-5-45
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AUXILIARY CONTROL VALVE 19
10 20
21
9 22
8 23
7
6 24
25
5 26
4 27
3 28
2
1
37
38 29
30
39 31
18 32
17 33
40 34
16
15 41 35
14 36
13 42
12 43
11 44
56 45
55
54
53 46
52 47
51
48
62
61
60
50
49
59
58
57
W198-02-05-001
W2-5-46
UPPERSTRUCTURE / Control Valve
Disassemble Auxiliary Control Valve
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1
before starting any repair work.
W2-5-47
UPPERSTRUCTURE / Control Valve
ASSEMBLE AUXILIARY CONTROL VALVE
Cross Section
X-X 37 39 40 38
41
43
62
42
44
1 to 18 A1 B1 19 to 36
A1 B1
X X
W198-02-05-002
W198-02-05-003
57
Cross Section
W-W
52 54 53 55 56 62 47
48 45
50 51
W W
W198-02-05-004
49
57 59 58 46
W198-02-05-005
W2-5-48
UPPERSTRUCTURE / Control Valve
Assemble Auxiliary Control Valve
W2-5-49
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-50
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
Removal
W176-02-06-002
W2-6-1
UPPERSTRUCTURE / Swing Device
Installation
W2-6-2
UPPERSTRUCTURE / Swing Device
(Blank)
W2-6-3
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING REDUCTION
GEAR
22
23 1
24
2
3
32 21
25 4
31 5
20 6
26 7
19
8
27
18 9
28 10
17
11
29
16
12
30 15 13
14
W178-02-06-004
W2-6-4
UPPERSTRUCTURE / Swing Device
Disassemble Swing Reduction Gear 3. Remove drain plug (31), then drain the oil.
: 8 mm
CAUTION: Swing device weight:
215 kg (480 lb)
4. Remove pipe (32) from housing (25).
CAUTION: When hoisting the swing device, : 18 mm
do not string the rope suddenly.
5. Put alignment marks at the jointed portion be-
1. Secure the swing device body with nylon slings, tween motor (1) and ring gear (24), between ring
then hoist it by crane. gear (24) and housing (25).
11. Remove 2nd stage sun gear (20) from 2nd carrier
(18).
W178-02-06-012
W2-6-5
UPPERSTRUCTURE / Swing Device
23
25 21
4
7
8
18
10
17
11
16
12
30 15
W178-02-06-004
W2-6-6
UPPERSTRUCTURE / Swing Device
IMPORTANT: The hole for the spring pin located
CAUTION: Housing (25) assembly weight:
on the 1st stage carrier is not a
through one. Take care to the tap- 122 kg (270 lb)
ping-in distance when tapping the
spring pin in. 21. Install eyebolt (M16) into bolt (23) hole in housing
13. Tap spring pin (5) on the 1st stage carrier (21) (25). Lift housing (25). Remove bracket (ST 5097),
assembly into pin (4) using special tool (ST 1462). which has been installed at the pinion gear side.
Stop tapping when the spring pin is driven to the : 30 mm
middle of the pin hole. Do not try to tap spring pin
(5) to the end. CAUTION: Before pressing shaft (30), pro-
vide a protection cover (outer diameter: 380
14. Remove pin (4), planetary gear (7), needle bear- mm (15”), inner diameter: 110 mm (4.3”),
ing (6), thrust plate (8) from 1st stage carrier (21). thickness: 25 to 30 mm (0.98” to 1.18”)). Then,
use the press to remove the shaft while cov-
15. Remove remaining two sets of pin (4), planetary ering housing (25) and roller bearing (14) with
gear (7), needle bearing (6), thrust plate (8) from the protection cover may result in personal
1st stage carrier (21) according to the removing injury due to metal fragments flying off if the
procedure in step 13 and step 14. housing and/or bearing is broken. Use a
press of capacity less than 30 tons (66000 lb).
16. Remove thrust plate (3) from 1st stage carrier Be sure to degrease the housing inside be-
(21). fore heating the bearing. Failure to degrease
may cause a fire.
IMPORTANT: The surface of the pin except for
both ends is a rotating surface for 22. Install the protection cover on housing (25). Push
the needle bearing. the upper end of shaft (30) with a press and re-
Take care not to damage it. move it from housing (25). The inner race of roller
17. Clamp the pin (4) with a vise. Push the spring pin bearing (26) and sleeve (28) are removed with the
out using special removing tool (ST 1462). (3 shaft.
places)
25 30 14
18. Disassemble the 2nd stage carrier (18) assembly Press
according to the removing procedure for the 1st
stage carrier (21) assembly. However 6 needle Protection
bearings (12) and 6 thrust plates (11) are used on Protection
Cover
the 2nd stage carrier (18) assembly. Cover
Moreover, use ST 1463 as the extractor for spring
pin (10) .
20. Remove bearing nut (15) from shaft (30) using W1F3-02-06-001
ST 2926
15
W178-02-06-008
W2-6-7
UPPERSTRUCTURE / Swing Device
25
26
27
28
29
30
14
W178-02-06-004
W2-6-8
UPPERSTRUCTURE / Swing Device
23. Attach the shaft (30) assembly to the special tool IMPORTANT: Push the shaft of the special tool
bearing removal set. into the gully side of the pinion.
NOTE: Use the following parts as the special tool Secure the shaft with the hose clamp
set for removing roller bearing (26). in order not to loosen and separate
Part Size Remarks CAUTION: Shaft weight: 40 kg (90 lb)
Shaft Length: 200 mm 8 used. All should be
or Bolt (8 in) identical in length with no CAUTION: Be sure to use the guide when
Diameter: 19 mm wear and deformation on pushing shaft (30) with a press
(3/4 in) both ends.
Material: S35C (JIS), Press
1035 (AISI)
Oil Passage
Outer Race
W157-02-06-012
Shaft (30)
Roller Bearing
(26) Inner Race
W178-02-06-001
Sleeve (28)
Shaft
W157-02-06-013
Guide
W2-6-9
UPPERSTRUCTURE / Swing Device
W2-6-10
UPPERSTRUCTURE / Swing Device
(Blank)
W2-6-11
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING REDUCTION GEAR
1
2 4
3 5
22
21 6
20
7
18
24
8
19 10
11
23
13
12
11
17
9
16
32
15
14
26
29 25 31
27
28
30
W178-02-06-003
W2-6-12
UPPERSTRUCTURE / Swing Device
Assemble Swing Reduction Gear
1. Install O-ring (29) onto sleeve (28). 5. Apply THREEBOND #1215 on the outer surface
of oil seal (27). Put oil seal (27) flat on housing
(25) and push oil seal (27) in gently. Then place
CAUTION: Shaft + sleeve + outer race
seal mounting tool (ST 2925) on oil seal (27) and
weight: 36 kg (80 lb) tap the seal mounting tool in by hammering di-
rectly.
2. Install sleeve (28) and the inner race of roller
bearing (26) into shaft (30). Press sleeve and in- NOTE: If special tool (ST 2925) is used to replace
ner race using bearing mounting tool (ST 2923). the seal, no need to remove the sleeve.
NOTE: Press-in distance of the bearing inner race
can be assured by using the bearing
ST 2925
mounting tool. 27
25
Press
ST 2923
W178-02-06-007
26
6. Apply grease to the inner surface of oil seal (27)
28 all around. Apply grease to the outer surface of
sleeve (28) on shaft (30).
30
NOTE: Apply grease carefully when installing the
shaft to avoid accidental curling of the seal
lip from the shaft.
W178-02-06-013
W2-6-13
UPPERSTRUCTURE / Swing Device
24
23
15
14
25
27
30
W178-02-06-003
W2-6-14
UPPERSTRUCTURE / Swing Device
15. Lift and place the housing (25) assembly on
CAUTION: Housing + outer races (2 used)
bracket (ST 5097). Secure the housing (25) as-
weight: 65 kg (140 lb) sembly with 2 bolts (M20) while the stopper at the
bottom of bracket is located at the middle of two
9. Install eyebolt (M16) into the ring gear mounting teeth of the pinion gear. Secure the bracket on a
bolt (23) hole in housing (25). Then lift and place workbench.
housing (25) on shaft (30). Check and align : 30 mm
carefully to protect the oil seal (27) lip from curl-
25
ing.
10. Tap the inner race of roller bearing (14) into shaft
(30) with a bar and hammer. Tap the inner race
ST 5097
until two threads of shaft bearing nut (15) appear. Stopper
NOTE: The fitting between the inner race and shaft
is tight.
14. Place mounting tool (ST 2924) onto the inner race
of roller bearing (14). Push the inner race down
using a press.
NOTE: Press-in distance of the inner race can be
assured by using the mounting tool.
ST 2924
14
W178-02-06-011
W2-6-15
UPPERSTRUCTURE / Swing Device
4
3 5
22
21 6
7
18
8
10
11
13
12
11
17
9
16
15
30
W178-02-06-003
W2-6-16
UPPERSTRUCTURE / Swing Device
IMPORTANT: Take care to the direction of the IMPORTANT: Pay attention to the mounting direc-
bearing nut. tion of spring pin (10) and thrust
Grease must be applied for keeping plate (19).
correct tightening torque. 18. Assemble second stage carrier (18) according to
16. Apply a film of grease on the threaded surface of following steps.
bearing nut (15), then install bearing nut (15) on Install needle bearing (12) (2 used) into
shaft (30) with the stepped side of bearing nut planetary gear (13). Clamp planetary gear (13)
facing roller bearing (14). Tighten the bearing nut with two pieces of thrust plate (11), then install
using mounting tool (ST 2926). them together into second stage carrier (18).
: 350 N⋅m (36 kgf⋅m, 260 Ibf⋅ft)
NOTE: Grease must be applied for keeping correct When mounting needle bearings (12) (2 used),
tightening torque. the spring pin hole (in mounting pin (9)) should
be facing out. Align the spring pin hole in
second stage carrier (18) with that of pin (9).
ST 2926
15
Tap spring pin (10) into second stage carrier
(18) using the special tool (ST 1463). At this
time, the slit of the spring pin should face the
end of pin (19).
10
W178-02-06-008
Slit
17. Install lock plate (16) onto bearing nut (15) with
W178-02-06-002
bolt (17). In case the spline of lock plate and that
of shaft (30) are not aligned, tighten the bearing
Install thrust plate (19) into second stage
nut in tightening direction until both splines are
carrier (18), while the oil groove of thrust plate
aligned.
(19) is facing upward.
: 17 mm
Install needle bearings (12) (4 used), thrust
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
plates (11) (4 used), pins (9) (2 used) and
spring pins (10) (2 used) into two remaining
holes of the second stage carrier according to
the same procedure mentioned above.
W2-6-17
UPPERSTRUCTURE / Swing Device
22
21
20
18
24
23
16
32
25 31
30
W178-02-06-003
W2-6-18
UPPERSTRUCTURE / Swing Device
IMPORTANT: Take care to the mounting direction 28. Fill gear oil into ring gear (24) until the middle part
of the 2nd stage carrier. of the 1st stage sun gear (2) is submerged.
20. Install the 2nd stage carrier (18) assembly onto (Approx. 6.2 L (1.64 US gal.))
the spline of shaft (30), while the concave part of
the boss in bottom side of the carrier comes in 29. Clean off the old THREEBOND, then apply new
contact with lock plate (16). THREEBOND #1212 onto the motor (1) mounting
surface of ring gear (24).
Concave Part 18
16 CAUTION: Motor weight: 47 kg (100 lb)
30
30. Install eyebolt (M10) to motor (1) and lift motor (1)
off. Align the mating marks, and then fasten the
swing motor and ring gear (24) with bolts (22) (8
used).
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W178-02-06-014
Eyebolt Mounting
21. Install 2nd stage sun gear (20) into the 2nd stage Position
carrier (18) assembly with the small diameter part
of the 2nd stage sun gear facing up.
24. Install the 1st stage carrier (21) assembly onto the
spline of 2nd stage sun gear (20).
26. Install pipe (32) into housing (25) with seal tape
wound on the threaded part of the pipe.
: 18 mm
W2-6-19
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING MOTOR
11
8
7
6
5
4 10
3
2
24
25 29
26 30
1 27 31
28
23 27
26
25
24
12
13
14 22
15 21 32
16 20
W178-02-06-015
19
18
17
W2-6-20
UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor
CAUTION: Another method is to float fload
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1 brake piston (19) by blowing air from port B.
before starting the disassembly work. However, piston (13) may fly out when
blowing air. Do not use this method.
CAUTION: Swing motor assembly weight: 7. Install tool (ST 1468) into notch A of brake piston
47 kg (105 Ib) (19), then pull brake piston (19) out from casing
(1).
IMPORTANT: Do not disassemble relief valve (32).
1. Remove relief valves (32) (2 used) from valve
casing (28).
: 41 mm Notch A
13
2. Remove plugs (24) (2 used) from valve casing
1
(28). 19
: 14 mm
W2-6-21
UPPERSTRUCTURE / Swing Device
11
8
7
6
5
4 10
3
2
13
14
15
W178-02-06-015
W2-6-22
UPPERSTRUCTURE / Swing Device
IMPORTANT: Take care not to damage the slide
surface of rotor (9) and plunger (6).
9. Place casing (1) horizontally. Remove rotor (9),
retainer (8), plate (7) and plungers (6) (9 used)
from shaft (4).
17. Remove spring (14) and ball (15) from casing (1).
W2-6-23
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR
27 26 25 24
12
13
14
15
16
29
T178-03-02-004 T178-03-02-003
31 30
31
30
28 32
22 21
20
23
19
18
10
17
6
11
9 8
7 3
5
1
4 T178-03-02-002
W2-6-24
UPPERSTRUCTURE / Swing Device
Assemble Swing Motor
IMPORTANT: Be sure to install the inner race of 11. Install brake piston (19) into casing (1) while
bearing (3) with the flange facing the aligning the mating mark.
stepped side of shaft (4). NOTE: If it is not easy to install O-rings (17, 18)
into brake piston (19) due to the resistant
1. Push the inner races of bearings (3, 22) into shaft force from the O-rings, tap them evenly
(4) with a press. with a plastic hammer to force them in.
IMPORTANT: Push oil seal (2) in, with its lip facing 12. Install springs (20) (24 used) onto brake piston
up. (19).
2. Push oil seal (2) into casing (1) with a guide plate.
W2-6-25
UPPERSTRUCTURE / Swing Device
Drain Port 27 26 25 24
13
14
15
29
T178-03-02-004 T178-03-02-003
28 32
22 21
23
4 T178-03-02-002
W2-6-26
UPPERSTRUCTURE / Swing Device
IMPORTANT: If the inner parts of piston (13) need 21. Fill hydraulic oil through the drain port.
to be replaced, replace the piston as NOTE: Amount of Hydraulic oil: 0.8 L (0.211US
an assembly. gal)
Be sure to align the end face of the
piston with that of casing (1).
13. Install ball (15), spring (14) and piston (13) into
housing (1).
W2-6-27
UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD
Swing Motor
D D
W107-02-06-139
W107-02-06-140
W2-6-28
UPPERSTRUCTURE / Swing Device
3. Thickness of shoe
Unit: mm (in)
Standard Allowable Limit
5.5 (0.22) 5.3 (0.21)
W107-02-06-142
W107-02-06-143
W2-6-29
UPPERSTRUCTURE / Swing Device
(Blank)
W2-6-30
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL PILOT VALVE
12
W1F3-02-07-004
W2-7-1
UPPERSTRUCTURE / Pilot Valve
1. Insert pilot valve (11) into the lever stand and align 6
the mating marks made when disassembling. 7
8
2. Install pilot valve (11) to the lever stand with bolts 5 9
(4) (4 used). 10
11
: 13 mm 4
: 20 N⋅m (2.1 kgf⋅m, 15 lbf⋅ft)
4. Insert lever (5) (with grip (6)) into boots (8). Install
lever (5) into pilot valve (11). 12
3 W1F3-02-07-003
W2-7-2
UPPERSTRUCTURE / Pilot Valve
W2-7-3
UPPERSTRUCTURE / Pilot Valve
5
Installation of Blade/Stabilizer Pilot Valve
W2-7-4
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-7-5
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE FRONT/SWING PILOT
VALVE
10
10
11
1
11 12
12
2 13
13
14
5
5
6 15
6
16
7
7
17
8
8
18
9
9
19
19
20
20
W1F3-02-07-001
1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing
2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Seal Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)
W2-7-6
UPPERSTRUCTURE / Pilot Valve
Disassemble Front/Swing Pilot Valve
• Be sure to read “Precautions for Disassembly and IMPORTANT: Put on the mating mark to install the
Assembly” thoroughly on page W1-1-1 before plate (4) in the right direction.
starting any repair work. 4. Remove plate (4) from casing (14).
• The spool (13) diameter and the casing (14) bore
are selectively fitted. Do not replace individually. IMPORTANT: When bushings (6) (4 used) are still
• Discriminate between the disassembled parts by in casing (14), pry the bushing while
port No. where the parts are located in order to moving pusher (8) left and right.
avoid confusion. The port Nos. are indicated on Meanwhile take care not to damage
the periphery of casing (14) by embossed letters. the pusher.
IMPORTANT: Put port Nos. on the spool (13)
1. Clamp the pilot valve to vise with port plate (8) assembly and springs (10) (4 used)
facing downward and secure it. so as to avoid confusing each port.
Take care not to damage spool (13).
2. Put a wrench on cam (2) and secure it. Then 5. Remove the pusher (8) assembly, the spool (13)
remove screw joint (1) and the cam from universal assembly and springs (10) (4 used) from casing
joint (3). (14).
: 22 mm, 32 mm
6. Remove pushers (8) (4 used), O-rings (7) (4
used) and oil seals (5) (4 used) from bushings (6)
CAUTION: As soon as loosening universal
(4 used).
joint (3), the plate (4), bushings (6) (4 used)
and pushers (8) (4 used) may come up same
time for springs (10) (4 used) being
compressed. Take care not to let these parts
fly out.
Section A-A
ST 7260
A A
W577-02-06-003
W2-7-7
UPPERSTRUCTURE / Pilot Valve
11
11 12
12
13
13
14
15
16
18
9
9
20
W1F3-02-07-001
W2-7-8
UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Do not remove the spool (13)
assembly unless necessary.
IMPORTANT: When removing spool (13) from
spring seats (9) (4 used), push the
spool in the spring seat, then direct
it towards the bigger hole while
remove it. However, do not push the
spring seat in more than 6 mm (0.24
in).
13
11
9
W577-02-06-004
W2-7-9
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE FRONT/SWING PILOT VALVE
1
3
8
5
4
6
11
10
12
13
14
16
15
17
18
19
20 W1F3-02-07-002
W2-7-10
UPPERSTRUCTURE / Pilot Valve
Assemble Front/Swing Pilot Valve
• Be sure to read “Precautions for Disassembly and IMPORTANT: Install spring (10) in the same
Assembly” thoroughly on page W1-1-1 before position of when disassembling.
starting the assembly work. 5. Install springs (10) (4 used) to casing (14).
• The seal parts shall be replaced with new ones
when assembling. IMPORTANT: Install the spool (13) assemblies (4
used) in the same position of when
1. Install bushing (16) and O-ring (15) to casing (14). disassembling.
6. Install the spool (13) assemblies (4 used) to
2. Install spring pin (17) to port plate (18) and seal casing (14).
washers (19) (2 used) to socket bolts (20) (2
used) respectively. 7. Install O-rings (7) (4 used) and oil seals (5) (4
used) to bushings (6) (4 used).
IMPORTANT: Tighten socket bolts (20) (2 used) in
turn slowly. IMPORTANT: Apply a film of hydraulic oil to the
3. Install the port plate (18) assembly to casing (14) circumference of pushers (8) (4
with socket bolts (20) (2 used). used).
: 6 mm 8. Install pushers (8) (4 used) to bushings (6) (4
: 20.5±2 N⋅m used).
(2.1±0.2 kgf⋅m, 15±1.4 lbf⋅ft)
IMPORTANT: When it is difficult to install plate (4)
IMPORTANT: When installing spool (13) to spring because of the strong force from
seats (9) (4 used), insert the spool springs (10) (4 used), put the
through bigger one of the two holes bushing (6) assemblies (4 used) on
on the spring seat and move the the four holes of casing (14) and
spool to the smaller hole. However, then add plate (4). Simultaneously
do not insert the spool more than 6 press the bushing assemblies (4
mm (0.24 in). used) and tighten the universal joint
(3) temporarily.
9. Align the mating mark put when disassembling to
install the bushing (6) assemblies (4 used) and
plate (4) to casing (14).
13
9
W577-02-06-004
W2-7-11
UPPERSTRUCTURE / Pilot Valve
1
3
14
W1F3-02-07-002
W2-7-12
UPPERSTRUCTURE / Pilot Valve
10. Install universal joint (3) to casing (14) using
special tool (ST 7260).
: 24 mm
: 47±2.9 N⋅m
(4.8±0.3 kgf⋅m, 35±2.2 lbf⋅ft)
W2-7-13
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE TRAVEL, POSITIONING /
AUXILIARY, BLADE / STABILIZER PILOT
VALVE
20
7 20
8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15
15
4
11 14
14
3
3 12
13
2
2
21
1
1
W1LA-02-06-001
W2-7-14
UPPERSTRUCTURE / Pilot Valve
Disassemble Travel, Positioning/Auxiliary and
Blade/Stabilizer Pilot Valve
• Be sure to read “Precautions for Disassembly and IMPORTANT: Shim (17) adjusts the pressure of the
Assembly” thoroughly on page W1-1-1 before spool (15) assemblies (2 used), they
starting any repair work. had better not be disassembled. If
• As casing (21) and spool (15) cannot be disassembling the spool (15)
disassembled, they cannot be replaced with new assemblies, record the number and
ones one by one. thickness of shim (17).
• Put identification tags on the disassembled parts
by port to aid when re-assembling. IMPORTANT: Be sure not to remove bushing (4)
from cover (11) unless bushing (4) is
IMPORTANT: Put the mating marks onto cam (9), damaged.
pin (10), cover (11), and casing (21) 8. Pull bushings (4) (2 used) out of cover (11).
before disassembling.
1. Clamp the pilot valve in a vise to remove boot (7)
from cover (11).
2. Remove set screw (8) from cam (9). Pull pin (10)
out to remove cam (9) from cover (11).
: 2 mm
W2-7-15
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL, POSITIONING /
AUXILIARY, BLADE / STABILIZER PILOT
VALVE
8 10
7
9
5
20
3
6
2
11
19
18
14
17
16
12
13
15 W1LA-02-06-002
21
W2-7-16
UPPERSTRUCTURE / Pilot Valve
Assemble Travel, Positioning/Auxiliary and
Blade/Stabilizer Pilot Valve
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the assembly work.
• Clean the parts and put them by port for
assembling.
W585-02-06-005
Lip Part
W2-7-17
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-7-18
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE
Removal
1. Remove spring (3).
1
IMPORTANT: Attach identification tags to dis-
connected hoses for re-assembly.
2. Disconnect hoses (6 to 13) and pipes (14, 15). 2
: 17 mm, 19 mm, 22 mm 3
13 14 2
12 15
11
Installation
4
1. Install pilot shut-off valve (4) with bolts (2) (2
used).
: 17 mm 6
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
10
2. Install lever (1) with spring pin (5).
W2-8-1
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
W2-8-2
UPPERSTRUCTURE / Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1 be-
fore starting the repair work.
W2-8-3
UPPERSTRUCTURE / Pilot Shut-Off Valve
ASSEMBLE PILOT SHUT-OFF VALVE
12 13 11 4 5 Z
W178-02-08-006
Section Z-Z
10 6 7 8 9 4 3 2 1 11
13
T178-03-07-002
W2-8-4
UPPERSTRUCTURE / Pilot Shut-Off Valve
Assemble Pilot Shut-Off Valve
W2-8-5
UPPERSTRUCTURE / Pilot Shut-Off Valve
(Blank)
W2-8-6
UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL CON-
TROL VALVE
Removal
1. Remove the mounting bolts (14 used) of the
swing device upper side covers (2 used) and the
cab rear cover. Then, remove the covers (3
used).
: 17 mm
Installation
1. Apply LOCTITE to socket bolts (20) (4 used). In-
stall the signal control valve with them. T176-04-04-001
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W2-9-1
UPPERSTRUCTURE / Signal Control Valve
E
M
D
H
B
F
SB
PI G
K N
I
SH
J
DF
SA L
T178-03-06-016
W2-9-2
UPPERSTRUCTURE / Signal Control Valve
3
1
Pressure Sensor 5
(Auxiliary)
13
2 4
SK SE
Pressure Sensor 8
(Swing)
14
Control 7
Valve Side
9
6
10
SN
SL
11
T1F3-03-06-003
12 SP
Control Valve Side
Port Name Connecting to Note
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port 10 Plug
Port 11 Control Valve Travel Reverse Pilot Pressure
Port 12 Control Valve Travel Forward Pilot Pressure
Port 13 Pilot Pressure Shift Valve Positioning Raise/Auxiliary Open Pilot Pressure
Port 14 Pilot Pressure Shift Valve Positioning Lower/Auxiliary Close Pilot Pressure
Port SE Plug
Port SN Plug
Port SP Shuttle Valve Pump 1 Flow Rate Control Valve Control Pressure
Port SL Plug
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
W2-9-3
UPPERSTRUCTURE / Signal Control Valve
Control
Valve Side
SN
T1F3-03-06-004
W2-9-4
UPPERSTRUCTURE / Travel Shockless Valve
REMOVE AND INSTALL TRAVEL
SHOCKLESS VALVE
Installation 3
W1F3-02-10-001
4
W2-10-1
UPPERSTRUCTURE / Travel Shockless Valve
CONSTRUCTION OF TRAVEL
SHOCKLESS VALVE
13
1
14
4
4
T1F3-03-08-005 T1F3-03-08-004
5
Section A
7
T1F3-03-08-006
8 9 10 11 12
Section B
W2-10-2
UPPERSTRUCTURE / Travel Shockless Valve
W2-10-3
UPPERSTRUCTURE / Travel Shockless Valve
(Blank)
W2-10-4
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL 4-UNIT SOLE-
NOID VALVE UNIT
Removal
3, 4
1. Disconnect the harness connector of each
proportional solenoid valve (13 to 16). 5, 6
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
W2-11-1
UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE PROPORTIONAL SOLE-
NOID VALVE
1
3
2
4
5
7
8
9
10
13
11
12 14
15
16
17
18
W157-02-11-016
W2-11-2
UPPERSTRUCTURE / Solenoid Valve
Disassemble Proportional Solenoid Valve
W2-11-3
UPPERSTRUCTURE / Solenoid Valve
ASSEMBLE PROPORTIONAL SOLENOID
VALVE
4 2 6 1 8 16 13 14 10 15 18
3, 5
9 7 11 12 17
W157-02-11-001
W2-11-4
UPPERSTRUCTURE / Solenoid Valve
Assemble Proportional Solenoid Valve
IMPORTANT: Apply grease to O-rings (13, 14, 15) IMPORTANT: Lock nut (2), adjusting screw (4),
and apply a film of hydraulic oil to spring (5) and O-ring (3) are not
sleeve (16). separated, so no need to assemble
When inserting the sleeve, be sure them.
to align the ports of the sleeve with When assembling solenoid (6), take
the ports in the housing. care not to drop spring (7).
Install sleeve so that the end faces 3. Install solenoid (6) with socket bolts (1) (2 used).
of sleeve and body come to the : 3 mm
same point. : 2.9 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft)
1. Install washer (18), plate (17) into the housing.
Install O-rings (13, 14, 15) on sleeve (16), and 6
then insert the sleeve (16) assembly into the
housing.
16
15 7
14
13
1
W157-02-11-011
Housing
W157-02-11-005
10 Housing
16
12
11
W157-02-11-009
W2-11-5
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL 3-UNIT SOLE-
NOID VALVE (FOR PUMP CONTROL)
Removal
1. Open cover (2) of the machine right side and se-
cure it with stopper (1).
T1F3-01-02-010
W2-11-6
UPPERSTRUCTURE / Solenoid Valve
Installation 6
1. Install bracket (4) on solenoid valve unit (5) with 3 4
5
the bolts (2 used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
MCBB-07-003
W2-11-7
UPPERSTRUCTURE / Solenoid Valve
CONSTRUCTION OF 3-UNIT SOLENOID
VALVE (FOR PUMP CONTROL)
1
5
6
7
8
9
10
11
12
13
14
15
16
T1F3-03-10-016
W2-11-8
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL 2-UNIT SOLE-
NOID VALVE (FOR BLADE/STABILIZER)
Removal
IMPORTANT: The one side of solenoid valve unit
cannot be removed. Be sure to re-
move the solenoid valve unit as the
plate (7) assembly.
Installation
1. Install the solenoid valve units (2 used) on plate
(7) with bolts (8) (4 used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
W2-11-9
UPPERSTRUCTURE / Solenoid Valve
CONSTRUCTION OF 2-UNIT SOLENOID
VALVE (FOR BLADE/STABILIZER)
T1F3-03-08-001
6
W2-11-10
UPPERSTRUCTURE / Pilot Relief Valve
REMOVE AND INSTALL PILOT RELIEF
VALVE
Removal
Installation
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
4
2
2. Connect hoses (2) (6 used).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)
W2-12-1
UPPERSTRUCTURE / Pilot Relief Valve
CONSTRUCTION OF PILOT RELIEF 1 2 3, 4 5 6
VALVE
W1GL-02-12-002
T1F3-03-08-002
10 9 Section A
8 7
11
12
B
13
Section B 14 T1F3-03-08-003
T1F3-03-08-008
W2-12-2
UPPERSTRUCTURE / Steering Valve
REMOVE AND INSTALL STEERING VALVE
2. Remove bolts (2) (4 used) from stand (1) to re- Brake Valve
move steering valve (4).
Stand Mount-
ing Bolt
Installation
2
1. Install steering valve (4) to stand (1) with bolts (2)
(4 used).
: 17 mm Attachment Pedal W1F3-02-14-002
4
W216-02-12-005
W2-13-1
UPPERSTRUCTURE / Steering Valve
DISASSEMBLE STEERING VALVE
14
19
17
18
16
39
5
38
37 15
36
35
6
5
4 33
2 3 12
1 13 20
12 21
11 32
10 31
9 6
5 24
8 4
7 3 30 34
2 28
1 27
26
25
24
29
23 28
22 27
26
T1F3-03-07-004
W2-13-2
UPPERSTRUCTURE / Steering Valve
Disassemble steering valve
IMPORTANT: The O-ring (1), plug (2), spring (3), 4. Remove drive (25) and plate (23) to remove
holder (4), ball (5) and seat (6) are O-ring (22) from housing assembly (14). Remove
adjustment parts. Do not disassem- screw (20) from housing (15) with a screwdriver.
ble them. If disassemble them, the
setting may change, malfunction of 5. Dismount the steering valve from the vise. Turn
the base machine may result. the housing (15) over. Remove ball (21), springs
IMPORTANT: Cover the open ends of vice with (28) (2 used), plugs (27) (2 used), and balls (26)
cloth. Lightly secure the valve. (2 used) from housing (15). Place the steering
1. Secure the steering valve in a vice with cap (32) valve on a clean cloth with care not to damage
upward. the machined surfaces. Remove retaining ring (8)
from housing (15) with a screwdriver.
32
Vice
15
W202-02-14-002
W202-02-14-006
W2-13-3
UPPERSTRUCTURE / Steering Valve
19
17
18
39
5 16
38
37 15
36
35
5
4
2 3 12
1 13
12 21
11
10
9
5
4
7 3
2
1
26
26
T1F3-03-07-004
W2-13-4
UPPERSTRUCTURE / Steering Valve
7. Remove seal (11) and dust seal (7) from bushing
(9).
NOTE: Take care not to damage bushing (9) when
removing seal (11).
W2-13-5
UPPERSTRUCTURE / Steering Valve
ASSEMBLE STEERING VALVE
16 15 21 20 22 30 31
32
12 34
11
A B
25
33
7
24
8
T1F3-03-07-002
9 10 13 17 18 19 23 24 29
View A C View B
D
E
D
E
D
E
D E
T487-03-02-005
W1F3-02-13-001
Section C-C
Section E-E
36 35 37 38 39
T1F3-03-07-003
Section D-D
T487-03-02-006
26 27 28
6 5 4 3 2 1 T487-03-02-007
W2-13-6
UPPERSTRUCTURE / Steering Valve
W2-13-7
UPPERSTRUCTURE / Steering Valve
16 15
32
A B
25
T1F3-03-07-002
17 18 19
View A C View B
D
E
D
E
D
E
D E
T487-03-02-005
W1F3-02-13-001
Section C-C
Section E-E
36 35 37 38 39
T1F3-03-07-003
Section D-D
T487-03-02-006
26 27 28
6 5 4 3 2 1 T487-03-02-007
W2-13-8
UPPERSTRUCTURE / Steering Valve
Assemble Steering Valve
Precautions for before assemble 3. Install pin (18) into spool (19) and sleeve (16).
• Check all parts for scores or coarse surfaces. Level the ends of pin (18) with the outer diameter
If any, grind to a smooth finish using an oil stone. of sleeve (16).
W202-02-14-021
Spool (19)
ST 2497
Center Spring (17)
Sleeve (16)
W202-02-14-020
W2-13-9
UPPERSTRUCTURE / Steering Valve
15 21 20 22
12
11
A B
8
T1F3-03-07-002
9 10 13 19 23
View A C View B
D
E
D
E
D
E
D E
T487-03-02-005
W1F3-02-13-001
Section C-C
Section E-E
T1F3-03-07-003
Section D-D
T487-03-02-006
26 27 28
T487-03-02-007
W2-13-10
UPPERSTRUCTURE / Steering Valve
5. Install O-ring (10), bearing races (12) (2 used) 9. Lightly hold housing (15) with a vise.
and thrust needle (13) to housing (15).
10. Install O-ring (22) in housing (15). Install ball (21)
and screw (20) in housing (15) as illustrated be-
13 low. Install balls (26) (2 used), plugs (27) (2 used),
12 and springs (28) (2 used) in housing (15) as illus-
trated below. Put plate (23) on housing (15). Align
10 the bolt holes with tapped holes on housing (15).
15
Screw (20)
Ball (21)
W202-02-14-023
Housing (15)
8
Spring (28)
7
15
Plug (27)
11 10
12
Ball (26)
9
Housing (15)
W212-02-14-002
W2-13-11
UPPERSTRUCTURE / Steering Valve
16 15 30 31
32
12 34
11
A B
25
33
24
T1F3-03-07-002
13 18 19 23 24 29
View A C View B
D
E
D
E
D
E
D E
T487-03-02-005
W1F3-02-13-001
Section C-C
Section E-E
36 35 37 38 39
T1F3-03-07-003
Section D-D
T487-03-02-006
T487-03-02-007
W2-13-12
UPPERSTRUCTURE / Steering Valve
IMPORTANT: Steps 11 to 13 described above are 14. Install spacer (31) into rotor (30). Install O-ring
important procedure to determine (24) on cap (32). Install cap (32) on rotor (30).
the valve timing. Carefully follow the
procedures in these steps. 15. Install screws (33) (6 used) and screw (34) onto
11. Turn spool (19) and the sleeve (16) assembly so cap (32), tighten them with the specified torque.
that pin (18) is parallel to the port face on housing Tool: 5/16 inch-12 Point Flange Head Socket
(15). Draw line (B) on the end face of the spline : 28.5 N⋅m (2.9 kgf⋅m, 21 Ibf⋅ft)
on drive (25) so that line (B) is parallel to line (C)
at the yoke of drive (25). Insert drive (25) to install
the yoke of drive (25) onto pin (18). (Line (B) on 16. Install valve seat (39), poppet (38) and spring
the end face of the spline on drive (25) is parallel (37) into housing (15) then secure them with plug
to the port face on housing (15).) (35).
B
Rotor (30)
C A
Draw Line (a)
Star (29)
Drive (25)
B
Bolt Hole
Yoke
Drive (25) C
W487-03-08-006
D
Drive (25)
Make surface of pin
(18) paralleled with
port face
Pin (18)
Yoke
Housing (15) W487-03-08-007
W2-13-13
UPPERSTRUCTURE / Steering Valve
(Blank)
W2-13-14
UPPERSTRUCTURE / Brake Valve
REMOVE AND INSTALL BRAKE VALVE
1 2
CAUTION: Be sure to bleed air from hydrau-
lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)
Removal
Installation
W2-14-1
UPPERSTRUCTURE / Brake Valve
DISASSEMBLE BRAKE VALVE
1
5 11
28
27 8
4 7
26
10
6
7
12
9
13
15
14
16
25
9
29 24 3
17
23
30
42 31
32 22
21 16
33
34 20
35 18
36 19
41 20
40
37
39
28
43 38
44
45
46
47
43
44
45
46 48 47
W1F3-02-14-003
W2-14-2
UPPERSTRUCTURE / Brake Valve
W2-14-3
UPPERSTRUCTURE / Brake Valve
5 11
28
27 8
4 7
26
10
6
7
12
9
13
15
14
16
25
9
29 24 3
17
23
30
42 31
32 22
21 16
33
34 20
35 18
36 19
41 20
40
37
39
28
43 38
44
45
46
47
43
44
45
46 48 47 W1F3-02-14-003
W2-14-4
UPPERSTRUCTURE / Brake Valve
Disassemble Brake Valve
• Be sure to read “Precautions for Disassembly IMPORTANT: As the action force from springs is
and Assembly” thoroughly on page W1-1-1 be- applied to socket bolt (42), slowly
fore starting the disassembly work. remove socket bolt (42) while push
S cylinder (39) on top.
IMPORTANT: Before disassembling, put matching 9. Remove socket bolts (42) (4 used) from S cylin-
marks on bracket (25), T flange (27), der (39).
P cylinder (38), S cylinder (39).
1. Secure S cylinder (39) on a vice with the S cylin- 10. Remove S cylinder (39) and the P cylinder (38)
der (39) facing lower side. Except the roller (18) assembly from T flange (27).
parts, remove cotter pins (3) (3 used) then re-
move pins (8), (10), (16).
11. Pulling out the spool (47) assembly from P cylin-
der (38).
2. Remove spring pin (13) from yoke (15) to remove
pin (12).
12. Remove plunger (46), spring (48) and retaining
ring (44), retainer (45) from the spool (47) as-
3. Remove cotter pin (3) from link (17) then remove sembly.
pin (16), washers (20) (2 used) and roller (18).
W2-14-5
UPPERSTRUCTURE / Brake Valve
ASSEMBLE BRAKE VALVE 2
1
12
11
8
15
14
25 27 38 42 39 41
16
10
16
18 21 24
23 W1F3-02-14-004
34 30 28 46 44 28 47 43 40
41
46
45
37 22 26 36 35 32 29 33 31 47 48 45 43 T1F3-03-09-002
View A 13 5
12
7
15
8
9
3
24
25
17
10
3 16
18 19 20 W1F3-02-14-005
W2-14-6
UPPERSTRUCTURE / Brake Valve
W2-14-7
UPPERSTRUCTURE / Brake Valve
2
1
12
11
8
15
14
25 27 38 42 39 41
16
17
10
16
18 21 24
23 W1F3-02-14-004
34 30 28 46 44 28 47 43 40
41
46
45
37 22 26 36 35 32 29 33 31 47 48 45 43 T1F3-03-09-002
View A 13 5
12
7
15
8
9
3
24
25
17
10
3 16
18 19 20 W1F3-02-14-005
W2-14-8
UPPERSTRUCTURE / Brake Valve
Assemble Brake Valve
• Be sure to read “Precautions for Disassembly 10. Install spring (48), plunger (46) and spring (43)
and Assembly” thoroughly on page W1-1-1 be- into P cylinder (38).
fore starting the assembly work.
11. Align the matching marks while placing S cylinder
1. Install oil seal (26) into T flange (27). (39) onto P cylinder (38).
2. Secure T flange (27) in a vice with oil seal (26) 12. Install retainer (45) and retaining ring (44) to
facing down. spool (47).
3. Install O-ring (28) to T flange (27). 13. Install the spool (47) assembly to S cylinder (39).
4. Apply hydraulic oil onto all parts of rod (29), pilot 14. Install plunger (46), spring (43) and plug (41) to S
piston (36), push rod (37), plunger (46), spool cylinder (39).
(47). : 130 to 180 N⋅m
(13.0 to18.0 kgf⋅m, 94 to 130 Ibf⋅ft)
5. Install push rod (37), pilot piston (36) and retainer
(35), retainer (34), return spring (30), balance 15. Joint T flange (27), P cylinder (38), S cylinder (39)
spring (33), spring (32), holder (31), rod (29) into with socket bolts (42) (4 used).
T flange (27) in that order. : 60 to 75 N⋅m
(6.0 to 7.5 kgf⋅m, 43 to 54 Ibf⋅ft)
6. Install O-ring (28) to P cylinder (38).
W2-14-9
UPPERSTRUCTURE / Brake Valve
2
1
12
11
8
15
14 25 27 39
16
17
10
16
18
21 23 24 W1F3-02-14-004
22 T1F3-03-09-002
View A 13
12
15
3
24
25
17
10
16
3
3
W1F3-02-14-005
18 20
W2-14-10
UPPERSTRUCTURE / Brake Valve
16. Secure the cylinder assembly in a vice with the S 26. Secure link (17) with lock nut (6).
cylinder (39) side facing down. : 6.0 to 10 N⋅m
(0.6 to 1.0 kgf⋅m, 4.3 to 7.2 Ibf⋅ft)
17. Install bracket (25) to T flange (27) with socket
bolts (24) (4 used). 27. Install rubber (1) onto brake pedal (2).
: 60 to 75 N⋅m
(6.0 to 7.5 kgf⋅m, 43 to 54 Ibf⋅ft)
19. Apply grease onto all pin hole of brake pedal (2),
bracket (25), yoke (15) and link (17).
20. Install yoke (15) into brake pedal (2) with pin (12)
and spring pin (13).
22. Install the link (17) assembly with pin (10) and
bracket (25). Lock them with cotter pin (3).
24. Install yoke (15) to link (17) with pin (16), lock
them with cotter pin (3).
25. Adjust the play of link (17) with stopper bolt (4) to
0 mm.
W2-14-11
UPPERSTRUCTURE / Brake Valve
(Blank)
W2-14-12
UPPERSTRUCTURE / Accumulator Charging Valve
REMOVE AND INSTALL ACCUMULATOR
CHARGING VALVE
Removal
Installation
W2-15-1
UPPERSTRUCTURE / Accumulator Charging Valve
CONSTRUCTION OF ACCUMULATOR
CHARGING VALVE
5
2
4
7
10
11
12
13
14
24
23 15
21
16
17
22
18
19
20
W1F3-02-15-001
W2-15-2
UPPERSTRUCTURE / Accumulator Charging Valve
W2-15-3
UPPERSTRUCTURE / Accumulator Charging Valve
(Blank)
W2-15-4
UPPERSTRUCTURE / Transmission Control Valve
REMOVE AND INSTALL TRANSMISSION
CONTROL VALVE
Removal
W1GL-02-16-001
Installation 2 4 3
W2-16-1
UPPERSTRUCTURE / Transmission Control Valve
CONSTRUCTION OF TRANSMISSION
CONTROL VALVE
28 29 30 31
1 2
B C
27
18 13
A
W1GL-02-16-002 12
17 16 15 14 W1F3-02-16-001
Section B
19
1 *2 5 6 7
20
21
22
23
*1 8
24
25
9
12 11 10 W1GL-02-16-003
T1F3-03-03-006
Section C
Section A
26
W2-16-2
UPPERSTRUCTURE / Transmission Control Valve
W2-16-3
UPPERSTRUCTURE / Transmission Control Valve
(Blank)
W2-16-4
MEMO
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SECTION 3
UNDERCARRIAGE
―CONTENTS―
Group 1 Swing Bearing Group 5 Axle
Remove and Install Swing Bearing ......... W3-1-1 Remove and Install Axle ......................... W3-5-1
Disassemble Swing Bearing ................... W3-1-4 Disassemble Front Axle.......................... W3-5-6
Assemble Swing Bearing........................ W3-1-6 Assemble Front Axle ............................ W3-5-12
Disassemble Front Differential.............. W3-5-20
Group 2 Travel Motor Assemble Front Differential .................. W3-5-24
Remove and Install Travel Motor ............ W3-2-1
Disassemble Rear Axle ........................ W3-5-28
Disassemble Travel Motor...................... W3-2-4
Assemble Rear Axle ............................ W3-5-34
Assemble Travel Motor ........................ W3-2-12
Disassemble and ASSEMBLE
Disassemble Brake Valve .................... W3-2-18
Rear Differential................................... W3-5-40
Assemble Brake Valve ......................... W3-2-20
Disassemble Steering Cylinder ............. W3-5-44
Group 3 Center Joint Assemble Steering Cylinder ................. W3-5-46
Remove and Install Center Joint ........... W3-3-1
Group 6 Axle Lock Cylinder
Disassemble Center Joint....................... W3-3-4
Remove and Install
Assemble Center Joint ......................... W3-3-6
Axle Lock Cylinder .............................. W3-6-1
Maintenance Standard ........................... W3-3-9
Disassemble and Assemble
Group 4 Transmission Axle Lock Cylinder .............................. W3-6-4
Remove and Install Transmission............ W3-4-1
Group 7 Operate-Check Valve
Disassemble Transmission ..................... W3-4-6
Remove and Install Operate-Check
Disassemble Final Drive and
Valve (for Axle Lock Cylinder) ................ W3-7-1
Differential.......................................... W3-4-16
Construction of Operate-Check
Assemble Final Drive and Differential.... W3-4-18
Valve (for Axle Lock Cylinder)................ W3-7-2
Assemble Transmission........................ W3-4-20
Adjusting Gear Clearance..................... W3-4-30
CBBW-3-1
(Blank)
CBBW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstruc-
ture must be removed first. For removal and installa-
tion of the upperstructure, refer to “Remove and Install
Main Frame” section.
In this section, the procedure starts on the premise
that the upperstructure has already been removed.
Mark
Removal
1. Put mating marks on inner race (1) of swing
bearing (4) and chassis (2).
1 2
W105-03-01-001
W158-03-01-001
ST 0050
W110-03-01-004
4
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
Clean the matching surfaces of the chassis and
swing bearing.
10°
19°
W158-03-01-001
W3-1-2
UNDERCARRIAGE / Swing Bearing
4. After installing the swing bearing, fill the grease
Grease Level
bath with grease (Shell Alvania EP2 or equiva- Swing Bearing Pinion
lent) until the pinion of the swing bearing is
covered A in grease.
A: 5 mm (0.2 in)
W175-03-01-002
Grease Bath
W3-1-3
UNDERCARRIAGE / Swing Bearing
DISASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
W3-1-4
UNDERCARRIAGE / Swing Bearing
Disassemble Swing Bearing
1
2
A
W105-03-01-007 7
B
4
W105-03-01-008
9, 10 W105-03-01-010
W3-1-5
UNDERCARRIAGE / Swing Bearing
ASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
W3-1-6
UNDERCARRIAGE / Swing Bearing
Assemble Swing Bearing
IMPORTANT: Be sure to apply grease to balls (6) 2. Tap plug (4) into outer race (1) and then, drive
and to supports (9). pin (3) into the pin hole.
Crimp the head of pin (3) with a punch.
CAUTION: Swing bearing weight:
220 kg (490 Ib) 3
2 4
W142-03-01-007
W142-03-01-006
W3-1-7
UNDERCARRIAGE / Swing Bearing
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Motor
REMOVE AND INSTALL TRAVEL MOTOR
Removal
W3-2-1
UNDERCARRIAGE / Travel Motor
Installation
Front Side
W3-2-2
UNDERCARRIAGE / Travel Motor
(Blank)
W3-2-3
UNDERCARRIAGE / Travel Motor
DISASSEMBLE TRAVEL MOTOR
52 53 1 2 3 4 5 6 7 8
50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18
42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32
59 2 W1GL-03-02-007
45, 46, 47
16, 17
57
57
56
56
54
W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003
W3-2-4
UNDERCARRIAGE / Travel Motor
W3-2-5
UNDERCARRIAGE / Travel Motor
52 53 1 2 3 4 5 6 7 8
50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18
42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32
59 2 W1GL-03-02-007
45, 46, 47
16, 17
57
57
56
56
54
W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003
W3-2-6
UNDERCARRIAGE / Travel Motor
Disassemble Travel Motor
• Be sure to read “Precautions for Disassembly CAUTION: Take care when removing cover
and Assembly” thoroughly on page W1-1-1 be- (17) as the spring inside may fly out.
fore starting any repair work.
5. Remove socket bolts (54) (4 used). Remove
O-ring (16) and cover (17).
CAUTION: Travel Motor Weight: : 6 mm
85 kg (190 lb)
6. Remove bushing (9), spring (6), collar (7) and
1. Set the travel motor onto wooden block (100×500 spring (5) from head cover (1) in order.
mm (3.9×19.7 in)) with drive shaft (37) facing
down. 7. Remove spring collar (8) and spring (11) from
NOTE: When the work bench is used cover (17).
Work bench: ST 5092
Upper Plate: ST 7333 8. Remove O-rings (10, 16) (3 used respectively),
adjusting screw (18), lock nut (19) and pin (20)
2. Remove socket bolts (59) (2 used). Remove from cover (17).
brake valve (2) and O-rings (3) (2 used).
: 5 mm 9. Remove retaining ring (12) from the inside of
cover (17). Remove the sleeve (14) assembly.
IMPORTANT: Do not to disassemble relief valves
(57) (2 used). 10. Pull control piston (13) out from sleeve (14) then
3. Remove relief valves (57) (2 used) and plugs remove retaining ring (15) from control piston
(56) (2 used) from head cover (1). (13).
: 27 mm, 32 mm
11. Remove socket bolts (58) (4 used) from head
4. Record the measurement of A part before re- cover (1). Remove cover (47) and O-rings (45),
moving cover (17). (46).
: 10 mm
17
17 18 19
W1GL-03-02-006
W3-2-7
UNDERCARRIAGE / Travel Motor
42 41
21
39
23 22
37
36
34 31
33 32
W1GL-03-02-007
W1F3-03-02-002
55
36
55 36 W1F3-03-02-003
W3-2-8
UNDERCARRIAGE / Travel Motor
12. Record measurements of B, C parts before re- 16. Secure rotor (23) by using screw bar (M8, Pitch
moving lock nuts (22, 41) and adjusting screws 1.25 mm (0.05 in), Length 120 mm (4.7 in)) to
(21, 42). prevent rotor (23) removing, then remove adjust-
ing screw (42).
B Screw Bar
Lock Nut
C Washer
42 41
22 21
W1GL-03-02-003
W1GL-03-02-005
13. Loosen lock nuts (22, 41) and remove adjusting 17. Place housing (36) horizontally. Remove key (33)
screws (21), (42). from drive shaft (37).
: 19 mm
: 6 mm 18. Remove retaining ring (34) from housing (36).
Remove shim (32).
14. Install adjusting screw (42) (M12, Pitch 1.75 mm
(0.1 in), Length 100 mm (3.9 in)) into the location 19. Place the housing (36) assembly on press stand
where adjusting screw (21) is inserted, the angle with rotor (23) side facing down. Pull drive shaft
of center shaft (39) should be zero. (37) assembly out.
Temporarily
Mounting Adjusting
Screw (42)
W1GL-03-02-004
39
W3-2-9
UNDERCARRIAGE / Travel Motor
52 53 1 4
50 51
49
W1GL-03-02-007
W1F3-03-02-002
W1F3-03-02-003
W3-2-10
UNDERCARRIAGE / Travel Motor
21. Secure head cover (1) on the vice with valve
plate (48) facing up.
26. Pull servo piston (52) out from head cover (1).
W3-2-11
UNDERCARRIAGE / Travel Motor
ASSEMBLE TRAVEL MOTOR
52 53 1 2 3 4 5 6 7 8
50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18
42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32
59 2 W1GL-03-02-007
45, 46, 47
16, 17
57
57
56
56
54
W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003
W3-2-12
UNDERCARRIAGE / Travel Motor
W3-2-13
UNDERCARRIAGE / Travel Motor
52 53 1 2 3 4 5 6 7 8
50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18
42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32
59 2 W1GL-03-02-007
45, 46, 47
16, 17
57
57
56
56
54
W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003
W3-2-14
UNDERCARRIAGE / Travel Motor
Assemble Travel Motor
• Be sure to read “Precautions for Disassembly 7. Install retaining rings (15, 12) to control piston
and Assembly” thoroughly on page W1-1-1 be- (13) and sleeve (14).
fore starting any repair work.
8. Apply hydraulic oil to cover (17), control piston
1. Secure head cover (1) to a vice with valve plate (13) and sleeve (14).
(48) facing up.
9. Install O-ring (10) to cover (17).
2. Apply hydraulic oil on servo piston (52), then in-
sert it into head cover (1) and install pin (4). 10. Install control piston (13) to sleeve (14), then in-
sert the sleeve (14) assembly and pin (20) into
3. Apply LOCTITE #241 on lock pin (53) and insert cover (17).
it into servo piston (52) to secure pin (4).
11. Install spring collar (8) and spring (11) into the
4. Install rings (51) (2 used) to piston (50). Install cover (17) assembly.
piston (50) to servo piston (52) with socket bolt
(49). 12. Install O-rings (16) (3 used) onto head cover (1)
: 12 mm and the cover (17) mounting surface.
: 190 N⋅m (19.5 kgf⋅m, 140 lbf⋅ft)
13. Install spring (5), collar (7), spring (6) and bush-
5. Install O-ring (45) to head cover (1), install O-ring ing (9) into the large chamber of head cover (1).
(46) to cover (47). Install cover (47) to head cover
(1) with socket bolts (58) (4 used). 14. Install the cover (17) assembly to head cover (1)
: 10 mm with socket bolts (54) (4 used).
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft) : 6 mm
: 96 N⋅m (9.8 kgf⋅m, 71 lbf⋅ft)
6. Install adjusting screw (18) and lock nut (19) into
cover (17) with the measurement of A part as re-
corded before disassembling.
18 19
W1GL-03-02-006
W3-2-15
UNDERCARRIAGE / Travel Motor
42 41
21
39
23 22
37
36
34 31
33 32
W1GL-03-02-007
57
57
56
56
W1F3-03-02-002
55
36
55 36 W1F3-03-02-003
W3-2-16
UNDERCARRIAGE / Travel Motor
CAUTION: After heating housing (36), start 20. Install adjusting screw (42) (M12, Pitch 1.75 mm
installation work. (0.1 in), Length 100 mm (3.9 in)) into the location
where adjusting screw (21) is inserted, the angle
15. Heat housing (36) to 50 to 80°C, then install the of center shaft (39) should be zero.
drive shaft (37) assembly into housing (36). If the
drive shaft (37) assembly cannot be installed, in-
sert it by using a bar.
16. Install oil seal (31) and shim (32) into housing
(36) with the rotor (23) side facing down, then in-
stall retaining ring (34).
Temporarily
17. Install key (33) into drive shaft (37). Mounting Adjusting
Screw (42)
18. Place the travel motor on wooden block (100×
500 mm (3.9×20 in)) with the drive shaft (37)
facing down. W1GL-03-02-008
Washer 23. Install adjusting screw (42), lock nut (41), adjust-
ing screw (21) and lock nut (22) into housing (36)
with the measurements of B and C as recorded
before disassembling.
W1GL-03-02-003
C
42 41
22 21
W1GL-03-02-005
W3-2-17
UNDERCARRIAGE / Travel Motor
DISASSEMBLE BRAKE VALVE B
8
16, 17
W1F3-03-02-002
1 2 3
13 14 15
12
Section A
7 6
11 10 9
8
Section B
T1F3-03-05-034
1- O-Ring (2 Used) 6- Check Valve (2 Used) 11 - Check Valve Assembly (2 Used) 16 - Plug
2- Cover 7- O-Ring (2 Used) 12 - Cover 17 - Orifice
3- Socket Bolt (4 Used) 8- Plug 13 - Socket Bolt (4 Used)
4- Plug (2 Used) 9- O-Ring 14 - Valve Casing
5- Spring (2 Used) 10 - Shuttle Valve 15 - Counterbalance Valve
W3-2-18
UNDERCARRIAGE / Travel Motor
Disassemble Brake Valve
W3-2-19
UNDERCARRIAGE / Travel Motor
ASSEMBLE BRAKE VALVE B
8
16, 17
W1F3-03-02-002
1 2 3
13 14 15
12
Section A
7 6
11 10 9
8
Section B
T1F3-03-05-034
1- O-Ring (2 Used) 6- Check Valve (2 Used) 11 - Check Valve Assembly (2 Used) 16 - Plug
2- Cover 7- O-Ring (2 Used) 12 - Cover 17 - Orifice
3- Socket Bolt (4 Used) 8- Plug 13 - Socket Bolt (4 Used)
4- Plug (2 Used) 9- O-Ring 14 - Valve Casing
5- Spring (2 Used) 10 - Shuttle Valve 15 - Counterbalance Valve
W3-2-20
UNDERCARRIAGE / Travel Motor
Assemble Brake Valve
W3-2-21
UNDERCARRIAGE / Travel Motor
(Blank)
W3-2-22
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Removal
1. Remove the swing device upper side cover
mounting bolts (2 used) and remove the cover.
: 17 mm
Center Joint
2. Disconnect connectors (6) (2 places upper and
lower).
4. Remove bolts (4) (3 used) and pull out the slip ring
(3) assembly from center joint. (Length: approx.
670 mm (26.4 in))
W3-3-1
UNDERCARRIAGE / Center Joint
Installation
W3-3-2
UNDERCARRIAGE / Center Joint
6 5
T1F3-03-10-014
W3-3-3
UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT
2
3
12 3
11
6
10 T1F3-03-10-001
9
8 7
W3-3-4
UNDERCARRIAGE / Center Joint
Disassemble Center Joint
CAUTION: Center joint weight: 93kg (210 lb) IMPORTANT: Use two picks for easy removal.
Take care not to damage the seal
1. Remove mounting bolt (6) of cover (10) diagonally, groove with the picks.
and install eyebolts (M10, Pitch 1.5 mm, length 18 5. Remove oil seals (5) (15 used) from body (4).
mm: ST 0001). Then, secure center joint on
workbench (ST 5103).
W202-03-03-011
W3-3-5
UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT
2
3
12 3
11
6
10 T1F3-03-10-001
9
8 7
W3-3-6
UNDERCARRIAGE / Center Joint
Assemble Center Joint
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W3-3-7
UNDERCARRIAGE / Center Joint
When replacing the body or spindle with a new one,
the following procedures are required:
W105-03-03-029
W3-3-8
UNDERCARRIAGE / Center Joint
MAINTENANCE STANDARD
T157-01-01-040
W3-3-9
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-10
UNDERCARRIAGE / Transmission
REMOVE AND INSTALL TRANSMISSION
Removal
1 2 3 4 5 6 7 8
IMPORTANT: In order to keep the balance of
weight, remove the travel motor
when removing the transmission.
1. Disconnect hoses (8) (2 used), and hose (7) from
travel motor (10). Cap all disconnected hose
ends.
: 17 mm, 27 mm
: 12 mm
20 Rear
IMPORTANT: Attach identification tags to hoses to Side
aid re-assembly.
2. Remove nut (20) (4 used) and plate (3). Remove
cover (19).
: 17 mm
19 18 17 16 15 14 12, 13 11 10 9
3. Disconnect hoses (1) (2 used) and hose (11) from W1F3-03-02-004
Rear
Side
18 16 15 14 12, 13 11 10 9
W1F3-03-02-005
W3-4-1
UNDERCARRIAGE / Transmission
CAUTION: 3 21 22
Transmission (16) weight : 140 kg (310 lb)
Travel motor (10) weight : 85 kg (190 lb)
Plate (3) weight : 43 kg (951 lb)
18 17 16 10
W1F3-03-02-004
W3-4-2
UNDERCARRIAGE / Transmission
Installation
25 2 3
CAUTION: Travel motor (10) weight:
85 kg (190 lb)
Transmission (16) weight: 140 kg (310 lb)
Plate (3) weight: 43 kg (95 lb)
W3-4-3
UNDERCARRIAGE / Transmission
W3-4-4
UNDERCARRIAGE / Transmission
(Blank)
W3-4-5
UNDERCARRIAGE / Transmission
56
DISASSEMBLE TRANSMISSION
55
W1F3-03-05-005
A Part
W1F3-03-05-006
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
A Part
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-6
UNDERCARRIAGE / Transmission
W3-4-7
UNDERCARRIAGE / Transmission
B Part
65 66 108
109
63
110
64
111
W1F3-03-05-005
W1F3-03-05-006
57 58 59 60 61 62 63, 64 65 66 67 68 69 70 71 72 73 74
75, 76
B Part 77
107 78
106
79
105
80
103, 104
81
82
102 83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-8
UNDERCARRIAGE / Transmission
W3-4-9
UNDERCARRIAGE / Transmission
56
55
W1F3-03-05-005
A Part
W1F3-03-05-006
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
A Part
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-10
UNDERCARRIAGE / Transmission
Disassemble Transmission
1. Disconnect hoses (56) (2 used) and pipe (55) 8. Remove screw and breather from gear case (47).
from gear case (47). : 5 mm
: 19 mm, 27 mm : 12 mm
Breather
NOTE: Plug port A then supply air by using pres- 11. Remove gasket (22) from gear case (47) by using
sure to pull piston (19) out. an offset driver.
W1GL-03-04-009
W3-4-11
UNDERCARRIAGE / Transmission
A Part
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-12
UNDERCARRIAGE / Transmission
16. Remove retaining ring (26) from gear case (47),
and then pull the shaft (3) assembly out from gear
case (47).
23. Remove disc carrier (41) and shim (43) from shaft
(3).
31. Remove ring (51) and seal (50) from flange (1).
W3-4-13
UNDERCARRIAGE / Transmission
B Part
65 66 108
109
63
110
64
111
W1F3-03-05-005
W1F3-03-05-006
57 58 59 60 61 62 63, 64 65 66 67 68 69 70 71 72 73 74
75, 76
B Part 77
107 78
106
79
105
80
103, 104
81
82
102 83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-14
UNDERCARRIAGE / Transmission
33. Remove retaining ring (107) from gear (69). Re-
move the carrier (62) assembly from gear case
(47).
38. Remove plug (65) from gear case (47), tap and
remove spring pin (109) to gear case (47) inside
from shift fork (63).
: 10 mm
39. Pull the lever (76) assembly out from gear case
(47) then remove shift fork (63) from inside.
W3-4-15
UNDERCARRIAGE / Transmission
DISASSEMBLE FINAL DRIVE AND DIF-
FERENTIAL
79
80
81
82
83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-16
UNDERCARRIAGE / Transmission
Disassemble Final Drive and Differential
W3-4-17
UNDERCARRIAGE / Transmission
ASSEMBLE FINAL DRIVE AND DIFFERENTIAL
79
80
81
82
83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-18
UNDERCARRIAGE / Transmission
Assemble Final Drive
1. Insert bearing (79) into cover (80), and lock it with 8. Install flanges (83, 98) to gear (88), and attach
retaining ring (90). O-rings (87, 96).
2. Attach seal (89) and O-ring (113) to cover (80). 9. Mount flanges (83, 98) with plates (86, 99), and
bolts (85) (2 used) and (100), and then fasten
3. Install cover (91) and the cover (80) assembly to them with lock plates (84, 101).
gear (88). : 17 mm
: 46 N⋅m (5.0 kgf⋅m) (34 lb)
4. Install cover (112) to gear case (47).
2.0+1.0 mm W1GL-03-04-001
(0.08+0.04 in)
W3-4-19
UNDERCARRIAGE / Transmission
ASSEMBLB TRANSMISSION
56
55
W1F3-03-05-005
A Part W1F3-03-05-006
A Part
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-20
UNDERCARRIAGE / Transmission
W3-4-21
UNDERCARRIAGE / Transmission
B Part
65 66 108
109
63
110
64
111
W1F3-03-05-005
B Part
W1F3-03-05-006
57 58 59 60 61 62 63, 64 65 66 67 68 69 70 71 72 73 74
75, 76
77
107 78
106
79
105
80
103, 104
81
82
102 83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-22
UNDERCARRIAGE / Transmission
W3-4-23
UNDERCARRIAGE / Transmission
B Part
65 66 108
109
63
110
64
111
W1F3-03-05-005
B Part
W1F3-03-05-006
57 58 59 60 61 62 63, 64 65 66 67 68 69 70 71 72 73 74
75, 76
77
107 78
106
79
105
80
103, 104
81
82
102 83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-24
UNDERCARRIAGE / Transmission
Assemble Transmission
W3-4-25
UNDERCARRIAGE / Transmission
56
55
W1F3-03-05-005
A Part
W1F3-03-05-006
A Part
8 9 10 11 114 13 14 15 16 17、18 19 20 21 22 23 24 25
26
6
27
28、29、30、31
5
32
4 33
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-26
UNDERCARRIAGE / Transmission
13. Install bearing (10) into shaft (3) and secure them 18. Install plate (114) and the piston (45) assembly to
with retaining ring (4). the shaft (3) assembly, and then install shim (43)
into inside.
14. Install piston rings (12) (2 used) to shaft (3).
19. Install seal ring (24) to disc carrier (41), install the
15. Install shaft (3) to flange (1) and secure it with disc carrier (41) assembly to the shaft (3)
retaining ring (53). assembly.
Install seal (50) into the flange (1) inside, secure it
with ring (51). 20. Install plate (28) friction plates (29) (11 used) and
plates (30) (10 used), spacer (31) to the shaft (3)
16. Install retaining ring (54), U-ring (35) and O-ring assembly (disc carrier) in order.
(36) to shaft (3) in order.
21. Install bearing (37) to cover (39), secure it with
retaining ring (32).
CAUTION: When install U-ring (35), be sure
to put the groove of U-ring (35) facing the disc 22. Install ring gear (27) to the shaft (3) assembly
carrier (41) side. (plate part).
24. Install sun gear (38), shim (33) and retaining ring
49 (34) to the shaft (3) assembly.
W3-4-27
UNDERCARRIAGE / Transmission
56
ASSEMBLB TRANSMISSION
73
55
75, 76
W1F3-03-05-005
A Part
W1F3-03-05-006
A Part
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-28
UNDERCARRIAGE / Transmission
27 Install O-ring (23) to gasket (22). 36. Install piston (13), spring (9) and plug (7) to drive
case (6) in order.
28. Install O-ring (21) to the gear case (47) inside, : 24 mm
install gasket (22) and secure them with retaining : 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
ring (20).
37. Install O-ring (5) to drive case (6).
29. Install seal ring (17) and backup rings (18) (2
used) to the gear case (47) inside. Install O-ring 38. Install shaft (73) to shaft (3), install shift interlock
(15). controller (75) to gear case (47) with socket bolts
(76) (3 used).
30. Install piston (19) to gear case (47). : 6 mm
: 23 N⋅m (2.5 kgf⋅m, 18.1 lbf⋅ft)
31. Align disc springs (49) (2 used) on piston (19)
surface. 39. Connect hoses (56) (2 used) and pipe (55) to gear
case (47).
49
19
114 W1GL-03-04-010
33. Install drive case (6) to gear case (47) with socket
bolts (48) (9 used) and retaining ring (11).
: 10 mm
: 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
W3-4-29
UNDERCARRIAGE / Transmission
ADJUSTING GEAR CLEARANCE
W1GL-03-05-021
W1GL-03-05-019 W1GL-03-05-020
Clearance of pinion
W1GL-03-05-027
Clearance of pinion
W1GL-03-05-027
W3-4-30
UNDERCARRIAGE / Axle
REMOVE AND INSTALL AXLE
1
CAUTION: Be sure to bleed air from
hydraulic oil tank before starting the work.
2
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.) 3
T1F3-01-02-002
3
2. Jack up frame (1) with tire (3) floated then put the
blocks under the machine.
90 to 110°
CAUTION: Tire (3) weight: 98 kg (220 lb)
Tire ring (2) weight: 17 kg (38 lb)
W3-5-1
UNDERCARRIAGE / Axle
2. Lock pin (8) with bolt (9) and nuts (10) (2 used).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) 13, 14 W1F3-03-05-013
12 11
4
3. Connect steering hoses (14) to steering cylinder
(13).
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)
6. Install tire (3), tire ring (2) and tire (3) to front axle 2
(6) in order, then temporarily tighten them with
4
nuts (4). (The installing order for both sides are
the same.)
: 30 mm 3
T1F3-01-02-002
W3-5-2
UNDERCARRIAGE / Axle
T1F3-01-02-002
2. Jack up frame (3) with tire (1) floated, then put the
blocks under the machine.
5 6
5. Remove nuts (9) (8 used). Propeller shaft (10).
: 14 mm
6. Lift rear axle (7) off to remove nut (6) (8 used) and 9
bolts (8) (8 used).
: 30 mm 7
8
W1F3-03-05-014
W3-5-3
UNDERCARRIAGE / Axle
6
Installation of Rear Axle 5
1. Lift rear axle (7), then install rear axle (7) to frame 10
(3) with bolts (8) (8 used) and nuts (6) (8 used).
9
: 30 mm
: 560 N⋅m (57.0 kgf⋅m, 410 lbf⋅ft)
7
2. Connect brake pipe (5).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 8
W1F3-03-05-014
4
CAUTION: Propeller shaft (10) weight:
30 kg (66 lb)
1 1
3. Install propeller shaft (10) to rear axle (7) with nuts
(9) (8 used). 2
: 14 mm
: 108 N⋅m (11gf⋅m, 80 lbf⋅ft) 3
4. Install tire (1), tire ring (2) and tire (1) into rear axle 4
(7) in order then temporarily tighten them with nuts
(4) (10 used). The installing order for both sides 2
are the same.
: 30 mm
T1F3-01-02-002
5. Remove the block from frame (3).
W3-5-4
UNDERCARRIAGE / Axle
(Blank)
W3-5-5
UNDERCARRIAGE / Axle
DISASSEMBLE FRONT AXLE
2
3 8
4 7
5 6
1
4
3
2
10 9
22 23
16 24
17 21
19 20
18
15
13 14
11 12
25
46
45
44
26
28
27 41 42 43
40
38 39
36 37
34 35
32 33
30 31 47
29
34 48
61
60
57 58 59 49
56
50
51
52
53
55 54
W1F3-03-05-011
W3-5-6
UNDERCARRIAGE / Axle
W3-5-7
UNDERCARRIAGE / Axle
2
3
8
4 7
1
6
5
4
3
2
9
10 16 22 23
24
17
21
18 19 20
15
14
11
12 13
25
45 46
26 44
27 43
28 41 42
39 40
38
35 36 37
33 34
32
30 31
47
29
48
60 61
58 59 49
57
56
50
51
52
55 54 53
W1F3-03-05-011
W3-5-8
UNDERCARRIAGE / Axle
Disassemble Front Axle
1. Remove plugs (49, 62) and drain oil. 9. Remove bearing nut (42) from joint housing (15).
: 8 mm, 22 mm
10. Remove the ring gear (30) assembly from joint
Remove bolts (48) (2 used). Remove planetary housing (15).
carrier (50) from hub carrier (22).
: 8 mm 11. Pull the piston (38) assembly from ring gear (30).
62
49 W1GL-03-05-006
W3-5-9
UNDERCARRIAGE / Axle
2
3
1 4
6
5
4
3
2
16 22
24
17
20 21
18 19
15
14
11 13
26
27
W1F3-03-05-011
W3-5-10
UNDERCARRIAGE / Axle
15. Remove O-ring (31) from ring gear (30).
24. Pull double joint shaft (11) out from body (1).
26. Remove shaft seals (6, 13) from joint housing (15)
and body (1). The other side should be removed
in the same way.
W3-5-11
UNDERCARRIAGE / Axle
ASSEMBLE FRONT AXLE
4 17 2 16 20 21 25 24 35 36 37 40 41 38 44 47 45 46
18
6
52
1
51
5
8 53
54、55
61
13
60
7 43
59
11
58
3 49
15 50
26 27 29 31 14 19 22 48 23 32 33 34 39 30 42 56 57
W1F3-03-05-003
W3-5-12
UNDERCARRIAGE / Axle
W3-5-13
UNDERCARRIAGE / Axle
4 17 2 16 20 21 25 24 35 36 37 40 41 38 44 47 45 46
18
6
52
1
51
5
8 53
54、55
61
13
60
7 43
59
11
58
3 49
15 50
26 27 29 31 14 19 22 48 23 32 33 34 39 30 42 56 57
W1F3-03-05-003
W3-5-14
UNDERCARRIAGE / Axle
Assemble Front Axle
W3-5-15
UNDERCARRIAGE / Axle
35 36 37 40 41 38
60
43
59
11
58
15
29 31 32 33 34 39 30 42 56 57
W1F3-03-05-003
W3-5-16
UNDERCARRIAGE / Axle
13. Install rings (36, 41) and U-rings (37, 40) to piston IMPORTANT: When installing the ring gear (30)
(38). Apply grease after installing them. assembly to joint housing (15),
tighten bearing nut (42) while
rotating the ring gear (30) assembly
38 in the direction of clockwise and
counterclockwise several times.
B A
38
39
32 56
43 W1F3-03-05-021
W3-5-17
UNDERCARRIAGE / Axle
44 47 45 46
52
51
53
54、55
61
49
50
22 48 23 30
W1F3-03-05-003
W3-5-18
UNDERCARRIAGE / Axle
IMPORTANT: There are two cut-off grooves on the 30. After assembling the front axle, install straight
periphery of each of six plates (44). edge to adjust toe-in.
When attaching, align directions of Straight Edge
cut-off grooves. A1
24. Install plate (44), friction plate (47) into the inside
of ring gear (30) in order, then install plate (45)
and secure them with retaining ring (46).
29. Supply oil into the differential and the wheel hub,
then install plug (62).
: 22 mm
: 79 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
Differential
Front Axle: 8.5 L (2.2 US gal.)
Wheel Hub Front:
Each 2.1 L (0.55 US gal.) x 2
W3-5-19
UNDERCARRIAGE / Axle
DISASSEMBLE FRONT DIFFERNTIAL
1
2
3
4
5
6
7
8
9
10
11
14
15
16
17
18
19 13 12
18
19
17
16
20
21
22 23 18
19
30
18 29
28
24 26 27
25
31
32
33
34
W1F3-03-05-017
1- Lock Plate 10 - Bearing 19 - Pinion Gear (4 Used) 28 - Shim
2- Nut 11 - Drive Pinion 20 - Differential Case 29 - O-Ring
3- Washer 12 - Spring Pin (4 Used) 21 - Washer (12 Used) 30 - Body
4- Flange 13 - Spring Pin (4 Used) 22 - Socket Bolt (12 Used) 31 - Bolt (16 Used)
5- Guard 14 - Bevel Gear 23 - Spider 32 - Washer (16 Used)
6- Seal 15 - Differential Case 24 - Body 33 - Plug
7- Bearing 16 - Thrust Washer (2 Used) 25 - Shim 34 - Plug
8- Ring 17 - Side Gear (2 USed) 26 - Bearing
9- Shim 18 - Thrust Washer (4 Used) 27 - Bearing
W3-5-20
UNDERCARRIAGE / Axle
Disassemble the Front Differential
To disassemble the differential, it is needed to remove 9. Remove side gear (17), thrust washers (18) (4
left and right tie rods. See “Remove Steering Cylinder”. used), piston gears (19) (4 used) and spider (23)
from differential case (20).
W3-5-21
UNDERCARRIAGE / Axle
1
2
3
4
5
6
7
8
9
10
11
14
24
W1F3-03-05-017
W3-5-22
UNDERCARRIAGE / Axle
11. Remove lock plate (1) from flange (4).
12. Remove nut (2), washer (3) and flange (4) from
drive pinion (11).
W3-5-23
UNDERCARRIAGE / Axle
ASSEMBLE FRONT DIFFERENTIAL
1 2 3 4
7
8
9
14 29 27 28
10
11
21 30
22
25
Axle Shaft
Axle Shaft
15
20
24
W1F3 05-03-016
26 17 16 19 23 18 12, 13 32 31
W3-5-24
UNDERCARRIAGE / Axle
Assemble the Front Differential
8. Install four spring pins (13) and spring pins (12) (4
1. Install shim (9) and the outer races of bearings used) to differential case (15), and then mount
(10, 7) to body (24). bevel gear (14).
2. Install the inner race of bearing (10) with drive 9. Place the assembly on work bench, with bevel
pinion (11). gear (14) positioned lower.
W3-5-25
UNDERCARRIAGE / Axle
1 2 3 4
9
14 29 27 28
10
11
21 30
22
25
Axle Shaft
Axle Shaft
15
20
24
W1F3-03-05-016
26 17 16 19 23 18 12, 13 32 31
W3-5-26
UNDERCARRIAGE / Axle
16. Affix differential assembly to bevel gear (14) with
socket bolts (22) (12 used) and washers (21) (12
used).
: 10 mm
: 145 N⋅m (15 kgf⋅m, 107 lbf⋅ft)
18. Install shim (25) and the outer race of bearing (26)
to body (24).
23. Apply oil inside body (24), and install plug (34).
Front axle: 8.5 L (2.25 US gal.)
W3-5-27
UNDERCARRIAGE / Axle
DISASSEMBLE REAR AXLE
3 4
2
6 5
17 18
16
15
7 14
8 13
12
11
10
9
32
19
30 31
29
26 27 28
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49
W1F3-03-05-018
W3-5-28
UNDERCARRIAGE / Axle
W3-5-29
UNDERCARRIAGE / Axle
3 4
2
6 5
17 18
16
15
7 14
13
8
12
11
10
9
32
19
30 31
29
28
26 27
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49
W1F3-03-05-018
W3-5-30
UNDERCARRIAGE / Axle
Disassemble Rear Axle
1. Remove plugs (44, 51) and drain oil. 11. Remove nuts (27) (6 used) from the piston (26).
: 8 mm、22 mm Remove bolts (20) (6 used), spring guides (21) (6
used) and springs (22) (6 used).
2. Remove bolts (43) (2 used). Remove planetary : 10 mm
carrier (45) from hub carrier (13).
: 8 mm 12. Remove piston (26) and plate (23) from ring gear
(17).
13
13. Remove U-ring (25, 28) and ring (24, 29) from
piston (26).
43
14. Remove O-ring (18) from ring gear (17).
43
45
15. Remove O-ring (14) from hub carrier (13).
44 W1GL-03-05-006
10. Pull the piston (26) assembly out from ring gear
(17).
W3-5-31
UNDERCARRIAGE / Axle
3 4
2
6 5
15
13
11 12
10
9
36
W1F3-03-05-018
W3-5-32
UNDERCARRIAGE / Axle
17. Remove the hub carrier (13) assembly from
knuckle (4).
20. Remove bolts (5) (18 used) and washer (16 used).
Remove knuckle (4) from body (1).
21. Remove O-ring (3), screen sheet (9) and seal (36)
from knuckle (4).
W3-5-33
UNDERCARRIAGE / Axle
ASSEMBLE REAR AXLE
3 4
2
6 5
17 18
16
15
7 14
8 13
12
11
10
9
32
19
30 31
29
28
26 27
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49
W1F3-03-05-018
W3-5-34
UNDERCARRIAGE / Axle
W3-5-35
UNDERCARRIAGE / Axle
3 4
2
6 5
17 18
16
15
7 14
13
8
11 12
10
9
32
30 31
29
26 27 28
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49
W1F3-03-05-018
W3-5-36
UNDERCARRIAGE / Axle
Assemble Rear Axle
1. Insert axle shaft (2) into body (1) inside. 10. Install the piston (26) to assembly ring gear (17)
and secure it with bolts (20) (6 used), spring
IMPORTANT: Be sure to check that axle shaft (2) guides (21) (6 used), springs (22) (6 used) and
and differential are connected. nuts (27) (6 used).
: 10 mm
2. Install the inner race of bearing (11) and bushing
(12) to knuckle (4). 11. Install bolt so that the dimension A should be 3.75
to 4.25 mm (0.15 to 0.17 in).
3. Install O-ring (3), screen sheet (9) and seal (36) to : 10 mm
knuckle (4). : 11 N⋅m (1.1 kgf⋅m, 8 lbf⋅ft)
8. Install rings (24, 29) and U-rings (25, 28) to piston W1F3-03-05-023
(26).
Apply grease after installing them. 12. After adjusting, secure nuts (27) (6 used) with
LOCTITE #242.
28 29
24 25
26
W1F3-03-05-022
W3-5-37
UNDERCARRIAGE / Axle
4
2 3
6 5
17 18
16
15
7 14
13
8
12
11
10
9
32
30 31
29
26 27 28
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49 W1F3-03-05--018
W3-5-38
UNDERCARRIAGE / Axle
IMPORTANT: When installing the ring gear (17) 21. Install O-ring (14) to hub carrier (13).
assembly to knuckle (4), tighten
bearing nut (30) while rotating the 22. Install the planetary carrier (45) assembly to hub
ring gear (17) assembly in the carrier (13) with bolt (43) (2 used).
direction of clockwise and : 8 mm
counterclockwise several times. : 55 N⋅m (5.6 kgf⋅m, 41 lbf⋅ft)
13. Install the ring gear (17) assembly to knuckle (4) 23. Install plug (44) to planetary carrier (45). Supply
with bearing nut (30). oil to differential and wheel hub inside.
: 1550 + 550 N⋅m Differential: 2.0 L (0.528 US gal.)
(160 + 55 kgf⋅m, 1140 + 410 lbf⋅ft)
19. Install plate (32) and friction plate (33) into the
inside of ring gear (17) in order, install plate (34)
secure it with retaining ring (35).
W3-5-39
UNDERCARRIAGE / Axle
DISASSEMBLE and ASSEMBLE REAR DIFFERENTIAL
1
2
3
4
5
6
7
8
9
10
11
15 14
16
17
18
19 12
13
18
19
17
16
20
21
22
18
17 23 19
30
18
29
28
27
26
25
24
31
32
35
33
34
36
W1F3-03-05-019
W3-5-40
UNDERCARRIAGE / Axle
W3-5-41
UNDERCARRIAGE / Axle
1
2
3
4
5
6
7
8
9
10
11
15 14
16
17
18
19 12
13
18
19
17
16
20
21
22
18
17 23 19
30
18
29
28
27
26
25
24
31
32
35
33
34
36
W1F3-03-05-019
W3-5-42
UNDERCARRIAGE / Axle
Disassemble and Assemble Rear Differential
W3-5-43
UNDERCARRIAGE / Axle
DISASSEMBLE STEERING CYLINDER
1 2 3 4 5
W1F3-03-05-001
14 13 12 32 11 10 9 32 8 7 6
19
15 16 17 18 20 21 22 23 22
30 31 30 29 28 27 26 25 24
W1F3-03-05-010
W3-5-44
UNDERCARRIAGE / Axle
Disassemble Steering Cylinder
W3-5-45
UNDERCARRIAGE / Axle
ASSEMBLE STEERING CYLINDER
1 2 3 4 5
W1F3-03-05-001
14 13 12 32 11 10 9 32 8 7 6
11 16 15 3 20 30 31 10 30 29 26
17 18 19 21 22 23 22 28 27 W1F3-03-05-002
W3-5-46
UNDERCARRIAGE / Axle
Assemble Steering Cylinder
1. Attach O-rings (30) (2 used) to cylinder (31), and 13. Lock nuts (7, 13) with split pins (6, 14).
apply grease to mounting face.
IMPORTANT: Be sure to install piston rod (3) so
2. Install O-ring (26), U-ring (28) and scraper ring that the dimensions of part A on
(27) to guide (29), and apply grease to the inside both sides are the same.
and outside of guide (29).
11. Install tie rods (8, 12) assembly to piston rod (3).
: 32 mm, 55 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)
W3-5-47
UNDERCARRIAGE / Axle
(Blank)
W3-5-48
UNDERCARRIAGE / Axle Lock Cylinder
REMOVE AND INSTALL AXLE LOCK
CYLINDER
Removal
3
1. Disconnect pipes (1) (2 used) from check valve (2).
Cap the open ends.
: 19 mm
4
IMPORTANT: Do not remove check valve (2). The
rod (6) will drop when cap is re-
moved because the air supplying.
5
W1F3-03-06-002
W3-6-1
UNDERCARRIAGE / Axle Lock Cylinder
Installation
1. Remove socket bolts (7) (2 used), then install
eyebolts (M8, Pitch 1.25 mm) to the removed bolt
holes. 7
1
4. Connect pipes (1) (2 used). 2
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
3
W1F3-03-06-003
W3-6-2
UNDERCARRIAGE / Axle Lock Cylinder
(Blank)
W3-6-3
UNDERCARRIAGE / Axle Lock Cylinder
DISASSEMBLE AND ASSEMBLE AXLE
LOCK CYLINDER
2
A
1
3
W1F3-03-06-002
7 View A
5 4
W1F3-03-06-001
W3-6-4
UNDERCARRIAGE / Axle Lock Cylinder
Disassemble Axle Lock Cylinder Assemble Axle Lock Cylinder
• Be sure to read “Precautions for Disassembly and • Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before Assembly” thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.
CAUTION: Axle lock cylinder weight: CAUTION: Housing (3) weight: 16 kg (35 lb)
30 kg (66 lb) Rod (4) weight: 11.5 kg (25 lb)
1. Place the axle lock cylinder on a workbench 1. Install seal (7), dust seal (6) and retaining ring (5)
horizontally. to housing (3).
2. Remove socket bolts (1) (4 used) and remove IMPORTANT: Apply hydraulic oil to the inner sur-
check valve (2). face of housing (3) and seals (6, 7).
W3-6-5
UNDERCARRIAGE / Axle Lock Cylinder
(Blank)
W3-6-6
UNDERCARRIAGE / Operate-Check Valve
REMOVE AND INSTALL OPERATE-CHECK
VALVE (FOR AXLE LOCK CYLINDER)
Removal
Axle Lock Cylinder
1. Disconnect pipes (2) (2 used) from operate-check
valve (1). Cap the open ends.
: 19 mm
W1F3-03-06-003
Installation
1. Install operate-check valve (1) to the axle lock
cylinder with socket bolts (3) (4 used).
: 6 mm
: 20 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 3
W1F3-03-06-002
W3-7-1
UNDERCARRIAGE / Operate-Check Valve
CONSTRUCTION OF OPERATE-CHECK
VALVE (FOR AXLE LOCK CYLINDER)
1 2 3 4 5 6 7 8
T1F3-03-10-002
W3-7-2
MEMO
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SECTION 4
FRONT ATTACHMENT
— CONTENTS —
Group 1 Front Attachment Group 3 Hose-Rupture Safety Valve
Hydraulic Circuit Pressure Remove and Install
Release Procedure...............................W4-1-1 Hose-Rupture Safety Valve.................. W4-3-1
Remove and Install Monoblock Boom Construction of
Front Attachment ..................................W4-1-2 Hose-Rupture Safety Valve.................. W4-3-4
Remove and Install 2-Piece Boom
Front Attachment ................................W4-1-10
Group 4 Operate-Check Valve
Remove and Install Operate-Check
Maintenance Standard .........................W4-1-18
Valve (for Blade/Stabilizer) ................... W4-4-1
Standard Dimensions for
Construction of Operate-Check
Arm and Bucket Connection...............W4-1-21
Valve (for Blade/Stabilizer) ................... W4-4-2
Standard Dimensions for
Arm and Boom Connection ................W4-1-22
Group 2 Cylinder
Remove and Install Cylinder
(Monoblock Boom, 2-Piece Boom).......W4-2-1
Disassemble Cylinder
(Boom (Monoblock/2-Piece) and
Bucket)................................................W4-2-20
Assemble Cylinder
(Boom (Monoblock/2-Piece) and
Bucket)................................................W4-2-22
Disassemble Cylinder (Positioning) .....W4-2-24
Assemble Cylinder (Positioning) ..........W4-2-26
Disassemble Cylinder (Arm) ................W4-2-27
Assemble Cylinder (Arm) .....................W4-2-29
Disassemble Cylinder
(Stabilizer, Blade)................................W4-2-31
Assemble Cylinder
(Stabilizer, Blade)................................W4-2-33
Maintenance Standard .........................W4-2-35
CBBW-4-1
(Blank)
CBBW-4-2
FRONT ATTACHMENT / Front Attachment
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE
*Positioning/
Attachment Pedal (3) 3 2
Auxiliary
*Stabilizer/Blade Stabilizer/Blade Lever (6)
NOTE: *: Optional
W4-1-1
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL MONOBLOCK 1
BOOM FRONT ATTACHMENT
Removal
W1GL-04-01-006
W4-1-2
FRONT ATTACHMENT / Front Attachment
4. Place the boom cylinder on a bench of 1 m height.
Start the engine. Operate the boom lever to re-
Bench
tract the boom cylinder. Secure the boom cylin-
der rod as illustrated by using a wire.
Stop the engine.
Boom Cylinder
5. Remove the boom cylinder.
Refer to “Remove Boom Cylinder” on page
W4-2-10. Wire
W554-02-03-007
CAUTION: The pin sometimes releases
suddenly. Be sure no one stands in the way.
W1F3-01-04-002
W1F3-04-01-010
7 8
W4-1-3
FRONT ATTACHMENT / Front Attachment
10. Open cover (9). Remove bolts (10) (4 used) and
cover (11). 9
: 17 mm
11 10 W1F3-02-03-001
W4-1-4
FRONT ATTACHMENT / Front Attachment
B W1F3-04-01-002
NOTE: When boom foot pin (12) cannot be re- D 1978 (78)
moved, adjust the position of the boom
foot pin (12) hole by hoisting and lowering
12
the front attachment.
Bracket
W178-04-01-001
W4-1-5
FRONT ATTACHMENT / Front Attachment
Installation Boom and Arm Cylinder
Center of Gravity
Boom Assembly
CAUTION: Prevent person from injury. Metal Center of Gravity A
fragments may fly when a hammer is used to
install the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.
C
1. Hoist the front attachment. Move the machine
forward, aligning the boom foot pin (12) holes.
Insert the thrust plates into boom left and right B W1F3-04-01-002
sides and adjust the clearance between the plate
and frame within 1 mm.
Unit: mm (in)
(Adjust the position of the boom foot pin hole by
A 3035 (119)
hoisting and lowering the front attachment.)
B 3340 (131)
C 782 (31)
D 1978 (78)
12
11 10 W1F3-02-03-001
W4-1-6
FRONT ATTACHMENT / Front Attachment
5. Remove the caps from hoses and pipings. Install
the bucket cylinder hoses (7) and the arm cylin-
der hoses (8).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
W1F3-04-01-010
7 8
3 2
7. Hoist the boom cylinder. Insert thrust plates (2) (2
used), and then drive in pin (3) to install boom
cylinders to both sides.
6 Boom Cylinder
8. Install stopper (5) and secure it with bolt (6) and
nuts (4) (2 used). (2 places both left and right)
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 405 Ibf⋅ft)
5
4
W178-04-01-004
W4-1-7
FRONT ATTACHMENT / Front Attachment
9. Connect grease pipe (1) onto the boss at boom
cylinder rod side. (2 places both left and right)
1
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
W105-04-01-002
Left Boom
Cylinder Rod
Side
Boom Foot
Side
W1F3-04-01-010
W4-1-8
FRONT ATTACHMENT / Front Attachment
11. Install thrust plates (17) into arm left and right
sides. Adjust total clearance of left and right
within 1.5 mm or less. Arm and Bucket
Center of Gravity
12. After installing arm, add grease to grease fitting
(18) on the boom-connecting boss of the arm.
18 18
M157-07-157
W4-1-9
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL 2-PIECE BOOM
FRONT ATTACHMENT 1
Removal
: 24 mm 1
2, 3
5
CAUTION: Boom cylinder weight:
160 kg (352 lb)
W1F3-04-01-008
W4-1-10
FRONT ATTACHMENT / Front Attachment
4. Place the boom cylinder on a bench of 1 m height.
Start the engine. Operate the boom lever to re-
tract the boom cylinder. Secure the boom cylin-
Bench
der rod as illustrated by using a wire.
Stop the engine.
Boom Cylinder
5. Remove the boom cylinder.
Refer to “Remove Boom Cylinder” on page
W4-2-10. Wire
W554-02-03-007
CAUTION: The pin sometimes comes out
suddenly. Be sure no one stands in the way.
7 W1F3-01-04-002
8 W1F3-04-01-013
W4-1-11
FRONT ATTACHMENT / Front Attachment
10. Open cover (9). Remove bolts (10) (4 used) and
cover (11). 9
: 17 mm
11 10 W1F3-02-03-001
W4-1-12
FRONT ATTACHMENT / Front Attachment
B
Front Attachment Assembly
Center of Gravity
CAUTION: Front attachment weight:
3212 kg (7081 lb)
C
W1F3-04-01-001
Unit: mm (in)
A 3155 (124)
B 2573 (101)
C 4031 (159)
D 944 (37)
E 1750 (69)
F 2286 (90)
14. Pull boom foot pin (12) out while rotating the plate
slowly by hand.
NOTE: When boom foot pin (12) cannot be re-
moved, adjust the position of the boom Plate
Insert a bar.
foot pin hole by hoisting and lowering the
front attachment. Bracket
W4-1-13
FRONT ATTACHMENT / Front Attachment
Installation
Boom and Arm Cylinder
Center of Gravity
A
CAUTION: Prevent person from injury. Metal
fragments may fly when a hammer is used to Front Attachment Assembly B
Center of Gravity
install the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.
13
14
15
11 10 W1F3-02-03-001
W4-1-14
FRONT ATTACHMENT / Front Attachment
5. Remove the caps from hoses and pipings. Install 7
bucket cylinder hoses (7) and arm cylinder hoses
(8).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
8. Install stopper (5) and secure it with bolt (6) and Boom Cylinder W105-04-02-040
nuts (4) (2 used). (2 places both left and right)
: 30 mm 1
: 550 N⋅m (56 kgf⋅m, 405 Ibf⋅ft) 2, 3
5
4, 6
Boom Cylinder
W1F3-04-01-008
W4-1-15
FRONT ATTACHMENT / Front Attachment
9. Connect grease pipe (1) onto the boss at boom
cylinder rod side. (2 places both left and right) 1
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
W1F3-04-01-007
Second
Boom Foot
Side
Left Boom
Foot Side
Right Boom
Foot Side
MCBB-07-007
W4-1-16
FRONT ATTACHMENT / Front Attachment
11. Install thrust plates (17) into arm left and right
sides. Adjust total clearance of left and right Arm and Bucket
within 1.5 mm or less. Center of Gravity
17 17
W1GL-04-01-012
18
W1GL-04-01-011
W4-1-17
FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD
Pin and Bushing
N
C
L
A
M
E B
D
K
I J
G
H
W1GL-04-01-002 W1F3-04-01-001
Unit: mm (in)
W4-1-18
FRONT ATTACHMENT / Front Attachment
Unit: mm (in)
W4-1-19
FRONT ATTACHMENT / Front Attachment
Point
B C
W105-04-01-020
Unit: mm (in)
B 79 (3.11) -
Replace
C 95 (3.74) -
D 81 (3.19) -
Side Cutter
C
D
W155-04-01-002
Unit: mm (in)
B 245 (9.65) -
Replace
C 330 (12.99) -
D 135 (5.32) -
W4-1-20
FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
W1CF-04-01-007
Section A Section B
Unit: mm (in)
a 370 (14.6)
b 0
c 540 (21.3)
d 520 (20.5)
e -
f 1430 (56.3)
g 449 (17.7)
h 326 (12.8)
i 80 (3.15)
j 400 (15.7)
k 31 (1.22)
l 433 (17.0)
m 307 (12.1)
n 80 (3.1)
o 90°
p 60°
q 449 (17.7)
W4-1-21
FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
W1F3-04-01-004
W1F3-04-01-003
Section C
W1GL-04-01-010
Unit: mm (in)
s 80 (3.15)
t 307 (12.1)
u 421 (16.6)
W4-1-22
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
(MONOBLOCK BOOM, 2-PIECE BOOM)
Remove Bucket Cylinder 1
4 5
2. After stopping the engine, push the pressure
release button on the air breather to release any
remaining pressure from the hydraulic oil tank.
Then remove the cap.
Release the bucket circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure” 6
on page W4-1-1.)
W4-2-1
FRONT ATTACHMENT / Cylinder
5. Disconnect bucket cylinder hoses (12) (2 used)
at the bucket cylinder (1) bottom. Attach caps 10
onto the open ends.
: 36 mm
12 W187-04-02-004
W4-2-2
FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder
2. Insert bolt (15) into arm stopper (14) and pin (11).
Install nut (13). 12 W187-04-02-004
9 W102-04-02-005
W4-2-3
FRONT ATTACHMENT / Cylinder
5. Start the engine and operate the bucket lever to
align the cylinder rod side pin hole with those of 16 4 17 5
links (16, 18). Insert thrust plate (5) and pin (7).
6. Insert bolt (4) into stopper (17) and pin (7). Install
nut (6).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft)
W157-04-01-015
18 18
W4-2-4
FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder
1
CAUTION: Prevent person from injury. Metal
fragments may fly when a hammer is used to
remove the pins. Be sure to wear necessary
2
protection, such as goggles, hardhat and etc.
3. Remove nut (8) and bolt (10) from pin (5) at the
arm cylinder (1) rod side.
: 30 mm
6 1
W187-04-02-010
W4-2-5
FRONT ATTACHMENT / Cylinder
6. Disconnect hoses (11) (2 used) from the bottom Monoblock Boom
of arm cylinder (1). Attach a cap onto the open
ends. In case the hose-rupture safety valve is 12
equipped, refer to the “Remove and Install 1
Hose-Rupture Safety Valve”.
: 36 mm
11
W1F3-04-01-005
2-Piece Boom
1
11
11 12
W1F3-04-01-007
W102-04-02-016
9. Remove nuts (15) and bolt (17) from the tube 13
17
side of arm cylinder (1). Push out pin (14). 14
1
Remove thrust plates (13) and remove arm
cylinder (1).
: 30 mm
15
W187-04-02-007
W4-2-6
FRONT ATTACHMENT / Cylinder
Install Arm Cylinder
13
17
IMPORTANT: When pressing the bushing in, if a 14
1
hammer is used, the bushing may
be damaged. Use a press.
12
1. Attach a sling at arm cylinder (1) where can make
the cylinder level. Lift arm cylinder (1). Align the 1
cylinder tube side hole with the arm cylinder
mounting hole on boom.
: 19 mm 2-Piece Boom
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 1
: 36 mm 11
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
W1F3-04-01-007
W4-2-7
FRONT ATTACHMENT / Cylinder
4. Remove wire (7) from arm cylinder (1) rod (6). Lift 6 1
arm cylinder (1) off. Start the engine. Operate the
arm lever and align the arm cylinder rod side pin
hole with the arm cylinder mounting hole on arm
(18).
18
5. Install thrust plate (3) and pin (5).
Install bolt (10) to pin (5) and stopper (9), and put 7
nut (8) on bolt (10).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft) W187-04-02-010
18
8
W187-04-02-006
W4-2-8
FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder Monoblock Boom
1
CAUTION: Prevent person from injury. Metal
fragments may fly when a hammer is used to
remove the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.
4, 6 2
3. Remove nut (5), bolt (7) and stopper (6) from the
boom cylinder (2) rod to push pin (4) out. W1F3-04-01-008
Remove thrust plate (3).
: 27 mm
Bench
2
W105-04-02-035
W4-2-9
FRONT ATTACHMENT / Cylinder
7. Remove hoses (12) (4 used) from boom cylinder
(2) at the boom cylinder bottom. Cover all
openings with plug to hoses and with cap to
boom cylinder. In case the hose-rupture safety
valve is equipped, refer to the “Remove and
Install Hose-Rupture Safety Valve”.
Plug: 13/16-12UNF
: 36 mm
W105-04-02-036
2
8. Loosen nut (10) at the boom cylinder bottom side 11
of the main frame and remove bolt (8). 8
Remove pin (9) completely.
Remove thrust plate (11).
: 24 mm
9
9 10
10
12
W178-04-02-009
W105-04-02-040
W4-2-10
FRONT ATTACHMENT / Cylinder
Install Boom Cylinder
9 10
4. Connect hoses (12) (4 used) on boom cylinders
(2) (2 used).
: 36 mm 10
12
W178-04-02-009
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
W4-2-11
FRONT ATTACHMENT / Cylinder
5. Lift boom cylinder (2). Operate the boom lever.
Align the pin hole at cylinder rod side with the
mounting hole of the boom cylinder.
Monoblock Boom
1
8. Connect grease hoses (1).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
W1F3-04-01-007
2-Piece Boom
4 1
5, 6 2
W1F3-04-01-008
W4-2-12
FRONT ATTACHMENT / Cylinder
Remove Positioning Cylinder
(2-Piece Boom Only)
W4-2-13
FRONT ATTACHMENT / Cylinder
Install Positioning Cylinder
W4-2-14
FRONT ATTACHMENT / Cylinder
Remove Blade Cylinder
on page W4-1-1.)
3, 4 5 6 7
3. Disconnect hoses (10) (4 used) from blade
cylinder (8). Cap the disconnected hose ends.
: 19 mm, 27 mm
W4-2-15
FRONT ATTACHMENT / Cylinder
Install Blade Cylinder
3, 4 5 6 7
: 24 mm 3, 4, 5, 6 9
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
W1GL-04-01-013
W4-2-16
FRONT ATTACHMENT / Cylinder
Remove Stabilizer Cylinder
9
CAUTION: Stabilizer cylinder weight:
88 kg (195 lb)
10, 11
Sleeper
7. Remove ring (2) and lock pin (3) of the stabilizer
cylinder (6) bottom side. Pull out pin (1). 8
W4-2-17
FRONT ATTACHMENT / Cylinder
Install Stabilizer Cylinder
5
CAUTION: Prevent person from injury. Metal
fragments may fly when a hammer is used to
7
install the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.
9
W1F3-04-01-011
W4-2-18
FRONT ATTACHMENT / Cylinder
(Blank)
W4-2-19
FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER
(BOOM (MONOBLOCK/2-PIECE and
BUCKET)
11 1 2 3 4 7 5 6 9 10
8
14 13 19 16 20 21 22 12
20 16 15 17 18 19 24 23
W158-04-02-016
Bucket Cylinder
11 1 2 3 4 7 5 6 9 10
20 19 20 21 22 12
W1F3-04-04-005
16 15 17 18 16 19 24 23
W4-2-20
FRONT ATTACHMENT / Cylinder
Disassemble Boom (Monoblock/2-Piece and
Bucket Cylinders
• Be sure to read “Precautions for Disassembly 5. Remove set screw (22) and steel ball (23).
and Assembly” thoroughly on page W1-1-1 be- NOTE: Set screw (22) was crimped with a punch
fore starting the repair work. in two places after it was tightened. Before
loosening set screw (22), cut away the
The disassembly procedure below starts on the prem- crimped portions.
ise that the hydraulic lines and the line securing bands
have been removed. 6. Loosen nut (24) using special tool (ST 5908).
Remove piston (15), shim (21) and cushion bear-
CAUTION: Cylinder weight: ing (13).
Boom cylinder (Monoblock): 150 kg (330 lb) In case of the boom cylinder remove cushion
Boom cylinder (2-Piece): 160 kg (350 lb) seal (14).
Bucket cylinder: 125 kg (275 lb) Tools for turning nut:
Boom : 85 mm (ST 3304)
1. Lift and horizontally secure the cylinder on a Bucket : 80 mm (ST 3262)
workbench. Then, drain the hydraulic oil from the
ST 5908
cylinder.
W158-04-02-022
W102-04-02-027
7. Remove seal ring (17), slide rings (19, 20) (2
used for each), O-ring (18) and backup rings (16)
2. Fully extend cylinder rod (11). Hold the rod end. (2 used) from piston (15).
Remove socket bolts (8) from cylinder head (7).
8. Remove cylinder head (7) from cylinder rod (11).
3. Pull out cylinder head (7) from cylinder tube (12)
by tapping by using a plastic hammer. 9. Remove O-ring (10) and backup rings (9, 2) from
cylinder head (7). Then remove wiper ring (1),
IMPORTANT: Be sure to pull out piston rod (11) U-ring (3), backup ring (4), snap ring (6) and
straight to prevent the sliding sur- bushing (5).
faces from being damaged. Tools for removing bushing:
4. Secure cylinder rod (11) on special tool (ST Boom : 80 mm (ST 8019/ST 1286)
5908). Put matching marks between cylinder rod Bucket : 75 mm (ST 8018/ST 1285)
(11) and nut (24).
ST 5908
W158-04-02-022
W4-2-21
FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER
(BOOM (MONOBLOCK/2-PIECE and
BUCKET)
Boom Cylinder (Monoblock/2-Piece Boom)
1 2 3 4 5 6 7 8 9, 10 11 12 13 14 15 16 17, 18 19 20 21 21
22, 23
24
Bucket Cylinder
Hole (1 Place)
1 2 3 4 5 6 7 8 9, 10 11 12 13 15 16 17, 18 19 20 21
22, 23
24
W4-2-22
FRONT ATTACHMENT / Cylinder
Assemble Boom (Monoblock/2-Piece) and
Bucket Cylinders
1. Press bushing (5) into cylinder head (7). 8. Install shim (21) to cylinder rod (11). Tighten nut
Tools for installing bushing: (24) using special tool (ST 5908) while aligning
Boom : 80 mm (ST 8019/ST1286) the matching mark on the rod with that on nut
Bucket : 75 mm (ST 8018/ST1285) (24).
ST 5908
IMPORTANT: Be sure to install rings in correct
direction.
2. Install U-ring (3), backup ring (2), buffer ring (4),
and snap ring (6) to cylinder head (7).
Boom : ST 8019/1297
Bucket : ST 8018/1296 Tools for tightening nut:
Boom : 85 mm (ST 3304)
4. Install O-ring (10) and backup ring (9) to cylinder Bucket : 80 mm (ST 3262)
head (7). Boom cylinder
: 3800 N⋅m (390 kgf⋅m, 2800 lbf⋅ft)
IMPORTANT: When installing slide rings (19) and Bucket cylinder
(20), do not align their split portion. : 4780 N⋅m (490 kgf⋅m, 2800 lbf⋅ft)
5. Install O-ring (18), backup rings (16) (2 used),
seal ring (17), and slide rings (19, 20) (2 used for 9. Align the holes of piston rod (11) and nut (24),
each) to piston (15). then install steel ball (23).
6. Install the cylinder head (7) assembly into piston 10. Crimp the head of set screw (22) at two places
rod (11). with a punch.
Tools for installing cylinder head: : 10 mm
Boom : ST 8019/2345 : 57±10.5 N⋅m
Bucket : ST 8018/2344 (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft)
IMPORTANT: Be sure that the slit in cushion seal IMPORTANT: Take care not to damage rings. In-
(14) is facing piston and that the oil stall the piston rod (11) assembly
groove in cushion bearing (13) is into cylinder tube (12) while aligning
facing correct direction. it with the center of cylinder tube
7. Install cushion bearing (13) to piston rod (11). In- (12).
stall the piston (15) assembly to the piston rod 11. Horizontally secure cylinder tube (12) on a work-
(11). bench. Insert the piston rod (11) assembly into
In case of the boom cylinder, install cushion seal cylinder tube (12).
(14).
12. Install cylinder head (7) into cylinder tube (12)
13 with socket bolts (8) (12 used).
Oil Groove : 10 mm
Nut Side : 171 N⋅m (17.5 kgf⋅m)
Head Side Nut Side
W18B-04-02-011
W4-2-23
FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER (Positioning)
Positioning Cylinder
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21
Hole (1 Place) 22
16
W1F3-04-04-007
W4-2-24
FRONT ATTACHMENT / Cylinder
Disassemble Positioning Cylinder
• Be sure to thoroughly read all “Precautions for 5. Remove set screw (21) and steel ball (22).
Disassembly and Assembly Work” on page NOTE: Set screw (21) was crimped with a punch
W1-1-1 before starting the disassembly work. in two places after it was tightened. Before
loosening set screw (21), cut away the
The disassembly procedure below starts on the prem- crimped portions.
ise that the hydraulic line and the line securing bands
have been removed. 6. Loosen nut (20) using special tool (ST 5908).
Remove piston (13) and shim (19)
Tool for tightening nut: 135 mm (ST 3283)
CAUTION: Positioning Cylinder weight:
290 kg (640 lb) 7. Remove seal ring (15), slide rings (17, 18),
O-ring (18), backup rings (14) (2 used) from pis-
1. Lift and place the cylinder horizontally on a work ton (13).
bench. Drain hydraulic oil from the cylinder.
8. Remove cylinder head (7) from piston rod (11).
W102-04-02-027
ST 5908
W158-04-02-022
W4-2-25
FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER (Positioning)
Positioning Cylinder
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21
Hole (1 Place) 22
16
W1F3-04-04-007
W4-2-26
FRONT ATTACHMENT / Cylinder
Assemble Positioning Cylinder
1. Press bushing (5) into cylinder head (7). 8. Install shim (19) to cylinder rod (11). Tighten nut
Tools for pressing bushing: 120 mm (ST 1374) (20) by using special tool (ST 5908) while align-
ing the matching mark on the rod with that on the
IMPORTANT: Be sure to install rings in correct nut.
direction. Tool for turning nuts:135 mm (ST 3283)
2. Install U-ring (3), backup ring (2), buffer ring (4), : 14700 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
and snap ring (6) to cylinder head (7).
ST 5908
3. Install wiper ring (1) to cylinder head (7) by using
a plastic hammer.
Wiper ring pressing tool ST 1480
W4-2-27
FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER (ARM)
Arm Cylinder
11 1 2 3 4 7 5 6 9 10
14 13 15 16 25 26 28 22 12
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
W4-2-28
FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
• Be sure to read “Precautions for Disassembly 5. Remove set screw (22) and steel ball (23).
and Assembly” thoroughly on page W1-1-1 be- NOTE: Set screw (22) was crimped with a punch
fore starting the repair work. in two places after it was tightened. Before
loosening set screw (22), cut away the
The disassembly procedure below starts on the prem- crimped portions.
ise that the hydraulic lines and the line securing bands
have been removed. 6. Loosen nut (24) using special tool (ST 5908).
Remove piston (15), shim (21), cushion bearing
CAUTION: Arm cylinder weight : (13) and cushion seal (14).
220 kg (490 lb) Tool for tightening nut: 90 mm (ST 3263)
ST 5908
1. Lift and horizontally secure the cylinder on a
workbench. Then, drain the hydraulic oil from the
cylinder.
W158-04-02-022
2. Fully extend cylinder rod (11). Lift and hold the 8. Remove cylinder head (7) from cylinder rod (11).
rod. Remove socket bolts (8) from cylinder head
(7). 9. Remove O-ring (10) and backup rings (9, 2) from
cylinder head (7). Then remove wiper ring (1),
IMPORTANT: Be sure to pull out piston rod (11) U-ring (3), backup ring (4), snap ring (6) and
straight to prevent the sliding sur- bushing (5).
faces from being damaged. Tool for removing bushing: 90 mm (ST 8024/ST
3. Pull out cylinder head (7) with piston rod still at- 1991)
tached from cylinder tube (12) by using a plastic
hammer. 10. Remove stopper (28) from piston rod (11) with a
screwdriver. Remove cushion bearing (27), cush-
4. Secure cylinder rod (11) on special tool (ST ion seal (26) and snap ring (25).
5908). Put matching mark between cylinder rod
(11) and nut (24).
ST 5908
W158-04-02-022
W4-2-29
FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER (ARM)
Arm Cylinder
Hole (1 Place)
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20 21
22, 23
24
25
26
27
28
W1F1-04-02-003
W4-2-30
FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder
1. Press bushing (5) into cylinder head (7). 9. Install shim (21) to cylinder rod (11). Tighten nut
Tools for pressing bushing: ST 8024/ST 1911 (24) using special tool (ST 5908) while aligning
the matching mark on the rod with that on the nut.
IMPORTANT: Be sure to install rings in correct Tool for tightening nut: 90 mm (ST 3263)
direction. : 7230 N⋅m (740 kgf⋅m, 5330 Ibf⋅ft)
2. Install U-ring (3), backup ring (2), buffer ring (4),
and retaining ring (6) to cylinder head (7). ST 5908
IMPORTANT: When installing slide rings (19) and 10. Align the hole of piston rod (11) and nut (24), then
(20), do not align their split portion. install steel ball (23).
5. Install seal ring (17), O-ring (18), and slide rings
(19, 20) (2 used for each) to piston (15). 11. After tightening set screw (22), crimp the head of
set screw (22) at two places with a punch.
6. Install the cylinder head (7) assembly into piston : 57±10.5 N⋅m
rod (11). (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft)
Tools for installing cylinder head:
ST 8024/ST 2510
CAUTION: Be sure to keep cylinder rod (11)
aligning with the center of cylinder tube (12)
IMPORTANT: Be sure that the slit in cushion seal
when inserting in order to avoid damaging
(14) is facing piston and that the oil
rings.
groove in cushion bearing (13) is
facing correct direction.
12. Horizontally secure cylinder tube (12) on a work-
7. Install cushion seal (14) to cylinder rod (11). In-
bench. Insert the piston rod (11) assembly into
stall cushion bearing (13) and the piston (15) as-
cylinder tube (12).
sembly to cylinder rod (11)
13. Install cylinder head (7) into cylinder tube (12)
13
with socket bolts (8) (12 used).
Oil Groove
Nut Side
: 267 N⋅m (27 kgf⋅m, 200 Ibf⋅ft)
W18B-04-02-011
W4-2-31
FRONT ATTACHMENT / Cylinder
DISASSEMBLE CYLINDER
(STABILIZER, BLADE)
Stabilizer Cylinder
W1GL-04-02-001
Blade Cylinder
W1GL-04-02-002
Section A
1 Lock Washer 3 4 10 11 12 13 14 15 16 15 14 13
Slit 18
Hole (1 Place) Black 19
Green
20
2
5 6 7 8 9
17 W1GL-04-02-003
W4-2-32
FRONT ATTACHMENT / Cylinder
Disassemble Stabilizer and Blade Cylinders
• Be sure to read “Precautions for Disassembly 4. Secure piston rod (10) on special tool (ST 5908).
and Assembly” thoroughly on page W1-1-1 be- Put matching mark between piston rod (10) and
fore starting the repair work. nut (18).
• The disassembly procedure below starts on the
ST 5908
premise that the hydraulic lines and the line se-
curing bands have been removed.
CAUTION:
Stabilizer cylinder weight: 88 kg (195 lb)
Blade cylinder weight: 55 kg (120 lb)
W158-04-02-022
1. Lift and horizontally secure the cylinder on a
workbench. Then, drain the hydraulic oil from the 5. Remove set screw (19) and steel ball (20).
cylinder.
NOTE: Set screw (19) was crimped with a punch
in two places after it was tightened. Before
loosening set screw (19), cut away the
crimped portions.
W4-2-33
FRONT ATTACHMENT / Cylinder
ASSEMBLE CYLINDER
(STABILIZER, BLADE)
Stabilizer Cylinder
W1GL-04-02-001
Blade Cylinder
W1GL-04-02-002
Section A
1 Lock Washer 3 4 10 11 12 13 14 15 16 15 14 13
Slit 18
Hole (1 Place) Black 19
Green
20
2
5 6 7 8 9
17 W1GL-04-02-003
W4-2-34
FRONT ATTACHMENT / Cylinder
Assemble Stabilizer and Blade Cylinders
• Be sure to read “Precautions for Disassembly 8. Install piston (12) to piston rod (10). Tighten nut
and Assembly” thoroughly on page W1-1-1 be- (18) using special tool (ST 5908) while aligning
fore starting the repair work. the matching mark on the rod with that on nut
(18).
1. Press bushing (6) into cylinder head (2) by using Tools for turning nut:
the special tool. Install retaining ring (7) in cylin- Stabilizer cylinder: 85 mm (ST 3304)
der head (4). : 3560 N⋅m (360 kgf⋅m, 2630 Ibf⋅ft)
Tools for pressing bushing: Blade cylinder: 75 mm (ST 3271)
Stabilizer cylinder: 70 mm (ST 8017) : 2480 N⋅m (250 kgf⋅m, 1830 Ibf⋅ft)
Blade cylinder: 60 mm (ST 8017)
W4-2-35
FRONT ATTACHMENT / Cylinder
MAITENANCE STANDARD
Piston Rod Rod Bend and Run Out
Dial Gauge
Piston Rod
A
W166-04-02-022
1 m (3.9 in)
W105-04-02-094 V Block
Unit: mm (in)
Recommended Size After Unit: mm (in)
Cylinder Name Bend Run out Remedy
Re-manufacturing (A)
-0.023 -0.0009 0.5 (0.020) 1.0 (0.039) Repair
Boom 80 (3.15 ) 1.0 (0.039) 2.0 (0.079) Replace
-0.053 -0.0021
-0.029 -0.0011
Positioning 90 (3.54 )
-0.057 -0.0022
-0.023 -0.0009
Bucket 75 (2.95 )
-0.053 -0.0021
W4-2-36
FRONT ATTACHMENT / Hose-Rupture Safety Valve
REMOVE AND INSTALL HOSE-RUPTURE
SAFETY VALVE
Removal of Hose-Rupture Safety Valve for Arm
Cylinder 1 2 3, 4
W4-3-1
FRONT ATTACHMENT / Hose-Rupture Safety Valve
W4-3-2
FRONT ATTACHMENT / Hose-Rupture Safety Valve
W4-3-3
FRONT ATTACHMENT / Hose-Rupture Safety Valve
CONSTRUCTION OF HOSE-RUPTURE
SAFETY VALVE
20 21
19
3
18 4
17 5
7
16 15 14 13
8
9
10
11
12
W1GL-04-03-002
W4-3-4
FRONT ATTACHMENT / Hose-Rupture Safety Valve
Tightening Torque
Item No. Part Name Quantity Wrench Size Remark
N⋅m (kgf⋅m) (lbf⋅ft)
1 Casing 1
2 Plug 3
3 O-Ring 3
4 Spool 1
5 O-Ring 1
6 Plug 1
7 Spring Seat 1
8 Backup Ring 1
9 O-Ring 1
10 Spring 1
11 Poppet 1
12 Body 1
13 O-Ring 2
14 Seat 1
15 O-Ring 1
16 Stopper 1
17 Set Screw 1
18 Lock Nut 1
19 O-Ring 1
20 Cover 1
21 Spring 1
W4-3-5
FRONT ATTACHMENT / Hose-Rupture Safety Valve
3 4 5 6 7 8
2
1
29 30 31
28 9
27
10
26
11
25
12
13
14
15
16
17
24 23 22 21 18
19
20
W1GL-04-03-001
W4-3-6
FRONT ATTACHMENT / Hose-Rupture Safety Valve
W4-3-7
FRONT ATTACHMENT / Hose-Rupture Safety Valve
(Blank)
W4-3-8
FRONT ATTACHMENT / Operate-Check Valve
REMOVE AND INSTALL OPERATE-CHECK
VALVE (FOR BLADE/STABILIZER)
1
Removal
2
IMPORTANT: Before working, lower the blade onto
the ground.
IMPORTANT: Before working, be sure to secure
the stabilizer beam and stabilizer
with the lock pin.
1. Remove bolts (2) (4 used) then remove protection
cover (1).
: 19 mm
6, 7
Installation
W4-4-1
FRONT ATTACHMENT / Operate-Check Valve
CONSTRUCTION OF OPERATE-CHECK
VALVE (FOR BLADE/STABILIZER)
4
5
11 10 9 8 7
T1F3-03-10-003
W4-4-2
MEMO
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SECTION 5
ENGINE AND ACCESSORY
CONTENTS
General Information Engine Assembly 2
General Repair Instructions ........................... 1-2 (Inspection and Repair)
Notes on the Format of This Manual .............. 1-2 Cylinder Head ................................................ 4-2
Angular Nut and Bolt Tightening Method...... 1-16 Rocker Arm Shaft and Rocker Arm................. 4-8
Major Parts Fixing Nuts and Bolts ................ 1-18 Idler Gear and Idler Gear Shaft ...................... 4-9
CBBW-5-1
Lubricating System Troubleshooting
General Description ....................................... 6-2 Hard Starting ................................................ 11-2
Oil Pump ........................................................ 6-3 1) Starter Inoperative ................................. 11-2
Oil Cooler....................................................... 6-5 2) Starter Operates but
Engine does not Turn Over .................... 11-3
Cooling System
3) Engine Turns Over but does not Start
General Description ....................................... 7-2
Fuel is Being Delivered to the
Thermostat..................................................... 7-3
Injection Pump ....................................... 11-4
Fuel System 4) Engine Turns Over but does not Start .... 11-5
General Description ....................................... 8-2 Unstable Low Idling ...................................... 11-6
Injection Nozzle ............................................. 8-3 Insufficient Power......................................... 11-8
Injection Pump Calibration Data..................... 8-8 Excessive Fuel Consumption ......................11-11
Excessive Oil Consumption........................ 11-13
Turbocharger Overheating ............................................... 11-14
General Description ....................................... 9-2 Whity Exhaust Smoke ................................ 11-16
Turbocharger Identification ............................ 9-3 Dark Exhaust Smoke.................................. 11-17
Troubleshooting ............................................. 9-5 Oil Pressure does not Rise......................... 11-18
Inspection and Repair .................................... 9-7 Abnormal Engine Noise.............................. 11-20
CBBW-5-2
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
REPLY: