Hitachi EX2500-5 - Workshop Manual

EX2500-5
Manual No. : KM-141-E

Vol. No. : W141-E-01
Workshop Manual
Excavator
Workshop Manual
EX2500-5
Excavator
Service Manual (Manual No. KM-141-E) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TO141-E
Technical Manual (Troubleshooting) : Vol. No. TT141-E
Workshop Manual : Vol. No. W141-E
PRINTED IN SINGAPORE (PS) 2005.03
EX2500-5 TM/WSH 1 9/3/05, 17:23

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for 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
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
• 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
• This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in

this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe
operating practices.
001-E01A-0001
SA-001
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating

the degree or level of hazard - DANGER,
WARNING, or CAUTION - are used with the safety
alert symbol.
• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
• CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in
minor or moderate injury.
• DANGER or WARNING safety signs are

located near specific hazards. General
precautions are listed on CAUTION safety
signs. SA-1223
• CAUTION also calls attention to safety messages in

this manual.
• To avoid confusing machine protection with

personal safety messages, a signal word
IMPORTANT indicates a situation which, if not
avoided, could result in damage to the machine.
• NOTE indicates an additional explanation for an

element of information.
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the

machine and all safety messages in this manual.
• Safety signs should be installed, maintained and

replaced when necessary.
• If a safety sign or operator's manual is damaged

or missing, replace it with new one.
• Learn how to operate the machine and its controls

correctly and safely. SA-003
• Allow only trained, qualified, authorized personnel

to operate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may

impair its function and/or safety and affect
machine life.
• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
S003-E01B-0003
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label
attached on the fire extinguisher to use it
properly.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors,
ambulance service, hospital, and fire department
posted near your telephone. SA-437
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.

Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full

attention of the operator. Do not wear radio or
music headphones while operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such

as earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434 SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
• In the walk-around inspection be sure to cover all

points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-3
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount

or dismount a moving machine.
SA-439
• Be careful of slippery conditions on platforms,

steps, and handrails when leaving the machine.
008-E01A-0439
ADJUST THE OPERATOR'S SEAT
• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator
leading to misoperations.
• The seat should be adjusted whenever changing

the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again. SA-378
009-E01A-0378
SA-4
SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may

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

examine webbing, buckle and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine. SA-237
• Be sure to remain seated with the seat belt

securely fastened at all times when the machine
is in operation to minimize the chance of injury
from an accident.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.
• Take extra care not to run over bystanders.

Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-426
machine.
011-E01A-0426
SA-5
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
• Start the engine only when seated in the

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

levers are in neutral.
012-E01B-0444
HANDLE STARTING AIDS SAFELY

Starting fluid:
• Starting fluid is highly flammable.
• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and
cables.
• Remove container from machine if engine does
not need starting fluid.
• To prevent accidental discharge when storing a
pressurized container, keep the cap on the
container, and store it in a cool, well-protected SA-293
location.
• Do not incinerate or puncture a starting fluid
container.
036-E01A-0293
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to

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

could result in a battery explosion or a runaway
machine.
S013-E01A-0032
SA-6
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.

Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
SA-379
014-E01B-0379
PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordi-
nate the job site. Make sure that all personnel obey
the signal person’s directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
• Incorrect travel pedal/lever operation may result in

serious injury death.
• Before driving the machine, confirm the position

of the undercarriage in relation to the operator’s
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
SA-491
017-E01A-0491
SA-7
SAFETY
DRIVE MACHINE SAFELY
• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.
• Pushing down on the front of the travel pedals or

pushing the levers forward moves the machine
towards the idlers. (Refer to the Steering the
Machine Using Pedals/Levers section in the
operator's manual for correct travel operation.)
• Traveling on a grade may cause the machine to slip SA-387
or to overturn, possibly resulting in serious injury or

death.
• When traveling up or down a grade, keep the

bucket in the direction of travel, approximately
0.5 to 1.0 m (approximately 2 to 3 ft)(A) above
the ground.
• If machine starts to skid or becomes unstable,
lower the bucket immediately.
SA-388
• Driving across the face of a slope or steering on

a slope may cause the machine to skid or
turnover. If the direction must be changed, move
the machine to level ground, then, change the
direction to ensure safe operation.
SA-441
S019-E02B-0590
SA-589
SA-8
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch off. SA-391
• Run the engine at slow idle speed without load

for 5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E02A-0493 SA-392
SA-9
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
SA-383
• Keep the travel alarm in working condition (if

equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person. SA-384
• No machine motions shall be made unless

signals are clearly understood by both signalman
and operator.
• Learn the meanings of all flags, signs, and

markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in

good condition.
• Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.
• Read and understand all operating instructions in

the operator’s manual.
S021-E01A-0494
SA-10
SAFETY
AVOID TIPPING
• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or SA-012
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is
unavoidable.
• Reduce swing speed as necessary when
swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to

become soft and make ground travel unstable. SA-440
S025-E02B-0495
SA-11
SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER

move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site. SA-381
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may

be struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,

be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
SA-014
is safely and securely situated on supporting
blocks or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-12
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,

serious injury may result.
• Guard against injury from flying pieces of metal

or debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position.
• Close windows, roof vent, and cab door. SA-390
• Lock all access doors and compartments.
033-E02B-0390
SA-13
SAFETY
HANDLE FLUIDS SAFELY－AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the
machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are SA-018
flammable.
• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
034-E01A-0496 SA-019
SA-14
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing

work.
• Keep work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.
• Before servicing the machine:
1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle switch off.
4) Run the engine at slow idle speed without load
for 5 minutes. SA-028
5) Turn the key switch to OFF to stop engine.

6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a “Do Not Operate” tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
• If a maintenance procedure must be performed

with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or SA-527
replace as necessary. Refer to the section

discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• 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 SA-037
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
S500-E02B-0497
SA-15
SAFETY
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine,

attach a “Do Not Operate” tag on the control
lever.
SA-287
S501-E01A-0287
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without

securing the machine first.
• Always lower the attachment to the ground

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

• Entanglement in moving parts can cause serious
injury.
• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026 SA-026
SA-16
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or

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

SA-344
• As pieces may fly off, be sure to keep body and

face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.
SA-034
504-E01A-0034
USE TOOLS PROPERLY

• Use tools appropriate for the work to be done.
• Makeshift tools, parts, and procedures can create
safety hazards.
• For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
• Use only recommended replacement parts.
(See the parts catalog.)
SA-040
S522-E01A-0040
SA-17
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the SA-039
stop. Allow all pressure to be released before

removing the cap.
• The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become

hot during operation.
The engine, hoses, lines and other parts become
hot as well.
SA-225
• Wait for the oil and components to cool before

starting any maintenance or inspection work.
505-E01B-0498
REPLACE RUBBER HOSES

PERIODICALLY
• Rubber hoses that contain flammable fluids under

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

cause a fire, fluid injection into skin, or the front SA-019
attachment to fall on a person nearby, which may

result in severe burns, gangrene, or otherwise
serious injury or death.
506-E01A-0019
SA-18
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
• Relieve the pressure by moving the control levers
several times. Tighten all connections before
applying pressure. SA-031
• Search for leaks with a piece of cardboard; take

care to protect hands and body from
high-pressure fluids. Wear a face shield or
goggles for eye protection.
• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E01A-0499 SA-044
SA-19
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 for oil leaks.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
SA-019
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
• Check before starting work for missing or
damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,

accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the

machine daily and by removing spilled or
accumulated flammables immediately.
Check Key Switch:
• If a fire breaks out, failure to stop the engine will

escalate the fire, hampering fire fighting.
• Always check key switch function before

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

them before operating the machine.
S508-E05B-0019
SA-20
SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to stop the engine will

escalate fire, hampering fire fighting.
• Check the emergency engine stop switch

function every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to
the EMERG. STOP position.
3) Confirm that the engine(s) stop.
• If any abnormalities are found, be sure to repair

them before operating the machine.
Check Heat Shields:
• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be

repaired or replaced before operating the
machine.
S508-E05B-0019
EVACUATING IN CASE OF FIRE

Evacuating in Case of Fire:
• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the emergency engine

stop switch to the EMERG. STOP position if there
is time.
• Use a fire extinguisher if there is time.
• Exit the machine. Refer to the section
“HANDLING LADDER/EMERGENCY ROPE” or
“EMERGENCY ROPE” in the operator’s manual
SA-393
for details on the procedures for emergency exits
from the machine.
S518-E01A-0393
SA-21
SAFETY
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.
• If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016 SA-016
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
• Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a

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

welding, soldering, etc..
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that
contain flammable fluids.
• Clean them thoroughly with nonflammable
solvent before welding or flame cutting them.
510-E01B-0030
SA-22
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

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

1) If you sand or grind paint, avoid breathing the SA-029
dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
• Keep sparks, lighted matches, and flame away

from the top of battery.
• Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Battery electrolyte is poisonous. If the battery SA-032
should explode battery electrolyte may be splashed

into eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking

electrolyte specific gravity.
512-E01B-0032
SA-23
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
AVOID HARMFUL ASBESTOS DUST

• Inhaled asbestos fibers may cause lung cancer.
• Avoid breathing dust that may be generated

when han-dling components containing asbestos
fibers.
• Components that may contain asbestos fibers
are some gaskets. The asbestos used in these
components is usually found in a resin or sealed
in some way. Normal handling is not hazardous
as long as airborne dust containing asbestos is
not generated.
• Avoid creating dust. Never use compressed air
SA-029
for cleaning. Avoid brushing or grinding
asbestos-containing materials. When servicing,
wear an approved respirator. A special vacuum
cleaner is recommended to clean asbestos. If not
available, wet the asbestos containing materials
with a mist of oil or water.
• Be sure to comply with all applicable rules and
regulations for the work place.
Follow all local environmental rules and
regulations for the disposal of asbestos.
• Keep bystanders away from the areas where
asbestos particles may be in the air.
514-E01A-0029
SA-24
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals
used with your machine include such items as
lubricants, coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know

exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids.

Do not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air SA-226
can damage the Earth’s atmosphere.

Government regulations may require a certified
air conditioning service center to recover and
recycle used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
SA-25
SAFETY
BEFORE RETURNING THE MACHINE TO
THE CUSTOMER
• After maintenance or repair work is complete,
confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced.
S517-E01A-0435 SA-435
SA-26
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Bleeding Air from Hydraulic
Oil Tank
SECTION 2 UPPERSTRUCTURE
WORKSHOP MANUAL Group 1 Cab
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 Shuttle Valve
Group 10 Solenoid Valve
Group 11 Oil Cooler Fan Motor
Group 12 Compressor Drive Motor
Group 13 Air Conditioner
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Travel Brake Valve
Group 4 Drive Tumbler
Group 5 Center Joint
All information, illustrations and speci-
fications in this manual are based on Group 6 Adjuster Cylinder
the latest product information available
at the time of publication. The right is
Group 7 Front Idler
reserved to make changes at any time Group 8 Upper and Lower Roller
without notice.
Group 9 Track Shoes
Group 10 Accumulator
Group 11 Welding Repair Procedure
SECTION 4 FRONT ATTACHMENT
COPYRIGHT(C)2005
Hitachi Construction Machinery Co., Ltd. Group 1 Front Attachment
Tokyo, Japan
All rights reserved
Group 2 Cylinder
Group 3 Bushing and Point
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specification Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 General 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 Others(Upperstructure)
Group 3 Electrical System Group 7 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 Procedure
SECTION 1
GENERAL INFORMATION
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Maintenance Standard Terminology ......... W1-1-7
Group 2 Tightening Torque

Tightening Torque Specification ............... W1-2-1
Torque Chart ............................................ W1-2-3
Piping Joint .............................................. W1-2-6
Periodic Replacement of Parts............... W1-2-10
Group 3 Bleeding Air from Hydraulic

Oil Tank
Bleeding Air from Hydraulic Oil Tank ........ W1-3-1
Vacuum.................................................... W1-3-2
141W-1-1
(Blank)
141W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassembling instructed.
/ assembling procedures beforehand, to help avoid • If a part or component cannot be removed after
incorrect disassembling of components as well as removing its securing nuts and bolts, do not
personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the

area for disassembling work.
W1-1-1
• 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
clean and dry.
motor housing, damage to the
• If an anti-corrosive agent has been used on a
motor 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.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
W1-1-2
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation T142-05-03-007
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
T142-05-03-008
W1-1-3
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check the slide surface on seal ring (A) for

scuffing, scoring, corrosion, deformation or B W105-03-05-019
uneven wear.
(3) Check O-ring (B) for tears, breaks,

deformation or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting

bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect
(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.
(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal a a
mating face (C) by measuring the distances
A
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating. B
b b
a=b a≠b
W110-03-05-004
W1-1-4
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

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

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

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

adjusted to specification.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or adjustment is impossible after exceed-

ing this limit.
3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.
W1-1-7
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
No. Descriptions Bolt Dia Q’ty Wrench Torque

mm Size (mm) Nxm (kgfxm) (lbfxft)
1 Engine cushion rubber mounting bolt 36 8 55 3140 (320) (2310)
2 Engine bracket mounting bolt a 30 12 46 1420 (145) (1050)
b 20 16 30 540 (55) (400)
c 22 6 32 740 (75) (540)
3 Hydraulic oil tank mounting bolt 30 10 46 1420 (145) (1050)
4 Fuel tank mounting bolt 30 16 46 1420 (145) (1050)
5 Pump transmission mounting bolt 12 16 19 108 (11) (80)
6 Pump device mounting bolt 24 12 36 690 (70) (510)
7 Fan drive pump mounting bolt 20 4 30 390 (40) (290)
8 Gear pump mounting bolt 12 4 19 88 (9) (65)
9 Control valve mounting nut 20 12 30 390 (40) (290)
10 Swing device mounting bolt 33 50 50 2550 (260) (1880)
11 Swing motor mounting nut 20 16 30 390 (40) (290)
12 Battery mounting bolt 10 16 17 49 (5) (36)
13 Cab mounting bolt 18 10 27 205 (21) (152)
14 Cab bed mounting bolt 16 40 24 205 (21) (152)
15 Swing bearing mounting bolt 48 60 75 4900 (500) (3620)
16 Counterweight mounting nut 48 6 75 5150 (525) (3800)
17 Engine bed mounting bolt 30 28 46 1420 (145) (1050)
18 Oil cooler mounting nut 24 8 36 690 (70) (510)
19 Radiator mounting nut 27 4 41 1370 (140) (1010)
20 Fan motor bracket mounting bolt 12 12 19 88 (9) (65)
21 Travel device mounting bolt 27 24 41 1370 (140) (1010)
36 56 55 3140 (320) (2310)
20 30 30 390 (40) (290)
16 32 24 205 (21) (152)
22 Travel motor mounting bolt 22 8 32 740 (75) (540)
23 Upper roller mounting bolt 22 24 32 540 (55) (400)
24 Lower roller mounting bolt 36 64 55 3140 (320) (2310)
25 Track pin-retaining bolt 30 156 46 1910 (195) (1410)
26 Side frame mounting bolt 48 68 75 4900 (500) (3620)
27 Front pin-retaining bolt 24 28 36 690 (70) (510)
20 16 30 390 (40) (290)
16 6 24 265 (27) (195)
W1-2-1
NOTE 1.Apply lubricant (e.g. white zinc B dis-
solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.
3.Apply LOCTITE to threads before in-
stalling and tightening swing bearing
mounting bolts and lower roller mounting
bolts.
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

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

correctly when assembling the machine or compo-
nents.
Specified Tightening Torque Chart
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.2) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.4) (135) 140 (14.3) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.2) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.3) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (199) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (199) (1440) 750 (76.5) (550)
M36 55 27 3200 (326) (2360) 2450 (250) (1810) 950 (97.0) (700)
W1-2-3
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.
Bolt Tightening Order
When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.
Tighten from center and diago-
Equally tighten upper and lower alter- Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
Service Recommendations for Spilt Flange
IMPORTANT: 1. Be sure to clean and Inspect

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

ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply
Nut and Bolt Locking RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009
RIGHT RIGHT WRONG

ening, not while loosening.
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-5
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37°
30°
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
2. Scratches or other damage to

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

Description mm Torque
Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0,21.5)
22 22 39 (4.0,28.5)
27 27 93 (9.5,69)
32 32 137 (14.0,101)
36 36 175 (18.0,129)
41 41 205 (21.0,151)
37°female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0,21.5)
22 19 39 (4.0,28.5)
27 22 93 (9.5,69)
32 27 137 (14.0,101)
36 32 175 (18.0,129)
41 36 205 (21.0,151)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.
W1-2-6
O-ring Seal Joint 9
7 6
O-ring (6) seats against the end face of adapter (7) to

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

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 1
in O-ring groove (e). Tightening M104-07-033
nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening Torque
groove (e) or sealing surface mm mm
(10). Union Nut Hose Fittings N⋅m (kgf⋅m, lbf⋅ft)
Damage to O-ring (6) will cause 19 17 29.5 (3.0,21.5)
oil leakage. 22 19 69 (7.0,51)
4. If nut (9) is loose and oil is leak- 27 22 93 (9.5,69)
ing, do not re-tighten nut (9). Re- 32 27 137 (14.0,101)
place O-ring (6) with a new one 36 30,32 175 (18.0,129)
and check that O-ring (6) is cor- 41 36 205 (21.0,151)
rectly seated in place, tighten nut 46 41 205 (21.0,151)
(9).
W1-2-7
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread

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

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 14.5 (1.5,10.5) 34 (3.5,25)
22 29.5 (3.0,21.5) 49 (5.0,36)
27 49 (5.0,36) 93 (9.5,69)
36 69 (7.0,51) 157 (16,116)
41 108 (11,80) 205 (21,151)
50 157 (16,116) 320 (33,235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.
• Application Procedure W105-01-01-019
Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs

depending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W1-2-8
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.
Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print WRONG RIGHT
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other
If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
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
Engine Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Base Machine
Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Front Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings

and
gaskets, when replacing hoses.
W1-2-10
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK
CAUTION: 1. Escaping fluid under pressure

can penetrate the skin and
eyes, causing serious injury.
Avoid this hazard by relieving
pressure before disconnecting
hydraulic or other lines.
2. Hydraulic oil may be hot just
after operation. Hot hydraulic
oil may spurt, possibly causing
severe burns. Be sure to wait
for oil to cool before starting
work.
3. Do not loosen air breather cap
on hydraulic oil tank quickly. Air
breather cap may fly off due to
internal pressure. Always turn
the air breather cap slowly to
release any remaining pressure
before removing it.
Preparation
1. Park the machine on a level solid surface. Lower

the front attachment to the ground.
T142-05-03-007
T142-05-03-008
2. Stop the engine. Loosen the lock of the air

breather cap (1) on the hydraulic oil tank with a
hexagon wrench.
: 4 mm
3. Turn air breather cap (1) approximately 30°

counterclockwise to release any remaining pres-
sure.
Hexagon Wrench
W118-02-03-018
W1-3-1
GENERAL / Bleeding Air from Hydraulic Oil Tank
VACUUM
2
1. Bleed air from hydraulic oil tank. 3
(Refer to Bleeding Air from Hydraulic Oil Tank on 1
page W1-3-1) Port
2. Remove socket bolt (2) of air breather cap (1) at

one side to remove air breather cap (1). 4
: 4 mm
3. Remove filter (3). Wind an adhesive tape around

bayonet assembly (4) approx. one and half turns
so that the port is plugged. Reinstall filter (3) and
air breather cap (1) to the original position.
4. Remove other side air breather cap (1). Connect

a vacuum pump. Operate the vacuum pump con-
tinuously to create negative pressure in the hy-
draulic oil tank.
IMPORTANT: After completing the work, be sure W118-02-05-001
to remove the adhesive tape from

bayonet assembly (4).
Hose
Vacuum Pump
Adapter
Hydraulic Oil
Tank
W141-01-03-001
W1-3-2
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SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Disassemble Air Compressor
Dimensions of the Cab Glass ...............W2-1-1 Drive Pump and Pilot Pump ............. W2-4-64
Assemble Air Compressor
Group 2 Counterweight Drive Pump and Pilot Pump ............. W2-4-70
Remove and Install Counterweight .......W2-2-1 Maintenance Standard ....................... W2-4-74
Disassemble Lubrication Pump
Group 3 Main Frame for Pump Transmission..................... W2-4-76
Assemble Lubrication Pump
Remove and Install Main Frame ...........W2-3-1
for Pump Transmission..................... W2-4-78
Maintenance Standard ....................... W2-4-80
Group 4 Pump Device
Remove and Install Pump Device .........W2-4-1
Disassemble Main Pump ......................W2-4-6
Group 5 Control Valve
Remove and Install Control Valve ........ W2-5-1
Assemble Main Pump .........................W2-4-16
Disassemble Control Valve .................. W2-5-4
Maintenance Standard ........................W2-4-24
Assemble Control Valve ..................... W2-5-12
Disassemble Regulator
Disassemble and Assemble
for Main Pump ..................................W2-4-26
Main Relief Valve,
Assemble Regulator for Main Pump....W2-4-32
Overload Relief Valve ....................... W2-5-16
Components of 4-Spool Pump ............W2-4-39
Make-up Valve Construction .............. W2-5-18
Disassemble Oil Cooler Fan
Drive Pump .......................................W2-4-40
Assemble Oil Cooler Fan Group 6 Swing Device
Drive Pump .......................................W2-4-44 Remove and Install Swing Device ........ W2-6-1
Maintenance Standard ........................W2-4-50 Disassemble Swing Reduction Gear .... W2-6-4
Disassemble Regulator Assemble Swing Reduction Gear ....... W2-6-10
for Oil Cooler Fan Drive Pump ..........W2-4-52 Disassemble Swing Motor.................. W2-6-18
Assemble Regulator Assemble Swing Motor....................... W2-6-22
for Oil Cooler Fan Drive Pump ..........W2-4-58 Maintenance Standard ....................... W2-6-26
Valve Unit ......................................... W2-6-28
141W-2-1
Group 7 Pilot Valve Group 12Compressor Drive Motor
Remove and Install Remove and Install
Front/Swing Pilot Valve .......................W2-7-1 Compressor Drive Motor .................. W2-12-1
Remove and Install Travel and Disassemble Compressor
Bucket Open/Close Pilot Valve............W2-7-3 Drive Motor ...................................... W2-12-4
Pilot Line Connection............................W2-7-6 Assemble Compressor Drive Motor.... W2-12-6
Disassemble Front/Swing Pilot Valve....W2-7-8
Assemble Front/Swing Pilot Valve ......W2-7-10 Group 13 Air Conditioner
Disassemble Travel Work after Replacing Component ...... W2-13-1
Bucket Open/Close Pilot Valve..........W2-7-14 Add Compressor Oil ........................... W2-13-1
Assemble Travel Charge Air Conditioner
Bucket Open/Close Pilot Valve..........W2-7-16 with Refrigerant ................................ W2-13-2
Group 8 Pilot Shut-Off Valve

Remove and Install
Pilot Shut-off Valve..............................W2-8-1
Disassemble Pilot Shut-off Valve ..........W2-8-4
Assemble Pilot Shut-off Valve ...............W2-8-6
Group 9 Shuttle Valve

Remove and Install Shuttle Valve .........W2-9-1
Shuttle Valve .......................................W2-9-3
Group 10 Solenoid Valve

Remove and Install Solenoid Valve.....W2-10-1
Solenoid Valve Construction ...............W2-10-4
Group 11 Oil Cooler Fan Motor

Remove and Install
Oil Cooler Fan Motor......................... W2-11-1
Disassemble Oil Cooler Fan Motor ..... W2-11-6
Assemble Oil Cooler Fan Motor .......... W2-11-8
Maintenance Standard ...................... W2-11-10
141W-2-2
UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
Unit: mm
Material: JIS R 3211, ANSI AS2, ECE ANNEX5 or equivalent
NOTE: 1 mm = 0.03937 in
1378±1.5
1 6
4-R91
7
1
Laminated glass
Color : Transparent
1679
+2.0
-0
Thickness : 10 mm
Chamfer all fringe Corners
2
5
3
4
W146-02-01-002
W117-02-01-002
1369±1.5
4-R61
4-R61
2
3
Tempered glass
Color : Bronze Tempered glass
Thickness : 5 mm Color : Bronze
769±1.0 Thickness : 5 mm
Chamfer all fringe
917±1.0 Corners
W117-02-01-004
1256±1.5 433±1.0
W117-02-01-003
W2-1-1
UPPERSTRUCTURE / Cab
NOTE: 1 mm = 0.03937 in
129
129
5-R61 4-R61
4 5
Tempered glass Tempered glass
Color : Bronze Color : Bronze
762±1.0 Thickness : 6 mm 777±1.0 Thickness : 5 mm
Chamfer all fringe Corners Chamfer all fringe Corners
W146-02-01-001
512±1.0 W117-02-01-006
514±1.0
1400±1.0 667±1.0
4-R61
7
4-R61
Tempered glass
6 Color : Bronze
Tempered glass Thickness : 5 mm
Color : Bronze 645±1.0
Chamfer all fringe
848±1.0 Thickness : 6 mm Corners
185 403±1.0
W117-02-01-008
1296±1.0
W117-02-01-007
W2-1-2
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
CAUTION: Park the machine on a solid

level surface. Lower the bucket to the
ground steady before starting work.
Be sure not to operate the machine or the
front attachment with the counterweight
having been removed. Otherwise the ma-
chine may tip over.
Removal
T142-05-03-007
1. Park the machine on a solid level surface with

the front positioned as illustrated on the right.
2. Remove bolts (2) (8 used) to remove covers (1) T142-05-03-008

(2 used) from the counterweight. Lifting Bracket
: 17 mm
1
2
CAUTION: Counterweight weight:

30700 kg (67690 Ib)
3. Install the shackle to the lifting bracket in the top

of the counterweight. Hold the counterweight by
crane.
4. Remove U-nuts (6) (6 used) and washers (5) (6

used).
: 75 mm
W141-02-02-001
NOTE: If U-nut (6) is removed from bolt (4), it can
fall freely. Catch U-nut (6) by hand or re-
Lifting Bracket
ceive it with a tray.
CAUTION: Bolt (4) weight: 22 kg (50 Ib) 3
5. Pull bolt (4) and washer (3) up from the bottom

by hand. Attach nylon sling on the neck of bolt (4),
lift and remove the bolts from counterweight by 4
crane. (6 places)
5
6 W141-02-02-002
W2-2-1
6. Lift and remove the counterweight from the main
frame by crane.
Counterweight
Main Frame W141-02-02-003
W2-2-2
Installation
CAUTION: Counterweight weight:

30700 kg (67690 Ib)
1. Install shackles and a wire in the lifting bracket on Counterweight

the top of counterweight, then lift the counter-
weight by crane.
2. Place the counterweight onto the main frame

while aligning the bolt hole in the counterweight Main Frame W141-02-02-003
with that in the main frame.
CAUTION: Bolt (4) weight: 22 kg (50 Ib) Lifting Bracket
IMPORTANT: Apply lubricant onto bolt (4).

3. Install washer (3) onto bolt (4). Attach the nylon 3
sling to the neck of bolt (4), lift the bolts by crane
to install the bolts into the bolt holes. (6 places)
4
IMPORTANT: Install washer (5) onto bolt (4) with
the grooved surface facing down-
ward. 5
4. Temporarily tighten washers (5) (6 used) and
U-nuts (6) (6 used) onto bolts (4) (6 used). 6 W141-02-02-002
5. Tighten bolts (4) (6 used). Lifting Bracket

: 75 mm
1
: 5150 N⋅m (525 kgf⋅m, 3800 Ibf⋅ft) 2
6. Install covers (1) (2 used) onto the counterweight

with bolts (2) (8 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W141-02-02-001
W2-2-3
(Blank)
W2-2-4
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
Removal
1. Remove the front attachment and counterweight

from main frame (2). (Refer to the Remove and
Install front attachment section on page W4-1-1, 1
refer to the Remove and Install counterweight
section on page W2-2-1.)
2
IMPORTANT: Tag each hose, piping and electrical

cable to aid re-assembly.
2. Disconnect all hoses, piping and electrical cable
from main frame (2) assembly and engine unit (1)
assembly.
W141-02-03-001
Wrech Size Remarks
： 17 mm Bolt
： 19 mm Bolt
： 19 mm Hose
： 36 mm Hose
： 50 mm Hose
： 60 mm Hose
： 10 mm Socket Bolt
： 17 mm Socket Bolt
NOTE: Cap all end of disconnected hoses and
piping with plugs and caps.
Lifting
Bracket
CAUTION: Engine unit (1) assembly weight:
15000 kg (33070 Ib)
3. Install shackle, wire and chain block to the lifting 1

bracket (4 places) on the top of engine unit (1)
and hold it by crane.
W141-02-03-004
4. Remove bolts (3) (28 used) and washers (4) (28 1

used), lift the engine unit (1) assembly by crane
and remove the fuel tank from main frame (2).
: 46 mm
3
4
2
W141-02-03-002
W2-3-1
5. Place the engine unit (1) assembly on the
wooden blocks.
NOTE: Wooden block dimensions
Length 500 mm (19.7 in), width 700 mm 1
(27.6 in), height 500 mm (19.7 in)
6. Disconnect all hoses and piping from center joint

(5) at track frame side. Remove stopper (6) from
center joint (5). (Refer to the Remove and Install
the Center Joint section on page W3-5-1) Wooden Blocks
W141-02-03-005
5 6
IMPORTANT: Tag piping to aid re-assembly.
7. Disconnect all greasing pipes between main
frame (2) and swing bearing (7).
: 17 mm
NOTE: Cap all ends of disconnected hoses and
piping with plugs.
W141-02-03-003
7
2
W141-02-03-008
W2-3-2
8. Insert counterweight mounting bolt (8) (1 used)

into the front side (1 place) mounting bolt hole in Boom Joint Pin
counterweight. (2 places)
CAUTION: The main frame (2) assembly Counterweight

Mounting Bolt Hole
weight: 41000 kg (90390 Ib)
IMPORTANT: Put soft waste on the place where

wire is attached to prevent main
frame (2) from being damaged.
9. Attach the wire and chain block onto main frame 2 8
(2) where the counterweight is mounted. Then W141-02-03-006
hold the frame by crane.

NOTE: Attach wire to the place where is in the
front of bolt (8).

wire is attached to prevent the boom
joint pin from being damaged.
10. Attach the wire and chain block to the boom joint
pin on main frame (2). Then hold it by crane. (2 2
places)
11. Remove bolts (9) (60 used) and washers (10) (60 7
used) which are used to connect main frame (2)
and swing bearing (7).
: 75 mm
9, 10
12. Lift the main frame (2) assembly and remove it
from swing bearing (7) by crane.
M117-07-028
W2-3-3
13. Place the main frame (2) assembly on the

wooden blocks.
NOTE: Wooden block dimensions
Length 1000 mm (39.4 in), width 500 mm
(19.7 in), height 1400 mm (55.1 in) 2
W141-02-03-007
Wooden Blocks
W2-3-4
Installation
• As for the method to lift following parts and the
position of lifting holes, refer to Removal section.
IMPORTANT: Clean the matching surface thor-

oughly.
1. Install tapper (M48, Pitch 4.0 mm) to all swing
2
bearing (7) mounting bolt holes in main frame (2).
W141-02-03-007
Wooden Blocks
Swing Bearing
(7) Mounting
Bolt Hole
2
Tagger
CAUTION: Main the frame (2) assembly

weight: 41000 kg (90390 Ib) W18B-02-03-033
2. Lift the main frame (2) assembly by crane.
3. Hold main frame (2) to the position 100 mm (3.9

in) above the mounting position for swing bearing 2
(7).
W141-02-03-009
4. Align the spline on pinion gear (11) of swing de-

vice with that on inner gear (12) of swing bearing
(7) with hook wrench and pipe. (4 places) Pipe Hook Wrench
Pinion gear (11) diameter: 450 mm (17.7 in)
11
W18B-02-03-031
12
W2-3-5
5. Lower main frame (2) till the clearance between
main frame (2) and swing bearing (7) is 30 mm
Hole for Dowel Pin (31) 2
(1.1 in).
6. Check the dowel pin (13) holes (2 places) in main

frame (2) and dowel pins (13) (2 used) of swing
bearing (7) visually while aligning them to place 13
main frame (2) on swing bearing (7).
7
W18B-02-03-032
IMPORTANT: Apply grease to the bolts.

7. Install bolts (9) (60 used) and washers (10) (60 2
used) temporarily.
: 75 mm
7
8. Tightening bolts (9) (60 used).
: 75 mm
: 4900 N⋅m (500 kgf⋅m, 3620 Ibf⋅ft)
9, 10
9. Connect all greasing pipes between main frame
(2) and swing bearing (7).
Pipe M117-07-028
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18.0 Ibf⋅ft)
Bolt
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
7
2
W141-02-03-008
5 6
10. Install stopper (6) to center joint (5). Connect all
hoses and piping to center joint (5) at the track
frame side. (Refer to Remove and Install Center
Joint on page W3-5-1.)
W141-02-03-003
W2-3-6
11. Install hand tap (M30, Pitch 3.0 mm) to all bolt
holes of engine unit (1) in the main frame (2). 1
CAUTION: Fuel tank (1) weight: 3

15000 kg (33070 Ib) 4
IMPORTANT: Apply lubricant oil onto bolts.

12. Lift the engine unit (1) assembly by crane, then 2
install it to main frame (2) with bolts (3) (28 used) W141-02-03-002
and washers (4) (28 used).
: 46 mm
: 1950 N⋅m (200 kgf⋅m, 1440 Ibf⋅ft) Lifting Bracket
13. Connect all hoses, piping and electrical cable

between main frame (2) assembly and engine 1
unit (1) assembly.
Torque Remarks
Wrench Size N⋅m kgf⋅m
(Ibf⋅ft)
: 17 mm 50 5.1 (37) Bolt W141-02-03-004
: 19 mm 90 9.2 (66) Bolt

: 19 mm 29.5 3 (21.5) Hose
: 36 mm 175 18 (129) Hose
: 50 mm Hose
: 60 mm Hose
: 10 mm 90 9.2 (67) Socket Bolt
: 17 mm 400 41.0 (300) Socket Bolt
14. Install the counterweight and front attachment to

main frame (2). (Refer to Remove and Install
Counterweight on page W2-2-1, Remove and In-
stall Front Attachment on page W4-1-1) 1
W141-02-03-001
W2-3-7
(Blank)
W2-3-8
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
IMPORTANT: Be sure to bleed air from hydraulic 1
oil tank before starting work. (Refer 2
to “Bleeding Air from Hydraulic Oil
Tank” on page W1-3-1)
Removal
IMPORTANT: Tag hoses and piping to aid in 1 2 3

re-assembly.
1. Remove band (1) (4 used) to remove pipes (2) (4
used) and hoses (3) (2 used).
: 13 mm 2
NOTE: Cap all ends of disconnected hoses and
piping with plugs.
W141-02-04-001
1
CAUTION: Cover (4, 6) weight: 4 5

Each 35 kg (77 Ib) 8
Cover (5, 7) weight: Each 20 kg (44 Ib) 6
7
2. Remove bolts (8) (16 used) to remove covers (4,
5) and covers (6, 7).
: 19 mm
8
M141-01-028
3. Remove bolts (10) (24 used) and split flanges

(11) (12 used) to disconnect delivery hoses (9) (6
used) from the pump side. 9 9
10, 11
10, 11
W141-02-04-003
W2-4-1
4. Disconnect hoses (12) (4 used) at 4-spool pump
to the 4-spool pump side.
15
: 36 mm Mounting Bolt
: 8 mm
5. Disconnect all pilot hoses, drain hoses and elec-

trical cables from main pump (15).
: 17 mm, 19 mm, 27 mm, 36 mm
6. Separate manifolds (14) (3 used) from main

pumps (15) (3 used).
: 17 mm
14
12 13
T117-02-01-001
7. Separate suction pipes (16) (5 used) from main

pumps (15) (3 used) and 4-spool pump (13).
: 19 mm
: 8 mm, 14 mm
16
CAUTION: Main pump (15) weight: Each

300 kg (660 Ib) W141-02-04-002
4-spool pump (13) weight: 96 kg (220 Ib)

Pump Transmission
8. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
the body of main pumps (15) (3 used). Attach a Eyebolt
wire to eyebolts (2 used) and hold the pump by 19, 20
crane.
Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
15
the body of 4-spool pump (13). Attach a wire to
eyebolts (2 used) to hold the pump.
9. Remove bolts (19) (12 used), socket bolts (21) (4

used), spring washers (20) (12 used) and (22) (4 21, 22
used). Lift and remove main pumps (15) (3 used)
and 4-spool pump (13) from the pump transmis-
sion.
: 36 mm
: 17 mm Eyebolt 13
W18B-02-04-037
W2-4-2
Installation
Pump Transmission
CAUTION: Main pump (15) weight: Each
300 kg (660 Ib) Eyebolt
4-spool pump (13) weight: 96 kg (210 Ib) 19, 20
IMPORTANT: Apply THREEBOND #1215 to the

15
mounting surface for each pump on
pump transmission.
1. Hoist main pumps (15) (3 used) and 4-spool
pump (13) to install them to the pump transmis-
sion with bolts (19) (12 used), socket bolts (21) (4 21, 22
used), spring washers (20) (12 used) and (22) (4
used).
: 36 mm
: 690 N⋅m (70.0 kgf⋅m, 510 Ibf⋅ft)
: 17 mm Eyebolt 13
: 390 N⋅m (40.0 kgf⋅m, 290 Ibf⋅ft) W18B-02-04-037
2. Install suction pipes (16) (5 used) to 4-spool

pump (13) and main pumps (15) (3 used) with
bolts (18) (8 used) and socket bolts (17) (30
used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
: 8 mm 17
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 18
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
16
W141-02-04-002
15
3. Connect hoses (12) (4 used) to 4-spool pump Mounting Bolt
(13).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
4. Install manifolds (14) (3 used) onto main pump

(15).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
14
12 13
T117-02-01-001
W2-4-3
5. Connect all pilot hoses and electrical cables to
main pumps (15) (3 used).
: 17 mm Mounting Bolt
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 19 mm
: 30 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
15
T117-02-01-001
6. Install bolts (10) (24 used) onto split flanges (11)

9 9
(12 used) to connect delivery hoses (9) (6 used)
to main pump (15).
: 19 mm
: 30 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
10, 11
10, 11
W141-02-04-003
4 5 8
CAUTION: Cover (4, 6) weight: 6
Each 35 kg (77 Ib)
7
Cover (5, 7) weight: Each 20 kg (44 Ib)
7. Install covers (4, 5) and covers (6, 7) with bolts

(8) (16 used). 8
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
M141-01-028
W2-4-4
8. Install pipes (2) (4 used) and hoses (3) (2 used)
with bands (1) (4 used). 1
: 13 mm 2
: 20 N⋅m (2.0 kgf⋅m, 15 Ibf⋅ft)
1 2 3
W141-02-04-001
1
W2-4-5
DISASSEMBLE MAIN PUMP
・ The components of front housing (28) are same
as that of rear housing (62). 17 18
16
19
20
15 21
14 22
13
12
11 23
10
24
25
9
8 27
26
7 28
6 29
5 30 49
4 46 47 48
3 31
45
2
1
32
33 30
44
43
42
41
40
39 50
38
12
51
37
35 36
56
34 54 55
11 10
16
19
52
46
30
45 57
53 58
48 44 3
49 59
60
61
63 62
23
52 51
12
64
65
12
66
67
68 W18B-02-04-038
W2-4-6
1- Socket Bolt (4 Used) 18 - Socket Bolt (4 Used) 35 - Bushing (2 Used) 52 - O-Ring (15 Used)
2- Front Cover 19 - Stopper L (2 Used) 36 - Shoe Plate (2 Used) 53 - Rear Valve Plate
3- O-Ring (3 Used) 20 - Backup Ring (2 Used) 37 - Plunger (18 Used) 54 - Rear Regulator
4- Retaining Ring (2 Used) 21 - O-Ring (2 Used) 38 - Retainer (2 Used) 55 - Socket Bolt (4 Used)
5- Spacer (2 Used) 22 - Servo Piston (2 Used) 39 - Spherical Bushing (2 Used) 56 - Socket Bolt (4 Used)
6- Bearing (2 Used) 23 - Stopper Screw (8 Used) 40 - Spacer (2 Used) 57 - Rear Cover
7- Spacer (2 Used) 24 - O-Ring (2 Used) 41 - Spring (18 Used) 58 - Oil Seal
8- Front Shaft 25 - Plug (2 Used) 42 - Cylinder Block (2 Used) 59 - Socket Bolt (2 Used)
9- Socket Bolt (2 Used) 26 - Plug (4 Used) 43 - Front Valve Plate 60 - Rear Shaft
10 - Lock Nut (2 Used) 27 - Orifice (4 Used) 44 - Needle Bearing (2 Used) 61 - Rear Cover
11 - Adjusting Screw (2 Used) 28 - Front Housing 45 - O-Ring (2 Used) 62 - Rear Housing
12 - Spring Pin (5 Used) 29 - O-Ring (4 Used) 46 - Plug (2 Used) 63 - Socket Bolt (4 Used)
13 - Stopper S (2 Used) 30 - O-Ring (4 Used) 47 - Eyebolt (2 Used) 64 - Valve Cover R
14 - Backup Ring (2 Used) 31 - Front Cover 48 - Adjusting Screw (2 Used) 65 - O-Ring
15 - O-Ring (2 Used) 32 - Washer (8 Used) 49 - Lock Nut (2 Used) 66 - O-Ring
16 - Displacement Angle Shift 33 - Socket Bolt (4 Used) 50 - Valve Cover F 67 - Booster
Pin (2 Used)
17 - Front Regulator 34 - Swash Plate (2 Used) 51 - Pin (2 Used) 68 - Coupling
W2-4-7
17 18
11 23
10
25
28
29
30 48 49
31
33 30
43
50
54 55
11 10
30
53
48
49 59
60
61
63 62
23
52
64
65
66
67
68 W18B-02-04-038
W2-4-8
Disassemble Main Pump
IMPORTANT: Do not attempt to remove lock nuts 6. Remove socket bolts (9) (2 used), (33) (4 used),
(10) (2 used), (49) (2 used), adjusting (59) (2 used) and (63) (4 used) from front hous-
screws (11) (2 used) and (48) (2 ing (28) and rear housing (62).
used). The set flow rate may : 8 mm, 17 mm
change.
1. Remove plugs (25) (2 used) from front housing IMPORTANT: Take care that front valve plate (43)
(28) and rear housing (62) to drain out hydraulic may come off.
oil from the pump. 7. Separate front housing (28) from valve cover F
: 32 mm (50).
2. Remove socket bolts (18) (4 used) to remove 8. Remove O-rings (29) (2 used) and (30) from
front regulator (17) from front housing (28). At valve cover F (50).
this time, make sure that O-ring on front regulator
(17) side does not come off.
: 6 mm 9. Separate valve cover F (50) from valve cover R
(64).
3. Remove socket bolts (55) (4 used) to remove
rear regulator (54) from rear housing (62). At this 10. Remove O-rings (52) (3 used), (65) and (66) from
time, make sure that O-ring on rear regulator (54) valve cover R (64).
side does not come off.
: 6 mm 11. Remove coupling (68) and booster (67) from rear
shaft (60).
4. Remove stopper screws (23) (8 used) from front
housing (28) and rear housing (62). IMPORTANT: Take care that rear valve plate (53)
may come off.
12. Separate rear housing (62) from valve cover R
CAUTION: Main pump weight: (64).
290 kg (640 Ib)
5. Turn the main pump over with the regulator

mounting surface facing downward. At this time,
take care not to damage the mounting surface of
the regulator.
NOTE: Install shackle onto the flange holes in rear
cover (61) and front cover (31), then turn
them over.
W2-4-9
16
19
22
13
12
8
7 28
6 29
5 30
4
3 31
2
1
44
43
42
41
40
39 50
38
12
37
36
34
53
44
12
64
12
W18B-02-04-038
W2-4-10
IMPORTANT: Front valve plate (43) and rear valve 18. Tap front housing (28) with a plastic hammer
plate (53) look similar. Do not con- lightly to remove front cover (31) from front hous-
fuse them when handling them. ing (28). Then remove O-rings (30) and (29) (2
13. Remove front valve plate (43) and rear valve used).
plate (53) from valve cover F (50) and valve
cover R (64). 19. Remove swash plate (34) and shoe plate (36)
from front housing (28).
14. Remove spring pins (12) (4 used) from front
cover (31), valve cover F (50) and valve cover R 20. Tap on the flange at front housing (28) side of
(64). front shaft (8) with a plastic hammer to remove
the shaft from front cover (31). At this time, shaft
IMPORTANT: Do not remove needle bearings (44) (8) is still with bearing (6) on.
(2 used) unless necessary.
15. Remove needle bearings (44) (2 used) from 21. Remove retaining ring (4) from front shaft (8) to
valve cover F (50) and valve cover R (64). remove spacer (5), bearing (6) and spacer (7).
16. Pull out cylinder block (42) from housing (28). At 22. Pull out stopper S (13) and stopper L (19) from
this time, springs (41) (9 used), spacer (40), front housing (28).
spherical bushing (39), retainer (38) and plungers
(37) (9 used) can be removed together with cyl- NOTE: Screw bolts (M6, Pitch 1.0 mm) into the
inder block (42). center holes of stopper.
17. Remove socket bolts (1) (4 used) to remove front IMPORTANT: As LOCTITE has been applied on
cover (2) and O-ring (3) from front cover (31). the contacting part between servo
: 6 mm piston (22) and displacement angle
shift pin (16). Do not disassemble
NOTE: There are pull-out holes in front cover (2). them unless necessary.
Remove the front cover with bolts (M8, 23. Heat displacement angle shift pin (16) with a drier.
Pitch 1.25 mm). Secure servo piston (22) with a pair of pliers or
some tools like while preventing it from being
damaged. Remove displacement angle shift pin
(16) while rotating it. Press servo piston (22) out
from front housing (28).
W2-4-11
19
20
15 21
14
13
12
27
26
7 28
6
5 30
4
42
41
40
39
38
37
36
56
34
57
58
44 3
60
61
62
W18B-02-04-038
W2-4-12
24. Remove O-rings (15, 21), backup rings (14, 20) 30. Remove O-ring (30) and spring pin (12) from rear
from stopper S (13) and stopper L (19). cover (61).
25. Remove plugs (26) (4 used) and orifices (27) (4 31. Remove swash plate (34) and shoe plate (36)
used) from front housing (28) and rear housing from rear housing (62).
(62).
: 4 mm, 5 mm 32. Tap the flange at rear housing (62) side on rear
shaft (60) with a plastic hammer to remove rear
26. Remove socket bolts (56) (4 used) to remove shaft (60) from rear cover (61). At this time, rear
rear cover (57) and O-ring (3) from rear cover shaft (60) is still with bearing (6) on.
(61).
: 6 mm 33. Remove retaining ring (4) from rear shaft (60) to
NOTE: There are pull-out holes in rear cover (57). remove spacer (5), bearing (6) and spacer (7).
Remove the rear cover with bolts (M8,
Pitch 1.25 mm). 34. Pull out stopper S (13) and stopper L (19) from
rear housing (62).
27. Remove oil seal (58) from rear cover (57). NOTE: Screw bolt (M6, Pitch 1.0 mm) into the
center hole of stopper S (13) and stopper L
IMPORTANT: Wind vinyl tape to the rotating sur- (19) and pull it out.
face of needle bearing (44) on rear
shaft (60) to protect it from being 35. Remove O-rings (15, 21), backup rings (14, 20)
damaged. from stopper S (13) and stopper L (19).
28. Remove cylinder block (42) from rear housing
(62). At this time, cylinder block (42) is still with
springs (41) (9 used), spacer (40), spherical
bushing (39), retainer (38) and plungers (37) (9
used) attached.
29. Separate rear housing (62) from rear cover (61).

NOTE: Tap the flange of rear cover (61) with a
plastic hammer lightly to remove rear
cover (61) from rear housing (62) side. At
this time, rear cover (61) is still with rear
shaft (60) attached.
W2-4-13
16
22
16
62
W18B-02-04-038
W2-4-14
IMPORTANT: As LOCTITE has been applied on
the contacting part between servo
piston (22) and displacement angle
shift pin (16). Do not disassemble
them unless necessary.
36. Heat displacement angle shift pin (16) with a drier.

Secure servo piston (22) with a pair of pliers to
prevent servo piston (22) from being damaged.
Remove displacement angle shift pin (16) while
rotating it. Press servo piston (22) out from rear
housing (62).
W2-4-15
ASSEMBLE MAIN PUMP
Front Pump Rear Pump
31 39 34 36 38 35 28 30 50 49 66 30 52 20, 21 19 22 16 13 14, 15 61 10
48 11
10
11 12
12
1 56
3
57
60
A A 58
3
2 63
33
A A
32 30 37 40 41 42 43 12 51 44 68 12 64 67 51 53 62 4 5 30 6 32 7
W18B-02-04-039
Section A-A
W18B-02-04-040
27
26
W2-4-16
1- Socket Bolt (4 Used) 18 - *Socket Bolt (4 Used) 35 - Bushing (2 Used) 52 - O-Ring (15 Used)
2- Front Cover 19 - Stopper L (2 Used) 36 - Shoe Plate (2 Used) 53 - Rear Valve Plate
3- O-Ring (2 Used) 20 - Backup Ring (2 Used) 37 - Plunger (18 Used) 54 - *Rear Regulator
4- Retaining Ring (2 Used) 21 - O-Ring (2 Used) 38 - Retainer (2 Used) 55 - *Socket Bolt (4 Used)
5- Spacer (2 Used) 22 - Servo Piston (2 Used) 39 - Spherical Bushing (2 Used) 56 - Socket Bolt (4 Used)
6- Bearing (2 Used) 23 - *Stopper Screw (8 Used) 40 - Spacer (2 Used) 57 - Rear Cover
7- Spacer (2 Used) 24 - *O-Ring (2 Used) 41 - Spring (18 Used) 58 - Oil Seal
8- Front Shaft 25 - *Plug (2 Used) 42 - Cylinder Block (2 Used) 59 - *Socket Bolt (2 Used)
9- *Socket Bolt (2 Used) 26 - *Plug (4 Used) 43 - Front Valve Plate 60 - Rear Shaft
10 - Lock Nut (2 Used) 27 - *Orifice (4 Used) 44 - Needle Bearing (2 Used) 61 - Rear Cover
11 - Adjusting Screw (2 Used) 28 - Front Housing 45 - *O-Ring (2 Used) 62 - Rear Housing
12 - Spring Pin (5 Used) 29 - *O-Ring (4 Used) 46 - *Plug (2 Used) 63 - Socket Bolt (4 Used)
13 - Stopper S (2 Used) 30 - O-Ring (4 Used) 47 - *Eyebolt (2 Used) 64 - Valve Cover R
14 - Backup Ring (2 Used) 31 - Front Cover 48 - Adjusting Screw (2 Used) 65 - *O-Ring
15 - O-Ring (2 Used) 32 - Washer (8 Used) 49 - Lock Nut (2 Used) 66 - O-Ring
16 - Displacement Angle Shift 33 - Socket Bolt (4 Used) 50 - Valve Cover F 67 - Booster
Pin (2 Used)
17 - Front *Regulator 34 - Swash Plate (2 Used) 51 - Pin (2 Used) 68 - Coupling
NOTE: As for parts with * mark, refer to W2-4-6.
W2-4-17
31 14 13 34 36 16 28 22 19 20, 21 52 20, 21 19 22 16 34 36 13 14, 15 61
12
12
60
A A
A A
30 64 62 4 5 30 6 7
W18B-02-04-039
Section A-A
W18B-02-04-040
27
26
W2-4-18
Assemble Main Pump
IMPORTANT: Apply LOCTITE #1305N to the screw IMPORTANT: Apply grease on the matching sur-
part of servo piston (22). faces between swash plate (34) and
1. Install displacement angle shift pins (16) (2 used) shoe plate (36). After installing
and servo pistons (22) (2 used) onto front hous- swash plate (34), check whether it
ing (28) and rear housing (62). can move smoothly by hand.
7. Place front housing (28) and rear housing (62)
2. Install O-rings (15) (2 used), (21) (2 used), with the mounting surface of regulator facing
backup rings (14) (2 used), (20) (2 used) onto downward. Install swash plates (34) (2 used) with
stopper S (13) (2 used) and stopper L (19) (2 shoe plates (36) (2 used) onto displacement an-
used). gle shift pins (16) (2 used).
NOTE: Install shoe plate (36) with the chamfer
side facing swash plate (34).
3. Install the stopper S (13) assembly and the stop-
per L (19) assembly into front housing (28) and
rear housing (62). 8. Install spring pins (12) (2 used) and O-rings (30)
(2 used) onto front cover (31) and rear cover (61).
Install O-rings (29) (2 used) onto front housing
4. Install spacers (7) (2 used), bearings (6) (2 used),
(28).
spacers (5) (2 used), retaining rings (4) (2 used)
onto front shaft (8) and rear shaft (60) in this or-
der. 9. Install O-rings (52) (6 used) between front hous-
ing (28), valve cover R (64) and rear housing (62)
respectively.
5. Install orifices (27) (4 used) and plugs (26) (4
used) onto front housing (28) and rear housing
(62). 10. Align the front cover (31) assembly with front
: 4 mm housing (28), and rear cover (61) assembly with
: 9 N⋅m (0.9 kgf⋅m, 6.5 Ibf⋅ft) rear housing (62), then install them with socket
: 5 mm bolts (9) (2 used) and (59) (2 used) respectively.
: 10 N⋅m (0.9 kgf⋅m, 6.5 Ibf⋅ft) : 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 Ibf⋅ft)
6. Install the front shaft (8) assembly and the rear
shaft (60) assembly onto front cover (31) and
rear cover (61).
W2-4-19
39 38 28 30 52 50 66 52
60
A A
33
A A
32 37 40 41 42 43 12 44 68 12 64 67 53 62
W18B-02-04-039
Section A-A
W18B-02-04-040
W2-4-20
11. Install springs (41) (18 used), spacers (40) (2 17. Install valve cover F (50) to the front housing (28)
used), spherical bushings (39) (2 used), retainers assembly with socket bolts (33) (4 used) and
(38) (2 used), plungers (37) (18 used) onto cyl- washers (32) (4 used).
inder blocks (42) (2 used) in this order. : 17 mm
: 490 N⋅m (50 kgf⋅m, 360 Ibf⋅ft)
12. Install the plunger (37) assemblies (2 used) onto
front housing (28) and rear housing (62). 18. Install stopper screws (23) (4 used) into the front
NOTE: It is easier to do the assembly work if housing (28) assembly.
aligning front shaft (8) and rear shaft (60) : 4 mm
respectively with the spline slots in cylinder : 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
block (42) and spherical bushing (39) be-
fore assembling. 19. Install O-rings (52) (3 used) between valve cover
F (50) and valve cover R (64).
13. Install needle bearings (44) (2 used) into valve
cover F (50) and valve cover R (64). 20. Install plug (25), O-ring (24), plug (46) and O-ring
(45) to the front housing (28) assembly.
14. Install spring pin (12), O-rings (30) and (52) (6 : 19 mm
used) into valve cover F (50). : 36 N⋅m (3.7 kgf⋅m, 27.0 Ibf⋅ft)
: 32 mm
: 167 N⋅m (17 kgf⋅m, 123 Ibf⋅ft)
15. Install spring pins (12) (2 used), O-rings (52) (3
used) and (66) to valve cover R (64).
21. Install valve cover R (64) onto the rear housing
(62) assembly.
IMPORTANT: Apply grease to the mounting sur-
face before installing valve plates
(43) and (53). Install the valve plates 22. Install coupling (68) and booster (67) onto rear
with the spherical side facing cylin- shaft (60).
der block (42) side.
16. Install valve plates (43) and (53) onto valve cover
F (50) and valve cover R (64).
W2-4-21
31 28 61
1 56
3
57
A A 58
3
2 63
A A
62 32
W18B-02-04-039
Section A-A
W18B-02-04-040
W2-4-22
23. Install the rear housing (62) assembly to the front 28. Install rear cover (57) onto rear cover (61) with
housing (28) assembly with socket bolts (63) (4 socket bolts (56) (4 used).
used) and washers (32) (4 used). : 6 mm
: 17 mm : 30 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 490 N⋅m (50 kgf⋅m, 360 Ibf⋅ft)
24. Install stopper screws (23) (4 used) into the rear CAUTION: Main pump weight:
housing (62) assembly. 290 kg (640 Ib)
: 4 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft) 29. Hoist the pump assembly and place it with the
mounting surface of regulator facing upward.
25. Install plug (25), O-ring (24), plug (46) and O-ring
NOTE: Install a shackle to the holes in the flanges
(45) onto the rear housing (62) assembly.
of front cover (31) and rear cover (61),
: 19 mm
then hoist the body.
: 36 N⋅m (3.7 kgf⋅m, 27.0 Ibf⋅ft)
: 32 mm
: 167 N⋅m (17 kgf⋅m, 123 Ibf⋅ft) 30. Install front regulator (17) and rear regulator (54)
with socket bolts (18) (4 used) and (55) (4 used).
: 6 mm
26. Install O-ring (3) onto front cover (2), then install
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
them onto front cover (31) with socket bolts (1) (4
used).
: 6 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
27. Install oil seal (58) and O-ring (3) onto rear cover
(57).
W2-4-23
MAINTENANCE STANDARD
1. Clearance between plunger (37) diameter (d) and

cylinder block (42) bore (D)
Unit: mm (in)
d D
Standard Allowable
Limit
D-d 0.047 (0.002) 0.094 (0.004)
W117-02-02-009
2. Spring (41) free length (L)

Unit: mm (in)
Standard Allowable
Limit
L 49.5 (1.95) 48.0 (1.89)
L
W117-02-02-010
3. Clearance between plunger (37) and shoe (e)

and shoe thickness (t)
Unit: mm (in)
Standard Allowable
Limit
e
e 0 to 0.1 0.35 t
(0 to 0.004) (0.01)
t 6.5 (0.26) 6.3 (0.25) W117-02-02-011
4. Distance between retainer (38) bottom and

Stand
spherical bushing (39) top
Unit: mm (in)
H
Standard Allowable h
Limit
W117-02-02-012
H-h 33.0 (1.3) 32.0 (1.3)
W2-4-24
(Blank)
W2-4-25
DISASSEMBLE REGULATOR FOR MAIN PUMP
13
12
11
10
9
8
7
6 14
5 16
4 17
3 18
19
2
20
1 15
22
21 23
27
24
28 25
29 26
30
33 32 31 52
53
51
50
34 49
35 48
36 47
37 41 42
43 45 46
38 54
39
40 55
44
76
77
58
72
57
56
73
63
74 71 62
70
69 64 61
60
75 65 59
66
67
68 W18B-02-04-051
W2-4-26
1- Pin 21 - Pin 40 - Cover 59 - Lock Ring

2- Sleeve 22 - O-Ring 41 - O-Ring 60 - O-Ring
3- O-Ring 23 - Stopper 42 - O-Ring (3 Used) 61 - Supporting Plug
4- O-Ring 24 - Spring 43 - Socket Bolt (2 Used) 62 - Pin
5- Sleeve 25 - Spring Seat 44 - Casing 63 - Pin (2 Used)
6- Compensating Piston 26 - Pilot Piston 45 - Socket Bolt (2 Used) 64 - O-Ring
7- Compensating Rod 27 - Spool 46 - O-Ring (2 Used) 65 - Stopper
8- Spring Seat 28 - Sleeve 47 - Adjusting Screw 66 - Ball
9- Spring 29 - Retaining Ring 48 - Adjusting Screw 67 - Seat
10 - Spring 30 - Spring 49 - Lock Nut 68 - O-Ring
11 - Piston 31 - Spring 50 - O-Ring 69 - O-Ring
12 - Stopper 32 - Spring Seat 51 - Cover 70 - O-Ring
13 - O-Ring 33 - Retaining Ring 52 - Socket Bolt (4 Used) 71 - O-Ring
14 - Pin 34 - Socket Bolt (4 Used) 53 - Lock Nut 72 - O-Ring
15 - Pin 35 - Cover 54 - Lock Nut 73 - Cover
16 - Lever 36 - O-Ring (3 Used) 55 - Adjusting Screw 74 - Socket Bolt (2 Used)
17 - Feedback Lever 37 - Seat 56 - Lock Ring 75 - Socket Bolt (2 Used)
18 - Pin 38 - Ball 57 - O-Ring 76 - O-Ring
19 - Pin 39 - Stopper 58 - Supporting 77 - Plug
20 - Lever
W2-4-27
13
12
11
10
9
8
30
52
53
51
50
34 49
35 48
36 47
37 41 42
43 45
38 54
39
40 55
44
76
77
72
73
63
74 71
70
69 64
75 65
66
67
68 W18B-02-04-051
W2-4-28
Disassemble Regulator for Main Pump
1. Remove socket bolts (43) (2 used) and (45) (2 7. Pull out piston (11) and stopper (12) from the
used) to remove the regulator from the main cover (51) assembly.
pump. Remove pins (63) (2 used), O-rings (64,
68) from casing (44). 8. Remove O-ring (13) from stopper (12).
: 6 mm
9. Remove socket bolts (74) (2 used) and (75) (2

2. Remove socket bolts (34) (4 used) to remove used) to remove cover (73) from casing (44).
covers (35, 40), O-rings (36) (3 used), (41) and : 5 mm
(42) (3 used) from casing (44).
: 5 mm
10. Remove O-rings (69, 70, 71, 72) and spring (30)
from casing (44).
3. Remove plug (77) and O-ring (76) from cover
(35).
IMPORTANT: Seat (67) may fly out from casing
(44). A pair of pliers should be used
IMPORTANT: Seat (37) may fly out from cover (40). to remove the regulator while taking
A pair of pliers should be used to care not to damage it. If there are
remove it while taking care not to something dirt inside, clean it with
damage it. Do not remove stopper the air compressor.
(39) unless necessary. If there are Do not remove stopper (65) unless
something dirt inside, clean it with necessary.
the air compressor. 11. Pull out seal (67) and ball (66) from casing (44).
4. Remove seat (37) and ball (38) from cover (40).
IMPORTANT: Do not disassemble lock nuts (49,

53, 54), adjusting screws (48, 47, 55).
The flow rate setting of the pump
will change if disassembling them.
cover (51) and O-ring (50) from casing (44).
: 5 mm
IMPORTANT: When removing cover (51), take care

that springs (9, 10) inside may fly
out.
6. Remove springs (9, 10), and spring seat (8) from
casing (44).
W2-4-29
7
6 14
5 16
4 17
3 18
2
20
1 15
22
21 23
27
24
28 25
29 26
33 32 31
51
44
58
57
56
62
61
60
59
W18B-02-04-051
W2-4-30
12. Remove retaining ring (33) from spool (27) to 22. Pull out compensating rod (7), compensating pis-
remove spring seat (32), spring (31) and sleeve ton (6) and sleeve (5) from casing (44).
(28). NOTE: Tap compensating rod (7) lightly while
pushing it out from cover (51) side with a
13. Remove retaining ring (29) from sleeve (28). round bar (Dia. 4 mm (0.2 in)).
14. Remove pin (1), sleeve (2) and O-ring (3) from 23. Remove compensating piston (6) and O-ring (4)
casing (44). from sleeve (5).
15. Remove lock rings (56, 59) from casing (44). 24. Pull out pilot piston (26) and spool (27) from cas-
ing (44).
IMPORTANT: Supporting plugs (58) and (61) look
quite similar. Make matching marks 25. Pull out spring seat (25), spring (24), stopper (23)
on them to prevent them from being and O-ring (22) from casing (44).
installed to the wrong position. NOTE: Insert a round bar (Dia. 4 mm (0.2 in)) into
16. Screw the bolts (M6, Pitch 1.0 mm) into the cen- pilot piston (26) side to push out the pilot
ter screw holes in supporting plugs (58, 61), then piston.
pull them out from casing (44). At this time, sup-
porting plug (61) is still with pin (62) attached.
26. Remove O-ring (22) from stopper (23).
17. Remove pin (62) from supporting plug (61).
18. Remove O-rings (57, 60) from supporting plugs

(58, 61).
IMPORTANT: Do not remove pin (21) from lever

(20).
19. Remove lever (20) from casing (44) with a pair of
pincers.
20. Remove pin (18) from feedback lever (17) with a

round bar (4 mm (0.2 in)).
Remove feedback lever (17) from spool (27).
IMPORTANT: Do not remove pins (14, 15) from

lever (16).
21. Remove lever (16) from compensating rod (7).
W2-4-31
ASSEMBLE REGULATOR FOR MAIN
PUMP
42 39 38 37 36
52 A
65
34
66
67
W18B-02-04-042
B C 40 35
68
73 26 44 62 19 20 25 24 23 22
Section A-B
54
74
70 55
75
51
63
21
43 45
W117-02-02-006
72 30 31 29 28 27 14 16 8 46
D
9 50
Section A-C 53
10 11 49
33
48
32
3
4 5 6 7 15 12 13 47
18
17
D W117-02-02-007
56 61 57
Section D-D
58
59
60
64 15 21 62 W18B-02-04-043
W2-4-32
1- Pin 21 - Pin 40 - Cover 59 - Lock Ring

2- Sleeve 22 - O-Ring 41 - *O-Ring 60 - O-Ring
3- O-Ring 23 - Stopper 42 - O-Ring (3 Used) 61 - Supporting Plug
4- O-Ring 24 - Spring 43 - Socket Bolt (2 Used) 62 - Pin
5- Sleeve 25 - Spring Seat 44 - Casing 63 - Pin (2 Used)
6- Compensating Piston 26 - Pilot Piston 45 - Socket Bolt (2 Used) 64 - O-Ring
7- Compensating Rod 27 - Spool 46 - O-Ring (2 Used) 65 - Stopper
8- Spring Seat 28 - Sleeve 47 - Adjusting Screw 66 - Ball
9- Spring 29 - Retaining Ring 48 - Adjusting Screw 67 - Seat
10 - Spring 30 - Spring 49 - Lock Nut 68 - O-Ring
11 - Piston 31 - Spring 50 - O-Ring 69 - *O-Ring
12 - Stopper 32 - Spring Seat 51 - Cover 70 - O-Ring
13 - O-Ring 33 - Retaining Ring 52 - Socket Bolt (4 Used) 71 - *O-Ring
14 - Pin 34 - Socket Bolt (4 Used) 53 - Lock Nut 72 - O-Ring
15 - Pin 35 - Cover 54 - Lock Nut 73 - Cover
16 - Lever 36 - O-Ring (3 Used) 55 - Adjusting Screw 74 - Socket Bolt (2 Used)
17 - Feedback Lever 37 - Seat 56 - Lock Ring 75 - Socket Bolt (2 Used)
18 - Pin 38 - Ball 57 - O-Ring 76 - *O-Ring
19 - Pin 39 - Stopper 58 - Supporting 77 - *Plug
20 - Lever
NOTE: As for the parts with * mark, refer to W2-4-26.
W2-4-33
W18B-02-04-042
B C
26 44 20
Section A-B
21
W117-02-02-006
30 31 29 28 27 16
D
Section A-C
33
32
3
4 5 6 7 15
18
17
D W117-02-02-007
56 61 57
Section D-D
58
59
60
62 W18B-02-04-043
W2-4-34
Assemble Regulator for Main Pump
7. Align pin (21) of lever (20) with the pin groove in
IMPORTANT: Be sure that the direction to install pilot piston (26) to install lever (20).
compensating rod (7) is as illus-
trated. IMPORTANT: Supporting plugs (56) and (61) are
quite similar. Be sure to align the
1. Install compensating rod (7) into casing (44). matching marks made when disas-
sembling to prevent them from be-
2. Align pin (15) of lever (16) with the groove in ing installed to wrong position.
compensating rod (7) to install lever (16). 8. Install O-rings (57, 60) onto supporting plugs (56,
61).
3. Install retaining ring (29) onto sleeve (28).
9. Install pin (62) into supporting plug (61). Insert
IMPORTANT: Check spool (27) that it should supporting plug (61) into casing (44) to align pin
move smoothly before installing it. (62) with the pin hole in lever (20). Install lock
4. Insert sleeve (28) and spool (27) into casing (44). ring (59) onto supporting plug (61).
IMPORTANT: Take care not to install feedback 10. Install supporting plug (56) into casing (44), then
lever (17) in wrong direction. install lock ring (58).
5. Align the pin (18) hole in feedback lever (17) with
the pin hole in spool (27). 11. Install spring (31) and spring seat (32) into spool
Install feedback lever (17) into spool (27) with pin (27), then install retaining ring (33).
(18).
12. Install spring (30) to spool (27).
IMPORTANT: Be sure that the direction to install

Compensating Rod (7) Side Lever (16) Side compensating piston (6) is as illus-
trated.
13. Install O-ring (4) and compensating piston (6)
onto sleeve (5).
17
14. Install sleeve (5), O-ring (3), sleeve (2) and pin
W18B-02-04-018 (1) into casing (44).
IMPORTANT: Check piston (26) that it should

move smoothly before installing it.
6. Insert pilot piston (26) into casing (44).
W2-4-35
42 38 37 36
52 A
34
66
67
W18B-02-04-042
B C 40 35
68
73 44 25 24 23 22
Section A-B
74
70
75
51
63
43 45
W117-02-02-006
72 8
D
9 50
Section A-C
10 11
12 13
D W117-02-02-007
Section D-D
64 W18B-02-04-043
W2-4-36
15. Install O-rings (69, 71, 70, 72) onto casing (44). 23. Install ball (66) and seat (67) into casing (44).
Install cover (73) onto casing (44) with socket
bolts (74) (2 used) and (75) (2 used). 24. Install pins (63) (2 used), O-rings (64, 68) to the
: 5 mm regulator.
: 11.5 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
25. Install the regulator onto the pump body with
16. Install ball (38), seat (37), O-rings (41) and (42) socket bolts (43) (2 used) and (45) (2 used).
(3 used) onto cover (40). : 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
17. Install plug (77), O-ring (76) and O-rings (36) (3
used) onto cover (35). Then install the cover onto
casing (44) with socket bolts (34) (4 used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
18. Install O-ring (22) onto stopper (23).
19. Install spring seat (25), spring (24) and stopper

(23) into casing (44).
20. Install O-ring (13) and piston (11) into stopper

(12).
21. Install spring seat (8), spring (9, 10) into casing
(44).
22. Install stopper (12) and O-ring (50) onto the

cover (51) assembly, then install the cover (51)
assembly onto casing (44) with socket bolts (52)
(4 used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
W2-4-37
(Blank)
W2-4-38
COMPONENTS OF 4-SPOOL PUMP
A B C D
T117-02-01-017
Left Side Engine

A- Oil cooler fan drive pump (Plunger pump) C- Air compressor drive pump (Tandem gear pump end)
B- Pilot pump (Tandem gear pump mission side) D- Pump mission oil lubrication pump (Gear pump)
Right Side Engine

A- Oil cooler fan drive pump (Plunger pump) C- Auxiliary
B- Pilot pump (Tandem gear pump mission side) D- Pump mission oil lubrication pump (Gear pump)
W2-4-39
DISASSEMBLE OIL COOLER FAN DRIVE PUMP 17
18
16 20 21 22
19
15 23
14
13
12
11
10 24 25
26
27
9 28
8
7
6
5 29
30
4 31
3 32 51
2
1 50
49
48
47
44 46
45
43
42
52
53
54
40 41
55
39
37 38 62
35
34 36 64 63 59 58
56
66 65 61 57
60
33
W18B-02-04-027
1- Socket Bolt (4 Used) 18 - Socket Bolt (4 Used) 35 - Shoe Plate 51 - Socket Bolt (4 Used)
2- Cover 19 - Servo Piston 36 - Plunger (9 Used) 52 - Plug
3- O-Ring 20 - O-Ring 37 - Retainer 53 - O-Ring
4- Oil Seal 21 - Backup Ring 38 - Spherical Bushing 54 - Casing
5- Shaft 22 - Stopper 39 - Spacer 55 - Socket Bolt (3 Used)
6- Spacer 23 - O-Ring 40 - Spring (9 Used) 56 - O-Ring (4 Used)
7- Bearing 24 - O-Ring 41 - Cylinder 57 - Seat
8- Spacer 25 - Plug 42 - Stopper 58 - Steel Ball
9- Retaining Ring 26 - Lock Nut 43 - Steel Ball 59 - Stopper
10 - Lock Nut 27 - Eyebolt 44 - Seat 60 - Plug
11 - Adjusting Screw 28 - Housing 45 - Valve Cover 61 - O-Ring
12 - Spring Pin 29 - O-Ring (2 Used) 46 - Adjusting Screw 62 - Spring Pin
13 - Stopper 30 - O-Ring 47 - Lock Nut 63 - Pin
14 - Backup Ring 31 - Cover 48 - Coupling 64 - O-Ring
15 - O-Ring 32 - Socket Bolt (4 Used) 49 - O-Ring 65 - Needle Bearing
16 - Displacement Angle Shift Pin 33 - Swash Plate 50 - Plate 66 - Valve Plate
17 - Regulator 34 - Bushing
W2-4-40
Disassemble Oil Cooler Fan Drive Pump
IMPORTANT: Do not attempt to remove adjusting 6. Remove socket bolts (55) (3 used) to remove
screw (11), lock nut (10), adjusting casing (54) and O-rings (56) (4 used) from valve
screw (46) and lock nut (47). The set cover (45).
flow rate may change. : 5 mm
1. Remove plug (60) to drain hydraulic oil from the
pump. 7. Remove plug (52) and O-ring (53) from casing
: 19 mm (54).
: 19 mm
regulator (17). IMPORTANT: Do not remove seats (44, 57).
: 6 mm Fill air through valve cover (45) with
seats (44, 57) attached from stop-
pers (42, 59) side. If the air can not
CAUTION: Pump weight: 68 kg (150 lb) flow freely, there may be dirt on
seats (44, 57). A compressor should
IMPORTANT: Take care not to dent or scratch on be used to clean the parts.
the matching surface of regulator on 8. Remove stoppers (42, 59), steel balls (43, 58)
housing (28). from valve cover (45).
3. Place housing (28) with the mounting side for
regulator facing downward. Remove socket bolts
(51) (4 used) to remove plate (50), O-ring (49) IMPORTANT: Wind vinyl tape to the rotating sur-
and coupling (48) from valve cover (45). face of needle bearing (65) on shaft
: 10 mm (5) to protect the surface.
9. Pull out cylinder block (41) from the housing (28).
At this time, springs (40) (9 used), spacer (39),
IMPORTANT: At this time, do not remove cover spherical bushing (38), retainer (37) and plungers
(31) from housing (28). (36) (9 used) can be removed together with cyl-
Valve plate (66) may come off. Take inder block (41).
care of it.
valve cover (45) from housing (28).
: 17 mm
IMPORTANT: Do not remove needle bearings (65)

unless necessary.
5. Remove valve plate (66) and O-ring (64) from
valve cover (45).
W2-4-41
16 20 21 22
19
14 15
13
9 28
8
7
6
5
4 31
3
2
1
45
35
34
33
W18B-02-04-027
W2-4-42
10. Remove socket bolts (1) (4 used) from cover (31) 17. Place housing (28) with the mounting surface of
to remove cover (2). regulator facing upward.
: 6 mm
NOTE: Remove cover (2) by screwing bolt (M8, 18. Screw the bolt (M5, Pitch 0.75 mm) into the cen-
Pitch 1.25 mm) into the pull-out hole. ter of stoppers (13, 22) to remove it from housing
(28).
11. Remove O-ring (3) and oil seal (4) from cover (2). 19. Remove backup rings (14, 21), O-rings (15, 20)
from stoppers (13, 22).
12. Tap the flange part of cover (31) at housing (28)
side lightly to separate cover (31) from housing NOTE: The matching part between displacement
(28). angle shift pin (16) and servo piston (19)
has been applied with LOCTITE. Do not
remove them unless necessary.
IMPORTANT: Do not remove bushing (34) unless
necessary.
13. Remove swash plate (33) and shoe plate (35) out 20. Heat displacement angle shift pin (16) with a drier.
from housing (28). Secure servo piston (19) with a pair of pliers or
some tools like while preventing it from being
14. Tap shaft (5) lightly at valve cover (45) side with a damaged. Remove displacement angle shift pin
plastic hammer to pull shaft (5) out from cover (16) while rotating it. Pull servo piston (19) out
(31). from housing (28).
15. Remove retaining ring (9) from shaft (5) to re-

move spacer (8) and the inner plate and outer
race of bearing (7).
16. Remove inner race of bearing (7) and spacer (6)

from shaft (5).
W2-4-43
ASSEMBLE OIL COOLER FAN DRIVE
PUMP
14, 15 13 35 19 33 16 28 34 22 20, 21 64 66 47 46
31
10
50
11
12
51
30
1 49
6
5
48
3 W18B-02-04-034
32
7 8 9 37 36 38 39 40 41 62 60, 61 63 65 45
42
43
44
23
57
58
54 59
W18B-02-04-044
52, 53 55
56
W2-4-44
1- Socket Bolt (4 Used) 18 - *Socket Bolt (4 Used) 35 - Shoe Plate 51 - Socket Bolt (4 Used)
2- Cover 19 - Servo Piston 36 - Plunger (9 Used) 52 - Plug
3- O-Ring 20 - O-Ring 37 - Retainer 53 - O-Ring
4- Oil Seal 21 - Backup Ring 38 - Spherical Bushing 54 - Casing
5- Shaft 22 - Stopper 39 - Spacer 55 - Socket Bolt (3 Used)
6- Spacer 23 - O-Ring 40 - Spring (9 Used) 56 - O-Ring (4 Used)
7- Bearing 24 - *O-Ring 41 - Cylinder 57 - Seat
8- Spacer 25 - *Plug 42 - Stopper 58 - Steel Ball
9- Retaining Ring 26 - *Lock Nut 43 - Steel Ball 59 - Stopper
10 - Lock Nut 27 - *Eyebolt 44 - Seat 60 - Plug
11 - Adjusting Screw 28 - Housing 45 - Valve Cover 61 - O-Ring
12 - Spring Pin 29 - *O-Ring (2 Used) 46 - Adjusting Screw 62 - Spring Pin
13 - Stopper 30 - *O-Ring 47 - Lock Nut 63 - Pin
14 - Backup Ring 31 - Cover 48 - Coupling 64 - O-Ring
15 - O-Ring 32 - Socket Bolt (4 Used) 49 - O-Ring 65 - Needle Bearing
16 - Displacement Angle Shift Pin 33 - Swash Plate 50 - Plate 66 - Valve Plate
17 - *Regulator 34 - Bushing
W2-4-45
14, 15 13 35 19 33 16 28 34 22 20, 21
31
12
30
1
6
3 W18B-02-04-034
7 8 9
W18B-02-04-044
W2-4-46
Assemble Oil Cooler Fan Drive Pump
IMPORTANT: Apply LOCTITE #1303B to the 9. Install spacer (6) and inner race of bearing (7)
threaded part of servo piston (19). onto shaft (5).
1. Insert servo piston (19) into housing (28). Install
displacement angle shift pin (16) to servo piston IMPORTANT: Install the outer race and inner plate
(19). of bearing (7) with the mating marks
facing housing (28) side.
2. Install O-ring (15) and backup ring (14) to stopper 10. Install the outer race of bearing (7), inner plate,
(13). spacer (8) and retaining ring (9) onto shaft (5) in
Install O-ring (20) and backup ring (21) to stopper that order.
(22).
3. Install stoppers (13, 22) to housing (28). IMPORTANT: Do not tap shaft (5) with a hammer.
11. Install shaft (5) to cover (31).
IMPORTANT: Apply grease to the mounting sur- At this time, tap the outer race of bearing (7) with
face of shoe plate (35) and install a plastic hammer lightly to install it. Then tap
shoe plate (35) onto swash plate them into the most inside with a bar and hammer.
(33) with the chamfer side facing
swash plate (33). 12. Install O-ring (3) and oil seal (4) to cover (2).
4. Install shoe plate (35) to swash plate (33).
13. Install cover (2) onto cover (31) with socket bolts
5. Place housing (28) with the mounting surface of (1) (4 used).
regulator facing downward. : 6 mm
: 29.4 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
6. Install swash plate (33) into housing (28) and in-
sert displacement angle shift pin (16) into bush-
ing (34) on swash plate (33).
IMPORTANT: Check swash plate (33) that it

should move smoothly before in-
stalling cover (31).
7. Install spring pin (12) and O-ring (30) onto cover
(31).
IMPORTANT: Check swash plate (33) that it must

be inserted in the slide surface of
cover (31). Check swash plate (33)
that it must be inserted in dis-
placement angle shift pin (16).
8. Install housing (28) to cover (31).
W2-4-47
28 64 66
50
51
49
5
48
W18B-02-04-034
32
37 36 38 39 40 41 62 60, 61 63 65 45
42
43
44
57
58
54 59
W18B-02-04-044
52, 53 55
56
W2-4-48
14. Install springs (40) (9 used), spacer (39), spheri- 22. Install O-ring (49) onto plate (50).
cal bushing (38), retainer (37) and plungers (36)
(9 used) into cylinder block (41) in that order. 23. Install coupling (48) to the end of shaft (5).
15. Install the cylinder block (41) assembly into shaft 24. Install plate (50) onto valve plate (45) and tighten
(5). it with socket bolts (51) (4 used).
: 10 mm
IMPORTANT: It is easier to do the assembly work : 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
if aligning the spline slots in cylin-
der block (41) and spherical bushing 25. Install O-ring (53) and plug (52) onto casing (54).
(38) before assembling. : 19 mm
16. Install seat (44), steel ball (43) and stopper (42) : 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
into valve cover (45).
26. Install O-rings (56) (4 used) onto valve cover (45)
17. Install seat (57), steel ball (58) and stopper (59) and tighten casing (54) with socket bolts (55) (3
into valve cover (45). used).
: 5 mm
18. Install O-rings (64, 61) and plug (60) to valve : 11.8 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
cover (45).
: 19 mm
: 36.3 N⋅m (3.7 kgf⋅m, 27.0 Ibf⋅ft) 27. Install regulator (17) onto valve cover (45) with
socket bolts (18) (4 used).
: 6 mm
19. Install needle bearing (65) into valve cover (45). : 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
NOTE: Apply much of grease to the needle part of
needle bearing for easier to install shaft (5)
end in.
IMPORTANT: Apply grease to the flat side of valve

plate (66) to prevent it from coming
off.
20. Install spring pin (62) and pin (63) to valve cover
(45). Then install valve plate (66).
21. Install the valve cover (45) assembly to housing

(28) and tighten it with socket bolts (32) (4 used).
: 17 mm
: 431.2 N⋅m (44 kgf⋅m, 320 Ibf⋅ft)
W2-4-49
1. Clearance between plunger (36) diameter (d) and

cylinder block (41) bore (D)
Unit: mm (in)
d D
Standard Allowable Limit
D-d 0.047 (0.002) 0.094 (0.004)
W117-02-02-009
2. Spring (40) free length (L)

Unit: mm (in)
L 49.5 (1.95) 48.0 (1.89)
L
3. Clearance between plunger (36) and shoe (e),
and shoe thickness (t) W117-02-02-010
Unit: mm (in)
0 to 0.1 0.35
e
(0 to 0.004) (0.01)
t 6.5 (0.26) 6.3 (0.25)
e
t
4. Distance between retainer (37) bottom and W117-02-02-011
spherical bushing (38) top
Unit: mm (in)
H-h 16.5 (0.6) 15.5 (0.6) Stand
H
h
W117-02-02-012
W2-4-50
(Blank)
W2-4-51
DISASSEMBLE REGULATOR FOR OIL
COOLER FAN DRIVE PUMP
12
11
10
9
8
7
6 13
5 15
4 16
3 17
2 18
19
1 14
20
21
22
26 23
24
27
28 25
29 46
32 31 30
47
45
44
43
42
37 39 41
34
40
33
48
35 49
36
38
63 50
51
52
64
53
65
66 57
62 61 56
60 55
58 54
59
W18B-02-04-045
W2-4-52
1- Pin 18 - Pin 35 - O-Ring 51 - Supporting Plug

2- Sleeve 19 - Lever 36 - O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - Socket Bolt (4 Used) 62 - O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (2 Used)
16 - Feed Back Lever 33 - Socket Bolt (4 Used) 50 - Pin 66 - Socket Bolt (2 Used)
17 - Pin 34 - Cover
W2-4-53
12
11
10
9
8
3
2
1
26
27
28
29 46
32 31 30
47
45
44
43
42
37 39 41
34
33
48
35 49
36
38
63 50
51
64
53
65
66 57
62 61 56
60
58 54
59
W18B-02-04-045
W2-4-54
Disassemble Regulator for Oil Cooler Fan Drive
Pump
1. Remove socket bolts (37) (2 used) and (39) (2 8. Remove retaining ring (32) from spool (26) to
used) to remove regulator from the pump. remove spring seat (31), spring (30) and sleeve
Remove pins (57) (2 used), O-rings (58, 59) from (27).
casing (38).
: 6 mm 9. Remove retaining ring (28) from sleeve (27).
2. Remove socket bolts (33) (4 used) to remove 10. Remove pin (1), sleeve (2) and O-ring (3) from
cover (34), O-rings (35) and (36) (3 used) from casing (38).
casing (38).
: 5 mm 11. Remove lock rings (53, 54) from casing (38).
IMPORTANT: Do not disassemble lock nuts (43, IMPORTANT: Supporting plugs (51) and (56) look
48, 47), adjusting screws (42, 49) similar. Make mating marks on them
and (41). The flow rate setting will to prevent them from being installed
change if disassembling them when in wrong position.
removing cover (45), take care that 12. Screw bolts (M6, Pitch 1.0 mm) to the screw hole
springs (9, 10) inside may fly out. of the center on supporting plug (51, 56) and pull
3. Remove socket bolts (46) (4 used) to remove the out them from casing (38).
cover (45) assembly and O-ring (44) from casing At this time, supporting plug (51) is still with pin
(38). (50) attached.
: 5 mm
13. Remove pin (50) from supporting plug (51).
4. Remove springs (9, 10) and spring seat (8) from
casing (38).
5. Pull out stopper (11) and O-ring (12) from the

cover (45) assembly.

used) to remove cover (64) from casing (38).
: 5 mm
7. Remove O-rings (60, 61, 62, 63) and spring (29)

from casing (38).
W2-4-55
7
6
5 15
4 16
17
19
14
20
21
22
26 23
24
25
41
38
51
52
56
55
W18B-02-04-045
W2-4-56
14. Remove O-rings (52, 55) from supporting plugs
(51, 56).

(19).
15. Remove lever (19) from casing (38) with a pair of
pincers.
16. Remove pin (17) to remove feedback lever (16)

with a round bar (4 mm (0.2 in)).

(15).
17. Remove lever (15) from casing (38).
18. Pull out pilot piston (25) from casing (38).
19. Insert a round bar (Dia. 4 mm (0.2 in)) into pilot

piston (25) side to remove spring seat (24),
spring (23) and stopper (22) from casing (38).
20. Remove O-ring (21) from stopper (22).
21. Insert a round bar (Dia. 4 mm (0.2 in)) into ad-

justing screw (41) side to remove compensating
rod (7) and the sleeve (5) assembly from casing
(38).
22. Remove compensating rod (7), compensating

piston (6) and O-ring (4) from sleeve (5).
23. Remove spool (26) from casing (38).
W2-4-57
ASSEMBLE REGULATOR FOR OIL
COOLER FAN DRIVE PUMP A 34 33
B C W117-02-02-016
Section A-B
64 38 25 18 19 20 23 22 21
65
61 48
49
66
37 24 39
W117-02-02-006
D Section A-C
63 29 30 28 27 26 17 50 15 8 9 10 44 40 45 47
31
32
3 41
1 43
2
42
4 6 5 7 D 16 14 58 57 11 12
13 51 52 W117-02-02-017
53
Section D-D
54
14 56 55
W18B-02-04-046
W2-4-58
1- Pin 18 - Pin 35 - *O-Ring 51 - Supporting Plug

2- Sleeve 19 - Lever 36 - *O-Ring (3 Used) 52 - O-Ring
3- O-Ring 20 - Pin 37 - Socket Bolt (2 Used) 53 - Lock Ring
4- O-Ring 21 - O-Ring 38 - Casing 54 - Lock Ring
5- Sleeve 22 - Stopper 39 - Socket Bolt (2 Used) 55 - O-Ring
6- Compensating Piston 23 - Spring 40 - O-Ring 56 - Supporting Plug
7- Compensating Rod 24 - Spring Seat 41 - Adjusting Screw 57 - Pin (2 Used)
8- Spring Seat 25 - Pilot Piston 42 - Adjusting Screw 58 - O-Ring
9- Spring 26 - Spool 43 - Lock Nut 59 - *O-Ring
10 - Spring 27 - Sleeve 44 - O-Ring 60 - *O-Ring
11 - Stopper 28 - Retaining Ring 45 - Cover 61 - O-Ring
12 - O-Ring 29 - Spring 46 - *Socket Bolt (4 Used) 62 - *O-Ring
13 - Pin 30 - Spring 47 - Lock Nut 63 - O-Ring
14 - Pin 31 - Spring Seat 48 - Lock Nut 64 - Cover
15 - Lever 32 - Retaining Ring 49 - Adjusting Screw 65 - Socket Bolt (2 Used)
16 - Feed Back Lever 33 - Socket Bolt (4 Used) 50 - Pin 66 - Socket Bolt (2 Used)
17 - Pin 34 - Cover
W2-4-59
B C W117-02-02-016
Section A-B
38 25 19 20
W117-02-02-006
D Section A-C
29 30 28 27 26 17 50 15
31
32
7 D 16 14
51 52 W117-02-02-017
53
Section D-D
54
56 55
W18B-02-04-046
W2-4-60
Assemble Regulator for Oil Cooler Fan Drive
Pump
IMPORTANT: Check pilot piston (25) that it should

IMPORTANT: Check the installation directions of move smoothly after installing it.
compensating rod (7) as illustrated. 6. Insert pilot piston (25) into casing (38).
1. Insert compensating rod (7) into casing (38).
7. Install O-rings (52, 55) onto supporting plugs (51,
2. Install pin (14) to lever (15). Insert lever (15) to 56).
casing (38). Align the groove of compensating
rod (7) with pin (14) to install pin (14).
IMPORTANT: Supporting plugs (51) and (56) look
3. Install retaining ring (28) to sleeve (27). similar. Make marks on them to pre-
vent them from being installed in
wrong position.
IMPORTANT: Check spool (26) that it should 8. Align the groove in pilot piston (25) with pin (20)
move smoothly after inserting it. on lever (19) and install lever (19).
4. Insert sleeve (27) and spool (26) into casing (38).
9. Install pin (50) to supporting plug (51) and align it
IMPORTANT: Be sure to install feed back lever with the hole in lever (19).Then install supporting
(16) in correct direction. plug (51).
5. Align the pin hole (the hole in upper side) in feed
back lever (16) with the pin hole in spool (26), 10. Install lock ring (53) onto supporting plug (51).
then install pin (17).
11. Install casing (38) to supporting plug (56) where
lock ring (54) should be installed.
12. Install spring (30), spring seat (31) to spool (26)

Compensating Rod Lever (26) Side where retaining ring (32) should be installed then.
(7) Side
13. Install spring (29) to casing (38).
W18B-02-04-018
W2-4-61
A 34 33
B C W117-02-02-016
Section A-B
64 38 23 22 21
65
61
66
37 24 39
W117-02-02-006
D Section A-C
63 8 9 10 44 45
3
1
2
4 6 5 D 58 57 11 12
W117-02-02-017
Section D-D
W18B-02-04-046
W2-4-62
IMPORTANT: Check that the installation direction 25. Install pins (57) (2 used) and O-rings (58) and
of compensating piston (6) should (59) into casing (38).
be as illustrated.
14. Install O-ring (4) and compensating piston (6) 26. Install the regulator onto the pump body with
onto sleeve (5). socket bolts (37) (2 used) and (39) (2 used).
: 6 mm
15. Install sleeve (5), O-ring (3), sleeve (2) and pin : 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
16. Install O-rings (60, 61, 62, 63) onto casing (38).
17. Install cover (64) onto casing (38) with socket

bolts (65) (2 used) and (66) (2 used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
18. Install O-rings (35) and (36) (3 used) onto cover

(34).
19. Install cover (34) onto casing (38) with socket

bolts (33) (4 used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
21. Install spring seat (24), spring (23) and stopper

23. Install spring seat (8), springs (9, 10) to casing

(38).
24. Install stopper (11) and O-ring (44) onto the cover
(45) assembly and install the cover (45) assem-
bly onto casing (38) with socket bolts (46) (4
used).
: 5 mm
: 11.5 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft)
W2-4-63
DISASSEMBLE AIR COMPRESSOR DRIVE
PUMP AND PILOT PUMP
16
15
14
13
12
10
9
8
7 11 30
29
5 6
28
4 27
3 26
2
1 25
24 44
23 43
22 42
21
20
17
18 41
40
39
38
19 37
36
35
34
33
31
32
45
W18B-02-04-015
W2-4-64
1- Coupling 13 - O-Ring 24 - Coupling 35 - Plate

2- O-Ring 14 - Knock Pin (2 Used) 25 - O-Ring 36 - Knock Pin (2 Used)
3- Nut (4 Used) 15 - Plate 26 - Center Plate 37 - Pressure Plate
4- Spring Washer (4 Used) 16 - Knock Pin (2 Used) 27 - Backup Ring 38 - Seal Plate
5- Stud Bolt (4 Used) 17 - O-Ring 28 - Seal Plate 39 - Insulation Plate
6- Cover 18 - Cover 29 - Insulation Plate 40 - Backup Ring
7- Backup Ring 19 - Socket Bolt (2 Used) 30 - Pressure Plate 41 - O-Ring
8- Seal Plate 20 - Pressure Plate 31 - Driven Gear 42 - Flange
9- Insulation Plate 21 - Seal Plate 32 - Drive Gear 43 - Oil Seal
10 - Pressure Plate 22 - Insulation Plate 33 - O-Ring 44 - Snap Ring
11 - Drive Gear 23 - Backup Ring 34 - Knock Pin (2 Used) 45 - Stabilizer (4 Used)
12 - Driven Gear
W2-4-65
15
14
13
12
10
9
8
7 30
11 29
6
28
4 27
3 26
2
1 25
24
23
22
21
20
17
18
19
35
33
31
32
45
W18B-02-04-015
W2-4-66
Disassemble Air Compressor Drive Pump and
Pilot Pump
CAUTION: The pilot pump weight: 27 kg 8. Remove plate (15) from center plate (26).
(60 lb) NOTE: Tap the outer race of cover (6) while
removing it with a plastic hammer lightly.
1. Remove O-ring (2) from cover (6). Remove
coupling (1) from drive gear (11).
9. Remove backup ring (23), insulation plate (22),
seal plate (21) and pressure plate (20) from plate
2. Remove socket bolts (19) (2 used) from cover (6) (15).
to remove cover (18) and O-ring (17).
: 8 mm 10. Remove O-ring (25) from center plate (26).
3. Remove nuts (3) (4 used) and spring washers (4) 11. Remove center plate (26) from plate (35).
(4 used) from cover (6).
: 22 mm 12. Pull out coupling (24) from center plate (26).
4. Remove cover (6) from plate (15). 13. Remove stabilizers (45) (2 used) and O-ring (33)
NOTE: Cover (6) has been secured with knock from plate (35).
pins (14) (2 used). Tap the outer race of
cover (6) with a plastic hammer lightly while 14. Remove backup ring (27), seal plate (28) and
removing the cover. insulation plate (29) from plate (35) with a
bamboo spatula.
5. Remove backup ring (7), seal plate (8) and
insulation plate (9) from plate (15) with bamboo IMPORTANT: Pull out driven gear (31) and drive
spatula. gear (32) at same time.
15. Pull out driven gear (31) and drive gear (32) from
plate (35). At this time, pressure plate (30) is also
IMPORTANT: Do not confuse driven gears (12) removed.
and (31) when storing them.
Remove driven gear (12) and drive
gear (11) at same time.
6. Remove driven gear (12) and drive gear (11) from
plate (15). At this time, pressure plate (10) is also
removed.
IMPORTANT: Do not remove knock pin (14) unless

necessary.
7. Remove O-ring (13) and stabilizers (45) (2 used)
from plate (15).
W2-4-67
44
43
42
41
40
39
38
37
36
35
W18B-02-04-015
W2-4-68
16. Remove plate (35) from flange (42).

necessary.
17. Remove backup ring (40), insulation plate (39),
seal plate (38) and pressure plate (37) from plate
(35).
18. Remove O-ring (41) from flange (42).
19. Remove snap ring (44) and oil seal (43) from
flange (42).
NOTE: Stud bolt (5) is still left in the flange (42). Do
not remove it unless necessary.
W2-4-69
ASSEMBLE AIR COMPRESSOR DRIVE
PUMP AND PILOT PUMP
B C B C
5 6 14 13 12 15 25 16 26 34 33 35 31 41 36 42
3
4
2 1 10 11 20 24 30 32 37 43 44
B C B C
38 40
19 17 45 39
18
View A 9
7
8
Section B Section C W18B-02-04-050
1- Coupling 13 - O-Ring 24 - Coupling 35 - Plate

2- O-Ring 14 - Knock Pin (2 Used) 25 - O-Ring 36 - Knock Pin (2 Used)
3- Nut (4 Used) 15 - Plate 26 - Center Plate 37 - Pressure Plate
4- Spring Washer (4 Used) 16 - Knock Pin (2 Used) 27 - *Backup Ring 38 - Seal Plate
5- Stud Bolt (4 Used) 17 - O-Ring 28 - *Seal Plate 39 - Insulation Plate
6- Cover 18 - Cover 29 - *Insulation Plate 40 - Backup Ring
7- Backup Ring 19 - Socket Bolt (2 Used) 30 - Pressure Plate 41 - O-Ring
8- Seal Plate 20 - Pressure Plate 31 - Driven Gear 42 - Flange
9- Insulation Plate 21 - *Seal Plate 32 - Drive Gear 43 - Oil Seal
10 - Pressure Plate 22 - *Insulation Plate 33 - O-Ring 44 - Snap Ring
11 - Drive Gear 23 - *Backup Ring 34 - Knock Pin (2 Used) 45 - Stabilizer (4 Used)
12 - Driven Gear
W2-4-70
Assemble Air Compressor Drive Pump and Pilot 10. Install pressure plate (30), insulation plate (29),
Pump seal plate (28), backup ring (27) onto plate (35)
from center plate (26) side.
1. Install oil seal (43) and snap ring (44) onto flange
(42). 11. Install O-ring (33), knock pins (34) (2 used) and
stabilizers (45) (2 used) onto plate (35).
2. Install O-ring (41) and knock pins (36) (2 used)
onto flange (42). IMPORTANT: Check the matching surfaces of
center plate (26) and plate (35) are
3. Place plate (35) so that it can align with center matched closely.
plate (26) temporarily. 12. Install center plate (26) onto the plate (35)
assemble. Install coupling (24) onto center plate
NOTE: Install plate (35) onto center plate (26)
(26).
temporarily to prevent backup ring (27)
from coming out and to prevent the gear
from operating during installation to drop 13. Install O-ring (25) and knock pins (16) (2 used)
backup ring (27). onto center plate (26).
4. Install driven gear (31) and drive gear (32) onto 14. Align plate (15) with cover (6) while placing cover
plate (35). (6) temporarily.
NOTE: Install plate (15) onto cover (6) temporarily
5. Install pressure plate (37) onto plate (35) with the to prevent backup ring (7) from coming out
groove side of pressure plate (37) facing flange and to prevent the gear from operating
(42) side. during installation to drop backup ring (7).
6. Install seal plate (38), insulation plate (39) and 15. Install driven gear (12) and drive gear (11) onto
backup ring (40) onto pressure plate (37). plate (15).
7. Install flange (42) onto the plate (35) assembly. 16. Install pressure plate (20) onto plate (15) with the
groove facing cover (6) side.
8. Remove center plate (26) from the flange (42) 17. Install seal plate (21), insulation plate (22) and
assembly and secure it on a vice with the oil seal backup ring (23) onto pressure plate (20).
(43) side facing downward.
18. Install the center plate (26) assembly onto the
9. Tap plate (35) with a plastic hammer lightly to plate (15) assembly.
install it to flange (42) completely.
W2-4-71
B C B C
5 6 14 13 15
3
4
2 1 10 11
B C B C
19 17 45
18
View A 9
7
8
Section B Section C W18B-02-04-050
W2-4-72
19. Remove cover (6) from the plate (15) assembly.
20. Install O-ring (13), knock pins (14) (2 used) and

stabilizers (45) (2 used) onto plate (15).
21. Install pressure plate (10), insulation plate (9),

seal plate (8) and backup ring (7) onto plate (15).
22. Install cover (6) onto plate (15), and tighten it with
stud bolts (5) (4 used), spring washers (4) (4
used) and nuts (3) (4 used).
: 22 mm
: 26 N⋅m (2.6 kgf⋅m, 19.0 Ibf⋅ft)
23. Install O-ring (17) onto cover (6).
24. Install cover (18) onto cover (6), and tighten it with
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 Ibf⋅ft)
25. Install coupling (1) to drive shaft (11).
26. Install O-ring (2) to cover (6).
W2-4-73
Drive Gears (11, 32), Driven Gears (12, 31)

Plates (15, 35) φb< φ27.48 mm (1.1 in)
a≥0.15 mm (0.006 in) ｂ
a
W117-02-02-022
W117-02-02-021
W2-4-74
(Blank)
W2-4-75
DISASSEMBLE LUBRICATION PUMP FOR
PUMP TRANSMISSION 14
12 13
11
10
9
6 8
7
1 5
4
3
2
15
W18B-02-04-014
1- Bolt (4 Used) 5- Driven Gear 9- Gasket A 13 - Oil Seal

2- Cover 6- Knock Pin 10 - Gasket B 14 - Snap Ring
3- O-Ring 7- Plate 11 - Balancing Seal 15 - Drive Gear
4- Side Plate B 8- Side Plate A 12 - Flange
W2-4-76
Disassemble Lubrication Pump for Pump
Transmission
IMPORTANT: Flange (12) may deform if it is

clamped into a vise tightly. Take care
of it.
1. Secure flange (12) into a vice. Remove bolts (1)
(4 used) to remove cover (2) from plate (7).
: 14 mm
NOTE: The cover (2) can be secured on plate (7)
with knock pin (6). Tap cover (2) with a
plastic hammer while removing it.
2. Remove O-ring (3) from cover (2).
3. Remove side plate B (4) from driven gear (5) and

drive gear (15).
IMPORTANT: Slowly rotating driven gear (5) and

drive gear (15) while pulling them
out.
4. Remove driven gear (5) and drive gear (15) from
plate (7).

necessary.
5. Remove plate (7) from flange (12).
6. Remove side plate A (8), gasket A (9), gasket B

(10) and balancing seal (11) from flange (12).
NOTE: When removing gasket A (9), gasket B (10)
and balancing seal (11), a bamboo spatula
can be used.
7. Remove snap ring (14) and oil seal (13) from

flange (12).
W2-4-77
ASSEMBLE LUBRICATION PUMP FOR
PUMP TRANSMISSION
1 2 5 6 7 12
C
View D
15 3 4 8 13 14
Detail C
9 10 11
Section B-B Section A-A W117-02-02-020
1- Bolt (4 Used) 5- Driven Gear 9- Gasket A 13 - Oil Seal

2- Cover 6- Knock Pin 10 - Gasket B 14 - Snap Ring
3- O-Ring 7- Plate 11 - Balancing Seal 15 - Drive Gear
4- Side Plate B 8- Side Plate A 12 - Flange
W2-4-78
Assemble Lubrication Pump for Pump
Transmission
1. Install oil seal (13) and snap ring (14) onto flange
(12).
2. Apply grease on the groove of balancing seal (11)

in flange (12). Install balancing seal (11), gasket B
(10), gasket A (9) and side plate A (8) to flange
(12).
3. Install plate (7) onto flange (12).
4. Apply grease to the inner surface of plate (7).
IMPORTANT: Install drive gear (15) while rotating

it slowly.
5. Install drive gear (15) to flange (12).
6. Install driven gear (5) to flange (12).
IMPORTANT: Tighten bolt (1) evenly, drive gear

(15) may not rotate.
8. Install cover (2) to plate (7) and tighten it with
bolts (1) (4 used).
: 17 mm
: 34 to 39 N⋅m
(3.5 to 4.0 kgf⋅m, 25.5 to 29 Ibf⋅ft)
IMPORTANT: Check that drive gear (15) should

rotate smoothly after installation.
W2-4-79
Plate (7) Drive Gear (15), Driven Gear (5)

a≥0.15 mm (0.006 in) φb< φ14.96 mm (0.6 in)
ｂ
a
W117-02-02-022
W117-02-02-021
W2-4-80
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE

oil tank before starting work. (Refer
to “item of Bleeding Air from
Hydraulic Oil Tank” on page W1-3-1)
Removal
IMPORTANT: Attach identification tags on all

disconnected pipes to aid in
reassembly.
1. Disconnect all piping ends from the control valves.
(The number of piping ends differ depending on
which control valve is to be removed.)
: 12 mm, 17 mm
: 17 mm, 19 mm, 22 mm M117-07-081
NOTE: Attach a cap on each disconnected pipe

ends.
2. Remove control valve mounting nuts (1) (12

used).
: 30 mm
CAUTION: The control valve weight:

425 kg (940 lb)
3. Attach a nylon sling between the plungers of

control valve and overload relief valve to hang
them onto the housing.
W2-5-1
Installation
1
CAUTION: Control valve weight:
425 kg (940 lb)
1. Install the control valve and tighten it with nut (1)

(12 used).
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)
2. Reconnect all piping ends and hoses to the

control valve.
: 12 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 17 mm
: 540 N⋅m (55 kgf⋅m, 400 Ibf⋅ft) M117-07-081
Pilot Hose
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
Actuator Pipe
: 17 mm
: 49 N⋅m (5.0 kgf⋅m, 36 Ibf⋅ft)
: 19 mm
: 88 N⋅m (9.0 kgf⋅m, 65 Ibf⋅ft)
IMPORTANT: After reinstalling the control valve,

check the hydraulic oil level. Check
for any oil leaks from pipe
connections.
W2-5-2
(Blank)
W2-5-3
DISASSEMBLE CONTROL VALVE
5 6 7 8
Overload Relief Valve
Makeup Valve
Main Relief Valve
Makeup Valve
T117-02-03-002
Center Control Valve
1 2 3 4 Overload 9 10 11 12
Overload
Relief Valve
Relief Valve
Makeup Makeup
Valve Main Relief Valve
Valve
Main Relief
Valve
Makeup Makeup
Valve Valve
Overload Overload
Relief Valve Relief Valve
T117-02-03-003 T117-02-03-001
Right Control Valve Left Control Valve
NOTE: This illustration shows the control valve LD: Loading Shovel
location viewed from the front of the BH: Back Hoe
loading shovel.
1 - Boom 4- Swing 7- Bucket Open / Close (LD) 10 - Arm

Bucket (BH)
2 - Bucket 5- Right Travel 8 - Arm 11 - Boom
3 - Arm Extend (LD) 6- Boom Raise / Bucket Tilt Back 9 - Left Travel 12 - Bucket
Arm (BH) (LD)
Boom (BH)
W2-5-4
18
17
19
2 20
Direction to Remove Spool 21
3
11
12
16
4 15
14
5 22
13 23
6 24
7 4 25
1
8 5 26 11
9
29 6
28 10
7
8 26
4 12
9
28 5
10
28
12 6
29 7
8
27 28
9 10 4
14
15 28 5
11
24 16
25 29
23 7
34 6
30 8
17 35
31 28
28
12 29
12 41
11
21 28
33 36
32 35
11 2
40 39
36
38
37
W118-02-03-014
1 - Outlet Section 12 - Make-Up Valve (5 Used) 22 - Spool End (4 Used) 32 - Plug (4 Used)
2 - Nut (8 Used) 13 - Spool (4 Used) 23 - Spring Seat (8 Used) 33 - O-Ring (4 Used)
3 - Tie Rod (4 Used) 14 - Spring Seat (8 Used) 24 - Spring (8 Used) 34 - Housing
(Bucket Open/Close)
4 - Socket Bolt (16 Used) 15 - Spring (8 Used) 25 - Spring Seat (8 Used) 35 - Plug (2 Used)
5 - Plate (4 Used) 16 - Spring Seat (8 Used) 26 - Overload Relief Valve 36 - O-Ring (2 Used)
(2 Used)
6- Plug (4 Used) 17 - O-Ring (8 Used) 27 - Housing (Arm) 37 - Inlet Section
7- Backup Ring (4 Used) 18 - Cap (4 Used) 28 - O-Ring (8 Used) 38 - Main Relief Valve
8- O-Ring (4 Used) 19 - Plug (4 Used) 29 - O-Ring (4 Used) 39 - O-Ring
9- Spring (4 Used) 20 - O-Ring (4 Used) 30 - Spool End (4 Used) 40 - Housing (Right Travel)
10 - Poppet (3 Used) 21 - Socket Bolt (16 Used) 31 - Cap (4 Used) 41 - Housing (Boom
Raise/Bucket Roll-In)
11 - Overload Relief Valve (5 Used)
W2-5-5
Left Control Valve
18
17
19
11 20
12 21
2 16
15
14
3 22
13 23
4 24
25
5 Direction to Remove Spool
6
7 12
1 4
8 5
9 11
28 10 6 7
29 8
9 4
28 10 12
29 5 11
28
12 6
7
28 8
47 9
14 10 4
15
28 5
11 16
24 25 48
23 7 6
30 49
17 8
31 35
28 28
12
12 11 29
41
33 21 28
36
32 35
11 2
40 39
36
38 37
W118-02-03-016
1- Outlet Section 12 - Make-Up Valve (6 Used) 23 - Spring Seat (8 Used) 36 - O-Ring (2 Used)
2- Nut (8 Used) 13 - Spool (4 Used) 24 - Spring (8 Used) 37 - Inlet Section
3- Tie Rod (4 Used) 14 - Spring Seat (8 Used) 25 - Spring Seat (8 Used) 38 - Main Relief Valve
4- Socket Bolt (16 Used) 15 - Spring (8 Used) 28 - O-Ring (8 Used) 39 - O-Ring
5- Plate (4 Used) 16 - Spring Seat (8 Used) 29 - O-Ring (4 Used) 40 - Housing (Left Travel)
6- Plug (4 Used) 17 - O-Ring (8 Used) 30 - Spool End (4 Used) 41 - Housing (Arm)
7- Backup Ring (4 Used) 18 - Cap (4 Used) 31 - Cap (4 Used) 47 - Housing (Bucket)
8- O-Ring (4 Used) 19 - Plug (4 Used) 32 - Plug (4 Used) 48 - Housing (Boom)
9- Spring (3 Used) 20 - O-Ring (4 Used) 33 - O-ring (4 Used)
10 - Poppet (3 Used) 21 - Socket Bolt (16 Used) 35 - Plug (2 Used)
11 - Overload Relief Valve (6 Used) 22 - Spool End (4 Used)
W2-5-6
Right Control Valve
18
17
19
Direction to Remove
20
2
Spool 21
11 12
3
16
4 15
5 14 22
23
6 13 24
１
7 25
4 26 11
8 5
9
29 28
10 6
7
8
26
28 5
9 4
28 10 12
12 6
29 7
8 5 4
28 9
27 11
14 28 10 6
11 15 7
24 25 8
23 16 29
30 9
17 34
31 28 10
12 28
43 12
29 42
28 44
11
41
33 21 12 2
32
39
11
11 36
40
36
12
Direction to Insert 37
Spool
38
W141-02-05-001
1- Outlet Section 12 - Make-Up Valve (8 Used) 23 - Spring Seat (8 Used) 34 - Housing (Bucket)
2- Nut (8 Used) 13 - Spool (4 Used) 24 - Spring (8 Used) 35 - Plug (2 Used)
3- Tie Rod (4 Used) 14 - Spring Seat (8 Used) 25 - Spring Seat (8 Used) 36 - O-Ring (2 Used)
4- Socket Bolt (16 Used) 15 - Spring (8 Used) 26 - Overload Relief Valve (2 Used) 37 - Inlet Section
5- Plate (4 Used) 16 - Spring Seat (8 Used) 27 - Housing (Boom) 38 - Main Relief Valve
6- Plug (4 Used) 17 - O-Ring (8 Used) 28 - O-Ring (8 Used) 39 - O-Ring
7- Backup Ring (4 Used) 18 - Cap (4 Used) 29 - O-Ring (4 Used) 40 - Housing (Swing)
8- O-Ring (4 Used) 19 - Plug (4 Used) 30 - Spool End (4 Used) 41 - Housing (Arm Extend)
9- Spring (4 Used) 20 - O-Ring (4 Used) 31 - Cap (4 Used) 42 - Socket Bolt (4 Used)
10 - Poppet (3 Used) 21 - Socket Bolt (16 Used) 32 - Plug (4 Used) 43 - Cover
11 - Overload Relief Valve 22 - Spool End (4 Used) 33 - O-Ring (4 Used) 44 - O-Ring
(8 Used)
W2-5-7
18
17
19
2 20
Direction to Remove Spool
21
3
11
12
16
4 15
14
5 22
13 23
6 24
7 4 25
1
8 5 26 11
9 6
29
28 10 7
8 4 26
9 12
28 5
10
28
12 6
7
29 8
27 28
9 4
14 10
15 28 5
11
24 16
25 29 6
23 7
30 34
17 8 35
31 28
28
12 29
12 11 41 28
21
33 36
32 35
11 2
40 39
36
Direction to Install Spool 38
37
W118-02-03-014
(Bucket Open/Close)
5 - Plate (4 Used) 16 - Spring Seat (8 Used) 26 - Overload Relief Valve 36 - O-Ring (2 Used)
(2 Used)
7- Backup Ring (4 Used) 18 - Cap (4 Used) 28 - O-Ring (8 Used) 38 - Main Relief Valve
8- O-Ring (4 Used) 19 - Plug (4 Used) 29 - O-Ring (4 Used) 39 - O-Ring
9- Spring (4 Used) 20 - O-Ring (4 Used) 30 - Spool End (4 Used) 40 - Housing (Right Travel)
W2-5-8
Disassemble Control Valve
(Center Control Valve)
・ The procedure to disassemble and assemble
CAUTION: Inlet section (37) weight:
center control valve is described here. As for
other control valves, their basic structure are 61 kg (130 lb)
similar except the shape of the spool. Outlet section (1) weight: 30 kg (70 Ib)
Housing (40, 41, 34, 27) weight:
Each 80 kg (180 lb)
IMPORTANT: Many components of the control
valve are in similar shape and the 5. Loosen socket bolts (4) (16 used) to remove
direction to assemble them is plates (5) (4 used) from housings (40, 41, 34, 27).
determined, so marks should be : 14 mm
made before disassembling them so
as to prevent them from being
assembled in wrong direction and 6. Remove plugs (6) (4 used), springs (9) (3 used),
position. poppets (10) (4 used) from housings (40, 41, 34,
27).
NOTE: Pull out plug (6) from housing with the
CAUTION: Control valve weight: bamboo spatula (2 used) inserted into the
425 kg (940 lb) groove in plug (6) outer side.
Bamboo Spatula
1. Put the control valve assembly on a clean work
Housing
bench.
IMPORTANT: Do not disassemble the overload

relief valve as adjusting by special
tester will be needed.
2. Remove overload relief valves (11) (5 used), (26)
6
(2 used) from housing (27, 34, 41).
When removing, attach the spanner to the body
side of overload relief valve. W18B-02-04-012
: 38 mm
7. Remove backup rings (7) (4 used) and O-rings (8)
3. Remove make-up valve (12) (5 used) from (4 used) from plugs (6) (4 used).
housing (27, 34, 41).
: 38 mm 8. Loosen nuts (2) and pull out tie rods (3).
: 36 mm
4. Remove main relief valve (38) from inlet section NOTE: Install eyebolts (M20, Pitch 2.5 mm) into
(37). the screw holes for pipe while hoisting each
: 38 mm section and housing of control valve. Then
hoist it up. While doing this, be sure to
prevent O-ring from coming off.
W2-5-9
18
19
17
20
21
22
13
1
29 28
28 29
28
28
27
14 29 28
15
16
25
24 34
23
30 28
17 29 28
31
28
41 39
21
33 36
32
40
36
37
W118-02-03-014
W2-5-10
9. Separate inlet section (37), housings (40, 41, 34, IMPORTANT: Do not remove spool end (30) unless
27) and outlet section (1) individually. it is damaged. When removing it, do
the work in following procedure.
10. Remove O-rings (36) (2 used) and (39) from inlet 15. Secure spool (13) in a vise with wooden pieces
section (37) and O-rings (28) (4 used) and (29) (4 inserted at both sides. Heat the outer diameter of
used) from housings (40, 41, 34, 27) respectively. spool end (30) to 200 to 250 °C (392 to 482 °F).
Rotate the spool end and remove from it the spool.
Remove spring seats (14, 16, 25), springs (24,
11. Loosen socket bolts (21) (16 used), remove caps 15), spring seat (23) from the spool end.
(18) (4 used), (31) (4 used) from housings (40, 41,
34, 27). Remove O-rings (17) (8 used) from caps
(18) (4 used) and (31) (4 used). IMPORTANT: Do not remove plug (19) unless it is
: 14 mm damaged. When removing it, do the
work in following procedure.
16. Remove O-ring (17) from cap (18).
12. Secure spool end (30) with a screwdriver. Attach Heat plug (19) mounting diameter of cap (18) to
spanner to spool end (22), and rotate it to remove 200 to 250 °C (392 to 482 °F).
spool end (22) from spool (13). (4 places) Remove plug (19) from cap (18).
: 36 mm Remove O-ring (20) from plug (19).
NOTE: As different LOCTITE types are used on : 27 mm
spool end (22) and (30), spool end (22)
side is to be removed.
IMPORTANT: Do not remove plug (32) unless it is
damaged. When removing it, do the
13. Remove spring seats (23, 25, 16, 14) and springs work in following procedure.
(24, 15) from each spool end (22). (4 places) 17. Remove O-ring (17) from cap (31).
Heat plug (32) mounting diameter of cap (31) to
IMPORTANT: Rotate spool (13) while pulling it out 200 to 250 °C (392 to 482 °F).
slowly. Remove plug (32) from cap (31).
14. Remove spool (13) from each housings (27, 34, Remove O-ring (33) from plug (32).
40, 41). : 27 mm
W2-5-11
ASSEMBLE CONTORL VALVE

1 3 2 27 34 11
21
12 12
18
11
19
12
26
A 11
11
12
B 12
11
21
32
31
W118-02-03-006
41 40 38 2 3 37
Section A and B 27, 34 9 4 6 5 7, 8 10
Port A Port B
23 16 15 24 25 17 17 14 21 24 15 22
19, 20
32 33 31 30 21 14 25 16 23 18
13
W118-02-03-008
(Bucket Open/Close)
5 - Plate (4 Used) 16 - Spring Seat (8 Used) 26 - Overload Relief Valve 36 - *O-Ring (2 Used)
(2 Used)
7- Backup Ring (4 Used) 18 - Cap (4 Used) 28 - *O-Ring (8 Used) 38 - Main Relief Valve
8- O-Ring (4 Used) 19 - Plug (4 Used) 29 - *O-Ring (4 Used) 39 - *O-Ring
9- Spring (4 Used) 20 - *O-Ring (4 Used) 30 - Spool End (4 Used) 40 - Housing (Right Travel)
W2-5-12
Assemble Control Valve
IMPORTANT: Apply grease on the O-rings to 5. Install main relief valve (38) onto inlet section
prevent O-rings (28, 29) from coming (37).
off. : 38 mm
1. Install O-rings (28) (8 used), (29) (4 used) onto : 100 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
housing (40, 41, 34, 27).
6. Insert the spool (13) assembly into housings (40,
IMPORTANT: Apply grease on the O-rings to 41, 34, 27).
prevent O-rings (36, 39) from coming
off. 7. When spool end (30) had been removed,
2. Install O-rings (36) (2 used) and (39) to inlet reassemble it in following procedure.
section (37). • Secure spool (13) in a vise with wooden pieces
inserted at both sides.
• Apply LOCTITE #638 to the screw on spool end
CAUTION: Inlet Section (37) weight:
(30).
61 kg (130 lb) • Install spring seats (23, 25, 14, 16) and springs
Outlet section (1) weight: 30 kg (70 lb) (15, 24) onto the spool end.
Housing (40, 41, 34, 27), weight: • Install the spool end onto the spool.
Each 80 kg (180 lb) : 118 N⋅m (12 kgf⋅m, 87 Ibf⋅ft)
IMPORTANT: Check and arrange all housings and
sections to keep them in right order IMPORTANT: Rotate spool (13) while inserting the
and direction. spools into each housing slowly.
IMPORTANT: Be sure to check O-ring for not 8. Install spool (13) assemblies (4 used) into
coming off and not being blown out housing (27, 34, 40, 41).
while assembling.
3. Lift each sections and housings by crane and 9. Apply LOCTITE #242 to the screw on spool ends
arrange them in order. (22) (4 used).
NOTE: Install the eyebolts (M20, Pitch 2.5 mm)
into mounting bolt holes in pipes while 10. Install spring seats (23, 25, 14, 16) and springs
lifting each section and housing. (15, 24) onto spool ends (22) (4 used).
4. Pass tie rods (3) (4 used) respectively through 11. Secure spool end (30) with a screwdriver. Attach
each sections and housings and tighten them with spanner onto spool end (22) and rotate it to install
nuts (2) (8 used). the spool end (22) into spool (13). (4 places)
: 136 mm : 36 mm
: 637 N⋅m (65 kgf⋅m, 470 Ibf⋅ft) : 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W2-5-13
1 27 34 11
21
12 12
11 18
19, 20
12 26
A 11
11
12
B 12
11
21
32
31
W118-02-03-006
41 40
Section A and B
27, 34 9 4 6 5 7, 8 10
Port A Port B
17 21
19, 20
32 33 31 30 21 18
13
W118-02-03-008
W2-5-14
12. When plug (19) was removed, re-assemble it as 16. Assemble plug (6) to housing (27, 34, 41) as
follows. follows.
• Install O-ring (20) into plug (19). ・ Install backup ring (7) and O-ring (8) onto plug (6).
• Apply LOCTITE #638 onto the screw of the plug. At this time O-ring is facing inside of housing.
• Install the plug into cap (18). ・ Install poppet (10) and spring (9) to the housing.
: 8 mm ・ Install plug (6) to the housing.
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
17. Assemble plug (6) to housing (40) as follows.
13. When plug (32) was removed, re-assemble it in ・ Install backup ring (7) and O-ring (8) onto plug (6).
that order. At this time O-ring is facing inside of housing.
• Install O-ring (33) onto plug (32). ・ Install plug (6) to the housing.
• Apply LOCTITE #638 onto the screw of the plug.
• Install the plug into cap (31). 18. Install plates (5) (4 used) onto housings (40, 41,
: 27 mm 34, 27) with socket bolts (4) (16 used).
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft) : 14 mm
: 185 N⋅m (19 kgf⋅m, 137 Ibf⋅ft)
IMPORTANT: If the gap between cap (31) and the
housing is over 5 mm, plug (32) is in 19. Install make-up valves (12) (5 used) into housings
certain failure to be installed into the (41, 34, 27).
slot in spool end (30). Re-assemble
NOTE: When installing make-up valve (12) to cap
them again.
(31) side, install it from outlet section (1) in
14. Install O-rings (17) (4 used) to caps (31) (4 used),
order.
then install them into housings (40, 41, 34, 27)
When installing make-up valve (12) to cap
with socket bolts (21) (8 used).
(18) side, it is easy to be tightened if it is
Then install spool (13) while rotating it to insert
installed from inlet section (37) side in
plug (32) into the slot in spool end (30).
order.
: 14 mm
: 185 N⋅m (19 kgf⋅m, 137 Ibf⋅ft)
20. Install overload relief valves (11) (5 used), (26) (2
15. Install O-rings (17) (4 used) to caps (18) (4 used), used) into housings (41, 34, 27).
then install them into housings (40, 41, 34, 27)
: 14 mm
: 185 N⋅m (19 kgf⋅m, 137 Ibf⋅ft)
W2-5-15
DISASSEMBLE AND ASSEMBLE MAIN
RELIEF VALVE, OVERLOAD RELIEF
VALVE
3 4 7 11 12 5 1 11 2
14
13
15
17
W18B-02-04-009
16
9 10 6 8
1- Cap 6- Pilot Poppet 11 - O-Ring 16 - O-Ring

2- Plug 7- Spring 12 - Name Plate 17 - Backup Ring
3- Sleeve 8- Pilot Spring 13 - Lock Nut
4- Main Poppet 9- O-Ring 14 - O-Ring
5- Pilot Seat 10 - Backup Ring 15 - Adjusting Screw
W2-5-16
Disassemble and Assemble Main Relief Valve, Assemble
1. Install O-ring (16) and backup ring (17) onto main
IMPORTANT: It is necessary to test the poppet (4).
performance of the overload relief
valve itself and adjust it. Do not 2. Install main poppet (4) into sleeve (3).
disassemble it unless problem is
found.
3. Install O-ring (9) and backup ring (10) onto pilot
Disassemble seat (5).
1. Put matching marks onto plug (2) and adjusting 4. Install spring (7) into sleeve (3).
screw (15).
5. Install plug (2) into sleeve (3).
2. Attach spanner on plug (2), loosen lock nut (13) to NOTE: When installing plug (2) into sleeve (3),
remove adjusting screw (15). At this time, take sleeve (3) should be placed vertically.
care not to drop pilot spring (8) and pilot poppet
(6). IMPORTANT: When inserting pilot poppet (6) in,
: 17 mm, 38 mm be sure that it is installed into pilot
: 6 mm seat (5) securely.
6. Install pilot poppet (6) and pilot spring (8) into plug
IMPORTANT: Pilot seat (5) is secured onto plug (2), (2), then align the matching marks made before
so it cannot be disassembled. disassembling. Install adjusting screw (15) onto
3. Secure cap (1) in a vise, loosen and remove plug plug (2) and lock them with lock nut (13).
(2) from cap (1). At this time, plug (2) is still with : 17 mm
pilot seat (5) on it. : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 38 mm : 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
4. Remove spring (7) and sleeve (3) from cap (1).
7. Install O-ring (11) to plug (2) then install the plug
5. Remove O-ring (9) and backup ring (10) from pilot to cap (1).
seat (5). : 38 mm
: 150 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
6. Remove main poppet (4) from sleeve (3).

IMPORTANT: When assembling work is finished,
be sure to check that main poppet
7. Remove O-ring (16) and backup ring (17) from (4) can move up and down.
main poppet (4).
W2-5-17
MAKE-UP VALVE CONSTRUCTION
3 7 8 2 6 9 1
W18B-02-04-008
4 5
Torque
Part Name Q’ty Remarks
N⋅m kgf⋅m (Ibf⋅ft)
1- Plug 1 98 10 (72) : 38 mm
2- Sleeve 1
3- Poppet 1
4- Washer 1
5- Lock Nut 1
6- Spring 1
7- O-Ring 1
8- Backup Ring 1
9- O-Ring 1
W2-5-18
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
IMPORTANT: Be sure to bleed air from hydraulic

Removal
1. Disconnect all pipes from swing device (1).
: 19 mm, 36 mm, 41 mm
: 10 mm
NOTE: Cap all disconnected pipe openings.
2. Disconnect the swing device upper side on the

hoses (Rear side 3 used, front side 2 used) for
front.
: 14 mm, 17 mm
M117-07-082
3. Put mating marks on swing device (1) and the 1 2
frame.
4. Remove bolts (2) (25 used) from the frame.

Remove the cork from pulling-out bolt holes (4
used) in the flange of swing device (1). Screw the
pulling-out bolts (M33, Pitch 3.0 mm) in the two
pulling-out bolt holes in swing device and raise
swing device (1) from the frame.
: 50 mm
CAUTION: Swing device (1) weight:

1950 kg (4300 lb)
5. Remove pulling-out bolts (4 used) from the flange

of swing device (1) and install eyebolts (M33,
Pitch 3.0 mm) (4 used) instead.
Then, hoist swing device (1) and remove it by
crane.
W2-6-1
Installation
CAUTION: Swing device (1) weight:
1950 kg (4300 lb)
1. Install eyebolts (M33, Pitch 3.0 mm) (4 used) into

pulling-out bolt holes (4 places) in the flange of
swing device (1).
Lift swing device (1) by crane and lower to place it
on the frame. At this time, align the mating marks
when disassembling.
2. Install swing device (1) into the frame with bolts

(2) (25 used). Then remove eyebolt.
: 50 mm
: 2550 N⋅m (260 kgf⋅m, 1880 lbf⋅ft)
3. Connect the pipes and hoses to swing device (1).

: 10 mm 1 2
M117-07-082
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)
NOTE: Take notice of the length of socket bolts
which are used to install the flange of hose.
They are different in length.
M12, Length 60 mm
M12, Length 45 mm
W18B-02-05-001
4. Connect the swing device upper side on the hoses

(Rear side 3 used, front side 2 used) for front.
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
: 17 mm
: 540 N⋅m (55 kgf⋅m, 410 lbf⋅ft)
5. Be sure to check that proper quantity of lubricant

(gear oil #90) is filled into the reduction gear with a
level gauge.
Oil quantity: 100 L (26.4 US gal)
W2-6-2
(Blank)
W2-6-3
DISASSEMBLE SWING REDUCTION GEAR
33
1 14
15 34
16
35
2
36
5
17
37
18
6 38
19 21
7 39
8 20 22
23 40 41
9 24 42
22 43
10
21 44
11
45
12
25 46
13 26 47
27
48
28
49
29 26 50
30 31 25 51
32
W117-02-04-003
1 - Swing Motor 15 - Stud Bolt (4 Used) 27 - Retaining Ring (4 Used) 39 - Bearing
2 - Bolt (24 Used) 16 - Washer (4 Used) 28 - Second Stage Planetary 40 - O-Ring
Gear (4 Used)
3- Washer (24 Used) 17 - Bolt (6 Used) 29 - Pin (4 Used) 41 - Retainer
4- Cover 18 - Lock Washer (3 Used) 30 - Lock Plate (4 Used) 42 - O-Ring
5- First Stage Ring Gear 19 - Lock Plate (3 Used) 31 - Lock Washer (4 Used) 43 - Oil Seal
6- First Stage Sun Gear 20 - Pin 32 - Bolt (8 Used) 44 - Cover
7- Thrust Plate 21 - Bearing (6 Used) 33 - Second Stage Ring Gear 45 - Washer (14 Used)
8- Retaining Ring 22 - Spacer (6 Used) 34 - Retaining Ring 46 - Bolt (14 Used)
9- First Stage Carrier 23 - Retaining Ring (3 Used) 35 - Bearing 47 - Pinion Gear
10 - Second Stage Sun Gear 24 - First Stage Planetary 36 - Housing 48 - Plate
Gear (3 Used)
11 - Bolt (4 Used) 25 - Bearing (8 Used) 37 - Shaft 49 - Washer (4 Used)
12 - Thrust Plate 26 - Spacer (8 Used) 38 - Deflector 50 - Bolt (4 Used)
13 - Second Stage Carrier 51 - Wire
14 - Nut (4 Used)
W2-6-4
Disassemble Swing Reduction Gear
CAUTION: Swing device weight: CAUTION: Cover (4) weight: 56 kg (120 lb)
1950 kg (4300 lb)
5. Remove bolts (2) (24 used), install eyebolts (M20,
1. Place the swing device on a workbench, drain the Pitch 2.5 mm) to the lifting hole of cover (4), then
gear oil from drain cock. lift and remove the cover from ring gear (5).
Gear oil: Approx. 100 L (26.4 US gal) : 41 mm
: 36 mm
CAUTION: First stage ring gear (5) weight:

CAUTION: Swing motor (1) weight: 110 kg (240 lb)
230 kg (510 lb) Second stage ring gear (33) weight:
120 kg (260 lb)
2. Loosen nuts (14) (4 used). Remove two of the 12
cover mounting bolts from swing motor (1) (Refer 6. Install eyebolts (M16, Pitch 2.0 mm) to the lifting
to the illustration for Disassemble Swing Motor on holes in first stage ring gear (5) and lift up to
page W2-6-18), then install eyebolts (M16, Pitch remove first stage ring gear (5) from second stage
2.0 mm). Lift and remove swing motor (1) from the ring gear (33) by crane. In the same way, install
swing reduction gear by crane. eyebolts (M16, Pitch 2.0 mm) to the lifting holes of
: 24 mm, 30 mm second stage ring gear (33), then lift and remove
second stage ring gear (33) from housing (36) by
CAUTION: Swing reduction gear weight: crane.
1720 kg (3800 lb)
7. Remove first stage sun gear (6) and thrust plate
3. Install eyebolts (M33, Pitch 3.0 mm) (2 used) to (7) from first stage carrier (9).
pulling-out bolt holes (4 places) in housing (36).
Lift and place the swing reduction gear on a
workbench by crane with pinion gear (47)
face-down.
Workbench
Pinion Gear
400 mm
(15.7 in)
W141-02-06-002
4. Put the matching marks on cover (4), ring gears

(5, 33) and housing (36).
W2-6-5
34
35
36
37
38
39
40
9 41
42
10
43
11 44
12
45
46
13
47
48
49
50
29
51
W117-02-04-003
W2-6-6
CAUTION: First stage carrier (9) CAUTION: Pinion gear (47) weight:
assembly weight: 125 kg (280 lb) 150 kg (330 lb)
8. Install eyebolts (M16, Pitch 2.0 mm) to the lifting 14. Install eyebolts (M12, Pitch 1.75 mm) to the lifting
holes on first stage carrier (9), lift and remove the holes in pinion gear (47), then lift and remove it
first stage carrier (9) assembly (with second stage from shaft (37) by crane.
sun gear (10) attached) from second stage carrier
(13) by crane.
CAUTION: Cover (44) weight: 25 kg (60 Ib)
9. Loosen bolts (11) (4 used) to remove thrust plate
(12) from shaft (37). 15. Remove bolts (46) (14 used) and washers (45)
: 30 mm (14 used) to remove cover (44) from housing (36).
: 27 mm
CAUTION: Second stage carrier (13)
assembly weight: 185 kg (410 lb) 16. Remove oil seal (43) and O-ring (42) from cover
(44).
10. Install eyebolts (M16, Pitch 2.0 mm) into the
center holes in pin (29) (4 used). Lift and remove 17. Remove retainer (41) from shaft (37) to remove
the second stage carrier (13) assembly from shaft O-ring (40) from retainer (41).
(37) by crane.
NOTE: By placing the second stage carrier (13)
assembly on the wooden block, the CAUTION: Shaft (37) assembly weight:
following work is easy to do. 340 kg (750 lb)
13
screw hole for bolt (50) in shaft (37), then, lift and
remove the shaft from housing (36) by crane.
NOTE: The shaft (37) is still with bearings (35, 39)
and deflector (38).
Wooden Block
(Height: 200 mm (7.9 in)) W18B-02-05-003
11. Remove retaining ring (34) from housing (36).
CAUTION: Housing (36) assembly weight:

975 kg (2150 lb)
12. Attach a nylon sling to housing (36) body to hoist

and turn over it. (Pinion gear (47) turned in the
upper side)
13. Cut wire (51) to remove bolts (50) (4 used),

washers (49) (4 used) and plate (48).
: 46 mm
W2-6-7
35
37
18
7
38
8 19 21
20 22
39
23
9 24
21
25
26
13 27
28
26
29 31 25
30 32
W117-02-04-003
W2-6-8
CAUTION: Bearing (35) weight: 23 kg (51 lb) CAUTION: Second stage carrier (13)
Bearing (39) weight: 80 kg (180 lb) assembly weight: 185 kg (410 lb)
19. Pulling out bearings (35, 39) from shaft (37) with a 22. Disassemble the second stage carrier (13)
press. assembly as follows.
• Install eyebolts (M16, Pitch 2.0 mm) into the lifting
20. Remove deflector (38) from shaft (37). holes in pin (29).
• Holding pin (29) by crane.
• Straighten the bending of lock washer (31),
CAUTION: First stage carrier (9) remove bolts (32) (2 used) from second stage
assembly weight: 125 kg (280 lb) carrier (13).
First stage carrier (9) weight: 60 kg (130 lb) : 24 mm
• Remove lock plate (30) from pin (29), lift and
21. Disassemble the first stage carrier (9) assembly remove pin (29) from second stage carrier (13) by
as follows. crane.
• Straighten the bending of lock washer (18), • Remove the second stage planetary gear (28)
remove bolts (17) (2 used) from first stage carrier assembly from second stage carrier (13).
(9). (3 places) • Remove bearings (25) (2 used), spacers (26) (2
: 24 mm used) and retaining ring (27) from second stage
• Remove lock plate (19) from pin (20) to remove planetary gear (28).
pin (20) from first stage carrier (9). (3 places) • Disassemble the left pin (29) and second stage
• Remove the first stage planetary gear (24) planetary gear (28) in the same way.
assembly from first stage carrier (9). (3 places)
• Remove bearings (21) (2 used), spacers (22) (2
used) and retaining ring (23) from first stage
planetary gear (24). (3 places)
• Remove retaining ring (8) from second stage sun
gear (10).
• Install eyebolts (M16, Pitch 2.0) into the lifting
hole in first stage carrier (9), then, lift and remove
it from second stage sun gear (10) by crane.
W2-6-9
ASSEMBLE SWING REDUCTION GEAR
8 6 7 15
1
14
4 16
2 17
18, 19
3
21
9 22
5 23
24
20
28
13 27
26
33 25
10 29
11 30, 31
12
32
34
35
36
37
38
39
44
45 42
46 40
43
41 47
W141-02-06-003
48 51 50 49
1- Swing Motor 15 - Stud Bolt (4 Used) 27 - Retaining Ring (4 Used) 39 - Bearing

2- Bolt (24 Used) 16 - Washer (4 Used) 28 - Second Stage Planetary 40 - O-Ring
3- Washer (24 Used) 17 - Bolt (6 Used) Gear (4 Used) 41 - Retainer
4- Cover 18 - Lock Washer (3 Used) 29 - Pin (4 Used) 42 - O-Ring
5- First Stage Ring Gear 19 - Lock Plate (3 Used) 30 - Lock Plate (4 Used) 43 - Oil Seal
6- First Stage Sun Gear 20 - Pin 31 - Lock Washer (4 Used) 44 - Cover
7- Thrust Plate 21 - Bearing (6 Used) 32 - Bolt (8 Used) 45 - Washer (14 Used)
8- Retaining Ring 22 - Spacer (6 Used) 33 - Second Stage Ring Gear 46 - Bolt (14 Used)
9- First Stage Carrier 23 - Retaining Ring (3 Used) 34 - Retaining Ring 47 - Pinion Gear
10 - Second Stage Sun Gear 24 - First Stage Planetary 35 - Bearing 48 - Plate
11 - Bolt (4 Used) Gear (3 Used) 36 - Housing 49 - Washer (4 Used)
12 - Thrust Plate 25 - Bearing (8 Used) 37 - Shaft 50 - Bolt (4 Used)
13 - Second Stage Carrier 26 - Spacer (8 Used) 38 - Deflector 51 - Wire
14 - Nut (4 Used)
W2-6-10
Assemble Swing Reduction Gear
CAUTION: First stage carrier (9) weight: CAUTION: Second stage carrier (13) weight:
60 kg (130 lb) 105 kg (230 lb)
1. Assemble the first stage carrier (9) assembly as 2. Assemble the second stage carrier (13) assembly
follows. as follows.
• Install retaining ring (23), spacers (22) (2 used) • Install retaining ring (27), spacers (26) (2 used)
and bearings (21) (2 used) to first stage planetary and bearings (25) (2 used) to second stage
gear (24). (3 places) planetary gear (28).
• Install eyebolts (M16, Pitch 2.0 mm) into the lifting • Install the second stage planetary gear (28)
holes (3 used) in first stage carrier (9). Lift and assembly to second stage carrier (13).
install first stage carrier (9) onto second stage sun • Install eyebolts (M16, Pitch 2.0 mm) into the lifting
gear (10) by crane. holes in pin (29). Lift it by crane.
• Install retaining ring (8) to second stage sun gear • Insert pin (29) into the pin hole in second stage
(10). carrier (13). As soon as the groove in lock plate
• Install the first stage planetary gear (24) assembly (30) is coming out from the bottom side of second
onto first stage carrier (9). (3 places) stage carrier (13), hole it in position.
• Insert lock plate (19) into the groove for it in pin • Install lock plate (30), lock washer (31) and bolts
(20), then install pin (20) into first stage carrier (9). (32) (2 used) to pin (29).
(3 places) : 24 mm
• Install lock washer (18) and bolts (17) (2 used) to : 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
first stage carrier (9). (3 places) • Bend lock washer (31) along bolts (32) (2 used)
: 24 mm head to thrust it.
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft) • Assemble the left pin (29) and second stage
• Bend both ends of lock washer (18) along the planetary gear (28) in the same way.
bolts (17) (2 used) to thrust it. (3 places)
3. Install retaining ring (34) onto housing (36).
W2-6-11
13
29
35
36 37
38
39
44
45 42
46
40
47
43
41
W141-02-06-003
48 51 50 49
W2-6-12
CAUTION: Bearing (39) weight: 80 kg CAUTION: Cover (44) weight: 25kg (60 lb)
(180 lb)
11. Install cover (44) onto housing (36) with bolts (46)
4. Heat bearing (39) to 60 °C (140 °F) with oil bath (14 used) and washers (45) (14 used).
or heater, then press it into shaft (37). : 27 mm
NOTE: Fitting bearing (39), the outer race and : 295 N⋅m (30 kgf⋅m, 220 Ibf⋅ft)
inner race at same time by pressing.
CAUTION: Pinion gear (47) weight: 150 kg
5. Install deflector (38) into shaft (37). (330 lb)
IMPORTANT: Install pinion gear (47) with plate (48)

CAUTION: Bearing (35) weight: 23 kg (50 lb)
mounting side facing forward.
12. Install eyebolts (M12, Pitch 1.75 mm) into lifting
6. Heat bearing (35) to 60 °C (140 °F) with oil bath hole in pinion gear (47). Lift and install pinion gear
or heater, then press it into shaft (37). (47) into shaft (37) by crane.
IMPORTANT: Install retainer (41) with the groove 13. Install plate (48) onto shaft (37) with bolts (50) (4
in O-ring (40) facing bearing (39) used) and washers (49) (4 used). After tightening
side. bolt (50), bend wire (51) to secure it.
7. Install O-ring (40) to retainer (41). : 46 mm
: 1950 N⋅m (200 kgf⋅m, 1450 Ibf⋅ft)
8. Install retainer (41) onto shaft (37) with the side
that O-ring (40) installed facing inside.
CAUTION: Housing (36) assembly weight:
975 kg (2150 lb)
CAUTION: Shaft (37) assembly weight:
340 kg (750 lb)
IMPORTANT: Place a wooden block under the
mounting flange on main frame to
9. Install eyebolts (M30, Pitch 3.0 mm) into the hole
prevent housing (36) from tilting.
for bolt (50) in shaft (37). Lift and install shaft (37)
14. Attach nylon sling to the body of housing (36). Lift
into housing (36) by crane. Tap the housing to
and turn the housing over to place it on a
listen to the ring to confirm whether installation is
workbench.
completed.
10. Install oil seal (43) and O-ring (42) onto cover (44).
CAUTION: Second stage carrier (13)
Then install oil seal (43) with its lip facing inside.
assembly weight: 185 kg (410 lb)
15. Install eyebolts (M16, Pitch 2.0 mm) to lifting hole

in pins (29) (4 used). Install the second stage
carrier (13) assembly into shaft (37) with their
spline aligned.
W2-6-13
6 7
Lifting Hole
Lifting Hole
13
33
11
12
37
36
Lifting Hole Lifting Hole

W141-02-06-003
W2-6-14
IMPORTANT: Install thrust plate (12) with the oil
groove facing upward.
16. Apply LOCTITE #242 to bolts (11) (4 used), then
install thrust plate (12) onto shaft (37).
: 30 mm
: 540 N⋅m (55 kgf⋅m, 400 Ibf⋅ft)
CAUTION: First stage (9) assembly weight:

125 kg (280 lb)
17. Install eyebolts (M16, Pitch 2.0 mm) into lifting

hole in first stage carrier (9). Lift the first stage
carrier (9) assembly by crane and install it to
second stage carrier (13).
IMPORTANT: Install thrust plate (7) with the oil

groove facing downward.
18. Install thrust plate (7) and first stage sun gear (6)
to first stage carrier (9).
CAUTION: Second stage ring gear (33)

weight: 120 kg (260 lb)
19. Apply THREEBOND #1215 on the mounting

surface of second stage ring gear (33) on housing
(36). Install eyebolts (M16, Pitch 2.0 mm) into the
lifting hole in second stage ring gear (33). Then lift
and install it onto housing (36) by crane.
At this time align the hole for bolt (2) in second
stage ring gear (33) with the hole in housing (36).
W2-6-15
14
Lifting Hole
16
1
4
2
3
Lifting Hole
33
37
Lifting Hole Lifting Hole

W141-02-06-003
W2-6-16
CAUTION: First stage ring gear (5) weight:

110 kg (240 lb)
20. Apply THREEBOND #1215 on the first stage ring

gear (5) mounting surface of second stage ring
gear (33). Install eyebolts (M16, Pitch 2.0 mm) to
the lifting hole in first stage ring gear (5), then lift
and install first stage ring gear (5) onto second
stage ring gear (33) by crane.
At this time, align the hole for bolt (2) in first stage
ring gear (5) with the hole in second stage ring
gear (33).
CAUTION: Cover (4) weight: 56 kg (120 lb)
21. Apply THREEBOND #1215 on the cover (4)

mounting surface of first stage ring gear (5).
Install eyebolts (M20, Pitch 2.5 mm) to the lifting
hole in cover (4), then lift and install cover (4) onto
first stage ring gear (5) by crane.
22. Tighten cover (4) with bolts (2) (24 used) and
washers (3) (24 used).
: 41 mm
: 1030 N⋅m (105 kg⋅m, 760 Ibf⋅ft)
23. Fill the gear oil to the swing device.

Gear oil: 100 L (26.4 US gal)
24. Align the matching surface of swing motor (1) and

cover (4), apply THREEBOND #1215 on them.
CAUTION: Swing motor (1) weight:

230 kg (510 lb)
25. Remove two of 12 cover mounting bolts (Refer to

the illustration of Disassemble Swing Motor on
page W2-6-18) from swing motor (1). Install
eyebolts (M16, Pitch 2.0 mm) and lift it by crane.
Install swing motor (1) onto cover (4) with nuts
(14) (4 used) and spring washers (16) (4 used).
: 30 mm
: 390 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)
W2-6-17
DISASSEMBLE SWING MOTOR
10
9 11
5
6
7
6
5 12
4 13
3
14
2 15
1
16
17 14
18
19
20
21
22
23 32
24
25
26
27
31
28
30
33
34
29
35
36
37
38
39
38
W118-02-04-002
39
38
1- Socket Bolt (6 Used) 11 - O-Ring (2 Used) 21 - Guide Ring 31 - Bolt (12 Used)
2- Cover 12 - Shim 22 - Valve Plate 32 - Socket Bolt (9 Used)
3- O-Ring 13 - Spacer 23 - Rotor 33 - Cover
4- Oil Seal 14 - Retaining Ring (2 Used) 24 - Disc Spring (4 Used) 34 - O-Ring
5- Retaining Ring (2 Used) 15 - Coupling 25 - Shim 35 - Piston
6- Spacer (2 Used) 16 - Socket Bolt (3 Used) 26 - Holder 36 - Piston Ring
7- Bearing 17 - Cover 27 - Retainer 37 - Piston Ring
8- Shaft 18 - Pin 28 - Plunger (9 Used) 38 - Plate (9 Used)
9- Casing 19 - O-Ring 29 - Shoe Plate 39 - Friction Plate (8 Used)
10 - Plug (2 Used) 20 - Bearing 30 - Spring (12 Used)
W2-6-18
Disassemble Swing Motor
CAUTION: Swing motor weight: 195 kg 7. Remove piston rings (36, 37) from piston (35).
(430 lb)
8. Remove retaining rings (14) and coupling (15)
1. Place the swing motor on a workbench. Remove from shaft (8).
plug (10) from casing (9) to drain hydraulic oil.
: 36 mm
9. Remove plates (38) (9 used), friction plates (39)
(8 used), shim (12) and spacer (13) from cover
2. Remove bolts (31) (2 used) diagonally. Install (17).
eyebolts (M16, Pitch 2.0 mm).
Lift the swing motor by crane and place it on
wooden blocks (2 used) vertically. 10. Remove retaining ring (14) from shaft (8).
: 24 mm
IMPORTANT: Valve plate (22) may come off
Swing Motor together with cover (17). Take care
not to drop valve plate (22).
11. After removing socket bolts (16) (3 used) and (32)
Wooden Block (9 used), install eyebolts (M16, Pitch 2.0 mm) into
the hole for bolt (31) in cover (17). Lift it by crane
and remove cover (17) from casing (9).
150 mm : 14 mm
(5.9 in)
W18B-02-05-004 12. Remove valve plate (22), guide ring (21) and
O-ring (19) from cover (17).
3. Put matching marks on casing (9) and covers (17, NOTE: Do not remove bearing (20) unless
33). necessary.
4. Loosen bolts (31) (10 used) evenly. Remove 13. Lay casing (9) on a workbench with the main pipe
cover (33) from cover (17). Remove O-ring (34) mounting surface facing upward.
from cover (33).
: 24 mm
NOTE: Cover (33) gradually comes up by spring CAUTION: Rotor (23) assembly weight:
(30) force. 41 kg (90 lb)
5. Remove springs (30) (12 used) from cover (17). 14. Attach the nylon sling on the body of rotor (23) to
remove it from casing (9). At this time, plunger
(28), holder (26) and retainer (27) can be
6. Install eyebolts (M16, Pitch 2.0 mm) to the center
removed together with rotor (23).
hole of piston (35). Lift and remove piston (35)
from cover (17) by crane.
15. Attach the vinyl tape to the inner race of bearing
(20) to protect it.
W2-6-19
5
6
7
6
5
4
3
2
1
23
24
25
26
27
28
33
29
W118-02-04-002
W2-6-20
16. Remove plungers (28) (9 used), retainer (27),
holder (26), disc spring (24) and shim (25) from
rotor (23).
17. Remove socket bolts (1) (6 used) to remove cover

(2) from casing (9).
: 8 mm
18. Remove oil seal (4) and O-ring (3) from cover (2).
19. Tap shaft (8) at cover (33) side with a plastic

hammer to remove the shaft from casing (9).
20. Remove retaining rings (5) (2 used) from shaft (8)

to remove spacers (6) (2 used).
21. Push shaft (8) with a press to pull out the inner
race of bearing (7).
22. Tap shoe plate (29) with a copper bar to remove it

from casing (9).
23. Tap the outer race of bearing (7) with a copper bar
to remove it from casing (9).
W2-6-21
ASSEMBLE SWING MOTOR
16 34 30 14 35 33 15 31
36
Measure Clearance A
37
38
39
17 32
12
13
19
20
18
21 22
9
23
11
10
10
11 24
25
26
28
5
6
27
7
W117-02-04-005
29 1 2 4 8 5 6 3
1- Socket Bolt (6 Used) 11 - O-Ring (2 Used) 21 - Guide Ring 31 - Socket Bolt (12 Used)
2- Cover 12 - Shim 22 - Valve Plate 32 - Socket Bolt (9 Used)
3- O-Ring 13 - Spacer 23 - Rotor 33 - Cover
4- Oil Seal 14 - Retaining Ring (2 Used) 24 - Disc Spring (4 Used) 34 - O-Ring
5- Retaining Ring (2 Used) 15 - Coupling 25 - Shim 35 - Piston
6- Spacer (2 Used) 16 - Socket Bolt (3 Used) 26 - Holder 36 - Piston Ring
7- Bearing 17 - Cover 27 - Retainer 37 - Piston Ring
8- Shaft 18 - Pin 28 - Plunger (9 Used) 38 - Plate (9 Used)
9- Casing 19 - O-Ring 29 - Shoe Plate 39 - Friction Plate (8 Used)
10 - Plug (2 Used) 20 - Bearing 30 - Spring (12 Used)
W2-6-22
Assemble Swing Motor
1. Install retaining ring (5) and spacer (6) onto the IMPORTANT: The sliding surface of rotor (23) may
rotor side of shaft (8). be in contact with that of valve plate.
Take care not to damage it.
2. Install the inner race and inner plate of bearing (7), 9. Assemble rotor (23) as follows.
then heat them to temperature of approx. 60 °C • Place rotor (23) with its sliding surface facing
(140 °F) with heater or oil bath. down.
• Then assemble disc springs (24) (4 used) on the
3. Press bearing (7) onto shaft (8) with the inner boss so that the outer race is matching with the
plate facing inside with a press. outer race, inner race is matching with the inner
race.
4. Install spacer (6) and retaining ring (5) to shaft (8). Then put shim (25) over the spring and cover
them with holder (26). At this time, holder (26)
5. While tapping the outer race of bearing (7) with a should align with the spline in rotor (23).
copper bar, install shaft (8) into casing (9). 25
24
6. Press oil seal (4) in cover (2) and install O-ring (3)
onto cover (2). 26
7. Secure cover (2) to casing (9) with socket bolts 23

(1) (6 used).
: 8 mm
: 57 N⋅m (5.8kgf⋅m, 42 Ibf⋅ft)
W18B-02-04-010
IMPORTANT: Install shoe plate (29) with the

• Put retainer (27) on holder (26) with its chamfer
chamfer part facing inside.
side facing down.
IMPORTANT: When shoe plate (29) has been
installed, rotate it by hand. If it can’t 27
be turned, seizure will result. It
should be re-assembled in such
case.
8. Apply grease on the chamfer surface and outer
race of shoe plate (29).
Install shoe plate (29) into casing (9). Chamfer Side
W176-02-06-016
26
• Align the plunger hole of retainer (27) with that of

rotor (23), then inset plungers (28) (9 used).
CAUTION: Rotor (23) assembly weight:

41 kg (90 lb)
10. Assemble the rotor (23) assembly into shaft (8).
W2-6-23
16 34 30 14 35 33 15 31
36
37
38
39
17 32
12
13
19
18
21 22
11
10
10
11
W117-02-04-005
8
W2-6-24
11. Install guide ring (21) and O-ring (19) onto cover IMPORTANT: Align the notches on plates (38) (9
(17). used) and friction plates (39) (8
used). Adjust shims (12) so that the
12. Apply grease to valve plate (22). Install valve depth from cover (17) end face to
plate (22) on cover (17) while aligning pin (18) plate (38) surface is 3.3 mm (0.13 in).
position.
17
CAUTION: Casing (9) assembly weight:

120 kg (265 lb) A
13. Install eyebolts (M16, Pitch 2.0 mm) into the cover
mounting bolts (32) hole in casing (9). 38
Lift casing (9) by crane and place it on the
wooden block vertically.
W18B-02-04-013
Wooden Block 9
(Height 150 mm 17. Install plates (38) (9 used) and friction plates (39)
(5.9 in))
(8 used) alternately in this order into the space
between cover (17) and coupling (15).
18. Install piston rings (36, 37) onto piston (35).
19. Install piston (35) into cover (17).
W18B-02-04-011 20. Install springs (30) (12 used) on piston (35).
IMPORTANT: Take care not to drop valve plate (22) 21. After installing O-ring (34) onto cover (33), secure
from cover (17). cover (33) to cover (17) with socket bolts (31) (12
14. Secure cover (17) onto casing (9) with socket used).
bolts (16) (3 used) and (32) (9 used). : 24 mm
: 14 mm : 235 N⋅m (24 kgf⋅m, 175 Ibf⋅ft)
: 210 N⋅m (21.5 kgf⋅m, 47 Ibf⋅ft)
22. Install O-rings (11) (2 used) onto plugs (10) (2
15. Install retaining ring (14), coupling (15) and used). Install plugs (10) (2 used) into casing (9).
retaining ring (14) onto shaft (8). : 36 mm
: 167 N⋅m (17 kgf⋅m, 123 Ibf⋅ft)
16. Install spacer (13) and shims (12) in cover (17).
W2-6-25
MAINTENANCE STANDARD Dial Gauge
1. Clamp the plunger in a vise. Set a dial gauge on

the shoe. Measure clearance (A) between the
plunger spherical tip and the shoe bottom while
moving the shoe up and down. A
If clearance (A) is over the allowable limit, replace
the plunger and shoe as an assembly. Guide
Unit: mm (in)
Standard Dimension Allowable Limit
A 0 0.3 (0.01)
Vise W115-02-04-062
2. Measure plunger diameter (B) at three places Cushion

(upper, middle and lower), with a micrometer.
Measure rotor bore (C) at two places with a
cylinder gauge. （B）（B）（B）
Unit: mm (in)
Standard Dimension Allowable Limit W115-02-04-065
C-B 0.045 (0.002) 0.096 (0.004 )
（C）（C）
（C）（C）
3. Measure shoe flange thickness (D) with a

micrometer.
W115-02-04-066
Unit: mm (in)
D 10.0 (0.4) 9.8 (0.4)
4. Measure height H and h.

E=H-h
（D）
W115-02-04-068
Unit: mm (in)

E 47.5 (1.9) 46.7 (1.8) 26 27
H
h
W115-02-04-069
W2-6-26
5. Measure dimension (F).
17
Unit: mm (in) F
F 3.3 (0.1) 4.3 (0.2)
38
Remedy: Adjust shims.
6. Measure the disc spring height.

W18B-02-04-013
Unit: mm (in)
Cover
I-i 7.8 (0.3) 7.4 (0.3)
Casing
Valve Plate
i
7. Measure the brake spring length.
Unit: mm (in) W117-02-04-006

54 (2.1) 53.6 (2.1)
Remedy: Replace the spring.
8. Measure the thickness of the plate and friction

plate (17 used in total).
Unit: mm (in)

36.8 (1.5) 36.2 (1.4)
Remedy: Replace the plates and friction plates.
W2-6-27
DISASSEMBLE AND ASSEMBLE VALVE
UNIT
1 2 3 4 5 4 3 2
6 6
W118-02-04-003
11 10
1 - Plug (2 Used) 4 - Poppet (2 Used) 7 - O-Ring (2 Used) 10 - O-Ring (2 Used)

2 - O-Ring (2 Used) 5 - Housing 8 - Relief Valve (2 Used) 11 - Backup Ring (4 Used)
3 - Spring (2 Used) 6 - Plug (2 Used) 9 - Plug (2 Used)
W2-6-28
Disassemble Valve Unit Assemble Valve Unit
1. Install the relief valve (8) assemblies (2 used) to

CAUTION: Valve unit weight: 31kg (68 lb)
housing (5).
: 41 mm
1. Loosen plugs (1) (2 used) to remove springs (3) : 176 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
(2 used) and poppets (4) (2 used).
: 14 mm
2. Install plugs (9) (2 used) to housing (5).
: 41 mm
2. Remove plugs (6) (2 used). : 176 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 6 mm
3. Install plugs (6) (2 used) to housing (5).
3. Remove plugs (9) (2 used). : 6 mm
: 41 mm : 36 N⋅m (3.7 kgf⋅m, 27 Ibf⋅ft)
IMPORTANT: Do not disassemble the relief valve 4. Install spring (3) to poppet (4) and insert the
(8) assembly. poppet to housing (5). (2 places)
4. Attach the spanner to the body of relief valve (8) Install plugs (1) (2 used) to housing (5).
assembly, remove the relief valve from housing : 14 mm
(5). (2 places) : 334 N⋅m (34 kgf⋅m, 250 Ibf⋅ft)
: 41 mm
W2-6-29
(Blank)
W2-6-30
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL FRONT / SWING
1
PILOT VALVE
2
oil tank before starting work. (Refer 2 6
5
to “item of Bleeding Air from Hy- 4 3
draulic Oil Tank” on page W1-3-1) 5
6
Removal 8 10
1. Remove bolts (10) (21 used) from stand (15) to

remove covers (11, 12). 7
8 11
: 10 mm
9 15
2. Raise boots (5) on the left lever to disconnect
plug (3).
10
3. Raise boots (5) (2 used) and loosen lock nuts (4) 12

(2 used) to remove levers (2) (2 used) with grip
(1) together. 13
: 19 mm
14
4. Remove boots (5) (2 used) from pilot valves (8)

(2 used).
W18B-02-06-005
5. Remove grips (14) (2 used) to remove cloth (13)

(2 used).
: 17 mm
IMPORTANT: Put tags on disconnected hoses for

identification to aid in re-assembly.
(Refer to page W2-7-6 for port loca-
tions.)
6. Disconnect all hoses (9) (12 used) from pilot
valves (8) (2 used).
: 22 mm
IMPORTANT: Put the mating marks on pilot valve

(8) and stand (15) to aid in re-as-
sembly.
7. Remove bolts (6) (8 used) to remove packing (7)
(2 used) and pilot valves (8) (2 used) from stand
(15).
: 10 mm
W2-7-1
Installation
1
2
1. Insert pilot valves (8) (2 used) into stand (15) and
align the mating marks made when disassem- 4
2 6
bling. 5
4 3
2. Install packing (7) (2 used) and pilot valves (8) (2 5
used) to stand (15) with bolts (6) (8 used). 6
: 10 mm 8 10
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.2 to 2.9 Ibf⋅ft)
7
8 11
3. Connect the hoses (9) (12 used) to pilot valves
(8) (2 used).
9 15
: 22 mm
: 40 N⋅m (4 kgf⋅m, 29.0 Ibf⋅ft)
10
4. Insert levers (2) (2 used) (with grip (1)) into boots 12

(5) (2 used). Install levers (2) (2 used) into pilot
valves (8) (2 used). When installing, lever (2) with 13
horn button should be installed on left side.
14
5. Secure levers (2) (2 used) to pilot valves (8) (2
used) with lock nuts (4) (2 used).
: 19 mm W18B-02-06-005
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
6. Raise boot (5) to connect plug (3).
7. Attach cloth (13) to hose (9) and secure it with

grips (14) (2 used). (2 places both on left and
right)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
8. Install covers (11, 12) with bolts (10) (21 used) on

the stands.
: 10 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.2 to 2.9 Ibf⋅ft)
W2-7-2
REMOVE AND INSTALL TRAVEL AND
BUCKET OPEN / CLOSE PILOT VALVE

to “item of Bleeding Air from Hy-
draulic Oil Tank” on page W1-3-1)
Removal
1. Remove bolts (10) (4 used) and (14) (4 used) to

remove supports (9, 17) from cover (12).
: 10 mm
1 2
2. Remove bolts (15) (4 used) to remove cover (13) 3
from cover (12).
2 23
: 17 mm
7
5
3. Remove bolts (11) (8 used) to remove cover (12) 4
from the floor. 8
: 17 mm
22
21 9
4. Remove bolts (7) (6 used) to remove covers (8, 20 10
5 6 11
16) from the floor.
: 17 mm 19
18
5. Cut wire (18) to pull out spring pin (19) with a

round bar (6mm (0.2 in)) and hammer. (2 places)
17 12
16
6. Remove the left and right open / close pedal (5) 15 13
from pilot valve (6). 14 11
W18B-02-06-002
7. Remove bolts (3) (2 used) to remove travel pedal

(2) from the lever (1) assembly. (2 places)
: 17 mm
8. Cut wire (21) to pull out spring pin (22) with a

round bar (6 mm (0.2 in)) and hammer. (2 places)
9. Remove the left and right travel lever (1) assem-

bly from pilot valve (20).
W2-7-3
IMPORTANT: Put tags to disconnected hoses for
identification to aid in re-assembly.
(Refer to page W2-7-7 for port loca-
tions.)
10. Disconnect hoses (11 used) from pilot valves (6,

20).
NOTE: Connect each hoses under cab.
11. Remove bolts (4) (2 used) and (23) (2 used) to

remove pilot valves (6, 20) from the floor.
: 17 mm 23
20
6
W18B-02-06-002
W2-7-4
Installation
1. Install pilot valves (6, 20) with bolts (4) (2 used) 9. Install supports (9, 17) to cover (12) with bolts
and (23) (2 used). (10) (4 used) and (14) (4 used).
: 17 mm : 10 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) : 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.2 to 2.9 Ibf⋅ft)
IMPORTANT: All work to connect hoses is done
under cab floor by using a ladder. IMPORTANT: When all hoses are connected, start
Be careful to work on it. engine and check the hose connec-
2. Connect hoses (11 used) to pilot valves (6, 20). tions for oil leaks.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29.0 Ibf⋅ft)
3. Install the travel lever (1) assembly to pilot valve

(20) with spring pin (22) and secure it by wire 1 2
(21). (2 places) 3
2 23
4. Install pedal (2) to the travel lever (1) assembly 7
with bolts (3) (2 used). (2 places)
5
: 17 mm
4
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 8
5. Install open / close pedal (5) to pilot valve (6) with 22

21 9
spring pin (19) and secure it with wire (18). (2 20 10
places) 5 6 11
19
6. Install covers (8, 16) to the floor with bolts (7) (6 18
used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 17 12
16
15 13
7. Install cover (12) to the floor with bolts (11) (8 11
14
used). W18B-02-06-002
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
8. Install cover (13) to cover (12) with bolts (15) (4

used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W2-7-5
PILOT LINE CONNECTION
Right Pilot Valve

5
6 Front
1
Port
Connected to Remarks
4 No.
Right Left
1 Manifold 1 Bucket tilt-in pilot pressure
2 Manifold 1 Boom raise pilot pressure
3 Shut-off valve Back to oil tank
Rear 4 Manifold 1 Bucket tilt-out pilot pressure
2 3
5 Manifold 1 Boom lower pilot pressure
T118-05-02-028 6 Shut-off valve Pilot primary pressure
Left Pilot Valve
4
2 Front
3
Port
6 No.
Right Left
1 Manifold 1 Right swing pilot pressure
2 Shut-off valve Port T back to oil tank
3 Manifold 1 Arm retract pilot pressure (LD),
Rear Arm extend pilot pressure (BH)
1 5 4 Manifold 1 Right swing pilot pressure
T118-05-02-028 5 Shut-off valve Pilot primary pressure
6 Manifold 1 Arm extend pilot pressure (LD)
Arm retract pilot pressure (BH)
NOTE: The above figures show the pilot valve port

layout with the ISO control lever pattern.
LD:
ISO Pattern Lever HITACHI Pattern Lever
Left swing Arm retract
Right swing Arm extend
Arm extend Right swing
Arm retract Left swing
BH:
ISO Pattern Lever HITACHI Pattern Lever
Left swing Arm roll-out
Right swing Arm roll-in
Arm roll-out Right swing
Arm roll-in Left swing
NOTE: LD: Loading Shovel

BH: Back-hoe
W2-7-6
Travel Pilot Valve
6 Front
1
5 2 Port
Right Left No.
1 Manifold 1 Left travel forward pilot
4 pressure
3 2 Shut-off valve Pilot primary pressure
Rear Bucket open / close Parking brake relief pressur
pilot valve
3 Manifold 1 Left travel reverse pilot
T118-05-02-029
pressure
4 Manifold 1 Right travel reverse pilot
Bucket Open / Close Pilot Valve (LD Only) pressure
5 Shut-off valve Back to oil tank
Bucket open / close Back to oil tank (LD only)
pilot valve
Front
4 6 Manifold 1 Right travel forward pilot
1 pressure
3 2
Right Left
Rear Port
No.
1 Manifold 1 Bucket close pilot pressure
T118-05-02-030 2 Travel pilot valve, Pilot primary pressure,
Manifold 1 swing parking brake relief
pressure
3 Travel pilot valve Back to oil tank
4 Manifold 1 Bucket open pilot pressure
W2-7-7
DISASSEMBLE FRONT / SWING PILOT
VALVE
11
1
12
13 2
14
15 3
16
4
17
7
18
19 8
20
9
21
22 10
23
W18B-02-06-003
1- Lock Nut 7- Seal (4 Used) 13 - Spring Seat (4 Used) 19 - O-Ring

2- Plate 8- Cap (4 Used) 14 - Spring Seat (4 Used) 20 - Pin
3- Joint 9- O-Ring (4 Used) 15 - Spool (4 Used) 21 - O-Ring
4- Plate 10 - Collar (4 Used) 16 - Piston (4 Used) 22 - Body
5- Plunger (4 Used) 11 - Inner Spring (4 Used) 17 - Body 23 - Socket Bolt
6- Retainer (4 Used) 12 - Outer Spring (4 Used) 18 - O-Ring (6 Used)
NOTE: There are two kinds of outer springs (12).
W2-7-8
Disassemble Front / Swing Pilot Valve
IMPORTANT: Spools (15) (4 used) and body (17) 6. Remove seal (7) and O-ring (9) from cap (8). (4
are selective fitted between the di- places)
ameter and bore. There are two
kinds of outer springs (12). Distin- IMPORTANT: When the spool (15) assembly has
guish the disassembled parts by been removed, piston (16) may re-
port No. where the parts are located. main inside of body (17). Be sure to
The port numbers are stamped on check it.
the periphery of body (22). 7. Remove collar (10), spool (15) and piston (16)
IMPORTANT: When removing lock nut (1), plate from body (17) with a magnet. (4 places)
(2) shall be used to bear the thrust
force. If the force is applied to body 8. Turn body (17) over to remove socket bolt (23),
(17), joint (3) may be damaged by then remove body (22) from body (17).
such a strong force.
NOTE: When body (22) can not be removed, tap
1. Remove lock nut (1) to remove plate (2) from body (22) lightly with a plastic hammer.
joint (3). This is an easy way to remove it.
: 19 mm
9. Remove O-ring (21) from body (22).
CAUTION: When removing joint (3) from 10. Remove O-rings (19) and (18) (6 used) from
body (17), plunger (5) may fly out. It is nec- body (17).
essary to hold plate (4) by your left hand.
2. Clamp the flat surface of body (17) in a vise CAUTION: When removing spring seat (14)
lightly. Clamp the lower part of joint (3) with pipe from spool (15), be careful that spring seat
wrench to remove the joint from body (17). (14) may fly out by the force from inner
spring (11).
3. Remove plate (4) from body (17).
11. Remove spring seat (14) from spool (15) to re-
IMPORTANT: If plunger (5) can not be pulled out move inner spring (11), outer spring (12) and
for being stuck in the half way, do spring seat (13). (4 places)
not pull it by force. It should be
pushed back first and then pull it
out while rotating it.
4. Pull plunger (5) out from body (17). At this time
the plunger is still with retainer (6) and cap (8)
attached. (4 places)
5. Remove retainer (6) and cap (8) from plunger (5).

(4 places)
W2-7-9
ASSEMBLE FRONT / SWING PILOT VALVE
3
2
4
7
9
8
6
10
14
11
12
13
15
17
16
18
21
W18B-02-07-003
22 19 23
1- Lock Nut 7- Seal (4 Used) 13 - Spring Seat (4 Used) 19 - O-Ring

2- Plate 8- Cap (4 Used) 14 - Spring Seat (4 Used) 20 - *Pin
3- Joint 9- O-Ring (4 Used) 15 - Spool (4 Used) 21 - O-Ring
4- Plate 10 - Collar (4 Used) 16 - Piston (4 Used) 22 - Body
5- Plunger (4 Used) 11 - Inner Spring (4 Used) 17 - Body 23 - Socket Bolt
6- Retainer (4 Used) 12 - Outer Spring (4 Used) 18 - O-Ring (6 Used)
NOTE: There are two kinds of outer springs (12).

As for the part with * mark, refer to W2-7-8.
W2-7-10
Assemble Front / Swing Pilot Valve
IMPORTANT: Apply hydraulic oil into body (17) 6. Insert the plunger (5) assemblies (4 used) into
and spool (15) before installation. body (17).
IMPORTANT: As the components of pilot valve are
easily contaminated by dirt, each IMPORTANT: Be sure to align the hole in plate (4)
position should be thoroughly with that in body (17), then install
cleaned before starting the assem- them.
bly work.
IMPORTANT: There are two kinds of outer spring 7. Install plate (4) to body (17).
(12).
(Free length 55.7 mm (2.2 in), 1 8. Apply grease to the bending part of the joint (3).
used; free length 48 mm (1.9 in), 3 No clearance should be left there.
used) Apply much grease on the top of plungers (5) (4
Install the longer spring in free used).
length onto spool (15) in following
ports.
Right pilot valve: port 6 IMPORTANT: Apply THREEBOND #1910 on the
Left pilot valve: port 3 screw sections of joint (3). Install
In addition, spring seat (13) should joint (3) with the small end of the
be installed with its concave side screw facing body (17) side.
facing the spring side. 9. Hold plate (4) by hands to install joint (3). Install
IMPORTANT: Be sure to install spool (15) into the plate (2) onto joint (3) and tighten it. The clear-
former port before disassembling. ance between plate (2) and plunger (5) then
1. Install spring seat (13), inner spring (11) and should be kept in 0 to 0.2 mm (0 to 0.008 in)
outer spring (12) into spool (15) with spring seat : 17 mm
(14) assembled ready. (4 places) : 29 to 32 N⋅m
(3 to 3.3 kgf⋅m, 21.5 to 24.0 Ibf⋅ft)
2. Insert the spool (15) assembly into body (17).
10. Install lock nut (1) to joint (3) to secure plate (2).
3. Insert collars (10) (4 used) into body (17). At this moment plate (2) should be used to bear
the thrust force.
IMPORTANT: Install seal (7) with its lip facing : 19 mm, 32 mm
body (17) side. : 39 to 42 N⋅m
4. Install O-rings (9) (4 used) and seals (7) (4 used) (4 to 4.3 kgf⋅m, 29.0 to 31.5 Ibf⋅ft)
to caps (8) (4 used).
11. Turn the body (17) assembly over. Insert spools
5. Insert plungers (5) (4 used) into caps (8) (4 used), (15) (4 used) with the small end of pistons (16) (4
then install retainer (6). used) facing inside.
12. Install O-rings (18) (6 used) and (19) onto the

body (17) assembly.
W2-7-11
17
21
W18B-02-07-003
22 23
W2-7-12
13. Install O-ring (21) to body (22).
14. Align *pin (20) position to install body (22) to body

(17), then tighten it with socket bolt (23).
: 10 mm
: 69 to 78 N⋅m (7 to 8 kgf⋅m, 51 to 58 Ibf⋅ft)
NOTE: As for the part with * mark, refer to W2-7-8.
W2-7-13
DISASSEMBLE TRAVEL BUCKET OPEN /
CLOSE PILOT VALVE
18
19 1
3
20 4
21 5
22
22
6
7
8
23
24
17 9
16
25
15 10
11
26 12
27 28
14
14
29 13
13
30
W18B-02-06-004
1- Dust Seal (4 Used) 9- Spool (4 Used) 17 - Pin (2 Used) 24 - Cam (2 Used)

2- Bushing (4 Used) 10 - Spring Guide (4 Used) 18 - Bolt (4 Used) 25 - Holder
3- Oil Seal (4 Used) 11 - Outer Spring (4 Used) 19 - Cover 26 - Casing
4- O-Ring (4 Used) 12 - Piston (4 Used) 20 - Spring Pin (2 Used) 27 - Plug (2 Used)
5- Pusher (4 Used) 13 - Plug (4 Used) 21 - Spring Pin (2 Used) 28 - O-Ring (2 Used)
6- Retainer (4 Used) 14 - O-Ring (4 Used) 22 - Bushing (2 Used) 29 - O-Ring
7- Inner Spring (4 Used) 15 - Washer (2 Used) 23 - Bushing (2 Used) 30 - Adapter
8- Shim (4 Used) 16 - Socket Bolt (2 Used)
W2-7-14
Disassemble Travel Bucket Open / Close Pilot
Valve
IMPORTANT: Spools (9) (4 used) and casing (26) IMPORTANT: When removing the spool (9) as-
are selective fitted in the diameter sembly, piston (12) may remain in-
and bore. Distinguish the disas- side of the casing (26). Be sure to
sembled parts by port No. where the check for it.
parts are located. The port numbers 7. Remove the spool (9) assembly and piston (12)
are stamped on the periphery of from casing (26) with magnet.
casing (26).
8. Remove outer springs (11) (4 used) from casing
1. Remove bolts (18) (2 used) to remove cover (19) (26).
from holder (25).
: 10 mm 9. Turn casing (26) over. Remove adapter (30),
O-ring (29), plugs (13) (4 used) and O-rings (14)
(4 used) from casing (26).
CAUTION: If socket bolts (16) (2 used) are : 22 mm
removed from casing (26), holder (25) may fly
out by the spring force from spool (9). Hold IMPORTANT: The number of shim (8) installed is
holder (25) by hand. determined by testing and adjusting
during assembling work. Keep track
2. Clamp the flat surface of casing (26) in a vise of the shims so as to install them
lightly. Remove socket bolts (16) (2 used) and back to the spool by the exact num-
washers (15) (2 used) from casing (26). ber.
: 8 mm 10. Remove retainer (6) from the spool (9) assembly
to remove inner spring (7), shims (8) (several)
3. Remove holder (25) from casing (26). and spring guide (10). (4 places)
4. Remove bushing (2) and pusher (5) together IMPORTANT: Spring pins (20 and 21) were
from casing (26). caulked to the head of cam (24) with
punch when they had been installed.
5. Remove bushing (2) from pusher (5). Remove the caulked part with
grinder, or similar. before removing
6. Remove dust seal (1), oil seal (3) and O-ring (4) them.
from bushing (2). 11. Secure holder (25) in a vise. Pull spring pins (20,
21) out from cam (24) using ST 1237. (2 places)
IMPORTANT: Do not remove pin (17), cam (24),

bushings (22, 23) from holder (25)
unless they are damaged.
12. Remove pin (17) and cam (24) from holder (25).
(2 places)
W2-7-15
ASSEMBLE TRAVEL BUCKET OPEN /
CLOSE PILOT VALVE
A
24 18 20 21
19
5
Section A-A
2
17 23 22 16 1
25
4
15
3 A
6
10
11
7
8
W18B-02-07-004
26
12
T115-02-05-004
14 13 29 30
1- Dust Seal (4 Used) 9- Spool (4 Used) 17 - Pin (2 Used) 24 - Cam (2 Used)

2- Bushing (4 Used) 10 - Spring Guide (4 Used) 18 - Bolt (2 Used) 25 - Holder
3- Oil Seal (4 Used) 11 - Outer Spring (4 Used) 19 - Cover 26 - Casing
4- O-Ring (4 Used) 12 - Piston (4 Used) 20 - Spring Pin (2 Used) 27 - *Plug (2 Used)
5- Pusher (4 Used) 13 - Plug (4 Used) 21 - Spring Pin (2 Used) 28 - *O-Ring (2 Used)
6- Retainer (4 Used) 14 - O-Ring (4 Used) 22 - Bushing (2 Used) 29 - O-Ring
7- Inner Spring (4 Used) 15 - Washer (2 Used) 23 - Bushing (2 Used) 30 - Adapter
8- Shim (4 Used) 16 - Socket Bolt (2 Used)
W2-7-16
Assemble Travel Bucket Open / Close Pilot Valve
IMPORTANT: Check that cam (24) can move
IMPORTANT: Spool (9) and casing (26) are selec- smoothly after installation.
tive fitted in their diameter and bore. 6. Install cam (24) to holder (25) with pin (17) and
So these parts can not be replaced tap to install spring pins (21, 20). After installing,
singly. caulk spring pins (21, 20) to the head of cam (24)
IMPORTANT: As the components of pilot valve are with a punch. (2 places)
easily contaminated by dirt, each
position should be thoroughly 7. Apply much grease to the head of pusher (5).
cleaned before starting the assem-
bly work. 8. Place holder (25) on casing (26), hold it by hand
IMPORTANT: The number of shim (8) is deter- and install the holder with socket bolt (16) and
mined during the performance test. washer (15).
They should be assembled to the : 18 mm
former spool before disassembling. : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
IMPORTANT: Install retainer (6) with the stepped
part facing the spring side.
1. Install shim (8), inner spring (7) and spring guide 9. Turn the casing (26) assembly over, insert pis-
(10) to spool (9) in that order, then install retainer tons (12) (4 used) to spools (9) (4 used).
(6). (4 places)
10. Install plugs (13) (4 used), O-rings (14) (4 used),
adapter (30) and O-ring (29) to casing (26).
IMPORTANT: Insert the spool (9) assembly to the : 8 mm
port where it was removed. : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2. Install outer springs (11) (4 used) to casing (26), : 22 mm
insert the spool (9) assemblies (4 used). : 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
3. Install dust seal (1), oil seals (3) (4 used) and
O-rings (4) (4 used) to bushings (2) (4 used). 11. Place cover (19) on casing (26), install it with
bolts (18) (2 used).
: 10 mm
IMPORTANT: Apply hydraulic oil to the outer race : 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
of bushings (2) (4 used).
4. Insert pushers (5) (4 used) into bushings (2) (4
used).
IMPORTANT: Apply grease to the head of pusher

(5).
5. Insert the pusher (5) assemblies (4 used) into
casing (26).
W2-7-17
(Blank)
W2-7-18
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE
Removal 2 3 4
Front
CAUTION: Lock valve is located on the ceil-
1
ing of a room under cab. Remove and install
Right Left
it after getting the scaffold.
8 Rear
1. Remove nut (10) to disconnect ball joint (9).
: 13 mm 5
IMPORTANT: Put tags to hoses to aid in 9

re-assembly. 7
6 10
2. Disconnect hoses (1 to 8). 11 W146-02-07-001
: 19 mm, 22 mm
1- Hose (From Right Pilot Valve)
3. Remove socket bolts (11) (2 used) to remove the 2- Hose (To Right Pilot Valve)
pilot shut-off valve. 3- Hose (To Travel Pilot Valve)
: 8 mm 4- Hose (To Left Pilot Valve)
5- Hose (From Left Pilot Valve)
6- Hose SV (From Pilot Filter)
7- Hose DG (To Oil Tank)
8- Hose (From Travel Pilot Valve)
9- Ball Joint
10 - Nut
11 - Socket Bolt (2 used)
W2-8-1
Installation
2 3 4
1. Install the pilot shut-off valve with socket bolts
(11) (2 Used). Front
: 8 mm 1
: 50 N⋅m (5.1 kgf⋅m, 36 lbf⋅ft) Right Left
2. Connect hoses (1 to 8).

8 Rear
: 19 mm, 22 mm
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) 5
: 22 mm
: 40 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft) 9
7
6 10
3. Connect ball joint (9). 11 W146-02-07-001
: 13 mm
: 10 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft) 1- Hose (From Right Pilot Valve)
2- Hose (To Right Pilot Valve)
3- Hose (To Travel Pilot Valve)
4- Hose (To Left Pilot Valve)
5- Hose (From Left Pilot Valve)
6- Hose SV (From Pilot Filter)
7- Hose DG (To Oil Tank)
8- Hose (From Travel Pilot Valve)
9- Ball Joint
10 - Nut
11 - Socket Bolt (2 used)
W2-8-2
(Blank)
W2-8-3
DISASSEMBLE PILOT SHUT-OFF VALVE
1
2
3
4
13
12
5
6
7
8
11
9
10
W146-02-07-002
1- Retaining Ring 5- O-Ring 9 - Spring Pin 12 - Stopper Bolt

2- Washer 6- Backup Ring 10 - Lever 13 - Body
3- Backup Ring 7- Washer 11 - Spool
4- O-Ring 8- Retaining Ring
W2-8-4
Disassemble Pilot Shut-Off Valve
IMPORTANT: Do not remove spool (11) unless

necessary. If so, looseness occurs
between spool (11) and lever (10).
Be sure to replace it with an assem-
bly of spool (11), lever (10) and
spring pin (9).
1. Remove retaining ring (1) and washer (2) from
body (13) to remove spool (11).
2. Remove washer (7) from spool (11).
3. Remove backup rings (3, 6) and O-rings (4, 5)

from body (13).
IMPORTANT: Do not remove stopper bolt (12)

unless necessary.
W2-8-5
ASSEMBLE PILOT SHUT-OFF VALVE
1 2 3 4 13
10
12
7
8
11
W105-02-08-003
5 6
1- Retaining Ring 5- O-Ring 9 - Spring Pin 12 - Stopper Bolt

2- Washer 6- Backup Ring 10 - Lever 13 - Body
3- Backup Ring 7- Washer 11 - Spool
4- O-Ring 8- Retaining Ring
W2-8-6
Assembling Pilot Shut-Off Valve
1. Coat O-ring (5) and backup ring (6) with grease.

Install O-ring (5), backup ring (6), and washer (7)
into body (13).
2. Coat spool (11) with hydraulic oil. Install spool

(11) in body (14).
3. Coat O-ring (4) and backup ring (3) with grease.

Install O-ring (4), backup ring (3), and washer (2)
into body (13). Install retaining ring (1) on spool
(11).
W2-8-7
(Blank)
W2-8-8
UPPERSTRUCTURE / Shuttle Valve
REMOVE AND INSTALL SHUTTLE VALVE
IMPORTANT: Be sure to bleed air from hydraulic Front
Right Left
Removal
IMPORTANT: Tag piping and hoses to aid Rear

re-assembly. Pilot Panel
1. Disconnect all piping and hoses from each shut-
tle valves.
: 17 mm, 22 mm,
2. Remove the bolts (2 used for each) from each

shuttle valves (1, 2) to remove shuttle valves (1,
2).
: 10 mm, 17 mm
3. Remove the bolts (4 used for each) from each

shuttle valves (3, 4, 5, 6) to remove shuttle valves
(3, 4, 5, 6).
: 13 mm, 17 mm
T141-01-03-008
1 2
Control Valve Panel
T141-05-02-006
3 4 5 6
W2-9-1
Installation
1. Install shuttle valves (3, 4, 5, 6) to bracket with Front

the bolts (4 used for each).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
Right Left
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2. Install shuttle valves (1, 2) to bracket with the Rear

bolts (2 used for each). Pilot Panel
: 10 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.2 to 2.9 Ibf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
3. Connect all piping and hoses to each shuttle

valves.
Pipe
: 17 mm
: 34 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
Hose (Nut)
: 22 mm
T141-01-03-008
: 40 N⋅m (4 kgf⋅m, 29 Ibf⋅ft) 1 2
Control Valve Panel
T141-05-02-006
3 4 5 6
W2-9-2
DISASSEMBLE AND ASSEMBLE SHUT-
TLE VALVE
Shuttle Valve 2
Shuttle Valve 1
1 2 3
A
6
11
10
A Section A-A 9
W18B-02-10-003 8 W18B-02-10-004
Tightening Torque
Part Name Q’ty Wrench Size Remarks
N⋅m (kgf⋅m) (Ibf⋅ft)
1- Body 1
2- Plug 4 ： 6 mm 20 (2.0) (14.5)
3- O-Ring 4
4- Seat 3
5- Steel Ball 3
6- Plug 3 ： 4 mm 7 (0.7) (5)
7- Body 1
8- Plug 1 ： 6 mm 20 (2.0) (14.5)
9- O-Ring 1
10- Seat 1
11- Steel Ball 1
W2-9-3
Shuttle Valves 3, 4, 5, 6
4
5
6
7
4
4 5
5 6
6 7
7 W18B-02-10-001
8
Tightening Torque
Part Name Q’ty Wrench Size Remarks
N⋅m kgf⋅m (Ibf⋅ft)
1- Seal 1
2- Steel Ball 2 -
3- Body 1
4- Steel Ball 3 8 mm
5- Plug 3 ： 5 mm
6- O-Ring 3
7- Plug 3 ： 6 mm 20 (2.0) (14.5)
8- Seal 1
W2-9-4
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID
VALVE
Pump Control
Panel
Removal
(Swing Pilot Shut-Off Solenoid Valve, Travel Mode
Selection Solenoid Valve, Fan Motor Solenoid Valve,
Power Decrease Solenoid Valve, EHC Valve (Power
Decrease), Selection Valve (Pump Flow Rate Con- Swing Pilot
trol Valve)) Pilot Panel
Shut-off Solenoid
Valve
T141-04-02-002
IMPORTANT: Put tags disconnected pipes and

Travel Mode Selection
electrical cables to aid re-assembly. Pilot Panel
Solenoid Valve
1. Disconnect all hydraulic lines and electrical ca-
bles from the solenoid valves.
: 17 mm, 19 mm, 27 mm
2. Remove socket bolts (1) to remove the solenoid

valves.
: 4 mm
T141-01-03-008
Pump Control Panel Fan Motor Solenoid

Valve
Power Decrease
Solenoid Valve
EHC Valve
(Power Decrease)
Selection Valve
(Pump Flow Rate
Control Valve)
T117-06-02-031
W2-10-1
Installation
Pump Control
1. Install the solenoid valves with socket bolts (1). Panel
: 4 mm
: 7 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)
2. Reconnect all hydraulic lines and electrical ca-

bles to the solenoid valves.
Pipe
: 17 mm
: 34⋅ N⋅m (3.5 kgf⋅m, 25.5 lbf⋅ft)
: 27 mm
: 93⋅ N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) Swing Pilot
Pilot Panel
Hose Fitting Shut-off Solenoid
Valve
: 19 mm T141-04-02-002
Travel Mode Selection

Pilot Panel
Solenoid Valve
T141-01-03-008
Pump Control Panel Fan Motor Solenoid

Valve
Power Decrease
Solenoid Valve
EHC Valve
(Power Decrease)
Selection Valve
(Pump Flow Rate
Control Valve)
T117-06-02-031
W2-10-2
(Blank)
W2-10-3
SOLENOID VALVE CONSTRUCTION
Swing Pilot Shut-Off Solenoid Valve, EHC Valve
(Power Decrease)
2 3 4 5 6 7 8 9 W117-02-07-004
Tightening Torque
Part Name Q’ty Wrench Size
N⋅m (kgf⋅m) (lbf⋅ft)
1 - Socket Bolt 4 ： 4 mm 7 (0.7) (5.1)
2 - Plug 1 ： 27 mm 49 (5) (36)
3 - O-Ring 2
4 - Spring 2
5 - Square Ring 4
6 - Spool 1
7 - Casing 1
8 - Spring Seat 2
9 - Solenoid 1
W2-10-4
Travel Mode Selection Solenoid Valve
18
17 1
16 2
15 3
14 4
5
13
12 6
11
7
10
9 8
W140-02-11-002
Tightening Torque
Part Name Q'ty Wrench Size
1 - Screw 1 : 32 mm 34.3 (3.5) (25.3)
2 - Coil 1
3 - Spacer 1
4 - Housing 1
5 - O-Ring 1
6 - Pipe 1
7 - Seat 1
8 - Spring 1
9 - Housing 1
10 - Spring 1
11 - O-Ring 1
12 - O-Ring 1
13 - O-Ring 1
14 - Body 1
15 - Spool 1
16 - Rod 1
17 - Stopper 1
18 - Plunger 1
W2-10-5
Fan Motor Solenoid Valve
W117-02-07-002
2 3 4 5 6 7 8
Tightening Torque
Part Name Q’ty Wrench Size
1 - Socket Bolt 4 ： 4 mm 7 0.7 5.1
2 - Solenoid 2 ： 27 mm 49 5 36
3 - O-Ring 2
4 - Square Ring 4
5 - Spool 1
6 - Casing 1
7 - Spring Seat 2
8 - Spring 2
W2-10-6
Selection Valve
1 2 3 4 5 6
7
W141-02-10-001
10 9 8
14 13 12 11
Tightening Torque Tightening Torque

Part Name Q’ty Wrench Size Part Name Q’ty Wrench Size
N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
1 - Piston 1 8 - Cover 1
2 - Socket 9 - Socket
4 ： 4 mm 7 (0.7) (5) 4 ： 3 mm 2.9 (0.3) (2.2)
Bolt Bolt
3 - Adapter 1 10 - Seat 2
4 - Cover 1 11 - O-Ring 4
5 - Spring 1 12 - Spool 1
13 - Socket
6 - O-Ring 3 4 ： 4 mm 7 (0.7) (5)
Bolt
7 - Spring 1 14 - Body 1
W2-10-7
Power Decrease Solenoid Valve
18
10
9
5
4
17
3 16
2
1 15
14
13
12
11
T142-02-05-014
Tightening Torque Tightening Torque

Part Name Q’ty Wrench Size Part Name Q’ty Wrench Size
N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
1 - Socket
4 ： 3 mm 2.9 (0.3) (2.2) 10 - Bushing 1
Bolt
2 - Cover 1 11 - Piston 1
3 - Solenoid
1 12 - Spring 1
Valve
4 - O-Ring 1 13 - O-Ring 1
14 - Spring
5 - Casing 1 1
Seat
6 - O-Ring 3 15 - Screw 1 ： 13 mm
7 - Plug 2 ： 4 mm 7 (0.7) (5) 16 - O-Ring 1
8 - Sleeve 1 17 - Nut 1 ： 10 mm
18 - Socket
9 - Spool 1 4 ： 4 mm 7 (0.7) (5)
Bolt
W2-10-8
UPPERSTRUCTURE / Oil Cooler Fan Motor
REMOVE AND INSTALL OIL COOLER FAN
MOTOR
to “Bleeding Air from Hydraulic Oil 2
3
Removal
• There are two kinds of oil cooler fan motors (for
front side and for rear side). The oil fan motor il-
lustrated here is the one for front side. 1 Bolt Holes
for Pipe
Clamp
1. Disconnect all hoses and pipes from oil cooler
fan motor (1) and bracket (3).
: 17 mm, 22 mm, 36 mm
2. Remove bolts (4) (20 used) to remove nets (5) (2 2

used) and plates (6) (4 used).
: 17 mm W141-02-11-001
CAUTION: Bracket (3) assembly weight:

90 kg (200 lb)
3. Install eyebolts (M12, Pitch 1.75 mm) into the bolt

holes (2 places) for pipe clamp in bracket (3) and 4
hold it by crane. Remove bolts (2) (6 used) to lift
and remove the bracket (3) assembly by crane.
: 19 mm 5
W141-02-11-002
W2-11-1
CAUTION: The fan (7) assembly weight:

32 kg (80 lb) 7
4. Attach nylon sling on fan (7) and hold it by crane.

Remove bolts (9) (6 used) and bolt (10) to re-
move the fan (7) assembly from oil cooler fan
motor (1).
: 19 mm A A
CAUTION: Oil cooler fan motor (1) weight:

24 kg (60 lb) 1
5. Attach nylon sling on the body of oil cooler fan

motor (1) and hold it by crane.
W146-02-09-002
6. Remove oil cooler fan motor mounting bolts (8) (4 8 7

9
used) to remove oil cooler fan motor (1) from 1
bracket (3).
: 19 mm 10
7. Remove coupling (11) from oil cooler fan motor

(1).
11
3
Section A-A W118-02-09-004
W2-11-2
Installation
1. Install coupling (11) to oil cooler fan motor (1). 1 8 9

7
CAUTION: Oil cooler fan motor (1) weight:

24 kg (60 lb) 10
2. Install oil cooler fan motor (1) onto bracket (3)

with mounting bolts (8) (4 used).
11
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
3
Section A-A W118-02-09-004
CAUTION: Fan (7) assembly weight: 7

32 kg (80 lb)
3. Hoist the fan (7) assembly and install it to oil A A

cooler fan motor (1) with bolts (9) (6 used) and
bolt (10).
: 19 mm
1
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
W146-02-09-002
CAUTION: Bracket (3) assembly weight:

90 kg (200 lb)
2
4. Hoist the bracket (3) assembly and install it to the
oil cooler with bolts (2) (6 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
Oil Cooler
1
3
W141-02-11-001
W2-11-3
5. Install plates (6) (4 used) and nets (5) (2 used) to
the oil cooler with bolts (4) (20 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) 4
6. Connect all hoses and pipes except drain hose to Oil Cooler
oil cooler fan motor (1) and bracket (3). Fill hy- 5
draulic oil from the hole to be connected with the
drain hose, and then, install the drain hose.
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 22 mm
: 40 N⋅m (4 kgf⋅m, 28.5 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
6
7. Start the engine and loosen the drain hose a little

bit so that the air is bled out until only hydraulic
oil comes out. W141-02-11-002
Drain Hose
1
3
W141-02-11-001
W2-11-4
(Blank)
W2-11-5
DISASSEMBLE OIL COOLER FAN MOTOR
1
2
3
5 7
8
9
16
17
10
11
22
12
13
14
18
15
19
20
21
23
24
25
26
27
28
29
30 W141-02-11-004
31
1- Housing 9- Socket Bolt (6 Used) 17 - Plunger (7 Used) 25 - Bearing
2- O-Ring 10 - Valve 18 - Screw (7 Used) 26 - Bearing Nut
3- Cover 11 - Cylinder Block 19 - Plate 27 - Shim (Several)
4- Valve Block 12 - Shim 20 - Shim 28 - O-Ring
5- Plug 13 - Spring Seat 21 - Shaft 29 - Oil Seal
6- Knock Pin 14 - Disc Spring (4 Used) 22 - Key 30 - Seal Case
7- Washer (6 Used) 15 - Center Pin 23 - Bearing 31 - Retaining Ring
8- Socket Bolt (6 Used) 16 - Piston Ring (14 Used) 24 - Case
W2-11-6
Disassemble Oil Cooler Fan Motor
1. Remove plug (5) to bleed hydraulic oil from the IMPORTANT: Do not remove piston ring (16) un-
motor. less necessary.
: 10 mm 7. Remove shim (12), spring seat (13) and disc
springs (14) (4 used) from cylinder block (11).
2. Remove key (22) from shaft (21). Remove socket
bolts (9) (6 used) to remove valve block (4) from
cover (3).
: 8 mm
IMPORTANT: Take care not to drop valve plate

(10) when removing cover (3).
Knock pin (6) was pressed to cover
(3). Do not remove the knock pin
unless necessary.
3. Remove socket bolts (8) (6 used) and washer (7)
(6 used) to remove cover (3), O-ring (2) and
valve plate (10) from housing (1).
: 8 mm
4. Remove retaining ring (31) from housing (1) and

with a puller to remove the shaft (21) assembly
from housing (1).
5. Remove seal case (30), oil seal (29), O-ring (28)

and shim (27) from the shaft (21) assembly.
IMPORTANT: Do not remove bearings (25, 23)

unless necessary. If they are re-
moved, replaced them with new
ones.
6. Remove screws (18) (7 used) from shaft (21) to
remove plate (19), center pin (15), plunger (17)
and cylinder block (11) from shaft (21).
W2-11-7
ASSEMBLE OIL COOLER FAN MOTOR
25 24 23 20 19
30 26 28 15
17
21 22
1
2
3
29 9
31 27 5
11
6
7, 8 10 W141-02-11-003
1- Housing 9- Socket Bolt (6 Used) 17 - Plunger (7 Used) 25 - Bearing

2- O-Ring 10 - Valve 18 - Screw (7 Used) 26 - Bearing Nut
3- Cover 11 - Cylinder Block 19 - Plate 27 - Shim (Several)
4- Valve Block 12 - Shim 20 - Shim 28 - O-Ring
5- Plug 13 - Spring Seat 21 - Shaft 29 - Oil Seal
6- Knock Pin 14 - Disc Spring (4 Used) 22 - Key 30 - Seal Case
7- Washer (6 Used) 15 - Center Pin 23 - Bearing 31 - Retaining Ring
8- Socket Bolt (6 Used) 16 - Piston Ring (14 Used) 24 - Case
W2-11-8
Assemble Oil Cooler Fan Motor
NOTE: As for items 12, 13, 14, 16 and 18, refer to 10. Install plug (5) into housing (1).
the illustration for disassembling. : 10 mm
: 59 to 76 N⋅m
1. Install shim (12), spring seal (13) and disc (6 to 7.8 kgf⋅m, 43 to 56 Ibf⋅ft)
springs (14) (4 used) onto cylinder block (11).
Then pass center pin (15) and plungers (17) (7
used) through plate (19) and install them into
cylinder block (11).
2. Install shim (20) and plate (19) onto shaft (21)

with screw (18).
3. Install the shaft (21) assembly into housing (1).
4. Install shim (27) onto shaft (21).
5. Install O-ring (28) and oil seal (29) onto seal case
(30).
6. Install the seal case (30) assembly onto shaft

(21).
7. Install retaining ring (31) onto housing (1).
8. Install valve plate (10), O-ring (2) onto cover (3)

and install cover (3) with socket bolts (8) (6
used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
9. Install key (22) into shaft (21). Install valve block

(4) onto cover (3) with socket bolts (9) (6 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W2-11-9
1. The clearance between outer diameter (d) of

center pin (15) and bore (D) of cylinder block (11),
and the clearance between outer diameter (d′) of
piston (17) and bore (D′) of cylinder block (11)
d D
Unit: mm (in)
0.004 to 0.022 0.05
D-d
(0.0002 to 0.001) (0.002) W117-02-02-009
0.005 to 0.029 0.05

D′-d′
(0.0002 to 0.001) (0.002)
W2-11-10
UPPERSTRUCTURE / Compressor Drive Motor
REMOVE AND INSTALL COMPRESSOR
DRIVE MOTOR
to “item of Bleeding Air from
Hydraulic Oil Tank” on page W1-3-1)
3
Removal
5
2
1. Remove bolts (13) (14 used) to remove guard
cover (14). 1
: 17 mm
2. Disconnect hoses (6, 7, 8) from compressor drive

motor (9). M141-07-029
: 27 mm, 36 mm
Adjusting Bolt
3. Loosen the adjusting bolts (3 used) to remove
V-belts (5) (6 used) from pulley (4).
: 13 mm
4. Remove bolts (11) (4 used) to remove cover (12)

and compressor drive motor (9).
6
: 19 mm 14
7
5. Remove center bolt (2), bolts (1) (3 used) and 8
plate (3) to remove pulley (4) from compressor 13
drive motor (9).
: 10 mm, 13 mm 9
10
6. Remove bolts (10) (4 used) to remove 11
compressor drive motor (9) from cover (12).
12
Adjusting Bolt
Installation M141-07-050
1. Install compressor drive motor (9) to cover (12)

: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
W2-12-1
IMPORTANT: Do not tap pulley (4) with a hammer
when installing pulley (4) to
compressor drive motor (9).
Heat its inner diameter first, then
install pulley (4). 4
2. Install the shaft key to compressor drive motor (9).
Install pulley (4) to the shaft.
3. Install plate (3), center bolt (2) and bolts (1) (3 3

used) onto pulley (4).
: 10 mm 5
2
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.2 to 2.9 Ibf⋅ft)
: 13 mm 1
: 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)
4. Install compressor drive motor with bolts (11) (4

used). M141-07-029
5. Attach V-belts (5) (6 used) on pulley (4). Adjust the Adjusting Bolt
tension of belt with adjusting bolts (3 places).
NOTE: The procedure for adjusting V-belt tension:
Press the belt at middle point (A) by fingers
with 98 N (10 kgf, 22 Ibf) to adjust the sag
dimension B to 13 to 14 mm (0.51 to 0.55 in).
6
6. Connect hoses (6, 7, 8) to compressor drive motor 14
7
(9).
: 27 mm 8
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft) 13
: 36 mm
9
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
10
11
7. Install guard cover (14) with bolts (13) (14 used).
: 17 mm 12
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
Adjusting Bolt M141-07-050
W18B-02-13-003
W2-12-2
(Blank)
W2-12-3
DISASSEMBLE COMPRESSOR DRIVE
MOTOR 9
8
7
6
4
3
21
20
2
1 12 19
18
11
10 17
16
22
15
14
13
23
24 31
30
29
28
27
26
25 W118-02-10-001
1- Plug (2 Used) 9- Spring Guide 17 - Plunger (9 Used) 25 - O-Ring

2- O-Ring (2 Used) 10 - Socket Bolt (4 Used) 18 - Swash Plate 26 - Pin (2 Used)
3- Cover 11 - Washer (4 Used) 19 - Shaft 27 - Housing
4- Needle Bearing 12 - Pin (2 Used) 20 - Key 28 - Spacer
5- Valve Plate 13 - Rotor 21 - Bearing 29 - Retaining Ring
6- Retaining Ring 14 - Pin (3 Used) 22 - Pin 30 - Oil Seal
7- Spring Guide 15 - Spherical Bushing 23 - Plug 31 - Retaining Ring
8- Spring 16 - Retainer 24 - O-Ring
W2-12-4
Disassemble
1. Remove plug (23) from housing (27) to drain oil 8. Remove retaining ring (29), spacer (28) from shaft
out from the housing. (19). Then remove bearing (21) from shaft (19).
IMPORTANT: When removing cover (3), cover (3) 9. Remove bearing (21) from shaft (19) with a guide
is still attached with valve plate (5). bar and a hammer.
Take care not to drop the valve plate.
2. Remove socket bolts (10) (4 used) and washers IMPORTANT: In case oil seal (30) is removed, be
(11) (4 used) to remove cover (3) from housing sure to replace it with a new one.
(27). 10. Remove retaining ring (31) from housing (27) to
: 10 mm remove oil seal (30).
3. Remove valve plate (5), needle bearing (4) and

pins (12) (2 used) from cover (3).
IMPORTANT: The end of shaft (19) is matched with

the inner race on needle bearing (4).
Wind vinyl tape onto the shaft to
protect it from damage.
4. Remove O-ring (25), rotor (13), spherical bushing
(15), retainer (16) and plungers (17) (9 used) from
housing (27).
5. Remove pins (14) (3 used) from rotor (13).

NOTE: Do not remove spring (8) unless necessary.
6. Remove key (20) from shaft (19).
7. Tap and remove shaft (19) from the key (20)

mounting side with a plastic hammer. At this time,
swash plate (18), pin (22) and bearing (21) are
also removed out together with shaft (19) from
housing (27).
W2-12-5
ASSEMBLE COMPRESSOR DRIVE
MOTOR
10 1 23 24 15 17 16 18
28
29
20
1 2 4 3 12 26 25 5 6 7 19 13 8 9 14 27 21 22 30 31
W118-02-10-002
1- Plug (2 Used) 9- Spring Guide 17 - Plunger (9 Used) 25 - O-Ring

2- O-Ring (2 Used) 10 - Socket Bolt (4 Used) 18 - Swash Plate 26 - Pin (2 Used)
3- Cover 11 - Washer (4 Used) 19 - Shaft 27 - Housing
4- Needle Bearing 12 - Pin (2 Used) 20 - Key 28 - Spacer
5- Valve Plate 13 - Rotor 21 - Bearing 29 - Retaining Ring
6- Retaining Ring 14 - Pin (3 Used) 22 - Pin 30 - Oil Seal
7- Spring Guide 15 - Spherical Bushing 23 - Plug 31 - Retaining Ring
8- Spring 16 - Retainer 24 - O-Ring
W2-12-6
Assemble
IMPORTANT: Install oil seal (30) with its seal lip 11. Install plungers (17) (9 used) into retainer (16).
facing inside of housing (27).
1. Apply grease to oil seal (30), then install it into 12. Apply grease to pins (14) (3 used), then install the
housing (27). pins to rotor (13).
2. Install retaining ring (31) into housing (27). 13. Install spherical bushing (15), the plungers (17) (9
used) into rotor (13).
IMPORTANT: The key groove in shaft (19) and the
outer race on the other side of shaft 14. Turn shaft (19) to install the rotor (13) assembly
(19) are matched with the inner race into shaft (19).
of needle bearing (4). Be sure not to
damage them.
3. Press bearing (21) on shaft (19). 15. Place the housing (27) assembly with the
mounting surface for cover (3) facing upward.
4. Install spacer (28) and retaining ring (29) to shaft
(19). 16. Supply grease to the needle part of needle
bearing (4) on cover (3). Push the needle to the
outer race direction.
5. Place housing (27) with its cover (3) side facing
upward.
17. Install pins (12) (2 used) to cover (3).
6. Install pin (22) into housing (27).
IMPORTANT: Apply grease to cover (3) side of
valve plate (5) to prevent it from
7. Press the shaft (19) assembly into housing (27). coming off.
18. Install valve plate (5) onto cover (3).
8. Place housing (27) horizontally.
19. Install O-ring (25) and pins (26) (2 used) into
9. Install swash plate (18) into housing (27) with a housing (27).
bar and hammer.
20. Install cover (3) onto housing (27) with socket
IMPORTANT: Press and fit swash plate (18) till its bolts (10) (4 used) and washers (11) (4 used).
bottom side makes full contact with : 10 mm
housing (27). Make sure that shaft : 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
(19) is 18.5 mm (0.73 in) higher than
to top of housing (27). 21. Install key (20) into shaft (19).
10. Install spring guide (9), spring (8), spring guide (7)
and retaining ring (6) into rotor (13).
NOTE: Since the force of spring (8) is too strong to
install the retaining ring (6), a press should
be used to install it.
W2-12-7
(Blank)
W2-12-8
UPPERSTRUCTURE / Air Conditioner
WORK AFTER REPLACING COMPONENT
The following work is required after replacing
compressor, high pressure hose, low pressure hose,
condenser, receiver tank, liquid hose, and air
conditioner unit.
The same work is required when gas leakage is
found.
1. Add compressor oil
2. Charge air conditioner with refrigerant

・ Purging
・ Charge air conditioner with refrigerant
・ Warm up operation
・ Inspection
ADD COMPRESSOR OIL

Compressor oil quantity to be added after component
replacement:
・ 220 cm3 (0.23 US qt) :
After replacement of the compressor, high
pressure hose, condenser, receiver tank, liquid
hose, or air conditioner unit.
・ 100 cm3 (0.11 US qt) :
After replacement of the low pressure hose.
W2-13-1
CHARGE AIR CONDITIONER WITH
REFRIGERANT
Necessity of Purging
Be sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit.
1. Pressure rise in the high pressure side

Air
If air remains in the air conditioner circuit, this
disturbs the heat exchange between refrigerant
and air in the condenser, causing pressure to rise
in the high pressure side (compressor side).
Usually, refrigerant gas is easily liquefied;
however, air cannot be liquefied and remains as
a gas in the condenser because the temperature
at which air liquefies is extremely low. That is,
liquidation of the refrigerant gas in the condenser
decreases by the amount of air in the circuit, and Pressure increases if air
W115-02-10-001
the gas pressure in the high pressure side remains in the air
conditioner circuit
increases accordingly.
2. Metal corrosion
If air remains in the air conditioner circuit, a

chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.
Hydrochloric acid Hydrochloric acid W115-02-10-002

corrodes metals if
moisture exists
Metal corrosion
3. Plugging of the expansion valve by moisture
When high pressure refrigerant gas passes

through the expansion valve, gas pressure
decreases and temperature drops. Moisture
included in high pressure refrigerant gas in the
air conditioner circuit freezes at the expansion
valve orifice, plugging refrigerant flow. Operation Plugged refrigerant
of the air conditioner becomes unstable and flow
Ice produced at the
cooling efficiency lowers. expansion valve disturbs
W115-02-10-003
refrigerant flow, lowering
cooling efficiency
Low cooling
efficiency
W2-13-2
Purging Procedure Gauge Manifold
IMPORTANT: Never mistake the charge hose Low Pressure

connections. Valve
1. Close the high and low pressure valves on the Low Pressure
Charge Hose High Pressure
gauge manifold (Parts Number 4360564).
Valve
Connect the high-pressure-side charge hose and
the low-pressure-side charge hoses to the High Pressure
high-pressure-side charge valve (“D” marked) Charge Hose
and to the low-pressure-side charge valve (“S” Center Pressure
marked) located on the compressor, respectively. Charge Hose
Vacuum Pump
Connect the charge hose located on the center of
the manifold bottom to the vacuum pump (Parts
Number 4360565).
NOTE: Vacuum Pump Joint Adapter (Parts
Number 4360566).
W115-02-10-005
Low Pressure
Side S
Compressor
D
High Pressure
Side
T142-02-05-018
Fully Open
2. Open the high pressure and low pressure valves
in the gauge manifold. Perform purging for 10
minutes or more by operating the vacuum pump. Fully Open
In Operation
W115-02-10-005
W2-13-3
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again. Close
3. When the low pressure gauge reading falls
below-755 mmHg, stop the vacuum pump and Close
close the high and low pressure valves. Wait for
approximately five minutes and confirm that the
pointer does not return to 0.
In Operation
W115-02-10-005
4. With the high pressure and low pressure valves

of the gauge manifold closed, connect the charge
hose to the refrigerant container (Parts Number
4347644).
Refrigerant Container
W115-02-10-007
5. Loosen the charge hose connection to the gauge

manifold and open the refrigerant container valve
to purge air in the charge hose with the
refrigerant pressure. Loosen
Open
W115-02-10-007
W2-13-4
IMPORTANT: Always stop the engine when
High
charging the air conditioner with Pressure
refrigerant. Never position the Gauge
refrigerant container upside down Tighten
during charging operation. When
changing the refrigerant container
during charging operation, be sure Open
to purge air from the charge hose,
as shown in step 10.
6. Fully tighten the charge hose connection to the
gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with Open
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
reading reaches 98 kPa (1 kgf/cm2, 14 psi).
NOTE: Use warm water of 40 °C (104 °F) or less
to warm the refrigerant container to aid in
charging operation.
W115-02-10-007
IMPORTANT: Use the leak tester for R134a.

7. After charging, check the line connections for gas
leaks using leak tester (Parts Number 4360567). W115-02-10-008
W2-13-5
8. Confirm that the high pressure and low
pressure valves in the gauge manifold and the
refrigerant container valve are closed.
Start the engine and operate the air conditioner.
Operating Conditions of the Air Conditioner:

Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
IMPORTANT: Never open the high pressure valve

in the gauge manifold.
9. Open the low pressure valve in the gauge Open
manifold and the refrigerant container valve to
charge with refrigerant until the bubbles seen in
the receiver/drier sight glass disappear.
NOTE: The required refrigerant quantity is 1400
g±50 g (3±0.01 lb).
Open
W115-02-10-007
10. If the refrigerant container becomes empty during

the charging work, replace it with a new Close
refrigerant container as follows:
(1) Close the high pressure and low pressure
valves on the manifold gauge.
(2) Replace the empty container with a new
one.
(3) Tighten, then slightly loosen the refrigerant
container joint.
(4) Slightly open the low pressure valve on the
manifold gauge. Close
(5) When the refrigerant container joint starts to
leak, immediately tighten the refrigerant
container joint and close the low pressure
valve on the manifold gauge.
11. After charging, close the low pressure valve in

the gauge manifold and the refrigerant container
valve, and stop the engine.
W115-02-10-007
W2-13-6
IMPORTANT: If the air conditioner is operated
with very low refrigerant, a bad load
will be exerted on the compressor. If
the air conditioner is overcharged
with refrigerant, cooling efficiency
will lower and abnormal high
pressure will arise in the air Sight Glass
conditioner circuit, causing danger.
12. Start the engine and operate the air-conditioner
again.
Observe the sight glass of the receiver/drier to
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Receiver/Drier
Cooler Switch : ON
NOTE: As the bubbles in the sight glass vary
W115-02-10-009
depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .
Checking procedures: Stop the air conditioner and

wait until refrigerant returns to the balanced pressure.
Then, start the air conditioner again.
Relation between Refrigerant Quantity and
Refrigerant Flow in Sight Glass:
Refrigerant Flow in Sight Glass
Refrigerant
(approx. 1 min. after air conditioner Explanation for Refrigerant Flow in Sight Glass
Quantity
switch is turned ON)
(immediately after) (approx. 1 mm after) Immediately after the air conditioner is turned ON,
Adequate few bubbles are seen. Then the flow becomes trans-
parent and shows thin milk white color.
W115-02-10-016
No bubbles are seen after the air conditioner is

Overcharged turned ON.
W115-02-10-017
Bubbles are seen continuously after the air condi-

Not Enough tioner is turned ON.
W115-02-10-018
CAUTION: Wait until the high-pressure-side

W115-02-10-019
pressure drops to less than 980 kPa (10
Bubbles exist: Bubbles are seen in refrigerant flow
kgf/cm2, 142 psi) before attempting to dis-
as both liquid refrigerant and refrigerant gas exist,
connect the high-pressure-side charge hose.
being mixed.
Otherwise, refrigerant and compressor oil
may gush out.
W115-02-10-020
Transparent: Refrigerant flow is transparent as only

liquid refrigerant exists. 13. After checking refrigerant quantity, disconnect the
low-pressure-side charge hose first. Wait for the
high-pressure-side pressure to drop to less than
980 kPa (10 kgf/cm2, 142 psi). Disconnect the
115-02-10-021
high-pressure-side charge hose.
Milk white: Refrigerant flow shows thin milk white
as oil and refrigerant are separated.
W2-13-7
Warm-up Operation
After charging the air conditioner, carry out warm-up
operation for five minutes to lubricate system with
compressor oil.
Operating Conditions of the Air Conditioner

Cooler Switch : ON
Inspection
After warm-up operation, carry out gas leak check
and performance check.
1. Check the air conditioner for gas leaks using a

leak tester. Leak Tester
(1) Perform checking under well-ventilated
conditions.
(2) Thoroughly wipe off dust from the charge
hose connections of the compressor.
(3) Pay special attention to check the line
connections.
(4) If any gas leaks are found, retighten the line
connections.
CAUTION: Refrigerant will produce

W115-02-10-013
poisonous material if exposed to heat of
1000 °C (1800 °F) or more. Never bring
refrigerant close to a fire.
2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner
component.
Retighten Line
(1) Check each component for abnormalities. Connection
(2) Carry out ON-OFF check of the compressor
clutch.
(3) Check compressor fan belt tension.
(4) Check the coolant level in the radiator.
(5) Operate the air conditioner and check the
performance. W115-02-10-014
W2-13-8
3. The checklist before the summer season is as
follows:
(1) Check each air conditioner component for
abnormalities.
(2) Check the line connections for oil leaks.
(3) Check refrigerant quantity.
(4) Check the engine cooling circuit.
(5) Check belts for wear. Replace if necessary.
4. Off-Season Maintenance
(1) During off-season, operate the idler pulley
and compressor at least once a month for a
short time to check for any abnormal
sounds.
(2) Do not remove the compressor belts during
off-season. Operate the compressor
occasionally at slow speed for 5 to 10
minutes with the belt slightly loosened in
order to lubricate the machine parts.
W2-13-9
(Blank)
W2-13-10
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SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing Group 7 Front Idler
Remove and Install Swing Bearing .......... W3-1-1 Remove and Install Front Idler .................W3-7-1
Disassemble Front Idler ...........................W3-7-6
Group 2 Travel Device Assemble Front Idler ................................W3-7-8
Remove and Install Travel Device............ W3-2-1 Maintenance Standard ...........................W3-7-10
Disassemble Travel Reduction Gear........ W3-2-4
Assemble Travel Reduction Gear .......... W3-2-14 Group 8 Upper and Lower Roller
Disassemble Travel Motor ..................... W3-2-22 Remove and Install Upper/ Lower Roller ..W3-8-1
Assemble Travel Motor .......................... W3-2-30 Disassemble Upper Roller........................W3-8-6
Disassemble and Assemble Travel Assemble Upper Roller ............................W3-8-8
Speed Mode Selector Valve ................. W3-2-36 Disassemble Lower Roller......................W3-8-10
Maintenance Standard ........................... W3-2-38 Assemble Lower Roller ..........................W3-8-12
Maintenance Standard ...........................W3-8-14
Group 3 Travel Brake Valve
Remove and Install Travel Brake Valve.... W3-3-1 Group 9 Track Shoes
Disassemble Travel Brake Valve.............. W3-3-4 Remove and Install Track Shoes ..............W3-9-1
Assemble Travel Brake Valve .................. W3-3-6 Disassemble and Assemble
Track Shoes ...........................................W3-9-6
Group 4 Drive Tumbler Maintenance Standard .............................W3-9-7
Remove Drive Tumbler ............................ W3-4-1
Install Drive Tumbler ................................ W3-4-8 Group 10 Accumulator
Maintenance Standard ........................... W3-4-18 Remove and Install Accumulator ............W3-10-1
Disassemble Accumulator ......................W3-10-4
Group 5 Center Joint Assemble Accumulator ...........................W3-10-6
Remove and Install Center Joint .............. W3-5-1
Disassemble Center Joint ........................ W3-5-4 Group 11 Welding Repair Procedure
Assemble Center Joint............................. W3-5-6 Welding Repair Procedure ..................... W3-11-1
Welding Rod Specification...................... W3-11-2
Group 6 Adjuster Cylinder Repair Track Shoes (Shoe Lugs) ........... W3-11-3
Remove and Install Adjuster Cylinder ...... W3-6-1 Repair Rollers ........................................ W3-11-6
Disassemble Adjuster Cylinder ................ W3-6-6 Repair Drive Tumbler ........................... W3-11-10
Assemble Adjuster Cylinder ..................... W3-6-8
141W-3-1
(Blank)
141W-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Removal
1. Remove the front attachment, counterweight and

main frame. (Refer to “Remove and Install Front
Attachment” on page W4-1-1, refer to “Remove 2 Track Frame
and Install Counterweight” on page W2-2-1, refer
to “Remove and Install Frame” on page W2-3-1)
1
2. Remove bolts (1) (60 used) from swing bearing

(2).
: 75 mm
3. Put matching marks between inner race and

outer race of swing bearing (2) and between
outer race and track frame. W18B-03-01-005
4. Pass the eye of lifting rope through the bolt hole Lifting Rope
in the outer race in swing bearing (2) (3 places).
Pass a steel rib through the eye.
CAUTION: Swing bearing (2) weight:

5270 kg (11620 lb)
5. Lift and remove swing bearing (2) from the track

frame by crane.
Steel Rib W18B-03-01-002
W141-03-01-001
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
CAUTION: Swing bearing (2) weight:

5270 kg (11620 lb)
IMPORTANT: Install swing bearing (2) with

mark(s) in the inner race facing the
left side of machine, while with mark
(A) facing the right side of machine
and with mark (S) in the outer race 2
facing the right side of machine,
while with mark (A) facing the left
side of machine.
1. Lift swing bearing (2) by crane. Place swing
bearing (2) on the track frame while matching
marks made before removal is combined to
aligning it with dowel pin (3) (2 places) to a rough
standard.
NOTE: As for lifting swing bearing (2) refer to
Removal section. W141-03-01-001
2 3
W141-03-01-002
2. Apply lubricant onto the threads of bolts (1) (60

used). Insert bolts (1) (60 used) into swing bear- 2 Track Frame
ing (2), then tighten them.
: 75 mm
: 4900 N⋅m (500 kgf⋅m, 3620 lbf⋅ft) 1
3. Install the main frame, counterweight and front

attachment. (Refer to “Remove and Install Front
Attachment” on page W4-1-1, refer to “Remove
and Install Counterweight” on page W2-2-1, refer
to “Remove and Install Frame” on page W2-3-1) W18B-03-01-005
W3-1-2
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
IMPORTANT: Be sure to bleed air from hydraulic CAUTION: Travel reduction gear (4) weight:
oil tank before staring work. (Refer 2530 kg (5580 lb)
Tank”) 5. Attach a sling and wire into the hoist hole. With
travel reduction gear (4) held by crane, remove
Removal the mounting bolts (6) (28 used). Insert bolts (6)
into pulling holes (2 places) to make the travel
reduction gear (4) rise from the side frame, then
1. Disconnect all hydraulic hoses and pipes from remove it.
travel motor (2). : 55 mm
: 19 mm, 22 mm, 36 mm Lifting Hole
: 14 mm
1 2
CAUTION: Travel motor (2) weight:

3
280 kg (620 lb)
Pulling
Hole
2. Attach a nylon sling to travel motor (2) body and
hoist it a little bit. Remove bolts (1) (4 used) to
4
remove travel motor (2).
: 32 mm
IMPORTANT: There may be pressure accumulated

inside of travel device. Loosen level
plug (3) by 2 to 3 turns slowly to
Pulling
bleed any pressure out from the Hole
travel device before draining gear
oil out.
3. Remove drain plug (5) to drain gear oil out. Install
drain plug (5) again after draining the gear oil 6 5 W117-03-02-001
thoroughly.
: 23 mm
: 69 N⋅m (7 kgf⋅m, 50 lbf⋅ft)
NOTE: In case level plug (3) is removed when
draining, gear oil can be drained out
quickly.
Gear oil volume: 141 L (37.3 US gal)
4. Remove the corks (2 used) from the pulling hole

of travel reduction gear (4).
W3-2-1
6. Set wooden blocks at firm and steady place as
shown in right illustration.
4
NOTE: Wooden block dimensions: (Just for refer-
ence)
Height 250 mm (9.8 in), Width 200 mm
(7.87 in), Length 200 (7.87 in)
7. Place travel reduction gear (4) onto the wooden

blocks.
Wooden Block Wooden Block
1000 mm W18B-03-02-004
W3-2-2
Installation
1. Apply THREEBOND #1215 to the mating surface IMPORTANT: With the travel motor having been
for the reduction gear (4) on the side frame. installed, refill hydraulic oil into the
travel motor. Also be sure to per-
form break-in operation after in-
CAUTION: Travel reduction gear (4) weight: stalling to prevent the travel motor
2530 kg (5580 lb) and/or travel reduction gear from
seizure.
2. Lift travel reduction gear (4) by crane, then install Break-in operation:
travel reduction gear (4) onto the side frame with 1. Fuel control lever: Min. speed
bolts (6) (28 used). After tightening bolt (6), 2. Travel mode: Slow speed
tighten bolt (7) to the specified torque (400 N⋅m 3. Operation duration: Over 2 minutes
(41 kgf⋅m, 295 lbf⋅ft)).
: 27 mm
Lifting Hole
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
1 2
: 55 mm
: 3140 N⋅m (320 kgf⋅m, 2310 lbf⋅ft)
3
3. Install the corks (2 used) into pulling hole of travel Pulling
reduction gear (4). Hole
CAUTION: Travel motor (2) weight: 4

280 kg (620 lb)
4. Lift travel motor (2) by crane to install it onto the

travel reduction gear with bolts (1) (4 used).
5. Connect all hoses and piping to travel motor (2). Pulling

Hole
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft) 6 5 W117-03-02-001
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
6. Fill gear oil through level plug (3). After filling gear
oil in, install level plug (3).
: 24 mm
: 196 N⋅m (20 kgf⋅m, 145 lbf⋅ft)
NOTE: Gear oil: Gear lubricant SP 90
Gear oil volume: 141 L (37.3 Us gal)
W3-2-3
DISASSEMBLE TRAVEL REDUCTION
GEAR 8
6
5
4
3
1 2
9
10
11
22
21
12
20
19
18
13 17
16
15 23
14
24
25
26
27 41
28
30 29 40
31
32 39
33 38
34 37
36
42
35
43
50
51 45
44
52
53
57
56
46
55 48
47
49
54
W141-03-02-006
1 - Second Stage Planetary 16 - Retaining Ring 31 - Cork (2 Used) 46 - Cork (2 Used)

Gear (4 Used)
2 - Spherical Bearing (4 Used) 17 - Ball Bearing 32 - Cork (2 Used) 47 - Knock Pin (2 Used)
3 - Spacer (4 Used) 18 - Retaining Ring 33 - Washer (14 Used) 48 - Washer (21 Used)
4 - Retaining Ring (4 Used) 19 - First Stage Carrier 34 - Bolt (14 Used) 49 - Bolt (21 Used)
5 - Spacer (4 Used) 20 - Second Stage Sun Gear 35 - Cover 50 - Boss
6 - Spherical Bearing (4 Used) 21 - Seat 36 - Roller Bearing 51 - Retaining Ring
7 - Pin (4 Used) 22 - Plate 37 - Pinion Gear 52 - Ball Bearing
8 - Second Stage Ring Gear 23 - Pin (3 Used) 38 - Roller Bearing 53 - O-Ring
9 - Bolt (8 Used) 24 - Roller Bearing (3 Used) 39 - Gear 54 - Cork (2 Used)
10 - Lock Washer (4 Used) 25 - Spacer (3 Used) 40 - Ball Bearing 55 - Bolt (6 Used)
11 - Lock Plate (4 Used) 26 - Retaining Ring (3 Used) 41 - Casing 56 - Spring Washer (6 Used)
12 - Second Stage Carrier 27 - Spacer (3 Used) 42 - Cork (2 Used) 57 - Cover
13 - First Stage Ring Gear 28 - Roller Bearing (3 Used) 43 - Washer (20 Used)
14 - First Stage Sun Gear 29 - First Stage Planetary Gear 44 - Bolt (20 Used)
(3 Used)
15 - Stopper Pin 30 - Retaining Ring (3 Used) 45 - Ball Bearing
W3-2-4
Disassemble Travel Reduction Gear
1. Remove Corks (54) (2 used) from cover (57). CAUTION: Cover (35) weight: 83 kg (185 lb)
2. Remove bolts (55) (6 used) and spring washers IMPORTANT: Do not remove dowel pins (47) (2
(56) (6 used) from cover (57). used) unless necessary.
: 24 mm 10. Insert bolts (M16, Pitch 2.0 mm) into the pulling
holes (2 places) in cover (35) to make cover (35)
3. Insert bolts (M16, Pitch 2.0 mm) into the pulling float from casing (41).
holes (2 places) in cover (57) to make cover (57) Install eyebolts (M16, Pitch 2.0 mm) (2 used) and
float from cover (35). (M22, Pitch 2.5 mm) (2 used) into cover (35),
57 then lift and remove cover (35) from casing (41).
While removing cover (35) it should be removed
Pulling Hole
with the outer race of roller bearing (36) still on.
Pulling Hole
: 24 mm
Lifting Hole
(M22, Pitch 2.5 mm)
Pulling Hole
(M16, Pitch 2.0 mm)
Pulling Hole
W141-03-02-004
(M16, Pitch 2.0 mm)
CAUTION: Cover (57) assembly weight: 26

kg (57 lb) 35
4. Install eyebolts (M16, Pitch 2.0 mm) into the pull-

ing holes (2 places) in cover (57), then lift and
remove cover (57) from cover (35) by crane.
5. Remove O-ring (53) from cover (57).
6. Install bolts (M16, Pitch 2.0 mm) into the bolt hole
of boss (50). W141-03-02-005
IMPORTANT: Ball bearing (52) is installed by 11. Install eyebolts (M16, Pitch 2.0 mm) to the lifting
pressing. Do not remove the ball holes (2 places) in gear (39).
bearing unless necessary.
7. Remove boss (50), retaining ring (51) and ball
bearing (52) from cover (57).
8. Remove corks (46) (2 used) from cover (35).
9. Remove bolts (49) (21 used) and washers (48)

(21 used) from cover (35).
: 24 mm
W3-2-5
19
13
14
41
40
39
38
37
36
35
43
45
44
49
W141-03-02-006
W3-2-6
CAUTION: Gear (39) assembly: CAUTION: Casing (41) weight: 154 kg (340 lb)
150 kg (340 lb)
16. Insert bolt (M20, Pitch 2.5 mm) into the pulling
12. Lift and remove gear (39) from casing (41) by holes (2 places) in casing (41) to make casing
crane. (41) float from first stage ring gear (13).
While removing ball bearings (40, 45) it should Install eyebolts (M16, Pitch 2.0 mm) (4 used) into
be removed with gear (39) still on. bolt (49) hole of casing (41) to lift and remove
casing (41) from first stage ring gear (13) by
13. Remove ball bearings (40, 45) from gear (39) crane.
with a puller.
IMPORTANT: Take note of the position and direc- Lifting Hole

(M16, Pitch 2.0
tion to install pinion gears (37) in mm)
order to set them to their original
Pulling Hole
position before being removed. (M20, Pitch 2.5 mm)
14. Remove pinion gears (37) from casing (41).
At this time, keep pinion gear (37) still with the inner
race of roller bearing (38). Pulling Hole
(M20, Pitch 2.5
NOTE: Keep the inner race of roller bearing (36, mm)
38) for pinion gear (37) still attached on
pinion gear (37), while the outer race at- 35
tached in casing (41) and cover (35).
The bearing may be damaged in case it is
mismatched.

(20 used) from casing (41).
: 30 mm
W141-03-02-005
CAUTION: First stage sun gear (14) weight:

27 kg (60 lb)
17. Install eyebolts (M16, Pitch 2.0 mm) into the lift-
ing hole on first stage sun gear (14). Lift and re-
move first stage sun gear (14) from first stage
carrier (19).
W3-2-7
21
20
19
18
13 17
16
15
23
24
25
26
27
28
29
30
33
34
W141-03-02-006
W3-2-8
IMPORTANT: Keep roller bearings (24, 28) and
CAUTION: First stage carrier (19) assembly first stage planetary gear (29) as an
weight: 480 kg (1060 lb) assembly.
21. Remove roller bearings (24) (3 used) and (28) (3
18. Install eyebolts (M16, Pitch 2.0 mm) in the lifting used) from first stage planetary gears (29) (3
holes in pins (23) (3 used). Lift pins (23) (3 used) used) with a puller to remove spacers (25) (3
by crane to remove the first stage carrier (19) used), (27) (3 used) and retaining rings (26) (3
assembly from first stage ring gear (13). While used).
removing, the first stage carrier (19) assembly
will be removed with second stage sun gear (20) 22. Remove retaining ring (18) from second stage
still attached. sun gear (20).
19. Remove retaining ring (30) from pin (23). Lower
pin (23) down carefully to remove the pin from CAUTION: First stage carrier (19) weight:
first stage carrier (19). Remove pins (23) left in 190 kg (420 lb)
same procedure.
NOTE: If retaining ring (30) is difficult to remove, 23. Pass a nylon sling through pin (23) holes (3
push up pin (23) from under to make re- places) in first stage carrier (19). Lift and remove
taining ring (30) float from first stage carrier first stage carrier (19) from second stage sun
(19). gear (20) by crane.
CAUTION: First stage planetary gear (29) CAUTION: Second stage sun gear (20)
assembly weight: 55 kg (125 lb) weight: 86 kg (190 lb)
20. Until the hole of the center appears first stage 24. Install eyebolts (M16, Pitch 2.0 mm) to lifting
planetary gear (29) drawn. Hoist and remove first holes (2 places) in second stage sun gear (20)
stage planetary gear (29) from first stage carrier and position the second stage sun gear horizon-
(19). (3 places) tally by crane.
While doing this, first stage planetary gear (29)
may be removed with roller bearings (24, 28) still 25. Insert a bronze bar (Dia. 40 mm (1.57 in), Length
attached. 300 mm (11.81 in)) to the hole in second stage
sun gear (20) at seat (21) side. Tap the bronze
bar lightly with a plastic hammer to remove stop-
per (15).
26. Remove retaining ring (16) from second stage

sun gear (20) to remove ball bearing (17) with a
puller.

(14 used) from first stage ring gear (13).
: 27 mm
W3-2-9
6
5
4
3
2
1 9
10
11
12
13
40
44
W141-03-02-006
W3-2-10
CAUTION: First stage ring gear (13) weight: 30. Place the second stage (12) assembly on the
320 kg (710 lb) wooden blocks.
28. Insert the bolts (M20, Pitch 2.5 mm) into pulling NOTE: Dimensions for the wooden block
holes (2 places) in first stage ring gear (13) to Height 250 mm (9.8 in), Width 460 mm
make first stage ring gear (13) float from second (18.1 in), Length 460 mm (18.1 in)
stage ring gear (8).
Install eyebolts (M20, Pitch 2.5 mm) (4 used) to 12
bolt (44) hole of first stage ring gear (13), then lift
and remove first stage ring gear (13) from sec-
ond stage ring gear (8). Wooden Block
: 27 mm
Lifting Hole
(M24, Pitch 3.0 mm) Pulling Hole W18B-02-05-003
(M18, Pitch 2.5 mm)
31. Install eyebolts (M16, Pitch 2.0 mm) into the lift-
ing hole in pin (7), then hold it by crane.
32. Remove bolts (9) (8 used), lock washers (10) (4

used) and lock plates (11) (4 used) from second
stage carrier (12).
: 30 mm
33. Lift and remove pin (7) from second stage carrier
(12) by crane. Remove pins (7) (3 used) left from
second stage carrier (12) in same procedure.
CAUTION: Second stage planetary gear (1)

1 assembly weight: 71 kg (157 lb)
Pulling Hole
(M18, Pitch 2.5 mm) 34. Until the hole of the center appears second stage
W118-03-01-005
planetary gear (1) drawn. Lift and remove the
second stage planetary gear (1) assembly from
second stage carrier (12) by crane. (4 places)
CAUTION: Second stage carrier (12) assem-
bly weight: 860 kg (1900 1b) IMPORTANT: Keep spherical bearings (2, 6) and
second stage planetary gear (1) as
29. Install eyebolts (M16, Pitch 2.0 mm) in the lifting an assembly.
hole in pins (7) (4 used). Lift and remove the 35. Remove spherical bearings (2) (4 used) and (6)
second stage carrier (12) assembly from second (4 used) from second stage planetary gears (1)
stage ring gear (8) by crane. (4 used) with a puller to remove spacers (3) (4
used), (5) (4 used) and retaining rings (4) (4
used).
W3-2-11
22
21
12
W141-03-02-006
W3-2-12
36. Pass a nylon sling through the pin (7) hole of
second stage carrier (12).
CAUTION: Second stage carrier (12) weight:

490 kg (1080 lb)
37. Hoist and hold position second stage carrier (12)

horizontally.
38. Remove plate (22) from second stage carrier (12)

with a bar and hammer.
IMPORTANT: Between plate (22) and seat (21) are

caulked at two places with a punch
after being assembled. Be sure to
grind the caulked part with a grinder
before removing.
39. Install bolt (M12, pitch 1.75 mm) into bolt hole of
seat (21) to remove seat (21) from plate (22).
W3-2-13
ASSEMBLE TRAVEL REDUCTION GEAR
21 22 20 12 8 17 33, 34 13 18 16 19 38 41
37
36
35
39
15
53
14
52
50
57
51
45
55, 56
40
7
48, 49
9 30
23
11
10 6 1 5 4 3 2 24 29 25 26 27 28 43, 44
W141-03-02-001
1 - Second Stage Planetary 16 - Retaining Ring 31 - *Cork (2 Used) 46 - *Cork (2 Used)
Gear (4 Used)
2 - Spherical Bearing (4 Used) 17 - Ball Bearing 32 - *Cork (2 Used) 47 - *Knock Pin (2 Used)
3 - Spacer (4 Used) 18 - Retaining Ring 33 - Washer (14 Used) 48 - Washer (21 Used)
4 - Retaining Ring (4 Used) 19 - First Stage Carrier 34 - Bolt (14 Used) 49 - Bolt (21 Used)
5 - Spacer (4 Used) 20 - Second Stage Sun Gear 35 - Cover 50 - Boss
6 - Spherical Bearing (4 Used) 21 - Seat 36 - Roller Bearing 51 - Retaining Ring
7 - Pin (4 Used) 22 - Plate 37 - Pinion Gear 52 - Ball Bearing
8 - Second Stage Ring Gear 23 - Pin (3 Used) 38 - Roller Bearing 53 - O-Ring
9 - Bolt (8 Used) 24 - Roller Bearing (3 Used) 39 - Gear 54 - *Cork (2 Used)
10 - Lock Washer (4 Used) 25 - Spacer (3 Used) 40 - Ball Bearing 55 - Bolt (6 Used)
11 - Lock Plate (4 Used) 26 - Retaining Ring (3 Used) 41 - Casing 56 - Spring Washer (6 Used)
12 - Second Stage Carrier 27 - Spacer (3 Used) 42 - *Cork (2 Used) 57 - Cover
13 - First Stage Ring Gear 28 - Roller Bearing (3 Used) 43 - Washer (20 Used)
14 - First Stage Sun Gear 29 - First Stage Planetary Gear 44 - Bolt (20 Used)
(3 Used)
15 - Stopper Pin 30 - Retaining Ring (3 Used) 45 - Ball Bearing
W3-2-14
Assemble Travel Reduction Gear
IMPORTANT: Install seat (21) with the oil groove IMPORTANT: Secure bolt (9) with lock washer (10)
facing cover (57). bent.
1. Install seat (21) to plate (22). Then tap them and 5. Install eyebolts (M16, Pitch 2.0 mm) into the lift-
listen to ring to judge if installation is completed, ing hole in pin (7), lift it by crane and install the
caulk seat (21) and plate (22) at 2 places (sym- pins into second stage carrier (12). (4 places)
metrically) with a punch to secure them together. Install lock plate (11) and lock washer (10) with
bolts (9) (2 used) to each pins (7).
2. Install plate (22) onto second stage carrier (12). : 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
CAUTION: Second stage planetary gear (1) 6. Tap ball bearing (17) into second stage sun gear
weight: 58 kg (130 lb) (20) with a bar and hammer, then install retaining
ring (16). Tap stopper pin (15) into ball bearing
IMPORTANT: When replacing spherical bearings (17) with a bar and hammer.
(2, 6) with new ones, be sure to re-
place it as assembly and install the
bearing with matching mark A fac- CAUTION: First stage carrier (19) weight:
ing inside. 190 kg (420 lb)
3. Install retaining rings (4) (4 used) and spacers (3)
(4 used) and (5) (4 used) onto second stage 7. Pass a nylon sling through the hole in pin (23) on
planetary gears (1) (4 used), then press spherical first stage carrier (19), then lift it by crane and
bearings (2) (4 used) and (6) (4 used) in with a place it on second stage sun gear (20). Install
press. retaining ring (18) onto second stage sun gear
NOTE: Manufacture number and matching mark A (20).
are stamped in the plates both on inner
race and outer race of spherical bearings CAUTION: First stage planetary gear (29)
(2) and (6). weight: 48 kg (106 lb)
CAUTION: Second stage planetary gear (1) IMPORTANT: When replacing roller bearings (24,
assembly weight: 71 kg (157 lb) 28) with new ones, be sure to re-
place it as assembly and install the
IMPORTANT: Second stage planetary gear (1) roller bearing with matching mark A
aligning the matching marks made facing inside.
before disassembling. 8. Install retaining rings (26) (3 used) and spacers
4. Attach a nylon sling to second stage planetary (25) (3 used) and (27) (3 used) onto first stage
gear (1). Lift the second stage planetary gear (1) planetary gears (29) (3 used), then press the
assembly by crane and insert it onto second roller bearings (24, 28) outer races (2 used each)
stage carrier (12). (4 places) with a press. Install each inner race to the roller
bearings (24, 28) outer race.
NOTE: Manufacture number and matching mark A
are stamped in the plates both on inner
race and outer race of roller bearings (24,
28).
W3-2-15
12 8 33, 34 13 19
30
23
7 29 44
W141-03-02-001
W3-2-16
CAUTION: First stage planetary gear (29) CAUTION: Second stage carrier (12) assem-
assembly weight: 55 kg (125 lb) bly weight: 860 kg (1900 lb)
9. Attach a nylon sling to first stage planetary gear 13. Install eyebolts (M16, Pitch 2.0 mm) to the lifting
(29). Lift and insert the first stage planetary gear hole in pins (7) (4 used) on the second stage car-
(29) assembly into first stage carrier (19) by rier (12) assembly, then lift and install onto sec-
crane. (3 places) ond stage ring gear (8) by crane.
CAUTION: First stage carrier (19) assembly CAUTION: First stage ring gear (13) weight:
weight: 450 kg (1000 lb) 320 kg (710 lb)
10. Pass the nylon sling through the holes (3 places) IMPORTANT: Apply THREEBOND #1215 onto the
for pin (33) on first stage carrier (19), then lift it by matching surface of first stage ring
crane and place the first stage carrier on wooden gear (13) and second stage ring
blocks. gear (8).
NOTE: The dimensions for wooden block: 14. Install eyebolts (M20, Pitch 2.5 mm) (3 used)
Height 100mm (3.9 in), Width 300 mm onto first stage ring gear (13).
(11.8 in), Length 300 mm (11.8 in) Lift first stage ring gear (13) by crane. Then place
and install the ring gear onto second stage ring
gear (8) with bolts (34) (14 used) and washers
(33) (14 used).
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
19
Lifting Hole
(M20, Pitch 2.5 mm) 1
Wooden Block
20
W141-03-02-007
11. Install pin (23) into under the first stage carrier
(19). Hold it just when the groove of retaining ring
(30) in pin (23) is coming out from first stage car-
rier (19).
Install retaining ring (30) onto pin (23).
12. Install pins (23) (2 used) left into first stage carrier
(19) by same procedure.
W118-03-01-005
W3-2-17
20 13 19 38 41
37
36
35
39
14
45
40
48, 49
23
W141-03-02-001
W3-2-18
CAUTION: First stage carrier (19) assembly CAUTION: Cover (35) weight: 83 kg (183 lb)
15. Install eyebolts (M16, Pitch 2.0 mm) to the lifting matching surface of cover (35) and
hole in pins (23) (3 used) on first stage carrier casing (41).
(19) (with second stage sun gear (20) attached), 20. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and
then lift and install it onto first stage ring gear (13) (M22, Pitch 2.5 mm) (2 used) onto cover (35).
by crane. Lift cover (35) by crane, then place and install it
onto casing (41).
CAUTION: First stage sun gear (14) weight: Lifting Hole
27 kg (60 lb) (M22, Pitch 2.5 mm)
16. Install eyebolts (M12, Pitch 2.0 mm) to the lifting

hole in first stage sun gear (14), then lift and in- Pulling Hole
stall it onto first stage carrier (19) by crane. (M16, Pitch 2.0 mm)
IMPORTANT: Install pinion gear (37) to the former

position and in the same direction
before disassembled. Dowel Pin
Hole
17. Install pinion gear (37) onto casing (41). 3
NOTE: In case pinion gear (37) is installed at dif-
ferent position or in different direction, the
assembly of outer race and inner race to
roller bearings (36, 38) may be different,
Dowel Pin
too. Hole
It is likely that this may result in the roller
bearings (36, 38) being damaged.
Pulling Hole
(M16, Pitch 2.0 mm)
IMPORTANT: When replacing ball bearings (40,
45) with new ones, it should be re- W141-03-02-005
placed as assembly.
21. Tap dowel pins (47) (2 used) into dowel hole of
18. Heat ball bearings (40, 45) to 90 °C (194 °F) with
cover (35) with a hammer.
bearing heater, then install ball bearings (40, 45)
into gear (39).
22. Tighten bolts (49) (21 used) and washers (48)
(21 used).
CAUTION: Gear (39) assembly weight: : 24 mm
150 kg (340 lb) : 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
19. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to

the lifting holes (2 places) in gear (39), then lift
and install it into casing (41) by crane.
W3-2-19
13 41
35
39
53
14
52
50
57
51
55, 56
43, 44
W141-03-02-001
W3-2-20
23. Install eyebolts (M16, Pitch 2.0 mm) (2 used) and 25. Install ball bearing (52) and boss (50) onto cover
(M22, Pitch 2.5 mm) (2 used) onto the casing (57) with a bar and hammer to install retaining
(41) assembly. ring (51).

Lifting Hole
(M22, Pitch 2.5 mm) Pulling Hole 27. Install eyebolts (M16, pitch 2.0 mm) onto the pull-
(M16, Pitch 2.0
Pulling Hole ) ing hole of cover (57).
(M16, Pitch 2.0 mm)
CAUTION: Cover (57) assembly weight: 26

4
kg (60 lb)
28. Hoist cover (57) to install it onto cover (35) with

bolts (55) (6 used) and spring washers (56) (6
used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
29. Install corks (35) (2 used) onto first stage ring

gear (13).
30. Install corks (42) (2 used) onto casing (41).

W141-03-02-003
31. Install corks (46) (2 used) onto cover (35).
CAUTION: Casing (41) assembly weight: 32. Install corks (54) (2 used) onto cover (57).
400 kg (890 lb)
NOTE: As for corks (31, 32, 42, 46, 54), refer to
W3-2-4.
matching surface of casing (41) and
first stage ring gear (13).
24. Lift the casing (41) assembly by crane, then
place it on first stage ring gear (13) while aligning
the splines of gear (39) with those of first stage
sun gear (14). Install bolts (44) (20 used) and
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
W3-2-21
DISASSEMBLE TRAVEL MOTOR
48
50 45
49
51 46
52 50
45 53
44
43
43
44
55
54
37
36 53
7
6
41
5 42
40 39
4
3 38
2 35
1
33
32 34
8 31
9
10 26
11
27
12
47
13 28
17
29
18
15
19 30
20
21
22
23
24
14
25
16
W18B-03-02-002
W3-2-22
1- Bolt (6 Used) 15 - Plug 29 - Socket Bolt (9 Used) 43 - Socket Bolt (8 Used)

2- Cover 16 - Cover 30 - Valve Plate 44 - Cover (2 Used)
3- O-Ring 17 - O-Ring 31 - O-Ring 45 - O-Ring (2 Used)
4- Oil Seal 18 - Spring (10 Used) 32 - Needle Bearing 46 - Stopper
5- Drive Shaft 19 - Brake Piston 33 - Socket Bolt (14 Used) 47 - Spacer
6- Roller Bearing 20 - O-Ring 34 - Knock Pin 48 - Plug
7- Retaining Ring 21 - O-Ring 35 - Front Casing 49 - O-Ring
8- Valve Plate 22 - Brake Casing 36 - O-Ring 50 - Piston Assembly (2 Used)
9- Rotor 23 - Retaining Ring 37 - Swash Plate 51 - Stopper
10 - Spring (9 Used) 24 - Friction Plate (8 Used) 38 - Plate 52 - O-Ring
11 - Bushing 25 - Plate (9 Used) 39 - Socket Bolt (3 Used) 53 - O-Ring (4 Used)
12 - Retainer Plate 26 - Coupling 40 - Casing 54 - O-Ring
13 - Plunger (9 Used) 27 - Shim 41 - Plug 55 - Plug
14 - Socket Bolt (12 Used) 28 - O-Ring 42 - O-Ring
W3-2-23
48
53
55
41
5
40 39
35
34
32
8 31
26
27
47
28
17
29
18
19 30
20
21
22
23
24
25 14
16
W18B-03-02-002
W3-2-24
Disassemble Travel Motor
IMPORTANT: Put matching marks on the match- 11. Remove plates (25) (9 used), friction plates (24)
ing part of casing (40), valve cover (8 used), shim (27) and spacer (47) from valve
(30) and front casing (35) before cover (30).
disassembling.
1. Remove plug (41, 55, 48) to drain all hydraulic oil 12. Install eyebolts (M12, Pitch 1.75 mm) (2 used)
from casing (40). into the hole for socket bolt (14) in valve cover
: 36 mm (30).
CAUTION: The travel motor assembly CAUTION: Valve cover (30) weight:
weight: 280 kg (620 lb) 46 kg (100 lb)
2. Place the travel motor with cover (16) facing up- IMPORTANT: When removing valve cover (30),
ward. valve plate (8) also can be removed.
Take care not to drop valve plate (8).
3. Remove socket bolts (14) (12 used) to remove Dowel pin (34) is installed by press.
cover (16) from brake casing (22). Do not remove the dowel pin unless
: 10 mm necessary.
4. Remove O-ring (17) from cover (16). used) to lift and remove valve cover (30) from
casing (40) by crane. At this time, valve cover
5. Remove spring (18) (10 used) from brake piston (30) is still with the outer race of needle bearing
(19). (32) attached.
: 14 mm
6. Remove brake casing (22) from valve cover (30).
At this time, brake piston (19) also can be re- IMPORTANT: Do not remove needle bearing (32)
moved. unless necessary. When it is re-
moved, be sure to replace it with a
7. Tap brake piston (19) from casing (40) side with a new one.
plastic hammer and remove the brake piston 14. Remove valve plate (8) and O-ring (31) from
from brake casing (22). valve cover (30).
8. Remove O-rings (20, 21) from brake casing (22). 15. Remove O-rings (53) (2 used) from casing (40).
9. Remove O-ring (28) from valve cover (30).
10. Remove retaining ring (23) from drive shaft (5) to

remove coupling (26).
W3-2-25
55
5
40 41
4
3
2 35
1
32
9
10
11
12
13
W18B-03-02-002
W3-2-26
CAUTION: Casing (40) assembly weight: 20. Remove bushing (11) and springs (10) (9 used)
180 kg (400 lb) from rotor (9).
Rotor (9) + plunger (13) assembly weight:
45 kg (100 lb) IMPORTANT: The oil seal (4) can not be reused
when it is removed. Be sure to re-
IMPORTANT: Attach vinyl tape onto the inner race place it with a new one.
of needle bearing (32) to prevent it 21. Remove bolts (1) (6 used) to remove cover (2)
from being damaged. from front casing (35).
16. Place casing (40) horizontally with plug (41) or : 17 mm
plug (55) facing down. Pull the rotor (9) assembly
from drive shaft (5) till half of rotor (9) is out of 22. Remove oil seal (4) and O-ring (3) from cover (2).
casing (40).
CAUTION: Be sure to tie nylon sling tight

enough, because it is applied in oil and may
be very slippery.
17. Attach nylon sling on the out race of rotor (9),

then hold the rotor horizontally by crane.
Hold rotor (9) horizontally and remove the rotor
from drive shaft (5) carefully. At this time, rotor (9)
is still with plunger (13), spring (10), bushing (11)
and retainer plate (12) attached.
NOTE: When remove rotor (9) assembly, if special
tool (ST 7283) is used, it is easy to do the
work.
ST 7283
9 W18B-03-02-006
18. Remove retainer plate (12) from rotor (9). At this

time ,retainer plate (12) is still with plungers (13)
(9 used) attached.
19. Remove plungers (13) (9 used) from retainer

plate (12).
W3-2-27
50
51
52 45
45 46
50 43
44
43 44
53
37
40
6 38
5 36
35
33
W18B-03-02-002
W3-2-28
27. Remove O-rings (45) (2 used) from stoppers (46,
CAUTION: Drive shaft (5) assembly weight: 51).
25 kg (60 lb)
IMPORTANT: Do not remove roller bearing (6) CAUTION: Front casing (35) weight:
unless necessary. When it is re- 36 kg (80 lb)
moved, be sure to replace it with a Casing (40) weight: 57 kg (130 lb)
new one.
23. Attach nylon sling to rotor (9) side of drive shaft 28. Remove socket bolts (33) (14 used) to remove
(5), then hold it horizontally by crane. Tap drive front casing (35) and swash plate (37) from cas-
shaft (5) from casing (40) side with a plastic ing (40). At this time, swash plate (37) is still with
hammer and remove drive shaft (5) from front plate (38) attached.
casing (35). : 14 mm
24. Remove socket bolts (43) (8 used) to remove 29. Remove O-ring (36) from front casing (35), and
covers (44) (2 used) from casing (40). remove O-rings (53) (2 used) from casing (40).
: 14 mm
30. Remove plate (38) from swash plate (37).
IMPORTANT: Keep stoppers (46, 51) safe so as to
install them to the former position. IMPORTANT: After disassembling, measure di-
25. Remove stopper (46, 51) and piston assemblies mensions for each parts while refer-
(50) (2 used) from casing (40). ring to the maintenance standard on
NOTE: Push out stoppers (46, 51) and piston as- page W3-2-38. If the measured val-
sembly (50) from casing (40) by fingers. ues of any parts are beyond the al-
lowable limit, replace the parts with
26. Remove O-ring (52) from stopper (51). new ones.
W3-2-29
ASSEMBLE TRAVEL MOTOR
43 44 45 51 50 48 49 46 34 32 26 27 39 30 28 23 22
52 16
53
7
14
1 19
15
5 18
47
17
4
20
3
W18B-03-02-007
6
33 35 36 40 37 38 12 13 11 10 9 31 29 8 24 25 21
1- Bolt (6 Used) 15 - Plug 29 - Socket Bolt (9 Used) 43 - Socket Bolt (8 Used)

2- Cover 16 - Cover 30 - Valve Plate 44 - Cover (2 Used)
3- O-Ring 17 - O-Ring 31 - O-Ring 45 - O-Ring (2 Used)
4- Oil Seal 18 - Spring (10 Used) 32 - Needle Bearing 46 - Stopper
5- Drive Shaft 19 - Brake Piston 33 - Socket Bolt (14 Used) 47 - Spacer
6- Roller Bearing 20 - O-Ring 34 - Knock Pin 48 - Plug
7- Retaining Ring 21 - O-Ring 35 - Front Casing 49 - O-Ring
8- Valve Plate 22 - Brake Casing 36 - O-Ring 50 - Piston Assembly (2 Used)
9- Rotor 23 - Retaining Ring 37 - Swash Plate 51 - Stopper
10 - Spring (9 Used) 24 - Friction Plate (8 Used) 38 - Plate 52 - O-Ring
11 - Bushing 25 - Plate (9 Used) 39 - Socket Bolt (3 Used) 53 - O-Ring (4 Used)
12 - Retainer Plate 26 - Coupling 40 - Casing 54 - *O-Ring
13 - Plunger (9 Used) 27 - Shim 41 - *Plug 55 - *Plug
14 - Socket Bolt (12 Used) 28 - O-Ring 42 - *O-Ring
NOTE: As for the items with *, refer to the illustra-
tion on page W3-2-22.
W3-2-30
Assemble Travel Motor
9. Install piston assembly (50), stopper (51) and

CAUTION: Casing (40) weight: 57 kg (130 lb) cover (44) onto front casing (35), then tighten
them with socket bolts (43) (4 used).
1. Place casing (40) horizontally with plug (41) or : 14 mm
plug (55) facing downward. : 235 ± 35 N⋅m
(24 ± 3.6 kgf⋅m, 175 ± 26.0 lbf⋅ft)
2. Apply grease to matching surface of swash plate
(37) and plate (38), then install plate (38) onto
swash plate (37). CAUTION: The drive shaft (5) assembly
3. Install swash plate (37) onto casing (40).
IMPORTANT: In case roller bearing (6) has been
removed, be sure to replace it with a
CAUTION: Front casing (35) weight: new one. Roller bearing (6) should
36 kg (80 lb) be done shrinkage fitting to de-
magnetize.
4. Install O-rings (53) (2 used) onto the cover (2) 10. Attach nylon sling on drive shaft (5), hold it hori-
side of casing (40) and install O-ring (36) onto zontally by crane. Insert the drive shaft (5) as-
front casing (35). sembly into front casing (35), then tap to install it
with a hammer lightly.
5. Install front casing (35) onto casing (40) with
socket bolts (33) (14 used) while aligning the IMPORTANT: Since oil seal (4) can’t be reused, be
matching marks made before disassembling. sure to replace it with a new one if
: 14 mm ever removed.
: 235 ± 35 N⋅m 11. Install oil seal (4) and O-ring (3) onto cover (2).
(24 ± 3.6 kgf⋅m, 175 ± 26.0 lbf⋅ft)
12. Install cover (2) onto front casing (35) with bolts
6. Install O-ring (45) onto stopper (46). (1) (6 used).
: 17 mm
7. Install O-rings (45, 52) onto stopper (51). : 57 ± 8.8 N⋅m
(5.8 ± 0.9 kgf⋅m, 42 ± 2.0 lbf⋅ft)
IMPORTANT: Be sure that swash plate (37) can
move within the tilt stopper. If it fails
to do so, go back to procedure 2 CAUTION: Rotor (9) weight: 39 kg (90 lb)
and reassemble it.
8. Install piston assembly (50), stopper (46) and 13. Install springs (10) (9 used) and bushing (11) into
cover (44) onto the valve cover (30) side and rotor (9).
tighten them with socket bolts (43) (4 used).
: 14 mm 14. Install plungers (13) (9 used) onto retainer plate
: 235 ± 35 N⋅m (12).
(24 ± 3.6 kgf⋅m, 175 ± 26.0 lbf⋅ft)
W3-2-31
34 32 26 27 39 30 28 23 22
16
53
19
5 18
47
17
20
W18B-03-02-007
40 13 9 31 29 8 24 25 21
W3-2-32
CAUTION: Rotor (9) + plunger (13) assembly CAUTION: Valve cover (30) assembly
weight: 45 kg (100 lb) weight: 46 kg (100 lb)
IMPORTANT: Apply hydraulic oil to the mounting 19. Lift valve cover (30) by crane to install it into cas-
hole for plunger (13) on rotor (9). ing (40), while aligning the matching marks on
15. Install the plunger (13) assembly to the rotor (9) valve cover (30) and casing (40) made before
assembly. disassembling. Install socket bolts (29) (9 used)
and (39) (3 used).
16. Attach nylon sling on the outside of rotor (9), then : 14 mm
hold it horizontally by crane. Hold rotor (9) hori- : 235 ± 35 N⋅m
zontally while aligning the splines, then install the (24 ± 3.6 kgf⋅m, 175 ± 26.0 Ibf⋅ft)
rotor onto drive shaft (5).
NOTE: If special tool (ST 7283) is used to remove 20. Install spacer (47), coupling (26) and retaining
the rotor (9) assembly, it is easy to do the ring (23) to drive shaft (5).
work.
IMPORTANT: After assembling, measure the
5 height between the end of valve
cover (30) and the plate. If the
measured height is beyond the
ST 7283
specified dimension, remove all
plates (25), friction plates (24) and
shims (27). Then adjust the height to
the specified dimension. (Refer to
item 7 in Maintenance Standard on
page W3-2-39.)
21. Insert shim (27) into valve cover (30), install fric-
9 W18B-03-02-006
tion plates (24) (8 used) and plates (25) (9 used)
onto coupling (26) alternatively.
IMPORTANT: When needle bearing (32) is re-
moved, be sure to replace it with a 22. Install O-rings (20, 21) onto brake casing (22),
new one. Press needle bearing (32) then install O-ring (17) onto cover (16).
to valve cover (30) with a steel bar
and hammer. 23. Install brake piston (19) into brake casing (22) by
17. Apply grease to matching surfaces of valve plate taping the brake piston with a plastic hammer.
(8) and valve cover (30), then install valve cover
(30) while aligning with knock pin (34). 24. Install springs (18) (10 used) into brake piston
(19).
18. Install O-rings (53) (2 used) onto cover (16) side
of casing (40) and install O-rings (31, 28) onto 25. Install cover (16) onto brake casing (22).
valve cover (30).
W3-2-33
48 49 30 22
16
14
W18B-03-02-007
40
W3-2-34
26. Install brake casing (22) and cover (16) onto
valve cover (30) with socket bolts (14) (12 used).
: 10 mm
: 98 ± 15 N⋅m
(10 ± 1.5 kgf⋅m, 72 ± 11.0 Ibf⋅ft)
27. Install O-rings (42, 54, 49) onto plug (41, 55, 48),
then install them into casing (40).
: 36 mm
: 170 N⋅m (17 kgf⋅m, 123 Ibf⋅ft)
W3-2-35
DISASSEMBLE AND ASSEMBLE TRAVEL
SPEED MODE SELECTOR VALVE
1 2 3 4 5 6 18 7 8 9 10 11
Screw Hole
W117-03-02-005
17 16 15 14 13 12
1- Plug 6- Valve Casing 11 - O-Ring (6 Used) 15 - Spacer (2 Used)

2- O-Ring 7- Piston 12 - O-Ring (3 Used) 16 - O-Ring (3 Used)
3- Spring 8- Plug 13 - Plug (3 Used) 17 - Plug (3 Used)
4- Spring Seat 9- Socket Bolt (4 Used) 14 - Piston 18 - O-Ring
5- Spool 10 - Orifice (2 Used)
W3-2-36
Disassemble Travel Speed Mode Selector Valve Assemble Travel Speed Mode Selector Valve
1. Remove socket bolts (9) (4 used) to remove 1. Install O-rings (12) (3 used) to plugs (13) (3
travel speed mode selector valve from the travel used), then install the plugs into valve casing (6).
motor.
: 6 mm 2. Insert piston (14) and spacers (15) (2 used) into
valve casing (6).
2. Remove O-rings (11) (6 used) from valve casing
(6). 3. Install O-rings (16) (3 used) to plugs (17) (3
used), then install the plugs into valve casing (6)
3. Remove orifices (10) (2 used) from valve casing : 6 mm
(6). : 19.5 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
: 2.5 mm
4. Install spring seat (4) and spring (3) to spool (5),
4. Remove plugs (17) (3 used), plug (1) and plug then insert the spool into valve casing (6).
(8) from valve casing (6). Then remove O-rings
(16) (3 used), O-rings (2, 18) from each plugs. 5. Install O-ring (2) to plug (1), then install the plug
: 6 mm, 8 mm into valve casing (6).
: 24 mm : 8 mm
: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
5. Pull piston (7) out from plug (8).
6. Install piston (7) and O-ring (18) to plug (8) and
6. Remove spring (3), spring seat (4) and spool (5) install the plug into valve casing (6).
from valve casing (6). : 24 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
7. Pull spacers (15) (2 used) out from valve casing
(6) through the screw holes (M5, Pitch 0.8 mm) 7. Install orifices (10) (2 used) to valve casing (6).
to remove piston (14). : 2.5 mm
: 7 N⋅m (0.7 kgf⋅m, 5.5 Ibf⋅ft)
8. Remove plugs (13) (3 used) from valve casing
(6). Remove O-rings (12) (3 used) from plugs 8. Install O-rings (11) (6 used) to valve casing (6).
(13) (3 used).
9. Install valve casing (6) to the travel motor with
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
W3-2-37
Dial Gauge
1. Secure plunger with shoe in a vise.
Install the dial gauge to the shoe and move the Shoe
shoe up and down. Measure the clearance (A)
between the plunger and spherical part of shoe. Plunger
Clearance (A)
When the clearance is beyond the allowable limit,
replace the plunger and shoe as assembly.
Guide
Unit: mm (in)
A 0 0.3 (0.01)
W115-02-04-062
Vise Guide Plate
2. Measure the outer diameter (d) of plunger at 3 Plunger

points of upper, middle and skirt in cross direction
with a micro meter.
Measure the inner diameter (D) of rotor at 2
points in cross direction with a cylinder gauge. (d) (d) (d)
W115-02-04-065
Unit: mm (in) Rotor

D-d 0.048 (0.002) 0.096 (0.004)

(D) (D)
(D) (D)
W115-02-04-066
W3-2-38
3. Measure the thickness (B) of shoe flange. Shoe Plunger
Unit: mm (in)
B 10.9 (0.43) 10.7 (0.42) B W115-02-04-068
Bushing
4. Measure height dimensions H and h.
C=H-h
Unit: mm (in)
Standard Allowable Limit H
ｈ
C 40.1 (1.58) 39.3 (1.55)
W115-02-04-069
Stand Retainer Plate

5. Measure the free length of spring (18).
Unit: mm (in)
Standard Allowable
Free length 54 (2.13) 53.6 (2.11)
6. Measure height dimensions D for plate (25) (9

D
used) and friction plates (24) (8 used).
Unit: mm (in)
Standard Allowable Limit E
D 36.8 (1.45) 36.2 (1.43)
25
7. Measure height dimensions E between the end
of valve cover (30) and for plate (25). 30
24
Unit: mm (in)
W118-03-01-010
E 3.1 (0.12) 3.6 (0.14)
W3-2-39
(Blank)
W3-2-40
UNDERCARRIAGE / Travel Brake Valve
REMOVE AND INSTALL TRAVEL BRAKE
VALVE
to “Bleed Air from Hydraulic Oil
Tank” on page W1-3-1) 2 1
Removal
IMPORTANT: Attach identification tags to hoses

and pipes to aid reassembly.
1. Disconnect hoses (2 used) and pipes (2 used)
from travel brake valve (1).
: 14 mm
NOTE: Cap all disconnected hoses and pipes.
2. Install eyebolts (M16, Pitch 2.0 mm) on the holes W141-03-03-001
(2 places) for pipe mounting bolt, then hold travel

brake valve (1) by crane.
CAUTION: Travel brake valve (1) weight:

55 kg (120 lb)
3. Remove bolts (2) (4 used) to remove travel brake

valve (1) from the track frame.
: 24 mm
W3-3-1
Installation
CAUTION: Travel brake valve (1) weight:

55 kg (120 lb)

2 1
holes (2 places) for pipe mounting bolt, lift travel
brake valve (3) by crane.
2. Install travel brake valve (1) onto travel frame

: 24 mm
: 270 Nxm (27.5 kgfxm, 200 Ibf⋅ft)
3. Connect hoses (2 used) and pipes (2 used) to

travel brake valve (1).
: 14 mm
: 210 Nxm (21.5 kgfxm, 156 Ibf⋅ft) W141-03-03-001
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE TRAVEL BRAKE VALVE
1 2
13
12 2
11
10
9
1
8 7
5
6
14
15 4
16
17
18
17
16 8
9
10
26 11
25 12
24
13
23
22
21
20
15 19
14
W18B-03-03-002
1- Socket Bolt (8 Used) 8- Spring Seat (2 Used) 15 - Cap Assembly (2 Used) 22 - Spring (4 Used)
2- Relief Valve (2 Used) 9- Spring (2 Used) 16 - Spring (2 Used) 23 - Steel Ball (4 Used)
3- Body 10 - Spring Seat (2 Used) 17 - Check Valve (2 Used) 24 - Cap (2 Used)
4- Orifice 11 - O-Ring (2 Used) 18 - Plunger 25 - Backup Ring (2 Used)
5- O-Ring (3 Used) 12 - Backup Ring (2 Used) 19 - Plug (4 Used) 26 - O-Ring (2 Used)
6- Plug (3 Used) 13 - Plug (2 Used) 20 - O-Ring (4 Used)
7- Orifice 14 - Socket Bolt (8 Used) 21 - Spring Guide (4 Used)
W3-3-4
Disassemble 8. Remove the plunger (18) assembly from the vise.
1. Remove socket bolts (14) (8 used) from body (3). IMPORTANT: When removing plug (13), the plug
: 14 mm may fly out a little under the force
from spring (9). Take care not to
IMPORTANT: Take care not to damage body (3) drop plug (13), spring seat (10) and
and cap assembly (15). spring (9).
2. Tap cap assemblies (15) (2 used) lightly with a 9. Remove plug (13) by hand. Remove spring seat
plastic hammer while removing the cap assem- (10) and spring (9).
blies from both sides of body (3).
10. Remove O-rings (11) (2 used) and backup rings
IMPORTANT: When removing plug (13), the plug (12) (2 used) from plugs (13) (2 used).
may fly out a little under the force
from spring (9). Take care not to 11. Remove spring (16). Check valve (17) and spring
drop plug (13), spring seat (10) and seat (8) from plunger (18).
spring (9).
3. Loosen plugs (13) (2 used) at both sides of body
(3) sametime. However remove one of plugs (13) 12. Remove O-rings (26) (2 used) and backup ring
only. Then remove spring seat (10) and spring (25) (2 used) from caps (24) (2 used).
(9).
: 36 mm 13. Remove plugs (19) (4 used) from caps (24) (2
used). Remove O-rings (20) (4 used) from plugs
4. Remove spring (16) and check valve (17) from (19) (4 used).
the side of plunger (18) with plug (13) removed. : 14 mm
5. Turn the plunger (18) assembly slowly to remove 14. Remove spring guides (21) (4 used), springs (22)
it from the side with plug (13) unloosened. Re- (4 used) and steel balls (23) (4 used) from caps
move spring seat (8) from body (3) at opposite (24) (2 used).
side.
15. Remove socket bolts (1) (8 used) from body (3).
6. Secure plug (13) on plunger (18) in a vise. : 10 mm
7. Pass a bar through the hole of plunger (18), then IMPORTANT: Do not disassemble relief valve (2).
turn the bar to loosen plug (13) to remove it. Otherwise the setting of pressure
may change.
16. Remove relief valves (2) (2 used) from body (3).
W3-3-5
ASSEMBLE TRAVEL BRAKE VALVE
19 24 10 14 9 25 4 8 17 16 18 3 7 11 12 23 22
21
20
13 2
1
26
T144-03-05-002
1- Socket Bolt (8 Used) 8- Spring Seat (2 Used) 15 - *Cap Assembly (2 Used) 22 - Spring (4 Used)
2- Relief Valve (2 Used) 9- Spring (2 Used) 16 - Spring (2 Used) 23 - Steel Ball (4 Used)
3- Body 10 - Spring Seat (2 Used) 17 - Check Valve (2 Used) 24 - Cap (2 Used)
4- Orifice 11 - O-Ring (2 Used) 18 - Plunger 25 - Backup Ring (2 Used)
5- *O-Ring (3 Used) 12 - Backup Ring (2 Used) 19 - Plug (4 Used) 26 - O-Ring (2 Used)
6- *Plug (3 Used) 13 - Plug (2 Used) 20 - O-Ring (4 Used)
7- Orifice 14 - Socket Bolt (8 Used) 21 - Spring Guide (4 Used)
NOTE: As for the items with *, refer to the illustra-

tion on the W3-2-4.
W3-3-6
Assemble 9. Turn and insert plunger (18) assembly into body
(3) slowly from the side with no plug (13) at-
1. Install relief valves (2) (2 used) onto body (3) with tached.
: 10 mm IMPORTANT: Install spring seat (8) with the deep
: 98 to 108 N⋅m chamfer side facing plunger (18).
(10 to 11 kgf⋅m, 72 to 80 Ibf⋅ft) 10. Install check valve (17), spring (16), spring seat
(8) and spring (9) into plunger (18) at the other
2. Install steel balls (23) (4 used), springs (22) (4 side.
used) and spring guides (21) (4 used) into caps
(24) (2 used). IMPORTANT: Install spring seat (10) with the
chamfer part facing plug (13).
3. Install O-rings (20) (4 used) onto plugs (19) (4 11. Install spring seat (10) into plug (13) by turning
used), and install the plugs to caps (24) (2 used). slowly.
: 14 mm
: 14.7 to 16.7 N⋅m IMPORTANT: Be sure to screw plug (13) in, while
(1.5 to 1.7 kgf⋅m, 11.0 to 12.5 Ibf⋅ft) pressing it down as it is under the
force from spring (9).
4. Install backup rings (25) (2 used) and O-rings 12. Install plug (13) into plunger (18).
(26) (2 used) onto caps (24) (2 used).
13. Tighten plug (13) at both sides sametime.
IMPORTANT: Install spring seat (8) with the large : 36 mm
chamfer side facing plunger (18). : 255 to 274 N⋅m
5. Secure plunger (18) in a vise. Install check valve (26 to 28 kgf⋅m, 190 to 205 Ibf⋅ft)
(17), spring (16), spring seat (8) and spring (9)
into one side of plunger (18). 14. Install cap assemblies (15) (2 used) onto body (3)
6. Install backup rings (12) (2 used) and O-rings : 14 mm
(11) (2 used) onto plugs (13) (2 used). : 196 to 216 N⋅m
(20 to 22 kgf⋅m, 144 to 159 Ibf⋅ft)
IMPORTANT: Install spring seat (10) with the
chamfer part facing plug (13).
7. Turn and install spring seat (10) to plug (13) care-
fully.
IMPORTANT: Be sure to screw plug (13) in, while

pressing it down, as it is under the
force from spring (9).
8. Screw plug (13) into plunger (18) by hand.
W3-3-7
(Blank)
W3-3-8
UNDERCARRIAGE / Drive Tumbler
REMOVE DRIVE TUMBLER
2. Separate the track. (Refer to “Remove and Install
1. Raise one side of the track off the ground with Track” on page W3-9-1)
the front attachment. Then, place a wooden block
under the track frame to support the raised track. 3. Remove the drive tumbler (Refer to “Remove and
Install Travel Device” on page W3-2-1).
NOTE: Drive tumbler is installed in the side frame.

Disassemble the drive tumbler to remove
it.
90° to 100°
W118-03-03-001
Outer Side Inner Side
W145-03-03-001
W3-4-1
3
2 1
4
8
10 9
11
12
13
14
15
16
17
20
18
26 19
25
21
24 22
23 W117-03-03-001
1- Bolt (12 Used) 8- Spacer 15 - Shim: 0.5 mm (2 Used) 22 - Bolt (8 Used)

2- Washer (12 Used) 9- Floating Seal (2 Used) 16 - Plate 23 - Cork (2 Used)
3- Cover 10 - Drive Tumbler 17 - O-Ring 24 - Plug (2 Used)
4- Cartridge 11 - Spacer 18 - Shim: 0.1 mm (6 Used) 25 - Bolt (12 Used)
5- O-Ring 12 - Cartridge 19 - Shim: 0.3 mm (4 Used) 26 - Washer (12 Used)
6- Bearing 13 - Bearing 20 - Cover
7- Shaft 14 - Shim: 0.1 mm (5 Used) 21 - Washer (8 Used)
W3-4-2
Remove Drive Tumbler
CAUTION: Take care not to injure hands

with the power wrench reaction bar.
1. Remove bolts (25) and washers (26) from cover

(20) with a power wrench.
: 41 mm
2. Remove corks (23) (2 used) from cover (20).

Insert bolts (M36, Pitch 3.0 mm) into the pulling
holes (2 places) to make cover (20) float.
3. Install eyebolt (M36, Pitch 3.0 mm) into the pull-

ing hole in cover (20) to hold it by crane. Pull out
and remove cover (20) form cartridge (12) by
crane. Remove O-ring (17), shim (18, 19) from
cover (20).
CAUTION: Plate (16) weight: 68 kg (150 lb)

4. Remove bolts (22) and washers (21) with a

power wrench. Remove plate (16) from shaft (7).
Remove shims (14, 15) from plate (16).
: 41 mm
5. Remove bolts (1) and washers (2) from cover (3)

with a power wrench.
6. Insert bolts (M27, Pitch 3.0 mm) (2 used) into the

pulling holes (2 places) in cover (3) to make
cover (3) float. Install eyebolt (M27, Pitch 3.0
mm) into the pulling hole in cover (3), then lift and
remove it by crane.
W3-4-3
8
10
9
11
12
13
W117-03-03-001
W3-4-4
CAUTION: Drive tumbler weight: ST 1437

1220 kg (2690 lb)
10
7. Securely hold drive tumbler (10) by crane. Attach
a hydraulic jack and special tool (ST 1437) to the
outer side of the drive tumbler.
NOTE: Hydraulic jack capacity: 50 tons
7
CAUTION: Bearing (6) and shaft (7) com-

bined weight: 722 kg (1710 lb)
8. Remove bearing (6), shaft (7) and cartridge (4) Hydraulic Jack
with a hydraulic jack. W115-03-06-010
9. Remove bearing (6) and shaft (7) from cartridge M45, Length 1600 mm Bolt ST 1437
(4) with a hydraulic press.
CAUTION: Cartridge (4) weight:

155 kg (350 lb) 6
IMPORTANT: For handling of floating seal, refer to 7

the section “Precautions for Float- M45 Nut
ing Seal Handling” on page W1-1-4.
10. Remove O-ring (5) and floating seal (9) from car- 4
tridge (4).
CAUTION: Cartridge (12) and bearing (13)

combined weight: 193 kg (430 lb)
IMPORTANT: Do work while the drive tumbler Hydraulic Jack

held it with lifting tool.
11. Screw in bolts (M27, Pitch 3.0 mm) (2 used) to
the pull-out bolt holes (2 place) in cartridge (12), 13 W141-03-04-001
to raise them. Install eyebolts (M27, Pitch 3.0
mm) into cartridge (12) pull-out bolt hole (1 place).
Remove cartridge (12) by crane. Remove spacer
(11).
: 41 mm
W3-4-5
10
9
12
13
W117-03-03-001
W3-4-6
CAUTION: Drive tumbler (10) weight:

1220 kg (2690 lb)
12. Remove and lift drive tumbler (10) by crane.
IMPORTANT: For handling of floating seal, refer to

the section “Precautions for Float-
13. Remove one half of floating seals (9) from car-
tridges (12).
CAUTION: Bearing (13) weight:

220 kg (490 lb)
14. Remove bearing (13) from cartridge (12) with a

hydraulic press.
NOTE: If bearing (13) does not come out, cut
bearing (13) with a gas torch.

the section “Precautions for Float-
15. Remove other half of floating seals (9) from both
ends of drive tumbler (10).
W3-4-7
INSTALL DRIVE TUMBLER
10
12 4
11
17
23 24 13
3
20 9
16
14, 15
21, 22
8
25, 26 6
18, 19 1, 2
W141-03-04-002
1- Bolt (12 Used) 8- Spacer 15 - Shim: 0.5 mm (2 Used) 22 - Bolt (8 Used)

2- Washer (12 Used) 9- Floating Seal (2 Used) 16 - Plate 23 - Cork (2 Used)
3- Cover 10 - Drive Tumbler 17 - O-Ring 24 - Plug (2 Used)
4- Cartridge 11 - Spacer 18 - Shim: 0.1 mm (6 Used) 25 - Bolt (12 Used)
5- O-Ring 12 - Cartridge 19 - Shim: 0.3 mm (4 Used) 26 - Washer (12 Used)
6- Bearing 13 - Bearing 20 - Cover
7- Shaft 14 - Shim: 0.1 mm (5 Used) 21 - Washer (8 Used)
W3-4-8
Install Drive Tumbler
5. Install cartridge (12) and dummy base (ST 2669)
CAUTION: Bearing weight: 104 kg (230 lb) on the outer side of frame with bolts (25) (4
Shaft weight: 513 kg (1140 lb) used).
: 41 mm
1. Heat bearing (6) to 110 °C (230 °F) in an oil bath. : 460 N⋅m (46 kgf⋅m, 333 lbf⋅ft)
Install bearing (6) onto shaft (7) with a press.

ST 2669
the section “precautions for Float-
ing seal Handling” on page W1-1-4.
2. Install one half of floating seal (9) on cartridges
(12, 4). Install O-ring (5) on cartridge (4).
CAUTION: Drive tumbler (10) weight:

1220 kg (2690 lb)

3. Install other half of floating seal (9) on both ends W118-03-03-006
of drive tumbler (10). Lift, place and hold drive

tumbler (10) in the installation place on the side
frame by crane.
CAUTION: Cartridge (12) weight:

120 kg (270 lb)
Cartridge (4) weight: 155 kg (350 lb)
4. Install cartridge (4) on the inner side of frame with

bolts (1) (4 used) and washers (2) (4 used).
: 41 mm
: 460 N⋅m (46 kgf⋅m, 333 lbf⋅ft)
W3-4-9
10
11
12
8
25, 26
W141-03-04-002
W3-4-10
6. Cool the shaft (7) assembly with dry ice. Install 8. Install base (ST 2668), nut (ST 2913) and hy-
flange (ST 2667) and bolts (ST 2576) onto the draulic jack (ST 7134) onto bolt (ST 2576). Install
shaft assembly. shaft (7) into drive tumbler with a hydraulic jack.
NOTE: Apply gear oil to the shaft after removing NOTE: If the stroke of the jack is not long enough
the frost on the shaft for pulling, install spacer (ST 2916) be-
tween nut (ST 2913) and hydraulic jack
ST 2667 (ST 7134), then try to pull shaft (7) again.
ST 2669 1
Outer Side Frame
ST 2667
ST 2668
ST 2576
W115-03-06-029
ST 2913
CAUTION: Shaft (7) assembly weight:
ST 2916
670 kg (1480 lb)
ST 7134
7. Install spacer (8) onto shaft (7). Insert shaft (7)
into drive tumbler (10) from the inner side of the
W118-03-03-008
side frame by crane.
NOTE: Be sure to install spacer (8) with the oil 9. Remove bolts (25) (4 used) to remove mounted
grooves facing drive tumbler (10). minor base (ST 2699) from cartridge (12).
: 41 mm
Inner Side Outer Side
Frame Frame NOTE: If dummy base (ST 2699) does not remove,
install bolt (M16, Pitch 2.0 mm) into
dummy base (ST 2911) hoist holes to re-
move it.
10. Apply a coat of grease to shaft (7). Install spacer

(11).
NOTE: Be sure to install spacer (11) with the oil
groove facing drive tumbler (10).
ST 2576
W115-03-06-031
W3-4-11
4
12
13
3
1, 2
W141-03-04-002
W3-4-12
11. Apply a coat of grease to the inside of cartridge
(12). Install bearing (13) onto shaft (7). Install CAUTION: Take care not to injure hands with
base (ST 2668), hydraulic jack (ST 7134) and nut the power wrench reaction bar.
(ST 2913) onto bolt (ST 2576). Install bearing
(13) into cartridge (12) with a hydraulic jack. 12. Remove bolts (1) (4 used) and washers (2) (4
used).
NOTE: If the stroke of the jack is not long enough, : 41 mm
install a spacer (ST 2916) between nut (ST
2913) and the hydraulic jack (ST 7134), try
to press the bearing (13) into cartridge (12) CAUTION: Cover (3) weight: 46 kg (110 lb)
again.
13. Install cover (3) with bolts (1) (12 used) and
ST 2668 ST 2913 washers (2) (12 used).
: 41 mm
: 1400 N⋅m (140 kgf⋅m, 1013 lbf⋅ft)
ST 2576
ST 2669 ST 7134
W118-03-03-007
13
ST 2667
ST 2668
ST 2576
ST 2913
ST 2916
ST 7134
W118-03-03-009
W3-4-13
12
13
20
16
14, 15
21, 22
W141-03-04-002
W3-4-14
CAUTION: Take care not to injure hands CAUTION: Plate (16) weight: 24 kg (60 lb)
14. With a power wrench, temporarily secure car- with the power wrench reaction bar.
tridge (12) with bolts (J932770) (4 used).
: 41 mm 17. With a power wrench, secure plate (16) onto
: 1400 N⋅m (140 kgf⋅m, 1013 lbf⋅ft) shaft (7) with bolts (22) and washers (21) (8 used
each).
IMPORTANT: When measuring dimension (F), in- : 41 mm
stall cartridge (12) and secure it by : 1400 N⋅m (140 kgf⋅m, 1013 lbf⋅ft)
temporarily tightening bolts
(J932770) (4 used) without installing 21, 22 20 16 13 12
cover (20).
15. Measure dimensions (F, G).
IMPORTANT: When dimension (E) value goes be-

yond the scope which can be ad-
justed by shim (14, 15), this installa- (E)
(G) (F)
tion quality is considered bad. In
this case, return to procedure 1 and
attach and combine once again.
16. According to formula (G-F), calculate dimension W115-03-06-037
standard valve (0 to 0.1 mm) to adjust shim (14, 7
15). Install shims (14, 15) onto shaft (7).
NOTE: Dimension (E) = Clearance between
plate (16) and bearing.
Standard value range: 0 to 0.1 mm
Dimension (F) = Height from bearing (13)
end to shaft (7) end.
Dimension (G) = Shims (14), (15) + Height
of the stepped part of plate (16).
1 mm = 0.03937 in
W3-4-15
12
13
20
25, 26
18, 19
W141-03-04-002
W3-4-16

25, 26 13 20 12
18. With a power wrench, temporarily secure car-
tridge (12) with bolts (J932770).
: 41 mm (K)
: 1400 N⋅m (140 kgf⋅m, 1013 lbf⋅ft)
IMPORTANT: When measuring dimension (L), in- (M) (L)

stall cartridge (12) and secure it by
temporarily tightening bolts
(J932770) (4 used) without installing
cover (20).
W115-03-06-038
19. Measure dimensions (L, M). 12 7
20. According to formula (L-M), calculate dimension NOTE: Dimension (K) = Clearance between cover
standard value (0 to 0.1 mm) to adjust shims (18, (20) and bearing (13).
19). Install shims (18, 19) onto cartridge (12). Dimension (L) = Shims (18, 19) + Height
from cartridge (12) end to bearing (13) end.
Dimension (M) = Height of the stepped
part of cover (20).
Take care not to injure hands with the power
1 mm = 0.03937 in
wrench reaction bar.
21. With a power wrench, secure cover (20) onto

cartridge (12) with bolts (25) and washers (26)
(each 12 used).
: 41 mm
: 1400 N⋅m (140 kgf⋅m, 1013 lbf⋅ft)
W3-4-17
Up to serial No. 529
A D E
H F
B C B
W115-03-06-041
Unit: mm (1 mm = 0.03937 in)

Standard Allowable
Key Letter and Part Name Corrective Measure
Dimensions Wear Limit
A : Tumbler (Outer Diameter) 1346 1316 Repair or Replace
B : Tread Width 100 (80) Repair or Replace
C : Tread Interval 148 (178) Repair or Replace
D : Bearing (Inner Diameter) 300 - -
E : Bearing (Outer Diameter) 340 - -
F : Claw Length 146 (125) Repair or Replace
G : Claw Height 80 (70) Repair or Replace
H : Reference 273 - -
NOTE: If welding is required for repair, refer to

“Welding Repair Procedure (W3-11-1)” and
to the pattern drawings attached in the
back of this book.
Values on ( ) are just for reference.
W3-4-18
Serial No. 530 and up
A D E
H F
B C B
W115-03-06-041
Unit: mm (1 mm = 0.03937 in)

Standard Allowable
Key Letter and Part Name Corrective Measure
Dimensions Wear Limit
A : Tumbler (Outer Diameter) 667 652 Repair or Replace
B : Tread Width 100 (80) Repair or Replace
C : Tread Interval 148 (178) Repair or Replace
D : Bearing (Inner Diameter) 300 - -
E : Bearing (Outer Diameter) 340 - -
F : Claw Length 160 (150) Repair or Replace
G : Claw Height 88 (78) Repair or Replace
H : Reference 267 - -

“Welding Repair Procedure (W3-11-1)” and
to the pattern drawings attached in the
back of this book.
W3-4-19
(Blank)
W3-4-20
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT

to “item of Bleeding Air from Hy- 1
draulic Oil Tank” on page W1-3-1) Main Frame
2
Removal
IMPORTANT: Put tags the disconnected pipes and

hoses to aid in re-assembly.
1. Disconnect all hoses and pipes from the center
joint.
Hose
: 19 mm, 22 mm, 36 mm, 41 mm
Elbow
: 32 mm
Socket Bolt W145-03-04-001
: 14 mm, 17 mm
2. Remove bolts (3) (3 used) to remove stopper (4)

from the center joint.
: 32 mm 3
CAUTION: Center joint weight:

261 kg (575 lb)
4
3. Install eyebolt (M16, Pitch 2.0 mm) into the bolt

holes (2 places) of the center joint upper part.
It hold by crane.
IMPORTANT: Put matching marks on body (1) and W146-03-05-001
the main frame.

4. Remove center joint mounting bolts (2) (4 used)
Bolt Hole
to lift the center joint by crane from the main (M16, Pitch 2.0 mm)
frame.
: 30 mm
W118-03-04-003
W3-5-1
Installation
CAUTION: Center joint weight:

261 kg (575 lb)
1
1. Install the center joint to the main frame with Main Frame
center joint mounting bolts (2) (4 used). 2
: 30 mm
: 550 N⋅m (56 kgf⋅m, 405 lbf⋅ft)
2. Install stopper (4) on the center joint with bolt (3)

(3 used).
: 32 mm
: 750 N⋅m (76.5 kgf⋅m, 550 lbf⋅ft)
3. Connect all hoses and pipes to the center joint.

Hose
: 19 mm W145-03-04-001
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

: 22 mm
: 40 N⋅m (4 kgf⋅m, 28.5 lbf⋅ft)
: 36 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 3
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
Elbow
: 32 mm 4
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)
Socket Bolt
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 156 lbf⋅ft)
: 17 mm W146-03-05-001
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
W3-5-2
(Blank)
W3-5-3
DISASSEMBLE CENTER JOINT
2
18
3
4
17
16 5
6
15
14
13
12
11
8
9
10
W118-03-04-002
1- Bolt (8 Used) 6- Ball (36 Used) 11 - Spindle 16 - Spring Washer (8 Used)

2- Spring Washer (6 Used) 7- Ball (39 Used) 12 - Ring Plate 17 - Bolt (8 Used)
3- O-Ring 8- O-Ring (4 Used) 13 - Body 18 - Cover
4- O-Ring 9- Plug (4 Used) 14 - O-Ring
5- Plate 10 - Plug (3 Used) 15 - Seal (5 Used)
W3-5-4
Disassemble Center Joint
IMPORTANT: Put mathing marks on body (13) and CAUTION: Spindle (11) weight:
spindle (11). 98 kg (216 lb)
1. Remove bolts (1) (8 used) and spring washers Body (13) weight: 139 kg (306 lb)
(2) (8 used), then remove cover (18) from body
(13) by installing removal bolts (1) (2 used) in the IMPORTANT: Ball (7) sometimes drops out from
bolt holes (2 places) on cover (18). spindle (11), when spindle (11) is
: 24 mm removed from body (13). Do not
Bolt Hole damage ball (7).
(M16, Pitch 2.0 mm) 3. Install jigs (A) to spindle (11) and body (13),
then remove spindle (11) from body (13) using
jigs (A).
No. List of jigs (A):
ST 2440, ST 2441, ST 2917,
ST 2443, ST 2444, J901640 (2 used),
J951016 (3 used), J901232 (2 used)
18
J 951016 ST 2440
ST 2917 ST 2441
J 901232 ST 2444
ST 2443
W118-03-04-003
J 901640
2. Remove bolts (17) (8 used), spring washers (16)

(8 used) and plate (5), then remove balls (6) (36
used).
: 19 mm
W146-03-05-003
4. Remove seals (15) (5 used) and O-ring (14) from

body (1).
5. Remove balls (7) (39 used) and ring plate (12)

from spindle (11).
6. Remove Plug (9) (4 used) from spindle (11).

: 41 mm
W3-5-5
ASSEMBLE CENTER JOINT
4 16, 17
1, 2
18
5
3
6
15
13
14
A
7
12
11
W118-03-04-001
10 9
1- Bolt (8 Used) 6- Ball (36 Used) 11 - Spindle 16 - Spring Washer (8 Used)

2- Spring Washer (6 Used) 7- Ball (39 Used) 12 - Ring Plate 17 - Bolt (8 Used)
3- O-Ring 8- O-Ring (4 Used) 13 - Body 18 - Cover
4- O-Ring 9- Plug (4 Used) 14 - O-Ring
5- Plate 10 - Plug (3 Used) 15 - Seal (5 Used)
W3-5-6
Assemble Center Joint
1. Apply a coat of grease to ring plate (12) and balls 6. Install O-ring (4 and 3) into cover (18). Install
(7) (39 used) when installing ring plate (12) and cover (18) to body (13) with bolts (1) (8 used)
balls (7) onto spindle (11). and spring washers (2) (8 used).
: 24 mm
2. Install seals (15) (5 used) and O-ring (14) into : 210 N⋅m (21.5 kgf⋅m, 156 lbf⋅ft)
body (13).
7. Install Plug (9) (4 used) onto spindle (11).
: 41 mm
CAUTION: Spindle (11) weight: : 205 N⋅m (21.5 kgf⋅m, 156 lbf⋅ft)
98 kg (216 lb)
Body (13) weight: 139 kg (306 lb) 8. After assembling, fill grease into a part (A) on
page W3-5-6.
IMPORTANT: Apply hydraulic oil inner surface of
body (13) and seal (15).
Also, take care not to damage spin-
dle (11) with ball (7).
3. Install body (1) into spindle (6) using jigs (A).
No. List of Jigs (A):
ST 2440, ST 2441, ST 2917,
ST 2443, ST 2444, J901640 (2 used),
J951016 (3 used), J901232 (2 used)
J 951016 ST 2440
ST 2917 ST 2441
J 901232 ST 2444
ST 2443
J 901640
W146-03-05-003
4. Apply a coat of grease to balls (6) (36 used)

when installing the balls into the grooves of spin-
dle (11) and body (13).
5. Install plate (5) on balls (6) (36 used). Tighten

bolts (17) (8 used) and spring washers (16) (8
used) to install balls (6) (36 used) in the groove
between spindle (11) and body (13).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)
W3-5-7
(Blank)
W3-5-8
UNDERCARRIAGE / Adjuster Cylinder
REMOVE AND INSTALL ADJUSTER CYL-
INDER
CAUTION: The adjuster cylinder is highly

pressurized. Do not loosen the valve quickly
and/or excessively. Valve (1) may fly off and
grease may spurt, possibly causing personal 1
injury. It is enough to loosen valve (1) 1 to 1.5
turns.
When loosening valve (1), loosen it slowly
and keep body and face away from the valve. 2
Also, never attempt to remove the grease fit-
ting (2).
M117-07-074
Removal
1. Loosen valve (1) of the adjuster cylinder to dis-
charge grease for loosening the track.
: 24 mm
2. Put a container of the drain hydraulic oil under

the stop valve (4) of accumulator (3). 3
NOTE: Container volume: 10 L (2.6 US gal)
4
3. Remove plug (5) from stop valve (4) of accumu-
lator (3).
: 19 mm
M141-01-012
CAUTION: Do not open stop valve (4)

quickly as high-pressure hydraulic oil in ac-
cumulator (3) may spurt out. Open carefully,
keeping body parts and face away from the
stop valve. 4
4. Open stop valve (4) to drain hydraulic oil from

accumulator (3).
5 M141-07-039
W3-6-1
5. Separate the track.
IMPORTANT: Attach identification tags to all dis- 6 7 8 9 10

connected hoses for easier reas-
sembling.
6. Disconnect all pipes from the adjuster cylinder
(6).
: 19 mm, 27 mm Forklift
7. Remove bolts (11) (8 used) to remove stoppers

(10) (2 used) from the both sides of side frame
(12).
: 24 mm
CAUTION: Front idler (9) weight: W118-03-05-002
1480 kg (3263 Ib) Eyebolt 12 11
8. Pull out front idler (9) from side frame (12) by

forklift.
Rod (7) is being connected with yoke (8) for front
idler (9).
CAUTION: Adjuster cylinder (6) weight: 6

527 kg (1162 Ib)
9. Attach a wire rope to two eyebolts on adjuster

cylinder (6).
10. About 2/3 pulls out adjuster cylinder (6) by forklift.
11. Attach a nylon sling to adjuster cylinder (6) body

and hoist it a little bit.
12. Pull out adjuster cylinder (6) from side frame (12).
W141-03-06-001
Eyebolt 12
W3-6-2
Installation
.
6 7 8 9 10
CAUTION: Front idler (9) weight:
1480 kg (3263 Ib)
Adjuster cylinder (6) weight:
527 kg (1162 Ib)
1. About 2 / 3 insert adjuster cylinder (6) into side

frame (12) by forklift.
2. Insert front idler (9) into side frame (12) and hoist
it a little bit.
3. Insert yoke (8) rod (7) into adjuster cylinder (6).

W118-03-05-002
Eyebolt 12 11
4. Push front idler (9) and adjuster cylinder (6) into
side frame (12).
5. Install stoppers (10) (2 used) to the both sides of

side frame (12) with bolts (11) (8 used).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf·ft)
3
6. Connect all pipes to adjuster cylinder (6).
: 19 mm 4
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf·ft)
: 27 mm
: 95 N⋅m (9.5 kgf⋅m, 69 Ibf·ft)
5 M141-01-012
7. Connect the track. (Refer to "Remove and Install

Track" on page W3-9-1)
M117-07-074
W3-6-3
8. Close stop valve (4) to install plug (5).
: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf·ft) 6 7 8 9 10
9. Tighten valve (1) of the adjuster cylinder.

: 24 mm
: 150 N⋅m (15 kgf⋅m, 108 Ibf·ft)
10. Start the engine. Operate the travel lever in the

forward direction to fill adjuster cylinder (6) with
hydraulic oil. At this time, a load is applied so that
the pressure of 24.5 MPa (250 kgf/cm2) over oc-
curs in a traveling circuit.
11. Grease via grease fitting (2) to adjust the track W118-03-05-002
Eyebolt 12 11
sag. (Refer to “Remove and Install Track” on
page W3-9-1)
5 M141-01-012
M117-07-074
W3-6-4
(Blank)
W3-6-5
DISASSEMBLE ADJUSTER CYLINDER
9 10 7 1 2 4 3 5 6 11
Adjuster Side Cushion Side
W146-03-06-002
8 14 12 15 16 12 13
1- Piston (2 Used) 6- Retaining Ring (2 Used) 11 - Flange 15 - Switch Valve

2- Wear Ring (4 Used) 7- Cylinder 12 - Washer (20 Used) 16 - Retaining Ring
3- U-Ring (2 Used) 8- Rod 13 - Bolt (16 Used))
4- Backup Ring (2 Used) 9- O-Ring (2 Used) 14 - Bolt (4 Used)
5- Ring Plate (2 Used) 10 - Flange
W3-6-6
Disassemble Adjuster Cylinder
7. Remove retaining ring (16).
CAUTION: Adjuster cylinder weight:
527 kg (1162 Ib) 8. Remove switch valve (15) with a bolt (M10, Pitch
Rod (8) weight: 71 kg (157 Ib) 1.5 mm).
1. Stand the adjuster cylinder with the cushion side 9. Remove retaining rings (6) (2 used), ring plates
on the bottom. Attach eyebolt (M16, Pitch 2.0 (5) (2 used), backup rings (4) (2 used), U-rings (3) (2
mm) to rod (8). Lift and remove rod (8) from the used), wear rings (2) (4 used) from pistons (1) (2
adjuster cylinder by crane. used).
10. Remove O-rings (9) (2 used) from flanges (10,

CAUTION: Flange (10) weight: 32 kg (71 Ib) 11).
2. Remove bolts (14) (4 used) and washer (12) (4

used) to remove flange (10) from cylinder (7).
: 32 mm
CAUTION: Piston (1) weight: 43 kg (95 Ib)
3. Attach eyebolt (M16, Pitch 2.0 mm) to piston (1)

on the adjuster side. Lift and remove piston (1)
from the adjuster cylinder by crane.
CAUTION: Adjuster cylinder weight:

382 kg (842 Ib)
4. Turn over the adjuster cylinder.
CAUTION: Flange (11) weight: 37 kg (82 Ib)

(16 used) to remove flange (11) from the adjuster
cylinder.
: 46 mm
6. Attach eyebolt (M16, Pitch 2.0 mm) to piston (1)

on the cushion side. Lift and remove piston (1)
from the adjuster cylinder by crane.
W3-6-7
ASSEMBLE ADJUSTER CYLINDER
9 10 14 12 7 1 2 4 3 5 6 12 13 11
Adjuster Side Cushion Side
W146-03-06-002
8 Fill up with Grease 15 16 Fill up with Grease
1- Piston (2 Used) 6- Retaining Ring (2 Used) 11 - Flange 15 - Switch Valve

2- Wear Ring (4 Used) 7- Cylinder 12 - Washer (20 Used) 16 - Retaining Ring
3- U-Ring (2 Used) 8- Rod 13 - Bolt (16 Used)
4- Backup Ring (2 Used) 9- O-Ring (2 Used) 14 - Bolt (4 Used)
5- Ring Plate (2 Used) 10 - Flange
W3-6-8
Assemble adjuster Cylinder
CAUTION: Cylinder (7) weight: CAUTION: Flange (10) weight: 32 kg (71 Ib)
296 kg (653 Ib)
8. Install O-ring (9) onto flange (10). Fill grease into
1. Place cylinder (7) with the cushion side facing up. the groove in flange (10), and then, install it to
cylinder (7) with bolts (14) (4 used) and washers
IMPORTANT: For preventing rust from entering, (12) (4 used).
apply hydraulic oil to switch valve : 32 mm
(15), and then install it. : 750 N⋅m (75 kgf⋅m, 540 Ibf·ft)
2. Install switch valve (15) into cylinder (7). Install
retaining ring (16) onto cylinder (7).
CAUTION: Rod (8) weight: 64 kg (141 Ib)
IMPORTANT: Do not expose backup ring (4) to air

until the moment just before as- IMPORTANT: Apply grease around outer
sembly due to its hygroscopicity circum-ference of rod (8).
property. 9. Install eyebolt (M16, Pitch 2.0 mm) into rod (8)
3. Install retaining rings (6) (2 used), ring plates (5) and hoist it so as to install it to flange (10) on ad-
(2 used), backup rings (4) (2 used), U-rings juster side.
(3) (2 used) and wear rings (2) (4 used) onto
pistons (1) (2 used).
4. Install piston (1) on the cushion side of cylinder

(7).
CAUTION: Flange (11) weight: 37 kg (82 Ib)
5. Install O-rings (9) onto flange (11). Apply grease

into the groove in flange (11), and then, install it
to cylinder (7) with bolts (13) (16 used) and
: 32 mm
: 750 N⋅m (75 kgf⋅m, 540 Ibf·ft)
CAUTION: Piston (1) + Flange (11) + Cylinder

(7) weight: 382 kg (842 Ib)
6. Turn over the adjuster cylinder.
7. Install piston (1) to the adjuster side of cylinder

(7).
W3-6-9
(Blank)
W3-6-10
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER

grease may spurt, possibly causing personal
turns. 1
and keep body and face away from the valve.
2
ting (2).
Removal
1. Loosen valve (1) of the adjuster cylinder to dis- M117-07-074

: 24 mm

the stop valve (4) of accumulator (3).
NOTE: Container volume: 10 L (2.6 US gal)
3
lator (3).
: 19 mm 4
CAUTION: Do not open stop valve (4) M141-01-012

stop valve.
4
accumulator (3).
M141-07-039
5
W3-7-1
5. Disconnect the track. (Refer to “Remove and In-
stall Track” on page W3-9-1)
6 7 8 9 10
6. Disconnect all pipes from the adjuster cylinder
(6).
: 19 mm, 27 mm
7. Remove bolts (11) (8 used) to remove stoppers Forklift

(10) (2 used) from the both sides of side frame
(12).
CAUTION: Front idler (9) weight:

1480 kg (3263 Ib)
8. Pull out front idler (9) from side frame (12) by Eyebolt 12 11
W118-03-05-002
forklift.
Rod (7) is being connected with yoke (8) of front
idler (9).
W3-7-2
Installation
CAUTION: Front idler (9) weight: 6 7 8 9 10
1480 kg (3263 Ib)
1. Insert front idler (9) onto side frame (12) by forklift

to insert yoke (8) and rod (7) into adjuster cylin-
der (6).
2. Install stoppers (10) (2 used) to the both sides of

side frame (12) with bolts (11) (2 used).
: 32 mm
: 750 N⋅m (76.5 kgf⋅m, 540 Ibf·ft)
3. Connect all pipes to adjuster cylinder (6). W118-03-05-002

: 19 mm 12 11
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf·ft)
: 27 mm
: 95 N⋅m (9.5 kgf⋅m, 69 Ibf·ft)
4. Connect the track. (Refer to “Remove and Install

Track Shoe” on page W3-9-1)
5. Close stop valve (4) to install plug (5). 3

: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf·ft)
4
: 24 mm
M141-01-012
: 150 N⋅m (15 kgf⋅m, 108 Ibf·ft) 5
7. Start the engine. Operate the travel lever in the

forward direction to fill adjuster cylinder (6) with
hydraulic oil. At this time, a load is applied so that
the pressure of 24.5 MPa (250 kgf/cm2) over oc-
curs in a traveling circuit.
1
M117-07-074
W3-7-3
8. Grease via grease fitting (2) to adjust the track
sag. (Refer to “Remove and Install Track” on
page W3-9-1)
M117-07-074
W3-7-4
(Blank)
W3-7-5
DISASSEMBLE FRONT IDLER
8
7
1
6
5
2
4
3 4
2 5
1
6 9
10
Hoist Hole
12
W117-03-06-001
11
1 - Plug (2 Used) 4 - O-Ring 7 - Idler 10 - Rod

2 - Bearing (2 Used) 5 - Floating Seal 8 - Axle 11 - Bolt (4 Used)
3 - Pin (2 Used) 6 - Bushing 9 - Yoke 12 - Washer (4 Used)
W3-7-6
Disassemble Front Idler
CAUTION: Bearing (2) + axle (8) weight:
288 kg (635 Ib)
CAUTION: Front idler weight:
1480 kg (3263 Ib) 7. Push out axle (8) from idler (7) with a press.
Rod (10) weight: 71 kg (157 Ib) Bearing (2) is being connected with the opposite
side of axle (8).
1. Secure the front idler in a stable condition. Install
Press
eyebolt (M16, Pitch 2.0 mm) into the hoist hole in
rod (10) and hoist it to remove rod (10) from yoke
(9). 8
CAUTION: Yoke (9) weight: 214 kg (472 Ib)

7
2. Attach wire rope to the yoke (9) and hold it by crane
and remove bolts (11) (4 used) and washers (12)
(4 used) to remove yoke (9).
: 50 mm
2
3. Loosen plugs (1) (2 used) to release oil from W146-03-07-003
bearings (2) (2 used).
： 8 mm 8. Tap pin (3) out from axle (8) with a bar and
hammer to remove bearing (2) on the opposite
side.
CAUTION: Bearing (2) weight: 71 kg (157 Ib)
9. Remove O-ring (4) from axle (8).
4. Tap pin (3) out with a bar and a hammer, and
then, remove bearing (2) from axle (8).(One side
only)
5. Remove O-ring (4) from axle (8).
10. Remove floating seal (5) from idler (7) and bear-
ing (2).
ing seal Handling” on page W1-1-4. CAUTION: Idler (7) weight: 874 kg (1927 Ib)
6. Remove floating seal (5) from idler (7) and bear-
ing (2). 11. If bushing (6) needs to be replaced, perform clad-
ding of welding with electrode at four points
around the bore of bushing (6) by every 90º, so
as to make bushing (6) contract. Remove it from
idler (7).
90°
90°
W105-03-05-012
W3-7-7
ASSEMBLE FRONT IDLER
10 9 12, 11 1 2 7
4 5 6 3
W145-03-06-001
W117-03-06-002
1 - Plug (2 Used) 4 - O-Ring 7 - Idler 10 - Rod

2 - Bearing (2 Used) 5 - Floating Seal 8 - Axle 11 - Bolt (4 Used)
3 - Pin (2 Used) 6 - Bushing 9 - Yoke 12 - Washer (4 Used)
W3-7-8
Assemble Front Idler
1. Press bushings (6) (2 used) into idler (7) with a 6. Install O-ring (4) and bearing (2) on the opposite
press. side onto axle (8). Tap in pin (3) while aligning the
pin hole.
2. Install O-rings (4) in the grooves on axle (8). In-
stall floating seal (5) to bearing (2) and idler 2 5 4 7
(7).(One side only)
CAUTION: Bearing (2) weight: 71 kg (157 Ib)

Axle (8) weight: 146 kg (322 Ib)
3. Install bearing (2) to axle (8) of the side that at-

tached O-Ring (4). Align the pin holes. Tap in pin
(3). 8
8
W157-03-05-005
3
CAUTION: Idler (7) assembly weight:

2
1190 kg (2623 Ib)
Yoke (7) weight: 214 kg (472 Ib)
7. Secure yoke (9) to the idler (7) assembly with

bolts (11) (4 used) and washers (12) (4 used).
W105-03-05-014 : 50 mm
: 2600 N⋅m (260 kgf⋅m, 1880 Ibf·ft)
CAUTION: Axle (8) assembly weight:
217 kg (478 Ib) CAUTION: Rod (10) weight: 71 kg (157 Ib)
4. Press the axle (8) assembly into idler (7) with a 8. Hoist rod (10) to install it into yoke (9).
press.
9. Refill engine oil from plug (1) of bearing (2). (2
5. Install floating seal (5) to idler (7) and bearing (2) places on both right and left)
on the opposite side.
Engine Oil: 1.3 L (0.34 US gal,) (API class CD、
SAE30)
10. Install plug (7) to bearing (2). (2 places on both

right and left)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf·ft)
W3-7-9
MAITENANCE STANDARD
B C
G A
276
D E D
W115-03-04-023
Unit: mm (1 mm = 0.03937 in)

Item Standard Allowable Limit Remedy
A : Idler Outer Thickness 1342 1312 Repair or Replace
B : Axle Outer Dia 185-0.1-0.146 (183) Repair or Replace
B’ : Bushing Inner Dia 185+0.526+0.464 (188) Replace
B’’ : Bushing Outer Dia 205+0.367+0.322 - Replace
C : Bushing Flange Thickness 15 (12) Replace
D : Tread Width 90 (70) Repair or Replace
E : Tread Distance 148 (188) Repair or Replace
F : Fork Guide Interval 476±3 (485) Repair or Replace
F’ : Pedestal Width 320 (310) Repair or Finish
G : Fork Guide Height 247 (270) Repair or Finish
G’ : Pedestal Height 330 (315) Repair or Replace
NOTE: Values in ( ) are just for reference.
W3-7-10
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL UPPER/LOWER
ROLLER

grease may spurt, possibly causing personal 1
turns.
and keep body and face away from the valve. 2
ting (2).
M117-07-074
Remove Upper Roller
: 24 mm
2. Put a container of the drain hydraulic oil under 3

NOTE: Container volume: 10 L (2.6 US gal) 4

lator (3).
M141-01-012
: 19 mm

cumulator (3) may spurt out. Open carefully, 4
stop valve.

accumulator (3).
5 M141-07-039
W3-8-1
5. Lift up the track as shown in figure by crane and
make a gap between the track and upper roller Protector
(7) until upper roller (7) can be removed.
Wire rope: 62 mm×12 m (2.4 in×39 ft 4 in)
CAUTION: Take care not to injure hands by

the power wrench reaction bar.
6. Loosen and remove mounting bolts (6) on upper

roller with a power wrench.
: 32 mm
W118-03-07-002
6
CAUTION: Upper roller (7) weight:
100 kg (220 Ib)
7. Remove upper roller (7) by forklift or other tool

7
from the side frame.
Side Frame
W117-03-07-003
Install Upper Roller

CAUTION: Upper roller (7) weight:
100 kg (220 Ib)
1. Install upper roller (7) on the side frame by forklift 6

or other tools.
CAUTION: Take care not to injure hands by 7

2. Secure upper roller mounting bolts (6) with a

power wrench. Side Frame
: 32 mm
: 740 N⋅m (75 kgf⋅m, 540 Ibf·ft)
W117-03-07-003
W3-8-2
Remove Lower Roller
1. Jack up the machine body as illustrated and set

wooden block under the track frame.
CAUTION: Lower roller (8) weight: 90 to 110°

442 kg (974 Ib)
2. Use a forklift to hold lower roller (8). T142-05-03-012

3. Remove lower roller mounting bolt (9) with a

power wrench.
: 55 mm
W3-8-3
Install Lower Roller
CAUTION: Lower roller (8) weight:
442 kg (974 Ib)
1. Set and hold lower roller (8) under the side frame
by forklift.
2. Temporally tighten lower roller (8) with lower

roller mounting bolt (9).
: 55 mm
8
3. Remove the forklift.

9
W117-03-07-004
4. Secure lower roller mounting bolts (9) with a

power wrench.
： 55 mm
： 3140 N⋅m (320 kgf⋅m, 2314 Ibf·ft)
5. Close stop valve (4) and install plug (5). 3

： 19 mm
4
： 30 N⋅m (3 kgf⋅m, 21.5 Ibf·ft)
5 M141-01-012
W3-8-4
6. Secure valve (1) of grease fitting (2).
: 24 mm
: 150 N⋅m (15 kgf⋅m, 108 Ibf·ft)
7. Turn the track forward and backward two

revolu-tions each.
8. Turn track backward 1/4 revolution.

1
NOTE: Roll track in reverse diretion to move the
track sag part to the lower side.
9. Supply grease via grease fitting (2) to expand the 2

track.(Refer to “Remove and Install Track” on
page W3-9-1)
M117-07-074
Track sag (A) specification: 465 to 535 mm

(18.3 to 21.1 in)
NOTE: Clean the side frame and track before
measuring the track sag.
W118-03-07-001
W3-8-5
DISASSEMBLE UPPER ROLLER
2
3
4 1
5
7
8
7
6
5
4
3
2
1
W117-03-07-001
2 5 3 7 6 8 1
W117-03-07-005
1 - Plug (2 Used) 3 - Collar (2 Used) 5 - O-Ring (2 Used) 7 - Bushing (2 Used)

2 - Pin (2 Used) 4 - Floating Seal (2 Used) 6 - Axle 8 - Roller
W3-8-6
Disassemble Upper Roller
CAUTION: Roller (8) assembly weight: IMPORTANT: For handling of floating seal, refer to
100 kg (220 Ib) the section “precautions for Float-
8. Remove floating seal (4) from roller (8) and collar
1. Remove plugs (1) to drain engine oil.
(3).
: 6 mm
9. Remove O-rings (5) (2 used) from axle (6).
2. Tap out pin (2) from collar (3) with an adapter bar
and hammer.
10. If bushing (7) needs to be replaced, perform clad-
NOTE: In case pin (2) cannot be pulled out, a ding of welding with electrode at four points
press can be used. around the bore of bushing (7) by every 90º, so
as to make bushing (7) contract. Then remove it
CAUTION: Axle (6) + collar (3) weight: from roller (8).
26 kg (57 Ib)
90°
3. Push axle (6) out of roller (8) with a press. Collar
(3) on the other side is still connected with axle
(6) then. 90°
4. Remove collar (3) from axle (6).
IMPORTANT: For handling of floating seal, refer to W105-03-05-012

(3).
6. Tap out pin (2) from collar (3) and axle (6) with a
bar and hammer.
NOTE: In case pin (2) cannot be pulled out, a
press can be used.
7. Remove collar (3) on the other side of axle (6)

with a press.
W3-8-7
ASSEMBLE UPPER ROLLER
2
3
4 1
5
7
8
7
6
5
4
3
2
1
W117-03-07-001
2 5 3 7 6 8 1
W117-03-07-005

W3-8-8
Assemble Upper Lower
CAUTION: Roller (8) weight: 72 kg (159 Ib) 9. Install collar (3) onto axle (6). Tap pin (2) in with a
hammer while aligning its hole.
1. Press bushings (7) (2 used) into roller (8) with a
press. 10. Fill engine oil via plug (1) hole in collar (3).
Engine oil: API class CD SAE30
2. Apply grease to O-ring (5) and install O-ring (5)
Volume: 700 mL (0.18 US gal)
onto one side of axle (6).
11. Apply LOCTITE #503 to plug (1), then install it
3. Install collar (3) onto the side of axle (6) with
into collar (3).
O-ring (5) installed. Tap in pin (2) with a hammer
: 6 mm
while alinging its hole position.
: 35 N⋅m (3.5 kgf⋅m, 25.3 Ibf·ft)
4. Install floating seal (4) onto one side of roller (8)
and collar (3) where axle (6) will be inserted.
CAUTION: Axle (6) + collar (3) weight:

26 kg (57 Ib)
5. Press the axle (6) assembly into roller (8) with a

press.
CAUTION: Roller (8) assembly weight:

100 kg (220 Ib)
6. Attach a nylon sling to the middle of roller (8) as-

sembly then hoist it and turn it over.
7. Apply grease to O-ring (5), then install O-ring (5)

onto axle (6).
8. Install floating seal (4) onto roller (8) and collar

(3).
W3-8-9
DISASSEMBLE LOWER ROLLER
3
4
5
7
8
2
7
1
6
5
4
W117-03-07-002
3
2 5 3 8 7 6 1
4 W117-03-07-006

W3-8-10
Disassemble Lower Roller
CAUTION: Roller (8) assembly weight: IMPORTANT: For handling of floating seal, refer to
442 kg (974 Ib) the section “precautions for Float-
1. Remove plugs (1) to drain engine oil. 8. Remove floating seal (4) from roller (8) and collar
: 6 mm (3).
2. Tap out pin (2) from collar (3) with a bar and 9. Remove O-rings (5) (2 used) from axle (6).
hammer.
10. If bushing (7) needs to be replaced, perform clad-
press can be used.
as to make bushing (7) contract. Remove it from
CAUTION: Axle (6) + collar (3) weight: roller (8).
165 kg (364 Ib) 90°
3. Push out axle (6) from roller (8) with a press.

Collar (3) of the other side will be removed to- 90°
gether with axle (6).
4. Remove collar (3) from axle (6).

W105-03-05-012

(3).
6. Tap out pin (2) from collar (3) with a bar and
hammer.
press can be used.
CAUTION: Axle weight: 106 kg (234 Ib)
7. To remove collar (3) on the other side of axle (6)

with a press.
W3-8-11
ASSEMBLE LOWER ROLLER
3
4
5
7
8
2
7
1
6
5
4
W117-03-07-002
3
2 5 3 8 7 6 1
4 W117-03-07-006

W3-8-12
Assemble Lower Roller
9. Install collar (3) onto axle (6). Align pin (2) hole
and tap in pin (2) with a hammer.
CAUTION: Roller (8) weight: 256 kg (564 Ib)
10. Refill engine oil via plug (1) hole in collar (3).
1. Press bushings (7) (2 used) into roller (8) with a
press. Engine oil: API class CD SAE30
Volume: 900 mL (0.2 US gal)
CAUTION: Axle (6) weight: 106 kg(234 Ib)
11. Apply LOCTITE #503 to plug (1) and tighten plug
(1) on collar (3).
2. Apply a film of grease to O-ring (5), install O-ring
: 8 mm
(5) onto one side of axle (6) only.
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf·ft)
3. Install collar (3) onto the side of axle (6) that
O-ring (5) is being installed. Then align pin (2)
hole and tap pin (2) in with a hammer.
4. Install floating seal (4) onto one side of roller (8)

and collar (3) where axle (6) will be inserted.
CAUTION: Axle (6) + collar (3) weight:

165 kg (364 Ib)
5. Press the axle (6) assembly into roller (8) with a

press.
CAUTION: Roller (8) assembly weight:

442 kg (974 Ib)
6. Attach a nylon sling to the middle of roller (8) as-

sembly and hoist it to turn it over.
7. Apply grease to O-ring (5) and install it onto axle

(6).
8. Install floating seal (4) onto roller (8) and collar

(3).
W3-8-13
Upper Roller
298
148
10°
A B C
60 W117-03-07-007
Unit: mm (1 mm = 0.03937 in)

Item Standard Dimensions Allowable Wear Remedy
Limit
A: Roller (Outside Diameter) 330 300 Repair or Replace
B: Axle (Outside Diameter) 75-0.06-0.09 (73) Replace
C: Bushing (Inside Diameter) 75+0.35+0.3 (78) Replace
Bushing (Outside Diameter) 87+0.155+0.120 - Replace
D: Bushing (Flange Thickness) 6.0 0-0.1 (4.5) Replace
“Welding Repair Procedure” (W3-11-1).
Values in ( ) are for reference only.
W3-8-14
Lower Roller
D
C
A
W117-03-07-008
Unit: mm (1 mm = 0.03937 in)

Item Standard Dimensions Allowable Wear Remedy
Limit
A: Roller (Outside Diameter) 440 410 Repair or Replace
B: Tread Interval 148 (108) Repair or Replace
C: Axle (Outside Diameter) 160-0.085-0.125 (158) Replace
C’: Bushing (Inside Diameter) 160+0.063+0.58 (163) Replace
Bushing (Outside Diame- 180+0.32+0.28 - Replace
ter)
D: Bushing (Flange Thickness) 15 0-0.1 (13.5) Replace
W3-8-15
(Blank)
W3-8-16
UNDERCARRIAGE / Track Shoes
REMOVE AND INSTALL TRACK SHOES
Removal
Track Wooden Blocks Side Frame
1. Set wooden blocks between the side frame and
track.
NOTE: Wooden block size (Reference)
L 600 mm (23.6 in), W 300 mm (11.8 in), H
430 mm (16.9 in)
W146-03-09-006
CAUTION: The adjuster cylinder is under

high pressure. Do not loosen valve (1)
quickly or loosen too much since valve (1)
may fly out and high-pressure grease in the
adjusting cylinder may spurt out. It is
enough to loosen valve (1) just for 1 to 1.5
turns.
Loosen carefully, keeping body parts and 1
face away from the valve. Never attempt to
loosen grease fitting (2).
2
2. Loosen valve (1) of the adjuster cylinder and dis-
charge grease to loosen the track.
: 24 mm
M117-07-074
NOTE: With valve (1) loosened, reverse a little to
make the track getting sag.

NOTE: Container volume: 10 L (2.6 US gal) 3
4. Remove plug (5) from stop valve (4) of accumu- 4

lator (3).
: 19 mm
M141-01-012
5 M141-07-039
W3-9-1

keeping body parts and face away from stop
valve (4).
5. Open stop valve (4) to drain hydraulic oil from 3

accumulator (3).
4
6. Close stop valve (4).
NOTE: If you start the engine with stop valve open,
hydraulic oil will spurt out from stop valve M141-01-012
(4), once the travel lever is operated.

4
7. With a power wrench, loosen and remove bolts
(9) and nuts (7) from the front idler side shoe (6).
: 46 mm
8. Pull out joint pins (8) from shoes (6) and separate
the shoes (6).
9. Jack up machine body and put a stand under the M141-07-039

track frame to support the machine.
W18B-03-09-001
T142-05-03-012
W3-9-2
CAUTION: Each shoe (6) weight:

279 kg (615 Ib) Wooden Blocks Side Frame
Front
10. Slowly operate travel lever on the side with track

being removed to reverse position to extend the
track.
CAUTION: Track weight: 11770 kg (25950 Ib)

W146-03-09-003
11. Pull out track from the downside of side frame by

crane.
W3-9-3
Installation
CAUTION: Track weight: 11770 kg (25950 Ib) Wooden Blocks Side Frame
Front
IMPORTANT: Be sure not to disorient shoe direc-

tion. Put casting number of shoe (6)
at the inner side of the side frame.
1. Set wooden blocks on the side frame to jack up
the machine.
NOTE: Wooden block size (Reference value)
L 600 mm (23.6 in), W 300 mm (11.8 in), H W146-03-09-003
430 mm (16.9 in)
CAUTION: Each shoe (6) weight:

279 kg (615 Ib)
Wooden Blocks 10
2. Set the track shoes under the side frame and
Front
lower machine on the track shoes. Hoist drive
tumbler (10) of track and make claws of shoe grip
drive tumbler (10).
3. Start the engine and slowly operate the lever for-

wards. Roll up the track shoes while turning drive
W146-03-09-004
tumbler (10).
4. Install and tighten chain blocks (11, 12) into the

joint of track. Tighten the opposite side in the 10
same way. Forward
Front
CAUTION: When aligning joint pin (8) hole of
shoe (6), never insert fingers into the hole.
5. Align joint pin (8) hole in shoe (6) while adjusting

chain blocks (11, 12). Tap joint pin (8) in with a W146-03-09-005
hammer.
11
6
8
8
12
W146-03-09-002
W3-9-4
6 8 7 9
with the power wrench reaction bar. 7 6 9 8
6. Apply LOCTITE #262 on bolts (9), install the re-

taining bolts and nuts (7) with a power wrench.
: 46 mm
: 1950 N⋅m (195 kgf⋅m, 1410 Ibf·ft)
7. Install plug (5) into stop valve (4).

: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf·ft)
8. Tighten valve (1) on the adjuster cylinder.

W118-03-08-005
: 24 mm
: 150 N⋅m (15 kgf⋅m, 108 Ibf·ft)
9. Jack up the machine. Turn the track forward and

backward two revolutions each. 4
10. Turn the track backward 1/4 revolution.

NOTE: Turn the track backward to bring sag part
to downside.
11. Add grease via grease fitting (2) and make the
track in tension.
Track Sag Specification (A): 465 to 535 mm 5 M141-07-039
(18.3 to 21.1 in)

NOTE: Clean the side frame and track shoes be-
fore measuring the tension amount.
M117-07-074
W118-03-07-001
W3-9-5
DISASSEMBLE AND ASSEMBLE TRACK
SHOES
4 3
1
W117-03-08-001
3 4 2 1
Section A W141-03-09-001
1 - Pin 2 - Bolt 3 - U-Nut 4 - Shoe
W3-9-6
Up to serial No. 529.
133±1.5
90
93
W141-03-09-003
B
104
C 283
D
E
3
300+ 0
W141-03-09-006
35
440±0.5
W141-03-09-002
Unit: mm (1 mm = 0.03937 in)

Item Standard Dimensions Allowable Wear Limit Remedy
A: Tread (Height) 80 (90) Repair or Replace
B: Tread (Total Width) 180 ± 1.5 (160) Repair or Replace
C: Pin (Outer Diameter) 75-0.3-0.4 (70) Replace or Used Oversize Pin
+0.5
D: Pin (Inner Diameter) 75 +0.2 (80) Used Oversize Pin
E: Grouser (Height) 30 0 Repair or Replace
F: Shoe (Pitch) *1320 *1354 Replace With Oversize Pin
*: The mark shows dimensions across three shoes.
W3-9-7
Serial No. 530 and up.

133±1.5
90
93
W141-03-09-003
B
104
C 283
D
E
3
300+ 0
W141-03-09-006
35
440±0.5
W141-03-09-002
Unit: mm (1 mm = 0.03937 in)

Item Standard Dimensions Allowable Wear Limit Remedy
A: Tread (Height) 80 (90) Repair or Replace
B: Tread (Total Width) 168 ± 1.5 (148) Repair or Replace
C: Pin (Outer Diameter) 75-0.3-0.4 (70) Replace or Used Oversize Pin
+0.5
D: Pin (Inner Diameter) 75 +0.2 (80) Used Oversize Pin
E: Grouser (Height) 30 0 Repair or Replace
F: Shoe (Pitch) *1320 *1354 Replace With Oversize Pin
*: The mark shows dimensions across three shoes.
W3-9-8
UNDERCARRIAGE / Accumulator
REMOVE AND INSTALL ACCUMULATOR
1
Removal

pressurized. Do not loosen the valve quickly Adjuster W146-03-06-001
Cylinder
grease may spurt, possibly causing personal
turns.
and keep body and face away from the valve.
1
ting (2).
Removal
2
: 24 mm M117-07-074

NOTE: Container volume: 10L (2.6 US gal)
W3-10-1

stop valve.
3
4
lator (3). Open stop valve (4) to drain hydraulic oil 7
from accumulator (3).
: 19 mm
IMPORTANT: Put tags to all hoses to aid 5 M141-01-012
re-assembly. 6
4. Disconnect all hoses and pipes from the accu-
mulator (3) assembly.
: 19 mm, 22 mm, 27 mm, 36 mm
8
CAUTION: Accumulator (3) weight: 95 kg
(210 lb) 7
Accumulator (6) weight: 60 kg (132 lb)
5. While holding accumulator (3, 6) by chain block,

remove and lowered U-bolt (8) and nut (7) to re-
move and lowered accumulator (3, 6). 9 M141-01-013
: 24 mm
5 M141-01-012
W3-10-2
Installation
6
CAUTION: Accumulator (3) weight:

95 kg (210 lb)
Accumulator (6) weight: 60 kg (132 lb)
8
1. Hoist accumulators (3) and (6) by chain block.
Then, install accumulators (3) and (6) onto 7
bracket (9) with U-bolts (8) and nuts (7).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 156 lbf⋅ft)
2. Connect all hoses and pipes to accumulator (3) 9 M141-01-013

and (6).
: 19 mm
: 30 N⋅m (3 kg f⋅m, 21.5 lbf⋅ft)
: 22 mm
: 40 N⋅m (4 kg f⋅m, 28.5 lbf⋅ft)
: 27 mm
3
: 95 N⋅m (9.5 kg f⋅m, 68 lbf⋅ft)
: 36 mm
4
: 180 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
3. Install plug (5) on stop valve (4). Close stop valve

(4).
: 19 mm 5 M141-01-012
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

: 24 mm
: 150 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
1
5. Grease via grease fitting and make the track in
tensing.(Refer to “Remove and Install Track” on
page W3-9-1)
2
M117-07-074
W3-10-3
DISASSEMBLE ACCUMULATOR
26
25
24
23
22
21
1
20
19
18
17
16
2
15
3
14
4
13 7
10
11
12
W118-03-08-003
1 - Shell 8- Backup Ring 15 - O-Ring 22 - O-Ring

2 - Oil Port Assembly 9- Spacer 16 - Gas Plug 23 - Gas Valve
3 - Gasket 10 - Lock Nut 17 - Retaining Ring 24 - Cap
4 - Bleed Plug 11 - O-Ring 18 - Washer 25 - Wire
5 - Retaining Ring 12 - Bushing 19 - O-Ring 26 - Valve Guard
6 - Washer 13 - Bladder 20 - Backup Ring
7 - O-Ring 14 - Valve Stem 21 - Ring
W3-10-4
Disassemble Accumulator
7. Remove backup ring (20), O-ring (19) and
washer (18) from gas plug (16).
CAUTION: The accumulator is charged with
high pressure gas, do not attempt to weld or 8. Turn shell (1) over 180 degrees (oil port assem-
torch- cut it, nor expose it to the flame. bly (2) side upward).
1. Clean the outside of the accumulator before dis- 9. Remove bleed plug (4) from oil port assembly (2).
assembling. Cut and remove wire (25). Remove Loosen lock nut (10) with a hook spanner
valve guard (26). wrench.
2. Remove cap (24) from valve stem (14) of bladder 10. Remove lock nut (10) and spacer (9) from oil port
(13). assembly (2).
IMPORTANT: Before installing the charge valve, 11. Remove backup ring (8), O-ring (7) and washer
turn handle (A) counterclockwise (6) from oil port assembly (2).
and handle (B) clockwise.
3. Install charge valve (Parts Number: 4032854) 12. Pick up and remove retaining ring (5) from shell
onto valve stem (14). Turn handle (A) clockwise. (1) with fingers.
Carefully turn handle (B) counterclockwise to
open the charge valve to release nitrogen gas 13. Remove oil port assembly (2) from shell (1).
from the bladder until the gauge shows zero
pressure. 14. Insert fingers into shell (1), catch at bladder (13)
with fingers.
A Draw out bladder (13) from oil port assembly (2)
side opening.
B
15. Remove retaining ring (17), gas plug (16) and
O-ring (15) from valve stem (14).
Charge Valve
Accumulator W115-03-08-029
4. Remove the charge valve from valve stem (14).
5. Carefully loosen gas valve (23) and remove it

from valve stem (14).
6. Loosen ring (21) with a hook spanner wrench

and remove it from valve stem (14).
W3-10-5
ASSEMBLE ACCUMULATOR
12 11 2 10 9 5 13 1 17 16 21 14 25 26
3 4 8 7 6 15 18 19 20 22 23 24
W118-03-08-002
1 - Shell 8- Backup Ring 15 - O-Ring 22 - O-Ring

2 - Oil Port Assembly 9- Spacer 16 - Gas Plug 23 - Gas Valve
3 - Gasket 10 - Lock Nut 17 - Retaining Ring 24 - Cap
4 - Bleed Plug 11 - O-Ring 18 - Washer 25 - Wire
5 - Retaining Ring 12 - Bushing 19 - O-Ring 26 - Valve Guard
6 - Washer 13 - Bladder 20 - Backup Ring
7 - O-Ring 14 - Valve Stem 21 - Ring
W3-10-6
Assemble Accumulator
12. Install gasket (3) and bleed plug (4) onto oil port
1. Install O-ring (15), gas plug (16) and retaining assembly (2).
ring (17) into valve stem (14).
13. Turn shell (1) over 180 degrees (valve stem (14)
2. Insert the head of the pulling chain into shell (1) side upward).
via valve stem (14) side opening. Then, draw out
the head of the pulling chain from the opposite IMPORTANT: After charging with nitrogen gas,
side. smear gas valve (23) with soap bub-
Install the head of the pulling chain onto valve ble to check gas leakage.
stem (14) to install bladder (13) and valve stem 14. Install O-ring (22) onto gas valve (23). Install gas
(14) into shell (1). valve (23) on valve stem (14). Charge bladder
(13) with nitrogen gas with a charge valve.(Refer
to “Charge Nitrogen Gas” on page W3-10-10)
The head
Charge valve
Pulling Chain
Nitrogen Gas
Accumulator Cylinder
W18B-03-10-001
W145-03-09-003
3. Pull valve stem (14) out of shell (1) with a pulling 15. Install cap (24) onto gas valve (23).
chain.
16. Install valve guard (26) on valve stem (14) and
4. Install washer (18), O-ring (19) and backup ring tighten valve guard (26).
(20) in the groove of gas plug (16).
17. Connect wire (25) to valve guard (26) and ring
5. Tighten ring (21) to gas plug (16) with a hook (21).
spanner wrench.
6. Turn shell (1) over 180 degrees (oil port assem-

bly installing side upward).
7. Install oil port assembly (2) on shell (1).
8. Pick up and install retaining ring (5) into shell (1)

with fingers.
9. Pull out oil port assembly (2) and align it with re-
taining ring (5).
10. Install washer (6), O-ring (7) and backup ring (8)
in the groove of oil port assembly (2).
11. Install spacer (9) and lock nut (10) onto oil port
assembly (2).
Tighten lock nut (10) with a hook spanner wrench.
W3-10-7
Maintenance
IMPORTANT: Perform check of gas pressure once

a year for function maintenance of
accumulator.
The accumulator bladder has been charged with

high pressure nitrogen gas of 9.8 MPa (100 kgf/cm2,
1420 psi). Check the gas pressure at least once a
year to maintain correct accumulator functions.
Accumulator malfunctions are mainly caused by
damage in the bladder. If the following symptoms are
found, disassemble the accumulator and check the
bladder for damage. If the bladder is damaged, re-
place it with a new one and recharge it with nitrogen
gas.
・ Gas leaks from the bleed plug when the plug is

loosened.
・ Mixture of gas and oil gushes from the stop valve
on draining hydraulic oil from the accumulator.
・ The gas pressure in the bladder is extremely low.
・ The pressure gauge reading of the charged gas
pressure in the bladder is 0 MPa (0 kgf/cm2, 0
psi).
・ Oil mist gushes from the charge valve assembly
port when discharging gas.
Use the charge valve and hose assembly to check

gas pressure in the bladder and charge the bladder
with nitrogen gas.
1-1 Number Charge Valve Assembly

1 Charge Valve
1 2-2 1-1 Pressure Gauge
1-2
1-2 Plug
2-1
1-3 Connector
2 2 Hose Assembly
1-3 2-1 Hose
2-2 Joint
2-3 2-3 Joint
Parts No. 4032854
Nitrogen Gas Cylinder
Accumulator
W115-03-08-032
W3-10-8
Check Gas Pressure
1. Release air pressure from the hydraulic oil tank.

(Refer to “Bleed Air from Hydraulic Oil tank”)
Remove plug (5), slowly open stop valve (4) to
drain hydraulic oil from the accumulator.
: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
4 Accumulator
2. Remove wire (25). Remove valve guard (26) and
cap (24) from the accumulator.
Turn handle (A) counterclockwise and handle (B)
clockwise before installation of charge valve. 5 M141-01-012
Then, Install charge valve onto valve stem (14)

on the accumulator.
A
3. Slowly turn handle (A) clockwise to open gas
valve (23) on the accumulator. Use a pressure
gauge to show the gas pressure in the accumu- Pressure
lator. Wait one minute, then, read the pressure Gauge
B
value shown on the pressure gauge.
Specified pressure valve: 9.8±0.5 MPa (100±5
Charge Valve
kgf/cm2, 1420±71 psi) at 20 °C (68 °F).
Valve Stem
4. If the gas pressure reading is less than 8.3 MPa
(85 kgf/cm2, 1210 psi), charge nitrogen gas into
bladder (13) according to step 2 for charge pro- Accumulator
cedure. W115-03-08-028
A
5. After checking, turn handle (A) counterclockwise
to close gas valve (23). Turn handle (B)
counter-clockwise to release the residual pres- B
sure in the charge valve.
W115-03-08-029
W3-10-9
6. Remove the charge valve from the accumulator. 13 14 25 26
Check gas valve (23) for gas leaks. Install cap
(24), valve guard (26) and wire (25) on the ac-
cumulator.
7. Closing the stop valve the plug is attached.

: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
Charge Nitrogen Gas 23 24
W118-03-08-002
1. Remove the valve guard and cap from the ac-
cumulator. Before installing the charge valve, turn
handle (A) counterclockwise and handle (B)
clockwise. Then, install the charge valve onto the A C
accumulator valve stem (14).
B
2. Connect the hose assembly to the charge valve
and the nitrogen gas tank. Install handle (C) onto
gas tank valve.
3. Lightly turn handle (C) to open the nitrogen gas

tank valve.
Lightly turn handle (B) counterclockwise to re-
lease the residual gas in the hose assembly and
close handle (B).
Nitrogen Gas Tank
4. Turn handle (A) clockwise to charge the bladder
with nitrogen gas.
Accumulator
Check the charged gas by opening or closing W18B-03-10-001
handle (C) by a reasonable amount. Close han-

dle (C) when the charged gas pressure reaches
11.8 MPa (123 kgf/cm2, 1710 psi).
NOTE: Accumulator gas capacity: 18.2 L (4.8 US
gal).
5. Carefully turn handle (B) counterclockwise to re-

lease gas pressure in the bladder until it reaches
9.8±0.5 MPa (100±5 kgf/cm2, 1420±71 psi), then,
close handle (B).
W3-10-10
CAUTION: The charged gas pressure in the

bladder varies depending on the temperature Gas Pressure
(MPa)
as shown in right diagram.
6. Turn handle (A) counterclockwise to close the 110 2

gas valve and check the gas valve for gas leak- 10.5 MPa (107 kgf/cm )
age. Remove the charge valve from the accumu-
2
lator. 9.8 MPa (100 kgf/cm )
100
9.1 MPa
2
(93 kgf/cm )
90
0 10 20 30 40
W115-03-08-033
Temperature (°C)
Temperature Gas Pressure

(°C) (°F) MPa (psi)
2
(kgf/cm )
A 0 0 9.1 (93) 1322
B 20 68 9.8 (100) 1422
C 40 104 10.5 (107) 1522
W3-10-11
(Blank)
W3-10-12
UNDERCARRIAGE / Welding Repair Procedure
WELDING REPAIR PROCEDURE
Preparation
Equipment Required
Welder and Accessories ×1 unit
Welding Rods ×1 set
Standard Tools ×1 set
Grinder ×1 unit
Gas Torch ×1 set
Touch Up Paint ×1 unit
Thermal Chalks (Thermocrayon) ×1 set
Precautions for Welding:

1. Attach the ground cable as near as possible to
the welding area. If the ground cable is far from
the welding area, the electrical equipment or
other components may be damaged.
2. Be careful not to produce welding defects such
as under cuts when welding.
3. Be careful not to damage other components by
spattering during welding.
4. Be sure to make welding beads smooth and flat
with a grinder.
5. Before performing grinder work, be sure to wear
safety glasses or goggles.
Thermal Chalks
For correct welding, use thermal chalk
(thermocrayon) to measure the temperature of the
components to be welded before and after the
welding.
Thermal Chalk Specification: M-300 (250 to 300 °C,

482 to 572 °F)
How to use thermal chalks:

Mark the preheated components with thermal chalk. Thermal Chalk
If the chalk mark is melted, the temperature of the
component is higher than the regulated temperature.
Do not use thermal chalk while heating the
components.
W115-03-11-001
W3-11-1
WELDING ROD SPECIFICATION
IMPORTANT: In order to dry the welding rods, NOTE: 1 °C=1.8 °C+32

heat them to 300 to 350 °C for one 1 mm=0.03937 in
hour before using.
Welding Rods for Underlaying: JIS Z 3211 D4316

Shinko Make LB26×4 mm dia. or equivalent to AWS
7016, BSE 614 H
Example of Chemical Composition (%) of Deposited Metal

C Si Mn P S
0.08 0.44 0.97 0.013 0.009
Example of Mechanical Properties of Deposited Metal

Yield Point Breaking Strength Elongation Absorption Energy Heat
N / mm2 (kgf / mm2) N / mm2 (kgf / mm2) % J (kgf⋅m) Treatment
470 (48) 540 (55) 33 220 (22) As Welded
410 (42) 500 (51) 34 240 (24) 620 °C×1 hr
Dimensions and Current Range (AC or DC ⊕)

Rod Diameter (mm) 2.0 2.6 3.2 4.0 5.0 6.0 7.0 8.0
Rod Length (mm) 300 350 350 400 450 450 450 450
Flat Welding
Vertical 35 to 60 55 to 85 100 to 140 140 to 190 190 to 250 260 to 320 300 to 380 340 to 440
Current Overhead
Range (A) Vertical
Overhead 30 to 55 50 to 80 90 to 130 120 to 180 160 to 210 - - -
Welding
Welding Rods for Overlaying:

JIS DF 2A-450-B Shinko Make HF-450×5 mm dia.
or Philip 450 or Acrossdiamond 500
Example of Chemical Composition (%) of Deposited Metal

C Si Mn P S Cr Mo V
0.20 1.21 0.39 0.011 0.008 2.54 0.57 0.30
Example of Hardness of Deposited Metal (Vickers Hardness)

As Welded Heat Treatment
Pre-Heat Temperature / Pre-Heat Temperature /
Temperature between Temperature between 550 °C×6 hr 625 °C×6 hr
Welding Paths (150 °C) Welding Paths (300 °C)
452 408 443 348
Dimensions and Current Range (AC or DC⊕)

Rod Diameter (mm) 4.0 5.0 6.0
Rod Length (mm) 400 400 450
Current Range (A) Flat welding 140 to 180 190 to 240 220 to 300
Rod End Color: Red
Derivative Color: Pink
W3-11-2
REPAIR TRACK SHOES (SHOE LUGS)
1. Prepare patterns (A, B) shown in the appendix.
Measure wear amounts of the track shoes using
patterns (A, B), as illustrated. If the track shoe is
excessively worn, repair it following steps 2
through 6.
Standard Dimensions
133 W115-03-11-003
(A) Plane
90
Pattern (A) Unit: mm
80
W115-03-11-004
Standard Dimensions
(B) Plane 180 Unit: mm
104
Pattern (B), Up to
serial No. 529
W141-03-09-007
168
125 Unit: mm
Pattern (B),
serial No. 530
and up
NOTE: 1 mm=0.03937 in
W141-03-09-008
W3-11-3
2. Preheat the shoe lug to 250 to 300 °C (482 to
572 °F) with an acetylene torch.
Correctly measure the preheating temperature
with thermal chalk.
W115-03-11-006
IMPORTANT: Keep the temperature between

welding paths of the track shoe at
200 to 250 °C (392 to 482 °F) while
performing underlaying.
3. Perform underlaying with the designated welding
rod (LB-26×4 mm dia.) until it reaches one or two
layers short of the finish dimension.
W115-03-11-007
W3-11-4
4. Perform overlaying with designated welding rod
(HF450×5 mm dia.).
NOTE: Keep the temperature between welding
paths of the track shoe at 200 to 250 °C
(392 to 482 °F) while performing
overlaying. Be careful not to excessively
heat the track shoe. The hardness will be
decreased.
Do not overlay more than two lays in
welding for the purpose of wear allowance
increase. Cracks will result.
W115-03-11-008
IMPORTANT: Track shoe will crack if quickly

cooled
W115-03-11-009
5. Immediately after the overlaying, heat the track
shoe at 350 to 400 °C (662 to 752 °F) for 15
minutes. Cover the shoe with glass wool or other
equivalent material to avoid quick cooling.
6. Correctly finish the lug with a grinder. Use

patterns (A, B) to check the lug dimensions.
W115-03-11-010
W115-03-11-011
W3-11-5
REPAIR ROLLERS
Pattern
NOTE: The drawings on this page are those of the

upper roller. However, the repair procedure
below can be applied to both the upper
and lower rollers
1. Fabricate paper patterns by utilizing patterns

provided on the back of this book. Using paper
patterns, measure wear amount of the roller. If
the wear amount exceeds 10 mm (0.39 in), repair W115-03-11-014
the roller as follows: Pattern
2. Perform underlaying minimum 5 to 6 mm (0.2 to

0.24 in). The 6 to 8 mm (0.23 to 0.31 in) thick-
ness of underlaying is permissible.
W115-03-11-015
W115-03-11-016
3. Preheat the upper roller to 250 to 300 °C (482 to

572 °F) with an acetylene torch. Correctly Preheating
measure the preheating temperature with thermal
chalk.
Thermal Chalk
W115-03-11-017
W3-11-6
4. Perform underlaying so that the thickness of the
wear resisting welding to be done next is 4 to 5
mm (0.16 to 0.2 in). Perform welding
symmetrically in order to avoid deformation of the
roller periphery. Keep the temperature between
welding paths of the roller at 250 to 300 °C (482 4
1
to 572 °F) while performing underlaying.
5. After underlaying, finish the roller surfaces with a 2

3
grinder.
W115-03-11-018
6. Perform overlaying with the designated welding

rod of HF450×5 mm dia. or other equivalent. The
thickness of the overlaying is 4 to 5 mm (0.16 to
0.2 in). Keep the temperature between welding W115-03-11-019
paths of the roller at 250 to 300 °C (482 to 572

°F) while performing overlaying.
NOTE: Be careful not to excessively heat the roller.
The hardness will be decreased.
Do not overlay more than two lays in
welding for the purpose of wear allowance
increase. Cracks will result.
W115-03-11-020
W3-11-7
7. Cover the roller with glass wool or other equiva-
lent material to avoid quick cooling.
8. After 24 hours, check that the roller is free from

cracks.
Correctly finish the roller using a grinder. Use
pattern (A) and (B) to check the roller shape, as
illustrated to the right.
W115-03-11-021
W115-03-11-022
W115-03-11-014
W3-11-8
REPAIR DRIVE TUMBLER
1. Before welding, clean the drive tumbler to
remove mud and sand.
Remove rust and surface unevenness with a
grinder.
W115-03-11-024
2. Preheat the drive tumbler to 250 to 300 °C (482

to 572 °F) with a touch.
NOTE: Correctly measure the preheating
temperature with thermal chalk.
1 mm=0.03937 in
W115-03-11-025

Unit: mm
φ1346
W115-03-11-026
Serial No. 530 and up.
667
W141-03-11-001.TIF
W3-11-9
3. Perform underlaying with LB-26 or other
equivalent welding rod.
To maintain the temperature balance while
welding, the succeeding welding spot should be
on a diagonal line, as illustrated.
NOTE: Visually check that the welding beads are
free from cracks.
The minimum thickness of one layer of
underlaying is 5 to 6 mm (0.2 to 0.23 in)
even if the wear amount is less than 5 to 6
mm (0.2 to 0.23 in). Perform second and
third layers of underlaying.
W115-03-11-027
NOTE: Keep the temperature between welding
Thermal Chalk
paths of the drive tumbler at 200 to 250 °C
(392 to 482 °F) while performing
underlaying.
IMPORTANT: Finish the drive tumbler so that its

periphery surface smoothly
contacts with the track shoes.
Keep the temperature between
welding paths of the drive tumbler
at 200 to 250 °C (392 to 482 °F) while
performing overlaying. W115-03-11-028
4. Perform overlaying with HF-450 or other

equivalent welding rod.
NOTE: 1 mm = 0.3937 in
5. Immediately after the overlaying, heat the drive

tumbler at 350 to 400 °C (662 to 752 °F) for 10 to
15 minutes.
W115-03-11-029

φ1346 Underlaying:
5 to 6 mm
Overlaying
200 mm
Finish to be flat
W115-03-11-030
W3-11-10
6. Cover the drive tumbler with glass wool or other
equivalent materials to avoid quick cooling.
Glass Wool
W115-03-11-031
7. After 24 hours, remove the glass wool cover from

the drive tumbler and check for cracks with a
color check.
W115-03-11-032
8. Finish the drive tumbler surface to the correct
dimensions with a grinder. Use the paper pattern
shown in the appendix to check the finished di-
mension and shape.
W115-03-11-033
W3-11-11
(Blank)
W3-11-12
MEMO
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SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment ...... W4-1-1
Group 2 Cylinder
Remove and Install Cylinder .................... W4-2-1
Disassemble Cylinder ............................ W4-2-32
Assemble Cylinder ................................. W4-2-40
Main Points to Bleed Air ......................... W4-2-48
Maintenance Standard ........................... W4-2-50
Group 3 Bushing and Point

Remove and Install Bushing .................... W4-3-1
Maintenance Standard ............................. W4-3-4
141W-4-1
(Blank)
141W-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT
oil tank before starting work. (Refer Hydraulic Hose
to “item of Bleeding Air from Hy- Greasing Hose
Remove Front Attachment (Loading Shovel)
1. Bleed air from hydraulic oil tank. Stop the engine

and operate the lever several times to release the
remaining pressure from the circuit. (Refer to
“item of Bleeding Air from Hydraulic Oil Tank” on
page W1-3-1)
W18B-04-01-015
Hydraulic Hose
2. Disconnect all hydraulic hoses and greasing
hoses between the arm and bucket, then install
plated plug to the opening ends.
: 36 mm
: 14 mm
3. Disconnect the hydraulic hose between the boom

and arm, then install plated plug to the opening
ends. (2 Places)
W18B-04-01-024
: 14 mm
Boom
Greasing Hose
4. Disconnect the greasing hose between the boom

and arm.
: 36 mm
Arm
W18B-04-01-022
W4-1-1
5. Disconnect the greasing hose for arm cylinder
rod side and level cylinder rod side from the cyl- Level Cylinder
inder rod side. Greasing Hose
: 19 mm
Arm Cylinder
W18B-04-01-023
6. Remove the bucket cylinder. (2 places) (Refer to Bucket Cylinder

“Remove and Install Bucket cylinder” on page
W4-2-14)
W18B-04-01-017
Move O-ring
7. Move the O-ring from the arm end to boss side of
bucket. (2 places)
Bucket Arm
W183-04-01-002
W4-1-2
CAUTION: Bucket weight:

19400 kg (42770 lb)
8. Install shackle, wire and chain block to the lifting

bracket (2 places) of bucket. Hold the bucket by
crane.
Lifting
Bracket
Bucket
W18B-04-01-018
9. Remove bolts (2) (4 used) and spring washers

(3) (4 used) from pin stopper (4) at arm end to Arm
remove stopper (4) from the bucket. (2 places)
: 30 mm
Bucket
CAUTION: Pin (1) weight: 135 kg (300 lb)
10. Pull pin (1) out to the position where the arm can
be removed from the bucket. Attach nylon sling
on the body of pin (1) to lift and remove it by
crane. (2 places)
W18B-04-01-076
11. Lift the bucket by crane and remove it from the

arm. Arm
Remove shim (5) from the pin hole. Bucket
2, 3
5 W141-04-01-002
W4-1-3
12. Start the engine, place arm end onto wooden
block.
Arm
Wooden Block W18B-04-01-021
13. Bleed air from hydraulic oil tank. Stop the engine Boom
page W1-3-1) Arm
14. Disconnect all hydraulic hoses between the boom Hydraulic

Hose
and arm to the arm side, Install plated plugs to
the opening ends.
: 14 mm, 17 mm
W141-04-01-003
CAUTION: Arm weight: 9520 kg (20990 lb)

brackets (2 places) to the arm. Hold the arm by
crane.
Lifting Body Side
Bracket
W141-04-01-006
W4-1-4
CAUTION: Level cylinder weight: Lifting Bracket

1880 kg (4150 lb) Level Cylinder
Arm cylinder weight: 2240 kg (4940 lb)
16. Attach chain block between the lifting bracket for

boom bottom plate and the rod side of cylinder
tube to hold the level and arm cylinder.
17. Pull the pin out from level cylinder rod end to the
positions where the cylinder rod can be removed.
In such case, do not remove the pin left on the Arm Cylinder
W18B-04-01-028
arm.
18. Start the engine to retract cylinder and secure cyl-

inder tube with a wire to prevent the rod from ex-
tending out.
19. Pull the pin out from arm cylinder rod end to the Arm
positions where the cylinder rod can be removed.
In such case, do not remove the pin left on the
arm.
20. Start the engine to retract cylinder and secure cylin-

der tube with a wire to prevent the rod from ex- W18B-04-01-026
tending out.
21. Remove bolts (7) (2 used), spring washers (8) (2

used) to remove plate (9). (2 places)
: 36 mm
22. Pull pin (6) out to the positions where the arm can
be removed from the boom. Attach nylon sling to
the body of pin (6) to lift and remove it by crane.
(2 places)
W18B-04-01-030
Arm
Boom
7, 8
6 9
10
W141-04-01-004
W4-1-5
23. Lift the arm by crane and remove it from the
boom.
24. Place arm on the wooden blocks.

NOTE: Wooden blocks dimensions
Length 800 mm (31.5 in), Width 900 mm
(35.4 in), Height 800 mm (31.5 in)
W141-04-01-005
Wooden Block
Level Cylinder
25. Hoist the chain block which is holding the level
cylinder and arm cylinder as much as possible,
then secure the chain block to the boom.
Arm Cylinder
Chain Block W18B-04-01-037
26. Disconnect the greasing hoses between main

frame and the boom cylinder rod. (2 places)
: 19 mm
Greasing Hose M141-07-015
27. Disconnect the greasing hoses between the arm

and main frame from the boom bottom plate.
: 36 mm
Boom Greasing Hose W18B-04-01-036
W4-1-6
CAUTION: Boom assembly weight:

25600 kg (56440 lb) Lifting Bracket
28. Install a shackle and wire to the boom lifting

bracket (2 places). Hoist the boom by crane and
hold it.
CAUTION: Boom cylinder weight:

2970 kg (6550 lb)
W18B-04-01-039
29. Install a wire and chain block to the rod side of
boom cylinder tube to hold the boom cylinder rod Lifting Bracket
via the lifting bracket on boom bulkhead and the
chain block. (2 places)
Boom
30. Remove the pin from boom cylinder rod side. (2
places) (Refer to “Remove and Install Boom Cylin- Pin
der” on page W4-2-2)
31. Start the engine to retract the cylinder, secure the

cylinder tube with a wire to prevent the rod from
extending out.
W18B-04-01-041
32. Bleed air from hydraulic oil tank. Stop the engine Boom Cylinder
page W1-3-1)
W4-1-7
33. Remove bolt (11) to remove all clamp (12) from
11、12
the hydraulic hose between the boom and main
frame.
Hydraulic
: 19 mm Hose
34. Disconnect the hydraulic hose between the boom

and main frame at the main frame side and install
a plated plug to the opening ends. (Refer to “item
of Bleeding Air from Hydraulic Oil Tank” on page
W1-3-1)
Boom
NOTE: In case hydraulic hose is removed, much
oil will flow out. Be sure to provide a larger
container to collect oil. W141-04-01-009
: 14 mm, 17 mm Main Frame

25600 (56440 lb)
35. Install a shackle, wire and chain block to the lift-

ing bracket (1 places) for the other of boom. Hold Lifting Bracket
the boom by crane.
36. Hoist the chain block which is holding the boom

cylinder as much as possible, then secure the
chain block to the boom. (2 places)
Chain Block
Boom Cylinder
W141-04-01-007
W4-1-8
37. Remove bolts (14) (2 used), Spring washers (15)
(2 used) from plate (16) to remove plate (16) from
the frame. (2 places)
: 36 mm
38. Pull pin (13) out to the positions from where the
boom can be removed from the frame. Attach
nylon sling to the body on pin (13), Lift and re-
move it by crane. (2 places)
W18B-04-01-044
Boom Main Frame

39. Lift and remove the boom assembly from the
frame by crane. 14, 15
Remove shim (17) from the pin hole.
13
16
40. Place the boom assembly on the wooden block.

NOTE: The specification of wooden block.
Length 800 mm (31.5 in), Width 900 mm
(35.4 in), Height 1200 mm (47.2 in) 17
W141-04-01-008
CAUTION: In case the boom is removed

(counterweight is still on) travel and swing
operations can not be carried out for the
machine can turn over according to the road
conditions.
W18B-04-01-047
Wooden Blocks
W4-1-9
Install front attachment (Loading Shovel)
・ For the method to lift each parts and the numbers
of lifting holes, refer to “Removed” Section on
page W4-1-1.

25600kg (56440 lb)
1. Hoist the boom assembly to align the pin holes in

the connecting parts both of boom and main
frame.
Install shim (17) onto the pin hole.
W18B-04-01-044

Boom Main Frame
2. Attach nylon sling to the middle part of pin (13)
and lift it by crane. Insert pin (13) into the pin hole
14, 15
in the boom foot side and install plate (16) to the
main frame with spring washers (15) (2 used)
13
and bolts (14) (2 used) (2 places). 16
: 36 mm
: 700 N⋅m (71.5 kgf⋅m, 540 lbf⋅ft)
17
W141-04-01-008
W4-1-10
remaining pressure from the circuit. (Refer to 11, 12
page W1-3-1) Hydraulic
Hose
4. Connect all hydraulic hoses between the boom

and the main frame.
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
: 17 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) Boom
5. Install clamp (10) to hydraulic hose between the W141-04-01-009
boom and the main frame with bolt (9). Main Frame
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)
6. Remove the wire which is used to secure the

boom cylinder rod (2 places).

2970 kg (6550 lb)
7. Start the engine and extend rod to align the pin

holes both in boom cylinder rod end and the main
frame. Install the pins into the holes. (2 places)
(Refer to “Remove and Install Boom Cylinder” on
page W4-2-2)
8. Connect greasing hose between the boom and

Boom Cylinder
the main frame.
: 36 mm
W18B-04-01-039
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
W4-1-11
9. Connect greasing hoses both for the boom cyl-
inder rod pin and between main frame. (2 places)
: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
CAUTION: Arm weight:

9520 kg (20990 lb)
10. Hoist the arm to align it with the pin hole in boom
end.
11. Attach nylon sling to the body of pin (6) and lift it
by crane. Insert pin (6) to the pin hole in boom
end, install plate (9) to the boom with spring
washers (8) (2 used) and bolts (7) (2 used). (2
places)
: 36 mm W18B-04-01-030
: 700 N⋅m (71.5 kgf⋅m, 520 lbf⋅ft) Arm

Boom
7, 8
6 9
10
W141-04-01-004
W4-1-12
12. Remove the wire which is used to secure the arm
cylinder rod.
hole is the rod end of arm cylinder. Install the pin
into the hole.
14. Remove the wire which is used to secure level cyl-

inder rod.
15. Start the engine and extend the rod to align the
pin hole in the rod end of level cylinder, Install the
W18B-04-01-026
pin into the hole.
16. Place the arm end on the wooden block.
Arm
Wooden Block W18B-04-01-021
Boom
page W1-3-1) Arm
18. Connect all hydraulic hoses between the boom Hydraulic

and arm. Hose
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
: 17 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) W141-04-01-003
W4-1-13
CAUTION: Bucket weight: Arm

19400 kg (42770 lb)
19. Hoist the bucket. Start the engine to raise the arm
up and align the pin hole in the arm end.
Bucket
20. Attach nylon sling to the body of pin (1) and hoist
it by crane. Insert pin (1) to the pin hole, then in-
stall stopper (4) to the bucket with spring washers
(3) (4 used) and bolts (2) (4 used). (2 places) W18B-04-01-076
Arm
: 30 mm
Bucket
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
2, 3
5 W141-04-01-002
Moving of the O-ring

21. Move the O-ring from the arm end to the posi-
tions specified. (2 places)
Bucket Arm
22. Install the bucket cylinder. (2 places) (Refer to W183-04-01-004
“Remove and install bucket cylinder” on page

W4-2-14).
W4-1-14
23. Connect greasing hose on arm cylinder and level
Level Cylinder
cylinder rod side.
Greasing Hose
: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
Arm Cylinder
W18B-04-01-023
24. Connect greasing hose between the boom and Boom

Greasing Hose
arm.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
Arm
W18B-04-01-022
Hydraulic Hose
25. Bleed air from hydraulic oil tank. Stop the engine Greasing Hose
page W1-3-1)
26. Connect all hydraulic hoses and greasing hoses

between the arm and bucket.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft) W18B-04-01-015
W4-1-15
27. Connect hydraulic hose between the boom and
arm. (2 places)
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
28. Apply grease through grease fittings before in-

stalling bucket, arm and boom. (For numbers of
greasing positions, refer to Greasing Section in
Operation’s Manual.) Hydraulic Hose
IMPORTANT: After completing work, fill the hy-

draulic oil tank with hydraulic oil to
the specified level. Bleed air re-
maining in each cylinder. (Refer to
Procedures for Air Bleeding on page
W4-2-48)
W18B-04-01-024
W4-1-16
Remove Front Attachment (Backhoe)
Moving of O-ring
1. Move O-ring from the mounting part of link A,

bucket and arm to the boss side of bucket. (4
places)
Bucket
W183-04-01-002
Arm
2. Start the engine, position the front as illustrated
on the right. Boom
NOTE: If boom and arm are positioned at 120 to

140°. It is easier to do the following work.
Link A
120° to 140°
(3) (3 used) from the stopper (4) of mounting pin
at link A and bucket to remove stopper (4) form
the bucket. (2 places)
: 24 mm
W18B-04-01-049
Bucket
CAUTION: Pin (1) weight: 105 kg (240 lb) 2,3
4. Pull pin (1) out to the positions where link A can

be removed from the bucket. Attach nylon sling to
the body of pin (1), Lift the pin and remove it by
4
crane. (2 places)
Link A
W146-04-01-001
5. Retract the bucket cylinder and secure it to the Bucket Cylinder

cylinder tube with a wire to prevent it from ex-
tending. (2 places).
W18B-04-01-050
W4-1-17
CAUTION: Bucket weight:

11000 kg (24260 lb)

holes (2 places) on the bucket and hold it by
crane.
Lifting Hole
W18B-04-01-051
Arm
7. Remove bolts (5) (12 used) from pin cover (6) (2

used) at the arm end to remove covers (6) (2
used) from the bucket. (2 places) Bucket
NOTE: There are lifting holes in cover (6). Install

eyebolts (M10, Pitch 1.5 mm) to hoist the
cover and remove it by crane.
: 19 mm
8. Remove O-rings (8) (2 used) from covers (6) (2 W18B-04-01-052
used). Arm
Bucket
CAUTION: Pin (7) weight: 153 kg (340 lb) 5

7
9. Pull pin (7) out to the position where the arm can
be removed from the bucket. Attach nylon sling to
the body of pin (7). Hoist the pin and remove it by 8
crane. (2 places)
6
10. Hoist the bucket and remove it from the arm.
W141-04-01-010
W4-1-18
Arm
W18B-04-01-053
Wooden Block
12. Bleed air from hydraulic oil tank. Stop the engine B
and operate the lever several times to release
the remaining pressure from the circuit. (Refer to
Arm
page W1-3-1)
13. Disconnect all hydraulic hoses from the bucket Arm

cylinder at the bucket cylinder side, then install
A
plated plug to the opening part.
: 14 mm, 17 mm
Hydraulic Hose
14. Disconnect greasing hoses between the boom
and arm. W18B-04-01-054
: 19 mm, 36 mm
Greasing Hose
15. Disconnect greasing hose from arm cylinder rod Section A W141-04-01-011
side.
Greasing Hose
: 19 mm
W18B-04-01-056
Section B
W4-1-19
CAUTION: Arm cylinder weight: Arm Cylinder

2150 (4740 lb)
16. Attach a wire on the arm cylinder rod side and

hold the arm cylinder by crane. (2 places)
17. Remove the pin of the arm cylinder rod at bucket

side. (2 places) (Refer to “Remove and Install
Wooden Block
Arm Cylinder” on page W4-2-8)
18. Place wooden block between the arm cylinder

and boom. (2 places)
W18B-04-01-057
19. Start the engine to retract cylinder, Place the arm

cylinder rod side on wooden blocks. (2 places)
20. Secure the rod of arm cylinder to the cylinder

tube with a wire to prevent the rod from extending.
(2 places)

holes (2 places) on the arm.
Lifting
Bracket
Arm
W18B-04-01-059
W4-1-20
CAUTION: Arm assembly weight:

15300 kg (33730 lb)
Boom
22. Hoist the arm and hold it.
23. Remove bolts (10) (4 used) and spring washers Arm

(11) (4 used) from stopper (12) for the boom end
pin to remove stopper (12) (2 used) from the arm.
(2 places)
: 30 mm
CAUTION: Pin (9) weight: 150 kg (340 lb) Boom

W18B-04-01-060
Arm
24. Pull pin (9) out to the position where the boom
can be removed from the arm. Attach nylon sling 9 10, 11
to the body of pin (9), hoist the pin and remove it
by crane. (2 places)
12
25. Hoist the arm assembly and remove it from the
boom.
W141-04-01-012
26. Place the arm assembly on the wooden block. Arm Assembly
27. Place the boom end on the wooden block.
Wooden Block
W18B-04-01-062
Boom
W18B-04-01-063
Wooden Block
W4-1-21
28. Disconnect greasing hoses for the boom cylinder
rod pin from each pin side. (2 places)
: 19 mm
29. Disconnect greasing hose between the boom Greasing Hose

and main frame from the boom side. M141-07-015
: 36 mm

28800 kg (63500 lb)
holes (4 places) in the boom and hold it by crane.
Lifting
Bracket

3120 kg (6880 lb)
31. Install a wire and chain block to the rod side on

boom cylinder tube. Hold the boom cylinder at
W18B-04-01-066
rod side via the lifting bracket on boom side plate
with the chain block. (2 places) Lifting
Bracket
Boom
W18B-04-01-067
Boom Cylinder
W4-1-22
32. Remove the pin from the boom cylinder rod end.
(2 places) (Refer to “Remove and Install Boom
Cylinder” on page W4-2-2)
33. Start the engine to retract the cylinder. Secure the

cylinder tube with a wire to prevent it from ex-
tending.
Boom Cylinder W18B-04-01-068
34. Bleed air from hydraulic oil tank. Stop the engine 13, 14
“item of Bleeding Air from Hydraulic Oil Tank” on Hydraulic
Hose
page W1-3-1)
35. Remove bolt (13) to remove all clamp (14) from

hydraulic hose between the boom and main
frame.
: 19 mm
Boom
36. Disconnect all hydraulic hoses from boom side W141-04-01-013
between the boom and main frame. Then install

Main Frame
plate plug to the opening end. (Refer to “item of
Bleeding Air from Hydraulic Oil Tank” on page
W1-3-1)
NOTE: In case hydraulic hose is removed, much
oil will flow out. Be sure to provide a larger
container to collect oil.
: 17 mm
W4-1-23
37. Hoist the chain block which is holding the boom
cylinder as much as possible, then secure the
chain block to the boom. (2 places)
Chain Block
38. Remove bolts (16) (2 used) and spring washers Boom
(17) (2 used) to remove plate (18) from the main
frame. (2 places)
: 36 mm
CAUTION: Pin (15) Weight: 147 kg (330 lb)

Boom Cylinder
can be removed from the arm. Attach nylon sling
to the body of pin (15), hoist the pin and remove W18B-04-01-071
it by crane. (2 places)
Boom Main Frame
40. Hoist the boom assembly to remove it from the

main frame. 16, 17
Remove shim (19) from the pin hole
15
18
41. Place boom assembly on the wooden block.
NOTE: Wooden blocks dimensions
Length 800 mm (31.5 in), width 900 mm
(39.4 in), Height 1100 mm (43.3 in).
19
W141-04-01-008
Boom Assembly
Wooden
Blocks
W18B-04-01-072
W4-1-24
Install Front Attachment (Backhoe)
・ For the method to lift each parts and the num-
bers of lifting holes, refer to “Removal” section on
page W4-1-17.
Boom

28800kg (63500 lb)
1. Hoist the boom, align the connecting pin holes

both in boom and main frame.

W18B-04-01-071
2. Attach nylon sling to the body of pin (15) and Boom Main Freme
hoist it by crane. Insert pin (15) into the pin hole,
install plate (18) to the main frame with spring 16, 17
washers (17) (2 used) and bolts (16) (2 used). (2
places)
15
: 36 mm 18
: 700 N⋅m (71.5 kgf⋅m, 520 lbf⋅ft)
3. Start the engine to lower the boom, place it on

the wooden block.
19
W141-04-01-008
W4-1-25
and operate the lever several times to release 13, 14
“item of Bleeding Air from Hydraulic Oil Tank” on Hydraulic
page W1-3-1) Hose
5. Connect all hydraulic hoses between the boom

and main frame. (Refer to “item of Bleeding Air
from Hydraulic Oil Tank” on page W1-3-1)
: 17 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft)
Boom
W141-04-01-013
6. Install clamp (14) to hydraulic hose between the
boom and main frame with bolt (13). Main Frame
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 lbf⋅ft)

boom cylinder rod. (2 places)

3120 kg (6880 lb)

holes both in boom cylinder rod end and the main
frame. Install the pins into the holes. (2 places)
(Refer to “Remove and Install Boom Cylinder” on
page W4-2-2)
9. Connect greasing hose between boom and main

frame.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
Boom Cylinder W18B-04-01-068
W4-1-26
10. Connect greasing hoses to the boom cylinder rod
side. (2 places)
: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
CAUTION: Arm assembly weight:

15300 kg (33730 lb)
11. Hoist the arm to align the pin hole of boom end.
Boom
12. Attach nylon sling to the body of pin (9) and hoist
Arm
it by crane. Insert pin (9) to the pin hole, install
stopper (12) to the arm with spring washers (11)
(4 used) and bolts (10) (4 used). (2 places)
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
W18B-04-01-060
Boom
Arm
9 10, 11
12
W141-04-01-012
W4-1-27
Arm Cylinder
14. Remove the wire which is used to secure the arm

cylinder rod. (2 places)
CAUTION: Arm cylinder weight:

2150 kg (4740 lb)
15. Hoist the arm cylinder at rod side. Start the en-
gine. Extend the arm cylinder rod to align the pin
hole in the rod end. (2 places)
W18B-04-01-057
16. Install pin to the arm cylinder rod end. (2 places) Wooden Block
(Refer to “Remove and Install Arm Cylinder” on
page W4-2-8)
B
Arm
page W1-3-1)
Boom
18. Connect all hydraulic hoses between the bucket A

cylinder.
: 14 mm
Hydraulic Hose
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
: 17 mm
: 400 N⋅m (41 kgf⋅m, 300 lbf⋅ft) W18B-04-01-054
19. Connect all greasing hoses to the boom end and Greasing Hose
between the boom and arm.
: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
Section A W141-04-01-011
W4-1-28
20. Connect greasing hose to the arm cylinder rod Greasing Hose
side.
: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
W18B-04-01-056
Section B
21. Start the engine to raise the arm.
Arm
NOTE: If the boom and arm are positioned at 120
to 140°. It is easier to do the following Boom
work.
CAUTION: Bucket weight: Bucket

11000 kg (24260 lb) 120° to 140°
22. Hoist the bucket to align the pin hole in the arm
end.
23. Install O-rings (8) (2 used) onto covers (6) (2 W18B-04-01-052
used). Arm
Bucket
CAUTION: Pin (7) weight: 153 kg (340 lb) 5

7
Cover (6) weight: 35 kg (80 lb)
IMPORTANT: When installing cover (6), be sure

that the guard of grease fitting is in 8
right direction.
24. Attach nylon sling to the body of pin (7) and hoist 6
covers (6) (2 used) to the bucket with bolts (5) W141-04-01-010
(12 used). (2 places)

Bucket
NOTE: There are two lifting holes in cover (6). In-
stall eyebolts (M10, Pitch 1.5 mm) into the Cup Greasing
holes, then hoist the cover and install it by Hose
crane.
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W141-04-01-014
Greasing Hose
W4-1-29
bucket cylinder rod. (2 places) Arm
26. Start the engine and extend the rod, align the
pinholes in connecting part of link A and bucket.
Link A
27. Attach nylon sling to the body on pin (1) and hoist
stopper (4) to the bucket with spring washers (3)
(3 used) and bolts (2) (3 used). (2 places)
: 24 mm W18B-04-01-049
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

Bucket
2, 3
4
28. Move the O-ring from the mounting part of link A,
bucket and arm to the boss side of bucket. (4
places) 1
29. After installing the bucket, arm and boom, apply Link A
W146-04-01-001
grease via the grease fitting. (As for the position
to apply grease, refer to Greasing section in Op- Moving of O-ring
erator Manual.)
IMPORTANT: When all installation work is fin-

ished, fill hydraulic oil to the speci-
fied level. In addition, bleed air from Bucket
each cylinder. (Refer to main point to
Bleed Air on page W4-2-48)
W183-04-01-002
W4-1-30
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER

W4-2-1
Remove And Install Boom Cylinder
Hydraulic Hose
(Loading shovel)
Boom Cylinder
A
B
W18B-04-01-017
Hydraulic Hose
(Backhoe)
Boom Cylinder
B
A
W18B-04-02-004
Boom Cylinder Boom Cylinder

1 2 Main Frame
6
Boom 3
7 9
4
5 10
W141-04-02-002 W141-04-02-001
Section A Section B
1 - Spacer 4 - Spring Washer (2 Used) 7 - Bolt (2 Used) 9 - Pin

2 - Plate 5 - Pin 8 - Spring Washer (2 Used) 10 - Shim (Several)
3 - Bolt (2 Used) 6 - Plate
W4-2-2
Removal
5. Start the engine and retract the rod. Secure the
1. Disconnect greasing hose from the boom cylin- rod of boom cylinder to the cylinder tube with a
der rod side. wire to prevent the rod from extending.
: 19 mm Remove shim (10) (several) from the pin hole.
6. Stop the engine and operate the lever several

CAUTION: Boom cylinder weight: times to release any remaining pressure from the
2970 kg (6550 Ib) (Loading Shovel) circuit. Release air from hydraulic oil tank. (Refer
3120 kg (6880 Ib) (Backhoe) to “item of Bleeding Air from Hydraulic Oil Tank”
on page W1-3-1)
2. Attach a nylon sling to boom cylinder and hold it
by crane. 7. After disconnecting all hydraulic hoses from
boom cylinder, install plated plugs to all opening
3. Remove bolts (7) (2 used) and spring washers ends.
(8) (2 used) from rod side to remove plate (6) : 14 mm, 17 mm
from the main frame.
: 36 mm
CAUTION: Pin (9) weight: 146 kg (330 Ib)

cylinder can be removed from the main frame.
Attach a nylon sling to the body of pin (9), hoist
the pin and remove it.
W4-2-3
Hydraulic Hose
(Loading Shovel)
Boom Cylinder
A
B
W18B-04-01-017
Hydraulic Hose
(Backhoe)
Boom Cylinder
B
A
W18B-04-02-004
Boom Cylinder Boom Cylinder

2 Main Frame
1
Boom
3
W141-04-02-002 W141-04-02-001
Section A Section B
W4-2-4
(4) (2 used) from the bottom side to remove plate
(2).
: 36 mm

cylinder can be removed from the boom. Attach
nylon sling to the body of pin (5). Hoist the pin
and remove it.
10. Hoist the boom cylinder and remove it.

Remove spacer (1) from the pin hole.
11. Remove the boom cylinder at opposite side by

same procedures.
W4-2-5
Hydraulic Hoses
(Loading Shovel)
Boom Cylinder
A
B
W18B-04-01-017
Hydraulic Hoses
(Backhoe)
Boom Cylinder
B
A
W18B-04-02-004
Boom Cylinder
2 Main Frame
1 Boom Cylinder 6
Boom 3
7 9
4
5 10
W141-04-02-002 W141-04-02-001
Section A Section B
1 - Spacer 4 - Spring Washer (2 Used) 7 - Bolt (2 Used) 9 - Pin

2 - Plate 5 - Pin 8 - Spring Washer (2 Used) 10 - Shim (Several)
W4-2-6
Installation

2970 kg (6550 Ib) (Loading Shovel) 7. Attach nylon sling to the body of pin (9) and hoist
3120 kg (6880 Ib) (Backhoe) it by crane. Insert pin (9) into the hole, then install
plate (6) to the main frame with bolts (7) (2 used)
1. Attach nylon sling to the boom cylinder and hoist and spring washers (8) (2 used).
it by crane. : 36 mm
: 700 N⋅m (71.5 kgf⋅m, 520 Ibf⋅ft)
2. Align the pin holes in the boom cylinder bottom
and in the boom. 8. Install the boom cylinder at opposite side by
Install spacer (1) into the pin hole. same procedures.
CAUTION: Pin (5) weight: 150 kg (330 Ib) 9. Connect all greasing hoses to boom cylinder.
: 19 mm
3. Attach nylon sling to the body of pin (5) and hoist : 30 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
it by crane. Insert pin (5) into the hole then install
plate (2) to the boom with bolts (3) (2 used) and 10. Loosen the air breather on the cylinder to bleed
spring washers (4) (2 used). all air from the cylinder. (Refer to W4-2-48)
: 36 mm
: 700 N⋅m (71.5 kgf⋅m, 520 Ibf⋅ft)
4. Connect all hydraulic hoses to the boom cylinder.

: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
: 17 mm
: 400 N⋅m (41 kgf⋅m, 300 Ibf⋅ft)
5. Remove the wire which is used to secure the rod

part.
6. Start the engine. Hoist boom cylinder at rod side

while extending rod to align the pin holes in the
main frame and boom cylinder rod end.
Install shim (10) (several) into the pin hole.
W4-2-7
Remove and Install Arm Cylinder
(Loading Shovel)
C A
Hydraulic Hose
D
W18B-04-01-017
Hydraulic Hoses
(Backhoe)
B
C
W18B-04-02-004
Arm Cylinder
9 10
Boom
3, 4
7, 8
2
6
1 5
Section A (Loading Shovel)

W141-04-02-004
W118-04-01-007
Arm Cylinder Boom Arm Cylinder
3, 4 Section C
Boom
Arm Cylinder Lift-
ing Bracket Boom
W18B-04-02-007
View D (Loading Shovel)
Section B (Backhoe)
W141-04-02-003
1 - Pin 4 - Spring Washer (2 Used) 7 - Bolt (2 Used) 9 - Plate (Only for Backhoe)
2 - Plate 5 - Pin 8 - Spring Washer (2 Used) 10 - Plate (Only for Backhoe)
W4-2-8
Removal
1. Disconnect greasing hose from the arm cylinder. CAUTION: Pin (5) weight:
: 19 mm 106 kg (240 Ib) (Loading shovel)
137 kg (310 Ib) (Backhoe)
CAUTION: Arm cylinder weight: 5. (Loading Shovel)

2240 kg (4940 Ib) (Loading shovel) Hold pin (5) and remove it by fork lift.
2150 kg (4740 Ib) (Backhoe) (Backhoe)
Attach nylon sling to the body of pin (5) and hoist
2. (Loading Shovel) the pin and remove it by crane.
Attach a nylon sling to the lifting brackets of arm
cylinder and boom lower cover, then hold them 6. Start the engine and retract the rod. Secure the
by chain block. rod of arm cylinder to the cylinder tube with a
wire to prevent the rod from extending.
Lifting Bracket (Backhoe Only)
Remove plate (9, 10) from the pin hole.

times to release any remaining pressure from the
circuit. Release air from hydraulic oil tank. (Refer
to “item of Bleeding Air from Hydraulic Oil Tank”
on page W1-3-1)
Arm Cylinder W18B-04-02-005
(Backhoe) 8. Disconnect all hydraulic hoses from the arm cyl-

Attach a nylon sling to the arm cylinder and hold inder bottom end, then install plated plug to the
it by crane. opening ends.
: 14 mm, 17 mm
(8) (2 used) from the rod side and remove plate 9. Remove bolts (3) (2 used) and spring washers
(6) from the arm. (4) (2 used) from the bottom side to remove plate
: 36 mm (2) from the boom.
: 36 mm
4. Pull pin (5) out to the position where the arm cyl-
inder can be removed from the arm. 10. Pull pin (1) out to the position where the arm cyl-
inder can be removed from the boom.
W4-2-9
(Loading Shovel)
C A
Hydraulic Hose
D
W18B-04-01-017
Hydraulic Hoses
(Backhoe)
B
C
W18B-04-02-004
Arm Cylinder
Boom
W141-04-02-004
W118-04-01-007
Arm Cylinder Boom Arm Cylinder Section C
Boom
Lifting Bracket for

Arm Cylinder Boom
Section B (Backhoe)
W18B-04-02-007
W141-04-02-003 View D (Loading Shovel)
W4-2-10
CAUTION: Pin (1) weight:107 kg (240 Ib)
11. (Loading Shovel)

Hold pin (1) by forklift and remove it.
(Backhoe)
Attach nylon sling to the body of pin (1), hoist the
pin and remove it by crane.
12. (Loading Shovel)

Lower the arm cylinder by chain block and re-
move it.
(Backhoe)
Hoist the arm cylinder and remove it.
13. (Backhoe only)

Remove other cylinders by same procedures.
W4-2-11
(Loading Shovel)
C A
Hydraulic Hose
D
W18B-04-01-017
Hydraulic Hose
(Backhoe)
B
C
W18B-04-02-004
Arm Cylinder
9 10
Boom
3, 4
7, 8
2
6
1 5
Section A (Loading Shovel)

W141-04-02-004
W118-04-01-007
Arm Cylinder Boom Arm Cylinder
3, 4 Section C
Boom
Arm Cylinder Lift-
ing Bracket Boom
W18B-04-02-007
View D (Loading Shovel)
Section B (Backhoe)
W141-04-02-003
1 - Pin 4 - Spring Washer (2 Used) 7 - Bolt (2 Used) 9 - Plate (Only for Backhoe)
2 - Plate 5 - Pin 8 - Spring Washer (2 Used) 10 - Plate (Only for Backhoe)
W4-2-12
Installation
・ For the method to lift each parts and the num- 5. Connect all hydraulic hoses to the arm cylinder.
bers of lifting holes, refer to “Removal” section on : 14 mm
page W4-2-8. : 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
・ (Loading Shovel Only) : 17 mm
In case the level cylinder was removed, install : 400 N⋅m (41 kgf⋅m, 300 Ibf⋅ft)
the level cylinder at first.
(Refer to Remove and Install Level Cylinder on
page W4-2-24) 6. Remove wire which is used to secure the rod.
7. (Loading Shovel)
CAUTION: Arm cylinder weight: Start the engine. Hoist the arm cylinder at rod
2240 kg (4940 Ib) (Loading Shovel) side by chain block and extend the rod to align
2150 kg (4740 Ib) (Backhoe) the pin holes in the arm and arm cylinder rod end.
(Backhoe)
1. (Loading shovel) Start the engine. Hoist the arm cylinder at its rod
Hoist the arm cylinder by chain block. side by crane and extend the rod to align the pin
(Backhoe) holes in the arm and cylinder rod side.
Hoist the arm cylinder by crane. Install plate (9, 10) into the pin hole.
2. Align the pin hole in arm cylinder bottom side with

that of the boom. CAUTION: Pin (5) weight:
106 kg (240 Ib) (Loading Shovel)
137 kg (310 Ib) (Backhoe)
CAUTION: Pin (1) weight:107 kg (240 Ib)
8. (Loading Shovel)
3. (Loading Shovel) Hoist pin (5) by fork lift.
Hoist pin (1) by forklift. (Backhoe)
(Backhoe) Attach nylon sling to the body of pin (5) and hoist
Attach nylon sling to the body of pin (1) and hoist it by crane.
it by crane.
9. Insert pin (5) into the pin hole and install plate (6)
4. Insert pin (1) into the pin hole, install plate (2) to to the arm with bolts (7) (2 used) and spring
the boom with bolts (3) (2 used) and spring washers (8) (2 used).
washers (4) (2 used). : 36 mm
: 36 mm : 700 N⋅m (71.5 kgf⋅m, 520 Ibf⋅ft)
: 700 N⋅m (71.5 kgf⋅m, 520 Ibf⋅ft)
10. (Backhoe Only)
Install other cylinders by same procedures.
11. Connect all greasing hoses to the arm cylinder.

: 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
12. Loosen the air breather on the cylinder to bleed

all air from the cylinder. (Refer to W4-2-48)
W4-2-13
Remove and Install Bucket Cylinder
(Loading Shovel)
Hydraulic Hose
C
A
W18B-04-01-017
Bucket Cylinder
Bucket Bucket Cylinder
Bucket
4
2, 3 7, 8
5
9
1
10
W118-04-01-007
Section B
Section A W141-04-02-005
Bucket Cylinder
Lifting Bracket Arm
W18B-04-02-020
View C
1 - Stopper 4 - Spacer 7 - Bolt (2 Used) 9 - Plate

2 - Bolt (4 Used) 5 - Pin 8 - Spring Washer (2 Used) 10 - Pin
3 - Spring Washer (4 Used) 6 - Spacer
W4-2-14
Removal
1. Disconnect all greasing hoses of the bucket cyl- wire is attached to prevent arm boss
inder from bucket cylinder side. from being damaged.
: 19 mm 6. Attach a wire to the rod side of the bucket cylin-
der tube. Pass the wire through the outside and
inside of the arm boss to hold rod side of the
CAUTION: Bucket cylinder weight: bucket cylinder tube by crane.
1820 kg (4020 Ib)
Pass the wire through
the outside and inside
2. Attach a nylon sling to the bottom side of the
bucket cylinder tube. Attach a chain block to lift-
ing bracket between nylon sling and arm lower Arm Boss
plate, then hold bottom side of the bucket cylin-
der tube.
Bucket
3. Remove bolts (2) (4 used) and spring washers Cylinder
(3) (4 used) from the bottom side to remove
stopper (1) from the bucket.
: 30 mm
W141-04-02-013
4. Pull pin (5) out to the position where the bucket
(8) (2 used) from the rod side to remove plate (9)
cylinder can be removed from the bucket. Attach
from the boom.
a nylon sling to the body of pin (5), hoist the pin
: 36 mm
and remove it.
5. Loosen chain block to remove bucket cylinder CAUTION: Pin (10) weight: 107 kg (240 Ib)
bottom side. Remove spacer (4, 6) from the pin
hole in the bucket. 8. Pull out pin (10) on position where the bucket
cylinder can be removed from the boom. Attach a
nylon sling to the body of pin (10), hoist the pin
by crane and remove it.
9. Hold the bucket cylinder by crane while starting

the engine to retract the rod.
W4-2-15
Hydraulic Hose
C
A
W18B-04-01-017
Bucket Cylinder
Bucket
W118-04-01-007
Section B
Section A W141-04-02-005
Bucket Cylinder
Lifting Bracket Arm
W18B-04-02-020
View C
W4-2-16
circuit. (Refer to “item of Bleeding Air from Hy-
11. Disconnect all hydraulic hoses at bucket cylinder

side. Then install plated plug to the opening
ends.
: 14 mm, 17 mm
IMPORTANT: Place wooden block on the place

where the bucket cylinder will be
lowered down.
12. Lower the bucket cylinder down and remove it by
crane.
13. Secure the bucket cylinder rod end to cylinder

tube with a wire to prevent the rod from extend-
ing.
14. Remove the opposite cylinder by same proce-

dures.
W4-2-17
Hydraulic Hose
C
A
W18B-04-01-017
Bucket Cylinder
Bucket
4
2, 3 7, 8
5
9
1
10
W118-04-01-007
Section B
Section A W141-04-02-005
Bucket Cylinder
Lifting Bracket Arm
W18B-04-02-020
View C
1 - Stopper 4 - Spacer 7 - Bolt (2 Used) 9 - Plate

2 - Bolt (4 Used) 5 - Pin 8 - Spring Washer (2 Used) 10 - Pin
3 - Spring Washer (4 Used) 6 - Spacer
W4-2-18
Installation
・ For the method to lift each parts and the num- 6. Attach a nylon sling to the bottom side of the
bers of lifting holes, refer to “Removal” section on bucket cylinder tube. Attach a chain block to the
page W4-2-14. lifting bracket between nylon sling and arm under
plate, then align the pin hole of bucket with that in
1. Remove the wire which is used to secure the rod. bucket cylinder bottom end.
IMPORTANT: Install spacer (6) with the chamfer

CAUTION: Bucket cylinder weight: side facing the cylinder side.
1820 kg (4020 Ib) 7. Install spacer (4, 6) to the pin hole.

wire is attached to prevent arm boss CAUTION: Pin (5) weight: 114 kg (260 Ib)
from being damaged.
2. Attach a wire to the rod side of bucket cylinder 8. Attach a nylon sling to the body of pin (5) and
tube. Pass the wire through the outside and in- hoist it by crane. Insert pin (5) into the pin hole,
side of the arm boss to hold rod side of the then install stopper (1) to the bucket with bolts (2)
bucket cylinder tube by crane. (4 used) and spring washers (3) (4 used).
: 30 mm
3. While holding the bucket cylinder by crane, con- : 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
nect all hydraulic hoses to the bucket cylinder.
: 14 mm 9. Install the opposite cylinder by same procedures.
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
: 17 mm 10. Connect all greasing hoses to the bucket cylin-
: 400 N⋅m (41 kgf⋅m, 300 Ibf⋅ft) der.
: 19 mm
4. Start the engine, hoist bucket cylinder rod side : 30 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
while extending rod to align the pin holes in boom
and in bucket cylinder rod end. 11. Loosen the air breather on the cylinder to bleed
all air from the cylinder. (Refer to W4-2-48)
5. Attach a nylon sling to the body on pin (10) and

hoist it by crane. Insert pin (10) into the pin hole
and install plate (9) to the boom with bolts (7) (2
used) and spring washers (8) (2 used).
: 36 mm
: 700 N⋅m (71.5 kgf⋅m, 520 Ibf⋅ft)
W4-2-19
Remove and Install Bucket Cylinder
(Backhoe)
Hydraulic Hose
Link A
Link B W18B-04-02-004
Link A Bucket Cylinder

Bucket Cylinder
Link B Arm
5
1 2, 3
C
6, 7
4 8
9
Section B W141-04-02-007
Section A W118-04-01-021
Greasing Fitting
Link A
Link B
W141-04-02-006
1 - Pin 4 - Stopper 6 - Bolt (2 Used) 8 - Plate

2 - Bolt (3 Used) 5 - Pin 7 - Spring Washer (2 Used) 9 - Spacer
3 - Spring Washer (3 Used)
W4-2-20
Removal
1. Disconnect all greasing hoses of the bucket cyl- times to release remaining pressure from the
inder from bucket cylinder side. circuit. (Refer to “item of Bleeding Air from
: 19 mm, 22 mm Hydraulic Oil Tank” on page W1-3-1)
2. Position the front attachment in the picture shown 8. Disconnect all hydraulic hoses at bucket cylinder
below. Insert wooden block between link A, B and side. Then install plated plug to the opening
the arm. ends.
: 14 mm, 17 mm
Link B
Link A (7) (2 used) from the bottom side to remove plate
(8) from the arm.
: 36 mm

W18B-04-02-008
Wooden Blocks
cylinder can be removed from the arm. Attach
CAUTION: Bucket cylinder weight: nylon sling to the body of pin (5), then hoist the
1270 kg (2800 Ib) pin and remove it.
3. Attach a nylon sling on the bucket cylinder and 11. Hoist the bucket cylinder and remove it. Remove
hold it by crane. spacer (9) from the pin hole in the arm.

12. Remove the opposite cylinder by same proce-
(3) (3 used) from the rod side to remove stopper
dures.
(4) from link B.
: 24 mm

cylinder can be removed from the link A. Attach a
nylon sling to he body of pin (1), then hoist the
pin and remove it by crane.

cylinder rod end to the cylinder tube with a wire to
prevent the rod from extending.
W4-2-21
Hydraulic Hose
Link A
Link B W18B-04-02-004
Link A Bucket Cylinder

Bucket Cylinder
Link B Arm
5
1 2, 3
C
6, 7
4 8
9
Section B W141-04-02-007
Section A W118-04-01-021
Greasing Fitting
Link A
Link B
W141-04-02-006
1 - Pin 4 - Stopper 6 - Bolt (2 Used) 8 - Plate

2 - Bolt (3 Used) 5 - Pin 7 - Spring Washer (2 Used) 9 - Spacer
3 - Spring Washer (3 Used)
W4-2-22
Installation

CAUTION: Bucket cylinder weight:
1270 kg (2800 Ib) IMPORTANT: Install stopper (4). Be sure to keep
the grease fitting in right direction.
1. Attach a nylon sling to the bucket cylinder and 7. Attach a nylon sling to the body of pin (1) and
hoist it by crane. hoist it by crane. Insert pin (1) into the pin hole,
then install stopper (4) to the link B with bolt (2)
IMPORTANT: Install spacer (9) with the chamfer (3 used) and spring washers (3) (3 used).
side facing cylinder bottom side. : 24 mm
2. Align the pin hole in arm with that in the bucket : 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
cylinder bottom side.
Install spacer (9) into the pin hole. 8. Install the opposite cylinder by same procedures.
9. Connect all greasing hoses to the bucket cylin-

CAUTION: Pin (5) weight: 83 kg (190 Ib) der.
: 19 mm
3. Attach a nylon sling to the body of pin (5) and : 30 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
hoist it by crane. Insert pin (5) into the pin hole, : 22 mm
then install plate (4) to the arm with bolts (2) (2 : 40 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
used) and spring washers (3) (2 used).
: 36 mm
: 950 N⋅m (97 kgf⋅m, 700 Ibf⋅ft) 10. Loosen the air breather on the cylinder to bleed
all air from the cylinders. (Refer to W4-2-48)
4. Connect all hydraulic hoses to the bucket cylin-
der.
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
: 17 mm
: 400 N⋅m (41 kgf⋅m, 300 Ibf⋅ft)
5. Remove the wire which is used to secure the rod.
6. Start the engine, hoist rod side of the bucket cyl-

inder tube by crane while extending the rod to
align the pin holes in the link A, B and bucket cyl-
inder rod end.
W4-2-23
Remove and Install Level Cylinder
(Loading Shovel Only)
Hydraulic Hose
A
B
W18B-04-01-017
Level Cylinder
Level Cylinder
Arm
8 Arm
6, 7
1
2, 3
4
5
Section A
W118-04-01-005
Section B W118-04-01-006
Level Cylinder
Lifting Bracket Boom
W18B-04-02-007
View C
1 - Pin 3 - Spring Washer (2 Used) 5 - Pin 7 - Spring Washer (2 Used)

2 - Bolt (2 Used) 4 - Plate 6 - Bolt (2 Used) 8 - Plate
W4-2-24
Removal
IMPORTANT: Remove the arm cylinder before 6. Stop the engine, operate the lever several times
removing the level cylinder. (Refer to release any remaining pressure from the cir-
to W4-2-8 for Remove and Install cuit. (Refer to “item of Bleeding Air from Hydraulic
Arm Cylinder) Oil Tank” on page W1-3-1)
1. Disconnect greasing hose from level cylinder rod 7. Disconnect all the hydraulic hoses from the level
side. cylinder and install plated plug to the opening
: 19 mm ends.
: 17 mm
CAUTION: Level cylinder weight: 8. Remove bolts (6) (2 used) and spring washers
1880 kg (4150 Ib) (7) (2 used) from bottom side to remove plate (8)
from the boom.
2. Attach a nylon sling to the level cylinder and hold : 36 mm
it by chain block (2 used).
Lifting Bracket
9. Pull pin (5) out to the position where the level cyl-
inder can be removed from the boom. Holding
pin (5) by fork lift and removing it.
Level Cylinder 10. Lower the level cylinder down by chain block to
W18B-04-02-006
remove it.
3. Remove bolts (2) (2 used), spring washers (3) (2

used) from rod side to remove plate (4) from the
arm.
: 36 mm
4. Pull pin (1) out to the position where the level

cylinder can be removed from the arm, while
holding pin (1) by fork lift and removing it.

level cylinder rod end to the cylinder tube with a
wire to prevent the rod from extending.
W4-2-25
Hydraulic Hose
A
B
W18B-04-01-017
Level Cylinder
Level Cylinder
Arm
Arm
8
6, 7
1
2, 3
4
5
Section A
W118-04-01-005
Section B W118-04-01-006
Level Cylinder
Lifting Bracket Boom
W18B-04-02-007
View C
1 - Pin 3 - Spring Washer (2 Used) 5 - Pin 7 - Spring Washer (2 Used)

2 - Bolt (2 Used) 4 - Plate 6 - Bolt (2 Used) 8 - Plate
W4-2-26
Installation
・ For the method to lift each parts and the num- 9. Insert pin (1) into the pin hole and install plate (4)
bers of lifting holes, refer to “Removal” section on to the arm with bolts (2) (2 used), spring washers
page W4-2-24. (3) (2 used).
: 36 mm
: 950 N⋅m (97 kgf⋅m, 700 Ibf⋅ft)
CAUTION: Level cylinder weight:
1880 kg (4150 Ib)
10. Connect greasing hose to the level cylinder.
1. Lift the level cylinder by chain block. : 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
2. Align pin holes in both boom and level cylinder
bottom. 11. Loosen the air breather on the cylinder to bleed
all air from the cylinders. (Refer to W4-2-48)
3. Hoist pin (5) by fork lift.
4. Insert pin (5) into the pin hole and install plate (8)
to the boom with bolts (6) (2 used) and spring
: 36 mm
: 950 N⋅m (97 kgf⋅m, 700 Ibf⋅ft)
5. Connect all hydraulic hoses of the level cylinder.

: 17 mm
: 400 N⋅m (41 kgf⋅m, 300 Ibf⋅ft)
7. Start the engine while hoisting rod side of the

level cylinder tube by chain block. Extend rod to
align pin holes in the arm and level cylinder rod.
8. Hoist pin (1) by fork lift.
W4-2-27
Remove and Install Dump Cylinder
(Loading Shovel Only)
W18B-04-01-001
Bucket
Dump Cylinder Dump Cylinder
Bucket
3
8
C
5, 6
2
Section B W118-04-02-004
9
1
Section A W118-04-02-007
Greasing Port
Bucket
View C W141-04-02-008
1 - Lock Plate 4 - Stopper 6 - Spring Washer (3 Used) 8 - Pin

2 - Socket Bolt (5 Used) 5 - Bolt (3 Used) 7 - Spacer (2 Used) 9 - O-Ring
3 - Pin
W4-2-28
Removal
1. Remove bolts (12) (14 used) to remove side and dump cylinder rod end to the cylinder tube with a
front covers (10, 11) from the bucket. wire to prevent the rod from extending.
: 19 mm
10 circuit. (Refer to “item of Bleeding Air from Hy-
8. Disconnect all hydraulic hoses from the dump

12
cylinder and install plated plug to the opening
11 ends.
: 10 mm, 12 mm
Side of Bucket
W141-04-02-009
9. Remove bolt (5) (3 used), spring washers (6) (3
used) and stopper (4) from the cylinder bottom to
remove stopper (4) from the bucket.
2. Disconnect all greasing hoses from dump cylin- : 24 mm
der rod side.
: 19 mm 10. Remove O-ring (9) from stopper (4).
CAUTION: Dump cylinder weight: CAUTION: Pin (8) weight: 44 kg (100 Ib)
430 kg (950 Ib)
11. Pull pin (8) out to the position where the dump
3. Attach a nylon sling to the dump cylinder and cylinder can be removed from the bucket. Attach
hold it by crane. a nylon sling to the body of pin (8), hoist the pin
and remove it.
4. Remove socket bolts (2) (5 used) from rod side
and remove lock plate (1) from the bucket. 12. Hoist the dump cylinder and remove it. Remove
: 19 mm spacers (7) (2 used) from the pin hole.
CAUTION: Pin (3) weight: 34 kg (80 Ib) 13. Remove the opposite cylinder by same proce-
dures.
5. Pull pin (3) out to the position where dump cylin-
der can be removed from the bucket. Attach a
nylon sling to the body of pin (3). Then hoist the
pin by crane and remove it.
W4-2-29
W18B-04-01-001
Bucket
Dump Cylinder Dump Cylinder
Bucket
3 8
C
5, 6
2
Section B W118-04-02-004
9
1
Section A W118-04-02-007
Greasing Port
Bucket
View C W141-04-02-008
1 - Lock Plate 4 - Stopper 6 - Spring Washer (3 Used) 8 - Pin

2 - Socket Bolt (5 Used) 5 - Bolt (3 Used) 7 - Spacer (2 Used) 9 - O-Ring
3 - Pin
W4-2-30
Installation
・ For the method to lift each parts and the num-
bers of lifting holes, refer to “Removal” section on CAUTION: Pin (3) weight: 34 kg (80 Ib)
page W4-2-28.
8. Attach a nylon sling to the body of pin (3) and
hoist it. Insert pin (3) into the pin hole and as-
CAUTION: Dump cylinder weight: semble lock plate (1) to the bucket with socket
430 kg (950 Ib) bolts (2) (5 used) while aligning the groove in pin
(3).
1. Attach a nylon sling to the dump cylinder and : 19 mm
hoist it by crane. : 1030 N⋅m (105 kgf⋅m, 760 Ibf⋅ft)
2. Align the pin holes both in dump cylinder bottom 9. Hoist covers (10, 11) to install it to the side of
side and bracket, then install spacers (7) (2 used) bucket with bolts (12) (14 used).
to the pin hole. : 19 mm
: 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)
3. Install O-ring (9) to stopper (4).
CAUTION: Pin (8) weight: 44 kg (100 Ib) 10
IMPORTANT: Install stopper (4). Be sure to keep

the grease fitting in right directing.
4. Attach a nylon sling to the body of pin (8) and
hoist it by crane. Insert pin (8) into the pin hole 12
11
and install stopper (4) to the bucket with bolts (5)
(3 used) and spring washers (6) (3 used).
: 24 mm Side of Bucket
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) W141-04-02-009
5. Connect all hydraulic hoses to the dump cylinder.

: 10 mm 10. Install the opposite cylinder by same procedures.
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
: 12 mm 11. Connect all greasing hoses to the dump cylinder.
: 140 N⋅m (14 kgf⋅m, 103 Ibf⋅ft) : 19 mm
: 30 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
12. Loosen the air breather on the cylinder to bleed
7. Start the engine. Hoist rod side of the dump cyl- all air from the cylinder. (Refer to W4-2-48)
inder tube while extending the rod to align the pin
holes in bucket and in dump cylinder rod end.
W4-2-31
DISASSEMBLE CYLINDER
Boom, Arm Cylinder

(Loading Shovel, Backhoe)
27
26
25
24
1
23
22
21
20
19
18
17
16
28 2
29
3
4
5
13
15 6
7
9
10
11
12
14
W141-04-02-014
1- Piston Rod 9- Bushing 17 - Slide Ring 25 - Slide Ring

2- Wiper Ring 10 - Retaining Ring 18 - Slide Ring 26 - Slide Ring
3- Slide Ring 11 - Backup Ring 19 - Seal Ring 27 - Cushion Bearing
4- Backup Ring 12 - O-Ring 20 - Seal Ring 28 - Steel Ball
5- U-Ring Packing 13 - Socket Bolt 21 - Piston 29 - Set Screw
(Boom: 17 Used)
(Arm: 11 Used)
6 - Ring 14 - Air Breather 22 - Backup Ring
7 - Air Breather 15 - Cylinder Tube 23 - O-Ring
8 - Cylinder Head 16 - Nut 24 - Backup Ring
W4-2-32
Bucket Cylinder
(Loading Shovel, Backhoe)
23
22
21
1
20
19
18
17
16
27
15 24
25 2
3
4
13 5
14 6
7
9
10
11
12
26
W141-04-02-010
1- Piston Rod 8- Cylinder Head 15 - Nut 22 - Slide Ring

2- Wiper Ring 9- Bushing 16 - Slide Ring 23 - Cushion Bearing
3- Ring 10 - Retaining Ring 17 - Slide Ring 24 - Steel Ball
4- Backup Ring 11 - Backup Ring 18 - Seal Ring 25 - Set Screw
5- U-Ring Packing 12 - O-Ring 19 - Seal Ring 26 - Air Breather
6- Ring 13 - Air Breather 20 - Piston 27 - Shim
7- Socket Bolt 14 - Cylinder Tube 21 - Backup Ring
(LD: 10 Used)
(BH: 8 Used)
BH:Backhoe
W4-2-33
Level Cylinder
(Loading Shovel)
25
24
23
22
21
1
20
19
18
17
16
15 26
27
2
3
4
14 5
6
13
7
9
10
11
12
W18B-04-02-017
1- Piston Rod 8- Cylinder Head 15 - Nut 22 - O-Ring

2- Wiper Ring 9- Bushing 16 - Slide Ring 23 - Backup Ring
3- Slide Ring 10 - Retaining Ring 17 - Slide Ring 24 - Slide Ring
4- Backup Ring 11 - Backup Ring 18 - Seal Ring 25 - Slide Ring
5- U-Ring Packing 12 - O-Ring 19 - Seal Ring 26 - Steal Ball
6- Ring 13 - Air Breather 20 - Piston 27 - Set Screw
7- Socket Bolt (17 Used) 14 - Cylinder Tube 21 - Backup Ring
W4-2-34
Dump Cylinder
(Loading Shovel)
22
21
20
1
19
18
17
16
15
23
14
24
2
3
4
5
13 6
7
9
10
11
12
W141-04-02-015
1- Piston Rod 8- Cylinder Head 15 - Slide Ring 22 - Cushion Bearing

2- Wiper Ring 9- Bushing 16 - Slide Ring 23 - Steel Ball
3- Ring 10 - Retaining Ring 17 - Seal Ring 24 - Set Screw
4- Backup Ring 11 - Backup Ring 18 - Seal Ring
5- U-Ring Packing 12 - O-Ring 19 - Piston
6- Ring 13 - Cylinder Tube 20 - Slide Ring
7- Socket Bolt (8 Used) 14 - Nut 21 - Slide Ring
W4-2-35
• Shim (30) are not used

in the boom, arm cylin-
der.
• O-ring (23), backup rings
(22, 24) are not used in 27
the bucket cylinder. 26
• Cushion bearing (27), 25
shim (30) and air 24
breather (14) are not 23 1
used in the level cylin- 22
der.
21
(22, 24), shim (30), air 20
breather (7) and (14) are 19
not used in the dump 18
cylinder. 17
30
16 2
28
29 3
4
5
13
15 6
7
9
10
11
12
14
W141-04-02-014

(Boom, Level: 17 Used),
(Arm: 11 Used),
(Bucket: 10 Used (LD)),
(Bucket: 8 Used (BH)),
(Dump: 8 Used)
6 - Ring 14 - Air Breather 22 - Backup Ring 30 - Shim

BH: Backhoe
W4-2-36
Disassemble Cylinder 3. Remove set screw (29) and steel ball (28) from
nut (16) to remove nut (16) and shim (30).
1. Disconnect piping from cylinder tube (15). NOTE: As set screw (29) has been caulked with a
Arm punch at two places after it was screw on.
: 24 mm Loosen set screw (29) after cutting the
Bucket punched portion with a drill.
: 22 mm Shim (30) is not used in the boom, arm,
Boom, Arm, Bucket level and dump cylinder.
: 14 mm, 17 mm
Level Set screw (29)
: 17 mm Dump
Dump : 14 mm
: 10 mm, 12 mm Arm, Bucket
: 17 mm
Boom, Level
CAUTION: Piston rod (1) assembly weight: : 19 mm
Loading Shovel Backhoe Nut (16) turning tool
Boom 1600 kg (3530 Ib) 1550 kg (3420 Ib) Boom, Level
Arm 1090 kg (2410 Ib) 1040 kg (2300 Ib) : 250 mm
Bucket 795 kg (1760 Ib) 630 kg (1390 Ib) Arm
Level 930 kg (2050 Ib) - : 220 mm
Dump 226 kg (500 Ib) - Bucket (Loading shovel)
: 190 mm
IMPORTANT: Pull out the piston rod (1) assembly Bucket (Backhoe)
straight so that its spline surface : 180 mm
can not be damaged when removing Dump
the piston rod (1) assembly. : 150 mm
2. Remove socket bolt (13) and hoist the piston rod
(1) assembly to remove it. 4. Remove piston (21) and cushion bearing (27)
Boom, Bucket (Loading shovel), Level, Dump from piston rod (1).
: 24 mm
NOTE: Cushion bearing (27) is not used in the
Arm, Bucket (Backhoe)
level cylinder.
: 27 mm
W4-2-37
27
26
25
24
23 1
22
21
20
19
18
17
3
4
5
6
9
10
W141-04-02-014
W4-2-38
IMPORTANT: Take care not to damage the com-
CAUTION: Piston rod (1) weight: ponents when removing seals.
Loading shovel Backhoe 6. Remove O-Ring (23), backup rings (22, 24), slide
Boom 1350 kg (2980 Ib) 1300 kg (2870 Ib) rings (17, 18, 25, 26), seal rings (19, 20) from
Arm 900 kg (1990 Ib) 840 kg (1860 Ib) piston (21).
Bucket 670 kg (1480 Ib) 530 kg (1170 Ib)
Level 680 kg (1500 Ib) -
Dump 131 kg (290 Ib) - 7. Remove wiper ring (2), slide ring (3), U-ring pack-
ing (5), backup ring (4), ring (6), bushing (9) and
retaining ring (10) from cylinder (8).
CAUTION: Cylinder head (8) assembly NOTE: When removing bushing (9), tap the split
weight: part of bushing (9) with a screwdriver, de-
Loading shovel Backhoe form bushing (9) to remove it while taking
Boom 175 kg (390 Ib) 175 kg (390 Ib) care not to damage cylinder head (8).
Arm 131 kg (290 Ib) 140 kg (310 Ib)
Bucket 85 kg (190 Ib) 62 kg (140 Ib)
Level 175 kg (390 Ib) -
Dump 65 kg (150 Ib) -
5. Attach a nylon sling to cylinder head (8) and hold

it by crane. To protect the seal of cylinder head
(8), wind protection tape around the nut of piston
rod (1) and remove the cylinder head (8) assem-
bly from piston rod (1).
W4-2-39
ASSEMBLE CYLINDER
• Shim (30) are not used

in the boom, arm cylin-
der.
(22, 24) are not used in
the bucket cylinder. 2
• Cushion bearing (27), 8 3
shim (30) and air 13 4, 5
breather (14) are not 6
used in the level cylin- 9
der. 10
(22, 24), shim (30), air 11, 12
breather (7) and (14) are
not used in the dump 1
cylinder.
15
27
22, 23, 24
26
21
25
30 19, 20
18
17
16
29
28
W118-04-01-012
(Boom, Level: 17 Used),
(Arm: 11 Used),
(Bucket: 10 Used (LD)),
(Bucket: 8 Used (BH)),
(Dump: 11 Used)
6 - Ring 14 - Air Breather 22 - Backup Ring 30 - Shim

BH: Backhoe
W4-2-40
Assemble Cylinder
• Degrease and clean the disassembled parts as
well as dry them before assembling. In addition, if CAUTION: Cylinder head (8) assembly
seal parts are heated to temperature of 80 °C weight:
(176 °F), it is easier to do the assembly work. Loading shovel Backhoe
Boom 175 kg (390 Ib) 175 kg (390 Ib)
IMPORTANT: Install backup ring (4) to cylinder Arm 131 kg (290 Ib) 140 kg (310 Ib)
rod (1) at pin hole side of cylinder Bucket 85 kg (190 Ib) 62 kg (140 Ib)
rod and U-ring packing (5) to piston Level 175 kg (390 Ib) -
(21) side. Install U-ring packing (5) Dump 65 kg (150 Ib) -
with its lip portion facing to piston CAUTION: Piston rod (1) weight:
(21) side. Loading shovel Backhoe
Install ring (6) with the lip side fac- Boom 1350 kg (2980 Ib) 1300 kg (2870 Ib)
ing to piston (21) side. Arm 900 kg (1990 Ib) 840 kg (1860 Ib)
1. Install retaining ring (10), bushing (9), ring (6), Bucket 670 kg (1480 Ib) 530 kg (1170 Ib)
U-ring packing (5), backup ring (4), slide ring (3) Level 680 kg (1500 Ib) -
and wiper ring (2) to cylinder head (8). Dump 131 kg (290 Ib) -
IMPORTANT: Assemble backup ring (11) onto 3. Wind protection tape around nut thread of piston
cylinder rod at pin hole side of cyl- rod (1) and install the cylinder head (8) assembly
inder rod and O-ring (12) onto pis- to piston rod (1) while rotating it.
ton (21) side.
2. Install backup ring (11) and O-ring (12) onto cyl-
inder head (8).
W4-2-41
27
22, 23, 24
26
21
25
19, 20
30
18
17
16
W118-04-01-012
W4-2-42
IMPORTANT: Degrease the screw part of cylinder IMPORTANT: When assembling rings (17, 18, 25,
head (1) and cushion bearing (27) 26), do not position their spilt por-
thoroughly. By failing to do so, nut tions at same place.
(16) cannot be tightened to the 7. Install rings (17, 18, 25, 26) to the outer periphery
specified torque exactly. of piston (21).
IMPORTANT: Install cushion bearing (27) with the
notch side facing to cylinder head IMPORTANT: Degrease both ends of piston (21)
(8). thoroughly. If failure to do so, nut
4. Degrease cylinder rod (1) and cushion bearing (16) cannot be tightened to the
(27). specified torque exactly.
Install cushion bearing (27) to cylinder rod (1). 8. Install piston (21) to cylinder rod (1) with its step
NOTE: Measure the outer diameter of cushion surface facing to nut (18) side after it was de-
bearing (27) before assembly. (Refer to greased at both ends.
Maintenance Standard section on page
W4-2-51) IMPORTANT: Degrease nut (16) thoroughly. If fail-
NOTE: Cushion bearing (27) is not used in the ure to do so, it cannot be tightened
level cylinder. to the specified torque exactly.
NOTE: Notch is not used on the cushion bearing 9. Degrease nut (16) and shim (30) and install it to
(27) of dump cylinder. piston rod (1), then screw the nut to the specified
torque.
27 NOTE: If the parts are not degreased thoroughly,
Notch they will be over lubricated. In such case,
cushion bearing (27) will expand if the
parts are tightened too much.
Boom
W18B-04-02-011
: 250 mm
: 68600 ± 3430 N·m
5. Install O-ring (23), backup rings (22, 24) to the (7000 ± 350 kgf·m, 50600 ± 2530 lbf·ft)
bore of piston (21). Arm
NOTE: O-ring (23), backup rings (22, 24) are not : 220 mm
used in the dump cylinder. : 63700 ± 3185 N·m
(6500 ± 325 kgf·m, 47000 ± 2350 lbf·ft)
6. Install seal rings (19, 20) to the outer diameter of Bucket (Looding Shovel)
piston (21). Then install seal rings (19, 20) with : 190 mm
bamboo spatula, while taking care to install them : 58800 ± 2940 N·m
into their right grooves respectively. (6000 ± 300 kgf·m, 43400 ± 2170 lbf·ft)
Bucket (Backhoe)
: 180 mm
: 59600 ± 2980 N·m
(6080 ± 305 kgf·m, 44000 ± 2210 lbf·ft)
Level
: 250 mm
: 53050 ± 2653 N·m
(5410 ± 270 kgf·m, 39100 ± 1950 lbf·ft)
Dump
: 150 mm
: 22300 ± 1115 N·m
(2270 ± 115 kgf·m, 16400 ± 830 lbf·ft)
W4-2-43
13
15
27
16
29
28
W118-04-01-012
W4-2-44
IMPORTANT: The outer diameter dimensions of IMPORTANT: Caulk set screw (29) at 2 places di-
cushion bearing (27) are not same agonally with a punch after the
before and after nut (16) is tightened. screw is tightened.
Measure the outer diameter of the 11. Install steel ball (28) and set screw (29) to nut
nut after it is tightened to make sure (16).
whether the dimension is within the Dump
limit or not. : 14 mm
10. Measure the outer diameter of cushion bearing : 96.6 ± 18 N·m
(27) at 2 places (A), (B) after tightening. (9.8 ± 1.86 kgf·m, 71 ± 13.5 lbf·ft)
If the measured values are not within the speci- Arm, Bucket
fied limit, do the work again from step 4. : 17 mm
NOTE: Notch is not used on the cushion bearing : 180 ± 36 N·m
(27) of dump cylinder. (18.4 ± 3.7 kgf·m, 133 ± 26.8 lbf·ft)
A B Boom, Level
: 19 mm
Notch : 471 ± 83 N·m
(48 ± 9 kgf·m, 347 ± 65 lbf·ft)
CAUTION: Piston rod (1) assembly weight:

Loading shovel Backhoe
Boom 1600 kg (3530 Ib) 1550 kg (3420 Ib)
Arm 1090 kg (2410 Ib) 1040 kg (2300 Ib)
W18B-04-02-014 Bucket 795 kg (1760 Ib) 630 kg (1390 Ib)
Level 930 kg (2050 Ib) -
Standard Dimensions Unit: mm (in) Dump 226 kg (500 Ib) -
After Tightening
Cylinder
Part A Part B IMPORTANT: Insert the piston rod (1) assembly
φ247.81 φ248.00 straight while aligning the center of
Boom (Loading Shovel)
(φ9.756) (φ9.764) cylinder tube (15) so that its ring
φ247.73 φ248.00 surface can not be damaged when
Boom (Backhoe)
(φ9.753) (φ9.764) inserting the piston rod (1) assem-
Arm (Loading Shovel)
φ227.61 φ228.00 bly.
(φ8.961) (φ8.976) 12. Insert the piston rod (1) assembly to the cylinder
φ217.81 φ218.00 tube (15) with socket bolt (13).
Arm (Backhoe)
(φ8.575) (φ8.583) Boom, Bucket (Looding shovel)
φ187.89 φ188.00 : 24 mm
Bucket (Loading Shovel)
(φ7.397) (φ7.402) : 1910 ± 353 N·m
φ177.70 φ178.00 (195 ± 36 kgf·m, 1410 ± 260 lbf·ft)
Bucket (Backhoe)
(φ6.996) (φ7.008) Arm, Bucket (Backhoe)
φ137.72 φ138.00 : 27 mm
Dump
(φ5.422) (φ5.433) : 471 ± 83 N·m
(48 ± 9 kgf·m, 1820 ± 340 lbf·ft)
W4-2-45
15
W118-04-01-012
W4-2-46
13. Connect piping to cylinder tube (15) with the
socket bolts.
Arm
: 24 mm
: 96.8 N⋅m (9.85 kgf⋅m, 71 Ibf⋅ft)
Bucket
: 22 mm
: 89.3 ± 16.7 N⋅m
(9.11 ± 1.7 kgf⋅m, 66 ± 12 Ibf⋅ft)
Boom, Arm, Bucket
: 14 mm
: 265 N⋅m
(27 kgf⋅m, 195 Ibf⋅ft)
: 17 mm
: 443 ± 82.4 N⋅m
(45.1 ± 8.4 kgf⋅m, 326 ± 60 Ibf⋅ft)
Level
: 17 mm
: 443 ± 82.4 N⋅m
(45.1 ± 8.4 kgf⋅m, 326 ± 60 Ibf⋅ft)
Dump
: 10 mm
: 64 ± 12 N⋅m
(6.5 ± 1.2 kgf⋅m, 47 ± 8 Ibf⋅ft)
: 12 mm
: 108 ± 21 N⋅m
(11 ± 2.1 kgf⋅m, 79 ± 15 Ibf⋅ft)
W4-2-47
MAIN POINTS TO BLEED AIR
Boom Cylinder
Bottom Side
Positions of Air Breathers Arm Cylinder
Bottom Side
(Loading Shovel)
Bucket Cylinder
Rod Side
Level Cylinder
Rod Side
Arm Cylinder
Rod Side Boom Cylinder
Rod Side
Bucket Cylinder
Bottom Side
W18B-04-01-001
Positions of Air Breathers

(Backhoe) Arm Cylinder Arm Cylinder
Rod Side Bottom Side
Bucket Cylinder
Bottom Side
Boom Cylinder
Bottom Side
Boom Cylinder
Rod Side
Bucket Cylin-
der Rod Side
W118-04-02-011
W4-2-48
Main Points to Bleed Air
・Main points to bleed air from each cylinder are 6. Remove the rubber cap from cylinder bottom side
same. Refer to following procedures to bleed air and loosen the air breather.
from the each cylinder. : 19 mm
7. Operate the lever slowly to retract the cylinder as

CAUTION: High pressure hydraulic oil may much as possible and bleed air from the air
penetrate skin and eyes, causing severe in- breather until only oil oozes.
jury. Release pressure from hydraulic pipes
of the machine before removing the hydrau-
lic lines. 8. Tighten the air breather on cylinder bottom side
Hydraulic oil and machine may be hot just and install the rubber cap.
after operation, possibly causing severe : 19 mm
burns if touched. Be sure to wait for them to : 44 N⋅m (4.5 kgf⋅m, 32.5 Ibf⋅ft)
cool down before starting any repair work.
1. Decrease the engine to slow speed before bleed-

ing air. Operate the cylinder slowly to the stroke
end for 5 to 6 times.
2. Place front attachment as illustrated on page

W4-2-48.
3. Remove the rubber cap from cylinder rod side

and loosen the air breather.
NOTE: As the hydraulic hoses of boom cylinder
and level cylinder are connected, air can
be bled from them at the same time.
4. Operate the lever slowly to extend the cylinder as

much as possible to bleed air from the air
breather until only oil oozes.
: 19 mm
5. Tighten the air breather on cylinder rod side and

install the rubber cap.
: 19 mm
: 44 N⋅m (4.5 kgf⋅m, 32.5 Ibf⋅ft)
W4-2-49
a b
Cylinder Tube
1. Tube (a)
・Check the surface of the tube inside and outside
for any damage.
A
2. Pin bushing (b)

・Check inner surface for any damage.
W145-04-01-015
Piston Rod d c
1. Rod (c)
・Put two V blocks onto flat and level ground at 1
meter distance between them. Then place cylin-
der rod on the V blocks and install dial gauge to
measure the run-out of the rod when rotate the C
cylinder rod by 1 turn. The rod should be cali-
brated when the run-out is over 1.0 mm (0.04 in).
If the run-out is over 2.0 mm (0.08 in), the rod
should be replaced. W166-04-02-023
・Check whether the wear on the surface of outer

Dial Gauge
diameter is 0.2 mm (0.008 in) more than speci-
Piston Rod
fied dimension (c) at length of 200 mm (7.9 in).
・Check the surface for any damage.
・Check plated portion for any rust.
・Check cushion portion for any damage
2. Pin bushing (d) W166-04-02-022
・Check inner surface for any damage. 1m

V Block
Standard Dimensions Unit : mm (in)
Loader Shovel Backhoe

Boom Level Arm Bucket Dump Boom Arm Bucket
Cylinder Tube 0 0 0 0
280
0
11
0 0
9.8
0 0
8.5
0 0
12.2
0 0 0
11 -0.003
0
9.1
0
310 12.2 310 12.2 250 215 310 280 230
Inner Dia (A) -0.081 -0.003 -0.081 -0.003 -0.081 -0.003 -0.072 -0.003 -0.072 -0.003 -0.081 -0.003 -0.081 -0.072 -0.003
Rod
-0.015 -0.001 -0.015 -0.001 -0.015 -0.001
8.3 -0.001 -0.014
7.1 -0.001 -0.014
5.1 -0.001 -0.015
9 -0.001 -0.015 -0.014
6.7 -0.001
Dimensions 230
-0.035
9
-0.001
230
-0.035
9
-0.001
210
-0.035 -0.001
180
-0.032 -0.001
130
-0.032 -0.001
230
-0.035 -0.001
210
-0.035
8.3 -0.001 170
-0.032 -0.001
(C) After
W4-2-50
Standard Dimensions of Cushion Bearing
Unit:mm (in) A B
Cylinder Standard
Boom (Loading Shovel) -0.235 -0.01
φ248 (φ9.7 )
-0.264 -0.01
Boom (Backhoe) -0.290 -0.01
φ248 (φ9.7 )
-0.319 -0.01
Arm (Loading Shovel) -0.170 -0.01
φ228 (φ8.9 )
-0.199 -0.01
Arm (Backhoe) -0.430 -0.02
φ218 (φ8.6 )
-0.459 -0.02
Bucket (Loading Shovel) -0.170 -0.01
φ188 (φ7.4 )
-0.199 -0.01 W18B-04-02-014
Bucket (Backhoe) -0.360 -0.01
φ178 (φ7.0 )
-0.385 -0.02
Dump -0.320 -0.01
φ138 (φ5.4 ) e f
-0.345 -0.01
e f
NOTE: Notch is not used on the cushion bearing
of dump cylinder.
Pipe
1. Pipe (e)
・Check for any damage in depth more than 0.1
mm (0.004 in). g
・Check for any deformation and damage g
2. Socket bolt (f) T182-05-02-004
・Check for any heavy rust.

・Check thread for any damage.
3. O-ring (g)
・Replacement should be carried out as long as
they are disassembled.
Piston • Cylinder Head

・Check the surface of inside and outside for any
damage.
・Check grooves for any damage.
・Should internal leakage be found, check seals for
damage.
・Replace when the base metal of bushing slide
surface shows.
W4-2-51
(Blank)
W4-2-52
FRONT ATTACHMENT / Bushing and Point
REMOVE AND INSTALL BUSHING
Removal Installation
1. Remove dust seal (1). 1. Cool bushing (2) in dry ice.
2. If bushing (7) needs to be replaced, perform clad- 2. Install bushing (2) and dust seal (1).
as to make bushing (7) contract.
NOTE: In case the bushing is difficult to remove,
use a torch to remove it.
Loading Shovel Front
B
C
W118-04-01-003
3
2 2 2
1
W166-04-02-009
Section A W141-04-03-001
Section B
1 - Dust Seal 2 - Bushing 3 - Spacer
W4-3-1
Backhoe
B
A
A A
W118-04-02-011
2 3 2 2 2
1
1 1 W118-04-01-021
W166-04-02-009 W141-04-01-010
Section A Section B Section C
1 - Dust Seal 2 - Bushing 3 - Spacer
W4-3-2
(Blank)
W4-3-3
Pin and Bushing (Loading Shovel)
G
B
A
C C
F F
W118-04-01-003
W4-3-4
Unit: mm
Allowable
Part Name Location Specification Limit
Pin Dia. 220－0.1－0.2 216
Bushing Inner Dia. (Boom Side) 220+0.6+0.5 222
A : Boom and Arm Bushing Outer Dia. 255+0.5+0.45 －
Bushing Bore Dia. (Arm Side) 220+0.6+0.5 222
Bushing Outer Dia. 255+0.452+0.4 －
Pin Dia. 180－0.1－0.2 176
B : Bucket Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 180+0.10 －
Bearing Inner Dia. (Cylinder Side) 180+0.006－0.071 182
－0.1
Pin Dia. 200 －0.2 196
Pin Hole Inner Dia. (Boom Side) 200+0.10 －
C : Level Cylinder, and Boom and Arm Pin Hole Inner Dia. (Arm Side) 200+0.10 －
Bearing Inner Dia. (Rod Side) 200+0.25+0.05 202
(Bottom Side) 200+0.006－0.071 202
Pin Dia. 180－0.1－0.2 176
Bushing Inner Dia. (Arm Side) 180+0.5+0.4 182
D : Arm and Bucket Bushing Outer Dia. 210+0.4+0.35 －
Bushing Inner Dia. (Bucket Side) 180+0.5+0.4 182
Pin Dia. 180－0.1－0.2 176
E : Bucket Cylinder and Bucket
－0.1
Pin Dia. 180 －0.2 176
F : Arm Cylinder, and Boom and Arm Pin Hole Inner Dia. (Boom/Arm Side) 180+0.10 －
Bearing Inner Dia. (Cylinder Side) 180+0.25+0.05 182
Pin Dia. 200－0.1－0.2 196
G : Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 200+0.10 －
NOTE: 1 mm=0.03937 in
W4-3-5
W118-04-01-003
W4-3-6
Unit: mm
Allowable
Pin Dia. 130－0.1－0.2 126
H : Dump Cylinder and Front Bucket Bushing Inner Dia. (Bucket Side) 130+0.4+0.3 134
－0.1
Pin Dia. 160 －0.2 156
Bushing Inner Dia. (Rear Side) 160+0.45+0.35 162
I : Rear Bucket and Front Bucket Bushing Outer Dia. 190+0.35+0.3 －
Bushing Inner Dia. (Front Side) 160+0.45+0.35 162
Pin Dia. 120－0.1－0.2 116
J : Dump Cylinder and Rear Bucket Pin Hole Inner Dia. (Bucket Side) 120+0.20 －
－0.3
Pin Dia. 200 －0.4 196
K : Boom and Main Frame Bushing Outer Dia. 230+0.45+0.4 －
Bushing Inner Diameter (Frame Side) 200+0.43+0.33 202
Pin Dia. 200－0.3－0.4 196
Bushing Inner Dia. (Frame Side) 200+0.43+0.33 202
L : Boom Cylinder and Main Frame
NOTE: 1 mm=0.03937 in
W4-3-7
Pin and Bushing (Backhoe)
F D
E C
A W118-04-02-011
W4-3-8
Unit: mm
Allowable
Pin Dia. 200－0.3－0.4 196
A: Boom Cylinder and Main Frame
－0.10
Pin Dia. 200 －0.20 196
B: Boom and Main Frame Bushing Outer Dia. 235+0.4+0.35 －
Pin Dia. 200－0.10－0.20 196
C: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 200+0.100 －
－0.10
Pin Dia. 180 －0.20 176
D: Boom and Arm Cylinder Pin Hole Inner Dia. (Boom Side) 180+0.10 －
－0.1
Pin Dia. 200 －0.2 196
E: Boom and Arm Bushing Outer Dia. 230+0.45+0.4 －
Pin Dia. 200－0.10－0.20 196
F: Arm Cylinder and Arm Pin Hole Inner Dia. (Arm Side) 200+0.10 －
－0.10
Pin Dia. 160 －0.20 156
G: Arm and Bucket Cylinder Pin Hole Inner Dia. (Arm Side) 160+0.10 －
NOTE: 1 mm=0.03937 in
W4-3-9
H
I
J K
W118-04-02-011
W4-3-10
Unit: mm
Allowable
Part Name Location Specification
Limit
Pin Dia. 160－0.10－0.20 156
Bushing Inner Dia. (Link A Side) 160+0.45+0.35 164
Bushing Outer Dia 190+0.36+0.39 －
Bushing Inner Dia. (Link B Side: Outer Hand) 160+0.45+0.35 164
H: Bucket Cylinder and Link
Bushing Inner Dia. (Link B Side: Inner Hand) 160+0.45+0.35 164

－0.10
Pin Dia. 160 －0.20 156
Bushing Inner Dia. (Link A Side) 160+0.5+0.4 164
I: Link and Bucket Bushing Outer Dia. 190+0.36+0.32 －
Pin Dia. 180－0.10－0.20 176
J: Arm and Bucket Bushing Outer Dia. 215+0.4+0.35 －
Bushing Outer Dia. 210+0.396+0.35
Pin Dia. 120－0.10－0.20 116
Bushing Outer Dia. 140+0.27+0.23
K: Arm and Link Bushing Inner Dia. (Link B Side: Outer Hand) 120+0.38+0.28 124
Bushing Inner Dia. (Link B Side: Inner Hand) 120+0.38+0.28 124
NOTE: 1 mm=0.03937 in
W4-3-11
Point
164
W141-04-03-002
Tooth Point Shroud
Location Specification Allowable Limit Corrective Measure

3 3
PCSA 14.0m (35.5 yd )
470 (235) Replace
Loading Shovel Bucket
A : Tooth Point PCSA 13.8 m3 (38.0 yd3),
CECE 12.2m3 (34.0 yd3) 469 (234.5) Replace
Backhoe Bucket
B : Shroud (Loading Shovel only) 280.5 (160) Replace
NOTE: 1 mm=0.03937 in
W4-3-12
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

THE ATTACHED PATTERN LIST
The following patterns are attached to this manual.
1. Track Shoe Pattern (A).
2. Track Shoe Pattern (B). Up to serial No. 529.
3. Track Shoe Pattern (B). Serial No. 529 and up.
4. Upper Roller Pattern.
5. Lower Roller Pattern.
6. Drive Tumbler Pattern (A). Up to serial No. 529.
7. Drive Tumbler Pattern (A). Serial No. 529 and up.
8. Drive Tumbler Pattern (B). Up to serial No. 529.
9. Drive Tumbler Pattern (B). Serial No. 529 and up.

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EX2500-5

Manual No. : KM-141-E

PRINTED IN SINGAPORE (PS) 2005.03

EX2500-5 TM/WSH 1 9/3/05, 17:23

• Each page has a number, located on the center

Consecutive Page Number for Each Group

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

• DANGER indicates an imminently hazardous

• WARNING indicates a potentially hazardous

• CAUTION indicates a potentially hazardous

• DANGER or WARNING safety signs are

• CAUTION also calls attention to safety messages in

• To avoid confusing machine protection with

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the

• Safety signs should be installed, maintained and

• If a safety sign or operator's manual is damaged

• Learn how to operate the machine and its controls

• Allow only trained, qualified, authorized personnel

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

• The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

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

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

• Wear close fitting clothing and safety equipment

You may need:

Respirator or filter mask.

• Avoid wearing loose clothing, jewelry, or other

• Operating equipment safely requires the full

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

• Wear a suitable hearing protective device such

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

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

• When you get on and off the machine, always

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount

• Be careful of slippery conditions on platforms,

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

• The seat should be adjusted whenever changing

• If the machine should overturn, the operator may

• Prior to operating the machine, thoroughly

• Be sure to remain seated with the seat belt

MOVE AND OPERATE MACHINE SAFELY

• Take extra care not to run over bystanders.

• Start the engine only when seated in the

• Before starting the engine, confirm that all control

HANDLE STARTING AIDS SAFELY

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

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

• Failure to follow correct jump starting procedures

• Riders on machine are subject to injury such as

• Only the operator should be on the machine.