160W Workshop Manuel PDF

Manual No.
: KM-CBBE
Vol. No. : WCBBE-00
160W
Workshop Manual
Wheeled Excavator Workshop Manual

160W
Wheeled Excavator
Service Manual (Manual No. KM-CBBE) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TOCBBE
Technical Manual (Troubleshooting) : Vol. No. TTCBBE
Workshop Manual : Vol. No. WCBBE
PRINTED IN SINGAPORE (PS)
Zaxis160W Wheeled-Wsh 1 24/6/03, 3:51 PM

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-0688
SA-688
UNDERSTAND SIGNAL WORDS

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

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

element of information.
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the

machine and all safety messages in this manual.
• Safety signs should be installed, maintained and
replaced when necessary.
• If a safety sign or this manual is damaged or
missing, order a replacement from your author-
ized dealer in the same way you order other re-
placement parts (be sure to state machine model
and serial number when ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorized personnel SA-003
to operate the machine.

• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may
impair its function and/or safety and affect ma-
chine life.
• The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
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 au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department SA-437
posted near your telephone.
004-E01A-0437
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
Respirator or filter mask. SA-438
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
SA-3
SAFETY
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
• In the walk-around inspection be sure to cover all
points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all

dirt and/or oil from the soles of your work boots. If
any controls such as a pedal is operated while
with dirt and/or oil on the soles of the operator’s
work boots the operator’s foot may slip off the
pedal, possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified lo-
cations.
• Avoid storing transparent bottles in the cab. Don’t
attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.

• When you mounting and dismounting the ma-
chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount
or dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
SA-439
008-E01B-0439
ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator
leading to misoperations.
• The seat should be adjusted whenever changing
the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again.
SA-378
009-E01A-0378
SA-6
SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may

become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
• Prior to operating the machine, thoroughly
examine webbing, buckle and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt SA-237
securely fastened at all times when the machine

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

• Bystanders can be run over.
• Take extra care not to run over bystanders.
Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
machine. SA-083
011-E01A-0426
SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
• Start the engine only when seated in the
operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control
levers are in neutral.
SA-084
012-E01B-0444
JUMP STARTING
• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to
follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway SA-032
machine.
S013-E01A-0032
SA-8
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.
014-E01B-0379
SA-091
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 steering wheel shift 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.
017-E01A-0491
SA-092
SA-9
SAFETY
DRIVE MACHINE SAFELY (WORK SITE)
• Before driving the machine, always confirm that the

steering wheel/shift lever direction corresponds to
the direction you wish to drive.
• Be sure to detour around any obstructions.
• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or SA-090
death.
• When driving up or down a slope, keep the
bucket facing the direction of travel, approxi-
mately 0.5 to 1.0 m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.
SA-288
• Driving across the face of a slope or steering on

a slope may cause the machine to skid or over-
turn. If the direction must be changed, move the
machine to level ground, then, change the direc-
tion to ensure sage operation.
019-E05B-0090
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCI-DENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park ma-
chine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Place the shift lever in neutral, and put the brake
switch in the P (parking brake) position.
• Turn the auto-idle switch and the H/P mode
switch off.
• Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK posi-
SA-278
tion.
• Block both tires and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E01A-0270
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
• No machine motions shall be made unless
signals are clearly understood by both signalman SA-384
and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
• Read and understand all operating instructions in
the operator’s manual.
S021-E01A-0494
SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death. SA-012
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 5 degrees if crossing the grade is
unavoidable. SA-562
• Reduce swing speed as necessary when

swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-13
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
SA-089
site.
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may

be struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,
be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
is safely and securely situated on supporting
SA-014
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-14
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.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Place the shift lever in neutral, and put the brake
switch in the P (parking brake) position.
• Turn auto-idle switch and auto-acceleration
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 up the pilot shut-off lever further to release
SA-093
the catch, so that the left console can be moved

upward (“CONSOLE UP” position).
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E07B-0093
SA-15
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

flammable. SA-018
• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when

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

Less than 15°
ing/unloading the machine:
1. Select firm level ground.
SA-094
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when load-
ing/unloading the machine.
4. Always turn the auto-idle switch,
auto-acceleration switch and the H/P mode
switch OFF when loading or unloading the ma-
chine, to avoid unexpected speed increase due
to unintentional operation of a control lever.
5. Always select the slow travel with the fast/slow
travel switches.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is un-
avoidable, first move back to the ground or flat-
bed, modify traveling direction, and begin to
drive again.
7. Do not operate any levers besides the travel lev-
ers when driving up or down the ramp.
8. The top end of the ramp where it meets the flat-
bed is a sudden bump. Take care when traveling
over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10.Keep the arm tucked under and rotate the up- Less than 15°
perstructure slowly for best stability.
11.Turn the brake switch to the parking (P) position. SA-095
Place blocks in front of and behind the tires to

secure the machine.
12.Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the op-
erator’s manual for details.
035-E06A-0395
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing

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

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes.
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.
SA-18
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527
inside the machine.

• Always use a work light protected with a guard.
In case the light bulb is broken, spilled fuel, oil
antifreeze fluid, or window washer fluid may
catch fire.
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine, at-
tach a “Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without
securing the machine first.
• Always lower the attachment to the ground
before you work on the machine.
• If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on
cinder blocks, hollow tires, or props that may
crumble under continuous load. Do not work
under a machine that is supported solely by a
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-20
SAFETY
PREVENT PARTS FROM FLYING
• Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E03A-0344
SA-344
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
SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can
cause serious injury or death.
• Do not attempt to mount a tire unless you have
the proper equipment and experience to perform
the job. Have it done by your authorized dealer or
a qualified repair service.
• Always maintain the correct tire pressure. DO
NOT inflate tire above the recommended pres-
sure.
• When inflating tires, use a chip-on chuck and ex-
tension hose long enough to allow you to stand to
one side and not in front of or over the tire as-
sembly. Use a safety cage it available.
• Inspect tires and wheels daily. Do not operate
with low pressure, cuts bubbles, damaged rims,
or missing lug bolts and nuts. SA-249
• Never cut or weld on an inflated tire or rim as-

sembly. Heat from welding could cause an in-
crease in pressure and may result in tire explo-
sion.
521-E02A-0249
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
• 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.
• Wait for the oil and components to cool before
starting any maintenance or inspection work.
505-E01B-0498 SA-225
REPLACE RUBBER HOSES

PERIODICALLY
• Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the
page of “Periodic replacement of parts” in the
operator’s manual.)
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front SA-019
attachment to fall on a person nearby, which may

result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or SA-031
goggles for eye protection.

• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E03A-0499
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019
hoses.
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.
SA-24
SAFETY
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
• Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S508-E02B-0019
SA-25
SAFETY
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the key switch to the
OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• In an emergency, if the cab door and/or the front SA-393
window cannot be opened, break the front or rear

window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
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
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that SA-818
there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a
torch near pressurized fluid lines or other
flammable materials.
• Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc..
SA-030
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that
contain flammable fluids.
• Clean them thoroughly with nonflammable
solvent before welding or flame cutting them.
510-E01B-0030
SA-27
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the
dust. SA-029
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 hy-
drometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Do not continue to use or charge the battery
when electrolyte level is lower than specified. Ex-
plosion of the battery may result. SA-032
• Loose terminals may produce sparks. Securely

tighten all terminals.
• Battery electrolyte is poisonous. If the battery
should explode battery electrolyte may be splashed
into eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking
electrolyte specific gravity.
512-E01C-0032
SA-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when
servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY

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

recommended equipment.
S515-E01A-0309
SA-29
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids.
Do not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air
can damage the Earth’s atmosphere. SA-226
Government regulations may require a certified

air conditioning service center to recover and
recycle used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete,
confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-30
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling and
Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil Tank
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Signal Control Valve
Group 10 Travel Shockless Valve
Group 11 Solenoid Valve
Group 12 Pilot Relief Valve
Group 13 Steering Valve
Group 14 Brake Valve
Group 15 Accumulator Charging Valve
Group 16 Transmission Control Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Motor
All information, illustrations and speci- Group 3 Center Joint
fications in this manual are based on
the latest product information available Group 4 Transmission
at the time of publication. The right is
reserved to make changes at any time
Group 5 Axle
without notice. Group 6 Axle Lock Cylinder
Group 7 Operate-Check Valve
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
COPYRIGHT(C)2003 Group 2 Cylinder
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan Group 3 Hose-Rupture Safety Valve
All rights reserved
SECTION 5 ENGINE
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Signal Control Valve
Group 3 Electrical System Group 7 Steering Valve
Group 8 Brake Valve
Group 9 Transmission Control Valve
Group 10 Others (Upperstructure)
Group 11 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Component Layout
Group 2 Standard Group 3 Troubleshooting A
Group 3 Engine Test Group 4 Troubleshooting B
Group 4 Excavator Test Group 5 Troubleshooting C
Group 5 Component Test Group 6 Electrical System Inspection
Group 6 Adjustment Group 7 ICX
SECTION 1
GENERAL
— CONTENTS —
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling.................................................W1-1-1
Maintenance Standard Terminology.......... W1-1-7
Group 2 Tightening Torque

Tightening Torque Specification ..................W1-2-1
Torque Chart ................................................W1-2-2
Piping Joint ..................................................W1-2-5
Periodic Replacement of Parts .................. W1-2-9
Group 3 Painting
Painting.................................................... W1-3-1
Group 4 Bleeding Air from Hydraulic Oil

Tank
Bleeding Air from Hydraulic Oil tank .......... W1-4-1
CBBW-1-1
(Blank)
CBBW-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 instructed.
disassem-bling/assembling procedures beforehand, • If a part or component cannot be removed after
to help avoid incorrect disassembling of removing its securing nuts and bolts, do not
components as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
• 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 mo-
clean and dry.
tor housing, damage to the motor
• If an anti-corrosive agent has been used on a
may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
• Utilize matching marks when assembling. trapped in the cylinder tube, dam-
• Be sure to use the designated tools to assemble age to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
• Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to • Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. • Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
• 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
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level. W1F3-01-04-001
• Stop the engine. Recheck hydraulic oil level. Re-

plenish oil as necessary.
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. Correct Eyehole
• Attach protectors (soft material) on the corners of Lifting Method
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use W102-04-02-016
slings with the same width and length to keep the Incorrect Eyehole
lifted load balanced. Lifting Method
• When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions. W105-04-01-008
• Avoid dragging slings on the ground, throwing

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
2. Before using a nylon sling, visually check the ny- Scuffing
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.
W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
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
Bolt Dia Wrench Torque
No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
Engine cushion rubber mounting nut 14 4 22 140 (14.0) (103)
1
Engine cushion rubber mounting bolt 16 2 24 235 (24) (175)
Engine bracket mounting bolt 10 7 17 50 (5.1) (37)
2
Engine bracket mounting nut 10 1 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
17 24.5 (2.5) (18)
19 30 (3.1) (22)
22 40 (4.1) (30)
ORS and metal face seal fittings for hydraulic hoses and
5 27 95 (9.7) (70)
piping
32 140 (14.3) (105)
36 175 (17.8) (130)
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 14 4 22 140 (14.0) (103)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 12 30 500 (51) (370)
12
10 Swing motor mounting bolt (Hex. 8 10 90 (9.2) (67)
Wrench)
11 Battery mounting nut 10 2 17 50 (5.1) (37)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
Swing bearing mounting bolt to upperstructure 20 31 30 510 (52) (375)
13
Swing bearing mounting bolt to chassis 20 36 30 490 (50) (360)
14 * Center joint lock mounting bolts 16 5 24 270 (27.5) (200)
15 * Transmission mounting bolts 20 3 30 550 (56.0) (410)
16
16 * Travel motor mounting bolts (Hex. 4 14 270 (27.5) (200)
Wrench)
17 * Propel shaft mounting nuts 10 32 14 76 (8) (60)
19 * Rear axle mounting bolts 20 8 30 550 (56.0) (410)
20 Wheel pin nuts 22 40 30 600 (61) (440)
6 － 10 10 (1) (7.4)
21 Cover mounting bolt 10 － 17 50 (5.1) (37)
12 － 19 90 (9.2) (66)
8 4 pairs 13 10.3 to (1.05 to (7.59 to
22 Flexible master coupling of piping
12.4 1.26) 9.11)
23 T-bolt clamp of low pressure piping － 11 6.0 (0.6) (4.3)
* : Apply LOCTITE to the threads.
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.
W1-2-1
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.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt H Bolt, Socket bolt M Bolt
Dia. Size Wrench
Size N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.0) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)
W1-2-2
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
W1-2-3
Service Recommendations for Split 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 RIGHT WRONG

tightening 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
W1-2-4
PIPING JOINT
IMPORTANT: The torques given in the chart are 1 4 3 5 2
for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
Union Joint
M202-07-051
Joint Body
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
IMPORTANT: 1. Do not over-tighten nut (3). Ex- 37°

cessive force will be applied to
30°
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be
sure to tighten nut (3) to specifi-
cations. Male Union Joint Female Union Joint
2. Scratches or other damage to
sealing surfaces (4) or (5) will W105-01-01-017
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 78 (8.0, 58)
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 78 (8.0, 58)
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.
W1-2-5
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).
W1-2-6
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
W1-2-7
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
W1-2-8
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic
inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Fuel hose (Fuel tank to injection pump) Every 2 years
Engine
Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Brake valve seals (Rubber parts) Every 2 years
Upperstructure Brake hose Every 2 years
Brakes Stop light switch Every 2 years
Center joint seals (Rubber parts) Every 2 years
Undercarriage
Brake hose Every 1 years
Steering hose Every 2 years
Steering Mechanism Steering cylinder seals (Rubber parts) Every 2 years
Steering valve seals (Rubber parts) Every 2 years
Pump suction hose Every 2 years
Base Machine Pump delivery hose Every 2 years
Swing hose Every 2 years
Hydraulic
Boom cylinder line hose Every 2 years
System
Arm cylinder line hose Every 2 years
Front Attachment
Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
W1-2-9
(Blank)
W1-2-10
GENERAL / Painting
PAINTING
Surfaces to Be Painted Painting Colour

• Main surface of upperstructure YR-01 [TAXI yellow]
Bed cover High-grade beige
Tool box, Tool box cover High-grade black
Inner face Grey
• Front attachment YR01 [TAXI yellow]
• Chassis (undercarriage) N1.0 [Black]
• Floor plate M/F cation colour
• A part of rear left of cab YR-01 [TAXI yellow]
Final painted colour

• Inside and outside surface of cab High-grade beige
[KASAI PAINT LF-113-230B
• Right window beam, U bolt
(Charcoal series black, semi glossy)]
• Suspension lifter (chair bottom) [N2.0 (Black) ]
• Lever (lock, foot rest) [N2.0 (Black) ]
• Torsion bar [N4.0 (Grey) ]
• Engine cover High-grade black
• Ladder rail on right side of upperstructure High-grade black
• Mirror stay (cab side and right side stay) High-grade black
• Head light bracket [N1.0 (Black) ]
• Antislip cover KASAI PAINT Amilack 1400 Deep Black.
W1F3-01-03-001
Tool Box Cover 350 900

Bed Cover
W1-3-1
GENERAL / Painting
A
YR-01
(TAXI Yellow) Out Surface of Hinge Swing
Portion YR-01 (TAXI Yellow)
185
Door Catch Cover YR-01

(TAXI Yellow)
720
W178-01-03-003
5
Section A Section B
Mask Garnished Portion
Door
YR-01(TAXI Yellow) Panel Behind the
Door
10
Painting Area of the Door W178-01-03-005
YR-01 (TAXI Yellow)
W178-01-03-004
Front Attachment
Antislip Cover
YR-01 (TAXI Yellow)
KASAI PAINT
Amilack 1400
Deep Black
Upper Side
of Frame
W178-01-03-007
IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, take care not
to pour washing liquid directly on W1F3-01-03-002
them. The ambient temperature
should not exceed 70 °C when
painting and drying.
W1-3-2
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK
CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
first. Loosen the hydraulic oil tank cap to
release any remaining pressure.
Preparation
1. Place the machine on a firm, level surface and
lower the bucket to the ground.
W1F3-01-04-001
2. Stop the engine. Push pressure release button (1)

1
on the air breather to release any remaining
pressure from hydraulic oil tank (3).
3. Remove cap (2) of hydraulic oil tank (3).

: 5 mm 2
W1F3-01-04-002
Vacuum Pump
Hose
4. Connect a vacuum pump with the hole removed
cap (2) to maintain negative pressure in the
hydraulic oil tank (3). Adapter
NOTE: Be sure to run the vacuum pump
continuously while working.
W562-02-03-008
W1-4-1
GENERAL / Bleeding Air from Hydraulic Oil Tank
(Blank)
W1-4-2
MEMO
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SECTION 2
UPPERSTRUCTURE
— CONTENTS —
Group 1 Cab Group 5 Control Valve
Remove and Install Cab .........................W2-1-1 Remove and Install Control Valve.......... W2-5-1
Dimensions of the Cab Glass.................W2-1-7 Disassemble Control Valve
(4-Spool Section) ................................. W2-5-2
Group 2 Counterweight Disassemble Control Valve
Remove and Install Counterweight ........W2-2-1
(5-Spool Section) ................................. W2-5-8
Group 3 Main Frame Disassemble and Assemble
Remove and Install Main Frame ............W2-3-1 4-Spool and 5-Spool Sections............ W2-5-14
Assemble Control Valve
Group 4 Pump Device (4-Spool Section) ............................... W2-5-16
Remove and Install Pump Device ..........W2-4-1 Assemble Control Valve
Disassemble Pump Device ....................W2-4-4 (5-Spool Section) ............................... W2-5-24
Assemble Pump Device .......................W2-4-12 Remove and Install
Disassemble Regulator ........................W2-4-24 Auxiliary Control Valve ....................... W2-5-33
Assemble Regulator .............................W2-4-26 Disassemble Auxiliary Control Valve ... W2-5-34
Disassemble Solenoid Valve ................W2-4-28 Assemble Auxiliary Control Valve ........ W2-5-36
Assemble Solenoid Valve.....................W2-4-30
Disassemble and Assemble Group 6 Swing Device
Pilot Pump ..........................................W2-4-32 Remove and Install Swing Device ......... W2-6-1
Maintenance Standard .........................W2-4-34 Disassemble Swing Reduction Gear ..... W2-6-4
Assemble Swing Reduction Gear ........ W2-6-10
Disassemble Swing Motor ................. W2-6-18
Assemble Swing Motor ........................ W2-6-22
Maintenance Standard ......................... W2-6-26
CBBW-2-1
Group 7 Pilot Valve Group 12 Pilot Relief Valve
Remove and Install Pilot Valve...............W2-7-1 Remove and Install Pilot Relief Valve .. W2-12-1
Disassemble Front/Swing Pilot Valve.....W2-7-6 Construction of Pilot Relief Valve......... W2-12-2
Assemble Front/Swing Pilot Valve........W2-7-10
Disassemble Travel,
Group 13 Steering Valve
Remove and Install Steering Valve ...... W2-13-1
Positioning/Auxiliary
Disassemble Steering Valve ................ W2-13-2
Blade/Stabilizer Pilot Valve .................W2-7-14
Assemble Steering Valve ..................... W2-13-6
Assemble Travel,
Positioning/Auxiliary Group 14 Brake Valve
Blade/Stabilizer Pilot Valve .................W2-7-16 Remove and Install Brake Valve .......... W2-14-1
Disassemble Brake Valve .................... W2-14-2
Group 8 Pilot Shut-Off Valve
Assemble Brake Valve ......................... W2-14-6
Remove and Install
Pilot Shut-Off Valve...............................W2-8-1 Group 15 Accumulator Charging Valve
Disassemble Pilot Shut-Off Valve...........W2-8-2 Remove and Install
Assemble Pilot Shut-Off Valve ...............W2-8-4 Accumulator Charging Valve.............. W2-15-1
Construction of
Group 9 Signal Control Valve
Accumulator Charging Valve.............. W2-15-2
Remove and Install Signal
Control Valve ........................................W2-9-1 Group 16 Transmission Control Valve
Remove and Install
Group 10 Travel Shockless Valve
Transmission Control Valve ............. W2-16-1
Remove and Install
Construction of
Travel Shockless Valve.......................W2-10-1
Transmission Control Valve ............. W2-16-2
Construction of
Travel Shockless Valve.......................W2-10-2
Group 11 Solenoid Valve

Remove and Install 4-Unit
Solenoid Valve Unit ............................ W2-11-1
Disassemble Proportional
Solenoid Valve .................................... W2-11-2
Assemble Proportional
Solenoid Valve .................................... W2-11-4
Remove and Install 2-Unit Solenoid
Valve (for Pump Control) .................... W2-11-6
Construction of 2-Unit Solenoid
Valve (for Pump Control) .................... W2-11-7
Remove and Install 2-Unit Solenoid
Valve (for Blade/Stabilizer) ................. W2-11-8
Construction of 2-Unit Solenoid
Valve (for Blade/Stabilizer) ................. W2-11-9
CBBW-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Removal
1. Remove seat mounting nuts (2) (4 used) to re-
move seat (1).
: 17 mm
2
1
W1F3-02-01-001
2. Remove bolts (4) (2 used) behind the cab to re-

move rear deck (3).
: 17 mm
4
3. Raise duct (5) to remove it. 5
4. Remove air filter (6). Remove clips (7) (2 used) W178-02-01-012

with a plier, then remove duct (8) from the cab.
W1F3-02-01-002
W2-1-1
5. Disconnect cable connectors (10, 11, 12, 13) on
the right side in the cab and ground (9) at rear
side in the cab.
: 13 mm
10
11
12
13
6. Remove washer vinyl hose (14) at rear side in the

cab. W178-02-01-014
14
W178-02-01-015
16
7. Remove cap (15) from duct cover (17) with a
screwdriver. Remove screw (16) with a screw- 17
driver then remove duct cover (17).
15
W178-02-01-016
8. Remove screw (18) and bolt (21) then remove

duct (19, 20).
: 17 mm 18
Mating Surface
19
W178-02-01-017
20 21
W2-1-2
CAUTION: Cab weight: 290 kg (640 lb) Lifting Point
9. Remove cab mounting bolts (23) and nut (24).

: 17 mm
: 24 mm
: 8 mm
W178-02-01-018
23
24
W157-02-01-010
10. Lift the cab off.
W157-02-01-001
W2-1-3
Installation
CAUTION: Cab weight: 290 kg (640 lb)
1. Lift the cab.
W157-02-01-001
2. Install cab mounting bolts (23) and nuts (24). 23

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
: 24 mm
: 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 24
W157-02-01-010
6
3. Install duct (8) to the rear console of the cab with
clips (7) (2 used). Install filter (6) into duct (8).
7
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 Ibf⋅ft)
W1F3-02-01-002
4. Install harness connectors (10, 11, 12, 13) at the

right side of the cab and install ground connector
(9) at rear side in the cab.
: 13 mm 9
: 20 N⋅m (2.0 kgf⋅m, 15 Ibf⋅ft)
10
11
12
13
W178-02-01-014
W2-1-4
5. Connect washer vinyl hose (14) at the rear of the
cab inside.
14
6. While aligning the mounting hole for duct (5), W178-02-01-015
press it to install the hose into the hole.
4
5
7. Install rear beck (3) with bolt (4).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
W178-02-01-012
8. Install duct (20) with bolt (21). Install duct (19) into
duct (20) and secure them with bolts (18).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
18
Mating Surface
19
W178-02-01-017
20 21
W2-1-5
9. Install duct cover (17) with screws (16). Install
caps (15) onto duct cover (17).
16
17
15
W178-02-01-016
10. Install seat (1) with nuts (2).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2
1
W1F3-02-01-001
W2-1-6
DIMENSIONS OF THE CAB GLASS
Chamfer
A
Unit: mm Here
R2
67 303.5 Chamfer along the
11 Periphery unless
Otherwise Specified
R98 R35
4-φ13 0 -1
Section A R3018
W178-02-01-019
405 30 Chamfer Both
Sides
375
238 51 612
R118
(5 mm)
343.5 148.5
196
100
50
R70
370.5
W178-02-01-006
B
Along the Along the W178-02-01-002
Periphery Periphery
c1 c1
14
733
R58
R58
R11508
Section B W178-02-01-019
R1808
882.5 997
(4 mm)
R308 R1898
R258
100
150
943
W178-02-01-007
W2-1-7
Unit: mm
Chamfer Here
Chamfer Here
85.4
Charmfer Slightly
343.3 213 unless the periphery
Polish Chamfered
R105
R72 R10
R105
(4 mm)
Chamfer Slightly unless the
Periphery Polish Chamfered 39.5 D
733
733
C R2465
2-φ12.2 +0.5-0
(4 mm) Section C and D 6.754°

40
W178-02-01-019
Polish Chamfer
Both Sides
289.5
3-R4 50
2-R4
86.9 50 50
556.3
W178-02-01-011 50
423
W178-02-01-008
366.1 104.5
R12 R95
(5 mm) Chamfer along

982.7 the Periphery
W178-02-01-004
R2002
872
R123
R5 for 3 Places 38.2

R14
364.7 51
R2475 470.6
Chamfer along W178-02-01-009
(5 mm)
the Periphery
R115
888.58
W178-02-01-010
W2-1-8
Remove Cab Glass
Procedures to remove left-hand cab glass, lower
glass of the door and upper front glass
Mounting Rubber Section
Mounting Rubber Glass

CAUTION: When removing broken or
cracked glass beware of the danger of glass
shards that may cause serious injury.
Before removing, gummed tape or something
like should be used to paste the broken or
cracked glass ready to reinforce them so as Cab
to prevent hurt from occurring. Be sure to Seal Rubber
remove glass pieces away.
Take protective measures before removing.
Reinforce broken or cracked glass with
gummed tape to assist in safe removal. W178-02-01-022
W178-02-01-004
1. Insert bamboo spatula into position A in mounting

rubber to pry the mounting rubber apart along all A
periphery. It is easier to remove glass when air is
entered between cab and mounting rubber.
2. Tap glass from the side in cab by palm of the hand
to take the glass off. Two men are required to do
the work.
IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special Cab
bonding agent. The cab glass may
Seal Rubber
fall if the special bonding agent is
not used. The cab glass assembly
cannot be replaced individually. Be
sure to change the cab glass as an
W178-02-01-022
assembly.
The upper front glass is
arched-fringed. If this glass needs to
be replaced, contact with the
nearest HITACHI dealers to replace
it as an assembly.
W2-1-9
Procedure to Remove Right-Hand Cab Glass Mounting Rubber Section
Cab Inside
1. Insert a bamboo spatula into position A in Glass
Mounting Rubber
mounting rubber to pry the mounting rubber apart
along all periphery. It is easier to remove the glass
A
when air is entered between cab and mounting
rubber.
Cab

W216-02-01-005
the work.
W178-02-01-002
Glass
Mounting Rubber
Procedure to Remove Rear Side Cab Glass

Cab Inside Stopper
1. Remove stopper (groove rubber) with a screw-
(Groove Rubber)
driver.
A
A
2. Insert a bamboo spatula into position A in Cab
mounting rubber to pry the mounting rubber apart
along all periphery. W216-02-01-003

the work.
W178-02-01-005
W2-1-10
Left-Hand Cab Glass
Cab Glass Installation Procedure
Procedure for installing left-hand cab glass, lower
glass of the door and upper front glass
A
1. Install the seal rubber on the left-hand cab glass CSE Braid
and lower glass of the door.
Section A
Seal Rubber
Put Connect End in Center

of Glass Edge and Then
adhere It
W178-02-01-021
Lower Glass Of Door

50
5
W178-02-01-023 A
CSE Braid
Seal Rubber
10 10
2. When the mounting rubber is already on the glass, W178-02-01-020
pull and fasten the mounting rubber onto the Mounting Rubber Section
mounting face of cab.
IMPORTANT: Be sure to install the cab glass and

mounting rubber using the special
bonding agent. The cab glass may
fall if the special bonding agent is
not used. The cab glass assembly
cannot be replaced individually. Be
sure to change the cab glass as an
Cab
assembly.
The upper front glass is arched- Seal Rubber
fringed. If this glass needs to be re-
placed, replaced it as an assembly.
W178-02-01-022
W178-02-01-004
W2-1-11
Procedure for Installing Right-Hand Cab Glass Mounting Rubber Section
1. Install the mounting rubber into the surrounding of Glass

Mounting Rubber
cab glass. Bond the connectors of mounting
rubber with the bonding agent (Cemedine 366
Standard or equivalent).
Cab
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little extra, install
by pressing with hands.
W216-02-01-005
2. Put and fasten the mounting rubber on the

mounting face of cab after installing rubber.
W178-02-01-002
Procedure for Installing Rear Cab Glass

1. Insert mounting rubber around the cab glass. In-
stall the connectors or mounting rubber with the Glass
Mounting
bonding agent (Cemedine 366 Standard or Rubber
equivalent).
Stopper
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little extra, install
by pressing with hands.
Cab
2. After installing the glass assembly on the cab,
insert the stopper into rubber. W216-02-01-003
IMPORTANT: The rear side glass is arched-fringed.

If this glass needs to be replaced,
contact with the nearest HITACHI
dealers to replace it as an assembly.
W178-02-01-005
W2-1-12
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTER-
WEIGHT
Removal
FLENO LINKBOLT 1
CAUTION: Counterweight Weight: Mounting Holes
3770 kg (8320 lb) 2
1. Remove caps (1) from upper counterweight (2).

Install FLENO LINKBOLTs to counterweight (2).
NOTE: FLENO LINKBOLTs specification
(B-36: M36, Pitch 4.0)
2. Lift and hold counterweight (2).
3. Remove counterweight mounting bolts (4) (4 3

used).
: 50 mm 4
IMPORTANT: The wire of combination lamp has

been connected to back of coun- W1F3-02-02-001
terweight (2). Before remove coun-

terweight (2), disconnect the wire.
CAUTION: When disconnecting wire take
care not to get hands caught between coun-
terweight (2) and frame.
2
4. Lift and dislocate counterweight (2) to backward
approx. 200mm (7.9 in). Remove connectors of
both side combination lamps.
3
5. Lift counterweight (2) off the frame.
W178-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight Weight:
3770 kg (8320 lb)
1. Lift and place counterweight (2) on the frame

leaving 200 mm (7.9 in) between frame backside
and counterweight (2).
2. Connect connectors of both side combination

lamps.
2
3. Lift and place counterweight (2) on mounting po- 4
3
sition.
W178-02-02-003
4. Temporarily tighten counterweight (2) onto the
frame with washers (3) (4 used) and bolts (4) (4
used).
5. Tighten counterweight mounting bolts (4) (4

used) with a power wrench and toque wrench.
: 50 mm
: 2600 N⋅m (265 kgf⋅m, 1920 Ibf⋅ft)
6. Remove FLENO LINKBOLTs then install caps

(1).
Toque Wrench
Power Wrench W178-02-02-004
W178-02-02-001
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
CAUTION: Be sure to bleed air from

hydraulic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil
Tank” on page W1-4-1.)
Removal
CAUTION: Counterweight weight: 3770 kg Counterweight

(8320 Ib)
1. Remove the counterweight.

(Refer to “Remove and Install Counterweight”
group.)
: 50 mm
CAUTION: Front attachment assembly W178-02-02-003
weight:
Monoblock boom: 2680 kg (5910 Ib) Monoblock Boom
2-Piece boom: 3220 kg (7100 Ib)
2. Remove the front attachment assembly.

(Refer to “Remove and Install Front Attachment”
group on page W4-1-2.)
: 27 mm, 30 mm, 36 mm
W1F3-04-01-002
2-Piece Boom
W1F3-04-01-001
W2-3-1
CAUTION: Center joint weight: 93 kg Stopper

(210 Ib)
3. Remove the stopper and hoses.

(Refer to “Remove and Install Center Joint” Center Joint
group.)
: 24 mm, 36 mm
W1F3-03-03-003
CAUTION: Upperstructure weight: 4350 kg

(9600 Ib)
IMPORTANT: Make sure rear wire ropes not to

touch engine.
4. Attach wire ropes to the rear (counterweight
bracket) of the frame and boom bracket.
NOTE: It is easy to adjust the wire ropes length Rear
and level the frame if a chain block is
W105-02-03-004
used.
Front
5. Put mating marks on the upperstructure and the W105-02-03-005
outer race of the swing bearing.
Loosen the mounting bolt of the swing bearing
and remove it.
: 27 mm
NOTE: Chain block shall be used to adjust and
level the frame, then lift it slightly off the
undercarriage.
W1F3-03-01-002
Bolt
W2-3-2
Installation
CAUTION: Upperstructure weight: 4350 kg

(10980 Ib)
1. Fasten wire ropes to the main frame. Level the

main frame by adjusting the chain block. Lift and
install the main frame to the undercarriage.
NOTE: As for lifting method, refer to Removal
section.
2. Align the mating mark on the outer race of the

upperstructure and the swing bearing.
Install the mounting bolt to the swing bearing and
tighten it temporarily. Remove wire ropes and
tighten the mounting bolts to the swing bearing to
specification.
Upperstructure Side:
: 27 mm W1F3-03-01-002
: 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
Undercarriage Side: Bolt
: 30 mm Bolt
: 500 N⋅m (51 kgf⋅m, 370 Ibf⋅ft)
Stopper
3. Connect the hoses (15 used) to the center joint.

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
Center Joint
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
4. Apply LOCTITE#262 to the bolts (5 used). Install

W1F3-03-03-003
the stopper with them.
: 24 mm
: 265 N⋅m (27 kgf⋅m, 195 Ibf⋅ft)
CAUTION: Counterweight weight: 3770 kg Counterweight

(8320 Ib)
5. Install counterweight (6).

(Refer to “Remove and Install Counterweight”
group.)
: 50 mm
: 2600 N⋅m (265 kgf⋅m, 1920 Ibf⋅ft)
W178-02-02-003
W2-3-3
CAUTION: Front attachment assembly Monoblock Boom

weight:
Monoblock boom: 2680 kg (5910 Ib)
2-Piece boom: 3220 kg (7100 Ib)
6. Install front attachment assembly. Then, fill with

hydraulic oil.
(Refer to “Remove and Install Front Attachment”
group on page W4-1-2.)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft) W1F3-04-01-002
: 30 mm
: 540 N⋅m (55 kgf⋅m, 400 Ibf⋅ft) 2-Piece Boom
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
7. Start the engine and set the front attachment in

posture for checking hydraulic oil level in its tank.
Inspect the hydraulic oil level and check if any oil
leakage is available.
W1F3-04-01-001
W2-3-4
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

Removal Steering Pump Pilot Pump

1. Remove the cover, bracket and engine cover of
the pump device upper side.
2. Disconnect all hoses, pipings and wire harness

connectors from the pump device.
Upper side
• Hoses (5 used) Pilot Filter
• Regulator pilot hoses (4 used)
Pump Device
Center side
• Main hoses (2 used)
• Pilot pump hose (3 used)
• Wire Harness Connector (1 used)
Lower side Steering
Filter
• Suction pipe (1 used)
• Wire Harness Connectors (5 used)
• Pilot hose (1 used)
• Pilot pump hoses (2 used)
CAUTION: Pump Device Weight:

MCBB-07-026
95 kg (210 lb)
3. Attach a nylon sling to the pump device and hold it
by crane.
4. Remove pump device mounting socket bolts (4

used). Hoist the pump device and remove it.
W2-4-1
Installation
CAUTION: Pump Device Weight:

95 kg (210 lb) Steering Pump Pilot Pump
1. Attach a nylon sling to the pump device and hoist
it by crane. Install the pump device to the pump
cover with socket bolts (4 used).
: 14 mm
: 200 to 270 N⋅m
(20 to 27 kgf⋅m, 145 to 195 Ibf⋅ft)
Pilot Filter
2. Connect all hoses and pipings.
Pump Device
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18.0 kgf⋅m, 130 Ibf⋅ft)
Steering
Filter
3. Connect wire harness connectors.
IMPORTANT: Bleed the air from the pump. (Refer

to W1-1-2)
Be sure to check hydraulic oil level
and any oil leaks after assembling.
: 36 mm MCBB-07-026
: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
W2-4-2
(Blank)
W2-4-3
DISASSEMBLE MAIN PUMP
22
21
18 20
19
17
16
15
14
13
12
11
23
10 24
9
8
7
6
5
4 25
3
39
2
1 26 38
37
36
27
35
40
34 41
33 42
30 32 43
29 31 44
28 45
46
47
51
52 50 48
53
63
54 49
62
61
60
64
55
56 59
65
57 66
58 67
68
69
71 70
W1F3-02-04-001
W2-4-4
1- Socket Bolt (2 Used) 19 - Servo Piston (2 Used) 37 - Needle Bearing 55 - Spring Pin
2- Steering Pump 20 - O-Ring (2 Used) 38 - Gear 56 - Pin
3- Cover 21 - Backup Ring (2 Used) 39 - O-Ring 57 - O-Ring (2 Used)
4- O-Ring 22 - Stopper (2 Used) 40 - Socket Bolt (4 Used) 58 - Plug (2 Used)
5- Retaining Ring (2 Used) 23 - O-Ring (2 Used) 41 - Cover 59 - O-Ring
6- Spacer (2 Used) 24 - Plug (2 Used) 42 - Oil Seal 60 - Spring Pin (2 Used)
7- Bearing (2 Used) 25 - O-Ring (2 Used) 43 - O-Ring 61 - Pin
8- Spacer (2 Used) 26 - Plug (8 Used) 44 - Shaft 62 - Socket Bolt (4 Used)
9- Shaft 27 - Socket Bolt (4 Used) 45 - Housing 63 - Cover
10 - Cover 28 - Swash Plate (2 Used) 46 - O-Ring (18 Used) 64 - Socket Bolt (2 Used)
11 - Nut (2 Used) 29 - Bushing (2 Used) 47 - O-Ring (2 Used) 65 - Cover
12 - Adjusting Screw (2 Used) 30 - Shoe Plate (2 Used) 48 - Valve Plate 66 - O-Ring
13 - Spring Pin (2 Used) 31 - Plunger (18 Used) 49 - Needle Bearing 67 - PTO Gear Case
14 - Stopper (2 Used) 32 - Retainer (2 Used) 50 - Eye Bolt 68 - Socket Bolt (4 Used)
15 - Backup Ring (2 Used) 33 - Spherical Bushing (2 Used) 51 - Nut (2 Used) 69 - O-Ring
16 - O-Ring (2 Used) 34 - Spring (18 Used) 52 - Adjusting Screw (2 Used) 70 - Pilot Pump
17 - Housing 35 - Cylinder Block (2 Used) 53 - Plug (8 Used) 71 - Socket Bolt (2 Used)
18 - Tilt Pin (2 Used) 36 - Valve Plate 54 - Valve Cover
W2-4-5
22
21
18 20
19
17
16
15
14
13
12
11
23
10 24
9
8
7
6
5
4 25
3
39
2
1 26 38
37
36
27
35
40
34 41
33 42
30 32 43
29 31 44
28 45
46
47
51
52 50 48
53
63
54 49
62
61
60
64
55
56 59
65
57 66
58 67
68
69
71 70
W1F3-02-04-001
W2-4-6
Disassemble Main Pump
• Be sure to read “Precautions for Disassembly and IMPORTANT: Take care that valve plate (36) and
Assembly Work” thoroughly on page W1-1-1 (48) may come off when parts
before starting the disassembly work. separated. Do not remove needle
• For removal of the regulator, refer to “Remove bearings (37) and (49) unless
Regulator”section. necessary. In case they are removed,
replace them with new ones.
IMPORTANT: Do not disassemble nut (11), 6. Separate housing (17), valve cover (54) and the
adjusting screw (12), nut (51) and housing (45) assemblies. Be sure to remove
adjusting screw (52) of main pump 1 O-rings (25) (2 used), (39), (43), (46) (18 used), spring
and 2. The set flow rate may be pins (55) (2 used) and (60) (2 used) when
changed. separating these assemblies.
1. Remove plugs (24) (2 used) and O-rings (23) (2
used) to drain hydraulic oil from the main pump. 7. Remove valve plate (36) and pin (56) from valve
: 36 mm cover (54).
2. Remove socket bolts (68) (4 used), remove the 8. Remove cylinder block (35) from housing (17) and
PTO gear case (67) assembly and o-ring (59) the housing (45) assembly. Springs (34) (9 used),
housing from valve cover (54). spherical bushing (33), retainer (32) and plungers
: 8 mm (31) (9 used) will be removed together with
cylinder block (35).
3. Remove socket bolts (1) (2 used), remove NOTE: Slowly remove cylinder block (35) while
steering pump (2), cover (3) and O-ring (4) from turning it to left and right softly by both
cover (10). hands.
: 8 mm
9. Remove retainer (32) from the cylinder block (35)
4. Remove eye bolt (50) from valve cover (54). assembly. Plungers (31) (9 used) will be removed
together with retainer (32).
CAUTION: Pump Device Weighet:
95 kg (210 lb) 10. Remove plungers (31) (9 used) from retainer (32).
IMPORTANT: Take care not to dent or scratch the
contact surface of regulator. 11. Remove spherical bushing (33) from cylinder
After installing swash plate (28), block (35), then remove springs (34) (9 used).
check if it moves smoothly.
5. Attach a nylon sling to the main pump. Turn the 12. Tap cover (10) with a plastic hammer to remove it.
main pump over with the regulator mounting side Remove O-rings (46) (2 used) and spring pin (13)
facing downward. Remove socket bolts (27) (4 as well.
used) and (62) (4 used).
: 14 mm 13. Remove swash plate (28) and shoe plate (30)
from housing (17).
W2-4-7
22
21
18 20
19
17
16
15
14
10
9
8
7
6
5
45
48
54
61
W1F3-02-04-001
W2-4-8
IMPORTANT: As LOCTITE (middle strength) has
been applied on the contacting part
between servo piston (19) and tilt
pin (18), do not disassemble them
unless required. When
disassembling them, do not damage
servo piston (19).
14. Remove stoppers (14), (22), backup rings (15),
(21), O-rings (16) and (20) from housing (17) to
remove servo piston (19) and tilt pin (18).
15. Tap the end of shaft (9) with a plastic hammer to

remove it from cover (10).
16. Remove retaining ring (5) from shaft (9) to remove

spacer (6).
17. Remove bearing (7) from shaft (9) with a press to

remove spacer (8).
18. Remove valve plate (48) and pin (61) from valve
cover (54).
19. Disassemble the housing (45) assembly

according to the same procedure as 8 to 17.
W2-4-9
ASSEMBLE MAIN PUMP
63 33 45 28 30 29 39 46 52 51 22 21 20 17 18 19 14 16 15 10 11
12
13
4
3
40
1
43 5
44 42
9
41
27
62
47 32 31 34 35 36 56 55 37 38 54 49 61 47 60 48 8 25 7 6
T1F3-03-01-003
1- Socket Bolt (2 Used) 19 - Servo Piston (2 Used) 37 - Needle Bearing 55 - Spring Pin
2- *Steering Pump 20 - O-Ring (2 Used) 38 - Gear 56 - Pin
3- Cover 21 - Backup Ring (2 Used) 39 - O-Ring 57 - *O-Ring (2 Used)
4- O-Ring 22 - Stopper (2 Used) 40 - Socket Bolt (4 Used) 58 - *Plug (2 Used)
5- Retaining Ring (2 Used) 23 - *O-Ring (2 Used) 41 - Cover 59 - *O-Ring
6- Spacer (2 Used) 24 - *Plug (2 Used) 42 - Oil Seal 60 - Spring Pin (2 Used)
7- Bearing (2 Used) 25 - O-Ring (2 Used) 43 - O-Ring 61 - Pin
8- Spacer (2 Used) 26 - *Plug (8 Used) 44 - Shaft 62 - Socket Bolt (4 Used)
9- Shaft 27 - Socket Bolt (4 Used) 45 - Housing 63 - Cover
10 - Cover 28 - Swash Plate (2 Used) 46 - O-Ring (18 Used) 64 - *Socket Bolt (2 Used)
11 - Nut (2 Used) 29 - Bushing (2 Used) 47 - O-Ring (2 Used) 65 - *Cover
12 - Adjusting Screw (2 Used) 30 - Shoe Plate (2 Used) 48 - Valve Plate 66 - *O-Ring
13 - Spring Pin (2 Used) 31 - Plunger (18 Used) 49 - Needle Bearing 67 - *PTO Gear Case
14 - Stopper (2 Used) 32 - Retainer (2 Used) 50 - *Eye Bolt 68 - *Socket Bolt (4 Used)
15 - Backup Ring (2 Used) 33 - Spherical Bushing (2 Used) 51 - Nut (2 Used) 69 - *O-Ring
16 - O-Ring (2 Used) 34 - Spring (18 Used) 52 - Adjusting Screw (2 Used) 70 - *Pilot Pump
17 - Housing 35 - Cylinder Block (2 Used) 53 - Plug (8 Used) 71 - *Socket Bolt (2 Used)
18 - Tilt Pin (2 Used) 36 - Valve Plate 54 - Valve Cover
NOTE: As for the components with * mark, refer to

W2-3-4.
W2-4-10
Assemble Main Pump
IMPORTANT: Apply LOCTITE (middle strength) to 8. Install O-ring (43) and oil seal (42) onto cover (41).
the matching part between servo Install cover (41) onto cover (63) with socket bolts
piston (19) and tilt pin (18). (40) (4 used).
1. Install tilt pin (18), servo piston (19), O-rings (16), : 5 mm
(20), backup rings (15), (21), stopper (14) and : 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
(22) into both housing (17) and housing (45).
9. Install springs (34) (9 used) and spherical bushing
2. Install spring pin (13) and O-ring (25) onto covers
(33) into cylinder block (35).
(10) and (63). Install them onto housings (17) and
(45).
10. Install plungers (31) (9 used) into retainer (32),
and install retainer (32) into cylinder block (35).
3. Tap the covers (10) and (63) with a plastic
hammer onto housings (17) and (45).
11. Aligning the splines, then install the cylinder block
(35) assembly onto both shaft (9) and shaft (44).
IMPORTANT: Take care not to dent or scratch the
contact surface of regulator.
After installing swash plate (28), IMPORTANT: Apply grease to the back of valve
check if it moves smoothly. plate (48) to prevent it from coming
4. Place housings (17) and (45) on a workbench off.
with their regulator mounting side facing down. 12. Install pin (61), valve plate (48), O-rings (46) (6
Install swash plate (28) with shoe plate (30) onto used), O-ring (47) and spring pin (60) onto valve
tilt pin (18). cover (54). Install valve cover (54) onto housing
(17) with socket bolts (27) (4 used).
5. Install spacer (8) onto shaft (9) and (44), then Temporarily secure socket bolts (27) (4 used) so
install bearing (7) with a press. that shaft (44) can be turned by hand.
: 14 mm
6. Install spacer (6) and retaining ring (5) onto each
shaft (9) and shaft (44). Install each shaft (9) and
(44) into covers (10) and (63) with a press.
7. Install O-rings (4) onto cover (3). Install cover (3)

and steering pump (2) with socket bolts (1) (2
used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
W2-4-11
45 39 46 17 18
44
9
27
62
38 54
T1F3-03-01-003
NOTE: As for components (59), (67) and (68), refer

to W2-3-4.
W2-4-12
13. Install gear (38) into shaft (9).
14. Install O-rings (46) (3 used) and O-rings (39) onto

valve cover (54). Connect the housing (17)
assembly and the housing (45) assembly with
socket bolts (62) (4 used).
Temporarily tighten socket bolts (62) (4 used) and
align the spline part with that of gear (38) while
turning shaft (44) by hand to connect them.
: 14 mm
15. Tighten socket bolts (27) (4 used) and (62) (4

used).
: 14 mm
: 240 N⋅m (24 kgf⋅m, 170 Ibf⋅ft)
16. Install O-ring (59) and the PTO gear case (67)
assembly with socket bolts (68) (4 used) onto
valve cover (54).
: 8 mm
: 33 N⋅m (3.5 kgf⋅m, 24.5 Ibf⋅ft)
IMPORTANT: When installing regulator, be sure to

insert the feedback lever of regulator
into tilt pin (18).
W2-4-13
MAINTENANCE STANDARD
31 35
1. Clearance between plunger (31) diameter (d) and
cylinder block (35) bore (D).
D-d Unit: mm (in)

d D
Standard Allowable Limit
0.028 (0.017) 0.056 (0.002)
W117-02-02-009
34
2. Spring (34) free length (L).

Unit: mm (in)
31.3 (1.23) 30.2 (1.19)
L
W117-02-02-010
3. Clearance between plunger (31) and shoe (e) and

shoe thickness (t).
e Unit: mm (in) 31
0 to 0.1 Shoe
0.3(0.012)
(0 to 0.004)
t Unit: mm (in)
e
Standard Allowable Limit t
3.9 (0.154) 3.7 (0.146)
W117-02-02-011
Stand 32 33
4. Distance between retainer (32) bottom and
spherical bushing (33) top.
H-h Unit: mm (in) h H
19.0 (0.75) 18.2 (0.72) W117-02-02-012
W2-4-14
(Blank)
W2-4-15
DISASSEMBLE REGULATOR
(MAIN PUMP 2 SIDE)
12
11
10
9
8
7
D
6 B 21
5 F 22
23
4 24
3
2 25
1 20 26
19 A 31
G 30
18 E
C 29
17
16 28
15
14
13 27
32
34
33
47
46
35
36 45
37
44
43 48
42
39 41 49
40
38
D 50
E
67
51
66
52
53
64 59 54
65
A 58
B 57
C 62 56
63 55
60 W1F3-02-04-006
61
W2-4-16
1- Pin 19 - Spool 36 - O-Ring 52 - Supporting Plug

2- Sleeve 20 - Pin 37 - O-Ring (2 Used) 53 - O-Ring
3- O-Ring 21 - Lever 38 - Socket Bolt (2 Used) 54 - Retaining Ring
4- O-Ring 22 - Feedback Lever 39 - Socket Bolt (2 Used) 55 - Retaining Ring
5- Sleeve 23 - Pin 40 - O-Ring 56 - O-Ring
6- Compensating Piston 24 - Pin 41 - Adjusting Screw 57 - Supporting Plug
7- Compensating Rod 25 - Lever 42 - Adjusting Screw 58 - Pin
8- Spring Seat 26 - Pin 43 - Nut 59 - Pin
9- Spring 27 - Pilot Piston 44 - O-Ring 60 - O-Ring
10 - Spring 28 - Spring Seat 45 - Cover 61 - O-Ring (7 Used)
11 - Stopper 29 - Spring 46 - Socket Bolt (4 Used) 62 - O-Ring (2 Used)
12 - O-Ring 30 - Stopper 47 - Nut 63 - O-Ring
13 - Retaining Ring 31 - O-Ring 48 - Nut 64 - O-Ring
14 - Spring Seat 32 - Socket Bolt (4 Used) 49 - Adjusting Screw 65 - Socket Bolt (2 Used)
15 - Spring 33 - Cover 50 - Housing 66 - Socket Bolt (2 Used)
16 - Spring 34 - Solenoid Valve 51 - Pin 67 - Cover
17 - Retaining Ring 35 - O-Ring
18 - Sleeve
W2-4-17
12
11
10
9
8
7
D
6 B 21
5 F 22
23
4 24
3
2 25
1 20 26
19 A 31
G 30
18 E
C 29
17
16 28
15
14
13 27
32
34
33
47
46
35
36 45
37
44
43 48
42
39 41 49
40
38
D 50
E
67
51
66
52
F
G 53
59 54
64
65
A 58
B 57
C 62 56
63 55
60 W1F3-02-04-006
61
W2-4-18
Disassemble Regulator
(Main Pump 2 Side)
• Be sure to read “Precautions for Disassembly and 9. Remove socket bolts (46) (5 used) from cover
Assembly Work” thoroughly on page W1-1-1 (45) to remove cover (45), stopper (11), springs
before starting the disassembly work. (10) and (9), spring seat (8), stopper (30), spring
(29) and spring seat (28).
1. Remove socket bolts (38) (2 used) and (39) (2 : 5 mm
used) to remove the regulator from the main
pump. IMPORTANT: Do not remove pin (58) from
: 6 mm supporting plug (57). Make matching
marks between support plugs (52),
2. Remove solenoid valve (34) from housing (50). (57) and housing (50) to prevent
: 32 mm them from confusion.
10. Remove retaining rings (54) and (55) from
IMPORTANT: Do not remove adjusting screws (41), housing (50) to remove supporting plugs (52) and
(42), (49) and nuts (43), (47), (48). The (57) using puller bolts (M6).
flow rate setting of the pump will
change after removing. IMPORTANT: Do not remove pin (26) from lever
3. Remove socket bolts (32) (4 used) from cover (25).
(33), remove cover (33) from housing (50). 11. Remove lever (25) from housing (50) with a pairs
: 5 mm or tweezers etc. to remove pilot piston (27).
4. Remove O-ring (35), (36) and (37) (2 used) from IMPORTANT: In case pin (23) cannot be removed,
cover (33). remove sleeve (18) first to remove
pin (23) with making play for spool
5. Remove O-rings (60), (61) (7 used) and pin (59) (19).
from housing (50). 12. Insert a copper bar into the supporting plug (52)
hole to remove pin (23) from feedback lever (22).
6. Remove socket bolts (65) (2 used) and (66) (2 used) After that, remove feedback lever (22), sleeve (18),
from cover (67) to remove cover (67), spring (16) retaining ring (17) and spool (19).
and O-ring (63), (64) and (62) (2 used).
: 5 mm IMPORTANT: Do not remove pins (20) and (51)
from lever (21).
7. Remove pin (1), sleeve (2), O-rings (3) and (4), 13. Remove lever (21) with a pairs of tweezers etc.
sleeve (5) and compensating piston (6) from from housing (50) to remove compensating rod
housing (50). (7).
8. Remove retaining ring (13) from housing (50) to

remove spring seat (14) and spring (15).
W2-4-19
ASSEMBLE REGULATOR A
(MAIN PUMP 2 SIDE) B
52 53
54
51
55
56
57
A
50 24 23 25 27 28 29 30 45 T1F3-03-01-006
Section B-B
46
48
49
63 38 60 58 22 26 39 31
T1F3-03-01-007
Section A-A 67 16 64 14 15 17 19 18 21 8 9 10 44 45 47
13
41
66
43
3 42
65
1 2 4 5 6 7 20 59 40 12 11
T1F3-03-01-008
W2-4-20
1- Pin 19 - Spool 36 - *O-Ring 52 - Supporting Plug

2- Sleeve 20 - Pin 37 - *O-Ring (3 Used) 53 - O-Ring
3- O-Ring 21 - Lever 38 - Socket Bolt (2 Used) 54 - Retaining Ring
4- O-Ring 22 - Feedback Lever 39 - Socket Bolt (2 Used) 55 - Retaining Ring
5- Sleeve 23 - Pin 40 - O-Ring 56 - O-Ring
6- Compensating Piston 24 - Pin 41 - Adjusting Screw 57 - Supporting Plug
7- Compensating Rod 25 - Lever 42 - Adjusting Screw 58 - Pin
8- Spring Seat 26 - Pin 43 - Nut 59 - Pin
9- Spring 27 - Pilot Piston 44 - O-Ring 60 - O-Ring
10 - Spring 28 - Spring Seat 45 - Cover 61 - *O-Ring (7 Used)
11 - Stopper 29 - Spring 46 - Socket Bolt (4 Used) 62 - O-Ring (2 Used)
12 - O-Ring 30 - Stopper 47 - Nut 63 - O-Ring (7 Used)
13 - Retaining Ring 31 - O-Ring 48 - Nut 64 - O-Ring
14 - Spring Seat 32 - Socket Bolt (4 Used) 49 - Adjusting Screw 65 - Socket Bolt (2 Used)
15 - Spring 33 - Cover 50 - Housing 66 - Socket Bolt (2 Used)
16 - Spring 34 - Solenoid Valve 51 - Pin 67 - Cover
17 - Retaining Ring 35 - *O-Ring
18 - Sleeve
NOTE: As for parts with * mark, refer to W2-3-16.
W2-4-21
52 53
54
51
55
56
57
A
50 24 23 25 27 28 29 30 45 T1F3-03-01-006
Section B-B
46
48
49
63 38 60 58 22 26 39 31
T1F3-03-01-007
Section A-A 67 16 64 14 15 17 19 18 21 8 9 10 44 45 47
13
41
66
43
3 42
65
1 2 4 5 6 7 20 59 40 12 11
T1F3-03-01-008
NOTE: As for parts (51) with * mark, refer to W2-3-16.
W2-4-22
Assemble Regulator
(Main Pump 2 Side)
1. Insert compensating rod (7) and lever (21) into IMPORTANT: Supporting plug (57) and (52) can be
housing (50). installed in either hole. Be sure to
install them according to the
2. Align pin (51) of lever (21) with the pin hole in matching mark made when
housing (50) inside. Align pin (20) with stepped disassembling and never confuse
joint portion of compensating rod (7) to install them, otherwise the pump control
lever (21) into housing (50). will be out of order.
8. Align pin (58) of supporting plug (57) with the pin
3. Install retaining ring (17) to sleeve (18) and insert hole of lever (25) to insert pin (58) and install
sleeve (18) and spool (19) into housing (50). retaining ring (55).
IMPORTANT: Check spool (19) if it should move 9. Insert supporting plug (52) into housing (50) and
smoothly before installing feedback install retaining ring (54).
lever (22). Be sure to install spool
(19) and feedback lever (22) in the 10. Install O-ring (31) onto stopper (30).
correct direction. Do not make any
mistake while doing this procedure. 11. Install spring seat (28), spring (29) and stopper
4. Align the pin hole in feedback lever (22) with the (30) to housing (50).
pin hole in spool (19), and tap pin (23) from the
mounting hole of supporting plug (52) with a 12. Install O-ring (12) onto stopper (11).
plastic hammer.
13. Place O-ring (44) in housing (50). After that, insert
spring seat (8), springs (9) and (10) and stopper
5. Insert pilot piston (27) and lever (25) into housing (11) into housing (50). Install cover (45) to housing
(50). (50) with socket bolts (46) (4 used).
: 5 mm
IMPORTANT: Check pilot piston (27) if it should : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft)
move smoothly before installing
lever (25). 14. Install spring (15), spring seat (14) and retaining
6. Align pin (26) of lever (25) with stepped joint ring (13) onto spool (19).
portion of pilot piston (27) to install lever (25).
15. Place ring (4) to sleeve (5) and install sleeve (5),
7. Install O-rings (53) and (56) to supporting plugs compensating piston (6), O-ring (3), sleeve (2)
(52) and (57) respectively. and pin (1) into housing (50).
W2-4-23
T1F3-03-01-006
50
Section B-B
63 38 60 39
T1F3-03-01-007
Section A-A
66
65
T1F3-03-01-008
NOTE: As for parts (62) and (61), refer to W2-3-16.
W2-4-24
16. Install spring (16), O-rings (64), (63) and (62) (2
used) into housing (50) and install cover (67) to
housing (50) with socket bolts (66) (2 used) and
(65) (2 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft)
17. Install O-rings (60) and (61) (7 used) to housing

(50).
18. Install the regulator onto the main pump with

socket bolts (38) (2 used) and (39) (2 used).
: 6 mm
: 29 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
W2-4-25
DISASSEMBLE REGULATOR 12
(MAIN PUMP 1 SIDE) 11
10
9
8
7
6 D 21
B
5 22
F 23
4
3 24
2 25
1 20
19 26
A 31
18 G 30
E
17 C 29
16
15 28
14
27
13
32
33
34
58
57
38
39
40 56
41 35
42 36
43 37 55
44 54
53
52 59
50 60
51
49
46
45 47
48
61
D
E
62
63
F
75 G 64
69 65
A
68
B 67
C
73 70 66
74 71
W1F3-02-04-007
72
W2-4-26
1- Pin 20 - Pin 39 - Stopper 2 58 - Nut

2- Sleeve 21 - Lever 40 - Adjusting Screw 59 - Nut
3- O-Ring 22 - Feedback Lever 41 - O-Ring 60 - Adjusting Screw
4- O-Ring 23 - Pin 42 - Socket Bolt (2 Used) 61 - Housing
5- Sleeve 24 - Pin 43 - Cover 62 - Pin
6- Compensating Piston 25 - Lever 44 - Nut 63 - Supporting Plug
7- Compensating Rod 26 - Pin 45 - Socket Bolt (4 Used) 64 - O-Ring
8- Spring Seat 27 - Pilot Piston 46 - Cover 65 - Retaining Ring
9- Spring 28 - Spring Seat 47 - O-Ring (3 Used) 66 - Retaining Ring
10 - Spring 29 - Spring 48 - O-Ring 67 - O-Ring
11 - Stopper 30 - Stopper 49 - Socket Bolt (2 Used) 68 - Supporting Plug
12 - O-Ring 31 - O-Ring 50 - Socket Bolt (2 Used) 69 - Pin
13 - Retaining Ring 32 - Block 51 - O-Ring 70 - Pin
14 - Spring Seat 33 - Socket Bolt (2 Used) 52 - Adjusting Screw 71 - O-Ring
15 - Spring 34 - Socket Bolt (2 Used) 53 - Adjusting Screw 72 - O-Ring (7 Used)
16 - Spring 35 - Stopper 1 54 - Nut 73 - O-Ring (2 Used)
17 - Retaining Ring 36 - Piston 1 55 - O-Ring 74 - O-Ring
18 - Sleeve 37 - Piston 2 56 - Cover 75 - O-Ring
19 - Spool 38 - O-Ring 57 - Socket Bolt (4 Used)
W2-4-27
12
11
10
9
8
7
6 D 21
B
5 22
4
F 23
3 24
2 25
1 20
19 26
A 31
18 G 30
E
17 C 29
16
15 28
14 27
13
32
33
34
58
57
38
39
40 56
41 35
42 36
43 37 55
44 54
53
52 59
50 60
51
49
46
45 47
48
61
D
E
62
63
F
75 G 64
69 65
A
68
B 67
C
73 70 66
74 71
W1F3-02-04-007
72
W2-4-28
Disassemble Regulator
(Main Pump 1 Side)
• Be sure to read “Precautions for Disassembly and 9. Remove pin (1), sleeve (2), O-rings (3) and (4),
Assembly Work” thoroughly on page W1-1-1 sleeve (5) and compensating piston (6) from
before starting the disassembly work. housing (61).
1. Remove socket bolts (49) (2 used) and (50) (2 10. Remove retaining ring (13) from housing (61) to
used) to remove the regulator from the main remove spring seat (14) and spring (15).
pump.
: 6 mm 11. Remove socket bolts (57) (4 used) from cover
(56) to remove cover (56), stopper (11), springs
IMPORTANT: Do not remove adjusting screws (52), (10) and (9), spring seat (8), stopper (30), spring
(53), (60) and nuts (54), (58), (59). The (29) and spring seat (28).
flow rate setting of the pump will : 5 mm
change after removing.
2. Remove socket bolts (45) (4 used) from cover IMPORTANT: Do not remove pin (69) from
(46) to remove covers (46). supporting plug (68). Make matching
: 5 mm marks between support plugs (63),
(68) and housing (61) to prevent
3. Remove O-ring (47) (3 used) and (48) from cover them from confusion.
(46). 12. Remove retaining rings (65) and (66) from
housing (61) to remove supporting plugs (63) and
4. Remove O-rings (71), (72) (7 used) and pin (70) (68) using forcing bolts (M6).
from housing (61).
IMPORTANT: Do not remove pin (26) from lever
5. Remove socket bolts (34) (2 used) and (33) (2 (25).
used) from block (32) to remove block (32), spring 13. Remove lever (25) from housing (61) with a pairs
(16) and O-ring (75), (74) and (73) (2 used). of tweezers etc. to remove pilot piston (27).
: 5 mm
IMPORTANT: In case pin (23) cannot be removed,
6. Remove socket bolts (42) (2 used) to remove remove sleeve (18) first to remove
cover (43) from block (32). pin (23) with making play for spool
: 5 mm (19).
14. Insert a copper bar into the supporting plug (63)
7. Press piston 1 (36) from block (32) and hole to remove pin (23) from feedback lever (22).
compensating rods (7) side to remove the stopper After that, remove feedback lever (22), sleeve
2 (39) assembly, piston (39) and stopper (35). (18), retaining ring (17) and spool (19).
8. Remove O-ring (41) and O-ring (38) from stopper

(39).
W2-4-29
7
D 21
B
F
20
A
G
E
C
61
D
E
62
F
G
A
B
C
W1F3-02-04-007
W2-4-30
IMPORTANT: Do not remove pins (20) and (62)

from lever (21).
15. Remove lever (21) with a pairs of tweezers etc.
from housing (61) to remove compensating rod
(7).
W2-4-31
63 64
65
66
67
68
A
41 38 32 35 61 24 23 25 27 28 29 30 T1F3-03-01-006
Section B-B
56
57
42
59
60
40
44
T1F3-03-01-004
43 39 37 36 74 49 71 69 22 26 50 31
Section A-A 16 75 14 15 17 19 18 21 8 9 10 55 51 56 58
62
13
52
3
54
34
53
33 1 2 4 5 6 7 20 70 12 11 T1F3-03-01-005
W2-4-32
1- Pin 20 - Pin 39 - Stopper 2 58 - Nut

2- Sleeve 21 - Lever 40 - Adjusting Screw 59 - Nut
3- O-Ring 22 - Feedback Lever 41 - O-Ring 60 - Adjusting Screw
4- O-Ring 23 - Pin 42 - Socket Bolt (2 Used) 61 - Housing
5- Sleeve 24 - Pin 43 - Cover 62 - Pin
6- Compensating Piston 25 - Lever 44 - Nut 63 - Supporting Plug
7- Compensating Rod 26 - Pin 45 - Socket Bolt (4 Used) 64 - O-Ring
8- Spring Seat 27 - Pilot Piston 46 - Cover 65 - Retaining Ring
9- Spring 28 - Spring Seat 47 - *O-Ring (3 Used) 66 - Retaining Ring
10 - Spring 29 - Spring 48 - *O-Ring 67 - O-Ring
11 - Stopper 30 - Stopper 49 - Socket Bolt (2 Used) 68 - Supporting Plug
12 - O-Ring 31 - O-Ring 50 - Socket Bolt (2 Used) 69 - Pin
13 - Retaining Ring 32 - Block 51 - O-Ring 70 - Pin
14 - Spring Seat 33 - Socket Bolt (2 Used) 52 - Adjusting Screw 71 - O-Ring
15 - Spring 34 - Socket Bolt (2 Used) 53 - Adjusting Screw 72 - *O-Ring (7 Used)
16 - Spring 35 - Stopper 1 54 - Nut 73 - O-Ring (2 Used)
17 - Retaining Ring 36 - Piston 1 55 - O-Ring 74 - O-Ring
18 - Sleeve 37 - Piston 2 56 - Cover 75 - O-Ring
19 - Spool 38 - O-Ring 57 - Socket Bolt (4 Used)
W2-4-33
A
B
63 64
65
66
67
68
A
41 38 32 35 61 24 23 25 27 28 29 30 T1F3-03-01-006
Section B-B
56
57
42
59
60
40
44
T1F3-03-01-004
43 39 37 36 74 49 71 69 22 26 50 31
Section A-A 16 75 14 15 17 19 18 21 8 9 10 55 51 56 58
13 62
52
3
54
34
53
33 1 2 4 5 6 7 20 70 12 11 T1F3-03-01-005
W2-4-34
Assemble Regulator
(Main Pump 1 Side)
1. Insert compensating rod (7) and lever (21) into IMPORTANT: Supporting plugs (68) and (63) can
housing (61). be installed in either hole. Be sure to
install them according to the
2. Align pin (62) of lever (21) with the pin hole in the matching mark made when
housing (61) inside. Align pin (20) with stepped disassembling and never confuse
joint portion of compensating rod (7) to install them, otherwise the pump control
lever (21) into housing (61). will be out of order.
8. Align pin (69) of supporting plug (68) with the pin
3. Install Assemble retaining ring (17) to sleeve (18) (69) hole of lever (25) to insert the pin and install
and insert sleeve (18) and spool (19) into housing retaining ring (66).
(61).
9. Insert supporting plug (63) into housing (61) and
IMPORTANT: Check spool (19) if it should move install retaining ring (65).
smoothly before installing feedback
lever (22). Be sure to install spool 10. Install O-ring (31) onto stopper (30).
(19) and feedback lever (22) in the
correct direction. Do not make any 11. Install spring seat (28), spring (29) and stopper
mistake while doing this procedure. (30) to housing (61).
4. Align the pin hole in feedback lever (22) with the
pin hole in spool (19), and tap pin (23) from the 12. Install O-ring (12) onto stopper (11).
mounting hole of supporting plug (63) with a
plastic hammer. 13. Place O-ring (55) in housing (61). After that, insert
spring seat (8), springs (9) and (10) and stopper
(11) into housing (50).
5. Insert pilot piston (27) and lever (25) into housing Install cover (56) to housing (61) with socket bolts
(61). (57) (5 used).
: 5 mm
IMPORTANT: Check pilot piston (27) if it should : 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft)
move smoothly before installing
lever (25). 14. Install spring (15), spring seat (14) and retaining
6. Align pin (26) of lever (25) with stepped joint ring (13) onto spool (19).
portion of pilot piston (27) to install lever (25).
15. Install O-ring (4) to sleeve (5) and install sleeve
7. Install O-rings (64) and (67) to supporting plugs (5), compensating piston (6), O-ring (3), sleeve (2)
(63) and (68) respectively. and pin (1) into housing (61).
W2-4-35
A
B
T1F3-03-01-006
41 38 32 35 61
Section B-B
42
T1F3-03-01-004
43 39 37 36 74 49 71 69 50
Section A-A 16 75
34
33 11 T1F3-03-01-005
NOTE: As for parts (45), (46), (47), (48) and (72),

refer to W2-3-26.
W2-4-36
16. Install O-rings (38), (41) and piston (37) to
stopper 2 (39)
17. Install stopper 1 (35) and piston 1 (36) and the

stopper (39) assembly to block (32)
18. Install cover (43) to block (32) with socket bolts

(42) (2 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft)
19. Install spring (16), O-rings (75), (74) and (73) (2

used) into housing (61) and install block (32) with
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft)
20. Install O-ring (48) and (47) (3 used) to cover (46)

and install the cover (46) assembly onto housing
(61) with socket bolts (45) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 Ibf⋅ft)
21. Install O-rings (71) and (72) (7 used) to housing

(61).
22. Install the regulator onto the main pump with

: 6 mm
: 29 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
W2-4-37
DISASSEMBLE PTO GEAR BOX
1
4
3
2 7
1
8
6
5
10
9
11
12
13
12 W1F3-02-04-002
14
1- Spacer (2 Used) 5- Retaining Ring 9 - Plug 12 - Bearing (2 Used)

2- Retaining Ring 6- Pin 10 - O-Ring (1B P24) 13 - Gear
3- Bearing 7- Pin (2 Used) 11 - Gear Case 14 - Retaining Ring
4- Gear 8- Socket Bolt (4 Used)
W2-4-38
Disassemble PTO Gear Box
1. Remove plug (9) from gear case (11).
2. Remove socket bolts (8) (4 used) to remove gear

case (11) from pump casing.
: 8 mm
3. Remove retaining ring (5) from gear case (11) to

pull out pin (6).
4. Remove spacer (1) (2 used) and the gear (4)

assembly from gear case (11).
5. Remove retaining ring (2) from gear (4) to remove

bearing (3).
6. Remove retaining ring (14) from gear case (11) to

remove bearing (12) (2 used) and gear (13).
NOTE: Do not remove bearing (12) from gear (13).

In case they are removed, replace them
with new ones.
W2-4-39
ASSEMBLE PTO GEAR BOX
12 9 9
14 10
13
11
8
2 8
1
Gear Casing
6 7
4
3
5 4 5
W1F3-02-04-004
W1F3-02-04-003
3 2
1- Spacer (2 Used) 5- Retaining Ring 9 - Plug 12 - Bearing (2 Used)

2- Retaining Ring 6- Pin 10 - O-Ring (1B P24) 13 - Gear
3- Bearing 7- Pin (2 Used) 11 - Gear case 14 - Retaining Ring
4- Gear 8- Socket Bolt (4 Used)
W2-4-40
Assemble PTO Gear Box
1. Install the gear (13) assembly into gear case

(11) to install retaining ring (14).
2. Install bearing (3) into gear (4). Lock bearing (3)

with retaining ring (2)
3. Install the gear (4) assembly and spacer (1) (2

used). Install pin (6) onto gear case (11) to lock
pin (6) with retaining ring (5).
4. Install O-ring (10) and plug (9) into gear case (11).
5. Install the gear case (11) assembly to the pump

casing with socket bolts (8) (4 used).
: 8 mm
: 33 N⋅m (3.5 kgf⋅m, 24.5 Ibf⋅ft)
W2-4-41
DISASSEMBLE AND ASSEMBLE PILOT
PUMP AND STEERING PUMP
27
13
26
10
10
12
1
9
6
26
14
27
6
9
2
3
5
16
15
7
12
W137-02-04-034
W2-4-42
Tightening Torque
Wrench Size
No. Part Name Q’ty (kgf⋅m) Remarks
mm N⋅m
(Ibf·ft)
1 Housing 1
2 Flange 1
3 Oil Seal 1 Apply grease to the lip of seal when assembling
5 Retaining Ring 1
6 Seal 2 Apply grease when assembling
7 Cover 1
9 Backup Ring 2 Apply grease when assembling
10 Key 2
12 O-Ring 2 Apply grease when assembling
13 Gear 1
14 Gear 1
15 Washer 2
(4 to 4.5)
16 Bolt 2 : 17 39 to44
(29 to 32.5)
26 Bushing 4 Apply a film of hydraulic oil when installing
27 Bushing 4 Apply a film of hydraulic oil when installing
W2-4-43
(Blank)
W2-4-44
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
CAUTION: Be sure to bleed air from hydrau-

lic oil tank before starting the work. 2
Removal
IMPORTANT: Attach identification tags to dis-

connected hoses for re-assembly.
1. Disconnect all hoses and pipes from signal con- 3
trol valve (2) (Refer to W2-9-1.) Cap open ends.
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) 1
4
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
2. Disconnect all hoses and pipes from 4-unit sole-

noid valve unit and pilot relief valve. (Refer to
W2-11-1 and W2-12-1.)
3. Remove bolts (4) (3 used) then remove signal

control valve (2) with bracket (3) from control
valve (1). W1F3-02-05-004
: 22 mm
: 140 N⋅m (14.3 kgf⋅m, 103 Ibf⋅ft)
Swing
Arm 1
connected hoses for re-assembly. Boom 2
4. Disconnect all hoses, pipes and connectors from Auxiliary
the control valve. Cap open ends. Arm 2
: 17 mm Boom 1
Bucket
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)
Travel
: 19 mm Positioning
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
Front Side
T176-03-03-038
W2-5-1
CAUTION: Control valve weight: 136 kg

(300 lb) Pilot Relief Valve
5. Remove control valve mounting bolts (5) (4 used).

1
Install eyebolts (M14, Pitch 2.0 mm) (2 used) into
bolt hole (6) on the top of control valve (1). Lift
control valve (1) off.
: 22 mm
: 140 N⋅m (14.3 kgf⋅m, 103 Ibf⋅ft)
Installation
NOTE: Refer to “Removal” section above for
wrench sizes and tightening torques.
5
CAUTION: Control valve weight: 130 kg
(290 lb)
W1F3-02-05-001
1. Lift control valve (1) and install control valve (1)

with bolts (5) (4 used).
2. Connect all hoses, pipes and connectors to con-

trol valve (1).
6
3. Install signal control valve (2) with bracket (3) to
control valve (1) with bolts (4) (3 used).
4. Connect all hoses and pipes to the 4-unit sole-

noid valve unit, pilot relief valve and signal control
valve (2). (Refer to W2-9-1, W2-11-1 and
W2-12-1)
6
IMPORTANT: After completing installation, check
hydraulic oil level. Add oil as nec-
essary. Run the engine. Check the
component for any oil leaks.
W1F1-02-05-003
W2-5-2
(Blank)
W2-5-3
DISASSEMBLE 4-SPOOL CONTROL
VALVE
41
X
1
2
42
3 29
23 43 47
4
5 30
44 48
6 24
7 31
Arm Re-
8generative 45
25 49
9Valve
(Switch 32
10 Valve) 26 50
Boom
Anti- 36 33 46
Drift 11 51
Valve
27
12 34
13 28
14 37 52
Check Valve
15 35 (Main Relief
38
16 Circuit)
17
39
18
40
W
60 62
61 63
64
65
W
58
66
59
67
72
X W1F1-02-05-004
1- O-Ring 16 - Plug 35 - Spring Seat 50 - Spring

2- Screw 17 - Spring 36 - Main Spool 51 - Spring Seat
3- Backup Ring 18 - Poppet 37 - Poppet 52 - Main Spool
4- O-Ring 23 - O-Ring 38 - Spring 58 - Cap
5- O-Ring 24 - Bolt 39 - O-Ring 59 - Nut
6- O-Ring 25 - Spring Seat 40 - Plug 60 - Plug
7- Backup Ring 26 - Spring 41 - O-Ring 61 - O-Ring
8- Backup Ring 27 - Spring Seat 42 - Bolt 62 - Cap
9- O-Ring 28 - Main Spool 43 - Spring Seat 63 - Retaining Ring
10 - Sleeve 29 - O-Ring 44 - Spring 64 - Shim
11 - Spool 30 - Screw 45 - Spring Seat 65 - Nut
12 - Washer 31 - O-Ring 46 - Main Spool 66 - Pilot housing
13 - Spring 32 - Bolt 47 - O-Ring 67 - Socket bolt
14 - Backup Ring 33 - Spring Seat 48 - Bolt 72 - Housing
15 - O-Ring 34 - Spring 49 - Spring Seat
W2-5-4
Disassemble 4-Spool Control Valve Upper Sec-
tion
• Be sure to read “Precautions for Disassembly IMPORTANT: Put mating marks on main spools
and Assembly” thoroughly on page W1-1-1 be- (28, 36, 46, 52) and housing (72) in
fore starting the disassembly work. order to avoid confusion during re-
• Attach identification tags to the spool and mount- assembling.
ing positions in the housing in order to avoid 7. Clamp main spools (28, 36, 46, 52) in a vise with
misassembling. padded wooden pieces, then remove bolts (24,
32, 42, 48), spring seats (25, 33, 43, 49), springs
1. Remove socket bolts (67) (11 used) from housing (26, 34, 44, 50) and spring seats (27, 35, 45 and
(72), and then remove pilot housing (66). 51).
: 8 mm : 17 mm
2. Remove boom anti-drift valve assembly (5 to 16), 8. Remove plug (40), O-ring (39), spring (38) and
O-ring (4) and backup ring (3) from pilot housing poppet (37) from spool (36).
(66). : 17 mm
NOTE: Pry the boom anti-drift valve assembly by
hand and remove it from pilot housing (66). 10. Remove spring (17) and poppet (18) from hous-
ing (72).
3. Remove plug (16), O-ring (15), backup ring (14),
spring (13), washer (12) and spool (11) from
sleeve (10).
4. Remove O-rings (5, 6, 9) and backup rings (7, 8)

from sleeve (10).
5. Remove cap (62), retaining ring (63), shim (64)

and nut (65) from pilot housing (66).
Remove screw (30) from the pilot housing, then
O-ring (29) from screw (30).
: 17 mm
: 4 mm
5. Remove cap (58) and nut (59) from pilot housing

(66).
Remove screw (2) from pilot housing (66), then
O-ring (1) from screw (2).
: 17 mm
: 4 mm
IMPORTANT: Remove main spool assemblies (28,

36, 46, 52) while carefully moving
them. If they stick, even a little, try it
again instead of pulling roughly.
6. Remove main spool assemblies (28, 36, 46, 52)
and O-rings (23, 31, 41, 47) from housing (72).
W2-5-5
Arm Re-
generative
Valve
Boom (Switch
Anti- Valve)
Drift 19
Valve
20
21 53
54 Check Valve
55 (Main Relief
22 Circuit)
56
57
W
69
70
71 W
68
72
X W1F1-02-05-004
19 - Spring 53 - Plug 57 - Poppet 70 - Backup Ring

20 - Washer 54 - Backup Ring 68 - Overload Relief Valve 71 - O-Ring
21 - O-Ring 55 - O-Ring 69 - Overload Relief Valve 72 - Housing
22 - Spool 56 - Spring
W2-5-6
11. Remove spring (19), washer (20), O-ring (21)
and spool (22) from housing (72).
12. Remove plug (53), backup ring (54), O-ring (55),

spring (56) and poppet (57) from housing (72).
: 14 mm
IMPORTANT: Never turn the lock nut. If turned,

the set pressure may be changed.
13. Turn the cartridges of overload relief valves (68,
69). Remove overload relief valves (68, 69) from
housing (72).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017
14. Remove backup ring (70) and O-ring (71) from

housing (72).
W2-5-7
72
Bypass Shut-Out Valve
79
78
77 83
76 82
81
Check Valve 80
75 Orifice (Arm 1 87
74 Load Check 86
Parallel 85
73 (Arm 2
Circuit)
Tandem 84
98
Circuit) 97
96
95
94
93 Bucket Flow
92 Rate Control
91 Valve (Poppet
90 Valve)
89
99 88 108
109
107
Bucket Flow Rate

Control Valve
(Switch Valve)
102
103
100 104
101 105
W176-02-05-012
106
72 - Housing 82 - Poppet 92 - O-Ring 101 -Socket Bolt

73 - Plug 83 - Bushing 93 - Spring 102 -Spool
74 - O-Ring 84 - O-Ring 94 - Plug 103 -Washer
75 - Plug 85 - Backup Ring 95 - O-Ring 104 -Spring
76 - O-Ring 86 - Spring 96 - Spring 105 -O-Ring
77 - Spring 87 - Poppet 97 - Poppet 106 -Plug
78 - Seat 88 - O-Ring 98 - Valve Seat 107 -O-Ring
79 - Spool 89 - Backup Ring 99 - Pilot Plate 108 -O-Ring
80 - Plug 90 - Bushing 100 -Socket Bolt 109 -Backup Ring
81 - Spring 91 - Backup Ring
W2-5-8
Disassemble 4-Spool Control Valve Side Section
15. Remove plug (106), then spring (104), washer
(103), spool (102) and O-ring (105).
: 36 mm
16. Loosen socket bolts (100) (7 used) and (101) (3

used). Remove pilot plate (99), O-ring (107, 108)
and backup ring (109).
: 6 mm, 8 mm
17. Remove bushing (90) from pilot plate (99), then

O-rings (88, 92), backup ring (89, 91) and spring
(93) from bushing (90).
18. Remove plug (94) from housing (72).

Clamp the step portion of plug (94) with wooden
pieces and secure it in a vise. Then remove valve
seat (98), poppet (97), spring (96) and O-ring
(95) from plug (94).
19. Remove O-ring (84), backup ring (85), spring

(86) and poppet (87) from housing (72). (2
places).
20. Remove plug (80), spring (81), poppet (82) and

bushing (83) from housing (72).
21. Remove plug (75), O-ring (76), spring (77), seat

(78) and spool (79) from housing (72).
W2-5-9
72
115
110
116 119
111 117
118
112
Check Valve (Flow
113 Combiner Circuit) 120
114
Auxiliary Flow
Rate Control
Valve
121
122
W1F1-02-05-005
72- Housing 113 -Backup Ring 117 -O-Ring 120 -O-Ring

110 -Poppet 114 -Plug 118 -Plug 121 -Pilot Housing
111 -Spring 115 -Poppet 119 -Overload Relief Valve 122 -Socket Bolt
112 -O-Ring 116 -Spring
W2-5-10
Disassemble 4-Spool Control Valve Lower Sec-
tion
22. Turn the cartridge of overload relief valve (119)
and remove it from housing (72).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017
23. Remove socket bolts (122) (5 used) from housing

(72), then remove pilot housing (121) and O-ring
(120).
: 8 mm
24. Remove plug (118), O-ring (117), spring (116)

and poppet (115) from housing (72).
: 14 mm
25. Remove plug (114), backup ring (113), O-ring

(112), spring (111) and poppet (110) from housing
(72).
: 14 mm
W2-5-11
DISASSEMBLE 5-SPOOL CONTROL
VALVE
184
183
185
123
124
125 155
156
126 149
127 186
128 157
129 150
130 158
165
131 151
144 159
171
132 152
134 145 166
Arm Anti-Drift 177
Valve
135 133 146 153 160 167 172
136
143 147
137
141 168 173
138 178
148 154
139 169 174 179
140 161
142 175 180
162
163 170
181
164 176
182
187
W176-02-05-011
W2-5-12
123 -Backup Ring 140 -Poppet 157 -Spring Seat 174 -Spring
124 -O-Ring 141 -Backup Ring 158 -Spring 175 -Spring Seat
125 -Plug 142 -O-Ring 159 -Spring Seat 176 -Main Spool
126 -O-Ring 143 -Overload Relief Valve 160 -Main Spool 177 -O-Ring
127 -O-Ring 144 -Plug 161 -Poppet 178 -Bolt
128 -O-Ring 145 -O-Ring 162 -Spring 179 -Spring Seat
129 -Backup Ring 146 -Backup Ring 163 -O-Ring 180 -Spring
130 -Backup Ring 147 -O-Ring 164 -Plug 181 -Spring Seat
131 -O-Ring 148 -Main Relief Valve 165 -O-Ring 182 -Main Spool
132 -Sleeve 149 -O-Ring 166 -Bolt 183 -Socket Bolt
133 -Spool 150 -Bolt 167 -Spring Seat 184 -Plug
134 -Washer 151 -Spring Seat 168 -Spring 185 -O-Ring
135 -Spring 152 -Spring 169 -Spring Seat 186 -Pilot Housing
136 -Backup Ring 153 -Spring Seat 170 -Main Spool 187 -Housing
137 -O-Ring 154 -Main Spool 171 -O-Ring
138 -Plug 155 -O-Ring 172 -Bolt
139 -Spring 156 -Bolt 173 -Spring Seat
W2-5-13
183
123
124
125 155
156
126 149
127 186
128 157
129 150
130 158
165
131 151
159
171
132 152 166
134
Arm Anti-Drift 177
Valve
135 133
153 160 167 172
136
143
137
141 168 173
138 178
148 154
139 169 174
179
140 161
175 180
142
162
170
163
181
164 176
182
187
W176-02-05-011
W2-5-14
Disassemble 5-Spool Control Valve Upper Sec-
tion
1. Remove socket bolts (183) (10 used) from hous- 7. Remove plug (164), O-ring (163), spring (162)
ing (187) to remove pilot housing (186). and poppet (161) from main spool (160).
: 8 mm : 17 mm
2. Remove arm anti-drift valve assembly (125 to 8. Remove spring (139), poppet (140), backup ring
138) and O-ring (124), backup ring (123) from (141), and O-ring (142) from housing (187).
pilot housing (186).
NOTE: Pry out the arm anti-drift valve assembly IMPORTANT: Never turn the lock nut. If turned,
by hand while removing pilot housing the set pressure may be changed.
(186). 9. Turn the cartridges of overload relief valve (143)
and main relief valve (148) to remove them from
3. Remove plug (138), O-ring (137), backup ring housing (187).
(136), spring (135), washer (134) and spool (133) : 27 mm
from sleeve (132).
Lock Nut
4. Remove plug (125), O-rings (126, 127, 128, 131) Cartridge
and backup rings (129, 130) from sleeve (132).
5. Remove the main spool (154, 160, 170, 176,

182) assemblies and O-rings (149, 155, 165, 171,
177) from housing (187). W176-02-06-017
IMPORTANT: Put mating marks on main spools

(154, 160, 170, 176, 182) and hous-
ing (187) in order to avoid confusion
during reassembling.
6. Clamp the main spool (154, 160, 170, 176, 182)
assemblies in a vise, then remove bolts (150, 156,
166, 172, 178), spring seats (151, 157, 167, 173,
179), springs (152, 158, 168, 174, 180), and
spring seats (153, 159, 169, 175, 181).
: 17 mm
W2-5-15
Load Check
Valve (Arm 1 Load Check Valve
Parallel Circuit) 213 (Arm 2 Parallel
Aux. Flow Rate Control 197 Circuit)
Valve (Poppet Valve) 214
198 215
199 208
209 216
200
201 210
Load Check 202 211
191 Valve (Travel 203 212
Parallel Cir- 193 204
192 cuit) 194 205
195 206
196 207
188
189
190
187
223
224
Aux. Flow Rate 222

Control Valve 225
(Switch Valve)
226
221
220
219
218 W176-02-05-013
217
W2-5-16
187 -Housing 197 -O-Ring 207 -Valve Seat 217 -Plug

188 -Socket Bolt 198 -Backup Ring 208 -O-Ring 218 -O-Ring
189 -Cover 199 -Bushing 209 -Backup Ring 219 -Spring
190 -O-Ring 200 -Backup Ring 210 -Plug 220 -Washer
191 -Socket Bolt 201 -O-Ring 211 -Spring 221 -Spool
192 -Pilot Plate 202 -Spring 212 -Poppet 222 -Socket Bolt
193 -O-Ring 203 -Plug 213 -O-Ring 223 -Socket Bolt
194 -Backup Ring 204 -O-Ring 214 -Backup Ring 224 -Pilot Plate
195 -Spring 205 -Spring 215 -Spring 225 -O-Ring
196 -Poppet 206 -Poppet 216 -Poppet 226 -O-Ring
W2-5-17
Load Check
Valve (Arm 1 Load Check Valve
Parallel Circuit) 213 (Arm 2 Parallel
Aux. Flow Rate Control 197 Circuit)
Valve (Poppet Valve) 214
198 215
199 208
209 216
200
201 210
Load Check 202 211
191 Valve (Travel 203 212
Parallel Cir- 193 204
192 cuit) 194 205
195 206
196 207
187
223
224
Aux. Flow Rate 222

Control Valve 225
(Switch Valve)
226
221
220
219
218 W176-02-05-013
217
W2-5-18
Disassemble 5-Spool Control Valve Side Section
10. Remove plug (217), then remove O-ring (218),
spring (219), washer (220) and spool (221).
: 36 mm
11. Remove socket bolts (222, 223), then remove pi-

lot plate (224), O-rings (225, 226).
: 6 mm, 8 mm
12. Remove bushing (199) from pilot plate (224),

then remove O-rings (197, 201), backup rings
(198, 200) and spring (202) from bushing (199).
13. Remove plug (203) from pilot plate (224) mount-

ing surface of housing (187).
Clamp the stepped portion of plug (203) with
wood pieces in a vise, then remove valve seat
(207), poppet (206), spring (205) and O-ring
(204).

(195) and poppet (196) from the pilot plate (224)
mounting surface of housing (187).

mounting surface of housing (187). (3 places)

(187), then remove pilot plate (192).
: 6 mm
17. Remove O-ring (208), backup ring (209), plug

(210), spring (211) and poppet (212) from the pi-
lot plate (192) mounting surface of housing (187).
(2 places)

mounting surface of housing (187).
W2-5-19
187
244
235 243 245
236 246
227
228 237
247
229
238
230
248
239
231
232 254
233
234
Auxiliary Flow
Combiner
249 252
Valve
250 253
251
W1F3-02-05-007
187 - Housing 233 - Spring 243 - Overload Relief Valve 249 - Socket Bolt
227 - Plug 234 - Bolt 244 - O-Ring 250 - O-Ring
228 - Spring 235 - Plug 245 - Backup Ring 251 - Plug
229 - Poppet 236 - Spring 246 - O-Ring 252 - O-Ring
230 - Spool 237 - Poppet 247 - Plug 253 - Plug
231 - O-Ring 238 - Spool 248 - O-Ring 254 - Pilot Housing
232 - Washer 239 - O-Ring
W2-5-20
Disassemble 5-Spool Control Valve Lower Sec-
tion
19. Turn the cartridge of overload relief valve (243) to
remove it from housing (187).
: 27 mm
Lock Nut
Cartridge
W176-02-06-017

(187), then remove pilot housing (254) and
O-ring (248) (5 used).
: 8 mm
21. Remove O-rings (231, 239), flow combiner valve

assembly (235 to 242), and auxiliary flow com-
biner valve assembly (227 to 234) from housing
(187).
IMPORTANT: Do not remove plug (227), spring

(228), poppet (229) from spool (230).
When replacing these parts, replace
them as an assembly.
22. Clamp spool (230) with wood pieces in a vise,
then remove bolt (234), spring (233) and washer
(232).
: 17 mm
NOTE: Do not remove plug (235), spring (236),

poppet (237) and spool (238).
W2-5-21
SEPARATE AND COMBINE 4-SPOOL AND
5-SPOOL CONTROL VALVES
187
262
261
256
257
259
258
72 260
263
264
265
255 266 267
268
269
270
271
272
273 277
274 275 276
W176-02-05-015
72 - Housing 260 -O-Ring 266 -O-Ring 272 -O-Ring

187 -Housing 261 -O-Ring 267 -Backup Ring 273 -Backup Ring
255 -Socket Bolt 262 -Backup Ring 268 -O-Ring 274 -O-Ring
256 -O-Ring 263 -O-Ring 269 -O-Ring 275 -Backup Ring
257 -O-Ring 264 -Backup Ring 270 -O-Ring 276 -O-Ring
258 -O-Ring 265 -O-Ring 271 -O-Ring 277 -Backup Ring
259 -Backup Ring
W2-5-22
Separate Combine
1. Install O-rings (256 to 258, 260, 261, 263, 265,
CAUTION: Housing (72) weight: 266, 268 to 272, 274, 276) and backup rings (259,
45 kg (100 Ib) 262, 264, 267, 273, 275, 277) into housing (187).
Housing (187) weight: 50 kg (110 Ib)
1. Remove socket bolts (255) (9 used), then sepa- CAUTION: Housing (72) weight:
rate housing (72) and housing (187). 45 kg (100 Ib)
: 12 mm Housing (187) weight: 50 kg (110 Ib)
2. Remove O-rings (256 to 258, 260, 261, 263, 265, 2. Connect housing (72) and housing (187) with
266, 268 to 272, 274, 276) and backup rings (259, socket bolt (255).
262, 264, 267, 273, 275, 277) from housing : 12 mm
(187). : 108+9.8 N⋅m (11+1 kgf⋅m, 80+7 lbf⋅ft)
W2-5-23
ASSEMBLE 4-SPOOL CONTROL VALVE
Main Spool Main Spool

(28, 46, 52) (36)
A
61 60 31 41 47 43, 25, 49 33
23
19 44, 26, 50
34
20 42, 24, 48 32
21
45, 27, 51 35
53
22
54, 55
56
57
72
46, 28, 52 36
37
38
52 39
28 36 46 W1F1-02-05-007 40
Boom Anti-Drift Valve W176-02-05-024
Section A Boom 1
5
63, 64
10
62 6
65 11
66
29
7
30 8
58
14 9
59
1 12
2 15 13
16
Boom
Anti-Drift 17
Valve 18
W176-02-05-025
3 4 W176-02-05-022
W2-5-24
1- O-Ring 19 - Spring 37 - Poppet 55 - O-Ring

2- Screw 20 - Washer 38 - Spring 56 - Spring
3- Backup Ring 21 - O-Ring 39 - O-Ring 57 - Poppet
4- O-Ring 22 - Spool 40 - Plug 58 - Cap
5- O-Ring 23 - O-Ring 41 - O-Ring 59 - Nut
6- O-Ring 24 - Bolt 42 - Bolt 60 - Plug
7- Backup Ring 25 - Spring Seat 43 - Spring Seat 61 - O-Ring
8- Backup Ring 26 - Spring 44 - Spring 62 - Cap
9- O-Ring 27 - Spring Seat 45 - Spring Seat 63 - Retaining Ring
10 - Sleeve 28 - Main Spool 46 - Main Spool 64 - Shim
11 - Spool 29 - O-Ring 47 - O-Ring 65 - Nut
12 - Washer 30 - Screw 48 - Bolt 66 - Pilot Housing
13 - Spring 31 - O-Ring 49 - Spring Seat 67 - *Socket Bolt
14 - Backup Ring 32 - Bolt 50 - Spring 68 - *Overload Relief Valve
15 - O-Ring 33 - Spring Seat 51 - Spring Seat 69 - *Overload Relief Valve
16 - Plug 34 - Spring 52 - Main Spool 70 - *Backup Ring
17 - Spring 35 - Spring Seat 53 - Plug 71 - *O-Ring
18 - Poppet 36 - Main Spool 54 - Backup Ring 72 - Housing
NOTE: As for mark *, refer to W2-5-4, W-2-5-6.
W2-5-25
Main Spool Main Spool

(28, 46, 52) (36)
A
31 41 47 43, 25, 49 33
23
44, 26, 50
19 34
42, 24, 48 32
20
21 45, 27, 51 35
53
22
54, 55
56
57
72
46, 28, 52 36
37
38
52 39
40
28 36 46 W1F1-02-05-007
Boom 1 Boom Anti-Drift Valve W176-02-05-024
Section A 5
63, 64 10
62 6
65 11
66
29 7
30 8
58 14 9
59
12
1
15 13
2
16
Boom 17
Anti-Drift
Valve 18
W176-02-05-025
3 4 W176-02-05-022
W2-5-26
Assemble 4-Spool Control Valve Upper Section
1. Clamp main spool (36) with wood pieces in a vise, IMPORTANT: When replacing sleeve (10) or spool
then install poppet (37), spring (38), O-ring (39) (11), replace them together.
and plug (40). 6. Assemble O-ring (15), backup ring (14), spring
: 17 mm (13), washer (12), and spool (11) onto plug (16),
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) then install them onto sleeve (10).
NOTE: When assembling washer (12), the cham-
2. Install spring seats (27, 35, 45, 51), springs (26, fer side shall be facing to the spring side.
34, 44, 50), spring seats (25, 33, 43, 49) and
bolts (24, 32, 42, 48) onto spools (28, 36, 46, 52) 7. Install boom anti-drift valve assembly (5 to 16)
respectively. onto pilot housing (66).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft) IMPORTANT: When replacing housing (72) or
poppet (18), tap poppet (18) with a
3. Install screw (30) and O-ring (29) onto pilot steel bar.
housing (66), then install nut (65), shim (64), re- 8. Install poppet (18) and spring (17) into housing
taining ring (63) and cap (62) into screw (30). (72).
: 4 mm
: 17 mm 9. Install spool (22), O-ring (21), washer (20) and
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) spring (19) into housing (72).
NOTE: When assembling washer (20), the cham-
4. Install screw (2) and O-ring (1) onto pilot housing
fer side shall be facing to the spring side.
(66), then install nut (59) and cap (58) onto screw
(2).
10. Install poppet (57), spring (56), O-ring (55),
: 4 mm
backup ring (54) and plug (53) into housing (72).
: 17 mm
: 14 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)
5. Install backup rings (7, 8) and O-rings (5, 6, 9)
11. Install main spool assemblies (28, 36, 46, 52),
onto sleeve (10).
O-rings (4, 23, 31, 41, 47, 71) and backup rings
NOTE: Check the assembling location of backup (3, 70) into housing (72) respectively.
rings (7, 8) and O-rings (6, 9).
9 8 7 6
W176-02-05-023
W2-5-27
A
B Arm 2 Arm 1
66 C
Section B
72 69
Load Check Valve (Arm
69 2 Tandem Circuit)
68
86 87
99
D
67
101 72
100
T176-03-03-038
Section D 106 105 104 103 102
Bucket Flow Rate 80 81 82 83
Control Valve Check Valve Orifice
(Switch Valve) (Arm 1 Parallel Cir-
cuit)
T176-03-03-006
94
88
93
89 Section C Boom 1
90 95
Boom 2
91 96
92
97
98 Bucket Flow Rate Con-
trol Valve (Poppet Valve)
W176-02-05-026
Section A Swing
84, 85
86
75
87
74 Load Check Valve
(Boom 1 Parallel Cir-
73
cuit)
T176-03-03-005
76 77 78 79
Bypass Shut-Out Valve T176-03-03-007
W2-5-28
66 - Pilot Housing 79 - Spool 90 - Bushing 101- Socket Bolt

67 - Socket Bolt 80 - Plug 91 - Backup Ring 102- Spool
68 - Overload Relief Valve 81 - Spring 92 - O-Ring 103- Washer
69 - Overload Relief Valve 82 - Poppet 93 - Spring 104- Spring
72 - Housing 83 - Bushing 94 - Plug 105- O-Ring
73 - Plug 84 - O-Ring 95 - O-Ring 106- Plug
74 - O-Ring 85 - Backup Ring 96 - Spring 107- *O-Ring
75 - Plug 86 - Spring 97 - Poppet 108- *O-Ring
76 - O-Ring 87 - Poppet 98 - Valve Seat 109- *Backup Ring
77 - Spring 88 - O-Ring 99 - Pilot Plate 217- *Plug
78 - Seat 89 - Backup Ring 100- Socket Bolt
NOTE: As for mark *, refer to W2-5-8, W2-5-16.
W2-5-29
A Arm 2 Arm 1
B Section B
66 C
69
72
Load Check Valve (Arm
2 Tandem Circuit)
69
86 87
68
99
D
67
101 72
100
T176-03-03-038
80 81 82 83
Section D 106 105 104 103 102 Check Valve Orifice
(Arm 1 Parallel Cir-
Bucket Flow Rate cuit)
Control Valve T176-03-03-006
(Switch Valve)
Section C Boom 1
88
93
89 Boom 2
90 95
91 96
92
97
98 Bucket Flow Rate Con-
trol Valve (Poppet Valve)
W176-02-05-026
Section A Swing
84, 85
86
87
Load Check Valve
75 (Boom 1 Parallel Cir-
cuit)
T176-03-03-005
76 77 78 79
Bypass Shut-Out Valve T176-03-03-007
W2-5-30
IMPORTANT: Never turn the lock nut. If turned, 19. Install O-rings (107, 108) and backup ring (109)
the set pressure may be changed. into housing (72). Install pilot plate (99) with
12. Install pilot housing (66) onto housing (72) with socket bolts (100) (7 used) and (101) (3 used).
socket bolts (67) (11 used). Turn the cartridges of : 6 mm
overload relief valves (68, 69) to install them into : 25 N⋅m (2.5 kgf･m, 18 Ibf⋅ft)
housing (72). : 8 mm
: 8 mm : 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 27 mm 20. Tighten plug (106) which has been temporarily
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 Ibf⋅ft) tightened in step 13.
: 36 mm
: 200 N⋅m (20 kgf⋅m, 145 Ibf⋅ft)
Lock Nut
Cartridge 21. Install spool (79), seat (78), spring (77), O-ring
(76) and plug (75) into housing (72).
: 27 mm
: 180+3 N⋅m (18+0.3 kgf⋅m, 130.2+2.2
Ibf⋅ft)
W176-02-06-017
NOTE: Apply grease onto O-rings of overload re- NOTE: Install seat (78) with the chamfered side
lief valves (68, 69). (In order to protect facing the spring.
O-rings from breakage).
Assemble 4-Spool Valve Side Section

13. Install spool (102), washer (103), spring (104)
and O-ring (105) onto pilot plate (99), then install
plug (106) (Temporarily tighten it).
: 36 mm
NOTE: Tighten plug (106), after installation of pilot
plate (99) to housing (72). Check the plugs
identification because plug (106) and plug
(217) have different length of screw thread.
14. Install poppet (97), spring (96), O-ring (95) and

plug (94) onto valve seat (98).
15. Install O-rings (88, 92) and backup rings (89, 91)
onto bushing (90).
16. Install valve seat (98) assembly, spring (93) and

bushing (90) into housing (72).
17. Install poppet (87), spring (86), O-ring (84) and

backup ring (85) into housing (72). (2 places)
18. Install bushing (83), poppet (82), spring (81) and

plug (80) into housing (72).
W2-5-31
Section A
72
121
122
B 119 T176-03-03-036
W176-02-05-020
120 120 120 120
Section B
115
110
111
112, 113
117
114
118 116 T1F3-03-03-013

Aux. Flow Rate
Control Valve
72 - Housing 113 -Backup Ring 117 -O-Ring 120 -O-Ring

110 -Poppet 114 -Plug 118 -Plug 121 -Pilot Housing
111 -Spring 115 -Poppet 119 -Overload Relief Valve 122 -Socket Bolt
112 -O-Ring 116 -Spring
W2-5-32
Assemble 4-Spool Control Valve Lower Section
22. Install O-ring (120) onto housing (72), then install
pilot housing (121) with socket bolts (122) (5
used).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
23. Install poppet (115), spring (116), O-ring (117)

and plug (118) into housing (72).
: 14 mm
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)

backup ring (113) and plug (114) into housing
(72).
: 14 mm
: 120+20 N⋅m (12+2 kgf⋅m, 87+14.5 lbf⋅ft)

25. Turn the cartridge of overload relief valve (119) to
install it into housing (72).
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 57.9+2.2 lbf⋅ft)
Lock Nut
Cartridge
W176-02-06-017
NOTE: Apply grease to O-ring of the overload re-

lief valve. (In order to protect O-ring from
breakage.)
W2-5-33
ASSEMBLE 5-SPOOL CONTROL VALVE
Main Spool Main Spool (160)
(154, 170, 176, 182)
177 171 165 155 149
Section A
151, 167,
157
173, 179
158
152, 168,
174, 180
156
150, 166,
172, 178
159
153, 169,
175, 181
160
154, 170,
176, 182
161
182 176 170 160 154 162
W176-02-05-021
163
Arm Anti-Drift Valve
B 184 185 164
A
Arm Anti-Drift Valve
143 W176-02-05-024
Section B 132 125

127
126
186 128
183 129
133
148 130
187
131
136
134
137
135
138
139
140
W176-02-05-027
T176-03-03-038
W2-5-34
123 -*Backup Ring 140 -Poppet 157 -Spring Seat 174 -Spring
124 -*O-Ring 141 -*Backup Ring 158 -Spring 175 -Spring Seat
125 -Plug 142 -*O-Ring 159 -Spring Seat 176 -Main Spool
126 -O-Ring 143 -Overload Relief Valve 160 -Main Spool 177 -O-Ring
127 -O-Ring 144 -*Plug 161 -Poppet 178 -Bolt
128 -O-Ring 145 -*O-Ring 162 -Spring 179 -Spring Seat
129 -Backup Ring 146 -*Backup Ring 163 -O-Ring 180 -Spring
130 -Backup Ring 147 -*O-Ring 164 -Plug 181 -Spring Seat
131 -O-Ring 148 -Main Relief Valve 165 -O-Ring 182 -Main Spool
132 -Sleeve 149 -O-Ring 166 -Bolt 183 -Socket Bolt
133 -Spool 150 -Bolt 167 -Spring Seat 184 -Plug
134 -Washer 151 -Spring Seat 168 -Spring 185 -O-Ring
135 -Spring 152 -Spring 169 -Spring Seat 186 -Pilot Housing
136 -Backup Ring 153 -Spring Seat 170 -Main Spool 187 -Housing
137 -O-Ring 154 -Main Spool 171 -O-Ring
138 -Plug 155 -O-Ring 172 -Bolt
139 -Spring 156 -Bolt 173 -Spring Seat
NOTE: As for mark *, refer to W2-5-12
W2-5-35
Main Spool Main Spool (160)

(154, 170, 176, 182)
177 171 165 155 149

Section A 151, 167,
157
173, 179
158
152, 168,
174, 180
156
150, 166,
172, 178
159
153, 169,
175, 181
160
154, 170,
176, 182
161
162
182 176 170 160 154
Arm Anti-Drift Valve W176-02-05-021
163
B
A 164
143 Arm Anti-Drift Valve
W176-02-05-024
Section B 132 125

127
186 126
128
183
129
148 133
187 130
131
136
134
137
135
138
139
140
T176-03-03-038 W176-02-05-027
W2-5-36
Assemble 5-Spool Control Valve Upper Section
1. Clamp main spool (160) with wood pieces in a 5. Install arm anti-drift valve assembly (125 to 138)
vise. Install poppet (161), spring (162), O-ring onto pilot housing (186).
(163) and plug (164).
: 17 mm IMPORTANT: Tap poppet (140) with a steel bar
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) when replacing housing (187) or
poppet (140).
2. Install spring seats (153, 159, 169, 175, 181), 6. Install poppet (140) and spring (139), O-ring
springs (152, 158, 168, 174, 180), spring seats (142) and backup ring (141) onto housing (187).
(151, 157, 167, 173, 179), and bolts (150, 156,
166, 172, 178) onto main spools (154, 160, 170, 7. Install main spool assemblies (154, 160, 170, 176,
176, 182) respectively. 182), O-rings (124, 149, 155, 165, 171, 177) and
: 17 mm backup ring (123) into housing (187).
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
3. Install backup rings (129, 130) and O-rings (126, the set pressure may be changed.
127, 128, 131) and plug (125) onto sleeve (132). 8. Install pilot housing (186) onto housing (187) with
NOTE: Check the mounting location of backup socket bolts (183) (10 used). Turn the cartridges
rings (129, 130) and O-rings (128, 131). of overload relief valve (143) and main relief
valve (148) to install them into housing (187).
: 8 mm
131 130 129 128
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 27 mm
: 78+3 N⋅m (8+0.3 kgf⋅m, 58+2.2 lbf⋅ft)
Lock Nut
Cartridge
W176-02-05-023
IMPORTANT: When replacing sleeve (132) or

spool (133), replace them together. W176-02-06-017
4. Install O-ring (137), backup ring (136), spring
(135), washer (134) and spool (133) into plug
(138), then install them on sleeve (132).
NOTE: Assemble washer (134) with the cham-
fered side facing the spring.
W2-5-37
Boom 2
191 Section B Positioning Section C
192 187
223
222
224 Load Check Valve
(Positioning
Tandem Circuit)
F
E
D 216
C 215 216
Aux. Flow B 215
Rate A 213, 214
Control Load
Valve 193, Check
194 Valve
T176-03-03-036
217 218 219 220 221 (Boom 2
Section Ｆ Parallel
Aux. Flow Rate Circuit) 2
195
Control Valve
(Switch Valve) 196
Load
Check
203 Valve
197 (Positioning
202 Section D W176-02-05-029
Parallel Circuit)
198 Arm 1 Swing Section E
199 204
200 205
201 Load
206
Load Check Check
207 Aux. Flow Rate Control Valve (Arm 1 Valve
Valve (Poppet Valve) Parallel Circuit) (Swing
Circuit)
W176-02-05-026
Section A
216 216
216
215 215
215 208,
213,
209
213, 214 214
210
Check Valve
(Main Circuit)
210
208,
209
211
212
Load Check
Valve (Arm 1
Tandem Circuit)
W176-02-05-030
W176-02-05-028
W2-5-38
187 -Housing 197 -O-Ring 207 -Valve seat 217 -Plug

188 -*Socket Bolt 198 -Backup Ring 208 -O-Ring 218 -O-Ring
189 -*Cover 199 -Bushing 209 -Backup Ring 219 -Spring
190 -*O-Ring 200 -Backup Ring 210 -Plug 220 -Washer
191 -Socket Bolt 201 -O-Ring 211 -Spring 221 -Spool
192 -Pilot Plate 202 -Spring 212 -Poppet 222 -Socket Bolt
193 -*O-Ring 203 -Plug 213 -O-Ring 223 -Socket Bolt
194 -*Backup Ring 204 -O-Ring 214 -Backup Ring 224 -Pilot Plate
195 -*Spring 205 -Spring 215 -Spring 225 -*O-Ring
196 -*Poppet 206 -Poppet 216 -Poppet 226 -*O-Ring
NOTE: As for mark *, refer to W2-5-16.
W2-5-39
191 187 Boom 2

192 Section B Positioning Section C
223
222
Load Check Valve
224 (Positioning
Tandem Circuit)
F E
D 216
C
215 216
B
215
A
213, 214
Aux. Flow Rate Load
193, Check
Control Valve
T176-03-03-036 194 Valve
(Boom 2
Parallel
Circuit) 2
217 218 219 220 221 195
Section Ｆ 196
Aux. Flow Rate
Control Valve Load
(Switch Valve) Check
Valve
Section D (Positioning
203 Parallel Circuit) W176-02-05-029
197 Arm 1 Swing Section E

202
198
199 204
Load
200 205 Load Check Check
201 Valve (Arm 1 Valve
206 Parallel Circuit)
207 (Swing
Aux. Flow Rate Control Circuit)
Valve (Poppet Valve)
W176-02-05-026
Section A 216 216
215 215
208,
216 213,
209
214
215 210
213, 214
Check Valve 210
(Main Circuit) 208,
209
211
212
Load Check
Valve (Arm 1
Tandem Circuit)
W176-02-05-030
W176-02-05-028
W2-5-40
Assemble 5-Spool Control Valve Side Section
9. Install spool (221), washer (220), spring (219)
and O-ring (218) into pilot plate (224), then install
plug (217) (temporarily).
: 36 mm
NOTE: Tighten plug (217) after installing pilot plate
(224) on housing (187). Check the length
of the threaded portion because the thread
length of plug (217) and plug (106) is dif-
ferent.
10. Install poppet (206), spring (205), O-ring (204)

and plug (203) onto valve seat (207).
11. Install O-rings (197, 201) and backup rings (198,

200) onto bushing (199).
12. Install valve seat (207) assembly, spring (202)

and bushing (199) into housing (187).

and backup ring (214) into housing (187). (3
places)
14. Install poppet (196), spring (195), backup ring

(194), and O-ring (193) into housing (187).
15. Install O-rings (225, 226) onto housing (187). In-

stall pilot plate (224) into housing (187) with
socket bolts (222, 223).
: 6 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
16. Tighten plug (217) which is temporarily tightened

in step 9.
: 36 mm
: 200 N⋅m (20 kgf⋅m, 145 lbf⋅ft)
17. Install poppet (212), spring (211), plug (210),

backup ring (209) and O-ring (208) into housing
(187) (2 places).
18. Install poppet (216), spring (215), backup ring

(214) and O-ring (213) into housing (187).
19. Install pilot plate (192) onto housing (187) with

: 6 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W2-5-41
Section B
187
247
249
254
A
243
T176-03-03-036
W176-02-05-021
248 248 248 248 248
Section A
227
235
236 228
237
229 Aux. Flow
Combiner
238 Valve
230
239, 240 231, 232
233
234
W1F3-02-05-002
187 - Housing 233 - Spring 243 - Overload Relief Valve 249 - Socket Bolt
227 - Plug 234 - Bolt 244 - *O-Ring 250 - *O-Ring
228 - Spring 235 - Plug 245 - *Backup Ring 251 - *Plug
229 - Poppet 236 - Spring 246 - *O-Ring 252 - *O-Ring
230 - Spool 237 - Poppet 247 - *Plug 253 - *Plug
231 - O-Ring 238 - Spool 248 - O-Ring 254 - Pilot Housing
232 - Washer 239 - O-Ring
NOTE: As for mark *, refer to W2-5-20.
W2-5-42
Assemble 5-Spool Control Valve Lower Section IMPORTANT: Never turn the lock nut. If turned,
IMPORTANT: Overall dimensions of spool (230) the set pressure may be changed.
have been determined. When dis- 24. Turn the cartridge of overload relief valve (243) to
assembling or replacing poppet install it into housing (187).
(229), spring (228), plug (227), re- : 27 mm
place them as an assembly. : 78+3 N⋅m (8+0.3 kgf⋅m, 57.9+2.2 lbf⋅ft)
then install washer (232), spring (233) and bolt Lock Nut
(234).
Cartridge
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
W176-02-06-017
IMPORTANT: Overall dimensions of spool (238) NOTE: Apply grease on the O-ring of overload re-
have been determined. When dis- lief valve (243). (In order to protect the
assembling or replacing poppet O-ring from breakage.)
(237), spring (236), plug (235), re-
place them as an assembly.
then install washer (240), spring (241) and bolt
(242).
: 17 mm
: 12 N⋅m (1.2 kgf⋅m, 8.7 lbf⋅ft)
22. Install O-rings (231, 239), flow combiner valve as-

sembly (235 to 242) and auxiliary flow combiner
valve assembly (227 to 234) onto housing (187).
23. Install O-rings (248) (5 used) onto housing (187).

Then install pilot housing (254) with socket bolts
(249) (9 used).
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W2-5-43
(Blank)
W2-5-44
REMOVE AND INSTALL AUXILIARY
CONTROL VALVE

lic oil tank before starting the work.
(Refer to “Bleeding Air from Hydraulic Oil Cab Side
2
1
Removal 3

1. Disconnect hoses (4) (6 used) from valve (3).
Cap open ends.
: 19 mm, 27 mm
2. Remove bolts (1) (3 used) and remove valve (3)

from bracket (2).
: 17 mm
W1F3-02-05-005
Installation 4
1. Install valve (3) on bracket (2) with bolts (1) (3

used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
2. Connect hoses (4) (6 used) to valve (3).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
IMPORTANT: After installation, check the hydrau-

lic oil level. Run the engine and
check for oil leaks.
W2-5-45
DISASSEMBLE AUXILIARY CONTROL VALVE 19
10 20
21
9 22
8 23
7
6 24
25
5 26
4 27
3 28
2
1
37
38 29
30
39 31
18 32
17 33
40 34
16
15 41 35
14 36
13 42
12 43
11 44
56 45
55
54
53 46
52 47
51
48
62
61
60
50
49
59
58
57
W198-02-05-001
1- Nut 17 - Sleeve 33 - Backup Ring 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Poppet 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Drive Screw
14 - O-Ring 30 - Pin 46 - Cover 61 - Plate
15 - Backup Ring 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring
W2-5-46
Disassemble Auxiliary Control Valve
• Be sure to read “Precautions for Disassembly
and Assembly” thoroughly on page W1-1-1
before starting any repair work.
1. Loosen socket bolts (45) (2 used), (48), and (49)

to remove covers (46, 50) and O-rings (47, 56).
: 6 mm
IMPORTANT: Remove the spool (57) assembly (51

to 59) while carefully moving them.
If they stick, even a little, try it again
instead of pulling roughly.
2. Remove spool (57) assembly (51 to 59) from

housing (62).
3. Secure spool (57) with wooden pieces in a vice.

Remove end spool (51), seat (52), springs (53,
54) and seat (55).
: 8 mm
IMPORTANT: As the set pressure may be changed,

be sure not to disassemble overload
relief valve assemblies (1 to 18) and
(19 to 36).
4. Remove overload relief valve assembly (1 to 18)
and (19 to 36) from housing (62).
: 32 mm
NOTE: As each set pressure is different, be sure
to install overload relief valve assemblies
(1 to 18) and (19 to 36) correctly.
5. Remove sleeve (41) assembly (37 to 42) from

housing (62).
: 36 mm
6. Pull out spring (43) and poppet (44) from housing

(62).
7. Secure seat (37) in a vice. Remove sleeve (41),

spring (40), valve (39), and O-rings (38, 42).
: 36 mm
NOTE: As plate (61) is installed with drive screw
(60), be sure not to disassemble the plate.
W2-5-47
ASSEMBLE AUXILIARY CONTROL VALVE
Cross Section
X-X 37 39 40 38
41
43
62
42
44
1 to 18 A1 B1 19 to 36
A1 B1
X X
W198-02-05-002
W198-02-05-003
57
Cross Section
W-W
52 54 53 55 56 62 47
48 45
50 51
W W
W198-02-05-004
49
57 59 58 46
W198-02-05-005
1- Nut 17 - Sleeve 33 - Backup Ring 48 - Socket Bolt

2- Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt
3- O-Ring 19 - Nut 35 - Sleeve 50 - Cover
4- Spring 20 - Bolt 36 - O-Ring 51 - End Spool
5- Valve 21 - O-Ring 37 - Seat 52 - Seat
6- Sleeve 22 - Spring 38 - O-Ring 53 - Spring
7- Backup Ring 23 - Valve 39 - Valve 54 - Spring
8- O-Ring 24 - Sleeve 40 - Spring 55 - Seat
9- O-Ring 25 - Backup Ring 41 - Sleeve 56 - O-Ring
10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool
11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring
12 - Pin 28 - Spring 44 - Poppet 59 - Plug
13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Drive Screw
14 - O-Ring 30 - Pin 46 - Poppet 61 - Plate
15 - Backup Ring 31 - Valve 47 - O-Ring 62 - Housing
16 - Valve 32 - O-Ring
W2-5-48
Assemble Auxiliary Control Valve
1. Secure seat (37) in a vice. Install O-ring (38),

valve (39), spring (40), sleeve (41) and O-ring
(42).
: 36 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
2. Install poppet (44) and spring (43) into housing

(62).
3. Install sleeve (41) assembly (37 to 42) to housing

(62).
: 36 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
IMPORTANT: As each set pressure is different, be

sure to install overload relief valve
assemblies (1 to 18) and (19 to 36)
correctly.
4. Install overload relief valve assembly (1 to 18)
and (19 to 36) to housing (62).
: 32 mm
: 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
5. Secure spool (57) with wooden pieces in a vice.

Install O-ring (58) to plug (59). Install plug (59) to
spool (57). Install seat (55), springs (53, 54), seat
(52), and end spool (51) to spool (57).
: 5 mm
: 9.8 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)
: 8 mm
: 18.6 N⋅m (1.9 kgf⋅m, 13.7 lbf⋅ft)
IMPORTANT: After installing spool (57) assembly

(51 to 59) into housing (62), push
them by hand to confirm smooth-
ness.
6. Insert spool (57) assembly (51 to 59) to housing
(62) through port A1 side.
NOTE: When installing the spool assembly, be
sure to install it straight to prevent it from
damaging spool (57) inside housing (62).
7. Install O-ring (56) to cover (50) and O-ring (47) to

cover (46). Install them to housing (62) with
socket bolts (45) (2 used), (48), and (49).
: 6 mm
: 25.5 N⋅m (2.6 kgf⋅m, 18.8 lbf⋅ft)
W2-5-49
(Blank)
W2-5-50
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

lic oil tank before starting the work. 1 2 3 4 5 6
Removal
IMPORTANT: Attach identification tags to discon-

nected hoses for re-assembly.
1. Disconnect the harness (1) connector and hoses
(2 to 6). Cap the disconnected hose ends.
• Main hose: 2 used
• Makeup hose: 1 used
• Drain hose: 1 used
• Pilot hose: 1 used
: 17 mm, 19 mm, 36 mm
: 8 mm
IMPORTANT: As for the handling of floating seal, M178-07-014

refer to the “Handling of Floating 8 7
Seal” on page W1-1-5. Front
2. Lift swing motor (8) off.
Nylon sling (eye-type at both ends): 2 pieces
Nylon Sling
CAUTION: Swing device weight:

220 kg (485 lb)
3. Remove bolts (7) (12 used). Lift the swing device

off the main frame.
: 30 mm
8
NOTE: When lifting the swing device, the machine
may float together with it. Therefore,
remove plugs (9) (2 places) to lift the swing
device off the main frame with pulling bolt
(M20, Pitch 2.5 mm).
The number of hoses around the swing de- 9
vice is different according to the specifica- 9
tion of front attachment.
Be sure not to damage the hoses when
removing and installing the swing device.
W176-02-06-002
W2-6-1
Installation

220 kg (485 lb) 1 2 3 4 5 6
1. Install the swing device with bolts (7) (12 used).

: 30 mm
: 500 N·m (50 kgf·m, 360 Ibf⋅ft)
IMPORTANT: Apply liquid packing to both

mounting surfaces on the swing
device and frame.
2. Connect hoses (2 to 6) and the harness (1)
connector.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 8 mm M178-07-014
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 8 7
Front
IMPORTANT: Be sure to fill the swing motor with
hydraulic oil after installing it. After
completing installation, check
hydraulic oil level. Add oil as
necessary. Run the engine and
check the component for any oil
leaks.
W2-6-2
(Blank)
W2-6-3
DISASSEMBLE SWING REDUCTION
GEAR
22
23 1
24
2
3
32 21
25 4
31 5
20 6
26 7
19
8
27
18 9
28 10
17
11
29
16
12
30 15 13
14
W178-02-06-004
1- Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- 1st Stage Sun Gear 10 - Spring Pin (3 Used) 18 - 2nd Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - 2nd Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - 1st Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (8 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
W2-6-4
Disassemble Swing Reduction Gear 3. Remove drain plug (31), then drain the oil.
: 8 mm
215 kg (480 lb)
4. Remove pipe (32) from housing (25).
CAUTION: When hoisting the swing device, : 18 mm
do not string the rope suddenly.
5. Put alignment marks at the jointed portion be-
1. Secure the swing device body with nylon slings, tween motor (1) and ring gear (24), between ring
then hoist it by crane. gear (24) and housing (25).
Nylon Sling CAUTION: Swing motor weight:

45 kg (105 lb)
6. Remove bolts (22) (8 used). Remove motor (1)

from ring gear (24).
: 10 mm
NOTE: THREEBOND has been applied on the
joint faces. Insert a screw driver into the
gap between the swing motor and the ring
gear, then pry it up for easy removing.
7. Remove first stage sun gear (2) from first stage

carrier (21).
8. Remove first stage carrier (21) assembly from

ring gear (24).
9. Remove the ring gear (24) mounting bolt (23) (12

used).
W176-02-06-002 : 14 mm
2. Install the swing device on the bracket (ST 5097).

CAUTION: Ring gear weight: 23 kg (50 lb)
Secure it with bolts (M20) (2 used). Insert the
stopper located at the bottom of the bracket into
10. Install eyebolts (M12) (2 used) to the hole for the
the middle of two teeth of the pinion gear. Secure
motor (1) mounting bolt on ring gear (24). Lift the
the bracket on a working bench.
ring gear off housing (25).
: 30 mm
Swing Device NOTE: THREEBOND has been applied on the
joint surface. Insert a screwdriver into the
gap between the ring gear and housing.
ST 5097
Stopper Then pry it up for easy removing.
11. Remove 2nd stage sun gear (20) from 2nd carrier
(18).
12. Remove the 2nd stage carrier (18) assembly from

shaft (30).
W178-02-06-012
W2-6-5
23
25 21
4
7
8
18
10
17
11
16
12
30 15
W178-02-06-004
W2-6-6
IMPORTANT: The hole for the spring pin located
CAUTION: Housing (25) assembly weight:
on the 1st stage carrier is not a
through one. Take care to the tap- 122 kg (270 lb)
ping-in distance when tapping the
spring pin in. 21. Install eyebolt (M16) into bolt (23) hole in housing
13. Tap spring pin (5) on the 1st stage carrier (21) (25). Lift housing (25). Remove bracket (ST 5097),
assembly into pin (4) using special tool (ST 1462). which has been installed at the pinion gear side.
Stop tapping when the spring pin is driven to the : 30 mm
middle of the pin hole. Do not try to tap spring pin
(5) to the end. CAUTION: Before pressing shaft (30), pro-
vide a protection cover (outer diameter: 380
14. Remove pin (4), planetary gear (7), needle bear- mm (15”), inner diameter: 110 mm (4.3”),
ing (6), thrust plate (8) from 1st stage carrier (21). thickness: 25 to 30 mm (0.98” to 1.18”)). Then,
use the press to remove the shaft while cov-
15. Remove remaining two sets of pin (4), planetary ering housing (25) and roller bearing (14) with
gear (7), needle bearing (6), thrust plate (8) from the protection cover may result in personal
1st stage carrier (21) according to the removing injury due to metal fragments flying off if the
procedure in step 13 and step 14. housing and/or bearing is broken. Use a
press of capacity less than 30 tons (66000 lb).
16. Remove thrust plate (3) from 1st stage carrier Be sure to degrease the housing inside be-
(21). fore heating the bearing. Failure to degrease
may cause a fire.
IMPORTANT: The surface of the pin except for
both ends is a rotating surface for 22. Install the protection cover on housing (25). Push
the needle bearing. the upper end of shaft (30) with a press and re-
Take care not to damage it. move it from housing (25). The inner race of roller
17. Clamp the pin (4) with a vise. Push the spring pin bearing (26) and sleeve (28) are removed with the
out using special removing tool (ST 1462). (3 shaft.
places)
25 30 14
18. Disassemble the 2nd stage carrier (18) assembly Press
according to the removing procedure for the 1st
stage carrier (21) assembly. However 6 needle Protection
bearings (12) and 6 thrust plates (11) are used on Protection
Cover
the 2nd stage carrier (18) assembly. Cover
Moreover, use ST 1463 as the extractor for spring
pin (10) .
19. Remove bolt (17) to remove lock plate (16).

: 17 mm
20. Remove bearing nut (15) from shaft (30) using W1F3-02-06-001
special nut removing tool (ST 2926).
ST 2926
15
W178-02-06-008
W2-6-7
25
26
27
28
29
30
14
W178-02-06-004
W2-6-8
23. Attach the shaft (30) assembly to the special tool IMPORTANT: Push the shaft of the special tool
bearing removal set. into the gully side of the pinion.
NOTE: Use the following parts as the special tool Secure the shaft with the hose clamp
set for removing roller bearing (26). in order not to loosen and separate
Part Size Remarks CAUTION: Shaft weight: 40 kg (90 lb)
Shaft Length: 200 mm 8 used. All should be
or Bolt (8 in) identical in length with no CAUTION: Be sure to use the guide when
Diameter: 19 mm wear and deformation on pushing shaft (30) with a press
(3/4 in) both ends.
Material: S35C (JIS), Press
1035 (AISI)
Hose Standard Diame- 2 used. Shaft (30)

Clamp ter: 8-1/2” (Appli- Roller Bearing
cable Diameter: (26) Inner Race
185 to 215 mm) Sleeve (28)
Guide Height: 160 mm

(6.3 in)
Outer Diameter: Guide
260 mm (10.24 in)
Inner Diameter:
240 mm (9.45 in)
W157-02-06-014
24. Push the spline side of shaft (30) with a press.

Bearing Removal Tool The inner race of roller bearing (26) and sleeve
(28) are removed from the shaft.
Shaft
Hose Clamp
25. Remove O-ring (29) from sleeve (28).
26. Insert a round bar into the oil passage in housing

(25). Tap the outer race of roller bearing (26) out.
Oil Passage
Outer Race
W157-02-06-012
Shaft (30)
Roller Bearing
(26) Inner Race
W178-02-06-001
Sleeve (28)
Shaft
W157-02-06-013
Guide
W2-6-9
CAUTION: Housing (25) weight:

60 kg (130 lb)
27. Secure housing (25) body with nylon sling, hoist it

by crane. Turn the up side of the housing down.
28. Insert a screwdriver into the notch on housing

(25) where oil seal (27) is mounted. Remove the
oil seal.
NOTE: THREEBOND has been applied on the
periphery of oil seal. Thus, it can not be
reused.
29. Insert a bar at the back side of the outer race of

roller bearing (14). Remove the outer race from
housing (25) while tapping with a bar and ham-
mer.
W2-6-10
(Blank)
W2-6-11
ASSEMBLE SWING REDUCTION GEAR
1
2 4
3 5
22
21 6
20
7
18
24
8
19 10
11
23
13
12
11
17
9
16
32
15
14
26
29 25 31
27
28
30
W178-02-06-003
1- Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- 1st Stage Sun Gear 10 - Spring Pin (3 Used) 18 - 2nd Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - 2nd Stage Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - 1st Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (8 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
W2-6-12
Assemble Swing Reduction Gear
1. Install O-ring (29) onto sleeve (28). 5. Apply THREEBOND #1215 on the outer surface
of oil seal (27). Put oil seal (27) flat on housing
(25) and push oil seal (27) in gently. Then place
CAUTION: Shaft + sleeve + outer race
seal mounting tool (ST 2925) on oil seal (27) and
weight: 36 kg (80 lb) tap the seal mounting tool in by hammering di-
rectly.
2. Install sleeve (28) and the inner race of roller
bearing (26) into shaft (30). Press sleeve and in- NOTE: If special tool (ST 2925) is used to replace
ner race using bearing mounting tool (ST 2923). the seal, no need to remove the sleeve.
NOTE: Press-in distance of the bearing inner race
can be assured by using the bearing
ST 2925
mounting tool. 27
25
Press
ST 2923
W178-02-06-007
26
6. Apply grease to the inner surface of oil seal (27)
28 all around. Apply grease to the outer surface of
sleeve (28) on shaft (30).
30
NOTE: Apply grease carefully when installing the
shaft to avoid accidental curling of the seal
lip from the shaft.
W178-02-06-013
CAUTION: Housing + outer race weight:

63 kg (140 lb)
CAUTION: Housing weight: 60 kg (130 lb)
7. Secure housing (25) body with a nylon sling and
3. Secure housing (25) body with a nylon sling, and
lift housing (25) off. Place ring gear (24) with the
then lift housing (25). Place sleeve (28) with the
mounting side up.
mounting side up.
8. Tap the outer race of roller bearing (14) evenly
4. Tap the outer race of roller bearing (26) evenly by
using a bar and hammer while installing the outer
using a bar and hammer while installing the outer
race into housing (25). Tap the bearing and listen
race into housing (25). Tap the bearing and listen
to ring to confirm if installation is completed.
to ring to confirm if installation is completed.
W2-6-13
24
23
15
14
25
27
30
W178-02-06-003
W2-6-14
15. Lift and place the housing (25) assembly on
CAUTION: Housing + outer races (2 used)
bracket (ST 5097). Secure the housing (25) as-
weight: 65 kg (140 lb) sembly with 2 bolts (M20) while the stopper at the
bottom of bracket is located at the middle of two
9. Install eyebolt (M16) into the ring gear mounting teeth of the pinion gear. Secure the bracket on a
bolt (23) hole in housing (25). Then lift and place workbench.
housing (25) on shaft (30). Check and align : 30 mm
carefully to protect the oil seal (27) lip from curl-
25
ing.
10. Tap the inner race of roller bearing (14) into shaft
(30) with a bar and hammer. Tap the inner race
ST 5097
until two threads of shaft bearing nut (15) appear. Stopper
NOTE: The fitting between the inner race and shaft
is tight.
11. Screw-in bearing nut (15) to shaft (30). Tighten as

much as possible by hand. W178-02-06-012
NOTE: Prevent shaft (30) from falling down when

lifting housing (25).
CAUTION: Housing + shaft + bearing weight:

122 kg (270 lb)
12. Install eyebolt (M16) into the ring gear mounting

bolt (23) hole in housing (25).
Lift and place housing (25) on a press.
13. Remove bearing nut (15) from shaft (30).
14. Place mounting tool (ST 2924) onto the inner race
of roller bearing (14). Push the inner race down
using a press.
NOTE: Press-in distance of the inner race can be
assured by using the mounting tool.
ST 2924
14
W178-02-06-011
W2-6-15
4
3 5
22
21 6
7
18
8
10
11
13
12
11
17
9
16
15
30
W178-02-06-003
W2-6-16
IMPORTANT: Take care to the direction of the IMPORTANT: Pay attention to the mounting direc-
bearing nut. tion of spring pin (10) and thrust
Grease must be applied for keeping plate (19).
correct tightening torque. 18. Assemble second stage carrier (18) according to
16. Apply a film of grease on the threaded surface of following steps.
bearing nut (15), then install bearing nut (15) on Install needle bearing (12) (2 used) into
shaft (30) with the stepped side of bearing nut planetary gear (13). Clamp planetary gear (13)
facing roller bearing (14). Tighten the bearing nut with two pieces of thrust plate (11), then install
using mounting tool (ST 2926). them together into second stage carrier (18).
: 350 N⋅m (36 kgf⋅m, 260 Ibf⋅ft)
NOTE: Grease must be applied for keeping correct When mounting needle bearings (12) (2 used),
tightening torque. the spring pin hole (in mounting pin (9)) should
be facing out. Align the spring pin hole in
second stage carrier (18) with that of pin (9).
ST 2926
15
Tap spring pin (10) into second stage carrier
(18) using the special tool (ST 1463). At this
time, the slit of the spring pin should face the
end of pin (19).
10
W178-02-06-008
Slit
17. Install lock plate (16) onto bearing nut (15) with
W178-02-06-002
bolt (17). In case the spline of lock plate and that
of shaft (30) are not aligned, tighten the bearing
Install thrust plate (19) into second stage
nut in tightening direction until both splines are
carrier (18), while the oil groove of thrust plate
aligned.
(19) is facing upward.
: 17 mm
Install needle bearings (12) (4 used), thrust
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
plates (11) (4 used), pins (9) (2 used) and
spring pins (10) (2 used) into two remaining
holes of the second stage carrier according to
the same procedure mentioned above.
IMPORTANT: Take care to the mounting location

of thrust plate (8).
19. Assemble the following parts to form the 1st stage
carrier (21) assembly according to the same
procedures 18 to 22 for 2nd stage carrier assem-
bly: planetary gears (7) (3 used), needle bearings
(6) (3 used), thrust plates (8) (3 used), pins (4) (3
used), spring pins (5) (3 used) and thrust plate (3).
Thrust plate (8) is installed under needle bearing
(6). Special tool (ST 1462) should be used as the
extractor for the spring pin.
W2-6-17
22
21
20
18
24
23
16
32
25 31
30
W178-02-06-003
W2-6-18
IMPORTANT: Take care to the mounting direction 28. Fill gear oil into ring gear (24) until the middle part
of the 2nd stage carrier. of the 1st stage sun gear (2) is submerged.
20. Install the 2nd stage carrier (18) assembly onto (Approx. 6.2 L (1.64 US gal.))
the spline of shaft (30), while the concave part of
the boss in bottom side of the carrier comes in 29. Clean off the old THREEBOND, then apply new
contact with lock plate (16). THREEBOND #1212 onto the motor (1) mounting
surface of ring gear (24).
Concave Part 18
16 CAUTION: Motor weight: 47 kg (100 lb)
30
30. Install eyebolt (M10) to motor (1) and lift motor (1)
off. Align the mating marks, and then fasten the
swing motor and ring gear (24) with bolts (22) (8
used).
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)
W178-02-06-014
Eyebolt Mounting
21. Install 2nd stage sun gear (20) into the 2nd stage Position
carrier (18) assembly with the small diameter part
of the 2nd stage sun gear facing up.
22. Clean off old THREEBOND and apply new

THREEBOND #1215 onto the mounting surface
of ring gear (24) inside of housing (25).
W178-02-06-005
CAUTION: Ring gear weight: 23 kg (51 lb)
23. Install eyebolt (M12) to the motor mounting

threaded hole on ring gear (24). Lift the ring gear
off, install the ring gear on housing (25) with
socket bolts (23) (12 used) while aligning the
mating marks.
: 14 mm
: 205 N⋅m (21 kgf⋅m, 150 Ibf⋅ft)
24. Install the 1st stage carrier (21) assembly onto the
spline of 2nd stage sun gear (20).
IMPORTANT: Take care to the mounting direction

of the sun gear.
25. Install 1st stage sun gear (2) into the 1st stage
carrier (21) assembly with the stepped side of the
sun gear facing down.
26. Install pipe (32) into housing (25) with seal tape
wound on the threaded part of the pipe.
: 18 mm
27. Wind seal tape on drain plug (31), then install

drain plug (31) into pipe (32).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
W2-6-19
DISASSEMBLE SWING MOTOR
11
8
7
6
5
4 10
3
2
24
25 29
26 30
1 27 31
28
23 27
26
25
24
12
13
14 22
15 21 32
16 20
W178-02-06-015
19
18
17
1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Plate (4 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Friction Plate (3 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)
W2-6-20
Disassemble Swing Motor
CAUTION: Another method is to float fload
and Assembly” thoroughly on page W1-1-1 brake piston (19) by blowing air from port B.
before starting the disassembly work. However, piston (13) may fly out when
blowing air. Do not use this method.
CAUTION: Swing motor assembly weight: 7. Install tool (ST 1468) into notch A of brake piston
47 kg (105 Ib) (19), then pull brake piston (19) out from casing
(1).
IMPORTANT: Do not disassemble relief valve (32).
1. Remove relief valves (32) (2 used) from valve
casing (28).
: 41 mm Notch A
13
2. Remove plugs (24) (2 used) from valve casing
1
(28). 19
: 14 mm
3. Remove springs (26) (2 used) and poppets (27)

(2 used) from valve casing (28). Port B
4. Make mating marks at the joint surface between

valve casing (28) and casing (1). Then loosen
socket bolts (29) (4 used). At this moment, there
is a clearance between valve casing (28) and
casing (1). Take this clearance down.
: 17 mm
T178-03-02-003
5. Remove valve casing (28) from casing (1).

NOTE: At this moment, valve casing (28) may be 8. Remove O-rings (17, 18) from casing (1).
with valve plate (21) attached. Take care do
not drop valve plate (21).
IMPORTANT: Be sure not to damage the mating

surface when separating valve plate
(21) from valve casing (28) or rotor
(9) with a screwdriver. (Be sure not
to mismatch the surfaces of the
valve plate when installing.)
6. If valve plate (21) is still on rotor (9) in step 5,
remove the valve plate from the rotor. Remove
springs (20) (24 used).
W2-6-21
11
8
7
6
5
4 10
3
2
13
14
15
W178-02-06-015
W2-6-22
IMPORTANT: Take care not to damage the slide
surface of rotor (9) and plunger (6).
9. Place casing (1) horizontally. Remove rotor (9),
retainer (8), plate (7) and plungers (6) (9 used)
from shaft (4).
10. Remove plates (10) (4 used), friction plates (11)

(3 used) from housing (1).
IMPORTANT: Take care not to damage the slide

surface of shoe plate (5).
11. Remove shoe plate (5) from casing (1).
12. Tap shaft (4) with a plastic hammer lightly and

remove shaft (4) from casing (1).
13. Push out oil seal (2) from casing (1).
14. Remove the outer race of bearing (3) from casing

(1) with a guide bar.
15. Remove the inner race of roller bearing (3) from

shaft (4) with a press.
IMPORTANT: Filter and orifice are mounted inside

of piston (13). Do not disassemble
them unless they are clogged or
deformed. Disassemble them only
when absolutely needed.
If the inner parts need to be replaced,
replace them as an assembly.
16. Remove piston (13) from casing (1) with pliers.
17. Remove spring (14) and ball (15) from casing (1).
W2-6-23
ASSEMBLE SWING MOTOR
27 26 25 24
12
13
14
15
16
29
T178-03-02-004 T178-03-02-003
31 30
31
30
28 32
22 21
20
23
19
18
10
17
6
11
9 8
7 3
5
1
4 T178-03-02-002
1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Plate (4 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Friction Plate (3 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)
W2-6-24
Assemble Swing Motor
IMPORTANT: Be sure to install the inner race of 11. Install brake piston (19) into casing (1) while
bearing (3) with the flange facing the aligning the mating mark.
stepped side of shaft (4). NOTE: If it is not easy to install O-rings (17, 18)
into brake piston (19) due to the resistant
1. Push the inner races of bearings (3, 22) into shaft force from the O-rings, tap them evenly
(4) with a press. with a plastic hammer to force them in.
IMPORTANT: Push oil seal (2) in, with its lip facing 12. Install springs (20) (24 used) onto brake piston
up. (19).
2. Push oil seal (2) into casing (1) with a guide plate.
3. Install the outer race of bearing (3) into casing (1)

with a guide bar.
IMPORTANT: Wind tape on the spline at the end of

shaft (4) to prevent damaging oil
seal (2) from being damaged.
4. Place casing (1) horizontally. Install shaft (4) into
casing (1).
5. Place casing (1) vertically with the valve casing

(28) mounting surface up. Then install shoe plate
(5) with its chamfered inner side facing inside.
IMPORTANT: When installing retainer (8) into

plunger (6), be sure to place the
notch side of the retainer facing
shoe plate (5).
6. Assemble plate (7) and retainer (8) with the notch
matched. Then install plungers (6) (9 used).
IMPORTANT: Apply hydraulic oil into the plunger

hole in rotor (9), then install plunger
(6).
7. Insert the plunger (6) assembly into rotor (9).
8. Place casing (1) horizontally. Install the rotor (9)

assembly onto shaft (4).
IMPORTANT: 4 notchs are on the outer side of

plate (10). And 4 notchs are on the
spline teeth side of friction plate (11).
Be sure to align each notch at the
same place when installing.
9. Place casing (1) vertically. Alternately install
plates (10) (4 used), friction plates (11) (3 used)
into casing (1).
10. Install O-ring (17) and (18) onto casing (1).
W2-6-25
Drain Port 27 26 25 24
13
14
15
29
T178-03-02-004 T178-03-02-003
28 32
22 21
23
4 T178-03-02-002
W2-6-26
IMPORTANT: If the inner parts of piston (13) need 21. Fill hydraulic oil through the drain port.
to be replaced, replace the piston as NOTE: Amount of Hydraulic oil: 0.8 L (0.211US
an assembly. gal)
Be sure to align the end face of the
piston with that of casing (1).
13. Install ball (15), spring (14) and piston (13) into
housing (1).
IMPORTANT: Tap the bearing type indicated

surface with a plastic hammer while
installing roller bearing (22).
14. Tap the outer race of bearing (22) with a plastic
hammer while installing it into valve casing (28).
IMPORTANT: Take care to the surfaces of valve

plate (21).
(Install the valve plate with the notch
in the port facing rotor (9).)
15. Install O-ring (23) onto valve casing (28). Then
install valve plate (21).
NOTE: Apply grease onto valve plate (21) to avoid
valve plate (21) coming off from valve
casing (28).
16. Apply grease to the needle part on bearing (22).
NOTE: It is easy to install shaft (4) into bearing (22)

by pushing the needle with grease.
17. Align the mating marks in valve casing (28) and

casing (1), while placing valve casing (28) onto
casing (1). Be sure to confirm that the clearance
between valve casing (28) and casing (1) is same
to that before disassembling. If the clearance is
larger than that before disassembling, reinstallation
shall be carried out from step 5.
18. Install valve casing (28) onto casing (1) with

: 17 mm
: 430 N⋅m (44 kgf⋅m, 320 Ibf⋅ft)
19. Install poppets (27) (2 used) and springs (26) ( 2

used) into valve casing (28). Tighten plug (24)
with O-ring (25) attached.
: 14 mm
: 330 N⋅m (34 kgf⋅m, 245 Ibf⋅ft)
20. Install relief valves (32) (2 used) into valve casing

(28).
: 41 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
W2-6-27
Swing Motor
1. Clearance between the out diameter of plunger

d
and the inner bore of cylinder
D-d Unit: mm (in)

0.027 (0.0011) 0.052 (0.0020)
W107-02-06-138
D D
W107-02-06-139
2. Clearance between plunger and shoe at the

crimped position
Unit: mm (in)
0 (0) 0.3 mm (0.0118 in)
δ
W107-02-06-140
W2-6-28
3. Thickness of shoe
Unit: mm (in)
5.5 (0.22) 5.3 (0.21)
W107-02-06-142
4. Thickness of friction plate

Unit: mm (in)
2.0 (0.08) 1.8 (0.07)
W107-02-06-143
W2-6-29
(Blank)
W2-6-30
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL PILOT VALVE
The following is explained on the lever stand in the left.

As for that in the right, perform the same procedure.

Removal of Front/Swing Pilot Valve
1. Remove screws (3) (5 used) from the lever stand 1, 2

then remove covers (1, 2).
3
2. Remove the clip band and disconnect the plug
receptacle.
3. Lower boots (8). Loosen lock nut (7) then remove

lever (5) and grip (6).
: 22 mm
3 W1F3-02-07-003
4. Raise boots (8). Remove screws (9) (4 used) then

remove cover (10) and boots (8).
6
IMPORTANT: Attach identification tags to 7
disconnected hoses for re-assembly. 8
5 9
5. Disconnect hoses (12) (6 used) from pilot valve 10
(11). Cap all open ends. 11
: 19 mm 4
IMPORTANT: Put mating marks on pilot valve (11)

and lever stand to aid in reassembly.
6. Remove bolts (4) (4 used) then remove pilot valve
(11) from the lever stand.
: 13 mm
12
W1F3-02-07-004
W2-7-1
Installation of Front/Swing Pilot Valve
1. Insert pilot valve (11) into the lever stand and align 6
the mating marks made when disassembling. 7
8
2. Install pilot valve (11) to the lever stand with bolts 5 9
(4) (4 used). 10
11
: 13 mm 4
: 20 N⋅m (2.1 kgf⋅m, 15 lbf⋅ft)
3. Connect hoses (12) (6 used) to pilot valve (11).

: 19 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
4. Insert lever (5) (with grip (6)) into boots (8). Install
lever (5) into pilot valve (11). 12
5. Secure lever (5) to pilot valve (11) with lock nut

(7).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
W1F3-02-07-004
6. Connect the plug receptacle and Install the clip

band.
7. Install boots (8) with cover (10) and screws (9) (4

used).
9. Install covers (1, 2) on the lever stand with screws 1, 2

(3) (5 used).
3
IMPORTANT: After installation, check the
hydraulic oil level. Run the engine
and check for oil leaks.
3 W1F3-02-07-003
W2-7-2

Tank” on page W1-4-1.) 1, 2, 3
Removal of Travel Pilot Valve
1. Remove rubber (1) from forward/reverse travel

pedal (2).
2. Remove socket bolts (3) (2 used) from pilot valve

(6) then remove forward/reverse travel pedal (2).
Brake Pedal
: 6 mm
IMPORTANT: Attach identification tags to

disconnected hoses for re-assembly.
3. Disconnect hoses (5) (4 used) from pilot valve (6). Attachment Pedal
Cap all open ends.
: 19 mm W1F3-02-14-002
4. Remove bolts (4) (2 used) then remove pilot valve 4

(6).
: 17 mm
Installation of Travel Pilot Valve
1. Install pilot valve (6) with bolts (4) (2 used).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

: 19 mm 6 W1F3-02-14-001
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 5
3. Install forward/reverse travel pedal (2) on pilot

valve (6) with socket bolts (3) (2 used).
: 6 mm
: 20 N⋅m (2.1 kgf⋅m, 15 lbf⋅ft)
4. Install rubber (1) on forward/reverse travel pedal

(2).

W2-7-3

3 4
Removal of Blade/Stabilizer Pilot Valve
2
1. Remove the under cover.
1
: 17 mm
2. Remove socket bolts (2) (2 used) and remove the

bracket (1) assembly from pilot valve (4).
: 6 mm

3. Disconnect hoses (5) (4 used) from pilot valve (4).
Cap all open ends.
: 19 mm, 22 mm
W1F3-02-07-006
4. Remove bolts (6) (2 used) and remove pilot valve
(4) from bracket (3). 5
: 17 mm 3
5
Installation of Blade/Stabilizer Pilot Valve
1. Install pilot valve (4) on bracket (3) with bolts (6) (2

used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W1F3-02-07-005
6 4
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)
3. Install the bracket (1) assembly to pilot valve (4)

with socket bolts (2) (2 used).
: 6 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)

W2-7-4
(Blank)
W2-7-5
DISASSEMBLE FRONT/SWING PILOT
VALVE
10
10
11
1
11 12
12
2 13
13
14
5
5
6 15
6
16
7
7
17
8
8
18
9
9
19
19
20
20
W1F3-02-07-001
1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing
2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Seal Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)
W2-7-6
Disassemble Front/Swing Pilot Valve
• Be sure to read “Precautions for Disassembly and IMPORTANT: Put on the mating mark to install the
Assembly” thoroughly on page W1-1-1 before plate (4) in the right direction.
starting any repair work. 4. Remove plate (4) from casing (14).
• The spool (13) diameter and the casing (14) bore
are selectively fitted. Do not replace individually. IMPORTANT: When bushings (6) (4 used) are still
• Discriminate between the disassembled parts by in casing (14), pry the bushing while
port No. where the parts are located in order to moving pusher (8) left and right.
avoid confusion. The port Nos. are indicated on Meanwhile take care not to damage
the periphery of casing (14) by embossed letters. the pusher.
IMPORTANT: Put port Nos. on the spool (13)
1. Clamp the pilot valve to vise with port plate (8) assembly and springs (10) (4 used)
facing downward and secure it. so as to avoid confusing each port.
Take care not to damage spool (13).
2. Put a wrench on cam (2) and secure it. Then 5. Remove the pusher (8) assembly, the spool (13)
remove screw joint (1) and the cam from universal assembly and springs (10) (4 used) from casing
joint (3). (14).
: 22 mm, 32 mm
6. Remove pushers (8) (4 used), O-rings (7) (4
used) and oil seals (5) (4 used) from bushings (6)
CAUTION: As soon as loosening universal
(4 used).
joint (3), the plate (4), bushings (6) (4 used)
and pushers (8) (4 used) may come up same
time for springs (10) (4 used) being
compressed. Take care not to let these parts
fly out.
3. Install special tool (ST 7260) on universal joint (3).

Rotate special tool (ST 7260) to left and remove
universal joint (3).
: 24 mm
Section A-A
ST 7260
A A
W577-02-06-003
W2-7-7
11
11 12
12
13
13
14
15
16
18
9
9
20
W1F3-02-07-001
W2-7-8
IMPORTANT: Do not remove the spool (13)
assembly unless necessary.
IMPORTANT: When removing spool (13) from
spring seats (9) (4 used), push the
spool in the spring seat, then direct
it towards the bigger hole while
remove it. However, do not push the
spring seat in more than 6 mm (0.24
in).
13
11
9
W577-02-06-004
7. Remove spring seats (9) (4 used), springs (11) (4

used) and washers (12) (4 used) from spool (13).
8. Clamp the pilot valve on a vise and secure the

pilot valve with the port plate (18) facing upward.
9. Remove socket bolts (20) (2 used) from casing

(14).
: 6 mm
10. Remove port plate (18), O-ring (15) and bushing

(16) from casing (14).
W2-7-9
ASSEMBLE FRONT/SWING PILOT VALVE
1
3
8
5
4
6
11
10
12
13
14
16
15
17
18
19
20 W1F3-02-07-002
1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing

2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Seal Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)
W2-7-10
Assemble Front/Swing Pilot Valve
• Be sure to read “Precautions for Disassembly and IMPORTANT: Install spring (10) in the same
Assembly” thoroughly on page W1-1-1 before position of when disassembling.
starting the assembly work. 5. Install springs (10) (4 used) to casing (14).
• The seal parts shall be replaced with new ones
when assembling. IMPORTANT: Install the spool (13) assemblies (4
used) in the same position of when
1. Install bushing (16) and O-ring (15) to casing (14). disassembling.
6. Install the spool (13) assemblies (4 used) to
2. Install spring pin (17) to port plate (18) and seal casing (14).
washers (19) (2 used) to socket bolts (20) (2
used) respectively. 7. Install O-rings (7) (4 used) and oil seals (5) (4
used) to bushings (6) (4 used).
IMPORTANT: Tighten socket bolts (20) (2 used) in
turn slowly. IMPORTANT: Apply a film of hydraulic oil to the
3. Install the port plate (18) assembly to casing (14) circumference of pushers (8) (4
with socket bolts (20) (2 used). used).
: 6 mm 8. Install pushers (8) (4 used) to bushings (6) (4
: 20.5±2 N⋅m used).
(2.1±0.2 kgf⋅m, 15±1.4 lbf⋅ft)
IMPORTANT: When it is difficult to install plate (4)
IMPORTANT: When installing spool (13) to spring because of the strong force from
seats (9) (4 used), insert the spool springs (10) (4 used), put the
through bigger one of the two holes bushing (6) assemblies (4 used) on
on the spring seat and move the the four holes of casing (14) and
spool to the smaller hole. However, then add plate (4). Simultaneously
do not insert the spool more than 6 press the bushing assemblies (4
mm (0.24 in). used) and tighten the universal joint
(3) temporarily.
9. Align the mating mark put when disassembling to
install the bushing (6) assemblies (4 used) and
plate (4) to casing (14).
13
9
W577-02-06-004
4. Install washers (12) (4 used), springs (11) (4

used), spring seats (9) (4 used) to spools (13) (4
used) in order.
W2-7-11
1
3
14
W1F3-02-07-002
W2-7-12
10. Install universal joint (3) to casing (14) using
special tool (ST 7260).
: 24 mm
: 47±2.9 N⋅m
(4.8±0.3 kgf⋅m, 35±2.2 lbf⋅ft)
11. Screw universal joint (3) until pushers (8) (4 used)

contact with cam (2) evenly.
IMPORTANT: When tightening screw joint (1), do

not move the location of cam (2).
12. Secure cam (2) with the spanner. Then install
screw joint (1) to universal joint (3).
: 32 mm
: 22 mm
: 69±4.9 N⋅m
(7.0±0.5 kgf⋅m, 51±3.6 Ibf⋅ft)
13. Apply grease to the rotation portion of universal

joint (3) and the top face of pusher (8).
W2-7-13
DISASSEMBLE TRAVEL, POSITIONING /
AUXILIARY, BLADE / STABILIZER PILOT
VALVE
20
7 20
8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15
15
4
11 14
14
3
3 12
13
2
2
21
1
1
W1LA-02-06-001
1- O-Ring (2 Used) 7- Boot 13 - Plug 19 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 14 - O-Ring 20 - Spring (2 Used)
3- Packing (2 Used) 9- Cam 15 - Spring (2 Used) 21 - Spring Guide (2 Used)
4- Bushing (2 Used) 10 - Pin 16 - Spool (2 Used) 22 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 17 - Washer (2 Used) 23 - Casing
6- Socket Bolt (2 Used)
W2-7-14
Disassemble Travel, Positioning/Auxiliary and
Blade/Stabilizer Pilot Valve
• Be sure to read “Precautions for Disassembly and IMPORTANT: Shim (17) adjusts the pressure of the
Assembly” thoroughly on page W1-1-1 before spool (15) assemblies (2 used), they
starting any repair work. had better not be disassembled. If
• As casing (21) and spool (15) cannot be disassembling the spool (15)
disassembled, they cannot be replaced with new assemblies, record the number and
ones one by one. thickness of shim (17).
• Put identification tags on the disassembled parts
by port to aid when re-assembling. IMPORTANT: Be sure not to remove bushing (4)
from cover (11) unless bushing (4) is
IMPORTANT: Put the mating marks onto cam (9), damaged.
pin (10), cover (11), and casing (21) 8. Pull bushings (4) (2 used) out of cover (11).
before disassembling.
1. Clamp the pilot valve in a vise to remove boot (7)
from cover (11).
2. Remove set screw (8) from cam (9). Pull pin (10)
out to remove cam (9) from cover (11).
: 2 mm
NOTE: LOCTITE is applied onto the set screw.

Steel ball (5) cannot be disassembled from
cam (9).
3. Loosen and remove socket bolts (6) (2 used)

alternately. Remove cover (11) from casing (21).
: 6 mm
4. Remove pusher (20) assemblies (2 used) from

casing (21).
5. Remove bushings (2) (2 used) from pusher (20)

assembly. Remove O-rings (1) (2 used) and
packings (3) (2 used) from bushings (2) (2 used).
IMPORTANT: Put identification tags on the

disassembled parts by port.
6. Remove spool (15) assemblies (2 used) and
springs (14) (2 used) from casing (21).
7. Remove spring guides (19) (2 used), springs (18)

(2 used), washers (16) (2 used), and shims (17)
(2 used) from spool (15) assemblies (2 used).
W2-7-15
ASSEMBLE TRAVEL, POSITIONING /
AUXILIARY, BLADE / STABILIZER PILOT
VALVE
8 10
7
9
5
20
3
6
2
11
19
18
14
17
16
12
13
15 W1LA-02-06-002
21
1- O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3- Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4- *Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6- Socket Bolt (2 Used)
NOTE: As for the item with mark “ * ”, refer to

W2-7-14.
W2-7-16
Assemble Travel, Positioning/Auxiliary and
Blade/Stabilizer Pilot Valve
• Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before
starting the assembly work.
• Clean the parts and put them by port for
assembling.
1. Install bushings (4) (2 used) to cover (11).
IMPORTANT: Be sure to install shim (17) to the

original condition.
2. Install washers (16) (2 used), shims (17) (2 used),
springs (18) (2 used), and spring guides (19) (2
used) to spools (15) (2 used) in this order.
IMPORTANT: Be sure to install the spool (15)

assembly into the original hole when
disassembling.
3. Install springs (14) (2 used) and spool (15)
assemblies (2 used) to casing (21).
4. Install O-rings (1) (2 used) and packings (3) (2

used) to bushings (2) (2 used).
3
W585-02-06-005
Lip Part
5. Install pushers (20) (2 used) to bushing (2)

assemblies (2 used). Install the bushing (2)
assemblies to casing (21).
6. Clamp casing (21) in a vise. Tighten cover (11)

: 6 mm
: 23.5 N⋅m (2.4 kgf⋅m, 17 lbf⋅ft)
7. Install cam (9) to cover (11) with pin (10).
8. Apply LOCTITE #241 onto set screw (8). Install

set screw (8) to cam (9) with pin (10).
: 2 mm
: 5 N⋅m (0.5 kgf⋅m, 4 lbf⋅ft)
9. Install boot (7) to cover (11).
W2-7-17
(Blank)
W2-7-18
UPPERSTRUCTURE / Pilot Shut-Off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

Removal
1. Remove spring (3).
1
2. Disconnect hoses (6 to 13) and pipes (14, 15). 2
: 17 mm, 19 mm, 22 mm 3
3. Remove spring pin (5) then remove lever (1). 5

4
4. Remove bolts (2) (2 used) and remove pilot
shut-off valve (4).
: 17 mm W178-02-08-001
13 14 2
12 15
11
Installation
4
1. Install pilot shut-off valve (4) with bolts (2) (2
used).
: 17 mm 6
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
10
2. Install lever (1) with spring pin (5).
3. Connect hoses (6 to 13) and pipes (14, 15).

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 7
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 8
: 22 mm 9 W178-02-08-002
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)
4. Install spring (5).
W2-8-1
DISASSEMBLE PILOT SHUT-OFF VALVE
3
6
2
7
1
8
9
13 10
11
12
W178-02-08-005
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt (3 Used)

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-2
Disassemble Pilot Shut-Off Valve
and Assembly” thoroughly on page W1-1-1 be-
fore starting the repair work.
1. Put the mating marks on body (4) and bracket

(11). Remove retaining ring (6), washer (7),
backup ring (8) and O-ring (9) from body (4) to
remove the spool (10) assembly.
2. Remove washer (1), backup ring (2) and O-ring

(3) from body (4).
3. Clamp spool (10) with a wooden pieces in a vise.

Remove socket bolts (13) (3 used) and bracket
(11).
: 4 mm
NOTE: Do not remove pin (12) unless necessary.
4. Remove socket bolt (5) from body (4).

: 8 mm
W2-8-3
ASSEMBLE PILOT SHUT-OFF VALVE
12 13 11 4 5 Z
W178-02-08-006
Section Z－Z
10 6 7 8 9 4 3 2 1 11
13
T178-03-07-002
1- Washer 5- Socket Bolt 9- O-Ring 13 - Socket Bolt (3 Used)

2- Backup Ring 6- Retaining Ring 10 - Spool
3- O-Ring 7- Washer 11 - Bracket
4- Body 8- Backup Ring 12 - Pin
W2-8-4
Assemble Pilot Shut-Off Valve
1. Apply LOCTITE#262 on socket bolt (5) and install

socket bolt (5) to body (4).
: 8 mm
: 29.4 N⋅m (3.0 kgf⋅m, 21.7 Ibf⋅ft)
2. Clamp spool (10) with a wooden pieces in a vise.

Apply LOCTITE#262 on socket bolts (13) (3
used), then install bracket (11) onto spool (10).
: 4 mm
: 3.9 N⋅m (0.4 kgf⋅m, 2.9 lbf⋅ft)
3. Install O-ring (3), backup ring (2) and washer (1)

to body (4).
4. Apply hydraulic oil to spool (10) and install spool

(10) to body (4).
5. Install O-ring (9), backup ring (8) and washer (7)

to body (4), and install retaining ring (6) to spool
(10).
W2-8-5
(Blank)
W2-8-6
UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL CON-
TROL VALVE

Removal
1. Remove the mounting bolts (14 used) of the
swing device upper side covers (2 used) and the
cab rear cover. Then, remove the covers (3
used).
: 17 mm

connected hoses for re-assembly. Signal Control Valve
2. Disconnect all hoses and pipes from each port.
: 17 mm, 19 mm, 22 mm
NOTE: When removing pipe from signal control
valve, if a snap-on tool (GAN850812B: tool
size: 19.05 mm) is used, it may be easier
to remove the pipe.
Control Valve
3. Disconnect the pressure sensor connectors
(swing, auxiliary).
4. Remove socket bolts (20) (4 used) and remove

the signal control valve. 20
: 8 mm
Installation
1. Apply LOCTITE to socket bolts (20) (4 used). In-
stall the signal control valve with them. T176-04-04-001
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
2. Connect all hoses and pipes to each port.

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)
3. Connect the pressure sensor connectors (swing,

auxiliary).
W2-9-1
Pilot Valve Side

PH
C
A
E
M
D
H
B
F
SB
PI G
Pilot Valve Side
K N
I
SH
J
DF
SA L
T178-03-06-016
Pilot Valve Side

Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Left Swing Pilot Pressure
Port F Left Pilot Valve Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I  Plug
Port J  Plug
Port K Travel Shockless Valve Travel Reverse Pilot Pressure
(Travel Pilot Valve)
Port L Travel Shockless Valve Travel Forward Pilot Pressure
(Travel Pilot Valve)
Port M Positioning/Auxiliary Pilot Valve Positioning Raise/Auxiliary Open Pilot Pressure
Port N Positioning/Auxiliary Pilot Valve Positioning Lower/Auxiliary Close Pilot Pressure
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI 4-Unit Solenoid Valve Unit Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Shuttle Valve Brake Release Pressure
(Swing Parking Brake)
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
W2-9-2
Control Valve Side
3
1
Pressure Sensor 5
(Auxiliary)
13
2 4
SK SE
Pressure Sensor 8
(Swing)
14
Control 7
Valve Side
9
6
10
SN
SL
11
T1F3-03-06-003
12 SP
Control Valve Side
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port 10  Plug
Port 11 Control Valve Travel Reverse Pilot Pressure
Port 12 Control Valve Travel Forward Pilot Pressure
Port 13 Pilot Pressure Shift Valve Positioning Raise/Auxiliary Open Pilot Pressure
Port 14 Pilot Pressure Shift Valve Positioning Lower/Auxiliary Close Pilot Pressure
Port SE  Plug
Port SN  Plug
Port SP Shuttle Valve Pump 1 Flow Rate Control Valve Control Pressure
Port SL  Plug
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
W2-9-3
NOTE: Machines Equipped with Optional Auxiliary

Flow Combining System
Control Valve Side

SM
Control
Valve Side
SN
T1F3-03-06-004
Control Valve Side

Port SM Auxiliary Flow Combiner Solenoid Valve Auxiliary Flow Combiner Valve Shift Pressure
Port SN Auxiliary Flow Combiner Reducing Valve Auxiliary Flow Combiner Valve Shift Pressure
NOTE: The reducing valve and the auxiliary flow

combiner solenoid valve are installed only
on the machines equipped with the op-
tional auxiliary flow combining system.
W2-9-4
UPPERSTRUCTURE / Travel Shockless Valve
REMOVE AND INSTALL TRAVEL
SHOCKLESS VALVE

Accumulator
Removal Charging Valve
3
1. Open the cover of the machine left side. Then,

lock the cover with the stopper.

2. Disconnect connectors (4) (2 used) and hoses (3)
(5 used). Cap open ends.
: 19 mm
1, 2
3. Remove bolts (2) (2 used) and remove travel
shockless valve (1).
: 17 mm
Installation 3
W1F3-02-10-001
4
1. Install travel shockless valve (1) with bolts (2) (2

used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
2. Connect hoses (3) (5 used) and connectors (4) (2

used).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
3. Close the cover.
W2-10-1
CONSTRUCTION OF TRAVEL
SHOCKLESS VALVE
13
1
14
4
4
T1F3-03-08-005 T1F3-03-08-004
5
Section A
7
T1F3-03-08-006
8 9 10 11 12
Section B
W2-10-2
Item Wrench Size Tightening Torque

Part Name Q’ty Remark
No. (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Solenoid 2
2 O-Ring 2 1B P14
3 Spool 2
4 Body 1
5 Spring 2
6 Plug 6
7 Orifice 2 1.6 to 2.0 (0.16 to 0.2) (1.2 to 1.5)
8 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13.0)
9 Steel Ball 2 9/32
10 Spring 2
11 O-Ring 4 1B P8
12 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13.0)
13 Nut 2 ： 19 4.9 (0.5) (3.6)
14 Tube 2 30 to 37 (3.1 to 3.8) (22 to 27)
W2-10-3
(Blank)
W2-10-4
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL 4-UNIT SOLE-
NOID VALVE UNIT

Removal
3, 4
1. Disconnect the harness connector of each
proportional solenoid valve (13 to 16). 5, 6

connected hoses for re-assembly. 2
2. Disconnect pilot hoses and pipes (1 to 9, 11, 12, 18
17, 18). Cap open ends.
: 17 mm, 19 mm 1
Solenoid Valve Unit
3. Remove bolts (10) (2 used) and remove the so-
lenoid valve unit.
: 8 mm
17
16
7
15
Installation 14
13
1. Install the solenoid valve unit with bolts (10) (2
used). 12
: 8 mm 11
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
10 8
9
2. Connect pilot hoses and pipes (1 to 9, 11, 12, 17,
18). W1F3-02-11-001
: 17 mm
: 25 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
3. Connect the harness connector of each

proportional solenoid valve (13 to 16).
W2-11-1
DISASSEMBLE PROPORTIONAL SOLE-
NOID VALVE
1
3
2
4
5
7
8
9
10
13
11
12 14
15
16
17
18
W157-02-11-016
1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- Spring 10 - Spool
W2-11-2
Disassemble Proportional Solenoid Valve
IMPORTANT: Take care not to lose spring (7) pro-

vided in the groove of solenoid (6)
when removing solenoid (6).
Do not disassemble lock nut (2) and
adjusting screw (4).
1. Remove socket bolts (1) (2 used) and solenoid
(6).
: 3 mm
2. Pull out spool (10) and remove diaphragm (9),

washer (11) and spring (12).
3. Pull sleeve (16) out and remove O-rings (13, 14,

15), washer (18) and plate (17).
W2-11-3
ASSEMBLE PROPORTIONAL SOLENOID
VALVE
4 2 6 1 8 16 13 14 10 15 18
3, 5
9 7 11 12 17
W157-02-11-001
1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- Spring 10 - Spool
W2-11-4
Assemble Proportional Solenoid Valve
IMPORTANT: Apply grease to O-rings (13, 14, 15) IMPORTANT: Lock nut (2), adjusting screw (4),
and apply a film of hydraulic oil to spring (5) and O-ring (3) are not
sleeve (16). separated, so no need to assemble
When inserting the sleeve, be sure them.
to align the ports of the sleeve with When assembling solenoid (6), take
the ports in the housing. care not to drop spring (7).
Install sleeve so that the end faces 3. Install solenoid (6) with socket bolts (1) (2 used).
of sleeve and body come to the : 3 mm
same point. : 2.9 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft)
1. Install washer (18), plate (17) into the housing.
Install O-rings (13, 14, 15) on sleeve (16), and 6
then insert the sleeve (16) assembly into the
housing.
16
15 7
14
13
1
W157-02-11-011
Housing
W157-02-11-005
IMPORTANT: Take care not to damage the edge

portion in the bore of sleeve (16)
when inserting the spool (10) as-
sembly.
After inserting spool in, check that
the spool slides in and out smoothly
without any restriction about 3 to 5
mm (0.12 to 0.20 in).
Apply hydraulic oil to the spool.
2. Install diaphragm (9), washer (11) and spring (12)
to spool (10). Then, install the spool (10) assem-
bly into sleeve (16).
10 Housing
16
12
11
W157-02-11-009
W2-11-5
NOID VALVE (FOR PUMP CONTROL)
NOTE: As for disassemble and assemble propor-

tional solenoid valve, refer to “Disassemble
and Assemble Proportional Solenoid
Valve” on page W2-11-2.

lic oil tank before starting the work. 1 2
Removal
1. Open cover (2) of the machine right side and se-
cure it with stopper (1).
2. Remove the bolts (4 used) and remove the cover

of the pump device upper side.
: 17 mm
3. Disconnect connectors (8) from solenoid valves

(7).
MCBB-07-003
4. Disconnect hoses (6) (4 used) and hoses (9) (3 6
used) from solenoid valve unit (5). Cap open 3 4
5
ends.
: 17 mm, 19 mm
5. Remove bolts (3) (4 used) and remove the sole-

noid valve unit (5) assembly from the frame.
: 17 mm
7
6. Remove the bolts (2 used) and remove solenoid
valve unit (5) from bracket (4).
: 17 mm
T1F3-01-02-010
W2-11-6
Installation 6
1. Install bracket (4) on solenoid valve unit (5) with 3 4
5
the bolts (2 used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
2. Install the solenoid valve unit (5) assembly on the

frame with bolts (3) (4 used).
7
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
3. Connect hoses (6) (4 used) and (9) (3 used) to

solenoid valve unit (5). Connect the connectors
to solenoid valve (7).
: 17 mm T1F3-01-02-010
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft) 8
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft) 9
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft) 1 2
4. Install the removed cover with the bolts (4 used).

: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
5. Remove stopper (1) then close cover (2).
MCBB-07-003
W2-11-7
CONSTRUCTION OF 3-UNIT SOLENOID
VALVE (FOR PUMP CONTROL)
1
5
6
7
8
9
10
11
12
13
14
15
16
T1F3-03-10-016

1 Adjust Screw 3
2 Lock Nut 3 : 10 5+2−0 (0.5+0.2−0) (3.7+1.5−0)
3 Solenoid 3
4 Socket Bolt 6 : 4 5+2−0 0.5+0.2−0 3.7+1.5−0
5 Spring 3
6 O-Ring 3
7 Diaphragm 3
8 Washer 3
9 O-Ring 3
10 Spring 3
11 O-Ring 3
12 Spool 3
13 O-Ring 3
14 Sleeve 3
15 Plate 3
16 Washer 3
W2-11-8
NOID VALVE (FOR BLADE/STABILIZER)

Tank” on page W1-4-1.) Solenoid Valve Solenoid Valve
for Blade for Stabilizer
Removal
IMPORTANT: The one side of solenoid valve unit
cannot be removed. Be sure to re-
move the solenoid valve unit as the
plate (7) assembly.

1. Disconnect hoses (3, 5, 6) (4 used) and (9) (2
used). Cap open ends.
: 22 mm, 19 mm
2. Disconnect connectors (2) (2 used) and (4) (2

used). W1F3-04-04-004
3. Remove bolts (1) (5 used) and remove the plate

(7) assembly. 1 2 3 1 4 5
: 17 mm
4. Remove bolts (8) (4 used) and remove the sole-

noid valve units (2 used) from plate (7).
: 17 mm
Installation
1. Install the solenoid valve units (2 used) on plate
(7) with bolts (8) (4 used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
2. Install the plate (7) assembly with bolts (1) (5

9 7, 8 6 1
used).
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft) Solenoid Valve Solenoid Valve
for Blade for Stabilizer
W1F3-02-11-002
3. Connect connectors (2) (2 used) and (4) (2
used).
4. Connect hoses (3, 5, 6) (4 used) and (9) (2

used).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)
W2-11-9
CONSTRUCTION OF 2-UNIT SOLENOID
VALVE (FOR BLADE/STABILIZER)
T1F3-03-08-001
6

1 Solenoid 2
2 Piston 2
3 O-Ring 2 1B P14
4 Body 1
5 Spool 2
6 Spring 2
W2-11-10
UPPERSTRUCTURE / Pilot Relief Valve
REMOVE AND INSTALL PILOT RELIEF
VALVE

Removal
1. Remove the bolts (6 used) then remove the cover 1 2 3

of the swing device upper side.
: 17 mm

disconnected hoses for
re-assembly.
2. Disconnect hoses (2) (6 used). Cap open ends.
: 17 mm, 19 mm, 27 mm
3. Remove bolts (4) (2 used) and remove pilot relief

valve (1) from bracket (3).
: 17 mm
Installation
1. Install pilot relief valve (1) on bracket (3) with bolts

(4) (2 used). W1F3-02-12-001
: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
4
2
2. Connect hoses (2) (6 used).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)
3. Install the removed cover with the bolts (6 used).

: 17 mm
: 50 N·m (5.1 kgf·m, 37 Ibf⋅ft)
W2-12-1
UPPERSTRUCTURE / Pilot Relief Valve
CONSTRUCTION OF PILOT RELIEF 1 2 3, 4 5 6
VALVE
W1GL-02-12-002
T1F3-03-08-002
10 9 Section A
8 7
11
12
B
13
Section B 14 T1F3-03-08-003
T1F3-03-08-008

1 Body 1
2 Plug 1 59±5.9 (6.0±0.6) (44±4.4)
3 Shim 1 0.5 mm
4 Shim 1 0.2 mm
5 Spring 1
6 O-Ring 1 1B P24
7 O-Ring 3 1B P11
8 Plug 3 26.5±3.0 (2.7±0.3) (19.5±2.2)
9 Plug 1 39±4.0 (4.0±0.4) (28.5±3.0)
10 O-Ring 1 1B P14
11 Check Valve 1
12 Spring 1
13 O-Ring 1 1B
14 Plug 1 49±4.9 (5.0±0.5) (36±3.6)
W2-12-2
UPPERSTRUCTURE / Steering Valve
REMOVE AND INSTALL STEERING VALVE

Travel Pilot Valve
1
Removal
IMPORTANT: Attach identification tags to hoses
to aid re-assembly.
1. Disconnect hoses (3) (4 used) from steering
valve (4). Cap the open ends.
2. Remove bolts (2) (4 used) from stand (1) to re- Brake Valve
move steering valve (4).
Stand Mount-
ing Bolt
Installation
2
1. Install steering valve (4) to stand (1) with bolts (2)
(4 used).
: 17 mm Attachment Pedal W1F3-02-14-002
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2. Connect hoses (3) (4 used) to steering valve (4).

1
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)
: 27 mm 2 Floor Plate
: 78 N⋅m (8 kgf⋅m, 58 Ibf⋅ft)
3
4
W216-02-12-005
W2-13-1
DISASSEMBLE STEERING VALVE
14
19
17
18
16
39
5
38
37 15
36
35
6
5
4 33
2 3 12
1 13 20
12 21
11 32
10 31
9 6
5 24
8 4
7 3 30 34
2 28
1 27
26
25
24
29
23 28
22 27
26
T1F3-03-07-004
1- O-Ring (2 Used) 11 - Seal 21 - Ball 31 - Spacer

2- Plug (2 Used) 12 - Bearing Race (2 Used) 22 - O-Ring 32 - Cap
3- Spring (2 Used) 13 - Thrust Needle 23 - Plate 33 - Screw (6 Used)
4- Holder (2 Used) 14 - Housing Assembly 24 - O-Ring (2 Used) 34 - Screw
5- Ball (2 Used) 15 - Housing 25 - Drive 35 - Plug
6- Seat (2 Used) 16 - Sleeve 26 - Ball (2 Used) 36 - O-Ring
7- Dust Seal 17 - Center Spring (6 Used) 27 - Plug (2 Used) 37 - Spring
8- Retaining Ring 18 - Pin 28 - Spring (2 Used) 38 - Poppet
9- Bushing 19 - Spool 29 - Star 39 - Valve Seat
10 - O-Ring 20 - Screw 30 - Rotor
W2-13-2
Disassemble steering valve
IMPORTANT: The O-ring (1), plug (2), spring (3), 4. Remove drive (25) and plate (23) to remove
holder (4), ball (5) and seat (6) are O-ring (22) from housing assembly (14). Remove
adjustment parts. Do not disassem- screw (20) from housing (15) with a screwdriver.
ble them. If disassemble them, the
setting may change, malfunction of 5. Dismount the steering valve from the vise. Turn
the base machine may result. the housing (15) over. Remove ball (21), springs
IMPORTANT: Cover the open ends of vice with (28) (2 used), plugs (27) (2 used), and balls (26)
cloth. Lightly secure the valve. (2 used) from housing (15). Place the steering
1. Secure the steering valve in a vice with cap (32) valve on a clean cloth with care not to damage
upward. the machined surfaces. Remove retaining ring (8)
from housing (15) with a screwdriver.
32
Vice
15
W202-02-14-002
W202-02-14-006
6. Turn spool (19) and sleeve (16) so that pin (18) is

horizontal. From the cap (32) side, push spool
2. Remove screws (33) (6 used) and (34) to remove (19) and sleeve (16) to remove bushing (9) from
cap (32). Remove O-ring (24) from cap (32). the steering valve.
Tool: 5/16 inch-12 Point Flange Head Socket
3. Remove rotor (30) to remove O-ring (24) and

spacer (31) from rotor (30).
NOTE: Take care not to allow star (29) to drop out
of rotor (30) when removing rotor (30).
W2-13-3
19
17
18
39
5 16
38
37 15
36
35
5
4
2 3 12
1 13
12 21
11
10
9
5
4
7 3
2
1
26
26
T1F3-03-07-004
W2-13-4
7. Remove seal (11) and dust seal (7) from bushing
(9).
NOTE: Take care not to damage bushing (9) when
removing seal (11).
8. Remove bearing races (12) (2 used) and thrust

needle (13) from spool (19).
9. Remove spool (19) and the sleeve (16) assembly

from housing (15).
NOTE: Remove the sleeve (16) assembly from
housing (15) while slowly turning the
sleeve (16) assembly so that sleeve (16)
doesn’t score housing (15).
10. Remove pin (18) from the sleeve (16) assembly.
11. Push spool (19) of sleeve (16) inside into forward

slightly then remove center springs (17) (6 used)
from spool (19).
12. Turn spool (19) lightly while removing it from

sleeve (16).
13. Remove O-ring (10) from housing (15)
14. Remove plug (35) from housing (15).
15. Remove spring (37), poppet (38) and valve seat

(39) from housing (15) with a magnet.
W2-13-5
ASSEMBLE STEERING VALVE
16 15 21 20 22 30 31
32
12 34
11
A B
25
33
7
24
8
T1F3-03-07-002
9 10 13 17 18 19 23 24 29
View A C View B
D
E
D
E
D
E
D E
T487-03-02-005
W1F3-02-13-001
Section C-C
Section E-E
36 35 37 38 39
T1F3-03-07-003
Section D-D
T487-03-02-006
26 27 28
6 5 4 3 2 1 T487-03-02-007
W2-13-6
1- O-Ring (2 Used) 11 - Seal 21 - Ball 31 - Spacer

2- Plug (2 Used) 12 - Bearing Race (2 Used) 22 - O-Ring 32 - Cap
3- Spring (2 Used) 13 - Thrust Needle 23 - Plate 33 - Screw (6 Used)
4- Holder (2 Used) 14 - Housing Assembly 24 - O-Ring (2 Used) 34 - Screw
5- Ball (2 Used) 15 - Housing 25 - Drive 35 - Plug
6- Seat (2 Used) 16 - Sleeve 26 - Ball (2 Used) 36 - O-Ring
7- Dust Seal 17 - Center Spring (6 Used) 27 - Plug (2 Used) 37 - Spring
8- Retaining Ring 18 - Pin 28 - Spring (2 Used) 38 - Poppet
9- Bushing 19 - Spool 29 - Star 39 - Valve Seat
10 - O-Ring 20 - Screw 30 - Rotor
W2-13-7
16 15
32
A B
25
T1F3-03-07-002
17 18 19
View A C View B
D
E
D
E
D
E
D E
T487-03-02-005
W1F3-02-13-001
Section C-C
Section E-E
36 35 37 38 39
T1F3-03-07-003
Section D-D
T487-03-02-006
26 27 28
6 5 4 3 2 1 T487-03-02-007
W2-13-8
Assemble Steering Valve
Precautions for before assemble 3. Install pin (18) into spool (19) and sleeve (16).
• Check all parts for scores or coarse surfaces. Level the ends of pin (18) with the outer diameter
If any, grind to a smooth finish using an oil stone. of sleeve (16).
IMPORTANT: Align the spring grooves on spool

(19) and sleeve (16). Pin (18)
1. Install spool (19) into sleeve (16) while turning
spool (19).
Spring Groove
W202-02-14-021
4. Install sleeve (16) assembly into housing (15)

from the cap (32) mounting side.
NOTE: Take care not to install the sleeve (16) as-
sembly with excessive force into housing
Spool (19) (15). While keeping pin (18) in the hori-
zontal position and slightly turning the
Sleeve (16) W202-02-14-019
sleeve (16) assembly right and left, install
the sleeve (16) assembly into housing (15)
until the rear ends of both the sleeve (16)
2. Place spool (19) and sleeve (16) on a flat plate
assembly and housing (15) level off.
so that the spring grooves on them align. Install
center springs (17) into special tool (ST 2497)
with the back of 2-sets of three center springs
(17) contacted each other. Install center springs
(17) into spool (19) and sleeve (16) using special
tool (ST 2497).
Spool (19)
ST 2497
Center Spring (17)
Sleeve (16)
W202-02-14-020
W2-13-9
15 21 20 22
12
11
A B
8
T1F3-03-07-002
9 10 13 19 23
View A C View B
D
E
D
E
D
E
D E
T487-03-02-005
W1F3-02-13-001
Section C-C
Section E-E
T1F3-03-07-003
Section D-D
T487-03-02-006
26 27 28
T487-03-02-007
W2-13-10
5. Install O-ring (10), bearing races (12) (2 used) 9. Lightly hold housing (15) with a vise.
and thrust needle (13) to housing (15).
10. Install O-ring (22) in housing (15). Install ball (21)
and screw (20) in housing (15) as illustrated be-
13 low. Install balls (26) (2 used), plugs (27) (2 used),
12 and springs (28) (2 used) in housing (15) as illus-
trated below. Put plate (23) on housing (15). Align
10 the bolt holes with tapped holes on housing (15).
15
Screw (20)
Ball (21)
W202-02-14-023
Housing (15)
6. Install dust seal (7) and seal (11) to bushing (9).
7. Install bushing (9) to spool (19) while tapping

bushing (9) with a plastic hammer.
NOTE: Check that bushing (9) comes in contact
with bearing race (12) flat.
W487-03-08-004
Driver
8
Spring (28)
7
15
Plug (27)
11 10
12
Ball (26)
9
Housing (15)
W212-02-14-002
8. Install retaining ring (8) to housing (15).

NOTE: After installing retaining ring (8) into hous-
ing (15), make sure that retaining ring (8)
is correctly seated in the groove on hous-
ing (15) by expanding the inner diameter of W487-03-08-005
retaining ring (8) with a screwdriver.
W2-13-11
16 15 30 31
32
12 34
11
A B
25
33
24
T1F3-03-07-002
13 18 19 23 24 29
View A C View B
D
E
D
E
D
E
D E
T487-03-02-005
W1F3-02-13-001
Section C-C
Section E-E
36 35 37 38 39
T1F3-03-07-003
Section D-D
T487-03-02-006
T487-03-02-007
W2-13-12
IMPORTANT: Steps 11 to 13 described above are 14. Install spacer (31) into rotor (30). Install O-ring
important procedure to determine (24) on cap (32). Install cap (32) on rotor (30).
the valve timing. Carefully follow the
procedures in these steps. 15. Install screws (33) (6 used) and screw (34) onto
11. Turn spool (19) and the sleeve (16) assembly so cap (32), tighten them with the specified torque.
that pin (18) is parallel to the port face on housing Tool: 5/16 inch-12 Point Flange Head Socket
(15). Draw line (B) on the end face of the spline : 28.5 N⋅m (2.9 kgf⋅m, 21 Ibf⋅ft)
on drive (25) so that line (B) is parallel to line (C)
at the yoke of drive (25). Insert drive (25) to install
the yoke of drive (25) onto pin (18). (Line (B) on 16. Install valve seat (39), poppet (38) and spring
the end face of the spline on drive (25) is parallel (37) into housing (15) then secure them with plug
to the port face on housing (15).) (35).
B
Rotor (30)
C A
Draw Line (a)
Star (29)
Drive (25)
B
Bolt Hole
Yoke
Drive (25) C
W487-03-08-006
D
12. Install O-ring (24) to rotor (30). Plate (23)
13. Face the O-ring (24) mounting side of rotor (30)

toward plate (23). Draw line (a) on star (29) so
that two tooth bottoms at the opposite sides are
on line (A). Install star (29) onto drive (25) while
aligning the spline pitch so that line (A) is parallel
to line (B).
Recheck that lines (A, B, C, and D) are all parallel
to each other. Align the bolt holes of rotor (30)
with those of housing (15) without disengaging
the splines on drive (25) and star (29).
Pin (18)
Port Face
W202-02-14-031
Port Face
Drive (25)
Make surface of pin
(18) paralleled with
port face
Pin (18)
Yoke
Housing (15) W487-03-08-007
W2-13-13
(Blank)
W2-13-14
UPPERSTRUCTURE / Brake Valve
REMOVE AND INSTALL BRAKE VALVE
1 2
Removal
IMPORTANT: Attach tags to the disconnected

hoses to aid re-assembling. 1
1. Disconnect hoses (1) (6 used) from brake valve
(2). Cap the disconnected hose ends.
: 17, 22, 27 mm
2. Remove bolts (4) (4 used) from frame (3) to re- W1F3-02-14-001
move brake valve (2).

: 17 mm
Installation
1. Install brake valve (2) to frame (3) with bolts (4)

(4 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
4
2. Connect all hoses (1) (6 used) to brake valve (2).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 Ibf⋅ft)
W1F3-02-14-002
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)
W2-14-1
DISASSEMBLE BRAKE VALVE
1
5 11
28
27 8
4 7
26
10
6
7
12
9
13
15
14
16
25
9
29 24 3
17
23
30
42 31
32 22
21 16
33
34 20
35 18
36 19
41 20
40
37
39
28
43 38
44
45
46
47
43
44
45
46 48 47
W1F3-02-14-003
W2-14-2
1- Rubber 13 - Spring Pin 25 - Bracket 37 - Push Rod

2- Brake Pedal 14 - Bushing 26 - Oil Seal 38 - P Cylinder
3- Cotter Pin (4 Used) 15 - Yoke 27 - T Flange 39 - S Cylinder
4- Stopper Bolt 16 - Pin (2 Used) 28 - O-Ring (2 Used) (1B, G45) 40 - O-Ring (1B, P32)
5- Bushing 17 - Link 29 - Rod 41 - Plug
6- Lock Nut 18 - Roller 30 - Return Spring 42 - Socket Bolt (4 Used)
7- Bushing (2 Used) 19 - Bushing 31 - Holder 43 - Spring (2 Used)
8- Pin 20 - Washer (2 Used) 32 - Spring 44 - Retaining Ring (2 Used)
9- Bushing (2 Used) 21 - Seat 33 - Balance Spring 45 - Retainer (2 Used)
10 - Pin 22 - Stopper 34 - Retainer 46 - Plunder (2 Used)
11 - Boots 23 - Boots 35 - Retainer 47 - Spool (2 Used)
12 - Pin 24 - Socket Bolt (4 Used) 36 - Pilot Piston 48 - Spring
W2-14-3
5 11
28
27 8
4 7
26
10
6
7
12
9
13
15
14
16
25
9
29 24 3
17
23
30
42 31
32 22
21 16
33
34 20
35 18
36 19
41 20
40
37
39
28
43 38
44
45
46
47
43
44
45
46 48 47 W1F3-02-14-003
W2-14-4
Disassemble Brake Valve
• Be sure to read “Precautions for Disassembly IMPORTANT: As the action force from springs is
and Assembly” thoroughly on page W1-1-1 be- applied to socket bolt (42), slowly
fore starting the disassembly work. remove socket bolt (42) while push
S cylinder (39) on top.
IMPORTANT: Before disassembling, put matching 9. Remove socket bolts (42) (4 used) from S cylin-
marks on bracket (25), T flange (27), der (39).
P cylinder (38), S cylinder (39).
1. Secure S cylinder (39) on a vice with the S cylin- 10. Remove S cylinder (39) and the P cylinder (38)
der (39) facing lower side. Except the roller (18) assembly from T flange (27).
parts, remove cotter pins (3) (3 used) then re-
move pins (8), (10), (16).
11. Pulling out the spool (47) assembly from P cylin-
der (38).
2. Remove spring pin (13) from yoke (15) to remove
pin (12).
12. Remove plunger (46), spring (48) and retaining
ring (44), retainer (45) from the spool (47) as-
3. Remove cotter pin (3) from link (17) then remove sembly.
pin (16), washers (20) (2 used) and roller (18).
13. Remove return spring (30), holder (31), rod (29),

4. Remove seat (21), stopper (22) and boots (23) balance spring (33), spring (32), retainers (34),
from T flange (27). (35) and pilot piston (36), push rod (37) from T
flange (27).
5. Remove socket bolts (24) (4 used) to remove
bracket (25) from T flange (27).
6. Secure the T flange (27) position on a vice with

the push rod (37) side facing down.
IMPORTANT: The spool (47) assembly also is

used in P cylinder (38). Be sure
store the parts correctly without
mixing.
7. Pulling out plug (41), spring (43) and the spool
(47) assembly from S cylinder (39).
8. Remove plunger (46) and retaining ring (44), re-

tainer (45) from the spool (47) assembly.
W2-14-5
ASSEMBLE BRAKE VALVE 2
1
12
11
8
15
14
25 27 38 42 39 41
16
10
16
18 21 24
23 W1F3-02-14-004
34 30 28 46 44 28 47 43 40
41
46
45
37 22 26 36 35 32 29 33 31 47 48 45 43 T1F3-03-09-002
View A 13 5
12
7
15
8
9
3
24
25
17
10
3 16
18 19 20 W1F3-02-14-005
W2-14-6
1- Rubber 13 - Spring Pin 25 - Bracket 37 - Push Rod

2- Brake Pedal 14 - Bushing 26 - Oil Seal 38 - P Cylinder
3- Cotter Pin (4 Used) 15 - Yoke 27 - T Flange 39 - S Cylinder
4- *Stopper Bolt 16 - Pin (2 Used) 28 - O-Ring (2 Used) (1B, G45) 40 - O-Ring (1B, P32)
5- Bushing 17 - Link 29 - Rod 41 - Plug
6- *Lock Nut 18 - Roller 30 - Return Spring 42 - Socket Bolt (4 Used)
7- Bushing (2 Used) 19 - Bushing 31 - Holder 43 - Spring (2 Used)
8- Pin 20 - Washer (2 Used) 32 - Spring 44 - Retaining Ring (2 Used)
9- Bushing (2 Used) 21 - Seat 33 - Balance Spring 45 - Retainer (2 Used)
10 - Pin 22 - Stopper 34 - Retainer 46 - Plunder (2 Used)
11 - Boots 23 - Boots 35 - Retainer 47 - Spool (2 Used)
12 - Pin 24 - Socket Bolt (4 Used) 36 - Pilot Piston 48 - Spring
W2-14-7
2
1
12
11
8
15
14
25 27 38 42 39 41
16
17
10
16
18 21 24
23 W1F3-02-14-004
34 30 28 46 44 28 47 43 40
41
46
45
37 22 26 36 35 32 29 33 31 47 48 45 43 T1F3-03-09-002
View A 13 5
12
7
15
8
9
3
24
25
17
10
3 16
18 19 20 W1F3-02-14-005
W2-14-8
Assemble Brake Valve
• Be sure to read “Precautions for Disassembly 10. Install spring (48), plunger (46) and spring (43)
and Assembly” thoroughly on page W1-1-1 be- into P cylinder (38).
fore starting the assembly work.
11. Align the matching marks while placing S cylinder
1. Install oil seal (26) into T flange (27). (39) onto P cylinder (38).
2. Secure T flange (27) in a vice with oil seal (26) 12. Install retainer (45) and retaining ring (44) to
facing down. spool (47).
3. Install O-ring (28) to T flange (27). 13. Install the spool (47) assembly to S cylinder (39).
4. Apply hydraulic oil onto all parts of rod (29), pilot 14. Install plunger (46), spring (43) and plug (41) to S
piston (36), push rod (37), plunger (46), spool cylinder (39).
(47). : 130 to 180 N⋅m
(13.0 to18.0 kgf⋅m, 94 to 130 Ibf⋅ft)
5. Install push rod (37), pilot piston (36) and retainer
(35), retainer (34), return spring (30), balance 15. Joint T flange (27), P cylinder (38), S cylinder (39)
spring (33), spring (32), holder (31), rod (29) into with socket bolts (42) (4 used).
T flange (27) in that order. : 60 to 75 N⋅m
(6.0 to 7.5 kgf⋅m, 43 to 54 Ibf⋅ft)
6. Install O-ring (28) to P cylinder (38).
7. Align the matching marks while placing P cylinder

(38) on the T flange (27) assembly.
8. Install retainer (45) and retaining ring (44) to

spool (47).
9. Install the spool (47) assembly to P cylinder (38).
W2-14-9
2
1
12
11
8
15
14 25 27 39
16
17
10
16
18
21 23 24 W1F3-02-14-004
22 T1F3-03-09-002
View A 13
12
15
3
24
25
17
10
16
3
3
W1F3-02-14-005
18 20
W2-14-10
16. Secure the cylinder assembly in a vice with the S 26. Secure link (17) with lock nut (6).
cylinder (39) side facing down. : 6.0 to 10 N⋅m
(0.6 to 1.0 kgf⋅m, 4.3 to 7.2 Ibf⋅ft)
17. Install bracket (25) to T flange (27) with socket
bolts (24) (4 used). 27. Install rubber (1) onto brake pedal (2).
: 60 to 75 N⋅m
(6.0 to 7.5 kgf⋅m, 43 to 54 Ibf⋅ft)
18. Install boots (23), stopper (22) and seat (21) to T

flange (27).
19. Apply grease onto all pin hole of brake pedal (2),
bracket (25), yoke (15) and link (17).
20. Install yoke (15) into brake pedal (2) with pin (12)
and spring pin (13).
21. Install roller (18), washers (20) (2 used) onto link

(17) with pin (16). Lock them with cotter pin (3).
22. Install the link (17) assembly with pin (10) and
bracket (25). Lock them with cotter pin (3).
23. Install boots (11) to the brake pedal (2) assembly,

then install it to bracket (25) with pin (8). Lock
them with cotter pin (3).
24. Install yoke (15) to link (17) with pin (16), lock
them with cotter pin (3).
25. Adjust the play of link (17) with stopper bolt (4) to
0 mm.
W2-14-11
(Blank)
W2-14-12
UPPERSTRUCTURE / Accumulator Charging Valve
REMOVE AND INSTALL ACCUMULATOR
CHARGING VALVE

Removal

disconnected hoses for 1 2 2
re-assembly.
1. Disconnect connector (1) and hoses (2) (4 used).
Cap open ends.
: 17 mm, 22 mm, 27 mm
2. Remove socket bolts (4) (2 used) and remove

accumulator charging valve (3).
: 5 mm
Installation
1. Install accumulator charging valve (3) with socket

bolts (4) (2 used).
: 5 mm
: 12 N·m (1.2 kgf·m, 8.9 Ibf⋅ft) 3, 4 Travel Shockless Valve
W1F3-02-10-001
2. Connect connector (1) and hoses (2) (4 used).

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 Ibf⋅ft)
W2-15-1
CONSTRUCTION OF ACCUMULATOR
CHARGING VALVE
5
2
4
7
10
11
12
13
14
24
23 15
21
16
17
22
18
19
20
W1F3-02-15-001
W2-15-2

1 Lock Nut 1
2 Adjusting Screw 1
3 Nut 1 45 (4.6) (33)
4 O-Ring 1
5 Spring Seat 2
6 Spring 1
7 Spool 1
8 Plug 1 18 (1.8) (13)
9 Body 1
10 Plug 1 40 (4.1) (29.5)
11 Piston 1
12 O-Ring 1
13 Spring 1
14 Spring Seat 1
15 Spring 1
16 O-Ring 1
17 O-Ring 1
18 Backup Ring 1
19 Check Valve 1
20 Sleeve 1 10 (1.0) (7.4)
21 Plug 3 7 (0.7) (5.2)
22 Compensator Plunger 1
23 Spring 1
24 O-Ring 3
W2-15-3
(Blank)
W2-15-4
UPPERSTRUCTURE / Transmission Control Valve
REMOVE AND INSTALL TRANSMISSION
CONTROL VALVE

Removal
1. Open the front right side cover of the machine.

1 2
disconnected hoses for
re-assembly.
2. Disconnect connectors (1) (2 used) and hoses (2)
(6 used). Cap open ends.
: 19 mm
3. Remove bolts (3) (2 used) and remove

transmission control valve (4).
: 17 mm
W1GL-02-16-001
Installation 2 4 3
1. Install transmission control valve (4) with bolts (3)

(2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
2. Connect connectors (1) (2 used) and hoses (2) (6

used).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
W2-16-1
CONSTRUCTION OF TRANSMISSION
CONTROL VALVE
28 29 30 31
1 2
B C
27
18 13
A
W1GL-02-16-002 12
17 16 15 14 W1F3-02-16-001
Section B
19
1 *2 5 6 7
20
21
22
23
*1 8
24
25
9
12 11 10 W1GL-02-16-003
T1F3-03-03-006
Section C
Section A
26
W2-16-2

1 Solenoid 1
2 Body 1
3 Orifice 1 5.1 to 6.4 (0.5 to 0.7) (3.8 to 4.7)
4 Orifice 1 7.8 to 9.8 (0.8 to 1.0) (5.8 to7.2)
5 O-Ring 2 1B P14
6 Spool 1
7 Plug 3
8 Spring 2
9 Spool 1
10 Plug 2 31 to 37 (3.2 to 3.8) (23 to 27)
11 O-Ring 3 1B P11
12 Solenoid 1 4.9 (0.5) (3.6)
13 Plug 1 : 22 74 to 88 (7.5 to 9.0) (55 to 65)
14 Spring 1
15 O-Ring 2 1B P20
16 Spring 1
17 Plug 1 19 to 23 (1.9 to 2.3) (14 to 17)
18 Plunger 1
19 Adjusting Screw 1 : 5
20 Seal Lock Nut 1 : 17 20 to 29 (2.0 to 3.0) (14.5 to 21.5)
21 Spring Guide 1
22 Spring 1
23 Guide 1 74 to 88 (7.5 to 9.0) (55 to 65)
24 Spring Guide 1
25 Spool 1
26 Plug 3
27 Plug 1 13.0 to 17.5 (1.3 to 1.8) (9.6 to 13.0)
28 O-Ring 1 1B P8
29 Orifice 1 5.1 to 6.4 (0.5 to 0.7) (3.8 to 4.7)
30 Spool 1
31 Spring Guide 1
*1 Nut 2 : 19 4.9 (0.5) (3.6)
*2 Tube 2 30 to 37 (3.1 to 3.8) (22 to 27)
W2-16-3
(Blank)
W2-16-4
MEMO
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SECTION 3
UNDERCARRIAGE
―CONTENTS―
Group 1 Swing Bearing Group 5 Axle
Remove and Install Swing Bearing ......... W3-1-1 Remove and Install Axle ......................... W3-5-1
Disassemble Swing Bearing ................... W3-1-4 Disassemble Front Axle.......................... W3-5-6
Assemble Swing Bearing........................ W3-1-6 Assemble Front Axle ............................ W3-5-12
Disassemble Front Differential.............. W3-5-20
Group 2 Travel Motor Assemble Front Differential .................. W3-5-24
Remove and Install Travel Motor ............ W3-2-1
Disassemble Rear Axle ........................ W3-5-28
Disassemble Travel Motor...................... W3-2-4
Assemble Rear Axle ............................ W3-5-34
Assemble Travel Motor ........................ W3-2-12
Disassemble and ASSEMBLE
Disassemble Brake Valve .................... W3-2-18
Rear Differential................................... W3-5-40
Assemble Brake Valve ......................... W3-2-20
Disassemble Steering Cylinder ............. W3-5-44
Group 3 Center Joint Assemble Steering Cylinder ................. W3-5-46
Remove and Install Center Joint ........... W3-3-1
Group 6 Axle Lock Cylinder
Disassemble Center Joint....................... W3-3-4
Remove and Install
Assemble Center Joint ......................... W3-3-6
Axle Lock Cylinder .............................. W3-6-1
Maintenance Standard ........................... W3-3-9
Disassemble and Assemble
Group 4 Transmission Axle Lock Cylinder .............................. W3-6-4
Remove and Install Transmission............ W3-4-1
Disassemble Transmission ..................... W3-4-6
Remove and Install Operate-Check
Disassemble Final Drive and
Valve (for Axle Lock Cylinder) ................ W3-7-1
Differential.......................................... W3-4-16
Construction of Operate-Check
Assemble Final Drive and Differential.... W3-4-18
Valve (for Axle Lock Cylinder)................ W3-7-2
Assemble Transmission........................ W3-4-20
Adjusting Gear Clearance..................... W3-4-30
CBBW-3-1
(Blank)
CBBW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstruc-
ture must be removed first. For removal and installa-
tion of the upperstructure, refer to “Remove and Install
Main Frame” section.
In this section, the procedure starts on the premise
that the upperstructure has already been removed.
Mark
Removal
1. Put mating marks on inner race (1) of swing
bearing (4) and chassis (2).
1 2
W105-03-01-001
2. Remove bolts (3) (36 used) from inner race (1) of

swing bearing (4).
: 30 mm
W158-03-01-001
CAUTION: Swing bearing weight:

220 kg (490 Ib)
3. Attach lifting tools (ST 0050), lift swing bearing

(4) off.
ST 0050
W110-03-01-004
4
W3-1-1
Installation
Clean the matching surfaces of the chassis and
swing bearing.
1. Apply THREEBOND#1102 to the matching sur-

faces of the chassis and swing bearing.

220 kg (490 Ib)
IMPORTANT: Failure to align the mating marks W110-03-01-004
may result in misalignment of the

inner race soft zone. Front Side Position for Grease Fitting
2. Lift the swing bearing. Align the mating marks “S” (Soft Zone)
both on the chassis and swing bearing. Marking Position
8°
Position of Plug
10°
19°
Position for Grease

Fitting
W178-03-01-001
3. Install bolts (3) (36 used) to the inner race of the

swing bearing and tighten to specification.
: 30 mm
: 490 N⋅m (50 kgf⋅m, 360 Ibf⋅ft)
W158-03-01-001
W3-1-2
4. After installing the swing bearing, fill the grease
Grease Level
bath with grease (Shell Alvania EP2 or equiva- Swing Bearing Pinion
lent) until the pinion of the swing bearing is
covered A in grease.
A: 5 mm (0.2 in)
W175-03-01-002
Grease Bath
W3-1-3
DISASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6 - Ball (121 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (121 Used)
3 - Pin
W3-1-4
Disassemble Swing Bearing
• Be sure to read “Precautions for Disassembly CAUTION: Swing bearing weight:

and Assembly” thoroughly on page W1-1-1 be- 220 kg (490 Ib)
fore starting any repair work.
3. Unseat outer race (1) of swing bearing horizon-
1. Tap stopper pin (3) of plug (4) up from the bottom tally and slightly by crane using lifting tools (ST
side. 0050). Remove seals (2, 5).
NOTE: Since pin (3) was crimped after being in- 4. Place the inner race (7) of swing bearing onto
stalled, grind the crimped part with a wooden blocks while holding outer race (1) by
grounder. crane.
5. Remove balls (6) (121 used) and supports (9)

3
(121 used) out from the plug hole, while rotating
the outer race (1).
Magnet rod (A) can be used to remove the balls
out, and a hooked wire (B) can be used to re-
4 move supports (9).
1
2
A
W105-03-01-007 7
2. Pull plug (4) out.

NOTE: Insert a bolt into the hole (M10, Pitch 1.5
mm) from it plug (4) was pull out. Then tap
or pull the bolt from inside.
6 5 W105-03-01-009
B
4
W105-03-01-008
9, 10 W105-03-01-010
6. Remove seal (2) from outer race (1) and remove

seal (5) from inner race (7) with scrapper.
W3-1-5
ASSEMBLE SWING BEARING
1 2 3
9 7 6 5 W157-03-01-003
9
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6 - Ball (121 Used) 8 - Grease Fitting (2 Used)

2 - Seal 5 - Seal 7 - Inner Race 9 - Support (121 Used)
3 - Pin
W3-1-6
Assemble Swing Bearing
IMPORTANT: Be sure to apply grease to balls (6) 2. Tap plug (4) into outer race (1) and then, drive
and to supports (9). pin (3) into the pin hole.
Crimp the head of pin (3) with a punch.
220 kg (490 Ib) 3
1. Lift the outer race horizontally and match it with 1

the inner race coaxially.
Rotating the outer race, insert balls (6), support
(9) into the plug hole one by one with a round
bar.
2 4
W142-03-01-007
3. Install lifting tools (ST 0050) onto outer race (4)

and lift outer race (4). Thoroughly degrease the
slots for seals (2, 5). Apply THREEBOND # 1745
(to seal (2)) and # 1735 (to seal (5)). Then as-
6 semble seals (2, 5) into the slots.
5 4. Fill grease 0.5 L (0.132 US gal) (Alvania EP2

W142-03-01-005
grease or equivalent) through the grease fitting
(8). Rotate the outer race while filling.
NOTE: Fill grease from two places (0.30 L).
W142-03-01-006
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Motor
REMOVE AND INSTALL TRAVEL MOTOR

Removal

connected hoses to aid
re-assembly.
Front Side
1. Remove socket bolts (1) (8 used) and split
flanges (8) (4 used) from travel motor (7). Dis- 2 3 4 5
connect main hoses (2) (2 used), then cap all dis-
connected hose ends.
2. Disconnect drain hose (4) and pilot hose (3). Cap 1

all disconnected hose ends.
6
: 27 mm
CAUTION: Travel Motor Weight:

85 kg (190 lb)
3. Loosen mounting socket bolts (5) (4 used) from 2 8 7

travel motor (7), then support the lower side of W1F3-03-02-001
travel motor (7) by a forklift. Remove socket bolts

(5) (4 used).
4. Remove travel motor (7) from transmission (6).
W3-2-1
Installation
Front Side
CAUTION: Travel Motor Weight: 2 3 4 5

85 kg (190 lb)
1. Install travel motor (7) onto transmission (6) with

socket bolts (5) (4 used). 1
6
2. Connect drain hose (4) and pilot hose (3).
: 22 mm
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
3. Connect main hoses (2) (2 used) with socket

bolts (1) (8 used) and split flanges (8) (4 used).
2 8 7
W1F3-03-02-001
W3-2-2
(Blank)
W3-2-3
DISASSEMBLE TRAVEL MOTOR
52 53 1 2 3 4 5 6 7 8
50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18
42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32
59 2 W1GL-03-02-007
45, 46, 47
16, 17
57
57
56
56
54
W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003
W3-2-4
1- Head Cover 16 - O-Ring (3 Used) 31 - Oil Seal 46 - O-Ring

2- Brake Valve 17 - Cover 32 - Shim 47 - Cover
3- O-Ring (2 Used) 18 - Adjusting Screw 33 - Key 48 - Valve Plate
4- Pin 19 - Lock Nut 34 - Retaining Ring 49 - Socket Bolt
5- Spring 20 - Pin 35 - Retaining Ring 50 - Piston
6- Spring 21 - Adjusting Screw 36 - Housing 51 - Ring (2 Used)
7- Collar 22 - Lock Nut 37 - Drive Shaft 52 - Servo Piston
8- Spring Collar 23 - Rotor 38 - Retainer Plate 53 - Lock Pin
9- Bushing 24 - Adjusting Plate 39 - Center Joint 54 - Socket Bolt (4 Used)
10 - O-Ring 25 - Spring 40 - Plunger (7 Used) 55 - Socket Bolt (8 Used)
11 - Spring 26 - Screw Bolt (7 Used) 41 - Lock Nut 56 - Plug (2 Used)
12 - Retaining Ring 27 - Bearing 42 - Adjusting Screw 57 - Relief Valve (2 Used)
13 - Control Piston 28 - Ring 43 - O-Ring 58 - Socket Bolt (4 Used)
14 - Sleeve 29 - Bearing 44 - Pin (2 Used) 59 - Socket Bolt (2 Used)
15 - Retaining Ring 30 - Adjusting Shim 45 - O-Ring
W3-2-5
52 53 1 2 3 4 5 6 7 8
50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18
42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32
59 2 W1GL-03-02-007
45, 46, 47
16, 17
57
57
56
56
54
W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003
W3-2-6
Disassemble Travel Motor
• Be sure to read “Precautions for Disassembly CAUTION: Take care when removing cover
and Assembly” thoroughly on page W1-1-1 be- (17) as the spring inside may fly out.
5. Remove socket bolts (54) (4 used). Remove
O-ring (16) and cover (17).
CAUTION: Travel Motor Weight: : 6 mm
85 kg (190 lb)
6. Remove bushing (9), spring (6), collar (7) and
1. Set the travel motor onto wooden block (100×500 spring (5) from head cover (1) in order.
mm (3.9×19.7 in)) with drive shaft (37) facing
down. 7. Remove spring collar (8) and spring (11) from
NOTE: When the work bench is used cover (17).
Work bench: ST 5092
Upper Plate: ST 7333 8. Remove O-rings (10, 16) (3 used respectively),
adjusting screw (18), lock nut (19) and pin (20)
2. Remove socket bolts (59) (2 used). Remove from cover (17).
brake valve (2) and O-rings (3) (2 used).
: 5 mm 9. Remove retaining ring (12) from the inside of
cover (17). Remove the sleeve (14) assembly.
IMPORTANT: Do not to disassemble relief valves
(57) (2 used). 10. Pull control piston (13) out from sleeve (14) then
3. Remove relief valves (57) (2 used) and plugs remove retaining ring (15) from control piston
(56) (2 used) from head cover (1). (13).
: 27 mm, 32 mm
11. Remove socket bolts (58) (4 used) from head
4. Record the measurement of A part before recover (1). Remove cover (47) and O-rings (45),
moving cover (17). (46).
: 10 mm
17
17 18 19
W1GL-03-02-006
W3-2-7
42 41
21
39
23 22
37
36
34 31
33 32
W1GL-03-02-007
W1F3-03-02-002
55
36
55 36 W1F3-03-02-003
W3-2-8
12. Record measurements of B, C parts before re- 16. Secure rotor (23) by using screw bar (M8, Pitch
moving lock nuts (22, 41) and adjusting screws 1.25 mm (0.05 in), Length 120 mm (4.7 in)) to
(21, 42). prevent rotor (23) removing, then remove adjust-
ing screw (42).
B Screw Bar
Lock Nut
C Washer
42 41
22 21
W1GL-03-02-003
W1GL-03-02-005
13. Loosen lock nuts (22, 41) and remove adjusting 17. Place housing (36) horizontally. Remove key (33)
screws (21), (42). from drive shaft (37).
: 19 mm
: 6 mm 18. Remove retaining ring (34) from housing (36).
Remove shim (32).
14. Install adjusting screw (42) (M12, Pitch 1.75 mm
(0.1 in), Length 100 mm (3.9 in)) into the location 19. Place the housing (36) assembly on press stand
where adjusting screw (21) is inserted, the angle with rotor (23) side facing down. Pull drive shaft
of center shaft (39) should be zero. (37) assembly out.
20. Pull oil seal (31) out from housing (36).
Temporarily
Mounting Adjusting
Screw (42)
W1GL-03-02-004
39
15. Put matching marks onto the contact surface of

head cover (1) and housing (36). Remove socket
bolts (55) (8 used). Remove head cover (1) from
housing (36).
: 14 mm
W3-2-9
52 53 1 4
50 51
49
W1GL-03-02-007
W1F3-03-02-002
W1F3-03-02-003
W3-2-10
21. Secure head cover (1) on the vice with valve
plate (48) facing up.
22. Remove socket bolt (49) and piston (50) from

servo piston (52).
: 12 mm
23. Remove rings (51) (2 used) from piston (50).
CAUTION: Heat lock pin (53). Take care not

to burn yourself.
24. Heat the mounting portion of lock pin (53) using a

torch.
NOTE: LOCTITE is used for lock pin (53). Heat it
with slow fire.
25. Remove pin (4) from servo piston (52).
26. Pull servo piston (52) out from head cover (1).
W3-2-11
ASSEMBLE TRAVEL MOTOR
52 53 1 2 3 4 5 6 7 8
50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18
42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32
59 2 W1GL-03-02-007
45, 46, 47
16, 17
57
57
56
56
54
W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003
W3-2-12
1- Head Cover 16 - O-Ring (3 Used) 31 - Oil Seal 46 - O-Ring

2- Brake Valve 17 - Cover 32 - Shim 47 - Cover
3- O-Ring (2 Used) 18 - Adjusting Screw 33 - Key 48 - Valve Plate
4- Pin 19 - Lock Nut 34 - Retaining Ring 49 - Socket Bolt
5- Spring 20 - Pin 35 - Retaining Ring 50 - Piston
6- Spring 21 - Adjusting Screw 36 - Housing 51 - Ring (2 Used)
7- Collar 22 - Lock Nut 37 - Drive Shaft 52 - Servo Piston
8- Spring Collar 23 - Rotor 38 - Retainer Plate 53 - Lock Pin
9- Bushing 24 - Adjusting Plate 39 - Center Joint 54 - Socket Bolt (4 Used)
10 - O-Ring 25 - Spring 40 - Plunger (7 Used) 55 - Socket Bolt (8 Used)
11 - Spring 26 - Screw Bolt (7 Used) 41 - Lock Nut 56 - Plug (2 Used)
12 - Retaining Ring 27 - Bearing 42 - Adjusting Screw 57 - Relief Valve (2 Used)
13 - Control Piston 28 - Ring 43 - O-Ring 58 - Socket Bolt (4 Used)
14 - Sleeve 29 - Bearing 44 - Pin (2 Used) 59 - Socket Bolt (2 Used)
15 - Retaining Ring 30 - Adjusting Shim 45 - O-Ring
W3-2-13
52 53 1 2 3 4 5 6 7 8
50 51 9 10
49
48
11
45, 46, 47
12
44
13
14
43 15
16, 17
18
42 41 20
40 21
39 19
23 22
38 24
37 25
26
36
27
28
35 29
30
34 31
33 32
59 2 W1GL-03-02-007
45, 46, 47
16, 17
57
57
56
56
54
W1F3-03-02-002
58 55
36
55 36 W1F3-03-02-003
W3-2-14
Assemble Travel Motor
• Be sure to read “Precautions for Disassembly 7. Install retaining rings (15, 12) to control piston
and Assembly” thoroughly on page W1-1-1 be- (13) and sleeve (14).
8. Apply hydraulic oil to cover (17), control piston
1. Secure head cover (1) to a vice with valve plate (13) and sleeve (14).
(48) facing up.
9. Install O-ring (10) to cover (17).
2. Apply hydraulic oil on servo piston (52), then in-
sert it into head cover (1) and install pin (4). 10. Install control piston (13) to sleeve (14), then in-
sert the sleeve (14) assembly and pin (20) into
3. Apply LOCTITE #241 on lock pin (53) and insert cover (17).
it into servo piston (52) to secure pin (4).
11. Install spring collar (8) and spring (11) into the
4. Install rings (51) (2 used) to piston (50). Install cover (17) assembly.
piston (50) to servo piston (52) with socket bolt
(49). 12. Install O-rings (16) (3 used) onto head cover (1)
: 12 mm and the cover (17) mounting surface.
: 190 N⋅m (19.5 kgf⋅m, 140 lbf⋅ft)
13. Install spring (5), collar (7), spring (6) and bush-
5. Install O-ring (45) to head cover (1), install O-ring ing (9) into the large chamber of head cover (1).
(46) to cover (47). Install cover (47) to head cover
(1) with socket bolts (58) (4 used). 14. Install the cover (17) assembly to head cover (1)
: 10 mm with socket bolts (54) (4 used).
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft) : 6 mm
: 96 N⋅m (9.8 kgf⋅m, 71 lbf⋅ft)
6. Install adjusting screw (18) and lock nut (19) into
cover (17) with the measurement of A part as re-
corded before disassembling.
18 19
W1GL-03-02-006
W3-2-15
42 41
21
39
23 22
37
36
34 31
33 32
W1GL-03-02-007
57
57
56
56
W1F3-03-02-002
55
36
55 36 W1F3-03-02-003
W3-2-16
CAUTION: After heating housing (36), start 20. Install adjusting screw (42) (M12, Pitch 1.75 mm
installation work. (0.1 in), Length 100 mm (3.9 in)) into the location
where adjusting screw (21) is inserted, the angle
15. Heat housing (36) to 50 to 80°C, then install the of center shaft (39) should be zero.
drive shaft (37) assembly into housing (36). If the
drive shaft (37) assembly cannot be installed, in-
sert it by using a bar.
16. Install oil seal (31) and shim (32) into housing
(36) with the rotor (23) side facing down, then in-
stall retaining ring (34).
Temporarily
17. Install key (33) into drive shaft (37). Mounting Adjusting
Screw (42)
18. Place the travel motor on wooden block (100×
500 mm (3.9×20 in)) with the drive shaft (37)
facing down. W1GL-03-02-008
NOTE: When using work stand:

21. Align the matching marks and install head cover
Work Bench: ST 5092
(1) to housing (36) with socket bolts (55) (8
Upper Plate: ST 7333
used).
: 14 mm
19. Remove screw bar, lock nut and washer from ro-
: 295 N⋅m (30 kgf⋅m, 215 lbf⋅ft)
tor (23).
Screw Bar 22. Remove temporarily tightened adjusting screw
Lock Nut (42).
Washer 23. Install adjusting screw (42), lock nut (41), adjust-
ing screw (21) and lock nut (22) into housing (36)
with the measurements of B and C as recorded
before disassembling.
W1GL-03-02-003
C
42 41
22 21
W1GL-03-02-005
24. Install relief valves (57) (2 used) and plug (56) to

head cover (1).
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
: 32 mm
: 83±5 N⋅m (8.5±0.5 kgf⋅m, 62±3.6 lbf⋅ft)
W3-2-17
DISASSEMBLE BRAKE VALVE B
8
16, 17
W1F3-03-02-002
1 2 3
13 14 15
12
Section A
7 6
11 10 9
8
Section B
T1F3-03-05-034
1- O-Ring (2 Used) 6- Check Valve (2 Used) 11 - Check Valve Assembly (2 Used) 16 - Plug
2- Cover 7- O-Ring (2 Used) 12 - Cover 17 - Orifice
3- Socket Bolt (4 Used) 8- Plug 13 - Socket Bolt (4 Used)
4- Plug (2 Used) 9- O-Ring 14 - Valve Casing
5- Spring (2 Used) 10 - Shuttle Valve 15 - Counterbalance Valve
W3-2-18
Disassemble Brake Valve
1. Remove socket bolts (13) (4 used). Remove

cover (12) from valve casing (14).
: 10 mm
2. Remove socket bolts (3) (4 used). Remove cover

(2) from valve casing (14).
: 10 mm
IMPORTANT: Be sure to turn counterbalance

valve when pulling it out. It may be
stuck otherwise.
3. Turn counterbalance valve (15) while pulling it
out from valve casing (14) slowly.
CAUTION: When removing plug (4), spring

(5) will fly out due to spring force.
4. Remove plugs (4) (2 used), springs (5) (2 used)

and check valve (6).
: 36 mm
5. Pull check valve assembly (11) out from valve

casing (14) with a socket wrench.
6. Remove plug (8) from valve casing (14).
7. Pull shuttle valve (10) out from valve casing (14)

with a socket wrench.
: 4 mm
8. Remove plug (16) from valve casing (14).
9. Remove orifice (17) from valve casing (14).

: 3 mm
W3-2-19
ASSEMBLE BRAKE VALVE B
8
16, 17
W1F3-03-02-002
1 2 3
13 14 15
12
Section A
7 6
11 10 9
8
Section B
T1F3-03-05-034
1- O-Ring (2 Used) 6- Check Valve (2 Used) 11 - Check Valve Assembly (2 Used) 16 - Plug
2- Cover 7- O-Ring (2 Used) 12 - Cover 17 - Orifice
3- Socket Bolt (4 Used) 8- Plug 13 - Socket Bolt (4 Used)
4- Plug (2 Used) 9- O-Ring 14 - Valve Casing
5- Spring (2 Used) 10 - Shuttle Valve 15 - Counterbalance Valve
W3-2-20
Assemble Brake Valve
1. Install orifice (17) and plug (16) to valve casing

(14).
2. Install shuttle valve (10) and plug (8) into valve

casing (14).
3. Install check valve assemblies (11) (2 used) to

valve casing (14).
4. Install check valves (6) (2 used) to check the

valve assembly (11).
5. Install spring (5) to plug (4), then install the plug

(4) assembly to valve casing (14).
: 36 mm
: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)
IMPORTANT: Turn counterbalance valve (15)

slowly while inserting it to valve
casing (14) and check that it can
move smoothly.
6. Insert counterbalance valve (15) into valve cas-

ing (14).
7. Install cover (12) to valve casing (14) with socket

bolts (13) (4 used).
: 10 mm
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft)
8. Install cover (2) to valve casing (14) with socket

bolts (3) (4 used).
: 10 mm
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft)
W3-2-21
(Blank)
W3-2-22
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT

NOTE: When removing and installing the center

joint, remove the main hoses (5 used) on
the back of boom and remove the center
joint easily. 1 2 3 4
Removal
1. Remove the swing device upper side cover
mounting bolts (2 used) and remove the cover.
: 17 mm
Center Joint
2. Disconnect connectors (6) (2 places upper and
lower).
3. Remove bolts (5) (2 places upper and lower).

: 17 mm
4. Remove bolts (4) (3 used) and pull out the slip ring
(3) assembly from center joint. (Length: approx.
670 mm (26.4 in))
5. Remove bolts (2) (5 used) and remove stopper

(1).
: 24 mm

6. Disconnect hoses (37 used) from the center joint.
Plug all disconnected hose ends and the ports on
the center joint.
: 17 mm, 19 mm, 22 mm, 27 mm, 36 mm 6 5
NOTE: Upperstructure side: 15 used T1F3-03-10-014
Undercarriage side: 22 used
Refer to COMPONENT OPERATION /
Others (Undercarriage) group in the T/M on
page T3-11-2.
W3-3-1
7. Install eyebolts (M16, Pitch 2.0 mm) (2 used) into

the bolt (2) holes. 1 2 3 4
CAUTION: Center joint assembly weight:

93 kg (210 lb).
Center Joint
IMPORTANT: The propeller shaft and transmission
are under the center joint. When
lifting the center joint while
disassembling, be careful not to
damage the propeller shaft and
transmission.
8. Remove bolts (7) (4 used), and then lift the center
joint assembly.
: 22 mm
Installation
CAUTION: Center joint assembly weight:

93 kg (210 lb).
IMPORTANT: The propeller shaft and transmission

6 5
are under the installation position of
center joint. When lifting the center T1F3-03-10-014
joint, take care not to damage the
propeller shaft and transmission.
Chassis Frame
1. Apply LOCTITE to bolts (7) (4 used). Lift the
center joint, then install the center joint on the 7
chassis frame with bolts (7) (4 used).
: 22 mm
: 180 N⋅m (18.5 kgf⋅m, 130 lbf⋅ft)
2. Connect hoses (37 used) to the center joint.

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W1F3-03-03-002
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
W3-3-2
3. Apply LOCTITE#577 to bolts (2) (5 used). Install

stopper (3) with bolts (2) (5 used). 1 2 3 4
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
4. Insert slip ring (3) into the center joint.

Center Joint
5. Install slip ring (3) with bolts (4) (3 used).
6. Connect connector (6) (2 places upper and lower).
7. Secure connector (6) with bolt (5) (2 places upper

and lower).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
6 5
T1F3-03-10-014
W3-3-3
DISASSEMBLE CENTER JOINT
2
3
12 3
11
6
10 T1F3-03-10-001
9
8 7
1 - Spindle 4- Body 7- O-Ring 10 - Cover

2 - O-Ring 5- Oil Seal (15 Used) 8- Bolt (4 Used) 11 - Plate
3 - Bushing (2 Used) 6- Bolt (6 Used) 9- O-Ring 12 - O-Ring
W3-3-4
Disassemble Center Joint
CAUTION: Center joint weight: 93kg (210 lb) IMPORTANT: Use two picks for easy removal.
Take care not to damage the seal
1. Remove mounting bolt (6) of cover (10) diagonally, groove with the picks.
and install eyebolts (M10, Pitch 1.5 mm, length 18 5. Remove oil seals (5) (15 used) from body (4).
mm: ST 0001). Then, secure center joint on
workbench (ST 5103).
IMPORTANT: Be sure to make the mating marks

on body (4) and spindle (1).
2. Remove bolts (6) (6 used) and remove cover (10)
and O-rings (11, 12).
: 17 mm
3. Remove bolt (8) and remove plate (11). 3

: 17 mm
4, 5
IMPORTANT: Take care not to scratch the seal
slide face of spindle (1).
4. Install puller onto the center joint, pull out spindle
(1). W105-03-03-015
Puller
6. Remove bushings (3) (2 used) and O-rings (2, 12)

from body (4).
W202-03-03-011
NOTE: There is a hole for the harness at the

center of spindle (1). Make a plate to cover
the hole. Place the plate cap between the
puller and spindle (1) to pull out spindle.
W3-3-5
ASSEMBLE CENTER JOINT
2
3
12 3
11
6
10 T1F3-03-10-001
9
8 7
1 - Spindle 4- Body 7- O-Ring 10 - Cover

2 - O-Ring 5- Oil Seal (15 Used) 8- Bolt (4 Used) 11 - Plate
3 - Bushing (2 Used) 6- Bolt (6 Used) 9- O-Ring 12 - O-Ring
W3-3-6
Assemble Center Joint
CAUTION: Body (4) weight: 40 kg (89 lb)
1. Install O-rings (2, 12) into body (4).
NOTE: If bushing (3) is removed, be sure to

reinstall bushing (3) before reassembling.
2. Install oil seals (5) (15 used) into body (4).
IMPORTANT: After installing the seals, apply

grease to the inner wall of body (4),
and the seals.
3. Put spindle (1) on workbench, install spindle (1)

into body (4), align the mating marks made during
disassembly.
IMPORTANT: Slowly and straightly insert spindle

(1) along with the center of body (4),
because the clearance between
body (4) and spindle (1) is
approximately 0.1 mm. 0.1 mm
4. Tap body (4) lightly with a plastic hammer, insert

body (4) until it touches spindle (1).
5. Install plate (11) onto spindle (1) with bolts (8) (4

used).
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
6. Install O-ring (7) to body (4) and install O-ring (9)

to spindle (1).
7. Install cover (10) with bolts (6) (6 used). W105-03-03-024
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W3-3-7
When replacing the body or spindle with a new one,
the following procedures are required:
Press bushing (3) into body. 1

1. Clean body (4) and bushing (3).
2. Press bushing (3) into body (4) using pressing
4
tool.
Pressing force: 0.5 to 1.5 tons

Pressing tool (1): ST 7331 3
W105-03-03-029
W3-3-8
Parts Name Allowable Limit (basis of judgement) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Scored, abnormal wear Replace
3. Uneven wear (wear range is less Replace
than 180°)
uneven wear
Bushing
T157-01-01-040
Sliding surface of Scored or something hurt it. Replace

sealed part
Sliding surface of 1) Scored more than 0.1 mm (0.004 in). Replace
body and spindle 2) Scored less than 0.1 mm (0.004 in) Repair with oil stone
except sealed deep.
part
Body, Spindle 1) Wear more than 0.5 mm (0.02 in) Replace
deep.
Abnormal wear.
Sliding surface of
2) Wear less than 0.5 mm (0.02 in) Repair to smooth
plate
deep.
3) Scored less than 0.5 mm (0.02 in) Repair to smooth
deep and able to repair.
1) Wear less than 0.5 mm (0.02 in). Replace
Sliding surface of 2) Wear less than 0.5 mm (0.02 in). Repair to smooth
Cover plate 3) Scored less than 0.5 mm (0.02 in) Repair to smooth
and able to repair.
W3-3-9
(Blank)
W3-3-10
UNDERCARRIAGE / Transmission
REMOVE AND INSTALL TRANSMISSION

When removing and installing the transmission, the

propeller shaft and the pipe of travel motor must be
removed. Refer to the pages for the “Remove and In-
stall Propeller Shaft”, “Remove and Install Travel Mo-
tor”.
IMPORTANT: Be sure to bleed air from hydraulic

and brake circuits when installing
transmission.
Refer to TROUBLESHOOTING /
Troubleshooting B group in the T/M.
Removal
1 2 3 4 5 6 7 8
IMPORTANT: In order to keep the balance of
weight, remove the travel motor
when removing the transmission.
1. Disconnect hoses (8) (2 used), and hose (7) from
travel motor (10). Cap all disconnected hose
ends.
: 17 mm, 27 mm
: 12 mm
20 Rear
IMPORTANT: Attach identification tags to hoses to Side
aid re-assembly.
2. Remove nut (20) (4 used) and plate (3). Remove
cover (19).
: 17 mm
19 18 17 16 15 14 12, 13 11 10 9
3. Disconnect hoses (1) (2 used) and hose (11) from W1F3-03-02-004
transmission (16). Cap all disconnected hose

3 4 5 7
ends.
: 19 mm
4. Remove nut (12, 13). Remove cover (5).

: 19 mm
5. Disconnect connector (4) from transmission (16).

: 13 mm
Rear
Side
18 16 15 14 12, 13 11 10 9
W1F3-03-02-005
W3-4-1
CAUTION: Propeller shaft (9) weight: 3 4 5 7

30 kg (66 lb)
6. Remove nuts (15) (8 used), and then insert bar

inside fork (14) and lever it toward the rear side in
order to lower propeller shaft (9) onto the ground.
: 14 mm
CAUTION: Propeller shaft (23) weight:

30 kg (66 lb) Rear
Side
7. Remove nuts (24) (8 used), and then insert bar in
between flanges (21, 22), and lever it toward the
front side in order to lower propeller shaft (23) to
the ground. 18 16 15 14 12, 13 11 10 9
: 14 mm W1F3-03-02-005
CAUTION: 3 21 22
Transmission (16) weight : 140 kg (310 lb)
Travel motor (10) weight : 85 kg (190 lb)
Plate (3) weight : 43 kg (951 lb)
8. Loosen bolts (18) (3 used) at plate (3), hold the 23

lower side of transmission by using a forklift, and 24
then remove bolts (18) (3 used).
: 30 mm Front
Side
IMPORTANT: It is afraid that connector (2) and
wiring might be broken if transmis- 1
sion (16) assembly is lowered di- 18
rectly onto the ground.
W1F3-03-04-001
9. Lower transmission (16) assembly slightly (about
100 mm), disconnect connector (2), remove clip
(17), and lower transmission (16) onto the ground. 1 2 3
: 17 mm
10. Remove bolts (25) (3 used), and then remove

plate (3) form transmission (16).
: 30 mm
Rear
25 Side
18 17 16 10
W1F3-03-02-004
W3-4-2
Installation
25 2 3
CAUTION: Travel motor (10) weight:
85 kg (190 lb)
Transmission (16) weight: 140 kg (310 lb)
Plate (3) weight: 43 kg (95 lb)
1. Install plate (3) to transmission (16) with bolts (25)

(3 used).
: 30 mm
: 540 N⋅m (55 kgf⋅m, 400 lbf⋅ft) 20
2. Connect connector (2). Install clip (17) to plate (3).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
3. Install the transmission (16) assembly to chassis 19 18 17 16 W1F3-03-02-004

: 30 mm 3 21 22
: 540 N⋅m (55 kgf⋅m, 400 lbf⋅ft)
30 kg (66 lb)
23
4. Install propeller shaft (23) to flange (21) with nuts
(24) (8 used). 24
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
5. Connect hoses (1) (2 used) to transmission (16).

1
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 18 16
4 5 W1F3-03-04-001
6. Install cover (19) to plate (3) with bolts (30) (4
used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
7. Connect hose (11) and connector (4) to transmis-

sion (16).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
8. Install cover (5) to transmission (16) with bolt (12)

and nut (13)
: 13 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
16 12, 13 11
W1F3-03-02-005
W3-4-3
9. Connect hoses (6) and (7) to travel motor (10).

: 17 mm 6 7 8
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 27 mm
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
10. Connect hoses (8) (2 used) to travel motor (10).

: 12 mm
: 140 N⋅m (14.0 kgf⋅m, 103 lbf⋅ft)

30 kg (66 lb)
11. Connect propeller shaft (9) to transmission (16)

with nuts (15) (8 used) at fork (14).
: 14 mm 16 15 14 10 9
: 108 N⋅m (11.0 kgf⋅m, 80 lbf⋅ft) W1F3-03-02-005
W3-4-4
(Blank)
W3-4-5
56
DISASSEMBLE TRANSMISSION
55
W1F3-03-05-005
A Part
W1F3-03-05-006
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
A Part
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-6
1- Flange 15 - O-Ring 29 - Friction Plate (11 Used) 43 - Shim

2- Relief Valve 16 - O-Ring 30 - Plate (10 Used) 44 - Friction Plate (6 Used)
3- Shaft 17 - Seal Ring 31 - Spacer 45 - Piston
4- Retaining Ring 18 - Backup Ring (2 Used) 32 - Retaining Ring 46 - Disc Spring (3 Used)
5- O-Ring 19 - Piston 33 - Shim 47 - Gear Case
6- Drive Case 20 - Retaining Ring 34 - Retaining Ring 48 - Socket Bolt (9 Used)
7- Plug 21 - O-Ring 35 - U-Ring 49 - Disc Spring (2 Used)
8- O-Ring 22 - Gasket 36 - O-Ring 50 - Seal
9- Spring 23 - O-Ring 37 - Bearing 51 - Ring
10 - Bearing 24 - Seal Ring 38 - Sun Gear 52 - O-Ring (2 Used)
11 - Retaining Ring 25 - Plate 39 - Cover 53 - Retaining Ring
12 - Piston Ring (2 Used) 26 - Retaining Ring 40 - Retaining Ring 54 - Retaining Ring
13 - Piston 27 - Ring Gear 41 - Disc Carrier 55 - Hose
14 - Seal Ring 28 - Plate 42 - Plate (6 Used) 56 - Hose (2 Used)
W3-4-7
B Part
65 66 108
109
63
110
64
111
W1F3-03-05-005
W1F3-03-05-006
57 58 59 60 61 62 63, 64 65 66 67 68 69 70 71 72 73 74
75, 76
B Part 77
107 78
106
79
105
80
103, 104
81
82
102 83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-8

7- Plug 21 - O-Ring 35 - Ring 49 - Disc Spring (2 used)
11 - Retaining Ring 25 - Plate 39 - Cover 53 - Retaining
12 - Piston Ring (2 Used) 26 - Retaining Ring 40 - Retaining Ring 54 - Retaining
13 - Piston 27 - Ring Gear 41 - Disc Carrier 55 - Hose
57 - Retaining Ring (3 Used) 71 - Bearing 85 - Bolt (2 Used) 100 - Bolt (2 Used)

58 - Plate (3 Used) 72 - Bearing 86 - Plate 101 - Lock Plate
59 - Needle bearing (3 Used) 73 - Shaft 87 - O-Ring 102 - Clutch
60 - Planetary Gear (3 Used) 74 - Bearing 88 - Gear 103 - Shim
61 - Needle bearing 75 - Shift Interlock Controller 89 - Seal 104 - Retaining Ring
62 - Carrier 76 - Socket Bolt (3 Used) 90 - Retaining Ring 105 - Retaining Ring
63 - Shift fork 77 - Gear 91 - Cover 106 - Bearing
64 - Shoe (2 Used) 78 - Cover 92 - Bolt (7 Used) 107 - Retaining Ring
65 - Plug 79 - Bearing 93 - Bearing 108 - Socket Bolt
66 - Pin 80 - Cover 94 - Seal 109 - Spring Pin
67 - Retaining Ring 81 - Plate 95 - Plate 110 - Lever
68 - Retaining Ring 82 - Bolt (8 Used) 96 - O-Ring 111 - Bolt
69 - Gear 83 - Flange 97 - Bolt (8 Used) 112 - Cover
70 - Plug 84 - Lock Plate 98 - Flange 113 - O-Ring
99 - Plate 114 - Plate
W3-4-9
56
55
W1F3-03-05-005
A Part
W1F3-03-05-006
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
A Part
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-10
Disassemble Transmission
1. Disconnect hoses (56) (2 used) and pipe (55) 8. Remove screw and breather from gear case (47).
from gear case (47). : 5 mm
: 19 mm, 27 mm : 12 mm
Breather
2. Loosen plug (7).

: 24 mm
3. Remove socket bolts (48) (9 used) and retaining

ring (11). Remove drive case (6) from gear case
(47).
: 12 mm
4. Remove plug (7), O-ring (8), spring (9) and the

piston (13) assembly from drive case (6).
: 24 mm
5. Remove seal ring (14) from piston (13).

Screw W1GL-03-04-009
6. Remove disc springs (49) (2 used) from piston

(19). 9. Remove O-ring (15), seal ring (17) and backup
rings (18) (2 used) from gear case (47).
7. Pull piston (19) out from gear case (47) by using a
compressor. 10. Remove retaining ring (20) from gear case (47).
NOTE: Plug port A then supply air by using pres- 11. Remove gasket (22) from gear case (47) by using
sure to pull piston (19) out. an offset driver.
A 12. Remove O-ring (23) from gasket (22).
13. Remove O-ring (21) from gear case (47).
14. Remove plates (42) (6 used) and friction plates

(44) (6 used) from gear case (47).
15. Remove plate (25) from gear case (47).

B
W1GL-03-04-009
W3-4-11
A Part
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-12
16. Remove retaining ring (26) from gear case (47),
and then pull the shaft (3) assembly out from gear
case (47).
17. Secure the shaft (3) assembly on a vice with relief

valve (2) facing down.
18. Remove retaining ring (34) and shim (33) from

shaft (3). Remove sun gear (38).
19. Remove retaining ring (40) from ring gear (27).

Remove ring gear (27) from piston (45).
20. Remove the cover (39) assembly from shaft (3).
21. Remove retaining ring (32) from cover (39). Re-

move bearing (37) from cover (39).
22. Remove spacer (31), plates (30) (10 used) and

friction plates (29) (11 used) and plate (28) from
shaft (3).
23. Remove disc carrier (41) and shim (43) from shaft
(3).
24. Remove seal ring (24) from disc carrier (41).
25. Remove piston (45), disc springs (46) (3 used)

and plate (114) from shaft (3).
26. Remove retaining ring (54) from shaft (3).
27. Remove shaft (3) from a vice.
28. Remove retaining rings (4, 53) from shaft (3) to

remove shaft (3) from flange (1).
29. Remove bearing (10) and relief valve (2) from

shaft (3).
30. Remove piston ring (12) from shaft (3).
31. Remove ring (51) and seal (50) from flange (1).
32. Remove O-rings (52) (2 used) from flange (1).
W3-4-13
B Part
65 66 108
109
63
110
64
111
W1F3-03-05-005
W1F3-03-05-006
57 58 59 60 61 62 63, 64 65 66 67 68 69 70 71 72 73 74
75, 76
B Part 77
107 78
106
79
105
80
103, 104
81
82
102 83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-14
33. Remove retaining ring (107) from gear (69). Re-
move the carrier (62) assembly from gear case
(47).
34. Remove retaining rings (57) (3 used) and plates

(58) (3 used) from carrier (62).
35. Remove planetary gears (60) (3 used) and needle

bearings (61) (3 used) from carrier (62).
36. Remove retaining ring (105) from carrier (62).

Remove bearing (106) from carrier (62).
37. Remove bolt (111) from lever (110). Remove

clutch (102) and shoes (64) (2 used) from shift
fork (63).
: 17 mm
38. Remove plug (65) from gear case (47), tap and
remove spring pin (109) to gear case (47) inside
from shift fork (63).
: 10 mm
39. Pull the lever (76) assembly out from gear case
(47) then remove shift fork (63) from inside.
40. Remove socket bolts (76) (3 used). Remove shift

interlock controller (75) from gear case (47).
: 6 mm
41. Pull shaft (73) out from gear (69).
42. Remove retaining ring (67) from gear case (47).

Remove the gear (68) assembly from gear case
(47).
43. Remove retaining ring (104) and shim (103) from

gear (69). Remove gear (77) from gear (69).
44. Remove the cover (78) assembly from gear (69).
45. Remove retaining ring (68) from cover (78). Re-

move bearing (71) from cover (78).
46. Remove bearing (72) from gear (69).
W3-4-15
DISASSEMBLE FINAL DRIVE AND DIF-
FERENTIAL
79
80
81
82
83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
47 - Gear Case 85 - Bolt (2 Used) 92 - Bolt (2 Used) 99 - Plate

79 - Bearing 86 - Plate 93 - Bearing 100 - Bolt (2 Used)
80 - Cover 87 - O-Ring 94 - Seal 101 - Lock Plate
81 - Plate 88 - Gear 95 - Plate 112 - Cover
82 - Bolt (8 Used) 89 - Seal 96 - O-ring 113 - O-ring
83 - Flange 90 - Retaining Ring 97 - Bolt (8 Used)
84 - Lock Plate 91 - Cover 98 - Flange
W3-4-16
Disassemble Final Drive and Differential
1. Remove bolts (85, 100) (2 used respectively) from

lock plate (84, 100).
2. Remove plate (86, 99), O-ring (87, 96) from gear

(88).
: 17 mm
3. Remove the flange (83, 98) assembly from gear

(88).
NOTE: When bolts (82, 97) are not replaced, do
not remove plates (81, 95) from flanges (83,
98).
4. Remove seal (89, 94) from cover (80) and gear

case (47).
5. Remove bolts (92) (7 used) from cover (80) then

pull cover (80) out using removed bolts (92) (3
used).
: 19 mm
6. Remove the cover (80) assembly and cover (91)

from gear (88).
7. Remove retaining ring (90) from cover (80).

Remove bearing (79) and O-ring (113) from cover
(80).
8. Remove bearing (93) and cover (112) from gear

case (47).
W3-4-17
ASSEMBLE FINAL DRIVE AND DIFFERENTIAL
79
80
81
82
83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
47 - Gear Case 85 - Bolt (2 Used) 92 - Bolt (7 Used) 99 - Plate

79 - Bearing 86 - Plate 93 - Bearing 100 - Bolt (2 Used)
80 - Cover 87 - O-Ring 94 - Seal 101 - Lock Plate
81 - Plate 88 - Gear 95 - Plate 112 - Cover
82 - Bolt (8 Used) 89 - Seal 96 - O-ring 113 - O-ring
83 - Flange 90 - Retaining Ring 97 - Bolt (8 Used)
84 - Lock Plate 91 - Cover 98 - Flange
W3-4-18
Assemble Final Drive
1. Insert bearing (79) into cover (80), and lock it with 8. Install flanges (83, 98) to gear (88), and attach
retaining ring (90). O-rings (87, 96).
2. Attach seal (89) and O-ring (113) to cover (80). 9. Mount flanges (83, 98) with plates (86, 99), and
bolts (85) (2 used) and (100), and then fasten
3. Install cover (91) and the cover (80) assembly to them with lock plates (84, 101).
gear (88). : 17 mm
: 46 N⋅m (5.0 kgf⋅m) (34 lb)
4. Install cover (112) to gear case (47).
5. Install the gear (88) assembly into gear case (47),

and lock it with bolts (92) (7 used).
: 19 mm
: 79 N⋅m (8 kgf⋅m) (58 lb)
6. Install bearing (93) into the gear (88) assembly.
7. Install seal (94) into gear case (47) as shown

below.
98 94 47
2.0+1.0 mm W1GL-03-04-001
(0.08+0.04 in)
W3-4-19
ASSEMBLB TRANSMISSION
56
55
W1F3-03-05-005
A Part W1F3-03-05-006
A Part
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-20

7- Plug 21 - O-Ring 35 - U-Ring 49 - Disc Spring (2 Used)
13 - Piston 27 - Ring Gear 41 - Disc Carrier 55 - Pipe
W3-4-21
B Part
65 66 108
109
63
110
64
111
W1F3-03-05-005
B Part
W1F3-03-05-006
57 58 59 60 61 62 63, 64 65 66 67 68 69 70 71 72 73 74
75, 76
77
107 78
106
79
105
80
103, 104
81
82
102 83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-22

7- Plug 21 - O-Ring 35 - Ring 49 - Disc Spring (2 used)
13 - Piston 27 - Ring Gear 41 - Disc Carrier 55 - Pipe
57 - Retaining Ring (3 Used) 71 - Bearing 85 - Bolt (2 Used) 100 - Bolt (2 Used)

58 - Plate (3 Used) 72 - Bearing 86 - Plate 101 - Lock Plate
59 - Needle bearing (3 Used) 73 - Shaft 87 - O-Ring 102 - Clutch
60 - Planetary Gear (3 Used) 74 - Bearing 88 - Gear 103 - Shim
61 - Needle bearing 75 - Shift Interlock Controller 89 - Seal 104 - Retaining Ring
62 - Carrier 76 - Socket Bolt (3 Used) 90 - Retaining Ring 105 - Retaining Ring
63 - Shift fork 77 - Gear 91 - Cover 106 - Bearing
64 - Shoe (2 Used) 78 - Cover 92 - Bolt (7 Used) 107 - Retaining Ring
65 - Plug 79 - Bearing 93 - Bearing 108 - Socket Bolt
66 - Pin 80 - Cover 94 - Seal 109 - Spring Pin
67 - Retaining Ring 81 - Plate 95 - Plate 110 - Lever
68 - Retaining Ring 82 - Bolt (8 Used) 96 - O-Ring 111 - Bolt
69 - Gear 83 - Flange 97 - Bolt (8 Used) 112 - Cover
70 - Plug 84 - Lock Plate 98 - Flange 113 - O-Ring
99 - Plate 114 - Plate
W3-4-23
B Part
65 66 108
109
63
110
64
111
W1F3-03-05-005
B Part
W1F3-03-05-006
57 58 59 60 61 62 63, 64 65 66 67 68 69 70 71 72 73 74
75, 76
77
107 78
106
79
105
80
103, 104
81
82
102 83
101 84
85
100
86
99 87
98 88
89
90
91
92
97 96 95 94 93 112 47 113
W1F3-03-05-008
W3-4-24
Assemble Transmission
1. Install bearing (73) and needle bearing (60) to

gear (68).
2. Install bearing (71) to cover (78) and secure it with

retaining ring (68).
3. Install gear (69) to the cover (78) assembly.
4. Install the cover (78) assembly to gear case (47)

and secure them with retaining ring (67).
5. Install gear (69) and shim (103) to gear (77),

secure them with retaining ring (104).
6. Install shoes (64) (2 used) to shift fork (63), install

the shift fork (63) assembly to cluch (102).
7. Install the shift fork (63) assembly into gear case

(47). Install the pin (66) assembly to gear case
(47). Align the spring pin (109) hole of pin (66) to
secure them with spring pin (109).
8. Install lever (110) to gear case (47) with bolt (111).

: 17 mm
: 65 N⋅m (6.6 kgf⋅m, 48 lbf⋅ft)
9. Install plug (65) to gear case (47).

: 10 mm
: 95 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
10. Install bearing (106) to carrier (62) and secure it

with retaining ring (105).
11. Install needle bearings (59) (3 used), planetary

gears (60) (3 used), plates (58) (3 used) and
retaining rings (57) (3 used) to carrier (62) in
order.
12. Install the carrier (62) assembly to gear (69) and

secure them with retaining ring (107).
W3-4-25
56
55
W1F3-03-05-005
A Part
W1F3-03-05-006
A Part
8 9 10 11 114 13 14 15 16 17、18 19 20 21 22 23 24 25
26
6
27
28、29、30、31
5
32
4 33
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-26
13. Install bearing (10) into shaft (3) and secure them 18. Install plate (114) and the piston (45) assembly to
with retaining ring (4). the shaft (3) assembly, and then install shim (43)
into inside.
14. Install piston rings (12) (2 used) to shaft (3).
19. Install seal ring (24) to disc carrier (41), install the
15. Install shaft (3) to flange (1) and secure it with disc carrier (41) assembly to the shaft (3)
retaining ring (53). assembly.
Install seal (50) into the flange (1) inside, secure it
with ring (51). 20. Install plate (28) friction plates (29) (11 used) and
plates (30) (10 used), spacer (31) to the shaft (3)
16. Install retaining ring (54), U-ring (35) and O-ring assembly (disc carrier) in order.
(36) to shaft (3) in order.
21. Install bearing (37) to cover (39), secure it with
CAUTION: When install U-ring (35), be sure
to put the groove of U-ring (35) facing the disc 22. Install ring gear (27) to the shaft (3) assembly
carrier (41) side. (plate part).
17. Install disc springs (46) (3 used) to piston (45).

23. Install the cover (39) assembly to the ring gear
(27) assembly, secure them with retaining ring
(40).
24. Install sun gear (38), shim (33) and retaining ring
49 (34) to the shaft (3) assembly.
25. Install gear case (47) to the shaft (3) assembly,

secure it with retaining ring (26).
46
CAUTION: Install plate (25) with the

machined part facing retaining ring (26).
26. Install plate (25), friction plates (44) (6 used) and

45
plates (42) (6 used) to the ring gear (27) out race
part alternatively.
W1GL-03-04-010
114
W3-4-27
56
ASSEMBLB TRANSMISSION
73
55
75, 76
W1F3-03-05-005
A Part
W1F3-03-05-006
A Part
8 9 10 11 114 13 14 15 16 17, 18 19 20 21 22 23 24 25
26
6
27
28, 29, 30, 31
5
32
4 33
3 34
54
2 35
12 36
37
38
39
1
40
41
53 50 52 51 49 48 47 46 45 44 43 42
W1F3-03-05-007
W3-4-28
27 Install O-ring (23) to gasket (22). 36. Install piston (13), spring (9) and plug (7) to drive
case (6) in order.
28. Install O-ring (21) to the gear case (47) inside, : 24 mm
install gasket (22) and secure them with retaining : 140 N⋅m (14 kgf⋅m, 101 lbf⋅ft)
ring (20).
37. Install O-ring (5) to drive case (6).
29. Install seal ring (17) and backup rings (18) (2
used) to the gear case (47) inside. Install O-ring 38. Install shaft (73) to shaft (3), install shift interlock
(15). controller (75) to gear case (47) with socket bolts
(76) (3 used).
30. Install piston (19) to gear case (47). : 6 mm
: 23 N⋅m (2.5 kgf⋅m, 18.1 lbf⋅ft)
31. Align disc springs (49) (2 used) on piston (19)
surface. 39. Connect hoses (56) (2 used) and pipe (55) to gear
case (47).
49
19
114 W1GL-03-04-010
32. Install O-ring (16) to the flange of piston (19) side

on drive case (6).
33. Install drive case (6) to gear case (47) with socket
bolts (48) (9 used) and retaining ring (11).
: 10 mm
: 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
34. Install seal ring (14) to piston (13).
35. Install O-ring (8) to plug (7).
W3-4-29
ADJUSTING GEAR CLEARANCE
When assembling the drive pinion, error in adjusting

shim may occur due to the big gear clearance.
A) Correct clearance between gear and pinion.
Meshing Surface (Concave Part) Meshing Surface (Convex Part)
W1GL-03-05-021
W1GL-03-05-019 W1GL-03-05-020
B) Increasing clearance of pinion is necessary.
Clearance of pinion
W1GL-03-05-027
Reducing Thickness of Shim for Pinion

W1GL-03-05-022 W1GL-03-05-023
C) Decreasing clearance of pinion is necessary.
Clearance of pinion
W1GL-03-05-027
Increasing Thickness of Shim for Pinion

W1GL-03-05-025
W1GL-03-05-026
W3-4-30
UNDERCARRIAGE / Axle
REMOVE AND INSTALL AXLE
1
2
Tank” on page W1-4-1.) 3
Removal of Front Axle

1. Loosen mounting nuts (4) (20 used) from tires (3)
(4 used) and tire rings (2) (2 used).
2
: 30 mm
4
T1F3-01-02-002
3
2. Jack up frame (1) with tire (3) floated then put the
blocks under the machine.
90 to 110°
CAUTION: Tire (3) weight: 98 kg (220 lb)
Tire ring (2) weight: 17 kg (38 lb)
3. Remove nuts (4) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used).
W1GL-03-08-003
: 30 mm Front Axle Block
4. Disconnect brake hoses (5) (2 used) and grease

hose (7).
: 17 mm, 22 mm 5
7
8
5. Disconnect steering hoses (14) (2 used) from
6
steering cylinder (13).
: 22 mm 9
5
10
CAUTION: Propeller shaft weight:
20 kg (44 lb)
6. Remove nuts (12) (8 used) and propeller shaft

(11).
13, 14 12 W1F3-03-05-013
11
7. Remove nuts (10) (2 used) and bolt (9). 4
: 24 mm
CAUTION: Front axle (6) weight:

590 kg (1300 lb)
CAUTION: Pin (8) weight: 14 kg (31 lb) (Outer
Diameter 60 mm (2.4 in))
1. Lift front axle (6) off to remove pin (8), then

remove front axle (6).
W3-5-1
Installation of Front Axle

5
CAUTION: Front axle (9) weight: 7
8
590 kg (1300 lb)
6
CAUTION: Pin (8) weight: 14 kg (31 lb) (Outer
Diameter 60 mm (2.4 in)) 9
5
10
1. Lift front axle (6) off, then install front axle (6) with
pin (8).
2. Lock pin (8) with bolt (9) and nuts (10) (2 used).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft) 13, 14 W1F3-03-05-013
12 11
4
3. Connect steering hoses (14) to steering cylinder
(13).
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)
4. Connect brake hoses (5) (2 used) and grease

hose (7).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)

30 kg (66 lb)
5. Install propeller shaft (11) with bolts and nuts (12) 1

(8 used).
: 14 mm
2
: 108 N⋅m (11.0 kgf⋅m, 80 lbf⋅ft)
3

6. Install tire (3), tire ring (2) and tire (3) to front axle 2
(6) in order, then temporarily tighten them with
4
nuts (4). (The installing order for both sides are
the same.)
: 30 mm 3
T1F3-01-02-002
7. Remove the block from frame (1).
8. Tight tires (3) (4 used) and tire rings (2) (2 used)

with nuts (4) (20 used):
: 30 mm
: 600 N⋅m (61 kgf⋅m, 440 lbf⋅ft)
Front Axle Block W1GL-03-08-003
W3-5-2
CAUTION: Be sure to bleed air from 1 1

(Refer to “Bleeding Air from Hydraulic Oil 2
3
Removal of Rear Axle
1. Loosen mounting nuts (4) (20 used) from tires (1)
(4 used) and tire rings (2).
: 30 mm
4
T1F3-01-02-002
2. Jack up frame (3) with tire (1) floated, then put the
blocks under the machine.

90° to 110°
3. Remove nuts (4) (20 used). Remove tires (1)
(4 used) and tire rings (2) (2 used).
: 30 mm
4. Remove brake pipes (5) (2 used).
CAUTION: Propeller shaft (10) weight: Rear Axle Block

30 kg (66 lb) SA-096
5 6
5. Remove nuts (9) (8 used). Propeller shaft (10).
: 14 mm
CAUTION: Rear Axle Weight: 440 kg (97.0 lb) 10
6. Lift rear axle (7) off to remove nut (6) (8 used) and 9
bolts (8) (8 used).
: 30 mm 7
8
W1F3-03-05-014
W3-5-3
6
Installation of Rear Axle 5
CAUTION: Rear axle (7) weight:

440 kg (970 lb)
1. Lift rear axle (7), then install rear axle (7) to frame 10
(3) with bolts (8) (8 used) and nuts (6) (8 used).
9
: 30 mm
: 560 N⋅m (57.0 kgf⋅m, 410 lbf⋅ft)
7
2. Connect brake pipe (5).
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 8
W1F3-03-05-014
4
30 kg (66 lb)
1 1
3. Install propeller shaft (10) to rear axle (7) with nuts
(9) (8 used). 2
: 14 mm
: 108 N⋅m (11gf⋅m, 80 lbf⋅ft) 3

4. Install tire (1), tire ring (2) and tire (1) into rear axle 4
(7) in order then temporarily tighten them with nuts
(4) (10 used). The installing order for both sides 2
are the same.
: 30 mm
T1F3-01-02-002
5. Remove the block from frame (3).
6. Tighten tires (1) (4 used) and tire rings (2) (2

used) with nuts (4) (20 used)
: 30 mm
: 600 N⋅m (61 kgf⋅m, 440 lbf⋅ft)
90 ～ 110°
Rear Axle Block SA-096
W3-5-4
(Blank)
W3-5-5
DISASSEMBLE FRONT AXLE
2
3 8
4 7
5 6
1
4
3
2
10 9
22 23
16 24
17 21
19 20
18
15
13 14
11 12
25
46
45
44
26
28
27 41 42 43
40
38 39
36 37
34 35
32 33
30 31 47
29
34 48
61
60
57 58 59 49
56
50
51
52
53
55 54
W1F3-03-05-011
W3-5-6
1- Body 19 - Gasket Ring 37 - U-Ring 55 - Retaining Ring (4 Used)

2- O-Ring (2 Used) 20 - Bearing 38 - Piston 56 - Lock Washer
3- Seal Ring (2 Used) 21 - Bushing 39 - Nut (6 Used) 57 - Gear
4- Bearing (2 Used) 22 - Hub Carrier 40 - U-Ring 58 - Retaining Ring
5- Bushing 23 - O-Ring 41 - Ring 59 - Retaining Ring
6- Shaft Seal 24 - Bearing 42 - Bearing Nut 60 - Sun Gear Shaft
7- Axle Shaft 25 - Wheel Stud (10 Used) 43 - Retaining Ring 61 - Washer
8- Retaining Ring 26 - Bearing Pin 44 - Plate (6 Used) 62 - Plug
9- Bolt (16 Used) 27 - Bolt (4 Used) 45 - Plate
10 - Washer (16 Used) 28 - Stopper Bolt 46 - Retaining Ring
11 - Double Joint Shaft 29 - O-Ring 47 - Friction Plate (5 Used)
12 - Retaining Ring 30 - Ring Gear 48 - Bolt (2 Used)
13 - Shaft Seal 31 - O-Ring 49 - Plug
14 - Bushing 32 - Bolt (6 Used) 50 - Planetary Carrier
15 - Joint Housing 33 - Spring Guide (6 Used) 51 - Thrust Plate (4 Used)
16 - Bolt 34 - Spring (6 Used) 52 - Planetary Gear (4 Used)
17 - Bearing Pin 35 - Plate 53 - Needle Bearing (4 Used)
18 - Shim 36 - Ring 54 - Thrust Plate (4 Used)
W3-5-7
2
3
8
4 7
1
6
5
4
3
2
9
10 16 22 23
24
17
21
18 19 20
15
14
11
12 13
25
45 46
26 44
27 43
28 41 42
39 40
38
35 36 37
33 34
32
30 31
47
29
48
60 61
58 59 49
57
56
50
51
52
55 54 53
W1F3-03-05-011
W3-5-8
Disassemble Front Axle
1. Remove plugs (49, 62) and drain oil. 9. Remove bearing nut (42) from joint housing (15).
: 8 mm, 22 mm
10. Remove the ring gear (30) assembly from joint
Remove bolts (48) (2 used). Remove planetary housing (15).
carrier (50) from hub carrier (22).
: 8 mm 11. Pull the piston (38) assembly from ring gear (30).
12. Remove nuts (39) (6 used) from the piston (38)

22 assembly. Remove bolts (32) (6 used), spring
guides (33) (6 used) and springs (34) (6 used).
: 10 mm
48
13. Remove plate (35) from ring gear (30).
48
14. Remove U-rings (40, 37) and rings (41, 36) from
piston (38).
50
62
49 W1GL-03-05-006
3. Remove retaining rings (55) (4 used). Remove

thrust plates (54) (4 used), planetary gears (52) (4
used), needle bearings (53) (4 used) and thrust
plates (51) (4 used) from planetary carrier (50).

Remove plate (45), plates (44) (6 used) and
friction plate (47) (5 used).
5. Remove retaining ring (59) from sun gear shaft

(60). Remove gear (57).
6. Remove retaining ring (58) from gear (57).
7. Remove lock washer (56) and retaining ring (43)

from ring gear (30).
8. Pull sun gear shaft (60) from double joint shaft

(11).
W3-5-9
2
3
1 4
6
5
4
3
2
16 22
24
17
20 21
18 19
15
14
11 13
26
27
W1F3-03-05-011
W3-5-10
15. Remove O-ring (31) from ring gear (30).
16. Remove O-ring (23) from hub carrier (22).
17. Remove O-ring (29) from joint housing (15).
18. Remove the hub carrier (22) assembly from joint

housing (15).
19. Remove outer races of bearings (20, 24), bushing

(21) and gasket ring (19) from hub gear (22).
IMPORTANT: When removing bearing pins (17, 26),

the inner race of bearing (4) should
be removed together. Take care not
to damage it.
20. Remove bolts (27) (4 used). Remove bearing pin

(26), O-ring (2) and seal ring (3) from joint
housing (15).
: 24 mm
21. Remove bolts (16) (4 used). Remove bearing pin

(17), shim (18), O-ring (2), and seal ring (3) from
joint housing (15).
: 24 mm
22. Remove joint housing (15) from body (1).
23. Pull outer race of bearing (4) (2 used) from body

(1).
24. Pull double joint shaft (11) out from body (1).
25. Remove bearing inner races (4) (2 used) from

bearing pins (17, 26).
26. Remove shaft seals (6, 13) from joint housing (15)
and body (1). The other side should be removed
in the same way.
NOTE: Remove bushings (5, 14) from body (1)

and joint housing (15) if necessary
W3-5-11
ASSEMBLE FRONT AXLE
4 17 2 16 20 21 25 24 35 36 37 40 41 38 44 47 45 46
18
6
52
1
51
5
8 53
54、55
61
13
60
7 43
59
11
58
3 49
15 50
26 27 29 31 14 19 22 48 23 32 33 34 39 30 42 56 57
W1F3-03-05-003
W3-5-12
1- Body 17 - Bearing Pin 33 - Spring Guide (6 Used) 48 - Bolt (2 Used)

2- O-Ring (2 Used) 18 - Shim 34 - Spring (6 Used) 49 - Plug
3- Seal ring (2 Used) 19 - Gasket Ring 35 - Plate 50 - Planetary Carrier
4- Bearing (2 Used) 20 - Bearing 36 - Ring 51 - Thrust Plate (4 Used)
5- Bushing 21 - Bushing 37 - U-Ring 52 - Planetary Gear (4 Used)
6- Shaft Seal 22 - Hub Carrier 38 - Piston 53 - Needle Bearing (4 Used)
7- Axel Shaft 23 - O-Ring 39 - Nut (6 Used) 54 - Thrust Plate (4 Used)
8- Retaining Ring 24 - Bearing 40 - U-Ring 55 - Retaining Ring (4 Used)
9- *Bolt (16 Used) 25 - Wheel Stud (10 Used) 41 - Ring 56 - Lock Washer
10 - *Washer (16 Used) 26 - Bearing Pin 42 - Bearing Nut 57 - Gear
11 - Double Joint Shaft 27 - Bolt (4 Used) 43 - Retaining Ring 58 - Retaining Ring
12 - *Retaining Ring 28 - *Stopper Bolt 44 - Plate (6 Used) 59 - Retaining Ring
13 - Shaft Seal 29 - O-Ring 45 - Plate 60 - Sun Gear Shaft
14 - Bushing 30 - Ring Gear 46 - Retaining Ring 61 - Washer
15 - Joint Housing 31 - O-Ring 47 - Friction Plate (5 Used) 62 - Plug
16 - Bolt (4 Used) 32 - Bolt (6 Used)
NOTE: As for marked “ * ”, refer to page W3-5-6
W3-5-13
4 17 2 16 20 21 25 24 35 36 37 40 41 38 44 47 45 46
18
6
52
1
51
5
8 53
54、55
61
13
60
7 43
59
11
58
3 49
15 50
26 27 29 31 14 19 22 48 23 32 33 34 39 30 42 56 57
W1F3-03-05-003
W3-5-14
Assemble Front Axle
1. Install shaft seals (6, 13) to body (1) and joint

housing (15).
2. Install outer races (2 used) of bearing (4) to body

(1).
3. Insert double joint shaft (11) into body (1).
IMPORTANT: Be sure to check double joint shaft

(11) and differential are connected.
4. Apply grease onto O-rings (2) (2 used). Install

O-rings (2) (2 used), seal rings (3) (2 used) and
inner races (2 used) of bearing (4) to bearing pins
(17, 26).
5. Apply grease on shim (18) then install it to the

bearing pin (17) assembly.
6. Install inner race of bearing (20) to joint housing

(15).
7. Install joint housing (15) to body (1) with the

bearing pins (17) and (26) assembly and secure
them with bolts (16) (4 used) and bolts (27) (4
used).
: 24 mm
: 280 N⋅m (29 kgf⋅m, 207 lbf⋅ft)
8. Install gasket ring (19) and the outer races of

bearings (20, 24) to hub carrier (22).
9. Install the hub carrier (22) assembly to joint

housing (15), install bushing (21) and the inner
race of bearing (24).
10. Install ring gear (30) to hub carrier (22) and

temporary tighten them with bearing nut (42).
: 1550 + 500 N⋅m
(155 + 51 kgf⋅m, 1140 + 370 lbf⋅ft)
11. Measure the preload of hub carrier (22).

Preload: 8 to 12 N⋅m
(0.8 to 1.2 kgf⋅m, 5.9 to 8.9 lbf⋅ft)
12. If the preload torque is within specified value,

remove bearing nut (42) and ring gear (30) again
W3-5-15
35 36 37 40 41 38
60
43
59
11
58
15
29 31 32 33 34 39 30 42 56 57
W1F3-03-05-003
W3-5-16
13. Install rings (36, 41) and U-rings (37, 40) to piston IMPORTANT: When installing the ring gear (30)
(38). Apply grease after installing them. assembly to joint housing (15),
tighten bearing nut (42) while
rotating the ring gear (30) assembly
38 in the direction of clockwise and
counterclockwise several times.
19. Install the ring gear (30) assembly to joint housing

(15) with bearing nut (42).
: 1550 + 500 N⋅m
36 37 (155 + 51 kgf⋅m, 1140 to 370 lbf⋅ft)
40 41 W1F3-03-05-020
20. Lock bearing nut (42) with retaining ring (43).

14. Install piston (38) to ring gear (30). Secure it with
plate (35), bolts (32) (8 used), spring guides (33) 21. Apply grease on thrust washer (56) and adhere it
(6 used), springs (34) (6 used) and nuts (39) (6 to retaining ring (43).
used).
: 10 mm 22. Insert double joint shaft (11) into sun gear shaft
(60).
15. Install bolt so that the dimensions A should be 0.5
to 1.5 mm (0.02 to 0.06 in) and B should be 3.75 23. Insert sun gear shaft (60) into gear (57) and
to 4.25 mm (0.15 to 0.17 in). secure it with retaining ring (58, 59)
: 10 mm
: 11 N⋅m (1.1 kgf⋅m, 8 lbf⋅ft)
B A
38
39
32 56
43 W1F3-03-05-021
16. After adjusting, secure nuts (39) (6 used) with

LOCTITE # 242.
17. Apply grease on O-ring (29) then install it to ring

gear (30).
18. Apply grease on O-ring (31) then install it to joint

housing (15).
W3-5-17
44 47 45 46
52
51
53
54、55
61
49
50
22 48 23 30
W1F3-03-05-003
W3-5-18
IMPORTANT: There are two cut-off grooves on the 30. After assembling the front axle, install straight
periphery of each of six plates (44). edge to adjust toe-in.
When attaching, align directions of Straight Edge
cut-off grooves. A1
24. Install plate (44), friction plate (47) into the inside
of ring gear (30) in order, then install plate (45)
and secure them with retaining ring (46).
25. Install O-ring (23) into the groove on the outer A2

race of hub carrier (22).
Straight Edge Tie Rod End Tie Rod End
W1GL-03-05-017
26. Install thrust plate (51), needle bearing (53),
planetary gear (52) and thrust plate (54) to
planetary carrier (50) in order and lock them with Measure the dimension A1 between the notch marked
retaining ring (55). (3 places) on straight edge, and measure the dimension A2 after
rotating both sides of wheel hub to 180°. Then adjust
with tie rod end so that dimension of A1 and A2 is the
NOTE: When disassembling, washer (61) should same
not be removed normally. When replace
planetary carrier (50), it should be replaced
together with washer (61).
27. Install the planetary carrier (50) assembly to the

hub carrier (22) assembly and secure them with
: 8 mm
: 55 N⋅m (5.6 kgf⋅m, 40 lbf⋅ft)
28. Install plug (49) into planetary carrier (50).

: 8 mm
: 69 N⋅m (7.0 kgf⋅m, 50 lbf⋅ft)
29. Supply oil into the differential and the wheel hub,
then install plug (62).
: 22 mm
: 79 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
Differential
Front Axle: 8.5 L (2.2 US gal.)
Wheel Hub Front:
Each 2.1 L (0.55 US gal.) x 2
W3-5-19
DISASSEMBLE FRONT DIFFERNTIAL
1
2
3
4
5
6
7
8
9
10
11
14
15
16
17
18
19 13 12
18
19
17
16
20
21
22 23 18
19
30
18 29
28
24 26 27
25
31
32
33
34
W1F3-03-05-017
1- Lock Plate 10 - Bearing 19 - Pinion Gear (4 Used) 28 - Shim
2- Nut 11 - Drive Pinion 20 - Differential Case 29 - O-Ring
3- Washer 12 - Spring Pin (4 Used) 21 - Washer (12 Used) 30 - Body
4- Flange 13 - Spring Pin (4 Used) 22 - Socket Bolt (12 Used) 31 - Bolt (16 Used)
5- Guard 14 - Bevel Gear 23 - Spider 32 - Washer (16 Used)
6- Seal 15 - Differential Case 24 - Body 33 - Plug
7- Bearing 16 - Thrust Washer (2 Used) 25 - Shim 34 - Plug
8- Ring 17 - Side Gear (2 USed) 26 - Bearing
9- Shim 18 - Thrust Washer (4 Used) 27 - Bearing
W3-5-20
Disassemble the Front Differential
To disassemble the differential, it is needed to remove 9. Remove side gear (17), thrust washers (18) (4
left and right tie rods. See “Remove Steering Cylinder”. used), piston gears (19) (4 used) and spider (23)
from differential case (20).
CAUTION: Front axle weight:

10. Remove side gear (17) and slide washer (16)
590 kg (1300 lb)
form differential case (20).
1. Remove plugs (33, 34), and discharge oil.

: 19 mm
2. Remove bolts (31) (16 used) and washers (32)

(16 used), and separate bodies (24, 30).
: 27mm
3. Remove the outer race of bearing (27), shim (28)

and O-ring (29) from body (30).
4. Remove the outer race of bearing (26) and shim

(25) from body (24).
5. Remove the inner races of bearings (27, 26) from

differential cases (15, 20) assemblies.
IMPORTANT: Make sure to mark matching mark

before disassembling the
differential.
6. With bevel gear (14) positioned lower, remove

socket bolts (22) (12 used), washers (21) (12
used), and separate differential cases (15, 20).
: 10 mm
7. Drive bevel gear (14) out of differential case (15),

by using a plastic hammer.
8. Remove spring pins (12) (4 used), spring pins

(13) (4 used) and thrust washer (16) from
differential case (15).
W3-5-21
1
2
3
4
5
6
7
8
9
10
11
14
24
W1F3-03-05-017
W3-5-22
11. Remove lock plate (1) from flange (4).
12. Remove nut (2), washer (3) and flange (4) from
drive pinion (11).
NOTE: Do not remove guard (5) from flange (4)

unless replacement is made.
13. Drive drive pinion (11) out of bevel gear (14), by

using a plastic hammer.
14. Withdraw inner race of bearing (10) and ring (8)

from drive pinion (11).
15. Remove the inner races of bearings (10, 7), shim

(9) and seal (6) from body (24).
W3-5-23
ASSEMBLE FRONT DIFFERENTIAL
1 2 3 4
7
8
9
14 29 27 28
10
11
21 30
22
25
Axle Shaft
Axle Shaft
15
20
24
W1F3 05-03-016
26 17 16 19 23 18 12, 13 32 31
1 - Lock Plate 10 - Bearing 19 - *Pinion Gear (4 Used) 28 - Shim

2 - Nut 11 - Drive Pinion 20 - Defferential Cace 29 - O-Ring
3 - Washer 12 - Spring Pin (4 Used) 21 - Washer (12 Used) 30 - Body
4 - Flange 13 - Spring Pin (4 Used) 22 - Socket Bolt (12 Used) 31 - Bolt (16 Used)
5 - Guard 14 - Bevel Gear 23 - Spider 32 - Washer (16 Used)
6 - Seal 15 - Defferential Cace 24 - Body 33 - *Plug
7 - Bearing 16 - Threst Washer (2 Used) 25 - Shim 34 - *Plug
8 - Ring 17 - Side Gear (2 Used) 26 - Bearing
9 - Shim 18 - Threst Washer (4 Used) 27 - Bearing
NOTE: As for marked “ * ”, refer to page W3-5-20
W3-5-24
Assemble the Front Differential
8. Install four spring pins (13) and spring pins (12) (4
1. Install shim (9) and the outer races of bearings used) to differential case (15), and then mount
(10, 7) to body (24). bevel gear (14).
2. Install the inner race of bearing (10) with drive 9. Place the assembly on work bench, with bevel
pinion (11). gear (14) positioned lower.
10. Grease thrust faces of side gears (17) (2 used),

3. Install the drive pinion (11) assembly to body (24); and install thrust washers (16) (2 used).
temporarily assemble ring (8), inner races of ring
(7) of bearing, flange (4) and washer (3). Tighten 11. Grease and install pinion gears (19) (4 used) and
them with nut (2). four thrust washers (18) to spider (23).
: 41 mm
: 430 N⋅m (4.2 kgf⋅m, 30 lbf⋅ft) 12. Install the side gear (17) assembly to differential
case (15).
4. Adjust pre load of drive pinion (11) to 1.0 – 2.0
N⋅m (0.1 – 0.2 kgf⋅m, 0.74 – 1.48 lbf⋅ft). 13. Install the spider (23) assembly to differential case
(15).
5. Remove nut (2), washer (3) and flange (4) again.
: 41 mm 14. Grease and install the side gear (17) assembly to
differential case (20).
6. Attach seal (6) to body (24).
15. Install the differential case (20) assembly to the
7. Attach flange (4) and washer (3) to drive pinion differential case (15) assembly by aligning
(11) assembly with nut (2), and affix them with matching marks.
lock plate (1).
: 41 mm
: 430 N⋅m (4.2 kgf⋅m, 30 lbf⋅ft)
W3-5-25
1 2 3 4
9
14 29 27 28
10
11
21 30
22
25
Axle Shaft
Axle Shaft
15
20
24
W1F3-03-05-016
26 17 16 19 23 18 12, 13 32 31
W3-5-26
16. Affix differential assembly to bevel gear (14) with
socket bolts (22) (12 used) and washers (21) (12
used).
: 10 mm
: 145 N⋅m (15 kgf⋅m, 107 lbf⋅ft)
17. Install the inner races of bearings (26, 27) to

differential assembly.
18. Install shim (25) and the outer race of bearing (26)
to body (24).
19. Install shim (28), the outer race of bearing (27),

and O-ring (29) to body (30).
20. Install differential assembly to body (24).
21. Affix body (30) to body (24) assembly with bolts

(31) (16 used) and washers (32) (16 used).
: 27 mm
: 410 N⋅m (42 kgf⋅m, 300 lbf⋅ft)
22. Attach plug (33) to body (24).

: 19 mm
: 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
23. Apply oil inside body (24), and install plug (34).
Front axle: 8.5 L (2.25 US gal.)
W3-5-27
DISASSEMBLE REAR AXLE
3 4
2
6 5
17 18
16
15
7 14
8 13
12
11
10
9
32
19
30 31
29
26 27 28
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49
W1F3-03-05-018
W3-5-28
1- Body 14 - O-Ring 27 - Nut (6 Used) 40 - O-Ring

2- Axle Shaft 15 - Bearing 28 - U-Ring 41 - Sun Gear Shaft
3- O-Ring 16 - O-Ring 29 - Ring 42 - Washer
4- Knuckle 17 - Ring Gear 30 - Bearing Nut 43 - Bolt (2 Used)
5- Bolt (18 Used) 18 - O-Ring 31 - Retaining Ring 44 - Plug
6- Washer (18 Used) 19 - Wheel Stud (10 Used) 32 - Plate (6 Used) 45 - Planetary Carrier
7- Bolt (16 Used) 20 - Bolt (6 Used) 33 - Friction Plate (5 Used) 46 - Thrust Plate (4 Used)
8- Washer (16 Used) 21 - Spring Guide (6 Used) 34 - Plate 47 - Planetary Gear (4 Used)
9- Screen Sheet 22 - Spring (6 Used) 35 - Retaining Ring 48 - Needle Bearing (4 Used)
10 - Gasket Ring 23 - Plate 36 - Seal 49 - Thrust Plate (4 Used)
11 - Bearing 24 - Ring 37 - Lock Washer 50 - Retaining Ring (4 Used)
12 - Bushing 25 - U-Ring 38 - Gear 51 - Plug
13 - Hub Carrier 26 - Piston 39 - Retaining Ring
W3-5-29
3 4
2
6 5
17 18
16
15
7 14
13
8
12
11
10
9
32
19
30 31
29
28
26 27
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49
W1F3-03-05-018
W3-5-30
Disassemble Rear Axle
1. Remove plugs (44, 51) and drain oil. 11. Remove nuts (27) (6 used) from the piston (26).
: 8 mm、22 mm Remove bolts (20) (6 used), spring guides (21) (6
used) and springs (22) (6 used).
2. Remove bolts (43) (2 used). Remove planetary : 10 mm
carrier (45) from hub carrier (13).
: 8 mm 12. Remove piston (26) and plate (23) from ring gear
(17).
13
13. Remove U-ring (25, 28) and ring (24, 29) from
piston (26).
43
14. Remove O-ring (18) from ring gear (17).
43
45
15. Remove O-ring (14) from hub carrier (13).
51 16. Remove O-ring (16) from knuckle (4).
44 W1GL-03-05-006
3. Remove retaining rings (50) (4 used). Remove

thrust plates (49) (4 used), planetary gears (47) (4
used), needle bearings (48) (4 used) and thrust
plates (46) (4 used) from planetary carrier (45).
NOTE: When disassembling, the washer (42)

should not be removed normally. When
replace planetary carrier (45), it should be
replaced together with washer (42).

Remove plate (34), plates (32) (6 used) and
friction plates (33) (5 used).
5. Remove retaining ring (39). Remove the sun gear

shaft (41) assembly from axle shaft (2).
6. Remove gear (38) and O-ring (40) from sun gear

shaft (41).
7. Remove lock washer (37) and retaining ring (31)

from knuckle (4).
8. Remove bearing nut (30) from knuckle (4).
9. Remove the ring gear (17) assembly from knuckle

(4).
10. Pull the piston (26) assembly out from ring gear
(17).
W3-5-31
3 4
2
6 5
15
13
11 12
10
9
36
W1F3-03-05-018
W3-5-32
17. Remove the hub carrier (13) assembly from
knuckle (4).
18. Remove the outer races of bearings (11, 15) and

gasket ring (10) from hub carrier (13).
19. Remove the inner race of bearing (11) and

bushing (12) from knuckle (4).
20. Remove bolts (5) (18 used) and washer (16 used).
Remove knuckle (4) from body (1).
21. Remove O-ring (3), screen sheet (9) and seal (36)
from knuckle (4).
22. Pull axle shaft (2) out from body (1).
W3-5-33
ASSEMBLE REAR AXLE
3 4
2
6 5
17 18
16
15
7 14
8 13
12
11
10
9
32
19
30 31
29
28
26 27
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49
W1F3-03-05-018
W3-5-34
1- Body 14 - O-Ring 27 - Nut (6 Used) 40 - O-Ring

2- Axle Shaft 15 - Bearing 28 - U-Ring 41 - Sun Gear Shaft
3- O-Ring 16 - O-Ring 29 - Ring 42 - Washer
4- Knuckle 17 - Ring Gear 30 - Bearing Nut 43 - Bolt (2 Used)
5- Bolt (18 Used) 18 - O-Ring 31 - Retaining Ring 44 - Plug
6- Washer (18 Used) 19 - Wheel Stud (10 Used) 32 - Plate (6 Used) 45 - Planetary Carrier
7- Bolt (16 Used) 20 - Bolt (6 Used) 33 - Friction Plate (5 Used) 46 - Thrust Plate (4 Used)
8- Washer (16 Used) 21 - Spring Guide (6 Used) 34 - Plate 47 - Planetary Gear (4 Used)
9- Screen Sheet 22 - Spring (6 Used) 35 - Retaining Ring 48 - Needle Bearing (4 Used)
10 - Gasket Ring 23 - Plate 36 - Seal 49 - Thrust Plate (4 Used)
11 - Bearing 24 - Ring 37 - Lock Washer 50 - Retaining Ring (4 Used)
12 - Bushing 25 - U-Ring 38 - Gear 51 - Plug
13 - Hub Carrier 26 - Piston 39 - Retaining Ring
W3-5-35
3 4
2
6 5
17 18
16
15
7 14
13
8
11 12
10
9
32
30 31
29
26 27 28
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49
W1F3-03-05-018
W3-5-36
Assemble Rear Axle
1. Insert axle shaft (2) into body (1) inside. 10. Install the piston (26) to assembly ring gear (17)
and secure it with bolts (20) (6 used), spring
IMPORTANT: Be sure to check that axle shaft (2) guides (21) (6 used), springs (22) (6 used) and
and differential are connected. nuts (27) (6 used).
: 10 mm
2. Install the inner race of bearing (11) and bushing
(12) to knuckle (4). 11. Install bolt so that the dimension A should be 3.75
to 4.25 mm (0.15 to 0.17 in).
3. Install O-ring (3), screen sheet (9) and seal (36) to : 10 mm
knuckle (4). : 11 N⋅m (1.1 kgf⋅m, 8 lbf⋅ft)
4. Install knuckle (4) to body (1) with bolt (5) (18

used) and washer (6) (18 used). 27
20
5. Install the outer race of bearing (11, 15) and
gasket ring (10) into hub carrier (13).
6. Install the hub carrier (13) assembly to knuckle (4),

then install the inter race of bearing (15) to hub
carrier (13).
26
7. Install O-ring (16) to knuckle (4) then install O-ring A
(18) to ring gear (17).
8. Install rings (24, 29) and U-rings (25, 28) to piston W1F3-03-05-023
(26).
Apply grease after installing them. 12. After adjusting, secure nuts (27) (6 used) with
LOCTITE #242.
28 29
24 25
26
W1F3-03-05-022
9. Install plate (23) to piston (26).
W3-5-37
4
2 3
6 5
17 18
16
15
7 14
13
8
12
11
10
9
32
30 31
29
26 27 28
25
24
22 23
21
20
33
43
42
40 41
39 44
38
35 36 37
34
45
46
47
48
50 49 W1F3-03-05--018
W3-5-38
IMPORTANT: When installing the ring gear (17) 21. Install O-ring (14) to hub carrier (13).
assembly to knuckle (4), tighten
bearing nut (30) while rotating the 22. Install the planetary carrier (45) assembly to hub
ring gear (17) assembly in the carrier (13) with bolt (43) (2 used).
direction of clockwise and : 8 mm
counterclockwise several times. : 55 N⋅m (5.6 kgf⋅m, 41 lbf⋅ft)
13. Install the ring gear (17) assembly to knuckle (4) 23. Install plug (44) to planetary carrier (45). Supply
with bearing nut (30). oil to differential and wheel hub inside.
: 1550 + 550 N⋅m Differential: 2.0 L (0.528 US gal.)
(160 + 55 kgf⋅m, 1140 + 410 lbf⋅ft)
14. Lock bearing nut (30) with retaining ring (31).
15. Apply grease on lock washer (37) and adheres to

16. Install retaining ring (39) to gear (38), then install

O-ring (40) to sun gear shaft (41).
17. Install the sun gear shaft (41) assembly to the

gear (38) assembly.
18. Install the gear (38) assembly to axle shaft (2).
19. Install plate (32) and friction plate (33) into the
inside of ring gear (17) in order, install plate (34)
secure it with retaining ring (35).
IMPORTANT: Install thrust plates (46, 49) with the

wide side of L-link facing bearing
side.
20. Install thrust plate (46), needle bearing (48),

planetary gear (47) and thrust plate (49) to
planetary carrier (45) in order and lock them with
retaining ring (50). (4 places)
NOTE: When disassembling, the washer (42)

should not be removed normally. When
replace planetary carrier (45), it should be
replaced together with washer (42).
W3-5-39
DISASSEMBLE and ASSEMBLE REAR DIFFERENTIAL
1
2
3
4
5
6
7
8
9
10
11
15 14
16
17
18
19 12
13
18
19
17
16
20
21
22
18
17 23 19
30
18
29
28
27
26
25
24
31
32
35
33
34
36
W1F3-03-05-019
W3-5-40
1- Lock Plate 10 - Bearing 19 - Pinion Gear (4 Used) 28 - Shim

2- Nut 11 - Drive Pinion 20 - Differential Case 29 - O-Ring
3- Washer 12 - Spring Pin (4 Used) 21 - Washer (12 Used) 30 - Body
4- Flange 13 - Spring Pin (4 Used) 22 - Socket Bolt (12 Used) 31 - Bolt (16 Used)
5- Guard 14 - Bevel Gear 23 - Spider 32 - Washer (16 Used)
6- Seal 15 - Differential Case 24 - Body 33 - Plug
7- Bearing 16 - Thrust Washer (2 Used) 25 - Shim 34 - Plug
8- Ring 17 - Side Gear (2 Used) 26 - Bearing 35 - Axle Shaft
9- Shim 18 - Thrust Washer (4 Used) 27 - Bearing 36 - Axle Shaft
W3-5-41
1
2
3
4
5
6
7
8
9
10
11
15 14
16
17
18
19 12
13
18
19
17
16
20
21
22
18
17 23 19
30
18
29
28
27
26
25
24
31
32
35
33
34
36
W1F3-03-05-019
W3-5-42
Disassemble and Assemble Rear Differential
The structure of rear differential and front differential

are the same.
Refer to W 3-5-20 to W 3-5-27 for front differential.
Oil Quantity: 10.3 L (2.7 US gal.)
W3-5-43
DISASSEMBLE STEERING CYLINDER
1 2 3 4 5
W1F3-03-05-001
14 13 12 32 11 10 9 32 8 7 6
19
15 16 17 18 20 21 22 23 22
30 31 30 29 28 27 26 25 24
W1F3-03-05-010
1- Ball Joint 9- Joint 17 - Scraper Ring 25 - Collar

2- Collar 10 - Differential Housing 18 - U-Ring 26 - O-Ring
3- Piston Rod 11 - Joint 19 - Bolt (4 Used) 27 - Scraper Ring
4- Collar 12 - Tie Rod 20 - Guide 28 - U-Ring
5- Ball Joint 13 - Nut 21 - Shim 29 - Guide
6- Lock Pin 14 - Lock Pin 22 - V Type Backup Ring (2 Used) 30 - O-Ring (2 Used)
7- Nut 15 - O-Ring 23 - Seal Ring 31 - Cylinder
8- Tie Rod 16 - Collar 24 - O-Ring 32 - Lock Nut (2 Used)
W3-5-44
Disassemble Steering Cylinder
1. Remove pins (6, 14) and nuts (7,13) from ball

joints (1, 5).
: 41 mm
2. Remove ball joints (1, 5) from wheel hub.
3. Move collars (2, 4) toward body (10) of the

differential. Remove tie rods (8, 12) from piston
rod (3), by using wrenches at joints (9, 11) and
piston rod (3).
: 32 mm, 55 mm
4. Remove bolts (19, 22) (4 used respectively).

Remove guide (20) from differential housing (10).
: 22 mm
5. Pull the piston rod (3) out from cylinder (31).
6. Remove cylinder (31) from differential housing

(10).
7. Remove O-ring (30) (2 used) from cylinder (31)
8. Remove the guide (29) assembly from differential

housing (10).
9. Remove V type backup rings (22) (2 used) and

seal ring (23) from piston rod (3).
10. Remove scraper rings (17) (2 used), U-rings (18)

(2 used) and shim (21) from guide (20).
11. Remove O-ring (26), scraper ring (27), and u-ring

from guide (29).
12. Remove O-rings (15, 24) from collars (16, 25).
13. Remove O-rings (30) (2 used) from cylinder (31).
W3-5-45
ASSEMBLE STEERING CYLINDER
1 2 3 4 5
W1F3-03-05-001
14 13 12 32 11 10 9 32 8 7 6
11 16 15 3 20 30 31 10 30 29 26
17 18 19 21 22 23 22 28 27 W1F3-03-05-002
1- Ball Joint 9- Joint 17 - Scraper Ring 25 - * Collar

2- Collar 10 - Differential Housing 18 - U-Ring 26 - O-Ring
3- Piston Rod 11 - Joint 19 - Bolt (4 Used) 27 - Scraper Ring
4- Collar 12 - Tie Rod 20 - Guide 28 - U-Ring
5- Ball Joint 13 - Nut 21 - Shim 29 - Guide
6- Lock Pin 14 - Lock Pin 22 - V Type Backup Ring (2 Used) 30 - O-Ring (2 Used)
7- Nut 15 - O-Ring 23 - Seal Ring 31 - Cylinder
8- Tie Rod 16 - Collar 24 - *O-Ring 32 - Lock Nut (2 Used)
W3-5-46
Assemble Steering Cylinder
1. Attach O-rings (30) (2 used) to cylinder (31), and 13. Lock nuts (7, 13) with split pins (6, 14).
apply grease to mounting face.
IMPORTANT: Be sure to install piston rod (3) so
2. Install O-ring (26), U-ring (28) and scraper ring that the dimensions of part A on
(27) to guide (29), and apply grease to the inside both sides are the same.
and outside of guide (29).
3. Install U-ring (18), scraper ring (17) and shim (21)

to guide (20), and apply grease to the inside.
4. Install seal ring (23) and two V-shaped backup

rings on piston rod (3), and apply grease to them.
5. Install O-rings (15, 24) to collars (16, 25)

respectively, and apply grease to them.
A A W1GL-03-05-016
6. Install guide (29) assembly to body (10) of the
differential.
14. After adjusting, mount them with lock nut (32).
7. Install the cylinder (31) assembly to body (10) of : 19 mm
the differential. : 70 to 80 N⋅m
(7.0 to 8.0 kgf⋅m, 50 to 58 lbf⋅ft)
8. Install the piston rod (3) assembly on cylinder
(31).
9. Affix guide (20) to body (10) of the differential with

: 22 mm
: 185 N⋅m (18.9 kgf⋅m, 136 lbf⋅ft)
10. Install collars (16, 25) on piston rod (3).
NOTE: Carry out assembly so that chamfered side

of collars (16, 25) faces body (10) of the
differential.
11. Install tie rods (8, 12) assembly to piston rod (3).
: 32 mm, 55 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)
12. Install ball joints (1, 5) to wheel hub, and affix

them with nuts (7, 13).
: 41 mm
: 300 N⋅m (30 kgf⋅m, 220 lbf⋅ft)
W3-5-47
(Blank)
W3-5-48
UNDERCARRIAGE / Axle Lock Cylinder
REMOVE AND INSTALL AXLE LOCK
CYLINDER

In this section, the procedure starts on the premise that 1

the front axle has already been removed. 2
Removal
3
1. Disconnect pipes (1) (2 used) from check valve (2).
Cap the open ends.
: 19 mm
4
IMPORTANT: Do not remove check valve (2). The
rod (6) will drop when cap is re-
moved because the air supplying.
5
2. Remove socket bolts (7) (2 used), then install 6

eyebolts (M8, Pitch 1.25 mm) to the removed bolt
holes. W1F3-03-06-003
: 6 mm
CAUTION: Axle lock cylinder weight:

30 kg (66 lb)
7
3. Attach a wire rope on eyebolt to hold it by crane.
4. Remove bolts (5) (4 used) from chassis (4).

: 22 mm 2
5. Lower axle lock cylinder (3) while lifing it off chas-

sis (4).
W1F3-03-06-002
W3-6-1
Installation
1. Remove socket bolts (7) (2 used), then install
eyebolts (M8, Pitch 1.25 mm) to the removed bolt
holes. 7

30 kg (66 lb)
2
2. Hoist axle lock cylinder (3) and place it on chassis
(4). Install them with bolts (5) (4 used).
: 22 mm
: 180 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
3. Remove eyebolt, then install socket bolts (7) (2 3

used).
: 6 mm
: 20 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) W1F3-03-06-002
1
4. Connect pipes (1) (2 used). 2
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
3
W1F3-03-06-003
W3-6-2
(Blank)
W3-6-3
DISASSEMBLE AND ASSEMBLE AXLE
LOCK CYLINDER
2
A
1
3
W1F3-03-06-002
7 View A
5 4
W1F3-03-06-001
1 - Socket Bolt (4 Used) 3 - Housing 5 - Retaining Ring 7 - Seal

2 - Check Valve 4 - Rod 6 - Dust Seal
W3-6-4
Disassemble Axle Lock Cylinder Assemble Axle Lock Cylinder
• Be sure to read “Precautions for Disassembly and • Be sure to read “Precautions for Disassembly and
Assembly” thoroughly on page W1-1-1 before Assembly” thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.
CAUTION: Axle lock cylinder weight: CAUTION: Housing (3) weight: 16 kg (35 lb)
30 kg (66 lb) Rod (4) weight: 11.5 kg (25 lb)
1. Place the axle lock cylinder on a workbench 1. Install seal (7), dust seal (6) and retaining ring (5)
horizontally. to housing (3).
2. Remove socket bolts (1) (4 used) and remove IMPORTANT: Apply hydraulic oil to the inner sur-
check valve (2). face of housing (3) and seals (6, 7).
2. Install rod (4) to housing (3).

CAUTION: Housing (3) weight: 16 kg (35 lb)
Rod (4) weight: 11.5 kg (25 lb)
3. Supply air to the hole of the housing (3) port to 30 kg (66 lb)
push rod (4) out.
3. Temporarily install check valve (2) to the housing
4. Remove retaining ring (5) from housing (3) and (3) assembly with socket bolts (1) (2 used).
remove dust seal (6, 7).
W3-6-5
(Blank)
W3-6-6
UNDERCARRIAGE / Operate-Check Valve
REMOVE AND INSTALL OPERATE-CHECK
VALVE (FOR AXLE LOCK CYLINDER)

(Refer to “Bleeding Air from Hydraulic Oil 2
Tank” on page W1-4-1.) 1
Removal
Axle Lock Cylinder
1. Disconnect pipes (2) (2 used) from operate-check
valve (1). Cap the open ends.
: 19 mm
2. Remove socket bolts (3) (4 used) to remove op-

erate-check valve (1) from the axle lock cylinder.
Cap the open ends of the axle lock cylinder.
: 6 mm
W1F3-03-06-003
Installation
1. Install operate-check valve (1) to the axle lock
cylinder with socket bolts (3) (4 used).
: 6 mm
: 20 N⋅m (2.0 kgf⋅m, 14.5 lbf⋅ft) 3
2. Connect pipes (2) (2 used).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
1
W1F3-03-06-002
Axle Lock Cylinder
W3-7-1
UNDERCARRIAGE / Operate-Check Valve
CONSTRUCTION OF OPERATE-CHECK
VALVE (FOR AXLE LOCK CYLINDER)
1 2 3 4 5 6 7 8
T1F3-03-10-002
Wrench Size Tighten Torque

Item Parts Name Q’ty Remarks
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 ：27 120±12 (12±0.12) (89±8.9)
2 O-Ring 1 1B P18
3 Piston 1
4 Body 1
5 Sleeve 1
6 Poppet 1
7 O-Ring 1 1B P26
8 Spring 1
9 Plug 1 ：36 360±36 (36±3.6) (265±26.5)
W3-7-2
MEMO
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SECTION 4
FRONT ATTACHMENT
— CONTENTS —
Group 1 Front Attachment Group 3 Hose-Rupture Safety Valve
Hydraulic Circuit Pressure Remove and Install
Release Procedure...............................W4-1-1 Hose-Rupture Safety Valve.................. W4-3-1
Remove and Install Monoblock Boom Construction of
Front Attachment ..................................W4-1-2 Hose-Rupture Safety Valve.................. W4-3-4
Remove and Install 2-Piece Boom
Front Attachment ................................W4-1-10
Remove and Install Operate-Check
Maintenance Standard .........................W4-1-18
Valve (for Blade/Stabilizer) ................... W4-4-1
Standard Dimensions for
Construction of Operate-Check
Arm and Bucket Connection...............W4-1-21
Valve (for Blade/Stabilizer) ................... W4-4-2
Standard Dimensions for
Arm and Boom Connection ................W4-1-22
Group 2 Cylinder
Remove and Install Cylinder
(Monoblock Boom, 2-Piece Boom).......W4-2-1
Disassemble Cylinder
(Boom (Monoblock/2-Piece) and
Bucket)................................................W4-2-20
Assemble Cylinder
(Boom (Monoblock/2-Piece) and
Bucket)................................................W4-2-22
Disassemble Cylinder (Positioning) .....W4-2-24
Assemble Cylinder (Positioning) ..........W4-2-26
Disassemble Cylinder (Arm) ................W4-2-27
Assemble Cylinder (Arm) .....................W4-2-29
Disassemble Cylinder
(Stabilizer, Blade)................................W4-2-31
Assemble Cylinder
(Stabilizer, Blade)................................W4-2-33
Maintenance Standard .........................W4-2-35
CBBW-4-1
(Blank)
CBBW-4-2
FRONT ATTACHMENT / Front Attachment
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE
NOTE: Do not start the engine. Operate pilot

pump with the power from battery to de-
liver pilot pressure to the spool of control
valve. 6 1
5
1. Push pilot control shut-off lever (1) forward
(UNLOCK position).
2. Pull engine stop knob (2) fully out and secure it

using special tool (ST 7334).
IMPORTANT: Battery will deplete. Be sure to op-

erate key switch for short period.
3. Turn the key switch to START position and oper-
4
ate the lever for releasing pressure from hydrau-
lic circuit 4 to 5 times.
Releasing Circuit Operating Lever

Boom/Bucket Right Control Lever (5)
Arm Left Control Lever (4) MCBB-01-016
*Positioning/
Attachment Pedal (3) 3 2
Auxiliary
*Stabilizer/Blade Stabilizer/Blade Lever (6)
NOTE: *: Optional
4. Push engine stop knob (2) in.
W4-1-1
REMOVE AND INSTALL MONOBLOCK 1
BOOM FRONT ATTACHMENT
Removal
CAUTION: Prevent person from injury. Metal

fragments may fly when a hammer is used to
remove the pins. Be sure to wear necessary
protection, such as goggles, hardhat and etc.
1. Remove grease hose (1) from the adapter on the

boss at the boom cylinder rod side. (2 places
both left and right) Boom Cylinder
: 17 mm
2. Remove nuts (4) and bolts (6) from boom cylin-

der rod pin (3). Then remove stopper (5). (2 W1F3-04-01-007
places both left and right)

: 24 mm
2, 3 1 5
CAUTION: Boom cylinder weight:
150 kg (330 lb)
3. Hoist and hold the boom cylinder. By using a bar

and hammer, drive pin (3) into the position where
thrust plate (2) can be removed.
NOTE: When pin (3) cannot be removed, start the
engine and operate the boom lever to ad- 4, 6
just the hole position of the boom cylinder
Boom Cylinder
piston rod end.
W1GL-04-01-006
W4-1-2
4. Place the boom cylinder on a bench of 1 m height.
Start the engine. Operate the boom lever to re-
Bench
tract the boom cylinder. Secure the boom cylin-
der rod as illustrated by using a wire.
Stop the engine.
Boom Cylinder
5. Remove the boom cylinder.
Refer to “Remove Boom Cylinder” on page
W4-2-10. Wire
6. Remove other boom cylinder in the same proce-

dures as steps 3 to 5.
W554-02-03-007
CAUTION: The pin sometimes releases
suddenly. Be sure no one stands in the way.
7. Tap pin (3) out by using a bar and hammer. Re-

move thrust plate (2).
Pressure
8. After stopping the engine, push the pressure re- Release
Button
lease button on the air breather to release any
remaining pressure from the hydraulic oil tank. Cap
Remove the cap to release the residual pressure
from the hydraulic circuit.
Hydraulic
Refer to “Hydraulic Circuit Pressure Release Oil Tank
Procedure” on page W4-1-1.
W1F3-01-04-002
9. Disconnect hoses (7), (8) for bucket cylinder and

arm cylinder. Attach a cap onto all the open ends
of disassembled hoses.
: 36 mm
W1F3-04-01-010
7 8
W4-1-3
10. Open cover (9). Remove bolts (10) (4 used) and
cover (11). 9
: 17 mm
11 10 W1F3-02-03-001
W4-1-4
CAUTION: Boom foot pin (12) weight:

12
33 kg (73 lb)
11. Remove bolt (15), spring washer (16), plate (14)

and block (13) from the plate of boom foot pin
(12).
: 27 mm 13
14
15
16
W178-04-01-001
Boom and Arm Cylinder

Center of Gravity
CAUTION: Front attachment weight: Boom Assembly
Center of Gravity A
2670 kg (5890 lb)
12. Attach a wire rope onto the boom. Slightly hoist to

take up any slack of wire rope.
B W1F3-04-01-002
13. Insert a bar between the plate of boom foot pin

(12) and the bracket. Slightly pull the plate out. Unit: mm (in)
A 3035 (119)
14. Pull boom foot pin (12) out while rotating the plate B 3340 (131)
slowly by hand. C 782 (31)
NOTE: When boom foot pin (12) cannot be re- D 1978 (78)
moved, adjust the position of the boom
foot pin (12) hole by hoisting and lowering
12
the front attachment.
15. After hoisting the front attachment, move the

machine backward.
16. Place the front attachment on wooden blocks.

Plate
Insert a bar.
Bracket
W178-04-01-001
W4-1-5
Installation Boom and Arm Cylinder
Center of Gravity
Boom Assembly
CAUTION: Prevent person from injury. Metal Center of Gravity A
install the pins. Be sure to wear necessary
CAUTION: Front attachment weight:

2671 kg (5890 lb) D
C
1. Hoist the front attachment. Move the machine
forward, aligning the boom foot pin (12) holes.
Insert the thrust plates into boom left and right B W1F3-04-01-002
sides and adjust the clearance between the plate
and frame within 1 mm.
Unit: mm (in)
(Adjust the position of the boom foot pin hole by
A 3035 (119)
hoisting and lowering the front attachment.)
B 3340 (131)
C 782 (31)
D 1978 (78)
12
2. Drive in boom foot pin (12). Install stopper bolt

(15), washer (16), plate (14) and block (13).
13
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 14
15
16
W178-04-01-001
Center of Gravity
3. Install cover (11) with bolts (10) (4 used).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
4. Close cover (9).
11 10 W1F3-02-03-001
W4-1-6
5. Remove the caps from hoses and pipings. Install
the bucket cylinder hoses (7) and the arm cylin-
der hoses (8).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 Ibf⋅ft)
W1F3-04-01-010
7 8

150 kg (330 lb)
6. Install the boom cylinder.

Refer to “Install Boom Cylinder” on page
W4-2-12.
Boom Cylinder W105-04-02-040
3 2
7. Hoist the boom cylinder. Insert thrust plates (2) (2
used), and then drive in pin (3) to install boom
cylinders to both sides.
6 Boom Cylinder
8. Install stopper (5) and secure it with bolt (6) and
nuts (4) (2 used). (2 places both left and right)
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 405 Ibf⋅ft)
5
4
W178-04-01-004
W4-1-7
9. Connect grease pipe (1) onto the boss at boom
cylinder rod side. (2 places both left and right)
1
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
W105-04-01-002
10. Add grease to the boom cylinder rod side, bottom

Right Boom
side and boom foot side. Cylinder Rod
Side
Arm Cylinder
Bottom Side
Left Boom
Cylinder Rod
Side
Boom Foot
Side
W1F3-04-01-010
W4-1-8
11. Install thrust plates (17) into arm left and right
sides. Adjust total clearance of left and right
within 1.5 mm or less. Arm and Bucket
Center of Gravity
12. After installing arm, add grease to grease fitting
(18) on the boom-connecting boss of the arm.
IMPORTANT: For handling of HN bushing for the

front attachment, check following
requirements.
Precautions for pressing the bushing in: F
If a hammer is used to drive the bushing in, the bush-
ing may be damaged. Use a press.
E W1F3-04-01-002
Precautions when reinforcing the arm:
Welding heat for arm reinforcement may cause oil to Unit: mm (in)
leak from the bushing and decrease lubrication per- E 3661 (144)
formance. F 782 (31)
If oil leak occurs because of heated bushing after
welding, replace the bushing.
Special tools should be used to pull the bushing out or

press it in.
Special Tool: ST 1454
17 17
18 18
M157-07-157
W4-1-9
REMOVE AND INSTALL 2-PIECE BOOM
FRONT ATTACHMENT 1
Removal

1. Remove grease hose (1) from the adapter on the

boss at the boom cylinder rod side. (2 places
both left and right)
: 17 mm
2. Remove nuts (4) and bolts (6) from boom cylin-

der rod front pin (3). Then remove stopper (5). (2
places both left and right) W1F3-04-01-007
: 24 mm 1
2, 3
5
160 kg (352 lb)
3. Hoist and hold the boom cylinder. By using a bar

and hammer drive pin (3) into the position where
thrust plate (2) can be removed.
4, 6
NOTE: When pin (3) cannot be removed, start the
engine and operate the boom lever to ad- Boom Cylinder
just the hole position of the boom cylinder
piston rod end.
W1F3-04-01-008
W4-1-10
4. Place the boom cylinder on a bench of 1 m height.
Start the engine. Operate the boom lever to re-
tract the boom cylinder. Secure the boom cylin-
Bench
der rod as illustrated by using a wire.
Stop the engine.
Boom Cylinder
5. Remove the boom cylinder.
Refer to “Remove Boom Cylinder” on page
W4-2-10. Wire
6. Remove other boom cylinder in the same proce-

dures as steps 3 to 5.
W554-02-03-007
CAUTION: The pin sometimes comes out
suddenly. Be sure no one stands in the way.
7. Tap pin (3) out by using a bar and hammer. Re-

move thrust plate (2).
8. After stopping the engine, push the pressure re- Pressure

lease button on the air breather to release any Release
Button
remaining pressure from the hydraulic oil tank.
Remove the cap to release the residual pressure Cap
from the hydraulic circuit.
Refer to “Hydraulic Circuit Pressure Release
Hydraulic
Procedure” on page W4-1-1. Oil Tank
7 W1F3-01-04-002
9. Disconnect hoses (7, 8) for bucket cylinder and

arm cylinder. Attach a cap onto all the open ends
of disassembled hoses.
: 36 mm
8 W1F3-04-01-013
W4-1-11
10. Open cover (9). Remove bolts (10) (4 used) and
cover (11). 9
: 17 mm
11 10 W1F3-02-03-001
W4-1-12
CAUTION: Boom foot pin (12) weight:

12
33 kg (73 lb)
11. Remove bolt (15), spring washer (16), plate (14)

and block (13) from the plate of boom foot pin
(12).
: 27 mm 13
14
15
16
W178-04-01-001
Center of Gravity
A
B
Front Attachment Assembly
Center of Gravity
3212 kg (7081 lb)
12. Attach a wire rope onto the boom. Slightly hoist to

take up any slack of wire rope. F
E
D
C
W1F3-04-01-001
Unit: mm (in)
A 3155 (124)
B 2573 (101)
C 4031 (159)
D 944 (37)
E 1750 (69)
F 2286 (90)
13. Insert a bar between the plate of boom foot pin 12

(12) and the bracket. Slightly pull the plate out.
14. Pull boom foot pin (12) out while rotating the plate
slowly by hand.
NOTE: When boom foot pin (12) cannot be re-
moved, adjust the position of the boom Plate
Insert a bar.
foot pin hole by hoisting and lowering the
front attachment. Bracket
15. After hoisting the front attachment, move the

W178-04-01-001
machine backward.
16. Place the front attachment on wooden blocks.
W4-1-13
Installation
Center of Gravity
A
fragments may fly when a hammer is used to Front Attachment Assembly B
Center of Gravity

3212 kg (7081 lb)
F
1. Hoist the front attachment. Move the machine E
D
forward, aligning the boom foot pin holes.
Insert the thrust plates into boom left and right
sides and adjust the clearance between the plate C
and frame within 1 mm. W1F3-04-01-001
(Adjust the position of the boom foot pin hole by

Unit: mm (in)
hoisting and lowering the front attachment.)
A 3155 (124)
B 2573 (101)
C 4031 (159)
D 944 (37)
E 1750 (69)
F 2286 (90)
2. Drive in boom foot pin (12). Install stopper bolt 12

(15), washer (16), plate (14) and block (13).
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)
13
14
15
3. Install cover (11) with bolts (10) (4 used). 16

: 17 mm W178-04-01-001
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 9
4. Close cover (9).
11 10 W1F3-02-03-001
W4-1-14
5. Remove the caps from hoses and pipings. Install 7
bucket cylinder hoses (7) and arm cylinder hoses
(8).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

160 kg (352 lb) 8 W1F3-04-01-013
6. Install the boom cylinder.

Refer to “Install Boom Cylinder” on page
W4-2-12.
7. Hoist the boom cylinder. Insert thrust plates (2) (2

used), and then drive in pin (3) to install boom
cylinders to both sides.
8. Install stopper (5) and secure it with bolt (6) and Boom Cylinder W105-04-02-040
nuts (4) (2 used). (2 places both left and right)
: 30 mm 1
: 550 N⋅m (56 kgf⋅m, 405 Ibf⋅ft) 2, 3
5
4, 6
Boom Cylinder
W1F3-04-01-008
W4-1-15
9. Connect grease pipe (1) onto the boss at boom
cylinder rod side. (2 places both left and right) 1
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 Ibf⋅ft)
W1F3-04-01-007
10. Add grease to the boom cylinder rod side, bottom

side and boom foot side.
Right Boom
Cylinder Rod Side
Arm Cylin-
der Bottom
Side
Lift Boom
Cylinder
Rod Side
Second
Boom Foot
Side
Left Boom
Foot Side
Right Boom
Foot Side
MCBB-07-007
W4-1-16
11. Install thrust plates (17) into arm left and right
sides. Adjust total clearance of left and right Arm and Bucket
within 1.5 mm or less. Center of Gravity
12. After installing arm, add grease to grease fitting

(18) on the boom-connecting boss of the arm.
IMPORTANT: For handling of HN bushing for the

front attachment, check following
requirements. D
Precautions for pressing the bushing in:
If a hammer is used to drive the bushing in, the bush- C
ing may be damaged. Use a press. W1F3-04-01-001
Precautions when reinforcing the arm: Unit: mm (in)

Welding heat for arm reinforcement may cause oil to C 4031 (159)
leak from the bushing and decrease lubrication per- D 944 (37)
formance.
If oil leak occurs because of heated bushing after
welding, replace the bushing. 307±1.0 mm
(12±0.04 in)
Special tools should be used to pull the bushing out or
press it in.
Special Tool: ST 1454
17 17
W1GL-04-01-012
18
W1GL-04-01-011
W4-1-17
Pin and Bushing
N
C
L
A
M
E B
D
K
I J
G
H
W1GL-04-01-002 W1F3-04-01-001
Unit: mm (in)
Item Standard Allowable Limit Remedy

Pin 80 (3.15) 79.0 (3.11)
A
Bushing 80 (3.15) 81.5 (3.21)
Pin 80 (3.15) 79.0 (3.11)
B Boss (Main Frame) 80 (3.15) 81.5 (3.21)
Bushing (Boom Cylinder) 80 (3.15) 81.5 (3.21)
Pin 80 (3.15) 79.0 (3.11)
C Bushing (Boom Cylinder) 80 (3.15) 81.5 (3.21)
Boss (Boom) 80 (3.15) 81.5 (3.21)
Replace
Pin 80 (3.15) 79.0 (3.11)
D
Bushing 80 (3.15) 81.5 (3.21)
Pin 71 (2.80) 70.0 (2.76)
E Boss (Arm) 71 (2.80) 72.5 (2.85)
Bushing (Arm Cylinder) 71 (2.80) 72.5 (2.85)
Pin 71 (2.80) 70.0 (2.76)
F Boss (Boom) 71 (2.80) 72.5 (2.85)
Bushing (Arm Cylinder) 71 (2.80) 72.5 (2.85)
W4-1-18
Unit: mm (in)
Item Standard Allowable Limit Remedy

Pin 65 (2.56) 64.0 (2.52)
G Boss (Arm) 65 (2.56) 66.5 (2.62)
Bushing (Bucket Cylinder) 65 (2.56) 66.5 (2.62)
Pin 71 (2.80) 70.0 (2.76)
H Bushing 71 (2.80) 72.5 (2.85)
Bushing (Bucket Cylinder) 71 (2.80) 72.5 (2.85)
Pin 71 (2.80) 70.0 (2.76)
I
Bushing 71 (2.80) 72.5 (2.85)
Pin 80 (3.15) 79.0 (3.11)
J Replace
Bushing 80 (3.15) 81.5 (3.21)
Pin 80 (3.15) 79.0 (3.11)
K
Bushing 80 (3.15) 81.5 (3.21)
Pin 110 (4.33) 109.0 (4.29)
L
Bushing 110 (4.33) 111.5 (4.39)
Pin 110 (4.33) 109.0 (4.29)
M
Bushing 110 (4.33) 111.5 (4.39)
Pin 80 (3.15) 79.0 (3.11)
N
Bushing 80 (3.15) 81.5 (3.21)
IMPORTANT: When replacing HN bushing, press

fit it in with a press.
W4-1-19
Point
B C
W105-04-01-020
Unit: mm (in)
Standard Allowable Limit Remedy
A 178.5 (7.028) 90 (3.54)
B 79 (3.11) －
Replace
C 95 (3.74) －
D 81 (3.19) －
Side Cutter
C
D
W155-04-01-002
Unit: mm (in)
Standard Allowable Limit Remedy
A 229 (9.02) 149 (5.87)
B 245 (9.65) －
Replace
C 330 (12.99) －
D 135 (5.32) －
W4-1-20
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
W1CF-04-01-007
Section A Section B
Unit: mm (in)
a 370 (14.6)
b 0
c 540 (21.3)
d 520 (20.5)
e －
f 1430 (56.3)
g 449 (17.7)
h 326 (12.8)
i 80 (3.15)
j 400 (15.7)
k 31 (1.22)
l 433 (17.0)
m 307 (12.1)
n 80 (3.1)
o 90°
p 60°
q 449 (17.7)
W4-1-21
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
W1F3-04-01-004
W1F3-04-01-003
Section C
W1GL-04-01-010
Unit: mm (in)
s 80 (3.15)
t 307 (12.1)
u 421 (16.6)
W4-1-22
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
(MONOBLOCK BOOM, 2-PIECE BOOM)
Remove Bucket Cylinder 1

fragments may fly when a hammer is used to 3
protection, such as goggles, hardhat and etc. 2
3
1. Insert wooden block (3) between bucket cylinder
(1) and arm (2). W554-04-02-006
4 5
2. After stopping the engine, push the pressure
release button on the air breather to release any
Then remove the cap.
Release the bucket circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure” 6
on page W4-1-1.)
CAUTION: Secure the link with a wire to

prevent it from falling before pushing pin (7) 7
out. 1 W158-04-02-006
8
3. Remove nut (6) and bolt (4). Push out pin (7).
Remove thrust plate (5).
: 30 mm
4. To prevent rod (8) of bucket cylinder (1) from

extending, pass wire (9) through the cylinder rod
hole and secure wire (9) to the bucket cylinder
(1) tube.
9
W102-04-02-005
W4-2-1
5. Disconnect bucket cylinder hoses (12) (2 used)
at the bucket cylinder (1) bottom. Attach caps 10
onto the open ends.
: 36 mm
CAUTION: Bucket cylinder weight:

15
125 kg (280 lb)
6. Lift bucket cylinder (1) off. Remove nut (13) and 11

bolt (15). Push pin (11) out. 13
7. Remove bucket cylinder (1).

1
12 W187-04-02-004
W4-2-2
Install Bucket Cylinder
IMPORTANT: When pressing the bushing in, if a

hammer is used, the bushing may 10
be damaged. Use a press.

15
protection, such as goggles, hardhats and
etc. 14 11
13
CAUTION: Bucket cylinder weight:
125 kg (280 lb)
1. Lift bucket cylinder (1). Align cylinder tube side 1

pin hole with the bucket cylinder mounting hole
on arm. Install thrust plate (10) and pin (11).
2. Insert bolt (15) into arm stopper (14) and pin (11).
Install nut (13). 12 W187-04-02-004
: 180 N⋅m (18.5 kgf⋅m, 133 Ibf⋅ft)
3. Connect the bucket cylinder hoses (12) (2 used). 1

8
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
4. Remove wire (9) from rod (8) of bucket cylinder

(1).
9 W102-04-02-005
W4-2-3
5. Start the engine and operate the bucket lever to
align the cylinder rod side pin hole with those of 16 4 17 5
links (16, 18). Insert thrust plate (5) and pin (7).
6. Insert bolt (4) into stopper (17) and pin (7). Install
nut (6).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft)
IMPORTANT: In case link (18) has been removed

from the arm, never forget to
reinsert thrust plate (19). 7 18 6
W158-04-02-006
IMPORTANT: Fill the hydraulic oil to the specified
level after installation. Start the
19 19
engine. Fully stroke each cylinder
several times to bleed any air
remaining in the circuit. Check for
any oil leakage.
W157-04-01-015
18 18
W4-2-4
Remove Arm Cylinder
1
2
1. Insert wooden block (3) between arm cylinder (1)

and boom (2). 3
2. After stopping the engine, push the pressure W187-04-02-005

remaining pressure from the hydraulic oil tank. 4
10 5
Release the arm circuit pressure. (Refer to
1
“Hydraulic Circuit Pressure Release Procedure”
on page W4-1-1.)
3. Remove nut (8) and bolt (10) from pin (5) at the
arm cylinder (1) rod side.
: 30 mm
4. Push pin (5) out. Remove thrust plate (4).

8
W187-04-02-006
6 1
5. To prevent arm cylinder (1) rod (6) from

extending, pass wire (7) through the cylinder rod
hole and secure wire (7) to the arm cylinder (1)
tube.
W187-04-02-010
W4-2-5
6. Disconnect hoses (11) (2 used) from the bottom Monoblock Boom
of arm cylinder (1). Attach a cap onto the open
ends. In case the hose-rupture safety valve is 12
equipped, refer to the “Remove and Install 1
Hose-Rupture Safety Valve”.
: 36 mm
7. Disconnect grease hose (12) from arm cylinder

(1).
11
W1F3-04-01-005
2-Piece Boom
1
11
11 12
W1F3-04-01-007
CAUTION: Arm cylinder weight:

210 kg (460 lb) 1
8. Attach a sling at the arm cylinder (1) center of

gravity. Lift arm cylinder (1) off.
W102-04-02-016
9. Remove nuts (15) and bolt (17) from the tube 13
17
side of arm cylinder (1). Push out pin (14). 14
1
Remove thrust plates (13) and remove arm
cylinder (1).
: 30 mm
15
W187-04-02-007
W4-2-6
Install Arm Cylinder
13
17
IMPORTANT: When pressing the bushing in, if a 14
1
hammer is used, the bushing may

install the pins. Be sure to wear necessary 15
CAUTION: Arm cylinder weight: W187-04-02-007
210 kg (460 lb) Monoblock Boom
12
1. Attach a sling at arm cylinder (1) where can make
the cylinder level. Lift arm cylinder (1). Align the 1
cylinder tube side hole with the arm cylinder
mounting hole on boom.
2. Install thrust plate (13) and pin (14). Install bolt

(17) to pin (14) and stopper (16). Then install nut
(15).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft) 11
3. Connect grease hose (12) and the arm cylinder

hoses (11) (2 used). W1F3-04-01-005
: 19 mm 2-Piece Boom
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) 1
: 36 mm 11
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 Ibf⋅ft)
IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine. Check the
connections for any oil leakage.
11 12
W1F3-04-01-007
W4-2-7
4. Remove wire (7) from arm cylinder (1) rod (6). Lift 6 1
arm cylinder (1) off. Start the engine. Operate the
arm lever and align the arm cylinder rod side pin
hole with the arm cylinder mounting hole on arm
(18).
18
5. Install thrust plate (3) and pin (5).
Install bolt (10) to pin (5) and stopper (9), and put 7
nut (8) on bolt (10).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft) W187-04-02-010
IMPORTANT: After installation, operate the 10 4

9 5
cylinder several times to stroke end
to bleed air from the circuit.
18
8
W187-04-02-006
W4-2-8
Remove Boom Cylinder Monoblock Boom
1
1. Remove grease hoses (1) from boom cylinder.

150 kg (330 lb)
2. Attach a wire rope to boom cylinder (2) and lift W1F3-04-01-007

2-Piece Boom 1
boom cylinder (2) off. 4
5
4, 6 2
3. Remove nut (5), bolt (7) and stopper (6) from the
boom cylinder (2) rod to push pin (4) out. W1F3-04-01-008
: 27 mm
4. Place boom cylinder (2) on a bracket. Remove 7

boom cylinder at other side by the same method.
5. Operate the boom lever to retract the boom. To

prevent the boom cylinder (2) rod from stretching,
pass the wire through the cylinder rod hole and
secure the wire to the cylinder tube.
6
6. After stopping the engine, push the pressure 5 3 4 3 2
release button on the air breather to release any W158-04-02-013

Release the boom circuit pressure. (Refer to
on page W4-1-1.)
Bench
2
W105-04-02-035
W4-2-9
7. Remove hoses (12) (4 used) from boom cylinder
(2) at the boom cylinder bottom. Cover all
openings with plug to hoses and with cap to
boom cylinder. In case the hose-rupture safety
valve is equipped, refer to the “Remove and
Install Hose-Rupture Safety Valve”.
Plug: 13/16-12UNF
: 36 mm
W105-04-02-036
2
8. Loosen nut (10) at the boom cylinder bottom side 11
of the main frame and remove bolt (8). 8
Remove pin (9) completely.
: 24 mm
9
9 10
10
12
W178-04-02-009

150 kg (330 lb)
9. Attach a wire rope at boom cylinder (2) where

can make the cylinder level. Lift boom cylinder (2)
off.
Remove boom cylinder at other side by the same
method.
W105-04-02-040
W4-2-10
Install Boom Cylinder
IMPORTANT: When pressing the bushing in, if a

hammer is used, the bushing may


150 kg (330 lb)
1. Attach a sling at boom cylinder (2) where can 2

make the cylinder level. Lift boom cylinder (2).
W105-04-02-040
Align the cylinder tube side hole with the boom
cylinder mounting hole on boom.
2
2. Insert thrust plate (11) and pin (9). Install bolt (8), 11
8
then tighten with nut (10).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 Ibf⋅ft)
3. Install the boom cylinder at other side by same

9
method.
9 10
4. Connect hoses (12) (4 used) on boom cylinders
(2) (2 used).
: 36 mm 10
12
W178-04-02-009
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

W4-2-11
5. Lift boom cylinder (2). Operate the boom lever.
Align the pin hole at cylinder rod side with the
mounting hole of the boom cylinder.
6. Install thrust plate (3) and pin (4). 7
7. Install bolt (7) to pin (4) and stopper (6). Then

install nut (5).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 Ibf⋅ft)
6
5
3 4 3 2
W158-04-02-013
Monoblock Boom
1
8. Connect grease hoses (1).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)
9. Install the boom cylinder at other side by same

method.
IMPORTANT: After installation, operate the

W1F3-04-01-007
2-Piece Boom
4 1
5, 6 2
W1F3-04-01-008
W4-2-12
Remove Positioning Cylinder
(2-Piece Boom Only)

CAUTION: Positioning cylinder weight:

2
305 kg (670 lb)
1. Attach a nylon sling to positioning cylinder (3). Lift

and hold positioning cylinder (3).
1、5
release button on the air breather to release any 10, 11 3
8 9
Release the positioning circuit pressure. (Refer to
on page W4-1-1.)
W1F3-04-04-003
3. Remove nuts (5) (2 used) and bolt (1) from 6

stopper (4) of the second boom.
: 30 mm
3
4. Drive pin (2) into the second boom at approx.
160 mm (6.3 in)
5. Disconnect hoses (6) (2 used) and hoses (7) (3

used) from positioning cylinder (3). Attach caps
onto the open ends.
: 19 mm, 36 mm 7
6. Remove nuts (10) (2 used) and bolt (11) from

stopper (8) of the first boom.
Drive pin (9) in by using a bar and hammer.
: 30 mm

305 kg (670 lb) W1F3-04-03-001
7. Lift positioning cylinder (3) off.
W4-2-13
Install Positioning Cylinder

4

305 kg (670 lb)
1. Lift positioning cylinder (3). Align the pin holes on 2, 13

both cylinder bottom side and first boom.
Install thrust plate (12) and drive pin (9).
2. Align the pin holes of stopper (8) and pin (9). 1, 5

Install bolt (11) and nuts (10) (2 used).
: 30 mm 10, 11 3
: 550 N⋅m (56.0 kgf⋅m, 406 lb)
IMPORTANT: Fill hydraulic oil to the specified 8 9, 12

3. Connect hoses (7) (3 used) and (6) (2 used) to W1F3-04-04-003
positioning cylinder (3).

: 19 mm 6
: 29.5 N⋅m (3.0 kgf⋅m, 22 lb)
: 36 mm 3
: 175 N⋅m (18.0 kgf⋅m, 129 lb)
4. Start the engine, extend positioning cylinder (3).

Align the pin holes of the positioning cylinder (3)
rod and the second boom. Install thrust plate (13)
and drive pin (2).
7
5. Align the pin holes of stopper (4) and pin (2).
Install bolt (1) and nuts (5) (2 used).
: 30 mm
: 550 N⋅m (56.0 kgf⋅m, 406 lb)

to bleed air from the circuit. W1F3-04-03-001
W4-2-14
Remove Blade Cylinder
IMPORTANT: Before working, lower the blade

onto the ground. 1

2
1. Remove bolts (2) (4 used) to remove protection

cover (1).
: 19 mm

Release the blade circuit pressure. (Refer to
“Hydraulic Circuit Pressure Release Procedure” W1GL-04-01-013
on page W4-1-1.)
3, 4 5 6 7
3. Disconnect hoses (10) (4 used) from blade
cylinder (8). Cap the disconnected hose ends.
: 19 mm, 27 mm
CAUTION: Blade cylinder (8) weight:

70 kg (155 lb)
4. Attach a nylon sling to blade cylinder (8). Lift and 8

hold blade cylinder (8).
5. Remove nuts (6) (8 used) and bolts (5) (2 used).

Pull out pins (3) (2 used).
Remove thrust plate (4) from the both blade W1GL-04-02-004
cylinder (8) bottom and rod sides. 10
3, 4, 5, 6 9
: 24 mm
6. Lift blade cylinder (8) off.
W4-2-15
Install Blade Cylinder
3, 4 5 6 7

CAUTION: Blade cylinder (8) weight:

55 kg (120 lb)
8
1. Lift and hold blade cylinder (8). Align the pin (3)
holes of the blade cylinder (8) bottom side and
bracket (7) and the rod side and blade (9).
Install thrust plate (4) and drive pins (3) (2 used).
Install bolts (5) (2 used) and nuts (6) (4 used). 10 W1GL-04-02-004
: 24 mm 3, 4, 5, 6 9
: 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)
2. Connect hoses (10) (4 used) to blade cylinder 1

(8).
: 19 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18.0 lbf⋅ft) 2
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
3. Install protection cover (1) to blade cylinder (8)

: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)

W1GL-04-01-013
W4-2-16
Remove Stabilizer Cylinder
In this section, the procedure starts on the premise 1, 2, 3, 4 6 7 8

5
that the stabilizer operate-check valve has already
been removed. For removal and installation of the
operate-check valve, refer to “Remove and Install
Operate-Check Valve” section.
9
fragments may fly when a hammer is used to 10, 11
remove the pins. Be sure to wear necessary 12
1. Remove bolts (9) (3 used) to remove cover (7).

: 17 mm
Operate-Check Valve
W1F3-04-01-011
remaining pressure from the hydraulic oil tank. 13
Then remove the cap. 9
Release the stabilizer circuit pressure. (Refer to 7
on page W4-1-1.)
3. Disconnect hoses (13) (2 used) from stabilizer

cylinder (6). Attach caps onto the open ends.
: 19 mm, 27 mm
4. Attach a nylon sling to the rod side of the

stabilizer cylinder (6) tube. Lift stabilizer cylinder Operate-Check
(6) off. Valve Hose W1F3-04-01-012
5. Remove bolts (12) (3 used), pin (10) and thrust 5

plate (11) from stabilizer (8).
: 17 mm 7
9
CAUTION: Stabilizer cylinder weight:
88 kg (195 lb)
10, 11
6. Lift stabilizer cylinder (6) off. Insert the sleeper

under the stabilizer cylinder (6) tube. 6 12
Sleeper
7. Remove ring (2) and lock pin (3) of the stabilizer
cylinder (6) bottom side. Pull out pin (1). 8
8. Pull out stabilizer cylinder (6) from stabilizer

beam (5). W1GL-04-02-006
W4-2-17
Install Stabilizer Cylinder
5
7
9
CAUTION: Stabilizer cylinder weight: 10, 11

88 kg (195 lb)
6 12
1. Lift stabilizer cylinder (6). Align the pin (1) holes
of the stabilizer cylinder (6) bottom side and Sleeper
stabilizer beam (5).
Install thrust plate (4) and drive pin (1). 8
2. Install lock pin (3) and ring (2) to pin (1).

W1GL-04-02-006
3. Connect hoses (13) (2 used) onto stabilizer 13

cylinder (6). 9
: 19 mm 7
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft)
4. Start the engine and extend stabilizer cylinder (6)

to align the rod with connecting pin hole.
5. Install thrust plate (11), pin (10) and bolts (12) (3

used) to stabilizer (8). Operate-Check
: 17 mm Valve Hose W1F3-04-01-012
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
6. Install cover (7) with bolts (9) (3 used). 1, 2, 3, 4 6 7 8

5
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

9
10, 11
12
W1F3-04-01-011
W4-2-18
(Blank)
W4-2-19
DISASSEMBLE CYLINDER
(BOOM (MONOBLOCK/2-PIECE and
BUCKET)
Boom Cylinder (Monoblock/2-Piece Boom)
11 1 2 3 4 7 5 6 9 10
8
14 13 19 16 20 21 22 12
20 16 15 17 18 19 24 23
W158-04-02-016
Bucket Cylinder
11 1 2 3 4 7 5 6 9 10
20 19 20 21 22 12
W1F3-04-04-005
16 15 17 18 16 19 24 23
1- Wiper Ring 7- Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2- Backup Ring 8- Socket Bolt (12 Used) 14 - Cushion Seal 20 - Slide Ring (2 Used)
3- U-Ring 9- Backup Ring 15 - Piston 21 - Shim
4- Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5- Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6- Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
W4-2-20
Disassemble Boom (Monoblock/2-Piece and
Bucket Cylinders
• Be sure to read “Precautions for Disassembly 5. Remove set screw (22) and steel ball (23).
and Assembly” thoroughly on page W1-1-1 be- NOTE: Set screw (22) was crimped with a punch
fore starting the repair work. in two places after it was tightened. Before
loosening set screw (22), cut away the
The disassembly procedure below starts on the prem- crimped portions.
ise that the hydraulic lines and the line securing bands
have been removed. 6. Loosen nut (24) using special tool (ST 5908).
Remove piston (15), shim (21) and cushion bear-
CAUTION: Cylinder weight: ing (13).
Boom cylinder (Monoblock): 150 kg (330 lb) In case of the boom cylinder remove cushion
Boom cylinder (2-Piece): 160 kg (350 lb) seal (14).
Bucket cylinder: 125 kg (275 lb) Tools for turning nut:
Boom : 85 mm (ST 3304)
1. Lift and horizontally secure the cylinder on a Bucket : 80 mm (ST 3262)
workbench. Then, drain the hydraulic oil from the
ST 5908
cylinder.
W158-04-02-022
W102-04-02-027
7. Remove seal ring (17), slide rings (19, 20) (2
used for each), O-ring (18) and backup rings (16)
2. Fully extend cylinder rod (11). Hold the rod end. (2 used) from piston (15).
Remove socket bolts (8) from cylinder head (7).
8. Remove cylinder head (7) from cylinder rod (11).
3. Pull out cylinder head (7) from cylinder tube (12)
by tapping by using a plastic hammer. 9. Remove O-ring (10) and backup rings (9, 2) from
cylinder head (7). Then remove wiper ring (1),
IMPORTANT: Be sure to pull out piston rod (11) U-ring (3), backup ring (4), snap ring (6) and
straight to prevent the sliding sur- bushing (5).
faces from being damaged. Tools for removing bushing:
4. Secure cylinder rod (11) on special tool (ST Boom : 80 mm (ST 8019/ST 1286)
5908). Put matching marks between cylinder rod Bucket : 75 mm (ST 8018/ST 1285)
(11) and nut (24).
ST 5908
W158-04-02-022
W4-2-21
ASSEMBLE CYLINDER
(BOOM (MONOBLOCK/2-PIECE and
BUCKET)
Boom Cylinder (Monoblock/2-Piece Boom)
Hole (1 Place) Be sure with the slit facing

piston (15).
1 2 3 4 5 6 7 8 9, 10 11 12 13 14 15 16 17, 18 19 20 21 21
22, 23
24
Be sure with oil groove facing W1F1-04-02-001

correct direction when assembling
Bucket Cylinder
Hole (1 Place)
1 2 3 4 5 6 7 8 9, 10 11 12 13 15 16 17, 18 19 20 21
22, 23
24
Be sure with oil groove facing

correct direction when assembling W1F1-04-02-002
1- Wiper Ring 7- Cylinder Head 13 - Cushion Bearing 19 - Slide Ring (2 Used)

2- Backup Ring 8- Socket Bolt (12 Used) 14 - Cushion Seal 20 - Slide Ring (2 Used)
3- U-Ring 9- Backup Ring 15 - Piston 21 - Shim
4- Buffer Ring 10 - O-Ring 16 - Backup Ring (2 Used) 22 - Set Screw
5- Bushing 11 - Piston Rod 17 - Seal Ring 23 - Steel Ball
6- Snap Ring 12 - Cylinder Tube 18 - O-Ring 24 - Nut
W4-2-22
Assemble Boom (Monoblock/2-Piece) and
Bucket Cylinders
1. Press bushing (5) into cylinder head (7). 8. Install shim (21) to cylinder rod (11). Tighten nut
Tools for installing bushing: (24) using special tool (ST 5908) while aligning
Boom : 80 mm (ST 8019/ST1286) the matching mark on the rod with that on nut
Bucket : 75 mm (ST 8018/ST1285) (24).
ST 5908
IMPORTANT: Be sure to install rings in correct
direction.
2. Install U-ring (3), backup ring (2), buffer ring (4),
and snap ring (6) to cylinder head (7).
3. Install wiper ring (1) to cylinder head (7) by using

a plastic hammer.
Tools for installing wiper ring: W158-04-02-022
Boom : ST 8019/1297
Bucket : ST 8018/1296 Tools for tightening nut:
Boom : 85 mm (ST 3304)
4. Install O-ring (10) and backup ring (9) to cylinder Bucket : 80 mm (ST 3262)
head (7). Boom cylinder
: 3800 N⋅m (390 kgf⋅m, 2800 lbf⋅ft)
IMPORTANT: When installing slide rings (19) and Bucket cylinder
(20), do not align their split portion. : 4780 N⋅m (490 kgf⋅m, 2800 lbf⋅ft)
5. Install O-ring (18), backup rings (16) (2 used),
seal ring (17), and slide rings (19, 20) (2 used for 9. Align the holes of piston rod (11) and nut (24),
each) to piston (15). then install steel ball (23).
6. Install the cylinder head (7) assembly into piston 10. Crimp the head of set screw (22) at two places
rod (11). with a punch.
Tools for installing cylinder head: : 10 mm
Boom : ST 8019/2345 : 57±10.5 N⋅m
Bucket : ST 8018/2344 (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft)
IMPORTANT: Be sure that the slit in cushion seal IMPORTANT: Take care not to damage rings. In-
(14) is facing piston and that the oil stall the piston rod (11) assembly
groove in cushion bearing (13) is into cylinder tube (12) while aligning
facing correct direction. it with the center of cylinder tube
7. Install cushion bearing (13) to piston rod (11). In- (12).
stall the piston (15) assembly to the piston rod 11. Horizontally secure cylinder tube (12) on a work-
(11). bench. Insert the piston rod (11) assembly into
In case of the boom cylinder, install cushion seal cylinder tube (12).
(14).
12. Install cylinder head (7) into cylinder tube (12)
13 with socket bolts (8) (12 used).
Oil Groove : 10 mm
Nut Side : 171 N⋅m (17.5 kgf⋅m)
Head Side Nut Side
W18B-04-02-011
W4-2-23
DISASSEMBLE CYLINDER (Positioning)
Positioning Cylinder
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21
Hole (1 Place) 22
16
W1F3-04-04-007
1- Wiper Ring 7- Cylinder Head 13 - Piston 19 - Shim

2- Backup Ring 8- Socket Bolt (2 Used) 14 - Backup Ring (2 Used) 20 - Nut
3- U-Ring 9- Backup Ring 15 - Seal Ring 21 - Set Screw
4- Buffer Ring 10 - O-Ring 16 - O-Ring 22 - Steel Ball
5- Bushing 11 - Piston Rod 17 - Slide Ring
6- Retaining Ring 12 - Cylinder Tube 18 - Slide Ring
W4-2-24
Disassemble Positioning Cylinder
• Be sure to thoroughly read all “Precautions for 5. Remove set screw (21) and steel ball (22).
Disassembly and Assembly Work” on page NOTE: Set screw (21) was crimped with a punch
W1-1-1 before starting the disassembly work. in two places after it was tightened. Before
ise that the hydraulic line and the line securing bands
Remove piston (13) and shim (19)
Tool for tightening nut: 135 mm (ST 3283)
CAUTION: Positioning Cylinder weight:
290 kg (640 lb) 7. Remove seal ring (15), slide rings (17, 18),
O-ring (18), backup rings (14) (2 used) from pis-
1. Lift and place the cylinder horizontally on a work ton (13).
bench. Drain hydraulic oil from the cylinder.
8. Remove cylinder head (7) from piston rod (11).
9. Remove O-rings (10), backup rings (9, 2) from

U-ring (3), buffer ring (4), snap ring (6), and
bushing (5).
Tool for removing bushing: 120 mm (ST 1374)
W102-04-02-027
2. Fully extend piston rod (11). Secure the rod end.

Remove socket bolts (8) from cylinder head (7).
IMPORTANT: Be sure to pull out piston rod (11)

straight to prevent the sliding sur-
faces from being damaged.
3. Pull out cylinder head (7) from cylinder tube (12)

by tapping by using a plastic hammer.
4. Secure cylinder rod (11) on special tool (ST

5908). Put matching mark between piston rod
(11) and nut (20).
ST 5908
W158-04-02-022
W4-2-25
ASSEMBLE CYLINDER (Positioning)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21
Hole (1 Place) 22
16
W1F3-04-04-007
1- Wiper Ring 7- Cylinder Head 13 - Piston 19 - Shim

2- Backup Ring 8- Socket Bolt (2 Used) 14 - Backup Ring (2 Used) 20 - Nut
3- U-Ring 9- Backup Ring 15 - Seal Ring 21 - Set Screw
4- Buffer Ring 10 - O-Ring 16 - O-Ring 22 - Steel Ball
5- Bushing 11 - Piston Rod 17 - Slide Ring
6- Retaining Ring 12 - Cylinder Tube 18 - Slide Ring
W4-2-26
Assemble Positioning Cylinder
Tools for pressing bushing: 120 mm (ST 1374) (20) by using special tool (ST 5908) while align-
ing the matching mark on the rod with that on the
IMPORTANT: Be sure to install rings in correct nut.
direction. Tool for turning nuts:135 mm (ST 3283)
2. Install U-ring (3), backup ring (2), buffer ring (4), : 14700 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
and snap ring (6) to cylinder head (7).
ST 5908
a plastic hammer.
Wiper ring pressing tool ST 1480
4. Install O-ring (10) and backup ring (9) to cylinder

head (7).
5. Install O-ring (16), backup ring (14) (2 used), seal W158-04-02-022
ring (15), slide rings (17, 18) (2 used) to piston

(13). 9. Align the hole on cylinder rod (11) with that on nut
(20). Insert steel ball (23) into the hole and
6. Install the cylinder head (7) assembly into piston tighten set screw (22).
rod (11). After tightening set screw (22), crimp the head of
set screw (22) at two places with a punch.
: 14 mm
7. Install the cylinder head (13) assembly into piston
: 96.6±18.2 N⋅m
rod (11).
(9.8±1.8 kgf⋅m, 71±13 lbf⋅ft)
IMPORTANT: Be sure to keep cylinder rod (11)

aligning with the center of cylinder
tube (12) when inserting in order to
avoid damaging rings.
10. Horizontally secure cylinder tube (12) on a work-
bench. Insert the piston rod (11) assembly into
cylinder tube (12).

: 17 mm
: 711 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
W4-2-27
DISASSEMBLE CYLINDER (ARM)
Arm Cylinder
11 1 2 3 4 7 5 6 9 10
14 13 15 16 25 26 28 22 12
20 19 16 17 18 19 20 27 21 24 23
W158-04-02-017
1- Wiper Ring 8- Socket Bolt (12 Used) 15 - Piston 22 - Set Screw

2- Backup Ring 9- Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
3- U-Ring 10 - O-Ring 17 - Seal Ring 24 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Snap Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Snap Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper (2 Used)
W4-2-28
Disassemble Arm Cylinder
• Be sure to read “Precautions for Disassembly 5. Remove set screw (22) and steel ball (23).
and Assembly” thoroughly on page W1-1-1 be- NOTE: Set screw (22) was crimped with a punch
fore starting the repair work. in two places after it was tightened. Before
ise that the hydraulic lines and the line securing bands
Remove piston (15), shim (21), cushion bearing
CAUTION: Arm cylinder weight : (13) and cushion seal (14).
220 kg (490 lb) Tool for tightening nut: 90 mm (ST 3263)
ST 5908
1. Lift and horizontally secure the cylinder on a
workbench. Then, drain the hydraulic oil from the
cylinder.
W158-04-02-022
7. Remove seal ring (17), slide rings (19, 20) (2

used), O-ring (18), backup rings (16) (2 used)
W102-04-02-027
from piston (15).
2. Fully extend cylinder rod (11). Lift and hold the 8. Remove cylinder head (7) from cylinder rod (11).
rod. Remove socket bolts (8) from cylinder head
(7). 9. Remove O-ring (10) and backup rings (9, 2) from
IMPORTANT: Be sure to pull out piston rod (11) U-ring (3), backup ring (4), snap ring (6) and
straight to prevent the sliding sur- bushing (5).
faces from being damaged. Tool for removing bushing: 90 mm (ST 8024/ST
3. Pull out cylinder head (7) with piston rod still at- 1991)
tached from cylinder tube (12) by using a plastic
hammer. 10. Remove stopper (28) from piston rod (11) with a
screwdriver. Remove cushion bearing (27), cush-
4. Secure cylinder rod (11) on special tool (ST ion seal (26) and snap ring (25).
5908). Put matching mark between cylinder rod
(11) and nut (24).
ST 5908
W158-04-02-022
W4-2-29
ASSEMBLE CYLINDER (ARM)
Arm Cylinder
Be sure with the slit facing

piston.
Hole (1 Place)
1 2 3 4 5 6 7 8 9, 10
11 12 13 14 15 16 17, 18 19 20 21
22, 23
24
25
26
27
28
W1F1-04-02-003
Be sure with oil groove facing

correct direction when assembling.
1- Wiper Ring 8- Socket Bolt (12 Used) 15 - Piston 22 - Set Screw

2- Backup Ring 9- Backup Ring 16 - Backup Ring (2 Used) 23 - Steel Ball
3- U-Ring 10 - O-Ring 17 - Seal Ring 24 - Nut
4- Buffer Ring 11 - Piston Rod 18 - O-Ring 25 - Retaining Ring
5- Bushing 12 - Cylinder Tube 19 - Slide Ring (2 Used) 26 - Cushion Seal
6- Retaining Ring 13 - Cushion Bearing 20 - Slide Ring (2 Used) 27 - Cushion Bearing
7- Cylinder Head 14 - Cushion Seal 21 - Shim 28 - Stopper (2 Used)
W4-2-30
Assemble Arm Cylinder
Tools for pressing bushing: ST 8024/ST 1911 (24) using special tool (ST 5908) while aligning
the matching mark on the rod with that on the nut.
IMPORTANT: Be sure to install rings in correct Tool for tightening nut: 90 mm (ST 3263)
direction. : 7230 N⋅m (740 kgf⋅m, 5330 Ibf⋅ft)
2. Install U-ring (3), backup ring (2), buffer ring (4),
and retaining ring (6) to cylinder head (7). ST 5908

a plastic hammer.
Tool for pressing wiper ring: ST 8024/ST 1368
4. Install O-ring (10) and backup ring (9) to cylinder

head (7). W158-04-02-022
IMPORTANT: When installing slide rings (19) and 10. Align the hole of piston rod (11) and nut (24), then
(20), do not align their split portion. install steel ball (23).
5. Install seal ring (17), O-ring (18), and slide rings
(19, 20) (2 used for each) to piston (15). 11. After tightening set screw (22), crimp the head of
6. Install the cylinder head (7) assembly into piston : 57±10.5 N⋅m
rod (11). (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft)
Tools for installing cylinder head:
ST 8024/ST 2510
CAUTION: Be sure to keep cylinder rod (11)
aligning with the center of cylinder tube (12)
IMPORTANT: Be sure that the slit in cushion seal
when inserting in order to avoid damaging
(14) is facing piston and that the oil
rings.
groove in cushion bearing (13) is
facing correct direction.
12. Horizontally secure cylinder tube (12) on a work-
7. Install cushion seal (14) to cylinder rod (11). In-
bench. Insert the piston rod (11) assembly into
stall cushion bearing (13) and the piston (15) as-
cylinder tube (12).
sembly to cylinder rod (11)
13
Oil Groove
Nut Side
: 267 N⋅m (27 kgf⋅m, 200 Ibf⋅ft)
Head Side Nut Side
W18B-04-02-011
IMPORTANT: Be sure that cushion seal (26) slit is

facing piston and that the oil groove
in cushion bearing (27) is facing
correct direction.
8. Install retaining ring (25) and cushion seal (26) to
piston rod (11). Install cushion bearing (27) and
stopper (28) to the piston rod.
W4-2-31
DISASSEMBLE CYLINDER
(STABILIZER, BLADE)
Stabilizer Cylinder
W1GL-04-02-001
Blade Cylinder
W1GL-04-02-002
Section A
1 Lock Washer 3 4 10 11 12 13 14 15 16 15 14 13
Slit 18
Hole (1 Place) Black 19
Green
20
2
5 6 7 8 9
17 W1GL-04-02-003
1- Wiper Ring 6- Bushing 11 - Cylinder Tube 16 - Seal Ring

2- Cylinder Head 7- Retaining Ring 12 - Piston 17 - O-Ring
3- O-Ring 8- Backup Ring 13 - Slide Ring (2 Used) 18 - Nut
4- Buffer Ring 9- O-Ring 14 - Slide Ring (2 Used) 19 - Set Screw
5- U-Ring 10 - Piston Rod 15 - Backup Ring (2 Used) 20 - Steel Ball
W4-2-32
Disassemble Stabilizer and Blade Cylinders
• Be sure to read “Precautions for Disassembly 4. Secure piston rod (10) on special tool (ST 5908).
and Assembly” thoroughly on page W1-1-1 be- Put matching mark between piston rod (10) and
fore starting the repair work. nut (18).
• The disassembly procedure below starts on the
ST 5908
premise that the hydraulic lines and the line se-
curing bands have been removed.
CAUTION:
Stabilizer cylinder weight: 88 kg (195 lb)
Blade cylinder weight: 55 kg (120 lb)
W158-04-02-022
1. Lift and horizontally secure the cylinder on a
workbench. Then, drain the hydraulic oil from the 5. Remove set screw (19) and steel ball (20).
cylinder.
NOTE: Set screw (19) was crimped with a punch
in two places after it was tightened. Before
crimped portions.
6. Loosen and remove nut (18) using special tool

(ST 5908).
Remove piston (12) from piston rod (10).
Tools for turning nut:
W102-04-02-027
Stabilizer cylinder: 85 mm (ST 3304)
Blade cylinder: 75 mm (ST 3271)
2. Let the lock washer in cylinder tube (11) bend.
By using a hook spanner wrench, loosen cylinder 7. Remove cylinder head (2) from cylinder rod (10).
head (2) by 1 to 2 turns.
Hook spanner wrench: IMPORTANT: When removing the seal parts, take
Stabilizer cylinder: ST 3223 care not to damage them.
Blade cylinder: ST 3219 Do not reuse slide rings (13) and
(14). When dissembling cylinder, re-
NOTE: The lock washer in cylinder head (2) is
place them with new ones.
provided on cylinder tube (11) to from an
integral part.
8. Remove slide rings (13, 14) (2 used for each),
backup rings (15) (2 used), seal ring (16) and
IMPORTANT: Be sure to pull out piston rod (10)
O-ring (17) from piston (15).
straight to prevent the sliding sur-
faces from being damaged.
9. Remove wiper ring (1), U-ring (5), buffer ring (5),
3. Fully extend piston rod (10). Hold the rod end by
retaining ring (7) and bushing (6) from the cylin-
crane. Remove cylinder head (2). Pull out the
der head (1) inside.
piston rod (10) assembly from cylinder tube (11).
Tools for removing bushing:
Stabilizer cylinder: 70 mm (ST 8017)
10. Remove O-rings (3, 9) and backup ring (8) from

the cylinder head (2) outside.
W4-2-33
ASSEMBLE CYLINDER
(STABILIZER, BLADE)
Stabilizer Cylinder
W1GL-04-02-001
Blade Cylinder
W1GL-04-02-002
Section A
1 Lock Washer 3 4 10 11 12 13 14 15 16 15 14 13
Slit 18
Hole (1 Place) Black 19
Green
20
2
5 6 7 8 9
17 W1GL-04-02-003
1 - Wiper Ring 6- Bushing 11 - Cylinder Tube 16 - Seal Ring

2 - Cylinder Head 7- Retaining Ring 12 - Piston 17 - O-Ring
3 - O-Ring 8- Backup Ring 13 - Slide Ring (2 Used) 18 - Nut
4 - Buffer Ring 9- O-Ring 14 - Slide Ring (2 Used) 19 - Set Screw
5 - U-Ring 10 - Piston Rod 15 - Backup Ring (2 Used) 20 - Steel Ball
W4-2-34
Assemble Stabilizer and Blade Cylinders
• Be sure to read “Precautions for Disassembly 8. Install piston (12) to piston rod (10). Tighten nut
and Assembly” thoroughly on page W1-1-1 be- (18) using special tool (ST 5908) while aligning
fore starting the repair work. the matching mark on the rod with that on nut
(18).
1. Press bushing (6) into cylinder head (2) by using Tools for turning nut:
the special tool. Install retaining ring (7) in cylin- Stabilizer cylinder: 85 mm (ST 3304)
der head (4). : 3560 N⋅m (360 kgf⋅m, 2630 Ibf⋅ft)
Tools for pressing bushing: Blade cylinder: 75 mm (ST 3271)
Stabilizer cylinder: 70 mm (ST 8017) : 2480 N⋅m (250 kgf⋅m, 1830 Ibf⋅ft)
IMPORTANT: Install U-ring (5) with the lip facing ST 5908

the bushing (6) side.
Install buffer ring (4) with the pro-
trusion part and slit facing the
bushing (6) side.
2. Install U-ring (5) and buffer ring (4) to cylinder
head (2).
W158-04-02-022
3. Install wiper ring (1) to cylinder head (2) with a

plastic hammer. 9. Align the hole on cylinder rod (10) with that on
Tools for pressing wiper ring: nut (18). Insert steel ball (20) into the hole and
Stabilizer cylinder: ST 8051 tighten set screw (19).
Blade cylinder: ST8049 After tightening set screw (19), crimp the head of
IMPORTANT: Install backup ring (8) to the piston Stabilizer cylinder:
rod (10) side of O-ring (9). : 10 mm
4. Install O-ring (3), (9) and backup ring (8) to cyl- : 57±10.5 N⋅m
inder head (2). (5.8±1.1 kgf⋅m, 42±7.7 lbf⋅ft)
Blade cylinder:
5. Install the cylinder head (2) assembly into piston : 8 mm
rod (10). : 31.5±5.88 N⋅m
Tools for installing cylinder head: (3.2±5.88 kgf⋅m, 23±4 lbf⋅ft)
Stabilizer/Blade cylinder: ST 8017
Blade cylinder: ST8012 IMPORTANT: Be sure to keep piston rod (10)
aligning with the center of cylinder
IMPORTANT: Make sure that O-ring (17) is not tube (11) when inserting in order to
twisted after installing it. avoid damaging the piston rings.
6. Install backup rings (15) (2 used), and O-ring (17) IMPORTANT: Apply THREEBOND #1901 onto the
and seal ring (16) onto sleeve (12) with a wooden thread of cylinder head (2).
spatula so that they are not installed in the slide 10. Securely place cylinder tube (11) on a workbench,
ring (13) groove. insert the piston rod (10) assembly into cylinder
tube (11).
IMPORTANT: When installing slide rings (13), (14)
do not align their split portion. 11. Tighten cylinder head (2) to cylinder tube (11)
7. Install slide rings (13), (14) to piston (12). using R wrench. Bend the lock washer to prevent
cylinder head (2) from loosening.
R wrench:
Stabilizer cylinder: ST 3223
: 1060 N⋅m (108 kgf⋅m, 780 Ibf⋅ft)
Blade cylinder: ST 3219
: 735 N⋅m (75 kgf⋅m, 540 Ibf⋅ft)
W4-2-35
MAITENANCE STANDARD
Piston Rod Rod Bend and Run Out
Dial Gauge
Piston Rod
A
W166-04-02-022
1 m (3.9 in)
W105-04-02-094 V Block
Unit: mm (in)
Recommended Size After Unit: mm (in)
Cylinder Name Bend Run out Remedy
Re-manufacturing (A)
-0.023 -0.0009 0.5 (0.020) 1.0 (0.039) Repair
Boom 80 (3.15 ) 1.0 (0.039) 2.0 (0.079) Replace
-0.053 -0.0021
-0.029 -0.0011
Positioning 90 (3.54 )
-0.057 -0.0022
-0.023 -0.0009
Bucket 75 (2.95 )
-0.053 -0.0021
Wear to inner Diameter of Rod Bushing

Unit: mm (in)
Cylinder Standard inner Allowabl
Remedy
Name Dimeter (C) e Limit
-0.06 -0.002 +0.3
Boom 80 (3.15 ) Replace
-0.19 -0.007 (0.012)
-0.06 -0.002 +0.3 C
Arm 90 (3.54 ) Replace
-0.19 -0.007 (0.012)
-0.06 -0.002 +0.3
Bucket 75 (2.95 ) Replace
-0.19 -0.007 (0.012)
W4-2-36
FRONT ATTACHMENT / Hose-Rupture Safety Valve
REMOVE AND INSTALL HOSE-RUPTURE
SAFETY VALVE
Removal of Hose-Rupture Safety Valve for Arm
Cylinder 1 2 3, 4

on page W4-1-1.)
IMPORTANT: Attach identification tags to the

hydraulic hoses and pipes for
re-assembly.
2. Disconnect hoses (2) and (5) (2 used) from 5
hose-rupture safety valve (6).
Attach a cap onto the open ends. W1GL-04-03-005
: 17 mm, 19 mm, 27 mm
6
3. Remove socket bolts (4) (4 used) then remove
pipe (3) from hose-rupture safety valve (6).
: 10 mm

hose-rupture safety valve (6) from the arm
cylinder.
: 10 mm
Installation of Hose-Rupture Safety Valve for Arm

Cylinder
1. Install hose-rupture safety valve (6) onto the arm

cylinder with socket bolts (1) (4 used).
: 10 mm
: 93±2 N⋅m (9.5±0.2 kgf⋅m, 69±1.5 lbf⋅ft)
2. Install pipe (3) onto hose-rupture safety valve (6)

: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
3. Connect hoses (2) and (5) (2 used).

: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m,18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

W4-3-1
Removal of Hose-Rupture Safety Valve for

1. After stopping the engine, push the pressure 1 8 2

Release the arm circuit pressure. (Refer to 3
on page W4-1-1.)

re-assembly. 6
2. Disconnect hoses (1, 2, 3) and (7) from
hose-rupture safety valve (5).
Attach a cap onto the open ends.
: 19 mm, 36 mm
4
3. Remove the pipe (6) securing bolt (8) and the
pipe clamp.
W1F3-04-03-001
: 22 mm 7 5

pipe (6) and hose-rupture safety valve (5) from
the positioning cylinder.
: 10 mm
Installation of Hose-Rupture Safety Valve for

1. Install hose-rupture safety valve (5) and pipe (6)

onto the positioning cylinder with socket bolts (4)
(4 used).
: 10 mm
: 93±2 N⋅m (9.5±0.2 kgf⋅m, 69±1.5 lbf⋅ft)
2. Connect hoses (1), (2), (3) and (7).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
3. Secure the pipe clamp with bolt (8).

: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

W4-3-2
Removal of Hose-Rupture Safety Valve for Boom

Cylinder

remaining pressure from the hydraulic oil tank. 1 2 3
on page W4-1-1.)

re-assembly.
2. Disconnect hoses (3) (4 used) and (5) (2 used)
from hose-rupture safety valve (6).
: 19 mm, 36 mm
3. Remove the pipe (7) securing bolts (1, 2) and the

pipe clamp.
: 17 mm, 22 mm
4. Remove socket bolts (4) (4 used) then remove 4

W1GL-04-03-003
7 6 5
pipe (7) and hose-rupture safety valve (6) from
the boom cylinder.
: 10 mm
Installation of Hose-Rupture Safety Valve for

Boom Cylinder
1. Install hose-rupture safety valve (6) and pipe (7)

onto the boom cylinder with socket bolts (4) (4
used).
: 10 mm
: 93±2 N⋅m (9.5±0.2 kgf⋅m, 69±1.5 lbf⋅ft)
2. Connect hoses (3) (4 used) and (5) (2 used).

: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
3. Secure the pipe clamp with bolts (1, 2).

: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 22 mm
: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

W4-3-3
CONSTRUCTION OF HOSE-RUPTURE
SAFETY VALVE
For Arm Cylinder

1 2
20 21
19
3
18 4
17 5
7
16 15 14 13
8
9
10
11
12
W1GL-04-03-002
W4-3-4
Tightening Torque
Item No. Part Name Quantity Wrench Size Remark
N⋅m (kgf⋅m) (lbf⋅ft)
1 Casing 1
2 Plug 3
3 O-Ring 3
4 Spool 1
5 O-Ring 1
6 Plug 1
7 Spring Seat 1
8 Backup Ring 1
9 O-Ring 1
10 Spring 1
11 Poppet 1
12 Body 1
13 O-Ring 2
14 Seat 1
15 O-Ring 1
16 Stopper 1
17 Set Screw 1
18 Lock Nut 1
19 O-Ring 1
20 Cover 1
21 Spring 1
W4-3-5
For Boom/Positioning Cylinder
3 4 5 6 7 8
2
1
29 30 31
28 9
27
10
26
11
25
12
13
14
15
16
17
24 23 22 21 18
19
20
W1GL-04-03-001
W4-3-6
Item Tightening Torque

Part Name Quantity Wrench Size Remark
No. N⋅m (kgf⋅m) (lbf⋅ft)
1 Pilot Poppet 1
2 Adapter 1 : 24 mm
3 Plain Washer 1
4 Lock Nut 1 : 17 mm
5 Set Screw 1 : 5 mm
6 O-Ring 1
7 Spring 1
8 O-Ring 1
9 Casing 1
10 Backup Ring 1
11 O-Ring 1
12 O-Ring 1
13 Spool 1
14 Plug 1 : 32 mm
15 Plug 1
16 Backup Ring 1
17 O-Ring 1
18 Spring 1
19 Poppet 1
20 Body 1
21 O-Ring 2
22 Seat 1
23 O-Ring 1
24 Stopper 1
25 Set Screw 1 : 3 mm
26 Lock Nut 1 : 10 mm
27 O-Ring 1
28 Cover 1 : 32 mm
29 Spring 1
30 Plug 3 : 3 mm
31 O-Ring 3
W4-3-7
(Blank)
W4-3-8
FRONT ATTACHMENT / Operate-Check Valve
REMOVE AND INSTALL OPERATE-CHECK
1
Removal
2
IMPORTANT: Before working, lower the blade onto
the ground.
IMPORTANT: Before working, be sure to secure
the stabilizer beam and stabilizer
with the lock pin.
1. Remove bolts (2) (4 used) then remove protection
cover (1).
: 19 mm
2. Disconnect hoses (5) (4 used) from operate-check

valve (4). Attach a cap onto the open ends. W1GL-04-01-013
: 17 mm, 19 mm, 22 mm, 27 mm
3 4
bracket (7).
4. Remove plug (3) then remove operate-check

valve (4).
6, 7
Installation
1. Install operate-check valve (4) on the blade

cylinder with plug (3).
: 36 mm
: 128±6.4 N⋅m (13±0.7 kgf⋅m, 94±4.7 lbf⋅ft) W1GL-04-02-004
2. Install bracket (7) on the blade cylinder with 5

: 6 mm Float
: 26.5 N⋅m (2.7 kgf⋅m, 19.5 Ibf⋅ft) Stabilizer Beam Lock Pin
3. Connect hoses (5) (4 used) to operate-check

valve (4).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf⋅ft) 4 Stabilizer
: 22 mm
: 39 N⋅m (4.0 kgf⋅m, 28.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 Ibf⋅ft)
4. Install protection cover (1) with bolts (2) (4 used).

5
: 19 mm W1F3-04-01-011
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W4-4-1
FRONT ATTACHMENT / Operate-Check Valve
CONSTRUCTION OF OPERATE-CHECK
4
5
11 10 9 8 7
T1F3-03-10-003
Item Tightening Torque

Part Name Q’ty Wrench Size Remark
No. N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 : 5 mm
2 O-Ring 1 1B P11
3 Casing 1
4 O-Ring 1 1B P26
5 Plug 1 : 36 mm 360±36 (37±3.7) (265±26.5)
φ
6 Spring 1 1.0×φ8.5×31.0 mm
7 Poppet 1
8 Check Valve 1
9 Piston 1
10 O-Ring 1 1B P24
11 Plug 1 : 36 mm 240±24 (24±2.4) (175±17.5)
W4-4-2
MEMO
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SECTION 5
ENGINE AND ACCESSORY
 CONTENTS 
General Information Engine Assembly 2
General Repair Instructions ........................... 1-2 (Inspection and Repair)
Notes on the Format of This Manual .............. 1-2 Cylinder Head ................................................ 4-2
Main Data and Specifications......................... 1-6 Valve Guide.................................................... 4-3
Performance Curve........................................ 1-8 Valve Spring ................................................... 4-6
External View ................................................1-11 Tappet ............................................................ 4-7
Tightening Torque Specifications ................. 1-14 Push Rod ....................................................... 4-8
Angular Nut and Bolt Tightening Method...... 1-16 Rocker Arm Shaft and Rocker Arm................. 4-8
Major Parts Fixing Nuts and Bolts ................ 1-18 Idler Gear and Idler Gear Shaft ...................... 4-9
Identifications............................................... 1-26 Camshaft...................................................... 4-10

Cylinder Body and Liner ............................... 4-11
Maintenance Piston and Piston Ring ................................. 4-17
Lubricating System ........................................ 2-2
Piston Pin..................................................... 4-18
Fuel System................................................... 2-3
Connecting Rod ........................................... 4-19
Cooling System.............................................. 2-6
Crankshaft.................................................... 4-21
Valve Clearance Adjustment .......................... 2-6
Flywheel....................................................... 4-28
Injection Timing.............................................. 2-8
Timing Gear Case Cover.............................. 4-28
Compression Pressure Measurement .......... 2-12
Turbocharger Inspection .............................. 2-13 Engine Assembly 3 (Reassembly)
Engine Repair Kit ......................................... 2-14 Piston and Connecting Rod
Recommended Lubricants ........................... 2-15 Reassembly Steps........................................ 5-2
Engine Oil Viscosity Chart ........................... 2-15 Cylinder Head Reassembly Steps .................. 5-4
Rocker Arm and Rocker Arm Shaft
Engine Assembly 1 (Disassembly) Reassembly Steps........................................ 5-7
External Parts Disassembly Steps ................. 3-2
Major Component Reassembly Steps 1.......... 5-8
Major Components......................................... 3-6
Major Component Reassembly Steps 2........ 5-13
Rocker Arm and Rocker Arm Shaft
External Parts Reassembly Steps
Disassembly Steps..................................... 3-10
(Left-Hand Side) ......................................... 5-18
Cylinder Head Disassembly Steps ................3-11
External Parts Reassembly Steps
Piston and Connecting Rod
(Right-Hand Side)....................................... 5-21
Disassembly Steps..................................... 3-12
Engine Tuning Operation.............................. 5-25
NOTE: Refer to AA-4BG1TCG-01 engine model.
CBBW-5-1
Lubricating System Troubleshooting
General Description ....................................... 6-2 Hard Starting ................................................ 11-2
Oil Pump ........................................................ 6-3 1) Starter Inoperative ................................. 11-2
Oil Cooler....................................................... 6-5 2) Starter Operates but
Engine does not Turn Over .................... 11-3
Cooling System
3) Engine Turns Over but does not Start
General Description ....................................... 7-2
Fuel is Being Delivered to the
Thermostat..................................................... 7-3
Injection Pump ....................................... 11-4
Fuel System 4) Engine Turns Over but does not Start .... 11-5
General Description ....................................... 8-2 Unstable Low Idling ...................................... 11-6
Injection Nozzle ............................................. 8-3 Insufficient Power......................................... 11-8
Injection Pump Calibration Data..................... 8-8 Excessive Fuel Consumption ......................11-11
Excessive Oil Consumption........................ 11-13
Turbocharger Overheating ............................................... 11-14
General Description ....................................... 9-2 Whity Exhaust Smoke ................................ 11-16
Turbocharger Identification ............................ 9-3 Dark Exhaust Smoke.................................. 11-17
Troubleshooting ............................................. 9-5 Oil Pressure does not Rise......................... 11-18
Inspection and Repair .................................... 9-7 Abnormal Engine Noise.............................. 11-20
Engine Electricals Special Tool List

Starter Identification ..................................... 10-2 Special Tool List ........................................... 12-2
Starter Main Data and Specifications ........... 10-3
Starter Sectional View.................................. 10-4 Repair Standards
Performance ................................................ 10-4 Repair Standards ......................................... 13-1
Disassembly ................................................ 10-5
Conversion Table
Inspection and Repair .................................. 10-8
Length .......................................................... 14-1
Reassembly ............................................... 10-12
Area ............................................................. 14-3
Adjustment................................................. 10-13
Volume ......................................................... 14-3
Performance Test....................................... 10-14
Mass ............................................................ 14-5
Alternator Identification .............................. 10-15
Pressure....................................................... 14-6
Main Data and Specifications..................... 10-16
Torque .......................................................... 14-7
Alternator Sectional View ........................... 10-17
Temperature ................................................. 14-8
Charging Circuit ......................................... 10-17
Structure .................................................... 10-18
Disassembly .............................................. 10-19
Inspections ................................................ 10-22
Reassembly ............................................... 10-24 NOTE: Refer to AA-4BG1TCG-01 engine model.
Bench Test ................................................. 10-25
Current Output Test.................................... 10-26
Fault Finding .............................................. 10-27
Specifications............................................. 10-27
CBBW-5-2
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
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:
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Manual No.

Wheeled Excavator Workshop Manual

PRINTED IN SINGAPORE (PS)

Zaxis160W Wheeled-Wsh 1 24/6/03, 3:51 PM

• Each page has a number, located on the center

Consecutive Page Number for Each Group

• This is the SAFETY ALERT SYMBOL.

UNDERSTAND SIGNAL WORDS

• CAUTION also calls attention to safety messages in

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the

to operate the machine.

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

posted near your telephone.

WEAR PROTECTIVE CLOTHING

Be sure to wear the correct equipment and clothing

• Prolonged exposure to loud noise can cause

• Before entering the cab, thoroughly remove all

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

ADJUST THE OPERATOR'S SEAT

• If the machine should overturn, the operator may

securely fastened at all times when the machine

MOVE AND OPERATE MACHINE SAFELY

• Battery gas can explode, resulting in serious injury.

• Riders on machine are subject to injury such as

PROVIDE SIGNALS FOR FOBS INVOLV-

• For jobs involving multiple numbers of machines,

CONFIRM DIRECTION OF MACHINE TO

• Incorrect steering wheel shift lever operation may

• Before driving the machine, always confirm that the

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

• Driving across the face of a slope or steering on

To avoid back-over and swing accidents:

MACHINE WILL TIP OVER FASTER THAN YOU

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when

• Reduce swing speed as necessary when

• Serious injury or death can result if the machine or

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

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

PARK MACHINE SAFELY

the catch, so that the left console can be moved

• Handle fuel with care; it is highly flammable. If fuel

• All fuels, most lubricants, and some coolants are

• Store flammable fluids well away from fire

• The danger of tipping is present when

Take the following precautions when load-

Place blocks in front of and behind the tires to

• Understand service procedures before doing

• Before servicing the machine:

inside the machine.

• Unexpected machine movement can cause serious

SUPPORT MACHINE PROPERLY

STAY CLEAR OF MOVING PARTS

• Travel reduction gears are under pressure.

STORE ATTACHMENTS SAFELY

SUPPORT MAINTENANCE PROPERLY

• Never cut or weld on an inflated tire or rim as-

• The hydraulic oil tank is pressurized. Again, be

Hot fluids and surfaces:

REPLACE RUBBER HOSES

attachment to fall on a person nearby, which may

• Fluids such as diesel fuel or hydraulic oil under