ZX470-5G Workshop Manual

PART NO.
WJAC-EN-00
ZX470-5G • 470LC-5G • 470H-5G • 470LCH-5G • 470R-5G • 470LCR-5G HYDRAULIC EXCAVATOR WORKSHOP MANUAL
Workshop Manual
ZX
470-5G
470LC-5G
470H-5G
470LCH-5G
URL:http://www.hitachi-c-m.com 470R-5G
470LCR-5G
Hydraulic Excavator
Service Manual consists of the following separate Part No.
WJAC-EN-00
Technical Manual (Operational Principle) : Vol. No.TOJAC-EN

Technical Manual (Troubleshooting) : Vol. No.TTJAC-EN
Workshop Manual : Vol. No.WJAC-EN
PRINTED IN JAPAN (K) 2012, 02
INTRODUCTION
To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
Form” at the end of this manual. (Note: Do not tear off
 Be sure to thoroughly read this manual for correct the form. Copy it for usage.):
product information and service procedures.  Publications Marketing & Product Support Hitachi
Construction Machinery Co. Ltd.
 TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: dc@hitachi-kenki.com
Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures.  Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / disassemble procedures.
Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group
IN-01
INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential d CAUTION:
Indicated potentially hazardous situation which could, if
for personal injury of machine damage.
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed
instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention to
component/part weights. f NOTE:
Indicates supplementary technical information or know-
To avoid injury and damage, be sure to use appropriate
how.
lifting techniques and equipment when lifting heavy
parts.
Units Used
SI Units (International System of Units) are used in this Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
manual. MKSA system units and English units are also
indicated in parentheses just behind SI units. A table for conversion from SI units to other system units
is shown below for reference purposes.
Quantity To Convert From Into Multiply By

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

different from the above-mentioned table.
IN-02
SYMBOL AND ABBREVIATION
Symbol / Name Explanation

Abbreviation
TO Technical manual (Operational principle)Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
VGS Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged
system to supercharge the exhaust energy while running
the engine at slow idle speed. VGS optimizes the turbine
rotation, improves the performance at slow-speed torque
and the acceleration, reduces fuel consumption, and reduces
particulate matter (PM) by adjusting the nozzle opening of
turbine housing.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
SY-1
SYMBOL AND ABBREVIATION
Symbol / Name Explanation

Abbreviation
DPF Diesel Particulate Filter DPF is a filter which removes particulate matter (PM)
including the toxic substance of exhaust gas of the diesel
engine. Exhaust particulate removal equipment.
DPD Diesel Particulate Diffuser DPD is an exhaust emission control system, a type of DPF,
which cleans up particulate matter (PM) of diesel engine
exhaust gas. DPD is a ceramic filter which traps and filters
PM of exhaust gas. DPD burns up accumulated PM when PM
increases and regenerates the filter.
DOC Diesel Oxidation Catalyst Oxidation catalyst for the diesel engine. Diesel oxidation
catalyst oxidizes unburnt fuel and raises exhaust
temperature.
CSF Catalyzed Soot Filter Filter. The filter traps, burns, and remove particulate matter
(PM) by using high-temperature-exhaust gas with diesel
oxidation catalyst. Catalyst is applied onto the filter. This
advances PM burning.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the
intake manifold and combines it with intake-air. Therefore,
combustion temperature is lowered and generation of oxide
of nitrogen (NOx) is controlled.
SY-2
SAFETY
Recognize Safety Information

 These are the SAFETY ALERT SYMBOLS.
 When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
 Follow recommended precautions and safe operating
practices.
SA-688
Understand Signal Words

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

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

element of information.
SA-1
SAFETY
Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in the operator's manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or the operator's manual is damaged or
missing, order a replacement from your authorized dealer
in the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering).
 Learn how to operate the machine and its controls correctly
and safely.
 Allow only trained, qualified, authorized personnel to
operate the machine. SA-003
 Keep your machine in proper working condition.
 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.
SA-2
SAFETY
Prepare for Emergencies
 Be prepared if a fire starts or if an accident occurs.
 Keep a first aid kit and fire extinguisher on hand.
 Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
 To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
 Establish emergency procedure guidelines to cope with
fires and accidents.
 Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone.
SA-437
Wear Protective Clothing

 Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
SA-438
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
 Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
 Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
SA-3
SAFETY
Protect Against Noise

 Prolonged exposure to loud noise can cause impairment or
loss of hearing.
 Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
SA-434
Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
 In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.
SA-435
SA-4
SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not mess up around the operator's seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
 Keep all flammable objects and/or explosives away from
the machine.
 After using the ashtray, always cover it to extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
 Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.
SA-5
SAFETY
Use Handholds and Steps

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

 A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
 The seat should be adjusted whenever changing the
operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror SA-378
is broken, immediately replace it with a new one.
SA-6
SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with
a control lever and/or pedal, possibly resulting in serious
personal injury or death.
 Before leaving the machine, be sure to first lower the front
attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF
to stop the engine.
 Before leaving the machine, close all windows, doors, and
access covers and lock them up.
Fasten Your Seat Belt

 If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
 Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
 Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to SA-237
minimize the chance of injury from an accident.
 We recommend that the seat belt be replaced every three
years regardless of its apparent condition.
SA-7
SAFETY
Move and Operate Machine Safely

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

 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
 Start the engine only when seated in the operator's seat.
 NEVER start the engine while standing on the track or on
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders. SA-444
SA-8
SAFETY
Jump Starting
 Battery gas can explode, resulting in serious injury.
 If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
 The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
 Never use a frozen battery.
 Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
Keep Riders off Machine

 Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
 Only the operator should be on the machine. Keep riders
off.
 Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-379
SA-9
SAFETY
Precautions for Operations

 Investigate the work site before starting operations.
 Be sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
 Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
 When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M178-05-007
SA-10
SAFETY
Investigate Job Site Beforehand

 When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
 Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles or banks
from collapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
 When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
SA-11
SAFETY
 Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
 If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
 Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
 Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent M104-05-016
machine tipping over from occurring. When operating on
rough terrain or on slopes:
 Reduce the engine speed.
 Select slow travel speed mode.
 Operate the machine slowly and be cautious with
machine movements.
Install OPG Guard

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

OPG: Operator Protective Guard
SA-490
SA-12
SAFETY
Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.
SA-481
Confirm Direction of Machine to Be Driven

 Incorrect travel pedal/lever operation may result in serious
injury or death.
 Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when travel pedals/levers are
operated to the front.
SA-491
SA-13
SAFETY
Drive Machine Safely

 Before driving the machine, always confirm that the travel
levers/pedals direction corresponds to the direction you
wish to drive.
 Be sure to detour around any obstructions.
 Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do A
not allow personnel to stay around the machine while
traveling.
 Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.
 Never attempt to ascend or descend 35 degrees or
steeper slopes.
 Be sure to fasten the seat belt.
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 0.2 to 0.3 m (A)
above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If A SA-658
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.
SA-441
WRONG
SA-590
SA-14
SAFETY
 Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
 Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
 Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
 Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
 Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
 Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
 When crossing train tracks, use wood plates in order not
to damage them.
 Do not make contact with electric wires or bridges.
 When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
 When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
 Avoid operations that may damage the track and
undercarriage components.
 During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.
SA-15
SAFETY
Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
 Select level ground when possible to park the machine.
 Do not park the machine on a grade.
 Lower the bucket and/or other work tools to the ground.
 Turn the auto-idle switch OFF and the power mode switch
ECO.
 Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
 Stop the engine and remove the key from the key switch.
SA-391
 Pull the pilot control shut-off lever to LOCK position.
 Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.
SA-2273
SA-16
SAFETY
Avoid Injury from Back-Over and Swing

Accidents
 If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
 Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
 Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
 USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW. SA-383
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
 No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
 Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
 Keep windows, mirrors, and lights clean and in good
condition.
 Dust, heavy rain, fog, etc., can reduce visibility. As visibility
decreases, reduce speed and use proper lighting.
 Read and understand all operating instructions in the SA-384
operator’s manual.
SA-17
SAFETY
Keep Person Clear from Working Area

 A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or death.
 Keep all persons clear from the area of operation and
machine movement.
 Before operating the machine, set up barriers to the
sides and rear area of the bucket swing radius to prevent
anyone from entering the work area.
SA-386
Never Position Bucket Over Anyone

 Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
SA-487
SA-18
SAFETY
Avoid Undercutting
 In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage
perpendicular to the edge of the excavation with the travel
motors at the rear.
 If the footing starts to collapse and if retreat is not
possible, do not panic. Often, the machine can be secured
by lowering the front attachment, in such cases.
SA-488
Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE
--- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
 The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
 Be extra careful before operating on a grade.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the SA-012
machine.
 Reduce operating speeds to avoid tipping or slipping.
 Avoid changing direction when traveling on grades.
 NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
 Reduce swing speed as necessary when swinging loads.
 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become
soft and make ground travel unstable.
SA-440
SA-19
SAFETY
Never Undercut a High Bank

 The edges could collapse or a land slide could occur causing
SA-489
Dig with Caution

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

 If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
 Take care to avoid hitting overhead obstacles with the
boom or arm.
SA-389
SA-20
SAFETY
Avoid Power Lines

 Serious injury or death can result if the machine or front
attachments are not kept a safe distance from electric lines.
 When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
 Check and comply with any local regulations that may
apply.
 Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381
Precautions for Lightning

 The machine is vulnerable to lightning strikes.
 In the event of an electrical storm, immediately stop
operation, and lower the bucket to the ground. Evacuate
to a safe place far away from the machine.
 After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only after
repairing them.
SA-1088
SA-21
SAFETY
Object Handling
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
resulting in serious injury or death.
 When using the machine for craning operations, be sure
to comply with all local regulations.
 Do not use damaged chains or frayed cables, sables,
slings, or ropes.
 Before craning, position the upperstructure with the
travel motors at the rear.
 Move the load slowly and carefully. Never move it
suddenly.
 Keep all persons well away from the load.
 Never move a load over a person’s head.
 Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
 Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
SA-014
Protect Against Flying Debris

 If flying debris hit eyes or any other part of the body, serious
injury may result.
 Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
 Keep bystanders away from the working area before
striking any object.
 Always close the front windows, doors, door windows and
the overhead window when operating the machine.
SA-432
SA-22
SAFETY
Park Machine Safely

To avoid accidents:
 Park machine on a firm, level surface.
 Lower bucket to the ground.
 Turn auto-idle switch OFF and power mode switch ECO.
 Run engine at slow idle speed without load for 5 minutes.
 Turn key switch to OFF to stop engine.
 Remove the key from the key switch.
 Pull the pilot control shut-off lever to the LOCK position.
 Close windows, roof vent, and cab door.
 Lock all access doors and compartments.
SA-390
Handle Fluids Safely−Avoid Fires

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

 Store flammable fluids well away from fire hazards.
 Do not incinerate or puncture pressurized containers. SA-018
 Do not store oily rags; they can ignite and burn
spontaneously.
 Securely tighten the fuel and oil filler cap.
SA-019
SA-23
SAFETY
Transport Safely
 Take care the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
 Observe the related regulations and rules for safe
transportation.
 Select an appropriate truck or trailer for the machine to
be transported.
 Be sure to use a signal person.
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight. SA-395
3. Turn auto-idle switch OFF and turn mode switch to ECO

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

TRANSPORTING section in the operator's manual.
SA-24
SAFETY
Practice Safe Maintenance

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

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

8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
 If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
 If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support any
machine elements that must be raised for service work.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter in the operator's manual. SA-527
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
SA-25
SAFETY
 Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
 Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
Warn Others of Service Work

 Unexpected machine movement can cause serious injury.
 Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS3076175 SS2045102
Support Machine Properly

 Never attempt to work on the machine without securing
the machine first.
 Always lower the attachment to the ground before you
work on the machine.
 If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
SA-527
SA-26
SAFETY
Stay Clear of Moving Parts

 Entanglement in moving parts can cause serious injury.
 To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
SA-026
SA-2294
Prevent Parts from Flying

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

 As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
 GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
SA-27
SAFETY
Store Attachments Safely

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.
SA-034
Prevent Burns
Hot spraying fluids:
 After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
 To avoid possible injury from hot spraying water. DO
NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to SA-039
release all pressure before removing the cap.
Hot fluids and surfaces:
 Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
 Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
SA-28
SAFETY
Replace Rubber Hoses Periodically

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

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

 Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
 Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
SA-044
SA-29
SAFETY
Prevent Fires
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to fires.
 Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
 Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
 Do not bend or strike high-pressure lines.
 Never install bent or damaged lines, pipes, or hoses.
 Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
SA-019
Check for Shorts:
 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
 Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.
SA-30
SAFETY
Clean up Flammables:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammables immediately. Check and clean high
temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammables away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammables such as
dead leaves from entering. However, flammables which
have passed through the wire screen may cause fires.
Check and clean the machine every day and immediately
remove accumulated flammables.
Check Key Switch:

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

 Damaged or missing heat shields may lead to fires.
 Damaged or missing heat shields must be repaired or

replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as mufflers may cause fire. Always close the engine cover
while operating the machine.
SA-31
SAFETY
Evacuating in Case of Fire

 If a fire breaks out, evacuate the machine in the following
way:
 Stop the engine by turning the key switch to the OFF
position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method in the operator's manual.
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.
SA-016
SA-32
SAFETY
Precautions for Welding and Grinding
 Welding may generate gas and/or small fires.
 Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe place
before starting welding.
 Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
 Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
 After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818
SA-33
SAFETY
Avoid Heating Near Pressurized Fluid Lines

 Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
 Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
 Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc..
SA-030
Avoid Applying Heat to Lines Containing

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

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

 Do not disassemble the unit.
 Keep the units away from open flames and fire.
 Do not bore a hole, do not cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing the unit, sealed gas must be released.
Consult your nearest Hitachi dealer.
SA-34
SAFETY
Remove Paint Before Welding or Heating

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

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silicon dust or other contamination
may cause sickness.
 Depending on the work site conditions, the risk
of inhaling asbestos fiber, silicon dust or other
contamination may exist. Spray water to prevent asbestos
fibers, silicon dust or other contamination from becoming
airborne. Do not use compressed air.
 When operating the machine in a work site where
asbestos fibers, silicon dust or other contamination SA-029
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contamination.
 Keep bystanders out of the work site during operation.
 Asbestos fibers might be present in imitation parts. Use
only genuine Hitachi Parts.
SA-35
SAFETY
Prevent Battery Explosions

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

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

 If spilled onto skin, refrigerant may cause a cold contact
burn.
 Refer to the instructions described on the container for
proper use when handling the refrigerant.
 Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
 Never touch the refrigerant.
SA-405
SA-36
SAFETY
Handle Chemical Products Safely

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

 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
 Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
 Do not pour waste onto the ground, down a drain, or into
any water source.
 Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations SA-226
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
 Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
SA-37
SAFETY
Never Ride Attachment

Never allow anyone to ride attachments or load. This is an
extremely dangerous practice.
Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.
SA-38
SAFETY
Precaution for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which is
situated at the back of the driver's seat. There is a possibility
that a medical device, including an implantable device
such as a cardiac pacemaker, would be affected and would
malfunction by the electrical waves emitted from the
communication terminal equipment.
Any person affixed with a medical device such as the above SA-2302
should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.662 inches) apart at
all times. If such condition cannot be met, please contact our
company's nearest dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.
Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipments:
E-GSM900 0.573 W/Kg (914.80 MHz)
DCS-1800 0.130 W/Kg (1710.20 MHz)
WCDMA Band I 0.271 W/Kg (1950.00 MHz)
*This data was measured by having each type of

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

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).
In EU Member nation: *Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).
SA-39
SAFETY
 Never attempt to disassemble, repair, modify or displace the
communication terminal, antennas or cables. Failure to do
so may result in damage and/or fire to the base machine or
to the communication terminal. (When required to remove
or install the communication terminal, consult your nearest
Hitachi dealer.)
 Do not pinch or forcibly pull cables, cords or connectors.

Failure to do so may cause short circuit or broke circuit that
may result in damage and/or fire to the base machine or to
the communication terminal.
SA-40
SAFETY
Before Returning The Machine To The Customer

 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced
SA-435
SA-41
SAFETY
MEMO
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SA-42
SECTION AND GROUP SECTION 1 GENERAL INFORMATION
CONTENTS Group 1 Precautions for Disassembling and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil Tank
Group 5 Hydraulic Circuit Pressure Release Procedure
Group 6 Preparation
WORKSHOP MANUAL SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure
Group 2 Undercarriage
Group 3 Attachment
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Engine
Group 5 Radiator
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Swing Device
Group 11 Pilot Valve
Group 12 Solenoid Valve
Group 13 Signal Control Valve
Group 14 Shockless Valve
All information, illustrations and SECTION 4 UNDERCARRIAGE
specifications in this manual are based on Group 1 Swing Bearing
the latest product information available
at the time of publication. The right is Group 2 Travel Device
reserved to make changes at any time
without notice.
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 5 ATTACHMENT
Group 1 Front Attachment
COPYRIGHT(C)2012
Hitachi Construction Machinery Co., Ltd.
Group 2 Cylinder
Tokyo, Japan
All rights reserved SECTION 6 ENGINE
TECHNICAL MANUAL (Operational Principle) TECHNICAL MANUAL (Troubleshooting)
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specification Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Excavator Test
Group 1 Controller Group 5 Component Test
Group 2 Control System Group 6 Adjustment
Group 3 Hydraulic System SECTION 5 TROUBLESHOOTING
Group 4 Electrical System Group 1 Diagnosing Procedure
SECTION 3 COMPONENT OPERATION Group 2 Monitor
Group 1 Pump Device Group 3 e-Service
Group 2 Swing Device Group 4 Component Layout
Group 3 Control Valve Group 5 Troubleshooting A
Group 4 Pilot Valve Group 6 Troubleshooting B
Group 5 Travel Device Group 7 Air Conditioner
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling
and Assembling.........................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Painting Specification...................................................W1-3-1-1
Final Painted Color.........................................................W1-3-1-1
Group 4 Bleeding Air
Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1
Bleeding Air from Hydraulic System........................W1-4-1-2
Bleeding Air from Fuel System...................................W1-4-1-3
Bleeding Air from Radiator..........................................W1-4-1-4
Group 5 Pressure Release Procedure
Hydraulic Circuit Pressure Release Procedure......W1-5-1-1
Group 6 Preparation
Preparation before Inspection
and Maintenance.......................................................W1-6-1-1
JACW-1-1
(Blank)
JACW-1-2
SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling
Precautions for Disassembling and  If a part or component cannot be removed after

Assembling removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), then take the
Precautions for Disassembling appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and tag
 Clean the Machine
them if necessary.
Thoroughly wash the machine before bringing it
 Store common parts, such as bolts and nuts with
into the shop. Bringing a dirty machine into the shop
reference to where they are to be used and in a
may cause machine components to be contaminated
manner that will prevent loss.
during disassembling / assembling, resulting in
 Inspect the contact or sliding surfaces of
damage to machine components, as well as decreased
disassembled parts for abnormal wear, sticking, or
efficiency in service work.
other damage.
 Measure and record the degree of wear and
 Inspect the Machine
clearances.
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
 Precautions for Assembling
incorrect disassembling of components as well as
 Be sure to clean all parts and inspect them for any
personal injury.
damage. If any damage is found, repair or replace
Check and record the items listed below to prevent
part.
problems from occurring in the future.
 Dirt or debris on the contact or sliding surfaces may
 The machine model, machine serial number, and
shorten the service life of the machine. Take care not
hour meter reading.
to contaminate any contact or sliding surfaces.
 Reason for disassembly (symptoms, failed parts, and
 Apply appropriate lubricant oil onto parts in order to
causes).
prevent them from seizing.
 Clogging of filters and oil, water or air leaks, if any.
 Be sure to replace O-rings, backup rings, oil seals, and
Capacities and condition of lubricants.
floating seals with new ones once they have been
 Loose or damaged parts.
disassembled. Apply grease before installing
 Be sure that liquid-gasket-applied surfaces are clean
 Prepare and Clean Tools and Disassembly Area
and dry.
Prepare the necessary tools to be used and the area for
 If an anti-corrosive agent has been used on a new
disassembling work.
part, be sure to thoroughly clean the part to remove
the agent.
Precautions for Disassembling and Assembling
 Fit the matching marks made when disassembling
 Precautions for Disassembling and assemble them.
 Cap the open ends in case the hoses and pipes  Be sure to use the designated tools to assemble
have been disconnected. In addition, attach an bearings, bushings, and oil seals.
identification tag onto the connectors, hoses, and  Keep a record of the number of tools used for
pipes for assembling. disassembly / assembly. After assembling is
 Before disassembling, clean the exterior of the completed, count the number of tools so as to make
components and place on a workbench. sure that no forgotten tools remain in the assembled
 Drain hydraulic oil and gear oil from the hydraulic machine.
components and reduction gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling if
necessary.
 Be sure to use the specified special tools when
instructed.
W1-1-1-1
SECTION 1 GENERAL
Precautions for Using Floating Seal 1
1. In general, replace the floating seal with a new one

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

will occur. Be sure to do the following to prevent
trouble.
 Clean the floating seal and seal mounting bores with
cleaning solvent. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a - Correct c - Twist of O-Ring
 After installing the floating seal, check that O-ring b - Incorrect d - Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
(e) and (f ) at point (A) and (B), as illustrated. If these
distances differ, correct O-ring (2) seating. a A b A
B B
A=B A≠B
W178-02-11-003
a - Correct e - Sliding Surface

b - Incorrect f - Seal Mating Surface
W1-1-1-2
SECTION 1 GENERAL
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings a
safely.
 Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
 Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load with
a temperature of 100 °C (212 °F) or more, reduce the
load weight.
 Do not lift acid or alkali chemicals. W102-04-02-016
 Take care not to allow the sling to become wet. The
a - Correct Eyehole Lifting
load may slip.
Method
 When required to use more than one sling, use slings
with the same width and length to keep the lifted b
load balanced.
 When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
 Avoid using twisted, bound, connected, or hitched
slings.
 Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
 When removing the slings from under the load, take
care not to damage the nylon slings. Avoid contact W105-04-01-008
with protrusions.
 Avoid dragging slings on the ground, throwing b - Incorrect Eyehole Lifting
Method
slings, or pushing slings with a metal object.
 When using with other types of slings (wire rope) or
accessories (shackle), protect the joint so that the
nylon sling is not damaged.
 Store the nylon slings indoors so that they won’t
deteriorate with heat, sun light, or chemicals.
c W162-01-01-009
c - Bent of Sling
W1-1-1-3
SECTION 1 GENERAL
dCAUTION: If a load is lifted with a damaged

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

sling for any damage corresponding to examples
shown to the right. If any damage is found, cut and
discard the sling.
Even if no damage is found, do not use slings older
than 7 years.
Damaged Appearance a
a
W162-01-01-002 W162-01-01-006
e
a - Broken Sewing Thread a - Broken Sewing Thread e - Separation of Belt
b f
W162-01-01-003 W162-01-01-007
b
b - Scuffing b - Scuffing f - Scoring
c
c g
W162-01-01-004
W162-01-01-008
c - Fuzz d - Broken Sewing Thread
c - Fuzz g - Broken Warp
W162-01-01-005
a - Broken Sewing Thread
W1-1-1-4
SECTION 1 GENERAL
Maintenance Standard Terminology
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification. Allowable errors will be
indicated if necessary.
“Allowable Limit”
1. Normal machine performance cannot be
accomplished after exceeding this limit.
2. Repair or adjustment is difficult after exceeding this
limit.
3. Repair or adjustment is impossible after exceeding
this limit.
Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.
W1-1-1-5
SECTION 1 GENERAL
(Blank)
W1-1-1-6
SECTION 1 GENERAL
Group 2 Tightening
Tightening Bolts and Nuts
dCAUTION: Use tools appropriate for the work

to be done. Makeshift tools and procedures
can create safety hazards. For loosening and
tightening nuts and bolts, use correct size tools.
Otherwise, tightening tools may slip, potentially
causing personal injure.
fNOTE:
 Apply lubricant (e.g. white zinc B dissolved into spindle

oil) to bolts and nuts to reduce friction coefficient of
them.
 Make sure bolt and nut threads are clean before
WDAA-01-02-001
installing.
Bolt Types
Tighten the nuts or bolts correctly to the torque
specifications.
As the different types and grades of bolt are used,
use and tighten the correct bolts correctly when
assembling the machine or components.
Specified Tightening Torque Chart
Hexagon
Wrench
Bolt Dia. Wrench WDAA-01-02-002 WDAA-01-02-003 WDAA-01-02-004
Size
Size
Socket Bolt
N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft) N·m (kgf·m) (lbf·ft)
M6 10 5 3 to 4 (0.3 to 0.4) (2.2 to 3)
M8 13 6 30 (3) (22) 20 (2) (15) 10 (1) (7.4)
M10 17 8 65 (6.5) (48) 50 (5) (37) 20 (2) (15)
M12 19 10 110 (11) (81) 90 (9) (66) 35 (3.5) (26)
M14 22 12 180 (18) (133) 140 (14) (103) 55 (5.5) (41)
M16 24 14 270 (27) (200) 210 (21) (155) 80 (8) (59)
M18 27 14 400 (40) (300) 300 (30) (220) 120 (12) (89)
M20 30 17 550 (55) (410) 400 (40) (300) 170 (17) (125)
M22 32 750 (75) (550) 550 (55) (410) 220 (22) (162)
M24 36 950 (95) (700) 700 (70) (520) 280 (28) (205)
M27 41 1400 (140) (1030) 1050 (105) (770) 400 (40) (300)
M30 46 1950 (195) (1440) 1450 (145) (1070) 550 (55) (410)
M33 50 2600 (260) (1920) 1950 (195) (1440) 750 (75) (550)
M36 55 3200 (320) (2360) 2450 (245) (1810) 950 (95) (700)
W1-2-1-1
SECTION 1 GENERAL
Group 2 Tightening
IMPORTANT: The following items are applied to both

fine and coarse pitch threads.
 Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it)
 Torque tolerance is ±10 %.
 Use the bolts of correct length. The bolts that
are too long cannot be tightened as the bolt tip
comes into contact with the bottom of bolt hole.
Also the bolts that are too short cannot develop
sufficient tightening force.
 The torque given in the chart on the previous
page are for general use only, however,
a different torque is given for a specific
application. Use the specified torque.
 Clean the nut and bolt threads and remove dirt
or corrosion before installing.
Tightening Order
When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.
a b c
1 12 9 4 1 6 7 14
1.4 6 3
4 5
2 13 8 5 2 3 10 11
2.3
W105-01-01-003
a - Equally tighten upper and b - Tighten diagonally c - Tighten from center

lower alternately diagonally
W1-2-1-2
SECTION 1 GENERAL
Group 2 Tightening
Precautions for Spilt Flange

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

 Lock Plate
W105-01-01-008
IMPORTANT: Do not reuse the lock plates. Do not try
to bend the same point twice.
Correct Incorrect
 Split Pin
IMPORTANT: Do not turn in the loosening direction
in order to align the grooves and holes on the nut.
a b
Always turn in the tightening direction. Do not
reuse the split pins.
Correct Correct Incorrect
 Wire
IMPORTANT: Attach wire to bolts in the bolt-
tightening direction. Do not reuse the wire.
a
WDAA-01-02-007
a- Bend along edge sharply b- Do not bend it round
Correct Correct
Incorrect
Correct d Incorrect
c
WDAA-01-02-008
c- Tighten d- Loosen
W1-2-1-3
SECTION 1 GENERAL
Group 2 Tightening
Piping Joint
IMPORTANT: The torque given in table below are for
general use only, however, a different torque is
given for a specific application. Use the specified
1 4 3 5 2
torque.
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
a - Joint Body WDAA-01-02-009
IMPORTANT: a
Do not over-tighten union nut (3). Excessive

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

Description
Union Nut N·m (kgf·m) (lbf·ft)
30° male 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 270 (27) (200)
55 380 (38) (280)
60 380 (38) (280)
37° female 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
fNOTE: Tightening torque of 37° male coupling without

union is similar to tightening torque of 37° female.
W1-2-1-4
SECTION 1 GENERAL
Group 2 Tightening
Pipe Joint
Pipe connection (metal joint)
(Union Nut Wrench Size: 17, 19, 22, 27)
Metal (3) of adapter (1) and pipe (2) seals pressure oil.
 Precautions for use

Do not damage sealing surfaces (4) and (5) when
disassembling and assembling. 1 4 5 3 2
Tightening Torque
Use the specified tightening torque in the table below.
Wrench Size (mm) 17 19 22 27
N·m 25 30 40 80
Tightening
(kgf·m) (2.5) (3) (4) (8) M1M7-07-005
Torque
(lbf·ft) (18) (22) (30) (59)
O-ring Seal Joint

O-ring (6) is installed against the end surface of adapter
(7) and seals pressure oil.
IMPORTANT:
7 6 9
Replace O-ring (6) with a new one when

reinstalling.
Before tightening union nut (9), confirm that

O-ring (6) is seated correctly in O-ring groove
(8). Tightening union nut (9) with O-ring (6)
displaced will damage O-ring (6), resulting in oil
leakage.
Do not damage O-ring groove (8) of adapter (7)
 8 10 a
WDAA-01-02-011
or sealing surface (10) on the hose side. Damage a - Joint Body
to O-ring (6) may cause oil leakage.
If union nut (9) is found to be loose, causing

oil leakage, do not tighten it to stop the leak. Wrench Size mm Tightening Torque
Instead, replace O-ring (6) with a new one, then Union Nut N·m (kgf·m) (lbf·ft)
tighten union nut (9) after confirming that 19 30 (3) (22)
O-ring (6) is securely seated in O-ring groove (8). 22 70 (7) (52)
27 95 (9.5) (70)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 350 (35) (260)
W1-2-1-5
SECTION 1 GENERAL
Group 2 Tightening
Quick Coupling
3 1
1. Coupling procedure
 Push socket ring (1) into plug (3) by rotating it fully
counterclockwise and then pulling it toward you.
 Release socket ring (1). Check that socket ring (1)
is returned by the spring force and the coupling is
locked completely by ball (2). At this time, check if
socket ring (1) is returned to the original position (to
M1M7-07-006
the rightmost direction). 2
2. Separating procedure
 Remove the hose by rotating socket ring (1) fully
counterclockwise and then pulling it. Because no
check function is attached inside, be careful that oil
flows out.
 Cap the removed hoses using special plug.
dCAUTION:
 When disconnecting, do not damage joint
surface.
 When disconnecting, clean the joint part and
thoroughly wipe off the cleaning solution to
prevent any foreign material from entering.
 Complete the joint disconnecting / connecting
procedure. Check enough if oil leaks especially
after installation.
 After installation, check if socket ring (1)
is returned to the original position (to the
rightmost direction).
W1-2-1-6
SECTION 1 GENERAL
Group 2 Tightening
Screw-In Connection R G
30°
Depending on types of screw and sealing, different
types of screw-in connection are used.
IMPORTANT: Check that the thread pitch and thread

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

Joint Body FC material SS material
19 15 (1.5, 11) 35 (3.5, 26)
22 30 (3, 22) 50 (5, 37)
27 50 (5, 37) 95 (9.5, 70)
36 70 (7, 52) 160 (16, 118)
Seal Tape Application 41 110 (11, 81) 200 (20, 148)
Seal tape is used in order to seal clearances between 50 160 (16, 118) 330 (33, 245)
male and female threads so that any leaks between 60 200 (20, 148)
threads may be prevented. Therefore, apply just
enough seal tape to fill up thread clearances. Do not
overwrap.
fNOTE: Unit: N·m (kgf·m, lbf·ft)
 Application Procedure
Check that the thread surface is clean and, free of dirt c
or damage. Apply the seal tape around threads in order
to leave one to two pitch threads uncovered. Wrap the
seal tape in the same direction as the threads.
d e
W105-01-01-019
c - Internal Thread e - Clearance
d - External Thread
Low-Pressure-Hose Clamp Tightening f
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
T-Bolt Type Band Clamp:

4.5 N·m (0.45 kgf·m, 3.3 lbf·ft)
Worm Gear Type Band Clamp:

6 to 7 N·m (0.6 to 0.7 kgf·m, 4.4 to 5.2 lbf·ft)
f - Leave one to two pitch

M114-07-041
threads uncovered
g h
WDAA-01-02-012 M114-07-043
g - T-Bolt Type Band Clamp h - Worm Gear Type Band Clamp
W1-2-1-7
SECTION 1 GENERAL
Group 2 Tightening
Connecting Hose
dCAUTION: When replacing the hoses, use only

genuine Hitachi service parts. Using hoses other
Incorrect Correct
than genuine Hitachi hoses may cause oil leaks,

hose rupture or separation of fitting, possibly
resulting in a fire on the machine. Do not install
hoses kinked. Application of high oil pressure,
vibration, or an impact to a kinked hose may
result in oil leaks, hose rupture or separation of
fitting. Utilize the print marks on hoses when W105-01-01-011
installing in order to prevent hose from being
kinked. Take necessary measures to protect hoses
from rubbing against each other. If the hoses rub Incorrect a Correct
against each other, wear to the hoses may result
and lead to hose rupture. Take care so that the
hoses do not come into contact with the moving
parts or sharp objects.
W105-01-01-012
a - Rubbing Against Each Other
Incorrect Correct
b b
W105-01-01-013
a - Rubbing Against Each Other b - Clamp
Incorrect Correct
a
b
W105-01-01-014
a - Rubbing Against Each Other b - Clamp
W1-2-1-8
SECTION 1 GENERAL
Group 3 Painting
Painting specification
Surfaces to Be Painted Painting Colour

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

Shaded area on cab (Only the left side) Shining Silver
Suspension lifter N2.0 [Black]
Lever (Travel, pilot shut-off, foot rest) High Grade Black
Eruption plate Deep Black
Ladder, Handrail High Grade Black
Mirror stay High Grade Black
Muffler exhaust pipe B701K (Black heat-resistant painting)
W1-3-1-1
SECTION 1 GENERAL
Group 3 Painting
4
1 4
WJAC-01-03-003
WJAC-01-03-001
2
WJAC-01-03-002 A
WJBA-01-03-004
a
Section A
10 mm W1J1-01-03-005
6
6
WJAC-01-03-004
a - Paint all circumference in the lower hinge swing position shining

silver.
1- Ladder 3- Main Frame 5- Shaded Area on Cab
2- Step (Front, Rear) 4- Handrail 6- Cover [High Grade Black]
W1-3-1-2
SECTION 1 GENERAL
Bleeding Air from Hydraulic Oil Tank
dCAUTION: Escaping fluid under pressure may

penetrate the skin and eyes, and cause serious
injury. Release the pressure before disconnecting
the hydraulic pipings or removing other
equipment. Hot hydraulic oil just after operation
may spout out and cause severe burns. Wait until
oil cools before starting any work. Do not turn cap
(2) of hydraulic oil tank (3) quickly. Cap (2) may fly
off by internal pressure. Release any remaining
pressure before removing cap (2).
Preparation
1. Park the machine on a solid and level surface.
Set the front attachment in position for checking 1 2 3
hydraulic oil level.
2. Stop the engine. Push air bleed button (1) of

hydraulic oil tank (3) and bleed air from hydraulic oil
tank (3).
3. Remove cap (2) of hydraulic oil tank (3).
W1R7-01-04-001
4. Install vacuum pump (a) to the position where cap

(2) has been removed. Operate vacuum pump (a) a
and maintain negative pressure in hydraulic oil tank
(3).
b
fNOTE: Operate vacuum pump (a) continuously while
working. c
W1R7-01-04-002
a - Vacuum Pump
b - Hose
c - Adapter
W1-4-1-1
SECTION 1 GENERAL
Bleeding Air from Hydraulic System

Bleed air from the hydraulic system as follows when
hydraulic oil has been drawn, the suction filter and
suction pipe have been replaced, or the pump device,
swing motor, travel motor, cylinders have been removed/
installed.
IMPORTANT: If air is accumulated inside of the pump IMPORTANT: If air is accumulated inside of the
and if the engine starts in lacking of hydraulic oil, cylinder and if the cylinder is operated suddenly
the pump may be damaged. in lacking of hydraulic oil, the seal may be
 Bleeding Air from Pump damaged or the cylinder may seize.
 Remove the air bleed plug on top of the pump. Add  Bleeding Air from Hydraulic Circuit
hydraulic oil to the pump.  After refilling hydraulic oil, start the engine. While
 After the pump is filled with hydraulic oil, temporarily operating each cylinder, swing motor, and travel
tighten the plug. Then, start the engine and run it at motor evenly, operate the machine under light loads
slow idle speed. for 10 to 15 minutes. Slowly start each operation
 Slightly loosen the plug and bleed air from the pump (never fully stroke the cylinders during initial
until hydraulic oil comes out from the gap. operation stage).
 After bleeding all air, securely tighten the plug.  As the pilot circuit has an air bleed device, air in the
pilot circuit will be bled while performing the above
IMPORTANT: If air is accumulated inside of the motor operation for approx. 5 minutes.
and if the engine starts in lacking of hydraulic oil,  Reset the front attachment in position for checking
the motor may be damaged. hydraulic oil level.
 Bleeding Air from Travel Motor, Swing Motor  Stop the engine. Check hydraulic oil level. Replenish
 Remove the air bleed plug (top) from the travel hydraulic oil if necessary.
motor and swing motor. Fill the motor case with
hydraulic oil.
W1-4-1-2
SECTION 1 GENERAL
Bleeding Air from Fuel System

Air in the fuel system may make the engine hard to
start or make it run irregularly. After draining water and
sediment from the fuel filter, replacing the fuel filter,
cleaning the fuel solenoid pump strainer or running
the fuel tank dry, be sure to bleed the air from the fuel
system.
Air Bleeding Procedures
dCAUTION: Fuel leaks may lead to fires.
1. Check that fuel cock (1) on bottom of the fuel tank is

opened. 1
2. Loosen priming pump (3).
3. Loosen joint bolt (2) on the fuel main filter.
j : 12 mm
4. Supply fuel by reciprocating priming pump (3).
After no air bubbles are spouted through joint bolt M1U1-07-015
(2), tighten joint bolt (2).
j : 12 mm 2
5. After tightening joint bolt (2), reciprocate priming

pump (3) until its movement becomes slow.
6. Tighten priming pump (3).
7. Wipe off any spilled fuel.
8. Start the engine. Check that no fuel leaks are
present. If the engine does not start, repeat the
above procedures from step 1.
3
M111-07-046
W1-4-1-3
SECTION 1 GENERAL
Bleeding Air from Radiator
dCAUTION: Do not loosen the radiator cap until

the system has cooled. Hot steam may spout out
and cause severe burns. Wait until coolant cools
and loosen the cap slowly. Release all pressure
and remove the cap.
Preparation
1. Park the machine on a solid and level surface.
Set the front attachment in position for checking
hydraulic oil level.
2. Stop the engine. Remove the radiator cap.
W1-4-1-4
SECTION 1 GENERAL
Hydraulic Circuit Pressure Release Procedure

Release any remaining pressure as follows before
removing/installing the front attachment.
1. Set pilot shut-off lever (1) to the UNLOCK position.

2. Turn engine stop switch (2) ON.
fNOTE: Perform step 1 and step 2, and set the key switch
to the START position. Although the starter rotates, the
engine does not start.
IMPORTANT: Battery will deplete. Operate the key
switch for short period.
3. With the key switch set in the START position, 1 2
operate the control lever in order to release any M1U1-01-029
pressure in the hydraulic circuit 4 to 5 times.
4. Return pilot shut-off lever (1) to the LOCK position.
5. Turn engine stop switch (2) OFF.
W1-5-1-1
SECTION 1 GENERAL
(Blank)
W1-5-1-2
SECTION 1 GENERAL
Group 6 Preparation
Preparation before Inspection and

Maintenance
dCAUTION: Components, hydraulic oil, lubricant,

and coolant just after operation are too hot. Wait
until they cool. Then, start the work.
Before performing the maintenance procedures given in

the following chapters, park the machine as described
below, unless otherwise specified. M104-07-021
1. Park the machine on a level surface. 1

2. Lower the bucket to the ground.
3. Turn the auto-idle switch OFF.
4. Set the engine control dial to the slow idle position.
Run the engine at slow idle speed without load for
five minutes.
5. Set the key switch to the OFF position. Stop the
engine. Remove the key from the key switch. If
maintenance should be performed with the engine
running, do not leave the machine unattended.
6. Set pilot shut-off lever (1) to the LOCK position. 2
7. Before performing any work on the machine, attach
tag (2) on the door or control lever.
WDAA-01-06-001
W1-6-1-1
SECTION 1 GENERAL
Group 6 Preparation
(Blank)
W1-6-1-2
MEMO
MEMO
SECTION 2
MAINTENANCE STANDARD
CONTENTS
Main Pump........................................................................W2-1-1-1
Swing Motor.....................................................................W2-1-2-1
Travel Motor......................................................................W2-2-1-1
Sprocket.............................................................................W2-2-1-2
Center Joint.......................................................................W2-2-2-1
Front Idler..........................................................................W2-2-3-1
Upper Roller......................................................................W2-2-4-1
Lower Roller......................................................................W2-2-4-2
Track.....................................................................................W2-2-5-1
Remove and Install Bushing.......................................W2-3-1-1
Pin and Bushing...............................................................W2-3-1-3
Side Cutter.........................................................................W2-3-1-5
Point.....................................................................................W2-3-1-5
Standard Dimensions for Arm and Bucket
Connection..................................................................W2-3-1-6
Standard Dimensions for Arm and Boom
Connection..................................................................W2-3-1-8
Cylinder..............................................................................W2-3-2-1
JACW-2-1
(Blank)
JACW-2-2
SECTION 2 MAINTENANCE STANDARD
Main Pump
1. Clearance between plunger (32) outer diameter (A)
and cylinder block (27) bore diameter (B).
A B
B-A Unit: mm (in)

Standard Allowable Limit
0.038 (0.001) 0.078 (0.003)
W117-02-02-009
2. Free length (C) of cylinder spring (28)
C Unit: mm (in)
40.9 (1.61) 40.1 (1.58)
3. Clearance (D) between plunger (32) and shoe

C
bottom and shoe thickness (E)
W117-02-02-010
D Unit: mm (in)
0 to 0.1 (0 to 0.004) 0.35 (0.014)
E Unit: mm (in)
D
5.4 (0.21) 5.0 (0.20) E
W117-02-02-011
4. The difference between the surface of retainer (30)
to the top of spherical bushing (29)
F-G Unit: mm (in) a

13.5 (0.53) 12.5 (0.49) G F
W117-02-02-012
a- Base
W2-1-1-1
(Blank)
W2-1-1-2
Swing Motor
1. Clearance between plunger outer diameter (A) and
rotor inner bore (B)
A
B-A Unit: mm (in)
0.027 (0.0011) 0.052 (0.0020)
W107-02-06-138
B B
2. Clearance (C) between plunger (6) and shoe bottom

C Unit: mm (in)
W107-02-06-139
0 (0) 0.3 (0.0118)
W107-02-06-140
W107-02-06-141
W2-1-2-1
3. Shoe thickness (D)
D Unit: mm (in)
5.5 (0.22) 5.3 (0.21)
D
W107-02-06-142
4. Friction plate (11) thickness (E)

E
E Unit: mm (in)
2.0 (0.08) 1.8 (0.07) W107-02-06-143
W2-1-2-2
Travel Motor
1. Clearance between inner diameter (A) of rotor (14)
and outer diameter (B) of plunger (10):
A-B: 0.06 mm (0.002 in) or less

A B
W507-02-04-009
2. Clearance between plunger (10) and shoe engaging
(C):
C: 0.4 mm (0.016 in) or less
3. Clearance between inner diameter (D) and outer

diameter (E) at the mounting position (4) of housing
(1) and piston (4): W107-02-06-140
D-E: 0.03 mm (0.001 in) or less
4. Wear amount on the sliding surfaces of rotor (14)

and valve plate (15):
Check there is no abnormal scratch, wear or score.
D
Damage and wear amount within 0.02 mm (0.001
in) or less.
W162-03-02-005
W2-2-1-1
Sprocket
B
C
D
E
A
W105-03-07-042
Unit: mm (in)
Standard Allowable Limit Remedy
A 92 (3.6) [82 (3.2)]
B 131.6 (5.2) 126.6 (4.9)
C 167.6 (6.6) - Build up and finishing
D 177.5 (7.0) 172.5 (6.8)
E 215.9 (8.5) -
fNOTE: Value in [ ] is just for reference.
W2-2-1-2
Center Joint
Item Allowable Limit (basis of judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Seizure and abnormal wear Replace
3. Uneven wear within 180 ˚
Wear Area Within
Half Range
Bushing
Replace
T157-01-01-040
Sliding surface
Heavily damaged one by seizure or foreign matter Replace
with seals
Sliding surface 1 Excessively worn one by seizure or foreign matter, or one
between body Replace
having the score of 0.1 mm (0.004 in) or more
and spindle other
than sliding Repair the surface
surfaces with 2 One having the score of less than 0.1 mm (0.004 in) smooth by using
seals an oil stone
Body, Spindle
1 One that has worn 0.5 mm (0.02 in) or more, or excessively
Replace
worn
Repair the surface
Sliding surface 2 One that has worn 0.5 mm (0.02 in) or less
smooth
with ring
3 One that has scores due to seizure or foreign matter but
Repair the surface
the damage is less than the allowable wear limit 0.5 mm
smooth
(0.02 in) and is repairable
1 One that has worn 0.5 mm (0.02 in) or more Replace
Repair the surface
Sliding surface 2 One that has worn less than 0.5 mm (0.02 in)
Cover smooth
with ring
3 One that has scores due to seizure or foreign matter but
Repair the surface
the damage is less than the allowable wear limit 0.5 mm
smooth
(0.02 in) and is repairable
W2-2-2-1
(Blank)
W2-2-2-2
Front Idler
C
D
E
A
W166-03-05-001
B
Unit: mm (in)
A 102 (4.0) [82.3 (3.2)]
B 200 (7.9) -
Cladding by welding and
C 630 (24.8) [591.6 (23.3)]
finish or replace
D 675 (26.6) -
E 45 (1.8) -
Axle and Bushing

Axle Outside Dia. 110 (4.33) [109.2 (4.30)]
Inside Dia. 110 (4.33) [111 (4.37)] Replace
Bushing
Flange Thickness 6 (0.24) [5.2 (0.21)]
fNOTE: Values in [ ] are just for reference.
W2-2-3-1
(Blank)
W2-2-3-2
Upper Roller
Roller
W157-03-06-003
Unit: mm (in)
A 103 (4.1) -
B 210 (8.3) - Replace
C 170 (6.7) [160 (6.3)]
Axle and Bushing

Unit: mm (in)
Axle Outside Dia. 60 (2.4) [59.2 (2.3)]
Bushing
Flange Thickness 4.5 (0.2) [3.7 (0.1)]
fNOTE: The values in [ ] are just for reference.
W2-2-4-1
Lower Roller
Roller
W157-03-06-003
Unit: mm (in)
A 214 (8.4) [249 (9.8)]
B 284 (11.2) - Cladding by welding and
C 35 (1.4) [17.5 (0.7)] finish or replace
D 200 (7.9) [182 (7.2)]
Axle and Bushing

Unit: mm (in)
Axle Outside Dia. 85 (3.3) [84.2 (3.3)]
Bushing
Flange Thickness 6 (0.2) [5.2 (0.2)]
W2-2-4-2
Track
Link
Measure the length of four links.
1. Do not measure the part included the master pin.
2. Measure the length with tension on the track.
W155-03-07-001
Unit: mm (in)
A 863.6 (34) [905.3 (35.6)] Cladding by welding and
B 129 (5.1) [122 (4.8)] finish or replace
Master Pin
C B C
A W800-03-07-028
Unit: mm (in)
A 254 (10) -
B 47.3 (1.86) [44.3 (1.74)] Replace
C 47.57 (1.87) -
W2-2-5-1
Master Bushing
W105-03-07-023
Unit: mm (in)
A 160.8 (6.3) -
B 47.9 (1.89) [59.9 (2.36)] Replace
C 71.35 (2.81) [66.4 (2.61)]
Grouser Shoe
W105-03-07-024
Unit: mm (in)
A 247 (9.7) -
B 15 (0.6) - Replace
C 36 (1.4) 24 (0.9)
W2-2-5-2
Bushing
W105-03-07-023
Unit: mm (in)
A 169 (6.7) -
B 48.4 (1.91) [49.4 (1.95)] Replace
C 71.35 (2.81) [66.4 (2.61)]
Pin
A W142-03-07-004
Unit: mm (in)
A 254 (10) - Cladding by welding and
B 47.6 (1.87) [44.6 (1.76)] finish or replace
W2-2-5-3
(Blank)
W2-2-5-4
Remove and Install Bushing
D
C
W166-04-02-005
1 2 1 2 1 2 1 2 3
2
A: Bucket and Link A
W166-04-02-012
1 2 3
B: Link A C: Boom and Arm

W166-04-02-013 W166-04-02-014
1 2 3 2 1 2 3
D: Boom and Main Frame E: Arm and Link B F: Arm and Bucket
W166-04-02-010 W166-04-02-015 W166-04-02-016
1- Dust Seal 2- Bushing 3- Spacer
W2-3-1-1
Removal
1. Remove dust seal (1) and bushing (2).
fNOTE: If bushing (2) cannot be removed, burn off

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

A: Bucket side ............................................ ST 2881
Link A side ............................................. ST 2873
B: Link A ...................................................... ST 2873
C: Arm ......................................................... ST 2877
D: Boom side ............................................. ST 2877
Main frame side .................................. ST 2886
E: Arm .......................................................... ST 2882
F: Bucket side ............................................ ST 2881
Arm side .................................................. ST 2873
W2-3-1-2
Pin and Bushing
D F
C G
H
B I
E
A
K
J
W105-04-01-018
Unit: mm (in)
Position Item Standard Allowable Limit
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Frame Side) 110 (4.33) 111.5 (4.39)
A: Boom Cylinder and Main Frame Bushing Outer Dia. 130 (5.12) -
Bearing Inner Dia. (Cylinder Side) 110 (4.33) 111.5 (4.39)
Pin Outer Dia. 120 (4.72) 119 (4.69)
Bushing Inner Dia. (Frame Side) 120 (4.72) 121.5 (4.78)
B: Boom and Main Frame Bushing Outer Dia. 140 (5.51) -
Bushing Inner Dia. (Boom Side) 120 (4.72) 121.5 (4.78)
Bushing Outer Dia. 140 (5.51) -
Pin Outer Dia. 120 (4.72) 119 (4.69)
C: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 120 (4.72) -
W2-3-1-3
Unit: mm (in)
Position Item Standard Allowable Limit
Pin Outer Dia. 110 (4.33) 109 (4.29)
D: Boom and Arm Cylinder Pin Hole Inner Dia. (Boom Side) 110 (4.33) -
Pin Outer Dia. 120 (4.72) 119 (4.29)
Bushing Inner Dia. (Boom Side) 120 (4.72) 121.5 (4.78
E: Boom and Arm Bushing Outer Dia. 140 (5.51) -
Bushing Inner Dia. (Arm Side) 120 (4.72) 121.5 (4.78)
Pin Outer Dia. 110 (4.33) 109 (4.29)
F: Arm Cylinder and Arm Pin Hole Inner Dia. (Arm Side) 110 (4.33) -
Pin Outer Dia. 100 (3.94) 99 (3.90)
G: Arm and Bucket Cylinder Pin Hole Inner Dia. (Arm Side) 100 (3.94) -
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Link A Side) 110 (4.33) 111.5 (4.39)
H: Bucket Cylinder and Link Bushing Outer Dia. 130 (5.12) -
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Link A Side) 110 (4.33) 111.5 (4.39)
I: Link and Bucket Bushing Outer Dia. 130 (5.12) -
Bushing Inner Dia. (Bucket Side) 110 (4.33) 109 (4.29)
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Arm Side) 110 (4.33) 111.5 (4.39)
J: Arm and Bucket Bushing Outer Dia. 130 (5.12) -
Bushing Inner Dia. (Bucket Side) 110 (4.33) 111.5 (4.39)
Pin Outer Dia. 100 (3.94) 99 (3.90)
K: Arm and Link Bushing Inner Dia. (Arm Side) 100 (3.94) 101.5 (4.00)
IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a press.
W2-3-1-4
Side Cutter
B A
W166-04-01-011
Unit: mm (in)
A 305 (12.0) 200 (7.9)
Replace
B 40 (1.6) -
Point
B C
A
W1J1-04-01-002
Unit: mm (in)
A 254 (10.0) 127 (5.0)
B 140 (5.5) -
Replace
C 137 (5.4) -
D 129 (5.1) -
W2-3-1-5
Standard Dimensions for Arm and Bucket

Connection
IMPORTANT: If the front attachment of a previous
model machine is used, use the grease intervals
for previous model machine.
Section A Section B
WJAA-02-03-001
W2-3-1-6
Unit: mm (in)
Model ZX470-5B ZX450-3/500LC-3 ZX450 ZX400-5
a 520 (20.47)   
b 10 (0.39)   
c 750 (29.53)   
d 710 (27.95)   
e - - - -
f 1911 (75.24)  1896 (74.65) 
g -  643 (25.32) 
470.5 to 471.0
h   
(18.52 to 18.54)
i 130 (5.12)   
j 558 (21.97)   
k 106 (4.17)   
l 648 (25.51)  643 (25.32) 
m 471 (18.54)   
n 130 (5.12)   
o 45 °   
p 45 °   
q 680 (26.77)   
fNOTE: Dimension h: 470.5 to 471.0 mm (18.52 to 18.54

in) includes the clearance for shims to adjust bucket
clearance.
Dimensions o and p: 45 ° means the angle for the bolt
hole.
W2-3-1-7
Standard Dimensions for Arm and Boom

Connection
IMPORTANT: If the front attachment of a previous
model machine is used, use the grease intervals
for previous model machine.
Section C
WJAA-02-03-002
Unit: mm (in)
Model ZX470-5B ZX450-3/500LC-3 ZX450 EX400-5
s 140 (5.51)   
t 471 (18.54)   
u 632 (24.88)   
W2-3-1-8
Cylinder
Rod Rod Bend and Run Out
a b
A
1m
W105-04-02-094 c W166-04-02-022
a- Cylinder Rod c- V Block

b- Dial Gauge
Unit: mm (in) Unit: mm (in)
Recommended Size After Bend Run Out Remedy
Cylinder Name
Re-manufacturing (A) 0.5 (0.02) 1.0 (0.04) Repair
Boom 115-0.012-0.027 (4.5-0.0005-0.0011) 1.0 (0.04) 2.0 (0.08) Replace
Arm 130+0.031-0.061 (5.1+0.0012-0.0024)
Bucket 120+0.027-0.057 (4.7+0.0011-0.0022)
W2-3-2-1
(Blank)
W2-3-2-2
MEMO
MEMO
SECTION 3
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Group 11 Pilot Valve
Removal and Installation of Cab...............................W3-1-1-1 Removal and Installation of Pilot Valve
Dimensions of Cab Glass (Standard Cab)...............W3-1-2-1 (Left)............................................................................ W3-11-1-1
Dimensions of Cab Glass (H Cab)........................... W3-1-2-20 Removal and Installation of Pilot Valve
(Right)......................................................................... W3-11-2-1
Group 2 Counterweight Removal and Installation of Travel Pilot
Removal and Installation of Counterweight.........W3-2-1-1 Valve............................................................................ W3-11-3-1
Group 3 Main Frame Disassembly of Pilot Valves (Right and Left)...... W3-11-4-1
Removal and Installation of Main Frame................W3-3-1-1 Assembly of Pilot Valves (Right and Left)............ W3-11-4-4
Disassembly of Travel Pilot Valve............................ W3-11-5-1
Group 4 Engine Assembly of Travel Pilot Valve................................. W3-11-5-5
Removal and Installation of Engine.........................W3-4-1-1
Group 5 Radiator Assembly Removal and Installation of Pilot Shut-Off
Replacement of Radiator and Oil Cooler................W3-5-1-1 Solenoid Valve......................................................... W3-12-1-1
Group 6 Hydraulic Oil Tank Removal and Installation of 4-Spool
Removal and Installation of Hydraulic Oil Solenoid Valve Unit .............................................. W3-12-2-1
Tank................................................................................W3-6-1-1 Removal and Installation of 2-Spool
Solenoid Valve Unit................................................ W3-12-3-1
Group 7 Fuel Tank Disassembly of Pilot Shut-Off Solenoid
Removal and Installation of Fuel Tank.....................W3-7-1-1 Valve............................................................................ W3-12-4-1
Assembly of Pilot Shut-Off Solenoid Valve......... W3-12-4-3
Group 8 Pump Device Structure of 4-Spool Solenoid Valve Unit............ W3-12-5-1
Removal and Installation of Pump Device.............W3-8-1-1
Structure of 2-Spool Solenoid Valve Unit............ W3-12-6-1
Disassembly of Main Pump.........................................W3-8-2-1
Assembly of Main Pump...............................................W3-8-2-8 Group 13 Signal Control Valve
Disassembly of Regulator for Main Pump..............W3-8-3-1 Removal and Installation of Signal Control
Assembly of Regulator for Main Pump...................W3-8-3-3 Valve............................................................................ W3-13-1-1
Structure of Pilot Pump................................................W3-8-4-1 Structure of Signal Control Valve........................... W3-13-2-1
Structure of A Sensor.....................................................W3-8-5-1
Group 9 Control Valve Removal and Installation of Shockless Valve..... W3-14-1-1
Removal and Installation of Control Valve.............W3-9-1-1 Structure of Shockless Valve.................................... W3-14-2-1
Disassembly and Assembly of Valve Unit...............W3-9-2-1
Disassembly of Control Valve (4-Spool Side)........W3-9-3-1
Assembly of Control Valve (4-Spool Side)..............W3-9-3-9
Disassembly of Control Valve (5-Spool Side)........W3-9-4-1
Assembly of Control Valve (5-Spool Side)..............W3-9-4-8
Removal and Installation of Swing Device......... W3-10-1-1
Disassembly of Swing Device.................................. W3-10-2-1
Assembly of Swing Device....................................... W3-10-2-7
Disassembly of Swing Motor................................... W3-10-3-1
Assembly of Swing Motor......................................... W3-10-3-4
JACW-3-1
(Blank)
JACW-3-2
Group 1 Cab
Removal and Installation of Cab
6 3 2
5 4 1 WDAA-03-01-023 WJAA-03-01-013
IMPORTANT: Cap the open ends in case the hoses

and pipes have been disconnected. In addition, d CAUTION: Seat (2) weight: 46 kg (105 lb)
attach an identification tag onto the connectors, 3. Remove socket bolts (3) (4 used). Remove seat (2).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which l : 6 mm
secure the hoses have been removed. 4. Remove floor mat (4).
5. Remove bolts, washers (5) (4 used). Remove travel
Removal control levers (6) (2 used).
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.) j : 17 mm
2. Open door (1).
W3-1-1-1
Group 1 Cab
9
B
WDAA-03-01-048
Detail A 7
14 12 WDAA-03-01-050
11 10 11
Detail B
8 7 WDAA-03-01-049
13 WDAA-03-01-051
6. Remove bolts, washers (7) (3 used). Remove bracket

(8).
j : 19 mm
7. Remove cover (9).
8. Disconnect plug (10) and connectors (11) (2 used).
9. Remove bolt, washer (12) and screw (13). Remove
cover (14).
j : 13 mm
W3-1-1-2
Group 1 Cab
15 29 26, 28 68 69 33 31
A B
25
20, 21
20, 21 22, 23, 24

WDAA-03-01-052
WDAA-03-01-053
32 30
18
71 70
Detail A Detail B
WDAA-03-01-062 WDAA-03-01-065
19 16, 17, 18
10. Open cover (15). 14. Remove caps (26) (2 used). Remove screws (28) (2
used). Remove cover (29) and duct (33).
11. Remove caps (16) (2 used). Remove seals (17) (2
used) and screws (18) (3 used). Remove cover (19). 15. Remove bolts, washers (30) (2 used).
12. Remove bolts, washers (20) (2 used) and washers j : 17 mm
(21) (2 used).
16. Remove bolt, washer (31). Remove cover (32).
j : 13 mm
j : 13 mm
13. Remove caps (22) (3 used). Remove seals (23) (3
used) and screws (24) (3 used). Remove cover (25). 17. Remove screws (68) (2 used). Remove duct (69).
18. Remove bolt, washer (70). Remove duct (71).
j : 13 mm
W3-1-1-3
Group 1 Cab
A B
WDAA-03-01-063 WDAA-03-01-064
34
Detail A Detail B
34 35 34 WDAA-03-01-054 37 36 37 WDAA-03-01-055
19. Remove clip (35).

20. Disconnect connectors (34) (7 used).
21. Remove clip (36).
W3-1-1-4
Group 1 Cab
1 41 A
43
44
WJAA-03-01-015
42
Detail A 46 45
38 40 39
WDAA-03-01-056
48 47
TDAA-05-08-006
23. Shut door (1). 29. Remove bolt (45). Disconnect connector (46).
24. Open cover (38). j : 13 mm
25. Remove filter (39). 30. Push the lock and shift lever (47). Disconnect
26. Remove screws (40) (6 used). Remove filter case (41). connector (48).
27. Open cover (42). 31. Open door (1).
28. Remove bolts, washers (43) (4 used). Remove cover

(44).
j : 17 mm
W3-1-1-5
Group 1 Cab
49
WJAA-03-01-016
73 72
WJAA-03-01-014
a - Lifting Bracket
d CAUTION: The cab (49) assembly weight:

Standard machine: 450 kg (995 lb)
H spec. machine: 550 kg (1220 lb)
32. Attach nylon slings onto lifting bracket (a) (4 places)
of cab (49). Hoist and hold the cab (49) assembly.
dDo
CAUTION: Remove cover (72) while holding it.
not drop cover (72).
(72).
j : 19 mm
W3-1-1-6
Group 1 Cab
55, 56 54 55, 56 52, 53
74, 75, 76
WJAA-03-01-017
54 52, 53 54 55, 56 50, 51 55, 56

WJAA-03-01-018
34. Remove bolt (74), washer (75), and spacer (76). 37. Remove bolts, washers (54) (5 used).
j : 32 mm j : 17 mm
35. Remove socket bolts (50) (2 used) and washers (51) 38. Remove nuts (55) (4 used) and washers (56) (4 used).
(2 used). Remove the cab (49) assembly.
l : 8 mm j : 24 mm
36. Remove socket bolts (52) (5 used) and washers (53)
(5 used).
l : 8 mm
W3-1-1-7
Group 1 Cab
57 60 61 62 63 Detail A 66
66
64
59 62
WDAA-03-01-061
58 65
64
57 60 77 62 WDAA-03-01-060
67
WDAA-03-01-067
39. Disconnect connectors (57) (5 used). 44. Remove bolts, washers (64) (4 used). Remove MC
(65).
40. Remove screws (58) (4 used). Remove monitor
controller (59). j : 13 mm
41. Remove bolt, washer (77).
d(64
CAUTION:
lb)
Bracket assembly (67) weight: 29 kg
j : 17 mm
45. Remove bolts, washers (66) (6 used). Remove
42. Remove screws (60) (4 used). Disconnect connector
bracket assembly (67).
(61).
43. Remove screws (62) (5 used). Remove cover (63). j : 17 mm
W3-1-1-8
Group 1 Cab
57 60 61 62 63 Detail A 66
66
64
59
62
WDAA-03-01-061
58 65
64
57 60 77, 78 62 WDAA-03-01-060
67
WDAA-03-01-067
Installation 4. Connect connector (61) with screws (60) (4 used).
d(64
CAUTION:
lb)
Bracket assembly (67) weight: 29 kg 5. Install clamp (78) with bolt, washer (77).
j : 17 mm
1. Install bracket assembly (67) with bolts, washers (66)
(6 used). m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm 6. Install monitor controller (59) with screws (58) (4

used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
7. Connect connectors (57) (5 used).
2. Install MC (65) with bolts, washers (64) (4 used).
j : 13 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Install cover (63) with screws (62) (5 used).
W3-1-1-9
Group 1 Cab
a 55, 56 54 55, 56 52, 53
49
WJAA-03-01-014
54 52, 53 54 55, 56 50, 51 55, 56
a - Lifting Bracket WJAA-03-01-018
11. Install washers (53) (5 used) and socket bolts (52) (5

d CAUTION: The cab (49) assembly weight: used).
Standard machine: 450 kg (995 lb) j : 8 mm
H spec. machine: 550 kg (1220 lb) m : 50 N·m (5 kgf·m, 37 lbf·ft)
8. Attach nylon slings onto lifting bracket (a) (4 places)
of cab (49). Hoist the cab (49) assembly. 12. Install washers (51) (2 used) and socket bolts (50) (2
used).
9. Install the cab (49) assembly with washers (56) (4
used) and nuts (55) (4 used). j : 8 mm
j : 24 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 210 N·m (21 kgf·m, 155 lbf·ft)
10. Install bolts, washers (54) (5 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-10
Group 1 Cab
74, 75, 76
WJAA-03-01-017 WJAA-03-01-016
73 72
13. Install spacer (76), washer (75), and bolt (74).
j : 32 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft)

14. Install cover (72) with bolts, washers (73) (6 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-1-1-11
Group 1 Cab
1 41
A
43
44
WJAA-03-01-015
42
Detail A 46 45
38 40 39
WDAA-03-01-056
48 47
TDAA-05-08-006
15. Open cover (42). 19. Open cover (38).

16. Connect connector (48). Shift lever (47) and lock it. 20. Install filter case (41) with screws (40) (6 used).
IMPORTANT: Do not use an impact wrench when 21. Install filter (39).
tightening bolt (45). Using an impact wrench may
22. Shut cover (38).
result in damage to the cover.
17. Connect connector (46) with bolt (45). 23. Open door (1).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-12
Group 1 Cab
A B
WDAA-03-01-063 WDAA-03-01-064
34
Detail A Detail B
34 35 34 WDAA-03-01-054 37 36 37 WDAA-03-01-055

25. Install clip (36).
27. Install clip (35).
W3-1-1-13
Group 1 Cab
15 29 26, 28 68 69 33 31
A B
25
20, 21
20, 21 22, 23, 24

WDAA-03-01-052
WDAA-03-01-053
32 30
18
71 70
Detail A Detail B
WDAA-03-01-062 WDAA-03-01-065
19 16, 17, 18
28. Install duct (71) with bolt, washer (70). 33. Install cover (25) with screws (24) (3 used). Install
seals (23) (3 used) and caps (22) (3 used).
j : 13 mm
34. Install washers (21) (2 used) and bolts, washers (20)
m : 20 N·m (2 kgf·m, 15 lbf·ft) (2 used).
29. Install duct (69) with screws (68) (2 used). j : 13 mm
30. Install cover (32) with bolt, washer (31).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
j : 13 mm 35. Open cover (15).
m : 20 N·m (2 kgf·m, 15 lbf·ft) 36. Install cover (19) with screws (18) (3 used). Install
seals (17) (2 used) and caps (16) (2 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

32. Install duct (33) and cover (29) with screws (28) (3
used). Install caps (26) (2 used).
W3-1-1-14
Group 1 Cab
9
B
WDAA-03-01-048
Detail A 7
14 12 WDAA-03-01-050
11 10 11
Detail B
8 7 WDAA-03-01-049
13 WDAA-03-01-051
37. Install cover (14) with screw (13) and bolt, washer
(12).
j : 13 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

38. Connect connectors (11) (2 used) and plug (10).
39. Install cover (9).
40. Install bracket (8) with bolts, washers (7) (3 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-1-1-15
Group 1 Cab
6 3 2
5 4 1 WDAA-03-01-023 WJAA-03-01-013
41. Install travel control levers (6) (2 used) with bolts,

washers (5) (4 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

42. Install floor mat (4).
d CAUTION: Seat (2) weight: 46 kg (105 lb)

43. Install seat (2) with socket bolts (3) (4 used).
j : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-1-1-16
Group 1 Cab
Dimensions of Cab Glass (Standard Cab)
Unit: mm Section A
WDAA-03-01-036
WDAA-03-01-030
a - Black Ceramic Painted b - Black Ceramic Painted Range WDAA-03-01-001

Surface
Section B Detail C
a - Black Ceramic Painted

WDAA-03-01-002
Surface WDAA-03-01-035
W3-1-2-1
Group 1 Cab
Unit: mm
WDAA-03-01-030
a - Black Ceramic Painted WDAA-03-01-034

Surface
Section A

Surface
W3-1-2-2
Group 1 Cab
Unit: mm
Section A
WDAA-03-01-004
WDAA-03-01-031
a - Chamfer along the Periphery WDAA-03-01-003
W3-1-2-3
Group 1 Cab
Unit: mm
Section A
WDAA-03-01-006
WDAA-03-01-031
a - Chamfer along the Periphery WDAA-03-01-005
W3-1-2-4
Group 1 Cab
Unit: mm Section A
WDAA-03-01-038
WDAA-03-01-031 a - Black Ceramic Painted d - Shaded Paint along the
Surface Periphery Here
a - Black Ceramic Painted c - Chamfer here. WDAA-03-01-007

Surface
b - Black Ceramic Painted Range
Section B Section C
WDAA-03-01-008 WDAA-03-01-009
W3-1-2-5
Group 1 Cab
Unit: mm
WDAA-03-01-031
a - Black Ceramic Painted b - Black Ceramic Painted Range WDAA-03-01-010

Surface
Section A Detail B
WDAA-03-01-038 WDAA-03-01-011
a - Black Ceramic Painted d - Shaded Paint along the

Surface Periphery Here
W3-1-2-6
Group 1 Cab
Unit: mm
WDAA-03-01-031

Surface
b - Black Ceramic Painted Range
c - Chamfer here.
Section A Section B
a - Black Ceramic Painted WDAA-03-01-038 WDAA-03-01-008

Surface
d - Dotted edge along the
Periphery Here
W3-1-2-7
Group 1 Cab
Unit: mm Section A

WDAA-03-01-030 Surface
d - Shaded Paint along the
Periphery Here
WDAA-03-01-013
a - Black Ceramic Painted b - Black Ceramic Painted Range
Surface
W3-1-2-8
Group 1 Cab
Procedure to Remove Cab Glass
Procedures to Remove Right-Hand Glass (1), Rear Left- 1

Hand Glass (2), Lower Door Glass (3), and Rear Glass (4)
dCAUTION: When removing the broken or cracked

glass, the glass shards may cause serious injury.
Before removing, use the duct tape or equivalent
in order to paste the broken or cracked glass and
reinforce them. Remove the glass pieces away.
WDAA-03-01-030
1. Remove resin panel (5), garnish (6), and the spacer
around the glass.
6
2
6
2. Prick a hole in adhesive (b) by using awl (a) (or a
knife). 3
5 WDAA-03-01-031
7
8
a
3. Pass piano wire (c) (or a metal wire) through the b

hole. W1SE-02-01-033
7 - Cab a - Awl
8 - Glass b - Adhesive
c - Piano Wire W1SE-02-01-034
W3-1-2-9
Group 1 Cab
IMPORTANT: The piano wire is easily broken if a part

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

and cab. b
c
a - Cab Outside W1SE-02-01-035

b - Adhesive
c - Cab Inside
W3-1-2-10
Group 1 Cab
Procedure to Install Cab Glass
Procedures to Install Right-Hand Glass (1), Rear Left-Hand 1

Glass (2), Lower Door Glass (3), and Rear Glass (4)
1. Cut off the residual adhesive from the cab (7) side
by 1 to 2 mm deep all around by using a knife or
similar.
fNOTE: Do not damage the cab (7) paint.

WDAA-03-01-030
3
2 WDAA-03-01-031
2. Clean the cutting edge of adhesive at cab (7) side by
using white spirit. 7
W1SE-02-01-036
IMPORTANT: Primer should be shaken for about 1
minute and mix thoroughly before opening the a - Knife b - Cut off adhesive by 1 to 2 mm
cap. After opening Primer, apply Primer as quickly deep.
as possible and close the cap immediately after
using. After opening Primer, all the contents
should be used within 180 days (or 2 hours with
the cap off). 7
3. Apply Primer for paint (Sika Aktivator DM-1) to the c
cutting edge of adhesive at cab (7) side by using a
brush. Wait for about 15 minutes in order to let it d
dry by itself.
W1SE-02-01-038
c - Apply Primer by using a d - Cutting edge of adhesive at

brush. cab (7) side
W3-1-2-11
Group 1 Cab
4. Clean the mating edge of the new glass by using

clean rag and ethyl alcohol.
IMPORTANT: Primer (Sika Primer 206G+P) should

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

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

solid: 8 hours (just for reference)
W3-1-2-12
Group 1 Cab
Unit: mm
Rear Glass Right-Hand Glass
WDAA-03-01-039
Rear Left-Hand Glass

WDAA-03-01-040
Lower Door Glass
WDAA-03-01-041 WDAA-03-01-042
Spacer A Spacer B Spacer C
WDAA-03-01-043 WDAA-03-01-044 WDAA-03-01-045

a - Two-Side Adhesive Tape a - Two-Side Adhesive Tape
Dam Rubber
WDAA-03-01-046
W3-1-2-13
Group 1 Cab
Unit: mm
Left-Hand Glass
1 - Spacer A a - From Radius Curve End

WDAA-03-01-014
2 - Dam Rubber b - Glass External Form Line
3 - Stopper c - Adhesive Range
Section A Section B Section C
WDAA-03-01-017 WDAA-03-01-018 WDAA-03-01-019

d - Clearance between glass and panel: 6 mm e - Glass e - Glass
e - Glass
Section D Detail E
WDAA-03-01-020 WDAA-03-01-024
e - Glass f - Apply Super X.
W3-1-2-14
Group 1 Cab
Unit: mm
Right-Hand Glass
1 - Spacer A a - From Radius Curve End WDAA-03-01-016

2 - Spacer C b - Glass External Form Line
3 - Dam Rubber c - Adhesive Range
Section A Section B Section C
WDAA-03-01-022 WDAA-03-01-027 WDAA-03-01-028

e - Glass d - Glass and panel: Clearance OR-02: 8 mm a - From Radius Curve End
e - Glass e - Glass
W3-1-2-15
Group 1 Cab
Unit: mm
Rear Glass
Section A
WDAA-03-01-021
a - From Radius Curve End

e - Glass
WDAA-03-01-015
1 - Spacer B b - Glass External Form Line

a - From Radius Curve End c - Adhesive Range
Section B Section C
WDAA-03-01-025 WDAA-03-01-026
d - Glass and panel: Clearance e - Glass

OR-02: 8 mm
e - Glass
W3-1-2-16
Group 1 Cab
8 to 9 mm
a
13 to 15 mm
b
W1SE-02-01-027
12
W1SE-02-01-043
b - Cut nozzle end into V-shaped. f
W1JB-02-01-031
a - Apply adhesive (bead) here. e - Apply bead so that bead triangle may be
even.
f - Panel
W1SE-02-01-028
c - Remove the seal.

d - Adhesive Cartridge
13. The required amount (just for reference) of adhesive and primer
Painted Surface or Glass Surface

Adhesive Surface
Adhesive Primer Primer
Sika Tack Go! Sika Aktivator DM-1 Sika Primer 206G+P
310 ml Cartridge 250 ml Can 30 ml Bottle

Lower Door Glass 170 ml 0.6 ml 0.5 ml
Rear Left-Hand Glass 220 ml 0.55 ml 0.5 ml
Rear Right-Hand Glass 105 ml 1 ml 0.9 ml
Rear Glass 205 ml 0.5 ml 0.45 ml
W3-1-2-17
Group 1 Cab
Procedures to Install Upper Door Glass

1. Before installing the glass, remove garnish (2) 1
around sash assembly (1) from the cab inside for
easy removal. Push sash assembly (1) by hands and
remove the sash outside.
2
2. Install glass A (3) and glass B (4) into the sash

grooves.
3 4
WDAA-03-01-031
3. Install sash assembly (1) onto the door from the
outside of cab. Secure sash assembly (1) at the
inside of cab by using garnish (2).
W3-1-2-18
Group 1 Cab
Procedures to Install Upper Front Glass
1. Stick the seal to the lower side of the front upper

glass by using Cemedine Super X.
Stick and secure both right and left ends (the thicker
part) of the seal to the glass by using adhesive.
Stick the mating surface of seal (1) and the glass
by using Cemedine Super X so that no visible
undulation or boss can be found.
fNOTE: Cemedine Super X No. 8008

Glue-state adhesive, tubed
Cemedine 366 Deluxe
IMPORTANT: The front glass is arched-fringed. When
replacing the glass, contact with the nearest
HITACHI Office and replace it as an assembly.
WDAA-03-01-029
Detail A (Inside) Detail A (Outside)
WDAA-03-01-032 WDAA-03-01-033
a - Cemedine Super X No. 8008 a - Cemedine Super X No. 8008

b - Cemedine 366 Deluxe b - Cemedine 366 Deluxe
c - Fill seal for the inside of installation point here. e - No gap between drainage and wedge
d - Do not apply seal to this groove.
W3-1-2-19
Group 1 Cab
Dimensions of Cab Glass (H Cab)
fNOTE: The glasses are same to those of the standard

cab except for the front glass.
Unit: mm
WJAA-03-01-001
WJAA-03-01-002
W3-1-2-20
Group 1 Cab
Procedures to Install Front Glass (H Cab)

Upper Front Glass Lower Front Glass
4
a a
b
b
WJAA-03-01-005
2
3
WJAA-03-01-004
1. Install Z rubber (2) around glass (1). WJAA-03-01-007

2. Install only A part (4) of wedge (3) into the groove 1- Glass 3- Wedge
on Z rubber (2). 2- Z Rubber 4- A Part
a - Connecting Position b - Drainage Hole Position
W3-1-2-21
Group 1 Cab
2
5
WJAA-03-01-006
c
1
WJAA-03-01-012
2
1
2
5 5
6
WJAA-03-01-009 WJAA-03-01-010
1
3. Install cord (5) around the inside of Z rubber (2). 2
Apply soapy water onto the cord (5) part.
3
4. Install Z rubber (2) to cab (6) from the lower side of
glass (1) while pulling cord (5).
6
IMPORTANT: Use a tool, which the edge of
screwdriver is rounded, in order not to damage Z
rubber (2). WJAA-03-01-011
5. Install wedge (3) into the groove on Z rubber (2).
1 - Glass 5 - Cord
2 - Z Rubber 6 - Cab
3 - Wedge
a - Connecting Position c - Get cord (5) long enough to
b - Drainage Hole Position remove.
W3-1-2-22
Removal and Installation of Counterweight
3 1
Detail A
4 2
5
WJAA-03-02-002
WJAA-03-02-001
Removal
maintenance. (Refer to W1-6-1.)
dCAUTION: Remove cover (2) while holding it. Do

not drop cover (2).
(2).
j : 19 mm
dCAUTION: Remove cover (4) while holding it.Do

not drop cover (4).
(4).
j : 19 mm
4. Disconnect connector (5).
W3-2-1-1
13
14
15
16
17 10
13 9
14 11
15 12
16
17 6
10
9 11
11
7
a 9
8
15
8 13,14
7
16,17
a - Bracket W1J1-02-02-003
12
WJAA-03-02-003
dCAUTION:
(20100 lb)
Counterweight (6) weight: 9100 kg
5. Attach a wire rope onto lifting bracket (a) (2 places)

of counterweight (6). Hoist and hold counterweight
(6).
6. Remove bolts (7) (2 used), washers (8) (2 used), nuts
(9) (2 used), shim (10), and washers (11) (2 used).
j : 65 mm
fNOTE: Shim (10) is installed to the clearance between

nut (9) and main frame (12).
7. Remove bolts (13) (4 used), lock washers (14)
(2 used), plates (15) (2 used), and shims (16, 17)
(several). Remove counterweight (6).
j : 36 mm
W3-2-1-2
13
14
15
16
17 10
13 9
14 11
15 12
16
17 6
10
9 11
11
a 9
15
8 13,14
7
16,17
a - Bracket W1J1-02-02-003
12
WJAA-03-02-003
Installation
dCAUTION:
(20100 lb)
Counterweight (6) weight: 9100 kg
1. Attach a wire rope onto lifting bracket (a) (2 places)

of counterweight (6). Hoist counterweight (6).
2. Install counterweight (6) with bolts (7) (2 used),
washers (8) (2 used), washers (11) (2 used), nuts (9)
(2 used), and shim (10).
j : 65 mm
m : 2350 N·m (235 kgf·m, 1730 lbf·ft)

3. Install shims (16, 17) (several), plates (15) (2 used),
lock washers (14) (2 used), and bolts (13) (4 used).
j : 36 mm
m : 440 N·m (44 kgf·m, 320 lbf·ft)
fNOTE: Adjust shims (16, 17) so that there is no

clearance between main frame (12) and plate (15).
W3-2-1-3
3 1
Detail A
4 2
5
WJAA-03-02-002
WJAA-03-02-001
4. Connect connector (5).

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-2-1-4
Group 3 Main Frame
Removal and Installation of Main Frame
3 1
WJAC-03-03-001

and pipes have been disconnected. In addition,
attach an identification tag onto the connectors,
hoses and install the clips in case the clips which
secure the hoses have been removed.
Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)
dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove cab (1). (Refer to W3-1-1.)
3. Remove counterweight (2). (Refer to W3-2-1.)
4. Remove front attachment (3). (Refer to W5-1-1.)
5. Remove boom cylinder (4). (Refer to W5-2-1.)
W3-3-1-1
Group 3 Main Frame
11
9, 10
8 6 7 5 WJAA-03-03-002
6. Place a container under center joint (5). Disconnect

hoses (6) (4 used).
j : 41 mm
7. Disconnect hose (7).
j : 27 mm
j : 17 mm
9. Remove bolts (9) (2 used) and washers (10) (4 used).
Remove stopper (11).
j : 22 mm
W3-3-1-2
Group 3 Main Frame
12
WJAC-03-03-002
a - Special Tool (ST0248) b - Boom Mounting Bracket Hole

Mounting Part
dCAUTION:
(21900 lb)
Main frame (12) weight: 9900 kg
10. Install the special tools (ST0248) to counterweight

mounting parts (a) (2 places) of the main frame (12)
rear side.
11. Attach wire ropes onto the special tools (ST0248)
and boom mounting bracket holes (b) (2 places).
W3-3-1-3
Group 3 Main Frame
12 15 14
13 15 WJAA-03-03-005
WJAA-03-03-004
e - Front Attachment Side
12. Reduce slack of the wire rope by using a chain

block. Put the matching marks onto main frame (12)
and outer race (13) of the swing bearing.
13. Remove bolts (14) (29 used).
j : 46 mm
fNOTE: LOCTITE #262 has been applied onto bolts (15) (7

used).
j : 46 mm
15. Adjust the chain block in order to level main frame
(12). Hoist and remove main frame (12).
W3-3-1-4
Group 3 Main Frame
12
WJAC-03-03-002
a - Special Tool (ST0248) b - Boom Mounting Bracket Hole

Mounting Part
Installation
dCAUTION:
(21900 lb)
Main frame (12) weight: 9900 kg
1. Install the special tools (ST0248) to counterweight

mounting parts (a) (2 places) of the main frame (12)
rear side.
2. Attach wire ropes onto the special tools (ST0248)
and boom mounting bracket holes (b) (2 places).
3. Adjust the chain block in order to level main frame
(12).
W3-3-1-5
Group 3 Main Frame
12 15 14
13 WJAA-03-03-004 15 WJAA-03-03-005
e - Front Attachment Side
4. Fit the matching marks made when disassembling

and install main frame (12) to outer race (13) of the
swing bearing. Install bolts (14) (29 used).
j : 46 mm
m : 1950 N·m (195 kgf·m, 1440 lbf·ft)

5. Apply LOCTITE #262 onto bolts (15) (7 used). Install
bolts (15) (7 used).
j : 46 mm
m : 1950 N·m (195 kgf·m, 1440 lbf·ft)
W3-3-1-6
Group 3 Main Frame
11
9, 10
8 6 7 WJAA-03-03-002
6. Install stopper (11) with washers (10) (4 used) and

bolts (9) (2 used).
j : 22 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)

7. Connect hose (8).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

j : 27 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)

9. Connect hoses (6) (4 used).
j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)
W3-3-1-7
Group 3 Main Frame
3 1
WJAC-03-03-001
10. Install boom cylinder (4). (Refer to W5-2-1.)

11. Install front attachment (3). (Refer to W5-1-1.)
12. Install counterweight (2). (Refer to W3-2-1.)
13. Install cab (1). (Refer to W3-1-1.)
14. Bleed air from the hydraulic system. (Refer to W1-
4-1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
W3-3-1-8
Group 4 Engine
Removal and Installation of Engine
1 4
2, 3
WJAA-03-04-001 WJAA-03-04-002

Removal
maintenance. Close the fuel cock. (Refer to W1-6-1.)
2. Open cover (1).
3. Remove wing nuts (2) (4 used) and washers (3) (4
used). Remove cover (4).
W3-4-1-1
Group 4 Engine
WJAA-03-04-003 WJAC-03-08-001
7, 8
4. Disconnect ground (5).

(Refer to W1-4-1.)
(7) and O-ring (8).
j : 17 mm
6. Drain off hydraulic oil by using an oil feed pump.
fNOTE: Oil amount: 310 L (81.9 US gal)
W3-4-1-2
Group 4 Engine
9 10
11 12 WJAC-03-08-002 13 14 WJAC-03-08-006
dCAUTION: Handrail (10) weight: 21 kg (47 lb) dCAUTION:

(51 lb)
The cover (14) assembly weight: 23 kg
7. Attach nylon slings onto handrail (10). Hoist and
hold handrail (10). 10. Remove bolts, washers (13) (19 used). Remove the
cover (14) assembly.
Handrail (10). j : 19 mm
j : 19 mm
dCAUTION: Step (12) weight: 26 kg (58 lb)

9. Remove bolts, washers (11) (6 used). Remove step
(12).
j : 19 mm
W3-4-1-3
Group 4 Engine
15
18
WJAC-03-04-001 20 16, 17 19 WJAC-03-04-002
11. Open engine cover (15).
dCAUTION: The engine cover (15) assembly

weight: 24 kg (53 lb)
12. Attach nylon slings onto engine cover (15). Hoist
and hold engine cover (15).
13. Remove pin (16) and washers (17) (2 used). Remove
the support (19) side of stopper (18).
14. Remove bolts, washers (20) (6 used) from the inside
of engine cover (15). Remove the engine cover (15)
assembly.
j : 17 mm
W3-4-1-4
Group 4 Engine
21
24
WJAC-03-04-001 26 25 22, 23
WJAC-03-04-003
15. Open engine cover (21).
dCAUTION: The engine cover (21) assembly

17. Remove pin (22) and washers (23) (2 used). Remove
the support (25) side of stopper (24).
18. Remove bolts, washers (26) (6 used) from the inside
of engine cover (21). Remove the engine cover (21)
assembly.
j : 17 mm
W3-4-1-5
Group 4 Engine
28 27 29
210
209
30
34
35
WJAC-03-04-004
31, 32, 33 34 WJAC-03-04-005
dCAUTION:
(49 lb)
19. Remove bolts, washers (28) (21 used). Remove the

j : 19 mm
(210).
j : 17 mm
j : 17 mm
22. Remove bolts, washers (31) (2 used), rubbers (32) (2
used), and spacers (33) (2 used).
j : 19 mm
j : 19 mm
W3-4-1-6
Group 4 Engine
41 37 42 38, 39, 40 37
37 36 37
WJAC-03-04-006
dCAUTION:
kg (84 lb)
The support (36) assembly weight: 38
24. Attach nylon slings onto the support (36) assembly.

Hoist and hold the support (36) assembly.
support (36) assembly.
j : 19 mm
j : 19 mm
j : 19 mm
W3-4-1-7
Group 4 Engine
46 43 45 44 48 47 WJAC-03-04-009
WJAC-03-04-008
28. Remove clamps (43, 44). Remove duct (45).

29. Remove clamp (46).
j : 7 mm
30. Remove bolts (47) (2 used). Remove duct (48).
j : 14 mm
W3-4-1-8
Group 4 Engine
49 50 58, 59 53 54
58, 59
55
56
51 52 58, 59 57 WJAC-03-04-010
dCAUTION: Cover (49) weight: 27 kg (60 lb) dCAUTION: Remove cover (55) while holding it.
Do not drop cover (55).
dCAUTION: Remove cover (49) while holding it.
Do not drop cover (49). 34. Remove bolts, washers (56) (5 used). Remove cover
(55).
(49). j : 19 mm
j : 19 mm
dCAUTION:
(51 lb)
dCAUTION: Cover (51) weight: 24 kg (53 lb)

dCAUTION: Remove cover (51) while holding it. dCAUTION: Remove the cover (57) assembly while
holding it. Do not drop the cover (57) assembly.
35. Remove bolts, washers (58) (6 used) and washers
(59) (6 used). Remove the cover (57) assembly.
(51).
j : 19 mm
j : 19 mm
dCAUTION: Remove cover (53) while holding it.

(53).
j : 19 mm
W3-4-1-9
Group 4 Engine
222 170, 171 213 172
WJAC-03-04-034
221 173, 174 WJAC-03-04-025
36. Remove bolt, washer (170) and clip (171).
j : 17 mm
37. Remove clamp (172). Disconnect hose (213).
38. Place a container under coolant outlets (173, 221).
Loosen cocks (174, 222). Drain off coolant.
fNOTE: Coolant amount: 61 L (16.1 US gal)
W3-4-1-10
Group 4 Engine
60, 61 WJAC-03-04-011
66, 67 65 64 62, 63, 211 WJAC-03-04-012
39. Remove clamp (60). Disconnect tube (61). 40. Remove nuts (62) (6 used) and washers (63) (6 used).
j : 14 mm
dCAUTION:
kg (95 lb)
The muffler (64) assembly weight: 43
41. Attach nylon slings onto the body of the muffler

(64) assembly. Hoist and hold the muffler (64)
assembly.
42. Remove U-bolts (65) (2 used), nuts (66) (8 used), and
j : 19 mm
43. Remove the muffler (64) assembly.
44. Remove gasket (211).
W3-4-1-11
Group 4 Engine
70
WJAC-03-08-034
68 69 WJAC-03-04-013
45. Open covers (68, 69). 46. Remove bolt, washer (70).
j : 17 mm
W3-4-1-12
Group 4 Engine
208
61
WJAC-03-04-014 WJAC-03-04-033
47. Remove tube (61) upward.

48. Remove pump device (208). (Refer to W3-8-1.)
W3-4-1-13
Group 4 Engine
157
WJAC-03-04-020
WJAC-03-04-018
49. Disconnect engine stop cable (136). 56. Remove bolt (150), spring washer (151), washer
(152), and clip (153).
50. Remove nut (137) and spring washer (138).
Disconnect engine control cable (139). j : 17 mm
j : 10 mm 57. Disconnect terminal (157).
51. Disconnect terminals (140, 141).
53. Remove bolts (143) (3 used), washers (144) (3 used),
and clips (145) (3 used).
j : 17 mm
W3-4-1-14
Group 4 Engine
159 160 161 162 163 164
158 WJAC-03-04-021 211 212 WJAC-03-04-022

j : 41 mm
j : 41 mm
61. Remove clip (211). Disconnect tube (212).
62. Remove clip (161). Disconnect hose (162).
63. Remove clip (163). Disconnect hose (164).
W3-4-1-15
Group 4 Engine
165 167, 168, 169 177 178 177
165 166 165 166 175 176

WJAC-03-04-023 WJAC-03-04-026
64. Disconnect terminals (165) (4 used).

66. Remove bolt (167), washer (168), and clip (169).
j : 17 mm
67. Remove clamps (177) (2 used). Disconnect hose
(178).
j : 8 mm
68. Remove band (175). Remove rubber (176).
W3-4-1-16
Group 4 Engine
183 181, 182
179 180
WJAC-03-04-022 WJAC-03-04-027
69. Remove clamps (179) (2 used). Disconnect hose

(180).
j : 7 mm
70. Remove nut (181) and washer (182). Disconnect
ground (183).
j : 22 mm
W3-4-1-17
Group 4 Engine
185 184 132, 133 134 135
186 187, 188, 189 214 WJAC-03-04-032

WJAC-03-04-028

72. Release the belt tension by moving pulley (185) up
and down by using adjusting bolt (184).
IMPORTANT: Do not disconnect hoses (2 used) of
compressor (186).
73. Remove socket bolts (187) (4 used), spring washers
(188) (4 used), and washers (189) (4 used). Place the
compressor (186) assembly horizontally.
l : 6 mm
74. Install bracket (135) with bolts, washers (134) (4
used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

75. Install washers (133) (4 used) and bolts (132) (4
used).
j : 22 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-4-1-18
Group 4 Engine
Detail A Detail B
b C
a 190 a 197 197 191
198 203 192
193
199 199 194
200
200
195
201
201
202 196
204
A B WJAC-03-04-030
WJAC-03-04-029
a- Lifting Bracket b- Counterweight Side

c- Front Attachment Side
83. Place engine (190) on wooden blocks.

dCAUTION: The engine (190) assembly weight:
1220 kg (2690 lb) 84. Remove cushion (195) at the counterweight and
front attachment sides.
76. Install shackles to lifting brackets (a) (3 places) of
engine (190). Attach nylon slings onto the shackles 85. Remove bolts (202) (2 used), washers (201) (2
(3 used). Hoist and hold the engine (190) assembly. used), cushion (199), and stopper (200) at the
counterweight side.
77. Remove bolt (191), nut (196), plate (192), and
cushion (193) at the counterweight side. j : 27 mm
j : 32 mm 86. Remove bolts (204) (2 used), washers (201) (2
used), cushion (199), and stopper (200) at the front
78. Remove bolt (191) at the front attachment side in
attachment side.
the same way as step 77.
79. Remove bolt (197) and washer (198) at the j : 27 mm
counterweight side.
j : 32 mm
80. Remove bolt (197) and spacer (203) at the front
attachment side.
j : 32 mm
81. Hoist engine (190) by 15 mm.
82. Move engine (190) to the pump device side by 50
mm. Remove engine (190).
W3-4-1-19
Group 4 Engine
190 135
134
132, 133
207 205, 206 WJAC-03-04-031
87. Remove bolts (132) (4 used) and washers (133) (4

used).
j : 22 mm
bracket (135).
j : 19 mm
used). Remove bracket (207).
fNOTE: LOCTITE #262 has been applied onto bolts (205)

(4 used).
j : 22 mm
90. Remove bracket (207) at the counterweight side in
the same way as step 89.
91. Remove the adapter with engine (190) attached if
necessary.
W3-4-1-20
Group 4 Engine
190 135
134
132, 133
207 205, 206 WJAC-03-04-031
Installation
1. Install all removed adapters to engine (190).
bracket (207) with washers (206) (4 used) and bolts
(205) (4 used).
j : 22 mm
m : 175 N·m (17.5 kgf·m, 129 lbf·ft)

3. Install bracket (207) at the counterweight side in the
same way as step 2.
4. Install bracket (135) with bolts, washers (134) (4
used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

5. Install washers (133) (4 used) and bolts (132) (4
used).
j : 22 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-4-1-21
Group 4 Engine
Detail A Detail B
b C
a 190 a 197 197 191
198 203 192
193
199 199 194
200
200
195
201
201
202 196
204
A B WJAC-03-04-029 WJAC-03-04-030
a- Lifting Bracket b- Counterweight Side

c- Front Attachment Side
6. Install stopper (200), cushion (199), washers (201)

(2 used), and bolts (204) (2 used) at the front dCAUTION: The engine (190) assembly weight:
1220 kg (2690 lb)
attachment side.
9. Install shackles to lifting brackets (a) (3 places) of
j : 27 mm engine (190). Attach nylon slings onto the shackles
(3 used). Hoist the engine (190) assembly.
m : 390 N·m (39 kgf·m, 290 lbf·ft)
10. Install engine (190) with cushion (193), plate (192),
7. Install stopper (200), cushion (199), washers (201) (2
nut (196), and bolt (191).
used), and bolts (202) (2 used) at the counterweight
side. j : 32 mm
m : 390 N·m (39 kgf·m, 290 lbf·ft) 11. Install bolt (191) at the front attachment side in the
same way as step 10.
8. Install cushion (195) at the counterweight and front
attachment sides. 12. Install the counterweight side of engine (190) with
washer (198) and bolt (197).
j : 32 mm
m : 740 N·m (74 kgf·m, 550 lbf·ft)

13. Install the front attachment side of engine (190)
with spacer (203) and bolt (197).
j : 32 mm
m : 740 N·m (74 kgf·m, 550 lbf·ft)
W3-4-1-22
Group 4 Engine
185 184
186 187, 188, 189 214

WJAC-03-04-028
14. Install the compressor (186) assembly with washers

(189) (4 used), spring washers (188) (4 used), and
socket bolts (187) (4 used).
j : 6 mm
m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22

lbf·ft)
IMPORTANT: The belt does not fit when replacing
with a new one. Therefore, adjust the belt tension
again after running the engine at slow idle for 3 to
5 minutes.
15. Adjust the belt tension by moving pulley (185) up
and down by using adjusting bolt (184).
W3-4-1-23
Group 4 Engine
183 181, 182
179 180 WJAC-03-04-022 WJAC-03-04-027
17. Connect ground (183) with washer (182) and nut

(181).
j : 22 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)

18. Connect hose (180) with clamps (179) (2 used).
j : 7 mm
m : 5 to 6 N·m (0.5 to 0.6 kgf·m, 3.7 to 4.4 lbf·ft)
W3-4-1-24
Group 4 Engine
165 167, 168, 169 177 178 175 177
165 166 165 166 176

WJAC-03-04-023 WJAC-03-04-026
19. Install rubber (176) with band (175).

20. Install hose (178) with clamps (177) (2 used).
j : 8 mm

22. Connect terminals (165) (4 used).
23. Install clip (169), washer (168), and bolt (167).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-4-1-25
Group 4 Engine
159 160 161 162 163 164
WJAC-03-04-021 211 212 WJAC-03-04-022

158
24. Connect hose (164) with clip (163).

25. Connect hose (162) with clip (161).
26. Connect tube (212) with clip (211).
j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)

j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)

W3-4-1-26
Group 4 Engine
157
WJAC-03-04-020
WJAC-03-04-018
30. Connect terminal (157).

31. Install clip (153), washer (152), spring washer (151),
and bolt (150).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

33. Install clips (145) (3 used), washers (144) (3 used),
and bolts (143) (3 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

34. Connect hose (147) with clamp (146).
36. Connect terminals (140, 141).
37. Connect engine control cable (139) with spring
washer (138) and nut (137).
j : 10 mm
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

38. Connect engine stop cable (136).
W3-4-1-27
Group 4 Engine
208
132, 133 134 135
WJAC-03-04-032 WJAC-03-04-033

used).
j : 22 mm
bracket (135).
j : 19 mm
41. Install pump device (208). (Refer to W3-8-1.)
W3-4-1-28
Group 4 Engine
61 121
61
70
WJAC-03-04-014
WJAC-03-08-034
42. Install tube (61) to cover (121). 43. Install tube (61) with bolt, washer (70).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-4-1-29
Group 4 Engine
66, 67 65 64 62, 63, 211

60, 61 WJAC-03-04-011 WJAC-03-04-012
44. Install gasket (211). 48. Install washers (63) (6 used) and nuts (62) (6 used).
dCAUTION:
kg (95 lb)
The muffler (64) assembly weight: 43 j : 14 mm
m : 21 to 35 N·m (2.1 to 3.5 kgf·m, 15.5 to 26

45. Attach nylon slings onto the body of the muffler
lbf·ft)
(64) assembly. Hoist and hold the muffler (64)
assembly. 49. Install washers (67) (4 used), nuts (66) (8 used), and
U-bolts (65) (2 used).
46. Fit the muffler (64) assembly to tube (61). Install the
muffler (64) assembly. j : 19 mm
47. Connect tube (61) with clamp (60).
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
W3-4-1-30
Group 4 Engine
46 48 43 45 44 47
WJAC-03-04-008 WJAC-03-04-009
50. Install duct (48) with clamp (46).
j : 7 mm

51. Install bolts (47) (2 used).
j : 14 mm
m : 44 to 60 N·m (4.4 to 6.0 kgf·m, 32.5 to 44

lbf·ft)
52. Install duct (45) with clamps (43, 44).
W3-4-1-31
Group 4 Engine
219 170, 171 213 172
WJAC-03-04-024 WJAC-03-04-025
53. Install hose (213) with clamp (172).

54. Install hose (219) with clip (171) and bolt, washer
(170).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-4-1-32
Group 4 Engine
WJAA-03-04-003
7, 8 WJAC-03-08-001
55. Add coolant to the radiator.

56. Fill hydraulic oil to the hydraulic oil tank.

57. Install O-ring (8) and cover (7) with bolts, washers
(6) (6 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

58. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
59. Bleed air from the fuel system. (Refer to W1-4-1.)
60. Connect ground (5).
IMPORTANT: Check the hydraulic oil level and the
coolant level. Start the engine and check for any
oil leaks and coolant leaks.
IMPORTANT: Tighten clamp (179) in step 18 and

clamp (177) in step 20 again after the engine
starts.
W3-4-1-33
Group 4 Engine
1 4
2, 3
WJAA-03-04-001 WJAA-03-04-002
61. Install cover (4) with washers (3) (4 used) and wing
nuts (2) (4 used).
62. Close cover (1).
W3-4-1-34
Group 4 Engine
49 50 58, 59 53 54
58, 59
55
56
51 52 58, 59 57
WJAC-03-04-010
dCAUTION:
(51 lb)
The cover (57) assembly weight: 23 kg dCAUTION: Cover (51) weight: 24 kg (53 lb)
63. Install the cover (57) assembly with washers (59) (6
used) and bolts, washers (58) (6 used). j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft) dCAUTION: Cover (49) weight: 27 kg (60 lb)

j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-4-1-35
Group 4 Engine
41 37 42 38, 39, 40 37
37 36 37
WJAC-03-04-006
68. Install the cover (42) assembly with bolts, washers

(41) (2 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

69. Install spacers (40) (2 used), rubbers (39) (2 used),
and bolts, washers (38) (2 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
kg (28 lb)

71. Install the support (36) assembly with bolts, washers
(37) (8 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-4-1-36
Group 4 Engine
28 27 29
210
209
30
34
35
WJAC-03-04-004
31, 32, 33 34 WJAC-03-04-005
72. Install the cover (35) assembly with bolts, washers 75. Install cover (210) with bolts, washers (209) (5 used).
(34) (2 used).
j : 17 mm
j : 19 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION:
(49 lb)

j : 19 mm
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-4-1-37
Group 4 Engine
21
24
WJAC-03-04-001 26 25 22, 23 WJAC-03-04-003
dCAUTION: Engine cover (21) weight: 23 kg (51 lb)

78. Install engine cover (21) with bolts, washers (26) (6
used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

79. Install the support (25) side of stopper (24) with
washers (23) (2 used) and pin (22).
80. Close engine cover (21).
W3-4-1-38
Group 4 Engine
15 18
WJAC-03-04-001 20 16, 17 19 WJAC-03-04-002
dCAUTION: Engine cover (15) weight: 24 kg (53 lb)

82. Install engine cover (15) with bolts, washers (20) (6
used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

83. Install the support (19) side of stopper (18) with
washers (17) (2 used) and pin (16).
84. Close engine cover (15).
W3-4-1-39
Group 4 Engine
9 10
13 14 11 12
WJAC-03-08-006 WJAC-03-08-002
dCAUTION:
(51 lb)
The cover (14) assembly weight: 23 kg dCAUTION: Step (12) weight: 26 kg (58 lb)
86. Install step (12) with bolts, washers (11) (6 used).
(13) (19 used). j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft) dCAUTION: Handrail (10) weight: 21 kg (47 lb)

hold handrail (10).
88. Install handrail (10) with bolts, washers (9) (6 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-4-1-40
Group 4 Engine
68 69
WJAC-03-08-030
89. Perform engine speed adjustment and engine

learning. (Refer to TROUBLESHOOTING / Operational
Performance Test in the separated volume, T/M.)
90. Close covers (68, 69).
W3-4-1-41
Group 4 Engine
(Blank)
W3-4-1-42
Group 5 Radiator Assembly
Replacement of Radiator and Oil Cooler
2, 3 WJAC-03-08-001 WJAC-03-05-002
8 9

and pipes have been disconnected. In addition, d(49
CAUTION:
lb)
hoses, and pipes for assembling. Connect the 4. Remove bolts, washers (9) (21 used). Remove the
hoses and install the clips in case the clips which cover (8) assembly.
j : 19 mm
Removal
(Refer to W1-6-1.)
d(Refer
CAUTION: Bleed air from the hydraulic oil tank.
to W1-4-1.)
(2) and O-ring (3).
j : 17 mm
W3-5-1-1
16
14
11
18, 19
10
18, 19
WJAC-03-05-003 WJAC-03-05-004
13 12 15

(11). d(58
CAUTION:
lb)
The door (16) assembly weight: 26 kg
j : 17 mm 8. Remove nuts (18) (6 used) and washers (19) (6 used).

6. Remove bolt, washer (12). Remove cover (13). Remove the door (16) assembly.
j : 17 mm j : 19 mm
7. Open engine covers (14, 15).
W3-5-1-2
80 23
20
79 WJAC-03-05-005 WJAC-03-05-007
dkgCAUTION:
(60 lb)

bracket (80).
j : 19 mm
11. Remove bolts, washers (20) (2 used).
j : 19 mm
W3-5-1-3
22 22
23
21
21
WJAC-03-05-005 WJAC-03-05-006
j : 19 mm
support (23) assembly.
j : 19 mm
W3-5-1-4
5 4 7 6
24 25 26, 27
WJAC-03-05-020 WJAC-03-05-010
dnot
CAUTION: Remove cover (4) while holding it. Do
drop cover (4).
(4).
j : 19 mm
dnot
drop cover (6).
(6).
j : 19 mm
16. Place a container under the disconnecting part of
hose (26). Remove socket bolts (24) (4 used) and
flanges (25) (2 used). Disconnect hose (26). Remove
O-ring (27).
l : 10 mm
W3-5-1-5
33 34 32 33
30, 31 28 29
WJAC-03-05-008 WJAC-03-05-011
17. Place a container under the disconnecting part of

hose (30). Remove socket bolts (28) (4 used) and
flanges (29) (2 used). Disconnect hose (30). Remove
O-ring (31).
l : 10 mm
IMPORTANT: Take care not to disconnect hose (32).
condenser (34) assembly.
j : 17 mm
W3-5-1-6
Detail A
37
36 35
a
39 38
WJAC-03-05-015 WJAC-03-05-016
a- Lifting Hole
d36CAUTION:
kg (80 lb)
The oil cooler (39) assembly weight:
19. Install shackles to lifting holes (a) (2 places) of the

oil cooler (39) assembly. Attach nylon slings onto
shackles. Hoist and hold the oil cooler (39) assembly.
20. Remove bolts, washers (38) (8 used). Remove the oil
cooler (39) assembly.
j : 17 mm
21. Remove wing bolts (35) (2 used) and nuts (36) (2
W3-5-1-7
40, 41
42 43 WJAC-03-05-001
22. Place a container under coolant outlet (40). Loosen

cock (41). Drain off coolant.

23. Remove clamps (42) (2 used). Disconnect hose (43).
j : 7 mm
W3-5-1-8
52 51 70
56, 57 b 48, 49, 50 46 47 44
45
54
WJAC-03-05-018
58, 59 53 WJAC-03-05-019
b- Lifting Hole b- Lifting Hole
24. Remove clamp (46). Disconnect hose (47). 30. Remove bolt (56) and spring washer (57).
j : 8 mm j : 24 mm
25. Remove clamp (44). Disconnect hose (45). 31. Remove bolt (58) and spring washer (59).
26. Remove bolt, washer (48), washer (49), and clip (50). j : 24 mm
j : 17 mm
(54).
j : 17 mm
28. Remove band (51). Remove rubber (52).
j : 19 mm
dkgCAUTION:
(200 lb)
The radiator (70) assembly weight: 90
29. Install shackles to lifting holes (b) (2 places) of the

radiator (70) assembly. Attach nylon slings onto
shackles. Hoist and hold the radiator (70) assembly.
W3-5-1-9
60, 61 70 60, 61
WJAC-03-05-001
32. Remove bolts (60) (4 used) and spring washers (61)

(4 used). Remove the radiator (70) assembly.

used).
j : 24 mm
W3-5-1-10
Detail B
C
78
77 73
76 C
71
B
WJAC-03-05-015
WJAC-03-05-017
69 68 70 75 74 72
C- Lifting Hole

shroud (69).
j : 17 mm
34. Remove packings (71) (2 used) from shroud (69).
d CAUTION: Radiator (70) weight: 53 kg (120 lb)

35. Install shackles (2 used) to lifting holes (c) (2 places)
of radiator (70). Attach nylon slings onto shackles.
Hoist and hold radiator (70).
radiator (70).
j : 19 mm
37. Remove packings (73, 74, and 76) (2 used for each)
from radiator (70).
38. Remove packings (75) (2 used) and packing (77)
from frame (78).
W3-5-1-11
Detail B
C
78
77 73
76 C
71
B
WJAC-03-05-015
WJAC-03-05-017
69 68 70 75 74 72
C- Lifting Hole
Installation
1. Tape two-side adhesive tape to packings (75, 77).
Install packings (75) (2 used) and packing (77) to
frame (78).
2. Tape two-side adhesive tape to packings (73, 74,
and 76). Install packings (73, 74, and 76) (2 used for
each) to radiator (70).
d CAUTION: Radiator (70) weight: 53 kg (120 lb)

3. Install shackles (2 used) to lifting holes (c) (2 places)
of radiator (70). Attach nylon slings onto shackles.
Hoist and hold radiator (70).
4. Install radiator (70) with bolts, washers (72) (10
used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

5. Tape two-side adhesive tape to packing (71). Install
packings (71) (2 used) to shroud (69).
6. Install shroud (69) with bolts, washers (68) (10 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-1-12
70
WJAC-03-05-018 WJAC-03-05-019
b- Lifting Hole b- Lifting Hole
dkgCAUTION:
(200 lb)
The radiator (70) assembly weight: 90
7. Install shackles to lifting holes (b) (2 places) of the

radiator (70) assembly. Attach nylon slings onto
shackles. Hoist and hold the radiator (70) assembly.
W3-5-1-13
60, 61 70 60, 61
WJAC-03-05-001 58, 59 WJAC-03-05-022

the radiator (70) assembly with spring washers (61)
(4 used) and bolts (60) (4 used).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)

9. Install spring washer (59) and bolt (58).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
W3-5-1-14
52 51
56, 57 48, 49, 50 46 47 44
45
54
WJAC-03-05-018
WJAC-03-05-019
53
10. Install spring washer (57) and bolt (56).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)

11. Install rubber (52) with band (51).
j : 8 mm

14. Install clip (50), washer (49), and bolt, washer (48).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-1-15
43 42
WJAC-03-05-001
16. Connect hose (43) with clamps (42) (2 used).
j : 7 mm

17. Add coolant to the radiator.
W3-5-1-16
37 Detail A
36 35
A
a
a
39 38
WJAC-03-05-015 WJAC-03-05-016
a- Lifting Hole
18. Install cover (37) with nuts (36) (2 used) and wing
d36CAUTION:
kg (80 lb)
The oil cooler (39) assembly weight:
19. Install shackles to lifting holes (a) (2 places) of the

oil cooler (39) assembly. Attach nylon slings onto
shackles. Hoist and hold the oil cooler (39) assembly.
20. Install the oil cooler (39) assembly with bolts,
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-5-1-17
33 34 32 33
30, 31 28 29
42
WJAC-03-05-008 WJAC-03-05-011
IMPORTANT: Take care not to disconnect hose (32).

21. Install the condenser (34) assembly with bolts,
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

22. Install O-ring (31) to hose (30). Connect hose (30)
with flanges (29) (2 used) and socket bolts (28) (4
used).
j : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-18
24 25 26, 27
WJAC-03-05-010 2, 3 WJAC-03-08-001

used).
j : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)


25. Install cover (2) and O-ring (3) with bolts, washers
(1) (6 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

4-1.)
IMPORTANT: Check the hydraulic oil level and the
coolant level. Start the engine and check for any
oil and coolant leaks.
IMPORTANT: Tighten clamp (46) in step 13 and
clamp (42) in step 16 again after the engine starts.
W3-5-1-19
5 4 7 6
WJAC-03-05-020
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-20
23 22
80 22
21
79
21
WJAC-03-05-005 WJAC-03-05-006
dkgCAUTION:
(60 lb)

30. Install the support (23) assembly with bolts, washers
(21) (5 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-21
16
20
18, 19
18, 19
WJAC-03-05-004 WJAC-03-05-007
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
d(58
CAUTION:
lb)
The door (16) assembly weight: 26 kg
34. Install the door (16) assembly with washers (19) (6

used) and nuts (18) (6 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-22
14
11
10
WJAC-03-05-002 WJAC-03-05-003
8 9 13 12 15
35. Close engine covers (14, 15).

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
d(49
CAUTION:
lb)
38. Install the cover (8) assembly with bolts, washers (9)
(21 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-5-1-23
(Blank)
W3-5-1-24
Removal and Installation of Hydraulic Oil

Tank
2 5 7
6 8
WJAA-03-07-002
WJAC-03-08-001
3, 4

and pipes have been disconnected. In addition, dCAUTION: Cover (5) weight: 21 kg (47 lb)
not drop cover (5).
(5).
Removal
j : 19 mm
dCAUTION: Bleed air from the hydraulic oil tank
before doing any work. (Refer to W1-4-1.)
not drop cover (7).
2. Bleed air from the hydraulic system. (Refer to W1- 6. Remove bolts, washers (8) (5 used). Remove cover
4-1.) (7).
3. Remove bolts, washers (2) (6 used). Remove cover j : 19 mm
(3) and O-ring (4).
j : 17 mm
W3-6-1-1
12 2
11
9 10 3, 4
WJAA-03-07-003 WJAC-03-08-001
7. Remove plug (9).

8. Place a container under hydraulic oil tank (10).
9. Slowly open drain cock (11) and drain off remaining
hydraulic oil.
10. Close drain cock (11).
11. Install plug (9) to the original position.
j : 19 mm
13. Install O-ring (4) and cover (3) with bolts, washers
(2) (6 used).
j : 17 mm
W3-6-1-2
13, 14, 15 18, 19, 20 22
17 16 21
WJAC-03-07-001
14. Remove bolt, washer (13), spacer (14), and rubber

(15).
j : 19 mm
j : 19 mm
16. Remove bolts, washers (18) (2 used), spacers (19) (2
used), and rubbers (20) (2 used).
j : 19 mm
(22).
j : 19 mm
W3-6-1-3
25 24
23 27 25 26 25 WJAC-03-06-001
18. Open cover (23).
dCAUTION: Handrail (24) weight: 24 kg (53 lb)

hold handrail (24).
handrail (24).
j : 19 mm
(27).
j : 19 mm
W3-6-1-4
28 29 28 30 31
30 WJAC-03-06-002
30 31
WJAA-03-07-006

(29).
j : 19 mm
bracket (31).
j : 19 mm
W3-6-1-5
82 84 32
76 89 84 77, 78 79 85 80, 81 83
84
82
86 87 88 87
32 33
WJAC-03-06-008
WJAA-03-07-007
24. Disconnect tube (76). 30. Remove bolts, washers (32) (4 used). Remove cover
(33).
26. Remove bolt (77) and nuts (78) (2 used). Remove j : 19 mm
washer fluid tank (79). 31. Remove bolts, washers (86) (2 used).
j : 10 mm j : 19 mm
27. Remove bolt, washer (80) and clip (81). 32. Remove bolts, washers (87) (4 used). Remove cover
(88).
j : 17 mm
28. Remove bolts, washers (82) (6 used). Remove cover j : 19 mm
(83).
j : 19 mm
(85).
j : 19 mm
W3-6-1-6
34 35
WJAC-03-06-003
WJAC-03-06-006
33. Open covers (34, 35). 38. Remove bolts, washers (44) (2 used). Remove clips
(45) (2 used).
34. Remove bolt, washer (38). Remove clip (39).
j : 17 mm
j : 17 mm
35. Remove bolt, washer (40). Remove clips (41) (2
used). j : 27 mm
j : 17 mm 40. Remove coupling (47). Disconnect pipe (48).
36. Disconnect hoses (42) (2 used). 41. Remove coupling (49). Disconnect pipe (50).
j : 17 mm
37. Disconnect hoses (43) (3 used).
j : 19 mm
W3-6-1-7
WJAC-03-06-004 WJAC-03-06-005
42. Remove bolt, washer (51). Remove clips (52) (2 47. Remove bolt, washer (57). Remove clip (58).
used).
j : 17 mm
j : 17 mm
j : 27 mm
j : 41 mm
j : 19 mm
j : 17 mm
45. Disconnect hoses (56) (3 used). 4-spool solenoid valve unit (62).
j : 27 mm j : 17 mm
j : 19 mm
W3-6-1-8
10 67 74, 75 72 74, 75
a WJAC-03-06-009
a - Screw Hole
74, 75 69 70, 71 73 74, 75

WJAC-03-06-007
54. Place a container under hose (73). Remove hose

d CAUTION: Hydraulic oil tank (10) weight: 290 kg
(640 lb)
clamps (72) (2 used). Disconnect hose (73).
51. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to j : 11 mm

screw holes (a) (2 places) of hydraulic oil tank (10). 55. Remove bolts (74) (8 used) and spacers (75) (8 used).
Attach wire ropes onto the eyebolts. Hoist and hold
hydraulic oil tank (10). fNOTE: LOCTITE #262 has been applied onto bolts (74) (8
used).
j : 24 mm
56. Move hydraulic oil tank (10) to the cab side without
j : 17 mm touching step (67) while holding. Remove hydraulic
oil tank (10).
W3-6-1-9
10 67 74, 75 72 74, 75
a WJAC-03-06-009
a - Screw Hole
74, 75 69 70, 71 73 74, 75

WJAC-03-06-007
Installation 4. Install clip (71) with bolt, washer (70).
dCAUTION:
(640 lb)
Hydraulic oil tank (10) weight: 290 kg j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
screw holes (a) (2 places) of hydraulic oil tank (10). 5. Connect connector (69).
Attach wire ropes onto the eyebolts. Hoist hydraulic
oil tank (10). Move hydraulic oil tank (10) from the
cab side without touching step (67) while holding.
hydraulic oil tank (10) with spacers (75) (8 used) and
j : 24 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft)

3. Connect hose (73) with hose clamps (72) (2 used).
j : 11 mm
W3-6-1-10
WJAC-03-06-004
WJAC-03-06-005
6. Install 4-spool solenoid valve unit (62) with bolts, 11. Connect hoses (56) (3 used).
j : 27 mm
j : 17 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
j : 19 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
m : 30 N·m (3 kgf·m, 22 lbf·ft)
j : 41 mm
j : 27 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)
m : 80 N·m (8 kgf·m, 59 lbf·ft)
14. Install clips (52) (2 used) with bolt, washer (51).
9. Install clip (58) with bolt, washer (57).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-6-1-11
WJAC-03-06-006
15. Connect pipe (50) with coupling (49). 20. Connect hoses (42) (2 used).
16. Connect pipe (48) with coupling (47). j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
j : 27 mm 21. Install clips (41) (2 used) with bolt, washer (40).
m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 17 mm
18. Install clips (45) (2 used) with bolts, washers (44) (2
m : 50 N·m (5 kgf·m, 37 lbf·ft)
used).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lb)
W3-6-1-12
3, 4 34 35 WJAC-03-06-003
WJAC-03-08-001

(3) and O-ring (4).
j : 17 mm

(2) (6 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

4-1.)
W3-6-1-13
82 84 32
76 89 84 77, 78 79 85 80, 81 83
84
82
86 87 88 87
WJAC-03-06-008
32 33 WJAA-03-07-007
28. Install cover (88) with bolts, washers (87) (4 used). 33. Install clip (81) with bolt, washer (80).
j : 19 mm j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)

29. Install bolts, washers (86) (2 used). 34. Install washer fluid tank (79) with nuts (78) (2 used)
and bolt (77).
j : 19 mm
j : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)
j : 19 mm
36. Connect tube (76).
m : 90 N·m (9 kgf·m, 66 lbf·ft)
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-6-1-14
28 29 28 30 31
30 WJAC-03-06-002
30 31
WJAA-03-07-006
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-6-1-15
25 24
23 27 25 26 25 WJAC-03-06-001
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION: Handrail (24) weight: 24 kg (53 lb)

40. Attach nylon slings onto handrail (24). Hoist
handrail (24).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-6-1-16
12
5 7
6 8
WJAA-03-07-003 WJAA-03-07-002
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-6-1-17
13, 14, 15 18, 19, 20 22
17 16 21
WJAC-03-07-001
46. Install cover (22) with rubbers (20) (2 used), spacers

(19) (2 used), and bolts, washers (18) (2 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

48. Install cover (17) with rubber (15), spacer (14), and
bolt, washer (13).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

49. Install bolt, washer (16).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-6-1-18
Group 7 Fuel Tank
Removal and Installation of Fuel Tank
1 2, 3, 4 7, 8, 9 11
6 5 10 WJAC-03-07-001

daCAUTION: Fuel is highly flammable. Never bring
fire close to fuel.
(11).
IMPORTANT: Cap the open ends in case the hoses j : 19 mm

Removal
2. Remove cap (1).
3. Place a container. Drain off fuel by using an oil feed
pump.
fNOTE: Amount of oil: 705 L (187 US gal)

4. Remove bolt, washer (2), spacer (3), and rubber (4).
j : 19 mm
j : 19 mm
j : 19 mm
W3-7-1-1
Group 7 Fuel Tank
18
12 16 12 13, 14, 15
22
19, 20, 21
18
WJAC-03-07-001 23 WJAA-03-08-009
17
j : 19 mm
and spacers (15) (2 used). Remove the handrail (16)
assembly.
j : 19 mm
10. Remove rubber (17).
j : 19 mm
and spacers (21) (2 used). Remove the handrail (22)
assembly.
j : 19 mm
13. Remove rubber (23).
W3-7-1-2
Group 7 Fuel Tank
25 24 70, 71 69
35 69 WJAC-03-07-002 70, 71 WJAC-03-07-010
d(49
CAUTION:
lb)

j : 19 mm
15. Open covers (35, 69).
16. Remove bolts, washers (70) (4 used) and shims (71)
(4 used). Remove cover (69).
j : 19 mm
W3-7-1-3
Group 7 Fuel Tank
27 28
26
29
33
34
WJAC-03-07-003
30, 31, 32 33

(27).
j : 17 mm
j : 17 mm
j : 19 mm
j : 19 mm
W3-7-1-4
Group 7 Fuel Tank
37 36
39 38
WJAC-03-07-004
38 WJAC-03-07-005
21. Remove clamp (36).

22. Disconnect plugs (37) (2 used).
23. Remove bolts, washers (38) (4 used). Remove the air
cleaner (39) assembly.
j : 19 mm
W3-7-1-5
Group 7 Fuel Tank
53, 54 55 53, 54 46, 47 42 43 46, 47
40
41
WJAC-03-07-006 WJAC-03-07-007
53, 54 49 50, 51, 52 48, 72 44, 45
24. Remove bolts, washers (40) (2 used). Remove water

separator (41).
j : 17 mm
25. Remove bolts, washer (44) and clip (45).
j : 17 mm
27. Remove bolts, washers (46) (2 used) and clips (47) (2
used).
j : 17 mm
28. Remove cover (72). Disconnect plugs (48) (2 used).
30. Remove bolt, washer (50), clip (51), and clip (52).
j : 17 mm
used). Remove the reserve tank (55) assembly.
j : 19 mm
W3-7-1-6
Group 7 Fuel Tank
57 59 61
56 58 60 WJAA-03-08-006
dDo
(56).
j : 19 mm
dDo
(58).
j : 19 mm
dDo
(60).
j : 19 mm
W3-7-1-7
Group 7 Fuel Tank
62
a
WJAC-03-07-011
a - Screw Hole
d CAUTION: Fuel tank (62) weight: 305 kg (675 lb)

35. Install eyebolts (M12, Pitch 1.75 mm) to screw holes
(a) (3 places) of fuel tank (62). Attach nylon slings
onto eyebolts. Hoist and hold fuel tank (62).
W3-7-1-8
Group 7 Fuel Tank
62
67, 68 63 64 67, 68
67, 68 66 65 67, 68 WJAA-03-08-007 WJAC-03-07-009
36. Place a container under hoses (63, 64). Remove

clamps (65, 66). Disconnect hoses (63, 64). Drain fuel
completely.
j : 7 mm
37. Remove bolts (67) (8 used) and spacers (68) (8 used).
Remove fuel tank (62).

used).
j : 24 mm
W3-7-1-9
Group 7 Fuel Tank
62
WJAC-03-07-011
a - Screw Hole
Installation
d CAUTION: Fuel tank (62) weight: 305 kg (675 lb)

1. Install eyebolts (M12, Pitch 1.75 mm) to screw holes
(a) (3 places) of fuel tank (62). Attach nylon slings
onto eyebolts. Hoist fuel tank (62).
W3-7-1-10
Group 7 Fuel Tank
62
67, 68 63 64 67, 68
67, 68 66 65 67, 68 WJAA-03-08-007 WJAC-03-07-009

fuel tank (62) with spacers (68) (8 used) and bolts
(67) (8 used).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)

3. Connect hoses (63, 64) with clamps (65, 66).
j : 7 mm
W3-7-1-11
Group 7 Fuel Tank
57 59 61
56 58 60 WJAA-03-08-006
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-7-1-12
Group 7 Fuel Tank
53, 54 55 53, 54 46, 47 42 43 46, 47
40
41
WJAC-03-07-006 WJAC-03-07-007
53, 54 49 50, 51, 52 48, 72 44, 45
7. Install the reserve tank (55) assembly with washers 14. Install water separator (41) with bolts, washers (40)
(54) (4 used) and bolts (53) (4 used). (2 used).
j : 19 mm j : 17 mm

8. Install clip (51) and clip (52) with bolt, washer (50).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

10. Connect plugs (48) (2 used). Install cover (72).
11. Install clips (47) (2 used) with bolts, washers (46) (2
used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-7-1-13
Group 7 Fuel Tank
37 36
39 38
WJAC-03-07-004
38 WJAC-03-07-005
15. Install the air cleaner (39) assembly with bolts,

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

16. Connect plugs (37) (2 used).
17. Install clamp (36).
W3-7-1-14
Group 7 Fuel Tank
27 28
26
29
33
34
WJAC-03-07-003
30, 31, 32 33

(33) (2 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-7-1-15
Group 7 Fuel Tank
25 24 70, 71 69
35 69 WJAC-03-07-002 70, 71 WJAC-03-07-010
22. Install cover (69) with shims (71) (4 used) and bolts,
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

d(49
CAUTION:
lb)

(25) (21 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-7-1-16
Group 7 Fuel Tank
18
12 16 12 13, 14, 15
22
19, 20, 21
18
WJAC-03-07-001 23 WJAA-03-08-009
17
25. Install rubber (23).

26. Install the handrail (22) assembly with spacers (21)
(2 used), washers (20) (2 used), and bolts (19) (2
used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

28. Install rubber (17).
29. Install the handrail (16) assembly with spacers (15)
(2 used), washers (14) (2 used), and bolts (13) (2
used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-7-1-17
Group 7 Fuel Tank
62 2, 3, 4 7, 8, 9 11
6 5 10 WJAC-03-07-001

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

33. Install cover (6) with rubber (4), spacer (3), and bolt,
washer (2).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

35. Fill fuel tank (42) with fuel.
fNOTE: Amount of oil: 705 L (187 US gal)

IMPORTANT: Take care not to contaminate fuel tank
(62) with dust, water, or sand when refueling.
36. Bleed air from the fuel system. (Refer to W1-4-1.)
W3-7-1-18
Group 8 Pump Device
Removal and Installation of Pump Device
3 4
2, 82 WJAC-03-08-001 5 6 WJAC-03-08-002

and pipes have been disconnected. In addition, d CAUTION: Handrail (4) weight: 21 kg (47 lb)
attach an identification tag onto the connectors, 4. Attach nylon slings onto handrail (4). Hoist and hold
hoses, and pipes for assembling. Connect the handrail (4).
handrail (4).
Removal
j : 19 mm
(Refer to W1-6-1.)
d CAUTION: Step (6) weight: 26 kg (58 lb)
6. Remove bolts, washers (5) (6 used). Remove step (6).
d(Refer
to W1-4-1.) j : 19 mm
(2) and O-ring (82).
j : 17 mm
W3-8-1-1
Group 8 Pump Device
WJAC-03-08-006 15, 83 WJAC-03-08-032

7 8
8. Remove clamp (83). Disconnect tube (15).

d(51
CAUTION:
lb)
9. Open cover (9).
cover (8) assembly.
j : 19 mm
W3-8-1-2
Group 8 Pump Device
18 21
21
13, 14 12 11 81, 84, 102 WJAC-03-08-031

19 18 20 WJAC-03-08-014
10. Remove nuts (81) (6 used) and washers (84) (6 used).
j : 14 mm
d CAUTION: Cover (20) weight: 27 kg (60 lb)
dDo
dkgCAUTION:
(95 lb)
The muffler (11) assembly weight: 43
11. Attach nylon slings onto the muffler (11) assembly. (20).
Hoist and hold the muffler (11) assembly.
j : 19 mm
12. Remove U-bolts (12) (2 used), nuts (13) (8 used), and
j : 19 mm
13. Remove the muffler (11) assembly.
dDo
14. Remove gasket (102). 16. Remove bolts, washers (18) (5 used). Remove cover
(19).
j : 19 mm
W3-8-1-3
Group 8 Pump Device
100
WJAC-03-08-013
16 17 WJAC-03-08-034
17. Open covers (16, 17). 18. Remove bolt, washer (100).
j : 17 mm
W3-8-1-4
Group 8 Pump Device
15 WJAC-03-08-033 WJAC-03-08-015
19. Remove tube (15) upward. 20. Disconnect hose (29).
j : 36 mm
j : 27 mm
22. Remove socket bolts (26) (4 used) and flanges (27)
(2 used). Disconnect hose (24). Remove O-ring (25).
l : 10 mm
l : 10 mm
W3-8-1-5
Group 8 Pump Device
WJAC-03-08-016 WJAC-03-08-017
24. Disconnect hose (32). 27. Disconnect hose (37).
j : 41 mm j : 41 mm
25. Disconnect hose (31). 28. Disconnect hose (38).
j : 41 mm j : 17 mm
26. Remove socket bolts (34) (4 used). Disconnect pipe
(35). Remove O-ring (36).
l : 14 mm
W3-8-1-6
Group 8 Pump Device
42 42 46 46
WJAC-03-08-020 WJAC-03-08-019
39, 40, 41 42 46 43, 44, 45
29. Remove bolts (39) (3 used), washers (40) (3 used), 31. Remove bolts (43) (3 used), washers (44) (3 used),
and clips (41) (3 used). and clips (45) (3 used).
j : 17 mm j : 17 mm
30. Disconnect connectors (42) (3 used). 32. Disconnect connectors (46) (3 used).
W3-8-1-7
Group 8 Pump Device
48, 49
51 53, 54, 55 88, 89, 90 56 94, 95, 96
WJAC-03-08-035 73, 74, 75 60 58

WJAC-03-08-022
33. Remove bolts, washer (48) and clip (49). 36. Remove bolt (73), spring washer (74), and washer
(75). Remove cover (60).
j : 17 mm
j : 19 mm
34. Remove bolts (88) (8 used), spring washers (89) (8
used), and washers (90) (8 used). Remove cover (56). 37. Remove bolts (94) (3 used), spring washers (95) (3
used), and washers (96) (3 used). Remove cover (58).
j : 19 mm
j : 19 mm
j : 19 mm
W3-8-1-8
Group 8 Pump Device
61
85, 86, 87 52 91, 92, 93 57
59
WJAC-03-08-022 WJAC-03-08-023
97, 98, 99
38. Remove bolts (91) (3 used), spring washers (92) (3 41 Remove bolts, washers (61) (2 used).
j : 19 mm
j : 19 mm
j : 19 mm
j : 19 mm
W3-8-1-9
Group 8 Pump Device
63 64
WJAC-03-08-024 WJAC-03-08-025
62 66 65
42. Remove bolts, washers (63) (2 used). 44. Remove bolts, washers (65) (3 used). Remove the
bracket (66) assembly.
j : 19 mm
j : 19 mm
j : 19 mm
W3-8-1-10
Group 8 Pump Device
76 68, 69 67 WJAC-03-08-026 71, 72 70 WJAC-03-08-027
a- Eyebolt (M12, Pitch 1.75 mm)

used). dlb)
CAUTION: Pump device (70) weight: 260 kg (575
j : 22 mm 47. Install eyebolts (a) (2used) to pump device (70).

46. Remove bolts, washers (76) (4 used). Remove Attach nylon slings onto eyebolts (a) (2 used). Hoist
bracket (67). and hold pump device (70).
j : 19 mm
used). Move pump device (70) 50 mm in parallel.
Remove pump device (70).
j : 19 mm
49. Remove the adapter with pump device (70)
attached if necessary.
W3-8-1-11
Group 8 Pump Device
77
WJAC-03-08-028 WJAC-03-08-029
78 80 79
IMPORTANT: Coupling (78) cannot be reused. IMPORTANT: Coupling flange (80) cannot be reused.
50. Remove socket bolt (77). Remove coupling (78). 51. Remove socket bolts (79) (8 used). Remove coupling
flange (80).
l : 14 mm
fNOTE: LOCTITE #262 has been applied onto socket
l : 8 mm
W3-8-1-12
Group 8 Pump Device
77
WJAC-03-08-029 WJAC-03-08-028
80 79 78
Installation
1. Apply LOCTITE #262 onto socket bolts (79) (8 used).
IMPORTANT: Replace coupling flange (80) with the
new one.
2. Install coupling flange (80) with socket bolts (79) (8
used).
l : 8 mm
m : 69 N·m (6.9 kgf·m, 51 lbf·ft)

IMPORTANT: Replace coupling (78) with the new
one.
3. Install coupling (78) with socket bolt (77).
l : 14 mm
m : 295 N·m (29.5 kgf·m, 220 lbf·ft)
W3-8-1-13
Group 8 Pump Device
WJAC-03-08-027 WJAC-03-08-026
71, 72 70 76 68, 69 67
a- Eyebolt (M12, Pitch 1.75 mm)
4. Install all removed adapters to pump device (70). 7. Install bracket (67) with bolts, washers (76) (4 used).
dlb)
CAUTION: Pump device (70) weight: 260 kg (575 j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

5. Install eyebolts (a) (2used) to pump device (70).
Attach nylon slings onto eyebolts (a) (2 used). Hoist 8. Install washers (69) (4 used) and bolts (68) (4 used).
pump device (70).
j : 22 mm
6. Install pump device (70) with washers (72) (20 used)
and bolts (71) (10 used). m : 180 N·m (18 kgf·m, 133 lbf·ft)
j : 19 mm
m : 88 N·m (8.8 kgf·m, 65 lbf·ft)
W3-8-1-14
Group 8 Pump Device
63 64
WJAC-03-08-025 WJAC-03-08-024
66 65 62
9. Install the bracket (66) assembly with bolts, washers 10. Install the cover (62) assembly with bolts, washers
(65) (3 used). (64) (3 used).
j : 19 mm j : 19 mm

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-8-1-15
Group 8 Pump Device
61
85, 86, 87 52 91, 92, 93 57
WJAC-03-08-023 WJAC-03-08-022
59 97, 98, 99
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

13. Install cover (59) with washers (99) (5 used), spring
washers (98) (5 used), and bolts (97) (5 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-8-1-16
Group 8 Pump Device
101 51 48, 49 50
51 53, 54, 55 88, 89, 90 56 94, 95, 96
WJAC-03-08-022 WJAC-03-08-035
73, 74, 75 60 58
16. Install cover (58) with washers (96) (3 used), spring 20. Install cover (56) with washers (90) (8 used), spring
washers (95) (3 used), and bolts (94) (3 used). washers (89) (8 used), and bolts (88) (8 used).
j : 19 mm j : 19 mm

17. Install cover (60) with washer (75), spring washer 21. Install clip (49) and bolt, washer (48).
(74), and bolt (73).
j : 17 mm
j : 19 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
18. Pass engine control cable (50) and engine stop
cable (101) through cover (51).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-8-1-17
Group 8 Pump Device
46 46 42 42
WJAC-03-08-019 WJAC-03-08-020
46 43, 44, 45 39, 40, 41 42
22. Connect connectors (46) (3 used). 24. Connect connectors (42) (3 used).
23. Install clips (45) (3 used), washers (44) (3 used), and 25. Install clips (41) (3 used), washers (40) (3 used), and
bolts (43) (3 used). bolts (39) (3 used).
j : 17 mm j : 17 mm
W3-8-1-18
Group 8 Pump Device
WJAC-03-08-017 WJAC-03-08-016
26. Connect hose (38). 28. Install O-ring (36) to pipe (35). Connect pipe (35)
with socket bolts (34) (4 used).
j : 17 mm
l : 14 mm
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)
m : 210 N·m (21 kgf·m, 155 lbf·ft)
j : 41 mm
j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)
m : 200 N·m (20 kgf·m, 148 lbf·ft)
j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)
W3-8-1-19
Group 8 Pump Device
18 21
21
WJAC-03-08-015 19 18 20 WJAC-03-08-014

with flanges (47) (2 used) and socket bolts (10) (4 d CAUTION: Cover (19) weight: 24 kg (53 lb)
used). 35. Install cover (19) with bolts, washers (18) (5 used).
l : 10 mm j : 19 mm

used).
j : 19 mm
l : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
j : 27 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)

j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-8-1-20
Group 8 Pump Device
15
100
15 52 WJAC-03-08-033
WJAC-03-08-034
37. Install tube (15) to cover (52). 38. Install tube (15) with bolt, washer (100).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-8-1-21
Group 8 Pump Device
13, 14 12 11 81, 84, 102 WJAC-03-08-031 15, 83 WJAC-03-08-032
39. Install gasket (102). 43. Install washers (84) (6 used) and nuts (81) (6 used).
dkgCAUTION:
(95 lb)
The muffler (11) assembly weight: 43 j : 14 mm
m : 21 to 35 N·m (2.1 to 3.5 kgf·m, 15.5 to 26.0

40. Attach nylon slings onto the muffler (11) assembly.
lbf·ft)
Hoist and hold the muffler (11) assembly.
44. Install washers (14) (4 used), nuts (13) (8 used), and
41. Fit the muffler (11) assembly to tube (15). Install the
U-bolts (12) (2 used).
muffler (11) assembly.
42. Connect tube (15) with clamp (83). j : 19 mm
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

W3-8-1-22
Group 8 Pump Device
3 4
WJAC-03-08-006 5 6 WJAC-03-08-002
7 8
d(51
CAUTION:
lb)
The cover (8) assembly weight: 23 kg d CAUTION: Step (6) weight: 26 kg (58 lb)
47. Install step (6) with bolts, washers (5) (6 used).
46. Install the cover (8) assembly with bolts, washers (7)
(19 used). j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft) d CAUTION: Handrail (4) weight: 21 kg (47 lb)

48. Attach nylon slings onto handrail (4). Hoist and hold
handrail (4).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-8-1-23
Group 8 Pump Device
2, 82 WJAC-03-08-001 16 17 WJAC-03-08-030
50. Fill hydraulic oil to the hydraulic oil tank. 53. Close covers (16, 17).

(1) (6 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

4-1.)
W3-8-1-24
Group 8 Pump Device
Disassembly of Main Pump
59 60
94 15 62 63
97 91 68 58
67 60
92 88 72
87 73 64
71
65
89, 90
86 70
19
96 69 59
19
93 77 60
98 60 66
95 78 16
80 79
66
16
18
75 74 68
81 67
75 76
82 74
83 27
38
84 29
37 30
32 24
33
36 26
35
28
42 32
85 16 24
38
48 37 25
44 27
36 28
45 34 29
31
30
45 33
44 35
49 43
50
34
42
44 43
45 3 39 40
4
46 2 41
8
22 7
21
47 20
1 6
5
23
49 98
50
19 11
18
51
53 10
9
56
12
17
52 13
16
54
55
57 98 15
14 WJAC-03-09-001
W3-8-2-1
Group 8 Pump Device
1- Valve Cover 28- Cylinder Spring (18 Used) 55- Stopper L (2 Used) 82- Oil Seal
2- Nut (2 Used) 29- Spherical Bushing (2 Used) 56- O-Ring (2 Used) 83- Front Cover
3- Set Screw (2 Used) 30- Retainer (2 Used) 57- Backup Ring (2 Used) 84- Retaining Ring
4- Socket Bolt (2 Used) 31- Roller Bearing 58- Pump Casing 85- Socket Bolt (11 Used)
5- Booster 32- Plunger (18 Used) 59- Eyebolt (2 Used) 86- A Sensor
6- O-Ring 33- Shoe Plate (2 Used) 60- Plug (20 Used) 87- Angle Sensor
7- Booster Cover 34- Swash Plate (2 Used) 62- O-Ring (5 Used) 88- O-Ring
8- Socket Bolt (5 Used) 35- Pin (2 Used) 63- O-Ring (2 Used) 89- Socket Bolt (2 Used)
9- O-Ring 36- Tilt Bushing (2 Used) 64- Name Plate 90- Washer (2 Used)
10- Cover 37- Tilt Pin (2 Used) 65- Rivet (2 Used) 91- Cover
11- Socket Bolt (2 Used) 38- Feedback Pin (2 Used) 66- Tapered Screw with Orifice (4 92- Leaf Spring
12- Socket Bolt (2 Used) 39- Bolt (2 Used) Used) 93- Socket Bolt (2 Used)
13- Socket Bolt (9 Used) 40- Feedback Lever (2 Used) 67- Plug (3 Used) 94- O-Ring
14- Plug (2 Used) 41- Pin (2 Used) 68- O-Ring (3 Used) 95- Cover
15- O-Ring (6 Used) 42- Swash Plate Stand (2 Used) 69- Socket Bolt (8 Used) 96- Socket Bolt (2 Used)
16- Plug (14 Used) 43- Pin (2 Used) 70- Socket Bolt (8 Used) 97- Feedback Shaft
17- Valve Plate Pin (2 Used) 44- Retaining Ring (3 Used) 71- Servo Cover (2 Used) 98- Pin (4 Used)
18- Seat Packing (2 Used) 45- Bearing Spacer (3 Used) 72- Nut (2 Used)
19- Spring Pin (4 Used) 46- Roller Bearing 73- Set Screw (2 Used)
20- Stopper 1 (2 Used) 47- Drive Shaft 74- Retaining Ring (2 Used)
21- Steel Ball (2 Used) 48- Driven Shaft 75- Spacer (2 Used)
22- Seat (2 Used) 49- Bearing Spacer (2 Used) 76- Drive Gear
23- Plug (2 Used) 50- Retaining Ring (2 Used) 77- Driven Gear
24- Needle Bearing (2 Used) 51- Backup Ring (2 Used) 78- Spacer
25- Valve Plate R 52- O-Ring (2 Used) 79- Retaining Ring
26- Valve Plate L 53- Stopper S (2 Used) 80- Front Casing
27- Cylinder Block (2 Used) 54- Servo Piston (2 Used) 81- O-Ring
W3-8-2-2
Group 8 Pump Device
Disassembly of Main Pump
dCAUTION:
(575 lb)
The pump assembly weight: 260 kg
IMPORTANT: Place a rubber plate or cloth on a

workbench in order not to damage the parts.
1. Secure pump casing (58) on a workbench
horizontally by using the screw hole (M10, Pitch 1.
5 mm, Depth 16 mm, 2 places) on the bottom of
pump casing (58).
W16J-02-04-004
a - Screw Hole
2. Remove plug (67). Drain oil from pump casing (58).

IMPORTANT: Put the mark on the removed regulator
when keeping in order not to confuse.
3. Remove two regulators of pump 1 and pump 2 from
pump casing (58). (Refer to W3-8-3-1.)
l : 6 mm
4. Remove the pilot pump from booster cover (7).
l : 8 mm
5. Remove socket bolts (96) (2 used) from cover (91).
Remove cover (95) from cover (91).
l : 5 mm
(2 used) from cover (91). Remove angle sensor (87)
from cover (91). Do not drop O-ring (88) and leaf
spring (92) when removing it.
W3-8-2-3
Group 8 Pump Device
7. Remove socket bolts (93) (2 used) from cover (91).

Remove cover (91) and O-ring (100) from pump
casing (58).
l : 6 mm
8. Remove socket bolts (8) (5 used). Remove booster
cover (7) and O-ring (6) from valve cover (1).
l : 8 mm
9. Remove booster (5) from driven shaft (48).
10. Remove socket bolts (11) (2 used). Remove cover
(10) and O-ring (9) from valve cover (1).
l : 8 mm
dCAUTION: Valve cover (1) weight: 60 kg (135 lb)

the bolt holes of valve cover (1). Attach nylon slings
onto the eyebolts. Hoist and hold valve cover (1).
12. Remove socket bolt (4), socket bolts (12) (2 used),
and socket bolts (13) (9 used) from valve cover (1).
Tap and remove valve cover (1) from pump casing
(58) by using a plastic hammer.
l : 17 mm
fNOTE: Spring pins (19) (2 used) and pins (98) (2 used)

are located between valve cover (1) and pump casing
(58). When the contacting part of valve cover (1) and
pump casing (58) is secured tight, tap and remove valve
cover (1) by using a plastic hammer.
IMPORTANT: Do not remove needle bearing (24)

unless necessary.
When it has been removed, replace it with the new
one.
13. Remove stoppers (20) (2 used), steel balls (21) (2
used), and seats (22) (2 used) from valve cover (1).
14. Remove seat packing (18) from pump casing (58).
W3-8-2-4
Group 8 Pump Device
15. Remove O-rings (15, 62, and 63) from pump casing
(58).
16. Remove valve plate (25) from drive shaft (47).
17. Remove valve plate (26) from driven shaft (48).
18. Remove the cylinder block (27) assemblies (2 used)
from drive shaft (47) and driven shaft (48) of pump
casing (58).
19. Remove plungers (32) (18 used), retainers (30) (2
used), spherical bushings (29) (2 used), and cylinder
springs (28) (18 used) from cylinder blocks (27) (2
used).
20. Remove the swash plate (34) assemblies (2 used)
from pump casing (58).
21. Remove shoe plates (33) (2 used) from swash plates
(34) (2 used).
IMPORTANT: Do not disassemble tilt pin (37)
assemblies and servo piston (54) unless necessary.
Do not turn nuts (2, 72) and set screws (3, 73). If
turning, the setting changes.
22. Remove socket bolts (70) (8 used). Remove servo
covers (71) (2 used), stoppers L (55) (2 used), and
stoppers S (53) (2 used) from pump casing (58).
l : 10 mm
IMPORTANT: Do not disassemble tilt pin (37) and
feedback pin (38) unless necessary.
When they have been disassembled, replace them
with the new ones.
fNOTE: THREEBOND #1305N has been applied on the
contacting part between tilt pin (37) assemblies and
servo piston (54).
23. Warm up tilt pin (37) assemblies (2 used) by using
a drier. Remove servo pistons (54) (2 used) from tilt
pin (37) assemblies (2 used).
l : 17 mm
W3-8-2-5
Group 8 Pump Device
24. Remove backup rings (57) (2 used) and O-rings (56)

(2 used) from stoppers L (55) (2 used).
25. Remove backup rings (51) (2 used) and O-rings (52)
(2 used) from stoppers S (53) (2 used).
26. Remove retaining ring (84) and front cover (83) from
front casing (80).
27. Remove oil seal (82) and O-ring (81) from front
cover (83).
dCAUTION: Front casing (80) weight: 32 kg (71 lb)

28. Install lifting tools to the engine mounting bolt
hole of front casing (80). Attach nylon slings onto
the lifting tools. Hoist and hold front casing (80).
Remove socket bolts (85) (11 used) from front
casing (80). Remove front casing (80) from pump
casing (58).
l : 10 mm
fNOTE: Spring pins (19) (2 used) and pins (98) (2 used)

are located between front casing (80) and pump casing
(58). When the contacting part of front casing (80) and
pump casing (58) is secured tight, tap and remove front
casing (80) by using a plastic hammer.
29. Remove retaining rings (74) (2 used), bearing
spacers (75) (2 used), and drive gear (76) from drive
shaft (47).
30. Remove retaining ring (79), bearing spacer (78), and
driven gear (77) from driven shaft (48).
31. Remove retaining rings (50) (2 used) and bearing
spacers (49) (2 used) from pump casing (58).
W3-8-2-6
Group 8 Pump Device
32. Tap the valve cover (1) end of drive shaft (47) by
using a plastic hammer and remove drive shaft (47)
toward the front casing (80) side from pump casing
(58).
33. Tap the valve cover (1) end of driven shaft (48) by
using a plastic hammer and remove driven shaft
(48) toward the front casing (80) side from pump
casing (58).
IMPORTANT: Do not remove roller bearings (31, 46)
unless necessary. Attach plates onto the outer ring
of roller bearings (31, 46) and push out them by
using a press.
When it has been removed, replace it with the new
one.
34. When replacing roller bearing (46) in drive shaft
(47), remove retaining ring (44) and bearing spacer
(45). Remove roller bearing (46) from drive shaft (47)
by using a press.
35. When replacing roller bearing (31) in driven shaft
(48), remove retaining rings (44) (2 used) and
bearing spacers (45) (2 used). Remove roller bearing
(31) from driven shaft (48) by using a press.
36. Remove socket bolts (69) (8 used). Remove swash
plate stands (42) (2 used) from pump casing (58).
l : 6 mm
W3-8-2-7
Group 8 Pump Device
Assembly of Main Pump
57, 56 54 34 38 37 64, 65 59 20 21
55
52, 51 2 3 17 4
70 36 53
72 16 22
15
73 62
71
98 63
85
69
Section X-X
10
11
62
43
19
66
16 42 60 29 28 33 30 68 67 27 32 18 13 23 16
35 40 41 86
80 44 45 31 67, 68 39
67, 68
78
58 98 60 26 5 6 8
79
48 7
50
77
76
81
84
82
19
47
83
74
75 24
46
49 25
18 45 44 35 86 1 14, 15 12
Section A-A
WJAC-03-09-002
W3-8-2-8
Group 8 Pump Device
88 97
96
95
87 92 89, 90 91 93 94
W16J-02-04-006
1- Valve Cover 28- Cylinder Spring (18 Used) 55- Stopper L (2 Used) 82- Oil Seal
2- Nut (2 Used) 29- Spherical Bushing (2 Used) 56- O-Ring (2 Used) 83- Front Cover
3- Set Screw (2 Used) 30- Retainer (2 Used) 57- Backup Ring (2 Used) 84- Retaining Ring
4- Socket Bolt (2 Used) 31- Roller Bearing 58- Pump Casing 85- Socket Bolt (11 Used)
5- Booster 32- Plunger (18 Used) 59- Eyebolt (2 Used) 86- A Sensor
6- O-Ring 33- Shoe Plate (2 Used) 60- Plug (20 Used) 87- Angle Sensor
7- Booster Cover 34- Swash Plate (2 Used) 62- O-Ring (5 Used) 88- O-Ring
8- Socket Bolt (5 Used) 35- Pin (2 Used) 63- O-Ring (2 Used) 89- Socket Bolt (2 Used)
9- O-Ring 36- Tilt Bushing (2 Used) 64- Name Plate 90- Washer (2 Used)
10- Cover 37- Tilt Pin (2 Used) 65- Rivet (2 Used) 91- Cover
11- Socket Bolt (2 Used) 38- Feedback Pin (2 Used) 66- Tapered Screw with Orifice (4 92- Leaf Spring
12- Socket Bolt (2 Used) 39- Bolt (2 Used) Used) 93- Socket Bolt (2 Used)
13- Socket Bolt (9 Used) 40- Feedback Lever (2 Used) 67- Plug (3 Used) 94- O-Ring
14- Plug (2 Used) 41- Pin (2 Used) 68- O-Ring (3 Used) 95- Cover
15- O-Ring (6 Used) 42- Swash Plate Stand (2 Used) 69- Socket Bolt (8 Used) 96- Socket Bolt (2 Used)
16- Plug (14 Used) 43- Pin (2 Used) 70- Socket Bolt (8 Used) 97- Feedback Shaft
17- Valve Plate Pin (2 Used) 44- Retaining Ring (3 Used) 71- Servo Cover (2 Used) 98- Pin (4 Used)
18- Seat Packing (2 Used) 45- Bearing Spacer (3 Used) 72- Nut (2 Used)
19- Spring Pin (4 Used) 46- Roller Bearing 73- Set Screw (2 Used)
20- Stopper 1 (2 Used) 47- Drive Shaft 74- Retaining Ring (2 Used)
21- Steel Ball (2 Used) 48- Driven Shaft 75- Spacer (2 Used)
22- Seat (2 Used) 49- Bearing Spacer (2 Used) 76- Drive Gear
23- Plug (2 Used) 50- Retaining Ring (2 Used) 77- Driven Gear
24- Needle Bearing (2 Used) 51- Backup Ring (2 Used) 78- Spacer
25- Valve Plate R 52- O-Ring (2 Used) 79- Retaining Ring
26- Valve Plate L 53- Stopper S (2 Used) 80- Front Casing
27- Cylinder Block (2 Used) 54- Servo Piston (2 Used) 81- O-Ring
W3-8-2-9
Group 8 Pump Device
Assembly of Main Pump 7. Install retaining ring (74), spacer (75), drive gear
(76), spacer (75), and retaining ring (74) to drive
IMPORTANT: Before assembling, apply hydraulic oil
shaft (47).
onto parts in order to prevent them from seizing.
Place a rubber plate or cloth on a workbench in
order not to damage the parts.
1. Secure pump casing (58) on a workbench
horizontally by using the screw hole (M10, Pitch 1.
5 mm, Depth 16 mm, 2 places) on the bottom of
pump casing (58).
W16J-02-04-004
a- Screw Hole
2. Apply THREEBOND #1305N onto the thread part of

3. Install swash plate stand (42) (2 used) to pump
casing (58) with socket bolts (69) (8 used).
l : 6 mm
m : 29 N·m (2.9 kgf·m, 21.5 lbf·ft)
dCAUTION:
hot.
Take care as roller bearing (46) is too
4. Warm up roller bearing (46) to 50 to 70 °C (122

to 158 °F) by using a heater. Install roller bearing
(46) to drive shaft (47) by using a bar and a plastic
hammer.
fNOTE: Check that roller bearing (46) is installed

completely.
5. Install bearing spacer (45) and retaining ring (44) to
drive shaft (47).
6. Install drive shaft (47) to pump casing (58) by using
a plastic hammer. Install bearing spacer (49) and
retaining ring (50) to pump casing (58).
W3-8-2-10
Group 8 Pump Device
8. Install retaining ring (44) and bearing spacer (45) to

driven shaft (48).
dCAUTION:
hot.
Take care as roller bearing (31) is too
9. Warm up roller bearing (31) to 50 to 70 °C (122 to

158 °F) by using a heater. Install roller bearing (31)
to driven shaft (48) by using a bar and a plastic
hammer.
fNOTE: Check that roller bearing (31) is installed

completely.
driven shaft (48).
11. Install driven shaft (48) to pump casing (58) by using
a plastic hammer.
pump casing (58).
13. Install driven gear (77), spacer (78), and retaining
ring (79) to driven shaft (48).
14. Install spring pins (19) (2 used) and pins (98) (2
used) to pump casing (58).
15. Apply grease onto the seat packing (18) mounting
surface of pump casing (58). Install seat packing (18)
to pump casing (58).
dCAUTION: Front casing (80) weight: 32 kg (71 lb)

16. Install lifting tools to the engine mounting bolt hole
of front casing (80). Attach nylon slings onto the
lifting tools. Hoist and hold front casing (80). Install
front casing (80) to pump casing (58) with socket
l : 10 mm
m : 98 N·m (9.8 kgf·m, 72 lbf·ft)

17. Apply grease onto the lip part in oil seal (82). Install
oil seal (82) to front cover (83) with the lip part
facing to the front cover (83) side.
18. Install O-ring (81), front cover (83), and retaining
ring (84) to front casing (80).
19. Install O-rings (52) (2 used) and backup rings (51) (2
used) to stoppers S (53) (2 used).
20. Install O-rings (56) (2 used) and backup rings (57) (2
used) to stoppers L (55) (2 used).
W3-8-2-11
Group 8 Pump Device
21. Apply THREEBOND #1305N onto the tilt pin (37)

assembly mounting position in servo pistons (54) (2
used).
IMPORTANT: Do not damage tilt pin (37) and
feedback pin (38).
22. Install servo pistons (54) (2 used) and tilt pin (37)
assemblies (2 used) to pump casing (58).
l : 17 mm
m : 480 N·m (48 kgf·m, 350 lbf·ft)

23. Install stoppers L (55) (2 used) and stoppers S (53) (2
used) to pump casing (58).
53 51
a
56
38
52
37 54
55
36 57
35
42
43
33
34 W16J-02-04-007
a - Tilt Pin assembly Mounting

Position
24. Install servo covers (71) (2 used) to pump casing (58)

l : 10 mm
m : 98 N·m (9.8 kgf·m, 72 lbf·ft)

25. Fit tilt bushing (36) of swash plate (34) to tilt pin
(37) assemblies. Install swash plate (34) to swash
plate stand (42). Check if swash plate (34) moves
smoothly.
W3-8-2-12
Group 8 Pump Device
26. Install shoe plates (33) (2 used) to swash plate (34).
95 88 96 97
40
39
a 41
87 92 89, 90 91 93 94
W16J-02-04-008
a - With the Mating Mark Facing b - Apply Grease (CENTOPLEX2

the Opposite of Lead Line Made by NOK) onto the
Mounting Portion of Leaf
Spring
27. Install O-ring (94) and cover (91) to pump casing

(58) with socket bolts (93) (2 used). Check that pin
(41) in the swash plate (34) of feedback lever (40)
end is installed in the groove on feedback shaft (97)
of A sensor (86).
l : 6 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

28. Install leaf spring (92) and O-ring (88) to cover (91).
Apply grease (CENTOPLEX2 made by NOK) onto leaf
spring (92) before installing angle sensor (87).
29. Install angle sensor (87) to cover (91) with washers
(90) (2 used) and socket bolts (89) (2 used).
l : 5 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

30. Install cover (95) to cover (91) with socket bolts (96)
(2 used).
l : 5 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-8-2-13
Group 8 Pump Device
31. Check that swash plate (34) is held together with

swash plate stand (42) and swash plate (34) is held
together with tilt pin (37) assemblies.
32. Install cylinder springs (28) (18 used), spherical
bushings (29) (2 used), retainers (30) (2 used), and
plungers (32) (18 used) to cylinder blocks (27) (2
used).
33. Fit the splines and install the cylinder block (27)
assemblies (2 used) to drive shaft (47) and driven
shaft (48).
IMPORTANT: The shapes of valve plates (25, 26) are
different.
34. Fit the valve plate pin (17) positions and install valve
plates (25, 26) to valve cover (1).
fNOTE: Install valve plate (25) to the drive shaft (47) side.
Install valve plate (26) to the driven shaft (48) side.
a a
25 26
W16J-02-04-015
a - Notch
35. Install seats (22) (2 used), steel balls (21) (2 used),

and stoppers (20) (2 used) to valve cover (1).
36. Install needle bearings (24) (2 used) to valve cover
(1).
37. Install O-rings (15, 62, and 63) and seat packing (18)
to pump casing (58).
W3-8-2-14
Group 8 Pump Device
dCAUTION: Valve cover (1) weight: 60 kg (135 lb)

38. Install the special tools to the ends of drive shaft
(47) and driven shaft (48).
148 mm
130.7 mm
φ387
φ34.5
97.7 mm
-0.075
0
+0.05
+0.15
R30
R2
R10
30 °
151 mm
133.7 mm
φ387
φ32
43.9 mm
+0.05
+0.15
-0.075
0
R30
R1
R10
30 °
W16J-02-04-009
39. Install spring pins (19) (2 used) and pins (48) (2

used) to valve cover (1). Tap and install valve cover
(1) to pump casing (58) by using a plastic hammer.
40. Install valve cover (1) to pump casing (58) with
socket bolt (4), socket bolts (12) (2 used), and socket
l : 17 mm
m : 630 N·m (63 kgf·m, 460 lbf·ft)

41. Install booster (5) to driven shaft (48). Install O-ring
(6) to booster cover (7). Install booster cover (7) to
valve cover (1) with socket bolts (8) (5 used).
l : 8 mm
m : 57 N·m (5.7 kgf·m, 42 lbf·ft)
W3-8-2-15
Group 8 Pump Device
42. Install O-ring (9) to valve cover (1). Install cover (10)
to valve cover (1) with socket bolts (11) (2 used).
l : 8 mm
m : 57 N·m (5.7 kgf·m, 42 lbf·ft)

43. Install two regulators of pump 1 and pump 2 to
pump casing (58) with the socket bolts (6 used).
Install feedback pin (38) of tilt pin (37) to the
feedback lever of the regulator at this time. (Refer to
W3-8-3-1.)
l : 6 mm
m : 29 N·m (2.9 kgf·m, 21.5 lbf·ft)

44. Install the pilot pump to booster cover (7) with the
spring washers (2 used) and socket bolts (2 used).
l : 8 mm
m : 49 N·m (4.9 kgf·m, 36 lbf·ft)
W3-8-2-16
Group 8 Pump Device
Disassembly of Regulator for Main Pump
7
6
5
4 8
3 9
2
34 26 1
33
28 32
31
30
11
10
27 29 13
26 14
5
18 15
19 16
20
25 21 17
22
11
23 W16J-02-04-002
24
1- Casing 10- Support Plug 20- Pilot Piston 29- Socket Bolt (2 Used)
2- Spring Seat 11- O-Ring (2 Used) 21- Sleeve 30- O-Ring (2 Used)
3- Pilot Spring 13- Pin 22- O-Ring 31- Seat
4- Adjusting Disc 14- O-Ring (5 Used) 23- Plug 32- Steel Ball
5- O-Ring (2 Used) 15- O-Ring 24- Socket Bolt (4 Used) 33- Stopper
6- Cover 16- Pin 25- Socket Bolt 34- Socket Bolt (6 Used)
7- Socket Bolt (4 Used) 17- Feedback Lever 26- Plug (9 Used)
8- Nut 18- Spool 27- Valve Casing
9- Adjusting Screw 19- Sleeve 28- Pump Control Solenoid Valve
W3-8-3-1
Group 8 Pump Device
Disassembly of Regulator for Main Pump

10. Remove adjusting disc (4) from casing (1) by using a
 The same type of regulators are installed to
bolt (M4). Remove O-ring (5) from adjusting disc (4).
pump 1 and pump 2. Do not confuse them as the
characteristics are different. The procedures for pump 1 11. Remove pilot spring (3) and spring seat (2) from
regulator are explained here. casing (1).
1. Remove socket bolts (34) (6 used). Remove the
12. Remove O-ring (30), seat (31), steel ball (32), and
regulator from the main pump.
stopper (33) from casing (1).
l : 6 mm
IMPORTANT: Do not remove pin (13) unless
necessary.
2. Remove O-rings (5, 14, and 15) from casing (1).
3. Remove socket bolts (29) (2 used). Remove pump
control solenoid valve (28) from valve casing (27).
l : 4 mm
4. Remove plug (23) from valve casing (27). Remove
O-ring (11) from plug (23).
l : 6 mm
5. Remove socket bolt (25) and socket bolts (24) (4
used). Remove valve casing (27) from casing (1).
l : 5 mm
IMPORTANT: Do not turn nut (8) and adjusting screw
(9). If turning, the setting changes.
6. Remove socket bolts (7) (4 used). Remove cover (6)
from casing (1).
l : 5 mm
7. Remove support plug (10) from casing (1). Remove
O-ring (11) from support plug (10).
l : 6 mm
IMPORTANT: Do not remove pin (16) unless
necessary.
8. Remove feedback lever (17) from casing (1).
9. Remove O-ring (22), sleeve (21), pilot piston (20),
spool (18), and sleeve (19) from casing (1).
W3-8-3-2
Group 8 Pump Device
Assembly of Regulator for Main Pump

Section A-A
29
16
34
10 26
1
30
11
15
17
A
27 26 31 32 33 28
2 4 3
25 9
11, 23
24
8
7
6
21
20
22
5 5
14
13
W16J-02-04-010
19 18 A
W3-8-3-3
Group 8 Pump Device
1- Casing 10- Support Plug 20- Pilot Piston 29- Socket Bolt (2 Used)
2- Spring Seat 11- O-Ring (2 Used) 21- Sleeve 30- O-Ring (2 Used)
3- Pilot Spring 13- Pin 22- O-Ring 31- Seat
4- Adjusting Disc 14- O-Ring (5 Used) 23- Plug 32- Steel Ball
5- O-Ring (2 Used) 15- O-Ring 24- Socket Bolt (4 Used) 33- Stopper
6- Cover 16- Pin 25- Socket Bolt 34- Socket Bolt (6 Used)
7- Socket Bolt (4 Used) 17- Feedback Lever 26- Plug (9 Used)
8- Nut 18- Spool 27- Valve Casing
9- Adjusting Screw 19- Sleeve 28- Pump Control Solenoid Valve
W3-8-3-4
Group 8 Pump Device
Assembly of Regulator for Main Pump 13. Install pump control solenoid valve (28) to valve
casing (27) with socket bolts (29) (2 used).
onto parts in order to prevent them from seizing. l : 4 mm
1. Install sleeve (19) and spool (18) to casing (1).
m : 7 N·m (0.7 kgf·m, 5.2 lbf·ft)
2. Fit and install pin (16) of feedback lever (17) to the
pin (16) hole on sleeve (19). 14. Install O-rings (5, 14, and 15) to casing (1).
3. Install O-ring (11) to support plug (10). 15. Install the regulator to the main pump with socket
4. Move feedback lever (17) so that the support plug
(10) hole on feedback lever (17) can be seen from l : 6 mm
the mounting hole on support plug (10). Install
support plug (10) to casing (1) while fitting support m : 29 N·m (2.9 kgf·m, 21.5 lbf·ft)
plug (10) to the support plug (10) hole on feedback
lever (17).
l : 6 mm
m : 36 N·m (3.6 kgf·m, 26.5 lbf·ft)

5. Install O-ring (5) to adjusting disc (4).
6. Install spring seat (2), pilot spring (3), and adjusting
disc (4) to casing (1).
7. Install cover (6) to casing (1) with socket bolts (7) (4
used).
l : 5 mm
m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)

8. Install stopper (33), steel ball (32), seat (31), and
O-ring (30) to casing (1).
9. Install sleeve (21), pilot piston (20), and O-ring (22)
to casing (1).
10. Install valve casing (27) to casing (1) with socket bolt
(25) and socket bolts (24) (4 used).
l : 5 mm
m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)

11. Install O-ring (11) to plug (23).
12. Install plug (23) to valve casing (27).
l : 6 mm
m : 16 N·m (1.6 kgf·m, 12 lbf·ft)
W3-8-3-5
Group 8 Pump Device
(Blank)
W3-8-3-6
Group 8 Pump Device
Structure of Pilot Pump
1
2
3
4
13
5 6
10
11
3
12
1
11
10
9
8
7
14
15
6
W137-02-04-034
W3-8-4-1
Group 8 Pump Device
Wrench Size Tightening Torque

No. Part Name Quantity Remark
(mm) N·m (kgf·m) (lbf·ft)
1 Bushing 4 Apply hydraulic oil when assembling.
2 Gear 1
3 Bushing 4 Apply hydraulic oil when assembling.
4 Knock Pin 2
5 Key 2
6 O-Ring 2 Apply grease when assembling.
7 Retaining Ring 1
Apply grease onto the lip part when
8 Oil Seal 1
assembling.
9 Flange 1
10 Backup Ring 2 Apply grease when assembling.
11 Seal 2 Apply grease when assembling.
12 Gear 1
13 Housing 1
14 Bolt 4 j : 17 35 (3.5) (26)
15 Cover 1
W3-8-4-2
Group 8 Pump Device
Structure of A Sensor
2 1 3 4 5 6 7 8 9
16 15 14, 13 12 11 10
W16J-02-04-006
a- With the Mating Mark Facing b- Apply Grease (CENTOPLEX2

the Opposite of Lead Line Made by NOK) onto the
Mounting Portion of Leaf
Spring
W3-8-5-1
Group 8 Pump Device

No. Part Name Quantity Remark
(mm) N·m (kgf·m) (lbf·ft)
1 Cover 1
2 Socket Bolt 2 l:5 10 (1) (7.4)
3 O-Ring 1
4 Feedback Shaft 1
5 Oil Seal 1
6 Retaining Ring 1
7 Ball Bearing 2
8 Spacer 1
9 Retaining Ring 1
10 O-Ring 1
11 Socket Bolt 2 l:6 30 (3) (22)
12 Cover 1
13 Washer 2
14 Socket Bolt 2 l:5 10 (1) (7.4)
Apply grease (CENTOPLEX2 Made
15 Leaf Spring 1
by NOK) when assembling.
16 Angle Sensor 1
W3-8-5-2
Removal and Installation of Control Valve
2, 3, 4 7, 8, 9 11
6 5 10 WJAC-03-07-001

Removal

(Refer to W1-4-1.)
j : 19 mm
j : 19 mm
j : 19 mm
(11).
j : 19 mm
W3-9-1-1
WJAC-03-09-006 WJAC-03-09-020

bracket (13).
j : 17 mm
bracket (15).
j : 17 mm
8. Place a container under control valve (64).
9. Remove signal control valve (20). (Refer to W3-13-1.)
10. Remove 2-spool solenoid valve unit (19). (Refer to
W3-12-3.)
11. Disconnect the both ends of hoses (16) (2 used).
j : 19 mm
j : 19 mm
j : 17 mm
W3-9-1-2
WJAC-03-09-005 WJAC-03-09-007
14. Remove bolts, washers (21) (4 used). Disconnect the

hose (22) assembly. Remove O-ring (23).
j : 19 mm
15. Remove bolts, washers (24) (4 used). Disconnect the
pipe (25) assembly. Remove O-ring (26).
j : 19 mm
16. Remove coupling (82). Disconnect the pipe (25)
assembly.
W3-9-1-3
117, 118 41 117, 118 38, 39
WJAC-03-09-008
40 WJAA-03-10-026
17. Remove bolt, washer (27). Remove clip (28). 25. Remove bolt, washer (38). Remove clip (39).
j : 17 mm j : 17 mm
18. Remove bolt, washer (29). Remove clip (30). 26. Remove bolts, washers (40) (2 used). Place the
bracket (41) assembly outside of the work area.
j : 17 mm
j : 19 mm
j : 17 mm
l : 12 mm
j : 36 mm
j : 17 mm
24. Remove bolts, washers (117) (2 used) and clips (118)
(2 used).
j : 17 mm
W3-9-1-4
53
55
WJAC-03-09-009 94, 95 54 WJAA-03-10-028
27. Remove socket bolts (42) (24 used) and flanges (43) 31. Remove bolts, washers (94) (2 used) and clips (95) (2
(12 used). Disconnect hoses (44) (6 used). Remove used).
O-rings (45) (6 used).
j : 17 mm
l : 12 mm
32. Remove bolts, washers (53, 54) (2 used for each).
28. Remove bolt (46), spring washer (47), and nut (48). Remove bracket (55).
Remove clamps (49) (2 used).
j : 19 mm
j : 19 mm
29. Remove socket bolts (83) (8 used). Disconnect the
pipe (50, 51) assemblies. Remove O-rings (85) (2
used).
l : 12 mm
j : 17 mm
W3-9-1-5
WJAC-03-09-010 WJAC-03-09-011

bracket (57).
j : 19 mm
(12 used). Disconnect hoses (60) (6 used). Remove
O-rings (61) (6 used).
l : 12 mm
j : 17 mm
W3-9-1-6
WJAC-03-08-030 WJAC-03-09-021
119
36. Open cover (119).

j : 17 mm
j : 27 mm
39. Remove bolt, washer (103) and clip (104).
j : 17 mm
WJAC-03-09-024
W3-9-1-7
96
WJAA-03-07-002 99 WJAC-03-09-022
97

dDo
(96).
j : 19 mm
W3-9-1-8
64
100, 101 WJAC-03-09-023 a - Lifting Hole WJAA-03-10-032
42. Remove bolts, washers (100) (2 used) and clips (101)

(2 used).
j : 17 mm
dweight:
CAUTION: The control valve (64) assembly
490 kg (1090 lb)
lifting holes (a) (2 places) of control valve (64).
Attach nylon slings onto the eyebolts (2 used). Hoist
and hold the control valve (64) assembly.
W3-9-1-9
92, 93 64
92, 93 91, 93
91, 93 WJAC-03-09-014 WJAC-03-09-013

used).
j : 30 mm
45. Remove bolts (92) (2 used) and spacers (93) (2
used). Place the control valve (64) assembly on a
workbench.

used).
j : 30 mm
W3-9-1-10
WJAC-03-09-026
WJAC-03-09-025
j : 17 mm
j : 19 mm
48. Disconnect the both ends of hose (106).
j : 17 mm
W3-9-1-11
WJAC-03-09-027 WJAC-03-09-028
j : 17 mm
j : 19 mm
j : 19 mm
j : 17 mm
W3-9-1-12
114 115
64
WJAA-03-10-032
WJAC-03-09-029 a- Lifting Hole

116 112, 113
dCAUTION:
lb)
Control valve (64) weight: 430 kg (950

and hold control valve (64).
55. Remove bolts (112) (4 used) and spacers (113) (4
used). Remove control valve (64) from brackets (114,
115).
fNOTE: LOCTITE #262 has been applied on bolt (112).

j : 30 mm
56. Remove the adapter with control valve (64)
W3-9-1-13
114 115
64
WJAA-03-10-032
WJAC-03-09-029 a- Lifting Hole

116 112, 113
Installation
1. Install all removed adapters to control valve (64).
dCAUTION:
lb)
Control valve (64) weight: 430 kg (950

and hold control valve (64).
control valve (64) to brackets (114, 115) with spacers
(113) (4 used) and bolts (112) (4 used).
j : 30 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft)

W3-9-1-14
WJAC-03-09-027 WJAC-03-09-028
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

7. Connect the both ends of hoses (109) (3 used).
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

8. Connect the both ends of hoses (108) (3 used).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
W3-9-1-15
WJAC-03-09-026
WJAC-03-09-025
9. Connect the both ends of hose (106).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
W3-9-1-16
92, 93 64
92, 93 91, 93
91, 93 WJAC-03-09-014 WJAC-03-09-013
dweight:
CAUTION: The control valve (64) assembly
490 kg (1090 lb)
a

the control valve (64) assembly.
the control valve (64) assembly with spacers (93) (2
used) and bolts (92) (2 used).
j : 30 mm 64
m : 400 N·m (40 kgf·m, 300 lbf·ft)

spacers (93) (4 used) and bolts (91) (4 used).
WJAA-03-10-032
j : 30 mm
a- Lifting Hole
m : 400 N·m (40 kgf·m, 300 lbf·ft)
W3-9-1-17
100, 101 WJAC-03-09-023 99 WJAC-03-09-022
15. Install bolts, washers (100) (2 used) and clips (101) (2

used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-9-1-18
WJAC-03-08-030 WJAC-03-09-021
119
17. Install clip (104) and bolt, washer (103).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 27 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)

j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

WJAC-03-09-024
W3-9-1-19
WJAC-03-09-010 WJAC-03-09-011
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

22. Install O-rings (61) (6 used) to hoses (60) (6 used).
Connect hoses (60) (6 used) with flanges (59) (12
used) and socket bolts (58) (24 used).
l : 12 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-9-1-20
53
55
WJAC-03-09-009 94, 95 54 WJAA-03-10-028
24. Install bracket (55) with bolt, washer (53, 54) (2 used 28. Install clamps (49) (2 used) with nut (48), spring
for each). washer (47), and bolt (46).
j : 19 mm j : 19 mm

25. Install clips (95) (2 used) with bolts, washers (94) (2 29. Install O-rings (45) (6 used) to hoses (44) (6 used).
used). Connect hoses (44) (6 used) with flanges (43) (12
j : 17 mm
l : 12 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 140 N·m (14 kgf·m, 103 lbf·ft)
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

27. Install O-rings (85) (2 used) to the pipe (50, 51)
assemblies. Connect the pipe (50, 51) assemblies
l : 12 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)
W3-9-1-21
117, 118 41 117, 118 38, 39
WJAC-03-09-008 40 WJAA-03-10-026
30. Install the bracket (41) assembly with bolts, washers 36. Connect connectors (31) (3 used).
(40) (2 used).
j : 19 mm
j : 17 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
32. Install clips (118) (2 used) and bolts, washers (117) (2
used).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

j : 36 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)

used).
l : 12 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)
W3-9-1-22
WJAC-03-09-005 WJAC-03-09-007
40. Connect the pipe (25) assembly with coupling (82).

41. Install O-ring (26) to the pipe (25) assembly. Install
the pipe (25) assembly with bolts, washers (24) (4
used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

42. Install O-ring (23) to the hose (22) assembly. Install
the hose (22) assembly with bolts, washers (21) (4
used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-9-1-23
WJAC-03-09-006 WJAC-03-09-004
43. Connect hose (18). 45. Connect the both ends of hoses (16) (2 used).
j : 17 mm j : 19 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft) m : 30 N·m (3 kgf·m, 22 lbf·ft)

44. Connect hoses (17) (4 used). 46. Install 2-spool solenoid valve unit (19). (Refer to W3-
12-3.)
j : 19 mm
47. Install signal control valve (20). (Refer to W3-13-1.)
m : 30 N·m (3 kgf·m, 22 lbf·ft)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-9-1-24
2, 3, 4 7, 8, 9 11 96
6 5 10 WJAC-03-07-001 WJAA-03-07-002
97

4-1.)
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

washer (2).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-9-1-25
(Blank)
W3-9-1-26
Disassembly and Assembly of Valve Unit
WJAA-03-10-020
W3-9-2-1
13
WJAA-03-10-021
W3-9-2-2
View A
54
55
55
56
56
53
56
55
55
WJAA-03-10-019
54 41
W3-9-2-3
1- Housing 33- Plug (4 Used) 65- Cap (2 Used) 96- Flow Rate Control Valve (2
2- Spool 34- Cover (2 Used) 66- Cap (2 Used) Used)
3- Spool 35- Socket Bolt (4 Used) 67- O-Ring (5 Used) 97- Socket Bolt (12 Used)
4- Spool 36- Flange (5 Used) 68- Spring (2 Used) 98- Spring (3 Used)
5- Spool 37- O-Ring (5 Used) 69- Spool (2 Used) 99- Piston (3 Used)
6- Spool (2 Used) 38- Socket Bolt (20 Used) 70- Cap 100- Check Valve (3 Used)
7- Cap (2 Used) 39- Check Valve 71- Cap 101- Poppet
8- Backup Ring (2 Used) 40- Overload Relief Valve (6 Used) 72- Check Valve (2 Used) 102- Poppet
9- O-Ring (2 Used) 41- O-Ring (14 Used) 73- Cap (2 Used) 103- Check Valve
10- Spacer (2 Used) 42- Backup Ring (10 Used) 74- Check Valve (2 Used) 104- Piston
11- Spring (2 Used) 43- O-Ring (10 Used) 75- Cap 105- Cap
12- Check Valve (2 Used) 44- Cap (2 Used) 76- Sleeve (2 Used) 106- Backup Ring
13- Housing 45- O-Ring (4 Used) 77- Piston (2 Used) 107- O-Ring
14- Spool 46- Cap (2 Used) 78- O-Ring (2 Used) 108- Check Valve
15- Spool 47- Backup Ring (7 Used) 79- Backup Ring (2 Used) 109- Spring
16- Spool 48- Spring (10 Used) 80- Spool (2 Used) 110- Check Valve
17- Cap 49- Check Valve (7 Used) 81- Spring 111- Arm Rod Anti-Drift Valve
18- Spring 50- Socket Bolt (8 Used) 82- O-Ring (3 Used) 112- Flow Rate Control Valve
19- O-Ring (13 Used) 51- Washer (14 Used) 83- Spring Guide (2 Used) Assembly
20- Spacer 52- Socket Bolt (6 Used) 84- Sleeve 113- Socket Bolt (6 Used)
21- Spool 53- O-Ring 85- O-Ring (2 Used) 114- Piston
22- Main Relief Valve 54- O-Ring (2 Used) 86- Cap (2 Used) 115- Cap
23- Cover 55- O-Ring (5 Used) 87- Boom 2 Anti-Drift Valve 116- Backup Ring
24- O-Ring (18 Used) 56- O-Ring (6 Used) 88- Socket Bolt (5 Used) 117- O-Ring
25- Spring Guide (18 Used) 57- Boom Overload Relief Valve 89- Spring (3 Used) 118- Spring
26- Spring (9 Used) 58- Cap (2 Used) 90- Poppet (3 Used) 119- Check Valve
27- Cap (9 Used) 59- Cap (2 Used) 91- O-Ring (2 Used) 120- Poppet
28- Cover 60- O-Ring (12 Used) 92- Spring 121- Spring
29- Cover 61- O-Ring (4 Used) 93- Sleeve 122- Cap
30- Cap (8 Used) 62- Backup Ring (5 Used) 94- O-Ring (3 Used) 123- Cap
31- O-Ring (11 Used) 63- Cap 95- Flow Rate Control Valve 124- Spool
32- Socket Bolt (26 Used) 64- Piston (2 Used) 125- Auxiliary Flow Combiner Valve
a Load Check Valve f Check Valve k Load Check Valve p Load Check Valve
b Arm Regeneration Cut Valve g Bypass Shut-Out Valve l Check Valve q Bypass Shut-Out Valve
c Bucket Regeneration Cut Valve h Load Check Valve m Check Valve
d Check Valve i Load Check Valve n Check Valve
e Flow Combiner Valve j Boost Check Valve o Load Check Valve
W3-9-2-4
Disassembly of Housing Assembly of Housing

1. Remove socket bolt (50) and washer (51) from IMPORTANT: Before assembling, apply hydraulic oil
housing (1). onto parts in order to prevent them from seizing.
1. Install O-rings (41) (2 used), O-ring (53), O-rings (54)
l : 14 mm
(2 used), O-rings (55) (5 used), and O-rings (56) (6
2. Remove socket bolts (50) (7 used), socket bolts (52) used) to housing (1).
(6 used), and washers (51) (13 used) from housing
2. Install housing (13) to housing (1) with socket bolts
(13).
(50) (7 used), socket bolts (52) (6 used), and washers
l : 14 mm (51) (13 used).
3. Remove housing (13) from housing (1). l : 14 mm
4. Remove O-rings (41) (2 used), O-ring (53), O-rings m : 250 N·m (25 kgf·m, 185 lbf·ft)
(54) (2 used), O-rings (55) (5 used), and O-rings (56)
(6 used) from housing (1). 3. Install washer (51) and socket bolt (50) to housing
(1).
l : 14 mm
m : 250 N·m (25 kgf·m, 185 lbf·ft)
W3-9-2-5
(Blank)
W3-9-2-6
Disassembly of Control Valve (4-Spool Side)
e d
c
WJAA-03-10-003
W3-9-3-1
13
WJAA-03-10-004
W3-9-3-2
4- Spool 36- flange (5 Used) 68- Spring (2 Used) 98- Spring (3 Used)
W3-9-3-3
Disassembly of Control Valve (4-Spool Side) Disassembly of Check Valve (39)

Disassembly of Spools (6, 14, 15, and 16) IMPORTANT: Do not disassemble check valve (39)
unless necessary.
(28) and O-rings (24) (4 used) from housing (13). 8. Remove check valve (39) from housing (13).
l : 10 mm j : 41 mm
2. Remove socket bolts (32) (3 used) and socket bolts 9. Remove O-rings (41, 43) and backup ring (42) from
(35) (2 used). Remove cover (34) and O-rings (24) (3 check valve (39).
used) from housing (13). Disassembly of Main Relief Valve (22)
l : 10 mm IMPORTANT: As the setting changes, do not
disassemble the relief valve. If the relief valve is
disassembled, pressure should be adjusted. (Refer
(23) and O-ring (24) from housing (13).
to TROUBLESHOOTING / Operational Performance
l : 10 mm Test in the separated volume, T/M.)
10. Remove main relief valve (22) from housing (13).
4. Put the matching marks on housing (13) and spools
(6, 14, 15, and 16). j : 41 mm
IMPORTANT: Do not disassemble spools (6, 14, 15, 11. Remove O-ring (19) from main relief valve (22).
and 16) unless necessary.
5. Remove spools (6, 14, 15, and 16) from housing (13).
Disassembly of Boom Overload Relief Valve (57)
IMPORTANT: As the setting changes, do not
Test in the separated volume, T/M.)
6. Remove boom overload relief valve (57) from
housing (13).
j : 41 mm
7. Remove O-rings (41, 43), and backup ring (42) from
boom overload relief valve (57).
W3-9-3-4
Disassembly of Overload Relief Valve (40) Disassembly of Bucket Regeneration Cut Valve (c)
IMPORTANT: As the setting changes, do not 22. Remove sleeve (84) from housing (13).
disassembled, pressure should be adjusted. (Refer j : 36 mm
to TROUBLESHOOTING / Operational Performance 23. Remove sleeve (76), spool (80), spring (81), and
Test in the separated volume, T/M.) spring guide (83) from housing (13).
12. Remove overload relief valves (40) (3 used) from
24. Remove piston (77), backup ring (79), and O-ring
housing (13).
(78) from sleeve (76).
j : 41 mm 25. Remove O-ring (82) and cap (86) from sleeve (84).
13. Remove O-rings (41, 43) (3 used for each) and
l : 12 mm
backup rings (42) (3 used) from overload relief
valves (40) (3 used). 26. Remove O-ring (85) from cap (86).
Disassembly of Load Check Valve (a)
14. Remove cap (123) from housing (13).
l : 14 mm
15. Remove spring (48) and check valve (49) from
housing (13).
16. Remove O-rings (61, 19) and backup ring (62) from
cap (123).
Disassembly of Arm Regeneration Cut Valve (b)
17. Remove sleeve (93) from housing (13).
j : 36 mm
18. Remove sleeve (76), spool (80), spring (92), and
spring guide (83) from housing (13).
19. Remove piston (77), backup ring (79), and O-ring
(78) from sleeve (76).
20. Remove O-ring (82) and cap (86) from sleeve (93).
l : 12 mm
21. Remove O-ring (85) from cap (86).
W3-9-3-5
Disassembly of Check Valve (d)

j : 14 mm
28. Remove check valve (49) and spring (48) from
housing (13).
cap (63).
Disassembly of Flow Combiner Valve (e)
j : 46 mm
31. Remove spring (18) spacer (20), and spool (21) from
housing (13).
Disassembly of Check Valve (f)

l : 14 mm
housing (13).
35. Remove O-ring (19) and backup ring (47) from cap
(46).
l : 17 mm
W3-9-3-6
Disassembly of Flow Rate Control Valve (95) Disassembly of Bypass Shut-Out Valve (g)
IMPORTANT: Do not disassemble flow rate control 45. Remove cap (65) from housing (13).
valve (95) unless necessary.
j : 46 mm
38. Remove socket bolts (97) (4 used). Remove flow rate
control valve (95) from housing (13). 46. Remove spool (69) and spring (68) from housing
(13).
l : 12 mm
47. Remove piston (64), cap (66), and O-ring (67) from
39. Remove piston (99), spring (98), check valve (100), cap (65).
and poppet (101) from housing (13).
j : 46 mm
40. Remove O-rings (60, 94) from flow rate control valve
(95). 48. Remove O-ring (67) from cap (66).
Disassembly of Flow Rate Control Valve Assembly
(112) Disassembly of Load Check Valve (h)
valve assembly (112) unless necessary.
l : 14 mm
41. Remove socket bolts (113) (6 used). Remove flow
rate control valve assembly (112) from housing (13). 50. Remove spring (48) and check valve (74) from
housing (13).
l : 12 mm
42. Remove spring (89) and poppet (90) from housing (73).
(13).
43. Remove piston (99), spring (98), check valve (100),
and piston (114) from housing (13).
44. Remove O-rings (60) (4 used) and O-rings (91, 94)
from flow rate control valve assembly (112).
W3-9-3-7
l : 14 mm
(70).
54. Remove socket bolts (38) (8 used).
l : 12 mm
55. Remove flanges (36) (2 used) from housing (13).
56. Remove O-rings (37) (2 used) from flanges (36) (2
used).
j : 46 mm
W3-9-3-8
Assembly of Control Valve (4-Spool Side)

13 A 97 113 35 32
B
C
32 32
TJAA-03-03-006
Section A Section C
13 24 28
40
H
41
42,43 b
14
94
15
95 101
34 16
24 49
6 61,62
23 99 48
24
98 19
100
TJAA-03-03-041 a 23 WJAA-03-10-006
Section B Section D
39
60 89 90
41
36 42,43
38 91
37
112 114
66 g 94
67
42,43
99
41
98
65 67 64 68 69 WJAA-03-10-005 100
57
WJAA-03-10-007
W3-9-3-9
Section E Section H (Arm Regeneration Cut Valve (b))

40
I 86 85
41
42,43 c
74
93 83
48
92
73 82
h 80
47,19
77 78,79
76
42,43
41
WJAA-03-10-009
40
WJAA-03-10-008
Section F Section I (Bucket Regeneration Cut Valve (c))
86 85
84 83
70 81
82
80
77 78, 79
47,19 76
WJAA-03-10-010 WJAA-03-10-009
58 45
Section G
19 63 d 22
19
48
62,61
49
44 21
45
49 20
48 19
47,19 18
WJAA-03-10-011
46 f 17 e
W3-9-3-10
W3-9-3-11
Assembly of Control Valve (4-Spool Side) Assembly of Bypass Shut-Out Valve (g)
IMPORTANT: Before assembling, apply hydraulic oil 9. Install O-ring (67) to cap (66).
10. Install O-ring (67), cap (66), and piston (64) to cap
1. Install O-ring (45) to cap (44). (65).
Install cap (44) to housing (13).
j : 46 mm
j : 46 mm
m : 250 N·m (25 kgf·m, 185 lbf·ft)
m : 250 N·m (25 kgf·m, 185 lbf·ft)
11. Install spring (68) and spool (69) to housing (13).
2. Install O-rings (37) (2 used) to flanges (36) (2 used).
12. Install cap (65) to housing (13).
3. Install flanges (36) (2 used) to housing (13) with
socket bolts (38) (8 used). j : 46 mm
l : 12 mm m : 250 N·m (25 kgf·m, 185 lbf·ft)
m : 140 N·m (14 kgf·m, 103 lbf·ft)

Assembly of Flow Rate Control Valve Assembly
4. Install backup ring (47) and O-ring (19) to cap (70). (112)
5. Install cap (70) to housing (13). 13. Install O-rings (91, 94) and O-rings (60) (4 used) to
flow rate control valve assembly (112).
l : 14 mm
14. Install piston (114), check valve (100), spring (98),
m : 350 N·m (35 kgf·m, 260 lbf·ft) and piston (99) to housing (13).
15. Install poppet (90) and spring (89) to housing (13).
Assembly of Load Check Valve (h)
16. Install flow rate control valve assembly (112) to
6. Install backup ring (47) and O-ring (19) to cap (73). housing (13) with socket bolts (113) (6 used).
7. Install check valve (74) and spring (48) to housing
(13).
l : 14 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
W3-9-3-12
Assembly of Flow Rate Control Valve (95) Assembly of Check Valve (d)
17. Install O-rings (60, 94) to flow rate control valve (95). 28. Install backup ring (62) and O-rings (61, 19) to cap
(63).
18. Install poppet (101), check valve (100), spring (98),
and piston (99) to housing (13). 29. Install spring (48) and check valve (49) to housing
(13).
19. Install flow rate control valve (95) to housing (13)
with socket bolts (97) (4 used). 30. Install cap (63) to housing (13).
l : 12 mm l : 14 mm
20. Install O-ring (45) to cap (58).
Assembly of Bucket Regeneration Cut Valve (c)
l : 17 mm
32. Install cap (86) and O-ring (82) to sleeve (84).
m : 400 N·m (40 kgf·m, 300 lbf·ft)
l : 12 mm
Assembly of Check Valve (f) m : 180 N·m (18 kgf·m, 133 lbf·ft)
22. Install backup ring (47) and O-ring (19) to cap (46). 33. Install O-ring (78), backup ring (79), and piston (77)
to sleeve (76).
(13). 34. Install spring guide (83), spring (81), spool (80), and
sleeve (76) to sleeve (84).
35. Install sleeve (84) to housing (13).
l : 14 mm
j : 36 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
Assembly of Flow Combiner Valve (e)
26. Install spool (21), spacer (20), and spring (18) to
housing (13).
j : 46 mm
m : 250 N·m (25 kgf·m, 185 lbf·ft)
W3-9-3-13
Assembly of Arm Regeneration Cut Valve (b) Assembly of Overload Relief Valve (40)
36. Install O-ring (85) to cap (86). IMPORTANT: As the setting changes, do not
37. Install cap (86) and O-ring (82) to sleeve (93).
l : 12 mm to TROUBLESHOOTING / Operational Performance
m : 180 N·m (18 kgf·m, 133 lbf·ft) 44. Install backup rings (42) (3 used) and O-rings (41,
38. Install O-ring (78), backup ring (79), and piston (77) 43) (3 used for each) to overload relief valves (40) (3
to sleeve (76). used).
39. Install spring guide (83), spring (92), spool (80), and 45. Install overload relief valves (40) (3 used) to housing
sleeve (76) to sleeve (93). (13).
40. Install sleeve (93) to housing (13). j : 41 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
Assembly of Main Relief Valve (22)
Assembly of Load Check Valve (a) IMPORTANT: As the setting changes, do not
41. Install backup ring (62) and O-rings (61, 19) to cap disassembled, pressure should be adjusted. (Refer
(123). to TROUBLESHOOTING / Operational Performance
42. Install check valve (49) and spring (48) to housing Test in the separated volume, T/M.)
(13). 46. Install O-ring (19) to main relief valve (22).
43. Install cap (123) to housing (13). 47. Install main relief valve (22) to housing (13).
l : 14 mm j : 41 mm
W3-9-3-14
Assembly of Check Valve (39) Assembly of Spools (6, 14, 15, and 16)
48. Install backup ring (42) and O-rings (41, 43) to check 52. Fit the matching marks made when disassembling
valve (39). and install spools (6, 14, 15, and 16) to housing (13).
49. Install check valve (39) to housing (13). 53. Install O-ring (24) and cover (23) to housing (13)
j : 41 mm
l : 10 mm
m : 100 N·m (10 kgf·m, 74 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
Assembly of Boom Overload Relief Valve (57)
54. Install O-rings (24) (3 used) and cover (34) to
housing (13) with socket bolts (32) (3 used) and
to TROUBLESHOOTING / Operational Performance l : 10 mm
50. Install backup ring (42) and O-rings (41, 43) to boom m : 90 N·m (9 kgf·m, 66 lbf·ft)
overload relief valve (57). 55. Install O-rings (24) (4 used) and cover (28) to
51. Install boom overload relief valve (57) to housing housing (13) with socket bolts (32) (6 used).
(13).
l : 10 mm
j : 41 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
m : 100 N·m (10 kgf·m, 74 lbf·ft)
W3-9-3-15
(Blank)
W3-9-3-16
Disassembly of Control Valve (5-Spool Side)
i j k
WJAA-03-10-001
W3-9-4-1
WJAA-03-10-002
W3-9-4-2
W3-9-4-3
Disassembly of Control Valve (5-Spool Side) Disassembly of Auxiliary Flow Combiner Valve (125)
Disassembly of Spools (2, 3, 4, 5, and 6) 8. Remove auxiliary flow combiner valve (125) from
housing (1).
(29) and O-rings (24) (5 used) from housing (1). j : 32 mm
l : 10 mm 9. Remove O-ring (19) from auxiliary flow combiner
valve (125).
2. Remove socket bolts (32) (3 used) and socket bolts
(35) (2 used). Remove cover (34) and O-rings (24) (3
used) from housing (1). Disassembly of Boom 2 Anti-Drift Valve (87)
l : 10 mm IMPORTANT: Do not disassemble boom 2 anti-drift

valve (87) unless necessary.
3. Remove socket bolts (32) (4 used). Remove covers
10. Remove socket bolts (88) (4 used). Remove boom 2
(23) (2 used) and O-rings (24) (2 used) from housing
anti-drift valve (87) from housing (1).
(1).
l : 12 mm
l : 10 mm
11. Remove spring (89) and poppet (90) from housing
4. Put the matching marks on housing (1) and spools
(1).
(2, 3, 4, 5, and 6).
12. Remove O-ring (91) and O-rings (60) (2 used) from
IMPORTANT: Do not disassemble spools (2, 3, 4, 5,
boom 2 anti-drift valve (87).
and 6) unless necessary.
5. Remove spools (2, 3, 4, 5, and 6) from housing (1).
Disassembly of Overload Relief Valve (40)

6. Remove overload relief valves (40) (5 used) from
housing (1).
j : 41 mm
7. Remove O-rings (41, 43) (5 used for each) and
backup rings (42) (5 used) from overload relief
valves (40) (5 used).
W3-9-4-4
Disassembly of Load Check Valve (i) Disassembly of Check Valve (l)

13. Remove cap (105) from housing (1). 22. Remove cap (115) from housing (1).
l : 14 mm l : 10 mm
14. Remove check valve (108), spring (109), and check 23. Remove spring (118) and check valve (119) from
valve (110) from housing (1). housing (1).
15. Remove backup ring (62), O-ring (61), backup ring 24. Remove O-ring (117) and backup ring (116) from
(62), O-ring (107), backup ring (106), and O-ring (82) cap (115).
from cap (105).
Disassembly of Check Valve (m)
Disassembly of Boost Check Valve (j)
l : 14 mm
j : 36 mm
17. Remove spring (121) and poppet (120) from housing (1).
housing (1).
18. Remove O-ring (67) from cap (122). (46).
Disassembly of Load Check Valve (k)
l : 17 mm
l : 14 mm
housing (1).
cap (124).
W3-9-4-5
Disassembly of Arm Rod Anti-Drift Valve (111) Disassembly of Flow Rate Control Valve (96b)
IMPORTANT: Do not disassemble arm rod anti-drift IMPORTANT: Do not disassemble flow rate control
valve (111) unless necessary. valve (96b) unless necessary.
30. Remove socket bolts (88) (4 used). Remove arm rod 36. Remove socket bolts (97) (4 used). Remove another
anti-drift valve (111) from housing (1). flow rate control valve (96b) from housing (1).
l : 12 mm l : 12 mm
31. Remove spring (89) and poppet (90) from housing 37. Remove piston (99), spring (98), check valve (100),
(1). and poppet (102) from housing (1).
32. Remove O-ring (91) and O-rings (60) (3 used) from 38. Remove O-rings (60, 94) from flow rate control valve
arm rod anti-drift valve (111). (96b).
Disassembly of Flow Rate Control Valve (96a) Disassembly of Check Valve (n)
valve (96a) unless necessary.
l : 14 mm
33. Remove socket bolts (97) (4 used). Remove flow rate
control valve (96a) from housing (1). 40. Remove spring (48) and check valve (74) from
housing (1).
l : 12 mm
34. Remove piston (104), spring (48), and check valve (73).
(103) from housing (1).
35. Remove O-rings (60, 94) from flow rate control valve Disassembly of Load Check Valve (o)
(96a).
l : 14 mm
43. Remove check valve (72), spring (48), and check
valve (49) from housing (1).
(75).
W3-9-4-6
Disassembly of Load Check Valve (p)

l : 14 mm
46. Remove check valve (72), spring (48), and check
valve (49) from housing (1).
(71).
Disassembly of Bypass Shut-Out Valve (q)

j : 46 mm
49. Remove spool (69) and spring (68) from housing (1).
50. Remove piston (64), cap (66), and O-ring (67) from
cap (65).
j : 46 mm
j : 46 mm
54. Remove socket bolts (38) (12 used).
l : 12 mm
55. Remove flanges (36) (3 used) from housing (1).
Remove O-rings (37) (3 used) from flanges (36) (3
used).
W3-9-4-7
Assembly of Control Valve (5-Spool Side)
32 J 1 88 44,45 97 45,58
N
O
P
88 TJAA-03-03-007
Section J Section L
29 24 1
89
24
2 23 60
111
24
91
3 94
34 90 60
4 96b
5 102
100
24 99
19
6 23
125
42,43
41
98 40 WJAA-03-10-013
TJAA-03-03-010
Section K Section M
j 122 60 87
k 40
67
41 121
19 42,43 120
n 91
124 74 89
90
61,62 94 73
19,47
96a l
48 119 38
49 118
116,117 37
60 36
42,43
41
103 48 104 WJAA-03-10-012 115 48 40 WJAA-03-10-014
W3-9-4-8
Section N
40
41
42,43
37
48 36
Q
38
o 19,47
75
38
37
49
36
42,43
41 TJAA-03-03-017
72 40 WJAA-03-10-015
Section O Section Q
i
19
82 107,106 m
105 62,61,62
46
108
19,47
109 71
110
47 48 49 T450-03-03-008
p
49 48 72 WJAA-03-10-016
Section P
q 67
66
64
69 68 67 65 WJAA-03-10-017
W3-9-4-9
W3-9-4-10
Assembly of Control Valve (5-Spool Side) Assembly of Load Check Valve (o)
IMPORTANT: Before assembling, apply hydraulic oil 12. Install backup ring (47) and O-ring (19) to cap (75).
13. Install check valve (49), spring (48), and check valve
1. Install O-rings (37) (3 used) to flanges (36) (3 used). (72) to housing (1).
2. Install flanges (36) (3 used) to housing (1) with 14. Install cap (75) to housing (1).
l : 14 mm
l : 12 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
m : 140 N·m (14 kgf·m, 103 lbf·ft)
3. Install O-ring (45) to cap (44). Assembly of Check Valve (n)
4. Install cap (44) to housing (1). 15. Install backup ring (47) and O-ring (19) to cap (73).
j : 46 mm 16. Install check valve (74) and spring (48) to housing
(1).
m : 250 N·m (25 kgf·m, 185 lbf·ft)
Assembly of Bypass Shut-Out Valve (q) l : 14 mm

5. Install O-ring (67) to cap (66). m : 350 N·m (35 kgf·m, 260 lbf·ft)
6. Install O-ring (67), cap (66), and piston (64) to cap
(65).
7. Install spring (68) and spool (69) to housing (1).
j : 46 mm
m : 250 N·m (25 kgf·m, 185 lbf·ft)
Assembly of Load Check Valve (p)

9. Install backup ring (47) and O-ring (19) to cap (71).
10. Install check valve (49), spring (48), and check valve
(72) to housing (1).
l : 14 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
W3-9-4-11
Assembly of Flow Rate Control Valve (96b) 27. Install O-ring (45) to cap (58).
18. Install O-rings (60, 94) to flow rate control valve 28. Install cap (58) to housing (1).
(96b).
l : 17 mm
19. Install poppet (102), check valve (100), spring (98),
and piston (99) to housing (1). m : 400 N·m (40 kgf·m, 300 lbf·ft)
20. Install flow rate control valve (96b) to housing (1)
with socket bolts (97) (4 used). Assembly of Check Valve (m)
l : 12 mm 29. Install backup ring (47) and O-ring (19) to cap (46).
m : 140 N·m (14 kgf·m, 103 lbf·ft)
(1).
Assembly of Flow Rate Control Valve (96a)
21. Install O-rings (60, 94) to another flow rate control l : 14 mm
valve (96a).
m : 350 N·m (35 kgf·m, 260 lbf·ft)
22. Install check valve (103), spring (48), and piston
(104) to housing (1).
Assembly of Check Valve (l)
23. Install flow rate control valve (96a) to housing (1)
32. Install backup ring (116) and O-ring (117) to cap
(115).
l : 12 mm 33. Install check valve (119) and spring (118) to housing
(1).
m : 140 N·m (14 kgf·m, 103 lbf·ft)
Assembly of Arm Rod Anti-Drift Valve (111) l : 10 mm
24. Install O-ring (91) and O-rings (60) (3 used) to arm
m : 80 N·m (8 kgf·m, 59 lbf·ft)
rod anti-drift valve (111).
26. Install arm rod anti-drift valve (111) to housing (1)
l : 12 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)
W3-9-4-12
Assembly of Load Check Valve (k) Assembly of Boom 2 Anti-Drift Valve (87)
35. Install backup ring (62) and O-rings (61, 19) to cap 44. Install O-ring (91) and O-rings (60) (2 used) to boom
(124). 2 anti-drift valve (87).
36. Install check valve (49) and spring (48) to housing 45. Install poppet (90) and spring (89) to housing (1).
(1).
46. Install boom 2 anti-drift valve (87) to housing (1)
37. Install cap (124) to housing (1). with socket bolts (88) (4 used).
l : 14 mm l : 12 mm
Assembly of Boost Check Valve (j)
Assembly of Auxiliary Flow Combiner Valve (125)
47. Install O-ring (19) to auxiliary flow combiner valve
(125).
48. Install auxiliary f low combiner valve (125) to
j : 36 mm housing (1).
m : 180 N·m (18 kgf·m, 133 lbf·ft) j : 32 mm
m : 83 N·m (8.3 kgf·m, 61 lbf·ft)

Assembly of Load Check Valve (i)
41. Install O-ring (82), backup ring (106), O-ring (107),
backup ring (62), O-ring (61), and backup ring (62)
to cap (105).
42. Install check valve (110), spring (109), and check
valve (108) to housing (1).
l : 14 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
W3-9-4-13
Assembly of Overload Relief Valve (40)

48. Install backup rings (42) (5 used) and O-rings (41,
43) (5 used for each) to overload relief valves (40) (5
used).
49. Install overload relief valves (40) (5 used) to housing
(1).
j : 41 mm
m : 100 N·m (10 kgf·m, 74 lbf·ft)
Assembly of Spools (2, 3, 4, 5, and 6)

and install spools (2, 3, 4, 5, and 6) to housing (1).
51. Install O-rings (24) (2 used) and covers (23) (2 used)
to housing (1) with socket bolts (32) (4 used).
l : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

housing (1) with socket bolts (32) (3 used) and
l : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

housing (1) with socket bolts (32) (6 used).
l : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-9-4-14
Removal and Installation of Swing Device
1, 2, 3
5 4 WJAC-03-07-001

Removal

(Refer to W1-4-1.)
j : 19 mm
j : 19 mm
W3-10-1-1
19, 20
17, 18 22 19, 20 17, 18

WJAC-03-10-002 WJAC-03-10-001
4. Place a container under swing devices (23, 24).

Remove socket bolts (9) (16 used) and flanges (10) dCAUTION: Swing devices (23, 24) weight: 230 kg
(510 lb) for each
(8 used). Disconnect hoses (11) (4 used). Remove
O-rings (12) (4 used). 12. Attach nylon slings onto the body of swing motor.
Hoist and hold swing devices (23, 24).
l : 8 mm
j : 32 mm
j : 27 mm
6. Disconnect hose (7). used). Remove swing devices (23, 24).
j : 27 mm j : 32 mm
7. Disconnect hoses (8) (2 used). 15. Remove the adapter with swing devices (23, 24)
j : 36 mm
j : 19 mm
j : 19 mm
10. Remove clamps (15) (2 used). Disconnect hoses (16)
(2 used).
11. Place a container under hose (22). Remove hoses
(22) (2 used).
j : 41 mm
W3-10-1-2
19, 20
17, 18 22 19, 20 17, 18

WJAC-03-10-002 WJAC-03-10-001
Installation 7. Connect hose (14).

1. Install all removed adapters to swing devices (23, j : 19 mm
24).
m : 30 N·m (3 kgf·m, 22 lbf·ft)
dCAUTION: Swing devices (23, 24) weight: 230 kg
(510 lb) for each 8. Connect hose (13).
2. Apply THREEBOND #1215 onto the main frame j : 19 mm
mounting surface of swing devices (23, 24). Attach
nylon slings onto the body of swing motor. Hoist m : 30 N·m (3 kgf·m, 22 lbf·ft)
swing devices (23, 24). 9. Connect hoses (8) (2 used).
3. Install swing devices (23, 24) with washers (18) (22
used) and bolts (17) (22 used). j : 36 mm

m : 750 N·m (75 kgf·m, 550 lbf·ft)
4. Install spacers (20) (4 used) and bolts (19) (4 used). j : 27 mm

m : 750 N·m (75 kgf·m, 550 lbf·ft)
5. Connect hoses (22) (2 used). j : 27 mm

12. Install O-rings (12) (4 used). Connect hoses (11) (4
m : 200 N·m (20 kgf·m, 148 lbf·ft) used) with flanges (10) (8 used) and socket bolts (9)
6. Connect hoses (16) (2 used) with clamps (15) (2 (16 used).
used).
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-10-1-3
1, 2, 3
5 4 WJAC-03-07-001

4-1.)
washer (1).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-10-1-4
Disassembly of Swing Device

1
24 3
25
28 27
26
4
23
22 5
21
20 6
19
7
18
8
29
17
16
9
15
30
16
31
14 10
32
33 11
12
34
13
35
WJAA-03-11-008
1- Motor 10- Bolt (2 Used) 19- Thrust Plate (3 Used) 28- Cork (2 Used)
2- Socket Bolt (8 Used) 11- Lock Plate 20- Planetary Gear (3 Used) 29- Oil Seal
3- Ring Gear 12- Bearing Nut 21- Needle Bearing (3 Used) 30- Roller Bearing
4- First Stage Sun Gear 13- Roller Bearing 22- Spring Pin (3 Used) 31- Screw (4 Used)
5- Thrust Plate 14- Thrust Plate (3 Used) 23- Pin (3 Used) 32- Magnet (4 Used)
6- First Stage Carrier 15- Planetary Gear (3 Used) 24- Socket Bolt (12 Used) 33- Sleeve
7- Second Stage Sun Gear 16- Needle Bearing (6 Used) 25- Drain Plug 34- O-Ring
8- Thrust Plate 17- Spring Pin (3 Used) 26- Cock 35- Shaft
9- Second Stage Carrier 18- Pin (3 Used) 27- Housing
W3-10-2-1
Disassembly of Swing Device
dCAUTION: Swing device (b) weight: 230 kg (510 dCAUTION: Motor (1) weight: 50 kg (115 lb)
lb) 4. Put the matching marks on the jointed part of
motor (1) and ring gear (3), and ring gear (3) and
housing (27). Remove socket bolts (2) (8 used). Hoist
swing device (b). Hoist the swing device.
and remove motor (1).
a
l : 10 mm
fNOTE: Insert a screwdriver into the clearance between

motor (1) and ring gear (3), and float up motor (1) in
b
order to remove easily.
5. Remove first stage sun gear (4). Remove the first
stage carrier (6) assembly from ring gear (3).
W16J-02-06-003
a - Eyebolt Mounting Position b - Swing Device
2. Place swing device (b) on bracket (ST 5101). Secure

swing device (b) on a bracket with bolts (M22,
Pitch 2.5 mm) (2 used). Secure the bracket on a
workbench in order to receive the reaction force.
j : 32 mm
b
ST 5101
W1V7-02-06-001
b - Swing Device
3. Remove drain plug (25). Turn cock (26). Drain oil

from swing device (b). Remove cock (26) from
housing (27).
j : 26 mm
fNOTE: Drain Plug: R1/2
W3-10-2-2
11. Place block (a) on a press. Place the housing (27)

d CAUTION: Ring gear (3) weight: 23 kg (51 lb) assembly on block (a).
6. Remove socket bolts (24) (12 used). Install eyebolts
(M12, Pitch 1.75 mm) to the motor mounting screw
part of ring gear (3). Hoist ring gear (3). Remove ring
27
gear (3) from housing (27).
l : 14 mm
fNOTE: TREEBOND has been applied onto the mating

surface of housing (27) and ring gear (3). Insert a
screwdriver into the notch between jointed parts and
separate the surface in order to remove easily.
dCAUTION: The second stage carrier (9) assembly

7. Remove second stage sun gear (7) and the second
stage carrier (9) assembly from housing (27). a W1HH-02-06-012
8. Remove bolts (10) (2 used). Remove lock plate (11) a - Block

from bearing nut (12).
j : 17 mm
9. Remove bearing nut (12) from shaft (35) by using
the special tool (ST 2926).
35
ST 2926
W178-02-06-008
dCAUTION: The housing (27) assembly weight:

120 kg (265 lb)
the bolt (24) hole of housing (27). Remove bolts
(M22, Pitch 2.5 mm) (2 used) which secure housing
(27) and bracket (ST 5101). Hoist the housing (27)
assembly and remove the bracket.
j : 32 mm
W3-10-2-3
dCAUTION: If pushing shaft (35) by using a press

(c), provide a protection cover (b) (outer diameter:
290 mm (11.4 in), inner diameter: 90 mm (3.5 in),
thickness: 25 to 30 mm (1.0 to 1.2 in)). Housing
(27) and roller bearing (13) are broken and flown
off. The metal fragments may result in personal
injury. Press at 30 ton or less.Degrease the
housing inside before heating roller bearing (13).
Failure to degrease may cause a fire.
12. Cover housing (27) with protection cover (b) and
remove shaft (35) by using press (c). At this time, the
inner race of roller bearing (30) and sleeve (33) are
removed with shaft (35) together.
35 14
27
W157-02-06-010
b - Protection Cover
W1V7-02-06-002
b - Protection Cover
c - Press
W3-10-2-4
13. Remove outer race of roller bearing (13) from

housing (27). dCAUTION: Push shaft (35) inside the guide by
using a press.
dCAUTION:
(135 lb)
The shaft (35) assembly weight: 60 kg 15. Install shaft (35) with a special tool attached to a
press (e). Remove the inner race of roller bearing
14. Set a special tool to the shaft (35) assembly. (30).
fNOTE: Use the following parts as a special tool when 16. Remove sleeve (33) from shaft (35). Remove the
O-ring (34), screws (31) (4 used) and magnets (32) (4
removing roller bearing (30).
used) from sleeve (33).
 Shaft (b) or bolt: lengh: 270 mm (10.6 in), diameter:
19 mm (0.75 in) (8 used) (All shoud be identical in
lengh with no wear and deformation on both ends.) e
Material: S35C
 Hose clamp (c): standard diameter: 8-1/2inch 35
(applicable diameter: 185 to 215 mm (7.3 to 8.5 in) (2
used) 30
 Guide (d): height: 230 mm (9.1 in), outer diameter: 230 33
mm (9.1 in), inner diameter: 210 mm (8.3 in)
a
b d
c
W157-02-06-014
d - Guide
e - Press
W157-02-06-012
35
30
33
c
b
d
W157-02-06-013
a - Special tool when removing c - Hose Clamp
roller bearing (30) d - Guide
b - Shaft
W3-10-2-5
17. Insert a round bar into housing (27). Tap and

remove the outer race of roller bearing (30).
dCAUTION: Housing (27) weight: 70 kg (155 lb)

18. Attach a nylon sling onto the body of housing
(27). Hoist nad turn over the housing (27). Insert a
screwdriver into the notch on housing (27) where
oil seal (29) is mounted. Remove oil seal (29).
fNOTE: THREEBOND has been applied onto the outer

surface of oil seal (29). Therefore, the oil seal cannot be
reused.
dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to prevent
personal injury.
19. Tap the outer race of roller bearing (13) by using
a bar and a hammer. Remove the outer race from
housing (27).

personal injury.
20. Remove spring pins (22) (3 used) from first stage
carrier (6) by using a round bar and hammer.
21. Remove pins (23) (3 used), first stage planetary
gears (20) (3 used), thrust plates (19) (3 used), and
needle bearings (21) (3 used) from first stage carrier
(6).
22. Remove thrust plate (5) from first stage carrier (6).

personal injury.
23. Remove spring pins (17) (3 used) from second stage
carrier (9) by using a round bar and hammer.
24. Remove pins (18) (3 used), second stage planetary
gears (15) (3 used), thrust plates (14) (3 used), and
needle bearings (16) (6 used) from second stage
carrier (9).
25. Remove thrust plate (8) from second stage carrier
(9).
W3-10-2-6
Assembly of Swing Device

22 23 20 4 5 1
2
21
19 6
17 3
15 7
9
16
24
8
18
10
11
14
12
27 13
26
25
32
30
29
31 33
34
35
WJAA-03-11-009
1- Motor 10- Bolt (2 Used) 19- Thrust Plate (3 Used) 28- Cork (2 Used)
2- Socket Bolt (8 Used) 11- Lock Plate 20- Planetary Gear (3 Used) 29- Oil Seal
3- Ring Gear 12- Bearing Nut 21- Needle Bearing (3 Used) 30- Roller Bearing
4- First Stage Sun Gear 13- Roller Bearing 22- Spring Pin (3 Used) 31- Screw (4 Used)
5- Thrust Plate 14- Thrust Plate (3 Used) 23- Pin (3 Used) 32- Magnet (4 Used)
6- First Stage Carrier 15- Planetary Gear (3 Used) 24- Socket Bolt (12 Used) 33- Sleeve
7- Second Stage Sun Gear 16- Needle Bearing (6 Used) 25- Drain Plug 34- O-Ring
8- Thrust Plate 17- Spring Pin (3 Used) 26- Cock 35- Shaft
9- Second Stage Carrier 18- Pin (3 Used) 27- Housing
W3-10-2-7
Assembly of Swing Device

dCAUTION: Shaft (35) weight: 36 kg (80 lb)
8. Install sleeve (33) and the inner race of roller
1. Install needle bearings (21) (3 used) to first stage bearing (30) to shaft (35). Install the inner race of
planetary gears (20) (3 used). roller bearing (30) to sleeve (33) by using special
2. Install thrust plate (5) to first stage carrier (6) with tool (ST 7295) and press (b).
the oil groove up.
fNOTE: The press-in distance of the inner race of roller
3. Install first stage planetary gears (20) (3 used) and bearing (30) can be assured by using the special tool
thrust plates (19) (3 used) to first stage carrier (6). when installing.
4. Fit pin (23) to the spring pin (22) holes on first stage
carrier (6). Install pins (23) (3 used) by using a plastic
hammer.

a hammer is used. Wear necessary protection, b
personal injury.
IMPORTANT: Check the direction of spring pin (22). ST 7295 30
5. Install spring pin (22) to first stage carrier (6) with
the slit (a) of spring pin (22) facing to the end of pin 33
(23) by using hammer.
35
22 W1V7-02-06-004
b - Press
23
W1V7-02-06-003
a - Slit
6. Assemble second stage carrier (9) in the same way

as steps 1 to 5. Assemble thrust plate (8), second
planetary gears (15) (3 used), needle bearings (16) (6
used), thrust plates (14) (3 used), pins (18) (3 used),
and spring pins (17) (3 used).
7. Install O-ring (34), magnets (32) (4 used) and screws
(31) (4 used) to sleeve (33).
W3-10-2-8
dCAUTION: Housing (27) weight: 70 kg (155 lb) dCAUTION: Metal fragments may fly off when
9. Attach a nylon sling onto the body of housing (27).
Hoist and place housing (27) with the sleeve (33) such as goggles, helmets, etc in order to prevent
mounting side up. personal injury.
14. Evenly tap and install the outer race of roller bearing
(13) to housing (27) evenly by using a bar and a
hammer. Tap and listen to ring in order to check if
such as goggles, helmets, etc in order to prevent the installation is completed.
personal injury.
10. Evenly tap and install the outer race of roller bearing dCAUTION: Metal fragments may fly off when
(30) to housing (27) evenly by using a bar and a
hammer. Tap and listen to ring in order to check if such as goggles, helmets, etc in order to prevent
the installation is completed. personal injury.
15. Install the inner race of roller bearing (13) to shaft
(35) by using a bar and a hammer. Tap the inner
race until the upper end on the inner race of roller
such as goggles, helmets, etc in order to prevent bearing (14) reaches two threads for bearing nut
personal injury. (12) in shaft.
11. Apply THREEBOND #1215 onto the outer surface of
oil seal (29). Place oil seal (29) flat on housing (27)
and push by hands in gently. Place the special tool
of seal (ST 7300) on oil seal (29). Tap it in by using a
hammer straight.
ST 7300 29
27
WIHH-02-06-010
12. Apply grease onto the inner surface of oil seal (29).
Therefore, apply grease onto the outer surface of
sleeve (33) with shaft (35) attached.
13. Turn over a housing (27). Install eyebolts (M16, Pitch
2.0 mm) (2 used) to the bolt (24) hole of housing
(27). Hoist housing (27). Slowly place and install
housing (27) to shaft (35). At this time, Check and fit
carefully in order not to curl the lip of oil seal (29).
W3-10-2-9
16. Install bearing nut (12) to shaft (35) and tighten by

hand.
fNOTE: Prevent shaft (35) from falling off when hoisting

housing (27).
dCAUTION: The housing (27) assembly weight:

130 kg (290 lb)
the bolt (24) hole of housing (27). Hoist and place
housing (27) on a press.
18. Remove bearing nut (12) from shaft (35).
19. Place inner race special tool (ST 2924) onto the roller
bearing (13) inner race. Install the inner race by
using a press.
fNOTE: The specified press-in distance of the inner race

can be assured by using the special tool when installing.
13 ST 2924
WIHH-02-06-009
20. Hoist and place the housing (27) assembly on

bracket (ST 5101). Install the housing (27) assembly
with bolts (M22, Pitch 2.5 mm) (2 used). At this time,
insert the stopper (a) at the bottom of the bracket
between teeth of the pinion gear. Secure bracket on
a workbench in order to receive the reaction force.
j : 32 mm
27
ST 5101
a
W1V7-02-06-001
a - Stopper
W3-10-2-10
IMPORTANT: Check the direction to install bearing

nut (12). dCAUTION:
(51 lb)
Second stage carrier (9) weight: 23 kg
21. Apply grease onto the thread part of bearing nut
(12). Install the thread part of bearing nut (12) to IMPORTANT: Check the direction to install second
shaft (35).At this time, face the step side of bearing stage carrier (9).
nut (12) to the roller bearing (13) side. Tighten 23. Install the second stage carrier (9) assembly to the
bearing nut (13) by using special tool (ST 2926) to spline in shaft (35).
the specified torque.
9
m : 490 N·m (49 kgf·m, 360 lbf·ft)
35
fNOTE: Apply grease for keeping correct tightening
torque.
12
W1V7-02-06-005
24. Install second stage sun gear (7) to the second stage
carrier (9) assembly.
25. Apply THREEBOND #1215 onto the ring gear (3)
mounting surface of housing (27). Clean off old
ST 2926 adhesive in advance.
W178-02-06-008
22. Install lock plate (11) to bearing nut (12) with bolts
(10) (2 used). In case the spline of lock plate (11) and
that of shaft (35) are not aligned, tighten bearing
nut (12) in tightening direction until both splines
are aligned.
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-10-2-11
dCAUTION: Ring gear (3) weight: 23 kg (51 lb)

the motor mounting screw part of ring gear (3)
before hoisting. Fit the matching marks made when
disassembling and install ring gear (3) to housing
(27). Tighten socket bolts (24) (12 used).
l: 14 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)

27. Fit the spline and install the first stage carrier (6)
assembly to second stage sun gear (7).
IMPORTANT: Check the direction to install first stage
sun gear (4).
28. Install first stage sun gear (4) to the first stage carrier
(6) assembly with the step part down.
29. Install cock (26) to housing (27). Install a seal tape
onto drain plug (25). Install drain plug (25) to cock
(26).
j : 26 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
fNOTE: Drain Plug: R1/2

30. Add gear oil (6.7 L (1.77 US gal)) to housing (27).
31. Apply liquid packing (THREEBOND #1215) onto the
motor (1) mounting surface of ring gear (3).
dCAUTION: Motor (1) weight: 50 kg (115 lb)

32. Hoist motor (1). Fit the matching marks made when
diassembling. Install motor (1) to ring gear (3) with
l : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-10-2-12
Disassembly of Swing Motor
11
9
8
7
6
5 10
4
3
2
24
25 29
26
1 27 30
28
23 27
26
25
24
12
13
14
15 22
21 31
16 20
19
18
17
WJAA-03-11-007
1- Casing 9- Rotor 17- O-Ring 25- O-Ring (2 Used)

2- Oil Seal 10- Plate (4 Used) 18- O-Ring 26- Spring (2 Used)
3- Bearing 11- Friction Plate (3 Used) 19- Brake Piston 27- Poppet (2 Used)
4- Shaft 12- O-Ring 20- Spring (24 Used) 28- Valve Casing
5- Shoe Plate 13- Piston 21- Valve Plate 29- Socket Bolt (4 Used)
6- Plunger (9 Used) 14- Spring 22- Bearing 30- Plug (2 Used)
7- Plate 15- Ball 23- O-Ring 31- Relief Valve (2 Used)
8- Retainer 16- Plug (2 Used) 24- Plug (2 Used)
W3-10-3-1
Disassembly of Swing Motor
dCAUTION:
kg (110 lb)
The swing motor assembly weight: 48 8. Put the matching marks on casing (1) and brake
piston (19). Attach a claw of the special tool (ST
1468) onto brake piston (19) groove. Remove brake
piston (19) from casing (1) by using the special tool
(ST 1468).
disassemble relief valve (32).
1. Remove relief valves (31) (2 used) from valve casing
(28).
j : 41 mm ST 1468
2. Remove plug (24) from valve casing (28). Remove 19
l : 14 mm 1
3. Remove spring (26) and poppet (27) from valve

casing (28).
4. Remove another poppet (27) in the same way as
step 2 to step 3. W1HH-02-06-006
5. Put the matching marks on valve casing (28) and
9. Remove O-rings (17, 18) from casing (1).
casing (1). Remove socket bolts (29) (4 used). At this
time, record the clearance between valve casing
(28) and casing (1).
l : 17 mm
IMPORTANT: Do not remove bearing (22) unless
necessary.
6. Remove valve casing (28) from casing (1). As valve
plate (21) may be removed with valve casing (28)
together, do not drop valve plate (21). Remove
O-ring (23) from valve casing (28).
IMPORTANT: Do not damage the mating surfaces
when separating valve plate (21) from valve
casing (28) or rotor (9) by using a screwdriver.
7. If valve plate (21) is still attached on rotor (9) side
in step 6, remove valve plate (21) from the rotor (9).
Remove springs (20) (24 used) from brake piston
(19).
W3-10-3-2
IMPORTANT: Do not damage the sliding surfaces of

rotor (9) and plunger (6).
10. Place casing (1) horizontally. Remove rotor (9),
retainer (8), plate (7), and plungers (6) (9 used) from
shaft (4).
11. Remove plates (10) (4 used) and friction plates (11)
(3 used) from casing (1).
IMPORTANT: Do not damage the sliding surface of
shoe plate (5).
12. Remove shoe plate (5) from casing (1).
13. Tap and remove shaft (4) from casing (1) by using a
plastic hammer.
14. Remove the inner race of bearing (3) from shaft (4)
by using a press.

personal injury.
15. Remove the outer race of bearing (3) from casing (1)
by using a bar and a hammer.
16. Remove oil seal (2) from casing (1).
IMPORTANT: The filter and orifice are installed inside
piston (13). Do not disassemble piston (13) unless
they are clogged or deformed. If the inner parts of
piston (13) are replaced, replace piston (13) as an
assembly.
17. Remove piston (13) from casing (1) by using a pair
of pliers.
18. Remove O-ring (12) from piston (13).
19. Remove spring (14) and ball (15) from casing (1).
20. Remove plugs (16) (2 used) from casing (1).
l : 6 mm
W3-10-3-3
Assembly of Swing Motor
27 26
12
25
13
24 14
15
16
29
WJAA-03-11-001 WJAA-03-11-003
31
21 30 22 28
23 20
18 19
9
17
11
6
10
7
1 8
4 2 3 5
WJAA-03-11-002
W3-10-3-4
1- Casing 9- Rotor 17- O-Ring 25- O-Ring (2 Used)

2- Oil Seal 10- Plate (4 Used) 18- O-Ring 26- Spring (2 Used)
3- Bearing 11- Friction Plate (3 Used) 19- Brake Piston 27- Poppet (2 Used)
4- Shaft 12- O-Ring 20- Spring (24 Used) 28- Valve Casing
5- Shoe Plate 13- Piston 21- Valve Plate 29- Socket Bolt (4 Used)
6- Plunger (9 Used) 14- Spring 22- Bearing 30- Plug (2 Used)
7- Plate 15- Ball 23- O-Ring 31- Relief Valve (2 Used)
8- Retainer 16- Plug (2 Used) 24- Plug (2 Used)
W3-10-3-5
Assembly of Swing Motor

IMPORTANT: Before assembling, apply hydraulic oil 11. Install the rotor (9) assembly to shaft (4).
IMPORTANT: There are 4 notches on the outer side of
1. Install plugs (16) (2 used) to casing (1). plate (10). There are 4 notches on the inner side of
friction plate (11).
l : 6 mm
12. Place casing (1) vertically. Alternately install plates
m : 35 N·m (3.5 kgf·m, 26 lbf·ft) (10) (4 used) and friction plates (11) (3 used) and
align each notch at the same place.
2. Install O-ring (12) to piston (13).
13. Install O-rings (17, 18) to casing (1).
IMPORTANT: If the inner parts of piston (13) are 14. Fit the matching marks and install brake piston (19)
replaced, replace piston (13) as an assembly. to casing (1).
3. Install ball (15), spring (14), and piston (13) to casing
(1) in order to fit the end of piston (13) to that of fNOTE: If it is not easy to install O-rings (17, 18) into
brake piston (27) due to the resistant force from O-rings
casing (1).
(17, 18), tap brake piston (19).
4. Install oil seal (2) to casing (1) by using a plate with 15. Install springs (20) (24 used) to brake piston (19).
the lip part up.

personal injury.
5. Install the outer race of bearing (3) to casing (1) by

using a bar and a hammer.
6. Install the inner race of bearings (3, 22) to shaft (4)
with the flange facing to the step side of shaft (4) by
using a press.
7. Wind the tape onto the spline at the end of shaft (4)
in order not to damage oil seal (2). Place casing (1)
with the plug (16) side up. Install shaft (4) to casing
(1).
8. Install shoe plate (5) to casing (1) with the
chamfered surface facing inside.
9. Fit the notches on plate (7) and retainer (8). Install
plungers (6) (9 used) to the plate (7) assembly.
Install retainer (8) to plunger (6) with the notch
facing to the shoe plate (5) side.
10. Install the plunger (6) assembly into rotor (9).
W3-10-3-6
16. Tap and install the outer race, the bearing type
indicated surface of bearing (22) to valve casing (28)
by using a plastic hammer.
IMPORTANT: Check the surfaces of valve plate (21).
17. Install O-ring (23) to valve casing (28). Apply grease
onto valve plate (21) in order to prevent from falling
off from valve casing (28). Install valve plate (21) to
valve casing (28) with the notch in the port facing to
rotor (9).
18. Apply grease onto the needle part of bearing (22) in
order to install shaft (4) to bearing (22) easily.
19. Fit the matching marks on casing (1) and valve
casing (28). Place valve casing (28) on to casing.
Check that a clearance between valve casing (28)
and casing (1) is equal to that before disassembling.
If the clearance is larger than that before
disassembling, repeat the procedures from step 8.
20. Install valve casing (28) to casing (1) with socket
l : 17 mm
ml : 440 N·m (44 kgf·m, 320 lbf·ft)

21. Install poppet (27) and spring (26) to valve casing
(28). Install O-ring (25) to plug (24). Install plug (24)
to valve casing (28).
l : 14 mm
m : 340 N·m (34 kgf·m, 251 lbf·ft)

22. Install another poppet (27) in the same way as step
21.
23. Install relief valves (32) (2 used) to valve casing (28).
j : 41 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
W3-10-3-7
(Blank)
W3-10-3-8
Removal and Installation of Pilot Valve (Left)
3, 33 2
3, 33
1 WDAA-03-01-023 WJAA-03-01-013

and pipes have been disconnected. In addition, dCAUTION: Seat (2) weight: 46 kg (105 lb)
attach an identification tag onto the connectors, 3. Remove socket bolts (3) (4 used) and washers (33) (4
hoses, and pipes for assembling. Connect the used). Remove seat (2).
secure the hoses have been removed. l : 6 mm
Removal

(Refer to W1-4-1.)
2. Open door (1).
W3-11-1-1
Detail B
14
13
14
21 23 22
15
B
17
10
16
WDAA-03-12-002
9
7, 8 12 11 WDAA-03-12-001
20 18 19
4. Remove socket bolts (7) (2 used) and washers (8) (2

used). Remove lever (9).
l : 6 mm
(2 used). Remove armrest (12).
l : 6 mm
6. Raise boot (13) and remove screws (14) (3 used).
7. Raise cover (15). Disconnect connector (16). Remove
cover (15).
8. Remove screw (17), bolt, washer (18), and washer
(19). Remove cover (20).
j : 10 mm
9. Remove screws (21, 22) (2 used for each). Remove
cover (23).
W3-11-1-2
25 27 26 30, 31
WDAA-03-12-023 WDAA-03-12-019
28 24 29 32
10. Remove clip bands (24, 25).

11. Loosen lock nut (26). Remove the lever (27)
assembly.
j : 19 mm, 22 mm
j : 19 mm
(4 used). Remove pilot valve (29) and boot (32).
l : 6 mm
14. Remove the adapter with pilot valve (29) attached if
necessary.
W3-11-1-3
25 27 26 30, 31
WDAA-03-12-023 WDAA-03-12-019
28 24 29 32
Installation
1. Install all removed adapters to pilot valve (29).
2. Install pilot valve (29) and boot (32) with washers
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

4. Tighten lock nut (26) and install the lever (27)
assembly.
j : 19 mm, 22 mm
m : 55 N·m (5.5 kgf·m, 41 lbf·ft)

5. Install clip bands (25, 24).
W3-11-1-4
Detail B
14
13
14
21 23 22
15
B
17
10
16
WDAA-03-12-002
9
7, 8 12 11 WDAA-03-12-001
20 18 19
6. Install cover (23) with screws (22, 21) (2 used for 13. Install lever (9) with washers (8) (2 used) and socket
each). bolts (7) (2 used).
7. Install cover (20) with washer (19), bolt, washer (18), l : 6 mm
and screw (17).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
j : 10 mm
m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft)

9. Raise cover (15). Connect connector (16).
4-1.)
11. Install screws (14) (3 used). Lower boot (13).
12. Install armrest (12) with washers (11) (2 used) and
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-11-1-5
3, 33 2
3, 33
1 WDAA-03-01-023 WJAA-03-01-013
dCAUTION: Seat (2) weight: 46 kg (105 lb)

14. Install seat (2) with washers (33) (4 used) and socket
bolts (3) (4 used).
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

15. Shut door (1).
W3-11-1-6
Removal and Installation of Pilot Valve

(Right)
3, 31 2
3, 31
1 WDAA-03-01-023 WJAA-03-01-013

and pipes have been disconnected. In addition, dCAUTION: Seat (2) weight: 46 kg (105 lb)
attach an identification tag onto the connectors, 3. Remove socket bolts (3) (4 used) and washers (31) (4
hoses, and pipes for assembling. Connect the used). Remove seat (2).
secure the hoses have been removed. l : 6 mm
Removal

(Refer to W1-4-1.)
2. Open door (1).
W3-11-2-1
Detail A
14
13
15 11
10 12
16
WDAA-03-12-006
9 11
7 8
WDAA-03-12-005
4. Remove socket bolts (7) (2 used) and washers (8) (2

used). Remove armrest (9).
l : 6 mm
5. Remove tray (10). Remove screws (11) (3 used).
6. Raise cover (12). Disconnect connectors (13) (2
7. Raise boot (14). Remove screws (15) (2 used).
Remove cover (16).
W3-11-2-2
19 20 17 18 20 24
23
24
WDAA-03-12-007
21 22 25 24
WDAA-03-12-005
8. Remove clip bands (17, 18).

9. Loosen lock nut (19). Remove the lever (20)
assembly.
j : 19 mm, 22 mm
10. Remove bolts, washers (21) (3 used). Tilt the bracket
(22) assembly with the cover (23) side up.
j : 17 mm
11. Remove screws (24) (3 used) and washer (25).
Remove cover (23).
W3-11-2-3
A Detail A
28, 29
30
WDAA-03-12-008
26
27 26 WDAA-03-12-020
j : 19 mm
(4 used). Remove pilot valve (27) and boot (30).
l : 6 mm
necessary.
W3-11-2-4
A Detail A
28, 29
30
WDAA-03-12-008
26
27 26 WDAA-03-12-020
Installation
2. Install pilot valve (27) and boot (30) with washers
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-11-2-5
19 20 17 18 20 24
23
24
WDAA-03-12-007
21 22 25 24
WDAA-03-12-005
4. Install cover (23) with washer (25) and screws (24) (3

used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

6. Tighten lock nut (19) and install the lever (20)
assembly.
j : 19 mm, 22 mm
m : 55 N·m (5.5 kgf·m, 41 lbf·ft)

7. Install clip bands (18, 17).
W3-11-2-6
Detail A
14
13
15 11
10 12
16
WDAA-03-12-006
9 11
7 8
WDAA-03-12-005
8. Install cover (16) with screws (15) (2 used).

10. Raise cover (12). Connect connectors (13) (2 used).
4-1.)
12. Install boot (14).
13. Install screws (11) (3 used). Install tray (10).
14. Install armrest (9) with washers (8) (2 used) and
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-11-2-7
3 2
1 WDAA-03-01-023 WJAA-03-01-013
dCAUTION: Seat (2) weight: 46 kg (105 lb)

15. Install seat (2) with washers (31) (4 used) and socket
bolts (3) (4 used).
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

16. Shut door (1).
W3-11-2-8
Removal and Installation of Travel Pilot Valve
2 3 12, 13
WJAA-03-01-016 4 5 WJAA-03-12-001
IMPORTANT: Cap the open ends in case the hoses 5. Place a container under pilot valve (4). Disconnect
and pipes have been disconnected. In addition, hoses (5) (6 used).
hoses, and pipes for assembling. Connect the j : 19 mm
Removal
1. Swing the upperstructure by 90 degrees and set the
machine for inspection and maintenance. (Refer to
W1-6-1.)

(Refer to W1-4-1.)
2. Open door (1).
3. Remove the floor mat.

not drop cover (3).
4. Remove bolts, washers (2) (4 used), bolts (12) (3
j : 17 mm
W3-11-3-1
WDAA-03-12-017 WDAA-03-12-018
6. Remove bolts, washers (7) (4 used). Remove levers

(8) (2 used) and pedals (9) (2 used).
j : 17 mm
(2 used). Remove pilot valve (4).
l : 8 mm
necessary.
W3-11-3-2
WDAA-03-12-017 WDAA-03-12-018
Installation
2. Install pilot valve (4) with washers (11) (2 used) and
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Install pedals (9) (2 used) and levers (8) (2 used) with
bolts, washers (7) (4 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-11-3-3
2 3 12, 13
WJAA-03-01-016 4 5 WJAA-03-12-001
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

4-1.)
6. Install cover (3) with washers (13) (3 used), bolts (12)
(3 used), and bolts, washers (2) (4 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

7. Install the floor mat.
8. Shut door (1).
W3-11-3-4
Disassembly of Pilot Valves (Right and Left)
17
16
15
14
13
12
11
10
18
9
7
6 19
23
5 20
4 21
22
3
WDAA-03-12-021
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing
W3-11-4-1
Disassembly of Pilot Valves (Right and Left)

3. Attach a spanner onto the upper part of universal
IMPORTANT: Casing (18) is made of aluminium.
joint (15). Remove universal joint (15).
Strong force deforms it. Handle it with care.
IMPORTANT: Spool (19) has been selected to match j : 17 mm
the hole on casing (18). The dimensions of balance
springs (3, 4) and return springs (5, 6) as well as fNOTE: Universal joint (15) has been secured on casing
those of pushers (9, 10) are different. Arrange (18) by using LOCTITE #262.
the disassembled parts together with the port in 4. Remove plate (14).
order not to confuse. The port number is stamped
IMPORTANT: Do not damage sleeve (12). Insert a soft
on the outer surface of casing (18).
rubber between sleeve (12) and a tool. Oil seal (11)
IMPORTANT: Do not remove screw joint (17) while cannot be removed from sleeve (12).
securing casing (18) in a vise. The strong torque
Sleeve (12) and oil seal (11) should be replaced as
may act on screw joint (17).
an assembly.
1. Secure screw joint (17) in a vise. Turn cam (16) by
5. Remove sleeves (12) (4 used) upward by using a pair
using a spanner. Remove screw joint (17).
of pliers. Remove O-rings (19) (4 used) from sleeves
j : 19 mm, 32 mm (12) (4 used).
IMPORTANT: The dimensions of pushers (9, 10) for
2. Secure the flat surface of casing (18) in a vise. ports (1, 3) and for ports (2, 4) are different. Keep
Remove cam (16) from universal joint (15). the disassembled parts together by the port
number in order not to confuse.
j : 32 mm 6. Remove pushers (9, 10) (2 used for each) from
casing (18).
W3-11-4-2
7. When compressing the spring, do not lower spool IMPORTANT: The quantity of shims (2) has been
(19). Install the special tool (ST 4145) to the port determined for each port during the performance
hole on casing (18) as illustrated. testing. Do not lose shim (2). Keep shim (2)
carefully in order to install shim (2) to the original
l : 6 mm port when assembling.
9. Remove the special tool (ST4146). Remove spring
guides (7) (4 used), return springs (5, 6) (2 used for
each), and balance springs (3, 4) (2 used for each)
from spools (19) (4 used).
18 10. Remove shim (2) and spacers (1) (4 used) from
spools (19) (4 used).
IMPORTANT: Spool (19) has been selected to match
the hole on casing (18). Spool (19) and casing (18)
should be replaced as an assembly.
11. Remove the special tool (ST 4145) from casing (18).
Slowly turn and remove spool (19) from casing (18).
W178-02-07-048
ST 4145 IMPORTANT: Retaining ring (22) may come off while
disassembling. Do not drop retaining ring (22)
8. Install the special tool (ST 4146) to the pusher hole inside casing (18). If retaining ring (22) falls inside
on casing (18). Push the special tool (ST 4146) and casing (18), remove retaining ring (22) completely.
compress the spring. Tighten the special tool (ST Retaining ring (22) cannot be reused.
4146) by using the socket bolt (M14, Pitch 2.0 mm). 12. Remove retaining ring (22) from casing (18) by
Remove retaining rings (8) (4 used) from spools (19) using a screwdriver. Install a bolt (M8, Pitch 1.25
(4 used) by using a screwdriver. mm) to plug (21). Remove plug (21) from casing
(18). Remove O-ring (20) from plug (21).
l : 12 mm
j : 13 mm
ST 4146
13. Remove filter (23) from casing (18).
j : 10 mm
18
W178-02-07-048
W3-11-4-3
Assembly of Pilot Valves (Right and Left)
17
15
16
11
14 9, 10
13
12
8
7
3, 4
5, 6
2
1
21
20
23 18 19
22
WDAA-03-12-022
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13- O-Ring (4 Used) 19- Spool (4 Used)
2- Shim (Several) 8- Retaining Ring (4 Used) 14- Plate 20- O-Ring
3- Balance Spring (2 Used) 9- Pusher (2 Used) 15- Universal Joint 21- Plug
4- Balance Spring (2 Used) 10- Pusher (2 Used) 16- Cam 22- Retaining Ring
5- Return Spring (2 Used) 11- Oil Seal (4 Used) 17- Screw Joint 23- Filter
6- Return Spring (2 Used) 12- Sleeve (4 Used) 18- Casing
W3-11-4-4
Assembly of Pilot Valves (Right and Left)

IMPORTANT: Refer to the table in the left in order to
assemble the parts correctly.
3. Install spacer (1), shim (2), and balance spring (3) to
IMPORTANT: The pilot valve is the susceptible
spool (19). Install return spring (5) to casing (18).
hydraulic component to contamination. Keep the
parts clean when assembling. 4. Install spring guide (7) to return spring (5) with the
protrusion up.
fNOTE: The table below shows the relations between 5. Install other spools (19) (3 used) in the same way as
step 1 to step 4.
each port and the parts. Do not confuse them when
assembling. 6. Install the special tool (ST 4146) to the pusher (9, 10)
Spool Shim holes on casing (18). Push the special tool (ST 4146)
Port No. Pushers (9, 10) and compress the spring. Tighten the special tool
(19) (2)
1 One outer groove (ST 4146) by using a bolt (M14, Pitch 2.0 mm).
Two outer l : 12 mm
2
Same to the Same to the grooves
3 former one former one One outer groove ST 4146
Two outer
4
grooves
ST 4144
Return Springs Balance Springs
Port No.
(5, 6) (3, 4)
1 Short Short
2 Long Long
3 Short Short
4 Long Long
1. Check the port hole number and insert same spool

(19) before disassembling. Install the thinner end W178-02-07-049
of spool (19) into the port hole on casing (18) by ST 4145
turning slowly.
7. Install retaining ring (8) to the ring holder (ST 4144).
fNOTE: Spool (19) has been selected to match the port
hole. Spool (19) and casing (18) should be replaced as an
assembly.
2. Install the special tool (ST 4145) to the port hole on
casing (18) in order not to lower spool (19) when
the spring is compressed.
j : 6 mm
W3-11-4-5
8. Install retaining ring (8) to the groove on the head IMPORTANT: Fit the bolt hole on plate (14) to the
of spool (21) extending from the special tool (ST screw hole on casing (18).
4146). 16. Apply LOCTITE #262 onto the screw part of
IMPORTANT: Check the position to install pusher (9). universal joint (15). Place plate (14) on casing (18).
Install universal joint (15).
9. Install pusher (9).
After pushing pusher (9) several times by hand, j : 17 mm
remove it. Check if retaining ring (8) comes off or
balance spring (3) is located correctly. m : 25 N·m (2.5 kgf·m, 19 lbf·ft)
Install pusher (9) to casing (18) after checking.
IMPORTANT: Check the tightness of cam (16).
10. Install other pushers (9, 10) in the same way as step 17. Install cam (16) to universal joint (15). The clearance
8 to step 9. between cam (16) and pushers (9, 10) (2 used for
11. Apply grease onto the ball part at the ends of each) should be 0 to 0.2 mm.
pushers (9, 10) (2 used for each). 18. Secure cam (16) by using a spanner. Tighten screw
12. Apply grease onto the joint part of universal joint joint (17) by using a spanner.
(15).
j : 19 mm, 32 mm
13. Apply grease onto the inner surface of oil seals (11)
(4 used). m : 70 N·m (7 kgf·m, 51 lbf·ft)
19. Install plug (23) to casing (18).
fNOTE: Sleeve (12) and oil seal (11) should be replaced
as an assembly. l : 10 mm
14. Install oil seals (11) (4 used) to sleeves (12) (4 used).
Push the sleeve (12) assemblies (4 used) by hand m : 20 N·m (2 kgf·m, 15 lbf·ft)
until O-ring (13) is inserted into the hole on sleeves
(12) (4 used).
15. Secure casing (18) in a vise lightly.
W3-11-4-6
Disassembly of Travel Pilot Valve
3
4
7 35
34
33
32
8 31
9
30
10 29
11
28
14
27
12
15 26
13
25
16
17 24
18
19 23
36
20
21 22
WDAA-03-12-024
1- Bolt, Washer (2 Used) 10- Spring Pin 19- O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring (4 Used) 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (16 Used) 26- Spacer (4 Used) 35- Pin
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used) 36- Plug
W3-11-5-1
Disassembly of Travel Pilot Valve

IMPORTANT: Casing (23) is made of aluminium.
the hole of casing (23). Spool (24) and casing (23)
Strong force deforms it. Handle it with care.
should be replaced as an assembly.
IMPORTANT: Put the mark on spools (24) (4 used)
the hole on casing (23).
when keeping in order to easily install spools (24)
Arrange the disassembled parts together with (4 used) to the original hole.
each port in order not to confuse.
5. Remove the spool (24) assembly from casing (23) by
The port number is stamped on the outer surface rotating.
of casing (23). Spring guide (17), balance spring (18), shims (27) (3
1. Secure casing (23) in a vise. Remove bolts, washers used), and spacer (26) are removed with spool (24)
(1) (2 used). Remove cover (2) from holder (7). together.
j : 10 mm IMPORTANT: The quantity of shims (27) have been
determined during the performance testing at the
2. Remove socket bolts (30) (2 used) and spring factory. When keeping, pair shim (27) with each
washers (29) (2 used). Remove the holder (7) spool.
assembly from casing (23).
6. Compress balance spring (18). Remove spring guide
l : 8 mm (17), balance spring (18), shims (27) (3 used), and
spacer (26) from spool (24).
3. Remove the pusher (16) assemblies (4 used) from
casing (23). 7. Remove spring (25) from casing (23).
4. Remove pushers (16) (4 used) from bushings (15) 8. Remove other spools (24) in the same way as step 5
(4 used). Remove oil seals (28) (4 used) and O-rings to step 7.
(14) (4 used) from bushings (15) (4 used) by using a
bamboo spatula.
W3-11-5-2
11. Remove O-ring (33) from pin (35).

d CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, 12. Remove other bracket (11) in the same way as step
such as goggles, helmets, etc in order to prevent 9 to step 11.
personal injury. 13. Place holder (7) with the casing (23) mounting
IMPORTANT: Place a stand under bracket (11) and surface up.
receive a reaction force. If holder (7) bears the
reaction force, strong force acts on pin (35). dCAUTION: Metal fragments may fly off when
Therefore, pin (35) may be deformed.
9. Place a stand under bracket (11).
personal injury.
The inner surfaces of the spring pins (12, 13) holes
on bracket (11) are stepped-shape. The spring pin 14. The holes of spring pins (3, 4) (2 used for each) in
can only be removed in one direction. cam (5) are stepped-shape. Tap the bottom of cam
Tap and remove spring pins (12, 13) from bracket (5) and remove spring pins (3, 4) (2 used for each)
(11) at the same time by using the special tool (ST from cams (5) (2 used) at the same time by using the
1237). Remove bracket (11) from pin (35). special tool (ST 1237).
Do not remove spring pin (10) with bracket (11) As the holes of spring pins (3, 4) (2 used for each)
attached unless necessary. are crimped, spring pins (3, 4) may feel tight when
The hole end of spring pin (10) has been crimped. removing.
12, 13
11
35
10
W176-02-07-019
a - Crimped Position
b - Stand
10. Remove socket bolts (9) (2 used) and spring washers

(8) (2 used). Remove damper (32) and rubber seat
(31) from pin (35). O-ring (34) is removed together.
l : 5 mm
W3-11-5-3

personal injury.
15. Remove pin (35) by using a bar and a hammer. At
the same time, cams (5) (2 used) are removed.
Do not remove bushings (6) (4 used) with holder
(7) attached unless necessary. If removing, remove
bushings (6) (4 used) by tapping by using the
special tool (ST 7256).
Remove O-rings (19) (2 used) from plugs (20) (2
used).
l : 5 mm
Remove O-rings (22) (2 used) from plugs (21) (2
used).
l : 6 mm
W3-11-5-4
Assembly of Travel Pilot Valve
11 32 31 1 2 35 6 12 10 13 7 5 3, 4 30
29
34 15
9
33
8 17
28
18
14
25
27
16
26
24
23
36
WDAA-03-12-025
1- Bolt, Washer (2 Used) 10- Spring Pin 19- *O-Ring (2 Used) 28- Oil Seal (4 Used)
2- Cover 11- Bracket (2 Used) 20- *Plug (2 Used) 29- Spring Washer (2 Used)
3- Spring Pin (2 Used) 12- Spring Pin (2 Used) 21- *Plug (2 Used) 30- Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13- Spring Pin (2 Used) 22- *O-Ring (2 Used) 31- Rubber Seat (2 Used)
5- Cam (2 Used) 14- O-Ring 23- Casing 32- Damper (2 Used)
6- Bushing (4 Used) 15- Bushing (4 Used) 24- Spool (4 Used) 33- O-Ring (2 Used)
7- Holder 16- Pusher (4 Used) 25- Spring (4 Used) 34- O-Ring (2 Used)
8- Spring Washer (4 Used) 17- Spring Guide (16 Used) 26- Spacer (4 Used) 35- Pin
9- Socket Bolt (4 Used) 18- Balance Spring (4 Used) 27- Shim (12 Used) 36- Plug
fNOTE: As for the parts with mark *, refer to W3-11-5-1.
W3-11-5-5
Assembly of Travel Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil dCAUTION: Metal fragments may fly off when
IMPORTANT: The pilot valve is the susceptible
personal injury.
hydraulic component to contamination. Keep the
parts clean when assembling. fNOTE: Bushings (6) (4 used) are identical.
1. Insert spacer (26), shims (27) (3 used), and balance  Insert bushings (6) (4 used) into the special tool
spring (18) into spool (24) in sequence. Install shim (ST 7256). Tap the special tool (ST 7256) by using a
(27) as the same condition before disassembling. hammer and install bushing (6) to the end of hole on
holder (7).
IMPORTANT: Check the direction to install spring
Stop tapping when the bushing (6) end is flush with
guide (17).
the hole end.
2. Compress balance spring (18) by hand. Install spring
guide (17) to spool (24) with the stepped part down. 7 ST 7256
IMPORTANT: Before inserting the parts into holder

(7) and casing (23), apply hydraulic oil.
3. Insert spring (25) into casing (23).
6
4. Insert the spool (24) assembly into the original port W178-02-11-310
before disassembling. Insert the spool (24) assembly
into casing (23) by rotating.
5. Install oil seal (28) to bushing (15).
6. Apply grease onto the inner surface of oil seal (28).
7. Install O-ring (14) and pusher (16) to bushing (15).
8. Apply grease onto the head of pusher (16).
9. Insert the pusher (16) assembly into casing (23).
10. Install other spools (24) in the same way as step 1 to
step 9.
11. When bushing (6) has been removed from holder
(7), install bushings (6) (4 used) to holder (7) by
using the special tool (ST 7256) in the following
procedures.
W3-11-5-6
 Install bushing (6) on the opposite side in the same 12. Install O-rings (33) (2 used) to pin (35). Apply grease
way. onto O-rings (33) (2 used). Install pin (35) and cams
6 (5) (2 used) to holder (7).
ST 7256 7
personal injury.
IMPORTANT: Check the direction to install spring
pins (3, 4).
W178-02-11-311
13. Install spring pins (3, 4) to cam (5) by using the
special tool (ST 1237). Secure cam (5) and pin (35).
 Install bushing (6) in the near side as illustrated. Stop At this time, the slits of spring pins (3, 4) should be
tapping when the bushing (6) end is flush with the positioned 90SDgr away each other.
outside of holder (7). Tap and install spring pins (3, 4) until spring pins
(3, 4) come in contact with the stepped part in the
6
hole.
7 ST 7256
3 a b
W178-02-11-312
a - Outside of Holder 4 W178-02-07-050
a - Slit
b - Slit
 Install bushing (6) in the near and opposite side as
illustrated. 14. Crimp the hole end of cam (5) where spring pins (3,
4) are inserted by using a punch.
6
15. Install other cam (5) in the same way as step 13 to
ST 7256 7 step 14.
W178-02-11-313
W3-11-5-7
16. Place holder (7) on the casing (23) assembly. Install 21. As for the direction to install bracket (11), refer to
holder (7) to casing (23) with socket bolts (30) (2 the figure in Disassembly of Travel Pilot Valve on
used) and spring washers (29) (2 used). W3-11-5-1. Install bracket (11) to pin (35). Fit the
Check the mark direction and install holder (7). holes to insert spring pins (12, 13).
l : 8 mm IMPORTANT: Place a stand under bracket (11) and

receive a reaction force. If holder (7) bears the
m : 50 N·m (5 kgf·m, 37 lbf·ft) reaction force, strong force acts on pin (35).
Therefore, pin (35) may be deformed.
17. Install rubber seats (31) (2 used) to pin (35).
22. Place a stand under bracket (11).
IMPORTANT: Check the direction of damper (32). Install spring pins (12, 13) to bracket (11) until they
The inner surface of damper (32) is edged-shape. come in contact with the stepped part by using
If damper (32) is pried when installing, O-ring (33) the special tool (ST 1237). The slits of spring pins (2
may be damaged. used) should be positioned 90° away each other.
18. Install dampers (32) (2 used) to pin (35) with the
lever up.
19. Secure damper (32) and rubber seat (31) to holder b c
(7) with socket bolts (9) (4 used) and spring washers
(8) (4 used). 11 35
l : 5 mm
m : 7 N·m (0.7 kgf·m, 5 lbf·ft)

12, 13
20. Apply grease onto O-ring (34). Push O-rings (34) (2 a
used) to the end of pin (35).
W176-02-07-011
a - Stand
b - Crimped Position
c - Crimped Position
W3-11-5-8
23. Crimp the hole edge of bracket (11) where spring

pins (12, 13) are inserted by using a punch.
24. Install other bracket (11) in the same way as step 22
to step 23.
25. Install cover (2) to holder (7) with bolts, washers (1)
(2 used).
j : 10 mm
m : 5 N·m (0.5 kgf·m, 3.5 lbf·ft)

26. Apply grease onto the spring pin (10) contact part
of dampers (32) (2 used).
27. Install O-rings (19) (2 used) to plugs (20) (2 used).
Install plugs (20) (2 used) to casing (23).
j : 5 mm
m : 10 N·m (1 kgf·m, 7.5 lbf·ft)

Install plugs (21) (2 used) to casing (23).
j : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-11-5-9
(Blank)
W3-11-5-10
Removal and Installation of Pilot Shut-Off

Solenoid Valve
4 2, 3 WJAA-03-01-016

Removal
1. Swing the upperstructure by 90 degrees and set the
machine for inspection and maintenance. (Refer to
W1-6-1.)

(Refer to W1-4-1.)
2. Open door (1).
3. Remove a floor mat.

not drop cover (4).
4. Remove bolts, washers (2) (7 used) and washers (3)
(3 used). Remove cover (4).
j : 19 mm
W3-12-1-1
6
8
WJAA-03-13-007 WDAA-03-13-007
7

6. Place a container under pilot shut-off solenoid valve
(6). Disconnect hoses (7) (10 used).
j : 19 mm
7. Remove bolts, washers (8) (2 used). Remove pilot
shut-off solenoid valve (6).
j : 17 mm
8. Remove the adapter with pilot shut-off solenoid
valve (6) attached if necessary.
W3-12-1-2
6
8
WJAA-03-13-007 WDAA-03-13-007
7
Installation
1. Install all removed adapters to pilot shut-off
solenoid valve (6).
2. Install pilot shut-off solenoid valve (6) with bolts,
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-12-1-3
4 2, 3 WJAA-03-01-016

4-1.)
6. Install cover (4) with washers (3) (3 used) and bolts,
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

7. Install a floor mat.
8. Shut door (1).
W3-12-1-4
Section 3 UPPERSTRUCTURE
Removal and Installation of 4-Spool Solenoid

Valve Unit
2 3 4
WJAA-03-07-002 WJAA-03-07-013
IMPORTANT: Cap the open ends in case the hoses 3. Open covers (3, 4).
Removal
d(Refer
to W1-4-1.)
d CAUTION: Cover (1) weight : 24 kg (53 lb)

dnot
drop cover (1).
(1).
j : 19 mm
W3-12-2-1
WJAC-03-12-010
4. Disconnect connectors (7) (4 used). 8. Remove bolts, washers (11) (2 used). Remove
4-spool solenoid valve unit (12).
5. Place a container under 4-spool solenoid valve unit
(12). Disconnect hose (8). j : 17 mm
j : 27 mm 9. Remove the adapter with 4-spool solenoid valve
unit (12) attached if necessary.
j : 17 mm
j : 19 mm
W3-12-2-2
WJAC-03-12-010
Installation 6. Connect connectors (7) (4 used).

1. Install all removed adapters to 4-spool solenoid
valve unit (12).
2. Install 4-spool solenoid valve unit (12) with bolts,
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

j : 27 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)
W3-12-2-3
2 3 4
WJAA-03-07-002 WJAA-03-07-013
7. Shut covers (3, 4).

4-1.)
d CAUTION: Cover (1) weight : 24 kg (53 lb)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-12-2-4
Removal and Installation of 2-Spool Solenoid

Valve Unit
2, 3, 4 7, 8, 9 11
6 5 10 WJAC-03-07-001

Removal

(Refer to W1-4-1.)
j : 19 mm
j : 19 mm
j : 19 mm
(11).
j : 19 mm
W3-12-3-1
WJAC-03-12-001

7. Place a container under 2-spool solenoid valve unit
(11). Disconnect hoses (14) (2 used).
j : 19 mm
j : 17 mm
2-spool solenoid valve unit (11).
j : 17 mm
10. Remove the adapter with 2-spool solenoid valve
unit (11) attached if necessary.
W3-12-3-2
WJAC-03-12-001
Installation
1. Install all removed adapters to 2-spool solenoid
valve unit (11).
2. Install 2-spool solenoid valve unit (11) with bolts,
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-12-3-3
2, 3, 4 7, 8, 9 11
6 5 10 WJAC-03-07-001

4-1.)
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

washer (2).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-12-3-4
SECTION 3 UPPER STRUCTURE
Disassembly of Pilot Shut-Off Solenoid Valve
WDAA-03-13-014
1- Socket Bolt (2 Used) 4- Body 7- O-Ring

2- Solenoid 5- Spool 8- Plug
3- O-Ring 6- Spring 9- Filter
W3-12-4-1
Disassembly of Pilot Shut-Off Solenoid Valve

IMPORTANT: Filter (9) cannot be removed.
1. Put the matching marks on body (4) and solenoid
(2). Secure body (4) in a vise. Remove socket bolts
(1) (2 used) from body (4). Remove solenoid (2) and
O-ring (3) from body (4).
l : 4 mm
2. Remove plug (8) from body (4). Remove O-ring (7)
from plug (8).
l : 6 mm
3. Remove spring (6) and spool (5) from body (4).
W3-12-4-2
Assembly of Pilot Shut-Off Solenoid Valve
2
1
3
T1V1-03-07-012
1- Socket Bolt (2 Used) 4- Body 7- O-Ring

2- Solenoid 5- Spool 8- Plug
3- O-Ring 6- Spring 9- Filter
W3-12-4-3
Assembly of Pilot Shut-Off Solenoid Valve

1. Secure body (4) in a vise. Insert spool (5) and spring
(6) into body (4).
2. Install O-ring (7) to plug (8). Install plug (8) to body
(4).
l : 6 mm
m : 27 N·m (2.7 kgf·m, 20 lbf·ft)

IMPORTANT: When solenoid (2) is installed after
installing O-ring (3) to body (4), O-ring (3) may be
damaged.
3. Install O-ring (3) to solenoid (2). Fit the matching
marks and install solenoid (2) to body (4).
4. Install solenoid (2) to body (4) with socket bolts (1)
(2 used).
l : 4 mm
m : 4 N·m (0.4 kgf·m, 3 lbf·ft)
W3-12-4-4
Structure of 4-Spool Solenoid Valve Unit
2 3
WJAA-03-13-001
4
3 6 7 8 9 10
11
15 14 13 12
WJAA-03-13-002
W3-12-5-1

No. Part Name Q’ty (mm) Remark
N·m (kgf·m, lbf·ft)
1 Body 1
2 Socket Bolt 8 l:4 5 (0.5, 3.7)
3 Solenoid 4
4 Plug (Filter) 4 l:6 10 (1, 7.4)
5 Plug (Filter) 1 l : 10 20 (2, 15)
6 Washer 4
7 Spring 4
8 Spool 4
9 Sleeve 4
10 Plate 4
11 Wave Spring 4
12 O-Ring 4
13 O-Ring 4
14 O-Ring 4
15 O-Ring 4
W3-12-5-2
Structure of 2-Spool Solenoid Valve Unit
1
5
4 WJAA-03-13-003
3 6 7 8 9 10
11
15 14 13 12
WJAA-03-13-004
W3-12-6-1

1 Body 1
2 Socket Bolt 4 l:4 5 (0.5, 3.7)
3 Solenoid 2
4 Plug (Filter) 2 l:6 10 (1, 7.4)
5 Plug (Filter) 1 l : 10 20 (2, 15)
6 Washer 2
7 Spring 2
8 Spool 2
9 Sleeve 2
10 Plate 2
11 Wave Spring 2
12 O-Ring 2
13 O-Ring 2
14 O-Ring 2
15 O-Ring 2
W3-12-6-2
Removal and Installation of Signal Control

Valve
2, 3, 4 7, 8, 9 11
6 5 10 WJAC-03-07-001

Removal

(Refer to W1-4-1.)
j : 19 mm
j : 19 mm
j : 19 mm
(11).
j : 19 mm
W3-13-1-1
Pilot Valve Side

15
14
b
15
15
a WJAC-03-13-001
a- Pilot Valve Side b- Control Valve Side 15 WJAA-03-14-002
6. Place a container under signal control valve (14).

Disconnect hoses (15) (18 used).
j : 19 mm
W3-13-1-2
Control Valve Side
10 11 9
14
b
9
10
9
10
12, 13
a WJAC-03-13-001
a- Pilot Valve Side b- Control Valve Side 10 11 9 WJAA-03-14-003
j : 19 mm
j : 17 mm
(4 used). Remove signal control valve (14).
l : 8 mm
11. Remove the adapter with signal control valve (14)
W3-13-1-3
Control Valve Side
10 11 9
14
b
9
10
9
10
12, 13
a WJAC-03-13-001
a- Pilot Valve Side b- Control Valve Side

10 11 9 WJAA-03-14-003
Installation
1. Install all removed adapters to signal control valve
(14).
2. Install signal control valve (14) with washers (13) (4
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-13-1-4
Pilot Valve Side

15
14
b
15
15
a WJAC-03-13-001
a- Pilot Valve Side b- Control Valve Side 15 WJAA-03-14-002
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-13-1-5
2, 3, 4 7, 8, 9 11
6 5 10 WJAC-03-07-001

4-1.)
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

washer (2).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-13-1-6
Structure of Signal Control Valve

13
12 4
11
4 10
7 8
7
7
4 4
W1JB-02-10-002
W3-13-2-1
15
16
17
18
19
14 16
17 20
21
19
16 20
17
18
19
20
14
22
23
24
25
26
27
19
28
17
16
29
20
19 14
5 18
17
16
20 19
21
17
16
20
19
18
17
16
W1JB-02-10-003
1- Bolt (3 Used) 9- Body 3 17- O-Ring (7 Used) 25- O-Ring

2- Body 1 10- Gasket 18- Spring (4 Used) 26- Spring
3- Gasket 11- Body 4 19- Spring Guide (7 Used) 27- Spool
4- Filter (17 Used) 12- Gasket 20- Spool (6 Used) 28- Spring
5- Body 2 13- Body 5 21- Spring (2 Used) 29- Plate
6- Gasket 14- Socket Bolt (11 Used) 22- Plate
7- Shuttle Valve (2 Used) 15- Plate 23- O-Ring
8- Spring (4 Used) 16- Plug (7 Used) 24- Shuttle Valve
W3-13-2-2
Removal and Installation of Shockless Valve
Detail A
3 1 2
WJAA-03-15-001
A
WJAA-03-02-001
IMPORTANT: Cap the open ends in case the hoses 2. Disconnect hoses (1) (2 used).
attach an identification tag onto the connectors, j : 19 mm
hoses, and pipes for assembling. Connect the 3. Remove bolts, washers (2) (2 used). Remove
hoses and install the clips in case the clips which shockless valve (3).
Removal j : 13 mm
1. Set the machine position for inspection and 4. Remove the adapter with shockless valve (3)
maintenance. (Refer to W1-6-1.) attached if necessary.

(Refer to W1-4-1.)
W3-14-1-1
Detail A
3 1 2
WJAA-03-15-001
A
WJAA-03-02-001
Installation 4. Bleed air from the hydraulic system. (Refer to W1-

4-1.)
1. Install all removed adapters to shockless valve (3).
2. Install shockless valve (3) with bolts, washers (2) (2
used).
j : 13 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-14-1-2
Structure of Shockless Valve
4 5 6 7
T183-03-07-008

1 Plug 2 l:8 40 (4, 30)
2 O-Ring 2
3 Body 1
4 Spring 2
5 Plunger 1
6 Ring 1
7 Orifice 1
W3-14-2-1
(Blank)
W3-14-2-2
MEMO
MEMO
SECTION 4
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
Removal and Installation of Swing Bearing..........W4-1-1-1
Disassembly of Swing Bearing...................................W4-1-2-1
Assembly of Swing Bearing.........................................W4-1-2-4
Group 2 Travel Device
Removal and Installation of Travel Device.............W4-2-1-1
Disassembly of Travel Device......................................W4-2-2-1
Assembly of Travel Device...........................................W4-2-2-8
Disassembly of Travel Motor.......................................W4-2-3-1
Assembly of Travel Motor............................................W4-2-3-5
Disassembly of Brake Valve.........................................W4-2-4-1
Assembly of Brake Valve...............................................W4-2-4-4
Removal and Installation of Center Joint...............W4-3-1-1
Disassembly of Center Joint........................................W4-3-2-1
Assembly of Center Joint.............................................W4-3-2-3
Replacement of Body and Spindle...........................W4-3-2-6
Removal and Installation of Track Adjuster...........W4-4-1-1
Disassembly of Track Adjuster....................................W4-4-2-1
Assembly of Track Adjuster.........................................W4-4-2-6
Group 5 Front Idler
Removal and Installation of Front Idler...................W4-5-1-1
Disassembly of Front Idler...........................................W4-5-2-1
Assembly of Front Idler.................................................W4-5-2-4
Group 6 Upper and Lower Rollers
Removal and Installation of Upper Roller..............W4-6-1-1
Removal and Installation of Lower Roller..............W4-6-2-1
Disassembly of Lower Roller.......................................W4-6-3-1
Assembly of Lower Roller.............................................W4-6-3-3
Group 7 Track
Removal and Installation of Track.............................W4-7-1-1
JACW-4-1
(Blank)
JACW-4-2
SECTION 4 UNDERCARRIAGE
Removal and Installation of Swing Bearing

1 4
a 1
W105-03-01-002
2 3
a- Matching Mark 3
W142-03-01-001
ST 0051
1
W110-03-01-004
Before removing and installing the swing bearing, the

upperstructure must be removed first. (Refer to W3-3-1.) dCAUTION:
(1440 lb)
Swing bearing (1) weight: 650 kg
Therefore, the procedure starts on the premise that the
upperstructure has already been removed here. 3. Install special tools (ST 0051) (3 used) to swing
bearing (1). Attach wire ropes onto special tools
Removal (ST 0051) (3 used). Hoist swing bearing (1). Remove
swing bearing (1).
1. Put matching mark (a) on inner race (2) of swing
bearing (1) and track frame (3). fNOTE: THREEBOND #1102 has been applied between
2. Remove bolts (4) (40 used). swing bearing (1) and track frame (3).
j : 41 mm
W4-1-1-1
a 1 ST 0051
1 W110-03-01-004
e b
2 3
a- Matching Mark
W142-03-01-001
c
WJAA-04-01-003
b- Position for Grease Fitting
c- Soft Zone Marking Position
d- Position for Plug
e- Front Side
Installation IMPORTANT: If matching marks (a) do not fit, the soft

zone position of inner race will be dislocated.
1. Clean the mounting surfaces of track frame (3) and
swing bearing (1). 4. Fit matching marks (a) on track frame (3) and inner
race (2) of swing bearing (1).
2. Apply THREEBOND #1102 onto the swing bearing
(1) mounting surface of track frame (3).
dCAUTION:
(1440 lb)
Swing bearing (1) weight: 650 kg
3. Install special tools (ST 0051) (3 used) to swing

bearing (1). Attach wire ropes onto special tools (ST
0051) (3 used). Hoist swing bearing (1).
W4-1-1-2
1 4
1 f 7
5mm
W105-03-01-002 6
W175-03-01-002
f- Grease Level
5. Install swing bearing (1) with bolts (4) (40 used).
j : 41 mm
m : 1400 N·m (140 kgf·m, 1030 lbf·ft)

6. After installing swing bearing (1), add grease
(Alvania EP2 or equivalent) to grease bath (6) until
pinion (7) of the swing device is 5 mm (0.2 in) under
grease.
fNOTE: Grease amount: 17 L (4.5 US gal)
W4-1-1-3
(Blank)
W4-1-1-4
Disassembly of Swing Bearing

1 2 3
7 6
5
8
W1J1-03-01-001
9
1
WJAA-04-01-001
1- Outer Race 5- Seal 9- Grease Fitting

2- Seal 6- Ball (86 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (86 Used)
W4-1-2-1
Disassembly of Swing Bearing 3. Install bolt (10) to the screw hole (M10, Pitch 1.5
mm) of plug (4). Tap from within or pull bolt (10)
and remove plug (4) from outer race (1).

personal injury.
1. Grind off the crimped part of pin (3) by using a
grinder. Tap the bottom side of pin (3) of plug (4) by 1
using a bar and a hammer. Remove pin (3) of plug
(4).
3
4
W178-02-11-196
10
W178-02-11-195
dCAUTION:
lb)
Swing Bearing weight: 650 kg (1440
4. Place inner race (7) of swing bearing on a wooden

2. Thread hole (a) of plug (4) by using a tap (M10, Pitch
block by using the special tool (ST 0051). Hoist outer
1.5 mm).
race (1) horizontally. Hold outer race (1).
a- Hole
W4-1-2-2
5. Remove balls (6) (86 used) and supports (8) (86

used) from the plug (4) hole while rotating outer
race (1).
1
2
11 7
6 5
W178-02-11-197
12
8
W178-02-11-198
fNOTE: Remove ball (6) by using magnet (11). Use wire

(12) and remove support (8).
6. Remove seals (2, 5) from outer race (1) and inner
race (7) by using a scrapper.
W4-1-2-3
Assembly of Swing Bearing

1 2 3
8 7 6 5
W178-02-11-193
9
1
WJAA-04-01-001
1- Outer Race 5- Seal 9- Grease Fitting

2- Seal 6- Ball (86 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (86 Used)
W4-1-2-4
Assembly of Swing Bearing
dCAUTION:
lb)
Swing Bearing weight: 650 kg (1440 dCAUTION: Metal fragments may fly off when
1. Install special tools (ST 0051) (3 used) to outer race such as goggles, helmets, etc in order to prevent
(1). Attach a wire rope onto special tools (ST 0051) personal injury.
(3 used). Hoist the swing bearing horizontally. Align 2. Install plug (4) to outer race (1) by using a hammer.
outer race (1) and inner race (7) coaxially. Apply Secure plug (4) to outer race (1) with pin (3). Crimp
grease onto balls (6) (86 used) and supports (8) (86 the pin (3) hole of outer race (1) by using a punch (2
used). Install balls (6) (86 used) and supports (8) (86 places).
used) alternately from the plug (4) hole by using a
round bar while turning outer race (1).
1
2
6
W178-02-11-201
5
W178-02-11-199
W178-02-11-200
W4-1-2-5
3. Degrease the groove part for seals (2, 5) completely.

Apply THREEBOND #1530D onto seals (2,5).Install
seals (2, 5) to outer race (1) and inner race (7).
4. Add grease (Alvania EP2 or equivalent) to the swing
bearing through grease fitting (9). At this time, add
grease while turning outer race (1).
fNOTE: Grease amount: 1.2 L (0.3 US gal)
W4-1-2-6
Removal and Installation of Travel Device
WJAA-04-02-013
Removal
4. Install eyebolts (M16, Pitch 2 mm) to the bolt (2)
hole. Attach nylon slings onto the eyebolts. Hoist
and hold cover (4).
hoses and install the clips in case the clips which 5. Remove bolts (11) (5 used) and spring washers (12)
secure the hoses have been removed. (5 used). Remove cover (4).
j : 24 mm
Removal

(Refer to W1-4-1.)
2. Disconnect track (1). (Refer to W4-6-1.)
3. Remove bolt (2) and washers (3) (2 used).
j : 24 mm
W4-2-1-1
WJAA-04-02-014
6. Place a container under travel device (5). Remove

socket bolts (13) (8 used) and flanges (14) (4 used). dlb)
CAUTION: Travel device (5) weight: 680 kg (1500
Disconnect hoses (6) (2 used).
9. Attach nylon slings onto travel device (5). Hoist and
l : 10 mm hold travel device (5). Remove bolts (9) (20 used)
7. Disconnect hose (7). and washers (10) (20 used). Hoist and remove travel
device (5).
j : 27 mm
j : 32 mm
10. Remove the adapter with travel device (5) attached
j : 19 mm if necessary.
11. Remove another travel device in the same way as
step 1 to step 10.
W4-2-1-2
WJAA-04-02-014
Installation 4. Connect hose (7).

1. Install all removed adapters to travel device (5). j : 27 mm
dlb)
CAUTION: Travel device (5) weight: 680 kg (1500 m : 80 N·m (8 kgf·m, 59 lbf·ft)
5. Connect hoses (6) (2 used) with flanges (14) (4 used)
2. Attach nylon slings onto travel device (5). Hoist
and socket bolts (13) (8 used).
travel device (5). Install travel device (5) with
washers (10) (20 used) and bolts (9) (20 used). l : 10 mm
m : 750 N·m (75 kgf·m, 550 lbf·ft)
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W4-2-1-3
WJAA-04-02-013
6. Connect track (1). (Refer to W4-6-1.)

7. Install another travel device in the same way as step
9. Install eyebolts (M16, Pitch 2 mm) to the bolt (2)
1 to step 6.
hole. Attach nylon slings onto the eyebolts. Hoist
8. Bleed air from the hydraulic system. (Refer to W1- cover (4).
4-1.)
10. Install cover (4) with spring washers (12) (5 used)
IMPORTANT: Check the hydraulic oil level. Start the and bolts (11) (5 used).
engine and check for any oil leaks. In order to
prevent the travel motor from seizing, perform j : 24 mm
the break-in operation after installing.
m : 210 N·m (21 kgf·m, 155 lbf·ft)
11. Install washers (3) (2 used) and bolt (2).
Condition: 1. Engine speed: Slow idle speed
2. Travel mode switch: Slow speed j : 24 mm
3. Operation duration: Over 2 minutes m : 210 N·m (21 kgf·m, 155 lbf·ft)
12. Install another cover (4) in the same way as step 9 to
step 11.
W4-2-1-4
Disassembly of Travel Device

10
9
8
7
6
5
4
3
2 24 25 26
23
22
21
1 20
19 27
18
17
28
16
15 29
30
14
31
32
11 12 13 33
34
35
36 51
37
39 38
40
42 41
50
49
48
47
46
45
43 44 W1J1-03-02-006
1- Travel Motor 15- Washer (24 Used) 28- Spacer 40- Needle Bearing (4 Used)
2- Bolt (4 Used) 16- Bolt (24 Used) 29- First Stage Carrier 41- Needle Bearing (4 Used)
3- Spring Washer (4 Used) 17- Third Stage Carrier 30- Thrust Plate (3 Used) 42- Thrust Plate (4 Used)
4- O-Ring 18- Third Stage Sun Gear 31- Spring Pin (3 Used) 43- Shaft
5- Housing 19- Second Stage Carrier 32- Second Stage Planetary Gear 44- Ring Gear
6- Floating Seal 20- Spacer (3 Used) 45- Bolt (30 Used)
7- Roller Bearing 21- Second Stage Sun Gear 33- Pin (3 Used) 46- Retaining Ring
8- Drum 22- Thrust Plate (3 Used) 34- Needle Bearing (3 Used) 47- Stopper Pin
9- Roller Bearing 23- Needle Bearing (3 Used) 35- Thrust Plate (3 Used) 48- Ball Bearing
10- O-Ring 24- Pin (3 Used) 36- Thrust Plate (4 Used) 49- Cover
11- Bearing Nut 25- First Stage Planetary Gear (3 37- Third Stage Planetary Gear (4 50- Bolt (16 Used)
12- Lock Plate Used) Used) 51- Plug (3 Used)
13- Bolt (2 Used) 26- Thrust Plate (3 Used) 38- Spring Pin (4 Used)
14- Sprocket 27- Spring Pin (3 Used) 39- Pin (4 Used)
W4-2-2-1
Disassembly of Travel Device
dCAUTION: There may be pressure accumulated dCAUTION:

lb)
Travel motor (1) weight: 134 kg (300
inside of the travel device. Loosen the air bleed
plug slowly. Release any remaining pressure 2. Put the matching marks on travel motor (1) and
completely. Remove the drain plug and drain gear housing (5). Install an eyebolt (M12, Pitch 1.75 mm)
oil. If the air bleed plug is loosened suddenly, the to lifting hole (c) ( 2 places) of travel motor (1).
plug may be fly out and gear oil may gush out. Attach a nylon sling onto the eyebolt. Hoist and
Keep body and face away from plug. hold travel motor (1). Remove bolts (2) (4 used) and
spring washers (3) (4 used) from travel motor (1).
dCAUTION: Travel Device weight: 671 kg (1480 lb) Remove travel motor (1) from housing (5). Remove
1. Attach a nylon sling onto the body of travel device. O-ring (4) from travel motor (1).
Hoist and hold the travel device. Place a container
under the travel device. Loosen plug (51a) by 2 to l : 27 mm
3 turns. Remove plug (51b). Drain gear oil from
the travel device. Place the travel device on a
workbench with the travel motor (1) side up. 2, 3
fNOTE: Amount of oil: 11.0 L (2.9 US gal) 5
j : 14 mm
51a
c
c - Lifting Hole
W16J-03-02-002
51b
WJAA-04-02-004
W4-2-2-2
7. Remove shaft (43) from first stage carrier (29).

d CAUTION: Travel reduction gear weight: 540 kg
(1200 lb)
Remove the first stage carrier (29) assembly and
second stage sun gear (21) from second stage
3. Attach a nylon sling onto the body of drum and carrier (19).
ring gear (44). Hoist the travel reduction gear. Place
the travel reduction gear on a workbench with the dCAUTION: The second stage carrier (19)
assembly weight: 25 kg (60 lb)
cover (49) side up.
8. Attach two nylon slings onto second stage carrier
dCAUTION: Cover (49) weight: 22 kg (49 lb) (19). Hoist second stage carrier (19). Remove the
4. Put the matching marks on cover (49) and ring gear second stage carrier (19) assembly and third stage
(44). Install an eyebolt (R3/4) to the plug (51) hole (2 sun gear (18) from third stage carrier (17).
places) of cover (49). Attach a nylon sling onto the
eyebolt. Hoist and hold cover (49). Remove bolts
(50) (16 used) from cover (49). Remove cover (49)
from ring gear (44).
j : 22 mm
fNOTE: THREEBOND #1389B has been applied between

ring gear (44) and cover (49). If it is difficult to remove,
pry it out by using a screwdriver.

5. Put the matching marks on ring gear (44) and drum
(8). Install an eyebolt (M14, Pitch 2.0 mm) to the bolt
(50) hole (2 places) of ring gear (44). Attach a nylon
sling onto the eyebolt. Hoist and hold ring gear (44).
6. Remove bolts (45) (30 used) from ring gear (44).
Remove ring gear (44) from drum (8). Remove
O-ring (10) from drum (8).
j : 27 mm
W4-2-2-3
dCAUTION: The third stage carrier (17) assembly

9. Attach two nylon slings onto third stage carrier (17).
Hoist third stage carrier (17). Remove the third stage
carrier (17) assembly from drum (8).
10. Remove bolts (13) (2 used) from lock plate (12).
Remove lock plate (12) from bearing nut (11).
j : 19 mm
11. Install the special tool (ST 3136) to bearing nut (11).
Remove bearing nut (11) from housing (5).
ST 3136
W1JB-03-02-003
W4-2-2-4
16. Put the matching marks on sprocket (14) and drum

d CAUTION: Drum (8) + sprocket (14) + others
(8).
IMPORTANT: The housing (5) side of drum (8) is the dCAUTION: Sprocket (14) weight: 85 kg (190 lb)
seal sliding surface for housing (5). Place it on a
wooden block after removing.
dCAUTION: When removing sprocket (14),
gather up the nylon sling and hoist sprocket (14)
12. Put the matching marks on drum (8) and housing horizontally. Do not drop sprocket (14).
(5). Install an eyebolt (M18, Pitch 2.5 mm) to the bolt 17. Remove bolts (16) (24 used) and washers (15) (24
(45) hole (2 places) of drum (8). Attach a nylon sling used) from sprocket (14). Attach a nylon sling onto
onto the eyebolt. Hoist and hold drum (8). sprocket (14). Hoist sprocket (14). Remove sprocket
13. Remove the drum (8) assembly from housing (5). (14) from drum (8).
Remove the inner race of roller bearing (9) from
j : 32 mm
drum (8).
IMPORTANT: Handle floating seal (6) with care. fNOTE: LOCTITE #262 has been applied on bolt (16).
(Refer to W4-2-5.)
14. Remove one side of floating seal (6) from housing
(5).

personal injury.
IMPORTANT: Do not remove the inner race of roller
bearing (7) unless necessary. When it has been
removed, replace it with the new one.
15. Remove the inner race of roller bearing (7) from
housing (5) by using a bar and a hammer.
W4-2-2-5

such as goggles, helmets, etc in order to prevent such as goggles, helmets, etc in order to prevent
personal injury. personal injury.
IMPORTANT: Do not remove the outer race of roller IMPORTANT: Do not remove the outer race of roller
bearing (7) unless necessary. When it has been bearing (9) unless necessary. When it has been
removed, replace it with the new one. removed, replace it with the new one.
18. Remove the outer race of roller bearing (7) from 21. Remove the outer race of roller bearing (9) from
drum (8) by using a bar and a hammer. drum (8) by using a bar and a hammer.
dCAUTION:
lb)
Drum (8) + others weight: 100 kg (225 22. Remove spring pin (38) from third stage carrier
(17) by using a round bar (diameter: 8 mm, 0.3 in).
Remove pin (39), third stage planetary gear (37),
19. Install an eyebolt (M22, Pitch 2.5 mm) to the bolt
and thrust plates (36, 42) from third stage carrier
(16) hole (2 places) of drum (8) through the motor
(17). Remove needle bearings (40, 41) from third
(1) side. Attach a nylon sling onto the eyebolt. Hoist
stage planetary gear (37).
and turn over drum (8).
IMPORTANT: Handle floating seal (6) with care.
(Refer to W4-2-5.)
20. Remove one side of floating seal (6) from drum (8).
W4-2-2-6
23. Remove spring pins (38) (3 used), pins (39) (3

used), third stage planetary gears (37) (3 used),
thrust plates (36, 42) (3 used for each), and needle
bearings (40, 41) (3 used for each) from third stage
carrier (17) in the same way as step 22.
24. Disassemble the first stage carrier (29) assembly and
the second stage carrier (19) assembly in the same
way as step 22 and step 23.
Spring pin (27)
Diameter of round bar: 4 mm (0.16 in)
Spring pin (31)
Diameter of round bar: 5 mm (0.20 in)
25. Remove spacer (28) from first stage carrier (29).
Remove spacer (20) from second stage carrier (19).
W4-2-2-7
Assembly of Travel Device
14 15 16
1 2 3 4 5 6 8 7 9 11 10 45 44 17 18 20 19 21 28 29
51
49
46
48
47
43
25
26
27
24
23
22
50
36 38 35 32 34 33 30 31
12 13 42 37 41 40 39
T16J-03-05-001
1- Travel Motor 15- Washer (24 Used) 28- Spacer 40- Needle Bearing (4 Used)
2- Bolt (4 Used) 16- Bolt (24 Used) 29- First Stage Carrier 41- Needle Bearing (4 Used)
3- Spring Washer (4 Used) 17- Third Stage Carrier 30- Thrust Plate (3 Used) 42- Thrust Plate (4 Used)
4- O-Ring 18- Third Stage Sun Gear 31- Spring Pin (3 Used) 43- Shaft
5- Housing 19- Second Stage Carrier 32- Second Stage Planetary Gear 44- Ring Gear
6- Floating Seal 20- Spacer (3 Used) 45- Bolt (30 Used)
7- Roller Bearing 21- Second Stage Sun Gear 33- Pin (3 Used) 46- Retaining Ring
8- Drum 22- Thrust Plate (3 Used) 34- Needle Bearing (3 Used) 47- Stopper Pin
9- Roller Bearing 23- Needle Bearing (3 Used) 35- Thrust Plate (3 Used) 48- Ball Bearing
10- O-Ring 24- Pin (3 Used) 36- Thrust Plate (4 Used) 49- Cover
11- Bearing Nut 25- First Stage Planetary Gear (3 37- Third Stage Planetary Gear (4 50- Bolt (16 Used)
12- Lock Plate Used) Used) 51- Plug (3 Used)
13- Bolt (2 Used) 26- Thrust Plate (3 Used) 38- Spring Pin (4 Used)
14- Sprocket 27- Spring Pin (3 Used) 39- Pin (4 Used)
W4-2-2-8
Assembly of Travel Device

dCAUTION: Drum (8) weight: 100 kg (225 lb)
dCAUTION: Housing (5) weight: 90 kg (200 lb)
1. Attach a nylon sling onto the body of housing (5). such as goggles, helmets, etc in order to prevent
Hoist housing (5). Place housing (5) with the motor personal injury.
(1) side down. IMPORTANT: Do not tap except for the outer race of
IMPORTANT: Handle floating seal (6) with care. roller bearing (7).
(Refer to W4-2-5.) 4. Install an eyebolt (M22, Pitch 2.5 mm) to the bolt
2. Apply grease onto O-ring of one side of floating seal (16) hole (2 places) of drum (8) through the motor
(6). Install one side of floating seal (6) to housing (1) side. Attach a nylon sling onto the eyebolt. Hoist
(5). Apply gear oil onto the whole sliding surface on drum (8). Place drum (8) with the ring gear (44)
floating seal (6). side down. Evenly tap and install the outer race of
roller bearing (7) to drum (8) by using a bar and a
fNOTE: If it is difficult to install O-ring of floating seal hammer.
(6), push O-ring to the periphery direction by using a
bamboo spatula. fNOTE: Check that the outer race of roller bearing (7) is
installed completely.
personal injury.
dCAUTION:
hot.
Be careful as roller bearing (7) is too
3. Warm up the inner race of roller bearing (7) to 50

to 70 °C (122 to 158 °F) by using a heater. Install
the inner race of roller bearing (7) to housing (5) by
fNOTE: Check that the inner race of roller bearing (7) is

W4-2-2-9

(Refer to W4-2-5.) dCAUTION: Sprocket (14) weight: 85 kg (190 lb)
5. Apply grease onto O-ring of other side of floating
seal (6). Install one side of floating seal (6) to drum
dCAUTION: When installing sprocket (14),
gather up the nylon sling and hoist sprocket (14)
(8). horizontally. Do not drop cover (14).
IMPORTANT: Fit the chamfered side of sprocket (14)
fNOTE: If it is difficult to install O-ring of floating seal
to the drum (8) side.
(6), push O-ring to the periphery direction by using a
bamboo spatula. 8. Attach two nylon slings onto sprocket (14). Hoist
sprocket (14). Place sprocket (14) onto drum (8).
(45) hole (2 places) of drum (8) through the ring 9. Degrease the bolt (16) holes on drum (8) and bolts
gear (44) side. Attach a nylon sling onto the eyebolt. (16) (24 used). Apply LOCTITE #262 onto bolts (16)
Hoist drum (8). Place drum (8) with the ring gear (24 used). Install sprocket (14) to drum (8) with bolts
(44) side up. (16) (24 used) and spring washers (15) (24 used).

j : 32 mm
such as goggles, helmets, etc in order to prevent m : 750 N·m (75 kgf·m, 550 lbf·ft)
personal injury.
IMPORTANT: Do not tap except for the outer race of
roller bearing (9).
7. Evenly tap and install the outer race of roller bearing
(9) to drum (8) by using a bar and a hammer.
fNOTE: Check that the outer race of roller bearing (9) is

W4-2-2-10
dCAUTION: Drum (8) + sprocket (14) + others

10. Hoist the drum (8) assembly. Fit the matching marks
made when disassembling and place the drum (8)
assembly straight on housing (5). At this time, check
that the clearance between housing (5) and drum
(8) is even all around.
11. While applying the weight and shaking drum (8),
push drum (8) into housing (5) straight.

personal injury.
dCAUTION:
hot.
Be careful as roller bearing (9) is too
12. Warm up the inner race of roller bearing (9) to 50

to 70 °C (122 to 158 °F) by using a heater. Install
the inner race of roller bearing (9) to housing (5) by
fNOTE: Check that the inner race of roller bearing (9) is

IMPORTANT: Check the direction to install bearing
nut (11).
13. Apply grease onto the thread part of bearing nut
(11). Install bearing nut (11) to housing (5) with the
machine surface facing to the roller bearing (9) side.
Tighten bearing nut (11) by hand.
W4-2-2-11
14. Install bearing nut (11) by using the special tool (ST IMPORTANT: There is an identification groove on one
3136) and a torque wrench. side of third stage planetary gear (37). Install third
stage planetary gear (37) with the identification
m : 500 N·m (50 kgf·m, 370 lbf·ft) groove side facing to the cover (49) side.
ST 3136 19. Install needle bearings (40, 41) to third stage
planetary gear (37).
20. Secure third stage planetary gear (37) between
thrust plates (36, 42). Install them to third stage
carrier (17).
21. Install pin (39) to third stage carrier (17). At this time,
fit the spring pin (38) holes of third stage carrier (17)
and pin (39).
22. Install spring pin (38) to third stage carrier (17) with
W1JB-03-02-003 the slit (a) side facing to the second stage carrier
(19) side.
15. After installing bearing nut (11), tap the sprocket 38
(14) end by using a hammer and reduce play. Rotate 39
a
sprocket (14) both clockwise and counterclockwise
by 4 to 5 turns.
16. Repeat step 14 and step 15.
a - Slit W178-02-11-210
17. Tighten bearing nut (11) in the same way as step 14
again. 23. Install other third stage planetary gears (37) (3 used)
to third stage carrier (17) in the same way as step 19
m : 500 N·m (50 kgf·m, 370 lbf·ft) to step 22.
IMPORTANT: In case the spline of lock plate (12) and
that of housing (5) do not fit, tighten bearing nut
(11) in tightening direction until both splines fit.
18. Degrease the bolt (13) holes on bearing nut (11) and
bolts (13) (2 used). Apply LOCTITE #262 onto bolts
(13) (2 used). Install lock plate (12) to bearing nut
(11) with bolts (13) (2 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W4-2-2-12
36. Secure first stage planetary gear (25) between

d CAUTION: The third stage carrier (17) assembly
thrust plates (22, 26). Install them to first stage
carrier (29).
24. Attach two nylon slings onto the third stage
37. Install pin (24) to first stage carrier (29). At this time,
carrier (17) assembly. Hoist the third stage carrier
fit the spring pin (27) holes of first stage carrier (29)
(17) assembly. Install the third stage carrier (17)
and pin (24).
assembly to housing (5).
38. Install spring pin (27) to first stage carrier (29) with
25. Install third stage sun gear (18) to third stage carrier
the slit (b) side facing to the cover (49) side.
(17) with the small outer diameter side up.
24 27
26. Install spacer (20) to second stage carrier (19). b
27. Install needle bearing (34) to second stage

planetary gear (32).
28. Secure second stage planetary gear (32) between b - Slit W178-02-11-210
thrust plates (30, 35). Install them to second stage
39. Install other first stage planetary gears (25) (2 used)
carrier (19).
to first stage carrier (29) in the same way as step 35
29. Install pin (33) to second stage carrier (19). At this to step 38.
time, fit the spring pin (31) holes of second stage
40. Install the first stage carrier (29) assembly to second
carrier (19) and pin (33).
stage carrier (19).
30. Install spring pin (31) to second stage carrier (19)
with the slit (a) side facing to the cover (49) side.
33 31
a
a - Slit W178-02-11-210
31. Install other second stage planetary gears (32) (2

used) to second stage carrier (19) in the same way
as step 27 to step 30.
dCAUTION: The second stage carrier (19)

assembly weight: 25 kg (56 lb)
32. Attach two nylon slings onto the second stage
carrier (19) assembly. Hoist the second stage carrier
(19) assembly. Install the second stage carrier (19)
assembly to third stage sun gear (18).
33. Install second stage sun gear (21) to second stage
carrier (19) with the small outer diameter side up.
34. Install spacer (28) to first stage carrier (29).
35. Install needle bearing (23) to first stage planetary
gear (25).
W4-2-2-13
41. Insert the spline side of shaft (43) into the center 50. Degrease the bolt (50) holes on ring gear (44) and
of second stage sun gear (21). Rotate sprocket (14) bolts (50) (16 used). Apply LOCTITE #262 onto bolts
slowly by hand. Engage travel motor (1) and first (50) (16 used). Install cover (49) to ring gear (44)
stage planetary gears (25) (3 used) with shaft (43), with bolts (50) (16 used).
and install them.
j : 22 mm
42. Install O-ring (10) to drum (8).
m : 180 N·m (18 kgf·m, 133 lbf·ft)
51. Install a seal tape onto plugs (51) (3 used). Install
plugs (51) (3 used) to cover (49).
(50) hole of ring gear (44). Attach a nylon sling onto
the eyebolt. Hoist ring gear (44). Fit the matching l : 14 mm
marks made when disassembling and place ring
gear (44) onto drum (8). m : 70 N·m (7 kgf·m, 52 lbf·ft)
44. Degrease the bolt (45) holes on drum (8) and bolts
(45) (30 used). Apply LOCTITE #262 onto bolts (45)
(30 used). Install ring gear (44) to drum (8) with
j : 27 mm
m : 400 N·m (41 kgf·m, 300 lbf·ft)

45. Attach a tube bar onto ball bearing (48). Tap a tube
bar by using a hammer and install ball bearing (48)
to cover (49).
fNOTE: Ball bearing (48) inner diameter: 45mm (1.8 in),

outer diameter: 68 mm (2.7 in)

personal injury.
46. Attach a tube bar onto stopper pin (47). Tap a tube
bar by using a hammer and install stopper pin (47)
to ball bearing (48).
fNOTE: Stopper pin (47) inner diameter: 26 mm (1.0 in),

outer diameter: 52 mm (2.0 in)
IMPORTANT: Install retaining ring (46) with the
chamfered surface facing to the cover (49) side.
47. Install retaining ring (46) to cover (49).

48. Clean the mating surfaces of ring gear (44) and
cover (49). Apply THREEBOND #1389B.
49. Install an eyebolt (PT3/4) to the plug (51) hole (2
places) of cover (49). Attach a nylon sling onto the
eyebolt. Hoist cover (49). Place cover (49) onto ring
gear (44).
W4-2-2-14
dCAUTION:
(1200 lb)
Travel reduction gear weight: 540 kg

hole (2 places) of the flange part in housing (5).
Attach a nylon sling onto the eyebolt. Hoist and
turn over the travel reduction gear.
53. Fill gear oil to the travel reduction gear.
fNOTE: Amount of oil: 11.0 L (2.9 US gal)

54. Install O-ring (4) to motor (1).
dCAUTION: Motor (1) weight: 134 kg (300 lb)

lifting hole (c) of motor (1). Attach a nylon sling onto
the eyebolts. Hoist motor (1). Fit the splines of shaft
(43) and motor (1). Install motor (1) to housing (5)
and driven shaft (45).
2, 3 5
c - Lifting Hole
W16J-03-02-002
56. Install motor (1) to housing (5) with bolts (2) (4

used) and spring washers (3) (4 used).
j : 27 mm
m : 300 N·m (31 kgf·m, 220 lbf·ft)
W4-2-2-15
(Blank)
W4-2-2-16
Disassembly of Travel Motor

1 2 3 4
7
6
5
2
17
16
15
14
13
12
11
10 25
9
24
8
23
22
21
20
18
30
29
28
27
19
26
W1J1-03-02-002
1- Housing 9- Swash Plate 17- Roller Bearing 25- O-Ring

2- O-Ring (4 Used) 10- Plunger (9 Used) 18- Plate (5 Used) 26- Spring (10 Used)
3- Spring (2 Used) 11- Retainer 19- Friction Plate (4 Used) 27- Pin
4- Piston (2 Used) 12- Bushing 20- Backup Ring 28- Pin (4 Used)
5- Oil Seal 13- Spring (9 Used) 21- O-Ring 29- Brake Valve
6- Roller Bearing 14- Rotor 22- O-Ring 30- Socket Bolt (9 Used)
7- Shaft 15- Valve Plate 23- Backup Ring
8- Steel Ball (2 Used) 16- Collar 24- Brake Piston
W4-2-3-1
Disassembly of Travel Motor IMPORTANT: Do not remove roller bearing (17)

unless necessary. Remove roller bearing (17) by
dCAUTION:
lb)
The travel motor weight: 134 kg (300 using a small puller if necessary. As the outer race
is deformed, roller bearing (17) cannot be reused.
1. Attach a nylon sling onto the travel motor. Hoist the IMPORTANT: Do not damage valve plate (15).
travel motor. Place the travel motor with the brake
3. Remove valve plate (15), pin (27), and pins (28) (4
valve (29) side up.
used) from brake valve (29).
dCAUTION: Brake valve (29) weight: 39 kg (86 lb) 4. Wrap the tape on the thrust surface of shaft (7) for
IMPORTANT: Evenly loosen socket bolts (30) (9 used). roller bearing (17) in order to protect.
When loosening socket bolt (30), valve housing
5. Remove springs (26) (10 used) from housing (1).
(29) is floated from case (1) by the reaction force of
springs (13, 26). At this time, record the clearance 6. Remove O-ring (25) and O-rings (2) (4 used) from
between case (1) and valve housing (29). housing (1).
IMPORTANT: When removing the brake valve (29)
assembly, do not drop valve plate (15). dCAUTION: When removing brake piston (24),
cover with a cloth in order not to fly out brake
2. Remove socket bolts (30) (9 used). Install an eyebolt piston (24).
(M12, Pitch 1.75 mm) to the lifting hole (a) of brake
7. Apply air 100 to 300 kPa (1.0 to 3.0 kgf/cm2, 15 to 44
valve (29). Attach a nylon sling onto the eyebolt.
psi) to the brake releasing oil passage in housing (1).
Hoist brake valve (29). Remove brake valve (29) from
Float and remove brake piston (24).
housing (1).
l : 14 mm
1 29 30
W16J-03-02-002
a - Lifting Hole
W4-2-3-2
8. Remove O-rings (21, 22), and backup rings (20, 23)

from brake piston (24). dCAUTION: When removing swash plate (9), cover
with a cloth in order not to fly out piston (4).
9. Remove plates (18) (5 used) and friction plates (19)
IMPORTANT: When swash plate (9) cannot be
(4 used) from housing (1).
removed, apply air 100 to 300 kPa (1.0 to 3.0 kgf/
10. Remove rotor (14), springs (13) (9 used), bushing cm2, 15 to 44 psi) through the piston oil passage
(12), retainer (11), and plungers (10) (9 used) from hole. Swash plate (9) and piston (4) are removed.
housing (1). 12. Remove swash plate (9) from housing (1).
dCAUTION:
kg (145 lb)
The housing (1) assembly weight: 65 13. Remove balls (8) (2 used), pistons (4) (2 used), and
springs (3) (2 used) from housing (1) by using a
11. Attach a nylon sling onto housing (1). Hoist magnet.
the housing (1) assembly. Place the housing (1) 14. Attach a bar onto the bottom the spline hole of
assembly horizontally with the brake releasing oil shaft (1). Tap and remove shaft (1) and roller bearing
passage (a) down. (6) from housing (1) by using a bar and a plastic
hammer.
fNOTE: When facing the brake releasing oil passage (a)
upward, the thicker part of swash plate (9) faces upward.
When placing the housing (1) assembly horizontally,
swash plate (9) suddenly may come out. such as goggles, helmets, etc in order to prevent
personal injury.
15. Remove the outer race of roller bearing (6) from
housing (1) by using a bar and a hammer.
1
a WJAA-04-02-008
a - Brake Releasing Oil Passage
W4-2-3-3
IMPORTANT: Oil seal (5) cannot be reused.

16. Remove oil seal (5) from housing (1) by using a
screwdriver.
fNOTE: THREEBOND #1104 or #1215 has been applied

onto the outer surface of the oil seal.
IMPORTANT: When removing shaft (7) from roller
bearing (6), do not drop shaft (7).
17. Secure the inner race of roller bearing (6) remained
on shaft (7) in a vise. Remove shaft (7) from roller
bearing (6) by using a bar and a plastic hammer.
WJAA-04-02-007
W4-2-3-4
Assembly of Travel Motor
27 30 26 22,23 24 20,21 7 4 3
16
29 8
17
15
28
25
2
14 10 18 19 11 12 9 6 5
W1J1-03-02-003
1- Housing 9- Swash Plate 17- Roller Bearing 25- O-Ring

2- O-Ring (4 Used) 10- Plunger (9 Used) 18- Plate (5 Used) 26- Spring (10 Used)
3- Spring (2 Used) 11- Retainer 19- Friction Plate (4 Used) 27- Pin
4- Piston (2 Used) 12- Bushing 20- Backup Ring 28- Pin (4 Used)
5- Oil Seal 13- Spring (9 Used) 21- O-Ring 29- Brake Valve
6- Roller Bearing 14- Rotor 22- O-Ring 30- Socket Bolt (9 Used)
7- Shaft 15- Valve Plate 23- Backup Ring
8- Steel Ball (2 Used) 16- Collar 24- Brake Piston
W4-2-3-5
Assembly of Travel Motor

IMPORTANT: Before assembling, apply hydraulic oil dCAUTION: Metal fragments may fly off when
dCAUTION: Housing (1) weight: 60 kg (135 lb) personal injury.
1. Attach a nylon sling onto housing (1). Hoist housing 6. Install the inner race to shaft (7) with the flange part
(1). Place housing (1) with the brake valve (29) side facing to the stepped part of shaft (7) by using a bar
up. and a hammer.
2. Apply OCEAN grease #7 onto the inner surface of oil 7. Install springs (3) (2 used) and pistons (4) (2 used) to
seal (5). housing.
3. Apply THREEBOND #1104 or #1215 onto the outer IMPORTANT: The small diameter side of shaft (7) is
surface of oil seal (5). matched with the inner race on roller bearing (17).
4. Clean the oil seal (5) mating part of housing (1). Do not damage the inner race of roller bearing
Install oil seal (5) to housing (1) by using a plate, a (17).
bar, and a plastic hammer. 8. Install shaft (7) to housing (1) by using a plastic
hammer.
a hammer is used. Wear necessary protection, fNOTE: Shaft (7) can be inserted without tapping when
such as goggles, helmets, etc in order to prevent aligning them correctly.
personal injury.
5. Install the outer race of roller bearing (6) to housing
(1) by using a bar and a hammer.
W4-2-3-6
9. Install balls (8) (2 used) to housing (1). IMPORTANT: Install retainer (11) with the chamfered
surface (b) facing to the bushing (12) side.
10. Apply grease onto the ball (8) hole on swash plate
(9). Align the position of balls (8) (2 used) and install 12. Install springs (13) (9 used), bushing (12), retainer
swash plate (9) to housing (1). (11), and plungers (10) (9 used) to rotor (14).
dCAUTION:
kg (145 lb)
The housing (1) assembly weight: 65 11
11. Attach a nylon sling onto housing (1). Hoist

the housing (1) assembly. Place the housing (1)
b 12
assembly horizontally with the brake releasing oil
passage (a) down.
W178-02-11-225
fNOTE: When facing the brake releasing oil passage (a) b - Chamfered Surface Side
upward, the thicker part of swash plate (9) faces upward.
13. Install the rotor (14) assembly to housing (1).
When placing the housing (1) assembly horizontally,
swash plate (9) suddenly may come out.
dCAUTION:
kg (190 lb)
The housing (1) assembly weight: 85
1 14. Attach a nylon sling onto housing (1). Hoist

the housing (1) assembly. Place the housing (1)
assembly with the brake valve (29) mounting
surface side up.
IMPORTANT: Check the order to install friction plate
(19) and plate (18).
15. Install friction plates (19) (4 used) and plates (18) (5
used) to housing.
16. Apply grease onto O-rings (21, 22) and backup rings
(20, 23). Install O-rings (21, 22) and backup rings (20,
23) to brake piston (24).
a WJAA-04-02-008
a - Brake Releasing Oil Passage
W4-2-3-7
IMPORTANT: Check the direction to install brake IMPORTANT: The spring (26) mounting holes
piston (24). Install brake piston (24) with the notch (12 places) on brake piston (24) are located
vertical corresponding to the pin (28) mounting corresponding to springs (26) (10 used). Check the
hole on housing (1). position to install springs (26).
17. Install brake piston (24) to housing (1) by using a 18. Install springs (26) (10 used) to brake piston (24).
plastic hammer.
24
f NOTE: As O-ring (22) is positioned around brake piston
(24), brake piston (24) cannot be fully inserted. When
installing brake valve (29), tighten brake piston (24) with
socket bolt (30).
b
26
26
1
b
W16J-03-02-003
24 b - Not used
19. Install O-rings (2) (4 used) and O-ring (25) to
a
housing (1).
20. Add hydraulic oil into housing (1) until plate (18) is
submerged.
28 W16J-03-02-003
a - Notch
W4-2-3-8
21. Install pin (27) to brake valve (29). 25. Install collar (16) to shaft (7).
IMPORTANT: Check the direction to install pin (28).
22. Install pins (28) (4 used) to brake valve (29) with the
dCAUTION: Brake valve (29) weight: 39 kg (29 lb)
IMPORTANT: When installing valve housing (29)
large diameter side facing to brake valve (29). to housing (1), check that a clearance between
housing (1) and valve housing (29) is equal to that
before disassembling. If the dimension differs,
disassemble and assemble again.
personal injury. IMPORTANT: Do not drop valve plate (15).If valve
plate (15) is damaged, oil leakage will occur.
IMPORTANT: Check the direction to install the outer
race of roller bearing (17). 26. Install brake valve (29) to housing (1) with socket
23. Install the outer race of roller bearing (17) to brake
valve (29) with the stamped mark facing outside by l : 14 mm
m : 300 N·m (30 kgf·m, 221 lbf·ft)
24. Apply grease onto the flat surface of valve plate
(15). Fit the valve plate (15) with the pin (27)
position and install valve plate (15) to brake valve
(29).
fNOTE: Valve plate (15) is secured to brake valve (29)

tightly in order not to drop brake valve (15) when turning
over.
W4-2-3-9
(Blank)
W4-2-3-10
Disassembly of Brake Valve

1
2
5 6
3 7 9
4 8 10
11
12
35
36
37
38
39
40
41
42
43
44
48
47 49
10 46
9
13
16
17 14
18 15
19
20
21
51 22
24
4 26
3 27
28
2 23 30 31
1 25 32
45 33
29 34
44
43
50 42 5
41 36
40
39 35
38
37
WJAA-04-02-012
1- Plug (2 Used) 14- O-Ring 27- Spring (2 Used) 40- Spring Seat (2 Used)
2- O-Ring (2 Used) 15- Plug 28- Spring Guide (2 Used) 41- Plug (2 Used)
3- Spring (2 Used) 16- Poppet Seat (2 Used) 29- O-Ring (2 Used) 42- O-Ring (2 Used)
4- Check Valve (2 Used) 17- Backup Ring (2 Used) 30- Backup Ring (2 Used) 43- Spring (2 Used)
5- Relief Valve 18- O-Ring (2 Used) 31- O-Ring (2 Used) 44- Check Valve (2 Used)
6- Plug 19- Backup Ring (2 Used) 32- Plug (2 Used) 45- Spool
7- O-Ring 20- Poppet (2 Used) 33- Nut (2 Used) 46- Valve Housing
8- Spring 21- Relief Housing (2 Used) 34- Set Screw (2 Used) 47- Pin (4 Used)
9- Plug (6 Used) 22- Piston (2 Used) 35- Socket Bolt (8 Used) 48- Pin
10- O-Ring (6 Used) 23- Backup Ring (2 Used) 36- Cap (2 Used) 49- Orifice
11- Orifice (2 Used) 24- O-Ring (2 Used) 37- O-Ring (2 Used) 50- Spool Assembly
12- Socket Bolt (9 Used) 25- Backup Ring (2 Used) 38- Spring Seat (2 Used) 51- Orifice (2 Used)
13- Valve Assembly 26- Spring Seat (2 Used) 39- Spring (2 Used)
W4-2-4-1
Disassembly of Brake Valve

IMPORTANT: Spool assembly (50), valve assembly
disassemble relief valves (5) (2 used). As the
(13), orifices (11, 49, and 51), and the plug should
setting changes, do not turn set screws (34) (2
be replaced as the valve housing (46) assembly.
used). Attach an identification tag onto relief
dCAUTION: The brake valve weight: 39 kg (86 lb) valves (5) (2 used) for assembling.
1. Secure the brake valve on a workbench. IMPORTANT: Do not move piston (22) attached on
the outer surface of relief valve (5). O-ring (24)
2. Remove plug (6) from valve housing (46). Remove
may be damaged.
O-ring (7) from plug (6). Remove spring (8) from
valve housing (46) by using a magnet. 6. Remove relief valves (5) (2 used) from valve housing
(46).
l : 10 mm
j : 36 mm
3. Remove plug (15) from valve housing (46). Remove
22 24 5
l : 10 mm
IMPORTANT: Remove valve housing assembly 34
(13) by rotating. If they stick even a little, try
again instead of pulling them roughly. Do not
disassemble valve assembly (13).
4. Remove valve assembly (13) from valve housing WJAA-04-02-010
(46). 7. Hold one cap (36). Evenly loosen and remove socket
5. Remove plugs (1) (2 used) from valve housing (46). bolts (35) (4 used) from cap (36). Remove cap (36)
Remove O-rings (2) (2 used) from plugs (1) (2 used). from valve housing (46).
Remove springs (3) (2 used) and check valves (4) (2
used) from valve housing (46) by using a magnet. l : 10 mm
l : 14 mm fNOTE: If cap (36) cannot be removed, tap by using

a plastic hammer. Tap cap (36) with socket bolt (35)
attached (loosened).
W4-2-4-2
8. Remove socket bolts (35) (4 used) from another cap

(36). Remove cap (36) from valve housing (46).
l : 10 mm
9. Remove spring seats (38) (2 used), springs (39) (2
used), and spring seats (40) (2 used) from valve
housing (46).
IMPORTANT: Remove spool assembly (50) by
rotating. If they stick even a little, try again
instead of pulling them roughly.
10. Remove spool assembly (50) from valve housing
(46).
11. Secure spool assembly (50) by using wooden pieces
in a vise.
12. Remove plugs (41) (2 used) from spool (45). Remove
O-rings (42) (2 used) from plugs (41) (2 used).
Remove springs (43) (2 used) and check valves (44)
(2 used) from spool (45).
W4-2-4-3
Assembly of Brake Valve

Relief Valve (5)
18 26 24 27 31 29 32 33
17,19 20 22 23,25 28 30
10 11 6 7 36 38 41
37
39
51
42
35 40
43
44
A A A 45
9
49
8
50
13
14
48 47
12
15
46 5 2 1 3 4
WJAA-04-02-011
W4-2-4-4
1- Plug (2 Used) 14- O-Ring 27- Spring (2 Used) 40- Spring Seat (2 Used)
2- O-Ring (2 Used) 15- Plug 28- Spring Guide (2 Used) 41- Plug (2 Used)
3- Spring (2 Used) 16- Poppet Seat (2 Used) 29- O-Ring (2 Used) 42- O-Ring (2 Used)
4- Check Valve (2 Used) 17- Backup Ring (2 Used) 30- Backup Ring (2 Used) 43- Spring (2 Used)
5- Relief Valve 18- O-Ring (2 Used) 31- O-Ring (2 Used) 44- Check Valve (2 Used)
6- Plug 19- Backup Ring (2 Used) 32- Plug (2 Used) 45- Spool
7- O-Ring 20- Poppet (2 Used) 33- Nut (2 Used) 46- Valve Housing
8- Spring 21- Relief Housing (2 Used) 34- Set Screw (2 Used) 47- Pin (4 Used)
9- Plug (6 Used) 22- Piston (2 Used) 35- Socket Bolt (8 Used) 48- Pin
10- O-Ring (6 Used) 23- Backup Ring (2 Used) 36- Cap (2 Used) 49- Orifice
11- Orifice (2 Used) 24- O-Ring (2 Used) 37- O-Ring (2 Used) 50- Spool Assembly
12- Socket Bolt (9 Used) 25- Backup Ring (2 Used) 38- Spring Seat (2 Used) 51- Orifice (2 Used)
13- Valve Assembly 26- Spring Seat (2 Used) 39- Spring (2 Used)
W4-2-4-5
Assembly of Brake Valve 6. Install the spool (45) assembly approximately half
way into valve housing (46).
onto parts in order to prevent them from seizing. 7. Install O-rings (37) (2 used) to caps (36) (2 used).
IMPORTANT: Check the direction to install valve 8. Install spring seat (40), spring (39), and spring seat
assembly (13). (38) to valve housing (46). Install cap (36) with
1. Install O-rings (7, 14) to plugs (6, 15). Install valve socket bolts (35) (4 used).
assembly (13), spring (8), and plugs (6, 15) to valve
housing (46). l : 10 mm
l : 10 mm m : 110 N·m (11 kgf·m, 81 lbf·ft)

9. Install another cap (36) in the same way as step 8.
m : 65 N·m (6.5 kgf·m, 48lbf·ft)
Install check valves (4) (2 used), springs (3) (2 used),
and plugs (1) (2 used) to valve housing (46).
l : 14 mm
m : 420 N·m (42 kgf·m, 310 lbf·ft)

IMPORTANT: Install relief valve (5) to the original
position before disassembly.
3. Install relief valves (5) (2 used) to valve housing (46).
j : 36 mm
m : 420 N·m (42 kgf·m, 310 lbf·ft)

5. Install check valves (44) (2 used), springs (43) (2
used), and plugs (41) (2 used) to spool (45).
W4-2-4-6

these procedures:
2
hardening.

trouble.
cleaning solvent. a
d
W178-02-11-002
B B
A=B A≠B
W178-02-11-003

W4-2-5-1
(Blank)
W4-2-5-2
Removal and Installation of Center Joint
WJAA-04-03-001
IMPORTANT: Cap the open ends in case the hoses 4. Disconnect hose (4).
attach an identification tag onto the connectors, j : 17 mm
hoses, and pipes for assembling. Connect the 5. Remove bolts (8) (2 used) and washers (9) (2 used).
hoses and install the clips in case the clips which Remove stopper (10). Remove washers (14) (2 used)
secure the hoses have been removed. between stopper (10) and center joint (1) at this
time.
Removal
j : 22 mm

(Refer to W1-4-1.)
2. Place a container under center joint (1). Disconnect
hoses (2) (4 used).
j : 41 mm
j : 27 mm
W4-3-1-1
WJAA-04-03-002
6. Remove adapters (15) (4 used). 10. Disconnect hoses (7) (2 used).
j : 41 mm j : 19 mm
dCAUTION: Center joint (1) weight: 52 kg (115 lb) 11. Remove bolts (12) (4 used) and washers (13) (4
used). Remove center joint (1).
7. Install eyebolts (G1) to the plug (15) hole (2 places
in diagonal position) of center joint (1). Attach nylon j : 24 mm
slings onto the eyebolts. Hoist and hold center joint
(1). 12. Remove the adapter with center joint (1) attached if
necessary.
j : 27 mm
j : 41 mm
W4-3-1-2
WJAA-04-03-002
Installation 5. Connect hoses (6) (4 used).

1. Install all removed adapters to center joint (1). j : 41 mm
dCAUTION: Center joint (1) weight: 52 kg (115 lb) m : 200 N·m (20 kgf·m, 148 lbf·ft)
2. Install eyebolts (G1) to the plug (15) hole (2 places
in diagonal position) of center joint (1). Attach nylon
slings onto the eyebolts. Hoist center joint (1). j : 27 mm
3. Install center joint (1) with washers (13) (4 used) and
m : 80 N·m (8 kgf·m, 59 lbf·ft)
7. Install adapters (15) (4 used).
j : 24 mm
j : 41 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
m : 210 N·m (21 kgf·m, 155 lbf·ft)
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W4-3-1-3
WJAA-04-03-001
8. Install washers (14) (2 used) between stopper (10) 10. Connect hose (3).
and center joint (1). Install stopper (10) with washers
(9) (2 used) and bolts (8) (2 used). j : 27 mm

m : 140 N·m (14 kgf·m, 103 lbf·ft)
9. Connect hose (4). j : 41 mm

m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
4-1.)
W4-3-1-4
Disassembly of Center Joint

00B
00A
01
02
03
05
06
07
08
04
09
10
W16J-03-03-001
00A- Spindle 02- Dust Seal 05- Bushing 08- O-Ring

00B- Plug (With Ball) 03- O-Ring 06- Ring 09- Cover
01- Body 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
W4-3-2-1
Disassembly of Center Joint IMPORTANT: For easy removal of oil seal (04), use the
pins (2 used). Do not damage the seal groove.
dCAUTION: Center joint weight: 52 kg (115 lb)
6. Remove oil seals (04) (6 used), O-ring (03), and dust
1. Remove bolts, washers (10) (2 used) diagonally. seal (02) from body (01).
Install an eyebolt (M12, Pitch 1.75 mm) to the bolt
(10) hole (2 places) of body (01). Attach a nylon sling
onto the eyebolt. Hoist the center joint. Secure the
center joint on a workbench.
j : 17 mm
2. Put the matching marks on body (01) and spindle
(00A). Remove other bolts, washers (10) (2 used).
Remove cover (09) from body (01).
j : 17 mm
3. Remove O-ring (08), retaining ring (07), and ring (06)
from body (01).
4. Install the special tools (ST 1033, ST 1020) to body
(01) with bolts, washers (10) (2 used).
j : 17 mm
W178-02-11-240
IMPORTANT: Do not damage the seal surface.

ST 1020 7. When replacing bushing (05), build-up weld at 4
places in its inner diameter by using a welding rod.
ST 1033
10 Shrink and remove bushing (05).
01
W183-03-03-004
IMPORTANT: Do not damage the the seal sliding

surface of spindle (00A).
5. Remove spindle (00A) from body (01).
W4-3-2-2
Assembly of Center Joint
00A
02
03
05
04
01
06
08
10
07
09
W183-03-08-001
00A- Spindle 02- Dust Seal 05- Bushing 08- O-Ring

03- O-Ring 06- Ring 09- Cover
00B- *Plug (With Ball)
04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body
fNOTE: As for the parts with mark *, refer to W4-3-2-1.
W4-3-2-3
Assembly of Center Joint

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not damage bushing (05).
onto parts in order to prevent them from seizing. IMPORTANT: The clearance between body (01) and
IMPORTANT: When assembling the seals, apply spindle (00A) should be 0.1 mm (0.004 in). Insert
grease (Apolloil Autorex C) and install seals to body (01) along axis straight and slowly. Do not
each groove. damage the seal.
IMPORTANT: If bushing (05) has been removed, IMPORTANT: Install body (01) so that the ring (06)
install bushing (05) first. (Refer to W4-3-2-6.) mounting part (b) is flat.
1. Apply grease onto the mounting part for dust seal 3. Apply grease onto the oil seal (04) inside, the
(02) on body (01). Install dust seal (02) to body (01) bushing (05) inside, and the dust seal (02) sliding
with the metal part (a) facing to the body (01) side. surface of spindle (00A). Place spindle (00A) on a
workbench. Fit the matching marks made when
disassembling and install body (01) to spindle (00A).
a 02
b 00A
W800-03-03-001 01
01
a - Metal Part
2. Install O-ring (03) and oil seals (04) (6 used) to body
(01).
W800-03-03-002
b - Ring (06) Mounting Part
W4-3-2-4
IMPORTANT: Install ring (06) with the chamfered

surface facing to the spindle (00A) side.
4. Install ring (06) and O-ring (08) to body (01).
5. Install retaining ring (07) to spindle (00A).
6. Install cover (09) to body (01) with bolts, washers
(10) (4 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W4-3-2-5
Replacement of Body and Spindle

ST 2670
IMPORTANT: When replacing body (01) or spindle
(00A) with the new one, the following procedures
are required. 01
In case of Body (01)

1. Clean body (01) and bushing (05).
05
2. Apply grease onto the bushing (05) mounting part
on body (01).
3. Install bushing (05) to body (01) by using the special
tool (ST 2670).
fNOTE: Pushing force: 0.5 to 1.5 t (1100 to 3310 lb)
W178-02-11-242
In case of spindle (00A) 00B C

1. Clean spindle (00A). 00A
2. Install plug (00B) to spindle (00A) by using the
special tool (ST 2560).
3. Install ball (a) of plug (00B) so that the top of each
ball is 0.4 mm (0.02 in) or more lower than the
respective sleeve (c) edge as illustrated in detail C.
WDAA-04-03-005
ST 2560 Detail C
b
c
WDAA-04-03-006 WDAA-04-03-007
a - Ball b - 0.4 mm or more

c - Sleeve
W4-3-2-6
Removal and Installation of Track Adjuster
W142-03-04-002
Before removing and installing the track adjuster, the

tracks and front idler must be removed first. (Refer to W4-
7-1 and W4-5-1.)
tracks and front idler have already been removed here.
Removal
dlb)
CAUTION: Track adjuster (1) weight: 240 kg (530
dthe
CAUTION: Track adjuster (1) may fly out due to
spring force when removing track adjuster
(1). Do not stand in the same direction to remove
track adjuster (1) or where it may fly out.
1. Attach nylon slings onto track adjuster (1). Hoist and
hold track adjuster (1). Remove track adjuster (1).
fNOTE: If it is difficult to remove it, pry it out by using a

pry bar.
W4-4-1-1
W142-03-04-002
W16J-03-04-002
2
Installation
dlb)
CAUTION: Track adjuster (1) weight: 240 kg (530
1. Attach nylon slings onto track adjuster (1). Hoist

track adjuster (1).
2. Install track adjuster (1) with the grease outlet (2)
side down.
W4-4-1-2
Disassembly of Track Adjuster

2
3
4
5
6
7
1
8
9
10
11
12
13
14
15
W1J1-03-04-002
16
1- Socket Bolt (4 Used) 5- Wear Ring 9- O-Ring 13- Nut

2- O-Ring 6- U-Ring 10- Spacer 14- Bolt
3- Guide 7- Retaining Ring 11- Spring 15- Rod
4- Piston Rod 8- Cylinder 12- Bracket 16- Valve
W4-4-2-1
Disassembly of Track Adjuster 2. Check that valve (16) is loose. Compress spring (11)
of the track adjuster by using the special tool (ST
 Use a pump unit which has the maximum pressure
4932) so that clearance (h) between bracket (12)
of 69 MPa (700 kgf/cm2, 9950 psi) and the flow rate
and nut (13) is 10 mm (0.4 in).
of 8 to 10 liters (2.1 to 2.6 US gal). Set the main relief
pressure to 49 MPa (500 kgf/cm2, 7110 psi), the
propelling power to 80 t (176000 lb) or lower.
d CAUTION: The spring (11) force is extremely
large. Carry out the disassembly and assembly
h
work carefully. Inspect the special tool for any

damage thoroughly in order to perform the work
safely.
12
dCAUTION: Track adjuster weight: 240 kg (530 lb)
13
15
1. Attach a nylon sling onto the track adjuster. Hoist
the track adjuster. Install the track adjuster to holder
(e) of the special tool (ST 4932). 14
ST 4932 16
W142-03-04-020
h - Clearance
W142-03-04-019
e - Holder
W4-4-2-2
3. Put the matching marks on rod (15) and nut (13). 9. Install an eyebolt (M16, Pitch 2.0 mm) to piston
rod (4). Attach a nylon sling onto spring (11). Pass a
4. Remove valve (16) from rod (15).
nylon sling through the eyebolt on piston rod (4).
j : 24 mm Hoist and place the spring (11) assembly on holder
(e).
5. Remove bolt (14) from nut (13).
j : 17 mm
6. Remove nut (13) from rod (15).
j : 100 mm 4
7. Retract the cylinder of the special tool (ST 4932)
slowly and extend spring (11) to the free length.
fNOTE: Spring (11) free length: 782 mm (30.8 in)

11
dCAUTION:
kg (530 lb)
The spring (11) assembly weight: 240
8. Secure bracket (12) and spring (11) by using wire

(g). Attach a nylon sling onto spring (11). Hoist
the spring (11) assembly. Remove the spring (11)
assembly from the special tool (ST 4932).
e
W142-03-04-006
e - Holder
11 ST 4932
12
W142-03-04-005
g - Wire
W4-4-2-3
13. Remove socket bolts (1) (4 used) from guide (3).

d CAUTION: The cylinder (8) assembly weight: 75
kg (170 lb)
Remove guide (3) from piston rod (4).
10. Remove the cylinder (8) assembly from spring (11). l : 12 mm
2 3
1
15
11
W142-03-04-010
14. Remove piston rod (4) from cylinder (8).

15. Remove O-ring (2) from guide (3).
W142-03-04-007
dCAUTION: Spring (11) weight: 122 kg (270 lb)

11. Remove wire (g) which secure spring (11) and
bracket (12). Attach a nylon sling onto spring (11).
Hoist spring (11). Remove spring (11) from holder
(e).
dCAUTION: Bracket (12) weight: 22 kg (49 lb)

12. Remove spacer (10) and bracket (12) from holder
(e).
W4-4-2-4
dCAUTION: Cylinder (8) weight: 39 kg (86 lb)

Rod (15) weight: 21 kg (47 lb)
16. Install an eyebolt (M16, Pitch 1.5 mm) to rod (15).
Attach a nylon sling onto the eyebolt. Hoist cylinder
(8). Remove rod (15) from cylinder (8).
17. Remove O-ring (9) from cylinder (8).
18. Remove retaining ring (7), U-ring (6), and wear ring
(5) from piston rod (4).
W4-4-2-5
Assembly of Track Adjuster
16 13 12 11 9 6 5 8 3 4
14 15 10 a 7 1 2 b
W1J1-03-04-001
a - Grease Chamber b - Grease Groove c - Lifting Hole f - Grease Outlet
1- Socket Bolt (4 Used) 5- Wear Ring 9- O-Ring 13- Nut

2- O-Ring 6- U-Ring 10- Spacer 14- Bolt
3- Guide 7- Retaining Ring 11- Spring 15- Rod
4- Piston Rod 8- Cylinder 12- Bracket 16- Valve
W4-4-2-6
Assembly of Track Adjuster

1. Apply grease onto wear ring (5) and U-ring (6).
2. Install wear ring (5) to piston rod (4).
3. Install U-ring (6) to piston rod (4) with the lip part
facing to the rod (15) side.
4. Install retaining ring (7) to piston rod (4).
dCAUTION: Rod (15) weight: 21 kg (47 lb)

5. Apply grease onto O-ring (9). Install O-ring (9) to
cylinder (8). Install an eyebolt (M16, Pitch 1.5 mm) to
the rod (15) lifting hole (d). Attach a nylon sling onto
the eyebolt. Hoist the rod. Install rod (15) to cylinder
(8).
6. Fill grease chamber (a) with grease.
7. Apply hydraulic oil onto piston rod (4).
d
9
15
8
WJAA-04-04-001
W4-4-2-7
8. Install an eyebolt (M16, Pitch 2.0 mm) to piston

rod (4). Attach a nylon sling onto the eyebolt. Hoist dCAUTION: Bracket (12) weight: 22 kg (49 lb)
Spring (11) weight: 122 kg (270 lb)
the rod. Insert piston rod (4) to cylinder (8) and
completely bleed air from grease chamber (a) and 12. Attach a nylon sling onto bracket (12). Hoist bracket
rod (15). (12). Place bracket (12) and spacer (10) onto holder
(e). Attach a nylon sling onto spring (11). Hoist
9. Fill grease groove (b) with grease.
spring (11). Place spring (11) onto bracket (12).
10. Apply grease onto O-ring (2). Apply LOCTITE #262 Secure bracket (12) and spring (11) by using a wire.
onto socket bolts (1) (4 used).
11. Install O-ring (2) to guide (3). Install guide (3) to
cylinder (8) with socket bolts (1) (4 used).
l : 12 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft) 8
3 1
10
11
12 e
W142-03-04-018
W142-03-04-007
e - Holder
dCAUTION:
kg (170 lb)
The cylinder (8) assembly weight: 75
13. Fit the cylinder (8) assembly with spacer (10) and
bracket (12), and install the cylinder (8) assembly to
the bracket (12) assembly.
W4-4-2-8
IMPORTANT: Slowly compress spring (11) while

d CAUTION: The spring (11) assembly weight: 240
kg (530 lb)
fitting the center of rod (15) with that of bracket
(12) by using a pry bar. Do not damage the threads
14. Attach a nylon sling onto spring (11). Pass a nylon on rod (15).
sling through the eyebolt on piston rod (4). Hoist 16. Operate the cylinder of the special tool (ST 4932)
and place the spring (11) assembly slowly and and remove wire (g). Compress spring (11) to the
horizontally. specified spring (11) length.
fNOTE: Specified spring length: 620 mm (24.4 in)
ST 4932
11
11
12
W142-03-04-006
15. Install the spring (11) assembly to the special tool

(ST 4932) with grease outlet (f ) on rod (15) facing W142-03-04-015
down.Remove the eyebolt from piston rod (4).
g - Wire
ST 4932
W142-03-04-005
W4-4-2-9
IMPORTANT: Check that the grease outlet of rod (15)

is fitting with that of nut (13).
and install nut (13) to rod (15). Secure nut (13) to rod
(15) with bolt (14).
j : 100 mm
j : 17 mm
m : 40 N·m (4 kgf·m, 30 lbf·ft)
13
15
14
16
W142-03-04-020
18. Install valve (16) to rod (15).
j : 24 mm
m : 150 N·m (15 kgf·m, 111 lbf·ft)

19. Retract the cylinder of special tool (ST 4932).
dCAUTION: Track adjuster weight: 240 kg (530 lb)

20. Attach a nylon sling onto the track adjuster. Hoist
the track adjuster. Remove the track adjuster from
special tool (ST4932).
dCAUTION: If only the spring assembly is

transported, use a firm steel box and take any
other precautions in order to carry the track
adjuster safely.
W4-4-2-10
Group 5 Front Idler
Removal and Installation of Front Idler
1 1
3 2 a
W17P-03-05-001 W105-03-05-003
a- Wooden Block
Before removing and installing the front idler, the tracks 2. Attach nylon slings onto yoke (2) and bearing (3).
must be removed first. (Refer to W4-7-1.) Hoist and hold front idler (1). Remove front idler (1).
3. Place front idler (1) on wooden blocks (a) (2 used).
tracks have already been removed here.
Removal
dCAUTION: Front idler (1) weight: 290 kg (640 lb)

dCAUTION: Front idler (1) may fly out due to the
spring force when removing front idler (1). Do not
stand in the same direction to remove front idler
(1) or where front idler (1) may fly out.
1. Pull out front idler (1) to the position where nylon
slings can be attached onto yoke (2).
fNOTE: If it is difficult to remove it, use a pry bar.
W4-5-1-1
Group 5 Front Idler
3 2 W17P-03-05-001
Installation
dCAUTION: Front idler (1) weight: 290 kg (640 lb)

1. Attach nylon slings onto yoke (2) and bearing (3).
Hoist front idler (1).
2. Install front idler (1) to the track frame, the position
where nylon slings can be removed.
3. Remove the nylon slings.
4. Install front idler (1).
W4-5-1-2
Group 5 Front Idler
Disassembly of Front Idler

2
1
3 8
5
6
7
10
11
6 9
5
3 12
2
1
14
13
W1J1-03-05-001
1- Bearing (2 Used) 5- Floating Seal (2 Used) 9- Guard 13- Bolt (4 Used)

2- Pin (2 Used) 6- Bushing (2 Used) 10- Bolt (3 Used) 14- Spring Washer (4 Used)
3- O-Ring (2 Used) 7- Idler 11- Spring Washer (3 Used)
4- Axle 8- Plug (2 Used) 12- Yoke
W4-5-2-1
Group 5 Front Idler
Disassembly of Front Idler

1. Remove bolts (10) (3 used) and spring washers (11)
dCAUTION:
(515 lb)
The idler (7) assembly weight: 232 kg
(3 used) from guard (9). Remove guard (9) from yoke

(12). Axle (4) weight: 28 kg (62 lb)
j : 19 mm Bearing (1) weight: 27 kg (60 lb)
5. Put the matching marks on bearing (1) and axle (4).
d CAUTION: Yoke (12) weight: 44 kg (98 lb) Remove the axle (4) assembly from idler (7) by using
a press.
2. Attach a nylon sling onto yoke (12). Hoist and hold
yoke (12). Remove bolts (13) (4 used) and spring
washers (14) (4 used). Remove yoke (12) from 1 4
bearings (1) (2 used).
j : 30 mm 7
3. Remove plug (8) from bearing (1). Drain off oil.
l : 6 mm

personal injury. W105-03-05-008
4. Remove pin (2) from bearing (1) by using a bar and
a hammer. IMPORTANT: Handle floating seal (5) with care.
(Refer to W4-5-3.)
6. Remove bearing (1) from the upper side of idler (7).
Remove floating seals (5) (2 used) from idler (7) and
bearings (1) (2 used).
W105-03-05-009
W4-5-2-2
Group 5 Front Idler
IMPORTANT: Do not remove bushing (6) unless

d CAUTION: The axle (4) assembly weight: 54 kg
(120 lb)
necessary.
10. When replacing bushing (6), remove bushings (6)
IMPORTANT: Place wooden block (a) under bearing (2 used) from idler (7) by using the special tool (ST
(1) in order not to damage bearing (1). 1973) and a press.
7. Attach a nylon sling onto the axle (4) assembly.
Hoist the axle (4) assembly. Place bearing (1) onto
wooden block (a).
ST 1973
2
1
a
6
W105-03-05-011
W105-03-05-010
a - Wooden Block

personal injury.
8. Remove pin (2) from bearing (1) at the other side by
using a bar and a hammer. Put the matching marks
on bearing (1) and axle (4). Remove axle (4) from
bearing (1) by using a press.
9. Remove O-rings (3) (2 used) from axle (4).
W4-5-2-3
Group 5 Front Idler
Assembly of Front Idler
1 2 5 7 4 6 3 7 8 9 10 11
3 5 2 1 14 13 12
W1J1-03-05-002
1- Bearing (2 Used) 5- Floating Seal (2 Used) 9- Guard 13- Bolt (4 Used)

2- Pin (2 Used) 6- Bushing (2 Used) 10- Bolt (3 Used) 14- Spring Washer (4 Used)
3- O-Ring (2 Used) 7- Idler 11- Spring Washer (3 Used)
4- Axle 8- Plug (2 Used) 12- Yoke
W4-5-2-4
Group 5 Front Idler
Assembly of Front Idler IMPORTANT: Handle floating seal (5) with care.
(Refer to W4-5-3.)
onto parts in order to prevent them from seizing. 4. Apply grease onto O-ring of floating seal (5). Install
floating seal (5) to idler (7) and bearing (1).
dCAUTION: Idler (7) weight: 150 kg (335 lb)
1. Install bushings (6) (2 used) to idler (7) by using the dCAUTION:
(120 lb)
The axle (4) assembly weight: 54 kg
special tool (ST 1973) and a press.
5. Attach a nylon sling onto bearing (1) of the axle (4)
assembly. Hoist the axle (4) assembly. Install the axle
(4) assembly to idler (7) from the side where floating
seal (5) has already been installed.
ST 1973
W105-03-05-011
dCAUTION: Axle (4) weight: 28 kg (62 lb)

Bearing (1) weight: 27 kg (60 lb)
2. Attach a nylon sling onto axle (4). Hoist axle (4).
Place axle (4) vertically. Install O-ring (3) to the
upper side of axle (4).

personal injury.
and install bearing (1) to axle (4) by using a plastic
hammer. Install pin (2) to bearing (1) by using a bar
and a hammer.
2
4
1
3 W105-03-05-014
W4-5-2-5
Group 5 Front Idler
6. Apply LOCTITE #503 onto plug (8). Install plug (8) to

bearing (1). dCAUTION: Metal fragments may fly off when
l : 6 mm such as goggles, helmets, etc in order to prevent
personal injury.
m : 20 N·m (2 kgf·m, 15 lbf·ft)
dCAUTION:
(405 lb)
The idler (7) assembly weight: 183 kg and install bearing (1) to axle (4) by using a plastic
hammer. Install pin (2) to bearing (1) by using a bar
7. Attach a nylon sling onto the idler (7) assembly. and a hammer.
Hoist the idler (7) assembly. Turn over the idler (7) 10. Add engine oil (API CD class, SAE #30) through the
assembly. plug (8) hole of bearing (1).
(Refer to W4-5-3.)
11. Apply LOCTITE #503 onto plug (8). Install plug (8) to
8. Install other O-ring (3) to axle (4). Apply grease onto bearing (1).
O-ring of floating seal (5). Install other floating seal
(5) to idler (7) and bearing (1). l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

1 5 3 7
dCAUTION: Yoke (12) weight: 44 kg (98 lb)
12. Attach a nylon sling onto yoke (12). Hoist yoke (12).
1
Fit the bolt (13) holes of bearing (1) and yoke (12).
13. Install yoke (12) to bearings (1) (2 used) with bolts
(13) (4 used) and spring washers (14) (4 used).
l : 30 mm
4 m : 400 N·m (40 kgf·m, 300 lbf·ft)
W157-03-05-005 14. Install guard (9) to yoke (12) with bolts (10) (3 used)
and spring washers (11) (3 used).
l : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W4-5-2-6
Group 5 Front Idler

these procedures:
2
hardening.

trouble.
cleaning solvent. a
d
W178-02-11-002
B B
A=B A≠B
W178-02-11-003

W4-5-3-1
Group 5 Front Idler
(Blank)
W4-5-3-2
Removal and Installation of Upper Roller
2 1
W105-03-06-001 W800-03-07-002
dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (1) may fly out
and the high-pressure grease may spout out, do
not loosen valve (1) quickly and/or excessively.
Keep body parts and face away from valve (1) and
loosen valve (1) carefully. Do not loosen grease
fitting (2).
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
IMPORTANT: Loosening valve (1) 1 to 1.5 turns is
enough. Do not loosen valve (1) over those turns.
Removal
2. Loosen valve (1) of the track adjuster. Drain grease
from the cylinder.
j : 24 mm
W4-6-1-1
4 3
6, 7 5 b W116-03-06-002 3 W116-03-06-003
a- Oil Jack
b- Wooden Block
3. Raise track (4) until enough clearance is observed

between upper roller (3) and track (4) by using the
oil jack.
4. Insert wooden blocks (b) between upper roller (3)
and track frame (5).
5. Remove bolts (6) (4 used) and washers (7) (4 used)
from upper roller (3).
j : 27 mm
dCAUTION: Upper roller (3) weight: 39 kg (86 lb)

6. Attach nylon slings onto the body of upper roller
(3). Hoist upper roller (3). Remove upper roller (3).
W4-6-1-2
4 3
6, 7 5 b W116-03-06-002 3 W116-03-06-003
a- Oil Jack
b- Wooden Block
2 1
Wxxx-03-07-001
a - Track Sag Specification
W800-03-07-002
Installation 5. Raise the track to be adjusted. Rotate the track in

the reverse direction a little.
dCAUTION: Upper roller (3) weight: 39 kg (86 lb)
6. Apply grease through grease fitting (2) and adjust
1. Attach nylon slings onto the body of upper roller
the track (4) tension.
(3). Hoist upper roller (3).
2. Install upper roller (3) with washers (7) (4 used) and fNOTE: Track sag specification (c):
bolts (6) (4 used).  ZX470-5B, 470H-5B, 470R-5B : 380 to 430 mm (15.0 to
16.9 in)
j : 27 mm
 ZX470LC-5B, 470LCH-5B, 470LCR-5B : 390 to 440 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft) (15.4 to 17.3 in)
3. Remove wooden blocks (b) and oil jack (a) between
track (4) and track frame (5).
4. Tighten valve (1) of the track adjuster.
j : 24 mm
m : 150 N·m (15 kgf·m, 111 lbf·ft)
dCAUTION: Securely support the raised machine

by using the blocks.
W4-6-1-3
W158-03-06-001
7. Lower the track.

IMPORTANT: The upper roller cannot be
disassembled. Replace it as an assembly.
8. Add engine oil (API CD class, SAE #30) through the
plug (9) hole of cover (8).
fNOTE: Amount of oil: 120 mL (0.13 US qt)

9. Apply LOCTITE #503 onto plug (9).
10. Install plug (9).
l : 6 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W4-6-1-4
Removal and Installation of Lower Roller

3, 4 6
90˚~110˚
2 1 a WJAA-04-06-001 b M104-07-067
a - Wooden Block b - Stand
Removal
2. Put the matching marks on track guard (1) and track
frame (2).
dCAUTION: If removing bolt (3) without holding

track guard (1), track guard (1) falls off.
3. Insert wooden blocks (a) under track guard (1).
j : 32 mm
j : 32 mm
6. Swing the upperstructure by 90 degrees so that
the angle between boom and arm should be 90 °
to 110°. Lower the boom with the round bottom
contacting with the ground. Raise the track frame.
Place stand (b) under the track frame and support
the machine at this time.
W4-6-2-1
W800-03-07-002
1 9
W105-03-06-001
WJAA-04-06-002

fitting (8).
loosening.
7. Loosen valve (7). Drain grease. Loosen the
track until the clearance enough to remove track
guard (1) and lower roller (9) is obtained.
j : 24 mm
dCAUTION: Track guard (1) weight: 40 kg (89 lb)

Lower roller (9) weight: 80 kg (180 lb)
8. Remove track guard (1) and lower roller (9) by using
a forklift.
W4-6-2-2
1 9 3, 4 6
2 1 a WJAA-04-06-001
WJAA-04-06-002
10
Installation
dCAUTION: Track guard (1) weight: 40 kg (89 lb)

Lower roller (9) weight: 80 kg (180 lb)
1. Set track guard (1) and lower roller (9) on track link
(10) by using a forklift while fitting the matching
marks made when removing.
2. Lower the machine so that the position to install
lower roller (9) can be adjusted.
3. Fit the bolt (6) holes of track frame (2) and lower
roller (9). Apply LOCTITE #262 onto bolts (6) (4
used). Install lower roller (9) with bolts (6) (4 used).
j : 32 mm
m : 750 N·m (75 kgf·m, 550 lbf·ft)

track guard (1) with spacers (4) (4 used) and bolts (3)
(4 used) by using a pry bar.
j : 32 mm
m : 750 N·m (75 kgf·m, 550 lbf·ft)
W4-6-2-3
W800-03-07-002 Wxxx-03-07-001
5. Tighten valve (7).
j : 24 mm
m : 150 N·m (15 kgf·m, 111 lbf·ft)
dCAUTION: Securely support the raised machine

by using the blocks.
6. Raise the track to be adjusted. Rotate the track in
the reverse direction a little.
7. Apply grease through grease fitting (8) and adjust
the track tension.
fNOTE: Track sag specification (a)

 ZX470-5B, 470H-5B, 470R-5B : 380 to 430 mm (15.0 to
16.9 in)
 ZX470LC-5B, 470LCH-5B, 470LCR-5B : 390 to 440 mm
(15.4 to 17.3 in)
W4-6-2-4
Disassembly of Lower Roller

5
6
4
6
1
3
W166-03-06-006
1- Floating Seal (2 Used) 3- O-Ring (2 Used) 5- Pin (2 Used) 7- Bushing (2 Used)

2- Axle 4- Collar (2 Used) 6- Plug (2 Used) 8- Roller
W4-6-3-1
Disassembly of Lower Roller 4. Remove pin (5) from the axle (2) assembly. Remove
axle (2) from collar (4) by using a press.
dCAUTION: Lower roller weight: 80 kg (180 lb)
3 4
1. Remove plug (6) from the end of collar (4). Drain oil
from roller (8).
l : 6 mm
dCAUTION:
lb)
Axle (2) + collar (4) weight: 25 kg (56
2

personal injury.
2. Put the matching marks on collar (4) and axle (2).
Remove pin (5) from collar (4) at one side by using W178-02-11-268
a round bar and a hammer. Remove axle (2) from
roller (8), from the side where pin (5) was removed 5. Remove O-rings (3) (2 used) from axle (2).
by using a press. At this time, pin (5) and collar (4)
on the opposite side are removed with axle (2)
together.
dCAUTION: Roller (8) weight: 47 kg (105 lb)
IMPORTANT: Do not remove bushing (7) unless
necessary.
fNOTE: Diameter of round bar: 25 mm (1.0 in)
6. Remove bushing (7) by using the special tool (ST
4 1 8 1 1955) and a press.
ST 1955
1
4
2 8
W105-03-06-026
W178-02-11-269
(Refer to W4-6-4.)
3. Remove floating seals (1) (2 used) from both sides of
roller (8) and collars (4) (2 used).
W4-6-3-2
Assembly of Lower Roller
4 5 6
8 2 7 1 3 W162-03-06-002
1- Floating Seal (2 Used) 3- O-Ring (2 Used) 5- Pin (2 Used) 7- Bushing (2 Used)

2- Axle 4- Collar (2 Used) 6- Plug (2 Used) 8- Roller
W4-6-3-3
Assembly of Lower Roller

dCAUTION: Roller (8) weight: 47 kg (105 lb)

IMPORTANT: Do not damage bushing (7).
1. Install bushings (7) (2 used) to roller (8) by using a
press.
dCAUTION: Axle (2) weight: 20 kg (45 lb)

2. Apply grease onto O-ring (3) at one side. Install
O-ring (3) to axle (2).
IMPORTANT: Do not damage O-ring (3).
3. Fit the pin (5) hole and install collar (4) to one side of
axle (2) with pin (5).
2 5
4
W105-03-06-031

(Refer to W4-6-4.)
4. Install floating seal (1) to roller (8) and collar (4).
8 1
1 4
W157-03-06-008
W4-6-3-4
dCAUTION:
(180 lb)
The roller (8) assembly weight: 80 kg
The axle (2) assembly weight: 25 kg (56 lb)

5. Install the axle (2) assembly to the roller (8)
assembly.
6. Apply grease onto O-ring (3) at the other side. Install
O-ring (3) to the roller (8) assembly.
(Refer to W4-6-4.)
7. Install floating seal (1) to roller (8) and collar (4) at
the other side.
IMPORTANT: Do not damage O-ring (3).
8. Fit the pin (5) hole and install collar (4) to axle (2)
with pin (5).
9. Install a seal tape onto plug (6).
10. Add engine oil (API CD class, SAE #30) through the
plug (6) hole of collar (4). Tighten plug (6).
l : 6 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W4-6-3-5
(Blank)
W4-6-3-6

these procedures:
2
hardening.

trouble.
cleaning solvent. a
d
W178-02-11-002
B B
A=B A≠B
W178-02-11-003

W4-6-4-1
(Blank)
W4-6-4-2
Group 7 Track
Removal and Installation of Track
3
5 4
2
1 W800-03-07-027
b - Grease Outlet
a
W105-03-07-006
a - Wooden Block
Removal
2. Rotate the tracks so that master pin (1) is positioned
over the front idler (2) side of the track adjuster.
Insert wooden blocks (a) under shoe (3) and
support it.

fitting (5).
loosening.
3. Loosen valve (4). Drain grease and loosen the tracks.
j : 24 mm
W4-7-1-1
Group 7 Track
3
6, 7 3
1
3
6, 7
c
W105-03-07-006
W1J7-03-07-002
c - Chain Block
dCAUTION: Shoe (3) weight:
600 mm: 29 kg (64 lb)
750 mm: 36 kg (80 lb)
900 mm: 43 kg (95 lb)
4. Remove bolts (6) (8 used) and nuts (7) (8 used) from
shoes (3) (2 used) at the front and rear of master pin
(1). Remove shoes (3) (2 used).
j : 32 mm
5. Secure shoes (3) (2 used) at the front and rear of
master pin (1) by using chain blocks (c).
W4-7-1-2
Group 7 Track
Assembly of Special Tool (ST 1532) for Removal /

Installation of Master Pin
12
11
10
9
1
8
10
15
19
18
11 12
17
16
15
10
9
10 16
9
W1J7-03-07-001
8 - Hydraulic Cylinder (ST 1512) 12 - Pusher (ST 1521) 15 - Extension (3 Kinds) 18 - Guide (ST 1525)
9 - Screw (2 Used) (ST 1516) 13 - Handling Screw (ST 1514) 19 - Guide Pin (ST 1529)
10 - Nut (2 Used) (ST 1515) (ST 1530) 16 - Nut (2 Used) (ST 1515)
11 - Frame (ST 1513) 14 - Adapter (ST 1518) 17 - Pilot (ST 1517)
W4-7-1-3
Group 7 Track
Assembly of Special Tool (ST 1532) for Removal / 12. Install hoses (d) (2 used) of electric pump (ST 1531)
Installation of Master Pin to hydraulic cylinder (8).
The procedures for assembly of special tool (ST 1532) for
10
removal / installation of master pin are explained. Theses
are not unnecessary in case the special tool (ST 1532) 9
for removal / installation of master pin has already been
assembled.
8
IMPORTANT: Screws (9) (2 used) should be installed
to the hole of hydraulic cylinder (8) surely. In case
screws (9) (2 used) are not installed surely, they
may come off from hydraulic cylinder (8) when
removing and installing master pin (1).
6. Install screws (9) (2 used) to hydraulic cylinder (8). A
IMPORTANT: In case dimensions (A) of nuts (10) (2

used) are different, screw (9) may be deformed
when removing and installing master pin (1).
Install nuts (10) (2 used) so that dimensions (A)
from hydraulic cylinder (8) should be same.
7. Install nuts (10) (2 used) to screws (9) (2 used) so
that dimensions (A) from hydraulic cylinder (8) d
should be same.
W1J7-03-07-005
d CAUTION: Frame (11) weight: 74 kg (165 lb)

d - Hose
8. Install frame (11) to the nut (10) position of screws
(9) (2 used). Install nut (16).
9. Install extension (15) to hydraulic cylinder (8).
fNOTE: There are three kinds of extension (15). Their

dimensions are different. In case the stroke of hydraulic
cylinder (8) is insufficient when removing and installing
master pin (1), add other extensions (15).
10. Install pilot (17) and pusher (12) to extension (15).
11. Install adapter (14) to frame (11) with handling
screw (13).
W4-7-1-4
Group 7 Track
14
12
ST 1532
W1J7-03-07-004
ST 1532
9
W1J7-03-07-003
e - Nylon Sling
dCAUTION: Special tool (ST 1532) for removal /

installation of master pin weight: 150 kg (335 lb)
13. Attach nylon slings (e) onto screw (9) (2 places) of
special tool (ST 1532) for removal / installation of
master pin. Hoist special tool (ST 1532) for removal
/ installation of master pin. Move special tool (ST
1532) for removal / installation of master pin to
the master pin (1) mounting position. Adjust nylon
slings (e) so that the height of adapter (14) and
pusher (12) in special tool (ST 1532) for removal /
installation of master pin should be aligned with
that of master pin (1).
W4-7-1-5
Group 7 Track
16
10
14 9
12
8
1 17
15
ST 1532
W1J7-03-07-004
W1J7-03-07-005
IMPORTANT: Align the center of adapter (14) 15. Extend hydraulic cylinder (8) and push out master
and pusher (12) with that of master pin (1). pin (1).
When removing master pin (1) with the centers
misaligned, special tool (ST 1532) for removal / fNOTE: In case the stroke of hydraulic cylinder (8) is
installation of master pin may be deformed and insufficient, retract it once and add shorter extensions
damaged. (15) between extension (15) and pilot (17). In case the
stroke of hydraulic cylinder (8) is insufficient in spite
14. Fit the end of master pin (1) to the adapter (14) hole
of using extensions (15) (3 used), move the mounting
of special tool (ST 1532) for removal / installation of
position of nuts (10, 16) (2 used for each) to the hydraulic
master pin. Adjust hydraulic cylinder (8) and push
cylinder (8) side.
pusher (12) to the end of master pin (1). Check the
mounting condition of master pin (1) and special
tool (ST 1532) for removal / installation of master
pin.
W4-7-1-6
Group 7 Track
90˚ to 110˚
f
f - Stand
ST 1532
9
M104-07-067
W1J7-03-07-003
c - Chain Block
16. Remove special tool (ST 1532) for removal /

installation of master pin and chain blocks (c).
17. Set the angle between boom and arm to 90˚ to
110˚. Lower the boom with the round bottom
contacting with the ground. Raise the track frame.
Place stand (f ) under the track frame and support
the machine at this time.
W105-03-07-011
dCAUTION: The track assembly weight:
600 mm: 2640 kg (5830 lb)
750 mm: 3030 kg (6680 lb)
900 mm: 3370 kg (7430 lb)
18. Slowly operate the travel control lever for the track
to be removed to the reverse position and extend
the track.
W4-7-1-7
Group 7 Track
20
a b
W105-03-07-014
21
W105-03-07-013
a - Front Idler Side

b - Sprocket (20) Side
W105-03-07-015
Installation
1. Raise the machine. Set the track under the machine
so that sprocket (20) should mesh with the track
end.Check the direction of the track at this time.
dCAUTION: The track assembly weight:

600 mm: 2640 kg (5830 lb)
750 mm: 3030 kg (6680 lb)
900 mm: 3370 kg (7430 lb)
2. Hoist and mesh the track with the claws of sprocket
(20)
3. With the machine raised, slowly operate the travel
control lever for the track to be installed in the
forward direction. Wind the track while rotating
travel device (21).
W4-7-1-8
Group 7 Track
c
W1J7-03-07-007
W1J7-03-07-002
4. Wind track link (22) until the connection part of c - Chain Block
track link (22) reaches the front idler (2) side.
IMPORTANT: The taper part of guide pin (19) should
19
be inserted first.
5. Secure shoes (3) (2 used) by using chain blocks (c). 12 18
Fit the master pin (1) mounting hole of track link 17 22
(22) by using chain blocks (c). Install guide pin (19) 15
to the master pin (1) mounting hole.
1
ST 1532
W1J7-03-07-006
6. Install extension (15), pilot (17), pusher (12), and

master pin (1) to special tool (ST 1532) for removal /
installation of master pin.
fNOTE: Master pin (1) is symmetrical. The installing

direction is not specified.
7. Install guide (18) to master pin (1).
W4-7-1-9
Group 7 Track
19
e 14
22
W1J7-03-07-006
ST 1532
9
W1J7-03-07-003
e - Nylon Sling
dCAUTION: Special tool (ST 1532) for removal /

installation of master pin weight: 150 kg (335 lb)
8. Attach nylon slings (e) onto screw (9) (2 places) of
special tool (ST 1532) for removal / installation of
master pin. Hoist special tool (ST 1532) for removal
/ installation of master pin. Move special tool (ST
1532) for removal / installation of master pin to the
master pin (1) mounting position of track link (22).
Adjust nylon slings (e) so that the hole height of
adapter (14) in special tool (ST 1532) for removal /
installation of master pin should be aligned with the
master pin (1) mounting hole of track link (22).
W4-7-1-10
Group 7 Track
16
10
19 9
14
17
22
15
1
W1J7-03-07-006
W1J7-03-07-005
IMPORTANT: Align the center of adapter (14) and 10. Extend hydraulic cylinder (8) and insert master pin
master pin (1) with that of the master pin (1) (1) until guide pin (19) is pushed out.
mounting hole. When installing master pin (1)
with the centers misaligned, special tool (ST 1532) fNOTE: In case the stroke of hydraulic cylinder (8) is
for removal / installation of master pin may be insufficient, retract it once and add shorter extensions
deformed and damaged. (15) between extension (15) and pilot (17). In case the
stroke of hydraulic cylinder (8) is insufficient in spite
9. Fit the end of guide pin (19) to the adapter (14) hole
of using extensions (15) (3 used), move the mounting
of special tool (ST 1532) for removal / installation of
position of nuts (10, 16) (2 used for each) to the hydraulic
master pin. Adjust hydraulic cylinder (8) and push
cylinder (8) side.
master pin (1) until it comes in contact with guide
pin (19). Check the mounting condition of guide
pin (19) and special tool (ST 1532) for removal /
installation of master pin.
W4-7-1-11
Group 7 Track
3
6, 7
c
6, 7
3
ST 1532
22
W1J7-03-07-003 W105-03-07-006
c - Chain Block
11. Remove special tool (ST 1532) for removal /

installation of master pin and chain blocks (c) from
track link (22).
dCAUTION: Shoe (3) weight:

600 mm: 29 kg (64 lb)
750 mm: 36 kg (80 lb)
900 mm: 43 kg (95 lb)
12. Install shoes (3) (2 used) with nuts (7) (8 used) and
bolts (6) (8 used).
j : 32 mm
m : 1370 N·m (137 kgf·m, 1010 lbf·ft)
W4-7-1-12
Group 7 Track
5 4
W800-03-07-027
WXXX-03-07-001
13. Tighten valve (4). Apply grease through grease

fitting (5) and adjust the track tension.
j : 24 mm
m : 150 N·m (15 kgf·m, 111 lbf·ft)
fNOTE: Track sag specification (A)

 ZX470-5B, 470H-5B: 380 to 430 mm (15.0 to 16.9 in)
 ZX470LC-5B, 470LCH-5B, 470LCR-5B: 390 to 440 mm
(15.4 to 17.3 in)
W4-7-1-13
Group 7 Track
10
9
19
12 18
17
8
15
10
9
W1J7-03-07-006
14. Remove extension (15), pilot (17), pusher (12), and W1J7-03-07-005
d
guide (18) from special tool (ST 1532) for removal /
installation of master pin. d - Hose
15. Remove hoses (d) (2 used) of electric pump (ST

1531) from hydraulic cylinder (8). Disassemble
special tool (ST 1532) for removal / installation
of master pin in the reverse way as assembly
procedures on W4-7-1-4 when disassembling and
keeping it.
fNOTE: Put the matching marks on screw (9) and nut

(10) for assembly before removing nuts (10) (2 used)
from screws (9) (2 used).
W4-7-1-14
MEMO
MEMO
SECTION 5
FRONT ATTACHMENT
CONTENTS
Removal and Installation of Front
Attachment..................................................................W5-1-1-1
Removal and Installation of Bushing.......................W5-1-2-1
Group 2 Cylinder
Removal and Installation of Boom Cylinder..........W5-2-1-1
Removal and Installation of Arm Cylinder.............W5-2-2-1
Removal and Installation of Bucket Cylinder........W5-2-3-1
Disassembly of Boom Cylinder..................................W5-2-4-1
Assembly of Boom Cylinder........................................W5-2-4-4
Disassembly of Arm Cylinder......................................W5-2-5-1
Assembly of Arm Cylinder...........................................W5-2-5-4
Disassembly of Bucket Cylinder................................W5-2-6-1
Assembly of Bucket Cylinder......................................W5-2-6-4
JACW-5-1
(Blank)
JACW-5-2
SECTION 5 FRONT ATTACHMENT
Removal and Installation of Front

Attachment
and pipes have been disconnected.In addition,
Removal
W1J1-04-01-001
1. Park the machine on a solid and level surface. Fully
retract the arm and bucket cylinders and lower the
2
front attachment onto the ground.
2. Disconnect plugs of the boom light between front
attachment and main frame.
3. Disconnect lubrication hose (2) from the rod side of
boom cylinder (1). (2 places at right and left) 1
j : 19 mm
4. Remove bolts (5) (4 used), washer (3), and stopper
(4). (2 places at right and left)
W105-04-01-002
j : 30 mm
dCAUTION: Boom cylinder weight: 430 kg (950 lb)

1
such as goggles, helmets, etc in order to prevent 3

personal injury. 4
5. Hoist and hold boom cylinder (1). Push out pin (6) to 5
the position where the cylinder rod can be removed
by tapping by using a bar and a hammer.
fNOTE: When pin (6) cannot be removed, start the

6
engine, operate the boom control lever, and adjust the
rod end pin (6) hole on boom cylinder (1).
W166-04-01-005
W5-1-1-1
6. Insert plate (a) between boom cylinder (1) and the

main frame. Lower boom cylinder (1). 1
7. Remove another boom cylinder (1) in the same way

as step 5 to step 6.
8. Start the engine. Operate the boom control lever
and retract the rod of boom cylinder (1). In order
not to extend the rod, pass a wire through the rod
hole and secure the rod to the cylinder tube. Stop
the engine.
dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.)
a
(Refer to W1-4-1.) a- Plate W157-04-01-005
9. Remove socket bolts (12) (16 used). Disconnect
hoses (11) (4 used).
l : 12 mm
10. Remove bolts (13) (2 used) and plate (14) from
boom foot pin (15).
j : 30 mm
12
11
11 M1J1-07-049
13
14
15
W105-04-01-007
W5-1-1-2
dCAUTION: Front attachment (standard) weight:

8000 kg (17700 lb)
11. Attach wire ropes onto the boom. Hoist and hold
the front attachment.
12. Screw threaded rod (b) of the special tool (ST 1975)
into the hole on boom foot pin (15). Screw nut (c)
and remove boom foot pin (15).
j : 36 mm
13. Hoist the front attachment and the machine
backward.
14. Place wooden blocks under the front attachment. W105-04-01-008
Lower the front attachment.
15
ST 1975
b- Threaded Rod c- Nut
W105-04-01-022
W157-04-01-004
W5-1-1-3
Installation
dCAUTION: Front attachment (standard) weight:

8000 kg (17700 lb)
1. Hoist the front attachment and fit the boom foot
pin (15) holes on the main frame and boom. Insert
shims into left and right sides of the boom foot.
Adjust the clearance within 1.5 mm.
fNOTE: Shim Thickness: 3.2 mm, 2.3 mm, 1.0 mm

2. Install boom foot pin (15) by using a hammer. Install
plate (14) with bolts (13) (2 used).
j : 30 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft)

3. Connect hoses (11) (4 used) with socket bolts (12) 13
(16 used).
l : 12 mm
14
m : 140 N·m (14 kgf·m, 103 lbf·ft)
15
W105-04-01-007
12
11
11 M1J1-07-049
W5-1-1-4
dCAUTION: Boom cylinder weight: 430 kg (950 lb)

IMPORTANT: Add hydraulic oil to the specified level.
Start the engine and check the hose connections
for any oil leaks.
1
4. Hoist boom cylinder (1). Start the engine.Extend
boom cylinder (1) and fit the pin (6) holes on the
boom and boom cylinder (1).

personal injury.
5. Install pin (6) by using a hammer. Install boom
cylinder (1) on both sides. W157-04-01-006
6. Install washer (3) and stopper (4) with bolts (5) (4

used). (2 places at right and left) 1
j : 30 mm
3
m : 400 N·m (40 kgf·m, 300 lbf·ft) 4
7. Connect lubrication hose (2) to the rod side of 5

boom cylinder (1).
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft) 6
8. Connect plugs of the boom light.
W166-04-01-005
W105-04-01-002
W5-1-1-5
9. Apply grease to boom foot side (e) and boom

cylinder rod side (d). d
e
10. After completing the work, add hydraulic oil to the
specified level.
11. Operate each cylinder to the stroke end several
times and bleed air from the circuit. Check for any
oil leaks of the hose connections.
d- Boom Cylinder Rod Side e- Boom Foot Side
W166-04-01-102
W5-1-1-6
IMPORTANT: When the arm has been removed from g 14 f

the boom, perform the following procedures
when installing the arm.
12. Install plate (14) to the right and left of arm (f ).
13. Insert shims between arm (f ) and plate (4). Adjust
the clearance within 1.5 mm.
fNOTE: Shim Thickness: 1.0 mm, 2.0 mm

14. Apply grease onto the joint pins of boom and arm
and the arm cylinder rod side by using a grease gun
after installing the arm.
IMPORTANT: As for handling of HN bushing for the
front attachment, check the followings.
Precautions when installing the bushing f- Arm g- Boom
When installing the bushing by using a hammer, the
W166-04-01-100
bushing may be damaged.Install the bushing by using a
press.
Precautions when reinforcing the arm h i

The heat when welding in order to reinforce the arm
may cause oil leakage from the bushing and decrease
lubrication performance.
When welding heat causes oil leakage of the bushing,
replace it.
h- Joint Pins of Boom and Arm

i- Arm Cylinder Rod Side
WJAA-05-01-002
W5-1-1-7
(Blank)
W5-1-1-8
Group1 Front Attachment
Removal and Installation of Bushing
d
c
b
a
W166-04-02-005
f
1 2 2 1 2 3
1 2 1
2
a W166-04-02-012
1 2 3
b
W166-04-02-013 c
W166-04-02-014
1 2 3 2 1 2 3
d W166-04-02-010
e W166-04-02-015 f W166-04-02-016
a- Bucket and Link A c- Boom and Arm e- Arm and Link B

b- Link A d- Boom and Main Frame f- Arm and Bucket
1- Dust Seal 2- Bushing 3- Spacer
W5-1-2-1
Group1 Front Attachment
Removal
1. Remove dust seal (1) and bushing (2).
fNOTE: In case bushing (2) cannot be removed, burn off

it.
Installation
1. Cool bushing (2) by using dry ice.
2. Install bushing (2) and dust seal (1).
fNOTE: Install bushing (2) by using the tools below.
Tool for Bushing

a: Bucket Side..................................................... ST 2881
Link A Side...................................................... ST 2873
b: Link A................................................................ ST 2873
c: Arm.................................................................... ST 2877
d: Boom Side....................................................... ST 2877
Main Frame Side........................................... ST 2886
e: Arm.................................................................... ST 2882
f: Bucket Side..................................................... ST 2881
Arm Side.......................................................... ST 2873
W5-1-2-2
Group 2 Cylinder
Removal and Installation of Boom Cylinder

7 2
hoses, and pipes for assembling. Connect the 1
Removal
1. Disconnect hose (2) from boom cylinder (1).
8
6
j : 19 mm 5
4
dCAUTION:
lb)
Boom cylinder (1) weight: 430 kg (950 3 W166-04-01-003
2. Attach nylon slings onto boom cylinder (1). Hoist

and hold boom cylinder (1).

personal injury.
used), stopper (5), and washers (6) from the boom
cylinder (1) rod side. Push pin (8) in boom (7) by
using a hammer.
j : 30 mm
4. Place boom cylinder (1) on stand (a). Remove
another boom cylinder (1) in the same way.
5. Starts the engine. Operate the boom control lever
and retract boom cylinder (1). In order not to extend
the rod, pass a wire through the rod hole and secure
the rod to the cylinder tube.
a
1
a- Stand W105-04-02-035
W5-2-1-1
Group 2 Cylinder
6. Stop the engine.

9

(Refer to W1-4-1.)
7. Disconnect hoses (9) (4 used) from boom cylinders
(1) (2 used).
j : 41 mm

1 A

W166-04-01-002
personal injury.
8. Remove bolt (10), spring washer (11), and washer
(12) from the cylinder bottom side. Remove pin (13). Section A
Remove spacer (14) and shims (15) (several).
j : 30 mm 13
dCAUTION:
lb)
Boom cylinder (1) weight: 430 kg (950
9. Remove boom cylinder (1). 10, 11, 12

10. Remove the other boom cylinder in the same way.
15 1 14 W162-04-01-025
1
W105-04-02-040
W5-2-1-2
Group 2 Cylinder
Installation
IMPORTANT: If a hammer is used to install the 9
bushing, the bushing may be damaged.Install the
bushing by using a press.
dCAUTION:
lb)
Boom cylinder (1) weight: 430 kg (950
1. Hoist boom cylinder (1). Fit the hole at boom

cylinder tube side to the mounting hole on the
main frame.

1 A

W166-04-01-002
personal injury.
2. Install shims (15) (several), spacer (14), and pin (13).
Install washer (12), spring washer (11), and bolt (10). Section A
j : 30 mm
13
m : 400 N·m (40 kgf·m, 300 lbf·ft)
3. Install the other boom cylinder in the same way.
4. Connect hoses (9) (4 used) to boom cylinders (1) (2 10, 11, 12
used).
j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)

15 1 14 W162-04-01-025
1
W105-04-02-040
W5-2-1-3
Group 2 Cylinder

engine and check for any oil leaks. 7 2
5. Remove the wires from the boom cylinder (1) rod
side. Starts the engine. Operate the boom control
lever and fit the hole at cylinder rod side to the
mounting hole on boom. 1

personal injury.
6. Install pin (8). 8
6
7. Install washer (6), stopper (5), spring washers (4) (4 5
used), and bolts (3) (4 used). 4
3 W166-04-01-003
j : 30 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft)

8. Connect hose (2) to boom cylinder (1).
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

9. Install another boom cylinder (1) in the same way.
IMPORTANT: After completing the work, operate
boom cylinder (1) several times to the stroke end
and bleed air from the circuit.
a
1
a- Stand W105-04-02-035
W5-2-1-4
Group 2 Cylinder
Removal and Installation of Arm Cylinder

IMPORTANT: Cap the open ends in case the hoses 1
Removal
1. Disconnect hose (8) from arm cylinder (1).
3
j : 19 mm 2
2. Place wooden block (3) between arm cylinder (1) W162-04-01-008
and boom (2).
3. Remove nuts (4) (2 used), bolt (5), and stopper (6)
from the arm cylinder (1) rod side. 8
j : 30 mm

7

personal injury.
4. Remove pin (7).
1
5
5. Starts the engine.Operate the arm control lever and
retract arm cylinder (1). In order not to extend the
6
rod, pass a wire through the rod hole and secure the
rod to the cylinder tube.
4
W166-04-01-004
W5-2-2-1
Group 2 Cylinder
6. Stop the engine.

1 9, 10 11, 12

(Refer to W1-4-1.)
7. Remove socket bolts (9) (8 used) and flanges (10) 13
(4 used). Disconnect hoses (11) (2 used) from arm
cylinder (1). Remove O-rings (12) (2 used) from
l : 12 mm
8. Disconnect hose (13) from arm cylinder (1).
W162-04-01-008
j : 19 mm
dCAUTION:
lb)
Arm cylinder (1) weight: 660 kg (1460
9. Attach nylon slings onto arm cylinder (1). Hoist and 1

hold arm cylinder (1).
15
d CAUTION: Metal fragments may fly off when

16
personal injury. 17
10. Remove nuts (14) (2 used), bolt (15), and stopper
(16) from the arm cylinder (1) bottom side. 14
j : 30 mm
11. Remove pin (17).
W166-04-01-006
12. Remove arm cylinder (1).
W5-2-2-2
Group 2 Cylinder
Installation
IMPORTANT: If a hammer is used to install the
1 9, 10 11, 12
bushing, the bushing may be damaged.Install the
dCAUTION:
lb)
13
1. Hoist arm cylinder (1). Fit the hole at the cylinder
bottom side to the pin (17) mounting hole on the
boom.

2. Install pin (17).

3. Install stopper (16), bolt (15), and nuts (14) (2 used)
to pin (17).
1
j : 30 mm
15
m : 400 N·m (40 kgf·m, 300 lbf·ft)
4. Connect hose (13) to arm cylinder (1). 16
j : 19 mm 17
m : 30 N·m (3 kgf·m, 22 lbf·ft) 14

5. Install O-rings (12) (2 used) to hoses (11) (2 used).
Connect hoses (11) (2 used) to arm cylinder (1) with
flanges (10) (4 used) and socket bolts (9) (8 used).
W166-04-01-006
l : 12 mm
m : 140 N·m (14 kgf·m 103 lbf·ft)
W5-2-2-3
Group 2 Cylinder
dCAUTION:
lb)
1
IMPORTANT: Add hydraulic oil. Start the engine and

check for any oil leaks.
6. Remove the wires from the arm cylinder (1) rod side.
Hoist arm cylinder (1). Start the engine.Operate the
arm control lever and fit the hole at cylinder rod
side to the pin (7) mounting hole on arm.

3
2
W162-04-01-008
personal injury.
7. Install pin (7).
8. Install stopper (6), bolt (5), and nuts (4) (2 used) to
pin (7). 8
j : 30 mm
7
m : 400 N·m (40 kgf·m, 300 lbf·ft)
9. Connect hose (8) to arm cylinder (1).
j : 19 mm
1
m : 30 N·m (3 kgf·m 22 lbf·ft) 5
IMPORTANT: After completing the work, operate

6
arm cylinder (1) several times to the stroke end
and bleed air from the circuit.
4
W166-04-01-004
W5-2-2-4
Group 2 Cylinder
Removal and Installation of Bucket Cylinder

attach an identification tag onto the connectors, 1
3
Removal
2
1. Insert wooden blocks (3) (2 used) under the arm (2) 3
top and between arm (2) and bucket cylinder (1).
W178-02-11-287
dCAUTION: Before removing pin (7), secure the
link by using a wire in order not to fall off.
4 5
personal injury.
2. Remove nuts (6) (2 used) and bolt (4). Remove pin
(7). Remove shims (5) (several). 6
j : 30 mm
W158-04-02-006
3. Starts the engine. Operate the bucket control lever
and retract bucket cylinder (1). In order not to
1
extend the rod, pass a wire through the rod hole
and secure the rod to the cylinder tube.
W102-04-02-005
W5-2-3-1
Group 2 Cylinder
4. Stop the engine.

10,11 8 9 12

(Refer to W1-4-1.)
5. Remove socket bolts (8) (8 used) and flanges (9) (4 1

used). Disconnect hoses (10) (2 used) from bucket
cylinder (1). Remove O-rings (11) (2 used) from
l : 10 mm
6. Disconnect hose (12) from bucket cylinder (1). W166-04-01-009
j: 19 mm
1
d CAUTION: Bucket cylinder (1) weight: 410 kg
(905 lb)

14
such as goggles, helmets, etc in order to prevent 16

personal injury.
7. Hoist bucket cylinder (1). Remove nuts (13) (2 used),
bolt (14), and stopper (15). Remove pin (16). 15
13
j : 30 mm
8. Remove bucket cylinder (1). W166-04-01-006
W5-2-3-2
Group 2 Cylinder
Installation
IMPORTANT: If a hammer is used to install the 10,11 8 9 12
bushing, the bushing may be damaged. Install the
dCAUTION:
(905 lb)
Bucket cylinder (1) weight: 410 kg

a hammer is used. Wear necessary protection, 1
personal injury.
1. Hoist bucket cylinder (1). Fit the hole at cylinder
bottom side to the cylinder mounting hole on arm.
Install pin (16). W166-04-01-009
2. Install stopper (15), bolt (14), and nuts (13) (2 used)
to pin (16). 1
j : 30 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft) 14

3. Connect hose (12) to bucket cylinder (1).
16
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

15
4. Install O-rings (11) (2 used) to hoses (10) (2 used). 13
Connect hoses (10) (2 used) to bucket cylinder (1)
used). W166-04-01-006
l: 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W5-2-3-3
Group 2 Cylinder
5. Remove the wires from the bucket cylinder (1) rod

side.

a hammer is used. Wear necessary protection, 1
personal injury.
3
6. Starts the engine. Operate the bucket control lever
and fit the hole at cylinder rod side to the holes of 2
link A (17) and link B (18). Install shims (5) (several) 3
and pin (7).
W178-02-11-287
7. Install bolt (4) and nuts (6) (2 used) to pin (7).
j : 30 mm 17 4 5
m : 400 N·m (40 kgf·m, 300 lbf·ft)

IMPORTANT: After completing the work, operate the
bucket cylinder several times to the stroke end
and and bleed air from the circuit.
6
7 18
W158-04-02-006
W102-04-02-005
W5-2-3-4
Group 2 Cylinder
Disassembly of Boom Cylinder
12
13
14
15
16
22
15
14
17
18
19
20
21
2
5
6
7
8
9
10
11
W1J1-04-02-020
1- Cylinder Rod 7- Backup Ring 13- Cushion Bearing 19- Steel Ball
2- Wiper Ring 8- U-Ring 14- Slide Ring (2 Used) 20- Set Screw
3- Socket Bolt (8 Used) 9- Ring 15- Slide Ring (2 Used) 21- Cylinder Tube
4- Cylinder Head 10- Bushing 16- Seal Ring 22- O-Ring
5- Backup Ring 11- Retaining Ring 17- Piston
6- O-Ring 12- Cushion Seal 18- Nut
W5-2-4-1
Group 2 Cylinder
Disassembly of Boom Cylinder 4. Install cylinder rod (1) to the special tool (ST 5908).
Put the matching marks on cylinder rod (1) and nut
 The procedure starts on the premise that the piping
(18).
and the bands securing the piping have been
ST 5908
removed.
d CAUTION: Boom cylinder weight: 430 kg (950 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.
W158-04-02-022
5. Cut away the crimped part (2 places) of set screw

(20) by using a hand drill. Remove set screw (20) and
steel ball (19).
l : 6 mm
W102-04-02-027 6. Remove nut (18) from cylinder rod (1) by using the
special tools (ST 5908, ST 3268). Remove piston (17)
2. Fully extend cylinder rod (1). Remove socket bolts from cylinder rod (1).
(3) (8 used) from cylinder head (4).
j : 125 mm
l : 19 mm
IMPORTANT: Slide rings (14, 15) cannot be reused.
IMPORTANT: Do not damage the sliding surface of Replace them with new ones when assembling.
cylinder rod (1).
7. Remove slide rings (14, 15) (2 used for each), seal
3. Tap and remove cylinder head (4) with cylinder ring (16), and O-ring (22) from piston (17).
rod (1) together from cylinder tube (21) by using a
plastic hammer.
W5-2-4-2
Group 2 Cylinder
8. Remove cushion bearing (13), cushion seal (12), and

cylinder head (4) from cylinder rod (1).
9. Remove O-ring (6), backup ring (5), wiper ring (2),
retaining ring (11), ring (9), U-ring (8), and backup
ring (7) from cylinder head (4).
10. Remove bushing (10) from cylinder head (4) by
using the special tool (ST 2671).
fNOTE: Cylinder rod (1) outer diameter: 115 mm (4.5 in)
W5-2-4-3
Group 2 Cylinder
Assembly of Boom Cylinder
2 8 9 3 4 6 21 1 13 14 15 16 15 14 18 20
17 22 19
12
7 10 11 5
a
W1J7-04-02-005
a - Slit
W5-2-4-4
Group 2 Cylinder
Assembly of Boom Cylinder 5. Install U-ring (8) to cylinder head (4) with the lip
part facing to the bushing (10) side.
onto parts in order to prevent them from seizing. 6. Install wiper ring (2) to cylinder head (4) by using
1. Install bushing (10) to cylinder head (4) by using the the special tool (ST 2671) and a plastic hammer.
special tool (ST 2671). 7. Install O-ring (6) and backup ring (5) to cylinder
head (4).
2. Install retaining ring (11) to cylinder head (4). 8. Install O-ring (22) and seal ring (16) to piston (17) by
using the special tool (ST 2970). After installing seal
3. Install ring (9) to cylinder head (4) with the lip part ring (16), adjust seal ring (16) by using the special
facing to the bushing (10) side. tool (ST 2970).
4. Install backup ring (7) to cylinder head (4).
fNOTE: Cylinder tube (21) inner bore: 170 mm (6.7 in)
W5-2-4-5
Group 2 Cylinder
9. Install slide rings (14, 15) (2 used for each) with their 15. Install ball (19) and set screw (20) to nut (18).Crimp
slits positioned 180° away facing to the opposite set screw (20) by using a punch (2 places).
each other.
l : 6 mm
10. Install the cylinder head (4) assembly to cylinder rod
(1) by using the special tool (ST 2671). m : 64 N·m (6.4 kgf·m, 47 lbf·ft)
11. Install cushion seal (12) to cylinder rod (1) with slit 16. Secure cylinder tube (21) on a workbench
(a) facing to the piston (17) side. horizontally.
12. Install cushion bearing (13) to cylinder rod (1) with IMPORTANT: Do not damage the rings.
the chamfered surface facing of cushion bearing 17. Fit to the center of cylinder tube (21) and insert the
(13) to the cylinder head (4) side. cylinder rod (1) assembly straight.
13. Install the piston (17) assembly to cylinder rod (1). 18. Install cylinder head (4) to cylinder tube (21) with
14. Fit the matching marks made when disassembling socket bolts (3) (8 used).
and install nut (18) to cylinder rod (1) by using the
j : 19 mm
special tools (ST 5908, ST 3268).
m : 1230 N·m (123 kgf·m, 910 lbf·ft)
j : 125 mm
m : 14200 N·m (1420 kgf·m, 10500 lbf·ft)
ST 5908
W158-04-02-022
W5-2-4-6
Group 2 Cylinder
Disassembly of Arm Cylinder
12
13
17
14
15
16
22
15
14
19 20 1
18
21
7
8
9
10
11
5
6
W1J1-04-02-021
W5-2-5-1
Group 2 Cylinder
Disassembly of Arm Cylinder 4. Install cylinder rod (1) to the special tool (ST 5908).
(18).
and the bands securing the piping have been ST 5908
removed.
d CAUTION: Arm cylinder weight: 660 kg (1460 lb)
cylinder.
W158-04-02-022

steel ball (19).
l : 8 mm
W102-04-02-027 6. Remove nut (18) from cylinder rod (1) by using the
j : 135 mm
l : 22 mm
cylinder rod (1).
plastic hammer.
W5-2-5-2
Group 2 Cylinder
8. Remove cushion bearing (13), cushion seal (12), and

cylinder head (4) from cylinder rod (1).
W5-2-5-3
Group 2 Cylinder
Assembly of Arm Cylinder
2 8 9 3 4 6 21 1 13 14 15 16 15 14 18 20
17 22 19
12
7 10 11 5
a
W1J7-04-02-005
a - Slit
W5-2-5-4
Group 2 Cylinder
Assembly of Arm Cylinder 5. Install U-ring (8) to cylinder head (4) with the lip
special tool (ST 8023). 7. Install O-ring (6) and backup ring (5) to cylinder
head (4).
W5-2-5-5
Group 2 Cylinder
9. Install slide rings (14, 15) (2 used for each) with their 15. Install ball (19) and set screw (20) to nut (18).Crimp
slits positioned 180° away facing to the opposite set screw (20) by using a punch (2 places).
each other.
l : 8 mm
10. Install the cylinder head (4) assembly to cylinder rod
(1) by using the special tool (ST 8023). m : 100 N·m (10 kgf·m, 74 lbf·ft)
11. Install cushion seal (12) to cylinder rod (1) with slit 16. Secure cylinder tube (21) on a workbench
(a) facing to the piston (17) side. horizontally.
12. Install cushion bearing (13) to cylinder rod (1) with IMPORTANT: Do not damage the rings.
the chamfered surface facing of cushion bearing 17. Fit to the center of cylinder tube (21) and insert the
(13) to the cylinder head (4) side. cylinder rod (1) assembly straight.
13. Install the piston (17) assembly to cylinder rod (1). 18. Install cylinder head (4) to cylinder tube (21) with
14. Fit the matching marks made when disassembling socket bolts (3) (8 used).
j : 22 mm
m : 1560 N·m (156 kgf·m, 1150 lbf·ft)
j : 135 mm
m : 27300 N·m (2730 kgf·m, 20100 lbf·ft)
ST 5908
W158-04-02-022
W5-2-5-6
Group 2 Cylinder
Disassembly of Bucket Cylinder
13
17
14
15
16
1
22
15
14
18 19 20
21
7
8
9
10
11
5
6
W1J1-04-02-022
1- Cylinder Rod 7- Backup Ring 14- Slide Ring (2 Used) 20- Set Screw
2- Wiper Ring 8- U-Ring 15- Slide Ring (2 Used) 21- Cylinder Tube
3- Socket Bolt (8 Used) 9- Ring 16- Seal Ring 22- O-Ring
4- Cylinder Head 10- Bushing 17- Piston
5- Backup Ring 11- Retaining Ring 18- Nut
6- O-Ring 13- Cushion Bearing 19- Steel Ball
W5-2-6-1
Group 2 Cylinder
Disassembly of Bucket Cylinder 4. Install cylinder rod (1) to the special tool (ST 5908).
(18).
and the bands securing the piping have been
ST 5908
removed.
d CAUTION: Bucket cylinder weight: 410 kg (905
lb)
cylinder.
W158-04-02-022

steel ball (19).
l : 8 mm
W102-04-02-027
6. Remove nut (18) from cylinder rod (1) by using the
j : 130 mm
l : 19 mm
cylinder rod (1).
plastic hammer.
W5-2-6-2
Group 2 Cylinder
8. Remove cushion bearing (13) and cylinder head (4)

from cylinder rod (1).
W5-2-6-3
Group 2 Cylinder
Assembly of Bucket Cylinder
2 8 9 3 4 6 21 1 13 14 15 16 15 14 18 20
17 22 19
7 10 11 5
W1J7-04-02-007
1- Cylinder Rod 7- Backup Ring 14- Slide Ring (2 Used) 20- Set Screw
2- Wiper Ring 8- U-Ring 15- Slide Ring (2 Used) 21- Cylinder Tube
3- Socket Bolt (8 Used) 9- Ring 16- Seal Ring 22- O-Ring
4- Cylinder Head 10- Bushing 17- Piston
5- Backup Ring 11- Retaining Ring 18- Nut
6- O-Ring 13- Cushion Bearing 19- Steel Ball
W5-2-6-4
Group 2 Cylinder
Assembly of Bucket Cylinder 5. Install U-ring (8) to cylinder head (4) with the lip
special tool (ST8036). 7. Install O-ring (6) and backup ring (5) to cylinder
head (4).
W5-2-6-5
Group 2 Cylinder
9. Install slide rings (14, 15) (2 used for each) with their 15. Secure cylinder tube (21) on a workbench
slits positioned 180° away facing to the opposite horizontally.
each other.
IMPORTANT: Do not damage the rings.
10. Install the cylinder head (4) assembly to cylinder rod 16. Fit to the center of cylinder tube (21) and insert the
(1) by using the special tool (ST 2810). cylinder rod (1) assembly straight.
11. Install cushion bearing (13) to cylinder rod (1) with 17. Install cylinder head (4) to cylinder tube (21) with
the chamfered surface facing of cushion bearing socket bolts (3) (8 used).
(13) to the cylinder head (4) side.
l : 19 mm
12. Install the piston (17) assembly to cylinder rod (1).
13. Fit the matching marks made when disassembling m : 1140 N·m (114 kgf·m, 840 lbf·ft)
j : 130 mm
m : 20900 N·m (2090 kgf·m, 15400 lbf·ft)

ST 5908
W158-04-02-022
14. Install ball (19) and set screw (20) to nut (18).Crimp
set screw (20) by using a punch (2 places).
l : 8 mm
m : 100 N·m (10 kgf·m, 74 lbf·ft)
W5-2-6-6
MEMO
MEMO
SECTION 6
ENGINE AND ACCESSORY

CONTENTS
General Information Engine Mechanical
General Repair Instruction....................................................0A-1 Service Precautions.................................................................6A-2
Illustration Arrows...................................................................0A-2 General Description................................................................6A-2
Abbreviations Charts..............................................................0A-3 Fan Center..................................................................................6A-4
Nut and Bolt Angular Tightening Method......................0A-4 Turbocharger.............................................................................6A-7
Standard Bolt Torque Specifications.................................0A-6 Exhaust Manifold.....................................................................6A-9
Recommended Thread Locking Agents..........................0A-8 Inlet Manifold......................................................................... 6A-10
Main Data and Specification................................................0A-9 Water Pump............................................................................ 6A-13
Performance Curve.............................................................. 0A-11 Alternator................................................................................. 6A-15
Engine External Drawing................................................... 0A-12 Oil Cooler................................................................................. 6A-18
Service Standard................................................................... 0A-13 Injection Pump...................................................................... 6A-20
Torque Specifications.......................................................... 0A-19 Coupling Assembly.............................................................. 6A-24
Special Tools........................................................................... 0A-27 Cylinder Head......................................................................... 6A-27
Troubleshooting.................................................................... 0A-29 Rocker Arm and Shaft Assembly..................................... 6A-47
Lubricant Application.......................................................... 0A-39 Camshaft.................................................................................. 6A-52
Sealant Application.............................................................. 0A-39 Timing Gears........................................................................... 6A-57
Flywheel Housing................................................................. 6A-66
Service Information Oil Pan....................................................................................... 6A-69
Identification.............................................................................0B-1 Piston......................................................................................... 6A-73
Lubrication System..................................................................0B-2 Crankshaft............................................................................... 6A-88
Fuel System................................................................................0B-2 Crank Pulley............................................................................ 6A-99
Cooling System.........................................................................0B-6 Flywheel.................................................................................6A-102
Valve Clearance Adjustment................................................0B-7 Cylinder Block......................................................................6A-104
Compression Pressure Measurement...............................0B-9
Recommended Lubricants................................................ 0B-10 Engine Cooling
Engine Oil Viscosity Chart.................................................. 0B-10 Service Precautions.................................................................6B-1
General Description................................................................6B-2
Water Pump...............................................................................6B-3
Thermostat.................................................................................6B-8
JACW-6-1
Engine Fuel
Service Precautions.................................................................6C-1
General Description................................................................6C-2
Fuel Filter.....................................................................................6C-5
Injection Nozzle Holder.........................................................6C-7
Injection Pump...................................................................... 6C-13
Injection Nozzle Holder-Tow-Stage
Injection Type................................................................... 6C-17
Starting and Charging
Service Precautions..............................................................6D3-1
Alternator.................................................................................6D3-2
Starter Motor....................................................................... 6D3-11
Engine Lubrication
Service Precaution.................................................................. 6G-1
General Description............................................................... 6G-2
Oil Pump.................................................................................... 6G-4
Oil Cooler.................................................................................6G-12
Engine Induction
Service Precaution....................................................................6J-1
Turbocharger..............................................................................6J-2
JACW-6-2
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 1
GENERAL INFORMATION 0A–1
GENERAL INFORMATION
CONTENTS
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B
GENERAL INFORMATION
CONTENTS
General Repair Instruction . . . . . . . . . . . . . . . . . . . . 0A-1 Engine External Drawing . . . . . . . . . . . . . . . . . . . . 0A-12
Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Service Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-13
Abbreviations Charts . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 0A-19
Nut and Bolt Angular Tightening Method. . . . . . . . . 0A-4 Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-27
Standard Bolts Torque Specification . . . . . . . . . . . . 0A-6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-29
Recommended Thread Locking Agents . . . . . . . . . 0A-8 Lubricants Application . . . . . . . . . . . . . . . . . . . . . . 0A-39
Main Data and Specification. . . . . . . . . . . . . . . . . . . 0A-9 Sealant Application . . . . . . . . . . . . . . . . . . . . . . . . . 0A-39
Performance Curve. . . . . . . . . . . . . . . . . . . . . . . . . 0A-11
General Repair Instruction 12. When a service operation is completed, make a final
check to be sure the service has been done properly
1. Before performing service operations, disconnect and the problem has been corrected.
ground cable from the battery to reduce the chance of 13. Allow the engine to cool before beginning any service
cable damage and burning due to short circuiting. procedure.
2. Use a cover on body, seats and floor to protect them This will eliminate the danger of fire and possible
against damage and contamination. injury.
3. Brake fluid and anti-freeze solution must be handled 14. Hot steam under pressure may escape from the
with reasonable care, as they can cause paint damage. radiator if the coolant is drained while the engine is
4. The use of proper tools and recommended essential hot. This can result in serious burns. Allow the engine
and available tools, where specified, is important for to cool before draining the coolant.
efficient and reliable performance of service repairs. 15. Hot engine oil can cause severe skin burns. Allow the
5. Use genuine Isuzu parts. engine to cool before draining the engine oil.
6. Used cotter pins, plastic clips, gaskets, O-rings oil 16. While working around a running engine, avoid contact
seals, lock washers and self-locking nuts should be with moving parts and hot surfaces to prevent
discarded and new ones should be installed, as possible bodily injury.
normal function of the parts cannot be maintained if 17. Wear safety glasses when using compressed air, as
these parts are reused. flying dirt particles may cause eye injury.
7. To facilitate proper and smooth reassembly 18. Always wear safety goggles when working with fuel in
operation, keep disassembled parts neatly in groups. order to protect the eye from fuel splash.
Keeping fixing bolts and nuts separate is very
19. Test fluid from the injection nozzle tester will spray out
important, as they vary in hardness and design
of the injection nozzle under great pressure.
depending on position of installation.
It can easily puncture a person’s skin.
8. Clean the parts before inspection or reassembly. Also
clean oil ports, etc. using compressed air, and make Keep your hands away from the injection nozzle at all
certain they are free from restrictions. time.
9. Lubricate rotating and sliding faces of the parts with 20. Do not use your fingers to feel for fuel leaks at fittings.
oil or grease before installation. Fuel pressure is high enough to penetrate the skin.
10. When necessary, use a sealer on gaskets to prevent 21. Be careful when changing fuel system components:
leakage. Diesel fuel is flammable. Be sure that the ignition key
of OFF. Do not smoke or allow sources of open flame
11. Carefully observe all specifications for bolt and nut
in the area while changing fuel system components.
torques.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 2
0A–2 GENERAL INFORMATION
Illustration Arrows
Arrows are designed for specific purposed to aid your understanding of technical illustration.
Arrow Type Application Arrow Type Application
• Ambient/Clean air flow

Front of Engine
• Cool air flow
• Gas other than

Up Side ambient air
• Hot air flow
• Ambient air mixed with

another gas
Task Related
• Can indicate
temperature change
View Detail Motion of direction
Lubrication point oil or

View Angle
A fluid
Dimension (1:2) Lubrication point grease
Sectioning (1:3) Lubrication point jelly

69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 3
Abbreviations Charts lb in – Inch Pounds

LF – Left Front
List of industrial abbreviations which may be used in
LH – Left Hand
this manual
LR – Left Rear
A – Ampere(s) LS – Left Side
AC – Alternating Current L-4 – In-Line Four Cylinder Engine
ACL – Air Cleaner Max – Maximum
Adj – Adjust Min – Minimum
AMP – Ampere(s) mm – Millimeter
ASM –Assembly N – Newtons
ATDC – After Top Dead Center NA – Naturally Aspirated
Auto – Automatic NC – Normally Closed
Bat – Battery N·m – Newton Meters
B+ – Battery Positive Voltage NO – Normally Open
BHP – Brake Horsepower NOX – Nitrogen, Oxides of
BTDC – Before Top Dead Center OD – Outside Diameter
°C – Degrees Celsius OHC – Overhead Camshaft
cc – Cubic Centimeter PCV – Positive Crankcase Ventilation
CID – Cubic Inch Displacement PRESS – Pressure
CO – Carbon Monoxide PROM – Programmable Read Only Memory
Conn – Connector PSI – Pounds per Square Inch
Crank – Crankshaft PSP – Power Steering Pressure
Cu. In. – Cubic Inch Pt. – Pint
Cyl – Cylinder(s) PWM – Pulse Width Modulate
DOHC – Double Overhead Camshaft Qt. – Quart
DTC – Diagnostic Trouble Code REF – Reference
DTM – Diagnostic Test Mode RF – Right Front
DTT – Diagnostic Test Terminal RH – Right Hand
ECM – Engine Control Module RPM – Revolutions Per Minute
ECT – Engine Coolant Temperature RPM Sensor – Engine Speed Sensor
EGR – Exhaust Gas Recirculation RR – Right Rear
Exh – Exhaust RS – Right Side
°F – Degrees Fahrenheit RTV –Room Temperature Vulcanizing
FL – Fusible Link SAE – Society of Automotive Engineers
FLW – Fusible Link Wire Sec – Secondary
FP – Fuel Pump SI – System International
FRT – Front SOHC – Single Overhead Camshaft
ft – Foot Sol – Solenoid
Gal – Gallon SPEC – Specification
GND – Ground Speedo – Speedometer
Gov – Governor ST – Start / Scan Tool
g – Gram Sw – Switch
Harn – Harness SYN – Synchronize
HC – Hydrocarbons Tach – Tachometer
HD – Heavy Duty TDC – Top Dead Center
Hg – Hydrargyrum (Mercury) Term – Terminal
IC – Integrated Circuit / Ignition Control TEMP – Temperature
ID – Identification / Inside Diameter TURBO – Turbocharger
IGN – Ignition V – Volt(s)
INJ – Injection VAC – Vacuum
Int – Intake V-ref – ECM Reference Voltage
kg – Kilograms VSS – Vehicle Speed Sensor
km – Kilometers VSV – Vacuum Switch Valve
km/h – Kilometer per Hour V-6 – Six Cylinder “Vee” Engine
kPa – Kilopascals V-8 – Eight Cylinder “Vee” Engine
kV – Kilovolts (thousands of volts) W – Watt(s)
kW – Kilowatts w/ – With
L – Liter w/o – Without
lb ft – Foot Pounds WOT – Wide Open Throttle
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 4
Nut and Bolt Angular Tightening

Method
The angular tightening method uses the plastic region of
high tensile steel nuts and bolts to precision tighten Line
important engine fasteners.
Because of the method's nature, there is a limit to the
number of times a particular fastener may be reused. This
limit is specified in this Manual where applicable. C D
1. Carefully wash the nuts and bolts to remove all oil and
grease.
2. Apply a coat of molybdenum disulfide grease to the
threads and setting faces of the nuts and bolts.
3. Tighten the nuts and bolts to the specified torque
(snug torque) with a torque wrench.
4. Draw a line A–B across the center of each nut or bolt
after tighten the snug torque.
F00EY00002
Center line 6. Draw another line F – G on the face of each of the

parts to be clamped. This line will be in the direction
of the specified angle Q across the center E of the
nut or bolt.
A B
Specified angle Q
F00EY00001
5. Draw another line C – D on the face of each of the

parts to be clamped. This line should be an extension
G
of the line A – B.
Coincide line
F00EY00003
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 5
7. Use a socket wrench to tighten each nut or bolt to the

point where the line A – B is aligned with the line F
– G.
Tighten
C D
B
F
F00EY00005
Example: Specified Angle and Tightening Rotation

A 30° 1 / 12 of a turn
B 60° 1 / 6 of a turn
C 90° 1 / 4 of a turn
D 180° 1 / 2 of a turn
E 360° One full turn
A B C D
E
F00EY00004
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 6
Standard Bolts Torque Specification

The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
STANDARD BOLT N·m (kgf·m/lb.ft)

Bolt
Identification
Bolt
Diameter ×
pitch (mm)
M6 × 1.0 4 – 8 (0.4 – 0.8/3 – 6) 5 – 10 (0.5 – 1.0/4 – 7)
M8 × 1.25 8 – 18 (0.8 – 1.8/6– 13) 12 – 23 (1.2 – 2.3/9 – 17) 17 – 30 (1.7 – 3.1/12 – 22)
M10 × 1.25 21 – 34 (2.1 – 3.5/5 – 25) 28 – 46 (2.8 – 4.7/20 – 33) 37 – 62 (3.8 – 6.4/28 – 46)
* M10 × 1.5 20 – 33 (2.0 – 3.4/15 – 25) 28 – 45 (2.8 – 4.6/20 – 33) 36 – 60 (3.7 – 6.1/27– 44)
M12 × 1.25 49 – 74 (5.0 – 7.5/36 – 54) 61 – 91 (6.2 – 9.3/45 – 67) 76 – 114 (7.7 – 11.6/56 – 84)
* M12 × 1.75 45 – 69 (4.6 – 7.0/33 – 51) 57 – 84 (5.8 – 8.6/42 – 62) 72 – 107 (7.3 – 10.9/53 – 79)
M14 × 1.5 77 – 115 (7.8 – 11.7/56 – 85) 93 – 139 (9.5 – 14.2/69 – 103) 114 – 171 (11.6 – 17.4/84 – 126)
* M14 × 2.0 72 – 107 (7.3 – 10.9/53 – 79) 88 – 131 (9.0 – 13.4/65 – 97) 107 – 160 (10.9 – 16.3/79 – 118)
M16 × 1.5 104 – 157 (10.6 – 16.0/77 – 116) 135 – 204 (13.8 – 20.8/100 – 150) 160 – 240 (16.3 – 24.5/118 – 177)
* M16 × 2.0 100 – 149 (10.2 – 15.2/74 – 110) 129 – 194 (13.2 – 19.8/96 – 143) 153 – 230 (15.6 – 23.4/113 – 169)
M18 × 1.5 151 – 226 (15.4 – 23.0/110 – 166) 195 – 293 (19.9 – 29.9/144 – 216) 230 – 345 (23.4 – 35.2/169 – 255)
* M18 × 2.5 151 – 226 (15.4 – 23.0/110 – 166) 196 – 294 (20.0 – 30.0/145 – 217) 231 – 346 (23.6 – 35.5/171 – 255)
M20× 1.5 206 – 310 (21.0 – 31.6/152 – 229) 270 – 405 (27.5 – 41.3/199 – 299) 317 – 476 (32.3 – 48.5/234 – 351)
* M20× 2.5 190 – 286 (19.4 – 29.2/140 – 211) 249 – 375 (25.4 – 38.2/184 – 276) 293 – 440 (29.9 – 44.9/216 – 325)
M22× 1.5 251 – 414 (25.6 – 42.2/185 – 305) 363 – 544 (37.0 – 55.5/268 – 401) 425 – 637 (43.3 – 64.9/313 – 469)
* M22× 2.5 218 – 328 (22.2 – 23.4/161 – 242) 338 – 507 (34.5 – 51.7/250 – 374) 394 – 592 (40.2 – 60.4/291 – 437)
M24× 2.0 359 – 540 (36.6 – 55.0/265 – 398) 431 – 711 (43.9 – 72.5/318 – 524) 554 – 831 (56.5 – 84.7/409 – 613)
* M24× 3.0 338 – 507 (34.5 – 51.7/250 – 374) 406 – 608 (41.4 – 62.0/299 – 448) 521 – 782 (53.1 – 79.7/384 – 576)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials such
as casting.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 7
The tightening torque values given in the table below are applicable to the bolts unless otherwise specified.
FLANGED HEAD BOLT N·m (kgf·m/lb.ft)

Bolt
Identification
Bolt
Diameter ×
pitch (mm)
M6 × 1.0 5 – 9 (0.5 – 0.9/4 – 7) 6 – 12 (0.6 – 1.2/4 – 9)
M8 × 1.25 11 – 20 (1.1 – 2.0/8 – 15) 15 – 28 (1.6 – 2.9/12 – 21) 18 – 34 (2.1 – 3.4/15 – 25)
M10 × 1.25 23 – 39 (2.4 – 3.9/17 – 28) 35 – 59 (3.6 – 6.1/26 – 44) 42 – 71 (4.3 – 7.2/31 – 52)
* M10 × 1.5 22 – 37 (2.3 – 3.8/17 – 28) 35 – 58 (3.5 – 5.8/25 – 42) 40 – 67 (4.1 – 6.8/30 – 49)
M12 × 1.25 55 – 82 (5.6 – 8.4/40 – 61) 77 – 117 (7.9 – 11.9/57 – 86) 85 – 128 (8.7 – 13.0/63 – 94)
* M12 × 1.75 51 – 77 (5.2 – 7.8/38 – 56) 71 – 107 (7.3 – 10.9/53 – 79) 80 – 119 (8.1 – 12.2/59 – 88)
M14 × 1.5 83 – 125 (8.5 – 12.7/62 – 92) 115 – 172 (11.7 –17.6/85 – 127) 123 – 185 (12.6 – 18.9/91 – 137)
* M14 × 2.0 77 – 116 (7.9 – 11.8/57 – 85) 108 – 162 (11.1 – 16.6/80 – 120) 116 – 173 (11.8 – 17.7/85 – 128)
M16 × 1.5 116 – 173 (11.8 – 17.7/85 – 128) 171 – 257 (17.4 – 26.2/126 – 190) 177 – 265 (18.0 – 17.1/130 – 196)
* M16 × 2.0 109 – 164 (11.2 – 16.7/81 – 121) 163 – 244 (16.6 – 24.9/120 – 180) 169 – 253 (17.2 – 25.8/124 – 187)
A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 8
Recommended Thread Locking

Agents
LOCTITE Type LOCTITE Color
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 271 Red
Application Steps
1. Completely remove all lubricant and moisture from the

bolts and the female-threaded surfaces of the parts to
be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
Apply LOCTITE to at least 1/3 of the

bolt's threaded area
F00RW014
3. Tighten the bolts to the specified torque.

After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until LOCTITE
hardens.
NOTE: When the application procedures are specified in
this manual, follow them.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 9
Main Data and Specifications

ITEMS 6WG1TQA
Engine type Four cycle, water cooled, in-line, overhead camshaft
direct injection
Combustion chamber Open type in piston crown
Cylinder liner Dry type
Timing drive system Gear drive
No. of cylinders – bore × stroke mm (in) 6 – 147 × 154 (5.79 × 6.06)
Rated output kW/min–1 235.4/1800
Max. torque kW/min–1 1274.9/1500
No. of piston rings Four rings (Compression rings: 3, Oil ring: 1)
Total piston displacement L (cid) 15.681 (956.9)
Compression ratio (to 1) 16.4
Compression pressure at 200 min–1
MPa (kg/cm2/psi) 2.75 (28/400) or more
Engine dimensions mm (in) 1,642 × 1007 × 1,287 (64.6 × 39.6 × 50.7)
Engine weight (Dry) kg (lb) 1,252 (2,764)
Fuel injection order 1–5–3–6–2–4
Fuel injection timing (TDC) deg 11
Specified fuel type SAE No.2 diesel fuel
Idling speed min–1 900
Valve clearances Intake mm (in) 0.40 (0.016)
Exhaust mm (in) 0.40 (0.016)
Intake valves Open at (BTDC) deg 21
Close at (ABDC) deg 27
Exhaust valves Open at (BBDC) deg 52
Close at (ATDC) deg 17
Injection pump Bosch, in-line P-Type
Governor type Mechanical
Injection nozzle Multi-hole type
Injection nozzle opening pressure
MPa (kg/cm2/psi) 20.1 (205/2,920)
Main fuel filter type Paper element
Lubrication system
Lubrication method Full flow pressure circulation
Specified engine oil (API grade) CD
Oil pressure (at oil gallery)
kPa (kg/cm2/psi)/min–1 300 (3.1/44.1)/1,200
390 (4.0/56.9)/2,000
Condition: SAE 30 API CD grade engine oil at an
oil temperature of 80°C (176°F)
Oil pump type Gear (Timing gear drive)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 10
ITEMS 6WG1TQA
Relief valve opening pressure
kPa (kg/cm2/psi)
1st stage 440 (4.5/64.0)
2nd stage 690 (7.0/99.5)
Oil pressure switch operating pressure
kPa (kg/cm2/psi) 10 (0.1/0.7)
Main oil filter type Paper element
Bypass valve opening pressure
kPa (kg/cm2/psi) 200 (2.0/28.4)
Oil volume L (qts) 52 (55) with combined main and partial oil filter
Oil cooler Plate type – Water cooled in water jacket
Oil thermostat opening temperature
°C (°F) 98.0 (208)
Cooling system Pressured compulsory circulation water
Coolant volume L (qts) 36 (38)
Water pump type Centrifugal impeller, Gear drive
Delivery volume
Lit/min. (Imp. gal/US gal) 420 (92.4/111.0) Pump speed at 2,840 rpm
Thermostat type Wax pellet
Valve initial opening temperature °C (°F) 82 (180)
Valve lift mm (in) 11.0 (0.433)
Air cleaner
Alternator capacity V–A 24 – 50 Mitsubishi
Regulator type IC (Built-in)
Brush length mm (in) Brush less
Starter motor output V – kW 24 – 7 Mitsubishi
Number of poles 4
Turbocharger model RHC 92
Manufacturer Ishikawajima Harima Heavy Industry (IHI)
Note: Some values are different due to the difference of the models and the specifications.
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 11
Performance Curve
1. MODEL AA-6WG1TQA
Condition
Break in period Fully Air cleaner Non
Cooling fan φ 850 Exhaust silencer Non
Alternator No load Ambient condition Standard
240 1400
Torque (Nm)
220 1200
200 1000
180
Power Output (kW)
160
140
120
240 SFC (g/kW/h)

100 230
220
210
200
1000 1200 1400 1600 1800 2000
Engine Speed (min-1)

F06EY00020
Note: Some values are different due to the difference of the models and the specifications.
0A–12
ENGINE EXTERNAL DRAWING

MODEL AA-6WG1 TQA
Oil filler cap
PCV
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 12
GENERAL INFORMATION
Exhaust manifold Turbocharger Inlet duct Fan guide Fuel pump Oil dipstick
Water outlet pipe
Injection pump Fuel filter
Cooling fan
Fan pulley
Alternator
Crank pulley
Water pump
Coupling cover Starter motor
Water drain plug Water inlet pipe
Thermostat housing
Oil drain plug Breather hose
Oil port cover
Note: Some components and shapes are different due to the difference of the models and the specifications.
015EY00001
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 13
Service Standard
ITEMS SERVICE STANDARD SERVICE LIMIT
ENGINE
Compression Pressure 27.5 (28 / 400 ) / 200 21.6 ( 22 / 312 )
MPa(kg/cm2/psi)/min–1 or more, after warm up the
engine.
CYLINDER HEAD and VALVE
Camshaft End Play mm(in) 0.085 – 0.170 (0.0033-0.0067) 0.25 ( 0.0098 )
Clearance between Camshaft and
0.065 – 0.125 (0.0026-0.0049) 0.15 ( 0.0059 )
Bracket mm(in)
Idle Gear “C” End Play mm(in) 0.05 – 0.14 (0.0020-0.0055) 0.25 ( 0.0098 )
Clearance between Shaft and Idle “C” Gear
0.04 – 0.105 (0.0016-0.0041) 0.2 ( 0.0079 )
mm(in)
Valve Spring Free Height mm(in) Outer
Inlet 79.3 (3.1220) 75.3 ( 2.965 )
Exhaust 102.7 (4.0433) 97.6 ( 3.843 )
Inner
Inlet – –
Exhaust 96.5 (3.7992) 91.7 ( 3.6102 )
Valve Spring Squareness mm(in) Inlet 3.5 (0.1378) 4.8 ( 0.1890 )
Exhaust
Outer 4.5 (0.1772) 6.2 ( 0.2441 )
Inner 4.2 (0.1654) 5.9 ( 0.2323 )
Valve Spring tension N(kg/lb)/mm Outer
Inlet 392
372 ( 37.9/83.6)/64
(40.0/88.2)/64
Exhaust 610
579 ( 59.0/130)/69
(62.2/137)/69
Inner
Inlet – –
Exhaust 224
213 ( 21.7/47.8 )/66
(22.8/50.3)/66
Valve Stem and Guide Clearance Inlet 0.040 – 0.077
0.15 ( 0.0059 )
mm(in) (0.0016 – 0.0030)
Exhaust 0.065 – 0.102
0.25 ( 0.0098 )
(0.0026 – 0.0040)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 14

Valve Stem Outside Diameter mm(in) Inlet 10.0 (0.3937) 9.92 ( 0.3906 )
Exhaust 10.0 (0.3937) 9.90 ( 0.3898 )
Bridge Guide and Bridge Clearance
0.020 – 0.057 (0.0080-0.0022) 0.10 ( 0.0039 )
mm(in)
Valve Thickness mm(in) Inlet 2.14 (0.0843) 1.64 ( 0.0646 )
Exhaust 2.3 (0.0906) 1.8 ( 0.0709 )
Valve Depression mm(in) Inlet 1.9 (0.0748) 2.9 ( 0.1142 )
Exhaust 1.8 (0.0709) 2.8 ( 0.1102 )
Valve Contact Width mm(in) Inlet 3.3 (0.1299) 3.7 ( 0.1457 )
Exhaust 2.6 (0.1024) 3.0 ( 0.1181 )
Valve Contact Surface Angle deg Inlet 30 –
Exhaust 45 –
Valve Seat Angle deg Inlet 30 –
Exhaust 45 –
Valve Bridge Guide Upper End Height
49.0 (1.9291) –
mm(in)
Valve Guide Upper End Height mm(in) Inlet 27.0 (1.0630) –
Exhaust 29.0 (1.1417) –
ROCKER ARM AND CAMSHAFT
Rocker Arm Shaft Run Out mm(in) – 0.3 ( 0.012 )
Rocker Arm Shaft Outside Diameter 27.979 – 28.000
27.85 (1.0965)
mm(in) (1.1015-1.1024)
Rocker Arm Bushing Inside Diameter 28.020 – 28.053
–
mm(in) (1.1031 – 1.1044)
Rocker Arm and Rocker Arm Shaft 0.020 – 0.074
0.2 (0.0079)
Clearance mm(in) (0.0008 – 0.0029)
Rocker Arm Roller and Pin Clearance 0.036 – 0.069
0.15 (0.0059)
mm(in) (0.0014 – 0.0027)
Camshaft Journal Diameter mm(in) 39.915 – 39.940
39.89 (1.57047)
(1.5715 – 1.5724)
Cam Height (Nose Height) mm(in) Inlet 9.4 (0.3700) 8.85 ( 0.3484 )
Exhaust 10.4 (0.4094) 9.75 ( 0.3839 )
Camshaft Run Out mm(in) 0.080 (0.0031) 0.100 ( 0.0039 )
Camshaft Bearing Inside Diameter 40.015 – 40.040
–
mm(in) (1.5754 – 1.5764)
Clearance Camshaft and Cam Bearing 0.065 – 0.125 0.15
mm(in) (0.0026 – 0.0049) ( 0.0059 )
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 15

TIMING GEAR TRAIN
Idle Gear Backlash mm(in) 0.095 – 0.135 0.25
( 0.0037 – 0.0053 ) ( 0.0098 )
Idle Gear End Play mm(in) “A” 0.155 – 0.220 0.35
(0.0061 – 0.0089) ( 0.0138 )
“B” 0.050 – 0.140 0.25
(0.0020 – 0.0055) ( 0.0098 )
“C” 0.050 – 0.140 0.25
(0.0020 – 0.0055) ( 0.0098 )
Idle Gear Spindle Outside Diameter “A” 56.93 – 56.96 56.85
mm(in) (2.2413 – 2.2425) ( 2.2382 )
“B” 141.93 – 141.96 141.85
(5.5878 – 5.5890) ( 5.5846 )
“C” 48.93 – 48.96 48.85
(1.9264 – 1.9286) ( 1.9232 )
Clearance Between Idle Gear and “A”
Spindle mm(in) 0.040 – 0.105 0.20
“B”
(0.0015 – 0.0041) ( 0.0079 )
“C”
CRANKSHAFT
Crankshaft End Play mm(in) 0.10 – 0.28 (0.0039-0.0110) 0.35 ( 0.0138 )
Crankshaft Journal Diameter mm(in) No.4 104.850 – 104.875
–
(4.1279 – 4.1289)
Others 104.880 – 104.905
–
(4.1291 – 4.1309)
Crankpin Diameter mm(in) 91.895 – 91.925
–
(3.6179 – 3.6191)
Crankshaft Run Out mm(in) 0.120 (0.0005) 0.15 ( 0.0059 )
Crankshaft End Play mm(in) 0.10 – 0.28
0.30 (0.0121)
(0.0039 – 0.0110)
Crank Bearing Spread mm(in) – 111.5 ( 4.3898 )
Clearance Crankshaft journal and No.4 0.075 – 0.150
Bearing mm(in) Journal (0.0030 – 0.0059)
0.16 (0.0063)
Others 0.045 – 0.120
(0.0018 – 0.0047)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 16

PISTON AND CONNECTING ROD
Piston Ring Gap mm(in) 1st, 3rd 0.35 – 0.50
(0.0138 – 0.0197)
2nd 0.80 – 0.95
1.00 (0.0394)
(0.0315 – 0.0374)
Oil 0.30 – 0.50
(0.0118 – 0.0197)
Clearance Piston Ring and Groove 1st 0.115 – 0.160 0.24
mm(in) (0.0045 – 0.0063) (0.0094)
2nd 0.10 – 0.135 0.20
3rd (0.0039 – 0.0053) (0.0079)
Oil 0.025 – 0.065 0.15
(0.0010 – 0.0026) (0.0059)
Piston Pin Diameter mm(in) 55.995 – 56.000 55.970
(2.2015 – 2.2047) (2.2035)
Clearance Piston Pin and Hole mm(in) 0.008 – 0.021 0.05
(0.0003 – 0.0008) (0.0020)
Clearance Connecting Rod Small End 0.020 – 0.037 0.10
Bushing and Piston Pin mm(in) (0.0008 – 0.0015) (0.0039)
Connecting Rod Alignment mm(in) 0.05 (0.002 or less) 0.10 (0.0039)
Clearance Crankpin and Connecting 0.033 – 0.103 0.16
Rod Bearing mm(in) (0.0013 – 0.0041) (0.0063)
Clearance Connecting Rod and 0.175 – 0.290 0.35
Crankshaft mm(in) (0.0069 – 0.0114) (0.0138)
Clearance Piston and Cylinder Liner 0.166 – 0.200
–
mm(in) (0.0065 – 0.0079)
PISTON AND CYLINDER LINER GRADE
Cylinder Measuring point mm(in) 130 (5.1181)
Cylinder Liner Inside Diameter mm(in) 147.011 – 147.030
–
(5.7878 – 5.7886)
Piston Measuring Point from
113 (4.4488) –
Piston Top mm(in)
Piston Outside Diameter mm(in) 146.830 – 146.845
–
(5.7807 – 5.7813)
Clearance Cylinder Liner and Cylinder 0.001 – 0.030
Block mm(in) (0.00004 – 0.00118)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 17

CYLINDER BLOCK AND CYLINDER LINER
GRADE
Cylinder Block Bore Diameter mm(in) Grade
“1” 151.600 – 151.610
–
(5.9685 – 5.9689)
“2” 151.611 – 151.630
–
“3” (5.9689 – 5.9697)
Cylinder Liner Outside Diameter mm(in) Grade
“1X” 151.590 – 151.599
–
(5.9681 – 5.9685)
“3X” 151.600 – 151.610
–
(5.9685 – 5.9689)
CYLINDER BODY
Cylinder Liner Bore mm(in) Nominal Measurement
147.3 (5.7992)
147.0 (5.7874)
Cylinder Block Upper Face Warpage
0.0075 (0.0030) or less 0.2 (0.008)
mm(in)
Cylinder Liner Projection mm(in) 0.05 – 0.09
–
(0.0020 – 0.0035)
Projection Height Between Adjacent
0.02 (0.0008) or less –
Cylinder mm(in)
LUBRICATING SYSTEM
Clearance Oil Pump Body and Driven 0.050 – 0.098
0.15 (0.0059)
Gear mm(in) (0.0020 – 0.0039)
Side Clearance Oil Pump Cover and 0.040 – 0.094
–
Gear mm(in) (0.0016 – 0.0037)
Oil Pump Gear Shaft Diameter mm(in) 20.0 (0.7874) 19.9(0.7835)
Clearance Oil Pump Gear Shaft and 0.040 – 0.074
–
Body mm(in) (0.0015 – 0.0029)
An Interference Oil Pump Drive Gear 0.019 – 0.047
–
and Driven Gear mm(in) (0.0007 – 0.0019)
Oil Thermostat Opening Temperature
98.0 (208.4) –
°C (°F)
ENGINE COOLING SYSTEM
Clearance Water Pump Impeller and 1.7 – 2.7
3.2 (0.1260)
Pump Body mm(in) (0.0669 – 0.1063)
Thermostat Opening Temperature Initial Opening 82 (180.0) –
°C (°F) Full Opening 95 (203.0) –
Thermostat Full Valve Lift mm(in) 11 (0.433) –
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 18

ENGINE ELECTRICAL
Alternator
Rotor Coil Resistance ohm 11.7 –
Starter Motor
Commutator Undercut mm(in) 0.5 (0.197) 0.2 (0.0079)
Commutator Outside Diameter mm(in) 32 (1.26) 31.4 (1.24)
Brush Length mm(in) 18 (0.709) 11 (0.43)
TURBOCHARGER
Turbine Shaft End Play mm(in) 0.075 – 0.110
0.12 (0.0047)
(0.0030 – 0.0043)
Clearance Turbine Shaft and Bearing 0.130 – 0.235
0.275 (0.0108)
mm(in) (0.0051 – 0.0093)
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 19
Torque Specifications
Auxiliary Parts N·m (kgf·m/lb ft)
118(12/87) 118(12/87)
52(5.3/38) 103(10.5/76)
52(5.3/38)
F06EY00021
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 20
Engine External Parts

N·m (kgf·m/lb ft)
43(4.4/32)
52(5.3/38)
39(4.0/29)
88(9.0/65)
108(11/80)
43(4.4/32) 20(2.0/14)
50(5.1/37)
39(4.0/29)
43(4.4/32)
F06EY00022
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 21
Cylinder Head
N·m (kgf·m/lb ft)
20(2.05/14.8)
15(1.5/11)
90(9.2/67)
Apply engine oil 49(5.0/36)
137(14/101)
M18: 177 (18/130)

245 (25/181)
60° 90°
M12: 76 (7.7/57)
M10: 38 (3.9/28)
M18: Apply molybdenum
disulfide grease
M12,M10: Apply engine oil
Apply engine oil
39(4.0/29)
Apply Loctite FMD-127
F06EY00166
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 22
Oil Pan
N·m (kgf·m/lb ft)
69(7.0/51)
55(5.6/41)
38(3.9/28)
38(3.9/28)
25(2.5/18)
19(1.9/14)
PAW0Z0LF001301
PAW0Z0LF001301
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 23
Timing Gears
N·m (kgf·m/lb ft)
135(13.8/100)
49(5.0/36)
39(4.0/29)
Apply Loctite FMD-127
39(4.0/29)
108(11.0/80)
52(5.3/38)
46(4.7/34)
22(2.2/16)
96(9.8/71)
267(27.2/197)
Apply engine oil
014EY00127
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 24
N·m (kgf·m/lb ft)
(Without Cooling Fan)
135 {13.8 / 100}
49 {5.0 / 36}
39 {4.0 / 29}
39 {4.0 / 29}
108 {11.0 / 80}
39 {4.0 / 29}
M8 23 {2.3 / 17}
M10 43 {4.4 / 32}

96 {9.8 / 71}
267 {27.2 / 197}
PAW0Z0LF001401
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 25
Flywheel
N·m (kgf·m/lb ft)
136(13.8/100)
136(13.8/100)
Apply Loctite
FMD-127
136(13.8/100)
M14: 123 (12.5/90)

M 8 : 22 (2.2/16)
78(8.0/58) 60° 30°

136(13.8/100)
Apply molybdenum disulfide grease
015EY00080
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 26
Piston, Connecting Rod, Crankshaft

N·m (kgf·m/lb ft)
98(10/72) 30° 30°

M12: 96(9.8/71)
Apply engine oil
M18: 49(5/36) 88(9/65) 105°

51743A
00/06/27 0
一般輸出
015EY00081
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 27
Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME
1-8522-1187-0
1-8523-0013-0
Installer; Valve stem seal
Remover; Nozzle holder
for intake
1-8531-7019-0 1-85221-184-0
Adapter; Compression Installer; Valve stem seal
gauge for exhaust
5-8840-0266-0 1-8522-1025-0
Angle gauge Setting tool; Piston ring
901LX030
1-8523-5013-0 1-8522-0052-0
Compressor; Valve spring Remover; Slinger
9-8523-1202-0
1-8522-0059-0
Remover; Valve
Setting tool; Piston
guide/Installer
9-8522-1324-0
1-8522-0043-0
Installer; Valve bridge
Installer; Oil seal
guide
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 28
TOOL NO.
ILLUSTRATION
TOOL NAME
1-8521-0064-0
Remover; Crankshaft gear
1-8522-0045-0
Installer; Crankshaft gear
1-8521-0062-0
Remover; Impeller
11.3 ± 0.1
1-8522-0047-0
Installer; Seal Unit
1-8521-0067-0
Puller; Seal ring
1-8522-1034-0
Installer; Seal ring
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 29
Troubleshooting
1. Hard starting
Condition Possible Cause Correction
Starter motor does not turn over Loose battery cable terminals
Poor battery connections due to rusting Clean and/or retighten the battery cable
terminals
Battery discharged or weak Recharge or replace the battery
Fusible link shorted Replace the fusible link
Defective starter switch or starter relay Replace the starter switch or starter relay
Defective magnetic switch of starter Repair or replace the magnetic switch
motor or starter relay or starter relay
Defective starter motor Repair or replace the starter motor
Starter motor operates but Loose battery cable terminals
engine does not turn over Poor battery connections due to rusting Clean and/or retighten the battery cable
terminals
Battery discharged or weak Recharge or replace the battery
Loose fan belts Adjust the fan belt tension
Defective starter motor pinion gear Replace pinion gear
Defective magnetic switch of the starter Repair or replace the magnetic switch
motor
Worn starter motor Replace the brush and /or brush spring
Weak brush spring
Piston,crank bearing seizure,or other Repair or replace the related parts
damage
Engine turns over but does not Air in the fuel system Bleed air from the fuel system
start Defective engine stop mechanism Replace the engine stop mechanism
Control wire improperly adjusted” Adjust the control wire
Fuel tank is empty Fill the fuel tank
Clogged or damaged fuel lines Repair or replace the fuel lines
Loose fuel line connections Retighten the fuel line connections
Clogged fuel filter element Replace the fuel filter element or cartridge
Fuel feed pump strainer is clogged Clean the fuel pump strainer
Defective feed pump Repair or replace the feed pump
Poor return of the engine stop button Completely return the engine stop button
Use of the wrong fuel Use the recommended fuel
Water particles in the fuel Change fuel
Air in the injection pump Bleed air from the fuel system
Injection nozzle sticking Replace the injection nozzle
Injection nozzle starting pressure too low Adjust or replace the injection nozzle
Improper spray condition
Improper injection pump control rack Repair or replace the injection pump
operation control rack
Injection pump plunger worn or stuck Replace the injection pump plunger
assembly
Injection pump camshaft seizure or Replace the injection pump camshaft
other damage
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 30
2. Unstable Idling
Trouble in the engine stop Poor return of the engine stop button Completely return the engine stop
mechanism button
Trouble in the fuel system Fuel system leakage or blockage Repair or replace the fuel system
Air in the fuel system Bleed the air from the fuel system
Water particles in the fuel Replace fuel
Clogged fuel filter element Replace the fuel filter element or
cartridge
Injection nozzle starting pressure too Adjust or replace the injection nozzle
low
Defective delivery valve resulting in fuel Replace the delivery valve
drippage after fuel injection
Injection timing improperly adjusted Adjust the injection timing
Insufficient injection volume Adjust the injection volume
Broken plunger spring of the injection Replace the plunger spring
pump
Worn plunger of the injection pump Replace the plunger assembly
Worn camshaft of the injection pump Replace the camshaft
Worn roller tappet of the injection pump Replace the roller tappet
Trouble in the valve gear train Valve clearance improperly adjusted Adjust the valve clearance
Worn camshaft Replace the camshaft
Low compression pressure Blown out cylinder head gasket Replace the related parts
Worn cylinder liner
Piston ring sticking or broken
Improper seating between the valve and
valve seat
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 31
3. Insufficient Power
Trouble in the air intake system Clogged air cleaner element Clean or replace the air cleaner element
Trouble in the fuel system Water particles in fuel system Replace fuel
Clogged fuel filter element Replace the fuel filter element or
cartridge
Clogged strainer or defective fuel feed Repair or replace the feed pump
pump
low
Improper spray condition Adjust or replace the injection nozzle
Fuel injection pipes damaged or Replace the injection pipes
obstructed
Defective delivery valve Replace the delivery valve
Repair or replace the timing advancer
Worn plunger of the injection pump Replace the plunger assembly
Worn camshaft of the injection pump Replace the camshaft
Trouble in the turbocharged Exhaust gas leakage from the exhaust Repair or replace the related parts
system system
Air leakage from the intake system Repair or replace the related parts
Defective turbocharger assembly Replace the turbocharger assembly
Worn cylinder liner
valve seat
Trouble in the valve gear train Valve clearance improperly adjusted Adjust the valve clearance
Worn camshaft lobe Replace the camshaft
Valve spring weak or broken Replace the valve spring
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 32
4. Excessive Fuel Consumption

Trouble in the fuel system Fuel leakage Repair or replace the fuel system
related parts
low
Improper spray condition Adjust or replace the injection nozzle
Trouble in the air intake system Clogged air cleaner element Clean or replace air cleaner element
Improper idle speed Poorly adjusted idling speed Adjust idling speed
Trouble in the cooling system Defective thermostat Replace
Trouble in the lubricating system Improper engine oil viscosity Replace engine oil
Trouble in turbocharged system Air leakage from the turbocharger intake Repair the turbocharger intake side
side
Defective turbocharger assembly Replace the turbocharger assembly
Worn cylinder liner
valve seat.
Trouble in the valve gear train Valve clearance improperly adjusted Adjust the camshaft
Worn camshaft lobe Replace the camshaft
Valve spring weak or broken Replace the valve spring
5. Excessive Oil Consumption

Trouble in the lubricating system Engine oil unsuitable Replace engine oil
Too much engine oil volume Correct engine oil volume
Leakage Oil leakage from the oil seal and/or Replace the oil seal and/or gasket
gasket
Oil leaking into the combustion Worn valve stems and valve guides Replace the intake and exhaust valves
chamber due to poor seal in the and valve guides
valve system Worn valve stem oil seal Replace the oil seal
Improper sealing Worn or broken seal ring in the Replace the seal ring
turbocharger
Worn cylinder liner
valve seat.
Trouble in the ventilation Clogged air breather Clean the air breather
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 33
6. Engine Cooling Trouble

Overheating Insufficient cooling water Replenish coolant
Defective pressure cap or clogged Replace the radiator pressure cap or
radiator core clean radiator core
Defective water pump Repair or replace the water pump
Defective sealing cap resulting in the Replace the sealing cap
cooling water leakage
Defective thermostat Replace the thermostat
Cooling system clogged by foreign Take out the foreign material from the
material cooling system
Fuel injection timing improperly Adjust the fuel injection timing
adjusted
7. White Exhaust Smoke

Trouble in the fuel system Water particles in fuel Replace the fuel
Retarded fuel injection timing Adjust the fuel injection timing
Worn cylinder liner
valve seat.
Trouble in the cooling system Defective thermostat Replace the thermostat
Trouble in the turbocharger Defective turbocharger Repair or replace
system
8. Black Exhaust Smoke

Trouble in the fuel system Clogged air cleaner element Clean or replace the air cleaner element
Trouble in the fuel system Injection nozzle starting pressure tool Adjust or replace the injection nozzle
low
Advanced fuel injection timing Adjust the fuel injection timing
Excessive injection volume Adjust the injection volume
Trouble in the valve train Worn camshaft lobe Replace the camshaft
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 34
9. Lubrication Problems
Oil pressure does not rise Improper engine oil viscosity Replace the engine oil
Insufficient engine oil Correct the engine oil volume
Defective oil pressure gauge or unit Repair or replace the oil pressure gauge
or unit
Clogged oil filter element Replace the oil filter element or
cartridge
Relief valve sticking and/or weak by- Replace the relief valve and/or by-pass
pass valve spring valve spring
Clogged oil pump strainer Clean the oil pump strainer
Worn oil pump related parts Replace the oil pump related parts
Worn rocker arm bushing Replace the rocker arm bushing
Worn camshaft and camshaft bearing Replace the camshaft and camshaft
bearing
Worn crankshaft and bearings Replace the crankshaft and/or bearing
Oiling jet valve does not close Replace the oiling jet
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 35
10. Abnormal Engine Noise

Start the engine and allow it to warm up before beginning the troubleshooting procedure.

Engine knocking Use of wrong fuel Use correct fuel
Fuel injection timing improperly Adjust the injection timing
adjusted
Improper injection nozzle starting Adjust or replace the injection nozzle
pressure
Broken piston ring resulting in low Replace the piston ring
compression pressure
Defective fuel injection nozzle resulting Replace the fuel injection nozzle
in fuel drippage after fuel injection
Gaseous leakage noise Loosely connected exhaust pipes Tighten the exhaust pipe connection
Broken exhaust pipes Replace the exhaust pipes
Loose injection nozzles and/or glow Tighten the injection nozzles and/or
plug glow plug
Replace the washer
Loosely connected exhaust manifold Tighten the exhaust manifold
connections
Damaged cylinder head gasket Replace the cylinder head gasket
Continuous noise Loose fan belt Readjust the belt tension
Loose cooling fan Retighten cooling fan
Worn or damaged water pump bearing Replace the water pump bearing
Worn or damaged alternator bearing Replace the alternator bearing
Valve clearance improperly adjusted Adjust the valve clearance
Slapping noise Valve clearance improperly adjusted Adjust the valve clearance
Damaged rocker arm Replace the rocker arm
Worn or damaged crankshaft and/or Replace the crankshaft and/or thrust
thrust bearings bearing
Worn or damaged crankshaft and/or Replace the crankshaft and/or
connecting rod bearings connecting rod bearings
Worn or damaged connecting rod Replace the connecting rod bushing
bushing and piston pin and/or piston pin
Worn or damaged piston and cylinder Replace the piston and cylinder liner
liner
Foreign material in the cylinder
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 36
11. Alternator
Battery dead Loose alternator drive belt Adjust
Low battery fluid Replenish
Defective battery terminals Replace
Blown fuse Replace
Poor contact between the fuse holder Repair
and fuse
Low battery fluid specific gravity Adjust
Broken or poorly connected starter Repair
switch and regulator terminal wire
Broken or poorly connected regulator Repair
terminal and alternator terminal wire
Defective alternator ground circuit Repair
Defective voltage regulator Replace
Defective diode Replace
Grounded or broken alternator stator Repair or replace
coil
Broken rotor coil Replace
Excessive electrical load Check the alternator output at normal
operating speed
Battery overcharged Poor connections or open circuit Correct
Poor ground connection of voltage Correct
regulator
Voltage set of regulator too high Replace
Defective voltage regulator Replace
Flashing charge light or Loose belt Adjust
fluctuating ammeter indication Defective starter switch contacts Replace
Broken or poorly connected wiring Replace or reconnect
Charge light on but gim while Loose starter switch terminal wiring Retighten
operating Excessive resistance of alternator and Replace the wire with a large one
fuse holder terminal wire
Defective starter switch contacts Replace
Alternator noise Defective alternator bearing Replace or regrease
Exposed stator coil wires Replace
Short circuit of the stator coil Replace
Charge circuit fuse blown Grounded terminal wiring Repair
Defective alternator end flame diode Replace the end flame assembly
Out of voltage regulator adjustment Replace
Reversed battery connections Correct
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 37
12. Starter Motor

Starter and magnetic switch Low battery fluid level Replenish
does not operate Low battery specific gravity Recharge or replace
Poor battery switch contacts Replace
Defective starter switch Replace
Defective magnetic switch pull-in coil Replace
and plunger
Broken armature coil Replace
Broken field coil Replace
Broken magnetic switch Replace
Broken holding coil Replace
Magnetic switch operates but Low battery fluid level Replenish
the starter does not turn Low battery specific gravity Recharge or replace
Poor starting circuit contacts Repair
Poor contacts of magnetic switch Replace
terminal
Worn brushes Replace
Shorted armature Repair or replace
Starter runs slowly Bad contact of magnetic terminal circuit Repair
switches
Excessive brush wear Replace
Shorted starter motor armature Repair or replace
Starter operates but the engine No engaging of pinion and ring gear Repair or replace the running clutch and
does not start driving lever
Slippage of overrunning clutch Replace
Abnormal operating noise Excessive bushing wear Replace
Excessive pinion gear wear Replace overrunning clutch and pinion
gear
Rough sliding action pinion gear Lubricate or replace the overrunning
clutch
Excessive ring gear wear Replace overrunning clutch and ring
gear
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 38
13. Turbocharger
Engine has less than normal Restricted air cleaner Clean or replace
power Restricted intake pipe and hose Clean or replace
Loose connection of the turbocharger inlet and Repair
outlet
Restricted exhaust and silencers Repair
Restricted air breather Clean or replace
Impact damage of the compressor wheel Replace
Impact damage of the turbine wheel Replace
Carbon build-up on the turbine wheel Replace
Dragging or seized rotating assembly Replace
Blue or black smoke Restricted air cleaner Clean or replace
Leakage from turbocharger oil seal Replace
Restricted turbocharger oil drain pipe Repair or replace
Restricted air breather Clean
Impact damage of compressor wheel Replace
Impact damage of turbine wheel Replace
Restricted center housing oil drain passage Clean or replace
Excessive oil consumption Restricted air breather Clean
Leakage from turbocharger oil seal Replace
Impact damage of compressor wheel Replace
Impact damage of turbine wheel Replace
Excessive oil pressure Repair
Excessive turbocharger noise Restricted intake and exhaust system joints Repair
Damaged intake and exhaust system gasket Repair
Rough rotation of turbocharger rotating parts Replace
Rubbing compressor wheel against housing Replace
Damaged compressor wheel Replace
Rubbing turbine wheel against housing Replace
Damaged turbine wheel Replace
Carbon built-up on the turbine wheel Clean or replace
Too low engine oil level Correct
Contaminated oil level Replace oil
Restricted turbocharger oil feed pipe Repair or replace
Carbon built-up on the turbine housing Clean
Dirty compressor housing Clean
Worn turbine shaft bearings Replace
Excessive rotating part wear Contaminated engine oil Change
Wrong grade or type of engine oil Change
Restricted turbocharger oil feed pipe Clean or replace
Defective turbocharger oil seal Replace
Oil sludgy and coking turbine shaft Replace
In adequate oil supply Correct
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 39
Lubricants Application
Name of Sealant or
Location for Application
Lubricant
Engine Oil Turbocharger bearing
Inside of camshaft bracket
Idle gear shaft & fixing bolt
Bridge
Rocker arm
Camshaft cam nose
Crank pulley fixing bolt threads and seating face
Inside and outside of cylinder liner
Connrod bearing sliding face
Crankshaft bearing sliding face
Thrust bearing
Piston and piston rings
Piston pin
Molybdenum disulfied grease Crankcase fixing bolt threads and seating face
Cylinder head fixing bolt thread and seating face
Connrod bearing fixing bolt thread and seating face
Sealant Application
Location
Name of sealant
Name of part Name of mating part
1 Crankcase Cylinder block Loctite FMD-127
2 Gearcase Cylinder block Loctite FMD-127
3 Flywheel housing Cylinder block Loctite FMD-127
4 Gearcase Cylinder head Loctite FMD-127
5 Gearcase Upper cylinder block Loctite FMD-127
6 Upper and lower gearcase Cylinder head Loctite FMD-127
7 Crankcase Gearcase Cemedyn LG-020L
8 Crankcase Flywheel housing Cemedyn LG-020L
9 Oil cooler Cylinder block Three Bond 1207C
10 Nozzle sleeve Cylinder head Loctite TL290
11 Thermometer unit threads Cylinder head Loctite No.271 or Three Bond No. 1241
12 Oil pressure switch threads Cylinder block Loctite No.271 or Three Bond No. 1241
69697_ESS-172A_SEC0A 11.8.8 10:18 AM ページ 40
MEMO
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 1
SERVICE INFORMATION 0B–1
GENERAL INFORMATION
SERVICE INFORMATION
CONTENTS
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-1 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . 0B-7
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-2 Compression Pressure Measurement . . . . . . . . . . . 0B-9
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-2 Recommended Lubricants . . . . . . . . . . . . . . . . . . . 0B-10
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-6 Engine Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . 0B-10
Identification
Engine Serial Number
The engine serial number is stamped on the front, upper area of the cylinder block.
Engine model Serial number
6WG1 000000
015EY00002
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 2
0B–2 SERVICE INFORMATION
Lubrication System 2. Before installing a new fuel filter, apply fuel to the
gasket of the cartridge.
Oil filter replacement 3. Turn the fuel filter until the filter gasket comes in
The oil filter is remotely mounted on the equipment side. contact with its sealed face.
1. Set a filter wrench at the cartridge and remove the oil 4. Use the filter wrench to turn in the fuel filter by
filter. additional 2/3 of a turn.
Discard the used cartridge.
2. Before installing the new oil filter, apply engine oil to
the gasket of the cartridge.
3. Turn the oil filter until the filter gasket comes in contact
with its sealed face.
4. Use the filter wrench to turn in the oil filter by additional
one full turn.
NOTE: Be careful not to spill out the fuel retaining in the

fuel filter when the filter is removed. After changing the
fuel filter element, conduct fuel air bleeding and check for
fuel leaks.
Injection Timing Adjustment

050EY00002
Injection Timing Inspection

Fuel System 1. Disconnect the negative battery cable.
Fuel filter replacement procedure 2. Rotate the crankshaft in the normal direction of engine
rotation to align the injection timing mark on the
1. Use a filter wrench to remove the cartridge.
flywheel with the timing pointer.
Discard the used cartridge.
• Injection Timing (Static-TDC): 11 degree
T
C
5
10
15
015EY00003
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 3
3. Check that the timing advancer notched line is aligned

with the injection pump notched line.
If the notched lines are out of alignment, the injection
timing must be adjusted.
4. Move the timing advancer to the correct timing.

5. Tighten the two coupling bolts.
6. Rotate the crankshaft two turns in normal direction of
crankshaft rotation.
7. Verify the new setting is correct injection timing.
Injection Timing Adjustment
8. Connect the negative battery cable.
1. Rotate the crankshaft in normal direction of rotation
until the timing mark on the timing advancer can be
seen.
2. Align the injection timing mark on the flywheel with the
pointer.
T
C
5
10
15
015EY00003
3. Loosen the two coupling bolts.

69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 4
Injection Nozzle
Opening Pressure and Spray Condition
Check
1. Use an injection nozzle tester to check the nozzle
opening pressure. 1 2 3
If the opening pressure is above or below the specified
value, the injection nozzle must be replaced or
adjusted.
Refer to “Adjustment of Injection Nozzle Opening
Pressure”.
Injection Nozzle Opening Pressure:
20.1 MPa (205 kg/cm2 / 2,915 psi)
040EY00030
Injection Nozzle Adjustment

1. Attach the injection nozzle holder to the injection
nozzle tester.
2. Apply pressure to the nozzle tester.
Note the pressure at which the injection nozzle opens.
Injection Nozzle Opening Pressure:
20.1 MPa (205 kg/cm2 / 2,915 psi)
An adjusting shim of 0.007 mm (0.0003 in) allows the

press to change by about 98 kPa (1.0 kg/cm2 / 14.2 psi).
The adjusting shim thickness calculation method as
040EY00023
follows.
The adjusting shim thickness calculation method.
WARNING:
P × π/4 × (A2 – B2)
Test fluid from the injection nozzle tester will spray = Shim thickness (mm)
out of the injection nozzle under great pressure. It can C
easily puncture a person’s skin.
Keep your hands away from the injection nozzle at all P (kPa) = (Target injection nozzle opening pressure
times. – Indicated value (pressure) of nozzle
tester)
2. Check the spray condition. A (cm) = Needle diameter 0.6 cm
If the spray condition is bad, the injection nozzle must B (cm) = Sheet diameter 0.3 cm
be replaced or reconditioned. C (N/mm) = Spring constant 264.0 N/mm
(1) Correct
(2) Incorrect (Restrictions in orifice)
(3) Incorrect (Dripping)
If lapping is required, refer to “Nozzle Lapping
Procedure of FUEL SYSTEM”.
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 5
After calculating shim thickness, select shims from below 2. With a wrench, loosen the air plug (1) of the fuel filter
list. and pump the fuel until all the air bubbles in it
Adjusting Shim Availability mm disappear by being pumped out through the air plug.
Thickness Part number 3. There are no bubbles and the fuel comes out in a solid
stream.
0.50 5-15339-007-0
Now securely tighten the air plug and priming pump
0.52 5-15339-018-0 cap.
0.54 5-15339-019-0
0.56 5-15339-020-0
Feed pump strainer
0.58 5-15339-021-0
Remove the joint bolt on the intake side of the feed pump,
0.60 5-15339-008-0 then screw out the strainer counterclockwise and clean it.
0.70 5-15339-009-0 Then, operate the priming pump on the injection pump to
0.80 5-15339-010-0 bleed the fuel system.
0.90 5-15339-011-0
1.00 5-15339-012-0
0.10 8-94128-982-0
0.20 8-94128-983-0
0.30 8-94128-984-0
0.40 8-94128-985-0
Air Bleeding
When servicing the fuel filters or if the fuel tank is emptied,
air might be allowed to go into the fuel system. With air in
the fuel system, smooth flow of fuel into the engine is Strainer
interrupted and to prevent this, bleeding of the fuel system
should be performed.
1. Loosen the priming pump cap and pump the fuel into
the injection pump by manually operating the priming
040EY00008
pump (2).
Fuel tank
Remove the drain plug and drain the water and sediment
completely.
1
040EY00006
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 6
Cooling System Drive Belt Inspection (Scrum belt)

1. Tighten the idle pulley lock nut and generator section
Drive Belt Inspection (Single belt) lock nut.
Check the drive belt tension. 2. Adjust the belt tension so it becomes equal to the
Depress the drive belt mid-portion with a 100 N (10kg/22 standard value by adjusting the idle pulley adjusting
lb) force. bolt and generator section adjusting bolt.
Drive Belt Deflection: 8 – 12 mm (0.31 – 0.47 in)
3. The deflection when 98 N {10 kg/22 lb} is applied to
the center between the idle pulley and generator
pulley
Drive Belt Deflection: 6 – 8 mm (0.24 – 0.31 in)
1 2
4
3
033EY00001 5
Check the drive belts for cracking and other damage.
PAW5Z0MH000801
Name
1. Lock Nut (Generator)
2. Adjusting Bolt (Generator)
3. Lock Nut
4. Adjusting Bolt (Idle Pulley)
5. Belt Tension Measurement Position
6. Mounting Bolt
033EY00009
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 7
Check the drive belt for cracking and other damage. Valve Clearance Adjustment
The following instructions assume that valve clearance is
adjusted beginning with the No. 1 piston at top dead
center (TDC) on the compression stroke.
Check alignment timing mark between timing advancer
and mark line on injection pump body. In this position
indicate T.D.C. of No. 1 piston.
Valve clearance must be adjusted when the engine is
cold.
When remove the head cover, wipe off spilled oil with a
rag.
1. Bring the piston in the No. 1 or No. 6 cylinder to the
top dead center on the compression stroke by turning
the crankshaft until the T.D.C. line on the flywheel is
aligned with the timing pointer.
Check the rocker arm shaft bracket nuts for looseness
and retighten as necessary before adjusting the valve
PAW5Z0SH006001 clearance.
015EY00070
2. Check that the No. 1 intake and exhaust rocker arms

have play. If they have play, it indicates that the No. 1
piston is at TDC (Top Dead Center) on the
compression stroke. If the No. 1 exhaust valves are
depressed, the No. 6 piston is at TDC on the
compression stroke.
3. Adjust valve clearances for the No. 1 or No. 6 cylinder
which its piston is at TDC on compression stroke.
1. Loosen each adjusting screw (1) on the bridge (2)
and rocker arm (3).
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 8
4. In this condition, the opposite end of the bridge is

raised. Readjust by loosening the adjusting screw
1 on the bridge until there is a slight drag on the
feeler gauge and tighten the lock nut securely.
3
No.1 cylinder T. D. C.
(comp. stroke)
1 2 3 4 5 6
E I E I E I E I E I E I
Front
014EY00129
Valve Clearance: 0.4 mm (0.0016 in)

2. Insert a feeler gauge between the rocker arm (1)
and the cam (2) and adjust by turning the adjusting
screw on the rocker arm until there is a sight drag 014EY00125
on the feeler gauge. Tighten the lock nut securely. 4. Rotate the crankshaft 360° and realign the T.C. mark
on the flywheel with the pointer and adjust clearance
for remaining valves.
1
The “●” mark in the illustration indicates the cylinders
and valves to be adjusted.
No.6 cylinder T. D. C.
(comp. stroke)
1 2 3 4 5 6
E I E I E I E I E I E I
2
014EY00130
Front
3. With a feeler gauge inserted, screw in the

adjusting screw on the bridge gradually until it
touches to the end of the valve stem, and make
sure that the movement of the feeler gauge 014EY00126
becomes hard.
NOTE: Be sure to move the No. 1 cylinder to TDC on the
compression stroke after completing the valve clearance
adjustment procedure.
Torque: 79 N·m (8.0 kg·m/58 lb·ft)
Rocker Arm Adjusting Screw Nut
Torque: 54 N·m (5.5 kg·m/40 lb·ft)
Bridge Adjusting Screw Nut
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 9
Intake and Exhaust Valve Arrangement

Cylinder No. 1 2 3 4 5 6
Valve Names E I E I E I E I E I E I
No. 1 cyl. at TDC on compression ● ● ● ● ● ●
No. 6 cyl. at TDC on compression ● ● ● ● ● ●
I : Intake valve. E: Exhaust valve
Compression Pressure Measure

To measure the compression pressure, the engine must
be cold. Engine coolant temperature should be at 20°C.
Battery and starter motor condition must be normal.
1. Remove the injection nozzle assembly and the
injection fuel pipe from the each cylinder, using nozzle
holder remover: 1-8523-0013-0.
011EY00025
4. Crank the engine with starter motor (about 200 min–1)

and take the compression gauge reading.
5. Repeat the procedure (Step 2 to 4) for the remaining
cylinder.
Compression Pressure
Standard : 2.75 MPa (28.0 kg/cm2 / 400 psi)
011EY00026
Limit : 2.26 MPa (23.0 kg/cm2 / 327 psi)
2. Install the compression gauge adapter 5-8531-7019- Compression pressure should be approximately the
0 to the No. 1 cylinder injection nozzle installation same for each cylinder.
hole. A variation exceeding 200 kPa (2.0 kg/cm2 / 28 psi) is
3. Install the compression gauge to the compression unacceptable.
gauge adapter.
69697_ESS-172A_SEC0B 11.8.4 2:58 PM ページ 10
Recommended Lubricants
ENGINE TYPE TYPES OF LUBRICANTS (API)
Diesel engine oil

Without turbocharger & With turbocharger
CD grade
Engine Oil Viscosity Chart
ENGINE OIL VISCOSITY GRADE-AMBIENT TEMPERATURE
[Single grade]
SAE 20,20W SAE 40,50
SAE 10W SAE 30
Ambient -30ºC -15ºC -0ºC 15ºC 25ºC 30ºC

temperature (-22ºF) (0ºF) (32ºF) (60ºF) (80ºF) (90ºF)
[Multi grade] SAE 10W-30
SAE 15W-40,20W-40,20W-50
F00EY00006
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 1
ENGINE MECHANICAL 6A–1
ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . 6A Starting and Charging . . . . . . . . . . . . . . . . . . . . . . . 6D3
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C Engine Induction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J
ENGINE MECHANICAL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-50
General Description. . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52
Engine Cleanliness and Care . . . . . . . . . . . . . . . 6A-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-52
General Information on Engine Service . . . . . . . 6A-2 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-53
Fan Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Timing Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-59
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-61
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-67
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-69
Inlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-10 Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-73
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-73
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-77
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-15 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-92
Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-93
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-97
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Crank Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99
Coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-99
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-100
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-24 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-100
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-102
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-102
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-30 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-103
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-35 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-103
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-38 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-104
Rocker Arm and Shaft Assembly. . . . . . . . . . . . . 6A-47 Inspection and Repair. . . . . . . . . . . . . . . . . . . 6A-105
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-47 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-109
Inspection and Repair. . . . . . . . . . . . . . . . . . . . 6A-48
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 2
6A–2 ENGINE MECHANICAL
Service precaution clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
CAUTION: Always use the correct fastener in the damage to the oil pick-up unit.
proper location. When you replace a fastener, use • The 12-volt electrical system is capable of damaging
ONLY the exact part number for that application. circuits. When performing any work where electrical
ISUZU will call out those fasteners that require a terminals could possibly be grounded, the ground
replacement after removal. ISUZU will also call out cable of the battery should be disconnected at the
the fasteners that require thread lockers or thread battery.
sealant. UNLESS OTHERWISE SPECIFIED, do not
• Any time the intake air duct or air cleaner is removed,
use supplemental coatings (Paints, greases, or
the intake opening should be covered. This will
other corrosion inhibitors) on threaded fasteners or
protect against accidental entrance of foreign material
fastener joint interfaces. Generally, such coatings
into the cylinder which could cause extensive damage
adversely affect the fastener torque and the joint
when the engine is started.
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these General
instructions can help you avoid damage to parts and The 6WG1 engine is a four-cycle, six-cylinder, in-line,
systems. direct fuel injection type diesel engine with the piston
displacement of 15.681 L (957 cid). It features a gear-
General Description driven OHC (overhead camshaft) timing train and
unique mechanisms and systems designed for
Engine Cleanliness and Care outstanding quietness, economy and durability.
An industrial engine is a combination of many machines,
honed, polished and lapped surfaces with tolerances
Cylinder Head
that are measured in the thousandths of a millimeter (ten The cylinder head is made of cast iron and has a cross-
thousandths of an inch). Accordingly, when any internal flow layout with the intake system in the left side and the
engine parts are serviced, care and cleanliness are exhaust system in the right side, designed to reduce
important. Throughout this section, it should be resistance in the intake and exhaust system.
understood that proper cleaning and protection of The cylinder head gasket is of the laminated of least
machined surfaces and friction areas is part of the repair fatigue in combination with the angular cylinder head
procedure. This is considered standard shop practice bolt tightening method, equally designed to increase
even if not specifically stated. reliability against gaseous and water leakage.
• A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate Cylinder Block
the surfaces on initial operation. The cylinder block is made of cast iron having dry
• Whenever valve train components, pistons, piston cylinder liner and seven bearings. The bearing cap has
rings, connecting rods, rod bearings, and crankshaft a ladder frame construction integrating the crankcase to
journal bearings are removed for service, they should increase rigidity.
be retained in oder. The cylinder liner is made of thin special iron alloys and
• At the time of installation, they should be installed in is combined with the chrome-plate piston ring to ensure
the same locations and with the same mating good resistance against wear.
surfaces as when removed.
• Battery cables should be disconnected before any
Piston
major work is performed on the engine. Failure to The piston is made of aluminum alloy. A ring trigger is
disconnect cables may result in damage to wire cast into the first and second ring groove and chrome
harness or other electrical parts. plating is applied to four sides of the first and third ring to
• The in-line cylinders of this engine are identified by ensure sufficient strength and wear resistance of the
numbers; Cylinders 1, 2, 3. …, as counted from ring and the ring groove.
crankshaft pulley side to flywheel side.
Crankshaft
General Information on Engine Service The crankshaft is made of forge steel with seven
bearings and twelve counter weights to reduce
The following information on engine service should be
revolution load to the bearing. The crankshaft is treated
noted carefully, as it is important in preventing damage
by soft nitriding to enhance the crankshaft strength.
and contributing to reliable engine performance:
• When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 3
Gear Train
The gear train is located at the front of cylinder block to
minimize influence of the torsional vibration of the
crankshaft and the radiant sound.
Noise is further reduced, to the same level as a timing
belt driven system, by integrating the crankshaft gear
with the crankshaft by shrink fit careful tuning of the gear
precision, contact gear ratio, backlash, bearing rigidity
neutral frequency, etc.
Combustion System
The combustion chamber has a clean and simple design
for maximum operating economy also easy starting. A
direct fuel injection system is adopted.
The injection nozzles are placed at the center of each
cylinder. Intake ports generate optimum swirl effect
while exhaust ports minimize exhaust resistance.
Isuzu’s unique combustion chamber design provides
maximum power output and fuel economy.
Value Arrangement
Each cylinder has two intake valves and two exhaust
valves.
To ensure high efficiency and complete combustion, the
intake system has a Isuzu’s unique designed inlet ports.
The two exhaust valves are connected to a single port.
Lubrication
All engine parts are lubricated by a gear pump pressure
circulation system.
Oil flows from the oil pump though oil cooler to main oil
filter for oil cooling and oil cleaning.
From the main oil filter it moves to the cylinder block oil
gallery and the oil circulates to lubricates the engine
parts.
Oil jets are installed to the cylinder block main oil gallery.
The jet spray oil to the inside portions of the pistons for
lubrication and cooling.
Oil Pump and Oil Filter

The oil pump is a gear type with a relief valve. The pump
is driven by the timing gear. A full flow main oil filter with
a highly efficient paper element used.
Should the element become clogged with sludge or
other foreign material, a by-pass valve open to route the
oil directly to the oil gallery.
Oil Cooler
The temperature of the engine oil circulating through the
lubricating system tends to rise with an accompanying
decrease in lubricating efficiency.
The oil cooler maintains the oil temperature at the
optimum level for effective engine lubrication.
The oil cooler consists of the body and the cooling
element.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 4
Fan Center
Removal
1. Remove the fan guide.
4 1
033EY00002
4. Remove the fan center (1) from the timing gearcase

(2).
2. Remove the cooling fan (2) from the fan center (1).
033EY00011
033EY00010
3. Remove the fan belt

• Loosen the alternator mounting bolt (2).
• Loosen the sliding piece nut (4).
• Adjust the adjusting bolt (3) to remove the fan belt.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 5
Installation 4. Install the cooling fan to the fan center and tighten
the fixing nuts to the specified torque.
1. Install the fan center (1) to the timing gearcase (2) Torque: 52 N·m (5.3 kgm)
and tighten the fixing nuts to the specified torque.
NOTE: Install the fan to the installation direction
Torque: 52 N·m (5.3 kgm) properly.
1 1
033EY00011
033EY00010
2. Install the fan belt. 5. Install the fan guide to the water outlet pipe and
3. Adjust the fan belt tension by adjusting the adjusting bracket on the gearcase with the mounting rubbers.
bolt. • Tighten the fixing bolt to the specified torque.
• Depress the fan belt at the midway between the Torque: 52 N·m (5.3 kgm)
alternator pulley and fan center pulley with 100 N
(10 kg).
Belt deflection : 8 – 12 mm
• Tighten the alternator fixing nut to the specified
torque.
Torque: 147 N·m (15.0 kgm)
033EY00001
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 6
• Adjust the clearance between the fan and fan

guide.
Clearance: 7 – 13 mm
033EY00013
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 7
Turbocharger
Removal
1. Remove the inlet pipe from the air cleaner to the
turbocharger.
2. Remove the inlet duct from the inlet pipe to the
turbocharger.
3. Remove the oil feed pipe.
• Discard the gaskets.
4. Remove the oil drain pipe.
• Discard the gaskets.
5. Remove the turbocharger.
NOTE: Plug the turbocharger body oil ports and
openings to prevent the entry of foreign material or dust.
033EY00003
2. Install the oil drain pipe for the turbocharger and

tighten the bolt to the specified torque.
3. Install the oil feed pipe for the turbocharger and
tighten the bolt to the specified torque.
Torque:
Turbocharger side: 50 N·m (5.1 kgm)
Oil port cover side: 34 N·m (3.5 kgm)
Installation
1. Install the turbocharger assembly with the gasket to
the exhaust manifold and tighten the nuts to the
specified torque.
NOTE: Lubricate the turbine shaft dripping the engine oil
from the oil feed hole and turning the turbine wheel by
hand.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 8
4. Install the inlet duct from the inlet pipe to the

turbocharger and tighten the fixing bolts to the
specified torque.
• Connect the rubber hose between the inlet duct
and turbocharger.
• Install the heat protector to the rubber hose.
5. Install the inlet pipe from the air cleaner to the
turbocharger.
Tighten the inlet pipe fixing bolts to the specified
torque.
Inlet pipe at turbocharger side
Torque: 5.4 N·m (0.55 kgm)
Inlet pipe at bracket side
Inlet pipe bracket
Torque: 118 N·m (12 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 9
Exhaust Manifold
Removal
1. Remove the inlet pipe from air cleaner to
turbocharger.
2. Remove inlet duct from the inlet pipe to the 2
1 3
turbocharger.
3. Remove the turbocharger oil feed pipe.
4. Remove the turbocharger oil drain pipe.
5. Remove the turbocharger. 5
Refer to “Turbocharger” in this section. 3
1 4 2 6
6. Remove the exhaust manifold.
Clean the sealing surfaces of the exhaust manifold. Indicator
027EY00016
2. Install the turbocharger assembly with the gasket to

the exhaust manifold.
Refer to “Turbocharger” in this section.
027EY00011
Installation
1. Install the exhaust manifold assembly with the new
gasket to the cylinder head.
Tighten the nuts to the specified torque in the order
shown.
036EY00003
3. Install the oil drain pipe for the turbocharger.

4. Install the oil feed pipe for the turbocharger.
5. Install the inlet duct from the inlet pipe to the
turbocharger.
6. Install the inlet pipe from the air cleaner to the
turbocharger.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 10
Inlet Manifold
Removal
1. Remove the breather hose.
2. Remove the oil dipstick and guide tube.
3. Remove the fuel pipes.
4. Remove the air pipe for the boost.
5. Remove the injection pipes.
6. Remove the fuel filter and bracket.
7. Remove the inlet pipe.
NOTE: Plug the outlet of the turbocharger compressor.
8. Remove the inlet cover.
9. Remove the inlet manifold.
10. Clean the sealing surfaces of the inlet manifold.
Installation
1. Install the inlet manifold with new gaskets.
• Install the rubber boot and spring.
3. Install the inlet pipe with new gasket.
• Tighten the nut to the specified torque.
Tighten the fixing bolt to the specified torque.
Rubber boot
Indicator
10
6 7
2 3 11
12 9 5 1 4 8
025EY00006
2. Install the inlet cover with new gasket.

4. Install the fuel filter and bracket to the inlet manifold.
Torque:
Fuel Filter: 52 N·m (5.3 kgm)
Bracket : 50 N·m (5.1 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 11
5. Install the injection pipes, tightening to the specified. 7. Install the guide tube to the cylinder block in the
Torque: order shown.
Cylinder head side: 29 N·m (3.0 kgm) Torque:
Injection pump side: 39 N·m (4.0 kgm) Bolt (1) 88 N·m (9.0 kgm)
Bolt (2) 49 N·m (5.0 kgm)
6. Install the fuel pipe to tighten to the specified torque

as follows.
M8 eye bolt
M10 eye bolt
M12 eye bolt
M14 eye bolt
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 12
8. Connect the breather hose to the breather and clamp

the hose.
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 13
Water Pump
Removal 2. Install the thermostat housing.
• Install the thermostat to the oil cooler.
1. Remove the water inlet pipe.
Refer to “Thermostat installation” in this manual.
2. Remove the thermostat housing.
• Tighten the bolts to the specified torque.
3. Remove the water pump (1).
030EY00006
031EY00007
Installation
1. Install the water pump (1) with new gasket, tighten to
• First tighten the bolts (2) to the oil cooler side then
tighten
031EY00008
3. Install the water inlet pipe (1) to the oil cooler.

Tighten the bolts to the specified torque.
030EY00006
69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 14

69697_ESS-172A_SEC6A-1 11.8.8 1:45 PM ページ 15
Alternator
Removal
1. Remove the sliding piece nut (4).
2. Remove the adjust plate fixing bolt (1).
3. Remove the alternator fixing bolt (2).
4. Remove the fan belt. 4 1
5. Remove the alternator.
2
4 1
033EY00002
033EY00002
Installation
Single belt
1. Install the alternator.
2. Install the adjusting plate.
3. Install the fan belt.
4. Adjust the belt tension by adjusting the bolt (3).
• Depress the fan belt at the midway between the
alternator. 033EY00001
Belt Deflection: 8 – 12 mm (0.3150 – 0.4724 in)

5. Tighten the alternator fixing bolt to the specified
torque.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 16
Scrum belt 1
1. Install the generator to the bracket and adjusting 2
plate.
2 3 3
5
4
PAW5Z0SH006201
Name
PAW5Z0SH006101 1. Push Gauge
2. Iron Plate
3. Deflection
Name
1. Belt
2. Adjusting Nut • Loosen the generator mounting bolt and lock nut,
3. Adjusting Bolt (Generator) then loosen the idle pulley lock nut.
4. Bolt (Generator)
• In order to set the deflection to within the stan-dard
value range when approximately 98 N {10 kg/22 lb}
of force is applied to the central sec-tion of the belt,
correctly adjust the balance using the generator
2. Install the belt (for the generator) and adjust the
adjusting bolt and idle pul-ley adjusting bolt.
tension of the belt.
• After adjusting the tension of the belt, tighten the
• Secure the reliable standard position by setting a
lock nuts (1) and (3), and the mounting bolt (6).
standard string (1) or a weighted at both ends
string (2) on the back of the belt. Torque:
Idle pulley: 147 N·m {15.0 kg m}
PAW5Z0SH006301
• Arrange the push gauge so that the edge of the

push gauge presses uniformly on the overall width
of the belt, or set an iron plate with a thickness of
about 2 mm {0.08 in} on the belt.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 17
1 2
4
3
PAW5Z0MH000801
Name
1. Lock Nut (Generator)
2. Adjusting Bolt (Generator)
3. Lock Nut (Idle Pulley)
5. Belt Tension Measurement Position
6. Bolt
Belt Deflection: 6 – 8 mm (0.2362 – 0.3150 in)

69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 18
Oil Cooler
Removal
1. Remove the turbocharger oil feed pipe.
2. Remove the turbocharger oil drain pipe.
3. Remove the oil port cover.
4. Remove the water inlet pipe.
5. Remove the water pump.
Refer to “Water Pump” in this section.
6. Remove the oil cooler assembly.
• Remove the water drain pipe (1).
• Install the two removed fixing bolts to the holes (2)
for replacement and screw the bolts, then remove
the oil cooler.
050EY00010
• Install the water drain pipe (1) and tighten the

connector (2).
• Tighten the bracket (3) to the specified torque.
1 2
050EY00009
2
Installation
1. Install the oil cooler with gaskets.
• Install the gasket shown in the illustration.
3 4
• Install the oil cooler assembly to the cylinder block
1
and tighten the bolts to the specified torque in the
order shown.
050EY00011
2. Install the thermostat housing.

• Install the thermostat to the oil cooler.
Refer to “Thermostat Installation” in this manual.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 19
031EY00007
5. Install the turbocharger oil feed pipe.

6. Install the turbocharger oil drain pipe.
Refer to “Turbocharger” in this section.
031EY00008
3. Install the water inlet pipe to the oil cooler.

4. Install the oil port cover with new gasket.
Tighten the fixing bolts to the specified torque.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 20
Injection Pump
Removal the foreign material or dust.
1. Remove the oil level gauge and guide tube.

2. Remove the coupling cover.
3. Remove the fuel pipes and fuel leak off pipe.
9. Remove the injection pump bracket.
Installation
1. Install the injection pump bracket to the cylinder
4. Remove the injection pipe with clips. block.
• Install the bracket into place over the bracket
locating dowel pin on the cylinder block.
• Install the gaskets on the bracket.
• Tighten the bracket fixing bolts to the specified
torque.
Torque: 108 N·m (11 kgm)
5. Remove the air pipe for the boost.

6. Remove oil feed pipe and oil return pipe for the
injection pump.
7. Loosen the two coupling fixing bolts and the four
injection pump fixing bolts.
8. Remove the injection pump.
NOTE: Plug the injection pump delivery holder ports with
the shipping caps or equivalent to prevent the entry of
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 21
2. Install the injection pump

• Align the flywheel injection timing mark with the
flywheel housing pointer by rotating crankshaft
counterclockwise.
Injection timing (BTDC): 11 deg.
4 2
1 3
T
C
5
10
15
• Make sure the injection pump alignment on the

injection pump, and tighten the coupling bolts to
Torque:
015EY00003 Timing advancer side: 62 N·m (6.3 kgm)
• Align the injection timing mark on the timing Coupling ASM side: 88 N·m (9.0 kgm)
advancer with the injection pump body pointer.
3. Install the injection pump coupling cover.

• Install the injection pump assembly to the injection Tighten the fixing bolts to the specified torque.
pump bracket. Torque:
• Tighten the bolts to the specified torque in the Bolt (1) : 50 N·m (5.1 kgm)
order shown.
Bolt (2) : 52 N·m (5.3 kgm)
Bolt (3) : 50 N·m (5.1 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 22
1
3
4. Install the oil pipe to the injection pump. 6. Install the fuel pipe to tighten to the specified torque
Torque: as follows.
M10 27 N·m (2.8 kgm) M8 eye bolt
M14 41 N·m (4.2 kgm) Torque: 15 N·m (1.5 kgm)
M18 58 N·m (5.9 kgm) M10 eye bolt
M12 eye bolt
M14 eye bolt
5. Install the injection pipes.

Tighten the injection pipe sleeve nuts to the specified
torque.
Torque:
Cylinder head side: 29 N·m (3.0 kgm)
Injection pump side: 39 N·m (4.0 kgm)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 23
7. Install the air pipe for the boost.

8. Install the guide tube to the cylinder block in the
order shown.
Torque:
Bolt (1) 88 N·m (9.0 kgm)
Bolt (2) 49 N·m (5.0 kgm)
1
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 24
Coupling Assembly
Removal Installation
1. Remove the coupling cover. 1. Install the coupling assembly to the gearcase.
2. Remove the oil feed pipe from the cylinder block to • Install the gear to the coupling assembly.
coupling assembly. • Apply molybdenum disulfide grease to the thread
3. Loosen the coupling fixing bolt (1) and remove the portion and flange surface of bolts and the washer,
coupling disc fixing bolt (2), (3). tightening the bolts to the specified torque in the
order shown.
Torque: 39 N·m (4.0 kgm) → 105 deg.
2
040EY00024
4. Remove the coupling.

5. Remove the coupling assembly fixing bolts and nut.
6. Remove the coupling assembly. • Align the flywheel “T/C” mark with the flywheel
housing pointer by rotating the crankshaft
counterclockwise.
038EY00001
015EY00070
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 25
• Install the new gasket to the coupling assembly. 2. Install the coupling oil pipe from the cylinder block to
• Install the injection pump coupling to the coupling the coupling assembly.
assembly shaft. Torque: M10 27 N·m (2.8 kgm)
• Align the mark “A” on the coupling with the
coupling assembly body pointer.
S
A
Mark A
039EY00003
039EY00001
3. Install the coupling.
• Tighten the coupling fixing bolt (1) to the specified
• Install the coupling assembly to the gearcase. torque.
• Check alignment mark “S” with the coupling Torque: 88 N·m (9.0 kgm)
assembly body pointer after installing the coupling • Tighten the fixing bolt (3) to the specified torque.
assembly to the timing gearcase.
• Tighten the coupling assembly fixing bolts and nut
to the specified torque.
2
S
A
Mark S
040EY00024
• Align the injection timing mark on the flywheel with

039EY00001
the flywheel housing pointer by rotating crankshaft
counterclockwise.
Injection timing (BTDC): 11 deg.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 26
T
C
5
10
15
015EY00003
• Align the injection timing mark on the timing

advancer with the injection pump body pointer.
• Tighten the coupling bolt to the specified torque.

• Rotate the crankshaft two turns in normal direction
of crankshaft rotation.
Verify that the injection timing is correct.
4. Install the coupling cover.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 27
Cylinder Head
Removal
6 7
4 10
11
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 28
Legend (7) Nozzle clamp

(1) Cylinder head cover (8) Nozzle holder assembly
(2) Gasket (9) Idle gear C and shaft
(3) Rocker arm assembly (10) Cylinder head assembly
(4) Bridge (11) Cylinder head gasket
(5) Camshaft assembly
(6) Leak off pipe
1. Remove the cylinder head cover (and Insulator). 4. Remove the bridge.
2. Remove the gasket of the cylinder head cover. NOTE: Sort or organize the bridge for assembly to
original location.
3. Remove the rocker arm assembly.

• Loosen the rocker arm shaft bracket bolts from 5. Remove the camshaft.
both outside bolt. • Use a feeler gauge to measure the camshaft end
play before removing.
Standard: 0.008 – 0.170 mm (0.0033 – 0.0067 in.)
Limit: 0.25 mm (0.0098 in)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 29
• Loosen the camshaft bracket fixing nuts from both

outside nut.
6. Remove the leak off pipe.
7. Remove the nozzle clamp.
8. Remove the nozzle holder assembly.
• Use the nozzle holder remover 1-8523-0013-0 to
remove the nozzle holder.
NOTE: Take care not to damage the injection nozzle tips
during injection nozzle holder removal.
10. Remove the cylinder head assembly.

• First loosen the bolts B – D.
• Loosen the cylinder head bolts a little at a time in
the numerical order shown in the illustration.
NOTE: Failure to loosen the cylinder bolts in numerical
order a little at a time will adversely affect the cylinder
head lower surface.
11. Remove the cylinder head gasket.
011EY00026 Discard the cylinder head gasket.
9. Remove the idle gear “C” and shaft.
• Use a feeler gauge to measure the idle gear “C”
end play.
Standard: 0.05 – 0.14 mm (0.0020 – 0.0055 in.)
Limit: 0.25 mm (0.098 in.)
F 8
B
1 9 G N
M E 7
2 ; H O
L D 6
P
3 A I
C K C 5
4 B J
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 30
Installation • Apply molybdeum disulfide grease to the cylinder

head bolts (M18) threads and setting faces.
1. Install the new cylinder head gasket. • Apply engine oil to the cylinder head bolts (M10
• Clean the cylinder block surface. and M12) threads and setting faces.
• Apply Loctite FMD127 or equivalent to the cylinder • Tighten the M18 cylinder head bolts in three steps
block and the timing gearcase fitting faces. using the angular tightening method.
The sealant must be 1.0 – 2.0 mm (0.04 – 0.08 in) Follow the tightening order shown in the
thick and 5.0 mm (0.20 in.) wide. illustration.
The sealant must not obstruct the cylinder oil port. • Tighten the M10 and M12 cylinder head bolts to
NOTE: Cylinder head bolts may be installed as many as
four (4) times, and then must be replaced.
Replace if any doubt exists.
M18 bolt
Torque:
1st step 177 N·m (18 kgm)
2nd step 245 N·m (25 kgm)
3rd step 60 – 90 deg.
M12 bolt
M10 bolt
NOTE: Cover the timing gear hole by cloth for
preventing into foreign materials.
012EY00016
• Install the new cylinder head gasket to the cylinder

block.
2. Install the cylinder head assembly.
• Align the cylinder block dowel pins and the cylinder
head dowel holes.
Carefully place the cylinder head on the cylinder
head gasket.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 31
M12
M10
3. Install the idle gear “C” and shaft.

• Apply engine oil to the idle gear “C” shaft bolts.
• Tighten the idle gear “C” shaft bolt to the specified
torque.
011EY00026
6. Install the leak off pipe.

Tighten to specified torque.
4. Install the nozzle holder assembly.

5. Install the nozzle clamp.
Tighten the nozzle clamp bolt to the specified torque.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 32
014EY00068
7. Install the camshaft assembly. • Apply engine oil to the camshaft bearing sliding
• Align the flywheel TDC mark with the pointer by surfaces.
rotating the crankshaft normal direction. Same • Install the camshaft bearing caps to use same
time check alignment timing mark on injection stamped mark (1).
pump for No. 1 piston TDC. • Apply engine oil to the threads and tighten to the
specified torque.
1
015EY00070
• Apply engine oil to the camshaft bearing sliding

surfaces before installing the camshaft assembly. 014EY00069
• Install the camshaft assembly to the cylinder head. 8. Install the bridge.
• Carefully align the camshaft gear hole mark and • Loosen adjusting screw.
pointer (1) on the cylinder head shown in the • Apply engine oil on the bridge guide.
illustration.
• Install the bridge, the adjusting screw (1) facing to
the intake manifold side.
NOTE: Bridges must be reinstalled into their original
location and position.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 33
6 4 2 1 3 5 7
014EY00070
9. Install the rocker arm assembly. 10. Install the gasket of the head cover.
• Tighten the bolts in numerical order to the specified 11. Install the cylinder head cover.
torque shown in the illustration. • Apply Loctite FMD127 or equivalent to the upper
Torque: 90 N·m (9.2 kgm) surface of cylinder head and timing gear case
fitting area shown as illustration.
The sealant must be 1.0 – 2.0 mm (0.04 – 0.08 in.)
thick and 5.0 mm (0.20 in.) wide.
LOCTITE FMD127
011EY00027
• Tighten cylinder head cover bolt, follow the

numerical order shown in the illustration.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 34
10 13
11 12 1 14 15 16
9
8
17
7
6 5 4 3 2 20 19 18
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 35
Disassembly
10
9 11
12
9 15
16 19
20
13
1 21
17
8
3
2
18 6
5 14
6
4
14
Legend (11) Spring upper seat

(1) Thermometer unit (12) Valve spring
(2) Gearcase (13) Spring lower seat
(3) Gasket (14) Valve
(4) Idle gear shaft (“C”) (15) Valve stem seal
(5) Idle gear “C” (16) Valve guide
(6) Gasket (17) Bridge guide
(7) Inlet manifold (18) Valve seat insert
(8) Exhaust manifold (19) Injection nozzle sleeve
(9) Seal rings (20) Gasket
(10) Split collar (21) Cylinder head
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 36
1. Remove the thermometer unit. 5. Remove the gasket of the inlet manifold.
2. Remove the gearcase. 6. Remove the inlet manifold assembly.
3. Remove the shaft of the idle gear “C”. 7. Remove the exhaust manifold assembly.
Measure end play between the cylinder head and 8. Remove the seal rings.
idle gear “C”. 9. Remove the split collar.
Standard: 0.05 – 0.014 mm (0.0020 – 0.0055 in.) • Place the cylinder head on a flat wooden surface.
Limit: 0.25 mm (0.0098 in.) • Use the valve spring compressor 1-8523-5013-0 to
remove the split collar.
NOTE: Do not allow the valve to fall from the cylinder
head.
4. Remove the idle gear “C”.

• Disassemble the shaft of idle gear “C”. 014EY00061
• Disassemble the idle gear “C”.

10. Remove the spring upper seat.
11. Remove the valve spring.
12. Remove the spring lower seat.
13. Remove the valve.
If the intake and exhaust valves are to be reinstalled,
mark their installation position by tagging each valve
with the cylinder number from which it was removed.
If the intake and exhaust valves are to be replaced,
the valve guides must also be replaced.
14. Remove the valve stem seal.
Discard the valve stem seal.
15. Remove the valve guide.
Use valve guide remover 9-8523-1202-0 to remove
the valve guide.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 37
16. Remove the bridge guide. 18. Remove the injection nozzle sleeve.
• Electric welding (1) the bolt to bridge guide, use • Use suitable size brass bar to hit nozzle sleeve
sliding hammer to remove the bridge guide. from lower side cylinder head.
011EY00028
17. Remove the valve seat insert.

• Heat up (about 600 – 700°C) two point on the valve
seat insert by gas torch, allow the valve seat insert
to cool for few minutes.
• This will invite contraction and make removal of the
valve seat insert easier.
• Use screwdriver to pry the valve seat insert free.
Take care not to damage the cylinder head.
• Carefully remove carbon and other foreign
materials from the cylinder head insert bore.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 38
Inspection and Repair Shaft Idle Gear “C” and Idle Gear “C”
Make the necessary adjustments, repair and part 1. Measure the outside diameter of shaft idle gear “C”.
replacements if excessive wear or damage is Standard: 48.93 – 48.96 mm (1.9264 – 1.9286 in.)
discovered during inspection. Limit: 48.85 mm (1.9232 in.)
2. Measure the clearance between the shaft and idle
Bridge gear “C”.
Inspect any cracking, damage on bridge and inspect any Standard: 0.04 – 0.105 mm (0.0016 – 0.0041 in.)
separation wear out and damage on the surface of
Limit: 0.2 mm (0.0079 in.)
bridge.
Clearance between Camshaft and Bracket Valve Spring

Measure the clearance between the camshaft and 1. Use a vernier caliper to measure the valve spring
camshaft bracket. free height.
Standard: 0.065 – 0.125 mm (0.0026 – 0.0049 in.) If the measured value is less than the specified limit,
Limit: 0.15 mm (0.0059 in.) the valve spring must be replaced.
Valve spring free height
Inlet spring:
Standard: 79.3 mm (3.122 in.)
Limit: 75.3 mm (2.965 in.)
Exhaust spring: outer
Standard: 102.7 mm (4.0433 in.)
Limit: 97.6 mm (3.0843 in.)
Exhaust spring: inner
Limit: 91.7 mm (3.0610 in.)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 39
3. Use a spring tester to measure the valve spring

tension.
If the measured value is less than the specified limit,
the valve spring must be replaced.
Valve spring tension
Inlet spring:
Standard: 392 N (40.0 kg)/64 mm
Limit: 294 N (38.0 kg)/64 mm
Standard: 610N (62.2 kg)/69 mm
Limit: 579 N (59.0 kg)/69 mm
Standard: 224 N (22.8 kg)/66 mm
Limit: 213 N (21.7 kg)/66 mm
2, Use a surface plate and a square to measure the

valve spring squareness.
If the measured value exceeds the specified limit, the
valve spring must be replaced.
Valve spring squareness
Inlet spring:
Limit: 4.8 mm (0.189 in.)
Limit: 6.2 mm (0.244 in.)
Limit: 5.9 mm (0.232 in.)
Valve Stem
1. Set the dial indicator to the valve stem measuring
point.
2. Move the valve stem end from side to side.
Read the dial indicator.
Note the total indicator reading.
If the measured value exceed the specified limit, the
valve and the valve guide must be replaced as a set.
Valve stem and Valve guide clearance
Inlet:
Standard: 0.040 – 0.077 mm (0.0016 – 0.0030 in.)
Limit: 0.15 mm (0.0059 in.)
Exhaust:
Standard: 0.065 – 0.102 mm (0.0026 – 0.0040 in.)
Limit: 0.25 mm (0.0098 in.)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 40
Bridge Guide and Bridge Clearance

1. Use a caliper calibrator or a telescoping gauge to
measure the valve bridge (2) inside diameter.
2. Calculate the difference between the valve bridge
inside diameter and the valve bridge guide (1)
outside diameter.
If the clearance exceeds the specified limit, the valve
10mm(0.4in) bridge must be replaced.
Bridge guide and bridge clearance
Standard: 0.020 – 0.057 mm (0.0080 – 0.0022 in.)
Limit: 0.10 mm (0.0039 in.)
014EY00062 1
3. Measure the valve stem diameter at three points.

the valve and the valve guide must be replaced as a 2
set.
Valve stem outside diameter
Inlet:
Limit: 9.92 mm (0.3906 in.)
Exhaust:
014EY00063
Limit: 9.90 mm (0.3898 in.)
Valve Thickness and Depression

1. Measure the valve thickness.
the valve and the valve seat insert must be replaced
as a set.
Valve thickness
Inlet:
Limit: 1.64 mm (0.0646 in.)
Exhaust:
Limit: 1.8 mm (0.0709 in.)
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 41
Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness.
Make smooth the valve contact surfaces.
2. Measure the valve contact width.
valve seat insert must be corrected or replaced.
Valve contact width
Inlet:
Limit: 3.4 mm (0.1339 in.)
Exhaust:
Standard 2.5 mm (0.0984 in.)
Limit: 2.9 mm (0.1141 in.)
2. Install the new valve (1) to the cylinder head (2).

3. Use a depth gauge or a straight edge with steel rule
to measure the valve depression from the cylinder
head lower surface.
valve seat insert and/or the valve must be replaced.
Valve depression
Inlet:
Limit: 2.9 mm (0.1142 in.)
Exhaust:
Limit: 2.8 mm (0.1102 in.)
014EY00065
Contact Surface Angle on Valve

1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
2
valve, valve guide and valve seat as a set.
Valve contact surface angle
Standard:
Inlet: 30 degree
Exhaust: 45 degree
1
014EY00064
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 42
3. Apply abrasive compound to the valve seat insert

surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. check to see if the valve contact width is correct.
7. Check to see if the valve seat insert surface is in
contact with the entire circumference of the valve.
014EY00071
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter (15°, 45°, and 75° blades) to
minimize scratches and other rough areas. This will
bring the contact width back to the standard value.
Reassembly
150° 1. Install the injection nozzle sleeve with new gasket to
90° the cylinder head.
30° • Clean the nozzle sleeve circumference and the
nozzle sleeve fitting faces of cylinder head.
• Apply the recommended sealant (LOCTITE TL290
or equivalent) to the nozzle sleeve outer
circumference (1).
• Apply engine oil to the nozzle sleeve gaskets.
• Install the new gaskets to the nozzle sleeve gasket
groove.
• Use a bench press to install the nozzle sleeve.
Apply pressure to the nozzle sleeve gradually.
CAUTION: Do not apply an excessive amount of
pressure with the bench press. Damage to the
011EY00032
injection nozzle sleeve and cylinder head will result.
Remove only the scratches and rough areas. Do not
cut away too much. Take care not to cut away
unblemished areas of the valve seat surface.
Valve seat angle
Inlet: 30 degree
Exhaust: 45 degree
NOTE: Use an adjustable valve cutter pilot. Do not allow
the valve cutter pilot to wobble inside the valve guide.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 43
3. Install the bridge guide.

• Apply engine oil to the valve bridge guide outer
circumference.
• Attach the valve bridge guide installer 9-8522-
1324-0 to the bridge guide.
• Use a brass hammer to tap the guide into position
from the cylinder head upper face.
• Measure the height of the valve bridge guide upper
1 end from the cylinder head upper face (cylinder
head cover fitting surface).
Valve bridge guide upper end height
011EY00029
2. Install the valve seat insert into the cylinder head. 49.0mm
• Carefully place the attachment (1) (having a
smaller outside diameter than the valve seat insert)
on the valve seat insert (2).
NOTE: The smooth side of the attachment must contact
the valve seat insert.
• Use a bench press (3) to gradually apply pressure
to the attachment and press the valve seat insert
into place.
CAUTION: Do not apply excessive amount of
pressure with the bench press. Damage to the valve
seat insert will result.
4. Install the valve guide into the cylinder head.

• Apply engine oil to the valve guide outer
circumference.
• Attach the valve guide replacer 9-8523-1202-0 to
the valve guide.
• Use a hammer to drive the valve guide into position
from the cylinder head upper face.
• Measure the height of the valve guide upper end
from the upper face of the cylinder head.
Valve guide upper end height
Intake side: 27.0 mm (1.0630 in.)
Exhaust side: 29.0 mm (1.1417 in.)
NOTE: If the valve guide has been removed, both the
valve and the valve guide must be replaced as a set.
• The valve should be lapped before final assembly

to ensure a good valve seal.
Refer to “Valve Seat Insert Correction” in this
section.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 44
014EY00066
5. Install the spring lower seat to the cylinder head. • Install the intake valve springs with their fine
6. Install the valve stem seal on the valve guide. pitched end facing down. (Painted yellow)
• Apply engine oil to the oil seal inner face. • There are not assembly direction on both inner and
• Use the oil seal installer 1-8522-1187-0 for inlet outer exhaust valve spring.
and 1-8522-1184-0 for exhaust to install the oil
seal to the valve guide.
014EY00067
8. Install the spring upper seat and split collar.

• Use the spring compressor 1-8523-5013-0 to
7. Install the valve spring and valve. compress the valve spring.
• Apply engine oil to each valve stem before • Install the split collars (1) to the valve stem.
installation. Do not allow the valve to fall from the cylinder
• Install the inlet and exhaust valves. head.
• Turn the cylinder head up to install the valve • Set the split collars by tapping around the head of
springs. each collar with a rubber hammer.
Take care not to allow the installed valves to fall
free.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 45
1
2
014EY00061 027EY00014
9. Install the exhaust manifold assembly to the cylinder • The bracket tightening manner as follows.
head. Tighten the bracket (1) and (3) with out washer.
• Check that the seal ring (1) gaps are positioned Put the bracket (2) on the washer, and tighten
120 degrees apart form each other. together with exhaust manifold.
There is installation direction on seal ring as
illustration.
• Install the exhaust manifold gasket. The direction
indicator must be faced lower side.
1 2 3
1 5
3
1 4 2 6
Indicator
Rear
Front 027EY00016
10. Install the intake manifold assembly.

• Tighten the nut to numerical order shown in the
027EY00013
illustration.
• Install the rubber boot and spring with tightening
• Install distance tube (1), washer (3) and disk spring specified torque.
(2). Torque: 20 N·m (2.0 kgm)
The convex side of disk spring must be faced to
exhaust manifold nut.
• Tighten the exhaust manifold nut to specified
torque. Follow the tightening order shown in the
illustration.
69697_ESS-172A_SEC6A-1 11.8.8 1:46 PM ページ 46
Rubber boot
Indicator
2
10
6 7
2 3 11
12 9 5 1 4 8 1
025EY00006 011EY00031
11. Install the idle gear “C” and the shaft of the idle gear 13. Install the thermometer unit.
“C”. • Apply Loctite FMD127 or equivalent to thread on
• Apply engine oil to the shaft of the idle gear “C”. thermometer unit.
• Install the shaft with idle gear “C” to cylinder head. • Tighten the thermometer unit to the specified
• Tighten the bolts to the specified torque. torque.
Torque: 39 N·m (4.0 kgm) Torque: 20 N·m (2.0 kgm)
Cylinder
head side
011EY00030
12. Install the gearcase with new gasket (1).

• Apply Loctite FMD127 or equivalent to the gear-
case fitting area (2) or the cylinder head shown in
the illustration.
The sealant must be 0.3 mm (0.012 in.) thick and
5 mm (0.20 in.) wide.
The sealant (2) must not obstruct the bolt holes the
of cylinder head.
69697_ESS-172A_SEC6A-2 11.8.5 10:45 AM ページ 47
Rocker Arm and Shaft Assembly

Disassembly
3
2
Front Mark
014EY00072
Legend (4) Bracket

(1) Bracket (5) Rocker Arm Shaft
(2) Rocker Arm
(3) Spring
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 48
1. Remove the rocker arm and shaft assembly.

• Loosen the bolt of the rocker arm shaft bracket
from out side bolt a little at time and remove rocker
arm and shaft assembly.
• Disassembly the bracket, rocker arm, spring,
bracket and rocker arm shaft.
014EY00073
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting
portion outside diameter.
If the measured value is less than the specified limit, the
rocker arm shaft must be replaced.
Rocker arm shaft outside diameter
Inspection and Repair Standard: 27.979 – 28.000 mm (1.1015 – 1.1024 in.)
Make the necessary adjustments, repairs, and part Limit: 27.85 mm (1.0965 in.)
replacements if excessive wear or damage is
discovered during inspection.
Rocker Arm Shaft Run-Out

1. Place the rocker arm shaft on V-blocks.
2. Use a dial indicator to measure the rocker arm shaft
central portion run-out.
If the run-out is very slight, correct the rocker arm
shaft run-out with a bench press. The rocker arm
must be at cold condition.
If the measured rocker arm shaft run-out exceeds
the specified limit, the rocker arm shaft must be
replaced.
Rocker arm shaft run-out
Limit: 0.3 mm (0.012 in.)
014EY00074
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 49
Rocker Arm Bushing Inside Diameter Rocker Arm Roller and Rocker Arm Pin
Use either a vernier caliper or a dial indicator to measure 1. Pass a string through the rocker arm-roller (1)
the rocker arm bushing inside diameter. clearance and measure the roller protrusion while
Rocker arm bushing inside diameter pulling both ends of the string in the arrow indicated
Standard: 28.020 – 28.053 mm (1.1031 – 1.1044 in.) directions to push out the roller.
Rocker arm and rocker arm shaft clearance 2. Mark the measuring point and draw out the string.
Measure the roller protrusion again while the roller is
Standard: 0.020 – 0.074 mm (0.0008 – 0.0029 in.)
pushed in.
Limit: 0.2 mm (0.0079 in.)
3. Note the difference in the above measurements is
the standard roller rocker arm and pin clearance.
If the clearance exceeds the limit, the rocker arm
must be replaced.
Rocker arm roller and pin clearance
Standard: 0.036 – 0.069 mm (0.0014 – 0.0027 in.)
Limit: 0.15 mm (0.0059 in.)
014EY00075
Check to see if the rocker arm and rocker arm shaft oil
port is free of obstructions.
If necessary, use compressed air to clean the rocker
arm and rocker arm shaft oil port.
014EY00076
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 50
Reassembly
3
2
Front Mark
014EY00072
Legend (4) Bracket

(1) Bracket (5) Rocker Arm Shaft
(2) Rocker Arm
(3) Spring
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 51
1. Install the bracket, spring, rocker arm and bracket to

the rocker arm shaft.
2. Apply engine oil to the roller portion of the rocker arm
and threads of the adjusting screw.
3. Put the rocker arm and shaft assembly on the
cylinder head.
4. Temporally tighten the bolts of the rocker arm and
shaft assembly to the cylinder head, sufficiently
loosen the adjusting screw.
5. Tighten the bolts of the rocker arm and shaft
assembly to the specified torque by numerical order
shown in the illustration.
6 4 2 1 3 5 7
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 52
Camshaft
Disassembly
Legend (4) Camshaft bearing lower

(1) Camshaft gear (5) Camshaft
(2) Key
(3) Camshaft bearing cap
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 53
1. Remove the camshaft gear.

• Check visually gear for excessive wear or damage.
• Use an universal puller to pull out the camshaft
gear with wooden plate (1) for prevent make
damage gear.
2. Loosen nuts to remove the camshaft bearing cap.
3. Remove the camshaft. 2
014EY00078
2. Measure the cam height A and B with a micrometer.

1
the camshaft must be replaced.
Cam height (A – B)
Inlet
014EY00077
Limit: 8.85 mm (0.3484 in.)
Inspection and Repair Exhaust
Make the necessary adjustments, repairs, and part
Limit: 9.75 mm (0.3839 in.)
1. Use a micrometer to measure each camshaft journal
diameter in two directions ((1) and (2)). If the
measured value is less than the specified limit, the
camshaft must be replaced. B
Camshaft journal diameter
Standard: 39.915 – 39.940 mm (1.5715 – 1.5724 in.)
A
Limit: 39.890 mm (1.5705 in.)
014EY00079
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 54
3. Mount the camshaft on V-blocks.

Measure the run-out with a dial indicator on the No. 4
camshaft journal.
camshaft must be replaced.
Camshaft run-out
Standard: 0.080 mm (0.0031 in.)
Limit: 0.100 mm (0.0039 in.)
4. Use an inside dial indicator to measure the camshaft

bearing inside diameter.
Camshaft bearing inside diameter
Standard: 40.015 – 40.040 mm (1.5754 – 1.5764 in.)
If the clearance between the camshaft bearing inside
diameter and the journal exceeds the specified limit,
the camshaft bearing must be replaced.
Camshaft bearing clearance
Standard: 0.065 – 0.125 mm (0.0026 – 0.0049 in.)
Limit: 0.15 mm (0.0059 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 55
Reassembly
Legend (4) Camshaft

(1) Camshaft gear (5) Camshaft bearing lower
(2) Key
(3) Camshaft bearing cap
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 56
1. Install the camshaft bearing lower.

• Install the camshaft bearing lower to the cylinder
head.
• Apply engine oil to the bearing portion.
2. Install the camshaft.
• Put camshaft onto the lower camshaft bearing.
• Apply engine oil to the journal of camshaft.
3. Install the camshaft bearing cap.
• Install the camshaft bearing cap on the stud bolts
to use same stamped mark of lower bearing.
• Apply engine oil to the threads of the stud bolt and
nut seat.
• Tighten the camshaft bearing cap nut to the
specified torque.
014EY00080
4. Insert the key to the camshaft.

5. Install the camshaft gear and tighten the bolt to the
specified torque.
• Apply engine oil to the threads of the bolt.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 57
Timing Gear
Timing Gear and Associated Parts
11
7
6
10
8
9
1
4
2
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 58
Legend (7) Gasket

(1) Fan center assembly (8) Distance bolt
(2) Crank pulley (9) Idle gear “A”
(3) Gearcase cover (10) Idle gear “B”
(4) Gasket (11) Timing gearcase
(5) Oil seat (front)
(6) Oil pump
(Without Cooling Fan)
11
7
6
10
8
5
9
4
1
PAW0Z0LF001001
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 59
Legend (7) Gasket

(1) Fan center assembly (8) Distance bolt
(2) Crank pulley (9) Idle gear “A”
(3) Gearcase cover (10) Idle gear “B”
(4) Gasket (11) Timing gearcase
(5) Oil seat (front)
(6) Oil pump
Removal
1. Remove the fan center.
2. Remove the crank pulley.
3. Remove the front oil seal to use the oil seal remover
1-8522-0052-0.
CAUTION: Take care not to damage or deform the
sealing flange surface of the gearcase.
5. Remove the oil pump with the gasket.

Discard the gasket.
6. Remove the idle gear “A”.
• Before loosening the idle gear fixing bolts,
measure the backlash of the idle gear “A” and “B”.
Idle gear backlash
Standard: 0.095 – 0.135 mm (0.0037 – 0.0053 in.)
020E100035
Limit: 0.23 mm (0.0091 in.)
4. Remove the gearcase cover.
Remove the gearcase cover gasket and discard it.
020E100030
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 60
• Measure the end play of the idle gear “A” (1) and Inspection and Repair
“B” (2).
Idle gear “A” end play 1. Visually inspect the idle gear and idle gear spindle
for damage or wear.
Standard: 0.155 – 0.220 mm (0.0061 – 0.0089 in.)
2. Use a micrometer to measure the idle gear spindle
Limit: 0.35 mm (0.0138 in.) out side diameter.
Idle gear “B” end play Spindle outside diameter for idle gear “A”
Standard: 0.050 – 0.140 mm (0.0020 – 0.0055 in.) Standard: 56.93 – 56.96 mm (2.2413 – 2.2425 in.)
Limit: 0.25 mm (0.0098 in.) Limit: 56.85 mm (2.2382 in.)
Spindle outside diameter for idle gear “B”
2 Standard: 141. 93 – 141.96 mm (5.5878 – 5.5890 in.)
Limit: 141.85 mm (5.5846 in.)
Spindle outside diameter for idle gear “C”
Standard: 48.93 – 48.96 mm (1.9264 – 1.9286 in.)
Limit: 48.85 mm (1.9232 in.)
1
3. Use a cylinder bore dial indicator to measure the idle
gear inside diameter.
4. Calculate the clearance between the idle gear and
idle gear spindle.
Clearance for idle gear “A”, “B”, and “C”
Standard: 0.040 – 0.105 mm (0.0016 – 0.0041 in.)
Limit: 0.02 mm (0.0079 in.)
If the measured value exceeds from the specified limit,
the idle gear spindle or idle gear must be replaced.
020E100031
7. Remove the idle gear “B”.

• Scribe a front mark on the thrust plate to aid in
assembly.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 61
Installation
5
Y
Y
Y
Y
020E100033
Legend (4) Idle gear “A”

(1) Camshaft gear (5) Crankshaft gear
(2) Idle gear “C” (6) Idle gear “B”
(3) Injection pump gear
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 62
1. Install the timing gearcase.

• Clean the sealing surface block and remove
sealant residue.
1
• Apply a 4 mm bead of Loctite FMD127 or
equivalent to the cylinder block.
The sealant must not obstruct the cylinder block
bolt holes.
• Install the timing gearcase to the cylinder block.
M14 Bolt
M10 Bolt
014EY00084
3. Install the idle gear “A” to the timing gearcase.

• Align the flywheel TDC mark with the pointer by
rotating the crankshaft normal direction. Same
time check alignment of the timing mark on the
injection pump for No. 1 piston TDC.
2. Install the idle gear “B”.

• Apply engine oil to the bushing area of the idle gear
and both thrust plate (1) surface.
• Face front the scribed mark on the thrust plate.
015EY00070
• Apply engine oil to the bushing of the idle gear “A”.

• Install the idle gear “A” with the idle gear shaft to
the timing gearcase.
The timing marks (“O”, “I”, “Y”) must be aligned as
• Tighten the idle gear “A” shaft bolts to the specified
torque.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 63
Y
Y
Y
Y
020E100024 051HT002
4. Install the distance bolt to the gearcase. 6. Install the timing gearcase cover.
Tighten the distance bolts to the specified torque. • Apply Loctite FMD127 or equivalent to the timing
Torque: 39 N·m (4.0 kgm) gearcase fitting face.
• Install the timing gearcase cover with new gasket.
With cooling fan
M10 bolts
M8 bolts
020HV001
5. Install the oil pump assembly.

• Install the new gasket to the oil pump assembly.
• Install the oil pump assembly to the cylinder pump.
• Tighten the oil pump bolts to the specified torque.
CAUTION: Do not tighten arrow mark bolt shown in
the illustration.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 64
HCW31BSH019301
Without cooling fan 7. Install the oil seal with the slinger.
M10 bolts
M8 bolts
020EY00028
A
1
HCW31BSH019201
4
After press
Before press
3 2
015EX00001
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 65
Legend 8. Install the crankshaft pulley assembly.

(1) Crankshaft • Install the crankshaft pulley.
(2) Slinger • Apply engine oil to the bolt threads.
(3) Oil seal • Tighten the crankshaft pulley bolts to the specified
(4) Adapter torque.
(5) Sleeve Torque: 267 N·m (27.2 kgm)
• Apply engine oil to the entire circumference of the

oil seal.
• Use the oil seal installer 1-8522-0043-0 to install
the oil seal.
• Tighten the center bolt until the sleeve comes into
contact with the adapter stopper.
• After pressing the oil seal, make sure that the
distance between the crankshaft end surface and
the oil seal is A as specified.
Distance (A): 6.7 – 7.3 mm (0.264 – 0.287 in)
• There is identification color on the oil seal.
For front oil seal: Dark violet color
For rear oil seal: Gray color
• If there is small scratch on the crankshaft, apply
Threebond 127C or equivalent to the oil slinger
015EY00096
9. Install the fan center (1) to the gearcase cover (2).

Tighten the fixing nuts to the specified torque.
;À@;
@

À À@;;À@;À@
;À@;À@
1mm
1
3mm
2
020MT001
033EY00011
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 66
Flywheel Housing
Removal
3 4
Legend (5) Flywheel housing

(1) N-TDC sensor (6) Oil seal
(2) Washer (7) Slinger
(3) Flywheel
(4) Stiffener
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 67
1. Loosen the flywheel fixing bolts. Installation

Remove the flywheel.
1. Install the flywheel housing to the cylinder block.
2. Use the oil seal remover 1-8522-0052-0 to remove
• Apply a 4 mm bead of Loctite FMD127 or
the oil seal from the crankshaft.
equivalent to the cylinder block as shown in the
• Take care not to damage on the inserting surface illustration.
of the housing.
The sealant must not obstruct the cylinder bolt
holes.
• Install the flywheel housing.
M14 bolt
M8 bolt
020E100036
3. Remove the stiffeners.

4. Remove the flywheel housing.
2. Install the stiffeners (1) to the flywheel housing.

020E100037
013EY00015
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 68
3. Install the oil seal with the slinger. 4. Install the flywheel to the crankshaft.
• Apply engine oil to the entire circumference of the • Apply molybdenum disulfied grease to the bolt and
oil seal. setting face.
• Use the oil seal installer 1-8522-0043-0 to install • Tighten the flywheel bolts in three steps using the
the oil seal. angular tightening method.
• Tighten the center bolt until the sleeve comes into Torque:
contact with the adapter stopper. 1st step: 79 N·m (8.0 kgm)
• After pressing the oil seal, make sure that the 2nd step: 60 deg.
distance between the crankshaft end surface and
3rd step: 30 deg.
the oil seal is A as specified.
Distance (A): 6.7 – 7.3 mm (0.264 – 0.287 in) • Follow the numerical order as shown in the
illustration.
• There is identification color on the oil seal.
For front oil seal: Dark violet color
For rear oil seal: Gray color
• Do not make separation between the oil seal and
slinger.
A
1
After press
Before press
2 3
015EY00203
Legend
(1) Crankshaft
(2) Slinger
(3) Oil seal
(4) Adapter
(5) Sleeve
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 69
Oil Pan
Removal
8
7
6
5 4
2 3
2
1
PAW0Z0LF000701
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 70
Legend (5) Oil strainer

(1) Oil pan (6) Oil strainer bracket
(2) Oil pan gasket (or bracket) (7) Gasket
(3) Oil pan spacer (8) Oil jet assembly
(4) Oil pan spacer gasket
1. Remove the oil pan.

Remove the oil pan gasket.
Discard the oil pan gasket.
2. Remove the oil pan spacer.
Remove the oil pan spacer gasket.
Discard the oil pan spacer gasket. 4
3. Remove the oil strainer.
6
4. Remove the oil strainer bracket.
5
5. Remove the oil jet assembly.
CAUTION: Take care not to bend the oil jet tubing. 2
3
Do not attempt to repair a damaged oil jet. If 1
damaged, replace the oil jet with a new one.
Installation
1. Install the oil jet assembly to the cylinder block.
Tighten the joint bolt to the specified torque.
3. Install the oil pan spacer with new gasket.
• Apply Cemedain LG-020L or equivalent to the
cylinder block, flywheel housing and gearcase
fitting face.
The sealant must be 3 – 4 mm of bead.
Sealant
2. Install the oil strainer with new gasket and the oil
strainer bracket.
Tighten the bolts in numerical order as shown in the
illustration.
012EY00017

Tighten the bolts in numerical order as shown in
the illustration.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 71
then re-apply the gasket and pro-ceed to re-

assemble the parts.
• When installing the oil pan, erect about four guide
studs for positioning in the oil pan spacer bolt
holes.
20 1
• After tightening the oil pan, do not remove any of
the protruding gasket from the inner or outer
circumference of the oil pan.
Front 21
• Do not fill the engine with oil or start the engine
36 until at least 30 minutes has passed since the parts
were installed.
3
2
013EY00016
1
4. Install the oil pan to the oil pan spacer.
Without liquid gasket
• Install the oil pan with new gasket.
Tighten the bolts to the specified torque in numerical
order as shown in the illustration.
V 1
Front
3
2
3 2 PAW5Z0MH000501
Name
1. Line connected to the bolt hole perimeter line (inner
side)
2. Oil pan R finish line
3. Apply to the constant clearance along the oil pan
013EY00017
angle R
With liquid gasket
• Degrease the installation surface of the oil pan
flange side, flange R, and oil pan spacer.
• Apply liquid gasket along the line on the dia-gram
below.
Liquid gasket: TB1207B
• Aim for a liquid gasket diameter of ø 4 mm {0.16 in}
(ø 3.5 — 4.5 mm {0.14 — 0.18 in}).
• Apply liquid gasket, then assemble the oil pan
within 7 minutes. If more than 7 minutes passes,
use a gasket remover to remove the liquid gasket,
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 72
2
PAW5Z0SH002801
Name
1. Aim to apply so that the edge of the gasket is on the
R finish line
2. Aim to apply so that the edge of the liquid gasket
includes the bolt hole outer circumference
PAW5ZHSH000401
• Tighten to the specified torque.

69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 73
Piston
Removal
2
4
015EY00097
Legend (3) Crankshaft

(1) Piston with connecting rod (4) Connecting rod bearing cap
(2) Connecting rod bearing
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 74
1. Remove the cylinder head assembly. 4. Remove the connecting rod bearing.
Refer to “Cylinder Head” in this section. • Mark, sort or organize the connecting rod bearing
2. Remove the oil pan. for assembly to the original location.
Refer to “Oil Pan” in this section.
3. Remove the piston with connecting rod. Installation
• Remove the carbon deposits from the upper potion
of the cylinder wall by the scraper. 1. Install the piston with the connecting rod.
• Loosen the connecting rod cap nuts. • Clean the piston in solvent. Remove all sludge.
• Move the piston to the top of the cylinder and tap it • Carefully wipe any foreign materials inside cylinder
with a hammer grip or similar object from the bore and piston with connecting rod. Clean the
connecting rod lower side to drive it out. bearing cap and bearing
CAUTION: Take care not to damage the oil jets. • Install the connecting rod upper bearing to the
connecting rod.
012EY00018
• Install the connecting rod lower bearing to the

connecting rod.
• Apply engine oil to the cylinder wall, upper/lower
bearing surface and crank pin of crankshaft.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 75
012EY00028 015EY00134
• Position the piston ring gaps as shown in the • Use the piston setting tool 1-8522-0059-1 to install
illustration. the piston with the connecting rod to the cylinder
Gap position block. At this time rotate the crankshaft until the
(1) 1st compression ring crankpin is at bottom dead center.
(2) 2nd compression ring
(3) 3rd compression ring
(4) Oil ring
(5) Coil expander
Front mark
1 2,5
4 3
CAUTION: Do not bend or damage the oil jet.
• Apply molybdenum disulfied grease to the threads

and setting faces of each connecting rod bolts.
012HW002
• Position the piston head front mark (1) so that it is

facing front of the engine.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 76
• Tighten the connecting rod cap nuts in three steps

using the angular tightening method.
Torque:
1st step: 98 N·m (10.0 kgm)
2nd step: 30 deg.
3rd step: 30 deg.
• Check the crankshaft rotation smoothly.
2. Install the oil pan to the cylinder block.
Refer to “Oil Pan” to this section.
3. Install the cylinder head to the cylinder block.
Refer to “Cylinder Head” in this section.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 77
Disassembly
3 4
2
Legend (5) Connecting rod

(1) Piston rings (6) Connecting rod cap
(2) Snap ring (7) Bearing
(3) Piston pin
(4) Piston
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 78
NOTE: When removing the piston and connection rod

assembly, pull the connecting rod in parallel with the
cylinder bore.
1. Remove the connecting rod cap.
2. Remove the bearings.
• Take out the connecting rod bearing cap nuts and
disassemble the bearing cap with the lower
bearing.
• Mark, sort or organize the connecting rod bearing
for assembly to the original location.
3. Remove the piston rings.
• Clamp the connecting rod in a vise. 1
Take care not to damage the connecting rod.
• Use piston ring replacer to reassemble the piston
rings.
Do not attempt to use some other tool to 015EY00098
disassemble the piston rings. Piston ring stretching

5. Remove the piston pin.
will result in reduced piston ring tension.
6. Remove the piston.
7. Remove the connecting rod.
Tap the piston pin out with a hammer and a brass
bar.
Mark, sort or organize the piston and piston rings for
assembly to the original location.
Inspection and Repair

Make the necessary adjustments, repairs and part
Piston Ring Gap

1. Insert the piston ring horizontally (in the position it
would assume if it were installed to the position) into
the cylinder liner bore.
2. Push the piston ring into the cylinder liner bore until it
reaches the point where the cylinder liner bore is the
smallest.
Do not allow the piston ring to slant to one side or the
4. Remove the snap ring.
other. It must be perfectly horizontal.
Use a pair of snap ring pliers to remove the snap
rings.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 79
Piston Ring and Piston Ring Groove

Clearance
1. Visually inspect the piston ring grooves.
If a piston ring groove is damaged or distorted, the
piston must be replaced.
2. Use a feeler gauge to measure the clearance
between the piston ring and the piston ring groove at
several points around the piston.
3. When measuring the clearance for 1st piston ring,
press the 1st piston ring by straight gauge show in
the illustration.
015EY00099
3. Use a feeler gage to measure the piston ring gap.

piston ring must be replaced.
2
Piston ring gap
1st, 3rd ring:
Standard: 0.35 – 0.50 mm (0.0138 – 0.0197 in.)
Limit: 1.0 mm (0.0394 in.)
2nd ring:
Standard: 0.80 – 0.95 mm (0.0315 – 0.0374 in.)
Limit: 1.0 mm (0.0394 in.) 015EY00101
Oil ring:
Piston ring and piston ring groove clearance
Standard: 0.30 – 0.50 mm (0.0118 – 0.0197 in.)
1st ring:
Limit: 1.0 mm (0.0394 in.)
Standard: 0.115 – 0.160 mm (0.0045 – 0.0063 in.)
Limit: 0.24 mm (0.0094 in.)
2nd, 3rd ring:
1 Standard: 0.10 – 0.135 mm (0.0039 – 0.0053 in.)
Limit: 0.20 mm (0.787 in.)
Oil ring:
Standard: 0.025 – 0.065 mm (0.0010 – 0.0026 in.)
Limit: 0.15 mm (0.0059 in.)
015EY00100
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 80
Piston Pin Diameter

Use a micrometer to measure the piston pin outside
diameter at several points
If the measured value is less than the specified limit, the
piston pin must be replaced.
Piston pin diameter
Standard: 55.995 – 56.000 mm (2.2015 – 2.2047 in.)
Limit: 55.970 mm (2.2035 in.)
Piston Ring Expansion Force

Use an expansion force gauge to measure the piston
ring expansion force.
Piston ring expansion force
1st ring:
Standard: 38.5 – 49.2 N
(3.92 – 8.64 kg/8.64 – 11.07 lb)
Limit: 29 N (3.0 kg/6.6 lb)
2nd ring: Piston Pin Hole and Piston Pin Clearance
Standard: 29.9 – 38.7 N Use a inside dial indicator to measure the piston pin hole
(3.05 – 3.95 kg/6.73 – 8.71 lb) (in the piston).
Limit: 20 N (2.0 kg/4.4 lb) Piston pin hole and piston pin clearance
3rd ring: Standard: 0.008 – 0.021 mm (0.0003 – 0.0008 in.)
Standard: 28.1 – 36.6 N Limit: 0.05 mm (0.0020 in.)
(2.87 – 3.73 kg/6.33 – 8.22 lb)
Limit: 20 N (2.0 kg/4.4 lb)
Oil ring: Piston Pin and Connecting Rod Small End
Standard: 85.3 – 104.9 N Bushing Clearance
(8.7 – 10.7 kg/19.2 – 23.6 lb) Use a caliper calibrator and dial indicator to measure the
Limit: 64 N (6.5 kg/14.3 lb) clearance between the piston pin and connecting rod
small end bushing
If the clearance between the piston pin and the
connecting rod small end bushing exceeds the specified
limit, replace the piston pin and/or the connecting rod
assembly.
Small end bushing clearance
Standard: 0.020 – 0.037 mm (0.0079 – 0.0016 in.)
Limit: 0.10 mm (0.0039 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 81
Crankshaft and Connecting Rod Bearing

Clearance
1. Clean the crankshaft, connecting rod, bearing cap,
and bearings.
2. Install the bearing to the connecting rod and bearing
cap.
3. Apply a coat of molybdenum disulfide grease to the
bearing cap bolt threads and setting faces.
4. Prevent the connecting rod from moving.
5. Tighten the bearing cap to the specified torque.
Connecting rod bearing cap nut torque
1st step: 98.1 N·m (10.0 kgm/72.3 lb·ft)
2nd step: 30 deg.
3rd step: 30 deg.
6. Use a dial indicator to measure the connecting rod
bearing inside diameter.
015EY00102
Crankpin and connecting rod bearing clearance

Standard: 0.033 – 0.103 mm (0.0013 – 0.0041 in.)
Connecting Rod Alignment
Limit: 0.16 mm (0.0063 in.)
Use a connecting rod aligner to measure the distortion
and the parallelism between the connecting rod big end
hole and the connecting rod small end hole.
If either the measured distortion or parallelism exceeds
the specified limit, the connecting rod must be replaced.
Connecting rod alignment
Per length of 100 mm (3.94 in.)
Standard: 0.05 mm (0.002 in.) or less
Limit: 0.20 mm (0.008 in.) 1 2 B
A
A
1 2 B
7. If the clearance between the measured bearing

inside diameter and the crankpin exceeds the
specified limit, the bearing and/or crankshaft must be
replace.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 82
Piston and Liner Bore Clearance

Measure the cylinder liner bore after installing the
cylinder liner. Then select the appropriate piston for the
installed cylinder liner.
1. Measure the cylinder liner bore.
1 2 A Refer to the “Cylinder Liner Bore Measurement”.
Measuring Point 130 mm (5.118 in.)
B B
Cylinder liner bore
A
Standard: 147.011 – 147.030 mm
(5.7878 – 5.7886 in.)
Connecting Rod and Crankshaft Clearance 130mm

1. Fix the connecting rod assembly to the crankshaft by
The fixing manner is follow as mentioned above.
2. Use a feeler gauge to measure the clearance
between the connecting rod and crankshaft.
connecting rod must be replaced.
Connecting rod and crankshaft clearance 012EY00022
Standard: 0.175 – 0.290 mm (0.0069 – 0.0114 in.)

2. Measure the piston outside diameter (Reference).
Limit: 0.35 mm (0.0138 in.)
Piston Measuring Point 113 mm (4.449 in.)
113mm
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 83
The grade mark is stamped on the top of the piston

installed at the factory, but the piston for service part
does not have any grade.
Piston outside
Standard: 146.830 – 146.845 mm
(5.7805 – 5.7813 in.)
Piston and Liner bore clearance
Standard: 0.166 – 0.200 mm (0.0065 – 0.0079 in.)
If the piston and liner clearance exceeds the standard
value, the piston and/or liner must be replaced.
CAUTION: Cylinder liner kit clearances are preset.
However, the cylinder liner installation procedure
may result in slight decreases in cylinder liner
clearances. Always measure the cylinder liner
clearance after installation to be sure that its is
correct.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 84
Reassembly
3 4
2
Legend (5) Connecting rod

(1) Piston rings (6) Connecting rod cap
(2) Snap ring (7) Bearing
(3) Piston pin
(4) Piston
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 85
1. Install the snap ring.

Use a pair of sanp ring pliers to reassemble the snap
ring to the piston.
2. Install the connecting rod and piston pin.
1 2 3
• Clamp the connecting rod in the vise.
Take care not to damage the connecting rod.
• Install the piston so that the piston head front mark
and the connecting rod front mark are set in the
same direction.
1N 2N 3N
Red Blue Green
015EY00103
1
1
3
015EY00098
• Apply engine oil to the piston pin.

• Insert the piston pin to the connecting rod through
4
piston pin hole on the piston.
• Install the snap ring.
3. Install the piston ring.
• Apply engine oil to the piston rings.
• Confirm the discrimination mark on the piston ring.
015EY00104
Discrimination mark
1st ring: Red color • Use the piston ring setting tool 1-8522-1025-0 to
2nd ring: Blue color reassemble the four piston rings according to top
mark on the piston ring.
3rd ring: Green color
The oil ring does not have top mark.
Oil ring: Not available
NOTE: Insert the expander coil into the oil ring groove so
that there is no gap on either side of the expander coil
before installing the oil ring.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 86
Gap position
(1) 1st compression ring
(2) 2nd compression ring
(3) 3rd compression ring
(4) Oil ring
(5) Coil expander
Front mark
1 2,5
4 3
012HW002
• Apply molybdenum disulfide grease to the two

piston skirts.
This will facilitate smooth break-in when the engine
is first started after reassembly.
• Apply engine oil to the upper connecting rod
1
bearing.
• Apply engine oil to the cylinder wall.
• Position the front mark on the piston head so that it
is facing the front of the engine.
015EY00098
• Check to see if the piston rings rotate smoothly in

the piston ring grooves.
4. Install the connecting rod bearing.
Carefully wipe any oil or other foreign material from Front mark
the connecting rod bearing back face and the
bearing fitting surface.
5. Install the connecting rod cap. Engine front
• Fit the lower connecting rod bearing to the
connecting rod cap.
• Apply engine oil to the circumference of the each Front mark
piston ring, piston and crankpin.
• Position the piston ring gaps as shown in the
illustration.
015HV014
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 87
• Use the piston ring setting tool 1-8522-0059-0 to

compress the piston rings.
• Use a hummer grip to push the piston in until the

connecting rod marks contact with the crankpin.
As the same time, rotate the crankshaft until the
crankpin is at bottom dead center.
• Align the connection rod cap cylinder number

marks and the connecting rod cylinder number
marks.
• Install the connection rod caps.
• Apply molybdenum disulfide grease to the threads
and setting faces of each connecting rod bolts and
nuts.
• Tighten the connecting rod nut to the specified
torque.
Torque:
2nd step: 30°
3rd step: 30°
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 88
Crankshaft
Removal
2
6
5
6
6
5
6
3
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 89
Legend (4) Crankshaft

(1) Piston with connecting rod (5) Crankshaft bearing
(2) Connecting rod bearing (6) Crankshaft thrust bearing
(3) Lower crankcase
1. Remove the cylinder head assembly.

2. Remove the oil pan.
1
3. Remove the timing gear.
Refer to “Timing Gear” in this section.
4. Remove the flywheel.
Refer to “Flywheel” in this section. 1 5 9 C B 8 4
5. Remove the piston with connecting rod.
2 6 0 D A 7 3
Refer to “Piston” in this section.
6. Remove the lower crankcase.
• Measure the crankshaft end play at the No. 1
crankshaft journal before removing the crankshaft
thrust bearing. 1
If the measured value exceeds the specified limit,
the crankshaft thrust bearing must be replaced.
Crankshaft end play 012EY00024
Standard: 0.04 – 0.18 mm (0.0016 – 0.0070 in.) 7. Remove the crankshaft from the cylinder block.
Limit: 0.35 mm (0.0138 in.) 8. Remove the crankshaft bearing.
• Mark, sort or organize the connecting bearing for
assembly to the original location.
9. Remove the crankshaft thrust bearing.
Installation
1. Install the crankshaft bearing to the cylinder block.
• Carefully wipe any foreign materials from the fitting
area of the cylinder block and upper crankshaft
bearing.
All upper bearing have oil grooves.
• Install the upper bearings to the original location, if
to be reused.
CAUTION: Do not apply engine oil to the bearing
back faces and cylinder block bearing fitting
surfaces.
012EY00023
• Loosen the crankcase lower bolt. A little at a time in

the numerical order shown in the illustration.
• Use M10 bolts into the holes (1) for replacement to
remove the crankcase lower.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 90
Dowel pin hole

Cylinder body side
Crankcase side
Oil groove
012EY00025 015EY00108
2. Install the crankshaft to the cylinder block. 4. Install the lower crankcase to the cylinder block.
• Clean the crankshaft in solvent. Remove all sludge • Carefully wipe any foreign materials from the fitting
or restrictions from the oil passages. area of the crankcase.
• Apply engine oil to the crankshaft journal and • Apply Loctite FMD127 or equivalent to cylinder
crankshaft bearing surfaces before installing the block lower surfaces.
crankshaft. The sealant must be 0.3 mm thick and 4 mm wide.
• Install the crankshaft bearings and thrust bearing.
CAUTION: Do not apply engine oil to the bearing
back.
NOTE: The thrust bearing oil grooves must be facing the

sliding face.
Apply FMD-127
FMD-127 {
} FMD-127
Ft Rr
FMD-127 {
} FMD-127
FMD-127
015EY00107
Cylinder body lower surface
3. Install the crankshaft thrust bearing.

• Apply engine oil to the thrust bearing oil grooves
side.
• Install the upper thrust bearing to both side of the
No. 1 journal by hand. 012EY00026
NOTE: The thrust bearing oil groove must be faced the

sliding side.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 91
5. Install the piston with the connecting rod.

Refer to “Piston” in this section.
6. Install the flywheel to the crankshaft.
Refer to “Flywheel Housing” in this section.
7. Install the timing gears to the cylinder block.
Refer to “Timing Gear” in this section.
8. Install the oil pan to the cylinder block.
9. Install the cylinder head to the cylinder block.
Oil groove
015EY00109
• Install the lower crankcase to the cylinder block.

• Apply molybdenum disulfide grease to the
crankcase bolts (M18) threads and setting faces.
• Apply engine oil to the crankcase bolts (M12)
threads and setting faces.
Order 1 to 14 in the three steps using the angular
tightening method.
M18 bolt
Torque:
2nd step: 88 N·m (9.0 kgm)
3rd step: 90 – 120 deg.
M12 bolt
0 6 2 3 7
D A
C B
9 5 1 4 8
012Ey00027
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 92
Disassembly
Legend
(1) Crankshaft
(2) Bearings
(3) Crankshaft gear
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 93
1. Remove the crankshaft assembly (1) from the

cylinder block.
2. Remove the crankshaft bearing and thrust bearing
(2).
3. Use the crankshaft gear remover 1-8521-0064-0 to
A 12
remove the crankshaft gear (3).
If the slinger on the crankshaft remain, remove
B B
slinger by the slinger remover 1-8521-0027-0.
CAUTION: The crankshaft must not be ground as it A
has been treated by soft nitriding to enhance the
crankshaft strength.
Crankshaft Run-Out
• Set a dial indicator to the center of the crankshaft
No. 4 journal.
• Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
the crankshaft must be replaced.
Crankshaft run-out
Standard: 0.120 mm (0.0005 in.)
Limit: 0.15 mm (0.0059 in.)
Crankshaft Journal and Crankpin Diameter

• Use a micrometer to measure the crankshaft
journal diameter across points shown in the
illustration.
• Use a micrometer to measure the crankshaft
journal diameter at the two points as shown in the
illustration (1) and (2).
• Repeat steps 1) and 2) to measure the crankpin
diameter.
If the measured values are less than the standard
value, the crankshaft must be replaced.
Crankshaft journal and Crankpin diameter
Standard
No. 4 journal: 104.850 – 104.875 mm
(4.1279 – 4.1289 in.)
Others: 104.880 – 104.905 mm (4.1291 – 4.1309 in.)
Crankpin: 91.895 – 91.925 mm (3.6179 – 3.6191 in.)
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 94
Bearing Spread
Use a vernier caliper to measure the bearing spread.
the bearing must be replaced.
Bearing spread: 0 6 2 3 7
Limit: 111.5 mm (4.3898 in.)

D A
C B
9 5 1 4 8
012EY00027
• Measure the crankshaft bearing inside diameter by

a dial indicator.
• If the clearance between the crankshaft journal
and bearing exceeds the specified limit, the
crankshaft must be replaced.
No. 4 journal
015EY00110
Standard: 0.081 – 0.144 mm (0.0032 – 0.0057 in.)
Limit: 0.16 mm (0.0063 in.)
Crankshaft Journal and Bearing Others
Clearance Standard: 0.051 – 0.114 mm (0.0020 – 0.0045 in.)
• Clean the cylinder block and lower crankcase, the Limit: 0.16 mm (0.0063 in.)
journal bearing fitting surface, and the journal
bearings.
• Install the bearings to the cylinder block and lower
crankcase.
• Reassembly the lower crankcase to cylinder block.
• Apply molybdenum disulfide grease to the M18
bolts and apply engine oil to the M12 bolts thread
and it seat.
• Tighten the lower crankcase to the specified torque
in the numerical order shown in the illustration.
Crankcase bolt torque
M18 bolt
3rd step: 90 – 120°
M12 bolt
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 95
• Tighten the lower crankcase to the specified torque

in the numerical order shown in the illustration.
Crankcase bolt torque
M18 bolt
A 12 1st step: 49 N·m (5.0 kgm)
B B 3rd step: 90 – 120°
M12 bolt
A
0 6 2 3 7
D A
Crankshaft Journal and Bearing Clearance
C B
(with plastigage)
• Clean the cylinder block and lower crankcase, the 9 5 1 4 8
journal bearing fitting surface, and the journal
bearings.
• Install the bearings to the cylinder block and lower
crankcase.
• Reassembly the lower crankcase to the cylinder
block.
012EY00027
• Cut the plastigage same wide of crankshaft journal
and put it on the crankshaft journal. • Carefully disassembly the lower crankcase from
• Apply molybdenum disulfide grease to the M18 the cylinder block.
bolts and apply engine oil to the M12 bolts thread • Measure the width of plastigage by the scale which
and it seat. printed on the plastigage envelop.
• If the clearance between the crankshaft journal
and bearing exceeds the specified limit, the
crankshaft must be replaced.
Crankshaft journal and bearing clearance
No. 4 journal
Standard: 0.081 – 0.144 mm (0.0032 – 0.0057 in.)
Limit: 0.16 mm (0.0063 in.)
Others
Standard: 0.051 – 0.114 mm (0.0020 – 0.0045 in.)
Limit: 0.16 mm (0.0063 in.)
015EY00111
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 96
Crankshaft Tufftriding Judgment

• Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty
seconds, the crankshaft is usable.
If discoloration appears (the surface being tested
will become the color of copper), the crankshaft
must be replaced.
• Steam clean the crankshaft surface immediately
after completing the test.
NOTE: the ammonium cuprous chloride solution is
highly corrosive. Be cause of this, it is imperative that the
surfaces being tested by cleaned immediately after
completing the test.
015EY00112
Crankshaft Tufftriding Inspection

• Use an organic cleaner to thoroughly clean the
crankshaft.
There must be not traces of oil on the surface to be
inspected.
• Prepare a 5 – 10% solution of ammonium cuprous
chloride (dissolved in distilled water).
• Use a syringe to apply the solution to the surface to
be inspected.
Hold the surface to be inspected perfectly
horizontal to prevent the solution from running.
NOTE: Do not allow the solution to come in contact with
the oil ports and their surrounding area.
The portion to be tested

must be held horizontally Test liquid should
so as not to let the test not be applied to
solution flow. the area around the
oil port.
The sliding surface
of the pin
or journal.
Approximatery
10mm (0.4in)
015EY00113
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 97
Reassembly
Legend
(1) Crankshaft
(2) Bearings
(3) Crankshaft gear
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 98
1. Install the crankshaft gear to the crankshaft.

• Use the oil heater to heat the crankshaft gear to
170 – 180°C (338 – 350°F).
• With the timing alignment mark “O” on the side of
crankshaft gear turned outward, align the key
groove on the crankshaft gear with the crankshaft
dowel pin position.
• Hammer it in with a crankshaft gear installer 1-
8522-0045-0 until it hits the bottom.
CAUTION: When hammered in with the gear slanted,
the crankshaft gear may be caught in the middle and
cannot be hammered in fully. Hammer it in quickly
enough not to allow a shaft line along the gear and
the crankshaft to slant.
2. Install the bearings.

Install the crankshaft bearings and thrust bearings.
Refer to “Crankshaft” in this section.
3. Install the crankshaft to the cylinder block.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 99
Crank Pulley
Disassembly
015EY00114
Legend
(1) Crank pulley
(2) Crankshaft damper
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 100
1. Loose the crankshaft pulley fixing bolts to Inspection

disassemble the crank pulley.
Visually inspect the crankshaft damper for cracking or
separation.
015EY00096
2. Loose the fixing bolts to disassemble the crankshaft

damper.
Reassembly
1. Install the crankshaft damper.
• Install the crankshaft damper to the crankshaft,
and two grooves face to the front side.
• Tighten the bolts in numerical order to the specified
torque shown in the illustration.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 101
2. Install the crank pulley.

• Apply engine oil to the threads of fixing bolts.
• Set the crank pulley to the crankshaft damper.
• Tighten the bolts in numerical order to the specified
torque shown in the illustration.
015EY00096
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 102
Flywheel
Disassembly
015EY00115
Legend
(1) Ring gear
(2) Flywheel
(3) Washer
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 103
1. Loose the fixing bolts to remove flywheel from the Reassembly

crankshaft.
2. Put the flywheel with ring gear on the wood piece, 1. Heat the ring gear evenly with a burner to invite
and strike around the edges of the ring gear with a thermal expansion.
hammer and brass bar to remove it. Do not allow the temperature of the gas burner to
exceed 200°C (390°F).
2. Install the ring gear to the flywheel when it is
sufficiently heated.
The ring gear must be installed with the chamfer
facing the flywheel.
WARNING: Take care not to burn yourself on the
heated ring gear.

1. Visually inspect the flywheel for cracking, scratching
or worn out.
2. Visually inspect the ring gear for damage.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 104
Cylinder Block
Disassembly
3
2
012EY00029
Legend (4) Oil pressure switch

(1) Oil relief valve (5) Oil jet
(2) Cylinder liner (6) Lower crankcase
(3) Cylinder block
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 105
1. Remove the lower crankcase. Inspection and Repair

• Loosen the fixing bolts to disassemble the lower
crankcase. Make the necessary adjustment, repairs, and part
replacement if excessive wear or damage is discovered
• Put it on the wood plate or piece.
during inspection.
2. Remove the oil jet.
Loosen the bolt to disassemble the oil jet. Cylinder Block Flatness
NOTE: Take care do not bend or damage the oil jet. • Remove the cylinder liners.
3. Remove the cylinder liner. • Visually inspect the cylinder block any cracking or
• Use a scraper to remove carbon deposit. damage and the oil and/or water holes for choking.
• Use a cylinder bore dial indicator to measure the If possible it is required to specially inspect by dye
cylinder bore at measuring point in the thrust and penetrant flaw detector.
axial direction of the crankshaft.
Measuring point: 20 – 25 mm (0.79 – 1.0 in.)
the cylinder liner must be replaced.
Cylinder liner bore
Limit: 147.3 mm (5.7992 in.)
NOTE: If the inside of the cylinder liner is scored or
scratched, the cylinder liner must be replaced.
20∼
25mm
• Use a straight edge (1) and a feeler gauge (2) to

measure upper face warpage of the cylinder block
on the four sides and two diagonals of upper face
Upper face warpage
Standard: 0.075 N·m (0.0030 in.) or less
Limit: 0.2 mm (0.008 in.)
4. Visually inspect the cylinder block for damage. the cylinder block must be replaced.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 106
20∼
25mm
012EY00030
• Inspect water leakage to apply water pressure in Cylinder Liner Grade Selection and
the cylinder body water jacket.
Standard Fitting Interference
Water Pressure: 490 kPa (5 kg/cm2)
Accurately measured fitting interference and proper
If water leakage is fund, the cylinder block must be cylinder liner grade selection are extremely important.
replaced. If the cylinder liner fitting interference is too small,
engine cooling efficiency will be adversely affected.
Cylinder Liner Bore If the cylinder liner fitting interference is too large, it will
• Use a scraper to remove carbon deposit. be difficult to insert the cylinder liner into the cylinder
• Use a cylinder bore dial indicator to measure the block.
cylinder bore at measuring point in the thrust and A mark was stamped on the right side of the cylinder
axial direction of the crankshaft. block during production to indicate the correct liner.
Measuring point: 20 – 25 mm (0.79 – 1.0 in.) The liner grade (1, 2, 3) is indicated in metal stamp.
Cylinder liner grade
Cylinder liner bore
Limit: 147.3 mm (5.7992 in.) Line Cylinder Bore Service Liner Outside
Grade Diameter mm (in.) Grade Diameter mm (in.)
the cylinder liner must be replaced. 151.600 – 151.610 151.590 – 151.599
1 1X
NOTE: If the inside of the cylinder liner is scored or (5.9685 – 5.9689) (5.9681 – 5.9685)
scratched, the cylinder liner must be replaced. 151.611 – 151.630 151.600 – 151.610
2·3 3X
(5.9689 – 5.9697) (5.9685 – 5.9689)
The cylinder liner grade is stamped on the outside of the

cylinder liner.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 107
Lower Crankcase
Visually inspect the lower crankcase for cracking or
damage.
If possible it is required to specially inspect by dye
penetrant flaw detector.
Liner outside
Grade No.
012EY00020
Oil Jet
Check the oil port on the oil jet for choking.
Grade No.
012EY00021
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 108
Relief Valve
Inspect the relief valve for choking.
012EY00031
Cylinder Liner Projection

• Use a dial indicator or a straight edge and feeler
gauge to measure the cylinder liner projection.
Cylinder liner projection
Standard: 0.05 – 0.09 mm (0.0020 – 0.0035 in.)
The difference in the cylinder liner projection height
between any adjacent cylinders must not exceed
limit.
Projection height between adjacent cylinder:
0.02 mm (0.0008 in.) or less
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 109
Reassembly
3
2
012EY00029
Legend (4) Oil pressure switch

(1) Oil relief valve (5) Oil jet
(2) Cylinder liner (6) Lower crankcase
(3) Cylinder block
.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 110
1. Install the cylinder liner into the cylinder block.

• Use new kerosene or diesel fuel to thoroughly
clean the cylinder liner and bore.
• Use compressed air to brow-dry cylinder liner and
bore surface.
WARNING: Pressure air can cause personal injury
when using pressure air for cleaning. Wear safety
glasses and protection clothing.
NOTE: All foreign materials must be carefully removed

from the cylinder liner and the cylinder bore before
installation.
• Apply engine oil to outside surface cylinder liner.
• Install the cylinder liner into the cylinder block from
the top of the cylinder block by your hand.
• Check cylinder liner projection.
NOTE:
1) Do not apply unreasonableness stress or hit the
cylinder liner during installing.
2) Take care to not remove the cylinder liner when 2. Install the oil jet to the cylinder block.
cylinder block turns over. Tighten to the specified torque.
Be sure direction of the oil jet tip to cooling hole of
piston.
Do not bend or damage the oil jet.
3. Install the crankshaft to the cylinder block.

4. Install the lower crankcase.
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 111
5. Install the oil relief valve.

• Apply engine oil to the relief valve assembly with
new gasket.
• Install the relief valve to the cylinder block to the
specified torque.
012EY00032
6. Install the oil pressure unit.

• Install the adapter with new gasket to the cylinder
block to the specified torque.
012EY00033
69697_ESS-172A_SEC6A-2 11.8.5 10:46 AM ページ 112
MEMO
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 1
ENGINE COOLING 6B–1
ENGINE COOLING
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6B-1 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6B-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-3 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6B-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-10
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6B-5
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
Service precaution
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 2
6B–2 ENGINE COOLING
General Description
Coolant Flow Chart
Cylinder
Head
Air
Radiator
Thermostat Water Pump Oil Cooler Cylinder Compressor

Body (If equiped)
030EY00017
Cooling Flow Thermostat

The cooling system main parts consist of the radiator, A wax pellet type thermostat is used.
the water pump, the water outlet pipe and the
thermostat.
This top-bypass type cooling system controls the cooling
water temperature though the thermostat installed at the
water pump inlet.
The system maintains optimum cooling water volume
and minimizes cooling water temperature fluctuation
and hunting.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 3
Water Pump
Water Pump Exploded View
12
11
10
9
3
030EY00008
Legend (7) Gasket

(1) Rear cover (8) Shaft
(2) Bearing (9) Seal unit
(3) Gear (10) Impeller
(4) Bearing (11) Joint pipe
(5) Oil seal (12) Front cover
(6) Pump body
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 4
Disassembly • Use the bench press the rear cover side to

disassemble the bearings (1) and gear (2).
1. Loosen the rear cover fixing bolts to remove the front
cover.
2. Use the impeller remover (1) 1-8521-0062-0 to
remove the impeller from the shaft.
2
1
030EY00010
8. Remove the oil seal (1).

9. Remove the seal unit (2).
030EY00009 NOTE: Do not make scratch or damage seating surface
of the oil seal and the seal unit on the pump body when
3. Remove the rear cover. disassemble them from the pump body.
4. Remove the small bearing.
5. Remove the gear.
6. Remove the large bearing.
7. Remove the shaft.
• Use bench press from the impeller side to 2
disassembly the shaft with the bearings and the
gear.
030EY00011
10. Remove the pump body.

69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 5
Inspection and Repair 3. Inspect the shaft for damage or worn out.
Make the necessary adjustments, repair and part

replacement if excessive or damage wear is discovered
during inspection.
1. Inspect the impeller for corrosion and the seal unit for
worn out touching surface or some damage.
030EY00012
Reassembly
1. Install the oil seal to the pump body.
• Apply engine oil to inside and outside of the oil
seal.
2. Inspect the bearings. • Seal lip face to upper and carefully press fit the oil
seal to the pump body.
• Wash bearing in the clean kerosene.
• Visually check scratches or damages on the ball
and bearing race.
• Rotate the bearing on your hand for hearing
abnormal noise.
• Check abnormal clearance between the ball and
bearing race.
2. Install the large bearing to the shaft.

• Apply engine oil to the shaft.
• Use a bench press to press the large bearing onto
the shaft.
• Use a bench press to press the shaft with large
bearing into the pump body.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 6
030EY00013
4. Use the bench press to gradually press the bearing

small (1) into the rear cover.
1
3. Install the gear on the shaft.
• Place the gear long boss side facing to bearing 030EY00014
large on the shaft. 5. Install the rear cover.

• Use a bench press to press the gear onto the shaft • Use a bench press to install the rear cover
as shown in the illustration. assembly into the shaft shown in the illustration.
• Same time align bolt holes between rear cover
and pump body.
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 7
030EY00016
6. Use seal unit installer (1) 1-8522-0047-0 to install the 8. Set the gasket to the pump body.
seal unit (2). 9. Install the front cover.
• Align bolt hole together with rear cover assembly.
• Tighten the bolt from rear cover side to the
specified torque.
1
2
030EY00015
7. Use the bench press to gradually press the impeller

(1) until make specified clearance between the
impeller and pump body (2).
Clearance between impeller and pump body
Standard: 1.7 – 2.7 mm (0.0669 – 0.1063 in.)
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 8
Thermostat
Disassembly
4
5
031EY00012
Legend (4) Thermostat housing

(1) Seal ring (5) Gasket
(2) Thermostat (6) Temperature switch
(3) Gasket
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 9
1. Loosen the fixing bolts to remove the thermostat

housing.
Discard the gaskets.
2. Remove the thermostat housing.
• Carefully remove the thermostat from the oil
cooler case.
3. Remove the seal ring.
• Loosen the seal ring puller 1-8521-0067-0 to take
out the seal rings.
2
replacements if excessive or damage wear is
1. Visually inspect leakage of wax pellet, some damage
of the spring or caulking position on the thermostat.
2. Perform the operating test.
Completely submerge the thermostat in water. 031EY00013
Heat the water.

Stir the water constantly to avoid direct heat being
applied to the thermostat.
Measure the thermostat initial opening temperature.
Thermostat initial opening temperature 79°C (174°F)
Measure the thermostat full opening temperature.
Thermostat full opening temperature 95°C (203°F)
Measure the valve lift at the thermostat full open
position.
Valve lift at full open position: 11 mm (0.433 in.)
69697_ESS-172A_SEC6B 11.8.8 1:48 PM ページ 10
Reassembly
1. Use the seal ring installer 1-8522-1034-0 to install
the seal ring to the oil cooler case, as the direction of
seal ring shown in the illustration.
4. Install the temperature switch on the portion “A” of

the thermostat housing.
031EY00016
2. Carefully install the thermostat to oil cooler case

031EY00015
3. Install the thermostat housing with new gaskets.

• Set the gasket to the thermostat housing to install
the thermostat housing with the new gasket.
• Pushing the thermostat housing to oil cooler case,
initially tighten the water pump side bolts then
tighten the oil cooler side bolts to the specified
torque.
Bolt Torque: 39 N·m (4.0 kgm)
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 1
ENGINE FUEL 6C–1
ENGINE FUEL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6C-1 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6C-2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-13
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-5 Calibration Data. . . . . . . . . . . . . . . . . . . . . . . . . 6C-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-5 Injection Nozzle Holder – Two-Stage
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6C-6 Injection Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-17
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-6 Nozzle and Holder Specification . . . . . . . . . . . . 6C-17
Injection Nozzle Holder . . . . . . . . . . . . . . . . . . . . . 6C-7 Reassembly and Opening Pressure
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-7 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6C-8
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-10
Service precaution
systems.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 2
6C–2 ENGINE FUEL
General Description
Fuel System Operation When working on the fuel system, there are several
things to keep in mind:
The engine crankshaft drives the fuel injection pump
• Any time the fuel system is being worked on,
which in turn, drives the fuel feed pump.
disconnect the negative battery cable except for
The fuel feed pump draws fuel from the fuel tank,
those tests where the battery voltage is required.
through the fuel/water separator and transfers it, by way
of the secondary fuel filter, into the injection pump. The • Always keep a dry chemical (Class B) fire
governor regulates the flow of fuel to the delivery valves. extinguisher near the work area.
At the correct timing intervals a plunger in the injection • Always relieve the line pressure before servicing any
pump sends fuel, at high pressure, through a delivery fuel system components.
valve to one of the fuel injection nozzles. • Do not attempt repair on the fuel system until you
Fuel pressure causes a needle valve in the fuel injection have read the instructions and checked the pictures
nozzle to open. Fuel is then injected through injection relating to the repair.
nozzle holes into the cylinder in a fine spray.
Excess fuel is directed back to the fuel tank by means of
the fuel return lines.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 3
ENGINE FUEL 6C–3
Fuel Flow Diagram
040EY00031
The fuel system consists of the fuel tank, the water Fuel Filter
sedimentor, the fuel filter, the injection pump, and the
The purpose of the fuel filter is to clean the fuel in any
injection nozzle.
dirt particles that can cause wear on the fuel injection
The fuel from the fuel tank passes through the water
nozzle’s sliding surface. The water separator is located
sedimentor and the fuel filter where water particles and
between the fuel tank and the fuel feed pump.
other foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to Fuel Feed Pump
the injection nozzle in the metered volume at the
optimum timing for efficient engine operation. The fuel feed pump draws fuel from the fuel tank to the
fuel filter. It delivers the fuel, under pressure, to the
Water Sedimentor injection pump through fuel filter.
An independent priming pump permits manual fuel feed
When the condensed water in the water sedimentor
while the engine is not running.
comes to the warning level indicated on its plastic body,
drain the water immediately from the drain plug located
bottom of water sedimentor.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 4
6C–4 ENGINE FUEL
Injection Pump
Major components of the injection pump are the pump
body and plunger unit, the governor, the timing advancer
and the feed pump.
An aneroid compensator is available as an option.
The injection pump is the nucleus of the diesel engine
fuel system. It pressurizes and delivers a metered
volume of fuel to the engine cylinders at the optimum
time for the current engine load and speed.
The injection pump plungers are pushed up by cam
lobes. They are returned to their original position by the
plunger springs. This action creates a reciprocal motion.
The plunger barrel receives fuel from the feed pump and
filter through its inlet port when the injection pump
plunger is on the down stroke.
Surplus fuel is delivered to the injection pump fuel
chamber through the plunger outlet port when the
plunger is on its up stroke.
The injection pump has an identification plate attached
to the pump body.
Governor
The injection pump is equipped with a RSV type,
variable speed governor.
Diesel engine operating speed and load will very widely
during the course of normal driving.
If the engine speed falls too low, the engine may run
sluggishly or stall. If the engine speed becomes too high,
the engine overrun will result.
The governor acts to maintain engine speed within
acceptable limits, thus protection against engine stall
and/or overrun.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 5
ENGINE FUEL 6C–5
Fuel Filter
Disassembly
Legend
(1) Fuel filter
(2) Overflow valve
(3) Fuel filter body
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 6
6C–6 ENGINE FUEL
1. Remove the fuel filter with using the filter wrench. Reassembly
CAUTION: Be careful not to spill out the fuel
remaining in the fuel filter when the filter is removed. 1. Install the overflow valve to the fuel filter body.
2. Install the fuel filter.
• Before installating a new fuel filter, apply fuel to
the gasket.
• Turn the new fuel filter until the filter gasket comes
in contact with its sealed face.
• Use a filter wrench to turn in the fuel filter by
additional 1/2 – 3/4 of a turn.
040EY00007
2. Remove the overflow valve.

3. Remove the fuel filter body.

Inspection the overflow valve for restriction or leak.
Overflow valve opening pressure 280 – 310 kPa
(40 – 46 psi).
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 7
ENGINE FUEL 6C–7
Injection Nozzle Holder

Disassembly
4
6
3
2
7
8
9
10
1
040EY00032
Legend (6) Nozzle holder body

(1) Retainer nut (7) Adjusting shim
(2) Nozzle (8) Spring
(3) Nozzle holder pin (9) Pin
(4) Spring seat (10) Spacer
(5) Gasket
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 8
6C–8 ENGINE FUEL
1. Remove the retaining nut. CAUTION:

• Clamp the injection nozzle holder in a vice. 1. Wash all the part removed and arrange them on a
• Use a wrench to remove the injection nozzle cylinder basis, care should be taken not to miss
retainer nut. any parts.
2. Soak the nozzle assembly in a parts receptacle
filled clean diesel fuel.
3. Care should be taken not to miss shim, if used.

Retaining Nut
Inspect the retaining nut for any wear or corrosion.
2. Remove the nozzle from the nozzle holder.

• Keep the nozzle along with the needle valve
separately to maintain the original nozzle to
needle valve combination.
• Clean the nozzle in the clean diesel fuel.
Injection Nozzle Needle Valve

1. Remove the needle valve from the nozzle body.
2. Carefully wash the nozzle needle and the nozzle
body in the clean diesel fuel.
3. Check that the nozzle needle moves smoothly inside
the nozzle body.
If the nozzle does not move smoothly, it must be
repaired (See “Nozzle Lapping Procedure”) or
replaced nozzle assembly.
3. Remove the nozzle holder pin, spacer,spring seat,

spring and adjusting shim from the nozzle holder.
Keep the adjusting shims in the original groups to
hold the initial shim to the nozzle spring combination.
4. Remove the nozzle holder body.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 9
ENGINE FUEL 6C–9
Spring Nozzle Lapping Procedure

Inspect the spring for any wear, fell and corrosion. 1. Lap the nozzle needle (1), and the nozzle body (2) by
applying a compound of oxidized chrome with animal
oil.
NOTE: Do not apply an excessive amount of the
oxidized chrome with animal oil compound to the
injection needle valve seat area.
2. Carefully wash the needle valve and the nozzle body
in clean diesel fuel after lapping.
040EY00033
Nozzle Body and Needle Valve 2 1
Check the nozzle body and the needle valve for damage
and deformation.
The nozzle and body assembly must be replaced if
either of these two conditions are discovered during
040EY00034
inspection.
NOTE: New nozzles must be cleaned in a solvent to
remove protective coating. The nozzle body and needle
must always be replaced as an assembly.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 10
6C–10 ENGINE FUEL
Reassembly
4
6
3
2
7
8
9
10
1
040EY00032
Legend (6) Nozzle holder body

(1) Retainer nut (7) Adjusting shim
(2) Nozzle (8) Spring
(3) Nozzle holder pin (9) Pin
(4) Spring seat (10) Spacer
(5) Gasket
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 11
ENGINE FUEL 6C–11
1. Install the locating pin to the nozzle holder body. Adjustment of Injection Nozzle Opening
2. Install the adjusting shim, spring and spring seat into Pressure
the nozzle holder body.
After reassembling the injection nozzle, recheck the
3. Install the spacer to the nozzle holder body over the opening pressure and spray condition.
locating pin. With the nozzle holder set to the nozzle tester, adjust the
4. Install the locating pin to the nozzle. pressure with an adjusting shim so that the pressure
5. Install the nozzle to the nozzle holder. becomes equal to the specified injection nozzle opening
pressure.
Injection nozzle opening pressure: 20.1 MPa
(2920 psi)
An adjusting shim of 0.007 mm (0.0003 in.) allows the
press to change by about 100 kPa (14.2 psi).
The adjusting shim thickness calculation method as
follows.
WARNING: The test fluid from the injection nozzle
tester will spraying out of the injection nozzle under
great pressure. It can easily puncture a person’s
skin. Keep your hands away from the injection
nozzle at all times.
The adjusting shim thickness calculation method.

P × π/4 × (A2 – B2)
= Additional shim thickness (mm)
C × 100
P (kPa) = (Target injection nozzle opening pressure

– Indicated value (pressure) of nozzle
6. Install the retaining nut tester)
• Clamp the injection nozzle holder in a vice. A (cm) = Needle diameter. 0.6 cm
• Tighten the retaining nut to the specified torque. B (cm) = Sheet diameter. 0.3 cm
C (N/mm) = Spring constant. 264.0 N/mm
7. Install the new gasket to the nozzle holder.

69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 12
6C–12 ENGINE FUEL
Adjusting Shims
After calculates shim thickness to select shims from
below list.
mm
Thickness Part number
0.50 5-15339-007-0
0.52 5-15339-018-0
0.54 5-15339-019-0
0.56 5-15339-020-0
0.58 5-15339-021-0
0.60 5-15339-008-0
0.70 5-15339-009-0
0.80 5-15339-010-0
0.90 5-15339-011-0
1.00 5-15339-012-0
0.10 8-94128-982-0
0.20 8-94128-983-0
0.30 8-94128-984-0
0.40 8-94128-985-0
Spray Pattern
Check the spray condition to shown in the illustration.
If the spray conditions is not suitable pattern, the
injection nozzle must be replaced or readjusted.
1 2 3
040EY00030
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 13
ENGINE FUEL 6C–13
Injection Pump
Identification
1. It is important that you refer to the injection pump
assembly number on the identification plate to
determine the applicable calibration data in this
section for the injection pump being serviced.
2. In the event this section does not contain calibration
data applicable to the injection pump being serviced,
contact the nearest manufacturer’s authorized
service facility (Bosch Automotive System Corp. or
Robert Bosch GMBH).
3. Refer to the Isuzu Injection Pump Assembly Number
stamped on the injection pump assembly
Identification Plate to order a replacement injection
pump.
MADE IN
JAPAN
ISUZU part number

ZEXEL pump assembly number
F06HV015
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 14
6C–14 ENGINE FUEL
Injection Pump Calibration Data

Test Conditions
Injection nozzle ZEXEL No. 105780-0000

Injection nozzle holder ZEXEL NO. 105780-2080
Injection starting pressure 17.2 MPa
Injection line dimensions Inside diameter = 3 mm
Outside diameter = 8 mm
Length = 600 mm
Transfer pump pressure 255 kPa
Test diesel fuel ISO4113 or SAE standard test oil (SAEJ967d)
Fuel temperature 39 – 41°C (109.2 – 114.8°F)
Pump rotation Clockwise viewed from the drive side
Overflow valve opening pressure 255 kPa (2.6 kg/cm2 / 37.0 psi)
CAUTION:
Strictly observe the above test conditions during injection pump fuel injection volume adjustment.
Failure to observe the test conditions will result in misadjustment of the injection pump fuel injection volume.
Misadjustment of the fuel injection volume will result in serious engine damage.
Injection Timing
Pre-stroke 5.6 ± 0.05 mm (0.220 ± 0.01 in.)

Injection order and interval 1–5–3–6–2–4
Plungers are numbered from the drive side.
Tappet clearance Manually rotate the camshaft several times to make
sure that it rotates smoothly.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 15
ENGINE FUEL 6C–15
Injection Volume and Governor Performance Diagram

6WG1TQA
Injection Pump Assembly Number
ISUZU No. ZEXEL No. Remarks ISUZU No. ZEXEL No. Remarks
1-15603-341-0 106671-6440
Injection Volume
Control rack Pump speed Injection volume Variance Boost pressure
Remarks
position (mm) (min–1) (mm3/1,000 strokes) (%) (kPa)
11.9 900 221 ± 2 ±3 more than 128 Basic
6.6 450 9 ± 3.2 ± 13

69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 16
6C–16 ENGINE FUEL
Governor Performance
NOTCH ; 5
RACK LIMIT
14.0
IDLING SUB SPRING SET
RACK POSITION (mm)

E BOOST COMPENSATION
12.7±0.1 STROKE : 0.8±0.1mm
11.9 B A
10.2 D
350
7.2 GOVERNOR SPRING SET
6.7
6.6 C
0 +25
250 450 900 +15 1000±15
(420)
PUMP SPEED (min-1)
040EY00039
Speed Control Lever and Stop Lever
※ SPEED LEVER STOP LEVER
IDLE~STOP
18
°±
5° °
°± 5 ±5
°
19 STOP
53°
5°
13° °±
± 3° 22
5°
70°±
STOP FULL SPEED NORMAL
IDLING
040EY00036
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 17
ENGINE FUEL 6C–17
Injection Nozzle Holder – Two-Stage Injection Type

Nozzle and Holder Specification
ITEMS 6WG1
Injection nozzle & holder assembly type KBL2.4/S, two-spring
Injection nozzle type Hole
Number of injection nozzle orifices Eight holes
Orifices diameter mm (in) 0.24 (0.0094)
Opening pressure MPa (kg/cm2 / psi) 1st stage 17.7 (180/2,560)
2nd stage 22.1 (225/3,200)
Nozzle needle valve full-lift mm (in) 0.32 (0.0126)
Nozzle needle valve pre-lift mm (in) 0.06 (0.0024)
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 18
6C–18 ENGINE FUEL
Reassembly and Opening Pressure Adjustment
15
7
14
8
1 9
10
11
12
4
13
040H100004
Legend (8) Shim (Second opening pressure adjustment)

(1) Nozzle holder body (9) Spring seat
(2) shim (First opening pressure adjustment) (10) Lift piece
(3) First spring (11) Spacer & pin
(4) Spring seat (12) Nozzle & pin
(5) Collar (13) Retaining nut
(6) Second spring (14) Gasket
(7) Push rod (15) Eye bolt
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 19
ENGINE FUEL 6C–19
Adjustment Procedure
As adjustment of the two-stage injection type nozzle holder is made in hundredths of a millimeter, clean the parts
thoroughly in light oil to completely remove any dirt or foreign matter.
1 First nozzle opening pressure adjustment Adjust the first nozzle opening pressure using the shim.
2 Full needle valve lift confirmation Confirm the full needle valve lift in accordance with the closed
method.
3 Pre-lift confirmation Confirm pre-lift in accordance with the closed method.

CAUTION:
If not as specified, replace the nozzle assembly, lift piece,
pins and spacer using the nozzle service kit.
4 Second nozzle opening pressure Confirm the second nozzle opening pressure in accordance with
confirmation the closed method.
5 Second nozzle opening pressure

Adjust the second nozzle opening pressure using the shim.
adjustment
6 Final inspection Confirm the condition of the fuel spray with the nozzle and nozzle
holder assembled.
Adjustment Service Data
Nozzle needle valve full-lift 0.32 mm (0.0126 in)

Nozzle needle valve pre-lift 0.06 mm (0.0024 in) at 18.7 MPa (190 kg/cm2, 2,700 psi)
Nozzle pressure 1st stage 17.7 MPa (180 kg/cm2, 2,560 psi)
2nd stage 23.0 – 24.0 MPa (235 – 245 kg/cm2, 3,340 – 3,480 psi)
at lift 0.11 mm (0.0043 in) = (pre lift + 0.05 mm (0.0020 in))
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 20
6C–20 ENGINE FUEL
First Nozzle Opening Pressure Adjustment 3. Install the collar, second spring, shim, spring seat
and pushrod in the nozzle holder.
1. Clamp the nozzle holder in a vise.
Second nozzle opening pressure

Nozzle holder body adjusting shim Push rod
Second spring
Collar
Spring seat
040MV017
040MV015
4. Install the pins, lift piece and spacer in the nozzle

2. Install the shim, first spring and spring seat in the
holder.
nozzle holder.
Spring seat Spacer

Lift piece
First spring
Pin
First nozzle opening pressure
adjusting shim
040MV018
040MV016
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 21
ENGINE FUEL 6C–21
5. Install the pins in the spacer. 8. Tighten the adjustment retaining nut to the specified
6. Install the nozzle on the spacer. torque.
Torque: 34 N·m (3.5 kg·m / 25 lb·ft)
Nozzle
Torque wrench
Pin
Retaining nut
(special tool)
040MV019
040MV014-1
7. Hand-tighten the adjustment retaining nut together
with the gasket to the nozzle holder. 9. Set the nozzle holder to the nozzle tester.
Retaining nut: 157892-4000 (★Bosch AS) 10. Operate the nozzle tester and measure the first
5-86777-145-0 (ISUZU) nozzle opening pressure.
Gasket: 157892-1500 (★Bosch AS) 11. If the first nozzle opening pressure is not as
specified, disassemble the nozzle holder and
5-86777-146-0 (ISUZU)
replace the shim until the pressure is as specified.
(★Bosch Automotive Systems Corporation)
Nozzle tester
Nozzle holder
Retaining nut
(Special tool) Nozzle
Gasket
040MV030
040MV010
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 22
6C–22 ENGINE FUEL
CAUTION: Full needle valve lift confirmation

• Use a micrometer to measure shim thickness.
1. Install the gasket and plug on the adjustment
• Use some combination of 3 adjusting shims to retaining nut.
adjust the pressure.
Gasket: 026508-1140 (Bosch AS)
• First nozzle opening pressure adjusting shims
894227-6020 (ISUZU)
mm (in)
Plug: 157892-1600 (Bosch AS)
Part No. Thickness
5-86777-141-0 (ISUZU)
115349-1120 0.40 (0.0157)
115349-1130 0.50 (0.0197)
115349-1140 0.52 (0.0205)
115349-1150 0.54 (0.0213)
115349-1160 0.56 (0.0220)
Plug
115349-1170 0.58 (0.0228)
115349-1180 0.60 (0.0236)
115349-1190 0.70 (0.0276)
Gasket
Thickness
040MV013
2. Position the nozzle holder with the nozzle facing

φ3.8mm down and install the dial gauge holder on the nozzle
holder.
φ8.9mm
Dial gauge holder: 157892-5000 (Bosch AS)
586777-1420 (ISUZU)
040MY00023
Holder (special tool)
040MV012
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 23
ENGINE FUEL 6C–23
3. Install the nut on the dial gauge holder. 5. Secure the dial gauge to the nozzle holder using the
Nut: 157892-1000 (Bosch AS) nut so that the pin contacts the tip of the first spring
seat.
586777-143-0 (ISUZU)
CAUTION:
• Secure the dial gauge so that a stroke of 2 mm
(0.0787 in) can be measured.
• Do not over-tighten the nut as the dial gauge
shaft may jam. (Confirm from the dial gauge
Nut (special tool) that the shaft moves smoothly.)
Holder (special tool)
Dial gauge
Nut
Holder
Pin
040MV011
4. Install the pin to the dial gauge.

Note: The lengths of the pins do not include the threaded
Nozzle holder
portions.
Pin (l = 86 mm): 157892-6400 (Bosch AS)
Dial gauge: 157892-3800 (Bosch AS) First spring seat
(General type)
Dial gauge Pin
040MV009
040MV029
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 24
6C–24 ENGINE FUEL
6. Set the nozzle holder to the nozzle tester and put Pre-lift confirmation
needle to zero on the dial gauge.
1. With the needle valve at full lift, release the nozzle
7. Operate the nozzle tester to bleed any air from inside tester handle.
the retaining nut and to confirm that no fuel leaks.
Note: The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
Nozzle tester
Nozzle holder
300
200
100 400
0 500
kgf／cm2
Pressure gauge
040MV030
8. Operate the nozzle tester and increase the in-line

pressure to 34.3 – 44.1 MPa ( 350 – 450 kg/cm2 / 040MV007
4977 – 6399 psi) so that the nozzle’s needle valve

moves through its full lift.
Record full lift ‘L’. (Rear dial gauge)
Nozzle Holder Assy: 115300-3722 (ISUZU)
Nozzle full lift: 0.32 ± 0.02 mm (0.0126 ± 0.0008 (mm)
L
in)
Note: The above operation is used to determine whether
Needle Valve lift
the nozzle seat is worn and whether the nozzle

assembly is in good condition.
(MPa)
17.7 22.1
L In line pressure
Needle Valve lift
040H100006
0 First nozzle 34.3∼44.1MPa

opening pressure {350∼450kgf/cm 2 }
In line pressure
040MV008
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 25
ENGINE FUEL 6C–25
2. Read the needle valve lift ‘l’ from the dial gauge 4. If pre-lift is not as specified, replace the pins, lift
indication (once the needle valve has descended piece, spacer and nozzle assembly as a set with the
when the second spring has stopped operating). service kit.
Refer to the pre-lift measuring point for ‘l’. Service kit; Bosch AS: 105019-2310
Pre-lift measuring point: Service kit; ISUZU: 115319-007-1
Read the dial gauge at first nozzle opening pressure
+approx 1 MPa (10 kg/cm2).
Pre-lift: 0.06 m (0.0024 in.) at pressure 18.6 MPa
(190 kg/cm2/2700 psi)
Note: This point can be found while the pressure is
decreasing.
Pin
Lift piece
Spacer
Capsule
L
Measuring point
of prelift Nozzle
Needle valve lift
assembly
0 040HV031
First nozzle
opening pressure
confirmation
1. After pre-lift confirmation, operate the nozzle tester
040H100007
to increase in-line pressure to 34.3 – 44.1 MPa (350
– 450 kg/cm2 / 4977 – 6399 psi) so that the nozzle’s
needle valve moves through its full lift.
Pushrod Second spring

Nozzle tester
Spring seat Adjusting shim Nozzle holder
Spacer
Lift piece
Needle valve
040MV005
040MV030
3. Confirm that pre-lift ‘l’ is as specified.
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 26
6C–26 ENGINE FUEL
2. Release the nozzle tester handle so that in-line Second nozzle opening pressure
pressure decreases. adjustment
Note: The in-line pressure will decrease and needle
If the second nozzle opening pressure is not as
valve lift (as indicated on the dial gauge) will also
specified, disassemble the nozzle from the nozzle
decrease a little.
holder and replace the shim until the pressure is as
specified.
CAUTION:
• Because the second opening pressure changes
when the first opening pressure changes, the
L second opening pressure must be adjusted
Needle valve lift(mm)
when the first opening pressure changes.

• Use some combination of 3 adjusting shims to
adjust the pressure.
+0.05 • Use a micrometer to measure shim thickness.
0
Second nozzle 34.3-44.1MPa
opening pressure (350-450kg/cm2)

adjusting shim Push rod
Second spring
040H100008
Collar
3. Then, read the pressure gauge indication (second Spring seat
nozzle opening pressure) the instant that the dial
gauge indicates the specified needle valve lift
(usually pre-lift l + 0.05 mm (0.002 in)).
Second nozzle opening pressure: 23.0 - 24.0 MPa
(235 - 240 kg/cm2/3340 - 3480 psi) at lift 0.11 mm
(0.0043 in)
040MV017
• Second nozzle opening pressure adjusting shims

mm (in)
When needle valve lift is
+ 0.05mm Part No. Thickness
90
10
115349-1200 0.40 (0.0157)
80
20 115349-1210 0.50 (0.0197)
70 115349-1220 0.52 (0.0205)
30
115349-1230 0.54 (0.0213)
60
40
50 115349-1240 0.56 (0.0220)
Full needle valve lift
115349-1250 0.58 (0.0228)
Dial gauge
115349-1260 0.60 (0.0236)
115349-1270 0.70 (0.0276)
040H100005
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 27
ENGINE FUEL 6C–27
2. Remove the adjustment retaining nut and gasket.

3. Install the original retaining nut, confirm that the pins
are inserted fully into the nozzle, and then hand-
tighten the retaining nut. Then, tighten the original
retaining nut to the specified torque.
Torque: 69 N·m (7.0 kg·m / 51 lb·ft)
Thickness
φ4.8mm
Torque wrench
φ9.9mm
Retaining nut
040MY00024 (special tool)
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV014-1
4. Set the nozzle holder to the nozzle tester and check

first nozzle opening pressure, spray condition, seat
Dial gauge
oil tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift
piece, pins and spacer as a set with the nozzle
service kit.
Nut
CAUTION:
Dial gauge
holder Pre-lift will not be as specified if only the nozzle is
replaced.
Nozzle tester
040MV028
Nozzle holder
040MV030
69697_ESS-172A_SEC6C 11.8.4 3:26 PM ページ 28
MEMO
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 1
STARTING AND CHARGING 6D3–1
STARTING AND CHARGING

CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . 6D3-1 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-11
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-2 General Description. . . . . . . . . . . . . . . . . . . . . 6D3-11
General Description. . . . . . . . . . . . . . . . . . . . . . 6D3-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-5 Inspection and Repair . . . . . . . . . . . . . . . . . . . 6D3-16
Inspection and Repair . . . . . . . . . . . . . . . . . . . . 6D3-7 Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-18
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3-8
Service precaution
systems.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 2
6D3–2 STARTING AND CHARGING
Alternator
General Description
5 6
4
7
8
1
9
10
060EY00002
Legend (6) Rotor

(1) Rear bracket (7) Bearing
(2) IC regulator (8) Pulley
(3) Bearing (9) Front bracket
(4) Rectifier (10) Field coil assembly
(5) Stator
This alternator is a brushless unit. This alternator has three terminals; a terminal-B (DC
The main components are the rotor, stator, rectifier power output terminal), terminal-L and terminal-R.
assembly, front bracket, rear bracket, IC regulator, Since terminal-L is connected to the field coil, it is an
bearings and pulley. input terminal of initial exciting current together with
The movable parts in the assembly are the rotor and terminal-R until the alternator begins to generate.
pulley. Also, it has another function of a voltage output terminal
The field coil is fixed to the rear bracket. (current output capacity is only one ampere).
To rectify 3-phase alternator in the stator coil to direct When terminal-L voltage reaches to battery voltage it
current, 6 main diodes and 2 additional diodes are used: turns the indicator lamp off.
3 main diodes are called “positive diode”, while the The bearings are sealed so that no periodic lubrication is
others are called “negative” diode. required.
Also, 3 small diodes called “diode trio” are used and the The IC regulator is a solid state unit so that it can be
field current is supplied from these diodes. serviced as an assembly.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 3
Identification MITSUBISHI IDENTIFICATION PLATE

The alternator identification plate is attached to the
alternator rear bracket. The ISUZU part number, the
manufacturer’s code number, and other important A
information are stamped on the plate.
Refer to the identification plate together with the “Main
B
Data and Specifications” Tables and accompanying C D
charts in this Manual when requesting service
assistance from a qualified electrical repair shop.
If you are unable to locate the data applicable to your E
engine, please contact ISUZU MOTORS LIMITED
through your machine supplier.
A: Isuzu part number

B: Manufacturer’s short type name
C: System voltage output
D: Manufacturer’s lot no.
E: Bar code
Charging Circuit
ADDITIONAL B
DIODES
DIODE TRIO INDICATOR LAMP
STATOR
L
COIL
L KEY
SWITCH
R R
BATTERY
(24V)
E
FIELD
COIL
IC REGULATOR
E
ALTERNATOR
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 4
Main Data and Specifications
Isuzu Part No. 1-81200-5901

Manufacturer’s code No. (MITSUBISHI) A004T05485
Rated voltage (V) 24
Rated output (A) 50
Rated speed (min–1) 5000
Rated output at r.p.m (Amp./Volt/min–1) 50/27/5000
No-load output at 0 Amp. (Volt/min–1) 24/900
Direction of rotation as viewed Clockwise
from pulley side
Polarity grounded (–)
Pulley diameter mm (in.) 80 (3.15)
Coil resistance at 20°C
Field coil (Ω) 4.5 – 5.2
Regulator’s applicable
Isuzu part No. 1-81260-0170
Manufacturer’s code No. A866X38282
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 5
Disassembly
7
5
6
9
8
060EY00004
Legend (6) Nut

(1) IC regulator (7) Side entry terminal
(2) Terminal stud (8) Terminal stud
(3) Side entry terminal (Terminal B) (9) Tube
(4) Rectifier assembly
(5) Cap
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 6
NOTE: Before disassembling alternator, be sure to put

match marks at two locations (front bracket and rear
1
bracket) so that any possible mistake can be avoided.
1. Remove four through bolts. Pry between stator and
front bracket with the blade of a screwdriver.
Carefully separate the front bracket, pulley and rotor
assembly away from the stator and rear bracket 2
assembly.
NOTE: Do not insert screwdriver too deep, or the stator
coil will be damaged.
2. Cramp the rotor in a vice, being careful not to distort
the rotor poles (1), and remove the pulley securing
nut, pulley, fan, spacer and front bracket.
NOTE: When a vice or tool is used to secure the rotor,
be sure to hold the location “A”. Do not hold the location
“B” as it does not have enough structural strength. 3
060EY00003
7. Remove the cap and nut from the terminal stud on

Ｂ the rectifier.
Pry between the rear bracket and side entry terminal,
and remove the side entry terminal.
The tube will remain in the bracket.
NOTE: Do not loss the tube.
8. Remove the rectifier retaining screw and two IC
regulator retaining screws.
Separate the stator and rectifier assemblies, as a
ＡＡ unit, from the rear bracket.
Then remove IC regulator.
1
9. Unsolder four stator coil leads and remove the stator
from the rectifier.
NOTE: High temperature solder (Melting point of 230°C)
060EY00030
is used to secure stator coil leads to rectifier terminals.
3. If necessary to remove the front bracket bearing, Disconnect quickly, use a 180 – 280 watts soldering iron
remove four retainer screws and press the bearing more than about 5 seconds because the diode may be
out of bracket with a suitable socket. damaged if it is overheated.
NOTE: Do not remove bearing for normal service. If the
bearing is removed, the bearing must be replaced.
4. If necessary to remove the rotor bearing, remove the
bearing with a normal bearing puller.
NOTE: Do not remove bearing for normal service. If
bearing is removed, the bearing must be replaced.
5. To move the coil assembly from the rear bracket;
first, remove two screws (2) that hold the terminal
plate of coil to the IC regulator.
If the screws (2) are removed before removing
screws (3) that hold the coil assembly to the rear
bracket, the terminal plate may be broken.
While being careful not to damage the terminal plate,
hold the coil assembly by hand.
Then, remove the coil assembly by removing the
screw (3).
6. Disconnect the connector (1).
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 7
Inspections and Repair Rotor

1. Check the bearing for any scraping noise,
Stator roughness, or grease leakage (If the amount of
Visually inspect the stator for damage, a loose grease leakage is very small, wipe it away.), and
connection, or discolored windings. replace it as necessary.
1. Check for continuity between each pair of the stator It is more effective to check with the bearing fitted
coil leads (1) using a circuit tester. into the rotor shaft than to check the bearing itself
Replace the stator if there is no continuity. (with no parts mounted).
Coil Assembly
1. Measure the coil resistance between both terminals
(1) on the terminal plate (2) using an ohmmeter.
If it is not within the specification, replace the coil
assembly.
1
060EY00007
2. Check for continuity between the stator coil leads

and core using a circuit tester.
Replace the stator if there is no continuity.
060EY00005
Rectifier Assembly
1 1. Check positive diodes and positive side additional
diode for continuity between the positive heat sink
(2) and each of four diodes terminals (1) with a circuit
tester.
If there is continuity in both directions, the diode is
shorted.
Replace the rectifier assembly.
2 If there is no continuity in both directions, the diode is
open-circuit.
2. Check negative diodes and negative side additional
diode for continuity between the negative heat sink
060EY00008 (3) and each of four diodes terminals (1) with a circuit
tester. If there is continuity in both directions, the
diode is shorted. Replace the rectifier assembly.
If there is no continuity in both directions, the diode is
open-circuit.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 8
3. Using a circuit tester, check the diode trio for 3. Tightening torque.
continuity in both directions. • Pulley securing nut. : 147 N·m
If there is either continuity or open circuit in both • Through bolts. : 5.1 N·m
directions, the diode trio is defective. • Bearing retainer screws. : 3.6 N·m
Replace the rectifier assembly. • Coil assembly retaining screws. : 3.6 N·m
• Rectifier retaining screw. : 3.6 N·m
• Regulator retaining screws. : 3.4 N·m
• Nut for stud bolt. : 8.8 N·m
1
4. To assemble the rear bracket / stator assembly and
front bracket / rotor assembly.
• Since the rotor bearing and rear bracket fitting is
tight, before installing the rotor into the rear
bracket assembly, heat the area around the
bearing box of the rear bracket to 50 to 60°C.
• After the alternator has been completely
assembled, rotate the pulley slowly by hand to be
sure that the rotor turns smoothly.
Bench Test
3
2
To check the alternator on a test bench, proceed as
follows:
060EY00006 Regulated Voltage Test

1. Make connections as shown in the illustration.
Front bracket bearing Use a 0 – 100 ampere scale ammeter and a 0 – 30
Check the bearing for any scraping noise, roughness, or volt scale voltmeter.
grease leakage (If the amount of leakage is very small, Use a variable load resistor of capacity 0 – 50
wipe it away.) and replace it as necessary. ampere minimum.
It is more effective to check with the bearing fitted into 2. Close switch 1. Open switch 2.
the front bracket than to check the bearing itself (with no Lamp should light. If the lamp does not light, check
parts mounted). voltage at terminal-L.
When the voltage is nearly to battery voltage, check
Regulator the alternator.
The regulator cannot be checked with a circuit tester. When the voltage is low, the lamp or relational wiring
After the alternator has been completely assembly, the is open circuit.
unit should be tested to make certain it will control the
3. Slowly increase the alternator speed.
alternator voltage properly.
Be sure the lamp goes out until the alternator speed
reaches to approx. 1300 min–1.
Reassembly Observe the voltage.
To reassemble the alternator, follow the reverse of If the voltage is uncontrolled with speed and
disassembling procedure, and observe the following increases above 30V, a defective IC regulator is
precautions: suspected.
1. Lubrication is not required. Both bearing are If the voltage does not increase higher than battery
prelubricated. voltage, this means alternator does not generate.
NOTE: For the rotor bearing with resin bands, grease Recheck the alternator.
should not be applied. Remove oils completely to 4. Increase the alternator speed to approx. 500 min–1
prevent creep of the bearing if found on the bearing box. and take the ammeter reading.
2. High temperature solder (Melting point of 230°C) If the ammeter reading is 5A or less, take the
should be used. voltmeter reading without changing the alternator
Solder quickly, use a 180 – 270 watts soldering iron speed (approx. 500 min–1).
no more than about 5 seconds because the rectifier The reading is the regulated voltage.
may be damaged if it is overheated.
If the ammeter reading is more than 5A, continue to
charge battery until the reading falls to less than 5A
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 9
or replace the battery with a fully charged one.

If the regulated voltage does not meet the specified
limits, it will have to be replaced.
AMMETER SWITCH 1
A
LAMP (24V) SWITCH 2

B (3W MAX.)
L
R
V ALTERNATOR BATTERY
(24V)
LOAD
VOLTMETER RESISTOR
Current Output Test

The current output test determines whether or not
alternator is capable of supplying its rated current
output.
1. After the regulated voltage test is completed, reduce
the alternator revolution.
2. Close the switch 1. Be sure the lamp lights.
3. Set the load resistor in maximum resistance value
position (Minimum current draw) and close the
switch 2.
4. Increase and hold the alternator speed to 5000 min–1
and adjust the load resistor to obtain maximum
current output.
Run the alternator for 15 minutes at this speed and
output to rise in the alternator temperature.
After 15 minutes rotate the alternator to specified
speed (2500 and 5000 min–1) and adjust the load
resistor to obtain maximum current output.
The output should be within the specified limits.
If the output is less than the specified limits, recheck
the alternator.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 10
Troubleshooting

No output Disconnected terminal connection Repair terminal connection
Open or short system circuit Repair the system circuit
Open field coil Replace the filed coil
Defective diode Replace the diode
Defective IC regulator Replace the regulator
Low output Loosened terminal connection Retighten the terminal connection
Loosened cooling fan belt Adjust the belt tension
Short field coil Replace the field coil
Short stator coil Replace the stator coil
Defective regulator Replace the regulator
Defective battery Replace the battery
Poor terminal contact Repair the terminal contact
Overcharging Defective regulator Replace the regulator
Defective battery Replace the battery
Unstable current Poor terminal contact Repair the terminal contact
Loosened cooling fan belt Adjust the belt tension
Short field coil Replace the field coil
Intermittent contact in wiring Repair the wiring
Poor terminal contact Repair the terminal contact
Defective regulator Replace the regulator
Abnormal noise Improper alternator installation Correct the installation
Defective bearing Replace the bearing
Contact between the rotor core and Replace the rotor core or stator core
stator core
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 11
Starter Motor
General Description
060EY00009
The starter motor adapts the planetary gears in

reduction gear mechanism.
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 12
Main Data and Specifiction
Isuzu Part No. 1-81100-3411

Mitsubishi code No. M009T80971
Rated voltage V 24
Rated output kW 7.0
Rating Sec 30
Direction of rotation Clockwise
(Viewed from the pinion side)
Terminal voltage (No. Load) V 23
Minimum current (No. Load) A 85
Starter motor minimum operating speed min–1 3300
(No. Load)
Pinion gear
Modules 3.5
Number of teeth 11
Outside diameter mm (in.) 48.9 (1.93)
Yoke outside diameter mm (in.) 105 (4.13)
Brush length
Standard mm (in.) 18 (0.71)
Limit mm (in.) 11 (0.43)
Brush spring standard fitting load N 29 – 39
Commutator
Outside diameter
Standard mm (in.) 32 (1.26)
Limit mm (in.) 31.4 (1.23)
Depth of undercut mica
Standard mm (in.) 0.5 (0.02)
Limit mm (in.) 0.2 (0.008)
Pinion projection
Standard mm (in.) 0.5 – 2.0 (0.0197 – 0.079)
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 13
Identification
MITSUBISHI starter motor is identified by the name
plate attached to the yoke. (Illustration)
(1) Manufacturer’s type
(2) Isuzu part number
(3) Bar code
NOTE: Always check the identification number before
beginning a service operation.
Applicable service data will vary according to the
identification number. Use of the wrong service data will
result in starter damage.
MITSUBISHI
ELECTRIC CORP, JAPAN 24V
TYPE 1
NO.
2
060EY00012
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 14
Disassembly
20
7
19
4
3
2
1
27
9
18
13
17
16
15
14
12 26
11
25
21
10 24
22
23
060EY00029
Legend (14) Gear shaft

(1) Snap ring (15) Planetary gear
(2) Stop ring (16) Ball
(3) Pinion (17) Gasekt
(4) Pinion spring (18) Plate
(5) Screw (19) Armature
(6) Pinion case (20) Bearing
(7) Bearing (21) Gasket
(8) Magnetic switch (22) Yoke
(9) Lever (23) Brush
(10) Clutch (24) Gasket
(11) Internal gear (25) Brush holder
(12) Washer (26) Rear cover
(13) E-type stop ring (27) Through bolt
51743/ESS-172/SEC6D3 2011.6.21 0:49 PM ページ 15
NOTE:
• When disassembling the starter motor, to make 5
reassembling easier, mark to match the magnetic
switch and yoke. 4
• First remove the pinion, or the pinion can not be
3
disassembled when proceeding disassembly without 6
disassembling the pinion. 2
1
1. Remove the pinion.
• Remove the pinion at the location travelling to
cranking position.
SW 1
SW 2 060EY00015
Legend
(1) Pinion
24 V
(2) Clutch shaft
(3) Snap ring
(4) Stop ring
(5) Pipe
(6) Pinion spring
2. Remove the magnetic switch.

3. Loosen the brush holder fixing screw and the
060EY00014
through bolt.
• Connect the starter motor to the battery. When Remove the rear bracket and gasket.
closing the switch SW1 and SW2, the pinion Discard the gasket.
travels to cranking position and the armature 4. Hold the socket (major diameter 32 mm) on the
rotates. Then opening the switch SW2, the armature commutator and remove the yoke
armature stops to rotate. assembly, sliding the brush onto the socket.
NOTE: Remove the pinion in 10 seconds as the • Removing this way makes reassembling easier.
armature generates heat with being energized. 5. Pull up the brush spring and remove the brush.
• Hold the suitable pipe on the stop ring. Hit the pipe 6. Remove the brush holder after removing the brush.
with a hammer, and remove and expose the stop
7. Pull out the armature from the planetary gear and
ring, then remove the snap ring, stop ring, pinion,
remove the bearing with a puller.
and pinion spring.
Be careful not to lose the ball.
Discard the snap ring.
8. Remove the plate and gasket.
9. Remove the planetary gears.
10. Put the internal gear, gear shaft overrunning clutch,
and lever together, then remove them from the front
bracket.
11. Remove the lever.
• Remember the lever installation direction.
12. Remove the E-type stop ring.
Then remove the overrunning clutch from the gear
shaft assembly.
Discard the E-type stop ring.
13. Remove the internal gear and washer for adjusting
the gear shaft end play together.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 16

Armature
1. Use a circuit tester to measure the armature for
continuity.
Step 1. Hold the circuit tester probes against two
commutator segments.
Step 2. Repeat step 1 at different segment of the
commutator.
There should be continuity between all segment of
the commutator.
3. Measure the commutator outside diameter.

If the measurement is less than limit, replace the
commutator assembly.
Standard: 32 mm
Limit: 31.4 mm
2. Use a circuit tester to measure the armature for

grounding.
Step 1. Hold one probe of the circuit tester against
the commutator segment.
Step 2. Hold the other probe of the circuit tester
against the armature shaft.
If the circuit tester indicates continuity, the armature
is grounded, replace the armature assembly.
4. Inspect the commutator mica segment for excessive

wear.
If the mica segment depth is less than the limit,
replace the commutator.
Measure the mica segment depth.
Standard: 0.5 mm
Limit: 0.2 mm
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 17
060EY00016 060EY00017
5. Inspect the gear for damage or wear.

Replace the armature if any damage is discovered. Brush and Brush Holder
6. Inspect the bearing for abnormal noise, rattling or 1. Measure the brush length.
grease leakage. If the measured value exceeds the limit, replace the
Replace the bearing if any malfunction is discovered. brush and/or yoke.
Standard: 18 mm
Limit: 11 mm
Field Coil 2. Visually check the brush spring for weakness and
1. Use a circuit tester to check for any broken winding. rusting.
A broken wire is indicated if no continuity is found Replace the brush spring if it is weak or rusted.
between the field coil and lead wire. Use a spring balancer to measure the spring tension.
Replace the field coil. If the measured value exceeds the limit, replace the
brush spring.
Standard: 29 – 39 N
Limit: 13.7 N
3. Use a circuit tester to check the brush holder
insulation.
• Touch one probe the field winding lead wire.
• Touch the other probe to the brush.
There should be no continuity.
If continuity is found, repair or replace the brush
holder.
060EY00018
2. Check for continuity between the field coil and the

yoke.
Repair or replace the yoke assembly if continuity is
found.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 18
Front Bracket
Check the bearing and oil seal for damage.
Replace the front bracket assembly if the malfunction is
found.
Internal Gear and Planetary Gear

Check for the gear for abnormal wear or damage.
Replace the gear if the malfunction is found.
Magnetic Switch
Check for continuity across the magnetic switch
terminal-M (1) and body. If no continuity is found,
replace the magnetic switch.
Check for continuity across the magnetic switch
terminal-M and terminal-B (3). If continuity is found,
replace the magnetic switch.
060EY00019
Overrunning Clutch and Pinion 2
Check the pinion teeth for excessive wear and damage.

Rotate the pinion in the drive direction of starter motor.
The pinion should rotate smoothly. Rotate the pinion in
the opposite direction. The pinion should lock.
Replace the overrunning clutch, if any malfunction is
discovered.
NOTE: The inside of the overrunning clutch is filled with
grease.
Do not soak in any liquid cleaner or solvent because 1 3
grease leakages may result.
Wipe the dirt of the overrunning clutch with a clean rag.
060EY00021
Reassembly
To reassemble the starter motor, follow the reverse of
disassembling procedure, and observe the following
precautions:
1. Lubricate the following portion:
• Surrounding armature bearing (1) : a little
• Plunger (2) : a little
• Gear shaft spline and sliding part (3)
• Clutch shaft (4)
• Oil seal (5)
• Pinion of overrunning clutch (6)
• Sliding part of lever with overrunning clutch (7)
060EY00020
• Sleeve bearing and ball (8)
• Armature shaft gear, internal gear and planetary
gears (9)
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 19
Recommended lubricant type:

Portion (1) to (6) : MUL TEMP OA–171 or equivalent
Portion (7) to (9) : Molycoat R AG650 or equivalent
(Dow Corning)
5
6
1
9 8 7
060EY00010
2. Tightening torque
Nut (1) : 20 – 26 N·m
Bolt (2) : 4.9 – 8.8 N·m
Bolt (3) : 7.8 – 13 N·m
Bolt (4) : 2.4 – 4.4 N·m
1 2
060EY00031
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 20
3. Armature shaft axial play

Any adjustment is not required.
Install the ball to the top of the armature shaft.
4
4. Gear shaft axial play
Any adjustment is not required. 3 5
Install the washer between the internal gear and 2
gear shaft. 1
060EY00023
4 6. Inspect the projection position of the pinion.

• After reassembling the starter motor, inspect the
2 projection position of the pinion.
1 Projection position: 0.5 to 2 mm
060EY00022
Legend
(1) Overrunning clutch
SW 1 B
(2) Internal gear
S SW 2
(3) Washer
M
(4) E-type stop ring
(5) Gear shaft 24 V
Install the washer, internal gear and overrunning clutch

to the gear shaft.
Then install the E-type stop ring.
5. Install the pinion to the clutch shaft.
• Install the pinion spring (5), pinion (1), and stop
ring (4) in sequence to the clutch shaft (2).
• Install the snap ring (3) finally.
• Then put the stop ring on the snap ring in place.
060EY00024
• Connect the starter motor to the battery.

When the switch (1) and (2) are turned on, the
pinion will travel forward to the cranking position.
At this time, the armature will rotate.
Next, stop to rotate the armature with the switch
(2) turned off.
• Lightly push the head of overrunning clutch shaft
by hand and measure the movement (return) of
the clutch shaft.
If the value is within 0.5 – 2.0 mm, it is the normal
position. If it is outside the limit, adjust the packing
(0.5 mm ) between the front bracket and magnetic
switch, or replace the lever.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 21
060EY00025
7. Conduct the performance test.

• Connect the starter motor as shown in the
illustration.
A SW B
S
1
M
3
V
060EY00026
Legend
(1) Battery
(2) Amperemeter
(3) Voltmeter
• Measure the speed, current and voltage with the

switch turned on.
If the value is outside the limit, disassemble and
inspect.
51743/ESS-172/SEC6D3 2011.6.21 0:50 PM ページ 22
MEMO
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 1
ENGINE LUBRICATION 6G–1
ENGINE LUBRICATION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6G-1 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-12
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6G-2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-12
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-4 Inspection and Repair . . . . . . . . . . . . . . . . . . . . 6G-13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-14
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6G-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G-9
Service precaution
systems.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 2
6G–2 ENGINE LUBRICATION
General Description
Lubricating Oil Flow
Lubrication system is of pressure feed circulation
system with a gear type oil pump driven by crankshaft.
Oil flows from the oil pump though oil cooler to main oil
filter for oil cooling and oil cleaning.
From the main oil filter it moves to the cylinder block oil
gallery and the oil circulates to lubricates the engine
parts.
Oil jets are installed to the cylinder block main oil gallery
in the inside portion of the cylinder block.
The jet sprays oil to the inside portions of the pistons for
lubrication and cooling.
Oil Pump and Oil Filter

The oil pump is of a gear type with a relief valve. The
pump is driven by the timing gear.
A full flow main oil filter with a highly efficient paper
element used.
Should the element become clogged with sludge or
other foreign material, a by-pass valve open to route the
oil directly to the oil gallery.
A warning lamp will light at this time to warn the operator
of the equipment the oil directly to the oil gallery.
The oil is cleaned and delivered to the oil pan.
Oil Cooler
The temperature of the engine oil circulating through the
lubricating system tends to rise with an accompanying
decrease in lubricating efficiency.
The oil cooler maintains the oil temperature at the
optimum level for effective engine lubrication.
The oil cooler consists of the body and the cooling
element.
LUBRICANT FLOW CHART
CYLINDER BODY
CYLINDER BODY LEFT HAND OIL GALLERY
RIGHT HAND OIL GALLERY
REMOTE OIL PRESS.

TYPE UNIT & TIMING
CYLINDER HEAD INJECTION
OIL FILTER SWITCH GEAR PUMP
OILING JET
2
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 3
TURBO
OIL FILTER CHARGER
RELIEF OIL PORT
VALVE COVER
CAMSHAFT IDLE IDLE COUPLING
JOURNAL IDLE GEAR OILING JET GEAR GEAR or
(No2 & 5) "A" "B" "C" AIR COMPRESSOR
ROCKER
RELIEF
OIL ARM CRANKSHAFT
VALVE
COOLER SHAFT JOURNAL
4
OIL CAMSHAFT ROCKER

THERMOVALVE JOURNAL ARM & CRANKPIN
(No1,3,4,6) VALVE
CONNECTING
1 ROD
OIL BUSHING
PUMP RELIEF
VALVE
STRAINER OIL PAN

Relief valve opening pressure kPa (kg/cm2/psi) 4 Oil thermostat opening temperature °C (°F) 98 (208)
ENGINE LUBRICATION
1 690 (7.0/99.5)
2 200 (2.0/28.4)
3 440 (4.5/64.0)
F06EY00033
6G–3
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 4
Oil Pump
Oil Pump Construction
8 9
2
11 10
051EY00026
Legend (7) Oil pump cover

(1) Oil pump body (8) Relief valve
(2) Oil pump driven gear (9) Split pin
(3) Ball (10) Spring seat
(4) Driven gear (11) Spring
(5) Drive gear
(6) Driven gear
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 5
Disassembly
2
8
5 9
3
4
11
7 10
Legend (7) Oil pump drive gear

(1) Cover (8) Oil pump cover
(2) Ball (9) Oil pump driven gear
(3) Split pin (10) Drive gear shaft
(4) Spring seat (11) Oil pump body
(5) Spring
(6) Oil relief valve
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 6
1. Loosen bolts to remove the cover 5. Loosen the fixing bolts to remove the oil pump cover.
2. Take out the ball from the oil pump assembly.
3. Remove the split pin, spring seat, spring and oil relief
valve.
6. Take out the oil pump driven gears and drive gear
shaft from oil pump body.
4. Use a gear puller to pull out the oil pump drive gear.

Ball
Carefully inspect the ball scratches or damage.
Oil Relief Valve

Inspect the oil relief valve seat portion damage and
spring damage.
NOTE: If there is some scratch or damage, the ball and
relief valve must be replaced.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 7
Clearance Between Oil Pump Body and Oil Pump Gear Shaft Outside Diameter and
Driven Gear Clearance between Oil Pump Gear Shaft
Use a feeler gauge to measure the clearance between and Oil Pump Body
the oil pump body and driven gear. Use an inside and outside micrometer to measure the oil
Standard: 0.050 – 0.098 mm (0.0020 – 0.0039 in.) pump gear shaft outside diameter and oil pump body
Limit: 0.15 mm (0.0059 in.) holes.
Oil pump gear shaft diameter
Nominal measurement: 20.0 mm (0.7874 in.)
Limit: 19.9 mm (0.7835 in.)
Clearance between oil pump gear shaft and oil
pump body
Standard: 0.040 – 0.074 mm (0.0016 – 0.0029 in.)
NOTE: If measuring value exceeds, the parts must be
replaced.
Side Clearance Between Oil Pump Cover

and Gears
Use a feeler gauge to measure the side clearance
between the oil pump cover and gears.
Standard: 0.040 – 0.094 mm (0.0016 – 0.0037 in.)
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 8
Interference between Oil Pump Drive Gear

and Drive Gear Shaft
Measure the inside diameter of oil pump drive gear and
outside diameter of drive gear shaft.
An interference
Standard: 0.019 – 0.047 mm (0.0007 – 0.0019 in.)
NOTE: The measuring value exceeds from limit or
standard, the parts must be replaced.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 9
Reassembly
2
8
5 9
3
4
11
7 10
Legend (7) Oil pump drive gear

(1) Cover (8) Oil pump cover
(2) Ball (9) Oil pump driven gear
(3) Split pin (10) Drive gear shaft
(4) Spring seat (11) Oil pump body
(5) Spring
(6) Oil relief valve
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 10
1. Apply engine oil to the drive gear (1) and install the 4. Install the oil pump cover.
drive gear to the oil pump body. Tighten the bolts to the specified torque.
2. Install the oil pump drive gear (2). Torque:
• Put the oil pump drive gear (2) on the bed of bench M8: 17 N·m (1.8 kgm)
press, place the oil pump body with the drive gear
M10: 39 N·m (4.0 kgm)
shaft.
• Use bench press to press the drive gear shaft into
the oil pump drive gear as shown in the illustration.
5. Install the oil relief valve, spring and spring seat to

051EY00027 the oil pump body.
6. Install the split pin into the oil pump body and lock it.
3. Install the oil pump driven gear.
7. Install the ball
• Apply engine oil and install the oil pump driven
gear to the oil pump body. 8. Install the cover
051EY00028
NOTE: Make sure the oil pump assembly to move

smoothly.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 11

69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 12
Oil Cooler
Disassembly
2
11
10
9
8
4
3 7
Legend (7) Oil thermostat

(1) Water guide (8) Spacer
(2) Oil cooler element (9) Supporter
(3) Gasket (10) Seal ring
(4) Gasket (11) Oil cooler body
(5) Oil pipe
(6) Gasket
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 13
1. Loosen the bolts to remove the water guide. Inspection and Repair
2. Loose the nuts to remove the oil cooler element with
the gaskets. Make the necessary adjustments, repairs and part
3. Loosen the bolts to remove the oil pipe with the
gasket.
Oil Cooler Element
Inspect the oil cooler element for cracking or damage.
4. Carefully remove the oil thermostat.
Oil Thermostat
1. Inspect for wear or damage on the piston and valve
seat.
2. Check for damage or decrease of the spring force.
3. Inspect opening temperature with oil heater.
Opening temperature: 98.0°C (208.4°F)
5. Remove the spacer, supporter and seal ring from the

oil cooler body.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 14
Reassembly
2
11
10
9
8
4
3 7
Legend (7) Oil thermostat

(1) Water guide (8) Spacer
(2) Oil cooler element (9) Supporter
(3) Gasket (10) Seal ring
(4) Gasket (11) Oil cooler body
(5) Oil pipe
(6) Gasket
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 15
1. Be sure seal ring direction shown in the illustration.
050EY00020
Legend 5. Install the oil cooler element with new gaskets.

(1) Seal ring • Apply Three Bond 1208 to grooves to install the
(2) Rotation stopper gaskets.
(3) Supporter • Install the gaskets to the oil cooler element.
• Reassemble the oil cooler element to the oil cooler
2. Install the supporter into the oil cooler body. body.
• Align the rotation stopper (2) on the supporter to • Tighten the fixing nuts for oil cooler element to the
the oil cooler body as shown in the illustration. specified torque.
050EY00021
050EY00022
3. Install the spacer and oil thermostat into the oil

cooler body. 6. Install the water guide.
4. Install the oil pipe to the oil cooler body.
• Install the oil pipe with new gasket to the oil cooler
body.
• Tighten the oil pipe to the specified torque.
69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 16
MEMO
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 1
ENGINE INDUCTION 6J–1
ENGINE INDUCTION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . . . . 6J-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-4
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-2 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . 6J-5
General Description . . . . . . . . . . . . . . . . . . . . . . . 6J-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J-7
Service precaution
systems.
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 2
6J–2 ENGINE INDUCTION
Turbocharger
General Description
037EY00003
Major turbocharger components consist of the Center The turbocharger increases air intake efficiency, the
Housing and Rotating Assembly (CHRA), the results in increased engine power, reduced fuel
compressor housing, and the turbine housing. consumption and minimal engine noise.
Rotating parts include the turbine shaft, the compressor Turbocharger rotating parts operate at very high speeds
wheel, the shaft bearings, the thrust bearings and the oil and temperatures. The parts materials have been
seal ring. There parts are supported by the center carefully selected and machined to extremely high
housing. precision.
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 3
Identification Turbocharger Servicing

The turbocharger name plate gives the date of 1. Refer to TROUBLESHOOTING in this Manual to
manufacturer and other important information required determine whether or not turbocharger repair or
to identify the unit when service inquiries are made. overhaul is required.
The turbocharger name plate has the following 2. The following procedures should also be performed
information stamped on it. Refer to the illustration. (either with the turbocharger on the equipment or
(1) Turbocharger specification, production year and removed form the equipment but not disassembled)
production month. to determine whether or not turbocharger repair or
Example: VIBU overhaul is required.
(2) Production date, serial number and production line * Visual checks
name. * Clearance measurements
Example: RHC92 * End play measurements
(3) Part number assigned is ISUZU MOTORS LIMITED. Refer to INSPECTION AND REPAIR.
Example: 1144003281 3. The turbocharger compressor and turbine housing
Part numbers (3) indicate specific designs or may be removed from the center housing and
configurations. rotating assembly (CHRA) for further visual
inspection.
Refer to DISASSEMBLY and REASSEMBLY.
Precaution
Turbocharger servicing requires great care and
Name plate example expertise.
Faulty turbocharger servicing procedures can result in
Turbo Spec. 1 serious damage to pistons, valves, cylinder liners, and
other important engine parts.
Serial No.RHC9 2 ISUZU does not recommended the performance of any
servicing procedure not specified described in this
Parts No. 3
Manual.
Contact your nearest IHI service facility to have the
turbocharger assembly repaired or overhauled.
The identification plate and assembly number will be
required by the service facility.
A list of IHI Turbocharger Service Network locations is
given at the end of this Section.
037EY00010
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 4
Disassembly
3
4
036HT001
Legend (4) Compressor housing

(1) Lock plate and bolt (5) Center housing and rotating assembly
(2) Turbine housing
(3) Lock plate and bolt
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 5
1. Remove the lock plate and bolt. Take care not to allow foreign material to enter the
Apply a setting mark across the center housing and center housing.
rotating assembly (1), the turbine housing (2), and NOTE: Disassembly and servicing of the center housing
the compressor housing (3). and rotating assembly is not recommended.

Make the necessary adjustment, repairs, and part
3
Minor servicing operations are described in this Section.
Contact the nearest IHI SERVICE FACILITY for major
1 repairs and maintenance.
Refer to IHI SERVICE NETWORK at the end of this
Section for the location of your area’s IHI SERVICE
FACILITY.
2 Turbine shaft End Play

1. Set a dial indictor to the turbine shaft end.
2. Apply a force of 11.7 N (1.2 kg/2.6 lb) alternately to
the compressor wheel end and the the turbine wheel
end.
037EY00005
3. Read the dial indicator.
Turbine shaft end play
Standard: 0.075 – 0.110 mm (0.0030 – 0.0043 in.)
Limit: 0.12 mm (0.0047 in.)
037EY00006
2. Remove the turbine housing.

3. Remove the lock plate and bolt.
4. Remove the compressor housing.
5. Remove the center housing and rotating assembly.
• Loosen the lock plate bolts. Turbine Shaft Bearing Clearance
• Disassembly the parts. Due to the unique location of the center housing casting
Handle the parts with extreme care. internal opening, access to the shaft wheel is difficult. To
check the turbine shaft and bearing clearance, a special
Be particularly careful not to damage the turbine
gauge arm assembly must be fabricated for use with a
wheel blades and the compressor wheel blades.
dial gauge.
The assembly can be constructed from any conveniently
available material. However, it must conform to the
dimensions shown in the illustration.
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 6
1. Pass the gauge arm assembly through the oil outlet

port and the casting internal opening.
The curved end of the gauge arm assembly must
make contact with the wheel shaft.
037EY00007
2. Set the dial gauge to “0”.

3. Grasp both ends of the shaft at the wheel hubs.
Move the shaft gently back and forth in a motion that
is parallel to the plane of the oil drain flange face.
Note the dial gauge reading.
If the dial gauge reading is above or below the
standard range, the center housing and rotating
assembly must be replaced.
Standard: 0.130 – 0.235 mm (0.0051 – 0.0093 in.)
Limit: 0.275 mm (0.0108 in.)
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 7
Reassembly
3
4
036HT001
Legend (4) Compressor housing

(1) Lock plate and bolt (5) Center housing and rotating assembly
(2) Turbine housing
(3) Lock plate and bolt
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 8
1. Install the center housing and rotating assembly to

the compressor housing.
• Apply Threebond 1215 or equivalent to the flange
surface of compressor houisng shown in the
illustration.
037EY00006
2. Install the turbine housing.

• Align the setting marks (applied at disassembly)
on the center housing and rotating assembly and
the turbine housing.
037EY00008 Handle the parts with extreme care to avoid
• Align the setting marks (applied at disassembly) damaging the turbine shaft wheel blades.
on the center housing and rotating assembly and • Apply an anti-seizing agent (LOCTITE
the compressor housing. ANTISEIZE LUBRICANT or equivalent) to the
Handle the parts with extreme care to avoid bolt.
damaging the compressor wheel blades. • Tighten the bolt to the specified torque.
• Apply an anti-seizing agent (LOCTITE Torque: 28 N·m (2.85 kgm)
ANTISEIZE LUBRICANT or equivalent) to the • Check that the rotating assembly turns smoothly.
new bolt threads or the V-band threads.
• Install the new lock plate and bolts to the
compressor housing.
3
037EY00005
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 9
IHI SERVICE NETWORK

For inquiries relating to turbochargers, please contact you ISUZU distributor or the nearest IHI Turbocharger Service
Facility.
HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD. (IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430
CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s Republic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN
TAIWAN
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(3)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX: 11320 IHICO
THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL: 66-(2)-236-2390, 7356, 9099
FAX: 66-(2)-236-7340
TLX: 82375 IHICO TH
MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALYASIA
TEL: 60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX: IHI KLMA 20257
INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI, M.H. Thamrin, No. 9, Jakarta, INDONESIA
TEL: 62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX: 44175 IHIJKT
69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 10
MEMO
MEMO
MEMO
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:
FAX: (Located at the bottom center in the page. If two or more revisions
are requested, use the comment column)
E-mail:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

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PART NO.

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

Quantity To Convert From Into Multiply By

fNOTE: The numerical value in this manual might be

Symbol / Name Explanation

Symbol / Name Explanation

Recognize Safety Information

Understand Signal Words

 CAUTION also calls attention to safety message in this

 NOTE: indicates an additional explanation for an

Follow Safety Instructions

Wear Protective Clothing

You may need:

Protect Against Noise

Use Handholds and Steps

Adjust the Operator's Seat

Fasten Your Seat Belt

Move and Operate Machine Safely

Operate Only from Operator's Seat

Keep Riders off Machine

Precautions for Operations

Investigate Job Site Beforehand

Install OPG Guard

ROPS: Roll Over Protective Structure

Provide Signals for Jobs Involving Multiple

Confirm Direction of Machine to Be Driven

Drive Machine Safely

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

Avoid Injury from Rollaway Accidents

Avoid Injury from Back-Over and Swing

Keep Person Clear from Working Area

Never Position Bucket Over Anyone

 Be careful when working on frozen ground.

Never Undercut a High Bank

Dig with Caution

Operate with Caution

Avoid Power Lines

Precautions for Lightning

Protect Against Flying Debris

Park Machine Safely

Handle Fluids Safely−Avoid Fires

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

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

Be sure to further follow the details described in the

Practice Safe Maintenance

Before servicing the machine:

7. Remove the key from the key switch.

 If a maintenance procedure must be performed with the

Warn Others of Service Work

Support Machine Properly

Stay Clear of Moving Parts

Prevent Parts from Flying

 Travel reduction gears are under pressure.

Store Attachments Safely

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

Hot fluids and surfaces:

Replace Rubber Hoses Periodically

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

Avoid High-Pressure Fluids

Check Key Switch:

Check Heat Shields:

 Damaged or missing heat shields must be repaired or

Evacuating in Case of Fire

Beware of Exhaust Fumes