INTRODUCTION

TO THE READER

• This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
• Be sure to thoroughly read this manual for cor-
rect product information and service procedures.
• If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
ual.
(Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162

ADDITIONAL REFERENCES

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

MANUAL COMPOSITION

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

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

PAGE NUMBER
• Each page has a number, located on the center
lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

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

IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS

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

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

UNITS USED

• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

IN-02
 SAFETY

RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.

001-E01A-0001

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 spe-
cific hazards. General precautions are listed on CAUTION
safety signs.
• Some safety signs don’t use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.

• To avoid confusing machine protection with personal safety

messages, a signal word IMPORTANT indicates a situation
which, if not avoided, could result in damage to the ma- SA-1223
chine.

• NOTE indicates an additional explanation for an element

of information.

002-E01A-1223

SA-1
 SAFETY

FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
• Safety signs should be installed, maintained and replaced
when necessary.
• If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
• Learn how to operate the machine and its controls correctly
and safely.
• Allow only trained, qualified, authorized personnel to oper- SA-003
ate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, func-
tion, 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 equip-
ment 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 hazard-
ous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your autho-
rized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003

SA-2
 SAFETY

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label 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,
SA-437
hospital, and fire department posted near your tele-
phone.
004-E01A-0437

WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment appropri-
ate to the job.

You may need:

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

• Avoid wearing loose clothing, jewelry, or other items that

can catch on control levers or other parts of the machine.
• Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
005-E01A-0438

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment or
loss of hearing.
• Wear a suitable hearing protective device such as ear-
muffs or earplugs to protect against objectionable or
uncomfortably loud noises.

006-E01A-0434
SA-434

SA-3
 SAFETY

INSPECT MACHINE
• Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
• In the walk-around inspection be sure to cover all points
described in the “PRE-START INSPECTION” chapter in the
operator’s manual.

007-E01A-0435 SA-435

GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots the operator’s foot
may slip off the pedal, possibly resulting in a personal ac-
cident.
• Do not leave parts and/or tools lying around the operator’
s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not at-
tach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly start-
ing a fire.
• Refrain from listening to the radio, or using music head-
phones or mobile telephones in the cab while operating
the machine.
• Keep all flammable objects and/or explosives away from
the machine.
• After using the ashtray, always cover it to extinguish the
match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the tem-
perature in the cab increases, the lighter may explode.

524-E01A-0000

SA-4
 SAFETY

USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or dis-
mount a moving machine.
• Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.

SA-439
008-E01A-0439

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
• The seat should be adjusted whenever changing the op-
erator 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
SA-378
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.

009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAV-

ING 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, 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.

SA-5
 SAFETY

FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the opera-
tor may be crushed by the overturning machine, resulting in
serious injury or death.
• Prior to operating the machine, thoroughly examine web-
bing, buckle and attaching hardware. If any item is dam-
aged 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
minimize the chance of injury from an accident. SA-237

• We recommend that the seat belt be replaced every three

years regardless of its apparent condition.

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or oper-
ating the machine.
• Always keep the travel alarm and horn in working condi-
tion (if equipped). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine. SA-083
• Use appropriate illumination. Check that all lights are op-
erable before operating the machine. If any faulty illumi-
nation is present, immediately repair it.

011-E01A-0398

HANDLE STARTING AIDS SAFELY

Starting fluid:

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not need
starting fluid.
• To prevent accidental discharge when storing a pressur-
ized container, keep the cap on the container, and store it
in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
SA-293

036-E01A-0293-3

SA-6
 SAFETY

OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
• Start the engine only when seated in the operator's seat.
• NEVER start the engine while standing on the track or on
ground.
• Do not start engine by shorting across starter 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-084

012-E01B-0431

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” chap-
ter 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

S013-E01A-0032

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
• Only the operator should be on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.

014-E01B-0427

SA-091

SA-7
 SAFETY

PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety equip-
ment 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.

M202-05-014

SA-8
 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 fall-
ing 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 excava-
tions and road shoulders.
• When working on an incline or on a road shoulder, em- SA-085
ploy a signal person as required.
• Confirm that your machine is equipped 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.
• Make sure the worksite has sufficient strength to firmly sup-
port the machine.
When working close to an excavation or at road shoulders,
operate the machine with the tracks positioned perpendicu-
lar 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 a soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm M202-05-015
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
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 ma-
chine movements.

SA-9
 SAFETY

EQUIPMENT OF HEAD GUARD, ROPS, FOPS

In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)

ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure

SA-686

PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

TIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines, provide
signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s directions.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN

• Incorrect steering wheel/forward/reverse pedal operation
may result in serious injury death.
• Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when steering wheel is operated to
the front.

SA-092
017-E01A-0491

SA-10
 SAFETY

DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the steer-
ing wheel/forward/reverse switch 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
not allow personnel to stay around the machine while
traveling.

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

SA-090
turn, possibly resulting in serious injury or death.
• Never attempt to ascend or descend 35 degrees or steep-
er slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket fac-
ing the direction of travel, approximately 0.5 to 1.0 m (A)
above the ground.
• If the machine starts to skid or becomes unstable, imme-
diately lower the bucket to the ground and stop.

SA-288

AVOID INJURY FROM ROLLAWAY ACCIDENTS

• Death or serious injury may result if you attempt to mount
or stop a moving machine.

To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the ground.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 5 min-
utes to cool down the engine.
• Stop the engine and remove the key from the key switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tires and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
SA-278
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.

020-E02A-0493

SA-11
 SAFETY

AVOID INJURY FROM BACK-OVER AND SWING

ACCIDENTS
• If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
• Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
• Keep the travel alarm in working condition (if 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 SA-383
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW.
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman 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 con-
dition.
• Dust, heavy rain, fog, etc., can reduce visibility. As visibility SA-384

decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the
operator’s manual.

021-E01A-0494

SA-12
 SAFETY
KEEP PERSON CLEAR FROM WORKING AREA
• A person may be hit severely by the swinging front attach-
ment 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 any-
one from entering the work area.

022-E01A-0386

M202-05-014

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.

023-E01A-0487 SA-682

AVOID UNDERCUTTING
• Always confirm that ground conditions are strong enough
to support the machine weight when operating near a cliff.
Operate the machine with the chassis frame positioned
perpendicular to the cliff face so that the machine can more
easily evacuate if the cliff face collapses.
• If the footing starts to collapse and if retreat is not pos-
sible, do not panic. Often, the machine can be secured by
lowering the front attachment, in such cases.

024-E01A-0488 SA-683

SA-13
 SAFETY

AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA-
CHINE---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 ma-
SA-088
chine.
• 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.

025-E03B-0463
SA-684

NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur causing
serious injury or death.

026-E01A-0519

SA-685

SA-14
 SAFETY

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.
Have them mark all underground utilities. SA-086

027-E01A-0382

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.

028-E01A-0389 SA-087

SA-15
 SAFETY

AVOID POWER LINES

• Serious injury or death can result if the machine or front at-
tachments 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 ap-
ply.
• 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-089
029-E01A-0381

PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately stop op-
eration, 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 repair-
ing them.

SA-1241

OBJECT HANDLING
• If a lifted load should fall, any person nearby may be struck
by the falling load or may be crushed underneath it, result-
ing 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 sud-
denly.
• 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.

032-E01A-0132
SA-014

SA-16
 SAFETY

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body, serious
injury may result.
• Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
• Keep bystanders away from the working area before strik-
ing any object.

031-E01A-0432

SA-432

PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn auto-idle switch OFF.
• Run engine at slow idle speed without load for 5 minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK position. SA-093

• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.

HANDLE FLUIDS SAFELY−AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and/or a fire may occur, possibly resulting in
serious injury or death.
• Do not refuel the machine while smoking or when near
open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are flammable.

SA-018
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spontane-
ously.
• Securely tighten the fuel and oil filler cap.

034-E01A-0496

SA-019

SA-17
 SAFETY

TRANSPORT SAFELY
• Take care the machine may turn over when loading or un-
loading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe trans-
portation.
• 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:
Less than 15°
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the SA-094
machine weight.
3. Turn auto-idle switch OFF.
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 travel-
ing 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 Less than 15°
sudden bump. Take care when traveling over it.
SA-095
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 TRANS-

PORTING section.

035-E07A-0454

SA-18
 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 min-
utes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving SA-028
the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.

• If a maintenance procedure must be performed with the

engine running, do not leave machine unattended.
• If the machine must be raised, maintain a 90 to 100˚ angle
between the boom and arm. Securely support any ma-
chine 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 SA-527
“MAINTENANCE” chapter in the operator’s manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable 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.

500-E02C-0520

SA-19
 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.

501-E01A-0287
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 sup-
port 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

519-E01A-0527

STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.

502-E01A-0026
SA-026

SA-20
 SAFETY

PREVENT PARTS FROM FLYING

• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.

503-E01B-0344
SA-344

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
• Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.

504-E01A-0034 SA-034

SUPPORT MAINTENANCE PROPERLY

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

521-E02A-0249

SA-21
 SAFETY

PREVENT BURNS
Hot spraying fluids:

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

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
• To avoid possible injury from hot spraying water. DO NOT
remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all pres-
sure to be released before removing the cap.
SA-039
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.

Hot fluids and surfaces:

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

SA-225
505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

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

• 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.

S506-E01A-0019

SA-22
 SAFETY

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
• Avoid this hazard by relieving pressure before disconnect-
ing 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 skin
SA-031
must be surgically removed within a few hours or gan-
grene may result.

507-E03A-0499

SA-292

SA-044

SA-23
 SAFETY

PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or hoses.

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..

Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine
daily and by removing spilled or accumulated flammables
immediately.

Check Key Switch:

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

508-E02B-0019

Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be repaired or
replaced before operating the machine.

508-E02A-0393

SA-24
 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. SA-393
Refer the explanation pages on the Emergency Evacuation
Method.

18-E02B-0393

SS-1510

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause sick-
ness or death.
• If you must operate in a building, be sure there is ad-
equate ventilation. Either use an exhaust pipe extension
to remove the exhaust fumes or open doors and windows
to bring enough outside air into the area.

509-E01A-0016

SA-016

PRECAUTIONS FOR WELDING AND GRINDING

• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated and pre-
pared 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

523-E01A-0818

SA-25
 SAFETY

AVOID HEATING NEAR PRESSURIZED FLUID LINES

• Flammable spray can be generated by heating near pres-
surized 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..

AVOID APPLYING HEAT TO LINES CONTAINING SA-030

FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain flam-
mable fluids.
• Clean them thoroughly with nonflammable solvent be-
fore welding or flame cutting them.

510-E01B-0030

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. Dis-
pose 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.

511-E01A-0029

SA-26
 SAFETY

BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work site. Inha-
lation of asbestos fibers may be the cause of lung cancer.
• Depending on the wok site conditions, the risk of inhaling
asbestos fiber may exist. Spray water to prevent asbestos
from becoming airborne. Do not use compressed air.
• When operating the machine in a work site where asbes-
tos might be present, be sure to operate the machine
from the upwind side and wear a mask rated to prevent
the inhalation of asbestos.
• Keep bystanders out of the work site during operation.
• Asbestos might be present in imitation parts. Use only SA-029
genuine Hitachi Parts.

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 elec-
trolyte level is lower than specified. Explosion of the bat-
tery may result.
• Loose terminals may produce sparks. Securely tighten all SA-032
terminals.

• Battery electrolyte is poisonous. If the battery should ex-

plode, battery electrolyte may be splashed into eyes, pos-
sibly resulting in blindness.
• Be sure to wear eye protection when checking electrolyte
specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM SAFELY

• If spilled onto skin, refrigerant may cause a cold contact
burn.
• Refer to the 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.

513-E01A-0405
SA-405

SA-27
 SAFETY

HANDLE CHEMICAL PRODUCTS SAFELY

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

515-E01A-0309

DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the environ-
ment 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
may require a certified air conditioning service center to SA-226

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.

516-E01A-0226

SA-28
 SAFETY

BEFORE RETURNING THE MACHINE TO THE CUS-

TOMER
• After maintenance or repair work is complete, confirm that:
• The machine is functioning properly, especially the safety
systems.
• Worn or damaged parts have been repaired or replaced

S517-E01A-0435

SA-435

SA-29
 SAFETY
(Blank)

SA-30
 SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil Tank
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
WORKSHOP MANUAL Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Electric Lever
Group 9 Signal Control Valve
Group 10 Shockless Valve
Group 11 Solenoid Valve
Group 12 Pilot Shut-Off Solenoid Valve
Group 13 Steering Valve
Group 14 Brake Valve
Group 15 Accumulator Charging Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Motor
Group 3 Center Joint
Group 4 Transmission
All information, illustrations and speci-
fications in this manual are based on Group 5 Axle
the latest product information available Group 6 Axle Lock Cylinder
at the time of publication. The right is
reserved to make changes at any time Group 7 Operate-Check Valve
without notice.
Group 8 Solenoid Valve
Group 9 Transmission Changeover Solenoid Valve
Group 10 Propeller Shaft
SECTION 4 FRONT ATTACHMENT
COPYRIGHT(C)2007
Hitachi Construction Machinery Co., Ltd.
Group 1 Front Attachment
Tokyo, Japan
Group 2 Cylinder
All rights reserved
Group 3 Hose-Rupture Valve
Group 4 Operate-Check Valve
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Controller Group 5 Electric Lever
Group 2 Control System Group 6 Transmission
Group 3 ECM System Group 7 Axle
Group 4 Hydraulic System Group 8 Travel Motor
Group 5 Electrical System Group 9 Signal Control Valve
Group 10 Steering Valve
Group 11 Brake Valve
Group 12 Others (Upperstructure)
Group 13 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
Group 1 Introduction Group 2 Monitor Unit
Group 2 Standard Group 3 Dr. ZX
Group 3 Engine Test Group 4 ICF
Group 4 Excavator Test Group 5 Component Layout
Group 5 Component Test Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection
 SECTION 1
GENERAL

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

Group 2 Tightening
Tightening Torque Specification.................. W1-2-1
Torque Chart................................................ W1-2-2
Piping Joint .................................................. W1-2-5
Periodic Replacement of Parts ................. W1-2-9

Group 3 Painting
Painting ................................................... W1-3-1

Group 4 Bleeding Air from Hydraulic Oil

Tank
Bleeding Air from Hydraulic Oil tank ...........W1-4-1

CEBW-1-1
(Blank)

CEBW-1-2
 GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine
Thoroughly wash the machine before bringing it into
the shop. Bringing a dirty machine into the shop
may cause machine components to be
contaminated during disassembling/assembling,
resulting in damage to machine components, as
well as decreased efficiency in service work.
• Inspect the Machine
Be sure to thoroughly understand all
disassem-bling/assembling procedures beforehand,
to help avoid incorrect disassembling of
components as well as personal injury.
Check and record the items listed below to prevent
problems from occurring in the future.
• The machine model, machine serial number, and
hour meter reading.
• Reason for disassembly (symptoms, failed parts,
and causes).
• Clogging of filters and oil, water or air leaks, if
any.
• Capacities and condition of lubricants.
• Loose or damaged parts.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the
area for disassembling work.
W1-1-1
• Precautions for Disassembling
• To prevent dirt from entering, cap or plug the
removed pipes.
• Before disassembling, clean the exterior of the
components and place on a work bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
• If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
tag them as necessary.
• Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
• Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking,
or other damage.
• Measure and record the degree of wear and
clearances.
 GENERAL / Precautions for Disassembling and Assembling
• Precautions for Assembling
• Be sure to clean all parts and inspect them for
any damage. If any damage is found, repair or
replace part.
• Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
• Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
• Be sure that liquid-gasket-applied surfaces are
clean and dry.
• If an anti-corrosive agent has been used on a
new part, be sure to thoroughly clean the part to
remove the agent.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
• Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no forgotten tools remain in the
assembled machine.
W1-1-2
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and in-
stallation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
IMPORTANT: If the engine is started with air
trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the mo-
tor may result.
If the cylinder is operated with air
trapped in the cylinder tube, dam-
age to the cylinder may result.
Be sure to bleed air before starting
the engine.
• Bleeding Air from Hydraulic Pump
• Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.
 GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
WCJB-01-04-001
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.

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

(1) Keep seal rings together as a matched set

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

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

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

uneven wear.

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

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage

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

(1) Clean the floating seal and seal mounting

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

(2) Clean the floating seal and seal mounting

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

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

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

b b

a=b a≠b
W110-03-05-004

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

1. Follow the precautions below to use nylon slings

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

lifted load balanced. Incorrect Eyehole

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

slings or pushing slings with a metal object.

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

Bent Sling W162-01-01-009

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

CAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may re- Damaged Appearance
Broken Sewing Thread
sult. Be sure to visually check the nylon sling
for any damage before using.

2. Before using a nylon sling, visually check the ny-

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

W162-01-01-003

Fuzz

Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Separation of W162-01-01-006
Scoring
Belt

W162-01-01-007
Fuzz Scuffing
Broken Warp

W162-01-01-008

W1-1-6
 GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY

“Standard”
1. Dimension for parts on a new machine.

2. Dimension of new components or assemblies

adjusted to specification.

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

2. Repair or adjustment is impossible after exceed-

ing this limit.

3. Therefore, in consideration of operation efficiency

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

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

W1-1-8
 GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION

Bolt Dia Wrench Torque

No. Descriptions Q’ty
mm Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Engine cushion rubber mounting nut 14 4 22 140 (14.0) (103)
Engine cushion rubber mounting bolt 16 2 24 235 (24) (175)
2
Engine bracket mounting bolt 10 7 17 50 (5.1) (37)
Engine bracket mounting nut 10 1 17 50 (5.1) (37)
3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155)
4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)
17 24.5 (2.5) (18)
19 30 (3.1) (22)
22 40 (4.1) (30)
ORS and metal face seal fittings for hydraulic hoses and
5 27 95 (9.7) (70)
piping
32 140 (14.3) (105)
36 175 (17.8) (130)
41 210 (21.5) (155)
6 Pump mounting bolt 10 8 17 50 (5.1) (37)
7 Control valve mounting bolt 14 4 22 140 (14.0) (103)
8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155)
9 Swing device mounting bolt 20 10 30 500 (51) (370)
10
10 Swing motor mounting bolt (Hex. 7 8 65 (6.6) (48)
Wrench)
11 Battery mounting nut 10 2 17 50 (5.1) (37)
12 Cab mounting nut 16 4 24 210 (21.5) (155)
13 Swing bearing mounting bolt to upperstructure 18 30 27 400 (41.0) (295)
Swing bearing mounting bolt to chassis 16 36 24 270 (27.5) (200)
14 Center joint lock mounting bolts Ú 16 5 24 270 (27.5) (200)
15 Transmission mounting bolts Ú 20 3 30 550 (56.0) (410)
16
16 Travel motor mounting bolts Ú (Hex. 4 14 270 (27.5) (200)
Wrench)
17 Propel shaft mounting nuts Ú 10 32 14 76 (8) (60)
19 Rear axle mounting bolts Ú 20 8 30 560 (57) (410)
20 Wheel pin nuts 20 40 30 500 (51) (370)
6 - 10 10 (1) (7.4)
21 Cover mounting bolt 10 - 17 50 (5.1) (37)
12 - 19 90 (9.2) (66)
10.3 to (1.05 to (7.59 to
22 Flexible master coupling of piping 8 4 pairs 13
12.4 1.26) 9.11)
23 T-bolt clamp of low pressure piping - - 11 6.0 (0.6) (4.3)
Ú Apply LOCTITE to the threads. 2.Make sure bolt and nut threads are clean
NOTE 1.Apply lubricant (e.g. white zinc B dis- before installing.
solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
(Except for Sprocket mounting bolt.)

W1-2-1
 GENERAL / Tightening
TORQUE CHART

CAUTION: Use tools appropriate for the

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

Bolt Types

Tighten nuts or bolts correctly to torque specifications.

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

correctly when assembling the machine or compo-

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

W162-01-01-001

Specified Tightening Torque Chart

Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M552-07-092

Socket Bolt
N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)
M8 13 6 30 (3.0) (21.5) 20 (2.0) (14.5) 10 (1.0) (7.2)
M10 17 8 65 (6.5) (47) 50 (5.0) (36) 20 (2.0) (14.5)
M12 19 10 110 (11) (80) 90 (9.0) (65) 35 (3.5) (25.5)
M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40)
M16 24 14 270 (27) (195) 210 (21) (152) 80 (8.0) (58)
M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87)
M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123)
M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159)
M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205)
M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290)
M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400)
M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540)
M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)

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

Bolt Tightening Order

When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.
Tighten from center and diagonally
Equally tighten upper and lower alternately Tighten diagonally

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

4 5
2 13 8 5 2 3 10 11

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

W1-2-3
 GENERAL / Tightening
Service Recommendations for Split Flange

IMPORTANT: 1. Be sure to clean and Inspect

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

an air wrench often causes tight- RIGHT WRONG

ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply

Nut and Bolt Locking RIGHT RIGHT WRONG

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

• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009

RIGHT RIGHT WRONG

ening, not while loosening.

• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT

Tighten

W105-01-01-010

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

IMPORTANT: The torques given in the chart are

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

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

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

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

2. Scratches or other damage to

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

Wrench Size Wrench Size mm Tightening

Description mm Torque
Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5, 18)
19 19 29.5 (3.0, 21.5)
22 22 39 (4.0, 28.5)
27 27 78 (8.0, 58)
32 32 137 (14.0,101)
36 36 175 (18.0, 129)
41 41 205 (21.0,1 51)
37°female 17 14 24.5 (2.5, 18)
19 17 29.5 (3.0, 21.5)
22 19 39 (4.0, 28.5)
27 22 78 (8.0, 58)
32 27 137 (14.0, 101)
36 32 175 (18.0, 129)
41 36 205 (21.0, 151)
NOTE: Tightening torque of 37° male coupling without union is similar
to tightening torque of 37° female.

W1-2-5
 GENERAL / Tightening
O-ring Seal Joint 9
7 6

O-ring (6) seats against the end face of adapter (7) to seal
pressure oil.

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

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

with O-ring (6) displaced will damage

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

W1-2-6
 GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different types 30°
of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread pitch

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

Male Tapered Thread

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

• Application Procedure W105-01-01-019

Leave one to two pitch threads uncovered

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

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs de-

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

M114-07-043 M114-07-042

W1-2-7
 GENERAL / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to use
only genuine Hitachi service parts. Using hoses
other than genuine Hitachi hoses may cause oil
leaks, hose rupture or Separation of fitting, pos-
sibly resulting in a fire on the machine.

Do not install hoses kinked. Application of high

oil pressure, vibration, or an impact to a kinked W105-01-01-011
hose may result in oil leaks, hose rupture or
separation of fitting. Utilize Print marks on hoses
when installing to prevent hose from being WRONG RIGHT
kinked. Rubbing Against
Each Other
If hoses rub against each other, wear to the
hoses will result, leading to hose rupture. Take
necessary measures to protect hoses from rub-
bing against each other.
W105-01-01-012

Take care so that hoses do not come into contact

WRONG RIGHT
with moving parts or sharp objects.
Clamp Clamp

Rubbing Against
Each Other

W105-01-01-013

WRONG RIGHT

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

W1-2-8
 GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS

The parts listed below deteriorate as the machine ages

and are worn out or fatigued by repeated loads, resulting
in possible severe personal injury and/or machine trouble.
The service life of these parts cannot be detected
through machine operation or visual inspection.
Therefore, these parts should be replaced at regular in-
tervals even if no abnormalities are noticed. In case any
abnormalities are found on a part at any time regardless
of its specified replacement interval, immediately replace
the part.

Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine Oil filter hose (Engine to oil filter) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Pump delivery hose Every 2 years
Base Machine
Swing hose Every 2 years
Hydraulic
Travel Hose Every 2 years
System
Boom cylinder line hose Every 2 years
Front-End Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings
and gaskets, when replacing hoses.

W1-2-9
 GENERAL / Tightening
(Blank)

W1-2-10
 GENERAL / Painting
PAINTING

Painting specification
Surfaces to Be Painted Painting Colour
• Main surface of upperstructure (except cab) YR-01 [TAXI yellow]
Main frame HG Beige Deep
Internal parts Black
• Front attachment YR-01 [TAXI yellow]
• Track (including swing bearing) N1.0 [Black]
• Floor plate M/F Cation (allowed)

Final painted color

• Inside and outside surface of cab HG Beige Deep
• Shaded area on cab outside Shining Silver
• Right window guards, U-Bolt [KANSAI PAINT LF-113-230B
(Charcoal series black, half glossy)]
• Suspension lifter (chair bottom) [N2.0 (Black)]
• Lever (Pilot shut-off, foot rest) High Grade Black
• Engine cover TAXI Yellow
• Cover, Step HG Beige Deep
• Handrail on upperstructure right side HG Beige Deep
• Mirror stay: cab side, right side High Grade Black
• Nonslip cover KANSAI PAINT Amilac 1400 (Deep Black)
• Rear camera cover HG Beige Deep
• Head light bracket HG Beige Deep

W1-3-1
 GENERAL / Painting

Paint all circumference

in the hinge swing
Mirror Stay position shining silver

Shaded Area
[Shining Silver]

Engine Cover

Camera Cover

Decal
[TAXI Yellow]

WCEB-01-03-001

Head Light Bracket

Decal Mirror Stay Handrail Right Side Cover

[Shining Silver]

WCEB-01-03-002

Decal Step Head Light Bracket Mirror Stay

[TAXI Yellow]

W1-3-2
 GENERAL / Painting

Align with the panel

[Shining Silver]

Panel Door Panel Behind the

Door

10
Painting Area of the Door W178-01-03-005
YR-01(TAXI Yellow)

WCEB-01-03-003 Section A
Detail B

Nonslip Cover
KANSAI PAINT
Amilac 1400
(Deep Black)

WCEB-01-03-004
Upper Side of Frame

IMPORTANT: When cleaning arm, cylinder, etc.

fitted with HN bushing, take care not
to pour washing liquid directly on
them. The ambient temperature
should not exceed 70 °C (158 °F)
when painting and drying.

W1-3-3
 GENERAL / Painting
(Blank)

W1-3-4
 GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK

CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.

Preparation
1. Place the machine on a firm, level surface and WCJB-01-04-001

lower the bucket to the ground.

2. Stop the engine. Push the air bleed valve (1) on 2

the air breather to release any remaining pressure
from hydraulic oil tank (3).

3. Remove cap (2) of hydraulic oil tank (3).

WCEB-01-04-001
4. Connect a vacuum pump with the hole removed
cap (2) to maintain negative pressure in the
Vacuum Pump
hydraulic oil tank (3).
NOTE: Be sure to run the vacuum pump Hose
continuously while working.

Adapter

W562-02-03-008

W1-4-1
 GENERAL / Bleeding Air from Hydraulic Oil Tank
(Blank)

W1-4-2
 MEMO

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 MEMO

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UPPERSTRUCTURE
— CONTENTS —
Group 1 Cab
Removal and Installation of Cab ............ W2-1-1
Dimensions of Cab Glass .................... W2-1-12
Group 2 Counterweight
Removal and Installation of
Counterweight ...................................... W2-2-1
Group 3 Main Frame
Removal and Installation of
Main Frame .......................................... W2-3-1
Group 4 Pump Device
Removal and Installation of
Pump Device ........................................ W2-4-1
Disassembly of Pump Device .............. W2-4-10
Assembly of Pump Device ................... W2-4-22
Disassembly of Regulator .................... W2-4-42
Assembly of Regulator......................... W2-4-44
Structure of Pilot Pump ........................ W2-4-46
CEBW-2-1
SECTION 2
Group 5 Control Valve
Removal and Installation of
Control Valve ........................................W2-5-1
Disassembly of Control Valve
4-Spool Side .......................................W2-5-12
Disassembly of Control Valve
5-Spool Side .......................................W2-5-20
Assembly and Disassembly of
4-Spool Side and 5-Spool Side...........W2-5-26
Assembly of Control Valve
4-Spool Side .......................................W2-5-28
Assemble of Control Valve
5-Spool Side .......................................W2-5-36
Removal and Installation of Positioning
Control Valve ......................................W2-5-43
Disassembly of Positioning
Control Valve ......................................W2-5-44
Assembly of Positioning
Control Valve ......................................W2-5-46
Group 6 Swing Device
Removal and Installation of
Swing Device ........................................W2-6-1
Disassembly of Swing Device ................W2-6-6
Assembly of Swing Device ...................W2-6-14
Disassembly of Swing Motor ..............W2-6-22
Assembly of Swing Motor .....................W2-6-26
Disassembly of Valve Unit ....................W2-6-32
Assembly of Valve Unit.........................W2-6-34
Structure of Swing Dampener Valve.....W2-6-36
Maintenance Standard..........................W2-6-37
Group 7 Pilot Valve
Removal and Installation of Pilot Valve.. W2-7-1
Removal and Installation of
Travel Pilot Valve................................ W2-7-11
Disassembly of Front/Swing
Pilot Valves......................................... W2-7-16
Assembly of Front/Swing Pilot Valves.. W2-7-20
Disassembly of Travel and
Auxiliary/Positioning Pilot Valves ....... W2-7-24
Assembly of Travel and
Auxiliary/Positioning Pilot Valves ....... W2-7-26
Group 8 Electric Lever
Removal and Installation of
Electric Lever........................................ W2-8-1
Disassembly of Electric Lever................ W2-8-8
Assembly of Electric Lever................... W2-8-10
Group 9 Signal Control Valve
Removal and Installation of Signal
Control Valve ........................................ W2-9-1
Structure of Signal Control Valve ........... W2-9-6
Group 12 Pilot Shut-Off Solenoid Valve
Removal and Installation of Pilot
Shut-Off Solenoid Valve......................W2-12-1
Structure of Pilot Shut-Off
Solenoid Valve ....................................W2-12-3
Group 13 Steering Valve
Removal and Installation of
Steering Valve.....................................W2-13-1
Group 14 Brake Valve
Removal and Installation of
Brake Valve.........................................W2-14-1
Disassembly of Brake Valve .................W2-14-4
Assembly of Brake Valve......................W2-14-8
Group 15 Accumulator Charge Valve
Removal and Installation of
Accumulator Charge Valve .................W2-15-1
Structure of Accumulator
Charge Valve ......................................W2-15-4

Group 10 Shockless Valve

Removal and Installation of
Shockless Valve ................................. W2-10-1
Structure of Swing Shockless Valve .... W2-10-6
Structure of Travel Shockless Valve .... W2-10-8

Group 11 Solenoid Valve

Removal and Installation of 3-Spool
Solenoid Valve Unit ............................ W2-11-1
Structure of 3-Spool Solenoid Valve
Unit ..................................................... W2-11-5
Disassembly and Assembly of
3-Spool Solenoid Valve Unit.............. W-2-11-6
Removal and Installation of Solenoid Valve
Unit (For Electric Lever Operation) .... W2-11-8
Structure of Solenoid Valve Unit
(For Electric Lever Operation).......... W2-11-12
Removal and Installation of
1-Spool Solenoid Valve Unit............. W2-11-13
Structure of 1-Spool Solenoid
Valve Unit ......................................... W2-11-15

CEBW-2-2
 UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION OF CAB

Removal

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

1 2 3 4 5
1. Remove sems bolts (4) (2 used) from safety belts
(6) (2 used). Remove safety belts (6) (2 used)
from brackets (5) (2 used).
: 16 mm

WCEB-02-01-001

4 5 2 3

WCEB-02-01-017

2. Remove socket bolts (3) (4 used) from seat (1).

Remove seat (1) from plate (2). 3 1
: 6 mm

2
WCEB-02-01-002

7
3. Remove mat (8) from the inside of cab (7).

8 WCEB-02-01-003

W2-1-1
 UPPERSTRUCTURE / Cab
4. Remove sems bolts (10) (2 used) from cover (9).
: 13 mm

10

W1JB-02-01-004

5. Remove caps (11) (6 used) from cover (9).

Remove screws (12) (6 used) from cover (9). 7

6. Remove cover (9) from cab (7). 11, 12

11, 12

7. Remove sems bolts (16) (4 used) from cover (14). W1JB-02-01-005

Remove cover (14) from brackets (13, 15). 13
: 17 mm

14

WCEB-02-01-008
16 16 15

8. Remove sems bolts (17) (5 used) from bracket 13

13 17
(13). Move the bracket (13) assembly forward
from bracket (15).
: 13 mm, 17 mm
17

15

17 WCEB-02-01-018 WCEB-02-01-019

W2-1-2
 UPPERSTRUCTURE / Cab
9. Remove screws (19) (2 used) from cover (18). 18 19
Remove cap (20) and screw (21) from cover (18).
Remove cover (18) from cab (7).

W1JB-02-01-001
20, 21 7

22 7
10. Remove sems bolts (23) (2 used) from bracket
(24). Remove bracket (24) from cab (7) and duct
(22). Remove duct (22) from bracket (15).
: 13 mm 23

24

15

WCEB-02-01-016
23

25

11. Open cover (25).

WCEB-02-01-005

CAUTION: Cover (25) weight: 20 kg (45 lb) 25

26, 27, 28

12. Attach a nylon sling onto cover (25). Hoist and

hold cover (25). 29

13. Remove nuts (26) (4 used), spring washers (27)

(4 used) and washers (28) (4 used) from cover
(25). Remove cover (25) from support (29).
: 17 mm

WCEB-02-01-007

W2-1-3
 UPPERSTRUCTURE / Cab
14. Disconnect vinyl hose (31) from washer tank (30). 30
Cap the open ends.

31 WCEB-02-01-006

32
15. Remove clamps (33) (3 used) from the outside of
the cab (7) rear. Disconnect connectors (32) (5 33
used).

WCEB-02-01-014

34 35
16. Remove sems bolts (34) (6 used) from cover (35).
Remove cover (35) from main frame (36). 36
: 17 mm

WCEB-02-13-001

17. Remove anchor bolt (39), washer (38) and spacer

(37) from cab (7) and main frame (36).
: 32 mm 7

37

38

WCEB-02-01-013
36 39

W2-1-4
 UPPERSTRUCTURE / Cab

CAUTION: Cab (7) weight: 550 kg (1220 lb) Lifting 42 7 Lifting

Bracket Bracket
18. Attach a nylon sling onto the bracket in cab (7).
Hold cab (7).

19. Remove nuts (40) (4 used) and washers (41) (4

used) from cab (7).
: 24 mm
40, 41
20. Remove socket bolts (42) (6 used) from cab (7). 40, 41
: 8 mm
42
21. Remove bolts (43) (5 used) and washers (44) (5
used) from cab (7). 40, 41
: 17 mm W1JB-02-01-006

43, 44 42

CAUTION: Cab (7) weight: 550 kg (1220 lb)

22. Remove cab (7) from main frame (36).

36

WCEB-02-01-009

W2-1-5
 UPPERSTRUCTURE / Cab
Installation

CAUTION: Cab (7) weight: 550 kg (1220 lb)

1. Attach a nylon sling onto cab (7). Hoist and align

cab (7) with the mounting hole on main frame
(36).

36

WCEB-02-01-009

2. Install cab (7) to main frame (36) with nuts (40) (4

Lifting 42 7 Lifting
used) and washers (41) (4 used). Bracket Bracket
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

3. Install cab (7) to main frame (36) with socket bolts

(42) (6 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
40, 41
40, 41
4. Install cab (7) to main frame (36) with bolts (43) (5
used) and washers (44) (5 used).
42
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 40, 41
W1JB-02-01-006

43, 44 42

5. Install duct (22) to bracket (15). 22 7

6. Install bracket (24) to cab (7) and duct (22) with

sems bolts (23) (2 used).
: 13 mm 23
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
24

15

WCEB-02-01-016
23

W2-1-6
 UPPERSTRUCTURE / Cab
7. Install cover (18) to cab (7) with screws (19) (2 18 19
used). Install cover (18) to cab (7) with screw (21).
Install cap (20) to screw (21).

20, 21 7 W1JB-02-01-001

8. Align the bracket (13) assembly with the mounting 13

hole on bracket (15). Install the bracket (13) 13 17
assembly to bracket (15) with sems bolts (17) (5
used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 17
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
15

17 WCEB-02-01-018 WCEB-02-01-019

9. Install cover (14) to brackets (13, 15) with sems 13

bolts (16) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

14

WCEB-02-01-008
16 16 15

10. Install cover (9) to cab (7) with screw (12) (6 used). 7
Install caps (11) (6 used) to screws (12) (6 used).
11, 12

11, 12

W1JB-02-01-005

W2-1-7
 UPPERSTRUCTURE / Cab
11. Install cover (9) to cab (7) with sems bolts (10) (2
used). 7
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
9

10

W1JB-02-01-004

12. Connect connectors (32) (5 used). Secure

32
connectors (32) (3 used) with clamps (33) (3
used). 33

WCEB-02-01-014

13. Secure cab (7) to main frame (36) with anchor bolt
(39), washer (38) and spacer (37).
: 32 mm 7
: 550 N⋅m (55 kgf⋅m, 406 lbf⋅ft)
37

38

WCEB-02-01-013
36 39

34 35

14. Install cover (35) to main frame (36) with sems 36

bolts (34) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-13-001

W2-1-8
 UPPERSTRUCTURE / Cab
15. Connect vinyl hose (31) to washer tank (30). 30

31 WCEB-02-01-006

CAUTION: Cover (25) weight: 20 kg (45 lb) 25

26, 27, 28
16. Attach a nylon sling onto cover (25). Hoist and
align cover (25) with the mounting hole on support 29
(29). Secure cover (25) to support (29) with
washers (28) (4 used), spring washers (27) (4
used) and nuts (26) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-01-007

17. Shut cover (25). 25

WCEB-02-01-005

3 1
CAUTION: Seat (1) weight: 40 kg (90 lb)

18. Install seat (1) to plate (2) with socket bolts (3) (4
used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

2
WCEB-02-01-002

W2-1-9
 UPPERSTRUCTURE / Cab
19. Install safety belts (6) (2 used) to brackets (5) (2 1 2 3 4 5
used) with sems bolts (4) (2 used).
: 16 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-01-001

4 5 2 3

WCEB-02-01-017

7
20. Install mat (8) to the inside of cab (7).

8 WCEB-02-01-003

W2-1-10
 UPPERSTRUCTURE / Cab
(Blank)

W2-1-11
 UPPERSTRUCTURE / Cab
DIMENSIONS OF CAB GLASS

Black Ceramic
NOTE: Unit: mm (1 mm=0.039 in) 115 Coating Range

70

21

107
60 2-R50 2-R50
C0.5 2-R250
2-R127 2-R20
2-R10

70
C0.5
106.6 A
Black Ceramic W1JB-02-01-013 1081
Coating Surface R50
R2975 (4 mm)
Section A R800
φ28
R75 B
R120
Black
R40 268
Ceramic 20 70
Coating
Surface 16.5
50 W1JB-02-01-011
2R-5
271 21
214 21
847

Black Ceramic
Coating Range

R1075

W1JB-02-01-009
C
372.9
(4 mm)
22
50

54.1 25 W1JB-02-01-012

25 84

865

C0.5
R2

W1JB-02-01-014 W1JB-02-01-019
C0.5
Black Ceramic
Coating Surface
Section C
Section B

W2-1-12
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

360.7

4-R4
3-R4

2-φ12.2 +0.5
(4 mm) 139.7 -0
R150 6445
50 (4 mm)
50 WCEB-02-01-012 40±0

631
37 228.2

50

50 WCEB-02-01-011
383.2

312.6

C0.5
4Ｒ-4

C0.5
R2800
Black Ceramic
Coating Surface
(4 mm)
Section A W1JB-02-01-013
644.5
40±0.5

WCEB-02-01-004
228.2

93°
50

50 WCEB-02-01-010

460.2

Glass Mark (Back)

860.8
Black Ceramic 833
Coating Range 506
63.5 581
50 438.5 26.5
2-φ21 353.5
2-R4
R150 64.5
R2854
R50 109.5 336
R25 102.5
A

498.5 448 1
R58 R75 (4 mm) R60 152.5
R250 185
R964 R103
R5031 34
R42 R329
R10
118
R5004 82

327.5
R10 R60 W1JB-02-01-018
17 173

W2-1-13
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

Black Ceramic
Coating Range

R30 30
39
29

652
87.5 (4 mm) R200
87.5
R200
R500 R500 A
R50 185 185
45
70
R50
4-R10 205
848 W1JB-02-01-021

WCEB-02-01-015

567.5 Black Ceramic

Coating Range
496

123.5 80 59.5
C0.5
3-R4 85
75.5 100 R25

C0.5 R25
R20 R25 R25 B
Black Ceramic W1JB-02-01-013 87.7° R75
Coating Surface
Section A R4139.5
887 1008
1099
1145.5
R4044.5
1127.3 19.5

(4 mm)

R40
R35
C0.5 R100
R35
R550
R135 φ83
13°
A
W1JB-02-01-014 228
112
C0.5 109°
105
65° R250
R20 102°
Section B R70 R60
W1JB-02-01-017
76
140
78.5 57 195
447
483

W2-1-14
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

C1

C1
Black Ceramic W1JB-02-01-013
Coating Surface
Section A

W1JB-02-01-009

1646.47

1599.44

187 Black Ceramic Coating Range 313.6

R20
80 50

106 R300
2-R25
R2145 50
R30
696.73 R75
50
1230

R2940
900

(5 mm) 1205
A
R25
90 1496.7
40 R30
R3025
1636.3
R30 R50
R20 158 R10
873.14

R2875
150 145

R575 R50
R125

R1040 R30 R50

R1525 28°
W1JB-02-01-020
R55 R30
393
400

807.65

963.7

W2-1-15
 UPPERSTRUCTURE / Cab
Removal of Cab Glass
Right-Hand Glass

Procedures to Remove Right-Hand Glass, Rear

Left-Hand Glass, Lower Door Glass and Rear Glass

CAUTION: When removing the broken or

cracked glass, the glass shards may cause
serious injury.
Before removing, use the gummed tape or
something like in order to paste the broken or
cracked glass and reinforce them. Remove
the glass pieces away.
W1JB-02-01-009

1. Remove the resin panel, garnish and spacer

around the glass. Rear Glass

Rear
Left-Hand
Garnish Glass

Garnish

2. Prick a hole in the adhesive by using an awl (or

cutter knife). Lower Door Resin Panel WCEB-02-01-015
Glass

3. Pass a piano wire (or a wire) through the hole.

Cab
Cab Glass
Awl

Adhesive W1SE-02-01-033

Piano Wire
(or Metal Wire)

W1SE-02-01-034

W2-1-16
 UPPERSTRUCTURE / Cab
4. Wind the both ends of piano wire onto the
screwdriver. Draw the wire back and forth in order
to cut the adhesive between cab and glass.
Remove the glass from the cab. Cab Glass (Cab Outside)

NOTE: Cut off the middle of adhesive between Cab Glass

glass and cab.
Piano wire is easily broken if a part of piano
wire turns hot. Change the position and cut
the adhesive.

Adhesive
(Cab Inside)

W1SE-02-01-035

W2-1-17
 UPPERSTRUCTURE / Cab
Installation of Cab Glass
Right-Hand Glass

Procedures to Install Right-Hand Glass, Rear

Left-Hand Glass, Lower Door Glass and Rear Glass

1. Cut off residual adhesive at the cab side to make

1 to 2 mm (0.04 to 0.08 in) deep all around by
using a cutter knife or similar.
NOTE: Do not damage the cab paint.

W1JB-02-01-009

Rear Glass

Lower Door Rear Left-Hand W1JB-02-01-010

Glass Glass

Cab

2. Clean the cutting edge of adhesive at cab side by

Cutter Knife
using white spirit.

Cut off adhesive by 1 to 2 mm

（0.04 to 0.08 in） deep.
W1SE-02-01-036

IMPORTANT: Primer should be shaken for about 1

minute and mix thoroughly before Cab
Apply Primer 24 by
opening the cap. using a brush.
After opening Primer, apply Primer
as quickly as possible and replace Cutting Edge of
the cap immediately after using. Adhesive at Cab
After opening Primer, all the Side
contents should be used within 180
W1SE-02-01-038
days (or 2 hours with the cap off).
3. Apply Primer for paint (Sika Aktivator DM-1) 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.
NOTE: The painting primer should be applied
evenly in order to leave no blemishes.

W2-1-18
 UPPERSTRUCTURE / Cab
4. Clean the mating edge of new glass by using
clean rag and ethyl alcohol.
IMPORTANT: Primer (Sika Primer Z06G+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 replace
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 Z06G+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.
(As for the position to apply Primer, refer to
W2-1-21.)
11. Suck, raise the glass by using sucker lifter
4355282 (refer to W2-1-21), and adhere it to the
cab within 5 minutes.
NOTE: Install the glass while aligning 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 gummed tape until
the adhesive becomes solid in order to prevent
them from being mispositioned or coming off.
(Refer to W2-1-20.)
NOTE: Time for adhesive (Sika Tack-Drive) to
become solid: 8 hours (just for reference)

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 W2-1-21.)

7. Cut off the nozzle of adhesive cartridge (Sika

Tack-Drive) into V-shaped by using a knife. (Refer
to W2-1-21.)

8. Remove the seal of cartridge. Install the V-shaped

nozzle.

9. Install the cartridge to the manual coking gun.

10. Evenly apply adhesive to the old adhesive left at

cab side.
(As for the position to apply adhesive, refer to
W2-1-21.)

W2-1-19
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm (1 mm=0.039 in)

Rear Glass Right-Hand Glass

350 500
250 300

100

200
200 200 500

200

200 200

250 300
W1JB-02-01-029

200
200
100
100 W1JB-02-01-030

Rear Left-Hand Glass

150 200

Lower Door Glass

200

500

200
W1JB-02-01-035
W1JB-02-01-038

W2-1-20
 UPPERSTRUCTURE / Cab

NOTE: Unit: mm Spacer C

(1 mm=0.039 in) Spacer B
Spacer A 20
2
6
20 6
4 R0.5
20 6 4
8 78°
R8 75° R10
4 6 R0.5
3
R5 84°
6 R0.5 12 10.5

Two Side W1JB-02-01-024

3 Adhesive Tape
Two Side W1JB-02-01-023
10.5
Adhesive Tape
W1JB-02-01-022

Dam Rubber

30 6.4

W1JB-02-01-025
Lower Door Grass

Rear Left-Hand Glass

Right-Hand Glass
Suction Lifter
Spacer A
Rubber
Dam
Rubber
Spacer B Spacer A
Spacer B
Spacer A Dam W1JB-02-01-039
Rubber
Spacer B
Rear Glass

Spacer C
W1JB-02-01-027
W1JB-02-01-026

W1JB-02-01-042
8 to 9 mm

13 to 15 mm
Adhesive
Cut nozzle
end into
V-shaped.

W1SE-02-01-027

Apply adhesive
9 evenly.

12 Remove
the seal.
W1JB-02-01-031

Adhesive
W1SE-02-01-043
Cartridge
Panel

W1SE-02-01-028

W2-1-21
 UPPERSTRUCTURE / Cab
13. The required amount (just for reference) of adhesive and primer

Painted Surface or Glass Surface

Adhesive Surface
Adhesive Primer Primer
Sika Tack-Drive Sika Aktivator DM-1 Sika Primer 206G+P
(Sika Tack-Drive) (Sika Aktivator DM-1) 30 ml Bottle
310 ml Cartridge 250 ml Can
Upper Front Glass 310 ml 0.75 ml 0.67 ml
Lower Door Glass 150 ml 0.5 ml 0.45 ml
Rear Left-Hand Glass 250 ml 0.65 ml 0.6 ml
Rear Right-Hand Glass 100 ml 1 ml 0.9 ml
Rear Glass 210 ml 0.5 ml 0.45 ml

W2-1-22
 UPPERSTRUCTURE / Cab
Installation of Upper Door Glass
Sash
1. Before installing the glass, remove the garnish Assembly
around sash assembly from the cab inside for
easy removal. Push the sash assembly by hands
and remove the sash outside.
Garnish

2. Install glass A and glass B into the sash grooves.

3. Install the sash assembly, which the glass is

Glass A Glass B
installed on, onto the door from the outside of cab.
Secure the sash assembly at the inside of cab by W1JB-02-01-010

using the garnish.

W2-1-23
 UPPERSTRUCTURE / Cab
Installation of Upper Front Glass
Adhere the glass in the same method as
right-hand glass.
1. Stick seal (1) to the lower side of front upper glass
by using Cemedine Super X.
Stick and secure both right and left ends (the
thicker part) of seal (1) to the glass by using
Cemedine Super X.
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.

NOTE: Cemedine Super X Black No.8008

Glue-state adhesive, tubed

IMPORTANT: The upper front glass is

arched-fringed. When replacing the
glass, contact with the nearest
HITACHI Office and replace it as an
assembly.

W1JB-02-01-034

Cemedine Super Upper Cemedine Super X Upper

X Seal Here Glass Glass

Seal (1) Seal (1)

Lower Lower
Glass Glass
W1JB-02-01-032 W1JB-02-01-033

W2-1-24
 UPPERSTRUCTURE / Counterweight
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT

Removal
1. Open cover (1). 1

WCEB-02-02-008

2 3 4
2. Disconnect connector (2) and plug (7).
5
3. Remove sems bolt (5) from clip (6). Remove
wiring (4) and clip (6) from counterweight (3).
: 17 mm 6

7
WCEB-02-02-001

8
4. Open cover (8).

WCEB-04-02-005

9
5. Disconnect connector (9).

WCEB-02-02-002

W2-2-1
 UPPERSTRUCTURE / Counterweight
6. Open cover (10). 10

WCEB-04-01-005

7. Disconnect connector (11).

11

WCEB-02-02-003

CAUTION: Counterweight (3) weight: 3000 kg

(6620 lb) 12
3
8. Remove caps (12) (2 used) from counterweight
(3). Install the sling bolts to the holes.
NOTE: Sling bolt (B-36, M36, Pitch: 4.0 mm)

9. Attach a wire rope to the sling bolts. Hoist and

hold counterweight (3).

CAUTION: Be careful to avoid getting your

13
hand caught by reaction bar on the power
wrench.
14
10. Remove bolts (14) (4 used) and washers (13) (4
used) from counterweight (3) by using a power WCEB-02-02-004

wrench.
: 41 mm
3
11. Hoist and remove counterweight (3) from main
frame (15).

13

14

15 WCEB-02-02-005

W2-2-2
 UPPERSTRUCTURE / Counterweight
Installation

CAUTION: Counterweight (3) weight: 3000 kg

(6620 lb)
3
1. Hoist and align counterweight (3) with the
mounting holes on main frame (15).

2. Temporary install counterweight (3) to main frame

(15) with bolts (14) (4 used) and washers (13) (4 13
used).

14

15 WCEB-02-02-005

CAUTION: Be careful to avoid getting your

hand caught by reaction bar on the power 3
wrench.

3. Remove the wire rope and the sling bolts from

counterweight (3). Tighten bolts (14) (4 used) by
using a power wrench and torque wrench.
: 41 mm
: 1150 N⋅m (118 kgf⋅m, 848 lbf⋅ft)

Torque
Wrench
Power WCEB-02-02-006
Wrench

4. Install caps (12) (2 used) to counterweight (3). 12

WCEB-02-02-007

W2-2-3
 UPPERSTRUCTURE / Counterweight
5. Connect connectors (9, 11). 9 11

WCEB-02-02-002 WCEB-02-02-003

8
6. Shut covers (8, 10).

WCEB-04-02-005

10

WCEB-04-01-005

7. Secure wiring (4) to counterweight (3) with clip (6)

3 4
and sems bolt (5).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 5

WCEB-02-02-001

W2-2-4
 UPPERSTRUCTURE / Counterweight
8. Connect connector (2) and plug (7).
2

7
WCEB-02-02-001

9. Shut cover (1).

WCEB-02-02-008

W2-2-5
 UPPERSTRUCTURE / Counterweight
(Blank)

W2-2-6
 UPPERSTRUCTURE / Main Frame
REMOVAL AND INSTALLATION OF MAIN
FRAME

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on
W1-4-1.)

Removal Counterweight

CAUTION: Counterweight weight: 3000 kg

(6620 lb)
Washer
1. Remove the counterweight.
(Refer to REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.) Bolt
: 41 mm
WCEB-02-02-005

Monoblock Boom

CAUTION: The front attachment assembly

weight:
Monoblock boom: 2000 kg (4410 lb)
2-piece boom: 2415 kg (5330 lb)

2. Remove the front attachment assembly.

(Refer to REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 27 mm, 30 mm, 36 mm

WCEB-02-03-001

2-Piece Boom

WCEB-02-03-002

W2-3-1
 UPPERSTRUCTURE / Main Frame

CAUTION: Center joint weight: 93 kg (210 lb)

Slip Ring Bolt Connector

3. Remove the bolt, stopper and slip ring from the

center joint. Disconnect the hose from the center
joint. (Refer to REMOVAL AND INSTALLATION
OF CENTER JOINT on W3-3-1.) Hose
: 10 mm, 24 mm, 27 mm

Stopper

Center Joint WCEB-03-03-001

Wire Rope
CAUTION: Upperstructure weight: 4000 kg
(8820 lb)

IMPORTANT: Do not damage the engine due to

the wire ropes attached from the
rear side of the frame.
4. Attach the wire ropes onto the rear side of the
frame and the boom mounting part. Take up slack
of the wire rope.
NOTE: If the chain block is used, it is not only Rear Side of Frame WCEB-02-03-003

easy to adjust the length of wire rope, but

Wire Rope
also easy to level the center of gravity.

WCEB-02-03-005

5. Put the matching marks on the upperstructure

and the outer race of the swing bearing.
Remove the swing bearing mounting bolt.
: 27 mm

6. Adjust a chain block in order to level the center of

gravity. Hoist and remove the frame.

WCEB-02-03-004
Bolt

W2-3-2
 UPPERSTRUCTURE / Main Frame
Installation

CAUTION: Upperstructure weight: 4000 kg

(8820 lb)

1. Attach the wire ropes onto the frame. Adjust the

chain block in order to level the center of gravity.
Hoist and place the frame onto the undercarriage.
(Refer to the Removal procedures.)

2. Align the matching marks on the upperstructure

and the outer race of the swing bearing.
Install and temporarily tighten the mounting bolts
for the swing bearing. Remove the wire ropes.
Tighten the mounting bolts for the swing bearing.
: 27 mm
: 400 N·m (41 kgf·m, 295 lbf·ft)

Bolt WCEB-02-03-004

3. Connect the hoses (15 used) to the center joint. Slip Ring Connector
Bolt
: 17 mm
: 24.5 N·m (2.5 kgf·m, 18 lbf·ft)
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
: 22 mm Hose
: 39 N·m (4 kgf·m, 29 lbf·ft)
: 27 mm
: 78 N·m (8 kgf·m, 58 lbf·ft)
: 36 mm Stopper
: 175 N·m (18 kgf·m, 129 lbf·ft)

4. Apply LOCTITE #262 onto the bolts (5 used).

Install the stopper to the center joint with the bolts Center Joint WCEB-03-03-001
(5 used).
: 24 mm
: 265 N·m (27 kgf·m, 195 lbf·ft)

5. Install the slip ring to the stopper.

: 10 mm
: 3.3 to 4.2 N·m
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

W2-3-3
 UPPERSTRUCTURE / Main Frame

CAUTION: Counterweight weight: 3000 kg

(6620 lb) Counterweight

6. Install the counterweight.

(Refer to RRMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
: 41 mm Washer
: 1400 N·m (143 kgf·m, 1033 lbf·ft)

Bolt

WCEB-02-02-005

Monoblock Boom
CAUTION: The front attachment assembly
weight:
Monoblock boom: 2000 kg (4410 lb)
2-piece boom: 2415 kg (5330 lb)

7. Install the front attachment assembly to the

upperstructure. Add hydraulic oil.
(Refer to REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 27 mm
: 93 N·m (9.5 kgf·m, 69 lbf·ft)
: 30 mm
: 540 N·m (55 kgf·m, 398 lbf·ft)
: 36 mm
: 175 N·m (18 kgf·m, 129 lbf·ft)
WCEB-02-03-001

8. Start the engine. Set the front attachment in 2-Piece Boom

posture for checking hydraulic oil level. Check for
hydraulic oil level and any oil leakage.

WCEB-02-03-002

W2-3-4
 UPPERSTRUCTURE / Pump Device
REMOVAL AND INSTALLATION OF PUMP
DEVICE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 1

Removal
1. Open cover (1).

WCEB-02-04-005

2, 3
2. Remove sems bolts (4) (12 used) from cover (2).
Remove cover (2) from cover (3) and support (5).
: 17 mm

WCEB-02-04-020

6 7 8
3. Remove sems bolts (6) (6 used) from cover (7).
Remove cover (7) from main frame (8).
: 17 mm

WCEB-02-04-001

W2-4-1
 UPPERSTRUCTURE / Pump Device
4. Disconnect hoses (13) (7 used) from filters (14) (7
used). Cap the open ends. Attach an identification 10, 11 12 13 14
tag onto the disconnected hoses for assembling.
: 17 mm, 19 mm, 27 mm 9

5. Remove sems bolt (10) from clip (11). Remove

clip (11) from cover (9). 13
: 17 mm

6. Disconnect connector (12).

WCEB-02-04-006

7. Disconnect connectors (17) (7 used) from pump 16 17

device (20).

8. Remove socket bolts (15) (8 used) and split

flanges (19) (4 used). Disconnect hoses (18) (2
used) from pump device (20). Cap the open ends.
: 10 mm

15 18

15

WCEB-02-04-006

19 20 19

20 21 22
9. Disconnect hose (16) from suction pipe (21). Cap
the open ends.
: 41 mm

10. Remove socket bolts (22) (4 used) from suction 17 17

pipe (21). Disconnect suction pipe (21) from pump
device (20).
: 10 mm 16

21

WCEB-02-04-009

W2-4-2
 UPPERSTRUCTURE / Pump Device
11. Disconnect hoses (24) (2 used) from regulators
(23) (2 used). Cap the open ends. 23
: 19 mm
24

WCEB-02-04-007

12. Remove socket bolts (27) (2 used) from clips (26)

(2 used). Remove clips (26) (2 used) from
connectors (25) (2 used) and pump device (20). 20
: 6 mm

13. Disconnect hoses (28) (3 used) from pilot pump

(30). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 27 mm

14. Remove sems bolts (29) (6 used) from cover (9).

Remove the cover (9) assembly from cover (3) WCEB-02-04-009

and support (5). 28 25, 26, 27

: 17 mm
9
30
29

3
5

WCEB-02-04-006
29
20
15. Remove socket bolts (32) (8 used). Remove split
flanges (31) (4 used). Disconnect hoses (33) (2
used) from pump device (20). Cap the open ends. 31
: 8 mm
32

33

WCEB-02-04-009

W2-4-3
 UPPERSTRUCTURE / Pump Device
16. Remove sems bolts (34) (2 used) from plate (35). 34 35 20
Remove plate (35) and the bracket (36) assembly
from pump device (20).
: 17 mm

36

WCEB-02-04-008

17. Remove nuts (38) (2 used), spring washers (39) 38, 39, 40
(2 used) and bolts (40) (2 used) from clamp (42).
Make muffler (37) free from exhaust pipe (41).
: 19 mm
37
CAUTION: The muffler (37) assembly weight:
23 kg (51 lb)

18. Attach a nylon sling onto muffler (37). Hoist and 41

hold muffler (37).
42
19. Remove sems bolts (43) (3 used) from bracket
(44). Remove the muffler (37) assembly from
44 43 20 WCEB-02-04-002
pump device (20).

20
CAUTION: Pump device (20) weight: 164 kg
Eyebolt
(362 lb) Mounting
Hole

WCEB-02-04-003

20. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to

pump device (20). Attach a nylon sling onto the
eyebolt. Hoist and hold pump device (20).
45
21. Remove sems bolts (46) (3 used) from pump
device (20). Remove pump device (20) from
engine (45).
: 17 mm

46

20 WCEB-02-04-002

W2-4-4
 UPPERSTRUCTURE / Pump Device
Installation

CAUTION: Pump device (20) weight: 164 kg 20

(362 lb)
Eyebolt
1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to Mounting
pump device (20). Attach a nylon sling onto Hole
eyebolt. Hoist and hold pump device (20).

WCEB-02-04-003

2. Align pump device (20) with the mounting hole on

engine (45). Install pump device (20) to engine
(45) with sems bolts (46) (3 used).
: 17 mm 37 45
: 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)

CAUTION: The muffler (37) assembly weight:

23 kg (51 lb)

3. Attach a nylon sling onto the muffler (37) assembly.

46
Hoist and align the muffler (37) assembly with the
mounting hole on pump device (20). Install 44 43 20 WCEB-02-04-002

bracket (44) to pump device (20) with bolts (43) (3

used).
: 17 mm
: 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)

38, 39, 40

4. Align clamp (42) with the center between exhaust

pipe (41) and the muffler (37) pipe part. Secure
37
exhaust pipe (41) and muffler (37) with bolts (40)
(2 used), spring washers (39) (2 used) and nuts
(38) (2 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 41

42

WCEB-02-04-002

W2-4-5
 UPPERSTRUCTURE / Pump Device
34 35 20
5. Install the bracket (36) assembly to pump device
(20) with sems bolts (34) (2 used) and plate (35).
: 17 mm
: 65 N⋅m (6.5 kgf⋅m, 48 lbf⋅ft)

36

WCEB-02-04-008

6. Connect suction pipe (21) to pump device (20) 20 21 22

with socket bolts (22) (4 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

7. Connect hose (16) to suction pipe (21).

: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

21

16 WCEB-02-04-009

8. Connect hoses (33) (2 used) to pump device (20)

with split flanges (31) (4 used) and socket bolts
20
(32) (8 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
31
32

33

9. Connect hoses (28) (3 used) to pilot pump (30).

: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
WCEB-02-04-009

28
30

WCEB-02-04-006

W2-4-6
 UPPERSTRUCTURE / Pump Device
10. Install the cover (9) assembly to cover (3) and 9
support (5) with sems bolts (29) (6 used).
: 17 mm 29
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
3
11. Connect hoses (18) (2 used) to pump device (20) 5
with split flanges (19) (4 used) and socket bolts
(15) (8 used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft) 18

15

WCEB-02-04-006

29 19 20 19

12. Connect hoses (24) (2 used) to regulators (23) (2 23

used).
: 19 mm
24
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

13. Connect connectors (17) (7 used) to pump device

(20).

17

WCEB-02-04-007

20

14. Connect hoses (13) (7 used) to filters (14) (2 10, 11 12 13 14

used).
: 17 mm 9
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 13
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

15. Install clip (11) to hoses (13) (2 used). Secure clip

(11) to cover (9) with sems bolt (10).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) WCEB-02-04-006

16. Connect connector (12).

W2-4-7
 UPPERSTRUCTURE / Pump Device
6 7 8
17. Install cover (7) to main frame (8) with sems bolts
(6) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-04-001

18. Install cover (2) to cover (3) and support (5) with 2, 3
sems bolts (4) (12 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-04-020

19. Shut cover (1). 1

WCEB-02-04-005

W2-4-8
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-4-9
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF PUMP DEVICE 4

1 2 3 5

18
15 16 17
6 14

13

12
58 11
7 10

9 14
57
15 16 17
56
55
54 19
8

53 12
20
11
51 10
9

21
52 22
23 28
51 50 24
21
22

27

26

49 25

37
29
30 38
26 35 39
40
31 36
48 34
47
32
33

41
42
43
44

46 45
44 WCEB-02-04-014

W2-4-10
 UPPERSTRUCTURE / Pump Device

72
71
70 73
69
68
67 74
66 71
65
75

60 62
63
64 69
63
62 68
60 60
61 62 78
82 63 76
59 81
60 63 77
62
60
83 61 79
82
60 80
59 60
72

83
WCEB-02-04-011

1 - Socket Bolt (4 Used) 22 - Plug (2 Used) 43 - Retaining Ring 64 - Right Valve Plate
2 - Right Regulator 23 - O-Ring 44 - Ball Bearing (2 Used) 65 - Backup Ring
3 - Socket Bolt (2 Used) 24 - Stopper 45 - Gear 66 - O-Ring
4 - Socket Bolt (2 Used) 25 - Plug 46 - Gear Shaft 67 - Spring Pin (2 Used)
5 - Socket Bolt (2 Used) 26 - Retaining Ring (2 Used) 47 - Retaining Ring 68 - Pressure Sensor (2 Used)
6 - Left Regulator 27 - Gear 48 - Oil Seal 69 - O-Ring (2 Used)
7 - O-Ring (4 Used) 28 - Gasket 49 - Gear Casing 70 - Selector Head
8 - O-Ring (6 Used) 29 - Gear 50 - Spring Pin (2 Used) 71 - O-Ring (4 Used)
9 - Bearing Nut (2 Used) 30 - Plug 51 - Oil Seal (2 Used) 72 - Socket Bolt (16 Used)
10 - Bearing (2 Used) 31 - Elbow 52 - Retaining Ring (2 Used) 73 - Stopper S (2 Used)
11 - Ring (2 Used) 32 - Plug 53 - Pump Casing 74 - O-Ring (2 Used)
12 - Bearing (2 Used) 33 - O-Ring 54 - Spring Washer (6 Used) 75 - Socket Bolt (12 Used)
13 - Shaft 34 - Gasket 55 - Bolt (6 Used) 76 - Set Screw (2 Used)
14 - Pin (2 Used) 35 - Socket Bolt (2 Used) 56 - Spring Pin (2 Used) 77 - Servo Piston (2 Used)
15 - Center Shaft (2 Used) 36 - Pipe 57 - O-Ring (2 Used) 78 - Pin (2 Used)
16 - Spring (2 Used) 37 - Level Gauge 58 - O-Ring (2 Used) 79 - O-Ring (2 Used)
17 - Plunger (14 Used) 38 - Socket Bolt (2 Used) 59 - Pin (2 Used) 80 - Stopper (2 Used)
18 - Rotor (2 Used) 39 - Spring Washer (2 Used) 60 - Retaining Ring (12 Used) 81 - Left Valve Plate
19 - Shaft 40 - Washer (2 Used) 61 - Pin (2 Used) 82 - Pin (4 Used)
20 - Slide Ring 41 - Pilot Pump 62 - Lever (4 Used) 83 - Link (2 Used)
21 - O-Ring (2 Used) 42 - Retaining Ring 63 - Pin (4 Used)

W2-4-11
 UPPERSTRUCTURE / Pump Device
4
1 2 3 5

70

58
7

57

53

49
25

37
30 38
35 39
40
31 36
34

32

41

WCEB-02-04-013

W2-4-12
 UPPERSTRUCTURE / Pump Device
Disassembly of Pump Device
1. Remove plug (25) from gear casing (49).
: 17 mm
2. Remove plug (32) from gear casing (49). Drain off
gear oil from gear casing (49). (Approx. 1.0 L, 0.3
US gal)
: 22 mm
3. Remove socket bolts (1) (4 used) from right
regulator (2). Raise right regulator (2) to the
direction of selector head (70). Remove right
regulator (2) from pump casing (53).
: 8 mm
4. Remove socket bolts (3) (2 used) and socket bolts
(5) (2 used) from left regulator (6). Raise left
regulator (6) to the direction of selector head (70).
Remove left regulator (6) from pump casing (53).
Do not remove socket bolt (4).
: 8 mm
5. Remove O-rings (7) (4 used) and O-rings (57, 58)
(2 used for each) from pump casing (53).
7. Hoist the pump casing (53) assembly. Place the
pump casing (53) assembly with gear casing (49)
facing downward. Place the wooden block (80
mm ( 3.1 in) or more square) under gear casing
(49).
8. Remove socket bolts (35) (2 used) from pipe (36).
Remove level gauge (37), pipe (36) and gasket
(34) from gear casing (49).
: 6 mm
9. Remove socket bolts (38) (2 used), spring
washers (39) (2 used) and washers (40) (2 used)
from pilot pump (41). Tap the flange of pilot pump
(41) by using a plastic hammer and remove pilot
pump (41) from gear casing (49).
: 8 mm
NOTE: THREEBOND has been applied onto the
mounting surface of pilot pump (41).
10. Remove plug (30) and elbow (31) from gear
casing (49).
: 30 mm

CAUTION: The pump casing (53) assembly

weight: 160 kg (360 lb)

CAUTION: When hoisting the pump casing

(53) assembly, turn to the gear
casing (49) side and do not take
pump casing (53) off the ground.

6. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to

the thread hole for socket bolts (1, 3) of pump
casing (53). Attach a nylon sling onto eyebolts (2
used).

W2-4-13
 UPPERSTRUCTURE / Pump Device

16

8 16

53

72

71 73
70
69 74
68
71
66
65 75

69

68

79
80

72

WCEB-02-04-012

W2-4-14
 UPPERSTRUCTURE / Pump Device
11. Remove the pressure sensors (68) (2 used)
assembly from selector head (70).
: 27 mm
12. Remove socket bolts (72) (16 used) from stoppers
S (73) (2 used) and stoppers L (80) (2 used).
Remove stoppers S (73) (2 used) and stoppers L
(80) (2 used) from selector head (70).
: 6 mm
NOTE: O-rings (74, 79) are installed to stopper S
(73) and stopper L (80). If it is difficult to
remove the stopper, tap the outer periphery
of the stopper. Turn the stopper until about
half of the hole for the mounting bolt can be
seen. Insert a screwdriver into the
mounting bolt hole. Remove the stopper by
using a screwdriver.
Stopper
W178-02-11-082
13. Remove O-rings (71) (4 used) from selector head
(70).
14. Remove O-rings (74, 79) (2 used for each) from
stoppers S (73) (2 used) and stoppers L (80) (2
used).
W2-4-15
15. Record the clearance between pump casing (53)
and selector head (70). Remove socket bolts (75)
(12 used) from selector head (70).
: 10 mm
NOTE: While loosening socket bolt (75), selector
head (70) will push out due to the force of
spring (16).
CAUTION: Selector head (70) weight: 28 kg
(62 lb)
16. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the bolt hole on the upper surface of selector
head (70). Hoist and remove selector head (70)
from pump casing (53). O-ring (66) may be
removed with the lower surface of selector head
(70) attached. Check O-ring (66).
17. Remove O-rings (8) (6 used), O-ring (66) and
backup ring (65) from pump casing (53).
 UPPERSTRUCTURE / Pump Device

18
15 16 17

13

15 16 17
55
54 19

53

50
28

27

49 70

29 75

60 62
63
64
63
62
60 60
61 62 78
82 63 76
59 81
60 63 77
62
60
83 61
82
60
59 60

83
WCEB-02-04-012

W2-4-16
 UPPERSTRUCTURE / Pump Device
18. Warm up set screws (76) (2 used) by using a drier.
Remove set screws (76) (2 used) from servo CAUTION: Pump casing (53) weight: 105 kg
pistons (77) (2 used). Remove pins (78) (2 used) (240 lb)
from servo pistons (77) (2 used).
: 6 mm 24. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the socket bolt (75) hole on pump casing (53).
19. Remove servo pistons (77) (2 used) from selector Hoist and remove pump casing (53) from gear
head (70). casing (49). Shafts (13, 19) and gears (27, 29) are
removed with pump casing (53) together.
20. Both right valve plate (64) and left valve plate (81) Place pump casing (53) with the mounting surface
are very similar and their installing directions are for the regulator facing upward.
determined. Record the position and the direction
of right valve plate (64) and left valve plate (81) 25. Remove spring pins (50) (2 used) and gasket (28)
before removing. Remove retaining rings (60) (4 from gear casing (49).
used) from pins (63) (4 used). Remove right valve
plate (64) and left valve plate (81) from links (83)
(2 used). Do not remove pins (63) (4 used) unless
necessary.

21. Remove rotor (18), spring (16), the center shaft

(15) assembly and plungers (17) (7 used) from
pump casing (53) in this order. (Both right and left
pumps)
NOTE: When removing plunger (17), turn plunger
(17) inside and remove plunger (7).

IMPORTANT: As the pump performance may be

changed, do not deform link (83).
22. Remove the link (83) assemblies (2 used)from
pump casing (53). Do not disassemble the link
(83) assembly unless necessary.
NOTE: If it is difficult to remove the link (83)
assembly, use a screwdriver.

23. Remove bolts (55) (6 used) and spring washer

(54) from pump casing (53).
: 24 mm

W2-4-17
 UPPERSTRUCTURE / Pump Device

13

12

10

19

53 12

10

21
22
23
24
21
22

27
26

70

29
26

WCEB-02-04-012

W2-4-18
 UPPERSTRUCTURE / Pump Device
26. Put the matching marks on the meshed position
of splines on shafts (13, 19) and gears (27, 29). CAUTION: Pump casing (53) weight: 70 kg
Put the matching marks on the meshed position (160 lb)
of gears (27, 29).
31. Attach a nylon sling onto pump casing (53). Hoist
27 29 and place pump casing (53) on the wooden
blocks with the pump transmission side facing
downward. Use the wooden block: 100 mm (3.9
in) or more square.

32. Remove shafts (13, 19) from pump casing (53) by

19
using special tools (ST 1470, ST 1471). Bearings
13
(10, 12) are removed with shafts (13, 19) together.
W137-02-04-007 ST 1470

27. Remove retaining rings (26) (2 used) from shafts ST 1471

(13, 19). Remove gears (27, 29) from shafts (13,
19).
13

CAUTION: Pump casing (53) weight: 70 kg 19

(160 lb)

28. Attach a nylon sling onto pump casing (53). Hoist 53

and place pump casing (53) with the mounting
side for selector head (70) facing downward.

29. Remove stoppers (24) (2 used) from pump casing W178-02-04-054

(53). Remove O-rings (23) (2 used) from stoppers
(24) (2 used).
: 19 mm

30. Remove plugs (22) (2 used) from pump casing

(53). Remove O-rings (21) (2 used) from plugs
(22) (2 used).
: 8 mm

W2-4-19
 UPPERSTRUCTURE / Pump Device

13

12
11
10

19

53 12
20
11
51 10
9

52

51

49

48
47

42
43
44

46 45
44 WCEB-02-04-014

W2-4-20
 UPPERSTRUCTURE / Pump Device
33. Remove slide ring (20) from pump casing (53).
34. Remove bearing nuts (9) (2 used) from shafts (13,
19) by using special tool (ST 3058).
39. Remove ball bearing (44) and gear shaft (46)
from the upper side of gear casing (49) by using
special tool (ST 1393).

ST 3058

9
46

44

W137-02-04-023

W178-02-11-085

35. Remove bearings (10, 12) (2 used for each) and

rings (11) (2 used) from shafts (13, 19) by using a 40. Remove gear (45) and ball bearing (44) from gear
press. casing (49).

41. Install a shackle to the bolt hole on the periphery

CAUTION: Pump casing (53) weight: 42 kg of gear casing (49). Hoist and turn over gear
(93 lb) casing (49) by using a nylon sling.

36. Attach a nylon sling onto pump casing (53). Hoist 42. Remove retaining ring (47) and oil seal (48) from
and place pump casing (53) with the mounting gear casing (49).
surface for the regulator facing upward.

37. Remove retaining rings (52) (2 used) and oil seals

(51) (2 used) from pump casing (53).

38. Remove retaining ring (42) from gear casing (49).

Remove retaining ring (43) from gear shaft (46).

W2-4-21
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF PUMP DEVICE
81 66 65 18 16 15 17 12 20 11 10 9 51 29

26

19

52

13

26

27

64 60, 63 62 18 82 16 15 17 12 11 10 9 51

72 73 71 74 8 7 56 57 61 60 59 58 53

70

79

76

78

79
W178-02-11-086

72 67 22 21 83 14 24 23
80

W2-4-22
 UPPERSTRUCTURE / Pump Device

38, 39, 40 41 34, 35, 36 43 42 45 44

32, 33 31 30 6 5 4 3 37

46

25

47

48

50

49

WCEB-02-04-004
68 75 2 1 55 54 28

1- Socket Bolt (4 Used) 22 - Plug (2 Used) 43 - Retaining Ring 64 - Right Valve Plate
2- Right Regulator 23 - O-Ring 44 - Ball Bearing (2 Used) 65 - Backup Ring
3- Socket Bolt (2 Used) 24 - Stopper 45 - Gear 66 - O-Ring
4- Socket Bolt (2 Used) 25 - Plug 46 - Gear Shaft 67 - Spring Pin (2 Used)
5- Socket Bolt (2 Used) 26 - Retaining Ring (2 Used) 47 - Retaining Ring 68 - Pressure Sensor (2 Used)
6- Left Regulator 27 - Gear 48 - Oil Seal 69 - O-Ring (2 Used)
7- O-Ring (4 Used) 28 - Gasket 49 - Gear Casing 70 - Selector Head
8- O-Ring (6 Used) 29 - Gear 50 - Spring Pin (2 Used) 71 - O-Ring (4 Used)
9- Bearing Nut (2 Used) 30 - Plug 51 - Oil Seal (2 Used) 72 - Socket Bolt (16 Used)
10 - Bearing (2 Used) 31 - Elbow 52 - Retaining Ring (2 Used) 73 - Stopper S (2 Used)
11 - Ring (2 Used) 32 - Plug 53 - Pump Casing 74 - O-Ring (2 Used)
12 - Bearing (2 Used) 33 - O-Ring 54 - Spring Washer (6 Used) 75 - Socket Bolt (12 Used)
13 - Shaft 34 - Gasket 55 - Bolt (6 Used) 76 - Set Screw (2 Used)
14 - Pin (2 Used) 35 - Socket Bolt (2 Used) 56 - Spring Pin (2 Used) 77 - Servo Piston (2 Used)
15 - Center Shaft (2 Used) 36 - Pipe 57 - O-Ring (2 Used) 78 - Pin (2 Used)
16 - Spring (2 Used) 37 - Level Gauge 58 - O-Ring (2 Used) 79 - O-Ring (2 Used)
17 - Plunger (14 Used) 38 - Socket Bolt (2 Used) 59 - Pin (2 Used) 80 - Stopper L (2 Used)
18 - Rotor (2 Used) 39 - Spring Washer (2 Used) 60 - Retaining Ring (12 Used) 81 - Left Valve Plate
19 - Shaft 40 - Washer (2 Used) 61 - Pin (2 Used) 82 - Pin (4 Used)
20 - Slide Ring 41 - Pilot Pump 62 - Lever (4 Used) 83 - Link (2 Used)
21 - O-Ring (2 Used) 42 - Retaining Ring 63 - Pin (4 Used)

W2-4-23
 UPPERSTRUCTURE / Pump Device

43 42 44 45 44

32, 33

49
WCEB-02-04-004

12 11 10

19

13

12 11 10 W178-02-11-089

W2-4-24
 UPPERSTRUCTURE / Pump Device
Assembly of Pump Device

1. Tap and install ball bearing (44) into gear casing

(49) with the stamped mark facing inside by using
a bar and hammer. Tap and listen to ring in order
to check that ball bearing (44) is installed
completely.
2. Place gear (45) on ball bearing (44). Insert gear
shaft (46) while aligning with the spline.
CAUTION: Be careful as bearing (10) is too
hot.
9. Apply hydraulic oil onto the inside of bearings (10)
(2 used). Install bearings (10) (2 used) to shafts
(13, 19) by using a press.

3. Tap and install ball bearing (44) into gear shaft

(46) with the stamped mark facing outside by
using a bar and hammer. Tap and listen to ring in
order to check that ball bearing (44) is installed
completely.

4. Install retaining ring (42) to gear casing (49).

Install retaining ring (43) to gear shaft (46).

5. Install O-ring (33) to plug (32). Install plug (32) to

gear casing (49).
: 22 mm
: 70 N⋅m (7 kgf⋅m, 52 lbf⋅ft)

6. Warm up bearings (10, 12) (2 used for each) to 50

to 80 °C (122 to 176 °F).

CAUTION: Be careful as bearing (12) is too

hot.

7. Apply hydraulic oil onto the inside of bearings (12)

(2 used). Install bearings (12) (2 used) to shafts
(13, 19) by using a press.

8. Install rings (11) (2 used) to shafts (13, 19).

W2-4-25
UPPERSTRUCTURE / Pump Device

WCEB-02-04-004

53 12 20 10 9

19

13

12 10 9 W178-02-11-089

W2-4-26
 UPPERSTRUCTURE / Pump Device
10. Set the pre-loads of bearings (10, 12) installed on
shaft (13) according to the following procedures.
• Apply hydraulic oil onto the thread part of bearing
nut (9). Tighten bearing nut (9) until bearing nut
(9) comes in contact with bearing (10) by using
special tool (ST 3058).
ST 3058

9
10

W178-02-11-090

• Install special tool (ST 3070) to bearing (10).

Rotate 2 to 3 turns and measure the starting
torque.

ST 3070

10

W178-02-11-091

• Adjust bearing nut (9) until the starting torque

reaches specification.
: 1.96±0.49 N⋅m
(0.20±0.05 kgf⋅m, 1.45±0.36 lbf⋅ft)
NOTE: If the starting torque is higher than the limit
of specified torque, loosen bearing nut (9).
Tap the shaft end and release the load of
bearing (10).

11. Set the pre-loads of bearings (10, 12) installed on

shaft (19) in the same way as step 10.

12. Install slide ring (20) to the side to insert shaft (19)
in pump casing (53).

W2-4-27
UPPERSTRUCTURE / Pump Device

53 12 10 51

19

52

13

51

Regulator Mounting Surface 53

W178-02-11-092
24 23

W2-4-28
 UPPERSTRUCTURE / Pump Device
13. Warm up pump casing (53) to 50 to 80 °C (122 to 19. Install special tools (ST 2649, ST 2650) over the
176 °F). spline parts of shafts (13, 19).
NOTE: If special tools are not available, wind the
14. Apply hydraulic oil onto the outside of bearings vinyl tape over the spline part of the shaft in
(10, 12) installed on shaft (19). Install shaft (19) to order not to damage oil seal (51).
pump casing (53) by using special tool.
If it is difficult to insert shaft (19), tap shaft (19) by
using a bar.
Special Tool
ST 2650

51
M8, Pitch 1.25 mm

53

19

W178-02-11-094
ST 2649
Wooden Block
Wooden Block 20. Apply grease onto the inside of oil seals (51) (2
used). Evenly tap and install oil seals (51) (2
W178-02-11-093
used) to shafts (13, 19).

15. Install shaft (13) to pump casing (53) in the same 21. Remove special tools (ST 2649, ST 2650) from
way as step 14. shafts (13, 19).

16. Wait for pump casing (53) in order to cool down to 22. Install retaining rings (52) (2 used) to pump casing
the temperature lower than 40 °C (104 °F). (53).

17. Install O-ring (23) to stopper (24). Install stopper

(24) to pump casing (53).
: 19 mm
: 34.5 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

CAUTION: Pump casing (53) weight: 65 kg

(150 lb)

18. Attach a nylon sling onto pump casing (53). Hoist

and place pump casing (53) with the mounting
surface for the regulator facing upward.

W2-4-29
UPPERSTRUCTURE / Pump Device

45

50

49
WCEB-02-04-004

75 53 55 54 28

53 29

26

19

13

26

17 27 W178-02-11-096

W2-4-30
 UPPERSTRUCTURE / Pump Device
23. Align the matching marks and install gears (27,
29) to shafts (13, 19). Install retaining rings (26) (2
used) to shafts (13, 19).
When replacing the shaft and the gear, install the
gear according to the following procedure.
• Secure special tool (ST 7934) to the plunger (17)
mounting side of shafts (13, 19).
19
ST 7934 13
CAUTION: Pump casing (53) weight: 70 kg
(160 lb)
25. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the socket bolt (75) hole on pump casing (53).
Hoist pump casing (53).
While engaging gear (45) with gear (29), install
pump casing (53) to gear casing (49) with bolts
(55) and spring washers (54) (6 used for each).
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)

M8, Pitch 1.25 mm W178-02-11-097

• Turn shafts (13, 19) clockwise, viewed from the

mounting side for gears (27, 29), until shafts (13,
19) come into contact with special tool. (Remove
a play in periphery direction.)
• Install gear (27) and retaining ring (26) to the
spline of shaft (13).
• Insert gear (29) into the spline of shaft (19) and
engage with gear (27). If gear (29) does not
engage, turn and adjust shaft (19) in a play range
of special tool.
• Install retaining ring (26) to the spline of shaft
(19).
• Remove special tool (ST 7934).

24. Install spring pins (50) (2 used) to gear casing

(49). Install gasket (28).

W2-4-31
 UPPERSTRUCTURE / Pump Device
34, 35, 36
38, 39, 40 41 41 38 39, 40

49
WCEB-02-04-004

62 83 15 14 17 53
70

19

13

W178-02-11-096
62 59, 61 83 15 14 17

W2-4-32
 UPPERSTRUCTURE / Pump Device
26. Apply THREEBOND #1215 onto the mounting 30. Insert plungers (17) (7 used for each) into shafts
surface of pilot pump (41). Install pilot pump (41) (13, 19).
to gear casing (49) with socket bolts (38), spring
washers (39) and washers (40) (2 used for each). 31. Apply grease onto pins (14) (2 used). Install pin
: 8 mm (14) to center shafts (15) (2 used).
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
32. Apply grease onto the spherical surface of center
27. Install gasket (34) and pipe (36) to gear casing shafts (15) (2 used). Install center shafts (15) (2
(49) with socket bolts (35) (2 used). used) to shafts (13, 19).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

IMPORTANT: As the pump performance may be

changed, do not deform link (83).
28. Align with the groove for pin (59) on pump casing
(53) and install the link (83) assemblies (2 used),
with lever (62) facing to the selector head (70)
side.
NOTE: Both surfaces of pin (59) are parallel to
each other. Align the parallel surface with
the groove.
59
83
61
53

Parallel Parallel W178-02-11-098

Surface Surface
29. Apply hydraulic oil onto the plunger (17) mounting
surface of shafts (13, 19).

W2-4-33
 UPPERSTRUCTURE / Pump Device

60 62 16 79 18 15 14 17 53

63

81

64 60, 63 62 18 83 16 15 14 17 W178-02-11-099

8 65 18 53

70 19

W178-02-04-016
67 14

W2-4-34
 UPPERSTRUCTURE / Pump Device
33. Install springs (16) (2 used) to center shafts (15) 38. Install backup ring (65), O-ring (66) and O-rings
(2 used). (8) (6 used) to pump casing (53).

34. Insert center shafts (15) (2 used) and plungers 39. Install spring pins (67) (2 used) to pump casing
(17) (14 used) into rotors (18) (2 used). (53).

35. Insert the round file into the center hole on center
shaft (15). While rotating center shaft (15) by
using the round file, insert pin (14) into the groove
of rotor (18). (Both right and left pumps)
NOTE: If pin (14) does not enter into the groove on
rotor (18), selector head (70) cannot be
installed to pump casing (53).

36. Insert pins (63) (2 used) of right valve plate (64)

into the hole on levers (62) (2 used) for right
regulator (2). Install retaining rings (60) (2 used).
Check the direction to install right valve plate (64).
81 64
Upward

W178-02-11-100

37. Insert pins (63) (2 used) of left valve plate (81)

into the hole on levers (62) (2 used) for left
regulator (6). Install retaining rings (60) (2 used).
Check the direction to install left valve plate (81).

W2-4-35
 UPPERSTRUCTURE / Pump Device

Eyebolt
Mounting Hole

75

WCEB-02-04-004

70 75

72 71 73 74 18 53

70

77

76

78

Mounting Surface for

Suction Pipe
W178-02-04-016

79 72 64, 81 80 67 14

W2-4-36
 UPPERSTRUCTURE / Pump Device
40. Apply hydraulic oil onto servo pistons (77) (2
used). Insert servo pistons (77) (2 used) into
selector head (70).
41. Apply LOCTITE LI829 onto the thread part of set
screws (76) (2 used). Install pins (78) (2 used) to
servo pistons (77) (2 used) with set screws (76) (2
used).
: 6 mm
: 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
CAUTION: Selector head (70) weight: 29 kg
(64 lb)
45. Install O-rings (74) (2 used) to stoppers S (73) (2
used). Apply grease onto O-rings (74) (2 used).
Install stoppers S (73) (2 used) to selector head
(70) with socket bolts (72) (8 used).
: 6 mm
: 19.5 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
46. Install O-rings (79) (2 used) to stoppers L (80) (2
used). Apply grease onto O-rings (79) (2 used).
Install stoppers L (80) (2 used) to selector head
(70) with socket bolts (72) (8 used).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

42. Install eyebolts (M12, Pitch 1.75 mm) (2 used)

into the thread hole for the suction pipe on
selector head (70). Attach a nylon sling onto
eyebolts (2 used). Hoist selector head (70).
Place selector head (70) on pump casing (53)
while aligning selector head (70) with spring pin
(67).
NOTE: Check the clearance between selector
head (70) and pump casing (53) in order to
compare with the clearance before
disassembling. If the clearance is larger,
pin (14) may not be inserted into the groove
on rotor (18), or pin (78) may not be
inserted into the holes on valve plates (64,
81).

43. Install selector head (70) to pump casing (53) with

socket bolts (75) (12 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

44. Install O-rings (71) (4 used) to selector head (70).

W2-4-37
 UPPERSTRUCTURE / Pump Device

47

19

48

49
WCEB-02-04-004

53 7 56 57 61 58

5 6 3

83 2 1
WCEB-02-04-015

W2-4-38
 UPPERSTRUCTURE / Pump Device
47. Install O-rings (58) (2 used), O-rings (57) (2 used),
O-rings (7) (4 used) and spring pins (56) (2 used) CAUTION: Pump device weight: 160 kg (360
to pump casing (53). lb)

48. Install right regulator (2) to pump casing (53)
according to the following procedure.
• Adjust the sleeve position so that two grooves in
both sleeves on right regulator (2) are in a line.
• Place right regulator (2) on pump casing (53).
Insert pin (61) for link (83) into two grooves on the
sleeve.
• Move right regulator (2) so that spring pin (56) out
of pump casing (53) can enter into right regulator
(2).
• Install right regulator (2) to pump casing (53) with
socket bolts (1) (4 used).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
61
2 Sleeve
50. Hoist and place selector head (70) with the
regulator mounting side facing upward.
51. Insert special tool (ST 2650) to shaft (19). Apply
grease onto oil seal (48). Install oil seal (48) to
shaft (19).
Remove special tool (ST 2650). Tap and install oil
seal (48).
NOTE: If special tool (ST 2650) is not available,
wind the vinyl tape over the spline parts of
shaft (19) in order to protect oil seal (48).
Install oil seal (48).
ST 2650
48

53 W178-02-11-101
83 56
W178-02-11-103
49. Install left regulator (6) to pump casing (53) with
socket bolts (3) (2 used) and socket bolts (5) (2 52. Install retaining ring (47) to gear casing (49).
used) in the same way as step 48.
: 8 mm
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W2-4-39
 UPPERSTRUCTURE / Pump Device

31 30 37 36 25

49

WCEB-02-04-004

68

W178-02-04-016

W2-4-40
 UPPERSTRUCTURE / Pump Device
53. Wind the seal tape onto elbow (31). Install elbow
(31) to gear casing (49). Add engine oil (1.0 L, 0.3
US gal) through the elbow (31) hole.

54. Wind the seal tape onto plug (30). Install plug (30)
to elbow (31).
: 30 mm
: 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

49 30

31

W1V1-02-04-010

IMPORTANT: The breather hole of plug (25) is

located at the left side, viewed from
the front of gear casing (49).
55. Wind the seal tape onto plug (25). Install plug (25)
to gear casing (49).
: 17 mm
: 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

56. Insert level gauge (37) into pipe (36).

57. Install pressure sensors (68) (2 used) to selector

head (70).
: 27 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

W2-4-41
 UPPERSTRUCTURE / Pump Device
DISASSEMBLY OF REGULATOR

Left Regulator

Right Regulator 2 14
13
3 12
WCEB-02-04-016
11
10
9

4 15

16

17

5 6
7
8

18
19 28
20
23
24 21
22

31 32
25 30 33
29 34
26
35
27 36
37
28 38
39
40
41
WCEB-02-04-019
42

1- Pipe 12 - Cylinder 23 - Lock Nut 33 - Lock Nut

2- Socket Bolt (2 Used) 13 - O-Ring 24 - Lock Nut 34 - Lock Nut
3- Solenoid Valve 14 - Piston 25 - Cover 35 - Cover
4- O-Ring 15 - Sleeve 26 - Set Bolt 36 - Adjuster
5- Low Pressure Sensor 16 - Spool 27 - Lock Nut 37 - O-Ring
6- O-Ring 17 - Spring 28 - Socket Bolt (8 Used) 38 - Stopper
7- O-Ring 18 - Spring 29 - O-Ring 39 - O-Ring
8- O-Ring 19 - O-Ring 30 - Cylinder 40 - Spring
9- Piston 20 - Stopper 31 - Piston 41 - Spool
10 - O-Ring 21 - O-Ring 32 - Casing 42 - Sleeve
11 - Backup Ring 22 - Adjuster

W2-4-42
 UPPERSTRUCTURE / Pump Device
Disassembly of Regulator IMPORTANT: As the setting changes, do not turn
• The regulators are used for right pump and left lock nuts (33, 34).
pump. The inner structure in the regulator is fully 4. Remove socket bolts (28) (4 used) from cover
identical, and the difference is only in its (35). Remove cover (35) and piston (14) from
accessories. casing (32). The stopper (38) assembly is
Here the left regulator is explained. removed with cover (35) together.
: 6 mm
IMPORTANT: As the setting changes, do not
disassemble adjusting screws (23, 5. Remove springs (17, 18) from casing (32).
24, 26, 27, 33 and 34).
When adjusting screws (23, 24, 26, 6. Insert a round bar into the hole on casing (32).
27, 33 and 34) must be disassembled, Push the spool (16) end. Remove cylinder (12),
carry out adjustment according to sleeve (15) and spool (16) from casing (32).
the procedure of performance test Piston (9) is removed with cylinder (12) together.
after assembling.
7. Remove piston (9) from cylinder (12).
1. Clamp casing (32) in a vise. Remove pipe (1)
from casing (32). 8. Remove spring (40) from casing (32).
: 22 mm
9. Insert a round bar into the hole on casing (32).
2. Remove socket bolts (2) (2 used) from solenoid Push the spool (41) end. Remove cylinder (30),
valve (3). Remove the solenoid valve (3) sleeve (42) and spool (41) from casing (32).
assembly and O-rings (6, 7, 8) from casing (32). Piston (31) is removed with cylinder (30) together.
: 8 mm
10. Remove piston (31) from cylinder (30).
IMPORTANT: As the setting changes, do not turn
set bolt (26), lock nuts (23, 24 and
27).
3. Remove socket bolts (28) (4 used) from cover
(25). Remove cover (25) from casing (32). Set
bolt (26) and the stopper (20) assembly are
removed with cover (25) together.
: 6 mm

W2-4-43
 UPPERSTRUCTURE / Pump Device
ASSEMBLY OF REGULATOR
2 3, 6, 7, 8

4, 5

WCEB-02-04-016

24 23 22 19 21 20 18 17 15 16 32 9 10 11 12 13 14

35

26
38
27

28 WCEB-02-04-017

25 29 30 31 42 41 40 37 39 34 36 33

1 - Pipe 12 - Cylinder 23 - Lock Nut 33 - Lock Nut

2 - Socket Bolt (2 Used) 13 - O-Ring 24 - Lock Nut 34 - Lock Nut
3 - Solenoid Valve 14 - Piston 25 - Cover 35 - Cover
4 - O-Ring 15 - Sleeve 26 - Set Bolt 36 - Adjuster
5 - Low Pressure Sensor 16 - Spool 27 - Lock Nut 37 - O-Ring
6 - O-Ring 17 - Spring 28 - Socket Bolt (8 Used) 38 - Stopper
7 - O-Ring 18 - Spring 29 - O-Ring 39 - O-Ring
8 - O-Ring 19 - O-Ring 30 - Cylinder 40 - Spring
9 - Piston 20 - Stopper 31 - Piston 41 - Spool
10 - O-Ring 21 - O-Ring 32 - Casing 42 - Sleeve
11 - Backup Ring 22 - Adjuster

W2-4-44
 UPPERSTRUCTURE / Pump Device
Assembly of Regulator
IMPORTANT: Two holes for sleeves (15, 42) on
casing (32) are the same bores. The
shapes of various parts in casing
(32) are very similar. Check the
illustration and assemble the
regulator.
1. Clean all parts and apply hydraulic oil.
2. Insert spool (41) into sleeve (42). Install sleeve
(42) to the center of casing (32) by using a round
bar. Check the direction to install sleeve (42),
spool (41) and piston (31).
3. Install O-ring (29) to cylinder (30).
4. Insert piston (31) into cylinder (30). Install cylinder
(30) to casing (32).
5. Insert spool (16) into sleeve (15). Install sleeve
(15) to the center of casing (32) by using a round
bar. Check the direction to install sleeve (15) and
spool (16).
6. Install O-rings (10, 13) and backup ring (11) to
cylinder (12).
7. Insert piston (9) into cylinder (12). Install cylinder
(12) to casing (32).
8. Install piston (14) to cover (35) from the mounting
side for casing (32).
W2-4-45
9. Install O-ring (37) and spring (40) to the stopper
(38) assembly with cover (35) attached. Install
cover (35) to casing (32) with socket bolts (28) (4
used).
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
10. Install O-ring (21) and springs (17, 18) to the
stopper (20) assembly with cover (25) attached.
Install cover (25) to casing (32) with socket bolts
(28) (4 used).
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
11. Apply grease onto O-rings (6, 7 and 8). Install
O-rings (6, 7 and 8) to solenoid valve (3). Install
solenoid valve (3) to casing (32) with socket bolts
(2) (2 used).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
12. Apply grease onto the thread part of pipe (1).
Install pipe (1) to casing (32).
: 22 mm
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
 UPPERSTRUCTURE / Pump Device
STRUCTURE OF PILOT PUMP 9
8
6
1
2
3
7
6
5
4
3
2
1

10
11
13 12
6
1
2
3
7
6
14

3
2
1
15 WCEB-02-04-018

16
17

3 3 3 15

9
13

5
17

16

14

8 7 10 12 7

1 2 1 2 WCEB-02-04-010

W2-4-46
 UPPERSTRUCTURE / Pump Device

Wrench Size Tightening Torque

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
1 Plate Seal 4
2 Backup Ring 4
3 Side Plate 4
4 Rear Drive Gear 1
5 Driven Gear 1
6 Knock Pin 8
7 Gear Plate 2
8 Cover 1
9 Socket Bolt 4
10 Coupling 1
11 Stabilizer 2
12 Center Plate 1
13 Driven Gear 1
14 Front Drive Gear 1
15 Flange 1
16 Oil Seal 1
17 Retaining Ring 1

W2-4-47
 UPPERSTRUCTURE / Pump Device
(Blank)

W2-4-48
 UPPERSTRUCTURE / Control Valve
REMOVAL AND INSTALLATION OF CON-
TROL VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Open cover (1). 1

WCEB-02-05-002

3 4
2. Remove sems bolts (3) (6 used) from cover (4).
Remove cover (4) from cover (2), supports (5, 6)
2
and bracket (7).
: 17 mm

WCEB-02-05-001

5 6

WCEB-02-05-003

WCEB-02-05-004

W2-5-1
 UPPERSTRUCTURE / Control Valve
3. Remove sems bolts (9) (3 used) from cover (10).
Remove cover (10) from cover (8). 9
: 17 mm 10

WCEB-02-05-008

2 11
4. Remove sems bolts (11) (6 used) from cover (8).
Remove cover (8) from support (5) and cover (2).
: 17 mm
8
CAUTION: The cover (2) assembly weight: 27
kg (60 lb)

5. Attach a nylon sling onto cover (2). Hoist and hold

cover (2). Remove sems bolts (12) (2 used) from
cover (2). Remove the cover (2) assembly from
main frame (13).

WCEB-02-05-006
13 12

5 6
6. Remove sems bolts (14) (2 used) from support
(6).
: 17 mm 14

15

WCEB-02-05-003

7. Remove sems bolts (16) (4 used) from stay (15). 15

Remove stay (15) from bracket (17) and support
(6)
: 17 mm

WCEB-02-05-004

17 16

W2-5-2
 UPPERSTRUCTURE / Control Valve
8. Remove sems bolts (18) (5 used) from supports (5,
5 6
6). Remove supports (5, 6) from main frame (13).
: 17 mm, 19 mm

18 13 18 WCEB-02-05-003

9. Remove the bolts (13 used) from the clamps for

the pipings (26 used). Remove the clamps (13
used) from the pipings (26 used).
: 19 mm

10. Remove sems bolts (19) (3 used) from clamps

(20) (3 used).
: 17 mm
19

11. Remove sems bolts (25) (3 used) from clips (24) 20

(3 used).
: 17 mm 21

22

23 WCEB-02-05-010

12. Remove sems bolts (23) (4 used) from bracket

(22). Remove bracket (22) from brackets (21, 31).
: 19 mm

13. Remove sems bolt (28) from clip (27). Remove

clip (27) from bracket (30).
: 17 mm
24, 25

24, 25
14. Remove sems bolts (29) (2 used) from bracket
(30). Remove the bracket (26) assembly from
bracket (30).
: 17 mm

22

26
WCEB-02-05-009
30 29 23 27, 28

W2-5-3
 UPPERSTRUCTURE / Control Valve
15. Remove bolts (36) (2 used) from coupling (2).
Remove the coupling (34) assembly from the pip- 31 32 33
ings and hydraulic oil tank (35).
: 13 mm

16. Remove socket bolts (31) (104 used) from split

flanges (32) (52 used). Remove split flanges (32)
(52 used) from the pipings (26 used). Disconnect
34
the pipings (26 used) from control valve (33). Cap
the open ends. Attach an identification tag onto 35
the disconnected the pipings for assembling.
: 6 mm, 8 mm 36

32

17. Disconnect the hoses (35 used) from control valve 3-Spool Solenoid
WCEB-02-05-010

(33). Cap the open ends. Attach an identification Valve Unit

tag onto the disconnected hoses for assembling.
: 19 mm, 22 mm

18. Remove the 3-spool solenoid valve unit from con-

trol valve (33). (Refer to REMOVAL AND IN-
STALLATION OF 3-SOOL SOLENOID VALVE
UNIT on W2-11-1.)
Hose

19. Disconnect the connectors (2 used) from control

valve (34).

20. Disconnect the connectors (4 used).

Eyebolt Mounting WCEB-02-05-009

Hole
CAUTION: The control valve (33) assembly
weight: 155 kg (342 lb) 33

21. Install eyebolts (M14, Pitch 2.0 mm) (2 used) to

control valve (33). Attach a nylon sling onto eye-
bolts. Hoist and hold control valve (33).

Eyebolt Mounting
Hole
WCEB-02-05-012

W2-5-4
 UPPERSTRUCTURE / Control Valve

CAUTION: The control valve (33) assembly

weight: 155 kg (342 lb)

22. Remove bolts (38) (4 used) and washers (39) (4

used) from brackets (21, 31). Hoist and remove
the control valve (34) assembly from main frame
(13). 33
: 24 mm

CAUTION: Control valve (33) weight: 136 kg

(300lb)

23. While holding the control valve (33) assembly, 21, 39, 40
remove bolts (39) (6 used) and washers (40) (6
used) from brackets (21, 30). Remove brackets
(21, 30) from control valve (33).
: 22 mm
13

37, 38 WCEB-02-05-010

33

30

39, 40

13

37, 38 WCEB-02-05-009

W2-5-5
 UPPERSTRUCTURE / Control Valve
Installation Eyebolt Mounting
Hole

CAUTION: Control valve (33) weight: 136 kg 33

(300 lb)

1. Install eyebolts (M14, Pitch 2.0 mm) (2 used) to

control valve (33). Attach a nylon sling onto eye-
bolts. Hoist and hold control valve (33).

Eyebolt Mounting
Hole
WCEB-02-05-012

2. Install brackets (21, 30) to control valve (33) with

bolts (39) (6 used) and washers (40) (6 used).
: 22 mm
: 140 N⋅m (14 kgf⋅m, 10 lbf⋅ft) 33

CAUTION: The control valve (33) assembly

30
weight: 155 kg (300 lb)
39, 40
3. Hoist and align the control valve (33) assembly
with the mounting hole on main frame (13). Install
the control valve (33) assembly to main frame (13)
with bolts (37) (4 used) and washers (38) (4
used). 13
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
37, 38 WCEB-02-05-009

33

21, 39, 40

13

37, 38
WCEB-02-05-010

W2-5-6
 UPPERSTRUCTURE / Control Valve
4. Connect the pipings (26 used) to control valve 31 32 33
(33) with split flanges (32) (52 used) and socket
bolts (31) (104 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
: 8 mm
34
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
35

5. Connect the piping and hydraulic oil tank (35) with 36

the coupling (34) assembly. Secure coupling (34)
with bolts (36) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
32
6. Connect the hoses (35 used) to control valve (33).
: 19 mm 3-Spool Solenoid
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) Valve Unit WCEB-02-05-010

: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

7. Connect the connectors (2 used) to control valve

(33).

8. Connect the connectors (4 used). Hose

9. Install the 3-spool solenoid valve unit to control

valve (33). (Refer to REMOVAL AND INSTALLA-
TION OF 3-SPOOL SOLENOID VALVE UNIT on
W2-11-1.)

10. Secure harness (41) to bracket (30) with clip (27) WCEB-02-05-009

and sems bolt (28).

: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

11. Install the bracket (26) assembly to bracket (30)

with sems bolts (29) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

26
WCEB-02-05-009
30 29 27, 28, 41

W2-5-7
 UPPERSTRUCTURE / Control Valve
12. Install bracket (22) to brackets (21, 30) with sems
bolts (23) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

13. Secure the pilot hose to bracket (21) with clamps

(20) (3 used) and sems bolts (19) (3 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
19

20

21

22

23 WCEB-02-05-010

14. Secure the pilot hose to brackets (22, 30) with

clips (24) (3 used) and sems bolts (25) (3 used).
: 7 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

24, 25

24, 25

22

WCEB-02-05-009
30 23

5 6

15. Install supports (5, 6) to main frame (13) with

sems bolts (18) (5 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

18 13 18 WCEB-02-05-003

W2-5-8
 UPPERSTRUCTURE / Control Valve
16. Install stay (15) to support (6) with sems bolts (14)
6
(2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
14

15

WCEB-02-05-003

17. Install stay (15) to bracket (17) with sems bolts 15

(16) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-05-004

17 16

2
CAUTION: The cover (2) assembly weight: 27
kg (60 lb)

18. Attach a nylon sling onto the cover (2) assembly.

Hoist and align the cover (2) assembly with the
mounting hole on main frame (13). Install the
cover (2) assembly to main frame (13) with sems
bolts (12) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-05-006
13 12

W2-5-9
 UPPERSTRUCTURE / Control Valve
19. Install covers (2, 8) to supports (5, 6) with sems 2 11
bolts (11) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
8

5 6 WCEB-02-05-006

WCEB-02-05-003

20. Install cover (10) to support (5) with sems bolts (9) 9
10
(3 used).
: 17 mm 8
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-05-008
21. Install covers (2, 4) to supports (5, 6) and bracket 3 4
(7) with sems bolts (3) (6 used).
: 17 mm
2
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-05-001

WCEB-02-05-004

W2-5-10
 UPPERSTRUCTURE / Control Valve
22. Shut cover (1).

WCEB-02-05-002

W2-5-11
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE
4-SPOOL SIDE
X
1
2 47

3 29
23 48
4
5 30
6 49
24
7 31 41
8 50
25
9
Arm 32 42
10 Regenerative 26 51
Valve
(Switch Valve) 33
Boom 43
Anti-Drift 11 27
19 46
Valve
12 36
20 34 44 52 55
13
21 37 37
14 56
15 45
28 35 57
16 22 58
38
17 38 53
39 39 59
18 54
40
40
W
64 71
62
65
63 66
67 72
73 W
70

60 68
61 69

X 74 WCEB-02-05-013
1- O-Ring 20 - Washer 39 - O-Ring (2 Used) 57 - O-Ring
2- Screw 21 - O-Ring 40 - Plug (2 Used) 58 - Spring
3- Backup Ring 22 - Spool 41 - O-Ring 59 - Poppet
4- O-Ring 23 - O-Ring 42 - Bolt 60 - Cap
5- O-Ring 24 - Bolt 43 - Spring Seat 61 - Nut
6- O-Ring 25 - Spring Seat 44 - Spring 62 - Plug
7- Backup Ring 26 - Spring 45 - Spring Seat 63 - O-Ring
8- Backup Ring 27 - Spring Seat 46 - Main Spool 64 - Cap
9- O-Ring 28 - Main Spool 47 - O-Ring 65 - Retaining Ring
10 - Sleeve 29 - O-Ring 48 - Bolt 66 - Shim
11 - Spool 30 - Screw 49 - Spring Seat 67 - Nut
12 - Washer 31 - O-Ring 50 - Spring 68 - Pilot Housing
13 - Spring 32 - Bolt 51 - Spring Seat 69 - Socket Bolt (11 Used)
14 - Backup Ring 33 - Spring Seat 52 - Main Spool 70 - Overload Relief Valve
15 - O-Ring 34 - Spring 53 - O-Ring 71 - Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Plug 72 - Backup Ring
17 - Spring 36 - Main Spool 55 - Plug 73 - O-Ring
18 - Poppet 37 - Poppet (2 Used) 56 - Backup Ring 74 - Housing
19 - Spring 38 - Spring (2 Used)

W2-5-12
 UPPERSTRUCTURE / Control Valve
Disassembly of control valve 4-Spool side (Up-
per)
• Attach an identification tag which specifies the
location of spool in the housing for each spool in
order to assemble correctly.
1. Remove socket bolts (69) (11 used) from pilot
housing (68). Remove pilot housing (68) from
housing (74).
: 6 mm
2. Remove boom anti-drift valve assembly (5 to 16),
O-ring (4) and backup ring (3) from pilot housing
(68).
NOTE: Remove the boom anti-drift valve assem-
bly from pilot housing (68) by prying by
hand.
3. Remove plug (16), O-ring (15), backup ring (14),
spring (13), washer (12) and spool (11) from
sleeve (10).
4. Remove O-rings (5, 6, 9) and backup rings (7, 8)
from sleeve (10).
5. Remove cap (64), retaining ring (65), shim (66)
and nut (67) from pilot housing (68).
Remove screw (30) from pilot valve (68). Re-
move O-ring (29) from screw (30).
6. Remove cap (60) and nut (61) from pilot housing
(68).
Remove screw (2) from pilot housing (68). Re-
move O-ring (1) from screw (2).
W2-5-13
IMPORTANT: Remove main spool assemblies (28,
36, 46, 52) by turning. If they stick
even a little, try again instead of
pulling roughly.
7. Remove the main spool (28, 36, 46, 52) assem-
blies and O-rings (23, 31, 41, 47) from housing
(74).
IMPORTANT: Put the matching marks on main
spools (28, 36, 46, 52) and housing
(74).
8. Clamp main spools (28, 36, 46, 52) in a vise by
using wooden pieces. Remove bolts (24, 32, 42,
48), spring seats (25, 33, 43, 49), springs (26, 34,
44, 50) and spring seats (27, 35, 45, 51) from
main spools (28, 36, 46, 52).
9. Remove plugs (40) (2 used), O-rings (39) (2
used), springs (38) (2 used) and poppets (37) (2
used) from spools (36, 46).
10. Remove plug (54) and O-ring (53) from spool
(52).
11. Remove spring (17) and poppet (18) from hous-
ing (74) by using a magnet.
12. Remove spring (19), washer (20), O-ring (21) and
spool (22) from housing (74).
13. Remove plug (55), backup ring (56), O-ring (57),
spring (58) and poppet (59) from housing (74).
 UPPERSTRUCTURE / Control Valve

W
71

72
73 W
70

X 74 WCEB-02-05-013

W2-5-14
 UPPERSTRUCTURE / Control Valve
IMPORTANT: Do not turn the lock nut as the set
pressure is changed.
14. Turn and remove the cartridges of overload relief
valves (70, 71) from housing (74).
: 27 mm
Lock Nut
Cartridge

W176-02-06-017

15. Remove backup ring (72) and O-ring (73) from

housing (74).

W2-5-15
 UPPERSTRUCTURE / Control Valve

74

Bypass Shut-Out Valve

80
79
81
78

87
86
85
84 91
77 83
76 82 90
Check Valve 89
75 Orifice Load Check
(Arm 2 88
(Arm 1 Parallel 102
Circuit) Tandem Circuit)
101
100
99
98
97 Bucket Flow Rate
96 Control Valve
95 (Poppet Valve)
94
93
103 92 117
116
112 115
114
113

107
104 105 108
106 109
110
WCEB-02-05-014
111

74 - Housing 85 - Spring 96 - O-Ring 107 -Spool

75 - Plug 86 - Poppet 97 - Spring 108 -Washer
76 - O-Ring 87 - Bushing 98 - Plug 109 -Spring
77 - Plug 88 - O-Ring 99 - O-Ring 110 -O-Ring
78 - O-Ring 89 - Backup Ring 100 - Spring 111 -Plug
79 - Spring 90 - Spring 101 - Poppet 112 -O-Ring (2 Used)
80 - Seat 91 - Poppet 102 - Valve Seat 113 -Plug
81 - Spool 92 - O-Ring 103 - Pilot Plate 114 -Backup Ring
82 - O-Ring 93 - Backup Ring 104 - Socket Bolt 115 -O-Ring
83 - Backup Ring 94 - Bushing 105 - Socket Bolt (5 Used) 116 -Spring
84 - Plug 95 - Backup Ring 106 - Socket Bolt (4 Used) 117 -Poppet

W2-5-16
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 4-Spool Side (Side)
16. Remove plug (111) from pilot plate (103). Re-
move spring (109), washer (108) and spool (107)
from pilot plate (103).
: 36 mm
17. Remove O-ring (110) from plug (111).
18. Remove socket bolt (104), socket bolts (105) (5
used), socket bolts (106) (4 used) from pilot plate
(103). Remove pilot plate (103) and O-ring (112)
from housing (74).
: 6 mm, 8 mm
19. Remove the bushing (94) assembly from pilot
plate (103). Remove O-rings (92, 96), backup
rings (93, 95) and spring (97) from bushing (94).
22. Remove O-ring (82), backup ring (83), plug (84),
spring (85), poppet (86) and bushing (87) from
housing (74).
23. Remove plug (75) from plug (77). Remove O-ring
(76) from plug (75).
: 6 mm
24. Remove plug (77), spring (79), seat (80) and
spool (81) from housing (74). Remove O-ring
(78) from plug (77).
25. Remove plug (113), spring (116) and poppet
(117) from housing (74). Remove backup ring
(114) and O-ring (115) from plug (113).

20. Remove plug (98) from housing (74).

Clamp the stepped part of plug (98) in a vise by
using wooden pieces. Remove valve seat (102),
poppet (101), spring (100) and O-ring (99) from
plug (98).

21. Remove O-ring (88), backup ring (89), spring

(90) and poppet (91) from housing (74). (2
places)

W2-5-17
 UPPERSTRUCTURE / Control Valve

74

123
118
124 127
125
119 126
120 Check Valve
121 (Flow Combiner Cir-
cuit)
128

114
122
Auxiliary Flow Rate
Control Valve

129

Auxiliary Flow Rate Control Valve

130

W1F1-02-05-005

74 - Housing 121 - Backup Ring 125 - O-Ring 128 - O-Ring (4 Used)

118 - Poppet 122 - Plug 126 - Plug 129 - Pilot Housing
119 - Spring 123 - Poppet 127 - Overload Relief Valve (2 Used) 130 - Socket Bolt (5 Used)
120 - O-Ring 124 - Spring

W2-5-18
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 4-Spool Side
(Lower)

IMPORTANT: Do not turn the lock nut as the set

pressure is changed.
26. Turn and remove the cartridge of overload relief
valves (127) (2 used) from housing (74).
: 27 mm
Lock Nut
Cartridge

W176-02-06-017

27. Remove socket bolts (130) (5 used) from pilot

housing (129). Remove pilot housing (129) and
O-ring (128) from housing (74).
: 6 mm

28. Remove plug (126), spring (124) and poppet

(123) from housing (74). Remove O-ring (125)
from plug (126).

29. Remove plug (122), spring (119) and poppet

(118) from housing (74). Remove backup ring
(121) and O-ring (120) from plug (122).

W2-5-19
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF CONTROL VALVE
5-SPOOL SIDE 192
192
191 193
131 193
132
163
133
164
134 157
135 194
136 165
137 158
138 166
173
139 159
167
179
140
160
174
Arm Anti-Drift 142 185
Valve 143 141 180
161 168 175
144 151
145 181
149 176 186
146 156
162
182 187
147 177
148 169
183 188
150
170
171 178
152 189

172 184

190

195

WCEB-02-05-027
131 - Backup Ring 147 - Spring 166 - Spring 181 - Spring Seat
132 - O-Ring 148 - Poppet 167 - Spring Seat 182 - Spring
133 - Plug 149 - Backup Ring 168 - Main Spool 183 - Spring Seat
134 - O-Ring 150 - O-Ring 169 - Poppet 184 - Main Spool
135 - O-Ring 151 - Overload Relief Valve (3 Used) 170 - Spring 185 - O-Ring
136 - O-Ring 152 - O-Ring 171 - O-Ring 186 - Bolt
137 - Backup Ring 156 - Main Relief Valve 172 - Plug 187 - Spring Seat
138 - Backup Ring 157 - O-Ring 173 - O-Ring 188 - Spring
139 - O-Ring 158 - Bolt 174 - Bolt 189 - Spring Seat
140 - Sleeve 159 - Spring Seat 175 - Spring Seat 190 - Main Spool
141 - Spool 160 - Spring 176 - Spring 191 - Socket Bolt (10 Used)
142 - Washer 161 - Spring Seat 177 - Spring Seat 192 - Plug (2 Used)
143 - Spring 162 - Main Spool 178 - Main Spool 193 - O-Ring (2 Used)
144 - Backup Ring 163 - O-Ring 179 - O-Ring 194 - Pilot Housing
145 - O-Ring 164 - Bolt 180 - Bolt 195 - Housing
146 - Plug 165 - Spring Seat

W2-5-20
 UPPERSTRUCTURE / Control Valve
Disassembly of 5-Spool Side (Upper)

1. Remove socket bolts (191) (10 used) from pilot
housing (194). Remove pilot housing (194) from
housing (195).
: 6 mm
2. Remove arm anti-drift valve assembly (133 to
146), O-ring (132) and backup ring (131) from
pilot housing (194).
NOTE: Remove the arm anti-drift valve assembly
from pilot housing (194) by prying by hand.
3. Remove plug (146), spring (143), washer (142)
and spool (141) from sleeve (140). Remove
backup ring (144) and O-ring (145) from plug
(146).
7. Remove plug (172), spring (170) and poppet
(169) from main spool (168). Remove O-ring
(171) from plug (172).
8. Remove spring (147), poppet (148), backup ring
(149) and O-ring (150) from housing (195).
IMPORTANT: Do not turn the lock nut as the set
pressure is changed.
9. Turn the cartridges of overload relief valves (151)
(3 used) and the cartridge of main relief valve
(156). Remove them from housing (195).
: 27 mm
Lock Nut
Cartridge

4. Remove plug (133), O-rings (134, 135, 136, 139)

and backup rings (137, 138) from sleeve (140).

5. Remove main spool assemblies (162, 168, 178, W176-02-06-017

184, 190) and O-rings (152, 157, 163, 173, 179,
185) from housing (195).

IMPORTANT: Put the matching marks on main

spools (162, 168, 178, 184, 190) and
housing (195).
6. Clamp main spools (162, 168, 178, 184, 190) in a
vise by using wooden pieces. Remove bolts (158,
164, 174, 180, 186), spring seats (159, 165, 175,
181, 187), springs (160, 166, 176, 182, 188) and
spring seats (161, 167, 177, 183, 189) from main
spools (162, 168, 178, 184, 190).

W2-5-21
 UPPERSTRUCTURE / Control Valve

Load Check 221 Load Check

Auxiliary Flow Rate 205 Valve (Arm 1 Valve (Arm 2
Control Valve Parallel Circuit) 222 Parallel Circuit)
206 223
(Poppet Valve) 207 216
217 224
208
209 218
Load Check 210 219
199 Valve 211 220
(Travel Parallel 201 212
200 Circuit) 202 213
203 214
204 215

196
197
198

195

231

232
230
233
Auxiliary Flow Rate 234
Control Valve
(Switch Valve) 229
228
227
226 WCAB-02-05-006
225
195 - Housing 205 - O-Ring 215 - Valve Seat 225 - Plug
196 - Socket Bolt 206 - Backup Ring 216 - O-Ring 226 - O-Ring
197 - Cover 207 - Bushing 217 - Backup Ring 227 - Spring
198 - O-Ring 208 - Backup Ring 218 - Plug 228 - Washer
199 - Socket Bolt (6 Used) 209 - O-Ring 219 - Spring 229 - Spool
200 - Pilot Plate 210 - Spring 220 - Poppet 230 - Socket Bolt (9 Used)
201 - O-Ring 211 - Plug 221 - O-Ring 231 - Socket Bolt
202 - Backup Ring 212 - O-Ring 222 - Backup Ring 232 - Pilot Plate
203 - Spring 213 - Spring 223 - Spring 233 - O-Ring
204 - Poppet 214 - Poppet 224 - Poppet 234 - O-Ring

W2-5-22
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 5-Spool Side (Side)

10. Remove plug (225) from pilot housing (232). 16. Remove socket bolts (199) (6 used) from pilot
Remove O-ring (226), spring (227), washer (228) plate (200). Remove pilot plate (200) from hous-
and spool (229) from pilot housing (232). ing (195).
: 36 mm : 6 mm

11. Remove socket bolts (230) (9 used) and Socket
Bolt (231) from pilot plate (232). Remove pilot
plate (232) and O-rings (233, 234) from housing
(195).
: 6 mm, 8 mm
12. Remove bushing (207) from pilot plate (232).
Remove O-rings (205, 209), backup rings (206,
208) and spring (210) from bushing (207).
17. Remove O-ring (216), backup ring (217), plug
(218), spring (219) and poppet (220) from the pi-
lot plate (200) mounting surface of housing (195).
(2 places)
18. Remove O-ring (221), backup ring (222), spring
(223) and poppet (224) from the pilot plate (200)
mounting surface of housing (195).

13. Remove plug (211) from the pilot plate (232)

mounting surface of housing (195).
Clamp the stepped part of plug (211) in a vise by
using wooden pieces. Remove valve seat (215),
poppet (214), spring (213) and O-ring (212) from
plug (211).

14. Remove O-ring (201), backup ring (202), spring

(203) and poppet (204) from the pilot plate (232)
mounting surface of housing (195).

15. Remove O-ring (221), backup ring (222), spring

(223) and poppet (224) from the pilot plate (232)
mounting surface of housing (195). (3 places)

W2-5-23
 UPPERSTRUCTURE / Control Valve

195

249
243 250
244 248
251
235
245
236 252
237 246

238 253
247

239 259
240

241

242
Auxiliary Flow
Combiner
Valve 254 257
255 258
255 256

256 WCAB-02-05-007

195 - Housing 241 - Spring 248 - Overload Relief Valve 254 - Socket Bolt (9 Used)
235 - Plug 242 - Bolt 249 - O-Ring 255 - O-Ring (2 Used)
236 - Spring 243 - Plug 250 - Backup Ring 256 - Plug (2 Used)
237 - Poppet 244 - Spring 251 - O-Ring 257 - O-Ring
238 - Spool 245 - Poppet 252 - Plug 258 - Plug
239 - O-Ring 246 - Spool 253 - O-Ring (5 Used) 259 - Pilot Housing
240 - Washer 247 - O-Ring

W2-5-24
 UPPERSTRUCTURE / Control Valve
Disassembly of Control Valve 5-Spool Side
(Lower)

IMPORTANT: Do not turn the lock nut as the set

pressure is changed.
19. Turn and remove the cartridge of overload relief
valve (248) from housing (195).
: 27 mm
Lock Nut
Cartridge

W176-02-06-017

20. Remove socket bolts (254) (9 used) from pilot

housing (259). Remove pilot housing (259) and
O-rings (253) (5 used) from housing (195).
: 6 mm

21. Remove O-rings (239, 247), spool assembly (243

to 246) and auxiliary flow combiner valve assem-
bly (235 to 242) from housing (195).

IMPORTANT: Do not remove plug (235), spring

(236) and poppet (237) from spool
(238). When replacing these parts,
replace them as an assembly.
22. Clamp spool (238) in a vise by using wooden
pieces. Remove bolt (242), spring (241) and
washer (240) from spool (238).

IMPORTANT: Do not remove plug (243), spring

(244) and poppet (245) from spool
(246). When replacing these parts,
replace them as an assembly.

W2-5-25
 UPPERSTRUCTURE / Control Valve
ASSEMBLY AND DISASSEMBLY OF
4-SPOOL SIDE AND 5-SPOOL SIDE

195

267
266

261
262
264
263

74
265
268
269
260 270
271 272
273
274
275

276
280
277 279
278
WCEB-02-05-021

74 - Housing 264 - Backup Ring 270 - O-Ring 276 - O-Ring

195 - Housing 265 - O-Ring 271 - O-Ring 277 - O-Ring
260 - Socket Bolt (9 Used) 266 - O-Ring 272 - Backup Ring 278 - Backup Ring
261 - O-Ring 267 - Backup Ring 273 - O-Ring 279 - O-Ring
262 - O-Ring 268 - O-Ring 274 - O-Ring 280 - Backup Ring
263 - O-Ring 269 - Backup Ring 275 - O-Ring

W2-5-26
 UPPERSTRUCTURE / Control Valve
Disassemble Assemble

1. Install O-rings (261 to 263, 265, 266, 268, 270,

CAUTION: Housing (74) weight: 45 kg (100
271, 273 to 277, 279) and backup rings (264, 267,
Ib)
269, 272, 278, 280) to housing (195).
Housing (195) weight: 49 kg (110 lb)

1. Remove socket bolts (260) (9 used) from housing
(74). Divide housing (74) and housing (195).
2. Remove O-rings (261 to 263, 265, 266, 268, 270,
271, 273 to 277, 279) and backup rings (264, 267,
269, 272, 278, 280) from housing (195).
CAUTION: Housing (74) weight: 45 kg (100
Ib)
Housing (195) weight: 49 kg (110 Ib)
2. Connect housing (74) and housing (195) with
socket bolts (260) (9 used).
: 12 mm
: 108+9.8 N·m (11+1 kgf·m 80+7 lbf·ft)

W2-5-27
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE
4-SPOOL SIDE 48
A
23 63 62 31 41 47 49
24 32, 42
19 25 33, 43 50

20 55 34, 44
26 51
21
56, 57
22 58 27 35, 45
59
74
52

28 36, 46
37

38

Boom 1
WCEB-02-05-016 39 53

65, 66 40 54
64 Boom Anti-Drift Valve WCEB-02-05-015
67 5
68 29 10
60 6
30 11
61
7
1 8
2 14 9
12
Boom
15 13
Anti-Drift Valve
16
17
18

3 4 Section A W176-02-05-022 W176-02-05-025

1- O-Ring 20 - Washer 39 - O-Ring (2 Used) 57 - O-Ring

2- Screw 21 - O-Ring 40 - Plug (2 Used) 58 - Spring
3- Backup Ring 22 - Spool 41 - O-Ring 59 - Poppet
4- O-Ring 23 - O-Ring 42 - Bolt 60 - Cap
5- O-Ring 24 - Bolt 43 - Spring Seat 61 - Nut
6- O-Ring 25 - Spring Seat 44 - Spring 62 - Plug
7- Backup Ring 26 - Spring 45 - Spring Seat 63 - O-Ring
8- Backup Ring 27 - Spring Seat 46 - Main Spool 64 - Cap
9- O-Ring 28 - Main Spool 47 - O-Ring 65 - Retaining Ring
10 - Sleeve 29 - O-Ring 48 - Bolt 66 - Shim
11 - Spool 30 - Screw 49 - Spring Seat 67 - Nut
12 - Washer 31 - O-Ring 50 - Spring 68 - Pilot Housing
13 - Spring 32 - Bolt 51 - Spring Seat 69 - *Socket Bolt (8 Used)
14 - Backup Ring 33 - Spring Seat 52 - Main Spool 70 - *Overload Relief Valve
15 - O-Ring 34 - Spring 53 - O-Ring 71 - *Overload Relief Valve
16 - Plug 35 - Spring Seat 54 - Plug 72 - *Backup Ring
17 - Spring 36 - Main Spool 55 - Plug 73 - *O-Ring
18 - Poppet 37 - Poppet (2 Used) 56 - Backup Ring 74 - Housing
19 - Spring 38 - Spring (2 Used)

NOTE: * Refer to W2-5-12.

W2-5-28
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 4-Spool Side (Upper)

1. Clamp main spools (36, 46) in a vise by using
wooden pieces. Install poppets (37) (2 used),
springs (38) (2 used), O-rings (39) (2 used) and
plugs (40) (2 used).
: 17 mm
: 25 N·m (2.5 kgf·m, 18 lbf·ft)
2. Install spring seats (27, 35, 45, 51), springs (26,
34, 44, 50), spring seats (25, 33, 43, 49) and
bolts (24, 32, 40, 42, 48) to spools (28, 36, 46,
52).
: 17 mm
: 12 N·m (1.2 kgf·m, 9 lbf·ft)
3. Install screw (30) and O-ring (29) to pilot housing
(68). Install nut (67), shim (66), retaining ring (65)
and cap (64) to screw (30).
: 17 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
4. Install screw (2) and O-ring (1) to pilot housing
(68). Install nut (61) and cap (60) to screw (2).
: 17 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
5. Install backup rings (7, 8) and O-rings (5, 6, 9) to
sleeve (10).
NOTE: Check the mounting positions of backup
rings (7, 8) and O-rings (6, 9).
10 9 8 7 6
IMPORTANT: When sleeve (10) or spool (11) is re-
placed, replace both of them as an
assembly.
6. Install O-ring (15), backup ring (14), spring (13),
washer (12) and spool (11) to plug (16). Install
the plug (16) assembly to sleeve (10).
NOTE: Install washer (12) with the chamfered side
facing to the spring (13) side.
7. Install boom anti-drift valve assembly (5 to 16) to
pilot housing (68).
IMPORTANT: When housing (74) or poppet (18) is
replaced, tap poppet (18) by using a
steel bar in order to make it fit.
8. Install poppet (18) and spring (17) to housing
(74).
9. Install spool (22), O-ring (21), washer (20) and
spring (19) to housing (74).
NOTE: Install washer (20) with the chamfered side
facing to the spring (19) side.
10. Install poppet (59), spring (58), O-ring (57),
backup ring (56) and plug (55) to housing (74).
: 14 mm
: 118+20 N·m (12+2 kgf·m, 87+15 lbf·ft)
11. Install main spool assemblies (28, 36, 46, 52),
O-rings (23, 31, 41, 47, 73) and backup ring (3,
72) to housing (74).

W176-02-05-023

W2-5-29
 UPPERSTRUCTURE / Control Valve

B Arm 2 Arm 1
C
70

68 71
69
Load Check Valve
(Arm 2 Tandem
71 Circuit)
90 91
74

103

84 85 86 87
104 105 106 74 WCEB-02-05-020 Check Valve Orifice
(Arm 1 Pallarel Curcit)
Section B
T176-03-03-006

Boom 1

Boom 2
111 110 109 108 107
Bucket Flow Rate
Control Valve
(Switch Valve)

98
92
97
93
88, 89
94 99
95 100
96
101
102 90
Bucket Flow Rate 91
Control Valve (Pop- Load Check Valve
pet Valve) (Boom 1 Pallarel
Section D Curcit)
W176-02-05-026

Section C
T176-03-03-005

68 - Pilot Housing 87 - Bushing 95 - Backup Ring 103 - Pilot Plate

69 - Socket Bolt (8 Used) 88 - O-Ring 96 - O-Ring 107 - Spool
70 - Overload Relief Valve 89 - Backup Ring 97 - Spring 108 - Washer
71 - Overload Relief Valve 90 - Spring 98 - Plug 109 - Spring
74 - Housing 91 - Poppet 99 - O-Ring 110 - O-Ring
84 - Plug 92 - O-Ring 100 - Spring 111 - Plug
85 - Spring 93 - Backup Ring 101 - Poppet 112 - *O-Ring
86 - Poppet 94 - Bushing 102 - Valve Seat

NOTE: * Refer to W2-5-16.

W2-5-30
 UPPERSTRUCTURE / Control Valve
IMPORTANT: Do not turn the lock nut of the relief
valve as the set pressure is
changed.
12. Install pilot housing (68) to housing (74) with
socket bolts (69) (8 used).
Turn and install the cartridges of overload relief
valves (70, 71) to housing (74).
: 6 mm
: 25 N·m (2.5 kgf·m, 18 lbf·ft)
: 27 mm
: 78+3 N·m (8+0.3 kgf·m, 58+3 lbf·ft)
Lock Nut
Cartridge
14. Install poppet (101), spring (100), O-ring (99) and
plug (98) to valve seat (102).
15. Install O-rings (92, 96) and backup rings (93, 95)
to bushing (94).
16. Install the valve seat (102) assembly, spring (97)
and bushing (94) to housing (74).
17. Install poppet (91), spring (90), O-ring (88) and
backup ring (89) to housing (74). (2 places)
18. Install bushing (87), poppet (86), spring (85) and
plug (84) to housing (74).

W176-02-06-017

NOTE: Apply grease onto O-rings of overload re-

lief valves (70, 71). (This prevents the
O-ring from being cut)

Assembly of Control Valve 4-Spool Side (Side)

13. Install spool (107), washer (108), spring (109)

and O-ring (110) to pilot plate (103). Temporarily
install plug (111) to pilot plate (103).
: 36 mm
110
103
111

Groove on the
outer surface
W1F3-02-05-006

NOTE: Tighten plug (111) after installing pilot plate

(103) to housing (74). There is a groove on
the outer surface of plug (111), but not of
plug (225).

W2-5-31
 UPPERSTRUCTURE / Control Valve

A
E

74
105

103,
112

104 111 106 WCEB-02-05-020

Swing

74

117

116
77
76 113

75
114, 115

78 79 80 81
Bypass Shut-Out Valve Section A T176-03-03-007

Section E

WCEB-02-05-022

74 - Housing 79 - Spring 105 - Socket Bolt (5 Used) 114 - Backup Ring

75 - Plug 80 - Seat 106 - Socket Bolt (4 Used) 115 - O-Ring
76 - O-Ring 81 - Spool 111 - Plug 116 - Spring
77 - Plug 103 - Pilot Plate 112 - O-Ring 117 - Poppet
78 - O-Ring 104 - Socket Bolt 113 - Plug

W2-5-32
 UPPERSTRUCTURE / Control Valve
19. Install O-ring (115) and backup ring (114) to plug
(113).

20. Install spring (116) and the plug (113) assembly

to housing (74) and poppet (117).

21. Install O-rings (112) (2 used) to housing (74). In-

stall pilot plate (103) to housing (74) with socket
bolts (105) (5 used), socket bolts (106) (4 used)
and socket bolt (104).
: 6 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 8 mm
: 49+5 N⋅m (5+0.5 kgf⋅m, 36+4 lbf⋅ft)

22. Completely tighten plug (111) which was tempo-

rarily tightened in step 13.
: 36 mm
: 177 N⋅m (18 kgf⋅m, 131 lbf⋅ft)

23. Install O-ring (76) and plug (75) to plug (77).

: 6 mm
: 29+9.8 N⋅m (3+1 kgf⋅m, 21+7 lbf⋅ft)

24. Install spool (81), seat (80), spring (79), O-ring

(78) and plug (77) to housing (74).
: 27 mm
: 177+29 N⋅m (18+3 kgf⋅m, 131+21 lbf⋅ft)
NOTE: Install seat (80) with the chamfered side
facing to the spring (79) side.

W2-5-33
 UPPERSTRUCTURE / Control Valve

74
127

129

130

A B WCEB-02-05-016
WCEB-02-05-019
128 128 128 128

Section A

123

118

119

120, 121

122 125 126 124 WCEB-02-05-017

Section B
Auxiliary Flow Rate Control Valve

74 - Housing 121 - Backup Ring 125 - O-Ring 128 - O-Ring (4 Used)

118 - Poppet 122 - Plug 126 - Plug 129 - Pilot Housing
119 - Spring 123 - Poppet 127 - Overload Relief Valve (4 Used) 130 - Socket Bolt (5 Used)
120 - O-Ring 124 - Spring

W2-5-34
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 4-Spool Side (Lower)

25. Install O-rings (128) (4 used) to housing (74). In-

stall pilot housing (129) to housing (74) with
socket bolts (130) (5 used).
: 6 mm
: 25+5 N·m (2.5+0.5 kgf·m, 18+4 lbf·ft)

26. Install poppet (123), spring (124), O-ring (125)

and plug (126) to housing (74).
: 14 mm
: 118+20 N·m (12+2 kgf·m, 87+15 lbf·ft)

27. Install poppet (118), spring (119), O-ring (120),

backup ring (121) and plug (122) to housing (74).
: 14 mm
: 118+20 N·m (12+2 kgf·m, 87+15 lbf·ft)

IMPORTANT: Do not turn the lock nut of the relief

valve as the set pressure is
changed.
28. Turn and install the cartridge of overload relief
valve (127) to housing (74).
: 27 mm
: 177+29 N·m (18+2.9 kgf·m, 131+21 lbf·ft)
Lock Nut
Cartridge

W176-02-06-017

NOTE: Apply grease onto O-rings of overload re-

lief valve (127). (This prevents O-ring from
being cut.)

W2-5-35
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF CONTROL VALVE
Main Spool Main Spool
5-SPOOL SIDE (154, 170, 176, 182) (160)
185 179 173 163 157 159, 175,
181, 187 165

160, 176, 166

182, 188
164
158, 174,
180, 186
167
161, 177,
183, 189 168
162, 178,
184, 190

169
170
171
172
Section A
190 184 178 168 162
WCEB-02-05-023

192,
Anti-Drift Valve 193 W176-02-05-024
B Arm Anti-Drift Valve
194
140 133
A
156 151 135
134
136
137
141
195 138

139
191
144
142
145
143
146
147
148

Section B W176-02-05-027
WCEB-02-05-020
131 - *Backup Ring 147 - Spring 166 - Spring 181 - Spring Seat
132 - *O-Ring 148 - Poppet 167 - Spring Seat 182 - Spring
133 - Plug 149 - *Backup Ring 168 - Main Spool 183 - Spring Seat
134 - O-Ring 150 - *O-Ring 169 - Poppet 184 - Main Spool
135 - O-Ring 151 - Overload Relief Valve (3 Used) 170 - Spring 185 - O-Ring
136 - O-Ring 152 - *O-Ring 171 - O-Ring 186 - Bolt
137 - Backup Ring 156 - Main Relief Valve 172 - Plug 187 - Spring Seat
138 - Backup Ring 157 - O-Ring 173 - O-Ring 188 - Spring
139 - O-Ring 158 - Bolt 174 - Bolt 189 - Spring Seat
140 - Sleeve 159 - Spring Seat 175 - Spring Seat 190 - Main Spool
141 - Spool 160 - Spring 176 - Spring 191 - Socket Bolt (10 Used)
142 - Washer 161 - Spring Seat 177 - Spring Seat 192 - Plug
143 - Spring 162 - Main Spool 178 - Main Spool 193 - O-Ring
144 - Backup Ring 163 - O-Ring 179 - O-Ring 194 - Pilot Housing
145 - O-Ring 164 - Bolt 180 - Bolt 195 - Housing
146 - Plug 165 - Spring Seat
NOTE: * Refer to W2-5-20.

W2-5-36
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 5-Spool Side (Upper)
1. Clamp main spool (168) by using wooden pieces
in a vise. Install poppet (169), spring (170), O-ring
(171) and plug (172) to main spool (168).
: 17 mm
: 25+5 N⋅m (2.5+0.5 kgf⋅m 18+4 lbf⋅ft)
2. Install spring seats (161, 167, 177, 183, 189),
springs (160, 166, 176, 182, 188), spring seats
(159, 165, 175, 181, 187) and bolts (158, 164,
174, 180, 186) to main spools (162, 168, 178,
184, 178).
: 17 mm
: 12+3 N⋅m (1.2+0.3 kgf⋅m, 9+2 lbf⋅ft)
3. Install O-rings (134, 135, 136, 139), backup rings
(137, 138) and plug (133) to sleeve (140).
NOTE: Check the mounting positions of backup
rings (137, 138) and O-rings (136, 139).
139 138 137 136
W176-02-05-023
IMPORTANT: When sleeve (140) or spool (141) is
replaced, replace both of them as an
assembly.
4. Install O-ring (145), backup ring (144), spring
(143), washer (142) and spool (141) to plug (146).
Install the plug (146) assembly to sleeve (140).
NOTE: Install washer (142) with the chamfered
side facing to the spring (143) side.
W2-5-37
5. Install arm anti-drift valve assembly (133 to 146)
to pilot housing (194).
IMPORTANT: When housing (195) or poppet (148)
is replaced, tap poppet (148) by us-
ing a steel bar in order to make it fit.
6. Install poppet (148), spring (147), O-ring (150)
and backup ring (149) to housing (195).
7. Install the main spool (162, 168, 178, 184, 190)
assemblies, O-rings (132, 152, 157, 163, 173,
179, 185) and backup ring (131) to housing (195).
IMPORTANT: Do not turn the lock nut of the relief
valve as the set pressure is
changed.
8. Install pilot housing (194) to housing (195) with
socket bolts (191) (10 used).
Turn the cartridges of overload relief valves (151)
(3 used) and the cartridge of main relief valve
(156). Install them to housing (195).
: 17 mm
: 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+4 lbf⋅ft)
: 27 mm
: 177+29 N⋅m (18+2.9 kgf⋅m, 131+21 lbf⋅ft)
Lock Nut
Cartridge
W176-02-06-017
 UPPERSTRUCTURE / Control Valve
Blade/Outrigger Boom 2
199
195
200
231
230 Load Check Valve
(Tandem Circuit)
232,
233,
234
F E
D
224 224
C
B
A 223 223
Auxiliary
Flow Rate
201, 221,
Control
Valve 225 202 222
226 227 228 229 WCEB-02-05-026

Auxiliary Flow Rate

Control Valve 203 Load
Check
(Switch Valve)
204 Valve
(Boom 2
Load Check
Pallarel
211 Valve
205 (Pallarel)
Circit)
210
206 Section C
Section B
207 212
WCEB-02-05-024
Swing
WCEB-02-05-025
Arm 1
208 213
209
214
215

Auxiliary Flow Rate Load

Control Valve Load Check
W176-02-05-026 Valve (Arm 1 Check
Section F (Poppet Valve)
Parallel Circuit) Valve
Main Releif Auxiliary (Swing
Flow Combiner Valve Circit)

224 224 224

223 223 223
216,
217 221,
221, 222 222
Check Valve 218
(Main Circuit)
218
216,
217
219
220
Load Check
Section A Valve
(Arm 1 Tandem
Section E
Circuit)
Section D W176-02-05-030
WCEB-02-05-018

195 - Housing 205 - O-Ring 215 - Valve Seat 225 - Plug

196 - Socket Bolt 206 - Backup Ring 216 - O-Ring 226 - O-Ring
197 - Cover 207 - Bushing 217 - Backup Ring 227 - Spring
198 - O-Ring 208 - Backup Ring 218 - Plug 228 - Washer
199 - Socket Bolt (6 Used) 209 - O-Ring 219 - Spring 229 - Spool
200 - Pilot Plate 210 - Spring 220 - Poppet 230 - Socket Bolt (9 Used)
201 - O-Ring 211 - Plug 221 - O-Ring 231 - Socket Bolt
202 - Backup Ring 212 - O-Ring 222 - Backup Ring 232 - Pilot Plate
203 - Spring 213 - Spring 223 - Spring 233 - O-Ring
204 - Poppet 214 - Poppet 224 - Poppet 234 - O-Ring

W2-5-38
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 5-Spool Side (Side)
9. Install spool (229), washer (228), spring (227)
and O-ring (226) to pilot plate (232). Temporarily
install plug (225).
: 36 mm
NOTE: Tighten plug (225) after installing pilot plate
(232) to housing (195). Plug (225) has no
groove on its outer surface.
10. Install poppet (214), spring (213), O-ring (212)
and plug (211) to valve seat (215).
11. Install O-rings (205, 209) and backup rings (206,
208) to bushing (207).
12. Install the valve seat (215) assembly, spring (210)
and bushing (207) to housing (195).
16. Completely tighten plug (225) which was tempo-
rarily tightened in step 9.
: 36 mm
: 177+29 N⋅m (18+2.9 kgf⋅m, 131+21 lbf⋅ft)
17. Install poppet (220), spring (219), plug (218),
backup ring (217) and O-ring (216) to housing
(195). (2 places)
18. Install poppet (224), spring (223), backup ring
(222) and O-ring (221) to housing (195).
19. Install pilot plate (200) to housing (195) with
socket bolts (199) (6 used).
: 6 mm
: 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+4 lbf⋅ft)

13. Install poppet (224), spring (223), O-ring (221)

and backup ring (222) to housing (195). (3
places)

14. Install poppet (204), spring (203), backup ring

(202) and O-ring (201) to housing (195).

15. Install O-rings (233, 234) to housing (195). Install

pilot plate (232) to housing (195) with socket bolts
(230) (9 used) and socket bolt (231).
: 6 mm
: 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+4 lbf⋅ft)
: 8 mm
: 49+5 N⋅m (4.9⋅0.5 kgf⋅m, 36+lbf⋅ft)

W2-5-39
 UPPERSTRUCTURE / Control Valve

195

252

254

259
A
248
WCEB-02-05-028 WCEB-02-05-023
253 253 253 253 253
Section B

235
243
244 236
245
237 Auxiliary Flow
Combiner
246 238 Valve
247 239, 240
241
242
Section A WCEB-02-05-018

195 - Housing 241 - Spring 248 - Overload Relief Valve 254 - Socket Bolt (9 Used)
235 - Plug 242 - Bolt 249 - *O-Ring 255 - *O-Ring (2 Used)
236 - Spring 243 - Plug 250 - *Backup Ring 256 - *Plug (2 Used)
237 - Poppet 244 - Spring 251 - *O-Ring 257 - *O-Ring
238 - Spool 245 - Poppet 252 - Plug 258 - *Plug
239 - O-Ring 246 - Spool 253 - O-Ring (5 Used) 259 - Pilot Housing
240 - Washer 247 - O-Ring

NOTE: * Refer to W2-5-24.

W2-5-40
 UPPERSTRUCTURE / Control Valve
Assembly of Control Valve 5-Spool Side (Lower)
IMPORTANT: If spool (238) is disassembled, or
poppet (237), spring (236) and plug
(235) are replaced, replace as an
assembly as the external dimen-
sions of spool (238) are specified.
20. Clamp spool (238) in a vise by using wooden
pieces. Install washer (240), spring (241) and bolt
(242) to spool (238).
: 17 mm
: 12+2 N⋅m (1.2+0.2 kgf⋅m, 9+1 lbf⋅ft)
NOTE: Install washer (240) with its chamfered
side facing to the spring (241) side.
IMPORTANT: If spool (246) is disassembled, or
poppet (245), spring (244) and plug
(243) are replaced, replace as an
assembly as the external dimen-
sions of spool (246) are specified.
21. Install O-rings (239, 247), spool (246) assembly
(243 to 246) and auxiliary flow combiner valve
assembly (235 to 242) to housing (195).
W2-5-41
22. Install O-rings (253) (5 used) to housing (195).
Install pilot housing (259) to housing (195) with
socket bolts (254) (9 used).
: 6 mm
: 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+4 lbf⋅ft)
IMPORTANT: Do not turn the lock nut of the relief
valve as the set pressure is
changed.
23. Turn and install the cartridge of overload relief
valve (248) to housing (195).
: 27 mm
: 177+29 N⋅m (18+2.9 kgf⋅m, 131+21 lbf⋅ft)
Lock Nut
Cartridge
W176-02-06-017
NOTE: Apply grease onto O-rings of the overload
relief valve. (This prevents O-ring from be-
ing cut.)
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-42
 UPPERSTRUCTURE / Control Valve
REMOVAL AND INSTALLATION OF
POSITIONING CONTROL VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK.)

Removal
1. Disconnect hoses (1) (6 used) from valve (3).
1 2 3 4
Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 19 mm, 27 mm
1
2. Remove sems bolts (2) (3 used) from valve (3).
Remove valve (3) from bracket (4).
: 17 mm

WCEB-02-05-011

Installation
1. Install valve (3) to bracket (4) with sems bolts (2)
(3 used).
: 17 mm 1 2 3 4
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect hoses (1) (6 used) to valve (3).

: 19 mm 1
: 29.5 N⋅m (3 kgf⋅m, 21 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

WCEB-02-05-011

W2-5-43
 UPPERSTRUCTURE / Control Valve
DISASSEMBLY OF POSITIONING
CONTROL VALVE 19
10 20
21
9 22
8 23
7
6 24
25
5 26
4 27
3 28
2
1

37

38 29
30
39 31
18 32
17 33
40 34
16
15 41 35
14 36
13 42
12 43
11 44

56 45
55
54
53 46
52 47
51
48 62
61
60

50
49
59
58
57
W198-02-05-001

1- Nut 17 - Sleeve 33 - Backup Ring (2 Used) 48 - Socket Bolt

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

W2-5-44
 UPPERSTRUCTURE / Control Valve
Disassembly of Positioning Control Valve

1. Remove socket bolts (45) (2 used) and socket 5. Remove sleeve assembly (37 to 42) from
bolts (48, 49) from covers (46, 50). Remove housing (62).
O-rings (47, 56) from covers (46, 50). : 36 mm

IMPORTANT: Turn and remove the spools. If they 6. Remove spring (43) and poppet (44) from
stick even a little, try again instead housing (62).
of pulling roughly.
7. Clamp seat (37) in a vise. Remove sleeve (41),
2. Remove spool assembly (51 to 59) from housing spring (40), valve (39) and O-rings (38, 42) from
(62). seat (37).
: 36 mm
3. Clamp spool (57) in a vise by using wooden
pieces. Remove end spool (51), seat (52),
springs (53, 54) and seat (55) from spool (57).
: 8 mm

IMPORTANT: Do not disassemble overload relief

valve assemblies (1 to 18), (19 to 36)
as the set pressures is changed.
4. Remove overload relief valve assemblies (1 to
18), (19 to 36) from housing (62).
: 32 mm
NOTE: Each of overload relief valve assemblies (1
to 18), (19 to 36) has a different set
pressure. Thus they should be identified
for reassembling.

W2-5-45
 UPPERSTRUCTURE / Control Valve
ASSEMBLY OF POSITIONING CONTROL
VALVE
Section X-X 37 39 40 38
41

43
62
42
44 19 to 36
1 to 18 A1 B1

A1 B1
X X

W198-02-05-002 W198-02-05-003

57
Section W-W

54 53 55 56 62
50 51 52 47

48 45

W W

W198-02-05-004
49
57 59 58 46
W198-02-05-005

1- Nut 17 - Sleeve 33 - Backup Ring (2 Used) 48 - Socket Bolt

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

W2-5-46
 UPPERSTRUCTURE / Control Valve
Assembly of Positioning Control Valve
1. Clamp seat (37) in a vise. Install O-ring (38),
valve (39), spring (40), sleeve (41) and O-ring
(42) to seat (37).
: 36 mm
: 59 N⋅m (6 kgf⋅m)
2. Insert poppet (44) and spring (43) into housing
(62).
3. Install the seat (37) assembly to housing (62).
: 36 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
IMPORTANT: Each of overload relief valve
assemblies (1 to 18), (19 to 36) has a
different set pressure. Do not install
at an incorrect position.
4. Install overload relief valve assemblies (1 to 18),
(19 to 36) to housing (62).
: 32 mm
: 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
IMPORTANT: Install the spool (57) assembly to
housing (62) and check if it moves
smoothly by hand.
7. Insert spool (57) assembly (51 to 59) into
housing (62) from the port A1 side.
NOTE: If spool assembly (51 to 59) is not
straightly inserted, the inner surface of
housing (62) or spool (57) may be
damaged and cannot be used. Insert it
straight.
8. Install O-rings (47, 56) to covers (46, 50). Install
covers (46, 50) to housing (62) with socket bolts
(45) (2 used) and socket bolts (48, 49).
: 6 mm
: 25.5 N⋅m (2.6 kgf⋅m, 19 lbf⋅ft)

5. Install O-ring (58) to plug (59).

6. Clamp spool (57) in a vise by using wooden

pieces. Install plug (59) to spool (57). Install seat
(55), springs (53, 54), seat (52) and end spool
(51) from the opposite side.
: 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft)
: 8 mm
: 18.6 N⋅m (1.9 kgf⋅m, 14 lbf⋅ft)

W2-5-47
 UPPERSTRUCTURE / Control Valve
(Blank)

W2-5-48
 UPPERSTRUCTURE / Swing Device
REMOVAL AND INSTALLATION OF SWING
DEVICE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to Bleed
Air from Hydraulic Oil Tank on W1-4-1.)
1 2 3 2 4
Removal
1. Remove sems bolts (2) (5 used) from cover (3).
Remove cover (3) from hydraulic oil tank (1) and
cover (4).
: 17 mm

WCEB-02-06-006

2. Disconnect hoses (6) (2 used) from swing damp-

ener valve (5) and swing motor (12). Cap the open 5 6 7 8, 9
ends.
: 19 mm
10
3. Disconnect hoses (7, 8) from swing motor (8). Cap
the open ends. Remove O-ring (9) from swing
motor (12). 11
: 19 mm, 36 mm

4. Remove socket bolts (10) (8 used) and split 12

flanges (11) (4 used) from hoses (13) (2 used).
Disconnect hoses (13) (2 used) from swing motor
(12). Cap the open ends. 13
: 6 mm

WCEB-02-06-003

5. Disconnect connector (14) from pressure switch 14

(15).

15 WCEB-02-06-005

W2-6-1
 UPPERSTRUCTURE / Swing Device

CAUTION: Swing device (16) weight: 131 kg

(290 lb)

6. Attach a nylon sling onto the body of swing motor

(12). Hoist and hold swing motor (12).
Nylon sling (eye-type at both ends): 2 used
12
7. Remove bolts (17) (10 used) and washers (18)
(10 used) from swing device (16). Remove swing
16
device (16) from main frame (19).
: 30 mm
NOTE: The number of hoses around the swing 17, 18
device is different according to specification
on the front attachment. When swing de-
vice is removed, check them.
WCEB-02-06-003
NOTE: When hoisting the swing device, the swing 19
device may be contacted with the hose.
Hoist the swing device slowly.
12
8. Remove pressure switch (15) from swing motor
(12).
: 24 mm

15 WCEB-02-06-005

9. Remove socket bolts (21) (4 used) from swing 20 5

dampener valve (5). Remove swing dampener
valve (5) from bracket (20).
: 6 mm

21 WCEB-02-06-003

W2-6-2
 UPPERSTRUCTURE / Swing Device
Installation 20 5
1. Install swing dampener valve (5) to bracket (20)
with socket bolts (21) (4 used).
: 6 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

21 WCEB-02-06-003

2. Install pressure switch (15) to swing motor (12). 12

: 24 mm
: 16 N⋅m (1.6 kgf⋅m, 12 lbf⋅ft)

15 WCEB-02-06-005

CAUTION: Swing device (16) weight: 131 kg

(290 lb)

IMPORTANT: Apply liquid packing onto the both

mounting surfaces on swing device
and frame.
3. Attach a nylon sling onto the body of swing motor
(12). Hoist swing motor (12). Align swing motor 12
(12) with the mounting hole on main frame (19).

4. Install swing device (16) to main frame (19) with 16

bolts (17) (10 used) and washers (18) (10 used).
: 30 mm
: 500 N⋅m (50 kgf⋅m, 369 lbf⋅ft) 17, 18

WCEB-02-06-003
19

W2-6-3
 UPPERSTRUCTURE / Swing Device
5. Connect hoses (13) (2 used) to swing motor (12)
with split flanges (11) (4 used) and socket bolts
(10) (8 used).
: 6 mm 10
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

11

12

13

6. Connect connector (14) to pressure switch (15).

WCEB-02-06-003

14

7. Install O-ring (9) to hose (8). Apply grease onto

15 WCEB-02-06-005
O-ring (9).

8. Connect hoses (7, 8) to swing motor (12). 5 6 7 8, 9

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

9. Connect hoses (6) (2 used) to swing dampener 12

valve (5) and swing motor (12).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

IMPORTANT: After completing the work, fill hy-

draulic oil from the drain port of
swing motor (12). Start the engine
and check for any oil leaks.
10. Fill hydraulic oil in swing motor (12).
WCEB-02-06-003

W2-6-4
 UPPERSTRUCTURE / Swing Device
11. Install cover (3) to hydraulic oil tank (1) and cover 1 2 3 2 4
(4) with sems bolts (2) (5 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-06-006

W2-6-5
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING DEVICE

22 1

23

24

3
25
32
21 4

31 5

20 6

26 7
19 8

27
18 9

28 10
17
11
29 16
12
15
13
30
14 11

WCEB-02-06-004

1- Swing Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- First Stage Sun Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (3 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (7 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe

W2-6-6
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Device 3. Remove drain plug (31) from pipe (32). Drain off
oil from the swing device.
: 8 mm
CAUTION: Swing device weight: 131 kg (290
lb) 4. Remove pipe (32) from housing (25).
: 18 mm
1. Wind a nylon sling onto the body of swing motor
(1). Hoist swing motor (1). 5. Put the matching marks at the jointed part be-
Nylon Sling
tween swing motor (1) and ring gear (24), be-
tween ring gear (24) and housing (25).

CAUTION: Swing motor (1) weight: 34 kg (75

lb)

6. Remove socket bolts (22) (7 used) from swing

motor (1). Remove swing motor (1) from ring gear
(24).
: 8 mm
NOTE: THREEBOND has been applied onto the
jointed surface. Insert a screwdriver into the
notch between jointed parts and separate
the surfaces in order to remove easily.

W176-02-06-002 7. Remove first stage sun gear (2) from first stage
carrier (21).
2. Place the swing device on bracket (ST 5098).
Secure the swing device on bracket (ST 5098) 8. Remove the first stage carrier (21) assembly from
with the bolts (M20) (2 used). At this time, insert ring gear (24).
the stopper at the bottom of bracket into the
clearance between teeth of the pinion gear. Se-
cure the bracket on a workbench in order to re-
duce the reaction force.
: 30 mm

Swing Device

ST 5098
Stopper

W178-02-06-012

W2-6-7
UPPERSTRUCTURE / Swing Device

23

24

3
25

21 4

20 6

18 9

10
17
11
16
12
15
13
30
11

WCEB-02-06-004

W2-6-8
 UPPERSTRUCTURE / Swing Device
9. Remove socket bolts (23) (2 used) from ring gear 16. Remove thrust plate (3) from first stage carrier
(24). (21).
: 12 mm
IMPORTANT: Do not damage the rotating surface
for the needle bearing of pin (4) ex-
CAUTION: Ring gear (24) weight: 13 kg (30 lb)
cept for the both ends.
10. Install eyebolts (M14, Pitch 2.0 mm) (2 used) to
17. Clamp the end of pin (4) opposite the spring pin
the swing motor (1) mounting thread part on ring
(5) hole in a vise. Tap and remove spring pins (5)
gear (24). Hoist and remove ring gear (24) from
(3 used) from first stage carrier (21) by using spe-
housing (25).
cial tool (ST 1462).
NOTE: THREEBOND has been applied on the
jointed surface. Insert a screwdriver into the 18. Disassemble the second stage carrier (18) as-
notch between jointed parts and separate sembly in the same way as the first stage carrier
the surfaces in order to remove easily. (21) assembly. Check a difference in the number of
thrust plates (11) (6 used).
11. Remove second stage sun gear (20) from second
stage carrier (18). 19. Remove bolts (17) (2 used) from lock plate (16).
Remove lock plate (16) from bearing nut (15).
12. Remove the second stage carrier (18) assembly : 17 mm
from shaft (30).
20. Remove bearing nut (15) from shaft (30) by using
IMPORTANT: The hole for spring pin (5) located on special tool (ST 2927).
first stage carrier (21) is not a ST 2927
through one. Check the tapping-in 15
distance of spring pin (5).
13. Tap spring pin (5) on first stage carrier (21) as-
sembly into pin (4) by using special tool (ST 1462).
Stop tapping when spring pin (5) reaches the
middle of the hole of first stage carrier (21) and do
not tap spring pin (5) to the end.

14. Remove pin (4), planetary gear (7), needle bear-

ing (6) and thrust plate (8) from first stage carrier W178-02-06-008

(21).
CAUTION: The housing (25) assembly
15. Remove other two sets of pin (4), planetary gear weight: 63 kg (140 lb)
(7), needle bearing (6) and thrust plate (8) from
first stage carrier (21) in the same orders as steps 21. Install eyebolts (M14, Pitch 2.0 mm) (2 used) into
13 and 14. the bolt (23) hole on housing (25). Hoist and hold
housing (25). Remove bracket (ST 5098) from
housing (25).
: 30 mm

W2-6-9
UPPERSTRUCTURE / Swing Device

25

26

28

30
14

WCEB-02-06-004

W2-6-10
 UPPERSTRUCTURE / Swing Device
23. Set special tool to the shaft (30) assembly.
CAUTION: If pushing shaft (30) by using a
press, provide a protection cover (outer di-
ameter: 290 mm (11.4 in), inner diameter: 90
mm (3.5 in), thickness: 25 to 30 mm (1.0 to 1.2
in)). Cover housing (25) with the protection
cover.
When housing (25) and/or roller bearing (14)
are broken and flown off without the protec-
tion cover, the metal fragments may result in
personal injury.
Press at 30 ton or less.
Degrease the housing (25) inside before
heating roller bearing (14). Failure to de-
grease may cause a fire.
NOTE: Use the following parts as special tool when
removing roller bearing (26).
Shaft or bolt: Length: 200 mm (7.9 in), Di-
ameter: 19 mm (0.7 in) 8 used. All should
be identical in length with no wear and de-
formation on both ends.
Material: S35C
Hose clamp: Standard diameter: 8-1/2 in,
(Tightening range: 185 to 215 mm (7.3 to
8.5 in)) 2 used.
Guide: Height: 160 mm (6.3 in), Outer di-
ameter: 230 mm (9.1 in), Inner diameter:
210 mm (8.3 in)

22. Press off shaft (30) from housing (25). The inner
race of roller bearing (26) and sleeve (28) are
removed with shaft (30) together. • Special tool when removing roller bearing
Hose Clamp Shaft
Press

30 14
25
Protection
Protection Cover
Cover

W157-02-06-012

W157-02-06-010 W157-02-06-011
30
26
28

Shaft
W157-02-06-013
Guide

CAUTION: Push the shaft of special tool in

the con cave part of pinion and secure by
using a hose clamp in order not to loosen the
shaft.

W2-6-11
UPPERSTRUCTURE / Swing Device

25

26

27

28

29

30
14

WCEB-02-06-004

W2-6-12
 UPPERSTRUCTURE / Swing Device

CAUTION: Shaft (30) weight: 17 kg (37 lb) CAUTION: Housing (25) weight: 36 kg (80 lb)

27. Fasten the body of housing (25) by using a nylon

CAUTION: When pushing shaft (30) by using
sling. Hoist and turn over housing (25).
a press inside the guide.
28. Insert a screwdriver into the notch on housing (25)
Press where oil seal (27) is mounted. Remove oil seal
30
(27).
NOTE: THREEBOND has been applied onto the
26
periphery of oil seal (27). Oil seal (27) can-
28
not be reused.

29. Tap and remove the outer race of roller bearing

Guide
(14) from housing (25) by using a bar and ham-
mer.

W157-02-06-014

24. Push the spline side on shaft (30) by using a press.

Remove the inner race of roller bearing (26) and
sleeve (28) from shaft (30).

25. Remove O-ring (29) from sleeve (28).

26. Insert a round bar into the oil passage in housing

(25). Tap and remove the outer race of roller
bearing (26).

25
Oil Passage

26

W178-02-06-001

W2-6-13
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING DEVICE

4 6 2
5
21

7
3
8
24

10 18

11 20

13 23

19
12
17
11 16
15

9
14

32

26 25

27
28

29
30
31
WCEB-02-06-001 WCEB-02-06-002

1- *Swing Motor 9- Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing

2- First Stage Sun Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing
3- Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal
4- Pin (3 Used) 12 - Needle Bearing (3 Used) 20 - Second Stage Sun Gear 28 - Sleeve
5- Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring
6- Needle Bearing (3 Used) 14 - Roller Bearing 22 - *Socket Bolt (7 Used) 30 - Shaft
7- Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug
8- Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe
NOTE: As for parts (1, 22), refer to W2-6-6.

W2-6-14
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Device

1. Install O-ring (29) to sleeve (28). 5. Apply THREEBOND #1215 onto the outer surface
of oil seal (27). Place oil seal (27) flat on housing
(25) and push by hands in gently. Place special
CAUTION: Shaft (30) + sleeve (28) + outer
tool (ST 2928) on oil seal (27). Tap in special tool
race weight: 22 kg (50 lb)
by using a hammer straight.
2. Install sleeve (28) and the inner race of roller ST 2928
bearing (26) to shaft (30). Install sleeve (28) and 27
the inner race of roller bearing (26) by using spe-
cial tool (ST 2929) and a press.
NOTE: The press-in distance of inner race of roller
bearing (26) can be assured by using spe- 25
cial tool.

W176-02-06-006

Press

6. Apply grease to the inner surface of oil seal (27).

Apply grease to the outer surface of sleeve (28)
attached with shaft (30).
ST 2929
NOTE: Apply grease carefully when installing shaft
26
(30) in order not to curl the lip.

28
CAUTION: Housing (25) + roller bearing (14)
30 outer races weight: 37 kg (80 lb)

7. Wind nylon sling onto the body of housing (25).

Hoist and place housing (25) with the ring gear
W178-02-06-013
(24) mounting side facing upward.

8. Tap and install the outer race of roller bearing (14)

CAUTION: Housing (25) weight: 36 kg (80 lb)
3. Fasten the body of housing (25) by using a nylon
sling. Hoist and place housing (25) with the
sleeve (28) mounting side facing upward.
to housing (25) by using a bar and hammer. Tap
and listen to ring in order to check if the installa-
tion is completed.

4. Evenly tap and install the outer race of roller

bearing (26) to housing (25) by using a bar and
hammer. Tap and listen to ring in order to check if
the installation is completed.

W2-6-15
 UPPERSTRUCTURE / Swing Device

15

14

26 25

27

30

WCEB-02-06-001 WCEB-02-06-002

W2-6-16
 UPPERSTRUCTURE / Swing Device
14. Place special tool (ST 2930) on the inner race of
CAUTION: Housing (25) + outer races (2
roller bearing (14). Install the inner race of roller
used) of roller bearings (14, 26) weight:
bearing (14) by using a press.
39 kg (90 lb)
NOTE: The specified press-in distance of inner
9. Install eyebolts (M14, Pitch 2.0 mm) (2 used) into race can be assured by using special tool.
the bolt (23) holes on housing (25). Hoist and ST 2930
place housing (25) on shaft (30). Check and align
carefully in order not to curl the oil seal (28) lip.
14
10. Tap and install the inner race of roller bearing (14)
to shaft (30) by using a bar and hammer. Tap the
inner race until the upper end of inner race
reaches two threads for bearing nut (15) in shaft
(30).
NOTE: The fitting between the inner race of roller
bearing (14) and shaft (30) is tight. W178-02-06-011

11. Tighten bearing nut (15) to shaft (30) by hand.
NOTE: Prevent shaft (30) from falling off when
hoisting housing (25).
CAUTION: Housing (25) + shaft (30) + roller
bearings (14, 26) weight: 60 kg (130 lb)
12. Hoist the housing (25) assembly by using eye-
bolts (M14, Pitch 2.0 mm) (2 used) installed in
step 9. Place the housing (25) assembly on the
press.
13. Remove bearing nut (15) from shaft (30).
15. Hoist and place the housing (25) assembly on
bracket (ST 5098). Install the housing (25) as-
sembly with bolts (M14, Pitch 2.5 m) (2 used). At
this time, insert the stopper at the bottom of
bracket into the clearance between teeth of the
pinion gear. Secure the bracket on a workbench in
order to reduce the reaction force.
: 30 mm
25
ST 5098
Stopper

W178-02-06-012

W2-6-17
 UPPERSTRUCTURE / Swing Device

4 6
5
21

7
3
8

10 18

11

13

19
12
17
11 16
15

9
14

30

WCEB-02-06-001 WCEB-02-06-002

W2-6-18
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Check the direction to install bearing
nut (15).
IMPORTANT: Apply grease for keeping correct
tightening torque.
16. Apply a film of grease onto the thread part of
bearing nut (15). Install bearing nut (15) to shaft
(30) with the step part of bearing nut (15) facing to
the roller bearing (14) side. Tighten bearing but
(15) by using special tool (ST 2927) to the speci-
fied torque.
: 390 N⋅m (40 kgf⋅m, 288 lbf⋅ft)
ST 2927
15
W178-02-06-008
17. Install lock plate (16) to bearing nut (15) with bolts
(17) (2 used). In case the spline of lock plate (16)
and that of shaft (30) are not aligned, tighten
bearing nut (15) in tightening direction until both
splines are aligned.
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W2-6-19
IMPORTANT: Check the direction to install spring
pin (10) and thrust plate (19).
18. Assemble second stage carrier (18) into an as-
sembly in the following way.
• Install needle bearing (12) to planetary gear (13).
Clamp planetary gear (13) between thrust plates
(11) (2 used) and install them to second stage
carrier (18).
• Install pin (9) to the position where needle bearing
(12) has been installed with the spring pin (10)
hole facing front. The spring pin (10) holes both in
second stage carrier (18) and pin (9) should be in
line.
• Install spring pin (10) to second stage carrier (18)
by using special tool (ST 1462). Face the slit of
spring pin (10) to the end of pin (9).
10
Slit
W178-02-06-002
• Install thrust plate (19) to second stage carrier
(18) with the oil groove facing upward.
• Install needle bearings (12) (2 used), thrust plates
(11) (4 used), pins (9) (2 used) and spring pins
(10) (2 used) to other hole (2 places) on the sec-
ond stage carrier (18) in the same way.
IMPORTANT: Check the position to install thrust
plate (8).
19. Assemble first stage carrier (21) into an assembly.
Install planetary gears (7) (3 used), needle bear-
ings (6) (3 used), thrust plates (8) (3 used), pins
(4) (3 used), spring pins (5) (3 used) and thrust
plate (3) in the same way as for second stage
carrier (18). Check that mounting position of
thrust plate (8) is located under needle bearing
(6).
 UPPERSTRUCTURE / Swing Device

21

24

18

20

23

16

32

25

30
31
WCEB-02-06-001 WCEB-02-06-002

NOTE: As for parts (1, 22), refer to W2-6-6.

W2-6-20
 UPPERSTRUCTURE / Swing Device
IMPORTANT: Check the direction to install second 24. Install the first stage carrier (21) assembly to the
stage carrier (18). spline of second stage sun gear (20).
20. Install the second stage carrier (18) assembly to
the spline of shaft (30). Check that the concave IMPORTANT: Check the direction to install first
part of boss in bottom side of second stage carrier stage sun gear (2).
(18) comes in contact with lock plate (16) at this 25. Install first stage sun gear (2) to the first stage
time. carrier (21) assembly with the step side facing
downward.
Can cave Part 18
16 26. Wind the seal tape onto the thread part of pipe
30
(32). Install pipe (32) to housing (25) with pipe
(32) facing downward.
: 18 mm

27. Wind the seal tape onto drain plug (31). Install
drain plug (31) to pipe (32).
: 8 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
W178-02-06-014

28. Add gear oil into ring gear (24) until gear oil
21. Install second stage sun gear (20) to the second
reaches the middle part of first stage sun gear (2).
stage carrier (18) assembly with the small di-
(Approx. 3.2 L, 0.8 US gal)
ameter part facing upward.
29. Apply THREEBOND #1215 onto the swing motor
22. Apply THREEBOND #1215 onto the ring gear
(1) mounting surface of ring gear (24). Clean off
(24) mounting surface of housing (25). Clean off
old adhesive in advance.
old adhesive in advance.

CAUTION: Swing motor (1) weight: 34 kg (70

CAUTION: Ring gear (24) weight: 13 kg (30 lb)
lb)
23. Install eyebolts (M6, Pitch 1.25 mm) (2 used) to
30. Fasten the body of swing motor (1) by using a
the motor mounting thread part on ring gear (24).
sling nylon. Hoist swings motor (1) and align the
Hoist and align ring gear (24) with the mounting
matching marks on ring gear (24). Install swing
hole on housing (25). Align the matching marks
motor (1) to ring gear (24) with socket bolts (22) (7
made when disassembling. Install ring gear (24)
used).
to housing (25) with socket bolts (23) (12 used).
: 8 mm
: 12 mm
: 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)
: 140 N⋅m (15 kgf⋅m, 103 lbf⋅ft)

W2-6-21
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF SWING MOTOR

34 １

33 2

32 3

4
31
5
30
6
29

28 7

27

26

8
25

9
24
10
23
11
22

23 12

13
22
14
23
15
22

23

22 16

17
21 18
19
20
W176-02-06-008

1- Rotor 10 - Retaining Ring 19 - Plug 27 - Valve Plate

2- Disc Spring (4 Used) 11 - Oil Seal 20 - Casing 28 - Knock Pin (2 Used)
3- Bushing 12 - Plug 21 - Drain Plug 29 - Disc Spring
4- Retainer 13 - O-Ring 22 - Friction Plate (4 Used) 30 - Needle Bearing
5- Plunger (9 Used) 14 - Spring 23 - Plate (4 Used) 31 - O-Ring
6- Swash Plate 15 - Poppet 24 - O-Ring 32 - Valve Unit
7- Shaft 16 - Plunger 25 - Piston 33 - Spring Washer (4 Used)
8- Retaining Ring 17 - Spring 26 - O-Ring 34 - Socket Bolt (4 Used)
9- Roller Bearing 18 - O-Ring

W2-6-22
 UPPERSTRUCTURE / Swing Device
Disassembly of Swing Motor

6. Apply air through the parking brake port of casing

CAUTION: Swing motor weight: 34 kg (70 lb)
1. Fasten the body of swing motor by using a nylon
sling. Hoist and place valve unit (32) with if facing
upward. As shaft (7) is out of casing (20), place
the swing motor on the wooden block (50 mm (2.0
in) or more square).
(20). Raise and remove piston (25).
NOTE: If piston (25) is not raised, push in piston
(25) by using special tools (ST 2921 and ST
2922) and retry to raise piston (25). As for
the operation of special tool, refer to the
assembly of the swing motor.

IMPORTANT: Do not drop valve plate (27).

2. Remove socket bolts (34) (4 used) from valve unit
(32). Remove valve unit (32) from casing (20). 20 Parking
Brake Port
: 14 mm

3. Wind the vinyl tape onto the tip of shaft (7). Pro-
tect shaft (7).
NOTE: The tip of shaft (7) is the rotating surface of
needle bearing (30).
W176-02-06-009

4. Remove needle bearing (30) from valve unit (32).

7. Remove rotor (1) from casing (20). At this time,
NOTE: Insert your finger in the back of needle
plates (23) (4 used) and friction plates (22) (4
bearing (30). Remove needle bearing (30)
used) are removed with rotor (1) together.
straight while rotating. If needle bearing
(30) cannot be removed, push in by using
8. Hold plungers (5) (2 used) at the opposite corner.
special tool (ST 2899) and pull up again. As
Remove plungers (5) (2 used) from casing (20).
for the assembly, refer to the assembly of
Disc spring (2), bushing (3) and retainer (4) are
the swing motor.
removed with plunger (5) together.
5. Remove disc spring (29) from casing (20).
9. Remove other plungers (5) (7 used) from casing
(20).

W2-6-23
 UPPERSTRUCTURE / Swing Device

30
6

10

11

12

14

15

16
17

19
20
W176-02-06-008

W2-6-24
 UPPERSTRUCTURE / Swing Device
10. Hang the claws of special tools (ST 1458) (2
used) to the inner diameter of swash plate (6).
Remove swash plate (6) from casing (20).
ST 1458
6 shaft (7) into special tool (ST 1459) with the spline
20
W176-02-06-011
11. Remove retaining ring (8) from casing (20).
12. Place casing (20) horizontally.
13. Tap the head at the spline of shaft (7) by using a
plastic hammer and remove shaft (7) from casing
(20). At this time, roller bearing (9) are removed
with shaft (7) together.
14. Tap and remove oil seal (11) by using a screw-
driver. As THREEBOND is applied to the outer
surface of oil seal (11), cannot be reused oil seal
(11).
IMPORTANT: Do not damage the oil seal (11) lip
surface of shaft (7).
15. Remove retaining ring (10) from shaft (7).
W2-6-25
IMPORTANT: When shaft (7) falls down from roller
bearing (9), the rotating surface of
needle bearing (30) may be damaged.
Hold shaft (7) in order not to drop.
16. Secure special tool (ST 1459) in a vise. Insert
side facing upward. Tap the spline side and re-
move roller bearing (9) from shaft (7) by using a
plastic hammer.
ST 1459
W176-02-06-021
17. Remove plug (12) from casing (20). Remove
spring (14) and poppet (15) from casing (20).
: 6 mm
18. Remove plug (19) from casing (20). Remove
spring (17) and plunger (16) from casing (20).
: 6 mm
NOTE: Do not remove a reinforcing mesh and a
filter are set inside plunger (16) unless
necessary. If the reinforcing mesh and the
filter are removed, clamp plunger (16) in a
vise. Remove plug (19) by using a 3 mm
hexagonal wrench. Before assembling,
degrease plunger (16) and plug (19). Apply
LOCTITE #242 onto the thread part.
Tighten them to torque of 5.9 N·m (0.6
kgf·m).
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF SWING MOTOR

34
32
33
30
28

29
27
16 17 18 19
15 31
14
25
13
26
12
24

23

22

5
Parking Brake Release Block
4
21

8
6

9
2

20
3

10 11 W176-02-06-012
7

1- Rotor 10 - Retaining Ring 19 - Plug 27 - Valve Plate

2- Disc Spring (4 Used) 11 - Oil Seal 20 - Casing 28 - Knock Pin (2 Used)
3- Bushing 12 - Plug 21 - Drain Plug 29 - Disc Spring
4- Retainer 13 - O-Ring 22 - Friction Plate (4 Used) 30 - Needle Bearing
5- Plunger (9 Used) 14 - Spring 23 - Plate (4 Used) 31 - O-Ring
6- Swash Plate 15 - Poppet 24 - O-Ring 32 - Valve Unit
7- Shaft 16 - Plunger 25 - Piston 33 - Spring Washer (4 Used)
8- Retaining Ring 17 - Spring 26 - O-Ring 34 - Socket Bolt (4 Used)
9- Roller Bearing 18 - O-Ring

W2-6-26
 UPPERSTRUCTURE / Swing Device
Assembly of Swing Motor

1. Place casing (20) with the mounting surface of IMPORTANT: Check the direction to install roller
valve unit (32) facing upward on the wooden bearing (9).
block (50 mm (2.0 in) or more square). 7. Install roller bearing (9) with all the stamped
marks on the outer race, inner race and inner ring
2. Install spring (17) to plunger (16). Install plunger plate facing outward.
(16) to the hole on the parking brake release
block of casing (20). Marked Surface on Marked Surface on
Outer Race Inner Race
3. Install O-ring (18) to plug (19). Install plug (19) to
the hole on the parking brake release block of
casing (20).
: 6 mm W176-02-06-014
: 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) Marked Surface on
Inner Ring Plate
4. Install spring (14) to poppet (15). Install poppet
(15) to the hole on the parking brake release IMPORTANT: Check the direction to install roller
block of casing (20). bearing (9).
8. Install the inner ring plate side of roller bearing (9)
5. Install O-ring (13) to plug (12). Install plug (12) to to the spline side of shaft (7) first. Push in roller
the hole on the parking brake release block of bearing (9) to the front end of the mating position
casing (20). with shaft (7). At this time, do not damage the seal
: 6 mm lip surface of shaft (9).
: 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
9. Insert the spline side of shaft (7) into special tool
6. Clean old adhesive on the mounting part of oil (ST 2896). Tap the opposite side of shaft (7) by
seal (11) on casing (20). using a plastic hammer and install roller bearing
Apply THREEBOND #1104 or #1215 onto the (9) to shaft (7).
outer surface of oil seal (11). Install oil seal (11) to
casing (20) by using special tools (ST 2897, ST
2898).
7

9
ST 2898
ST 2896

ST 2897
20
W176-02-06-018

10. Install retaining ring (10) to shaft (7). At this time,

11 W176-02-06-010 do not damage the seal lip surface of shaft (7).

W2-6-27
 UPPERSTRUCTURE / Swing Device

32

25

26

24

23

22

5
Parking Brake Release Block
4
21
8
6

20
3

11 W176-02-06-012
7

W2-6-28
 UPPERSTRUCTURE / Swing Device
11. Apply grease onto the inner surface of oil seal (11)
and the seal lip surface of shaft (7).
12. Install shaft (7) to casing (20). Tap and install shaft
(7) to casing (20) by using a plastic hammer. Tap
and listen to ring in order to check if the installa-
tion is completed.
13. Install retaining ring (8) to casing (20).
14. Apply grease onto the chamfered surface and
outer surface of swash plate (6).
15. Install swash plate (6) to casing (20) with the
chamfered surface facing downward.
NOTE: After installing swash plate (6), turn it. If
swash plate (6) does not turn, it may be
seizing. In that case, install swash plate (6)
again.
IMPORTANT: The flat surface of rotor (1) is a slid-
ing surface with the valve plate. Do
not damage the sliding surface.
16. Assemble rotor (1) into an assembly.
▪ Place rotor (1) with the flat surface facing
downward.
▪ Assemble disc springs (2) (4 used) as the outer
surface is matching with the outer surface and
the inner surface is matching with the inner
surface. Place them on the projection. Cover
them with bushing (3). Check the direction of
disc spring (2). Refer to the following.
2 3
W176-02-06-015
W2-6-29
▪ Place retainer (4) on bushing (3) with the
chamfered surface facing downward.
4
Chamfered
Surface
3 W176-02-06-016
▪ Align the plunger (5) hole of retainer (4) with
that of rotor (1). Install plungers (5) (9 used).
17. Place casing (20) horizontally with the drain plug
(21) side facing downward.
18. Install rotor (1) assembled in step 16 to casing
(20) while aligning with the spline of shaft (7).
IMPORTANT: Shaft (7) is out of casing (20). Place
casing (20) on the wooden block (50
mm or more square).
19. Place casing (20) vertically with the mounting
surface of valve unit (32) facing upward.
IMPORTANT: Check the installation order of plate
(23) and friction plate (22).
20. Install plates (23) (4 used) and friction plates (22)
(4 used) to casing (20) alternately. Install friction
plate (22) with the mold attached first.
21. Install O-rings (24, 26) to piston (25).
 UPPERSTRUCTURE / Swing Device

34
32
33
30
28

29
27

31

25

Parking Brake Release Block

20

W176-02-06-012

W2-6-30
 UPPERSTRUCTURE / Swing Device
22. Place piston (25) evenly on casing (20). Cover 25. Install O-ring (31) to valve unit (32).
special tools (ST 2921, ST 2922) on piston (25).
Tap piston (25) by using a hammer. 26. Apply grease onto the flat surface of valve plate
(27).
ST 2922
NOTE: Apply grease more in order not to drop
valve plate (27) when installing valve unit
(32) to casing (20).
ST 2921

IMPORTANT: Do not drop valve plate (27).

25 27. Install valve plate (27) while aligning with knock
20
pin (28) of valve unit (32). Turn over valve unit
(32). Place valve unit (32) on casing (20).

28. Install valve unit (32) to casing (20) with spring

washers (33) (4 used) and socket bolts (34) (4
used).
: 14 mm
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
W176-02-06-020

IMPORTANT: Check the direction of disc spring

(29).
23. Install disc spring (29) to casing (20). At this time,
install disc spring (29) with the outer surface side
facing to the back.

24. Install needle bearing (30) to valve unit (32) by

using special tool (ST 2899).

ST 2899

30

32

W176-02-06-019

W2-6-31
 UPPERSTRUCTURE / Swing Device
DISASSEMBLY OF VALVE UNIT

7
6

1 2 3 4 5 9

10

11

12
4
3
2
1

13
14
15
16

W176-02-06-007
16
15
14
13

1- Plug (2 Used) 5- Valve Housing 9- O-Ring (2 Used) 13 - Plug (2 Used)

2- O-Ring (2 Used) 6- Backup Ring (2 Used) 10 - Backup Ring (2 Used) 14 - O-Ring (2 Used)
3- Spring (2 Used) 7- O-Ring (2 Used) 11 - O-Ring (2 Used) 15 - Spring (2 Used)
4- Spring Seat (2 Used) 8- Relief Valve (2 Used) 12 - Spool 16 - Poppet (2 Used)

W2-6-32
 UPPERSTRUCTURE / Swing Device
Disassembly of Valve Unit
▪ As for Removal/Installation of the valve unit
from/to the swing motor, refer to Disassemble and
Assemble Swing Motor.
IMPORTANT: The lower surface of valve housing
(5) is the contact surface of the valve
plate. Do not damage the contact
surface.
1. Set the cloth on the workbench. Place valve
housing (5) on the cloth.
IMPORTANT: As the set pressure changes, do not
turn the lock nut.
2. Remove the relief valve (8) assemblies (2 used)
from valve housing (5).
: 32 mm
8 Lock Nut
W176-02-06-017
3. Remove backup rings (6, 10) (2 used for each)
and O-rings (7, 11, 9) (2 used for each) from relief
valves (8) (2 used).
W2-6-33
4. Remove plugs (13) (2 used) from valve housing
(5). Remove springs (15) (2 used) and poppets
(16) (2 used) from valve housing (5) by using a
magnet.
: 12 mm
5. Remove plugs (1) (2 used) from valve housing (5).
Remove springs (3) (2 used) from valve housing
(5).
: 8 mm
IMPORTANT: Do not damage the inside of valve
housing (5).
6. Insert a round bar into valve housing (5). Remove
spool (12) to the opposite side. At this time, spring
seat (4) is removed with spool (12) together. If
spool (12) cannot be removed, push back spool
(12) and remove spool (12) again.
7. Remove other spring seat (4) in valve housing (5)
by using a magnet.
 UPPERSTRUCTURE / Swing Device
ASSEMBLY OF VALVE UNIT
8

10

11

13

14

15

16

2 3 4 12 4 3 2
Section E

1 1

W176-02-06-013

1- Plug (2 Used) 5- Valve Housing 9- O-Ring (2 Used) 13 - Plug (2 Used)

2- O-Ring (2 Used) 6- Backup Ring (2 Used) 10 - Backup Ring (2 Used) 14 - O-Ring (2 Used)
3- Spring (2 Used) 7- O-Ring (2 Used) 11 - O-Ring (2 Used) 15 - Spring (2 Used)
4- Spring Seat (2 Used) 8- Relief Valve (2 Used) 12 - Spool 16 - Poppet (2 Used)

W2-6-34
 UPPERSTRUCTURE / Swing Device
Assembly of Valve Unit

1. Install O-rings (9) (2 used) to relief valves (8) (2
used).
2. Install O-rings (7, 11) (2 used for each) and
backup rings (6, 10) (2 used for each) to relief
valves (8) (2 used).
IMPORTANT: As the set pressure changes, do not
turn the lock nut in relief valve (8).
3. Install the relief valve (8) assemblies (2 used) to
valve housing (5).
: 32 mm
: 235 N⋅m (24 kgf⋅m, 173 lbf⋅ft)
Lock Nut
8
5. Install O-rings (14) (2 used) to plugs (13) (2 used).
Install plugs (13) (2 used) to valve housing (5).
: 12 mm
: 235 N⋅m (24 kgf⋅m, 173 lbf⋅ft)
6. Install spring seat (4) to spool (12) only at one
side. Install spring seat (4) to the center of valve
housing (5) from the side without spool (12). At
this time, do not drop spring seat (4) inside of
valve housing (5).
7. Push spool (12) more until the position right be-
fore the spool (12) end comes out from the oppo-
site-side hole on valve housing (5). When pushed
too much, spring seat (4) inserted to spool (12)
falls inside of valve housing (5).

8. Install spring seat (4) and spring (3) to the end of

spool (12) coming out from valve housing (5).
Push spool (12) into valve housing (5) to the step
part of spool (12).

9. Push back spool (12) approximately half way of

W176-02-06-017
valve housing (5). Install spring (3) to spool (12)
from the opposite-side hole.
4. Install poppets (16) (2 used) and springs (15) (2
used) to valve housing (5). 10. Install O-rings (2) (2 used) to plugs (1) (2 used).
Install plugs (1) (2 used) to valve housing (5).
: 8 mm
: 69 N⋅m (7 kgf⋅m, 51 lbf⋅ft)

W2-6-35
 UPPERSTRUCTURE / Swing Device
STRUCTURE OF SWING DAMPENER VALVE

1 2 3 4 5

WCEB-02-06-008

Wrench Size Tightening Torque

Item Part Name Q’ty Remarks
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Relief Valve 2 : 24 69 (7) (51)
2 Backup Ring 2
3 O-Ring 2
4 Casing 1 1B P20
5 Plug 2 :4 9 (1) (7)

W2-6-36
 UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARD

Swing Motor Shoe

1. Clearance between plunger and shoe bottom

Unit: mm (in)
Standard Allowable Limit
0 0.2 (0.008)
ε
ε≤0.2 mm (0.008 in) Plunger

W105-02-06-130

D
2. Clearance between plunger outer diameter and Rotor
rotor cylinder inner bore
Unit: mm (in)
Standard Allowable Limit
0 0.05 (0.002)

D-d≤0.05 mm (0.002 in)

W105-02-06-134

Plunger Assembly

d
Rotor

W105-02-06-135

W2-6-37
 UPPERSTRUCTURE / Swing Device

Parking Brake
A

W176-02-06-022
C
Unit: mm
Part Name Standard Allowable Limit Remedy
A Friction Plate Thickness 2.4 2.35
B Disc Spring (Overall height) 6.8 6.7
C Piston Thickness 41.0 -
D Plate Thickness 1.4 1.35
Remarks No wear on the piston as it does not slide.

IMPORTANT: The piston thickness is shown as

the distance from the contact point
of disc spring to the contact point of
plate.

NOTE: 1 mm = 0.03937 in

Plunger

W155-03-02-007

Unit: mm
Standard Allowable Limit Remedy
A 5.5 5.3 Replace

NOTE: 1 mm = 0.03937 in

W2-6-38
 UPPERSTRUCTURE / Pilot Valve
REMOVAL AND INSTALLATION OF PILOT
VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal of Left Pilot Valve 1 2 3 4 5

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

1. Remove sems bolts (4) (2 used) from seat belts

(6) (2 used). Remove seat belt (6) from brackets 6
(5) (2 used).
: 16 mm

WCEB-02-01-001

6 4 5 2 3

WCEB-02-01-017

2. Remove socket bolts (3) (4 used) from seat (1).

Remove seat (1) from plate (2).
: 6 mm 3

WCEB-02-01-002

2
7

3. Remove screws (9) (4 used) from boot (7). Raise

boot (7) from bracket (8). 8

W1JB-02-07-002

W2-7-1
 UPPERSTRUCTURE / Pilot Valve
4. Remove screw (10) from covers (11, 12).

10

12
11

WCEB-02-07-001

5. Remove sems bolt (14) from cover (11). Remove

screws (13) (3 used) from covers (11, 12). Re-
move covers (11, 12) from bracket (8).
: 10 mm 12

11

13

14 WCEB-02-07-003

11

13

12

8 13 WCEB-02-07-004

W2-7-2
 UPPERSTRUCTURE / Pilot Valve
6. Remove clip bands (17) (2 used) from lever (15) 15 16 17
and harness (18). Disconnect a connector from
harness (18).

7. Loosen lock nut (16). Remove lever (15) assem-

bly from pilot valve (19).
: 19 mm, 22 mm 18

8. Disconnect hoses (20) (6 used) from pilot valve

(6). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling. 19
: 19 mm

20

W1JB-02-07-005

9. Remove sems bolts (21) (4 used) from bracket (8). 21 8

Remove pilot valve (19) from bracket (8).
: 13 mm

19

W1JB-02-07-005

21

W2-7-3
 UPPERSTRUCTURE / Pilot Valve
Installation of Left Pilot Valve
21 8
1. Install pilot valve (19) to bracket (8) with sems
bolts (21) (4 used).
: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)

2. Connect hoses (20) (6 used) onto pilot valve (6).

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

20

W1JB-02-07-005

21

15 16 17
3. Install lever (15) assembly to pilot valve (19). Se-
cure lever (15) assembly to pilot valve (19) with
lock nut (16).
: 22 mm
: 55 N·m (5.5 kgf·m, 41 lbf·ft)
18
4. Connect harness (18) connector.

5. Install harness (18) to bracket (8) of pilot valve

(19) with clip band (17).
8

19

W1JB-02-07-005

6. Install cover (11, 12) to bracket (8) with round

head screws (13) (3 used) and sems bolt (14).
: 10 mm
: 3.3 to 4.2 N·m 12
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)
11

13

14
WCEB-02-07-003

W2-7-4
 UPPERSTRUCTURE / Pilot Valve
7. Install cover (11, 12) to bracket (8) with round
head screw (10).

10 8

12

11 WCEB-02-07-001

7
8. Install boot (7) to bracket (8) with round head
screws (9) (4 used).

W1JB-02-07-002

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

9. Install seat (1) to plate (2) with socket bolts (3) (4

used).
3
: 6 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)

10. Install seat belt (6) (2 used) to bracket (5) (2 used)

with sems bolts (4) (2 used).
: 16 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 2
WCEB-02-01-002

1 2 3 4 5

WCEB-02-01-001

W2-7-5
 UPPERSTRUCTURE / Pilot Valve
Removal of Right Pilot Valve

1. Remove the seat. (Refer to W2-7-1.)

2. Remove cap (3) (2 used) and round head screws 1 2

(1, 4) (1 each used) from cover (2). Remove cover 3, 4
(2) from bracket (7).

3. Remove sems bolt (6) from cover (5). 5

: 10 mm

4. Remove round head screw (9) from cover (8).

7 6
WCEB-02-07-006

8
3, 4

9
WCEB-02-07-005

5. Remove round head screws (11) (4 used) from 10

boot (10). Remove boot (10) from bracket (7).
7

11

W1JB-02-07-002

6. Remove round head screw (12) from cover (5, 8).

Remove covers (5, 8) from bracket (7). 12

8 5

W1JB-02-07-016

W2-7-6
 UPPERSTRUCTURE / Pilot Valve
7. Remove clip bands (15) (2 used) from lever (13)
and harness (16). Disconnect a connector from 13 14 15
harness (16).

8. Loosen lock nut (14). Remove lever (13) assem- 16

bly from pilot valve (17).
: 19 mm, 22 mm

17

W1JB-02-07-005

9. Remove sems bolts (19) (3 used) from bracket (7).

Remove bracket (7) assembly from stand (18).
Hoist bracket (7) assembly.
: 17 mm

19 18
WCEB-02-07-009

10. Disconnect hoses (20) (6 used) from pilot valve (6).

21 7
Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 19 mm

11. Remove sems bolts (21) (4 used) from bracket (7). 17

Remove pilot valve (17) from bracket (7).
: 13 mm

20

W1JB-02-07-005

21

W2-7-7
 UPPERSTRUCTURE / Pilot Valve
Installation of Right Pilot Valve 21 7

1. Install pilot valve (17) to bracket (7) with sems

bolts (21) (4 used).
: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft) 17

2. Connect hoses (20) (6 used) onto pilot valve (6).

: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
20

W1JB-02-07-005

21

13 14 15
3. Install lever (13) assembly to pilot valve (17). Se-
cure lever (13) assembly to pilot valve (17) with
lock nut (14).
: 22 mm 16
: 56 N·m (5.5 kgf·m, 41 lbf·ft)

4. Connect harness (16) connector.

7
5. Install harness (16) to pilot valve (17) and bracket
(7) with clip band (15) (2 used).
17

W1JB-02-07-005

6. Install cover (5) to bracket (7) with sems bolts (6).

: 10 mm
: 3.3 to 4.2 N·m
(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

7 6
WCEB-02-07-006

W2-7-8
 UPPERSTRUCTURE / Pilot Valve
7. Install bracket (7) assembly to stand (18) with
sems bolts (19) (3 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

8. Install cover (8) to bracket (7) with round head

screw (9).

9
19
18 8 WCEB-02-07-009

9. Install covers (5, 8) to bracket (7) with round head

screw (12). 12

8 5

W1JB-02-07-016

10
10. Install boot (10) to bracket (7) with round head
screws (11) (4 used).
7

11

W1JB-02-07-002

11. Install cover (2) to bracket (7) with round head

screws (1, 4) (2 each used). Attach cap (3) (2
2
used) to cover (2).
1
3, 4

8
5

7 6
WCEB-02-07-006

W2-7-9
 UPPERSTRUCTURE / Pilot Valve

21
CAUTION: Seat (21) weight: 40 kg (90 lb)

12. Install seat (21) to plate (23) with socket bolts (22)
(4 used).
22
: 6 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)

WCEB-02-01-002

23

13. Install seat belts (26) (2 used) to brackets (25) (2 21 23 22 24 25

used) with sems bolts (24) (2 used).
: 16 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)

26

WCEB-02-01-001

26 24 25 23 22

WCEB-02-01-017

W2-7-10
 UPPERSTRUCTURE / Pilot Valve
REMOVAL AND INSTALLATION OF
TRAVEL PILOT VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Remove mat (1) from cab (2) inside.

WCEB-02-01-003

2. Remove sems bolts (4) (2 used) from pedal (3).

Remove pedal (3) from bracket (5).
: 13 mm

WCEB-02-07-002
Auxiliary Brake Pedal
Pedal

3. Remove sems bolts (7) (2 used) from bracket (5).

Remove bracket (5) from travel pilot valve (6). 3
: 13 mm
4

7 6 WCEB-02-07-007

W2-7-11
 UPPERSTRUCTURE / Pilot Valve
4. Remove sems bolts (8) (6 used) from cover (9). 8 9 8
Remove cover (9) from main frame (10).
: 17 mm
10

WCEB-02-13-001

11 12 13
5. Disconnect hoses (11) (4 used) from travel pilot
valve (14). Cap the open ends. Attach an identifi-
cation tag onto the disconnected hoses for as-
14
sembling.
: 19 mm

6. Remove sems bolts (12) (2 used) from travel pilot

valve (14). Remove travel pilot valve (14) from
plate (13).
11
: 17 mm
WCEB-02-07-008

W2-7-12
 UPPERSTRUCTURE / Pilot Valve
Installation
1. Install travel pilot valve (14) to plate (13) with 11 12 13
sems bolts (12) (2 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft) 14

2. Connect hoses (11) (4 used) onto travel pilot valve

(14).
: 19 mm
: 29.5 N·m (3 kgf·m, 22 lbf·ft)
11
WCEB-02-07-008

3. Install bracket (5) to travel pilot valve (6) with

sems bolts (7) (2 used). 3
: 13 mm
: 20 N·m (2 kgf·m, 15 lbf·ft) 4

4. Install pedal (3) to bracket (5) with sems bolts (4)

(2 used).
: 13 mm 5
: 20 N·m (2 kgf·m, 15 lbf·ft)

7 6 WCEB-02-07-007

WCEB-02-07-002
Auxiliary Brake Pedal
Pedal

5. Install mat (1) to the cab (2) inside.

WCEB-02-01-003

W2-7-13
 UPPERSTRUCTURE / Pilot Valve
6. Install cover (9) to main frame (10) with sems bolts 8 9 8
(8) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf·ft) 10

WCEB-02-13-001

W2-7-14
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-7-15
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLY OF FRONT/SWING PILOT VALVES

10

10
11
1

11 12

12
2 13

13

14

5
5

6 15
6

16
7
7
17

8
8

18

9
9

19

19

20

20

W1F3-02-07-001

1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing

2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Sealing Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)

W2-7-16
 UPPERSTRUCTURE / Pilot Valve
Disassembly of Front/Swing Pilot Valves 3. Install special tool (ST 7260) to universal joint (3).
• Spool (13) has been selected to match the hole of Remove universal joint (3) from casing (14) by
casing (14). Therefore, the parts cannot be re- turning.
placed individually. : 24 mm
• Indicate the port number of the removed in order
not to confuse parts. The port numbers are
stamped on the outer surface of casing (14).

1. Clamp the pilot valve in a vice. Secure the plot

valve with the port plate (18) facing downward. Section A-A

2. Put the matching marks on plate (4) and casing

(14). Secure cam (2) by using a spanner. Remove
screw joint (1) and cam (2) from universal joint ST 7260
(3).
: 32 mm

CAUTION: Springs (10) (4 used) are in the

compressed condition. Therefore, when A A
loosening universal joint (3), plate (4), bush-
ings (6) (4 used), and pushers (8) (4 used) are 3
raised at the same time. Do not fly out them.

W577-02-06-003

4. Remove plate (4) from casing (14).

IMPORTANT: When bushing (6) (4 used) are still in

casing (14), remove pusher (8) by
moving left and right. Do not dam-
age pusher (8).
IMPORTANT: Indicate the port numbers of the
spool (13) assembly and springs (10)
(4 used) in order not to confuse the
parts. Do not damage spool (13).
5. Remove the pusher (8) assembly, the spool (13)
assembly and springs (10) (4 used) from casing
(14).

6. Remove pushers (8) (4 used), O-rings (7) (4

used) and oil seals (5) (4 used) from bushings (6)
(4 used).

W2-7-17
 UPPERSTRUCTURE / Pilot Valve

11

11 12

12
13

13

14

15

16

17

18

9
9

20

W1F3-02-07-001

W2-7-18
 UPPERSTRUCTURE / Pilot Valve
IMPORTANT: Do not disassemble the spool (13)
assembly unless necessary.
IMPORTANT: When removing spring seats (9) (4
used) from spool (13), push in
spring seat (9) once and remove it
by moving to a larger hole of 2 holes
on spring seat (9). At this time, do
not push in spring seat (9) for more
than 6 mm (0.2 in).

13

WCEB-02-07-010
11 9

7. Remove spring seats (9) (4 used), springs (11) (4

used) and washers (12) (4 used) from spool (13).

8. Clamp the pilot valve in a vice. Secure the pilot

valve with port plate (18) facing upward.

9. Remove socket bolts (20) (2 used) and seal

washers (19) (2 used) from port plate (18).

10. Remove port plate (18), O-ring (15), bushing (16)

and spring pin (17) from casing (14).

W2-7-19
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLY OF FRONT/SWING PILOT VALVES

1
3

8
5

4
6

11

10
12
13

14

16
15

17
18
19

20 W1F3-02-07-002

1- Screw Joint 6- Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing

2- Cam 7- O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin
3- Universal Joint 8- Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate
4- Plate 9- Spring Seat (4 Used) 14 - Casing 19 - Sealing Washer (2 Used)
5- Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)

W2-7-20
 UPPERSTRUCTURE / Pilot Valve
Assembly of Front/Swing Pilot Valves
• Replace the seals with the new ones.
1. Install bushing (16) and O-ring (15) to casing (14).
2. Install spring pin (17) to port plate (18). Install port
plate (18) to casing (14) with socket bolts (20) (2
used) and seal washers (19) (2 used).
: 20.5±2 N·m (2.1±0.2 kgf·m, 15±2 lbf·ft)
IMPORTANT: When installing spring seats (9) (4
used) to spool (13), insert spool (13)
from a larger hole of 2 holes on
spring seat (9) and move to a smaller
hole direction. At this time, do not
push in spool (13) for more than 6
mm (0.2 in).
13
WCEB-02-07-010
9
3. Install washers (12) (4 used), springs (11) (4
used) and spring seats (9) (4 used) to spools (13)
(4 used) in this order.
W2-7-21
IMPORTANT: Install spring (10) to the same posi-
tion before disassembling.
4. Install springs (10) (4 used) to casing (14).
IMPORTANT: Install the spool (13) assemblies (4
used) to the same position as it was
before disassembling.
5. Install the spool (13) assemblies (4 used) to cas-
ing (14).
6. Install O-rings (7) (4 used) and oil seals (5) (4
used) to bushings (6) (4 used).
IMPORTANT: Apply hydraulic oil onto the outer
surface of pushers (8) (4 used).
7. Install pushers (8) (4 used) to bushings (6) (4
used).
IMPORTANT: If installing plate (4) is difficult due
to strong springs (10) (4 used), place
the bushing (6) assemblies (4 used)
on 4 holes of casing (14). Place plate
(4) on them. Temporarily secure the
bushing (6) assemblies (4 used).
While holding it with universal joint
(3).
8. Install the bushing (6) assemblies (4 used) to
casing (14), by aligning the matching marks be-
fore disassembly.
UPPERSTRUCTURE / Pilot Valve

1
3

14

W1F3-02-07-002

W2-7-22
 UPPERSTRUCTURE / Pilot Valve
9. Install universal joint (3) to casing (14) by using
special toll (ST 7260).
: 24 mm
: 47.1±2.9 N·m
(4.8±0.3 kgf·m, 35±2 lbf·ft)

10. Screw in universal joint (3) until pushers (8) (4

used) come in contact with cam (2) evenly.

IMPORTANT: When tightening screw joint (1), do

not move cam (2).
11. Secure cam (2) by using a spanner. Install screw
joint (1) to universal joint (3).
: 32 mm
: 68.6±4.9 N·m
(7.0±0.5 kgf·m, 51±4 lbf·ft)

12. Apply grease onto the rotating part of universal

joint (3) and the top of pusher (8).

W2-7-23
 UPPERSTRUCTURE / Pilot Valve
DISASSEMBLY OF TRAVEL AND AUXIL-
IARY/POSITIONING PILOT VALVES

20

7 20

8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15

15
4
11
14
14
3

3 12
13
2
2

21
1
1

W1LA-02-06-001

1- O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3- Packing (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4- Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6- Socket Bolt (2 Used)

W2-7-24
 UPPERSTRUCTURE / Pilot Valve
Disassembly of Travel and Auxiliary/Positioning
Pilot Valves
• Spool (15) has been selected to match the hole of
casing (21). Therefore, the parts cannot be re-
placed individually.
• Indicate the port number of the removed in order
not to confuse.
IMPORTANT: Before disassembling, put the
matching marks on cam (9), pin (10),
cover (11) and casing (21).
1. Secure the pilot valve in a vise. Remove boot (7)
from cover (11).
2. Remove set screw (8) from cam (9). Remove pin
(10) from cover (11). Remove cam (9) from cover
(11).
NOTE: LOCTITE is applied onto the set screw
part.
NOTE: Steel ball (5) cannot be disassembled from
cam (9).
7. Remove spring guides (19) (2 used), springs (18)
(2 used), washers (16) (2 used) and shims (17) (2
used) from the spool (15) assemblies (2 used).
IMPORTANT: As the spool (15) assemblies (2
used) are adjusted by shim (17), do
not disassemble the spool (15) as-
sembly unless necessary. If the
spool (15) assembly is disassem-
bled, record the quantity and thick-
ness of shim (17).
IMPORTANT: Do not remove bushing (4) from
cover (11) unless bushing (4) is
damaged.
8. Remove bushings (4) (2 used) from cover (11).

3. Loosen and remove socket bolts (6) (2 used) from

cover (11) alternately. Remove cover (11) from
casing (21).

4. Remove the pusher (20) assemblies (2 used)

from casing (21).

5. Remove bushings (2) (2 used) from the pusher

(20) assembly. Remove O-rings (1) (2 used) and
packings (3) (2 used) from bushings (2) (2 used).

IMPORTANT: Indicate the port numbers in order

not to confuse the parts.
6. Remove the spool (15) assemblies (2 used) and
springs (14) (2 used) from casing (21).

W2-7-25
 UPPERSTRUCTURE / Pilot Valve
ASSEMBLY OF TRAVEL AND AUXIL-
IARY/POSITIONING PILOT VALVES
7 8 10 9

20

11

19

18

14

17

16

12

13

15
W1LA-02-06-002

21

1- O-Ring (2 Used) 7- Boot 12 - Plug 17 - Shim (2 Used)

2- Bushing (2 Used) 8- Set Screw 13 - O-Ring 18 - Spring (2 Used)
3- Packin (2 Used) 9- Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used)
4- *Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used)
5- Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing
6- Socket Bolt (2 Used)

NOTE: *Refer to W2-7-24.

W2-7-26
 UPPERSTRUCTURE / Pilot Valve
Assembly of Travel and Auxiliary/Positioning Pi- 8. Apply LOCTITE #241 onto setscrew (8). Secure
lot Valve cam (9) to pin (10) with setscrew (8).
• Clean not to confuse the parts. Arrange the parts : 5 N·m (0.5 kgf·m, 41 lbf·ft)
by port in order.
9. Install boot (7) to cover (11).
1. Install bushings (4) (2 used) to cover (11).

IMPORTANT: Install shim (17) as its thickness

becomes same before disassem-
bling.
2. Install washers (16) (2 used), shims (17) (2 used),
springs (18) (2 used) and spring guides (19) (2
used) to spools (15) (2 used) in this order.

IMPORTANT: Install the spool (15) assembly into

the same hole before disassembling.
3. Install spring (14) (2 used) to casing (21). Install
the spool (15) assemblies (2 used) to casing (21).

4. Install O-rings (1) (2 used) and packings (3) (2

used) to bushings (2) (2 used).
3

W585-02-06-005
Lip

5. Install pushers (20) (2 used) to the bushing (2)

assemblies (2 used). Install the pusher (20) as-
semblies (2 used) to casing (21).

6. Secure casing (21) in a vise. Install cover (11) to

casing (21) with socket bolts (6) (2 used).
: 23.5 N·m (2.4 kgf·m, 17 lbf·ft)

7. Install cam (9) to cover (11). Secure cam (9) to

cover (11) with pin (10).

W2-7-27
 UPPERSTRUCTURE / Pilot Valve
(Blank)

W2-7-28
 UPPERSTRUCTURE / Electric Lever
REMOVAL AND INSTALLATION OF
ELECTRIC LEVER

Removal of Auxiliary/Positioning Electric Lever

1 2
1. Remove sems bolts (2) (6 used) from cover (1).
Remove cover (1) from main frame (3). 3
: 17 mm

WCEB-02-13-001

2. Disconnect connector (4).

WCEB-02-08-002

5
3. Remove mat (6) from the inside of cab (5).

WCEB-02-01-003

4. Remove sems bolts (8) (2 used) from pedal (9).

Remove pedal (9) from bracket (10).
8
: 13 mm

5. Remove sems bolts (7) (2 used) from bracket (10). 7 9

Remove bracket (10) from electric lever (11).
: 13 mm

11 10
WCEB-02-08-001

W2-8-1
 UPPERSTRUCTURE / Electric Lever
6. Remove sems bolts (13) (4 used) from bracket
(12). Remove the bracket (12) assembly from
plate (14).
: 17 mm

WCEB-02-08-001
14 13 12

11
7. Remove sems bolts (15) (2 used) from electric
lever (11). Remove electric lever (11) from bracket
(12).
15
: 17 mm

WCEB-02-08-002

Installation of Auxiliary/Positioning Electric Lever

1. Install electric lever (11) to bracket (12) with sems 11

bolts (15) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
15

WCEB-02-08-002

2. Install the bracket (12) assembly to plate (14) with

sems bolts (13) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-08-001
14 13 12

W2-8-2
 UPPERSTRUCTURE / Electric Lever
3. Install bracket (10) to electric lever (11) with sems
bolts (7) (2 used).
: 13 mm 8
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

4. Install pedal (9) to bracket (10) with sems bolts (8) 7 9

(2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

11 10
WCEB-02-08-001

5. Install mat (6) to the inside of cab (5). 5

WCEB-02-01-003

6. Connect connector (4).

WCEB-02-08-002

1 2
7. Install cover (1) to main frame (3) with sems bolts
(2) (6 used). 3
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-13-001

W2-8-3
 UPPERSTRUCTURE / Electric Lever
Removal of Blade/Outrigger Electric Lever

1. Remove caps (4) (2 used) from cover (2). Remove

screws (5, 7) (2 used for each) from cover (2). 2
: 17 mm 3
1

2. Remove sems bolt (6) from cover (3).

: 10 mm 4, 5

8 7 6 WCEB-02-07-006

3. Remove screw (9) from cover (1).

9
WCEB-02-07-009

4. Remove screws (11) (4 used) from boot (10). 10

Raise boot (10) from bracket (8).
8

11

W1JB-02-07-002

5. Remove screw (12) from cover (1). Remove

covers (1, 3) from bracket (8).
12 10

W1JB-02-07-016

W2-8-4
 UPPERSTRUCTURE / Electric Lever
6. Disconnect connector (13).

WCEB-02-08-004
13

7. Remove socket bolts (18) (2 used) from lever (14). 14 15

Remove lever (14) from electric lever (17).
: 6 mm

8. Remove sems bolts (16) (2 used) from bracket

(15). Remove the bracket (15) assembly from
bracket (8).
16
: 17 mm

WCEB-02-08-003
18 17 8

9. Remove sems bolts (19) (2 used) from electric

lever (17). Remove electric lever (17) from bracket
(15). 19
: 17 mm

15

17

WCEB-02-08-004

W2-8-5
 UPPERSTRUCTURE / Electric Lever
Installation of Blade/Outrigger Electric Lever

1. Install electric lever (17) to bracket (15) with sems 19

bolts (19) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect connector (13).

15

17

WCEB-02-08-004
13

3. Install the bracket (15) assembly to bracket (8) 14 15

with sems bolts (16) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

4. Install lever (14) to electric lever (17) with socket

bolts (18) (2 used).
: 6 mm 16
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

WCEB-02-08-003
18 17 8

5. Install covers (1, 3) to bracket (8) with screw (12). 12 10

3
1

6. Install boot (10) to bracket (8) with screws (11) (4 W1JB-02-07-016

used). 10

11

W1JB-02-07-002

W2-8-6
 UPPERSTRUCTURE / Electric Lever
7. Install cover (1) to bracket (8) with screw (9).

1 WCEB-02-07-009

8. Install cover (3) to bracket (8) with sems bolt (6).

: 10 mm
: 3.3 to 4.2 N⋅m 2
3
(0.3 to 0.4 kgf⋅m, 2.4 to 3 lbf⋅ft)

9. Install cover (2) to bracket (8) with screws (5, 7) (2

used for each). 4, 5

10. Install caps (4) (2 used) to cover (2).

8 7 6 WCEB-02-07-006

W2-8-7
 UPPERSTRUCTURE / Electric Lever
DISASSEMBLY OF ELECTRIC LEVER

10

8 11
7

12

6
5 13
14

15

16

17

4 18
3
2
1
19

20

W1MG-02-07-003

1- Screw (2 Used) 6- Bushing (2 Used) 11 - Cam 16 - Bushing (2 Used)

2- Plate 7- Screw 12 - Socket Bolt (2 Used) 17 - Spring (2 Used)
3- Screw (2 Used) 8- Arm 13 - Holder 18 - Housing
4- Potentiometer 9- Boot 14 - O-Ring (2 Used) 19 - Clip
5- Pin 10 - Set Screw 15 - Bushing (2 Used) 20 - Screw

W2-8-8
 UPPERSTRUCTURE / Electric Lever
Disassembly of Electric Lever

IMPORTANT: Housing (18) is made of aluminum. IMPORTANT: Keep the disassembled parts
As too strong a force may deform or carefully in order to install them to
damage it, handle it with care. their original ports.

1. Secure housing (18) in a vise. 10. Remove the pusher (16) assemblies (2 used) and
springs (17) (2 used) from housing (18).
2. Remove screws (1) (2 used) from plate (2).
Remove plate (2) from housing (18). IMPORTANT: Do not damage bushing (15).

3. Remove screws (20) from clip (19). Remove clip 11. Remove pushers (16) (2 used) and O-rings (14) (2
(19) from housing (18). used) from bushings (15) (2 used).

4. Remove screws (3) (2 used) from potentiometer IMPORTANT: Bushing (6) cannot be reused.
(4). Remove potentiometer (4) from housing (18).
12. Remove bushings (6) (2 used) from holder (13).
5. Remove boot (9) from holder (13).

6. Remove set screw (10) from cam (11).

: 2.5 mm

7. Remove pin (5) from holder (13). Remove cam

(11) from holder (13).

8. Remove screw (7) from arm (8). Remove arm (8)

from cam (11).

IMPORTANT: The pusher (16) assembly may fly

out by spring (17).

9. Remove socket bolts (12) (2 used) from holder

(13). Remove holder (13) from housing (18).
: 5 mm

W2-8-9
 UPPERSTRUCTURE / Electric Lever
ASSEMBLY OF ELECTRIC LEVER

7 8 9

11
5, 6
16
14
12
15

3 13
17
4
18

T1MG-03-09-008

20 19

1- *Screw (2 Used) 6- Bushing (2 Used) 11 - Cam 16 - Pusher (2 Used)

2- *Plate 7- Screw 12 - Socket Bolt (2 Used) 17 - Spring (2 Used)
3- Screw (2 Used) 8- Arm 13 - Holder 18 - Housing
4- Potentiometer 9- Boot 14 - O-Ring (2 Used) 19 - Clip
5- Pin 10 - *Set Screw 15 - Bushing (2 Used) 20 - Screw

NOTE: As for the item with mark*, refer to W2-7-8.

W2-8-10
 UPPERSTRUCTURE / Electric Lever
Assembly of Electric Lever
1. Apply grease onto O-rings (14) (2 used).
2. Install O-rings (14) (2 used) to bushings (15) (2
used).
3. Apply grease onto the inner surface of bushings
(15) (2 used).
4. Install pushers (16) (2 used) to bushings (15) (2
used).
5. Install springs (17) (2 used) and the pusher (16)
assemblies (2 used) to housing (18).
6. Install bushings (6) (2 used) to holder (13).
7. Install holder (13) to housing (18) with socket bolts
(12) (2 used).
: 5 mm
: 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)
8. Apply grease onto the end of pushers (16) (2
used).
9. Install arm (8) to cam (11) with screw (7).
: 3 N⋅m (0.3 kgf⋅m, 2 lbf⋅ft)
10. Apply grease onto the mounting surfaces of holder
(13) and cam (11).
11. Install cam (11) to holder (13).
12. Apply LOCTITE #262 onto screw (10).
W2-8-11
13. Install pin (5) to holder (13). Secure pin (5) to cam
(11) with screw (10).
: 2.5 mm
: 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)
14. Apply grease to the gap between arm (8) and the
link part of potentiometer (4).
15. Apply LOCTITE #262 onto screws (3) (2 used).
IMPORTANT: Adjust the gap between arm (8) and
the link of potentiometer (4) to 0.4
mm on one side.
16. Install potentiometer (4) to housing (18) with
screws (3) (2 used).
: 1.0 N⋅m (0.1 kgf⋅m, 0.7 lbf⋅ft)
17. Secure the harness of potentiometer (4) with clip
(19).
18. Apply LOCTITE #262 onto screw (20).
19. Install clip (19) to housing (18) with screw (20).
: 0.8 N⋅m (0.1 kgf⋅m, 0.6 lbf⋅ft)
20. Apply THREEBOND #1104 onto the mating
surfaces of housing (18) and plate (2).
21. Install plate (2) to housing (18) with screws (1) (2
used).
22. Install boot (9) to holder (13).
 UPPERSTRUCTURE / Electric Lever
(Blank)

W2-8-12
 UPPERSTRUCTURE / Signal Control Valve
REMOVAL AND INSTALLATION OF
SIGNAL CONTROL VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Open cover (1). 1

WCEB-02-05-002

3
2. Remove sems bolts (3) (6 used) from cover (4).
Remove cover (4) from cover (2), supports (5) (2 4
2
used) and bracket (6).
: 17 mm
3

WCEB-02-05-001
5

WCEB-02-05-003

WCEB-02-05-004

W2-9-1
 UPPERSTRUCTURE / Signal Control Valve
3. Remove sems bolts (8) (3 used) from cover (7).
: 17 mm
2

7
CAUTION: The cover (2) assembly weight: 27
kg (60 lb)
8
4. Attach a nylon sling onto cover (2). Hoist and hold
cover (2). Remove sems bolts (9) (2 used) from
cover (2). Remove the cover (2) assembly from
main frame (10).
: 17 mm
WCEB-02-05-006
10 9
11 12

5. Disconnect hoses (11) (32 used) from signal

control valve (12). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm 11

13 12 WCEB-02-09-001

6. Disconnect connectors (13) (2 used) from signal

control valve (12).

WCEB-02-05-005

12
7. Remove socket bolts (14) (4 used) from signal
control valve (12). Remove signal control valve
(12) from bracket (15).
: 8 mm

14

15

WCEB-02-09-001

W2-9-2
 UPPERSTRUCTURE / Signal Control Valve
Installation 11 12
1. Install signal control valve (12) to bracket (15) with
socket bolts (14) (4 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
11
2. Connect hoses (11) (32 used) to signal control
valve (12).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
14

15

WCEB-02-09-001
13 12
3. Connect connectors (13) (2 used) to signal control
valve (12).

WCEB-02-05-005

CAUTION: The cover (2) assembly weight: 27 2

kg (60 lb) 7

4. Attach a nylon sling onto the cover (2) assembly.

Hoist and align the cover (2) assembly with the
mounting holes on main frame (10). 8

5. Install cover (2) to main frame (10) with sems bolts

(9) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCEB-02-05-006
10 9
5

6. Install cover (2) to support (5) and cover (7) with

sems bolts (8) (3 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-05-003

W2-9-3
 UPPERSTRUCTURE / Signal Control Valve
7. Install covers (2, 4) to supports (5) (2 used) and
3
bracket (6) with sems bolts (3) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 4
2

WCEB-02-05-001

WCEB-02-05-003

WCEB-02-05-004

8. Shut cover (1).

WCEB-02-05-002

W2-9-4
 UPPERSTRUCTURE / Signal Control Valve
(Blank)

W2-9-5
 UPPERSTRUCTURE / Signal Control Valve
STRUCTURE OF SIGNAL CONTROL VALVE
4 13

12

11
7

4
10

9
7 8
7 7

4
4

W1JB-02-10-002

W2-9-6
 UPPERSTRUCTURE / Signal Control Valve

15

14 16
17
18
19
16 20
17
21
19
16 20
17
18
19
20

14
22
23
24
25

26
27
19
28
17
16
20 29
19
18 14
5 17
20 16
19
21
17
20 16
19
18
17
16 W1JB-02-10-003

Detail of Body 2 (5)

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

W2-9-7
 UPPERSTRUCTURE / Signal Control Valve
(Blank)

W2-9-8
 UPPERSTRUCTURE / Shockless Valve
REMOVAL AND INSTALLATION OF
SHOCKLESS VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal of Swing Shockless Valve

1. Open side cover (1).

WCEB-02-05-002

2. Remove sems bolts (3) (4 used) from cover (4).

2
Remove cover (4) from main frame (2).
: 17 mm

4 WCEB-02-05-007

3. Disconnect hoses (5) (10 used) from swing

shockless valve (6). Cap the open ends. Attach an 5 6
identification tag onto the disconnected hoses for
assembling.
: 19 mm

4. Remove sems bolts (7) (2 used) from bracket (8).

Remove swing shockless valve (6) from bracket
(8). 5
: 17 mm

8 7 WCEB-02-10-002

W2-10-1
 UPPERSTRUCTURE / Shockless Valve
Installation of Swing Shockless Valve
5 6
1. Install swing shockless valve (6) to bracket (8)
with sems bolts (7) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect hoses (5) (10 used) to swing shockless 5

valve (6).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

8 7 WCEB-02-10-002

3. Install cover (4) to main frame (2) with sems bolts

(3) (4 used).
: 17 mm 3
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

4 WCEB-02-05-007

4. Shut side cover (1).

WCEB-02-05-002

W2-10-2
 UPPERSTRUCTURE / Shockless Valve
Removal of Travel Shockless Valve
1 2
1. Remove sems bolts (1) (6 used) from cover (2).
Remove cover (2) from main frame (3).
: 17 mm 3

WCEB-02-13-001

2. Disconnect connector (4) from pressure sensor 4 5 6 7

(5).

3. Disconnect connectors (6) (2 used).

4. Disconnect hoses (7) (6 used) from travel

shockless valve (8). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm
8

WCEB-02-10-003
7

10 9
5. Remove sems bolts (10) (4 used) from bracket (9).
Remove the travel shockless valve (8) assembly
from main frame (3).
: 17 mm
10
6. Remove sems bolts (11) (2 used) from bracket (9).
Remove travel shockless valve (8) from bracket
(9). 3
: 17 mm
8, 11

WCEB-02-10-003

W2-10-3
 UPPERSTRUCTURE / Shockless Valve
Installation of Travel Shockless Valve
10 9
1. Install travel shockless valve (8) to bracket (9) with
sems bolts (11) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
10
2. Install the bracket (9) assembly to main frame (3)
with sems bolts (10) (4 used).
: 17 mm 3
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
8, 11

WCEB-02-10-003

3. Connect hoses (7) (6 used) to travel shockless 4 5 6 7

valve (8).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

4. Connect connector (4) to pressure sensor (5).

5. Connect connectors (6) (2 used).

WCEB-02-10-003
7

1 2
6. Install cover (2) to main frame (3) with sems bolts
(1) (6 used).
: 17 mm 3
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-13-001

W2-10-4
 UPPERSTRUCTURE / Shockless Valve
(Blank)

W2-10-5
 UPPERSTRUCTURE / Shockless Valve
STRUCTURE OF SWING SHOCKLESS VALVE

Section D 1 2

B D
Section B

18 A
17
3
16

15

Orifice
4

14 5
C C
13 6
7
12
8

11 Section C 9

10

Section A
Orifice WCEB-02-10-001

W2-10-6
 UPPERSTRUCTURE / Shockless Valve

Tightening Torque
Part Name Q’ ty Wrench Size
N⋅m (kgf⋅m) (lbf⋅ft)
1 Check Valve 1
2 Retaining Ring 1
3 Body 1
4 Steel Ball 2
5 O-Ring 2
6 Plug 2
7 Spring 2
8 O-Ring 2
9 Plug 2 9.8 (1) (7)
10 Plug 2 8.8 (0.9) (6)
11 Plug 2 48.5 (4.9) (36)
12 O-Ring 2
13 Spring 2
14 Plunger 2
15 Ring 2
16 Spring 2
17 O-Ring 2
18 Plug 2 48.5 (4.9) (36)

W2-10-7
 UPPERSTRUCTURE / Shockless Valve
STRUCTURE OF TRAVEL SHOCKLESS
VALVE

13

1
14

4
4
T1F3-03-08-004

T1F3-03-08-005
5
Section A

7
T1F3-03-08-006

8 9 10 11 12

Section B

W2-10-8
 UPPERSTRUCTURE / Shockless Valve

Tightening Torque
Part Name Q’ ty Wrench Size
N⋅m (kgf⋅m) (lbf⋅ft)
1 Solenoid 2
2 O-Ring 2 1B P14
3 Spool 2
4 Body 1
5 Spring 2
6 Plug 6
7 Orifice 2 1.6 to 2.0 (0.16 to 0.2) (1.2 to 1.5)
8 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13)
9 Steel Ball 2 9/32
10 Spring 2
11 O-Ring 4 1B P8
12 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13)
13 Nut 2 : 19 mm 4.9 (0.5) (3.6)
14 Tube 2 30 to 37 (3 to 4) (22 to 27)

W2-10-9
 UPPERSTRUCTURE / Shockless Valve
(Blank)

W2-10-10
 UPPERSTRUCTURE / Solenoid Valve
REMOVAL AND INSTALLATION OF
3-SPOOL SOLENOID VALVE UNIT

CAUTION: Bleed air from hydraulic oil tank

before doing any work. (Refer to BLEED AIR
FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal 1
1. Open cover (1).

WCEB-02-05-002

2. Remove sems bolts (3) (6 used) from cover (4).

Remove cover (4) from cover (2), supports (5) (2 3
used) and bracket (6).
: 17 mm
2
4

WCEB-02-05-001

WCEB-02-05-003

WCEB-02-05-004

W2-11-1
 UPPERSTRUCTURE / Solenoid Valve
7 8
3. Disconnect connectors (13) (3 used).

4. Disconnect hoses (8) (14 used) from 3-spool

solenoid valve unit (9). Cap the open ends. Attach
an identification tag onto the disconnected hoses
for assembling.
: 19 mm, 22 mm 9

5. Disconnect pipings (7) (3 used) from 3-spool

10, 11
solenoid valve unit (9).
: 19 mm
12
6. Remove socket bolts (10) (2 used) and washers
(11) (2 used) from 3-spool solenoid valve unit (9).
Remove 3-spool solenoid valve unit (9) from WCEB-02-11-012
13
control valve (12).
: 8 mm

Installation 7 8
1. Install 3-spool solenoid valve unit (9) to control
valve (12) with socket bolts (10) (2 used) and
washers (11) (2 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect pipings (7) (3 used) to 3-spool solenoid 9

valve unit (9).
: 19 mm 10, 11
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
12
3. Connect hoses (8) (14 used) to 3-spool solenoid
valve unit (9).
: 19 mm
WCEB-02-11-012
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 13
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

4. Connect connectors (13) (3 used).

W2-11-2
 UPPERSTRUCTURE / Solenoid Valve
5. Install covers (2, 4) to supports (5) (2 used) and
3
bracket (6) with sems bolts (3) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 2 4

WCEB-02-05-001
5

WCEB-02-05-003

WCEB-02-05-004

6. Shut cover (1).

WCEB-02-05-002

W2-11-3
 UPPERSTRUCTURE / Solenoid Valve
(Blank)

W2-11-4
 UPPERSTRUCTURE / Solenoid Valve
STRUCTURE OF 3-SPOOL SOLENOID VALVE UNIT

WCEB-02-11-008

Proportional Solenoid Valve

Proportional Solenoid Valve

WCEB-02-11-009

Filter Plug

Plug Filter

WCEB-02-11-011

View A Section B
WCEB-02-11-010

W2-11-5
 UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLY AND ASSEMBLY OF 3-SPOOL SOLENOID VALVE UNIT

1
2
3
4
5

7
8
9
12
13 14
10 15
11 16

17
18
19

W18G-02-08-012

4 2 3, 5 6 1 8 12 13 17 10 18

19
W18G-02-08-013
7 9 14 15 16 11

1- Socket Bolt (4 Used) 6- Solenoid 11 - Orifice 16 - O-Ring

2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
4- Adjusting Bolt 9- Diaphragm 14 - O-Ring 19 - Wave Spring
5- Spring 10 - Spool 15 - O-Ring

W2-11-6
 UPPERSTRUCTURE / Solenoid Valve
Disassembly of 3-Spool Solenoid Valve Unit
IMPORTANT: Do not lose spring (7) in the hole of
solenoid (6) when removing
solenoid (6).
Do not disassemble pressure
adjusting lock nut (2) and adjusting
bolt (4).
1. Remove socket bolts (1) (2 used) from solenoid
(6). Remove solenoid (6) and O-ring (8) from the
housing.
: 4 mm
IMPORTANT: Do not remove orifice (11) from
spool (10).
2. Remove spool (10) from sleeve (17). Remove
diaphragm (9), washer (12) and spring (13) from
spool (10).
3. Remove sleeve (17) from the housing. Remove
plate (18) and wave spring (19) from the housing
by using a magnet.
4. Remove O-rings (14, 15, 16) from sleeve (17).
W2-11-7
Assembly of 3-Spool Solenoid Valve Unit
1. Install wave spring (19) and plate (18) to the
housing.
IMPORTANT: When inserting sleeve (17) into the
housing, align the hole on sleeve
(17) with that on the housing.
2. Install O-rings (14, 15, 16) to sleeve (17). Insert
sleeve (17) into the housing.
IMPORTANT: When inserting spool (10) into
sleeve (17), do not damage the edge
on sleeve (17).
After inserting spool (10), try to push
it about 3 to 5 mm (0.1 to 0.2 in) by
fingers. Check if spool (10) moves
smoothly.
3. Install diaphragm (9), washer (12) and spring (13)
to spool (10). Insert spool (10) into sleeve (17).
IMPORTANT: When installing solenoid (6), prevent
spring (7) from falling off.
4. Install spring (7) to solenoid (6). Install solenoid
(6) to the housing with socket bolts (1) (2 used).
: 4 mm
: 5+2−0 N⋅m (0.5+0.2−0 kgf⋅m, 4+1.5−0 lbf⋅ft)
 UPPERSTRUCTURE / Solenoid Valve
REMOVAL AND INSTALLATION OF
SOLENOID VALVE UNIT (FOR ELECTRIC
LEVER OPERATION)

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
1
Removal
1. Open cover (1).

WCEB-02-01-005

2. Disconnect connector (6) from washer tank (2).

2 3
3. Disconnect vinyl hose (7) from washer tank (2).
Cap the open ends.

4. Remove sems bolts (5) (4 used) from cover (4). 4

Remove cover (4) from cover (3).
: 17 mm
5

WCEB-02-11-001

7 6

5. Disconnect connector (9) from ECM (Engine

Controller) (8).

WCEB-02-11-003
9

W2-11-8
 UPPERSTRUCTURE / Solenoid Valve
6. Remove sems bolts (10) (4 used) from cover (3). 10 3
Remove the cover (3) assembly from bracket
(11).
: 17 mm

WCEB-02-11-001
11 10

12
7. Disconnect connectors (12) (5 used) from
solenoid valve unit (13). 13

8. Disconnect hoses (14) (9 used) from solenoid

valve unit (13). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
14
assembling.
: 19 mm
NOTE: The number of solenoid valve units, the
connectors and the hoses differ depending
on the front attachment specifications.

WCEB-02-11-004
12

9. Remove bolts (16) (4 used) and washers (17) (4 13

used) from bracket (15). Remove solenoid valve
unit (13) from bracket (15).
: 17 mm

16, 17 15 WCEB-02-11-004

W2-11-9
 UPPERSTRUCTURE / Solenoid Valve
12
Installation
1. Install solenoid valve unit (13) to bracket (15) with
13
bolts (16) (4 used) and washers (17) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect hoses (14) (9 used) to solenoid valve 14

unit (13).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Connect connectors (12) (5 used) to solenoid

valve unit (13).
16, 17 15 12
WCEB-02-11-004

4. Install the cover (3) assembly to bracket (11) with

sems bolts (10) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
10 2 3
5. Connect connector (6) and vinyl hose (7) to
washer tank (2).

WCEB-02-11-001
11 7 6

6. Connect connector (9) to ECM (Engine

Controller) (8).
8

WCEB-02-11-003
9

W2-11-10
 UPPERSTRUCTURE / Solenoid Valve
7. Install cover (4) to cover (3) with sems bolts (5) (4 3
used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
4

WCEB-02-11-001

1
8. Shut cover (1).

WCEB-02-01-005

W2-11-11
 UPPERSTRUCTURE / Solenoid Valve
STRUCTURE OF SOLENOID VALVE UNIT (FOR ELECTRIC LEVER OPERATION)

2 3 4 5 6 7

A A

A A

A A

WCEB-02-11-006

Section A WCEB-02-11-007

Wrench Size Tightening Torque

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Solenoid Valve Assembly 1
2 Solenoid Valve Assembly 2
3 Solenoid Valve Assembly 1
4 Socket Bolt 4 :6 19.5+5−0 (2+0.5−0) (14+4−0)
5 Washer 4
6 End Plate 1
7 Socket Bolt 18 4.9+5−0 (0.5+0.5−0) (4+4−0)
8 Lock Nut 8 4.9+5−0 (0.5+0.5−0) (4+4−0)

W2-11-12
 UPPERSTRUCTURE / Solenoid Valve
REMOVAL AND INSTALLATION OF
1-SPOOL SOLENOID VALVE UNIT

CAUTION: Bleed air from hydraulic oil tank

before doing any work. (Refer to BLEED AIR
FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Open cover (1).

WCEB-02-05-002

2. Remove sems bolts (4) (4 used) from cover (2).

Remove cover (2) from main frame (3). 2 3
: 17 mm

WCEB-02-05-007

3. Disconnect connector (5).

5 3
4. Disconnect hoses (6) (3 used) from 1-spool
solenoid valve unit (7). Cap the open ends. 6
: 17 mm
9
5. Remove sems bolts (8) (2 used) from 1-spool 7
solenoid valve unit (7). Remove 1-spool solenoid
valve unit (7) and clip (9) from main frame (3).
: 13 mm

8 6 WCEB-02-11-002

W2-11-13
 UPPERSTRUCTURE / Solenoid Valve
Installation
5 3
1. Install 1-spool solenoid valve unit (7) and clip (9)
to main frame (3) with sems bolts (8) (2 used). 6
: 13 mm
9
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
7
2. Connect hoses (6) (3 used) to 1-spool solenoid
valve unit (7).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
8 6 WCEB-02-11-002

3. Connect connector (5).

4. Install cover (2) to main frame (3) with sems bolts 2 3

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

WCEB-02-05-007

5. Shut cover (1).

WCEB-02-05-002

W2-11-14
 UPPERSTRUCTURE / Solenoid Valve
STRUCTURE OF 1-SPOOL SOLENOID VALVE UNIT

WCEB-02-11-005

Wrench Size Tightening Torque

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m)
1 Solenoid 1
2 Socket Bolt 2 4.9 to 5.9 (0.5 to 0.6) (3.6 to 4.4)
3 O-Ring 1
4 Spool 1
5 Spring 1
6 Housing 1
7 O-Ring 1
8 Plug 1 13.2 to 17.6 (1.3 to 1.8) (9.8 to 13)

W2-11-15
 UPPERSTRUCTURE / Solenoid Valve
(Blank)

W2-11-16
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
REMOVAL AND INSTALLATION OF PILOT
SHUT-OFF SOLENOID VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 1 2

Removal 3
1. Remove sems bolts (1) (6 used) from cover (2).
Remove cover (2) from main frame (3).
: 17 mm

WCEB-02-13-001

2. Disconnect hoses (4) (9 used) from pilot shut-off

solenoid valve (5). Cap the open ends. Attach an 4 3 5 6
identification tag onto the disconnected hoses for
7
assembling.
: 17 mm, 19 mm

3. Disconnect connector (8). 8

4. Remove sems bolts (6) (4 used) from bracket (7).

Remove the bracket (7) assembly from main
frame (3).
: 17 mm

WCEB-02-12-001

5 7, 9
5. Remove sems bolts (9) (2 used) from bracket (7).
Remove bracket (7) from pilot shut-off solenoid
valve (5).
: 17 mm

WCEB-02-12-001

W2-12-1
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
3 5 7, 9
Installation 6
1. Install bracket (7) to pilot shut-off solenoid valve
(5) with sems bolts (9) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install the bracket (7) assembly to main frame (3)

with sems bolts (6) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-12-001

3. Connect hoses (4) (9 used) to pilot shut-off

4 5
solenoid valve (5).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
8
4. Connect connector (8).

WCEB-02-12-001

1 2
5. Install cover (2) to main frame (3) with sems bolts
(1) (6 used). 3
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-13-001

W2-12-2
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
STRUCTURE OF PILOT SHUT-OFF SOLENOID VALVE

W1JB-02-08-001

3 4 5 6 7 8

W1JB-02-08-002

Wrench Size Tightening Torque

Item Part Name Q’ty Remarks
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 : 6 26.5 (2.7) (20)
2 O-Ring 1
3 Spring 1
4 Spool 1
5 Filter 1
6 Body 1
7 O-Ring 1
8 Solenoid 1
9 Socket Bolt 2 : 4 3.92 (0.4) (3)

W2-12-3
 UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
(Blank)

W2-12-4
 UPPERSTRUCTURE / Steering Valve
REMOVAL AND INSTALLATION OF
STEERING VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.) 2 3

Removal
1. Open door (4) and upper front glass (2).

2. Remove lower front glass (1) from cab (3).

WCEB-02-01-004

3. Remove mat (5) from the inside of cab (3).

4. Remove sems bolts (6) (2 used) from pedal (7).

Remove pedal (7) from bracket (8). WCEB-02-01-003

: 13 mm

8 WCEB-02-08-001

W2-13-1
 UPPERSTRUCTURE / Steering Valve
5. Remove caps (10) (5 used) from cover (9).
Remove screws (11) (5 used) from cover (9). 10, 11
Remove cover (9) from stand (15).

6. Remove caps (13) (3 used) from cover (12). 12, 13, 14

Remove screws (14) (5 used) from cover (12).
9
Remove cover (12) from stand (15).

15

WCEB-02-13-002

7. Remove screws (17) (4 used) from cover (16).

Remove cover (16) from stand (15).

16

15 17 WCEB-02-13-003

8. Remove sems bolts (18) (6 used) from cover (19). 18 19 18

Remove cover (19) from main frame (20).
: 19 mm 20

WCEB-02-13-001

9. Disconnect hoses (22) (5 used) from steering 21

valve (21). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 22 mm, 27 mm 22

WCEB-02-13-006

W2-13-2
 UPPERSTRUCTURE / Steering Valve
10. Remove sems bolts (23) (4 used) from stand (15).
Remove the steering valve (21) assembly from
stand (15).
: 17 mm
23

15

WCEB-02-13-004

21

WCEB-02-13-006

24

11. Remove socket bolts (24) (2 used) from priority

valve (25). Remove priority valve (25) and O-rings 25, 26
(26) (5 used) from steering valve (21).

21

WCEB-02-13-005

W2-13-3
 UPPERSTRUCTURE / Steering Valve
Installation 24
1. Install priority valve (25) to steering valve (21) with
O-rings (26) (5 used) and socket bolts (24) (2
used). 25, 26
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

21

WCEB-02-13-005

2. Install the steering valve (21) assembly to stand

(15) with sems bolts (23) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
23

15

WCEB-02-13-004

3. Connect hoses (22) (5 used) to steering valve 21

(21).
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm 22
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

WCEB-02-13-006

18 19 18
4. Install cover (19) to main frame (20) with sems
bolts (18) (6 used). 20
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-13-001

W2-13-4
 UPPERSTRUCTURE / Steering Valve
5. Install cover (16) to stand (15) with screws (17) (4
used).

16

15 17 WCEB-02-13-003

10, 11
6. Install cover (9) to stand (15) with screws (11) (5
used). Install caps (10) (5 used) to cover (9).

15

WCEB-02-13-002

7. Install cover (12) to stand (15) with screws (14) (5

used). Install caps (13) (3 used) to cover (12).
12, 13, 14

15

WCEB-02-13-002

6
8. Install pedal (7) to bracket (8) with sems bolts (6)
(2 used).
: 13 mm
7
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

8 WCEB-02-08-001

W2-13-5
 UPPERSTRUCTURE / Steering Valve
9. Install mat (5) to the inside of cab (3).
3

WCEB-02-01-003

2 3

10. Install lower front glass (1) to cab (3).

11. Shut upper front glass (2) and door (4).

WCEB-02-01-004

W2-13-6
 UPPERSTRUCTURE / Brake Valve
REMOVAL AND INSTALLATION OF
BRAKE VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
1. Remove mat (1) from the inside of cab (2). 1

WCEB-02-01-003

3 4 5
2. Remove sems bolts (3) (6 used) from cover (4).
Remove cover (4) from main frame (5).
: 17 mm

WCEB-02-13-001

6, 7 8 9
10
3. Disconnect connector (11).

4. Remove socket bolts (7) (2 used) from bracket (6).

Remove the bracket (6) assembly from bracket
(8).
: 6 mm

5. Disconnect hoses (9) (6 used) from brake valve

(10). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling. 11 WCEB-02-14-005
: 17 mm, 22 mm, 27 mm
12 10 13
6. Remove rubber (14) from brake pedal (15).

7. Remove sems bolts (12) (4 used) from plate (13).

Remove the brake valve (10) assembly from plate
(13).
: 17 mm

14, 15 12
WCEB-02-14-006

W2-14-1
 UPPERSTRUCTURE / Brake Valve
Installation 12 10 13
1. Align the brake valve (10) assembly with the
mounting hole on plate (13). Install the brake valve
(10) assembly to plate (13) with sems bolts (12) (4
used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install rubber (14) to brake pedal (15).

14, 15 12
WCEB-02-14-006

6, 7 8 9
3. Connect hoses (9) (6 used) to brake valve (10). 10
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m,58 lbf⋅ft)

4. Install the bracket (6) assembly to bracket (8) with

socket bolts (7) (2 used).
: 6 mm 11 WCEB-02-14-005

: 58.8 to 73.5 N⋅m

(6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)
3 4 5
5. Connect connector (11).

6. Install cover (4) to main frame (5) with sems bolts

(3) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-13-001

7. Install mat (1) to the inside of cab (2).

1

WCEB-02-01-003

W2-14-2
 UPPERSTRUCTURE / Brake Valve
(Blank)

W2-14-3
 UPPERSTRUCTURE / Brake Valve
DISASSEMBLY OF BRAKE VALVE
1

11
29 3

28
8
5 7
4

6 10
27
9
12

13
14
15

16
26

25

17
3
3
30 24 16
31
32 23
33 22
34 18
43
35
36

42 37 19
41
38
20

44 40 21
45
46
47 29
48

39

44
45
46
47
49
WCEB-02-14-004
48

W2-14-4
 UPPERSTRUCTURE / Brake Valve

1- Rubber 14 - Bushing 26 - Bracket 38 - Push Rod

2- Brake Pedal 15 - Yoke 27 - Oil Seal 39 - Cylinder
3- Split Pin (4 Used) 16 - Pin (2 Used) 28 - Flange 40 - Cylinder
4- Stopper Bolt 17 - Link 29 - O-Ring (2 Used) (1B, G45) 41 - O-Ring (1B, P32)
5- Bushing 18 - Roller Assembly 30 - Rod 42 - Plug
6- Lock Nut 19 - Bracket 31 - Return Spring 43 - Socket Bolt (4 Used)
7- Bushing (2 Used) 20 - Brake Switch 32 - Holder 44 - Spring (2 Used)
8- Pin 21 - Socket Bolt (2 Used) 33 - Spring 45 - Retaining Ring (2 Used)
9- Bushing (2 Used) 22 - Seat 34 - Balance Spring 46 - Retainer (2 Used)
10 - Pin 23 - Stopper 35 - Retainer 47 - Plunger (2 Used)
11 - Boot 24 - Boot 36 - Retainer 48 - Spool (2 Used)
12 - Pin 25 - Socket Bolt (4 Used) 37 - Pilot Piston 49 - Spring
13 - Spring Pin

W2-14-5
 UPPERSTRUCTURE / Brake Valve

11
29 3

28

4 5 7 8

6 10
27
9
12

13
14
15

16
26

25

17
3
3
30 24 16
31
32 23
33 22
34 18
43
35
36

42 37 19
41
38
20

44 40 21
45
46
47 29
48

39

44
45
46
47
49
WCEB-02-14-004
48

W2-14-6
 UPPERSTRUCTURE / Brake Valve
Disassembly of Brake Valve
IMPORTANT: Put the matching marks onto
bracket (26), flange (28), cylinder
(39) and cylinder (40) before disas-
sembling.
1. Secure the brake valve in a vise with the cylinder
(40) side facing downward.
2. Remove socket bolts (21) (2 used) from bracket
(19). Remove bracket (19) and brake switch (20)
from bracket (26).
: 6 mm
3. Remove split pins (3) (3 used) from pins (8, 10
and 16) except the roller assembly (18) part.
Remove pins (8, 10 and 16) from bracket (26) and
link (17).
4. Remove spring pin (13) from yoke (15). Remove
pin (12) from yoke (15).
5. Remove split pin (3) from pin (16). Remove pin
(16) and the roller (18) assembly from link (17).
6. Remove seat (22), stopper (23) and boot (24)
from flange (28).
7. Remove socket bolts (25) (4 used) from bracket
(26). Remove bracket (26) from flange (28).
8. Secure the flange (28) part in a vise with the push
rod (38) side facing downward.
W2-14-7
IMPORTANT: The spool (48) assembly is also used
inside cylinder (39). Keep them in
order not to confuse.
9. Remove plug (42), spring (44) and the spool (48)
assembly from cylinder (40).
10. Remove plunger (47), retaining ring (45) and re-
tainer (46) from the spool (48) assembly.
IMPORTANT: The reaction force of spring (44) acts
on socket bolt (43). While holding
cylinder (40), slowly remove socket
bolt (43).
11. Remove socket bolts (43) (4 used) from cylinder
(40).
12. Remove cylinder (40) and the cylinder (39) as-
sembly from flange (28).
13. Remove the spool (48) assembly from cylinder
(39).
14. Remove plunger (47), spring (44), retaining ring
(45) and retainer (46) from the spool (48) assem-
bly.
15. Remove return spring (31), holder (32), rod (30),
balance spring (34), spring (33), retainers (35, 36),
pilot piston (37) and push rod (38) from flange
(28).
16. Remove oil seal (27) from flange (28).
17. Remove O-rings (29) (2 used) from flange (28)
and cylinder (39).
 UPPERSTRUCTURE / Brake Valve
ASSEMBLY OF BRAKE VALVE
1
12
2
11
8
15

14 26 28 39 43 40

16

10
A 42
21

17

19

16

18

20
22 23 31 30 29 48 49 47 45 46 44 WCEB-02-14-001

22 24 25

42

47

41

WCEB-02-14-002
38 27 37 36 35 33 34 32 46 29 48 45

13 5

12
7
15

3 8
9
26

17
10
21

3
16

3 18

19
View A WCEB-02-14-003

W2-14-8
 UPPERSTRUCTURE / Brake Valve

1- Rubber 14 - Bushing 26 - Bracket 38 - Push Rod

2- Brake Pedal 15 - Yoke 27 - Oil Seal 39 - Cylinder
3- Split Pin (4 Used) 16 - Pin (2 Used) 28 - Flange 40 - Cylinder
4- * Stopper Bolt 17 - Link 29 - O-Ring (2 Used) (1B, G45) 41 - O-Ring (1B, P32)
5- Bushing 18 - Roller Assembly 30 - Rod 42 - Plug
6- * Lock Nut 19 - Bracket 31 - Return Spring 43 - Socket Bolt (4 Used)
7- Bushing (2 Used) 20 - Brake Switch 32 - Holder 44 - Spring (2 Used)
8- Pin 21 - Socket Bolt (2 Used) 33 - Spring 45 - Retaining Ring (2 Used)
9- Bushing (2 Used) 22 - Seat 34 - Balance Spring 46 - Retainer (2 Used)
10 - Pin 23 - Stopper 35 - Retainer 47 - Plunger (2 Used)
11 - Boot 24 - Boot 36 - Retainer 48 - Spool (2 Used)
12 - Pin 25 - Socket Bolt (4 Used) 37 - Pilot Piston 49 - Spring
13 - Spring Pin
NOTE: As for the item with mark *, refer to W2-14-4.

W2-14-9
 UPPERSTRUCTURE / Brake Valve

1
12
2
11
8
15

14 26 28 39 43 40

16

10
A 42
21

17

19

16

18

20
22 22 23 24 25 31 30 29 48 49 47 45 46 44 WCEB-02-14-001

42

47

41

WCEB-02-14-002
38 27 37 36 35 33 34 32 46 29 48 45

13 5

12
7
15

3 8
9
26

17
10
21

3
16

3 18

19
WCEB-02-14-003
View A

W2-14-10
 UPPERSTRUCTURE / Brake Valve
Assembly of Brake Valve
1. Install oil seal (27) to flange (28).
2. Secure flange (28) in a vise with the oil seal (27)
side facing downward.
3. Install O-ring (29) to flange (28).
4. Apply hydraulic oil onto rod (30), pilot piston (37),
push rod (38), plungers (47) (2 used) and spools
(48) (2 used).
5. Install push rod (38), pilot piston (37), retainer (36),
retainer (35), return spring (31), balance spring
(34), spring (33), holder (32) and rod (30) to flange
(28) in this order.
6. Install O-ring (29) to cylinder (39).
7. Align the matching marks and place cylinder (39)
onto the flange (28) assembly.
8. Install retainer (46) and retaining ring (45) to spool
(48).
9. Install the spool (48) assembly to cylinder (39).
W2-14-11
10. Install spring (49), plunger (47) and spring (44) to
cylinder (39).
11. Align the matching marks and place cylinder (40)
onto cylinder (39).
12. Install retainer (46) and retaining ring (45) to spool
(48).
13. Install the spool (48) assembly to cylinder (40).
14. Install plunger (47), spring (44) and plug (42) to
cylinder (40).
: 130 to 180 N⋅m
(13 to 18 kgf⋅m, 96 to 133 lbf⋅ft)
15. Connect flange (28), cylinder (39) and cylinder
(40) with socket bolts (43) (4 used).
: 60 to 75 N⋅m
(6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft)
 UPPERSTRUCTURE / Brake Valve

1
12
2
11
8
15

26 28 40

16

10
A
21

17

19

16

18

20
22 23 WCEB-02-14-001

22 24 25

WCEB-02-14-002

13

12

15

3 8

26

17
10
21

3
16

3 18

19
View A WCEB-02-14-003

W2-14-12
 UPPERSTRUCTURE / Brake Valve
16. Secure the cylinder assembly in a vise with the
cylinder (40) side facing downward.
17. Install flange (28) to bracket (26) with socket bolts
(25) (4 used).
: 60 to 75 N⋅m (6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft)
18. Install boot (24), stopper (23) and seat (22) to
flange (28).
19. Apply grease onto all pin holes on brake pedal (2),
bracket (26), yoke (15) and link (17).
26. Secure stopper bolt (4) to link (17) with lock nut
(6).
: 6.0 to 10 N⋅m (0.6 to 1 kgf⋅m, 4 to 7 lbf⋅ft)
27. Install rubber (1) to brake pedal (2).
28. Install brake switch (20) to bracket (19). Install the
bracket (19) assembly to bracket (26) with socket
bolts (21) (2 used).
: 6 mm
: 58.8 to 73.5 N⋅m
(6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)

20. Install yoke (15) to brake pedal (2) with pin (12)
and spring pin (13).

21. Install roller assembly (18) to link (17) with pin (16).
Secure pin (16) to link (17) with split pin (3).

22. Install the link (17) assembly to bracket (26) with

pin (10). Secure pin (10) to bracket (26) with split
pin (3).

23. Install boot (11) to the brake pedal (2) assembly.

Install brake pedal (2) to bracket (26) with pin (8).
Secure pin (8) to bracket (26) with split pin (3).

24. Install yoke (15) to link (17) with pin (16). Secure
pin (16) to link (17) with split pin (3).

25. Adjust play of link (17) to 0 mm with stopper bolt

(4).

W2-14-13
 UPPERSTRUCTURE / Brake Valve
(Blank)

W2-14-14
 UPPERSTRUCTURE / Accumulator Charge Valve
REMOVAL AND INSTALLATION OF AC-
CUMULATOR CHARGE VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
1 2 3
Removal
1. Remove sems bolts (1) (6 used) from cover (2).
Remove cover (2) from main frame (3).
: 17 mm

WCEB-02-13-001

2. Disconnect hoses (4) (8 used) from accumulator

4 5, 6 7
charge valve (5). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling. 8
: 17 mm, 22 mm, 27 mm

3. Remove sems bolts (7) (4 used) from bracket (8).

Remove the bracket (8) assembly from main frame
(3).
: 17 mm

4. Remove sems bolts (6) (4 used) from bracket (8).

Remove accumulator charge valve (5) from 3 WCEB-02-15-001

bracket (8).
: 17 mm

W2-15-1
 UPPERSTRUCTURE / Accumulator Charge Valve
Installation
1. Install accumulator charge valve (5) to bracket (8)
with sems bolts (6) (4 used). 4 5, 6 7
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 8

2. Install the bracket (8) assembly to main frame (3)

with sems bolts (7) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Connect hoses (4) (8 used) to accumulator charge

valve (5).
: 17 mm 3 WCEB-02-15-001

: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
1 2 3
4. Install cover (2) to main frame (3) with sems bolts
(7) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-13-001

W2-15-2
 UPPERSTRUCTURE / Accumulator Charge Valve
(Blank)

W2-15-3
 UPPERSTRUCTURE / Accumulator Charge Valve
STRUCTURE OF ACCUMULATOR CHARGE VALVE
1, 2 3, 4 5, 6 1, 2

3, 4

5, 6

WCEB-02-15-002

8 8

9 9

10 10

11 11

1 6

Section A 2 Section B

18 19 20 5 6
26
15 16 17 21 22 23 24 6 9

14 5
27
13
25 28

12 29

37

36
WCEB-02-15-003
35 34 33 32 31 1 2 30 3 4
Section C
Section D

W2-15-4
 UPPERSTRUCTURE / Accumulator Charge Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 4 4.9 (0.5) (4)
2 O-Ring 4
3 Plug 3 26.5 (3) (20)
4 O-Ring 3
5 Plug 5 9.8 (1) (7)
6 O-Ring 5
7 Body 1
8 Plug 2 12 (1.2) (9)
9 O-Ring 3
10 Spring 2
11 Plunger 2
12 Plug 1 58.8 (6) (43)
13 Screw 1
14 Lock Nut 1
15 O-Ring 1
16 Spring 1
17 Needle Valve 1
18 O-Ring 1
19 Backup Ring 1
20 O-Ring 1
21 O-Ring 1
22 Backup Ring 1
23 Sleeve 1
24 Piston 1
25 Orifice 1 9.8 (1) (7)
26 Plug 1 12 (1.2) (9)
27 Spring 1
28 Plunger 1
29 Sleeve 1
30 Plunger 1
31 O-Ring 1
32 Washer 1
33 Spring 1
34 Spring 1
35 Plug 1 48.5 (5) (36)
36 O-Ring 1
37 Plug 1 48.5 (5) (36)
NOTE: Tools : 22 mm, 24 mm, 32 mm
: 1/8, 4 mm, 5 mm, 6 mm

W2-15-5
 UPPERSTRUCTURE / Accumulator Charge Valve
(Blank)

W2-15-6
 MEMO

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 MEMO

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 SECTION 3
UNDERCARRIAGE

―CONTENTS―
Group 1 Swing Bearing Group 6 Axle Lock Cylinder
Removal and Installation of Removal and Installation of
Swing Bearing ......................................W3-1-1 Axle Lock Cylinder .............................. W3-6-1
Disassembly of Swing Bearing ................W3-1-4 Disassembly and Assembly of
Assembly of Swing Bearing.....................W3-1-6 Axle Lock Cylinder .............................. W3-6-4

Group 2 Travel Motor Group 7 Operate Check Valve

Removal and Installation of
Travel Motor .........................................W3-2-1
Disassembly of Travel Motor...................W3-2-4
Assembly of Travel Motor ..................... W3-2-12
Disassembly of Brake Valve.................. W3-2-20
Assembly of Brake Valve ...................... W3-2-22
Group 3 Center Joint
Removal and Installation of
Cebter Joint ..........................................W3-3-1
Disassembly of Center Joint....................W3-3-6
Assembly of Center Joint ......................W3-3-8
Maintenance Standard ........................... W3-3-11
Group 4 Transmission
Removal and Installation of
Transmission.........................................W3-4-1
Disassembly of Transmission ..................W3-4-6
Assembly of Transmission..................... W3-4-18
Removal and Installation of Operate Check
Valve (for Axle Lock Cylinder) .................W3-7-1
Structure of Operate Check Valve
(For Axle Lock Cylinder)..........................W3-7-2
Group 8 Solenoid Valve
Removal and Installation of
Outrigger/BladeSolenoid Valve Unit......W3-8-1
Structure of Solenoid Valve Unit ...............W3-8-3
Group 9 Transmission Changeover
Solenoid Valve
Removal and Installation of Transmission
Changeover Solenoid Valve..................W3-9-1
Group 10 Propeller Shaft
Removal and Installation of
Propeller Shaft.....................................W3-10-1

Group 5 Axle
Removal and Installation of Axle .............W3-5-1
Disassembly of Front Axle .................... W3-5-10
Assembly of Front Axle......................... W3-5-20
Disassembly of Rear Axle ..................... W3-5-30
Assembly of Rear Axle ......................... W3-5-36
Disassembly of Differential ................... W3-5-44
Assembly of Differential........................ W3-5-50

CEBW-3-1
(Blank)

CEBW-3-2
 UNDERCARRIAGE / Swing Bearing
REMOVAL AND INSTALLATION OF
SWING BEARING

Before removing and installing the swing bearing, the

upperstructure must be removed first. For removal
and installation of the upperstructure, refer to the
REMOVAL AND INSTALLATION OF MAIN FRAME on
W2-3-1.
The procedure starts on the premise that the upper- Matching Mark 1 2
structure has already been removed.

Removal
1. Put the matching marks on inner race (1) of the
swing bearing and track frame (2).

WCEB-03-01-001

2. Remove knock pin (3) from outer race (4) of the 3 4 5 1

swing bearing.

3. Remove bolts (5) (36 used) from inner race (1) of

the swing bearing.
: 24 mm

WCEB-03-01-001

CAUTION: Swing bearing weight: 157 kg

(350 lb)
2
4. Install special tools (ST 0050) (3 used) to the
swing bearing. Attach a wire rope onto special
tool. Hoist and remove the swing bearing from
track frame (2).

ST 0050
Swing Bearing
WCEB-03-01-002

W3-1-1
 UNDERCARRIAGE / Swing Bearing
Installation
Clean the mounting surfaces of track frame (2) and
the swing bearing.

1. Apply THREEBOND #1102 onto the swing bear-

ing mounting surface of track frame (2).
2

Swing Bearing
WCEB-03-01-002

CAUTION: Swing bearing weight: 157 kg Machine

Front
(350 lb)
Position for
IMPORTANT: If the matching mark do not align, Grease Fitting
the soft zone position of the inner ”S” (Soft Zone)
Marking Position
race will be dislocated.
2. Hoist and align swing bearing with the mounting 6°
holes on track frame (2). Position for
Plug
0.2

10°
21°

Position for
Position for
Knock Pin
Grease Fitting
WCEB-03-01-003

3 4 5 1 2
3. Install inner race (1) of the swing bearing to track
fame (2) with bolts (5) (36 used).
: 24 mm
: 270 N⋅m (27 kgf⋅m, 200 lbf⋅ft)

4. Install knock pin (3) to outer race (4) of the swing

bearing.

WCEB-03-01-001

W3-1-2
 UNDERCARRIAGE / Swing Bearing
5. After installing the swing bearing, add grease
Swing Bearing Grease Level Pinion
(Shell Alvania EP2 or equivalent) up to 19 mm
(0.75 in) height from the bottom of the grease
bath.

19 mm (0.75 in)

Grease Bath WCEB-03-01-004

W3-1-3
 UNDERCARRIAGE / Swing Bearing
DISASSEMBLY OF SWING BEARING

1 2 3

9 7 6 5 W155-03-01-001

6
9

W105-03-01-011

1- Outer Race 4- Plug 6- Ball (99 Used) 8- Grease Fitting (2 Used)

2- Seal 5- Seal 7- Inner Race 9- Support (99 Used)
3- Pin

W3-1-4
 UNDERCARRIAGE / Swing Bearing
Disassembly of Swing Bearing

1. Tap and remove pin (3) of plug (4) upward from
the bottom side.
NOTE: After installing pin (3), pin (3) was crimped.
Grind off the crimped part.
CAUTION: Swing bearing weight: 157 kg
(350 lb)
3. Place inner race (7) of the swing bearing onto a
wooden block by using special tool (ST 0050).
Hoist and hold outer race (1) slightly.

3 4. Remove balls (6) (99 used) and supports (9) (99

used) from the plug hole while rotating outer race
(1).
Use magnet (A) when removing ball (6). Use wire
(B) and remove support (9).
4

1
2

A
W105-03-01-007 7

2. Remove plug (4) from outer race (1).

NOTE: Install the bolt into the screw hole (M10,
Pitch 1.5 mm) of plug (4). Tap or pull the
bolt from the inner side. 6 5
W105-03-01-009

B
4

W105-03-01-010
W105-03-01-008 9
5. Separate outer race (1) from inner race (7).

6. Remove seals (2, 5) from outer race (1) and in-

ner race (7) respectively by using a scrapper.

W3-1-5
 UNDERCARRIAGE / Swing Bearing
ASSEMBLY OF SWING BEARING
1 2 3

9 7 6 5 W155-03-01-001

6
9

W105-03-01-011

1- Outer Race 4- Plug 6- Ball (99 Used) 8- Grease Fitting (2 Used)

2- Seal 5- Seal 7- Inner Race 9- Support (99 Used)
3- Pin

W3-1-6
 UNDERCARRIAGE / Swing Bearing
Assembly of Swing Bearing

IMPORTANT: Apply grease onto balls (6) (99 2. Tap and install plug (4) into outer race (1). Secure
used) and supports (9) (99 used) plug (4) to outer race (1) with pin (3). Crimp the
head of pin (3) by using a punch.
CAUTION: Swing bearing weight: 157 kg
(350 lb) 3
1. Hoist outer race (1) horizontally and align outer
race (1) with inner race (7) coaxially.
While rotating outer race (1), insert balls (6) and 1
supports (9) into the plug hole by using a round
bar.

2
W142-03-01-007

3. Install lifting tool (ST 0050) to outer race (1).

Hoist outer race (1). Thoroughly degrease the
slots for seals (2, 5). Apply THREEBOND #1745
to seal (2) and #1735 onto seal (5). Install seals
6
(2, 5) onto outer race (1) and inner race (7).
5 W142-03-01-005

4. Add grease 0.3 L (0.1 US gal.) (Alvania EP2

grease or equivalent) to the swing bearing
1 through grease fitting (8). At this time, rotate
outer race (1) and add grease.

W142-03-01-006

W3-1-7
 UNDERCARRIAGE / Swing Bearing
(Blank)

W3-1-8
 UNDERCARRIAGE / Travel Motor
REMOVAL AND INSTALLATION OF
TRAVEL MOTOR

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Before removing and installing travel motor (7), the

propeller shaft must be removed first. For removal and
installation of the propeller shaft, refer to REMOVAL
AND INSTALLATION OF PROPELLER SHAFT on
W3-10-1.
Therefore, in this section, the procedure starts from the
premise that the propeller shaft has already been
removed.

Removal
2
IMPORTANT: Attach an identification tag onto the
disconnected hoses for assembling. 3
1. Disconnect hoses (1) (7 used) and connector (3) 1
from travel motor (2). Cap the disconnected
hoses.
: 19 mm, 22 mm, 27 mm 4

CAUTION: Travel motor (2) weight: 80 kg

(180 lb) WCGB-03-05-030

5
2. Loosen socket bolts (4) (4 used) of travel motor
(2). While holding the lower side of travel motor
(2) by using a forklift, remove socket bolts (4) (4
used).
: 14 mm

3. Remove travel motor (2) from transmission (5).

W3-2-1
 UNDERCARRIAGE / Travel Motor
Installation
2
CAUTION: Travel motor (2) weight: 80 kg
(180 lb)
3
1. Install travel motor (2) to transmission (5) with 1
socket bolts (4) (4 used).
: 14 mm
: 270 N·m (27.5 kgf·m, 200 lbf·ft) 4

2. Connect hoses (1) (7 used) and connector (3) to

travel motor (2).
: 19 mm WCGB-03-05-030

: 29.5 N·m (3 kgf·m, 22 lbf·ft) 5

: 22 mm
: 39 N·m (4 kgf·m, 29 lbf·ft)
: 27 mm
: 64 N·m (6.5 kgf·m, 47 lbf·ft)
: 12 mm
: 180 N·m (18 kgf·m, 133 lbf·ft)

3. Install the propeller shaft to transmission (5).

(Refer to REMOVAL AND INSTALLATION OF
PROPELLER SHAFT on W3-10-1.)

IMPORTANT: After installing the travel motor (2),

fill hydraulic oil into the travel motor
(2). Perform break-in operation after
installing the travel motor (2) in order
to prevent the travel motor (2) and/or
travel reduction gear from seizuring.
Condition 1.Engine control dial: Slow idle
2.Travel speed mode switch: Slow
speed
3.Operation duration: Over 2 minutes

W3-2-2
 UNDERCARRIAGE / Travel Motor
(Blank)

W3-2-3
 UNDERCARRIAGE / Travel Motor
DISASSEMBLY OF TRAVEL MOTOR

47 1 2 3 4 5 6 7 8 9 10 11 12 13

46

45

44
14
43

42 15

41

40

39

16
37, 38
17

36
18

35
19

34
20

WCGB-03-02-004
33 32 31 30 29 28 27 26 25 24 23 22 21

A
48 37, 38 37, 38
View A

56
28, 53, 54
49 4, 55 49

52
50 50

51 WCGB-03-02-001
WCGB-03-02-002
51 8

W3-2-4
 UNDERCARRIAGE / Travel Motor

1- Adjusting Screw 15 - Shim 29 - Socket Bolt 43 - Spring Collar

2- Lock Nut 16 - Retaining Ring 30 - Ring (2 Used) 44 - Retaining Ring
3- Pin 17 - Adjusting Shim 31 - Servo Piston 45 - Control Piston
4- Solenoid Valve 18 - Retaining Ring 32 - Lock Pin 46 - Sleeve
5- O-Ring 19 - Screw Bolt (7 Used) 33 - Pin 47 - Retaining Ring
6- Adjusting Screw 20 - Drive Shaft 34 - Valve Plate 48 - Socket Bolt (2 Used)
7- Lock Nut 21 - Center Shaft 35 - Spring 49 - Relief Valve (2 Used)
8- Housing 22 - Spring 36 - Head Cover 50 - Plug (2 Used)
9- Plunger (7 Used) 23 - Rotor 37 - Brake Valve 51 - Socket Bolt (8 Used)
10 - Retainer Plate 24 - Lock Nut 38 - O-Ring (2 Used) 52 - Socket Bolt (4 Used)
11 - Bearing 25 - Adjusting Screw 39 - Spring 53 - O-Ring
12 - Ring 26 - O-Ring 40 - Collar 54 - O-Ring
13 - Bearing 27 - Piston 41 - Bushing 55 - O-Ring (4 Used)
14 - Oil Seal 28 - Cover 42 - Spring 56 - Socket Bolt (4 Used)

W3-2-5
 UNDERCARRIAGE / Travel Motor

47 1 2 3 4 5

46

45

44

43

42

41

40

39

37, 38

36

35

20
WCGB-03-02-004
28

48 37, 38 37, 38
View A

56

28, 53, 54
49 4, 55 49

52
50 50

WCGB-03-02-001
WCGB-03-02-002

W3-2-6
 UNDERCARRIAGE / Travel Motor
Disassembly of Travel Motor

CAUTION: Travel motor weight: 80 kg (180
lb)
1. Set the travel motor onto a wooden block
(100×500 mm, 3.9×19.7 in) with the drive shaft
(20) side facing downward.
NOTE: When the workbench is used.
Workbench: ST 5092
Upper Plate: ST 7333
2. Remove socket bolts (48) (2 used). Remove
brake valve (37) and O-rings (38) (2 used).
: 5 mm
6. Remove the bushing (41) assembly, spring (39),
collar (40) and spring (35) from head cover (36)
in this order.
7. Remove spring collar (43) and spring (42) from
the bushing (41) assembly.
8. Remove O-ring (5), O-rings (55) (4 used),
adjusting screw (1), lock nut (2) and pin (3) from
solenoid valve (4).
9. Remove retaining ring (44) from solenoid valve
(4). Remove the sleeve (46) assembly.

IMPORTANT: Do not disassemble relief valves
(49) (2 used).
3. Remove relief valves (49) (2 used) and plugs
(50) (2 used) from head cover (36).
: 27 mm, 32 mm
4. Before removing, record the dimension of part A.
1 2
10. Remove control piston (45) from sleeve (46).
Remove retaining ring (47) from control piston
(45).
11. Remove socket bolts (52) (4 used). Remove
cover (28) and O-rings (53, 54) from head cover
(36).
: 6 mm

W1GL-03-02-006

5. Remove socket bolts (56) (4 used). Remove

solenoid valve (4) from head cover (36).
When removing solenoid valve (4), prevent
spring (39) from flying out.
: 6 mm

W3-2-7
 UNDERCARRIAGE / Travel Motor

6 7 8 9

14

15

16

36

20
WCGB-03-02-004
26 25 24 23 21

View A

51 WCGB-03-02-001
WCGB-03-02-002
51 8

W3-2-8
 UNDERCARRIAGE / Travel Motor
12. Before removing, record the dimensions of part B 16. Secure rotor (23), center shaft (21) and plungers
and part C. (9) (7 used) by using a screw bar (M8, Pitch 1.25
mm, Length 120 mm). Remove adjusting screw
B (25) from housing (8).
Screw Bar
23
Lock Nut
C Washer

9 21
26 25
9

7 6
8

W1GL-03-02-003
W1GL-03-02-005

13. Loosen lock nuts (7, 24). Remove adjusting 17. Remove retaining ring (16) and shim (15) from
screws (6, 25) from housing (8). housing (8).

14. Install adjusting screw (25) (M12, Pitch 1.75 mm,
Length 100 mm) to adjusting screw (6) mounting
part, so that the angle of center shaft (21) should
be zero.
18. Set the housing (8) assembly in a vise with the
rotor (23) side facing downward. Remove the
drive shaft (20) assembly from housing (8).
19. Remove oil seal (14) from housing (8).

25
W1GL-03-02-004
21
15. Put the matching marks on the contacting surface
of head cover (36) and housing (8). Remove
socket bolts (51) (8 used). Remove head cover
(36) from housing (8).

W3-2-9
 UNDERCARRIAGE / Travel Motor

36

34

WCGB-03-02-004

33 32 31 30 29 27

View A

WCGB-03-02-001
WCGB-03-02-002

W3-2-10
 UNDERCARRIAGE / Travel Motor
20. Set head cover (36) in a vise with the valve plate
(34) side facing upward.

21. Remove socket bolt (29) and piston (27) from

servo piston (31).

22. Remove rings (30) (2 used) from piston (27).

CAUTION: Warm up lock pin (32). Take care

not to burn yourself.

23. Warm up the mounting part of lock pin (32) by

using a torch.
NOTE: Adhesive has been applied onto lock pin
(32). Warm up the adhesive by using slow
fire.

24. Remove pin (33) from servo piston (31).

25. Remove servo piston (31) from head cover (36).

W3-2-11
 UNDERCARRIAGE / Travel Motor
ASSEMBLY OF TRAVEL MOTOR

47 1 2 3 4 5 6 7 8 9 10 11 12 13

46

45

44
14
43

42 15

41

40

39

16
37, 38
17

36
18

35
19

34
20
WCGB-03-02-004

33 32 31 30 29 28 27 26 25 24 23 22 21

A
48 37, 38 37, 38
View A

56

28, 53, 54
49 4, 55 49

52
50 50

51 WCGB-03-02-001
WCGB-03-02-002
51 8

W3-2-12
 UNDERCARRIAGE / Travel Motor

1 - Adjusting Screw 15 - Shim 29 - Socket Bolt 43 - Spring Collar

2 - Lock Nut 16 - Retaining Ring 30 - Ring (2 Used) 44 - Retaining Ring
3 - Pin 17 - Adjusting Shim 31 - Servo Piston 45 - Control Piston
4 - Solenoid Valve 18 - Retaining Ring 32 - Lock Pin 46 - Sleeve
5 - O-Ring 19 - Screw Bolt (7 Used) 33 - Pin 47 - Retaining Ring
6 - Adjusting Screw 20 - Drive Shaft 34 - Valve Plate 48 - Socket Bolt (2 Used)
7 - Lock Nut 21 - Center Shaft 35 - Spring 49 - Relief Valve (2 Used)
8 - Housing 22 - Spring 36 - Head Cover 50 - Plug (2 Used)
9 - Plunger (7 Used) 23 - Rotor 37 - Brake Valve 51 - Socket Bolt (8 Used)
10 - Retainer Plate 24 - Lock Nut 38 - O-Ring (2 Used) 52 - Socket Bolt (4 Used)
11 - Bearing 25 - Adjusting Screw 39 - Spring 53 - O-Ring
12 - Ring 26 - O-Ring 40 - Collar 54 - O-Ring
13 - Bearing 27 - Piston 41 - Bushing 55 - O-Ring (4 Used)
14 - Oil Seal 28 - Cover 42 - Spring 56 - Socket Bolt (4 Used)

W3-2-13
 UNDERCARRIAGE / Travel Motor

47 1 2 3 4 5

46

45

44

43

42

41

40

39

36

35

34

WCGB-03-02-004

33 32 31 30 29 28 27

View A

56

28, 53, 54
4, 55

52

WCGB-03-02-001
WCGB-03-02-002

W3-2-14
 UNDERCARRIAGE / Travel Motor
Assembly of Travel Motor
1. Set head cover (36) in a vise with the valve plate
(34) side facing upward.
2. Apply hydraulic oil onto servo piston (31). Insert
servo piston (31) into head cover (36). Install pin
(33).
3. Apply LOCTITE #241 onto lock pin (32). Insert
lock pin (32) into servo piston (31). Secure pin
(33).
4. Install rings (30) (2 used) to piston (27). Install
piston (27) to servo piston (31) with socket bolt
(29).
5. Install O-rings (53, 45) and cover (28) to head
cover (36). Install cover (28) to head cover (36)
with socket bolts (52) (4 used).
: 6 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
6. Install adjusting screw (1) and lock nut (2) to
solenoid valve (4) with the dimension of part A
recorded before disassembling.
1 2
W1GL-03-02-006
W3-2-15
7. Install retaining rings (47, 44) to control piston
(45) and sleeve (46).
8. Apply hydraulic oil onto solenoid valve (4), control
piston (45) and sleeve (46).
9. Install O-ring (5) to solenoid valve (4).
10. Install control piston (45) to sleeve (46). Insert the
sleeve (46) assembly and pin (3) into solenoid
valve (4).
11. Install spring collar (43) and spring (42) to the
solenoid valve (4) assembly.
12. Install O-rings (55) (4 used) to the mounting
surface of head cover (36) and solenoid valve (4).
13. Install springs (35, 39), collar (40) and bushing
(41) to the large chamber side of head cover
(36).
14. Install the solenoid valve (4) assembly to head
cover (36) with socket bolts (56) (4 used).
 UNDERCARRIAGE / Travel Motor

6 7 8

14

15

16

36

20
WCGB-03-02-004
25 24 23 21

View A

51 WCGB-03-02-001
WCGB-03-02-002
51 8

W3-2-16
 UNDERCARRIAGE / Travel Motor
19. Temporarily install adjusting screw (25) (M12,
CAUTION: After warming up housing (8), Pitch 1.75 mm, Length 100 mm) to the adjusting
start the work. screw (6) mounting part, so that the angle of
center shaft (21) should be zero.
15. Warm up housing (8) to 50 to 80 °C (122 to
176 °F). Install the drive shaft (20) assembly to
housing (8). If the drive shaft (20) assembly
cannot be inserted, insert it by using a bar.
21
16. Face the rotor (23) side in housing (8) downward.
Install oil seal (14), shim (15) and retaining ring
25
(16) to housing (8).

17. Set the travel motor onto a wooden block

(100×500 mm, 3.9×19.7 in) with the drive shaft
(20) side facing downward. W1GL-03-02-008

NOTE: When the workbench is used.

Workbench: ST 5092 20. Align the matching marks. Install head cover (36)
Upper Plate: ST 7333 to housing (8) with socket bolts (51) (8 used).

18. Remove the screw bar, the lock nut and the 21. Remove temporarily installed adjusting screw
washer from rotor (23). (25) from housing (8).

22. Install adjusting screw (25), lock nut (24),

23 Screw Bar adjusting screw (6) and lock nut (7) to housing
Lock Nut (8) so that the dimensions of part B and part C
Washer
should be the same dimensions before
disassembling.
B

W1GL-03-02-003

25 24

8 7 6

W1GL-03-02-005

W3-2-17
 UNDERCARRIAGE / Travel Motor

37, 38

36

WCGB-03-02-004

48 37, 38 37, 38
View A

49 49

50 50

WCGB-03-02-001
WCGB-03-02-002

W3-2-18
 UNDERCARRIAGE / Travel Motor
23. Install relief valves (49) (2 used) and plugs (50)
(2 used) to head cover (36).
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 32 mm
: 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)

24. Install brake valve (37) and O-rings (38) (2 used)

to head cover (36) with socket bolts (48) (2
used).
: 5mm

W3-2-19
 UNDERCARRIAGE / Travel Motor
DISASSEMBLY OF BRAKE VALVE
A
View A
B
Brake Valve
7
Brake Valve
5, 6

WCGB-03-02-001

WCGB-03-02-002

2 3 4 8 9

10

Section C

11

12

13

17 16 15 14

7
Section B

WCGB-03-02-005

1- Cover 6- Orifice 10 - Socket Bolt (4 Used) 14 - O-Ring (2 Used)

2- Socket Bolt (4 Used) 7- Plug 11 - Plug 15 - O-Ring
3- Valve Casing 8- O-Ring (2 Used) 12 - Spring (2 Used) 16 - Shuttle Valve
4- Counterbalance Valve 9- Cover 13 - Check Valve 17 - Check Valve (2 Used)
5- Plug

W3-2-20
 UNDERCARRIAGE / Travel Motor
Disassembly of Brake Valve 7. Remove shuttle valve (16) from valve casing (3)
by using a socket wrench.
1. Remove socket bolts (2) (4 used). Remove cover : 4 mm
(1) and O-ring (8) from valve casing (3).
: 10 mm 8. Remove plug (5) from valve casing (3).

2. Remove socket bolts (10) (4 used). Remove 9. Remove orifice (6) from valve casing (3).
cover (9) and O-ring (8) from valve casing (3). : 3 mm
: 10 mm

IMPORTANT: When removing counterbalance

valve (4), remove counterbalance
valve (4) by turning in order to
prevent it from bounding.
3. Slowly remove counterbalance valve (4) from
valve casing (3) by turning.

CAUTION: When removing plug (11), prevent

spring (12) from flying out.

4. Remove plugs (11) (2 used), O-rings (14) (2

used), springs (12) (2 used) and check valve
(13).
: 36 mm

5. Remove check valve (17) from valve casing (3)

by using a socket wrench.

6. Remove plug (7) and O-ring (15) from valve

casing (3).

W3-2-21
 UNDERCARRIAGE / Travel Motor
ASSEMBLY OF BRAKE VALVE
A
View A
B Brake Valve

Brake Valve
5, 6

WCGB-03-02-001
WCGB-03-02-002

2 3 4 8 9

10

Section C

11

12

13

17 16 15 14

7
Section B

WCGB-03-02-005

1- Cover 6- Orifice 10 - Socket Bolt (4 Used) 14 - O-Ring (2 Used)

2- Socket Bolt (4 Used) 7- Plug 11 - Plug 15 - O-Ring
3- Valve Casing 8- O-Ring (2 Used) 12 - Spring (2 Used) 16 - Shuttle Valve
4- Counterbalance Valve 9- Cover 13 - Check Valve 17 - Check Valve (2 Used)
5- Plug

W3-2-22
 UNDERCARRIAGE / Travel Motor
Assembly of Brake Valve

1. Install orifice (6) and plug (5) to valve casing (3).

: 3 mm

2. Install shuttle valve (16) and plug (7) to valve

casing (3).

3. Install check valves (17) (2 used) to valve casing

(3).

4. Install check valve (13) to check valve (17).

5. Install springs (12) (2 used) to plugs (11) (2 used).

Install the plug (11) assemblies (2 used) and
O-rings (14) (2 used) to valve casing (3).
: 36 mm
: 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)

IMPORTANT: Slowly insert counterbalance valve

(4) into valve casing (3) by turning.
Check if counterbalance valve (4)
moves smoothly.
6. Insert counterbalance valve (4) into valve casing
(3).

7. Install cover (1) and O-ring (8) to valve casing (3)

with socket bolts (2) (4 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

8. Install cover (9) and O-ring (8) to valve casing (3)

with socket bolts (10) (4 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

W3-2-23
 UNDERCARRIAGE / Travel Motor
(Blank)

W3-2-24
 UNDERCARRIAGE / Center Joint
REMOVAL AND INSTALLATION OF CEN-
TER JOINT
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal
NOTE: If disconnecting the hoses (5 used) for the
front attachment, the center joint can be 1
removed easily. The number of hoses dif-
fers depending on the front attachment
specifications. 2, 3

1. Disconnect connectors (4, 6).

4
2. Remove bolt (2) and washer (3) from clips (5) (2
used). Remove clips (5) (2 used) from center joint
(1). 5
: 10 mm
WCEB-03-03-002
6

7 8 9

3. Disconnect connector (9).

4. Remove bolt (11) and washer (12) from clip (10).

Remove clip (10) from stopper (13). 10
: 17 mm

5. Remove sems bolts (8) (3 used) from slip ring (7).

11, 12
Remove the slip ring (7) assembly from stopper
(13). (Length: approx. 670 mm (26.4 in))
: 10 mm
13 WCEB-03-03-001

W3-3-1
 UNDERCARRIAGE / Center Joint
6. Remove bolts (15) (5 used) and washers (16) (5
14 15, 16
used) from stopper (13). Remove stopper (13)
from center joint (1).
: 24 mm

7. Disconnect hoses (14) (13 used) from center joint

(1). Cap the open ends. Attach an identification 14
tag onto the disconnected hoses for assembling.
: 19 mm, 22 mm, 27 mm, 36 mm
13

1 14 WCEB-03-03-001

17 1
8. Disconnect hoses (17) (22 used) from center joint
(1). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm, 22 mm, 27 mm, 41 mm

9. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to

the hole on bolt (15). Attach a nylon sling onto
17
eyebolts. Hoist and hold center joint (1).

CAUTION: The center joint (1) assembly

weight: 93 kg (210 lb)
WCEB-03-03-002

IMPORTANT: The propeller shaft and the travel

transmission are located under cen-
ter joint (1). When hoisting and re-
moving center joint (1), do not hit
them.
10. Remove bolts (19) (4 used) and washers (20) (4
used) from center joint (1). Hoist and remove the
center joint (1) assembly from track frame (18).
: 22 mm

18 19, 20 1 WCEB-03-03-002

W3-3-2
 UNDERCARRIAGE / Center Joint
Installation

CAUTION: The center joint (1) assembly

weight: 93 kg (210 lb)

IMPORTANT: The propeller shaft and the travel

transmission are located under the
center joint (1). Hoist center joint (1)
in order not to hit them.
1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to 17 1
center joint (1). Attach a nylon sling onto eyebolt.
Hoist and align center joint (1) with the mounting
hole on track frame (18).

2. Apply LOCTITE #262 onto bolts (19) (4 used). In-

stall center joint (1) to track frame (18) with bolts
(19) (4 used) and washers (20) (4 used). 17
: 22 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

3. Connect hoses (17) (22 used) to center joint (1).

: 19 mm
18 19, 20 1 WCEB-03-03-002
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

W3-3-3
 UNDERCARRIAGE / Center Joint
4. Connect hoses (14) (13 used) to center joint (1).
14 15, 16
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) 14
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
13
5. Apply LOCTITE #262 onto bolts (15) (5 used). In-
stall stopper (13) to center joint (1) with bolts (15)
(5 used) and washers (16) (5 used).
: 24 mm 1 WCEB-03-03-001
: 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)
7 8 9
6. Install the slip ring (7) assembly to center joint (1).
Install slip ring (7) to stopper (13) with sems bolts
(8) (3 used).
: 10 mm 10
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft) 11, 12

7. Install clip (10) to stopper (13) with bolt (11) and

13
washer (12).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
1 WCEB-03-03-001
8. Connect connector (9).

W3-3-4
 UNDERCARRIAGE / Center Joint
9. Install clips (5) (2 used) to center joint (1) with bolt
(2) and washer (3).
: 10 mm
2, 3
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft)
4
10. Connect connectors (4, 6).

WCEB-03-03-002
1 6

W3-3-5
 UNDERCARRIAGE / Center Joint
DISASSEMBLY OF CENTER JOINT

2
3

12 3
11

6
10 T1F3-03-10-001

9
8 7

1- Spindle 5- Oil Seal (15 Used) 8- Bolt (4 Used) 11 - Plate

2- O-Ring 6- Bolt (6 Used) 9- O-Ring 12 - O-Ring
3- Bushing (2 Used) 7- O-Ring 10 - Cover
4- Body

W3-3-6
 UNDERCARRIAGE / Center Joint
Disassembly of Center Joint
CAUTION: Body (4) weight: 39 kg (86 lb)

CAUTION: Center joint weight: 90 kg (198 lb)
1. Remove bolts (6) (2 used) on cover (10) diago-
nally. Install eyebolts (M10, Pitch 1.5 mm) (2
used) to the hole for bolt (6). Attach a nylon sling
onto eyebolt. Hoist and secure the center joint on
workbench (ST 5103).
: 17 mm
IMPORTANT: For easy removal, use the pins (2
used).
Do not damage the seal groove by
the pins.
5. Remove oil seals (5) (15 used) from body (4).

IMPORTANT: Put the matching marks on body (4)

and spindle (1).
2. Remove bolts (6) (4 used) from cover (10). Re-
move cover (10) and O-rings (7, 9) from body (4).
: 17 mm
3
3. Remove bolts (8) (4 used) from plate (11). Re-
move plate (11) from spindle (1). 4, 5
: 17 mm

IMPORTANT: Do not damage the seal sliding sur-

face of spindle (1). W105-03-03-015
4. Set the puller onto body (4). Remove body (4)
from spindle (1).
NOTE: There is a hole for the harness at the cen- 6. Remove bushings (3) (2 used) and O-rings (2, 12)
ter of spindle (1). Place a plate in order to from body (4).
cover the hole on spindle (1).
Puller

W202-03-03-011

W3-3-7
 UNDERCARRIAGE / Center Joint
ASSEMBLY OF CENTER JOINT

2
3

12 3
11

6
10 T1F3-03-10-001

9
8 7

1- Spindle 5- Oil Seal (15 Used) 8- Bolt (4 Used) 11 - Plate

2- O-Ring 6- Bolt (6 Used) 9- O-Ring 12 - O-Ring
3- Bushing (2 Used) 7- O-Ring 10 - Cover
4- Body

W3-3-8
 UNDERCARRIAGE / Center Joint
Assembly of Center Joint 5. Install plate (11) to spindle (1) with bolts (8) (4
used).
: 17 mm
CAUTION: Body (4) weight: 39 kg (86 lb) : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

1. Install O-rings (2, 12) to body (4). 6. Install O-rings (7,9) to body (4) and spindle (1)
respectively.
NOTE: If removing bushing (3) from body (4), in-
7. Install cover (10) to body (4) with bolts (6) (6
stall bushing (3) first. (Refer to the following
used).
page.)
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2. Install oil seals (5) (15 used) to body (4).

IMPORTANT: After installing the seals, apply

grease onto the inner surface of
body (4), the inner surface of the
circuit and the seals.

CAUTION: Spindle (1) weight: 51 kg (112 lb)

3. Place spindle (1) onto a workbench. Install body

(4) to spindle (1) and align the matching marks
made when disassembling.

IMPORTANT: There is almost no clearance be-

tween body (4) and spindle (1). In-
sert body (4) along the axis straight
and slowly.

Install body (4) so that part A (the plate (11) mounting

part) is flat.

A 1
4

W800-03-03-002

4. Lightly tap body (4) by using a plastic hammer.

Insert body (4) until body (4) comes in contact
with the flange of spindle (1).

W3-3-9
 UNDERCARRIAGE / Center Joint
When replacing body (4) with the new one, the fol-
lowing procedures are required.
1
Install bushings (3) (2 used) to body (4).
1. Clean body (4) and bushing (3).
4
2. Install bushing (3) to body (4) by using a press.
Pushing Force: 0.5 to 1.5 t (1100 to 3300 lb)
Pushing Tool (1): ST 7331
3

W105-03-03-029

W3-3-10
 UNDERCARRIAGE / Center Joint
MAINTENANCE STANDARD

Item Allowable Limit (basis of judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Seizure, abnormal wear Replace
3. Uneven wear within 180° Replace
Wear Area within
Half Range
Bushing

T157-01-01-040

Sliding surface with Heavily damaged one by seizure or foreign Replace

seals matter
1) Excessively worn one by seizure or for- Replace
Sliding surface between eign matter, or one having the score or
body and spindle other 0.1 mm (0.004 in) or more
than sliding surfaces 2) One having the score of less than 0.1 Replace the sur-
with seals mm (0.004 in) face smooth by
using an oil stone
Body Spindle
1) One that has worn 0.5 mm (0.02 in) or Replace
more, or excessively worn
2) One that has worn 0.5 mm (0.02 in) or Repair the surface
Sliding surface with less smooth
plate 3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less smooth
than the allowable wear limit 0.5 mm
(0.02 in) and is repairable
1) One that has worn 0.5 mm (0.02 in) or Replace
more
2) One that has worn less than 0.5 mm Repair the surface
Sliding surface with (0.02 in) smooth
Cover
plate 3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less smooth
than the allowable wear limit 0.5 mm
(0.02 in) and is repairable

W3-3-11
 UNDERCARRIAGE / Center Joint
(Blank)

W3-3-12
 UNDERCARRIAGE / Transmission
REMOVAL AND INSTALLATION OF
TRANSMISSION

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

When removing and installing the transmission, the

propeller shaft and the pipings of travel motor should
be removed first.
Refer to REMOVAL AND INSTALLATION OF TRAVEL
MOTOR on W3-2-1.

IMPORTANT: When removing and installing the

transmission, bleed air from the oil
pressure port and the brake before
doing any work.
Refer to TROUBLESHOOTING / T5-7
Troubleshooting B in Technical Man-
ual.

Removal

IMPORTANT: Remove the transmission with the

1
travel motor together in order to
keep the balance of weight.
1. Raise the machine until tire (1) at the rear axle
side is raised. Place a stand under frame (2).

2
2. Remove plugs (4) (2 used). Drain oil from the 1 W1GL-03-05-003

transmission.
: 14 mm Transmission 3
IMPORTANT: Attach an identification tag onto the
disconnected hoses for assembling.
3. Disconnect hoses (3) (9 used) and the connectors Travel
Motor
(2 used) from the transmission and the travel
motor. Cap the open ends of the disconnected
hoses.
: 17 mm, 22 mm, 27 mm
: 12 mm 4 WCEB-03-05-022

3
Transmission

WCEB-03-05-023
Travel
Motor

W3-4-1
 UNDERCARRIAGE / Transmission

CAUTION: Propeller shaft (6) weight: 30 kg Transmission

(70 lb)
Travel
4. Remove nuts (7) (8 used) from propeller shaft (6) Motor
in the front side. Insert a pry bar between the
transmission and propeller shaft (6). Pry them Front Side
toward the front side. Lower propeller shaft (6)
onto the ground.
: 14 mm
WCEB-03-05-022
7 6

CAUTION: Propeller shaft (10) weight: 30 kg

(70 lb) 8 9 2

5. Remove nuts (11) (8 used) from propeller shaft

(10) in the rear side. Insert a pry bar between the
transmission and propeller shaft (10). Pry them 10
toward the rear side. Lower propeller shaft (10)
onto the ground. 11
: 14 mm
Rear Side

CAUTION: Transmission assembly weight:

12
260 kg (573 lb)

6. Loosen bolts (12) (3 used) of plate (8). While Transmission

holding the lower side of the transmission by using W1F3-03-04-001

a forklift, remove bolts (12) (3 used).

: 30 mm

CAUTION: Plate (8) weight: 35 kg (80 lb)

7. Remove bolts (9) (3 used). Remove plate (8) from

the transmission.
: 30 mm
Transmission
CAUTION: Travel motor weight: 80 kg (180 lb)

8. Remove socket bolts (5) (4 used). Hoist and re- Travel

Motor
move the travel motor from the transmission.
: 14 mm Front Side

WCEB-03-05-022
5

W3-4-2
 UNDERCARRIAGE / Transmission
Installation
Transmission
CAUTION: Travel motor weight: 80 kg (180 lb)

1. Hoist the travel motor. Install the travel motor to Travel

Motor
the transmission with socket bolts (5) (4 used).
: 14 mm
: 270 N⋅m (27 kgf⋅m, 199 lbf⋅ft)

WCEB-03-05-022
5
CAUTION: Plate (8) weight: 35 kg (80 lb)

2. Install plate (8) to the transmission with bolts (9) (3 8 9 2

used).
: 30 mm
: 540 N⋅m (55 kgf⋅m, 398 lbf⋅ft)
10
CAUTION: Transmission assembly weight: 11
260 kg (573 lb)

3. Install the transmission assembly to frame (2) with

bolts (12) (3 used).
12
: 30 mm
: 540 N⋅m (55 kgf⋅m, 398 lbf⋅ft)
Transmission
W1F3-03-04-001

CAUTION: Propeller shaft (10) weight: 30 kg

(70 lb)

4. Install propeller shaft (10) to the transmission with

nuts (11) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

W3-4-3
 UNDERCARRIAGE / Transmission
3
5. Connect hoses (3) (9 used) and the connectors (2
used) to the travel motor and the transmission.
: 19 mm 3
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) Transmission
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m 58 lbf⋅ft)
: 12 mm WCEB-03-05-023
Travel
: 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft) Motor

CAUTION: Propeller shaft (6) weight: 30 kg Transmission 3

(70 lb)

6. Install propeller shaft (6) to the transmission with Travel

nuts (7) (8 used). Motor
7
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

7. Add oil to the transmission. Install plugs (4) (2 4 6 WCEB-03-05-022

used).
: 14 mm
: 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
NOTE: Gear Oil 3.0 L (0.8 US gal)

W3-4-4
 UNDERCARRIAGE / Transmission
(Blank)

W3-4-5
 UNDERCARRIAGE / Transmission
DISASSEMBLY OF TRANSMISSION

Part A

WCGB-03-04-001

Part A

3 4 5 6 7 8 9 10 9 11 12 13 14, 15 16, 17, 18, 19 20 21 22 23

2 24

1 25

26
54
27, 28
52, 53

51

50
27, 28

49
29
48
30, 31
47

WCGB-03-04-002
46 45 44 43 42 41 40 39 38 37 36 35 34 33 32

W3-4-6
 UNDERCARRIAGE / Transmission

Part B WCEB-03-04-001

Part B

57 58 59 60 61 62 63 64 65

66

67

68

55, 56 69

55, 56
75 70

71

72

WCEB-03-04-002

74 73

W3-4-7
 UNDERCARRIAGE / Transmission

1- Cover 21 - Bearing 41 - Friction Plate (10 Used) 61 - Bearing

2- Bolt (5 Used) 22 - Housing 42 - O-Ring 62 - Final Gear
3- O-Ring (5 Used) 23 - Bearing 43 - Ring 63 - Cover
4- Oil Seal 24 - O-Ring (2 Used) 44 - Ring 64 - Bolt (5 Used)
5- Pin (2 Used) 25 - Bolt (4 Used) 45 - Brake Piston 65 - Bearing
6- Oil Seal 26 - Shift Interlock Controller 46 - Disc Spring 66 - Cover
7- Oil Seal 27 - Socket Bolt (5 Used) 47 - Clutch Piston 67 - Shaft Seal
8- Seal Ring 28 - Washer (5 Used) 48 - Oil Seal 68 - Plate
9- O-Ring (2 Used) 29 - Plate 49 - Shaft 69 - Plate
10 - Gasket 30 - Bearing 50 - Spring 70 - O-Ring
11 - Plate (7 Used) 31 - Washer (2 Used) 51 - Holder 71 - Flange
12 - Friction Plate (6 Used) 32 - Planetary Carrier 52 - Bearing 72 - Retaining Ring
13 - Disc Plate 33 - Slot Pin (6 Used) 53 - Plate (2 Used) 73 - O-Ring (2 Used)
14 - Retaining Ring 34 - Ring Gear 54 - Disc Spring 74 - Screen Sheet
15 - Shim 35 - Retaining Ring 55 - Bolt (4 Used) 75 - O-Ring
16 - Planetary Gear (3 Used) 36 - Retaining Ring 56 - Washer (4 Used)
17 - Retaining Ring (3 Used) 37 - Bearing 57 - Plate
18 - Washer (3 Used) 38 - Collar 58 - Flange
19 - Bearing 39 - Disc Plate 59 - Plate
20 - Retaining Ring 40 - Plate (9 Used) 60 - Shaft Seal

W3-4-8
 UNDERCARRIAGE / Transmission
(Blank)

W3-4-9
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

22 24

26

27, 28

27, 28

WCGB-03-04-002

W3-4-10
 UNDERCARRIAGE / Transmission
Disassembly of Transmission

3. Remove plugs (81) (2 used) and seal rings (82) (2

CAUTION: Transmission
used) from housing (22).
weight: 135 kg (300 lb) : 8 mm
1. Attach a nylon sling onto the transmission. Hoist 81, 82
the transmission. Lower the transmission onto a
workbench.

2. Remove bolts (76, 78) (2 used for each) and seal

rings (77, 79) (2 used for each) from the trans-
mission. Disconnect pipings (80) (2 used) from the
transmission.
: 22 mm, 24 mm
22
76, 77 78, 79 80
WCGB-03-04-006

4. Remove socket bolts (27) (5 used) and washers

(28) (5 used). Remove shift interlock controller
(26) and O-rings (24) (2 used) from the transmis-
sion.
: 6 mm

5. Remove socket bolt (84). Remove travel N sensor

(83) and O-rings (85) (2 used) from housing (22).
: 6 mm

84, 85

WCEB-03-04-006

83

22

WCGB-03-04-006

W3-4-11
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

3 4 5 7 22

54

47

46 45

WCGB-03-04-002

W3-4-12
 UNDERCARRIAGE / Transmission
6. Remove bleeder (86) and plug (93) from housing 10. Remove spring (91), O-ring (92) and piston (93)
(22). from housing (22).
: 27 mm 22
: 8 mm

86, 87 22 91, 92, 93

WCGB-03-04-014

11. Remove disc springs (46, 54) from housing (22).

Remove clutch piston (47).
WCEB-03-04-006
12. Remove pins (5) (2 used) from housing (22).
7. Remove plugs (88, 89) from housing (22).
: 8 mm
13. Apply air to the hole of bleeder valve (90) on
88 89 22 housing (22). Remove brake piston (45). Remove
fitting (94) from housing (22).
: 17 mm

WCEB-03-04-005

8. Remove bleeder valve (90) from housing (22).

: 17 mm
22

94 90 WCEB-03-04-006

14. Remove oil seals (4, 7) from housing (22).

90 WCEB-03-04-006

9. Remove bolts (2) (5 used). Remove cover (1) and

O-ring (3) from housing (22).
: 19 mm

W3-4-13
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

6 8 9 10 11 12 13 14, 15 16, 17, 18, 19 20 21 22

23

25

52, 53

51

50

49
29
48
30, 31

45 44 43 42 41 40 39 38 37 36 35 34 33 32

WCGB-03-04-002

W3-4-14
 UNDERCARRIAGE / Transmission
15. Remove oil seals (6, 48) from brake piston (45).
IMPORTANT: Do not remove bearing (52) unless
necessary.
16. Remove bearing (52) and plales (53) (2 used)
from shaft (49).
17. Remove holder (51) and spring (50) from shaft
(49).
18. Remove the ring (44) assembly from housing (22).
19. Remove ring (43), seal ring (8), O-rings (9) (2
used), O-ring (42) and gasket (10) from the ring
(44) assembly.
20. Remove friction plates (12) (6 used), plates (11) (7
used) and disc plate (13) from housing (22).
21. Remove retaining ring (14) and shim (15) from
housing (22).
22. Remove friction plates (41) (10 used) and plates
(40) (9 used) from housing (22).
23. Remove disc plate (39) from housing (22).
24. Remove the shaft (49) assembly from housing
(22).
25. Remove shaft (49) from ring gear (34).
W3-4-15
26. Remove retaining ring (20) from shaft (49). Re-
move collar (38).
IMPORTANT: Do not remove bearing (37) unless
necessary.
27. Remove retaining rings (35, 36) from ring gear
(34). Remove bearing (37).
28. Remove bearing (30) and washers (31) (2 used)
from planetary carrier (32).
29. Remove bolts (25) (4 used). Remove plate (29)
from housing (22).
: 17 mm
30. Remove planetary carrier (32) from housing (22).
IMPORTANT: Do not remove bearings (21, 23)
unless necessary.
31. Remove the inner races of bearings (21, 23) from
planetary carrier (32).
IMPORTANT: Do not remove bearings (21, 23)
unless necessary.
32. Remove the outer races of bearings (21, 23) from
housing (22).
IMPORTANT: Do not remove bearing (19) unless
necessary.
33. Remove retaining rings (17) (3 used), washers
(18) (3 used) and bearings (19) (3 used) from
planetary gears (16) (3 used).
34. Remove slot pins (33) (6 used) from planetary
gear (16).
 UNDERCARRIAGE / Transmission

Part B WCEB-03-04-001

Part B

57 58 59 60 61 62 63 64 65

66

67

68

55, 56 69

55, 56
75 70

71

72

WCEB-03-04-002

22
74 73

W3-4-16
 UNDERCARRIAGE / Transmission
35. Remove bleeder valves (95) (2 used) from hous- 39. Remove bolts (64) (5 used). Install eyebolt (M10,
ing (22). Pitch 4.0 mm) to the bolt (55) hole. Remove with
: 17 mm cover (66) and final gear (62) from housing (22).
95 : 19 mm
22
40. Remove final gear (62) and cover (63) from cover
(66).

IMPORTANT: Do not remove bearing (65) unless

necessary.
41. Remove retaining ring (72) from cover (66). Re-
move bearing (65).

42. Remove O-rings (73) (2 used) from cover (66).

43. Remove screen sheet (74) from housing (22).

WCEB-03-04-005 IMPORTANT: Do not remove bearing (61) unless

necessary.
36. Remove bolts (55) (4 used) and washers (56) (4 44. Remove bearing (61) from housing (22).
used) from both sides of housing (22). Remove
plates (57, 69) and O-rings (70, 75) from housing
(22).
: 17 mm

37. Remove flanges (58, 71), plates (59, 68) and shaft
seals (60, 67) from housing (22).

38. Hoist the transmission with the rear axle mounting

side facing upward.

W3-4-17
 UNDERCARRIAGE / Transmission
ASSEMBLY OF TRANSMISSION

Part A

WCGB-03-04-001

Part A

4 5 6 7 8 9 10 9 11 12 13 14, 15 16, 17, 18, 19 20 21 22

3 23
24
2

25
1
26

54
27, 28
52, 53

51

50
27, 28

49
29
48
30, 31
47

46 45 44 43 42 41 40 39 38 37 36 35 34 33 32

WCGB-03-04-002

W3-4-18
 UNDERCARRIAGE / Transmission

Part B WCEB-03-04-001

Part B
57 58 59 60 61 62 63 64 65

66

67

68

55, 56 69

55, 56
75 70

71

72

WCEB-03-04-002

74 73

W3-4-19
 UNDERCARRIAGE / Transmission

1- Cover 21 - Bearing 41 - Friction Plate (10 Used) 61 - Bearing

2- Bolt (5 Used) 22 - Housing 42 - O-Ring 62 - Final Gear
3- O-Ring (5 Used) 23 - Bearing 43 - Ring 63 - Cover
4- Oil Seal 24 - O-Ring (2 Used) 44 - Ring 64 - Bolt (5 Used)
5- Pin (2 Used) 25 - Bolt (4 Used) 45 - Brake Piston 65 - Bearing
6- Oil Seal 26 - Shift Interlock Controller 46 - Disc Spring 66 - Cover
7- Oil Seal 27 - Socket Bolt (5 Used) 47 - Clutch Piston 67 - Shaft Seal
8- Seal Ring 28 - Washer (5 Used) 48 - Oil Seal 68 - Plate
9- O-Ring (2 Used) 29 - Plate 49 - Shaft 69 - Plate
10 - Gasket 30 - Bearing 50 - Spring 70 - O-Ring
11 - Plate (7 Used) 31 - Washer (2 Used) 51 - Holder 71 - Flange
12 - Friction Plate (6 Used) 32 - Planetary Carrier 52 - Bearing 72 - Retaining Ring
13 - Disc Plate 33 - Slot Pin (6 Used) 53 - Plate (2 Used) 73 - O-Ring (2 Used)
14 - Retaining Ring 34 - Ring Gear 54 - Disc Spring 74 - Screen Sheet
15 - Shim 35 - Retaining Ring 55 - Bolt (4 Used) 75 - O-Ring
16 - Planetary Gear (3 Used) 36 - Retaining Ring 56 - Washer (4 Used)
17 - Retaining Ring (3 Used) 37 - Bearing 57 - Plate
18 - Washer (3 Used) 38 - Collar 58 - Flange
19 - Bearing 39 - Disc Plate 59 - Plate
20 - Retaining Ring 40 - Plate (9 Used) 60 - Shaft Seal

W3-4-20
 UNDERCARRIAGE / Transmission
(Blank)

W3-4-21
 UNDERCARRIAGE / Transmission

Part B WCEB-03-04-001

Part B
57 58 59 60 61 62 63 64 65

66

67

68

55, 56 69

55, 56
75 70

71

72

WCEB-03-04-002

74 73
22

W3-4-22
 UNDERCARRIAGE / Transmission
Assembly of Transmission

1. Hoist and set housing (22) with the front axle IMPORTANT: Install cover (63) so that the convex
mounting side facing upward. part of the cover (63) back side can
enter into the groove of cover (66).
2. Install bearing (61) to housing (22). 6. Install cover (63) to cover (66).

3. Install screen sheet (74) to housing (22). At this 63

time, pass the slot pin through the hole on screen
sheet (74). 66

WCEB-03-04-003

22
7. Install final gear (62) to cover (66).

8. Hoist and set the housing (22) assembly with the

rear axle mounting side facing upward.
WCGB-03-04-009
Slot Pin
9. Warm bearing (61) by using a drier. Install the fi-
4. Install bearing (65) and retaining ring (72) to cover nal gear (62) assembly to housing (22).
(66).
10. Install cover (66) to housing (22) with bolts (64) (5
5. Apply hydraulic oil onto O-ring (73). Install O-rings used).
(73) (2 used) to cover (66). : 19 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)

W3-4-23
 UNDERCARRIAGE / Transmission

Part B WCEB-03-04-001

Part B
57 58 59 60

67

68

55, 56 69

75 70

71

WCEB-03-04-002

22

W3-4-24
 UNDERCARRIAGE / Transmission
IMPORTANT: Apply grease onto the seal and the
dust lip of shaft seal (67).
11. Apply alcohol to the outer surface of shaft seal
(67). Install shaft seal (67) to cover (66).
NOTE: Dimension A: 27.5+0.3 mm (1.1+0.01 in)
Dimension B: 17.6-0.5 mm (0.7-0.02 in)

71 68 67 66
A B

WCEB-03-04-004

IMPORTANT: Apply grease onto the seal and the

dust lip of shaft seal (60).
12. Apply alcohol to the outer surface of shaft seal
(60). Install shaft seal (60) to housing (22).

13. Install plates (59, 68) to flanges (58, 71).

14. Install flanges (58, 71) and O-rings (70, 75) to

housing (22).

15. Install plates (57, 69) to flanges (58, 71) with bolts
(55) (2 used) and washers (56) (2 used).
: 17 mm
: 46 N⋅m (4.7 kgf⋅m, 34 blf⋅ft)

W3-4-25
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

13 14, 15 16, 17, 18, 19 20 21 22

23

25

49
29

30, 31

39 38 37 36 35 34 33 32

WCGB-03-04-002

W3-4-26
 UNDERCARRIAGE / Transmission
16. Install the outer race of bearing (23) to housing
(22).
17. Hoist and set housing (22) with the rear axle
mounting side facing downward.
18. Install the outer race of bearing (21) to housing
(22).
19. Apply grease onto slot pin (33). Install slot pins
(33) (6 used) to planetary carrier (32).
NOTE: Dimension C: 28-1.0 mm (1.1-0.03 in)
33
32
C
WCGB-03-04-017
20. Install planetary gears (16) (3 used), bearings
(19) (3 used) and washers (18) (3 used) to
planetary carrier (32) with retaining rings (17) (3
used).
21. Install the inner race of bearing (21) to planetary
carrier (32).
22. Install planetary carrier (32) to housing (22).
23. Tighten planetary carrier (32) to housing (22) by
using special tool (ZF number: 5870 654 049).
W3-4-27
24. Hoist and set housing (22) with the rear axle
mounting side facing upward.
25. Install the inner race of bearing (23) to housing
(22).
26. Install plate (29) to housing (22) with bolts (25) (4
used). At this time, rotate planetary carrier (32)
clockwise and counterclockwise several times.
: 17 mm
: 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft)
27. Install collar (38) to shaft (49) and secure them
with retaining ring (20).
28. Secure bearing (37) to ring gear (34) with retain-
ing rings (36) (2 used).
29. Install shaft (49) to ring gear (34) and secure them
with retaining ring (35).
30. Hoist and set housing (22) with the rear axle
mounting side facing downward.
31. Install bearing (30) and washers (31) (3 used) to
planetary carrier (32).
32. Install the shaft (49) assembly to housing (22).
33. Secure the shaft (49) assembly to housing (22)
with retaining ring (14) and shim (15).
34. Install disc plates (13, 39) to housing (22).
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

11 12 22

54

52, 53

51

49

47

46 45
41 40

WCGB-03-04-002

W3-4-28
 UNDERCARRIAGE / Transmission
35. Install friction plates (12) (6 used) and plates (11) 42. Measure dimension F between housing (22) and
(7 used) to housing (22). clutch piston (47).
NOTE: Dimension F: 22.5 mm (0.9 in)
36. Remove friction plates (41) (10 used) and plates
(40) (9 used) from housing (22).

37. Apply hydraulic oil onto plate (53). Install holder

(51), bearing (52) and plates (53) (2 used) to shaft
(49). F

38. Install brake piston (45) without the seals to

housing (22). 47

22
39. Install clutch piston (47) without the seals to
housing (22). WCGB-03-04-018

43. Measure dimension G between housing (22) and

40. Install disc springs (46, 54) to housing (22).
brake piston (45).
41. Install special tool (ZF number: 5870 200 131) to NOTE: Dimension G: 11.9 mm (0.5 in)
housing (22) with the bolts (2 used). Measure
dimensions D and E of disc springs (46, 54).
: 19 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)
NOTE: Dimension D: 2.4+0.3 mm (0.09+0.01 in) G
Dimension E: 1.8+0.3 mm (0.07+0.01 in)
45
54 46
22

WCGB-03-04-018

E 44. Remove the bolts (2 used). Remove special tool

D (ZF number: 5870 200 131) and disc springs (46,
54) from housing (22).
: 19 mm
22
45. Remove brake piston (45), clutch piston (47),
WCGB-03-04-018
holder (51), bearing (52) and plates (53) (2 used)
from housing (22).

W3-4-29
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

3 4 5 6 7 8 9 10 9 22

54

52, 53

51

50

49

48
47

46 45 44 43 42

WCGB-03-04-002

W3-4-30
 UNDERCARRIAGE / Transmission
46. Apply hydraulic oil onto the seal surface of ring
(43) and O-ring (9). Install O-ring (9) to ring (43).
47. Install ring (43) to housing (22) by using a plastic
hammer.
48. Apply hydraulic oil onto the seal surface of ring
(44) and O-rings (9, 42). Install O-rings (9, 42), oil
seal (8) and gasket (10) to ring (44).
56. Install clutch piston (47) to housing (22). Push
clutch piston (47) toward the shaft. Install plugs
(81) (2 used) and seal rings (82) (2 used) to
housing (22).
: 8 mm
: 25 N⋅m (2.5 kgf⋅ft, 18 lbf⋅ft)
81,82

49. Install ring (44) to housing (22) by using a plastic

hammer.

50. Install spring (50) and holder (51) to shaft (49).

51. Apply hydraulic oil onto bearing (52). Install

bearing (52) and plates (53) (2 used) to shaft (49). 22

52. Apply hydraulic oil onto the seal surface of hous- WCGB-03-04-006

ing (22). Install oil seals (4, 7) to housing (22).

57. Install disc springs (46, 54) to housing (22).
53. Apply hydraulic oil onto the seal surface of brake
piston (45). Install oil seals (6, 48) to brake piston 58. Install piston (93), spring (91) and O-ring (92) to
(45). housing (22).
22
54. Install brake piston (45) to housing (22) by using a
plastic hammer.
91, 92, 93
55. Install pins (5) (2 used) to brake piston (45).

WCGB-03-04-014

59. Apply hydraulic oil onto O-ring (3). Install O-ring

(3) to cover (1).

60. Install cover (1) to housing (22) with bolts (2) (5

used).
: 19 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)

W3-4-31
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

2 22

WCGB-03-04-002

W3-4-32
 UNDERCARRIAGE / Transmission
61. Install plug (87) and bleeder (86) to housing (22). 63. Install bleeder valve (90), fitting (94) and plugs
Bleeder (86) (88, 89) to housing (22).
: 27 mm Bleeder Valve (90)
: 22 N⋅m (2.2 kgf⋅ft, 16 lbf⋅ft) : 17 mm
Plug (87) : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)
: 8 mm Fitting (94)
: 24 N⋅m (2.4 kgf⋅m, 59 lbf⋅ft) : 17 mm
: 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)
86, 87 22 Plugs (88, 89)
: 8 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

22

WCEB-03-04-006

62. Install bleeder valves (95) (2 used), to housing

(22). 94 90
Bleeder Valve (95) WCEB-03-04-006

: 17 mm
: 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft) 88 89 22
95 22

WCEB-03-04-005

WCEB-03-04-005

W3-4-33
 UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A
22

26

27, 28

27, 28

WCGB-03-04-002

W3-4-34
 UNDERCARRIAGE / Transmission
64. Install travel N sensor (83), socket bolt (84) and
O-ring (85) to housing (22).
: 6 mm
: 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft)
67. Add gear oil to the transmission. Install plug (76)
and O-ring (77) to the transmission.
: 14 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

84, 85

83

22

WCGB-03-04-006

65. Install shift interlock controller (26) to housing (22)

with socket bolts (27) (5 used) and washers (28)
(5 used).
: 6 mm
: 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft)

66. Connect pipings (80) (2 used) to the transmission

with bolts (76, 78) (2 used for each) and seal rings
(77, 79) (2 used for each).
: 22 mm
: 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 24 mm
: 45 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft)
76, 77 78, 79 80

WCEB-03-04-006

W3-4-35
 UNDERCARRIAGE / Transmission
(Blank)

W3-4-36
 UNDERCARRIAGE / Axle
REMOVAL AND INSTALLATION OF AXLE

Removal of Front Axle

3 2 3 3 2 3 4
1. Loosen nuts (1) (20 used) for tires (3) (4 used)
and tire rings (2) (2 used).
: 30 mm

2. Swing the machine by 90º. Raise the front axle 1

side of frame (4) until tire (3) is raised. Place a
stand under frame (4).
W1GL-03-05-003

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb) 5 Steering Cylinder Front Axle

3. Remove nuts (1) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used) from frame (4).
: 30 mm

4. Disconnect brake hoses (5) (2 used) from the

right and left sides of the front axle.
: 22 mm

WCEB-03-05-021

W3-5-1
 UNDERCARRIAGE / Axle
5. Disconnect grease hose (6) from pin (7).
: 17 mm
6 7
6. Disconnect steering hoses (8) (2 used) from the
steering cylinder.
: 22 mm

CAUTION: Propeller shaft (11) weight: 30 kg

(70 lb)
WCEB-03-05-026

7. Place the wooden block under propeller shaft (11).

Remove bolts (10) (8 used) and nuts (9) (8 used). 4 7 8
Remove propeller shaft (11) from the front axle.
: 14 mm

Steering Cylinder WCGB-03-05-025

Front Axle
8. Remove nuts (12) (2 used). Remove bolt (13)
from pin (7). 11
: 24 mm
9, 10
9. Hold the lower side of the front axle by using a
forklift.

CAUTION: Front axle weight: 630 kg (1390

lb)
CAUTION: Pin (7) weight: 14 kg (31 lb) (outer WCGB-03-05-028

diameter 70 mm (2.8 in))

4 13
10. Remove pin (7) from the front axle. Remove the
front axle from frame (4).

12

WCGB-03-05-027

W3-5-2
 UNDERCARRIAGE / Axle
Installation of Front Axle
4 13

CAUTION: Front axle weight: 630 kg (1390

lb) 6
7
CAUTION: Pin (7) weight: 14 kg (31 lb) (outer
diameter 70 mm (2.8 in))

1. Hold the front axle by using a forklift. Install the 12

front axle to frame (4) with pin (7).
WCEB-03-05-026

2. Secure pin (7) with bolt (13) and nuts (12) (2

used). 4 7 8
: 24 mm
: 270 N·m (27.5·kgfm, 199 lbf·ft)

3. Connect steering hoses (8) (2 used) to the steer-

ing cylinder.
: 22 mm
: 39 N·m (4.0 kgf·m, 29 lbf·ft)
Steering Cylinder WCGB-03-05-025

4. Connect brake hoses (5) (2 used) to the right and

left sides of the front axle. Steering Cylinder Front Axle
: 22 mm 5
: 39 N·m (4.0 kgf·m, 29 lbf·ft)

5. Connect grease hose (6) to pin (7).

: 17 mm
: 24.5 N·m (2.5 kgf·m, 18 lbf·ft)

CAUTION: Propeller shaft (11) weight：30 kg WCEB-03-05-021

(70 lb)
6. Install propeller shaft (11) to the front axle with
Front Axle
bolts (10) (8 used) and nuts (9) (8 used). 11
: 14 mm
: 108 N·m (11 kgf·m, 80 lbf·ft) 9, 10

WCGB-03-05-028

W3-5-3
 UNDERCARRIAGE / Axle

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb) 3 2 3 3 2 3 4

7. Install tire (3), tire ring (2) and tire (3) to the front
axle in this order and tighten them with nuts (1)
(10 used) temporarily.
: 30 mm

8. Install tire ring (2) and tires (3) (2 used) to the

other side of the front axle in the same way as
step 7. 1

9. Remove the stand from frame (4).

W1GL-03-05-003

10. Tighten tires (3) (4 used) and tire rings (2) (2

used) with nuts (1) (20 used).
: 30 mm
: 600 N·m (61 kgf·m, 443 lbf·ft)

W3-5-4
 UNDERCARRIAGE / Axle
Removal of Rear Axle

1. Loosen nuts (1) (20 used) for tires (3) (4 used) 4

and tire rings (2) (2 used). 3
: 30 mm

2. Swing the machine by 90º. Raise the rear axle

side of frame (4) until tire (3) is raised. Place a
stand under frame (4).

2
CAUTION: Tire (3) weight: 98 kg (220 lb)
Tire ring (2) weight: 25 kg (60 lb) 1 3 W1GL-03-05-003

3. Remove nuts (1) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used) from frame (4).
: 30 mm

CAUTION: Propeller shaft (7) weight: 30 kg Rear Axle

(70 lb)
7
4. Place a wooden block under propeller shaft (7).
5, 6
Remove bolts (6) (8 used) and nuts (5) (8 used).
Remove propeller shaft (7) from the rear axle.
: 14 mm

WCGB-03-05-028

W3-5-5
 UNDERCARRIAGE / Axle
7. Disconnect brake pipings (8) (2 used) from the 4 8
right and left sides of the rear axle.
: 19 mm

CAUTION: Rear axle weight: 550 kg (1220 lb)

8. Hold the lower side of the rear axle by using a

forklift.

9. Remove nuts (10) (8 used) from the right and left WCGB-03-05-023

sides of the rear axle. Remove bolts (9) (8 used) 9

from frame (4).
10
: 30 mm

10. Remove the rear axle from frame (4). 4

WCGB-03-05-022

W1GL-03-05-003

W3-5-6
 UNDERCARRIAGE / Axle
Installation of Rear Axle 4 8

CAUTION: Rear axle weight: 550 kg (1220 lb)

1. Hold the rear axle by using a forklift. Install the

rear axle to frame (4) with bolts (9) (8 used) and
nuts (10) (8 used).
: 30 mm
: 560 N·m (57 kgf·m, 413 lbf·ft)
WCGB-03-05-023

2. Connect brake pipings (8) (2 used) to the right 9

and left sides of the rear axle.
: 19 mm 10
: 29.5 N·m (3.0 kgf·m, 22 lbf·ft)

CAUTION: Propeller shaft (7) weight: 30 kg WCGB-03-05-022

(70 lb)
Rear Axle

3. Install propeller shaft (7) to the rear axle with nuts 7

(5) (8 used) and bolts (6) (8 used). 5, 6
: 14 mm
: 108 N·m (11 kgf·m, 80 lbf·ft)

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb)
WCGB-03-05-028
4. Install tire (3), tire ring (2) and tire (3) to the rear
axle in this order and tighten them with nuts (1)
(10 used) temporarily.
: 30 mm

5. Install tire ring (2) and tires (3) (2 used) to the 3

other side of the rear axle in the same way as
step 4.

1 3 W1GL-03-05-003

W3-5-7
 UNDERCARRIAGE / Axle
6. Remove the stand from frame (4).

7. Tighten tires (3) (4 used) and tire rings (2) (2

used) with nuts (1) (20 used). 4
: 30 mm 3
: 600 N·m (61 kgf·m, 443 lbf·ft)

1 3 W1GL-03-05-003

W3-5-8
 UNDERCARRIAGE / Axle
(Blank)

W3-5-9
 UNDERCARRIAGE / Axle
DISASSEMBLY OF FRONT AXLE
1

2
3
4
5
6
7

8
9
10
11
16 12
17 18 13
19
20
14
21 22 15
23
24
25
26
27
28
40
39
38 36 29
37 30
31
32
41
42
35
43 34
33

44
45
46
47
48
49
50
51
52

56
WCEB-03-05-001
55
54 53

W3-5-10
 UNDERCARRIAGE / Axle

1- Drive Housing 15 - Bushing 29 - Friction Plate (4 Used) 43 - Hub Carrier

2- Plug 16 - Plug 30 - Plate (5 Used) 44 - O-Ring
3- Axle Casing 17 - Pin 31 - Cover (4 Used) 45 - Bearing
4- Washer (16 Used) 18 - Socket Bolt (6 Used) 32 - Socket Bolt (16 Used) 46 - Snap Ring
5- Bolt (16 Used) 19 - Shim 33 - Bolt (3 Used) 47 - Ring Gear
6- Nut 20 - Seal Ring 34 - Spring (3 Used) 48 - Support
7- Lock Bolt 21 - Bushing 35 - Socket Bolt (3 Used) 49 - Retaining Ring (3 Used)
8- Retaining Ring (2 Used) 22 - Knuckle 36 - Pin 50 - Planetary Gear (3 Used)
9- Bearing 23 - O-Ring 37 - Bolt (6 Used) 51 - Roller Bearing (3 Used)
10 - Seal Ring 24 - O-Ring 38 - Seal Ring 52 - Planetary Carrier
11 - Bushing 25 - Backup Ring 39 - Ball Bushing 53 - Plug
12 - O-Ring 26 - O-Ring 40 - Plug 54 - Plug
13 - Double Joint Shaft 27 - Backup Ring 41 - Seal Ring 55 - Plate
14 - Shaft Seal 28 - Piston 42 - Bearing 56 - Nut (8 Used)

W3-5-11
 UNDERCARRIAGE / Axle

2
3

16

22

40

52

WCEB-03-05-001

53

W3-5-12
 UNDERCARRIAGE / Axle
Disassembly of Front Axle

CAUTION: Front axle weight: 630 kg (1390 lb) 5. Remove socket bolts (62) (5 used). Tap and re-
move steering cylinder (61) from drive housing (1)
1. Hoist the front axle. Lower the front axle on a by using a plastic hammer.
workbench. : 12 mm
62 1
2. Remove nut (58) from the right and left sides of
the front axle. Remove tie rods (57) (2 used) from
knuckle (22) in the right and left sides. 61
: 41 mm
57 58 22

3
WCEB-03-05-017

6. Remove O-rings (63) (2 used) from drive housing

(1).
WCEB-03-05-015
1 63

3. Warm the connection part of piston rod (59) and

tie rod (57) by using a drier. Attach a spanner onto
the connection part of the right and left sides of
the front axle. Remove tie rods (57) (2 used) from
piston rod (59).
: 55 mm
1
Connection Part

59 57
WCEB-03-05-019

7. Remove plugs (2, 16, 40 and 53) from the right

and left sides of the front axle. Drain gear oil from
the front axle.
60 Plug (2)
: 8 mm
WCEB-03-05-016 Plugs (16, 40, 53)
: 10 mm
4. Remove elbows (60) (2 used) from drive housing
(1).

W3-5-13
 UNDERCARRIAGE / Axle

22
23

29
30
31
32
41
42
43

44
45
46
47
48
49
50
51
52

56
WCEB-03-05-001

54

W3-5-14
 UNDERCARRIAGE / Axle
8. Remove nuts (64) (10 used), washers (65) (20
used) and plug (54) from planetary carrier (52).
: 30 mm
: 8 mm
52 64, 65
WCEB-03-05-010
9. Attach a nylon sling onto planetary carrier (52).
Pry the clearance between hub carrier (43) and
planetary carrier (52) by using a pry bar. Hoist and
remove planetary carrier (52) from the front axle.
10. Remove retaining rings (49) (3 used) from plane-
tary gears (50) (3 used). Remove planetary gears
(50) (3 used) and roller bearings (51) (3 used)
from planetary carrier (52).
11. Remove O-ring (44) from hub carrier (43).
12. Remove nuts (56) (8 used). Remove plate (55)
from the ring gear (47) assembly.
: 27 mm
13. Remove the ring gear (47) assembly from hub
carrier (43).
14. Remove snap ring (46) from the ring gear (47)
assembly. Remove support (48).
W3-5-15
IMPORTANT: Do not remove bearing (45) unless
necessary.
15. Pry the clearance between cover (31) and hub
carrier (43) by using a pry bar. Remove hub carrier
(43) and the inner race of bearing (45) from cover
(31). At this time, do not drop the inner race of
bearing (45).
IMPORTANT: Do not remove bearings (42, 45)
unless necessary.
16. Remove the outer races of bearings (42, 45) from
hub carrier (43).
17. Remove socket bolts (32) (16 used) from cover
(31).
: 8 mm
IMPORTANT: When removing cover (31), do not
drop plate (30) and friction plate (29).
18. Put the matching marks on cover (31) and knuckle
(22). Pry the clearance between cover (31) and
knuckle (22) by using a pry bar. Hoist and remove
cover (31) from knuckle (22).
19. Remove plates (30) (5 used) and friction plates
(29) (4 used) from cover (31).
20. Remove seal ring (41) from cover (31).
21. Remove O-ring (23) from knuckle (22).
 UNDERCARRIAGE / Axle

6
7

17 18
19
20
21 22
14
24 15
25
26
27
28
39
38 36
37

42
35
34
33

WCEB-03-05-001

W3-5-16
 UNDERCARRIAGE / Axle
IMPORTANT: Do not remove bearing (42) unless 27. Remove ball cover (68) from pin (36).
necessary.
22. Remove the inner race of bearing (42) from 68
knuckle (22). 36

IMPORTANT: Before removing bolt (33), record the

dimension of bolt (33) extended from
piston (28).
23. Remove bolts (33) (3 used), socket bolts (35) (3
used) and springs (34) (3 used) from piston (28).
WCEB-03-05-004
: 11 mm
: 5 mm
28. Hoist and hold knuckle (22). Remove bolts (18) (6
used) from the upper side of knuckle (22). Pry the
IMPORTANT: Do not fly out piston (28).
clearance between knuckle (22) and pin (17).
24. Remove cap (66) and plug (67) from knuckle (22).
Remove pin (17), shims (19) (3 used) and seal
Apply pressure air through the plug (67) hole and
ring (20) from knuckle (22).
remove piston (28) from knuckle (22).
: 10 mm
29. Hoist and hold knuckle (22). Remove knuckle (22)
22 from axle casing (3).
28
30. Remove seal ring (14) and bushing (15) from
knuckle (22).
66, 67
31. Remove bushing (21) and ball bushing (39) from
the upper and lower pins (17, 36) holes of knuckle
(22) by using a gear puller.

32. Remove nut (6) and lock bolt (7) from axle casing
(3).
WCEB-03-05-011 : 19 mm
: 6 mm
25. Remove O-rings (24, 26) and backup rings (25,
27) from piston (28).

26. Remove bolts (37) (6 used) from the lower side of

knuckle (22). Pry the clearance between knuckle
(22) and pin (36) by using a pry bar. Remove pin
(36) and seal ring (38) from knuckle (22).

W3-5-17
UNDERCARRIAGE / Axle

3
4
5

8
9
10
11
12
13

WCEB-03-05-001

W3-5-18
 UNDERCARRIAGE / Axle
33. Attach a nylon sling onto axle casing (3). Remove
bolts (5) (16 used) and washers (4) (16 used).
Remove axle casing (3) with double joint shaft
(13) together from drive housing (1).
: 19 mm

34. Remove double joint shaft (13) from axle casing

(3) by using a plastic hammer.

35. Remove retaining rings (8) (2 used) from the

bushing (11) assembly.

36. Remove the bushing (11) assembly from double

joint shaft (13).

IMPORTANT: Do not remove bearing (9) unless

necessary.
37. Remove bearing (9), seal ring (10) and O-ring (12)
from the bushing (11) assembly by using a gear
puller.

38. Remove the parts at the opposite side of the front

axle in the same way as steps 8 to 37.

39. Remove the differential from drive housing (1).

(Refer to Disassemble Differential on W3-5-44.)

W3-5-19
 UNDERCARRIAGE / Axle
ASSEMBLY OF FRONT AXLE

Detail of Drive Housing Inside

1

Planetary Carrier

WCEB-03-05-008

Detail of Planetary Carrier Inside

18 17 24, 25 26, 27 22 23 31 41 44 42 43 49

20 47

21 50

19 51
52
6
49
7
Drive Housing 13
9

10 56

WCEB-03-05-006
11 12 3 37 36 39 38 40 28 29 32 30 14 15 45 48 55

W3-5-20
 UNDERCARRIAGE / Axle

1- Drive Housing 15 - Bushing 29 - Friction Plate (4 Used) 43 - Hub Carrier

2- *Plug 16 - *Plug 30 - Plate (5 Used) 44 - O-Ring
3- Axle Casing 17 - Pin 31 - Cover (4 Used) 45 - Bearing
4- *Washer (16 Used) 18 - Socket Bolt (6 Used) 32 - Bolt (16 Used) 46 - *Snap Ring
5- *Bolt (16 Used) 19 - Shim 33 - *Bolt (3 Used) 47 - Ring Gear
6- Nut 20 - Seal Ring 34 - *Spring (3 Used) 48 - Support
7- Lock Bolt 21 - Bushing 35 - *Socket Bolt (3 Used) 49 - Retaining Ring (3 Used)
8- *Retaining Ring (2 Used) 22 - Knuckle 36 - Pin 50 - Planetary Gear (3 Used)
9- Bearing 23 - O-Ring 37 - Bolt (6 Used) 51 - Roller Bearing (3 Used)
10 - Seal Ring 24 - O-Ring 38 - Seal Ring 52 - Planetary Carrier
11 - Bushing 25 - Backup Ring 39 - Ball Bushing 53 - *Plug
12 - O-Ring 26 - O-Ring 40 - Plug 54 - *Plug
13 - Double Joint Shaft 27 - Backup Ring 41 - Seal Ring 55 - Plate
14 - Shaft Seal 28 - Piston 42 - Bearing 56 - Nut (8 Used)

NOTE: As for the item with mark *, refer to W3-5-10.

W3-5-21
 UNDERCARRIAGE / Axle

Planetary Carrier

WCEB-03-05-008

18 17 22

20

21

19

7
13
Drive Housing 9

10

WCEB-03-05-006
11 12 3 36 39 38 14 15

W3-5-22
 UNDERCARRIAGE / Axle
Assembly of Front Axle

1. Apply LOCTITE #242 onto bolt (5). Hoist axle 7. Install ball cover (68) to pin (36).
casing (3). Install axle casing (3) to drive housing
(1) with bolts (5) (16 used) and washers (4) (16 68
used). 36
: 19 mm
: 283 to 312 N·m
(29 to 32 kgf·m, 209 to 230 lbf⋅ft)

2. Install O-ring (12), seal ring (10), bearing (9) and

retaining ring (8) to bushing (11).
WCEB-03-05-004

3. Install the bushing (11) assembly and retaining

8. Install seal rings (20, 38) to pins (17, 36).
ring (8) to double joint shaft (13).
9. Apply grease onto bushing (15) and seal ring (14).
4. Install double joint shaft (13) to axle casing (3).
Install bushing (15) and seal ring (14) to knuckle
(22).
5. Apply LOCTITE #242 onto nut (6) and lock bolt (7).
Install nut (6) and lock bolt (7) to axle casing (3).
IMPORTANT: When installing double joint shaft
: 19 mm
(13) to knuckle (22), do not damage
: 60 to 70 N⋅m
bushing (15) and seal ring (14).
(6 to 7 kgf⋅m, 44 to 52 lbf⋅ft)
10. Apply grease onto double joint shaft (13). Hoist
: 6 mm
and install knuckle (22) to axle casing (3).
: 15 to 20 N⋅m
(1.5 to 2 kgf⋅m, 11 to 15 lbf⋅ft)
11. Apply grease onto pin (17). Install shims (19) (3
used) and pin (17) to the upper side of knuckle
6. Apply grease onto bushing (21) and ball bushing
(22) and secure them with bolts (18) (6 used).
(39). Install bushing (21) and ball bushing (39) to
axle casing (3). NOTE: Adjust the thickness of shim (19) from 1.5
to 2.0 mm (0.06 to 0.08 in).
: 15 mm
: 116 to 128 N⋅m
(12 to 13 kgf⋅m, 86 to 94 lbf⋅ft)

W3-5-23
 UNDERCARRIAGE / Axle

Planetary Carrier

WCEB-03-05-008

17 24, 25 26, 27 22 23 31 41 44 42 43

19

Drive Housing

WCEB-03-05-006
37 36 28 29 32 30

W3-5-24
 UNDERCARRIAGE / Axle
12. Apply grease onto pin (36). Install pin (36) the 18. Install plug (67) and cap (66) to knuckle (22).
lower side of to knuckle (22) and secure them with : 10 mm 22
bolts (37) (6 used). 28
: 15 mm
: 116 to 128 N⋅m
(12 to 13 kgf⋅m, 86 to 94 lbf⋅ft)
66, 67
13. Insert a pry bar between the pin (17) side of
knuckle (22) and axle casing (3). Move knuckle
(22) up and down. Measure the clearance be-
tween pin (17) and shim (19). In case the correct
dimension can not be obtained, adjust with shim
(19).
WCEB-03-05-011
NOTE: Correct dimension: 0.5 mm (0.02 in)
19. Install O-ring (23) and the inner race of bearing
14. Measure the torque of pin (17). (42) to knuckle (22).
NOTE: Correct torque: 40 to 80 Nm (4 to 8 kgfm,
30 to 59 lbf⋅ft) 20. Install seal ring (41) to cover (31).

15. Install O-rings (24, 26) and backup rings (25, 27) 21. Install the outer race of bearing (42) to hub carrier
to piston (28). (43).

IMPORTANT: When installing piston (28), do not
damage O-rings (24, 26) and backup
rings (25, 27).
16. Apply LOCTITE #270 onto socket bolt (35). Install
piston (28) to knuckle (22) with socket bolts (35)
(3 used) by using a plastic hammer.
: 5 mm
: 5 to 7 N⋅m
(0.5 to 0.7 kgf⋅m, 4 to 5 lbf⋅ft)
22. Install hub carrier (43) to cover (31).
23. Apply grease onto O-ring (44). Install O-ring (44)
to hub carrier (43).
24. Apply grease onto plate (30) and friction plate (29).
Install plates (30) (5 used) and friction plates (29)
(4 used) to the cover (31) assembly alternately. At
this time, align the claws of friction plate (29).

17. Apply LOCTITE #242 onto bolt (33). Install bolts 30

(33) (3 used) and springs (34) (3 used) to piston
(28).
: 11 mm 29
: 10 to 15 N⋅m
(1 to 1.5 kgf⋅m, 7 to 11 lbf⋅ft) 31
Claw

WCEB-03-05-005

W3-5-25
 UNDERCARRIAGE / Axle

Planetary Carrier

WCEB-03-05-008

22 31 43

47

50

51
52
49

Drive Housing
56

WCEB-03-05-006
29 32 30 45 48 55

W3-5-26
 UNDERCARRIAGE / Axle
IMPORTANT: When hoisting the cover (31) as-
sembly, do not drop plate (30) and
friction plate (29).
25. Hoist the cover (31) assembly and align the
matching marks on knuckle (22) and cover (31).
Install the cover (31) assembly to knuckle (22)
with bolts (32) (16 used) temporarily.
: 22 mm
26. Install the inner race of bearing (45) to hub carrier
(43) by using a plastic hammer.
27. Install support (48) and snap ring (46) to ring gear
(47).
33. Hoist planetary carrier (52). Install planetary car-
rier (52) to hub carrier (43).
34. Install plug (54) to planetary carrier (52).
: 8 mm
: 35 to 50 N⋅m
(3.6 to 5 kgf⋅m, 26 to 37 lbf⋅ft)
35. Install nuts (64) (16 used) and washers (65) (20
used) to planetary carrier (52).
: 30 mm
: 400 N⋅m (40 kgf⋅m, 295 lbf⋅ft)
52 64, 65

28. Hoist the ring gear (47) assembly. Install the ring
gear (47) assembly to hub carrier (43).

IMPORTANT: Apply LOCTITE #242 onto nut (56).

29. Apply grease to plate (55). Install plate (55) to ring
gear (47) with nuts (56) (8 used) temporarily.
: 27 mm
: 120 N⋅m (12 kgf⋅m, 89 lbf⋅ft)
WCEB-03-05-010

30. Tighten bolts (32) (16 used).

: 22 mm 36. Install the parts at the opposite side of the front
: 182 to 202 N⋅m axle in the same way as steps 1 to 35.
(19 to 21 kgf⋅m, 134 to 149 lbf⋅ft)
37. Apply grease onto O-ring (63). Install O-rings (63)
31. Tighten nuts (56) (8 used). (2 used) to drive housing (1).
: 22 mm
: 255 to 285 N⋅m 1 63
(26 to 29 kgf⋅m, 188 to 210 lbf⋅ft)

32. Install planetary gears (50) (3 used), roller bear-

ings (51) (3 used) and retaining rings (49) (3 used)
to planetary carrier (52).

WCEB-03-05-019

W3-5-27
 UNDERCARRIAGE / Axle

Planetary Carrier

WCEB-03-05-008

22

Drive Housing

WCEB-03-05-006
3 40

W3-5-28
 UNDERCARRIAGE / Axle
38. Apply LOCTITE #242 onto socket bolt (62). Install 41. Install tie rod (57) to the left and right sides of
steering cylinder (61) to drive housing (1) and knuckle (22). Install nut (58) to the pin of tie rod
secure if with socket bolts (62) (5 used). (57).
: 12 mm : 41 mm
: 180 to 200 N⋅m : 350 to 390 N⋅m
(18 to 20 kgf⋅m, 133 to 148 lbf⋅ft) (36 to 40 kgf⋅m, 258 to 288 lbf⋅ft)

62 1 57 58 22

61
3

WCEB-03-05-015

WCEB-03-05-017

42. Add gear oil to the left and right sides of the front
39. Install elbows (60) (2 used) to drive housing (1). axle. Install plugs (2, 16, 40 and 53).
Plug (2)
40. Apply LOCTITE #242 onto the connection part of
: 8 mm
piston rod (59) and tie rod (57). Install tie rods (57)
: 35 to 50 N⋅m
(2 used) to the left and right sides of piston rod
(3.6 to 5 kgf⋅m, 26 to 37 lbf⋅ft)
(59).
Plugs (16, 40, 53)
: 55 mm
: 10 mm
: 430 to 470 N⋅m
: 35 to 50 N⋅m
(43 to 47 kgf⋅m, 317 to 347 lbf⋅ft)
(3.6 to 5 kgf⋅m, 26 to 37 lbf⋅ft)
1
Connection Part

59 57

60

WCEB-03-05-016

W3-5-29
 UNDERCARRIAGE / Axle
DISASSEMBLY OF REAR AXLE
1
2
3
4
5

6
7
8
10 9
11
12
13
14
15
16
17
28 18
19

20
27
21
22
23
29
30
31 26
32 25
24
33
34
35
36
37
38
39
40
41
42

46
45 43 WCEB-03-05-002

44

W3-5-30
 UNDERCARRIAGE / Axle

1- Drive Housing 13 - Cover 25 - Spring (3 Used) 37 - Ring Gear

2- Plug 14 - O-Ring 26 - Bolt (3 Used) 38 - Support
3- Plug 15 - O-Ring 27 - Bolt (20 Used) 39 - Retaining Ring (3 Used)
4- Axle Casing 16 - Backup Ring 28 - Plug 40 - Planetary Gear (3 Used)
5- Bolt (16 Used) 17 - O-Ring 29 - Seal Ring 41 - Roller Bearing (3 Used)
6- O-Ring 18 - Backup Ring 30 - Bearing 42 - Planetary Carrier
7- Seal Ring 19 - Piston 31 - Hub Carrier 43 - Plug
8- Guide Ring 20 - Friction Plate (5 Used) 32 - Washer (20 Used) 44 - Plug
9- Shaft 21 - Plate (6 Used) 33 - Nut (10 Used) 45 - Plate
10 - Plug 22 - Cover 34 - O-Ring 46 - Nut (8 Used)
11 - Cap 23 - Socket Bolt (16 Used) 35 - Bearing
12 - Plug 24 - Bolt (3 Used) 36 - Snap Ring

W3-5-31
 UNDERCARRIAGE / Axle

2
3
4

7
8
10 9

28

20
21
22

30
31
32

33
34
35
36
37
38
39
40
41
42

46
45 43 WCEB-03-05-002

44

W3-5-32
 UNDERCARRIAGE / Axle
Disassembly of Rear Axle

CAUTION: Rear axle weight: 550 kg (1220 lb)

8. Remove nuts (46) (8 used). Remove plate (45)
from ring gear (37).
1. Hoist the rear axle. Lower the rear axle on a : 27 mm
workbench.
9. Pry the clearance between hub carrier (31) and
2. Remove plugs (2, 3, 10 and 43) from the left and ring gear (37) by using a pry bar. Remove the ring
right sides of the rear axle. Drain gear oil from the gear (37) assembly from hub carrier (31).
rear axle.
Plug (2) 10. Remove snap ring (36) from the ring gear (37)
: 8 mm assembly. Remove support (38).
Plugs (3, 10, 43)
: 10 mm
11. Remove guide ring (8) and seal ring (7) from axle
casing (4).
3. Remove plug (44) from planetary carrier (42).
: 8 mm
IMPORTANT: Do not remove bearing (35) unless
necessary.
4. Remove nuts (33) (10 used) and washers (32) (20
12. Pry the clearance between cover (22) and hub
used). Pry the clearance between planetary car-
carrier (31) by using a pry bar. Remove hub carrier
rier (42) and hub carrier (31) by using a pry bar.
(31) and the inner race of bearing (35) from cover
Remove planetary carrier (42) from the rear axle.
(22). At this time, do not drop the inner race of
: 30 mm
bearing (35).
5. Remove retaining rings (39) (3 used) from plane-
13. Remove the inner race of bearing (30) from axle
tary gears (40) (3 used). Remove planetary gears
casing (4).
(40) (3 used) and roller bearings (41) (3 used)
from planetary carrier (42).
14. Remove the outer races of bearings (30, 35) from
hub carrier (31).
6. Remove O-ring (34) from hub carrier (31).
15. Remove plug (28) from axle casing (4).
7. Remove shaft (9) from the rear axle. : 10 mm

W3-5-33
 UNDERCARRIAGE / Axle

4
5

10
11
12
13
14
15
16
17
18
19

20
27
21
22
23
29
31 26
25
24

WCEB-03-05-002

W3-5-34
 UNDERCARRIAGE / Axle
16. Remove socket bolts (23) (16 used) from cover
(22).
: 8 mm
IMPORTANT: When removing cover (22), do not
drop plate (21) and friction plate (20).
17. Put the matching marks on cover (22) and cover
(13). Pry the clearance between cover (22) and
cover (13) by using a pry bar. Hoist and remove
cover (22) from cover (13).
18. Remove plates (21) (6 used) and friction plates
(20) (5 used) from cover (22).
19. Remove seal ring (29) from hub carrier (31).
24. Put the matching marks on axle casing (4) and
cover (12). Remove bolts (27) (20 used). Remove
cover (12) from the rear axle.
: 22 mm
25. Remove O-ring (6) from axle casing (4).
26. Hoist and hold axle casing (4). Remove bolts (5)
(16 used). Hoist and remove axle casing (4) from
drive housing (1).
: 19 mm
27. Remove the parts at the opposite side of the rear
axle in the same way as steps 3 to 26.

20. Remove O-ring (14) from cover (13).

IMPORTANT: Before removing bolt (24), record the

dimension of bolt (24) extended from
piston (19).
21. Remove bolts (24) (3 used), socket bolts (26) (3
used) and springs (25) (3 used) from piston (19).
: 11 mm
: 5 mm

IMPORTANT: Do not fly out piston (19).

22. Remove cap (11) and plug (12) from cover (13).
Apply pressure air through the plug (12) hole and
remove piston (19) from cover (13).
: 10 mm

23. Remove O-rings (15, 17) and backup rings (16,

18) from piston (19).

W3-5-35
 UNDERCARRIAGE / Axle
ASSEMBLY OF REAR AXLE
Detail of Drive Housing Inside
1

Planetary Carrier

WCEB-03-05-009

Detail of Planetary Carrier Inside

15, 16 17, 18 14 20 21 23 29 34 30 35 36
13
37

11, 12 40
39
4
41

42
Drive Housing

46
7
45

27
38
6

28
WCEB-03-05-007
19 22 31 8

W3-5-36
 UNDERCARRIAGE / Axle

1 - Drive Housing 13 - Cover 25 - *Spring (3 Used) 37 - Ring Gear

2 - *Plug 14 - O-Ring 26 - *Bolt (3 Used) 38 - Support
3 - *Plug 15 - O-Ring 27 - Bolt (20 Used) 39 - Retaining Ring (3 Used)
4 - Axle Casing 16 - Backup Ring 28 - Plug 40 - Planetary Gear (3 Used)
5 - *Bolt (16 Used) 17 - O-Ring 29 - Seal Ring 41 - Roller Bearing (3 Used)
6 - O-Ring 18 - Backup Ring 30 - Bearing 42 - Planetary Carrier
7 - Seal Ring 19 - Piston 31 - Hub Carrier 43 - *Plug
8 - Guide Ring 20 - Friction Plate (5 Used) 32 - *Washer (20 Used) 44 - *Plug
9 - Shaft 21 - Plate (6 Used) 33 - *Nut (10 Used) 45 - Plate
10 - *Plug 22 - Cover 34 - O-Ring 46 - Nut (8 Used)
11 - Cap 23 - Socket Bolt (16 Used) 35 - Bearing
12 - Plug 24 - *Bolt (3 Used) 36 - Snap Ring

NOTE: As for the item with mark *, refer to W3-5-30.

W3-5-37
 UNDERCARRIAGE / Axle

Planetary Carrier

WCEB-03-05-009

15, 16 17, 18 29 30
13

11, 12

Drive Housing

WCEB-03-05-007
19 22 31 8

W3-5-38
 UNDERCARRIAGE / Axle
Assembly of Rear Axle
1. Hoist axle casing (4). Install axle casing (4) to
drive housing (1) with bolts (5) (16 used).
: 19 mm
: 283 to 312 N⋅m
(29 to 32 kgf⋅m, 209 to 230 lbf⋅ft)
2. Install O-ring (6) to axle casing (4).
3. Apply LOCTITE #242 onto bolt (27). Install cover
(13) to axle casing (4). Install bolts (27) (20 used)
to cover (13).
: 22 mm
: 283 to 312 N⋅m
(29 to 32 kgf⋅m, 209 to 230 lbf⋅ft)
4. Install O-rings (15, 17) and backup rings (16, 18)
to piston (19).
IMPORTANT: When installing piston (19), do not
damage O-rings (15, 17) and backup
rings (16, 18).
5. Install piston (19) to cover (13) by using a plastic
hammer.
W3-5-39
6. Apply LOCTITE #270 onto socket bolt (26). Install
socket bolts (26) (3 used) to piston (19).
: 5 mm
: 5 to 7 N⋅m
(0.5 to 0.7 kgf⋅m, 4 to 5 lbf⋅ft)
7. Apply LOCTITE #242 onto bolt (24). Install bolts
(24) (3 used) and springs (25) (3 used) to piston
(19).
: 11 mm
: 10 to 15 N⋅m
(1 to 1.5 kgf⋅m, 7 to 11 lbf⋅ft)
8. Install plug (12) and cap (11) to cover (13).
: 10 mm
9. Install O-ring (6), seal ring (7) and guide ring (8) to
axle casing (4).
10. Install the inner race of bearing (30) to axle casing
(4).
11. Install seal ring (29) to cover (22).
12. Install the outer race of bearing (30) to hub carrier
(31).
13. Install cover (22) to hub carrier (31).
 UNDERCARRIAGE / Axle

Planetary Carrier

WCEB-03-05-009

20 21 23 34 35 36

13 37

40
39

41

42
Drive Housing

46

45

38

WCEB-03-05-007
22 31

W3-5-40
 UNDERCARRIAGE / Axle
14. Apply grease onto plate (21) and friction plate (20).
Install plates (21) (6 used) and friction plates (20)
(5 used) to hub carrier (31) alternately. At this time,
align the claws of friction plate (20).
21
20
31
Claw
WCEB-03-05-005
IMPORTANT: When installing cover (22), do not
drop plate (21) and friction plate (20).
15. Hoist the cover (22) assembly and align the
matching marks on cover (13) and cover (22). In-
stall the cover (22) assembly to cover (13) with
bolts (23) (16 used) temporarily.
: 8 mm
16. Install the inner race of bearing (35) to hub carrier
(31) by using a plastic hammer.
17. Install support (38) and snap ring (36) to ring gear
(37).
18. Hoist ring gear (37). Install ring gear (37) to hub
carrier (31).
W3-5-41
IMPORTANT: Apply LOCTITE #242 onto nut (46).
19. Apply grease onto plate (45). Install plate (45) to
ring gear (37) with nuts (46) (8 used) temporarily.
: 27 mm
20. Tighten socket bolts (23) (16 used).
: 8 mm
: 182 to 202 N⋅m
(19 to 21 kgf⋅m, 134 to 149 lbf⋅ft)
21. Tighten nuts (46) (8 used).
: 27 mm
: 255 to 285 N⋅m
(26 to 29 kgf⋅m, 188 to 210 lbf⋅ft)
22. Install planetary gears (40) (3 used), roller bear-
ings (41) (3 used) and retaining rings (39) (3 used)
to planetary carrier (42).
23. Apply grease onto O-ring (34). Install O-ring (34)
to hub carrier (31).
24. Hoist planetary carrier (42). Install planetary car-
rier (42) to hub carrier (31).
 UNDERCARRIAGE / Axle

Planetary Carrier

WCEB-03-05-009

42

Drive Housing

WCEB-03-05-007

W3-5-42
 UNDERCARRIAGE / Axle
25. Install plug (44) to planetary carrier (42).
: 10 mm
: 40 to 50 N⋅m
(4 to 5 kgf⋅m, 30 to 37 lbf⋅ft)

26. Install the parts at the opposite side of the rear

axle in the same way as steps 1 to 25.

27. Add gear oil to the left and right sides of the rear
axle. Install plugs (2, 3, 10 and 43).
Plug (2)
: 8 mm
: 35 to 50 N⋅m
(3.6 to 5 kgf⋅m, 22 to 37 lbf⋅ft)
Plugs (3, 10, 43)
: 10 mm
: 35 to 50 N⋅m
(3.6 to 5 kgf⋅m, 22 to 37 lbf⋅ft)

W3-5-43
 UNDERCARRIAGE / Axle
DISASSEMBLY OF DIFFERENTIAL

NOTE: Disassembly of the differential is common

to the front axle and the rear axle.
The illustration shows the front axle.
1 2 3 4 5 6 7 8 9 10

11

11
10 12

9
13

14

20
15

19
16

18

A 17 WCEB-03-05-008

21 22 23 24 25 26 27
Section A

28

29

30

31

32 1
WCEB-03-05-012

W3-5-44
 UNDERCARRIAGE / Axle

1- Drive Housing 9- O-Ring 17 - Differential Case 25 - Bearing

2- Differential Case 10 - Cover 18 - Washer 26 - Seal Ring
3- Retaining Ring 11 - O-Ring 19 - Bearing 27 - Guard
4- Cover 12 - Bearing 20 - Side Gear 28 - Flange
5- Spider (2 Used) 13 - Bearing Nut 21 - Pinion 29 - O-Ring
6- Washer (4 Used) 14 - Washer 22 - Bearing 30 - Nut
7- Pinion Gear (4 Used) 15 - Side Gear 23 - Shim 31 - Dust Seal
8- Bevel Gear 16 - Bolt (16 Used) 24 - Bushing 32 - Shim

W3-5-45
 UNDERCARRIAGE / Axle

1 2 3 4 9 10

11

11
10 12

9
13

WCEB-03-05-008

21 25 26 27

28

29

30

31

1
WCEB-03-05-012

W3-5-46
 UNDERCARRIAGE / Axle
Disassembly of Differential

1. Remove the axle casing from drive housing (1). 5. Remove the differential from drive housing (1).
(Refer to Disassemble Front Axle on W3-5-10 and
Disassemble Rear Axle on W3-5-30.)
1
Differential
2. Remove socket bolt (33). Remove bearing nut
(13) from cover (10) by using special tool (DANA
Special tool No.：T6 2379).
: 6 mm

33 13

10

WCEB-03-05-013

6. Remove retaining ring (3) from drive housing (1).

Remove cover (4).

WCEB-03-05-014 7. Remove nut (30) and O-ring (29) from drive

housing (1).
3. Remove socket bolts (34) (4 used). Remove cover : 36 mm
(10) from drive housing (1).
: 10 mm 8. Remove flange (28) and guard (27) from drive
housing (1).
34 1

9. Remove dust seal (31) from flange (28).

10. Remove seal ring (26) from drive housing (1).

10
IMPORTANT: Do not remove bearing (25) unless
necessary.
11. Remove pinion (21) from drive housing (1) by us-
ing a plastic hammer. At this time, do not drop the
inner race of bearing (25).
WCEB-03-05-019

4. Remove the outer race of bearing (12) and

O-rings (9, 11) from cover (10).

W3-5-47
 UNDERCARRIAGE / Axle

1 2 5 6 7 8 10

12

14

20
15

19
16

18

17 WCEB-03-05-008

21 22 23 24 25

32 1
WCEB-03-05-012

W3-5-48
 UNDERCARRIAGE / Axle
IMPORTANT: Do not remove bearing (22) unless
necessary.
12. Remove bushing (24), shim (32) and the inner
race of bearing (22) from pinion (21).
IMPORTANT: Do not remove bearings (22, 25)
unless necessary.
13. Remove the outer races of bearings (22, 25) and
shim (23) from drive housing (1).
17. Remove washers (6) (2 used), (14, 18), pinion
gears (7) (4 used), side gears (15, 20) and spiders
(5) (2 used) from differential case (17).
18. Remove other cover (10) from drive housing (1) in
the same way as steps 2 to 4.
NOTE: Cover (10) is installed on only one side of
drive housing (1) of the rear axle.

14. Secure the differential in a vise. Remove the inner

race of bearings (12, 19) from the differential.

15. Remove bolts (16) (16 used) from bevel gear (8).
: 17 mm
16

WCEB-03-05-018

16. Remove socket bolts (35) (15 used) from differen-

tial case (2). Remove differential case (2) from
differential case (17).
: 8 mm 17
2

35

WCEB-03-05-020

W3-5-49
 UNDERCARRIAGE / Axle
ASSEMBLY OF DIFFERENTIAL

NOTE: Assembly of the differential is common to

the front axle and the rear axle.
The illustration shows the front axle.
11 2 3 4 5 6 7 8 9 10

15

14
13 12

9
1

14

20
2

19
7

18

A 9 WCEB-03-05-008

21 22 23 24 25 26 27

Section A

28

29

30

31

32 1
WCEB-03-05-012

W3-5-50
 UNDERCARRIAGE / Axle

1- Drive Housing 9- O-Ring 17 - Differential Case 25 - Bearing

2- Differential Case 10 - Cover 18 - Washer 26 - Seal Ring
3- Retaining Ring 11 - O-Ring 19 - Bearing 27 - Guard
4- Cover 12 - Bearing 20 - Side Gear 28 - Flange
5- Spider (2 Used) 13 - Bearing Nut 21 - Pinion 29 - O-Ring
6- Washer (4 Used) 14 - Washer 22 - Bearing 30 - Nut
7- Pinion Gear (4 Used) 15 - Side Gear 23 - Shim 31 - Dust Seal
8- Bevel Gear 16 - Bolt (16 Used) 24 - Bushing 32 - Shim

W3-5-51
 UNDERCARRIAGE / Axle

1 2 3 4 5 6 7 8

12

14

20
15

19
16

18

17 WCEB-03-05-008

21 22 23 24 25 26 27

28

30

31

32 1
WCEB-03-05-012

W3-5-52
 UNDERCARRIAGE / Axle
Assembly of Differential

1. Install washers (6) (2 used), (14, 18), pinion gears
(7) (4 used), side gears (15, 20) and spiders (5) (2
used) to differential case (17).
2. Apply LOCTITE #270 onto socket bolt (35). Install
differential case (2) to the differential case (17)
assembly with socket bolts (35) (15 used).
: 8 mm
: 78 to 86 N⋅m
(8 to 9 kgf⋅m, 58 to 63 lbf⋅ft)
17
2
35
WCEB-03-05-020
3. Install bevel gear (8) to the differential case (17)
assembly with socket bolts (16) (16 used).
: 17 mm
: 128 to 142 N⋅m
(13 to 14.5 kgf⋅m, 94 to 105 lbf⋅ft)
5. Install the outer races of bearings (22, 25) and
shim (23) to drive housing (1).
6. Apply hydraulic oil onto bearing (25). Install the
inner race of bearing (25) to drive housing (1).
7. Apply hydraulic oil onto bearing (22). Install the
inner race of bearing (22), shim (32) and bushing
(24) to pinion (21).
NOTE: Shim (32) thickness: 1.33 to 1.35 mm (0.05
to 0.05 in)
8. Install the pinion (21) assembly and flange (28) to
drive housing (1).
9. Apply LOCTITE #242 onto nut (30). Install nut (30)
to pinion (21).
: 36 mm
: 800 to 1000 N⋅m (80 to 100 kgf⋅m, 590 to
738 lbf⋅ft)
10. Measure the torque of pinion (21).
NOTE: Correct torque: 120 to 180 N⋅m (12 to 18
kgf⋅m, 89 to 1.33 lbf⋅ft)

16 11. Remove nut (30) and flange (28) from drive

housing (1).
8 : 36 mm

12. Install seal ring (26) to drive housing (1).

13. Install dust seal (31) to flange (28).

WCEB-03-05-018 14. Install guard (27) and flange (28) to drive housing
(1).
4. Install the inner races of bearings (12, 19) to the
differential.

W3-5-53
 UNDERCARRIAGE / Axle

1 3 4 9 10

11

11
10 12

9
13

WCEB-03-05-008

21

29

30

1
WCEB-03-05-012

W3-5-54
 UNDERCARRIAGE / Axle
15. Apply LOCTITE #242 onto nut (30). Install O-ring 19. Install bearing nut (13) to cover (10) by using
(29) and nut (30) to pinion (21). special tool (DANA Special tool No.：T6 2379).
: 36 mm Install socket bolt (33) to cover (10).
: 800 to 1000 N⋅m : 6 mm
(80 to 100 kgf⋅m, 590 to 738 lbf⋅ft) : 24 to 26 N⋅m
(2.4 to 2.7 kgf⋅m, 18 to 19 lbf⋅ft)
16. Install the differential to drive housing (1).
33 13

1 10
Differential

WCEB-03-05-014

20. Install cover (4) and retaining ring (3) to drive

housing (1).
WCEB-03-05-013

17. Apply grease onto O-rings (9, 11). Install O-rings 21. Install the axle casing to drive housing (1). (Refer
(9, 11) and the outer race of bearing (12) to cover to Assemble Front Axle on W3-5-20 and Assem-
(10). ble Rear Axle on W3-5-36.)

18. Apply LOCTITE #242 onto socket bolt (34). Install

cover (10) to drive housing (1). Secure cover (10)
with socket bolts (34) (4 used).
: 10 mm
: 116 to 128 N⋅m
(12 to 13 kgf⋅m, 86 to 94 lbf⋅ft)

34 1

10

WCEB-03-05-019

W3-5-55
 UNDERCARRIAGE / Axle
(Blank)

W3-5-56
 UNDERCARRIAGE / Axle Lock Cylinder
REMOVAL AND INSTALLATION OF AXLE
LOCK CYLINDER

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

The procedure starts on the premise that the front axle

has already been removed.

Removal 1 2 3
1. Disconnect hoses (1) (2 used) from operate check
valve (3). Cap the open ends.
: 19 mm

IMPORTANT: Do not remove operate check valve

(3). If removing operate check valve
(3), rod (4) may come off due to the
entering air.
2. Remove socket bolts (2) (2 used) from operate
check valve (3). Install eyebolts (M8, Pitch 1.25
mm) (2 used) into the hole. Attach a nylon sling
onto eyebolts. Hoist and hold operate check valve
(3).
: 6 mm
4 WCEB-03-06-001

WCEB-03-06-003
CAUTION: Axle lock cylinder (5) weight: 38
kg (84 lb)
5
3. Remove socket bolts (6) (3 used), washers (7) (3
used), bolt (8) and spacer (9) from axle lock Pulling-Out Hole
cylinder (5).
: 17 mm 6, 7
: 32 mm
9
Pulling-Out Hole
8

WCEB-03-06-001

W3-6-1
 UNDERCARRIAGE / Axle Lock Cylinder
10
CAUTION: Axle lock cylinder (5) weight: 38
kg (84 lb)

4. Install the bolts (M12, Pitch 1.75 mm) (2 used) into 5

the pulling-out hole on axle lock cylinder (5). Pulling-Out Hole
Tighten the bolts (2 used) alternately. Remove axle
lock cylinder (5) from track frame (10).
: 19 mm

Pulling-Out Hole

WCEB-03-06-001

W3-6-2
 UNDERCARRIAGE / Axle Lock Cylinder
Installation

CAUTION: Axle lock cylinder (5) weight: 38 10

kg (84 lb)

1. Apply LOCTITE #262 onto socket bolts (6) (3

used) and bolt (8). 5

2. Hoist and align axle lock cylinder (5) with the

mounting hole on track frame (10). Install axle lock
6, 7
cylinder (5) to track frame (10) with socket bolts (6) 9
(3 used), washers (7) (3 used), bolt (8) and spacer
(9).
: 17 mm
: 750 N⋅m (76.5 kgf⋅m, 553 lbf⋅ft)
: 32 mm
: 750 N⋅m (76.5 kgf⋅m, 553 lbf⋅ft)

8 WCEB-03-06-001

3. Remove eyebolts (2 used) from axle lock cylinder 2 3 5

(5).

4. Install operate check valve (3) to axle lock cylinder

(5) with socket bolts (2) (2 used).
: 6 mm
: 29.4 to 34.3 N⋅m
(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

WCEB-03-06-003

1 3

5. Connect hoses (1) (2 used) to operate check valve

(3).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

WCEB-03-06-001

W3-6-3
 UNDERCARRIAGE / Axle Lock Cylinder
DISASSEMBLY AND ASSEMBLY OF AXLE
LOCK CYLINDER

8, 9 10

8, 9 10 7

2 View A WCEB-03-06-003

1 WCEB-03-06-002

1- Retaining Ring 4- Dust Seal 7- Housing 9 - O-Ring

2- Dust Seal 5- Seal Ring 8- Operate Check Valve 10 - Socket Bolt (4 Used)
3- Air Ring (4 Used) 6- Rod

W3-6-4
 UNDERCARRIAGE / Axle Lock Cylinder
Disassembly of Axle Lock Cylinder Assembly of Axle Lock Cylinder

1. Install seal ring (5), dust seal (4) and air rings (3)
CAUTION: Axle lock cylinder weight: 38 kg
(4 used) to housing (7).
(84 lb)
2. Install dust seal (2) and retaining ring (1) to
1. Place the axle lock cylinder onto the workbench
housing (7).
horizontally.
IMPORTANT: Apply hydraulic oil onto the inner
2. Remove socket bolts (10) (4 used) from operate
surface of housing (7), dust seals (2,
check valve (8). Remove operate check valve (8)
4), seal ring (5) and air ring (3).
and O-ring (9) from housing (7).
3. Install rod (6) to housing (7).
3. Apply air to the port hole on housing (7) and
remove rod (6). CAUTION: Axle lock cylinder weight: 38 kg
(84 lb)
4. Remove retaining ring (1) and dust seal (2) from
housing (7). 4. Install operate check valve (8) to housing (7) with
socket bolts (10) (4 used) and O-ring (9).
5. Remove air rings (3) (4 used), dust seal (4) and : 6 mm
seal ring (5) from housing (7). : 29.4 to 34.3 N⋅m
(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

W3-6-5
 UNDERCARRIAGE / Axle Lock Cylinder
(Blank)

W3-6-6
 UNDERCARRIAGE / Operate Check Valve
REMOVAL AND INSTALLATION OF
OPERATE CHECK VALVE (FOR AXEL
LOCK CYLINDER)

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
1 2
Removal 3, 4
1. Disconnect hoses (1) (2 used) from operate check
valve (3). Cap the open ends.
: 19 mm
5
2. Remove socket bolts (2) (4 used) from operate
check valve (3). Remove operate check valve (3)
and O-ring (4) from axle lock cylinder (5). Cap the
open ends.
: 6 mm

WCEB-03-06-001

Installation 1 2 3, 4
1. Apply grease onto O-ring (4). Install O-ring (4) to
operate check valve (3).

2. Install operate check valve (3) to axle lock cylinder

5
(5) with socket bolts (2) (4 used).
: 6 mm
: 29.4 to 34.3 N⋅m
(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

3. Connect hoses (1) (2 used) to operate check valve

(3).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

WCEB-03-06-001

W3-7-1
 UNDERCARRIAGE / Operate Check Valve
STRUCTURE OF OPERATE CHECK VALVE (FOR AXEL LOCK CYLINDER)

1 2 3 4 5 6 7 8 9 10 11 12 13

WCEB-03-06-004

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 : 6.2 2±0.5 (0.2±0.05) (1.5±0.4)
2 O-Ring 1 1A P11
3 Plug 1 : 27 120±12 (12±1.2) (89±9)
4 O-Ring 1 1B P18
5 Piston 1
6 Body 1
7 Poppet 1
8 Sleeve 1
9 Spring 1
10 O-Ring 1 1B P11
11 Plug 1 : 36 500±50 (51±5) (369±37)
12 O-Ring 1 1B P26
13 Plug 1 :6 34.3±3.4 (3.5±0.3) (25±2.5)

W3-7-2
 UNDERCARRIAGE / Solenoid Valve
REMOVAL AND INSTALLATION OF
OUTRIGGER / BLADE SOLENOID VALVE
UNIT

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.) Solenoid Valve Unit

IMPORTANT: One side of the solenoid valve unit Solenoid Valve Unit
cannot be removed. Remove the
plate (2) assembly.

Removal
1. Disconnect hoses (3) (8 used) from solenoid valve
units (4) (2 used). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm, 22 mm

2. Disconnect connectors (1) (4 used) from solenoid

W1F3-04-04-004
valve units (4) (2 used).

3. Remove sems bolts (7) (4 used) from plate (2).

Remove the plate (2) assembly from track frame 1 Solenoid Valve Unit 2 3 Solenoid Valve Unit
(6).
: 17 mm

4. Remove sems bolts (5) (4 used) from plate (2).

Remove solenoid valve units (4) (2 used) from 1
plate (2).
: 17 mm
3

7 3 6 4, 5 WCEB-03-08-001

W3-8-1
 UNDERCARRIAGE / Solenoid Valve
Installation
1. Install solenoid valve units (4) (2 used) to plate (2)
with sems bolts (5) (4 used). Solenoid Valve Unit
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) Solenoid Valve Unit

2. Install the plate (2) assembly to track frame (6)

with sems bolts (7) (4 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Connect hoses (3) (8 used) to solenoid valve units

(4) (2 used).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) W1F3-04-04-004

4. Connect connectors (1) (4 used) to solenoid valve

units (4) (2 used).
1 Solenoid Valve Unit 2 3
Solenoid Valve Unit

7 3 6 4, 5 WCEB-03-08-001

W3-8-2
 UNDERCARRIAGE / Solenoid Valve
STRUCTURE OF SOLENOID VALVE UNIT

T1F3-03-08-001
5

Wrench Size Tightening Torque

No. Part Name Q’ty Remarks
(mm) N·m (kgf·m) (lbf·ft)
1 Solenoid 2
2 Piston 2
3 O-Ring 2 1B P14
4 Body 1
5 Spool 2
6 Spring 2

W3-8-3
 UNDERCARRIAGE / Solenoid Valve
(Blank)

W3-8-4
 UPPERSTRUCTURE / Transmission Changeover Solenoid Valve
REMOVEAL AND INSTALLATION OF
TRANSMISSION CHANGEOVER
SOLENOID VALVE

CAUTION: Bleed air from the hydraulic oil

tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
1 2
Removal
1. Disconnect connectors (1) (2 used).

2. Disconnect hoses (2) (4 used) from transmission

changeover solenoid valve (3). Cap the open ends.
Attach an identification tag onto the disconnected
hoses for assembling.
: 19 mm

3. Remove socket bolts (4) (3 used) from WCEB-03-09-001

transmission changeover solenoid valve (3). 5 4 3
Remove transmission changeover solenoid valve
(3) from bracket (5).
: 6 mm

Installation 1 2
1. Install transmission changeover solenoid valve (3)
to bracket (5) with socket bolts (4) (3 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

2. Connect hoses (2) (4 used) to transmission

changeover solenoid valve (3).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Connect connectors (1) (2 used) to transmission 5 4 3

WCEB-03-09-001

changeover solenoid valve (3).

W3-9-1
 UPPERSTRUCTURE / Transmission Changeover Solenoid Valve
(Blank)

W3-9-2
 UNDERCARRIAGE / Propeller Shaft
REMOVAL AND INSTALLATION OF
PROPELLER SHAFT

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

2. Lower the blade and the outrigger onto the ground.

3. Place the blocks in front of and behind the axle in

order to secure the machine.
WCEB-03-10-006

Removal
1. Remove grease fitting (3) from propeller shaft (1).
: 10 mm
A
B
IMPORTANT: Propeller shaft (1) cannot be C
removed individually. If removing
propeller shaft (1) individually, spline
seal (2) is damaged. Remove the WCEB-03-10-001

propeller shaft (1) assembly. 1

2 3 WCEB-03-10-007

Detail B

1 4 5

2. Remove nuts (4) (8 used) from flange (5).

: 14 mm
6
3. Insert a screwdriver between flange (5) and shaft
(6). Remove the propeller shaft (1) assembly from
shaft (6). Lower one side of the propeller shaft (1)
assembly onto the ground.

Detail C WCEB-03-10-003

W3-10-1
 UNDERCARRIAGE / Propeller Shaft
7 8 9 1
4. Remove nuts (9) (8 used) from flange (8).
: 14 mm

5. Insert a screwdriver between flange (8) and shaft

(7). Remove the propeller shaft (1) assembly from
shaft (7).

Detail A WCEB-03-10-002

6. Remove grease fitting (10) from propeller shaft

(12).
: 10 mm

IMPORTANT: Propeller shaft (12) cannot be

removed individually. If removing
A
propeller shaft (12) individually,
spline seal (11) is damaged. Remove D
the propeller shaft (12) assembly. E

WCEB-03-10-001

10 11 12

Detail E
WCEB-03-10-008

7. Remove nuts (15) (8 used) from flange (14).

: 14 mm
13 14 15 12
8. Insert a screwdriver between flange (14) and shaft
(13). Remove the propeller shaft (12) assembly
from shaft (13). Lower one side of the propeller
shaft (12) assembly onto the ground.

Detail D WCEB-03-10-004

W3-10-2
 UNDERCARRIAGE / Propeller Shaft
9. Remove nuts (16) (8 used) from flange (17).
: 14 mm

10. Insert a screwdriver between flange (17) and shaft

(18). Remove the propeller shaft (12) assembly
from shaft (18).

F
WCEB-03-10-001

12 16 17 18

Details F WCEB-03-10-005

Installation
1. Align flange (17) of the propeller shaft (12)
assembly with the mounting part of shaft (18).
Secure flange (17) to shaft (18) with nuts (16) (8
used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
D
F
WCEB-03-10-001

12 16 17 18

Details F WCEB-03-10-005

13 14 15 12
2. Align flange (14) of the propeller shaft (12)
assembly with the mounting part of shaft (13).
Secure flange (14) to shaft (13) with nuts (15) (8
used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

Details D WCEB-03-10-004

W3-10-3
 UNDERCARRIAGE / Propeller Shaft
3. Align flange (5) of the propeller shaft (1) assembly
with the mounting part of shaft (6). Secure flange
(5) to shaft (6) with nuts (4) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

A
C

WCEB-03-10-001

1 4 5

WCEB-03-10-003
Detail C

4. Align flange (8) of the propeller shaft (1) assembly 7 8 9 1

with the mounting part of shaft (7). Secure flange
(8) to shaft (7) with nuts (9) (8 used).
: 14 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

Detail A WCEB-03-10-002

5. Install grease fittings (3, 10) to propeller shafts (1,

12). Apply grease.
： 10 mm

3 WCEB-03-10-007

10 12

WCEB-03-10-008

W3-10-4
 MEMO

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 MEMO

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 SECTION 4
FRONT ATTACHMENT

— CONTENTS —
Group 1 Front Attachment Group 3 Hose Rupture Valve
Hydraulic Circuit Pressure Hydraulic Circuit Pressure
Release Procedure .............................. W4-1-1 Release Procedure ...............................W4-3-1
Removal and Installation of Removal and Installation of Hose
Front Attachment (Monoblock Boom) .. W4-1-2 Rupture Valve for Arm Cylinder ............W4-3-2
Removal and Installation of Removal and Installation of Hose Rupture
Front Attachment (2-Piece Boom)...... W4-1-11 Valve for Positioning Cylinder ...............W4-3-3
Maintenance Standard ......................... W4-1-20 Removal and Installation of Hose
Standard Dimensions for Rupture Valve for Boom Cylinder .........W4-3-5
Arm and Bucket Connection .............. W4-1-23 Structure of Hose Rupture Valve
Standard Dimensions for for Arm Cylinder ....................................W4-3-8
Arm and Boom Connection ................ W4-1-24 Structure of Hose Rupture Valves
for Boom and Positioning Cylinders ...W4-3-12
Group 2 Cylinder
Hydraulic Circuit Pressure Group 4 Operate Check Valve
Release Procedure .............................. W4-2-1 Remove and Install Operate Check
Removal and Installation of Cylinder ..... W4-2-2 Valve (for Blade and Outrigger) ............W4-4-1
Disassembly of Boom, Arm and Structure of Operate Check Valve ..........W4-4-3
Bucket Cylinders ................................ W4-2-26
Assembly of Boom, Arm and
Bucket Cylinders ................................ W4-2-32
Disassembly of Positioning Cylinder.... W4-2-38
Assembly of Positioning Cylinder ........ W4-2-42
Disassembly of Outrigger and
Blade Cylinders .................................. W4-2-46
Assembly of Outrigger and
Blade Cylinder .................................... W4-2-48
Maintenance Standard ......................... W4-2-54

CEBW-4-1
(Blank)

CEBW-4-2
 FRONT ATTACHMENT / Front Attachment
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE

NOTE: Operate the pilot pump by using the power

from the battery without starting the engine
and deliver the pilot pressure to the spool
of the control valve.

1. Turn the pilot shut-off lever to the UNLOCK posi-

tion.

2. Turn the engine stop switch ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.

IMPORTANT: The battery will deplete. Operate the

key switch for short period.
3. With the key switch in the START position, oper- WCEB-02-01-002
Engine Stop Switch
ate the lever 4 to 5 times in order to release any
pressure in the hydraulic circuit.

4. Return the pilot shut-off lever to the LOCK posi-

tion.

5. Turn the engine stop switch OFF.

W4-1-1
 FRONT ATTACHMENT / Front Attachment
REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT (MONOBLOCK
BOOM)

Removal 1 1
1. As for the lubrication hoses to the front attach-
ment, disconnect hoses (1) (2 used) to the boss
at the boom cylinder (3) rod side from the
adapter.
: 17 mm

WCGB-04-01-001

2. Remove nuts (7) (4 used) from bolts (4) (2 used).

Remove bolts (4) (2 used) and stoppers (5) (2
1 2 3 4
used) from pin (6).
: 24 mm
5
CAUTION: Boom cylinder (3) weight: 110 kg
(243 lb) 6
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec- 7
tion, such as goggles, hard hats, etc in order
to prevent personal injury.
WCGB-04-01-002
3. Attach a nylon sling onto the end of the boom
cylinder (3) tube. Hoist and hold the boom cylin-
der (3) tube. By using a bar and a hammer, tap
pin (6) into the position where thrust plate (2) can
be removed. Remove thrust plate (2).
NOTE: When pin (6) cannot be removed, start the
engine and operate the boom lever. Adjust
the rod pin hole on the boom cylinder.

W4-1-2
 FRONT ATTACHMENT / Front Attachment
4. Place the tube end of boom cylinder (3) on a
stand of 1 m (39 in) height.
Start the engine. Operate the boom lever and re- Stand
tract boom cylinder (3). 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.
3
Wire
5. Remove boom cylinder (3) from the boom.
Refer to Removal of Boom Cylinder on W4-2-10.

6. Remove other boom cylinder (3) in the same way

as steps 3, 4 and 5.
W554-02-03-007

CAUTION: Do not stand toward the removal 2 3

direction of the pins as the pins may come
off suddenly.

7. Slowly tap and remove pin (6) by using a bar and

a hammer. Remove thrust plate (2).
6
8. After stopping the engine, push the air bleed
valve. Bleed air from the hydraulic oil tank and
remove the cap.
Release the pressure in the hydraulic circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE WCGB-04-01-002
RRLEASE PROCEDURE on W4-1-1. Air Bleed Valve

Cap

Hydraulic
Oil Tank

9. Disconnect hoses (8, 9) (2 used for each) from WCEB-04-01-002

the bucket cylinder and the arm cylinder. Cap the

disconnected hoses and pipes.
: 36 mm

NOTE: The number of the hoses may differ de-

pending on the front attachment specifica-
tions.

W1F3-04-01-010

8 9

W4-1-3
 FRONT ATTACHMENT / Front Attachment
10. Open cover (10).

10

WCEB-02-05-002

11. Remove sems bolts (12) (6 used) from cover (13). 12

Remove cover (13) from cover (11), support (18)
and bracket (14).
: 17 mm 13
11
12. Remove sems bolts (17) (3 used) from cover (15). 14
Remove cover (15) from cover (16).
: 17 mm
15

WCEB-02-05-001
17 16
18

WCEB-02-05-003

14

WCEB-02-05-004

W4-1-4
 FRONT ATTACHMENT / Front Attachment

CAUTION: Boom foot pin (21) weight: 23 kg 19

(51 lb)
20
13. Remove nuts (22) (2 used) from bolt (19). Re-
move bolt (19) from main frame (20). 21
: 30 mm
22

WCEB-04-01-001

CAUTION: Front attachment weight: 2000 kg Boom

(4410 lb)

14. Attach a wire rope onto the boom. Hoist and hold
the boom.

CAUTION: Boom foot pin (21) weight: 23 kg

(51 lb) WCEB-02-03-001

15. Install the bolt (M20, Pitch 2.5 mm) to boom foot
pin (21). Attach a pry bar onto the bolt head. Pull
out boom foot pin (21).
: 30 mm
20
16. While turning the bolt gradually by hand, remove
boom foot pin (21) from main frame (20). 21
NOTE: When boom foot pin (21) cannot be re-
moved, adjust the position by using a lifting
rope for the front attachment.
WCEB-04-01-001
17. Hoist the front attachment assembly and move
the machine backward.

18. Place a wooden block. Lower the front attach-

ment assembly onto the wooden block.

W4-1-5
 FRONT ATTACHMENT / Front Attachment
Installation

Boom
CAUTION: Front attachment weight: 2000 kg
(4410 lb)

1. Hoist the front attachment assembly and move

the machine forward. Align the boom foot with the
mounting hole on main frame (20).
Insert a thrust plate into the left and right sides of
the boom. Adjust the clearance between the plate
and main frame (20) within 1 mm (0.04 in).
(Adjust the position by using a lifting rope for the
front attachment.)
WCEB-02-03-001

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec- 19
tion, such as goggles, hard hats, etc in order
to prevent personal injury. 20
CAUTION: Boom foot pin (21) weight: 23 kg
(51 lb) 21

2. Align the lock holes on foot pin (21) and the collar 22
hole on main frame (20). Install boom foot pin
(21). Secure boom foot pin (21) to main frame
(20) with bolt (19) and nuts (22) (2 used). WCEB-04-01-001

: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf⋅ft)
17

15

3. Install cover (15) to cover (16) with sems bolts

(17) (3 used).
: 17 mm 16 WCEB-02-05-008
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W4-1-6
 FRONT ATTACHMENT / Front Attachment
4. Install cover (13) to cover (11), support (18) and
12
bracket (14) with sems bolts (12) (6 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
13
11
14

WCEB-02-05-001

18

WCEB-02-05-003

14

WCEB-02-05-004

5. Shut cover (10).

10

WCEB-02-05-002

W4-1-7
 FRONT ATTACHMENT / Front Attachment
6. Remove the caps from the hoses and the pipes.
Connect hoses (8, 9) (3 used for each) to the
bucket cylinder and the arm cylinder.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

W1F3-04-01-010

8 9

CAUTION: Boom cylinder (3) weight: 110 kg

(243 lb)

7. Install boom cylinder (3).

Refer to Installation of Boom Cylinder on
W4-2-12.
Wire

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury. 3

8. Remove the wire from boom cylinder (3). Attach a

nylon sling onto the end of the boom cylinder (3)
WCEB-04-01-003
tube. Hoist and align the boom cylinder (3) tube
with the mounting hole on the boom.
6 2
9. Insert thrust plate (2) between the boom and
boom cylinder (3), and between boom cylinder
(3) and collar (5). Install pin (6). Install boom cyl-
3
inder (3) to the both sides.
4
10. Install stoppers (5) (2 used) to pin (6). Secure
stoppers (5) (2 used) to pin (6) with bolts (4) (2
used) and nuts (7) (4 used).
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)
5
7
W178-04-01-004

W4-1-8
 FRONT ATTACHMENT / Front Attachment
11. Connect lubrication hoses (1) (2 used) to the
boom cylinder (3) rod side. 1 1
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

3 3

WCGB-04-01-001

Left Boom Cylinder Arm Cylinder Right Boom

Rod Side Bottom Side Cylinder
Boom Foot Side Rod Side
12. Apply grease onto the boom cylinder (3) rod side,
the bottom side and the boom foot side.

WCGB-04-01-004

W4-1-9
 FRONT ATTACHMENT / Front Attachment
IMPORTANT: When removing the arm from the
boom, perform the following steps
when installing the arm.
13. Install thrust plates (23) to the left and right sides
of the arm. Adjust total clearance of left and right
within 1.5 mm (0.06 in). Boom

14. After installing the arm, apply grease onto grease Arm
fitting (24) in the boom connecting boss of the
arm.

IMPORTANT: For handling of HN bushing for the

front attachment, check the follow-
ings.
Precautions when installing the bushing
If a hammer is used, the bushing may be damaged.
Use a press. WCEB-02-03-001

Precautions when reinforcing the arm

The heat when welding in order to reinforce the arm
may cause oil leakage from HN bushing and decrease
lubrication performance.
When the welding heat causes the oil leakage of the
bushing, replace the bushing.

Use the special tool when removing or installing the

bushing.
Special tool: ST 1454 23 23

24 24

M157-07-157

W4-1-10
 FRONT ATTACHMENT / Front Attachment
REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT (2-PIECE BOOM)
1 1
Removal
1. As for the lubrication hoses to the front attach-
ment, disconnect hoses (1) (2 used) of to the
boss at the boom cylinder (3) rod side from the
adapter.
: 17 mm

WCGB-04-01-001

1 2 3 4
2. Remove nuts (7) (4 used) from bolts (4) (2 used).
Remove bolts (4) (2 used) and stoppers (5) (2
used) from pin (6).
5
: 24 mm

6
CAUTION: Boom cylinder (3) weight: 130 kg
(290 lb)
7
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
WCGB-04-01-002
to prevent personal injury.
3. Attach a nylon sling onto the end of the boom
cylinder (3) tube. Hoist and hold the boom cylin-
der (3) tube. By using a bar and a hammer, tap
pin (6) into the position where thrust plate (2) can 2, 6 4, 5 1
be removed. Remove thrust plate (2).
NOTE: When pin (6) can not be removed, start the
engine and operate the boom lever. Adjust
the rod pin hole on the boom cylinder.

7 3

WCEB-04-01-004

W4-1-11
 FRONT ATTACHMENT / Front Attachment
4. Place the tube end of boom cylinder (3) on a
stand of 1 m (39 in) height.
Start the engine. Operate the boom lever and re- Stand
tract boom cylinder (3). 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.
3
Wire
5. Remove boom cylinder (3) from the boom.
Refer to Removal of Boom Cylinder on W4-2-10.

6. Remove other boom cylinder (3) in the same way

as steps 3, 4 and 5.
W554-02-03-007

CAUTION: Do not stand toward the removal

direction of the pins as the pins may come 2 3
off suddenly.

7. Slowly tap and remove pin (6) by using a bar and

a hammer. Remove thrust plate (2).
6
8. After stopping the engine, push the air bleed val-
ve. Bleed air from the hydraulic oil tank and re-
move the cap.
Release the pressure in the hydraulic circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE WCGB-04-01-002
RRLEASE PROCEDURE on W4-1-1. Air Bleed Valve

9. Disconnect hoses (8) (4 used) and hoses (9) (3

used) from the bucket cylinder, the arm cylinder
Cap
and the positioning cylinder. Cap the discon-
nected hoses.
: 36 mm
NOTE: The number of the hoses may differ de-
pending on the front attachment specifica- Hydraulic
tions. Oil Tank

WCEB-04-01-002

8 8

9 9 WCGB-04-01-003

W4-1-12
 FRONT ATTACHMENT / Front Attachment
10. Open cover (10).

10

WCEB-02-05-002

11. Remove sems bolts (12) (6 used) from cover (13).

12
Remove cover (13) from cover (11), support (18)
and bracket (14).
: 17 mm
11 13

12. Remove sems bolts (17) (3 used) from cover (15).

Remove cover (15) from cover (16). 14
: 17 mm

15

WCEB-02-05-001
17 16

18

WCEB-02-05-003

14

WCEB-02-05-004

W4-1-13
 FRONT ATTACHMENT / Front Attachment

CAUTION: Boom foot pin (21) weight: 23 kg 19

(51 lb)
20
13. Remove nuts (22) (2 used) from bolt (19). Re-
move bolt (19) from main frame (20).
21
: 30 mm

22

WCEB-04-01-001

CAUTION: Front attachment weight: 2415 kg

Boom
(5324 lb)

14. Attach a wire rope onto the boom. Hoist and hold
the boom.

WCEB-02-03-002

CAUTION: Boom foot pin (21) weight: 23 kg

(51 lb)

15. Install the bolt (M20, Pitch 2.5 mm) to boom foot
20
pin (21). Attach a pry bar onto the bolt head. Pull
out boom foot pin (21).
: 30 mm 21

16. While turning the bolt gradually by hand, remove

boom foot pin (21) from main frame (20).
NOTE: When boom foot pin (21) cannot be re- WCEB-04-01-001

moved, adjust the position by using a lifting

rope for the front attachment.

17. Hoist the front attachment assembly and move

the machine backward.

18. Place a wooden block. Lower the front attach-

ment assembly onto the wooden block.

W4-1-14
 FRONT ATTACHMENT / Front Attachment
Installation

Boom
CAUTION: Front attachment weight: 2415 kg
(5324 lb)

1. Hoist the front attachment assembly and move

the machine forward. Align the boom foot with the
mounting hole on main frame (20).
Insert a thrust plate into the left and right sides of
the boom. Adjust the clearance between the plate
and main frame (20) within 1 mm (0.04 in).
(Adjust the position by using a lifting rope for the
front attachment.)
WCEB-02-03-002

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec- 19
tion, such as goggles, hard hats, etc in order
to prevent personal injury. 20

CAUTION: Boom foot pin (21) weight: 23 kg 21

(51 lb)
22
2. Align the lock holes on foot pin (21) and the collar
hole on main frame (20). Install boom foot pin
(21). Secure boom foot pin (21) to main frame WCEB-04-01-001

(20) with bolt (19) and nuts (22) (2 used).

: 30 mm 17
: 550 N⋅m (56 kgf⋅m, 410 lbf⋅ft)
15
3. Install cover (15) to cover (16) with sems bolts
(17) (3 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

16 WCEB-02-05-008

W4-1-15
 FRONT ATTACHMENT / Front Attachment
4. Install cover (13) to cover (11), support (18) and 12
bracket (14) with sems bolts (12) (6 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 11 13

14

WCEB-02-05-001

18

WCEB-02-05-003

14

WCEB-02-05-004

5. Shut cover (10).

10

WCEB-02-05-002

W4-1-16
 FRONT ATTACHMENT / Front Attachment
6. Remove the caps from the hoses and the pipes. 8 8
Connect hoses (8) (4 used) and hoses (9) (3
used) to the bucket cylinder and the arm cylinder.
: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

9 9 WCGB-04-01-003

CAUTION: Boom cylinder (3) weight: 130 kg

(290 lb)

7. Install boom cylinder (3).

Refer to Installation of Boom Cylinder on Wire
W4-2-12.

CAUTION: Metal fragments may fly off when 3

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.
WCEB-04-01-003

2 3 4
8. Remove the wire from boom cylinder (3). Attach a
nylon sling onto the end of the boom cylinder (3)
tube. Hoist and align the boom cylinder (3) tube 5
with the mounting hole on the boom.
6
9. Insert thrust plate (2) between the boom and
boom cylinder (3), and between boom cylinder 7
(3) and collar (5). Install pin (6). Install boom cyl-
inder (3) to the both sides.

10. Install stoppers (5) (2 used) to pin (6). Secure WCGB-04-01-002

stoppers (5) (2 used) to pin (6) with bolts (4) (2

used) and nuts (7) (4 used). 2, 6 4, 5
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf⋅ft)

7 3

WCEB-04-01-004

W4-1-17
 FRONT ATTACHMENT / Front Attachment
11. Connect lubrication hoses (1) (2 used) to the 1
boom cylinder (3) rod side.
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

WCEB-04-01-004

1 3

WCGB-04-01-002

12. Apply grease onto the boom cylinder (3) rod side,
the bottom side and the boom foot side.

Second Boom Foot Right

Second Boom Foot Left
Arm Cylinder Bottom Side
Boom Cylinder Rod Side
Left Boom Foot Side
Right Boom Foot Side

WCEB-04-01-007

W4-1-18
 FRONT ATTACHMENT / Front Attachment
IMPORTANT: When removing the arm from the
boom, perform the following steps
when installing the arm.
13. Install thrust plates (23) to the left and right sides Boom
of the arm. Adjust total clearance of left and right
within 1.5 mm (0.06 in). Arm

14. After installing the arm, apply grease onto grease

fitting (24) in the boom connecting boss of the
arm.

IMPORTANT: For handling of HN bushing for the

front attachment, check the follow-
ings.
Precautions when installing the bushing WCEB-02-03-002
If a hammer is used, the bushing may be damaged.
Use a press.
Unit: mm (in)
+1.0 +0.04
Precautions when reinforcing the arm 268 -0 (10.6 -0 )
The heat when welding in order to reinforce the arm
may cause oil leakage from HN bushing and decrease
lubrication performance.
When the welding heat causes the oil leakage of the
bushing, replace the bushing.

Use the special tool when removing or installing the

bushing.
Special tool: ST 1454

23 23

W1GL-04-01-012

24

W1GL-04-01-011

W4-1-19
 FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARD

Pin and Bushing

F
N
C
A
L M
E
B
D

G I K
J
H WCEB-02-03-001
WCEB-02-03-002

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
Pin 71 (2.8) 70.0 (2.8)
A
Bushing 71 (2.8) 72.5 (2.9)
Pin 80 (3.1) 79.0 (3.1)
B Boss (Main Frame) 80 (3.1) 81.5 (3.2)
Bushing (Boom Cylinder) 80 (3.1) 81.5 (3.2)
Pin 71 (2.8) 70.0 (2.8)
C Bushing (Boom Cylinder) 71 (2.8) 72.5 (2.9)
Boss (Boom) 71 (2.8) 72.5 (2.9)
Replace
Pin 71 (2.8) 70.0 (2.8)
D
Bushing 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
E Boss (Arm) 71 (2.8) 72.5 (2.9)
Bushing (Arm Cylinder) 71 (2.8) 72.5 (2.9)
Pin 71 (2.8) 70.0 (2.8)
F Boss (Boom) 71 (2.8) 72.5 (2.9)
Bushing (Arm Cylinder) 71 (2.8) 72.5 (2.9)

W4-1-20
 FRONT ATTACHMENT / Front Attachment

Unit: mm (in)
Part Name Standard Allowable Limit Remedy
Pin 60 (2.4) 59.0 (2.3)
G Boss (Arm) 60 (2.4) 61.5 (2.4)
Bushing (Bucket Cylinder) 60 (2.4) 61.5 (2.4)
Pin 65 (2.6) 64.0 (2.5)
H Bushing 65 (2.6) 66.5 (2.6)
Bushing (Bucket Cylinder) 65 (2.6) 66.5 (2.6)
Pin 65 (2.6) 64.0 (2.5)
I
Bushing 65 (2.6) 66.5 (2.6)
Pin 65 (2.6) 64.0 (2.5)
J Replace
Bushing 65 (2.6) 66.5 (2.6)
Pin 65 (2.6) 64.0 (2.5)
K
Bushing 65 (2.6) 66.5 (2.6)
Pin 80 (3.1) 79.0 (3.1)
L
Bushing 80 (3.1) 81.5 (3.2)
Pin 80 (3.1) 79.0 (3.1)
M
Bushing 80 (3.1) 81.5 (3.2)
Pin 71 (2.8) 70.0 (2.8)
N
Bushing 71 (2.8) 72.5 (2.9)

IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a
press and special tool (ST 1454).

W4-1-21
 FRONT ATTACHMENT / Front Attachment
Point

B C

W105-04-01-020

Unit: mm (in)
Standard Allowable Limit Remedy
A 178.5 (7) 90 (3.5)
B 79 (3.1) -
Replace
C 95 (3.7) -
D 81 (3.2) -

Side Cutter

C
D

W155-04-01-002

Unit: mm (in)
Standard Allowable Limit Remedy
A 229 (9) 149 (5.9)
B 245 (9.6) -
Replace
C 330 (13) -
D 135 (5.3) -

W4-1-22
 FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION

Section B
Section A
W1CF-04-01-007

Unit: mm (in)
a 352 (1.9)
b 10 (0.4)
c 505 (7.9)
d 460 (6.1)
e -
f 1230 (48)
g 377 (19)
h 255 (10)
i 65 (2.6)
j 362 (14)
k 70 (2.8)
l 377 (19)
m 255 (14)
n 65 (2.6)
o 90°
p 30°
q 398 (16)

W4-1-23
 FRONT ATTACHMENT / Front Attachment
STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION

WCEB-04-01-005

WCEB-04-01-006

Section C

W1GL-04-01-010

Unit: mm (in)
s 71 (2.8)
t 268 (10.6)
u 428 (17)

W4-1-24
 FRONT ATTACHMENT / Cylinder
HYDRAULIC CIRCUIT PRESSURE RE-
LEASE PROCEDURE

NOTE: Operate the pilot pump by using the power

from the battery without starting the engine
and deliver the pilot pressure to the spool
of the control valve.

1. Turn the pilot shut-off lever to the UNLOCK posi-

tion.

2. Turn the engine stop switch ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.

IMPORTANT: The battery will deplete. Operate the

key switch for short period.
3. With the key switch in the START position, oper- WCEB-02-01-002
Engine Stop Switch
ate the lever 4 to 5 times in order to release any
pressure in the hydraulic circuit.

4. Return the pilot shut-off lever to the LOCK posi-

tion.

5. Turn the engine stop switch OFF.

W4-2-1
 FRONT ATTACHMENT / Cylinder
REMOVAL AND INSTALLATION OF CYL-
INDER
1
Removal of Bucket Cylinder

1. Insert wooden block (3) between the ground and

the end of arm (2), and between arm (2) and
bucket cylinder (1). 3

2. Stop the engine. Push the air bleed button and 2

bleed air from the hydraulic oil tank. Remove the 3
cap.
Release the pressure in the bucket circuit. W554-04-02-006

Refer to HYDRAULIC CIRCUIT PRESSURE

RELEASE PROCEDURE on W4-2-1.

CAUTION: Before removing pin (7), fasten

the link by using a wire in order not to fall
off.
CAUTION: Metal fragments may fly off when 4 5
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

3. Remove nuts (6) (2 used) and bolt (4). Remove

pin (7) by tapping. Remove thrust plates (5) (4
used).
: 24 mm

4. In order not to extend rod (8) of bucket cylinder

7 6
(1), pass wire (9) through the cylinder rod hole
and secure to the bucket cylinder (1) tube. W158-04-02-006
8 1

9 W102-04-02-005

W4-2-2
 FRONT ATTACHMENT / Cylinder
5. Disconnect bucket cylinder hoses (12) (2 used)
10
at the bottom of bucket cylinder (1). Cap the open
ends
: 27 mm

CAUTION: Bucket cylinder (1) weight: 100

kg (220 lb) 15
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec- 11
tion, such as goggles, hard hats, etc in order 13
to prevent personal injury.

6. Hoist and hold bucket cylinder (1). Remove nuts

(13) (2 used) and bolt (15). Remove pin (11) by
tapping. Remove thrust plates (10) (2 used). 1
: 24 mm

7. Remove bucket cylinder (1).

12 W187-04-02-004

W4-2-3
 FRONT ATTACHMENT / Cylinder
Installation of Bucket Cylinder
10
IMPORTANT: If a hammer is used when installing
the bushing, the bushing may be
damaged. Use a press.

CAUTION: Bucket cylinder (1) weight: 100 15

kg (220 lb)
14
CAUTION: Metal fragments may fly off when 11
a hammer is used when installing pin (11). 13
Wear necessary protection, such as goggles,
hard hats, etc in order to prevent personal
injury.

1. Hoist bucket cylinder (1). Align the hole on the 1

Arm
cylinder tube side with the cylinder mounting hole
on the arm. Install thrust plates (10) (2 used) and
pin (11).

2. Install stopper (14) and pin (11) to the arm. Se- 12 W187-04-02-004

cure with bolt (15) and nuts (13) (2 used).

: 24 mm
: 180 N⋅m (18.5 kgf⋅m, 133 lbf·ft) 8 1

3. Connect bucket cylinder hoses (12) (2 used).

: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf·ft)

4. Remove wire (9) from rod (8) of bucket cylinder

(1).

9 W102-04-02-005

W4-2-4
 FRONT ATTACHMENT / Cylinder

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec- 16 4 17 5
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

5. Start the engine. Operate the lever and align the

hole on the bucket cylinder (1) rod side with
those on links (16, 18). Install thrust plates (5) (4
used) and pin (7).

6. Secure stopper (17) and pin (7) with bolt (4) and
7 18 6
nuts (6) (2 used).
: 24 mm W158-04-02-006

: 270 N⋅m (27 kgf⋅m, 200 lbf·ft)

IMPORTANT: In case link (18) has been removed

19 19
from the arm, insert thrust plate (19)
when installing link (18).
IMPORTANT: After completing the work, add hy-
draulic oil to the specified level.
Operate bucket cylinder (1) fully to
the stroke end several times and
bleed air from the circuit.
At the same time, check each con- W157-04-01-015
18 18
nection of the hoses for any oil
leaks.

W4-2-5
 FRONT ATTACHMENT / Cylinder
Removal of Arm Cylinder
1
1. Insert wooden block (3) between arm cylinder (1)
and boom (2).

2. Stop the engine. Push the air bleed button and

bleed air from the hydraulic oil tank. Remove the
2
cap.
Release the pressure in the arm circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.
3 W187-04-02-005

3. Remove nuts (8) (2 used) and bolt (10) from pin 10 4 5

(5) at the rod side in arm cylinder (1).
: 30 mm
1

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

4. Remove pin (5) by tapping. Remove thrust plates

(4) (4 used).
8

W187-04-02-006

6 1
5. In order not to extend rod (6) of arm cylinder (1),
pass wire (7) through the cylinder rod hole and
secure to the arm cylinder (1) tube.

7 W187-04-02-010

W4-2-6
 FRONT ATTACHMENT / Cylinder
6. Disconnect pipings (11) (2 used) at the bottom of
1
arm cylinder (1). Cap the open ends. (When a
hose rupture valve is provided, refer to RE-
MOVAL AND INSTALLATION OF HOSE RUP- 11
TURE VALVE on W4-3-1.)
: 36 mm

7. Disconnect lubrication hose (12) from arm cylin-

der (1).
: 19 mm 12

CAUTION: Arm cylinder (1) weight: 160 kg

(360 lb)
WCGB-04-01-001
8. Attach a nylon sling at the center of gravity of arm
cylinder (1). Hoist and hold arm cylinder (1).
1

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

9. Remove nuts (15) (2 used) and bolt (17) from the

tube side in arm cylinder (1). Remove pin (14).
Remove thrust plate (13). Hoist and remove arm
cylinder (1).
: 30 mm W102-04-02-016

17 13 14

15

W187-04-02-007

W4-2-7
 FRONT ATTACHMENT / Cylinder
Installation of Arm Cylinder
17 13 14
IMPORTANT: If a hammer is used when installing
the bushing, the bushing may be 1
damaged. Use a press.
CAUTION: Arm cylinder (1) weight: 160 kg
(360 lb)
16
15
1. Attach a nylon sling at the center of gravity of arm
cylinder (1). Hoist arm cylinder (1). Align the hole
on the cylinder tube side hole with the cylinder
mounting hole on the boom.
W187-04-02-007

1
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order 11
to prevent personal injury.

2. Install thrust plate (13) and pin (14). Secure pin

(14) and stopper (16) with bolt (17) and nuts (15)
(2 used).
12
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

3. Connect lubrication hose (12) and pipings (11) (2

used) of arm cylinder (1).
: 19 mm WCGB-04-01-001

: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)

: 36 mm
: 175 N⋅m (18 kgf⋅m, 129 lbf·ft)

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine and check for
any oil leaks at the hose connec-
tions.

W4-2-8
 FRONT ATTACHMENT / Cylinder
4. Remove wire (7) from rod (6) of arm cylinder (1).
6 1
Hold arm cylinder (1) and start the engine. Oper-
ate the lever and align the hole at the rod (6) side
with the mounting hole on arm (18).

1
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.
3
5. Install thrust plate (4) and pin (5). Secure pin (5) W187-04-02-010

and stopper (9) with bolt (10) and nuts (8) (2 9 10 4 5

used).
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

IMPORTANT: When completing the work, operate

arm cylinder (1) to the stroke end 18
several times and bleed air from the
circuit.

W187-04-02-006

W4-2-9
 FRONT ATTACHMENT / Cylinder
Removal of Boom Cylinder
1
1. Disconnect lubrication hose (1) from boom cylin-
der (2).
: 19 mm

CAUTION: Boom cylinder (2) weight:

Monoblock boom: 110 kg (250 lb)
2-piece boom: 125 kg (280 lb)
2
2. Attach a wire rope onto boom cylinder (2). Hoist
Boom
and hold boom cylinder (2). WCGB-04-01-002

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

3. Remove nuts (5) (2 used), bolt (7) and stopper

(6) from the boom cylinder (2) rod side. Remove
pin (4) by tapping. Remove thrust plates (3) (2 7
used).
: 24 mm

4. Place the rod side of boom cylinder (2) on a

stand. Remove other boom cylinder (2) in the
same way.
6
5. Operate the lever and retract boom cylinder (2). 5 3 4 3 2
In order not to extend the rod, pass a wire W158-04-02-013
through the rod hole and secure to the cylinder
tube.

6. Stop the engine. Push the air bleed button and

bleed air from the hydraulic oil tank.
Release the pressure in the circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.

2
Stand

W105-04-02-035

W4-2-10
 FRONT ATTACHMENT / Cylinder
7. Disconnect hoses (12) (4 used) at the bottom of
boom cylinder (2). Attach a plug onto the open
end of the hose. Cap the open end of boom cyl-
inder (2). (When a hose rupture valve is provided,
refer to REMOVEAL AND INSTALLATION OF
HOSE RUPTURE VALVE on W4-3-1.)
Plug 1 3/16-12UN
: 36 mm

CAUTION: Metal fragments may fly off when 2

a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order W105-04-02-036
to prevent personal injury.
2 8
11
8. Remove nuts (10) (2 used) and bolt (8) from the
cylinder bottom side of the main frame.
Remove pin (9) by tapping. Remove thrust plate
(11).
(Monoblock boom)
: 24 mm
(2-piece boom) 9
: 30 mm
9 10

CAUTION: Boom cylinder (2) weight: 12 10

Monoblock boom: 110 kg (250 lb) W178-04-02-009

2-piece boom: 125 kg (280 lb)

9. Attach a wire rope at the center of gravity of

boom cylinder (2). Hoist and remove boom cyl-
inder (2).
Remove other boom cylinder (2) in the same
way.

W105-04-02-040

W4-2-11
 FRONT ATTACHMENT / Cylinder
Installation of Boom Cylinder

CAUTION: Boom cylinder (2) weight:

Monoblock boom: 110 kg (250 lb)
2-piece boom: 125 kg (280 lb)

IMPORTANT: If a hammer is used when installing

the bushing, the bushing may be
damaged. Use a press.
1. Attach a wire rope at the center of gravity of
boom cylinder (2). Hoist boom cylinder (2). Align
the hole at the boom cylinder tube side with the
mounting hole on the main frame.

CAUTION: Metal fragments may fly off when 2

a hammer is used. Wear necessary protec-
W105-04-02-040
tion, such as goggles, hard hats, etc in order
to prevent personal injury.
2 8
2. Install thrust plate (11) and pin (9). Secure with 11
bolt (8) and nuts (10) (2 used).
(Monoblock boom)
: 24 mm
: 270 N⋅m (27.5 kgf⋅m, 200 lbf·ft)
(2-piece boom)
: 30 mm
: 550 N⋅m (56 kgf⋅m, 406 lbf·ft) 9

3. Install other boom cylinder (2) in the same way. 9 10

4. Connect hoses (12) (4 used) to boom cylinders 12 10

W178-04-02-009
(2) (2 used).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf·ft)

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine and check for
any oil leaks at the hose connec-
tions.

W4-2-12
 FRONT ATTACHMENT / Cylinder
5. Hoist boom cylinder (2). Start the engine. Oper-
ate the lever and align the hole at the cylinder rod
side with the mounting hole on the boom.
7
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

6. Insert thrust plate (3) and install pin (4).

6
7. Secure pin (4) and stopper (6) with bolt (7) and 5 3 4 3 2
nut (5). W158-04-02-013
: 24 mm
: 270 N⋅m (27 kgf⋅m, 200 lbf·ft)
1 7
8. Connect lubrication hose (1).
: 19 mm 4
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
6
9. Install other boom cylinder (2) in the same way.
5
IMPORTANT: When completing the work, operate
boom cylinder (2) to the stroke end
several times and bleed air from the
2
circuit.
Boom WCGB-04-01-002

W4-2-13
 FRONT ATTACHMENT / Cylinder
Removal of Positioning Cylinder
(2-Piece Boom Only)

1. Disconnect lubrication hose (1) from positioning

cylinder (2).
: 19 mm

CAUTION: Positioning cylinder (2) weight:

185 kg (410 lb)
2 1
WCCB-04-01-009
2. Attach a nylon sling onto positioning cylinder (2).
Hoist and hold positioning cylinder (2).

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protec- 3
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

3. Remove nuts (6) (2 used) and bolt (5) from stop-

4
per (3) of the second boom.
: 30 mm

4. Remove pin (4).

5, 6

W1F3-04-04-003

W4-2-14
 FRONT ATTACHMENT / Cylinder
5. Disconnect hoses (7) (2 used) and hoses (8) (3
used) from positioning cylinder (2). Cap the open 7
ends of the disconnected hoses.
: 19 mm, 36 mm 2

W1F3-04-03-001

6. Remove nuts (12) (2 used) and bolt (13) from

stopper (11) of the first boom.
Remove pin (9) and thrust plate (10) by using a
hammer and a bar.
: 30 mm

CAUTION: Positioning cylinder (2) weight:

185 kg (410 lb)

7. Hoist and remove positioning cylinder (2).

12, 13 2

9, 10
11

W1F3-04-04-003

W4-2-15
 FRONT ATTACHMENT / Cylinder
Installation of Positioning Cylinder
(2-Piece Boom Only)

CAUTION: Positioning cylinder (2) weight:

185 kg (410 lb)
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protec-
tion, such as goggles, hard hats, etc in order
to prevent personal injury.

1. Hoist positioning cylinder (2). Align the pin holes

at the bottom side with those of the first boom.
Insert thrust plate (10) and install pin (9) by tap-
ping.

2. Align the pin holes of stopper (11) and pin (9). In- 12, 13 2
stall and secure with bolt (13) and nuts (12) (2
used).
: 30 mm 11 9, 10
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

W1F3-04-04-003

W4-2-16
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Fill hydraulic oil to the specified
level. Start the engine and check for
any oil leaks at the hose connec-
tions. 3
3. Connect hoses (7) (2 used) and hoses (8) (3
used) to positioning cylinder (2).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
: 36 mm 4
: 175 N⋅m (18 kgf⋅m, 130 lbf·ft)

4. Start the engine and extend positioning cylinder

(2). Align the rod hole of positioning cylinder (2) 5, 6
with the hole of the second boom. Insert thrust
plate (10) and install pin (4) by tapping. 2

5. Align the pin holes of stopper (3) and pin (4). In-
stall bolt (5) and nuts (6) (2 used). 9, 10
: 30 mm
: 550 N⋅m (56 kgf⋅m, 410 lbf·ft)
W1F3-04-04-003

W1F3-04-03-001

6. Connect lubrication hose (1) to positioning cylin-

der (2).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

IMPORTANT: When completing the work, operate

positioning cylinder (2) to the stroke
end several times and bleed air from
the circuit.
WCCB-04-01-009

2 1

W4-2-17
 FRONT ATTACHMENT / Cylinder
Removal of Blade Cylinder

IMPORTANT: Before starting the work, lower the

blade onto the ground.

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, hard hats, etc in order to
prevent personal injury.

Removal 1 2, 3
1. Remove bolts (2) (4 used) and washers (3) (4
4
used) from cover (4). Remove cover (4) from
bracket (1).
: 19 mm

WCEB-04-02-001

5 6 7 8 9
2. Disconnect hoses (5) (4 used) from blade cylinder
10
(6). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm, 27 mm 11

CAUTION: Blade cylinder (6) weight: 50 kg

(110 lb)

3. Attach a nylon sling onto blade cylinder (6). Hoist

and hold blade cylinder (6).

4. Remove nuts (10) (4 used) from bolts (8) (2 used). WCEB-04-02-002

Remove bolts (8) (2 used) from pins (9, 13). Re-
move pins (9, 13) from bracket (11) and link (12).
: 24 mm
6
5. Remove thrust plates (7) (6 used) between the
bottom part and bracket (11) and between the rod
part and link (12) in blade cylinder (6).
8
7

12

13 10 WCEB-04-02-001

W4-2-18
 FRONT ATTACHMENT / Cylinder

CAUTION: Blade cylinder (6) weight: 50 kg 6 11

(110 lb)

6. Remove blade cylinder (6) from bracket (11) and

link (12).

12

WCEB-04-02-002

6 7 8 9
Installation of Blade Cylinder 10

CAUTION: Blade cylinder (6) weight: 50 kg 11

(110 lb)

1. Attach a nylon sling onto blade cylinder (6). Hoist

blade cylinder (6). Align the bottom and rod parts
of blade cylinder (6) with the mounting holes on
bracket (11) and link (12).

2. Install thrust plates (7) (6 used) to the bottom and

rod parts of blade cylinder (6). Install blade cylin- WCEB-04-02-002

der (6) to bracket (11) and link (12) with pins (9,
13).
6
3. Secure pins (9, 13) to bracket (11) and link (12)
with bolts (8) (2 used) and nuts (10) (4 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft) 8
7

12

13 10 WCEB-04-02-001
5 6
4. Connect hoses (5) (4 used) to blade cylinder (6).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf·ft)

WCEB-04-02-002

W4-2-19
 FRONT ATTACHMENT / Cylinder
5. Install cover (4) to bracket (1) with bolts (2) (4 2, 3
1
used) and washers (3) (4 used).
: 19 mm 4
: 90 N⋅m (9.2 kgf⋅m, 66 lbf·ft)

IMPORTANT: When completing the work, operate

the blade cylinder to the stroke end
several times and bleed air from the
circuit.

WCEB-04-02-001

W4-2-20
 FRONT ATTACHMENT / Cylinder
Removal of Outrigger Cylinder

CAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection,
such as goggles, hard hats, etc in order to
prevent personal injury.

1. Remove sems bolts (4) (3 used), washers (5) (2

used) and collars (6) (2 used) from cover (3).
Remove cover (3) from outrigger cylinder (2).
: 17 mm 1 2 3 4, 5, 6 4

2. Disconnect hoses (1) (4 used) from outrigger cyl-

inder (2). Cap the open ends. Attach an identifica-
tion tag onto the disconnected hoses for assem-
bling.
: 19 mm, 27 mm

3. Remove operate check valve (9) from outrigger

cylinder (2). (Refer to REMOVAL AND INSTAL-
9 7, 8 WCEB-04-02-004
LATION OF OPERATE CHECK VALVE on
W4-4-1.)

4. Disconnect piping (7) from outrigger cylinder (2).

Remove O-ring (8) from piping (7).
: 6 mm

2
CAUTION: Outrigger cylinder (2) weight: 70
kg (160 lb)

5. Attach a nylon sling onto the rod side of the out-

rigger cylinder (2) tube. Hoist and hold outrigger
cylinder (2).

WCEB-04-02-003

W4-2-21
 FRONT ATTACHMENT / Cylinder

CAUTION: Outrigger cylinder (2) weight: 70

kg (160 lb) 2 10, 11

6. Remove bolts (14) (3 used) and washers (15) (3

used) from pin (13). Remove pin (13) and thrust
plates (14) (3 used) from outrigger (12). 12
: 19 mm
13, 14
7. Hoist outrigger cylinder (2) a little. Insert a wooden
block under outriger cylinder (2). Lower outrigger 15, 16
cylinder (2).

CAUTION: The outrigger (12) assembly 17 WCEB-04-02-003

weight: 130 kg (290 lb)

8. Attach a nylon sling onto outrigger (12). Hoist and 17 10, 11

hold outrigger (12). Remove lock pin (11) from pin
(10). Remove pin (10) from outrigger beam (17).
Lower the outrigger (12) assembly.

Wooden Block
12

W1GL-04-02-006

CAUTION: Outrigger cylinder (2) weight: 70 18 17

kg (160 lb)

9. Attach a nylon sling onto outrigger cylinder (2).

Hoist and hold outrigger cylinder (2).

10. Remove ring (18) from pin (19). Remove lock pin
(20) from pin (19). Remove pin (19) and thrust
plates (21) (3 used) from outrigger beam (17).

11. Remove outrigger cylinder (2) from outrigger

beam (17).
19, 20, 21 2 WCEB-04-02-003

W4-2-22
 FRONT ATTACHMENT / Cylinder
Installation of Outrigger Cylinder

CAUTION: Outrigger cylinder (2) weight: 70

kg (160 lb) 18 17

1. Attach a nylon sling onto outrigger cylinder (2).

Hoist and align the hole on the bottom side with
the outrigger beam (17) mounting hole. Install
outrigger cylinder (2) to outrigger beam (17) with
thrust plates (21) (3 used) and pin (19).

2. Secure pin (19) to outrigger beam (17) with lock

pin (20) and ring (18).

19, 20, 21 2 WCEB-04-02-003

3. Install O-ring (8) to piping (7). Connect piping (7)

1 2
to outrigger cylinder (2).
: 6 mm
: 78±19 N⋅m (8±2 kgf⋅m, 58±6 lbf·ft)

4. Install operate check valve (9) to outrigger cylin-

der (2). (Refer to REMOVAL AND INSTALLATION
OF OPERATE CHECK VALVE on W4-4-1.)

5. Connect hoses (1) (4 used) to operate check

valve (9). 9 7, 8 WCEB-04-02-004
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf·ft)
2 3 4, 5, 6 4
6. Install cover (3) to outrigger cylinder (2) with sems
bolts (4) (3 used), washers (5) (2 used) and col-
lars (6) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf·ft)

WCEB-04-02-004

W4-2-23
 FRONT ATTACHMENT / Cylinder
IMPORTANT: After the hose is connected, operate 17 10, 11
the outrigger cylinder to the stroke
end several times and bleed air from
the circuit.
7. Extend the rod of outrigger cylinder (2) and align
with the mounting hole on outrigger (12). Install
the rod part of outrigger cylinder (2) to outrigger
(12) with thrust plates (14) (3 used) and pin (13). 13, 14

2
8. Install pin (13) to outrigger (12) with bolts (15) (3 15, 16
used) and washers (16) (3 used).
: 19 mm Wooden Block
: 90 N⋅m (9 kgf⋅m, 66 lbf·ft) 12

W1GL-04-02-006

9. Remove the wooden block from the inside of out-

rigger beam (17).
17 10, 11
10. Operate outrigger cylinder (2) and align the
mounting hole on outrigger (12) with that on out-
rigger beam (17). Secure outrigger (12) to outrig-
ger beam (17) with pin (10) and lock pin (11). 12

2 WCEB-04-02-003

W4-2-24
 FRONT ATTACHMENT / Cylinder
(Blank)

W4-2-25
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF BOOM, ARM AND
BUCKET CYLINDERS

Boom Cylinder
1 2 3 4 5 6 7 8 9 10 11

22 20 19 12
23

W1V1-04-02-007
26 25 17 18 24 19 21 18 17

Arm Cylinder 1 2 3 4 5 6 7 8 9 10 11

20 19 16 15 14 13 12
22
23

W1V1-04-02-008
26 25 17 18 24 19 21 18 17

W4-2-26
 FRONT ATTACHMENT / Cylinder
Bucket Cylinder

1 2 3 4 5 6 7 8 9 10 11

19 18 12
22
23

W1V1-04-02-009

17 18 24 19 21 20 17

1- Piston Rod 8- Bushing 15 - Cushion Seal 21 - Seal Ring

2- Wiper Ring 9- Snap Ring 16 - Snap Ring 22 - Set Screw
3- Backup Ring 10 - Backup Ring 17 - Slide Ring (2 Used) 23 - Steel Ball
4- U-Ring 11 - O-Ring 18 - Slide Ring (2 Used) 24 - Piston Nut
5- Buffer Ring 12 - Cylinder Tube 19 - Backup Ring (2 Used) 25 - Cushion Bearing
6- Socket Bolt (12 Used) 13 - Stopper (2 Used) 20 - O-Ring 26 - Cushion Seal
7- Cylinder Head 14 - Cushion Bearing

W4-2-27
 FRONT ATTACHMENT / Cylinder

1 6 7

14 12

W1V1-04-02-008

24

W4-2-28
 FRONT ATTACHMENT / Cylinder
Disassembly of Boom, Arm and Bucket Cylinders
• The disassembling procedure starts on the
premise that the hydraulic pipings and the bands
securing the pipings have been removed.
NOTE: The procedure for the arm cylinder is ex-
plained.
IMPORTANT: Pull out piston rod (1) straight in
order not to damage the sliding
surface.
3. Tap and remove cylinder head (7) with piston rod
(1) together from cylinder tube (12) by using a
plastic hammer.

4. Secure piston rod (1) to special tool (ST 5908).

CAUTION: Boom cylinder weight: Put the matching marks on piston rod (1) and the
Monoblock boom: 110 kg (250 lb) end of piston (24) (Arm cylinder: cushion bearing
2-piece boom: 125 kg (280 lb) (14)).
Arm cylinder weight: 160 kg (360 lb)
Bucket cylinder weight: 100 kg (220 lb)

1. Hoist the cylinder. Secure the cylinder horizontally

on a workbench. Drain hydraulic oil from the cyl-
inder.

Special Tool: ST 5908

W158-04-02-022

W102-04-02-027

2. Fully extend piston rod (1). Attach a nylon sling

onto piston rod (1). Hold piston rod (1). Remove
socket bolts (6) (12 used) from cylinder head (7).
Boom and bucket cylinders:
: 12 mm
Arm cylinder:
: 14 mm

W4-2-29
 FRONT ATTACHMENT / Cylinder

1 2 3 4 5 6 7 8 9 10 11

20 19 16 15 14 13
22
23

W1V1-04-02-008

26 25 17 18 24 19 21 18 17

W4-2-30
 FRONT ATTACHMENT / Cylinder
5. Cut away the crimped part by using a hand drill
and remove set screw (22). Remove steel ball
(23).
NOTE: Set screw (22) has been crimped by using
a punch at 2 places after installing.
Boom and bucket cylinders:
: 6 mm
Arm cylinder:
: 8 mm
6. Remove piston nut (24) by using special tool (ST
5908) and the special tool.
Remove cushion bearing (25) and cushion seal
(26) from piston rod (1).
(Cushion bearing (25) is not equipped for the
bucket cylinder. Cushion seal (26) is not equipped
for the bucket cylinder.)
Special tool (outer diameter at nut part):
Bucket cylinder: (ST 3271: 75 mm)
Boom cylinder: (ST 3242: 80 mm)
Arm cylinder: (ST 3263: 90 mm)
7. Remove slide rings (17) (2 used), slide rings (18)
(2 used), backup rings (19) (2 used), O-ring (20)
and seal ring (21) from piston nut (24).
8. Remove cylinder head (7) from piston rod (1).
9. Remove O-ring (11) and backup rings (10, 3) from
cylinder head (7). Remove wiper ring (2), U-ring
(4), buffer ring (5), snap ring (9) and bushing (8)
by using the special tool.
Special tool (rod outer diameter):
Boom and bucket cylinders: (ST 8017: 70 mm)
Arm cylinder: (ST 8019: 80 mm)
10. (Arm cylinder only)
Remove stoppers (13) (2 used) from piston rod
(1) by using a screwdriver. Remove cushion
bearing (14), cushion seal (15) and snap ring (16).

Special Tool: ST 5908

W158-04-02-022

W4-2-31
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF BOOM, ARM AND BUCKET CYLINDERS

Boom Cylinder
1 2 4 5 6 7 12 25 17 18 19 18 17 22

3 8 9 10, 11 26 24 20, 21 23 W1V1-04-02-005

Arm Cylinder
1 2 4 5 6 7 12 25 17 18 19 18 17 22 14

3 8 9 10, 11 26 24 20, 21 23 16 15 W1V1-04-02-003

Bucket Cylinder
1 2 4 5 6 7 12 17 18 19 18 17

22

3 8 9 10, 11 20, 21 23
W1V1-04-02-001

W4-2-32
 FRONT ATTACHMENT / Cylinder

1- Piston Rod 8- Bushing 15 - Cushion Seal 21 - Seal Ring

2- Wiper Ring 9- Snap Ring 16 - Snap Ring 22 - Set Screw
3- Backup Ring 10 - Backup Ring 17 - Slide Ring (2 Used) 23 - Steel Ball
4- U-Ring 11 - O-Ring 18 - Slide Ring (2 Used) 24 - Piston Nut
5- Buffer Ring 12 - Cylinder Tube 19 - Backup Ring (2 Used) 25 - Cushion Bearing
6- Socket Bolt (12 Used) 13 - Stopper (2 Used) 20 - O-Ring 26 - Cushion Seal
7- Cylinder Head 14 - Cushion Bearing

W4-2-33
 FRONT ATTACHMENT / Cylinder

1 2 4 5 7 17 18 19 18 17 14

13

3 8 9 10, 11 24 20, 21 16 15 W1V1-04-02-003

NOTE: The illustration shows the arm cylinder.

W4-2-34
 FRONT ATTACHMENT / Cylinder
Assembly of Boom, Arm and Bucket Cylinders
NOTE: The procedure for the arm cylinder is ex-
plained.
1. Install bushing (8) to cylinder head (7) by using
the special tool.
Special tool (rod outer diameter):
Boom and bucket cylinders: (ST 8017: 70 mm)
Arm cylinder: (ST 8019: 80 mm)
IMPORTANT: Check the direction to install.
2. Install U-ring (4), backup ring (3), buffer ring (5)
and snap ring (9) to cylinder head (7).
3. Install wiper ring (2) to cylinder head (7) by using
the special tool and a plastic hammer.
Special tool (rod outer diameter):
Boom and bucket cylinders: (ST 8017: 70 mm)
Arm cylinder: (ST 8019: 80 mm)
4. Install O-ring (11) and backup ring (10) to cylinder
head (7).
W4-2-35
5. Install O-ring (20) and seal ring (21) to piston nut
(24) by using special tool A.
After installing seal ring (21), adjust seal ring (21)
by using special tool B.
Special tools A and B (tube inner diameter):
Bucket cylinder: (ST 2181, 2205: 100 mm)
Boom cylinder: (ST 2977, 2332: 105 mm)
Arm cylinder: (ST 2183, 2207: 115 mm)
6. Install backup rings (19) (2 used), slide rings (17)
(2 used) and slide rings (18) (2 used) to piston nut
(24).
7. Install the cylinder head (7) assembly to piston
rod (1) by using the special tool.
Special tool (rod outer diameter):
Boom and bucket cylinders: (ST 8017: 70 mm)
Arm cylinder: (ST 8019: 80 mm)
IMPORTANT: Face the slit in cushion seal (15) to
the piston nut (24) side. Check the
direction of the oil groove in cushion
bearing (14).
8. (Arm cylinder only)
Install snap ring (16) and cushion seal (15) to
piston rod (1). Install cushion bearing (14) and
stoppers (13) (2 used).
 FRONT ATTACHMENT / Cylinder

1 6 7 12 25 22

26 24 23 W1V1-04-02-003

NOTE: The illustration shows the arm cylinder.

W4-2-36
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Face the slit in cushion seal (26) to
the piston nut (24) side. Check the
direction of the oil groove in cushion
bearing (25).
9. Install cushion seal (26) and cushion bearing (25)
to piston rod (1).
(Cushion bearing (25) and cushion seal (26) are
not equipped for the bucket cylinder.)
10. Align the matching marks and tighten piston nut
(24) by using special tool (ST 5908) and the spe-
cial tool.
Special tool (outer diameter at nut part):
Bucket cylinder: (ST 3271: 75 mm)
: 3540 N⋅m (359 kgf⋅m, 2620 lbf·ft)
Boom cylinder: (ST 3242: 80 mm)
: 3140 N⋅m (320 kgf⋅m, 2320 lbf·ft)
Arm cylinder: (ST 3263: 90 mm)
: 4320 N⋅m (441 kgf⋅m, 3190 lbf·ft)
Special Tool: ST 5908 W158-04-02-022
W4-2-37
11. Install steel ball (23) to piston rod (1). Tighten with
set screw (22). Crimp set screw (22) by using a
punch at 2 places.
Boom and bucket cylinders:
: 6 mm
: 31.5±5.9 N⋅m (3.2±0.6 kgf⋅m, 23±4 lbf·ft)
Arm cylinder:
: 8 mm
: 57±11 N⋅m (5.8±1.1 kgf⋅m, 42±7 lbf·ft)
CAUTION: Align the piston rod (1) assembly
with the center of cylinder tube (12) and in-
sert straight in order not to damage the rings.
12. Secure cylinder tube (12) horizontally on a work-
bench. Insert the piston rod (1) assembly into
cylinder tube (12).
13. Install cylinder head (7) to cylinder tube (12) with
socket bolts (6) (12 used).
Boom and bucket cylinders:
: 12 mm
: 170 N⋅m (17 kgf⋅m, 126 lbf·ft)
Arm cylinder:
: 14 mm
: 267 N⋅m (27 kgf⋅m, 197 lbf·ft)
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF POSITIONING CYLINDER

1
2 3 4
5
6 7
8 9
10
11
12
13

14 15
16
17
18
19 20 21

22

WCGB-04-02-010

1- Piston Rod 7- U-Ring 13 - Backup Ring 18 - O-Ring

2- Socket Bolt (14 Used) 8- Buffer Ring 14 - Piston 19 - Backup Ring (2 Used)
3- Cylinder Head 9- Bushing 15 - Slide Ring (2 Used) 20 - Set Screw
4- Retaining Ring 10 - Retaining Ring 16 - Wear Ring (2 Used) 21 - Piston Nut
5- Dust Seal 11 - O-Ring 17 - Seal Ring 22 - Cylinder Tube
6- Backup Ring 12 - O-Ring

W4-2-38
 FRONT ATTACHMENT / Cylinder
Disassembly of Positioning Cylinder
NOTE: The disassembling procedure starts on the
premise that the hydraulic pipings and the
bands securing the pipings have been re-
moved.
CAUTION: Positioning cylinder weight: 185
kg (410 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the cyl-
inder.
CAUTION: Do not drop piston rod (1) by tilt-
ing.
IMPORTANT: Pull out piston rod (1) straight in
order not to damage the sliding
surface.
4. Slowly remove piston rod (1) from cylinder tube
(22). At this time, cylinder head (3) is removed
with piston rod (1) together. Set a cloth onto a
wooden block. Place piston rod (1) horizontally on
the wooden block.

W102-04-02-027

2. Fully extend piston rod (1). Attach a nylon sling

onto piston rod (1). Hold piston rod (1). Remove
socket bolts (2) (14 used) from cylinder head (3).
: 14 mm

3. Remove cylinder head (3) from cylinder tube (22)

by using a pry bar.

W4-2-39
FRONT ATTACHMENT / Cylinder

1
2 3 4
5
6 7
8 9
10
11
12
13

14 15
16
17
18
19 20 21

22

WCGB-04-02-010

W4-2-40
 FRONT ATTACHMENT / Cylinder
5. Cut away the crimped part by using a hand drill 9. Remove bushing (9) from cylinder head (3) by
and remove set screw (20) from piston nut (21). using special tool (ST 2613). Remove O-rings (11,
NOTE: Set screw (20) has been crimped by using 12), backup rings (6, 13), dust seal (5), U-ring (7),
a punch at 2 places after installing. buffer ring (8) and retaining rings (4, 10) from
: 4 mm bushing (9).

6. Remove piston nut (21) from piston rod (1) by

using special tool (ST 3335). Remove piston (14)
from piston rod (1) by using special tool (ST
3338).

7. Remove seal ring (17), slide ring (15), wear ring

(16), O-ring (18), retaining rings (19) (2 used) and
backup rings (17) (2 used) from piston (14).

8. Remove cylinder head (3) from piston rod (1).

W4-2-41
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF POSITIONING CYLINDER

6, 7 8 2 11 12, 13 16 17 18, 19

1 4, 5 9, 10 3 22 14 15 21 20

WCEB-04-02-010

1- Piston Rod 7- U-Ring 13 - Backup Ring 18 - O-Ring

2- Socket Bolt (14 Used) 8- Buffer Ring 14 - Piston 19 - Backup Ring (2 Used)
3- Cylinder Head 9- Bushing 15 - Slide Ring (2 Used) 20 - Set Screw
4- Retaining Ring 10 - Retaining Ring 16 - Wear Ring 21 - Piston Nut
5- Dust Seal 11 - O-Ring 17 - Seal Ring 22 - Cylinder Tube
6- Backup Ring 12 - O-Ring

W4-2-42
 FRONT ATTACHMENT / Cylinder
Assembly of Positioning Cylinder
1. Install bushing (9) to cylinder head (3) by using 5. Install O-ring (18), backup rings (19) (2 used),
special tool (ST 2613). Install retaining ring (10). seal ring (17), slide rings (15) (2 used) and wear
ring (16) to piston (14) by using special tool (ST
2. Tap and install dust seal (5) to cylinder head (3) 2589).
by using special tool (ST 2614) and a plastic
hammer. 6. Install the cylinder head (3) assembly to piston
rod (1) by using special tool (ST 2675).
IMPORTANT: Check the installing direction.
3. Install U-ring (7), backup ring (2), buffer ring (8)
and retaining ring (4) to cylinder head (3).

4. Install O-rings (11, 12) and backup ring (13) to

cylinder head (3).

W4-2-43
 FRONT ATTACHMENT / Cylinder

1 2 3 22 14 21 20

WCEB-04-02-010

W4-2-44
 FRONT ATTACHMENT / Cylinder
6. Apply hydraulic oil onto the inner surface of piston
(14). Install piston (14) to piston rod (1) by using
special tool (ST 3338).
: 980±98 N⋅m (100±10 kgf⋅m, 720±72 lbf·ft)
7. Apply hydraulic oil onto piston nut (21). Install
piston nut (21) to piston rod (1) by using special
tool (ST 3335).
: 1860±185 N⋅m
(190±19 kgf⋅m, 1380±137 lbf·ft)
8. Apply LOCTITE #242 onto two to three threads of
set screw (20). Install set screw (20) to piston nut
(21). After tightening set screw (20), crimp set
screw (20) by using a punch at 2 places.
: 4 mm
: 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)
IMPORTANT: Align the piston rod (1) assembly
with the center of cylinder tube (22)
and insert straight in order not to
damage the rings.
10. Apply hydraulic oil onto the outer surface of piston
(14). Hoist cylinder tube (22). Secure cylinder
tube (22) horizontally on a workbench. Insert the
piston rod (1) assembly into cylinder tube (22).
11. Install cylinder head (3) to cylinder tube (22) by
using special tool (ST 2675). Tighten cylinder
head (3) with socket bolts (2) (14 used).
: 14 mm
: 470 to 490 N⋅m
(48 to 50 kgf⋅m, 345 to 360 lbf·ft)

W4-2-45
 FRONT ATTACHMENT / Cylinder
DISASSEMBLY OF OUTRIGGER AND BLADE CYLINDERS

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16 17

18

19

20

WCGB-04-02-002

1- Piston Rod 6- Seal 11 - O-Ring 16 - O-Ring

2- Cylinder Head 7- Bushing 12 - Piston 17 - Set Screw
3- Retaining Ring 8- Retaining Ring 13 - Seal Ring 18 - Piston Nut
4- Dust Seal 9- O-Ring 14 - Wear Ring 19 - Backup Ring (2 Used)
5- U-Ring 10 - Backup Ring 15 - Dust Ring 20 - Cylinder Tube

W4-2-46
 FRONT ATTACHMENT / Cylinder
Disassembly of Outrigger and Blade Cylinders
NOTE: The disassembling procedure starts on the
premise that the hydraulic pipings and the
bands securing the pipings have been re-
moved.
CAUTION: Outrigger cylinder weight: 70 kg
(160 lb)
Blade cylinder weight: 50 kg (110 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the cyl-
inder.
4. Cut away the crimped part by using a hand drill
and remove set screw (17) from piston nut (18).
NOTE: Set screw (17) has been crimped by using
a punch at 2 places after installing.
: 4 mm
5. Remove piston nut (18) by using special tool (ST
3333). Remove piston (12) from piston rod (1) by
using special tool (ST 3337).
6. Remove cylinder head (2) from piston rod (1).
IMPORTANT: When removing the seals, do not
damage the parts.
7. Remove seal ring (13), wear ring (14), dust ring
(15) and O-ring (16) from piston (12).

8. Remove retaining rings (3, 8), U-ring (5), dust seal

(4) and backup ring (10) from the inside of cylin-
der head (2). Remove bushing (7) by using spe-
cial tool (ST 2684).

9. Remove O-rings (9, 11) and backup ring (10) from

W102-04-02-027
the outside of cylinder head (2).
2. Raise a detent (a part of cylinder tube (20)) in the
groove on cylinder head (2). Pry and remove cyl-
inder head (2) from cylinder tube (20).
R wrench: (ST 3221)

CAUTION: Do not drop piston rod (1) by tilt-

ing.

IMPORTANT: Remove piston rod (1) straight in

order not to damage the rod surface.
3. Fully extend piston rod (1). Attach a nylon sling
onto piston rod (1). Hold piston rod (1). Slowly
remove piston rod (1) from cylinder tube (20). Set
a cloth onto a wooden block. Place piston rod (1)
horizontally on the wooden block.

W4-2-47
 FRONT ATTACHMENT / Cylinder
ASSEMBLY OF OUTRIGGER AND BLADE CYLINDER

Outrigger Cylinder
1 3, 4 5 9 6 7, 8 2 10, 11 20 12 13 14 15 16, 19 18 17

WCEB-04-02-012

Blade Cylinder
1 3, 4 5 9 6 7, 8 2 10, 11 20 12 13 14 15 16, 19 18 17

WCEB-04-02-011

W4-2-48
 FRONT ATTACHMENT / Cylinder

1- Piston Rod 6- Seal 11 - O-Ring 16 - O-Ring

2- Cylinder Head 7- Bushing 12 - Piston 17 - Set Screw
3- Retaining Ring 8- Retaining Ring 13 - Seal Ring 18 - Piston Nut
4- Dust Seal 9- O-Ring 14 - Wear Ring 19 - Backup Ring (2 Used)
5- U-Ring 10 - Backup Ring 15 - Dust Ring 20 - Cylinder Tube

W4-2-49
 FRONT ATTACHMENT / Cylinder

1 3, 4 5 9 6 7, 8 2 10, 11 12 13 14 15 16, 19 18 17

WCEB-04-02-012

NOTE: The illustration shows the outrigger cylinder.

W4-2-50
 FRONT ATTACHMENT / Cylinder
Assembly of Outrigger and Blade Cylinders
1. Install bushing (7) to cylinder head (2) by using
special tool (ST 2684). Install retaining ring (8).
IMPORTANT: Install U-ring (5) with its lip part fac-
ing to the bushing (7) side.
Install seal (6) with its projection part
and slit part facing to the bushing (7)
side.
2. Install U-ring (5) and seal (6) to cylinder head (2).
3. Install dust seal (4) and retaining ring (3) to cyl-
inder head (2) by using special tool (ST 2688).
IMPORTANT: Install backup ring (10) to the pin
hole side on piston rod (1).
4. Install O-rings (9, 11) and backup ring (10) to cyl-
inder head (2).
5. Install the cylinder head (2) assembly to piston
rod (1) by using special tool (ST 2692).
W4-2-51
IMPORTANT: After installing O-ring (16), check
that O-ring (16) is not twisted.
6. Install O-ring (16), backup rings (19) (2 used),
seal ring (13), wear ring (14) and dust ring (15) to
piston (12).
7. Apply hydraulic oil onto the inner surface of piston
(12). Install piston (12) to piston rod (1) by using
special tool (ST 3337).
: 490±49 N⋅m (50±5 kgf⋅m, 360±36 lbf·ft)
8. Apply hydraulic oil onto the threads of piston nut
(18). Install piston nut (18) to piston rod (1) by
using special tool (ST 3333).
: 980±98 N⋅m (100±10 kgf⋅m, 720±72 lbf·ft)
9. Apply LOCTITE #242 onto set screw (17). Install
set screw (17). After tightening set screw (17),
crimp set screw (17) by using a punch at 2 places.
: 4 mm
: 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)
 FRONT ATTACHMENT / Cylinder

2 20
1

WCEB-04-02-012

NOTE: The illustration shows the outrigger cylinder.

W4-2-52
 FRONT ATTACHMENT / Cylinder
IMPORTANT: Align the piston rod (1) assembly
with the center of cylinder tube (20)
straight in order not to damage the
rings.

10. Secure cylinder tube (20) horizontally on a work-

bench. Insert the piston rod (1) assembly into
cylinder tube (20).

11. Apply hydraulic oil onto the threads of cylinder

head (2). Install cylinder head (2) to cylinder tube
(20). Bend the detent and secure cylinder head
(2).
R wrench: (ST 3221)
: 490 to 690 N⋅m
(50 to 70 kgf⋅m, 360 to 510 lbf·ft)

W4-2-53
 FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD

Piston Rod Rod Bend and Run Out of Piston Rod

A Dial Gauge

Piston Rod

W105-04-02-094 W166-04-02-022

1m
V Block
Unit: mm (in) Unit: mm (in)
Recommended Size After Bend Run Out Remedy
Cylinder Name
Re-Manufacturing (A)
+0.023 +0.001 0.5 (0.02) 1.0 (0.04) Repair
Boom 70 (2.8 )
-0.053 -0.002
+0.023 +0.001 1.0 (0.04) 2.0 (0.08) Replace
Arm 80 (3.1 )
-0.057 -0.002
+0.023 +0.001
Bucket 70 (2.8 )
-0.053 -0.002
+0.027 +0.001
Positioning 95 (3.7 )
-0.057 -0.002
+0.023 +0.001
Blade 60 (2.4 )
-0.043 -0.002
+0.023 +0.001
Outrigger 60 (2.4 )
-0.043 -0.002

W4-2-54
 FRONT ATTACHMENT / Hose Rupture Valve
HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE

NOTE: Operate the pilot pump by using the power

from the battery without starting the engine
and deliver the pilot pressure to the spool of
the control valve.

1. Turn the pilot shut-off lever to the UNLOCK

position.

2. Turn the engine stop switch ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.

IMPORTANT: The battery will deplete. Operate the

key switch for short period.
3. With the key switch in the START position, WCEB-02-01-002
Engine Stop Switch
operate the lever 4 to 5 times in order to release
any pressure in the hydraulic circuit.

4. Return the pilot shut-off lever to the LOCK

position.

5. Turn the engine stop switch OFF.

W4-3-1
 FRONT ATTACHMENT / Hose Rupture Valve
REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR ARM CYLINDER

CAUTION: Loosen the relief valve of hose 5

1 2 3, 4
rupture valve (3) slowly and release the
pressure.

Removal
1. Disconnect hoses (1) (2 used) from hose rupture
valve (3). Cap the open ends. 6
: 19 mm

2. Remove socket bolts (6) (4 used) from piping (5).

: 8 mm

3. Remove socket bolts (2) (4 used) from hose

rupture valve (3). Remove hose rupture valve (3) 7
and O-ring (4) from arm cylinder (7).
: 8 mm WCEB-04-03-003

1 2 3, 4 5
Installation
1. Apply grease onto O-ring (4). Install O-ring (4) to
hose rupture valve (3).

2. Align hose rupture valve (3) with the mounting

holes on arm cylinder (7) and piping (5). Install
hose rupture valve (3) to arm cylinder (7) and 6
piping (5) with socket bolts (2, 6) (4 used for
each).
: 8 mm
: 52±10 N⋅m (5.2±1 kgf⋅m, 38±7 lbf⋅ft)

3. Connect hoses (1) (2 used) to hose rupture valve

7
(3).
: 19 mm WCEB-04-03-003

: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

W4-3-2
 FRONT ATTACHMENT / Hose Rupture Valve
REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR POSITIONING
CYLINDER

CAUTION: Loosen the relief valve of hose

rupture valve (7) slowly and release the 1 2 3 4
pressure.

Removal
1. Remove bolts (1) (2 used) from clamp (2).
Remove clamp (2) from bracket (3).
: 22 mm 5

2. Disconnect hoses (5) (3 used) from hose rupture

valve (7). Cap the open ends. Attach an 6
identification tag onto the disconnected hoses for
assembling.
: 19 mm 7, 8

3. Remove socket bolts (6) (4 used) from piping (4).

Disconnect piping (4) from positioning cylinder (9).
WCEB-04-03-004
Remove hose rupture valve (7) and O-ring (8) 9
from positioning cylinder (9). Cap the open ends.
: 10 mm

W4-3-3
 FRONT ATTACHMENT / Hose Rupture Valve
Installation
1. Apply grease onto O-ring (8). Install O-ring (8) to 1 2 3 4
hose rupture valve (7).

2. Install hose rupture valve (7) and piping (4) to

positioning cylinder (9) with socket bolts (6) (4
used).
: 10 mm
: 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft) 5

3. Connect hoses (5) (3 used) to hose rupture valve

(7). 6
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
7, 8
4. Secure piping (4) to bracket (3) with clamp (2) and
bolts (1) (2 used).
: 22 mm WCEB-04-03-004

: 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft) 9

W4-3-4
 FRONT ATTACHMENT / Hose Rupture Valve
REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR BOOM CYLINDER

CAUTION: Loosen the relief valve of hose

1 2 3 4 5
rupture valve (8) slowly and release the
pressure.

Removal
1. Remove bolt (4) from clamps (3) (2 used).
Remove clamps (3) (2 used) from bracket (2) and
piping (5).
: 19 mm

2. Disconnect hoses (6) (6 used) from hose rupture 6

valve (8). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm, 27 mm

3. Remove socket bolts (7) (4 used) from piping (5).

Disconnect piping (5) from boom cylinder (1).
Remove hose rupture valve (8) and O-ring (9) 8, 9 6 7 WCEB-04-03-002

from boom cylinder (1). Cap the open ends.

: 10 mm

W4-3-5
 FRONT ATTACHMENT / Hose Rupture Valve
Installation 1 2 3 4 5
1. Apply grease onto O-ring (9). Install O-ring (9) to
hose rupture valve (8).

2. Install hose rupture valve (8) and piping (5) to

boom cylinder (1) with socket bolts (7) (4 used).
: 10 mm
: 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft)

3. Connect hoses (6) (6 used) to hose rupture valve

(8). 6
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
8, 9 6 7 WCEB-04-03-002

4. Secure piping (5) to bracket (2) with clamps (3) (2

used) and bolt (4).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

W4-3-6
 FRONT ATTACHMENT / Hose Rupture Valve
(Blank)

W4-3-7
 FRONT ATTACHMENT / Hose Rupture Valve
STRUCTURE OF HOSE RUPTURE VALVE FOR ARM CYLINDER

9 10 11 12 13 14 15 16

3 4 5 6 7 8
2
17

1 18

19
47
20

21
46

22
45

23
44
24
43
25
42
26
41
27

40 28

29
39
30

38 31

37

32
36

35
33

34 WCEB-04-03-006

W4-3-8
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
1 Spacer 1
2 Plug 3 :5
3 O-Ring 3
4 Backup Ring 1
5 O-Ring 1
6 Orifice 2
7 Backup Ring 2
8 O-Ring 1
9 Lock Nut 1 : 17
10 Poppet 1
11 Set Screw 1 :6
12 Spring 1
13 O-Ring 1
14 Washer 1
15 Adapter 1 : 24
16 O-Ring 1
17 Backup Ring 1
18 O-Ring 1
19 Casing 1
20 O-Ring 1
21 Plug 1 : 32
22 Stopper 1
23 Spool 1
24 Sleeve 1
25 Backup Ring 1
26 O-Ring 1
27 O-Ring 3
28 Plug 1

W4-3-9
 FRONT ATTACHMENT / Hose Rupture Valve

47

46

45

44

43

42

41

40

29
39
30

38 31

37

32
36

35
33

34 WCEB-04-03-006

W4-3-10
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
29 Backup Ring 1
30 Spring 1
31 Holding Valve 1
32 Orifice 2
33 Body 1
34 O-Ring 1
35 O-Ring 1
36 Backup Ring 1
37 O-Ring 1
38 Backup Ring 1
39 Spring Seat 1
40 O-Ring 1
41 Piston 1
42 O-Ring 1
43 Cover 1 : 32
44 Stopper 1
45 Set Screw 1 :3
46 Lock Nut 1 : 10
47 Spring 1
Casing (19) and body (33)
4 :8
mounting socket bolt

W4-3-11
 FRONT ATTACHMENT / Hose Rupture Valve
STRUCTURE OF HOSE RUPTURE VALVES
FOR BOOM CYLINDER AND POSITIONING
CYLINDER

9 10 11 12 13 14 15 16

17
3 4 5 6 7 8
2

18
1

19

47
20

46
21

45 22

23

44 24
25

43 26

27
42
28

41 29

40
30
39

38 31

37
32

36

35
33

34
W1V1-04-03-001

W4-3-12
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
1 Spacer 1
2 Plug 3 :5

3 O-Ring 3
4 Backup Ring 1
5 O-Ring 1
6 Orifice 2
7 Backup Ring 2
8 O-Ring 1
9 Lock Nut 1 : 17

10 Poppet 1
11 Set Screw 1 :6

12 Spring 1
13 O-Ring 1
14 Washer 1
15 Adapter 1 : 24

16 O-Ring 1
17 Backup Ring 1
18 O-Ring 1
19 Casing 1
20 O-Ring 1
21 Plug 1 : 32

22 Stopper 1
23 Spool 1
24 Sleeve 1
25 Backup Ring 1
26 O-Ring 1
27 O-Ring 3
28 Plug 1

W4-3-13
 FRONT ATTACHMENT / Hose Rupture Valve

47

46

45

44

43

42

41 29

40
30
39

38 31

37
32

36

35

33

34
W1V1-04-03-001

W4-3-14
 FRONT ATTACHMENT / Hose Rupture Valve

Wrench Size Tightening Torque

No. Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
29 Backup Ring 1
30 Spring 1
31 Holding Valve 1
32 Orifice 2
33 Body 1
34 O-Ring 1
35 O-Ring 1
36 Backup Ring 1
37 O-Ring 1
38 Backup Ring 1
39 Spring Seat 1
40 O-Ring 1
41 Piston 1
42 O-Ring 1
43 Cover 1 : 32
44 Stopper 1
45 Set Screw 1 :3
46 Lock Nut 1 : 10
47 Spring 1
Casing (19) and body (33)
4 :8
mounting socket bolt

W4-3-15
 FRONT ATTACHMENT / Hose Rupture Valve
(Blank)

W4-3-16
 FRONT ATTACHMENT / Operate Check Valve
REMOVE AND INSTALL OPERATE CHECK Outrigger Beam Lock Pin Float
VALVE (FOR BLADE AND OUTRIGGER)

Removal
CAUTION: Lower the blade onto the ground
before doing any work.
Outrigger
CAUTION: Secure the outrigger beam and
the outrigger by using the lock pin before
doing any work.
1. Remove bolts (1) (4 used) and washers (2) (4
WCEB-04-04-002
used) from guard cover (3). Remove guard cover
(3) from brackets (4) (2 used). 1, 2
: 19 mm
3

WCEB-04-02-001

5 6
2. Disconnect hoses (5) (4 used) from operate check
valve (7). Cap the open ends.
: 19 mm, 27 mm
7, 8

3. Remove socket bolts (10) (4 used) from piping (9).

: 6 mm 9

4. Remove socket bolts (6) (4 used) from operate

check valve (7). Remove operate check valve (7) 10
and O-rings (8) (2 used) from cylinder (11). Cap
the open ends.
11
: 6 mm 5
WCEB-04-02-002

10

11

6 7, 8 WCEB-04-04-001

W4-4-1
 FRONT ATTACHMENT / Operate Check Valve
Installation
1. Apply grease onto O-rings (8) (2 used). 5 6

2. Install O-rings (8) (2 used) to operate check valve

(7).
7, 8
3. Install operate check valve (7) to cylinder (11) with
socket bolts (6) (4 used).
: 6 mm 9
: 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft)

4. Connect piping (9) to operate check valve (7) with 10

socket bolts (10) (4 used).
: 6 mm
11
: 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft) 5
WCEB-04-02-002

5. Connect hoses (5) (4 used) to operate check 9

valve (7).
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm 10
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

6. Install guard cover (3) to brackets (4) (2 used) with

bolts (1) (4 used) and washers (2) (4 used).
: 19 mm 11
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
6 7, 8 WCEB-04-04-001

1, 2

WCEB-04-02-001

Outrigger Beam Lock Pin Float

11
Outrigger

WCEB-04-04-002

W4-4-2
 FRONT ATTACHMENT / Operate Check Valve
STRUCTURE OF OPERATE CHECK VALVE

1 2 3 4 5 6 7 8 9 10

11

12

13

WCEB-04-03-001

Wrench Size Tightening Torque

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 2 : 6 mm 34.3±3.4 (3.5±0.3) (25±3)
2 O-Ring 2 1B P11
3 Plug 2 : 36 mm 500±50 (51±5) (369±37)
4 O-Ring 2 1B P26
5 Spring 2
6 Sleeve 2
7 Poppet 2
8 Piston 2
9 O-Ring 1 1B P18
10 Plug 1 : 36 mm 240±24 (24±2.4) (18±2)
11 Casing 1
12 Plug 1 : 36 mm 240±24 (24±2.4) (18±2)
13 O-Ring 1B P18

W4-4-3
 FRONT ATTACHMENT / Operate Check Valve
(Blank)

W4-4-4
 MEMO

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 MEMO

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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162

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