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 correct 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 manual.
(Note: Do not tear off the form. Copy it for usage.):
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
to this manual.
The Operators Manual
The Parts Catalog

The Engine Manual

Parts Catalog of the Engine
Hitachi Training Material

MANUAL COMPOSITION
This manual consists of three portions: the Technical Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Manual.
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 Technical Manual

(Troubleshooting):
technical information needed for operational performance tests, and troubleshooting procedures.
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 assemble/disassemble procedures.

PAGE NUMBER
Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : 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
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 appropriate lifting techniques and equipment when lifting
heavy parts.

CAUTION:
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
indicated in parenthheses just behind SI units.

Quantity
Length
Volume

Weight
Force
Torque

To Convert
From
mm
mm
L
L
m3
kg
N
N
Nm
Nm

Into
in
ft
US gal
US qt
yd3
lb
kgf
lbf
kgfm
lbfft

A table for conversion from SI units to other system

units is shown below for reference purposees.

Quantity

Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375

Pressure
Power
Temperature
Velocity
Flow rate

IN-02

To Convert
From
MPa
MPa
kW
kW
C
km/h
min-1
L/min
mL/rev

Into
kgf/cm2
psi
PS
HP
F
mph
rpm
US gpm
cc/rev

Multiply By
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0

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 specific hazards. General precautions are listed on CAUTION
safety signs.
Some safety signs dont 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 machine.

NOTE indicates an additional explanation for an element

of information.
002-E01A-1223

SA-1

SA-1223

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 operate the machine.
Keep your machine in proper working condition.
Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
The safety messages in this SAFETY chapter are intended to
illustrate basic safety procedures of machines. However it is
impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003

SA-2

SA-003

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 fireextinguisher manual.
Establish emergency procedure guidelines to cope with
fires and accidents.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department posted near your telephone.

SA-437

004-E01A-0437

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
005-E01A-0438

PROTECT AGAINST NOISE

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

006-E01A-0434
SA-434

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
operators manual.

007-E01A-0435

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 operators work boots the operators foot
may slip off the pedal, possibly resulting in a personal accident.
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 attach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly starting a fire.
Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating
the machine.
Keep all flammable objects and/or explosives away from
the machine.
After using the ashtray, always cover it to extinguish the
match and/or tobacco.
Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

524-E01A-0000

SA-4

SA-435

SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
Do not use any controls as hand-holds.
Never jump on or off the machine. Never mount or dismount a moving machine.
Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
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 operator for the machine.
The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
If not, move the seat forward or backward, and check
again.
Adjust the rear view mirror position so that the best rear
visibility is obtained from the operators seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATORS SEAT

Before rising from the operators 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

SA-378

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

SA-237

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

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

SA-083

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 pressurized 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.
036-E01A-0293-3

SA-6

SA-293

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 chapter in the operators manual.
The operator must be in the operators 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 operators 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 equipment appropriate for the job, such as a hard hat, etc.
when operating the machine.
Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.

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 falling and to prevent the ground, stockpiles, or banks from
collapsing.
Make a work plan. Use machines appropriate to the work
and job site.
Reinforce ground, edges, and road shoulders as necessary.
Keep the machine well back from the edges of excavations and road shoulders.
When working on an incline or on a road shoulder, employ 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 support the machine.

SA-085

When working close to an excavation or at road shoulders,

operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear, so that the
machine can more easily evacuate if the cliff face collapses.
If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on a soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent
machine tipping over from occurring. When operating on
rough terrain or on slopes:
Reduce the engine speed.
Select slow travel speed mode.
Operate the machine slowly and be cautious with machine movements.

SA-9

M202-05-015

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 MULTIPLE NUMBERS OF MACHINES

For jobs involving multiple numbers of machines, provide
signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal persons 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 operators 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.

017-E01A-0491

SA-10

SA-092

SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the steering 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 overturn, possibly resulting in serious injury or death.

SA-090

Never attempt to ascend or descend 35 degrees or steeper slopes.

Be sure to fasten the seat belt.
When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A)
above the ground.
If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

SA-288

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 minutes to cool down the engine.
Stop the engine and remove the key from the key switch.
Pull the pilot control shut-off lever to LOCK position.
Block both tires and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.

020-E02A-0493

SA-11

SA-278

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

021-E01A-0494

SA-12

SA-383

SA-384

SAFETY
KEEP PERSON CLEAR FROM WORKING AREA
A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an
other object, resulting in serious injury or death.
Keep all persons clear from the area of operation and
machine movement.
Before operating the machine, set up barriers to the sides
and rear area of the bucket swing radius to prevent anyone from entering the work area.

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 possible, do not panic. Often, the machine can be secured by
lowering the front attachment, in such cases.

024-E01A-0488

SA-13

SA-683

SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL
RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
Be extra careful before operating on a grade.
Prepare machine operating area flat.
Keep the bucket low to the ground and close to the machine.
Reduce operating speeds to avoid tipping or slipping.
Avoid changing direction when traveling on grades.
NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
Reduce swing speed as necessary when swinging loads.

SA-088

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-15

SA-087

SAFETY
AVOID POWER LINES
Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.
When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
Check and comply with any local regulations that may apply.
Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-089
029-E01A-0381

PRECAUTIONS FOR LIGHTENING

The machine is vulnerable to lighting strikes.
In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to
a safe place far away from the machine.
After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed safety
devices are found, operate the machine only after repairing them.

SA-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, resulting in serious injury or death.
When using the machine for craning operations, be sure
to comply with all local regulations.
Do not use damaged chains or frayed cables, sables,
slings, or ropes.
Before craning, position the upperstructure with the travel
motors at the rear.
Move the load slowly and carefully. Never move it suddenly.
Keep all persons well away from the load.
Never move a load over a person's head.
Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
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 striking any object.

031-E01A-0432
SA-432

PARK MACHINE SAFELY

To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Place 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.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.

SA-093

HANDLE FLUIDS SAFELYAVOID 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.
Store flammable fluids well away from fire hazards.
Do not incinerate or puncture pressurized containers.
Do not store oily rags; they can ignite and burn spontaneously.
Securely tighten the fuel and oil filler cap.

SA-018

034-E01A-0496

SA-019

SA-17

SAFETY
TRANSPORT SAFELY
Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.
Observe the related regulations and rules for safe transportation.
Select an appropriate truck or trailer for the machine to
be transported.
Be sure to use a signal person.
Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.

Less than 15

2. Always use a ramp or deck strong enough to support the

machine weight.

SA-094

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 traveling direction must be changed while the ramp, unload
the machine from the ramp, reposition the machine on
the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a
sudden bump. Take care when traveling over it.
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the TRANSPORTING section.

035-E07A-0454

SA-18

Less than 15
SA-095

SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before starting work.
Keep the work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is moving.
Keep hands, feet and clothing away from power-driven
parts.
Before servicing the machine:
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5 minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving
the control levers several times.

SA-028

7. Remove the key from the 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 machine elements that must be raised for service work.
Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
MAINTENANCE chapter in the operators 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

SA-527

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 support the machine on cinder blocks, hollow tires, or props
that may crumble under continuous load. Do not work
under a machine that is supported solely by a jack.

SA-527

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 serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended 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
may result in tire explosion.
521-E02A-0249

SA-21

SA-249

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

SA-039

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 operators manual.)
Failure to periodically replace rubber hoses may cause a fire,
fluid injection into skin, or the front attachment to fall on a
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
S506-E01A-0019

SA-22

SA-019

SAFETY
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
If an accident occurs, see a doctor familiar with this type
of injury immediately. Any fluid injected into the skin
must be surgically removed within a few hours or gangrene may result.

SA-031

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 machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
If any abnormalities are found, be sure to repair them
before operating the machine.
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.
Refer the explanation pages on the Emergency Evacuation
Method.

SA-393

18-E02B-0393

SS-1510

BEWARE OF EXHAUST FUMES

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

509-E01A-0016

SA-016

PRECAUTIONS FOR WELDING AND GRINDING

Welding may generate gas and/or small fires.
Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before
starting welding.
Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering.
523-E01A-0818

SA-25

SA-818

SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID LINES
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and
bystanders.
Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary fireresistant guards to protect hoses or other materials before
engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAINING

FLAMMABLE FLUIDS

SA-030

Do not weld or flame cut pipes or tubes that contain flammable fluids.
Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING

Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
Avoid potentially toxic fumes and dust.
Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.
Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with
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

SA-029

SAFETY
BEWARE OF ASBESTOS DUST
Take care not to inhale dust produced in the work site. Inhalation 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 asbestos 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
genuine Hitachi Parts.

SA-029

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 16C ( 60 F ) first.
Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.
Loose terminals may produce sparks. Securely tighten all
terminals.

SA-032

Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.
Be sure to wear eye protection when checking electrolyte
specific gravity.
512-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 machine include such items as lubricants, coolants, paints, and
adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the
risks are and how to do the job safely. Then follow procedures and use recommended equipment.
See your authorized dealer for MSDSs (available only in
English) on chemical products used with your machine.

SA-309

515-E01A-0309

DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel, coolant,
brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.

516-E01A-0226

SA-28

SA-226

SAFETY
BEFORE RETURNING THE MACHINE TO THE CUSTOMER
After maintenance or repair work is complete, confirm that:
The machine is functioning properly, especially the safety
systems.
Worn or damaged parts have been repaired or replaced

S517-E01A-0435

SA-435

SA-29

SAFETY
(Blank)

SA-30

SECTION AND GROUP

CONTENTS

SECTION 1 GENERAL INFORMATION

Group 1 Precautions for disassembling and Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil Tank

SECTION 2 UPPERSTRUCTURE
WORKSHOP MANUAL

Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Electric Lever
Group 9 Signal Control Valve
Group 10 Travel 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

All information, illustrations and specifications in this manual are based on

the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.

Group 1 Swing Bearing

Group 2 Travel Motor
Group 3 Center Joint
Group 4 Transmission
Group 5 Axle
Group 6 Axle Lock Cylinder
Group 7 Operate-Check Valve
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.
Tokyo, Japan
All rights reserved

Group 1 Front Attachment

Group 2 Cylinder
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
Group 4 Pilot Valve
SECTION 2 SYSTEM
Group 5 Electric Lever
Group 1 Controller
Group 6 Transmission
Group 2 Control System
Group 7 Axle
Group 3 ECM System
Group 8 Travel Motor
Group 4 Hydraulic System
Group 9 Signal Control Valve
Group 5 Electrical System
Group 10 Steering Valve
Group 11 Brake Valve
Group 12 Others (Upperstructure)
Group 13 Others (Undercarriage)

TECHNICAL MANUAL (Troubleshooting)

SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test

SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 ICF
Group 5 Component Layout
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................................................ W1-2-3
Piping Joint .................................................. W1-2-6
Periodic Replacement of Parts ............... W1-2-10

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

Group 4 Bleeding Air from Hydraulic Oil

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

CJBW-1-1

(Blank)

CJBW-1-2

GENERAL / Precautions for Disassembling and Assembling

PRECAUTIONS FOR
AND ASSEMBLING

DISASSEMBLING

Precautions for Disassembling and Assembling

Clean the Machine

Precautions for Disassembling

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

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

Bleeding Air from Hydraulic System

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.

When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and installation 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 housing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the motor may result.
If the cylinder is operated with air
trapped in the cylinder tube, damage 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 engine and run at slow idle speed.
Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
After bleeding all the air, securely tighten the
plug.

Bleeding Air from Travel Motor / Swing Motor

With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.

W1-1-2

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 operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
Reposition the front attachment to check hydraulic oil level.
Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.

W1-1-3

WCJB-01-04-001

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
uneven wear.
(3) Check O-ring (B) for
deformation or hardening.

tears,

W105-03-05-019

breaks,

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

Correct

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.
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal
mating face (C) by measuring the distances
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating.

Correct

W105-03-05-020

Incorrect

A
B

a=b

ab
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
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
Lower the temperature of the lifted load to lower
than 100 C (212 F). If unavoidably lifting a load
with a temperature of 100 C (212 F) or more,
reduce the load weight.
Do not lift acid or alkali chemicals.
Take care not to allow the sling to become wet.
The load may slip.
When required to use more than one sling, use
slings with the same width and length to keep the
lifted load balanced.
When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
Avoid using twisted, bound, connected, or
hitched slings.
Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
Avoid dragging slings on the ground, throwing
slings or pushing slings with a metal object.
When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
Store the nylon slings indoors so they wont deteriorate with heat, sun light, or chemicals.

Correct Eyehole
Lifting Method

W102-04-02-016

Incorrect Eyehole
Lifting Method

W105-04-01-008

Bent Sling

W1-1-5

W162-01-01-009

GENERAL / Precautions for Disassembling and Assembling

CAUTION: If a load is lifted with a damaged
nylon sling, serious personal injury may result. Be sure to visually check the nylon sling
for any damage before using.

Damaged Appearance

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.

Broken Sewing Thread

W162-01-01-002

Scuffing

W162-01-01-003

Fuzz
Broken Sewing
Thread

W162-01-01-004

Broken Sewing
Thread

W162-01-01-005

Broken Sewing
Thread

Scoring

Fuzz

Separation of
Belt

Scuffing

W162-01-01-006

W162-01-01-007

Broken Warp

W162-01-01-008

W1-1-6

GENERAL / Precautions for Disassembling and Assembling

MAINTENANCE STANDARD TERMINOLOGY
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 accomplished after exceeding this limit.
2. Repair or adjustment is impossible after exceeding this limit.
3. Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the Allowable Limit.

W1-1-7

GENERAL / Precautions for Disassembling and Assembling

(Blank)

W1-1-8

GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
No.

Bolt Dia

Descriptions

mm

Torque

Qty

Wrench
Size (mm)

Nm

(kgfm)

(lbfft)

(Pump Upper)

18

27

360

(37)

(265)

(Pump Lower)

16

24

210

(21.5)

(155)

Engine cushion rubber mounting nut (Fan Side)

14

22

140

(14.0)

(103)

Engine bracket mounting bolt and nut

10

17

50

(5.1)

(37)

Hydraulic oil tank mounting bolt

16

24

210

(21.5)

(155)

Fuel tank mounting bolt

16

24

210

(21.5)

(155)

17

24.5

(2.5)

(18)

19

30

(3.1)

(22)

22

40

(4.1)

(30)

27

95

(9.7)

(70)

32

140

(14.3)

(105)

36

175

(17.8)

(130)

41

210

(21.5)

(155)

Engine cushion rubber mounting

bolt

ORS and metal face seal fittings for hydraulic hoses

and piping

Pump mounting bolt

10

17

50

(5.1)

(37)

Control valve mounting bolt

16

24

210

(21.5)

(155)

Control valve bracket mounting bolt

16

24

210

(21.5)

(155)

Swing device mounting bolt

20

12

30

500

(51)

(370)

10

Swing motor mounting bolt

12
(Hex.
Wrench)

10

90

(9.2)

(66)

11

Battery mounting nut

10

17

50

(5.1)

(37)

12
13

Cab mounting nut

16

24

210

(21.5)

(155)

Swing bearing mounting bolt to upperstructure

20

32

30

510

(52)

(380)

Swing bearing mounting bolt to chassis

20

36

30

490

(50)

(360)

Center joint lock mounting bolts

16

24

270

(27.5)

(200)

14

15
16

Travel motor mounting bolts

16
(Hex.
Wrench)

14

270

(27.5)

(200)

17

Propel shaft mounting nuts

10

16

14

76

(8)

(60)

18

Center Bearing mounting bolt

10

17

50

(5.1)

(37)

19

Rear axle mounting bolts

24

36

950

(97.0)

(700)

20

Wheel pin nuts

22

40

30

600

(61)

(440)

21

Cover mounting bolt

6
10
12

10
17
19

10
50
90

(1)
(6.1)
(9.2)

(7.4)
(37)
(66)

22

Flexible master coupling of piping

4 pairs

13

10.3 to 12.4

(1.05 to
1.26)

(7.59 to
9.11)

23

Jubilee Clamp of low pressure piping

T-bolt clamp of low pressure piping

7
11

5.9
5.9

(0.6)
(0.6)

(4.3)
(4.3)

Apply LOCTITE to the threads.

W1-2-1

GENERAL / Tightening
NOTE 1.Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
(Except for Sprocket mounting bolt.)
2.Make sure bolt and nut threads are clean
before installing.

W1-2-2

GENERAL / Tightening
TORQUE CHART
CAUTION: Use tools appropriate for the
work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools
may slip, potentially causing personal 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
correctly when assembling the machine or components.
Hexagon T Bolt

SA-040

Hexagon H Bolt

Hexagon M Bolt

Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart

Bolt Dia.

Wrench
Size

Hexagon
Wrench
Size

M552-07-091

M552-07-092

M552-07-090

Socket Bolt
Nm

(kgfm)

(lbfft)

Nm

(kgfm)

(lbfft)

Nm

(kgfm)

(lbfft)

M6

10

M8

13

30

(3.0)

(21.5)

20

(2.0)

(14.5)

10

(1.0)

(7.2)

M10

17

65

(6.5)

(47)

50

(5.0)

(36)

20

(2.0)

(14.5)

3.3 to 4.2

(0.3 to 0.4) (2.4 to 3.0)

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)

W1-2-3

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 lubricant.
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 application.
5. Make sure that nut and bolt
threads are clean before installing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
Equally tighten upper and lower alternately

Tighten diagonally
1

1st to 4th

Tighten from center and diagonally

12

14

13

10

11

4
2
2nd to 3rd

W105-01-01-003

W1-2-4

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 extrusion. If defects cannot be polished out, replace the component.
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
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 diagonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes tightening of one bolt fully before
tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.

W105-01-01-015

WRONG

W105-01-01-016

W105-01-01-008

WRONG

RIGHT

Nut and Bolt Locking

Do not bend it round

Bend along edge sharply

RIGHT

WRONG

RIGHT

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
holes in the bolt and nut while tightening, not while loosening.

Bend along edge sharply

RIGHT

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

RIGHT

WRONG

Loosen

W105-01-01-009

WRONG

Tighten

W105-01-01-010

W1-2-5

GENERAL / Tightening
PIPING JOINT

IMPORTANT: 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 application.

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). Excessive force will be applied to

metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be
sure to tighten nut (3) to specifications.
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.

Description
30male

37female

Male Union Joint

Female Union Joint

W105-01-01-017

Wrench Size
mm
Union Nut
17
19
22
27
32
36
41
17
19
22
27
32
36
41

Wrench Size mm
Joint Body
17
19
22
27
32
36
41
14
17
19
22
27
32
36

Tightening
Torque
Nm (kgfm, lbfft)
24.5 (2.5, 18)
29.5 (3.0, 21.5)
39 (4.0, 28.5)
78 (8.0, 58)
137 (14.0,101)
175 (18.0, 129)
205 (21.0,1 51)
24.5 (2.5, 18)
29.5 (3.0, 21.5)
39 (4.0, 28.5)
78 (8.0, 58)
137 (14.0, 101)
175 (18.0, 129)
205 (21.0, 151)

NOTE: Tightening torque of 37 male coupling without union is similar

to tightening torque of 37 female.

W1-2-6

GENERAL / Tightening Torque

O-ring Seal Joint

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
O-ring groove (e). Tightening nut (9)
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).
Damage to O-ring (6) will cause oil
leakage.
4. If nut (9) is loose and oil is leaking,
do not re-tighten nut (9). Replace
O-ring (6) with a new one and check
that O-ring (6) is correctly seated in
place, tighten nut (9).

W1-2-7

Wrench Size
mm
Union Nut
19
22
27
32
36
41
46

Wrench Size
mm
Joint Body
17
19
22
27
30, 32
36
41

Hose Fittings
M104-07-033

Tightening Torque
Nm (kgfm, lbfft)
29.5 (3.0, 21.5)
69 (7.0, 51)
93 (9.5, 69)
137 (14.0, 101)
175 (18.0, 129)
205 (21.0, 151)
205 (21.0, 151)

GENERAL / Tightening Torque

Screw-In Connection
Depending on types of screw and sealing, different types
of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread pitch
and thread type (tapered or straight) are
the correct type before using any
screw-in connection.

PT

30

Male Tapered Thread

PF

Male Straight Thread

W105-01-01-018

Wrench Size
mm
Hose Fittings
19
22
27
36
41
50
60

Male Tapered Thread

Tightening Torque
Nm (kgfm, lbfft)
FC material
SS material
14.5 (1.5,10.5)
34 (3.5,25)
29.5 (3.0,21.5)
49 (5.0,36)
49 (5.0,36)
93 (9.5,69)
69 (7.0,51)
157 (16,116)
108 (11,80)
205 (21,151)
157 (16,116)
320 (33,235)
195 (20,144)

Seal Tape Application

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
clearances. Do not overwrap.

Internal Thread

External Thread

Clearance

Application Procedure

W105-01-01-019

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.

Leave one to two pitch threads uncovered

Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs depending on the type of clamp.
T-Bolt Type Band Clamp:
4.4 Nm ( 0.45 kgfm, 3.25 lbfft )
Worm Gear Type Band Clamp:
5.9 to 6.9 Nm (0.6 to 0.7 kgm, 4.3 to 5.1 lbfft)

M114-07-041

T-Bolt Type

M114-07-043

W1-2-8

Worm Gear Type

M114-07-042

GENERAL / Tightening Torque

Connecting Hose
RIGHT

WRONG
CAUTION: When replacing hoses, be sure to use
only genuine Hitachi service parts. Using hoses
other than genuine Hitachi hoses may cause oil
leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the machine.
Do not install hoses kinked. Application of high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leaks, hose rupture or
separation of fitting. Utilize Print marks on hoses
when installing to prevent hose from being
kinked.

W105-01-01-011

RIGHT

WRONG
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 rubbing against each other.
W105-01-01-012

Take care so that hoses do not come into contact

with moving parts or sharp objects.

WRONG
Clamp

RIGHT
Clamp

Rubbing Against
Each Other
W105-01-01-013

WRONG

Rubbing Against
Each Other

RIGHT

Clamp
W105-01-01-014

W1-2-9

GENERAL / Tightening Torque

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 intervals 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.

Periodic Replacement Parts

Engine

Base Machine
Hydraulic
System
Front-End
Attachment

Fuel hose (Fuel tank to filter)

Oil filter hose (Engine to oil filter)
Heater hose (Heater to engine)
Pump suction hose
Pump delivery hose
Swing hose
Travel Hose
Boom cylinder line hose
Arm cylinder line hose
Bucket cylinder line hose
Pilot hose

NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.

W1-2-10

Replacement
Intervals
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years
Every 2 years

GENERAL / Painting
PAINTING
Painting specification
Surfaces to Be Painted

Main surface of upperstructure (except cab)

Main frame
Internal parts
Front attachment
Track (including swing bearing)
Floor plate

Painting Colour
YR-01 [TAXI yellow]
HG Beige Deep
Black
YR-01 [TAXI yellow]
N1.0 [Black]
M/F Cation (allowed)

Final painted color

Inside and outside surface of cab

Shaded area on cab outside
Right window guards, U-Bolt

Suspension lifter (chair bottom)

Lever (Pilot shut-off, foot rest)
Engine cover
Cover, Step
Handrail on upperstructure right side
Mirror stay: cab side, right side
Nonslip cover
Rear camera cover
Head light bracket

HG Beige Deep
Shining Silver
[KANSAI PAINT LF-113-230B
(Charcoal series black, half glossy)]
[N2.0 (Black)]
High Grade Black
High Grade Black
HG Beige Deep
HG Beige Deep
High Grade Brack
KANSAI PAINT Amilac 1400 (Deep Black)
HG Beige Deep
HG Beige Deep

W1-3-1

GENERAL / Painting

Engine Cover

Mirror Stay

Camera Cover

WCJB-01-03-002

Decal
[TAXI Yellow]

Head Light Bracket

Mirror Stay

Handrail

Step

Mirror Stay

WCJB-01-03-001

Decal
[Shining Silver]

Decal
[Shining Silver]

W1-3-2

Right Side
Cover

Head Light Bracket

GENERAL / Painting
Paint all circumference in the hinge
swing position shining silver.
Shaded Area
[Shining Silver]
Door

Panel Behind the

Door
10

Painting Area of the Door

YR-01 (TAXI Yellow)

W178-01-03-005

Section A

WCJB-01-03-004

Nonslip Cover
KANSAI PAINT
Amilac 1400
(Deep Black)

Align with the panel.

[Shining Silver]

Panel

WCEB-01-03-003

Front Attachment
YR-01 (TAXI Yellow)

WCJB-01-03-003

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 when painting and drying.

W178-01-03-007

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
lower the bucket to the ground.

WCJB-01-04-001

1
2

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

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

WCEB-01-04-001

4. Connect a vacuum pump with the hole removed

cap (2) to maintain negative pressure in the
hydraulic oil tank (3).
NOTE: Be sure to run the vacuum pump
continuously while working.

Vacuum Pump
Hose

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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SECTION 2

UPPERSTRUCTURE
CONTENTS
Group 1 Cab

Group 5 Control Valve

Removal and Installation of Cab ............ W2-1-1

Dimensions of Cab Glass .................... W2-1-12

Removal and Installation of

Control Valve ........................................W2-5-1
Disassembly of Control Valve
4-Spool Side .........................................W2-5-6
Assembly of Control Valve
4-Spool Side .......................................W2-5-18
Disassembly of Control Valve
5-Spool Side .......................................W2-5-36
Assemble of Control Valve
5-Spool Side .......................................W2-5-48
Disassembly of Housing.......................W2-5-60
Assembly of Housing............................W2-5-62
Removal and Installation of
Positioning Control Valve....................W2-5-65
Disassembly of Position
Control Valve ......................................W2-5-66
Assembly of Positioning
Control Valve ......................................W2-5-68

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 .............. W2-4-14
Assembly of Pump Device ................... W2-4-26
Disassembly of Regulator .................... W2-4-46
Assembly of Regulator......................... W2-4-48
Structure of Pilot Pump ........................ W2-4-50

Group 6 Swing Device

Removal and Installation of
Swing Device ........................................W2-6-1
Disassembly of Swing Device ................W2-6-4
Assembly of Swing Device ...................W2-6-10
Disassembly of Swing Motor ..............W2-6-18
Assembly of Swing Motor .....................W2-6-22
Structure of Swing Dampener Valve.....W2-6-26
Maintenance Standard..........................W2-6-27

CJBW-2-1

Group 7 Pilot Valve

Group 12 Pilot Shut-Off Solenoid 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

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 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 15 Accumulator Charge Valve

Group 9 Signal Control Valve

Removal and Installation of Signal
Control Valve ........................................ W2-9-1
Structure of Signal Control Valve ........... W2-9-4

Group 10 Travel Shockless Valve

Removal and Installation of
Travel Shockless Valve ...................... W2-10-1
Structure of Travel Shockless Valve .... W2-10-4

Group 11 Solenoid Valve

Removal and Installation of 4-Spool
Solenoid Valve Unit ............................ W2-11-1
Structure of 4-Spool Solenoid Valve
Unit ..................................................... W2-11-3
Disassembly and Assembly of
4-Spool Solenoid Valve Unit.............. W-2-11-4
Removal and Installation of Solenoid Valve
Unit (For Electric Lever Operation) .... W2-11-6
Structure of Solenoid Valve Unit
(For Electric Lever Operation)............ W2-11-8

CJBW-2-2

Removal and Installation of

Accumulator Charge Valve .................W2-15-1
Structure of Accumulator
Charge Valve ......................................W2-15-4

UPPERSTRUCTURE / Cab
REMOVAL AND INSTALLATION OF CAB
Removal
CAUTION: Seat (1) weight: 40 kg (90 lb)
1

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
6

WCEB-02-01-001

WCEB-02-01-017

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

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

2
WCEB-02-01-002

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

W2-1-1

WCEB-02-01-003

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).

6. Remove cover (9) from cab (7).

11, 12

11, 12

7. Remove sems bolts (16) (4 used) from cover (14).

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

W1JB-02-01-005

13

14

16

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

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

13

16

15
17

WCEB-02-01-008

13

17

15

17

W2-1-2

WCEB-02-01-018

WCEB-02-01-019

UPPERSTRUCTURE / Cab
18

9. Remove screws (19) (2 used) from cover (18).

Remove cap (20) and screw (21) from cover (18).
Remove cover (18) from cab (7).

19

20, 21

W1JB-02-01-001

22

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

26

11. Open covers (25, 26).

WCJB-02-01-001

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

hold cover (25).
13. Remove nuts (28) (4 used), spring washers (29)
(4 used) and washers (30) (4 used) from cover
(25). Remove cover (25) from support (27).
: 17 mm

25

27

28, 29, 30

WCJB-02-01-003

W2-1-3

UPPERSTRUCTURE / Cab
31

14. Disconnect vinyl hose (32) from washer tank (31).

Cap the open ends.

32

WCJB-02-01-004

15. Remove sems bolts (35) (7 used) from cover (33).

Remove cover (33) from main frame (34).
: 17 mm

33

34

35

WCJB-02-01-005

16. Remove anchor bolt (38), washer (37) and spacer

(36) from cab (7) and main frame (34).
: 32 mm

7
36
37

34

38

WCEB-02-01-013

17. Remove vinyl hose (32) through the cab (7) side.

32

WCJB-02-01-004

W2-1-4

UPPERSTRUCTURE / Cab
39

18. Open cover (40).

40

41

42

19. Remove sems bolts (41) (4 used) from cover (39).

Remove cover (39) from stay (42).
: 17 mm

WCJB-02-01-002

43

20. Remove clamps (44) (3 used) from the outside of

the cab (7) rear. Disconnect connectors (43) (5
used).

44

WCEB-02-01-014

Lifting Bracket

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

47

Lifting Bracket

21. Attach a nylon sling onto the bracket in cab (7).

Hold cab (7).
22. Remove nuts (45) (4 used) and washers (46) (4
used) from cab (7).
: 24 mm

45, 46

45, 46

23. Remove socket bolts (47) (6 used) from cab (7).

: 8 mm
24. Remove bolts (48) (5 used) and washers (49) (5
used) from cab (7).
: 17 mm

47
45, 46
W1JB-02-01-006

48, 49

47

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

25. Remove cab (7) from main frame (34).

34
WCJB-02-01-006

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
(34).

34
WCJB-02-01-006

Lifting Bracket

2. Install cab (7) to main frame (34) with nuts (45) (4

used) and washers (46) (4 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)
3. Install cab (7) to main frame (34) with socket bolts
(47) (6 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

47

Lifting Bracket

45, 46

45, 46

4. Install cab (7) to main frame (34) with bolts (48) (5

used) and washers (49) (5 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

47
45, 46
W1JB-02-01-006

48, 49

47

22

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

6. Install bracket (24) to cab (7) and duct (22) with
sems bolts (23) (2 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

23
24
15
23

W2-1-6

WCEB-02-01-016

UPPERSTRUCTURE / Cab
18

7. Install cover (18) to cab (7) with screws (19) (2

used). Install cover (18) to cab (7) with screw (21).
Install cap (20) to screw (21).

19

20, 21

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

hole on bracket (15). Install the bracket (13)
assembly to bracket (15) with sems bolts (17) (5
used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

13

17

W1JB-02-01-001

13

17

15

17

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

bolts (16) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCEB-02-01-018

WCEB-02-01-019

13

14

16

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

16

15

WCEB-02-01-008

7
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).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

10

W1JB-02-01-004

12. Connect connectors (43) (5 used). Secure

connectors (43) (3 used) with clamps (44) (3
used).

43
44

WCEB-02-01-014

13. Secure cab (7) to main frame (34) with anchor bolt
(38), washer (37) and spacer (36).
: 32 mm
: 550 Nm (55 kgfm, 406 lbfft)

7
36
37

34

38

WCEB-02-01-013

31

14. Pass vinyl hose (32) through main frame (34).

Connect vinyl hose (32) to washer tank (31).
32

WCJB-02-01-004

W2-1-8

UPPERSTRUCTURE / Cab
15. Install cover (33) to main frame (34) with sems
bolts (35) (7 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

33

34

35

WCJB-02-01-005

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

align cover (25) with the mounting hole on support
(27). Secure cover (25) to support (27) with
washers (30) (4 used), spring washers (29) (4
used) and nuts (28) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

25

27

28, 29, 30

WCJB-02-01-003

25

17. Shut covers (25, 26).

26

WCJB-02-01-001

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

18. Install seat (1) to plate (2) with socket bolts (3) (4
used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)

2
WCEB-02-01-002

W2-1-9

UPPERSTRUCTURE / Cab
1

19. Install safety belts (6) (2 used) to brackets (5) (2

used) with sems bolts (4) (2 used).
: 16 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCEB-02-01-001

WCEB-02-01-017

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

21. Install cover (39) to stay (42) with sems bolts (41)
(4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

39

40

WCEB-02-01-003

41

42

22. Shut cover (40).

WCJB-02-01-002

W2-1-10

UPPERSTRUCTURE / Cab
(Blank)

W2-1-11

UPPERSTRUCTURE / Cab
DIMENSIONS OF CAB GLASS
NOTE: Unit: mm (1 mm=0.039 in)

Black Ceramic
Coating Range

115
70

21
60

C0.5

107

2-R50
2-R250

2-R50

2-R20
2-R10

2-R127

70

C0.5
Black Ceramic
Coating Surface

106.6
1081

W1JB-02-01-013

R50

(4 mm)

R2975

Section A

R800

28

R75
R120

Black
Ceramic
Coating
Surface

R40

2R-5

271

268

20 70

16.5

50

W1JB-02-01-011

21
847

214

21

Black Ceramic
Coating Range

R1075
W1JB-02-01-009

372.9

(4 mm)
22

50

54.1

25

W1JB-02-01-012

84

25
865

C0.5
R2

C0.5

W1JB-02-01-014

W1JB-02-01-019

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

(4 mm)

R150

2-12.2 +0.5
-0

139.7

50

6445

(4 mm)

50

400

WCEB-02-01-012

631
37

228.2

50
50

WCEB-02-01-011

383.2

312.6

C0.5
4-4

C0.5
R2800

Black Ceramic
Coating Surface

(4 mm)
Section A

W1JB-02-01-013

644.5

400.5
WCEB-02-01-004

228.2
93

50
50

WCEB-02-01-010

460.2
Glass Mark (Back)

860.8

Black Ceramic
Coating Range

833
506
63.5

581

64.5
R50

448

R964

R75
R58
R250 185
R103
R42 R329

R10

17

2-R4

R150

R2854

498.5

26.5

438.5
353.5

50
2-21

327.5
173

109.5

(4 mm)

R60

R25
1

102.5

R60

W2-1-13

R10
R5004

152.5

R5031

118

336

34

82

W1JB-02-01-018

UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)

Black Ceramic
Coating Range

30

R30

39

29
652

87.5

(4 mm)

R200

87.5

R200

R500

R500

R50 185

185
45
70
R50

4-R10

205

848

W1JB-02-01-021

WCEB-02-01-015

Black Ceramic
Coating Range

567.5
496
123.5 80

C0.5

3-R4
75.5

Black Ceramic
Coating Surface
Section A

R25

100

C0.5

R25
R20 R25
87.7 R75

W1JB-02-01-013

R25

R4139.5

887 1008

R4044.5

19.5

1127.3

59.5

85

1099

1145.5

(4 mm)
R40

C0.5

R35
R135

C0.5

R100

R35

R550

83
13
112
109

W1JB-02-01-014

A
228

105
65

Section B

R250

R20

102
W1JB-02-01-017

R60

R70

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
Coating Surface
Section A

W1JB-02-01-013

W1JB-02-01-009

1646.47
1599.44

Black Ceramic Coating Range

80

50
106

2-R25

50

R75

R3025

R20

R30

90

R30

R50
158

R2875

R575
R125
R1040

R10

R50

R30 R50

28

R1525
R30

R55

393
400
807.65
963.7

W2-1-15

1636.3

40

A
1496.7

R2940

(5 mm)

R25

1205

50

873.14

R30

150 145

696.73

R300

R2145

1230

R20

313.6

900

187

W1JB-02-01-020

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
Glass

Garnish

Garnish

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

cutter knife).

Lower Door
Glass

Resin Panel

WCEB-02-01-015

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.
NOTE: Cut off the middle of adhesive between
glass and cab.
Piano wire is easily broken if a part of piano
wire turns hot. Change the position and cut
the adhesive.

Glass (Cab Outside)

Cab

Cab Glass

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
Glass

Rear Left-Hand
Glass

W1JB-02-01-010

Cab

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

using white spirit.

Cutter Knife

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
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).
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

Cab

Apply Primer 24 by
using a brush.
Cutting Edge of
Adhesive at Cab
Side
W1SE-02-01-038

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)
Right-Hand Glass

Rear Glass
250

350

300

500
100

200
200

500

200
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

W2-1-20

W1JB-02-01-038

UPPERSTRUCTURE / Cab
NOTE: Unit: mm
(1 mm=0.039 in)

Spacer C
Spacer B

Spacer A

20
20

20

Two Side
Adhesive Tape

R0.5

R5

84

75

R0.5

R10

78

10.5

12

Two Side
Adhesive Tape

R8

R0.5

W1JB-02-01-024
W1JB-02-01-023

10.5
W1JB-02-01-022

Dam Rubber
30

6.4
6
W1JB-02-01-025

Lower Door Grass

Rear Left-Hand Glass

Right-Hand Glass

Suction Lifter

Spacer A
Rubber

Dam
Rubber
Spacer A

Spacer A
Spacer B

Spacer B
Dam
Rubber

W1JB-02-01-039

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
evenly.

Remove
the seal.

12
W1JB-02-01-031

Adhesive
Cartridge

W1SE-02-01-028

W2-1-21

W1SE-02-01-043

Panel

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

Upper Front Glass

Lower Door Glass
Rear Left-Hand Glass
Rear Right-Hand Glass
Rear Glass

Adhesive
Sika Tack-Drive
(Sika Tack-Drive)
310 ml Cartridge
310 ml
150 ml
250 ml
100 ml
210 ml

Painted Surface or
Adhesive Surface
Primer
Sika Aktivator DM-1
(Sika Aktivator DM-1)
250 ml Can
0.75 ml
0.5 ml
0.65 ml
1 ml
0.5 ml

W2-1-22

Glass Surface
Primer
Sika Primer 206G+P
30 ml Bottle
0.67 ml
0.45 ml
0.6 ml
0.9 ml
0.45 ml

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

Sash
Assembly

Garnish

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

3. Install the sash assembly, which the glass is
installed on, onto the door from the outside of cab.
Secure the sash assembly at the inside of cab by
using the garnish.

W2-1-23

Glass A

Glass B
W1JB-02-01-010

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
X Seal Here

Upper
Glass

Cemedine Super X

Seal (1)

Seal (1)

Lower
Glass

Lower
Glass

W1JB-02-01-032

W2-1-24

Upper
Glass

W1JB-02-01-033

UPPERSTRUCTURE / Counterweight
REMOVAL
AND
COUNTERWEIGHT

INSTALLATION

OF

Removal
1. Open cover (1).

WCJB-02-02-002

2. Disconnect plugs (2, 3).

WCJB-02-02-003

WCJB-02-02-004

3. Open cover (4).

4

WCJB-02-02-001

4. Disconnect connector (5).

WCJB-02-02-005

W2-2-1

UPPERSTRUCTURE / Counterweight
6

5. Open covers (6, 7).

WCJB-02-01-001

6. Disconnect connector (8).

8

WCEB-02-02-006

CAUTION: Counterweight (10) weight:

ZX210W-3: 3850 kg (8490 lb)
ZX220W-3: 4950 kg (11000 lb)

10

7. Remove caps (9) (2 used) from counterweight

(10). Install FLENO RINK BOLT into the holes
where caps (9) (2 used) were removed.
NOTE: Dimension of FLENO RINK BOLT (B-42,
M42, Pitch 4.5 mm)
8. Attach a wire rope onto FLENO RINK BOLT. Hoist
and hold counterweight (10).

11
12

CAUTION: When using a power wrench, do

not pinch your fingers by its reaction bar.

WCEB-02-02-004

9. Remove bolts (12) (4 used) and washers (11) (4

used) from counterweight (10) by using a power
wrench.
: 60 mm

10

10. Hoist and remove counterweight (10) from main

frame (13).
11

12
13

W2-2-2

WCEB-02-02-005

UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight (10) weight:
ZX210W-3: 3850 kg (8490 lb)
ZX220W-3: 4950 kg (11000 lb)
1. Hoist and align counterweight (10) with the
mounting holes on main frame (13).

10

2. Temporarily tighten counterweight (10) to main

frame (13) with bolts (12) (4 used) and washers
(11) (4 used).
11

CAUTION: When using a power wrench, do

not pinch your fingers by its reaction bar.
12

3. Remove the wire rope and FLENO RINK BOLT

from counterweight (10). Tighten bolts (12) (4
used) by using a power wrench and torque
wrench.
: 60 mm
: 3600 Nm (367 kgfm, 2660 lbfft)

13

WCEB-02-02-005

10

Torque Wrench
Power Wrench

WCEB-02-02-006

4. Install caps (9) (2 used) to counterweight (10).

10

WCEB-02-02-007

W2-2-3

UPPERSTRUCTURE / Counterweight
5

5. Connect connectors (5, 8).

WCJB-02-02-005

WCEB-02-02-006

6. Shut cover (4).

4

WCJB-02-02-001

7. Shut covers (7, 6).

WCJB-02-01-001

8. Connect plug (3).

WCJB-02-02-004

W2-2-4

UPPERSTRUCTURE / Counterweight
9. Connect plug (2).

WCJB-02-02-003

10. Shut cover (1).

WCJB-02-02-002

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:

ZX210W-3: 3850 kg (8490 lb)
ZX220W-3: 4950 kg (11000 lb)
Washer

1. Remove the counterweight.

(Refer to the REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
: 60 mm

Bolt

WCEB-02-02-005

Monoblock Boom

CAUTION: The front attachment assembly

weight:
Monoblock boom: 3430 kg (7570 lb)
2-piece boom: 4190 kg (9240 lb)
2. Remove the front attachment assembly.
(Refer to the REMOVAL AND INSTLLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 27 mm, 30 mm, 36 mm
WCJB-02-03-001

2-Piece Boom

WCJB-02-03-002

W2-3-1

UPPERSTRUCTURE / Main Frame

CAUTION: Center joint weight: 90 kg (200 lb)

Connector

Slip Ling

Hose

3. Remove the bolts, the stopper and the slip ring

from the center joint. Disconnect the hose from
the center joint. (Refer to the Remove and Install
Center Joint group on W3-3-1.)
: 10 mm, 19 mm, 22 mm, 27 mm, 36 mm

Stopper

Bolt

Center Joint

CAUTION: Upperstructure weight: 5400 kg

(12000 lb)
IMPORTANT: 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 chain block is used, it is not only easy to
adjust the length of wire rope, but also
easy to level the center of gravity.

WCJB-03-03-001

Wire Rope

Rear Side of Frame

WCEB-02-03-003

Wire Rope

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.
: 30 mm
6. Adjust a chain block in order to level the center of
gravity. Hoist and remove the frame.

WCJB-02-03-003

Bolt

W2-3-2

UPPERSTRUCTURE / Main Frame

Installation

CAUTION: Upperstructure weight: 5400 kg

(12000 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.
: 30 mm
: 520 Nm (53 kgfm, 390 lbfft)

WCJB-02-03-003

Bolt
Connector

Slip Ling

Hose

3. Connect the hoses (13 used) to the center joint.

: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)
4. Apply LOCTITE #262 onto the bolts (5 used).
Install the stopper to the center joint.
: 24 mm
: 265 Nm (27 kgfm, 195 lbfft)
5. Install the slip ring to the stopper.
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

W2-3-3

Stopper

Bolt

Center Joint

WCJB-03-03-001

UPPERSTRUCTURE / Main Frame

CAUTION: Counterweight weight:
ZX210W-3: 3850 kg (8490 lb)
ZX220W-3: 4950 kg (11000 lb)

Counterweight

6. Install the counterweight.

(Refer to the REMOVAL AND INSTALLATION OF
COUNTERWEIGHT on W2-2-1.)
: 60 mm
: 3530 Nm (360 kgfm, 2610 lbfft)

Washer

Bolt
WCEB-02-02-005

CAUTION: The front attachment assembly

weight:
Monoblock boom: 3430 kg (7570 lb)
2-piece boom: 4190 kg (9240 lb)
7. Install the front attachment assembly to the
upperstructure. Add hydraulic oil.
(Refer to the REMOVAL AND INSTALLATION OF
FRONT ATTACHMENT on W4-1-1.)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 30 mm
: 540 Nm (55 kgfm, 398 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)

Monoblock Boom

WCJB-02-03-001

2-Piece Boom

8. Start the engine. Set the front attachment in

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

WCJB-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).

WCJB-02-02-002

2. Open cover (2).

2

WCJB-02-02-001

3. Remove sems bolts (3) (4 used) from cover (4).

Remove cover (4) from main frame (5).
: 17 mm

WCJB-02-04-007

W2-4-1

UPPERSTRUCTURE / Pump Device

6

4. Remove sems bolts (6) (2 used) from bracket (7).

: 17 mm

5. Remove sems bolts (9) (6 used) from cover (8).

Remove cover (8) from bracket (7) and supports
(10, 11).
: 17 mm

10

11

6. Remove sems bolts (12) (6 used) and sems bolts

(15) (2 used) from bracket (7). Remove bracket
(7) from supports (13, 14) and cover (16).
: 17 mm

WCJB-02-04-003

9
12

14

WCJB-02-04-001

13

12

WCJB-02-04-001

15

WCJB-02-04-002

7
16

WCJB-02-04-003

W2-4-2

UPPERSTRUCTURE / Pump Device

7. Disconnect hoses (18) (2 used) from filter (19).
Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 27 mm

18

19

18

17

16

8. Remove sems bolts (20) (2 used) from clips (21)

(2 used). Remove clips (21) (2 used) from hoses
(22) (4 used).
: 17 mm

20, 21
22

WCJB-02-04-003

9. Disconnect connector (17).

: 17 mm

23

10. Disconnect connectors (24) (7 used) from pump

device (23).

24

WCEB-02-04-009

11. Remove socket bolts (26) (3 used) and clips (28)

(3 used). Remove harness (27) from pump device
(23).
: 5 mm

24

23

28
29

12. Remove socket bolts (30) (8 used) and split

flanges (31) (4 used). Disconnect hoses (29) (2
used) from pump device (23). Cap the open ends.
: 10 mm

27

WCJB-02-04-004

26
29

30
31

23

WCEB-02-04-009

W2-4-3

UPPERSTRUCTURE / Pump Device

32

13. Disconnect hose (34) from suction pipe (32). Cap

the open ends.
: 41 mm

33
23

14. Remove socket bolts (33) (4 used) from suction

pipe (32). Disconnect suction pipe (32) from pump
device (23).
: 10 mm

34

WCEB-02-04-009

15. Disconnect hoses (35) (2 used) from regulators

(36) (2 used). Cap the open ends.
: 19 mm

35

WCJB-02-04-003

36

16. Disconnect hoses (38) (4 used) from pilot pump

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

37

38

WCEB-02-04-009

17. Disconnect hoses (39) (3 used) from filter (40).

Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 22 mm, 27 mm

40

W2-4-4

39

WCJB-02-04-003

UPPERSTRUCTURE / Pump Device

13

18. Remove sems bolts (42) (5 used) from covers (41)

(2 used). Remove covers (41) (2 used) from
support (13) and cover (16).
: 17 mm

19. Remove sems bolts (43) (2 used) from cover (16).

Remove the cover (16) assembly from support
(13).
: 17 mm

41

42

16

WCJB-02-04-004

43

16

WCJB-02-04-003

23

20. Remove socket bolts (45) (8 used) and split

flanges (44) (4 used). Disconnect hoses (46) (2
used) from pump device (23). Cap the open ends.
: 8 mm

44
45
46

WCEB-02-04-009

21. Remove sems bolts (47) (2 used) from plate (48).

Remove plate (48) and the bracket (49) assembly
from pump device (23).
: 17 mm

47

48

23

46

49

WCEB-02-04-008

W2-4-5

UPPERSTRUCTURE / Pump Device

22. Remove nuts (51) (2 used), spring washers (52)
(2 used) and bolts (53) (2 used) from clamp (55).
: 19 mm

51, 52, 53
50

CAUTION: The muffler (50) assembly weight:

23 kg (51 lb)

54

23. Attach a nylon sling onto muffler (50). Hoist and

hold muffler (50).
55

24. Remove sems bolts (56) (3 used) from bracket

(57). Remove the muffler (50) assembly from
pump device (23).

WCJB-02-04-006

50

CAUTION: Pump device (23) weight: 164 kg

(370 lb)

57

56

WCJB-02-04-005

23
23

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

pump device (23). Attach a nylon sling onto
eyebolt. Hoist and hold pump device (23).

Eyebolt
Mounting
Hole

26. Remove sems bolts (59) (3 used) from pump

device (23). Remove pump device (23) from
engine (58).
: 17 mm

WCEB-02-04-003

58

59

23

W2-4-6

WCJB-02-04-005

UPPERSTRUCTURE / Pump Device

Installation
23

CAUTION: Pump device (23) weight: 164 kg

(370 lb)

Eyebolt
Mounting
Hole

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

pump device (23). Attach a nylon sling onto
eyebolt. Hoist and hold pump device (23).

WCEB-02-04-003

2. Align pump device (23) with the mounting hole on

engine (58). Install pump device (23) to engine
(58) with sems bolts (59) (3 used).
: 17 mm
: 65 Nm (6.5 kgfm, 48 lbfft)

58

50

CAUTION: The muffler (50) assembly weight:

23 kg

59

3. Attach a nylon sling onto muffler (50). Hoist and

align muffler (50) with the mounting hole on pump
device (23). Install bracket (57) to pump device
(23) with bolts (56) (3 used).
: 17 mm
: 65 Nm (6.5 kgfm, 48 lbfft)

4. Align clamp (55) with the center of exhaust pipe

(54) and the muffler (50) pipe. Secure exhaust
pipe (54) and muffler (50) with bolts (53) (2 used),
spring washers (52) (2 used) and nuts (51) (2
used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)

57

56

23

WCJB-02-04-005

51, 52, 53

50

54

55
WCJB-02-04-006

W2-4-7

UPPERSTRUCTURE / Pump Device

47

5. Install the bracket (49) assembly to pump device

(23) with sems bolts (47) (2 used) and plate (48).
: 17 mm
: 65 N65 Nm (6.5 kgfm, 48 lbfft)

48

23

49

WCEB-02-04-008

23

6. Connect suction pipe (32) to pump device (23)

with socket bolts (33) (4 used).
: 10 mm
: 90 Nm (9 kgfm, 66 lbfft)

32

33

7. Connect hose (34) to suction pipe (32).

: 41 mm
: 205 Nm (21 kgfm, 151 lbfft)
8. Connect hoses (46) (2 used) to pump device (23)
with split flanges (44) (4 used) and socket bolts
(45) (8 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)
9. Connect hoses (39) (4 used) to pilot pump (37).
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

34

WCEB-02-04-009

23

44

37

45
46

WCEB-02-04-009

38

W2-4-8

UPPERSTRUCTURE / Pump Device

10. Install the cover (16) assembly to support (13) with
sems bolts (43) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

43

16

WCJB-02-04-003

11. Install covers (41) (2 used) to support (13) and

cover (16) with sems bolts (42) (5 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

13

41

42

16

36
24

12. Install clips (28) (3 used) to harness (27). Install

clips (28) (3 used) to pump device (23) with socket
bolts (26) (3 used).
: 5 mm
: 10 Nm (1 kgfm, 7 lbfft)
13. Connect connectors (24) (7 used) to regulator (36)
and pump device (23).

23

28
29

14. Connect hoses (29) (2 used) to pump device (23)

with split flanges (31) (4 used) and socket bolts
(30) (8 used).
: 10 mm
: 90 Nm (9 kgfm, 66 lbfft)

27

WCJB-02-04-004

26
29

30
31

23
24

WCEB-02-04-009

W2-4-9

UPPERSTRUCTURE / Pump Device

15. Connect hoses (39) (3 used) to filter (40).
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

35

16. Connect hoses (35) (2 used) to regulators (36) (2

used).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
WCJB-02-04-003

40

17. Connect hoses (18) (2 used) to filter (19).

: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

18

18. Connect connector (17) to filter (19).

: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

17

19. Install clips (21) (2 used) to hoses (22) (4 used).

Secure clips (21) (2 used) to cover (16) with sems
bolts (20) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

39

36

19

18

16

20, 21
22

WCJB-02-04-003

W2-4-10

UPPERSTRUCTURE / Pump Device

20. Install bracket (7) to supports (13, 14) and cover
(16) with sems bolts (12) (6 used) and sems bolts
(15) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

12

14

13

12

WCJB-02-04-001

15

WCJB-02-04-002

16

21. Install cover (8) to supports (10, 11), cover (16)

and bracket (7) with sems bolts (9) (6 used) and
sems bolts (6) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-04-003

10

11

WCJB-02-04-001

7
6
16

WCJB-02-04-003

W2-4-11

UPPERSTRUCTURE / Pump Device

22. Install cover (4) to main frame (5) with sems bolts
(3) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-04-007

23. Shut covers (2, 1).

2

WCJB-02-02-001

WCJB-02-02-002

W2-4-12

UPPERSTRUCTURE / Pump Device

(Blank)

W2-4-13

UPPERSTRUCTURE / Pump Device

DISASSEMBLY OF PUMP DEVICE
1

18

15 16 17

14
13

12
58

10

11
14

57

15

56
54

55

16 17

19

8
12

53
51

10

52
51

50
22

21

24

23

22

11

20

21
28

27
26
49

25

30
48

37

29
26 35

31

36

40

39

38

34

47
33

32

41
44
46
44

W2-4-14

43

42

45
WCEB-02-04-014

UPPERSTRUCTURE / Pump Device

68

67

66

69

72

71

70

73
74
71

65

75
60

62

63

64
63

60

61

69
62

68

60
62

82

59

78

63

76

81
63

60
60

83

61
60

59

77

62

79

82

80
60

72

83
WCEB-02-04-011

1 - Socket Bolt (4 Used)

2 - Right Regulator
3 - Socket Bolt (2 Used)
4 - Socket Bolt (2 Used)
5 - Socket Bolt (2 Used)
6 - Left Regulator
7 - O-Ring (4 Used)
8 - O-Ring (6 Used)
9 - Bearing Nut (2 Used)
10 - Bearing (2 Used)
11 - Ring (2 Used)
12 - Bearing (2 Used)
13 - Shaft
14 - Pin (2 Used)
15 - Center Shaft (2 Used)
16 - Spring (2 Used)
17 - Plunger (14 Used)
18 - Rotor (2 Used)
19 - Shaft
20 - Slide Ring
21 - O-Ring (2 Used)

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

Plug (2 Used)
O-Ring
Stopper
Plug
Retaining Ring (2 Used)
Gear
Gasket
Gear
Plug
Elbow
Plug
O-Ring
Gasket
Socket Bolt (2 Used)
Pipe
Level Gauge
Socket Bolt (2 Used)
Spring Washer (2 Used)
Washer (2 Used)
Pilot Pump
Retaining Ring

43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 -

W2-4-15

Retaining Ring
Ball Bearing (2 Used)
Gear
Gear Shaft
Retaining Ring
Oil Seal
Gear Casing
Spring Pin (2 Used)
Oil Seal (2 Used)
Retaining Ring (2 Used)
Pump Casing
Spring Washer (6 Used)
Bolt (6 Used)
Spring Pin (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Pin (2 Used)
Retaining Ring (12 Used)
Pin (2 Used)
Lever (4 Used)
Pin (4 Used)

64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 -

Right Valve Plate

Backup Ring
O-Ring
Spring Pin (2 Used)
Pressure Sensor (2 Used)
O-Ring (2 Used)
Selector Head
O-Ring (4 Used)
Socket Bolt (16 Used)
Stopper S (2 Used)
O-Ring (2 Used)
Socket Bolt (12 Used)
Set Screw (2 Used)
Servo Piston (2 Used)
Pin (2 Used)
O-Ring (2 Used)
Stopper L (2 Used)
Left Valve Plate
Pin (4 Used)
Link (2 Used)

UPPERSTRUCTURE / Pump Device

1

6
70

58

7
57

53

49

25
37
30

35

31

36

40

39

38

34
32
41

WCEB-02-04-013

W2-4-16

UPPERSTRUCTURE / Pump Device

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).

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).

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).

W2-4-17

UPPERSTRUCTURE / Pump Device

16

16

53

72

68
66
65

69

70

73

71

74
71
75

69
68

79
80
72

WCEB-02-04-012

W2-4-18

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.

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).

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).

W2-4-19

UPPERSTRUCTURE / Pump Device

15

18

16 17

13

54

15

55

16 17

19

53

50

28

27
49

70

29

62

60

63

75

64
63

60

61

62

60
62

82

59

78

63

76

81
63

60
60

83

61
60

59

62

77

82
60

83
WCEB-02-04-012

W2-4-20

UPPERSTRUCTURE / Pump Device

18. Warm up set screws (76) (2 used) by using a drier.
Remove set screws (76) (2 used) from servo
pistons (77) (2 used). Remove pins (78) (2 used)
from servo pistons (77) (2 used).
: 6 mm
19. Remove servo pistons (77) (2 used) from selector
head (70).
20. Both right valve plate (64) and left valve plate (81)
are very similar and their installing directions are
determined. Record the position and the direction
of right valve plate (64) and left valve plate (81)
before removing. Remove retaining rings (60) (4
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.

CAUTION: Pump casing (53) weight: 105 kg

(240 lb)
24. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the socket bolt (75) hole on pump casing (53).
Hoist and remove pump casing (53) from gear
casing (49). Shafts (13, 19) and gears (27, 29) are
removed with pump casing (53) together.
Place pump casing (53) with the mounting surface
for the regulator facing upward.
25. Remove spring pins (50) (2 used) and gasket (28)
from gear casing (49).

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

W2-4-21

UPPERSTRUCTURE / Pump Device

13
12
10

19

53

12
10

21

24

23

22

21

22
27
26
70

26

29

WCEB-02-04-012

W2-4-22

UPPERSTRUCTURE / Pump Device

26. Put the matching marks on the meshed position
of splines on shafts (13, 19) and gears (27, 29).
Put the matching marks on the meshed position
of gears (27, 29).
27

13

CAUTION: Pump casing (53) weight: 70 kg

(160 lb)
31. Attach a nylon sling onto pump casing (53). Hoist
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.

29

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

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

19
W137-02-04-007

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

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

CAUTION: Pump casing (53) weight: 70 kg

(160 lb)
28. Attach a nylon sling onto pump casing (53). Hoist
and place pump casing (53) with the mounting
side for selector head (70) facing downward.
29. Remove stoppers (24) (2 used) from pump casing
(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

W2-4-23

ST 1470
ST 1471

13
19

53

W178-02-04-054

UPPERSTRUCTURE / Pump Device

13

10

11

12

19

12

53

20
10

51

11

52
51

49

48
47

44
46
44

W2-4-24

43

42

45
WCEB-02-04-014

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

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
press.

40. Remove gear (45) and ball bearing (44) from gear
casing (49).

CAUTION: Pump casing (53) weight: 42 kg

(93 lb)

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

of gear casing (49). Hoist and turn over gear
casing (49) by using a nylon sling.

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

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

42. Remove retaining ring (47) and oil seal (48) from
gear casing (49).

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).

W2-4-25

UPPERSTRUCTURE / Pump Device

ASSEMBLY OF PUMP DEVICE
81

66

65

18

16

15

17

12

20

11

10

51

29

26

19

52

13
26
27
64
72 73 71 74

60, 63
8

62
56

57

18

82

16

15

17

12

61

60

59

58

67 22

21

83

14

11 10

51

53

70
79

76

78
79
W178-02-11-086

80

72

W2-4-26

24

23

UPPERSTRUCTURE / Pump Device

38, 39, 40

41

32, 33

34, 35, 36
31

30

43

42

45

44

37
46
25

47

48
50
49
68

12345678910 11 12 13 14 15 16 17 18 19 20 21 -

Socket Bolt (4 Used)

Right Regulator
Socket Bolt (2 Used)
Socket Bolt (2 Used)
Socket Bolt (2 Used)
Left Regulator
O-Ring (4 Used)
O-Ring (6 Used)
Bearing Nut (2 Used)
Bearing (2 Used)
Ring (2 Used)
Bearing (2 Used)
Shaft
Pin (2 Used)
Center Shaft (2 Used)
Spring (2 Used)
Plunger (14 Used)
Rotor (2 Used)
Shaft
Slide Ring
O-Ring (2 Used)

75

22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

Plug (2 Used)
O-Ring
Stopper
Plug
Retaining Ring (2 Used)
Gear
Gasket
Gear
Plug
Elbow
Plug
O-Ring
Gasket
Socket Bolt (2 Used)
Pipe
Level Gauge
Socket Bolt (2 Used)
Spring Washer (2 Used)
Washer (2 Used)
Pilot Pump
Retaining Ring

43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 -

W2-4-27

55

Retaining Ring
Ball Bearing (2 Used)
Gear
Gear Shaft
Retaining Ring
Oil Seal
Gear Casing
Spring Pin (2 Used)
Oil Seal (2 Used)
Retaining Ring (2 Used)
Pump Casing
Spring Washer (6 Used)
Bolt (6 Used)
Spring Pin (2 Used)
O-Ring (2 Used)
O-Ring (2 Used)
Pin (2 Used)
Retaining Ring (12 Used)
Pin (2 Used)
Lever (4 Used)
Pin (4 Used)

54

64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 -

28

WCEB-02-04-004

Right Valve Plate

Backup Ring
O-Ring
Spring Pin (2 Used)
Pressure Sensor (2 Used)
O-Ring (2 Used)
Selector Head
O-Ring (4 Used)
Socket Bolt (16 Used)
Stopper S (2 Used)
O-Ring (2 Used)
Socket Bolt (12 Used)
Set Screw (2 Used)
Servo Piston (2 Used)
Pin (2 Used)
O-Ring (2 Used)
Stopper L (2 Used)
Left Valve Plate
Pin (4 Used)
Link (2 Used)

UPPERSTRUCTURE / Pump Device

43

42

44

45

44

32, 33

49
WCEB-02-04-004

12

11 10

19

13

12

W2-4-28

11 10

W178-02-11-089

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 Nm (7 kgfm, 52 lbfft)
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).

W2-4-29

UPPERSTRUCTURE / Pump Device

WCEB-02-04-004

53

12

20

10

19

13

12

W2-4-30

10

W178-02-11-089

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

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.
: 1.960.49 Nm
(0.200.05 kgfm, 1.450.36 lbfft)
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).

W2-4-31

UPPERSTRUCTURE / Pump Device

53

12

10

51

19

52

13

51
Regulator Mounting Surface

24

W2-4-32

53

23

W178-02-11-092

UPPERSTRUCTURE / Pump Device

13. Warm up pump casing (53) to 50 to 80 C (122 to
176 F).
14. Apply hydraulic oil onto the outside of bearings
(10, 12) installed on shaft (19). Install shaft (19) to
pump casing (53) by using special tool.
If it is difficult to insert shaft (19), tap shaft (19) by
using a bar.

19. Install special tools (ST 2649, ST 2650) over the

spline parts of shafts (13, 19).
NOTE: If special tools are not available, wind the
vinyl tape over the spline part of the shaft in
order not to damage oil seal (51).

Special Tool

ST 2650

51
M8, Pitch 1.25 mm

53
19
W178-02-11-094

ST 2649
Wooden Block

Wooden Block

W178-02-11-093

20. Apply grease onto the inside of oil seals (51) (2

used). Evenly tap and install oil seals (51) (2
used) to shafts (13, 19).

15. Install shaft (13) to pump casing (53) in the same

way as step 14.

21. Remove special tools (ST 2649, ST 2650) from

shafts (13, 19).

16. Wait for pump casing (53) in order to cool down to

the temperature lower than 40 C (104 F).

22. Install retaining rings (52) (2 used) to pump casing

(53).

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

(24) to pump casing (53).
: 19 mm
: 34.5 Nm (3.5 kgfm, 25 lbfft)

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.

W2-4-33

UPPERSTRUCTURE / Pump Device

45

50

49
WCEB-02-04-004

75

53

55

54

28

29

53

26

19

13

26

17

W2-4-34

27

W178-02-11-096

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

M8, Pitch 1.25 mm

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 Nm (15 kgfm, 108 lbfft)

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).

W2-4-35

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

62

59, 61

83

15

14

W2-4-36

17

W178-02-11-096

UPPERSTRUCTURE / Pump Device

26. Apply THREEBOND #1215 onto the mounting
surface of pilot pump (41). Install pilot pump (41)
to gear casing (49) with socket bolts (38), spring
washers (39) and washers (40) (2 used for each).
: 8 mm
: 49 Nm (5 kgfm, 37 lbfft)
27. Install gasket (34) and pipe (36) to gear casing
(49) with socket bolts (35) (2 used).
: 6 mm
: 19.5 Nm (2 kgfm, 14 lbfft)

30. Insert plungers (17) (7 used for each) into shafts

(13, 19).
31. Apply grease onto pins (14) (2 used). Install pin
(14) to center shafts (15) (2 used).
32. Apply grease onto the spherical surface of center
shafts (15) (2 used). Install center shafts (15) (2
used) to shafts (13, 19).

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.
83

59

61

53

Parallel
Surface

Parallel
Surface

W178-02-11-098

29. Apply hydraulic oil onto the plunger (17) mounting

surface of shafts (13, 19).

W2-4-37

UPPERSTRUCTURE / Pump Device

60

62

16 79 18 15

14

17

53

63

81

64

60, 63
8

65

62 18

83 16 15 14 17

18

W178-02-11-099

53

19

70

67

14

W2-4-38

W178-02-04-016

UPPERSTRUCTURE / Pump Device

33. Install springs (16) (2 used) to center shafts (15)
(2 used).

38. Install backup ring (65), O-ring (66) and O-rings

(8) (6 used) to pump casing (53).

34. Insert center shafts (15) (2 used) and plungers

(17) (14 used) into rotors (18) (2 used).

39. Install spring pins (67) (2 used) to pump casing

(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).

W2-4-39

UPPERSTRUCTURE / Pump Device

Eyebolt
Mounting Hole

75

WCEB-02-04-004

70

72

71

73

74

75

18

53

70
77

76

78
Mounting Surface for
Suction Pipe
W178-02-04-016

79

72

64, 81

80

67

14

W2-4-40

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 Nm (3.5 kgfm, 25 lbfft)

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 Nm (2.0 kgfm, 14 lbfft)
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 Nm (2 kgfm, 14 lbfft)

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 Nm (11 kgfm, 80 lbfft)
44. Install O-rings (71) (4 used) to selector head (70).

W2-4-41

UPPERSTRUCTURE / Pump Device

47

19
48

49
WCEB-02-04-004

53

56

57

61

58
5

83

W2-4-42

WCEB-02-04-015

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)
to pump casing (53).
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 Nm (5 kgfm, 37 lbfft)

CAUTION: Pump device weight: 160 kg (360

lb)
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

61

53

48

Sleeve

83

56

W178-02-11-101

49. Install left regulator (6) to pump casing (53) with

socket bolts (3) (2 used) and socket bolts (5) (2
used) in the same way as step 48.
: 8 mm
: 49 Nm (5 kgfm, 37 lbfft)

W178-02-11-103

52. Install retaining ring (47) to gear casing (49).

W2-4-43

UPPERSTRUCTURE / Pump Device

31

30

37

36

25

49

WCEB-02-04-004

68

W178-02-04-016

W2-4-44

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 Nm (4 kgfm, 29 lbfft)
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 Nm (4 kgfm, 29 lbfft)
56. Insert level gauge (37) into pipe (36).
57. Install pressure sensors (68) (2 used) to selector
head (70).
: 27 mm
: 98 Nm (10 kgfm, 72 lbfft)

W2-4-45

UPPERSTRUCTURE / Pump Device

DISASSEMBLY OF REGULATOR

Left Regulator

Right Regulator

13

WCEB-02-04-016

10

11

14

12

15

4
16
17
6

7
8

24

20

23
22

19

18

28

21

25
29

26

30

32

31

34

27
37
28

39

36

33

35

38

40
41
WCEB-02-04-019

42

12345678910 11 -

Pipe
Socket Bolt (2 Used)
Solenoid Valve
O-Ring
Low Pressure Sensor
O-Ring
O-Ring
O-Ring
Piston
O-Ring
Backup Ring

12 13 14 15 16 17 18 19 20 21 22 -

Cylinder
O-Ring
Piston
Sleeve
Spool
Spring
Spring
O-Ring
Stopper
O-Ring
Adjuster

23 24 25 26 27 28 29 30 31 32 -

W2-4-46

Lock Nut
Lock Nut
Cover
Set Bolt
Lock Nut
Socket Bolt (8 Used)
O-Ring
Cylinder
Piston
Casing

33 34 35 36 37 38 39 40 41 42 -

Lock Nut
Lock Nut
Cover
Adjuster
O-Ring
Stopper
O-Ring
Spring
Spool
Sleeve

UPPERSTRUCTURE / Pump Device

Disassembly of Regulator
The regulators are used for right pump and left
pump. The inner structure in the regulator is fully
identical, and the difference is only in its
accessories.
Here the left regulator is explained.
IMPORTANT: As the setting changes, do not
disassemble adjusting screws (23,
24, 26, 27, 33 and 34).
When adjusting screws (23, 24, 26,
27, 33 and 34) must be disassembled,
carry out adjustment according to
the procedure of performance test
after assembling.

IMPORTANT: As the setting changes, do not turn

lock nuts (33, 34).
4. Remove socket bolts (28) (4 used) from cover
(35). Remove cover (35) and piston (14) from
casing (32). The stopper (38) assembly is
removed with cover (35) together.
: 6 mm
5. Remove springs (17, 18) from casing (32).
6. Insert a round bar into the hole on casing (32).
Push the spool (16) end. Remove cylinder (12),
sleeve (15) and spool (16) from casing (32).
Piston (9) is removed with cylinder (12) together.
7. Remove piston (9) from cylinder (12).

1. Clamp casing (32) in a vise. Remove pipe (1)

from casing (32).
: 22 mm
2. Remove socket bolts (2) (2 used) from solenoid
valve (3). Remove the solenoid valve (3)
assembly and O-rings (6, 7, 8) from casing (32).
: 8 mm

8. Remove spring (40) from casing (32).

9. Insert a round bar into the hole on casing (32).
Push the spool (41) end. Remove cylinder (30),
sleeve (42) and spool (41) from casing (32).
Piston (31) is removed with cylinder (30) together.
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

W2-4-47

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

10 11

12

13

14

35

26
38
27
28

WCEB-02-04-017

25

29

1 - Pipe
2 - Socket Bolt (2 Used)
3 - Solenoid Valve
4 - O-Ring
5 - Low Pressure Sensor
6 - O-Ring
7 - O-Ring
8 - O-Ring
9 - Piston
10 - O-Ring
11 - Backup Ring

30

12 13 14 15 16 17 18 19 20 21 22 -

31

Cylinder
O-Ring
Piston
Sleeve
Spool
Spring
Spring
O-Ring
Stopper
O-Ring
Adjuster

41

42

23 24 25 26 27 28 29 30 31 32 -

W2-4-48

40

37

Lock Nut
Lock Nut
Cover
Set Bolt
Lock Nut
Socket Bolt (8 Used)
O-Ring
Cylinder
Piston
Casing

39

33 34 35 36 37 38 39 40 41 42 -

34

Lock Nut
Lock Nut
Cover
Adjuster
O-Ring
Stopper
O-Ring
Spring
Spool
Sleeve

36 33

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).

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 Nm (2 kgfm, 14 lbfft)
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 Nm (2 kgfm, 14 lbfft)
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 Nm (5 kgfm, 37 lbfft)
12. Apply grease onto the thread part of pipe (1).
Install pipe (1) to casing (32).
: 22 mm
: 34 Nm (3.5 kgfm, 25 lbfft)

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).

W2-4-49

UPPERSTRUCTURE / Pump Device

STRUCTURE OF PILOT PUMP

9
8
6
3

10
11
12

13

7
14
2

1
15
17

WCEB-02-04-018

16

15

13

17
16
14

10

12

W2-4-50

WCEB-02-04-010

UPPERSTRUCTURE / Pump Device

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Part Name
Plate Seal
Backup Ring
Side Plate
Rear Drive Gear
Driven Gear
Kmock Pin
Gear Plate
Cover
Socket Bolt
Coupling
Stabilizer
Center Plate
Driven Gear
Front Drive Gear
Flange
Oil Seal
Retaining Ring

Qty

Wrench Size
(mm)

4
4
4
1
1
8
2
1
4
1
2
1
1
1
1
1
1

W2-4-51

Tightening Torque
Nm
(kgfm, lbfft)

Remark

UPPERSTRUCTURE / Pump Device

(Blank)

W2-4-52

UPPERSTRUCTURE / Control Valve

REMOVAL
AND
CONTROL VALVE

INSTALLATION

OF

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 (3).

2. Remove sems bolts (2) (4 used) from cover (4).

Remove cover (4) from bracket (1).
: 17 mm

WCJB-02-01-002

3. Disconnect hoses (5) (3 used) from piping (6).

Cap the open ends.
: 19 mm, 27 mm, 50mm

4. Remove signal control valve (7) from bracket (8).

(Refer to REMOVAL AND INSTALLATION OF
SIGNAL CONTROL VALVE on W2-9-1.)

5. Remove 4-spool solenoid valve unit from control

valve
(9).
(Refer
to
REMOVAL
AND
INSTALLATION OF 4-SPOOL SOLENOID VALVE
UNIT on W2-11-1.)
6. Disconnect all connectors, hoses and pipings from
control valve (9). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm, 22 mm, 36 mm
: 8 mm

W2-5-1

10

WCJB-02-05-001

UPPERSTRUCTURE / Control Valve

Eyebolt Mounting Hole

Eyebolt Mounting Hole

CAUTION: The control valve (9) assembly

weight: 238 kg (560 lb)

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

control valve (9). Attach a nylon sling onto
eyebolts. Hoist and hold control valve (9).

WCJB-02-05-022

8. Remove bolts (12) (4 used) and washers (11) (4

used) from brackets (13, 16). Hoist and remove
the control valve (9) assembly from the main
frame.
: 24 mm
CAUTION: Control valve (9) weight: 216 kg
(480 lb)
9. While holding the control valve (9) assembly,
remove bolts (15) (4 used) and spacers (14) (4
used) from brackets (13, 16). Remove brackets
(13, 16) from control valve (9).
: 24 mm

12
11

12
11

16
14
15

13
14
15
WCJB-02-05-002

W2-5-2

UPPERSTRUCTURE / Control Valve

Eyebolt Mounting Hole

Installation

Eyebolt Mounting Hole

CAUTION: Control valve (9) weight: 216 kg

(480 lb)
1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
control valve (9). Attach a nylon sling onto the
eyebolt. Hoist and hold control valve (9).

WCJB-02-05-022

2. Install brackets (13, 16) to control valve (9) with

bolts (15) (4 used) and spacers (14) (4 used).
: 24 mm
: 210 Nm (21.5 kgfm, 165 lbfft)

12
11

11

CAUTION: The control valve (9) assembly

weight: 238 kg (560 lb)
16

3. Hoist and align the control valve (9) assembly with

the mounting hole on the main frame. Install the
control valve (9) assembly to the main frame with
bolts (12) (4 used) and washers (11) (4 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

W2-5-3

12

14
15

13
14
15
WCJB-02-05-002

UPPERSTRUCTURE / Control Valve

4. Connect all connectors, hoses and pipings to
control valve (9).
: 17 mm
: 25 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 30 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 40 Nm (4 kgfm, 30 lbfft)
: 36 mm
: 180 Nm (18 kgfm, 133 lbfft)
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-05-001

5. Install the 4-spool solenoid valve unit to control

valve
(9).
(Refer
to
REMOVAL
AND
INSTALLATION OF 4-SOOL SOLENOID VALVE
on W2-11-1.)
6. Install signal control valve (7) to control valve (9).
(Refer to REMOVAL AND INSTALLATION OF
SIGNAL CONTROL VALVE on W2-9-1.)

10

WCJB-02-05-001

7. Connect hoses (5) (3 used) to piping (6).

: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
: 50 mm
: 205 Nm (21 kgfm, 151 lbfft)

WCJB-02-05-001

W2-5-4

UPPERSTRUCTURE / Control Valve

8. Install cover (4) to bracket (1) with sems bolts (2)
(4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

9. Shut cover (3).

WCJB-02-01-002

W2-5-5

UPPERSTRUCTURE / Control Valve

DISASSEMBLY OF CONTROL VALVE 4-SPOOL SIDE
6
5
3

Check Valve
(Arm Regenerative
Circuit)

13

12

11

10
9

14
11

12
15

16

15
17
18

19
8
11

42
48

15

12

43

44

45

20

21

17

22

43

35

44

45

24

26

27

28

Boom Anti-Drift Valve

29

30

23

36

46

37

47

49

25

38

39

31

32

33

34

6
40

51

39

50
39

39

40
39

52
53

39
40

Bucket

39

40
52
54

55

56

39

Arm (2)

57
58

Boom (1)

41
59

Travel

41

41

41
59
63

Arm Regenerative Valve

60

62
61
WCJB-02-05-003

W2-5-6

UPPERSTRUCTURE / Control Valve

68
69
4

70

63
67

63

Flow Combiner Valve

71

72
71

67

63

73

67

59
59
59

63

16
15

74

1
66

65

15

74

64

15

59
Bypass
Shut-Out
Valve

103
104

106

107

11
11
11

105

12

108

12

12

Arm 2 Flow Rate

Control Valve
(Switch Valve)

113

99

109

87

114
115
116

117

115
116

122

77

77
119

117

118
120
121

123
124

Bucket Flow Rate

Control Valve

100
101
102
87
77
18

110
111
112

127

75

85
86
87
88
89
77

78
18

Boom Anti-Drift Valve

84

18

128
129 90
121
91
120
125
126
116
121 120
115
117
98

76
83

82

77
18
78

92
93

79
94

80
95

96

81
97
6

98
WCJB-02-05-004

W2-5-7

UPPERSTRUCTURE / Control Valve

12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 -

Housing
Poppet
Spring (2 Used)
O-Ring (4 Used)
Flange
Socket Bolt (13 Used)
Plug (2 Used)
O-Ring (2 Used)
Poppet
Spring
O-Ring (6 Used)
Plug (6 Used)
Flange
Poppet
O-Ring (6 Used)
Valve (2 Used)
Overload Relief Valve (2 Used)
O-Ring (12 Used)
O-Ring
Spring
Seat
Poppet
Backup Ring
O-Ring
O-Ring
Backup Ring
Sleeve
Spool
O-Ring
Body
Spring
Poppet
O-Ring

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 -

Plug
Spool
O-Ring
Backup Ring
Plug
Spring Seat (8 Used)
Spring (4 Used)
Bolt (4 Used)
Plug
Backup Ring (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Poppet
Spool
Plug
Poppet
Spool
Spool
Spring Seat (2 Used)
Spring
Spool
O-Ring
Backup Ring
Spool
Spring
O-Ring (8 Used)
O-Ring
Plug
Cap
Socket Bolt (14 Used)
Cap
O-Ring

66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 -

W2-5-8

Plug
Cap (3 Used)
Socket Bolt (2 Used)
Cap
Bolt
Spring Seat (2 Used)
Spring
Spool
Overload Relief Valve (2 Used)
Poppet
Spring
O-Ring (5 Used)
O-Ring (2 Used)
Body
O-Ring
Plug
O-Ring
Plug
Poppet
Poppet
Spring
Plug
Spring (3 Used)
Sleeve
Plug
O-Ring
Body
Spool
Spring
Spring Seat
O-Ring
Plug

98 - Socket Bolt (12 Used)

99 - Poppet
100 - Poppet
101 - Spring
102 - Plug
103 - Spool
104 - Spring
105 - Flange
106 - O-Ring
107 - Cap
108 - Socket Bolt (4 Used)
109 - Poppet
110 - Poppet
111 - Spring
112 - Plug
113 - Poppet
114 - Spring
115 - Plug (3 Used)
116 - O-Ring (3 Used)
117 - Spring Seat (3 Used)
118 - Spring
119 - Spool
120 - Plug (3 Used)
121 - O-Ring (3 Used)
122 - Spring
123 - Spool
124 - Body
125 - Spool
126 - Spring
127 - Plug
128 - Plug
129 - O-Ring

UPPERSTRUCTURE / Control Valve

(Blank)

W2-5-9

UPPERSTRUCTURE / Control Valve

6
5
3

Check Valve
(Arm Regenerative
Circuit)

2
7

13

12

8
10

11

14
11

12
15

16

15
17
18
8
11

12

15

20

21

17

22

24

25

26

27

28

29

23

Boom Anti-Drift Valve

30

31

32

35

34

47
51

33

50

54

55

56

59
57

63

59

58
Arm Regenerative Valve

62

WCJB-02-05-003

W2-5-10

UPPERSTRUCTURE / Control Valve

Disassembly of Control Valve 4-Spool Side

Disassembly of Spool
1. Remove socket bolts (63) (6 used) from cap (62).
Remove cap (62), O-rings (59) (4 used) and
O-ring (4) from housing (1).
: 8 mm
2. Put the matching marks on the spool (35, 47, 50,
51, 54) assemblies and housing (1). Remove the
spool (35, 47, 50, 51) assemblies, spring (58) and
the spool (54) assembly from housing (1).
NOTE: Do not disassemble the spool (54)
assembly unless necessary.

Disassembly of Boom Anti-Drift Valve

Disassembly of Overload Relief Valve (17)

IMPORTANT: Do not disassemble the overload
relief valve. When disassembling the
overload relief valve, pressure must
be
adjusted.
(Refer
to
TROUBLESHOOTING / Operational
Performance Test)
7. Remove overload relief valves (17) (2 used) from
housing (1).
: 32 mm
8. Remove valve (16) from housing (1).
: 32 mm

Disassembly of Check Valve

3. Loosen plug (34) from body (30).

: 38 mm
4. Remove socket bolts (6) (3 used) from body (30).
Remove the body (30) assembly, O-rings (18) (6
used) and O-ring (29) from housing (1).
: 8 mm
5. Remove piston (32) and spring (31) from body
(30).
6. Remove the sleeve (27) assembly, seat (21) and
spring (20) from housing (1).
Remove backup rings (23, 26), O-rings (24, 25),
poppet (22) and spool (28) from sleeve (27).

9. Remove plug (12), spring (10) and poppet (9)

from housing (1).
: 6 mm
10. Remove socket bolts (6) (2 used) from flange (5).
Remove flange (5), O-ring (4), spring (3) and
poppet (2) from housing (1).
: 8 mm
11. Remove socket bolts (6) (2 used) from flange (13).
Remove flange (13), O-ring (4), spring (3) and
poppet (14) from housing (1).
: 8 mm
12. Remove plugs (7, 12) (2 used for each) from
housing (1).
: 6 mm, 10 mm

W2-5-11

UPPERSTRUCTURE / Control Valve

42
48

43

44

45

43

44

35
45

36

46

37

47

49

38

39
40

51

39

50
39

39

40
39

52
53

39
40

Bucket

39

40
52

39

Arm (2)

Boom (1)

Travel

41

41

41

41

WCJB-02-05-003

W2-5-12

UPPERSTRUCTURE / Control Valve

Disassembly of Travel Spool (35)

Disassembly of Boom 1 Spool (50)

13. Clamp spool (35) in a vise by using wooden

pieces. Remove bolt (41), spring seat (39), spring
(40) and spring seat (39) from spool (35).
: 8 mm

17. Clamp spool (50) in a vise by using wooden

pieces. Remove bolt (41), spring seat (39), spring
(40) and spring seat (39) from spool (50).
: 8 mm

Disassembly of Bucket Spool (47)

18. Warm up the plug (48) part of spool (50) by using

a drier. Remove plug (48) from spool (50) by
using special tool (ST 5909). Remove O-ring (44)
and backup ring (43) from plug (48).

14. Clamp spool (47) in a vise by using wooden

pieces. Remove bolt (41), spring seat (39), spring
(40) and spring seat (39) from spool (47).
: 8 mm
15. Warm up the plug (42) part of spool (47) by using
a drier. Remove plug (42) from spool (47) by using
special tool (ST 5909). Remove O-ring (44) and
backup ring (43) from plug (42).
ST 5909

19. Remove spring (45) and poppet (49) from spool

(50).

Disassembly of Arm 2 Spool (51)

20. Clamp spool (51) in a vise by using wooden
pieces. Remove bolt (41), spring seats (39, 52),
springs (53, 40) and spring seats (52, 39) from
spool (51).
: 8 mm

W157-02-05-049

16. Remove spring (45) and poppet (46) from spool

(47).

W2-5-13

UPPERSTRUCTURE / Control Valve

68
69
4
63

70

67

63

Flow Combiner Valve

71

72
71

67

63

73

67

59
59
59

63

16
15

74

1
66

65

15

74

64

15

59

Arm 2 Flow Rate

Control Valve
(Switch Valve)

113

99

109
110
111
112
87

114
115
116

77
119
117

115
116

122

117

118
120
121

123
124

100
101
102
87
77
18

77

Bucket Flow Rate

Control Valve

84
85
86
87
88
89
77

78
18

127
18
128
129 90
121
91
120
125
126
116
121 120
115
117
98

92
93

94

95

96

97

98
WCJB-02-05-004

W2-5-14

UPPERSTRUCTURE / Control Valve

21. Remove socket bolts (63) (8 used) from caps (67)
(3 used) and cap (64). Remove caps (67) (3 used),
cap (64) and O-rings (59) (4 used) from housing
(1).
: 8 mm

Disassembly of Flow Combiner Valve

22. Remove socket bolts (68) (2 used) from cap (69).
Remove cap (69), O-ring (4) and the spool (73)
assembly from housing (1). Remove bolt (70),
spring seats (71) (2 used) and spring (72) from
spool (73).
: 5 mm

Disassemble Overload Relief Valve

IMPORTANT: Do not disassemble the overload
relief valve. When disassembling the
overload relief valve, pressure must
be
adjusted.
(Refer
to
TROUBLESHOOTING / Operational
Performance Test)
23. Remove overload relief valves (74) (2 used) from
housing (1).
: 32 mm

27. Remove sleeve (89), spring (88), plug (87), spring

(86) and poppets (85, 84) from housing (1).

Disassembly of Arm 2 Flow Rate Control Valve

28. Remove socket bolts (98) (8 used) from body
(124). Remove body (124), O-rings (77) (3 used),
O-rings (18) (2 used) (78) and plug (127) from
housing (1).
: 8 mm
29. Remove plugs (115) (3 used), spring seats (117)
(3 used), springs (118, 122, 126) and spools (119,
123, 125) from body (124).
: 24 mm
30. Remove plugs (120) (3 used) and plug (129) from
body (124).
31. Remove poppet (113) and spring (114) from
housing (1).
32. Remove the poppets (99, 109) assemblies and
springs (87) (2 used) from housing (1). Remove
plugs (102, 112), springs (101, 111) and poppets
(100, 110) from poppets (99, 109).

24. Remove valve (16) from housing (1).

: 32 mm

Disassembly of Bucket Flow Rate Control Valve

25. Remove socket bolts (98) (4 used) from body (92).
Remove body (92) and O-rings (18, 77) from
housing (1).
: 8 mm
26. Remove plug (97), spring seat (95), spring (94)
and spool (93) from body (92). Remove plug (90)
from body (92).
: 27 mm

W2-5-15

UPPERSTRUCTURE / Control Valve

103

Bypass
Shut-Out
Valve

104

106

107

11
11
11

105

12

108

12

12

Boom Anti-Drift Valve

75
76
77
18
78
79

WCJB-02-05-004

W2-5-16

UPPERSTRUCTURE / Control Valve

Disassembly of Boom Anti-Drift Valve
33. Remove socket bolts (6) (4 used) from body (79).
Remove body (79), O-rings (18) (3 used) and
O-rings (78, 77) from housing (1).
: 8 mm
34. Remove spring (76) and poppet (75) from housing
(1).

Disassembly of Bypass Shut-Out Valve

35. Remove socket bolts (6) (2 used) from flange
(105). Remove flange (105) and O-ring (4) from
housing (1).
: 8 mm
36. Remove spring (104) and spool (103) from
housing (1).
37. Remove socket bolts (108) (4 used) from cap
(107). Remove cap (107) and O-ring (106) from
housing (1).
: 8 mm
38. Remove plugs (12) (3 used) from housing (1).
: 8 mm

W2-5-17

UPPERSTRUCTURE / Control Valve

ASSEMBLY
OF
4-SPOOL SIDE

CONTROL

VALVE

63
60, 61

15, 16

15, 17

124 34

15, 17

63

59, 67

59, 62

63
59, 67

63

59, 64

65, 66
WCJB-02-05-006

Control Valve (Upper)

15, 17

79

Control Valve (Lower)

WCJB-02-05-005

15, 17

11, 12

9, 10, 11, 12

3, 4, 13, 14

6
105
92
11, 12

7, 8
106, 107

108

98

124

View A

15, 74

98

2, 3, 4, 5

1
WCJB-02-05-007

W2-5-18

View B

WCJB-02-05-008

UPPERSTRUCTURE / Control Valve

J I

8
A
W1V1-02-05-038

J I

Section C-C
(4-Spool Side)

WCJB-02-05-005

Control Valve (Upper)

Bucket

Travel

Boom 1

41
39

40
39

17
16

15

15

50

47
B

1
35

15
16
WCJB-02-05-020

Section D-D
(4-Spool Side)

46

49

45

45

1
15

43, 44

15

43, 44

42

74

48

Section E-E
(4-Spool Side)

W2-5-19

W1V1-02-05-036

74

Section F-F
(4-Spool Side)

W1V1-02-05-028

UPPERSTRUCTURE / Control Valve

61

Arm 2

62

60
41
39

17

52
53
52

15

39

51

1
65
W1V1-02-05-029

Section G-G
(4-Spool Side)

66
Section H-H
(4-Spool Side)

W1V1-02-05-030

62
58
57

103

104

4
105

56, 55
54

107, 108
106

Section I-I
(4-Spool Side)

W1V1-02-05-071

W2-5-20

Section J-J
(4-Spool Side)

WCJB-02-05-021

UPPERSTRUCTURE / Control Valve

97

73

96
95
94
92
93

4
71
72

91

71

90
89

69
84

70

85

77 18

W1V1-02-05-033
W1V1-02-05-040

Detail A

86 87 88

Detail B

34
33
30
32

77

18

120

31
28

29

27

22

18
26
25
24
23
21
20

121
1
18
78

119
124

81

118

80

117
116

79

115

82
75

77

76

99 100 101

102

87

83
Detail C

78

W1V1-02-05-032

Detail D

W1V1-02-05-031

115

127

120

116
117

121

126
125

123
122
117
116

121
109

110
111

77
112

120
87
Detail E

115

124
W1V1-02-05-042

W2-5-21

113

114

77
Detail F

18

124
W1V1-02-05-034

UPPERSTRUCTURE / Control Valve

1 - Housing
2 - Poppet
3 - Spring (2 Used)
4 - O-Ring (4 Used)
5 - Flange
6 - Socket Bolt (13 Used)
7 - Plug (2 Used)
8 - O-Ring (2 Used)
9 - Poppet
10 - Spring
11 - O-Ring (6 Used)
12 - Plug (6 Used)
13 - Flange
14 - Poppet
15 - O-Ring (6 Used)
16 - Valve (2 Used)
17 - Overload Relief Valve (2 Used)
18 - O-Ring (12 Used)
19 - O-Ring
20 - Spring
21 - Seat
22 - Poppet
23 - Backup Ring
24 - O-Ring
25 - O-Ring
26 - Backup Ring
27 - Sleeve
28 - Spool
29 - O-Ring
30 - Body
31 - Spring
32 - Poppet
33 - O-Ring

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 -

Plug
Spool
O-Ring
Backup Ring
Plug
Spring Seat (8 Used)
Spring (4 Used)
Bolt (4 Used)
Plug
Backup Ring (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Poppet
Spool
Plug
Poppet
Spool
Spool
Spring Seat (2 Used)
Spring
Spool
O-Ring
Backup Ring
Spool
Spring
O-Ring (8 Used)
O-Ring
Plug
Cap
Socket Bolt (14 Used)
Cap
O-Ring

66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 -

W2-5-22

Plug
Cap (3 Used)
Socket Bolt (2 Used)
Cap
Bolt
Spring Seat (2 Used)
Spring
Spool
Overload Relief Valve (2 Used)
Poppet
Spring
O-Ring (5 Used)
O-Ring (2 Used)
Body
O-Ring
Plug
O-Ring
Plug
Poppet
Poppet
Spring
Plug
Spring (3 Used)
Sleeve
Plug
O-Ring
Body
Spool
Spring
Spring Seat
O-Ring
Plug

98 - Socket Bolt (12 Used)

99 - Poppet
100 - Poppet
101 - Spring
102 - Plug
103 - Spool
104 - Spring
105 - Flange
106 - O-Ring
107 - Cap
108 - Socket Bolt (4 Used)
109 - Poppet
110 - Poppet
111 - Spring
112 - Plug
113 - Poppet
114 - Spring
115 - Plug (3 Used)
116 - O-Ring (3 Used)
117 - Spring Seat (3 Used)
118 - Spring
119 - Spool
120 - Plug (3 Used)
121 - O-Ring (3 Used)
122 - Spring
123 - Spool
124 - Body
125 - Spool
126 - Spring
127 - Plug
128 - O-Ring
129 - Plug

UPPERSTRUCTURE / Control Valve

(Blank)

W2-5-23

UPPERSTRUCTURE / Control Valve

63

65, 66

WCJB-02-05-005

59, 67

63

Control Valve (Upper)

59, 67

63

59, 64

Control Valve (Lower)

Arm 2

Boom 1

Buckets

WCJB-02-05-006

Travel

41

39

41

39

52
40

40

53

39
52

39

47

51

35
50

49

46

45

45

43, 44

43, 44
59
63
64

59
67
65

66

63

48
Section K-K

W2-5-24

42

WCJB-02-05-009

UPPERSTRUCTURE / Control Valve

Assembly of Control Valve 4-Spool Side

Assembly of Travel Spool

Assembly of Boom 1 Spool

1. Clamp spool (35) in a vise by using wooden

pieces. Install spring seat (39), spring (40), spring
seat (39) and bolt (41) to spool (35).
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)

Assembly of Bucket Spool

2. Clamp spool (47) in a vise by using wooden
pieces.
Install poppet (46) and spring (45) to the lower
side of spool (47).
3. Install O-ring (44) and backup ring (43) to plug
(42). Apply LOCTITE #271 onto the thread part of
plug (42).
4. Install plug (42) to spool (47) by using special tool
(ST 5909).
: 15 Nm (1.5 kgfm, 11 lbfft)
ST 5909

W157-02-05-049

5. Install spring seat (39), spring (40), spring seat

(39) and bolt (41) to the upper side of spool (47).
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)

6. Clamp spool (50) in a vise by using wooden

pieces.
Install poppet (49) and spring (45) to the lower
side of spool (50).
7. Install O-ring (44) and backup ring (43) onto plug
(48). Apply LOCTITE #271 onto the thread of part
of plug (48).
8. Install plug (48) to spool (50) by using special tool
(ST 5909).
: 15 Nm (1.5 kgfm, 11 lbfft)
9. Install spring seat (39), spring (40), spring seat
(39) and bolt (41) to the upper side of spool (50).
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)

Assembly of Arm 2 Spool

10. Clamp spool (51) in a vise by using wooden
pieces. Install spring seats (39, 52), springs (53,
40), spring seats (52, 39) and bolt (41) to spool
(51).
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)
11. Install O-ring (65) to plug (66). Install plug (66)
into cap (64).
: 20 Nm (2 kgfm, 15 lbfft)
12. Install O-rings (59) (4 used) onto housing (1).
Install caps (67) (3 used) and cap (64) to housing
(1) with socket bolts (63) (8 used).

W2-5-25

UPPERSTRUCTURE / Control Valve

63

60, 61

59, 62
Control Valve (Upper)

63

WCJB-02-05-005

Control Valve (Lower)

WCJB-02-05-006

61
60

62

58
57

59

59

4
55, 56

54

WCJB-02-05-009

Section K-K

W2-5-26

UPPERSTRUCTURE / Control Valve

13. Clamp spool (54) in a vise by using wooden
pieces. Install O-ring (55) and backup ring (56)
onto spool (57). Install spool (57) to spool (54).
Install spool (54) and spring (58) to housing (1).
14. Install the spool (51, 50, 47, 35) assemblies,
O-rings (59) (4 used) and O-ring (4) to housing (1).
Install cap (62) to housing (1) with socket bolts
(63) (6 used).
: 8 mm
: 42 Nm (4.3 kgfm, 31 lbfft)
15. Install O-ring (60) to plug (61). Install plug (61)
into cap (62).
: 22 mm
: 543 Nm (5.50.3 kgfm, 402 lbfft)

W2-5-27

UPPERSTRUCTURE / Control Valve

15, 17

6
105
98

92

15, 74

69

68

1
Control Valve (Front)

WCJB-02-05-007

Control Valve (Side)

103

97

WCJB-02-05-008

104

96
95
94
92
93

105, 6

91
1

90
89
84

85

77 18

86 87 88

W1V1-02-05-033

WCJB-02-05-021

Section of Bypass Shut-Out Valve

Bucket Flow Rate Control Valve (Detail B)

73
4

71
1

72
71

70

68, 69

Section of Flow Combiner Valve

(Detail A)

W2-5-28

W1V1-02-05-040

UPPERSTRUCTURE / Control Valve

Assembly of Bucket Flow Rate Control Valve

Assembly of Bypass Shut-Out Valve

16. Install O-rings (96, 91) to plugs (97, 90).

23. Install spool (103), spring (104) and O-ring (4) to

housing (1). Install flange (105) to housing (1)
with socket bolts (6) (4 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)

17. Install spring (94), spool (93), spring seat (95) and
plug (97) to body (92).
18. Install plug (90) to body (92).
19. Install poppet (85), spring (86) and plug (87) to
poppet (84). Install the poppet (84) assembly,
spring (88) and sleeve (89) into housing (1).
20. Install O-rings (18, 77) into housing (1). Install
body (92) to housing (1) with socket bolts (98) (4
used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)

Assembly of Flow Combiner Valve

21. Install spring seat (71), spring (72) and spring
seat (71) to bolt (70). Install bolt (70) to spool (73).

Assembly of Overload Relief Valve

IMPORTANT: If the overload relief valve is
disassembled, pressure must be
adjusted.
(Refer to TROUBLESHOOTING /
Operational Performance Test in the
separated volume, T/M.)
24. Install O-rings (15) (4 used) to overload relief
valves (17, 74) (2 used for each). Install overload
relief valves (17, 74) (2 used for each) to housing
(1).
: 32 mm
: 835 Nm (8.50.5 kgfm, 614 lbfft)

22. Install spool (73) and O-ring (4) to housing (1).

Install cap (69) to housing (1) with socket bolts
(68) (2 used).
: 5 mm
: 10 Nm (1 kgfm, 7 lbfft)

W2-5-29

UPPERSTRUCTURE / Control Valve

9, 10, 11, 12

3, 4, 13, 14

11, 12

1
7, 8
106, 107

108
Control Valve (Side)

1
WCJB-02-05-007

2, 3, 4, 5
Control Valve (Front)

W1V1-02-05-033

Bucket Flow Rate Control Valve (Detail B)

WCJB-02-05-008

WCJB-02-05-021

Section of Bypass Shut-Out Valve

Section of Flow Combiner Valve

(Detail A)

W2-5-30

W1V1-02-05-040

UPPERSTRUCTURE / Control Valve

Assembly of Check Valve
25. Install O-ring (11) to plug (12). Install poppets (9)
(2 used), spring (10) and plug (12) into housing
(1).
: 6 mm
: 763 Nm (7.70.3 kgfm, 562 lbfft)
26. Install plugs (7, 12) (2 used for each) to housing
(1).
: 6 mm
: 763 Nm (7.70.3 kgfm, 562 lbfft)
: 10 mm
: 106 to 141 Nm
(10.8 to 14.4 kgfm, 78 to 104 lbfft)
27. Install poppets (2, 14), springs (3) (2 used) and
O-rings (4) (2 used) to housing (1).
28. Install flanges (5, 13) to housing (1) with socket
bolts (6) (4 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)
29. Install O-ring (106) to housing (1). Install cap
(107) to housing (1) with socket bolts (108) (4
used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)

W2-5-31

UPPERSTRUCTURE / Control Valve

79

34

30

(Arm 2 Flow Rate Control Valve) 124

WCJB-02-05-007

Control Valve (Side)

34
33
30
32

77

18

120
121

31
28

29

27

22

18
26
25
24
23
21
20

1
18
78

119

81

118

80

117

124

116
79

115

82
75

77
76
Boom Anti-Drift Valve (Detail C)
78

99 100

101

102

87
W1V1-02-05-032

83
W1V1-02-05-031

Arm 2 Flow Rate Control Valve (Detail D)

115

127

120

116
117

121

126

109

110
111

77
112

125

123

121

122
117
116

120
87

124

W1V1-02-05-042

115
113

114

77

18

124
W1V1-02-05-034

Arm 2 Flow Rate Control Valve (Detail E)

Arm 2 Flow Rate Control Valve (Detail F)

W2-5-32

UPPERSTRUCTURE / Control Valve

Assembly of Boom Anti-Drift Valve

Assembly of Arm 2 Flow Rate Control Valve

30. Install backup rings (23, 26) and O-rings (24, 25)
to sleeve (27).

39. Install O-rings (116, 121) (3 used for each) to

plugs (115, 120) (3 used for each) as shown in
detail D, E and F.

31. Face the hole on spool (28) to the poppet (22)

side. Install spool (28), poppet (22), seat (21) and
spring (20) to sleeve (27). Install the sleeve (27)
assembly to housing (1).
NOTE: Apply grease onto seat (21) and spring
(20)in order to fall off.

40. Install spool (119), spring (118) and spring seat

(117) to body (124) as shown in detail D.
Temporarily tighten plugs (115, 120) to body
(124).

32. Install O-ring (33) to plug (34). Install spring (31),

piston (32), O-ring (29) and plug (34) to body (30).

41. Install spool (123), spring (122) and spring seat

(117) to body (124) as shown in detail F.
Temporarily tighten plugs (115, 120) to body
(124).

33. Install O-rings (18) (3 used) to housing (1). Install

the body (30) assembly to housing (1) with socket
bolts (6) (3 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)

42. Install plug (127), spool (125), spring (126) and

spring seat (117) to body (124) as shown in detail
E. Temporarily tighten plugs (115, 120) to body
(124).
43. Install poppet (100), spring (101) and plug (102)
to poppet (99)as shown in detail D. Install the
poppet (99) assembly, spring (87) O-rings (18, 77)
to housing (1).

34. Tighten plug (34).

35. Install O-rings (80, 82) to plugs (81, 83).
36. Install poppet (75), spring (76), O-rings (77, 78)
and O-rings (18) (3 used) to housing (1).
37. Install body (79) to housing (1) with socket bolts
(6) (4 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)

44. Install poppet (99), poppet (110), spring (111) and

plug (112) to poppet (109) as shown in detail E.
Install the poppet (109) assembly, spring (87),
O-ring (77, 78) into housing (1).
45. Install poppet (113), spring (114) and O-rings (77,
18) to housing (1) as shown in detail F.

38. Tighten plugs (81, 83).

W2-5-33

UPPERSTRUCTURE / Control Valve

(Arm 2 Flow Rate Control Valve)124

98
Control Valve (Side)

WCJB-02-05-007

120

124

115
Boom Anti-Drift Valve (Detail C)

W1V1-02-05-031

Arm 2 Flow Rate Control Valve (Detail D)

115

W1V1-02-05-032

120

120
115

W1V1-02-05-042

Arm 2 Flow Rate Control Valve (Detail F)

Arm 2 Flow Rate Control Valve (Detail E)

W2-5-34

W1V1-02-05-034

UPPERSTRUCTURE / Control Valve

46. Install body (124) to housing (1) with socket bolts
(98) (8 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)
47. Tighten plugs (115, 120) (3 used for each) to body
(124).

W2-5-35

UPPERSTRUCTURE / Control Valve

DISASSEMBLY OF CONTROL VALVE 5-SPOOL SIDE
3

7
6
5

11

10

9
12

13
14

15

1
16
14

17

15

18

12
19

13
20
21
31
27

28

29

26

33

35
30

32

Arm Anti-Drift Valve

25

24

Check Valve
(5-Spool Side Parallel Circuit)

23
37 22

34

38
36

39

40

41

42

8
46

43
44

48

43

47
43

43
44

50

45
43

43

49

Blade/Outrigger

45

44

51

43

44
49

43

Auxiliary

45
43

Boom 2

45

44
43

Arm 1

45
Swing

53

52

54

52

55

56
WCJB-02-05-010

W2-5-36

UPPERSTRUCTURE / Control Valve

58

57

58

57

59

79

60
62

63

64

9
66
67
68
69
70
71

63

64

65

72

77

8
73

7
6

10
9

76

Check Valve

85

78

75

Load Check Valve

(Blade/Outrigger)

20

Arm Anti-Drift Valve

92

89

93
94

97

90
94

3
2
53

13
96

53

102

99

104
53
105
106
107

52

100

87
Load Check Valve
(Travel)

91

95

98

101
103

86

88

92

93

65

9
66
67
81
82
83
84

Load Check Valve

(Boom 2 Parallel Circuit)

74

13

12
25

12

107
13
12

52
1

99

53

80

20

20

102

60

Arm 1 Flow Rate Control Valve

61

101

59

Auxiliary Flow Rate

Control Valve

52

53

99
52
52

13

12

99

WCJB-02-05-011

W2-5-37

UPPERSTRUCTURE / Control Valve

12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 -

Housing
O-Ring
Plug
Poppet
Spring
O-Ring (3 Used)
Flange (3 Used)
Socket Bolt (22 Used)
O-Ring (5 Used)
Spring (2 Used)
Poppet
O-Ring (4 Used)
Plug (4 Used)
O-Ring (2 Used)
Overload Relief Valve (2 Used)
O-Ring
Backup Ring
Plug
Main Relief Valve
O-Ring (6 Used)
O-Ring
Spacer
Backup Ring
O-Ring
Spring
Poppet
Spring

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -

Seat
Poppet
Backup Ring
O-Ring
O-Ring
Backup Ring
Sleeve
Spool
O-Ring
Body
Spring
Piston
O-Ring
Plug
Spool
Spring Seat (10 Used)
Spring (5 Used)
Bolt (5 Used)
Spool
Spool
Spool
Spring Seat (2 Used)
Spring
Spool
O-Ring (10 Used)
Socket Bolt (16 Used)
O-Ring

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 -

W2-5-38

Plug
Cap
Socket Bolt (8 Used)
Plug (2 Used)
O-Ring (2 Used)
Body (2 Used)
Spool
Spring
Spring Seat (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Sleeve (2 Used)
Spring (2 Used)
Plug
Spring
Poppet
Poppet
Plug
O-Ring
Flange
Spring
Poppet
Flange (2 Used)
Poppet (2 Used)
Spool
Spring
Plug

82 - Spring
83 - Poppet
84 - Poppet
85 - Poppet
86 - Cover (2 Used)
87 - O-Ring (2 Used)
88 - Plug
89 - O-Ring
90 - Spring
91 - Poppet
92 - Socket Bolt (4 Used)
93 - Cap (2 Used)
94 - Spring Seat (2 Used)
95 - Spring
96 - Spool
97 - Spring
98 - Spool
99 - Cap (4 Used)
100 - Cap
101 - Overload Relief Valve (2 Used)
102 - O-Ring (2 Used)
103 - Plug
104 - Backup Ring
105 - O-Ring
106 - Plug
107 - O-Ring

UPPERSTRUCTURE / Control Valve

(Blank)

W2-5-39

UPPERSTRUCTURE / Control Valve

8

7
6
4

5
11

10

9
14

15

1
14
15

19
20
21
31
27

28

29

26

33

35
30

32

Arm Anti-Drift Valve

34

25

23
37 22
38

36

Check Valve
(5-Spool Side Parallel Circuit)

24

39

40

41

42

8
46
48

47

Blade/Outrigger

51

Auxiliary
Boom 2
Arm 1

Swing

53

52

52

56
WCJB-02-05-010

W2-5-40

UPPERSTRUCTURE / Control Valve

Disassembly of Control Valve 5-Spool Side

Disassembly of Spool
1. Remove socket bolts (53) (6 used) from cap (56).
Remove cap (56) and O-rings (52) (5 used) from
housing (1).
: 8 mm
2. Put the matching marks on spools (42, 46, 47, 48,
51) and housing (1). Remove the spools (42, 46,
47, 48, 51) assemblies from housing (1).

Disassembly of Arm Anti-Drift Valve

3. Remove plug (41) from body (37).
: 38 mm
4. Remove socket bolts (8) (3 used) from body (37).
Remove the body (37) assembly, O-rings (21, 36)
and O-rings (20) (4 used) from housing (1).
: 8 mm
5. Remove piston (39) and spring (38) from body
(37).
: 38 mm
6. Remove spool (35), sleeve (34), poppet (29), seat
(28) and spring (27) from housing (1).
Remove backup rings (30, 33) and O-rings (31,
32) from sleeve (34).

Disassembly of Overload Relief Valve (15)

IMPORTANT: Do not disassemble the overload
relief valve. When disassembling the
overload relief valve, pressure must
be
adjusted.
(Refer
to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
7. Remove overload relief valves (15) (2 used) from
housing (1). Remove O-rings (14) (2 used) from
overload relief valves (15) (2 used).
: 32 mm
Disassembly of Main Relief Valve (19)
IMPORTANT: Do not disassemble the main relief
valve. When disassembling the main
relief valve, pressure must be
adjusted.
(Refer
to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
8. Remove main relief valve (19) from housing (1).
: 32 mm
Disassembly of Check Valve
9. Remove spacer (22), spring (25) and poppet (26)
from housing (1). Remove backup ring (23) and
O-ring (24) from spacer (22).
10. Remove socket bolts (8) (2 used) from flange (7).
Remove flange (7), O-ring (6), spring (5) and
poppet (4) from housing (1).
: 8 mm
11. Remove socket bolts (8) (2 used) from flange (7).
Remove flange (7), O-ring (9), spring (10) and
poppet (11) from housing (1).
: 8 mm

W2-5-41

UPPERSTRUCTURE / Control Valve

12

13

1
16

17

18

12
13

42
46

43
44

48

43

47
43

43
44

50

45

44

51

43

44
49

43

45
43

43

49

Blade/Outrigger

Auxiliary

45
43

Boom 2

45

44
43

Arm 1

45
Swing

WCJB-02-05-010

W2-5-42

UPPERSTRUCTURE / Control Valve

12. Remove plugs (13) (2 used) and plug (3) from
housing (1). Remove O-rings (12) (2 used) and
O-ring (2) from plugs (13) (2 used) and plug (3).
: 8 mm

Disassembly of Swing Spool (51)

18. Clamp spool (51) in a vise by using wooden
pieces. Remove bolt (45), spring seat (43), spring
(44) and spring seat (43) from spool (51).
: 8 mm

13. Remove plug (18) from housing (1). Remove

backup ring (17) and O-ring (16) from plug (18).
: 24 mm

Disassembly of Blade/Outrigger Spool (42)

14. Clamp spool (42) in a vise by using wooden
pieces. Remove bolt (45), spring seat (43), spring
(44) and spring seat (43) from spool (42).
: 8 mm

Disassembly of Auxiliary Spool (46)

15. Clamp spool (46) in a vise by using wooden
pieces. Remove bolt (45), spring seat (43), spring
(44) and spring seat (43) from spool (46).
: 8 mm

Disassembly of Boom 2 Spool (47)

16. Clamp spool (47) in a vise by using wooden
pieces. Remove bolt (45), spring seat (43), spring
(44) and spring seat (43) from spool (47).
: 8 mm

Disassembly of Arm 1 Spool (48)

17. Clamp spool (48) in a vise by using wooden
pieces. Remove bolt (45), spring seats (43, 49),
springs (44, 50) and spring seats (43, 49) from
spool (48).
: 8 mm

W2-5-43

UPPERSTRUCTURE / Control Valve

58

57

58

57

Auxiliary Flow Rate Control Valve

59

60
79

Arm 1 Flow Rate Control Valve

59

60

20
61

62

20

63

64

9
66
67
81
82
83
84

65

9
66
67
68
69
70
71

80

63

64

65
8

7
6
5

Check Valve

74

85

75
76
92

Digging Regenerative Valve

92

93

93 Auxiliary Flow Combiner Valve

6
94

97

94
95

98

101

96
53

102

99

53

52

100

101

52

53
102

20

Arm Anti-Drift Valve

99

53

52

53

99
52
52
99

WCJB-02-05-011

W2-5-44

UPPERSTRUCTURE / Control Valve

19. Remove socket bolts (53) (10 used) from caps
(99) (4 used) and cap (100). Remove caps (99) (4
used), cap (100) and O-rings (52) (5 used) from
housing (1).
: 8 mm

Disassembly of Arm Anti-Drift Valve

Disassembly of Digging Regenerative Valve and

Disassembly of Arm 1 Flow Rate Control Valve and

Auxiliary Flow Combiner Valve

20. Remove socket bolts (92) (4 used) from caps (93)
(2 used). Remove caps (93) (2 used), O-rings (6)
(2 used), spring seats (94) (2 used), springs (95,
97) and spools (96, 98) from housing (1).
: 5 mm

Auxiliary Flow Rate Control Valve

24. Loosen plugs (58, 65) (2 used for each) from
bodies (60) (2 used).

Disassembly of Overload Relief Valve (101)

IMPORTANT: Do not disassemble overload relief
valve (101). When disassembling the
overload relief valve, pressure must
be
adjusted.
(Refer
to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
21. Remove overload relief valves (101) (2 used)
from housing (1). Remove O-rings (102) (2 used)
from overload relief valves (101) (2 used).
: 32 mm
Disassembly of Check Valve

23. Remove socket bolts (8) (4 used) from flange (74).

Remove flange (74), O-rings (20) (3 used), O-ring
(9), spring (75) and poppet (76) from housing (1).
: 8 mm

25. Remove socket bolts (57) (8 used) from body (60)

(2 used). Remove O-rings (20, 9) (2 used for
each) from housing (1).
: 8 mm
26. Remove plugs (65) (2 used), spring seats (63) (2
used), springs (63, 80) and spools (61, 79) from
bodies (60) (2 used). Remove plugs (58) (2 used)
from bodies (60) (2 used).
27. Remove O-rings (59, 64) (2 used for each) from
plugs (58, 65) (2 used for each).
28. Remove sleeves (66) (2 used), springs (67) (2
used), plugs (68, 81), springs (69, 82) and
poppets (70, 71, 83, 84) from housing (1).

22. Remove socket bolts (8) (2 used) from flange (7).

Remove flange (7), O-ring (6), spring (5) and
poppet (85) from housing (1).
: 8 mm

W2-5-45

UPPERSTRUCTURE / Control Valve

Load Check Valve

(Boom 2 Parallel Circuit)

8
77

9
10
78
8

Load Check Valve

(Blade/Outrigger)

88

86

89

87

90
91

Load Check Valve

(Travel)

13

103
104
105

13

12
25

12

107
13

12

99

WCJB-02-05-011

W2-5-46

UPPERSTRUCTURE / Control Valve

Disassembly of Load Check Valve
29. Remove socket bolts (8) (4 used) from flange (77).
Remove flange (77), O-ring (9), spring (10) and
poppet (78) from housing (1).
: 8 mm

35. Remove plugs (13) (2 used) from housing (1).

Remove O-rings (12) (2 used) from plugs (13) (2
used).
: 8 mm

30. Remove socket bolts (8) (4 used) from cover (86).

Remove cover (86) and O-ring (87) from housing
(1).
: 8 mm
31. Remove plug (88), spring (90) and poppet (91)
from housing (1). Remove O-ring (89) from plug
(88).
: 24 mm
32. Remove plug (13), spring (25) and poppet (107)
from housing (1). Remove O-ring (12) from plug
(13).
: 8 mm
12

25

107

13

W1V1-02-05-016

33. Remove plug (103) from housing (1). Remove

backup ring (104) and O-ring (105) from plug
(103).
: 24 mm
34. Remove plug (3) from housing (1). Remove
O-ring (2) from plug (3).
: 10 mm

W2-5-47

UPPERSTRUCTURE / Control Valve

ASSEMBLY
OF
5-SPOOL SIDE

CONTROL

VALVE

53

54, 55

52, 56

53

53

52, 99

53 52, 100

53

52, 99 53

52, 99
53
52, 99
1

WCJB-02-05-006
WCJB-02-05-005

Control Valve (Upper)

19

15

18

15

41

Control Valve (Lower)

12, 13

37

8
7, 9, 10, 11

8
1
8
8
74

2, 3
57
57

4, 5, 6, 7
12, 13

93

W1V1-02-05-068

101

60 103 77 93
View A

60

101

99

53

WCJB-02-05-012

W2-5-48

View B

UPPERSTRUCTURE / Control Valve

19
1
12, 13
5
6
7

98
6
97
94
93

85

W1V1-02-05-043
WCJB-02-05-005

Section C-C
(5-Spool Side)

Control Valve (Upper)

Blade/Outrigger

Boom 2

Auxiliary

56

55

45
43

14, 15

54

14, 15

44
43

86

52

78
10
47
46

42

52
99

107

8
86

Section D-D
(5-Spool Side)

1
99

106

WCJB-02-05-013

101, 102

9
77
8

101, 102
Section E-E
(5-Spool Side)

W2-5-49

WCJB-02-05-014

W1V1-02-05-046

Section F-F
(5-Spool Side)

UPPERSTRUCTURE / Control Valve

Arm 1

Swing

45
43
49
50

44
15

49

78

14

43
48

10

51

9
D

77
1
102

101
W1V1-02-05-052
W1V1-02-05-051

Section G-G
(5-Spool Side)

Section H-H
(5-Spool Side)

W1V1-02-05-050

Section I-I
(5-Spool Side)

88

89

90

91

65

64
63
80
60
79

59
58
66
84

83

20

82 81 67

W1V1-02-05-033

Detail A

13

12 2
Detail B

W2-5-50

W1V1-02-05-053

UPPERSTRUCTURE / Control Valve

41
40
39
37
65

38

29

35

20

70

71

63
62
61

30
28
27
60

73

64

36
34
33
32
31

20

66 67

72

75

76

58

59

68

20

69

WCJB-02-05-015

Detail D

W1V1-02-05-054

Detail C

12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 -

Housing
O-Ring
Plug
Poppet
Spring
O-Ring (3 Used)
Flange (3 Used)
Socket Bolt (22 Used)
O-Ring (5 Used)
Spring (2 Used)
Poppet
O-Ring (4 Used)
Plug (4 Used)
O-Ring (2 Used)
Overload Relief Valve (2 Used)
O-Ring
Backup Ring
Plug
Main Relief Valve
O-Ring (6 Used)
O-Ring
Spacer
Backup Ring
O-Ring
Spring
Poppet
Spring

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -

Seat
Poppet
Backup Ring
O-Ring
O-Ring
Backup Ring
Sleeve
Spool
O-Ring
Body
Spring
Piston
O-Ring
Plug
Spool
Spring Seat (10 Used)
Spring (5 Used)
Bolt (5 Used)
Spool
Spool
Spool
Spring Seat (2 Used)
Spring
Spool
O-Ring (10 Used)
Socket Bolt (16 Used)
O-Ring

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 -

W2-5-51

Plug
Cap
Socket Bolt (8 Used)
Plug (2 Used)
O-Ring (2 Used)
Body (2 Used)
Spool
Spring
Spring Seat (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Sleeve (2 Used)
Spring (2 Used)
Plug
Spring
Poppet
Poppet
Plug
O-Ring
Flange
Spring
Poppet
Flange (2 Used)
Poppet (2 Used)
Spool
Spring
Plug

82 - Spring
83 - Poppet
84 - Poppet
85 - Poppet
86 - Cover (2 Used)
87 - O-Ring (2 Used)
88 - Plug
89 - O-Ring
90 - Spring
91 - Poppet
92 - Socket Bolt (4 Used)
93 - Cap (2 Used)
94 - Spring Seat (2 Used)
95 - Spring
96 - Spool
97 - Spring
98 - Spool
99 - Cap (4 Used)
100 - Cap
101 - Overload Relief Valve (2 Used)
102 - O-Ring (2 Used)
103 - Plug
104 - Backup Ring
105 - O-Ring
106 - Plug
107 - O-Ring

UPPERSTRUCTURE / Control Valve

53

54, 55

52, 56

53

53

52, 99

53 52, 100

53

52, 99 53

52, 99
53
52, 99
1

WCJB-02-05-005

Control Valve (Upper)

Blade/Outrigger

WCJB-02-05-006

Control Valve (Lower)

Auxiliary Boom 2

55
54

Arm 1

Swing

45

45
43
49
50
44
49
43

56

43
44
43
52

51
42

48
46
47
52

52
53
99

107

106

100

99
Section L-L

W2-5-52

99

99
WCJB-02-05-016

UPPERSTRUCTURE / Control Valve

Assembly of Blade/Outrigger Spool
1. Secure spool (42) in a vise by using wooden
pieces. Install spring seat (43), spring (44), spring
seat (43) and bolt (45) to spool (42).
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)

6. Install O-rings (52) (5 used) onto housing (1).

Install cap (100) and cap (99) (4 used) to housing
(1) with socket bolts (53) (10 used).
: 8 mm
: 422 Nm (4.30.2 kgfm, 311 lbfft)
7. Install the spools (42, 46, 47, 48, 51) assemblies
to housing (1).

Assembly of Auxiliary Spool

2. Secure spool (46) in a vise by using wooden
pieces. Install spring seat (43), spring (44), spring
seat (43) and bolt (45) to spool (46).
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)

Assembly of Boom 2 Spool

3. Secure spool (47) in a vise by using wooden
pieces. Install spring seat (43), spring (44), spring
seat (43) and bolt (45) to spool (47).
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)

Assembly of Arm 1 Spool

4. Secure spool (48) in a vise by using wooden
pieces. Install spring seats (43, 49), springs (44,
50), spring seats (43, 49) and bolt (45) to spool
(48).
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)

8. Install O-rings (52) (5 used) to housing (1). Install

cap (56) to housing (1) with socket bolts (53) (6
used).
: 8 mm
: 422 Nm (4.30.2 kgfm, 131 lbfft)
9. Install O-rings (54, 107) to plugs (55, 106). Install
plug (106) to cap (100).
: 22 mm
: 533 Nm (5.40.3 kgfm, 392lbfft)
10. Install plug (55) to cap (56).
: 22 mm
: 543 Nm (5.50.3 kgfm, 402 lbfft)

Assembly of Swing Spool

5. Secure spool (51) in a vise by using wooden
pieces. Install spring seat (43), spring (44), spring
seat (43) and bolt (45) into spool (51).
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)

W2-5-53

UPPERSTRUCTURE / Control Valve

8

16, 17, 18

86, 87

85

57

60

7
8
92
1
93

86, 87

8
77
Control Valve (Side)

Check Valve

W1V1-02-05-047

WCJB-02-05-012

65

66 67

83

84

64
63

98

80

79
1
97
94
66

58

59

81

20

82

WCJB-02-05-015

93
Auxiliary Flow Combiner Valve

77

10

WCJB-02-05-017

78

1
Load Check Valve

W1V1-02-05-049

W2-5-54

Section of Auxiliary Flow Rate Control Valve

(Detail A)

UPPERSTRUCTURE / Control Valve

Assembly of Auxiliary Flow Rate Control Valve

Assembly of Load Check Valve

11. Install O-rings (59, 64) to plugs (58, 65).

18. Install poppet (78), spring (10) and O-ring (9) to

housing (1).

12. Install spring (80), spool (79), spring seat (63) and
plug (65) to body (60).
13. Install plug (58) to body (60).
14. Install poppet (83), spring (82) and plug (81) to
poppet (84). Install the poppet (84) assembly,
spring (67) and sleeve (66) to housing (1).
15. Install O-rings (9, 20) into housing (1). Install body
(60) to housing (1) with socket bolts (57) (4 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)

Assembly of Check Valve

19. Install flange (77) to housing (1) with socket bolts

(8) (4 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)
20. Install O-ring (16) and backup ring (17) to plug
(18). Install plug (18) to housing (1).
21. Install O-rings (87) (2 used) to housing (1). Install
covers (86) (2 used) to housing (1) with socket
bolts (8) (8 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)

16. Install poppet (85), spring (5) and O-ring (6) to

housing (1). Install flange (7) to housing (1) with
socket bolts (8) (2 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)

Assembly of Auxiliary Flow Combiner Valve

17. Install spool (96), spring (95) and spring seat (94)
to housing (1). Install cap (93) to housing (1) with
socket bolts (92) (2 used).
: 5 mm
: 101 Nm (10.1 kgfm, 74 lbfft)

W2-5-55

UPPERSTRUCTURE / Control Valve

37

60
57

Control Valve (Front)

Control Valve (Side)

W1V1-02-05-068

WCJB-02-05-012

41
40
39
78
38
35

29
1

36
34
33
32
31

20
20

30
28
27
Section of Load Check Valve (Detail B)

W1V1-02-05-053

73

72

75

76

W1V1-02-05-054

Section of Anti-Drift Valve (Detail C)

65

66 67

70

71

64
63
62
61

W1V1-02-05-055

60

58

59

68

20

69

WCJB-02-05-015

Section of Arm Flow Rate Control Valve (Detail D)

W2-5-56

Section of Load Check Valve

UPPERSTRUCTURE / Control Valve

Assembly of Arm Anti-Drift Valve
22. Install backup rings (30, 33) and O-rings (31, 32)
to sleeve (34).
23. Face the hole on spool (35) to the poppet (29)
side. Install spool (35), poppet (29), seat (28) and
spring (27) to sleeve (34). Install the sleeve (34)
assembly to housing (1).
NOTE: Apply grease to seat (28) and spring (27) in
order not to drop.

31. Install O-rings (20) (3 used) and O-ring (9) to

housing (1). Install body (60) to housing (1) with
socket bolts (57) (4 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)

24. Install O-ring (40) onto plug (41). Install spring

(38), piston (39), O-ring (36) and plug (41) to body
(37).
25. Install O-rings (20) (3 used) and O-ring (21) to
housing (1). Install the body (37) assembly to
housing (1) with socket bolts (8) (2 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)
26. Tighten plug (41).

Assembly of Arm Flow Rate Control Valve

27. Install O-rings (59, 64) to plugs (58, 65).
28. Install spring (62), spool (61), spring seat (63) and
plug (65) to body (60).
29. Install plug (58) to body (60).
30. Install poppet (70), spring (69) and plug (68) to
poppet (71). Install the poppet (71) assembly,
spring (67) and sleeve (66) to housing (1).

W2-5-57

UPPERSTRUCTURE / Control Valve

19

14, 15

14, 15

12, 13

8
7, 9, 10, 11

2, 3

4, 5, 6, 7

1
101, 102

103, 104, 105

101, 102

Control Valve (Side)

88

89

90

12

12, 13
Control Valve (Front)

WCJB-02-05-012

W1V1-02-05-068

91

13
3

W1V1-02-05-053

Section of Load Check Valve (Detail B)

Section of Arm Anti-Drift Valve (Detail C)

77

10

W1V1-02-05-054

78

1
WCJB-02-05-015

Section of Arm Flow Rate Control Valve (Detail D)

W2-5-58

Section of Load Check Valve

W1V1-02-05-055

UPPERSTRUCTURE / Control Valve

Assembly of Load Check Valve
32. Install O-ring (89) to plug (88). Install poppet (91),
spring (90) and plug (88) to housing (1).
33. Install poppet (78), spring (10) and O-ring (9) to
housing (1). Install flange (77) to housing (1) with
socket bolts (8) (4 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)
34. Install O-rings (2, 12) to plugs (3, 13). Install plugs
(3, 13) to housing (1).

Assembly of Overload Relief Valve

IMPORTANT: If the overload relief valve is
disassembled, pressure must be
adjusted.
(Refer
to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
35. Install O-rings (14, 102) (2 used for each) to
overload relief valves (15, 101) (2 used for each).
Install overload relief valves (15, 101) (2 used for
each) to housing (1).
: 32 mm
: 835 Nm (8.50.5 kgfm, 614 lbfft)
36. Install O-ring (105) and backup ring (104) to plug
(103). Install plug (103) to housing (1).

Assembly of Main Relief Valve

IMPORTANT: If the main relief valve is
disassembled, pressure must be
adjusted.
(Refer
to
TROUBLESHOOTING / Operational
Performance Test in the separated
volume, T/M.)
37. Install main relief valve (19) to housing (1).
: 32 mm
: 835 Nm (8.50.5 kgfm, 614 lbfft)
Assembly of Check Valve
38. Install poppet (4), spring (5) and O-ring (6) to
housing (1). Install flange (7) to housing (1) with
socket bolts (8) (2 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)
39. Install poppet (11), spring (10) and O-ring (9) to
housing (1). Install flange (7) to housing (1) with
socket bolts (8) (2 used).
: 8 mm
: 613 Nm (6.20.3 kgfm, 452 lbfft)
40. Install O-rings (12) (2 used) to plugs (13) (2 used).
Install plugs (13) (2 used) to housing (1).
41. Install O-ring (2) to plug (3). Install plug (3) into
housing (1).

W2-5-59

UPPERSTRUCTURE / Control Valve

DISASSEMBLY OF HOUSING

4
4
4

5
4

4
4

4
6

6
5

W1V1-02-05-023

1 - Housing (5-Spool Side)

2 - Housing (4-Spool Side)

3 - Socket Bolt (9 Used)

4 - O-Ring (16 Used)

5 - O-Ring (12 Used)

W2-5-60

6-

O-Ring (3 Used)

UPPERSTRUCTURE / Control Valve

Disassembly of Housing
CAUTION: Housing (1, 2) weight: 150 kg (340
lb) for each
1. Remove socket bolts (3) (9 used) from housing
(1). Remove O-rings (4) (16 used), O-rings (5) (12
used) and O-rings (6) (3 used) from housing (1 or
2).
: 14 mm
2. Divide housing (1) and (2).

W2-5-61

UPPERSTRUCTURE / Control Valve

ASSEMBLY OF HOUSING
4

4
4
5

W1V1-02-05-011

2
3

3
3

3
WCJB-02-05-018

1 - Housing (5-Spool Side)

2 - Housing (4-Spool Side)

3 - Socket Bolt (9 Used)

4 - O-Ring (16 Used)

5 - O-Ring (12 Used)

W2-5-62

6-

O-Ring (3 Used)

UPPERSTRUCTURE / Control Valve

Assembly of Housing
1. Install O-rings (4) (16 used), O-rings (5) (12 used)
and O-rings (6) (3 used) to the housing (2)
mounting surface.
CAUTION: Housing (1, 2) weight: 150 kg (340
lb) for each
2. Install housing (1) to housing (2) with socket bolts
(3) (9 used).
: 14 mm
: 205 to 215 Nm
(21 to 22 kgfm, 152 to 159 lbfft)

W2-5-63

UPPERSTRUCTURE / Control Valve

(Blank)

W2-5-64

UPPERSTRUCTURE / Control Valve

REMOVAL AND INSTALLATION
POSITIONING CONTROL VALVE

OF

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. Disconnect hoses (1) (6 used) from valve (3).
Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 19 mm, 27 mm

2. Remove sems bolts (2) (3 used) from valve (3).

Remove valve (3) from bracket (4).
: 17 mm

WCJB-02-05-019

WCEB-02-05-011

Installation
1. Install valve (3) to bracket (4) with sems bolts (2)
(3 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

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

: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

WCEB-02-05-011

W2-5-65

UPPERSTRUCTURE / Control Valve

DISASSEMBLY
CONTROL VALVE

OF

POSITIONING

24

10

27

28

26

23

22

21

20

19

25

37

15

14
12

16

17

34

33

32

31

30

29

35

41

13

36

42
43
44

11

51

38
39
18
40

52

53

54

55

56

45
46
47

48

62
61
60

50
49
58

59

57
W198-02-05-001

12345678910 11 12 13 14 15 16 -

Nut
Bolt
O-Ring
Spring
Valve
Sleeve
Backup Ring (2 Used)
O-Ring
O-Ring
Spring
Spring
Pin
Valve
O-Ring
Backup Ring (2 Used)
Valve

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Sleeve
O-Ring
Nut
Bolt
O-Ring
Spring
Valve
Sleeve
Backup Ring (2 Used)
O-Ring
O-Ring
Spring
Spring
Pin
Valve
O-Ring

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 -

W2-5-66

Backup Ring (2 Used)

Valve
Sleeve
O-Ring
Seat
O-Ring
Valve
Spring
Sleeve
O-Ring
Spring
Poppet
Socket Bolt (2 Used)
Cover
O-Ring

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 -

Socket Bolt
Socket Bolt
Cover
End Spool
Seat
Spring
Spring
Seat
O-Ring
Spool
O-Ring
Plug
Rivet
Plate
Housing

UPPERSTRUCTURE / Control Valve

Disassembly of Positioning Control Valve
1. Remove socket bolts (45) (2 used) and socket
bolts (48, 49) from covers (46, 50). Remove
covers (46, 50) and O-rings (47, 56) from
housing (62).
IMPORTANT: Turn and remove the spools. If they
stick even a little, try again instead
of pulling roughly.

6. Remove sleeve assembly (37 to 42) from

housing (62).
: 36 mm
7. Remove spring (43) and poppet (44) from
housing (62).
8. Secure seat (37) in a vise. Remove sleeve (41),
spring (40) valve (39) and O-rings (38, 42) from
seat (37).
: 36 mm

2. Remove spool assembly (51 to 59) from housing

(62).
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
4. Remove plug (59) from spool (57). Remove
O-ring (58) from plug (59).
IMPORTANT: Do not disassemble overload relief
valve assemblies (1 to 18), (19 to 36)
as since they have been preset at
the set pressures.
5. 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.

W2-5-67

UPPERSTRUCTURE / Control Valve

ASSEMBLY OF POSITIONING CONTROL
VALVE
Section X-X

37

39 40

38
41
43
42

A1

44

A1

1 to 18

62
19 to 36

B1

B1

W198-02-05-003

57
W198-02-05-002

Section W-W

50 51

48

53 55 56 62
47

45

Nut
Bolt
O-Ring
Spring
Valve
Sleeve
Backup Ring (2 Used)
O-Ring
O-Ring
Spring
Spring
Pin
Valve
O-Ring
Backup Ring (2 Used)
Valve

57 59 58 46

W198-02-05-004

49

12345678910 11 12 13 14 15 16 -

54
52

W198-02-05-005

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Sleeve
O-Ring
Nut
Bolt
O-Ring
Spring
Valve
Sleeve
Backup Ring (2 Used)
O-Ring
O-Ring
Spring
Spring
Pin
Valve
O-Ring

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 -

W2-5-68

Backup Ring (2 Used)

Valve
Sleeve
O-Ring
Seat
O-Ring
Valve
Spring
Sleeve
O-Ring
Spring
Poppet
Socket Bolt (2 Used)
Cover
O-Ring

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 -

Socket Bolt
Socket Bolt
Cover
End Spool
Seat
Spring
Spring
Seat
O-Ring
Spool
O-Ring
Plug
Rivet
Plate
Housing

UPPERSTRUCTURE / Control Valve

Assembly of Positionnig 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 Nm (6 kgfm, 44 lbfft)
2. Insert poppet (44) and spring (43) into housing
(62).
3. Install the seat (37) assembly to housing (62).
: 36 mm
: 59 Nm (6 kgfm, 44 lbfft)
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 Nm (6 kgfm, 44 lbfft)

IMPORTANT: Install the spool (57) assembly into

housing (62) and check if it moves
smoothly by hand.
7. Insert spool (57) assemblies (51 to 59) into
housing (62) from the port A1 side.
NOTE: If any of spool assembly (51 to 59) is not
straight inserted, forced insertion can
result in flaws on the bore of housing (62)
or spool (57). 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 Nm (2.6 kgfm, 19 lbfft)

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 Nm (1 kgfm, 7 lbfft)
: 8 mm
: 18.6 Nm (1.9 kgfm, 14 lbfft)

W2-5-69

UPPERSTRUCTURE / Control Valve

(Blank)

W2-5-70

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.)
Removal
1. Open cover (2).

2. Remove sems bolts (3) (4 used) from cover (1).

Remove cover (1) from stay (4).
: 17 mm
3. Remove socket bolts (7) (8 used) and split flanges
(6) (4 used). Disconnect hoses (8) (12 used) from
swing motor (2). Remove O-rings (9) (2 used)
from hose (8). Remove swing dampener valve
(10) and O-ring (11) from swing motor (12).
: 8 mm

WCJB-02-01-002

8, 9

4. Disconnect hoses (5) (4 used) from swing motor

(12). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm, 36 mm
5. Disconnect connector (14) from pressure switch
(13).
6. Remove pressure switch (13) from swing motor
(12).
: 24 mm
7. Attach a nylon sling onto the body of swing motor
(12). Hoist and hold the swing motor (12)
assembly.
Nylon sling (eye-type at both ends): 2 pieces

W2-6-1

10, 11
5

12

14

13

WCJB-02-06-005

UPPERSTRUCTURE / Swing Device

CAUTION: Swing device (15) weight: 220 kg
(490 lb)
8. Disconnect hose (19) from center joint (20). Cap
the open ends.
: 27 mm
9. Remove bolts (16) (12 used) and washers (17)
(12 used) from swing device (15). Remove swing
device (15) from main frame (18).
: 30 mm

16, 17

15

18
19

NOTE: When hoisting swing device (15), the

machine may float up. If this occurs,
remove plugs (21) (2 places) and float
swing device (15) from main frame (18) by
using the pulling-out bolts (M20, Pitch 2.5
mm) (2 used).
NOTE: The number of hoses around the swing
device is different according to specification
of the front attachment. Do not damage the
hoses when removing and installing the
swing device.

20
21

WCJB-02-06-006

Installation
CAUTION: Swing device (15) weight: 220 kg
(490 lb)
1. Hoist and align swing device (15) with the
mounting holes on main frame (18). Install swing
device (15) to main frame (18) with bolts (16) (12
used) and washers (17) (12 used).
: 30 mm
: 500 Nm (50 kgfm, 37 lbfft)
IMPORTANT: Apply THREEBOND #1102 onto the
mounting surface of the swing
device and main frame (18).

W2-6-2

15

16, 17
18

WCJB-02-06-006

UPPERSTRUCTURE / Swing Device

2. Connect hose (19) to center joint (20).
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

14

13

3. Install pressure switch (13) to swing motor (12).

: 24 mm
: 16 Nm (1.6 kgfm, 12 lbfft)
12

4. Connect connector (14) to pressure switch (13).

19
20
WCJB-02-06-006

5. Connect hoses (5) (4 used) to swing motor (12).

: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)

8, 9

6. Apply grease onto O-rings (9, 11). Install O-rings

(9, 11) to hoses (8) (2 used) and swing dampener
valve (10).
7. Install swing dampener valve (10) and hoses (8)
(2 used) to swing motor (12) with split flanges (6)
(4 used) and socket bolts (7) (8 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

10, 11
5

12
WCJB-02-06-005

8. Install cover (1) to stay (4) with sems bolts (3) (4

used). Shut cover (2).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
IMPORTANT: After completing the work, fill the
swing motor with hydraulic oil.
Check the hydraulic oil level. Start
the engine and check for any oil
leaks.

W2-6-3

WCJB-02-01-002

UPPERSTRUCTURE / Swing Device

DISASSEMBLY OF SWING DEVICE

22
23

24

2
3

32

25

21

31

5
20

26

7
19

27
9

18
28

10
17

29

30

11

16

12

15

13

14

W178-02-06-004

12345678-

Motor
First Stage Planetary Gear
Thrust Plate
Pin (3 Used)
Spring Pin (3 Used)
Needle Bearing (3 Used)
Planetary Gear (3 Used)
Thrust Plate (3 Used)

910 11 12 13 14 15 16 -

Pin (3 Used)
Spring Pin (3 Used)
Thrust Plate (6 Used)
Needle Bearing (6 Used)
Planetary Gear (3 Used)
Roller Bearing
Bearing Nut
Lock Plate

17 18 19 20 21 22 23 24 -

W2-6-4

Bolt (2 Used)
Second Stage Carrier
Thrust Plate
Second Stage Sun Gear
First Stage Carrier
Socket Bolt (8 Used)
Socket Bolt (12 Used)
Ring Gear

25 26 27 28 29 30 31 32 -

Housing
Roller Bearing
Oil Seal
Sleeve
O-Ring
Shaft
Drain Plug
Pipe

UPPERSTRUCTURE / Swing Device

Disassembly of Swing Device
CAUTION: Swing device weight: 220 kg (490
lb)
CAUTION: When hoisting the swing device,
do not string the rope suddenly.
1. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
motor (1). Attach a nylon sling onto eyebolts.
Hoist motor (1).
Eyebolt
Mounting
Position

5. Put the matching marks at the jointed part

between motor (1) and ring gear (24), between
ring gear (24) and housing (25).
CAUTION: Motor (1) weight: 47 kg (110 Ib)
6. Remove socket bolts (22) (8 used) from motor (1).
Remove motor (1) from ring gear (24).
: 10 mm
NOTE: THREEBOND has been applied onto the
jointed surface. For easy removal, insert a
screwdriver into the gap around the jointed
part in order to float.
7. Remove first stage sun gear (2) from first stage
carrier (21).

W178-02-06-005

2. Place the swing device on bracket (ST 5097).

Secure the swing device onto the bracket by
using the bolts (M22, Pitch 2.5 mm) (2 used). At
this time, insert the stopper at the bottom of the
bracket between teeth of the pinion gear. Secure
the bracket on a workbench in order to reduce the
reaction force.
: 30 mm
Swing Device

Stopper

ST 5097

W178-02-06-012

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

ring gear (24).
9. Remove socket bolts (23) (12 used) from ring
gear (24).
: 14 mm
CAUTION: Ring gear (24) weight: 23 kg (51
Ib)
10. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the motor (1) mounting thread part on ring gear
(24). Attach a nylon sling onto eyebolts. Hoist and
remove ring gear (24) from housing (25).
NOTE: THREEBOND has been applied onto the
jointed surface. For easy removal, insert a
screwdriver into the gap around the jointed
part in order to float.
11. Remove second stage sun gear (20) from second
stage carrier (18).

3. Remove drain plug (31) from pipe (32). Drain off

oil from the swing device.
: 8 mm
4. Remove pipe (32) from housing (25).
: 18 mm

W2-6-5

UPPERSTRUCTURE / Swing Device

23

25

21

4
5
6
7
8

18

10
17
16
30

11
12

15

W178-02-06-004

W2-6-6

UPPERSTRUCTURE / Swing Device

12. Remove the second stage carrier (18) assembly
from shaft (30).

20. Remove bearing nut (15) from shaft (30), by using

special tool (ST 2926).
ST 2926

IMPORTANT: The hole for spring pin (5) located on

first stage carrier (21) is not a
through one. Check the tapping-in
distance of spring pin (5).
13. Tap spring pins (5) (3 used) installed to the first
stage carrier (21) assembly into pin (4) by using
special tool (ST 1462). At this time, stop tapping
when spring pin (5) reaches the middle of pin (4)
hole and do not tap spring pin (5) to the end.

15

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

bearing (6) and thrust plate (8) from first stage
carrier (21).
15. Remove other two sets of pin (4), planetary gear
(7), needle bearing (6) and thrust plate (8) from
first stage carrier (21) in the same order as steps
13 and 14.
16. Remove thrust plate (3) from first stage carrier
(21).
IMPORTANT: Do not damage the rotating surface
for the needle bearing of pin (4)
except for the both ends.
17. Secure the end of pins (4) (3 used) opposite the
spring pin (5) hole in a vise. Tap and remove
spring pins (5) (3 used) by using special tool
(ST 1462).

W178-02-06-008

CAUTION: The housing

weight: 122 kg (270 lb)

(25)

assembly

21. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to

the bolt (23) hole on housing (25). Attach a nylon
sling onto eyebolts. Hoist and remove bracket (ST
5097) from housing (25).
: 30 mm
22. After removing bracket (ST 5097), install bracket
(ST 1464). Set housing (25) to a press.
: 30 mm

18. Disassemble the second stage carrier (18)

assembly in the same way as the first stage carrier
(21) assembly. Note that second stage carrier (18)
assembly includes of needle bearings (12) (6
used) and thrust plates (11) (6 used). Use special
tool (ST 1463) when removing spring pins (10) (3
used).

Press

25

ST 1464

19. Remove bolts (17) (2 used) from lock plate (16).

Remove lock plate (16) from bearing nut (15).
W178-02-06-006

W2-6-7

UPPERSTRUCTURE / Swing Device

25

26

27

28

29

30
14

W178-02-06-004

W2-6-8

UPPERSTRUCTURE / Swing Device

23. Push shaft (30) by using a press. Remove shaft
(30) from housing (25). At this time, the inner race
of roller bearing (26) and sleeve (28) are removed
with shaft (30) together.

26. Remove the splined side of shaft (30) by using a

press. Remove the inner race of roller bearing
(26) and sleeve (28) from shaft (30).
27. Remove O-ring (29) from sleeve (28).

24. Place special tool (ST 1460) for removing roller

bearing (26) onto the stepped part of special tool
(ST 1461) for removing roller bearing (26).
ST 1460

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

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

Outer Race of
Roller Bearing
(26)

ST 1461

Oil Passage

W178-02-06-001

W178-02-06-010

CAUTION: Housing (25) weight: 60 kg (140

lb)
CAUTION: Shaft (30) weight: 40 kg (90 lb)
25. Insert the pinion gear of shaft (30) into tooth-hole
of special tool (ST 1460). Set them onto a press.
Press

30

30. Insert a screwdriver into the notch on housing

(25), where oil seal (27) is mounted. Remove oil
seal (27) from housing (25).
NOTE: THREEBOND has been applied onto the
periphery of oil seal (27). Therefore, oil seal
(27) cannot be reused.
31. Tap and remove the outer race of roller bearing
(14) from housing (25) by using a bar and
hammer.

26
ST 1460

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

sling. Hoist and turn over housing (25).

28

ST 1461

W178-02-06-009

W2-6-9

UPPERSTRUCTURE / Swing Device

ASSEMBLY OF SWING DEVICE

22

3
21

7
6

20

18

10

24

11

19

12

23

13

17

11

16

15

14

32
26

25

31

27
28
29

30

12345678-

Motor
First Stage Planetary Gear
Thrust Plate
Pin (3 Used)
Spring Pin (3 Used)
Needle Bearing (3 Used)
Planetary Gear (3 Used)
Thrust Plate (3 Used)

WCJB-02-06-001

910 11 12 13 14 15 16 -

Pin (3 Used)
Spring Pin (3 Used)
Thrust Plate (6 Used)
Needle Bearing (6 Used)
Planetary Gear (3 Used)
Roller Bearing
Bearing Nut
Lock Plate

17 18 19 20 21 22 23 24 -

Bolt (2 Used)
Second Stage Carrier
Thrust Plate
Second Stage Sun Gear
First Stage Carrier
Socket Bolt (8 Used)
Socket Bolt (12 Used)
Ring Gear

W2-6-10

25 26 27 28 29 30 31 32 -

Housing
Roller Bearing
Oil Seal
Sleeve
O-Ring
Shaft
Drain Plug
Pipe

UPPERSTRUCTURE / Swing Device

Assembly of Swing Device
1. Apply grease onto O-ring (29). Install O-ring (29)
onto sleeve (28).
CAUTION: Shaft (30) + sleeve (28) + roller
bearing (26) outer race weight: 36 kg (80 lb)
2. Install sleeve (28) and the inner race of roller
bearing (26) to shaft (30). Install sleeve (28) and
the inner race together by using special tool (ST
2923) and a press.
NOTE: The press-in distance of inner race of roller
bearing (26) can be assured by using
special tool.

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
tool (ST 2925) on oil seal (27). Tap in special tool
by using a hammer straight.
NOTE: The seal can be replaced by using special
tool (ST2925) without removing the sleeve.
ST 2925

27

25

Press

W178-02-06-007

6. Apply grease onto the inner surface of oil seal

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

ST 2923

26
28
30

CAUTION: Housing (25) + outer race weight:

63 kg (140 lb)
W178-02-06-013

CAUTION: Housing (25) weight: 60 kg (140

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.

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

sling. Hoist and place housing (25) with the ring
gear (24) side facing upward.
8. Tap and install the outer race of roller bearing (14)
to housing (25) by using a bar and hammer. Tap
and listen to ring in order to check if the
installation is completed.

4. Evenly tap and install the outer race of roller

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

W2-6-11

UPPERSTRUCTURE / Swing Device

24

23

15

14

25
27

30

WCJB-02-06-001

W2-6-12

UPPERSTRUCTURE / Swing Device

CAUTION: Housing (25) + outer races (2
used) weight: 65 kg (150 lb)
9. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
the bolt (23) hole on housing (25). Hoist and place
housing (25) on shaft (30) so that they are
matched. At this time, check and align carefully in
order to prevent the oil seal (27) lip from curling.

14. Place special tool (ST 2924) on the inner race of

roller bearing (14). Install the inner race by using a
press.
NOTE: The press-in distance of inner race can be
assured by using special tool.
ST 2924

14

10. Tap and install the inner race of roller bearing (14)
into 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 inner race and shaft
(30) is tight.
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
bearing total weight: 122 kg (270 lb)

(30)

W178-02-06-011

15. Hoist and place the housing (25) assembly on

bracket (ST 5097). Install bolts (M20, Pitch 2.5
mm) (2 used). At this time, insert the stopper at
the bottom of the bracket between teeth of the
pinion gear. Secure the bracket on a workbench in
order to reduce the reaction force.
: 30 mm

12. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to

the ring gear (24) mounting thread part on
housing (25). Hoist and place housing (25) on a
press.

25

ST 5097

13. Remove bearing nut (15) from shaft (30).

Stopper

W2-6-13

W178-02-06-012

UPPERSTRUCTURE / Swing Device

5
22

3
21

7
6
8

18

10
11

19

12
13

17

11

16

15

30

WCJB-02-06-001

W2-6-14

UPPERSTRUCTURE / Swing Device

IMPORTANT: Check the direction to install bearing
nut (15).
16. Apply a film of grease onto the thread part of
bearing nut (15). Install bearing nut (15) to shaft
(30). At this time, face the stepped side of bearing
nut (15) to the roller bearing (14) side. Tighten
bearing nut (15) by using special tool (ST 2926) to
the specified torque.
: 490 Nm (50 kgfm, 361 lbfft)
NOTE: Apply grease for keeping correct tightening
torque.

20. Install pin (9) to the position where planetary gear

(13) has been installed onto second stage carrier
(18) with the spring pin hole facing front. At this
time, the spring pin holes both in second stage
carrier (18) and pin (9) should be in line.
IMPORTANT: Check the direction of spring pin
(10).
21. Install spring pin (10) to second stage carrier (18)
by using spring pin removal and installation
special tool (ST 1463). At this time, face the slit of
spring pin to the end of pin (9).
10

ST 2926

15

Slit
W178-02-06-002

W178-02-06-008

17. Install lock plate (16) to bearing nut (15) with bolts
(17) (2 used). In case the splines of lock plate (16
and shaft (30) are not aligned, tighten bearing nut
(15) in tightening direction until both splines are
aligned.
IMPORTANT: Check the direction to install thrust
plate (19).
18. Install thrust plate (19) to second stage carrier
(18) with the oil groove surface facing outside.

22. Install planetary gears (13) (2 used), needle

bearings (12) (4 used), thrust plates (11) (4 used),
pins (9) (2 used) and spring pins (10) (2 used) into
other holes (2 places) on second stage carrier
(18) in the same way as steps 19 to 21.
IMPORTANT: Check the position to install thrust
plate (8).
23. Install thrust plate (3), planetary gears (7) (3 used),
needle bearings (6) (3 used), thrust plates (8) (3
used), pins (4) (3 used) and spring pins (5) (3
used) to the first stage carrier (21) in the same
way as steps 19 to 21. At this time, install thrust
plate (8) under needle bearing (6). Use special
tool (ST 1462).

19. Clamp planetary gear (13) and needle bearings

(12) (2 used) with thrust plates (11) (2 used).
Install them to second stage carrier (18).

W2-6-15

UPPERSTRUCTURE / Swing Device

22

21

20
18
24

23

16

32

31
25

30

WCJB-02-06-001

W2-6-16

UPPERSTRUCTURE / Swing Device

IMPORTANT: Check the direction to install second
stage carrier (18).
24. Install the second stage carrier (18) assembly to
the spline of shaft (30). At this time, the concave
part of the boss in bottom side of second stage
carrier (18) should come in contact with lock plate
18
Concave
(16).
Part

16

30

IMPORTANT: Check the direction to install first

stage sun gear (2).
30. Install first stage sun gear (2) into the first stage
carrier (21) assembly. At this time, face the
stepped part facing downward.
31. Wind the seal tape onto the thread part of pipe
(32). Install pipe (32) to housing (25). Face the
pipe (32) downward.
: 18 mm
32. Wind the seal tape onto drain plug (31). Install
drain plug (31) to pipe (32).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

W178-02-06-014

25. Install second stage sun gear (20) to the second

stage carrier (18) assembly with the small
diameter part facing upward.

33. Add gear oil to ring gear (24) until gear oil reaches
the middle part of first stage sun gear (2). (Approx.
6.9 L, 1.8 US gal)
34. Apply THREEBOND #1215 onto the motor (1)
mounting surface of ring gear (24). Clean old
adhesive in advance.

26. Apply THREEBOND #1215 onto the ring gear

(24) mounting surface of housing (25). Clean off
old adhesive in advance.
27. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the motor mounting thread part on ring gear (24).
Hoist and align ring gear (24) with the mounting
holes on housing (25). At this time, align the
matching marks made when disassembling.

CAUTION: Motor (1) weight: 47 kg (110 Ib)

35. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to
motor (1). Hoist and install motor (1) to ring gear
(24) with socket bolts (22) (8 used) while aligning
the matching marks.
: 10 mm
: 88 Nm (9 kgfm, 65 lbfft)

28. Install ring gear (24) into housing (25) with socket
bolts (23) (12 used).
: 14 mm
: 210 Nm (21.5 kgfm, 16 lbfft)

Eyebolt
Mounting
Position

29. Install the first stage carrier (21) assembly onto

the spline of second stage sun gear (20).
W178-02-06-005

W2-6-17

UPPERSTRUCTURE / Swing Device

DISASSEMBLY OF SWING MOTOR
10
9
8
7
6
5
4

11

3
2

24

25

26

29
27

15

14

27

17

Casing
Oil Seal
Bearing
Shaft
Shoe Plate
Plunger (9 Used)
Plate
Retainer

910 11 12 13 14 15 16 -

26

25

24

12

16

12345678-

31

28

23

13

30

Rotor
Friction Plate (3 Used)
Plate (4 Used)
O-Ring
Piston
Spring
Ball
Plug (2 Used)

17 18 19 20 21 22 23 24 -

18

19

20

O-Ring
O-Ring
Brake Piston
Spring (24 Used)
Valve Plate
Bearing
O-Ring
Plug (2 Used)

W2-6-18

21

22

32
W178-02-06-015

25 26 27 28 29 30 31 32 -

O-Ring (2 Used)
Spring (2 Used)
Poppet (2 Used)
Valve Casing
Socket Bolt (4 Used)
O-Ring (2 Used)
Plug (2 Used)
Relief Valve (2 Used)

UPPERSTRUCTURE / Swing Device

Disassembly of Swing Motor
CAUTION: The swing
weight: 47 kg (110 lb)

motor

assembly

IMPORTANT: Do not disassemble relief valve (32).

1. Remove relief valves (32) (2 used) from valve
casing (28).
: 41 mm
2. Remove plugs (24) (2 used) from valve casing
(28).
: 14 mm

IMPORTANT: Do not damage the mating surfaces

when separating valve plate (21)
from valve casing (28) or rotor (9) by
using a screwdriver. (Check the
surfaces of valve plate (2) in order
not to make a mistake for
assembling.)
7. If valve plate (21) is still on rotor (9) in step 5,
remove valve plate (21) from the rotor (19) side.
Remove springs (20) (24 used) from brake piston
(19).
CAUTION: There is also a method of
applying air from port B in order to float
brake piston (19). Prevent piston (13) from
flying out.

3. Remove springs (26) (2 used) and poppets (27)

(2 used) from valve casing (28).
4. Put the matching marks on the jointed surface
between valve casing (28) and casing (1).
Remove socket bolts (29) (4 used) from valve
casing (28). At this time, as the clearance exists
between valve casing (28) and casing (1), record
this clearance.
: 17 mm

8. Install special tool (ST 1468) to notch A of brake

piston (19). Remove brake piston (19) from
casing (1).

Notch A

5. Remove valve casing (28) from casing (1).

NOTE: At this time, as valve casing (28) may be
removed with valve plate (21) together, do
not drop valve plate (21).
6. Remove O-ring (23) from valve casing (28).

Port B

WCJB-02-06-003

9. Remove O-rings (17, 18) from casing (1).

W2-6-19

UPPERSTRUCTURE / Swing Device

10
9
8
7
6
5
4

11

3
2
1

15

14

13

W178-02-06-015

W2-6-20

UPPERSTRUCTURE / Swing Device

IMPORTANT: Do not damage the sliding surfaces
of rotor (9) and plunger (6).
10. Place casing (1) horizontally. Remove rotor (9),
retainer (8), plate (7) and plungers (6) (9 used)
from shaft (4).
11. Remove plates (11) (4 used) and friction plates
(10) (3 used) from casing (1).
IMPORTANT: Do not damage the sliding surface of
shoe plate (5).
12. Remove shoe plate (5) from casing (1).
13. Lightly tap and remove shaft (4) from casing (1)
by using a plastic hammer.
14. Remove the outer race of bearing (3) from casing
(1) by using a bar.
15. Remove oil seal (2) from casing (1).
16. Remove the inner race of roller bearing (3) from
shaft (4) by using a press.
IMPORTANT: Although the filter and the orifice are
installed to piston (13), do not
disassemble piston (13) unless they
are clogged or deformed.
When replacing the internal parts,
replace as an assembly.
17. Remove piston (13) from casing (1) by using a
pair of pliers.
18. Remove spring (14) and ball (15) from casing (1).

W2-6-21

UPPERSTRUCTURE / Swing Device

ASSEMBLY OF SWING MOTOR
27

26

25

12
24

13
14
15

16

29

WCJB-02-06-003
WCJB-02-06-002

31
30

32

28
22

21

23

20

18

19

17

11

10

7
5

3
1

4
12345678-

Casing
Oil Seal
Bearing
Shaft
Shoe Plate
Plunger (9 Used)
Plate
Retainer

WCJB-02-06-004

910 11 12 13 14 15 16 -

Rotor
Friction Plate (3 Used)
Plate (4 Used)
O-Ring
Piston
Spring
Ball
Plug (2 Used)

17 18 19 20 21 22 23 24 -

O-Ring
O-Ring
Brake Piston
Spring (24 Used)
Valve Plate
Bearing
O-Ring
Plug (2 Used)

W2-6-22

25 26 27 28 29 30 31 32 -

O-Ring (2 Used)
Spring (2 Used)
Poppet (2 Used)
Valve Casing
Socket Bolt (4 Used)
O-Ring (2 Used)
Plug (2 Used)
Relief Valve (2 Used)

UPPERSTRUCTURE / Swing Device

Assembly of Swing Motor
IMPORTANT: Install the inner race of bearing (3)
with the flange part facing to the
stepped side of shaft (4).
1. Install the inner races of bearings (3, 22) to shaft
(4) by using a press.
IMPORTANT: Install oil seal (2) with the lip part
facing upward.
2. Install oil seal (2) to casing (1) by using a plate.
3. Install the outer race of bearing (3) into casing (1)
by using a bar.

8. Place casing (1) horizontally. Install the rotor (9)

assembly to shaft (4) by turning shaft (4).
IMPORTANT: There are 4 notches on the outer
side of plate (11), and 4 notches at
the spline teeth side of friction plate
(10). Align each notch at the same
place when installing.
9. Place casing (1) vertically. Alternately install
plates (11) (4 used) and friction plates (10) (3
used) to casing (1).
10. Install O-rings (17, 18) onto casing (1).

IMPORTANT: Wind the tape onto the spline at the

end of shaft (4) in order not to
damage oil seal (2).
4. Install shaft (4) with casing (1).
5. Place casing (1) with the valve casing (28)
mounting surface facing upward. Install shoe
plate (5) with the chamfered surface facing inside.
IMPORTANT: Install retainer (8) to plunger (6) with
the notch facing to the shoe plate (5)
side.
6. Align the notches on plate (7) and retainer (8).
Install plungers (6) (9 used).

11. Align the matching marks and install brake piston

(19) into casing (1).
NOTE: If it is not easy to install brake piston (19)
due to the resistant force from O-rings (17,
18), tap them evenly by using a plastic
hammer.
12. Install springs (20) (24 used) to brake piston (19).

IMPORTANT: Install plunger (6) to after applying

hydraulic oil onto the plunger (6)
hole on rotor (9).
7. Install plungers (6) (9 used) to rotor (9).

W2-6-23

UPPERSTRUCTURE / Swing Device

27

26

25

24

13
14
15

29

WCJB-02-06-003
WCJB-02-06-002

32

28
22

21

23

1
4

WCJB-02-06-004

W2-6-24

UPPERSTRUCTURE / Swing Device

IMPORTANT: When replacing the inner parts of
piston (13), replace the piston (13)
as an assembly.
Install so that the ends of piston (13)
and casing (1) may be in the same
position.
13. Install ball (15), spring (14) and piston (13) to
casing (1).
IMPORTANT: Tap the bearing type indicated
surface by using a plastic hammer
and install roller bearing (22).
14. Install the outer race of bearing (22) to valve
casing (28) by using a plastic hammer.

18. Install valve casing (28) to casing (1) with socket

bolts (29) (4 used).
: 17 mm
: 430 Nm (44 kgfm, 317 lbfft)
19. Install poppets (27) (2 used) and springs (26) (2
used) into valve casing (28). Install plug (24) with
O-ring (25) attached.
: 14 mm
: 330 Nm (34 kgfm, 243 lbfft)
20. Install relief valves (32) (2 used) into valve casing
(28).
: 41 mm
: 175 Nm (18 kgfm, 129 lbfft)

IMPORTANT: Check the surfaces of valve plate

(21).
(Face the notch of the port to rotor
(9).)
15. Install O-ring (23) to valve casing (28). Install
valve plate (21) to valve casing (28).
NOTE: Apply grease onto valve plate (21) in order
to prevent valve plate (21) from falling off
from valve casing (28).
16. Apply grease onto the needle part of bearing (22).
NOTE: Shaft (4) can be inserted easily by holding
the needle with grease.
17. Align the matching marks on valve casing (28)
and casing (1). Place valve casing (28) onto
casing (1). Check that the clearance between
valve casing (28) and casing (1) is equal to that
before disassembling. At this time, if the
clearance is larger than that before disassembling,
repeat the installation from step 5.

W2-6-25

UPPERSTRUCTURE / Swing Device

STRUCTURE OF SWING DAMPENER VALVE

WCJB-02-06-007

Item
1
2
3
4
5
6
7

Parts Name
Swing Damperner
Assembly
Plug
Casing
O-Ring
Backup Ring
Case
Plug

Qty
valve

Wrench Size
(mm)

Nm

Tightening Torque
(kgfm)
(lbfft)

2
3
1
2
2
2
2

: 4

(0.9)

(7)

: 24
: 8

69

(7)

(51)

W2-6-26

Remark

UPPERSTRUCTURE / Swing Device

MAINTENANCE STANDARD
Swing Motor
1. Clearance between plunger outer diameter and
rotor inner bore

D-d
Standard

Allowable Limit

0.027 mm (0.001 in)

0.052 mm (0.002 in)

W107-02-06-138

W107-02-06-139

2. Clearance between plunger and shoe bottom

Standard

Allowable Limit

0 mm

0.3 mm (0.012 in)

Plunger

Shoe

W107-02-06-140

W2-6-27

UPPERSTRUCTURE / Swing Device

3. Shoe thickness
Standard

Allowable Limit

5.5 mm (0.22 in)

5.3 mm (0.2 in)

W107-02-06-142

4. Friction plate thickness

Standard

Allowable Limit

2.0 mm (0.08 in)

1.8 mm (0.07 in)

W107-02-06-143

W2-6-28

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

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
(5) (2 used).
: 16 mm

WCEB-02-01-001

WCEB-02-01-017

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

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

WCEB-02-01-002

2
7

3. Remove screws (9) (4 used) from boot (7). Raise

boot (7) from bracket (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). Remove covers (11, 12) from bracket (8).
: 10 mm

12
11

13

14

WCEB-02-07-003

11

13
12

W2-7-2

13

WCEB-02-07-004

UPPERSTRUCTURE / Pilot Valve

6. Remove clip bands (17) (2 used) from lever (15)
and harness (18). Disconnect a connector from
harness (18).

15

16

17

7. Loosen lock nut (16). Remove lever (15) assembly 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 mm

19

20

W1JB-02-07-005

9. Remove sems bolts (21) (4 used) from bracket (8).

Remove pilot valve (19) from bracket (8).
: 13 mm

21

19

W1JB-02-07-005

21

W2-7-3

UPPERSTRUCTURE / Pilot Valve

Installation of Left Pilot Valve

21

1. Install pilot valve (19) to bracket (8) with sems

bolts (21) (4 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)
2. Connect hoses (20) (6 used) onto pilot valve (6).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

19

20

W1JB-02-07-005

21
15

3. Install lever (15) assembly to pilot valve (19). Secure lever (15) assembly to pilot valve (19) with
lock nut (16).
: 22 mm
: 55 Nm (5.5 kgfm, 41 lbfft)

16

17

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 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

12
11

13
8
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

12

11

WCEB-02-07-001

8. Install boot (7) to bracket (8) with round head

screws (9) (4 used).

W1JB-02-07-002

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

9. Install seat (1) to plate (2) with socket bolts (3) (4
used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)

10. Install seat belt (6) (2 used) to bracket (5) (2 used)

with sems bolts (4) (2 used).
: 16 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCEB-02-01-002

2
1

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, 4) (1 each used) from cover (2). Remove cover
(2) from bracket (7).

3, 4

3. Remove sems bolt (6) from cover (5).

: 10 mm
4. Remove round head screw (9) from cover (8).
7

6
WCEB-02-07-006

8
3, 4
2
1
7
9

WCEB-02-07-005

10

5. Remove round head screws (11) (4 used) from

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
7
8

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
harness (16).

13

14

15

8. Loosen lock nut (14). Remove lever (13) assembly from pilot valve (17).
: 19 mm, 22 mm

16

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

7
19

18
WCEB-02-07-009

10. Disconnect hoses (20) (6 used) from pilot valve (6).

Cap the open ends. Attach an identification tag
onto the disconnected hoses for assembling.
: 19 mm

21

11. Remove sems bolts (21) (4 used) from bracket (7).

Remove pilot valve (17) from bracket (7).
: 13 mm

17

20

W1JB-02-07-005

21

W2-7-7

UPPERSTRUCTURE / Pilot Valve

Installation of Right Pilot Valve

21

1. Install pilot valve (17) to bracket (7) with sems

bolts (21) (4 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

17

2. Connect hoses (20) (6 used) onto pilot valve (6).

: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
20

W1JB-02-07-005

21
13

3. Install lever (13) assembly to pilot valve (17). Secure lever (13) assembly to pilot valve (17) with
lock nut (14).
: 22 mm
: 56 Nm (5.5 kgfm, 41 lbfft)

14

15

16

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 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

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 Nm (5 kgfm, 37 lbfft)
8. Install cover (8) to bracket (7) with round head
screw (9).

7
9

19

9. Install covers (5, 8) to bracket (7) with round head

screw (12).

18

WCEB-02-07-009

12
7
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
used) to cover (2).

2
1

3, 4

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).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)

22

WCEB-02-01-002

23

13. Install seat belts (26) (2 used) to brackets (25) (2

used) with sems bolts (24) (2 used).
: 16 mm
: 50 Nm (5 kgfm, 37 lbfft)

21

23

22

24

25

26

WCEB-02-01-001

26

24

25

23

22

WCEB-02-01-017

W2-7-10

UPPERSTRUCTURE / Pilot Valve

REMOVAL
AND
INSTALLATION
TRAVEL PILOT VALVE

OF

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.

2
WCEB-02-01-003

2. Remove sems bolts (4) (2 used) from pedal (3).

Remove pedal (3) from bracket (5).
: 13 mm

Auxiliary
Pedal

Brake Pedal

3. Remove sems bolts (7) (2 used) from bracket (5).

Remove bracket (5) from travel pilot valve (6).
: 13 mm

WCEB-02-07-002

3
4

W2-7-11

WCEB-02-07-007

UPPERSTRUCTURE / Pilot Valve

8

4. Remove sems bolts (8) (6 used) from cover (9).

Remove cover (9) from main frame (10).
: 17 mm

10

WCEB-02-13-001

5. Disconnect hoses (11) (4 used) from travel pilot

valve (14). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.
: 19 mm
6. Remove sems bolts (12) (2 used) from travel pilot
valve (14). Remove travel pilot valve (14) from
plate (13).
: 17 mm

11

12

13

14

11
WCEB-02-07-008

W2-7-12

UPPERSTRUCTURE / Pilot Valve

Installation
1. Install travel pilot valve (14) to plate (13) with
sems bolts (12) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

11

12

13

14

2. Connect hoses (11) (4 used) onto travel pilot valve

(14).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

11
WCEB-02-07-008

3. Install bracket (5) to travel pilot valve (6) with

sems bolts (7) (2 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

3
4

4. Install pedal (3) to bracket (5) with sems bolts (4)

(2 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

WCEB-02-07-007

Auxiliary
Pedal

Brake Pedal

WCEB-02-07-002

5. Install mat (1) to the cab (2) inside.

1

2
WCEB-02-01-003

W2-7-13

UPPERSTRUCTURE / Pilot Valve

6. Install cover (9) to main frame (10) with sems bolts
(8) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

10

WCJB-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

13

13
3

14

5
5
15

6
6

16

17
8

18
9

19
19
20
20
W1F3-02-07-001

12345-

Screw Joint
Cam
Universal Joint
Plate
Oil Seal (4 Used)

678910 -

Bushing (4 Used)
O-Ring (4 Used)
Pusher (4 Used)
Spring Seat (4 Used)
Spring (4 Used)

11 12 13 14 15 -

W2-7-16

Spring (4 Used)
Washer (4 Used)
Spool (4 Used)
Casing
O-Ring

16 17 18 19 20 -

Bushing
Spring Pin
Port Plate
Sealing Washer (2 Used)
Socket Bolt (2 Used)

UPPERSTRUCTURE / Pilot Valve

Disassembly of Front/Swing Pilot Valves
Spool (13) has been selected to match the hole of
casing (14). Therefore, the parts cannot be replaced individually.
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).

3. Install special tool (ST 7260) to universal joint (3).

Remove universal joint (3) from casing (14) by
turning.
: 24 mm

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
(3).
: 32 mm

ST 7260

CAUTION: Springs (10) (4 used) are in the

compressed condition. Therefore, when
loosening universal joint (3), plate (4), bushings (6) (4 used), and pushers (8) (4 used) are
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 damage 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

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

11

WCEB-02-07-010

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

2
8
5
4
6
7

9
11
10
12
13

14
16
15
17

18
19
20

12345-

Screw Joint
Cam
Universal Joint
Plate
Oil Seal (4 Used)

678910 -

Bushing (4 Used)
O-Ring (4 Used)
Pusher (4 Used)
Spring Seat (4 Used)
Spring (4 Used)

11 12 13 14 15 -

Spring (4 Used)
Washer (4 Used)
Spool (4 Used)
Casing
O-Ring

W2-7-20

16 17 18 19 20 -

W1F3-02-07-002

Bushing
Spring Pin
Port Plate
Sealing Washer (2 Used)
Socket Bolt (2 Used)

UPPERSTRUCTURE / Pilot Valve

IMPORTANT: Install spring (10) to the same position before disassembling.
4. Install springs (10) (4 used) to casing (14).

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).
: 20.52 Nm (2.10.2 kgfm, 152 lbfft)
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

3. Install washers (12) (4 used), springs (11) (4

used) and spring seats (9) (4 used) to spools (13)
(4 used) in this order.

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 casing (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 before disassembly.

W2-7-21

UPPERSTRUCTURE / Pilot Valve

1
3

2
8

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
: 47.12.9 Nm
(4.80.3 kgfm, 352 lbfft)
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
: 68.64.9 Nm
(7.00.5 kgfm, 514 lbfft)
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 AUXILIARY/POSITIONING PILOT VALVES

20

20

8
6

19

19
18

10

18

17
16

17
16

15

6
15
4
11

14
14

3
12

13

2
21

W1LA-02-06-001

123456-

O-Ring (2 Used)
Bushing (2 Used)
Packing (2 Used)
Bushing (2 Used)
Steel Ball (2 Used)
Socket Bolt (2 Used)

78910 11 -

Boot
Set Screw
Cam
Pin
Cover

12
13
14
15
16

Plug
O-Ring
Spring (2 Used)
Spool (2 Used)
Washer (2 Used)

W2-7-24

17
18
19
20
21

Shim (2 Used)
Spring (2 Used)
Spring Guide (2 Used)
Pusher (2 Used)
Casing

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 replaced 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) assembly unless necessary. If the
spool (15) assembly is disassembled, record the quantity and thickness 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 AUXILIARY/POSITIONING PILOT VALVES
7

10

20
3
6
2
11

1
19
18
14

17
16

12
13
15
W1LA-02-06-002

21
123456-

O-Ring (2 Used)
Bushing (2 Used)
Packin (2 Used)
*Bushing (2 Used)
Steel Ball (2 Used)
Socket Bolt (2 Used)

78910 11 -

Boot
Set Screw
Cam
Pin
Cover

12 13 14 15 16 -

Plug
O-Ring
Spring (2 Used)
Spool (2 Used)
Washer (2 Used)

NOTE: *Refer to W2-7-24.

W2-7-26

17 18 19 20 21 -

Shim (2 Used)
Spring (2 Used)
Spring Guide (2 Used)
Pusher (2 Used)
Casing

UPPERSTRUCTURE / Pilot Valve

Assembly of Travel and Auxiliary/Positioning Pilot Valve
Clean not to confuse the parts. Arrange the parts
by port in order.

8. Apply LOCTITE #241 onto setscrew (8). Secure

cam (9) to pin (10) with setscrew (8).
: 5 Nm (0.5 kgfm, 41 lbfft)
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 disassembling.
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
2
1

Lip

W585-02-06-005

5. Install pushers (20) (2 used) to the bushing (2)

assemblies (2 used). Install the pusher (20) assemblies (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 Nm (2.4 kgfm, 17 lbfft)
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
ELECTRIC LEVER

INSTALLATION

OF
1

Removal of Auxiliary/Positioning Electric Lever

1. Remove sems bolts (2) (6 used) from cover (1).

Remove cover (1) from main frame (3).
: 17 mm

WCJB-02-13-001

2. Disconnect connector (4).

4

WCEB-02-08-002

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).
: 13 mm
5. Remove sems bolts (7) (2 used) from bracket (10).
Remove bracket (10) from electric lever (11).
: 13 mm

11

W2-8-1

10

WCEB-02-08-001

UPPERSTRUCTURE / Electric Lever

6. Remove sems bolts (13) (4 used) from bracket
(12). Remove the bracket (12) assembly from
plate (14).
: 17 mm

14

13

12

WCEB-02-08-001

11

7. Remove sems bolts (15) (2 used) from electric

lever (11). Remove electric lever (11) from bracket
(12).
: 17 mm

15

WCEB-02-08-002

Installation of Auxiliary/Positioning Electric Lever

1. Install electric lever (11) to bracket (12) with sems
bolts (15) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

11

15

WCEB-02-08-002

2. Install the bracket (12) assembly to plate (14) with

sems bolts (13) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

14

W2-8-2

13

12

WCEB-02-08-001

UPPERSTRUCTURE / Electric Lever

3. Install bracket (10) to electric lever (11) with sems
bolts (7) (2 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)
4. Install pedal (9) to bracket (10) with sems bolts (8)
(2 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

11

5. Install mat (6) to the inside of cab (5).

10

WCEB-02-08-001

WCEB-02-01-003

6. Connect connector (4).

4

WCEB-02-08-002

7. Install cover (1) to main frame (3) with sems bolts

(2) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

2
3

WCJB-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).
: 17 mm

2. Remove sems bolt (6) from cover (3).

: 10 mm

4, 5

WCEB-02-07-006

3. Remove screw (9) from cover (1).

9
WCEB-02-07-009

10

4. Remove screws (11) (4 used) from boot (10).

Raise boot (10) from bracket (8).

8
11
3
1

W1JB-02-07-002

5. Remove screw (12) from cover (1). Remove

covers (1, 3) from bracket (8).

12

10
8

W1JB-02-07-016

W2-8-4

UPPERSTRUCTURE / Electric Lever

6. Disconnect connector (13).

WCEB-02-08-004

13

14

7. Remove socket bolts (18) (2 used) from lever (14).

Remove lever (14) from electric lever (17).
: 6 mm

15

8. Remove sems bolts (16) (2 used) from bracket

(15). Remove the bracket (15) assembly from
bracket (8).
: 17 mm

16

18

9. Remove sems bolts (19) (2 used) from electric

lever (17). Remove electric lever (17) from bracket
(15).
: 17 mm

17

WCEB-02-08-003

19

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
bolts (19) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

19

2. Connect connector (13).

15

17
WCEB-02-08-004

13

3. Install the bracket (15) assembly to bracket (8)

with sems bolts (16) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

14

15

4. Install lever (14) to electric lever (17) with socket

bolts (18) (2 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)

16

18

5. Install covers (1, 3) to bracket (8) with screw (12).

17

WCEB-02-08-003

10

12

8
3

6. Install boot (10) to bracket (8) with screws (11) (4

used).

W1JB-02-07-016

10
8
11

W1JB-02-07-002

W2-8-6

UPPERSTRUCTURE / Electric Lever

7. Install cover (1) to bracket (8) with screw (9).

8
9
1

8. Install cover (3) to bracket (8) with sems bolt (6).

: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2.4 to 3 lbfft)

WCEB-02-07-009

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).

W2-8-7

WCEB-02-07-006

UPPERSTRUCTURE / Electric Lever

DISASSEMBLY OF ELECTRIC LEVER

9
10

11

12

6
5

13
14
15
16
17

18

3
2
1

19
20

W1MG-02-07-003

12345-

Screw (2 Used)
Plate
Screw (2 Used)
Potentiometer
Pin

678910 -

Bushing (2 Used)
Screw
Arm
Boot
Set Screw

11 12 13 14 15 -

W2-8-8

Cam
Socket Bolt (2 Used)
Holder
O-Ring (2 Used)
Bushing (2 Used)

16 17 18 19 20 -

Bushing (2 Used)
Spring (2 Used)
Housing
Clip
Screw

UPPERSTRUCTURE / Electric Lever

Disassembly of Electric Lever
IMPORTANT: Housing (18) is made of aluminum.
As too strong a force may deform or
damage it, handle it with care.

IMPORTANT: Keep the disassembled parts

carefully in order to install them to
their original ports.
10. Remove the pusher (16) assemblies (2 used) and
springs (17) (2 used) from housing (18).

1. Secure housing (18) in a vise.

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

(19) from housing (18).

11. Remove pushers (16) (2 used) and O-rings (14) (2

used) from bushings (15) (2 used).

4. Remove screws (3) (2 used) from potentiometer

(4). Remove potentiometer (4) from housing (18).

IMPORTANT: Bushing (6) cannot be reused.

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

9
11

5, 6

16
14

12

15
13

17

18

T1MG-03-09-008

20

12345-

*Screw (2 Used)
*Plate
Screw (2 Used)
Potentiometer
Pin

678910 -

Bushing (2 Used)
Screw
Arm
Boot
*Set Screw

11 12 13 14 15 -

19

Cam
Socket Bolt (2 Used)
Holder
O-Ring (2 Used)
Bushing (2 Used)

NOTE: As for the item with mark*, refer to W2-7-8.

W2-8-10

16 17 18 19 20 -

Pusher (2 Used)
Spring (2 Used)
Housing
Clip
Screw

UPPERSTRUCTURE / Electric Lever

Assembly of Electric Lever

2. Install O-rings (14) (2 used) to bushings (15) (2

used).

13. Install pin (5) to holder (13). Secure pin (5) to cam
(11) with screw (10).
: 2.5 mm
: 7 Nm (0.7 kgfm, 5 lbfft)

3. Apply grease onto the inner surface of bushings

(15) (2 used).

14. Apply grease to the gap between arm (8) and the
link part of potentiometer (4).

4. Install pushers (16) (2 used) to bushings (15) (2

used).

15. Apply LOCTITE #262 onto screws (3) (2 used).

1. Apply grease onto O-rings (14) (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 Nm (0.7 kgfm, 5 lbfft)
8. Apply grease onto the end of pushers (16) (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 Nm (0.1 kgfm, 0.7 lbfft)
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 Nm (0.1 kgfm, 0.6 lbfft)

9. Install arm (8) to cam (11) with screw (7).

: 3 Nm (0.3 kgfm, 2 lbfft)
10. Apply grease onto the mounting surfaces of holder
(13) and cam (11).

20. Apply THREEBOND #1104 onto the mating

surfaces of housing (18) and plate (2).

11. Install cam (11) to holder (13).

21. Install plate (2) to housing (18) with screws (1) (2

used).

12. Apply LOCTITE #262 onto screw (10).

22. Install boot (9) to holder (13).

W2-8-11

UPPERSTRUCTURE / Electric Lever

(Blank)

W2-8-12

UPPERSTRUCTURE / Signal Control Valve

REMOVAL
AND
INSTALLATION
SIGNAL CONTROL VALVE

OF

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 (2).

2. Remove sems bolts (3) (4 used) from cover (1).

Remove cover (1) from stay (4).
: 17 mm

WCJB-02-01-002

3. Disconnect connectors (5) (2 used) from signal

control valve (6).
4. Disconnect hoses (7) (32 used) from signal
control valve (6). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm

5. Remove socket bolts (8) (4 used) from signal

control valve (6). Remove signal control valve (6)
from bracket (9).
: 8 mm
8
9
7

W2-9-1

WCJB-02-09-001

UPPERSTRUCTURE / Signal Control Valve

Installation
1. Install signal control valve (6) to bracket (9) with
socket bolts (8) (4 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

2. Connect hoses (7) (32 used) to signal control

valve (6).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

3. Connect connectors (5) (2 used) to signal control

valve (6).

9
WCJB-02-09-001

4. Install cover (1) to stay (4) with sems bolts (3) (4

used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

5. Shut cover (2).

WCJB-02-01-002

W2-9-2

UPPERSTRUCTURE / Signal Control Valve

(Blank)

W2-9-3

UPPERSTRUCTURE / Signal Control Valve

STRUCTURE OF SIGNAL CONTROL VALVE
13

12
7
11

4
10

9
8

7
6

2
4

W1JB-02-10-002

W2-9-4

UPPERSTRUCTURE / Signal Control Valve

15

16

14

16

16

17

17

17

18

19

21

19

18

19

20

20

20
14
22
23
24
25
26
27
19

20
5

19

21

20
19

18

17

16
29

18

20
19

28

17

17

17

14
16

16

16

W1JB-02-10-003

Detail of Body 2 (5)

12345678-

Bolt (3 Used)
Body 1
Gasket
Filter (17 Used)
Body 2
Gasket
Shuttle Valve (2 Used)
Spring (4 Used)

910 11 12 13 14 15 16 -

Body 3
Gasket
Body 4
Gasket
Body 5
Socket Bolt (11 Used)
Plate
Plug (7 Used)

17 18 19 20 21 22 23 24 -

W2-9-5

O-Ring (7 Used)
Spring (4 Used)
Spring Guide (7 Used)
Spool (6 Used)
Spring (2 Used)
Plate
O-Ring
Shuttle Valve

25 26 27 28 29 -

O-Ring
Spring
Spool
Spring
Plate

UPPERSTRUCTURE / Signal Control Valve

(Blank)

W2-9-6

UPPERSTRUCTURE / Travel Shockless Valve

REMOVAL AND INSTALLATION OF
TRAVEL 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 Travel Shockless Valve
WCJB-02-15-001

1. Remove sems bolts (1) (6 used) from cover (2).

Remove cover (2) from main frame (3).
: 17 mm
4

2. Disconnect connector (4) from pressure sensor

(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

10

WCEB-02-10-003

10

5. Remove sems bolts (10) (4 used) from bracket (9).

Remove the travel shockless valve (8) assembly
from main frame (3).
: 17 mm
6. Remove sems bolts (11) (2 used) from bracket (9).
Remove travel shockless valve (8) from bracket
(9).
: 17 mm

W2-10-1

8, 11

WCEB-02-10-003

UPPERSTRUCTURE / Travel Shockless Valve

Installation of Travel Shockless Valve
10

1. Install travel shockless valve (8) to bracket (9) with

sems bolts (11) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

10

2. Install the bracket (9) assembly to main frame (3)

with sems bolts (10) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

3
8, 11

WCEB-02-10-003

3. Connect hoses (7) (6 used) to travel shockless

valve (8).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

4. Connect connector (4) to pressure sensor (5).

5. Connect connectors (6) (2 used).

WCEB-02-10-003

6. Install cover (2) to main frame (3) with sems bolts

(1) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-15-001

W2-10-2

UPPERSTRUCTURE / Travel Shockless Valve

(Blank)

W2-10-3

UPPERSTRUCTURE / Travel Shockless Valve

STRUCTURE OF TRAVEL SHOCKLESS
VALVE

13

1
14
2
3
B

4
4
T1F3-03-08-004

T1F3-03-08-005

Section A

6
7
T1F3-03-08-006

10

11

12
Section B

W2-10-4

UPPERSTRUCTURE / Travel Shockless Valve

Part Name
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Solenoid
O-Ring
Spool
Body
Spring
Plug
Orifice
Plug
Steel Ball
Spring
O-Ring
Plug
Nut
Tube

Q ty
2
2
2
1
2
6
2
2
2
2
4
2
2
2

Wrench Size

Nm

Tightening Torque
(kgfm)

(lbfft)

1B P14

1.6 to 2.0
13.2 to 17.6

(0.16 to 0.2)
(1.3 to 1.8)

(1.2 to 1.5)
(9.7 to 13)

13.2 to 17.6
4.9
30 to 37

(1.3 to 1.8)
(0.5)
(3 to 4)

(9.7 to 13)
(3.6)
(22 to 27)

9/32
1B P8
: 19 mm

W2-10-5

UPPERSTRUCTURE / Travel Shockless Valve

(Blank)

W2-10-6

UPPERSTRUCTURE / Solenoid Valve

REMOVAL
AND
INSTALLATION
4-SPOOL SOLENOID VALVE UNIT

OF

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 (2).

2. Remove sems bolts (3) (4 used) from cover (1).

Remove cover (1) from stay (4).
: 17 mm

WCJB-02-01-002

3. Disconnect connectors (9) (4 used).

4. Disconnect hoses (6) (16 used) from 4-spool

solenoid valve unit (8). Cap the open ends. Attach
an identification tag onto the disconnected hoses
for assembling.
: 19 mm, 22 mm
6

5. Disconnect pipings (5) (3 used) from 4-spool

solenoid valve unit (8).
: 19 mm

WCJB-02-11-001

6. Remove socket bolts (10) (2 used) and washers

(11) (2 used) from 4-spool solenoid valve unit (8).
Remove 4-spool solenoid valve unit (8) from
control valve (7).
: 8 mm

WCJB-02-11-002

10, 11

W2-11-1

UPPERSTRUCTURE / Solenoid Valve

Installation
1. Install 4-spool solenoid valve unit (8) to control
valve (7) with socket bolts (10) (2 used) and
washers (11) (2 used).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-11-002

10, 11

2. Connect pipings (5) (3 used) to 4-spool solenoid

valve unit (8).
: 19 mm
: 50 Nm (5 kgfm, 37 lbfft)

3. Connect hoses (6) (16 used) to 4-spool solenoid

valve unit (8).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)

4. Connect connectors (9) (4 used).

9

5. Install cover (1) to stay (4) with sems bolts (3) (4

used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-11-001

6. Shut cover (2).

WCJB-02-01-002

W2-11-2

UPPERSTRUCTURE / Solenoid Valve

STRUCTURE OF 4-SPOOL SOLENOID VALVE UNIT

WCJB-02-11-003

Proportional Solenoid Valve

B
A

Proportional Solenoid Valve

WCJB-02-11-004

Filter

Plug
Plug

Filter

WCEB-02-11-011

View A

Section B
WCEB-02-11-010

W2-11-3

UPPERSTRUCTURE / Solenoid Valve

DISASSEMBLY AND ASSEMBLY OF 4-SPOOL SOLENOID VALVE UNIT
1
2
3

4
5
6
7
8
9

12
14

13
10

15
11

16

17

18

19

W18G-02-08-012

3, 5

12

13

17

10

18

19
W18G-02-08-013

7
12345-

Socket Bolt (4 Used)

Lock Nut
O-Ring
Adjusting Bolt
Spring

678910 -

Solenoid
Spring
O-Ring
Diaphragm
Spool

14
11 12 13 14 15 -

W2-11-4

Orifice
Washer
Spring
O-Ring
O-Ring

15

16
16 17 18 19 -

11
O-Ring
Sleeve
Plate
Wave Spring

UPPERSTRUCTURE / Solenoid Valve

Assembly of 4-Spool Solenoid Valve Unit

Disassembly of 4-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.

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. Remove O-rings (14, 15, 16) from sleeve (17).

4. Install spring (7) to solenoid (6). Install solenoid
(6) to the housing with socket bolts (1) (2 used).
: 4 mm
: 5+20 Nm (0.5+0.20 kgfm, 4+1.50 lbfft)

W2-11-5

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.)
Removal
1. Open cover (1).
1

WCEB-02-05-002

2. Remove sems bolts (3) (2 used) from cover (4).

Remove cover (2) from cover (4).
: 17 mm

WCJB-02-11-005

3. Disconnect connectors (7) (5 used) from solenoid

valve unit (6).
4. Disconnect hoses (5) (12 used) from solenoid
valve unit (6). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm
NOTE: The number of solenoid valve units, the
connectors and the hoses differ depending
on the front attachment specifications.

WCJB-02-11-006

W2-11-6

UPPERSTRUCTURE / Solenoid Valve

6

5. Remove bolts (8) (4 used) and washers (9) (4

used) from bracket (10). Remove solenoid valve
unit (6) from bracket (10).
: 17 mm

8, 9

10

Installation
1. Install solenoid valve unit (6) to bracket (10) with
bolts (8) (4 used) and washers (9) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-11-006

8, 9

2. Connect hoses (5) (12 used) to solenoid valve

unit (6).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

3. Connect connectors (7) (5 used) to solenoid valve

unit (6).

10

4. Install cover (2) to cover (4) with sems bolts (3) (2

used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-11-006

WCJB-02-11-005

5. Shut cover (1)

1

WCEB-02-05-002

W2-11-7

UPPERSTRUCTURE / Solenoid Valve

STRUCTURE OF SOLENOID VALVE UNIT (FOR ELECTRIC LEVER OPERATION)
2

1
WCEB-02-11-006

Section A

Wrench Size
(mm)

WCEB-02-11-007

Nm

Tightening Torque
(kgfm)

(lbfft)

19.5+50

(2+0.50)

(14+40)

18

4.9+50

(0.5+0.50)

(4+40)

4.9+50

(0.5+0.50)

(4+40)

Item

Part Name

Qty

Solenoid Valve Assembly

Solenoid Valve Assembly

Solenoid Valve Assembly

Socket Bolt

Washer

End Plate

Socket Bolt

Lock Nut

:6

W2-11-8

Remark

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.)
Removal
1. Remove sems bolts (1) (6 used) from cover (2).
Remove cover (2) from main frame (3).
: 17 mm

WCJB-02-15-001

2. Disconnect hoses (4) (9 used) from pilot shut-off

solenoid valve (5). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 19 mm

6
7

3. Disconnect connector (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

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

Installation
1. Install bracket (7) to pilot shut-off solenoid valve
(5) with sems bolts (9) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

7, 9

2. Install the bracket (7) assembly to main frame (3)

with sems bolts (6) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
WCEB-02-12-001

3. Connect hoses (4) (9 used) to pilot shut-off

solenoid valve (5).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

4. Connect connector (8).

WCEB-02-12-001

5. Install cover (2) to main frame (3) with sems bolts

(1) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-15-001

W2-12-2

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve

STRUCTURE OF PILOT SHUT-OFF SOLENOID VALVE

W1JB-02-08-001

2
1

9
W1JB-02-08-002

Item
1
2
3
4
5
6
7
8
9

Part Name
Plug
O-Ring
Spring
Spool
Filter
Body
O-Ring
Solenoid
Socket Bolt

Qty
1
1
1
1
1
1
1
1
2

Wrench Size
(mm)
: 6

: 4

Tightening Torque
Nm
(kgfm)
(lbfft)
26.5
(2.7)
(20)

3.92

W2-12-3

(0.4)

(3)

Remarks

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve

(Blank)

W2-12-4

UPPERSTRUCTURE / Steering Valve

REMOVAL
AND
STEERING VALVE

INSTALLATION

OF

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 door (4) and upper front glass (2).
2. Remove lower front glass (1) from cab (3).
4
1

WCEB-02-01-004

3. Remove mat (5) from the inside of cab (3).

3

4. Remove sems bolts (6) (2 used) from pedal (7).

Remove pedal (7) from bracket (8).
: 13 mm

WCEB-02-01-003

W2-13-1

WCEB-02-08-001

UPPERSTRUCTURE / Steering Valve

5. Remove caps (10) (5 used) from cover (9).
Remove screws (11) (5 used) from cover (9).
Remove cover (9) from stand (15).
6. Remove caps (13) (3 used) from cover (12).
Remove screws (14) (5 used) from cover (12).
Remove cover (12) from stand (15).

10, 11

12, 13, 14
9

15
WCEB-02-13-002

7. Remove screws (17) (4 used) from cover (16).

Remove cover (16) from stand (15).
16

15

8. Remove sems bolts (18) (6 used) from cover (19).

Remove cover (19) from main frame (20).
: 19 mm

18

17

19

WCEB-02-13-003

20

WCJB-02-13-001

9. Disconnect hoses (22) (5 used) from steering

valve (21). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 22 mm, 27 mm

21

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
(26) (5 used) from steering valve (21).

25, 26

21

WCEB-02-13-005

W2-13-3

UPPERSTRUCTURE / Steering Valve

24

Installation
1. Install priority valve (25) to steering valve (21) with
O-rings (26) (5 used) and socket bolts (24) (2
used).
: 39 Nm (4 kgfm, 29 lbfft)

25, 26

21

WCEB-02-13-005

2. Install the steering valve (21) assembly to stand

(15) with sems bolts (23) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

23
15

WCEB-02-13-004

3. Connect hoses (22) (5 used) to steering valve

(21).
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

21

22

WCEB-02-13-006

4. Install cover (19) to main frame (20) with sems

bolts (18) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

18

19

20

WCJB-02-13-001

W2-13-4

UPPERSTRUCTURE / Steering Valve

5. Install cover (16) to stand (15) with screws (17) (4
used).

16

15

6. Install cover (9) to stand (15) with screws (11) (5

used). Install caps (10) (5 used) to cover (9).

17

WCEB-02-13-003

10, 11

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

8. Install pedal (7) to bracket (8) with sems bolts (6)

(2 used).
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)

W2-13-5

WCEB-02-08-001

UPPERSTRUCTURE / Steering Valve

9. Install mat (5) to the inside of cab (3).
3

WCEB-02-01-003

10. Install lower front glass (1) to cab (3).

11. Shut upper front glass (2) and door (4).
4
1

WCEB-02-01-004

W2-13-6

UPPERSTRUCTURE / Brake Valve

REMOVAL AND
BRAKE VALVE

INSTALLATION

OF

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).

WCEB-02-01-003

2. Remove sems bolts (4) (6 used) from cover (3).

Remove cover (3) from main frame (5).
: 17 mm

WCJB-02-13-001

6, 7

3. Disconnect connector (11).

9
10

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.
: 17 mm, 22 mm, 27 mm
11

6. Remove rubber (14) from brake pedal (15).

12

WCEB-02-14-005

10

13

7. Remove sems bolts (12) (4 used) from plate (13).

Remove the brake valve (10) assembly from plate
(13).
: 17 mm

14, 15

W2-14-1

12

WCEB-02-14-006

UPPERSTRUCTURE / Brake Valve

Installation
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 Nm (5 kgfm, 37 lbfft)

12

10

13

2. Install rubber (14) to brake pedal (15).

14, 15

12

6, 7

WCEB-02-14-006

9
10

3. Connect hoses (9) (6 used) to brake valve (10).

: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm,58 lbfft)
4. Install the bracket (6) assembly to bracket (8) with
socket bolts (7) (2 used).
: 6 mm
: 58.8 to 73.5 Nm
(6 to 7.5 kgfm, 43 to 54 lbfft)

11

WCEB-02-14-005

5. Connect connector (11).

6. Install cover (3) to main frame (5) with sems bolts
(4) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCJB-02-13-001

7. Install mat (1) to the inside of cab (2).

WCEB-02-01-003

W2-14-2

UPPERSTRUCTURE / Brake Valve

(Blank)

W2-14-3

UPPERSTRUCTURE / Brake Valve

DISASSEMBLY OF BRAKE VALVE
1
2

29

11

3
28
5

27

10
9

12
13
14

15
16

26
25

17
3
30

24

16

31
23

32

22

33

18

34

43

35

36

42

37

19

41

44

45

38

20

40
46

47
48

21
29

39
44

45

46

47

49
48

W2-14-4

WCEB-02-14-004

UPPERSTRUCTURE / Brake Valve

12345678910 11 12 13 -

Rubber
Brake Pedal
Split Pin (4 Used)
Stopper Bolt
Bushing
Lock Nut
Bushing (2 Used)
Pin
Bushing (2 Used)
Pin
Boot
Pin
Spring Pin

14 15 16 17 18 19 20 21 22 23 24 25 -

Bushing
Yoke
Pin (2 Used)
Link
Roller Assembly
Bracket
Brake Switch
Socket Bolt (2 Used)
Seat
Stopper
Boot
Socket Bolt (4 Used)

26 27 28 29 30 31 32 33 34 35 36 37 -

W2-14-5

Bracket
Oil Seal
Flange
O-Ring (2 Used) (1B, G45)
Rod
Return Spring
Holder
Spring
Balance Spring
Retainer
Retainer
Pilot Piston

38 39 40 41 42 43 44 45 46 47 48 49 -

Push Rod
Cylinder
Cylinder
O-Ring (1B, P32)
Plug
Socket Bolt (4 Used)
Spring (2 Used)
Retaining Ring (2 Used)
Retainer (2 Used)
Plunger (2 Used)
Spool (2 Used)
Spring

UPPERSTRUCTURE / Brake Valve

1
2

29

11

3
28
4

27

10
9

12
13
14

15
16

26
25

17
3
30

24

16

31
23

32

22

33

18

34

43

35

36

42

37

19

41

44

45

38

20

40
46

47
48

21
29

39
44

45

46

47

49
48

W2-14-6

WCEB-02-14-004

UPPERSTRUCTURE / Brake Valve

Disassembly of Brake Valve
IMPORTANT: Put the matching marks onto
bracket (26), flange (28), cylinder
(39) and cylinder (40) before disassembling.
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).

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 retainer (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) assembly from flange (28).

4. Remove spring pin (13) from yoke (15). Remove

pin (12) from yoke (15).

13. Remove the spool (48) assembly from cylinder

(39).

5. Remove split pin (3) from pin (16). Remove pin

(16) and the roller (18) assembly from link (17).

14. Remove plunger (47), spring (44), retaining ring

(45) and retainer (46) from the spool (48) assembly.

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.

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).

W2-14-7

UPPERSTRUCTURE / Brake Valve

ASSEMBLY OF BRAKE VALVE
1

12

11

8
15
14

26

28

39

43

40

16
A

10

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

38

27

37

36

35

13

33

34

32

46

29

48

45

WCEB-02-14-002

5
12

15

8
9

26

17

10

21

16

18

19
View A

W2-14-8

WCEB-02-14-003

UPPERSTRUCTURE / Brake Valve

12345678910 11 12 13 -

Rubber
Brake Pedal
Split Pin (4 Used)
* Stopper Bolt
Bushing
* Lock Nut
Bushing (2 Used)
Pin
Bushing (2 Used)
Pin
Boot
Pin
Spring Pin

14 15 16 17 18 19 20 21 22 23 24 25 -

Bushing
Yoke
Pin (2 Used)
Link
Roller Assembly
Bracket
Brake Switch
Socket Bolt (2 Used)
Seat
Stopper
Boot
Socket Bolt (4 Used)

26 27 28 29 30 31 32 33 34 35 36 37 -

Bracket
Oil Seal
Flange
O-Ring (2 Used) (1B, G45)
Rod
Return Spring
Holder
Spring
Balance Spring
Retainer
Retainer
Pilot Piston

NOTE: As for the item with mark *, refer to W2-14-4.

W2-14-9

38 39 40 41 42 43 44 45 46 47 48 49 -

Push Rod
Cylinder
Cylinder
O-Ring (1B, P32)
Plug
Socket Bolt (4 Used)
Spring (2 Used)
Retaining Ring (2 Used)
Retainer (2 Used)
Plunger (2 Used)
Spool (2 Used)
Spring

UPPERSTRUCTURE / Brake Valve

1

12

11

8
15
14

26

28

39

43

40

16
A

10

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

38

27

37

36

35

13

33

34

32

46

29

48

45

WCEB-02-14-002

5
12

15

8
9

26

17

10

21

16

18

19
View A

W2-14-10

WCEB-02-14-003

UPPERSTRUCTURE / Brake Valve

Assembly of Brake Valve
10. Install spring (49), plunger (47) and spring (44) to
cylinder (39).

1. Install oil seal (27) to flange (28).

2. Secure flange (28) in a vise with the oil seal (27)
side facing downward.

11. Align the matching marks and place cylinder (40)

onto cylinder (39).

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).

12. Install retainer (46) and retaining ring (45) to spool

(48).
13. Install the spool (48) assembly to cylinder (40).

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.

14. Install plunger (47), spring (44) and plug (42) to

cylinder (40).
: 130 to 180 Nm
(13 to 18 kgfm, 96 to 133 lbfft)

6. Install O-ring (29) to cylinder (39).

15. Connect flange (28), cylinder (39) and cylinder

(40) with socket bolts (43) (4 used).
: 60 to 75 Nm
(6 to 7.5 kgfm, 44 to 55 lbfft)

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

UPPERSTRUCTURE / Brake Valve

1

12

11

8
15
26

28

40

16
A

10
21
17
19
16
18
20
22

22 23

WCEB-02-14-001

24

25

WCEB-02-14-002

13
12
15
3

26
17

10

21

16

18

19
View A

W2-14-12

WCEB-02-14-003

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 Nm (6 to 7.5 kgfm, 44 to 55 lbfft)
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 Nm (0.6 to 1 kgfm, 4 to 7 lbfft)
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 Nm
(6 to 7.5 kgfm, 43 to 54 lbfft)

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 ACCUMULATOR 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.)
Removal
1. Remove sems bolts (1) (6 used) from cover (2).
Remove cover (2) from main frame (3).
: 17 mm

WCJB-02-15-001

2. Disconnect hoses (4) (8 used) from accumulator

charge valve (5). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 17 mm, 22 mm, 27 mm

5, 6

7
8

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
bracket (8).
: 17 mm

W2-15-1

WCEB-02-15-001

UPPERSTRUCTURE / Accumulator Charge Valve

Installation
1. Install accumulator charge valve (5) to bracket (8)
with sems bolts (6) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

5, 6

7
8

2. Install the bracket (8) assembly to main frame (3)

with sems bolts (7) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
3. Connect hoses (4) (8 used) to accumulator charge
valve (5).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
4. Install cover (2) to main frame (3) with sems bolts
(7) (6 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

WCEB-02-15-001

WCJB-02-15-001

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

A
B
C
D

3, 4
5, 6

WCEB-02-15-002

10

10

11

11
1

6
5
2

Section A

18
15

19 20

Section B

16 17

21

22

23

14

24

26

6
5

13

9
27

25

28

12

29

37
36
35

34

33 32

31

30

Section D

W2-15-4

WCEB-02-15-003

Section C

UPPERSTRUCTURE / Accumulator Charge Valve

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

Part Name
Plug
O-Ring
Plug
O-Ring
Plug
O-Ring
Body
Plug
O-Ring
Spring
Plunger
Plug
Screw
Lock Nut
O-Ring
Spring
Needle Valve
O-Ring
Backup Ring
O-Ring
O-Ring
Backup Ring
Sleeve
Piston
Orifice
Plug
Spring
Plunger
Sleeve
Plunger
O-Ring
Washer
Spring
Spring
Plug
O-Ring
Plug

NOTE: Tools

Qty

Wrench Size
(mm)

4
4
3
3
5
5
1
2
3
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

: 22 mm, 24 mm, 32 mm
: 1/8, 4 mm, 5 mm, 6 mm

W2-15-5

Tightening Torque
Nm
(kgfm)
(lbfft)
4.9
(0.5)
(4)
26.5

(3)

(20)

9.8

(1)

(7)

12

(1.2)

(9)

58.8

(6)

(43)

9.8
12

(1)
(1.2)

(7)
(9)

48.5

(5)

(36)

48.5

(5)

(36)

Remark

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

Swing Bearing ......................................W3-1-1
Disassembly of Swing Bearing ................W3-1-4
Assembly of Swing Bearing.....................W3-1-6

Group 2 Travel Motor

Removal and Installation of

Axle Lock Cylinder .............................. W3-6-1
Disassembly and Assembly of
Axle Lock Cylinder .............................. W3-6-4

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

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 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

Group 9 Transmission Changeover

Solenoid Valve
Removal and Installation of Transmission
Changeover Solenoid Valve..................W3-9-1

Group 4 Transmission
Removal and Installation of
Transmission.........................................W3-4-1
Disassembly of Transmission ..................W3-4-6
Assembly of Transmission..................... W3-4-18

Group 10 Propeller Shaft

Group 5 Axle
Removal and Installation of Axle .............W3-5-1
Disassembly of Front Axle .................... W3-5-10
Assembly of Front Axle......................... W3-5-18
Disassembly of Rear Axle ..................... W3-5-28
Assembly of Rear Axle ......................... W3-5-34
Disassembly of Differential ................... W3-5-42
Assembly of Differential........................ W3-5-44
Disasembly of Steering Cylinder ........... W3-5-46
Assembly of Steering Cylinder .............. W3-5-48

CJBW-3-1

Removal and Installation of

Propeller Shaft.....................................W3-10-1

(Blank)

CJBW-3-2

UNDERCARRIAGE / Swing Bearing

REMOVAL AND
SWING BEARING

INSTALLATION

OF

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 upperstructure has already been removed.
1

Matching Mark

Removal
1. Put the matching marks on inner race (1) of the
swing bearing and track frame (2).

WCJB-02-03-003

2. Remove knock pin (3) from outer race (4) of the

swing bearing.

3. Remove bolts (5) (36 used) from track frame (2).

: 30 mm

WCJB-03-01-003

CAUTION: Swing bearing weight: 230 kg

(510 lb)
4. Install special tools (ST 0050) (3 used) to swing
bearing. Attach a wire rope onto special tool.
Hoist and remove swing bearing from track frame
(2).

ST 0050
W110-03-01-004

Swing Bearing

W3-1-1

UNDERCARRIAGE / Swing Bearing

Installation
Clean the mounting surfaces of track frame (2) and
swing bearing.

Swing Bearing

1. Apply THREEBOND #1102 onto the swing bearing mounting surface of track frame (2).

W110-03-01-004

CAUTION: Swing bearing weight: 230 kg

(510 lb)

Machine
Front

Position for
Grease Fitting

IMPORTANT: If the matching mark do not align,

the soft zone position of the inner
race will be dislocated.
2. Hoist and align swing bearing with the mounting
holes on track frame (2).

25

49
25.8
31
Position for
Grease Fitting

S (Soft Zone)
Marking Position
Position for
Plug

3. Install inner race (1) of the swing bearing to track

fame (2) with bolts (5) (36 used).
: 30 mm
: 500 Nm (51 kgfm, 368 lbfft)

Position for
Knock Pin

WCJB-03-01-002

4. Install knock pin (3) to outer race (4) of the swing

bearing.
WCJB-03-01-003

W3-1-2

UNDERCARRIAGE / Swing Bearing

5. After installing swing bearing, add grease (Shell
Alvania EP2 or equivalent) up to 28 mm (1.1 in)
height from the bottom of the grease bath.

Swing Bearing

Grease Level

Pinion

28 mm (1.1 in)

Grease Bath

W3-1-3

WCEB-03-01-004

UNDERCARRIAGE / Swing Bearing

DISASSEMBLY OF SWING BEARING
2

WCJB-03-01-001

9
3

W157-03-01-002

123-

Plug
Pin
Seal

45-

Outer Race
Ball (111 Used)

67-

W3-1-4

Seal
Inner Race

89-

Support (111 Used)

Grease Fitting (2 Used)

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: 230 kg

(510 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 (4) slightly.
4. Remove balls (5) (111 used) and supports (8)
(111 used) from the plug hole while rotating outer
race (4).
Use magnet (A) when removing ball (5). Use wire
(B) and remove support (8).

4
3
A

W105-03-01-007

2. Remove plug (1) from outer race (5).

NOTE: Install the bolt into the screw hole (M10,
Pitch 1.5 mm) of plug (1). Tap or pull the
bolt from the inner side.

W105-03-01-009

B
1

W105-03-01-010

W105-03-01-008

5. Separate outer race (4) from inner race (7).

6. Remove seals (3, 6) from outer race (4) and inner race (7) respectively by using a scrapper.

W3-1-5

UNDERCARRIAGE / Swing Bearing

ASSEMBLY OF SWING BEARING
2

WCJB-03-01-001

9
3

W157-03-01-002

123-

Plug
Pin
Seal

45-

Outer Race
Ball (111 Used)

67-

W3-1-6

Seal
Inner Race

89-

Support (111 Used)

Grease Fitting (2 Used)

UNDERCARRIAGE / Swing Bearing

Assembly of Swing Bearing
IMPORTANT: Apply grease onto balls (5) (111
used) and supports (8) (111 used)

2. Tap and install plug (1) into outer race (4). Secure
plug (1) to outer race (4) with pin (2). Crimp the
head of pin (2) by using a punch.

CAUTION: Outer race (4) weight: 96 kg (211

lb)
Inner race (7) weight: 114 kg (251 lb)

2
4

1. Hoist outer race (4) horizontally and align outer

race (4) with inner race (7) coaxially.
While rotating outer race (4), insert balls (5) and
supports (8) into the plug hole by using a round
bar.

W142-03-01-007

CAUTION: Swing bearing weight: 230 kg

(510 lb)

5
6

W142-03-01-005

3. Install lifting tool (ST 0050) to outer race (4).

Hoist outer race (4). Thoroughly degrease the
slots for seals (3, 6). Apply THREEBOND #1745
to seal (3) and #1530D to seal (6). Install seals (3,
6) to outer race (4) and inner race (7).
4. Add grease 0.5 L (0.1 US gal.) (Alvania EP2
grease or equivalent) to the swing bearing
through grease fitting (9). At this time, rotate
outer race (4) and add grease.

W142-03-01-006

W3-1-7

UNDERCARRIAGE / Swing Bearing

(Blank)

W3-1-8

UNDERCARRIAGE / Travel Motor

REMOVAL
AND
TRAVEL MOTOR

INSTALLATION

OF

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
IMPORTANT: Attach an identification tag onto the
disconnected hoses for assembling.
1. Disconnect hoses (1) (7 used) and connector (3)
from travel motor (2). Cap the disconnected
hoses.
: 19 mm, 22 mm, 27 mm

2
3
1

CAUTION: Travel motor (2) weight: 80 kg

(180 lb)
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

WCGB-03-05-030

UNDERCARRIAGE / Travel Motor

Installation
CAUTION: Travel motor (2) weight: 80 kg
(180 lb)
1. Install travel motor (2) to transmission (5) with
socket bolts (4) (4 used).
: 14 mm
: 270 Nm (27.5 kgfm, 199 lbfft)
2. Connect hoses (1) (7 used) and connector (3) to
travel motor (2).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 64 Nm (6.5 kgfm, 47 lbfft)
: 12 mm
: 180 Nm (18 kgfm, 133 lbfft)
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

2
3
1

WCGB-03-05-030

UNDERCARRIAGE / Travel Motor

(Blank)

W3-2-3

UNDERCARRIAGE / Travel Motor

DISASSEMBLY OF TRAVEL MOTOR

47

10

11

12

13

46
45
44

14

43
42

15

41
40
39
16

37, 38

17

36

18

35

19

34

20
33

32

31

30

29

28

27

26

25

24

23

22

21

WCGB-03-02-004

37, 38

48

37, 38

View A

56
28, 53, 54

4, 55

49

52

49
50

50

51
WCGB-03-02-002

51

W3-2-4

WCGB-03-02-001

UNDERCARRIAGE / Travel Motor

12345678910 11 12 13 14 -

Adjusting Screw
Lock Nut
Pin
Solenoid Valve
O-Ring
Adjusting Screw
Lock Nut
Housing
Plunger (7 Used)
Retainer Plate
Bearing
Ring
Bearing
Oil Seal

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Shim
Retaining Ring
Adjusting Shim
Retaining Ring
Screw Bolt (7 Used)
Drive Shaft
Center Shaft
Spring
Rotor
Lock Nut
Adjusting Screw
O-Ring
Piston
Cover

29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

W3-2-5

Socket Bolt
Ring (2 Used)
Servo Piston
Lock Pin
Pin
Valve Plate
Spring
Head Cover
Brake Valve
O-Ring (2 Used)
Spring
Collar
Bushing
Spring

43 44 45 46 47 48 49 50 51 52 53 54 55 56 -

Spring Collar
Retaining Ring
Control Piston
Sleeve
Retaining Ring
Socket Bolt (2 Used)
Relief Valve (2 Used)
Plug (2 Used)
Socket Bolt (8 Used)
Socket Bolt (4 Used)
O-Ring
O-Ring
O-Ring (4 Used)
Socket Bolt (4 Used)

UNDERCARRIAGE / Travel Motor

47

46
45
44
43
42
41
40
39
37, 38
36
35

20
WCGB-03-02-004

28

48

37, 38

View A

37, 38

56
28, 53, 54
52

49

4, 55

50

49
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
(100500 mm, 3.919.7 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
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

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.
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

14
15

16

36

20
26

25

24

23

21

WCGB-03-02-004

A
View A

51
WCGB-03-02-002

51

W3-2-8

WCGB-03-02-001

UNDERCARRIAGE / Travel Motor

12. Before removing, record the dimensions of part B
and part C.
B

16. Secure rotor (23), center shaft (21) and plungers

(9) (7 used) by using a screw bar (M8, Pitch 1.25
mm, Length 120 mm). Remove adjusting screw
(25) from housing (8).
23

Screw Bar
Lock Nut
Washer

9
26

25

21
9

6
W1GL-03-02-003

W1GL-03-02-005

13. Loosen lock nuts (7, 24). Remove adjusting

screws (6, 25) from housing (8).

17. Remove retaining ring (16) and shim (15) from

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
21

W1GL-03-02-004

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

33

32

31

30

29

WCGB-03-02-004

27

A
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

10

11

12

13

46
45
44

14

43
42

15

41
40
39
16

37, 38

17

36

18

35

19

34

20
33

32

31

30

29

28

27

26

25

24

23

22

21

WCGB-03-02-004

48

37, 38

37, 38

View A

56
28, 53, 54

49

52

4, 55

49

50

50

51
WCGB-03-02-002

51

W3-2-12

WCGB-03-02-001

UNDERCARRIAGE / Travel Motor

1 - Adjusting Screw
2 - Lock Nut
3 - Pin
4 - Solenoid Valve
5 - O-Ring
6 - Adjusting Screw
7 - Lock Nut
8 - Housing
9 - Plunger (7 Used)
10 - Retainer Plate
11 - Bearing
12 - Ring
13 - Bearing
14 - Oil Seal

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Shim
Retaining Ring
Adjusting Shim
Retaining Ring
Screw Bolt (7 Used)
Drive Shaft
Center Shaft
Spring
Rotor
Lock Nut
Adjusting Screw
O-Ring
Piston
Cover

29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

W3-2-13

Socket Bolt
Ring (2 Used)
Servo Piston
Lock Pin
Pin
Valve Plate
Spring
Head Cover
Brake Valve
O-Ring (2 Used)
Spring
Collar
Bushing
Spring

43 44 45 46 47 48 49 50 51 52 53 54 55 56 -

Spring Collar
Retaining Ring
Control Piston
Sleeve
Retaining Ring
Socket Bolt (2 Used)
Relief Valve (2 Used)
Plug (2 Used)
Socket Bolt (8 Used)
Socket Bolt (4 Used)
O-Ring
O-Ring
O-Ring (4 Used)
Socket Bolt (4 Used)

UNDERCARRIAGE / Travel Motor

47

28

27

46
45
44
43
42
41
40
39

36
35
34

33

32

31

30

29

WCGB-03-02-004

A
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.

7. Install retaining rings (47, 44) to control piston

(45) and sleeve (46).

2. Apply hydraulic oil onto servo piston (31). Insert

servo piston (31) into head cover (36). Install pin
(33).

8. Apply hydraulic oil onto solenoid valve (4), control

piston (45) and sleeve (46).
9. Install O-ring (5) to solenoid valve (4).

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 Nm (3 kgfm, 22 lbfft)
6. Install adjusting screw (1) and lock nut (2) to
solenoid valve (4) with the dimension of part A
recorded before disassembling.
1

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).

W1GL-03-02-006

W3-2-15

UNDERCARRIAGE / Travel Motor

14
15

16

36

20
25

24

23

21

WCGB-03-02-004

A
View A

51
WCGB-03-02-002

51

W3-2-16

WCGB-03-02-001

UNDERCARRIAGE / Travel Motor

CAUTION: After warming up housing (8),
start the work.
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.

19. Temporarily install adjusting screw (25) (M12,

Pitch 1.75 mm, Length 100 mm) to the adjusting
screw (6) mounting part, so that the angle of
center shaft (21) should be zero.

21

16. Face the rotor (23) side in housing (8) downward.

Install oil seal (14), shim (15) and retaining ring
(16) to housing (8).

25

17. Set the travel motor onto a wooden block

(100500 mm, 3.919.7 in) with the drive shaft
(20) side facing downward.
NOTE: When the workbench is used.
Workbench: ST 5092
Upper Plate: ST 7333

20. Align the matching marks. Install head cover (36)

to housing (8) with socket bolts (51) (8 used).

18. Remove the screw bar, the lock nut and the
washer from rotor (23).

21. Remove temporarily installed adjusting screw

(25) from housing (8).

23

W1GL-03-02-008

22. Install adjusting screw (25), lock nut (24),

adjusting screw (6) and lock nut (7) to housing
(8) so that the dimensions of part B and part C
should be the same dimensions before
disassembling.

Screw Bar
Lock Nut
Washer

C
W1GL-03-02-003

25
8

24
7

W1GL-03-02-005

W3-2-17

UNDERCARRIAGE / Travel Motor

WCGB-03-02-004

48

37, 38

View A

37, 38

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 Nm (8 kgfm, 58 lbfft)
: 32 mm
: 835 Nm (8.50.5 kgfm, 614 lbfft)
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

Brake Valve

7
Brake Valve

5, 6

WCGB-03-02-001
WCGB-03-02-002

10
1

Section C

11

12
13
17

16

15

14
7

Section B

WCGB-03-02-005

12345-

Cover
Socket Bolt (4 Used)
Valve Casing
Counterbalance Valve
Plug

6789-

Orifice
Plug
O-Ring (2 Used)
Cover

10 11 12 13 -

W3-2-20

Socket Bolt (4 Used)

Plug
Spring (2 Used)
Check Valve

14 15 16 17 -

O-Ring (2 Used)
O-Ring
Shuttle Valve
Check Valve (2 Used)

UNDERCARRIAGE / Travel Motor

Disassembly of Brake Valve
1. Remove socket bolts (2) (4 used). Remove cover
(1) and O-ring (8) from valve casing (3).
: 10 mm
2. Remove socket bolts (10) (4 used). Remove
cover (9) and O-ring (8) from valve casing (3).
: 10 mm

7. Remove shuttle valve (16) from valve casing (3)

by using a socket wrench.
: 4 mm
8. Remove plug (5) from valve casing (3).
9. Remove orifice (6) from valve casing (3).
: 3 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

Brake Valve

7
Brake Valve

5, 6

WCGB-03-02-001
WCGB-03-02-002

10
1

Section C

11

12
13
17

16

15

14
7

Section B
WCGB-03-02-005

12345-

Cover
Socket Bolt (4 Used)
Valve Casing
Counterbalance Valve
Plug

6789-

Orifice
Plug
O-Ring (2 Used)
Cover

10 11 12 13 -

W3-2-22

Socket Bolt (4 Used)

Plug
Spring (2 Used)
Check Valve

14 15 16 17 -

O-Ring (2 Used)
O-Ring
Shuttle Valve
Check Valve (2 Used)

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 Nm (17 kgfm, 123 lbfft)
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 Nm (11 kgfm, 81 lbfft)
8. Install cover (9) and O-ring (8) to valve casing (3)
with socket bolts (10) (4 used).
: 10 mm
: 110 Nm (11 kgfm, 81 lbfft)

W3-2-23

UNDERCARRIAGE / Travel Motor

(Blank)

W3-2-24

UNDERCARRIAGE / Center Joint

REMOVAL AND INSTALLATION OF CENTER 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
removed easily. The number of hoses differs depending on the front attachment
specifications.
1. Disconnect connectors (2) (2 used).

2. Remove bolt (3) and washer (4) from clips (1) (2

used). Remove clips (1) (2 used) from center joint
(5).
: 10 mm

3, 4

WCJB-03-03-002

3. Disconnect connector (6).

4. Remove bolt (9) and washer (10) from clip (7).

Remove clip (7) from stopper (8).
: 17 mm
5. Remove sems bolts (11) (3 used) from slip ring
(12). Remove the slip ring (12) assembly from
stopper (8). (Length: approx. 670 mm (26.4 in))
: 10 mm

9, 10
11
12

WCJB-03-03-001

W3-3-1

UNDERCARRIAGE / Center Joint

5

6. Remove bolts (14) (5 used) and washers (15) (5

used) from stopper (8). Remove stopper (8) from
center joint (5).
: 24 mm

13

7. Disconnect hoses (13) (13 used) from center joint

(5). Cap the open ends. Attach an identification
tag onto the disconnected hoses for assembling.
: 19 mm, 22 mm, 27 mm, 36 mm

14, 15

13

WCJB-03-03-001

8. Disconnect hoses (16) (23 used) from center joint

(5). 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 (14) of center joint (5). Attach a
nylon sling onto eyebolts. Hoist and hold center
joint (1).
CAUTION: The center joint (1) assembly
weight: 90 kg (200 lb)
IMPORTANT: The propeller shaft and the travel
transmission are located under center joint (5). When hoisting and removing center joint (5), do not hit
them.
10. Remove bolts (18) (4 used) and washers (19) (4
used) from center joint (5). Hoist and remove the
center joint (5) assembly from track frame (17).
: 22 mm

16

16

WCJB-03-03-002

18, 19
5
17

WCJB-03-03-003

W3-3-2

UNDERCARRIAGE / Center Joint

Installation
CAUTION: The center joint (5) assembly
weight: 90 kg (200 lb)
IMPORTANT: The propeller shaft and the travel
transmission are located under the
center joint (5). Hoist center joint (5)
in order not to hit them.
1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to
center joint (5). Attach a nylon sling onto eyebolt.
Hoist and align center joint (5) with the mounting
hole on track frame (17).
2. Apply LOCTITE #262 onto bolts (18) (4 used).
Install center joint (5) to track frame (17) with bolts
(18) (4 used) and washers (19) (4 used).
: 22 mm
: 175 Nm (18 kgfm, 129 lbfft)

16
18, 19

5
17

16

WCJB-03-03-003

3. Connect hoses (16) (23 used) to center joint (5).

: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 151 lbfft)

16

16

W3-3-3

WCJB-03-03-002

UNDERCARRIAGE / Center Joint

4. Connect hoses (13) (13 used) to center joint (5).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)

13

14, 15

5. Apply LOCTITE #262 onto bolts (14) (5 used).

Install stopper (8) to center joint (5) with bolts (14)
(5 used) and washers (15) (5 used).
: 24 mm
: 265 Nm (27 kgfm, 195 lbfft)

13

WCJB-03-03-001

6. Install the slip ring (12) assembly to center joint

(5). Install slip ring (12) to stopper (8) with sems
bolts (11) (3 used).
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

9, 10

7. Install clip (7) to stopper (8) with bolt (9) and

washer (10).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

11
12

8. Connect connector (6).

5

W3-3-4

WCJB-03-03-001

UNDERCARRIAGE / Center Joint

9. Install clips (1) (2 used) to center joint (5) with bolt
(3) and washer (4).
: 10 mm
: 3.3 to 4.2 Nm
(0.3 to 0.4 kgfm, 2 to 3 lbfft)

3, 4

10. Connect connectors (2) (2 used).

W3-3-5

WCJB-03-03-002

UNDERCARRIAGE / Center Joint

DISASSEMBLY OF CENTER JOINT

1, 2
3
3

3
4
5
6

13
12

11
11

11

8
WCGB-03-03-001

1234-

Plug (2 Used)
O-Ring (2 Used)
Spindle
O-Ring

567-

10

Body
Oil Seal (15 Used)
Cover

8 - Bolt (4 Used)
9 - O-Ring
10 - Plate

W3-3-6

11 - Socket Bolt (4 Used)

12 - O-Ring
13 - O-Ring

UNDERCARRIAGE / Center Joint

Disassembly of Center Joint
CAUTION: Center joint weight: 90 kg (200 lb)

6. Install eyebolts (M14, Pitch 1.75 mm) (2 used) to

the bolt (8) hole (2 places) on spindle (3). Hoist
and place spindle (3) onto the wooden blocks
horizontally.

1. Attach a nylon sling onto the body of body (5).

Hoist the center joint. Secure the center joint on a
workbench (ST 5109).

7. Remove O-ring (9), plugs (1) (2 used) and O-rings

(2) (2 used) from spindle (3).
: 12 mm

2. Remove socket bolts (11) (4 used) from cover (7).

Remove cover (7) and O-ring (12) from body (5).
: 12 mm

IMPORTANT: For easy removal, use the pins (2

used).
Do not damage the seal groove by
the pins.
8. Remove O-rings (4, 13) and oil seals (6) (15
used) from body (5).

3. Remove bolts (8) (4 used) from plate (10). Remove plate (10) from spindle (3).
: 19 mm
4. Install eyebolts (M14, Pitch 2.0 mm) (2 used) to
the socket bolt (11) hole (2 places) on body (5).
Hoist and hold body (5).
IMPORTANT: Do not damage the seal sliding surface of spindle (3).
5. Install the puller to the body (5). Remove body (5)
from spindle (3).
NOTE: There is a hole for the harness at the center of spindle (3). Prepare a cover in order
to cover the hole on spindle (3). Place the
cover between the puller and spindle (3).
Remove spindle (3).
Puller

5
4, 13, 6

W105-03-03-015

W202-03-03-011

W3-3-7

UNDERCARRIAGE / Center Joint

ASSEMBLY OF CENTER JOINT

1, 2
3
3

3
4
5
6

13
12

11
11

11

8
WCGB-03-03-001

1234-

Plug (2 Used)
O-Ring (2 Used)
Spindle
O-Ring

567-

10

Body
Oil Seal (15 Used)
Cover

8 - Bolt (4 Used)
9 - O-Ring
10 - Plate

W3-3-8

11 - Socket Bolt (4 Used)

12 - O-Ring
13 - O-Ring

UNDERCARRIAGE / Center Joint

Assembly of Center Joint
IMPORTANT: After installing the seals, apply
grease onto the inner surface of
body (5), the inner surface of the
circuit and the seals.
1. Install O-rings (4, 13) and oil seals (6) (15 used)
to body (5).
2. Apply grease onto O-rings (2) (2 used). Install
O-rings (2) (2 used) to plugs (1) (2 used).
3. Apply grease onto O-ring (9). Install plugs (1) (2
used) and O-ring (9) to spindle (3).
: 12 mm
: 14714.7 Nm
(151.5 kgfm, 10811 lbfft)

8. Install plate (10) to spindle (3) with bolts (8) (4

used).
: 19 mm
: 51 to 59 Nm
(5.2 to 6.0 kgfm, 38 to 44 lbfft)
9. Install O-ring (12) to cover (7).
10. Install cover (7) to body (5) with socket bolts (11)
(4 used).
: 12 mm
: 206 to 216 Nm
(21 to 22 kgfm, 152 to 159 lbfft)

4. Install eyebolts (M14, Pitch 1.75 mm) (2 used)

into the bolt (8) hole (2 places) on spindle (3).
5. Hoist spindle (3). Secure spindle (3) on a workbench (ST 5109).
IMPORTANT: There is almost no clearance between body (5) and spindle (3). Insert body (5) along the axis straight
and slowly.
6. Apply hydraulic oil onto the outer surface of spindle (3). Install eyebolts (M14, Pitch 2.0 mm) (2
used) to the bolt (8) hole (2 places) on body (5).
Hoist and install body (5) to spindle (3).
7. Lightly tap body (5) by using a plastic hammer.
Insert body (5) until body (5) comes in contact
with the flange of spindle (3).

W3-3-9

UNDERCARRIAGE / Center Joint

(Blank)

W3-3-10

UNDERCARRIAGE / Transmission
REMOVAL
AND
TRANSMISSION

INSTALLATION

OF

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, the pipings of the travel motor and one
part of the rear axle should be removed first.
Refer to REMOVAL AND INSTALLATION OF
PROPELLER SHAFT on W3-10-1, REMOVAL AND
INSTALLATION OF TRAVEL MOTOR on W3-2-1 and
REMOVAL AND INSTALLATION OF AXLE on W3-5-1.
IMPORTANT: When removing and installing the
transmission, bleed air from the
hydraulic port and the brake before
doing any work.
Refer to TROUBLESHOOTING / T5-7
Troubleshooting B in Technical
Manual.

Removal
IMPORTANT: Remove the transmission with the
travel motor together in order to
keep the balance of weight.
1. Loosen nuts (1) (20 used). Raise the machine
until tire (3) at the rear axle side is raised. Place a
stand under frame (4).
CAUTION: Tire (3) weight: 98 kg (220 lb)
Tire ring (2) weight: 25 kg (60 lb)
2. Remove nuts (1) (20 used). Remove tires (3) (4
used) and tire rings (2) (2 used).

W3-4-1

W1GL-03-05-003

UNDERCARRIAGE / Transmission
3. Remove plugs (8, 9). Drain oil from the
transmission.
: 14 mm

Transmission

CAUTION: Propeller shaft (11) weight: 35 kg

(80 lb)

4. Place a wooden block under propeller shaft (11).

Remove nuts (10) (8 used). Remove propeller
shaft (11) from the transmission.
: 14 mm
5. Disconnect hoses (7) (9 used) and connectors (6)
(2 used) from the transmission and travel motor
(5). Cap the disconnected hoses.
: 19 mm, 22 mm, 27 mm
: 12 mm
CAUTION: The
transmission
weight: 220 kg (490 lb)

12

WCGB-03-05-033

11

assembly

10

Transmission

6. Loosen bolts (13) (14 used).

: 19 mm

Rear Axle

7. Support the travel motor (5) part by using a forklift

and remove bolts (13) (14 used). Remove the
transmission assembly from the rear axle.
: 19 mm
CAUTION: Travel motor (5) weight: 80 kg
(180 lb)
8. Remove socket bolts (12) (4 used). Remove travel
motor (5) from the transmission.
: 14 mm

W3-4-2

13

WCGB-03-05-032

UNDERCARRIAGE / Transmission
Installation
CAUTION: Transmission weight: 135 kg (300
lb)

Transmission

1. Install plug (9) to the transmission. Temporarily

install plug (8).
: 14 mm
: 79 Nm (8 kgfm, 58 lbfft)

CAUTION: Travel motor (5) weight: 80 kg

(180 lb)
2. Install travel motor (5) onto the transmission with
socket bolts (12) (4 used).
: 14 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
3. Install the transmission assembly to the rear axle
with bolts (13) (14 used).
: 19 mm
: 230 Nm (23 kgfm, 170 lbfft)
4. Connect hoses (7) (9 used) and connectors (6) (2
used) to the transmission.
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 12 mm
: 140 Nm (14 kgfm, 103 lbfft)

W3-4-3

12

WCGB-03-05-033

11

10

9
Transmission

Rear Axle

13

WCGB-03-05-032

UNDERCARRIAGE / Transmission
CAUTION: Propeller shaft (11) weight: 35 kg
(80 lb)
Transmission

5. Install propeller shaft (11) to the transmission with

nuts (10) (8 used).
: 14 mm
: 108 Nm (11 kgfm, 80 lbfft)
6. Remove temporarily installed plug (8). Add oil to
the transmission. After adding oil, install plug (8) to
the transmission.
NOTE: Gear oil: 2.5 L (0.7 US gal.)
: 14 mm
: 79 Nm (8 kgfm, 58 lbfft)

W3-4-4

WCGB-03-05-033

11

10

UNDERCARRIAGE / Transmission
(Blank)

W3-4-5

UNDERCARRIAGE / Transmission
DISASSEMBLY OF TRANSMISSION

Part A

WCGB-03-04-001

Part A
3

10 9 11 12 13 14, 15

16, 17, 18, 19

20

21

22

23

24

25
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

W3-4-6

UNDERCARRIAGE / Transmission

Part B

55

Part B

56

57

WCGB-03-04-001

58
59
60
61

74

62

73

72

70, 71

63
69

68

22

67

66

W3-4-7

65

64

WCGB-03-04-003

UNDERCARRIAGE / Transmission

12345678910 11 12 13 14 15 16 17 18 19 20 -

Cover
Bolt (5 Used)
O-Ring (5 Used)
Oil Seal
Pin (2 Used)
Oil Seal
Oil Seal
Seal Ring
O-Ring (2 Used)
Gasket
Plate (7 Used)
Friction Plate (6 Used)
Disc Plate
Retaining Ring
Shim
Planetary Gear (3 Used)
Retaining Ring (3 Used)
Washer (3 Used)
Bearing
Retaining Ring

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 -

Bearing
Housing
Bearing
O-Ring (2 Used)
Bolt (4 Used)
Shift Interlock Controller
Socket Bolt (5 Used)
Washer (5 Used)
Plate
Bearing
Washer (2 Used)
Planetary Carrier
Slot Pin (6 Used)
Ring Gear
Retaining Ring
Retaining Ring
Bearing
Collar
Disc Plate
Plate (9 Used)

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 -

W3-4-8

Friction Plate (10 Used)

O-Ring
Ring
Ring
Brake Piston
Disc Spring
Clutch Piston
Oil Seal
Shaft
Spring
Holder
Bearing
Plate (2 Used)
Disc Spring
Bearing
Ring
Final Gear
O-Ring (3 Used)
O-Ring
Cover

61 62 63 64 65 66 67 68 69 70 71 72 73 74 -

Bearing
Pinion
Shim
Bushing
Shaft Seal
Cover
Screen Sheet
Flange
O-Ring
Bolt (2 Used)
Washer (2 Used)
Plate
Plate
Shaft Seal

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
CAUTION: Transmission weight: 135 kg (300
lb)
1. Attach a nylon sling onto the transmission. Hoist
the transmission. Lower the transmission onto a
workbench.
2. Remove bolts (75, 77) (2 used for each) and seal
rings (76, 78) (2 used for each) from the
transmission. Disconnect pipes (79) (2 used) from
the transmission.
: 22 mm, 24 mm
Transmission

4. Remove socket bolts (27) (5 used) and washers

(28) (5 used).
: 6 mm
5. Remove shift interlock controller (26) and O-rings
(24) (2 used) from the transmission.
6. Remove socket bolt (83). Remove travel N sensor
(82) and O-rings (84) (2 used) from housing (22).
: 6 mm
83, 84

82

22

79

77, 78

75, 76
WCGB-03-04-005

3. Remove plugs (80) (2 used) and seal rings (81) (2

used) from housing (22).
: 8 mm
22
80, 81

WCGB-03-04-013

W3-4-11

WCGB-03-04-006

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A
3

22

2
1
54

47

46

45

WCGB-03-04-002

W3-4-12

UNDERCARRIAGE / Transmission
7. Remove bleeder (85), spring (87), steel ball (88),
plug (90) and O-rings (86, 89) from housing (22).
: 27 mm
: 8 mm
2

10. Remove spring (94), O-ring (95) and piston (96)

from housing (22).
22

85

94, 95, 96

1
86

22

87
88
90

89
WCGB-03-04-014
WCGB-03-04-007

8. Remove bleeder valve (93) and plugs (91, 92)

from housing (22).
: 17 mm
: 8 mm
22

11. Remove disc springs (46, 54) from housing (22).

Remove clutch piston (47).
12. Remove pins (5) (2 used) from housing (22).
13. Apply air to the hole of bleeder valve (93) on
housing (22). Remove brake piston (45). Remove
fitting (97) from housing (22).
: 17 mm
22

91

93

92

97
WCGB-03-04-013

9. Remove bolts (2) (5 used). Remove cover (1) and

O-ring (3) from housing (22).
: 19 mm

93

WCGB-03-04-013

14. Remove oil seals (4, 7) from housing (22).

W3-4-13

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A
6

10

11

12 13

14, 15 16, 17, 18, 19

21

20

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).

26. Remove retaining ring (20) from shaft (49).

Remove 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).

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.

29. Remove bolts (25) (4 used). Remove plate (29)

from housing (22).
: 17 mm
30. Remove planetary carrier (32) from housing (22).

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).

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).

W3-4-15

UNDERCARRIAGE / Transmission

Part B

55

Part B

56

57

WCGB-03-04-001

58
59
60
61

74

62

73

72

70, 71

63
69

68

22

67

66

W3-4-16

65

64

WCGB-03-04-003

UNDERCARRIAGE / Transmission
35. Remove bleeder valves (98) (2 used), plugs (99)
(2 used), plugs (101) (3 used), seal rings (100) (2
used) and O-rings (102) (3 used) from housing
(22).
: 17 mm
22
99, 100
: 8 mm

40. Remove O-ring (59) and bushing (64) from pinion

(62).
IMPORTANT: Do not remove bearing (61) unless
necessary.
41. Remove the inner race of bearing (61) from pinion
(62).
IMPORTANT: Do not remove bearing (61) unless
necessary.
42. Remove shim (63) and the outer race of bearing
(61) from cover (60).

98

43. Remove cover (60) from housing (22).

44. Remove O-rings (58) (3 used) and shaft seal (65)
from cover (60).
101, 102
WCGB-03-04-008

36. Remove bolts (70) (2 used) and washers (71) (2

used). Remove plate (72) and O-ring (69) from
housing (22).
: 17 mm
37. Remove flange (68) and plate (73) from housing
(22).
38. Remove shaft seal (74) from housing (22).

45. Remove the final gear (57) assembly from

housing (22).
46. Remove cover (66) from final gear (57).
47. Remove screen sheet (67) from housing (22).
IMPORTANT: Do not remove bearing (55) unless
necessary.
48. Remove bearing (55) and ring (56) from housing
(22).

39. Remove pinion (62) from housing (22).

W3-4-17

UNDERCARRIAGE / Transmission
ASSEMBLY OF TRANSMISSION

Part A

WCGB-03-04-001

Part A

20

10 9 11 12 13 14, 15 16, 17, 18, 19

21

22

23

24
25

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

55

Part B

56

57

WCGB-03-04-001

58
59
60
61

74

62

73

72

70, 71

63
69

68

22

67

66

W3-4-19

65

64

WCGB-03-04-003

UNDERCARRIAGE / Transmission

12345678910 11 12 13 14 15 16 17 18 19 20 -

Cover
Bolt (5 Used)
O-Ring (5 Used)
Oil Seal
Pin (2 Used)
Oil Seal
Oil Seal
Seal Ring
O-Ring (2 Used)
Gasket
Plate (7 Used)
Friction Plate (6 Used)
Disc Plate
Retaining Ring
Shim
Planetary Gear (3 Used)
Retaining Ring (3 Used)
Washer (3 Used)
Bearing
Retaining Ring

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 -

Bearing
Housing
Bearing
O-Ring (2 Used)
Bolt (4 Used)
Shift Interlock Controller
Socket Bolt (5 Used)
Washer (5 Used)
Plate
Bearing
Washer (2 Used)
Planetary Carrier
Slot Pin (6 Used)
Ring Gear
Retaining Ring
Retaining Ring
Bearing
Collar
Disc Plate
Plate (9 Used)

40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 -

W3-4-20

Friction Plate (10 Used)

O-Ring
Ring
Ring
Brake Piston
Disc Spring
Clutch Piston
Oil Seal
Shaft
Spring
Holder
Bearing
Plate (2 Used)
Disc Spring
Bearing
Ring
Final Gear
O-Ring (3 Used)
O-Ring
Cover

61 62 63 64 65 66 67 68 69 70 71 72 73 74 -

Bearing
Pinion
Shim
Bushing
Shaft Seal
Cover
Screen Sheet
Flange
O-Ring
Bolt (2 Used)
Washer (2 Used)
Plate
Plate
Shaft Seal

UNDERCARRIAGE / Transmission
(Blank)

W3-4-21

UNDERCARRIAGE / Transmission

Part B

55

Part B

57

WCGB-03-04-001

58

60
61

63

22

67

66

W3-4-22

65

WCGB-03-04-003

UNDERCARRIAGE / Transmission
Assembly of Transmission
1. Hoist housing (22) with the rear axle mounting
side facing upward.
2. Install the outer race of bearing (55) to housing
(22).

5. Apply grease onto the seal and the dust lip part of
shaft seal (65). Apply gear oil onto the outer
circumference of shaft seal (65). Install shaft seal
(65) to cover (60).
NOTE: Dimension A: 69.5-0.5 mm (2.7-0.02 in)

3. Install screen sheet (67) to housing (22). At this

time, the slot pin should pass through the hole on
screen sheet (67).

65

60
22

WCGB-03-04-015

6. Install shim (63) to cover (60).

7. Install the outer race of bearing (61) to cover (60).
Slot Pin

4. Install final gear (57) to housing (22).

WCGB-03-04-009

8. Apply hydraulic oil onto O-ring (58). Install O-rings

(58) (3 used) to cover (60).
IMPORTANT: Install cover (66) so that the convex
part of the cover (60) back side can
enter the groove of cover (60).
9. Install cover (66) to cover (60).

66

60

WCGB-03-04-016

W3-4-23

UNDERCARRIAGE / Transmission

Part B

55

Part B

WCGB-03-04-001

56
59
60
61
62

72

70

69

68

22

64

W3-4-24

WCGB-03-04-003

UNDERCARRIAGE / Transmission
10. Install the cover (60) assembly to housing (22).
Temporarily tighten with nuts (103) (2 used) and
washers (104) (2 used).
: 19 mm
60

22
103, 104

WCGB-03-04-010

11. Install the inner race of bearing (61), bushing (64)

and O-ring (59) to pinion (62).
12. Install pinion (62) to housing (22). Install special
tool (ZF special tool No. 5870 654 049) to housing
(22). Tighten pinion (62).
13. Hoist and turn over housing (22) with the rear axle
mounting side facing downward.
14. Install ring (56) and the inner race of bearing (55)
to pinion (62).

15. Install O-ring (69) and plate (72) to housing (22).

Temporarily tighten with bolts (70) (2 used). At this
time, turn pinion (62) to both directions 7 times
and take up slack.
: 17 mm
: 46 Nm (4.7 kgfm, 34 lbfft)
16. Turn pinion (62) and measure the preload. If the
proper preload cannot be obtained, reassemble
from step 14.
NOTE: Proper preload: 1.5 to 3.0 Nm (0.2 to 0.3
kgfm, 1.0 to 2.0 lbfft)
17. Tighten pinion (62) in a direction opposite to step
12 by using special tool (ZF special tool No. 5870
654 049). Remove special tool (ZF special tool No.
5870 654 049).
18. Turn pinion (62) and measure the preload. If the
proper preload cannot be obtained, reassemble
from step 14.
NOTE: Proper preload: 1.5 to 3.0 Nm (0.2 to 0.3
kgfm, 1.0 to 2.0 lbfft)
19. Remove temporarily installed bolts (70) (2 used).
Remove flange (68) and plate (72) from housing
(22).
: 17 mm

W3-4-25

UNDERCARRIAGE / Transmission

Part B

WCGB-03-04-001

55

Part B

60
74
62

73

72

70, 71

69

68

WCGB-03-04-003

22

W3-4-26

UNDERCARRIAGE / Transmission
20. Apply grease onto the seal and the dust lip part of
shaft seal (74). Apply gear oil onto the outer
circumference of shaft seal (74). Install shaft seal
(74) to housing (22).
21. Install plate (73) to housing (22).
NOTE: Dimension B: 17.6-0.5 mm (0.7-0.02 in)
Dimension C: 27.5+0.3 mm(1.1+0.01 in)
74

23. Remove nuts (103) (2 used) and washers (104) (2

used) which are installed temporarily.
: 19 mm

22
103, 104

55
22

C
WCGB-03-04-010

24. Hoist housing (22) with the rear axle mounting

side facing upward.

73

WCGB-03-04-011

22. Install flange (68), O-ring (69) and plate (72) to

housing (22) with bolts (70) (2 used) and washers
(71) (2 used).
: 17 mm
: 46 Nm (4.7 kgfm, 34 lbfft)

25. Install the steel ball (diameter: 7.0 mm (0.3 in)) to

the center hole on pinion (62). Measure the
dimension. If the proper dimension cannot be
obtained, reassemble from step 12.
NOTE: Dimension D: 115.6 mm (4.6 in)
Dimension E: 730.05 mm (2.90.002 in)
62

D
E

60
22
WCGB-03-04-012

W3-4-27

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A
13 14, 15

16, 17, 18, 19

20

22

21

23
25

49
29
30, 31

39 38

37 36

35

34

33

32

WCGB-03-04-002

W3-4-28

UNDERCARRIAGE / Transmission
26. Install the outer race of bearing (23) to housing
(22).

34. Hoist housing (22) with the rear axle mounting

side facing upward.

27. Hoist housing (22) with the rear axle mounting

side facing downward.

35. Install the inner race of bearing (23) to housing

(22).

28. Install the outer race of bearing (21) to housing

(22).

36. Install plate (29) to housing (22) with bolts (25) (4

used). At this time, turn planetary carrier (32) to
both directions several times.
: 17 mm
: 46 Nm (4.7 kgfm, 34 lbfft)

29. Apply grease onto slot pin (33). Install slot pins
(33) (6 used) to planetary carrier (32).
NOTE: Dimension F: 28-1.0 mm (1.1-0.04 in)
33
32

37. Install collar (38) to shaft (49). Secure with

retaining ring (20).
38. Secure bearing (37) to ring gear (34) with
retaining rings (36) (2 used).

39. Install shaft (49) to ring gear (34). Secure with

retaining ring (35).
40. Hoist housing (22) with the rear axle mounting
side facing downward.
WCGB-03-04-017

30. 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).
31. Install the inner race of bearing (21) to planetary
carrier (32).

41. Install bearing (30) and washers (31) (3 used) to

planetary carrier (32).
42. Install the shaft (49) assembly to housing (22).
43. Secure the shaft (49) assembly to housing (22)
with retaining ring (14) and shim (15).
44. Install disc plates (13, 39) to housing (22).

32. Install planetary carrier (32) to housing (22).

33. Tighten planetary carrier (32) to housing (22) by
using special tool (ZF special tool No. 5870 654
049).

W3-4-29

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

W3-4-30

UNDERCARRIAGE / Transmission
45. Install friction plates (12) (6 used) and plates (11)
(7 used) to housing (22).
46. Remove friction plates (41) (10 used) and plates
(40) (9 used) from housing (22).

52. Measure dimension I of housing (22) and clutch

piston (47).
NOTE: Dimension I: 22.5 mm (0.9 in)

47. Apply hydraulic oil onto plate (53). Install holder

(51), bearing (52) and plates (53) (2 used) to shaft
(49).

48. Install brake piston (45) without the seals to

housing (22).

47
22

49. Install clutch piston (47) without the seals to

housing (22).
50. Install disc springs (46, 54) to housing (22).
51. Install special tool (ZF special tool No. 5870 200
131) to housing (22) with the bolts (2 used).
Measure dimensions G and H of disc springs (46,
54).
: 19 mm
: 80 Nm (8 kgfm, 59 lbfft)
NOTE: Dimension G: 2.4+0.3 mm (0.09+0.01 in)
Dimension H: 1.8+0.3 mm (0.07+0.01 in)
54

WCGB-03-04-018

53. Measure dimension J of housing (22) and brake

piston (45).
NOTE: Dimension J: 11.9 mm (0.47 in)

45

46

22
WCGB-03-04-018

H
G

22
WCGB-03-04-018

54. Remove the bolts (2 used). Remove special tool

(ZF special tool No. 5870 200 131) and disc
springs (46, 54) from housing (22).
: 19 mm
55. Remove brake piston (45), clutch piston (47),
holder (51), bearing (52) and plates (53) (2 used)
from housing (22).

W3-4-31

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A

10 9

22

2
1
54
52, 53
51
50
49
48
47

46

45

44 43 42

WCGB-03-04-002

W3-4-32

UNDERCARRIAGE / Transmission
56. Apply hydraulic oil onto the seal surface of ring
(43) and O-ring (9). Install O-ring (9) to ring (43).
57. Install ring (43) to housing (22) by using a plastic
hammer.

66. Install clutch piston (47) to housing (22). Push

clutch piston (47) toward the shaft. Install plugs
(80) (2 used) and seal rings (81) (2 used) to
housing (22).
80, 81

22

58. 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).
59. Install ring (44) to housing (22) by using a plastic
hammer.
60. Install spring (50) and holder (51) to shaft (49).
61. Apply hydraulic oil onto bearing (52). Install
bearing (52) and plates (53) (2 used) to shaft (49).
62. Apply hydraulic oil onto the seal surface of
housing (22). Install oil seals (4, 7) to housing
(22).
63. Apply hydraulic oil onto the seal surface of brake
piston (45). Install oil seals (6, 48) to brake piston
(45).
64. Install brake piston (45) to housing (22) by using a
plastic hammer.

WCGB-03-04-013

67. Install disc springs (46, 54) to housing (22).

68. Install piston (96), spring (94) and O-ring (95) to
housing (22).
22

94, 95, 96

65. Install pins (5) (2 used) to brake piston (45).

WCGB-03-04-014

69. Apply hydraulic oil onto O-ring (3). Install O-ring

(3) to cover (1).
70. Install cover (1) to housing (22) with bolts (2) (5
used).
: 19 mm
: 80 Nm (8 kgfm, 59 lbfft)

W3-4-33

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A
22

WCGB-03-04-002

W3-4-34

UNDERCARRIAGE / Transmission
71. Install O-rings (86, 89), plug (90), steel ball (88)
and spring (87) to housing (22).
: 8 mm
: 24 Nm (2.4 kgfm, 18 lbfft)
2

1
86

22

87
88
90

89

73. Install bleeder (85), bleeder valve (93), fitting (97)

and plugs (91, 92) to housing (22).
Bleeder (85)
: 27 mm
: 22 Nm (2.2 kgfm, 16 lbfft)
Bleeder valve (93)
: 17 mm
: 22 Nm (2.2 kgfm, 16 lbfft)
Fitting (97)
: 17 mm
: 22 Nm (2.2 kgfm, 16 lbfft)
Plugs (91, 92)
: 8 mm
: 25 Nm (2.5 kgfm, 18 lbfft)
22

WCGB-03-04-007

72. Install bleeder valves (98) (2 used), plugs (99) (2

used), plugs (101) (3 used), seal rings (100) (2
used) and O-rings (102) (3 used) to housing (22).
Bleeder valve (98)
: 17 mm
: 22 Nm (2.2 kgfm, 16 lbfft)
Plug (99)
: 8 mm
: 15 Nm (1.5 kgfm, 11 lbfft)
Plug (102)
: 8 mm
: 25 Nm (2.5 kgfm, 18 lbfft)
22

99, 100

98

101, 102
WCGB-03-04-008

W3-4-35

97
85

93

92

91

WCGB-03-04-013

UNDERCARRIAGE / Transmission

Part A

WCGB-03-04-001

Part A
22

26

27, 28

27, 28

WCGB-03-04-002

W3-4-36

UNDERCARRIAGE / Transmission
74. Install travel N sensor (82) to housing (22) with
socket bolt (83) and O-ring (84).
: 6 mm
: 23 Nm (2.3 kgfm, 17 lbfft)
85, 86

84

22

WCGB-03-04-006

75. Install shift interlock controller (26) to housing (22)

with socket bolts (27) (5 used) and washers (28)
(5 used).
: 6 mm
: 23 Nm (2.3 kgfm, 17 lbfft)
76. Connect pipes (81) (2 used) to the transmission
with bolts (75, 77) (2 used for each) and seal rings
(76, 78) (2 used for each).
: 22 mm
: 25 Nm (2.5 kgfm, 18 lbfft)
: 24 mm
: 45 Nm (4.5 kgfm, 33 lbfft)
Transmission

79

77, 79

75, 76
WCGB-03-04-005

W3-4-37

UNDERCARRIAGE / Transmission
(Blank)

W3-4-38

UNDERCARRIAGE / Axle
REMOVAL AND INSTALLATION OF AXLE
Removal of Front Axle

1. Loosen nuts (1) (20 used) for tires (3) (4 used)

and tire rings (2) (2 used).
: 30 mm

2. Swing the machine by 90. Raise the front axle

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)

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 (8) from pin (7).
: 17 mm

6. Disconnect steering hoses (6) (2 used) from the

steering cylinder.
: 22 mm
CAUTION: Propeller shaft (11) weight: 35 kg
(80 lb)
Steering Cylinder

7. Place a wooden block under propeller shaft (11).

Remove bolts (10) (8 used) and nuts (9) (8 used).
Remove propeller shaft (11) from the front axle.
: 14 mm

WCGB-03-05-024

Front Axle

11
9, 10

WCGB-03-05-028

8. Remove nuts (12) (2 used). Remove bolt (13)

from pin (7).
: 24 mm
9. Hold the lower side of the front axle by using a
forklift.
CAUTION: Front axle weight:
ZX210W-3: 750 kg (1660 lb)
ZX220W-3: 770 kg (1700 lb)

13

7
12

WCGB-03-05-027

CAUTION: Pin (7) weight: 18 kg (40 lb) (outer

diameter 70 mm (2.8 in))
10. Remove pin (7) from the front axle. Remove the
front axle from frame (4).

W3-5-2

UNDERCARRIAGE / Axle
Installation of Front Axle
4

CAUTION: Front axle weight:

ZX210W-3: 750 kg (1660 lb)
ZX220W-3: 770 kg (1700 lb)

13

CAUTION: Pin (7) weight: 18 kg (40 lb) (outer

diameter 70 mm (2.8 in))

7
12

1. Hold the front axle by using a forklift. Install the

front axle to frame (4) with pin (7).
2. Secure pin (7) with bolt (13) and nuts (12) (2
used).
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)

WCGB-03-05-027

3. Connect steering hoses (6) (2 used) to the

steering cylinder.
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
Steering Cylinder

4. Connect brake hoses (5) (2 used) to the right and

left sides of the front axle.
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
5. Connect grease hose (8) to pin (7).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)

WCGB-03-05-024

Front Axle

Steering Cylinder

WCEB-03-05-021

CAUTION: Propeller shaft (11) weight: 35 kg

(80 lb)
6. Install propeller shaft (11) to the front axle with
bolts (10) (8 used) and nuts (9) (8 used).
: 14 mm
: 108 Nm (11 kgfm, 80 lbfft)

Front Axle

11
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)

7. Install tire (3), tire ring (2) and tire (3) to the front
axle in this order. Temporarily tighten with nuts (1)
(10 used).
: 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.

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 Nm (60 kgfm, 440 lbfft)

W3-5-4

UNDERCARRIAGE / Axle
Removal of Rear Axle
1. Loosen nuts (1) (20 used) for tires (3) (4 used)
and tire rings (2) (2 used).
: 30 mm

4
3

2. Swing the machine by 90. Raise the rear axle

side of frame (4) until tire (3) is raised. Place a
stand under frame (4).

2
3

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb)

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

7, 8

CAUTION: Propeller shaft (6) weight: 30 kg

(70 lb)

WCGB-03-05-033

10

4. Place a wooden block under propeller shaft (6).

Remove bolts (8) (8 used) and nuts (7) (8 used).
Remove propeller shaft (6) from transmission (5).
: 14 mm
5. Disconnect hoses (9) (9 used) and connectors
(11) (2 used) from transmission (5) and travel
motor (10).
: 19 mm, 22 mm, 27 mm

W3-5-5

11
9

WCGB-03-05-030

UNDERCARRIAGE / Axle
CAUTION: The transmission (5) assembly
weight: 220 kg (490 lb)
6. Hold the lower side of the transmission (5)
assembly by using a forklift. Remove bolts (12)
(14 used). Remove the transmission (5) assembly
from the rear axle.
: 19 mm
7. Disconnect brake pipings (13) (2 used) from the
right and left sides of the rear axle.
: 19 mm

Rear Axle

5
12

WCGB-03-05-032

13

CAUTION: Rear axle weight:

ZX210W-3: 600 kg (1330 lb)
ZX220W-3: 630 kg (1390 lb)
8. Hold the lower side of the rear axle by using a
forklift.

WCGB-03-05-023

14

9. Remove nuts (15) (8 used) from the right and left

sides of the rear axle. Remove bolts (14) (8 used)
from frame (4).
: 30 mm

15

10. Remove the rear axle from frame (4).

WCGB-03-05-022

W1GL-03-05-003

W3-5-6

UNDERCARRIAGE / Axle
Installation of Rear Axle

13

CAUTION: Rear axle weight:

ZX210W-3: 600 kg (1330 lb)
ZX220W-3: 630 kg (1390 lb)
1. Hold the rear axle by using a forklift. Install the
rear axle to frame (4) with bolts (14) (8 used) and
nuts (15) (8 used).
: 30 mm
: 560 Nm (57 kgfm, 410 lbfft)

WCGB-03-05-023

14
15

2. Connect brake pipings (13) (2 used) to the right

and left sides of the rear axle.
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

CAUTION: The transmission (5) assembly

weight: 220 kg (490 lb)
WCGB-03-05-022

3. While holding the transmission (5) assembly by

using a forklift, align it with the rear axle. Install
the transmission (5) assembly to the rear axle
with bolts (12) (14 used).
: 19 mm
: 250 Nm (26 kgfm, 185 lbfft)
4. Connect hoses (9) (9 used) and connector (11) to
transmission (5) and travel motor (10).
(Hose):
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
(Socket bolt):
: 12 mm
: 140 Nm (14 kgfm, 105 lbfft)

W3-5-7

Rear Axle

5
12

WCGB-03-05-032

10
11
9

WCGB-03-05-030

UNDERCARRIAGE / Axle
CAUTION: Propeller shaft (6) weight: 35 kg
(80 lb)

5. Install propeller shaft (6) to transmission (5) with

nuts (7) (8 used) and bolts (8) (8 used).
: 14 mm
: 108 Nm (11 kgfm, 80 lbfft)
7, 8

CAUTION: Tire (3) weight: 98 kg (220 lb)

Tire ring (2) weight: 25 kg (60 lb)
6. Install tire (3), tire ring (2) and tire (3) to the rear
axle in this order. Temporarily tighten with nuts (1)
(10 used).
: 30 mm

WCGB-03-05-033

7. Install tire ring (2) and tires (3) (2 used) to the

other side of the rear axle in the same way as
step 6.

4
3

8. Remove the stand from frame (4).

9. Tighten tires (3) (4 used) and tire rings (2) (2
used) with nuts (1) (20 used).
: 30 mm
: 600 Nm (60 kgfm, 440 lbfft)

2
1

W3-5-8

W1GL-03-05-003

UNDERCARRIAGE / Axle
(Blank)

W3-5-9

UNDERCARRIAGE / Axle
DISASSEMBLY OF FRONT AXLE
6

7 8

10

5
4
2

11

12

7
21

20

22

19

13

23

25 26 27

24
17

18
29

28

16
14

15

30
31
32
33
43

37 38

34

35

39

40

41 42

44

36

45

46
48

69

68 67 66

65

64

63

59 58
62 61 60

W3-5-10

57

51
56 55 54 53 52

50

47

49

WCGB-03-05-001

UNDERCARRIAGE / Axle
1 - Axle Casing
2 - Bolt (16 Used)
3 - Washer (16 Used)
4 - Plug (2 Used)
5 - O-Ring (2 Used)
6 - Drive Housing
7 - Roller Bearing
8 - Shim
9 - O-Ring
10 -Bearing
11 -Bearing
12 -Tie Rod
13 -Tie Rod
14 -Bushing
15 -Shaft Seal
16 -Double Joint Shaft
17 -Shaft Seal
18 -Bushing

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -

Knuckle
Bolt (4 Used)
Bearing Pin
O-Ring
Seal
O-Ring
Bearing Nut
Thrust Plate
Thrust Plate
Socket Bolt
Retaining Ring
Seal
O-Ring
Shim
Bearing Pin
O-Ring
Shaft Seal
Bearing

37 - Hub Carrier
38 - Bushing
39 - Bearing
40 - O-Ring
41 - Friction Plate (6 Used)
42 - Plate (5 Used)
43 - Disc Plate
44 - Planetary Carrier
45 - Plug
46 - O-Ring
47 - Socket Bolt (2 Used)
48 - Retaining Ring (3 Used)
49 - Planetary Gear (3 Used)
50 - Washer (3 Used)
51 - Roller Bearing (3 Used)
52 - Washer (3 Used)
53 - Retaining Ring (3 Used)
54 - Retaining Ring (3 Used)

W3-5-11

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 -

Washer
O-Ring
Ring Gear
Knock Pin (4 Used)
Backup Ring
U-Ring
U-Ring
Backup Ring
Piston
Spring (8 Used)
Spring (8 Used)
Spring Seat (8 Used)
Bolt (8 Used)
Disc Carrier
O-Ring

UNDERCARRIAGE / Axle

6
5
4

12

19

13

25 26 27

29

28

43

40

41 42

37
44
45

46
47

69

68

67 66

65

62
64 63

61

60 59

W3-5-12

58

54 53 52
57 56 55

51 50

48
49

WCGB-03-05-001

UNDERCARRIAGE / Axle
Disassembly of Front Axle
8. Remove retaining ring (29) and thrust plates (26,
27) from knuckle (19).

CAUTION: Front axle weight:

ZX210W-3: 750 kg (1660 lb)
ZX220W-3: 770 kg (1700 lb)

9. Remove socket bolt (28) from bearing nut (25).

: 8 mm

1. Hoist the front axle. Lower the front axle on a

workbench.
2. Remove plugs (4) (2 used) and O-rings (5) (2
used) from drive housing (6). Remove plug (45)
and O-ring (46) from planetary carriers (44) in the
left and right sides. Drain gear oil from the front
axle.
: 14 mm
3. Disassemble tie rods (12, 13). (Refer to
DISASSEMBLY OF STEERING CYLINDER on
W3-5-46.)
CAUTION: Planetary carrier (44) weight: 30
kg (70 lb)
4. Attach a nylon sling onto planetary carrier (44).
Hoist and hold planetary carrier (44).
5. Remove socket bolts (47) (2 used) from planetary
carrier (44). Hoist and remove planetary carrier
(44) from the front axle.
: 8 mm

10. Remove bearing nut (25) and O-ring (56) from

knuckle (19).
: 41 mm
11. Pry the clearance between piston (63) and hub
carrier (37) by using a pry bar. Remove the ring
gear (57) assembly from hub carrier (37).
IMPORTANT: Before removing bolt (67), record the
dimension of bolt (67) extended from
piston (63).
12. Remove bolts (67) (8 used), spring seats (66) (8
used) and springs (64, 65) (8 used for each) from
ring gear (57).
13. Remove piston (63) from ring gear (57). Remove
U-rings (60, 61), backup rings (59, 62) and knock
pins (58) (4 used) from ring gear (57).
14. Remove disc plate (43) from hub carrier (37).
Remove plates (42) (5 used) and friction plates
(41) (6 used).
15. Remove O-ring (40). Remove disc carrier (68)
from knuckle (19). Remove O-ring (69).

6. Remove retaining rings (54) (3 used). Remove

planetary gears (49) (3 used) and washer (55)
from planetary carrier (44).
IMPORTANT: Do not remove roller bearing (51)
unless necessary.
7. Remove retaining rings (48, 53) (3 used for each),
washers (50, 52) (3 used for each) and roller
bearings (51) (3 used) from planetary gears (49)
(3 used).

W3-5-13

UNDERCARRIAGE / Axle
10

11
1

20
19

21
22
23
24

16
30
31
32
33

37 38

34

35

39

36

WCGB-03-05-001

W3-5-14

UNDERCARRIAGE / Axle
CAUTION: Hub carrier (37) weight: 38 kg (84
lb)
16. Attach a nylon sling onto hub carrier (37). Hold
hub carrier (37). Hoist and remove hub carrier
(37) from knuckle (19).
17. Remove O-ring (34) from knuckle (19).
IMPORTANT: Do not remove bearings (36, 39)
unless necessary.
18. Remove shaft seal (35) from hub carrier (37).
Remove the outer race of bearing (36) and
bearing (39).
IMPORTANT: Do not remove bearing (36) unless
necessary.
19. Remove bushing (38). Remove the inner race of
bearing (36) from knuckle (19).
IMPORTANT: When removing bearing pin (21), the
inner race of bearing (10) is removed
with bearing pin (21) together. Do
not damage the inner race of bearing
(10) and bearing pin (21).
20. Remove bolts (20) (4 used) from the upper side of
knuckle (19). Remove bearing pin (21), O-rings
(22, 24) and seal (23) from knuckle (19).
: 24 mm

IMPORTANT: When removing bearing pin (33), the

inner race of bearing (11) is removed
with bearing pin (33) together. Do
not damage the inner race of bearing
(11) and bearing pin (33).
22. Remove bolts (20) (4 used) from the lower side of
knuckle (19). Remove bearing pin (33), shim (32),
O-ring (31) and seal (30) from knuckle (19).
: 24 mm
IMPORTANT: Do not remove bearings (10, 11)
unless necessary.
23. Remove the inner races of bearings (10, 11) from
bearing pins (21, 33).
IMPORTANT: When removing double joint shaft
(16), do not damage the seal of axle
casing (1).
24. Pull out knuckle (19) with double joint shaft (16)
attached about 200 mm from axle casing (1). Hold
the axis of double joint shaft (16). Hoist and
remove the knuckle (19) assembly.

CAUTION: The knuckle (19) assembly: 76 kg

(170 lb)
21. Install eyebolts (M16, Pitch 1.75 mm) (2 used) to
the bolt (20) hole on the upper side of knuckle (19).
Attach a nylon sling onto eyebolts (2 used). Hoist
and hold knuckle (19).

W3-5-15

16

19

WCGB-03-05-002

UNDERCARRIAGE / Axle

7 8

10

11

19

17

18

16
14

15

WCGB-03-05-001

W3-5-16

UNDERCARRIAGE / Axle
25. Remove double joint shaft (16) from knuckle (19).

32. Remove differential (70) from drive housing (6).

26. Remove shaft seal (17) and bushing (18) from

knuckle (19).

27. Remove shaft seal (15) and bushing (14) from

axle casing (1).
IMPORTANT: Do not remove bearings (10, 11)
unless necessary.
28. Remove the outer races of bearings (10, 11) from
axle casing (1).

70

WCGB-03-05-003

CAUTION: Axle casing (1) weight:

ZX210W-3: 98 kg (220 lb)
ZX220W-3: 107 kg (240 lb)
29. Attach a nylon sling onto axle casing (1). Hoist
and hold axle casing (1). Remove bolts (2) (16
used) and washers (3) (16 used). Hoist and
remove axle casing (1) from drive housing (6).
: 27 mm
IMPORTANT: Do not remove roller bearing (7)
unless necessary.
30. Remove O-ring (9), shim (8) and roller bearing (7)
from axle casing (1).
31. Disassemble the other side of the front axle in the
same way as steps 4 to 30.

W3-5-17

UNDERCARRIAGE / Axle
ASSEMBLY OF FRONT AXLE
6

Detail of Drive Housing Inside

9

2, 3

2, 3
1

16

Planetary Carrier

Detail of Planetary Carrier Inside

21

35 24

36

40 38 37 68

WCGB-03-05-019

41 42 43 61, 62 63

Detail A

22, 23

53

54

52

50
44

10
48
1
49
51

Drive
Housing

25
27
29

16

55
14

26

15

28
45

30, 31
20

11

33

32 19 17

18 39 69 34

64, 65, 66, 67

W3-5-18

59, 60

56

57

46

WCGB-03-05-005

UNDERCARRIAGE / Axle
1 - Axle Casing
2 - Bolt (16 Used)
3 - Washer (16 Used)
4* - Plug (2 Used)
5* - O-Ring (2 Used)
6 - Drive Housing
7 - Roller Bearing
8 - Shim
9 - O-Ring
10 - Bearing
11 - Bearing
12* - Steering Cylinder
13* - Steering Cylinder
14 - Bushing
15 - Shaft Seal
16 - Double Joint Shaft
17 - Shaft Seal
18 - Bushing

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -

Knuckle
Bolt (4 Used)
Bearing Pin
O-Ring
Seal
O-Ring
Bearing Nut
Thrust Plate
Thrust Plate
Socket Bolt
Retaining Ring
Seal
O-Ring
Shim
Bearing Pin
O-Ring
Shaft Seal
Bearing

37 - Hub Carrier
38 - Bushing
39 - Bearing
40 - O-Ring
41 - Friction Plate (6 Used)
42 - Plate (5 Used)
43 - Disc Plate
44 - Planetary Carrier
45 - Plug
46 - O-Ring
47* - Socket Bolt (2 Used)
48 - Retaining Ring (3 Used)
49 - Planetary Gear (3 Used)
50 - Washer (3 Used)
51 - Roller Bearing (3 Used)
52 - Washer (3 Used)
53 - Retaining Ring (3 Used)
54 - Retaining Ring (3 Used)

NOTE: As for the item with mark*, refer to W3-5-10.

W3-5-19

55 - Washer
56 - O-Ring
57 - Ring Gear
58*- Knock Pin (4 Used)
59 - Backup Ring
60 - U-Ring
61 - U-Ring
62 - Backup Ring
63 - Piston
64 - Spring (8 Used)
65 - Spring (8 Used)
66 - Spring Seat (8 Used)
67 - Bolt (8 Used)
68 - Disc Carrier
69 - O-Ring

UNDERCARRIAGE / Axle

6
9

2, 3

2, 3
1

16

Planetary Carrier

21

WCGB-03-05-019

Detail A

22, 23
10
1
Drive
Housing

16
14
15
30, 31
11

33

32

19 17

WCGB-03-05-005

18

W3-5-20

UNDERCARRIAGE / Axle
Assembly of Front Axle
5. Tap and install the outer races of bearings (10, 11)
to axle casing (1) by using a plastic hammer.

1. Install differential (70) to drive housing (6).

6

IMPORTANT: When installing double joint shaft

(16), do not damage the seal of axle
casing (1).
6. Install double joint shaft (16) to axle casing (1).
70

WCGB-03-05-003

2. Install roller bearing (7), shim (8) and O-ring (9) to

the drive housing (6) mounting side on axle casing
(1).

7. Apply grease onto the seal and the dust lip part of
shaft seal (17). Apply LOCTITE #574 onto the
shaft seal (17) contact surface on knuckle (19).
Install bushing (18) and shaft seal (17) to knuckle
(19).
8. Install seal (30), O-ring (31), the inner race of
bearing (11) and washer (32) to bearing pin (33).
9. Apply anticorrosive (Weicon Antiseize (Never
Seez) ZF special tool No. 0671 196 001) onto the
collar part of bearing pin (33). Install seal (23) and
O-ring (22) to bearing pin (21).

CAUTION: Axle casing (1) weight:

ZX210W-3: 98 kg (220 lb)
ZX220W-3: 107 kg (240 lb)
3. Hoist axle casing (1). Install axle casing (1) to
drive housing (6) with bolts (2) (16 used) and
washers (3) (16 used).
: 27 mm
: 390 Nm (40 kgfm, 860 lbfft)
4. Apply grease onto the seal and the dust lip part of
shaft seal (15). Apply LOCTITE #574 onto the
shaft seal (15) contact surface on axle casing (1).
Install bushing (14) and shaft seal (15) to axle
casing (1).

W3-5-21

UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-019

21

35

24

36

40

38 37 68

Detail A

Drive
Housing

25

16

20

33

19

39

69

W3-5-22

57

WCGB-03-05-005

UNDERCARRIAGE / Axle
CAUTION: Knuckle (19) weight: 55.5 kg (130
lb)
IMPORTANT: When inserting double joint shaft
(16) to knuckle (19), do not damage
the seal.
10. Apply grease onto bearing pin (33). Install
eyebolts (M16, Pitch 1.75 mm) (2 used) to the bolt
(20) hole on the upper side of knuckle (19). Hoist
knuckle (19). Install knuckle (19) to axle casing (1).
Install bearing pin (33) to the lower side of knuckle
(19) with bolts (20) (4 used).
: 24 mm
: 280 Nm (28 kgfm, 205 lbfft)

IMPORTANT: When installing shaft seal (35),

check the mounting position and
dimension A. Install shaft seal (35)
with the marking of OUT-SIDE facing
upward and outward.
14. Apply LOCTITE #574 onto the shaft seal (35)
contact surface on hub carrier (37). Install shaft
seal (35) to hub carrier (37).
NOTE: Dimension A: 0 to 0.3 mm (0 to 0.01 in)
A

37

35

11. Apply grease onto bearing pin (21). Remove

eyebolts (2 used) from the upper side of knuckle
(19). Install bearing pin (21) and O-ring (24) to
knuckle (19) with bolts (20) (4 used).
: 24 mm
: 280 Nm (28 kgfm, 205 lbfft)

CAUTION: Hub carrier (37) weight: 38 kg (84

lb)

12. Install the inner race of bearing (36) and bushing

(38) to knuckle (19).

15. Hoist hub carrier (37). Install hub carrier (37) to

knuckle (19).

13. Apply hydraulic oil onto O-ring (40). Install O-ring

(40), the outer race of bearing (36) and bearing
(39) to hub carrier (37).

16. Install O-ring (69) and disc carrier (68) to knuckle

(19).

WCGB-03-05-006

17. Install ring gear (57) to knuckle (19).

18. When installing bearing nut (25), apply lubricant
(ZF special tool No. 0671 195 042 MOLYKOTE
PASTE 1000) onto the thread part of knuckle (19).
Install bearing nut (25) to knuckle (19) by using
special tool (ZF special tool No. 5870 656 097). At
this time, turn hub carrier (37) in both directions
several times in order to fit the rotor.
: 1400 Nm (140 kgfm, 1040 lbfft)

W3-5-23

UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-019

37

41 42 43 61, 62 63

Detail A

44

Drive
Housing

25
27
29
55
26
28

19

64, 65, 66, 67

W3-5-24

59, 60

56

57

WCGB-03-05-005

UNDERCARRIAGE / Axle
19. Remove bearing nut (25) from knuckle (19).
Remove ring gear (57) from knuckle (19).
: 41 mm

25. Align the marks and install the ring gear (57)
assembly to knuckle (19).
57

Mark

19

IMPORTANT: Check the mounting positions of

friction plate (41) and plate (42).
20. Install friction plates (41) (6 used) and plates (42)
(5 used) to hub carrier (37) alternately. Install disc
plate (43).
21. Apply grease onto O-ring (34). Install O-ring (34)
to knuckle (19).
22. Apply hydraulic oil onto U-rings (60, 61) and
backup rings (59, 62). Install U-rings (60, 61) and
backup rings (59, 62) to ring gear (57).

26. Apply hydraulic oil onto O-ring (56). Install O-ring

(56) to knuckle (19).

23. Install knock pins (58) (4 used) to piston (63).

NOTE: Dimension B: 16 mm (0.6 in)
63

WCGB-03-05-008

27. When installing bearing nut (25), apply lubricant

(ZF special tool No. 0671 195 042 MOLYKOTE
PASTE 1000) onto the thread part of knuckle (19).
Install bearing nut (25) to knuckle (19) by using
special tool (ZF special tool No. 5870 656 097).
Align the socket bolt (28) holes on knuckle (19)
and bearing nut (25). If it is difficult to align the
holes, retighten bearing nut (25).
: 1400+200 Nm (140+20 kgfm, 1040+150 lbfft)

58
B

WCGB-03-05-007

IMPORTANT: When tightening bolt (67), align with

the
dimension
before
disassembling.
24. Install piston (63) to ring gear (57). Secure piston
(63) with bolts (67) (8 used), spring seats (66) (8
used) and springs (64, 65).
: 10 mm
: 11 Nm (1 kgfm, 8 lbfft)

28. Install socket bolt (28) to bearing nut (25).

: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)
29. Install thrust plates (26, 27) to knuckle (19).
Secure with retaining ring (29).
30. Install washer (55) to planetary carrier (44).

W3-5-25

UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-019

Detail A

54

53

52

50
44
48
49
51

Drive
Housing

45
46

W3-5-26

WCGB-03-05-005

UNDERCARRIAGE / Axle
31. Install retaining rings (48, 53) (3 used for each),
washers (50, 52) (3 used for each) and roller
bearings (51) (3 used) to planetary gears (49) (3
used).
32. Install planetary gears (49) (3 used) to planetary
carrier (44) with retaining rings (54) (3 used).
CAUTION: Planetary carrier (44) weight: 30
kg (70 lb)
33. Hoist planetary carrier (44). Install planetary
carrier (44) to the front axle with socket bolts (47)
(2 used).
: 10 mm
: 90 Nm (9 kgfm, 66 lbfft)
34. Assemble the other side of the front axle in the
same way as steps 2 to 33.
35. Assemble tie rods (12, 13). (Refer to ASSEMBLY
OF STEERING CYLINDER on W3-5-48.)
36. Add gear oil to drive housing (6) and planetary
carriers (44) in the left and right sides. Install plugs
(4) (2 used) and O-rings (5) (2 used) to drive
housing (6). Install plug (45) and O-ring (46) to
planetary carriers (44) in the left and right sides.
: 14 mm
: 50 Nm (5 kgfm, 37 lbfft)

W3-5-27

UNDERCARRIAGE / Axle
DISASSEMBLY OF REAR AXLE
1
5
1

10

8
9

12

13 14

15

16

11

17 18 19

20

28

24
21 22 23

25

26 27
29
30
31

54 53 52

51 50 49 48 47 46

43 42
45 44

W3-5-28

40 39 38 37 36
41

34
35

33

32

WCGB-03-05-009

UNDERCARRIAGE / Axle
1 - Axle Casing
2 - O-Ring
3 - Shim
4 - Roller Bearing
5 - Drive Housing
6 - Washer (14 Used)
7 - Bolt (14 Used)
8 - Axle Shaft
9 - Plug
10 - O-Ring
11 - Washer (16 Used)
12 - Bolt (16 Used)
13 - O-Ring
14 - Knuckle

15 - Bearing Nut
16 - Washer
17 - Socket Bolt
18 - Sun Gear Shaft
19 - O-Ring
20 - Shaft Seal
21 - Bearing
22 - Hub Carrier
23 - Bushing
24 - Bearing
25 - O-Ring
26 - Friction Plate (6 Used)
27 - Plate (5 Used)
28 - Disc Plate

29 - Planetary Carrier
30 - Plug
31 - O-Ring
32 - Socket Bolt (2 Used)
33 - Retaining Ring (3 Used)
34 - Planetary Gear (3 Used)
35 - Washer (3 Used)
36 - Roller Bearing (3 Used)
37 - Washer (3 Used)
38 - Retaining Ring (3 Used)
39 - Retaining Ring (3 Used)
40 - Washer
41 - O-Ring
42 - Ring Gear

W3-5-29

43 44 45 46 47 48 49 50 51 52 53 54 -

Knock Pin (4 Used)

Backup Ring
U-Ring
U-Ring
Backup Ring
Piston
Spring (8 Used)
Spring (8 Used)
Spring Seat (8 Used)
Bolt (8 Used)
Disc Carrier
O-Ring

UNDERCARRIAGE / Axle

1
5
1
10
9

29

22

14

15

18

17

30

31

52

51

50

49

48 47

45 44 43 42
46

W3-5-30

41

35
36
39 38 37
40

33
34

32

WCGB-03-05-009

UNDERCARRIAGE / Axle
Disassembly of Rear Axle
1. Remove transmission (55) from the rear axle.
(Refer to REMOVAL OF TRANSMISSION on
W3-4-1.)
CAUTION: Rear axle weight:
ZX210W-3: 600 kg (1330 lb)
ZX220W-3: 630 kg (1390 lb)

IMPORTANT: Do not remove roller bearing (36)

unless necessary.
7. Remove retaining rings (33, 38) (3 used for each),
washers (35, 37) (3 used for each) and roller
bearings (36) (3 used) from planetary gears (34)
(3 used).
8. Remove sun gear shaft (18) from axle casing (1).

2. Hoist the rear axle. Lower the rear axle on a

workbench.
3. Remove plugs (9, 30) and O-rings (10, 31) from
drive housing (5) and planetary carriers (29) in the
left and right sides. Drain gear oil from the rear
axle.
: 14 mm
CAUTION: Planetary carrier (29) weight: 30
kg (70 lb)
4. Attach a nylon sling onto planetary carrier (29).
Hoist and hold planetary carrier (29).
5. Remove socket bolts (32) (2 used) from planetary
carrier (29). Hoist and remove planetary carrier
(29) from the rear axle.
: 8 mm

9. Remove socket bolt (17) from bearing nut (15).

: 8 mm
10. Remove O-ring (41) from knuckle (14).
11. Pry the clearance between piston (48) and hub
carrier (22) by using a pry bar. Remove the ring
gear (42) assembly from hub carrier (22).
IMPORTANT: Before removing bolt (52), record the
dimension of bolt (52) extended from
piston (48).
12. Remove bolts (52) (8 used), spring seats (51) (8
used) and springs (49, 50) (8 used for each) from
ring gear (42).
13. Remove piston (48) from ring gear (42). Remove
U-rings (45, 46), backup rings (44, 47) and knock
pins (43) (4 used) from ring gear (42).

6. Remove retaining rings (39) (3 used). Remove

planetary gears (34) (3 used) and washer (40)
from planetary carrier (29).

W3-5-31

UNDERCARRIAGE / Axle

1
5
2

4
7

6
8

12

13

28

22

14

11

19

54

20

23 24

25

26 27

21

53

WCGB-03-05-009

W3-5-32

UNDERCARRIAGE / Axle
14. Remove disc plate (28) from hub carrier (22).
Remove plates (27) (5 used) and friction plates
(26) (6 used).

21. Remove axle shaft (8) from axle casing (1).

CAUTION: Axle casing (1) weight:
ZX210W-3: 108 kg (240 lb)
ZX220W-3: 122 kg (270 lb)

15. Remove disc carrier (53) from knuckle (14).

Remove O-ring (54).
CAUTION: Hub carrier (22) weight: 38 kg (84
lb)
16. Attach a nylon sling onto hub carrier (22). Hold
hub carrier (22). Hoist and remove hub carrier
(22) from knuckle (14).
17. Remove O-ring (19) from knuckle (14).
IMPORTANT: Do not remove bearings (21, 24)
unless necessary.
18. Remove shaft seal (20), O-ring (25), the outer
race of bearing (21) and bearing (24) from hub
carrier (22).

22. Attach a nylon sling onto axle casing (1). Hold

axle casing (1). Remove bolts (12) (16 used) and
washers (11) (16 used). Hoist and remove axle
casing (1) from drive housing (5).
: 27 mm
IMPORTANT: Do not remove roller bearing (4)
unless necessary.
23. Remove O-ring (2), shim (3) and roller bearing (4)
from axle casing (1).
24. Disassemble the other side of the rear axle in the
same way as steps 4 to 23.
25. Remove differential (55) from drive housing (5).

IMPORTANT: Do not remove bearing (21) unless

necessary.
19. Remove bushing (23) and the inner race of
bearing (21) from knuckle (14).

CAUTION: Knuckle (14) weight: 34 kg (75 lb)

20. Attach a nylon sling onto knuckle (14). Hold
knuckle (14). Remove bolts (7) (14 used) and
washers (6) (14 used). Hoist and remove knuckle
(14) and O-ring (13) from the rear axle.
: 24 mm

W3-5-33

55

WCGB-03-05-011

UNDERCARRIAGE / Axle
ASSEMBLY OF REAR AXLE
Detail of Drive Housing Inside
1

12

11

11

12

Planetary Carrier

WCGB-03-05-012

Detail of Planetary Carrier Inside

6

13 14 20 21

22

25

23

24

26 27 28 49, 50, 51, 52

48

44, 45
42
29

46, 47
41
15
40

Drive
Housing

16
18

34

54

53

19
T21W-03-05-022

W3-5-34

UNDERCARRIAGE / Axle
1 - Axle Casing
2 - O-Ring
3 - Shim
4 - Roller Bearing
5 - Drive Housing
6 - Washer (14 Used)
7 - Bolt (14 Used)
8 - Axle Shaft
9* - Plug
10* - O-Ring
11 - Washer (16 Used)
12 - Bolt (16 Used)
13 - O-Ring
14 - Knuckle

15 - Bearing Nut
16 - Washer
17* - Socket Bolt
18 - Sun Gear Shaft
19 - O-Ring
20 - Shaft Seal
21 - Bearing
22 - Hub Carrier
23 - Bushing
24 - Bearing
25 - O-Ring
26 - Friction Plate (6 Used)
27 - Plate (5 Used)
28 - Disc Plate

29 - Planetary Carrier
30* -Plug
31* -O-Ring
32* -Socket Bolt (2 Used)
33* -Retaining Ring (3 Used)
34 - Planetary Gear (3 Used)
35* -Washer (3 Used)
36* -Roller Bearing (3 Used)
37* -Washer (3 Used)
38* -Retaining Ring (3 Used)
39* -Retaining Ring (3 Used)
40 - Washer
41 - O-Ring
42 - Ring Gear

NOTE: As for the item with mark*, refer to W3-5-28.

W3-5-35

43* - Knock Pin (4 Used)

44 - Backup Ring
45 - U-Ring
46 - U-Ring
47 - Backup Ring
48 - Piston
49 - Spring (8 Used)
50 - Spring (8 Used)
51 - Spring Seat (8 Used)
52 - Bolt (8 Used)
53 - Disc Carrier
54 - O-Ring

UNDERCARRIAGE / Axle

11

12

Planetary Carrier

WCGB-03-05-012

6 13

14 20 21

22

23

24
42

Drive
Housing

16
18

54

53

19
T21W-03-05-022

W3-5-36

UNDERCARRIAGE / Axle
Assembly of Rear Axle
1. Install differential (55) to drive housing (5).

6. Install the inner race of bearing (21) and bushing

(23) to knuckle (14).

55

IMPORTANT: When installing shaft seal (20), check

the
mounting
position
and
dimension A. Install shaft seal (20)
with the marking of OUT-SIDE facing
upward and outward.
7. Apply LOCTITE #574 onto the shaft seal (20)
contact surface on hub carrier (22). Install shaft
seal (20) to hub carrier (22).
NOTE: Dimension A: 0 to 0.3 mm (0 to 0.01 in)
A

WCGB-03-05-011

2. Install O-ring (2), shim (3) and roller bearing (4) to

axle casing (1).

22

20

CAUTION: Axle casing (1) weight:

ZX210W-3: 108 kg (240 lb)
ZX220W-3: 122 kg (270 lb)

WCGB-03-05-006

3. Attach a nylon sling onto axle casing (1). Hoist

axle casing (1). Install axle casing (1) to drive
housing (5) with bolts (12) (16 used) and washers
(11) (16 used).
: 27 mm
: 300 Nm (30 kgfm, 220 lbfft)

8. Install the outer race of bearing (21) and bearing

(24) to hub carrier (22).
9. Apply hydraulic oil onto O-ring (19). Install O-rings
(19, 54) and disc carrier (53) to knuckle (14).
10. Install ring gear (42) to knuckle (14).

4. Install axle shaft (8) to axle casing (1).

11. Install washer (16) to sun gear shaft (18).
CAUTION: Knuckle (14) weight: 34 kg (75 lb)
5. Install O-ring (13) to knuckle (14). Hoist knuckle
(14). Install knuckle (14) to the rear axle with bolts
(7) (14 used) and washers (6) (14 used).
: 24 mm
: 210 Nm (21 kgfm, 155 lbfft)

W3-5-37

UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-012

14

22

25

26 27 28 49, 50, 51, 52

48 44, 45
42
46, 47
41
15

Drive
Housing

18

T21W-03-05-022

W3-5-38

UNDERCARRIAGE / Axle
12. When installing bearing nut (15), apply lubricant
(ZF special tool No. 0671 195 042 MOLYKOTE
PASTE 1000) onto the thread part of knuckle (14).
Install sun gear shaft (18) and bearing nut (15) to
knuckle (14) by using special tool (ZF special tool
No. 5870 656 097). At this time, turn hub carrier
(22) in both directions several times in order to fit
the rotor.
: 1400 Nm (140 kgfm, 1040 lbfft)
13. Remove bearing nut (15) from knuckle (14).
Remove ring gear (42).
: 41 mm

IMPORTANT: When tightening bolt (52), align with

the
dimension
before
disassembling.
18. Install piston (48) to ring gear (42). Secure piston
(48) with bolts (52) (8 used), spring seats (51) (8
used) and springs (49, 50).
: 10 mm
: 11 Nm (1 kgfm, 8 lbfft)
19. Align the marks and install the ring gear (42)
assembly to knuckle (14).
42

Mark

14

IMPORTANT: Check the mounting positions of

friction plate (26) and plate (27).
14. Install friction plates (26) (6 used) and plates (27)
(5 used) to hub carrier (42) alternately. Install disc
plate (28).
15. Apply grease onto O-ring (25). Install O-ring (25)
to hub carrier (42).
16. Apply hydraulic oil onto U-rings (45, 46) and
backup rings (44, 47). Install U-rings (45, 46) and
backup rings (44, 47) to ring gear (42).
17. Install knock pins (43) (4 used) to piston (48).
NOTE: Dimension B: 16 mm (0.6 in)
48

WCGB-03-05-008

20. Apply hydraulic oil onto O-ring (41). Install O-ring

(41) to knuckle (14).
21. When installing bearing nut (15), apply lubricant
(ZF special tool No. 0671 195 042 MOLYKOTE
PASTE 1000) onto the thread part of knuckle (14).
Install bearing nut (15) to knuckle (14) by using
special tool (ZF special tool No. 5870 656 097).
Align the holes on knuckle (14) and bearing nut
(15). Secure with socket bolt (17).
: 1400+200 Nm (140+20 kgfm, 1040+150 lbfft)

43

WCGB-03-05-007

W3-5-39

UNDERCARRIAGE / Axle

Planetary Carrier

WCGB-03-05-012

14

29

15
40
Drive
Housing

34

T21W-03-05-022

W3-5-40

UNDERCARRIAGE / Axle
22. Install socket bolt (17) into bearing nut (15). If it is
difficult to align the holes on knuckle (14) and
bearing nut (15), retighten bearing nut (15).
: 8 mm
: 50 Nm (5 kgfm, 37 lbfft)
23. Install washer (40) to planetary carrier (29).
24. Install retaining rings (33, 38) (3 used for each),
washers (35, 37) (3 used for each) and roller
bearings (36) (3 used) to planetary gears (34) (3
used).
25. Install planetary gears (34) (3 used) to planetary
carrier (29) with retaining rings (39) (3 used).
CAUTION: Planetary carrier (29) weight: 30
kg (70 lb)
26. Hoist planetary carrier (29). Install planetary
carrier (29) to the rear axle with socket bolts (32)
(2 used).
: 10 mm
: 90 Nm (9 kgfm, 66 lbfft)
27. Assemble the other side of the rear axle in the
same way as steps 2 to 26.
28. Add gear oil to drive housing (5) and planetary
carriers (29) in the left and right sides. Install plugs
(9, 30) and O-rings (8, 31) to drive housing (5) and
planetary carriers (29) in the left and right sides.
: 14 mm
: 50 Nm (5 kgfm, 37 lbfft)

W3-5-41

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.
13

8
9

10 11

12

1
15
16
18

17

14

19

20
21

22

23

24
25
26
27

28

WCGB-03-05-013

1234567-

Bevel Gear
Differential Case
Washer (2 Used)
Side Gear (2 Used)
Pinion Gear (2 Used)
Washer (2 Used)
Washer (2 Used)

8910 11 12 13 14 -

Pinion Gear (2 Used)

Spider
Side Gear (2 Used)
Washer (2 Used)
Differential Case
Drive Housing
Socket Bolt (12 Used)

15 16 17 18 19 20 21 -

W3-5-42

Washer (12 Used)

Spider
Spring Pin (4 Used)
Spring Pin (4 Used)
Drive Pinion
Bearing
Shim

22 23 24 25 26 27 28 -

Spacer
Bearing
Seal
Guard
Flange
Washer
Nut

UNDERCARRIAGE / Axle
Disassembly of Differential
1. Remove nut (28) and washer (27) from drive
pinion (19).
: 41 mm

IMPORTANT: Do not remove bearings (29, 30)

unless necessary.
8. Secure the differential in a vise. Remove the inner
races of bearings (29, 30) from the differential.

2. Remove flange (26) and guard (25) from drive

housing (13).

30

Differential

3. Float seal (24) by using a screwdriver. Remove

drive pinion (19) from drive housing (13).
29

4. Remove spacer (22) from drive pinion (19).

IMPORTANT: Do not remove bearing (20) unless
necessary.
5. Remove the inner race of bearing (20) from drive
pinion (19).
IMPORTANT: Do not remove bearing (20) unless
necessary.
6. Remove the outer race of bearing (20) from drive
pinion (19).
IMPORTANT: Do not remove bearing (23) unless
necessary.
7. Remove shim (21) and bearing (23) from drive
pinion (19).

WCGB-03-05-014

9. Remove socket bolts (14) (12 used) and washers

(15) (12 used). Remove differential case (12).
: 10 mm
10. Remove spring pins (17, 18) (4 used for each),
washers (3, 6, 7, 11) (2 used for each), pinion
gears (5, 8) (2 used for each), side gears (4, 10)
(2 used for each) and spiders (9, 16) from
differential case (2).
11. Secure differential case (2) in a vise with bevel
gear (1) facing upward. Remove bevel gear (1)
from differential case (2).

W3-5-43

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.
14

15

12

13

17, 18

11
4

10

16

9
19
20
21
22

23
24
25

27

1 - Bevel Gear
2 - Differential Case
3 - Washer (2 Used)
4 - Side Gear (2 Used)
5* - Pinion Gear (2 Used)
6* - Washer (2 Used)
7 - Washer (2 Used)

28

8 - Pinion Gear (2 Used)

9 - Spider
10 - Side Gear (2 Used)
11 - Washer (2 Used)
12 - Differential Case
13 - Drive Housing
14 - Socket Bolt (12 Used)

15 16 17 18 19 20 21 -

NOTE: As for the item with mark*, refer to W3-5-42.

W3-5-44

Washer (12 Used)

Spider
Spring Pin (4 Used)
Spring Pin (4 Used)
Drive Pinion
Bearing
Shim

WCGB-03-05-015

26

22 23 24 25 26 27 28 -

Spacer
Bearing
Seal
Guard
Flange
Washer
Nut

UNDERCARRIAGE / Axle
Assembly of Differential
1. Install spring pins (17, 18) (4 used for each) to
differential case (2).

6. Install shim (21) and bearing (23) to drive pinion

(19).

2. Secure differential case (2) in a vise. Install bevel

gear (1) to differential case (2).

7. Install the outer race of bearing (20) to drive

pinion (19).

IMPORTANT: Install washers (3, 11) and washers

(7) (2 used) with the lugs facing
upward.
3. Install washers (3, 6, 7, 11) (2 used for each),
pinion gears (5, 8) (2 used for each), side gears (4,
10) (2 used for each) and spiders (9, 16) to
differential case (2).

8. Install the inner race of bearing (20) to drive pinion

(19).

4. Install differential case (12) to the differential case

(2) assembly. Secure socket bolt (14) and washer
(15).
: 10 mm
: 90 Nm (9 kgfm, 66 lbfft)

9. Install spacer (22) to drive pinion (19).

10. Install drive pinion (19) to drive housing (13).
11. Install guard (26) and flange (25) to drive housing
(13).
12. Install washer (27) and nut (28) to drive pinion
(19).
: 41 mm
: 1050 Nm (105 kgfm, 770 lbfft)

5. Secure the differential in a vise. Install the inner

races of bearings (29, 30).
30

Differential

29

WCGB-03-05-014

W3-5-45

UNDERCARRIAGE / Axle
DISASSEMBLY OF STEERING CYLINDER
1

T1GL-03-05-020

Connection
Part

10

Connection Part

11

15

14

13

12

16

19

18

17

20
WCGB-03-05-016

12345-

Axle Casing
Drive Housing
Tie Rod
Piston Rod
Retaining Ring

6 - U-Ring
7 - Wiper Ring
8 - O-Ring
9 - Guide Ring
10 - Piston

11 12 13 14 15 -

W3-5-46

Rod
Wiper Ring
U-Ring
Retaining Ring
Flange

16 17 18 19 20 -

Cylinder Tube
Guide Ring
Guide Ring
Seal
Bolt (5 Used)

UNDERCARRIAGE / Axle
Disassembly of Steering Cylinder
1. Remove nut (21). Remove tie rod (3) from axle
casing (1).
: 41 mm
3

21

5. Remove bolts (20) (5 used). Warm up the

connection part of the piston rod (4) assembly and
drive housing (2) by using a drier.
6. Tap and remove the piston rod (4) assembly from
drive housing (2) by using a plastic hammer.
7. Remove bolts (20) (5 used). Remove flange (15)
and retaining ring (14) from the piston rod (4)
assembly.

1
WCGB-03-05-017

2. Warm up the connection part of piston rod (4) and

tie rod (3) by using a drier. Attach a spanner onto
the connection part. Remove tie rod (3) from
piston rod (4).
: 46 mm

8. Remove retaining ring (5) from the piston rod (4)

assembly. Tap piston (10) to the position where
O-ring (8) can be removed by using a plastic
hammer. Remove O-ring (8) from the piston rod
(4) assembly.
9. Remove rod (11) and piston (10) from cylinder
tube (16). Remove piston (10) from rod (11).

3. Remove other tie rod (3) in the same way as steps

1 to 2.

10. Remove U-ring (13) and wiper ring (12) from

cylinder tube (16).

4. Remove elbows (22) (2 used) from drive housing

(2).

11. Remove U-ring (6), wiper ring (7), guide rings (9,
17, 18) and seal (19) from piston (10) and rod
(11).

22

1
4
Connection
Part
WCGB-03-05-018

W3-5-47

UNDERCARRIAGE / Axle
ASSEMBLY OF STEERING CYLINDER
1

T1GL-03-05-020

11

12345-

Axle Casing
Drive Housing
Tie Rod
Piston Rod
Retaining Ring

15

Connection
Part

14

16

Connection Part

19 18 17

13

12

T21W-03-05-020

10

6 - U-Ring
7 - Wiper Ring
8 - O-Ring
9 - Guide Ring
10 - Piston

11 12 13 14 15 -

NOTE: As for the item with mark*, refer to W3-5-46.

W3-5-48

Rod
Wiper Ring
U-Ring
Retaining Ring
Flange

16 - Cylinder Tube
17 - Guide Ring
18 - Guide Ring
19 - Seal
20* - Bolt (5 Used)

UNDERCARRIAGE / Axle
Assembly of Steering Cylinder
1. Install U-ring (13) and wiper ring (12) to cylinder
tube (16).

9. Install elbows (22) (2 used) to drive housing (2).

2

2. Install U-ring (6), wiper ring (7), guide rings (9, 17,
18) and seal (19) to piston (10) and rod (11).
3. When installing the rod (11) assembly to cylinder
tube (16), apply hydraulic oil onto the seals. Install
the rod (11) assembly to cylinder tube (16).

22

4. When installing piston (10) to rod (11), apply

hydraulic oil onto the seals. Install piston (10) to
rod (11). Push piston (10) to the position where
O-ring (8) can be installed.

4
Connection Part
WCGB-03-05-018

5. Install retaining ring (5) to the piston rod (4)

assembly.
6. Install flange (15) and retaining ring (14) to the
piston rod (4) assembly.
7. Apply LOCTITE #574 onto the drive housing (2)
contact surface (2 places) on the piston rod (4)
assembly. Install piston rod (4) to drive housing
(2).
8. Apply LOCTITE #243 onto bolt (20). Install bolts
(20) (5 used).
: 19 mm
: 79 Nm (7.9 kgfm, 58 lbfft)

IMPORTANT: Check the direction to install tie rod

(3).
10. Apply LOCTITE #243 onto the tie rod (3)
connection part of piston rod (4). Attach a spanner
onto the connection part of piston rod (4) and tie
rod (3). Install tie rod (3) to piston rod (4).
: 46 mm
: 450 Nm (45 kgfm, 330 lbfft)
11. Secure tie rod (3) to axle casing (1) with nut (21).
: 41 mm
: 100 Nm (10 kgfm, 74 lbfft)
3

21

1
WCGB-03-05-017

12. Install other tie rod (3) in the same way as steps
10 to 11.

W3-5-49

UNDERCARRIAGE / Axle
(Blank)

W3-5-50

UNDERCARRIAGE / Axle Lock Cylinder

REMOVAL AND INSTALLATION OF AXLE
LOCK CYLINDER
CAUTION: Release any pressure in 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.
1

Removal
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

WCEB-03-06-001

WCEB-03-06-003

CAUTION: Axle lock cylinder (5) weight: 61

kg (134 lb)
3. Remove socket bolts (6) (3 used), washers (7) (3
used), bolt (8) and spacer (9) from axle lock
cylinder (5).
: 19 mm
: 36 mm

5
Pulling-Out Hole

6, 7
9
Pulling-Out Hole

WCEB-03-06-001

W3-6-1

UNDERCARRIAGE / Axle Lock Cylinder

10

CAUTION: Axle lock cylinder (5) weight: 61

kg (134 lb)
4. Install the bolts (M12, Pitch 1.75 mm) (2 used) into
the pulling-out hole on axle lock cylinder (5).
Tighten the bolts (2 used) alternately. Remove axle
lock cylinder (5) from track frame (10).
: 19 mm

5
Pulling-Out Hole

Pulling-Out Hole

WCEB-03-06-001

W3-6-2

UNDERCARRIAGE / Axle Lock Cylinder

Installation
CAUTION: Axle lock cylinder (5) weight: 61
kg (134 lb)

10

1. Apply LOCTITE #262 onto socket bolts (6) (3

used) and bolt (8).
2. Hoist and align axle lock cylinder (5) with the
mounting hole on track frame (10). Install axle lock
cylinder (5) to track frame (10) with socket bolts (6)
(3 used), washers (7) (3 used), bolt (8) and spacer
(9).
: 19 mm
: 950 Nm (97 kgfm, 701 lbfft)
: 36 mm
: 950 Nm (97 kgfm, 701 lbfft)

6, 7

WCEB-03-06-001

3. Remove eyebolts (2 used) from axle lock cylinder

(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 Nm
(3 to 3.5 kgfm, 22 to 25 lbfft)

WCEB-03-06-003

5. Connect hoses (1) (2 used) to operate check valve

(3).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

WCEB-03-06-001

W3-6-3

UNDERCARRIAGE / Axle Lock Cylinder

DISASSEMBLY AND ASSEMBLY OF AXLE
LOCK CYLINDER

8, 9

10
A

6
8, 9

10

5
4
3
2

View A

123-

WCEB-03-06-003

WCEB-03-06-002

Retaining Ring
Dust Seal
Air Ring (4 Used)

456-

Dust Seal
Seal Ring
Rod

78-

W3-6-4

Housing
Operate Check Valve

9 - O-Ring
10 - Socket Bolt (4 Used)

UNDERCARRIAGE / Axle Lock Cylinder

Assembly of Axle Lock Cylinder

Disassembly of Axle Lock Cylinder

CAUTION: Axle lock cylinder weight: 61 kg
(134 lb)
1. Place the axle lock cylinder onto the workbench
horizontally.
2. Remove socket bolts (10) (4 used) from operate
check valve (8). Remove operate check valve (8)
and O-ring (9) from housing (7).

1. Install seal ring (5), dust seal (4) and air rings (3)
(4 used) to housing (7).
2. Install dust seal (2) and retaining ring (1) to
housing (7).
IMPORTANT: Apply hydraulic oil onto the inner
surface of housing (7), dust seals (2,
4), seal ring (5) and air ring (3).
3. Install rod (6) to housing (7).

3. Apply air to the port hole on housing (7) and

remove rod (6).
4. Remove retaining ring (1) and dust seal (2) from
housing (7).
5. Remove air rings (3) (4 used), dust seal (4) and
seal ring (5) from housing (7).

CAUTION: Axle lock cylinder weight: 61 kg

(134 lb)
4. Install operate check valve (8) to housing (7) with
socket bolts (10) (4 used) and O-ring (9).
: 6 mm
: 29.4 to 34.3 Nm
(3 to 3.5 kgfm, 22 to 25 lbfft)

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.)
Removal
1. Disconnect hoses (1) (2 used) from operate check
valve (3). Cap the open ends.
: 19 mm

3, 4

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. 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) with socket bolts (2) (4 used).
: 6 mm
: 29.4 to 34.3 Nm
(3 to 3.5 kgfm, 22 to 25 lbfft)

3, 4

3. Connect hoses (1) (2 used) to operate check valve

(3).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
WCEB-03-06-001

W3-7-1

UNDERCARRIAGE / Operate Check Valve

STRUCTURE OF OPERATE CHECK VALVE (FOR AXEL LOCK CYLINDER)

10

11

12

13

WCEB-03-06-004

No.
1
2
3
4
5
6
7
8
9
10
11
12
13

Part Name
Plug
O-Ring
Plug
O-Ring
Piston
Body
Poppet
Sleeve
Spring
O-Ring
Plug
O-Ring
Plug

Qty
1
1
1
1
1
1
1
1
1
1
1
1
1

Wrench Size
(mm)
: 6.2

Nm
20.5

Tightening Torque
(kgfm)
(lbfft)
(0.20.05) (1.50.4)

Remark
1A P11

: 27

12012

(121.2)

(899)
1B P18

1B P11
: 36

50050

(515)

(36937)
1B P26

:6

34.33.4

W3-7-2

(3.50.3)

(252.5)

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

cannot be removed. Remove the
plate (2) assembly.

Solenoid Valve Unit

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
valve units (4) (2 used).
3. Remove sems bolts (7) (4 used) from plate (2).
Remove the plate (2) assembly from track frame
(6).
: 17 mm

W1F3-04-04-004

Solenoid Valve Unit

3 Solenoid Valve Unit

4. Remove sems bolts (5) (4 used) from plate (2).

Remove solenoid valve units (4) (2 used) from
plate (2).
: 17 mm

W3-8-1

4, 5

WCEB-03-08-001

UNDERCARRIAGE / Solenoid Valve

Installation
1. Install solenoid valve units (4) (2 used) to plate (2)
with sems bolts (5) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

Solenoid Valve Unit

Solenoid Valve Unit

2. Install the plate (2) assembly to track frame (6)

with sems bolts (7) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)
3. Connect hoses (3) (8 used) to solenoid valve units
(4) (2 used).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)

W1F3-04-04-004

4. Connect connectors (1) (4 used) to solenoid valve

units (4) (2 used).
Solenoid Valve Unit

Solenoid Valve Unit

W3-8-2

4, 5

WCEB-03-08-001

UNDERCARRIAGE / Solenoid Valve

STRUCTURE OF SOLENOID VALVE UNIT

T1F3-03-08-001

5
6

No.
1
2
3
4
5
6

Part Name
Solenoid
Piston
O-Ring
Body
Spool
Spring

Qty

Wrench
Size (mm)

Nm

2
2
2
1
2
2

Tightening Torque
(kgfm)
(lbfft)

Remarks

1B P14

W3-8-3

UNDERCARRIAGE / Solenoid Valve

(Blank)

W3-8-4

UPPERSTRUCTURE / Transmission Changeover Solenoid Valve

REMOVAL 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.)

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
transmission changeover solenoid valve (3).
Remove transmission changeover solenoid valve
(3) from bracket (5).
: 6 mm

Installation
1. Install transmission changeover solenoid valve (3)
to bracket (5) with socket bolts (4) (3 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)

WCEB-03-09-001

2. Connect hoses (2) (4 used) to transmission

changeover solenoid valve (3).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
3. Connect connectors (1) (2 used) to transmission
changeover solenoid valve (3).

W3-9-1

WCEB-03-09-001

UPPERSTRUCTURE / Transmission Changeover Solenoid Valve

(Blank)

W3-9-2

LOWERSTRUCTURE / Propeller Shaft

REMOVEAL AND INSTALLATION
PROPELLER SHAFT

OF

Preparation
1. Place 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.
WCJB-03-10-004

W3-10-1

LOWERSTRUCTURE / Propeller Shaft

Removal and Installation of Propeller Shaft
Front Axle

5
3
Rear Axle

6
8

B
A

C
D

W1GL-03-08-001

10
1

View A

WCJB-03-10-001

View B

12

11

WCJB-03-10-002

View D

WCJB-03-10-003

13

3
Detail C

1234-

Flange
Nut (8 Used)
Propeller Shaft
Socket Bolt (4 Used)

5678-

14

15

16

Detail B
WCJB-03-10-005

Sems Bolt (2 Used)

Bracket
Flange
Propeller Shaft

910 11 12 -

W3-10-2

Nut (8 Used)
Flange
Bearing Assembly
Yoke

13 14 15 16 -

Nut
Spline Seal
Grease Fitting
Fork

WCEB-03-10-007

LOWERSTRUCTURE / Propeller Shaft

Removal
1. Remove grease fitting (15) from propeller shaft
(3).
: 10 mm

5. Remove nuts (9) (8 used) from the flange part of

propeller shaft (8).
: 14 mm

IMPORTANT: Propeller shaft (3) cannot be

removed individually. If removing
propeller shaft (3) individually,
spline seal (14) is damaged. Remove
the propeller shaft (3) assembly.
2. Remove nuts (2) (8 used) from the flange part of
propeller shaft (3).
: 14 mm

6. Remove sems bolts (5) (2 used) from bracket (6).

Place bearing assembly (11) onto bracket (6).
: 17 mm

3. Insert a pry bar between flange (1) and the flange

part of propeller shaft (3). Pry propeller shaft (3)
toward fork (16) and place propeller shaft (3) on
the ground.
4. Remove socket bolts (4) (4 used) from the flange
part of propeller shaft (3). Remove propeller shaft
(3) from flange (7).
: 8 mm

7. Move propeller shaft (8) toward bracket (6) side.

Pull out propeller shaft (8).
IMPORTANT: Do not remove bearing assembly
(11)
unless
necessary.
When
removing bearing assembly (11),
follow the procedure below. Dispose
removed bearing assembly (11).
8. Remove nut (13) from propeller shaft (8).
Remove yoke (12) from propeller shaft (8).
: 32 mm
9. Remove bearing assembly (11) from propeller
shaft (8).

W3-10-3

LOWERSTRUCTURE / Propeller Shaft

Front Axle

5
3
Rear Axle

6
8

B
A

C
D

W1GL-03-08-001

10
1

View A

WCJB-03-10-001

View B

12

11

WCJB-03-10-002

View D

WCJB-03-10-003

13

3
Detail C

14

15
Detail B

WCJB-03-10-005

W3-10-4

16

WCEB-03-10-007

LOWERSTRUCTURE / Propeller Shaft

Installation
1. Install bearing assembly (11) to propeller shaft
(8).
2. Install yoke (12) to propeller shaft (8). Secure
yoke (12) to propeller shaft (8) with nut (13).
: 32 mm
: 370 to 440 Nm (38 to 45 kgfm, 273 to
325 lbfft)
3. Apply LOCTITE #262 onto nuts (9) (8 used).
4. Insert the yoke (12) mounting side of propeller
shaft (8) into bracket (6). Install the flange part of
propeller shaft (8) to flange (10). Install propeller
shaft (8) to flange (10) with nuts (9) (8 used).
: 14 mm
: 76 Nm (7.8 kgfm, 56 lbfft)

6. Apply LOCTITE #262 onto socket bolts (4) (4

used). Align the flange part of propeller shaft (3)
with the mounting hole on flange (7). Secure
propeller shaft (3) to flange (7) with socket bolts
(4) (4 used).
: 8 mm
: 62 Nm (6.3 kgfm, 46 lbfft)
7. Apply LOCTITE #262 onto nuts (2) (8 used).
Align the flange part of propeller shaft (3) with the
mounting hole on flange (1). Secure propeller
shaft (3) to flange (1) with nuts (2) (8 used).
: 14 mm
: 76 Nm (7.8 kgfm, 56 lbfft)
8. Install grease fitting (15) to fork (16). Apply
grease.

5. Apply LOCTITE #262 onto sems bolts (5) (2

used). Install the propeller shaft (8) assembly to
bracket (6) with sems bolts (5) (2 used).
: 17 mm
: 50 Nm (5 kgfm,37 lbfft)

W3-10-5

LOWERSTRUCTURE / Propeller Shaft

(Blank)

W3-10-6

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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

Release Procedure .............................. W4-1-1
Removal and Installation of
Front Attachment .................................. W4-1-2
Maintenance Standard ......................... W4-1-12
Standard Dimensions for
Arm and Bucket Connection .............. W4-1-15
Standard Dimensions for
Arm and Boom Connection ................ W4-1-16

Hydraulic Circuit Pressure

Release Procedure ...............................W4-3-1
Removal and Installation of Hose
Rupture Valve for Arm Cylinder ............W4-3-2
Removal and Installation of Hose Rupture
Valve for Positioning Cylinder ...............W4-3-3
Removal and Installation of Hose
Rupture Valve for Boom Cylinder .........W4-3-5
Structure of Hose Rupture Valve
for Arm Cylinder ....................................W4-3-8
Structure of Hose Rupture Valves
for Boom Cylinder ...............................W4-3-12
Structure of Hose Rupture Valves
for Positioning Cylinder.......................W4-3-16

Group 2 Cylinder
Hydraulic Circuit Pressure
Release Procedure .............................. W4-2-1
Removal and Installation of Cylinder ..... W4-2-2
Disassembly of Boom, Arm and
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

Group 4 Operate Check Valve

CJBW-4-1

Remove and Install Operate Check

Valve (for Blade and Outrigger) ............W4-4-1
Structure of Operate Check Valve ..........W4-4-3

(Blank)

CJBW-4-2

FRONT ATTACHMENT / Front Attachment

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, 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.

W4-1-1

Engine Stop Switch

WCEB-02-01-002

FRONT ATTACHMENT / Front Attachment

REMOVAL AND INSTALLATION
FRONT ATTACHMENT

OF

Removal
1. As for the lubrication hoses to the front attachment, disconnect hoses (1) (2 used) to the boss
at the boom cylinder (3) rod side from the
adapter.
: 17 mm

2. Remove nuts (7) (4 used) from bolts (4) (2 used).

Remove bolts (4) (2 used) and stoppers (5) (2
used) from pin (6).
: 24 mm
CAUTION: Boom cylinder (3) weight:
Mono block boom: 172kg (380 lb)
2-piece boom: 161kg (360 lb)

3
WCGB-04-01-001

5
6

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.
3. Attach a nylon sling onto the end of the boom
cylinder (3) tube. Hoist and hold the boom cylinder (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

WCGB-04-01-002

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 retract 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.
5. Remove boom cylinder (3) from the boom.
Refer to Removal of Boom Cylinder on W4-2-10.

Stand

3
Wire

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 fly off
suddenly.

7. Slowly tap and remove pin (6) by using a bar and

a hammer. Remove thrust plate (2).
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
RELEASE PROCEDURE on W4-1-1.

WCGB-04-01-002

Air Bleed Valve

Cap
Hydraulic
Oil Tank

WCJB-01-04-002

9. Disconnect hoses (8) (6 used), (9) (4 used) (2)

from the bucket cylinder and the arm cylinder.
Cap the disconnected hoses and pipings.
: 19 mm, 27 mm, 36 mm, 41 mm
NOTE: The number of the hoses may differ depending on the front attachment specifications.
8
WCJB-04-01-001

W4-1-3

FRONT ATTACHMENT / Front Attachment

10. Open cover (10).

10

WCEB-02-05-002

11. Remove sems bolts (12) (4 used) from cover

(13).
: 17 mm

11

12

13

12. Remove sems bolts (16) (5 used) from cover

(15).
: 17 mm

14

16

13. Remove cover (13) from cover (11), bracket (14)

and support (117).
13

15

WCJB-04-01-002

12
15
16

17

WCJB-04-01-003

18
WCJB-04-01-004

14. Disconnect harness (20) from clips (21) (4 used)

at the back of cover (15).
15. Remove sems bolts (22) (2 used) from bracket
(19). Remove cover (15) from bracket (19) cover
(18).

19

20

15
21

22

WCJB-04-01-005

W4-1-4

FRONT ATTACHMENT / Front Attachment

CAUTION: Boom foot pin (26) weight: 46 kg

26

16. Remove bolt (23), spring washer (27), plate (24)

and block (25) from the plate of boom foot pin
(26).
: 27 mm
25
24
23
27
W178-04-01-001

Mono block Boom

CAUTION: Front attachment weight:

Mono block boom: 3430 kg (7570lb)
2-piece boom: 4190 kg (9240 lb)

Boom

17. Attach a wire rope onto the boom. Hoist and hold
the boom.

WCJB-02-03-001

2-Piece Boom
Boom

WCJB-02-03-002

W4-1-5

FRONT ATTACHMENT / Front Attachment

CAUTION: Boom foot pin (26) weight: 46 kg
18. Insert a pry bar between the plate of boom foot
pin (26) and the bracket. Pull out the plate a little.
: 30 mm
19. While turning the plate gradually by hand, remove boom foot pin (26).
NOTE: When boom foot pin (26) cannot be removed, adjust the position by using a lifting
rope for the front attachment.

26

Plate

20. Hoist the front attachment assembly and move

the machine backward.
21. Place a wooden block. Lower the front attachment assembly onto the wooden block.

W4-1-6

Insert a Bar.
Bracket

W178-04-01-001

FRONT ATTACHMENT / Front Attachment

Installation
Mono block Boom
Boom

CAUTION: Front attachment weight:

Mono block boom: 3430 kg (7570lb)
2-piece boom: 4190 kg (9240 lb)
1. Hoist the front attachment assembly and move
the machine forward. Align the boom foot with the
mounting hole on the frame.
Insert the thrust plate into the left and right sides
of the boom. Adjust the clearance between the
plate and the frame within 1 mm (0.04 in).
(Adjust the position by using a lifting rope for the
front attachment.)

WCJB-02-03-001

2-Piece Boom
Boom

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.
CAUTION: Boom foot pin (26) weight: 46 kg
(101 lb)
2. Install boom foot pin (26).Secure boom foot pin
(26) to the main frame with bolt (23), washer (27).
Plate (24) and block (25).
: 27 mm
: 400 Nm (41 kgfm, 295 lbfft)

WCJB-02-03-002

26

25
24
23
27
W178-04-01-001

W4-1-7

FRONT ATTACHMENT / Front Attachment

3. Install cover (15) to bracket (19) with sems bolts
(22) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

19

20

15
21

4. Secure harness (20) to cover (15) with clips (21)

(4 used).
22

WCJB-04-01-005

5. Align cover (13) with the mounting holes on cover

(11), bracket (14) and support (17).Install cover
(13) to cover (11), bracket (14) and support (17)
with sems bolts (12) (4 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

13

12
15
16

17

WCJB-04-01-003

18
WCJB-04-01-004

6. Install cover (15) to covers (13, 18) with sems

bolts (16) (5used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

11

12

13

14

16

15

WCJB-04-01-002

7. Shut cover (10).

10

WCEB-02-05-002

W4-1-8

FRONT ATTACHMENT / Front Attachment

8. Remove the caps from the hoses and the pipings.
Connect hoses (8) (6 used) and hoses (9) (4
used) to the bucket cylinder and the arm cylinder.
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 151 lbfft)

CAUTION: Boom cylinder (3) weight:

Mono block boom: 172kg (380 lb)
2-piece boom: 161kg (360 lb)

WCJB-04-01-001

9. 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 protection, such as goggles, hard hats, etc in order
to prevent personal injury.

10. 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
with the mounting hole on the boom.
11. Insert thrust plate (2) between the boom and
boom cylinder (3), and between boom cylinder
(3) and collar (5). Install pin (6). Install boom cylinder (3) to the both sides.
12. 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 Nm (27.5 kgfm, 200 lbfft)

WCEB-04-01-003

5
7
W178-04-01-004

W4-1-9

FRONT ATTACHMENT / Front Attachment

13. Connect lubrication hoses (1) (2 used) to the
boom cylinder (3) rod side.
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)

3
WCGB-04-01-001

14. Apply grease onto the boom cylinder (3) rod side,
the bottom side and the boom foot side.

Left Boom Cylinder

Rod Side
Boom Foot Side

Arm Cylinder
Bottom Side

Right Boom
Cylinder
Rod Side

WCGB-04-01-004

W4-1-10

FRONT ATTACHMENT / Front Attachment

CAUTION: Arm bucket assembly weight:
Mono block boom: 1650 kg (3640 lb)
2-piece boom : 1560 kg (3440lb)

Mono block Boom

Boom

IMPORTANT: When removing the arm from the

boom, perform the following steps
when installing the arm.
15. Install thrust plates (28) to the left and right sides
of the arm. Adjust total clearance of the left and
right sides within 1.5 mm (0.06 in).

Arm

16. After installing the arm, apply grease onto grease

fitting (29) in the boom connecting boss of the
arm.
IMPORTANT: For handling of HN bushing for the
front attachment, check the followings.
Precautions when installing the bushing
If a hammer is used, the bushing may be damaged.
Use a press.

WCJB-02-03-001

Piece Boom

Boom

Arm

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.
WCJB-02-03-002

Use the special tool when removing or installing the

bushing.
Special tool: ST 1454

23

23

24

24

M157-07-157

W4-1-11

FRONT ATTACHMENT / Front Attachment

MAINTENANCE STANDARD
Pin and Bushing
F

F
C

E
A
B

E
D
G

C
D
E

A
B

K
J
H

WCJB-02-03-001

Part Name

D
I

Pin
Bushing
Pin
Boss (Main Frame)
Bushing (Boom Cylinder)
Pin
Bushing (Boom Cylinder)
Boss (Boom)
Pin
Bushing
Pin
Boss (Arm)
Bushing (Arm Cylinder)
Pin
Boss (Boom)
Bushing (Arm Cylinder)

Standard
90 (3.5)
90 (3.5)
80 (3.1)
80 (3.1)
80 (3.1)
90 (3.5)
90 (3.5)
90 (3.5)
90 (3.5)
90 (3.5)
80 (2.8)
80 (2.8)
80 (2.8)
80 (2.8)
80 (2.8)
80 (2.8)

W4-1-12

Allowable Limit
89.0 (3.5)
91.5 (3.6)
79.0 (3.1)
81.5 (3.2)
81.5 (3.2)
89.0 (3.5)
91.5 (3.6)
91.5 (3.6)
89.0 (3.5)
91.5 (3.6)
79.0 (3.1)
81.5 (3.2)
81.5 (3.2)
79.0 (3.1)
81.5 (3.2)
81.5 (3.2)

WCJB-02-03-002

Unit: mm (in)
Remedy

Replace

FRONT ATTACHMENT / Front Attachment

Part Name
G

H
I
J
K
L
M

Standard
71 (2.8)
71 (2.8)
71 (2.8)
80 (3.1)
80 (3.1)
80 (3.1)
71 (2.8)
71 (2.8)
80 (3.1)
80 (3.1)
80 (3.1)
80 (3.1)
100 (3.9)
100 (3.9)
100 (3.9)
100 (3.9)

Pin
Boss (Arm)
Bushing (Bucket Cylinder)
Pin
Bushing
Bushing (Bucket Cylinder)
Pin
Bushing
Pin
Bushing
Pin
Bushing
Pin
Bushing
Pin
Bushing

IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a
press and special tool (ST 1454).

W4-1-13

Allowable Limit
70.0 (2.9)
72.5 (2.9)
72.5 (2.9)
79.0 (3.1)
81.5 (3.2)
81.5 (3.2)
70.0 (2.9)
72.5 (2.9)
79.0 (3.1)
81.5 (3.2)
79.0 (3.1)
81.5 (3.2)
99.0 (3.9)
101.5 (4.0)
99.0 (3.9)
101.5 (4.0)

Unit: mm (in)
Remedy

Replace

FRONT ATTACHMENT / Front Attachment

Point

W105-04-01-020

A
B
C
D

Standard
215
95 (3.7)
108
95

Allowable Limit
107.5 (4.2)
-

Unit: mm (in)
Remedy
Replace

Side Cutter
B

C
D
A

W155-04-01-002

A
B
C
D

Standard
278 (10.9)
295 (11.6)
433 (17)
135 (5.3)

Allowable Limit
181 (7.0)
-

W4-1-14

Unit: mm (in)
Remedy
Replace

FRONT ATTACHMENT / Front Attachment

STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION

Section A

Section B
W1CF-04-01-007

a
b
c
d
e
f
g
h
i
j
k
l
m
n
o
p
q

Unit: mm (in)
450 (17.7)
0
604 (23.8)
580 (22.8)
1471 (57.9)
433 (17)
305.5 (12)
80 (3.2)
475 (18.7)
31 (1.2)
433 (17)
307 (12)
80 (3.2)
3.7
3.7
449 (17.7)

W4-1-15

FRONT ATTACHMENT / Front Attachment

STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION

C
WCJB-04-01-006

Section C
W1GL-04-01-010

s
t
u

Unit: mm (in)
90 (3.5)
352 (13.9)
490 (19.3)

W4-1-16

FRONT ATTACHMENT / Cylinder

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, 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.

W4-2-1

Engine Stop Switch

WCEB-02-01-002

FRONT ATTACHMENT / Cylinder

REMOVAL AND INSTALLATION OF CYLINDER

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

2. Stop the engine. Push the air bleed button and

bleed air from the hydraulic oil tank. Remove the
cap.
Release the pressure in the bucket circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.

3
W554-04-02-006

CAUTION: Before removing pin (7), fasten

the link by using a wire in order not to fall
off.
4

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.

3. Remove nuts (6) (2 used) and bolt (4). Remove

pin (7) by tapping. Remove thrust plates (5) (4
used).
: 30 mm
4. In order not to extend rod (8) of bucket cylinder
(1), pass wire (9) through the cylinder rod hole
and secure to the bucket cylinder (1) tube.

6
W158-04-02-006

W4-2-2

W102-04-02-005

FRONT ATTACHMENT / Cylinder

5. Disconnect bucket cylinder hoses (12) (2 used)
at the bottom of bucket cylinder (1). Cap the open
ends
: 30 mm

10

CAUTION: Bucket cylinder (1) weight: 150

kg (340 lb)

15

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.
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).
: 24 mm

11
13

7. Remove bucket cylinder (1).

12

W4-2-3

W187-04-02-004

FRONT ATTACHMENT / Cylinder

Installation of Bucket Cylinder

10

CAUTION: Bucket cylinder (1) weight: 150

kg (340 lb)
CAUTION: Metal fragments may fly off when
a hammer is used when installing pin (11).
Wear necessary protection, such as goggles,
hard hats, etc in order to prevent personal
injury.

15
14

11

13

1. Hoist bucket cylinder (1). Align the hole on the

cylinder tube side with the cylinder mounting hole
on the arm. Install thrust plates (10) (2 used) and
pin (11).
1

Arm

2. Install stopper (14) and pin (11) to the arm. Secure with bolt (15) and nuts (13) (2 used).
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)
3. Connect bucket cylinder hoses (12) (2 used).
: 36 mm
: 175 Nm (18 kgfm, 140 lbfft)

12

W187-04-02-004

4. Remove wire (9) from rod (8) of bucket cylinder

(1).

W4-2-4

W102-04-02-005

FRONT ATTACHMENT / 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.

16

17

18

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
nuts (6) (2 used).
: 30 mm
: 550 Nm (56 kgfm, 410 lbfft)
IMPORTANT: In case link (18) has been removed
from the arm, insert thrust plate (19)
when installing link (18).
IMPORTANT: After completing the work, add hydraulic oil to the specified level.
Operate bucket cylinder (1) to the
stroke end several times and bleed
air from the circuit.
At the same time, check each connection of the hoses for any oil
leaks.

W4-2-5

6
W158-04-02-006

19

19

18

18

W157-04-01-015

FRONT ATTACHMENT / Cylinder

Removal of Arm Cylinder

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
cap.
Release the pressure in the arm circuit.
Refer to HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-2-1.

3. Remove nuts (8) (2 used) and bolt (10) from pin

(5) at the rod side in arm cylinder (1).
: 30 mm

10

W187-04-02-005

5
1

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.
4. Remove pin (5) by tapping. Remove thrust plates
(4) (4 used).
8
W187-04-02-006

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.

W4-2-6

W187-04-02-010

FRONT ATTACHMENT / Cylinder

6. Disconnect pipings (11) (2 used) at the bottom of
arm cylinder (1). Cap the open ends. (When a
hose rupture valve is provided, refer to REMOVAL AND INSTALLATION OF HOSE RUPTURE VALVE on W4-3-1.)
: 36 mm, 41 mm
7. Disconnect lubrication hose (12) from arm cylinder (1).
: 17 mm

1
11

12

CAUTION: Arm cylinder (1) weight: 255 kg

(570 lb)
8. Attach a nylon sling at the center of gravity of arm
cylinder (1). Hoist and hold arm cylinder (1).

WCGB-04-01-001

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.
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

CAUTION: Arm cylinder (1) weight: 255 kg

(5700 lb)

16

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.

W4-2-8

15

W187-04-02-007

1
11

2. Install thrust plate (13) and pin (14). Secure pin

(14) and stopper (16) with bolt (17) and nuts (15)
(2 used).
: 30 mm
: 550 Nm (56 kgfm, 410 lbfft)

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine and check for
any oil leaks at the hose connections.

14

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.

3. Connect lubrication hose (12) and pipings (11) (2

used) of arm cylinder (1).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 129 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 151 lbfft)

13

12

WCGB-04-01-001

FRONT ATTACHMENT / Cylinder

4. Remove wire (7) from rod (6) of arm cylinder (1).
Hold arm cylinder (1) and start the engine. Operate the lever and align the hole at the rod (6) side
with the mounting hole on arm (18).
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.

5. Install thrust plate (4) and pin (5). Secure pin (5)
and stopper (9) with bolt (10) and nuts (8) (2
used).
: 30 mm
: 550 Nm (56 kgfm, 410 lbfft)
IMPORTANT: When completing the work, operate
arm cylinder (1) to the stroke end
several times and bleed air from the
circuit.

3
9

10

W187-04-02-010

18

8
W187-04-02-006

W4-2-9

FRONT ATTACHMENT / Cylinder

Removal of Boom Cylinder
1

1. Disconnect lubrication hose (1) from boom cylinder (2).

: 17 mm
CAUTION: Boom cylinder (2) weight:
Monoblock boom: 175 kg (390 lb)
2-piece boom: 165 kg (370 lb)

2. Attach a wire rope onto boom cylinder (2). Hoist

and hold boom cylinder (2).

Boom

WCGB-04-01-002

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.
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
used).
: 30 mm

4. Place the rod side of boom cylinder (2) on a

stand. Remove other boom cylinder (2) in the
same way.

5. Operate the lever and retract boom cylinder (2).

In order not to extend the rod, pass a wire
through the rod hole and secure to the cylinder
tube.

2
W158-04-02-013

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.

Stand

2
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 cylinder (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
a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order
to prevent personal injury.
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).
: 24 mm

2
W105-04-02-036

11

CAUTION: Boom cylinder (2) weight:

Monoblock boom: 175 kg (390 lb)
2-piece boom: 165 kg (370 lb)

9
12

9. Attach a wire rope at the center of gravity of

boom cylinder (2). Hoist and remove boom cylinder (2).
Remove other boom cylinder (2) in the same
way.

10

10
W178-04-02-009

2
W105-04-02-040

W4-2-11

FRONT ATTACHMENT / Cylinder

Installation of Boom Cylinder
CAUTION: Boom cylinder (2) weight:
Monoblock boom: 175 kg (390 lb)
2-piece boom: 165 kg (370 lb)
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
a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order
to prevent personal injury.
2. Install thrust plate (11) and pin (9). Secure with
bolt (8) and nuts (10) (2 used).
: 24 mm
: 270 Nm (27.5 kgfm, 200 lbfft)

2
W105-04-02-040

11

3. Install other boom cylinder (2) in the same way.

4. Connect hoses (12) (4 used) to boom cylinders
(2) (2 used).
: 36 mm
: 175 Nm (18 kgfm, 130 lbfft)
IMPORTANT: Fill hydraulic oil to the specified
level. Start the engine and check for
any oil leaks at the hose connections.

W4-2-12

9
9
12

10

10
W178-04-02-009

FRONT ATTACHMENT / Cylinder

5. Hoist boom cylinder (2). Start the engine. Operate 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 protection, such as goggles, hard hats, etc in order
to prevent personal injury.
6. Insert thrust plate (3) and install pin (4).

7. Secure pin (4) and stopper (6) with bolt (7) and
nut (5).
: 30 mm
: 550 Nm (56 kgfm, 410 lbfft)

2
W158-04-02-013

8. Connect lubrication hose (1).

: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)

7
4
6

9. Install other boom cylinder (2) in the same way.

IMPORTANT: When completing the work, operate
boom cylinder (2) to the stroke end
several times and bleed air from the
circuit.

W4-2-13

2
Boom

WCGB-04-01-002

FRONT ATTACHMENT / Cylinder

Removal of Positioning Cylinder
(2-Piece Boom Only)
1. Disconnect lubrication hose (1) from positioning
cylinders (3) (2 used).
: 17 mm, 19 mm

CAUTION: Positioning cylinder (3) weight:

170 kg (375 lb)
2. Attach a nylon sling onto positioning cylinder (3).
Hoist and hold positioning cylinder (3).

3
6, 7

4, 5

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.
3. Remove nuts (7) (2 used) and bolt (6) from stopper (4) of the second boom.
: 30 mm

W1GL-04-01-008

4. Install pin (2) 160 mm by tapping. Remove thrust

plate (5).
5. Disconnect hoses (8) (3 used) and hoses (9) (3
used) from positioning cylinder (3). Cap the open
ends of the disconnected hoses.
: 22 mm, 36 mm

W4-2-14

W1GL-04-03-004

FRONT ATTACHMENT / Cylinder

6. Remove nuts (13) (2 used) and bolt (14) from
stopper (11) of the first boom.
Install pin (12) 160 mm by tapping by using a hammer and a bar. Remove thrust plate (10).
: 30 mm

10

CAUTION: Positioning cylinder (3) weight:

170 kg (375 lb)

11

7. Hoist and remove positioning cylinder (3).

3

8. Remove other positioning cylinder (3) in the

same way steps 2 to 7.

W4-2-15

14

13

12
W1GL-04-03-004

FRONT ATTACHMENT / Cylinder

Installation of Positioning Cylinder
(2-Piece Boom Only)
8

CAUTION: Positioning cylinder (3) weight:

170 kg (375 lb)
10

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. Hoist positioning cylinder (3). Align the pin holes
at the bottom side with those of the first boom.
Insert thrust plate (10) and install pin (12) by tapping.
2. Align the pin holes of stopper (11) and pin (12).
Install and secure with bolt (14) and nuts (13) (2
used).
: 30 mm
: 550 Nm (56 kgfm, 410 lbfft)
IMPORTANT: Fill hydraulic oil to the specified
level. Start the engine and check for
any oil leaks at the hose connections.
3. Connect hoses (8) (3 used) and hoses (9) (3
used) to positioning cylinder (3).
: 22 mm
: 39 Nm (4 kgfm, 29 lbfft)
: 36 mm
: 175 Nm (18 kgfm, 130 lbfft)

W4-2-16

11

14

13

12
W1GL-04-03-004

FRONT ATTACHMENT / Cylinder

4. Start the engine and extend positioning cylinder
(3). Align the rod hole of positioning cylinder (3)
with the hole of the second boom. Insert thrust
plate (5) and install pin (4) by tapping.

5. Align the pin holes of stopper (4) and pin (2). Install bolt (6) and nuts (7) (2 used).
: 30 mm
: 550 Nm (56 kgfm, 410 lbfft)
6. Connect lubrication hose (1) to positioning cylinder (3).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)

3
6, 7

IMPORTANT: When completing the work, operate

positioning cylinder (3) to the stroke
end several times and bleed air from
the circuit.

W4-2-17

4, 5

W1GL-04-01-008

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. Remove bolts (2) (4 used) and washers (3) (4
used) from cover (4). Remove cover (4) from
bracket (1).
: 19 mm

2, 3
4

WCEB-04-02-001

2. Disconnect hoses (5) (4 used) from blade cylinder

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

10
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).
Remove bolts (8) (2 used) from pins (9, 13). Remove pins (9, 13) from bracket (11) and link (12).
: 24 mm
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).

WCEB-04-02-002

7
12

13

W4-2-18

10

WCEB-04-02-001

FRONT ATTACHMENT / Cylinder

CAUTION: Blade cylinder (6) weight: 50 kg
(110 lb)

11

6. Remove blade cylinder (6) from bracket (11) and

link (12).
12

WCEB-04-02-002

Installation of Blade Cylinder

10

CAUTION: Blade cylinder (6) weight: 50 kg

(110 lb)

11

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 cylinder (6) to bracket (11) and link (12) with pins (9,
13).
3. Secure pins (9, 13) to bracket (11) and link (12)
with bolts (8) (2 used) and nuts (10) (4 used).
: 24 mm
: 210 Nm (21.5 kgfm, 155 lbfft)

WCEB-04-02-002

7
12

13

10

WCEB-04-02-001

4. Connect hoses (5) (4 used) to blade cylinder (6).

: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

WCEB-04-02-002

W4-2-19

FRONT ATTACHMENT / Cylinder

5. Install cover (4) to bracket (1) with bolts (2) (4
used) and washers (3) (4 used).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)

2, 3
4

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

4, 5, 6

2. Disconnect hoses (1) (4 used) from outrigger cylinder (2). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.
: 19 mm, 27 mm
3. Remove operate check valve (9) from outrigger
cylinder (2). (Refer to REMOVAL AND INSTALLATION OF OPERATE CHECK VALVE on
W4-4-1.)

7, 8

WCEB-04-02-004

4. Disconnect piping (7) from outrigger cylinder (2).

Remove O-ring (8) from piping (7).
: 6 mm
CAUTION: Outrigger cylinder (2) weight: 90
kg (200 lb)

5. Attach a nylon sling onto the rod side of the outrigger cylinder (2) tube. Hoist and hold outrigger
cylinder (2).

WCEB-04-02-003

W4-2-21

FRONT ATTACHMENT / Cylinder

CAUTION: Outrigger cylinder (2) weight: 90
kg (200 lb)

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).
: 19 mm

12
13, 14

7. Hoist outrigger cylinder (2) a little. Insert a wooden

block under outriger cylinder (2). Lower outrigger
cylinder (2).

CAUTION: The outrigger

weight: 145 kg (320 lb)

(12)

15, 16

assembly

WCEB-04-02-003

17

17

8. Attach a nylon sling onto outrigger (12). Hoist and

hold outrigger (12). Remove lock pin (11) from pin
(10). Remove pin (10) from outrigger beam (17).
Lower the outrigger (12) assembly.

10, 11

2
Wooden Block

12

W1GL-04-02-006

CAUTION: Outrigger cylinder (2) weight: 90

kg (200 lb)

18

17

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

W4-2-22

WCEB-04-02-003

FRONT ATTACHMENT / Cylinder

Installation of Outrigger Cylinder
CAUTION: Outrigger cylinder (2) weight: 90
kg (200 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

3. Install O-ring (8) to piping (7). Connect piping (7)

to outrigger cylinder (2).
: 6 mm
: 7819 Nm (82 kgfm, 586 lbfft)

WCEB-04-02-003

4. Install operate check valve (9) to outrigger cylinder (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).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
6. Install cover (3) to outrigger cylinder (2) with sems
bolts (4) (3 used), washers (5) (2 used) and collars (6) (2 used).
: 17 mm
: 50 Nm (5 kgfm, 37 lbfft)

7, 8

WCEB-04-02-004

4, 5, 6

WCEB-04-02-004

W4-2-23

FRONT ATTACHMENT / Cylinder

IMPORTANT: After the hose is connected, operate
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).
8. Install pin (13) to outrigger (12) with bolts (15) (3
used) and washers (16) (3 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)

17

10, 11

13, 14
2

15, 16

Wooden Block

12

W1GL-04-02-006

9. Remove the wooden block from the inside of outrigger beam (17).

17

10, 11

10. Operate outrigger cylinder (2) and align the

mounting hole on outrigger (12) with that on outrigger beam (17). Secure outrigger (12) to outrigger beam (17) with pin (10) and lock pin (11).

12

W4-2-24

WCEB-04-02-003

FRONT ATTACHMENT / Cylinder

(Blank)

W4-2-25

FRONT ATTACHMENT / Cylinder

DISASSEMBLY OF BOOM, ARM AND
BUCKET CYLINDERS
Boom Cylinder

20

22
23

26

25

17

18

24

19

21

19

18

10

11

W1V1-04-02-007

17
1

20 19

12

Arm Cylinder

22
23

16

15

14

13

10

11

12

W1V1-04-02-008

26

25

17

18

24

19

21

18

17

W4-2-26

FRONT ATTACHMENT / Cylinder

Bucket Cylinder
1

19

22
23

18

10 11

12

W1V1-04-02-009

17

1234567-

18

24

Piston Rod
Wiper Ring
Backup Ring
U-Ring
Buffer Ring
Socket Bolt (12 Used)
Cylinder Head

19

21

8910 11 12 13 14 -

20

Bushing
Snap Ring
Backup Ring
O-Ring
Cylinder Tube
Stopper (2 Used)
Cushion Bearing

17

15 16 17 18 19 20 -

W4-2-27

Cushion Seal
Snap Ring
Slide Ring (2 Used)
Slide Ring (2 Used)
Backup Ring (2 Used)
O-Ring

21 22 23 24 25 26 -

Seal Ring
Set Screw
Steel Ball
Piston Nut
Cushion Bearing
Cushion Seal

FRONT ATTACHMENT / Cylinder

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 explained.

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).
Put the matching marks on piston rod (1) and the
end of piston (24) (Arm cylinder: cushion bearing
(14)).

CAUTION: Boom cylinder weight:

Monoblock boom: 175 kg (390 lb)
2-piece boom: 165 kg (370 lb)
Arm cylinder weight: 225 kg (550 lb)
Bucket cylinder weight: 150 kg (335 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the cylinder.

Special Tool: ST 5908

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).
: 14 mm

W4-2-29

W158-04-02-022

FRONT ATTACHMENT / Cylinder

20

22
23

19

16

18

17

15

14

10

11

13

W1V1-04-02-008

26

25 17

18

24

19

21

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.
: 6 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) and cushion seal (26) are
not equipped for the bucket cylinder.)
Special tool (outer diameter at nut part):
Bucket cylinder: (ST 3244: 90 mm)
Boom cylinder:
Monoblock boom: (ST 3245: 95 mm)
2-piece boom: (ST 3246: 100 mm)
Arm cylinder: (ST 3249: 110 mm)

Special Tool: ST 5908

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):
Bucket cylinder: (ST 8019: 80 mm)
Boom cylinder: (ST 8020: 85 mm)
Arm cylinder: (ST 8025: 95 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).

W158-04-02-022

W4-2-31

FRONT ATTACHMENT / Cylinder

ASSEMBLY OF BOOM, ARM AND BUCKET CYLINDERS

Boom Cylinder
1

12

25

17

10, 11

26

18

19

24

18

17

20, 21

23

22

W1V1-04-02-005

Arm Cylinder
1

12

10, 11

25

17

26

18

24

19

18

20, 21

17 22

23 16

14

15

W1V1-04-02-003

Bucket Cylinder
1

12

17

18

19

18

17
22

20, 21

10, 11

23
W1V1-04-02-001

W4-2-32

FRONT ATTACHMENT / Cylinder

1234567-

Piston Rod
Wiper Ring
Backup Ring
U-Ring
Buffer Ring
Socket Bolt (12 Used)
Cylinder Head

8910 11 12 13 14 -

Bushing
Snap Ring
Backup Ring
O-Ring
Cylinder Tube
Stopper (2 Used)
Cushion Bearing

15 16 17 18 19 20 -

W4-2-33

Cushion Seal
Snap Ring
Slide Ring (2 Used)
Slide Ring (2 Used)
Backup Ring (2 Used)
O-Ring

21 22 23 24 25 26 -

Seal Ring
Set Screw
Steel Ball
Piston Nut
Cushion Bearing
Cushion Seal

FRONT ATTACHMENT / Cylinder

17

18

19

18

17

14

13

10, 11

24

NOTE: The illustration shows the arm cylinder.

W4-2-34

20, 21

16

15

W1V1-04-02-003

FRONT ATTACHMENT / Cylinder

Assembly of Boom, Arm and Bucket Cylinders
NOTE: The procedure for the arm cylinder is explained.
1. Install bushing (8) to cylinder head (7) by using
the special tool.
Special tool (rod outer diameter):
Bucket cylinder: (ST 8019: 80 mm)
Boom cylinder: (ST 8020: 85 mm)
Arm cylinder: (ST 8025: 90 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):
Bucket cylinder: (ST 8019: 80 mm)
Boom cylinder: (ST 8020: 85 mm)
Arm cylinder: (ST 8025: 90 mm)
4. Install O-ring (11) and backup ring (10) to cylinder
head (7).

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 2963, 2207: 115 mm)
Boom cylinder:
Monoblock boom: (ST 2964, 2208: 120 mm)
2-piece boom: (ST 2965, 2088: 125 mm)
Arm cylinder: (ST 2978, 2535: 135 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):
Bucket cylinder: (ST 8019: 80 mm)
Boom cylinder: (ST 8020: 85 mm)
Arm cylinder: (ST 8025: 90 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).

W4-2-35

FRONT ATTACHMENT / Cylinder

12

25

26

NOTE: The illustration shows the arm cylinder.

W4-2-36

22

24

23

W1V1-04-02-003

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 special tool.
Special tool (outer diameter at nut part):
Bucket cylinder: (ST 3244: 90 mm)
: 5600 Nm (570 kgfm, 4130 lbfft)
Boom cylinder:
Monoblock boom: (ST 3245: 95 mm)
: 5340 Nm (545 kgfm, 3940 lbfft)
2-picece boom: (ST 3245: 95 mm)
: 6000 Nm (610 kgfm, 4430 lbfft)
Arm cylinder:
Monoblock boom: (ST 3245: 95 mm)
: 8860 Nm (900 kgfm, 6540 lbfft)
2-picece boom: (ST 3245: 95 mm)
: 7900 Nm (810 kgfm, 5380 lbfft)

Special Tool: ST 5908

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.
: 6 mm
: 57 Nm (5.8 kgfm, 42 lbfft)
CAUTION: Align the piston rod (1) assembly
with the center of cylinder tube (12) and insert straight in order not to damage the rings.
12. Secure cylinder tube (12) horizontally on a workbench. 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).
: 14 mm
: 265 Nm (27 kgfm, 195 lbfft)
IMPORTANT: When replacing the bushing from
piston rod (1) or cylinder tube (12)
by using a hammer, the bushing may
be damaged. Use a press and special tool (ST 1454) when removing
and installing the bushing.

W158-04-02-022

W4-2-37

FRONT ATTACHMENT / Cylinder

DISASSEMBLY OF POSITIONING CYLINDER
1

14

15

16

17

18

19

20

10

11

12

13

21

22

WCGB-04-02-010

123456-

Piston Rod
Socket Bolt (14 Used)
Cylinder Head
Retaining Ring
Dust Seal
Backup Ring

78910 11 12 -

U-Ring
Buffer Ring
Bushing
Retaining Ring
O-Ring
O-Ring

13 14 15 16 17 -

Backup Ring
Piston
Slide Ring (2 Used)
Wear Ring (2 Used)
Seal Ring

W4-2-38

18 19 20 21 22 -

O-Ring
Backup Ring (2 Used)
Set Screw
Piston Nut
Cylinder Tube

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 removed.
CAUTION: Positioning cylinder weight: 170
kg (375 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the cylinder.

CAUTION: Do not drop piston rod (1) by tilting.

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

14

15

16

17

18

19

20

10

11

12

13

21

22

WCGB-04-02-010

W4-2-40

FRONT ATTACHMENT / Cylinder

5. Cut away the crimped part by using a hand drill
and remove set screw (20) from piston nut (21).
NOTE: Set screw (20) has been crimped by using
a punch at 2 places after installing.
: 4 mm

9. Remove bushing (9) from cylinder head (3) by

using special tool (ST 2613). Remove O-rings (11,
12), backup rings (6, 13), dust seal (5), U-ring (7),
buffer ring (8) and retaining rings (4, 10) from
bushing (9).

6. Remove piston nut (21) from piston rod (1) by

using special tool (ST 3327). Remove piston (14)
from piston rod (1) by using special tool (ST
3339).
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

9, 10

2, 11

12, 13

22

14

15

16

17

18, 19

21

20

4, 5
1

WCJB-04-02-002

123456-

Piston Rod
Socket Bolt (14 Used)
Cylinder Head
Retaining Ring
Dust Seal
Backup Ring

78910 11 12 -

U-Ring
Buffer Ring
Bushing
Retaining Ring
O-Ring
O-Ring

13 14 15 16 17 -

Backup Ring
Piston
Slide Ring (2 Used)
Wear Ring
Seal Ring

W4-2-42

18 19 20 21 22 -

O-Ring
Backup Ring (2 Used)
Set Screw
Piston Nut
Cylinder Tube

FRONT ATTACHMENT / Cylinder

Assembly of Positioning Cylinder
1. Install bushing (9) to cylinder head (3) by using
special tool (ST 2613). Install retaining ring (10).
2. Tap and install dust seal (5) to cylinder head (3)
by using special tool (ST 2614) and a plastic
hammer.

5. Install O-ring (18), backup rings (19) (2 used),

seal ring (17), slide rings (15) (2 used) and wear
ring (16) to piston (14) by using special tools (ST
2588, 2589).
6. Install the cylinder head (3) assembly to piston
rod (1) by using special tool (ST 2696).

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

22

14

21

20

WCJB-04-02-002

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 3339).
: 98098 Nm (10010 kgfm, 72072 lbfft)
7. Apply hydraulic oil onto piston nut (21). Install
piston nut (21) to piston rod (1) by using special
tool (ST 3327).
: 1860185 Nm
(19019 kgfm, 1380137 lbfft)
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
: 151.5 Nm (1.50.15 kgfm, 111 lbfft)

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 2696). Tighten cylinder
head (3) with socket bolts (2) (14 used).
: 14 mm
: 340 to 360 Nm
(35 to 37 kgfm, 255 to 270 lbfft)
IMPORTANT: When replacing the bushing from
piston rod (1) or cylinder tube (22)
by using a hammer, the bushing may
be damaged. Use a press and special tool (ST 1454) when removing
and installing the bushing.

W4-2-45

FRONT ATTACHMENT / Cylinder

DISASSEMBLY OF OUTRIGGER AND BLADE CYLINDERS
1

2
3

10

11
12

13

14

15

16

17
18

19

20

WCGB-04-02-002

12345-

Piston Rod
Cylinder Head
Retaining Ring
Dust Seal
U-Ring

678910 -

Seal
Bushing
Retaining Ring
O-Ring
Backup Ring

11 12 13 14 15 -

W4-2-46

O-Ring
Piston
Seal Ring
Wear Ring
Dust Ring

16 17 18 19 20 -

O-Ring
Set Screw
Piston Nut
Backup Ring (2 Used)
Cylinder Tube

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 removed.
CAUTION: Outrigger cylinder weight: 90 kg
(200 lb)
Blade cylinder weight: 50 kg (110 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the cylinder.

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
3334). 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 cylinder head (2). Remove bushing (7) by using special tool (ST 2685).

W102-04-02-027

9. Remove O-rings (9, 11) and backup ring (10) from

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 cylinder head (2) from cylinder tube (20) by using a
pry bar.
R wrench: (ST 3221)
CAUTION: Do not drop piston rod (1) by tilting.
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

7, 8

10, 11

20 12

13

14

15

16, 19

18

17

WCGB-04-02-004

Blade Cylinder

3, 4

7, 8

10, 11

20 12

13 14 15

16, 19

18

17

WCGB-04-02-003

W4-2-48

FRONT ATTACHMENT / Cylinder

12345-

Piston Rod
Cylinder Head
Retaining Ring
Dust Seal
U-Ring

678910 -

Seal
Bushing
Retaining Ring
O-Ring
Backup Ring

11 12 13 14 15 -

W4-2-49

O-Ring
Piston
Seal Ring
Wear Ring
Dust Ring

16 17 18 19 20 -

O-Ring
Set Screw
Piston Nut
Backup Ring (2 Used)
Cylinder Tube

FRONT ATTACHMENT / Cylinder

3, 4

7, 8

10, 11

12

13

14

15

16, 19

18

17

WCGB-04-02-004

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 2685). Install retaining ring (8).
IMPORTANT: Install U-ring (5) with its lip part facing 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 cylinder head (2) by using special tool (ST 2689).
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 cylinder head (2).
5. Install the cylinder head (2) assembly to piston
rod (1) by using special tool (ST 2693).

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).
: 74069 Nm (757 kgfm, 55051 lbfft)
8. Apply hydraulic oil onto the threads of piston nut
(18). Install piston nut (18) to piston rod (1) by
using special tool (ST 3334).
: 127098 Nm
(13010 kgfm, 94072 lbfft)
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
: 151.5 Nm (1.50.15 kgfm, 111 lbfft)

W4-2-51

FRONT ATTACHMENT / Cylinder

20

WCGB-04-02-004

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)
and insert straight in order not to
damage the rings.
10. Secure cylinder tube (20) horizontally on a workbench. 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 3223)
: 490 to 690 Nm
(50 to 70 kgfm, 360 to 510 lbfft)
IMPORTANT: When replacing the bushing from
piston rod (1) or cylinder tube (20)
by using a hammer, the bushing may
be damaged. Use a press and special tool (ST 1454) when removing
and installing the bushing.

W4-2-53

FRONT ATTACHMENT / Cylinder

MAINTENANCE STANDARD
Rod Bend and Run Out of Piston Rod

Piston Rod

Dial Gauge

A
Piston Rod

W166-04-02-022

W105-04-02-094

1m

Cylinder Name

Unit: mm (in)
Recommended Size After
Re-Manufacturing (A)

Boom

85

Arm

95

Bucket

80

Positioning

95

Blade

120

Outrigger

120

+0.027
-0.057
+0.027
-0.057
+0.027
-0.053
+0.027
-0.057
+0.023
-0.043
+0.023
-0.043

(3.3
(3.7
(3.1
(3.7
(4.7
(4.7

+0.001
-0.002
+0.001
-0.002
+0.001
-0.002
+0.001
-0.002
+0.001
-0.002
+0.001
-0.002

)
)

V Block

Bend

Unit: mm (in)
Run Out

Remedy

0.5 (0.02) 1.0 (0.04)

Repair

1.0 (0.04) 2.0 (0.08)

Replace

)
)
)
)

W4-2-54

FRONT ATTACHMENT / Hose Rupture Valve

HYDRAULIC
CIRCUIT
RELEASE PROCEDURE

PRESSURE

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,
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

Engine Stop Switch

WCEB-02-01-002

FRONT ATTACHMENT / Hose Rupture Valve

REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR ARM CYLINDER
CAUTION: Loosen the relief valve of hose
rupture valve (3) slowly and release the
pressure.

3, 4

Removal
1. Disconnect hoses (1) (2 used) from hose rupture
valve (3). Cap the open ends.
: 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)
and O-ring (4) from arm cylinder (7).
: 8 mm

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
piping (5) with socket bolts (2, 6) (4 used for
each).
: 8 mm
: 5210 Nm (5.21 kgfm, 387 lbfft)
3. Connect hoses (1) (2 used) to hose rupture valve
(3).
: 19 mm
: 29.5 Nm (3 kgfm, 21.5 lbfft)

W4-3-2

7
WCEB-04-03-003

3, 4

7
WCEB-04-03-003

FRONT ATTACHMENT / Hose Rupture Valve

REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR POSITIONING
CYLINDER
CAUTION: Loosen the relief valve of hose
rupture valve (8) slowly and release the
pressure.

Removal
1. Remove bolts (4) (2 used) from clamp (5).
Remove clamp (5) from bracket (6).
: 22 mm
2. Disconnect hoses (3) (3 used) from hose rupture
valve (8). Cap the open ends. Attach an
identification tag onto the disconnected hoses for
assembling.
: 19 mm
3. Remove socket bolts (1) (4 used). Disconnect
piping (2) from positioning cylinder (7). Remove
hose rupture valve (8) and O-ring (9) from
positioning cylinder (7). Cap the open ends.
: 10 mm

W4-3-3

8, 9

WCJB-04-03-003

FRONT ATTACHMENT / Hose Rupture Valve

Installation
1. Apply grease onto O-ring (9). Install O-ring (9) to
hose rupture valve (8).

2. Install hose rupture valve (8) and piping (2) to

positioning cylinder (7) with socket bolts (1) (4
used).
: 10 mm
: 931.8 Nm (9.30.2 kgfm, 691 lbfft)
3. Connect hoses (3) (3 used) to hose rupture valve
(8).
: 19 mm
: 29.5 Nm (3 kgfm, 21.5 lbfft)
4. Secure piping (2) to bracket (6) with clamp (5) and
bolts (4) (2 used).
: 22 mm
: 137 Nm (14 kgfm, 101 lbfft)

W4-3-4

8, 9

WCJB-04-03-003

FRONT ATTACHMENT / Hose Rupture Valve

REMOVAL AND INSTALLATION OF HOSE
RUPTURE VALVE FOR BOOM CYLINDER
CAUTION: Loosen the relief valve of hose
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
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)
from boom cylinder (1). Cap the open ends.
: 10 mm

W4-3-5

8, 9

WCEB-04-03-002

FRONT ATTACHMENT / Hose Rupture Valve

Installation
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
: 931.8 Nm (9.30.2 kgfm, 691 lbfft)
3. Connect hoses (6) (6 used) to hose rupture valve
(8).
: 17 mm
: 24.5 Nm (2.5 kgfm, 18 lbfft)
: 19 mm
: 29.5 Nm (3 kgfm, 21.5 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)
4. Secure piping (5) to bracket (2) with clamps (3) (2
used) and bolt (4).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)

W4-3-6

8, 9

WCEB-04-03-002

FRONT ATTACHMENT / Hose Rupture Valve

(Blank)

W4-3-7

FRONT ATTACHMENT / Hose Rupture Valve

STRUCTURE OF HOSE RUPTURE VALVE FOR ARM CYLINDER

10

11

12

13

14

15

16

8
17

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

No.

Part Name

Qty

Spacer

Plug

O-Ring

Backup Ring

O-Ring

Orifice

Backup Ring

O-Ring

Lock Nut

10

Poppet

11

Set Screw

12

Spring

13

O-Ring

14

Washer

15

Adapter

16

O-Ring

17

Backup Ring

18

O-Ring

19

Casing

20

O-Ring

21

Plug

22

Stopper

23

Spool

24

Sleeve

25

Backup Ring

26

O-Ring

27

O-Ring

28

Plug

Wrench Size
(mm)
:5

: 17
:6

: 24

: 32

W4-3-9

Tightening Torque
Nm

(kgfm, lbfft)

Remark

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

No.

Part Name

Qty

Wrench Size
(mm)

29

Backup Ring

30

Spring

31

Holding Valve

32

Orifice

33

Body

34

O-Ring

35

O-Ring

36

Backup Ring

37

O-Ring

38

Backup Ring

39

Spring Seat

40

O-Ring

41

Piston

42

O-Ring

43

Cover

44

Stopper

45

Set Screw

:3

46

Lock Nut

: 10

47

Spring

Casing (19) and body (33)

mounting socket bolt

: 32

:8

W4-3-11

Tightening Torque
Nm

(kgfm, lbfft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve

STRUCTURE OF HOSE RUPTURE VALVES
FOR BOOM CYLINDER

9
3

10

11

12 13 14

15

16
17

2
18

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

No.

Part Name

Qty

Spacer

Plug

O-Ring

Backup Ring

O-Ring

Orifice

Backup Ring

O-Ring

Lock Nut

10

Poppet

11

Set Screw

12

Spring

13

O-Ring

14

Washer

15

Adapter

16

O-Ring

17

Backup Ring

18

O-Ring

19

Casing

20

O-Ring

21

Plug

22

Stopper

23

Spool

24

Sleeve

25

Backup Ring

26

O-Ring

27

O-Ring

28

Plug

Wrench Size
(mm)

:5

: 17
:6

: 24

: 32

W4-3-13

Tightening Torque
Nm

(kgfm, lbfft)

Remark

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

No.

Part Name

Qty

Wrench Size
(mm)

29

Backup Ring

30

Spring

31

Holding Valve

32

Orifice

33

Body

34

O-Ring

35

O-Ring

36

Backup Ring

37

O-Ring

38

Backup Ring

39

Spring Seat

40

O-Ring

41

Piston

42

O-Ring

43

Cover

44

Stopper

45

Set Screw

:3

46

Lock Nut

: 10

47

Spring

Casing (19) and body (33)

mounting socket bolt

: 32

:8

W4-3-15

Tightening Torque
Nm

(kgfm, lbfft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve

STRUCTURE OF HOSE RUPTURE VALVES
FOR POSITIONING CYLINDER
9
3

10

11

12 13 14

15

16
17

2
18
1
19
50

20

49

21

48

22
23

47

24

46

25
26

45

27

44

28
29

43

30

42

31
32

41

33

40

34

39
35

38

36

37

WCJB-04-03-002

W4-3-16

FRONT ATTACHMENT / Hose Rupture Valve

No.

Part Name

Qty

Spacer

Plug

O-Ring

Backup Ring

O-Ring

Orifice

Backup Ring

O-Ring

Lock Nut

10

Poppet

11

Set Screw

12

Spring

13

O-Ring

14

Washer

15

Adapter

16

O-Ring

17

Backup Ring

18

O-Ring

19

Casing

20

O-Ring

21

Plug

22

Stopper

23

Spool

24

Sleeve

25

Backup Ring

26

O-Ring

27

O-Ring

28

Plug

29

Backup Ring

30

O-Ring

31

Plug

32

Orifice

Wrench Size
(mm)

:5

: 17
:6

: 24

: 32

W4-3-17

Tightening Torque
Nm

(kgfm, lbfft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve

50
49
48

47
46
45
44
43
42
41
33

40

34

39
35

38

36

37

WCJB-04-03-002

W4-3-18

FRONT ATTACHMENT / Hose Rupture Valve

No.

Part Name

Qty

Wrench Size
(mm)

33

Spring

34

Holding Valve

35

Orifice

36

Body

37

O-Ring

38

O-Ring

39

Backup Ring

40

O-Ring

41

Backup Ring

42

Spring Seat

43

O-Ring

44

Piston

45

O-Ring

46

Cover

47

Stopper

48

Set Screw

:3

49

Lock Nut

: 10

50

Spring

Casing (19) and body (36)

mounting socket bolt

: 32

:8

W4-3-19

Tightening Torque
Nm

(kgfm, lbfft)

Remark

FRONT ATTACHMENT / Hose Rupture Valve

(Blank)

W4-3-20

FRONT ATTACHMENT / Operate Check Valve

REMOVAL AND INSTALLATION OF OPERATE CHECK VALVE (FOR BLADE AND
OUTRIGGER)

Outrigger Beam

Lock Pin

Float

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
used) from guard cover (3). Remove guard cover
(3) from brackets (4) (2 used).
: 19 mm

WCEB-04-04-002

1, 2
3

WCEB-04-02-001

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

4. Remove socket bolts (6) (4 used) from operate

check valve (7). Remove operate check valve (7)
and O-rings (8) (2 used) from cylinder (11). Cap
the open ends.
: 6 mm

10

11

WCEB-04-02-002

10

11
6

W4-4-1

7, 8

WCEB-04-04-001

FRONT ATTACHMENT / Operate Check Valve

Installation
1. Apply grease onto O-rings (8) (2 used).

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
: 26.5 Nm (2.7 kgfm, 20 lbfft)

4. Connect piping (9) to operate check valve (7) with

socket bolts (10) (4 used).
: 6 mm
: 26.5 Nm (2.7 kgfm, 20 lbfft)

10

11

WCEB-04-02-002

5. Connect hoses (5) (4 used) to operate check

valve (7).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
: 27 mm
: 78 Nm (8 kgfm, 58 lbfft)

10

6. Install guard cover (3) to brackets (4) (2 used) with

bolts (1) (4 used) and washers (2) (4 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)

11
6

7, 8

WCEB-04-04-001

1, 2
3

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

10

11

12

13

WCEB-04-03-001

Item

Part Name

Qty

Plug

O-Ring

Plug

O-Ring

Spring

Sleeve

Poppet

Piston

O-Ring

10

Plug

11

Casing

12

Plug

13

O-Ring

Wrench Size
(mm)
: 6 mm

Tightening Torque
Nm
(kgfm)
(lbfft)
34.33.4 (3.50.3)
(253)

Remark
1B P11

: 36 mm

50050

(515)

(36937)
1B P26

1B P18
: 36 mm

24024

(242.4)

(182)

: 36 mm

24024

(242.4)

(182)
1B P18

W4-4-3

FRONT ATTACHMENT / Operate Check Valve

(Blank)

W4-4-4

MEMO
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Hitachi Construction Machinery Co. Ltd

Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162

Hitachi Ref. No.

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