30t WDDE-EN-00

PART NO.
WDDE-EN-00
ZX330-5G • 330LC-5G • 350H-5G • 350LCH-5G • 350K-5G • 350LCK-5G

Workshop Manual
ZX
330-5G
330LC-5G
HYDRAULIC EXCAVATOR
350H-5G
350LCH-5G
WORKSHOP MANUAL
URL:http://www.hitachi-c-m.com 350K-5G
350LCK-5G
Hydraulic Excavator
Service Manual consists of the following separate Part No.
WDDE-EN-00
Technical Manual (Operational Principle) : Vol. No.TODDE-EN

Technical Manual (Troubleshooting) : Vol. No.TTDDE-EN
Workshop Manual : Vol. No.WDDE-EN
PRINTED IN JAPAN (K) 2011, 10 Engine Manual : Vol. No.EDDE-EN
INTRODUCTION
To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
Form” at the end of this manual. (Note: Do not tear off
 Be sure to thoroughly read this manual for correct the form. Copy it for usage.):
product information and service procedures.  Publications Marketing & Product Support Hitachi
Construction Machinery Co. Ltd.
 TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: dc@hitachi-kenki.com
Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures.  Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / disassemble procedures.
Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group
IN-01
INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential d CAUTION:
Indicated potentially hazardous situation which could, if
for personal injury of machine damage.
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed
instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention to
component/part weights. f NOTE:
Indicates supplementary technical information or know-
To avoid injury and damage, be sure to use appropriate
how.
lifting techniques and equipment when lifting heavy
parts.
Units Used
SI Units (International System of Units) are used in this Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
manual. MKSA system units and English units are also
indicated in parentheses just behind SI units. A table for conversion from SI units to other system units
is shown below for reference purposes.
Quantity To Convert From Into Multiply By

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

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

Abbreviation
TO Technical manual (Operational principle)Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECF Engine Controller Engine controller. ECF controls EC motor according to the
machine operating condition.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
SY-1
SYMBOL AND ABBREVIATION
(Blank)
SY-2
SAFETY
Recognize Safety Information

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

 On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
 DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
 WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
 CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
 DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
 Some safety signs do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
SA-1223
 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.
SA-1
SAFETY
Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
 Learn how to operate the machine and its controls correctly
and safely.
 Allow only trained, qualified, authorized personnel to
operate the machine.
 Keep your machine in proper working condition. SA-003
 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.
 Never attempt to modify or disassemble the inlet/exhaust
parts and the muffler filter. Avoid giving shocks on the
muffler filter by striking elements with other objects or
dropping the elements. Failure to do so may affect the
exhaust gas purifying device, possibly damaging it or
lowering its performance.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.
SA-2
SAFETY
Prepare for Emergencies

 Be prepared if a fire starts or if an accident occurs.
 Keep a first aid kit and fire extinguisher on hand.
 Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
 To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
 Establish emergency procedure guidelines to cope with
fires and accidents.
 Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone. SA-437
Wear Protective Clothing

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

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

 Prolonged exposure to loud noise can cause impairment or
loss of hearing.
 Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
SA-434
Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
 In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.
SA-435
SA-4
SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not 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
 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.
SA-5
SAFETY
Use Handholds and Steps

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

 If a fire breaks out, evacuate the machine in the following
way:
 Stop the engine by turning the key switch to the OFF
position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method in the operator’s manual.
SS-1510
Beware of Exhaust Fumes

 Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
 If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
SA-016
SA-32
SAFETY
Precautions for Welding and Grinding
 Welding may generate gas and/or small fires.
 Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe place
before starting welding.
 Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
 Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
 After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818
SA-33
SAFETY
Avoid Heating Near Pressurized Fluid Lines

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).
SA-39
SAFETY
Before Returning the Machine to the Customer
 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced.
SA-435
SA-40
SECTION AND GROUP SECTION 1 GENERAL INFORMATION
CONTENTS Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Pressure Release Procedure
WORKSHOP MANUAL Group 6 Preparation
SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure
Group 2 Undercarriage
Group 3 Front Attachment
SECTION 3 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Engine
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Swing Device
Group 11 Pilot Valve
Group 12 Solenoid Valve
Group 13 Signal Control Valve
All information, illustrations and SECTION 4 UNDERCARRIAGE
specifications in this manual are based on
the latest product information available Group 1 Swing Bearing
at the time of publication. The right is Group 2 Travel Device
reserved to make changes at any time
without notice. Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Upper and Lower Rollers
Group 6 Track
SECTION 5 FRONT ATTACHMENT
COPYRIGHT(C)2011 Group 2 Cylinder
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle) TECHNICAL MANUAL (Troubleshooting)
SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Specification Group 1 Introduction
Group 2 Component Layout Group 2 Standard
Group 3 Component Specifications Group 3 Engine Test
SECTION 2 SYSTEM Group 4 Excavator Test
Group 1 Controller Group 5 Component Test
Group 2 Control System Group 6 Adjustment
Group 3 Hydraulic System SECTION 5 TROUBLESHOOTING
Group 4 Electrical System Group 1 Diagnosing Procedure
SECTION 3 COMPONENT OPERATION Group 2 Monitor
Group 1 Pump Device Group 3 e-Service
Group 2 Swing Device Group 4 Component Layout
Group 3 Control Valve Group 5 Troubleshooting A
Group 4 Pilot Valve Group 6 Troubleshooting B
Group 5 Travel Device Group 7 Air Conditioner
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling and
Assembling..................................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Painting..............................................................................W1-3-1-1
Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1
Bleeding Air from Hydraulic System........................W1-4-1-2
Bleeding Air from Fuel System...................................W1-4-1-3
Hydraulic Circuit Pressure Release Procedure......W1-5-1-1
Group 6 Preparation
Preparation before Inspection and
Maintenance...............................................................W1-6-1-1
DDEW-1-1
(Blank)
DDEW-1-2
SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling
Precautions for Disassembling and  If a part or component cannot be removed after

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

hose rupture or separation of fitting, possibly
resulting in a fire on the machine. Do not install
hoses kinked. Application of high oil pressure,
vibration, or an impact to a kinked hose may
result in oil leaks, hose rupture or separation of
fitting. Utilize the print marks on hoses when W105-01-01-011
installing in order to prevent hose from being
kinked. Take necessary measures to protect hoses
from rubbing against each other. If the hoses rub Incorrect a Correct
against each other, wear to the hoses may result
and lead to hose rupture. Take care so that the
hoses do not come into contact with the moving
parts or sharp objects.
W105-01-01-012
a - Rubbing Against Each Other
Incorrect Correct
b b
W105-01-01-013
a - Rubbing Against Each Other b - Clamp
Incorrect Correct
a
b
W105-01-01-014
a - Rubbing Against Each Other b - Clamp
W1-2-1-8
SECTION 1 GENERAL
Group 3 Painting
Painting
Painting specification
Surfaces to Be Painted Painting Colour
Main surface of upperstructure (except cab) YR-01 [TAXI yellow]
Main frame High Grade Black
Inner Gray
Front YR-01 [TAXI yellow]
Track (including swing bearing) N1.0 [Black]
Floor plate M/F Cation (allowed)
Final painted color

Inside and outside surface of cab High Grade Black
Shaded area on cab (Only the left side) (11) Shining Silver
Right window beam Charcoal Black
Seat stand [N2.0 (Black)]
Lever (Travel, pilot shut-off ) [N2.5 (Warm Gray)]
Engine cover (8) High Grade Black
Tool box (6), Tool box cover (4) High Grade Black
Cover (2), Step (3) High Grade Black
Handrail on upperstructure right side (1) High Grade Black
Mirror stay (5) High Grade Black
Nonslip plate KANSAI PAINT CO., LTD. 1400 (Deep Black)
Rear camera cover (9) High Grade Black
W1-3-1-1
SECTION 1 GENERAL
Group 3 Painting
WDCD-01-03-001
WDCD-01-03-002
WDAA-01-03-003
a - Paint all circumference in the lower hinge swing position shining

silver
1- Handrail on Upperstructure 3- Step 6- Tool Box 9- Camera Cover
Right Side 4- Tool Box Cover 7- Decal (TAXI Yellow) 10- Decal (TAXI Yellow)
2- Cover 5- Mirror Stay 8- Engine Cover 11- Shaded Area (Shining Silver)
W1-3-1-2
SECTION 1 GENERAL
Bleeding Air from Hydraulic Oil Tank
dCAUTION: Escaping fluid under pressure may

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

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

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

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

Air in the fuel system may make the engine hard to
start or make it run irregularly. After draining water and
sediment from the fuel filter, replacing the fuel filter,
cleaning the fuel solenoid pump strainer or running
the fuel tank dry, be sure to bleed the air from the fuel
system.
Air Bleeding Procedures

This machine is equipped with a fuel solenoid pump.
d CAUTION: Fuel leaks may lead to fires.
1
1. Check that fuel cock (1) on bottom of the fuel tank is
opened.
2. Set the key switch to the ON position and hold it in
that position for approx. three minutes. Therefore,
the electrical fuel pump operates and starts to
bleed air.
M1U1-07-015
3. While holding the key switch in the ON position,
reciprocate fuel main filter priming pump (2). After
air is bled from the main filter, return priming pump
(2) to the original position. 2
4. After the main filter is filled with fuel, hold the key
switch in the ON position for 30 seconds.
5. Start the engine. Check the fuel system for fuel
leaks.
IMPORTANT: Even if air is not thoroughly bled,
do not hold the key switch in the ON position
for more than five minutes. In case air is not
thoroughly bled, first return the key switch to the
OFF position. Then, after waiting for more than
30 seconds, set the key switch to the ON position
again. Failure to do so may cause damage to the
electrical pump and/or discharging the batteries.
M81U-07-030
W1-4-1-3
SECTION 1 GENERAL
Air Bleeding by Priming Pump

In case air is not bled due to malfunction of the fuel
solenoid pump, operating the priming pump only can
1
bleed air.
1. Check that fuel cock (1) on bottom of the fuel tank is
opened.
2. Loosen air bleed plug (4) on the fuel main filter.
j : 10 mm
3. Supply fuel by reciprocating priming pump (2). After M1U1-07-015
no air bubbles are spouted through air bleed plug
(4), tighten air bleed plug (4).
j : 10 mm
4. After tightening air bleed plug (4), reciprocate
priming pump (2) approx. 150 strokes. 3
5. Wipe off any spilled fuel.

6. Start the engine. Check that no fuel leaks are
present. If the engine does not start, repeat the
above procedures from step 1.
4
Air Bleeding by Cranking M1GR-07-010
Bleed air from the fuel system after changing the
common rail.
1. Bleed air until the engine supply pump entrance
2
enough according to the above-mentioned
procedures.
2. Operate the starter motor for long cranking within
20 seconds. If the engine falls to start, return the key
switch to the OFF position. Wait more than about 60
seconds, then try again.
M81U-07-030
W1-4-1-4
SECTION 1 GENERAL
Hydraulic Circuit Pressure Release Procedure

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

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

Maintenance
Before performing the maintenance procedures given in
the following chapters, park the machine as described
below, unless otherwise specified.
1. Park the machine on a level surface.

2. Lower the bucket to the ground. M104-07-021
3. Turn the auto-idle switch OFF.

4. Set the engine control dial to the slow idle position.
1
Run the engine at slow idle speed without load for
five minutes.
5. Set the key switch to the OFF position. Stop the
engine. Remove the key from the key switch. If
maintenance should be performed with the engine
running, do not leave the machine unattended.
6. Set pilot shut-off lever (1) to the LOCK position.
7. Before performing any work on the machine, attach
tag (2) on the door or control lever.
WDAA-01-06-001
W1-6-1-1
SECTION 1 GENERAL
Group 6 Preparation
(Blank)
W1-6-1-2
MEMO
MEMO
SECTION 2
MAINTENANCE STANDARD
CONTENTS
Pump Device....................................................................W2-1-1-1
Swing Motor.....................................................................W2-1-2-1
Travel Motor......................................................................W2-2-1-1
Sprocket.............................................................................W2-2-1-3
Front Idler..........................................................................W2-2-2-1
Upper Roller......................................................................W2-2-3-1
Lower Roller......................................................................W2-2-3-2
Track.....................................................................................W2-2-4-1
Pin and Bushing...............................................................W2-3-1-1
Side Cutter.........................................................................W2-3-1-3
Point.....................................................................................W2-3-1-3
Side Cutter.........................................................................W2-3-1-4
Point.....................................................................................W2-3-1-4
Standard Dimensions for Arm and Bucket
Connection..................................................................W2-3-1-5
Standard Dimensions for Arm and Boom
Connection..................................................................W2-3-1-6
Cylinder..............................................................................W2-3-2-1
DDEW-2-1
(Blank)
DDEW-2-2
Pump Device
W1V7-02-04-022
10 3
8 7 6 5 WDDE-02-01-001
1- Center Gear 4- Drive Disc 7- Valve Plate 10- Center Shaft

2- Center Shaft 5- Plunger (7 Used) 8- Servo Pin
3- Drive Gear (2 Used) 6- Cylinder Block 9- Servo Piston
W2-1-1-1
Unit: mm (in)
Standard Allowable Limit Remedy
Backlash of center gear (1) and drive gear 0.48 (0.019) 1.5 (0.059) Replace
(3)
Main Pump
1. Spline tooth thickness of center shaft (2) and drive
disc (4) (T1)
Unit: mm (in) T1
Standard Allowable Limit
d1
T1 4.9 (0.193) 3.5 (0.138)
T1
d2
2. Oil seal outer diameter (d1, d2) of center shaft (2) and
drive disc (4)
Unit: mm (in) 2
d1 55 (2.17) 54.8 (2.16)
WDDE-02-01-002
d2 60 (2.36) 59.8 (2.35) 4
3. Clearance between plunger (5) and drive disc (4)

Unit: mm (in) 5
0.060 (0.002) 0.4 (0.016) 4
4. Clearance between outer diameter (a) of plunger (5)

and inner diameter (D) of cylinder block (6)
Unit: mm (in)
D-a 0.044 (0.002) 0.08 (0.003)
W178-02-11-105
5 a
W178-02-11-106
W2-1-1-2
5. Clearance between plunger (5) and connecting rod

(b)
5
Unit: mm (in)
0.15 (0.006) 0.4 (0.016)
b
6. Clearance between inner diameter (D) of servo

small chamber and outer diameter (a) of servo b- Connecting Rod
piston (9) W178-02-11-107
Unit: mm (in) D
Standard Allowable Limit a c
D-a 0.089 (0.004) 0.2 (0.008)
7. Clearance between inner diameter (D) of servo large

chamber and outer diameter (a) of servo piston (9)
Unit: mm (in)
D-a 0.090 (0.004) 0.2 (0.008) 9
d
a
8. Clearance between outer diameter (a1) of servo pin W178-02-11-108
(8) and inner diameter (D1) of valve plate (7) D
c- Small Diameter Side
Unit: mm (in) d- Large Diameter Side
D1-a1 0.051 (0.002) 0.3 (0.012)
8 7 10
9. Clearance between outer diameter (a2) of center

shaft (10) and inner diameter (D2) of valve plate (7)
Unit: mm (in)
D2-a2 0.081 (0.003) 0.3 (0.012) a1, D1 a2, D2
WDDE-02-01-003
W2-1-1-3
(Blank)
W2-1-1-4
Swing Motor
1 3
W1V1-02-06-009
1- Rotor 2- Plunger (9 Used) 3- Friction Plate (3 Used)
W2-1-2-1
1. Clearance between outer diameter (d) of plunger (2)

and inner diameter (D) of rotor (1)
Unit: mm (in)
Standard Allowable Limit 2
D-d 0.028 (0.001) 0.058 (0.002)
d
W107-02-06-138
D D
W107-02-06-139
2. Clearance (δ) between plunger (2) and shoe (a)

bottom
2
Unit: mm (in)
0 (0) 0.3 (0.012) δ
a
a- Shoe
W107-02-06-140
W2-1-2-2
3. Shoe (a) thickness (t)

Unit: mm (in)
Standard Allowable Limit a
5.5 (0.22) 5.3 (0.21)
a- Shoe
W107-02-06-142
4. Friction plate (3) thickness (t)

Unit: mm (in) 3
2.0 (0.08) 1.6 (0.06) t
W107-02-06-143
W2-1-2-3
(Blank)
W2-1-2-4
Travel Motor
1 2
W1HH-03-02-006
1- Rotor 2- Plunger (9 Used)
W2-2-1-1
1. Clearance (ε) between and shoe (a) and plunger (2)

bottom a
Unit: mm (in)
0.25 (0.010) 0.5 (0.020)
ε≤0.5 mm (0.020 in)
ε
2
a- Shoe
W1V1-03-02-005
2. Clearance between outer diameter (d) of plunger (2)

and inner diameter (D) of rotor (1) D
Unit: mm (in)
0.035 (0.001) 0.08 (0.003)
D-d≤0.08 mm (0.003 in)
W105-02-06-134
W105-02-06-135
3. Shoe (a) thickness (t) a
Unit: mm (in)
6.0 (0.236) 5.6 (0.220)
t
2
a- Shoe
W1V1-03-02-005
W2-2-1-2
Sprocket
B
C
D
A W1HH-03-02-002
Unit: mm (in)
Standard Allowable Remedy
Dimension Limit
A 87 (3.43) [77 (3.03)] Build up
B 87.65 (3.45) 82.65 (3.25) welding and
C 124.25 (4.89) - hand finishing
D 132.05 (5.20) 127.05 (5.0)
E 216 (8.50) -
fNOTE: Values in [ ] are just for reference.
W2-2-1-3
(Blank)
W2-2-1-4
Front Idler
C D
W166-03-05-001
A
Unit: mm (in)
A 102 (4.0) [82 (3.22)] Build up welding and
B 204 (1.64) - hand finishing or
C 572 (22.5) [558 (22.0)] replace
D 617 (24.3) -
E 22.5 (0.89) 29.5 (1.16)
Axle and Bushing

Unit: mm (in)
Axle Outer Diameter 85.0 (3.35) [84.2 (3.31)] Replace
Bushing Inner Diameter 85.0 (3.35) [86.0 (3.39)]
Flange Thickness 2.0 (0.02) [1.2 (0.05)]
W2-2-2-1
(Blank)
W2-2-2-2
Upper Roller
A
B
WDDE-02-02-001
Unit: mm (in)
A 100 (3.9) - Replace
B 190 (7.5) -
C 150 (5.9) [140 (5.5)]
W2-2-3-1
Lower Roller
C A C
B
W1HH-03-06-002
Roller
Unit: mm (in)
A 199 (7.84) [217 (8.5)] Build up welding and
B 256 (10.1) - hand finishing or
C 28.5 (1.12) [19.5 (0.8)] replace
D 180 (7.09) 162 (69.4)
Axle and Bushing

Unit: mm (in)
Axle Outer Diameter 75 (3.0) [74.2 (2.9)] Replace
Bushing Inner Diameter 75 (3.0) [76 (3.0)]
Flange Thickness 2 (0.08) [1.2 (0.05)]
W2-2-3-2
Track
Link
Measure the length of four links.
 Do not measure the part included the master pin.
 Measure the length with tension on the track.
A
W155-03-07-001
Unit: mm (in)
A 865.92 (34.1) [893 (35.2)] Build up welding and
B 116 (4.6) [109 (4.29)] hand finishing or
replace
Grouser Shoe
W105-03-07-024
ZX350H-5G, 350LCH-5G, 350K-5G, 350LCK-5G

ZX330-5G, 330LC-5G Unit: mm (in) Unit: mm (in)
Shoe Size 600 mm Grouser Shoe Size 600 mm Grouser
Standard Allowable Remedy Standard Allowable Remedy
Limit Limit
A 250 (9.8) - Build up A 247 (9.7) - Build up
B 11 (0.43) - welding or B 11 (0.43) - welding or
C 30 (1.18) [21 (0.83)] replace C 36 (1.42) [27 (1.06)] replace
W2-2-4-1
Master Bushing
W105-03-07-023
Unit: mm (in)
Limit
A 148.3 (5.84) - Replace
B 45.45 (1.79) [48.5 (1.91)]
C 66.91 (2.63) [61.9 (2.43)]
Master Pin
W105-03-07-021
Unit: mm (in)
Limit
A 227.5 (8.96) - Replace
B 45.0 (1.77) [41.0 (1.61)]
W2-2-4-2
Pin
W142-03-07-004
A
Unit: mm (in)
Limit
A 242 (9.53) - Replace
B 44.69 (1.76) [41.7 (1.64)]
Bushing
W105-03-07-023
Unit: mm (in)
Limit
A 158.9 (6.26) - Replace
B 45.45 (1.79) [46.5 (1.83)]
C 66.91 (2.63) [61.9 (2.43)]
W2-2-4-3
(Blank)
W2-2-4-4
Pin and Bushing
F E
G
C
H
D J
A
I
K
B
W105-04-01-018
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
A Pin 110 (4.33) 109.0 (4.29) Replace
Bushing (Main Frame) 110 (4.33) 111.5 (4.39)
Bushing (Boom) 110 (4.33) 111.5 (4.39)
B Pin 110 (4.33) 109.0 (4.29)
Boss (Main Frame) 110 (4.33) 111.5 (4.39)
Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39)
C Pin 110 (4.33) 109.0 (4.29)
Boss (Boom) 110 (4.33) 111.5 (4.39)
Bushing (Boom Cylinder) 110 (4.33) 111.5 (4.39)
D Pin 110 (4.33) 109.0 (4.29)
Bushing (Boom) 110 (4.33) 111.5 (4.39)
Bushing (Arm) 110 (4.33) 111.5 (4.39)
E Pin 110 (4.33) 109.0 (4.29)
Boss (Arm) 110 (4.33) 111.5 (4.39)
Bushing (Arm Cylinder) 110 (4.33) 111.5 (4.39)
F Pin 110 (4.33) 109.0 (4.29)
Boss (Boom) 110 (4.33) 111.5 (4.39)
Bushing (Arm Cylinder) 110 (4.33) 111.5 (4.39)
W2-3-1-1
Unit: mm (in)
Part Name Standard Allowable Limit Remedy
G Pin 90 (3.54) 89.0 (3.50) Replace
Boss (Arm) 90 (3.54) 91.5 (3.60)
Bushing (Bucket Cylinder) 90 (3.54) 91.5 (3.60)
H Pin 100 (3.94) 99.0 (3.90)
Boss (Link B) 100 (3.94) 101.5 (3.99)
Bushing (Link A) 100 (3.94) 101.5 (3.99)
Bushing (Bucket Cylinder) 100 (3.94) 101.5 (3.99)
I Pin 90 (3.54) 89.0 (3.50)
Boss (Link B) 90 (3.54) 91.5 (3.60)
Bushing (Arm) 90 (3.54) 91.5 (3.60)
J Pin 100 (3.94) 99.0 (3.90)
Boss (Bucket) 100 (3.94) 101.5 (3.99)
Bushing (Link A) 100 (3.94) 101.5 (3.99)
K Pin 100 (3.94) 99.0 (3.90)
Boss (Bucket) 100 (3.94) 101.5 (3.99)
Bushing (Arm) 100 (3.94) 101.5 (3.99)
IMPORTANT: When replacing HN bushing for the
front attachment, install it by using a press.
W2-3-1-2
Side Cutter
(2021232, 2021233)
C
D
W105-04-01-019
Unit: mm (in)
Limit
A 258 (10.2) 168 (6.6) Replace
B 300 (11.8) -
C 400 (15.7) -
D 300 (11.8) -
Point
(4512365)
B C
W105-04-01-020
Unit: mm (in)
Limit
A 240 (9.4) 120 (4.7) Replace
B 96 (3.8) -
C 130 (5.1) -
D 105 (4.1) -
W2-3-1-3
Side Cutter
B
(4435856, 4435857)
C W1V7-04-01-002
Unit: mm (in)
Limit
A 214 (8.4) [139 (5.5)] Replace
B 140 (5.5) -
C 165 (6.5) -
D 525 (20.7) -
Point
(4400253)
B C
W1V7-04-01-003
Unit: mm (in)
Limit
A 229 (9.0) [114.5 (4.5)] Replace
B 125 (4.9) -
C 123 (4.8) -
D 116 (4.6) -
W2-3-1-4
Standard Dimensions for Arm and Bucket

Connection
WDCD-02-03-002
Section A Section B
WDCD-02-03-003
Unit: mm (in)
ZX330-5G, ZX350H-5G, ZX350K-5G, ZX330-3
330LC-5G 350LCH-5G 350LCK-5G
a 575 (22.6)   
b 10 (0.4)   
c 700 (27.6)  750 (29.5) 700 (27.6)
d 695 (27.4)   
e 585 (23.0)   
f 1661 (65.4) 1666 (65.6) 1661 (65.4) 
g 581 (22.9)   
h 418 (16.46)   
i 100 (3.9)   
j 578 (22.8)   
k 90 (3.5)   
l 581 (22.9)   
m 420 (16.5)   
n 100 (3.9)   
o 15 °   -45 °
p 15 °   0
q 600 (23.6)   
W2-3-1-5
Standard Dimensions for Arm and Boom

Connection
WDCD-02-03-001
Unit: mm (in) Section C

ZX330-5G Class ZX330-3,
330LC-3
s 110 (4.3) 
t 420.5 (16.55) 418.5 (16.47)
u 571 (22.5) 
IMPORTANT: If the front attachment of a previous

model machine is used, use the grease intervals
for previous model machine.
WDCD-02-03-004
s- Pin Hole Inner Diameter
W2-3-1-6
Cylinder
Rod Rod Bend and Run Out
b
a
A
W166-04-02-022
c d
W105-04-02-094 a- Cylinder Rod c- V Block
b- Dial Gauge d- 1 m (39.4 in)
Unit: mm (in) Unit: mm (in)

Cylinder Name Recommended Size After Re- Bend Run Out Remedy
manufacturing (A) 0.5 (0.020) 1.0 (0.039) Repair
Boom 100-0.012-0.027 (3.94-0.0005-0.001) 1.0 (0.039) 2.0 (0.079) Replace
Arm 115-0.012-0.027 (4.53-0.0005-0.001)
Bucket 95-0.012-0.027 (3.74-0.0005-0.001)
W2-3-2-1
(Blank)
W2-3-2-2
MEMO
MEMO
SECTION 3
UPPERSTRUCTURE
CONTENTS
Group 1 Cab Group 11 Pilot Valve
Removal and Installation of Cab...............................W3-1-1-1 Removal and Installation of Pilot Valve
Dimensions of Cab Glass..............................................W3-1-2-1 (Left)............................................................................ W3-11-1-1
Removal and Installation of Pilot Valve
Group 2 Counterweight (Right)......................................................................... W3-11-2-1
Removal and Installation of Counterweight.........W3-2-1-1 Removal and Installation of Travel Pilot Valve... W3-11-3-1
Group 3 Main Frame Disassembly of Pilot Valves (Right and Left)...... W3-11-4-1
Removal and Installation of Main Frame................W3-3-1-1 Assembly of Pilot Valves (Right and Left)............ W3-11-4-4
Disassembly of Travel Pilot Valve............................ W3-11-5-1
Group 4 Engine Assembly of Travel Pilot Valve................................. W3-11-5-5
Removal and Installation of Engine.........................W3-4-1-1
Group 6 Hydraulic Oil Tank Removal and Installation of Pilot Shut-Off
Removal and Installation of Hydraulic Oil Tank...W3-6-1-1 Solenoid Valve......................................................... W3-12-1-1
Group 7 Fuel Tank Removal and Installation of 3-Spool Solenoid
Removal and Installation of Fuel Tank.....................W3-7-1-1 Valve Unit.................................................................. W3-12-2-1
Disassembly of Pilot Shut-Off Solenoid Valve... W3-12-3-1
Group 8 Pump Device Assembly of Pilot Shut-Off Solenoid Valve......... W3-12-3-3
Removal and Installation of Pump Device.............W3-8-1-1 Structure of 3-Spool Solenoid Valve Unit............ W3-12-4-1
Removal and Installation of Coupling.....................W3-8-2-1
Disassembly of Pump Device.....................................W3-8-3-1 Group 13 Signal Control Valve
Assembly of Pump Device...........................................W3-8-3-4 Removal and Installation of Signal Control
Disassembly of Main Pump.........................................W3-8-4-1 Valve............................................................................ W3-13-1-1
Assembly of Main Pump...............................................W3-8-4-6 Structure of Signal Control Valve........................... W3-13-2-1
Disassembly of Regulator............................................W3-8-5-1
Assembly of Regulator..................................................W3-8-5-3
Disassembly of Pilot Pump . .......................................W3-8-6-1
Assembly of Pilot Pump................................................W3-8-6-3
Disassembly of Housing...............................................W3-9-2-1
Assembly of Housing.....................................................W3-9-2-3
Disassembly of Control Valve (4-Spool Side)........W3-9-3-1
Assembly of Control Valve (4-Spool Side)..............W3-9-3-8
Disassembly of Control Valve (5-Spool Side)........W3-9-4-1
Assembly of Control Valve (5-Spool Side)..............W3-9-4-8
Removal and Installation of Swing Device......... W3-10-1-1
Disassembly of Swing Device.................................. W3-10-2-1
Assembly of Swing Device....................................... W3-10-2-7
Disassembly of Swing Motor................................... W3-10-3-1
Assembly of Swing Motor......................................... W3-10-3-4
Structure of Swing Parking Brake Switch
Valve............................................................................ W3-10-4-1
DDEW-3-1
(Blank)
DDEW-3-2
Group 1 Cab
Removal and Installation of Cab
6 2
5 4 1 WDAA-03-01-023
3 WDAA-03-01-047
IMPORTANT: Cap the open ends in case the hoses 4. Remove floor mat (4).
and pipes have been disconnected. In addition,
5. Remove bolts, washers (5) (4 used). Remove travel
attach an identification tag onto the connectors,
control levers (6) (2 used).
hoses, and pipes for assembling. Connect the
hoses and install the clips in case the clips which j : 17 mm
secure the hoses have been removed.
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-6-1.)
2. Open door (1).
dCAUTION: Seat (2) weight: 42 kg (93 lb)

3. Remove socket bolts (3) (4 used). Remove seat (2).
l : 6 mm
W3-1-1-1
Group 1 Cab
WDAA-03-01-048
Detail A 7
14 12 WDAA-03-01-050
11 10 11
Detail B
8 7 WDAA-03-01-049
13 WDAA-03-01-051
6. Remove bolts, washers (7) (3 used). Remove bracket

(8).
j : 19 mm
7. Remove cover (9).
8. Disconnect plug (10) and connectors (11) (2 used).
9. Remove bolt, washer (12) and screw (13). Remove
cover (14).
j : 13 mm
W3-1-1-2
Group 1 Cab
15 29 26, 27, 28 68 69 33 31
A B
25
20, 21
20, 21 22, 23, 24

WDAA-03-01-052
WDAA-03-01-053
32 30
17, 18
71 70
Detail A Detail B
WDAA-03-01-062 WDAA-03-01-065
19 16, 17, 18
10. Open cover (15). 15. Remove bolts, washers (30) (2 used).
11. Remove caps (16) (2 used). Remove seals (17) (2 j : 17 mm
used) and screws (18) (3 used). Remove cover (19).
16. Remove bolt, washer (31). Remove cover (32).
12. Remove bolts, washers (20) (2 used) and washers
(21) (2 used). j : 13 mm
j : 13 mm 17. Remove screws (68) (2 used). Remove duct (69).
13. Remove caps (22) (3 used). Remove seals (23) (3 18. Remove bolt, washer (70). Remove duct (71).
used) and screws (24) (3 used). Remove cover (25).
j : 13 mm
14. Remove caps (26) (2 used). Remove seals (27) (2
used) and screws (28) (2 used). Remove cover (29)
and duct (33).
W3-1-1-3
Group 1 Cab
A B
WDAA-03-01-063 WDAA-03-01-064
34
Detail A Detail B
34 35 34 WDAA-03-01-054 37 36 37 WDAA-03-01-055
19. Remove clip (35).

20. Disconnect connectors (34) (7 used).
21. Remove clip (36).
W3-1-1-4
Group 1 Cab
1 41
WDCD-03-01-003 44 43 WDDE-03-01-002
38 40 39
Detail A 46 45
WDDE-03-01-001
79 80 48 47
TDAA-05-08-006
23. Shut door (1). 28. Remove bolts, washers (43) (2 used). Remove cover
(44).
24. Open cover (38).
25. Remove filter (39). j : 17 mm
26. Remove screws (40) (6 used). Remove filter case (41). 29. Remove bolt (45). Disconnect connector (46).
27. Remove bolts, washers (79) (2 used). Remove cover j : 13 mm

(80).
30. Push the lock and shift lever (47). Disconnect
j : 17 mm connector (48).
31. Open door (1).
W3-1-1-5
Group 1 Cab
a a 49
a - Lifting Bracket WDAA-03-01-058 73 72 WDAB-03-16-001
dCAUTION:
(930 lb)
The cab (49) assembly weight: 420 kg
32. Attach nylon slings onto lifting brackets (a) (4

places) of cab (49). Hoist and hold the cab (49)
assembly.
dCAUTION: Remove cover (72) while holding it.

Do not drop cover (72).
33. Remove bolts, washers (73) (6 used). Remove cover
(72).
j : 17 mm
W3-1-1-6
Group 1 Cab
49 55, 56 54 55, 56 52, 53
WDAB-03-01-001
54 52, 53 54 55, 56 50, 51 55, 56
74, 75, 76
WDAA-03-01-059
34. Remove bolt (74), washer (75), and spacer (76) at the
rear side.
j : 32 mm
35. Remove socket bolts (50) (2 used) and washers (51)
(2 used).
l : 8 mm
(5 used).
l : 8 mm
37. Remove bolts, washers (54) (5 used).
j : 17 mm
38. Remove nuts (55) (4 used) and washers (56) (4 used).
Remove the cab (49) assembly.
j : 24 mm
W3-1-1-7
Group 1 Cab
57 60 61 62 63 Detail A 66
66
64
59
65
WDAA-03-01-061
58
64
57 60 77 62 WDAA-03-01-060
67
WDAA-03-01-067

40. Remove screws (58) (4 used). Remove monitor
dCAUTION:
(64 lb)
Bracket assembly (67) weight: 29 kg
controller (59).
45. Remove bolts, washers (66) (6 used). Remove
41. Remove bolt, washer (77). bracket assembly (67).
j : 17 mm j : 17 mm
42. Remove screws (60) (4 used). Disconnect connector
(61).
43. Remove screws (62) (4 used). Remove cover (63).
44. Remove bolts, washers (64) (4 used). Remove MC
(65).
j : 13 mm
W3-1-1-8
Group 1 Cab
57 60 61 62 63 Detail A 66
66
64
59
65
WDAA-03-01-061
58
64
57 60 77, 78 62 WDAA-03-01-060
67
WDAA-03-01-067
Installation 5. Install clamp (78) with bolt, washer (77).
dCAUTION:
(64 lb)
Bracket assembly (67) weight: 29 kg j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

1. Install bracket assembly (67) with bolts, washers (66)
(6 used). 6. Install monitor controller (59) with screws (58) (4
used).
j : 17 mm
7. Connect connectors (57) (5 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
2. Install MC (65) with bolts, washers (64) (4 used).
j : 13 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Install cover (63) with screws (62) (4 used).
4. Connect connector (61) with screws (60) (4 used).
W3-1-1-9
Group 1 Cab
a a 49 55, 56 54 55, 56 52, 53
54 52, 53 54 55, 56 50, 51 55, 56
a - Lifting Bracket WDAA-03-01-058 WDAA-03-01-059
12. Install washers (51) (2 used) and socket bolts (50) (2

d CAUTION: The cab (49) assembly weight: 420 kg
(930 lb)
used).
8. Attach nylon slings onto lifting brackets (a) (4 j : 8 mm

places) of cab (49). Hoist the cab (49) assembly.
m : 50 N·m (5 kgf·m, 37 lbf·ft)
9. Install the cab (49) assembly with washers (56) (4
used) and nuts (55) (4 used).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)

10. Install bolts, washers (54) (5 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

11. Install washers (53) (5 used) and socket bolts (52) (5
used).
j : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-10
Group 1 Cab
49
WDAB-03-01-001
74, 75, 76
73 72 WDAB-03-16-001
13. Install spacer (76), washer (75), and bolt (74) at the
rear side.
j : 32 mm
m : 550 N·m (55 kgf·m, 410 lbf·ft)

14. Install cover (72) with bolts, washers (73) (6 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-11
Group 1 Cab
1 41
WDCD-03-01-003 44 43 WDDE-03-01-002
38 40 39
Detail A 46 45
WDDE-03-01-001
79 80 48 47
TDAA-05-08-006
15. Connect connector (48). Shift lever (47) and lock it. 18. Install cover (80) with bolts, washers (79) (2 used).
IMPORTANT: Do not use an impact wrench when j : 17 mm
tightening bolt (45). Using an impact wrench may
result in damage to the cover. m : 50 N·m (5 kgf·m, 37 lbf·ft)
16. Connect connector (46) with bolt (45). 19. Open cover (38).
j : 13 mm 20. Install filter case (41) with screws (40) (6 used).
m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 21. Install filter (39).
17. Install cover (44) with bolts, washers (43) (2 used). 22. Shut cover (38).
23. Open door (1).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-1-1-12
Group 1 Cab
A B
WDAA-03-01-063 WDAA-03-01-064
34
Detail A Detail B
34 35 34 WDAA-03-01-054 37 36 37 WDAA-03-01-055

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

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

32. Install duct (33) and cover (29) with screws (28) (2
used). Install seals (27) (2 used) and caps (26) (2
used).
W3-1-1-14
Group 1 Cab
WDAA-03-01-048
Detail A 7
14 12 WDAA-03-01-050
11 10 11
Detail B
8 7 WDAA-03-01-049
13 WDAA-03-01-051
37. Install cover (14) with screw (13) and bolt, washer
(12).
j : 13 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

38. Connect connectors (11) (2 used) and plug (10).
39. Install cover (9).
40. Install bracket (8) with bolts, washers (7) (3 used).
j : 19 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-1-1-15
Group 1 Cab
6 2
5 4 1 WDAA-03-01-023
3 WDAA-03-01-047
41. Install travel control levers (6) (2 used) with bolts,

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

42. Install floor mat (4).

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

Surface
Section B Detail C
a - Black Ceramic Painted

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

WDAA-03-01-034
Surface
Section A
a - Black Ceramic Painted WDAA-03-01-037

Surface
W3-1-2-2
Group 1 Cab
Unit: mm
Section A
WDAA-03-01-004
WDAA-03-01-031
a - Chamfer along the Periphery WDAA-03-01-003
W3-1-2-3
Group 1 Cab
Unit: mm
Section A
WDAA-03-01-006
WDAA-03-01-031
a - Chamfer along the Periphery WDAA-03-01-005
W3-1-2-4
Group 1 Cab
Unit: mm Section A

WDAA-03-01-031 Surface
d - Shaded Paint along the
Periphery Here
a - Black Ceramic Painted c - Chamfer here. WDAA-03-01-007

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

Surface
Section A Detail B
a - Black Ceramic Painted WDAA-03-01-038 WDAA-03-01-011

Surface
d - Dotted edge along the
Periphery Here
W3-1-2-6
Group 1 Cab
Unit: mm
WDAA-03-01-031

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

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

WDAA-03-01-030 Surface
d - Shaded Paint along the
Periphery Here

Surface
W3-1-2-8
Group 1 Cab
Procedure to Remove Cab Glass
Procedures to Remove Right-Hand Glass (1), Rear Left- 1

Hand Glass (2), Lower Door Glass (3), and Rear Glass (4)
d glass,
CAUTION: When removing the broken or cracked
the glass shards may cause serious injury.
Before removing, use the duct tape or equivalent

in order to paste the broken or cracked glass and
reinforce them. Remove the glass pieces away. WDAA-03-01-030
1. Remove resin panel (5), garnish (6), and the spacer
around the glass.
6
2
3
5 WDAA-03-01-031
2. Prick a hole in adhesive (b) by using awl (a) (or a 7

knife). 8
a
b
W1SE-02-01-033
7 - Cab a - Awl
8 - Glass b - Adhesive
3. Pass piano wire (c) (or a metal wire) through the

hole.
c - Piano Wire W1SE-02-01-034
W3-1-2-9
Group 1 Cab
IMPORTANT: The piano wire is easily broken if a part

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

b - Cemedine 366 Deluxe b - Cemedine 366 Deluxe
c - Fill seal for the inside of installation point here. e - No gap between drainage and wedge
d - Do not apply seal to this groove.
W3-1-2-19
Group 1 Cab
(Blank)
W3-1-2-20
Removal and Installation of Counterweight
10 9
WDDE-03-02-001 WDAB-03-02-001
Removal
2. Open the engine cover.
(10).
j : 17 mm
(2).
j : 17 mm
5. Disconnect connector (3).
6. Remove bolts, washers (4) (4 used). Remove the
rearview camera (5) assembly.
j : 17 mm
W3-2-1-1
WDAB-03-02-002
a - Bracket
d CAUTION: Counterweight (6) weight:

ZX330-5G, 330LC-5G: 6450 kg (14300 lb)
ZX350H-5G, 350LCH-5G: 7000 kg (15500 lb)
ZX350K-5G, 350LCK-5G: 7710 kg (17000 lb)
7. Attach wire ropes onto brackets (a) (2 places) of
counterweight (6). Hoist and hold counterweight
(6).
8. Remove bolts (7) (4 used) and washers (8) (4 used).
Remove counterweight (6).
ZX330-5G, 330LC-5G:
j : 50 mm
ZX350H-5G, 350LCH-5G, 350K-5G, 350LCK-5G:
j : 55 mm
W3-2-1-2
WDAB-03-02-002
a - Bracket
Installation
d CAUTION: Counterweight (6) weight:

ZX330-5G, 330LC-5G: 6450 kg (14300 lb)
ZX350H-5G, 350LCH-5G: 7000 kg (15500 lb)
ZX350K-5G, 350LCK-5G: 7710 kg (17000 lb)
1. Attach wire ropes onto brackets (a) (2 places) of
counterweight (6). Hoist counterweight (6).
2. Install counterweight (6) with washers (8) (4 used)
and bolts (7) (4 used).
ZX330-5G, 330LC-5G:
j : 50 mm
m : 2400 N·m (240 kgf·m, 1770 lbf·ft)

ZX350H-5G, 350LCH-5G, 350K-5G, 350LCK-5G:
j : 55 mm
m : 2840 N·m (284 kgf·m, 2090 lbf·ft)
W3-2-1-3
10 9
WDDE-03-02-001 WDAB-03-02-001
3. Install the rearview camera (5) assembly with bolts,

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

4. Connect connector (3).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

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

7. Shut the engine cover.
W3-2-1-4
Group 3 Main Frame
Removal and Installation of Main Frame

3
4
1
WDDE-03-03-001
IMPORTANT: Cap the open ends in case the hoses

hoses and install the clips in case the clips which
Removal
1. Set the machine for inspection and maintenance.
(Refer to W1-6-1.)
dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
2. Remove cab (1). (Refer to W3-1-1.)
3. Remove counterweight (2). (Refer to W3-2-1.)
4. Remove front attachment (3). (Refer to W5-1-1.)
5. Remove boom cylinder (4). (Refer to W5-2-1.)
W3-3-1-1
Group 3 Main Frame
12
WDAA-03-03-002 WDDE-03-03-002
a - Counterweight Mounting b - Boom Mounting Bracket Hole

Part
6. Place a container under center joint (5). Disconnect

hoses (6) (4 used). dCAUTION: Main frame (12) weight:
j : 36 mm ZX330-5G, 330LC-5G: 6990 kg (15500 lb)
7. Disconnect hose (7). ZX350H-5G, 350LCH-5G: 7230 kg (16000 lb)
j : 27 mm
ZX350K-5G, 350LCK-5G: 7390 kg (16300 lb)
10. Attach wire ropes onto counterweight mounting
8. Disconnect hose (8). part (a) (2 places) of the main frame (12) rear side
and boom mounting bracket hole (b) (2 places).
j : 17 mm
9. Remove bolts (9) (2 used) and spring washers (10) (2
used). Remove stopper (11).
j : 22 mm
W3-3-1-2
Group 3 Main Frame
12 13
15, 16
14
WDAB-03-03-003
11. Reduce slack of wire ropes by using a chain block.

Put the matching marks onto main frame (12) and
outer race (13) of the swing bearing.
12. Remove bolts (14) (32 used), bolts (15) (4 used), and
spacers (16) (4 used).
j : 41 mm
13. Adjust the chain block in order to level main frame
(12). Hoist and remove main frame (12).
W3-3-1-3
Group 3 Main Frame
a
12 13
15, 16
12
14
WDDE-03-03-002 WDAB-03-03-003
a - Counterweight Mounting b - Boom Mounting Bracket Hole

Part
Installation 3. Fit the matching marks made when disassembling

and install main frame (12) to outer race (13) of the
dCAUTION: Main frame (12) weight: swing bearing. Install spacers (16) (4 used), bolts
ZX330-5G, 330LC-5G: 6990 kg (15500 lb) (15) (4 used), and bolts (14) (32 used).
ZX350H-5G, 350LCH-5G: 7230 kg (16000 lb) j : 41 mm
ZX350K-5G, 350LCK-5G: 7390 kg (16300 lb) m : 1250 N·m (125 kgf·m, 920 lbf·ft)
1. Attach wire ropes onto counterweight mounting
part (a) (2 places) of the main frame (12) rear side
and boom mounting bracket hole (b) (2 places).
2. Adjust the chain block in order to level main frame
(12).
W3-3-1-4
Group 3 Main Frame
WDAA-03-03-005
4. Install stopper (11) with spring washers (10) (2 used)

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

5. Connect hose (8).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

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

7. Connect hoses (6) (4 used).
j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)
W3-3-1-5
Group 3 Main Frame
3
4
1
WDDE-03-03-001
8. Install boom cylinder (4). (Refer to W5-2-1.)

9. Install front attachment (3). (Refer to W5-1-1.)
10. Install counterweight (2). (Refer to W3-2-1.)
11. Install cab (1). (Refer to W3-1-1.)
12. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level. Start the
engine and check for any oil leaks.
W3-3-1-6
Group 4 Engine
Removal and Installation of Engine
111, 112, 113
WDDE-03-04-016 WDAB-03-04-002
IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts, washers (111) (6 used). Remove the
and pipes have been disconnected. In addition, cover (112) assembly and O-ring (113) from the top
attach an identification tag onto the connectors, of hydraulic oil tank.
secure the hoses have been removed. 6. Place a container. Drain off hydraulic oil by using an
oil feed pump.
Removal
fNOTE: Total oil amount of hydraulic oil tank: 298 L (78.7
US gal)
maintenance. Close the fuel cock. (Refer to W1-6-1.)

(Refer to W1-4-1.)
2. Open covers (1, 6).
3. Remove wing nuts (2) (4 used) and washers (3) (4
used). Remove covers (4) (2 used).
4. Disconnect ground (5).
W3-4-1-1
Group 4 Engine
7 13 14
Detail A
11 8, 9 10
A
12
WDDE-03-04-001 WDDE-03-04-002
dCAUTION: Engine cover (7) weight: 40 kg (89 lb)

7. Attach nylon slings onto engine cover (7). Hoist and
hold engine cover (7).
8. Remove pins (8) (2 used) and washers (9) (2 used).
Remove the support (11) side of stopper (10).
9. Remove bolts, washers (12) (4 used) from engine
cover (7). Remove engine cover (7).
j : 17 mm
(14).
j : 17 mm
W3-4-1-2
Group 4 Engine
16 15 17 18 WDDE-03-04-007 19, 20 WDDE-03-04-008

(15).
j : 17 mm

(17).
j : 17 mm
13. Place a container under coolant outlet (19). Loosen
cock (20). Drain off coolant.
fNOTE: Coolant amount: 32 L (8.45 US gal)
W3-4-1-3
Group 4 Engine
22 23 21 25 27 28 26
24 WDDE-03-04-003 WDDE-03-08-013
14. Remove counterweight (21). (Refer to W3-2-1.)

(23).
j : 17 mm
16. Open cover (24).
17. Remove bolts, washers (25) (7 used) and bolt,
washer (26). Remove cover (27).
j : 17 mm
j : 17 mm
W3-4-1-4
Group 4 Engine
39 29, 30 41 40
31 32
33 35 34 37 38 36 WDDE-03-08-010 WDDE-03-08-012
19. Remove bolts, washers (29) (2 used). Remove cover 23. Remove bolts, washers (39) (3 used) and bolt,
(30). washer (40). Remove cover (41).
j : 17 mm j : 17 mm
20. Remove clamp (31). Disconnect hose (32).
j : 7 mm
j : 17 mm
j : 17 mm
W3-4-1-5
Group 4 Engine
54 50 51, 52, 53 46, 47, 49
48
WDDE-03-04-004
24. Remove nuts (46) (4 used) and spring washers (47) 26. Remove bolts (51) (3 used), spring washers (52)
(4 used). Disconnect exhaust pipe (48). (3 used), and washers (53) (3 used). Remove the
muffler (50) assembly and gasket (49).
j : 17 mm
j : 17 mm
dCAUTION:
kg (73 lb)
The muffler (50) assembly weight: 33
27. Remove pump device (54). (Refer to W3-8-1.)
25. Attach nylon slings onto muffler (50). Hoist and hold 28. Remove the coupling of the engine. (Refer to W3-8-
the muffler (50) assembly. 2.)
W3-4-1-6
Group 4 Engine
58 57 59 60 63 65
56 55 61 62 WDDE-03-04-005 66 64 WDDE-03-04-006
29. Remove bolts, washers (55) (2 used). Remove cover 34. Remove bolts, washers (65) (2 used). Remove duct
(56). (66).
j : 17 mm j : 17 mm
(58).
j : 17 mm
(60).
j : 17 mm
(62).
j : 17 mm
33. Remove clamps (63, 64).
W3-4-1-7
Group 4 Engine
69 71
67 68 70 WDDE-03-04-009 WDDE-03-04-010

36. Remove bolt, washer (68).
j : 17 mm
37. Remove bolts, washers (69, 70) (2 used for each).
Remove support (71).
j : 17 mm
38. Remove clamps (72, 73). Disconnect the radiator
side of hose (74) and the engine side of hose (75).
pipe (77) assembly.
j : 17 mm
40. Remove clamps (78, 79). Disconnect hose (80).
W3-4-1-8
Group 4 Engine
93 92
WDDE-03-04-011 WDDE-03-04-012
41. Remove clamps (81) (2 used). Disconnect the

radiator side of hose (82) and the engine side of
hose (83).
42. Remove bolts, washers (84) (2 used) and clamp (85).
Remove the pipe (86) assembly.
j : 17 mm
43. Remove clamps (87, 88). Disconnect hose (89).
44. Remove band (90). Remove rubber (91).
45. Disconnect cables (92, 93).
W3-4-1-9
Group 4 Engine
94 97, 98
115 117
114
116
WDCD-03-04-018
100, 101 102 95, 96 99

WDDE-03-04-013
46. Disconnect terminals (94) (3 used). 52. Remove socket bolts (100) (4 used) and washers
(101) (4 used). Place the compressor (102) assembly
47. Remove clips (95) (2 used). Disconnect hoses (96) (2
horizontally.
used).
48. Remove clip (97). Disconnect hose (98). l : 6 mm
49. Disconnect hoses (99) (2 used).
j : 36 mm
50. Loosen lock nut (115) at the top of alternator (114)
and lock nut (116) at the bottom of it.
51. Release the belt tension by moving alternator (114)
back and forth by using adjusting bolt (117).
W3-4-1-10
Group 4 Engine
104
119 103 104 105 WDDE-03-04-014
53. Disconnect terminals (103) (2 used).

54. Disconnect ground (119) from the main frame.
56. Remove bolt, washer (105).
j : 17 mm
W3-4-1-11
Group 4 Engine
a 106 a
107, 108 107, 108
a- Lifting Bracket WDDE-03-04-015
61. Remove the adapter with engine (106) attached if

d CAUTION: Engine (106) weight: 650 kg (1440 lb) necessary.
57. Install shackles to lifting brackets (a) (2 places) of
engine (106). Attach nylon slings onto shackles.
Hoist and hold engine (106).
58. Remove bolts (107) (4 used) and washers (108)
(4 used) from the front attachment side and
counterweight side of engine (106).
j : 30 mm
59. Hoist engine (106) by 15 mm (0.59 in).
60. Move engine (106) to the pump device mounting
side by 50 mm (1.97 in). Remove engine (106).
W3-4-1-12
Group 4 Engine
a 106 a
107, 108 107, 108
a- Lifting Bracket WDDE-03-04-015
Installation
1. Install all removed adapters to engine (106).
dCAUTION: Engine (106) weight: 650 kg (1440 lb)

2. Install shackles to lifting brackets (a) (2 places) of
engine (106). Attach nylon slings onto shackles.
Hoist engine (106).
3. Install engine (106) with washers (108) (4 used) and
bolts (107) (4 used).
j : 30 mm
m : 550 N·m (55 kgf·m, 410 lbf·ft)
W3-4-1-13
Group 4 Engine
104
119 103 104 105, 109 WDDE-03-04-014
4. Install clamp (109) with bolts, washer (105).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

6. Connect ground (119) to the main frame.
7. Connect terminals (103) (2 used).
W3-4-1-14
Group 4 Engine
94 97, 98
115 117
114
116
WDCD-03-04-018
100, 101 102 95, 96 99

WDDE-03-04-013
8. Install the compressor (102) assembly with washers 12. Connect hoses (99) (2 used).
(101) (4 used) and socket bolts (100) (4 used).
j : 36 mm
l : 6 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
13. Connect hose (98) with clip (97).
9. Loosen lock nut (115) at the top of alternator (114)
14. Connect hoses (96) (2 used) with clips (95) (2 used).
and lock nut (116) at the bottom of it.
15. Connect terminals (94) (3 used).
10. Adjust the belt tension by moving alternator (114)
back and forth by using adjusting bolt (117).
11. Tighten lock nuts (115, 116) securely.
IMPORTANT: The belt does not fit when replacing
with a new one. Therefore, adjust the belt tension
again after running the engine at slow idle for 3 to
5 minutes.
W3-4-1-15
Group 4 Engine
93 92
WDDE-03-04-011 WDDE-03-04-012
16. Connect cables (93, 92).

17. Install rubber (91) with band (90).
18. Connect hose (89) with clamps (88, 87).
19. Install the pipe (86) assembly with clamp (85) and
bolts, washers (84) (2 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

20. Connect the engine side of hose (83) and the
radiator side of hose (82) with clamps (81) (2 used).
W3-4-1-16
Group 4 Engine
69 71
67 68, 110 70 WDDE-03-04-009 WDDE-03-04-010
21. Connect hose (80) with clamps (79, 78).

22. Install bolts, washers (76) (2 used) to the pipe (77)
assembly.
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

23. Connect the engine side of hose (75) and the
radiator side of hose (74) with clamps (73, 72).
24. Install support (71) with bolt, washer (70, 69) (2 used
for each).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

25. Install clamp (110) with bolts, washer (68).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-1-17
Group 4 Engine
58 57 59 60 63 65
56 55 61 62 WDDE-03-04-005 66 64 WDDE-03-04-006
27. Install duct (66) with bolts, washers (65) (2 used) 31. Install cover (56) with bolts, washers (55) (2 used).
and clamps (64, 63).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

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

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-4-1-18
Group 4 Engine
54 50 51, 52, 53 46, 47, 49
48
WDDE-03-04-004
32. Install the coupling of the engine. (Refer to W3-8-2.)

33. Install pump device (54). (Refer to W3-8-1.)
dCAUTION:
kg (73 lb)
34. Attach nylon slings onto muffler (50). Hoist and hold
the muffler (50) assembly.
35. Install the muffler (50) assembly with washers (53)
(3 used), spring washers (52) (3 used), and bolts (51)
(3 used).
j : 17 mm
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

36. Connect gasket (49) and exhaust pipe (48) with
spring washers (47) (4 used) and nuts (46) (4 used).
j : 17 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-4-1-19
Group 4 Engine
39 29, 30 41 40
31 32
33 35 34 37 38 36 WDDE-03-08-010 WDDE-03-08-012
37. Install cover (41) with bolt, washer (40) and bolts, 41. Install cover (30) with bolts, washers (29) (2 used).
j : 17 mm
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
38. Install cover (38) with bolt, washer (37) and bolts,
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

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

40. Connect hose (32) with clamp (31).
j : 7 mm
W3-4-1-20
Group 4 Engine
28, 118
WDDE-03-08-013 WDAB-03-04-002
42. Install clamp (118) with bolts, washers (28) (2 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

43. Connect ground (5).
44. Install covers (4) (2 used) with washers (3) (4 used)
and wing nuts (2) (4 used).
45. Add coolant to the radiator.
fNOTE: Coolant amount: 32 L (8.45 US gal)
W3-4-1-21
Group 4 Engine
111, 112, 113 21 25 27 26
WDDE-03-04-016 WDDE-03-08-013
46. Fill hydraulic oil to the hydraulic oil tank. 50. Install counterweight (21). (Refer to W3-2-1.)
fNOTE: Total oil amount of hydraulic oil tank: 298 L (78.7 51. Install cover (27) with bolt, washer (26) and bolts,
US gal)
47. Install O-ring (113). Install the cover (112) assembly j : 17 mm
to the top of hydraulic oil tank with bolts, washers
(111) (6 used). m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

48. Bleed air from the fuel system. (Refer to W1-4-1.)
1.)
W3-4-1-22
Group 4 Engine
22 23
24 WDDE-03-04-003 16 15 17 18 WDDE-03-04-007
52. Close cover (24).

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

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

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-4-1-23
Group 4 Engine
7 13 14
Detail A
11 8, 9 10
A
6 12
WDDE-03-04-001 WDDE-03-04-002
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
dCAUTION: Engine cover (7) weight: 40 kg (89 lb)

57. Attach nylon slings onto engine cover (7). Hoist
engine cover (7).
58. Install engine cover (7) with bolts, washers (12) (4
used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

59. Install the support (11) side of stopper (10) with
washers (9) (2 used) and pins (8) (2 used).
60. Close covers (6, 1).
W3-4-1-24
Removal and Installation of Hydraulic Oil

Tank
WDDE-03-06-001
1 3, 4
dCAUTION: Escaping fluid under pressure may

penetrate the skin and eyes, and cause serious
dCAUTION: Bleed air from hydraulic oil tank (1).
(Refer to W1-4-1.)
injury. Release the pressure before disconnecting 2. Remove bolts, washers (2) (6 used). Remove the
the hydraulic pipings or removing other cover (3) assembly and O-ring (4) from the upper
equipment. Hot hydraulic oil just after operation part of hydraulic oil tank (1).
may spout out and cause severe burns. Wait for oil
in order to cool before starting any work. Do not j : 17 mm
turn the cap of hydraulic oil tank (1) quickly. The
3. Place a container. Drain off hydraulic oil by using an
cap may fly off by internal pressure. Release any
oil feed pump.
remaining pressure and remove the cap.
fNOTE: Hydraulic oil tank (1) capacity: 298 L (78.7 US
IMPORTANT: Cap the open ends in case the hoses gal)
Removal
W3-6-1-1
5 10 7 6 13 17 16 14
8 9 10 11 WDDE-03-06-002 19 18 15 WDDE-03-06-003
4. Open cover (5). 8. Remove bolts, washers (12) (2 used).
dCAUTION: Remove cover (7) while holding it. Do

not drop cover (7).
j : 17 mm
9. Open engine cover (13).
(7). 10. Remove bolts, washers (14) (2 used). Remove cover
(15).
j : 17 mm
j : 17 mm
d CAUTION: Remove cover (9) while holding it. Do
not drop cover (9).
(17).
(9). j : 17 mm
j : 17 mm 12. Remove bolts, washers (18) (5 used). Remove cover

(19).
Do not drop cover (11). j : 17 mm
(11).
j : 17 mm
W3-6-1-2
WDDE-03-06-004
13. Place a container under hydraulic oil tank (1) and

suction pipe (20). Slowly turn drain plug (21). Drain
off hydraulic oil completely.
j : 27 mm
14. Remove hose clamps (22) (4 used). Disconnect hose
(23).
15. Remove bolts, washers (24) (4 used). Move cover
assembly (25).
j : 17 mm
W3-6-1-3
WDDE-03-06-006
a - Lifting Hole
16. Disconnect connector (27) of hydraulic oil

temperature sensor (26). dCAUTION:
(290 lb)
Hydraulic oil tank (1) weight: 130 kg

20. Install eyebolts (2 used) and nuts (2 used) to lifting
j : 17 mm holes (a) (2 places) of hydraulic oil tank (1). Attach
nylon slings onto the eyebolts. Hoist and hold
18. Remove couplings (29, 30). Disconnect pipes (31, hydraulic oil tank (1).
32) at the hydraulic oil tank (1) end.
21. Remove bolts, washers (34) (4 used). Hoist and
j : 13 mm remove hydraulic oil tank (1).
19. Disconnect hoses (33) (4 used). j : 27 mm
j : 19 mm
W3-6-1-4
WDDE-03-06-007
a - Lifting Hole
Installation 4. Connect pipes (32, 31) with couplings (30, 29).
dCAUTION:
(290 lb)
Hydraulic oil tank (1) weight: 130 kg j : 13 mm
m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft)

1. Install eyebolts (2 used) and nuts (2 used) to lifting
holes (a) (2 places) of hydraulic oil tank (1). Attach 5. Install clamps (35) (3 used) with bolts, washers (28)
nylon slings onto the eyebolts. Hoist hydraulic oil (3 used).
tank (1).
j : 17 mm
2. Install hydraulic oil tank (1) with bolts, washers (34)
(4 used). m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 27 mm 6. Connect connector (27) of hydraulic oil temperature

sensor (26).
m : 400 N·m (40 kgf·m, 300 lbf·ft)
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-6-1-5
1 3, 4
WDDE-03-06-005 WDDE-03-06-001
7. Install cover assembly (25) with bolts, washers (24) 11. Install O-ring (4).
(4 used).
12. Install the cover (3) assembly to the upper part of
j : 17 mm hydraulic oil tank (1) with bolts, washers (2) (6 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 17 mm
8. Connect hose (23) with hose clamps (22) (4 used). m : 50 N·m (5 kgf·m, 37 lbf·ft)
9. Check that drain plug (21) is tightened.
10. Fill hydraulic oil tank (1) with hydraulic oil.
fNOTE: Hydraulic oil tank (1) capacity: 298 L (78.7 US

gal)
W3-6-1-6
13 17 16 14
19 18 15 WDDE-03-06-003
13. Bleed air from the hydraulic system. (Refer to W1-4- 16. Install cover (17) with bolts, washers (16) (2 used).
1.)
j : 17 mm
engine and check for any oil leaks. m : 50 N·m (5 kgf·m, 37 lbf·ft)
14. Install cover (19) with bolts, washers (18) (2 used). 17. Install cover (15) with bolts, washers (14) (2 used).
j : 17 mm j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft) m : 50 N·m (5 kgf·m, 37 lbf·ft)
15. Install bolts, washers (18) (3 used). 18. Shut engine cover (13).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-6-1-7
5 12 7 6
8 9 10 11 WDDE-03-06-002
19. Install bolts, washers (12) (2 used). 22. Install cover (7) with bolts, washers (6) (6 used).
j : 17 mm j : 17 mm

20. Install cover (11) with bolts, washers (10) (2 used). 23. Shut cover (5).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-6-1-8
Group 7 Fuel Tank
Removal and Installation of Fuel Tank
2
5, 6
9 10
8 11
3, 4
WDCD-03-07-001
IMPORTANT: Cap the open ends in case the hoses 6. Remove bolts (5) (2 used) and washers (6) (2 used).
and pipes have been disconnected. In addition, Remove handrail (7).
hoses, and pipes for assembling. Connect the j : 19 mm
hoses and install the clips in case the clips which 7. Remove bolts, washers (8) (4 used). Remove step (9).
j : 17 mm
Removal 8. Remove bolts, washers (10) (4 used). Remove cover
(11).
maintenance. (Refer to W1-6-1.) j : 17 mm
2. Remove cap (1).
3. Place a container. Drain off fuel by using an oil feed
pump.
fNOTE: Amount of oil: 630 L (166 US gal)

4. Open cover (2).
j : 22 mm
W3-7-1-1
Group 7 Fuel Tank
a b
12 13 19
19 17
18
WDDE-03-07-001 WDCD-03-07-003
14 15, 16
a - Mounting Hole b- Mounting Hole

(13). dCAUTION: Fuel tank (19) weight: 210 kg (465 lb)
13. Install an eyebolt (M10, Pitch 1.5 mm) to mounting
j : 17 mm hole (a) of fuel tank (19). Install an eyebolt (M10,
10. Disconnect connector (14). Pitch 1.5 mm) and a nut to mounting hole (b) of
fuel tank (19). Attach nylon slings onto the eyebolts.
11. Remove bolt, washer (15). Remove clip (16). Hoist and hold fuel tank (19).
j : 17 mm
12. Remove hose clip (17). Disconnect hose (18).
W3-7-1-2
Group 7 Fuel Tank
19
WDCD-03-07-004
WDCD-03-07-005
20 21 23 22
16. Place a container under fuel tank (19). Remove hose

d CAUTION: Remove cover (21) while holding it.
clips (24, 25). Disconnect hoses (26, 27). Drain fuel
completely.
17. Remove bolts (28) (6 used) and washers (29) (6
(21).
used). Remove fuel tank (19).
j : 17 mm
j : 24 mm
d CAUTION: Remove cover (23) while holding it.
(23).
j : 17 mm
W3-7-1-3
Group 7 Fuel Tank
a b
19
19
WDDE-03-07-001 WDCD-03-07-003
a - Mounting Hole b- Mounting Hole
Installation
dCAUTION: Fuel tank (19) weight: 210 kg (465 lb)

1. Install an eyebolt (M10, Pitch 1.5 mm) to mounting
hole (a) of fuel tank (19). Install an eyebolt (M10,
Pitch 1.5 mm) and a nut to mounting hole (b) of
fuel tank (19). Attach nylon slings onto the eyebolts.
Hoist fuel tank (19).
W3-7-1-4
Group 7 Fuel Tank
19
WDCD-03-07-004
WDCD-03-07-005
20 21 23 22
2. Install fuel tank (19) with washers (29) (6 used) and

j : 24 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft)

3. Connect hoses (27, 26) with hose clips (25, 24).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-7-1-5
Group 7 Fuel Tank
12 13 19
19 17
18
WDDE-03-07-001 WDCD-03-07-003
14 15, 16
6. Connect hose (18) with hose clip (17).

7. Install clip (16) with bolt, washer (15).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-7-1-6
Group 7 Fuel Tank
2
5, 6
9 10
8 11
3, 4
19
WDCD-03-07-001
10. Install cover (11) with bolts, washers (10) (4 used). 13. Install washers (4) (2 used) and bolts (3) (2 used).
j : 17 mm j : 22 mm

11. Install step (9) with bolts, washers (8) (4 used). 14. Shut cover (2).
j : 17 mm 15. Fill fuel tank (19) with fuel.
m : 50 N·m (5 kgf·m, 37 lbf·ft) fNOTE: Amount of oil: 630 L (166 US gal)

16. Install cap (1).
12. Install handrail (7) with washers (6) (2 used) and
bolts (5) (2 used). 17. Bleed air from the fuel system. (Refer to W1-4-1.)
j : 19 mm
m : 110 N·m (11 kgf·m, 81 lbf·ft)
W3-7-1-7
Group 7 Fuel Tank
(Blank)
W3-7-1-8
Group 8 Pump Device
Removal and Installation of Pump Device
7 8 6 2 9 11 10
WDDE-03-06-001 12 WDDE-03-08-013
5 1 3, 4
IMPORTANT: Cap the open ends in case the hoses 5. Remove bolts, washers (7) (6 used). Remove cover
and pipes have been disconnected. In addition, (8).
hoses and install the clips in case the clips which 6. Remove bolts, washers (9) (7 used) and bolt, washer
secure the hoses have been removed. (10). Remove cover (11).
Removal j : 17 mm
1. Set the machine position for inspection and 7. Remove bolts, washers (12) (2 used).
maintenance. (Refer to W1-6-1-1.) j : 17 mm
dCAUTION: Bleed air from hydraulic oil tank (1).

(Refer to W1-4-1-1.)
cover (3) assembly and O-ring (4) from the top of
hydraulic oil tank (1).
j : 17 mm
3. Place a container. Drain off hydraulic oil by using an
oil feed pump.
fNOTE: Total oil amount of hydraulic oil tank (1): 298 L

(78.7 US gal)
4. Open cover (5) and engine cover (6).
W3-8-1-1
Group 8 Pump Device
23 13, 14 25 24 Detail A
15 16
17 19 18 21 22 20
WDDE-03-08-010 WDDE-03-08-012
8. Remove bolts, washers (13) (2 used). Remove cover 12. Remove bolts, washers (23) (2 used) and bolt,
(14). washer (24). Remove cover (25).
j : 17 mm j : 17 mm
9. Remove clamp (15). Disconnect hose (16).
j : 7 mm
j : 17 mm
j : 17 mm
W3-8-1-2
Group 8 Pump Device
30 26, 27, 28, 29
31, 32, 33 WDDE-03-08-011 WDDE-03-08-014
13. Remove bolts (26) (2 used) and nuts (27) (2 used). 16. Remove bolts, washers (34) (2 used).
Remove clamp (28) and gasket (29).
j : 10 mm
j : 17 mm
d CAUTION: The muffler (30) assembly weight:
30kg (67 lb)
14. Attach nylon slings onto muffler (30). Hoist and hold
the muffler (30) assembly.
15. Remove bolts (31) (3 used), spring washers (32)
(3 used), and washers (33) (3 used). Remove the
muffler (30) assembly.
j : 17 mm
W3-8-1-3
Group 8 Pump Device
WDDE-03-08-015 WDDE-03-08-016
18. Place a container under pump device (36) and 23. Disconnect hose (47).
pipe (37). Remove clamps (38) (4 used). Disconnect
rubber hose (39). j : 17 mm
19. Remove socket bolts (40) (8 used). Disconnect the 24. Disconnect hoses (48) (2 used).
pipe (37) assembly. Remove O-rings (56) (2 used).
j : 19 mm
l : 10 mm
20. Disconnect hose (41).
j : 36 mm
21. Remove socket bolts (42) (8 used) and flanges (43)
(4 used). Disconnect hoses (44) (2 used). Remove
O-rings (45) (2 used).
l : 10 mm
j : 27 mm
W3-8-1-4
Group 8 Pump Device
51, 52 49, 50
49, 50 36
WDDE-03-08-017

used).
j : 19 mm
dCAUTION:
lb)
Pump device (36) weight: 210 kg (465
26. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to the

bolt (49) holes (3 places). Attach nylon slings onto
the eyebolts. Hoist and hold pump device (36).
27. Remove bolts (51) (5 used) and spring washers (52)
(5 used). Remove pump device (36).
j : 17 mm
28. Remove the adapter with pump device (36)
attached if necessary.
W3-8-1-5
Group 8 Pump Device
51, 52 49, 50
49, 50 36
WDDE-03-08-017
Installation
1. Install all removed adapters to pump device (36).
dCAUTION:
lb)
Pump device (36) weight: 210 kg (465

bolt (49) holes (3 places). Attach nylon slings onto
the eyebolts. Hoist pump device (36).
3. Install pump device (36) with spring washers (52) (5
used) and bolts (51) (5 used).
j : 17 mm
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

4. Remove the eyebolts (3 used) from the bolt (49)
holes (3 places). Install washers (50) (3 used) and
j : 19 mm
W3-8-1-6
Group 8 Pump Device
WDDE-03-08-015 WDDE-03-08-016
5. Connect hoses (48) (2 used). 9. Connect hose (41).
j : 19 mm j : 36 mm

6. Connect hose (47). 10. Install O-rings (56) (2 used). Connect the pipe (37)
assembly with socket bolts (40) (8 used).
j : 17 mm
l : 10 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
m : 90 N·m (9 kgf·m, 66 lbf·ft)
11. Install rubber hose (39) with clamps (38) (4 used).
j : 27 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)

8. Install O-rings (45) (2 used). Connect hoses (44) (2
used) with flanges (43) (4 used) and socket bolts
(42) (8 used).
l : 10 mm
m : 110 N·m (11 kgf·m, 81 lbf·ft)
W3-8-1-7
Group 8 Pump Device
30 26, 27, 28, 29
54
31, 32, 33 WDDE-03-08-011 WDDE-03-08-018
12. Connect connectors (35) (3 used). 16. Install gasket (29) and clamp (28) to muffler (30) and
exhaust pipe (54) with nuts (27) (2 used) and bolts
13. Install clamps (53) (2 used) with bolts, washers (34)
(26) (2 used).
(2 used).
j : 17 mm
j : 10 mm
m : 7 to 10 N·m (0.7 to 1 kgf·m, 5.2 to 7.4 lbf·ft)
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)
dCAUTION:
kg (67 lb)
14. Attach nylon slings onto muffler (30). Hoist the

muffler (30) assembly.
15. Install the muffler (30) assembly with washers (33)
(3 used), spring washers (32) (3 used), and bolts (31)
(3 used).
j : 17 mm
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
W3-8-1-8
Group 8 Pump Device
23 13, 14 25 24 Detail A
15 16
17 19 18 21 22 20
WDDE-03-08-010 WDDE-03-08-012
17. Install hose (16) with clamp (15). 21. Install cover (14) with bolts, washers (13) (2 used).
18. Install cover (25) with bolt, washer (24) and bolts, j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

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

j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-8-1-9
Group 8 Pump Device
7 8 6 2 9 11 10
WDDE-03-06-001 12, 55 WDDE-03-08-013

5 1 3, 4
22. Install clamps (55) (2 used) with bolts, washers (12) 26. Install cover (11) with bolt, washer (10) and bolts,
(2 used). washers (9) (7 used).
j : 17 mm j : 17 mm

23. Fill hydraulic oil to hydraulic oil tank (1). 27. Install cover (8) with bolts, washers (7) (6 used).
fNOTE: Total oil amount of hydraulic oil tank (1): 298 L j : 17 mm

(78.7 US gal)
m : 50 N·m (5 kgf·m, 37 lbf·ft)
24. Install O-ring (4). Install the cover (3) assembly to
the top of hydraulic oil tank (1) with bolts, washers 28. Shut engine cover (6) and cover (5).
(2) (6 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

1-2.)
W3-8-1-10
Group 8 Pump Device
Removal and Installation of Coupling
9
8 9 5 6
3 1 4 2 7
WDDE-03-08-008 WDDE-03-08-009
Removal 4. Remove clamping screws (9) (2 used) from cylinder

hub (8). Remove cylinder hub (8) from the pump
1. Remove element (2) from insert (1) at the engine
device.
flywheel side.
IMPORTANT: Do not remove spring pin (3). l : 14 mm
2. Remove socket bolts (4) (4 used) from insert
(1). Remove inserts (1) (4 used) from the engine
flywheel.
l : 14 mm
IMPORTANT: Do not remove spring pin (5).
3. Remove socket bolts (7) (4 used) from insert (6).
Remove inserts (6) (4 used) from cylinder hub (8).
l : 14 mm
W3-8-2-1
Group 8 Pump Device
9
8 9 5 6
3 1 4 2 7
WDDE-03-08-008 WDDE-03-08-009
Installation
1. Install cylinder hub (8) to the pump device.
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
2. Secure cylinder hub (8) with clamping screws (9) (2 such as goggles, helmets, etc in order to prevent
used). personal injury.
5. Install spring pins (3) (4 used) to the engine flywheel
l : 14 mm by using a hammer.
m : 100 to 120 N·m (10 to 12 kgf·m, 74 to 89 6. Install inserts (1) (4 used) to the engine flywheel
lbf·ft) with socket bolts (4) (4 used).

l : 14 mm
such as goggles, helmets, etc in order to prevent m : 310 to 330 N·m (31 to 33 kgf·m, 230 to 245
personal injury. lbf·ft)
3. Install spring pins (5) (8 used) to cylinder hub (8) by 7. Install element (2) to inserts (1) (4 used) at the
using a hammer. engine flywheel side.
4. Install inserts (6) (4 used) to cylinder hub (8) with
socket bolts (7) (4 used).
l : 14 mm
m : 310 to 330 N·m (31 to 33 kgf·m, 230 to 245

lbf·ft)
W3-8-2-2
Group 8 Pump Device
Disassembly of Pump Device
WDDE-03-08-005
02- Casing 20- Spring Washer (2 Used) 59- Clamp (2 Used) 76- Bracket
04- Center Gear 22- Washer (2 Used) 60- Bolt 77- Socket Bolt
05- Center Shaft 23- Adapter 61- Nut 78- Spring Washer
07- Bearing 32- Main Pump (2 Used) 62- Spring Washer 81- Plug
08- Bearing 35- Bolt (8 Used) 63- Level Gauge 82- P Sensor (2 Used)
10- Retaining Ring 36- Seal Washer (4 Used) 64- Pipe
11- Oil Seal 37- Spring Washer (4 Used) 65- Socket Bolt (2 Used)
12- Seal Cover 40- Plug 66- Packing
13- O-Ring 50- Pipe (2 Used) 69- N Sensor
14- Retaining Ring 52- Pipe 70- O-Ring
18- Socket Bolt (2 Used) 55- Pipe 71- Washer
19- Pilot Pump 56- Pipe 72- Socket Bolt
W3-8-3-1
Group 8 Pump Device
Disassembly of Pump Device 8. Remove adapter (23) from pilot pump (19).
1. Remove P sensors (82) (2 used) from main pumps j : 27 mm
(32) (2 used).
9. Remove socket bolts (18) (2 used), spring washers
j : 27 mm (20) (2 used), and washers (22) (2 used). Remove
pilot pump (19) from casing (02).
2. Remove socket bolts (72, 77), washer (71), and
spring washer (78). Remove N sensor (69), O-ring l : 8 mm
(70), and bracket (76) from casing (02).
l : 5 mm
dCAUTION: Main pump (32) weight: 67 kg (150 lb)
10. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
3. Remove drain plug (81). Drain off engine oil from main pump (32). Attach nylon slings onto the
casing (02). eyebolts. Hoist and hold main pump (32).
j : 22 mm 11. Remove bolts (35) (4 used), seal washers (36) (2

used), and spring washers (37) (2 used). Remove
fNOTE: Oil amount: 1.4 L (1.48 US qt) main pump (32) from casing (02).
4. Remove plug (40) from casing (02).
j : 24 mm
j : 17 mm 12. Remove another main pump (32) in the same way
as step 10 to step 11.
dCAUTION: Pump device weight: 205 kg (455 lb)
13. Remove level gauge (63) from pipe (64).
5. Secure the pump device assembly on the
workbench (ST 5050). 14. Remove socket bolts (65) (2 used). Remove pipe (64)
6. Remove bolt (60). Remove nut (61), spring washer and packing (66) from casing (02).
(62), and clamps (59) (2 used) from pipes (55, 56).
l : 6 mm
j : 13 mm
7. Remove pipes (50) (2 used) and pipes (52, 55, 56)
from main pumps (32) (2 used).
j : 17 mm
W3-8-3-2
Group 8 Pump Device
20. Remove center gear (04) from casing (02).

d CAUTION: The casing (02) assembly weight: 49
kg (110 lb) 21. Remove bearing (08) from casing (02) by using the
special tool (ST 1235).
15. Remove casing (02) from the workbench. Turn
over and place the casing (02) assembly onto the
workbench. Remove retaining ring (14) from casing
(02).
16. Remove seal cover (12) from casing (02). ST 1235
17. Remove oil seal (11) from seal cover (12) by using
the special tool (ST 1234).
18. Remove O-ring (13) from casing (02). Remove
retaining ring (10) from center shaft (05).
dCAUTION:
kg (98 lb)
The casing (02) assembly weight: 44 W1V7-02-04-005
19. Turn over and place the casing (02) assembly onto a
press. Remove the center shaft (05) assembly from 22. Remove bearing (07) from center shaft (05) by using
casing (02) by using the special tool (ST 1236). a press or a puller.
ST 1236
W1V7-02-04-004
W3-8-3-3
Group 8 Pump Device
Assembly of Pump Device
50
35, 36
52
59
60, 61, 62
55
56
32 35, 37 76, 77, 78 69, 70, 71, 72
40 08 04 07
10 12
11
05
82
13 14
WDDE-03-08-006
23 19 18, 20, 22 02
W3-8-3-4
Group 8 Pump Device
View A
63
64
WDDE-03-08-007
65, 66 81
02- Casing 20- Spring Washer (2 Used) 59- Clamp (2 Used) 76- Bracket
04- Center Gear 22- Washer (2 Used) 60- Bolt 77- Socket Bolt
05- Center Shaft 23- Adapter 61- Nut 78- Spring Washer
07- Bearing 32- Main Pump (2 Used) 62- Spring Washer 81- Plug
08- Bearing 35- Bolt (8 Used) 63- Level Gauge 82- P Sensor (2 Used)
10- Retaining Ring 36- Seal Washer (4 Used) 64- Pipe
11- Oil Seal 37- Spring Washer (4 Used) 65- Socket Bolt (2 Used)
12- Seal Cover 40- Plug 66- Packing
13- O-Ring 50- Pipe (2 Used) 69- N Sensor
14- Retaining Ring 52- Pipe 70- O-Ring
18- Socket Bolt (2 Used) 55- Pipe 71- Washer
19- Pilot Pump 56- Pipe 72- Socket Bolt
W3-8-3-5
Group 8 Pump Device
Assembly of Pump Device
dCAUTION: Casing (02) weight: 39 kg (86 lb) dCAUTION:

kg (110 lb)
The casing (02) assembly weight: 49
1. Face the input shaft side of casing (02) up. Install
bearing (08) to casing (02) by using the special tool 5. Remove casing (02) from the press. Place casing (02)
(ST 2307). onto the workbench. Install retaining ring (10) to
center shaft (05). Install O-ring (13) to casing (02).
ST 2307 6. Install oil seal (11) to seal cover (12) by using the
7. Install the special tool (ST 2280) to center shaft (05).
Install seal cover (12) to casing (02).
8. Install retaining ring (14) to casing (02).
W1V7-02-04-007
2. Insert center gear (04) into casing (02) through the

main pump (32) mounting hole. Place center gear
(04) onto bearing (08).
3. Place casing (02) onto a press. Fit center shaft (05)
to the spline of center gear (04). Install center shaft
(05) to bearing (08) by using a press.
4. Install bearing (07) to casing (02) and center shaft
(05) by using the special tool (ST 2308) and a press.
ST 2308
W1V7-02-04-008
W3-8-3-6
Group 8 Pump Device
13. Apply THREEBOND #1215 onto the pilot pump (19)

d CAUTION: The casing (02) assembly weight: 49
kg (110 lb)
mounting surface of casing (02). Install pilot pump
(19) to casing (02) with washers (22) (2 used), spring
9. Turn over and place casing (02) onto the washers (20) (2 used), and socket bolts (18) (2 used).
workbench. Apply THREEBOND #1215 onto the
main pump (32) mounting surface. l : 8 mm
Workbench: ST 5050 m : 50 N·m (5 kgf·m, 37 lbf·ft)
dCAUTION: Main pump (32) weight: 67 kg (150 lb) 14. Install packing (66) and pipe (64) to casing (02) with
main pump (32). Attach nylon slings onto the l : 6 mm
eyebolts. Hoist main pump (32).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
11. Install main pump (32) to casing (02) with spring
washers (37) (2 used), seal washers (36) (2 used), and 15. Install adapter (23) to pilot pump (19).
j : 27 mm
j : 24 mm
m : 95 N·m (9.5 kgf·m, 70 lbf·ft)
m : 150 N·m (15 kgf·m, 11 lbf·ft)
35, 37
35, 36
35, 37
WDDE-03-08-019
12. Install another main pump (32) in the same way as

step 10 to step 11.
W3-8-3-7
Group 8 Pump Device
16. Install pipes (56, 55, 52) and pipes (50) (2 used). 19. Install P sensors (82) (2 used) to main pumps (32) (2
used).
j : 17 mm
j : 27 mm
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
m : 100 N·m (10 kgf·m, 74 lbf·ft)
17. Secure pipes (56, 55) with clamps (59) (2 used),
spring washer (62), bolt (60), and nut (61).
dCAUTION: Pump device weight: 205 kg (455 lb)
j : 13 mm 20. Place the pump device horizontally. Add engine oil
to casing (02). Install plug (40) to casing (02).
m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
j : 17 mm
18. Install bracket (76), O-ring (70), and N sensor (69) to
casing (02) with spring washer (78), washer (71), and m : 40 N·m (4 kgf·m, 30 lbf·ft)
socket bolts (77, 72).
fNOTE: Oil amount: 1.4 L (1.48 US qt)
l : 5 mm 21. Install level gauge (63) to pipe (64).
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-8-3-8
Group 8 Pump Device
Disassembly of Main Pump
5
15
4 14
12
2 3 13
1 11 12
16
17
18
19
20
10 26
9 25
8 25 34
7 24 35
32 36
27
23 12
25 31
22
28 30
21 29 25 25
39
40
45
28
48 47 41
25
46 29 23 42
49
50
43
44
34
WDDE-03-08-004
1- Retaining Ring 14- Bearing Nut 26- Feedback Pin 41- Set Screw
2- Drive Gear 15- Roller Bearing 27- Link 42- Servo Piston
3- O-Ring 16- Roller Bearing 28- Pin (2 Used) 43- O-Ring
4- Regulator 17- Spacer 29- Lever (2 Used) 44- Stopper L
5- Socket Bolt (4 Used) 18- Packing 30- Servo Pin 45- Valve Plate
7- Retaining Ring 19- Spring Pin (2 Used) 31- Head Cover 46- Cylinder Block
8- Seal Cover 20- Plug 32- Plug 47- Spring
9- Oil Seal 21- Pin 34- Socket Bolt (8 Used) 48- Center Shaft
10- O-Ring 22- Plunger (7 Used) 35- Stopper S 49- Drive Disc
11- Casing 23- Pin (2 Used) 36- O-Ring 50- P Sensor
12- O-Ring (10 Used) 24- Pin 39- Socket Bolt (8 Used)
13- Spring Pin (2 Used) 25- Retaining Ring (6 Used) 40- Spring Washer (8 Used)
W3-8-4-1
Group 8 Pump Device
Disassembly of Main Pump

Removal of Drive Gear
1. Remove retaining ring (1) from drive disc (49). 7. Remove packing (18) and O-rings (12) (3 used) from
casing (11).
2. Remove drive gear (2) from drive disc (49).
8. Place valve plate (45) on casing (11).
dCAUTION: Main pump weight: 67 kg (150 lb)
9. Remove cylinder block (46), valve plate (45), and the
3. Secure the main pump on the workbench (ST 5050).
link (27) assembly from casing (11).
4. Remove bolts (5) (4 used) from regulator (4).
10. Remove spring (47) from center shaft (48).
Remove regulator (4) from casing (11).
l : 8 mm
5. Remove O-rings (12) (5 used), O-ring (3), and spring
pins (13) (2 used) from casing (11).
6. Remove socket bolts (39) (8 used) and spring
washers (40) (8 used). Remove head cover (31) from
casing (11).
l : 10 mm
W3-8-4-2
Group 8 Pump Device
IMPORTANT: Do not lose pin (21) when removing 17. Remove plug (20) from casing (11).
center shaft (48).
l : 8 mm
11. Remove center shaft (48) from drive disc (49).
18. Turn over and place casing (11) on a press. Remove
12. Incline plungers (22) (7 used) to the center of drive
drive disc (49) with the bearing attached by using a
disc (49). Remove plungers (22) (7 used) upward.
press and the special tool (ST 1239).
13. Place casing (11) on the workbench. Remove
retaining ring (7) from casing (11).
14. Place casing (11) on the workbench with the drive
disc (49) side up. Remove seal cover (8) from casing ST 1239
(11) by using a screwdriver.
15. Remove oil seal (9) from seal cover (8) by using a
screwdriver.
16. Remove O-ring (10) from casing (11).
W1V7-02-04-010
10
W1V7-02-04-009
W3-8-4-3
Group 8 Pump Device
19. Place the drive disc (49) assembly on the special 22. Remove roller bearing (15) and spacer (17) from
tool (ST 5905) as illustrated in order to remove drive disc (49) by using puller (a).
bearing nut (14).
49
ST 5905 a
17
15
W1V7-02-04-011 a- Puller W1V7-02-04-013
20. Install the special tool (ST 3504) to the spline part of
drive disc (49). Loosen bearing nut (14). 23. Remove the outer race of roller bearing (16).
ST 3054 24. Remove roller bearing (15) from spacer (17) by using
ST 1271
W1V7-02-04-012
21. Remove bearing nut (14) from drive disc (49). W1V7-02-04-014
W3-8-4-4
Group 8 Pump Device
25. Install the special tool (ST 1272) between roller 28. Remove socket bolts (34) (4 used) from stopper L
bearing (16) and drive disc (49). Secure the drive (44). Remove stopper L (44) and O-ring (43) from
disc (49) assembly in a vise. Adjust the clearance in head cover (31).
order to use puller (a).
l : 6 mm
29. Remove set screw (41) from servo piston (42).
16
Remove servo pin (30) from head cover (31).
ST 1272
l : 6 mm
fNOTE: LOCTITE #829 has been applied onto set screw

(41). Warm up set screw (41) before removing.
30. Remove servo piston (42) from head cover (31).
49
W1V7-02-04-015
26. Set puller (a). Remove roller bearing (16) from drive
disc (49).
16
a- Puller
W1V7-02-04-016
27. Remove socket bolts (34) (4 used) from stopper S

(35). Remove stopper S (35), O-ring (36), and O-rings
(12) (2 used) from head cover (31).
l : 6 mm
W3-8-4-5
Group 8 Pump Device
Assembly of Main Pump
5 13 4 12 26 24 27 3
34 35 12 11 16 17 15 14 49
36 2
12 1
41
B 8
42 B
31
44 43 30 29 18 20 47 22 46 48 21 10 7 9 W1V7-02-04-023
34
45 19 28, 25 23
Section B-B
W1HH-02-04-006
W3-8-4-6
Group 8 Pump Device
32
50
39, 40
View A W173-02-04-002
1- Retaining Ring 14- Bearing Nut 26- Feedback Pin 41- Set Screw
2- Drive Gear 15- Roller Bearing 27- Link 42- Servo Piston
3- O-Ring 16- Roller Bearing 28- Pin (2 Used) 43- O-Ring
4- Regulator 17- Spacer 29- Lever (2 Used) 44- Stopper L
5- Socket Bolt (4 Used) 18- Packing 30- Servo Pin 45- Valve Plate
7- Retaining Ring 19- Spring Pin (2 Used) 31- Head Cover 46- Cylinder Block
8- Seal Cover 20- Plug 32- Plug 47- Spring
9- Oil Seal 21- Pin 34- Socket Bolt (8 Used) 48- Center Shaft
10- O-Ring 22- Plunger (7 Used) 35- Stopper S 49- Drive Disc
11- Casing 23- Pin (2 Used) 36- O-Ring 50- P Sensor
12- O-Ring (10 Used) 24- Pin 39- Socket Bolt (8 Used)
13- Spring Pin (2 Used) 25- Retaining Ring (6 Used) 40- Spring Washer (8 Used)
W3-8-4-7
Group 8 Pump Device
Assembly of Main Pump

IMPORTANT: Before assembling, apply hydraulic oil dCAUTION: Take care as the inner races of roller
bearings (15, 16) are too hot.
onto parts in order to prevent them from seizing.
1. Insert servo piston (42) into head cover (31). Insert 4. Warm up the inner races of roller bearings (15, 16)
servo pin (30) into the servo piston (42) hole to 50 to 80 °C (122 to 176 °F). Apply hydraulic oil
through the inlet port of head cover (31). Apply onto the inner surfaces of roller bearings (15, 16).
LOCTITE #829 onto the thread part of set screw
(41). Tighten set screw (41). Secure servo pin (30) to
servo piston (42).
l : 6 mm
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

2. Install O-ring (36) to stopper S (35). Install O-rings
(12) (2 used) to head cover (31). Install stopper S (35)
to head cover (31) with socket bolts (34) (4 used).
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

3. Install the special tool (ST 7923) to the large
chamber side of head cover (31). Set servo piston
(42) so that servo pin (30) should be located in the
center of the inlet port.
ST 7923
W173-02-04-015
W3-8-4-8
Group 8 Pump Device
5. Place drive disc (49) on a workbench with the spline 9. Place drive disc (49) on the special tool (ST 5905).
side up. Install roller bearing (16) to drive disc (49). Install bearing nut (14) to the thread part of drive
Apply hydraulic oil onto the rotating surfaces. disc (49). Tighten bearing nut (14) until it comes in
contact with roller bearing (15). Apply lubricating oil
6. Install the outer race of roller bearing (16).
onto the thread part of bearing nut (14).
7. Install the outer race of roller bearing (15) to spacer
(17) by using the special tool (ST 2408). 14
ST 5905
ST 2408
17
W1V7-02-04-019
W1V7-02-04-017
8. Install roller bearing (15) and spacer (17) to drive

disc (49). Check that roller bearings (15, 16) are
installed to drive disc (49) securely after they have
cooled down to ambient temperature. Apply
hydraulic oil onto the rotating surfaces. Install the
inner race of roller bearing (15) by using the special
tool (ST 7102).
ST 7102
W1V7-02-04-018
W3-8-4-9
Group 8 Pump Device
10. Insert the special tool (ST 3504) into the spline part
of drive disc (49). Turn drive disc (49) and tighten dCAUTION: Take care as casing (11) is too hot.
bearing nut (14). 12. Warm up casing (11) to 50 to 80 °C (122 to 176 °F).
Apply grease onto the inside of casing (11).
13. Install the drive disc (49) assembly to casing (11).
ST 3054 Check that drive disc (49) is installed securely
after casing (11) has cooled down to ambient
temperature.
14. Install O-ring (10) to the groove of casing (11). Apply
grease onto O-ring (10).
15. Install oil seal (9) to seal cover (8) by using the
special tool (ST 2409). Apply grease onto the lip
surface of oil seal (9).
W173-02-04-023 ST 2409
11. Measure the preload of roller bearings (15, 16). Set

the special tool (ST 5905). Install a torquemeter and
the adapter (ST 3055) to the spline part. Turn drive
disc (49) two to three times before recording in
8
order to move it smoothly and measure the torque.
Starting torque specification: 3±0.5 N·m (0.3±0.05 W173-02-04-019
kgf·m, 2.2±0.4 lbf·ft)
ST 3055
ST 5905
W173-02-04-024
W3-8-4-10
Group 8 Pump Device
16. Install the special tool (ST 2410) to the spline part 20. Install center shaft (48) to drive disc (49).
of drive disc (49). Install seal cover (8) to casing (11).
21. Install spring (47) to center shaft (48).
Tap seal cover (8) to casing (11) by using a plastic
hammer until the retaining ring (7) groove of casing 22. Install plungers (22) (7 used) and center shaft (48)
(11) is visible. to cylinder block (46). Insert pin (21) into the groove
ST 2410
of cylinder block (46) by turning the end of center
shaft (48) by using a radio plier.
8
49
11
W173-02-04-020
17. Install retaining ring (7) to casing (11). Check that

retaining ring (7) seats well in the groove.
18. Turn over and place casing (11) on a workbench
with the drive disc (49) side down. Apply hydraulic
oil onto the spherical surface of drive disc (49).
Incline plunger (22) to the center of drive disc (49).
Install plungers (22) (7 used).
19. Apply grease onto pin (21) in order to prevent from
falling off. Install pin (21) to center shaft (48).
W3-8-4-11
Group 8 Pump Device
23. Connect valve plate (45) to link (27). Place valve 28. Fit the spring pin (19) position. Install head cover
plate (45) inside casing (11). Insert pin (24) of the (31) to casing (11). Install head cover (31) to casing
link (27) assembly into the regulator mounting part (11) with socket bolts (39) (8 used) and spring
of casing (11). washers (40) (8 used).
24. Apply hydraulic oil onto the spherical surfaces of l : 10 mm
valve plate (45) and cylinder block (46). Face the
spherical surface of valve plate (45) to cylinder block m : 110 N·m (11 kgf·m, 81 lbf·ft)
(46). Insert the end of center shaft (48) into the hole
of valve plate (45).
25. Apply grease onto O-rings (12) (3 used). Install
O-rings (12) (3 used) and packing (18) to casing (11).
26. Install the special tool (ST 7094) to the drain port
of casing (11). Secure valve plate (45) at the center
position.
11
45
39, 40
W1V7-02-04-002
ST 7094
W1V7-02-04-020
27. Fit servo pin (30) of head cover (31) to the hole of
valve plate (45).
W3-8-4-12
Group 8 Pump Device
29. Remove the special tool (ST 7094) from casing (11).
Install plug (20) to casing (11). dCAUTION: Main pump weight: 67 kg (150 lb)
32. Fit feedback pin (26) of the pump to the notches on
l : 8 mm the sleeves (2 used) of regulator (4). Install regulator
(4) to casing (11).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
33. Install regulator (4) to casing (11) with socket bolts
30. Remove the special tool (ST 7923) from head cover
(5) (4 used) and spring washers (6) (4 used).
(31). Install O-ring (43) to stopper L (44). Install
stopper L (44) to head cover (31) with socket bolts l : 8 mm
(34) (4 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft)
j : 6 mm
34. Install drive gear (2) to drive disc (49).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
35. Install retaining ring (1) to drive disc (49).
43, 44
34
20
ST 7923 ST 7094
W1V7-02-04-021
31. Apply grease onto O-rings (3, 12). Install O-rings (12)
(5 used) and O-ring (3) to the regulator mounting
surface of casing (11).
fNOTE: Check that spring pins (13) (2 used) have been

installed.
W3-8-4-13
Group 8 Pump Device
(Blank)
W3-8-4-14
Group 8 Pump Device
Disassembly of Regulator 1
21
22
18 19 20
17
11 16
15
14
10 12
13 3
4
23
5
24
25
8
7 26
6
5
28 27
29
4
4
3
21 22
30
WDDE-03-08-003
32 31
1- Socket Bolt (8 Used) 11- Air Bleed Plug 19- O-Ring 27- Casing
3- Stopper (2 Used) 12- O-Ring 20- Front Cover 28- Piston
4- O-Ring (3 Used) 13- Spool 21- Lock Nut (2 Used) 29- Cylinder
5- O-Ring (2 Used) 14- Sleeve 22- Nut (2 Used) 30- Rear Cover
6- Stopper 15- Piston 23- Spring 31- Screw
7- Spring 16- O-Ring 24- Stopper 32- Lock Nut
8- Spring 17- Backup Ring 25- Spool
10- Socket Bolt (4 Used) 18- Cylinder 26- Sleeve
W3-8-5-1
Group 8 Pump Device
Disassembly of Regulator
1. Secure casing (27) in a vise. 9. Remove spring (23) from the front cover (20) side of
casing (27).
2. Remove air bleed plug (11) and O-ring (12) from
casing (27). 10. Push spool (25). Remove cylinder (29) and piston
(28) from the rear cover (30) side of casing (27).
j : 41 mm
11. Remove piston (28) and O-ring (4) from cylinder
3. Remove socket bolts (1) (8 used). Remove front (29).
cover (20) and rear cover (30) from casing (27).
12. Remove sleeve (26) from the front cover (20) side of
l : 6 mm casing (27). Remove spool (25) from sleeve (26).
IMPORTANT: Do not loosen stoppers (3, 6), lock nuts
(21, 32), and screw (31) as the setting changes.
4. Remove springs (7, 8) from the rear cover (30) side
of casing (27).
5. Push spool (13). Remove cylinder (18) from the front
cover (20) side of casing (27).
6. Remove piston (15), O-ring (16), and backup ring
(17) from cylinder (18).
7. Remove sleeve (14) and spool (13) from the front
cover (20) side of casing (27).
8. Remove spool (13) from sleeve (14).
W3-8-5-2
Group 8 Pump Device
Assembly of Regulator
21 3 22 23 24 26 25 27 28 29 32 31
19 17 16 15 18 13 14 8 7 4 5 22 6 3 21
WDDE-03-08-001
20 10 11 12 30
WDDE-03-08-002
1- Socket Bolt (8 Used) 11- Air Bleed Plug 19- O-Ring 27- Casing
3- Stopper (2 Used) 12- O-Ring 20- Front Cover 28- Piston
4- O-Ring (3 Used) 13- Spool 21- Lock Nut (2 Used) 29- Cylinder
5- O-Ring (2 Used) 14- Sleeve 22- Nut (2 Used) 30- Rear Cover
6- Stopper 15- Piston 23- Spring 31- Screw
7- Spring 16- O-Ring 24- Stopper 32- Lock Nut
8- Spring 17- Backup Ring 25- Spool
10- Socket Bolt (4 Used) 18- Cylinder 26- Sleeve
W3-8-5-3
Group 8 Pump Device
Assembly of Regulator
10. Install the front cover (20) assembly and spring (23)
IMPORTANT: Before assembling, apply hydraulic oil
to casing (27). Install the front cover (20) assembly
to casing (27) with socket bolts (1) (4 used).
1. Secure casing (27) in a vise.
l : 6 mm
2. Install spool (13) to sleeve (14).
3. Install the sleeve (14) assembly to the front cover m : 20 N·m (2 kgf·m, 15 lbf·ft)
(20) side of casing (27). 11. Apply grease onto O-ring (12). Install O-ring (12) to
4. Install spool (25) to sleeve (26). Install the sleeve (26) air bleed plug (11).
assembly to the rear cover (30) side of casing (27). 12. Install air bleed plug (11) to casing (27).
5. Install piston (28) to cylinder (29).
j : 41 mm
6. Install O-ring (4) to cylinder (29). Apply grease onto
O-ring (4). Install the cylinder (29) assembly to the m : 80 N·m (8 kgf·m, 59 lbf·ft)
rear cover (30) side of casing (27).
7. Install the rear cover (30) assembly and springs (7, 8)
to casing (27). Install the rear cover (30) assembly to
casing (27) with socket bolts (1) (4 used).
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

8. Install O-ring (16), backup ring (17), and piston (15)
to cylinder (18).
9. Apply grease onto O-ring (16). Install the cylinder
(18) assembly to the front cover (20) side of casing
(27).
W3-8-5-4
Group 8 Pump Device
Disassembly of Pilot Pump
3
5
2 6
7
8
1 9
10
11
12
13
4
12
11
8
14
15 W110-02-04-022
16
1- Key (2 Used) 5- Washer (4 Used) 9- Housing 13- Drive Gear

2- Bushing (2 Used) 6- Bolt (4 Used) 10- Knock Pin (2 Used) 14- Flange
3- Gear 7- Cover 11- Backup Ring (2 Used) 15- Oil Seal
4- Bushing (2 Used) 8- O-Ring (2 Used) 12- Seal (2 Used) 16- Retaining Ring
W3-8-6-1
Group 8 Pump Device
Disassembly of Pilot Pump

1. Secure the flange (14) part of pilot pump with the IMPORTANT: Do not lose key (1) between bushings.
cover (7) side up in a vise. 8. Remove seal (12) and backup ring (11) at the flange
2. Remove bolts (6) (4 used) and washers (5) (4 used). (14) side from bushings (2, 4).
9. Remove bushings (2, 4) at the flange (14) side from
j : 17 mm
housing (9). Remove drive gear (13) and gear (3)
3. Remove cover (7) from housing (9). from housing (9).
4. Remove O-ring (8) from cover (7). 10. Remove O-ring (8) from flange (14).
IMPORTANT: Do not remove knock pin (10) unless 11. Remove retaining ring (16) from flange (14).
necessary.
12. Remove oil seal (15) from flange (14) by using a
5. Remove housing (9) from flange (14). screwdriver.
6. Remove backup ring (11) and seal (12) at the cover
(7) side from bushings (2, 4).
IMPORTANT: Do not lose key (1) at the bushing
mating part.
7. Lightly push drive gear (13). Remove bushings (2, 4)
at the cover (7) side from housing (9).
W3-8-6-2
Group 8 Pump Device
Assembly of Pilot Pump
3
5
2 6
7
8
1 9
10
11
12
13
4
12
11
8
14
15 W110-02-04-022
16
1- Key (2 Used) 5- Washer (4 Used) 9- Housing 13- Drive Gear

2- Bushing (2 Used) 6- Bolt (4 Used) 10- Knock Pin (2 Used) 14- Flange
3- Gear 7- Cover 11- Backup Ring (2 Used) 15- Oil Seal
4- Bushing (2 Used) 8- O-Ring (2 Used) 12- Seal (2 Used) 16- Retaining Ring
W3-8-6-3
Group 8 Pump Device
Assembly of Pilot Pump

IMPORTANT: Before assembling, apply hydraulic oil 12. Secure flange (14), housing (9), and cover (7) with
onto parts in order to prevent them from seizing. bolts (6) (4 used) and washers (5) (4 used).
1. Install oil seal (15) to flange (14) by using a special
j : 17 mm
tool.
2. Install retaining ring (16) to flange (14). m : 35+5 N·m (3.5+0.5 kgf·m, 26+3.7 lbf·ft)
3. Install bushings (2, 4) at the cover (7) side to

housing (9) with the seal groove down.
fNOTE: Key (1) is located between bushings (2, 4).

4. Install drive gear (13) and gear (3) to housing (9).
5. Install bushings (2, 4) at the flange (14) side to
housing (9) with the seal groove up.
6. Install seal (12) and backup ring (11) to the groove
of bushings.
7. Install O-ring (8) to flange (14).
8. Fit the position of knock pin (10) in housing (9) and
install flange (14).
9. Turn over housing (9) and the flange (14) assembly.
Secure the flange (14) part in a vise. Do not drop
bushings and gears when turning over. Install seal
(12) and backup ring (11) to the groove of bushings.
10. Install O-ring (8) to cover (7).
11. Install cover (7) to housing (9).
W3-8-6-4
1 5 4 7 6
3 2
8 9
WDDE-03-06-001 WDDE-03-04-005

dCAUTION: Bleed air from the hydraulic oil tank
before doing any work. (Refer to W1-4-1.)
(3).
IMPORTANT: Cap the open ends in case the hoses j : 17 mm

and pipes have been disconnected. In addition, 4. Remove bolts, washers (4) (2 used). Remove cover
attach an identification tag onto the connectors, (5).
secure the hoses have been removed. 5. Remove bolts, washers (6) (2 used). Remove cover
(7).
Removal
j : 17 mm
maintenance. (Refer to W1-6-1.) 6. Remove bolts, washers (8) (6 used). Remove cover
(9).
j : 17 mm
W3-9-1-1
11 12 13
10, 81 13
WDCD-03-09-012 WDCD-03-09-002
7. Remove bolts, washers (10) (3 used) and clamp (81).
j : 17 mm
8. Remove 3-spool solenoid valve unit (11). (Refer to
W3-12-2.)
9. Disconnect the connectors and hoses connected to
signal control valve (12). (Refer to W3-13-1.)
W3-9-1-2
WDDE-03-09-002 WDDE-03-09-003
11. Disconnect hoses (14) (3 used). 15. Place a container under the disconnecting part of
pipe (21). Remove coupling (22). Disconnect the oil
j : 27 mm cooler side of pipe (21).
12. Remove bolts, washer (15) and clamp (16).
j : 13 mm
j : 19 mm 16. Remove socket bolts (23) (2 used). Disconnect the
13. Remove bolts, washers (17) (2 used) and clamps (18) control valve (24) side of pipe (21). Remove O-ring
(2 used). (25).
j : 19 mm l : 10 mm
14. Place a container under the disconnecting part
of pipe (19). Remove couplings (20) (2 used).
Disconnect the both ends of pipe (19).
j : 13 mm
W3-9-1-3
WDDE-03-09-004 WDDE-03-09-005
17. Place a container under control valve (24). 22. Remove socket bolts (37) (16 used), flanges (38) (6
Disconnect the both ends of pipes (26) (2 used). used), and flanges (41) (2 used). Disconnect hoses
(39) (4 used). Remove O-rings (40) (3 used) and
j : 17 mm O-ring (42).
l : 8 mm
j : 19 mm 23. Place a container under the disconnecting part of
19. Disconnect hose (28). pipe (43). Remove coupling (44). Disconnect the
hydraulic oil tank side of pipe (43).
j : 36 mm
j : 13 mm
(4 used). Disconnect hoses (31) (2 used). Remove 24. Remove socket bolts (45) (2 used). Disconnect the
O-rings (32) (2 used). control valve (24) side of pipe (43). Remove O-ring
(46).
l : 8 mm
l : 8 mm
21 Remove socket bolts (33) (4 used) and flanges (34)
(2 used). Disconnect hose (35). Remove O-ring (36).
l : 10 mm
W3-9-1-4
WDDE-03-09-007
a- Eyebolt Mounting Hole

(2 used). Disconnect hose (49). Remove O-ring (50). dCAUTION: The control valve (24) assembly
weight: 290 kg (640 lb)
l : 10 mm 30. Install eyebolts (M10, Pitch 1.75 mm) (2 used) to
26. Remove socket bolts (51) (8 used) and flanges (52) eyebolt mounting holes (a) (2 places) of control
(4 used). Disconnect hoses (53) (2 used). Remove valve (24). Attach nylon slings onto the eyebolts.
O-rings (54) (2 used). Hoist and hold the control valve (24) assembly.
31. Remove bolts (58) (2 used), bolts (59) (2 used),
l : 8 mm
washers (60) (2 used), and washers (61) (2 used).
27. Disconnect the front attachment side of hose (55). Place the control valve (24) assembly on a
workbench.
j : 41 mm
28. Disconnect the front attachment side of hose (56). j : 24 mm
j : 50 mm
29. Disconnect the center joint side of hoses (57) (2
used).
j : 36 mm
W3-9-1-5
72
WDDE-03-09-008 WDDE-03-09-006
32. Remove bolts (62) (3 used) and washers (63) 35. Disconnect hose (72).
(3 used). Remove the signal control valve (12)
assembly. j : 17 mm
j : 22 mm
33. Remove socket bolts (64) (20 used), flanges (65) (6
used), and flanges (66) (4 used). Disconnect hoses
(53) (2 used), hoses (57) (2 used), and hose (55).
Remove O-rings (67) (3 used) and O-rings (68) (2
used).
l : 8 mm
(2 used). Disconnect hose (56). Remove O-ring (71).
l : 10 mm
W3-9-1-6
75 75 a
74
82 73 83
WDCD-03-09-010 WDDE-03-09-009
j : 17 mm
dCAUTION:
lb)
Control valve (24) weight: 240 kg (530
37. Disconnect the both ends of hose (74). 42. Install eyebolts (M10, Pitch 1.75 mm) (2 used) to
eyebolt mounting holes (a) (2 places) of control
j : 17 mm valve (24). Attach nylon slings onto the eyebolts.
38. Disconnect hoses (75) (6 used). Hoist and hold control valve (24).
j : 19 mm used). Remove control valve (24) from brackets (82,
39. Disconnect the both ends of hose (76). 83).
j : 17 mm j : 24 mm
40. Disconnect hoses (77) (2 used). 44. Remove the adapter with control valve (24)
j : 17 mm
j : 19 mm
W3-9-1-7
75 75 a
74
82 73 83
WDCD-03-09-010 WDDE-03-09-009
Installation 5. Connect the control valve (24) side of hoses (77) (2

used).
1. Install all removed adapters to control valve (24).
j : 17 mm
dCAUTION:
lb)
Control valve (24) weight: 240 kg (530
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
6. Connect the both ends of hose (76).
valve (24). Attach nylon slings onto the eyebolts. j : 17 mm
Hoist and hold control valve (24).
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
3. Install control valve (24) to brackets (82, 83) with
washers (80) (4 used) and bolts (79) (4 used). 7. Connect the control valve (24) side of hoses (75) (6
used).
j : 24 mm
j : 19 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
m : 30 N·m (3 kgf·m, 22 lbf·ft)
4. Connect the control valve (24) side of hoses (78) (6
used). 8. Connect the both ends of hose (74).
j : 19 mm j : 17 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft) m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

9. Connect the control valve (24) side of hoses (73) (3
used).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
W3-9-1-8
72
WDDE-03-09-008 WDDE-03-09-006
10. Connect the control valve (24) side of hose (72). 13. Install the signal control valve (12) assembly with
washers (63) (3 used) and bolts (62) (3 used).
j : 17 mm
j : 22 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
m : 140 N·m (14 kgf·m, 103 lbf·ft)
11. Install O-ring (71). Install the control valve (24) side
of hose (56) with flanges (20) (2 used) and socket
l : 10 mm
m : 110 N·m (11 kgf·m, 81 lbf·ft)

12. Install O-rings (68) (2 used) and O-rings (67) (3
used). Connect the control valve (24) side of hose
(55) and hoses (57, 53) (2 used for each) with flanges
(66) (4 used), flanges (65) (6 used), and socket bolts
(64) (20 used).
l : 8 mm
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
W3-9-1-9
WDDE-03-09-007

dCAUTION: The control valve (24) assembly
weight: 290 kg (640 lb) j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft)
valve (24). Attach nylon slings onto the eyebolts. 19. Install O-rings (54) (2 used). Connect hoses (53) (2
Hoist the control valve (24) assembly. used) with flanges (52) (4 used) and socket bolts
(51) (8 used).
15. Install the control valve (24) assembly with washers
(61) (2 used), washers (60) (2 used), bolts (59) (2 l : 8 mm
used), and bolts (58) (2 used).
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
j : 24 mm
20. Install O-ring (50). Install hose (49) with flanges (48)
m : 270 N·m (27 kgf·m, 200 lbf·ft) (2 used) and socket bolts (47) (4 used).
16. Connect hoses (57) (2 used). l : 10 mm
j : 36 mm m : 110 N·m (11 kgf·m, 74 lbf·ft)
m : 180 N·m (18 kgf·m, 133 lbf·ft)
j : 50 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
W3-9-1-10
WDDE-03-09-004 WDDE-03-09-005
21. Install O-ring (46). Connect the control valve (24) 25. Install O-rings (32) (2 used). Connect hoses (31) (2
side of pipe (43) with socket bolts (45) (2 used). used) with flanges (30) (4 used) and socket bolts
(29) (8 used).
l : 8 mm
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
22. Connect the hydraulic oil tank side of pipe (43) with
coupling (44). 26. Connect hose (28).
j : 13 mm j : 36 mm
m : 10 to 13 N·m (1 to 1.3 kgf·m, 7.4 to 9.6 lbf·ft) m : 180 N·m (18 kgf·m, 133 lbf·ft)
23. Install O-ring (42) and O-rings (40) (3 used). Connect 27. Connect hose (27).
hoses (39) (4 used) with flanges (41) (2 used),
flanges (38) (6 used), and socket bolts (37) (16 used). j : 19 mm
l : 8 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

28. Connect the both ends of pipe (26).
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
24. Install O-ring (36). Connect hose (35) with flanges j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
l : 10 mm
m : 110 N·m (11 kgf·m, 81 lbf·ft)
W3-9-1-11
WDDE-03-09-002 WDDE-03-09-003
29. Install O-ring (25). Connect the control valve (24) 32. Install clamps (18) (2 used) with bolts, washers (17)
side of pipe (21) with socket bolts (23) (2 used). (2 used).
l : 10 mm j : 19 mm

30. Connect the oil cooler side of pipe (21) with 33. Install clamp (16) with bolts, washer (15).
coupling (22).
j : 19 mm
j : 13 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
31. Connect pipe (19) with couplings (20) (2 used).
j : 27 mm
j : 13 mm
m : 80 N·m (8 kgf·m, 59 lbf·ft)
W3-9-1-12
11 12 13
10, 81 13
WDCD-03-09-012 WDCD-03-09-002

36. Connect all removed hoses and connectors to signal
control valve (12). (Refer to W3-13-1.)
37. Install 3-spool solenoid valve unit (11). (Refer to W3-
12-2.)
38. Install clamp (81) with bolts, washers (10) (3 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-9-1-13
1 5 4 7 6
3 2
8 9
WDDE-03-06-001 WDDE-03-04-005

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

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

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

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

44. Shut engine cover (1).
W3-9-1-14
Disassembly of Housing
4
4 5
5 4
5 4
4
4 4
6
4 6
5
5
4
W1V7-02-05-016
1- Housing (5-Spool Side) 3- Socket Bolt (9 Used) 5- O-Ring (12 Used)

2- Housing (4-Spool Side) 4- O-Ring (16 Used) 6- O-Ring (3 Used)
W3-9-2-1
Disassembly of Housing
dCAUTION:
kg (290 lb)
The housing (1) assembly weight: 130
The housing (2) assembly weight: 120 kg (265 lb)

1. Remove socket bolts (3) (9 used).
l : 14 mm
2. Remove housing (2) from housing (1).
3. Remove O-rings (4) (16 used), O-rings (5) (12 used),
and O-rings (6) (3 used) from housing (1) or housing
(2).
W3-9-2-2
Assembly of Housing
4 5 2
4
4
5 6
4 5
6 6
5 5
4
4
W1V1-02-05-011
4 5
3
3
3 3
T1V7-03-03-002
1- Housing (5-Spool Side) 3- Socket Bolt (9 Used) 5- O-Ring (12 Used)

2- Housing (4-Spool Side) 4- O-Ring (16 Used) 6- O-Ring (3 Used)
W3-9-2-3
Assembly of Housing

1. Install O-rings (4) (16 used), O-rings (5) (12 used),
and O-rings (6) (3 used) to the mounting surface of
housing (2).
dCAUTION:
kg (290 lb)
The housing (2) assembly weight: 120 kg (265 lb)

2. Install housing (1) to housing (2) with socket bolts
(3) (9 used).
l : 14 mm
m : 210 to 220 N·m (21 to 22 kgf·m, 155 to 162

lbf·ft)
W3-9-2-4
Disassembly of Control Valve (4-Spool Side)

6
a
5
10 8
4 9 7
3 16 6
2
12
1 11
4
3
8 15
7
13 19
14 20 b
21
22
13 23
30
24
25
26
7 28
29 d
8 19 9 10
20 c 32
42 33
43 34
35
44 37
45 36
48 31
43 46
44 47 38
45
49 39 6
51
50 38 38
39
41
38
52 38 38
53 39 41 e
39 38
41 f
54 52
38 59
55 41
56 g
63
57
58 h 59
i
4
62
W1V7-02-05-017
W3-9-3-1
68
69
4
j
70
63 71
67 72
63 71
67 59 73
63
67
59 k
74
59
74
1
63
64
19
59
102
103
104
105 7
106 m 7
4 7 8
107 8
8
6
98
108 99
p 100 o n
109
110 111 101
83
87 75
112 84
87 77
77 76
113 13 85
13 78 86 82 81
77 77
114 128 87
118 13
88
89 13
115 77
127 91
116 117 40
126 92
114 119 120 79
120 93
119 90 94 80
95
115 96
124 6
115
121 116 114
122 97
123 120 119
116
97 125
W1V7-02-05-018
W3-9-3-2
1- Housing 35- O-Ring 70- Bolt 101- Plug

2- Poppet 36- Plug 71- Spring Seat (2 Used) 102- O-Ring
3- Spring (2 Used) 37- Spool 72- Spring 103- Cap
4- O-Ring (5 Used) 38- Spring Seat (8 Used) 73- Spool 104- Socket Bolt (4 Used)
5- Flange 39- Spring (4 Used) 74- Overload Relief Valve (2 Used) 105- Spool
6- Socket Bolt (13 Used) 40- Body 75- Poppet 106- Spring
7- O-Ring (6 Used) 41- Bolt (4 Used) 76- Spring 107- Flange
8- Plug (6 Used) 42- Plug 77- O-Ring (5 Used) 108- Poppet
9- O-Ring (2 Used) 43- Backup Ring (2 Used) 78- O-Ring 109- Poppet
10- Plug (2 Used) 44- O-Ring (2 Used) 79- O-Ring 110- Spring
11- Poppet 45- Spring (2 Used) 80- Plug 111- Plug
12- Spring 46- Poppet 81- O-Ring 112- Poppet
13- O-Ring (9 Used) 47- Spool 82- Plug 113- Spring
14- O-Ring 48- Plug 83- Poppet 114- Plug (3 Used)
15- Poppet 49- Poppet 84- Poppet 115- O-Ring (3 Used)
16- Flange 50- Spool 85- Spring 116- Spring Seat (3 Used)
20- Overload Relief Valve (2 Used) 52- Spring Seat (2 Used) 87- Spring (3 Used) 118- Spool
21- Spring 53- Spring 88- Sleeve 119- Plug (3 Used)
22- Seat 54- Spool 89- Plug 120- O-Ring (3 Used)
23- Poppet 55- O-Ring 90- O-Ring 121- Spring
24- Backup Ring 56- Backup Ring 91- Body 122- Spool
25- O-Ring 57- Spool 92- Spool 123- Body
26- O-Ring 58- Spring 93- Spring 124- Spool
28- Backup Ring 59- O-Ring (8 Used) 94- Spring Seat 125- Spring
29- Sleeve 62- Cap 95- O-Ring 126- O-Ring
30- Spool 63- Socket Bolt (14 Used) 96- Plug 127- Plug
31- O-Ring 64- Cap 97- Socket Bolt (12 Used) 128- Orifice
32- Body 67- Cap (3 Used) 98- Poppet
33- Spring 68- Socket Bolt (2 Used) 99- Poppet
34- Piston 69- Cap 100- Spring
a- Check Valve (Main Relief e- Travel (Right) k- Overload Relief Valve (Bucket: p- Arm 2 Flow Rate Control Valve
Circuit) f- Bucket Bottom Side) (Selector Valve)
b- Overload Relief Valve (Bucket: g- Boom 1 l- Overload Relief Valve (Boom:
Rod Side) h- Arm 2 Rod Side)
c- Overload Relief Valve (Boom: i- Arm Regenerative Valve m- Bypass Shut-Out Valve
Bottom Side) j- Flow Combiner Valve n- Boom Anti-Drift Valve
d- Boom Anti-Drift Valve o- Bucket Flow Rate Control Valve
W3-9-3-3
 Disassembly of Spool  Disassembly of Overload Relief Valve (20)

1. Remove socket bolts (63) (6 used). Remove cap (62), IMPORTANT: Do not disassemble the overload
O-rings (59) (4 used), and O-rings (4, 13, 14) from relief valve. If the overload relief valve has been
housing (1). disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
l : 8 mm Test in the separated volume, T/M.)
IMPORTANT: Do not disassemble the spool (54) 7. Remove overload relief valves (20) (2 used) and
assembly unless necessary. O-rings (19) (2 used) from housing (1).
2. Put the matching marks on the spool (37, 47, 50, 51,
j : 32 mm
54) assemblies and housing (1). Remove the spool
(37, 47, 50, 51, 54) assemblies and spring (58) from
housing (1).  Disassembly of Check Valve
8. Remove plug (8), O-ring (7), spring (12), and poppet
(11) from housing (1).
 Disassembly of Boom Anti-Drift Valve (Selector Valve)
3. Remove plug (36) and O-ring (35) from body (32). l : 10 mm
j : 38 mm 9. Remove socket bolts (6) (2 used). Remove flange (5),
O-ring (4), spring (3), and poppet (2) from housing
4. Remove socket bolts (6) (3 used). Remove the body
(1).
(32) assembly, O-rings (13) (4 used), and O-ring (31)
from housing (1). l : 8 mm
l : 8 mm 10. Remove socket bolts (6) (2 used).
5. Remove piston (34) and spring (33) from body (32). Remove flange (16), O-ring (4), spring (3), and
poppet (15) from housing (1).
6. Remove the sleeve (29) assembly, seat (22), and
spring (21) from housing (1). l : 8 mm
Remove backup rings (24, 28), O-rings (25, 26), 11. Remove plugs (8) (2 used) and O-rings (7) (2 used)
poppet (23), and spool (30) from sleeve (29). from housing (1).
l : 10 mm
12. Remove plugs (10) (2 used) and O-rings (9) (2 used)
from housing (1).
l : 6 mm
W3-9-3-4
 Disassembly of Travel (Right) Spool (37)  Disassembly of Boom 1 Spool (50)

13. Secure spool (37) in a vise by using wooden pieces. 17. Secure spool (50) in a vise by using wooden pieces.
Remove bolt (41), spring seats (38) (2 used), and Remove bolt (41), spring seats (38) (2 used), and
spring (39) from spool (37). spring (39) from spool (50).
l : 8 mm l : 8 mm
18. Warm the plug (48) part of spool (50) by using a
 Disassembly of Bucket Spool (47) drier. Remove plug (48) by using the special tool
14. Secure spool (47) in a vise by using wooden pieces. (ST 5909). Remove O-ring (44) and backup ring (43)
Remove bolt (41), spring seats (38) (2 used), and from plug (48).
spring (39) from spool (47).
19. Remove spring (45) and poppet (49) from spool (50).
l : 8 mm
15. Warm the plug (42) part of spool (47) by using a  Disassembly of Arm 2 Spool (51)
drier. Remove plug (42) by using the special tool 20. Secure spool (51) in a vise by using wooden pieces.
(ST 5909). Remove O-ring (44) and backup ring (43) Remove bolt (41), spring seats (38, 52) (2 used for
from plug (42). each), and springs (53, 39) from spool (51).
l : 8 mm
ST 5909
 Disassembly of Arm Regenerative Valve

21. Secure spool (54) in a vise by using wooden pieces.
Remove spool (57) from spool (54). Remove backup
W157-02-05-049 ring (55) and O-ring (56) from spool (57).
16. Remove spring (45) and poppet (46) from spool (47).
W3-9-3-5
22. Remove socket bolts (63) (8 used). Remove caps (67)  Disassembly of Arm 2 Flow Rate Control Valve
(3 used), cap (64), and O-rings (59) (4 used) from 28. Remove socket bolts (97) (8 used). Remove the body
housing (1). (123) assembly, O-rings (77) (3 used), O-rings (13) (2
used), O-ring (78), and orifice (128) from housing (1).
l : 8 mm
l : 8 mm
 Disassembly of Flow Combiner Valve 29. Remove plugs (114) (3 used), O-rings (115) (3 used),
23. Remove socket bolts (68) (2 used). Remove cap spring seats (116) (3 used), springs (117, 121, 125),
(69), O-ring (4), and the spool (73) assembly from and spools (118, 122, 124) from body (123).
housing (1). Remove bolt (70), spring seats (71) (2
used), and spring (72) from spool (73). j : 24 mm
30. Remove plugs (119) (3 used), plug (127), O-rings
l : 5 mm
(120) (3 used), and O-ring (126) from body (123).
31. Remove spring (113) and poppet (112) from
 Disassembly of Overload Relief Valve (74)
housing (1).
IMPORTANT: Do not disassemble the overload
relief valve. If the overload relief valve has been 32. Remove springs (87) (2 used) and the poppet (98,
disassembled, pressure should be adjusted. (Refer 108) assemblies from housing (1). Remove plugs
to TROUBLESHOOTING / Operational Performance (101, 111), springs (100, 110), and poppets (99, 109)
Test in the separated volume, T/M.) from poppets (98, 108).
24. Remove overload relief valves (74) (2 used) and
O-rings (19) (2 used) from housing (1).
j : 32 mm
 Disassembly of Bucket Flow Rate Control Valve

(91) assembly and O-rings (13, 77) from housing (1).
l : 8 mm
26. Remove plug (96), O-ring (95), spring seat (94),
spring (93), and spool (92) from body (91). Remove
plug (89) and O-ring (90) from body (91).
j : 27 mm
27. Remove sleeve (88), springs (85, 87), plug (86), and
poppets (84, 83) from housing (1).
W3-9-3-6
 Disassembly of Boom Anti-Drift Valve (Check Valve)

33. Remove socket bolts (6) (4 used). Remove body (40),
O-rings (13) (3 used), and O-ring (77) from housing
(1).
l : 8 mm
34. Remove plugs (80, 82) and O-rings (79, 81) from
body (40).
35. Remove spring (76) and poppet (75) from housing
(1).
 Disassembly of Bypass Shut-Out Valve

36. Remove socket bolts (6) (2 used). Remove flange
(107) and O-ring (4) from housing (1).
l : 8 mm
37. Remove spring (106) and spool (105) from housing
(1).
38. Remove socket bolts (104) (4 used). Remove cap
(103) and O-ring (102) from housing (1).
l : 8 mm
39. Remove plugs (8) (3 used) and O-rings (7) (3 used)
from housing (1).
l : 8 mm
W3-9-3-7
Assembly of Control Valve (4-Spool Side)
Control Valve (Upper) Control Valve (Lower)
59, 62 63
63 63
19, 20 19, 20
123 36 6 59, 67 63 59, 67 63 59, 67 59, 64

W1V7-02-05-027 W1V7-02-05-028
Control Valve (Side) Control Valve (Front)
19, 20 40 6 19, 20 7, 8, 11, 12 6 3, 4, 15, 16
6
107
7, 8
1
7, 8, 11, 12
103 104 97 123 19, 74 91 97 1 6 2, 3, 45
W1V7-02-05-029 W1V1-02-05-068
W3-9-3-8
Control Valve (Upper) Section C-C (4-Spool Side)

J I H G F E D C
A 7
W1V1-02-05-038
J I H G F E D C
W1V7-02-05-027
Section D-D (4-Spool Side) Section E-E (4-Spool Side) Section F-F (4-Spool Side)
f g
e
41
38 C
20
39 1
38
47
19
51 50
B
46 49 D
45 45 1
19
43, 44 19 43, 44
74
74 48
42
W1V1-02-05-035 W1V1-02-05-036 W1V1-02-05-028
W3-9-3-9
Section G-G (4-Spool Side) Section H-H (4-Spool Side)
h
61
60
41
38
52
20
53
52
1 19
38
37
E F
65
66
W1V1-02-05-029 W1V1-02-05-030
Section I-I (4-Spool Side) Section J-J (4-Spool Side)
105 106 4
58
57
107
56, 55
54
W1V1-02-05-071 W1V1-02-05-037
W3-9-3-10
Detail A Detail B
1 96
73
95
70
94
93
4
91
71 92
1
72 90
71 89
88
69 83 84 77 13 85 86 87
W1V1-02-05-040 W1V1-02-05-033
Detail C Detail D
36
35 77 13
32 1 119
34 120
33
118
30
31 123
29
23 1
13
13 78
28 80 117
26
116
25 79
24 115
22 114
21 40
81 98 99 100 101 87
82 W1V1-02-05-032
75 76 77
W1V1-02-05-031
Detail E Detail F
114 1 119
128
78 115
120
116
125
122
124
121
116
120 115
114
119
108 109 77
112 113 77 13 123
W1V1-02-05-042 W1V7-02-05-031
110 111 87 123
W3-9-3-11
1- Housing 35- O-Ring 70- Bolt 101- Plug

2- Poppet 36- Plug 71- Spring Seat (2 Used) 102- O-Ring
3- Spring (2 Used) 37- Spool 72- Spring 103- Cap
4- O-Ring (5 Used) 38- Spring Seat (8 Used) 73- Spool 104- Socket Bolt (4 Used)
5- Flange 39- Spring (4 Used) 74- Overload Relief Valve (2 Used) 105- Spool
6- Socket Bolt (13 Used) 40- Body 75- Poppet 106- Spring
7- O-Ring (6 Used) 41- Bolt (4 Used) 76- Spring 107- Flange
8- Plug (6 Used) 42- Plug 77- O-Ring (5 Used) 108- Poppet
9- O-Ring (2 Used) 43- Backup Ring (2 Used) 78- O-Ring 109- Poppet
10- Plug (2 Used) 44- O-Ring (2 Used) 79- O-Ring 110- Spring
11- Poppet 45- Spring (2 Used) 80- Plug 111- Plug
12- Spring 46- Poppet 81- O-Ring 112- Poppet
14- O-Ring 48- Plug 83- Poppet 114- Plug (3 Used)
15- Poppet 49- Poppet 84- Poppet 115- O-Ring (3 Used)
16- Flange 50- Spool 85- Spring 116- Spring Seat (3 Used)
20- Overload Relief Valve (2 Used) 52- Spring Seat (2 Used) 87- Spring (3 Used) 118- Spool
21- Spring 53- Spring 88- Sleeve 119- Plug (3 Used)
22- Seat 54- Spool 89- Plug 120- O-Ring (3 Used)
23- Poppet 55- O-Ring 90- O-Ring 121- Spring
24- Backup Ring 56- Backup Ring 91- Body 122- Spool
25- O-Ring 57- Spool 92- Spool 123- Body
26- O-Ring 58- Spring 93- Spring 124- Spool
28- Backup Ring 59- O-Ring (8 Used) 94- Spring Seat 125- Spring
29- Sleeve 62- Cap 95- O-Ring 126- *O-Ring
30- Spool 63- Socket Bolt (14 Used) 96- Plug 127- *Plug
31- O-Ring 64- Cap 97- Socket Bolt (12 Used) 128- Orifice
32- Body 67- Cap (3 Used) 98- Poppet
33- Spring 68- Socket Bolt (2 Used) 99- Poppet
34- Piston 69- Cap 100- Spring
e- Travel (Right) f- Bucket g- Boom 1 h- Arm 2
fNOTE: As for the item with mark *, refer to W3-9-3-2.
W3-9-3-12
Assembly of Control Valve (4-Spool Side)  Assembly of Boom 1 Spool (50)

Install poppet (49) and spring (45) to the bottom of
spool (50).
 Assembly of Travel (Right) Spool (37) 7. Install O-ring (44) and backup ring (43) to plug (48).
1. Secure spool (37) in a vise by using wooden pieces. Apply LOCTITE #271 onto the thread part of plug
Install spring seats (38) (2 used), spring (39), and (48).
bolt (41) to spool (37). 8. Install plug (48) to spool (50) by using the special
tool (ST 5909).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
9. Install spring seats (38) (2 used), spring (39), and
bolt (41) to the top of spool (50).
 Assembly of Bucket Spool (47)
2. Secure spool (47) in a vise by using wooden pieces. l : 8 mm
Install poppet (46) and spring (45) to the bottom of
spool (47). m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
3. Install O-ring (44) and backup ring (43) to plug (42).
Apply LOCTITE #271 onto the thread part of plug  Assembly of Arm 2 Spool (51)
(42). 10. Secure spool (51) in a vise by using wooden pieces.
Install spring seats (38, 52) (2 used for each), springs
4. Install plug (42) to spool (47) by using the special
(39, 53), and bolt (41) to spool (51).
tool (ST 5909).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
ST 5909
11. Install O-rings (59) (4 used) to housing (1). Install
caps (67) (3 used) and cap (64) to housing (1) with
W157-02-05-049
5. Install spring seats (38) (2 used), spring (39), and

bolt (41) to the top of spool (47).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
W3-9-3-13
 Assembly of Arm Regenerative Valve

Install O-ring (56) and backup ring (55) to spool (57).
Install spool (57) to spool (54). Install the spool (54)
assembly and spring (58) to housing (1).
 Assembly of Spool
13. Install the spool (51, 50, 47, 37) 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).
l : 8 mm
m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft)
W3-9-3-14
 Assembly of Bucket Flow Rate Control Valve  Assembly of Bypass Shut-Out Valve
14. Install O-rings (95, 90) to plugs (96, 89). 21. Install spool (105), spring (106), and O-ring (4) to
housing (1). Install flange (107) to housing (1) with
15. Install spring (93), spool (92), spring seat (94), and
plug (96) to body (91).
l : 8 mm
j : 27 mm
16. Install plug (89) to body (91). m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
17. Install poppets (83, 84), springs (85, 87), plug (86), 22. Install plugs (8) (3 used) and O-rings (7) (3 used) to
and sleeve (88) to housing (1). housing (1).
18. Install O-rings (13, 77) to housing (1). Install body

(91) to housing (1) with socket bolts (97) (4 used).  Assembly of Overload Relief Valves (20, 74)
IMPORTANT: If the overload relief valve has been
l : 8 mm disassembled, pressure should be adjusted.
(Refer to TROUBLESHOOTING / Operational
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
Performance Test in the separated volume, T/M.)
23. Install O-rings (19) (4 used) to overload relief valves
 Assembly of Flow Combiner Valve (20, 74) (2 used for each). Install overload relief
19. Install spring seats (71) (2 used) and spring (72) to valves (20, 74) (2 used for each) to housing (1).
bolt (70). Install bolt (70) to spool (73).
j : 32 mm
20. Install spool (73) and O-ring (4) to housing (1).
Install cap (69) to housing (1) with socket bolts (68) m : 85 N·m (8.5 kgf·m, 63 lbf·ft)
(2 used).
l : 5 mm
m : 10 N·m (1 kgf·m, 7.4 lbf·ft)
W3-9-3-15
 Assembly of Check Valve

24. Install O-rings (9) (2 used) to plugs (10) (2 used).
Install plugs (10) (2 used) to housing (1).
l : 6 mm
l : 10 mm
26. Install O-ring (7) to plug (8). Install poppet (11),
spring (12), and plug (8) to housing (1).
l : 10 mm
27. Install poppets (2, 15), springs (3) (2 used), and
O-rings (4) (2 used) to housing (1).
28. Install flanges (5, 16) to housing (1) with socket
bolts (6) (4 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

29. Install O-ring (102) to housing (1). Install cap (103)
to housing (1) with socket bolts (104) (4 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
W3-9-3-16
 Assembly of Boom Anti-Drift Valve (Selector Valve)  Assembly of Arm 2 Flow Rate Control Valve
30. Install backup rings (24, 28) and O-rings (25, 26) to 39. Install O-rings (115, 120) (3 used for each) to plugs
sleeve (29). (114, 119) (3 used for each) as shown in detail D, E,
and F.
31. Apply grease onto seat (22) and spring (21) in
order to prevent from falling off. Face the hole on 40. Install spool (118), spring (117), and spring seat
spool (30) to the poppet (23) side. Install spool (30), (116) to body (123) as shown in detail D. Temporarily
poppet (23), seat (22), and spring (21) to sleeve (29). tighten plugs (114, 119) to body (123).
Install the sleeve (29) assembly to housing (1).
j : 24 mm
32. Install O-ring (35) to plug (36). Install spring (33),
piston (34), O-ring (31), and plug (36) to body (32). 41. Install spool (122), spring (121), and spring seat
(116) to body (123) as shown in detail F. Temporarily
33. Install O-rings (13) (4 used) to housing (1). Install the tighten plugs (114, 119) to body (123).
body (32) assembly with socket bolts (6) (3 used).
42. Install spool (124), spring (125), and spring seat
l : 8 mm (116) to body (123) as shown in detail E. Temporarily
tighten plugs (114, 119) to body (123).
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
43. Install poppets (98, 99), spring (100), plug (101),
34. Tighten plug (36). spring (87), orifice (128), and O-rings (13, 77) to
housing (1) as shown in detail D.
j : 38 mm
44. Install poppets (108, 109), spring (110), plug (111),
spring (87), and O-rings (77, 78) to housing (1) as
 Assembly of Boom Anti-Drift Valve (Check Valve)
shown in detail E.
35. Install O-rings (79, 81) to plugs (80, 82).
45. Install poppet (112), spring (113), and O-rings (77,
36. Install poppet (75), spring (76), and O-rings (77, 13)
13) to housing (1) as shown in detail F.
to housing (1).
46. Install plug (127) and O-ring (126) to body (123).
37. Install body (40) to housing (1) with socket bolts (6)
(4 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

38. Tighten plugs (80, 82).
W3-9-3-17
47. Install body (123) to housing (1) with socket bolts

(97) (8 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

48. Tighten plugs (114, 119) (3 used for each) to body
(123).
j : 24 mm
W3-9-3-18

7
3 6
2 5
4
8
13
12
1 11 8
7
17
10 14
9 15
a
16
10
9 18
19
9 20 22 b
23
10 24
30
25
20 27
20 28
21 c
29
37 31
38 32
39 26 33
d 34
28
40 35
36
41
8
45 42
43
47 46 42 42
43 44
42 42
48 42 e
49 43 44
50 42
f
43
44
48
42 42 g
43 44
42 51
h
44 52
51
i
W1V7-02-05-019
55
W3-9-4-1
k
j 81
56 79
57
104 80
58
59
60 78
61
62
20 63 o 13
8
13 8 77
7
64 75
65 82
70
66 71 6
67
68 8 5
13
69 83
12
72 l
76
73 13
74
8
p n
91 20
87 84
r 85
88
6
91 89
93
92 90
96 q
6 m
92
97 93 10
94
16 10 9
95
15 9 38
14 52
86
s 98
3
2 52 51 10
98 9
52
99 51
100 52
98 103
52 51
98
51
51
10
9
W1V7-02-05-020
W3-9-4-2
1- Housing 28- Backup Ring (2 Used) 57- O-Ring 84- Cover (2 Used)
2- O-Ring (2 Used) 29- Sleeve 58- Socket Bolt (4 Used) 85- O-Ring (2 Used)
3- Plug (2 Used) 30- Spool 59- Spool 86- Poppet
4- Poppet 31- O-Ring 60- Spring 87- Plug
5- Spring (2 Used) 32- Body 61- Spring Seat 88- O-Ring
6- O-Ring (4 Used) 33- Spring 62- O-Ring 89- Spring
7- Flange (3 Used) 34- Piston 63- Plug 90- Poppet
8- Socket Bolt (29 Used) 35- O-Ring 64- Sleeve 91- Socket Bolt (4 Used)
9- O-Ring (7 Used) 36- Plug 65- Spring 92- Cap (2 Used)
10- Plug (7 Used) 37- Poppet 66- Plug 93- Spring Seat (2 Used)
11- Poppet 38- Spring (2 Used) 67- Spring 94- Spring
12- Spring (3 Used) 39- O-Ring 68- Poppet 95- Spool
13- O-Ring (6 Used) 40- Spacer 69- Poppet 96- Spring
14- O-Ring (2 Used) 41- Spool 70- Plug 97- Spool
15- Backup Ring (2 Used) 42- Spring Seat (10 Used) 71- O-Ring 98- Cap (4 Used)
16- Plug (2 Used) 43- Spring (5 Used) 72- Flange 99- Overload Relief Valve
17- Main Relief Valve 44- Bolt (5 Used) 73- Spring 100- O-Ring
18- O-Ring 45- Spool 74- Poppet 103- Cap
19- Overload Relief Valve 46- Spool 75- Flange (2 Used) 104- Body
20- O-Ring (9 Used) 47- Spool 76- Poppet (2 Used)
21- O-Ring 48- Spring Seat (2 Used) 77- Spring
22- Spring 49- Spring 78- Body
23- Seat 50- Spool 79- Plug
24- Poppet 51- O-Ring (10 Used) 80- O-Ring
25- Backup Ring 52- Socket Bolt (16 Used) 81- Socket Bolt (4 Used)
26- O-Ring 55- Cap 82- Poppet
27- O-Ring 56- Plug 83- Poppet
a- Main Relief Valve f- Auxiliary l- Check Valve (Auxiliary Flow o- Load Check Valve (Boom 2
b- Overload Relief Valve (Arm: g- Boom 2 Combiner Circuit) Parallel Circuit, Swing Circuit)
Rod Side) h- Arm 1 m- Load Check Valve (Travel (Left) p- Arm Anti-Drift Valve
c- Arm Anti-Drift Valve i- Swing Parallel Circuit) q- Auxiliary Flow Combiner Valve
d- Load Check Valve (Arm j- Arm 1 Flow Rate Control Valve n- Check Valve (Digging r- Digging Regenerative Valve
Regenerative Circuit) k- Load Check Valve (Auxiliary Regenerative Circuit) s- Overload Relief Valve (Arm:
e- Travel (Left) Parallel/Flow Combiner Circuit) Bottom Side)
W3-9-4-3
Disassembly of Control Valve (5-Spool Side)  Disassembly of Overload Relief Valve (19)
IMPORTANT: Do not disassemble the overload
relief valve. If the overload relief valve has been
 Disassembly of Spool
disassembled, pressure should be adjusted. (Refer
1. Remove socket bolts (52) (6 used). Remove cap
(55), O-rings (51) (5 used), and O-rings (20, 21) from
Test in the separated volume, T/M.)
housing (1).
7. Remove overload relief valve (19) and O-ring (18)
l : 8 mm from housing (1).
2. Put the matching marks on spools (41, 45, 46, 47, j : 32 mm
50) and housing (1). Remove the spool (41, 45, 46,
47, 50) assemblies from housing (1).
 Disassembly of Main Relief Valve (17)
IMPORTANT: Do not disassemble the main
 Disassembly of Arm Anti-Drift Valve relief valve. If the main relief valve has been
3. Remove plug (36) and O-ring (35) from body (32). disassembled, pressure should be adjusted. (Refer
j : 38 mm
4. Remove socket bolts (8) (3 used). Remove the body 8. Remove main relief valve (17) from housing (1).
(32) assembly, O-rings (31), and O-rings (20) (5 used)
from housing (1). j : 32 mm
l : 8 mm
 Disassembly of Load Check Valve (Arm Regenerative
5. Remove piston (34) and spring (33) from body (32). Parallel Circuit)
9. Remove spacer (40), spring (38), and poppet (37)
6. Remove spool (30), sleeve (29), poppet (24), seat from housing (1). Remove backup ring (28) and
(23), and spring (22) from housing (1). O-ring (39) from spacer (40).
Remove backup rings (25, 28) and O-rings (26, 27) 10. Remove socket bolts (8) (2 used). Remove flange (7),
from sleeve (29). O-ring (6), spring (5), and poppet (4) from housing
(1).
l : 8 mm
11. Remove socket bolts (8) (2 used). Remove flange
(7), O-ring (13), spring (12), and poppet (11) from
housing (1).
l : 8 mm
W3-9-4-4
12. Remove plugs (10) (3 used) and O-rings (9) (3 used)  Disassembly of Arm 1 Spool (47)
from housing (1). 18. Secure spool (47) in a vise by using wooden pieces.
Remove bolt (44), spring seats (42, 48) (2 used for
l : 8 mm each), and springs (49, 43) from spool (47).
13. Remove plug (3) and O-ring (2) from housing (1).
l : 8 mm
l : 10 mm
14. Remove plug (16), backup ring (15), and O-ring (14)  Disassembly of Swing Spool (50)
from housing (1). 19. Secure spool (50) in a vise by using wooden pieces.
Remove bolt (44), spring seats (42) (2 used), and
j : 24 mm spring (43) from spool (50).
l : 8 mm
 Disassembly of Travel (Left) Spool (41)
l : 8 mm
 Disassembly of Auxiliary Spool (45)

l : 8 mm
 Disassembly of Boom 2 Spool (46)

l : 8 mm
W3-9-4-5
20. Remove socket bolts (52) (10 used). Remove caps  Disassembly of Arm Anti-Drift Valve
(98) (4 used), cap (103), and O-rings (51) (5 used) 24. Remove socket bolts (8) (4 used). Remove flange
from housing (1). (72), O-rings (20) (2 used), O-ring (13), spring (73),
and poppet (74) from housing (1). Remove plug (70)
l : 8 mm and O-ring (71) from flange (72).
l : 8 mm
 Disassembly of Digging Regenerative Valve and
Auxiliary Flow Combiner Valve
21. Remove socket bolts (91) (4 used). Remove caps  Disassembly of Arm 1 Flow Rate Control Valve and
(92) (2 used), O-rings (6) (2 used), spring seats (93) Auxiliary Flow Rate Control Valve
(2 used), springs (96, 94), and spools (97, 95) from 25. Loosen plugs (56, 63) from body (104).
housing (1).
l : 5 mm (104) assembly and O-rings (20, 13) from housing
(1).
l : 8 mm
 Disassembly of Overload Relief Valve (99)
IMPORTANT: Do not disassemble the overload 27. Remove plug (63), O-ring (62), spring seat (61),
relief valve. If the overload relief valve has been spring (60), and spool (59) from body (104). Remove
disassembled, pressure should be adjusted. (Refer plug (56) and O-ring (57) from body (104).
28. Remove sleeve (64), springs (65, 67), plug (66), and
poppets (68, 69) from housing (1).
22. Remove overload relief valve (99) and O-ring (100)
from housing (1).
j : 32 mm
 Disassembly of Check Valve (Auxiliary Flow Combiner

Circuit)
23. Remove socket bolts (8) (2 used). Remove flange (7),
O-ring (6), spring (5), and poppet (83) from housing
(1).
l : 8 mm
W3-9-4-6
 Disassembly of Load Check Valve 34. Remove plug (16), backup ring (15), and O-ring (14)
29. Remove socket bolts (8) (8 used) from housing (1). from housing (1).
Remove flanges (75) (2 used), O-rings (13) (2 used),
springs (12) (2 used), and poppets (76) (2 used). j : 24 mm
35. Remove plug (3) and O-ring (2) from housing (1).
l : 8 mm
30. Remove socket bolts (8) (8 used). Remove covers l : 10 mm
(84) (2 used) and O-rings (85) (2 used) from housing 36. Remove plugs (10) (3 used) and O-rings (9) (3 used)
(1). from housing (1).
l : 8 mm l : 8 mm
31. Remove plug (10), O-ring (9), spring (38), and
poppet (86) from housing (1).
 Disassembly of Check Valve (Digging Regenerative
l : 8 mm Circuit)
37. Remove plug (87), O-ring (88), spring (89), and
38 86 poppet (90) from housing (1).
10 j : 24 mm
W1V1-02-05-016
32. Remove plug (79) and O-ring (80) from body (78).
33. Remove socket bolts (81) (4 used). Remove body
(78), O-ring (13), spring (77), and poppet (82) from
housing (1).
l : 8 mm
W3-9-4-7
Assembly of Control Valve (5-Spool Side)
Control Valve (Upper) Control Valve (Lower)
51, 55 52 52 51, 98 52 51, 98 52 51, 103 52 51, 98

52
51, 98
W1V7-02-05-027 W1V7-02-05-028
Control Valve (Side) Control Valve (Front)
17 19 36 32 9, 10 8
7, 11, 12, 13
8
8
72
75
8
2, 3
58
4, 5, 6, 7
10 104 99, 100 9, 10
W1V7-02-05-032 W1V1-02-05-068
W3-9-4-8
Control Valve (Upper) Section C-C (5-Spool Side)

J I H G F E D C
17
1
9, 10
7 97
5
6
83 96
93
92
J I H G F E D C
W1V1-02-05-043
W1V7-02-05-027
Section D-D (5-Spool Side) Section E-E (5-Spool Side) Section F-F (5-Spool Side)
e f g
54
55
53
44
42
43
14, 15, 16
42 76
84
51
8 12 46
41
45 13
75
A 8
1
8
1 103
51
98 84 1
W1V1-02-05-044 W1V7-02-05-025 W1V7-02-05-026
W3-9-4-9
Section G-G (5-Spool Side) Section H-H (5-Spool Side) Section I-I (5-Spool Side)
h
44 i
42
C
48
49
21 43
19
18 48 76
42
47 12 50
13
D
8
1
75
B
1
100
99
1
W1V1-02-05-050 W1V1-02-05-051 W1V1-02-05-052
Detail A Detail B
88 89 90
10
79 80 78 82 77 13
9 2 3
W1V7-02-05-033 W1V1-02-05-053
W3-9-4-10
Detail C Detail D
36
35
34 1
32 63
62
33
24 61
30
60
104
13
59
29
28
57
20 27
26 56
20 25 64
23 69 68 67 13 20 66 65
22
W1V1-02-05-033
71 70 13 73 74 W1V1-02-05-054
1- Housing 28- Backup Ring (2 Used) 57- O-Ring 84- Cover (2 Used)
2- O-Ring (2 Used) 29- Sleeve 58- Socket Bolt (4 Used) 85- *O-Ring (2 Used)
3- Plug (2 Used) 30- Spool 59- Spool 86- *Poppet
4- Poppet 31- *O-Ring 60- Spring 87- *Plug
5- Spring (2 Used) 32- Body 61- Spring Seat 88- O-Ring
6- O-Ring (4 Used) 33- Spring 62- O-Ring 89- Spring
7- Flange (3 Used) 34- Piston 63- Plug 90- Poppet
8- Socket Bolt (29 Used) 35- O-Ring 64- Sleeve 91- *Socket Bolt (4 Used)
9- O-Ring (7 Used) 36- Plug 65- Spring 92- Cap (2 Used)
10- Plug (7 Used) 37- *Poppet 66- Plug 93- Spring Seat (2 Used)
11- Poppet 38- *Spring (2 Used) 67- Spring 94- *Spring
12- Spring (3 Used) 39- *O-Ring 68- Poppet 95- *Spool
13- O-Ring (6 Used) 40- *Spacer 69- Poppet 96- Spring
14- O-Ring (2 Used) 41- Spool 70- Plug 97- Spool
15- Backup Ring (2 Used) 42- Spring Seat (10 Used) 71- O-Ring 98- Cap (4 Used)
16- Plug (2 Used) 43- Spring (5 Used) 72- Flange 99- Overload Relief Valve
17- Main Relief Valve 44- Bolt (5 Used) 73- Spring 100- O-Ring
18- O-Ring 45- Spool 74- Poppet 103- Cap
19- Overload Relief Valve 46- Spool 75- Flange (2 Used) 104- Body
20- O-Ring (9 Used) 47- Spool 76- Poppet (2 Used)
21- O-Ring 48- Spring Seat (2 Used) 77- Spring
22- Spring 49- Spring 78- Body
23- Seat 50- Spool 79- Plug
24- Poppet 51- O-Ring (10 Used) 80- O-Ring
25- Backup Ring 52- Socket Bolt (16 Used) 81- Socket Bolt (4 Used)
26- O-Ring 55- Cap 82- Poppet
27- O-Ring 56- Plug 83- Poppet
e- Travel (Left) g- Boom 2 i- Swing

f- Auxiliary h- Arm 1
fNOTE: As for the item with mark *, refer to W3-9-4-1

and W3-9-4-2.
W3-9-4-11
Assembly of Control Valve (5-Spool Side) 6. Install O-rings (51) (5 used) to housing (1). Install
cap (103) and caps (98) (4 used) to housing (1) with
onto parts in order to prevent them from seizing. l : 8 mm
 Assembly of Travel (Left) Spool (41)
1. Secure spool (41) in a vise by using wooden pieces. m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft)
Install spring seats (42) (2 used), spring (43), and 7. Install the spool (41, 45, 46, 47, 50) assemblies to
bolt (44) to spool (41). housing (1).
l : 8 mm 8. Install O-rings (51) (5 used) and O-rings (20, 21)
to housing (1). Install cap (55) to housing (1) with
m : 15 N·m (1.5 kgf·m, 11 lbf·ft) socket bolts (52) (6 used).
l : 8 mm
 Assembly of Auxiliary Spool (45)
2. Secure spool (45) in a vise by using wooden pieces. m : 43 N·m (4.3 kgf·m, 31.5 lbf·ft)
Install spring seats (42) (2 used), spring (43), and
bolt (44) to spool (45).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
 Assembly of Boom 2 Spool (46)

l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
 Assembly of Arm 1 Spool (47)

Install spring seats (42, 48) (2 used for each), springs
(43, 49), and bolt (44) to spool (47).
l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
 Assembly of Swing Spool (50)

l : 8 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
W3-9-4-12
 Assembly of Check Valve (Auxiliary Flow Combiner  Assembly of Check Valve (Digging Regenerative Circuit)
Circuit) 11. Install O-ring (88) to plug (87). Install poppet (90),
9. Install poppet (83), spring (5), and O-ring (6) to spring (89), and plug (87) to housing (1).
socket bolts (8) (2 used). j : 24 mm
l : 8 mm
 Assembly of Load Check Valve
m : 62 N·m (6.2 kgf·m, 46 lbf·ft) 12. Install poppets (76) (2 used), springs (12) (2 used),
and O-rings (13) (2 used) to housing (1).
 Assembly of Digging Regenerative Valve and Auxiliary 13. Install flanges (75) (2 used) to housing (1) with
Flow Combiner Valve socket bolts (8) (8 used).
10. Install spool (97, 95), springs (96, 94), O-rings (6) (2
l : 8 mm
used), and spring seats (93) (2 used) to housing (1).
Install caps (92) (2 used) to housing (1) with socket m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
14. Install O-ring (14) and backup ring (15) to plug (16).
l : 5 mm Install plug (16) to housing (1).
m : 10 N·m (1 kgf·m, 7.4 lbf·ft) j : 24 mm

15. Install O-rings (85) (2 used) to housing (1). Install
covers (84) (2 used) to housing (1) with socket bolts
(8) (8 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

16. Install poppet (82), spring (77), and O-ring (13) to
housing (1). Install body (78) to housing (1) with
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

17. Install O-ring (80) to plug (79). Install plug (79) to
body (78).
W3-9-4-13
18. Install O-ring (9) to plug (10). Install poppet (86),  Assembly of Arm 1 Flow Rate Control Valve
spring (38), and plug (10) to housing (1). 27. Install O-rings (57, 62) to plugs (56, 63).
l : 8 mm 28. Install spring (60), spool (59), spring seat (61), and
plug (63) to body (104).
housing (1). 29. Install plug (56) to body (104).
30. Install poppets (69, 68), springs (65, 67), plug (66),
l : 10 mm
and sleeve (64) to housing (1).
31. Install O-rings (13, 20) to housing (1). Install body
(104) to housing (1) with socket bolts (58) (4 used).
l : 8 mm
l : 8 mm
 Assembly of Arm Anti-Drift Valve m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

21. Install backup rings (25, 28) and O-rings (26, 27) to
sleeve (29).
22. Apply grease onto seat (23) and spring (22) in order
to prevent from falling off.
23. Face the hole on spool (30) to the poppet (24) side.
Install spool (30), poppet (24), seat (23), and spring
(22) to sleeve (29). Install the sleeve (29) assembly to
housing (1).
24. Install O-ring (35) to plug (36). Install spring (33),
piston (34), O-ring (31), and plug (36) to body (32).
j : 38 mm
25. Install O-rings (20) (5 used) to housing (1). Install the
body (32) assembly to housing (1) with socket bolts
(8) (3 used).
l : 8 mm
m : 62 N·m (6.2 kgf·m, 46 lbf·ft)

26. Tighten plug (36).
j : 38 mm
W3-9-4-14
 Assembly of Arm Anti-Drift Valve  Assembly of Load Check Valve (Arm Regenerative
32. Install O-ring (71) to plug (70). Install plug (70) to Circuit)
flange (72). 36. Install poppet (4), spring (5), and O-ring (6) to
33. Install flange (72), O-rings (20) (2 used), O-ring (13),
spring (73), and poppet (74) to housing (1) with
socket bolts (8) (4 used). l : 8 mm
l : 8 mm m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
m : 62 N·m (6.2 kgf·m, 46 lbf·ft) 37. Install poppet (11), spring (12), and O-ring (13) to
 Assembly of Overload Relief Valves (19, 99)
IMPORTANT: If the overload relief valve has been l : 8 mm
disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance m : 62 N·m (6.2 kgf·m, 46 lbf·ft)
38. Install backup ring (28) and O-ring (39) to spacer
34. Install O-rings (18, 100) to overload relief valves (19, (40). Install spacer (40), spring (38), and poppet (37)
99). Install overload relief valves (19, 99) to housing to housing (1).
(1).
j : 32 mm Install plugs (10) (3 used) to housing (1).
m : 85 N·m (8.5 kgf·m, 63 lbf·ft) l : 8 mm

 Assembly of Main Relief Valve housing (1).
IMPORTANT: If the main relief valve has been
disassembled, pressure should be adjusted. (Refer l : 10 mm
to TROUBLESHOOTING / Operational Performance 41. Install backup ring (15) and O-ring (14) to plug (16).
Test in the separated volume, T/M.) Install plug (16) to housing (1).
35. Install main relief valve (17) to housing (1).
j : 24 mm
j : 32 mm
m : 60 N·m (6 kgf·m, 44 lbf·ft)
W3-9-4-15
(Blank)
W3-9-4-16
Removal and Installation of Swing Device
2 1
WDDE-03-06-001

Removal

(Refer to W1-4-1.)
(2).
j : 17 mm
W3-10-1-1
WDDE-03-10-001

4. Place a container under swing device (4).
dCAUTION:
lb)
Swing device (4) weight: 390 kg (860
Disconnect hose (5).

8. Attach a nylon sling onto the body of swing motor.
j : 41 mm Hoist and hold swing device (4).
5. Disconnect hose (6). 9. Remove bolts (12) (14 used) and washers (13) (14
used). Remove swing device (4).
j : 27 mm
j : 32 mm
10. Remove the adapter with swing device (4) attached
j : 19 mm if necessary.
(4 used). Disconnect hoses (10) (2 used). Remove
O-rings (11) (2 used).
l : 8 mm
W3-10-1-2
WDDE-03-10-001
Installation
1. Install all removed adapters to swing device (4). 5. Connect hose (7).
dCAUTION:
lb)
Swing device (4) weight: 390 kg (860 j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)

2. Apply THREEBOND #1215 onto the main frame
mounting surface of swing device (4). Attach a 6. Connect hose (6).
nylon sling onto the body of swing motor. Hoist
swing device (4). j : 27 mm
3. Install swing device (4) with washers (13) (14 used) m : 80 N·m (8 kgf·m, 59 lbf·ft)
and bolts (12) (14 used). 7. Connect hose (5).
j : 32 mm j : 41 mm
m : 650±30 N·m (65±3 kgf·m, 480±22 lbf·ft) m : 200 N·m (20 kgf·m, 148 lbf·ft)
4. Install O-rings (11) (2 used). Connect hoses (10) (2 8. Connect connector (3).
used) with flanges (9) (4 used) and socket bolts (8)
(8 used).
l : 8 mm
m : 58 N·m (5.8 kgf·m, 43 lbf·ft)
W3-10-1-3
2 1
WDDE-03-06-001

1.)
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-10-1-4
Disassembly of Swing Device
23
24
1
25
22 2
33 26 21 4
32
5
20 6
27 7
19
8
28 9
18
29 10
13
17
30
16 11
15
31 12
14
13
WDAB-03-11-002
1- Motor 9- Pin (3 Used) 17- Bolt (2 Used) 26- Housing

2- First Stage Sun Gear 10- Spring Pin (3 Used) 18- Second Stage Carrier 27- Roller Bearing
3- Thrust Plate 11- Needle Bearing (6 Used) 19- Thrust Plate 28- Oil Seal
4- Pin (3 Used) 12- Second Stage Planetary Gear 20- Second Stage Sun Gear 29- Sleeve
5- Spring Pin (3 Used) (3 Used) 21- First Stage Carrier 30- O-Ring
6- Needle Bearing (3 Used) 13- Thrust Plate (6 Used) 22- Retaining Ring 31- Shaft
7- First Stage Planetary Gear (3 14- Roller Bearing 23- Socket Bolt (8 Used) 32- Drain Plug
Used) 15- Bearing Nut 24- Socket Bolt (12 Used) 33- Pipe
8- Thrust Plate (3 Used) 16- Lock Plate 25- Ring Gear
W3-10-2-1
Disassembly of Swing Device 3. Remove drain plug (32). Drain off oil from swing
device (b).
dCAUTION:
lb)
Swing device (b) weight: 390 kg (860
l : 8 mm
1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to 4. Remove pipe (33) from housing (26).
swing device (b). Hoist swing device (b).
a
j : 18 mm
dCAUTION: Motor (1) weight: 69 kg (155 lb)

5. Put the matching marks at the jointed part between
motor (1) and ring gear (25), between ring gear (25)
and housing (26). Remove socket bolts (23) (8 used).
Hoist and remove motor (1).
l : 10 mm
W1V7-02-06-006
a - Eyebolt Mounting Position
fNOTE: Insert a screwdriver between motor (1) and ring
gear (25). Float motor (1) for easy removal.
2. Place swing device (b) on the bracket (ST 5100). 6. Remove first stage sun gear (2). Remove the first
Secure swing device (b) onto the bracket by using stage carrier (21) assembly from ring gear (25).
the bolts (M22, Pitch 2.5 mm) (2 used). Secure the
bracket on a workbench in order to receive the
reaction force.
j : 32 mm
b
ST 5100
W1V7-02-06-001
b - Swing Device
W3-10-2-2
11. Install eyebolts (M18, Pitch 2.5 mm) (2 used) into the
d CAUTION: Ring gear (25) weight: 34 kg (75 lb) bolt (24) holes on housing (26). Remove the bolts
7. Remove socket bolts (24) (12 used). Install eyebolts (M22, Pitch 2.5 mm) (2 used) securing housing (26)
(M12, Pitch 1.75 mm) (2 used) to the motor and the bracket (ST 5100). Hoist the housing (26)
mounting thread part on ring gear (25). Hoist and assembly and remove the bracket.
remove ring gear (25) from housing (26).
j : 32 mm
l : 17 mm
12. Set blocks (a) on a press. Set the housing (26)
fNOTE: THREEBOND has been applied on the jointed assembly on blocks (a).
surfaces between housing (26) and ring gear (25). Attach
a screwdriver onto the notch between jointed portion. 26
Float it for easy removal.
dCAUTION: The second stage carrier (18)

assembly weight: 43 kg (95 lb)
8. Remove second stage sun gear (20) and the second
stage carrier (18) assembly from housing (26).
dCAUTION: The housing (26) assembly weight:

195 kg (430 lb)
9. Remove bolts (17) (2 used). Remove lock plate (16)
from bearing nut (15).
a W1HH-02-06-012
j : 17 mm
a - Block
10. Remove bearing nut (15) from shaft (31) by using
31
ST 2926
W178-02-06-008
W3-10-2-3
dCAUTION: If pushing shaft (31) by using press

(c), provide protection cover (b) (outer diameter:
369 mm (14.5 in), inner diameter: 90 mm (3.5 in),
thickness: 25 to 30 mm (1.0 to 1.2 in)). Push shaft
(31) with protection cover (b) on by using press (c).
When housing (26) and/or roller bearing (14) are
broken and flown off, the metal fragments may
result in personal injury. Use press (c) with the
capacity less than 30 tons (66000 lb). Degrease the
housing (26) inside before heating roller bearing
(14). Failure to degrease may cause a fire.
13. Put protection cover (b) onto housing (26) and

remove shaft (31) by using press (c). At this time, the
inner race of roller bearing (27) and sleeve (29) are
removed with shaft (31) together.
31 14
26
W157-02-06-010
b - Protection Cover
W1V7-02-06-002
b - Protection Cover
c - Press
W3-10-2-4
14. Remove the outer race of roller bearing (14) from

housing (26). dCAUTION: When pushing shaft (31) by using
press (e), set shaft (31) into guide (d).
dCAUTION:
(155 lb)
The shaft (31) assembly weight: 70 kg 16. Set shaft (31) with the special tool attached to press
(e). Remove the inner race of roller bearing (27).
15. Set the special tool to the shaft (31) assembly.
17. Remove sleeve (29) from shaft (31). Remove O-ring
f NOTE: Use the following parts as the special tool for (30) from sleeve (29).
roller bearing (27).
e
Part Size Remarks
Shaft (b) Length: 220 mm 8 used. All should be 31
or Bolt (8.7 in) identical in length
Diameter: 19 mm with no wear and 27
(3/4 in) deformation on
both ends. Material: 29
S35C
Hose Standard Diameter: 2 used.
Clamp (c) 8-1/2” (Applicable d
Diameter: 210 to
350 mm (8.3 to 13.8
in))
W157-02-06-014
Guide (d) Height: 160 mm (6.3
d - Guide
in) e - Press
Outer Diameter: 292
mm (11.5 in)
Inner Diameter: 272
mm (10.7 in)
a
b
c
W157-02-06-012
31
27
29
c
b
d
W157-02-06-013
a - Special Tool for Roller Bearing c - Hose Clamp
(27) d - Guide
b - Shaft
W3-10-2-5
18. Insert a round bar into the oil passage in housing 22. Remove pins (4) (3 used), first stage planetary gears
(26). Tap and remove outer race (b) of roller bearing (7) (3 used), thrust plates (8) (3 used), and needle
(27). bearings (6) (3 used) from first stage carrier (21).
23. Remove thrust plate (3) from first stage carrier (21).
a
24. Remove spring pins (10) (3 used) from second stage
carrier (18) by using a round bar and a hammer.
b
25. Remove pins (9) (3 used), second stage planetary
gears (12) (3 used), thrust plates (13) (6 used), and
needle bearings (11) (6 used) from second stage
carrier (18).
26. Remove thrust plate (19) from second stage carrier
W1HH-02-06-007 (18).
a - Hole for Round Bar
b - Outer Race
dCAUTION: Housing (26) weight: 110 kg (245 lb)

19. Fasten the housing (26) body by using a nylon
sling. Hoist and turn over housing (26). Insert a
screwdriver into the notch on housing (26) where
oil seal (28) is mounted. Remove oil seal (28).
fNOTE: THREEBOND has been applied on the periphery

of oil seal (28). Oil seal (28) cannot be reused.
20. Tap and remove the outer race of roller bearing (14)
from housing (26) by using a bar and a hammer.
21. Remove spring pins (5) (3 used) from first stage
carrier (21) by using a round bar and a hammer.
W3-10-2-6
Assembly of Swing Device
22
1 4
2
3 5
23
21
6
20 7
8
18 10
13
25 12
19 24
17 11
16
13
9
14 15
33 27
32
26
28
30
29
31
WDAB-03-11-001
1- Motor 9- Pin (3 Used) 17- Bolt (2 Used) 26- Housing

2- First Stage Sun Gear 10- Spring Pin (3 Used) 18- Second Stage Carrier 27- Roller Bearing
3- Thrust Plate 11- Needle Bearing (6 Used) 19- Thrust Plate 28- Oil Seal
4- Pin (3 Used) 12- Second Stage Planetary Gear 20- Second Stage Sun Gear 29- Sleeve
5- Spring Pin (3 Used) (3 Used) 21- First Stage Carrier 30- O-Ring
6- Needle Bearing (3 Used) 13- Thrust Plate (6 Used) 22- Retaining Ring 31- Shaft
7- First Stage Planetary Gear (3 14- Roller Bearing 23- Socket Bolt (8 Used) 32- Drain Plug
Used) 15- Bearing Nut 24- Socket Bolt (12 Used) 33- Pipe
8- Thrust Plate (3 Used) 16- Lock Plate 25- Ring Gear
W3-10-2-7
Assembly of Swing Device

IMPORTANT: Before assembling, apply hydraulic oil 8. Install sleeve (29) and the inner race of roller
onto parts in order to prevent them from seizing. bearing (27) to shaft (31). Install sleeve (29) and the
1. Install needle bearings (6) (3 used) to first stage inner race of roller bearing (27) by using special
planetary gears (7) (3 used). tools (ST 7289, ST 7292) and a press (b).
2. Install thrust plate (3) to first stage carrier (21) with fNOTE: The press-in distance of the inner race of roller
the oil groove up. bearing (27) can be assured by using the special tool.
3. Install first stage planetary gears (7) (3 used) and
thrust plates (8) (3 used) to first stage carrier (21).
4. Fit the hole on pin (4) to the spring pin hole on first b
stage carrier (21). Install pins (4) (3 used) by using a
ST 7292
plastic hammer.
IMPORTANT: Check the direction of spring pin (5). ST 7289 27
5. Face slit (a) of spring pin (5) to the end of pin (4).
29
Install spring pin (5) to first stage carrier (21) by
using a hammer. 31
5
4 W1V7-02-06-004
b - Press
a
a - Slit
W1V7-02-06-003
9. Fasten the housing (26) body by using a nylon sling.
Hoist and place housing (26) with the sleeve (29)
6. Assemble second stage carrier (18) in the same
mounting side up.
procedures as steps 1 to 5. Assemble thrust plate
(19), second stage planetary gears (12) (3 used), 10. Evenly tap and install the outer race of roller
needle bearings (11) (6 used), thrust plates (13) (6 bearing (27) to housing (26) by using a bar and a
used), pins (9) (3 used), and spring pins (10) (3 used). hammer. Tap and listen to ring in order to check if
the installation is completed.
7. Install O-ring (30) to sleeve (29).
W3-10-2-8
11. Apply THREEBOND #1215 onto the outer surface of 16. Tighten bearing nut (15) to shaft (31) by hand.
oil seal (28). Place oil seal (28) flat on housing (26)
and push by hand in gently. Place the special tool fNOTE: Prevent shaft (31) from falling off when hoisting
(ST 7291) on oil seal (28). Tap in the special tool by housing (26).
using a hammer straight.
dCAUTION: The housing (26) assembly weight:
195 kg (430 lb)
ST 7291 28 bolt (24) holes on housing (26). Hoist and place
housing (26) on a press.
26
18. Remove bearing nut (15) from shaft (31).
19. Place the special tool (ST 7290) onto the inner race
of roller bearing (14). Install the inner race by using
a press.
WIHH-02-06-010
fNOTE: The specified press-in distance of the inner race
can be assured by using the special tool.
12. Apply grease onto the inner surface of oil seal (28). 14 ST 7290
Apply grease onto the outer surface of sleeve (29)
attached on shaft (31).
13. Turn over housing (26). Install eyebolts (M18, Pitch
2.5 mm) (2 used) to the bolt (24) holes on housing
(26). Hoist and place housing (26) on shaft (31).
Check and align carefully in order to prevent the oil
seal (28) lip from curling.
WIHH-02-06-009
14. Evenly tap and install the outer race of roller bearing
(14) to housing (26) by using a bar and hammer. Tap
and listen to ring in order to check if the installation
is completed.
15. Tap and install the inner race of roller bearing (14)
into shaft (31) by using a bar and a hammer. Tap the
inner race until two threads of shaft (31) for bearing
nut (15) appear.
W3-10-2-9
20. Hoist and place the housing (26) assembly on the 23. Tighten bearing nut (15) by using the special tool
bracket (ST 5100). Install the housing (26) assembly (ST 2926) so that bearings of roller bearings (14, 17)
with bolts (M22, Pitch 2.5 mm) (2 used). Insert can fit. At this time, tighten bearing nut (15) so that
stopper (a) at the bottom of bracket between the rotation torque value necessary to turn housing
teeth of the pinion gear. Secure the bracket on a (26) should be equal to the value that is the rotation
workbench in order to receive the reaction force. torque value in step 22 plus 6 N·m (0.6 kgf·m, 4.4
lbf·ft).
j : 32 mm
26 15
ST 5100
a
ST 2926
W1V7-02-06-001
a - Stopper
W178-02-06-008
IMPORTANT: Check the direction to install bearing

nut (15). 24. Fit the spline part of lock plate (16) to that of shaft
21. Apply grease onto the thread part of bearing nut (31). Tighten bearing nut (15) further until the bolt
(15). Place the thread part of bearing nut (15) onto (17) hole of bearing nut (15) fit to that of lock plate
shaft (31).At this time, face the stepped side of (16).
bearing nut (15) to the roller bearing (14) side. 25. Install lock plate (16) to bearing nut (15) with bolts
22. Check the rotation torque value necessary to turn (17) (2 used).
housing (26) without tightening bearing nut (15).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-10-2-10
dCAUTION:
kg (95 lb)
Second stage carrier (18) weight: 43 dCAUTION: Ring gear (25) weight: 34 kg (75 lb)
IMPORTANT: Check the direction of second stage the motor mounting thread part on ring gear
carrier (18). (25). Hoist and install ring gear (25) to housing
26. Install the second stage carrier (18) assembly to the (26) while fitting the matching marks made when
spline of shaft (31). disassembling. Tighten socket bolts (24) (12 used).
18 l : 17 mm
31 m : 440 N·m (44 kgf·m, 320 lbf·ft)

30. Install the first stage carrier (21) assembly to the
spline of second stage sun gear (20).
IMPORTANT: Check the direction to install first stage
sun gear (2).
W1V7-02-06-005
31. Install first stage sun gear (2) to the first stage carrier
(21) assembly with the stepped side down.
27. Install second stage sun gear (20) to the second 32. Install the seal tape onto the thread part of pipe
stage carrier (18) assembly. (33). Install pipe (33) to housing (26). Face pipe (33)
28. Clean off old adhesive. Apply THREEBOND #1215 down.
onto the ring gear (25) mounting surface of housing
(26). j : 18 mm
W3-10-2-11
33. Install the seal tape onto drain plug (32). Install
drain plug (32) to pipe (33).
l : 8 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

34. Add gear oil (15.7 L (4.15 US gal.)) into housing (26).
35. Apply liquid packing (THREEBOND #1215) onto the
motor (1) mounting surface of ring gear (25).
dCAUTION: Motor (1) weight: 69 kg (155 lb)

36. Hoist motor (1) and fit the matching marks made
when disassembling. Install motor (1) to ring gear
(25) with socket bolts (23) (8 used).
l : 10 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
W3-10-2-12
Disassembly of Swing Motor
12
11
10
9
8
7
13
1 6
2 5
4
3
14 19
15
16 20
17
18 21
22
17
16
24 15
14
25
26 23
27
28
29
W1V1-02-06-007
1- Socket Bolt (3 Used) 9- Plate 18- Valve Casing 27- Brake Piston
2- Swing Parking Brake Switch 10- Retainer 19- Socket Bolt (4 Used) 28- O-Ring
Valve 11- Rotor 20- O-Ring (2 Used) 29- O-Ring
3- Casing 12- Friction Plate (3 Used) 21- Plug (2 Used)
4- Oil Seal 13- Plate (4 Used) 22- O-Ring
5- Bearing 14- Plug (2 Used) 23- Relief Valve (2 Used)
6- Shaft 15- O-Ring (2 Used) 24- Bearing
7- Shoe Plate 16- Spring (2 Used) 25- Valve Plate
8- Plunger (9 Used) 17- Poppet (2 Used) 26- Spring (20 Used)
W3-10-3-1
Disassembly of Swing Motor

IMPORTANT: Do not damage the mating surfaces
d CAUTION: The swing motor assembly weight: 69
kg (155 lb)
when separating valve plate (25) from valve
casing (18) or rotor (11) by using a screwdriver.
IMPORTANT: Do not disassemble relief valve (23). 7. If valve plate (25) is still attached on rotor (11) in
1. Remove relief valves (23) (2 used) from valve casing step 7, remove valve plate (25) from the rotor (11)
(18). side. Remove springs (26) (20 used).
j : 41 mm 8. Put the matching marks on casing (3) and brake
piston (27). Attach a claw of the special tool (ST
2. Remove plug (14) from valve casing (18). Remove 7288) onto the brake piston (27) groove by using
O-ring (15) from plug (14). the special tool (ST 7288). Raise and remove brake
l : 14 mm piston (27) straight.
3. Remove spring (16) and poppet (17) from valve

casing (18). ST 7288
4. Remove another poppet (17) in the same way as
step 3 to step 4. 27
5. Put the matching marks at the jointed surface

between valve casing (18) and casing (3). Remove
socket bolts (19) (4 used). Record the clearance
between valve casing (18) and casing (3).
l : 17 mm
IMPORTANT: Do not remove bearing (24) unless W1HH-02-06-006
necessary.
6. Remove valve casing (18) from casing (3). As valve 9. Remove O-rings (28, 29) from casing (3).
plate (25) may be removed with valve casing (18)
together, do not drop valve plate (25). Remove
O-ring (22).
W3-10-3-2
IMPORTANT: Do not damage the sliding surfaces of

rotor (11) and plunger (8).
10. Place casing (3) horizontally. Remove rotor (11),
retainer (10), plate (9), and plungers (8) (9 used)
from shaft (6).
11. Remove plates (13) (4 used) and friction plates (12)
(3 used) from casing (3).
IMPORTANT: Do not damage the sliding surface of
shoe plate (7).
12. Remove shoe plate (7) from casing (3).
13. Install a tape onto the spline at the end of shaft (6)
in order not to damage oil seal (4). Tap and remove
shaft (6) from casing (3) by using a plastic hammer.
14. Remove oil seal (4) from casing (3).

such as goggles, helmets, etc in order to prevent
personal injury.
15. Remove the outer race of bearing (5) from casing (3)
by using a bar and a hammer.
16. Remove the inner race of bearing (5) from shaft (6)
by using a press.
17. Remove socket bolts (1) (3 used) from swing parking
brake switch valve (2). Remove swing parking brake
switch valve (2) from casing (3).
l : 5 mm
W3-10-3-3
Assembly of Swing Motor

17
16
15
14
19
W1V1-02-06-008
21
20
18 23
26
27
24
28
29 22
25
2 12
13
1
8
11
10
9
7
5
3
4
6
W1V1-02-06-009
1- Socket Bolt (3 Used) 9- Plate 18- Valve Casing 27- Brake Piston
2- Swing Parking Brake Switch 10- Retainer 19- Socket Bolt (4 Used) 28- O-Ring
Valve 11- Rotor 20- O-Ring (2 Used) 29- O-Ring
3- Casing 12- Friction Plate (3 Used) 21- Plug (2 Used)
4- Oil Seal 13- Plate (4 Used) 22- O-Ring
5- Bearing 14- Plug (2 Used) 23- Relief Valve (2 Used)
6- Shaft 15- O-Ring (2 Used) 24- Bearing
7- Shoe Plate 16- Spring (2 Used) 25- Valve Plate
8- Plunger (9 Used) 17- Poppet (2 Used) 26- Spring (20 Used)
W3-10-3-4
Assembly of Swing Motor

8. Place casing (3) horizontally. Install the rotor (11)
assembly to shaft (6).
1. Install the inner race of bearings (5, 24) to shaft (6) IMPORTANT: There are four notches on the outer
by using a press. Install the inner race of bearing (5) side of plate (13). There are four notches on the
with the flange part facing to the stepped part of spline teeth side of friction plate (12).
shaft (6). 9. Place casing (3) vertically. Alternately install plates
(13) (4 used) and friction plates (12) (3 used) in order
2. Install oil seal (4) to casing (3) by using a plate with
to align each notch at the same place.
the lip part up.
10. Install O-rings (28, 29) to casing (3).
3. Install the outer race of bearing (5) to casing (3) by
using a bar. 11. Fit the matching marks and install brake piston (27)
to casing (3).
4. Install a tape onto the spline at the end of shaft (6)
in order not to damage oil seal (4). Place casing (3)
horizontally. Install shaft (6) to casing (3).
fNOTE: If it is not easy to install brake piston (27) due to
the resistant force from O-rings (28, 29), evenly tap brake
5. Place casing (3) vertically with the valve casing (18) piston (27) by using a plastic hammer.
mounting side up. Install shoe plate (7) to casing (3) 12. Install springs (26) (20 used) to brake piston (27).
with the chamfered surface facing inside.
6. Fit the notches on plate (9) and retainer (10). Install
plungers (8) (9 used). Install retainer (10) to plunger
(8) with the notch facing to the shoe plate (7) side.
7. Apply hydraulic oil onto the plunger hole on rotor
(11). Insert the plunger (8) assembly into rotor (11).
W3-10-3-5
13. Tap and install the outer race, the bearing type 17. Install valve casing (18) to casing (3) with socket
indicated surface of bearing (24) to valve casing (18) bolts (19) (4 used).
by using a plastic hammer.
l : 17 mm
IMPORTANT: Check the surfaces of valve plate (25).
14. Install O-ring (22) to valve casing (18). Install valve m : 440 N·m (44 kgf·m, 320 lbf·ft)
plate (25) to valve casing (18) with the notch in the
port facing to rotor (11). 18. Install poppet (17) and spring (16) to valve casing
Apply grease onto valve plate (25) in order to (18). Install O-ring (15) to plug (14). Install plug (14)
prevent from falling off from valve casing (18). to valve casing (18).
15. Apply grease onto the needle part of bearing (24) in
l : 14 mm
order to install shaft (6) to bearing (24) easily.
16. Fit the matching marks on valve casing (18) and m : 550 N·m (55 kgf·m, 410 lbf·ft)
casing (3). Place valve casing (18) onto casing (3). 19. Install another poppet (17) in the same way as step
Check that a clearance between valve casing (18) 18.
and casing (3) is equal to that before disassembling.
If the clearance is larger than that before 20. Install relief valves (23) (2 used) to valve casing (18).
disassembling, repeat the procedures from step 5. j : 41 mm
m : 180 N·m (18 kgf·m, 130 lbf·ft)

21. Install swing parking brake switch valve (2) to casing
(3) with socket bolts (1) (3 used).
l : 5 mm
m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)
W3-10-3-6
Structure of Swing Parking Brake Switch

Valve
5 6 7 8 9
4 10
3
2
W1V1-02-06-010
No. Part Name Q’ty Wrench Size Tightening Torque Remark

(mm) N·m (kgf·m) (lbf·ft)
1 O-Ring 1
2 Plug 1 l:6 37 (3.7) (27.5)
3 O-Ring 1
4 Casing 1
5 Socket Bolt 3 l:5 12 (1.2) (8.9)
6 Plunger Assembly 1
7 Spring 1
8 Steel Ball 1
9 Cap 1 l:6 1 (0.1) (0.7)
10 O-Ring 1
W3-10-4-1
(Blank)
W3-10-4-2
Removal and Installation of Pilot Valve (Left) 3
5 2
3
2
1 WDAA-03-01-023
6 WDAA-03-01-047

and pipes have been disconnected. In addition, dCAUTION: Seat (5) weight: 20 kg (45 lb)
attach an identification tag onto the connectors, 4. Remove socket bolts (6) (4 used). Remove seat (5).
hoses and install the clips in case the clips which l : 6 mm
Removal

(Refer to W1-4-1.)
2. Open door (1).
3. Remove bolts, washers (2) (2 used). Remove seat
belts (3) (2 used) and spacers (4) (2 used).
j : 24 mm
W3-11-1-1
Detail B
14
13
14
21 23 22
15
B
17
10
16
WDAA-03-12-002
9
7, 8 12 11 WDAA-03-12-001
20 18 19
5. Remove socket bolts (7) (2 used) and washers (8) (2

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

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

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

4. Tighten lock nut (26) and install the lever (27)
assembly.
j : 19 mm, 22 mm
m : 55 N·m (5.5 kgf·m, 40 lbf·ft)

5. Install clip bands (25, 24).
W3-11-1-4
Detail B
14
13
14
21 23 22
15
B
17
10
16
WDAA-03-12-002
9
7, 8 12 11 WDAA-03-12-001
20 18 19
6. Install cover (23) with screws (22, 21) (2 used for 13. Install lever (9) with washers (8) (2 used) and socket
each). bolts (7) (2 used).
7. Install cover (20) with washer (19), bolt, washer (18), l : 6 mm
and screw (17).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
j : 10 mm
m : 3.3 to 4.2 N·m (0.3 to 0.4 kgf·m, 2.4 to 3.0

lbf·ft)
9. Raise cover (15). Connect connector (16).
1.)
11. Install screws (14) (3 used). Lower boot (13).
12. Install armrest (12) with washers (11) (2 used) and
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-11-1-5
5 2
3
2
1 WDAA-03-01-023
6 WDAA-03-01-047

l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

15. Install spacers (4) (2 used) and seat belts (3) (2 used)
with bolts, washers (2) (2 used).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)

16. Shut door (1).
W3-11-1-6
Removal and Installation of Pilot Valve 3

(Right)
5 2
3
2
1 WDAA-03-01-023
6 WDAA-03-01-047

and pipes have been disconnected. In addition, dCAUTION: Seat (5) weight: 20 kg (45 lb)
attach an identification tag onto the connectors, 4. Remove socket bolts (6) (4 used). Remove seat (5).
hoses and install the clips in case the clips which l : 6 mm
Removal

(Refer to W1-4-1.)
2. Open door (1).
3. Remove bolts, washers (2) (2 used). Remove seat
belts (3) (2 used) and spacers (4) (2 used).
j : 24 mm
W3-11-2-1
Detail A
14
13
15 11
10 12
16
WDAA-03-12-006
9 11
7 8
WDAA-03-12-005
5. Remove socket bolts (7) (2 used) and washers (8) (2

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

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

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

used).
5. Install bracket (22) with bolts, washers (21) (3 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

6. Tighten lock nut (19) and install the lever (20)
assembly.
j : 19 mm, 22 mm
m : 55 N·m (5.5 kgf·m, 40 lbf·ft)

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

10. Raise cover (12). Connect connectors (13) (2 used).
1.)
12. Install boot (14).
13. Install screws (11) (3 used). Install tray (10).
14. Install armrest (9) with washers (8) (2 used) and
l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)
W3-11-2-7
5 2
3
2
1 WDAA-03-01-023
6 WDAA-03-01-047

l : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

16. Install spacers (4) (2 used) and seat belts (3) (2 used)
with bolts, washers (2) (2 used).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)

17. Shut door (1).
W3-11-2-8
Removal and Installation of Travel Pilot Valve
WDAA-03-13-005 WDAA-03-12-016
3 2
IMPORTANT: Cap the open ends in case the hoses 5. Place a container under pilot valve (4). Disconnect
and pipes have been disconnected. In addition, hoses (5) (4 used).
hoses and install the clips in case the clips which 6. Disconnect pipes (6) (2 used).
Removal j : 17 mm
1. Swing the upperstructure by 90 degrees and set the

machine position for inspection and maintenance.
(Refer to W1-6-1.)

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

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

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

3. Install pedals (9) (2 used) and levers (8) (2 used) with
bolts, washers (7) (4 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W3-11-3-3
WDAA-03-13-005 WDAA-03-12-016
3 2
4. Connect pipes (6) (2 used).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 19 lbf·ft)

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

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

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

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

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

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

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

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

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

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

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

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

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

12, 13
20. Apply grease onto O-ring (34). Push O-rings (34) (2

used) to the end of pin (35).
W176-02-07-011
a - Crimped Position
b - Stand
W3-11-5-8
23. Crimp the hole edge of bracket (11) where spring

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

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

Install plugs (21) (2 used) to casing (23).
j : 6 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

29. Install filter (36) to casing (23).
W3-11-5-9
(Blank)
W3-11-5-10
Removal and Installation of Pilot Shut-Off

Solenoid Valve
1
3 2
WDAA-03-13-005 WDAA-03-13-006
IMPORTANT: Cap the open ends in case the hoses 6. Place a container under pilot shut-off solenoid valve
and pipes have been disconnected. In addition, (5). Disconnect both ends of pipes (6, 7).
Removal
1. Swing the upperstructure by 90 degrees and set the
machine position for inspection and maintenance.
(Refer to W1-6-1.)

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

not drop cover (3).
(3).
j : 17 mm
W3-12-1-1
WDAA-03-13-007 WDAA-03-13-008
j : 19 mm
8. Remove bolts, washers (9) (2 used). Remove pilot
shut-off solenoid valve (5).
j : 17 mm
9. Remove the adapter with pilot shut-off solenoid
valve (5) attached if necessary.
W3-12-1-2
WDAA-03-13-007 WDAA-03-13-008
Installation
1. Install all removed adapters to pilot shut-off
solenoid valve (5).
2. Install pilot shut-off solenoid valve (5) with bolts,
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-12-1-3
3 2
WDAA-03-13-005 WDAA-03-13-006
4. Connect pipes (7, 6).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 19 lbf·ft)

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

8. Install the floor mat.
9. Shut door (1).
W3-12-1-4
Removal and Installation of 3-Spool Solenoid

Valve Unit
1 11 2
WDDE-03-06-001
12 3
Removal
(Refer to W1-6-1.)

(Refer to W1-4-1.)
(3).
j : 17 mm
W3-12-2-1
WDCD-03-12-001 WDCD-03-12-002

6. Place a container under 3-spool solenoid valve unit
(5). Disconnect hoses (6) (5 used).
j : 17 mm
7. Disconnect both ends of pipes (7) (6 used).
j : 17 mm
j : 19 mm
j : 17 mm
10. Remove socket bolts (10) (2 used). Remove 3-spool
solenoid valve unit (5).
l : 8 mm
11. Remove the adapter with 3-spool solenoid valve
unit (5) attached if necessary.
W3-12-2-2
WDCD-03-12-001 WDCD-03-12-002
Installation
1. Install all removed adapters to 3-spool solenoid 5. Connect pipes (7) (6 used).
valve unit (5).
j : 17 mm
2. Install 3-spool solenoid valve unit (5) with socket
bolts (10) (2 used). m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
l : 8 mm 6. Connect hoses (6) (5 used).
m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 17 mm
3. Connect hoses (9) (2 used). m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
j : 17 mm 7. Connect connectors (4) (3 used).
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-12-2-3
1 11 2
WDDE-03-06-001
12 3

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

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

W3-12-2-4
Disassembly of Pilot Shut-Off Solenoid Valve
WDAA-03-13-014
1- Socket Bolt (2 Used) 4- Body 7- O-Ring

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

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

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

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

IMPORTANT: When solenoid (2) is installed after
installing O-ring (3) to body (4), O-ring (3) may be
damaged.
3. Install O-ring (3) to solenoid (2). Fit the matching
marks and install solenoid (2) to body (4).
4. Install solenoid (2) to body (4) with socket bolts (1)
(2 used).
l : 4 mm
m : 4 N·m (0.4 kgf·m, 3 lbf·ft)
W3-12-3-4
Structure of 3-Spool Solenoid Valve Unit
4
3
WDCD-03-12-003
2
5 6 7 8 9 10
11
15 14 13 12
WDAA-03-13-013
W3-12-4-1
Wrench Size Tightening Torque

No. Part Name Q’ty (mm) Remark
N·m (kgf·m) (lbf·ft)
1 Body 1
2 Orifice 3 l:6 10+3 (1+0.3) (7.4+2.2)
3 Orifice 1 l : 10 20+5 (2+0.5) (15+3.7)
4 Socket Bolt 8 l:4 5+2 (0.5+0.2) (3.7+1.5)
5 Solenoid 3
6 Washer 1
7 Spring 1
8 Spool 1
9 Sleeve 1
10 Plate 1
11 Wave Spring 1
12 O-Ring 1
13 O-Ring 1
14 O-Ring 1
15 O-Ring 1
W3-12-4-2
Removal and Installation of Signal Control

Valve
1 15
16 3
WDDE-03-06-001 WDCD-03-13-001
hoses and install the clips in case the clips which 5. Disconnect connectors (4) (2 used).
Removal
(Refer to W1-6-1.)

(Refer to W1-4-1.)
(3).
j : 17 mm
W3-13-1-1
WDCD-03-13-002 WDCD-03-13-003
6. Place a container under signal control valve (5).

Disconnect hoses (6) (5 used).
j : 19 mm
j : 17 mm
j : 19 mm
j : 17 mm
j : 19 mm
j : 17 mm
W3-13-1-2
WDCD-03-13-004 WDCD-03-13-005
j : 19 mm
(4 used). Remove signal control valve (5).
l : 8 mm
14. Remove the adapter with signal control valve (5)
W3-13-1-3
WDCD-03-13-004 WDCD-03-13-005
Installation
1. Install all removed adapters to signal control valve
(5).
2. Install signal control valve (5) with washers (14) (4
used) and socket bolts (13) (4 used).
l : 8 mm
m : 20 N·m (2 kgf·m, 15 lbf·ft)

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-13-1-4
WDCD-03-13-002 WDCD-03-13-003
4. Connect hose (11). 8. Connect hoses (7) (3 used).
j : 17 mm j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft) m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

5. Connect hoses (10) (4 used). 9. Connect hoses (6) (5 used).
j : 19 mm j : 19 mm

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

j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W3-13-1-5
1 15
16 3
WDDE-03-06-001 WDCD-03-13-001

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

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

W3-13-1-6
Structure of Signal Control Valve

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

2- Body 1 10- Gasket 18- Spring (4 Used) 26- Spring
3- Gasket 11- Body 4 19- Spring Guide (7 Used) 27- Spool
4- Filter (17 Used) 12- Gasket 20- Spool (6 Used) 28- Spring
5- Body 2 13- Body 5 21- Spring (2 Used) 29- Plate
6- Gasket 14- Socket Bolt (11 Used) 22- Plate
7- Shuttle Valve (2 Used) 15- Plate 23- O-Ring
8- Spring (4 Used) 16- Plug (7 Used) 24- Shuttle Valve
W3-13-2-2
MEMO
MEMO
SECTION 4
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing
Removal and Installation of Swing Bearing..........W4-1-1-1
Disassembly of Swing Bearing...................................W4-1-2-1
Assembly of Swing Bearing.........................................W4-1-2-4
Group 2 Travel Device
Removal and Installation of Travel Device.............W4-2-1-1
Disassembly of Travel Device......................................W4-2-2-1
Assembly of Travel Device...........................................W4-2-2-5
Disassembly of Travel Motor.......................................W4-2-3-1
Assembly of Travel Motor............................................W4-2-3-4
Disassembly of Brake Valve.........................................W4-2-4-1
Assembly of Brake Valve...............................................W4-2-4-3
Group 3 Center Joint
Removal and Installation of Center Joint...............W4-3-1-1
Disassembly of Center Joint........................................W4-3-2-1
Assembly of Center Joint.............................................W4-3-2-3
Replacement of Body and Spindle...........................W4-3-2-6
Removal and Installation of Track Adjuster...........W4-4-1-1
Disassembly of Front Idler...........................................W4-4-2-1
Assembly of Front Idler.................................................W4-4-2-4
Removal and Installation of Upper Roller..............W4-5-1-1
Removal and Installation of Lower Roller..............W4-5-2-1
Disassembly of Lower Roller.......................................W4-5-3-1
Assembly of Lower Roller.............................................W4-5-3-3
Group 6 Track
Removal and Installation of Track.............................W4-6-1-1
DDEW-4-1
(Blank)
DDEW-4-2
SECTION 4 UNDERCARRIAGE
Removal and Installation of Swing Bearing
2 1
4, 5
ST 0050
a 3
a- Matching Mark
1
WDAA-04-01-001 W110-03-01-004
Before removing and installing the swing bearing, the

upperstructure must be removed first. (Refer to W3-3-1.) dCAUTION:
(1130 lb)
Swing bearing (1) weight: 510 kg
Therefore, the procedure starts on the premise that the
upperstructure has already been removed here. 3. Install special tools (ST 0050) (3 used) to swing
bearing (1). Attach a wire rope onto special tools
Removal (ST 0050) (3 used). Hoist swing bearing (1). Remove
swing bearing (1).
1. Put the matching marks (a) on inner race (2) of
swing bearing (1) and track frame (3).
2. Remove bolts (4) (36 used) and spring washers (5)
(36 used).
j : 41 mm
W4-1-1-1
2 1
ST 0050
1 W110-03-01-004
d
a
a 3
a- Matching Mark 4°
b
WDAA-04-01-001
14
°
c
4°
5.97°
WDAA-04-01-002
a- Position for Grease Fitting

b- Soft Zone Marking Position
c- Position for Plug
d- Front Side
Installation IMPORTANT: If the matching marks (a) do not fit, the

soft zone position of inner race will be dislocated.
1. Clean the mounting surfaces of track frame (3) and
swing bearing (1). 4. Fit the matching marks (a) on track frame (3) and
inner race (2) of swing bearing (1).
2. Apply THREEBOND #1102 onto the swing bearing
(1) mounting surface of track frame (3).
dCAUTION:
(1130 lb)
Swing bearing (1) weight: 510 kg
3. Install special tools (ST 0050) (3 used) to swing

bearing (1). Attach a wire rope onto special tools (ST
0050) (3 used). Hoist swing bearing (1).
W4-1-1-2
1
4, 5
a b 7
5mm
WDAA-04-01-001 W175-03-01-002
a- Swing Bearing
b- Grease Level
5. Install swing bearing (1) with spring washers (5) (36

used) and bolts (4) (36 used).
j : 41 mm
m : 1250 N·m (125 kgf·m, 920 lbf·ft)

6. After installing swing bearing (1), add grease
(Alvania EP2 or equivalent) to grease bath (6) until
pinion (7) of the swing device is 5 mm (0.2 in) under
grease.
fNOTE: Grease amount: 19 L (5.02 US gal)
W4-1-1-3
(Blank)
W4-1-1-4
Disassembly of Swing Bearing

1 2 3
8 7 6 5
W178-02-11-193
7 8
W178-02-11-194
1- Outer Race 5- Seal 9- Grease Fitting (2 Used)

2- Seal 6- Ball (95 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (95 Used)
W4-1-2-1
Disassembly of Swing Bearing 3. Install bolt (10) to the screw hole (M10, Pitch 1.5
mm) of plug (4). Tap or pull bolt (10) and remove
plug (4) from outer race (1).

personal injury.
1. Grind off the crimped part of pin (3) by using a
1
grinder. Tap the bottom side of pin (3) of plug (4) by
using a bar and a hammer. Remove pin (3) of plug
(4).
3
4
W178-02-11-196
10
dCAUTION:
lb)
Swing bearing weight: 510 kg (1130
W178-02-11-195
4. Place inner race (7) of the swing bearing on a
wooden block by using the special tool (ST 0050).
Hoist outer race (1) horizontally. Hold outer race (1).
2. Thread hole (a) of plug (4) by using a tap (M10, Pitch
1.5 mm).
WJAA-04-01-002
a- Hole
W4-1-2-2
5. Remove balls (6) (95 used) and supports (8) (95

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

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

1 2 3
8 7 6 5
W178-02-11-193
7 8
W178-02-11-194
1- Outer Race 5- Seal 9- Grease Fitting (2 Used)

2- Seal 6- Ball (95 Used)
3- Pin 7- Inner Race
4- Plug 8- Support (95 Used)
W4-1-2-4
Assembly of Swing Bearing
dCAUTION:
lb)
Swing bearing weight: 510 kg (1130 dCAUTION: Metal fragments may fly off when
1. Install special tools (ST 0050) (3 used) to outer race such as goggles, helmets, etc in order to prevent
(1). Attach a wire rope onto special tools (ST 0050) personal injury.
(3 used). Hoist the swing bearing horizontally. Align 2. Install plug (4) to outer race (1) by using a hammer.
outer race (1) and inner race (7) coaxially. Secure plug (4) to outer race (1) with pin (3).
Apply grease onto balls (6) (95 used) and supports Crimp the head of pin (3) by using a punch.
(8) (95 used).
Install balls (6) (95 used) and supports (8) (95 used)
alternately from the plug (4) hole by using a round
bar while turning outer race (1). 3
1
2
6 W178-02-11-201
3. Degrease the groove part for seals (2, 5) completely.

5
W178-02-11-199
Apply THREEBOND #1530D onto seals (2,5). Install
seals (2, 5) to outer race (1) and inner race (7).
4. Add grease (Alvania EP2 or equivalent) to the swing
bearing through grease fittings (9) (2 used). At this
time, add grease while turning outer race (1).
fNOTE: Grease amount: 0.9 L (0.95 US qt)
W178-02-11-200
W4-1-2-5
(Blank)
W4-1-2-6
Removal and Installation of Travel Device
WDAA-04-02-001 WDAA-04-02-002
Removal
IMPORTANT: Cap the open ends in case the hoses 5. Disconnect hose (7).
attach an identification tag onto the connectors, j : 27 mm
hoses, and pipes for assembling. Connect the 6. Disconnect hose (8).
secure the hoses have been removed. j : 17 mm
Removal dCAUTION:
lb)
Travel device (5) weight: 490 kg (1090
1. Set the machine position for inspection and 7. Attach a nylon sling onto travel device (5). Hoist and
maintenance. (Refer to W1-6-1.) hold travel device (5). Remove bolts (9) (24 used)
and washers (10) (24 used). Hoist and remove travel
(Refer to W1-4-1.)
device (5).
2. Disconnect track (1). (Refer to W4-6-1.) j : 30 mm

3. Remove bolts (2) (6 used) and washers (3) (6 used). 8. Remove the adapter with travel device (5) attached
Remove cover (4). if necessary.
j : 22 mm 9. Remove another travel device in the same way as

step 1 to step 7.
4. Place a container under travel device (5). Disconnect
hoses (6) (2 used).
j : 41 mm
W4-2-1-1
WDAA-04-02-002
Installation
1. Install all removed adapters to travel device (5).
dCAUTION:
lb)
Travel device (5) weight: 490 kg (1090
2. Attach a nylon sling onto travel device (5). Hoist

travel device (5). Install travel device (5) with
washers (10) (24 used) and bolts (9) (24 used).
j : 30 mm
m : 630 N·m (63 kgf·m, 460 lbf·ft)

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

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

j : 41 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
W4-2-1-2
WDAA-04-02-001
6. Connect track (1). (Refer to W4-6-1.)

7. Install another travel device in the same way as step
1 to step 6.
1.)
engine and check for any oil leaks. In order to
prevent the travel motor from seizing, perform
the break-in operation after installing.
Condition: Engine speed: Slow idle speed

Travel mode switch: Slow speed
Operation duration: Over 2 minutes
9. Install cover (4) with washers (3) (6 used) and bolts
(2) (6 used).
j : 22 mm
m : 180 N·m (18 kgf·m, 133 lbf·ft)

10. Install another cover in the same way as step 9.
W4-2-1-3
(Blank)
W4-2-1-4
Disassembly of Travel Device
WDAB-04-02-001
00- Travel Motor 15- Thrust Plate (8 Used) 28- Pin (3 Used) 41- Cover
02- Floating Seal 16- Pin (4 Used) 29- Spring Pin (3 Used) 42- Stopper
03- Roller Bearing (2 Used) 17- Spring Pin (4 Used) 30- Sun Gear 43- Bolt, Washer (20 Used)
04- Drum 18- Sun Gear 32- First Stage Carrier 44- Plug (3 Used)
05- Sprocket 20- Ring Gear 33- Spacer 45- Ball Bearing
06- Bolt (22 Used) 21- Bolt (34 Used) 34- Planetary Gear (3 Used) 46- Retaining Ring
07- Spring Washer (22 Used) 23- Second Stage Carrier 35- Needle Bearing (3 Used) 47- Lock Plate
09- Bearing Nut 24- Spacer 36- Thrust Plate (6 Used) 48- Bolt (2 Used)
11- Needle Bearing (8 Used) 25- Planetary Gear (3 Used) 37- Pin (3 Used) 49- Spacer
12- Third Stage Carrier 26- Needle Bearing (3 Used) 38- Spring Pin (3 Used)
13- Planetary Gear (4 Used) 27- Thrust Plate (6 Used) 39- Shaft
W4-2-2-1
Disassembly of Travel Device

IMPORTANT: Do not remove retaining ring (46),
dCAUTION: There may be pressure accumulated
inside of the travel device. Loosen the air bleed stopper (42), and ball bearing (45) unless
plug slowly. Release any remaining pressure necessary.
completely. Remove the drain plug and drain gear 4. Remove bolts, washers (43) (20 used). Remove cover
oil. If the air bleed plug is loosened suddenly, the (41).
plug may be fly out and gear oil may gush out.
Keep body and face away from plug. j : 19 mm
fNOTE: THREEBOND #1215 or LOCTITE #5020 has been

d CAUTION: Travel Device weight: 490 kg (1090 lb) applied between cover (41) and ring gear (20). For easy
removal, insert and tap a chisel between cover (41) and
1. Attach a nylon sling onto the body of travel device.
Hoist the travel device. Place the travel device on a ring gear (20).
workbench with the travel motor (00) side up. Install 5. Remove shaft (39) and the first stage carrier (32)
the special tool (ST 5102) to the travel device with assembly from second stage carrier (23).
bolts (M20, Pitch 2.5 mm) (2 used).
6. Remove sun gear (30) from second stage carrier
j : 30 mm (23).
7. Remove the second stage carrier (23) assembly from
ST 5102
ring gear (20).
00
W105-03-02-007
dCAUTION: Travel Device weight: 490 kg (1090 lb)

2. Attach a nylon sling onto the body of travel device.
Hoist the travel device. Place the travel device on a
workbench with the travel motor (00) side down.
fNOTE: Secure the spacer to the workbench tightly in

order to receive a reaction force when disassembling.
3. Remove plugs (44) (3 used).
l : 10 mm
W4-2-2-2
8. Remove sun gear (18) from third stage carrier (12). 12. Remove bearing nut (09) by using special tools (ST
3330, ST 3051, ST 3052, and ST 3053).
dCAUTION: Ring gear (20) weight: 53 kg (120 lb)
9. Remove bolts (21) (34 used). Install eyebolts (M12,
Pitch 1.75 mm) (2 used) to the bolt, washer (43)
holes (2 places) of ring gear (20). Attach nylon slings ST 3053
onto the eyebolts. Hoist and remove ring gear (20). ST 3052
j : 24 mm ST 3330
ST 3051
fNOTE: LOCTITE #262 (or THREEBOND #1386B) has been
applied on bolt (21).
09
fNOTE: THREEBOND #1389B has been applied between
ring gear (20) and drum (04). If it is difficult to remove,
pry it by using a screwdriver.
dCAUTION The third stage carrier (12) assembly

W1V1-03-02-009
10. Remove the third stage carrier (12) assembly from

drum (04).
dCAUTION:
kg (335 lb)
Sprocket (05) + drum (04) weight: 150
11. Remove bolts (48) (2 used). Remove lock plate (47)
from bearing nut (09). IMPORTANT: The travel motor (00) side of drum (04)
is the seal sliding surface for travel motor (00).
j : 19 mm Place it on a wooden block after removing.
bolt (21) holes (2 places) of drum (04). Attach nylon
slings onto the eyebolts. Hoist and remove the
drum (04) assembly from travel motor (00).
fNOTE: If it is difficult to remove, rotate sprocket (05).
W4-2-2-3
IMPORTANT: Handle floating seal (02) with care.

(Refer to W4-2-5.) dCAUTION: Metal fragments may fly off when
14. Remove one side of floating seal (02) from travel
motor (00).
personal injury.
15. Remove the inner race of roller bearing (03) from IMPORTANT: Do not remove roller bearing (03)
drum (04). unless necessary.
dCAUTION: Sprocket (05) weight: 69 kg (155 lb) 19. Remove the outer races of roller bearings (03) (2
used) from drum (04) by using a bar and a hammer.
dCAUTION: When removing sprocket (05),
gather up the nylon sling and hoist sprocket (05) 20. Remove spring pins (38) (3 used) from first stage
horizontally. Do not drop sprocket (05). carrier (32) by using the special tool (ST 1391).
16. Remove bolts (06) (22 used) and spring washers 21. Remove pins (37) (3 used), thrust plates (36) (6
(07) (22 used). Attach a nylon sling onto sprocket used), planetary gears (34) (3 used), needle bearings
(05). Hoist sprocket (05). Remove sprocket (05) from (35) (3 used), and spacer (33) from first stage carrier
drum (04). (32).
j : 32 mm 22. Remove spring pins (29) (3 used) from second stage

carrier (23) by using the special tool (ST 1391).
fNOTE: LOCTITE #262 (or THREEBOND #1386) has been
23. Remove pins (28) (3 used), thrust plates (27) (6
applied on bolt (06).
used), planetary gears (25) (3 used), needle bearings
dCAUTION: Drum (04) weight: 71 kg (160 lb) (26) (3 used), and spacer (24) from second stage
carrier (23).
bolt (06) holes on drum (04). Attach nylon slings 24. Remove spring pins (17) (4 used) from third stage
onto the eyebolts. Hoist drum (04). Place drum (04) carrier (12) by using the special tool (ST 1463).
with the ring gear (20) side down.
25. Remove pins (16) (4 used), thrust plates (15) (8
IMPORTANT: Handle floating seal (02) with care. used), planetary gears (13) (4 used), needle bearings
(Refer to W4-2-5.) (11) (8 used), and spacer (49) from third stage carrier
18. Remove one side of floating seal (02) from drum (12).
(04).
W4-2-2-4
Assembly of Travel Device
04 09 21
49
12 18 20
24 23 30 33 32
44
39
41
46
42
45
36
35
37
38
34
16
48 25 26 28 27 29 43
13 11 15 17
00 02 03
47
05
07 06
TDAB-03-05-001
00- Travel Motor 15- Thrust Plate (8 Used) 28- Pin (3 Used) 41- Cover
02- Floating Seal 16- Pin (4 Used) 29- Spring Pin (3 Used) 42- Stopper
03- Roller Bearing (2 Used) 17- Spring Pin (4 Used) 30- Sun Gear 43- Bolt, Washer (20 Used)
04- Drum 18- Sun Gear 32- First Stage Carrier 44- Plug (3 Used)
05- Sprocket 20- Ring Gear 33- Spacer 45- Ball Bearing
06- Bolt (22 Used) 21- Bolt (34 Used) 34- Planetary Gear (3 Used) 46- Retaining Ring
07- Spring Washer (22 Used) 23- Second Stage Carrier 35- Needle Bearing (3 Used) 47- Lock Plate
09- Bearing Nut 24- Spacer 36- Thrust Plate (6 Used) 48- Bolt (2 Used)
11- Needle Bearing (8 Used) 25- Planetary Gear (3 Used) 37- Pin (3 Used) 49- Spacer
12- Third Stage Carrier 26- Needle Bearing (3 Used) 38- Spring Pin (3 Used)
13- Planetary Gear (4 Used) 27- Thrust Plate (6 Used) 39- Shaft
W4-2-2-5
Assembly of Travel Device

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Handle floating seal (02) with care.
onto parts in order to prevent them from seizing. (Refer to W4-2-5.)
2. Apply grease onto O-ring of one side of floating seal
(02). Install one side of floating seal (02) to travel
motor (00). Apply gear oil onto the whole sliding
surface on floating seal (02).
personal injury. fNOTE: If it is difficult to install O-ring of floating seal
d CAUTION: Be careful as roller bearing (03) is too
hot.
(02), push O-ring to the periphery direction by using a
bamboo spatula.
IMPORTANT: When roller bearing (03) has been
removed, follow the procedure as steps 1, 3, 5, and
12. such as goggles, helmets, etc in order to prevent
1. Warm up the inner race of roller bearing (03) of the personal injury.
travel motor (00) side to 50 to 70 °C (122 to 158 IMPORTANT: Do not tap except for the outer race of
°F) by using a heater. Install the inner race of roller roller bearing (03).
bearing (03) of the travel motor (00) side to travel 3. Install the outer race of roller bearing (03) of the
motor (00). After roller bearing (03) of the travel cover (41) side to drum (04) by using a bar and a
motor (00) side cools, install roller bearing (03) of hammer.
the travel motor (00) side to travel motor (00).
fNOTE: Check that the outer race of roller bearing (03) of
fNOTE: Check that inner race of roller bearing (03) of the the cover (41) side is installed completely.
travel motor (00) side is installed completely.
03
03
04
00
WDCD-04-02-002 WDCD-04-02-002
W4-2-2-6

d CAUTION: Drum (04) weight: 71 kg (160 lb) (Refer to W2-4-5.)
4. Install eyebolts (M20, Pitch 2.5 mm) (2 used) to the 6. Apply grease onto O-ring of other side of floating
bolt (06) holes on drum (04). Attach nylon slings seal (02). Install one side of floating seal (02) to
onto the eyebolts. Hoist drum (04). Place drum (04) drum (04).
with the ring gear (20) side down.
fNOTE: If it is difficult to install O-ring of floating seal
(02), push O-ring to the periphery direction by using a
bamboo spatula.
personal injury. dCAUTION:
(155 lb)
Drum (04) assembly weight: 70 kg
IMPORTANT: Do not tap except for the outer race of
roller bearing (03). 7. Install eyebolts (M22, Pitch 2.5 mm) (2 used) to the
bolt (06) holes on drum (04). Attach nylon slings
5. Install the outer race of roller bearing (03) of the
onto the eyebolts. Hoist drum (04) assembly. Place
travel motor (00) side to drum (04) by using a bar
drum (04) assembly with the travel motor (00) side
and a hammer.
down.
fNOTE: Check that outer race of roller bearing (03) of the
dCAUTION: Sprocket (05) weight: 69 kg (155 lb)
travel motor (00) side is installed completely.
dCAUTION: When installing sprocket (05),
gather up the nylon sling and hoist sprocket (05)
00
04 03
horizontally. Do not drop sprocket (05).
IMPORTANT: Fit the chamfered side of sprocket (05)
to the drum (04) side.
8. Attach a nylon sling onto sprocket (05). Hoist
sprocket (05). Place sprocket (05) onto drum (04).
9. Degrease the bolt (06) holes on drum (04) and bolts
(06) (22 used). Apply LOCTITE #262 or THREEBOND
#1386B onto bolts (06) (22 used). Install sprocket
(05) to drum (04) with spring washers (07) (22 used)
j : 32 mm
WDCD-04-02-003
m : 680 N·m (68 kgf·m, 500 lbf·ft)
W4-2-2-7
IMPORTANT: Check the direction to install bearing

d CAUTION: Sprocket (05) + drum (04) assembly
nut (09).
13. Apply grease onto the thread part of bearing nut
10. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the (09). Install bearing nut (09) to travel motor (00) with
bolt (21) holes (2 places) of drum (04). Attach nylon the turned surface facing to the roller bearing (03)
slings onto the eyebolts. Hoist drum (04) assembly. side on the cover (41) side. Tighten bearing nut (09)
Place drum (04) straight on travel motor (00). At this by hand.
time, check that the clearance between travel motor
(00) and drum (04) is even all around. 14. Install bearing nut (09) by using special tools (ST
3330, ST 3051, ST 3052, and ST 3053) and a torque
11. While applying the weight and shaking drum (04), wrench.
push drum (04) into travel motor (00) straight.
m : 500 N·m (50 kgf·m, 370 lbf·ft)
dCAUTION:
hot.
Be careful as roller bearing (03) is too
12. Warm up the inner race of roller bearing (03) of

ST 3053
the cover (41) side to 50 to 70 °C (122 to 158 °F) by
using a heater. Install the inner race of roller bearing ST 3052
(03) of the cover (41) side to travel motor (00). After ST 3330
roller bearing (03) of the cover (41) side cools, install
roller bearing (03) of the cover (41) side to travel ST 3051
motor (00). 09
fNOTE: Install roller bearing (03) until the inner race side
of roller bearing (03) reaches three threads for bearing
nut (09).
fNOTE: Check that the inner race of roller bearing (03) of W1V1-03-02-009
the cover (41) side is installed completely.
15. After installing bearing nut (09), tap the sprocket
00 (05) end by using a hammer and reduce a
03 play. Rotate sprocket (05) both clockwise and
counterclockwise by 4 to 5 turns.
16. Repeat step 14 and step 15.
17. Tighten the bearing nut in the same way as step 14.
m : 500 N·m (50 kgf·m, 370 lbf·ft)
WDCD-04-02-003
W4-2-2-8
18. Degrease bolts (48) (2 used). Apply LOCTITE #262 23. Install pin (16) to third stage carrier (12). At this time,
or THREEBOND #1386B onto bolts (48) (2 used). fit the spring pin (17) hole of third stage carrier (12)
Degrease the bolt (48) hole of bearing nut (09). and the pin (16) hole.
19. Install lock plate (47) to bearing nut (09) with bolts 24. Install spring pin (17) to third stage carrier (12) with
(48) (2 used) so that the convex part of lock plate the slit (b) side facing to the second stage carrier
(47) can be fitted with the concave part (one of 2 (23) side.
places) of travel motor (00).
17
j : 19 mm 16
b
m : 90 N·m (9 kgf·m, 66 lbf·ft)
fNOTE: In case the bolt hole of lock plate (47) does not
fit, tighten bearing nut (09) in tightening direction until W178-02-11-210
the bolt hole fits. b - Slit
25. Install other planetary gears (13) (3 used) to third

stage carrier (12) in the same way as step 21 to step
24.
00
dCAUTION: The third stage carrier (12) assembly

03 09 47 48 W1V1-03-02-003 26. Install the third stage carrier (12) assembly to the
spline in travel motor (00).
20. Install spacer (49) to third stage carrier (12).
IMPORTANT: There is an identification groove on
one side of planetary gear (13). Install planetary
gear (13) with the identification groove side facing
to the spring pin (17) hole.
21. Install needle bearings (11) (2 used) to planetary
gear (13).
22. Secure planetary gear (13) between thrust plates
(15) (2 used). Install them to third stage carrier (12).
W4-2-2-9
27. Clean the mating surfaces of drum (04) and ring 34. Install spring pin (29) to second stage carrier (23)
gear (20) and apply THREEBOND #1389B. Degrease with the slit (a) side facing to the cover (41) side.
the bolt (06) hole of drum (04) after cleaning the
29
mating surfaces of drum (04) and ring gear (20). 28
Degrease the bolt (06) hole and apply LOCTITE #262 a
or THREEBOND #1386B.
dCAUTION: Ring gear (20) weight: 53 kg (120 lb)

W178-02-11-210
28. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the a - Slit
bolt, washer (43) holes (2 places) of ring gear (20).
Attach nylon slings onto the eyebolts. Hoist ring
35. Install other planetary gears (25) (2 used) to second
gear (20). Install ring gear (20) to drum (04) with
34.
j : 24 mm 36. Install the second stage carrier (23) assembly to ring
gear (20).
m : 270 N·m (27 kgf·m, 200 lbf·ft)
37. Install sun gear (30) to second stage carrier (23) with
29. Install sun gear (18) to third stage carrier (12) with
the thinner diameter part up.
the thinner diameter part up.
38. Install spacer (33) to first stage carrier (32).
30. Install spacer (24) to second stage carrier (23).
39. Install needle bearing (35) to planetary gear (34).
31. Install needle bearing (26) to planetary gear (25).
(36) (2 used). Install them to first stage carrier (32).
(27) (2 used). Install them to second stage carrier
(23). 41. Install pin (37) to first stage carrier (32). At this time,
fit the spring pin (38) hole of first stage carrier (32)
33. Install pin (28) to second stage carrier (23). At this
and the pin (37) hole.
time, fit the spring pin (29) hole of second stage
carrier (23) and the pin (28) hole.
W4-2-2-10
42. Install spring pin (38) to first stage carrier (32) with
the slit (b) side facing to the cover (41) side.
38
37
b
W178-02-11-210
b - Slit
43. Install other planetary gears (34) (2 used) to first

42.
44. Insert the spline side of shaft (39) into the center of
sun gear (30). Rotate sprocket (05) slowly by hand.
Engage travel motor (00) and planetary gear (34)
with shaft (39), and install them.
45. Install the first stage carrier (32) assembly to ring
gear (20).
46. Fill ring gear (20) with gear oil (SAE#90(GL-4)).
fNOTE: Oil amount: 10.5 L (2.77 US gal)

47. Clean the mating surfaces of ring gear (20) and
cover (41). Apply THREEBOND #1215 or LOCTITE
#5020. Install cover (41) to ring gear (20) with bolts,
j : 19 mm
m : 110 N·m (11 kgf·m, 81 lbf·ft)

48. Install a seal tape onto plugs (44) (3 used). Install
plugs (44) (3 used) to cover (41).
l : 10 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W4-2-2-11
(Blank)
W4-2-2-12
Disassembly of Travel Motor
WDAA-04-02-013
00- Housing 14- Plunger (9 Used) 23- Plate (4 Used) 32- Brake Valve
01- Oil Seal 16- Retainer 25- Brake Piston 33- Needle Bearing
03- Piston 17- Bushing 26- O-Ring 37- Knock Pin
07- Shaft 18- Swash Plate 28- O-Ring 39- Valve Plate
08- Retaining Ring 19- Spring (6 Used) 29- Disc Spring 40- Socket Bolt (8 Used)
09- Ball (2 Used) 21- Rotor 30- O-Ring 41- Spring
10- Roller Bearing 22- Friction Plate (4 Used) 31- O-Ring (2 Used) 42- Retaining Ring
W4-2-3-1
Disassembly of Travel Motor
dCAUTION: Travel motor weight: 140 kg (310 lb) dCAUTION: When removing brake piston (25),
cover with a cloth in order not to fly out brake
1. Attach a nylon sling onto the travel motor. Hoist the piston (25).
travel motor. Place the travel motor with the brake
IMPORTANT: The upper surface of brake piston (25)
valve (32) side up.
is seat surface (a) for high-pressure oil. Place brake
dCAUTION: Brake valve (32) weight: 23 kg (51 lb) piston (25) with seat surface (a) for high-pressure
oil up.
IMPORTANT: When removing the brake valve (32)
assembly, do not drop valve plate (39). 7. Apply air 100 to 300 kPa (1.0 to 3.0 kgf/cm2, 15 to
44 psi) to the brake releasing oil passage in housing
2. Remove socket bolts (40) (8 used). Install the special
(00). Float and remove brake piston (25).
tool (ST 0063) to the socket bolt (40) holes (2 places)
on brake valve (32). Attach nylon slings onto the
special tools. Hoist brake valve (32). Remove brake a
valve (32) from housing (00).
l : 17 mm
IMPORTANT: Do not remove needle bearing (33) 23
unless necessary. Remove needle bearing (33)
W178-02-11-215
by using a small puller if necessary. Needle a - Seat Surface of High-Pressure
bearing (33) cannot be reused as the outer race is Oil
deformed.
IMPORTANT: Do not damage valve plate (39). 8. Remove O-rings (26, 28) from brake piston (25).
3. Remove valve plate (39), knock pin (37), and O-ring 9. Remove plates (23) (4 used) and friction plates (22)
(30) from brake valve (32). (4 used) from housing (00).
4. Install a tape onto the thrust surface of shaft (07) 10. Remove rotor (21), springs (19) (6 used), bushing
and needle bearing (33) in order to protect. (17), retainer (16), and plungers (14) (9 used) from
housing (00).
5. Remove disc spring (29) from housing (00).
6. Remove O-rings (31) (2 used) from housing (00).
W4-2-3-2
14. Remove retaining ring (42) from housing (00).

d CAUTION: The housing (00) assembly weight: 96
kg (215 lb) 15. Attach a bar onto the bottom of the spline hole
of shaft (07). Tap and remove shaft (07) and roller
11. Attach a nylon sling onto housing (00). Hoist the
bearing (10) from housing (00) by using a bar and a
housing (00) assembly. Place the housing (00)
plastic hammer.
assembly horizontally with the brake releasing oil
passage (a) down. IMPORTANT: Oil seal (01) cannot be reused.
16. Remove oil seal (01) from housing (00) by using a
fNOTE: When facing the brake releasing oil passage
screwdriver.
(a) upward, the thicker part of swash plate (18) faces
upward. If placing housing (00) horizontally, swash plate
(18) may suddenly come out.
fNOTE: THREEBOND #1104 or #1215 has been applied
onto the outer surface of the oil seal.
17. Remove retaining ring (08) from shaft (07).
IMPORTANT: When removing shaft (07) from roller
bearing (10), do not drop shaft (07).
a 18. Secure the inner race part of roller bearing (10)
on shaft (07) in a vise opening. Remove shaft (07)
from roller bearing (10) by using a bar and a plastic
hammer.
10
WDAA-04-02-008 07
a - Brake Releasing Oil Passage
dCAUTION: When removing swash plate (18) with

applying air, hold piston (03) with a cloth in order
not to fly out.
IMPORTANT: When swash plate (18) cannot be W178-02-11-212
removed, apply 100 to 300 kPa (1.0 to 3.0 kgf/cm2,
14 to 43 psi) pressure air through the piston oil
passage port. Swash plate (18) and piston (03) are
removed.
12. Remove swash plate (18) from housing (00).
13. Remove balls (09) (2 used), piston (03), and spring
(41) from housing (00) by using a magnet.
W4-2-3-3
Assembly of Travel Motor

21
14 18
09
42
37 30 25
10
08 01
32
07
03 41 00
19 17 16
33 40 39 31 29 28 26 23
22 W1HH-03-02-006
00- Housing 14- Plunger (9 Used) 23- Plate (4 Used) 32- Brake Valve
01- Oil Seal 16- Retainer 25- Brake Piston 33- Needle Bearing
03- Piston 17- Bushing 26- O-Ring 37- Knock Pin
07- Shaft 18- Swash Plate 28- O-Ring 39- Valve Plate
08- Retaining Ring 19- Spring (6 Used) 29- Disc Spring 40- Socket Bolt (8 Used)
09- Ball (2 Used) 21- Rotor 30- O-Ring 41- Spring
10- Roller Bearing 22- Friction Plate (4 Used) 31- O-Ring (2 Used) 42- Retaining Ring
W4-2-3-4
Assembly of Travel Motor IMPORTANT: Check the direction to install roller

bearing (10).
onto parts in order to prevent them from seizing. IMPORTANT: Do not damage the seal lip surface of
shaft (07).
6. Insert roller bearing (10) to shaft (07) with the
inner ring plate side of roller bearing (10) facing to
1. Attach a nylon sling onto housing (00). Hoist the inner bore spline side of shaft (07) until roller
housing (00). Install housing (00) with the brake bearing (07) comes into the tight fitting part.
valve (32) side up.
7. Install roller bearing (10) to shaft (07) by using the
2. Apply OCEAN grease #7 onto the inner surface of oil special tool (ST 7268) and a plastic hammer.
seal (01).
3. Apply THREEBOND #1104 or #1215 onto the outer
surface of oil seal (01). b 07
4. Clean the oil seal (01) mating part of housing
(00). Install oil seal (01) to housing (00) by using a
the special tools (ST 7271, ST 7270) and a plastic
hammer. ST 7268
10
ST 7271 ST 7270
W178-02-11-230
a - Inner Ring Plate b - Inner Bore Spline

00
01
8. Install retaining ring (08) to shaft (07).
WDCD-04-02-006
5. Install inner ring plate (a) to roller bearing (10) with

the stamped mark facing outside.
10 a
W178-02-11-221
a - Inner Ring Plate
W4-2-3-5
9. Install spring (41) to housing (00). IMPORTANT: Install retainer (16) with chamfered
surface (b) facing to the bushing (17) side.
10. Install piston (03) to housing (00) with the stepped
side facing inside. 16. Install springs (19) (6 used), bushing (17), retainer
(16), and plungers (14) (9 used) to rotor (21).
IMPORTANT: The small diameter side of shaft (07)
is the inner race of needle bearing (33). Do not
16
damage the inner race of needle bearing (33).
11. Install shaft (07) to housing (00) by using a plastic
hammer.
17
fNOTE: When center position of shaft (07) is sufficiently b
adjusted, shaft (07) will be inserted without hitting it.

W178-02-11-225
12. Install retaining ring (42) to housing (00). b - Chamfered Side
13. Install balls (09) (2 used) to housing (00).

14. Apply grease onto the ball (09) hole of swash plate 17. Install the rotor (21) assembly to housing (00).
(18). Fit the position of balls (09) (2 used) and install
swash plate (18) to housing (00).
dCAUTION:
kg (215 lb)
15. Attach a nylon sling onto housing (00). Hoist the

assembly horizontally with brake releasing oil
passage (a) down.
fNOTE: When facing the brake releasing oil passage

(a) upward, the thicker part of swash plate (18) faces
upward. If placing housing (00) horizontally, swash plate
(18) may suddenly come out.
WDAA-04-02-008
a - Brake Releasing Oil Passage
W4-2-3-6
IMPORTANT: Check the direction to install disc

d CAUTION: The housing (00) assembly weight:
110 kg (245 lb)
spring (29).
22. Place disc spring (29) to brake piston (25) with the
18. Attach a nylon sling onto housing (00). Hoist the inner diameter contacting to brake piston (25).
assembly with the brake valve (32) mounting 23. Install O-rings (31) (2 used) to housing (00).
surface up. 24. Install O-ring (30) to brake valve (32).
IMPORTANT: Check the order to install friction plate 25. Add hydraulic oil to housing (00) until plate (23) is
(22) and plate (23). submerged.
19. Install friction plates (22) (4 used) and plates (23) (4
used) to housing (00).
20. Apply grease onto O-rings (28, 26). Install O-rings
(28, 26) to brake piston (25).

personal injury.
IMPORTANT: The upper surface of brake piston (25)
is the seat surface for high-pressure oil. Do not
damage brake piston (25).
IMPORTANT: Install brake piston (25) so that notch
(a) on the disc spring (29) mounting surface is
located opposite the brake releasing oil passage
(b) side.
21. Install brake piston (25) to housing (00) by using a
hammer.
fNOTE: As O-ring (28) is positioned around brake piston

(25), brake piston (25) cannot be fully inserted. When
installing brake valve (32), tighten brake piston (25) with
socket bolt (40).
00 a 25 b
WDCD-04-02-005
a - Notch
b - Brake Releasing Oil Passage
W4-2-3-7
IMPORTANT: Check the direction to install knock pin IMPORTANT: Do not drop valve plate (39). If valve
(37). plate (39) is damaged, oil leakage will occur.
26. Install knock pin (37) to brake valve (32) with the 29. Install brake valve (32) to housing (00) with socket
large diameter side facing to the brake valve (32) bolts (40) (9 used).
side.
l : 17 mm
a hammer is used. Wear necessary protection, m : 400 N·m (40 kgf·m, 300 lbf·ft)
personal injury.
IMPORTANT: Check the direction to install the outer
race of needle bearing (33).
27. Install the outer race of needle bearing (33) to brake
valve (32) with the stamped mark facing outside by
using the special tool (ST 2655) and a hammer.
ST 2655
32 33
W178-02-11-227
28. Apply grease onto the flat surface of valve plate

(39). Fit the knock pin (37) positions and install valve
plate (39) to brake valve (32).
fNOTE: Valve plate (39) is secured to brake valve (32)

tightly in order not to drop brake valve (32) when turning
over.
W4-2-3-8
Disassembly of Brake Valve
WDAA-04-02-014
01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug

01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring
01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug
02- Stopper (2 Used) 10- Spring (2 Used) 16- Spring 22A- O-Ring
03- Spring (2 Used)
W4-2-4-1
Disassembly of Brake Valve IMPORTANT: As the setting changes, do not

disassemble relief valve (15).
1. Remove plugs (05) (2 used) from casing (01A).
Remove O-rings (07) (2 used) from plugs (05) (2 IMPORTANT: Do not move piston (a) with the outer
used). surface of relief valve (15) attached. O-ring may be
damaged.
j : 41 mm 7. Remove relief valves (15) (2 used) from casing (01A).
2. Remove springs (03) (2 used) and stoppers (02) (2
j : 41 mm
used) from casing (01A) by using a magnet.
15
3. Remove spool (01B) from casing (01A) by using a
magnet.
IMPORTANT: Do not remove plug (22) unless
necessary.
4. Remove plug (22) from casing (01A). Remove O-ring
(22A) from plug (22).
l : 6 mm
a
5. Remove seat (13) from casing (01A).
W1V1-03-02-008
a - Piston
l : 5 mm
6. Remove ball (11) by using a magnet.
8. Remove springs (10) (2 used) and poppet (08) (2
used) from casing (01A) by using a magnet.
9. Remove plug (17) from casing (01A). Remove O-ring
(17A) from plug (17).
l : 6 mm
10. Remove spring (16) and spool (01C) from casing
(01A) by using a magnet.
W4-2-4-2
Assembly of Brake Valve
01A 05 07 03 02 01B 02 03 07 05
22A 22
17 17A 16 01C 08 10 15 11 13
WDAA-04-02-015
01A- Casing 05- Plug (2 Used) 11- Ball 17- Plug

01B- Spool 07- O-Ring (2 Used) 13- Seat 17A- O-Ring
01C- Spool 08- Poppet (2 Used) 15- Relief Valve (2 Used) 22- Plug
02- Stopper (2 Used) 10- Spring (2 Used) 16- Spring 22A- O-Ring
03- Spring (2 Used)
W4-2-4-3
Assembly of Brake Valve 8. Install springs (10) (2 used) to poppets (08) (2 used).
Install poppets (08) (2 used) to the hole of casing
(01A) completely.
9. Install relief valves (15) (2 used) to casing (01A)
1. Install spool (01B) into the center of casing (01A). while pushing poppets (2) (2 used).
2. Install O-ring (07), spring (03) and stopper (02) to j : 41 mm

plug (05). Install the plug (05) assembly to casing
(01A) with one thread tighten. m : 450 N·m (45 kgf·m, 330 lbf·ft)
IMPORTANT: Check the direction to install spool
fNOTE: If plug (05) is fully tightened, it is difficult to
(01C).
install other plug (05) as spool (01B) is pushed.
10. Install spool (01C) to casing (01A) with the hole side
3. Install O-ring (07), spring (03) and stopper (02) to
facing the near side.
other plug (05). Install the plug (05) assembly to
casing (01A) and tighten by hand. 11. Install spring (16) to casing (01A).
4. Tighten plugs (05) (2 used). 12. Install O-ring (17A) to plug (17). Install plug (17) to
casing (01A).
j : 41 mm
l : 6 mm
m : 350 N·m (35 kgf·m, 260 lbf·ft)
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
5. Install ball (11) to casing (01A).
6. Install seat (13) to casing (01A).
l : 5 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

7. Install O-ring (22A) to plug (22). Install plug (22) to
casing (01A).
l : 6 mm
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
W4-2-4-4

these procedures:
2
hardening.

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

W4-2-5-1
(Blank)
W4-2-5-2
Removal and Installation of Center Joint
WDAA-04-03-001
IMPORTANT: Cap the open ends in case the hoses 4. Disconnect hose (4).
attach an identification tag onto the connectors, j : 17 mm
Removal

(Refer to W1-4-1.)
2. Place a container under center joint (1). Disconnect
hoses (2) (4 used).
j : 41 mm
j : 27 mm
W4-3-1-1
WDAA-04-03-002
j : 27 mm
j : 36 mm
j : 17 mm
8. Remove bolts (8) (2 used) and spring washers (9) (2
used). Remove stopper (10).
j : 22 mm
9. Remove rubber (11).
dCAUTION: Center joint (1) weight: 27 kg (60 lb)

10. Install an eyebolt (M14, Pitch 2.0 mm) to the bolt
(8) hole (2 places) on center joint (1). Attach a nylon
sling onto an eyebolt of center joint (1). Hoist and
hold center joint (1).
used). Remove center joint (1).
j : 22 mm
12. Remove the adapter with center joint (1) attached if
necessary.
W4-3-1-2
WDAA-04-03-002
Installation 7. Connect hoses (6) (4 used).

1. Install all removed adapters to center joint (1). j : 36 mm
dCAUTION: Center joint (1) weight: 27 kg (60 lb) m : 180 N·m (18 kgf·m, 133 lbf·ft)
2. Install an eyebolt (M14, Pitch 2.0 mm) to the bolt
(8) hole (2 places) on center joint (1). Attach a nylon
sling onto an eyebolt. Hoist center joint (1). j : 27 mm
3. Install the center joint with washers (13) (4 used)
m : 80 N·m (8 kgf·m, 59 lbf·ft)
j : 22 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)

4. Install rubber (11).
5. Install stopper (10) with spring washers (9) (2 used)
j : 22 mm
m : 140 N·m (14 kgf·m, 103 lbf·ft)

j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
W4-3-1-3
WDAA-04-03-001
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)

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

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

1.)
W4-3-1-4
Disassembly of Center Joint
WDAA-04-03-003
00A- Spindle 03- O-Ring 06- Ring 09- Cover

00B- Plug (with Ball Attached) 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body 05- Bushing 08- O-Ring
02- Dust Seal
W4-3-2-1
Disassembly of Center Joint

IMPORTANT: For easy removal of oil seal (04), use the
d CAUTION: Center joint weight: 27 kg (60 lb) pins (2 used). Do not damage the seal groove.
1. Remove bolts, washers (10) (2 used) diagonally. 6. Remove oil seals (04) (6 used), O-ring (03), and dust
Install an eyebolt (M10, Pitch 1.5 mm) to the bolt seal (02) from body (01).
(10) hole (2 places) of body (01). Attach a nylon sling
onto an eyebolt. Hoist the center joint. Secure the
center joint on a workbench.
j : 17 mm
2. Put the matching marks on body (01) and spindle
(00A). Remove other bolts, washers (10) (2 used).
Remove cover (09) from body (01).
j : 17 mm
3. Remove O-ring (08), retaining ring (07), and ring (06)
from body (01).
4. Install the special tools (ST 1033, ST 1020) to body
(01) with bolts, washers (10) (2 used).
W178-02-11-240
j : 17 mm
IMPORTANT: Do not damage the seal groove.
7. When replacing bushing (05), weld four places on
10 the bushing (05) bore by using a welding bar. Shrink
and remove bushing (05).
01
W506-03-03-002
IMPORTANT: Do not damage the seal sliding surface

of spindle (00A).
5. Remove spindle (00A) from body (01).
W4-3-2-2
Assembly of Center Joint
00B
00A
02
03
05
04
01
06
07
08
09
10
W178-03-03-001
00A- Spindle 03- O-Ring 06- Ring 09- Cover

00B- Plug (with Ball Attached) 04- Oil Seal (6 Used) 07- Retaining Ring 10- Bolt, Washer (4 Used)
01- Body 05- Bushing 08- O-Ring
02- Dust Seal
W4-3-2-3
Assembly of Center Joint

IMPORTANT: Before assembling, apply hydraulic oil IMPORTANT: Do not damage bushing (05).
onto parts in order to prevent them from seizing. IMPORTANT: The clearance between body (01) and
IMPORTANT: When assembling the seals, apply spindle (00A) is approximately 0.1 mm. Insert
grease (Apolloil Autorex C) and install seals to body (01) along axis straight and slowly. Do not
each groove. damage the seal.
IMPORTANT: If bushing (05) has been removed, IMPORTANT: Do not make a step on ring (06)
install bushing (05) first. (Refer to W4-3-2-6.) mounting part (b).
1. Install dust seal (02) to spindle (00A) with lip part (a) 3. Place spindle (00A) on a workbench. Fit the
of dust seal (02) facing to body (01) side. matching marks made when disassembling and
install body (01) to spindle (00A).
02 b 00A
01
01
W178-03-03-002
a - Lip Part W800-03-03-002
b - Ring (06) Mounting Part
2. Install O-ring (03) and oil seals (04) (6 used) to body

(01).
W4-3-2-4
IMPORTANT: Install ring (06) with the chamfered

side facing to the spindle (00A) side.
4. Install ring (06) and O-ring (08) to body (01).
00A
01
06
08
WDAA-04-03-004
5. Install retaining ring (07) to spindle (00A).

6. Install cover (09) to body (01) with bolts, washers
(10) (4 used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
W4-3-2-5
Replacement of Body and Spindle

ST 2558
IMPORTANT: When replacing body (01) or spindle
(00A) with the new one, the following procedures
are required. 01
In case of Body (01)

1. Clean body (01) and bushing (05).
05
2. Install bushing (05) to body (01) by using the special
tool (ST 2558) and a press.
fNOTE: Pushing force: 0.5 to 1.5 t (1110 to 3310 lb)
W178-02-11-242
In case of spindle (00A)
00B C
1. Clean spindle (00A).
00A
2. Install plug (00B) to spindle (00A) by using the
3. Install ball (a) of plug (00B) so that the top of each
ball is 0.4 mm (0.02 in) or more lower than the
respective sleeve (c) edge as illustrated in detail C.
WDAA-04-03-005
ST 2559 Detail C
b
c
WDAA-04-03-006 WDAA-04-03-007
a - Ball b - 0.4 mm (0.02 in) or more

c - Sleeve
W4-3-2-6
Removal and Installation of Track Adjuster
c a 1
ST 1651
7 2
WDCD-04-04-002
a - Hoisting Position
c - Hoisting Position
Before removing and installing the track adjuster, the 3. Attach a weight onto part (b) of the special tool
tracks must be removed first. (Refer to W4-6-1.) (ST 1651). Set the track adjuster (7) assembly
Therefore, the procedure starts on the premise that the horizontally.
tracks have already been removed here.
4. Pull out the track adjuster (7) assembly until nylon
slings can be attached onto hoisting position (c) of
Removal
track adjuster (7).
dCAUTION:
(125 lb)
Special tool (ST 1651) weight: 56 kg 5. Attach nylon slings onto hoisting position (c) of
track adjuster (7). Hoist and hold track adjuster (7)
1. Install the special tool (ST 1651) to the yoke (2) part assembly.
of front idler (1).
6. Remove the special tool (ST 1651) from the front
dCAUTION: The track adjuster (7) assembly
idler (1). Remove the track adjuster (7) assembly.
2. Attach a vise onto hoisting position (a) of front idler

(1). Hoist and hold the track adjuster (7) assembly.
W4-4-1-1
7 3, 4
a 5, 6 a
WDCD-04-04-004 WDCD-04-04-003
a - Block
6. Place track adjuster (7) onto blocks (a) (4 used).

j : 24 mm

8. Turn over the track adjuster (7) assembly.
dCAUTION:
adjuster (7).
Take care not to turn over track
dCAUTION: Front idler (1) weight: 170 kg (375 lb)

Remove front idler (1).
j : 24 mm
W4-4-1-2
7 5, 6
a 3, 4 a
WDCD-04-04-004 WDCD-04-04-003
a - Block
Installation 4. Install washers (4) (2 used) and bolts (3) (2 used).
dCAUTION:
adjuster (7).
Take care not to turn over track j : 24 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft)

dCAUTION: Front idler (1) weight: 170 kg (375 lb)
Track adjuster (7) weight: 220 kg (490 lb)
1. Place track adjuster (7) and front idler (1) onto
blocks (a) (4 used) with the bolt (5) hole side up.
2. Install front idler (1) with washers (6) (2 used) and
bolts (5) (2 used).
j : 24 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft)

3. Turn over the track adjuster (7) assembly.
W4-4-1-3
c a 1
ST 1651
7 2
WDCD-04-04-002
a - Hoisting Position
c - Hoisting Position

dCAUTION: The track adjuster (7) assembly +
Special tool (ST 1651) weight: 450 kg (995 lb)
5. Attach nylon slings onto hoisting position (c) 9. Hoist and hold the track adjuster (7) assembly.
of track adjuster (7). Attach a vise onto hoisting Attach a weight (45 kg (100 lb)) onto part (b) of
position (a) of front idler (1). Hoist the track adjuster the special tool (ST 1651). Set the track adjuster (7)
(7) assembly. assembly horizontally.
6. Install the track adjuster (7) assembly to the track 10. Install the track adjuster (7) assembly to the track
frame until it reaches where nylon slings can be frame.
removed.
7. Remove nylon slings.
dCAUTION:
(125 lb)
Special tool (ST 1651) weight: 56 kg
8. Install the special tool (ST 1651) to the yoke (2) part
of front idler (1).
W4-4-1-4
Disassembly of Front Idler
WDCD-04-04-006
00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used)
01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used)
W4-4-2-1
Disassembly of Front Idler

IMPORTANT: Handle floating seals with care. (Refer
dCAUTION:
kg (375 lb)
The idler (03A) assembly weight: 170
to W4-4-4.)
1. Place the idler (03A) assembly horizontally. Remove 4. Remove bearing (00) from the upper side of idler
plug (06) on the lower side. Drain off engine oil from (03A). Remove floating seals (05) (2 used) from idler
the idler (03A) assembly. (03A) and bearing (00).
l : 6 mm
fNOTE: Oil amount: 0.38 L (0.4 US qt)

such as goggles, helmets, etc in order to prevent 00
personal injury. 05
2. Remove pin (04) from bearing (00) on the upper
side by using a round bar and a hammer.
03A
fNOTE: Diameter of round bar: 16 mm
dCAUTION:
(78 lb)
The axle (01) assembly weight: 35 kg 05
3. Put the matching marks on bearing (00) and axle 02

(01). Remove the axle (01) assembly from the idler
(03A) assembly by using a press.
01
00
00 01
W105-03-05-009
03A
W105-03-05-008
W4-4-2-2
dCAUTION:
(78 lb)
The axle (01) assembly weight: 35 kg dCAUTION: Idler (03A) weight: 120 kg (265 lb)
IMPORTANT: Do not remove bushing (03B) unless
IMPORTANT: Place wooden blocks under bearing necessary.
(00) in order not to damage bearing (00). 9. When replacing bushing (03B), remove it by the
5. Attach nylon slings onto the axle (01) assembly. special tool (ST 1911) and a press.
Hoist the axle (01) assembly. Place the bearing (00)
part of the axle (01) assembly onto wooden blocks.

personal injury.
6. Remove pin (04) by using a bar and a hammer.
03A ST 1911
fNOTE: Diameter of round bar: 16 mm
7. Put the matching marks on bearing (00) and axle
(01). Remove axle (01) from bearing (00) by using a
press.
8. Remove O-rings (02) (2 used) from axle (01).
03B
W105-03-05-011
04 02
00
a
01
02
W105-03-05-010
a- Wooden Block
W4-4-2-3
Assembly of Front Idler
03A
03B 04 00
06
01 05 02
WDCD-04-04-005
00- Bearing (2 Used) 02- O-Ring (2 Used) 03B- Bushing (2 Used) 05- Floating Seal (2 Used)
01- Axle 03A- Idler 04- Pin (2 Used) 06- Plug (2 Used)
W4-4-2-4
Assembly of Front Idler

dCAUTION: Idler (03A) weight: 120 kg (265 lb)
(Refer to W4-4-4.)
1. Install bushings (03B) (2 used) to idler (03A).
5. Apply engine oil onto the O-ring of floating seal
2. Place axle (01) vertically. Install O-ring (02) to the (05). Install floating seal (05) to idler (03A) and
upper side of axle (01). bearing (00).
3. Fit the matching marks on axle (01) and bearing
(00). Evenly tap and install bearing (00) to axle (01) dCAUTION:
(78 lb)
The axle (01) assembly weight: 35 kg
6. Attach nylon slings onto bearing (00) of the axle (01)
assembly. Hoist the axle (01) assembly. Install the
axle (01) assembly to idler (03A) on the side where
such as goggles, helmets, etc in order to prevent floating seal (05) has already been installed.
personal injury.
4. Install pin (04) by using a bar and a hammer.
05 00
04
01
00
01
03A
W157-03-05-006
02
7. Apply THREEBOND #2353 onto plug (06). Install
W105-03-05-014 plug (06) to bearing (00).
l : 6 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
W4-4-2-5
dCAUTION:
kg (335 lb)
The idler (03A) assembly weight: 150 dCAUTION: Metal fragments may fly off when
8. Attach nylon slings onto the idler (03A) assembly. such as goggles, helmets, etc in order to prevent
Hoist the idler (03A) assembly. Turn over the idler personal injury.
(03A) assembly. 12. Install pin (04) by using a bar and a hammer.
9. Install O-ring (02) to axle (01). 13. Add engine oil (API CD class, SAE #30) through the
plug (06) hole of bearing (00).
(Refer to W4-4-4.) fNOTE: Oil amount: 0.38 L (0.4 US qt)
10. Apply engine oil onto the O-ring of floating seal 14. Apply THREEBOND #2353 onto plug (06). Install
(05). Install floating seal (05) to idler (03A) and plug (06) to bearing (00).
bearing (00).
l : 6 mm
00 05 02 03A m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
00
01
W157-03-05-005
11. Fit the matching marks on axle (01) and bearing

(00). Evenly tap and install bearing (00) to axle (01)
W4-4-2-6

these procedures:
2
hardening.

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

W4-4-4-1
(Blank)
W4-4-4-2
Removal and Installation of Upper Roller
1 2
W105-03-06-001 TDAA-03-08-002
dCAUTION: The pressure inside the track adjuster

cylinder is high. Do not loosen valve (1) quickly or
too much as valve (1) may fly out or high-pressure
grease in the adjuster cylinder may gush out.
Keep body parts and face away from valve (1) and
loosen valve (1) carefully. Do not loosen grease
fitting (2).
IMPORTANT: When gravel or mud is packed between
sprockets and track links, remove them before
loosening.
IMPORTANT: Loosening valve (1) by 1 to 1.5 turns is
enough. Do not loosen valve (1) over those turns.
Removal
2. Loosen valve (1) in the track adjuster. Drain grease
from the cylinder.
j : 24 mm
W4-5-1-1
6
b a 5
4
W1V7-03-06-001
3 c 4
4
W105-03-06-003
a- Oil Jack
b- Nonskid Cloth
c- Wooden Block
3
W105-03-06-005
dCAUTION: Use nonskid cloth (b) between track

frame (3) and oil jack (a) in order not to slip.
3. Raise the track in order to get clearance between
upper roller (4) and track (5).
4. Place wooden block (c) between track (5) and track
frame (3).
dCAUTION: Upper roller (4) weight: 30 kg (67 lb)

5. Attach a nylon sling onto upper roller (4). Hoist and
hold upper roller (4).
6. Loosen bolts (6) (4 used) of upper roller (4). Remove
upper roller (4).
j : 27 mm
W4-5-1-2
b a 5
W1V7-03-06-001
3 c 4
W105-03-06-003
a- Oil Jack
b- Nonskid Cloth
c- Wooden Block
1 2
a
WXXX-03-07-001
a - Track sag specification
TDAA-03-08-002
Installation
dCAUTION: Upper roller (4) weight: 30 kg (67 lb) 5. Apply grease through grease fitting (2) and adjust
the track tension.
1. Attach a nylon sling onto upper roller (4). Hoist
upper roller (4). Install upper roller (4) with bolts (6)
(4 used).
fNOTE: Track sag specification (a): 340 to 380 mm (13.4
to 15 in)
j : 27 mm
m : 460 N·m (46 kgf·m, 360 lbf·ft)

2. Remove wooden block (c), oil jack (a), and nonskid
cloth (b) between track (5) and track frame (3).
3. Tighten valve (1) in the track adjuster.
j : 24 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION: Securely support the raised machine

by using blocks.
4. Raise the track to be adjusted. Rotate the track in
the reverse direction a little.
W4-5-1-3
W158-03-06-001
6. Lower the track.

IMPORTANT: Upper roller (4) cannot be
disassembled. Replace it as an assembly.
7. Add engine oil (API CD class, SAE #30) through the
plug (8) hole of cover (7).
fNOTE: Amount of oil: 0.16 L (0.17 US qt)

8. Apply THREEBOND #2353 onto plug (8).
9. Tighten plug (8).
l : 6 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W4-5-1-4
Removal and Installation of Lower Roller
3, 5 6 2 3, 5
90˚ to 110˚
1 a WDAA-04-05-001 b M104-07-067
a - Wooden Block b - Stand
Removal
2. Put the matching marks on track guard (1) and track
frame (2).
dCAUTION: When removing bolt (3) without

supporting track guard (1), track guard (1) falls
off.
3. Place wooden block (a) under track guard (1).
j : 32 mm
5. Remove bolts (6) (4 used).
j : 32 mm
6. Swing the upperstructure to position it 90°. Operate
the boom and the arm so that the angle between
them is 90° to 110°. Lower the boom with the round
bottom of bucket contacting with the ground. Raise
the machine. At this time, place stand (b) under the
track frame and support the machine.
W4-5-2-1
7 8
TDAA-03-08-002
W105-03-06-001
1 WDAA-04-05-002
dCAUTION: The pressure inside the track adjuster

cylinder is high. Do not loosen valve (7) quickly or
too much as valve (7) may fly out or high-pressure
grease in the adjuster cylinder may gush out.
fitting (8).
IMPORTANT: Loosening valve (7) by 1 to 1.5 turns is
loosening.
7. Loosen valve (7). Drain grease until the clearance is
enough to remove lower roller (9).
j : 24 mm
dCAUTION: Track guard (1) weight: 35 kg (78 lb)

Lower roller (9) weight: 57 kg (130 lb)
8. Remove track guard (1) and lower roller (9) by using
a forklift.
W4-5-2-2
3, 5 6 2 3, 5
9
10 1 WDAA-04-05-002 1 WDAA-04-05-003
Installation
dCAUTION: Track guard (1) weight: 35 kg (78 lb)

Lower roller (9) weight: 57 kg (130 lb)
1. Fit the matching marks made when removing and
place track guard (1) and lower roller (9) onto track
link (10) by using a forklift.
2. Lower the machine so that the position to install
lower roller (9) can be adjusted.
3. Fit the bolt (6) holes of track frame (2) and lower
roller (9). Install lower roller (9) with bolts (6) (4
used).
j : 32 mm
m : 840 N·m (84 kgf·m, 620 lbf·ft)

4. Install track guard (1) with washer (5) and bolt (3) by
using a pry bar.
j : 32 mm
m : 750 N·m (75 kgf·m, 550 lbf·ft)
W4-5-2-3
7 8
TDAA-03-08-002 WXXX-03-07-001
a - Track sag specification
5. Tighten valve (7).
j : 24 mm
m : 90 N·m (9 kgf·m, 66 lbf·ft)
dCAUTION: Securely support the raised machine

by using blocks.
6. Raise the track to be adjusted. Rotate the track in
the reverse direction a little.
7. Apply grease through grease fitting (8) and adjust
the track tension.
fNOTE: Track sag specification (a): 340 to 380 mm (13.4

to 15 in)
W4-5-2-4
Disassembly of Lower Roller
3
2
4 1
5
7
6
5
4
3
2
1
W157-03-06-004
1- Plug (2 Used) 3- Pin (2 Used) 5- Floating Seal (2 Used) 7- Roller

2- Collar (2 Used) 4- O-Ring (2 Used) 6- Bushing (2 Used) 8- Axle
W4-5-3-1
Disassembly of Lower Roller 4. Remove pin (3) from the axle (8) assembly. Remove
axle (8) from collar (2) by using a press.
dCAUTION: Lower roller weight: 57 kg (130 lb)
1. Remove plug (1) from the end of collar (2). Drain oil
from roller (7). 4 3 2
l : 6 mm

such as goggles, helmets, etc. in order to prevent 8
personal injury.
2. Put the matching marks on collar (2) and axle (8).
Remove pin (3) from collar (2) at one side by using
a round bar and a hammer. Remove axle (8) from
roller (7), from the side where pin (3) was removed
by using a press. At this time, pin (3) and collar (2)
W178-02-11-268
on the opposite side are removed with axle (8)
together.
5. Remove O-rings (4) (2 used) from axle (8).
fNOTE: Diameter of round bar: 14 mm (0.55 in)
dCAUTION: Roller (7) weight: 33 kg (73 lb)
2 5 7 5 IMPORTANT: Do not remove bushing (6) unless
necessary.
6. Remove bushing (6) by using the special tool (ST
1475) and a press.
5
2
ST 1475
8
6
W105-03-06-026
7

(Refer to W4-5-4.)
W178-02-11-269
3. Remove floating seals (5) (2 used) from both sides of
roller (7) and collars (2) (2 used).
W4-5-3-2
Assembly of Lower Roller
2 7 6 5 4 3 1
W105-03-06-023
1- Plug (2 Used) 3- Pin (2 Used) 5- Floating Seal (2 Used) 7- Roller

2- Collar (2 Used) 4- O-Ring (2 Used) 6- Bushing (2 Used) 8- Axle
W4-5-3-3
Assembly of Lower Roller

IMPORTANT: Do not dent the flange surface of 5. Install the axle (8) assembly to roller (7).
bushing (6).
6. Apply grease onto O-ring (4) at the other side. Install
1. Install bushings (6) (2 used) to roller (7) by using a O-ring (4) to the roller (7) assembly.
press.
2. Apply grease onto O-ring (4) at one side. Install (Refer to W4-5-4.)
O-ring (4) to axle (8).
7. Install floating seal (5) to roller (7) and collar (2) at
IMPORTANT: Do not damage O-ring (4). the other side.
3. Fit the pin (3) hole and install collar (2) to one side of IMPORTANT: Do not damage O-ring (4).
axle (8) with pin (3).
8. Fit the pin (3) hole and install collar (2) to axle (8)
with pin (3).
8 3 9. Apply THREEBOND #2353 onto plug (1). Add engine
oil (API CD class, SAE #30) through the plug (1) hole
of collar (2). Tighten plug (1).
l : 6 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
2
fNOTE: Amount of oil: 0.42 L (0.44 US qt)
W105-03-06-031

(Refer to W4-5-4.)
4. Install floating seal (5) to roller (7) and collar (2).
7 5
5 2
W157-03-06-008
W4-5-3-4
Group 5 Upper and Lower Roller

these procedures:
2
hardening.

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

W4-5-4-1
Group 5 Upper and Lower Roller
(Blank)
W4-5-4-2
Group 6 Track
Removal and Installation of Track
3
4 5
2
a
W105-03-07-006 WDCD-04-06-001
a - Wooden Block
Removal
2. Rotate the track so that master pin (1) is positioned
over front idler (2). Place wooden block (a) under
shoe (3) and support shoe (3).
dCAUTION: The pressure inside cylinder of the

track adjuster is high. As valve (4) may fly out
and the high-pressure grease may spout out, do
not loosen valve (4) quickly and/or excessively.
fitting (5).
IMPORTANT: Loosening valve (4) 1 to 1.5 turns is
loosening.
3. Loosen valve (4). Drain grease and loosen the track.
j : 24 mm
W4-6-1-1
Group 6 Track
7
6
1 1 7
a - Direction to Remove
W105-03-07-010
6
ST 1970
W105-03-07-009
W1V1-03-07-001
4. Remove snap ring (6) from master pin (1).
fNOTE: If snap ring (6) interferes with master link (7),

dCAUTION: The track adjuster may fly out due
to the spring force when removing the track. Do
push master pin (1) to the installing direction in order to not stand in the same direction to remove the
make clearance between snap ring (6) and master pin track adjuster or where it may fly out. Particularly,
(1). Then, remove master pin (1). strong force is always applied to the thread
part of the rod. If the rod and/or the threads are
damaged, metal fragments may fly out due to the
spring force.

personal injury.
IMPORTANT: Master pin (1) can be removed to only
one direction. Check direction (a) to remove
master pin (1).
5. Remove master pin (1) by using the special tool (ST
1970) and a hammer.
W4-6-1-2
Group 6 Track
90˚ to 110˚
a
a - Stand
M104-07-067 W105-03-07-011
6. Set the angle between boom and arm to 90˚ to

110˚. Lower the boom with the round bottom of the
bucket contacting with the ground. Raise the track
frame and pull out the track. Place stand (a) under
the track frame and support the machine at this
time.
dCAUTION: The track assembly weight:

ZX330-5G: 1750 kg (3860 lb)
ZX350H-5G, 350K-5G: 1860 kg (4110 lb)
ZX330LC-5G: 1870 kg (4130 lb)
ZX350LCH-5G, 350LCK-5G: 1980 kg (4370 lb)
7. Slowly operate a travel control lever on the side to
be removed the track to the reverse position and
extend the track.
W4-6-1-3
Group 6 Track
a b
W105-03-07-014
W105-03-07-013
a - Front Idler Side

b - Sprocket (8) Side
W105-03-07-015
Installation 3. Slowly operate a travel control lever on the side to

install the track in the forward direction with the
1. Raise the machine. Set the track under the machine
machine raised off the ground. Wind the track while
so that sprocket (8) meshes with the track end.
rotating travel device (9).
Check the direction of the track at this time.
dCAUTION: The track assembly weight:

ZX330-5G: 1750 kg (3860 lb)
ZX350H-5G, 350K-5G: 1860 kg (4110 lb)
ZX330LC-5G: 1870 kg (4130 lb)
ZX350LCH-5G, 350LCK-5G: 1980 kg (4370 lb)
2. Hoist and mesh the track with the claws of sprocket
(8).
W4-6-1-4
Group 6 Track
6
1 7
b - Direction to Install
W105-03-07-010
7
3
a
6
W105-03-07-016
a - Wooden Block
W105-03-07-009
4. Wind the track link until the connection part of the

track link reaches the front idler (2) side. Lower the
machine. Place wooden block (a) under shoe (3) and
support shoe (3).
IMPORTANT: Master pin (1) can be installed to only
one direction. Check direction (b) to install master
pin (1).
5. Install master pin (1) to the track.
IMPORTANT: Replace snap ring (6) with the new one.
6. Install snap ring (6).Snap ring (6) has the direction to
install. Install snap ring (6) to the groove of master
link (7) with the flat surface of a pair of pliers hole
facing the near side.
W4-6-1-5
Group 6 Track
4 5
11
13
12
10
WDCD-04-06-001
c b c
W197-03-07-001
13
b - Apply grease.
c - Do not apply grease.
WXXX-03-07-001
a - Track Sag Specification
IMPORTANT: If link (10) has been disassembled, fill 10. Install pin (12) to link (10) and bushing (11) while
grease (Daphne Epones SR) into the clearance holding them in order not to move due to grease.
between bushing (11) and pin (12).
11. Wipe off excess grease after installing pin (12).
IMPORTANT: If link (10) has been disassembled,
perform step 7 to step 11. 12. Tighten valve (4). Apply grease through grease
fitting (5) and adjust the track tension.
IMPORTANT: Check the direction to install seal (13).
7. Install seal (13) to link (10). j : 24 mm
8. Apply grease onto the bushing (11) end. Fit the pin m : 90 N·m (9 kgf·m, 66 lbf·ft)
(12) holes on link (10) and bushing (11). Stand them
on a flat plate. fNOTE: Track sag specification (a): 340 to 380 mm (13.4
to 15 in)
dCAUTION: Take care not to come off link (10).
9. Fill the bushing (11) inside with grease.
W4-6-1-6
MEMO
MEMO
SECTION 5
FRONT ATTACHMENT
CONTENTS
Removal and Installation of Front Attachment....W5-1-1-1
Group 2 Cylinder
Removal and Installation of Boom Cylinder..........W5-2-1-1
Removal and Installation of Arm Cylinder.............W5-2-2-1
Removal and Installation of Bucket Cylinder........W5-2-3-1
Disassembly of Boom, Arm, and Bucket
Cylinders.......................................................................W5-2-4-1
Assembly of Boom, Arm, and Bucket
Cylinders.......................................................................W5-2-4-5
Disassembly of Boom, Arm, and Bucket
Cylinders.......................................................................W5-2-5-1
Assembly of Boom, Arm, and Bucket
Cylinders.......................................................................W5-2-5-5
DDEW-5-1
(Blank)
DDEW-5-2
Removal and Installation of Front

Attachment
Removal
1. Park the machine on a solid, level surface. Fully
retract the bucket and arm cylinders and lower the
arm top onto the ground.

(Refer to W1-4-1.)
2. Disconnect lubrication hose (1) from adapter (a)
connecting to the boss at the boom cylinder rod
side. (2 places on both left and right)
j : 17 mm
W105-04-02-001
dCAUTION:
lb)
Boom cylinder (b) weight: 290 kg (640
3. Hoist and hold boom cylinder (b). Remove nuts 1

(4) (2 used) and bolt (6) from pin (3) of the boom
cylinder rod end. Remove stopper (5). (2 places on
both left and right) a
j : 30 mm b
a- Adaptor
b- Boom Cylinder
W105-04-01-002
3 2
6
b
5
4 9
b- Boom Cylinder
W178-04-01-004
W5-1-1-1
3 2
personal injury.
6
4. By using a bar and a hammer, tap pin (3) into the
b
position where thrust plate (2) can be removed.
Remove pin (3) and thrust plates (2, 9).
fNOTE: When pin (3) is impossible to remove, start the

engine and operate the boom control lever. Adjust the
cylinder rod pin hole of boom cylinder (b) while raising/ 5
lowering the front attachment.
4 9
5. Place the tube top of boom cylinder (b) on a stand
b- Boom Cylinder
of 1 m (39.4 in) height. Start the engine. Operate the
boom control lever and retract boom cylinder (b). W178-04-01-004
In order not to extend the rod, pass wire (a) through
the rod hole and secure the rod to the cylinder tube.
6. Stop the engine. Remove boom cylinder (b). (Refer
to W5-2-1.)
7. Remove another boom cylinder (b) in the same way
as step 5 to step 6. b

(Refer to W1-4-1.)
dCAUTION: Release any pressure in the hydraulic

circuit. (Refer to W1-5-1.) a
a- Wire
b- Boom Cylinder
W178-02-11-274
c- Air Bleed Valve
W1V1-04-01-008
W5-1-1-2
8. Disconnect hoses (7, 8) of the bucket cylinder and

arm cylinder. Cap the open ends of the removed
pipes and hoses.
j : 41 mm, 50 mm
7 8
9. Remove the mounting bolts (9 used) for tool box (b)
and cover (a). Remove tool box (b) and cover (a).
j : 17 mm
W1V1-04-01-001
a
b
a- Cover
b- Tool Box
W1V1-04-01-002
W5-1-1-3
10. Remove bolt (14), washer (15), plate (13), and block 11
(12) from plate (a) of boom foot pin (11).
j : 32 mm
dCAUTION:
weight:
The front attachment assembly a
ZX330-5G, 330LC-5G: 6040 kg (13320 lb) 12
ZX350H-5G, 350LCH-5G: 6660 kg (14690 lb) 13
ZX350K-5G, 350LCK-5G: 6550 kg (14450 lb) 14

15
11. Attach wire ropes onto the boom. Reduce slack of
the wire ropes. a- Plate
W178-02-11-280
12. Insert a pry bar between plate (a) of boom foot pin
(11) and bracket (c). Slightly pull out plate (a).
dCAUTION:
lb)
Boom foot pin (11) weight: 80 kg (180
13. Turn plate (a) upward by hand. Turn left and right
and pull out boom foot pin (11). (Adjust the position
by using the lifting ropes for the front attachment.) W178-02-11-281
14. Hoist front attachment assembly (d) and move the 11
machine backward.
15. Place wooden blocks. Place front attachment
assembly (d) onto the wooden blocks.
a b
a- Plate c- Bracket
b- Insert a Pry Bar
W178-02-11-280
d- Front Attachment Assembly
W178-02-11-282
W5-1-1-4
Installation a
dCAUTION: Front attachment assembly (a) weight:

ZX330-5G, 330LC-5G: 6040 kg (13320 lb)
ZX350H-5G, 350LCH-5G: 6660 kg (14690 lb)
ZX350K-5G, 350LCK-5G: 6550 kg (14450 lb)
1. Hoist front attachment assembly (a). Move the
machine forward and fit the boom foot to the
a- Front Attachment Assembly
mounting hole on the frame. Insert the thrust plate
into the left and right sides of boom and adjust the W178-02-11-282
clearance between plate and frame within 1 mm.
(0.039 in) (Adjust the position by using the lifting 11
ropes for the front attachment.)

personal injury.
12
dCAUTION:
lb)
Boom foot pin (11) weight: 80 kg (180
13
2. Install boom foot pin (11). Install bolt (14), washer
14
(15), plate (13), and block (12). 15
j : 32 mm W178-02-11-280
m : 750 N·m (75 kgf·m, 550 lbf·ft)

3. Install tool box (c) and cover (b) with the bolts (9
used).
j : 17 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)

b
c
b- Cover
c- Tool Box
W1V1-04-01-002
W5-1-1-5
4. Remove the caps from hoses and pipes. Connect

hoses (7, 8) of the bucket cylinder and arm cylinder.
j : 41 mm
m : 200 N·m (20 kgf·m, 148 lbf·ft) 7 8
j : 50 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft)
W1V1-04-01-001
dCAUTION:
lb)
Boom cylinder (a) weight: 290 kg (640
5. Hoist and install boom cylinder (a). (Refer to W5-2-

1.)
a
a- Boom Cylinder
W105-04-02-040
W5-1-1-6
3 2
personal injury. 6
6. Hoist and hold boom cylinder (a). Insert thrust a
plates (2, 9). Install pin (3) by using a bar and
hammer. Install boom cylinders (a) on both sides.
7. Install stopper (5). Tighten bolt (6) and nuts (4) (2
used). (2 places on both left and right)
5
j : 30 mm
4 9
m : 170 N·m (17 kgf·m, 125 lbf·ft) a- Boom Cylinder
8. Connect hose (1) to boom cylinder rod side (b). (2
places on both left and right) W178-04-01-004
j : 17 mm
1
m : 30 N·m (3 kgf·m, 22 lbf·ft)
9. Apply grease onto the rod side, bottom side, and b- Boom Cylinder Rod Side
boom foot side (c) of boom cylinder.
W105-04-01-002
b- Boom Cylinder Rod Side

c- Boom Foot Side
W1V1-04-01-001
W5-1-1-7
IMPORTANT: When removing the arm from the 16

boom, perform the following steps when
installing the arm.
10. Install thrust plates (14) into left and right sides
of the arm. Adjust total clearance of left and right
within 1.5 mm. (0.059 in)
14 14
11. Install the arm cylinder rod side to the arm. Apply
grease onto grease fittings (15, 16) on the boom
connecting boss of arm and the arm cylinder rod
side.
IMPORTANT: For handling of HN bushing for the 15 15

front attachment, check the followings.
Precautions when installing the bushing
If a hammer is used, the bushing may be damaged. Use a
special too and a press.
Special tool when installing bushing (bushing inner

diameter): W178-02-11-285
(ST 2883): 90 mm
(ST 2882): 100 mm
(ST 2875): 110 mm
Precautions when reinforcing arm

The heat when welding in order to reinforce the arm may
cause oil leakage and decrease lubrication performance.
When lubrication oil leaks, replace the bushing.
W5-1-1-8
Group 2 Cylinder
Removal and Installation of Boom Cylinder

1
Removal
1. Disconnect hose (1) from boom cylinder (2).
j : 17 mm
dCAUTION:
lb)
Boom cylinder (2) weight: 290 kg (640
2. Attach nylon slings onto boom cylinder (2). Hoist

2
and hold boom cylinder (2).

a hammer is used. Wear necessary protection, W105-04-02-032
personal injury.
3. Remove nuts (5) (2 used), bolt (7), and stopper (6)
from the boom cylinder (2) rod side. Push pin (4)
into the boom by using a bar and hammer. Remove 7
thrust plates (3, 8).
j : 30 mm
6
5 8 4 3 2
4. Place boom cylinder (2) on a stand. Remove the W158-04-02-013

other boom cylinder in the same way.
5. Operate the boom control lever and retract boom
cylinder (2). In order not to extend the rod, pass a
wire through the rod hole and secure the rod to the
cylinder tube.
2
W105-04-02-035
W5-2-1-1
Group 2 Cylinder
6. Stop the engine. 8

(Refer to W1-4-1.) 2 2

circuit. (Refer to W1-5-1.) A A
7. Disconnect hoses (8) (4 used) and hoses (9) (2 used)
from the bottom of boom cylinder (2). Cap the open
ends.
j : 17 mm, 41 mm

such as goggles, helmets, etc in order to prevent 9 M154-07-006
personal injury.
Section A
8. Remove bolt (10), washer (14) and plate (11) from
the cylinder bottom side. Remove pin (12) by using 2
a bar and hammer. Remove thrust plates (13).
j : 27 mm
12
dCAUTION:
lb)
9. Hoist and remove boom cylinder (2).

10. Remove the other boom cylinder in the same way.
11
10
13
14 W1V1-04-02-018
2
W105-04-02-040
W5-2-1-2
Group 2 Cylinder
Installation
IMPORTANT: If a hammer is used to install the
bushing, the bushing may be damaged. Install the
bushing by using a press.
dCAUTION:
lb)
1. Hoist boom cylinder (2). Fit the hole at boom

cylinder tube side to the mounting hole on the
main frame.

personal injury. 2
2. Fit thrust plates (13) and pin (12) with the mounting W105-04-02-040
hole on the main flame. Install pin (12) by using a
hammer. Install plate (11) and washer (14) to pin
(12) with bolt (10). 8
j : 27 mm
2 2
m : 400 N·m (40 kgf·m, 300 lbf·ft)
3. Install the other boom cylinder in the same way. A A
4. Connect hoses (8) (4 used) and hoses (9) (2 used) to

boom cylinders (2) (2 used).
j : 17 mm
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
j : 41 mm
9 M154-07-006
m : 200 N·m (20 kgf·m, 148 lbf·ft)
Section A
12
11
10
13
14 W1V1-04-02-018
W5-2-1-3
Group 2 Cylinder

5. Remove the wire from the boom cylinder (2) rod
side. Starts the engine. Operate the boom control
lever and fit the hole at cylinder rod side to the
mounting hole on boom.

personal injury.
6. Fit thrust plates (3, 8) and pin (4) with the mounting 7
hole on boom. Install pin (4) by using a bar and
hammer.
7. Install bolt (7) to pin (4) and stopper (6) with nuts (5)
(2 used).
j : 30 mm
6
m : 170 N·m (17 kgf·m, 125 lbf·ft) 5 8 4 3 2
8. Connect hose (1) to boom cylinder (2). W158-04-02-013
j : 17 mm
1
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
9. Install the other boom cylinder in the same way.
IMPORTANT: After completing the work, operate the
boom cylinder several times to the stroke end and
bleed air from the circuit.
W105-04-02-032
W5-2-1-4
Group 2 Cylinder
Removal and Installation of Arm Cylinder

1
Removal A
1. Place wooden block (3) between arm cylinder (1)

and boom (2).
2. Remove bolt (4), washer (16) and plate (5) from the
rod side of arm cylinder (1). 2
j : 27 mm
3
a hammer is used. Wear necessary protection, W1V7-04-02-009
personal injury.
Section A
3. Remove pin (6) by using a bar and hammer. Remove
thrust plates (7). 1
4. Operate the arm control lever and retract arm

cylinder (1). In order not to extend rod (8), pass wire 6
(9) through the rod hole and secure rod (8) to the
arm cylinder (1) tube.
5. Stop the engine.

(Refer to W1-4-1.) 5

circuit. (Refer to W1-5-1.)
4
7
16 W1V1-04-02-018
8 1
W1V7-04-02-010
W5-2-2-1
Group 2 Cylinder
6. Disconnect hoses (10) (2 used) and hose (11) from

the bottom of arm cylinder (1). Cap the open ends. 1 B 10
j : 17 mm, 50 mm
dCAUTION:
lb)
Arm cylinder (1) weight: 460 kg (1020 11
7. Attach nylon slings onto arm cylinder (1). Hoist and

hold arm cylinder (1).

personal injury.
8. Remove bolt (12), washer (11) and plate (13) from
the bottom side of arm cylinder (1). W1V7-04-02-011
j : 27 mm
9. Remove pin (14) by using a bar and hammer. Section B
Remove thrust plates (15). 1
10. Hoist and remove arm cylinder (1).
14
13
12
15
17 W1V1-04-02-018
W5-2-2-2
Group 2 Cylinder
Installation
dCAUTION:
lb)
Arm cylinder (1) weight: 460 kg (1020
1 B 10
1. Hoist arm cylinder (1). Fit the hole at the cylinder

bottom side to the pin (14) mounting hole on the
boom. 11

personal injury.
2. Fit thrust plates (15) and pin (14) with the cylinder
mounting hole on the boom. Install pin (14) by
using a hammer.
3. Install plate (13) and washer (17) to pin (14) with
bolt (12). W1V7-04-02-011
j : 27 mm
Section B
m : 400 N·m (40 kgf·m, 300 lbf·ft)
1
4. Connect hose (11) and hoses (10) (2 used) to arm
cylinder (1).
j : 17 mm 14
m : 25 N·m (2.5 kgf·m, 18 lbf·ft)
j : 50 mm
m : 270 N·m (27 kgf·m, 200 lbf·ft) 13
12
15
17 W1V1-04-02-018
W5-2-2-3
Group 2 Cylinder
dCAUTION:
lb)
Arm cylinder (1) weight: 460 kg (1020 8 1
IMPORTANT: Add hydraulic oil. Start the engine and

check for any oil leaks.
5. Remove wire (9) from rod (8) of arm cylinder (1).
Hoist arm cylinder (1). Start the engine. Operate the
arm control lever and fit the hole at cylinder rod 9
side to the pin (6) mounting hole on arm.

a hammer is used. Wear necessary protection, 2
W1V7-04-02-010

personal injury. A
6. Fit thrust plates (7) and pin (6) with the mounting
hole on arm (2). Install pin (6) by using a hammer.
7. Install plate (5) and washer (16) to pin (6) with bolt
(4).
j : 27 mm
m : 400 N·m (40 kgf·m, 300 lbf·ft)

IMPORTANT: After completing the work, operate the W1V7-04-02-009
arm cylinder several times to the stroke end and
bleed air from the circuit. Section A
7
16 W1V1-04-02-018
W5-2-2-4
Group 2 Cylinder
Removal and Installation of Bucket Cylinder

Removal
1. Insert wooden blocks (3) (2 used) under the arm (2)
1
top and between arm (2) and bucket cylinder (1).
dCAUTION: Before removing pin (7), secure the

link by using a wire in order not to fall off.

3
2
personal injury.
2. Remove nuts (6) (2 used) and bolt (4). Remove pin W178-02-11-287
(7) with using a bar and hammer. Remove thrust
plates (5). 4 5
j : 32 mm
W158-04-02-006
3. Operate the bucket control lever and retract bucket
cylinder (1). In order not to extend rod (8), pass wire
(9) through the rod hole and secure rod (8) to the 8 1
bucket cylinder (1) tube.
4. Stop the engine.

(Refer to W1-4-1.)

circuit. (Refer to W1-5-1.)
9 W102-04-02-005
W5-2-3-1
Group 2 Cylinder
5. Disconnect bucket cylinder hoses (12) (2 used) from 10

the bottom of bucket cylinder (1). Cap the open
ends.
j : 41 mm
15
dCAUTION:
(555 lb)
Bucket cylinder (1) weight: 250 kg
11
13

personal injury.
6. Hoist bucket cylinder (1). Remove nuts (13) (2 used) 1

and bolt (15). Remove pin (11) by using a bar and
hammer. Remove thrust plates (10).
j : 30 mm 12
WDDE-05-02-007
7. Hoist and remove bucket cylinder (1).
W5-2-3-2
Group 2 Cylinder
Installation
dCAUTION:
(555 lb)
Bucket cylinder (1) weight: 250 kg

10
personal injury.
1. Hoist bucket cylinder (1). Fit the hole at the cylinder
bottom side to the cylinder mounting hole on the 15
arm. Fit thrust plates (10) and pin (11) with the
cylinder mounting hole on the arm. Install pin (11)
by using a hammer. 14 11
2. Install bolt (15) to stopper (14) of the arm and pin 13
(11) with nuts (13) (2 used).
j : 30 mm
m : 170 N·m (17 kgf·m, 125 lbf·ft) 1

3. Connect hoses (12) (2 used) to bucket cylinder (1).
j : 41 mm
12
m : 200 N·m (20 kgf·m, 148 lbf·ft) WDDE-05-02-007
W5-2-3-3
Group 2 Cylinder
4. Remove wire (9) from rod (8) of bucket cylinder (1).

8 1

personal injury.
5. Start the engine and operate the bucket control
lever. Fit the hole at cylinder rod side to the holes
of link A (16) and link B (18). Fit thrust plates (5) and
pin (7) with the holes of link A (16) and link B (18).
Install pin (7) by using a hammer. 9 W102-04-02-005
6. Install bolt (4) to stopper (17) and pin (7) with nuts
(6) (2 used).
16 4 17 5
j : 32 mm
m : 220 N·m (22 kgf·m, 162 lbf·ft)

IMPORTANT: In case link B (18) has been removed
from the arm, insert thrust plate (19) when
installing.
IMPORTANT: After completing the work, operate the
bucket cylinder several times to the stroke end
and and bleed air from the circuit. 7 18 6
W158-04-02-006
19 19
W178-02-11-289
18 18
W5-2-3-4
Group 2 Cylinder
Disassembly of Boom, Arm, and Bucket ZX330-5G Class; Serial No. 040001 to 040006
Cylinders
Boom Cylinder
1 2 3 4 5 6 7 8 9 10 11
12
14, 15 13
24 25 23 22 21 22 23 20 19 20 16 WDDE-05-02-001
Arm Cylinder
1 2 3 4 5 6 7 8 9 10 11
12
14, 15 13
WDDE-05-02-002
24 25 23 22 21 22 23 20 19 20 16 17 18
W5-2-4-1
Group 2 Cylinder
Bucket Cylinder
1 2 3 4 5 6 7 8 9 10 11
12
14, 15 13
WDDE-05-02-003
24 25 23 22 21 22 23 20 19 20 16
1- Cylinder Rod 8- Retaining Ring 14- Steel Ball 21- Piston Seal
2- Dust Seal 9- O-Ring 15- Set Screw 22- Wear Ring (2 Used)
3- Backup Ring 10- Backup Ring 16- Nut 23- Dust Ring (2 Used)
4- U-Ring 11- O-Ring 17- Ring 24- Cushion Bearing
5- Seal 12- Socket Bolt (Boom: 12 Used) 18- Cushion Plunger 25- Piston
6- Cylinder Head (Arm, Bucket: 14 Used) 19- O-Ring
7- Bushing 13- Cylinder Tube 20- Backup Ring (2 Used)
W5-2-4-2
Group 2 Cylinder
Disassembly of Boom, Arm, and Bucket Cylinders
 The procedure starts on the premise that the

pipes and the bands securing the pipes have been
removed.
4. Secure cylinder rod (1) on the special tool for
fNOTE: The arm cylinder is explained here. cylinder (ST 5908). Put the matching marks on the
dCAUTION: Boom cylinder weight: 290 kg (640 lb) ends of cylinder rod (1) and nut (16).
Arm cylinder weight: 460 kg (1020 lb)

Bucket cylinder weight: 250 kg (555 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.
Special Tool for Cylinder: ST 5908
W158-04-02-022
W102-04-02-027
2. Fully extend and support cylinder rod (1). Remove

socket bolts (12) (14 used) from cylinder head (6).
Boom Cylinder: 12 used
Arm Cylinder: 14 used
Bucket Cylinder: 14 used
Boom Cylinder, Arm Cylinder
l : 17 mm
Bucket Cylinder
l : 14 mm
IMPORTANT: Pull out cylinder rod (1) straightly in
order not to damage the sliding surface.
3. Tap and remove cylinder head (6) with cylinder
rod (1) together from cylinder tube (13) by using a
plastic hammer.
W5-2-4-3
Group 2 Cylinder
5. Cut away the crimped part by using a hand drill. 8. Remove wear rings (22) (2 used), dust rings (23) (2
Remove set screw (15). Remove steel ball (14) used), piston seal (21), backup rings (20) (2 used),
together. and O-ring (19) from piston (25).
fNOTE: Set screw (15) has been crimped by using a 9. Remove cylinder head (6) from cylinder rod (1).
punch at two places after installing. 10. Remove dust seal (2), backup ring (3), U-ring (4), seal
l : 8 mm (5), bushing (7), retaining ring (8), O-ring (9), backup
ring (10), and O-ring (11) from cylinder head (6).
6. Remove nut (16) by using the special tool (ST 5908)
and the special tool for nut. IMPORTANT: Ring (17) and cushion plunger (18) can
not be disassembled.
W158-04-02-022
Special Tool for Nut:

Boom Cylinder, Bucket Cylinder
(ST 3318): 110 mm
Arm Cylinder
(ST 3276): 130 mm
7. Remove piston (25) by using the special tool for
piston. Remove cushion bearing (24) from cylinder
rod (1).
Special Tool for Piston:
(ST 3353): 110 mm
Arm Cylinder
(ST 3351): 135 mm
W5-2-4-4
Group 2 Cylinder
Assembly of Boom, Arm, and Bucket ZX330-5G Class; Serial No. 040001 to 040006
Cylinders
Boom Cylinder
1 2 4 5 12 6 11 13 24 25 23 21 23 14, 15
16
WDDE-05-02-004
3 7 8 9, 10 19, 20 22
Arm Cylinder
1 2 4 5 12 6 11 13 24 25 23 21 23 14, 15
16
18
WDDE-05-02-005
3 7 8 9, 10 19, 20 22 17
Bucket Cylinder
1 2 4 5 12 6 11 13 24 25 23 21 23 14, 15
16
WDDE-05-02-006
3 7 8 9, 10 19, 20 22
1- Cylinder Rod 8- Retaining Ring 14- Steel Ball 21- Piston Seal
2- Dust Seal 9- O-Ring 15- Set Screw 22- Wear Ring (2 Used)
3- Backup Ring 10- Backup Ring 16- Nut 23- Dust Ring (2 Used)
4- U-Ring 11- O-Ring 17- Ring 24- Cushion Bearing
5- Seal 12- Socket Bolt (Boom: 12 Used) 18- Cushion Plunger 25- Piston
6- Cylinder Head (Arm, Bucket: 14 Used) 19- O-Ring
7- Bushing 13- Cylinder Tube 20- Backup Ring (2 Used)
W5-2-4-5
Group 2 Cylinder
Assembly of Boom, Arm, and Bucket Cylinders
fNOTE: The arm cylinder is explained here. 7. Install the cylinder head (6) assembly to cylinder rod
(1).
1. Install bushing (7) to cylinder head (6).
Special Tool for Cylinder Head (Rod Outer Diameter):
Special Tool for Bushing (Rod Outer Diameter):
Boom Cylinder (ST 8027): 100 mm
Arm Cylinder (ST 8022): 115 mm
Bucket Cylinder (ST 8021): 95 mm
IMPORTANT: Check the direction of oil groove in
IMPORTANT: Check the direction to install.
cushion bearing (24).
2. Install U-ring (4), backup ring (3), seal (5), and
8. Install cushion bearing (24) to cylinder rod (1).
retaining ring (8) to cylinder head (6).
Install the piston (25) assembly to cylinder rod (1).
3. Install dust seal (2) to cylinder head (6) by using a
Special Tool for Piston:
plastic hammer.
Boom Cylinder, Bucket Cylinder (ST 3353): 110 mm
Special Tool for Wiper Ring (Rod Outer Diameter): m : 980 N·m (98 kgf·m, 720 lbf·ft)
Bucket Cylinder (ST 8021): 95 mm m : 980 N·m (98 kgf·m, 720 lbf·ft)
4. Install O-ring (9), backup ring (10), and O-ring (11) to 9. Fit the matching marks before disassembling
cylinder head (6). and tighten nut (16) by using the special tool for
cylinder (ST 5908) and the special tool for nut.
5. Install piston seal (21) to piston (25) by using special
tool A. After installing piston seal (21), adjust piston Special Tool for Nut:
seal (21) by using special tool B. Boom Cylinder, Bucket Cylinder (ST 3318): 110 mm
m : 1850 N·m (185 kgf·m, 1360 lbf·ft)
Special Tool A, Special Tool B (Tube Inner Diameter):
Boom Cylinder (ST 2979, ST 2310): 145 mm Arm Cylinder (ST 3276): 130 mm
Arm Cylinder (ST 2970, ST 2211): 170 mm m : 1850 N·m (185 kgf·m, 1360 lbf·ft)
Bucket Cylinder (ST 2967, ST 2090): 140 mm
6. Install wear rings (22) (2 used), dust rings (23) (2
used), O-ring (19), and backup rings (20) (2 used) to
piston (25).
W158-04-02-022
W5-2-4-6
Group 2 Cylinder
10. Insert steel ball (14) into nut (16). Tighten set screw
(15). Crimp set screw (15) by using a punch (2
places).
l : 8 mm
m : 65 N·m (6.5 kgf·m, 48 lbf·ft)
dCAUTION: Fit the cylinder rod (1) assembly to the

center of cylinder tube (13) and install it in order
not to damage the rings.
11. Secure cylinder tube (13) on a workbench
horizontally. Insert the cylinder rod (1) assembly
into cylinder tube (13).
12. Tighten cylinder head (6) to cylinder tube (13) with
socket bolts (12) (14 used) (boom cylinder; socket
bolts (12) (12 used)).
Boom Cylinder
l : 17 mm
m : 510 to 530 N·m (51 to 53 kgf·m, 380 to 390
lbf·ft)
Arm Cylinder
l : 17 mm
m : 680 to 740 N·m (68 to 74 kgf·m, 500 to 550
lbf·ft)
Bucket Cylinder
l : 14 mm
m : 360 to 390 N·m (36 to 39 kgf·m, 270 to 290
lbf·ft)
W5-2-4-7
Group 2 Cylinder
(Blank)
W5-2-4-8
Group 2 Cylinder
Disassembly of Boom, Arm, and Bucket ZX330-5G Class; Serial No.040007 and up
Cylinders
Boom Cylinder
1 2 3 4 5 6 7 8 9 10
11
21 22 26 25 22 21 13 12
14
W1V7-04-02-005
28 27 23 24 23 16 15
Arm Cylinder
1 2 3 4 5 6 7 8 9 10
11
21 22 23 26 25 24 23 22 21
20
12
13
28 27 14
19 18 17 16 15 W1V7-04-02-006
W5-2-5-1
Group 2 Cylinder
Bucket Cylinder
1 2 3 4 5 6 7 8 9 10
11
21 22 13 22 21 12
14
W1V7-04-02-007
27 23 26 25 24 23
1- Cylinder Rod 9- Backup Ring 17- Stopper (2 Used) 25- Seal Ring
2- Wiper Ring 10- O-Ring 18- Cushion Bearing 26- Piston
3- Backup Ring 11- Socket Bolt (12 Used) 19- Cushion Seal 27- Cushion Bearing
4- U-Ring 12- Cylinder Tube 20- Snap Ring 28- Cushion Seal
5- Buffer Ring 13- Set Screw 21- Slide Ring (2 Used)
6- Cylinder Head 14- Steel Ball 22- Slide Ring (2 Used)
7- Bushing 15- Nut 23- Backup Ring (2 Used)
8- Retaining Ring 16- Shim 24- O-Ring
W5-2-5-2
Group 2 Cylinder
Disassembly of Boom, Arm, and Bucket Cylinders
 The procedure starts on the premise that the

pipes and the bands securing the pipes have been
removed.
4. Secure cylinder rod (1) on the special tool for
fNOTE: The arm cylinder is explained here. cylinder (ST 5908). Put the matching marks on
dCAUTION: Boom cylinder weight: 290 kg (640 lb) the ends of cylinder rod (1) and nut (15) (bucket
cylinder; piston (26)).
Arm cylinder weight: 450 kg (995 lb)
Bucket cylinder weight: 250 kg (555 lb)
1. Hoist the cylinder. Secure the cylinder horizontally
on a workbench. Drain hydraulic oil from the
cylinder.
W158-04-02-022
W102-04-02-027
2. Fully extend and support cylinder rod (1). Remove

socket bolts (11) (12 used) from cylinder head (6).
Boom Cylinder, Arm Cylinder
l : 17 mm
Bucket Cylinder
l : 14 mm
IMPORTANT: Pull out cylinder rod (1) straightly in
order not to damage the sliding surface.
3. Tap and remove cylinder head (6) with cylinder
rod (1) together from cylinder tube (12) by using a
plastic hammer.
W5-2-5-3
Group 2 Cylinder
5. Cut away the crimped part by using a hand drill. 9. Remove O-ring (10) and backup rings (9, 3) from
Remove set screw (13). Remove steel ball (14). cylinder head (6). Remove wiper ring (2), U-ring (4),
buffer ring (5), retaining ring (8), and bushing (7).
fNOTE: Set screw (13) has been crimped by using a
Special Tool for Bushing
punch at two places after installing.
l : 12 mm Bucket Cylinder (ST 8021): 95 mm
10. (Only Arm Cylinder)
Arm Cylinder
Remove stoppers (17) (2 used) from cylinder rod
l : 14 mm (1) by using a screwdriver. Remove cushion bearing
(18), cushion seal (19), and snap ring (20).
6. Remove nut (15) (bucket cylinder; piston (26)) by
using the special tool (ST 5908) and the special
tool for nut. Remove shim (16), piston (26), cushion
bearing (27), and cushion seal (28) from cylinder rod
(1).(Nut (15), shim (16), and cushion seal (28) are not
equipped for the bucket cylinder.)
(ST 3314): 115 mm
Arm Cylinder
(ST 3276): 130 mm
W158-04-02-022
7. Remove seal ring (25), slide rings (22) (2 used), slide

rings (21) (2 used), O-ring (24), and backup rings
(23) (2 used) from piston (26).
8. Remove cylinder head (6) from cylinder rod (1).
W5-2-5-4
Group 2 Cylinder
Assembly of Boom, Arm, and Bucket ZX330-5G Class; Serial No.040007 and up
Cylinders
Boom Cylinder
1 2 4 5 11 6 12 27 21 22 23 22 21 13
3 7 8 9, 10 28 26 24, 25 16 15 14 W1V7-04-02-004
Arm Cylinder
1 2 4 5 11 6 12 27 21 22 23 22 21 13 20 18
17
3 7 8 9, 10 28 26 24, 25 16 15 14 19 W1V7-04-02-003
Bucket Cylinder
1 2 4 5 11 6 12 27 21 22 23 22 21 13
3 7 8 9, 10 24, 25 26 14
W1V7-04-02-002
1- Cylinder Rod 9- Backup Ring 17- Stopper (2 Used) 25- Seal Ring
2- Wiper Ring 10- O-Ring 18- Cushion Bearing 26- Piston
3- Backup Ring 11- Socket Bolt (12 Used) 19- Cushion Seal 27- Cushion Bearing
4- U-Ring 12- Cylinder Tube 20- Snap Ring 28- Cushion Seal
5- Buffer Ring 13- Set Screw 21- Slide Ring (2 Used)
6- Cylinder Head 14- Steel Ball 22- Slide Ring (2 Used)
7- Bushing 15- Nut 23- Backup Ring (2 Used)
8- Retaining Ring 16- Shim 24- O-Ring
W5-2-5-5
Group 2 Cylinder
Assembly of Boom, Arm, and Bucket Cylinders
fNOTE: The arm cylinder is explained here. 7. Install the cylinder head (6) assembly to cylinder rod
(1).
1. Install bushing (7) to cylinder head (6).
Special Tool for Cylinder Head (Rod Outer Diameter):
Special Tool for Bushing (Rod Outer Diameter):
IMPORTANT: Face the slit in cushion seal (28) to the
IMPORTANT: Check the direction to install.
piston side. Check the direction of oil groove in
2. Install U-ring (4), backup ring (3), buffer ring (5), and cushion bearing (27).
retaining ring (8) to cylinder head (6).
8. Install cushion seal (28) to cylinder rod (1). Install
3. Install wiper ring (2) to cylinder head (6) by using a cushion bearing (27) and piston (26) to cylinder rod
plastic hammer. (1). (Cushion seal (28) is not equipped for the bucket
cylinder.)
Special Tool for Wiper Ring (Rod Outer Diameter):
Boom Cylinder (ST 8027): 100 mm 9. Install shim (16) to cylinder rod (1). Fit the matching
Arm Cylinder (ST 8022): 115 mm marks before disassembling and tighten nut (15)
Bucket Cylinder (ST 8021): 95 mm (Shim (16) is not equipped for the bucket cylinder.
Bucket cylinder; piston (26)) by using the special
4. Install O-ring (10) and backup ring (9) to cylinder
tool for cylinder (ST 5908) and the special tool for
head (6).
nut.
5. Install O-ring (24) and seal ring (25) to piston (26) by
using special tool A. After installing seal ring (25),
adjust seal ring (25) by using special tool B.
m : 9100 N·m (910 kgf·m, 6710 lbf·ft)
Special Tool A, Special Tool B (Tube Inner Diameter):
Boom Cylinder (ST 2979, ST 2310): 145 mm
Arm Cylinder (ST 2970, ST 2211): 170 mm m : 21150 N·m (2115 kgf·m, 15600 lbf·ft)
Bucket Cylinder (ST 2967, ST 2090): 140 mm Bucket Cylinder (ST 3314): 115 mm
6. Install backup rings (23) (2 used), slide rings (22) (2 m : 12200 N·m (1220 kgf·m, 9000 lbf·ft)
used), and slide rings (21) (2 used) to piston (26).
W158-04-02-022
W5-2-5-6
Group 2 Cylinder
10. Install steel ball (14) and tighten it with set screw
(13). Crimp set screw (13) by using a punch (2
places).
l : 12 mm
m : 55 N·m (5.5 kgf·m, 41 lbf·ft)

Arm Cylinder
l : 14 mm
m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

IMPORTANT: Face the slit in cushion seal (19) to the
piston side. Check the direction of oil groove in
cushion bearing (18).
11. (Only Arm Cylinder)
Install snap ring (20), cushion seal (19), cushion
bearing (18), and stoppers (17) (2 used) to cylinder
rod (1).
dCAUTION: Fit the cylinder rod (1) assembly to the

center of cylinder tube (12) and install it in order
not to damage the rings.
12. Secure cylinder tube (12) on a workbench
horizontally. Insert the cylinder rod (1) assembly
into cylinder tube (12).
13. Tighten cylinder head (6) to cylinder tube (12) with
Boom Cylinder
l : 17 mm
m : 520 N·m (52 kgf·m, 380 lbf·ft)
Arm Cylinder
l : 17 mm
m : 710 N·m (71 kgf·m, 520 lbf·ft)
Bucket Cylinder
l : 14 mm
m : 390 N·m (39 kgf·m, 290 lbf·ft)
W5-2-5-7
Group 2 Cylinder
(Blank)
W5-2-5-8
MEMO
MEMO

30t WDDE-EN-00

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PART NO.

ZX330-5G • 330LC-5G • 350H-5G • 350LCH-5G • 350K-5G • 350LCK-5G

Technical Manual (Operational Principle) : Vol. No.TODDE-EN

Quantity To Convert From Into Multiply By

fNOTE: The numerical value in this manual might be

Symbol / Name Explanation

Recognize Safety Information

Understand Signal Words

 NOTE: indicates an additional explanation for an

Follow Safety Instructions

Prepare for Emergencies

Wear Protective Clothing

You may need:

Protect Against Noise

Use Handholds and Steps

Adjust the Operator's Seat

Fasten Your Seat Belt

Move and Operate Machine Safely

Operate Only from Operator's Seat

Keep Riders off Machine

Precautions for Operations

Investigate Job Site Beforehand

Install OPG Guard

ROPS: Roll Over Protective Structure

Provide Signals for Jobs Involving Multiple

Confirm Direction of Machine to Be Driven

Drive Machine Safely

 Driving on a slope may cause the machine to slip or SA-657

Avoid Injury from Rollaway Accidents

Avoid Injury from Back-Over and Swing

Keep Person Clear from Working Area

Never Position Bucket Over Anyone

 Be careful when working on frozen ground.

Never Undercut a High Bank

Dig with Caution

Operate with Caution

Avoid Power Lines

Precautions for Lightning

Protect Against Flying Debris

Park Machine Safely

Handle Fluids Safely−Avoid Fires

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

3. Turn auto-idle switch OFF and turn mode switch to PWR

Be sure to further follow the details described in the

Practice Safe Maintenance

Before servicing the machine:

7. Remove the key from the key switch.

 If a maintenance procedure must be performed with the

Warn Others of Service Work

Support Machine Properly

Stay Clear of Moving Parts

Prevent Parts from Flying

 Travel reduction gears are under pressure.

Store Attachments Safely

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

Hot fluids and surfaces:

Replace Rubber Hoses Periodically

 Failure to periodically replace rubber hoses may cause a fire,

Avoid High-Pressure Fluids

Check Key Switch:

Check Heat Shields:

 Damaged or missing heat shields must be repaired or

Evacuating in Case of Fire

Beware of Exhaust Fumes