Ex400-5 Workshop Manual

INTRODUCTION
TO THE READER
This manual is written for an experienced technician If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using Service Manual
Revision Request Form at the end of this man-
Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition Operation Manual of the Engine
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The Operators Manual
The Parts Catalog
MANUAL COMPOSITION
This manual consists of three portions: the Techni- Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
Information included in the Technical Manual Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- NOTE:
ate lifting techniques and equipment when lifting heavy Indicates supplementary technical information or
parts. know-how.
UNITS USED
2
SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature C F C1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgfm 1.0197 mL/rev cc/rev 1.0
Nm lbfft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
This is the SAFETY ALERT SYMBOL.
When you see this symbol on your machine or in

this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe
operating practices.
001-E01A-0688 SA-688
UNDERSTAND SIGNAL WORDS
On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING,
or CAUTION - are used with the safety alert symbol.
DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death
or serious injury.
WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor
or moderate injury.
DANGER or WARNING safety signs are located

near specific hazards. General precautions are
listed on CAUTION safety signs.
Some safety signs dont use any of the SA-1223

designated signal words above after the safety
alert symbol are occasionally used on this
machine.
CAUTION also calls attention to safety messages in

this manual.
To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could
result in damage to the machine.
NOTE indicates an additional explanation for an

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

chine and all safety messages in this manual.
Safety signs should be installed, maintained and re-

placed when necessary.
If a safety sign or this manual is damaged or miss-

ing, order a replacement from your authorized
dealer in the same way you order other replace-
ment parts (be sure to state machine model and
serial number when ordering).
SA-003
Learn how to operate the machine and its controls

correctly and safely.
Allow only trained, qualified, authorized personnel to

operate the machine.
Keep your machine in proper working condition.
Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.
The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of ma-
chines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES
Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.

Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
To ensure that a fire-extinguisher can be always
used when necessary, check and service the fire-
extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
Establish emergency procedure guidelines to
cope with fires and accidents.
Keep emergency numbers for doctors, ambu- SA-437
lance service, hospital, and fire department

posted near your telephone.
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.
Operating equipment safely requires the full

attention of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause

impairment or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434 SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.
In the walk-around inspection be sure to cover all

points described in the PRE-START
INSPECTION chapter in the operators manual.
S007-E01A-0435
SA-435
SA-3
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 operators work
boots the operators foot may slip off the pedal,
possibly resulting in a personal accident.
Dont leave parts and/or tools lying around the op-

erators seat. Store them in their specified loca-
tions.
Avoid storing transparent bottles in the cab. Dont

attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
Refrain from listening to the radio, or using music

headphones or mobile telephones in the cab while
operating the machine.
Keep all flammable objects and/or explosives

away from the machine.
After using the ashtray, always cover it to extin-

guish the match and/or tobacco.
Dont leave cigarette lighters in the cab. When the

temperature in the cab increases, the lighter may
explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you mounting and dismounting the ma-

chine, always face the machine and maintain a
three-point contact with the steps and handrails.
Do not use any controls as hand-holds.
Never jump on or off the machine. Never mount or

dismount a moving machine.
SA-439
Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
008-E01B-0439
ADJUST THE OPERATOR'S SEAT
A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator
leading to misoperations.
The seat should be adjusted whenever changing

the operator for the machine.
The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
If not, move the seat forward or backward, and
check again. SA-378
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
If the machine should overturn, the operator may

become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
Prior to operating the machine, thoroughly

examine webbing, buckle and attaching hardware.
If any item is damaged or worn, replace the seat
belt or component before operating the machine.
Be sure to remain seated with the seat belt SA-237
securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over.
Take extra care not to run over bystanders.

Confirm the location of bystanders before moving,
swinging, or operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-426
machine.
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious
injury or death.
Start the engine only when seated in the

operator's seat.
NEVER start the engine while standing on the
track or on ground.
Do not start engine by shorting across starter
terminals. SA-444
Before starting the engine, confirm that all control
levers are in neutral.
012-E01B-0444
JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to

follow the instructions shown in the OPERATING
THE ENGINE chapter in the operators manual.
The operator must be in the operators seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures SA-032
could result in a battery explosion or a runaway
machine.
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
Only the operator should be on the machine.

Keep riders off.
Riders also obstruct the operators view, resulting
in the machine being operated in an unsafe
manner.
SA-379
014-E01B-0379
PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES
For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal persons directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
Incorrect travel pedal/lever operation may result in

serious injury death.
Before driving the machine, confirm the position of

the undercarriage in relation to the operators po-
sition. 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
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the di-
rection 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. Dont allow personnel to stay around
the machine while traveling.
SA-387
Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-388
SA-441
Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
to ensure sage operation.
019-E01D-0492
SA-589
SA-9
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
machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.
Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK
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 a reasonable distance from other machines.
SA-392
020-E08A-0493
SA-10
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.
SA-383
Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person. SA-384
No machine motions shall be made unless signals

are clearly understood by both signalman and
operator.
Learn the meanings of all flags, signs, and

markings used on the job and confirm who has
the responsibility for signaling.
Keep windows, mirrors, and lights clean and in

good condition.
Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper
lighting.
Read and understand all operating instructions in

the operators manual.
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE---SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU

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

operating on a grade, possibly resulting in serious SA-012
injury or death.
To avoid tipping:
Be extra careful before operating on a grade.
Prepare machine operating area flat.

Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or
slipping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper SA-440
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.
S025-E01B-0495
SA-12
SAFETY
AVOID POWER LINES
Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
When operating near an electric line, NEVER

move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
Check and comply with any local regulations that
may apply.
Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site. SA-381
029-E01A-0381
OBJECT HANDLING
If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
When using the machine for craning operations,

be sure to comply with all local regulations.
Do not use damaged chains or frayed cables,
sables, slings, or ropes.
Before craning, position the upperstructure with
the travel motors at the rear.
Move the load slowly and carefully. Never move it
suddenly.
Keep all persons well away from the load.
Never move a load over a person's head.
Do not allow anyone to approach the load until it is
SA-014
safely and securely situated on supporting blocks
or on the ground.
Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-13
SAFETY
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,

serious injury may result.
Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
Keep bystanders away from the working area
before striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY
To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle / acceleration selector and H/P
mode switch off.
Run engine at slow idle speed without load for 5
minutes.
Turn key switch to OFF to stop engine.
Remove the key from the key switch.
Pull the pilot control shut-off lever to the LOCK
position. SA-390
Close windows, roof vent, and cab door.
Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELY
AVOID FIRES
Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
Do not refuel the machine while smoking or when

near open flame or sparks.
Always stop the engine before refueling the
machine.
Fill the fuel tank outdoors.
All fuels, most lubricants, and some coolants are SA-018

flammable.
Store flammable fluids well away from fire

hazards.
Do not incinerate or puncture pressurized
containers.
Do not store oily rags; they can ignite and burn
spontaneously.
Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-15
SAFETY
SAFETY TRANSPORTING
The danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
Be sure to observe local regulations when

transporting the machine on public roads.
Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /

unloading the machine: SA-395
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation of
a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.
S035-E08A-0395
SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before doing

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

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes. SA-028
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a Do Not Operate tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
If a maintenance procedure must be performed

with the engine running, do not leave machine
unattended.
If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
Never work under a machine raised by the boom.
Inspect certain parts periodically and repair or SA-527
replace as necessary. Refer to the section

discussing that part in the MAINTENANCE
chapter in the operators manual.
Keep all parts in good condition and properly
installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
When cleaning parts, always use nonflammable
detergent oil. Never use highly frammable oil such
as fuel oil and gasoline to clean parts or surfaces.
Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
Illuminate your work area adequately but safely.
S500-E02B-0497
SA-17
SAFETY
Use a portable safety light for working inside or
under the machine.
Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
Always use a work light protected with a guard. In SA-037
case the light bulb is broken, spilled fuel, oil

antifreeze fluid, or window washer fluid may catch
fire.
S500-E02B-0497
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.
S501-E01A-0287
SA-287
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
SA-527
machine that is supported solely by a jack.
519-E01A-0527
STAY CLEAR OF MOVING PARTS
Entanglement in moving parts can cause serious

injury.
To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-18
SAFETY
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.
As pieces may fly off, be sure to keep body and
face away from valve.
Travel reduction gears are under pressure.

SA-344
As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY
Stored attachments such as buckets, hydraulic

hammers, and blades can fall and cause serious
injury or death.
Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.
SA-034
504-E01A-0034
USE TOOLS PROPERLY
Use tools appropriate for the work to be done.

Makeshift tools, parts, and procedures can create
safety hazards.
For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
Use only recommended replacement parts.
(See the parts catalog.)
SA-040
S522-E01A-0040
SA-19
SAFETY
PREVENT BURNS
Hot spraying fluids:
After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the SA-039
stop. Allow all pressure to be released before
removing the cap.
The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
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.
SA-225
Wait for the oil and components to cool before

starting any maintenance or inspection work.
505-E01B-0498
REPLACE RUBBER HOSES

PERIODICALLY
Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
Periodically replace the rubber hoses. (See the

page of Periodic replacement of parts in the
operators manual.)
SA-019
Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may
result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard; take
care to protect hands and body from high- SA-031
pressure fluids. Wear a face shield or goggles for

eye protection.
If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E03A-0499
SA-044
SA-21
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- SA-019
cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
Short circuits can cause fires.
Clean and tighten all electrical connections.

Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
Check before starting work for missing or
damaged terminal caps.
DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris,

accumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the

machine daily and by removing spilled or
accumulated flammables immediately.
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.
S508-E02B-0019
SA-22
SAFETY
Check Emergency Engine Stop Switch:
If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:

Damaged or missing heat shields may lead to fires.
Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S508-E02B-0019
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.
SA-393
In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on EMERGENCY
EXIT in Operators Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.
If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND

GRINDING
Welding may generate gas and/or small fires.

Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before start-
ing grinding.
After finishing welding and grinding, recheck that SA-818
there are no abnormalities such as the area sur-

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

FLUID LINES
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
SA-030
hoses or other materials before engaging in
welding, soldering, etc..
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
Do not weld or flame cut pipes or tubes that

contain flammable fluids.
Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030
SA-24
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 SA-029
dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
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 ob-
ject across the posts. Use a voltmeter or hy-
drometer.
Do not charge a frozen battery; it may explode.
Warm the battery to 16 C ( 60 F ) first.
Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion SA-032
of the battery may result.
Loose terminals may produce sparks. Securely
tighten all terminals.
Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
Be sure to wear eye protection when checking

electrolyte specific gravity.
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold

contact burn.
Refer to the freon container for proper use when

servicing the air conditioning system.
Use a recovery and recycling system to avoid
venting freon into the atmosphere.
Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
Check the MSDS before you start any job using a SA-309
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.
S515-E01A-0309
SA-26
SAFETY
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do

not use food or beverage containers that may
mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain,
or into any water source.
Air conditioning refrigerants escaping into the air SA-226
can damage the Earths atmosphere.
Government regulations may require a certified air
conditioning service center to recover and recycle
used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
After maintenance or repair work is complete,

confirm that:
The machine is functioning properly, especially
the safety systems.
Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 1
GENERAL INFORMATION
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling........................................... W1-1-1
Maintenance Standard Terminology........ W1-1-6
Group 2 Tightening
Tightening Torque Specification.............. W1-2-1
Torque Chart .......................................... W1-2-3
Piping joint ............................................. W1-2-6
Periodic Replacement of Parts ............. W1-2-10
166W-1-1
(Blank)
166W-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
Clean the Machine Precautions for Disassembling
Thoroughly wash the machine before bringing it into To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop may removed pipes.
cause machine components to be contaminated Before disassembling, clean the exterior of the
during disassembling/assembling, resulting in components and place it on a work bench.
damage to machine components, as well as Before disassembling, drain gear oil from the
decreased efficiency in service work. reduction gear.
Be sure to provide appropriate containers for
draining fluids.
Inspect the Machine Use matching marks for easier reassembling.
Be sure to use the specified special tools, when
Be sure to thoroughly understand all dis- instructed.
assembling/assembling procedures beforehand, to If a part or component cannot be removed after
help avoid incorrect disassembling of components removing its securing nuts and bolts, do not
as well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. Orderly arrange disassembled parts. Mark and
tag them as necessary.
The machine model, machine serial number, and Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). Inspect the contact or sliding surfaces of
Clogging of filters and oil, water or air leaks, if any. disassembled parts for abnormal wear, sticking,
Capacities and condition of lubricants. or other damage.
Loose or damaged parts. Measure and record the degree of wear and
clearances.
Prepare and Clean Tools and Disassembly Area
Precautions for Assembling
Prepare the necessary tools to be used and the area
for disassembling work. Be sure to clean all parts and inspect them for any
damage. If any damage is found, repair or replace
it.
Dirt or debris on the contact or sliding surfaces
may shorten the service life of the machine. Take
care not to contaminate any contact or sliding
surfaces.
Be sure to replace O-rings, backup rings, and oil
seals with new ones once they are disassembled.
Apply a film of grease before installing.
Be sure that liquid-gasket-applied surfaces are
clean and dry.
If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to
remove the agent.
Utilize matching marks when assembling.
Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
Keep a record of the number of tools used for
disassembly/assembly. After assembling is
complete, count the number of tools, so as to
make sure that no tools are missing.
W1-1-1
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or cylin-
der is done, bleed air from the hydraulic system in the
following procedures:
IMPORTANT: If the engine is started with air

trapped in the hydraulic pump hous-
ing, damage to the pump may result.
If the hydraulic motor is operated
with air trapped in the hydraulic mo-
tor housing, damage to the motor
may result.
If the cylinder is operated with air
trapped in the cylinder tube, damage
to the cylinder may result.
Be sure to bleed air before starting
the engine.
Bleeding Air from Hydraulic Pump
Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
After bleeding all the air, securely tighten the plug.
Bleeding Air from Travel Motor / Swing Motor
With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
Bleeding Air from Hydraulic Circuit
After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
for approx. 5 minutes.
Reposition the front attachment to check hydraulic
oil level.
Stop the engine. Recheck hydraulic oil level. Re-
M104-07-021
plenish oil as necessary.
W1-1-2
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check the slide surface on seal ring surface

(A) for scuffing, scoring, corrosion, deformation B W105-03-05-019
or uneven wear.
(3) Check O-ring (B) for tears, breaks, deformation

or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting

bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect
(2) Clean the floating seal and seal mounting

bores. Check the bore surface for scuffing or
scoring by touching the surface with finger.
(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating face
a a
(C) by measuring the distances seal ring
A
surface (A) and seal mating face (C) at point
(a) and (b), as illustrated. If these distances
differ, correct the O-ring seating. B
b b
a=b ab
W110-03-05-004
W1-1-3
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

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

When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load. W105-04-01-008
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
Avoid using twisted, bound, connected, or hitched
slings.
Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions. Bent Sling W162-01-01-009
Avoid dragging slings on the ground, throwing
slings or pushing slings with a metal piece.
When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
Store the nylon slings indoors so they wont dete-
riorate with heat, sun light, or chemicals.
W1-1-4
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-5
MAINTENANCE STANDARD TERMINOL-
OGY
Standard
1. Dimension for parts on a new machine.
2. Dimension of components or assemblies adjusted

to specification.
Both dimensions are shown with tolerances as

necessary.
Allowable Limit
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or replacement is required before reaching

this limit.
Machine performance will decrease, and

maintenance and down time expense will increase as
machine operating hours accumulate. It is
recommended that parts are repaired or replaced
before reaching the Allowable Limit.
W1-1-6
GENERAL INFORMATION / Tightening
TIGHTENING TORQUE SPECIFICATIONS
Bolt and Nut on Base Machine Standard Torques
Wrench
Bolt Dia Torque
No. Location Qty Size
mm (mm) Nxm (kgfxm) (lbfxft)
1 Engine-cushion Front 22 2 32 740 (75) (540)
rubber mount- Engine-cushion rubber 22 2 32 740 (75) (540)
ing bolt Rear
Cushion rubber-machine 16 4 24 265 (27) (195)
2 Engine bracket mounting bolt 14 8 22 175 (18) (130)
3 Radiator mounting bolt 16 4 24 205 (21) (152)
4 Hydraulic oil tank mounting bolt 16 8 24 205 (21) (152)
5 Fuel tank mounting bolt 16 8 24 205 (21) (152)
6 3 -12UNF
1
ORS fittings for Hydraulic hoses and piping 16 36 175 (18) (130)
7 -12UNF
1 16

Fittings 41 205 (21) (152)
7 Pump transmission mounting bolt 12 12 19 88 (9) (65)
8 Pump mounting bolt 20 4 30 390 (40) (290)
9 Control valve mounting bolt (hexagon wrench) 20 4 17 390 (40) (290)
10 Swing device mounting bolt 22 26 32 740 (75) (540)
11 Swing motor mounting bolt (hexagon wrench) 18 24 14 295 (30) (220)
12 Battery mounting nut 8 3 13 19.5 (2) (14.5)
13 Cab mounting nut 16 6 24 205 (21) (152)
14 Swing bearing mounting bolt to upperstructure 27 36 41 1370 (140) (1010)
Swing bearing mounting bolt to undercarriage 27 36 41 1370 (140) (1010)
15 Travel device mounting bolt 22 40 32 740 (75) (540)
Travel motor mounting bolt 18 8 27 390 (40) (290)
Sprocket mounting bolt 22 48 32 740 (75) (540)
16 Upper roller mounting STD, H 18 16 27 390 (40) (290)
LC, LCH 18 24 27 390 (40) (290)
17 Lower roller mounting bolt STD, H 22 64 32 740 (75) (540)
LC, LCH 22 72 32 740 (75) (540)
18 Track Shoe bolt STD, H 24 392 32 1370 (140) (1010)
LC, LCH 24 424 32 1370 (140) (1010)
Continued on next page
W1-2-1
Bolt Dia Wrench Size Torque

No. Location Qty
mm (mm) Nxm (kgfxm) lbfxft
19 Track guard mounting bolt STD 22 28 32 740 (75) (540)
LC 22 36 32 740 (75) (540)
H 22 40 32 740 (75) (540)
LCH 22 40 32 740 (75) (540)
20 Track mounting bolt 33 36 50 1720 (175) (1260)
21 Coupling and clamp Coupling 8 13 10.5 to (1.05 to (7.6 to
of low preddure 12.5 1.26) 9.1)
piping Clamp 1 11 9.8 (1.0) (7.2)

4 -28
UNF
22 Counterweight mounting bolt 45 2 65 2350 (240) (1740)
Counterweight lock bolt 24 4 36 440 (45) (330)
23 Front pin lock bolt 20 15 30 390 (40) (290)
Front pin lock nut 20 7 30 390 (40) (290)
24 Front pin retain bolt (Loading shovel) 12 4 19 88 (9) (65)
16 6 24 205 (21) (152)
20 36 24 265 (57) (195)
12 30 540 (55) (398)
NOTE: 1. When tightening bolts and nuts, apply a

lubricant to threads to reduce friction.
(i.e.: White zinc B
dissolved into spindle oil)
2. Remove rust, soil, and dust before
tightening.
3. Use LOCTITE to the engine cushion
rubber mounting nuts and the lower
roller mounting bolts.
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and parts
create safety hazards. If an incorrect tool is
used, the tool may slip or come off or break,
resulting in personal injury.
Bolt Types
When tightening bolts and nuts, use the specified

torque. Bolts are classified according to materals and
applications. Be sure to use the correct bolts and nuts,
and tighten them to specification. SA-040
Hexagon 10.9 Bolt Hexagon 8.8 Bolt Hexagon 4.8 Bolt Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart
Bolt Wrench Hexagon

10.9 Bolt 8.8 Bolt, Socket bolt 4.8 Bolt
Dia. Size Wrench
Size Nxm kgfxm lbfxft Nxm kgfxm lbfxft Nxm kgfxm lbfxft
M 8 13 6 29.5 3 22 19.5 2 14.5 9.8 1 7.2
M 10 17 8 64 6.5 47 49 5 36 19.5 2 14.5
M 12 19 10 108 11 80 88 9 65 34 3.5 25.5
M 14 22 12 175 18 130 137 14 101 54 5.5 40
M 16 24 14 265 27 195 205 21 152 78 8 58
M 18 27 14 390 40 290 295 30 220 118 12 87
M 20 30 17 540 55 400 390 40 290 167 17 123
M 22 32 17 740 75 540 540 55 400 215 22 159
M 24 36 19 930 95 690 690 70 505 275 28 205
M 27 41 19 1370 140 1010 1030 105 760 390 40 290
M 30 46 22 1910 195 1410 1420 145 1050 540 55 400
M 33 50 24 2550 260 1880 1910 195 1410 740 75 540
M 36 55 27 3140 320 2310 2400 245 1770 930 95 690
W1-2-3
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to nuts
and bolts to reduce their friction
coefficients.
The plated bolts require no lubri-
cant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts that
are too short cannot develop suf-
ficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them alter-

nately, as shown, to ensure even tightening.
Tighten from center and diago-
Equally tighten upper and lower alter- Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
Service Recommendations for Spilt Flange
IMPORTANT: 1. Be sure to clean and Inspect seal-

ing surfaces. Scratches / rough-
ness cause leaks and seal wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
nent.
W105-01-01-015
2. Be sure to use only specified O-
WRONG
rings. Inspect O-rings for any
damage. Take care not to file O-
ring surfaces. When installing an
O-ring into a groove, use grease
to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
W105-01-01-016
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes tight- W105-01-01-008
ening of one bolt fully before RIGHT WRONG
tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.
Bend along edge sharply Do not bend it round

Nut and Bolt Locking
RIGHT RIGHT WRONG
Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tight- Bend along edge sharply
ening, not while loosening. W105-01-01-009
RIGHT RIGHT WRONG

Lock Wire
IMPORTANT: Apply wire to bolts in the bolt-
tightening direction, not in the bolt-
loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-5
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart are for

general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adaptor (l) and

hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37
30
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
2. Scratches or other damage to

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

Description mm mm Torque
Union Nut Hose Fittings Nm (kgfm, lbfft)
30male 19 19 59 (6,44)
22 22 98 (10,72)
27 27 118 (12,87)
36 36 235 (24,173)
41 41 295 (30,218)
50 50 490 (50,361)
60 60 670 (68,494)
70 70 980 (100,723)
37female 19 17 44 (4.5,32)
22 19 59 (6,44)
27 22 118 (12,87)
36 30,32 235 (24,173)
41 36 295 (30,218)
50 46 490 (50,361)
NOTE: Tightening torque of 37male coupling without union is similar
to tightening torque of 37female.
W1-2-6
O-ring Seal Joint 7 6 9
O-ring (6) seats against the end face of adaptor (7) to

seal pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 10
in O-ring groove (e). Tightening M104-07-033
nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring Wrench Size Wrench Size Tightening
groove (e) or sealing surface (10). mm mm Torque
Damage to O-ring (6) will cause Union Nut Hose Fittings Nm (kgfm, lbfft)
oil leakage. 19 17 59 (6,44)
4. If nut (9) is loose and oil is leak- 22 19 98 (10,72)
ing, do not re-tighten nut (9). Re- 27 22 118 (12,87)
place O-ring (6) with a new one 36 30,32 235 (24,173)
and check that O-ring (6) is cor- 41 36 295 (30,218)
rectly seated in place, tighten nut 50 46 490 (50,361)
(9).
W1-2-7
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018
(This machine is equipped with male-type taper thread
screwed joints except at the inspection joints.) Male Tapered Thread
Wrench Size Tightening
mm Torque
Hose Fittings Nm (kgfm, lbfft)
17,19 59 (6,44)
19,22 98 (10,72)
27,22 118 (12,87)
36,32 235 (24,173)
41 295 (30,218)
50 490 (50,301)
60 670 (68,494)
70 980 (100,723)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.
Application Procedure W105-01-01-019
Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs de-

pending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp: 4.4 Nm
(0.45 kgfm, 3.25 lbfft )
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp: 5.9 to 6.9 Nm
(0.6 to 0.7 kgm, 4.3 to 5.1 lbfft)
M114-07-043 M114-07-042
W1-2-8
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.
Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose rup-
ture or separation of fitting. Utilize Print WRONG RIGHT
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other
If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deteriora-
tion, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regardless
of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years
Engine Fuel hose (Fuel tank to injection pump) Every 2 years
Heater hose (Heater to engine) Every 2 years
Pump suction hose Every 2 years
Base Machine
Pump delivery hose Every 2 years
Hydraulic Swing hose Every 2 years
System Boom cylinder line hose Every 2 years
Front Arm cylinder line hose Every 2 years
Attachment Bucket cylinder line hose Every 2 years
Pilot hose Every 2 years
NOTE: Be sure to replace seals, such as O-rings

and
gaskets, when replacing hoses.
W1-2-10
MEMO
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SECTION 2
UPPERSTRUCTURE
CONTENTS

Group 1 Cab Disassemble Control Valve 5 ............. W2-5-34
Remove and Install Cab ...................... W2-1-1 Assemble Control Valve 5.................. W2-5-36
Dimensions of the Cab Glass .............. W2-1-7
Group 6 Swing Device
Group 2 Counterweight Remove and Install Swing Device........ W2-6-1
Remove and Install Counterweight ...... W2-2-1 Disassemble Swing Device.................. W2-6-4
Remove and Install Counterweight (With Assemble Swing Device .................... W2-6-10
Counterweight Removal Device) ........ W2-2-3 Disassemble Swing Motor ................. W2-6-14
Assemble Swing Motor ...................... W2-6-18
Group 3 Main Frame Maintenance Standard....................... W2-6-22
Remove and Install Main Frame .......... W2-3-1
Group 7 Pilot Valve
Group 4 Pump Device Remove and Install Right
Remove and Install Pump Device ........ W2-4-1 Pilot Valve (Front Attachment) ........... W2-7-1
Disassemble Pump Transmission........ W2-4-4 Remove and Install Left
Assemble Pump Transmission ............ W2-4-8 Pilot Valve (Front Attachment) ........... W2-7-5
Remove and Install Main Pump ......... W2-4-11 Remove and Install
Disassemble Main Pump ................... W2-4-14 Travel Pilot Valve ............................... W2-7-9
Assemble Main Pump........................ W2-4-20 Disassemble Front Attachment
Maintenance Standard ...................... W2-4-24 Pilot Valve........................................ W2-7-12
Disassemble Regulator ..................... W2-4-26 Assemble Front Attachment
Assemble Regulatoer ........................ W2-4-28 Pilot Valve........................................ W2-7-14
Disassemble and Assemble Disassemble Travel Pilot Valve.......... W2-7-18
Pilot Pump ....................................... W2-4-30 Assemble Travel Pilot Valve .............. W2-7-20
Bucket Open / Close and
Group 5 Control Valve Breaker Pilot Valve .......................... W2-7-24
Remove and Install Control Valve ........ W2-5-1 Assemble Bucket Open / Close and
Disassemble Control Valve 1 ............... W2-5-4 Breaker Pilot Valve .......................... W2-7-26
Assemble Control Valve 1.................... W2-5-8
Disassemble Control Valve 2 ............ W2-5-14 Group 8 Pilot Shut-Off Valve
Assemble Control Valve 2.................. W2-5-16 Remove and Install
Disassemble Control Valve 3 ............. W2-5-18 Pilot Shut-off Valve ............................ W2-8-1
Assemble Control Valve 3.................. W2-5-24 Disassemble Pilot Shut-off Valve ......... W2-8-4
Disassemble Control Valve 4 ............. W2-5-30 Assemble Pilot Shut-off Valve.............. W2-8-6
Assemble Control Valve 4.................. W2-5-32
166W-2-1
Group 9 Shockless Valve
Remove and Install Front Attachment
Shockeless Valve .............................. W2-9-1
Disassemble and Assemble Front
Attachment Shockless Valve.............. W2-9-3
Remove and Install Travel
Shockless Valve ................................ W2-9-7
Disassemble and Assemble
Travel Shockless Valve...................... W2-9-9
Group 10 Solenoid Valve

Remove and Install Three-Spool
Solenoid Valve................................. W2-10-1
Disassemble and Assemble
Three Spool Solenoid Valve ............. W2-10-3
166W-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Remove Cab
1. Remove seat mounting nuts (2) and (1).
: 13 mm
W157-02-01-005
2. Remove bolt (5) in the cab rear section, bolt (6) in

rear boxes (3 and 4) and rear boxes (3 and 4).
: 13 mm
3. Remove bolts (8) and lower cover (7) of the rear 3

box.
6
5
: 13 mm
6
5 8
4
W157-02-01-017
4. Remove filter (24), screw (9) and duct (10) from

the cab.
24 9
10 W158-02-01-001
W2-1-1
5. Disconnect harness connectors (11) located at the
rear inside the cab.
NOTE: Number of connectors differs depending on

the machine serial No.
11
6. Disconnect connectors for wiper limit switch (12), W166-02-01-001
cab light (13), speaker (14), antenna (15) and

ground (17) located in the cab.
Remove washer vinyl hose(16) located behind the 13 14
12
cab.
15
17
16 W162-02-01-002
7. Remove caps (20) from duct cover (18). Remove

screws (19) and duct cover (18). 18
20 19
W158-02-01-002
Duct Mating Face

21
8. While pushing the mating face of duct (21) back-
ward, remove duct (21).
W157-02-01-011
W2-1-2
9. Attach the sling belts to the top of the cab.
CAUTION: Cab weight:

Standard cab : 260 kg (573 lb)
Headguard-Integrated cab : 470 kg (1036 lb)
W157-02-01-009
10. Remove cab mounting bolts (22) and nuts (23).
: 17 mm 22
: 24 mm
: 8 mm
23
23
W157-02-01-010
11. Slowly lift the cab with a crane to remove the cab
from the machine.
W157-02-01-001
W2-1-3
Install Cab
1. Attach cab to crane with sling belts and install cab

onto the machine.
CAUTION: Cab weight:

Standard cab: 260 kg (573 lb)
Headguard-Integrated cab: 470 kg (1036 lb)
W157-02-01-001
22
2. Tighten cab mounting bolts (22) and nuts (23).
: 17 mm
: 49 Nxm (5 kgfxm, 36 lbfxft)
: 24 mm
23
: 8 mm
23
64 Nxm (6.5 kgfxm, 47 lbfxft) W157-02-01-010
3. Install duct (10) into the cab and tighten screw (9).
Install filter (24).
: 4.9 Nxm (0.5 kgfxm, 3.6 lbfxft)
24
9
10 W158-02-01-001
4. Connect harness connectors (11) at the rear,

inside the cab.
NOTE: Number of connectors differs depending on

the machine serial No.
11 W166-02-01-001
W2-1-4
5. Connect wiper limit switch (12), cab light (13),
speaker (14), antenna (15) and ground (17) in the
cab.
Connect washer vinyl hose (16) behind the cab. 13 14
12
: 19.5 Nxm (2 kgfxm, 14.5 lbfxft)
15
17
16 W162-02-01-002
6. Install rear box lower cover (7) and tighten bolts

(8).
: 13 mm
6
7. Install rear boxes (3 and 4) and tighten bolts (5 5
and 6).
6
: 13 mm
5 8
: 19.5 Nxm (2 kgfxm, 14.5 lbfxft) 4
W157-02-01-017
8. Push duct (21) to the cab front until the duct

mating face comes in contact.
Duct Mating Face
21
W157-02-01-011
W2-1-5
9. Install duct cover (18). Tighten screws (19) and
put caps (20) on.
18
20 19
10. Install seat (1) and tighten nuts (2). W158-02-01-002
: 13 mm
W157-02-01-005
W2-1-6
DIMENSIONS OF THE CAB GLASS
Standard Cab R2
A
Unit: mm
25.106
R11516
3.015
NOTE: 1 mm=0.03937 in
221.399R70
+10
4-13 1
(64.74)
R78142.25
Section A
Chamfer
both R9487
fringes 30
580
360.78 (87.81) Chamfer fringe
(5 mm) corners.
391.8 R3018 4
R118
51.03
154.81
188.5
R15
66.84
164.12 43.59
558.78
230.50
222.65
B 15
216. 73
All Around All Around

c1 c1
2-R59 R11509
R2309
900. 7
(4 mm) R4009
905
R9509 R1009
Section B R209 R509

R4009
R84
63.97
NOTE:Material: JIS-R3211, R3212 66.41
ANSI-AS2
87.84
ECE-ANNEX5 or 947.152
35.73
equivalent
756
4-R62
612
(5 mm)
W157-02-01-013
W2-1-7
Unit: mm
Chamfer fringe corners.
NOTE: 1 mm=0.03937 in
208 337.51.0
333.51.0 (38.5)
113.9 Chamfer fringe 22.5
corners.
9.2
R3
10.6
R30 R72.5 D
R105
7735.4
R2285.4 (4 mm) Chamfer 39.5 3.1
both 728.51.0
39.5 61.8 R3985.4 Chamfer fringes
both fringes Section C and D 40
C
488.5
40 2 12.2 +0.5
0
728.51.0 R120885.4
475.8 212.2 +0.5
0 290
2R4
60.1 (4 mm)
R1985.1
3R4 398.51.0
Chamfer fringe
5031.0 corners.
(38.5)
541.5
Chamfer fringe corners.
468.17
90.672
45.67
R2590
2R5
R2477
R5175
904.13
R3877
980 R8075
753.99
740.51
19.70
8 890.03 74.95 213.97 (5 mm)
R120
4R5 R12095 165 R12.5
227.39
276.58
R1145
3701.0 R1995
19.29
R895 R595 516.26
R295 33.60
R345 (5 mm) 549.86
11.22 39.63
18 50.71
8331.0 59
910
W157-02-01-014
W2-1-8
Headguard-Integrated Cab 416+0.5 -1.5
Unit: mm
NOTE: 1 mm=0.03937 in
4-R61
484
(4 mm)
811+0.5 -1.5
327
442.5+0.5 -1.5
753+0.5 -1 220.9
3-R61
857.5+0.5 -1 (5 mm)
915.8+0.5 -1
R191
973.9+0.5 -1
58.3
NOTE:Material: JIS-R3211, R3212 826+0.5 -1.5
ANSI-AS2
ECE-ANNEX5 or
equivalent 4-R73
2-R153
+0.5
1154 -1.5 (6 mm) R82
431
120
826+0.5 -1.5
304+0.5 -1.5 (6 mm) 4-R73
W166-02-01-005
W2-1-9
Unit: mm NOTE:Material: JIS-R3211, R3212

NOTE: 1 mm=0.03937 in ANSI-AS2
ECE-ANNEX5 or
equivalent
176 4151 262
R5 R5
2-R75.4
(376) 2-R75.4
383
2-11.2+0 -1 (4 mm)
2-11.2+0.5 -0
40
7271 7271
4 mm
40 39+0 -1
351
(344) 292.5
292.5 39+0 -1
R5 R5
3981
453 138
591
4231.0
4-R61
549
(5 mm)
873.51.0
769
140
324.5
305 6-R73
(5 mm)
5.14+0.5 -1.5
374
453.51.0
209
243 513 W166-02-01-006
8.46+0.5 -1.5
W2-1-10
Unit: mm
NOTE: 1 mm=0.03937 in
Serial Number 7495 and up (EX450H-5)
Serial Number 7670 and up (EX450LCH-5)
150
2-12
30
(4 mm) 435+0.5 -2
4-R41
720+0.5 -2
Serial Number 7495 and up (EX450H-5)

Serial Number 7670 and up (EX450LCH-5)
150
2-12
NOTE:Material: JIS-R3211, R3212 30
ANSI-AS2
ECE-ANNEX5 or (4 mm) 535+0.5 -2
equivalent
4-R41
720+0.5 -2
W166-02-01-007
W2-1-11
Cab Glass Installation Method
Mounting Rubber Section
Standard Cab
Procedure of installing left-hand cab glass Mounting Rubber
1. Install the mounting rubber on cab glass. Put and
fasten mounting rubber onto the mounting face of Cab Glass
cab.
IMPORTANT: Be sure to install the cab glass and Cab

mounting rubber using the special
Seal Rubber
bonding agent. The cab glass may
fall if the special bonding agent is
not used. The cab glass assembly
cant be replaced individually. Be
sure to change the cab glass as a W216-02-01-004
unit.
Procedure of installing right-hand cab glass

1. Insert mounting rubber into the surrounding of cab
glass. Stick the connectors of mounting rubber
with the bonding agent (Cemedine 366 Standard
or equivalent). W216-02-01-002
Mounting Rubber Section
NOTE: Rubber aging will cause the contraction of
rubber, be sure to leave a little bit long, and Cab Glass Mounting
Rubber
stick by pressing.
2. Put and fasten the mounting rubber on the mount-

ing face of cab, after installing rubber. Cab
W216-02-01-005
W216-02-01-006
W2-1-12
Procedure of installing rear cab glass
1. Insert mounting rubber around the cab glass. In- Mounting Rubber Section
stall the connectors of mounting rubber with the
bonding agent (Cemedine 366 Standard or Mounting Cab Glass
equivalent). Rubber

NOTE: Rubber aging will cause the rubber to con-
tract rubber, be sure to leave a little extra, Stopper
install by pressing with hands.
2. After installing glass assembly on the cab, insert

Cab
the stopper into rubber.
W216-02-01-003
W216-02-01-007
W2-1-13
Headguard-Integrated Cab Mounting Rubber Section
Procedure of installing front and both side cab glass
1. Insert mounting rubber into the surrounding of cab Cab Glass
Mounting Rubber
glass. Stick the connectors of mounting rubber
with the bonding agent (Cemedine 366 Standard
or equivalent).
NOTE: Rubber aging will cause the contraction of

rubber, be sure to leave a little bit long, and Cab
stick by pressing.
2. Put and fasten the mounting rubber on the mount-

ing face of cab, after installing rubber. W166-02-01-008
W166-02-01-009
W166-02-01-010
W166-02-01-011
W2-1-14
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUN-
TERWEIGHT
Removal
CAUTION: Counterweight weight: 9300 kg

(20500 lb)
1. Install lifting accessories and wire ropes to sling

brackets on the top of the counterweight. Set the
wire rope taut using a crane.
CAUTION: Watch out the power-wrench re-

action bar movement. Take care not to be hit
the reaction bar. W166-02-02-002
2. Using a power wrench, remove bolts (10), nuts (8),

shims (7), and washers (9).
1 2
NOTE: Shims (7) are used only when any gap 3 7
between nuts (8) and the lock brackets 4 8
5 9
exist. When no gap exists, shims are not 6
required.
1
2
: 65 mm
7
3
3. Remove bolts (1), lock washers (2), washers (3),
4
and spacers (4). If shims (5 and 6) are provided, 5
remove shims (5 and 6). 6
8 9
9
: 36 mm 10
W166-02-02-003
4. Remove the counterweight using a crane.
9
7
10
8
9
3
1, 2
W166-02-02-001
6, 5, 4
W2-2-1
Installation
CAUTION: Counterweight weight: 9300 kg

(20500 lb)
1. Install lifting accessories and wire ropes to sling

brackets on the top of the counterweight. Then, lift
the counterweight by crane.
CAUTION: Do not allow anyone under the

lifted counterweight.
2. Insert protrusions on the counterweight into holes

on the frame to install the counterweight.
W166-02-02-002
CAUTION: Watch out the power-wrench

reaction bar movement. Take care not to be
hit the reaction bar. 1 2
3 7
4 8
IMPORTANT: Apply lubricant to bolts (10) before 5 9
6
installing. Install shims (7) between
nuts (8) and the lock brackets with
the flange positioned in the upper 1
2
side. 7
3. Install bolts (10), nuts (8), shims (7), and washers

(9). Using a power wrench, tighten bolts (10).
3
: 65 mm 4
5
6
: 2350 Nxm (240 kgfxm, 1740 lbfxft) 8 9
9
10
W166-02-02-003
4. Install shims (5 and 6), spacers (4), washers (3)

lock washers (2), and bolts (1). Remove wire
ropes and lifting accessories.
9
: 36 mm
7
10
8
9
3
1, 2
W166-02-02-001
6, 5, 4
W2-2-2
REMOVE AND INSTALL COUNTER-
WEIGHT (WITH COUNTERWEIGHT RE-
MOVAL DEVICE)
Removal
NOTE: Counterweight removal procedure must be
performed with machine located on a level
surface.
1. Park the machine on a level surface with the up- M116-06-019

perstructure rotated 90.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
IMPORTANT: The turbocharger may be damaged if

the engine is not properly shut
down.
4. Run the engine at slow idle speed without load for

three minutes.
5. Stop the engine.
6. Pull the pilot control shut-off lever to the LOCK 2

position.
CAUTION: Avoid personal injury from unex-

pected counterweight movement. DO NOT go
directly under machine counterweight. To
remove or install counterweight hardware, go
under machine entering from the area on ei-
ther SIDE of the counterweight. The counter- 1 M111-06-023
weight weighs approximately 8200 kg (18100
lb). Clear everyone from the area before re-
moving or installing the counterweight.
7. Remove bolts (1) to remove counterweight top

cover plate (2).
8. Open the engine hood.
9. Remove bottom covers (3) and (5).

3 4 5
10. Remove cylinder guard (4). M116-06-020
W2-2-3
11. Set variable orifice (1) by turning in the direction of
the arrow until closed. Then open orifice 2 turns.
IMPORTANT: Linkage pivot areas may bind if not

properly lubricated resulting in fail-
ure of cylinder (3) to raise counter-
weight to full height.
12. Grease all pivot areas of counterweight lift linkage

(three fittings at the bottom and one fitting at the
top of the counterweight cylinder), the FIRST
TIME and every time the counterweight device is
operated.
1
M116-06-021
2
3
13. Open shut off valve (2) by turning the handle

counterclockwise to supply hydraulic pressure to
cylinder (3).
14. Make sure length (A) is correct and lock nuts (4)
M116-06-022
are not loose.
Length A: 1102 mm (4.330.08 in)
4
M116-06-023
W2-2-4
15. Remove both lock pins (3) from nut (2) on bolts
(1).
2 3
M116-06-024
16. Open the left rear access door and pull off lever
cover (4) of counterweight pilot control valve (5). 4
M111-06-024
17. Start the engine. Run machine in precision work

mode (6) with the engine control dial set to the
fully counterclockwise position (slow idle).
6
M166-01-016
W2-2-5
CAUTION: To insure good footing and visi-

bility, always stand on the machine catwalk
when operating counterweight pilot control
valve.
IMPORTANT: To prevent possible damage to hy-

draulic cylinder lines and adjustable
orifice canister, cylinder guard (See
step 10) must be removed before
lowering the counterweight. M116-06-025
18. Slowly move the counterweight pilot control valve

lever UP and DOWN several times to check the
response of cylinder control.
CAUTION: Keep hands (fingers) out of slots 1

(1) and out of movable parts of linkage during
cylinder movement.
19. Slide the lifting yokes forward to the upward posi-

tion of slot (1) away from the rear of counterweight
and slowly raise cylinder (counterweight pilot con-
trol valve lever UP) to hold both lifting yokes in
M116-06-026
the forward position.
20. Alternately loosen each bolt (2) 2 or 3 turns. 2
21. Using a screwdriver, pry the corner of lock plate 3

(4) away from the head of each of bolts (3).
22. Loosen each bolts (3) 5 mm (0.20 in).
M116-06-036
W2-2-6
NOTE: Lifting yokes must be in the forward posi-

A 1
tion or highest point of the slot.
23. Slowly move the counterweight pilot valve lever

UP until counterweight bottom bosses (2) move
away from machine mainframe (1) approximately
5 mm (0.20 in.) (A). This will ensure that the
weight of the counterweight is on the lift cylinder.
CAUTION: When the threads of tie bolt (7) 2

disengage from nut (6), nut (6) and nut spacer
may drop to the ground. Stay clear from un-
der the machine when removing bolts (7).
24. To avoid binding, loosen bolts (7) by alternately

turning each bolt one turn at-a-time.
NOTE: It is not necessary to remove bolts (7) from

the counterweight/frame holes. It is enough
nuts (6) are dropped down. The bolts (7)
will be removed from frame holes when the
counterweight is lowered by the lift cylinder. M116-06-028
25. Remove bolts (4), lock plates (5), spacers and 3

shims (3) from each counterweight boss. To avoid
binding, alternately loosen left hand and right
hand bolts (4) 2 or 3 turns at-a-time.
7 6
4
M116-06-036
W2-2-7
26. Slowly lower counterweight to the ground until all
weight is removed from the linkage and the yokes
move freely in their slots.
IMPORTANT: Do not operate the pilot control

valve with full stroke of lever. Move
the cylinder as slowly as possible. 1
27. Remove yoke-to-link pins (1).
28. Tighten adjusting cap screw jam nut.
29. Raise lift cylinder to end of its stroke.
30. Store yoke-to-link pins (1) by attaching pins to the

counterweight lift brackets.
M116-06-023
31. Close hydraulic shut off valve by turning valve
handle clockwise.
32. Install top cover to the counterweight and two bot-

tom covers to the machine mainframe.
33. Install lift cylinder lower guard.
34. Install the lever cover over the counterweight pilot

valve.
35. Close left rear access door and engine hood.
W2-2-8
Installation
NOTE: Counterweight installation procedure must
be performed with machine located on a
level surface.
1. Park the machine on a level surface.
2. Rotate upperstructure 90 with front attachment

on the ground.
3. Turn the auto-idle switch off. M116-06-029
IMPORTANT: The turbocharger may be damaged if 1

the engine is not properly shut
down. 3
3
4. Run the engine at slow idle speed without load for
three minutes.
3
5. Stop the engine.
6. Pull the pilot control shut-off lever to the LOCK

position.
M111-06-025
7. Open the engine hood.
3 3
8. Remove two pump drive covers (1) and (2) and
bolts (3). 2
3
9. Remove both machine mainframe bottom access 3
covers and counterweight top cover.
10. Remove the lift cylinder guard.
11. Turn the handle of shut off valve (4) (located

through opening under the engine) counterclock-
wise to open hydraulic pressure to cylinder (5).
M111-06-026
12. Start the engine. Run machine in precision work

mode with the engine dial set to the fully counter- 4
clockwise position (slow idle).
5
M116-06-022
W2-2-9
CAUTION: To insure good footing and visi- 1

bility, always stand on the machine catwalk
2
when operating counterweight pilot control
valve.
A 3
13. Lower the lift cylinder.
14. Install counterweight lifting yoke-link-pins (4) to

the counterweight pin brackets (5). Slide yoke (3) 4
forward to the top position of the slot in the coun-
terweight pin bracket.
5
15. When installing the counterweight for the first time,
check removal device adjustment as follows.
(When installing counterweight next times [not the
first time] see item 16.)
M116-06-023
(1) Adjust bolts (1) on each yoke (3) to length (A)

A: 1102 mm (4.30.08 in)
(2) Slowly raise the counterweight until the coun-
6
terweight bosses are set into the mainframe
holes. If alignment of the counterweight
bosses to the mainframe holes is incorrect
(Bosses cant be set into holes), lower the
counterweight to the ground and adjust length
(A) as required. After adjusting correct length
(A), tighten lock nut (2).
Tightening torque 390 Nxm (40 kgfxm, 290
lbfxft)
CAUTION:
Length (A) can not be made for more than M116-06-030
120 mm (4.7 in). Damage to bolts may oc-
cur.
Stop cylinder when bosses are set to the
main frame holes. Do not raise the cylinder
when bosses are engaged with the main
frame holes.
16. Make sure length (A) is correct and lock nut (2)
are not loose.
17. Put bolts (6) into the counterweight holes.
W2-2-10
18. Slowly raise the counterweight until the counter- 1 2 3
weight bosses are set into the main frame holes.
NOTE: When raising counterweight, bolts (1) are

set into frame holes.
19. Install spacers (2) and nut (3) at the pump side.
Turn nut (3) into bolts (1) until the end of the bolt
face with end of nut.
20. Install spacer (2) and nut (3) at the radiator side.
Turn nut (3) into bolts (1) until the end of the bolt
face with end of nut.
21. Lower the lift cylinder slightly until yoke (4) slide M116-06-031
backward in slots (5) to the REST position.
22. Install shims (6), spacer (7), new lock plate (9) 4
and bolts (8) to each of the lower counterweight
bosses.
5
23. Tighten bolts (1).
Tightening torque: 2400 Nxm (245 kgfxm, 1770
lbfxft)
NOTE: Tighten or loosen bolts (1) (from torque) to

align lock pins.
M116-06-032
24. Tighten bolts (8).
Tightening torque: 690 Nxm (70 kgfxm, 510 lbfxft)
6
7
1
M116-06-036
W2-2-11
25. Make sure the counterweight lift arms are below 1
the top surface of the counterweight and are not
touching the counterweight plate from inside.
Make sure yoke connected to the counterweight
pin brackets are not tight.
(If necessary, lower or raise cylinder slightly to
meet above requirements and check again
torques.)
26. Install lock pins (1) into the nuts from the top side
of the machine.
27. Bend one top and bottom corner of lock plate (2)
against the head of each bolt.
28. Close shut off valve (3).
29. Install two pump drive covers.
30. Install the both machine mainframe bottom ac-

cess covers and counterweight top cover.
M116-06-024
31. Install the cylinder guard.
M116-06-036
M116-06-022
W2-2-12
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
CAUTION: Escaping fluid under pressure

can penetrate the skin, causing serious
injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation.

Hot hydraulic oil may spout, possibly causing
severe burns. Be sure to wait for oil to cool
before starting work.
The hydraulic oil tank cap may pop off if

removed without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.
Preparation
1. Park the machine on a firm, level surface.
2. Stop the engine. Push the air release valve on top

of the hydraulic oil tank to release any remaining
pressure.
M104-07-021
3. Remove hydraulic oil tank cap. Connect a vacuum

pump to maintain negative pressure in the
hydraulic oil tank.
NOTE: Be sure to run the vacuum pump

continuously while working.
W166-02-03-011
W2-3-1
Removal
CAUTION: Approximate weight of cab:
Headguard-Integrated: 470 kg (1040 lb)
1. Remove cab assembly.

(See Remove Cab in this section.)
: 24 mm, 17 mm
: 8 mm
W157-02-01-001
CAUTION: Approximate weight of counter-
weight: 9300 kg (20500 lb)
2. Remove the counterweight.

(See Remove Counterweight in this section.)
Wrench size : 36 mm
: 65 mm
W155-02-02-001
W2-3-2
CAUTION: Approximate weight of front

attachment assembly;
Backhoe
7530 kg (16600 lb)
Loading shovel
9550 kg (21100 Ib) (EX400-5)
9880 kg (21800 Ib) (EX450H-5)
3. Remove front attachment assembly from the

upperstructure.
(See Remove Front Attachment in this section.) W105-02-03-002
: 19 mm, 30 mm, 36 mm, 41 mm
M162-07-071
4. Drain hydraulic oil from the hydraulic oil tank, and
ST 0915
disconnect hydraulic lines from the control valve Shackle
to the center joint on top of the center joint. ST 0915
Disconnect drain hose, and remove the fitting and

stopper from the center joint. 13 12
12
: 22 mm, 27 mm, 41 mm
Rear W166-02-03-009
W166-02-03-010
CAUTION: Approximate weight of main

frame;
9380 kg (20700 lb) (EX400-5)
9500 kg (21000 Ib) (EX450H-5)
5. Install special tool (ST 0915), bolts (12) (M45

Pitch3, 2 used) and nuts (13) to main frame.
Install shackles (4.8 ton) to special tool (ST 0915).
Front
6. Attach wire ropes to the front and shackle of main W105-02-03-005
frame. See wire ropes taut using a crane. Use 1
chain blocks (1) for easy adjustment of wire rope
lengths and to level the frame.
: 70 mm
IMPORTANT: Make sure rear slings and special

tool (ST0915) do not touch engine.
W157-02-03-002
W2-3-3
7. Put matching marks on swing bearing and main
frame. Remove bolts (2) and the knock pins from
the swing bearing.
: 41 mm
8. Lift main frame slightly from undercarriage.

Level main frame by adjusting chain blocks (1).
Remove main frame.

2
W105-02-03-007
W157-02-03-002
W2-3-4
Installation
CAUTION: Approximate weight of main
frame: 9380 kg (20700 lb) (EX400-5)
9500 kg (21000 Ib) (EX450H-5) 1
1. Fasten hoist to front and shackle of main frame.

Level main frame by adjusting chain blocks (1)
and lower main frame onto undercarriage.
Align the matching mark on the swing bearing with
that on the main frame.
W157-02-03-002
2. Install bolts (2) and the knock pins on the swing

bearing and tighten temporary.
Remove wire ropes and the special tool (ST
0915).
Install main frame and tighten bolts to
specification.
: 41 mm
Upperstructure side
: 1370 Nm (140 kgfm, 1010 lbfft) 2
W105-02-03-007
3. Connect drain hose (7) to the center joint.
Connect lines (3 to 6).

4
: 22 mm 3
: 39 Nm (4 kgfm, 29 lbfft) 5
6
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
M162-07-071
W2-3-5
CAUTION: Approximate weight of cab;

Headguard-Integrated cab: 470 kg (1040 lb)
4. Install cab (9). 9

(See Cab in this section.)
: 24 mm
: 205 Nm (21 kgfm, 159 lbfft)
: 17 mm
: 49 Nm (5 kgfm, 36 lbfft)
: 8 mm
: 64 Nm (6.5 kgfm, 47 lbfft)
W157-02-01-001
CAUTION: Approximate weight of counter-

weight: 9300 kg (20500 lb)
5. Install counterweight (10).

(See Counterweight in this section.)
Wrench size: 65 mm
: 2350 Nm (240 kgfm, 1740 lbfft) 10
CAUTION: Approximate weight of front

attachment assembly:
Backhoe
7530 kg (16600 lb) W155-02-02-001
Loading Shovel
9550 kg (21100 Ib) (EX400-5)
9880 kg (21800 Ib) (EX450H-5)
6. Install front attachment assembly (3).

(See Front Attachment in this section.)
: 19 mm
: 29 Nm (3 kgfm, 21.5 lbfft)
: 30 mm
: 540 Nm (55 kgfm, 400 lbfft)
: 36 mm
: 137 Nm (14 kgfm, 101 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft) W105-02-03-002
11
7. Fill the hydraulic oil tank with hydraulic oil to the

specified level.
Run the engine at slow idle. Check hose
connections for any oil leakage.
M104-07-021
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

can penetrate the skin, causing serious injury.
Avoid this hazard by relieving pressure
before disconnecting hydraulic lines.
Hydraulic oil may be hot after operation. Hot
hydraulic oil may spout, possibly causing
before starting any repair work.
The hydraulic oil tank cap may pop off by
remaining pressure if removed quickly.
Slowly loosen the cap to completely release
any remaining pressure.
Preparation
1. Park the machine on a level solid surface. Lower
the front attachment to the ground.
2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system.
2. Rotate the hydraulic oil tank cap approx. 30

counterclockwise to release trapped air in the
hydraulic oil tank.
W2-4-1
Remove Pump Device
1. Disconnect all hydraulic lines and electrical cables
Pump Device Mounting Bolt
from the pump.
: 19 mm, 27 mm, 32 mm, 36 mm, 41 mm

: 10 mm, 14 mm
CAUTION: Pump device weight:

275 kg (610 lb)
2. Sling the pump device with a crane or hoist.
3. Remove the pump device mounting bolts (12

used) and the pump device.
: 19 mm
Install Pump Device

1. Hoist the pump device.
W166-02-03-001
2. Install the pump with the mounting bolts.
3. Connect all hydraulic lines and electrical cables to
the pump.
4. Bleed air trapped inside the pump. (Refer to page Tightening Torque
W1-1-2.) Wrench Sizes Remarks
Nm (kgfm) (lbfft)
Hydraulic
IMPORTANT: After installing the pump, be sure to : 19 mm 29.5 (3) (21.5)
lines
perform break-in operation to Hydraulic
prevent seizure. : 27 mm 93 (9.5) (69)
lines
Hydraulic
Break-In Operation Process: : 32 mm 68.6 (7) (51)
lines
1. Start the engine and run at slow idle speed for
Hydraulic
20 minutes. Check for oil leaks while running : 36 mm 175 (18) (130)
lines
at slow idle.
Hydraulic
2. Increase the engine speed to the fast idle : 41 mm 205 (21) (152)
lines
speed. Raise and lower the boom for 20
minutes repeatedly. (Do not operate the Socket
: 10 mm 108 (11) (80)
control levers quickly. Slowly move the levers Bolts
to full stroke.) Socket
: 14 mm 265 (27) (195)
Bolts
W2-4-2
(Blank)
W2-4-3
DISASSEMBLE PUMP TRANSMISSION
8 9
1
10
11
12
13
14
15
16
17
W166-02-03-002
18
19
1- Casing 6- Cartridge 11 - O-Ring 16 - Retaining Ring

2- Bearing 7- Oil Seal 12 - Bearing 17 - Bearing
3- Gear 8- Bolt (8 Used) 13 - Retaining Ring 18 - O-Ring
4- Bearing 9- Bolt (5 Used) 14 - Sleeve 19 - Drain Plug
5- O-Ring 10 - Cartridge 15 - Gear
W2-4-4
Disassemble Pump Transmission
Before starting any repair work, thoroughly read 7. Remove cartridge (10) from casing (1). Remove
all Precautions for Disassembling and Assem- O-ring (11) from cartridge (10).
bling (W1-1-1).
8. Attach metal protector (dia. 25 mm) to top of
sleeve (14) and tap the protector over top of
CAUTION: Main pump assembly weight:
sleeve (14) with a plastic hammer until gear (15)
192 kg (425 lb)
comes in contact with casing (1). Remove sleeve
(14) from the inner race of bearing (12).
1. Remove drain plug (19) to drain gear oil from the
pump device. Remove the main pump assembly
9. Using a puller, remove the outer race of bearing
and the pilot pump from the pump device.
(12) from casing (1).
: 30 mm
10. Remove retaining ring (13) from sleeve (14).
: 8 mm

CAUTION: Pump transmission weight: 78 kg sleeve (3) and tap the protector over top of sleeve
(170 lb) (3) with a plastic hammer to remove sleeve (14)
and bearing (17) from casing (1).
2. Place casing (1) on a work bench with the main
pump mounting side facing downward. 12. Using a press, remove bearing (17) from sleeve
(14).
3. Remove bolts (9).
: 13 mm
CAUTION: Pump transmission weight: 78 kg

(170 lb)
4. Reposition casing (1) on the work bench so that

the engine mounting side faces downward.
NOTE: At this time, lay two wooden blocks (100

mm high) under the casing so that the
blocks are not under cartridges (6 and 10).

sleeve (14) and tap the protector over top of
sleeve (14) with a plastic hammer until gear (15)
comes in contact with casing (1). Then, cartridge
(10) and the outer race of bearing (12) will come
out of casing (1).
CAUTION: Pump transmission weight: 78 kg

(170 lb)
6. Lay two wooden blocks (150 mm high) on the

work bench. Place casing (1) on the wooden
blocks with the main pump mounting side facing
downward.
W2-4-5
8
1
14
15
16
W166-02-03-002
W2-4-6
13. Remove retaining ring (16) from sleeve (14).
14. Remove bolts (8) (8 used) and cartridge (6).
: 17 mm
15. Remove oil seal (7) and O-ring (5) from cartridge
(6).
CAUTION: Pump transmission weight:

70 kg (165 lb)
16. Lay two wooden blocks (150 mm high) on the

work bench. Place casing (1) on the wooden
blocks with the engine mounting side facing
downward.
17. Attach metal protector (dia. 75 mm) to top of gear

(3). Using a press, push gear (3) out of casing (1).
18. Take gear (15) out of casing (1).
19. Using a press or puller, remove bearings (2 and 4)

from gear (3).
W2-4-7
ASSEMBLE PUMP TRANSMISSION
4 6
2
5
3 7
17
8
14
11
10
12
16
9
15 13
W166-02-03-003
1- Casing 6- Cartridge 10 - Cartridge 14 - Sleeve

2- Bearing 7- Oil Seal 11 - O-Ring 15 - Gear
3- Gear 8- Bolt (8 Used) 12 - Bearing 16 - Retaining Ring
4- Bearing 9- Bolt (5 Used) 13 - Retaining Ring 17 - Bearing
5- O-Ring
W2-4-8
Assemble Pump Transmission
1. Press bearings (2 and 4) onto gear (3). 11. Press gear (3) into casing (1) so that gear (3)
meshes with gear (15).
2. Install retaining ring (16) to sleeve (14).
12. Attaching a protector on oil seal (7), press oil seal
3. Press bearing (17) onto sleeve (14). (7) into cartridge (6).
4. Install gear (15) into casing (1). 13. Apply grease on the inner lip of oil seal (7).
IMPORTANT: Press bearing (17) into casing (1) 14. Install O-ring (5) in cartridge (6).
until the end face of bearing (17) is
flush with the stepped face in the 15. Install cartridge (6) in casing (1) with bolts (8).
casing bore.
: 17 mm
5. With splines on sleeve (14) and gear (15) aligned, : 49 Nxm (5 kgfxm, 36 lbfxft)
press sleeve (14) with bearing (17) into casing (1).
CAUTION: Pump transmission weight:
CAUTION: Assembly weight of casing (1), 78 kg (170 lb)
gear (5), etc.: 60 kg (135 lb)
16. Check that bearing (17) and sleeve (14) are
6. Turn casing (1) over. correctly installed in casing (1) by softly tapping
bearing (17) with a plastic hammer.
7. Install retaining ring (13) to sleeve (14).
CAUTION: Main pump assembly weight:
8. After centering the outer and inner races of
192 kg (425 lb)
bearing (12), press the outer race of bearing (12)
into casing (1).
17. Install the main pump assembly and the pilot
pump on casing (1).
9. Install O-ring (11) around cartridge (10).
: 30 mm
10. Install cartridge (10) in casing (1) with bolts (9).
: 13 mm
: 8 mm
: 64 Nxm (6.5 kgfxm, 47 lbfxft)
18. Fill gear oil into casing (1).

Gear Oil: 2.2 L (2.3 US qt)
W2-4-9
(Blank)
W2-4-10
REMOVE AND INSTALL MAIN PUMP

Preparation
1. Park the machine on a level solid surface. Lower
2. After stopping the engine, move the control levers

several times to release any pressure remaining
in the system.
3. Rotate the hydraulic oil tank cap approx. 30

counterclockwise to release trapped air in the
hydraulic oil tank.
W2-4-11
Removal
1. Disconnect all hydraulic lines and electrical cables
from the pump.
: 19 mm, 27 mm, 32 mm, 36 mm, 41 mm Main Pump Mounting Bolt

: 10 mm, 14 mm
CAUTION: Main pump weight: 192 kg (425 lb)
2. Sling the main pump with a crane or hoist.

3. Remove the pump mounting bolts (4 used) and
the main pump.
: 30 mm
Installation
1. Hoist the main pump.
2. Install the pump with the mounting bolts.
3. Connect all hydraulic lines and electrical cables to
the pump.
4. Bleed air trapped inside the pump. (Refer to page
W1-1-2.)
W166-02-03-001
IMPORTANT: After installing the pump, be sure to

perform break-in operation to Tightening Torque
Wrench Sizes Remarks
prevent seizure. Nm (kgfm) (lbfft)
Hydraulic
: 19 mm 29.5 (3) (21.5)
Break-In Operation Process: lines
1. Start the engine and run at slow idle speed for Hydraulic
: 27 mm 93 (9.5) (69)
20 minutes. Check for oil leaks while running lines
at slow idle. Hydraulic
: 32 mm 68.6 (7) (51)
Increase the engine speed to the fast idle speed. lines
Raise and lower the boom for 20 minutes Hydraulic
repeatedly. (Do not operate the control levers : 36 mm 175 (18) (130)
lines
quickly. Slowly move the levers to full stroke.) Hydraulic
: 41 mm 205 (21) (152)
lines
Hydraulic
: 10 mm 108 (11) (80)
Bolts
Socket
: 14 mm 265 (27) (195)
Bolts
W2-4-12
(Blank)
W2-4-13
DISASSEMBLE MAIN PUMP
21 22
20 26
25
31 24
32 19
18 23
17
16
30 15
14
13
28 12
29
11
10
9
8
7
46 50
5 27 49
4 48
3
2 47
1
45
44
43
42
41 51
40
39
38
37 52 64
54 63
36
34 35 62
33
61
60
55
59
48
58
57
56
49 65
76
66
67
68
70
75 74 71
73 72 W166-02-03-008
W2-4-14
1- Socket Bolt (8 Used) 21 - Regulator (2 Used) 39 - Spacer (2 Used) 58 - Valve Plate

2- Cover 22 - Socket Bolt (12 Used) 40 - Spring (18 Used) 59 - O-Ring
3- O-Ring 23 - Servo Piston (2 Used) 41 - Cylinder Block (2 Used) 60 - O-Ring (3 Used)
4- Oil Seal 24 - O-Ring (2 Used) 42 - Valve Plate 61 - Housing
5- Shaft 25 - Backup Ring (2 Used) 43 - Bearing 62 - O-Ring
7- Bearing (2 Used) 26 - Stopper (2 Used) 44 - O-Ring 63 - Cover
8- Spacer (2 Used) 27 - O-Ring (4 Used) 45 - Cover 64 - Socket Bolt (8 Used)
9- Retaining Ring (2 Used) 28 - Taper Pin (4 Used) 46 - Plug (2 Used) 65 - Cover
10 - Socket Bolt (4 Used) 29 - Plug (4 Used) 47 - O-Ring (2 Used) 66 - Socket Bolt (4 Used)
11 - Cover 30 - A Sensor (2 Used) 48 - Screw (2 Used) 67 - Shaft
12 - Nut (4 Used) 31 - O-Ring (2 Used) 49 - Nut (2 Used) 68 - Pin
13 - Screw (2 Used) 32 - Plug (2 Used) 50 - Booster 70 - Spring Pin
14 - Pin (5 Used) 33 - Swash Plate 51 - Coupling 71 - Cover
15 - O-Ring (2 Used) 34 - Bushing 52 - Spring Pin (2 Used) 72 - O-Ring (2 Used)
16 - Stopper (2 Used) 35 - Shoe (9 Used) 54 - Pin 73 - Plug (2 Used)
17 - Backup Ring (2 Used) 36 - Plunger (9 Used) 55 - Shoe Plate (2 Used) 74 - O-Ring
18 - O-Ring (2 Used) 37 - Retainer (2 Used) 56 - Feed Back Link 75 - O-Ring
19 - Housing 38 - Spherical Bushing (2 Used) 57 - Bearing (2 Used) 76 - O-Ring (3 Used)
20 - Tilt Pin (2Used)
NOTE: Parts (7 to 9, 12 to 18, 20 to 41, 55, and 56)

in housing (61) are the same as those used
in housing (19).
W2-4-15
21 22
20 26
25
31 24
32 19
18 23
17
16
30 15
14
13
28 12
29
11
10
9
8
7
46 50
5 27 49
4 48
3
2 47
1
45
44
43
42
41 51
40
39
38
37 52 64
54 63
36
34 35 62
33
61
60
55
59
48
58
57
56
49 65
76
66
67
68
70
75 74 71
73 72 W166-02-03-008
W2-4-16
Disassemble Main Pump
Before starting any repair work, thoroughly read 5. Remove cylinder blocks (41) (2 used), springs
all Precautions for Disassembling and Assem- (40), (18 used) spacers (39) (2 used), spherical
bling (W1-1-1). bushings (38) (2 used), retainers (37) (2 used),
plungers (36) (9 used), and shoes (35) (9 used)
IMPORTANT: Do not remove screws (13 and 48) from housings (19 and 61), respectively.
and nuts (12 and 49). If removed, the
set flow rate will changed. 6. Remove socket bolts (1 and 64) (8 used), covers
(2 and 63) and O-rings (3 and 62). Remove oil
1. Remove plugs (32) and O-rings (31) (2 used) to seal (4) from cover (2).
drain hydraulic oil from the pump.
: 6 mm
: 36 mm
7. While tapping covers (11 and 65) with a plastic
2. Remove socket bolts (22) (6 used) and regulator hammer, remove the covers from housings (19
(21). Remove A sensors (30) . and 61). Remove O-rings (15 (2 used) and 27 (4
used)) and spring pins (14) (2 used).
: 6 mm
8. Remove swash plates (33) and shoe plates (55)
IMPORTANT: Take care not to allow valve plates (2 used) from housings (19 and 61).
(42 and 58) to drop when separating
housing (19), cover (45), cover (71), NOTE: Do not remove feedback links (56) unless
and housing (61) into each respec- required.
tive sub-assembly.
3. Insert pipes through bolt holes on covers (11 and

65) and hold the pipes not to allow the pump to
rotate. Then, remove socket bolts (10 and 66) (4
used). Separate housing (19), cover (45), cover
(71) and housing (61) into each respective sub-
assembly. Remove O-rings (44, 59, 60, 74 to 76)
and spring pins (52 and 70) .
: 17 mm
4. Remove booster (50), coupling (51), valve plate

(42) and pin (54) from cover (71). Remove valve
plate (58) and pin (68) from cover (71).
NOTE: Do not remove bearings (43 and 57) unless

required.
W2-4-17
20 26
25
24
19
18 23
17
16
11
9
8
7
61
65
67
W166-02-03-008
W2-4-18
9. While tapping shafts (5 and 67) with a plastic
hammer, remove shafts (5 and 67) from covers
(11 and 65).
10. Remove retaining rings (9) (2 used), spacers (8)

(2 used), bearings (7) (2 used) from shafts (5 and
67).
IMPORTANT: Servo piston (23) is connected to tilt

pin (20) with LOCTITE. Take care not
to damage servo piston (23) when
disassembling.
11. Remove stoppers (16 and 26) (2 used), servo

pistons (23) (2 used), and tilt pins (20) (2 used)
from housings (19 and 61).
12. Remove O-ring (18) and backup ring (17) from

stopper (16), and O-ring (24) and backup ring (25)
from stopper (26) respectively.
W2-4-19
ASSEMBLE MAIN PUMP
46, 47 24, 25
14 33 55 35 19 34 44 60 49 48 75 57 26 60 23 59 20 61 16 17, 18
12 74 76
65
13
11
1
2
5 64
62
67
63
4 9
3 8
10
66
15
27
30 37 38 36 39 41 40 42 52 54 43 45 51 50 71 68 70 58 56 7
31, 32 72, 73 28, 29 W162-02-04-003
1- Socket Bolt (8 Used) 21 - Regulator (2 Used) 39 - Spacer (2 Used) 58 - Valve Plate

2- Cover 22 - Socket Bolt (12 Used) 40 - Spring (18 Used) 59 - O-Ring
3- O-Ring 23 - Servo Piston (2 Used) 41 - Cylinder Block (2 Used) 60 - O-Ring (3 Used)
4- Oil Seal 24 - O-Ring (2 Used) 42 - Valve Plate 61 - Housing
5- Shaft 25 - Backup Ring (2 Used) 43 - Bearing 62 - O-Ring
7- Bearing (2 Used) 26 - Stopper (2 Used) 44 - O-Ring 63 - Cover
8- Spacer (2 Used) 27 - O-Ring (4 Used) 45 - Cover 64 - Socket Bolt (8 Used)
9- Retaining Ring (2 Used) 28 - Taper Pin (4 Used) 46 - Plug (2 Used) 65 - Cover
10 - Socket Bolt (4 Used) 29 - Plug (4 Used) 47 - O-Ring (2 Used) 66 - Socket Bolt (4 Used)
11 - Cover 30 - A Sensor (2 Used) 48 - Screw (2 Used) 67 - Shaft
12 - Nut (4 Used) 31 - O-Ring (2 Used) 49 - Nut (2 Used) 68 - Pin
13 - Screw (2 Used) 32 - Plug (2 Used) 50 - Booster 70 - Spring Pin
14 - Pin (5 Used) 33 - Swash Plate 51 - Coupling 71 - Cover
15 - O-Ring (2 Used) 34 - Bushing 52 - Spring Pin (2 Used) 72 - O-Ring (2 Used)
16 - Stopper (2 Used) 35 - Shoe (9 Used) 54 - Pin 73 - Plug (2 Used)
17 - Backup Ring (2 Used) 36 - Plunger (9 Used) 55 - Shoe Plate (2 Used) 74 - O-Ring
18 - O-Ring (2 Used) 37 - Retainer (2 Used) 56 - Feed Back Link 75 - O-Ring
19 - Housing 38 - Spherical Bushing (2 Used) 57 - Bearing (2 Used) 76 - O-Ring (3 Used)
20 - Tilt Pin (2Used)
NOTE: Parts (7 to 9, 12 to 18, 20 to 41, 55, and 56)

in housing (61) are the same as those used
in housing (19).
W2-4-20
Assemble Main Pump
1. Install O-rings (24) and backup rings (25) onto 7. Install springs (40) (9 used), spacer (39),
stoppers (26), O-rings (18) and backup rings (17) spherical bushing (38), plungers (36) (9 used),
onto stoppers (16), respectively. retainers (37) and shoes (35) (9 used) to cylinder
block (41). Install the cylinder blocks onto shafts
IMPORTANT: Apply LOCTITE (medium adhesive) (5 and 67) while aligning splines.
to the joint between servo piston
(23) and tilt pin (20). IMPORTANT: Apply grease to the valve plate (42).
2. Install A sensors (30) (2 used), tilt pins (20) (2 8. Install spring pins (52) (9 used), pin (54), valve
used), servo pistons (23) (2 used), and stoppers plate (42) and O-rings (44) to cover (45).
(16, 26) (2 used) into housings (19 and 61).
NOTE: When installing valve plate (42), align the
: 6 mm pin hole position with pin (54).
9. Secure housing (19) assembly to cover (45) with
3. Heat bearing (7). Install bearings (7), spacers (8) socket bolts (10) (4 used).
and retaining rings (9) onto shafts (5 and 67).
: 17 mm
4. Install pins (14), O-rings (15 and 27) to covers (11 : 430 Nxm (44 kgfxm, 320 lbfxft)
and 65). Install covers (11 and 65) to housings (19
and 61). 10. Install coupling (51) and booster (50) to cover
(45).
IMPORTANT: Install swash plates (33) to housing
(19 and 61) while installing feedback
link (56) to A sensor (30).
5. Install shoe plate (55) to swash plate (33). Install

swash plates (33) to housings (19 and 61) while
installing the swash plate onto tilt pin (20).
NOTE: After installing swash plate (33), make sure

that the swash plate can be moved
smoothly by hand.
6. Install oil seal (4), O-ring (3) to covers (2). Install

O-ring (3) to cover (63). Press shafts (5 and 67) in
covers (11 and 65). Secure covers (2 and 63) to
covers (11 and 65) with socket bolts (1 and 64).
: 6 mm
W2-4-21
19 74 75 76 60 59 20 61
66
31 45 71 68 70 58
W162-02-04-003
W2-4-22
IMPORTANT: Apply a film of grease to valve plate
(58).
11. Install spring pins (70), pin (68), valve plate (58)
and O-rings (60, 59, 74, 75, and 76) to cover (71).
NOTE: When installing valve plate (58), align the

pin hole position with pin (68).
12. Center housing (61) and cover (71). Then, secure

them to cover (45) assembly with socket bolts
(66) (4 used).
: 17 mm
13. Secure regulator (21) onto housing (19) with

socket bolts (22) (6 used) so that the regulator
feedback lever joints with tilt pin (20).
: 6 mm
14. Install O-rings (31) (2 used) and plugs (32) (2

used).
: 36 mm
W2-4-23
MAINTENANCE STANDARD
1. Clearance between plunger (36) outer diameter

(d) and cylinder block (41) bore diameter (D).
d D
D-d Unit : mm(in)
Standard Allowable Limit
0.038 (0.001) 0.078 (0.003)

W117-02-02-009
2. Free length (L) of spring (40)
L Unit : mm(in)
40.9 (1.610) 40.1 (1.579)
W117-02-02-010
3. Clearance (e) between plunger (36) and shoe (35)

and thickness (t) of shoe (35).
e Unit : mm(in)
0 0.1(0 0.004) 0.35 (0.014)
t Unit : mm(in) e
t
W117-02-02-011
5.4(0.213) 5.0 (0.197)
4. Height from the reverse face of retainer (37) to the

top of spherical bushing (38)
Base
H-h Unit : mm(in)

h H
13.5 (0.531) 12.5 (0.492)

W117-02-02-012
W2-4-24
(Blank)
W2-4-25
DISASSEMBLE REGULATOR 7
8
6
5 9
4
3
34
35 2
1
33
32 10
31
29 30 11
28
12
27 16
15 13
19 14
20
21 17
18
22
25
26
24
W166-02-03-006
23
1- Casing 10 - O-Ring 19 - Sleeve 28 - O-Ring

2- Spring Seat 11 - Plug 20 - Pilot Piston 29 - Plug
3- Spring 12 - Pin 21 - Sleeve 30 - O-Ring
4- Stopper 13 - O-Ring 22 - O-Ring 31 - Valve Seat
5- O-Ring 14 - O-Ring 23 - * Clamp 32 - Steel Ball
6- Cover 15 - O-Ring 24 - Pump Control Solenoid Valve 33 - Stopper
7- Socket Bolt (4 Used) 16 - Spool 25 - Valve Cover 34 - Socket Bolt (6 Used)
8- Screw 17 - Pin 26 - Socket Bolt (4 Used) 35 - Plug
9- Nut 18 - Feedback Lever 27 - Plug
NOTE: * Equipped on the machines with serial

number 7143 and later.
W2-4-26
Disassemble Regulator
Before starting any repair work, thoroughly read
all Precautions for Disassembling and Assem-
bling (W1-1-1).
1. Remove pump control solenoid valve (24).
: 32 mm
NOTE: Machine serial number 7143 and later:

Clamp (23) is installed for pump control
solenoid valve (24).
2. Loosen socket bolts (26) (4 used) and valve cover

(25).
: 4 mm
3. Remove O-ring (30), valve seat (31), steel ball

(32) and stopper (33) from casing (1).
4. Remove O-ring (22), sleeve (21) and pilot piston

5. Remove plug (11), feedback lever (18), pin (17),

sleeve (19), and spool (16).
: 6 mm
NOTE: Feedback lever (18) and pin (17) will come

off at the same time .
6. Loosen socket bolts (7) (4 used), cover (6).
: 4 mm
IMPORTANT: Do not remove screw (8) and nut (9).

If removed, the pump flow rate
setting will be changed.
7. Using forcing bolt (M4), remove stopper (4). Then,

remove spring (3) and spring seat (2).
W2-4-27
ASSEMBLE REGULATOR
23 24 25
32
28 29 30 31 33 1 2 3 4 5 6 7
34 35 10
9
11
26
8
21
20
22
16
15 19 14 18 17 12 13
W166-02-03-007
1- Casing 10 - O-Ring 19 - Sleeve 28 - O-Ring

2- Spring Seat 11 - Plug 20 - Pilot Piston 29 - Plug
3- Spring 12 - Pin 21 - Sleeve 30 - O-Ring
4- Stopper 13 - O-Ring 22 - O-Ring 31 - Valve Seat
5- O-Ring 14 - O-Ring 23 - * Clamp 32 - Steel Ball
6- Cover 15 - O-Ring 24 - Pump Control Solenoid Valve 33 - Stopper
7- Socket Bolt (4 Used) 16 - Spool 25 - Valve Cover 34 - Socket Bolt (6 Used)
8- Screw 17 - Pin 26 - Socket Bolt (4 Used) 35 - Plug
9- Nut 18 - Feedback Lever 27 - Plug
NOTE: * Equipped on the machines with serial

number 7143 and later.
W2-4-28
Assemble Regulator
1. Install sleeve (19) and spool (16) into casing (1).

Then, install feedback lever (18) to sleeve (19)
with pin (17).
NOTE: Take care not to mistake the direction of

sleeve (19) and spool (16) when installing.
2. Install O-ring (10) around plug (11). Align the pin

holes of feed back lever (18) and casing (1). Then,
install plug (11) with O-ring (10) into casing (1).
: 6 mm
: 19.5 Nxm (2 kgfxm, 15 lbfxft)
NOTE: After installing plug (11), check that the

feedback lever (18) moves smoothly.
3. Install spring seat (2), spring (3), stopper (4) and

O-ring (5) into casing (1). Secure cover (6) with
socket bolts (7) (4 used).
: 4 mm
: 12 Nxm (1.2 kgfxm, 8.7 lbfxft)
4. Install pilot piston (20), sleeve (21) and O-ring (22)

into casing (1).
5. Install stopper (33), steel ball (32), valve seat (31)

and O-ring (30) into casing (1).
6. Install pump control solenoid valve (24) to valve

cover (25). Secure valve cover (25) to casing (1)
with socket bolts (26) (4 used).
: 32 mm
: 4 mm
NOTE: Machine serial number 7143 and later:

clamp (23) is installed for pump control
solenoid valve (24).
W2-4-29
DISASSEMBLE AND ASSEMBLE PILOT
PUMP
27
13
26
10
10
1
12
9
6
26
14
27
6
9
2
3
5
16
15
7 W137-02-04-034
12
W2-4-30
Wrench Size Tightening Torque

Item Part Name Qty Remarks
(mm) Nxm (kgfxm) (lbfxft)
1 Housing 1
2 Flange 1
3 Oil Seal 1 When installing, apply a film
of grease to the lip.
5 Retaining Ring 1
6 Seal 2 When installing, apply
grease.
7 Cover 1
9 Backup Ring 2 When installing, apply
grease.
10 Key 2
12 O-Ring 2 When installing, apply
grease.
13 Gear 1
14 Gear 1
15 Washer 4
16 Bolt 4 : 17 39 to 44 (4 to 4.5) (29 to 33)
26 Bushing 2 When installing, apply hy-
draulic oil.
27 Bushing 2 When installing, apply
hydraulic oil.
W2-4-31
(Blank)
W2-4-32
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
CAUTION: Escaping pressure hydraulic oil

can penetrate the skin or eyes, causing
serious injury. Avoid this hazard by relieving
pressure before disconnecting hydraulic
lines.
before starting work.
The hydraulic oil tank cap may pop off due to
internal pressure if turned quickly. Slowly
turn the cap to release internal pressure
before completely removing the cap.
Preparation
1. Park the machine on firm and level surface. Lower
2. Stop the engine. Move all control levers to release

any pressure remaining in the system. Slowly turn
the hydraulic oil tank cap approx. 30 degrees
counterclockwise to release any remaining
pressure from the hydraulic oil tank.
Refer to Bleed Pressure from Hydraulic Circuit
on page W1-1-2.
3. Remove the cap and connect a vacuum pump.

Operate the vacuum pump constantly to maintain
the negative pressure in the hydraulic oil tank.
NOTE: Keep the vacuum pump running continu-

ously while working.
W2-5-1
Removal
NOTE: Attach identification tags to hoses to aid re-
assembly.
1. Disconnect all hoses, pipes, and connectors from Right Travel

Left Travel Front
Bucket
the control valve. Boom 1
Auxiliary
Arm 2
: 19 mm
: 19 mm Boom 2
: 88 Nxm (9 kgfxm, 65 lbfxft) Return Pipe
: 22 mm
Arm 1
: 36 mm
: 41 mm
Swing
: 12 mm
: 175 Nxm (18 kgfxm, 130 lbfxft) W166-02-04-017
NOTE: Cap all disconnected hose and pipe ends.
Bucket Right Travel

CAUTION: Control valve weight: 380 kg Boom 1
(840 lb)
Arm 2 Front
2. Remove control valve mounting bolts.
: 30 mm
Installation
NOTE: Refer to Removal section for wrench sizes

and tightening torques.
1. Install the control valve. Tighten the bolts.
2. Connect all hoses, pipes, and connectors to the Left Travel

control valve. Auxiliary
Boom 2
IMPORTANT: After installation, check the hydrau-
Swing Arm 1 W166-02-04-018
lic oil level. Run the engine and
check for oil leaks.
W2-5-2
(Blank)
W2-5-3
DISASSEMBLE CONTROL VALVE 1 1 2
19 3
4
2 2 4 5
3 5 6
4 6 7
7
20 3 8 8
9 9
21 10 10
2 11 11
22 12
23 3 12
4 13 13
24 14
25 5 14
18 26 6 15
7 16
17 27 8
9 17
16 10 15
15 29 16
14 28 18 17
13
12 16 31
11 18
10 17
18 11
17 9 1 12 32
16 13
15 8
14 7 14
13 6 15
12 5 18 33
11 4
10
9 3 2
8
7 19
6
5
4
3 38
2 35
37
54 36
35
35 34
45
44 37
30 43
32 42 36
35
53
41 34
31 40
39
46
35
37
47 36
35
35 34
37
48 36
35
35 34
37
36
35
52
34
51
50 49
W166-02-04-001
W2-5-4
1 - Overload Relief Valve 15 - Spring (6 Used) 29 - Overload Relief Valve 42 - Spacer

(2 Used)
2 - O-Ring (7 Used) 16 - O-Ring (6 Used) 30 - Overload Relief Valve 43 - O-Ring
3 - Backup Ring (7 Used) 17 - Adjusting Screw 31 - O-Ring (10 Used) 44 - Backup Ring
(6 Used)
4 - O-Ring (7 Used) 18 - Lock Nut (6 Used) 32 - Socket Bolt (20 Used) 45 - Cap
5 - Sleeve (6 Used) 19 - Overload Relief Valve 33 - Cover 46 - Spool (Boom 2)
(2 Used)
6- Poppet (6 Used) 20 - Sleeve 34 - Cap (5 Used) 47 - Spool (Auxiliary)
7- Piston (6 Used) 21 - Backup Ring (2 Used) 35 - Guide (10 Used) 48 - Spool (Left Travel)
8- Spring (6 Used) 22 - O-Ring 36 - Sleeve (5 Used) 49 - Cap (2 Used)
9- Spring (6 Used) 23 - Poppet 37 - Spring (5 Used) 50 - O-Ring (2 Used)
10 - O-Ring (6 Used) 24 - Spring 38 - Spool (Swing) 51 - O-Ring
11 - Backup Ring (12 Used) 25 - O-Ring 39 - Spool (Arm 1) 52 - Pump Control Valve
12 - O-Ring (6 Used) 26 - Backup Ring 40 - Check Valve 53 - Cover (5 Used)
13 - Seat (6 Used) 27 - Cap 41 - Spring 54 - Housing
14 - Poppet (6 Used) 28 - Makeup Valve
W2-5-5
1 2
19 3
4
2 2 4 5
3 5 6
4 6 7
7
20 3 8 8
9 9
21 10 10
2 11 11
22 12
23 3 12
4 13 13
24 14
25 5 14
18 26 6 15
7 16
17 27 8
9 17
16 10 15
15 29 16
14 28 18 17
13
12 16 31
11 18
10 17
18 11
17 9 1 12 32
16 13
15 8
14 7 14
13 6 15
12 5 18 33
11 4
10
9 3 2
8
7 19
6
5
4
3 38
2 35
37
54 36
35
35 34
45
44 37
30 43
32 42 36
35
53
41 34
31 40
39
46
35
37
47 36
35
35 34
37
48 36
35
35 34
37
36
35
52
34
51
50 49
W166-02-04-001
W2-5-6
Disassemble Control Valve 1
Thoroughly read Precaution for Disassembly and
Assembly on page W1-1-1 before starting repair Pump Control Valve
work. 10. Remove pump control valve (52) from housing
(54).
5-Spool Section
: 30 mm
CAUTION: Control valve weight:
380 kg (840 lb)
Overload Relief Valve
IMPORTANT: Do not disassemble the overload
1. Install two eye bolts (M12, pitch 1.75) to the
relief valve unless necessary.
control valve. Lay two wooden blocks (100 mm
square) on a work bench. Place the control valve
11. Remove overload relief valves (1) (2 used), (19)
on the wooden blocks using a crane.
(2 used), (29) and (30) from housing (54).
2. Remove socket bolts (32) (10 used) and cover
: 41 mm
(33) from housing (54).
12. Remove lock nut (18) and seat (13) from sleeve
: 10 mm
(5).
3. While checking fitness between housing (54) and
: 19 mm, 36 mm
spools (38 , 39 and 46 to 48) (5 used), slowly pull
the spools out of housing (54).
13. Remove adjusting screw (17), spring (15) and
poppet (14) from seat (13).
4. Remove O-rings (31) (5 used) from housing (54).
: 6 mm
5. Remove socket bolts (32) (10 used) on the control
valve bottom face and cover (53) (5 used) from
14. Remove springs (9 and 8), poppet (6) and piston
housing (54).
(7) from sleeve (5).
: 10 mm
Makeup Valve
15. Remove makeup valve (28) from housing (54).
6. Insert spool (38) into special tool (ST 4124) and
hold with a vise. Remove cap (34).
: 41 mm
: 10 mm
16. Remove cap (27), spring (24) and poppet (23)
from sleeve (20).
7. Remove guide (35), sleeve (36), spring (37) and
guide (35) from cap (34).
: 36 mm
8. Disassemble spools (39 and 46 to 48) following
the same procedures as described in steps 6 and
7.
9. Remove cap (45), spacer (42), spring (41) and

check valve (40) from spool (39).
: 8 mm
W2-5-7
ASSEMBLE CONTROL VALVE 1
Pump Control Valve (52) Top Face of Control Valve
51 50
A
52
49 54
32
29
W162-02-04-025
28
Overload Relief Valve (1) , (19), (29), (30) Makeup Valve (28)
2 7 6 4 5 9 15 13 16 2 23 21 4 24 20 25 27
19
1
W166-02-04-006
3 8 10 11 14 12 17 18 3 22 26
W162-02-04-028
W162-02-04-022
Section A-A 33 31 32
34
Bottom Face of Control Valve
35
38 54
37
36 39
1
35
40 19
54 41
42 30
32
43, 44
31
32 W166-02-04-008
W166-02-04-007
48 47 46 45 32 53
W2-5-8
1 - Overload Relief Valve 15 - Spring (6 Used) 29 - Overload Relief Valve 42 - Spacer

(2 Used)
2 - O-Ring (7 Used) 16 - O-Ring (6 Used) 30 - Overload Relief Valve 43 - O-Ring
3 - Backup Ring (7 Used) 17 - Adjusting Screw 31 - O-Ring (10 Used) 44 - Backup Ring
(6 Used)
4 - O-Ring (7 Used) 18 - Lock Nut (6 Used) 32 - Socket Bolt (20 Used) 45 - Cap
5 - Sleeve (6 Used) 19 - Overload Relief Valve 33 - Cover 46 - Spool (Boom 2)
(2 Used)
6- Poppet (6 Used) 20 - Sleeve 34 - Cap (5 Used) 47 - Spool (Auxiliary)
7- Piston (6 Used) 21 - Backup Ring (2 Used) 35 - Guide (10 Used) 48 - Spool (Left Travel)
8- Spring (6 Used) 22 - O-Ring 36 - Sleeve (5 Used) 49 - Cap (2 Used)
9- Spring (6 Used) 23 - Poppet 37 - Spring (5 Used) 50 - O-Ring (2 Used)
10 - O-Ring (6 Used) 24 - Spring 38 - Spool (Swing) 51 - O-Ring
11 - Backup Ring (12 Used) 25 - O-Ring 39 - Spool (Arm 1) 52 - Pump Control Valve
12 - O-Ring (6 Used) 26 - Backup Ring 40 - Check Valve 53 - Cover (5 Used)
13 - Seat (6 Used) 27 - Cap 41 - Spring 54 - Housing
14 - Poppet (6 Used) 28 - Makeup Valve
W2-5-9
Pump Control Valve (52) Top Face of Control Valve
51 50
A
52
49 54
32
29
W162-02-04-025
28
Overload Relief Valve (1) , (19), (29), (30) Makeup Valve (28)
2 7 6 4 5 9 15 13 16 2 23 21 4 24 20 25 27
19
1
W166-02-04-006
3 8 10 11 14 12 17 18 3 22 26
W162-02-04-028
W162-02-04-022
Section A-A 33 31 32
34
35
38 54
37
36 39
1
35
40 19
54 41
42 30
32
43, 44
31
32 W166-02-04-008
W166-02-04-007
48 47 46 45 32 53
W2-5-10
Assemble Control Valve 1
1. With the manifold mounting face positioned 9. After installing O-rings (4 and 2) and backup ring
downward, place housing (54) on a work bench. (3) onto sleeve (20), install sleeve (20) into
housing (54).
NOTE: Lay soft material between housing (54) and
the work bench. : 41 mm
2. Install O-rings (10 and 12) and backup ring (11) Pump Control Valve
onto seat (13) and O-ring (16) into adjusting screw 10. After installing O-ring (51) onto pump control
(17). valve (52), install pump control valve (52) into
housing (54).
3. Install poppet (14), spring (15), adjusting screw
(17) and lock nut (18) into seat (13). : 30 mm
: 19 mm
: 34 Nxm (3.5 kgfxm, 25.5 lbfxft) 5-Spool Section
: 6 mm 11. Install O-rings (31) (5 used) on the bottom face of
housing (54). Then, install covers (53) (5 used) to
4. After installing piston (7), springs (8 and 9) into housing (54) with socket bolts (32) (10 used).
poppet (6), install poppet (6) onto seat (13).
: 10 mm
5. Install seat (13) into sleeve (5). : 98 Nxm (10 kgfxm, 72 lbfxft)
: 36 mm 12. Insert spool (38) into special tool (ST 4124) and
: 98 Nxm (10 kgfxm, 72 lbfxft) hold with a vise. After installing guide (35), sleeve
(36), spring (37) and guide (35) onto cap (34),
IMPORTANT: Install overload relief valves (1, 19, install cap (34) onto spool (38).
29 and 30) in the same positions
where they were previously located. : 10 mm
6. Install overload relief valves (1) (2 used), (19) (2
used), (29) and (30) to housing (54). 13. Assemble spools (39 and 46 to 48) in the same
procedure as described in step 12.
: 41 mm
Makeup valve
7. Install O-ring (22) and backup ring (21) onto
poppet (23), and O-ring (25), backup ring (26)
onto cap (27).
8. Install poppet (23), spring (24) and cap (27) into

sleeve (20).
: 36 mm
W2-5-11
Top Face of Control Valve

Pump Control Valve (52)
A
54
32
W162-02-04-025
Overload Relief Valve (1) , (19), (29), (30) Makeup Valve (28) 33
W166-02-04-006
A
W162-02-04-028
W162-02-04-022
33 31 30
Section A-A
54
38
39
54
40
41
42 32
43, 44
32 W166-02-04-008
W166-02-04-007
48 47 46 45
W2-5-12
14. Install check valve (40), spring (41) and spacer
(42) into spool (39).
15. After installing O-ring (43) and backup ring (44)

onto cap (45), install cap (45) into spool (39).
: 8 mm
16. Install O-rings (31) (5 used) on housing (54).
IMPORTANT: Install each spool (38, 39, 46, 47 or

48) in the same position where it was
previously located.
17. Holding the spring section of each spool (38, 39,

46, 47 or 48), insert the spool into housing (54)
while slowly rotating the spool.
18. Install cover (33) to housing (54) with socket bolts

(32) (10 used).
: 10 mm
W2-5-13
DISASSEMBLE CONTROL VALVE 2
4
3
7
2 Orifice 3
1 2 Swing
1 3 9
6
5 2
1 Arm 1
8
6
5
10
3
2 Boom 2
31 1
8
6
5
11
12 Holding Valve (Arm)
13
22
14 21
15 20
16
17
18 23
19 12
11
24
25 3 29
26 2
27
1
28 8 Auxiliary
6
5
3 30
32 2
1
33 8
6 Left Travel
5
W166-02-04-009
1- O-Ring (6 Used) 10 - Cap 18 - O-Ring (3 Used) 26 - O-Ring

2- Backup Ring (6 Used) 11 - Cap (2 Used) 19 - Backup Ring 27 - Spring
3- Chip (6 Used) 12 - O-Ring (2 Used) 20 - Cover 28 - Poppet
4- Cap 13 - Spring 21 - Washer (4 Used) 29 - Cap
5- Check Valve (5 used) 14 - Poppet 22 - Socket Bolt (4 Used) 30 - Cap
6- Spring (5 Used) 15 - Sleeve 23 - Piston 31 - Housing
7- Cap 16 - Backup Ring 24 - O-Ring 32 - Socket Bolt (4 Used)
8- Check Valve(4 Used) 17 - O-Ring 25 - Backup Ring 33 - Washer (4 Used)
9- Cap
W2-5-14
Thoroughly read Precaution for Disassembly and
Assembly on page W1-1-1 before starting repair
work.
Holding Valve
1. Remove socket bolts (22) (4 used) and holding
valve cover (20) from housing (31).
: 12 mm
2. Remove spring (27) and poppet (28) from housing

(31).
3. Remove caps (11) (2 used), spring (13), poppet

(14), sleeve (15) and piston (23) from cover (20).
Attach a round bar approx. 10 mm in diameter to
sleeve (15). While tapping the bar, remove sleeve
(15) taking care not to damage cover (20).
: 10 mm
Load Check Valve

(Except for swing)
4. Remove caps (9, 10, 29 and 30) from housing

(31).
: 14 mm
5. Remove check valves (8) (4 used), springs (6) (4

used) and check valves (5) (4 used) from housing
(31).
(Swing)
6. Remove cap (7) from housing (31).
: 14 mm
7. Remove spring (6) and check valve (5) from

housing (31).
W2-5-15
Orifice Swing Arm 1

7 1
4 9
1 2 1
2
2
6 3
8
3 3
5
5 6
W162-02-04-027 W162-02-04-032
W162-02-04-031
Left Travel Auxiliary Boom 2 Holding Valve (Arm) Holding Valve (Arm)
Swing 23 18, 19 16, 17 14 13

31
20
12
11 12
24
32, 33 Orifice 11
25, 26 15
27
21, 22
28
Arm 1
W166-02-04-014 W162-02-04-037
Left Travel Auxiliary Boom 2

30 1 29 1 10 1
2 2 2
8 3 8 3 8 3
6 5 6 5 6 5
W162-02-04-035 W162-02-04-034 W162-02-04-033
1- O-Ring (6 Used) 10 - Cap 18 - O-Ring (3 Used) 26 - O-Ring

2- Backup Ring (6 Used) 11 - Cap (2 Used) 19 - Backup Ring 27 - Spring
3- Chip (6 Used) 12 - O-Ring (2 Used) 20 - Cover 28 - Poppet
4- Cap 13 - Spring 21 - Washer (4 Used) 29 - Cap
5- Check Valve (5 Used) 14 - Poppet 22 - Socket Bolt (4 Used) 30 - Cap
6- Spring (5 Used) 15 - Sleeve 23 - Piston 31 - Housing
7- Cap 16 - Backup Ring 24 - O-Ring 32 - Socket Bolt (4 Used)
8- Check Valve(4 Used) 17 - O-Ring 25 - Backup Ring 33 - Washer (4 Used)
9- Cap
W2-5-16
Load Check Valve

(Swing)
1. Install check valve (5) and spring (6) into housing

(31).
2. Install O-ring (1) and backup ring (2) onto cap (7),
and install cap (7) to housing (31).
: 14 mm
(Except for Swing)
3. Install check valve (5), spring (6) and check valve

(8) into housing (31).
4. Install O-rings (1) and backup rings (2) onto caps

(4, 9, 10, 29 and 30). Install caps (4, 9, 10, 29 and
30) to housing (31).
: 14 mm
Holding Valve
5. Install O-ring (26) and backup ring (25) onto
poppet (28). Install poppet (28) and spring (27)
into housing (31).
6. Install O-rings (17 and 18) and backup rings (16

and 19) into sleeve (15).
7. Install piston (23), sleeve (15), poppet (14) and

spring (13) into cover (20).
8. After installing O-rings (12) onto caps (11) (2

used), install caps (11) (2 used) into cover (20).
: 10 mm
9. Install O-ring (24) on cover (20).
10. Install cover (20) on housing (31) with socket bolts

(22) (4 used).
: 12 mm
: 175 Nxm (18 kgfxm, 130 lbxft)
W2-5-17
4
1 5
6
7
8 16
9
10 15 17
2
11
3 12
14
17 13
81
16
80 18
23
77 24
25 20
26 22
21
27 20
19
79 20
78
22
40 21
50 71 20
28 19
72
20
54 22
55 21
51 57 20
29 19
52 60
53 61 46 20
44
56 42 22
58 64 40 21
59 49 39 20
62 48 38 19
47
63
10 45 37
77 11 43 36
12 41 35
34
12 32
6
11 5 31
10 4
9 3
76 8 33
40 12 7 2
75 60 30
11 10
74 59 1
64 58
73 63
Flow Combiner Valve 62
61 54
5352
72 57
71
70 56 55
69 50
40 51
68
67
Shuttle Valve 66
65
W166-02-04-010
W2-5-18
1- Makeup Valve (2 Used) 22 - Spring (4 Used) 42 - Poppet 62 - Spring (4 Used)

2- Cap (2 Used) 23 - Spool (Arm 2) 43 - Seat 63 - Poppet (4 Used)
3- Backup Ring (2 Used) 24 - Cap 44 - Backup Ring 64 - Sleeve (4 Used)
4- O-Ring (2 Used) 25 - Backup Ring 45 - O-Ring 65 - Seat
5- Spring (2 Used) 26 - O-Ring 46 - Orifice 66 - O-Ring
6- Poppet (2 Used) 27 - Spool (Boom 1) 47 - Spring 67 - Ball
7- O-Ring (2 Used) 28 - Spool (Bucket) 48 - Poppet 68 - Cap
8- Backup Ring (4 Used) 29 - Spool (Right Travel) 49 - Sleeve 69 - Backup Ring
9- Sleeve (2 Used) 30 - Main Relief Valve 50 - Overload Relief Valve 70 - O-Ring
(4 Used)
10 - O-Ring (6 Used) 31 - Adjusting Screw 51 - Lock Nut (4 Used) 71 - Spring (2 Used)
11 - Backup Ring (6 Used) 32 - O-Ring 52 - Adjusting Screw 72 - Check Valve (2 Used)
(4 Used)
12 - O-Ring (6 Used) 33 - Lock Nut 53 - O-Ring (4 Used) 73 - Spool
13 - Housing 34 - Piston 54 - Spring (4 Used) 74 - Spacer
14 - O-Ring 35 - Sleeve 55 - Poppet (4 Used) 75 - Spring
15 - Pump Control Valve 36 - O-Ring 56 - Seat (4 Used) 76 - Cap
16 - O-Ring (8 Used) 37 - O-Ring 57 - O-Ring (4 Used) 77 - Chip (2 Used)
17 - Socket Bolt (16 Used) 38 - Lock Nut 58 - Backup Ring (8 Used) 78 - Backup Ring
18 - Cover 39 - Cap 59 - O-Ring (4 Used) 79 - Cap
19 - Cap (4 Used) 40 - O-Ring 60 - Spring (4 Used) 80 - Cover
20 - Guide (8 Used) 41 - Spring 61 - Piston (4 Used) 81 - Cover (3 Used)
21 - Sleeve (4 Used)
W2-5-19
4
1 5
6
7
8 16
9
10 15 17
2
11
3 12
14
17 13
81
16
80 18
23
24 20
25
26 22
21
27 20
19
20
22
21
50 20
28 19
20
54 22
55 21
51 57 20
29 19
52 60
53 61 20
56 22
58 64
21
59 20
62 19
63
10
11
12
12
6
11 5
10 4
9 3
8
12 7 2
60
11 10
64 59 1
Flow Combiner Valve 58
63
62 54
61 5352
57
56 55
50
51
Shuttle Valve
W166-02-04-010
W2-5-20
Thoroughly read Precaution for Disassembly and IMPORTANT: Do not disassemble the overload
Assembly on page W1-1-1 before starting repair relief valve unless necessary.
work.
9. Remove overload relief valves (50) (4 used) (two
4-Spool Section each located on top and bottom faces of the
1. Remove socket bolts (17) (8 used) and cover (18) housing) from housing (13).
from housing (13).
: 41 mm
: 10 mm
10. Remove lock nut (51) and seat (56) from sleeve
2. While inspecting the fitness between housing (13) (64).
and spools (23, 27, 28 and 29) (4 used), slowly
pull the spools out of the housing (13). : 19 mm, 36 mm
3. Remove O-rings (16) (4 used) from housing (13). 11. Remove adjusting screw (52), spring (54) and
poppet (55) from seat (56).
4. Remove socket bolts (17) (8 used) on the control
valve bottom side, covers (80) and (81) (3 used) : 6 mm
from housing (13).
12. Remove springs (62 and 60), poppet (63) and
: 10 mm piston (61) from sleeve (64).
5. Insert spool (23) into special tool (ST 4124) and Makeup Valve
hold them with a vise. Remove cap (19). 13. Remove makeup valves (1) (2 used) (one each
located on top and bottom faces of the housing)
: 10 mm from housing (13).
6. Remove guide (20), sleeve (21), spring (22) and : 41 mm

guide (20) from cap (19).
14. Remove cap (2), spring (5) and poppet (6) from
7. Disassemble spools (27, 28 and 29) following the sleeve (9).
same procedures as described in steps 5 and 6.
: 36 mm
Pump Control Valve
8. Remove pump control valve (15) from housing
(13).
: 30 mm
W2-5-21
13
79
71
72
46
44
42
40
49 39
48 38
47
45
77 43
41 35
34
31
76 33
75 30
74
73
Flow Combiner Valve
72
71
68
67
Shuttle Valve
65
W166-02-04-010
W2-5-22
Main Relief Valve
IMPORTANT: Do not disassemble the main relief
valve unless necessary.
15. Loosen and remove main relief valve (30) from

housing (13).
: 41 mm
16. Loosen lock nuts (33 and 38).
: 41 mm, 30 mm
17. Remove sleeve (35), spring (41) and poppet (42)

from cap (39).
18. Remove adjusting screw (31) and piston (34) from

sleeve (35).
19. Pull sleeve (49) out of seat (43) and remove

orifice (46), spring (47) and poppet (48) from
sleeve (49).
Shuttle Valve
20. Remove cap (68) and the shuttle valve from
housing (13).
: 41 mm
21. Remove spring (71) and check valve (72) from

housing (13).
22. Remove seat (65) and ball (67) from cap (68).
: 27 mm
Flow Combiner Valve

23. Remove cap (76), spring (75), spacer (74) and
spool (73) from housing (13).
: 46 mm
Check Valve
24. Remove cap (79), spring (71) and check valve
(72) from housing (13).
: 14 mm
W2-5-23
Overload Relief Valve (50) Pump Control Valve (15)
Top Face of Control Valve 30 12 61 63 10 64 62 54 56 53 14
A
13
68
17
50
11 60 59 58 55 57 52 51 W162-02-04-025
W162-02-04-022
1
Main Relief Valve (30) 38
15 40 39 35 33
48 47 45 43 41
49 31
A
W166-02-04-006

46 44 42 37 36 34 32
W162-02-04-038
13
Shuttle Valve Flow Combiner Valve
1
70 68 67 66 65 73 77 75 76
72
17
50
74 40
71 69 40 W162-02-04-024
W162-02-04-023
76
Section A-A
19 18 16 30
20
22
W166-02-04-008
21 13
Makeup Valve Check Valve 17

20
12 6 8 10 5 9 4 2 72 77 79 78
23 29
28
27
40
11 7 3 71
W162-02-04-028
W162-02-04-027
76
16 25, 26 24 80 17 81 W166-02-04-013
W2-5-24
1- Makeup Valve (2 Used) 22 - Spring (4 Used) 42 - Poppet 62 - Spring (4 Used)

2- Cap (2 Used) 23 - Spool (Arm 2) 43 - Seat 63 - Poppet (4 Used)
3- Backup Ring (2 Used) 24 - Cap 44 - Backup Ring 64 - Sleeve (4 Used)
4- O-Ring (2 Used) 25 - Backup Ring 45 - O-Ring 65 - Seat
5- Spring (2 Used) 26 - O-Ring 46 - Orifice 66 - O-Ring
6- Poppet (2 Used) 27 - Spool (Boom 1) 47 - Spring 67 - Ball
7- O-Ring (2 Used) 28 - Spool (Bucket) 48 - Poppet 68 - Cap
8- Backup Ring (4 Used) 29 - Spool (Right Travel) 49 - Sleeve 69 - Backup Ring
9- Sleeve (2 Used) 30 - Main Relief Valve 50 - Overload Relief Valve 70 - O-Ring
(4 Used)
10 - O-Ring (6 Used) 31 - Adjusting Screw 51 - Lock Nut (4 Used) 71 - Spring (2 Used)
11 - Backup Ring (6 Used) 32 - O-Ring 52 - Adjusting Screw 72 - Check Valve (2 Used)
(4 Used)
12 - O-Ring (6 Used) 33 - Lock Nut 53 - O-Ring 73 - Spool
13 - Housing 34 - Piston 54 - Spring (4 Used) 74 - Spacer
14 - O-Ring 35 - Sleeve 55 - Poppet (4 Used) 75 - Spring
15 - Pump Control Valve 36 - O-Ring 56 - Seat (4 Used) 76 - Cap
16 - O-Ring (8 Used) 37 - O-Ring 57 - O-Ring (4 Used) 77 - Chip (2 Used)
17 - Socket Bolt (16 Used) 38 - Lock Nut 58 - Backup Ring (8 Used) 78 - Backup Ring
18 - Cover 39 - Cap 59 - O-Ring (4 Used) 79 - Cap
19 - Cap (4 Used) 40 - O-Ring 60 - Spring (4 Used) 80 - Cover
20 - Guide (8 Used) 41 - Spring 61 - Piston (4 Used) 81 - Cover (3 Used)
21 - Sleeve (4 Used)
W2-5-25
Overload Relief Valve (50)

Top Face of Control Valve 30 12 61 63 10 64 62 54 56 53
A Pump Control Valve (15)
13
68
50
11 60 59 58 55 57 52 51 W162-02-04-025
W162-02-04-022
1
Main Relief Valve (30) 38
15 40 39 35 33
48 47 45 43 41
49 31
A
W166-02-04-006

46 44 42 37 36 34 32
W162-02-04-038
13
1
Shuttle Valve Flow Combiner Valve
17
50
W162-02-04-024
W162-02-04-023
76
Section A-A
30
W166-02-04-008
13
Makeup Valve
12 6 8 10 5 9 4 2
Check Valve
11 7 3
W162-02-04-028
W162-02-04-027
76
W166-02-04-013
W2-5-26
1. With the manifold mounting face positioned
downward, place housing (13) on a work bench. 11. Install piston (61), springs (60 and 62) to poppet
(63). Then, install poppet (63) to seat (56).
NOTE: Lay soft material between housing (13) and
the work bench. 12. Install seat (56) into sleeve (64).
Main Relief Valve : 36 mm

2. Install lock nut (38), piston (34) and O-rings (36 : 98 Nxm (10 kgfxm, 72 lbfxft)
and 37) to sleeve (35).
IMPORTANT: Install overload relief valves (50) in
3. Install lock nut (33) and O-ring (32) to adjusting the same positions where they were
screw (31). Then, install adjusting screw (31) to previously located. Be sure to adjust
sleeve (35). the overload relief set pressure.
(Refer to the Overload Relief Valve
4. Install poppet (42), spring (41) and sleeve (35) to Adjustment in the Operational
cap (39). Performance Test section in the
Technical Manual.)
5. Install spring (47) and orifice (46) into sleeve (49).
13. Install overload relief valves (50) (4 used) to
6. Install O-ring (45) and backup ring (44) onto seat housing (13).
(43).
: 41 mm
7. Install sleeve (49) onto seat (43). : 98 Nxm (10 kgfxm, 72 lbfxft)
IMPORTANT: Be sure to adjust the main relief set Makeup Valve

pressure. (Refer to the Main Relief 14. Install O-ring (7) and backup ring (8) to poppet (6),
Valve Adjustment in the Operational and O-ring (4) and backup ring (3) to cap (2).
Performance Test section in the
Technical Manual.) 15. Install poppet (6), spring (5) and cap (2) into
sleeve (9).
8. Install main relief valve (30) to housing (13).
: 36 mm
: 41 mm : 98 Nxm (10 kgfxm, 72 lbfxft)
16. Install O-rings (10 and 12) and backup ring (11)
Overload Relief Valve onto sleeve (9). Then, install sleeve (9) to housing
9. Install O-rings (57 and 59) and backup ring (58) (13).
onto seat (56). Install O-ring (53) to adjusting
screw (52). : 41 mm
10. Install poppet (55), spring (54), adjusting screw
(52) and lock nut (51) to seat (56).
: 19 mm
: 6 mm
W2-5-27
Overload Relief Valve (50) Pump Control Valve (15)

Top Face of Control Valve 14
A
13
68
17
W162-02-04-025
W162-02-04-022
Main Relief Valve (30)

15
A
W166-02-04-006

W162-02-04-038
13
Flow Combiner Valve
Shuttle Valve
70 68 67 66 65 73 75 76
72
17
74 40
71 69 40 W162-02-04-024
W162-02-04-023
76
Section A-A
19 18 16
20
22
W166-02-04-008
21 13
Makeup Valve Check Valve 17

20
72 79 78
23 29
28
27
40
71
W162-02-04-028
W162-02-04-027
76
16 80 17 81 W166-02-04-013
W2-5-28
Pump Control Valve Shuttle Valve
17. Install O-ring (14) onto pump control valve (15). 24. Install O-rings (40 and 70) and backup ring (69)
Then, install pump control valve (15) to housing onto cap (68), and O-ring (66) onto seat (65).
(13).
25. Install ball (67) and seat (65) into cap (68).
: 30 mm
: 59 Nxm (6 kgfxm, 43 lbfxft) : 27 mm
4-Spool Section
18. Install O-rings (16) (4 used) on the bottom face of 26. Install check valve (72), spring (71) and cap (68)
housing (13). Then, install covers (80) and (81) (3 into housing (13).
used) to housing (13) with socket bolts (17) (8
used). : 41 mm
: 10 mm
: 98 Nxm (10 kgfxm, 72 lbfxft) Flow Combiner Valve
27. Install O-ring (40) onto cap (76).
19. Insert spool (23) into special tool (ST 4124) and
hold with a vise. After installing guide (20), sleeve 28. Install spool (73), spacer (74), spring (75) and cap
(21), spring (22) and guide (20) onto cap (19), (76) into housing (13).
install cap (19) onto spool (23).
: 46 mm
Check Valve
20. Assemble spools (27, 28 and 29) (3 used) 29. Install O-ring (40) and backup ring (78) onto cap
following the same procedure as described in step (79).
19.
30. Install check valve (72), spring (71) and cap (79)
21. Install O-rings (16) (4 used) on housing (13). into housing (13).
IMPORTANT: Install each spool (23, 27, 28 or 29) in : 14 mm

the same position where it was : 345 Nxm (35 kgfxm, 255 lbfxft)
previously located. Install spool (27)
so that lock plug for cover (80) enter
into the spool groove.
22. Holding the spring section of each spool (23, 27,

28 or 29), insert the spool into housing (13) while
slowly rotating the spool.
23. Install cover (18) to housing (13) with socket bolts

(17) (8 used).
: 10 mm
W2-5-29
3
Center Bypass Valve 35
2
34
1
25
26
27
33 31
9 24
32 30
25
26
27
29
23
24
Arm 2 25
26
27
28 22
Boom 1 2
Bucket
1
21
4 20
5 19
16 18
17
15 9
14 8
7
6
5
13 4
12
11
Holding Valve (Boom) 10
W166-02-04-011
1- Socket Bolt (7 Used) 10 - Sleeve 19 - O-Ring 28 - Cap (2 Used)

2- Washer (7 Used) 11 - O-Ring 20 - Spring 29 - Cap
3- Housing 12 - Backup Ring 21 - Poppet 30 - Check Valve
4- Cap (2 Used) 13 - Cover 22 - Orifice 31 - Check Valve
5- O-Ring (2 Used) 14 - Socket Bolt (4 Used) 23 - Check Valve (2 Used) 32 - Cap (3 Used)
6- Spring 15 - Washer (4 Used) 24 - Spring (3 Used) 33 - Cap
7- Poppet 16 - Piston 25 - O-Ring (7 Used) 34 - Spool
8- Backup Ring 17 - O-Ring 26 - Backup Ring (7 Used) 35 - Spring
9- O-Ring (4 Used) 18 - Backup Ring 27 - Chip (7 Used)
W2-5-30
Disassemble Control Valve 4 Center Bypass Valve
Thoroughly read Precaution for Disassembly and 8. Loosen and remove cap (33) from housing (3).
Assembly on page W1-1-1 before starting to
work. : 46 mm
Holding Valve (Boom) 9. Remove spool (34) and spring (35) from housing
1. Remove socket bolts (14) (4 used) and holding (3).
valve cover (13) from housing (3).
Orifice
: 12 mm 10. Install special tool (ST 4941) of socket bolt (M5,
pitch: 1.0, length: 60 mm) into orifice (22).
2. Remove spring (20) and poppet (21) from housing
(3). 11. While holding socket bolt (M5, pitch: 1.0, length:
60 mm) so that the bolt does not rotate, turn the
3. Remove caps (4) (2 used), spring (6), poppet (7), bolt head of special tool (ST 4941) counter-
sleeve (10) and piston (16) from cover (13). clockwise to remove orifice (22) from housing (3).
Attach a round bar approx. 10 mm in diameter to
sleeve (10). While tapping the bar, remove sleeve : 4 mm
(10) taking care not to damage cover (13). : 17 mm
: 10 mm
Load Check Valve

(Arm 2)
4. Loosen and remove cap (29) from housing (3).
: 14 mm
5. Remove check valve (30), spring (24) and check

valve (31) from housing (3).
(Except for Arm 2)
6. Loosen and remove cap (28) from housing (3).
: 14 mm
7. Remove springs (24) (2 used) and check valve

(23) (2 used) from housing (3).
W2-5-31
Center Bypass Valve Arm 2 Boom 1, Bucket
34 35 26 33 9 29 28
25
32 25
26
26 27
27
30
23
24
31
24
27 25
W162-02-04-030 W162-02-04-029
W162-02-04-026
Arm 2 Boom 1 Bucket
Holding Valve (Boom)
13 16 9, 12 8, 11 7 6
3
1, 2
5
Center 1, 2
Bypass 5
4
Valve 4
1, 2 1, 2
17
18, 19 10
20 14, 15
W166-02-04-016
21
22
Holding Valve (Boom)
W162-02-04-037
1- Socket Bolt (7 Used) 10 - Sleeve 19 - O-Ring 28 - Cap (2 Used)

2- Washer (7 Used) 11 - O-Ring 20 - Spring 29 - Cap
3- Housing 12 - Backup Ring 21 - Poppet 30 - Check Valve
4- Cap (2 Used) 13 - Cover 22 - Orifice 31 - Check Valve
5- O-Ring (2 Used) 14 - Socket Bolt (4 Used) 23 - Check Valve (2 Used) 32 - Cap (3 Used)
6- Spring 15 - Washer (4 Used) 24 - Spring (3 Used) 33 - Cap
7- Poppet 16 - Piston 25 - O-Ring (7 Used) 34 - Spool
8- Backup Ring 17 - O-Ring 26 - Backup Ring (7 Used) 35 - Spring
9- O-Ring (4 Used) 18 - Backup Ring 27 - Chip (7 Used)
W2-5-32
Orifice Holding Valve

1. Install socket bolt (M5, pitch: 1.0, length: 60 mm) 8. After installing O-ring (19) and backup ring (18)
to orifice (22). Then, install orifice (22) into onto poppet (21), install poppet (21) and spring
housing (3) while tapping the bolt head. (20) into housing (3).

and 8) onto sleeve (10).
Load Check Valve
(Boom 1, Bucket) 10. Install piston (16), sleeve (10), poppet (7) and
spring (6) into cover (13).
2. Install check valve (23) and spring (24) into
housing (3). 11. Install O-ring (17) on cover (13).
3. Install O-ring (25) and backup ring (26) onto cap 12. After installing O-rings (5) onto caps (4) (2 used),
(28). Then, install cap (28) into housing (3). install caps (4) (2 used) into cover (13).
: 14 mm : 10 mm
: 345 Nxm (35 kgfxm, 255 lbfxft) : 49 Nxm (5 kgfxm, 36 lbfxft)
(Arm 2) 13. Install cover (13) to housing (3) with socket bolts
(14) (4 used).
4. Install check valve (31), spring (24) and check
valve (30) into housing (3). : 12 mm
5. Install O-ring (25) and backup ring (26) onto cap
(29). Then, install cap (29) into housing (3).
: 14 mm
Center Bypass Valve

6. Install O-ring (25) and backup ring (26) onto cap
(33).
7. Install spool (34), spring (35) and cap (33) into

housing (3).
: 46 mm
W2-5-33
1
2 18
13 17
12 3
11 4 19
10 5 20
9 16 17
8 15
20
7 14 31 32
Check Valve C 6 30
29
28
27
22
Check
Valve D
15
34 17 20
16 21
15 15
34
18
18 15
34
20
Check Valve B
15 5
22 4
17 27
15 Check
28 23
20 34 Valve A
21 16 29
20 30
15
32 31 34
3 26
5 33 25
4 7 24
6 8
43
18 42
41 35
2 36
37
38
40 39
Arm Regenerative Valve
W166-02-04-012
1- Backup Ring 12 - O-Ring 23 - Chip (2 Used) 34 - Socket Bolt (14 Used)

2- Backup Ring (3 Used) 13 - Cap 24 - Cap (2 Used) 35 - Spool
3- O-Ring (2 Used) 14 - Manifold 25 - Backup Ring (2 Used) 36 - Spring
4- Spring (4 Used) 15 - Washer (21 Used) 26 - O-Ring (2 Used) 37 - Spring Guide
5- Check Valve (4 Used) 16 - Socket Bolt (7 Used) 27 - Spring Guide (2 Used) 38 - O-Ring (2 Used)
6- Backup Ring (4 Used) 17 - O-Ring (5 Used) 28 - Spring (2 Used) 39 - Cap
7- O-Ring (2 Used) 18 - O-Ring (8 Used) 29 - Check Valve (2 Used) 40 - Sleeve
8- O-Ring (2 Used) 19 - O-Ring 30 - O-Ring (2 Used) 41 - Piston
9- Cap 20 - O-Ring (13 Used) 31 - Backup Ring (2 Used) 42 - O-Ring
10 - Check Valve 21 - O-Ring (3 Used) 32 - Seat (2 Used) 43 - Sleeve
11 - Spring 22 - O-Ring (2 Used) 33 - Backup Ring
W2-5-34
Disassemble Control Valve 5 Check Valve B
Thoroughly read Precaution for Disassembly and 8. Loosen and remove caps (24) (2 used) from
Assembly on page W1-1-1 before starting repair manifold (14).
work.
: 14 mm
Manifold
NOTE: Before placing 4-spool or 5-spool housing 9. Remove springs (4) (2 used) and check valve (5)
and manifold on a work bench, lay soft from manifold (14).
material on the work bench to protect the
housing or manifold mounting surface from Check Valve C
damaged. 10. Loosen and remove caps (9) from manifold (14).
1. Remove socket bolts (16) (6 used) and the 4- : 46 mm

spool side housing socket bolts (7 used) and the
4-spool side housing from manifold (14). 11. Remove spring (4) and check valve (5) from
manifold (14).
: 14 mm
12. Remove cap (13), spring (11) and check valve
2. Remove O-rings (17) (2 used), (18) (4 used), (20) (10) from cap (9).
(6 used), (21) and (22) from manifold (14).
: 8 mm
3. Remove socket bolts (16) (1 used), (34) (14 used)
and the 5-spool side housing socket bolts (4 Check Valve A, D
used) and the 5-spool side housing from manifold 13. Using a copper bar, tap spring guide (27) from 5-
(14). spool manifold (14) for the check valve A side and
4-spool manifold (14) for the check valve D side to
: 14 mm remove seat (32), check valve (29), spring (28),
and spring guide (27).
4. Remove O-rings (17) (3 used), (18) (4 used), (19)
(1 used), (20) (7 used), (21) (3 used) and (22) (1
used) from manifold (14).
Arm Regenerative Valve

5. Remove sleeve (40), spring (36) and spool (35)
from manifold (14).
: 46 mm
6. Using a screw driver, push check valve (5) from

the 5-spool housing side, remove sleeve (43),
spring (4) and check valve (5) from manifold (14).
7. Remove cap (39) and spring guide (37) from

sleeve (40).
: 12 mm
W2-5-35
Check Valve A, D Check Valve B

32
24
30 26
31
25 4
29 28 23 5
27
W162-02-04-044
W162-02-04-041
Manifold (4-Spool Side) Manifold (Top Face) Manifold (5-Spool Side)
18 22 18 15, 34 14 18 15, 34 19 15, 34
14 15, 34 14
18
17 Arm
Check 17
Regenerative
Valve C Valve
20
17
22
20
20
15, 16 Check Valve D
Check Valve C 15, 34
15, 16
Check Check Valve C
17 Valve B Check
Valve B
18 17
21 15, 34 18
21 20 18 18
W166-02-04-015
Arm Regenerative Valve Check Valve C
5 4 3 43 7 35 36 38 5 4 3 7 10 9 12
39
13
6 2 11 1, 8
6 33, 42 2 41 8 40 37 W162-02-04-039
W162-02-04-040
1- Backup Ring 12 - O-Ring 23 - Chip (2 Used) 34 - Socket Bolt (14 Used)

2- Backup Ring (3 Used) 13 - Cap 24 - Cap (2 Used) 35 - Spool
3- O-Ring (2 Used) 14 - Manifold 25 - Backup Ring (2 Used) 36 - Spring
4- Spring (4 Used) 15 - Washer (21 Used) 26 - O-Ring (2 Used) 37 - Spring Guide
5- Check Valve (4 Used) 16 - Socket Bolt (7 Used) 27 - Spring Guide (2 Used) 38 - O-Ring (2 Used)
6- Backup Ring (4 Used) 17 - O-Ring (5 Used) 28 - Spring (2 Used) 39 - Cap
7- O-Ring (2 Used) 18 - O-Ring (8 Used) 29 - Check Valve (2 Used) 40 - Sleeve
8- O-Ring (2 Used) 19 - O-Ring 30 - O-Ring (2 Used) 41 - Piston
9- Cap 20 - O-Ring (13 Used) 31 - Backup Ring (2 Used) 42 - O-Ring
10 - Check Valve 21 - O-Ring (3 Used) 32 - Seat (2 Used) 43 - Sleeve
11 - Spring 22 - O-Ring (2 Used) 33 - Backup Ring
W2-5-36
Assemble Control Valve 5 Arm Regenerative Valve
1. Place manifold (14) on a work bench with the 5- 10. Install piston (41), O-rings (3 and 42), backup
spool housing mounting face positioned upwards. rings (33) and (6) (2 used) to sleeve (43). Install
sleeve (43) into sleeve (40).
NOTE: Before placing the manifold on a work
bench, lay soft material on the work bench 11. Install O-rings (7 and 8) and backup ring (2) onto
to protect the housing mounting surface sleeve (40).
from damaged.
12. Install spool (35) into sleeve (40), and install
Check Valve C check valve (5) and spring (4) into sleeve (43)
2. Install check valve (10) and spring (11) into cap respectively. Then, install sleeve (40) into
(9). manifold (14).
3. Install O-ring (12) onto cap (13) and install cap : 46 mm

(13) into cap (9). : 175 Nxm (18 kgfxm, 130 lbfxft)
: 8 mm 13. Install spring (36) and spring guide (37) into

: 39 Nxm (4 kgfxm, 29 lbfxft) sleeve (40).
4. Install O-rings (3, 7, and 8), backup rings (1), (2) 14. Install O-ring (38) onto cap (39). Install cap(39)
(2 used) and (6) (2 used) onto cap (9). into sleeve (40).
5. Install check valve (5) and spring (4) into cap (9). : 12 mm
Install cap (9) into manifold (14). : 98 Nxm (10 kgfxm , 72 lbfxft)
: 46 mm 15. Install O-rings (17) (3 used), (18) (4 used), (19) (1

: 175 Nxm (18 kgfxm, 130 lbfxft) used), (20) (7 used), (21) (2 used) and (22) (1
used) on manifold (14).
Check Valve B
6. Install O-ring (26) (2 used) and backup ring (25) (2 16. Install manifold (14) to the 5-spool housing.
used) onto cap (24).
17. Tighten socket bolts (34) (14 used), (16) (1 used)
7. Install check valves (5) (2 used) and spring (4) (2 and the 5-spool housing socket bolts (4 used).
used) into cap (24) (2 used). Install cap (24) (2
used) into manifold (14). : 14 mm
: 14 mm
Check Valve D
8. Install spring guide (27), spring (28), and check
valve (29) into manifold (14).
9. Install O-ring (30) and backup ring (31) onto seat

(32). Install seat (32) into manifold (14).
W2-5-37
Check Valve A, D Check Valve B

32
30
31
29 28
27
W162-02-04-044
W162-02-04-041
Manifold (4-Spool Side) Manifold (Top Face) Manifold (5-Spool Side)
18 22 18 14
14 14
17 Check
Valve C
20
16 Check Valve D
20
17
18
21 20 18
W166-02-04-015
Arm Regenerative Valve Check Valve C
W162-02-04-039
W162-02-04-040
W2-5-38
Check Valve A
18. Install spring guide (27), spring (28), and check
valve (29) into manifold (14).
19. Install O-ring (30) and backup ring (31) onto seat
(32). Install seat (32) into manifold (14).
20. Install O-rings (17) (2 used), (18) (4 used), (20) (6

used), (21) (1 used) and (22) (1 used) on the 4-
spool housing mounting face of manifold (14).
21. Install the 4-spool housing to manifold (14).
22. Tighten socket bolts (16) (6 used) and the 4-spool

housing side socket bolts (7 used).
: 14 mm
W2-5-39
(Blank)
W2-5-40
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE

can penetrate the skin or eyes, causing
serious injury. Avoid this hazard by relieving
lines.
Hot hydraulic oil may spout after operation,
possibly causing severe burns. Wait for oil to
cool before starting any repair work.
The hydraulic oil tank cap may pop off if re-
moved without releasing internal pressure
first. Thoroughly release any remaining pres-
sure before removing the cap.
Preparation
1. Park the machine on a solid level surface. Lower
the bucket to ground.

pressure remaining in the system. Rotate the hy-
draulic oil tank cap approx. 30 counterclockwise
to release pressure remaining in the hydraulic oil
tank.
3. Remove the hydraulic oil tank cap. Connect a

vacuum pump and operate it continuously to
maintain negative pressure in the hydraulic oil
tank.
NOTE: Run the vacuum pump continuously while

working on the hydraulic system.
W2-6-1
Removal
1 2 3 4 5
1. Disconnect hoses (1 to 6 and 8 to 10) as
necessary.
: 41 mm
6
: 36 mm
: 27 mm 10
: 22 mm
: 39 Nxm (4 kgfxm, 29 lbfxft) 7
NOTE: Cap the disconnected hose ends. 9
8
2. Remove bolt (7) and spacer (11). W166-02-05-003
17
7
: 32 mm
3. Remove corks (12) (2 used) using a screw driver, 7

14
and clean forcing bolt holes using a tap (M22, 11
Pitch 2.5) 12 12
4. Install the forcing bolts (2 used), and attach nylon

slings to swing device assembly (13). 14
W166-02-05-008
CAUTION: Swing device assembly weight:

280 kg (620 lb) Forcing Bolt
14
Hole
5. Sling swing device assembly (13) with a crane or
hoist and separate swing device assembly (13) 14
from the main frame by prying on the forcing bolt Forcing Bolt
Front Side
Hole
head using a pry bar.
Drive out knock pins (14) (2 used) using a bar.
14
Forcing Bolt
Hole
Forcing Bolt
14 Hole
W166-02-06-004
6. Remove the other swing device assembly (13) Nylon Sling

following the same procedure.
13
W155-02-06-012
W2-6-2
Installation
17
NOTE: Refer to Removal section for wrench sizes 7
and tightening torque.
11
1. After applying a fluid packing to the mating sur- 7
faces on the swing device. 14
11
12 12
CAUTION: Swing device assembly weight:
280 kg (620 lb)
14
2. Place the swing device assembly on the main
frame. W166-02-05-008
Drive knock pins (14) (2 used) so that the swing

device assembly bolt hole is aligned with the main
frame bolt hole. 14
Forcing Bolt
Remove nylon sling. Hole
14
3. Install spacer (11) and bolts (7).
Drive new cork (12) into forcing bolt hole. Forcing Bolt
Front Side
Hole
11
4. Install the other swing device assembly following 11
the same procedure. 14
Forcing Bolt
5. Connect hoses (1 to 6 or 8 to 10). Hole
Forcing Bolt
IMPORTANT: Be sure to fill the swing motor with 14 Hole
hydraulic oil after installing it. Check
the oil level. Check for any oil leaks W166-02-06-004
after starting the engine.

1 2 3 4 5
10
8
W166-02-05-003
W2-6-3
DISASSEMBLE SWING DEVICE 1
25
26
27 4
5
28
6
29 7
21
30 22 8
23
24 9
31 20
10
11
32 19 8
12
18
33 13
17 14
13
15
16
W166-02-05-006
1 - Motor 10 - First Stage Planetary Gear 18 - Second Stage Carrier 26 - Housing

(3 Used)
2- Socket Bolt (12 Used) 11 - Spring Pin (6 Used) 19 - Thrust Plate 27 - O-Ring
3- Internal Gear 12 - Pin (3 Used) 20 - Second Stage Sun Gear 28 - Bearing
4- Internal Gear 13 - Thrust Plate (6 Used) 21 - First Stage Carrier 29 - Cover
5- First Stage Sun Gear 14 - Second Stage Planetary 22 - Bolt (8 Used) 30 - Oil Seal
Gear (3 Used)
6- Thrust Plate (2 Used) 15 - Spring Pin (3 Used) 23 - Screw (3 Used) 31 - Sleeve
7- Pin (3 Used) 16 - Bearing 24 - Magnet (3 Used) 32 - O-Ring
8- Thrust Plate (6 Used) 17 - Retaining Ring 25 - Pin (2 Used) 33 - Shaft
9- Needle Bearing (3 Used)
W2-6-4
Disassemble Swing Device
Before starting any repair work, thoroughly read 7. Remove retaining ring (17) from shaft (33).
bling (W1-1-1).
CAUTION: Housing (26), shaft (33) and other
part assembly weight: 145 kg (320 lb)
CAUTION: Swing motor weight: 60 kg
(130 lb) 8. Turn housing (26) over.
1. Drain gear oil from the swing device. Put matching 9. Remove bolts (22) and cover (29). Remove O-ring
marks at the mating sections of motor (1), internal (27) from cover (29).
gears (3 and 4) and housing (26). Remove socket
bolts (2). Remove motor (1) using a crane. : 19 mm
: 14 mm
parts assembly weight: 140 kg (310 lb)
2. Remove first stage sun gear (5). Remove first
stage carrier (21) assembly from internal gear (3).
10. Turn over housing (26).
3. Remove second stage sun gear (20) from second
stage carrier (18).
CAUTION: Internal gear (3) weight: 20 kg

(44 lb)
4. Remove internal gear (3) from internal gear (4).
NOTE: Insert a screw driver between internal

gears (3 and 4) to pry internal gear (3) up
for easy separation.
CAUTION: Second stage carrier (18)

assembly weight: 21 kg (46 lb)
5. Sling second stage carrier (18) with wires or belts.

Remove second stage carrier (18) using a crane.

(44 lb)
6. Remove internal gear (4) from housing (26).
NOTE: Insert a screw driver between internal gear

(4) and housing (26) to pry internal gear (4)
up for easy separation.
W2-6-5
26
28
33
W166-02-05-006
W2-6-6
CAUTION: Before pressing shaft (33), pro- Shaft (33)

vide a protection cover (outer diameter: 290 Bearing (28)
mm (11.4), inner diameter: 90 mm (3.5), Housing (26)
thickness: 25 to 30 mm). Then, use the press
to remove shaft (33) while covering housing
(26) and bearing (28) with the protection
Protection Cover
cover. Failure to use the protection cover may
result in personal injury due to metal frag-
ments flying out if housing (26) and/or break-
ing bearing (28). Use a press with the capac-
ity less than 30 tons (66000 lb). Be sure to
degrease the housing inside before heating
W157-02-06-010
bearing (28). Failure to degrease may cause a Press
fire.
11. Remove shaft (33) from housing (26) using a

press. Bearing Remove
Special Tool Set
12. Attach shaft (33) assembly to the special tool

bearing removal set.
NOTE: Use the following parts as the special tool

set for removing bearing (28).
Part Size Remarks W157-02-06-011
Shaft Length: 270 mm 6 to 8 used. All should be Hose Clamp

or Bolt (11 in) identical in length with no Shaft
Diameter: 19 mmwear and deformation on Hose Clamp
(3/4 in) both ends.
Material: S35C,
1035 (AISI)
Hose Standard Diame- 2 used.
Clamp ter: 8-1/2
(Applicable Di-
ameter: 185 to
215 mm)
Guide Height: 230 mm
(9 in)
Outer Diameter:
230 mm (9.06 in) W157-02-06-012
Inner Diameter:
210 mm (8.27 in) Shaft (33)
Bearing (28)
Sleeve
Shaft
W157-02-06-013
Guide
W2-6-7
26
5
28
6
29 7
21
30 22 8
23
24 9
31
10
11
32 19 8
12
18
33 13
14
13
15
16
W166-02-05-006
W2-6-8
CAUTION: Be sure to use the guide when Press

pushing shaft (33) with a press.
13. Attach shaft (33) with the special tool to a press.

Then, remove shaft (33).
14. Remove sleeve (31) from shaft (33). Remove O-

ring (32) from sleeve (31). Bearing (28)
Remove screw (23) (3 used) and magnet (24) (3 Sleeve (31)
used) from sleeve (31).
15. Remove oil seal (30) from cover (29).

Guide
16. Remove bearing (16) from housing (26).
17. Drive spring pin (11) out of first stage carrier (21)
using a round bar and a hammer.
W157-02-06-014
(dia.: 5.0 mm, length: 50 mm or longer)
18. Remove three pins (21), three first stage

planetary gears (10), six thrust plates (8) and
three needle bearings (9) from first stage carrier
(21).
19. Remove thrust plates (6) from first stage carrier

(21).
20. Disassemble second stage carrier (18) assembly

referring to steps 17 to 19 above.
NOTE: No needle bearings are used on second

stage planetary gear (14).
W2-6-9
ASSEMBLE SWING DEVICE
2 1 21 5 6 7
11
3
8
9
20
10
4
8
15
18
19
13
17
14
16 25
13
12
26
28
29
27
22
W166-02-05-007
31 32 33 24 30 23
1 - Motor 10 - First Stage Planetary Gear 18 - Second Stage Carrier 26 - Housing

(3 Used)
2- Socket Bolt (12 Used) 11 - Spring Pin (6 Used) 19 - Thrust Plate 27 - O-Ring
3- Internal Gear 12 - Pin (3 Used) 20 - Second Stage Sun Gear 28 - Bearing
4- Internal Gear 13 - Thrust Plate (6 Used) 21 - First Stage Carrier 29 - Cover
5- First Stage Sun Gear 14 - Second Stage Planetary 22 - Bolt (8 Used) 30 - Oil Seal
Gear (3 Used)
6- Thrust Plate (2 Used) 15 - Spring Pin (3 Used) 23 - Screw (3 Used) 31 - Sleeve
7- Pin (3 Used) 16 - Bearing 24 - Magnet (3 Used) 32 - O-Ring
8- Thrust Plate (6 Used) 17 - Retaining Ring 25 - Pin (2 Used) 33 - Shaft
9- Needle Bearing (3 Used)
W2-6-10
Assemble Swing Device
IMPORTANT: Set thrust plate (6) so that the 8. Install O-ring (32) on sleeve (31). Install sleeve
surface having oil grooves faces (31) onto shaft (33).
upwards.
9. Press bearing (28) onto shaft (33).
1. Install thrust plates (6) in first stage carrier (21).
CAUTION: Housing weight: 74 kg (163 lb)
2. Install one needle bearing (9) in each first stage
planetary gear (10) (3 used).
10. Place housing (26) with the swing motor mounting
side facing downward on a press. Install shaft (33)
IMPORTANT: Install thrust plates (8) with the
assembly into housing (26) using the press.
grooved side facing toward first
11. Install O-ring (27) in cover (29).
3. Install three first stage planetary gears (10) and
12. Install oil seal (30) on cover (29).
six thrust plates (8) into first stage carrier (21).
13. Install cover (29) on housing (26). Secure cover
4. Aligning the hole on pin (7) (3 used) with the
(29) with bolts (22) (8 used).
spring pin hole on first stage carrier (21), install
pins (7) into first stage carrier (21).
: 19 mm
5. Tap spring pin (11) into first stage carrier (21) and
pin (7) using a hammer.
NOTE: When tapping spring pin (11) into first stage parts assembly weight: 140 kg (310 lb)
carrier (21) and pin (7), face the slit of
spring pin (11) toward the end face of pin 14. Press bearing (16) into housing (26) and onto
(7). shaft (33).
11 Slit
6. Assemble second stage carrier (18) referring to

steps 1 to 5 above.
NOTE: No needle bearings are used on second

stage carrier (18).
7. Install magnets (24) (3 used) and screws (23) (3

used) on sleeve (31).
W2-6-11
2 1 21 5
20
18
26
17
W166-02-05-007
33
W2-6-12
15. Install retaining ring (17) on shaft (33). 22. Apply THREEBOND #1215 to internal gear (3)
mating face on internal gear (4).
CAUTION: Second stage carrier (18) assem-
bly weight: 21 kg (46 lb) CAUTION: Internal gear (3) weight: 20 kg
(44 lb)
16. Lift and install second stage carrier (18) assembly
into housing (26) with a crane. 23. Aligning the matching marks, put when disas-
sembling, install internal gear (3) on internal gear
17. Apply THREEBOND #1215 to internal gear (4) (4).
mounting face on housing (26).
24. Fill with gear oil.
Gear Oil: 5.3 L (5.6 US qt)
(44 lb)
18. Aligning the matching marks, put when disas- CAUTION: Swing motor weight: 60 kg
sembling, install internal gear (4) on housing (26). (130 lb)
19. Install second stage sun gear (20) into second 25. Lifting motor (1) with a crane, secure motor (1) on
stage carrier (18). the swing device with socket bolts (2).
20. Install first stage carrier (21) assembly on second : 14 mm

stage carrier (18). : 295 Nxm (30 kgfxm, 215 lbfxft)
21. Install first stage sun gear (5) into first stage
carrier (21).
IMPORTANT: Install first stage sun gear (5) with

the stepped end face positioned
downward.
W2-6-13
DISASSEMBLE SWING MOTOR
4 9
10
3 5
6 11
7
8 12
2
1 13
14
15 17
16
18
28 30
19
20
21
22 31
32
23
24
25
26
27 33
34
29
35
36
35
37
38
39
40
41
W166-02-05-005
1- Roller Bearing 12 - O-Ring 22 - Spacer 32 - Casing
2- O-Ring 13 - Friction Plate (2 Used) 23 - Rotor 33 - Shaft
3- Valve Casing 14 - Relief Valve (2 Used) 24 - Push Rod (12 Used) 34 - Retaining Ring
4- Socket Bolt (4 Used) 15 - Pin (2 Used) 25 - Spacer 35 - Spacer (2 Used)
5- Poppet (2 Used) 16 - Retaining Ring 26 - Holder 36 - Roller Bearing
6- Spring (2 Used) 17 - O-Ring 27 - Retainer Plate 37 - Retaining Ring
7- O-Ring (2 Used) 18 - Plate (3 Used) 28 - Plunger (9 Used) 38 - O-Ring
8- Plug (2 Used) 19 - Retaining Ring 29 - Thrust Plate 39 - Oil Seal
9- Valve Plate 20 - Spacer 30 - Plug 40 - Seal Cover
10 - Spring (16 Used) 21 - Spring 31 - O-Ring 41 - Retaining Ring
11 - Brake Piston
W2-6-14
Disassemble Swing Motor
Before starting any repair work, thoroughly read 6. Remove valve casing (3) from casing (32).
bling (W1-1-1). NOTE: Valve plate (9) may come off together with
valve casing (3). Carefully remove valve
CAUTION: Swing motor weight: 60 kg casing (3) so that valve plate (9) does not
(130 lb) drop.
1. Remove plug (30) from casing (32) to drain 7. If valve plate (9) has not been removed in the
hydraulic oil. previous step and remains on the rotor side,
remove valve plate (9) from the rotor. Then,
: 19 mm remove the 16 pieces of springs (10). If a screw
driver or similar tool is used to separate valve
Relief Valve plate (9) from the rotor , take care not to damage
the mating surface.
2. Remove two relief valves (14) from valve casing
(3). 8. Install a bolt into screw hole (M8, pitch 1.25) on
brake piston (11). Then, remove brake piston (11)
IMPORTANT: Do not disassemble relief valve (14). from casing (32).
: 36 mm 9. Remove O-rings (12 and 17) from casing (32).
Make-Up Valve
3. Remove two plugs (8).
: 14 mm
4. Remove two springs (6) and poppets (5).
5. Put a matching marks on the mating section

between valve casing (3) and casing (32). Loosen
and remove four socket bolts (4).
: 17 mm
NOTE: Note that valve casing (3) will be raised by

spring (10) force.
W2-6-15
1 13
15
16
18
28
19
20
21
22
32
23
24
25
26
27 33
34
29
35
36
35
37
39
40
41
W166-02-05-005
W2-6-16
10. Lay casing (32) and pull rotor (23) out of shaft
CAUTION: When removing retaining ring
(33).
(19), be sure to hold spacer (20) with a press
or a similar tool. Otherwise, retaining ring
11. Remove three plates (18) and two friction plates
(19) and spacer (20) will fly off, causing per-
sonal injury.
12. Remove retaining ring (41) and seal cover (40)
21. Holding spacer (20) with a press, remove
from casing (32).
retaining ring (19).
13. Remove shaft (33) from casing (32) by tapping
22. Remove spacer (22) and spring (21).
the end of shaft (33) with a plastic hammer.
14. Remove thrust plate (29).
15. Remove oil seal (39) from seal cover (40).
16. Using a puller, remove the outer race of roller

bearing (1) from valve casing (3). Remove O-ring
(2) and two pins (15).
17. Remove retaining ring (16) and the inner race of

roller bearing (1) from shaft (33).
18. Remove retaining rings (34 and 37) and two

spacers (35) from shaft (33).
19. Using a press, remove the inner race of roller

bearing (36) from shaft (33).
20. Remove nine plungers (28), retainer plate (27),

holder (26), spacer (25) and twelve push rods (24)
from rotor (23).
W2-6-17
ASSEMBLE SWING MOTOR
7 8 14
31, 30
1
3
20 W111-02-06-042
2 16
10
11 15
12 9
17
19
21 18
22
13
28
24 23
25
26
27
36
38
41 29 32
39
40 33 34, 35 37, 35 T166-03-02-002
1- Roller Bearing 12 - O-Ring 23 - Rotor 34 - Retaining Ring

2- O-Ring 13 - Friction Plate (2 Used) 24 - Push Rod (12 Used) 35 - Spacer (2 Used)
3- Valve Casing 14 - Relief Valve (2 Used) 25 - Spacer 36 - Roller Bearing
4- Socket Bolt (4 Used) 15 - Pin (2 Used) 26 - Holder 37 - Retaining Ring
5- Poppet (2 Used) 16 - Retaining Ring 27 - Retainer Plate 38 - O-Ring
6- Spring (2 Used) 17 - O-Ring 28 - Plunger (9 Used) 39 - Oil Seal
7- O-Ring (2 Used) 18 - Plate (3 Used) 29 - Thrust Plate 40 - Seal Cover
8- Plug (2 Used) 19 - Retaining Ring 30 - Plug 41 - Retaining Ring
9- Valve Plate 20 - Spacer 31 - O-Ring
10 - Spring (16 Used) 21 - Spring 32 - Casing
11 - Brake Piston 22 - Spacer 33 - Shaft
W2-6-18
Assemble Swing Motor
1. Install retaining ring (34) and one spacer (35) on 12. After installing nine plungers (28) to retainer plate
shaft (33). Press the inner race of roller bearing (27), apply a film of hydraulic oil to the plunger
(36) onto shaft (33). holes in rotor (23). Then, insert plungers (28) into
rotor (23).
2. After installing another spacer (35) on shaft (35),
install retaining ring (37). 13. Lay casing (32). Install rotor (23) assembly onto
shaft (33).
3. Press the inner race of roller bearing (1) onto
shaft (33). Install retaining ring (16). IMPORTANT: Plate (18) has notches on the outer
diameter. Friction plate (13) has
4. Using a metal bar extension and a hammer, install notches on the spline teeth. Install
the outer race of roller bearing (36) into casing plate (18) and friction plate (13) so
(32). that notch positions on both parts
align.
5. Install oil seal (39) into seal cover (40) using a
protection plate and a press. 14. Stand casing (32) upright. Install three plates (18)
and two friction plates (13) one by one alternately.
6. Install O-ring (38) in casing (32).
IMPORTANT: Install brake piston (11) so that the
7. Install shaft (33) and thrust plate (29) in casing slits on brake piston (11) are located
(32). as illustrated.
8. Apply a film of grease to the lip of oil seal (39).

Install seal cover (40) and retaining ring (41) into Slit
casing (32).
9. Install spacer (22), spring (21), and spacer (20)

into rotor (23), in that order.
10. Using a press, push spacer (20) until retaining

ring (19) is installed. Install retaining ring (19). Brake Piston
W142-02-06-011
11. Install twelve push rods (24) in rotor (23). Install
spacer (25) and holder (26) in rotor (23), in that
15. Install O-rings (17 and 12) in casing (32).
order.
W2-6-19
7 8 14
1
3
W111-02-06-042
2
10
11 15
12 9
17
32
T166-03-02-002
W2-6-20
16. Install brake piston (11) into casing (32). If brake
piston (11) is hard to move into casing (32)
because of friction between O-rings (12 and 17),
uniformly tap on the piston with a plastic hammer.
17. Install sixteen springs (10) in brake piston (11).
IMPORTANT: When installing roller bearing (1),

tap the side face on which the
bearing type is marked with a plastic
hammer.
18. Drive the outer race of roller bearing (1) into valve
casing (3) with a plastic hammer.
19. Install O-ring (2), two pins (15), and valve plate (9)
(with the flat surface facing the valve casing) to
valve casing (3).
NOTE: Apply a film of grease to valve plate (9) to

prevent valve plate (9) from coming out of
valve casing (3).
IMPORTANT: While taking care not to allow valve

plate (9) to drop off, align the match-
ing marks (put during disassembly).
20. Secure valve casing (3) to casing (32) with four

socket bolts (4).
: 17 mm
Makeup Valve
21. Install two poppets (5) and springs (6) in valve
casing (3). Tighten plugs (8) with O-rings (7).
: 14 mm
Relief Valve
22. Install two relief valves (14) to valve casing (3).
: 36 mm
W2-6-21
Swing motor
1. Clearance between Plunger and Rotor Bore.(D-d)
Standard Clearance Allowable Limit d
0.028 mm (0.001 in) 0.058 mm (0.002 in)
NOTE: 1 mm=0.03937 in
W107-02-06-138
D D
W107-02-06-139
2. Clearance between Plunger Top and Shoe Bottom

()
Standard Clearance Allowable Limit
0 0.3 mm (0.012 in)

NOTE: 1 mm=0.03937 in
W107-02-06-140
W107-02-06-141
W2-6-22
3. Shoe Thickness (t)
5.5 mm (0.217 in) 5.3 mm (0.209 in)
NOTE: 1 mm=0.03937 in t
W107-02-06-142
4. Friction Plate Thickness
4.0 mm (0.157 in) 3.6 mm (0.142 in)
NOTE: 1 mm=0.03937 in
W107-02-06-143
2
5. Holder Height from Retainer Plate Bottom Face
(H - h) 1
6.5 mm (0.256 in) 6.0 mm (0.236 in)
If dimension H - h is reduced to below 6 mm, h H

replace retainer plate (1) and holder (2).
W107-02-06-146
NOTE: 1 mm=0.03937 in
W2-6-23
(Blank)
W2-6-24
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL RIGHT PILOT
VALVE (FRONT ATTACHMENT)

Avoid this hazard by relieving pressure be-
fore disconnecting hydraulic lines.
hydraulic oil may spout, possibly causing se-
vere burns. Be sure to wait for oil to cool be-
fore starting any repair work.
any remaining pressure before removing.
Preparation

tank.
W2-7-1
Removal
1. Remove screws (6, 1, and 5)(two used each), 1 2 3
cover (7) and frame (2). Remove four screws (4)
and boot (3). 4
6
7
W157-02-07-007
2. Remove two bolts (8). Raise stand (9).

Move the console to the utmost front position.
: 17 mm
8 9 W157-02-07-008
3. Remove screws (10 and 12). Move cover (11) to

the right.
10
11
12
W157-02-07-009
W2-7-2
4. Remove screw joint (13) and the lever.
: 19 mm 13 14
IMPORTANT: Attach an identification tag to each

hose to aid re-assembly.
15
5. Disconnect hoses (15 to 20).
16
: 22 mm
17
NOTE: Cap all disconnected hose ends.
6. Remove three bolts (14) and the pilot valve.
: 13 mm
15- Hose H : (To bucket roll out side control valve)

16- Hose P3 : (From pilot shut-off valve)
17- Hose A : (To boom raise side control valve)
18- Hose G : (To bucket roll in side control valve)
19- Hose T6 : (To hydraulic oil tank) 20 19 18
20- Hose B : (To boom lower side control valve)
W157-02-07-004
Installation
1. Secure the pilot valve with three bolts (14).
13 14
: 13 mm
2. Connect hoses (15 to 20).

15
: 22 mm 16
3. Install the lever with screw joint (13). 17
: 19 mm
15- Hose H : (To bucket roll out side control valve)

16- Hose P3 : (From pilot shut-off valve)
17- Hose A : (To boom raise side control valve)
18- Hose G : (To bucket roll in side control valve)
19- Hose T6 : (To hydraulic oil tank)
20- Hose B : (To boom lower side control valve)
20 19 18
W157-02-07-004
W2-7-3
4. Secure cover (11) with screws (10 and 12).
10
11
12
W157-02-07-009
5. Securely install stand (9) with two bolts (8).
: 17 mm
8 9 W157-02-07-008
6. Secure frame (2) with two screws (1) and two 1 2 3

screws (5). Secure cover (7) with two screws (6).
Install boot (3) and tighten four screws (4). 4
5
IMPORTANT: After the work is complete, check
the hydraulic oil level. Check for oil 6
leaks while running the engine.
7
W157-02-07-007
W2-7-4
REMOVE AND INSTALL LEFT PILOT
VALVE (FRONT ATTACHMENT)

Preparation

any pressure remaining in the system. Rotate the
hydraulic oil tank cap approx. 30 counterclock-
wise to release pressure remaining in the hydrau-
lic oil tank.
W2-7-5
Removal
1. Remove screws (6, 1, and 5) (two each used),
cover (7) and frame (2). Remove four screws (4) 1 2 3
and boot (3).
4
6
7
W157-02-07-007
2. Remove two bolts (8). Raise stand (9).

Move the console to the utmost front position.
: 17 mm
8 9 W157-02-07-008
3. Remove screws (10 and 12). Move cover (11) to

the right.
10
11
12
W157-02-07-009
W2-7-6
4. Remove pat (13). After pushing pat (13) in the
direction of the arrow, detach the teeth at two
places. Then, move the pat to the opposite 13 14
direction of the arrow to remove the pat.
16
5. Remove two screws (15), two screws (16) and
cover (14). 15
6. Remove screw joint (17) and the lever. 16
: 19 mm
IMPORTANT: Attach an identification tag to each W157-02-07-010
7. Disconnect hoses (19 to 24). 17 18
: 22 mm
19
20
8. Remove three bolts (18) and the pilot valve.
21
: 13 mm
19 - Hose D : (To arm roll in side control valve)

20 - Hose P2 : (From pilot shut-off valve)
21 - Hose E : (To left swing control valve)
22 - Hose C : (To arm roll out side control valve)
23 - Hose T5 : (To hydraulic oil tank)
24 - Hose F : (To rightswing control valve)
24 23 22
W157-02-07-003
Installation
1. Install the pilot valve with three bolts (18).
17 18
: 13 mm
: 9.8 Nxm (1.0 kgfxm, 7 lbfxft)
19
2. Connect hoses (19) to (24).
20
: 22 mm
: 39 Nxm (4.0 kgfxm, 29 lbfxft) 21
3. Install the lever with screw joint (17).
: 19 mm
19 - Hose D : (To arm roll in side control valve)

20 - Hose P2 : (From pilot shut-off valve)
24 23 22
21 - Hose E : (To left swing control valve)
W157-02-07-003
22 - Hose C : (To arm roll out side control valve)
24 - Hose F : (To rightswing control valve)
W2-7-7
4. Install cover (14) with screws (15 and 16) ( 2 each
used). 13 14
16
15
5. Install pat (13) to cover (14).
16
W157-02-07-010
6. Secure cover (11) with screws (10 and 12).
10
11
12
7. Securely install stand (9) with two bolts (8). W157-02-07-009
: 17 mm
8 9 W157-02-07-008
8. Secure frame (2) with two screws (1) and two

screws (5).
1 2 3
4
9. Install boot (3). Tighten four screws (4).
10. Secure cover (7) with two screws (6). 6

7

the hydraulic oil level. Check for oil W157-02-07-007
W2-7-8
REMOVE AND INSTALL TRAVEL PILOT
VALVE

Preparation

lic oil tank.
W2-7-9
Removal
1. Remove bolts (2) and pedal (1).
: 17 mm
IMPORTANT: Attach an identification tag to each

1
2. Disconnect hoses (3 to 8).
: 22 mm
2
3. Remove bolts (9) and the pilot valve.

8 3
: 8 mm
4
9
Installation
1. Secure the pilot valve with bolts (9). 5
7 6
: 8 mm W157-02-07-005
2. Connect hoses (3 to 8).

3 - Hose L : (To right reverse travel side control valve)
4 - Hose J : (To left reverse travel side control valve)
: 22 mm 5 - Hose P1 : (From pilot shut-off valve)
: 39 Nxm (4.0 kgfxm, 29 lbfxft) 6 - Hose I : (To left forward travel side control valve)
7 - Hose K : (To right forward travel side control valve)
3. Secure pedal (1) with bolts (2). 8 - Hose T4 : (To hydraulic oil tank)
: 17 mm

hydraulic oil level. Check for oil
W2-7-10
(Blank)
W2-7-11
DISASSEMBLE FRONT ATTACHMENT
PILOT VALVE
1
23
22
21 2
21
20
3
20
19
18 19
18
17 4
17
5
5
6
16 6
7
7
8
11
15
9
14 10
13
12
W105-02-07-029
1- Screw Joint 7- Bushing (4 Used) 13 - Plate 19 - Spacer (4 Used)

2- Cam 8- Pusher A (2 Used) 14 - O-Ring 20 - Shim (20 Used)
3- Universal Joint 9- Spring Guide A (2 Used) 15 - Seal Washer 21 - Return Spring (4 Used)
4- Plate 10 - Spring Guide B (2 Used) 16 - Casing 22 - Balance Spring A (2 Used)
5- Oil Seal (4 Used) 11 - Pusher B (2 Used) 17 - Piston (4 Used) 23 - Balance Spring B (2 Used)
6- O-Ring (4 Used) 12 - Socket Bolt 18 - Spool (4 Used)
W2-7-12
Disassemble Front Attachment Pilot Valve
Before starting any repair work, thoroughly read 7. Remove two bolts temporarily tightened in step 2.
all Precautions for Disassembling and Assem- Gradually loosen special tool (ST 7924) until
bling (W1-1-1). pushers (8 and 11) and plate (4) are fully raised
Casing (16) and spools(18) are assembled by se- and remove special tool (ST 7924).
lective fitting. Do not replace each part individu-
ally. 8. Remove pushers (8 and 11) and plate (4) from
Balance springs A (22) in ports (1 and 3) are casing (16).
different from balance springs B (23) in ports (2
and 4). Be sure to install them in their correct 9. Remove pusher A (8), pusher B (11), O-ring (6)
locations. and oil seal (5) from bushing A (7).
Port Nos. are cast on the periphery of casing (16).
Group the disassembled parts by port No. and 10. Remove four spools (18) from casing (16).
attach identification tags.
11. While compressing balance spring A (22) and B
1. Loosen and remove screw joint (1) and cam (2). (23), remove spacer (19) from spool (18).
Remove balance spring A (22), B (23), shim (20),
: 19 mm, 32 mm spring guide A (9), B (10), and return spring (21)
from each spool (18).
2. Temporarily tighten plate (4) to casing (16) with
two bolts (M8, pitch 1.25). Loosen and remove
universal joint (3) from casing (16).
3. Turn casing (16) over and place it in a vise.

Remove socket bolt (12).
: 10 mm
4. Using a forcing bolt (M16, pitch 2), pull out plate

(13). Remove O-ring (14) from plate (13).
Remove seal washer (15) from casing (16).
5. Remove four pistons (17) from spools (18)

located in the ports.
6. Turn casing (16) over. Install special tool (ST

7924) into the universal joint connecting hole in
casing (16). Tighten plate (4) with special tool (ST
7924).
ST 7924
16
W105-02-07-009
W2-7-13
ASSEMBLE FRONT ATTACHMENT PILOT
VALVE
11
8
5
4
19 7
6
9
10 22
23 21
20
18 16
17
14
W166-02-06-001
12 15 13
1- Screw Joint 7- Bushing (4 Used) 13 - Plate 19 - Spacer (4 Used)

2- Cam 8- Pusher A (2 Used) 14 - O-Ring 20 - Shim (20 Used)
3- Universal Joint 9- Spring Guide A (2 Used) 15 - Seal Washer 21 - Return Spring (4 Used)
4- Plate 10 - Spring Guide B (2 Used) 16 - Casing 22 - Balance Spring A (2 Used)
5- Oil Seal (4 Used) 11 - Pusher B (2 Used) 17 - Piston (4 Used) 23 - Balance Spring B (2 Used)
6- O-Ring (4 Used) 12 - Socket Bolt 18 - Spool (4 Used)
W2-7-14
Assemble Front Attachment Pilot Valve
1. Insert special tool (ST 7099) into each port in
casing (16). Be sure to insert the smaller end of
the jig first.
IMPORTANT: The number of shims (20) has been

determined through performance
testing. Take care not to lose them.
Install spacer (19) with the stepped
side facing the spring.
2. Install shims (20), and balance spring A (22) and

B (23) (2 each used) onto spools (18) (4 used).
While compressing balance spring A (22) or B
(23), install spacer (19) (4 used) in the position
between spool (18) (4 used) and balance spring A ST 7099
W105-02-07-015
(22) or B (23) (2 each used).
IMPORTANT: Install spring guide A (9) and B (10)

with the stepped side facing the
spring.
3. Install return spring (21) (4 used) and spring guide

A (9) or B (10) (2 each used) onto spool (18) (4
used).
IMPORTANT: Be sure to install the spool to the

casing port from which the spool
was removed.
4. Install four spools (18) into casing (16).
5. After installing oil seals (5) and O-rings (6) (4 each

used) to bushing (7) (4 used), install pusher A (8)
and B (11) (2 used each ) into bushing (7) .
Special tool: ST 2292
6. Put each of the pusher assemblies onto their

respective spool assembly.
7. Install plate (4) on bushings (7) . Install special ST 7924

tool (ST 7924) into the universal joint connecting
hole in casing (16).
8. Gradually tighten the jig until the bottom of

bushings (7) is flush with the top face of casing
(16).
Remove special tool (ST 7099) from casing (16).
Tighten special tool (ST 7924) until plate (4)
comes in contact with the top face of casing (16).
9. Temporarily tighten plate (4) with bolts (M8, pitch

1.25). Then, remove special tool (ST 7924). W105-02-07-021
W2-7-15
11
8
18 16
17
14
W166-02-06-001
12
15 13
W2-7-16
10. With the smaller ends of pistons (17) (4 used)
facing the pusher side, insert pistons (17) into
spools (18) (4 used).
11. Install seal washer (15) to casing (16) and O-ring

(14) to plate (13).
12. Install plate (13) to casing (16) and secure it with

socket bolts (12).
: 10 mm
13. Turn casing (16) over. Apply LOCTITE #262 to

universal joint (3). Install universal joint (3) into
casing (16).
: 17 mm
14. Thoroughly apply grease to the joint region of

universal joint (3). Apply a film of grease to the top
of pushers A (8) (2 used) and pushers B (11) (2
used).
15. Install cam (2) onto universal joint (3).
16. Using a filler gauge, adjust the clearances be-

tween pusher A (8) and cam (2), and pusher B
(11) and cam (2) to 0 to 0.2 mm. Then, tighten
screw joint (1). Remove the two bolts used to
temporarily tighten plate (4).
: 17 mm, 32 mm
: 69 to 88 Nxm
(7 to 9 kgfxm, 50 to 65 lbfxft)
W2-7-17
DISASSEMBLE TRAVEL PILOT VALVE
27
26
1
25
2
24
3
23
4
22 5
8
21 6
7
20
19
18 8 9
17
16
10 11 10
15
13
14
12
W105-02-07-092
1- Cover 8- Pin (2 Used) 15 - O-Ring (2 Used) 22 - Balance Spring (4 Used)

2- Sems Bolt (2 Used) 9- Holder 16 - Casing 23 - Spring Guide (4 Used)
3- Spring Pin (2 Used) 10 - Bushing (2 Used) 17 - Piston (4 Used) 24 - Pusher (4 Used)
4- Spring Pin (2 Used) 11 - Bushing (2 Used) 18 - Spool (4 Used) 25 - Bushing (4 Used)
5- Cam (2 Used) 12 - Plug (4 Used) 19 - Spacer (4 Used) 26 - O-Ring (4 Used)
6- Socket Bolt 13 - O-Ring (4 Used) 20 - Shim (20 Used) 27 - Oil Seal (4 Used)
(2 Used)
7 - Spring Washer 14 - Plug (2 Used) 21 - Return Spring (4 Used)
(2 Used)
W2-7-18
Disassemble Travel Pilot Valve
bling (W1-1-1).
Casing (16) and spools (18) are assembled by se-
lective fitting. Do not replace any part individually.
1. Remove two sems bolts (2) and cover (1) from

holder (9).
: 10 mm
2. Turn casing (16) over and fasten it in a vise.

Remove four plugs (12) from casing (16).
Remove O-rings (13) from plugs (12).
3. Unfasten casing (16) from the vise and turn it over

to remove piston (17) from spool (18).
4. Turn over casing (16) and fasten it in a vise.

Loosen and remove one socket bolt (6). Then,
install special tool (ST 7925).
ST 7925
: 8 mm
5. Loosen and remove the other socket bolt (6).

Then, install special tool (ST 7925).
: 8 mm
6. Uniformly loosen both special tools (ST 7925) and

remove them from casing (16). W105-02-07-038
7. Fasten holder (9) in a vise. Remove spring pins (3

and 4) by special tool (ST 1237).
8. Remove pin (8) and cam (5) from holder (9). Do

not remove bushings (10 and 11) unless they are
damaged.
9. Remove the pusher assembly. Remove pusher

(24), O-ring (26), and oil seal (27) from bushing
(25).
10. Remove four spools (18) from casing (16).
11. While compressing balance spring (22), remove

spacer (19) from spool (18). Then, remove
balance spring (22) and shims (20). Remove
spring guide (23) and return spring (21) from each
port.
W2-7-19
ASSEMBLE TRAVEL PILOT VALVE
5 1 3, 4
24
6, 7
27
25
26
9
19
2 8 10 11 23
22
21
20
18
16
17
W105-02-07-064
13 12 15 14
1- Cover 8- Pin (2 Used) 15 - O-Ring (2 Used) 22 - Balance Spring (4 Used)

2- Sems Bolt (2 Used) 9- Holder 16 - Casing 23 - Spring Guide (4 Used)
3- Spring Pin (2 Used) 10 - Bushing (2 Used) 17 - Piston (4 Used) 24 - Pusher (4 Used)
4- Spring Pin (2 Used) 11 - Bushing (2 Used) 18 - Spool (4 Used) 25 - Bushing (4 Used)
5- Cam (2 Used) 12 - Plug (4 Used) 19 - Spacer (4 Used) 26 - O-Ring (4 Used)
6- Socket Bolt 13 - O-Ring (4 Used) 20 - Shim (20 Used) 27 - Oil Seal (4 Used)
(2 Used)
7 - Spring Washer 14 - Plug (2 Used) 21 - Return Spring (4 Used)
(2 Used)
W2-7-20
Assemble Travel Pilot Valve
the jig first.

2. Install shims (20) and balance springs (22) (4 ST 7099

used) onto spools (18) (4 used).
W105-02-07-043
While compressing balance spring (22), install
spacers (19) (4 used) in the position between
spool (18) and balance spring (22).
IMPORTANT: Install spring guide (23) with the

stepped side facing the spring.
3. Install return springs (21) (4 used) and spring

guide (23) (4 used)onto spools (18) (4 used).
IMPORTANT: Be sure to install the spool to the

casing port from which the spool
was removed.
4. Install four spool (18) assemblies into casing (16).
5. After installing oil seals (27) (4 used) and O-rings

(26) (4 used) to bushings (25) (4 used), install
pushers (24) (4 used) into bushings (25) (4 used).
Special tool: ST 2292
6. Put each of the pusher assemblies onto their ST 7925

respective spool assembly.
7. Install holder (9) on bushings (25). Install special

tools (ST 7925) into the bolt holes in casing (16).
8. Gradually tighten the jigs until the bottoms of

bushings (25) (4 used) are flush with the top face
of casing (16).
Tighten special tool (ST 7925) until holder (9)
comes in contact with the top face of casing
(16). W105-02-07-049
W2-7-21
5 1 3, 4
24
6, 7
2 8
18
16
17
W105-02-07-064
13 12
W2-7-22
9. Remove one special tool (ST 7925) and temporar-
ily tighten holder (9) with socket bolts (6) (2 used)
and spring washers (7) (2 used).
ST 7925
10. Remove the other special tool (ST 7925) and

temporarily tighten holder (9) with socket bolts (6)
(2 used). Tighten both socket bolts (6) to
specification.
: 8 mm
11. Turn over casing (16) and fasten in a vise. With

the smaller end of pistons (17) (4 used) facing the
W105-02-07-050
pusher side, insert pistons (17) (4 used) into
12. Install O-rings (13) (4 used) to plugs (12) (4 used).

Install plugs (12) to casing (16).
: 8 mm
IMPORTANT: When installing pin (8), face the pin

end closer to the spring pin hole
outward.
13. Turn casing (16) over and fasten in a vise. Apply a

film of grease to the top of pushers (24) (4 used).
Aligning pin holes on holder (9) and cams (5) (2
used), install pins(8) (2 used).
IMPORTANT: Install spring pins (3 and 4) until

their heads have sunk approx. 3 mm
from cam (5) surface. Then, crimp
the cam hole edge with a punch to
prevent spring pins (3 and 4) from
coming out.
14. Install spring pins (3 and 4) (2 each used) with

special tool (ST 1237).
15. Install cover (1) on holder (9) and secure the

cover with sems bolts (2) (2 used).
: 10 mm
W2-7-23
BUCKET OPEN / CLOSE AND BREAKER
PILOT VALVE
28
27
1
2
26
25 3
4
24
5
6
21
7
8
22
21 23
9
20 10
11
12
19
18
17
13
14 13
16
14
15
W166-02-06-002
1- Dust Seal 8- Shim (10 Used) 15 - Plug 22 - Holder
2- Bushing 9- Spool (2 Used) 16 - O-Ring 23 - Socket Bolt (2 Used)
3- Oil Seal 10 - Spring Guide (2 Used) 17 - Plug (4 Used) 24 - Cam
4- O-Ring 11 - Return Spring (2 Used) 18 - O-Ring (4 Used) 25 - Spring Pin
5- Pusher 12 - Piston (2 Used) 19 - Casing 26 - Spring Pin
6- Spacer (2 Used) 13 - O-Ring (2 Used) 20 - Pin 27 - Cover
7- Balance Spring (2 Used) 14 - Plug (2 Used) 21 - Bushing (2 Used) 28 - Sems Bolt (2 Used)
W2-7-24
Disassemble Bucket Open/Close and Breaker
Pilot Valve
bling (W1-1-1).
Casing (19) and spools (9) are assembled by se-
lective fitting. Do not replace any part individually.
1. Remove two sems bolts (28) (2 used) and cover

(27) from holder (22).
: 10 mm
2. Turn casing (19) over and fasten it in a vise.

Remove two plugs (14) and O-rings (13) (2 used)
from casing (19).
: 8 mm
3. Unfasten casing (19) from the vise and turn it over

to remove piston (12) from spool (9).
4. Fasten casing (19) in a vise. ST 7936

Remove spring pins (25 and 26) by special tool
(ST 1237).
5. Remove pin (20) and cam (24) from holder (22).

Do not remove bushings (21) unless they are
damaged.
NOTE: Remove pin (20) from the hydraulic breaker

W105-02-07-038
pilot valve on the opposite side of the side
face on which plug (17) is installed.
6. Loosen and remove the other socket bolt (23).

Then, install special tool (ST 7936).
: 10 mm
7. Uniformly loosen both special tools (ST 7936) and

remove holder (22) from casing (19).
8. Remove the pusher assembly. Remove pusher

(5), O-ring (4), and oil seal (3) from bushing (2).
9. Remove two spools (9) from casing (19).
10. While compressing balance spring (7), remove

spacer (6) from spool (9). Then, remove balance
spring (7) and shims (8). Remove spring guide
(10) and return spring (11) from each port.
W2-7-25
ASSEMBLE BUCKET OPEN / CLOSE AND
BREAKER PILOT VALVE
23 20 28 26 25 24 27
20
5
1
2
5
22
2
4
3
6
10
22 7
11
8
9
19 17
19
13
W166-02-06-003
14 12 15
1- Dust Seal 8- Shim (10 Used) 15 - Plug 22 - Holder

2- Bushing 9- Spool (2 Used) 16 - O-Ring 23 - Socket Bolt (2 Used)
3- Oil Seal 10 - Spring Guide (2 Used) 17 - Plug (4 Used) 24 - Cam
4- O-Ring 11 - Return Spring (2 Used) 18 - O-Ring (4 Used) 25 - Spring Pin
5- Pusher 12 - Piston (2 Used) 19 - Casing 26 - Spring Pin
6- Spacer (2 Used) 13 - O-Ring (2 Used) 20 - Pin 27 - Cover
7- Balance Spring (2 Used) 14 - Plug (2 Used) 21 - Bushing (2 Used) 28 - Sems Bolt (2 Used)
W2-7-26
Assemble Bucket Open/Close and Breaker Pilot
Valve
the jig first.

2. Install shims (8) and balance springs (9) (2 used)

onto spools (9) (2 used).
While compressing balance spring (7), install
spacers (6) (2 used) in the position between spool
(9) and balance spring (7).
IMPORTANT: Install spring guide (10) with the

stepped side facing the spring.
3. Install return springs (11) (2 used) and spring

guide (10) (2 used) onto spools (9) (2 used).
IMPORTANT: Be sure to install the spool (9) to the

casing port from which the spool (9)
was removed.
4. Install two spool (9) assemblies into casing (19).
5. After installing dust seal (1) (2 used) oil seals (3)

(2 used) and O-rings (4) (2 used) to bushings (2)
(2 used), install pushers (5) (2 used) into bushings
(2) (2 used).
Special tool: ST 2292 ST 7936
6. Put each of the pusher assemblies onto their

respective spool (9) assembly.
7. Install holder (22) on bushings (2). Install special

tools (ST 7936) into the bolt holes in casing (19).
8. Gradually tighten the jigs until the bottoms of

bushings (2) (2 used) are flush with the top face of
casing (19).
Tighten special tool (ST 7936) until holder (22) W105-02-07-049
comes in contact with the top face of casing (19).
W2-7-27
28
23 20 26 25 24 27
20
5
22
22
9
17
19
19
13
W166-02-06-003
14 12
W2-7-28
9. Remove one special tool (ST 7936) and temporar-
ily tighten holder (22) with socket bolts (23) (2
used).
ST 7936
10. Remove the other special tool (ST 7936) and

temporarily tighten holder (22) with socket bolts
(23) (2 used). Tighten both socket bolts (23) to
specification.
: 8 mm
11. Turn over casing (19) and fasten in a vise. With

the smaller end of pistons (12) (2 used) facing the
W105-02-07-050
pusher side, insert pistons (12) (2 used) into
12. Install O-rings (13) (2 used) to plugs (14) (2 used).

Install plugs (14) to casing (19).
: 8 mm
IMPORTANT: When installing pin (20), face the pin

end closer to the spring pin hole
outward.
Insert pin (20) into the bucket
open/close pilot valve from the side
face on which plug (17) is installed.
Insert pin (20) into the hydraulic
breaker pilot valve from the opposite
side to the side face on which plug
(17) is installed.
13. Turn casing (19) over and fasten in a vise. Apply a

film of grease to the top of pushers (5) (2 used).
Aligning pin holes on holder (22) and cams (24) (2
used), install pins (20) (2 used).
IMPORTANT: Install spring pins (25 and 26) until

their heads have sunk approx. 3 mm
from cam (24) surface. Then, crimp
the cam hole edge with a punch to
prevent spring pins (25 and 26) from
coming out.
14. Install spring pins (25 and 26) (2 each used) with
15. Install cover (27) on holder (22) and secure the

cover with sems bolts (28) (2 used).
: 10 mm
W2-7-29
(Blank)
W2-7-30
UPPERSTRUCTURE / Pilot Shut-off Valve
REMOVE AND INSTALL PILOT SHUT-OFF
VALVE

can penetrate the skin or eyes, causing seri-
ous injury. Avoid this hazard by relieving
lines.
Preparation

lic oil tank.

tank.

W2-8-1
Removal
1. Remove ball joint (10).
3
: 13 mm 2
1
IMPORTANT: Attach identification tags to hoses to
aid reassembly.
2. Disconnect hoses (1 to 9). Remove bolt (11) to

remove the pilot shut-off valve.
4
: 22 mm 11
: 8 mm 5
10
Installation
1. Secure the pilot shut-off valve with bolt (11).
9
: 8 mm 6
: 64 Nxm (6.5 kgfxm, 147 lbfxft) 8
2. Connect hoses (1 to 9). Install ball joint (10).
: 22 mm 7 W166-02-07-001
: 13 mm 1- Hose P2 : (To swing and arm pilot valve)

2- Hose P1 : (To travel right and left pilot valves)
: 9.8 Nxm (1 kgfxm, 7.3 lbfxft) 3- Hose P3 : (To boom and bucket pilot valve)
4- Hose T4 : (From travel right and left pilot valves)
5- Hose T1 : (To hydraulic oil tank)
6- Hose PC : (From pilot check valve)
7- Hose T5 : (From swing and arm pilot valve)
8- Hose : (From boom 2 control valve)
9- Hose T6 : (From bucket and boom pilot valve)
10- Ball Joint
11- Bolt
W2-8-2
(Blank)
W2-8-3
DISASSEMBLE PILOT SHUT-OFF VALVE
1
2
3
4
14
13
12
5
6
7
8
11
10
W190-02-08-004
1- Retaining Ring 5- O-Ring 9 - Spring Pin 12 - Socket Bolt

2- Washer 6- Backup Ring 10 - Lever 13 - Steel Ball
3- Backup Ring 7- Washer 11 - Spool 14 - Body
4- O-Ring 8- Retaining Ring
W2-8-4
Disassemble Pilot Shut-Off Valve
all Precautions for Disassembling and
Assembling (W1-1-1).
1. Remove retaining ring (1), washer (2) and spool

(11) from body (14).
2. Remove spring pin (9) from spool (11) to remove

lever (10).
NOTE: Put a matching mark on spool (11) and

lever (10).
3. Remove washer (7) and retaining ring (8) from

spool (11).
4. Remove backup rings (3 and 6) and O-rings (4

and 5) from body (14).
W2-8-5
ASSEMBLE PILOT SHUT-OFF VALVE
2 3 4 14
1
10
12
7 13
8
11
6
5
W105-02-08-003
1- Retaining Ring 5- O-Ring 9 - Spring Pin 12 - Socket Bolt

2- Washer 6- Backup Ring 10 - Lever 13 - Steel Ball
3- Backup Ring 7- Washer 11 - Spool 14 - Body
4- O-Ring 8- Retaining Ring
W2-8-6
Assemble Pilot Shut-Off Valve
IMPORTANT: Apply a film of grease to O-ring (5)
and backup ring (6).
1. Install O-ring (5), backup ring (6), washer (7) and

retaining ring (8) into body (14).
2. Aligning the matching marks on spool (11) and

lever (10), drive in spring pin (9).
IMPORTANT: Apply a film of hydraulic oil to spool

(11).
3. Install spool (11) into body (14).
IMPORTANT: Apply a film of grease to O-ring (4)

and backup ring (3).
4. Install O-ring (4), backup ring (3) and washer (2)

into body (14). Install retaining ring (1) on spool
(11).
W2-8-7
(Blank)
W2-8-8
UPPERSTRUCTURE / Shockless Valve
REMOVE AND INSTALL FRONT ATTACH-
MENT SHOCKLESS VALVE

lines.
Preparation

draulic oil tank cap approx. 30 counter-clockwise
tank.

tank.

W2-9-1
Removal
IMPORTANT: Attach identification tags to hoses to
6
aid re-assembly.
1 2 3 4 5
1. Disconnect hoses (2 to 6 and 8 to 13).
7
: 19 mm, 22 mm
2. Remove pressure switches (1 and 7).
: 14 mm
3. Remove two bolts (located on the bottom face of 8

the shockless valve) to remove the shackles
valve.
13
: 13 mm W162-02-08-001
12 11 10 9
Installation
1. Install the shackles valve with two bolts.
1- Pressure Switch (Boom Raise)
: 13 mm 2- Hose A : (From boom raise pilot valve)
: 19.5 Nxm (2 kgfxm, 14.5 lbfxft) 3- Hose B : (From boom lower pilot valve)
4- Hose C : (BH: From arm roll-out pilot valve)
(LD: From arm retract pilot valve)
2. Connect hoses (2 to 6 and 8 to 13).
5- Hose D : (BH: From arm roll-in pilot valve)
(LD: From arm extend pilot valve)
: 19 mm 6- Hose SJ : (To swing shuttle valve)
: 29.5 Nxm (3 kgfxm, 22 lbfxft) 7- Pressure Switch (Arm Roll-In)
8- Hose H3 : (To hydraulic oil tank)
: 22 mm 9- Hose 4 : (BH: To arm roll-out control valve)
: 39 Nxm (4 kgfxm, 29 lbfxft) (LD: To arm retract control valve)
10 - Hose 3 : (BH: To arm roll-in control valve)
(LD: To arm extend control valve)
3. Install pressure switches (1 and 7).
11 - Hose 2 : (To boom lower control valve)
12 - Hose 1 : (To boom raise control valve)
: 14 mm 13 - Hose H1 : (From pilot relief valve)
NOTE: BH: Backhoe

LD: Loading Shovel
W2-9-2
DISASSEMBLE AND ASSEMBLE FRONT
ATTACHMENT SHOCKLESS VALVE
1
2
3 6
4 2
5 7
17
11 8
12 1
16 2
1
2
10
11
12
16
14
9
15
2
1 14
15
2
1
8
7
10 2
11 6
12
13
W166-02-08-001
W2-9-3
Section Z-Z
8 8
7 7
2 6
6
2
8 4
1
7
2
3
5
6
6
2
2
7
8
Section X-X Section Y-Y
1 2 14 15 2 1 10 11 12 16
17 11 12 13 1 2 14 15 2 1
W162-02-08-002
W2-9-4

Item No. Part Name Quantity Remarks
1 Plug 9 : 5 14.5 (1.5) (11)
2 O-Ring 13
3 O-Ring 1
4 Guide 1
5 Steel Ball 1
6 Plug 4 : 6 19.5 (2) (14.5)
7 Spring 4
8 Steel Ball 4
9 Body 1
10 Plunger 2
11 Spring 4
12 O-Ring 4
13 Nipple 2 : 22 39 (4) (29)
14 Spool 4
15 Spring 4
16 Nipple 2 : 22 39 (4) (29)
17 Plunger 1
W2-9-5
(Blank)
W2-9-6
REMOVE AND INSTALL TRAVEL SHOCK-
LESS VALVE

lines.
Preparation

tank.

tank.

W2-9-7
Removal
IMPORTANT: Attach identification tags to hoses to 1 2 3 4
aid re-assembly.
1. Disconnect hoses (1 to 4 and 6 to 11).

5
: 19 mm, 22 mm
5
2. Remove bolts (5) to remove the shockless valve.
: 17 mm
Installation
1. Apply LOCTITE to bolts (5) and secure the

shockless valve.
6
: 17 mm
2. Connect hoses (1 to 4 and 6 to 11). W166-02-08-002

11 10 9 8 7
: 19 mm
1 - Hose 9 : (From left forward travel pilot valve)
2 - Hose 10 : (From left reverse travel pilot valve)
: 22 mm 3 - Hose 11 : (From right forward travel pilot valve)
: 39 Nxm (4 kgfxm, 29 lbfxft) 4 - Hose 12 : (From right reverse travel pilot valve)
5 - Bolt
6 - Hose H4 : (To hydraulic oil tank)
7 - Hose 12B : (To right reverse travel control valve)
8 - Hose 11B : (To right forward travel control valve)
9 - Hose 10B : (To left reverse travel control valve)
10 - Hose 9B : (To left forward travel control valve)
11 - Hose H2 : (From pilot relief valve)
W2-9-8
DISASSEMBLE AND ASSEMBLE TRAVEL
SHOCKLESS VALVE
12
10
3
4
B
C A 5
11 B
3
6
A
10
7
2 8
W111-02-09-004
W2-9-9
Section X-X
11
12 10 B C A 10 2 9 3
W162-02-08-005
1 2 A B 4 3 6
W2-9-10

Item No. Part Name Quantity Remarks
1 Plug 8 : 8 39 (4) (29)
2 O-Ring 8
3 Steel Ball 8
4 O-Ring 4
5 Filter Assembly 4A
5A Filter 4
5B Sleeve 4
6 Spring 4
7 O-Ring 4
8 Plug 4 : 6 19.5 (2) (14.5)
9 Plug 4 : 8 39 (4) (29)
10 Plunger 8
11 Plunger Assembly 4A
11A Plunger 4
11B Ring 4
11C Orifice 4
12 Body 1
W2-9-11
(Blank)
W2-9-12
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL THREE-SPOOL
SOLENOID VALVE

lines.

Preparation

tank.

tank.

W2-10-1
Removal
1. Disconnect all wire harnesses from the solenoid
valve. 1 2 3
2. Disconnect pilot pipes (1 to 3 and 5 to 9). 9
: 19 mm, 22 mm, 27 mm
3. Remove bolt (4) to remove the three-spool 4

solenoid valve. 5
8
: 17 mm 6
Installation
1. Secure the three-spool solenoid valve with bolt
(4).
: 17 mm
2. Connect pilot pipes (1 to 3 and 5 to 9). 7
: 19 mm T166-01-02-011
: 22 mm 1 - Hose SC : (To swing motor)

2 - Hose SB : (To Travel motor)
: 39 Nxm (4 kgfxm, 29 lbfxft) 3 - Hose SA : (To main relief valve)
4 - Bolt
: 27 mm 5 - Hose PD : (To pilot check valve)
6 - Hose H2 : (To shockless valve)
: 59 Nxm (6 kgfxm, 43 lbfxft) 7 - Hose H5 : (To hydraulic oil tank)
3. Connect all wire harnesses to the solenoid valve. 9 - Hose PB : (From pilot pump)
W2-10-2
DISASSEMBLE AND ASSEMBLE THREE-
SPOOL SOLENOID VALVE
20 21 22 23 24
19
18
17 1
2
16
3
15
14
5
13
12
6
11
T111-02-07-002
10 9 8 8
NOTE: 1 kgfxm=7.233 lbfxft
Wrench Tightening Torque Wrench Tightening Torque

Item Item
Part Name Quantity Size Part Name Quantity Size
No. (mm) Nxm (kgfxm) (lbfxft) No. (mm) Nxm (kgfxm) (lbfxft)
1 Plug 1 22 49 (5) (36) 13 Spool 1
Assembly
2 Shim 1 14 Rod 3
3 Spring 1 15 O-Ring 3
4 O-Ring 1 16 Stopper 3
5 Valve 1 17 Plunger 3
Assembly
6 Gasket 1 18 Screw 3 32 29.5 (3) (22)
7 Casing 1 19 Coil 3
Assembly
8 Spool 2 20 Spring 3
Assembly
9 Spring 3 21 Spring Seat 3
10 O-Ring 3 22 Pipe 3
11 O-Ring 3 23 Housing 3
12 O-Ring 3 24 Spacer 3
W2-10-3
(Blank)
W2-10-4
MEMO
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SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing ......... W3-1-1 Remove and Install Upper Roller ............ W3-6-1
Disassemble Swing Bearing ................... W3-1-3 Remove and Install Lower Roller ............ W3-6-4
Assemble Swing Bearing ........................ W3-1-5 Disassemble Upper Roller ...................... W3-6-8
Assemble Upper Roller......................... W3-6-10
Group 2 Travel Device Disassemble Lower Roller .................... W3-6-12
Remove and Install Travel Device .......... W3-2-1 Assemble Lower Roller......................... W3-6-14
Disassemble Travel Device .................... W3-2-4 Maintenance Standard ......................... W3-6-16
Assemble Travel Device ......................... W3-2-8
Disassemble Travel Motor .................... W3-2-14 Group 7 Track
Assemble Travel Motor......................... W3-2-18 Remove and Install Tracks ..................... W3-7-1
Disassemble Brake Valve ..................... W3-2-22 Maintenance Standard ........................... W3-7-7
Assemble Brake Valve.......................... W3-2-24
Maintenance Standard ......................... W3-2-26
Group 3 Center Joint

Remove and Install Center Joint............. W3-3-1
Disassemble Center Joint....................... W3-3-4
Assemble Center Joint ........................... W3-3-6
Maintenance Standard ........................... W3-3-8
Group 4 Track Adjuster

Remove and Install Track Adjuster ......... W3-4-1
Disassemble Track Adjuster ................... W3-4-2
Assemble Track Adjuster........................ W3-4-8
Group 5 Front Idler

Remove and Install Front Idler................ W3-5-1
Disassemble Front Idler ......................... W3-5-2
Assemble Front Idler .............................. W3-5-6
Maintenance Standard ........................... W3-5-8
166W-3-1
(Blank)
166W-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing the swing bearing, the upperstructure

must be removed first. For removal and installation of
the upperstructure, refer to Remove and Install Main
Frame" Remove and Install Front Attachment", and
Remove and Install Counterweight" section. In this
section, the procedure starts on the premise that the
upperstructure has already been removed. Matching Mark
Removal
1. Put matching marks on swing bearing inner race

(1) and track frame (2).
1 2
2. Disconnect all grease pipes to the swing bearing.
: 17 mm W142-03-01-001
3. Remove swing bearing inner race mounting bolts 3

(3) (36 used).
: 41 mm
W105-03-01-002
CAUTION: Swing bearing weight: 655 kg

(1450 lb)
4. Attach lifting tool (ST 9050) to hoist and remove

swing bearing (4).
4 W105-03-01-003
W3-1-1
Installation
Clean the track frame and the swing bearing mating

surfaces.
1. Coat THREEBOND #1102 to the swing bearing

mounting surface on the track frame.

(1450 lb)
4
W105-03-01-003
IMPORTANT: Be sure to align the matching marks.
Otherwise, the inner race soft zone
will be in the incorrect position.
2. Hoist swing bearing (4).

Align the swing bearing with the track frame using
the matching marks put during disassembly.
Plug Position
Soft Zone
Position
Soft Zone Position (Outer Race)
(Inner Race)
Greasing Hole Positions

(3 places)
W111-03-01-001
3. Apply LOCTITE #262 to swing bearing mounting

bolts (3) (36 used) and tighten to specification. 3
: 41 mm
4. Re-connect all grease pipes to the swing bearing.
: 17 mm
W105-03-01-002
W3-1-2
(Blank)
W3-1-3
DISASSEMBLE SWING BEARING
1 2 3
10 9, 8 7 6 5 W166-03-01-001
12
11
6
7
8
10
W111-03-01-008
1 - Outer Race 4 - Plug 7 - Inner Race 10 - Rod and Turnbuckle

(3 Used)
2 - Seal 5 - Seal 8 - Support (74 Used) 11 - Bolt (36 Used)
3 - Pin 6 - Ball (81 Used) 9 - Support (7 Used) 12 - Grease Fitting (3 Used)
W3-1-4
Disassemble Swing Bearing
Be sure to thoroughly read all Precautions for

Disassembly/Assembly work on page W1-1-1
before disassembling. 3
NOTE: Pin (3) head is crimped. Grind off the

crimped part.
1. Remove pin (3) located in plug (4) section by

hitting from the bottom side of the swing bearing.
4
NOTE: Screw bolt (M10, pitch 1.5) in the threaded
hole in plug (4). Tap the bolt head from the
bottom side or pull the bolt to remove the W105-03-01-007
plug.
2. Remove plug (4).

4
W105-03-01-008
2
CAUTION: Swing bearing weight: 655 kg 1
(1450 Ib)
3. Hoist swing bearing outer race (1) horizontally

slightly, using a crane. Remove seal (5) fastening
rod and turnbuckle (10) (3 used) to remove seals
(2 and 5). A
7
W105-03-01-009
6 5
4. While rotating inner race (7), remove balls (6) and

supports (8 and 9) from the plug hole.
Use round bar magnet (A) to take out balls. Use
tip bent wire (B) to remove supports (8 and 9).
B
8, 9 W105-03-01-010
W3-1-5
ASSEMBLE SWING BEARING
1 2 3
10 9, 8 7 6 5 W166-03-01-001
12
11
6
7
8
10
W111-03-01-008
1 - Outer Race 4 - Plug 7 - Inner Race 10 - Rod and Turnbuckle

(3 Used)
2 - Seal 5 - Seal 8 - Support (74 Used) 11 - Bolt (36 Used)
3 - Pin 6 - Ball (81 Used) 9 - Support (7 Used) 12 - Grease Fitting (3 Used)
W3-1-6
Assemble Swing Bearing

(1450 Ib)
1. Before assembling the swing bearing inner race

and outer race, completely remove any oil on the
groove surfaces of seal (2). Then, coat THREE-
BOND #1735 to the groove and install seal (2).
2
Install seal (5) in the groove on the inner race and
fasten the seal with rod and turnbuckle (10)
(tighten each turnbuckle 10 to 15 turns evenly).
6
IMPORTANT: Apply grease to balls (6) and 5
W142-03-01-005
supports (8 and 9). After installing all
balls (6) and supports (8 and 9),
confirm that the clearance between
the last ball and the first support is
35 5 mm. If not, adjust the number
of supports (8 or 9) so that the
specified clearance obtained.
355 mm (1.380.2 in)
9, 8
W142-03-01-006
W142-03-01-004
3
2. Install balls (6) (81 used) and supports (8 and 9)
(81 used in total) alternately from the plug hole.
Install plug (4) and pin (3) into outer race (1). 1
Crimp the head of pin (3) with a punch.
Sufficiently lubricate the swing bearing with
grease (Doubrex HK or equivalent).
W142-03-01-007
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE

can penetrate the skin, causing serious in-
jury.
Preparation
the bucket to the ground.

to release any pressure remaining in the hydraulic
oil tank.

tank.

W3-2-1
Removal
The procedure starts on the premise that the track
link has already been removed. Refer to page W3-7-
1 for track removal.
1. Loosen the cover mounting bolts to remove the

travel motor cover. Disconnect hoses (2 to 5).
: 22 mm
: 69 Nxm (7.0 kgfxm, 50 lbfxft) 3 2 1
: 27 mm
: 19 mm
: 10 mm
NOTE: Cap the disconnected hose and pipe ends.
2. Remove counterbalance valve (6). 6

4 5
: 10 mm
W111-03-02-001
3. Attach the travel device to a crane using wire

ropes.
CAUTION: Travel device weight: 500 kg

(1100 Ib)
4. Remove bolts (1). Remove the travel device using

the crane.
: 32 mm
Installation
NOTE: Refer to Removal section above for
wrench sizes and tightening torque.
1. Install the travel device using bolts (1).

2. Install counterbalance valve (6).
3. Re-connect hoses (2 to 5).
4. Install the cover.
IMPORTANT: After completing travel motor instal- W111-03-02-002

lation, be sure to fill the travel motor
with hydraulic oil. After completing
installation of the travel motor or the
travel device, be sure to perform test
driving to prevent motor seizure.
Test drive as follows:
1. Run the engine with the engine control dial in
the slow idle position.
Turn the travel speed mode switch to the slow
speed position.
2. Drive the machine for 2 minutes or more.
W3-2-2
(Blank)
W3-2-3
DISASSEMBLE TRAVEL DEVICE 9
7
7
6
5
4
3
2
1 10
12
13
14
10
15
16 11
17
18
19
20 16
21
36
31
30
35
34
33
32
31
26
29 40 37
28 41
27 42
25 26
24
38
23 45 39
22
43
44
T111-03-02-001
1- Motor 13 - Pin (3 Used) 24 - Bolt (2 Used) 35 - Spring Pin (3 Used)

2- Bolt (4 Used) 14 - Needle Bearing (3 Used) 25 - Sprocket 36 - First Stage Carrier
3- Spring Washer (4 Used) 15 - Second Stage Sun Gear 26 - Thrust Plate (8 Used) 37 - Plug (3 Used)
4- O-Ring 16 - Spacer (2 Used) 27 - Needle Bearing (8 Used) 38 - Bolt (16 Used)
5- Housing 17 - Second Stage Carrier 28 - Pin (4 Used) 39 - Cover
6- Floating Seal 18 - Third Stage Sun Gear 29 - Spring Pin (4 Used) 40 - Bearing
7- Roller Bearing (2 Used) 19 - Third Stage Carrier 30 - Third Stage Planetary Gear 41 - Stopper Pin
(4 Used)
8 - Drum 20 - Bolt (24 Used) 31 - Thrust Plate (6 Used) 42 - Retaining Ring
9 - O-Ring 21 - Spring Washer (24 Used) 32 - Needle Bearing (3 Used) 43 - Socket Bolt(30 )
10 - Thrust Plate (6 Used) 22 - Bearing Nut 33 - Pin (3 Used) 44 - Ring Gear
11 - Spring Pin (3 Used) 23 - Lock Plate 34 - Second Stage Planetary 45 - Propeller Shaft
Gear (4 Used)
12 - First Stage Planetary Gear
(3 Used)
W3-2-4
Disassemble Travel Device
CAUTION: Cover (39) weight: 22 kg (49 lb)
Be sure to thoroughly read Precautions for Dis-
assembly and Assembly on page W1-1-1 before
4. Remove bolts (38) (16 used). Install eye bolts (PT
starting any repair work.
3/4) to cover (39). Using a crane, remove cover
(39).
CAUTION: Pressure may remain in the travel
device. Slowly loosen the air bleed plug to : 22 mm
completely release the residual pressure.
Then, remove the drain plug and drain the 5. Remove socket bolts (43) (30 used).
gear oil into a container. If the air bleed plug
is loosened quickly, the plug may pop off : 27 mm
and/or gear oil may spout. Position your face
and body away from the plug.
CAUTION: Ring gear (44) weight: 70 kg
(155 lb)
CAUTION: Travel device weight: 500 kg
(1100 lb) 6. Install eye bolts (M14, pitch 2) to ring gear (44).
Using a crane, remove ring gear (44).
1. After loosening plug (37-B) 2 to 3 turns, remove
plug (37-A) to drain gear oil from the travel device. 7. Remove propeller shaft (45).
Lay the travel device on a work bench with motor
(1) positioned upward. 8. Remove first stage carrier (36) assembly from
second stage carrier (17) assembly.
: 14 mm
9. Remove second stage sun gear (15) from second
stage carrier (17).
37 -B
CAUTION: Second stage carrier (17) assem-
bly weight: 25 kg (55 lb)
10. Attach a wire rope or belt to second stage carrier

(17) assembly. Using a crane, remove second
stage carrier (17) assembly.
11. Remove third stage sun gear (18) from third stage
37 -A carrier (19).
W111-03-02-006
CAUTION: Third stage carrier (19) assembly
weight: 75 kg (165 lb)
CAUTION: Motor (1) weight: 125 kg (280 lb)
12. Attach a wire rope or belt to third stage carrier (19)
2. Remove bolts (2) (4 used). Hoist and remove assembly. Using a crane, remove third stage
motor (1) by crane. Remove O-ring (4) from motor carrier (19) assembly.
(1).
13. Remove O-ring (9) from drum (8).
: 27 mm
CAUTION: Travel device weight (Excluding

motor): 375 kg (830 lb)
3. Turn over the travel device using a crane.
W3-2-5
7
6
10
12
13
14
10
15
16 11
17
18
19
20 16
21
36
31
30
35
34
33
32
31
26
29
28
27
25 26
24
23
22
T111-03-02-001
W3-2-6
14. Remove bolts (24) (2 used) to remove lock plate
CAUTION: Drum (8) and other part assembly
(23).
: 19 mm
21. Turn drum (8) over. Remove the outer race of
roller bearing (7) from drum (8).
15. Install special tool (ST 3136) to bearing nut (22) to
remove bearing nut (22).
NOTE: If the inner race of roller bearing (7) can not
Special Tool : ST 3136 be removed, cut the inner race using a
torch to remove it. Take care not to damage
housing (5) at this time.
ST 3136
22. Using a round steel bar, remove spring pins (29)

(4 used) from third stage carrier (19).
23. Remove pins (28) (4 used), third stage planetary

gears (30) (4 used) and thrust plates (26) (8 used)
from third stage carrier (19).
24. Remove needle bearings (27) (8 used) from third

25. Disassemble first stage carrier (36) and second

W111-03-02-018 stage carrier (17) assemblies following the same
procedures in steps 22 to 24.
CAUTION: Drum (8), sprocket (25) and other
26. Remove spacers (16) from first stage carrier (36)
part assembly weight: 180 kg (400 lb)
and second stage carrier (17).
16. Install eye bolt (M18, pitch 2.5) to drum (8). Using
a crane, remove drum (8) assembly together with
one roller bearing (7) from housing (5). Remove
inner race of roller bearing (7).
17. Remove one half of floating seal (6) from housing

(5).
18. Remove one half of floating seal (6) from drum

(8).
19. Remove outer race of roller bearing (7) from drum

(8).
CAUTION: Sprocket (25) weight: 85 kg

(190 lb)
20. Remove bolts (20) (24 used) and sprocket (25)

from drum (8).
: 32 mm
W3-2-7
ASSEMBLE TRAVEL DEVICE
25 21 20 22 9
1 4 5 6 7 8
43 19 18 44 16 17 15
37
36
16
45
40
41
39
42
12
13
11
10
2 3
14
26 29 33 31 32 34 31 35 10 38
28 23 24 27 26 30
T111-03-04-002
1- Motor 13 - Pin (3 Used) 24 - Bolt (2 Used) 35 - Spring Pin (3 Used)

2- Bolt (4 Used) 14 - Needle Bearing (3 Used) 25 - Sprocket 36 - First Stage Carrier
3- Spring Washer (4 Used) 15 - Second Stage Sun Gear 26 - Thrust Plate (8 Used) 37 - Plug (3 Used)
4- O-Ring 16 - Spacer (2 Used) 27 - Needle Bearing (8 Used) 38 - Bolt (16 Used)
5- Housing 17 - Second Stage Carrier 28 - Pin (4 Used) 39 - Cover
6- Floating Seal 18 - Third Stage Sun Gear 29 - Spring Pin (4 Used) 40 - Bearing
7- Roller Bearing (2 Used) 19 - Third Stage Carrier 30 - Third Stage Planetary Gear 41 - Stopper Pin
(4 Used)
8 - Drum 20 - Bolt (24 Used) 31 - Thrust Plate (6 Used) 42 - Retaining Ring
9 - O-Ring 21 - Spring Washer (24 Used) 32 - Needle Bearing (3 Used) 43 - Socket Bolt (30 Used)
10 - Thrust Plate (6 Used) 22 - Bearing Nut 33 - Pin (3 Used) 44 - Ring Gear
11 - Spring Pin (3 Used) 23 - Lock Plate 34 - Second Stage Planetary 45 - Propeller Shaft
Gear (4 Used)
12 - First Stage Planetary Gear
(3 Used)
W3-2-8
Assemble Travel Device
CAUTION: Drum (8) and sprocket (25) as-
1. Install one half of floating seal (6) on housing (5)
sembly weight: 180 kg (400 lb)
using a wooden spatula or similar tool to guide the
seal along the periphery.
8. Turn drum (8) over . Install eye bolts (M18, pitch
2.5) to drum (8). Install drum (8) onto housing (5)
IMPORTANT: For handling of floating seal (6),
using a crane.
refer to the section Precautions for
floating seal handling on page W1-
9. Press ring gear side inner race of roller bearing
1-3.
(7) onto housing (5).
2. Install outer race of roller bearing (7) into motor
10. Tighten bearing nut (22) to housing (5) by hand.
(1) mounting side bore of drum (8).
11. Attach special tool (ST 3136) to bearing nut (22).
CAUTION: Drum (8) weight: 100 kg (220 lb) Tighten bearing nut (22) to specification using a
torque wrench.
3. After turning drum (8) over, install outer race of
roller bearing (7) into drum (8). Special Tool : ST 3136
CAUTION: Sprocket (25) weight: 85 kg : 41 mm

(190 lb) : 785 Nxm (80 kgfxm, 580 lbfxft)
4. Install sprocket (25) on drum (8).

ST 3136
5. Apply LOCTITE # 262 to bolts (20) (24 used) and
tighten the bolts with spring washers (21).
: 32 mm
CAUTION: Drum (8) and sprocket (25)

assembly weight: 180 kg (400 lb)
6. Turn drum (8) over. Install one half of floating seal

(6) to drum (8) using a wooden spatula or similar
to guide the seal along the periphery. W111-03-02-018
IMPORTANT: For handling of floating seal (6), 12. After tightening bearing nut (22) tap the end face
refer to the section Precautions for of drum (8) with a plastic hammer to secure
floating seal handling on page W1- appropriate play. Then, rotate drum (8) three turns
1-3. in both directions.
7. In case motor side inner race of roller bearing (7)

was removed from housing (5), install inner race
of roller bearing (7) onto housing (5).
W3-2-9
22 9
5 8
19 18 16 17 15
36
16
12
13
11
10
14
26 29 33 31 32 34 31 35 10
28 23 24 27 26 30
T111-03-04-002
W3-2-10
13. Repeat step 11. Then, tighten bearing nut (22) to 22. Install pins (13) (3 used) into first stage carrier
specification. Align bolt holes on housing (5) and (36), aligning the spring pin holes.
lock plate (23).
23. Drive spring pins (11) (3 used) into first stage
: 785 Nxm (80 kgfxm, 580 lbfxft) carrier (36) and pins (13) (3 used).
14. Apply LOCTITE #262 to bolts (24) (2 used). NOTE: Be sure that the slit part of spring pin (11)
Secure lock plate (23) to housing (5) with bolts faces the end face of pin (13).
(24).
: 19 mm
13
Slit
11
15. Install needle bearings (27) (8 used) into third
stage planetary gears (30) (4 used).
24. Assemble second stage carrier (17) following the
16. Putting thrust plates (26) (8 used) on both ends of same procedures in steps 19 to 23.
each third stage planetary gears (30) (4 used),
install them into third stage carrier (19). 25. Install O-ring (9) to drum (8).
17. Install pins (28) (4 used) into third stage carrier

(19), aligning the spring pin holes. CAUTION: Third stage carrier (19) assembly
18. Drive spring pins (29) into third stage carrier (19)
and pins (28). 26. Attach a wire rope or belt to third stage carrier (19)
assembly. Using a crane, install third stage carrier
(19) assembly into housing (5).
NOTE: Be sure that the slit part of spring pin (29)
faces the end face of pin (28).
27. With the lower tooth height side upward, install
third stage sun gear (18) into third stage carrier
28 (19).
29 Slit
Top Side
19. Install spacer (16) to first stage carrier (36).
20. Install needle bearings (14) (3 used) into first

stage planetary gears (12) (3 used).
18 W166-03-02-001
21. Putting thrust plates (10) on both ends of each

first stage planetary gears (12), install them into
first stage carrier (36).
W3-2-11
1 4 5 8
43 19 44 17 15
37
36
45
40
41
39
42
12
2 3
38
T111-03-04-002
W3-2-12
CAUTION: Second stage carrier (17) assem- CAUTION: Cover (39) weight: 22 kg (49 lb)
bly weight: 25 kg (55 lb)
37. Install eye bolts (PT 3/4) to cover (39). Install
28. Attach a wire rope or belt to second stage carrier cover (39) on ring gear (44) using a crane.
(17) assembly. Using a crane, install second stage
carrier (17) assembly onto third stage carrier (19). 38. Apply LOCTITE # 262 to bolts (38) (16 used).
Secure cover (39) to ring gear (44) by tightening
29. With the lower tooth height side upward, install the bolts.
second stage sun gear (15) into second stage
carrier (17). : 22 mm
Top Side 39. Wrap seal tape around plugs (37) (3 used). Install
the plugs to cover (39).
: 14 mm
15 CAUTION: Travel device weight (Excluding

W166-03-02-002 motor): 375 kg (830 lb)
30. Install first stage carrier (36) onto second stage 40. Turn the travel device over .
carrier (17).
41. Add gear oil into the travel device.
31. Insert propeller shaft (45) into the carrier center so
that the propeller shaft meshes with first stage Gear oil: 12 L (12.7 US qt)
planetary gears (12).
42. Install O-ring (4) to motor (1).
CAUTION: Ring gear (44) weight: 70 kg
(155 lb) CAUTION: Motor (1) weight: 125 kg (280 lb)
32. Install eye bolts (M14, pitch 2) to ring gear (44). 43. Hoist motor (1) by crane. While aligning spline
Install ring gear (44) onto drum (8) using a crane. teeth on propeller shaft (45) and motor (1), install
motor (1) on housing (5).
33. Apply LOCTITE # 262 to socket bolts (43) (30
used). Secure ring gear (44) to drum (8) by 44. Secure motor (1) to housing (5) with spring
tightening the bolts. washers (3) and bolts (2) (4 used each).
: 27 mm : 27 mm
34. In case bearing (40) and stopper pin (41) were

removed, install bearing (40) and stopper pin (41)
on cover (39).
35. Install retaining ring (42) to cover (39).
36. Coat THREEBOND # 1389 to cover (39) mount-

ing face on ring gear (44).
W3-2-13
DISASSEMBLE TRAVEL MOTOR
1
2 Travel Speed Shift Valve
3
4
29
5 28
6 27
4 26
3 25
2 24
1
22 30
23 7
32 31
8 31
15
9 33
34
10 35
36
37
11 38
56 12 39
13 45
14
42
21 41 44
20 43 46
19 40 47
18 48
17 49
16 50
51
52
53
54
55
W166-03-02-003
W111-03-02-049
1 - Plug (2 Used) 15 - Overload Relief Valve 29 - Friction Plate (3 Used) 43 - Plug (2 Used)
(2 Used)
2- O-Ring (2 Used) 16 - O-Ring (2 Used) 30 - Disc Plate (3 Used) 44 - O-Ring (2 Used)
3- Spring (2 Used) 17 - O-Ring (2 Used) 31 - Plug (6 Used) 45 - O-Ring (3 Used)
4- Valve (2 Used) 18 - Cover 32 - Casing 46 - Retaining Ring
5- Body 19 - O-Ring (3 Used) 33 - Spring (4 Used) 47 - Case
6- Socket Bolt (6 Used) 20 - Plug (3 Used) 34 - Piston (4 Used) 48 - O-Ring
7- O-Ring 21 - Socket Bolt (8 Used) 35 - Swash Plate 49 - Oil Seal
8- Collar 22 - O-Ring (7 Used) 36 - Plunger (9 Used) 50 - Retaining Ring
9- Needle Bearing 23 - Spring (12 Used) 37 - Retainer Plate 51 - Washer
10 - Pin 24 - Backup Ring 38 - Holder 52 - Bearing
11 - Plug (2 Used) 25 - O-Ring 39 - Rotor 53 - Shaft
12 - O-Ring (2 Used) 26 - Brake Piston 40 - Valve Plate 54 - Inner Race
13 - Plug (2 Used) 27 - O-Ring 41 - Spring (9 Used) 55 - Retaining Ring
14 - O-Ring (2 Used) 28 - Backup Ring 42 - Ball (2 Used) 56 - O-Ring (2 Used)
W3-2-14
Disassemble Travel Motor
Be sure to thoroughly read all Precautions for 8. Lay casing (32) and remove rotor (39)
Disassembly/Assembly work on page W1-1-1 before assembly from shaft (53).
disassembling.
9. Remove plungers (36) (9 used) and retainer
1. Remove socket bolts (6) (6 used) to remove body (5) plate (37) from rotor (39).
from cover (18).
10. Remove holder (38) and springs (41) (9 used)
: 6 mm from rotor (39).
2. Remove socket bolts (21) (8 used). Remove cover 11. Remove friction plates (29) (3 used) and disc
(18) from casing (32) using a crane. plates (30) (3 used) from casing (32).
: 14 mm 12. Install bolts (M8, pitch 1.25) to swash plate (35)

and remove swash plate (35) from casing (32).
3. Lay cover (18) with casing (32) mounting face
upward. Remove spring (23) (12 used), valve plate 13. Remove balls (42) (2 used), pistons (34) (4
(40), O-ring (7), O-rings (16 and 17) (2 used each) used) and springs (33) (4 used) from casing
and O-rings (22) (7 Used). (32).
NOTE: Occasionally, springs (23) and/or valve plate

(40) may remain in casing (32).
4. Remove collar (8) and needle bearing (9) from cover

(18).
5. Remove O-rings (45) (3 used) from casing (32).
CAUTION: When using compressed air to

remove brake piston (26), hold brake piston (26)
using a protector such as a cloth so that the
piston does not fly out.
6. Install bolts (M 8, pitch 1.25) (2 used) to brake piston

(26). Remove brake piston (26) from casing (32). Or,
remove brake piston (26) by applying compressed air
of 98 to 196 kPa (1 to 2 kgf/cm2, 14 to 28 psi) into the
parking brake release hydraulic circuit in casing (32).
NOTE: A bicycle pump can be used to supply

compressed air. Do not use a screw driver
which may score parts.
7. Remove O-rings (25 and 27) and backup rings (24

and 28) from brake piston (26).
W3-2-15
3
4
5
4
3
1
15 32
46
18 47
48
49
50
51
52
53
54
55
W111-03-02-049 W166-03-02-003
W3-2-16
14. Remove retaining ring (46) and case (47) from
casing (32).
15. While tapping the end face of shaft (53) with a plastic
hammer, remove shaft (53) along with bearing (52),
washer (51) and retaining ring (50) from casing (32).
16. Remove washer (51) and retaining ring (50) from

shaft (53).
17. Using a press, remove bearing (52) from shaft (53).
18. Remove oil seal (49) and O-ring (48) from case (47).
19. Remove retaining ring (55) and inner race (54) from
shaft (53).
NOTE: Inner race (54) is not required to be replaced if

no damage or flaking is present on it.
20. Secure body (5) in a vise to remove plugs (1) (2

used).
: 32 mm
21. Remove springs (3) (2 used) and valves (4) (2 used)

from body (5).
22. Remove overload relief valves (15) (2 used) from

cover (18).
: 36 mm
W3-2-17
ASSEMBLE TRAVEL MOTOR
16, 17 23 7 24 25 26 27 28 41 37 35 32 42 52 51 6 5 4 3 2 1
50
46
18
47
10
Travel Speed Shift Valve
8
9 45
53 11, 12
54
55 13, 14
49
19, 20
48
40
33
31
44, 43
22 45 31 29 30 39 36 38 34 15
21 56
W166-03-02-004
W111-03-02-076
1 - Plug (2 Used) 15 - Overload Relief Valve 29 - Friction Plate (3 Used) 43 - Plug (2 Used)
(2 Used)
2- O-Ring (2 Used) 16 - O-Ring (2 Used) 30 - Disc Plate (3 Used) 44 - O-Ring (2 Used)
3- Spring (2 Used) 17 - O-Ring (2 Used) 31 - Plug (6 Used) 45 - O-Ring (3 Used)
4- Valve (2 Used) 18 - Cover 32 - Casing 46 - Retaining Ring
5- Body 19 - O-Ring (3 Used) 33 - Spring (4 Used) 47 - Case
6- Socket Bolt (6 Used) 20 - Plug (3 Used) 34 - Piston (4 Used) 48 - O-Ring
7- O-Ring 21 - Socket Bolt (8 Used) 35 - Swash Plate 49 - Oil Seal
8- Collar 22 - O-Ring (7 Used) 36 - Plunger (9 Used) 50 - Retaining Ring
9- Needle Bearing 23 - Spring (12 Used) 37 - Retainer Plate 51 - Washer
10 - Pin 24 - Backup Ring 38 - Holder 52 - Bearing
11 - Plug (2 Used) 25 - O-Ring 39 - Rotor 53 - Shaft
12 - O-Ring (2 Used) 26 - Brake Piston 40 - Valve Plate 54 - Inner Race
13 - Plug (2 Used) 27 - O-Ring 41 - Spring (9 Used) 55 - Retaining Ring
14 - O-Ring (2 Used) 28 - Backup Ring 42 - Ball (2 Used) 56 - O-Ring (2 Used)
W3-2-18
Assemble Travel Motor
1. Install valves (4) (2 used) and springs (3) (2 used) 12. Install collar (8) and springs (23) (12 used) in
into body (5). cover (18).
2. Install O-rings (2) on plugs (1) (2 used) and install IMPORTANT: Coat valve plate (40) with grease to
plugs (1) into body (5). prevent the valve plate from drop-
ping while installing.
: 32 mm
: 83 Nxm (8.5 kgfxm, 62 lbfxft) 13. Install valve plate (40) to cover (18).
3. Press bearing (52) onto shaft (53). 14. Press shaft (53) into casing (32).
4. Install washer (51) and retaining ring (50) on shaft 15. Install case (47) and retaining ring (46) to casing
(53). (32).
5. Press inner race (54) onto shaft (53). 16. Install springs (33) (4 used), pistons (34) (4 used)
and balls (42) (2 used) in casing (32).
6. Install retaining ring (55) on shaft (53).
17. Using eye bolts (M8, pitch 1.25), install swash
7. Install oil seal (49) and O-ring (48) to case (47). plate (35) to casing (32).
8. Install springs (41) (9 used) and holder (38) to

rotor (39).
IMPORTANT: Plunger (36) flange must come in

contact with the inner diameter of
retainer plate (37) hole. Coat rotor
(39) and plungers (36) with hydraulic
oil.
9. Insert plungers (36) (9 used) into retainer plate

(37). Then, insert plungers (36) into rotor (39).
IMPORTANT: Press needle bearing (9) with the

imprinted stamp facing rotor (18).
10. Press needle bearing (9) into cover (18).
11. Install O-ring (7), O-rings (16 and 17) (2 used

each) and O-rings (22) (7 used) to cover (18).
W3-2-19
6 5
23 24 25 26 27 28 32
18
Travel Speed Shift Valve
45
53
40
45 29 30 39 21 56 15
W166-03-02-004
W111-03-02-076
W3-2-20
18. Lay casing (32) down. Install rotor (39) assembly
onto shaft (53).
19. Install friction plates (29) (3 used) and disc plates

(30) (3 used) one by one alternately. Install friction
plates (29) to casing (32) and disc plates (30) to
rotor (39).
20. Install O-rings (45) (3 used) to casing (32).
and 28) to brake piston (26). Install brake piston
(26) into casing (32).
IMPORTANT: Take care not to drop springs (23)

and valve plate (40).
22. Install cover (18) onto casing (32).
23. Tighten socket bolts (21) (8 used).
: 14 mm
24. Secure body (5) with socket bolts (6) (6 used).
: 6 mm
25. Install O-rings (56) to overload relief valves (15) (2

used). Install overload relief valves (15) (2 used)
into cover (18).
: 36 mm
W3-2-21
DISASSEMBLE BRAKE VALVE
1
2
3 5
4
6
7
2
8
9
12
11
10
13
19 15
20 16 14
21 17
18
W111-03-02-091
1- Plug (2 Used) 7- Backup Ring (2 Used) 12 - Plunger 17 - O-Ring (2 Used)

2- O-Ring (4 Used) 8- Plug (2 Used) 13 - Body 18 - Plug (2 Used)
3- Spring (2 Used) 9- Socket Bolt (8 Used) 14 - Socket Bolt (8 Used) 19 - Spring Seat (2 Used)
4- Ball (2 Used) 10 - Plug (2 Used) 15 - Check Valve (2 Used) 20 - Spring (2 Used)
5- Cap (2 Used) 11 - O-Ring (2 Used) 16 - Spring (2 Used) 21 - Spring Seat (2 Used)
6- O-Ring (2 Used)
W3-2-22
Disassemble Brake Valve

before disassembling.
1. Remove socket bolts (9).
: 10 mm
2. Remove caps (5) from body (13).
3. Remove O-ring (6) and backup ring (7) from cap

(5).
4. Remove plug (1), spring (3) and ball (4) from cap
(5).
: 14 mm
5. Remove spring seats (21 and 19) and spring (20)

from cap (5).
6. Remove plunger (12) from body (13).
7. Remove plugs (18).
: 14 mm
8. Remove springs (16) and check valves (15) from

body (13).
IMPORTANT: After attaching wooden pieces to

plunger (12) from being damaged,
hold it in a vise.
9. Install a round bar into a radial hole on plunger

(12) to prevent the plunger from turning. Then,
hold plunger (12) in a vise.
10. Loosen plugs (10) to remove from plunger (12).
: 19 mm
W3-2-23
ASSEMBLE BRAKE VALVE
9 11 19 13 12 6 7 20 21 5 10 2 8
16 18
15 17
1 2 14 3 4
W111-03-02-090
1- Plug (2 Used) 7- Backup Ring (2 Used) 12 - Plunger 17 - O-Ring (2 Used)

2- O-Ring (4 Used) 8- Plug (2 Used) 13 - Body 18 - Plug (2 Used)
3- Spring (2 Used) 9- Socket Bolt (8 Used) 14 - Socket Bolt (8 Used) 19 - Spring Seat (2 Used)
4- Ball (2 Used) 10 - Plug (2 Used) 15 - Check Valve (2 Used) 20 - Spring (2 Used)
5- Cap (2 Used) 11 - O-Ring (2 Used) 16 - Spring (2 Used) 21 - Spring Seat (2 Used)
6- O-Ring (2 Used)
W3-2-24
Assemble Brake Valve
IMPORTANT: After attaching wooden pieces to

plunger (12) to prevent plunger (12)
from being damaged, hold it in a
vise.
1. Install a round bar into a radial hole on plunger

(12) to prevent the plunger from turning. Then,
hold the plunger in a vise.
2. Install O-ring (11) to plug (10). Install plugs (10)

into plunger (12).
: 19 mm
3. Install check valves (15) and springs (16) into

body (13).
4. Install O-ring (17) to plug (18). Install plugs (18)

into body (13).
: 14 mm
5. Insert plunger (12) into body (13).
6. Install spring seats (19), springs (20) and spring

seats (21) onto plunger (12) in that order.
7. After installing O-ring (6), backup ring (7) to cap

(5), install caps (5) to body (13).
8. Tighten socket bolts (9).
: 10 mm
9. Install ball (4) and spring (3) into cap (5).
10. Install O-ring (2) to plug (1). Tighten plug (1).
: 14 mm
W3-2-25
1. Measure the end play between the plunger and

shoe while pushing and pulling the travel motor
plunger.
Unit : mm (in)
Max. 0.15 (0.006) 0.4 (0.016)
W111-03-02-106
2. Plunger and rotor bore clearance.

After measuring both the plunger diameter and
rotor bore, calculate the clearance.
Unit : mm (in)
Max. 0.045 (0.0018) 0.06 (0.0024)
Check the plunger surface visually. If any scores W111-03-02-107
are found, replace the plunger.
W111-03-02-108
3. After measuring the travel motor piston diameter

and the casing piston bore, calculate the
clearance.
Unit : mm (in)
Max. 0.018 (0.00071) 0.04 (0.0016)
Check the piston surface visually. If any scores

are found, replace the piston.
W162-03-02-005
W3-2-26
4. Measure the end play between the piston and
shoe while pushing and pulling the travel motor
piston.
Unit : mm (in)
Max. 0.5 (0.020) 0.7 (0.028)
5. Travel speed shift valve check W107-02-06-140
Measure the clearance between valve and body.

Valve
Unit : mm (in)
Max. 0.018 (0.0071) 0.04 (0.0016)
W111-03-02-109
Body
W3-2-27
Sprocket
C
D
E
A
W105-03-02-241

Remedy
mm (in) mm in
A 92 (3.62) 82 (3.23)
B 728.2 (28.67) 718 (28.27) After cladding
C 800.2 (31.50) by welding,
D 820 (32.28) 810 (31.89) finish manually.
E 215.9 (8.50)
W3-2-28
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT

The hydraulic oil tank cap may pop off by re-
maining pressure if removed quickly. Slowly
loosen the cap to completely release any re-
maining pressure.
Preparation

oil tank.

tank.

W3-3-1
Removal
1. Attach tags to all hoses connected to the center

joint to aid re-connection. Disconnect hoses (1, 2, 1 2 3
4 to 15) and remove adapters.
: 22 mm
: 39 Nxm (4.0 kgfxm, 29 lbfxft) 4 5
: 27 mm
: 41 mm
NOTE: Cap all disconnected hose and pipe ends.

7
2. Remove lock plate (3).
6
: 22 mm
: 137 Nxm (14 kgfxm, 101 lbfxft) M162-07-071
3. Install eye bolt (PF 1) to the center joint to lift the

center joint with a wire rope.
CAUTION: Center joint weight: 77 kg (170 lb) 8
4. Remove bolts (16). Then, remove the center joint

assembly while holding the center joint with a 16
crane. 9
: 24 mm 15
Installation
14
NOTE: Refer to Removal section above for
wrench sizes and tightening torque.
1. Install the center joint with bolts (16).
2. Connect hoses (1, 2, and 4 to 15) and adapters.

13 12 11 10 M162-07-067
3. Install lock plate (3) with bolts.
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE CENTER JOINT
3
4
5
6
7
11
10 12
13
14
15
16
17
18
W111-03-03-004
1- Spindle 6- Ball (26 Used) 11 - Spring Washer (4 Used) 15 - Backup Ring

2- O-Ring 7- Seal 12 - Ring 16 - O-Ring
3- Cover 8- Seal (5 Used) 13 - Retaining Ring 17 - Cover
4- Dust Seal 9- Body 14 - O-Ring 18 - Bolt (6 Used)
5- O-Ring 10 - Bolt (4 Used)
W3-3-4
Disassemble Center Joint

before disassembling. 17
CAUTION: Center joint weight: 77 kg (170 Ib)
1. Install eye bolt (M12, pitch 1.75) (ST 0002) to

18
cover (17). Lift the center joint and set it on a work
bench (ST 5078).
2. Remove bolts (18) and cover (17).

W111-03-03-006
: 19 mm
IMPORTANT: Put a matching mark on body (9) and

spindle (1).
3. Remove O-ring (14), retaining ring (13) and ring Matching

(12) from cover (17) and spindle (1). Mark
4. Using cover (17) mounting bolt (18) holes (2

used), install center joint removal special tool (ST
1930) to body (9).
: 19 mm
W142-03-03-004
5. Pull out spindle (1) from body (9) downward

approx. 50 mm.
After checking that balls (6) are on cover (3), take ST 1930
out balls (6) (26 used). Then, remove spindle (1)
downward. 18
IMPORTANT: Take care not to damage the seal

slide surface on spindle (1). Use two
picks to easily remove seal (8). 9
Take care not to damage the seal
groove with the pick.
6. Remove seals (8) (6 used) from body (9). W105-03-03-013
7. Remove dust seal (4) and O-ring (5) from body

(9).
W105-03-03-015
W3-3-5
ASSEMBLE CENTER JOINT
2
3
4
5
6
7
8
12
14
13
18
17
15
16
W111-03-03-003
1- Spindle 5- O-Ring 9- Body 15 - Backup Ring

2- O-Ring 6- Ball (26 Used) 12 - Ring 16 - O-Ring
3- Cover 7- Seal 13 - Retaining Ring 17 - Cover
4- Dust Seal 8- Seal (5 Used) 14 - O-Ring 18 - Bolt (6 Used)
W3-3-6
Assemble Center Joint
1
0.05 mm
1. Install O-ring (5) and dust seal (4) into body (9). (0.004 in)
2. Install seals (7) and (8) (5 used) into body (9).

9
3. Place spindle (1) on a work bench. Aligning the
matching marks put when disassembling, install
spindle into body (9).
IMPORTANT: Be sure to slowly push spindle (1)

into body. Failure to do so may dam-
age seals. Moreover, the clearance
between body (9) and spindle (1) is
approx. 0.05 mm (0.004 in) so that W105-03-03-024
body (9) and spindle (1) center must
be aligned during installation. 9
6
4. While tapping body (9) with a plastic hammer, 4
insert spindle (1) until the clearance between
cover (3) and dust seal (4) is 30 mm (1.2 in). Then, 30 mm (1.2 in)
place balls (6) (26 used) on cover (3) and insert
spindle (1) further until the top end face of spindle
(1) is flush with the top end of body (9).
3
IMPORTANT: Install ring (12) with the chamfered
edge facing the spindle.
1
W142-03-04-021
5. Install ring (12) to body (9).
IMPORTANT: Install retaining ring (13) with the

chamfered edge facing ring (12).
6. Install retaining ring (13) onto spindle (1).
7. Install O-rings (14 and 16) and backup ring (15) to 17

cover (17).
Secure cover (17) to body (9) with bolts (18) (6 9
used).
18
: 19 mm
IMPORTANT: Check for oil leaks while applying oil

pressure of 0.5 MPa (5 kgf/cm2, 71
psi) to the main and drain ports , W105-03-03-028
respectively.
W3-3-7
Part Name and Location Allowable Limit (basis of judgment) Remedy

Body, Spindle Sliding surfaces with Heavily damaged one by seizure or Replace
seals foreign matter.
Sliding surfaces be- 1) Excessively worn one by seizure or Replace
tween body and spin- foreign matter, or one having the
dle other than sliding score of 0.1 mm (0.004 in) or more.
surfaces with seals 2) One having the score of less than Repair the surface smooth.
0.1 mm (0.004 in).
Sliding surfaces with 1) One that has worn 0.5 mm (0.02 in) Replace
ring or more, or excessively worn.
2) One that has worn 0.5 mm (0.02 in) Repair the surface smooth.
or less.
3) One that has scores due to seizure Repair the surface smooth.
or foreign matter but the damage is
less than the allowable wear limit 0.5
mm (0.02 in) and is repairable.
Cover Sliding surfaces with 1) One that has worn 0.5 mm (0.02 in) Replace
ring or more.
2) One that has worn less than 0.5 mm Repair the surface smooth.
(0.02 in).
3) One that has scores due to seizure Repair the surface smooth.
or foreign matter but the damage is
less than the allowable wear limit 0.5
mm (0.02 in) and is repairable.
W3-3-8
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK AD-
JUSTER
Before removing the track adjuster, the tracks and the

front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to
applicable removal/installation sections. In this section,
the procedure starts on the premise that the tracks and
the front idler have already been removed.
CAUTION: When removing track adjuster (1),

track adjuster (1) may fly off by spring force.
Dont stand in the removal direction of track
adjuster (1) or in places where track adjuster
2
(1) may fly out. The rod screw is loaded by
spring force. Be alert that if the rod or screw 1
section is broken, the broken pieces may fly
out by spring force, causing personal injury
and/or death.
Removal
W142-03-04-002
CAUTION: Track adjuster weight: 250 kg
(550 lb)
3 2
1. After removing the front idler and yoke, remove
track adjuster (1) from track frame (2) by prying it
with a crowbar.
W166-03-04-002
Installation
4 3
1. As illustrated, install track adjuster (1) into spring
guide (3) on track frame (2). Check that the end
face of track adjuster (1) comes into contact with
the face of plate (4).
W166-03-04-005
W3-4-1
DISASSEMBLE TRACK ADJUSTER
1 2 3
5
6
7
10
16
11
15
12
14 W166-03-04-003
13
1- Socket Bolt (4 Used) 5- Wear Ring 9- Cylinder 13 - Nut

2- O-Ring 6- U-Ring 10 - O-Ring 14 - Bracket
3- Guide 7- Retaining Ring 11 - Bolt 15 - Spring
4- Piston Rod 8- Rod 12 - Valve 16 - Spacer
W3-4-2
Disassemble Track Adjuster
Be sure to thoroughly read Precautions for Dis-

assembly and Assembly on page W1-1-1 before
disassembling.
Use a pump unit which has the maximum pres-
2
sure of 69 MPa (700 kgf/cm , 9 950 psi) and the
flow rate of 8 to 10 liters (2.1 to 2.6 US gal.). Be
sure to set the main relief pressure to 49 MPa
2
(500 kgf/cm , 7 110 psi) (80 tons) or lower.
Be sure to use special tool (ST 4932) for assem-

bly/disassembly of the track adjuster.
ST 4932
CAUTION: Prevent personal injury. The
spring force of the track adjuster is ex-
tremely large. Thoroughly inspect the special
tool for any damage. Carefully perform
assembly work referring to the procedure
below.
CAUTION: Track adjuster assembly weight:

250 kg (550 lb)
Rest
1. Position the track adjuster on the rest of special
tool (ST 4932) using a crane.
W142-03-04-019
IMPORTANT: Compress spring (15) until the Clearance 10 mm

clearance between bracket (14) and
nut (13) is approximately 10 mm (0.4
in).
2. Loosen valve (12). Compress track adjuster 14

spring (15) using special tool (ST 4932). 13
11
3. Remove valve (12) and bolt (11) to remove nut 12
(13). Remove nut (13).
: 19 mm, 115 mm
W142-03-04-020
W3-4-3
16
15
14 W166-03-04-003
W3-4-4
4. Slowly return the piston of special tool (ST 4932)
until spring (15) extends to its free length.
15 (ST 4932)
CAUTION: Track adjuster weight (Nut ex-
cluded): 245 kg (540 lb)
5. Tie bracket (14) and spring (15) together using

14
wire. Fasten a sling belt to spring (15). Lift bracket
(14) and spring (15) together out of special tool
(ST 4932) using a crane.
W142-03-04-005
6. Install eye bolt (ST 0007: M10, Pitch 1.5) onto (ST 0007)
piston rod (4). Fasten a sling belt around spring
(15) and through the eye bolt. Lift and position the 4
assembly on the rest using a crane, as illustrated.
15
Rest
W142-03-04-006
CAUTION: Cylinder (9) assembly weight:

60 kg (130 lb) (ST 0007)
7. Lift and remove cylinder (9) assembly. 9
CAUTION: Spring weight: 140 kg (310 lb)
8. Remove the wire fastening spring (15) and

bracket (14). Lift and remove spring (15) using a
crane. 15
CAUTION: Bracket weight: 22 kg (50 lb)

Rest
9. Remove spacer (16) and bracket (14) out of the
rest.
W142-03-04-007
W3-4-5
1 2 3
5
6
7
10
W166-03-04-003
W3-4-6
10. Remove socket bolts (1) (4 used) and guide (3).
2
: 12 mm 3
1
11. Pull out piston rod (4) from cylinder (9).
4
12. Remove O-ring (2) from guide (3)
10
CAUTION: Cylinder (9) weight: 40 kg (88 Ib)

Rod (8) weight: 20 kg (44 Ib) 9
13. Remove rod (8) and O-ring (10) from cylinder (9).
8
14. Remove wear ring (5), retaining ring (7) and U-
ring (6) from piston rod (4). W142-03-04-010
5
6
7
W166-03-04-001
W3-4-7
ASSEMBLE TRACK ADJUSTER
12 11 14 8 16 10 6 9 3 2
Chamber B
13 15 7 5 1 4
W166-03-04-004
1- Socket Bolt (4 Used) 5- Wear Ring 9- Cylinder 13 - Nut

2- O-Ring 6- U-Ring 10 - O-Ring 14 - Bracket
3- Guide 7- Retaining Ring 11 - Bolt 15 - Spring
4- Piston Rod 8- Rod 12 - Valve 16 - Spacer
W3-4-8
Assemble Track Adjuster 4
1. Clean all parts. 5

Install U-ring (6), retaining ring (7), and wear ring 6
(5) to piston rod (4). 7
2. Apply a film of grease to O-ring (10) and install it

into cylinder (9).
Install rod (8) into cylinder (9).
3. Apply grease to U-ring (6), wear ring (5), cylinder 10 W166-03-04-001
(9) and piston rod (4). Install piston rod (4) into
cylinder (9).
IMPORTANT: Fill chamber (B) in cylinder (9) with 8

grease and insert piston rod (4) to
completely bleed air from part (B) 9
and from the inside of rod (8).
4. Install O-ring (2) on guide (3). Install guide (3) on

piston rod (4). Apply a LOCTITE #262 to socket
bolts (1) (4 used) and tighten socket bolts (1).
W142-03-04-012
: 12 mm
2
3
1
W142-03-04-018
W3-4-9
14 16 9
15 4
W166-03-04-004
W3-4-10
CAUTION: Bracket (14) weight: 22 kg (50 lb)

Spring (15) weight: 140 kg (310 Ib)
9
5. Place bracket (14) and spacer (16) on the rest.
Lift and place spring (15) onto the rest. Tie spring
(15) and bracket (14) together using pieces of
wire.
16
CAUTION: Cylinder (9) assembly weight:
60 kg (130 lb)
15
6. Install eye bolt (M10, Pitch 1.5) onto piston rod (4).
Lift and position cylinder (9) assembly in place Rest
14
onto spacer (16) and bracket (14) using a crane.
CAUTION: Track adjuster weight (excluding W142-03-04-007

nut): 245 kg (540 lb)
7. Fasten a sling belt around spring (15) through the 4

eye bolt. Lift and lay the assembly on a clean,
secured level surface using a crane.
8. Attach a sling belt through the spring part of the

assembly. Lift and position the track adjuster 15
assembly on special tool (ST 4932) while balanc-
ing it horizontally. Remove the eye bolt.
W142-03-04-006
ST 4932
W142-03-04-005
W3-4-11
12 11 14 8 15
620 mm (Free Length 774 mm)

13 (2 ft 0.4 in (Free Length 2 ft 6.5 in))
884 mm (2 ft 10.8 in)
W166-03-04-004
W3-4-12
IMPORTANT: Be sure to slowly compress spring
(15) while aligning the center of rod
(8) with the center of bracket (14)
using a crowbar. Take care not to
damage the threads on rod (8).
15
9. Remove wire from spring (15). Compress spring
(15) by operating the cylinder of special tool (ST ST 4932
4932) until the specified spring length is obtained.
Specified Spring Length: 620 mm (2 ft 0.4 in) 14
10. Install nut (13) and bolt (11) to rod (8).
: 115 mm Wire
: 19 mm
: 39 Nxm (4 kgfxm, 29 Ibfxft)
11. Tighten valve (12).
: 24 mm W142-03-04-015
: 147 Nxm (15 kgfxm, 108 Ibfxft)
12. Retract the cylinder of special tool (ST 4932).
CAUTION: Track adjuster weight : 250 kg 13

(550 Ib)
8
13. Securely fasten a sling belt to the track adjuster.

Lift and remove the track adjuster using a crane.
11
14. If the spring assembly must be transported, take 12
care not to damage it. Use a firm steel box for
transportation of the spring assembly and take
any other precautions in order to insure safe
W142-03-04-020
transport.
W3-4-13
(Blank)
W3-4-14
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Removal
Before removing the front idler, the tracks must be

removed first. For removal and installation of the
tracks, refer to Remove and Install Tracks section.
In this section, the procedure starts on the premise
that the tracks have already been removed.
CAUTION: When removing the front idler, the

front idler may come out explosively by
spring force. Dont stand in the removal W142-03-05-002
direction of the front idler or in a place where
the front idler may come out.
CAUTION: Front idler weight: 275 kg (610 lb) 4

3
1. Slide the front idler forward, using a crowbar.
2. Attach sling belts to bearing (1) and yoke (2)

sections. Remove the front idler assembly from
track frame (3) using a hoist.
3. Remove socket bolts (5) and remove guard (4) 1

from yoke (2). 2 5
W142-03-05-003
: 19 mm
4. When storing the front idler, place it on blocks as

shown.
W105-03-05-003
Installation
1. Attach front ider to a hoist, then install it to track

frame (3) following the removal procedures in the 3
reverse order.
Apply a film of grease to the sliding surface
between track frame (3) and bearing (1) after
cleaning.
W142-03-05-005
W3-5-1
DISASSEMBLE FRONT IDLER
1
2
3
6
7
8
6
4
5
4
3
2
10
11
W111-03-05-013
14 13 12
1- Pin (2 Used) 5- Axle 9 - Guard 12 - Yoke

2- Bearing (2 Used) 6- Bushing (2 Used) 10 - Bolt (3 Used) 13 - Bolt (4 Used)
3- Floating Seal (2 Used) 7- Idler 11 - Spring Washer (3 Used) 14 - Spring Washer (4 Used)
4- O-Ring (2 Used) 8- Plug (2 Used)
W3-5-2
Disassemble Front Idler
Be sure to thoroughly read Precautions for

Disassembly and Assembly on page W1-1-1
before starting disassembly.
1. Remove bolts (10), spring washers (11) and guard

(9).
: 24 mm
CAUTION: Yoke (12) weight: 56 kg (125 lb)
2. Remove bolt (13) and remove yoke (12). Remove

plug (8) from bearing (2) to drain oil into a
container.
: 30 mm
: 6 mm
3. Remove pin (1).

2 5
CAUTION: Idler assembly weight: 220 kg
(490 lb)
4. Set the idler assembly in a press as illustrated.

7
Apply the press on the axle end. Push axle (5) out
of bearing (2) using the press. Axle (5) and the
lower side bearing (2) will come off idler (7), and
the upper side bearing (2) will also be separated
from idler (7).
W105-03-05-008
CAUTION: Axle (5) weight: 28 kg (62 Ib)

Bearing (2) weight: 14 kg (30 Ib) 2
IMPORTANT: For handling of floating seal (3), 3

7
1-3.
5. Remove floating seal (3) from bearing (2) and

3
idler (7).
4
W105-03-05-009
W3-5-3
6
4
5
4
W111-03-05-013
W3-5-4
CAUTION: Axle (5) weight: 28 kg (62 lb)

4
6. Press out axle (5) to remove bearing (2) and O-
ring (4).
2
W105-03-05-010
7. In case of replacing bushing (6), remove the

bushing using a press and the special tool (ST
1973).
ST 1973
W105-03-05-011
W3-5-5
ASSEMBLE FRONT IDLER
2 3 6 4 1 12 9 10, 11
7 5 8 13, 14
W166-03-05-002
1- Pin (2 Used) 5- Axle 9 - Guard 12 - Yoke

2- Bearing (2 Used) 6- Bushing (2 Used) 10 - Bolt (3 Used) 13 - Bolt (4 Used)
3- Floating Seal (2 Used) 7- Idler 11 - Spring Washer (3 Used) 14 - Spring Washer (4 Used)
4- O-Ring (2 Used) 8- Plug (2 Used)
W3-5-6
Assemble Front Idler
CAUTION: Idler weight: 152 kg (335 Ib)
1. Install bushing (6) into idler (7) using a press.
CAUTION: Axle (5) weight: 28 kg (62 Ib) 1

Bearing (2) weight: 14 kg (30 Ib) 5
2. Install O-ring (4) (1 piece) onto axle (5). Aligning 2

the pin holes, install axle (5) into bearing (2) and
secure using pin (1). Take care not to damage O-
ring (4).
IMPORTANT: For handling of floating seal (3), W105-03-05-014

1-3. 7
3 2
3. Install floating seal (3) (one pair) into idler (7) and
into bearing (2)
CAUTION: Axle assembly weight: 42 kg

(93 Ib) 5
4. Insert axle (5) into idler (7) from the floating seal
installed side. Install O-ring (4) onto axle (5). W157-03-05-006
5. Install the other floating seal (3) (one pair) into

idler (7) and into the other bearing (2). 2 3 4
7
6. Install bearing (2) onto axle (5), aligning the pin 2
holes. Secure them using pin (1).
7. Add engine oil via plug (8) hole on bearing (2).

Apply sealant (LOCTITE #503 or equivalent) to
plug (8). Tighten plug (8). 5
: 6 mm
W157-03-05-005
Engine oil: API CD Class SAE 30

Quantity: 0.45 L (0.48 US qt)
CAUTION: Idler weight: 155 kg (345 Ib)

Yoke weight: 56 kg (125 Ib)
8. Install yoke (12) and tighten bolts (13) (4 used) 9. Install guard (9) and tighten spring washer (11) (3
and spring washer (14) (4 used). used) and bolt (10) (3 used).
: 30 mm : 19 mm
W3-5-7
Front Idler
C D
A W166-03-05-001
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 102 (4.02) 92 (3.62)
B 204 (8.03)
Cladding by
C 630 (24.80) 620 (24.41) welding and
finish or replace
D 675 (26.57)
E 22.2 (0.87)
Axle and Bushing
Unit: mm (in)
Allowable Allowable
Remedy
Limit Limit
Axle Outside Dia. 110 (4.33) 109.2 (4.30)
Inside Dia. 110 (4.33) 111 (4.37)
Replace
Bushing Flange
6.0 (0.24) 5.2 (0.20)
Thickness
W3-5-8
UNDERCARRIAGE / Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Grease pressure in the adjuster

cylinder is high. Do not loosen valve (1)
quickly or loosen it too much as valve (1) may
fly off or high-pressure grease in the
adjusting cylinder may spout out. Loosen
carefully, keeping body parts and face away
from valve (1).
Never loosen grease fitting (2).
W105-03-06-001
IMPORTANT: When gravel or mud is packed be-

1
tween sprockets and tracks, remove
it before loosening.
1. Loosen valve (1) to drain grease.
: 24 mm
Grease Outlet
M104-07-119
3
2. Jack tracks (3) up high enough to permit upper
roller (4) removal.
CAUTION: Use a nonskid cloth between

track frame (5) and jack to prevent slipping.
5 4
W105-03-06-002
3. Insert a wooden block between tracks (3) and

track frame (5).
W105-03-06-003
W3-6-1
4. Remove bolts (6).
: 27 mm
W157-03-06-001
CAUTION: Upper roller weight: 35 kg (77 lb)
5. Remove upper roller (4) from track frame (5).
5
W105-03-06-005
Installation
1. Install upper roller (4) with bolts (6) (4 used).
: 27 mm
5
W157-03-06-001
2. Remove the wooden block and jack.
W105-03-06-002
W3-6-2
3. Supply grease to grease fitting (2) to adjust tracks
tension. 2
Track sag specifications (A):

EX400-5, 450H-5: 380 to 430 mm
(15.0 to 16.9 in)
EX400LC-5, 450LC-5, 450LCH-5:390 to 440 mm
(15.4 to 17.3 in)
NOTE: Check track sag after thoroughly removing

soil stuck on the track area.
Grease Outlet
M104-07-119
W157-03-06-002
W3-6-3
REMOVE AND INSTALL LOWER ROLLER
Removal
1. Remove the track guard and bolts (1).
: 32 mm 1
2. Lift one side of the track frame height enough to W105-03-06-008
remove the lower roller.

Insert wooden blocks under track frame (2).
W105-03-06-009
CAUTION: Do not loosen valve (3) quickly or

loosen it too much as high-pressure grease
in the adjusting cylinder may spout out.
Loosen carefully, keeping body parts and
face away from valve (3).
Never loosen grease fitting (4).
W105-03-06-001
3. Loosen valve (3) to drain enough grease to permit

the roller removal. 3
: 24 mm
4
Grease Outlet
M104-07-119
W3-6-4
CAUTION: Lower roller weight: 80 kg (180 lb)
4. Remove lower roller (5) using a fork lift.
5 W105-03-06-011
Installation
1. Put lower rollers (5) on the tracks as illustration

using a fork lift.
5 W105-03-06-011
2
2. Lower track frame (2) enough to allow bolts (1) to
be installed into track frame (2).
W105-03-06-012
5
3. Align tapped holes in track frame (2) with rollers

(5) bolt holes.
Tighten bolt (1) (4 used).
: 32 mm
1
W105-03-06-008
W3-6-5
4. Supply grease through valve fitting (4) to adjust
tracks tension. 4

EX400-5, 450H-5: 380 to 430 mm
(15.0 to 16.9 in)
EX400LC-5, 450LC-5, 450LCH-5:390 to 440 mm
(15.4 to 17.3 in)
NOTE: Check track sag after thoroughly removing

soil stuck on the track area.
Grease Outlet
M104-07-119
W157-03-06-002
W3-6-6
(Blank)
W3-6-7
DISASSEMBLE UPPER ROLLER
11
10
9
6
5
4
3
2
1
12
W166-03-06-005
1 - Socket Bolt (3 Used) 4 - O-Ring 7 - Roller 10 - Axle

2 - Plug 5 - Thrust Plate 8 - Bushing 11 - Bracket
3 - Cover 6 - Bushing 9 - Floating Seal 12 - Socket Bolt (3 Used)
W3-6-8
Disassemble Upper Roller

before starting disassembly.
1. Remove plug (2) to drain oil.
: 6 mm
2. Remove socket bolts (1) (3 used) and cover (3).
: 8 mm
3. Remove socket bolt (12) (3 used) and thrust plate

(5).
: 8 mm
4. Remove axle (10) from roller (7).
5. Remove floating seal (9) from roller (7) and

bracket (11).
ST 1974
NOTE: Floating seal (9) can be reused if it is not
worn. Keep the floating seal in a matched
set and put cardboard between seals to 6
protect the sealing face.
6. When replacing bushings (6) and (8), remove the

8
bushing from the roller by using a press and
NOTE: Bushings can also be removed by cladding

four weld beads on the inside of bushing at
90 intervals.
Bushing will shrink enough to permit
removal using a hammer. W142-03-06-005
W3-6-9
ASSEMBLE UPPER ROLLER
11 10 9 7
2
12
8 6 4
W166-03-06-008
1 - Socket Bolt (3 Used) 4 - O-Ring 7 - Roller 10 - Axle

2 - Plug 5 - Thrust Plate 8 - Bushing 11 - Bracket
3 - Cover 6 - Bushing 9 - Floating Seal 12 - Socket Bolt (3 Used)
W3-6-10
Assemble Upper Roller
Before assembling
Clean all parts.
Remove all scratches and roughness on the parts
using an oil stone.
Replace all O-rings and seals with new ones.
IMPORTANT: Required pressing force to install

bushings (6) and (8) into roller (7) is
3 tons (6610 lb).
1. Install bushings (6) and (8) into roller (7) using a

press.
IMPORTANT: Apply a coat of grease to the O-ring

part of floating seal (9) and a film of
hydraulic oil to the steel ring part.
For handling of floating seal (9),
1-3.
2. Install floating seal (9) to roller (7) and to bracket

(11).
3. Insert axle (10) into roller (7).
4. Install thrust plate (5) to axle (10), tighten socket

bolt (12) (3 used).
: 8 mm
5. Apply grease to O-ring (4) and install it to cover

(3).
6. Install cover (3) to roller (7), and tighten socket

bolts (1) (3 used).
: 8 mm
7. Add engine oil via plug (2) hole on cover (3).

Engine oil : API CD Class SAE 30
Quantity : 120 cm3 (0.13 US qt)
8. Apply sealant (LOCTITE #503 or equivalent) to

plug (2). Tighten plug (2) to cover (3).
: 6 mm
W3-6-11
DISASSEMBLE LOWER ROLLER
4 6
7
6
3
4
W166-03-06-006
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-12
Disassemble Lower Roller

CAUTION: Lower roller weight: 80 kg (180 Ib) 4 1 8 1
1. Remove plugs (6) and pins (5) from collars (4),

and drain oil.
1
: 6 mm
4
2. Press down axle (2) until O-ring (3) comes out of
collar (4).
Remove collar (4) from axle (2).
3. Remove O-ring (3) from axle (2). 3

Remove axle (2) from roller (8).
W105-03-06-026
4. Remove floating seal (1) from roller (8) and collar 3 4

(4).
5. Press out axle (2), and remove collar (4) and O-

ring (3) from axle (2).
W105-03-06-027
6. In case of replacing bushings (7), remove the

bushings using a press and special tool (ST
1968).
ST 1968
W105-03-06-028
W3-6-13
ASSEMBLE LOWER ROLLER
4 5 6
8 2 7 1 3
W162-03-06-002
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-14
Assemble Lower Roller
2 5
CAUTION: Lower roller weight: 47 kg (105 Ib)
1. Install bushings (7) (2 used) onto roller (8) using a

press. Take care not to dent the flange surface of
bushings (7). Apply a coat of grease to O-ring (3)
and install onto axle (2).
2. Install collar (4) onto axle (2), aligning the pin 4 3

holes. Secure them using pin (5). Take care not to W166-03-06-009
damage O-ring (3). 8 1
IMPORTANT: For handling floating seal (1), refer

to the section Precautions for han-
dling floating seal on page W1-1-3.
1 4
3. Install floating seal (1) to roller (8) and to collar (4).
4. Insert axle (2) into roller (8). Install O-ring (3) and
the other collar (4). Secure them using pin (5).
5. Add engine oil via plug (6) hole on collar (4). Apply W157-03-06-008
sealant (LOCTITE #503 or equivalent) to plug (6). 4 1 2 8
Tighten plug (6).
Engine oil: API CD Class SAE 30

Quantity: 0.5 L (0.53 US qt)
: 6 mm
3
: 29.5 Nxm (3 kgfxm, 22 lbfxft) W157-03-06-009
5 8
4
W105-03-06-024
W3-6-15
Upper Roller
A
B
W166-03-06-007
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 103 (4.06)
Cladding by
B 190 (7.48) welding and finish
or replace
C 160 (6.30) 150 (5.91)
Axle and Bushing
Unit: mm (in)
Allowable
Standard Remedy
Limit
Axle Outside Dia. 60 (2.33) 59.2 (2.37)
Inside Dia. 60 (2.40) 61 (2.37) Replace
Bushing
Flange Thickness 4.5 (0.18) 3.7 (0.15)
W3-6-16
Lower Roller
C A C
B
W157-03-06-003
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 214 (8.43) 237.5 (9.35)
B 284 (11.18) Cladding by
welding and finish
C 35 (1.38) or replace
D 200 (7.87) 180 (7.09)
Axle and Bushing
Unit: mm (in)
Allowable
Standard Remedy
Limit
Axle Outside Dia. 85 (3.35) 84.2 (3.32)
Inside Dia. 85 (3.35) 86.0 (3.39) Replace
Bushing
Flange Thickness 6 (0.24) 5.2 (0.20)
W3-6-17
(Blank)
W3-6-18
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACKS
Removal
CAUTION: The adjusting cylinder is highly

pressurized. Loosening valve (1) quickly
and/or excessively may cause valve (1) to fly
off and the highly pressurized grease to
spout out, possibly resulting in personal
injury.
Be sure to loosen valve (1) slowly and
gradually, keeping face and body parts away
from valve (1). In addition, never attempt to
loosen grease fitting (2). W105-03-07-001
1. Rotate the tracks so that master pin (3) is 5

positioned over front idler (4).
Put a wooden block under track shoes (5), as
shown. 4
W105-03-07-006
1
2. To loosen the track tension, slowly turn valve (1)
counterclockwise one turn; grease will be
released via grease outlet.
: 24 mm
W105-03-07-002
Grease Outlet M104-07-119
W3-7-1
3. Remove pin (6), which is used to secure master
pin (3). 7
If it is difficult to remove pin (6), drive in master pin
(3) first using a hammer to make clearance 3
between pin (6) and master pin (3) before
attempting to pull out pin (6).
6
CAUTION: The front idler may jump out of

position due to strong spring force when the
track is disconnected. Never stand in front of
the front idler. Moreover, if the rod or the rod
screw is damaged, the damaged part may fly W166-03-07-001
off since strong spring force is always
applied to the rod screw.
In both cases, severe personal injury may
result. Take necessary precautions to prevent
personal injury.
W105-03-07-005
W3-7-2
4. Remove master pin (3) using special tool (ST ST 1970
1970).
IMPORTANT: The direction of removing is as

illustrated.
Be sure to strike the pin correctly.
3
W105-03-07-008
Pin
Direction for
removing
the master pin
Master Pin
W166-03-07-002
Boom
5. Raise the machine as illustrated with the angle
Arm
between the boom and the arm held at 90 to 110
and the bucket round bottom section placed on
the ground. 90 to 110
Put wooden blocks under the track frame to safely
support the raised machine.
W105-03-07-012
6. Slowly operate the raised side travel lever in the

reverse direction to remove the tracks from the
machine.
W105-03-07-011
W3-7-3
Installation
1. Raise the machine with the front attachment and

put the track under the lower roller so that the
sprocket tooth align with the end of the track.
Be sure to position the track in the correct Sprocket
Idler
direction, as illustrated. Side Side
W105-03-07-013
2. Lift the track, and place it on sprocket (1).
W105-03-07-014
3. With the machine kept raised, slowly turn the

raised side sprocket in the forward direction to
wind the track around the raised track frame.
W105-03-07-015
4. Turn sprocket (1) until the end of track (5) comes

on front idler (4).
Lower the machine and put a wooden block as
illustrated.
5
W105-03-07-016
W3-7-4
5. Install master pin (3), using a hammer and special
ST 1970
tool (ST 1970). 3
IIMPORTANT: Install the master pin in the correct

direction as illustrated below.
W105-03-07-017
Pin
Direction for
installing the
master pin
Master Pin
W166-03-07-002
6. Install pin (6).
IMPORTANT: Replace pin (6) with new one, when

installing master pin.
W166-03-07-001
W3-7-5
7. Charge grease to the cylinder through the grease
fitting to adjust the tracks tension.
: 24 mm

EX400-5, EX450H-5: 380 to 430 mm
(15.0 to 16.9 in)
EX400LC-5, EX450LCH-5: 390 to 440 mm
(15.4 to 17.3 in)
IMPORTANT: Check track sag after thoroughly

removing soil stuck on the track W105-03-07-018
area.
W157-03-06-002
W3-7-6
Link Pin and Track Bushing
Measure the length of four links, as illustrated,

with the tension on the track.
Do not measure the master-pin-included part of
the track.
A
W155-03-07-001
Unit: mm (in)
Standard Allowable Limit Remedy
A 865.5 (34.07) 897.5 (35.33) Cladding by
welding and
B 129 (5.08) 122 (4.80) finish or replace
Master Pin
W142-03-07-003
A
Unit: mm (in)
A 308 (12.13)
Replace
B 47.3 (1.86) 44.3 (1.74)
W3-7-7
Master Bushing
W105-03-07-023
Unit: mm (in)
Allowable
Standard Limit Remedy
A 160.80 (6.33)
B 47.90 (1.89) 50.90 (2.00) Replace
C 71.35 (2.81) 66.35 (2.61)
Grouser Shoe
W105-03-07-024
Unit: mm (in)
650 mm Grouser
Allowable
Standard Remedy
Limit
A 247 (9.72)
B 13 (0.51) Replace
C 36 (1.42) 21 (0.83)
W3-7-8
Bushing
W105-03-07-023
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 177 (6.97)
B 48.4 (1.91) 49.43 (1.95) Replace
C 71.35 (2.81) 66.35 (2.61)
Pin
W105-03-07-020
Unit: mm (in)
Allowable
Standard Remedy
Limit
A 254 (10.00)
Replace
B 47.57 (1.87) 44.57 (1.76)
W3-7-9
(Blank)
W3-7-10
MEMO
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SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment Group 3 Bushing and Point
Remove and Install Front Attachment..... W4-1-1 Remove and Install Bushing ................... W4-3-1
Maintenance Standard............................ W4-3-4
Group 2 Cylinder
Remove and Install Cylinder ................... W4-2-1
Hydraulic Circuit Pressure Release
Procedure........................................... W4-2-28
Disassemble Cylinder
(Applicable Machine Serial No.:
Backhoe: Up to 8058, and from 8065 to 8085,
Loading Shovel: All, Boom Cylinder,
the other Cylinders: All) ...................... W4-2-30
Assemble Cylinder
Loading Shovel: All, Boom Cylinder,
the other Cylinders: All) ...................... W4-2-42
Backhoe: From 8059 to 8064, and 8086
and after, Boom Cylinder) ................... W4-2-52
Assemble Cylinder
Backhoe: From 8059 to 8064, and 8086
and after, Boom Cylinder) ................... W4-2-54
Air Bleeding Procedure......................... W4-2-56
Maintenance Standard ......................... W4-2-57
166W-4-1
(Blank)
166W-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT
ATTACHMENT

can penetrate the skin, causing serious in-
jury.
Preparation
2. Stop the engine. Move all control levers to release W166-04-01-001

oil tank.

tank. W166-04-01-014

W4-1-1
Removal
13
(See Remove and Install Boom Cylinder section.)
1. Disconnect lubrecation pipes (13) from both boom
cylinder rod ends.
Adapter
: 19 mm
2. Remove bolts (4), stoppers (3) and washer (2)

from both boom cylinder rod ends.
W105-04-01-002
: 30 mm
5
CAUTION: Boom cylinder weight: 420 kg 2
(925 lb)
3
CAUTION: Prevent personal injury. Metal 4

fragments may fly off when a hammer is used
to remove pins. Be sure to wear necessary 1
protection, such as goggles, hardhat, etc.
3. Attach each boom cylinder to a crane.

Remove cylinder rod end pin (1) using a hammer W166-04-01-005
and bar.
W4-1-2
IMPORTANT: Avoid boom cylinder damage. A
grease fitting is located on the boom
cylinder. Be sure to position a
wooden block so that the grease
fitting does not come in contact with
the wooden block when the boom
cylinder is lowered.
4. Position a wooden block between the main frame

and the boom cylinder bottom, as illustrated.
Slowly lower the boom cylinder using the crane
onto the wooden block.
Wooden Block
(Backhoe)
W157-04-01-005
pressure remaining in the system. Push the air
release valve on top of the hydraulic oil tank to
release any remaining pressure. 7
Completely release the residual pressure from the
hydraulic circuit by performing the Hydraulic 8
Circuit Pressure Release Procedure. Refer to
page W4-2-28.
W166-04-01-102
(Loading Shovel)
6. Disconnect hoses (7), (8) and (9) of bucket
cylinder, arm cylinder and level cylinder.
Close all openings with plugs to keep clean.
: 36, 41 mm
: 10, 12 mm
8 7 9 W166-04-01-030
7. Remove lock plate (10) and bolt (11) from main

frame.
: 30 mm
11
10
12
W105-04-01-007
W4-1-3
CAUTION: Front assembly weight:

Backhoe 7530 kg(16600 lb)
(Standard Boom 7.0 M+Standard
arm 3.4 M+Bucket capacity 2.1
3
m)
Loading Shovel 9550 kg(21100 lb)
8. Attach the boom to a crane.

Slighty hoist the boom to take out any wire rope
slack.
9. Tighten the threaded end of the special tool (ST W105-04-01-008

1975) into the threaded hole of boom foot pin (12).
Assemble the other parts (pipe, seat, and thrust
bearing) of the special tool (ST 1975). Tighten the 12
nut on the other end of the special tool (ST 1975)
to pull boom foot pin (12) out.
ST 1975
: 36 mm
W04-01-022
10. Lift the front attachment. Drive the base machine

away from the front attachment and the crane.
W157-04-01-004
W4-1-4
Front Attachment Installation
CAUTION: Front assembly weight:

Backhoe 7530 kg(16600 lb)
(Standard Boom 7.0 M+Standard
arm 3.4 M+Bucket capacity 2.1
3
m)
Loading Shovel 9550 kg(21100 lb)
1. Align the boom foot boss with the main frame

boss. Insert a thrust plate to both right and left
sides of the boom foot boss to take out clearance
between the boom foot boss and the main frame W157-04-01-004
boss the remaining clearance should be less than 11
1 mm.
CAUTION: Prevent personal injury. Metal 12 10

fragments may fly off when a hammer is used
W105-04-01-007
to insert pins. Be sure to wear necessary
protection, such as goggles, hardhat, etc. (Backhoe)
2. Install boom foot pin (12) using a hammer and 7

bar. 8
Install bolt (11) (2 used) and lock plate (10).
: 30 mm
: 540 Nm (55 kgfm, 400 lbfft)
3. Remove the plugs from the pipes or hoses.

W166-04-01-102
Connect the arm, bucket and level hoses (7), (8), (Loading Shovel)
(9) to the pipes.
: 10 mm
: 108 Nm (11 kgm, 80 lbfft)
: 12 mm
: 175 Nm (18 kgm, 130 lbfft)
: 41 mm
: 205 Nm (21 kgfm, 152 lbfft)
IMPORTANT: Fill the hydraulic oil tank with

hydraulic oil to the specified level.
8 7 9 W166-04-01-030
Run the engine at idle. Check hose
connections for any oil leakage.
4. Attach the boom cylinder to a crane. Lift the boom

cylinder and align the boom cylinder rod with the
pin hole on the boom.
NOTE: For easy alignment, start the engine and

use the boom control lever.
W157-04-01-006
W4-1-5
CAUTION: Prevent personal injury. Metal

fragments may fly off when a hammer is used 5
to insert pins. Be sure to wear necessary 2
protection, such as goggles, hardhat, etc.
3
5. Drive pin (1) into the pin hole.
4
6. Install washer (2), stopper (3), tighten bolts (4).
1
(See Remove and Install Boom Cylinder section.)
: 30 mm
: 540 Nm (55 kgfm, 400 lbfft)
W166-04-01-005
13
7. Connect lubrication pipes (13) to each boom
cylinder rod. Tighten the connection to
specification.
: 19 mm
8. Fill grease via grease fitting Boom Cylinder rod

side and Boom Pivot. W105-04-01-002
(Backhoe)
IMPORTANT: Bleed air from hydraulic circuit. Boom
cylinder
rod side
Boom
Pivot
W166-04-01-102
(Loading Shovel)
Boom
cylinder
rod side
Boom
Pivot
W166-04-01-104
W4-1-6
IMPORTANT: In case the arm was separated from
the boom, perform steps 9 and 10 Backhoe Arm
when installing the arm. 14
9. Attach shim (14) on both sides of the arm. Install

the arm.
10. Fill grease via grease fitting Arm cylinder rod side
and Boom/Arm pin.
Boom
W166-04-01-100
Backhoe
Boom/Arm Pin
Arm cylinder rod

side
Boom/Arm Pin
W166-04-01-101
Loading Shovel
Level cylinder
rod side
Arm cylinder
rod side
Boom/Arm Pin W166-04-01-103
W4-1-7
(Blank)
W4-1-8
REMOVING AND INSTALLING CYLINDER

can penetrate the skin and eyes, causing se-
rious injury. Avoid this hazard by relieving
lines.
The hydraulic oil tank cap may pop off by re-
maining pressure if removed quickly. Slowly
loosen the cap to completely release any re-
maining pressure.
Preparation
1. Park the machine on a solid and level surface with
the front attachment positioned as illustrated
below.
W166-04-01-001
W166-04-01-014
W4-2-1
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL BOOM CYLINDER A
B
Backhoe
A W166-04-01-001
B
Loading Shovel
W166-04-01-014
A: Cylinder rod side B: Cylinder bottom side
Greasing Hose Hydraulic Hoses
6
1
2
3 7
4 W166-04-01-003 W166-04-01-002
5
6
2 7
3
8
5, 4 6
9
1
10
W162-04-01-025
W166-04-01-005 12 11
1 - Pin 4 - Spring Washer (8 Used) 7 - Pin (2 Used) 10 - Spring Washer (2 Used)

2 - Washer (2 Used) 5 - Bolt (2 Used) 8 - Washer (2Used 11 - Spacer
3 - Stopper (2 Used) 6 - Boom Cylinder (2 Used) 9 - Bolt (2 Used) 12 - Shim (2 Used)
W4-2-2
Installation
CAUTION: When driving the pin using a
hammer, metal debris may fly out, causing
personal injury. CAUTION: Boom cylinder weight:
Be sure to use proper safety equipment. 420 kg (925 Ib)
Pin (7) weight: 24 kg (53 Ib)
Removal
1. While hoisting boom cylinder (6) with a crane,
1. Disconnect greasing hoses (2 used) from boom align the cylinder bottom side pin hole with the
cylinders (6). main frame hole. Then, install spacer (11) inward
: 19 mm and shim (12) outward. Install pin (7) and secure it
with bolt (9), spring washer (10), and washer (8).
: 30 mm
CAUTION: Boom cylinder weight:
420 kg (925 Ib)
Pin (1) weight: 90 kg (198 lb)
2. Install the other side boom cylinder following the
same procedure.
2. While holding boom cylinder (6) with a crane,
remove bolts (5) (4 used), spring washers (4) (4
3. Connect the hydraulic hoses (4 used). Remove
used), stopper (3), and washer (2) on the cylinder
the wire securing the cylinder rod.
rod side. Drive pin (1) in until pin (1) comes out of
: 41 mm
the cylinder rod hole.
: 30 mm
4. Hoist the cylinder rod with a crane and extend the
3. Remove boom cylinder (6) on the other side in the
rod so that cylinder rod hole aligns with the boom
same procedures.
pin hole.
4. Start the engine. Fully retract boom cylinder (6).
Secure the rod with a wire winding through the rod CAUTION: Pin (1) weight: 90 kg (198 lb)
hole so that boom cylinder (6) wont extend.
5. Install pin (1) into the cylinder rod. Install the other
side cylinder on pin (1).
CAUTION: If the air breather cap on the
hydraulic oil tank is turned quickly, the air
6. Install bolts (5) (4 used), spring washers (4) (4
breather cap may fly off due to pressure
used), stopper (3) and washer (2) on the both
remaining inside. Slowly turn the air breather
ends of pin (1).
cap and remove after completely relieving
7. Connect the greasing hose (2 used).
: 19 mm
5. Stop the engine. Release any remaining air from
the hydraulic lines and oil tank. Disconnect hy-
draulic hoses (4 used) from the cylinder.
8. Release any air remaining in the cylinder. (Refer
: 41 mm
to page W4-2-56 for the Airbleeding procedure.)
CAUTION: Pin (7) weight: 24 kg (53 Ib)
6. Remove bolt (9), spring washer (10) and washer

(8) on the cylinder bottom side to remove pin (7).
Remove boom cylinder (6). Remove spacer (11)
and shim (12) [shim (12) is not always installed.]
: 30 mm
7. Remove boom cylinder (6) on the other side in the

same procedures.
W4-2-3
Remove and Install Arm Cylinder
(Backhoe)
W166-04-01-001
Greasing Hose
Hydraulic Hose
2
1 Greasing Hose
3 2
4
5
W166-04-01-004
W162-04-01-008
W166-04-01-006
1 - Pin (2 Used) 3 - Bolt (2 Used) 4 - Stopper (2 Used) 5 - Lock Nut (4 Used)

2 - Arm Cylinder
W4-2-4
Installation
personal injury. CAUTION: Arm cylinder weight: 655 kg
Be sure to use proper safety equipment. (1445 Ib)
Removal 1. While hoisting arm cylinder (2) with a crane, align

the cylinder bottom side pin hole with the arm
1. Disconnect the greasing hose from arm cylinder bracket hole.
(2) rod.
CAUTION: Pin weight: 25 kg (55 Ib)
: 19 mm
2. Hoist and insert pin (1) into the cylinder bottom
side pin hole. Install stopper (4), bolt (3), and lock
CAUTION: Arm cylinder weight: nuts (5) (2 used).
655 kg (1445 Ib)
Pin weight: 25 kg (55 Ib) : 30 mm
2. While holding arm cylinder (2) with a crane,
remove bolts (3) on the cylinder rod side, and pin 3. Reconnect the hydraulic hoses (2 used) and
(1). greasing hose on the arm cylinder bottom.
: 30 mm : 12 mm
3. Start the engine. Fully retract the arm cylinder. : 19 mm
Secure the rod with a wire winding through the rod : 34 Nxm (3.5 kgfxm, 25.5 lbfxft)
hole so that the arm cylinder wont extend.
4. While hoisting the cylinder rod with a crane,
remove the wire securing the cylinder rod.
5. Start the engine. Extend the rod so that cylinder
rod hole aligns with the arm cylinder pin hole.
any remaining pressure. CAUTION: Pin weight: 25 kg (55 Ib)
4. Stop the engine. Release any remaining air from 6. Hoist and insert pin (1) into the cylinder rod side
the hydraulic lines and oil tank. Disconnect pin hole. Install stopper (4), bolt (3), and lock nuts
hydraulic hoses (2 used) from the cylinder. (5) (2 used).
: 12 mm : 30 mm
7. Connect the greasing hose to arm cylinder rod

end side pin (1).
5. Remove bolt (3) on the arm cylinder bottom side,
: 19 mm
and pin (1). Remove arm cylinder (2) using a
crane.
8. Release any air remaining in the cylinder.
: 30 mm
(Refer to page W4-2-56 for the Airbleeding
procedure.)
W4-2-5
Remove and Install Arm Cylinder
(Loading Shovel)
B
A
W166-04-01-014

Hydraulic Hose
W166-04-01-021
Greasing Hose
2
Greasing Hose W166-04-01-020
W166-04-01-019
3
1 2 4
A, B Section W166-04-01-015
1 - Pin (2 Used) 3 - Spring Washer (4 Used) 5 - Plate (2 Used) 6 - Dust Seal (4 Used)
2 - Arm Cylinder 4 - Bolt (4 Used)
W4-2-6

personal injury.
Be sure to use proper safety equipment.
Removal
1. Disconnect the greasing hose from arm cylinder

(2) rod.
: 19 mm
CAUTION: Arm cylinder weight:

360 kg (794 Ib)
Pin weight: 21 kg (46 Ib)
2. While holding arm cylinder (2) with a chainblock,

remove bolts (4) (2 used), spring washer (3) (2
used) and plate (5) on the cylinder rod side, and
remove pin (1) and dust seal (6) (2 used).
: 24 mm
3. Start the engine. Fully retract the arm cylinder.

Secure the rod with a wire winding through the rod
hole so that the arm cylinder wont extend.


the hydraulic lines and oil tank. Disconnect
hydraulic hoses (2 used) and greasing hose from
the cylinder.
: 12 mm
: 19 mm
5. Remove bolt (4) (2 used), spring washer (3) (2

used) and plate (5) on the arm cylinder bottom
side, remove and pin (1) and dust seal (6) (2
used). Remove arm cylinder (2) using a crane.
: 30 mm
W4-2-7
B
A
W166-04-01-014

Hydraulic Hose
W166-04-01-021
Greasing Hose
2
Greasing Hose W166-04-01-020
W166-04-01-019
3
1 2 4
A, B Section W166-04-01-015
2 - Arm Cylinder 4 - Bolt (4 Used)
W4-2-8

7. Connect the greasing hose to arm cylinder rod
end side pin (1).
personal injury.
: 19 mm
Installation
8. Release any air remaining in the cylinder.
CAUTION: Arm cylinder weight: 360 kg (Refer to page W4-2-56 for the Air bleeding
(794 Ib) procedure.)
1. While hoisting arm cylinder (2) with a chainblock,

install dust seal (6) (2 used) into the cylinder
bottom side pin hole, align the cylinder bottom
side pin hole with the arm bracket hole.

side pin hole. Install plate (5), spring washer (3) (2
used), and bolt (4) (2 used).
: 24 mm
:265 Nxm (27 kgfxm, 195 lbfxft)
3. Reconnect the hydraulic hoses (2 used) and

greasing hose on the arm cylinder bottom.
: 12 mm
: 19 mm
4. While hoisting the cylinder rod with a chainblock,

remove the wire securing the cylinder rod.
5. Install dust seal (6) (2 used) into the cylinder rod

hole.
Start the engine. Extend the rod so that cylinder
rod hole aligns with the arm cylinder pin hole.
6. Hoist and insert pin (1) into the cylinder rod side
pin hole. Install plate (5), spring washer (3) (2
used), and bolt (4) (2 used).
: 24 mm
W4-2-9
Remove and Install Bucket Cylinder
(Backhoe)
W166-04-01-001
Hydraulic Hose
1 2 3 4
Greasing Hose
8
Wooden Block
6 W166-04-01-008
5
W166-04-01-009
2 3
5
9
3 2
W166-04-01-007
6 7 4
W166-04-01-006
1 - Link A 4 - Bucket Cylinder 6 - Link B (2 Used) 8 - Pin

2 - Lock Nut (4 Used) 5 - Pin 7 - Shim (2 Used) 9 - Stopper
3 - Bolt (2 Used)
W4-2-10
Installation
personal injury. CAUTION: Bucket cylinder weight: 400 kg
Be sure to use proper safety equipment. (880 lb)
Removal 1. While hoisting bucket cylinder (4) with a crane,

align the cylinder bottom side pin hole with the
1. Disconnect the greasing hose from bucket bucket cylinder bracket hole.
cylinder (4) bottom.
: 19 mm
CAUTION: Pin (8) weight: 20 kg (44 lb)
2. Lay a wooden block under link A (1). Then, fasten
link A (1) and links B(6) (2 used) with a wire so
side pin hole. Install stopper (9), bolt (3), and lock
that links B(6) (2 used) wont fall when pin (5) is
nuts (2) (2 used).
removed.
: 30 mm
CAUTION: Bucket cylinder weight: : 390 Nxm (40 kgfxm, 290 lbfxft)
400 kg (880 lb)
Pin (5) weight: 46 kg (101 Ib) 3. Reconnect the hydraulic hoses (2 used) and
greasing hose on the bucket cylinder bottom side.
3. While holding bucket cylinder (4) with a crane,
remove bolts (3) on the cylinder rod side, and pin : 10 mm
(5). Then, remove shims (7) (2 used). : 108 Nxm (11 kgfxm, 80 lbfxt)
: 30 mm : 19 mm
4. Start the engine. Fully retract bucket cylinder (4).
Fasten the rod with a wire winding through the rod 4. While hoisting the cylinder rod with a crane,
hole so that the bucket cylinder wouldnt extend. remove the wire fastening the cylinder rod. Start
the engine. Extend the rod so that cylinder rod
hole aligns with link A and B pin holes.
breather cap may fly off due to pressure CAUTION: Pin (5) weight: 46 kg (101 lb)
cap and remove after completely relieving 5. Hoist and insert pin (5) into the cylinder rod side
any remaining pressure. pin hole. Install bolt (3), and lock nuts (2) (2 used).
Insert shim (7) so that the clearance between link
5. Stop the engine. Release any remaining air from A (1) and link B (6) is less than max. 1.5 mm.
the hydraulic lines and oil tank.
: 30 mm
6. Disconnect hydraulic hoses (2 used) from the cyl- : 390 Nxm (40 kgfxm, 290 lbfxft)
inder bottom.
: 10 mm 6. Remove the wire which fastened links A and B to
prevent links B (6) (2 used) from dropping. Start
the engine and remove the wooden block laid
CAUTION: Pin (8) weight: 20 kg (44 Ib)
under link A.
7. Release any air remaining in bucket cylinder (4).
remove bolt (3) on the cylinder bottom side, and
(Refer to W4-2-56 for the Air bleeding procedure.)
pin (8).
: 30 mm
8. Remove bucket cylinder (4) using a crane.
W4-2-11
Remove and Install Bucket Cylinder
(Loading Shovel)
8
Wooden
Block Wooden Block
W166-04-01-014
Greasing Hose
Hydraulic Hose
Hydraulic Hose
8
W166-04-01-023
W166-04-01-022
10 8
11
1 12
2
13
3
4
5
6 14
7 9 8 W166-04-01-016
W166-04-01-017
A Section B Section
1- Link A 5- Spring Washer (4 Used) 9 - Dust Seal (4 Used) 12 - Spring Washer (4 Used)
2- Link B (2 Used) 6- Grease Fitting (2 Used) 10 - Plate (2 Used) 13 - Pin (2 Used)
3- Stopper (2 Used) 7- Pin 11 - Bolt (4 Used) 14 - Dust Seal (4 Used)
4- Bolt (4 Used) 8- Bucket Cylinder (2 Used)
W4-2-12
7. Disconnect hydraulic hoses (4 used) from the cyl-
inder.
personal injury.
: 10 mm
Removal CAUTION: Pin (7) weight: 93 kg (205 Ib)
1. Disconnect the greasing hose from bucket 8. While holding bucket cylinder (8) with a crane,
cylinder (8) (2 used) rod. remove bolt (4) (2 used), spring washer (5) (2
used) and stopper (3) on the cylinder bottom side.
: 19 mm Remove stopper (3) on the other side in the same
procedures.
2. Lay a wooden block under bucket and link A (1).
Then, fasten arm and links B (2) (2 used) with a : 24 mm
wire so that links B (2) (2 used) wont fall when pin
(7) is removed. 9. Remove grease fitting (6) (2 used) from pin (7).
Drive pin (7) using a hammer and bar for link B (2)
and cylinder (8) to remove position.
CAUTION: Bucket cylinder weight:
320 kg (705 lb)
10. Remove dust seal (9) (2 used) from the cylinder
Pin (12) weight: 21 kg (46 Ib)
bottom side.
Remove bucket cylinder (8) using a crane.
remove bolts (11) (2 used), spring washer (12) (2
used) and plate (10) on the cylinder rod side to
remove pin (7) and wire.
remove pin (12). Then, remove dust seal (14) (2
Remove bucket cylinder (8) using a crane.
used).
12. Remove dust seal (14) (2 used) from the cylinder
: 30 mm
rod side.
4. Remove bucket cylinder (8) on the other side in
the same procedures.
5. Start the engine. Fully retract bucket cylinder (8).

Fasten the rod with a wire winding through the rod
hole so that the bucket cylinder wouldnt extend.


the hydraulic lines and oil tank.
W4-2-13
8
Wooden
Block Wooden Block
W166-04-01-014
Greasing Hose
Hydraulic Hose
Hydraulic Hose
8
W166-04-01-023
W166-04-01-022
10 8
11
1 12
2
13
3
4
5
6 14
7 9 8 W166-04-01-016
W166-04-01-017
A Section B Section
1- Link A 5- Spring Washer (4 Used) 9 - Dust Seal (4 Used) 12 - Spring Washer (4 Used)
2- Link B (2 Used) 6- Grease Fitting (2 Used) 10 - Plate (2 Used) 13 - Pin (2 Used)
3- Stopper (2 Used) 7- Pin 11 - Bolt (4 Used) 14 - Dust Seal (4 Used)
4- Bolt (4 Used) 8- Bucket Cylinder (2 Used)
W4-2-14
7. Install pin (7) using a hammer and bar. Install
grease fitting (6) (2 used), stopper (3) (2 used),
bolt (4) (4 used) and spring washer (5) (4 used).
personal injury.
greasing hose. Install pin (13) following the same
Installation
procedure as descrebed in steps 3 to 5.
CAUTION: Bucket cylinder weight: 320 kg 9. Start the engine and remove the wooden block
(705 lb) under bucket and link A.
1. While hoisting bucket cylinder (8) with a crane, 10. Release any air remaining in bucket cylinder (8).
install dust seal (9) (2 used) into the cyinder (Refer to W4-2-56 for the Air bleeding procedure.)
bottom side pin hole, align the cylinder bottom
side pin hole, link A (1) and link B (2) with the
bucket cylinder bracket hole.

side pin hole to half position.

greasing hose on the bucket cylinder (8).
: 10 mm
: 108 Nxm (11 kgfxm, 80 lbfxt)
: 19 mm
4. While hoisting the cylinder rod with a crane,

remove the wire fastening the cylinder rod. Install
dust seal (14) into the cylinder rod hole. Start the
engine. Extend the rod so that cylinder rod hole
aligns with boom pin holes.
5. Hoist and insert pin (13) into the cylinder rod side
pin hole. Install bolt (11) (2 used), spring washer
(12) (2 used) and plate (10).
: 30 mm
6. Align the cylinder bottom side pin hole on the

other side following the same procedure as
described in step 1.
W4-2-15
Remove and Install Level Cylinder
(Loading Shovel)
B
A
W166-04-01-014
Greasing Hose
W166-04-01-021
Greasing Hose
W166-04-01-024 Hydraulic Hose
W166-04-01-019
3
1 2 4
A, B Section W166-04-01-015
2 - Level Cylinder 4 - Bolt (4 Used)
W4-2-16
6. While holding level cylinder (2) with a chain block,
remove bolts (4) (2 used), spring washers (3) (2
used), plate (5), and pin (1).
personal injury.
:24 mm
Removal
7. Remove dust seal (6) (2 used) from bottom side.
Remove level cylinder (2) using a crane.
IMPORTANT: 1. Remove the arm cylinder before
removing the level cylinder.
2. Disconnect hydraulic hoses from
both boom cylinders so that level
cylinder moved with both boom
cylinders.
1. Disconnect the greasing hose (2 used) from the

level cylinder (2).
: 19 mm
CAUTION: Level cylinder weight:

220 kg (485 Ib)
Pin weight: 21 kg (46 lb)
2. Hold level cylinder (2) with a chain block. Remove

bolts (4) (2 used), spring washers (3) (2 used),
and plate (5) from the rod side, and remove pin
(1).
: 24 mm
3. Start the engine and retract the cylinder. Secure

the rod with wire reeved through the rod hole so
that the cylinder does not extend.

4. Remove dust seal (6) (2 used) from rod side. Stop

the engine. Release any pressure remaining in
the hydraulic lines and bleed air trapped in the
hydraulic oil tank. Disconnect the hydraulic hoses
from the rod side.
: 10 mm
5. Disconnect the hydraulic hose from the bottom

side.
: 10 mm
: 19 mm
W4-2-17
B
A
W166-04-01-014
Greasing Hose
W166-04-01-021
Greasing Hose
W166-04-01-024 Hydraulic Hose
W166-04-01-019
3
1 2 4
A, B Section W166-04-01-015
2 - Level Cylinder 4 - Bolt (4 Used)
W4-2-18
6. Connect the greasing hose to the cylinder rod
side.
personal injury.
: 19 mm
: 44 Nm (4.5 kgfm, 32.5 lbfft)
Installation
7. Remove the air bleed plug from the cylinder to
bleed any air remaining in the cylinder. (Refer to
CAUTION: Level cylinder weight: W4-2-56 for the Air bleeding procedure.)
220 kg (485 Ib)
Pin (1) weight: 21 kg (46 lb)
1. Lift level cylinder (2) with a chain block, install

deust seal (6) (2 used) into the cylinder bottom
side pin hole and align the pin hole on the bottom
side. Install pin (1) into the cylinder and install
bolts (4), spring washers (3) (2 used each) and
plate (5).
: 24 mm
: 265 Nm (27 kgfm, 195 lbfft)
2. Connect the hydraulic hose and the greasing hose

to the cylinder bottom side.
: 10 mm
: 108 Nm (11 kgfm, 80 lbfft)
: 19 mm
: 44 Nm (4.5 kgfm, 32.5 lbfft)
3. While lifting the cylinder rod side using a chain

block, connect the hydraulic hoses to the cylinder.
Remove the binding wire from the rod end.
Install dust seal (6) (2 used) into the cylinder rod
side pin hole.
: 10 mm
: 108 Nm (11 kgfm, 80 lbfft)
4. Start the engine. Extend the rod so that cylinder

rod hole aligns with arm pin holes.
5. Install pin (1) on the cylinder rod side. Then, install

bolts (4), spring washers (3) (2 used each) and
plate (5).
: 24 mm
: 265 Nm (27 kgfm, 195 lbfft)
W4-2-19
Remove and Install Dump Cylinder
(Loading Shovel)
Hydraulic Hose
1 W166-04-01-026 A W166-04-01-025
Wooden Block
1 7 1 2
8
3
9
10 4
6 5
6
A Section B Section
W166-04-01-028
W166-04-01-027
1 - Dump Cylinder (2 Used) 4 - Socket Bolt (4 Used) 7 - Pin (2 Used) 9 - Bolt (4 Used)
2 - Pin (2 Used) 5 - Lock Plate (2 Used) 8 - Stopper (2 Used) 10 - Spring Washer (4 Used)
3 - Grease Fitting (2 Used) 6 - Dust Seal (8 Used)
W4-2-20

personal injury.
Removal
1. Lay a wooden block under bucket. Front Cover
2. Remove the front cover and side cover on the

bucket.
: 19, 24 mm
3. Remove grease fitting (3) from pin (2) at dump

cylinder (1) rod side.
: 10 mm
CAUTION: Dump cylinder weight: 57 kg

(126 Ib) W166-04-01-029
4. Hold the cylinder with a chain block. Remove

socket bolts (4) (2 used), and lock plate (5) on the
rod side, and remove pin (2).
: 14 mm
Side Cover
5. Remove dust seal (6) from the dump cylinder rod
side.
6. Start the engine and retract dump cylinder (1).

Secure the rod with a wire reeved through the rod
hole so that the cylinder does not extend.
CAUTION: If the air breather cap on the W166-04-02-021

7. Stop the engine. Release any pressure remaining

in the hydraulic lines and bleed air trapped in the
hydraulic oil tank. Disconnect the hydraulic hoses
(2 used) from the cylinder.
: 27 mm
W4-2-21
1 W166-04-01-026 A W166-04-01-025
1 7 1
10
6 6
A Section B Section
W166-04-01-028
W166-04-01-027
W4-2-22
8. While holding dump cylinder (1) with a crane, re-
move bolts (9) (2 used), spring washers (10) (2
used), and stopper (8) from the cylinder bottom.
Remove pin (7) completely. Remove dump cylin-
der (1) using a crane.
: 19 mm
9. Remove dust seals (6) (2 used) from the cylinder

bottom side.
10. Remove dump cylinder (1) on the other side in the

same procedures.
W4-2-23
Hydraulic Hose
1 W166-04-01-026 A W166-04-01-025
Wooden Block
1 7 1 2
8
3
9
10 4
6 5
6
A Section B Section
W166-04-01-028
W166-04-01-027
1 - Dump Cylinder (2 Used) 4 - Socket Bolt (4 Used) 7 - Pin (2 Used) 9 - Bolt (4 Used)
2 - Pin (2 Used) 5 - Lock Plate (2 Used) 8 - Stopper (2 Used) 10 - Spring Washer (4 Used)
3 - Grease Fitting (2 Used) 6 - Dust Seal (8 Used)
W4-2-24

personal injury.
Installation
CAUTION: Dump cylinder weight: 57 kg

(126 Ib)
1. While lifting dump cylinder (1) with a chain block,

align the pin holes at the bottom side. Install dust
seals (6) (2 used) into the cylinder bottom side.
Install pin (7) into the cylinder. Install stopper (8),
bolts (9) (2 used), and spring washers (10) (2
used) onto pin (7).
: 19 mm
2. Connect the hydraulic hoses (2 used) to dump cyl-

inder (1).
: 27 mm
: 118 Nm (12 kgfm, 87 lbfft)
3. Install dust seals (6) (2 used) into the cylinder rod

side.
4. While lifting the cylinder rod side with a chain

block, remove the wire. Start the engine and
extend the rod. Align the rod end pin holes.
: 14 mm
: 265 Nm (27 kgfm, 195 lbfft)
5. Install pin (2) into the cylinder rod side. Then,

install socket bolts (4) (2 used) and lock plate (5).
: 14 mm
: 265 Nm (27 kgfm, 195 lbfft)
6. Install grease fitting (3) to the end face of pin (2)

on the cylinder rod side.
: 10 mm
: 5.9 Nm (0.6 kgfm, 4.3 lbfft)
W4-2-25
Hydraulic Hose
A W166-04-01-025
1 W166-04-01-026
Wooden Block
W4-2-26
7. Start the engine and remove the wooden block
laid under bucket. Front Cover
8. Remove the air bleed plug from the cylinder to

bleed air remaining in the cylinder. (Refer to W4-
2-56 for the Air bleeding procedure.)
W166-04-01-029
9. Install the front cover and side cover on the

cylinder rod side.
Side Cover
: 19 mm
: 24 mm
: 205 Nm (21 kgfm, 152 lbfft)
W166-04-02-021
W4-2-27
HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE



pressure remaining in the system.
W4-2-28
(Blank)
W4-2-29
DISASSEMBLE CYLINDER
Loading Shovel: All)
Boom Cylinder
(Backhoe and Loading Shovel)
18
19
16
17
20 17
16 1
15
21 14
13
22
23
2
3
5
6
8
9
10
11
12
W166-04-02-001
1- Cylinder Rod 7- Slide Ring 13 - Set Screw 19 - Cushion Bearing
2- Wiper Ring 8- Backup Ring 14 - Steel Ball 20 - Seal Ring
3- Socket Bolt (8 Used) 9- U-Ring 15 - Piston 21 - Shim
4- Cylinder Head 10 - Buffer Ring 16 - Slide Ring (2 Used) 22 - Nut
5- Backup Ring 11 - Bushing 17 - Slide Ring (2 Used) 23 - Cylinder Tube
6- O-Ring 12 - Retaining Ring 18 - Cushion Seal
W4-2-30
Arm Cylinder
(Backhoe)
18
19
15
16
17
20
17
16
14 1
21
22 13
23
2
4
7
8
9
10
11
12
5
W166-04-02-002

W4-2-31
Arm Cylinder
(Loading Shovel)
19
15
16
17 1
20
17
16
21
22 14
13
23
2
3
4
7
8
9
10
11
12
5
6
W166-04-02-007
1- Cylinder Rod 7- Slide Ring 12 - Retaining Ring 17 - Slide Ring (2 Used)

2- Wiper Ring 8- Backup Ring 13 - Set Screw 19 - Cushion Bearing
3- Socket Bolt (8 Used) 9- U-Ring 14 - Steel Ball 20 - Seal Ring
4- Cylinder Head 10 - Buffer Ring 15 - Piston 22 - Nut
6- O-Ring
W4-2-32
Bucket Cylinder
(Backhoe)
19
15
16
17
20 1
17
16 22
14
13
23
2
3
4
7
8
9
10
11
12
5
6
W166-04-02-003

2- Wiper Ring 8- Backup Ring 13 - Set Screw 19 - Cushion Bearing
3- Socket Bolt (8 Used) 9- U-Ring 14 - Steel Ball 20 - Seal Ring
6- O-Ring
W4-2-33
Bucket Cylinder
(Loading Shovel)
19
15
16
17 1
20
17
16
21
22 14
13
23
2
3
4
7
8
9
10
11
12
5
6
W166-04-02-007

6- O-Ring 12 - Retaining Ring
W4-2-34
Level Cylinder
(Loading Shovel)
16
17
20 17
16 1
15
14
21
13
22
23
2
3
5
6
8
9
10
11
12
W166-04-02-006

2- Wiper Ring 8- Backup Ring 13 - Set Screw 20 - Seal Ring
3- Socket Bolt (8 Used) 9- U-Ring 14 - Steel Ball 21 - Shim
6- O-Ring
W4-2-35
Dump Cylinder
(Loading Shovel)
19
15
16
17 1
20
17
16
21
22 14
13
23
2
3
4
7
8
9
10
11
12
5
6
W166-04-02-007

W4-2-36
(Blank)
W4-2-37
Boom Cylinder
18
19
16
17
20 17
16 1
15
21 14
13
22
23
2
3
5
6
8
9
10
11
12
W166-04-02-001

W4-2-38
Disassembly Cylinder
Be sure to thoroughly read all Precautions for 2. Fully extend cylinder rod (1). Secure the rod end
Disassembly/Assembly work on page W1-1-1 be- using a crane. Remove socket bolts (3) from cyl-
fore disassembling. inder head (4).
The cylinder constructions are similar so that the
boom cylinder disassembly procedure is de- Loading Shovel
scribed as an example for all cylinders. : Boom, Arm, Bucket, Level 19 mm
The disassembly procedure blow starts on the : Dump 14 mm
premise that the hydraulic lines and the line secur- Buckhoe
ing bands have been removed. : Boom, Bucket 19 mm
: Arm 22 mm
CAUTION: Cylinder weight:
IMPORTANT: When removing cylinder rod (1), be
Loading Shovel Backhoe sure to pull cylinder rod (1) straight
Boom cylinder: 420 kg(925 lb) 420 kg(925 lb) out so as to not damage the sliding
Arm cylinder: 360 kg(794 lb) 655 kg(1445 lb) surface.
Bucket cylinder: 320 kg(705 lb) 400 kg(880 lb)
Level cylinder: 220 kg(485 lb) 3. While tapping cylinder head (4) with a plastic
Dump cylinder: 57 kg(126lb) hammer, remove cylinder head (4) along with cyl-
inder rod (1) from cylinder tube (23).
4. Secure cylinder rod (1) on special tool (ST 5908).

Put matching marks on the end faces of cylinder
rod (1) and nut (22).
ST 5908
W102-04-02-027
1. Hoist and horizontally secure the cylinder on a

work bench using a crane. Then, drain the hydrau-
lic oil from cylinder.
W158-04-02-022
CAUTION: Cylinder rod (1) weight: 5. Remove set screw (13).

Loading Shovel Backhoe
Boom: 198 kg(437 lb) 200 kg(440 lb) NOTE: After set screw (13) was installed, two
Arm: 153 kg(337 lb) 275 kg(605 lb) places were crimped. Remove the crimped
Bucket: 154 kg(340 lb) 170 kg(375 lb) places with a grinder to loosen set screw
Level: 93 kg(205 lb) (13).
Dump: 18 kg(40lb)
Loading Shovel
: Boom, Arm, Bucket, Level 6 mm
: Dump 5 mm
Buckhoe
: Boom, Bucket 8 mm
: Arm 6 mm
W4-2-39
14
13
5
6
11
12
W166-04-02-001
W4-2-40
6. Using special tool (ST 5908), remove nut (22) and
piston (15).

Boom: 120 mm (ST 3282) 120 mm (ST 3282)
Arm: 120 mm (ST 3282) 135 mm (ST 3283)
Bucket: 115 mm (ST 3314) 130 mm (ST 7213)
Level: 120 mm (ST 3282)
Dump: 75 mm (ST 3271)
In case of the boom cylinder remove nut (22),

remove shim (21) from cylinder rod (1).
ST 5908
NOTE: There is no shim (21) in bucket cylinder

(Backhoe).
7. Remove slide rings (16 and 17) (2 used each) and

seal ring (20) from piston (15).
8. Remove cushion bearing (19) and cylinder head W158-04-02-022
(4) from cylinder rod (1).

In case of the boom or arm cylinder, remove
cushion seal (18) from cylinder rod (1).
9. Remove wiper ring (2), slide ring (7), backup ring

(8) and U-ring (9) from cylinder head (4).
10. Remove retaining ring (12) and bushing (11) from

cylinder head (4).
11. Remove O-ring (6) and backup ring (5) from cyl-
inder head (4).
W4-2-41
ASSEMBLE CYLINDER
Loading Shovel: ALL)
Boom Cylinder (Backhoe and Loading Shovel)
1 2
7
10
8
11
9
12
5, 6 3
23
19
Slit
18
16
17
15 20
17
21
16
14 22
13
W162-04-02-004

W4-2-42
Arm Cylinder (Backhoe) Bucket Cylinder (Backhoe)
2
1
1 2
7
7 10
8
10 11
8
11 9
9 12
12 3
3 5, 6
5, 6
4
4
23
23
19
19
Slit
16
18
16 17
15
17 20
15 17
20
16
17 14
21 22
16
13
14 22
13
W162-04-02-004
W162-04-02-005
W4-2-43
Level Cylinder (Loading Shovel) Arm, Bucket, Dump Cylinder (Loading Shovel)
2
1
1 2
7
7 10
8
10 11
8
11 9
9 12
12 3
3 5, 6
5, 6
4
4
23
23
19
16
16 17
15
17 20
15 17
20
21 16
17 14
21 22
16
13
14 22
13
W166-04-02-019
W166-04-02-020
W4-2-44
(Blank)
W4-2-45
Boom Cylinder
1 2
7
10
8
11
9
12
5, 6 3
23
19
Slit
18
16
17
15 20
17
21
16
14 22
13
W162-04-02-004

W4-2-46
Assemble Cylinder
1. Press bushing (11) into cylinder head (4) using the IMPORTANT: Install slide rings (16 and 17) with
special tool. Install retaining ring (12) in cylinder their slits positioned opposite each
head (4). other.
Loading Shovel Backhoe 8. Install slide ring (16) (2 used) and (17) (2 used)
Boom: 115 mm (ST 8022) 115 mm (ST 8022) onto piston (15).
Arm: 115 mm (ST 8022) 135 mm (ST 8023)
Bucket: 115 mm (ST 8022) 120 mm (ST 8036) 9. Attach the special tool on piston (15) to retract
Level: 115 mm (ST 8022) seal ring (20) and slide rings (16 and 17).
Dump: 65 mm (ST 8015)
IMPORTANT: Install buffer ring (10) with the lip Boom: ST 2970 ST 2970
facing the cylinder bottom. Arm: ST 2970 ST 2971
Bucket: ST 2968 ST 2970
2. Install buffer ring (10) into cylinder head (4). Level: ST 2970
Dump: ST 2961
IMPORTANT: Install U-ring (9) with the lip facing
the cylinder bottom.
CAUTION: Cylinder rod (1) weight:
3. After installing backup ring (8) into cylinder head Loading Shovel Backhoe
(4), install U-ring (9). Boom: 198 kg(437 lb) 200 kg(440 lb)
Arm: 153 kg(337 lb) 275 kg(605 lb)
4. Install slide ring (7) in cylinder head (4). Bucket: 154 kg(340 lb) 170 kg(375 lb)
Level: 93 kg(205 lb)
IMPORTANT: Install wiper ring (2) with the lip Dump: 18 kg(40 lb)
facing outward.
5. Press wiper ring (2) into cylinder head (4) using

the special Tool.

Boom: 115 mm (ST 8022) 115 mm (ST 8022)
Arm: 115 mm (ST 8022) 135 mm (ST 8023)
Bucket: 115 mm (ST 8022) 120 mm (ST 8036)
Level: 115 mm (ST 8022)
Dump: 65 mm (ST 8015)
6. Install O-ring (6) and backup ring (5) around

cylinder head (4).
7. Install seal ring (20) around piston (15) using the

special Tool.

Boom: ST 2970 ST 2970
Arm: ST 2970 ST 2971
Bucket: ST 2968 ST 2970
Level: ST 2970
Dump: ST 2961
W4-2-47
19
Slit
18
15
21
14 22
13
W162-04-02-004
W4-2-48
10. Secure cylinder rod (1) on special tool (ST 5908). 16. Tighten nut (22) using the special tool.
ST 5908
Backhoe
Boom 120 mm (ST 3282)
: 14300 Nxm (1460 kgfxm, 10600 lbfxft)
Arm 135 mm (ST 3283)

: 27300 Nxm (2780 kgfxm, 20100 lbfxft)
W158-04-02-022 Backet 130 mm (ST 7213)

: 20900 Nxm (2130 kgfxm, 15400 lbfxft)
11. Install cylinder head (4) onto cylinder rod (1) using
the special tool. Loading Shovel
Boom 120 mm (ST 3282)
ST 8022 : Boom : 14300 Nxm (1460 kgfxm, 10600 lbfxft)
ST 8023 : Arm
ST 8036 : Bucket Arm 120 mm (ST 3282)
: 17800 Nxm (1810 kgfxm, 13100 lbfxft)
IMPORTANT: Install cushion seal (18) with the slit
facing the piston side. Backet 115 mm (ST 3314)
: 10300 Nxm (1050 kgfxm, 7600 lbfxft)
12. Install cushion seal (18) on cylinder rod (1) (boom
and arm cylinders). Level 120 mm (ST 3282)
: 13000 Nxm (1320 kgfxm, 9550 lbfxft)
IMPORTANT: When installing cushion bearing (19)
on cylinder rod (1), face the cushion Dump 75 mm (ST 3271)
groove narrow side toward the : 2600 Nxm (263 kgfxm, 1900 lbfxft)
cylinder bottm.
17. Install steel ball (14) into nut (22) and secure the
13. Install cushion bearing (19) onto cylinder rod (1). ball with set screw (13).
14. Install piston (15) onto cylinder rod (1). : 8 mm

15. Install nut (22) to cylinder rod (1). : 6 mm
In case the boom or arm cylinder, install shim (21) : 57 Nxm (5.8 kgfxm, 42 lbfxft)
before tightening nut (22). : 5 mm
: 31.55.88 Nxm
(3.20.6 kgfxm, 23.04.5 lbfxft)
18. Crimp two places around set screw (13) top fringe
to prevent the set screw (13) from loosening.
CAUTION: Cylinder tube (23) weight:

Boom: 170 kg(375 lb) 170 kg(375 lb)
Arm: 157 kg(346 lb) 265 kg(585 lb)
Bucket: 145 kg(320 lb) 170 kg(375 lb)
Dump: 25 kg(55 lb)
W4-2-49
23
19
Slit
18
W162-04-02-004
W4-2-50
19. Horizontally secure cylinder tube (23) on a work
bench.
CAUTION: Cylinder rod (1) weight:

Boom: 198 kg(437 lb) 200 kg(440 lb)
Arm: 153 kg(337 lb) 275 kg(605 lb)
Bucket: 154 kg(340 lb) 170 kg(375 lb)
Dump: 18 kg(40 lb)
IMPORTANT: When installing cylinder rod (1) into

cylinder tube (23), take care to
correctly align them and install the
rod staight so as not to damage
rings.
20. Insert cylinder rod (1) into cylinder tube (23).
21. Install cylinder head (4) into cylinder tube (23).

Tighten socket bolts (3) (8 used).
Backhoe
: 19 mm (Boom, Bucket)
: 22 mm (Arm)
Loading Shovel
: 19 mm (Boom, Arm, Bucket, Level)
: 14 mm (Dump)
W4-2-51
DISASSEMBLE CYLINDER
Backhoe: From 8059 to 8064, and 8086 and after)
Boom Cylinder
2
3
8 4
9 5
6
10 7
11
12
13
14
15
13
12
16
17
18
W158-04-02-019
1- Cylinder Rod 6- Bushing 11 - Cushion Ring 15 - Seal Ring

2- Retaining Ring 7- Retainong Ring 12 - Teflon Ring (2 Used) 16 - Set Screw
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 17 - Nut
4- Seal 9- Cylinder Head 14 - Piston 18 - Cylinder Tube
5- Ring 10 - O-Ring
W4-2-52
Be sure to thoroughly read all the precautions for 4. Secure cylinder rod (1) on special tool (ST 5908).
disassembly/assembly work on page W1-1-1 Put matching marks between cylinder rod (1) and
before starting the disassembly procedure. nut (17).
To avoid duplication, disassembling procedures of
ST 5908
the bucket cylinder are shown below as an
example, as the cylinders used are very similar in
construction.
The disassembly procedure below starts on the

premise that the hydraulic lines and the line securing
bands have been removed.
W158-04-02-022
CAUTION: Approximate weights of the

cylinders are as follows: 5. Remove set screw (16).
Boom cylinder : 220 kg (485 lb)
NOTE: Cut away its mushroomed portion using a
drill first, as set screw (16) was
mushroomed with a punch and hammer at
two places after it had been screwed in.
: 6 mm (Boom, Arm and Bucket)
6. Remove nut (17) using special tool (ST 5908).

Remove piston (14).
W102-04-02-027 Nut Turning Special Tools:
(Boom) : 125 mm (ST 3268)
1. Lift and securely place the cylinder on a
workbench using a crane. Be sure that the 7. Remove seal ring (15), wear ring (13), (2 used)
cylinder is placed horizontally. Drain hydraulic oil and teflon rings (12) (2 used) from piston (14).
from the cylinder.
8. Remove cushion ring (11) and cylinder head (9)
2. Fully extend cylinder rod (1). Secure the rod end from cylinder rod (1).
using a crane. Remove socket bolts (8) from
cylinder head (9). 9. Remove O-rings (10), retaining rings (2) and (7)
from cylinder head (9). Then remove dust seal (3),
: 19 mm (Boom cylinder) ring (5), seal (4), and bushing (6).
Special tools for bushing removal:
IMPORTANT: Be sure to pull cylinder rod (1) (Boom) : 115 mm (ST 2671)
straight so as not to damage the
sliding surfaces.
3. Pull out cylinder head (9) from cylinder tube (18)

by tapping with a plastic hammer.
W4-2-53
ASSEMBLE CYLINDER
Backhoe: From 8059 to 8064, and 8086 and after)
Boom Cylinder
2 3 4 5 6 9 7 12 13 15 13 12 14
8 10 1 18 11 17 16
W158-04-02-002
1- Cylinder Rod 6- Bushing 11 - Cushion Ring 15 - Seal Ring

2- Retaining Ring 7- Retaining Ring 12 - Teflon Ring (2 Used) 16 - Set Screw
3- Dust Seal 8- Socket Bolt (8 Used) 13 - Wear Ring (2 Used) 17 - Nut
4- Seal 9- Cylinder Head 14 - Piston 18 - Cylinder Tube
5- Ring 10 - O-Ring
W4-2-54
Assemble Cylinder
1. Install bushing (6) to cylinder head (9) using a Nut Turning Special Tools:
press. (Boom) : 125 mm (ST 3268)
Special tools for bushing installation:
(Boom) : 115 mm (ST 2671) : 142101421 Nm
(1450145 kgfm, 104883472 lbfft)
IMPORTANT: Be sure that the rings are installed
correctly. 9. Align the holes on cylinder rod (1) and nut (17).
Tighten set screw (16) into nut (17).
2. Install ring (5), seal (4), and retaining ring (7) to Mushroom the head of set screw (16) at two
cylinder head (9). places using a punch and hammer.
3. Install dust seal (3) to cylinder head (9) using a : 6 mm

plastic hammer. : 645.9 Nm (6.50.6 kgfm, 474.3 lbfft)
Special tools for dust seal installation:
(Boom) : 115 mm (ST 2672) IMPORTANT: Be sure to align cylinder rod (1) with
the center of cylinder tube (18) when
4. Install O-rings (10) and retaining ring (2) to inserting, in order to avoid
cylinder head (9). damaging the rings.
5. Install wear rings (13) (2 used), seal ring (15), 10. Secure cylinder tube (18) horizontally using a
teflon rings (12) (2 used) to piston (14). work bench. Insert cylinder rod (1) into cylinder
tube (18).
6. Install cylinder head (9) to cylinder rod (1).
11. Install cylinder head (9) to cylinder tube (18).
IMPORTANT: Be sure to install cushion ring (11) Tighten socket bolts (8) (8 used).
so that R part faces cylinder rod
nut (17) side. : 19 mm
: 1226123 Nm
7. Install cushion ring (11) to cylinder rod (1). Install (12512.5 kgfm, 90490 lbfft)
piston (14) to cylinder rod (1).
8. Install cylinder rod (1). Tighten nut (17) using

Be sure to align the machine mark on the rod with
that on the nut.
ST 5908
W158-04-02-022
W4-2-55
AIR BLEEDING PROCEDURE
When removing and installing cylinders for loading 1. Position the front attachment as illustrated below.
shovel front, do work in the similar procedures.
2. Start the engine and run at slow speed.
CAUTION: Hydraulic fluid under pressure
3. Raise the front attachment. Fully stroke each cyl-
can penetrate the skin or eyes causing seri-
inder for 10 to 15 minutes.
pressure before disconnecting any hydraulic
lines.
Hydraulic oil becomes hot during operation.
Disconnecting hydraulic lines soon after op-
eration can result in severe burns.
Wait for the oil and components to cool be-
W166-04-01-001
W166-04-01-014
W4-2-56
a b
Cylinder Tube
1. Tube Section (a)
Check if any score is present on both outer and

inner tube surfaces. A B
2. Pin and Bushing Section (b)
Check if bore dia (B) wear is 0.5 mm or more than W145-04-01-015

specification.
Check if any score is present on the bore
surfaces.
d c Piston
IMPORTANT: Use extra care to check the tube
bore as it is very difficult.
Piston Rod
D C
1. Rod Section (c)
Place two V-blocks 1 m apart on level ground. Lay
the cylinder rod across the V-blocks. Rotate the
rod one turn and measure the rod deflection using W166-04-02-023
a dial gauge. Measure the deflection in three
positions. If one measured deflection is 0.5 mm or
more, replace the rod.
Check if the rod is bent 0.5 mm or more per 1m NOTE: 1 mm=0.03937 in
long.
Check if the outer diameter (C) wear is 0.02 mm
or more per 200 mm long. Dial Gauge
Check if any score is present on the surface. Cylinder Rod
Check if the surface is rusting.
Check if the cushion installing section is
damaged.
2. Bushing Bore (d) Section

Check if the bushing bore (D) wear is 0.2 mm or W166-04-02-022
more than specification. 1m

Check if the bore is scored. V Block
W4-2-57
Hydraulic Pipe
1. Pipe (e) e f
e f
Check if 0.1 mm or deeper score is present on the
contact surface.
Check if the pipe is deformed or damaged.
2. Socket Bolt (f)

Check if the bolt is rusting.
Check if the threads are damaged.
g
g
3. O-Ring (g)
Be sure to replace with new one after
disassembling. T182-05-02-004
Piston and Cylinder Head

Check if the exterior and/or interior is scored.
Check if the groove is scored.
Check if seals are damaged and if internal oil
leakage exists.
Replace bushing if the base metal is exposed on
the slide surface.
Standard Dimension List Unit : mm (1 mm=0.03937 in)

Boom Level Arm Bucket Dump Boom Arm Bucket
+0.063 +0.063 +0.063 +0.054 +0.054 +0.063 +0.072 +0.063
Cylinder Tube Inner Dia. (A) 170 0
170 0
170 0
150 0
100 0
170 0
190 0
110 0
+0.25 +0.25 +0.25 +0.25 +0.25 +0.25 +0.25 +0.25

Cylinder Tube Bushing Bore Dia. 110+0.05 110+0.05 110+0.05 120+0.05 60+0.05 110+0.05 110+0.05 100+0.05
(B)
Rod Dia. (C) Recommended O.D
size after Re-plating -0.012 -0.012 -0.012
115-0.027 115-0.027 115-0.027 115-0.027
-0.012 -0.010 -0.012 -0.014
65-0.023 115-0.027 130-0.032 120-0.027
-0.012
+0.25 +0.25 +0.25 +0.006 +0.25 +0.25 +0.25 +0.25

Piston Rod Bushing Bore Dia. (D) 120+0.05 110+0.05 110+0.05 110-0.071 60+0.05 120+0.05 110+0.05 110+0.05
W4-2-58
FRONT ATTACHMENT / Bushing and Point
REMOVE AND INSTALL BUSHING
Buckhoe
d c
b
a
f
W166-04-02-005
Bucket
Link A Link A 1 2 3
1 2 Arm
Boom
1 2
a: Bucket and Link A

W166-04-02-012
1 2 3
Link B
b: Link A
W166-04-02-013
c: Arm
W166-04-02-014
1 2 3 2 1 2 3
Arm
2 Link A
Boom
Main Frame Arm
Bucket
d: Boom and Main Frame e: Arm
f: Arm and Bucket
W166-04-02-015
W166-04-02-010
W166-04-02-016
1 - Dust Seal 2 - Bushing 3 - Spacer
W4-3-1
Loading Shovel
e d
c
b
f
W166-04-02-004
2 1 1 2 1 2
Bucket
Boom
Link B
Arm
2
2 2
a: Bucket b: Bucket and Arm 2 Arm
W166-04-02-017 d: Boom and Arm
1 2 Boom 3 W166-04-02-018 3 1 2 W166-04-02-009
1
1
Link A
c: Link A, B
W166-04-02-008
2
f: Link A Bucket Side
W166-04-02-011
2
Main Frame
e: Boom and Main Frame

W166-04-02-010
1 - Dust Seal 2 - Bushing 3 - Spacer
W4-3-2
Removal
1. Remove dust seal (1) and bushing (2).
NOTE: In case the bushing is difficult to remove,

use a torch to remove it.
Installation
1. Cool bushing (2) in dry ice.
2. Install bushing (2) and dust seal (1).

Install bushing (2) using by install tools.
Bushing Install Tools

Buckhoe
a : Bucket Side .................................... ST 2881
Link A Side ..................................... ST 2873
b : Link A ............................................. ST 2873
c : Arm................................................. ST 2877
d : Boom Side...................................... ST 2877
Main Frame Side............................ ST 2886
e : Arm................................................. ST 2882
f : Bucket Side .................................... ST 2881
Arm Side ........................................ ST 2873
Loading Shovel
a : Bucket (Front) Side ........................ ST 2879
Bucket (Rear) Side......................... ST 2880
b : Bucket Side .................................... ST 2881
Arm Side ........................................ ST 2875
c : Link B (Arm Side) ........................... ST 2875
Link B (Bucket Cylinder Side) ........ ST 2876
Link A (Bucket Cylinder Side) ........ ST 2877
d : Boom Side...................................... ST 2878
Arm Side ........................................ ST 2876
e : Boom Side...................................... ST 2877
Main Frame Side............................ ST 2886
f : Link A Bucket Side ......................... ST 2875
W4-3-3
Pin and Bushing (Backhoe)
f
d
c g
h
a i
e
b
k
j
W105-04-01-018
W4-3-4
Unit: mm
Allowable
Part Name Location Specification
Limit
Pin Dia. 110 109
Bushing Inner Dia. (Frame Side) 110 111.5
a : Boom Cylinder and Main Frame
Bushing Outer Dia. 130 -
Bearing Inner Dia. (Cylinder Side) 110 111.5
Pin Dia. 120 119
b : Boom and Main Frame Bushing Outer Dia. 140 -
Bushing Inner Dia. (Boom Side) 120 121.5
Pin Dia. 120 119
c : Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 120 -
Pin Dia. 110 109
d : Boom and Arm Cylinder Pin Hole Inner Dia. (Boom Side) 110 -
Pin Dia. 120 109
e : Boom and Arm Bushing Outer Dia. 140 -
Bushing Inner Dia. (Arm Side) 120 121.5
Pin Dia. 110 109
f : Arm Cylinder and Arm Pin Hole Inner Dia. (Arm Side) 110 -
Pin Dia. 100 99
g : Arm and Bucket Cylinder Pin Hole Inner Dia. (Arm Side) 100 -
NOTE: 1 mm=0.03937 in
W4-3-5
Unit: mm
Allowable
Limit
Pin Dia. 110 109
Bushing Inner Dia. (Link A Side) 110 111.5
h : Bucket Cylinder and Link
Bushing Outer Dia 130 -
Pin Dia. 110 109
i : Link and Bucket Bushing Outer Dia. 130 -
Bushing Inner Dia. (Bucket Side) 110 109
Pin Dia. 110 109
j : Arm and Bucket Bushing Outer Dia. 130 -
Bushing Inner Dia. (Bucket Side) 110 111.5
Pin Dia. 100 99
k : Arm and Link Bushing Inner Dia. (Arm Side) 100 111.5
NOTE: 1 mm=0.03937 in
W4-3-6
(Blank)
W4-3-7
Pin and Bushing (Loading Shovel)
l a
f
d
i
j
c c
c
m
c
e k
h W166-04-02-004
W4-3-8
Unit: mm
Allowable
Limit
Pin Dia. 120 119
a : Boom and Arm Bushing Outer Dia. 140 -
Bushing Bore Dia. (Arm Side) 120 121.5
Pin Dia. 110 109
b : Bucket Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 110 -
Pin Dia. 110 109
Pin Hole Inner Dia. (Boom Side) 110 -
c : Level Cylinder, and Boom and Arm
Pin Hole Inner Dia. (Arm Side) 110 -
Arm Cylinder, and Boom and Arm
Bearing Inner Dia. (Rod Side) 110 111.5
(Bottom Side) 110 111.5
Pin Dia. 110 109
d : Arm and Bucket Bushing Outer Dia. 130 -
Bushing Inner Dia. (Bucket Side) 110 111.5
Pin Dia. 120 119
e : Bucket Cylinder and Link A, B
Bushing Inner Dia. (Link B Side) 120 121.5
Bushing Dia. 140 -
Pin Dia. 110 109
f : Arm and Link B Bushing Inner Dia. (Link B Side) 110 -
Bushing Dia. 130 -
Pin Dia. 120 119
g : Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 120 -
NOTE: 1 mm=0.03937 in
W4-3-9
Unit: mm
Allowable
Limit
Pin Dia. 110 109
h : Bucket and Link A Bushing Inner Dia. (Link A Side) 110 111.5
Bearing Dia. 130 -
Pin Dia. 60 59
i : Dump Cylinder and Front Bucket Bushing Inner Dia. (Bucket Side) 60 61.5
Pin Dia. 80 79
Bushing Inner Dia. (Rear Side) 80 81.5
j : Rear Bucket and Front Bucket Bushing Outer Dia. 95 -
Bushing Inner Dia. (Front Side) 80 81.5
Pin Dia. 60 59
k : Dump Cylinder and Rear Bucket Pin Hole Inner Dia. (Bucket Side) 60 -
Pin Dia. 120 119
l : Boom and Main Frame Bushing Outer Dia. 140 -
Bushing Inner Diameter (Frame Side) 120 121.5
Pin Dia. 110 109
m : Boom Cylinder and Main Frame
NOTE: 1 mm=0.03937 in
W4-3-10
Side Cutter
B A
W166-04-01-011
Unit: mm (in)
A 305 (12.0) 200 (7.87)
Replace
B 40 (1.57) -
Point (Backhoe)
B C
W105-04-01-020
Unit: mm (in)
A 228 (8.98) 115 (4.53)
B 120.7 (4.75)
Replace
C 141 (5.55)
D 120 (4.72)
W4-3-11
Point (Rock Bucket)
A
B C
W166-04-01-012
Unit: mm (in)
A 279.2 (11.0) 139.6 (5.5)
B 150 (5.9) -
Replace
C 150 (5.9) -
D 146 (5.7) -
Point (Loading Shovel)
B C
W166-04-01-013
Unit: mm (in)
A 280 (11.0) 140 (5.5)
B 140 (5.5)
Replace
C 144 (5.7)
D 144 (5.7)
W4-3-12
W4-3-13
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
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FAX:
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What safety symbols and notations are used in the manual?

What safety symbols and notations are used in the manual?

What are the different portions that make up the manual?

What are the different portions that make up the manual?

INTRODUCTION

Each page has a number, located on the center

Consecutive Page Number for Each Group

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

This is the SAFETY ALERT SYMBOL.

When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

On machine safety signs, signal words designating

DANGER indicates an imminently hazardous

WARNING indicates a potentially hazardous

CAUTION indicates a potentially hazardous

DANGER or WARNING safety signs are located

Some safety signs dont use any of the SA-1223

CAUTION also calls attention to safety messages in

To avoid confusing machine protection with personal

NOTE indicates an additional explanation for an

Carefully read and follow all safety signs on the ma-

Safety signs should be installed, maintained and re-

If a safety sign or this manual is damaged or miss-

Learn how to operate the machine and its controls

Allow only trained, qualified, authorized personnel to

Keep your machine in proper working condition.

Unauthorized modifications of the machine may

The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

Be prepared if a fire starts or if an accident occurs.

Keep a first aid kit and fire extinguisher on hand.

lance service, hospital, and fire department

Wear close fitting clothing and safety equipment

You may need:

Avoid wearing loose clothing, jewelry, or other

Operating equipment safely requires the full

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause

Wear a suitable hearing protective device such as

Inspect your machine carefully each day or shift by

In the walk-around inspection be sure to cover all

Before entering the cab, thoroughly remove all dirt

Dont leave parts and/or tools lying around the op-

Avoid storing transparent bottles in the cab. Dont

Refrain from listening to the radio, or using music

Keep all flammable objects and/or explosives

After using the ashtray, always cover it to extin-

Dont leave cigarette lighters in the cab. When the

Falling is one of the major causes of personal injury.

When you mounting and dismounting the ma-

Do not use any controls as hand-holds.

Never jump on or off the machine. Never mount or

ADJUST THE OPERATOR'S SEAT

A poorly adjusted seat for either the operator or for

The seat should be adjusted whenever changing

If the machine should overturn, the operator may

Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over.