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URL:http://www.hitachi-c-m.com
W1J1-E-00
Workshop Manual
450-3
450LC-3
470H-3
470LCH-3
500LC-3
520LCH-3
Hydraulic Excavator
W1J1-E-00
Page 1
2006.2.20, 12:25
INTRODUCTION
TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
Be sure to thoroughly read this manual for correct
product information and service procedures.
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual.
MANUAL COMPOSITION
This manual consists of three portions: the Technical Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Manual.
Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
PAGE NUMBER
Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual
W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
IMPORTANT:
CAUTION:
Indicated potentially hazardous situation which could,
if not avoided, result in personal injury or death.
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
3
m
kg
N
N
Nm
Nm
Into
in
ft
US gal
US qt
3
yd
lb
kgf
lbf
kgfm
lbfft
Quantity
Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375
Pressure
Power
Temperature
Velocity
Flow rate
IN-02
To Convert
From
MPa
MPa
kW
kW
C
km/h
-1
min
L/min
mL/rev
Into
Multiply By
2
kgf/cm
psi
PS
HP
F
mph
rpm
US gpm
cc/rev
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0
SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.
001-E01A-0001
SA-688
SA-1
SA-1223
SAFETY
FOLLOW SAFETY INSTRUCTIONS
003-E01B-0003
SA-2
SA-003
SAFETY
PREPARE FOR EMERGENCIES
SA-437
004-E01A-0437
SA-3
SA-428
SAFETY
PROTECT AGAINST NOISE
006-E01A-0434
SA-434
INSPECT MACHINE
007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
008-E01A-0439
SA-439
SA-6
SA-462
SAFETY
ENSURE SAFETY BEFORE RISING FROM
OR LEAVING OPERATOR'S SEAT
Before rising from the operator's seat to open/close
Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If
any item is damaged or worn, replace the seat
belt or component before operating the machine.
Be sure to remain seated with the seat belt securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent condition.
010-E01A-0237
SA-7
SA-237
SAFETY
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over.
Take extra care not to run over bystanders. Confirm the location of bystanders before moving,
swinging, or operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas. Coordinate hand signals before starting the machine.
Use appropriate illumination. Check that all lights
are operable before operating the machine. If any
faulty illumination is present, immediately repair it.
SA-426
011-E01A-0398
036-E01A-0293-3
SA-8
SA-293
SAFETY
OPERATE
SEAT
ONLY
FROM
OPERATOR'S
SA-444
JUMP STARTING
SA-9
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.
SA-379
M104-05-015
SA-10
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
SA-11
SA-380
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure
FOPS: Falling Object Protective Structure
SA-490
018-E01A-0481
SA-481
017-E01A-0491
SA-491
SA-12
SAFETY
DRIVE MACHINE SAFELY
SA-657
SA-658
SA-441
SA-442
SA-13
SAFETY
DRIVE MACHINE SAFELY
Travel Motor
M104-05-008
Arrow-Mark
SA-14
M178-03-001
SAFETY
Use wood plates in order not to damage the road
SA-15
SA-011
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 switch and the 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-391
SA-392
020-E02A-0493
SA-16
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
SA-17
SA-383
SA-384
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
A person may be hit severely by the swinging front
022-E01A-0386
SA-386
023-E01A-0487
SA-487
AVOID UNDERCUTTING
024-E01A-0488
SA-18
SA-488
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:
025-E03B-0463
026-E01A-0519
SA-489
SA-19
SAFETY
DIG WITH CAUTION
If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.
Contact your local "diggers hot line" if available in
your area, and/or the utility companies directly.
Have them mark all underground utilities.
SA-382
027-E01A-0382
If the front attachment or any other part of the machine hits against an overhead obstacle, such as a
bridge, both the machine and the overhead obstacle
will be damaged, and personal injury may result as
well.
SA-389
028-E01A-0389
SA-20
SAFETY
AVOID POWER LINES
SA-381
OBJECT HANDLING
SA-21
SA-014
SAFETY
PROTECT AGAINST FLYING DEBRIS
031-E01A-0432
SA-432
SA-390
SA-018
ards.
SA-22
SA-019
SAFETY
TRANSPORT SAFELY
035-E07A-0454
SA-23
SA-395
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before starting
work.
Keep the work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is
moving.
Keep hands, feet and clothing away from
power-driven parts.
Before servicing the machine:
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load
for 5 minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by
moving the control levers several times.
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.
SA-028
500-E02C-0520
SA-527
SA-24
SAFETY
If a maintenance procedure must be performed
SA-037
Before performing any work on the machine, attach a "Do Not Operate" tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
T1J1-01-01-001
SA-25
SAFETY
SUPPORT MACHINE PROPERLY
Never attempt to work on the machine without securing the machine first.
If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a machine that is supported solely by a jack.
519-E01A-0527
SA-527
502-E01A-0026
SA-026
SA-26
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
504-E01A-0034
SA-034
SA-27
SAFETY
PREVENT BURNS
Hot spraying fluids:
SA-039
SA-225
505-E01B-0498
REPLACE
CALLY
RUBBER
HOSES
PERIODI-
SA-28
SA-019
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-031
507-E03A-0499
SA-292
SA-044
SA-29
SAFETY
PREVENT FIRES
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to
fires.
Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose
oil-cooler flange bolts.
Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged lines, pipes, or
hoses.
SA-019
SA-30
SAFETY
EVACUATING IN CASE OF FIRE
SA-393
18-E02B-0393
SS-1510
PRECAUTIONS
GRINDING
FOR
WELDING
AND
SA-31
SA-818
SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
SA-32
SA-029
SAFETY
BEWARE OF ASBESTOS DUST
SA-029
SA-33
SA-032
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
Refer to the instructions described on the container for proper use when handling the refrigerant.
Use a recovery and recycling system to avoid
leaking refrigerant into the atmosphere.
Never touch the refrigerant.
513-E01A-0405
SA-405
515-E01A-0309
SA-34
SA-309
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.
SA-226
516-E01A-0226
S517-E01A-0435
SA-435
SA-35
SAFETY
(Blank)
SA-36
SECTION 3 UNDERCARRIAGE
All information, illustrations and specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2006
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 ICF
Group 5 Component Layout
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling.............................................T1-1-1
Group 3 Painting
Painting .................................................. W1-3-1
1J1W-1-1
(Blank)
1J1W-1-2
DISASSEMBLING
W1-1-1
W1-1-2
W1-1-3
M104-07-021
tears,
W105-03-05-019
breaks,
Correct
Incorrect
Correct
W105-03-05-020
Incorrect
A
B
a=b
ab
W110-03-05-004
W1-1-4
Correct Eyehole
Lifting Method
W102-04-02-016
Incorrect Eyehole
Lifting Method
W105-04-01-008
Bent Sling
W1-1-5
W162-01-01-009
Damaged Appearance
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years.
W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Scoring
Fuzz
Separation of
Belt
Scuffing
W162-01-01-006
W162-01-01-007
Broken Warp
W162-01-01-008
W1-1-6
Allowable Limit
1. Normal machine performance cannot be accomplished after exceeding this limit.
2. Repair or adjustment is impossible after exceeding this limit.
3. Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the Allowable Limit.
W1-1-7
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
No.
Descriptions
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Bolt Dia
Wrench
Qty
Size (mm)
mm
27
2
41
22
2
32
18
4
27
14
8
22
20
4
30
16
8
24
16
8
24
3
1
12UNF
36
16
41
1 7 12UNF
16
12
12
19
18
4
14 holes
12
2
19
20
4
30
20
6
30
22
26
32
18
24
14
12
2
19
16
6
24
22
2
32
30
36
46
27
36
41
22
48
32
18
8
27
22
48
32
1050
750
400
210
550
210
210
Torque
(kgfxm)
(105)
(76.5)
(41.0)
(21)
(56)
(21.5)
(21.5)
(lbfxft)
(775)
(550)
(295)
(155)
(405)
(155)
(155)
180
(18.0)
(135)
210
(21.0)
(155)
98
230
110
400
400
750
300
35
210
550
1950
1400
750
300
750
(9.2)
(23)
(11)
(41.0)
(41.0)
(76.5)
(30.5)
(3.5)
(21.5)
(55)
(195)
(143)
(76.5)
(30.5)
(76.5)
(66)
(170)
(81.0)
(295)
(295)
(550)
(220)
(26)
(155)
(405)
(1440)
(1030)
(550)
(220)
(550)
Nxm
18
24
27
400
(41.0)
(295)
20
22
22
24
24
24
24
22
22
22
22
24
33
33
8
24
64
72
64
392
424
392
16
28
40
16
28
36
36
30
32
32
36
32
32
32
32
32
32
36
36
50
50
13
1/4-28 UNF
11
550
750
750
950
1400
1400
1400
750
750
950
750
950
1750
2200
205 to
12.5
10
(55)
(76.5)
(76.5)
(95)
(143)
(143)
(143)
(76.5)
(76.5)
(95)
(76.5)
(95)
(178)
(224)
(1.05 to
1.26)
(1.0)
(405)
(550)
(550)
(700)
(1030)
(1030)
(1030)
(550)
(550)
(700)
(550)
(700)
(1290)
(1620)
(7.7 to
9.2)
(7.4)
W1-2-1
GENERAL / Tightening
No.
Descriptions
25
26
27
Bolt Dia
mm
45
24
10
20
20
NOTE: 1. Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2. Make sure bolt and nut threads are
clean before installing.
W1-2-2
Qty
2
4
4
15
7
Wrench
Size (mm)
65
36
8 holes
30
30
Torque
Nxm
2400
450
50
400
400
(kgfxm)
(240)
(45.0)
(5.1)
(41.0)
(41.0)
(lbfxft)
(1730)
(325)
(37)
(295)
(295)
GENERAL / Tightening
TORQUE CHART
CAUTION: Use tools appropriate for the
work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.
Make sure to employ correct bolts and tighten them
correctly when assembling the machine or components.
Hexagon T Bolt
SA-040
Hexagon H Bolt
Hexagon M Bolt
Socket Bolt
W162-01-01-001
Bolt Dia.
Wrench
Size
Hexagon
Wrench
Size
M552-07-091
M552-07-092
M552-07-090
Socket Bolt
Nm
(kgfm)
(lbfft)
Nm
(kgfm)
(lbfft)
Nm
(kgfm)
(lbfft)
M6
10
M8
13
30
(3.0)
(21.5)
20
(2.0)
(14.5)
10
(1.0)
(7.2)
M10
17
65
(6.5)
(47)
50
(5.0)
(36)
20
(2.0)
(14.5)
M12
19
10
110
(11)
(80)
90
(9.0)
(65)
35
(3.5)
(25.5)
M14
22
12
180
(18)
(130)
140
(14)
(101)
55
(5.5)
(40)
M16
24
14
270
(27)
(195)
210
(21)
(152)
80
(8.0)
(58)
M18
27
14
400
(40)
(290)
300
(30)
(215)
120
(12)
(87)
M20
30
17
550
(55)
(400)
400
(40)
(290)
170
(17)
(123)
M22
32
750
(75)
(540)
550
(55)
(400)
220
(22)
(159)
M24
36
950
(95)
(690)
700
(70)
(510)
280
(28)
(205)
M27
41
1400
(140)
(1010)
1050
(105)
(760)
400
(40)
(290)
M30
46
1950
(195)
(1410)
1450
(145)
(1050)
550
(55)
(400)
M33
50
2600
(260)
(1880)
1950
(195)
(1410)
750
(75)
(540)
M36
55
3200
(320)
(2310)
2450
(245)
(1770)
950
(95)
(690)
W1-2-3
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lubricant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific application.
5. Make sure that nut and bolt
threads are clean before installing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.
Equally tighten upper and lower alternately
Tighten diagonally
1
1st to 4th
14
13
10
11
6
4
5
2
2nd to 3rd
W105-01-01-003
W1-2-4
GENERAL / Tightening
Service Recommendations for Split Flange
IMPORTANT: 1. Be sure to clean and inspect
sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and diagonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
an air wrench often causes
tightening of one bolt fully before
tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts.
W105-01-01-015
WRONG
W105-01-01-016
W105-01-01-008
WRONG
RIGHT
RIGHT
WRONG
RIGHT
Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while loosening.
Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction. Do not reuse lock wires.
RIGHT
RIGHT
RIGHT
WRONG
Loosen
W105-01-01-009
WRONG
Tighten
W105-01-01-010
W1-2-5
GENERAL / Tightening
PIPING JOINT
IMPORTANT: The torques given in the chart are
for general use only.
Do not use these torques if a different torque is given for a specific application.
Union Joint
M202-07-051
Joint Body
Description
30male
37female
37
30
Wrench Size
mm
Union Nut
17
19
22
27
32
36
41
17
19
22
27
32
36
41
Wrench Size mm
Tightening Torque
Joint Body
17
19
22
27
32
36
41
14
17
19
22
27
32
36
Nm (kgfm, lbfft)
24.5 (2.5,18)
29.5 (3.0, 21.5)
39 (4.0, 28.5)
78 (8.0, 58)
137 (14.0,101)
175 (18.0,129)
205 (21.0,151)
24.5 (2.5,18)
29.5 (3.0, 21.5)
39 (4.0, 28.5)
78 (8.0, 58)
137 (14.0,101)
175 (18.0,129)
205 (21.0,151)
W1-2-6
GENERAL / Tightening
O-ring Seal Joint
Wrench Size
mm
Union Nut
19
22
27
32
36
41
46
W1-2-7
Wrench Size
mm
Joint Body
17
19
22
27
30,32
36
41
Joint Body
M104-07-033
Tightening Torque
Nm (kgfm, lbfft)
29.5 (3.0, 21.5)
69 (7.0, 51)
93 (9.5, 69)
137 (14.0,101)
175 (18.0,129)
205 (21.0,151)
205 (21.0,151)
GENERAL / Tightening
Screw-In Connection
PT
30
PF
Wrench Size
mm
Joint Body
19
22
27
36
41
50
60
Internal Thread
External Thread
Clearance
Application Procedure
W105-01-01-019
W1-2-8
M114-07-041
T-Bolt Type
M114-07-043
M114-07-042
GENERAL / Tightening
Connecting Hose
RIGHT
WRONG
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the machine.
Do not install hoses kinked. Application of
high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print
marks on hoses when installing to prevent
hose from being kinked.
W105-01-01-011
RIGHT
WRONG
Rubbing Against
Each Other
W105-01-01-012
WRONG
Clamp
RIGHT
Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG
Rubbing Against
Each Other
RIGHT
Clamp
W105-01-01-014
W1-2-9
GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
The parts listed below deteriorate as the machine
ages and are worn out or fatigued by repeated loads,
resulting in possible severe personal injury and/or
machine trouble. The service life of these parts cannot be detected through machine operation or visual
inspection.
Therefore, these parts should be replaced at regular
intervals even if no abnormalities are noticed. In case
any abnormalities are found on a part at any time
regardless of its specified replacement interval, immediately replace the part.
Periodic Replacement Parts
Engine
Basic Machine
Hydraulic
System
Front-End
Attachment
W1-2-10
Replacement
Intervals
Every 2 years or 6000 hours
Every 2 years or 6000 hours
Every 2 years or 6000 hours
Every 2 years or 6000 hours
Every 2 years or 6000 hours
Every 2 years or 6000 hours
Every 2 years or 6000 hours
Every 2 years or 6000 hours
Every 2 years or 6000 hours
Every 2 years or 6000 hours
Every 2 years or 6000 hours
GENERAL / Painting
PAINTING
Painting specification
Surfaces to Be Painted
Main surface of upperstructure
Painting Colour
YR-01 [TAXI yellow]
Bed cover
YR-01[TAXI yellow]
Inner surface
Grey
Front attachment
Track (undercarriage)
N1.0 [Black]
Shining silver
[N2.0 (Black)]
Floor plate
Grey [Cation]
Grid plate
Deep Black
Mirror stay
Camera cover
Ladder
Camera
Cover
Handrail
W1J1-01-03-002
W1J1-01-03-001
W1-3-1
GENERAL / Painting
Shaded Part: Shining Silver
Panel
W1J1-01-03-003
W1J1-01-03-004
(Door)
10
W1J1-01-03-005
Track (Undercarriage)
N1.0 (Black)
W178-01-03-008
Engine Cover
(TAXI Yellow)
W1J1-01-03-006
W1-3-2
W104-07-021
Vacuum pump
Hose
Adapter
W1-4-1
W1-4-2
MEMO
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SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Cab
Group 2 Counterweight
Remove and Install Counterweight ........ W2-2-1
1J1W-2-1
Group 14 Engine
1J1W-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Removal
CAUTION: Seat (1) weight: 40 kg (88 lb)
1. Remove bolts (2) (2 used). Remove the seat belt
from bracket (4).
: 16 mm
3
2
W1JB-02-01-008
W1JB-02-07-007
W2-1-1
W1JB-02-07-015
UPPERSTRUCTURE / Cab
7
8, 9
10
W1JB-02-01-003
11
12
W1JB-02-01-004
13, 14
11
W1JB-02-01-005
13, 14
15
16
17
18
15
W2-1-2
19
W1JB-02-01-040
UPPERSTRUCTURE / Cab
10. Remove screws (21) (2 used) from cover (20).
Remove cap (22) and screw (23) from cover (20).
Remove cover (20) from cab (5).
20
21
22, 23
W1JB-02-01-001
5
24
16
25
26
W1JB-02-01-041
27
28
29
30
W1J1-02-01-002
W2-1-3
UPPERSTRUCTURE / Cab
13. Remove bolts (33) (2 used), washers (32) (2
used) and spacers (31) (2 used) from the cab.
: 32 mm
Cab
W1J1-02-01-003
31, 32, 33
Bracket
36
Bracket
14. Attach a nylon sling onto the bracket and hold cab
(5).
15. Remove nuts (34) (6 used) and washers (35) (6
used) from cab (5).
: 24 mm
34, 35
34, 35
36
34, 35
W1JB-02-01-006
37, 38
36
W1J1-02-01-001
39
W2-1-4
UPPERSTRUCTURE / Cab
Installation
CAUTION: Cab (5) weight: 550 kg (1210 lb)
1. Attach a nylon sling onto cab (5) and hoist cab (5).
Align cab (5) with the mounting hole on main
frame (39).
5
W1J1-02-01-001
39
36
Bracket
34, 35
Bracket
34, 35
36
34, 35
W1JB-02-01-006
37, 38
Cab
31, 32, 33
W2-1-5
36
W1J1-02-01-003
UPPERSTRUCTURE / Cab
6. Install covers (28, 30) to the lower side of main
frame (39) with bolts (27, 29) (6 used for each).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
27
28
29
30
W1J1-02-01-002
24
16
25
26
W1JB-02-01-041
W2-1-6
UPPERSTRUCTURE / Cab
20
21
W1JB-02-01-001
15
16
17
18
15
19
W1JB-02-01-040
11. Install cover (11) to cab (5) with bolts (14) (5 used).
Install caps (13) (6 used) to screws (14) (6 used).
5
13, 14
11
13, 14
W1JB-02-01-005
11
12
W1JB-02-01-004
W2-1-7
UPPERSTRUCTURE / Cab
13. Install bracket (7) to bracket (10) and cab (5) with
bolts (8) (3 used) and washers (9) (3 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)
8, 9
10
W1JB-02-01-003
3
Seat Belt
14. Install seat (1) to bracket (4) with socket bolts (3)
(4 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)
W1JB-02-07-007
15. Install the seat belt to bracket (4) with bolts (2) (2
used).
: 16 mm
: 50 Nm (5 kgfm, 37 lbfft)
Seat Belt
2
W1JB-02-01-008
W2-1-8
W1JB-02-07-015
UPPERSTRUCTURE / Cab
DIMENSIONS OF THE CAB GLASS
NOTE: Unit: mm (1 mm=0.039 in)
Black Ceramic
Coating Range
115
70
21
60
C0.5
2-R20
2-R10
2-R127
Black Ceramic
Coating Surface
107
2-R50
2-R250
2-R50
70
C0.5
106.6
W1JB-02-01-013
1081
R50
Section A
(4 mm)
R2975
R800
28
R75
Black
Ceramic
Coating
Surface
R120
R40
2R-5
271
50
268
20 70
16.5
W1JB-02-01-011
21
214
847
21
Black Ceramic
Coating Range
R1075
372.9
(4 mm)
22
W1JB-02-01-009
50
54.1
25
W1JB-02-01-012
84
25
865
C0.5
W1JB-02-01-014
R2
C0.5
W1JB-02-01-019
Black Ceramic
Coating Surface
Section B
Section C
W2-1-9
UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)
375
214
R155
(4 mm)
(4 mm)
796.5
2-12.2 +0.5
-0
796.5
40
R2852
34.2
267.5
3-R4
50
50
234.5
50
W1JB-02-01-015
W1JB-02-01-016
50
390
13.9
434.5
C0.5
C0.5
Black Ceramic
Coating Surface
W1JB-02-01-013
Section A
W1JB-02-01-010
860.8
833
Black Ceramic
Coating Range
506
63.5
581
438.5
353.5
50
2-21
64.5
R50
448
R964
R75
R58
185
R250
R103
R42 R329
R10
17
2-R4
R150
R2854
498.5
26.5
327.5
173
109.5
(4 mm)
R60
R25
1
102.5
R60
W2-1-10
R10
R5004
152.5
R5031
118
336
34
82
W1JB-02-01-018
UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)
Black Ceramic
Coating Range
30
R30
39
29
652
87.5
(4 mm)
R200
87.5
R200
R500
R500
R50 185
185
45
70
R50
205
848
4-R10
W1JB-02-01-021
W1JB-02-01-010
Black Ceramic
Coating Range
567.5
496
C0.5
123.5 80
3-R4
Black Ceramic
Coating Surface
75.5
C0.5
R25
100
W1JB-02-01-013
R25
R20 R25
87.7 R75
Section A
887 1008
R4044.5
mm)
(4
19.5
R25
R4139.5
1127.3
59.5
85
1099
1145.5
C0.5
R40
R35
C0.5
W1JB-02-01-014
R135
R100
R35
R550
83
13
112
109
Section B
A
228
105
65
R250
R20
78.5
W1JB-02-01-017
76
140
195
57
447
483
W2-1-11
102
R60
R70
UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)
C1
C1
Black Ceramic
Coating Surface
W1JB-02-01-013
Section A
W1JB-02-01-009
1646.47
1599.44
Black Ceramic
Coating Range
187
80
50
106
2-R25
50
R75
R20
R30
90
R30
R50
158
R2875
R575
R125
R1040
R10
R50
R30 R50
28
R1525
R30
R55
393
400
807.65
963.7
W2-1-12
1636.3
R3025
1496.7
40
A
1205
R2940
(5 mm)
R25
873.14
50
1230
R30
150 145
696.73
R300
R2145
900
R20
313.6
W1JB-02-01-020
UPPERSTRUCTURE / Cab
Procedure to Remove Cab Glass
Right-Hand
Glass
Rear Glass
Rear
Left-Hand
Glass
Garnish
Garnish
Lower Glass
of Door
Resin Panel
W1JB-02-01-010
Cab
Cab Glass
Awl
Adhesive
W1SE-02-01-033
W1SE-02-01-034
W2-1-13
UPPERSTRUCTURE / Cab
4. Wind the both ends of piano wire onto the
screwdriver. Draw the wire back and forth in order
to cut the adhesive between cab and glass.
Remove the glass from the cab.
Cab
Cab Glass
Adhesive
(Cab Inside)
W1SE-02-01-035
W2-1-14
UPPERSTRUCTURE / Cab
Procedure to Install Cab Glass
Right-Hand Glass
W1JB-02-01-009
Rear Glass
Rear Left-Hand
Glass
W1JB-02-01-010
Cab
Cut Knife
Cab
Apply Primer 24
Cutting Edge of
Adhesive at Cab
Side
W1SE-02-01-038
W2-1-15
UPPERSTRUCTURE / Cab
4. Clean the mating edge of new glass by using
clean rag and ethylalcohol.
IMPORTANT: Primer Sika Primer Z06G+P
should be shaken for about 1 minute
and mix thoroughly before opening
the cap.
After opening Primer, apply Primer
as quickly as possible and replace
the cap immediately after using.
After opening Primer, all the
contents should be used within 180
days (or 2 hours with the cap off).
5. Apply Primer for glass (Sika Primer Z06G+P) to
the cutting edge of adhesive at cab side by using
a brush. Wait for about 15 minutes in order to let it
dry by itself.
(As for the position to apply Primer, refer to
W2-1-14.)
6. Install the spacer with facing to the glass surface
by using the instant adhesive.
(As for the positions to install spacers A, B and C
dam rubber, refer to W2-1-17.)
7. Cut off the nozzle of adhesive cartridge (Sika
Tack-Drive) into V-shaped by using a knife. (Refer
to W2-1-17.)
8. Remove the seal of cartridge. Install the V-shaped
nozzle.
9. Install the cartridge to the manual coking gun.
10. Apply adhesive to the adhesive position at cab
side so that the bead triangle may be even.
(As for the position to apply adhesive refer to
W2-1-14.)
11. Suck, raise the glass by using sucker lifter
4355282 (refer to W2-1-17), and adhere it to the
cab within 5 minutes.
NOTE: Install the glass while aligning the spacer
position on the glass. Remove all adhesive
except the mounting surface, before
solidifying by using white spirit.
12. Secure the glass by using the gummed tape until
the adhesive becomes solid in order to prevent
them from being mispositioned or coming off.
NOTE: Time for adhesive (Sika Tack-Drive) to
become solid: 8 hours (just for reference)
W2-1-16
UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)
Right-Hand Glass
Rear Glass
250
300
350
500
100
200
200
200
500
200
200
200
250
300
W1JB-02-01-029
200
200
100
100
W1JB-02-01-030
150 200
500
200
W1JB-02-01-035
W1JB-02-01-038
W2-1-17
UPPERSTRUCTURE / Cab
NOTE: Unit: mm
(1 mm=0.039 in)
Spacer C
Spacer B
Spacer A
20
20
4
6
Apply Adhesive
to Both Sides
20
6
R0.5
R5
84
6
R0.5
4
R8
R0.5
75
8
R10
78
12
Apply Adhesive
to Both Sides
3
10.5
10.5
W1JB-02-01-024
W1JB-02-01-023
W1JB-02-01-022
Dam Rubber
30
6.4
6
W1JB-02-01-025
Dam
Rubber
Spacer A
Rubber
Spacer B
Spacer A
Spacer A
Spacer B
Dam
Rubber
W1JB-02-01-039
Spacer B
Rear Glass
W1JB-02-01-027
W1JB-02-01-026
Spacer C
8 to 9 mm
Adhesive
Apply Bead Hear
W1JB-02-01-042
13 to 15 mm
Cut Nozzle
End into
V-Shaped
W1SE-02-01-027
12
Remove
the Seal
W1JB-02-01-031
Adhesive
Cartridge
W1SE-02-01-043
Panel
W1SE-02-01-028
W2-1-18
UPPERSTRUCTURE / Cab
13. The required amount (just for reference) of adhesive and primer
Adhesive
Sika Tack-Drive
310 ml Cratridge
Upper
Front
Glass
Lower Glass of
Door
Rear Left-Hand
Glass
Rear
Right-Hand
Glass
Rear Glass
Glass Surface
Primer
Sika Primer 206G+P
30 ml Bottle
310 ml
0.75 ml
0.67 ml
150 ml
0.5 ml
0.45 ml
250 ml
0.65 ml
0.6 ml
100 ml
1 ml
0.9 ml
210 ml
0.5 ml
0.45 ml
W2-1-19
UPPERSTRUCTURE / Cab
Procedures to Install Upper Door Glass
1. Before installing the glass, remove the garnish
around sash assembly from the cab inside for
easy removal. Push the sash assembly by hands
and remove the sash outside.
Sash
Assembly
Garnish
W2-1-20
Glass A
Glass B
W1JB-02-01-010
UPPERSTRUCTURE / Cab
Procedures to Install Upper Front Glass
Adhere the glass in the same
method as right-hand glass.
W1JB-02-01-034
Seal (1)
Lower Glass
W1JB-02-01-032
W2-1-21
Upper Glass
Seal (1)
Lower Glass
W1JB-02-01-033
UPPERSTRUCTURE / Cab
(Blank)
W2-1-22
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
Removal
CAUTION: Counterweight weight: 9150 kg
(20200 lb)
1. Attach a lifting tool, wire rope and chain block to
the lifting hole on counterweight in order to hold.
Adjust the wire rope length by using the chain
block and make the counterweight horizontal.
CAUTION: Do not stay under the lifted
counterweight.
W1J1-02-02-001
7
8
4
5
8
12
11
15
14
13
10
15
14
13
W1J1-02-02-002
8
1
7
3
1, 2
W1J1-02-02-003
4, 5
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation
CAUTION: Counterweight weight: 9150 kg
(20200 lb)
1. Attach a lifting tool, wire rope and chain block to
the lifting hole on counterweight in order to hoist.
Adjust the wire rope length by using the chain
block and make the counterweight horizontal.
CAUTION: Do not stay under the lifted
counterweight.
2. Install the projection of counterweight to the hole
on bracket.
W1J1-02-02-001
Bracket
7
8
4
5
8
12
11
15
14
13
10
15
14
13
W1J1-02-02-002
8
1
7
9
3
1, 2
W1J1-02-02-003
4, 5
Bracket
W2-2-2
Projection
CAUTION: Standard
front
attachment
assembly weight: 7920 kg (17470 lb)
3. Remove the front attachment assembly from the
main frame.
(Refer to the Remove and Install Front
Attachment section on W4-1.)
W2-3-1
W1JB-02-03-003
Rear
W1J1-02-03-001
Shackle
ST 0234
ST 0235
Bolt
W1J1-02-03-002
Bracket
ST 0234, ST 0235
Nut
Bolt
W166-02-03-010
Front
Wire Rope
Boom Bracket
W105-02-03-005
W2-3-2
W1JB-02-03-002
Main Frame
Track Frame
W2-3-3
W157-02-03-002
Main Frame
Track Frame
W157-02-03-002
Front
Wire Rope
Boom Bracket
W105-02-03-005
4
4
4
4
3
4
4
4
W1J1-02-03-004
2
W1J1-02-03-001
W2-3-4
W1J1-02-01-001
CAUTION: Front
attachment
weight: 7920 kg (17470 lb)
assembly
W1J1-02-02-001
M104-07-021
W2-3-5
W2-3-6
W1J1-02-13-001
4
5
7
Bracket
6
W1J1-02-13-020
W1J1-02-13-015
10
W1J1-02-13-003
W2-4-1
Rain Cover
16
11
Catch
17
W1J1-02-04-038
18
19
8
21
22
W1J1-02-04-040
23
24
25
26
W1J1-02-04-039
Main Frame
W2-4-2
27
28
Terminal
29
30
31
W1J1-02-04-042
32
W1J1-02-04-045
Main Frame
33
34
35
32
W1J1-02-04-046
W2-4-3
37
38
37
37
39
40
41
37
42
Harness
W1J1-02-04-041
43
32
W1J1-02-04-044
45
32
Bolt Mounting
Hole
W2-4-4
W1J1-02-04-043
32
45
W1J1-02-04-045
Main Frame
46
47, 48
52, 53
18. Remove hoses (46, 51, 54, 55, 56, 59). Cap the
hose and pump. Attach identification tags to the
removed hoses for reassembling.
: 17 mm, 19 mm, 27 mm, 36 mm, 41 mm
19. Remove all the connectors from the pump device.
49, 50
5
5
60, 61
57, 58
W2-4-5
5
56
W1J1-02-04-001
Eyebolt
W1J1-02-04-002
62, 63, 64
63, 64, 65
Pump Device
66
67
67
W1J1-02-04-047
68
W2-4-6
69
W1J1-02-04-048
68
69
W1J1-02-04-048
Pump Device
66
W2-4-7
67
67
W1J1-02-04-047
62, 63, 64
63, 64, 65
W1J1-02-04-003
Eyebolt
W1J1-02-04-002
46
47, 48
49, 50
52, 53
5
5
60, 61
57, 58
W2-4-8
5
56
W1J1-02-04-001
32
45
W1J1-02-04-045
Main Frame
43
32
45
32
Bolt Mounting
Hole
W2-4-9
W1J1-02-04-043
36
37
38
37
37
39
40
41
33
42
37
11. Install harness (33) with clamp (35) and bolts (34)
(2 used).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
W1J1-02-04-041
32
W1J1-02-04-045
Main Frame
33
34
35
32
W1J1-02-04-046
W2-4-10
27
28
Terminal
29
30
31
W1J1-02-04-042
17
18
19
8
21
22
W1J1-02-04-040
15
Rain Cover
16
11
W1J1-02-04-038
W2-4-11
10
W1J1-02-13-003
W1J1-02-13-001
4
8
7
6
W1J1-02-13-020
W2-4-12
W1J1-02-13-015
23
24
25
26
W1J1-02-04-039
Main Frame
W2-4-13
63
57
63
D
58
59
15
64
69
57
67
68
55
65
80
79
78
75
74
56
57
73
57
64 62
16
63
83
71
72
70
110
71
18
70
62
29
C
33
36
81
45
47
41
36
34
41
E
30
41
40
33 54
46
47
43
42
102
112
104
20
B
108
21
109
27
25
50
48
52
49
51
39
40
A
112
28
29
34
44
106
31, 32
C
38
28
37
39
46
30
31, 32
D
42
26
27
16
38
37
111
61
19
77
42
60
19
84
66
76
A
E
B
C
2
22
53
7
5
23
107
F
24
93
101
96
100
95
98
99
95
87
19
11
10
9
92
94
12
17
18
G
H
85
24
86
16
90
15
W2-4-14
13
88
14
89
91
W1J1-02-04-004
Valve Cover
2345678-
Nut (2 Used)
Set Screw (2 Used)
Socket bolt
Booster
O-Ring
Booster Cover
Socket Bolt (5 Used)
32 33 34 36 37 38 39 -
O-Ring
Cover
Socket Bolt (2 Used)
Socket Bolt (2 Used)
Socket Bolt (9 Used)
Plug (2 Used)
O-Ring (2 Used)
Plug (12 Used)
Valve Plate Pin (2 Used)
Seat Packing (2 Used)
Pin (4 Used)
Stopper 1 (2 Used)
Steel Ball (2 Used)
Seat (2 Used)
Plug (2 Used)
Needle Bearing (2 Used)
Valve Plate R
Valve Plate L
Cylinder Block (2 Used)
Cylinder Spring (18 Used)
Spherical Bushing (2
Used)
30 - Retainer (2 Used)
40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 -
910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 -
61 - Rivet (2 Used)
W2-4-15
93 - Transmission Cover
94 - O-Ring
95 - Needle Bearing (2 Used)
96 - Drive Gear
98 - Transmission Housing
99 - Pin (2 Used)
100 - Socket Bolt (8 Used)
101 - Eyebolt
102 - Relay Gear
104 - Needle Bearing
106 - Retaining Ring
107 - O-Ring
108 - Shaft
109 - Retaining Ring
110 - O-Ring
111 - Roller Bearing
112 - Bearing Spacer (3 Used)
D
A
E
B
55
63
G
C
F
D
H
C
E
4
7
A
B
11
F
10
12
13
G
H
W1J1-02-04-004
W2-4-16
W2-4-17
69
68
A
E
B
67
55
76
26
27
80
29
79
C
37
31, 32
D
30
33
H
28
81
C
37
45
32,
31
34
30
29
28
27
33
25
50
34
51
52
C
2
44
A
B
F
24
G
H
85
24
86
W1J1-02-04-004
W2-4-18
W2-4-19
55
65
A
E
B
19
84
76
75
74
73
83
70
71
72
71
70
G
C
F
D
H
81
39
C
E
45
47
46
41
42
111
42
41
41
46
39
43
42
44
A
B
47
G
H
W1J1-02-04-004
W2-4-20
W2-4-21
D
A
E
B
76
110
F
D
H
C
E
102
112
104
106
112
B
107
108 109
F
92
93
101
96
100
94
95
98
99
95
G
H
W1J1-02-04-004
W2-4-22
W2-4-23
52
51
38 37
56
55
17
66
68
69
20
21
15
22
67
81
58
65
59
Section X-X
10
34
9
36
76
16
11
39 57 29 33 28 31 30
15 14 27 32 18 13 23 16
58
40
62
26
41
73 47
46 42 111 42 41
45
74
75
47
71
71
19
77
44
86
80
70
24
79
25
80
12
78
72
18 46 43 42 41 85 88
89
91 90
Section A-A
W1J1-02-04-005
W2-4-24
109
106
112
98
95
95
96
94
W1J1-02-04-013
93
Fan Pump
92
Valve Cover
2345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 -
Nut (2 Used)
Set Screw (2 Used)
Socket bolt
Booster
O-Ring
Booster Cover
Socket Bolt (5 Used)
O-Ring
Cover
Socket Bolt (2 Used)
Socket Bolt (2 Used)
Socket Bolt (9 Used)
Plug (2 Used)
O-Ring (2 Used)
Plug (12 Used)
Valve Plate (2 Used)
Seat Packing (2 Used)
Pin (4 Used)
Stopper 1 (2 Used)
Steel Ball (2 Used)
Seat (2 Used)
Plug (2 Used)
Needle Bearing (2 Used)
Valve Plate R
Valve Plate L
Cylinder Block (2 Used)
Cylinder Spring (18 Used)
Spherical Bushing (2 Used)
Retainer (2 Used)
32 33 34 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 -
W2-4-25
93 - Transmission Cover
94 - O-Ring
95 - Needle Bearing (2 Used)
96 - Drive Gear
98 - Transmission Housing
99 - Pin (2 Used)
100 - Socket Bolt (8 Used)
101 - Eyebolt
102 - Relay Gear
104 - Needle Bearing
106 - Retaining Ring
107 - O-Ring
108 - Shaft
109 - Retaining Ring
110 - O-Ring
111 - Roller Bearing
112 - Bearing Spacer (3 Used)
55
Section X-X
39
41
73 47
18
42
111 42 41
45
74
75
47
71
71
Apply adhesive
(SEALAND L101) to
outer surface of oil
seal.
19
44
70
72
46 43 42 41
Section A-A
W1J1-02-04-005
W2-4-26
W2-4-27
52
37
66
55
67
81
Section X-X
34
36
76
39
80
79
78
76
Section A-A
W1J1-02-04-005
W2-4-28
50
52
37
51
36
39
34
W16J-02-04-007
W2-4-29
17
20
21
15
22
58
59
Section X-X
29
28 31 30
27 32
45
26
44
24
25
18
Section A-A
W1J1-02-04-005
W2-4-30
Notch
26: Counterclockwise
25: Clockwise
W16J-02-04-015
22. Align the valve plate pin (17) positions and install
valve plates (25, 26) to valve cover (1).
23. Install check valves (21, 20, 22) to valve cover
(1).
24. When replacing needle bearing (24), install
needle bearing (24) to valve cover (1) in drive
shaft (44) and driven shaft (45).
25. Install O-rings (15, 58, 59) and seat packing (18)
to valve cover (1) in pump casing (55).
W2-4-31
55
Section X-X
10
11
13
45
19
Gear Pump
44
12
Section A-A
W1J1-02-04-005
W2-4-32
0
-0.075
+0.15
34.5 +0.05
387
130.7 mm
97.7 mm
R30
R2
R10
30
151 mm
0
-0.075
+0.15
32 +0.05
387
133.7 mm
43.9 mm
R30
R1
30
R10
W16J-02-04-009
W2-4-33
102
104
110
100
42
107
108
109
106
112
98
95
95
96
94
W1J1-02-04-013
93
Fan Pump
92
W2-4-34
W2-4-35
W2-4-36
Unit: mm (in)
Standard
Allowable Limit
0.038 (0.001)
0.078 (0.003)
W117-02-02-009
Unit: mm (in)
Standard
Allowable Limit
40.9 (1.61)
40.1 (1.58)
L
W117-02-02-010
Unit: mm (in)
Standard
Allowable Limit
0 to 0.1 (0 to
0.35 (0.014)
0.004)
t
Unit: mm (in)
Standard
Allowable Limit
5.4 (0.21)
5.0 (0.20)
e
t
W117-02-02-011
Base
Unit: mm (in)
Standard
Allowable Limit
13.5 (0.53)
12.5 (0.49)
W117-02-02-012
W2-4-37
W2-4-38
3-Z
Less than 0.4Z (by lapping)
5
4
3
2
1
26
34
28
30
31
33
32
11
26
13
14
15
29
27
5
18
25
22
24
35
21
20
10
16
19
17
23
W16J-02-04-002
123456789-
Regulator Casing
Spring Seat
Pilot Spring
Adjusting Disc Q
O-Ring (2 Used)
Cover
Socket Bolt (4 Used)
Nut
Adjusting Screw
10 - Support Plug
11 - O-Ring (2 Used)
13 - Pin
14 - O-Ring (5 Used)
15 - O-Ring
16 - Pin
17 - Feedback Lever
18 - Spool
19 - Sleeve
20 21 22 23 24 25 26 27 28 -
Pilot Piston
Pf Sleeve
O-Ring
Plug
Socket Bolt (4 Used)
Socket Bolt
Plug (9 Used)
Valve Casing
Proportional Pressure
Reducing Valve
W2-4-39
29 30 31 32 33 34 35 -
2
1
34
28
31
32
33
10
27
18
25
21
20
19
17
24
W16J-02-04-002
W2-4-40
W2-4-41
29
16
34
10
26
1
35
30
15
17
A
27
26
31
32 33
28
9
25
11, 23
24
21
20
22
14
5
19
13
18
A
W16J-02-04-010
W2-4-42
123456789-
Regulator Casing
Spring Seat
Pilot Spring
Adjusting Disc Q
O-Ring (2 Used)
Cover
Socket Bolt (4 Used)
Nut
Adjusting Screw
10 - Support Plug
11 - O-Ring (2 Used)
13 - Pin
14 - O-Ring (5 Used)
15 - O-Ring
16 - Pin
17 - Feedback Lever
18 - Spool
19 - Sleeve
20 21 22 23 24 25 26 27 28 -
Pilot Piston
Pf Sleeve
O-Ring
Plug
Socket Bolt (4 Used)
Socket Bolt
Plug (9 Used)
Valve Casing
Proportional Pressure
Reducing Valve
W2-4-43
29 30 31 32 33 34 35 -
16
Pin Hole
10
1
30
17
A
27
31
32 33
16
25
24
21
20
22
19
Support Hole
18
A
W16J-02-04-010
W2-4-44
W2-4-45
10
11
12
50
49
45
48
14
13
16
22
A
26
7
27
54
20
19
54
23
24
15
55
28
43
21
44
59
58
39
40
46
38
55
37
47
36
35
B
42
34
57
32, 33
56
30
29
31
W1J1-02-04-006
W2-4-46
15 16 19 20 21 22 23 24 26 27 28 29 30 31 -
Housing
Tilt Pin
Stopper L
Backup Ring
O-Ring
Servo Piston
O-Ring (2 Used)
Plug (2 Used)
O-Ring
Swash Plate Stand
Socket Bolt (4 Used)
Swash Plate
Bushing
Shoe Plate
32 33 34 35 36 37 38 39 40 42 43 44 45 46 -
W2-4-47
Shoe (9 Used)
Plunger (9 Used)
Retainer Plate
Spherical Bushing
Spring (9 Used)
Cylinder Block
Valve Plate
Bearing
O-Ring
Cover
Adjusting Screw
Nut (2 Used)
Feedback Pin
Cover
47 48 49 50 51 54 55 56 57 58 59 -
10
24
15
28
43
44
46
39
47
38
37
36
35
B
42
34
32, 33
A
W1J1-02-04-006
W2-4-48
W2-4-49
45
16
19
22
12
15
7
27
B
31
29
A
W1J1-02-04-006
W2-4-50
W2-4-51
W2-4-52
27
12 13, 14
22
32
16
15
30
20, 21 19
41
44
43
9
10
40
11
26
23, 24
3
5
2
4
47
8
7
46
7
1
28
6
29 31 34 35 32, 33 36 37
48, 49, 50, 51
38 56 39
42
57
58, 59
W1J1-02-04-007
12345678910 11 12 13 14 -
15 16 19 20 21 22 23 24 26 27 28 29 30 31 -
Housing
Tilt Pin
Stopper L
Backup Ring
O-Ring
Servo Piston
O-Ring (2 Used)
Plug (2 Used)
O-Ring
Swash Plate Stand
Socket Bolt (4 Used)
Swash Plate
Bushing
Shoe Plate
32 33 34 35 36 37 38 39 40 42 43 44 45 46 -
W2-4-53
Shoe (9 Used)
Plunger (9 Used)
Retainer Plate
Spherical Bushing
Spring (9 Used)
Cylinder Block
Valve Plate
Bearing
O-Ring
Cover
Adjusting Screw
Nut (2 Used)
Feedback Pin
Cover
47 48 49 50 51 54 55 56 57 58 59 -
27
12 13, 14
22
32
16
15
20, 21 19
11
26
3
5
2
4
8
7
7
1
29 31 34 35 32, 33 36 37
38
W1J1-02-04-007
W2-4-54
W2-4-55
16
15
41
40
23, 24
47
46
3
28
38
42
W1J1-02-04-007
W2-4-56
W2-4-57
W2-4-58
Unit: mm (in)
Standard
Allowable Limit
0.028 (0.001)
0.056 (0.002)
W117-02-02-009
Unit: mm (in)
Standard
Allowable Limit
31.3 (1.23)
30.2 (1.19)
L
W117-02-02-010
Unit: mm (in)
Standard
Allowable Limit
0 to 0.1
0.3 (0.012)
(0 to 0.004)
t
Unit: mm (in)
Standard
Allowable Limit
3.9 (0.15)
3.7 (0.14)
e
t
W117-02-02-011
Base
Unit: mm (in)
Standard
Allowable Limit
19.0 (0.75)
18.3 (0.72)
W117-02-02-012
W2-4-59
11
10
9
8
7
6
B
F
5
2
19
17
13
22
23
4
20
14
15
21
24
25
30
18
20
CE
31
29
16
28
44
32
27
43
40
41
42
39
38
46
41
37
32
33
34
36
66
65
48
49
35
F
64
57
58
64
61
63
C
60
67
51
52
53
54
59
52
67
62
49
G
52
69
53
W1J1-02-04-008
W2-4-60
Pin
Sleeve
O-Ring (2 Used)
O-Ring
Sleeve
Compensating Piston
Compensating Rod
Spring Seat
Spring
Spring
Adjusting Disc
Retaining Ring
Spring Seat
Spring
Spring
Retaining Ring
18 19 20 21 22 23 24 25 27 28 29 30 31 32 33 34 -
Sleeve
Spool
Pin (2 Used)
Lever
Feedback Lever
Pin
Pin
Lever
Pilot Piston
Spring Seat
Spring
Adjusting Disc
O-Ring
Socket Bolt (8 Used)
Cover
O-Ring
35 36 37 38 39 40 41 42 43 44 46 48 49 51 52 53 -
W2-4-61
O-Ring (3 Used)
Socket Bolt (2 Used)
Socket Bolt (2 Used)
O-Ring
Adjusting Screw
Adjusting Screw
Nut (2 Used)
O-Ring
Cover
Nut
Adjusting Screw
Housing
Pin (2 Used)
Adjusting Plug
O-Ring (3 Used)
Retaining Ring (2 Used)
54 57 58 59 60 61 62 63 64 65 66 67 69 -
Adjusting Plug
Pin
O-Ring
O-Ring
O-Ring
O-Ring
Cover
Socket Bolt (4 Used)
Plug (11 Used)
Solenoid Valve
Socket Bolt (2 Used)
O-Ring (9 Used)
Plug
11
10
9
8
7
6
B
F
22
23
25
20
19
21
13
14
15
30
18
20
CE
16
29
28
44
32
27
43
40
41
39
46
41
37
32
33
36
66
65
48
49
49
F
A
63
51
53
54
52
62
53
W1J1-02-04-008
W2-4-62
W2-4-63
62
48
49
23
52
B
48
37
53
25
49
36
32
24
21
34
B
33
35
56
55
52, 69
20
64
67
63
59
64
54
26
22
66
65
29
30
32
Section A-A
31
45
46
43
60
68, 69
58 27 20
16
15
17 18
22
28
37
19
9
10
42
13
11
43
44
Section B-B
39
3
41
40
3
38
4
6
22
20
8
W1J1-02-04-009
W2-4-64
Pin
Sleeve
O-Ring (2 Used)
O-Ring
Sleeve
Compensating Piston
Compensating Rod
Spring Seat
Spring
Spring
Adjusting Disc
Retaining Ring
Spring Seat
Spring
Spring
Retaining Ring
18 19 20 21 22 23 24 25 27 28 29 30 31 32 33 34 -
Sleeve
Spool
Pin (2 Used)
Lever
Feedback Lever
Pin
Pin
Lever
Pilot Piston
Spring Seat
Spring
Adjusting Disc
O-Ring
Socket Bolt (8 Used)
Cover
O-Ring
35 36 37 38 39 40 41 42 43 44 46 48 49 51 52 53 -
W2-4-65
O-Ring (3 Used)
Socket Bolt (2 Used)
Socket Bolt (2 Used)
O-Ring
Adjusting Screw
Adjusting Screw
Nut (2 Used)
O-Ring
Cover
Nut
Adjusting Screw
Housing
Pin (2 Used)
Adjusting Plug
O-Ring (3 Used)
Retaining Ring (2 Used)
54 57 58 59 60 61 62 63 64 65 66 67 69 -
Adjusting Plug
Pin
O-Ring
O-Ring
O-Ring
O-Ring
Cover
Socket Bolt (4 Used)
Plug (11 Used)
Solenoid Valve
Socket Bolt (2 Used)
O-Ring (9 Used)
Plug
48
49
23
51
52
53
25
48
49
21
20
26 54
55
56
29
30
32
Section A-A
31
27
28
17 18
19
9
10
42
11
43
Section B-B
22
8
W1J1-02-04-009
W2-4-66
W2-4-67
62
48
48
37
36
32
34
33
35
63
66
65
Section A-A
16 15 17
14
Section B-B
18 19
13
3
1
2
4
6
5
W1J1-02-04-009
W2-4-68
W2-4-69
27
13
26
10
10
12
1
9
26
14
27
6
9
2
3
16
15
7
12
W137-02-04-034
W2-4-70
Item
Part Name
Qty
Housing
Flange
Oil Seal
Wrench
Size
(mm)
Tightening Torque
Nm
(kgfm)
Remarks
(Ibfft)
Retaining Ring
Seal
Cover
Backup Ring
10
Key
12
O-Ring
Apply
grease
to
O-ring
when installing
13
Gear
14
Gear
15
Washer
16
Bolt
26
Bushing
: 17
39 to 44
27
Bushing
W2-4-71
W2-4-72
Removal
W1J1-02-05-061
W1J1-02-10-001
Swing
Arm 2
Arm 1
Boom 1
Boom 2
Bucket
Auxiliary
Right Travel
Left Travel
W2-5-1
W1J1-02-05-058
6, 7
6, 7
W1J1-02-05-059
W1J1-02-05-058
W2-5-2
W1J1-02-10-001
W1J1-02-05-061
W2-5-3
10
11
13
12
14
9
16
15
17
18
19
8
20
21
22
Load Check Valve
23
24
25 Bypass Shut-Out Valve
26
31
30
28
29
35
27
32
24
25
33
36
34
10
40
19
8
41
44
42
37
38
43
10
39
17
45
15
47
48
49
50
14
46
14
45
44
43
51
41
15
52
17
39
8
19
35
8
46
55
47
48
49
54
53
37
W2-5-4
Cap
O-Ring
Spring
Poppet
O-Ring
Backup Ring
Sleeve
O-Ring (10 Used)
Backup Ring
Socket Bolt (12 Used)
Piston
O-Ring
Cap
O-Ring (3 Used)
15 16 17 18 19 20 21 22 23 24 25 26 27 28 -
Cap (2 Used)
Cover
Check Valve (3 Used)
Spring
Cap (3 Used)
O-Ring
Spring
Poppet
Cap
Backup Ring (2 used)
O-Ring (2 Used)
Spring
Check Valve
Cap
29 30 31 32 33 34 35 36 37 38 39 40 41 42 -
W2-5-5
O-Ring
Cap
Cap
O-Ring
Spool
Spring
Socket Bolt (8 Used)
Flange
O-Ring (2 Used)
Housing (4-Spool Side)
Spring (2 Used)
Spool
Guide (2 Used)
Spring
43 44 45 46 47 48 49 50 51 52 53 54 55 -
O-Ring (2 Used)
Cap (2 Used)
Cover (2 Used)
O-Ring (2 Used)
Piston (2 Used)
Spring (2 Used)
Check Valve (2 Used)
Poppet
Spring
Spool
Poppet
O-Ring
Flange
10
11
13
12
14
9
16
15
17
18
19
8
20
21
22
31
32
33
34
10
40
19
8
41
44
42
38
43
10
39
17
45
15
47
48
49
50
14
46
14
45
44
43
51
41
15
52
17
39
8
19
8
46
47
48
49
53
54
W2-5-6
W11-02-05-051
13. Remove cap (1), spring (3) and poppet (4) from
cover (16).
: 8 mm
14. Remove cap (13) and piston (11) from cover (16).
: 30 mm
W2-5-7
23
24
25
26
28
30
29
24
25
35
27
36
37
38
35
55
54
37
W11-02-05-051
W2-5-8
W2-5-9
38
10 Control Valve
10
33
34
32
31
Bypass Shut-Out
Valve
38
Bypass
Shut-Out
Valve
Load Check Valve
10
Boom Anti-Drift Valve
Arm Flow
Rate Control Figure of Control Valve (Right)
Valve
Arm Flow Rate
Control Valve
(Refer to Close-Up.)
38
38
42 (51)
40 (52)
45
45
44
14
15
41
45
12
23
9, 8
6, 5
1
4
19
39 17 46
3
2
15
8
21
18
17
25, 24
11
13
14
19
48
8
47
(
49
50 (53)
16
22
8
26
27
38
20
Close-Up of Boom Anti-Drift Valve
W2-5-10
Cap
O-Ring
Spring
Poppet
O-Ring
Backup Ring
Sleeve
O-Ring (10 Used)
Backup Ring
Socket Bolt (12 Used)
Piston
O-Ring
Cap
O-Ring (3 Used)
15 16 17 18 19 20 21 22 23 24 25 26 27 28 -
Cap (2 Used)
Cover
Check Valve (3 Used)
Spring
Cap (3 Used)
O-Ring
Spring
Poppet
Cap
Backup Ring (2 used)
O-Ring (2 Used)
Spring
Check Valve
Cap
29 30 31 32 33 34 35 36 37 38 39 40 41 42 -
W2-5-11
O-Ring
Cap
Cap
O-Ring
Spool
Spring
Socket Bolt (8 Used)
Flange
O-Ring (2 Used)
Housing (4-Spool Side)
Spring (2 Used)
Spool
Guide (2 Used)
Spring
43 44 45 46 47 48 49 50 51 52 53 54 55 -
O-Ring (2 Used)
Cap (2 Used)
Cover (2 Used)
O-Ring (2 Used)
Piston (2 Used)
Spring (2 Used)
Check Valve (2 Used)
Poppet
Spring
Spool
Poppet
O-Ring
Flange
38
10 Control Valve
10
33
34
32
31
38
Bypass
Shut-Out
Valve
Arm Flow
Rate Control Figure of Control Valve (Right)
Valve
Arm Flow Rate
Control Valve
(Refer to Close-Up.)
38
42 (51)
43
40 (52)
45
45
44
41
19
48
8
47
(
49
50 (53)
39 17 46
W2-5-12
W2-5-13
10
38
12
16
11
9, 8
6, 5
13
14
15
19
8
21
18
Close-Up of Boom Flow Rate Control
Valve, Arm Flow Rate Control Valve
25, 24
23
26
27
17
22
8
38
20
Close-Up of Boom Anti-Drift Valve
W1J1-02-05-044
W2-5-14
W2-5-15
VALVE
11
10
12
13
9
15
16
17
18
14
17
19
20
21
22
26
23
27
28
24
29
30
25
31
33
27
28
34
29
27
28
30
31
35
29
30
38
31
27
28
30
31
36
37
39
40
41
W11-02-05-052
W2-5-16
Cap
O-Ring
Spring
Poppet
O-Ring
Backup Ring
Sleeve
O-Ring
Backup Ring
Socket Bolt (4 Used)
Piston
12 13 14 15 16 17 18 19 20 21 22 -
O-Ring
Cap
Cover
Check Valve
Spring
O-Ring (5 Used)
Cap
O-Ring
Spring
Poppet
Cap
23 24 25 26 27 28 29 30 31 32 33 -
W2-5-17
O-Ring
Spool
Spring
Cap
Backup Ring (5 Used)
O-Ring (5 Used)
Check Valve (4 Used)
Spring (5 Used)
Check Valve (5 Used)
Cap
Cap
34 35 36 37 38 39 40 41 -
Cap
Cap
Cap
O-Ring
Socket Bolt (16 Used)
Flange (4 Used)
O-Ring (4 Used)
Housing (5-Spool Side)
11
10
12
13
9
15
16
17
18
14
17
19
20
21
22
26
23
27
28
24
29
30
25
31
33
27
28
34
29
27
28
30
31
35
29
30
38
31
27
28
30
31
36
37
39
40
41
W11-02-05-052
W2-5-18
W2-5-19
Arm Anti-Drift
Valve
10
41
Load Check
Valve-4
Load Check
Valve-1
Load Check
Valve-5
Bypass
Shut-Out
Valve
31
30
29
26
27, 28
31
41
30
29
33
41
29
32
41
27, 28
31
30
27, 28
29
34
41
27, 28
30
31
27, 28
35
30
14
31
11
9, 8
6, 5
13
12
18
17
16
20
15
21
17
19
Close-Up of Arm Anti-Drift Valve
W2-5-20
W1J1-02-05-045
Cap
O-Ring
Spring
Poppet
O-Ring
Backup Ring
Sleeve
O-Ring
Backup Ring
Socket Bolt (4 Used)
Piston
12 13 14 15 16 17 18 19 20 21 22 -
O-Ring
Cap
Cover
Check Valve
Spring
O-Ring (5 Used)
Cap
O-Ring
Spring
Poppet
Cap
23 24 25 26 27 28 29 30 31 32 33 -
W2-5-21
O-Ring
Spool
Spring
Cap
Backup Ring (5 Used)
O-Ring (5 Used)
Check Valve (4 Used)
Spring (5 Used)
Check Valve (5 Used)
Cap
Cap
34 35 36 37 38 39 40 41 -
Cap
Cap
Cap
O-Ring
Socket Bolt (16 Used)
Flange (4 Used)
O-Ring (4 Used)
Housing (5-Spool Side)
Load Check
Valve-2
Load Check
Valve-3
Arm Anti-Drift
Valve
10
24
25
23
41
22
41
Load Check
Valve-4
Load Check
Valve-1
Load Check
Valve-5
Bypass
Shut-Out
Valve
31
30
29
26
27, 28
41
30
29
33
41
30
32
29
27, 28
41
31
31
27, 28
29
34
41
27, 28
30
31
27, 28
35
30
31
41
W2-5-22
W1J1-02-05-045
W2-5-23
10
41
41
14
11
9, 8
6, 5
13
12
18
17
16
20
15
21
17
19
Close-Up of Arm Anti-Drift Valve
W2-5-24
W1J1-02-05-045
W2-5-25
19
20
38
21
39
40
30
Overload Relief
Valve
Arm Regenerative
Valve
31
19
20
2
3
4
5
6
7
9
24
21
25
22
26
27
28
23
10
11
8
12
13
14
33
34
35
24
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Check Valve-1
56
57
35
34
36
37
36
37
25
26
27
28
29
15
16
17
18
37
36
57
59
61
60
1
62
18
17
16
65
66
15
14
13
12
8
11
10
9
67
68
Overload Relief
Valve
W2-5-26
7
6
5
4
3
2
Check Valve-2
63
57
64
Flow Combiner
Valve
W11-02-05-053
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -
O-Ring (4 Used)
Cap (2 Used)
O-Ring (2 Used)
Spring Seat (2 Used)
Spring
Sleeve
O-Ring (2 Used)
Spool (2 Used)
Piston (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Sleeve
Spring
Sleeve
Sleeve
Backup Ring (2 Used)
O-Ring (3 Used)
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 -
W2-5-27
Spring (3 Used)
Check Valve (3 Used)
Adjusting Screw
O-Ring
Lock Nut
Piston
Sleeve
O-Ring
O-Ring
Lock Nut
Cap
O-Ring
Spring
Pilot Poppet
Pilot Seat
Backup Ring
O-Ring
53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 -
Spring
Main Poppet
Sleeve
Cap
O-Ring (3 Used)
Backup Ring
Cap
Spool
Spacer
Spring
Cap
O-Ring
Cap
O-Ring
Cap
19
20
38
21
39
40
30
Overload Relief
Valve
Arm Regenerative
Valve
31
19
20
2
3
4
5
6
7
9
24
21
25
22
26
27
28
23
10
11
8
12
13
14
33
34
35
24
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
Check Valve-1
56
57
35
34
36
37
36
37
25
26
27
28
29
15
16
17
18
1
Check Valve-2
65
66
67
68
Overload Relief
Valve
W2-5-28
W11-02-05-053
W2-5-29
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
37
36
57
59
61
60
1
62
Check Valve-2
63
57
64
Flow Combiner
Valve
W11-02-05-053
W2-5-30
W2-5-31
Overload
Relief Valve
Arm
Regenerative
Valve
Overload
Relief Valve
Flow Combiner
Valve
Check
Valve-2
4
7
Main Relief
Valve
9
5
15
6
Bucket
Regenerative
Valve
11, 10
16
12
13
Overload
Relief Valve
14
18, 17
Overload
Relief Valve
Main Relief Valve
(Refer to Close-Up.)
Overload
Relief Valve
Section of Bucket Regenerative
Section of Overload Relief Valve
Valve, Overload Relief Valve
Section of Arm
Regenerative Valve
19
Check Valve-1
56
57
38 19
20
42
40 20
23
45
31
39
46 21
41
24 43
54
30
47
25
48
49
27, 28
50 26
51, 52
36
55
33
21
36
34, 35
22
37
37
61
36
44
25
62
57, 59
53
27, 28
57 26
63
64 29
60
Check Valve-2
Flow Combiner
Valve
24
34, 35
37
Close-Up of Arm
Regenerative Valve
W2-5-32
Close-Up of Main
Relief Valve
Close-Up of Bucket
Regenerative Valve
W1J1-02-05-046
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -
O-Ring (4 Used)
Cap (2 Used)
O-Ring (2 Used)
Spring Seat (2 Used)
Spring
Sleeve
O-Ring (2 Used)
Spool (2 Used)
Piston (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Sleeve
Spring
Sleeve
Sleeve
Backup Ring (2 Used)
O-Ring (3 Used)
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 -
W2-5-33
Spring (3 Used)
Check Valve (3 Used)
Adjusting Screw
O-Ring
Lock Nut
Piston
Sleeve
O-Ring
O-Ring
Lock Nut
Cap
O-Ring
Spring
Pilot Poppet
Pilot Seat
Backup Ring
O-Ring
53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 -
Spring
Main Poppet
Sleeve
Cap
O-Ring (3 Used)
Backup Ring
Cap
Spool
Spacer
Spring
Cap
O-Ring
Cap
O-Ring
Cap
Overload
Relief Valve
4
7
9
5
15
6
11, 10
16
12
13
14
18, 17
1 (Refer to Close-Up.)
Bucket
Regenerative
Valve
Overload
Relief Valve
Section of Arm
Regenerative Valve
19
20
23
21
22
24
25
27, 28
26
29
Section of Check Valve-1, Main Relief
Valve, Check Valve-2, Flow Combiner
Valve
Close-Up of Arm
Regenerative Valve
Close-Up of Main
Relief Valve
Close-Up of Bucket
Regenerative Valve
W1J1-02-05-046
W2-5-34
W2-5-35
Main Relief
Valve
Bucket
Regenerative
Valve
Figure of Control Valve (Upper)
Section of Arm
Regenerative Valve
38 19
42
40 20
45
31
39
46 21
41
43
30
47
25
48
49
27, 28
50 26
51, 52
36
44
53
54
55
Section of Check Valve-1, Main Relief
Valve, Check Valve-2, Flow Combiner
Valve
Close-Up of Arm
Regenerative Valve
24
34, 35
33
37
Close-Up of Main Relief
Valve
Close-Up of Bucket
Regenerative Valve
W1J1-02-05-046
W2-5-36
11. Install O-rings (28, 35) and backup rings (27, 34)
to sleeve (33). Install sleeve (33) to sleeve (31).
12. Install spool (25), spring (30) and spring seat (21)
to sleeve (31).
IMPORTANT: Cap (19) is pushed outside by spring
(30). While pushing cap (19) to
sleeve (31), install cap (19).
13. Install O-ring (20) to cap (19). Clamp sleeve (31)
into a vise. Install cap (19) to sleeve (31).
: 14 mm
: 180 Nm (18.3 kgfm, 133 lbfft)
14. Install O-ring (24) to sleeve (31). Install sleeve
(31) to housing (1).
: 36 mm
: 180 Nm (18.3 kgfm, 133 lbfft)
W2-5-37
Check
Valve-2
Section of Arm
Regenerative Valve
Check Valve-1
56
57
36
34, 35
37
37
61
36
62
57, 59
60
Check Valve-2
57
63
64
Flow Combiner
Valve
Section of Check Valve-1, Check Valve-2,
Flow Combiner Valve
Close-Up of Arm
Regenerative Valve
W2-5-38
Close-Up of Main
Relief Valve
Close-Up of Bucket
Regenerative Valve
W1J1-02-05-046
W2-5-39
46
47
48
49
Overload Relief
Valve-2
1
2
3
50
53
51
4
5
6
7
8
9
10
11
12
13
14
15
16
6
5
19
20
21
22
23
24
26
Check Valve-2
Check Valve-3
38
36
52
44
45
24
39
23
54
55
56
40
Check Valve-1
32
31
33
32
37
34
33
35
41
42
57
43
28
29
30
37
34
35
64
27
30
29
28
29
30
28
57
58
59
60
61
62
56
55
54
23
24
52
51
53
63
50
49
48
47
46
Overload Relief Valve-1
W11-02-05-054
W2-5-40
Cap
O-Ring
Piston
Sleeve
Backup Ring (2 Used)
O-Ring (2 Used)
Poppet
Spring
Spring Seat
Spring
Pilot Poppet
Lock Nut
Backup Ring
O-Ring
Sleeve
O-Ring
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -
Pilot Seat
Spring
Spring
Piston
O-Ring (4 Used)
Backup Ring (10 Used)
Main Poppet
Sleeve
O-Ring (5 Used)
Backup Ring (5 Used)
O-Ring (5 Used)
Cap
O-Ring (2 Used)
Backup Ring (2 Used)
Spring (2 Used)
Check Valve (2 Used)
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 -
W2-5-41
Cap
O-Ring
Cap
O-Ring
Spacer
O-Ring
Spring
Check Valve
Cap
O-Ring
Lock Nut (4 Used)
Adjusting Screw (4 Used)
O-Ring (4 Used)
Spring (4 Used)
Pilot Poppet (4 Used)
Spring (4 Used)
52 53 54 55 56 57 58 59 60 61 62 63 64 -
O-Ring (4 Used)
Seat (4 Used)
Spring (4 Used)
Piston (4 Used)
Main Poppet (4 Used)
Sleeve (4 Used)
O-Ring
Cap
O-Ring
O-Ring (2 Used)
Flange
Socket Bolt (4 Used)
Housing (5-Spool Side)
46
47
48
49
Overload Relief
Valve-2
1
2
3
50
53
51
4
5
6
7
8
9
10
11
12
13
14
15
16
6
5
19
20
21
22
23
24
26
Check Valve-2
Check Valve-3
38
36
52
44
45
24
39
23
54
55
56
40
Check Valve-1
32
31
33
32
37
34
33
35
41
42
57
43
28
29
30
37
34
35
64
27
30
29
28
29
30
28
58
59
57
56
55
54
23
24
52
51
53
50
49
48
47
46
W2-5-42
W2-5-43
Overload Relief
Valve-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
6
5
19
20
21
22
23
24
26
64
27
28
29
30
W11-02-05-054
W2-5-44
W2-5-45
Check Valve-2
Check Valve-3
Check Valve-1
64
Check Valve-3
(Refer to Close-Up.)
64
Overload Relief
Valve-1
Overload Relief
Valve-1
Overload Relief
Valve-2
(Refer to Close-Up.)
Check Valve-2
(Refer to
Close-Up.)
Overload Relief
Valve-1
(Refer to Close-Up.)
Section of Check Valve-2,
Section of Check Valve-3,
Overload Relief valve-2
Overload Relief Valve-1
Overload Relief
Valve-1
(Refer to Close-Up.)
Section of Overload Relief Valve-1
38
Check Valve-1
(Refer to Close-Up.)
46
47
53
48
52
49
39
40
12
57
42
51
43
50
24, 23
28
54
15
Close-Up
of
Check Valve-3
27
5, 6
34
21, 20
33, 37
22
56
Close-Up of Overload
Relief Valve-1
41
16
31 (36)
32
55
29, 30
35
( )For Check Valve-2
Close-Up
of Check
Valve-1, Check Valve-2
W2-5-46
2
3
13
14
7
8
5, 6
9
10
11
19
28
24, 23
26
29, 30
Close-Up of Overload
Relief Valve-2
W1J1-02-05-047
Cap
O-Ring
Piston
Sleeve
Backup Ring (2 Used)
O-Ring (2 Used)
Poppet
Spring
Spring Seat
Spring
Pilot Poppet
Lock Nut
Backup Ring
O-Ring
Sleeve
O-Ring
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 -
Pilot Seat
Spring
Spring
Piston
O-Ring (4 Used)
Backup Ring (10 Used)
Main Poppet
Sleeve
O-Ring (5 Used)
Backup Ring (5 Used)
O-Ring (5 Used)
Cap
O-Ring (2 Used)
Backup Ring (2 Used)
Spring (2 Used)
Check Valve (2 Used)
36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 -
W2-5-47
Cap
O-Ring
Cap
O-Ring
Spacer
O-Ring
Spring
Check Valve
Cap
O-Ring
Lock Nut (4 Used)
Adjusting Screw (4 Used)
O-Ring (4 Used)
Spring (4 Used)
Pilot Poppet (4 Used)
Spring (4 Used)
52 53 54 55 56 57 58 59 60 61 62 63 64 -
O-Ring (4 Used)
Seat (4 Used)
Spring (4 Used)
Piston (4 Used)
Main Poppet (4 Used)
Sleeve (4 Used)
O-Ring
Cap
O-Ring
O-Ring (2 Used)
Flange
Socket Bolt (4 Used)
Housing (5-Spool Side)
Check Valve-2
Check Valve-3
Check Valve-1
64
Overload Relief
Figure of Control Valve (Upper) Valve-1
Overload Relief
Valve-1
64
Check Valve-3
(Refer to Close-Up.)
Overload Relief
Valve-1
(Refer to Close-Up.)
Check Valve-2
(Refer to Close-Up.)
Overload Relief
Valve-1
(Refer to Close-Up.)
Overload Relief
Valve-1
(Refer to Close-Up.)
Section of Check Valve-3,
Overload Relief Valve-1
Check Valve-1
(Refer to Close-Up.)
38
Overload Relief
Valve-1
(Refer to Close-Up.)
47
48
52
49
39
46
40
53
57
42
51
43
50
24, 23
28
54
29, 30
Close-Up of Check
Valve-3
55
31 (36)
32
56
34
Close-Up of Overload
Relief Valve-1
41
33, 37
35
(
Close-Up of Check
Valve-1, Check Valve-2
W2-5-48
Close-Up of
Overload Relief
Valve-2
W1J1-02-05-047
W2-5-49
Overload Relief
Valve-2
64
1
4
12
15
16
Close-Up
of
Check Valve-3 27
5, 6
21, 20
Close-Up of Overload
Relief Valve-1
22
(
Close-Up of Check
Valve-1, Check Valve-2
W2-5-50
2
3
13
14
7
8
5, 6
9
10
11
19
28
24, 23
26
29, 30
Close-Up of Overload
Relief Valve-2
W1J1-02-05-047
W2-5-51
VALVE
5
4
20
4
5
4
5
6
12
13
14
15
16
17
18
10
7
5
8
21
19
11
22
3
3
23
24
1
1
W1J1-02-05-055
W2-5-52
78910 11 12 -
Spring (4 Used)
Spool
Spool (Arm 2)
Spool
Spool (Boom 2)
Spool
13 14 15 16 17 18 -
W2-5-53
Check Valve
Spring
Spacer
O-Ring
Backup Ring
Cap
19 20 21 22 23 24 -
Spool (Bucket)
Spool
Spool (Travel)
Housing (4-Spool Side)
Cover
Cover
5
4
20
4
5
4
5
6
12
13
14
15
16
17
18
10
7
5
8
21
19
11
22
3
3
23
24
1
1
W1J1-02-05-055
W2-5-54
Disassemble Spool
1. Remove socket bolts (1) (6 used) from cover (2).
Remove cover (2) and O-rings (3) (4 used) from
housing (22).
: 10 mm
2. Remove socket bolts (1) (7 used) from covers (23,
24). Remove covers (23, 24) and O-rings (3) (4
used) from housing (22).
: 10 mm
IMPORTANT: Rotate and remove spool (9, 11, 19,
21) assemblies.
Do not disassemble spool (9, 11, 19,
21) assemblies unless necessary.
3. Remove spool (9, 11, 19, 21) assemblies from
housing (22).
4. Remove bolts (4) (4 used), spring guide (12) (4
used), springs (7) (4 used), sleeves (6) (4 used)
and spring guides (5) (4 used) from spools (8, 10,
12, 20).
: 10 mm
5. Remove cap (18), spacer (15), spring (14) and
check valve (13) from spool (12).
: 10 mm
W2-5-55
22
23
10
24
12
2
22
4
6
5
20
13
14
18
15
16, 17
23
11
19
21
24
W1J1-02-05-048
Section of 4-Spool
123456-
78910 11 12 -
Spring (4 Used)
Spool
Spool (Arm 2)
Spool
Spool (Boom 2)
Spool
13 14 15 16 17 18 -
W2-5-56
Check Valve
Spring
Spacer
O-Ring
Backup Ring
Cap
19 20 21 22 23 24 -
Spool (Bucket)
Spool
Spool (Travel)
Housing (4-Spool Side)
Cover
Cover
W2-5-57
VALVE
4
1
5
4
2
4
3
12
6
7
21
22
13
14
10
15
23
24
25
16
17
18
20
6
7
28
29
26
27
19
30
11
9
3
31
1
3
3
31
32
1
1
W1J1-02-05-056
W2-5-58
910 11 12 13 14 15 16 -
Spool (Travel)
Spool
Spool (Auxiliary)
Spool
Check Valve
Spring
Spacer
O-Ring
17 18 19 20 21 22 23 24 -
W2-5-59
Backup Ring
Cap
Spool (Boom 2)
Spool
Check Valve
Spring
Spacer
O-Ring
25 26 27 28 29 30 31 32 -
Backup Ring
Cap
Spool (Arm 2)
Spool
Spool (Swing)
Housing (5-Spool Side)
Cover (2 Used)
Cover
4
1
5
4
2
4
3
12
14
6
21
22
13
14
10
15
23
24
25
16
17
18
20
6
7
28
29
26
27
19
30
11
9
3
31
1
3
3
31
32
1
1
W1J1-02-05-056
W2-5-60
W2-5-61
30
1
31
31
32
11
19
27
29
4
6
7
1
5
30
28
10
20
12
13
21
14
22
15
23
18
24, 25
26
31
16, 17
32
W1J1-02-05-049
31
Section of 5-Spool
12345678-
910 11 12 13 14 15 16 -
Spool (Travel)
Spool
Spool (Auxiliary)
Spool
Check Valve
Spring
Spacer
O-Ring
17 18 19 20 21 22 23 24 -
W2-5-62
Backup Ring
Cap
Spool (Boom 2)
Spool
Check Valve
Spring
Spacer
O-Ring
25 26 27 28 29 30 31 32 -
Backup Ring
Cap
Spool (Arm 2)
Spool
Spool (Swing)
Housing (5-Spool Side)
Cover (2 Used)
Cover
W2-5-63
VALVE
REAR
3
4
5
6
W11-02-05-062
12-
34-
Check Valve
Spring
5-
W2-5-64
6-
Cap
W2-5-65
Check Valve
3
Section of Check Valve
W1J1-02-05-050
12-
34-
Check Valve
Spring
5-
W2-5-66
6-
Cap
W2-5-67
DISASSEMBLE HOUSING
4
2
3
5
6
4
3
3
8
10
5
4
10
8
9
W11-02-05-057
123-
456-
O-Ring (3 Used)
O-Ring (3 Used)
O-Ring (6 Used)
W2-5-68
W2-5-69
10, 8
2
9, 8
9, 8
9, 8
10, 8
2
4
5
W1J1-02-05-060
5
123-
456-
O-Ring (3 Used)
O-Ring (3 Used)
O-Ring (6 Used)
W2-5-70
used)
install
(1) to
(5) (6
W2-5-71
W2-5-72
Removal
W1J1-02-05-061
4
6
3
5
4
8
10
9
W1J1-02-06-001
11
12
13
14
14
15
W1J1-02-06-002
W2-6-1
Motor
Installation
1. Apply liquid packing (THREEBOND #1215) to the
mounting surface for main frame in swing device
(9).
W155-02-06-012
11
W2-6-2
12
13
14
14
15
W1J1-02-06-002
4
6
3
5
4
8
10
9
W1J1-02-06-001
W1J1-02-05-061
W2-6-3
24
25
26
27
4
23
28
22
21
20
19
7
18
29
17
16
9
30
15
31
10
14
32
11
33
12
34
13
35
W16J-02-06-001
123456789-
Motor
Socket Bolt (8 Used)
Ring Gear
First Stage Sun Gear
Thrust Plate
First Stage Carrier
Second Stage Sun Gear
Thrust Plate
Second Stage Carrier
10 11 12 13 14 15 16 17 18 -
Bolt (2 Used)
Lock Plate
Bearing Nut
Roller Bearing
Thrust Plate (3 used)
Planetary Gear (3 Used)
Thrust Plate (3 used)
Spring Pin (3 Used)
Pin (3 Used)
19 20 21 22 23 24 25 26 27 -
W2-6-4
28 29 30 31 32 33 34 35 -
Cork (2 Used)
Oil Seal
Roller Bearing
Screw (4 Used)
Magnet (4 Used)
Sleeve
O-Ring
Shaft
Eyebolt
Mounting
Positions
W16J-02-06-003
Stopper
Swing Device
ST 5101
Pinion Gear
W178-02-06-012
W2-6-5
24
27
23
22
21
6
20
19
7
18
17
16
9
15
14
10
11
12
35
W16J-02-06-001
W2-6-6
12
W178-02-06-008
(27)
assembly
W2-6-7
27
13
35
W16J-02-06-001
W2-6-8
Press
Press
27
Cover
27
ST 7298
W178-02-06-006
Cover
W157-02-06-010
W2-6-9
W157-02-06-011
27
30
13
35
W16J-02-06-001
W2-6-10
Shaft
Press
35
30
33
W157-02-06-012
Guide
35
30
W157-02-06-014
33
Shaft
Guide
W157-02-06-013
Press
W2-6-11
35
30
ST 7299
ST 7297
33
W178-02-06-009
27
Body
29
30
33
34
13
35
W16J-02-06-001
W2-6-12
27
Oil Passage
Outer Race
30
W178-02-06-001
W2-6-13
2
4
22
21
23
20
19
17
5
6
3
7
16
18
24
15
14
10
13
11
26
12
25
27
32
30
31
29
33
35
34
W16J-02-06-002
123456789-
Motor
Socket Bolt (8 Used)
Ring Gear
First Stage Sun Gear
Thrust Plate
First Stage Carrier
Second Stage Sun Gear
Thrust Plate
Second Stage Carrier
10 11 12 13 14 15 16 17 18 -
Bolt (2 Used)
Lock Plate
Bearing Nut
Roller Bearing
Thrust Plate (3 used)
Planetary Gear (3 Used)
Thrust Plate (3 used)
Spring Pin (3 Used)
Pin (3 Used)
19 20 21 22 23 24 25 26 27 -
W2-6-14
28 29 30 31 32 33 34 35 -
*Cork (2 Used)
Oil Seal
Roller Bearing
Screw (4 Used)
Magnet (4 Used)
Sleeve
O-Ring
Shaft
ST 7300
29
27
Press
W178-02-06-007
ST 7295
30
33
35
ST 7300
35
33
W178-02-06-013
ST 7296
27
29
W16J-02-06-004
W2-6-15
24
13
12
27
29
33
35
W16J-02-06-002
W2-6-16
(27)
assembly
(27)
assembly
12. Install eyebolt (M16, Pitch 2.0 mm) into the socket
bolt (24) hole (2 places) on housing (27). Hoist
and place housing (27) on a press.
(27)
assembly
ST 2924
13
W2-6-17
17
16
18
15
14
10
13
11
12
27
35
W16J-02-06-002
W2-6-18
27
ST 5101
Stopper
Pinion Gear
W178-02-06-012
12
W178-02-06-008
W2-6-19
5
22
23
20
19
17
3
7
9
16
18
15
14
13
11
27
35
W16J-02-06-002
W2-6-20
Concave
11
35
17
18
Motor Side
Slit
W178-02-06-002
W178-02-06-014
23. Install thrust plate (5) to first stage carrier (6) with
the oil groove side facing upward.
carrier
(9)
W2-6-21
2
4
5
6
3
7
24
26
25
27
W16J-02-06-002
W2-6-22
Eyebolt Mounting
Positions
W2-6-23
W16J-02-06-003
11
9
8
7
6
5
4
10
3
2
24
25
26
29
27
15
14
27
17
Casing
Oil Seal
Bearing
Shaft
Shoe Plate
Plunger (9 Used)
Plate
Retainer
910 11 12 13 14 15 16 -
26
25
24
12
16
12345678-
31
28
23
13
30
Rotor
Plate (4 Used)
Friction Plate (3 Used)
O-Ring
Piston
Spring
Ball
Plug (2 Used)
17 18 19 20 21 22 23 24 -
18
19
O-Ring
O-Ring
Brake Piston
Spring (24 Used)
Valve Plate
Bearing
O-Ring
Plug (2 Used)
W2-6-24
20
21
22
32
W178-02-06-015
25 26 27 28 29 30 31 32 -
O-Ring (2 Used)
Spring (2 Used)
Poppet (2 Used)
Valve Casing
Socket Bolt (4 Used)
O-Ring (2 Used)
Plug (2 Used)
Relief Valve (2 Used)
28
19
Notch A
Port B
W2-6-25
T178-03-02-003
11
9
8
7
6
5
4
10
3
2
24
25
26
29
27
15
14
31
28
27
23
13
30
26
25
24
12
16
17
W2-6-26
18
19
20
21
22
32
W178-02-06-015
W2-6-27
26
25 24
12
13
14
15
16
29
T178-03-02-004
T178-03-02-003
31
30
28
32
21
20
22
23
19
18
10
17
11
9
7
5
8
3
1
2
4
12345678-
Casing
Oil Seal
Bearing
Shaft
Shoe Plate
Plunger (9 Used)
Plate
Retainer
T178-03-02-002
910 11 12 13 14 15 16 -
Rotor
Plate (4 Used)
Friction Plate (3 Used)
O-Ring
Piston
Spring
Ball
Plug (2 Used)
17 18 19 20 21 22 23 24 -
O-Ring
O-Ring
Brake Piston
Spring (24 Used)
Valve Plate
Bearing
O-Ring
Plug (2 Used)
W2-6-28
25 26 27 28 29 30 31 32 -
O-Ring (2 Used)
Spring (2 Used)
Poppet (2 Used)
Valve Casing
Socket Bolt (4 Used)
O-Ring (2 Used)
Plug (2 Used)
Relief Valve (2 Used)
W2-6-29
27
26
25 24
12
13
14
15
16
29
T178-03-02-004
T178-03-02-003
31
30
28
32
21
20
22
23
19
18
10
17
11
9
7
5
8
3
1
2
T178-03-02-002
W2-6-30
W2-6-31
Unit: mm (in)
Standard
Allowable Limit
0.027 (0.0011)
0.052 (0.0020)
W107-02-06-138
W107-02-06-139
Allowable Limit
0 (0)
0.3 (0.0118)
W107-02-06-140
W107-02-06-141
W2-6-32
Allowable Limit
5.5 (0.22)
5.3 (0.21)
W107-02-06-142
Allowable Limit
2.0 (0.08)
1.8 (0.07)
W107-02-06-143
W2-6-33
W2-6-34
3
2
W1JB-02-01-008
W1JB-02-07-007
W2-7-1
W1JB-02-07-013
7, 8
10
W1JB-02-07-012
11
12
W1JB-02-07-002
13
11
W1JB-02-07-014
W2-7-2
14
15
16
17
18
W1JB-02-07-011
19
20
W1JB-02-07-005
22
22
W1JB-02-07-006
23
W2-7-3
24
22
W1JB-02-07-005
24
W2-7-4
24
22
W1JB-02-07-005
24
22
W1JB-02-07-006
23
18
19
20
21
22
W2-7-5
W1JB-02-07-005
15
16
17
W1JB-02-07-011
13
16
15
W1JB-02-07-014
11
12
W1JB-02-07-002
10
W2-7-6
W1JB-02-07-012
W1JB-02-07-013
7, 8
11. Install seat (1) to bracket (4) with socket bolts (3)
(4 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft))
12. Install the seat belt to bracket (4) with bolts (2) (2
used).
: 16 mm
: 50 Nm (5 kgfm, 37 lbfft)
3
2
W1JB-02-01-008
W1JB-02-07-007
W2-7-7
1, 2
W1JB-02-07-009
1, 2
3
4
7
5
W1JB-02-07-008
W1JB-02-07-002
10
8
7
W1JB-02-07-016
W2-7-8
11
12
13
14
W1JB-02-07-005
15
17
16
W1JB-02-07-008
18
19
W1JB-02-07-010
15
W1JB-02-07-006
20
W2-7-9
21
15
W1JB-02-07-005
21
W2-7-10
21
15
W1JB-02-07-005
21
15
W1JB-02-07-006
20
W2-7-11
11
12
13
14
15
W1JB-02-07-005
18
19
W1JB-02-07-010
6
5
17
16
W1JB-02-07-008
10
5
7
18
W1JB-02-07-016
W2-7-12
W1JB-02-07-002
W1JB-02-07-009
12. Install seat (1) to bracket (4) with socket bolts (3)
(4 used).
: 6 mm
: 20 Nm (2 kgfm, 15 lbfft)
W1JB-02-07-007
13. Install the seat belt to bracket (4) with bolts (2) (2
used).
: 16 mm
: 50 Nm (5 kgfm, 37 lbfft)
3
2
W1JB-02-01-008
W2-7-13
W1J1-02-08-001
W1JB-02-07-001
W2-7-14
W1JB-02-07-015
10
W1JB-02-07-003
11
W1JB-02-07-004
W2-7-15
11
W1JB-02-07-004
10
W1JB-02-07-003
W1JB-02-07-001
W2-7-16
W1J1-02-08-001
W2-7-17
W1JB-02-07-015
17
16
15
14
13
12
11
10
18
9
8
7
6
19
5
4
20
21
22
2
1
W178-02-07-064
123456-
Spacer (4 Used)
Shim (Several)
Balance Spring A (2 Used)
Balance Spring B (2 Used)
Return Spring A (2 Used)
Return Spring B (2 Used)
78910 11 12 -
13 14 15 16 17 -
W2-7-18
O-Ring (4 Used)
Plate
Universal Joint
Cam
Screw Joint
18 19 20 21 22 -
Casing
Spool (4 Used)
O-Ring
Plug
Retaining Ring
W2-7-19
18
8
7
6
19
5
4
21
22
2
1
W178-02-07-064
W2-7-20
ST 4146
22
W178-02-07-048
ST 4145
W2-7-21
17
15
16
14
11
9, 10
12
13
8
7
3, 4
5, 6
2
21
20
18
19
22
W1V1-02-07-001
123456-
Spacer (4 Used)
Shim (Several)
Balance Spring A (2 Used)
Balance Spring B (2 Used)
Return Spring A (2 Used)
Return Spring B (2 Used)
78910 11 12 -
13 14 15 16 17 -
W2-7-22
O-Ring (4 Used)
Plate
Universal Joint
Cam
Screw Joint
18 19 20 21 22 -
Casing
Spool (4 Used)
O-Ring
Plug
Retaining Ring
Spool
(19)
Shim
(2)
3
4
Port
No.
1
2
3
4
Return Springs
(5, 6)
Short
Long
Short
Long
Pushers A, B
(9, 10)
Outer grooves
(3 used)
Without outer
groove
Outer grooves
(3 used)
Without outer
groove
Balance Springs A, B
(3, 4)
Short
Long
Short
Long
ST 4145
W178-02-07-049
W2-7-23
17
15
16
14
11
13
9, 10
12
8
3, 4
18
W1V1-02-07-001
W2-7-24
W2-7-25
2
3
4
5
6
35
34
33
32
31
30
9
10
29
11
28
27
14
12
26
15
13
25
16
24
17
18
23
19
20
21
22
W178-02-07-063
123456789-
Bolt (2 Used)
Cover
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Bushing (4 Used)
Holder
Spring Washer (4 Used)
Socket Bolt (4 Used)
10 11 12 13 14 15 16 17 18 -
Spring Pin
Bracket (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
O-Ring (4 Used)
Bushing (4 Used)
Pusher (4 Used)
Spring Guide (16 Used)
Balance Spring (4 Used)
19 20 21 22 23 24 25 26 27 -
W2-7-26
O-Ring (2 Used)
Plug (2 Used)
Plug (2 Used)
O-Ring (2 Used)
Casing
Spool
Return Spring (4 Used)
Spacer (4 Used)
Shim (12 Used)
28 29 30 31 32 33 34 35 -
W2-7-27
3
4
6
3
4
10
11
12
13
35
34
33
32
31
9
10
31
11
32
33
34
35
12
13
23
19
20
21
22
W178-02-07-063
W2-7-28
10
Crimped Here
Stand
W176-02-07-019
W2-7-29
11
32
31 1
35
12
10
13
3, 4
30
29
34
9
15
33 28
17
18
14
25
27
16
26
24
23
W178-02-11-316
123456789-
Bolt (2 Used)
Cover
Spring Pin (2 Used)
Spring Pin (2 Used)
Cam (2 Used)
Bushing (4 Used)
Holder
Spring Washer (4 Used)
Socket Bolt (4 Used)
10 11 12 13 14 15 16 17 18 -
Spring Pin
Bracket (2 Used)
Spring Pin (2 Used)
Spring Pin (2 Used)
O-Ring
Bushing (4 Used)
Pusher (4 Used)
Spring Guide (16 Used)
Balance Spring (4 Used)
19 20 21 22 23 24 25 26 27 -
*, refer to
W2-7-30
*O-Ring (2 Used)
*Plug (2 Used)
*Plug (2 Used)
*O-Ring (2 Used)
Casing
Spool (4 Used)
Return Spring (4 Used)
Spacer (4 Used)
Shim (12 Used)
28 29 30 31 32 33 34 35 -
6
W176-02-11-310
ST 7256
ST 7256
W176-02-11-311
ST 7256
Outside of
Holder
W176-02-11-312
W176-02-11-313
W2-7-31
32
31
35
31
32
3, 4
30
29
34
9
33
23
W178-02-11-316
W2-7-32
Slit
Slit
W178-02-07-050
W2-7-33
11
32
35
12
10
13
19, 20
21, 22
W178-02-11-316
W2-7-34
Crimped
Here
11
Stand
Crimped
Here
35
12, 13
W176-02-07-011
W2-7-35
W2-7-36
W1J1-02-08-001
5
Footrest
W1JB-02-08-003
10, 11
W2-8-1
W1JB-02-08-004
Footrest
W1JB-02-08-004
10, 11
7
5
8
1
5. Install cover (2) onto main frame (1) with bolts (3)
(7 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)
W1JB-02-08-003
W2-8-2
W1J1-02-08-001
W1JB-02-08-001
2
1
9
Section A
Item
Part Name
Qty
Plug
O-Ring
Spring
Spool
Filter
Body
O-Ring
Solenoid
Socket bolt
Wrench Size
(mm)
: 6
W1JB-02-08-002
Tightening Torque
Remark
Nm
(kgfm)
(lbfft)
26.5
(2.7)
(19.5)
1B P11
1A P16
: 4
3.92
W2-8-3
(0.4)
2.9
W2-8-4
Removal
1. Remove bolts (2) (4 used). Remove covers (1) (2
used) from the main frame.
: 19 mm
W1J1-02-05-061
Signal Control
Valve
W1J1-02-10-001
W2-9-1
W1JB-02-09-005
6
3
W1JB-02-09-005
Signal Control
Valve
W1J1-02-10-001
W1J1-02-05-061
W2-9-2
Housing
W800-02-09-001
Proportional
Solenoid Valve
B
A
Proportional
Solenoid Valve
W800-02-09-002
Filter
Plug
Plug
Filter
W800-02-09-004
View A
W800-02-09-003
W2-9-3
Section B
4
5
6
7
8
9
12
14
13
10
15
11
16
17
18
19
W18G-02-08-012
3, 5
12
13
17
10
18
19
W18G-02-08-013
7
12345-
678910 -
Solenoid
Spring
O-Ring
Diaphragm
Spool
14
11 12 13 14 15 -
W2-9-4
Orifice
Washer
Spring
O-Ring
O-Ring
15
16
16 17 18 19 -
11
O-Ring
Sleeve
Plate
Wave Spring
W2-9-5
+2
-0
Nm (0.5
+0.2
-0
kgfm, 3.7
+0.15
-0
lbfft)
W2-9-6
INSTALL
SIGNAL
Removal
1. Remove bolts (2) (4 used). Remove covers (1) (2
used) from the main frame.
: 19 mm
W1J1-02-05-061
W1JB-02-05-004
8 mm
W1JB-02-10-001
W2-10-1
W1JB-02-10-001
W1JB-02-09-004
W1J1-02-05-061
W2-10-2
12
7
11
4
10
9
7
8
7
6
2
4
W1JB-02-10-002
W2-10-3
15
16
14
16
16
17
17
17
18
19
21
19
18
19
20
20
20
14
22
23
24
25
26
27
19
20
5
19
21
18
17
17
20
19
17
16
29
18
20
19
28
17
14
16
16
16
W1JB-02-10-003
Detail of Body 2
12345678-
Bolt (3 Used)
Body 1
Gasket
Filter (17 Used)
Body 2
Gasket
Shuttle Valve (2 Used)
Spring (4 Used)
910 11 12 13 14 15 16 -
Body 3
Gasket
Body 4
Gasket
Body 5
Socket Bolt (11 Used)
Plate
Plug (7 Used)
17 18 19 20 21 22 23 24 -
W2-10-4
O-Ring (7 Used)
Spring (4 Used)
Spring Guide (7 Used)
Spool (6 Used)
Spring (2 Used)
Plate
O-Ring
Shuttle Valve
25 26 27 28 29 -
O-Ring
Spring
Spool
Spring
Plate
AND
INSTALL
SHOCKLESS
Removal
1. Remove bolts (3) (6 used). Remove cover (2) from
main frame (1).
: 19 mm
W1J1-02-08-001
W2-11-1
W1JB-02-11-001
3. Install cover (2) onto main frame (1) with bolts (3)
(6 used).
: 19 mm
: 90 Nm (9 kgfm, 66 lbfft)
W2-11-2
W1JB-02-11-001
W1J1-02-08-001
3
T183-03-07-008
Item
Part Name
Qty
Plug
O-Ring
Body
Spring
Plunger
Ring
Orifice
Wrench Size
(mm)
: 8
Tightening Torque
Nm
(kgfm)
(lbfft)
39
(4)
(29)
W2-11-3
Remark
W2-11-4
Engine Cover
W1J1-02-05-061
Fan Motor
4
W1J1-02-12-001
W1J1-02-12-002
W2-12-1
W1J1-02-12-002
W2-12-2
8
6
W1J1-02-12-002
9
Fan Motor
4
W1J1-02-12-001
W1J1-02-05-061
W2-12-3
View A
A
W1JB-02-13-003
W1JB-02-13-002
10
11
12
13
14
18
17
16
15
Section B
Item
Part Name
Qty
W1JB-02-13-001
Wrench Size
(mm)
Item
Part Name
Qty
Pin
10
O-Ring
Poppet
11
Spring
Poppet
12
O-Ring
Backup Ring
13
Lock Nut
O-Ring
14
Screw
O-Ring
15
Body
Spring
16
Poppet
O-Ring
17
Adapter
Spring
18
Backup Ring
W2-12-4
Wrench Size
(mm)
17
32
32
2
1
Counterweight
Removal
Machine
Front
W1J1-02-13-007
Main Frame
Counterweight
4
W1J1-02-13-011
Radiator Assembly
Machine
Front
8, 9
7
Valve (9) is located behind cover (8).
W2-13-1
W1J1-02-13-008
Radiator Assembly
10
14
11
from
fresh
air
13
12
W1J1-02-13-013
16
15
W1J1-02-13-014
W2-13-2
17
18
W1J1-02-13-001
19
20
21
W1J1-02-13-015
18
22
23
W1J1-02-13-020
W2-13-3
24
19 mm
25
17
28
29
W1J1-02-13-003
28
26
27
View A
24
28
17
25
W1J1-02-13-002
Radiator Assembly
32
Counterweight
W2-13-4
34
33
W1J1-02-13-007
Main Frame
35
36, 37
Machine
Front
44, 45
42, 43
W1J1-02-13-005
41
46
47
48
49, 50
51
52
53
W1J1-02-13-017
61
60
54
59
58
57
56
W1J1-02-13-016
55
Detail for Part B
W2-13-5
64
Machine
Front
W1J1-02-13-004
65
66
67
W2-13-6
W1J1-02-13-017
70
Coolant
Reservoir
Machine
Front
W1J1-02-13-004
W1J1-02-13-018
Machine
Front
73
74
W1J1-02-13-008
W2-13-7
Machine
Front
W1J1-02-13-004
78
75
77
76
W1J1-02-13-021
Machine
Front
W1J1-02-13-008
W2-13-8
Lifting Hole
Machine
Front
W1J1-02-13-005
86
87
88
89
90
CAUTION: The
bracket
weight: 90 kg (200 lb)
(88)
assembly
91
W1J1-02-13-004
94
87
88
93
W2-13-9
92
W1JB-02-12-010
99
95
Shaft
96
92
94
36. Remove lock pin (95) and nut (96) from the shaft
in fan motor (98).
: 24 mm
IMPORTANT: Key (97) is attached with the shaft in
fan motor (98). Do not lose key (97).
37. Remove coupling (93) and fan guard (87) from
the shaft in fan motor (98).
93
97
98
88
CAUTION: The
bracket
weight: 70 kg (155 lb)
(88)
assembly
94
87
88
93
100, 101
106
W2-13-10
92
102
105
W1JB-02-12-010
103, 104
98
W1J1-02-13-019
98
W2-13-11
88
W1JB-02-12-011
100, 101
106
W2-13-12
W1JB-02-12-011
88
102
105
103, 104
98
W1J1-02-13-019
(88)
assembly
98
99
Shaft
88
W1JB-02-12-011
95
96
92
94
93
97
88
98
W1J1-02-13-010
W2-13-13
(88)
assembly
94
87
88
93
92
W1JB-02-12-010
88
98
91
W1J1-02-13-009
86
87
88
89
90
91
W1J1-02-13-004
W2-13-14
Lifting Hole
IMPORTANT: Before
installing
the
radiator
assembly to the main frame, check
the connections in hydraulic oil
cooler and hoses.
10. Temporarily tighten dust cover (2) with bolts (3) (2
used). Attach a wire rope to the lifting hole on the
radiator assembly. Hoist and move the radiator
assembly to the mounting position for radiator in
the main frame.
Machine
Front
3
2
W1J1-02-13-005
Machine
Front
79
W1J1-02-13-008
68, 69
Machine
Front
W2-13-15
W1J1-02-13-004
70
Coolant
Reservoir
Machine
Front
W1J1-02-13-004
78
75
77
76
W1J1-02-13-021
W2-13-16
Machine
Front
W1J1-02-13-004
71
72
Coupler
W1J1-02-13-018
Machine
Front
73
74
W1J1-02-13-008
W2-13-17
62, 63
64
Machine
Front
W1J1-02-13-004
65
66
67
W2-13-18
W1J1-02-13-017
35
20. Install clamps (50, 52) to pipe (51) with bolts (49,
53).
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
36, 37
Machine
Front
44, 45
42, 43
W1J1-02-13-005
41
46
47
48
49, 50
51
52
Machine
Front
53
Detail for Part A
61
22. Install clamps (58, 60) to pipe (59) with bolts (57,
61).
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
58
W1J1-02-13-017
60
54
59
57
56
W2-13-19
55
W1J1-02-13-016
2
3
W1J1-02-13-012
Radiator Assembly
Machine
Front
W1J1-02-13-008
14
11
13
12
10, 11 Close-Up
W2-13-20
W1J1-02-13-013
Radiator Assembly
W1J1-02-13-008
16
15
12 Close-Up
W2-13-21
W1J1-02-13-014
24
17
25
28
29
W1J1-02-13-003
31. Install covers (5, 31, 34) to the main frame with
bolts (6, 32, 33) (6 used for each) and the
View A
washers (24 used).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
28
26
27
24
28
32. Shut dust cover (2). Install dust cover (2) with
bolts (1, 3) (2 used for each) and the washers (4
used).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
17
25
Radiator Assembly
W1J1-02-13-002
31
32
Counterweight
W2-13-22
34
33
W1J1-02-13-007
Main Frame
17
18
W1J1-02-13-001
19
Bracket
20
21
W1J1-02-13-015
22
23
W1J1-02-13-020
W2-13-23
W2-13-24
21
22
23
W1JB-02-12-002
10
11
W1JB-02-12-001
20
123456-
19
End Cap
Rotor Insert Assembly
Vane Spring (24 Used)
Mount (12 Used)
Vane (12 Used)
Cam Ring
18
17
78910 11 12 -
16
13
14
15
16
17
18
15
14
Retaining Ring
Retaining Ring
Seal
Seal
Pin (2 Used)
Seal
W2-13-25
13
12
19
20
21
22
23
Needle Bearing
Socket Bolt (4 Used)
Ball
Valve
Screw
W2-13-26
UPPERSTRUCTURE / Engine
REMOVE AND INSTALL ENGINE
CAUTION: Release any pressure in the
hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4.)Remove the grounding wire
from the battery.
Removal
1. Drain off coolant (max. 55 L (14.5 US gal)) from
the radiator.
: 19 mm
W1J1-02-13-001
5
7
Bracket
6
W1J1-02-14-023
W1J1-02-13-003
W2-14-1
UPPERSTRUCTURE / Engine
CAUTION: Air cleaner cover (10) weight: 32
kg (71 lb)
10
Rain Cover
11
12
Catch
W1J1-02-04-038
13
14
15
14
W1J1-02-13-003
16
17
18
19
21
W2-14-2
20
W1J1-02-14-015
UPPERSTRUCTURE / Engine
CAUTION: Bracket (24) weight: 21 kg (46 lb)
8. Remove bolts (23) (4 used) from both ends of
bracket (24). Attach a nylon sling to bracket (24).
Hoist and remove bracket (24).
: 19 mm
22
23
24
25
27
W1J1-02-14-001
32, 33
31
30
29
28
27A
W1J1-02-14-004
30
32, 33
28
34
35
27A
31
36
W1J1-02-14-005
W2-14-3
UPPERSTRUCTURE / Engine
37
38, 39
40, 41
42
Pipe
43
44
40
41
45
W1J1-02-13-017
49
50
46, 47
51
50
49
48
W1J1-02-13-016
52
53, 54
55
56, 57
W1J1-02-13-004
W2-14-4
UPPERSTRUCTURE / Engine
19. Remove terminals (67) (2 used) from air cleaner
restriction switch (61). Remove clip (66). Loosen
nut (63) in band (62).
: 11 mm
61
62
67
63
64
65
66
W1J1-02-04-042
from
intake-air
70
68
W1J1-02-14-021
71
72
65
64
69
76
75
74
73
W2-14-5
W1J1-02-14-006
UPPERSTRUCTURE / Engine
77
W1J1-02-04-045
Main Frame
78
79
80
77
W1J1-02-04-046
81
82
83
82
82
84
85, 86
87
82
89
78
W2-14-6
W1J1-02-04-041
UPPERSTRUCTURE / Engine
64
77
W1J1-02-04-044
90
77
Bolt Mounting
Hole
W1J1-02-04-043
77
91
W1J1-02-04-045
Main Frame
W2-14-7
UPPERSTRUCTURE / Engine
Radiator Pipe
94
93
95
92
W1J1-02-14-022
Engine
96
97
98
100
99
W1J1-02-14-003
Alternator
101, 102
103
107, 108
106
109, 110
W2-14-8
104, 105
109, 110
W1J1-02-14-010
W1J1-02-14-011
UPPERSTRUCTURE / Engine
IMPORTANT: Before removing nut (111) from the
terminal in starter motor (112),
remove the grounding wire in
battery. If the work is continued with
the grounding wire connected, the
circuit may be shorted.
32. Remove nuts (111) (2 used). Remove harness
(114) from the terminal in starter motor (112).
Remove nut (113). Remove the grounding wire
from the bracket.
: 17 mm, 22 mm
111
112
Bracket
113
114
Grounding Wire
115, 116
Engine
W1J1-02-14-009
117
123
115, 116
122
121
120
119
115, 116
118
W1J1-02-14-007
124
125, 126
125, 126
127
125, 126
125, 126
129
Pump
W2-14-9
128
125, 126
W1J1-02-14-008
UPPERSTRUCTURE / Engine
Pipe
130
131
132
W1J1-02-14-002
Engine
133
W1J1-02-14-012
Engine
134
135
136, 137
138, 139
140, 141
148
146, 147
144, 145
W2-14-10
143
142
W1J1-02-04-001
UPPERSTRUCTURE / Engine
40. Remove bolts (150) (2 used), washers (151) (4
used), plates (149) (2 used), cushions (152) (2
used) and nuts (155) (2 used) from brackets
(153) (2 used).
: 41 mm
NOTE: After removing the engine from the main
frame, remove cushions (154) (2 used).
150, 151
149
W1J1-02-14-013
Air Compressor
150
151
149
152
153
154
152
155
Details when installing
W1J1-02-14-020
156
Starter Motor
W2-14-11
157, 158
W1J1-02-14-014
UPPERSTRUCTURE / Engine
CAUTION: Engine/pump weight: 1630 kg
(3590 lb)
42. Attach a wire rope to the lifting hole (3 places) on
engine. Hoist and remove the engine.
Lifting Hole
153
W1J1-02-14-016
Wooden
Block
Wooden
Block
Lower Surface on
Engine
Wooden Block Position
W2-14-12
153
W1J1-02-14-017
UPPERSTRUCTURE / Engine
Installation
1. Install cushion (154) to the place for brackets
(153) (2 used) in the main frame.
CAUTION: Engine/pump weight: 1630 kg
(3590 lb)
2. Attach a wire rope to the lifting hole (3 places) on
engine. Hoist and move the engine to the
mounting position for engine in the main frame.
152
153
154
W1J1-02-14-016
150, 151
Air Compressor
149
W1J1-02-14-013
150
151
149
152
153
154
152
155
Details when installing
W2-14-13
W1J1-02-14-020
UPPERSTRUCTURE / Engine
4. Install brackets (156) (2 used) with bolts (157) (2
used), washer (158) or the spacer. Install the
spacer instead of washer (158) to bracket (156)
at the muffler side.
: 32 mm
: 750Nm (77 kgfm, 553 lbfft)
156
Starter Motor
157, 158
W1J1-02-14-014
Engine
W1J1-02-14-012
Pipe
130
131
132
Engine
W2-14-14
W1J1-02-14-002
UPPERSTRUCTURE / Engine
7. Install bracket (77) with bolts (91) (4 used).
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
77
91
W1J1-02-04-045
Main Frame
64
77
W1J1-02-04-044
90
77
Bolt Mounting
Hole
W2-14-15
W1J1-02-04-043
UPPERSTRUCTURE / Engine
9. Install hose (76) to the pipe in engine. Tighten nut
(75). Tighten hose (76) with band (74). Install pipe
(69) to bracket (73) with clamp (72) and bolts (71)
(2 used).
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
: 11 mm
71
72
65
64
69
76
75
74
73
W1J1-02-14-006
W1J1-02-14-021
78
79
80
77
W1J1-02-04-046
W2-14-16
UPPERSTRUCTURE / Engine
12. Install hose (65) to the pipe in air cleaner (64).
Tighten nut (63). Tighten hose (65) with band (62).
Install clip (66).
: 11 mm
61
62
67
63
64
65
66
W1J1-02-04-042
14. Install covers (81, 83, 84, 87) with bolts (82) (18
used) and (89).
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
15. Install clips (86) (2 used) in harness (78) with
bolts (85) (2 used).
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
81
82
83
82
82
84
85, 86
87
82
89
78
W1J1-02-04-041
124
125, 126
125, 126
127
125, 126
125, 126
Pump
129
128
125, 126
W1J1-02-14-008
W2-14-17
UPPERSTRUCTURE / Engine
134
135
136, 137
138, 139
140, 141
148
146, 147
144, 145
143
115, 116
123
Engine
142
W1J1-02-04-001
117
115, 116
122
121
120
119
115, 116
118
W2-14-18
W1J1-02-14-007
UPPERSTRUCTURE / Engine
21. Install hoses (110) (2 used) to the fuel pipes (2
used) in engine. Tighten hoses (110) (2 used)
with bands (109) (2 used) by using a screwdriver.
109, 110
109, 110
95
96
W1J1-02-14-011
Engine
97
98
100
99
Push Here
Approx. 98 (10 kgf
Idle Pulley
W1J1-02-14-003
Slack
6 to 10 mm
(0.2 to 0.4 in)
Crank Pulley
95
W2-14-19
W1J1-02-14-018
UPPERSTRUCTURE / Engine
23. Install harness (106) to the terminals (2 used) in
alternator with nut (102) and screw (108). Install
terminal covers (101, 107). Install connector (103).
Install clips (104) (2 used) in harness (106) with
bolts (105) (2 used).
: 12 mm
: 13 mm
: 20 Nm (2 kgfm, 15 lbfft)
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
Alternator
107, 108
101, 102
106
103
104, 105
W1J1-02-14-010
111
112
Bracket
113
114
Grounding Wire
W1J1-02-14-009
Radiator Pipe
94
W2-14-20
93
92
W1J1-02-14-022
UPPERSTRUCTURE / Engine
26. Install hose (55) to the pipe in engine. Tighten
nuts (56) (2 used). Tighten hose (55) with bands
(57) (2 used).
: 11mm
52
53, 54
55
56, 57
W1J1-02-13-004
37
38, 39
40, 41
Pipe
42
43
44
40
41
45
W1J1-02-13-017
49
50
46, 47
51
50
49
48
W2-14-21
W1J1-02-13-016
UPPERSTRUCTURE / Engine
33. Install exhaust pipe (31) to the engine with nuts
(29) (8 used).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
CAUTION: Bracket (27A) weight: 30 kg (66
lb)
34. Hoist and hold bracket (27A). Install bracket
(27A) to the main frame with bolts (36) (4 used).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
32, 33
31
30
29
28
27A
W1J1-02-14-004
30
32, 33
28
34
35
27A
31
36
W1J1-02-14-005
W2-14-22
UPPERSTRUCTURE / Engine
37. Install bracket (22) with bolts (27) (2 used).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
22
23
24
25
27
26
40. Install covers (16, 18, 21) with bolts (17, 19) (5
used for each) and (20) (4 used).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
W1J1-02-14-001
16
17
18
19
21
W2-14-23
20
W1J1-02-14-015
UPPERSTRUCTURE / Engine
CAUTION: Air cleaner cover (10) weight: 32
kg (71 lb)
10
Rain Cover
11
12
Catch
W1J1-02-04-038
13
42. Install radiator covers (13, 15) with bolts (14) (18
used).
: 19 mm
: 90 Nm (9.2 kgfm, 66 lbfft)
14
15
14
W1J1-02-13-003
W1J1-02-13-003
W2-14-24
UPPERSTRUCTURE / Engine
44. Hoist and place engine cover (2) onto muffler
cover (1). Install hinges (6) (4 used) in engine
cover (2) with bolts (7) (8 used).
: 17 mm
: 50 Nm (5.1 kgfm, 37 lbfft)
45. Insert the end of stay and cylinder (3) into the
bracket and install with washers (4) (2 used) and
lock pins (5) (2 used).
W1J1-02-13-001
4
5
Bracket
7
6
W1J1-02-14-023
W2-14-25
UPPERSTRUCTURE / Engine
(Blank)
W2-14-26
MEMO
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SECTION 3
UNDERCARRIAGE
CONTENTNS
Group 1 Swing Bearing
Maintenance Standard..........................W3-5-14
Maintenance Standard..........................W3-6-12
Group 7 Track
Maintenance Standard..........................W3-7-13
1J1W-3-1
(Blank)
1J1W-3-2
Matching Mark
Removal
1. Put the matching marks on inner race (3) of
swing bearing (1) and track frame (2).
W142-03-01-001
W105-03-01-002
ST 9050
W3-1-1
W105-03-01-003
W105-03-01-003
Plug Position
Soft Zone Position
(Outer Race)
W1J1-03-01-002
W3-1-2
W105-03-01-002
Swing Bearing
Grease Level
Pinion
Grease Bath
W3-1-3
W175-03-01-002
W1J1-03-01-001
9
2
8
7
6
W157-03-01-002
1 - Outer Race
2 - Seal
3 - Pin
4 - Plug
5 - Seal
67-
W3-1-4
89-
3. Hoist outer race (1) of the swing bearing horizontally and slightly. Remove seals (2 and 5) from
outer race (1) and inner race (7).
4. Place inner race (7) of the swing bearing on the
wooden blocks. Hoist outer race (1).
W105-03-01-007
1
2
A
7
W105-03-01-009
B
W105-03-01-008
W3-1-5
W105-03-01-010
W1J1-03-01-001
9
2
8
7
6
W157-03-01-002
1 - Outer Race
2 - Seal
3 - Pin
4 - Plug
5 - Seal
67-
W3-1-6
89-
4. Install plug (4) into outer race (1). Secure plug (4)
with pin (3). Crimp the head of pin (3) by using a
punch.
5. Apply much grease to the swing bearing.
1
2
6
4
W142-03-01-005
W142-03-01-007
8
W142-03-01-006
355 mm
W142-03-01-004
W3-1-7
W3-1-8
Removal
Before removing the travel device, the tracks must be
removed first. For removal and installation of the tracks,
refer to Remove and Install Tracks section on W3-7-1.
In this section, the procedure starts on the premise that
the track have already been removed.
2, 3
W16J-03-02-006
8, 9
10
12
11
W16J-03-02-005
W111-03-02-002
W3-2-1
7
8, 9
10
12
11
W16J-03-02-005
2, 3
W16J-03-02-006
W3-2-2
W3-2-3
10
7
6
5
4
3
2
23
24
26
25
22
1
19
18
17
15
20
27
21
16
28
29
30
14
11
12
31
13
39
42
41
38
36 35
37
34
33
32
40
51
50
49
46
47
48
45
43
44
123456-
Motor
Bolt (4 Used)
Spring Washer (4 Used)
O-Ring
Housing
Floating Seal
14 15 16 17 18 19 -
Sprocket
Washer (24 Used)
Bolt (24 Used)
Third Stage Carrier
Third Stage Sun Gear
Second Stage Carrier
27 28 29 30 31 32 -
78910 11 -
Roller Bearing
Drum
Roller Bearing
O-Ring
Bearing Nut
20 21 22 23 24 -
Spacer
Second Stage Sun Gear
Thrust Plate (3 used)
Needle Bearing (3 Used)
Pin (3 Used)
33 34 35 36 37 -
12 - Lock Plate
13 - Bolt (2 Used)
38 -
39 - Pin (4 Used)
W3-2-4
W1J1-03-02-006
40 41 42 43 44 45 -
46 47 48 49 50 -
Retaining Ring
Stopper Pin
Ball Bearing
Cover
Bolt (16 Used)
51 - Plug (3 Used)
53
12
13
11
6
5
15
16
9
51
4
14
50
22
23
24
27
25
26
47
48
49
52
29
3
21
44
43
20
19
28
18
30
35
34
33
31
32
36
17
42
41
40
38
39
37
W17P-03-02-001
12345-
Motor
Bolt (4 Used)
Spring Washer (4 Used)
O-Ring
Housing
15 16 17 18 19 -
28 29 30 31 32 -
678911 -
Floating Seal
Roller Bearing
Drum
Roller Bearing
Bearing Nut
20 21 22 23 24 -
Spacer
Second Stage Sun Gear
Thrust Plate (3 used)
Needle Bearing (3 Used)
Pin (3 Used)
33 34 35 36 37 -
12 - Lock Plate
13 - Bolt (2 Used)
14 - Sprocket
38 -
Spacer
First Stage Carrier
Thrust Plate (3 used)
Spring Pin (3 Used)
Second Stage Planetary
Gear (3 used)
Pin (3 Used)
Needle Bearing (3 Used)
Thrust Plate (3 used)
Thrust Plate (4 used)
Third Stage Planetary Gear
(4 Used)
Spring Pin (4 Used)
39 - Pin (4 Used)
40 - Needle Bearing (4 Used)
W3-2-5
41 42 43 44 47 -
48 49 50 51 52 -
Ball Bearing
Cover
Bolt (20 Used)
Plug (3 Used)
Spring Washer (20 Used)
10
9
7
6
5
4
3
2
23
24
26
25
22
1
19
18
17
15
20
27
21
16
28
29
30
14
11
12
31
13
39
42
41
38
36 35
37
34
33
32
40
51
50
49
46
47
48
45
43
44
W3-2-6
W1J1-03-02-006
2, 3
Eyebolt
Mounting
Position
51-B
W16J-03-02-002
51-A
W111-03-02-006
W3-2-7
51
50
49
45
44
W3-2-8
W1J1-03-02-006
W3-2-9
53
51
50
49
52
44
W17P-03-02-001
W3-2-10
W3-2-11
23
24
26
25
22
19
20
27
21
18
17
28
29
30
31
11
12
13
39
41
42
38
36 35
37
34
33
32
40
43
W1J1-03-02-006
W3-2-12
W1JB-03-02-003
W3-2-13
7
6
5
15
16
14
45
W1J1-03-02-006
W3-2-14
W3-2-15
27
19
20
17
16
28
29
31
39
42
41
38
36
37
40
W1J1-03-02-006
W3-2-16
W3-2-17
14
5
2
11
10
45 44
17 18
20
19
21
28
29
51
49
46
48
47
43
25
26
27
24
23
22
50
35 32 34 33
36
12
13
42
37
40
Motor
Bolt (4 Used)
Spring Washer (4 Used)
O-Ring
Housing
Floating Seal
14 15 16 17 18 19 -
Sprocket
Washer (24 Used)
Bolt (24 Used)
Third Stage Carrier
Third Stage Sun Gear
Second Stage Carrier
27 28 29 30 31 32 -
78910 11 -
Roller Bearing
Drum
Roller Bearing
O-Ring
Bearing Nut
20 21 22 23 24 -
Spacer
Second Stage Sun Gear
Thrust Plate (3 used)
Needle Bearing (3 Used)
Pin (3 Used)
33 34 35 36 37 -
12 - Lock Plate
13 - Bolt (2 Used)
38 -
T16J-03-05-001
39
39 - Pin (4 Used)
W3-2-18
31
38
41
123456-
30
40 41 42 43 44 45 -
46 47 48 49 50 -
Retaining Ring
Stopper Pin
Ball Bearing
Cover
Bolt (16 Used)
51 - Plug (3 Used)
18
17
44
52
14
50
5
51
19
29
21
20
28
49
43
47
48
25
23
24
26
22
3
4
30
6
11
12
13
42
37 40
39 38
Motor
Bolt (4 Used)
Spring Washer (4 Used)
O-Ring
Housing
15 16 17 18 19 -
28 29 30 31 32 -
678911 -
Floating Seal
Roller Bearing
Drum
Roller Bearing
Bearing Nut
20 21 22 23 24 -
Spacer
Second Stage Sun Gear
Thrust Plate (3 used)
Needle Bearing (3 Used)
Pin (3 Used)
33 34 35 36 37 -
13 - Bolt (2 Used)
14 - Sprocket
38 -
Spacer
First Stage Carrier
Thrust Plate (3 used)
Spring Pin (3 Used)
Second Stage Planetary
Gear (3 used)
Pin (3 Used)
Needle Bearing (3 Used)
Thrust Plate (3 used)
Thrust Plate (4 used)
Third Stage Planetary Gear
(4 Used)
Spring Pin (4 Used)
39 - Pin (4 Used)
40 - Needle Bearing (4 Used)
W3-2-19
32
27
34
36 31 53
15 16
12345-
12 - Lock Plate
35
33
T17P-03-05-001
41 42 43 44 47 -
48 49 50 51 52 -
Ball Bearing
Cover
Bolt (20 Used)
Plug (3 Used)
Spring Washer (20 Used)
15 16
45 44
T16J-03-05-001
W3-2-20
W3-2-21
11
T16J-03-05-001
W3-2-22
W3-2-23
11
10
17
49
36
12
13
42
37
41
40
W3-2-24
39
38
T16J-03-05-001
W1JB-03-02-003
W3-2-25
45 44
17 18
19 21
28
29
49
43
25
26
27
24
23
22
50
35 32 34 33
36
42
37
41
40
W3-2-26
39
30
31
38
T16J-03-05-001
27
24
W1JB-03-02-005
21
Slit
W178-02-06-002
W1JB-03-02-004
18
W3-2-27
51
46
47
48
49
50
44
45
10
8
W1J1-03-02-007
ZAXIS500LC-3, 520LCH-3
W1J1-03-02-008
W3-2-28
W3-2-29
W1J1-03-02-007
ZAXIS500LC-3, 520LCH-3
51
47
48
50
49
52
53
8
44
W1J1-03-02-008
W3-2-30
W3-2-31
5
2
44
T16J-03-05-001
W3-2-32
2, 3
Eyebolt
Mounting
Position
W16J-03-02-002
W3-2-33
15
16
17
14
11
12
13
10
25
24
8
22
23
21
20
18
30
29
19
28
27
26
W1J1-03-02-002
12345678-
Case
O-Ring (4 Used)
Spring (2 Used)
Piston (2 Used)
Oil Seal
Roller Bearing
Shaft
Steel Ball (2 Used)
910 11 12 13 14 15 16 -
Swash Plate
Piston (9 Used)
Retainer
Holder
Spring (9 Used)
Cylinder Block
Valve Plate
Collar
17 18 19 20 21 22 23 24 -
W3-2-34
Roller Bearing
*Disc Plate
*Friction Plate
Backup Ring
O-Ring
O-Ring
Backup Ring
Brake Piston
25 26 27 28 29 30 -
O-Ring
Spring (10 Used)
Pin
Pin (4 Used)
Valve Housing
Socket Bolt (9 Used)
29
30
Eyebolt Mounting
Position
W16J-03-02-002
W3-2-35
4
1
7
5
9
8
W1J1-03-02-002
W3-2-36
W3-2-37
27
30
26
22, 23
24
20, 21
16
29
17
15
1
28
25
W1J1-03-02-003
2
Brake Release Circuit
12345678-
Case
O-Ring (4 Used)
Spring (2 Used)
Piston (2 Used)
Oil Seal
Roller Bearing
Shaft
Steel Ball (2 Used)
910 11 12 13 14 15 16 -
14
10
18
Swash Plate
Piston (9 Used)
Retainer
Holder
Spring (9 Used)
Cylinder Block
Valve Plate
Collar
19
17 18 19 20 21 22 23 24 -
W3-2-38
13
11
12
Roller Bearing
*Disc Plate (5 Used)
*Friction Plate (4 Used)
Backup Ring
O-Ring
O-Ring
Backup Ring
Brake Piston
25 26 27 28 29 30 -
O-Ring
Spring (10 Used)
Pin
Pin (4 Used)
Valve Housing
Socket Bolt (9 Used)
W3-2-39
27
26
22, 23
24
20, 21
16
29
17
15
1
28
W1J1-03-02-003
14
18
19
W3-2-40
12. Lightly tap and install brake piston (24) to case (1)
by using a plastic hammer.
IMPORTANT: As for springs (26) (10 used), there
are twelve spring (25) mounting
holes on brake piston (24). Check
the correct hole to install spring (26).
24
Free Hole
26
26
Free Hole
24
Notch
28
W16J-03-02-003
W16J-03-02-003
W3-2-41
30
24
29
1
28
25
W1J1-03-02-003
W3-2-42
17. Install eyebolt (M12, Pitch 1.75 mm) into the bolt
hole on valve housing (29). Attach a nylon sling
onto eyebolt.
Hoist valve housing (32). Align with the pin (28)
hole on brake piston (24) and place valve housing
(29) onto the case (1).
Install valve housing (29) to case (1) with socket
bolts (30) (9 used).
: 14 mm
: 43922 Nm
(452.2 kgfm, 32516 lbfft)
NOTE: Tighten socket bolts (30) (9 used) evenly.
1
29
30
W3-2-43
Eyebolt
Mounting Position
W16J-03-02-002
9
Plug
10
11
10
12
35
36
37
38
51
39
40
41
42
43
44
48
47
49
10
9
16
13
17
18
14
19
20
21
51
45
44
23
1
15
22
24
50
46
26
27
28
30
25
31
32
33
29
43
42
41
40
36
39
35
38
34
37
W1J1-03-02-004
12345678910 11 12 13 -
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Check Valve (2 Used)
Relief Valve (2 Used)
Plug
O-Ring
Spring
Plug (6 Used)
O-Ring (6 Used)
Orifice (2 Used)
Socket Bolt (9 Used)
Valve Assembly
14 15 16 17 18 19 20 21 22 23 24 25 26 -
O-Ring
Plug
Poppet Seat (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Poppet (2 Used)
Relief Housing (2 Used)
Piston (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Spring Seat (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 39 -
W3-2-44
Spring (2 Used)
Spring Guide (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Nut (2 Used)
Set Screw (2 Used)
Socket Bolt (8 Used)
Cap (2 Used)
O-Ring (2 Used)
Spring Seat (2 Used)
Spring (2 Used)
40 41 42 43 44 45 46 47 48 49 50 51 -
W3-2-45
18
21 26
24
27 31
29
32
33
34
1719
10
11
20
22
2325
30
28
36
38
41
37
39
35
A
51
42
40
43
44
48
13
45
14
50
47
12
15
46
5
12345678910 11 12 13 -
Plug (2 Used)
O-Ring (2 Used)
Spring (2 Used)
Check Valve (2 Used)
Relief Valve (2 Used)
Plug
O-Ring
Spring
*Plug (6 Used)
*O-Ring (6 Used)
*Orifice (2 Used)
Socket Bolt (9 Used)
Valve Assembly
14 15 16 17 18 19 20 21 22 23 24 25 26 -
O-Ring
Plug
Poppet Seat (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Poppet (2 Used)
Relief Housing (2 Used)
Piston (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
Spring Seat (2 Used)
27 28 29 30 31 32 33 34 35 36 37 38 39 -
W3-2-46
Section A-A-A
Spring (2 Used)
Spring Guide (2 Used)
O-Ring (2 Used)
Backup Ring (2 Used)
O-Ring (2 Used)
Plug (2 Used)
Nut (2 Used)
Set Screw (2 Used)
Socket Bolt (8 Used)
Cap (2 Used)
O-Ring (2 Used)
Spring Seat (2 Used)
Spring (2 Used)
40 41 42 43 44 45 46 47 48 49 50 51 -
4
W1J1-03-02-005
W3-2-47
Cylinder
Block
W507-02-04-009
Piston
Shoe
W107-02-06-140
3. Clearance between inner diameter and outer diameter at the mounting position of case and piston:
(D-d): 0.03 mm (0.001 in) or less
Piston
Case
D
W3-2-48
W162-03-02-005
B
C
D
E
A
W105-03-07-042
Allowable Limit
86.4 (3.4)
138.9 (5.5)
-
W3-2-49
Unit: mm (in)
Remedy
Build up and
finishing
Unit: mm (in)
Remedy
Build up and
finishing
W3-2-50
Machine Front
Removal
W16J-03-03-002
Spindle
17
Center Joint
W3-3-1
10
Track
Frame
15
14
11
13
12
Machine Front
W16J-03-03-003
16
Center Joint
17
10
Track
Frame
15
14
11
13
W16J-03-03-003
12
Machine Front
Machine Front
W3-3-2
5
4
W16J-03-03-002
Spindle
W3-3-3
3
4
5
8
9
10
11
12
W16J-03-03-001
1 - Plug
2 - Spindle
3 - Dust Seal
4 - O-Ring
5 - Bushing
6 - Oil Seal (6 Used)
7 - Body
8 - Ring
9 - Retaining Ring
W3-3-4
10 - O-Ring
11 - Cover
12 - Bolt (4 Used)
ST 1020
ST 1033
12
W105-03-03-015
W183-03-03-004
IMPORTANT: While welding, cover the seal surface in order to prevent it from being
spattered.
9. When replacing bushing (5), build-up weld at 90
(4 places) in its inner diameter by using a welding
rod. Shrink and remove bushing (5).
W3-3-5
3
4
5
7
8
10
12
9
11
W183-03-08-001
1 - *Plug
2 - Spindle
3 - Dust Seal
4 - O-Ring
5 - Bushing
6 - Oil Seal (6 Used)
7 - Body
8 - Ring
9 - Retaining Ring
W3-3-6
10 - O-Ring
11 - Cover
12 - Bolt (4 Used)
W800-03-03-001
W800-03-03-002
W3-3-7
7
8
10
12
9
11
W183-03-08-001
W3-3-8
W3-3-9
W105-03-03-029
W3-3-10
Remedy
Replace
Replace
Replace
Bushing
T157-01-01-040
1)
2)
Sliding surface with
ring
3)
1)
Cover
2)
Sliding surface with
ring
3)
W3-3-11
Replace
Replace
Replace
Repair the surface
smooth
Repair the surface
smooth
W3-3-12
AND
INSTALL
TRACK
AD-
2
1
W142-03-04-002
Removal
3
W16J-03-04-002
Installation
2
W3-4-1
W1J1-03-04-003
View
3
4
5
7
8
9
10
11
12
13
14
15
W1J1-03-04-002
16
1234-
5678-
Wear Ring
U-Ring
Retaining Ring
Cylinder
910 11 12 -
W3-4-2
O-Ring
Spacer
Spring
Bracket
13 14 15 16 -
Nut
Bolt
Rod
Valve
3
4
5
17
18
7
15
8
10
9
11
12
13
16
14
12345-
678910 -
U-Ring
Retaining Ring
Cylinder
O-Ring
Spacer
11 12 13 14 -
W3-4-3
Spring
Bracket
Nut
Bolt
W1J1-03-04-004
15 16 17 18 -
Rod
Valve
Backup Ring
Plate
3
4
5
7
8
9
10
11
12
13
14
15
W1J1-03-04-002
16
W3-4-4
IMPORTANT: Compress the spring until the clearance between bracket (12) and nut
(13) is approximately 10 mm (0.4 in).
2. Loosen valve (16). Compress spring (11) of the
track adjuster by using special tool (ST 4932).
: 24 mm
Clearance 10 mm (0.4 in)
CAUTION: As the spring force of track adjuster is extremely large, carry out the disassembly and assembly work carefully.
Thoroughly inspect the special tool for any
damage in order to perform the work safely.
12
15
13
14
16
W142-03-04-020
Rest
W142-03-04-019
W3-4-5
10
11
12
W1J1-03-04-002
(ZAXIS500LC-3, 520LCH-3)
4
10
11
12
W1J1-03-04-004
W3-4-6
Eyebolt
11
11
Rest
W142-03-04-006
ST 4932
12
W142-03-04-005
11
Rest
W142-03-04-007
W3-4-7
7
8
9
10
11
12
(ZAXIS500LC-3, 520LCH-3)
2
15
W1J1-03-04-002
3
4
5
17
18
7
15
8
10
9
11
12
W1J1-03-04-004
W3-4-8
3
1
8
15
W142-03-04-010
W3-4-9
16
13
12
11
Grease Outlet
W1J1-03-04-001
14
12345-
15
678910 -
10
U-Ring
Retaining Ring
Cylinder
O-Ring
Spacer
Chamber B
11 12 13 14 -
Spring
Bracket
Nut
Bolt
W3-4-10
15 16 17 18 -
Chamber A
Rod
Valve
**Backup Ring
**Plate
3
W166-03-04-001
2
1
W142-03-04-018
15
9
W142-03-04-012
W3-4-11
12
11
Grease Outlet
W1J1-03-04-001
15
10
W3-4-12
CAUTION: The
Cylinder
(8)
assembly
weight:
ZAXIS450-3,
450LC-3,
470H-3,
470LCH-3: 75 kg (165 lb)
ZAXIS500LC-3, 520LCH-3: 102 kg (225 lb)
11
W142-03-04-006
ST 4932
10
11
12
Rest
W142-03-04-007
W142-03-04-005
W3-4-13
16
13
12
11
15
Grease Outlet
14
C mm
W3-4-14
W1J1-03-04-001
IMPORTANT:
13
15
11
14
ST 4932
16
12
W142-03-04-020
Wire
W142-03-04-015
W3-4-15
W3-4-16
Removal
CAUTION: Front idler weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
281 kg (619 lb)
ZAXIS500LC-3, 520LCH-3: 353 kg (778 lb)
W142-03-05-002
1. Pry and remove the front idler and yoke (4) from
track frame (1) by using a pry bar.
2. Attach a nylon sling to bearing (5) and yoke (4)
sections. Hoist and remove the front idler assembly from track frame (1).
3. Remove socket bolts (2) and remove guard (3)
from yoke (4).
: 19 mm
: 90 Nm (9.2 kgfm, 66 Ibfft)
4
3
W17P-03-05-001
Wooden Block
W3-5-1
W17P-03-05-001
W3-5-2
W3-5-3
1
8
3
6
10
11
6
5
4
12
3
14
13
8
1234-
Bearing (2 Used)
Pin (2 Used)
O-Ring (2 Used)
Axle
W1J1-03-05-001
5678-
9 - Guard
10 - Bolt (3 Used)
11 - Spring Washer (3 Used)
W3-5-4
12 - Yoke
13 - Bolt (4 Used)
14 - Spring Washer (4 Used)
2
1
5
4
3
10
11
5
8
1
12
14
W1J1-03-05-003
13
1234-
Bearing (2 Used)
Pin (2 Used)
O-Ring (2 Used)
Axle
5678-
9 - Guard
10 - Bolt (3 Used)
11 - Spring Washer (3 Used)
W3-5-5
12 - Yoke
13 - Bolt (4 Used)
14 - Spring Washer (4 Used)
1
8
3
6
10
11
6
5
4
12
3
14
13
8
W1J1-03-05-001
ZAXIS500LC-3, 520LCH-3
2
1
5
4
3
10
11
5
8
1
12
14
13
W3-5-6
W1J1-03-05-003
5
7
5
3
4
W105-03-05-008
W3-5-7
1
3
6
5
4
2
3
1
W1J1-03-05-001
ZAXIS500LC-3, 520LCH-3
2
1
5
4
3
5
1
W1J1-03-05-003
W3-5-8
ST 1973
3
W105-03-05-011
1
Wooden Block
3
W105-03-05-010
W3-5-9
10
14
13
11
12
W1J1-03-05-002
1234-
Bearing (2 Used)
Pin (2 Used)
O-Ring (2 Used)
Axle
5678-
9 - Guard
10 - Bolt (3 Used)
11 - Spring Washer (3 Used)
W3-5-10
12 - Yoke
13 - Bolt (4 Used)
14 - Spring Washer (4 Used)
W105-03-05-014
W3-5-11
10
14
13
11
12
W1J1-03-05-002
W3-5-12
7
1
4
W157-03-05-005
W3-5-13
E
A
W166-03-05-001
A
B
C
D
E
Standard
116 (4.6)
234 (9.2)
716 (28.2)
761 (30)
(22.5 (0.9)
Unit: mm (in)
Allowable Limit
Remedy
[88.4 (3.5)]
Cladding by welding
[689 (27.1)]
and finish or replace
32.5 (1.3)
Axle
Bushing
NOTE: Values in [
Standard
Allowable Limit
Outside Dia.
110 (4.33)
[109.2 (4.30)]
Inside Dia.
111 (4.37)
[112 (4.41)]
Flange Thickness
6 (0.24)
[5.2 (0.21)]
W3-5-14
Unit: mm (in)
Remedy
Replace
E
A
W166-03-05-001
A
B
C
D
E
Standard
116 (4.6)
234 (9.2)
716 (28.2)
761 (30)
(22.5 (0.9)
Unit: mm (in)
Allowable Limit
Remedy
[88.4 (3.5)]
Cladding by welding
[689 (27.1)]
and finish or replace
32.5 (1.3)
Axle
Bushing
NOTE: Values in [
Allowable Limit
Outside Dia.
Standard
110 (4.33)
Inside Dia.
111 (4.37)
[112 (4.41)]
Flange Thickness
6 (0.24)
[5.2 (0.21)]
W3-5-15
Unit: mm (in)
Remedy
[109.2 (4.30)]
Replace
W3-5-16
W105-03-06-001
Grease Outlet
W800-03-07-002
Oil Jack
3
W116-03-06-001
Wooden Block
W116-03-06-002
W3-6-1
6
W116-03-06-002
W116-03-06-003
Installation
CAUTION: Upper roller (3) weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
39 kg (86 lb)
ZAXIS500LC-3, 520LCH-3: 46.5 kg (102.5 lb)
3
W116-03-06-003
W116-03-06-002
W3-6-2
W800-03-07-002
W3-6-3
W105-03-06-008
90 to 110
W800-03-07-003
W105-03-06-001
W3-6-4
Grease Outlet
W800-03-07-002
5
W105-03-06-010
Installation
CAUTION: Lower roller (5) weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
80 kg (176 lb)
ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb)
W105-03-06-011
5
W105-03-06-012
W105-03-06-008
W3-6-5
W105-03-06-012
W800-03-07-002
W800-03-06-001
W3-6-6
W3-6-7
5
8
7
1
3
4
W166-03-06-006
3 - O-Ring (2 Used)
4 - Collar (2 Used)
5 - Pin (2 Used)
6 - Plug (2 Used)
W3-6-8
7 - Bushing (2 Used)
8 - Roller
1
4
W105-03-06-026
W105-03-06-027
ST 1955
W105-03-06-028
W3-6-9
W162-03-06-002
3 - O-Ring (2 Used)
4 - Collar (2 Used)
5 - Pin (2 Used)
6 - Plug (2 Used)
W3-6-10
7 - Bushing (2 Used)
8 - Roller
W157-03-06-009
W16J-03-06-001
4
1
W105-03-06-024
W157-03-06-008
W3-6-11
A
B
W166-03-06-007
Allowable Limit
160 (6.3)
Unit: mm (in)
Remedy
Replace
ZAXIS500LC-3, 520LCH-3
Standard
114 (4.5)
220 (8.7)
180 (7.1)
A
B
C
Allowable Limit
[170 (6.7)]
Remedy
Replace
Outside Dia.
Inside Dia.
Flange Thickness
Standard
60 (2.4)
61 (2.4)
4.5 (0.2)
Allowabel Limit
[59.2 (2.3)]
[62 (2.4)]
[3.7 (0.1)]
Outside Dia.
Inside Dia.
Flange Thickness
Standard
68 (2.7)
69 (2.7)
4.5 (0.2)
Allowabel Limit
[67.2 (2.6)]
[70 (2.8)]
[3.7 (0.1)]
ZAXIS500LC-3, 520LCH-3
Axle
Bushing
NOTE: The values in [
W3-6-12
Unit: mm (in)
Remedy
Replace
Unit: mm (in)
Remedy
Replace
W157-03-06-003
Allowable Limit
[249 (9.8)]
[17.5 (0.7)]
180 (7.1)
ZAXIS500LC-3, 520LCH-3
A
B
C
D
Standard
246 (9.7)
320 (12.6)
37 (1.5)
220 (8.7)
Allowable Limit
[283 (11.1)]
[18.5 (0.7)]
[202 (8.0)]
Unit: mm (in)
Remedy
Clad by welding and
finish or replace
Unit: mm (in)
Remedy
Clad by welding and
finish or replace
Outside Dia.
Inside Dia.
Flange Thickness
Standard
85 (3.3)
86 (3.4)
6 (0.2)
Allowable Limit
[84.2 (3.3)]
[87.0 (3.4)]
[5.2 (0.2)]
Outside Dia.
Inside Dia.
Flange Thickness
Standard
100 (3.9)
101 (4.0)
6 (0.2)
Allowable Limit
[99.2 (3.9)]
[102 (4.0)]
[5.2 (0.2)]
ZAXIS500LC-3, 520LCH-3
Axle
Bushing
NOTE: The values in [
W3-6-13
Unit: mm (in)
Remedy
Replace
Unit: mm (in)
Remedy
Replace
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACK
Removal
CAUTION: Grease pressure in the adjuster
cylinder is high. Do not loosen valve (2)
quickly or too much as valve (2) may fly off
or high-pressure grease in the cylinder may
gush out.
Keep body parts and face away from valve (2)
and loosen valve (2) carefully. Do not loosen
grease fitting (1).
Adjuster Cylinder
W800-03-07-027
Wooden Block
W105-03-07-006
W3-7-1
With Step
Pin
W800-03-07-004
UNDERCARRIAGE / Track
CAUTION: Shoe (5) weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
600 mm: 28 kg (62 lb)
750 mm: 36 kg (79 lb)
900 mm: 42 kg (93 lb)
ZAXIS500LC-3, 520LCH-3:
600 mm: 32 kg (71 lb)
600 mm (WG): 31 kg (68 lb)
750 mm: 40 kg (88 lb)
900 mm: 48 kg (106 lb)
6
5
7
3
5
7
Chain Block
W3-7-2
W1J7-03-07-002
UNDERCARRIAGE / Track
(Blank)
W3-7-3
UNDERCARRIAGE / Track
ASSEMBLE SPECIAL TOOL WHEN REMOVING AND INSTALLING MASTER PIN
13
14
12
11
10
9
Master Pin When
Removing
10
15
19
*Hose
*: Electric Pump
(ST 1531) Accessory
10
15
16
17
11
12
18
16
W1J7-03-07-001
10
9
8-
Hydraulic Cylinder
(ST 1512)
9 - Screw (2 Used) (ST 1516)
15 - Extension (3 Types)
(ST 1514)
16 - Nut (2 Used) (ST 1515)
W3-7-4
UNDERCARRIAGE / Track
Assemble Special Tool (ST 1532)
Removing and Installing Master Pin
When
10
W3-7-5
W1J7-03-07-005
UNDERCARRIAGE / Track
CAUTION: Special tool (ST 1532) when
removing and installing master pin weight:
150kg (330 lb)
12. Attach a nylon sling to screws (9) (2 used) in
special tool (ST 1532) when removing and
installing master pin and hoist special tool. Move
special tool (ST 1532) when removing and
installing master pin to the mounting position for
master pin (3). Adjust length of the nylon sling and
align adapter (14) and pusher (12) in special tool
(ST 1532) when removing and installing master
pin with master pin (3).
Nylon Sling
ST 1532
W1J7-03-07-003
14
12
ST 1532
Detail B
W1J7-03-07-004
16
10
9
17
15 (Inside)
W1J7-03-07-005
W3-7-6
UNDERCARRIAGE / Track
15. Remove special tool (ST 1532) when removing
and installing master pin and a chain block from
track link (6).
Chain Block
ST 1532
W1J7-03-07-003
90 to 110
Block
W800-03-07-003
Travel
Device
W105-03-07-011
W3-7-7
UNDERCARRIAGE / Track
Installation
CAUTION: The track assembly weight:
ZAXIS450-3, 470H-3:
600 mm: 2450 kg (5401 lb)
750 mm: 2810 kg (6195 lb)
ZAXIS450LC-3, 470LCH-3:
600 mm: 2470 kg (5445 lb)
750 mm: 3040 kg (6702 lb)
900 mm: 3380 kg (7452 lb)
ZAXIS500LC-3, 520LCH-3:
600 mm: 2975 kg (6559 lb)
600 mm (WG): 2915 kg (6426 lb)
750 mm: 3380 kg (7452 lb)
900 mm: 3745 kg (8256 lb)
W800-03-07-003
Block
Sprocket
Side
Idler Side
20
W105-03-07-014
Upper Roller
20
W105-03-07-011
W3-7-8
UNDERCARRIAGE / Track
5. After the track is attached to front idler (4), raise
the machine. Remove the block. Lower the
machine.
W1J7-03-07-007
5
W1J7-03-07-002
Chain Block
19
12
18
17
15
3
ST 1532
W3-7-9
W1J7-03-07-006
UNDERCARRIAGE / Track
CAUTION: Special tool (ST 1532) when
removing and installing master pin weight:
150 kg (330 lb)
Nylon Sling
9
ST 1532
W1J7-03-07-003
14
19
A
B
3
W1J7-03-07-006
16
10
9
W3-7-10
15
17
(Inside)
W1J7-03-07-005
UNDERCARRIAGE / Track
12. Remove special tool (ST 1532) when removing
and installing master pin and a chain block from
track link (6).
Nylon Sling
Chain Block
ST 1532
6
W1J7-03-07-003
5
7
7
5
W105-03-07-006
W800-03-07-027
W800-03-06-001
W3-7-11
UNDERCARRIAGE / Track
15. Remove extension (15), pilot (17), pusher (12)
and guide (18) from special tool (ST 1532) when
removing and installing master pin.
19
17
12
18
15
W1J7-03-07-006
10
9
8
10
9
Hose
W3-7-12
W1J7-03-07-005
UNDERCARRIAGE / Track
MAINTENANCE STANDARD
Link
Measure the length of four links.
1. Do not measure the part included the master pin.
2. Measure the length with tension on the track.
A
W155-03-07-001
Unit: mm (in)
Remedy
Cladding by welding and
finish or replace
Allowable Limit
[905.3 (35.6)]
[122 (4.8)]
Allowable Limit
[944.3 (37.2)]
[127.6 (5.0)]
Remedy
Cladding by welding and
finish or replace
[ ]Reference
Master Pin
C
W800-03-07-028
Allowable Limit
[44.3 (1.74)]
Allowable Limit
[45.5 (1.79)]
-
Unit: mm (in)
Remedy
Replace
Remedy
Replace
[
W3-7-13
]Reference
UNDERCARRIAGE / Track
Master Bushing
W105-03-07-023
Allowable Limit
[59.9 (2.36)]
[66.4 (2.61)]
Allowable Limit
[52.2 (2.06)]
[74.0 (2.91)]
Unit: mm (in)
Remedy
Replace
Remedy
Replace
[
]Reference
Grouser Shoe
W105-03-07-024
Allowable Limit
24 (0.9)
Allowable Limit
24 (0.9)
Unit: mm (in)
Remedy
Replace
Remedy
Replace
[
W3-7-14
]Reference
UNDERCARRIAGE / Track
Bushing
W105-03-07-023
Unit: mm (in)
Remedy
Allowable Limit
[49.4 (1.95)]
[66.4 (2.61)]
Replace
Allowable Limit
[50.6 (1.99)]
[74.0 (2.91)]
Remedy
Replace
[
]Reference
Pin
W142-03-07-004
Allowable Limit
[44.6 (1.76)]
Allowable Limit
[45.8 (1.80)]
W3-7-15
Unit: mm (in)
Remedy
Cladding by welding and
finish or replace
Remedy
Cladding by welding and
finish or replace
[ ]Reference
UNDERCARRIAGE / Track
(Blank)
W3-7-16
MEMO
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SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Hydraulic Circuit Pressure Release
Procedure............................................. W4-1-1
Remove and Install Front Attachment ........ W4-1-2
Remove and Install Bushing .................... W4-1-10
Maintenance Standard............................... W4-1-12
Standard Dimensions for
Arm and Bucket Connection .................... W4-1-15
Standard Dimensions for
Arm and Boom Connection .................. W4-1-16
Group 2 Cylinder
Remove and Install Cylinder ................... W4-2-1
Disassemble Cylinders ......................... W4-2-14
Assemble Cylinders.............................. W4-2-22
Maintenance Standard.......................... W4-2-28
1J1W-4-1
(Blank)
1J1W-4-2
PRESSURE
1
M1U1-01-029
W4-1-1
INSTALL
FRONT
Removal
1. Park the machine on a solid, level surface. Fully
retract the bucket and arm cylinders and lower
the front attachment onto the ground.
W1J1-04-01-001
W105-04-01-002
3
4
5
W166-04-01-005
Plate
W157-04-01-005
W4-1-2
8
9
12
10
11
11
M1J1-07-049
13
15
14
W105-04-01-007
W4-1-3
attachment
W105-04-01-008
17. Install a bar of special tool (ST 1975) into the hole
on boom foot pin (15). Install the nut. Remove
boom foot pin (15).
: 36 mm
15
ST 1975
Bar
Nut
W105-04-01-022
W157-04-01-004
W4-1-4
attachment
Mounting Hole of
Main Frame
W157-04-01-004
13
15
14
W105-04-01-007
7
8
12
11
W4-1-5
10
11
M1J1-07-049
W157-04-01-006
1
3
4
5
W166-04-01-005
W105-04-01-002
W4-1-6
Boom
Cylinder
Rod Side
Boom
Foot
Side
W166-04-01-102
M1J1-03-001
W4-1-7
Arm
14
Boom
16. Insert the shim between the arm and shim (14) so
that the clearance between shim and arm is
within 1.5 mm.
Shim thickness: 1.0 mm or 2.0 mm
17. After installing the arm, apply grease into the
boom/arm joint pin and the rod side of arm
cylinder by using a grease gun.
As for the machine attached with the auto
lubrication device (Optional), turn the auto
lubrication switch ON
W166-04-01-100
Boom / Arm
Joint Pin
Arm Cylinder
Rod Side
Boom / Arm
Joint Pin
W166-04-01-101
W4-1-8
W4-1-9
b
a
e
W166-04-02-005
Bucket
Link A
Arm
Link A
2
a: Bucket and Link A
W166-04-02-012
Boom
3
Link B
b: Link A
W166-04-02-014
W166-04-02-013
Arm
Bucket
Main Frame
Boom
Link B
1-
Dust Seal
2 - Bushing
3 - Spacer
W4-1-10
W4-1-11
d
c
g
h
k
j
W105-04-01-018
Position
a: Boom Cylinder and Main Frame
Item
Pin
Outer Dia.
Bushing Inner Dia. (Frame Side)
Bushing Outer Dia.
Bearing Inner Dia. (Cylinder Side)
Pin
Outer Dia.
Bushing Inner Dia. (Frame Side)
Bushing Outer Dia.
Bushing Inner Dia. (Boom Side)
Bushing Outer Dia.
Pin
Outer Dia.
Pin Hole Inner Dia. (Boom Side)
Bearing Inner Dia. (Cylinder Side)
W4-1-12
Standard
110 (4.33)
110 (4.33)
130 (5.12)
110 (4.33)
120 (4.72)
120 (4.72)
140 (5.51)
120 (4.72)
140 (5.51)
120 (4.72)
120 (4.72)
120 (4.72)
Unit: mm (in)
Allowable Limit
109 (4.29)
111.5 (4.39)
111.5 (4.39)
119 (4.69)
121.5 (4.78)
121.5 (4.78)
119 (4.69)
121.5 (4.78)
Position
d: Boom and Arm Cylinder
Item
Pin
Outer Dia.
Pin Hole Inner Dia. (Boom Side)
Bearing Inner Dia. (Cylinder Side)
Pin
Outer Dia.
Bushing Inner Dia. (Boom Side)
Bushing Outer Dia.
Bushing Inner Dia. (Arm Side)
Bushing Outer Dia.
Pin
Outer Dia.
Pin Hole Inner Dia. (Arm Side)
Bearing Inner Dia. (Cylinder Side)
Pin
Outer Dia.
Pin Hole Inner Dia. (Arm Side)
Bearing Inner Dia. (Cylinder Side)
Pin
Outer Dia.
Bushing Inner Dia. (Link A Side)
Bushing Outer Dia.
Bearing Inner Dia. (Cylinder Side)
Pin
Outer Dia.
Bushing Inner Dia. (Link A Side)
Bushing Outer Dia.
Bushing Inner Dia. (Bucket Side)
Bushing Outer Dia.
Pin
Outer Dia.
Bushing Inner Dia. (Arm Side)
Bushing Outer Dia.
Bushing Inner Dia. (Bucket Side)
Bushing Outer Dia.
Pin
Outer Dia.
Bushing Inner Dia. (Arm Side)
Bushing Outer Dia.
W4-1-13
Standard
110 (4.33)
110 (4.33)
110 (4.33)
120 (4.72)
120 (4.72)
140 (5.51)
120 (4.72)
140 (5.51)
110 (4.33)
110 (4.33)
110 (4.33)
100 (3.94)
100 (3.94)
100 (3.94)
110 (4.33)
110 (4.33)
130 (5.12)
110 (4.33)
110 (4.33)
110 (4.33)
130 (5.12)
110 (4.33)
130 (5.12)
110 (4.33)
110 (4.33)
130 (5.12)
110 (4.33)
130 (5.12)
100 (3.94)
100 (3.94)
115 (4.53)
Unit: mm (in)
Allowable Limit
109 (4.29)
111.5 (4.39)
119 (4.29)
121.5 (4.78
121.5 (4.78)
109 (4.29)
111.5 (4.39)
99 (3.90)
101.5 (4.00)
109 (4.29)
111.5 (4.39)
111.5 (4.39)
109 (4.29)
111.5 (4.39)
109 (4.29)
109 (4.29)
111.5 (4.39)
111.5 (4.39)
99 (3.90)
101.5 (4.00)
-
W166-04-01-011
Unit: mm (in)
Standard
305 (12.0)
40 (1.6)
A
B
Allowable Limit
200 (7.9)
-
Remedy
Replace
Point
D
A
W1J1-04-01-002
Unit: mm (in)
A
B
C
D
Standard
254 (10.0)
140 (5.5)
137 (5.4)
129 (5.1)
Allowable Limit
127 (5.0)
-
W4-1-14
Remedy
Replace
Section B
Section A
Unit: mm (in)
Model ZX450-3/500LC-3
ZX450
EX400-5
a
520 (20.47)
b
10 (0.39)
c
750 (29.53)
d
710 (27.95)
e
f
1911 (75.24)
1896 (74.65)
g
643 (25.32)
470.5 to 471.0
h
(18.52 to 18.54)
i
110 (4.33)
j
558 (21.97)
k
106 (4.17)
l
648 (25.51)
643 (25.32)
m
471 (18.54)
n
110 (4.33)
o
45
p
45
q
680 (26.77)
W4-1-15
W187-04-01-003
Section C
W187-04-01-002
Model ZX450-3/500LC-3
s
140 (5.51)
t
471 (18.54)
u
632 (24.88)
ZX450
W4-1-16
Unit: mm (in)
EX400-5
W4-2-1
W1J1-04-01-001
W1J1-04-01-003
A: Rod Side
Lubrication Hose
B: Bottom Side
1
3
4
Hydraulic Hose
2
7
W166-04-01-002
W166-04-01-003
2
3
5, 4
1
10
12
W166-04-01-005
123-
Pin
Washer (2 Used)
Stopper (2 Used)
7 - Pin (2 Used)
8 - Washer (2 Used)
9 - Bolt (2 Used)
W4-2-2
W162-04-01-025
11
10 - Spring Washer (2 Used)
11 - Spacer
12 - Shim
W4-2-3
W1J1-04-01-003
A: Rod Side
Lubrication Hose
B: Bottom Side
1
3
4
Hydraulic Hose
2
7
W166-04-01-002
W166-04-01-003
2
3
5, 4
1
10
12
W166-04-01-005
123-
Pin
Washer (2 Used)
Stopper (2 Used)
7 - Pin (2 Used)
8 - Washer (2 Used)
9 - Bolt (2 Used)
W4-2-4
W162-04-01-025
11
10 - Spring Washer (2 Used)
11 - Spacer
12 - Shim
W4-2-5
W1J1-04-01-003
Lubrication Hose
Hydraulic Hose
3
5
Lubrication Hose
Wooden Block
Boom
W166-04-01-004
1
W162-04-01-008
4
1
5
2
W166-04-01-006
12-
Pin (2 Used)
Arm Cylinder
3-
Bolt (2 Used)
4 - Stopper (2 Used)
W4-2-6
W4-2-7
W1J1-04-01-003
Lubrication Hose
Hydraulic Hose
3
5
Lubrication Hose
Wooden Block
Boom
W166-04-01-004
W162-04-01-008
4
1
5
2
W166-04-01-006
12-
Pin (2 Used)
Arm Cylinder
3-
Bolt (2 Used)
4-
W4-2-8
Stopper (2 Used)
5-
5. Hoist pin (1). Insert pin (1) into the pin hole on
cylinder rod side and install pin (1) to the arm.
Install bolt (3) and lock nuts (5) (2 used) to
stopper (4) in the arm.
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)
6. Install the lubrication hose to pin (1) at the rod
side of arm cylinder (2).
: 19 mm
: 29.5 Nm (3 kgfm, 22 lbfft)
7. When completing the work, operate the arm
cylinder several times to the stroke end and
release the pressure in the circuit.
W4-2-9
W1J1-04-01-003
Hydraulic Hose
Lubrication Hose
4
8
Arm
5
Wooden Block
W16J-04-02-001
W166-04-01-009
1
4
2
3
8
5
9
3
2
W166-04-01-007
123-
W166-04-01-006
Link A
Lock Nut (4 Used)
Bolt (2 Used)
4 - Bucket Cylinder
5 - Pin
67-
W4-2-10
Link B (2 Used)
Shim (2 Used)
89-
Pin
Stopper
W4-2-11
W1J1-04-01-003
Hydraulic Hose
Lubrication Hose
4
8
5
Wooden Block
Arm
W16J-04-02-001
W166-04-01-009
1
4
2
3
8
5
9
3
2
W166-04-01-007
4
W166-04-01-006
123-
Link A
Lock Nut (4 Used)
Bolt (2 Used)
4 - Bucket Cylinder
5 - Pin
67-
W4-2-12
Link B (2 Used)
Shim (2 Used)
89-
Pin
Stopper
5. Hoist pin (5). While aligning, insert pin (5) into the
pin hole on cylinder rod side. Install bolt (3) and
lock nuts (2) (2 used). Insert shim (7) so that the
maximum clearance between link A (1) and link B
(6) is 1.5 mm or smaller.
: 30 mm
: 400 Nm (41 kgfm, 295 lbfft)
6. Remove the wire to secure links B (6) (2 used) in
order not to drop. Start the engine. Remove the
wooden block set under link A (1).
7. After completing the work, operate the bucket
cylinder several times to the stroke end and
release the pressure in the circuit.
W4-2-13
2
8
9
10
11
6
7
12
13
14
15
13
12
16
17
18
W158-04-02-001
1
2
3
4
5
Cylinder Rod
Retaining Ring
Dust Seal
Seal
Ring
678910 -
Bushing
Retaining Ring
Socket Bolt (8 Used)
Cylinder Head
O-Ring
11
12
13
14
Cushion Ring
Teflon Ring (2 Used)
Wear Ring (2 Used)
Piston
W4-2-14
15
16
17
18
Seal Ring
Set Screw
Nut
Cylinder Tube
W102-04-02-027
W158-04-02-022
W4-2-15
14
21
22
1
13
23
2
3
4
5
6
7
8
9
10
11
12
W166-04-02-002
123456-
Cylinder Rod
Wiper Ring
Cylinder Head
Socket Bolt (8 Used)
Slide Ring
Backup Ring
78910 11 12 -
U-Ring
Buffer Ring
Bushing
Retaining Ring
Backup Ring
O-Ring
13 14 15 16 17 18 -
Set Screw
Steel Ball
Cushion Seal
Cushion Bearing
Piston
Slide Ring (2 Used)
W4-2-16
19 20 21 22 23 -
16
17
18
19
20
19
18
22
14
23
13
2
3
4
5
6
7
8
9
10
11
12
W166-04-02-003
123456-
Cylinder Rod
Wiper Ring
Cylinder Head
Socket Bolt (8 Used)
Slide Ring
Backup Ring
78910 11 -
U-Ring
Buffer Ring
Bushing
Retaining Ring
Backup Ring
12 13 14 16 17 -
O-Ring
Set Screw
Steel Ball
Cushion Bearing
Piston
W4-2-17
18 19 20 22 23 -
14
1
13
23
2
3
4
5
6
7
8
9
10
11
12
W166-04-02-002
W4-2-18
ST 5908
W158-04-02-022
W4-2-19
15
16
17
18
19
20
19
18
1
21
22
2
3
5
6
7
8
9
10
11
12
W166-04-02-002
W4-2-20
ST 5908
W158-04-02-022
W4-2-21
10
12 13
18
15
13
11
17
12
14
16
W158-04-02-002
1
2
3
4
5
Cylinder Rod
Retaining Ring
Dust Seal
Seal
Ring
678910 -
Bushing
Retaining Ring
Socket Bolt (8 Used)
Cylinder Head
O-Ring
11
12
13
14
Cushion Ring
Teflon Ring (2 Used)
Wear Ring (2 Used)
Piston
W4-2-22
15
16
17
18
Seal Ring
Set Screw
Nut
Cylinder Tube
ST 5908
W158-04-02-022
W4-2-23
Bucket Cylinder
1
8
9
10
10
6
7
4
11, 12
11, 12
3
3
23
23
16
16
Slit
18
15
18
19
17
20
19
17
19
20
18
19
21
14
22
18
13
22
14
13
W162-04-02-004
123456-
Cylinder Rod
Wiper Ring
Cylinder Head
Socket Bolt (8 Used)
Slide Ring
Backup Ring
78910 11 12 -
U-Ring
Buffer Ring
Bushing
Retaining Ring
Backup Ring
O-Ring
W162-04-02-005
13 14 15 16 17 18 -
Set Screw
Steel Ball
Cushion Seal
Cushion Bearing
Piston
Slide Ring (2 Used)
W4-2-24
19 20 21 22 23 -
W158-04-02-022
W4-2-25
Bucket Cylinder
1
4
4
3
3
23
23
16
16
Slit
15
17
17
14
21
14
22
22
13
13
W162-04-02-004
W4-2-26
W162-04-02-005
17. Install steel ball (14) to nut (22). Install set screw
(13).
: 8 mm
: 100 Nm (10 kgfm, 74 lbfft)
W4-2-27
inner
bore
in
tube
W145-04-01-015
Cylinder Rod
1. Rod Section (3)
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
by using a dial gauge. Measure the deflection in
three positions. If one measured deflection is 1
mm or more, replace the rod.
Check the surface for any damage.
Check the plated part for any rust.
Check the cushion part for any damage.
Piston
W166-04-02-023
Dial Gauge
Cylinder Rod
W166-04-02-022
1m
V Block
Boom
Arm
+0.063
0
190
+0.25
110 +0.05
-0.012
130 -0.061
+0.25
110 +0.05
170
110 +0.05
115 -0.027
120 +0.05
110
+0.25
100 +0.05
+0.031
120 -0.057
+0.25
110 +0.05
0.125/1000
W4-2-28
Bucket
+0.072
0
+0.063
0
+0.25
+0.027
+0.25
1. Pipe (5)
Check for any damage in depth more than 0.1
mm (0.004 in).
Check for any deformation and damage
2. Socket bolt (6)
Check for any heavy rust.
Check the thread for any damage.
7
7
3. Ring (7)
Replace O-ring when disassembling.
T182-05-02-004
W4-2-29
W4-2-30
MEMO
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MODEL:
PUBLICATION NO.:
YOUR NAME:
DATE:
FAX:
PAGE NO.:
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