hitachi zx 210w-3, 220w-3

INTRODUCTION

IN-01

TO THE READER • This manual is written for an experienced technician

to provide technical information needed to maintain and repair this machine.

• Be sure to thoroughly read this manual for cor-

rect product information and service procedures.

• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this man-ual. (Note: Do not tear off the form. Copy it for us-age.):

Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7084 FAX: 81-29-831-1162

ADDITIONAL REFERENCES • Please refer to the materials listed below in addition

to this manual.

• The Operator’s Manual • The Parts Catalog

• The Engine Manual • Parts Catalog of the Engine • Hitachi Training Material

MANUAL COMPOSITION • This manual consists of three portions: the Techni-

cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Man-ual.

• Information included in the Technical Manual

(Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.

• Information included in the Technical Manual (Troubleshooting): technical information needed for operational per-formance tests, and troubleshooting procedures.

• Information included in the Workshop Manual:

technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assem-ble/disassemble procedures.

PAGE NUMBER • Each page has a number, located on the center

lower part of the page, and each number contains the following information: Example : T 1-3-5

Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual W: Workshop Manual

INTRODUCTION

IN-02

SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropri-ate lifting techniques and equipment when lifting heavy parts.

• CAUTION:

Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

• IMPORTANT:

Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

• NOTE: Indicates supplementary technical information or know-how.

UNITS USED • SI Units (International System of Units) are used in

this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Example : 24.5 MPa (250 kgf/cm2, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposees.

Quantity To Convert From Into Multiply By

MPa kgf/cm2 10.197 Pressure MPa psi 145.0 kW PS 1.360 Power kW HP 1.341

Temperature °C °F °C×1.8+32 km/h mph 0.6214 Velocity min-1 rpm 1.0

Flow rate L/min US gpm 0.2642 mL/rev cc/rev 1.0

Quantity To Convert From Into Multiply By

mm in 0.03937 Length mm ft 0.003281 L US gal 0.2642 L US qt 1.057

Volume

m3 yd3 1.308 Weight kg lb 2.205

N kgf 0.10197 Force N lbf 0.2248

N⋅m kgf⋅m 1.0197 Torque N⋅m lbf⋅ft 0.7375

SAFETY

SA-1

SA-688

SA-1223

RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.

• Follow recommended precautions and safe operating practices.

001-E01A-0001

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs are located near spe-cific hazards. General precautions are listed on CAUTION safety signs.

• Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the ma-chine.

• NOTE indicates an additional explanation for an element of information.

002-E01A-1223

SAFETY

SA-2

FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine and all safety messages in this manual.

• Safety signs should be installed, maintained and replaced when necessary.

• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

• Learn how to operate the machine and its controls correctly and safely.

• Allow only trained, qualified, authorized personnel to oper-ate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.

• Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, func-tion, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy.

• Do not use attachments and/or optional parts or equip-ment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy.

• The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazard-ous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your autho-rized dealer before operating or performing maintenance work on the machine.

003-E01B-0003

SA-003

SAFETY

SA-3

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.• Thoroughly read and understand the label attached on

the fire extinguisher to use it properly.• To ensure that a fire-extinguisher can be always used

when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual.

• Establish emergency procedure guidelines to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your tele-phone.

004-E01A-0437

WEAR PROTECTIVE CLOTHING

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

You may need:A hard hatSafety shoesSafety glasses, goggles, or face shieldHeavy glovesHearing protectionReflective clothingWet weather gearRespirator or filter mask.

Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

005-E01A-0438

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective device such as ear-muffs or earplugs to protect against objectionable or uncomfortably loud noises.

006-E01A-0434

SA-437

SA-434

SAFETY

SA-4

INSPECT MACHINE

• Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.

• In the walk-around inspection be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.

007-E01A-0435

GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal ac-cident.

• Do not leave parts and/or tools lying around the operator’s seat. Store them in their specified locations.

• Avoid storing transparent bottles in the cab. Do not at-tach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly start-ing a fire.

• Refrain from listening to the radio, or using music head-phones or mobile telephones in the cab while operating the machine.

• Keep all flammable objects and/or explosives away from the machine.

• After using the ashtray, always cover it to extinguish the match and/or tobacco.

• Do not leave cigarette lighters in the cab. When the tem-perature in the cab increases, the lighter may explode.

524-E01A-0000

SA-435

SAFETY

SA-5

USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.

• When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.

• Do not use any controls as hand-holds.• Never jump on or off the machine. Never mount or dis-

mount a moving machine.• Be careful of slippery conditions on platforms, steps, and

handrails when leaving the machine.

008-E01A-0439

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations.

• The seat should be adjusted whenever changing the op-erator for the machine.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.

• If not, move the seat forward or backward, and check again.

• Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAV-ING OPERATOR’S SEAT

• Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.

• Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.

• Before leaving the machine, close all windows, doors, and access covers and lock them up.

SA-439

SA-378

SAFETY

SA-6

FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the opera-tor may be crushed by the overturning machine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly examine web-bing, buckle and attaching hardware. If any item is dam-aged or worn, replace the seat belt or component before operating the machine.

• Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.

• We recommend that the seat belt be replaced every three years regardless of its apparent condition.

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or oper-ating the machine.

• Always keep the travel alarm and horn in working condi-tion (if equipped). It warns people when the machine starts to move.

• Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.

• Use appropriate illumination. Check that all lights are op-erable before operating the machine. If any faulty illumi-nation is present, immediately repair it.

011-E01A-0398

HANDLE STARTING AIDS SAFELY

Starting fluid:

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.• Keep starting fluid well away from batteries and cables.• Remove container from machine if engine does not need

starting fluid.• To prevent accidental discharge when storing a pressur-

ized container, keep the cap on the container, and store it in a cool, well-protected location.

• Do not incinerate or puncture a starting fluid container.

036-E01A-0293-3

SA-237

SA-083

SA-293

SAFETY

SA-7

OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.

• Start the engine only when seated in the operator's seat.• NEVER start the engine while standing on the track or on

ground.• Do not start engine by shorting across starter terminals.• Before starting the engine, confirm that all control levers

are in neutral.• Before starting the engine, confirm the safety around the

machine and sound the horn to alert bystanders.

012-E01B-0431

JUMP STARTING

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chap-ter in the operator’s manual.

• The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation.

• Never use a frozen battery.• Failure to follow correct jump starting procedures could

result in a battery explosion or a runaway machine.

S013-E01A-0032

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.

• Only the operator should be on the machine. Keep riders off.

• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

014-E01B-0427

SA-084

SA-032

SA-091

SAFETY

SA-8

PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.

• Be sure to wear close fitting clothing and safety equip-ment appropriate for the job, such as a hard hat, etc. when operating the machine.

• Clear all persons and obstacles from area of operation and machine movement.

Always beware of the surroundings while operating. When working in a small area surrounded by obstacles, take care not to hit the upperstructure against obstacles.

• When loading onto trucks, bring the bucket over the truck beds from the rear side. Take care not to swing the bucket over the cab or over any person.

M202-05-014

SAFETY

SA-9

INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from fall-ing and to prevent the ground, stockpiles, or banks from collapsing.

• Make a work plan. Use machines appropriate to the work and job site.

• Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excava-tions and road shoulders.

• When working on an incline or on a road shoulder, em-ploy a signal person as required.

• Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist.

• When the footing is weak, reinforce the ground before starting work.

• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.

• Beware the possibility of fire when operating the machine near flammable objects such as dry grass.

• Make sure the worksite has sufficient strength to firmly sup-port the machine.

When working close to an excavation or at road shoulders, operate the machine with the tracks positioned perpendicu-lar to the cliff face with travel motors at the rear, so that the machine can more easily evacuate if the cliff face collapses.

• If working on the bottom of a cliff or a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work on the area.

• Soft ground may collapse when operating the machine on it, possibly causing the machine to tip over. When working on a soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong and firm enough to easily support the machine.

• Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. When operating on rough terrain or on slopes:

• Reduce the engine speed.• Select slow travel speed mode.• Operate the machine slowly and be cautious with ma-

chine movements.

SA-085

M202-05-015

SAFETY

SA-10

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 StructureFOPS: Falling Object Protective Structure

PROVIDE SIGNALS FOR JOBS INVOLVING MUL-TIPLE NUMBERS OF MACHINES

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

018-E01A-0481

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN

• Incorrect steering wheel/forward/reverse pedal operation may result in serious injury death.

• Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when steering wheel is operated to the front.

017-E01A-0491

SA-686

SA-481

SA-092

SAFETY

SA-11

DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the steer-ing wheel/forward/reverse switch direction corresponds to the direction you wish to drive.

• Be sure to detour around any obstructions.• Avoid traveling over obstructions. Soil, fragments of rocks,

and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling.

• Driving on a slope may cause the machine to slip or over-turn, possibly resulting in serious injury or death.

• Never attempt to ascend or descend 35 degrees or steep-er slopes.

• Be sure to fasten the seat belt.• When driving up or down a slope, keep the bucket fac-

ing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground.

• If the machine starts to skid or becomes unstable, imme-diately lower the bucket to the ground and stop.

AVOID INJURY FROM ROLLAWAY ACCIDENTS

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

To avoid rollaways:• Select level ground when possible to park machine.• Do not park the machine on a grade.• Lower the bucket and/or other work tools to the ground.• Place FNR switch in neutral, and put the brake switch in

the P (parking brake) position.• Turn the auto-idle switch off.• Run the engine at slow idle speed without load for 5 min-

utes to cool down the engine.• Stop the engine and remove the key from the key switch.• Pull the pilot control shut-off lever to LOCK position.• Block both tires and lower the bucket to the ground.

Thrust the bucket teeth into the ground if you must park on a grade.

• Position the machine to prevent rolling.• Park a reasonable distance from other machines.

020-E02A-0493

SA-090

SA-288

SA-278

SAFETY

SA-12

AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS

• If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:• Always look around BEFORE YOU BACK UP AND SWING

THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.

• Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE

WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.

• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW.

Use hand signals, which conform to your local regulations, when work conditions require a signal person.

• No machine motions shall be made unless signals are clearly understood by both signalman and operator.

• Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.

• Keep windows, mirrors, and lights clean and in good con-dition.

• Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

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

021-E01A-0494

SA-383

SA-384

SAFETY

SA-13

KEEP PERSON CLEAR FROM WORKING AREA

• A person may be hit severely by the swinging front attach-ment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.

• Keep all persons clear from the area of operation and machine movement.

• Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent any-one from entering the work area.

022-E01A-0386

NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a truck cab.

Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

023-E01A-0487

AVOID UNDERCUTTING

• Always confirm that ground conditions are strong enough to support the machine weight when operating near a cliff. Operate the machine with the chassis frame positioned perpendicular to the cliff face so that the machine can more easily evacuate if the cliff face collapses.

• If the footing starts to collapse and if retreat is not pos-sible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.

024-E01A-0488

M202-05-014

SA-682

SA-683

SAFETY

SA-14

AVOID TIPPING

DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA-CHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULTMACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping:• Be extra careful before operating on a grade.

• Prepare machine operating area flat.• Keep the bucket low to the ground and close to the ma-

chine.• Reduce operating speeds to avoid tipping or slipping.• Avoid changing direction when traveling on grades.• NEVER attempt to travel across a grade steeper than 15

degrees if crossing the grade is unavoidable.• Reduce swing speed as necessary when swinging loads.

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become soft and make ground travel unstable.

025-E03B-0463

NEVER UNDERCUT A HIGH BANK

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

026-E01A-0519

SA-088

SA-684

SA-685

SAFETY

SA-15

DIG WITH CAUTION

• Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.

• Before digging check the location of cables, gas lines, and water lines.

• Keep the minimum distance required, by law, from cables, gas lines, and water lines.

• If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

• Contact your local “diggers hot line” if available in your area , and/or the utility companies directly.

Have them mark all underground utilities.

027-E01A-0382

OPERATE WITH CAUTION

• If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the boom or arm.

028-E01A-0389

SA-086

SA-087

SAFETY

SA-16

AVOID POWER LINES

• Serious injury or death can result if the machine or front at-tachments are not kept a safe distance from electric lines.

• When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.

• Check and comply with any local regulations that may ap-ply.

• Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.

029-E01A-0381

PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.

• In the event of an electrical storm, immediately stop op-eration, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.

• After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repair-ing them.

OBJECT HANDLING

• If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, result-ing in serious injury or death.

• When using the machine for craning operations, be sure to comply with all local regulations.

• Do not use damaged chains or frayed cables, sables, slings, or ropes.

• Before craning, position the upperstructure with the travel motors at the rear.

• Move the load slowly and carefully. Never move it sud-denly.

• Keep all persons well away from the load.• Never move a load over a person's head.• Do not allow anyone to approach the load until it is safely

and securely situated on supporting blocks or on the ground.

• Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.

032-E01A-0132

SA-089

SA-1241

SA-014

SAFETY

SA-17

PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body, serious injury may result.

• Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

• Keep bystanders away from the working area before strik-ing any object.

031-E01A-0432

PARK MACHINE SAFELY

To avoid accidents:• Park machine on a firm, level surface.• Lower bucket to the ground.• Place FNR switch in neutral, and put the brake switch in

the P (parking brake) position.• Turn auto-idle switch OFF.• Run engine at slow idle speed without load for 5 minutes.• Turn key switch to OFF to stop engine.• Remove the key from the key switch.• Pull the pilot control shut-off lever to the LOCK position.• Close windows, roof vent, and cab door.• Lock all access doors and compartments.

HANDLE FLUIDS SAFELY−AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when near open flame or sparks.

• Always stop the engine before refueling the machine. • Fill the fuel tank outdoors.

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

• Store flammable fluids well away from fire hazards.• Do not incinerate or puncture pressurized containers.• Do not store oily rags; they can ignite and burn spontane-

ously.• Securely tighten the fuel and oil filler cap.

034-E01A-0496

SA-432

SA-093

SA-018

SA-019

SAFETY

SA-18

TRANSPORT SAFELY

• Take care the machine may turn over when loading or un-loading the machine onto or off of a truck or trailer.

• Observe the related regulations and rules for safe trans-portation.

• Select an appropriate truck or trailer for the machine to be transported.

• Be sure to use a signal person.• Always follow the following precautions for loading or

unloading:1. Select solid and level ground.

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

3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the travel mode switch.

5. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp.

6. Never steer the machine while on the ramp. If the travel-ing direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

7. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it.

8. Place blocks in front of and behind the tires. Securely hold the machine to the truck or trailer deck with wire ropes.

Be sure to further follow the details described in the TRANS-PORTING section.

035-E07A-0454

SA-094

SA-095

Less than 15°

Less than 15°

SAFETY

SA-19

PRACTICE SAFE MAINTENANCE

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

parts.

Before servicing the machine:1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

4. Run the engine at slow idle speed without load for 5 min-utes.

5. Turn the key switch to OFF to stop engine.

6. Relieve the pressure in the hydraulic system by moving the control levers several times.

7. Remove the key from the switch.

8. Attach a “Do Not Operate” tag on the control lever.

9. Pull the pilot control shut-off lever to the LOCK position.

10. Allow the engine to cool.

• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.

• If the machine must be raised, maintain a 90 to 100˚ angle between the boom and arm. Securely support any ma-chine elements that must be raised for service work.

• Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter in the operator’s manual.

• Keep all parts in good condition and properly installed.• Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.• When cleaning parts, always use nonflammable detergent

oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.

• Disconnect battery ground cable (−) before making adjustments to electrical systems or before performing welding on the machine.

500-E02C-0520

SA-028

SA-527

SAFETY

SA-20

• Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.

• Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

501-E01A-0287

SUPPORT MACHINE PROPERLY

• Never attempt to work on the machine without securing the machine first.

• Always lower the attachment to the ground before you work on the machine.

• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not sup-port the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

519-E01A-0527

STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious injury.

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

502-E01A-0026

SA-037

SS2045102SS3076175

SA-527

SA-026

SAFETY

SA-21

PREVENT PARTS FROM FLYING

• Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.

• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

503-E01B-0344

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

504-E01A-0034

SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can cause seri-ous injury or death.

• Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service.

• Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure.

• When inflating tires, use a chip-on chuck and exten-sion hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available.

• Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts.

• Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion.

521-E02A-0249

SA-344

SA-034

SA-249

SAFETY

SA-22

PREVENT BURNS

Hot spraying fluids:

• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.

• To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pres-sure to be released before removing the cap.

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting any maintenance or inspection work.

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)

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

S506-E01A-0019

SA-039

SA-225

SA-019

SAFETY

SA-23

AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before disconnect-ing hydraulic or other lines.

• Tighten all connections before applying pressure.• Search for leaks with a piece of cardboard; take care to

protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gan-grene may result.

507-E03A-0499

SA-031

SA-292

SA-044

SAFETY

SA-24

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.

Check for Shorts:• Short circuits can cause fires.

• Clean and tighten all electrical connections.• Check before each shift or after eight(8) to ten(10) hours

operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight(8) to ten(10) hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc..

Clean up Flammables:• Spilled fuel and oil, and trash, grease, debris, accumulated

coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.

Check Key Switch:• If a fire breaks out, failure to stop the engine will escalate

the fire, hampering fire fighting.

Always check key switch function before operating the ma-chine every day:

1. Start the engine and run it at slow idle.

2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine.

508-E02B-0019

Check Heat Shields:• Damaged or missing heat shields may lead to fires.

• Damaged or missing heat shields must be repaired or replaced before operating the machine.

508-E02A-0393

SA-019

SAFETY

SA-25

EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the following way:

• Stop the engine by turning the key switch to the OFF position if there is time.

• Use a fire extinguisher if there is time.• Exit the machine.

• In an emergency, if the cab door or front window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer the explanation pages on the Emergency Evacuation Method.

18-E02B-0393

BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause sick-ness or death.

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

509-E01A-0016

PRECAUTIONS FOR WELDING AND GRINDING

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and pre-pared area. Store flammable objects in a safe place before starting welding.

• Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.

• Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding.

• After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

523-E01A-0818

SA-393

SS-1510

SA-016

SA-818

SAFETY

SA-26

AVOID HEATING NEAR PRESSURIZED FLUID LINES

• Flammable spray can be generated by heating near pres-surized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS

• Do not weld or flame cut pipes or tubes that contain flam-mable fluids.

• Clean them thoroughly with nonflammable solvent be-fore welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.• Do all such work outside or in a well-ventilated area. Dis-

pose of paint and solvent properly.

• Remove paint before welding or heating:1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

511-E01A-0029

SA-030

SA-029

SAFETY

SA-27

BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work site. Inha-lation of asbestos fibers may be the cause of lung cancer.

• Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air.

• When operating the machine in a work site where asbes-tos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.

• Keep bystanders out of the work site during operation.• Asbestos might be present in imitation parts. Use only

genuine Hitachi Parts.

PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.

• Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode. Warm the battery to 16˚C ( 60˚ F ) first.

• Do not continue to use or charge the battery when elec-trolyte level is lower than specified. Explosion of the bat-tery may result.

• Loose terminals may produce sparks. Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should ex-plode, battery electrolyte may be splashed into eyes, pos-sibly resulting in blindness.

• Be sure to wear eye protection when checking electrolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM SAFELY

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

• Refer to the instructions described on the container for proper use when handling the refrigerant.

• Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.

• Never touch the refrigerant.

513-E01A-0405

SA-029

SA-032

SA-405

SAFETY

SA-28

HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your ma-chine include such items as lubricants, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides specific de-tails on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a hazard-ous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow proce-dures and use recommended equipment.

• See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine.

515-E01A-0309

DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the environ-ment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

• Do not pour waste onto the ground, down a drain, or into any water source.

• Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

516-E01A-0226

SA-309

SA-226

SAFETY

SA-29

BEFORE RETURNING THE MACHINE TO THE CUS-TOMER

• After maintenance or repair work is complete, confirm that:

• The machine is functioning properly, especially the safety systems.

• Worn or damaged parts have been repaired or replaced

S517-E01A-0435

SA-435

SAFETY

SA-30

(Blank)

SECTION AND GROUP CONTENTS

WORKSHOP MANUAL

All information, illustrations and speci-fications 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)2007

Hitachi Construction Machinery Co., Ltd. Tokyo, Japan

All rights reserved

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

SECTION 2 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Pilot Valve Group 8 Electric Lever Group 9 Signal Control Valve Group 10 Travel Shockless Valve Group 11 Solenoid Valve Group 12 Pilot Shut-Off Solenoid Valve Group 13 Steering Valve Group 14 Brake Valve Group 15 Accumulator Charging Valve

SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Motor Group 3 Center Joint Group 4 Transmission Group 5 Axle Group 6 Axle Lock Cylinder Group 7 Operate-Check Valve Group 8 Solenoid Valve Group 9 Transmission Changeover Solenoid ValveGroup 10 Propeller Shaft

SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Hose-Rupture Valve Group 4 Operate-Check Valve

TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL

Group 1 Specifications Group 2 Component Layout Group 3 Component Specifications

SECTION 2 SYSTEM Group 1 Controller Group 2 Control System Group 3 ECM System Group 4 Hydraulic System Group 5 Electrical System

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Electric Lever Group 6 Transmission Group 7 Axle Group 8 Travel Motor Group 9 Signal Control Valve Group 10 Steering Valve Group 11 Brake Valve Group 12 Others (Upperstructure) Group 13 Others (Undercarriage)

TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PER-

FORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Unit Group 3 Dr. ZX Group 4 ICF Group 5 Component Layout Group 6 Troubleshooting A Group 7 Troubleshooting B Group 8 Electrical System Inspection

CJBW-1-1

SECTION 1

GENERAL

— CONTENTS — Group 1 Precautions for Disassembling

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

Group 2 Tightening

Tightening Torque Specification.................. W1-2-1 Torque Chart................................................ W1-2-3 Piping Joint .................................................. W1-2-6 Periodic Replacement of Parts ............... W1-2-10

Group 3 Painting

Painting ................................................... W1-3-1 Group 4 Bleeding Air from Hydraulic Oil

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

CJBW-1-2

(Blank)

GENERAL / Precautions for Disassembling and Assembling

W1-1-1

PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING

Precautions for Disassembling and Assembling • Clean the Machine

Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.

• Inspect the Machine

Be sure to thoroughly understand all disassem-bling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future.

• The machine model, machine serial number, and

hour meter reading. • Reason for disassembly (symptoms, failed parts,

and causes). • Clogging of filters and oil, water or air leaks, if

any. • Capacities and condition of lubricants. • Loose or damaged parts.

• Prepare and Clean Tools and Disassembly Area

Prepare the necessary tools to be used and the area for disassembling work.

• Precautions for Disassembling

• To prevent dirt from entering, cap or plug the

removed pipes. • Before disassembling, clean the exterior of the

components and place on a work bench. • Before disassembling, drain gear oil from the

reduction gear. • Be sure to provide appropriate containers for

draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when

instructed. • If a part or component cannot be removed after

removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it.

• Orderly arrange disassembled parts. Mark and tag them as necessary.

• Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss.

• Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage.

• Measure and record the degree of wear and clearances.


W1-1-2

• Precautions for Assembling • Be sure to clean all parts and inspect them for

any damage. If any damage is found, repair or replace part.

• Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces.

• Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing.

• Be sure that liquid-gasket-applied surfaces are clean and dry.

• If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent.

• Utilize matching marks when assembling. • Be sure to use the designated tools to assemble

bearings, bushings and oil seals. • Keep a record of the number of tools used for

disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine.

Bleeding Air from Hydraulic System When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and in-stallation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures:

IMPORTANT: If the engine is started with air

trapped in the hydraulic pump hous-ing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the mo-tor may result. If the cylinder is operated with air trapped in the cylinder tube, dam-age to the cylinder may result. Be sure to bleed air before starting the engine.

• Bleeding Air from Hydraulic Pump

• Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil.

• After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the en-gine and run at slow idle speed.

• Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out.

• After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor / Swing Motor

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


W1-1-3

• Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each op-eration (never fully stroke the cylinders during ini-tial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes.

• Reposition the front attachment to check hydrau-lic oil level.

• Stop the engine. Recheck hydraulic oil level. Re-plenish oil as necessary.

WCJB-01-04-001


W1-1-4

Floating Seal Precautions

1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures:

(1) Keep seal rings together as a matched set

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

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

scuffing, scoring, corrosion, deformation or uneven wear.

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

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.

(1) Clean the floating seal and seal mounting

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

(2) Clean the floating seal and seal mounting

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

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

is installed correctly on the seal ring. (4) After installing the floating seal, check that

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

W105-03-05-019

W105-03-05-020

W110-03-05-004

a≠b

b b

aa

a=b

C

A

B

Incorrect Correct

Incorrect

Correct

A

B


W1-1-5

Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings safely.

• Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping.

• Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight.

• Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet.

The load may slip. • When required to use more than one sling, use

slings with the same width and length to keep the lifted load balanced.

• When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force.

• Avoid using twisted, bound, connected, or hitched slings.

• Do not place any object on twisted or bent slings. (Refer to the right illustration.)

• When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions.

• Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object.

• When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged.

• Store the nylon slings indoors so they won’t dete-riorate with heat, sun light, or chemicals.

W102-04-02-016

W105-04-01-008

W162-01-01-009

Correct Eyehole Lifting Method

Incorrect Eyehole Lifting Method

Bent Sling


W1-1-6

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

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

Damaged Appearance

W162-01-01-002

W162-01-01-003

W162-01-01-004

W162-01-01-005

W162-01-01-006

W162-01-01-007

W162-01-01-008

Broken Sewing Thread

Scuffing


Fuzz

Broken SewingThread

Separation of Belt


Scuffing

Scoring

Broken Warp Fuzz


W1-1-7

MAINTENANCE STANDARD TERMINOL-OGY

“Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies

adjusted to specification.

“Allowable Limit” 1. Normal machine performance cannot be accom-

plished after exceeding this limit. 2. Repair or adjustment is impossible after exceed-

ing this limit. 3. Therefore, in consideration of operation efficiency

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


W1-1-8

(Blank)

GENERAL / Tightening

W1-2-1

TIGHTENING TORQUE SPECIFICATION

Bolt Dia Torque No. Descriptions

mm Q’ty

Wrench Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)

(Pump Upper) 18 2 27 360 (37) (265) Engine cushion rubber mounting bolt (Pump Lower) 16 4 24 210 (21.5) (155) 1 Engine cushion rubber mounting nut (Fan Side) 14 4 22 140 (14.0) (103)

2 Engine bracket mounting bolt and nut 10 8 17 50 (5.1) (37) 3 Hydraulic oil tank mounting bolt 16 4 24 210 (21.5) (155) 4 Fuel tank mounting bolt 16 4 24 210 (21.5) (155)

5 ORS and metal face seal fittings for hydraulic hoses and piping

17 19 22 27 32 36 41

24.5 30 40 95

140 175 210

(2.5) (3.1) (4.1) (9.7)

(14.3) (17.8) (21.5)

(18) (22) (30) (70)

(105) (130) (155)

6 Pump mounting bolt 10 8 17 50 (5.1) (37) 7 Control valve mounting bolt 16 4 24 210 (21.5) (155) 8 Control valve bracket mounting bolt 16 4 24 210 (21.5) (155) 9 Swing device mounting bolt 20 12 30 500 (51) (370)

10 Swing motor mounting bolt 12

(Hex. Wrench)

8 10 90 (9.2) (66)

11 Battery mounting nut 10 2 17 50 (5.1) (37) Cab mounting nut 16 4 24 210 (21.5) (155) 12

13 Swing bearing mounting bolt to upperstructure 20 32 30 510 (52) (380) Swing bearing mounting bolt to chassis 20 36 30 490 (50) (360)

14 Center joint lock mounting bolts 16 5 24 270 (27.5) (200) 15 - - - - - -

16 Travel motor mounting bolts 16

(Hex. Wrench)

4 14 270 (27.5) (200)

17 Propel shaft mounting nuts 10 16 14 76 (8) (60) 18 Center Bearing mounting bolt 10 2 17 50 (5.1) (37) 19 Rear axle mounting bolts 24 8 36 950 (97.0) (700) 20 Wheel pin nuts 22 40 30 600 (61) (440)

21 Cover mounting bolt 6

10 12

- - -

10 17 19

10 50 90

(1) (6.1) (9.2)

(7.4) (37) (66)

22 Flexible master coupling of piping 8 4 pairs 13 10.3 to 12.4 (1.05 to 1.26)

(7.59 to 9.11)

23 Jubilee Clamp of low pressure piping T-bolt clamp of low pressure piping

- -

- -

7 11

5.9 5.9

(0.6) (0.6)

(4.3) (4.3)

Apply LOCTITE to the threads.


W1-2-2

NOTE 1.Apply lubricant (e.g. white zinc B dis-solved into spindle oil) to bolts and nuts to reduce friction coefficient of them. (Except for Sprocket mounting bolt.)

2.Make sure bolt and nut threads are clean before installing.


W1-2-3

TORQUE CHART

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

Bolt Types Tighten nuts or bolts correctly to torque specifications. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or compo-nents.

SA-040

W162-01-01-001

Specified Tightening Torque Chart

M552-07-091

Socket Bolt M552-07-090

M552-07-092

Bolt Dia. Wrench

Size

Hexagon Wrench

Size

N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)M8 13 6 30 (3.0) (21.5) 20 (2.0) (14.5) 10 (1.0) (7.2)

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

Socket Bolt Hexagon M Bolt Hexagon H BoltHexagon T Bolt


W1-2-4

IMPORTANT: The following items are applied to both fine and coarse pitch threads.

1. Apply lubricant (i. e. white zinc B dissolved Into Spindle oil) to nuts and bolts to reduce their friction coefficients. The plated bolts require no lu-bricant.

2. Torque tolerance is ±10 %. 3. Be sure to use bolts of correct

length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force.

4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific ap-plication.

5. Make sure that nut and bolt threads are clean before install-ing.

Remove dirt or corrosion, if any.

Bolt Tightening Order When tightening two or more bolts, tighten them al-ternately, as shown, to ensure even tightening.

W105-01-01-003

16

42

3

Equally tighten upper and lower alternately Tighten diagonally Tighten from center and diagonally

1st to 4th

2nd to 3rd

13 11 10

14 12 7 6 1 4

3 2 58

9

5


W1-2-5

Service Recommendations for Split Flange IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches / roughness cause leaks and seal wear.

Unevenness causes seal extru-sion. If defects cannot be pol-ished out, replace the compo-nent.

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 di-agonally, as shown, to ensure even tightening.

5. Do not use air wrenches. Using an air wrench often causes tight-ening of one bolt fully before tightening of the others, result-ing in damage to O-rings or un-even tightening of bolts.

Nut and Bolt Locking • Lock Plate IMPORTANT: Do not reuse lock plates. Do not try

to bend the same point twice. • Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the

holes in the bolt and nut while tight-ening, not while loosening.

• Lock Wire IMPORTANT: Apply wire to bolts in the

bolt-tightening direction, not in the bolt-loosening direction.

W105-01-01-015

W105-01-01-016

W105-01-01-008

W105-01-01-009

W105-01-01-010

Bend along edge sharply Do not bend it round

Bend along edge sharply

Loosen

Tighten

WRONG

RIGHT RIGHT

RIGHT

WRONG

WRONG

RIGHT WRONG

WRONGRIGHT RIGHT


W1-2-6

PIPING JOINT IMPORTANT: The torques given in the chart are

for general use only. Do not use these torques if a differ-ent torque is given for a specific ap-plication.

Union Joint

Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT: 1. Do not over-tighten nut (3). Ex-

cessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adapter (1). Be sure to tighten nut (3) to specifi-cations.

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

M202-07-051

W105-01-01-017

Wrench Size mm

Wrench Size mm Tightening Torque

Description

Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft) 30°male 17 17 24.5 (2.5, 18)

19 19 29.5 (3.0, 21.5) 22 22 39 (4.0, 28.5) 27 27 78 (8.0, 58) 32 32 137 (14.0,101) 36 36 175 (18.0, 129) 41 41 205 (21.0,1 51)

37°female 17 14 24.5 (2.5, 18) 19 17 29.5 (3.0, 21.5) 22 19 39 (4.0, 28.5) 27 22 78 (8.0, 58) 32 27 137 (14.0, 101) 36 32 175 (18.0, 129) 41 36 205 (21.0, 151)

NOTE: Tightening torque of 37° male coupling without union is similar to tightening torque of 37° female.

37°

30°

Female Union JointMale Union Joint

1 3 5 2

Joint Body

4

GENERAL / Tightening Torque

W1-2-7

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

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

new one when reconnecting. 2. Before tightening nut (9), confirm

that O-ring (6) is seated correctly in O-ring groove (e). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.

3. Take care not to damage O-ring groove (e) or sealing surface (10).

Damage to O-ring (6) will cause oil leakage.

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

M104-07-033

Wrench Size

mm Wrench Size

mm Tightening Torque

Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft) 19 17 29.5 (3.0, 21.5) 22 19 69 (7.0, 51) 27 22 93 (9.5, 69) 32 27 137 (14.0, 101) 36 30, 32 175 (18.0, 129) 41 36 205 (21.0, 151) 46 41 205 (21.0, 151)

7 6 9

8 1Hose Fittings


W1-2-8

Screw-In Connection Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: Be sure to confirm that the thread pitch

and thread type (tapered or straight) are the correct type before using any screw-in connection.

Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap. • Application Procedure Confirm that the thread surface is clean and, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs de-pending on the type of clamp. T-Bolt Type Band Clamp: 4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)

W105-01-01-018

Male Tapered Thread

Wrench Size mm

Tightening Torque N⋅m (kgf⋅m, lbf⋅ft)

Hose Fittings FC material SS material 19 14.5 (1.5,10.5) 34 (3.5,25) 22 29.5 (3.0,21.5) 49 (5.0,36) 27 49 (5.0,36) 93 (9.5,69) 36 69 (7.0,51) 157 (16,116) 41 108 (11,80) 205 (21,151) 50 157 (16,116) 320 (33,235) 60 195 (20,144)

W105-01-01-019

M114-07-041

M114-07-043 M114-07-042

PF 30°

PT

Male Straight Thread Male Tapered Thread

Clearance External Thread

Internal Thread

Leave one to two pitch threads uncovered

T-Bolt Type Worm Gear Type


W1-2-9

Connecting Hose

CAUTION: When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, pos-sibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked 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. If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rub-bing against each other. Take care so that hoses do not come into contact with moving parts or sharp objects.

W105-01-01-011

W105-01-01-012

W105-01-01-013

W105-01-01-014

Rubbing Against Each Other

RIGHT

RIGHT

RIGHT

RIGHT

WRONG

WRONG

WRONG

WRONG



Clamp

Clamp Clamp


W1-2-10

PERIODIC REPLACEMENT OF PARTS

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

Periodic Replacement Parts Replacement Intervals

Fuel hose (Fuel tank to filter) Every 2 years Oil filter hose (Engine to oil filter) Every 2 years Engine Heater hose (Heater to engine) Every 2 years Pump suction hose Every 2 years Pump delivery hose Every 2 years Swing hose Every 2 years

Base Machine

Travel Hose Every 2 years Boom cylinder line hose Every 2 years Arm cylinder line hose Every 2 years Bucket cylinder line hose Every 2 years

Hydraulic System

Front-End

Attachment Pilot hose Every 2 years

NOTE: Be sure to replace seals, such as O-rings and gaskets, when replacing hoses.

GENERAL / Painting

W1-3-1

PAINTING Painting specification

Surfaces to Be Painted Painting Colour • Main surface of upperstructure (except cab) YR-01 [TAXI yellow]

Main frame HG Beige Deep Internal parts Black

• Front attachment YR-01 [TAXI yellow] • Track (including swing bearing) N1.0 [Black] • Floor plate M/F Cation (allowed)

Final painted color

• Inside and outside surface of cab HG Beige Deep • Shaded area on cab outside Shining Silver • Right window guards, U-Bolt [KANSAI PAINT LF-113-230B

(Charcoal series black, half glossy)] • Suspension lifter (chair bottom) [N2.0 (Black)] • Lever (Pilot shut-off, foot rest) High Grade Black • Engine cover High Grade Black • Cover, Step HG Beige Deep • Handrail on upperstructure right side HG Beige Deep • Mirror stay: cab side, right side High Grade Brack • Nonslip cover KANSAI PAINT Amilac 1400 (Deep Black) • Rear camera cover HG Beige Deep • Head light bracket HG Beige Deep

GENERAL / Painting

W1-3-2

WCJB-01-03-002

WCJB-01-03-001

Mirror Stay Engine Cover

Camera Cover

Decal [TAXI Yellow]

Head Light Bracket

Decal [Shining Silver]

Mirror Stay Handrail

Right Side Cover

Mirror Stay

Head Light Bracket

Step

Decal [Shining Silver]

GENERAL / Painting

W1-3-3

WCJB-01-03-004

WCEB-01-03-003

W178-01-03-007

W178-01-03-005

WCJB-01-03-003

IMPORTANT: When cleaning arm, cylinder, etc. fitted with HN bushing, take care not to pour washing liquid directly on them. The ambient temperature should not exceed 70 °C when paint-ing and drying.

Align with the panel. [Shining Silver]

Panel

Nonslip Cover KANSAI PAINT Amilac 1400 (Deep Black)

A

Paint all circumference in the hinge swing position shining silver.

Shaded Area [Shining Silver]

Front Attachment YR-01 (TAXI Yellow)

10

Door

Painting Area of the Door YR-01 (TAXI Yellow)

Panel Behind the Door

Section A

GENERAL / Painting

W1-3-4

(Blank)

GENERAL / Bleeding Air from Hydraulic Oil Tank

W1-4-1

BLEEDING AIR FROM HYDRAULIC OIL TANK

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

Preparation 1. Place the machine on a firm, level surface and

lower the bucket to the ground.

2. Stop the engine. Push the air bleed valve (1) on the air breather to release any remaining pressure from hydraulic oil tank (3).

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

4. Connect a vacuum pump with the hole removed cap (2) to maintain negative pressure in the hydraulic oil tank (3).

NOTE: Be sure to run the vacuum pump continuously while working.

WCJB-01-04-001

WCEB-01-04-001

W562-02-03-008

Adapter

Vacuum Pump

Hose

1

2

3

GENERAL / Bleeding Air from Hydraulic Oil Tank

W1-4-2

(Blank)

M E M O

........................................................................................................................................................................

........................................................................................................................................................................

........................................................................................................................................................................

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CJBW-2-1

SECTION 2

UPPERSTRUCTURE

— CONTENTS — Group 1 Cab

Removal and Installation of Cab............ W2-1-1 Dimensions of Cab Glass .................... W2-1-12

Group 2 Counterweight

Removal and Installation of Counterweight ...................................... W2-2-1

Group 3 Main Frame

Removal and Installation of Main Frame .......................................... W2-3-1

Group 4 Pump Device

Removal and Installation of Pump Device........................................ W2-4-1 Disassembly of Pump Device .............. W2-4-14 Assembly of Pump Device ................... W2-4-26 Disassembly of Regulator .................... W2-4-46 Assembly of Regulator......................... W2-4-48 Structure of Pilot Pump ........................ W2-4-50

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

Group 6 Swing Device

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

CJBW-2-2

Group 7 Pilot Valve Removal and Installation of Pilot Valve.. W2-7-1 Removal and Installation of Travel Pilot Valve................................ W2-7-11 Disassembly of Front/Swing Pilot Valves......................................... W2-7-16 Assembly of Front/Swing Pilot Valves.. W2-7-20 Disassembly of Travel and Auxiliary/Positioning Pilot Valves ....... W2-7-24 Assembly of Travel and Auxiliary/Positioning Pilot Valves ....... W2-7-26

Group 8 Electric Lever

Removal and Installation of Electric Lever........................................ W2-8-1 Disassembly of Electric Lever................ W2-8-8 Assembly of Electric Lever................... W2-8-10

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

Group 10 Travel Shockless Valve

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

Group 11 Solenoid Valve

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

Group 12 Pilot Shut-Off Solenoid Valve Removal and Installation of Pilot Shut-Off Solenoid Valve......................W2-12-1 Structure of Pilot Shut-Off Solenoid Valve ....................................W2-12-3

Group 13 Steering Valve

Removal and Installation of Steering Valve.....................................W2-13-1

Group 14 Brake Valve

Removal and Installation of Brake Valve.........................................W2-14-1 Disassembly of Brake Valve.................W2-14-4 Assembly of Brake Valve......................W2-14-8

Group 15 Accumulator Charge Valve

Removal and Installation of Accumulator Charge Valve .................W2-15-1 Structure of Accumulator Charge Valve ......................................W2-15-4

UPPERSTRUCTURE / Cab

W2-1-1

REMOVAL AND INSTALLATION OF CAB

Removal

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

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

: 16 mm

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

: 6 mm

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

WCEB-02-01-001

WCEB-02-01-017

WCEB-02-01-002

WCEB-02-01-003

4

6

3

7

53 21

1

2

8

4

6

5 32


W2-1-2

4. Remove sems bolts (10) (2 used) from cover (9). : 13 mm

5. Remove caps (11) (6 used) from cover (9). Remove screws (12) (6 used) from cover (9).

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

7. Remove sems bolts (16) (4 used) from cover (14). Remove cover (14) from brackets (13, 15).

: 17 mm

8. Remove sems bolts (17) (5 used) from bracket (13). Move the bracket (13) assembly forward from bracket (15).

: 13 mm, 17 mm

W1JB-02-01-004

W1JB-02-01-005

WCEB-02-01-008

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

7

9

11, 12

9

10

11, 12

13

16

14

16 15

13 17

17

15

13

17


W2-1-3

9. Remove screws (19) (2 used) from cover (18). Remove cap (20) and screw (21) from cover (18). Remove cover (18) from cab (7).

10. Remove sems bolts (23) (2 used) from bracket

(24). Remove bracket (24) from cab (7) and duct (22). Remove duct (22) from bracket (15).

: 13 mm 11. Open covers (25, 26).

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

hold cover (25). 13. Remove nuts (28) (4 used), spring washers (29)

(4 used) and washers (30) (4 used) from cover (25). Remove cover (25) from support (27).

: 17 mm

W1JB-02-01-001

WCEB-02-01-016

WCJB-02-01-001

WCJB-02-01-003

19 18

20, 21 7

15

22 7

23

24

23

28, 29, 30

25

27

25 26


W2-1-4

14. Disconnect vinyl hose (32) from washer tank (31). Cap the open ends.

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

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

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

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

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

WCJB-02-01-004

WCJB-02-01-005

WCEB-02-01-013

WCJB-02-01-004

34 33 35

34

37

38

36

7

31

32

32


W2-1-5

18. Open cover (40). 19. Remove sems bolts (41) (4 used) from cover (39).

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

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

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

CAUTION: Cab (7) weight: 550 kg (1220 lb) 21. Attach a nylon sling onto the bracket in cab (7).

Hold cab (7). 22. Remove nuts (45) (4 used) and washers (46) (4

used) from cab (7). : 24 mm

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

: 8 mm 24. Remove bolts (48) (5 used) and washers (49) (5

used) from cab (7). : 17 mm

CAUTION: Cab (7) weight: 550 kg (1220 lb) 25. Remove cab (7) from main frame (34).

WCJB-02-01-002

WCEB-02-01-014

W1JB-02-01-006

WCJB-02-01-006

47

47

7

45, 46

45, 46

48, 49

Lifting BracketLifting Bracket 47

45, 46

43

7

44

40 39 41 42

7

34


W2-1-6

Installation

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

1. Attach a nylon sling onto cab (7). Hoist and align cab (7) with the mounting hole on main frame (34).

2. Install cab (7) to main frame (34) with nuts (45) (4 used) and washers (46) (4 used).

: 24 mm : 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

3. Install cab (7) to main frame (34) with socket bolts

(47) (6 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

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

used) and washers (49) (5 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

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

6. Install bracket (24) to cab (7) and duct (22) with sems bolts (23) (2 used).

: 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

WCJB-02-01-006

W1JB-02-01-006

WCEB-02-01-016

15

22 7

23

24

23

47

47

7

45, 46

45, 46

48, 49

Lifting Bracket 47

45, 46

Lifting Bracket

7

34


W2-1-7

7. Install cover (18) to cab (7) with screws (19) (2 used). Install cover (18) to cab (7) with screw (21). Install cap (20) to screw (21).

8. Align the bracket (13) assembly with the mounting hole on bracket (15). Install the bracket (13) assembly to bracket (15) with sems bolts (17) (5 used).

: 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

9. Install cover (14) to brackets (13, 15) with sems bolts (16) (4 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

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

Install caps (11) (6 used) to screws (12) (6 used).

W1JB-02-01-001

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

WCEB-02-01-008

W1JB-02-01-005

19 18

20, 21 7

7

9

11, 12

13

16

14

16 15

13 17

17

15

13

17

11, 12


W2-1-8

11. Install cover (9) to cab (7) with sems bolts (10) (2 used).

: 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

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

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

13. Secure cab (7) to main frame (34) with anchor bolt

(38), washer (37) and spacer (36). : 32 mm : 550 N⋅m (55 kgf⋅m, 406 lbf⋅ft)

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

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

W1JB-02-01-004

WCEB-02-01-014

WCEB-02-01-013

WCJB-02-01-004

34

37

38

36

7

43

7

44

9

10

7

31

32


W2-1-9

15. Install cover (33) to main frame (34) with sems bolts (35) (7 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

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

align cover (25) with the mounting hole on support (27). Secure cover (25) to support (27) with washers (30) (4 used), spring washers (29) (4 used) and nuts (28) (4 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

17. Shut covers (25, 26).

CAUTION: Seat (1) weight: 40 kg (90 lb) 18. Install seat (1) to plate (2) with socket bolts (3) (4

used). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

WCJB-02-01-005

WCJB-02-01-003

WCJB-02-01-001

WCEB-02-01-002

3 1

2

34 33 35

25 26

28, 29, 30

25

27


W2-1-10

19. Install safety belts (6) (2 used) to brackets (5) (2 used) with sems bolts (4) (2 used).

: 16 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

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

21. Install cover (39) to stay (42) with sems bolts (41)

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

22. Shut cover (40).

WCEB-02-01-001

WCEB-02-01-017

WCEB-02-01-003

WCJB-02-01-002

4

6

53 21

7

8

4

6

5 32

40 39 41 42


W2-1-11

(Blank)


W2-1-12

DIMENSIONS OF CAB GLASS

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

W1JB-02-01-013

W1JB-02-01-009

W1JB-02-01-014

W1JB-02-01-011

W1JB-02-01-012

W1JB-02-01-019

2-R250 2-R50

2-R127

2-R50

2-R20 2-R10

70

50

214 21847 21

Black Ceramic Coating Surface

271

R2975

1081

60

2R-516.5

115

70

(4 mm)

R75

R800

R50

106.6

Black Ceramic Coating Range

(4 mm)

2584

865 25

50

372.9

22

R1075

54.1

C


R2

Section C


21

268

φ28

R40 7020

A

B

107

R120

Section A

C0.5


C0.5

Section B

C0.5

C0.5


W2-1-13


WCEB-02-01-012

WCEB-02-01-011

W1JB-02-01-013

WCEB-02-01-004

WCEB-02-01-010

W1JB-02-01-018

50

50

(4 mm)

631

139.7

(4 mm)

383.2 50

360.7

50

228.237

40±0

2-φ12.2+0.5 -0

860.8833

506581

438.5353.5

63.5

R5004

R5031

R58

118

R103

R329R42

R250 185R75

A R50

34 R10

109.5

1R60

R25

26.5 50

R150

(4 mm)

327.5173

448498.5

R2854

R964

R10 R60


2-φ21

336 64.5

102.5

152.5

2-R4

82

Section A

C0.5


C0.5

R150

460.2 50

50

(4 mm)

644.5

312.6

4Ｒ-4

R2800

Glass Mark (Back)

4-R4

6445

3-R4

228.2

40±0.5

93°

17


W2-1-14


WCEB-02-01-015

W1JB-02-01-013

W1JB-02-01-014

W1JB-02-01-021

W1JB-02-01-017

(4 mm) 87.5

29

652

A


848 205

39

R200

185

R500

R50

70

30

45

R30

4-R10

87.5

185

R200

R500

R50

1008

228

R35

φ83

10991145.5

887

R135

R35

R40

R550R100

112 13°

65°

75.5

1127.3 19.5

87.7°

85 100

R4139.5

R4044.5

105 109°

496

123.5 80 59.5

567.5

A

B


102°R250

R70

R20 R60

R20R25

3-R4

R25

R25

R25 R75

(4 mm)

Section B

C0.5

C0.5

Section A

C0.5


C0.5

76 140

195 78.5 57 447 483


W2-1-15


W1JB-02-01-009

W1JB-02-01-013

W1JB-02-01-020

Section A

C1


C1


696.73

A

400

R125

(5 mm)

R30

R25

R300

R2145

R2940

R2875 R575

1646.47

1599.44

313.6

50

106

40

R20

R20

50

R1525

R55 R30

393

807.65

963.7

28°

50

900

1230

873.

14

1205

1496

.7

1636

.3

145

150

R10

R30

90R30R50

R50

R50R30

R3025

R1040

R75

2-R25

187

80

158


W2-1-16

Removal of Cab Glass Procedures to Remove Right-Hand Glass, Rear Left-Hand Glass, Lower Door Glass and Rear Glass

CAUTION: When removing the broken or cracked glass, the glass shards may cause serious injury. Before removing, use the gummed tape or something like in order to paste the broken or cracked glass and reinforce them. Remove the glass pieces away.

1. Remove the resin panel, garnish and spacer

around the glass.

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

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

W1JB-02-01-009

WCEB-02-01-015

W1SE-02-01-033

W1SE-02-01-034

Right-Hand Glass

Adhesive

Awl Cab Glass

Cab

Piano Wire (or Metal Wire)

Rear Left-Hand Glass Garnish

Garnish

Resin Panel Lower Door Glass

Rear Glass


W2-1-17

4. Wind the both ends of piano wire onto the screwdriver. Draw the wire back and forth in order to cut the adhesive between cab and glass. Remove the glass from the cab.

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

W1SE-02-01-035

Adhesive

Cab

(Cab Inside)

Glass (Cab Outside)

Cab Glass


W2-1-18

Installation of Cab Glass

Procedures to Install Right-Hand Glass, Rear Left-Hand Glass, Lower Door Glass and Rear Glass

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

1 to 2 mm (0.04 to 0.08 in) deep all around by using a cutter knife or similar.

NOTE: Do not damage the cab paint.

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

IMPORTANT: Primer should be shaken for about 1

minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and replace the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off).

3. Apply Primer for paint (Sika Aktivator DM-1) to the cutting edge of adhesive at cab side by using a brush. Wait for about 15 minutes in order to let it dry by itself.

NOTE: The painting primer should be applied evenly in order to leave no blemishes.

W1JB-02-01-009

W1JB-02-01-010

W1SE-02-01-036

W1SE-02-01-038

Cut off adhesive by 1 to 2 mm （0.04 to 0.08 in） deep.

Cutter Knife

Cab

Cab

Cutting Edge of Adhesive at Cab Side

Apply Primer 24 by using a brush.

Right-Hand Glass

Rear Left-Hand Glass

Lower Door Glass

Rear Glass


W2-1-19

4. Clean the mating edge of new glass by using clean rag and ethyl alcohol.

IMPORTANT: Primer (Sika Primer Z06G+P) should

be shaken for about 1 minute and mix thoroughly before opening the cap. After opening Primer, apply Primer as quickly as possible and replace the cap immediately after using. After opening Primer, all the contents should be used within 180 days (or 2 hours with the cap off).

5. Apply Primer for glass (Sika Primer Z06G+P) to the cutting edge of adhesive at cab side by using a brush. Wait for about 15 minutes in order to let it dry by itself. (As for the position to apply Primer, refer to W2-1-21.)

6. Install the spacer with facing to the glass surface

by using the instant adhesive. (As for the positions to install spacers A, B and C dam rubber, refer to W2-1-21.)

7. Cut off the nozzle of adhesive cartridge (Sika

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

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

nozzle.

9. Install the cartridge to the manual coking gun. 10. Evenly apply adhesive to the old adhesive left at

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

11. Suck, raise the glass by using sucker lifter 4355282 (refer to W2-1-21), and adhere it to the cab within 5 minutes.

NOTE: Install the glass while aligning the spacer position on the glass. Remove all adhesive except the mounting surface, before solidifying by using white spirit.

12. Secure the glass by using the gummed tape until

the adhesive becomes solid in order to prevent them from being mispositioned or coming off. (Refer to W2-1-20.)

NOTE: Time for adhesive (Sika Tack-Drive) to become solid: 8 hours (just for reference)


W2-1-20


W1JB-02-01-029

W1JB-02-01-035

W1JB-02-01-030

W1JB-02-01-038

Rear Glass


Lower Door Glass

250 300

150 200

200

350 500

Right-Hand Glass

200

200

500

200

200

200

200

200

100

100

200

100

200

500

250 300


W2-1-21


W1JB-02-01-022

W1JB-02-01-025

W1JB-02-01-026

W1JB-02-01-031

W1JB-02-01-023

W1JB-02-01-027

W1SE-02-01-027

W1SE-02-01-028

W1JB-02-01-024

W1JB-02-01-039

W1JB-02-01-042

W1SE-02-01-043

Spacer A

Two Side Adhesive Tape

20 6

6

4

84° R5R0.5

6

30

Dam Rubber

20 6

6

4

3 10.5

84° R5R0.5

6.4

Right-Hand Glass

Dam Rubber

Spacer A

Spacer B

Dam Rubber

Spacer B

Adhesive

12

9

Spacer B

Two Side Adhesive Tape

20 6

12

36

475°R8

R0.5

Spacer A

Rubber

Spacer B


Cut nozzle end into V-shaped.

13 to 15 mm

8 to 9 mm

Remove the seal.

AdhesiveCartridge

Spacer C

20 6

10.5

2

8

4

78°R10

R0.5

Spacer A

Spacer C

Lower Door Grass

Rear Glass

Panel

Apply adhesive evenly.

Suction Lifter


W2-1-22

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

Painted Surface or Adhesive Surface

Glass Surface

Adhesive Sika Tack-Drive (Sika Tack-Drive) 310 ml Cartridge

Primer Sika Aktivator DM-1 (Sika Aktivator DM-1) 250 ml Can

Primer Sika Primer 206G+P 30 ml Bottle

Upper Front Glass 310 ml 0.75 ml 0.67 ml Lower Door Glass 150 ml 0.5 ml 0.45 ml Rear Left-Hand Glass 250 ml 0.65 ml 0.6 ml Rear Right-Hand Glass 100 ml 1 ml 0.9 ml Rear Glass 210 ml 0.5 ml 0.45 ml


W2-1-23

Installation of Upper Door Glass

1. Before installing the glass, remove the garnish around sash assembly from the cab inside for easy removal. Push the sash assembly by hands and remove the sash outside.

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

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

W1JB-02-01-010

Glass A Glass B

Sash Assembly

Garnish

Glass A Glass B

Garnish


W2-1-24

Installation of Upper Front Glass

1. Stick seal (1) to the lower side of front upper glass by using Cemedine Super X. Stick and secure both right and left ends (the thicker part) of seal (1) to the glass by using Cemedine Super X. Stick the mating surface of seal (1) and the glass by using Cemedine Super X so that no visible undulation or boss can be found.

NOTE: Cemedine Super X Black No.8008

Glue-state adhesive, tubed IMPORTANT: The upper front glass is

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

W1JB-02-01-034

W1JB-02-01-032

W1JB-02-01-033

Upper Glass

Cemedine Super X Seal Here

Lower Glass

Seal (1)

Upper Glass

Cemedine Super X

Lower Glass

Seal (1)

Adhere the glass in the same method as right-hand glass.

Seal (1) Seal (1)

UPPERSTRUCTURE / Counterweight

W2-2-1

REMOVAL AND INSTALLATION OF COUNTERWEIGHT

Removal 1. Open cover (1).

2. Disconnect plugs (2, 3).

3. Open cover (4).

4. Disconnect connector (5).

WCJB-02-02-002

WCJB-02-02-003

WCJB-02-02-004

WCJB-02-02-001

WCJB-02-02-005

3

4

2

1

5


W2-2-2

5. Open covers (6, 7).


CAUTION: Counterweight (10) weight: ZX210W-3: 3850 kg (8490 lb) ZX220W-3: 4950 kg (11000 lb)

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

(10). Install FLENO RINK BOLT into the holes where caps (9) (2 used) were removed.

NOTE: Dimension of FLENO RINK BOLT (B-42, M42, Pitch 4.5 mm)

8. Attach a wire rope onto FLENO RINK BOLT. Hoist

and hold counterweight (10).

CAUTION: When using a power wrench, do not pinch your fingers by its reaction bar.

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

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

: 60 mm 10. Hoist and remove counterweight (10) from main

frame (13).

WCJB-02-01-001

WCEB-02-02-006

WCEB-02-02-004

WCEB-02-02-005

6

910

8

11

12

13

10

11

12

7


W2-2-3

Installation

CAUTION: Counterweight (10) weight: ZX210W-3: 3850 kg (8490 lb) ZX220W-3: 4950 kg (11000 lb)

1. Hoist and align counterweight (10) with the

mounting holes on main frame (13).

2. Temporarily tighten counterweight (10) to main frame (13) with bolts (12) (4 used) and washers (11) (4 used).

CAUTION: When using a power wrench, do not pinch your fingers by its reaction bar.

3. Remove the wire rope and FLENO RINK BOLT

from counterweight (10). Tighten bolts (12) (4 used) by using a power wrench and torque wrench.

: 60 mm : 3600 N⋅m (367 kgf⋅m, 2660 lbf⋅ft)

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

WCEB-02-02-005

WCEB-02-02-006

WCEB-02-02-007

13

10

11

12

10

9

10

Torque Wrench

Power Wrench


W2-2-4

5. Connect connectors (5, 8).

6. Shut cover (4).


8. Connect plug (3).

WCJB-02-02-005 WCEB-02-02-006

WCJB-02-02-001

WCJB-02-01-001

WCJB-02-02-004

5 8

6 7

4

3


W2-2-5

9. Connect plug (2). 10. Shut cover (1).

WCJB-02-02-003

WCJB-02-02-002

2

1


W2-2-6

(Blank)

UPPERSTRUCTURE / Main Frame

W2-3-1

REMOVAL AND INSTALLATION OF MAIN FRAME

CAUTION: Bleed air from the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

Removal

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

1. Remove the counterweight.

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

: 60 mm

CAUTION: The front attachment assembly weight: Monoblock boom: 3430 kg (7570 lb) 2-piece boom: 4190 kg (9240 lb)

2. Remove the front attachment assembly.

(Refer to the REMOVAL AND INSTLLATION OF FRONT ATTACHMENT on W4-1-1.)

: 27 mm, 30 mm, 36 mm

WCEB-02-02-005

WCJB-02-03-001

WCJB-02-03-002

Counterweight

Washer

Bolt

Monoblock Boom

2-Piece Boom


W2-3-2

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

3. Remove the bolts, the stopper and the slip ring from the center joint. Disconnect the hose from the center joint. (Refer to the Remove and Install Center Joint group on W3-3-1.)

: 10 mm, 19 mm, 22 mm, 27 mm, 36 mm

CAUTION: Upperstructure weight: 5400 kg (12000 lb)

IMPORTANT: IMPORTANT: Do not damage the

engine due to the wire ropes attached from the rear side of the frame.

4. Attach the wire ropes onto the rear side of the frame and the boom mounting part. Take up slack of the wire rope.

NOTE: If chain block is used, it is not only easy to adjust the length of wire rope, but also easy to level the center of gravity.

5. Put the matching marks on the upperstructure and the outer race of the swing bearing. Remove the swing bearing mounting bolt.

: 30 mm

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

WCJB-03-03-001

WCEB-02-03-003

WCEB-02-03-005

WCJB-02-03-003

Rear Side of Frame

Wire Rope

Wire Rope

Slip Ling

Stopper

Center Joint

Hose

Bolt

Connector

Bolt


W2-3-3

Installation

CAUTION: Upperstructure weight: 5400 kg (12000 lb)

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

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

2. Align the matching marks on the upperstructure

and the outer race of the swing bearing. Install and temporarily tighten the mounting bolts for the swing bearing. Remove the wire ropes. Tighten the mounting bolts for the swing bearing.

: 30 mm : 520 N·m (53 kgf·m, 390 lbf·ft)

3. Connect the hoses (13 used) to the center joint. : 10 mm : 3.3 to 4.2 N·m

(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft) : 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft) : 22 mm : 39 N·m (4 kgf·m, 29 lbf·ft) : 27 mm : 78 N·m (8 kgf·m, 58 lbf·ft) : 36 mm : 175 N·m (18 kgf·m, 129 lbf·ft)

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

Install the stopper to the center joint. : 24 mm : 265 N·m (27 kgf·m, 195 lbf·ft)

5. Install the slip ring to the stopper.

: 10 mm : 3.3 to 4.2 N·m

(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

WCJB-02-03-003

WCJB-03-03-001

Slip Ling

Stopper

Center Joint

Hose

Bolt

Connector

Bolt


W2-3-4

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

6. Install the counterweight.

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

: 60 mm : 3530 N·m (360 kgf·m, 2610 lbf·ft)

CAUTION: The front attachment assembly weight: Monoblock boom: 3430 kg (7570 lb) 2-piece boom: 4190 kg (9240 lb)

7. Install the front attachment assembly to the

upperstructure. Add hydraulic oil. (Refer to the REMOVAL AND INSTALLATION OF FRONT ATTACHMENT on W4-1-1.)

: 27 mm : 93 N·m (9.5 kgf·m, 69 lbf·ft) : 30 mm : 540 N·m (55 kgf·m, 398 lbf·ft) : 36 mm : 175 N·m (18 kgf·m, 129 lbf·ft)

8. Start the engine. Set the front attachment in posture for checking hydraulic oil level. Check for hydraulic oil level and any oil leakage.

WCEB-02-02-005

WCJB-02-03-001

WCJB-02-03-002

Counterweight

Washer

Bolt

Monoblock Boom

2-Piece Boom

UPPERSTRUCTURE / Pump Device

W2-4-1

REMOVAL AND INSTALLATION OF PUMP DEVICE



2. Open cover (2).

3. Remove sems bolts (3) (4 used) from cover (4). Remove cover (4) from main frame (5).

: 17 mm

WCJB-02-02-002

WCJB-02-02-001

WCJB-02-04-007

1

2

3 4 5


W2-4-2

4. Remove sems bolts (6) (2 used) from bracket (7). : 17 mm

5. Remove sems bolts (9) (6 used) from cover (8). Remove cover (8) from bracket (7) and supports (10, 11).

: 17 mm

6. Remove sems bolts (12) (6 used) and sems bolts (15) (2 used) from bracket (7). Remove bracket (7) from supports (13, 14) and cover (16).

: 17 mm

WCJB-02-04-003

WCJB-02-04-001

WCJB-02-04-001

WCJB-02-04-002

WCJB-02-04-003

6

10

9

15

12

7

7

87

11 9

13 127

7 14

16


W2-4-3

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

: 27 mm

8. Remove sems bolts (20) (2 used) from clips (21) (2 used). Remove clips (21) (2 used) from hoses (22) (4 used).

: 17 mm

9. Disconnect connector (17). : 17 mm

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

device (23). 11. Remove socket bolts (26) (3 used) and clips (28)

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

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

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

: 10 mm

WCJB-02-04-003

WCEB-02-04-009

WCJB-02-04-004

WCEB-02-04-009

23

24

28

30

29

20, 21

16

22

1819 18

17

24

27 26

23

29

31

23


W2-4-4

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

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

pipe (32). Disconnect suction pipe (32) from pump device (23).

: 10 mm 15. Disconnect hoses (35) (2 used) from regulators

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

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

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

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

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

: 22 mm, 27 mm

WCEB-02-04-009

WCJB-02-04-003

WCEB-02-04-009

WCJB-02-04-003

37

35

36

40

23

32 33

34

38

39


W2-4-5

18. Remove sems bolts (42) (5 used) from covers (41) (2 used). Remove covers (41) (2 used) from support (13) and cover (16).

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

Remove the cover (16) assembly from support (13).

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

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

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

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

: 17 mm

WCJB-02-04-004

WCJB-02-04-003

WCEB-02-04-009

WCEB-02-04-008

23

44

46

45

47

49

48 23

16

13 41 42 16

43

46


W2-4-6

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

: 19 mm

CAUTION: The muffler (50) assembly weight: 23 kg (51 lb)

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

hold muffler (50). 24. Remove sems bolts (56) (3 used) from bracket

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

CAUTION: Pump device (23) weight: 164 kg (370 lb)

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

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

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

device (23). Remove pump device (23) from engine (58).

: 17 mm

WCJB-02-04-006

WCJB-02-04-005

WCEB-02-04-003

WCJB-02-04-005

23

Eyebolt Mounting Hole

54

51, 52, 53

55

50

50

56 23 57

58

23

59


W2-4-7

Installation

CAUTION: Pump device (23) weight: 164 kg (370 lb)


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

2. Align pump device (23) with the mounting hole on engine (58). Install pump device (23) to engine (58) with sems bolts (59) (3 used).

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

CAUTION: The muffler (50) assembly weight: 23 kg

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

align muffler (50) with the mounting hole on pump device (23). Install bracket (57) to pump device (23) with bolts (56) (3 used).

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

4. Align clamp (55) with the center of exhaust pipe (54) and the muffler (50) pipe. Secure exhaust pipe (54) and muffler (50) with bolts (53) (2 used), spring washers (52) (2 used) and nuts (51) (2 used).

: 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

WCEB-02-04-003

WCJB-02-04-005

WCJB-02-04-006

23


50

56 23 57

58

59

54

51, 52, 53

55

50


W2-4-8

5. Install the bracket (49) assembly to pump device (23) with sems bolts (47) (2 used) and plate (48).

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

6. Connect suction pipe (32) to pump device (23) with socket bolts (33) (4 used).

: 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

7. Connect hose (34) to suction pipe (32). : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

8. Connect hoses (46) (2 used) to pump device (23) with split flanges (44) (4 used) and socket bolts (45) (8 used).

: 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

9. Connect hoses (39) (4 used) to pilot pump (37). : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

WCEB-02-04-008

WCEB-02-04-009

WCEB-02-04-009

47

49

48 23

3332 23

23

44

46

45

38

34

37


W2-4-9

10. Install the cover (16) assembly to support (13) with sems bolts (43) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

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

cover (16) with sems bolts (42) (5 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

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

clips (28) (3 used) to pump device (23) with socket bolts (26) (3 used).

: 5 mm : 10 N⋅m (1 kgf⋅m, 7 lbf⋅ft)

13. Connect connectors (24) (7 used) to regulator (36)

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

with split flanges (31) (4 used) and socket bolts (30) (8 used).

: 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

WCJB-02-04-003

WCJB-02-04-004

WCEB-02-04-009

24

28 27 26

23

13 41 42 16

36

16

43

30

2929

31

23

24


W2-4-10

15. Connect hoses (39) (3 used) to filter (40). : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

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

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

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

: 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

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

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

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

Secure clips (21) (2 used) to cover (16) with sems bolts (20) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-04-003

WCJB-02-04-003

35

36 3940

20, 21

16

22

1819 18

17


W2-4-11

20. Install bracket (7) to supports (13, 14) and cover (16) with sems bolts (12) (6 used) and sems bolts (15) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

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

and bracket (7) with sems bolts (9) (6 used) and sems bolts (6) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCJB-02-04-001

WCJB-02-04-002

WCJB-02-04-003

WCJB-02-04-001

WCJB-02-04-003

15

12

13 127

7 14

16

10

9 87

11 9

6

16

7


W2-4-12


: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)


WCJB-02-04-007

WCJB-02-02-001

WCJB-02-02-002

2

3 4 5

1


W2-4-13

(Blank)


W2-4-14

DISASSEMBLY OF PUMP DEVICE

WCEB-02-04-014

6

7

57 56

58

5

4

3 1 2

55 54

51

53

52

51 50 22

21 24

23 22

21

910

1120

12

19

15

14

16 17

1817 15 1614

13

1211

10

9

8

47 48

49 25

26

27

28

292630

31

3233

34

35

37

3640

3938

4446 45

4443

4241


W2-4-15

WCEB-02-04-011

1 - Socket Bolt (4 Used) 22 - Plug (2 Used) 43 - Retaining Ring 64 - Right Valve Plate 2 - Right Regulator 23 - O-Ring 44 - Ball Bearing (2 Used) 65 - Backup Ring 3 - Socket Bolt (2 Used) 24 - Stopper 45 - Gear 66 - O-Ring 4 - Socket Bolt (2 Used) 25 - Plug 46 - Gear Shaft 67 - Spring Pin (2 Used) 5 - Socket Bolt (2 Used) 26 - Retaining Ring (2 Used) 47 - Retaining Ring 68 - Pressure Sensor (2 Used) 6 - Left Regulator 27 - Gear 48 - Oil Seal 69 - O-Ring (2 Used) 7 - O-Ring (4 Used) 28 - Gasket 49 - Gear Casing 70 - Selector Head 8 - O-Ring (6 Used) 29 - Gear 50 - Spring Pin (2 Used) 71 - O-Ring (4 Used) 9 - Bearing Nut (2 Used) 30 - Plug 51 - Oil Seal (2 Used) 72 - Socket Bolt (16 Used)

10 - Bearing (2 Used) 31 - Elbow 52 - Retaining Ring (2 Used) 73 - Stopper S (2 Used) 11 - Ring (2 Used) 32 - Plug 53 - Pump Casing 74 - O-Ring (2 Used) 12 - Bearing (2 Used) 33 - O-Ring 54 - Spring Washer (6 Used) 75 - Socket Bolt (12 Used) 13 - Shaft 34 - Gasket 55 - Bolt (6 Used) 76 - Set Screw (2 Used) 14 - Pin (2 Used) 35 - Socket Bolt (2 Used) 56 - Spring Pin (2 Used) 77 - Servo Piston (2 Used) 15 - Center Shaft (2 Used) 36 - Pipe 57 - O-Ring (2 Used) 78 - Pin (2 Used) 16 - Spring (2 Used) 37 - Level Gauge 58 - O-Ring (2 Used) 79 - O-Ring (2 Used) 17 - Plunger (14 Used) 38 - Socket Bolt (2 Used) 59 - Pin (2 Used) 80 - Stopper L (2 Used) 18 - Rotor (2 Used) 39 - Spring Washer (2 Used) 60 - Retaining Ring (12 Used) 81 - Left Valve Plate 19 - Shaft 40 - Washer (2 Used) 61 - Pin (2 Used) 82 - Pin (4 Used) 20 - Slide Ring 41 - Pilot Pump 62 - Lever (4 Used) 83 - Link (2 Used) 21 - O-Ring (2 Used) 42 - Retaining Ring 63 - Pin (4 Used)

72

73

74

75

6968

76

77

79 80

72

71

7170

696867

6665

60 62 63

64 63

6260

6263

8163

62

60

60 61

6059

83

61

60

59

83

60

82

82 78


W2-4-16

WCEB-02-04-013

6

7

57

58

54

3 1 2

53

49 25

30

31

32

34

35

37

36 4039

38

41

70


W2-4-17

Disassembly of Pump Device

1. Remove plug (25) from gear casing (49). : 17 mm

2. Remove plug (32) from gear casing (49). Drain off

gear oil from gear casing (49). (Approx. 1.0 L, 0.3 US gal)

: 22 mm

3. Remove socket bolts (1) (4 used) from right regulator (2). Raise right regulator (2) to the direction of selector head (70). Remove right regulator (2) from pump casing (53).

: 8 mm

4. Remove socket bolts (3) (2 used) and socket bolts (5) (2 used) from left regulator (6). Raise left regulator (6) to the direction of selector head (70). Remove left regulator (6) from pump casing (53). Do not remove socket bolt (4).

: 8 mm

5. Remove O-rings (7) (4 used) and O-rings (57, 58) (2 used for each) from pump casing (53).

CAUTION: The pump casing (53) assembly weight: 160 kg (360 lb)

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


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

7. Hoist the pump casing (53) assembly. Place the pump casing (53) assembly with gear casing (49) facing downward. Place the wooden block (80 mm (3.1 in) or more square) under gear casing (49).

8. Remove socket bolts (35) (2 used) from pipe (36).

Remove level gauge (37), pipe (36) and gasket (34) from gear casing (49).

: 6 mm

9. Remove socket bolts (38) (2 used), spring washers (39) (2 used) and washers (40) (2 used) from pilot pump (41). Tap the flange of pilot pump (41) by using a plastic hammer and remove pilot pump (41) from gear casing (49).

: 8 mm NOTE: THREEBOND has been applied onto the

mounting surface of pilot pump (41). 10. Remove plug (30) and elbow (31) from gear

casing (49). : 30 mm


W2-4-18

WCEB-02-04-012

53

16

16

8

72

73

74

75

69

68

7980

72

71

71 70

6968

6665


W2-4-19

11. Remove the pressure sensors (68) (2 used) assembly from selector head (70).

: 27 mm 12. Remove socket bolts (72) (16 used) from stoppers

S (73) (2 used) and stoppers L (80) (2 used). Remove stoppers S (73) (2 used) and stoppers L (80) (2 used) from selector head (70).

: 6 mm NOTE: O-rings (74, 79) are installed to stopper S

(73) and stopper L (80). If it is difficult to remove the stopper, tap the outer periphery of the stopper. Turn the stopper until about half of the hole for the mounting bolt can be seen. Insert a screwdriver into the mounting bolt hole. Remove the stopper by using a screwdriver.

W178-02-11-082

13. Remove O-rings (71) (4 used) from selector head

(70). 14. Remove O-rings (74, 79) (2 used for each) from

stoppers S (73) (2 used) and stoppers L (80) (2 used).

15. Record the clearance between pump casing (53) and selector head (70). Remove socket bolts (75) (12 used) from selector head (70).

: 10 mm NOTE: While loosening socket bolt (75), selector

head (70) will push out due to the force of spring (16).

CAUTION: Selector head (70) weight: 28 kg (62 lb)


the bolt hole on the upper surface of selector head (70). Hoist and remove selector head (70) from pump casing (53). O-ring (66) may be removed with the lower surface of selector head (70) attached. Check O-ring (66).

17. Remove O-rings (8) (6 used), O-ring (66) and

backup ring (65) from pump casing (53).

Stopper


W2-4-20

WCEB-02-04-012

53

75

70

76

77

78

55 54

50

19

15 16 17

18 1715 16

13

49

27

28

29

6263

6463

6260

6263

8163

62

60

6061

6059

83

61

60

59

83

60

82

82

60


W2-4-21

18. Warm up set screws (76) (2 used) by using a drier. Remove set screws (76) (2 used) from servo pistons (77) (2 used). Remove pins (78) (2 used) from servo pistons (77) (2 used).

: 6 mm 19. Remove servo pistons (77) (2 used) from selector

head (70). 20. Both right valve plate (64) and left valve plate (81)

are very similar and their installing directions are determined. Record the position and the direction of right valve plate (64) and left valve plate (81) before removing. Remove retaining rings (60) (4 used) from pins (63) (4 used). Remove right valve plate (64) and left valve plate (81) from links (83) (2 used). Do not remove pins (63) (4 used) unless necessary.

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

(15) assembly and plungers (17) (7 used) from pump casing (53) in this order. (Both right and left pumps)

NOTE: When removing plunger (17), turn plunger (17) inside and remove plunger (7).

IMPORTANT: As the pump performance may be

changed, do not deform link (83). 22. Remove the link (83) assemblies (2 used) from

pump casing (53). Do not disassemble the link (83) assembly unless necessary.

NOTE: If it is difficult to remove the link (83) assembly, use a screwdriver.

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

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

CAUTION: Pump casing (53) weight: 105 kg (240 lb)


the socket bolt (75) hole on pump casing (53). Hoist and remove pump casing (53) from gear casing (49). Shafts (13, 19) and gears (27, 29) are removed with pump casing (53) together. Place pump casing (53) with the mounting surface for the regulator facing upward.

25. Remove spring pins (50) (2 used) and gasket (28)

from gear casing (49).


W2-4-22

WCEB-02-04-012

53

70

19

13

27

29

22 21

24 23

22 21

10

12

12

10

26

26


W2-4-23

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

W137-02-04-007

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

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


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

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

29. Remove stoppers (24) (2 used) from pump casing

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

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

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

: 8 mm



and place pump casing (53) on the wooden blocks with the pump transmission side facing downward. Use the wooden block: 100 mm (3.9 in) or more square.

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

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

W178-02-04-054

29

1913

27

ST 1471

ST 1470

13

19

53


W2-4-24

WCEB-02-04-014

51

53

52

51

910 11

2012

19

13

1211

10

9

47 48

49

4446 45

4443

42


W2-4-25

33. Remove slide ring (20) from pump casing (53). 34. Remove bearing nuts (9) (2 used) from shafts (13,

19) by using special tool (ST 3058).

W137-02-04-023

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

rings (11) (2 used) from shafts (13, 19) by using a press.



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

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

(51) (2 used) from pump casing (53). 38. Remove retaining ring (42) from gear casing (49).

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

39. Remove ball bearing (44) and gear shaft (46) from the upper side of gear casing (49) by using special tool (ST 1393).

W178-02-11-085

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

casing (49). 41. Install a shackle to the bolt hole on the periphery

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

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

gear casing (49).

44

46

ST 3058

9


W2-4-26

ASSEMBLY OF PUMP DEVICE

W178-02-11-086

70

79

78

79

80

76

81 66 65 18 16 15 17 12

23

20 11 10 9 51 29

9 101112171516821862 60, 6364 51

26

19

52

13

26

27

535859606157 56 78 74 71 73 72

24148321226772


W2-4-27

WCEB-02-04-004

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

32, 33

38, 39, 40 41

31 30

75

6 5 4 3

34, 35, 36 43 42 45

46

25

47

48

50

49

2 1 55 54 28

37

44

68


W2-4-28

WCEB-02-04-004

W178-02-11-089

32, 33

43 42 45

49

4444

12 11 10

101112

19

13


W2-4-29

Assembly of Pump Device

1. Tap and install ball bearing (44) into gear casing (49) with the stamped mark facing inside by using a bar and hammer. Tap and listen to ring in order to check that ball bearing (44) is installed completely.

2. Place gear (45) on ball bearing (44). Insert gear

shaft (46) while aligning with the spline.

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

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

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

5. Install O-ring (33) to plug (32). Install plug (32) to gear casing (49).

: 22 mm : 70 N⋅m (7 kgf⋅m, 52 lbf⋅ft)

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

to 80 °C (122 to 176 °F).

CAUTION: Be careful as bearing (12) is too hot.

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

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

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

CAUTION: Be careful as bearing (10) is too hot.

9. Apply hydraulic oil onto the inside of bearings (10)

(2 used). Install bearings (10) (2 used) to shafts (13, 19) by using a press.


W2-4-30

WCEB-02-04-004

W178-02-11-089

53 12 20 10 9

9 1012

19

13


W2-4-31

10. Set the pre-loads of bearings (10, 12) installed on shaft (13) according to the following procedures.

• Apply hydraulic oil onto the thread part of bearing nut (9). Tighten bearing nut (9) until bearing nut (9) comes in contact with bearing (10) by using special tool (ST 3058).

W178-02-11-090

• Install special tool (ST 3070) to bearing (10). Rotate 2 to 3 turns and measure the starting torque.

W178-02-11-091

• Adjust bearing nut (9) until the starting torque

reaches specification. : 1.96±0.49 N⋅m

(0.20±0.05 kgf⋅m, 1.45±0.36 lbf⋅ft) NOTE: If the starting torque is higher than the limit

of specified torque, loosen bearing nut (9). Tap the shaft end and release the load of bearing (10).

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

shaft (19) in the same way as step 10. 12. Install slide ring (20) to the side to insert shaft (19)

in pump casing (53).

10

ST 3070

9 10

ST 3058


W2-4-32

W178-02-11-092

53 12 10 51

51

19

52

13

Regulator Mounting Surface

23

53

24


W2-4-33

13. Warm up pump casing (53) to 50 to 80 °C (122 to 176 °F).

14. Apply hydraulic oil onto the outside of bearings

(10, 12) installed on shaft (19). Install shaft (19) to pump casing (53) by using special tool. If it is difficult to insert shaft (19), tap shaft (19) by using a bar.

W178-02-11-093

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

way as step 14. 16. Wait for pump casing (53) in order to cool down to

the temperature lower than 40 °C (104 °F). 17. Install O-ring (23) to stopper (24). Install stopper

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



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

19. Install special tools (ST 2649, ST 2650) over the spline parts of shafts (13, 19).

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

W178-02-11-094

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

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

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

shafts (13, 19). 22. Install retaining rings (52) (2 used) to pump casing

(53).

19

53

M8, Pitch 1.25 mm

Special Tool

Wooden BlockWooden Block

51

ST 2650

ST 2649


W2-4-34

WCEB-02-04-004

W178-02-11-096

53 29

27

26

19

13

26

17

75

45

49

53 55 54 28

50


W2-4-35

23. Align the matching marks and install gears (27, 29) to shafts (13, 19). Install retaining rings (26) (2 used) to shafts (13, 19). When replacing the shaft and the gear, install the gear according to the following procedure.

• Secure special tool (ST 7934) to the plunger (17) mounting side of shafts (13, 19).

W178-02-11-097

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

mounting side for gears (27, 29), until shafts (13, 19) come into contact with special tool. (Remove a play in periphery direction.)

• Install gear (27) and retaining ring (26) to the spline of shaft (13).

• Insert gear (29) into the spline of shaft (19) and engage with gear (27). If gear (29) does not engage, turn and adjust shaft (19) in a play range of special tool.

• Install retaining ring (26) to the spline of shaft (19).

• Remove special tool (ST 7934). 24. Install spring pins (50) (2 used) to gear casing

(49). Install gasket (28).



the socket bolt (75) hole on pump casing (53). Hoist pump casing (53). While engaging gear (45) with gear (29), install pump casing (53) to gear casing (49) with bolts (55) and spring washers (54) (6 used for each).

: 24 mm : 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)

19

13ST 7934

M8, Pitch 1.25 mm


W2-4-36

WCEB-02-04-004

W178-02-11-096

38, 39, 40 41 38 39, 40

49

41

70

19

13

5362 83 15 14 17

62 83 15 14 1759, 61

34, 35, 36


W2-4-37

26. Apply THREEBOND #1215 onto the mounting surface of pilot pump (41). Install pilot pump (41) to gear casing (49) with socket bolts (38), spring washers (39) and washers (40) (2 used for each).

: 8 mm : 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

27. Install gasket (34) and pipe (36) to gear casing

(49) with socket bolts (35) (2 used). : 6 mm : 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

IMPORTANT: As the pump performance may be

changed, do not deform link (83). 28. Align with the groove for pin (59) on pump casing

(53) and install the link (83) assemblies (2 used) with lever (62) facing to the selector head (70) side.

NOTE: Both surfaces of pin (59) are parallel to each other. Align the parallel surface with the groove.

W178-02-11-098

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

surface of shafts (13, 19).

30. Insert plungers (17) (7 used for each) into shafts (13, 19).

31. Apply grease onto pins (14) (2 used). Install pin

(14) to center shafts (15) (2 used). 32. Apply grease onto the spherical surface of center

shafts (15) (2 used). Install center shafts (15) (2 used) to shafts (13, 19).

59

53 83

Parallel Surface

Parallel Surface

61


W2-4-38

W178-02-11-099

W178-02-04-016

81

63

5317141518791662 60

64 60, 63 62 18 83 16 15 14 17

53

19

18 8

1467

65

70


W2-4-39

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

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

(17) (14 used) into rotors (18) (2 used). 35. Insert the round file into the center hole on center

shaft (15). While rotating center shaft (15) by using the round file, insert pin (14) into the groove of rotor (18). (Both right and left pumps)

NOTE: If pin (14) does not enter into the groove on rotor (18), selector head (70) cannot be installed to pump casing (53).

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

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

W178-02-11-100

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

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

38. Install backup ring (65), O-ring (66) and O-rings (8) (6 used) to pump casing (53).

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

(53).

Upward81 64


W2-4-40

WCEB-02-04-004

W178-02-04-016


7570

75

70

78

Mounting Surface for Suction Pipe

76

77

5318 74 73 71 72

1480 64, 8172 79 67


W2-4-41

40. Apply hydraulic oil onto servo pistons (77) (2 used). Insert servo pistons (77) (2 used) into selector head (70).

41. Apply LOCTITE LI829 onto the thread part of set

screws (76) (2 used). Install pins (78) (2 used) to servo pistons (77) (2 used) with set screws (76) (2 used).

: 6 mm : 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)

CAUTION: Selector head (70) weight: 29 kg (64 lb)

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

into the thread hole for the suction pipe on selector head (70). Attach a nylon sling onto eyebolts (2 used). Hoist selector head (70). Place selector head (70) on pump casing (53) while aligning selector head (70) with spring pin (67).

NOTE: Check the clearance between selector head (70) and pump casing (53) in order to compare with the clearance before disassembling. If the clearance is larger, pin (14) may not be inserted into the groove on rotor (18), or pin (78) may not be inserted into the holes on valve plates (64, 81).

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

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

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

45. Install O-rings (74) (2 used) to stoppers S (73) (2 used). Apply grease onto O-rings (74) (2 used). Install stoppers S (73) (2 used) to selector head (70) with socket bolts (72) (8 used).

: 6 mm : 19.5 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)

46. Install O-rings (79) (2 used) to stoppers L (80) (2

used). Apply grease onto O-rings (79) (2 used). Install stoppers L (80) (2 used) to selector head (70) with socket bolts (72) (8 used).

: 6 mm : 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)


W2-4-42

WCEB-02-04-004

WCEB-02-04-015

47

48

49

19

53

2 1

7 56 57 61 58

5 3 6

83


W2-4-43

47. Install O-rings (58) (2 used), O-rings (57) (2 used), O-rings (7) (4 used) and spring pins (56) (2 used) to pump casing (53).

48. Install right regulator (2) to pump casing (53)

according to the following procedure. • Adjust the sleeve position so that two grooves in

both sleeves on right regulator (2) are in a line. • Place right regulator (2) on pump casing (53).

Insert pin (61) for link (83) into two grooves on the sleeve.

• Move right regulator (2) so that spring pin (56) out of pump casing (53) can enter into right regulator (2).

• Install right regulator (2) to pump casing (53) with socket bolts (1) (4 used).

: 8 mm : 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

W178-02-11-101

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

socket bolts (3) (2 used) and socket bolts (5) (2 used) in the same way as step 48.

: 8 mm : 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

CAUTION: Pump device weight: 160 kg (360 lb)

50. Hoist and place selector head (70) with the

regulator mounting side facing upward. 51. Insert special tool (ST 2650) to shaft (19). Apply

grease onto oil seal (48). Install oil seal (48) to shaft (19). Remove special tool (ST 2650). Tap and install oil seal (48).

NOTE: If special tool (ST 2650) is not available, wind the vinyl tape over the spline parts of shaft (19) in order to protect oil seal (48). Install oil seal (48).

W178-02-11-103

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

48

ST 2650

53

2 Sleeve 61

83 56


W2-4-44

WCEB-02-04-004

W178-02-04-016

31 30

68

49

37 36 25


W2-4-45

53. Wind the seal tape onto elbow (31). Install elbow (31) to gear casing (49). Add engine oil (1.0 L, 0.3 US gal) through the elbow (31) hole.

54. Wind the seal tape onto plug (30). Install plug (30)

to elbow (31). : 30 mm : 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

W1V1-02-04-010

IMPORTANT: The breather hole of plug (25) is

located at the left side, viewed from the front of gear casing (49).

55. Wind the seal tape onto plug (25). Install plug (25) to gear casing (49).

: 17 mm : 39.5 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

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

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

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

49

31

30


W2-4-46

DISASSEMBLY OF REGULATOR

WCEB-02-04-019

1 - Pipe 12 - Cylinder 23 - Lock Nut 33 - Lock Nut 2 - Socket Bolt (2 Used) 13 - O-Ring 24 - Lock Nut 34 - Lock Nut 3 - Solenoid Valve 14 - Piston 25 - Cover 35 - Cover 4 - O-Ring 15 - Sleeve 26 - Set Bolt 36 - Adjuster 5 - Low Pressure Sensor 16 - Spool 27 - Lock Nut 37 - O-Ring 6 - O-Ring 17 - Spring 28 - Socket Bolt (8 Used) 38 - Stopper 7 - O-Ring 18 - Spring 29 - O-Ring 39 - O-Ring 8 - O-Ring 19 - O-Ring 30 - Cylinder 40 - Spring 9 - Piston 20 - Stopper 31 - Piston 41 - Spool

10 - O-Ring 21 - O-Ring 32 - Casing 42 - Sleeve 11 - Backup Ring 22 - Adjuster

WCEB-02-04-016

Left Regulator

Right Regulator

1

2

3

910

1112

1314

4

5 67

17

16

15

8

1819

22

20

21 24 23

25

26

27

28

2930

31 32

42

28

41

4039

3837

3635

34 33


W2-4-47

Disassembly of Regulator • The regulators are used for right pump and left

pump. The inner structure in the regulator is fully identical, and the difference is only in its accessories. Here the left regulator is explained.

IMPORTANT: As the setting changes, do not

disassemble adjusting screws (23, 24, 26, 27, 33 and 34). When adjusting screws (23, 24, 26, 27, 33 and 34) must be disassembled, carry out adjustment according to the procedure of performance test after assembling.

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

from casing (32). : 22 mm

2. Remove socket bolts (2) (2 used) from solenoid

valve (3). Remove the solenoid valve (3) assembly and O-rings (6, 7, 8) from casing (32).

: 8 mm IMPORTANT: As the setting changes, do not turn

set bolt (26), lock nuts (23, 24 and 27).

3. Remove socket bolts (28) (4 used) from cover (25). Remove cover (25) from casing (32). Set bolt (26) and the stopper (20) assembly are removed with cover (25) together.

: 6 mm

IMPORTANT: As the setting changes, do not turn lock nuts (33, 34).

4. Remove socket bolts (28) (4 used) from cover (35). Remove cover (35) and piston (14) from casing (32). The stopper (38) assembly is removed with cover (35) together.

: 6 mm

5. Remove springs (17, 18) from casing (32).

6. Insert a round bar into the hole on casing (32). Push the spool (16) end. Remove cylinder (12), sleeve (15) and spool (16) from casing (32). Piston (9) is removed with cylinder (12) together.

7. Remove piston (9) from cylinder (12).

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

9. Insert a round bar into the hole on casing (32).

Push the spool (41) end. Remove cylinder (30), sleeve (42) and spool (41) from casing (32). Piston (31) is removed with cylinder (30) together.

10. Remove piston (31) from cylinder (30).


W2-4-48

ASSEMBLY OF REGULATOR

WCEB-02-04-016

WCEB-02-04-017

1 - Pipe 12 - Cylinder 23 - Lock Nut 33 - Lock Nut 2 - Socket Bolt (2 Used) 13 - O-Ring 24 - Lock Nut 34 - Lock Nut 3 - Solenoid Valve 14 - Piston 25 - Cover 35 - Cover 4 - O-Ring 15 - Sleeve 26 - Set Bolt 36 - Adjuster 5 - Low Pressure Sensor 16 - Spool 27 - Lock Nut 37 - O-Ring 6 - O-Ring 17 - Spring 28 - Socket Bolt (8 Used) 38 - Stopper 7 - O-Ring 18 - Spring 29 - O-Ring 39 - O-Ring 8 - O-Ring 19 - O-Ring 30 - Cylinder 40 - Spring 9 - Piston 20 - Stopper 31 - Piston 41 - Spool

10 - O-Ring 21 - O-Ring 32 - Casing 42 - Sleeve 11 - Backup Ring 22 - Adjuster

2

1

24

35

3, 6, 7, 8

4, 5

38

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

39 34 36 3342 41 40 3725 29 30 31

26

14

27

28


W2-4-49

Assembly of Regulator IMPORTANT: Two holes for sleeves (15, 42) on

casing (32) are the same bores. The shapes of various parts in casing (32) are very similar. Check the illustration and assemble the regulator.

1. Clean all parts and apply hydraulic oil.

2. Insert spool (41) into sleeve (42). Install sleeve

(42) to the center of casing (32) by using a round bar. Check the direction to install sleeve (42), spool (41) and piston (31).

3. Install O-ring (29) to cylinder (30).

4. Insert piston (31) into cylinder (30). Install cylinder

(30) to casing (32).

5. Insert spool (16) into sleeve (15). Install sleeve (15) to the center of casing (32) by using a round bar. Check the direction to install sleeve (15) and spool (16).

6. Install O-rings (10, 13) and backup ring (11) to

cylinder (12).

7. Insert piston (9) into cylinder (12). Install cylinder (12) to casing (32).

8. Install piston (14) to cover (35) from the mounting

side for casing (32).

9. Install O-ring (37) and spring (40) to the stopper (38) assembly with cover (35) attached. Install cover (35) to casing (32) with socket bolts (28) (4 used).

: 6 mm : 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

10. Install O-ring (21) and springs (17, 18) to the

stopper (20) assembly with cover (25) attached. Install cover (25) to casing (32) with socket bolts (28) (4 used).

: 6 mm : 19.6 N⋅m (2 kgf⋅m, 14 lbf⋅ft)

11. Apply grease onto O-rings (6, 7 and 8). Install

O-rings (6, 7 and 8) to solenoid valve (3). Install solenoid valve (3) to casing (32) with socket bolts (2) (2 used).

: 8 mm : 49 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

12. Apply grease onto the thread part of pipe (1).

Install pipe (1) to casing (32). : 22 mm : 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)


W2-4-50

STRUCTURE OF PILOT PUMP

WCEB-02-04-018

WCEB-02-04-010

1 2

3 4

5 6

7 3

21

68

9

1716

15

12

3

13

146

7

32

16

12 11

10

3

14

16

17

13

7

9

5

4

33

21

1210 7 8

2 1

15


W2-4-51

Tightening Torque Item Part Name Q’ty Wrench Size

(mm) N⋅m (kgf⋅m, lbf⋅ft) Remark

1 Plate Seal 4 2 Backup Ring 4 3 Side Plate 4 4 Rear Drive Gear 1 5 Driven Gear 1 6 Kmock Pin 8 7 Gear Plate 2 8 Cover 1 9 Socket Bolt 4

10 Coupling 1 11 Stabilizer 2 12 Center Plate 1 13 Driven Gear 1 14 Front Drive Gear 1 15 Flange 1 16 Oil Seal 1 17 Retaining Ring 1


W2-4-52

(Blank)

UPPERSTRUCTURE / Control Valve

W2-5-1

REMOVAL AND INSTALLATION OF CONTROL VALVE




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

3. Disconnect hoses (5) (3 used) from piping (6). Cap the open ends.

: 19 mm, 27 mm, 50mm

4. Remove signal control valve (7) from bracket (8). (Refer to REMOVAL AND INSTALLATION OF SIGNAL CONTROL VALVE on W2-9-1.)

5. Remove 4-spool solenoid valve unit from control

valve (9). (Refer to REMOVAL AND INSTALLATION OF 4-SPOOL SOLENOID VALVE UNIT on W2-11-1.)

6. Disconnect all connectors, hoses and pipings from

control valve (9). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 17 mm, 19 mm, 22 mm, 36 mm : 8 mm

WCJB-02-01-002

WCJB-02-05-001

5

1 2 3 2 4

6

8 910

7


W2-5-2

CAUTION: The control valve (9) assembly weight: 238 kg (560 lb)


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

8. Remove bolts (12) (4 used) and washers (11) (4 used) from brackets (13, 16). Hoist and remove the control valve (9) assembly from the main frame.

: 24 mm

CAUTION: Control valve (9) weight: 216 kg (480 lb)

9. While holding the control valve (9) assembly,

remove bolts (15) (4 used) and spacers (14) (4 used) from brackets (13, 16). Remove brackets (13, 16) from control valve (9).

: 24 mm

WCJB-02-05-022

WCJB-02-05-002

9

12

11

13

14

15

12

11

16

14

15

9

Eyebolt Mounting Hole Eyebolt Mounting Hole


W2-5-3

Installation

CAUTION: Control valve (9) weight: 216 kg (480 lb)


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

2. Install brackets (13, 16) to control valve (9) with bolts (15) (4 used) and spacers (14) (4 used).

: 24 mm : 210 N⋅m (21.5 kgf⋅m, 165 lbf⋅ft)

CAUTION: The control valve (9) assembly weight: 238 kg (560 lb)

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

the mounting hole on the main frame. Install the control valve (9) assembly to the main frame with bolts (12) (4 used) and washers (11) (4 used).

: 24 mm : 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)

WCJB-02-05-022

WCJB-02-05-002

9

Eyebolt Mounting Hole Eyebolt Mounting Hole

9

12

11

13

14

15

12

11

16

14

15


W2-5-4

4. Connect all connectors, hoses and pipings to control valve (9).

: 17 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 40 N⋅m (4 kgf⋅m, 30 lbf⋅ft) : 36 mm : 180 N⋅m (18 kgf⋅m, 133 lbf⋅ft) : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

5. Install the 4-spool solenoid valve unit to control valve (9). (Refer to REMOVAL AND INSTALLATION OF 4-SOOL SOLENOID VALVE on W2-11-1.)

6. Install signal control valve (7) to control valve (9).

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

7. Connect hoses (5) (3 used) to piping (6). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 50 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

WCJB-02-05-001

WCJB-02-05-001

WCJB-02-05-001

9

7

5 6

8

10 9


W2-5-5

8. Install cover (4) to bracket (1) with sems bolts (2) (4 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

9. Shut cover (3).

WCJB-02-01-002

1 2 3 2 4


W2-5-6

DISASSEMBLY OF CONTROL VALVE 4-SPOOL SIDE

WCJB-02-05-003

Boom Anti-Drift Valve2021

2223

2425

2627

28 29

30 31

3233

34

6

15 16

15

1718

87

17

19

15 11 12

35

Travel

3637

3839

40 39

41

Bucket

4644

45

47

3940

39

41

42 43

Boom (1)

3940

39

41

49 44

45

50

48 43

Arm (2)

51

39 52

53

5239

41

40

Arm Regenerative Valve

54 55

5657

5859

4

59

63

6260

61

1

Check Valve (Arm Regenerative Circuit)

34

5

6

78

910

1112

143

4

13 6

1112

2


W2-5-7

WCJB-02-05-004

68

11

12

11

12

11

12

1

Flow Combiner Valve

69

470

7172

7173

59 64

65 66

63

59

6763

67 63

63

59

59

67

16

74 15

1574 15

116

115

Bypass Shut-Out Valve

106 104

103

105

6

107

108

4

Boom Anti-Drift Valve

75

76

7718

78

798081

6

83 82

Arm 2 Flow Rate Control Valve (Switch Valve)

121

125

98

117 122

115

113

114

18 78

87

109 99

87

101102

7718

100110 111 112

77

77

116 117

119

120 121

118

123

124 121 120

127128

129

120

117

115

126116

Bucket Flow Rate Control Valve

9392

9495

96 97

98

77898887868584

18

9091


W2-5-8

1 - Housing 34 - Plug 66 - Plug 98 - Socket Bolt (12 Used)2 - Poppet 35 - Spool 67 - Cap (3 Used) 99 - Poppet 3 - Spring (2 Used) 36 - O-Ring 68 - Socket Bolt (2 Used) 100 - Poppet 4 - O-Ring (4 Used) 37 - Backup Ring 69 - Cap 101 - Spring 5 - Flange 38 - Plug 70 - Bolt 102 - Plug 6 - Socket Bolt (13 Used) 39 - Spring Seat (8 Used) 71 - Spring Seat (2 Used) 103 - Spool 7 - Plug (2 Used) 40 - Spring (4 Used) 72 - Spring 104 - Spring 8 - O-Ring (2 Used) 41 - Bolt (4 Used) 73 - Spool 105 - Flange 9 - Poppet 42 - Plug 74 - Overload Relief Valve (2 Used) 106 - O-Ring 10 - Spring 43 - Backup Ring (2 Used) 75 - Poppet 107 - Cap 11 - O-Ring (6 Used) 44 - O-Ring (2 Used) 76 - Spring 108 - Socket Bolt (4 Used)12 - Plug (6 Used) 45 - Spring (2 Used) 77 - O-Ring (5 Used) 109 - Poppet 13 - Flange 46 - Poppet 78 - O-Ring (2 Used) 110 - Poppet 14 - Poppet 47 - Spool 79 - Body 111 - Spring 15 - O-Ring (6 Used) 48 - Plug 80 - O-Ring 112 - Plug 16 - Valve (2 Used) 49 - Poppet 81 - Plug 113 - Poppet 17 - Overload Relief Valve (2 Used) 50 - Spool 82 - O-Ring 114 - Spring 18 - O-Ring (12 Used) 51 - Spool 83 - Plug 115 - Plug (3 Used) 19 - O-Ring 52 - Spring Seat (2 Used) 84 - Poppet 116 - O-Ring (3 Used) 20 - Spring 53 - Spring 85 - Poppet 117 - Spring Seat (3 Used)21 - Seat 54 - Spool 86 - Spring 118 - Spring 22 - Poppet 55 - O-Ring 87 - Plug 119 - Spool 23 - Backup Ring 56 - Backup Ring 88 - Spring (3 Used) 120 - Plug (3 Used) 24 - O-Ring 57 - Spool 89 - Sleeve 121 - O-Ring (3 Used) 25 - O-Ring 58 - Spring 90 - Plug 122 - Spring 26 - Backup Ring 59 - O-Ring (8 Used) 91 - O-Ring 123 - Spool 27 - Sleeve 60 - O-Ring 92 - Body 124 - Body 28 - Spool 61 - Plug 93 - Spool 125 - Spool 29 - O-Ring 62 - Cap 94 - Spring 126 - Spring 30 - Body 63 - Socket Bolt (14 Used) 95 - Spring Seat 127 - Plug 31 - Spring 64 - Cap 96 - O-Ring 128 - Plug 32 - Poppet 65 - O-Ring 97 - Plug 129 - O-Ring 33 - O-Ring


W2-5-9

(Blank)


W2-5-10

WCJB-02-05-003

Boom Anti-Drift Valve2021

2223

2425

26 27

28 29

30 31

3233

34

6

35

15 16

15

1718

87

17

15 11 12

47

5051

Arm Regenerative Valve

54 55

5657

5859

4

59

63

62

1

Check Valve (Arm Regenerative Circuit)

34

5

6

78

910

1112

143

4

13 6

1112

2


W2-5-11

Disassembly of Control Valve 4-Spool Side • Disassembly of Spool

1. Remove socket bolts (63) (6 used) from cap (62). Remove cap (62), O-rings (59) (4 used) and O-ring (4) from housing (1).

: 8 mm

2. Put the matching marks on the spool (35, 47, 50, 51, 54) assemblies and housing (1). Remove the spool (35, 47, 50, 51) assemblies, spring (58) and the spool (54) assembly from housing (1).

NOTE: Do not disassemble the spool (54) assembly unless necessary.

• Disassembly of Boom Anti-Drift Valve

3. Loosen plug (34) from body (30). : 38 mm

4. Remove socket bolts (6) (3 used) from body (30).

Remove the body (30) assembly, O-rings (18) (6 used) and O-ring (29) from housing (1).

: 8 mm

5. Remove piston (32) and spring (31) from body (30).

6. Remove the sleeve (27) assembly, seat (21) and

spring (20) from housing (1). Remove backup rings (23, 26), O-rings (24, 25), poppet (22) and spool (28) from sleeve (27).

• Disassembly of Overload Relief Valve (17) IMPORTANT: Do not disassemble the overload

relief valve. When disassembling the overload relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test)

7. Remove overload relief valves (17) (2 used) from housing (1).

: 32 mm

8. Remove valve (16) from housing (1). : 32 mm

• Disassembly of Check Valve

9. Remove plug (12), spring (10) and poppet (9) from housing (1).

: 6 mm 10. Remove socket bolts (6) (2 used) from flange (5).

Remove flange (5), O-ring (4), spring (3) and poppet (2) from housing (1).



: 8 mm 12. Remove plugs (7, 12) (2 used for each) from

housing (1). : 6 mm, 10 mm


W2-5-12

WCJB-02-05-003

35

Travel

3637

3839

40 39

41

Bucket

4644

45

47

3940

39

41

42 43

Boom (1)

3940

39

41

49 44

45

50

48 43

Arm (2)

51

39 52

53

5239

41

40


W2-5-13

• Disassembly of Travel Spool (35) 13. Clamp spool (35) in a vise by using wooden

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

: 8 mm • Disassembly of Bucket Spool (47) 14. Clamp spool (47) in a vise by using wooden


: 8 mm 15. Warm up the plug (42) part of spool (47) by using

a drier. Remove plug (42) from spool (47) by using special tool (ST 5909). Remove O-ring (44) and backup ring (43) from plug (42).

W157-02-05-049

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

(47).

• Disassembly of Boom 1 Spool (50) 17. Clamp spool (50) in a vise by using wooden


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

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

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

(50). • Disassembly of Arm 2 Spool (51) 20. Clamp spool (51) in a vise by using wooden

pieces. Remove bolt (41), spring seats (39, 52), springs (53, 40) and spring seats (52, 39) from spool (51).

: 8 mm

ST 5909


W2-5-14

WCJB-02-05-004

1

68

Flow Combiner Valve

69

470

7172

7173

59 64

65 66

63

59

6763

67 63

63

59

59

67

16

74 15

1574 15

Arm 2 Flow Rate Control Valve (Switch Valve)

121

125

98

117 122

116

115

115

113

114

18 78

87

109 99

87

101102

7718

100110 111 112

77

77

116 117

119

120 121

118

123

124 121 120

127128

129

120

117

115

126116

Bucket Flow Rate Control Valve

9392

9495

96 97

98

77898887868584

18

9091


W2-5-15

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

: 8 mm • Disassembly of Flow Combiner Valve 22. Remove socket bolts (68) (2 used) from cap (69).

Remove cap (69), O-ring (4) and the spool (73) assembly from housing (1). Remove bolt (70), spring seats (71) (2 used) and spring (72) from spool (73).

: 5 mm • Disassemble Overload Relief Valve IMPORTANT: Do not disassemble the overload

relief valve. When disassembling the overload relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test)

23. Remove overload relief valves (74) (2 used) from housing (1).

: 32 mm 24. Remove valve (16) from housing (1).

: 32 mm • Disassembly of Bucket Flow Rate Control Valve 25. Remove socket bolts (98) (4 used) from body (92).

Remove body (92) and O-rings (18, 77) from housing (1).

: 8 mm 26. Remove plug (97), spring seat (95), spring (94)

and spool (93) from body (92). Remove plug (90) from body (92).

: 27 mm

27. Remove sleeve (89), spring (88), plug (87), spring (86) and poppets (85, 84) from housing (1).

• Disassembly of Arm 2 Flow Rate Control Valve 28. Remove socket bolts (98) (8 used) from body

(124). Remove body (124), O-rings (77) (3 used), O-rings (18) (2 used) (78) and plug (127) from housing (1).

: 8 mm 29. Remove plugs (115) (3 used), spring seats (117)

(3 used), springs (118, 122, 126) and spools (119, 123, 125) from body (124).

: 24 mm 30. Remove plugs (120) (3 used) and plug (129) from

body (124). 31. Remove poppet (113) and spring (114) from

housing (1). 32. Remove the poppets (99, 109) assemblies and

springs (87) (2 used) from housing (1). Remove plugs (102, 112), springs (101, 111) and poppets (100, 110) from poppets (99, 109).


W2-5-16

WCJB-02-05-004

1

11

12

11

12

11

12

Boom Anti-Drift Valve

75

76

7718

78

79

6

Bypass Shut-Out Valve

106 104

103

105

6

107

108

4


W2-5-17

• Disassembly of Boom Anti-Drift Valve 33. Remove socket bolts (6) (4 used) from body (79).

Remove body (79), O-rings (18) (3 used) and O-rings (78, 77) from housing (1).

: 8 mm 34. Remove spring (76) and poppet (75) from housing

(1). • Disassembly of Bypass Shut-Out Valve 35. Remove socket bolts (6) (2 used) from flange

(105). Remove flange (105) and O-ring (4) from housing (1).

: 8 mm 36. Remove spring (104) and spool (103) from

housing (1). 37. Remove socket bolts (108) (4 used) from cap

(107). Remove cap (107) and O-ring (106) from housing (1).

: 8 mm 38. Remove plugs (12) (3 used) from housing (1).

: 8 mm


W2-5-18

ASSEMBLY OF CONTROL VALVE 4-SPOOL SIDE

WCJB-02-05-005

WCJB-02-05-007

WCJB-02-05-006

WCJB-02-05-008

92

69, 10, 11, 12

1

63

59, 62

60, 61

6 15, 17 34 124 15, 17

63

65, 6659, 67 59, 64 6359, 67

63

115, 74 98

105 6

6 79 15, 17

12498 108 106, 107

15, 17 3, 4, 13, 14

2, 3, 4, 5 6

Control Valve (Upper) Control Valve (Lower)

View A View B

115, 16

11, 12

11, 12

1

7, 8

B

A


W2-5-19

WCJB-02-05-005

W1V1-02-05-038

WCJB-02-05-020

W1V1-02-05-036

W1V1-02-05-028

1

Section C-C (4-Spool Side)

7

A

8

Control Valve (Upper)

C

C

D

D

E

E

F

F

G

G

H

H

I

I

J

J

1

Section D-D (4-Spool Side)

1

Section E-E (4-Spool Side)

Travel

B

17

15

1574

Bucket

1

Section F-F (4-Spool Side)

C

D

15

74

Boom 1

15

39

40

39 41

42

43, 44

45

46

48

43, 44

45

49

5047

16

15

16

35


W2-5-20

W1V1-02-05-029

W1V1-02-05-071

W1V1-02-05-030

WCJB-02-05-021

1

Section G-G (4-Spool Side)

1

Section H-H (4-Spool Side)

15

17

65

66

Arm 2

E F

Section J-J (4-Spool Side)

105

4 104 103

Section I-I (4-Spool Side)

61

6041

395253523951

54

56, 55

57 58

62

62

107, 108

106


W2-5-21

W1V1-02-05-040

W1V1-02-05-031

W1V1-02-05-042

W1V1-02-05-033

W1V1-02-05-032

W1V1-02-05-034

73

Detail A

70

1

4

71

72 71

69

97

Detail B

84

96

95949293

91

90

1

85 77 18 86 87 8889

115

Detail E

116117126

125

121

120

12778

87 124 112 111 77 109 110

81

Detail C

78181

22 29

34 33 30 32 31 28 27 18 26 25

75

80

79

24 23 21 20

76 77 83

82

120

Detail D

121

119

124

118

117

116

1877

87 102115

1

10110099

120

Detail F

121

123

122117116

18 124 115

1

114113 77


W2-5-22

1 - Housing 34 - Plug 66 - Plug 98 - Socket Bolt (12 Used)2 - Poppet 35 - Spool 67 - Cap (3 Used) 99 - Poppet 3 - Spring (2 Used) 36 - O-Ring 68 - Socket Bolt (2 Used) 100 - Poppet 4 - O-Ring (4 Used) 37 - Backup Ring 69 - Cap 101 - Spring 5 - Flange 38 - Plug 70 - Bolt 102 - Plug 6 - Socket Bolt (13 Used) 39 - Spring Seat (8 Used) 71 - Spring Seat (2 Used) 103 - Spool 7 - Plug (2 Used) 40 - Spring (4 Used) 72 - Spring 104 - Spring 8 - O-Ring (2 Used) 41 - Bolt (4 Used) 73 - Spool 105 - Flange 9 - Poppet 42 - Plug 74 - Overload Relief Valve (2 Used) 106 - O-Ring 10 - Spring 43 - Backup Ring (2 Used) 75 - Poppet 107 - Cap 11 - O-Ring (6 Used) 44 - O-Ring (2 Used) 76 - Spring 108 - Socket Bolt (4 Used)12 - Plug (6 Used) 45 - Spring (2 Used) 77 - O-Ring (5 Used) 109 - Poppet 13 - Flange 46 - Poppet 78 - O-Ring (2 Used) 110 - Poppet 14 - Poppet 47 - Spool 79 - Body 111 - Spring 15 - O-Ring (6 Used) 48 - Plug 80 - O-Ring 112 - Plug 16 - Valve (2 Used) 49 - Poppet 81 - Plug 113 - Poppet 17 - Overload Relief Valve (2 Used) 50 - Spool 82 - O-Ring 114 - Spring 18 - O-Ring (12 Used) 51 - Spool 83 - Plug 115 - Plug (3 Used) 19 - O-Ring 52 - Spring Seat (2 Used) 84 - Poppet 116 - O-Ring (3 Used) 20 - Spring 53 - Spring 85 - Poppet 117 - Spring Seat (3 Used)21 - Seat 54 - Spool 86 - Spring 118 - Spring 22 - Poppet 55 - O-Ring 87 - Plug 119 - Spool 23 - Backup Ring 56 - Backup Ring 88 - Spring (3 Used) 120 - Plug (3 Used) 24 - O-Ring 57 - Spool 89 - Sleeve 121 - O-Ring (3 Used) 25 - O-Ring 58 - Spring 90 - Plug 122 - Spring 26 - Backup Ring 59 - O-Ring (8 Used) 91 - O-Ring 123 - Spool 27 - Sleeve 60 - O-Ring 92 - Body 124 - Body 28 - Spool 61 - Plug 93 - Spool 125 - Spool 29 - O-Ring 62 - Cap 94 - Spring 126 - Spring 30 - Body 63 - Socket Bolt (14 Used) 95 - Spring Seat 127 - Plug 31 - Spring 64 - Cap 96 - O-Ring 128 - O-Ring 32 - Poppet 65 - O-Ring 97 - Plug 129 - Plug 33 - O-Ring


W2-5-23

(Blank)


W2-5-24

WCJB-02-05-005

WCJB-02-05-006

WCJB-02-05-009


Arm 2 Boom 1 Buckets Travel

39

52

53

52

51

50

49

45 43, 44

59 63 64

59

67

43, 4445 46

41

39

40

39 1

41

KK

Section K-K

47

35

63

65, 66

59, 67 59, 646359, 67

63

Control Valve (Lower)

1

1

42486366 65

40

39


W2-5-25

Assembly of Control Valve 4-Spool Side • Assembly of Travel Spool

1. Clamp spool (35) in a vise by using wooden pieces. Install spring seat (39), spring (40), spring seat (39) and bolt (41) to spool (35).

: 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Bucket Spool

2. Clamp spool (47) in a vise by using wooden pieces. Install poppet (46) and spring (45) to the lower side of spool (47).

3. Install O-ring (44) and backup ring (43) to plug

(42). Apply LOCTITE #271 onto the thread part of plug (42).

4. Install plug (42) to spool (47) by using special tool

(ST 5909). : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

W157-02-05-049

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

(39) and bolt (41) to the upper side of spool (47). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Boom 1 Spool

6. Clamp spool (50) in a vise by using wooden pieces. Install poppet (49) and spring (45) to the lower side of spool (50).

7. Install O-ring (44) and backup ring (43) onto plug

(48). Apply LOCTITE #271 onto the thread of part of plug (48).

8. Install plug (48) to spool (50) by using special tool

(ST 5909). : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

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

(39) and bolt (41) to the upper side of spool (50). : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Arm 2 Spool 10. Clamp spool (51) in a vise by using wooden

pieces. Install spring seats (39, 52), springs (53, 40), spring seats (52, 39) and bolt (41) to spool (51).

: 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

11. Install O-ring (65) to plug (66). Install plug (66)

into cap (64). : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

12. Install O-rings (59) (4 used) onto housing (1).

Install caps (67) (3 used) and cap (64) to housing (1) with socket bolts (63) (8 used).

ST 5909


W2-5-26

WCJB-02-05-005

WCJB-02-05-006

WCJB-02-05-009

6359, 62 60, 61

Control Valve (Lower) Control Valve (Upper)

61

60

54

55, 56

59 1

Section K-K

57

4

58

163

62

59


W2-5-27

13. Clamp spool (54) in a vise by using wooden pieces. Install O-ring (55) and backup ring (56) onto spool (57). Install spool (57) to spool (54). Install spool (54) and spring (58) to housing (1).

14. Install the spool (51, 50, 47, 35) assemblies,

O-rings (59) (4 used) and O-ring (4) to housing (1). Install cap (62) to housing (1) with socket bolts (63) (6 used).

: 8 mm : 42 N⋅m (4.3 kgf⋅m, 31 lbf⋅ft)

15. Install O-ring (60) to plug (61). Install plug (61)

into cap (62). : 22 mm : 54±3 N⋅m (5.5±0.3 kgf⋅m, 40±2 lbf⋅ft)


W2-5-28

WCJB-02-05-007

W1V1-02-05-033

WCJB-02-05-008

WCJB-02-05-021

W1V1-02-05-040

97

Bucket Flow Rate Control Valve (Detail B)

84

96

95949293

91

90

1

85 77 18 86 87 88 89

Section of Bypass Shut-Out Valve

1

105, 6

4104 103

73

Section of Flow Combiner Valve (Detail A)

70

1

4

71

72 71

68, 69

115, 74

105 6

15, 17

Control Valve (Side) 68

Control Valve (Front) 69

98

92


W2-5-29

• Assembly of Bucket Flow Rate Control Valve 16. Install O-rings (96, 91) to plugs (97, 90).

17. Install spring (94), spool (93), spring seat (95) and

plug (97) to body (92). 18. Install plug (90) to body (92).

19. Install poppet (85), spring (86) and plug (87) to

poppet (84). Install the poppet (84) assembly, spring (88) and sleeve (89) into housing (1).

20. Install O-rings (18, 77) into housing (1). Install

body (92) to housing (1) with socket bolts (98) (4 used).

: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

• Assembly of Flow Combiner Valve 21. Install spring seat (71), spring (72) and spring

seat (71) to bolt (70). Install bolt (70) to spool (73). 22. Install spool (73) and O-ring (4) to housing (1).

Install cap (69) to housing (1) with socket bolts (68) (2 used).

: 5 mm : 10 N⋅m (1 kgf⋅m, 7 lbf⋅ft)

• Assembly of Bypass Shut-Out Valve 23. Install spool (103), spring (104) and O-ring (4) to

housing (1). Install flange (105) to housing (1) with socket bolts (6) (4 used).

: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

• Assembly of Overload Relief Valve IMPORTANT: If the overload relief valve is

disassembled, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.)

24. Install O-rings (15) (4 used) to overload relief valves (17, 74) (2 used for each). Install overload relief valves (17, 74) (2 used for each) to housing (1).

: 32 mm : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)


W2-5-30

WCJB-02-05-007

W1V1-02-05-033

WCJB-02-05-008

WCJB-02-05-021

W1V1-02-05-040

1106, 107 108 Control Valve (Side)

11, 12

69, 10, 11, 12

1

7, 8

3, 4, 13, 14

6Control Valve (Front)

2, 3, 4, 5

Bucket Flow Rate Control Valve (Detail B) Section of Bypass Shut-Out Valve

Section of Flow Combiner Valve (Detail A)


W2-5-31

• Assembly of Check Valve 25. Install O-ring (11) to plug (12). Install poppets (9)

(2 used), spring (10) and plug (12) into housing (1).

: 6 mm : 76±3 N⋅m (7.7±0.3 kgf⋅m, 56±2 lbf⋅ft)

26. Install plugs (7, 12) (2 used for each) to housing

(1). : 6 mm : 76±3 N⋅m (7.7±0.3 kgf⋅m, 56±2 lbf⋅ft) : 10 mm : 106 to 141 N⋅m

(10.8 to 14.4 kgf⋅m, 78 to 104 lbf⋅ft) 27. Install poppets (2, 14), springs (3) (2 used) and

O-rings (4) (2 used) to housing (1). 28. Install flanges (5, 13) to housing (1) with socket

bolts (6) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

29. Install O-ring (106) to housing (1). Install cap

(107) to housing (1) with socket bolts (108) (4 used).

: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)


W2-5-32

WCJB-02-05-007

W1V1-02-05-031

W1V1-02-05-042

W1V1-02-05-032

W1V1-02-05-034

1

679

124Control Valve (Side)

(Arm 2 Flow Rate Control Valve)

6 34 30

115

Arm 2 Flow Rate Control Valve (Detail E)

116117126

125

121

120

127 78

87 124 112 111 77 109 110

120

Arm 2 Flow Rate Control Valve (Detail D)

121

119

124

118

117

116

1877

87 102115

1

10110099

120

Arm 2 Flow Rate Control Valve (Detail F)

121

123

122117116

18 124 115

1

114113 77

81

Boom Anti-Drift Valve (Detail C)

78181

22 29

34 33 30 32 31 28 27 18 26 25

75

80

79

24 23 21 20

76 77 83

82


W2-5-33

• Assembly of Boom Anti-Drift Valve 30. Install backup rings (23, 26) and O-rings (24, 25)

to sleeve (27). 31. Face the hole on spool (28) to the poppet (22)

side. Install spool (28), poppet (22), seat (21) and spring (20) to sleeve (27). Install the sleeve (27) assembly to housing (1).

NOTE: Apply grease onto seat (21) and spring (20)in order to fall off.

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

piston (32), O-ring (29) and plug (34) to body (30). 33. Install O-rings (18) (3 used) to housing (1). Install

the body (30) assembly to housing (1) with socket bolts (6) (3 used).

: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

34. Tighten plug (34).

35. Install O-rings (80, 82) to plugs (81, 83).

36. Install poppet (75), spring (76), O-rings (77, 78)

and O-rings (18) (3 used) to housing (1). 37. Install body (79) to housing (1) with socket bolts

(6) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

38. Tighten plugs (81, 83).

• Assembly of Arm 2 Flow Rate Control Valve 39. Install O-rings (116, 121) (3 used for each) to

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

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

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

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

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

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

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

43. Install poppet (100), spring (101) and plug (102)

to poppet (99)as shown in detail D. Install the poppet (99) assembly, spring (87) O-rings (18, 77) to housing (1).

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

plug (112) to poppet (109) as shown in detail E. Install the poppet (109) assembly, spring (87), O-ring (77, 78) into housing (1).

45. Install poppet (113), spring (114) and O-rings (77,

18) to housing (1) as shown in detail F.


W2-5-34

WCJB-02-05-007

W1V1-02-05-031

W1V1-02-05-042

W1V1-02-05-032

W1V1-02-05-034

98124Control Valve (Side)

(Arm 2 Flow Rate Control Valve)

115

Arm 2 Flow Rate Control Valve (Detail E)

120

120

Arm 2 Flow Rate Control Valve (Detail D)

115

120

Arm 2 Flow Rate Control Valve (Detail F)

115

Boom Anti-Drift Valve (Detail C)

124


W2-5-35

46. Install body (124) to housing (1) with socket bolts (98) (8 used).

: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

47. Tighten plugs (115, 120) (3 used for each) to body

(124).


W2-5-36

DISASSEMBLY OF CONTROL VALVE 5-SPOOL SIDE

WCJB-02-05-010

27 31

28 29

30 32

34 36

33 35

Arm Anti-Drift Valve

37

3839

4041

8

1

Blade/Outrigger

42

43 44

43

45

1213

20

21

2224

23 25

26

2 3

49

1011 12

56

7 87 8

13

14

19

15

16 17

1814 15

Check Valve (5-Spool Side Parallel Circuit)

Auxiliary

43

4443

45

46

Boom 2

43

4443

45

47

Arm 1

43

44

4345

48

5049

49

Swing

43

4443

45

51

52 53

54 5552

56


W2-5-37

WCJB-02-05-011

Auxiliary Flow Rate Control Valve 58

60 59

79 80

6364

65

57

20

9 66 67 81 82 83 84

8

7

6

5

85

1

Load Check Valve (Blade/Outrigger)

Load Check Valve(Travel)

8

86

87

88

89

90

91 6

9495


74

7273

75

76 20

8

9

Load Check Valve (Boom 2 Parallel Circuit)

9

10

78

77

8

96

93

92

92

936

94 97

98

3 2

Arm 1 Flow Rate Control Valve58

60 59

61 62

6364

65

57

20

9 66 67 68 69 70 71

131225

13

12

13

12 107

1312

101

53 99

52

53

99

52

53

99

52

53 100

52

53

99

52

102

103

101

102

104 105

106 107

Check Valve


W2-5-38

1 - Housing 28 - Seat 55 - Plug 82 - Spring 2 - O-Ring 29 - Poppet 56 - Cap 83 - Poppet 3 - Plug 30 - Backup Ring 57 - Socket Bolt (8 Used) 84 - Poppet 4 - Poppet 31 - O-Ring 58 - Plug (2 Used) 85 - Poppet 5 - Spring 32 - O-Ring 59 - O-Ring (2 Used) 86 - Cover (2 Used) 6 - O-Ring (3 Used) 33 - Backup Ring 60 - Body (2 Used) 87 - O-Ring (2 Used) 7 - Flange (3 Used) 34 - Sleeve 61 - Spool 88 - Plug 8 - Socket Bolt (22 Used) 35 - Spool 62 - Spring 89 - O-Ring 9 - O-Ring (5 Used) 36 - O-Ring 63 - Spring Seat (2 Used) 90 - Spring 10 - Spring (2 Used) 37 - Body 64 - O-Ring (2 Used) 91 - Poppet 11 - Poppet 38 - Spring 65 - Plug (2 Used) 92 - Socket Bolt (4 Used) 12 - O-Ring (4 Used) 39 - Piston 66 - Sleeve (2 Used) 93 - Cap (2 Used) 13 - Plug (4 Used) 40 - O-Ring 67 - Spring (2 Used) 94 - Spring Seat (2 Used) 14 - O-Ring (2 Used) 41 - Plug 68 - Plug 95 - Spring 15 - Overload Relief Valve (2 Used) 42 - Spool 69 - Spring 96 - Spool 16 - O-Ring 43 - Spring Seat (10 Used) 70 - Poppet 97 - Spring 17 - Backup Ring 44 - Spring (5 Used) 71 - Poppet 98 - Spool 18 - Plug 45 - Bolt (5 Used) 72 - Plug 99 - Cap (4 Used) 19 - Main Relief Valve 46 - Spool 73 - O-Ring 100 - Cap 20 - O-Ring (6 Used) 47 - Spool 74 - Flange 101 - Overload Relief Valve (2 Used)21 - O-Ring 48 - Spool 75 - Spring 102 - O-Ring (2 Used) 22 - Spacer 49 - Spring Seat (2 Used) 76 - Poppet 103 - Plug 23 - Backup Ring 50 - Spring 77 - Flange (2 Used) 104 - Backup Ring 24 - O-Ring 51 - Spool 78 - Poppet (2 Used) 105 - O-Ring 25 - Spring 52 - O-Ring (10 Used) 79 - Spool 106 - Plug 26 - Poppet 53 - Socket Bolt (16 Used) 80 - Spring 107 - O-Ring 27 - Spring 54 - O-Ring 81 - Plug


W2-5-39

(Blank)


W2-5-40

WCJB-02-05-010

Blade/Outrigger


1

42

20

21

2224

23 25

26

49

1011

56

7 87 8

14

19

15

14 15

Check Valve (5-Spool Side Parallel Circuit)

27 31

28 29

30 32

34 36

33 35

37

3839

4041

8

Auxiliary

46

Boom 2

47

Arm 1

48

Swing

51

52 53

52

56


W2-5-41

Disassembly of Control Valve 5-Spool Side • Disassembly of Spool

1. Remove socket bolts (53) (6 used) from cap (56). Remove cap (56) and O-rings (52) (5 used) from housing (1).

: 8 mm

2. Put the matching marks on spools (42, 46, 47, 48, 51) and housing (1). Remove the spools (42, 46, 47, 48, 51) assemblies from housing (1).

• Disassembly of Arm Anti-Drift Valve

3. Remove plug (41) from body (37). : 38 mm

4. Remove socket bolts (8) (3 used) from body (37).

Remove the body (37) assembly, O-rings (21, 36) and O-rings (20) (4 used) from housing (1).

: 8 mm

5. Remove piston (39) and spring (38) from body (37).

: 38 mm

6. Remove spool (35), sleeve (34), poppet (29), seat (28) and spring (27) from housing (1). Remove backup rings (30, 33) and O-rings (31, 32) from sleeve (34).

• Disassembly of Overload Relief Valve (15) IMPORTANT: Do not disassemble the overload

relief valve. When disassembling the overload relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.)

7. Remove overload relief valves (15) (2 used) from housing (1). Remove O-rings (14) (2 used) from overload relief valves (15) (2 used).

: 32 mm • Disassembly of Main Relief Valve (19) IMPORTANT: Do not disassemble the main relief

valve. When disassembling the main relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.)

8. Remove main relief valve (19) from housing (1). : 32 mm

• Disassembly of Check Valve

9. Remove spacer (22), spring (25) and poppet (26) from housing (1). Remove backup ring (23) and O-ring (24) from spacer (22).

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




: 8 mm


W2-5-42

WCJB-02-05-010

1

Blade/Outrigger

42

43 44

43

45

1213

2 3

12 13

16 17

18

Auxiliary

43

4443

45

46

Boom 2

43

4443

45

47

Arm 1

43

44

4345

48

5049

49

Swing

43

4443

45

51


W2-5-43

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

: 8 mm 13. Remove plug (18) from housing (1). Remove

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

• Disassembly of Blade/Outrigger Spool (42) 14. Clamp spool (42) in a vise by using wooden


: 8 mm • Disassembly of Auxiliary Spool (46) 15. Clamp spool (46) in a vise by using wooden


: 8 mm • Disassembly of Boom 2 Spool (47) 16. Clamp spool (47) in a vise by using wooden


: 8 mm • Disassembly of Arm 1 Spool (48) 17. Clamp spool (48) in a vise by using wooden

pieces. Remove bolt (45), spring seats (43, 49), springs (44, 50) and spring seats (43, 49) from spool (48).

: 8 mm

• Disassembly of Swing Spool (51) 18. Clamp spool (51) in a vise by using wooden


: 8 mm


W2-5-44

WCJB-02-05-011

Auxiliary Flow Rate Control Valve58

60 59

79 80

6364

65

57

20

9 66 67 81 82 83 84

8

7

6

5

85

1

694

95


74

75

76 20

8

9

96

93

92

92

936

94 97

98

Arm 1 Flow Rate Control Valve58

60 59

61 62

6364

65

57

20

9 66 67 68 69 70 71

101

53 99

52

53

99

52

53

99

52

53 100

52

53

99

52

102

101

102

Digging Regenerative Valve

Auxiliary Flow Combiner Valve

Check Valve


W2-5-45

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

: 8 mm • Disassembly of Digging Regenerative Valve and

Auxiliary Flow Combiner Valve 20. Remove socket bolts (92) (4 used) from caps (93)

(2 used). Remove caps (93) (2 used), O-rings (6) (2 used), spring seats (94) (2 used), springs (95, 97) and spools (96, 98) from housing (1).

: 5 mm • Disassembly of Overload Relief Valve (101) IMPORTANT: Do not disassemble overload relief

valve (101). When disassembling the overload relief valve, pressure must be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.)

21. Remove overload relief valves (101) (2 used) from housing (1). Remove O-rings (102) (2 used) from overload relief valves (101) (2 used).

: 32 mm • Disassembly of Check Valve 22. Remove socket bolts (8) (2 used) from flange (7).


: 8 mm

• Disassembly of Arm Anti-Drift Valve 23. Remove socket bolts (8) (4 used) from flange (74).

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

: 8 mm • Disassembly of Arm 1 Flow Rate Control Valve and

Auxiliary Flow Rate Control Valve 24. Loosen plugs (58, 65) (2 used for each) from

bodies (60) (2 used). 25. Remove socket bolts (57) (8 used) from body (60)

(2 used). Remove O-rings (20, 9) (2 used for each) from housing (1).

: 8 mm 26. Remove plugs (65) (2 used), spring seats (63) (2

used), springs (63, 80) and spools (61, 79) from bodies (60) (2 used). Remove plugs (58) (2 used) from bodies (60) (2 used).

27. Remove O-rings (59, 64) (2 used for each) from

plugs (58, 65) (2 used for each). 28. Remove sleeves (66) (2 used), springs (67) (2

used), plugs (68, 81), springs (69, 82) and poppets (70, 71, 83, 84) from housing (1).


W2-5-46

WCJB-02-05-011

1

Load Check Valve (Blade/Outrigger)

Load Check Valve(Travel)

8

86

87

88

89

90

91

Load Check Valve (Boom 2 Parallel Circuit)

9

10

78

77

8

3 2

131225

13

12

13

12 107

99

103 104

105


W2-5-47

• Disassembly of Load Check Valve 29. Remove socket bolts (8) (4 used) from flange (77).


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

Remove cover (86) and O-ring (87) from housing (1).

: 8 mm 31. Remove plug (88), spring (90) and poppet (91)

from housing (1). Remove O-ring (89) from plug (88).

: 24 mm 32. Remove plug (13), spring (25) and poppet (107)

from housing (1). Remove O-ring (12) from plug (13).

: 8 mm

W1V1-02-05-016

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

backup ring (104) and O-ring (105) from plug (103).

: 24 mm 34. Remove plug (3) from housing (1). Remove

O-ring (2) from plug (3). : 10 mm

35. Remove plugs (13) (2 used) from housing (1). Remove O-rings (12) (2 used) from plugs (13) (2 used).

: 8 mm

13 25 107 12


W2-5-48

ASSEMBLY OF CONTROL VALVE 5-SPOOL SIDE

WCJB-02-05-005

WCJB-02-05-012

WCJB-02-05-006

W1V1-02-05-068

60

15 19

View A

41 37

1

8

74

57

5352, 56 54, 55


52, 99


5352, 995352, 99 53 52, 1005352, 9953

8 12, 13

8

2, 3

7, 9, 10, 11

4, 5, 6, 7

View B

12, 13

1

153

15 18

8

57

101 93

60 5399101 93 77 103

B

A


W2-5-49

WCJB-02-05-005

W1V1-02-05-043

WCJB-02-05-013

WCJB-02-05-014

W1V1-02-05-046

19

Section C-C (5-Spool Side)

12, 13

7

5

85

6

1

98

6 97 94 93

1

Section D-D (5-Spool Side)

Section E-E (5-Spool Side)

8

1

86

Blade/Outrigger

86

A

8

14, 15

Auxiliary

1

Section F-F (5-Spool Side)

Boom 2

8779

10

78


C

C

D

D

E

E

F

F

G

G

H

H

I

I

J

J

99

52

42

52

43

44

43

45 56

46

54

55

107

101, 102

47

99106

14, 15

101, 102


W2-5-50

W1V1-02-05-050

W1V1-02-05-051

W1V1-02-05-052

W1V1-02-05-033

W1V1-02-05-053

Section G-G (5-Spool Side)

1

Section H-H (5-Spool Side)

Section I-I (5-Spool Side)

1

77

B

Arm 1

1

Swing

14

15

D

102

101

C

8

9

10

78

65

Detail A 84

64

63806079

59

58

1

83 9 20 82 81 67 66

Detail B

514843494450494345

89 90 91

1

13 12 2 3

88


W2-5-51

W1V1-02-05-054

Detail C

WCJB-02-05-015

Detail D

1 - Housing 28 - Seat 55 - Plug 82 - Spring 2 - O-Ring 29 - Poppet 56 - Cap 83 - Poppet 3 - Plug 30 - Backup Ring 57 - Socket Bolt (8 Used) 84 - Poppet 4 - Poppet 31 - O-Ring 58 - Plug (2 Used) 85 - Poppet 5 - Spring 32 - O-Ring 59 - O-Ring (2 Used) 86 - Cover (2 Used) 6 - O-Ring (3 Used) 33 - Backup Ring 60 - Body (2 Used) 87 - O-Ring (2 Used) 7 - Flange (3 Used) 34 - Sleeve 61 - Spool 88 - Plug 8 - Socket Bolt (22 Used) 35 - Spool 62 - Spring 89 - O-Ring 9 - O-Ring (5 Used) 36 - O-Ring 63 - Spring Seat (2 Used) 90 - Spring 10 - Spring (2 Used) 37 - Body 64 - O-Ring (2 Used) 91 - Poppet 11 - Poppet 38 - Spring 65 - Plug (2 Used) 92 - Socket Bolt (4 Used) 12 - O-Ring (4 Used) 39 - Piston 66 - Sleeve (2 Used) 93 - Cap (2 Used) 13 - Plug (4 Used) 40 - O-Ring 67 - Spring (2 Used) 94 - Spring Seat (2 Used) 14 - O-Ring (2 Used) 41 - Plug 68 - Plug 95 - Spring 15 - Overload Relief Valve (2 Used) 42 - Spool 69 - Spring 96 - Spool 16 - O-Ring 43 - Spring Seat (10 Used) 70 - Poppet 97 - Spring 17 - Backup Ring 44 - Spring (5 Used) 71 - Poppet 98 - Spool 18 - Plug 45 - Bolt (5 Used) 72 - Plug 99 - Cap (4 Used) 19 - Main Relief Valve 46 - Spool 73 - O-Ring 100 - Cap 20 - O-Ring (6 Used) 47 - Spool 74 - Flange 101 - Overload Relief Valve (2 Used)21 - O-Ring 48 - Spool 75 - Spring 102 - O-Ring (2 Used) 22 - Spacer 49 - Spring Seat (2 Used) 76 - Poppet 103 - Plug 23 - Backup Ring 50 - Spring 77 - Flange (2 Used) 104 - Backup Ring 24 - O-Ring 51 - Spool 78 - Poppet (2 Used) 105 - O-Ring 25 - Spring 52 - O-Ring (10 Used) 79 - Spool 106 - Plug 26 - Poppet 53 - Socket Bolt (16 Used) 80 - Spring 107 - O-Ring 27 - Spring 54 - O-Ring 81 - Plug

41 40 39 37 38 35

36 34 33 32

29

31 30 28 27

76 75 9 73 72

20

20

71

64

63

62

61

70 9 1676665

60 58 59 68 20 69


W2-5-52

WCJB-02-05-005

WCJB-02-05-006

WCJB-02-05-016

LL

5352, 56 54, 55


153

45

Blade/Outrigger Boom 2 Arm 1 Swing

43

44

4543495044

51

48

52

53

55

56

1

Auxiliary

4943

107 106 100

Section L-L

99 999999

52

43 52

54

42

46

47

52, 99


5352, 995352, 99 53 52, 1005352, 9953

1


W2-5-53

• Assembly of Blade/Outrigger Spool 1. Secure spool (42) in a vise by using wooden

pieces. Install spring seat (43), spring (44), spring seat (43) and bolt (45) to spool (42).

: 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Auxiliary Spool

2. Secure spool (46) in a vise by using wooden pieces. Install spring seat (43), spring (44), spring seat (43) and bolt (45) to spool (46).

: 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Boom 2 Spool

3. Secure spool (47) in a vise by using wooden pieces. Install spring seat (43), spring (44), spring seat (43) and bolt (45) to spool (47).

: 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Arm 1 Spool

4. Secure spool (48) in a vise by using wooden pieces. Install spring seats (43, 49), springs (44, 50), spring seats (43, 49) and bolt (45) to spool (48).

: 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

• Assembly of Swing Spool

5. Secure spool (51) in a vise by using wooden pieces. Install spring seat (43), spring (44), spring seat (43) and bolt (45) into spool (51).

: 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

6. Install O-rings (52) (5 used) onto housing (1). Install cap (100) and cap (99) (4 used) to housing (1) with socket bolts (53) (10 used).

: 8 mm : 42±2 N⋅m (4.3±0.2 kgf⋅m, 31±1 lbf⋅ft)

7. Install the spools (42, 46, 47, 48, 51) assemblies

to housing (1).

8. Install O-rings (52) (5 used) to housing (1). Install cap (56) to housing (1) with socket bolts (53) (6 used).

: 8 mm : 42±2 N⋅m (4.3±0.2 kgf⋅m, 13±1 lbf⋅ft)

9. Install O-rings (54, 107) to plugs (55, 106). Install

plug (106) to cap (100). : 22 mm : 53±3 N⋅m (5.4±0.3 kgf⋅m, 39±2lbf⋅ft)

10. Install plug (55) to cap (56).

: 22 mm : 54±3 N⋅m (5.5±0.3 kgf⋅m, 40±2 lbf⋅ft)


W2-5-54

WCJB-02-05-012

WCJB-02-05-017

W1V1-02-05-049

W1V1-02-05-047

WCJB-02-05-015

Check Valve 1

7 6 5 85

Auxiliary Flow Combiner Valve

1

98

6

97

94

93 Section of Auxiliary Flow Rate Control Valve

(Detail A)

Load Check Valve

1

77 9 10 78 8

86, 87

8 16, 17, 18

Control Valve (Side)

86, 87

57

7

8

92

8 77 8

84

64

63

80

79

83 9 1676665

66 58 59 81 20 82

60

93


W2-5-55

• Assembly of Auxiliary Flow Rate Control Valve 11. Install O-rings (59, 64) to plugs (58, 65).




poppet (84). Install the poppet (84) assembly, spring (67) and sleeve (66) to housing (1).

15. Install O-rings (9, 20) into housing (1). Install body

(60) to housing (1) with socket bolts (57) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

• Assembly of Check Valve 16. Install poppet (85), spring (5) and O-ring (6) to


: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

• Assembly of Auxiliary Flow Combiner Valve 17. Install spool (96), spring (95) and spring seat (94)

to housing (1). Install cap (93) to housing (1) with socket bolts (92) (2 used).

: 5 mm : 10±1 N⋅m (1±0.1 kgf⋅m, 7±4 lbf⋅ft)

• Assembly of Load Check Valve 18. Install poppet (78), spring (10) and O-ring (9) to

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

(8) (4 used). : 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)


(18). Install plug (18) to housing (1). 21. Install O-rings (87) (2 used) to housing (1). Install

covers (86) (2 used) to housing (1) with socket bolts (8) (8 used).

: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)


W2-5-56

WCJB-02-05-012

W1V1-02-05-053

WCJB-02-05-015

W1V1-02-05-068

W1V1-02-05-054

W1V1-02-05-055

414039783835

36343332

29

31302827

7675 9 73 72

20

20

Section of Anti-Drift Valve (Detail C)

Section of Arm Flow Rate Control Valve (Detail D)

Section of Load Check Valve

Section of Load Check Valve (Detail B)

Control Valve (Front)

1

Control Valve (Side)

37

1

60

57

71

64

63

62

61

70 9 1 67 66 65

60 58 59 68 20 69

8


W2-5-57

• Assembly of Arm Anti-Drift Valve 22. Install backup rings (30, 33) and O-rings (31, 32)

to sleeve (34). 23. Face the hole on spool (35) to the poppet (29)

side. Install spool (35), poppet (29), seat (28) and spring (27) to sleeve (34). Install the sleeve (34) assembly to housing (1).

NOTE: Apply grease to seat (28) and spring (27) in order not to drop.

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

(38), piston (39), O-ring (36) and plug (41) to body (37).

25. Install O-rings (20) (3 used) and O-ring (21) to

housing (1). Install the body (37) assembly to housing (1) with socket bolts (8) (2 used).

: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

26. Tighten plug (41).

• Assembly of Arm Flow Rate Control Valve 27. Install O-rings (59, 64) to plugs (58, 65).




poppet (71). Install the poppet (71) assembly, spring (67) and sleeve (66) to housing (1).

31. Install O-rings (20) (3 used) and O-ring (9) to housing (1). Install body (60) to housing (1) with socket bolts (57) (4 used).

: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)


W2-5-58

WCJB-02-05-012

W1V1-02-05-053

WCJB-02-05-015

W1V1-02-05-068

W1V1-02-05-054

W1V1-02-05-055

Section of Arm Anti-Drift Valve (Detail C)

8 77 9 10 78

1

Section of Load Check Valve

88 89 90 91

1

13

12 2 3

Section of Load Check Valve (Detail B)

Section of Arm Flow Rate Control Valve (Detail D)

8 12, 13

8

2, 3

7, 9, 10, 11

4, 5, 6, 7

Control Valve (Front) 12, 13

14, 15 19

Control Valve (Side) 103, 104, 105

1

101, 102

14, 15

101, 102


W2-5-59

• Assembly of Load Check Valve 32. Install O-ring (89) to plug (88). Install poppet (91),

spring (90) and plug (88) to housing (1). 33. Install poppet (78), spring (10) and O-ring (9) to


: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

34. Install O-rings (2, 12) to plugs (3, 13). Install plugs

(3, 13) to housing (1). • Assembly of Overload Relief Valve IMPORTANT: If the overload relief valve is


35. Install O-rings (14, 102) (2 used for each) to overload relief valves (15, 101) (2 used for each). Install overload relief valves (15, 101) (2 used for each) to housing (1).

: 32 mm : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)


(103). Install plug (103) to housing (1).

• Assembly of Main Relief Valve IMPORTANT: If the main relief valve is


37. Install main relief valve (19) to housing (1). : 32 mm : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)

• Assembly of Check Valve 38. Install poppet (4), spring (5) and O-ring (6) to


: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

39. Install poppet (11), spring (10) and O-ring (9) to


: 8 mm : 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)

40. Install O-rings (12) (2 used) to plugs (13) (2 used).

Install plugs (13) (2 used) to housing (1). 41. Install O-ring (2) to plug (3). Install plug (3) into

housing (1).


W2-5-60

DISASSEMBLY OF HOUSING

W1V1-02-05-023

1 - Housing (5-Spool Side) 3 - Socket Bolt (9 Used) 5 - O-Ring (12 Used) 6 - O-Ring (3 Used) 2 - Housing (4-Spool Side) 4 - O-Ring (16 Used)

3 3

4

54

4

6

5

4

4

5

5

64

4

4

45

1

2


W2-5-61

Disassembly of Housing

CAUTION: Housing (1, 2) weight: 150 kg (340 lb) for each

1. Remove socket bolts (3) (9 used) from housing

(1). Remove O-rings (4) (16 used), O-rings (5) (12 used) and O-rings (6) (3 used) from housing (1 or 2).

: 14 mm

2. Divide housing (1) and (2).


W2-5-62

ASSEMBLY OF HOUSING

W1V1-02-05-011

WCJB-02-05-018

1 - Housing (5-Spool Side) 3 - Socket Bolt (9 Used) 5 - O-Ring (12 Used) 6 - O-Ring (3 Used) 2 - Housing (4-Spool Side) 4 - O-Ring (16 Used)

4

5

4 6 5

4

4 5 2

4

5

6

5

65

4

4 5

1

2

3

3

3

3

3


W2-5-63

Assembly of Housing

1. Install O-rings (4) (16 used), O-rings (5) (12 used) and O-rings (6) (3 used) to the housing (2) mounting surface.

CAUTION: Housing (1, 2) weight: 150 kg (340 lb) for each

2. Install housing (1) to housing (2) with socket bolts

(3) (9 used). : 14 mm : 205 to 215 N·m

(21 to 22 kgf·m, 152 to 159 lbf⋅ft)


W2-5-64

(Blank)


W2-5-65

REMOVAL AND INSTALLATION OF POSITIONING CONTROL VALVE


Removal 1. Disconnect hoses (1) (6 used) from valve (3).


: 19 mm, 27 mm

2. Remove sems bolts (2) (3 used) from valve (3). Remove valve (3) from bracket (4).

: 17 mm

Installation 1. Install valve (3) to bracket (4) with sems bolts (2)


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

: 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

WCJB-02-05-019

WCEB-02-05-011

WCEB-02-05-011

1

43 21

1

43 21

3


W2-5-66

DISASSEMBLY OF POSITIONING CONTROL VALVE

W198-02-05-001

1 - Nut 17 - Sleeve 33 - Backup Ring (2 Used) 48 - Socket Bolt 2 - Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt 3 - O-Ring 19 - Nut 35 - Sleeve 50 - Cover 4 - Spring 20 - Bolt 36 - O-Ring 51 - End Spool 5 - Valve 21 - O-Ring 37 - Seat 52 - Seat 6 - Sleeve 22 - Spring 38 - O-Ring 53 - Spring 7 - Backup Ring (2 Used) 23 - Valve 39 - Valve 54 - Spring 8 - O-Ring 24 - Sleeve 40 - Spring 55 - Seat 9 - O-Ring 25 - Backup Ring (2 Used) 41 - Sleeve 56 - O-Ring 10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool 11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring 12 - Pin 28 - Spring 44 - Poppet 59 - Plug 13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Rivet 14 - O-Ring 30 - Pin 46 - Cover 61 - Plate 15 - Backup Ring (2 Used) 31 - Valve 47 - O-Ring 62 - Housing 16 - Valve 32 - O-Ring

109

8 7

6 5

4 3

2 1

11 12

13

14 15

16 17

18

2827

2625

2423

2221

20 19

3635

3433

3231

30 29

45 46

47

6261

60

56 55 54

53 52

51 48

49 50

5758

59

444342

41

40

3938

37


W2-5-67

Disassembly of Positioning Control Valve

1. Remove socket bolts (45) (2 used) and socket bolts (48, 49) from covers (46, 50). Remove covers (46, 50) and O-rings (47, 56) from housing (62).

IMPORTANT: Turn and remove the spools. If they

stick even a little, try again instead of pulling roughly.

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

(62).

3. Clamp spool (57) in a vise by using wooden pieces. Remove end spool (51), seat (52), springs (53, 54) and seat (55) from spool (57).

: 8 mm

4. Remove plug (59) from spool (57). Remove O-ring (58) from plug (59).

IMPORTANT: Do not disassemble overload relief

valve assemblies (1 to 18), (19 to 36) as since they have been preset at the set pressures.

5. Remove overload relief valve assemblies (1 to 18), (19 to 36) from housing (62).

: 32 mm NOTE: Each of overload relief valve assemblies (1

to 18), (19 to 36) has a different set pressure. Thus they should be identified for reassembling.

6. Remove sleeve assembly (37 to 42) from housing (62).

: 36 mm

7. Remove spring (43) and poppet (44) from housing (62).

8. Secure seat (37) in a vise. Remove sleeve (41),

spring (40) valve (39) and O-rings (38, 42) from seat (37).

: 36 mm


W2-5-68

ASSEMBLY OF POSITIONING CONTROL VALVE

W198-02-05-002

W198-02-05-004

W198-02-05-003

W198-02-05-005

1 - Nut 17 - Sleeve 33 - Backup Ring (2 Used) 48 - Socket Bolt 2 - Bolt 18 - O-Ring 34 - Valve 49 - Socket Bolt 3 - O-Ring 19 - Nut 35 - Sleeve 50 - Cover 4 - Spring 20 - Bolt 36 - O-Ring 51 - End Spool 5 - Valve 21 - O-Ring 37 - Seat 52 - Seat 6 - Sleeve 22 - Spring 38 - O-Ring 53 - Spring 7 - Backup Ring (2 Used) 23 - Valve 39 - Valve 54 - Spring 8 - O-Ring 24 - Sleeve 40 - Spring 55 - Seat 9 - O-Ring 25 - Backup Ring (2 Used) 41 - Sleeve 56 - O-Ring 10 - Spring 26 - O-Ring 42 - O-Ring 57 - Spool 11 - Spring 27 - O-Ring 43 - Spring 58 - O-Ring 12 - Pin 28 - Spring 44 - Poppet 59 - Plug 13 - Valve 29 - Spring 45 - Socket Bolt (2 Used) 60 - Rivet 14 - O-Ring 30 - Pin 46 - Cover 61 - Plate 15 - Backup Ring (2 Used) 31 - Valve 47 - O-Ring 62 - Housing 16 - Valve 32 - O-Ring

X X

WW

48 45

49

37 39 40 38 41

43 42 44

62

19 to 36

57

1 to 18

50 51 5254 53 56 62

47

46585957

55

Section X-X

Section W-W

B1 A1

B1 A1


W2-5-69

Assembly of Positionnig Control Valve 1. Clamp seat (37) in a vise. Install O-ring (38),

valve (39), spring (40), sleeve (41) and O-ring (42) to seat (37).

: 36 mm : 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)

2. Insert poppet (44) and spring (43) into housing

(62).

3. Install the seat (37) assembly to housing (62). : 36 mm : 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)

IMPORTANT: Each of overload relief valve

assemblies (1 to 18), (19 to 36) has a different set pressure. Do not install at an incorrect position.

4. Install overload relief valve assemblies (1 to 18), (19 to 36) to housing (62).

: 32 mm : 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)

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

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

pieces. Install plug (59) to spool (57). Install seat (55), springs (53, 54), seat (52) and end spool (51) from the opposite side.

: 9.8 N⋅m (1 kgf⋅m, 7 lbf⋅ft) : 8 mm : 18.6 N⋅m (1.9 kgf⋅m, 14 lbf⋅ft)

IMPORTANT: Install the spool (57) assembly into

housing (62) and check if it moves smoothly by hand.

7. Insert spool (57) assemblies (51 to 59) into housing (62) from the port A1 side.

NOTE: If any of spool assembly (51 to 59) is not straight inserted, forced insertion can result in flaws on the bore of housing (62) or spool (57). Insert it straight.

8. Install O-rings (47, 56) to covers (46, 50). Install

covers (46, 50) to housing (62) with socket bolts (45) (2 used) and socket bolts (48, 49).

: 6 mm : 25.5 N⋅m (2.6 kgf⋅m, 19 lbf⋅ft)


W2-5-70

(Blank)

UPPERSTRUCTURE / Swing Device

W2-6-1

REMOVAL AND INSTALLATION OF SWING DEVICE





3. Remove socket bolts (7) (8 used) and split flanges

(6) (4 used). Disconnect hoses (8) (12 used) from swing motor (2). Remove O-rings (9) (2 used) from hose (8). Remove swing dampener valve (10) and O-ring (11) from swing motor (12).

: 8 mm

4. Disconnect hoses (5) (4 used) from swing motor (12). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm, 36 mm

5. Disconnect connector (14) from pressure switch (13).

6. Remove pressure switch (13) from swing motor

(12). : 24 mm

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

(12). Hoist and hold the swing motor (12) assembly. Nylon sling (eye-type at both ends): 2 pieces

WCJB-02-01-002

WCJB-02-06-005

1

5

10, 11

2 3 4

6 8, 97

14 13

12

5


W2-6-2

CAUTION: Swing device (15) weight: 220 kg (490 lb)

8. Disconnect hose (19) from center joint (20). Cap

the open ends. : 27 mm

9. Remove bolts (16) (12 used) and washers (17)

(12 used) from swing device (15). Remove swing device (15) from main frame (18).

: 30 mm

NOTE: When hoisting swing device (15), the machine may float up. If this occurs, remove plugs (21) (2 places) and float swing device (15) from main frame (18) by using the pulling-out bolts (M20, Pitch 2.5 mm) (2 used).

NOTE: The number of hoses around the swing device is different according to specification of the front attachment. Do not damage the hoses when removing and installing the swing device.

Installation

CAUTION: Swing device (15) weight: 220 kg (490 lb)

1. Hoist and align swing device (15) with the

mounting holes on main frame (18). Install swing device (15) to main frame (18) with bolts (16) (12 used) and washers (17) (12 used).

: 30 mm : 500 N⋅m (50 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: Apply THREEBOND #1102 onto the

mounting surface of the swing device and main frame (18).

WCJB-02-06-006

WCJB-02-06-006

21

16, 17

18

19

20

15

16, 17

18

15


W2-6-3

2. Connect hose (19) to center joint (20). : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

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

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

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

5. Connect hoses (5) (4 used) to swing motor (12). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

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

(9, 11) to hoses (8) (2 used) and swing dampener valve (10).

7. Install swing dampener valve (10) and hoses (8)

(2 used) to swing motor (12) with split flanges (6) (4 used) and socket bolts (7) (8 used).

: 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

8. Install cover (1) to stay (4) with sems bolts (3) (4 used). Shut cover (2).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

IMPORTANT: After completing the work, fill the

swing motor with hydraulic oil. Check the hydraulic oil level. Start the engine and check for any oil leaks.

WCJB-02-06-006

WCJB-02-06-005

WCJB-02-01-002

14

19

20

12

13

5

10, 11

6 8, 97

12

5

1 2 3 4


W2-6-4

DISASSEMBLY OF SWING DEVICE

W178-02-06-004

1 - Motor 9 - Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing 2 - First Stage Planetary Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing 3 - Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal 4 - Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - Second Stage Sun Gear 28 - Sleeve 5 - Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring 6 - Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (8 Used) 30 - Shaft 7 - Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug 8 - Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe

1

2

3

4

5

6

7

8

9

10

11

12

13

22

21

19

18

16

17

15

14

20

24

23

25

26

29

28

30

27

32

31


W2-6-5

Disassembly of Swing Device

CAUTION: Swing device weight: 220 kg (490 lb)

CAUTION: When hoisting the swing device, do not string the rope suddenly.


motor (1). Attach a nylon sling onto eyebolts. Hoist motor (1).

W178-02-06-005

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

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

: 30 mm

W178-02-06-012

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

oil from the swing device. : 8 mm

4. Remove pipe (32) from housing (25).

: 18 mm

5. Put the matching marks at the jointed part between motor (1) and ring gear (24), between ring gear (24) and housing (25).

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

6. Remove socket bolts (22) (8 used) from motor (1). Remove motor (1) from ring gear (24).

: 10 mm NOTE: THREEBOND has been applied onto the

jointed surface. For easy removal, insert a screwdriver into the gap around the jointed part in order to float.

7. Remove first stage sun gear (2) from first stage

carrier (21).

8. Remove the first stage carrier (21) assembly from ring gear (24).

9. Remove socket bolts (23) (12 used) from ring

gear (24). : 14 mm

CAUTION: Ring gear (24) weight: 23 kg (51 Ib)


the motor (1) mounting thread part on ring gear (24). Attach a nylon sling onto eyebolts. Hoist and remove ring gear (24) from housing (25).

NOTE: THREEBOND has been applied onto the jointed surface. For easy removal, insert a screwdriver into the gap around the jointed part in order to float.

11. Remove second stage sun gear (20) from second

stage carrier (18).

Swing Device

Stopper ST 5097

Eyebolt Mounting Position


W2-6-6

W178-02-06-004

3

4

5

6

7

8

10

11

12

21

18

16

17

15

23

25

30


W2-6-7

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

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

first stage carrier (21) is not a through one. Check the tapping-in distance of spring pin (5).

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

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

bearing (6) and thrust plate (8) from first stage carrier (21).

15. Remove other two sets of pin (4), planetary gear

(7), needle bearing (6) and thrust plate (8) from first stage carrier (21) in the same order as steps 13 and 14.

16. Remove thrust plate (3) from first stage carrier

(21). IMPORTANT: Do not damage the rotating surface

for the needle bearing of pin (4) except for the both ends.

17. Secure the end of pins (4) (3 used) opposite the spring pin (5) hole in a vise. Tap and remove spring pins (5) (3 used) by using special tool (ST 1462).

18. Disassemble the second stage carrier (18)

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

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

Remove lock plate (16) from bearing nut (15).

20. Remove bearing nut (15) from shaft (30), by using special tool (ST 2926).

W178-02-06-008

CAUTION: The housing (25) assembly weight: 122 kg (270 lb)


the bolt (23) hole on housing (25). Attach a nylon sling onto eyebolts. Hoist and remove bracket (ST 5097) from housing (25).

: 30 mm 22. After removing bracket (ST 5097), install bracket

(ST 1464). Set housing (25) to a press. : 30 mm

W178-02-06-006

15

ST 2926

Press

25

ST 1464


W2-6-8

W178-02-06-004

14

25

26

29

28

30

27


W2-6-9

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

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

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

W178-02-06-010

CAUTION: Shaft (30) weight: 40 kg (90 lb) 25. Insert the pinion gear of shaft (30) into tooth-hole

of special tool (ST 1460). Set them onto a press.

W178-02-06-009

26. Remove the splined side of shaft (30) by using a press. Remove the inner race of roller bearing (26) and sleeve (28) from shaft (30).

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

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

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

W178-02-06-001

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

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

sling. Hoist and turn over housing (25). 30. Insert a screwdriver into the notch on housing

(25), where oil seal (27) is mounted. Remove oil seal (27) from housing (25).

NOTE: THREEBOND has been applied onto the periphery of oil seal (27). Therefore, oil seal (27) cannot be reused.

31. Tap and remove the outer race of roller bearing

(14) from housing (25) by using a bar and hammer.

ST 1461

ST 1460

Press

30

26

28ST 1460

ST 1461

Oil PassageOuter Race of Roller Bearing (26)


W2-6-10

ASSEMBLY OF SWING DEVICE

WCJB-02-06-001

1 - Motor 9 - Pin (3 Used) 17 - Bolt (2 Used) 25 - Housing 2 - First Stage Planetary Gear 10 - Spring Pin (3 Used) 18 - Second Stage Carrier 26 - Roller Bearing 3 - Thrust Plate 11 - Thrust Plate (6 Used) 19 - Thrust Plate 27 - Oil Seal 4 - Pin (3 Used) 12 - Needle Bearing (6 Used) 20 - Second Stage Sun Gear 28 - Sleeve 5 - Spring Pin (3 Used) 13 - Planetary Gear (3 Used) 21 - First Stage Carrier 29 - O-Ring 6 - Needle Bearing (3 Used) 14 - Roller Bearing 22 - Socket Bolt (8 Used) 30 - Shaft 7 - Planetary Gear (3 Used) 15 - Bearing Nut 23 - Socket Bolt (12 Used) 31 - Drain Plug 8 - Thrust Plate (3 Used) 16 - Lock Plate 24 - Ring Gear 32 - Pipe

1

2

3

21

20

18

24

19

23

17

16

15

26

27

28

30

4 5

22

7

6

8

10

11

12

13

11

9

14

32

3125

29


W2-6-11

Assembly of Swing Device

1. Apply grease onto O-ring (29). Install O-ring (29) onto sleeve (28).

CAUTION: Shaft (30) + sleeve (28) + roller bearing (26) outer race weight: 36 kg (80 lb)

2. Install sleeve (28) and the inner race of roller

bearing (26) to shaft (30). Install sleeve (28) and the inner race together by using special tool (ST 2923) and a press.

NOTE: The press-in distance of inner race of roller bearing (26) can be assured by using special tool.

W178-02-06-013

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


sling. Hoist and place housing (25) with the sleeve (28) mounting side facing upward.

4. Evenly tap and install the outer race of roller

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

5. Apply THREEBOND #1215 onto the outer surface of oil seal (27). Place oil seal (27) flat on housing (25) and push by hands in gently. Place special tool (ST 2925) on oil seal (27). Tap in special tool by using a hammer straight.

NOTE: The seal can be replaced by using special tool (ST2925) without removing the sleeve.

W178-02-06-007

6. Apply grease onto the inner surface of oil seal

(27). Apply grease onto the outer surface of sleeve (28) attached with shaft (30).

NOTE: Apply grease carefully when installing shaft (30) in order not to curl the lip.

CAUTION: Housing (25) + outer race weight: 63 kg (140 lb)


sling. Hoist and place housing (25) with the ring gear (24) side facing upward.

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

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

25

27ST 2925

26

28

30

Press

ST 2923


W2-6-12

WCJB-02-06-001

24

23

15

27

30

14

25


W2-6-13

CAUTION: Housing (25) + outer races (2 used) weight: 65 kg (150 lb)


the bolt (23) hole on housing (25). Hoist and place housing (25) on shaft (30) so that they are matched. At this time, check and align carefully in order to prevent the oil seal (27) lip from curling.

10. Tap and install the inner race of roller bearing (14)

into shaft (30) by using a bar and hammer. Tap the inner race until the upper end of inner race reaches two threads for bearing nut (15) in shaft (30).

NOTE: The fitting between inner race and shaft (30) is tight.

11. Tighten bearing nut (15) to shaft (30) by hand.

NOTE: Prevent shaft (30) from falling off when hoisting housing (25).

CAUTION: Housing (25) + shaft (30) + bearing total weight: 122 kg (270 lb)


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

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

14. Place special tool (ST 2924) on the inner race of roller bearing (14). Install the inner race by using a press.

NOTE: The press-in distance of inner race can be assured by using special tool.

W178-02-06-011

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

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

: 30 mm

W178-02-06-012

ST 2924

14

Stopper

ST 5097

25


W2-6-14

WCJB-02-06-001

3

21

18

19

17

16

15

30

4 5

22

7

6

8

10

11

12

13

11

9


W2-6-15

IMPORTANT: Check the direction to install bearing nut (15).

16. Apply a film of grease onto the thread part of bearing nut (15). Install bearing nut (15) to shaft (30). At this time, face the stepped side of bearing nut (15) to the roller bearing (14) side. Tighten bearing nut (15) by using special tool (ST 2926) to the specified torque.

: 490 N⋅m (50 kgf⋅m, 361 lbf⋅ft) NOTE: Apply grease for keeping correct tightening

torque.

W178-02-06-008

17. Install lock plate (16) to bearing nut (15) with bolts

(17) (2 used). In case the splines of lock plate (16 and shaft (30) are not aligned, tighten bearing nut (15) in tightening direction until both splines are aligned.

IMPORTANT: Check the direction to install thrust

plate (19). 18. Install thrust plate (19) to second stage carrier

(18) with the oil groove surface facing outside. 19. Clamp planetary gear (13) and needle bearings

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

20. Install pin (9) to the position where planetary gear (13) has been installed onto second stage carrier (18) with the spring pin hole facing front. At this time, the spring pin holes both in second stage carrier (18) and pin (9) should be in line.

IMPORTANT: Check the direction of spring pin

(10). 21. Install spring pin (10) to second stage carrier (18)

by using spring pin removal and installation special tool (ST 1463). At this time, face the slit of spring pin to the end of pin (9).

W178-02-06-002

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

bearings (12) (4 used), thrust plates (11) (4 used), pins (9) (2 used) and spring pins (10) (2 used) into other holes (2 places) on second stage carrier (18) in the same way as steps 19 to 21.

IMPORTANT: Check the position to install thrust

plate (8). 23. Install thrust plate (3), planetary gears (7) (3 used),

needle bearings (6) (3 used), thrust plates (8) (3 used), pins (4) (3 used) and spring pins (5) (3 used) to the first stage carrier (21) in the same way as steps 19 to 21. At this time, install thrust plate (8) under needle bearing (6). Use special tool (ST 1462).

15ST 2926

10

9

Slit


W2-6-16

WCJB-02-06-001

1

2

21

20

18

24

23

16

30

22

32

3125


W2-6-17

IMPORTANT: Check the direction to install second stage carrier (18).

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

W178-02-06-014

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

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

26. Apply THREEBOND #1215 onto the ring gear

(24) mounting surface of housing (25). Clean off old adhesive in advance.


the motor mounting thread part on ring gear (24). Hoist and align ring gear (24) with the mounting holes on housing (25). At this time, align the matching marks made when disassembling.

28. Install ring gear (24) into housing (25) with socket

bolts (23) (12 used). : 14 mm : 210 N⋅m (21.5 kgf⋅m, 16 lbf⋅ft)

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

the spline of second stage sun gear (20).

IMPORTANT: Check the direction to install first stage sun gear (2).

30. Install first stage sun gear (2) into the first stage carrier (21) assembly. At this time, face the stepped part facing downward.

31. Wind the seal tape onto the thread part of pipe

(32). Install pipe (32) to housing (25). Face the pipe (32) downward.

: 18 mm 32. Wind the seal tape onto drain plug (31). Install

drain plug (31) to pipe (32). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

33. Add gear oil to ring gear (24) until gear oil reaches

the middle part of first stage sun gear (2). (Approx. 6.9 L, 1.8 US gal)

34. Apply THREEBOND #1215 onto the motor (1)

mounting surface of ring gear (24). Clean old adhesive in advance.

CAUTION: Motor (1) weight: 47 kg (110 Ib) 35. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to

motor (1). Hoist and install motor (1) to ring gear (24) with socket bolts (22) (8 used) while aligning the matching marks.

: 10 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

W178-02-06-005

16

Concave Part

30

18

Eyebolt Mounting Position


W2-6-18

DISASSEMBLY OF SWING MOTOR

W178-02-06-015

1 - Casing 9 - Rotor 17 - O-Ring 25 - O-Ring (2 Used) 2 - Oil Seal 10 - Friction Plate (3 Used) 18 - O-Ring 26 - Spring (2 Used) 3 - Bearing 11 - Plate (4 Used) 19 - Brake Piston 27 - Poppet (2 Used) 4 - Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing 5 - Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used) 6 - Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used) 7 - Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used) 8 - Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)

1

2 3

4

5 6

7

8

9

10

11

12 13

14 15

16

2221

2019

1817

32

23

2425

2627

28

2930

31

2726

2524


W2-6-19

Disassembly of Swing Motor

CAUTION: The swing motor assembly weight: 47 kg (110 lb)

IMPORTANT: Do not disassemble relief valve (32).

1. Remove relief valves (32) (2 used) from valve casing (28).

: 41 mm

2. Remove plugs (24) (2 used) from valve casing (28).

: 14 mm

3. Remove springs (26) (2 used) and poppets (27) (2 used) from valve casing (28).

4. Put the matching marks on the jointed surface

between valve casing (28) and casing (1). Remove socket bolts (29) (4 used) from valve casing (28). At this time, as the clearance exists between valve casing (28) and casing (1), record this clearance.

: 17 mm

5. Remove valve casing (28) from casing (1). NOTE: At this time, as valve casing (28) may be

removed with valve plate (21) together, do not drop valve plate (21).

6. Remove O-ring (23) from valve casing (28).

IMPORTANT: Do not damage the mating surfaces

when separating valve plate (21) from valve casing (28) or rotor (9) by using a screwdriver. (Check the surfaces of valve plate (2) in order not to make a mistake for assembling.)

7. If valve plate (21) is still on rotor (9) in step 5, remove valve plate (21) from the rotor (19) side. Remove springs (20) (24 used) from brake piston (19).

CAUTION: There is also a method of applying air from port B in order to float brake piston (19). Prevent piston (13) from flying out.

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

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

WCJB-02-06-003

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

Notch A

Port B


W2-6-20

W178-02-06-015

1

2 3

4

5 6

7

8

9

10

11

13 14

15


W2-6-21

IMPORTANT: Do not damage the sliding surfaces of rotor (9) and plunger (6).

10. Place casing (1) horizontally. Remove rotor (9), retainer (8), plate (7) and plungers (6) (9 used) from shaft (4).

11. Remove plates (11) (4 used) and friction plates

(10) (3 used) from casing (1). IMPORTANT: Do not damage the sliding surface of

shoe plate (5). 12. Remove shoe plate (5) from casing (1).

13. Lightly tap and remove shaft (4) from casing (1)

by using a plastic hammer. 14. Remove the outer race of bearing (3) from casing

(1) by using a bar. 15. Remove oil seal (2) from casing (1).

16. Remove the inner race of roller bearing (3) from

shaft (4) by using a press. IMPORTANT: Although the filter and the orifice are

installed to piston (13), do not disassemble piston (13) unless they are clogged or deformed. When replacing the internal parts, replace as an assembly.

17. Remove piston (13) from casing (1) by using a pair of pliers.

18. Remove spring (14) and ball (15) from casing (1).


W2-6-22

ASSEMBLY OF SWING MOTOR

WCJB-02-06-002

WCJB-02-06-003

WCJB-02-06-004

1 - Casing 9 - Rotor 17 - O-Ring 25 - O-Ring (2 Used) 2 - Oil Seal 10 - Friction Plate (3 Used) 18 - O-Ring 26 - Spring (2 Used) 3 - Bearing 11 - Plate (4 Used) 19 - Brake Piston 27 - Poppet (2 Used) 4 - Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing 5 - Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used) 6 - Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used) 7 - Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used) 8 - Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)

25

16

14

13

12

29

26 27

24

15

32

21

20

19

11

6

8

3

2

31

30

28

22

23

18

17

9

5

1

4

7

10


W2-6-23

Assembly of Swing Motor IMPORTANT: Install the inner race of bearing (3)

with the flange part facing to the stepped side of shaft (4).

1. Install the inner races of bearings (3, 22) to shaft (4) by using a press.

IMPORTANT: Install oil seal (2) with the lip part

facing upward. 2. Install oil seal (2) to casing (1) by using a plate.

3. Install the outer race of bearing (3) into casing (1)

by using a bar. IMPORTANT: Wind the tape onto the spline at the

end of shaft (4) in order not to damage oil seal (2).

4. Install shaft (4) with casing (1).

5. Place casing (1) with the valve casing (28) mounting surface facing upward. Install shoe plate (5) with the chamfered surface facing inside.

IMPORTANT: Install retainer (8) to plunger (6) with

the notch facing to the shoe plate (5) side.

6. Align the notches on plate (7) and retainer (8). Install plungers (6) (9 used).

IMPORTANT: Install plunger (6) to after applying hydraulic oil onto the plunger (6) hole on rotor (9).

7. Install plungers (6) (9 used) to rotor (9).

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

assembly to shaft (4) by turning shaft (4). IMPORTANT: There are 4 notches on the outer

side of plate (11), and 4 notches at the spline teeth side of friction plate (10). Align each notch at the same place when installing.

9. Place casing (1) vertically. Alternately install plates (11) (4 used) and friction plates (10) (3 used) to casing (1).

10. Install O-rings (17, 18) onto casing (1).

11. Align the matching marks and install brake piston

(19) into casing (1). NOTE: If it is not easy to install brake piston (19)

due to the resistant force from O-rings (17, 18), tap them evenly by using a plastic hammer.

12. Install springs (20) (24 used) to brake piston (19).


W2-6-24

WCJB-02-06-002

WCJB-02-06-003

WCJB-02-06-004

32

21

28

22

23

9

1

4

25

14

13

29

26 27

24

15


W2-6-25

IMPORTANT: When replacing the inner parts of piston (13), replace the piston (13) as an assembly. Install so that the ends of piston (13) and casing (1) may be in the same position.

13. Install ball (15), spring (14) and piston (13) to casing (1).

IMPORTANT: Tap the bearing type indicated

surface by using a plastic hammer and install roller bearing (22).

14. Install the outer race of bearing (22) to valve casing (28) by using a plastic hammer.

IMPORTANT: Check the surfaces of valve plate

(21). (Face the notch of the port to rotor (9).)

15. Install O-ring (23) to valve casing (28). Install valve plate (21) to valve casing (28).

NOTE: Apply grease onto valve plate (21) in order to prevent valve plate (21) from falling off from valve casing (28).

16. Apply grease onto the needle part of bearing (22).

NOTE: Shaft (4) can be inserted easily by holding the needle with grease.

17. Align the matching marks on valve casing (28)

and casing (1). Place valve casing (28) onto casing (1). Check that the clearance between valve casing (28) and casing (1) is equal to that before disassembling. At this time, if the clearance is larger than that before disassembling, repeat the installation from step 5.

18. Install valve casing (28) to casing (1) with socket bolts (29) (4 used).

: 17 mm : 430 N⋅m (44 kgf⋅m, 317 lbf⋅ft)

19. Install poppets (27) (2 used) and springs (26) (2

used) into valve casing (28). Install plug (24) with O-ring (25) attached.

: 14 mm : 330 N⋅m (34 kgf⋅m, 243 lbf⋅ft)

20. Install relief valves (32) (2 used) into valve casing

(28). : 41 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)


W2-6-26

STRUCTURE OF SWING DAMPENER VALVE

WCJB-02-06-007

Tightening Torque Item Parts Name Q’ty Wrench Size(mm) N⋅m (kgf⋅m) (lbf⋅ft)

Remark

1 Swing Damperner valve Assembly 2

2 Plug 3 : 4 9 (0.9) (7) 3 Casing 1 4 O-Ring 2 5 Backup Ring 2 6 Case 2 : 24 69 (7) (51) 7 Plug 2 : 8

1 2 3

4 5 6 7


W2-6-27

MAINTENANCE STANDARD

Swing Motor

1. Clearance between plunger outer diameter and rotor inner bore

D-d

Standard Allowable Limit

0.027 mm (0.001 in) 0.052 mm (0.002 in)

2. Clearance between plunger and shoe bottom

Standard Allowable Limit 0 mm 0.3 mm (0.012 in)

W107-02-06-138

W107-02-06-139

W107-02-06-140

d

D D

δ

Plunger

Shoe


W2-6-28

3. Shoe thickness

Standard Allowable Limit

5.5 mm (0.22 in) 5.3 mm (0.2 in)

4. Friction plate thickness

Standard Allowable Limit 2.0 mm (0.08 in) 1.8 mm (0.07 in)

W107-02-06-142

W107-02-06-143

t

UPPERSTRUCTURE / Pilot Valve

W2-7-1

REMOVAL AND INSTALLATION OF PILOT VALVE


Removal of Left Pilot Valve


1. Remove sems bolts (4) (2 used) from seat belts (6) (2 used). Remove seat belt (6) from brackets (5) (2 used).

: 16 mm

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

: 6 mm

3. Remove screws (9) (4 used) from boot (7). Raise boot (7) from bracket (8).

WCEB-02-01-001

WCEB-02-01-017

WCEB-02-01-002

W1JB-02-07-002

8

9

1

1

2 3 4 5

6

3

2 7

325 46


W2-7-2

4. Remove screw (10) from covers (11, 12).

5. Remove sems bolt (14) from cover (11). Remove screws (13) (3 used) from covers (11, 12). Re-move covers (11, 12) from bracket (8).

: 10 mm

WCEB-02-07-001

WCEB-02-07-003

WCEB-02-07-004

14

11

12

12

10

11

13

12

13

8 13

11


W2-7-3

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

7. Loosen lock nut (16). Remove lever (15) assem-

bly from pilot valve (19). : 19 mm, 22 mm

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

(6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm

9. Remove sems bolts (21) (4 used) from bracket (8). Remove pilot valve (19) from bracket (8).

: 13 mm

W1JB-02-07-005

W1JB-02-07-005

17

18

16 15

19

8 21

21

19

20


W2-7-4

Installation of Left Pilot Valve

1. Install pilot valve (19) to bracket (8) with sems bolts (21) (4 used).

: 13 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

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

: 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft)

3. Install lever (15) assembly to pilot valve (19). Se-cure lever (15) assembly to pilot valve (19) with lock nut (16).

: 22 mm : 55 N·m (5.5 kgf·m, 41 lbf·ft)

4. Connect harness (18) connector.

5. Install harness (18) to bracket (8) of pilot valve

(19) with clip band (17).

6. Install cover (11, 12) to bracket (8) with round head screws (13) (3 used) and sems bolt (14).

: 10 mm : 3.3 to 4.2 N·m

(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

W1JB-02-07-005

W1JB-02-07-005

WCEB-02-07-003

17

18

16 15

19

8 21

19

20

21

8

13

8

14

12

11


W2-7-5

7. Install cover (11, 12) to bracket (8) with round head screw (10).

8. Install boot (7) to bracket (8) with round head screws (9) (4 used).


9. Install seat (1) to plate (2) with socket bolts (3) (4 used).

: 6 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

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

with sems bolts (4) (2 used). : 16 mm : 50 N·m (5 kgf·m, 37 lbf·ft)

WCEB-02-07-001

W1JB-02-07-002

WCEB-02-01-002

WCEB-02-01-001

10 8

12

11

8

9

7

1

3

2

1 2 3 4 5

6


W2-7-6

Removal of Right Pilot Valve

1. Remove the seat. (Refer to W2-7-1.)

2. Remove cap (3) (2 used) and round head screws (1, 4) (1 each used) from cover (2). Remove cover (2) from bracket (7).

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

: 10 mm

4. Remove round head screw (9) from cover (8).

5. Remove round head screws (11) (4 used) from boot (10). Remove boot (10) from bracket (7).

6. Remove round head screw (12) from cover (5, 8). Remove covers (5, 8) from bracket (7).

WCEB-02-07-006

WCEB-02-07-005

W1JB-02-07-002

W1JB-02-07-016

1

9

3, 42

7

5

2

6

3, 4

1

7

8

10

11

8

12

8

7

7

5


W2-7-7

7. Remove clip bands (15) (2 used) from lever (13) and harness (16). Disconnect a connector from harness (16).

8. Loosen lock nut (14). Remove lever (13) assem-

bly from pilot valve (17). : 19 mm, 22 mm

9. Remove sems bolts (19) (3 used) from bracket (7). Remove bracket (7) assembly from stand (18). Hoist bracket (7) assembly.

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


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

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

W1JB-02-07-005

WCEB-02-07-009

W1JB-02-07-005

16

15

7

18

14 13

19

17

17

7 21

21

20


W2-7-8

Installation of Right Pilot Valve

1. Install pilot valve (17) to bracket (7) with sems bolts (21) (4 used).

: 13 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

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

: 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft)

3. Install lever (13) assembly to pilot valve (17). Se-cure lever (13) assembly to pilot valve (17) with lock nut (14).

: 22 mm : 56 N·m (5.5 kgf·m, 41 lbf·ft)

4. Connect harness (16) connector.

5. Install harness (16) to pilot valve (17) and bracket

(7) with clip band (15) (2 used).

6. Install cover (5) to bracket (7) with sems bolts (6). : 10 mm : 3.3 to 4.2 N·m

(0.3 to 0.4 kgf·m, 2 to 3 lbf·ft)

W1JB-02-07-005

W1JB-02-07-005

WCEB-02-07-006

17

7 21

21

20

16

15 14 13

17

7

7

5

6


W2-7-9

7. Install bracket (7) assembly to stand (18) with sems bolts (19) (3 used).

: 17 mm : 50 N·m (5 kgf·m, 37 lbf·ft)

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

screw (9).

9. Install covers (5, 8) to bracket (7) with round head screw (12).

10. Install boot (10) to bracket (7) with round head

screws (11) (4 used). 11. Install cover (2) to bracket (7) with round head

screws (1, 4) (2 each used). Attach cap (3) (2 used) to cover (2).

WCEB-02-07-009

W1JB-02-07-016

W1JB-02-07-002

WCEB-02-07-006

7

18 19

9

8

12

8

7

5

10

11

7

13, 4

2

7

5

6

8


W2-7-10

CAUTION: Seat (21) weight: 40 kg (90 lb) 12. Install seat (21) to plate (23) with socket bolts (22)

(4 used). : 6 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

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

used) with sems bolts (24) (2 used). : 16 mm : 50 N·m (5 kgf·m, 37 lbf·ft)

WCEB-02-01-002

WCEB-02-01-001

WCEB-02-01-017

21 23 22 24 25

26

21

22

23

222325 2426


W2-7-11

REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE


Removal 1. Remove mat (1) from cab (2) inside.

2. Remove sems bolts (4) (2 used) from pedal (3). Remove pedal (3) from bracket (5).

: 13 mm

3. Remove sems bolts (7) (2 used) from bracket (5). Remove bracket (5) from travel pilot valve (6).

: 13 mm

WCEB-02-01-003

WCEB-02-07-002

WCEB-02-07-007 7

1

2

3

3

5

Auxiliary Pedal

Brake Pedal

4

6


W2-7-12


: 17 mm

5. Disconnect hoses (11) (4 used) from travel pilot valve (14). Cap the open ends. Attach an identifi-cation tag onto the disconnected hoses for as-sembling.

: 19 mm

6. Remove sems bolts (12) (2 used) from travel pilot valve (14). Remove travel pilot valve (14) from plate (13).

: 17 mm

WCEB-02-13-001

WCEB-02-07-008

8

11

10

9 8

14

12 13

11


W2-7-13

Installation 1. Install travel pilot valve (14) to plate (13) with

sems bolts (12) (2 used). : 17 mm : 50 N·m (5 kgf·m, 37 lbf·ft)

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

(14). : 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft)

3. Install bracket (5) to travel pilot valve (6) with sems bolts (7) (2 used).

: 13 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

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

(2 used). : 13 mm : 20 N·m (2 kgf·m, 15 lbf·ft)

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

WCEB-02-07-008

WCEB-02-07-007

WCEB-02-07-002

WCEB-02-01-003

11

14

12 13

11

7

3

5

4

6

3

Auxiliary Pedal

Brake Pedal

1

2


W2-7-14


: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf·ft)

WCJB-02-13-001

8 9 10


W2-7-15

(Blank)


W2-7-16

DISASSEMBLY OF FRONT/SWING PILOT VALVES

W1F3-02-07-001

1 - Screw Joint 6 - Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing 2 - Cam 7 - O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin 3 - Universal Joint 8 - Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate 4 - Plate 9 - Spring Seat (4 Used) 14 - Casing 19 - Sealing Washer (2 Used)5 - Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)

10

11

12

13

10

11

12

13

14

15

16

17

18

19

20

19

20

1

2

3

4

5

6

7

8

9

5

6

7

8

9


W2-7-17

Disassembly of Front/Swing Pilot Valves • Spool (13) has been selected to match the hole of

casing (14). Therefore, the parts cannot be re-placed individually.

• Indicate the port number of the removed in order not to confuse parts. The port numbers are stamped on the outer surface of casing (14).

1. Clamp the pilot valve in a vice. Secure the plot

valve with the port plate (18) facing downward.

2. Put the matching marks on plate (4) and casing (14). Secure cam (2) by using a spanner. Remove screw joint (1) and cam (2) from universal joint (3).

: 32 mm

CAUTION: Springs (10) (4 used) are in the compressed condition. Therefore, when loosening universal joint (3), plate (4), bush-ings (6) (4 used), and pushers (8) (4 used) are raised at the same time. Do not fly out them.

3. Install special tool (ST 7260) to universal joint (3). Remove universal joint (3) from casing (14) by turning.

: 24 mm

W577-02-06-003

4. Remove plate (4) from casing (14).

IMPORTANT: When bushing (6) (4 used) are still in

casing (14), remove pusher (8) by moving left and right. Do not dam-age pusher (8).

IMPORTANT: Indicate the port numbers of the spool (13) assembly and springs (10) (4 used) in order not to confuse the parts. Do not damage spool (13).

5. Remove the pusher (8) assembly, the spool (13) assembly and springs (10) (4 used) from casing (14).

6. Remove pushers (8) (4 used), O-rings (7) (4

used) and oil seals (5) (4 used) from bushings (6) (4 used).

ST 7260

Section A-A

3

A A


W2-7-18

W1F3-02-07-001

11

12

13

11

12

13

14

15

16

18

20

9 9

17


W2-7-19

IMPORTANT: Do not disassemble the spool (13) assembly unless necessary.

IMPORTANT: When removing spring seats (9) (4 used) from spool (13), push in spring seat (9) once and remove it by moving to a larger hole of 2 holes on spring seat (9). At this time, do not push in spring seat (9) for more than 6 mm (0.2 in).

WCEB-02-07-010

7. Remove spring seats (9) (4 used), springs (11) (4 used) and washers (12) (4 used) from spool (13).

8. Clamp the pilot valve in a vice. Secure the pilot

valve with port plate (18) facing upward.

9. Remove socket bolts (20) (2 used) and seal washers (19) (2 used) from port plate (18).

10. Remove port plate (18), O-ring (15), bushing (16)

and spring pin (17) from casing (14).

9 11

13


W2-7-20

ASSEMBLY OF FRONT/SWING PILOT VALVES

W1F3-02-07-002

1 - Screw Joint 6 - Bushing (4 Used) 11 - Spring (4 Used) 16 - Bushing 2 - Cam 7 - O-Ring (4 Used) 12 - Washer (4 Used) 17 - Spring Pin 3 - Universal Joint 8 - Pusher (4 Used) 13 - Spool (4 Used) 18 - Port Plate 4 - Plate 9 - Spring Seat (4 Used) 14 - Casing 19 - Sealing Washer (2 Used) 5 - Oil Seal (4 Used) 10 - Spring (4 Used) 15 - O-Ring 20 - Socket Bolt (2 Used)

1

8

4

9

11

3

2

5

6

7

16

17

10 12

13

14

15

18

19

20


W2-7-21

Assembly of Front/Swing Pilot Valves • Replace the seals with the new ones.

1. Install bushing (16) and O-ring (15) to casing (14).

2. Install spring pin (17) to port plate (18). Install port

plate (18) to casing (14) with socket bolts (20) (2 used) and seal washers (19) (2 used).

: 20.5±2 N·m (2.1±0.2 kgf·m, 15±2 lbf·ft) IMPORTANT: When installing spring seats (9) (4

used) to spool (13), insert spool (13) from a larger hole of 2 holes on spring seat (9) and move to a smaller hole direction. At this time, do not push in spool (13) for more than 6 mm (0.2 in).

WCEB-02-07-010

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

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

IMPORTANT: Install spring (10) to the same posi-tion before disassembling.

4. Install springs (10) (4 used) to casing (14). IMPORTANT: Install the spool (13) assemblies (4

used) to the same position as it was before disassembling.

5. Install the spool (13) assemblies (4 used) to cas-ing (14).

6. Install O-rings (7) (4 used) and oil seals (5) (4

used) to bushings (6) (4 used). IMPORTANT: Apply hydraulic oil onto the outer

surface of pushers (8) (4 used). 7. Install pushers (8) (4 used) to bushings (6) (4

used). IMPORTANT: If installing plate (4) is difficult due

to strong springs (10) (4 used), place the bushing (6) assemblies (4 used) on 4 holes of casing (14). Place plate (4) on them. Temporarily secure the bushing (6) assemblies (4 used). While holding it with universal joint (3).

8. Install the bushing (6) assemblies (4 used) to casing (14), by aligning the matching marks be-fore disassembly.

9

13


W2-7-22

W1F3-02-07-002

1

8

3

2

14


W2-7-23

9. Install universal joint (3) to casing (14) by using special toll (ST 7260).

: 24 mm : 47.1±2.9 N·m

(4.8±0.3 kgf·m, 35±2 lbf·ft) 10. Screw in universal joint (3) until pushers (8) (4

used) come in contact with cam (2) evenly. IMPORTANT: When tightening screw joint (1), do

not move cam (2). 11. Secure cam (2) by using a spanner. Install screw

joint (1) to universal joint (3). : 32 mm : 68.6±4.9 N·m

(7.0±0.5 kgf·m, 51±4 lbf·ft) 12. Apply grease onto the rotating part of universal

joint (3) and the top of pusher (8).


W2-7-24

DISASSEMBLY OF TRAVEL AND AUXIL-IARY/POSITIONING PILOT VALVES

W1LA-02-06-001

1 - O-Ring (2 Used) 7 - Boot 12 - Plug 17 - Shim (2 Used) 2 - Bushing (2 Used) 8 - Set Screw 13 - O-Ring 18 - Spring (2 Used) 3 - Packing (2 Used) 9 - Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used) 4 - Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used) 5 - Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing 6 - Socket Bolt (2 Used)

20

19

18

1716

15

14

21

13

12

14

15

1617

18

19

20

6

5

4

3

2

1 1

2

11

3

6

10 4

9

8

7


W2-7-25

Disassembly of Travel and Auxiliary/Positioning Pilot Valves • Spool (15) has been selected to match the hole of

casing (21). Therefore, the parts cannot be re-placed individually.

• Indicate the port number of the removed in order not to confuse.

IMPORTANT: Before disassembling, put the

matching marks on cam (9), pin (10), cover (11) and casing (21).

1. Secure the pilot valve in a vise. Remove boot (7) from cover (11).

2. Remove set screw (8) from cam (9). Remove pin

(10) from cover (11). Remove cam (9) from cover (11).

NOTE: LOCTITE is applied onto the set screw part.

NOTE: Steel ball (5) cannot be disassembled from cam (9).

3. Loosen and remove socket bolts (6) (2 used) from

cover (11) alternately. Remove cover (11) from casing (21).

4. Remove the pusher (20) assemblies (2 used)

from casing (21).

5. Remove bushings (2) (2 used) from the pusher (20) assembly. Remove O-rings (1) (2 used) and packings (3) (2 used) from bushings (2) (2 used).

IMPORTANT: Indicate the port numbers in order

not to confuse the parts. 6. Remove the spool (15) assemblies (2 used) and

springs (14) (2 used) from casing (21).

7. Remove spring guides (19) (2 used), springs (18) (2 used), washers (16) (2 used) and shims (17) (2 used) from the spool (15) assemblies (2 used).

IMPORTANT: As the spool (15) assemblies (2

used) are adjusted by shim (17), do not disassemble the spool (15) as-sembly unless necessary. If the spool (15) assembly is disassem-bled, record the quantity and thick-ness of shim (17).

IMPORTANT: Do not remove bushing (4) from cover (11) unless bushing (4) is damaged.

8. Remove bushings (4) (2 used) from cover (11).


W2-7-26

ASSEMBLY OF TRAVEL AND AUXIL-IARY/POSITIONING PILOT VALVES

W1LA-02-06-002

1 - O-Ring (2 Used) 7 - Boot 12 - Plug 17 - Shim (2 Used) 2 - Bushing (2 Used) 8 - Set Screw 13 - O-Ring 18 - Spring (2 Used) 3 - Packin (2 Used) 9 - Cam 14 - Spring (2 Used) 19 - Spring Guide (2 Used) 4 - *Bushing (2 Used) 10 - Pin 15 - Spool (2 Used) 20 - Pusher (2 Used) 5 - Steel Ball (2 Used) 11 - Cover 16 - Washer (2 Used) 21 - Casing 6 - Socket Bolt (2 Used)

NOTE: *Refer to W2-7-24.

9 1087

5

20

3

6

2

11

1

18

14

17

16

12

13

15

21

19


W2-7-27

Assembly of Travel and Auxiliary/Positioning Pi-lot Valve • Clean not to confuse the parts. Arrange the parts

by port in order.

1. Install bushings (4) (2 used) to cover (11). IMPORTANT: Install shim (17) as its thickness

becomes same before disassem-bling.

2. Install washers (16) (2 used), shims (17) (2 used), springs (18) (2 used) and spring guides (19) (2 used) to spools (15) (2 used) in this order.

IMPORTANT: Install the spool (15) assembly into

the same hole before disassembling. 3. Install spring (14) (2 used) to casing (21). Install

the spool (15) assemblies (2 used) to casing (21).

4. Install O-rings (1) (2 used) and packings (3) (2 used) to bushings (2) (2 used).

W585-02-06-005

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

assemblies (2 used). Install the pusher (20) as-semblies (2 used) to casing (21).

6. Secure casing (21) in a vise. Install cover (11) to

casing (21) with socket bolts (6) (2 used). : 23.5 N·m (2.4 kgf·m, 17 lbf·ft)

7. Install cam (9) to cover (11). Secure cam (9) to

cover (11) with pin (10).

8. Apply LOCTITE #241 onto setscrew (8). Secure cam (9) to pin (10) with setscrew (8).

: 5 N·m (0.5 kgf·m, 41 lbf·ft)

9. Install boot (7) to cover (11).

3

2

1

Lip


W2-7-28

(Blank)

UPPERSTRUCTURE / Electric Lever

W2-8-1

REMOVAL AND INSTALLATION OF ELECTRIC LEVER

Removal of Auxiliary/Positioning Electric Lever


: 17 mm




: 13 mm

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

: 13 mm

WCJB-02-13-001

WCEB-02-08-002

WCEB-02-01-003

WCEB-02-08-001

10

9

8

4

5

6

11

7

3

2 1


W2-8-2

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

: 17 mm

7. Remove sems bolts (15) (2 used) from electric lever (11). Remove electric lever (11) from bracket (12).

: 17 mm

Installation of Auxiliary/Positioning Electric Lever

1. Install electric lever (11) to bracket (12) with sems bolts (15) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install the bracket (12) assembly to plate (14) with sems bolts (13) (4 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-08-001

WCEB-02-08-002

WCEB-02-08-002

WCEB-02-08-001

12 13

15

11

14

15

11

12 13 14


W2-8-3

3. Install bracket (10) to electric lever (11) with sems bolts (7) (2 used).

: 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

4. Install pedal (9) to bracket (10) with sems bolts (8)



6. Connect connector (4).


: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-08-001

WCEB-02-01-003

WCEB-02-08-002

WCJB-02-13-001

10

9

8

11

7

5

6

4

3

2 1


W2-8-4

Removal of Blade/Outrigger Electric Lever

1. Remove caps (4) (2 used) from cover (2). Remove screws (5, 7) (2 used for each) from cover (2).

: 17 mm

2. Remove sems bolt (6) from cover (3). : 10 mm

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

4. Remove screws (11) (4 used) from boot (10). Raise boot (10) from bracket (8).

5. Remove screw (12) from cover (1). Remove covers (1, 3) from bracket (8).

WCEB-02-07-006

WCEB-02-07-009

W1JB-02-07-002

W1JB-02-07-016

1

4, 5

2

8

3

6

10

11

1

12

1

10

8

8

7

9

1

3


W2-8-5


7. Remove socket bolts (18) (2 used) from lever (14). Remove lever (14) from electric lever (17).

: 6 mm

8. Remove sems bolts (16) (2 used) from bracket (15). Remove the bracket (15) assembly from bracket (8).

: 17 mm

9. Remove sems bolts (19) (2 used) from electric lever (17). Remove electric lever (17) from bracket (15).

: 17 mm

WCEB-02-08-004

WCEB-02-08-003

WCEB-02-08-004

16

13

14 15

17 8 18

19

15

17


W2-8-6

Installation of Blade/Outrigger Electric Lever

1. Install electric lever (17) to bracket (15) with sems bolts (19) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)


3. Install the bracket (15) assembly to bracket (8) with sems bolts (16) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

4. Install lever (14) to electric lever (17) with socket

bolts (18) (2 used). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

5. Install covers (1, 3) to bracket (8) with screw (12).

6. Install boot (10) to bracket (8) with screws (11) (4 used).

WCEB-02-08-004

WCEB-02-08-003

W1JB-02-07-016

W1JB-02-07-002

19

15

17

13

16

14 15

17 8 18

12

1

10

8

10

11

8

3


W2-8-7

7. Install cover (1) to bracket (8) with screw (9).

8. Install cover (3) to bracket (8) with sems bolt (6). : 10 mm : 3.3 to 4.2 N⋅m

(0.3 to 0.4 kgf⋅m, 2.4 to 3 lbf⋅ft)

9. Install cover (2) to bracket (8) with screws (5, 7) (2 used for each).

10. Install caps (4) (2 used) to cover (2).

WCEB-02-07-009

WCEB-02-07-006

1

8

9

4, 5

2

8

3

6 7


W2-8-8

DISASSEMBLY OF ELECTRIC LEVER

W1MG-02-07-003

1 - Screw (2 Used) 6 - Bushing (2 Used) 11 - Cam 16 - Bushing (2 Used) 2 - Plate 7 - Screw 12 - Socket Bolt (2 Used) 17 - Spring (2 Used) 3 - Screw (2 Used) 8 - Arm 13 - Holder 18 - Housing 4 - Potentiometer 9 - Boot 14 - O-Ring (2 Used) 19 - Clip 5 - Pin 10 - Set Screw 15 - Bushing (2 Used) 20 - Screw

6

9

10

11

12

13

14

15

16

17

18

19

20

5

87

2 1

3 4


W2-8-9

Disassembly of Electric Lever IMPORTANT: Housing (18) is made of aluminum.

As too strong a force may deform or damage it, handle it with care.

1. Secure housing (18) in a vise.

2. Remove screws (1) (2 used) from plate (2).

Remove plate (2) from housing (18).

3. Remove screws (20) from clip (19). Remove clip (19) from housing (18).

4. Remove screws (3) (2 used) from potentiometer

(4). Remove potentiometer (4) from housing (18).

5. Remove boot (9) from holder (13).

6. Remove set screw (10) from cam (11). : 2.5 mm

7. Remove pin (5) from holder (13). Remove cam

(11) from holder (13).

8. Remove screw (7) from arm (8). Remove arm (8) from cam (11).

IMPORTANT: The pusher (16) assembly may fly

out by spring (17).

9. Remove socket bolts (12) (2 used) from holder (13). Remove holder (13) from housing (18).

: 5 mm

IMPORTANT: Keep the disassembled parts

carefully in order to install them to their original ports.

10. Remove the pusher (16) assemblies (2 used) and

springs (17) (2 used) from housing (18). IMPORTANT: Do not damage bushing (15). 11. Remove pushers (16) (2 used) and O-rings (14) (2

used) from bushings (15) (2 used). IMPORTANT: Bushing (6) cannot be reused. 12. Remove bushings (6) (2 used) from holder (13).


W2-8-10

ASSEMBLY OF ELECTRIC LEVER

T1MG-03-09-008

1 - *Screw (2 Used) 6 - Bushing (2 Used) 11 - Cam 16 - Pusher (2 Used) 2 - *Plate 7 - Screw 12 - Socket Bolt (2 Used) 17 - Spring (2 Used) 3 - Screw (2 Used) 8 - Arm 13 - Holder 18 - Housing 4 - Potentiometer 9 - Boot 14 - O-Ring (2 Used) 19 - Clip 5 - Pin 10 - *Set Screw 15 - Bushing (2 Used) 20 - Screw

NOTE: As for the item with mark*, refer to W2-7-8.

5, 6

13 17 18

15

14 16

11

12

3

4

1920

8 97


W2-8-11

Assembly of Electric Lever

1. Apply grease onto O-rings (14) (2 used).

2. Install O-rings (14) (2 used) to bushings (15) (2 used).

3. Apply grease onto the inner surface of bushings

(15) (2 used).

4. Install pushers (16) (2 used) to bushings (15) (2 used).

5. Install springs (17) (2 used) and the pusher (16)

assemblies (2 used) to housing (18).

6. Install bushings (6) (2 used) to holder (13).

7. Install holder (13) to housing (18) with socket bolts (12) (2 used).

: 5 mm : 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)

8. Apply grease onto the end of pushers (16) (2

used).

9. Install arm (8) to cam (11) with screw (7). : 3 N⋅m (0.3 kgf⋅m, 2 lbf⋅ft)

10. Apply grease onto the mounting surfaces of holder

(13) and cam (11). 11. Install cam (11) to holder (13).

12. Apply LOCTITE #262 onto screw (10).

13. Install pin (5) to holder (13). Secure pin (5) to cam

(11) with screw (10). : 2.5 mm : 7 N⋅m (0.7 kgf⋅m, 5 lbf⋅ft)

14. Apply grease to the gap between arm (8) and the

link part of potentiometer (4). 15. Apply LOCTITE #262 onto screws (3) (2 used).

IMPORTANT: Adjust the gap between arm (8) and

the link of potentiometer (4) to 0.4 mm on one side.

16. Install potentiometer (4) to housing (18) with

screws (3) (2 used). : 1.0 N⋅m (0.1 kgf⋅m, 0.7 lbf⋅ft)

17. Secure the harness of potentiometer (4) with clip

(19). 18. Apply LOCTITE #262 onto screw (20).

19. Install clip (19) to housing (18) with screw (20).

: 0.8 N⋅m (0.1 kgf⋅m, 0.6 lbf⋅ft) 20. Apply THREEBOND #1104 onto the mating

surfaces of housing (18) and plate (2). 21. Install plate (2) to housing (18) with screws (1) (2

used). 22. Install boot (9) to holder (13).


W2-8-12

(Blank)

UPPERSTRUCTURE / Signal Control Valve

W2-9-1

REMOVAL AND INSTALLATION OF SIGNAL CONTROL VALVE





3. Disconnect connectors (5) (2 used) from signal control valve (6).

4. Disconnect hoses (7) (32 used) from signal

control valve (6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 17 mm, 19 mm

5. Remove socket bolts (8) (4 used) from signal control valve (6). Remove signal control valve (6) from bracket (9).

: 8 mm

WCJB-02-01-002

WCJB-02-09-001

1 2 3 4

5 6 7

7

8

9


W2-9-2

Installation 1. Install signal control valve (6) to bracket (9) with

socket bolts (8) (4 used). : 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect hoses (7) (32 used) to signal control

valve (6). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Connect connectors (5) (2 used) to signal control

valve (6).

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

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

5. Shut cover (2).

WCJB-02-09-001

WCJB-02-01-002

1 2 3 4

5 6 7

7

8

9


W2-9-3

(Blank)


W2-9-4

STRUCTURE OF SIGNAL CONTROL VALVE

W1JB-02-10-002

7

7

11

12

4 13

4

5

6

78

9

10

4

2

3

4

77

4

1


W2-9-5

W1JB-02-10-003

1 - Bolt (3 Used) 9 - Body 3 17 - O-Ring (7 Used) 25 - O-Ring 2 - Body 1 10 - Gasket 18 - Spring (4 Used) 26 - Spring 3 - Gasket 11 - Body 4 19 - Spring Guide (7 Used) 27 - Spool 4 - Filter (17 Used) 12 - Gasket 20 - Spool (6 Used) 28 - Spring 5 - Body 2 13 - Body 5 21 - Spring (2 Used) 29 - Plate 6 - Gasket 14 - Socket Bolt (11 Used) 22 - Plate 7 - Shuttle Valve (2 Used) 15 - Plate 23 - O-Ring 8 - Spring (4 Used) 16 - Plug (7 Used) 24 - Shuttle Valve

Detail of Body 2 (5)

15

14

16 17

1819

20

2627

17

1928

16

29 14

5

20

17

1918

16

20

17

1921

16

2019

1817

16

25

2423

22

14

16 17

2119

20

16 17

1819

20


W2-9-6

(Blank)

UPPERSTRUCTURE / Travel Shockless Valve

W2-10-1

REMOVAL AND INSTALLATION OF TRAVEL SHOCKLESS VALVE


Removal of Travel Shockless Valve



2. Disconnect connector (4) from pressure sensor (5).

3. Disconnect connectors (6) (2 used).

4. Disconnect hoses (7) (6 used) from travel

shockless valve (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm

5. Remove sems bolts (10) (4 used) from bracket (9). Remove the travel shockless valve (8) assembly from main frame (3).

: 17 mm

6. Remove sems bolts (11) (2 used) from bracket (9). Remove travel shockless valve (8) from bracket (9).

: 17 mm

WCJB-02-15-001

WCEB-02-10-003

WCEB-02-10-003

2

8

4

8, 11

9

10

3

10

7

5 6 7

1 3


W2-10-2

Installation of Travel Shockless Valve

1. Install travel shockless valve (8) to bracket (9) with sems bolts (11) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install the bracket (9) assembly to main frame (3)

with sems bolts (10) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Connect hoses (7) (6 used) to travel shockless valve (8).

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

4. Connect connector (4) to pressure sensor (5).

5. Connect connectors (6) (2 used).


: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-10-003

WCEB-02-10-003

WCJB-02-15-001

8

4

7

5 6 7

8, 11

9

10

3

10

2 1 3


W2-10-3

(Blank)


W2-10-4

STRUCTURE OF TRAVEL SHOCKLESS VALVE

T1F3-03-08-005

T1F3-03-08-004

T1F3-03-08-006

1

13

2

3

5 Section A

14

4

4

A

B

6

Section B

7

8 9 10 11 12


W2-10-5

Tightening Torque Part Name Q’ ty Wrench Size N⋅m (kgf⋅m) (lbf⋅ft)

1 Solenoid 2 2 O-Ring 2 1B P14 3 Spool 2 4 Body 1 5 Spring 2 6 Plug 6 7 Orifice 2 1.6 to 2.0 (0.16 to 0.2) (1.2 to 1.5)8 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13) 9 Steel Ball 2 9/32

10 Spring 2 11 O-Ring 4 1B P8 12 Plug 2 13.2 to 17.6 (1.3 to 1.8) (9.7 to 13) 13 Nut 2 : 19 mm 4.9 (0.5) (3.6) 14 Tube 2 30 to 37 (3 to 4) (22 to 27)


W2-10-6

(Blank)

UPPERSTRUCTURE / Solenoid Valve

W2-11-1

REMOVAL AND INSTALLATION OF 4-SPOOL SOLENOID VALVE UNIT






4. Disconnect hoses (6) (16 used) from 4-spool solenoid valve unit (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm, 22 mm

5. Disconnect pipings (5) (3 used) from 4-spool solenoid valve unit (8).

: 19 mm

6. Remove socket bolts (10) (2 used) and washers (11) (2 used) from 4-spool solenoid valve unit (8). Remove 4-spool solenoid valve unit (8) from control valve (7).

: 8 mm

WCJB-02-01-002

WCJB-02-11-001

WCJB-02-11-002

2 1 3 4

76 5

8 9

6

8

710, 11


W2-11-2

Installation 1. Install 4-spool solenoid valve unit (8) to control

valve (7) with socket bolts (10) (2 used) and washers (11) (2 used).

: 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect pipings (5) (3 used) to 4-spool solenoid valve unit (8).

: 19 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Connect hoses (6) (16 used) to 4-spool solenoid

valve unit (8). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

4. Connect connectors (9) (4 used).

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

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

6. Shut cover (2).

WCJB-02-11-002

WCJB-02-11-001

WCJB-02-01-002

76 5

8 9

6

2 1 3 4

8

710, 11


W2-11-3

STRUCTURE OF 4-SPOOL SOLENOID VALVE UNIT

WCJB-02-11-003

WCJB-02-11-004

WCEB-02-11-010

WCEB-02-11-011

Filter Plug

View A

Filter Plug

Section B

Proportional Solenoid Valve

A

B

Proportional Solenoid Valve


W2-11-4

DISASSEMBLY AND ASSEMBLY OF 4-SPOOL SOLENOID VALVE UNIT

W18G-02-08-012

W18G-02-08-013

1 - Socket Bolt (4 Used) 6 - Solenoid 11 - Orifice 16 - O-Ring 2 - Lock Nut 7 - Spring 12 - Washer 17 - Sleeve 3 - O-Ring 8 - O-Ring 13 - Spring 18 - Plate 4 - Adjusting Bolt 9 - Diaphragm 14 - O-Ring 19 - Wave Spring 5 - Spring 10 - Spool 15 - O-Ring

1 2

3 4

5

6

78

9

1310

11

1718

19

14 15

16

12

3, 5 4 2 6 1 8 12 13 17 10 18

19

11 16 151497


W2-11-5

Disassembly of 4-Spool Solenoid Valve Unit IMPORTANT: Do not lose spring (7) in the hole of

solenoid (6) when removing solenoid (6). Do not disassemble pressure adjusting lock nut (2) and adjusting bolt (4).

1. Remove socket bolts (1) (2 used) from solenoid

(6). Remove solenoid (6) and O-ring (8) from the housing.

: 4 mm IMPORTANT: Do not remove orifice (11) from

spool (10).

2. Remove spool (10) from sleeve (17). Remove diaphragm (9), washer (12) and spring (13) from spool (10).

3. Remove sleeve (17) from the housing. Remove

plate (18) and wave spring (19) from the housing by using a magnet.

4. Remove O-rings (14, 15, 16) from sleeve (17).

Assembly of 4-Spool Solenoid Valve Unit

1. Install wave spring (19) and plate (18) to the housing.

IMPORTANT: When inserting sleeve (17) into the

housing, align the hole on sleeve (17) with that on the housing.

2. Install O-rings (14, 15, 16) to sleeve (17). Insert

sleeve (17) into the housing. IMPORTANT: When inserting spool (10) into

sleeve (17), do not damage the edge on sleeve (17). After inserting spool (10), try to push it about 3 to 5 mm (0.1 to 0.2 in) by fingers. Check if spool (10) moves smoothly.

3. Install diaphragm (9), washer (12) and spring (13)

to spool (10). Insert spool (10) into sleeve (17). IMPORTANT: When installing solenoid (6), prevent

spring (7) from falling off.

4. Install spring (7) to solenoid (6). Install solenoid (6) to the housing with socket bolts (1) (2 used).

: 4 mm : 5+2

−0 N⋅m (0.5+0.2−0 kgf⋅m, 4+1.5

−0 lbf⋅ft)


W2-11-6

REMOVAL AND INSTALLATION OF SOLENOID VALVE UNIT (FOR ELECTRIC LEVER OPERATION)



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

: 17 mm

3. Disconnect connectors (7) (5 used) from solenoid valve unit (6).

4. Disconnect hoses (5) (12 used) from solenoid

valve unit (6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm NOTE: The number of solenoid valve units, the

connectors and the hoses differ depending on the front attachment specifications.

WCEB-02-05-002

WCJB-02-11-005

WCJB-02-11-006

1

6

7

2

5

3

4


W2-11-7

5. Remove bolts (8) (4 used) and washers (9) (4 used) from bracket (10). Remove solenoid valve unit (6) from bracket (10).

: 17 mm

Installation 1. Install solenoid valve unit (6) to bracket (10) with

bolts (8) (4 used) and washers (9) (4 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Connect hoses (5) (12 used) to solenoid valve

unit (6). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Connect connectors (7) (5 used) to solenoid valve

unit (6).

4. Install cover (2) to cover (4) with sems bolts (3) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

5. Shut cover (1)

WCJB-02-11-006

WCJB-02-11-006

WCJB-02-11-005

WCEB-02-05-002

1

2

3

4

6

8, 9

10

6

7

5

8, 9

10


W2-11-8

STRUCTURE OF SOLENOID VALVE UNIT (FOR ELECTRIC LEVER OPERATION)

WCEB-02-11-006

WCEB-02-11-007

Tightening Torque Item Part Name Q’ty Wrench Size

(mm) N⋅m (kgf⋅m) (lbf⋅ft) Remark

1 Solenoid Valve Assembly 1



4 Socket Bolt 4 : 6 19.5+5−0 (2+0.5

−0) (14+4−0)

5 Washer 4

6 End Plate 1

7 Socket Bolt 18 4.9+5−0 (0.5+0.5

−0) (4+4−0)

8 Lock Nut 8 4.9+5−0 (0.5+0.5

−0) (4+4−0)

8

Section A

6

1

7 543 2

A A

A A

A A

A

A

UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve

W2-12-1

REMOVAL AND INSTALLATION OF PILOT SHUT-OFF SOLENOID VALVE


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


2. Disconnect hoses (4) (9 used) from pilot shut-off solenoid valve (5). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 17 mm, 19 mm


4. Remove sems bolts (6) (4 used) from bracket (7). Remove the bracket (7) assembly from main frame (3).

: 17 mm

5. Remove sems bolts (9) (2 used) from bracket (7). Remove bracket (7) from pilot shut-off solenoid valve (5).

: 17 mm

WCJB-02-15-001

WCEB-02-12-001

WCEB-02-12-001

6

7

8

5 3 4

7, 9 5

1 2 3


W2-12-2

Installation 1. Install bracket (7) to pilot shut-off solenoid valve

(5) with sems bolts (9) (2 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)



3. Connect hoses (4) (9 used) to pilot shut-off solenoid valve (5).

: 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)



: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-12-001

WCEB-02-12-001

WCJB-02-15-001

7, 9 536

8

5 4

1 2 3


W2-12-3

STRUCTURE OF PILOT SHUT-OFF SOLENOID VALVE

W1JB-02-08-001

W1JB-02-08-002

Tightening Torque Item Part Name Q’ty Wrench Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)

Remarks

1 Plug 1 : 6 26.5 (2.7) (20) 2 O-Ring 1 3 Spring 1 4 Spool 1 5 Filter 1 6 Body 1 7 O-Ring 1 8 Solenoid 1 9 Socket Bolt 2 : 4 3.92 (0.4) (3)

53 4 6 7 8

2

1

9


W2-12-4

(Blank)

UPPERSTRUCTURE / Steering Valve

W2-13-1

REMOVAL AND INSTALLATION OF STEERING VALVE


Removal 1. Open door (4) and upper front glass (2).

2. Remove lower front glass (1) from cab (3).



: 13 mm

WCEB-02-01-004

WCEB-02-01-003

WCEB-02-08-001

3

4

3

8

7

2

1

5

6


W2-13-2

5. Remove caps (10) (5 used) from cover (9). Remove screws (11) (5 used) from cover (9). Remove cover (9) from stand (15).

6. Remove caps (13) (3 used) from cover (12).

Remove screws (14) (5 used) from cover (12). Remove cover (12) from stand (15).

7. Remove screws (17) (4 used) from cover (16). Remove cover (16) from stand (15).


: 19 mm

9. Disconnect hoses (22) (5 used) from steering valve (21). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 22 mm, 27 mm

WCEB-02-13-002

WCEB-02-13-003

WCJB-02-13-001

WCEB-02-13-006

12, 13, 14

21

22

15

10, 11

9

18 19 20

15

16

17


W2-13-3

10. Remove sems bolts (23) (4 used) from stand (15). Remove the steering valve (21) assembly from stand (15).

: 17 mm 11. Remove socket bolts (24) (2 used) from priority

valve (25). Remove priority valve (25) and O-rings (26) (5 used) from steering valve (21).

WCEB-02-13-004

WCEB-02-13-006

WCEB-02-13-005

23

24

25, 26

15

21

21


W2-13-4

Installation 1. Install priority valve (25) to steering valve (21) with

O-rings (26) (5 used) and socket bolts (24) (2 used).

: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

2. Install the steering valve (21) assembly to stand (15) with sems bolts (23) (4 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

3. Connect hoses (22) (5 used) to steering valve (21).



: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-13-005

WCEB-02-13-004

WCEB-02-13-006

WCJB-02-13-001

24

25, 26

21

23

15

21

22

18 19 20


W2-13-5

5. Install cover (16) to stand (15) with screws (17) (4 used).

6. Install cover (9) to stand (15) with screws (11) (5 used). Install caps (10) (5 used) to cover (9).

7. Install cover (12) to stand (15) with screws (14) (5 used). Install caps (13) (3 used) to cover (12).

8. Install pedal (7) to bracket (8) with sems bolts (6) (2 used).

: 13 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

WCEB-02-13-003

WCEB-02-13-002

WCEB-02-13-002

WCEB-02-08-001

15

16

17

15

10, 11

9

12, 13, 14

15

8

7

6


W2-13-6

9. Install mat (5) to the inside of cab (3). 10. Install lower front glass (1) to cab (3).

11. Shut upper front glass (2) and door (4).

WCEB-02-01-003

WCEB-02-01-004

3

4

2

1

3

5

UPPERSTRUCTURE / Brake Valve

W2-14-1

REMOVAL AND INSTALLATION OF BRAKE VALVE


Removal 1. Remove mat (1) from the inside of cab (2).


: 17 mm


4. Remove socket bolts (7) (2 used) from bracket (6). Remove the bracket (6) assembly from bracket (8).

: 6 mm

5. Disconnect hoses (9) (6 used) from brake valve (10). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 17 mm, 22 mm, 27 mm

6. Remove rubber (14) from brake pedal (15).

7. Remove sems bolts (12) (4 used) from plate (13). Remove the brake valve (10) assembly from plate (13).

: 17 mm

WCEB-02-01-003

WCJB-02-13-001

WCEB-02-14-005

WCEB-02-14-006

1

2

106, 7

11

8 9

12 10 13

14, 15 12

54 3


W2-14-2

Installation 1. Align the brake valve (10) assembly with the

mounting hole on plate (13). Install the brake valve (10) assembly to plate (13) with sems bolts (12) (4 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

2. Install rubber (14) to brake pedal (15).

3. Connect hoses (9) (6 used) to brake valve (10). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m,58 lbf⋅ft)

4. Install the bracket (6) assembly to bracket (8) with

socket bolts (7) (2 used). : 6 mm : 58.8 to 73.5 N⋅m

(6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)



: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)


WCEB-02-14-006

WCEB-02-14-005

WCJB-02-13-001

WCEB-02-01-003

1

2

106, 7

11

8 9

12 10 13

14, 15 12

54 3


W2-14-3

(Blank)


W2-14-4

DISASSEMBLY OF BRAKE VALVE

WCEB-02-14-004

1

2

329

28

27

4

6

5 78

11

9

10

12

13

15

16

17

3

18

16

19

20

21

26

25

24

2322

38

37

3635

34 33

32 31

30

39

29

40

41 42

43

48 47

46 45

44

48

4746

4544

49

14

3


W2-14-5

1 - Rubber 14 - Bushing 26 - Bracket 38 - Push Rod 2 - Brake Pedal 15 - Yoke 27 - Oil Seal 39 - Cylinder 3 - Split Pin (4 Used) 16 - Pin (2 Used) 28 - Flange 40 - Cylinder 4 - Stopper Bolt 17 - Link 29 - O-Ring (2 Used) (1B, G45) 41 - O-Ring (1B, P32) 5 - Bushing 18 - Roller Assembly 30 - Rod 42 - Plug 6 - Lock Nut 19 - Bracket 31 - Return Spring 43 - Socket Bolt (4 Used) 7 - Bushing (2 Used) 20 - Brake Switch 32 - Holder 44 - Spring (2 Used) 8 - Pin 21 - Socket Bolt (2 Used) 33 - Spring 45 - Retaining Ring (2 Used) 9 - Bushing (2 Used) 22 - Seat 34 - Balance Spring 46 - Retainer (2 Used)

10 - Pin 23 - Stopper 35 - Retainer 47 - Plunger (2 Used) 11 - Boot 24 - Boot 36 - Retainer 48 - Spool (2 Used) 12 - Pin 25 - Socket Bolt (4 Used) 37 - Pilot Piston 49 - Spring 13 - Spring Pin


W2-14-6

WCEB-02-14-004

43

45 44

1

2

329

28

27

4

6

5 7 8

11

9

10

12

13

15

16

17

3

18

16

19

20

21

26

25

24

2322

38

37

3635

34 33

32 31

30

39

29

40

41 42

48 47

46

48

4746

4544

49

14

3


W2-14-7

Disassembly of Brake Valve IMPORTANT: Put the matching marks onto

bracket (26), flange (28), cylinder (39) and cylinder (40) before disas-sembling.

1. Secure the brake valve in a vise with the cylinder (40) side facing downward.

2. Remove socket bolts (21) (2 used) from bracket

(19). Remove bracket (19) and brake switch (20) from bracket (26).

: 6 mm

3. Remove split pins (3) (3 used) from pins (8, 10 and 16) except the roller assembly (18) part. Remove pins (8, 10 and 16) from bracket (26) and link (17).

4. Remove spring pin (13) from yoke (15). Remove

pin (12) from yoke (15).

5. Remove split pin (3) from pin (16). Remove pin (16) and the roller (18) assembly from link (17).

6. Remove seat (22), stopper (23) and boot (24)

from flange (28).

7. Remove socket bolts (25) (4 used) from bracket (26). Remove bracket (26) from flange (28).

8. Secure the flange (28) part in a vise with the push

rod (38) side facing downward.

IMPORTANT: The spool (48) assembly is also used inside cylinder (39). Keep them in order not to confuse.

9. Remove plug (42), spring (44) and the spool (48) assembly from cylinder (40).

10. Remove plunger (47), retaining ring (45) and re-

tainer (46) from the spool (48) assembly. IMPORTANT: The reaction force of spring (44) acts

on socket bolt (43). While holding cylinder (40), slowly remove socket bolt (43).

11. Remove socket bolts (43) (4 used) from cylinder (40).

12. Remove cylinder (40) and the cylinder (39) as-

sembly from flange (28). 13. Remove the spool (48) assembly from cylinder

(39). 14. Remove plunger (47), spring (44), retaining ring

(45) and retainer (46) from the spool (48) assem-bly.

15. Remove return spring (31), holder (32), rod (30),

balance spring (34), spring (33), retainers (35, 36), pilot piston (37) and push rod (38) from flange (28).

16. Remove oil seal (27) from flange (28).

17. Remove O-rings (29) (2 used) from flange (28)

and cylinder (39).


W2-14-8

ASSEMBLY OF BRAKE VALVE

WCEB-02-14-001

WCEB-02-14-002

WCEB-02-14-003

1

26

A

28 39 43 40

25

42

2

8

31

42

5

2422

12

11

15

14

16

10

21

17

19

16

18

20

47

41

29 48 49 47 45 46

35 33 34 32 46 29 45

44

48 363727 38

3022 23

12

15

8

9

17

21

16

18

19

3

3

10

26

3

7

13

View A


W2-14-9

1 - Rubber 14 - Bushing 26 - Bracket 38 - Push Rod 2 - Brake Pedal 15 - Yoke 27 - Oil Seal 39 - Cylinder 3 - Split Pin (4 Used) 16 - Pin (2 Used) 28 - Flange 40 - Cylinder 4 - * Stopper Bolt 17 - Link 29 - O-Ring (2 Used) (1B, G45) 41 - O-Ring (1B, P32) 5 - Bushing 18 - Roller Assembly 30 - Rod 42 - Plug 6 - * Lock Nut 19 - Bracket 31 - Return Spring 43 - Socket Bolt (4 Used) 7 - Bushing (2 Used) 20 - Brake Switch 32 - Holder 44 - Spring (2 Used) 8 - Pin 21 - Socket Bolt (2 Used) 33 - Spring 45 - Retaining Ring (2 Used) 9 - Bushing (2 Used) 22 - Seat 34 - Balance Spring 46 - Retainer (2 Used)

10 - Pin 23 - Stopper 35 - Retainer 47 - Plunger (2 Used) 11 - Boot 24 - Boot 36 - Retainer 48 - Spool (2 Used) 12 - Pin 25 - Socket Bolt (4 Used) 37 - Pilot Piston 49 - Spring 13 - Spring Pin

NOTE: As for the item with mark *, refer to W2-14-4.


W2-14-10

WCEB-02-14-001

WCEB-02-14-002

WCEB-02-14-003

View A

5

12

15

8

9

17

21

16

18

19

3

3

10

26

3

7

13

1

26

A

28 39 43 40

25

42

2

8

24

12

11

15

14

16

10

21

17

19

16

18

20 31

42

47

41

29 48 49 47 45 46

35 33 34 32 46 29 45

44

48 363727 38

3022 23 22


W2-14-11

Assembly of Brake Valve

1. Install oil seal (27) to flange (28).

2. Secure flange (28) in a vise with the oil seal (27) side facing downward.

3. Install O-ring (29) to flange (28).

4. Apply hydraulic oil onto rod (30), pilot piston (37),

push rod (38), plungers (47) (2 used) and spools (48) (2 used).

5. Install push rod (38), pilot piston (37), retainer (36),

retainer (35), return spring (31), balance spring (34), spring (33), holder (32) and rod (30) to flange (28) in this order.

6. Install O-ring (29) to cylinder (39).

7. Align the matching marks and place cylinder (39)

onto the flange (28) assembly.

8. Install retainer (46) and retaining ring (45) to spool (48).

9. Install the spool (48) assembly to cylinder (39).

10. Install spring (49), plunger (47) and spring (44) to

cylinder (39). 11. Align the matching marks and place cylinder (40)

onto cylinder (39). 12. Install retainer (46) and retaining ring (45) to spool

(48). 13. Install the spool (48) assembly to cylinder (40).

14. Install plunger (47), spring (44) and plug (42) to

cylinder (40). : 130 to 180 N⋅m

(13 to 18 kgf⋅m, 96 to 133 lbf⋅ft) 15. Connect flange (28), cylinder (39) and cylinder

(40) with socket bolts (43) (4 used). : 60 to 75 N⋅m

(6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft)


W2-14-12

WCEB-02-14-001

WCEB-02-14-002

WCEB-02-14-003

1

26

A

28 40

25

2

8

2422

12

11

15

16

10

21

17

19

16

18

20 22 23

12

15

8

17

21

16

18

19

3

3

10

26

3

13

View A


W2-14-13

16. Secure the cylinder assembly in a vise with the cylinder (40) side facing downward.

17. Install flange (28) to bracket (26) with socket bolts

(25) (4 used). : 60 to 75 N⋅m (6 to 7.5 kgf⋅m, 44 to 55 lbf⋅ft)

18. Install boot (24), stopper (23) and seat (22) to

flange (28). 19. Apply grease onto all pin holes on brake pedal (2),

bracket (26), yoke (15) and link (17). 20. Install yoke (15) to brake pedal (2) with pin (12)

and spring pin (13). 21. Install roller assembly (18) to link (17) with pin (16).

Secure pin (16) to link (17) with split pin (3). 22. Install the link (17) assembly to bracket (26) with

pin (10). Secure pin (10) to bracket (26) with split pin (3).

23. Install boot (11) to the brake pedal (2) assembly.

Install brake pedal (2) to bracket (26) with pin (8). Secure pin (8) to bracket (26) with split pin (3).

24. Install yoke (15) to link (17) with pin (16). Secure

pin (16) to link (17) with split pin (3). 25. Adjust play of link (17) to 0 mm with stopper bolt

(4).

26. Secure stopper bolt (4) to link (17) with lock nut (6).

: 6.0 to 10 N⋅m (0.6 to 1 kgf⋅m, 4 to 7 lbf⋅ft) 27. Install rubber (1) to brake pedal (2).

28. Install brake switch (20) to bracket (19). Install the

bracket (19) assembly to bracket (26) with socket bolts (21) (2 used).

: 6 mm : 58.8 to 73.5 N⋅m

(6 to 7.5 kgf⋅m, 43 to 54 lbf⋅ft)


W2-14-14

(Blank)

UPPERSTRUCTURE / Accumulator Charge Valve

W2-15-1

REMOVAL AND INSTALLATION OF AC-CUMULATOR CHARGE VALVE


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


2. Disconnect hoses (4) (8 used) from accumulator charge valve (5). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 17 mm, 22 mm, 27 mm

3. Remove sems bolts (7) (4 used) from bracket (8). Remove the bracket (8) assembly from main frame (3).

: 17 mm

4. Remove sems bolts (6) (4 used) from bracket (8). Remove accumulator charge valve (5) from bracket (8).

: 17 mm

WCJB-02-15-001

WCEB-02-15-001

5, 6 74

8

3

32 1


W2-15-2

Installation 1. Install accumulator charge valve (5) to bracket (8)




3. Connect hoses (4) (8 used) to accumulator charge

valve (5). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

4. Install cover (2) to main frame (3) with sems bolts

(7) (6 used). : 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

WCEB-02-15-001

WCJB-02-15-001

5, 6 74

8

3

32 1


W2-15-3

(Blank)


W2-15-4

STRUCTURE OF ACCUMULATOR CHARGE VALVE

WCEB-02-15-002

WCEB-02-15-003

33 34 35

7

1, 2 3, 4 5, 6 1, 2

3, 4

5, 6

A

B

C

D

26 2221

1

Section A

Section D

Section B

Section C 32 1 4

6 2019

6

5

27

28

29

2

10 10

1111

8 8

99

13

5

25

12

37

36

62423

5 18

17 16 15

3031 32

14

9


W2-15-5

Tightening Torque No. Part Name Q’ty Wrench Size

(mm) N⋅m (kgf⋅m) (lbf⋅ft) Remark

1 Plug 4 4.9 (0.5) (4) 2 O-Ring 4 3 Plug 3 26.5 (3) (20) 4 O-Ring 3 5 Plug 5 9.8 (1) (7) 6 O-Ring 5 7 Body 1 8 Plug 2 12 (1.2) (9) 9 O-Ring 3

10 Spring 2 11 Plunger 2 12 Plug 1 58.8 (6) (43) 13 Screw 1 14 Lock Nut 1 15 O-Ring 1 16 Spring 1 17 Needle Valve 1 18 O-Ring 1 19 Backup Ring 1 20 O-Ring 1 21 O-Ring 1 22 Backup Ring 1 23 Sleeve 1 24 Piston 1 25 Orifice 1 9.8 (1) (7) 26 Plug 1 12 (1.2) (9) 27 Spring 1 28 Plunger 1 29 Sleeve 1 30 Plunger 1 31 O-Ring 1 32 Washer 1 33 Spring 1 34 Spring 1 35 Plug 1 48.5 (5) (36) 36 O-Ring 1 37 Plug 1 48.5 (5) (36)

NOTE: Tools : 22 mm, 24 mm, 32 mm

: 1/8, 4 mm, 5 mm, 6 mm


W2-15-6

(Blank)

M E M O

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CJBW-3-1

SECTION 3

UNDERCARRIAGE

―CONTENTS― Group 1 Swing Bearing

Removal and Installation of Swing Bearing ......................................W3-1-1 Disassembly of Swing Bearing ................W3-1-4 Assembly of Swing Bearing.....................W3-1-6

Group 2 Travel Motor

Removal and Installation of Travel Motor .........................................W3-2-1 Disassembly of Travel Motor...................W3-2-4 Assembly of Travel Motor .....................W3-2-12 Disassembly of Brake Valve..................W3-2-20 Assembly of Brake Valve ......................W3-2-22

Group 3 Center Joint

Removal and Installation of Cebter Joint ..........................................W3-3-1 Disassembly of Center Joint....................W3-3-6 Assembly of Center Joint ......................W3-3-8

Group 4 Transmission

Removal and Installation of Transmission.........................................W3-4-1 Disassembly of Transmission ..................W3-4-6 Assembly of Transmission.....................W3-4-18

Group 5 Axle

Removal and Installation of Axle .............W3-5-1 Disassembly of Front Axle ....................W3-5-10 Assembly of Front Axle.........................W3-5-18 Disassembly of Rear Axle.....................W3-5-28 Assembly of Rear Axle .........................W3-5-34 Disassembly of Differential ...................W3-5-42 Assembly of Differential........................W3-5-44 Disasembly of Steering Cylinder ........... W3-5-46 Assembly of Steering Cylinder .............. W3-5-48

Group 6 Axle Lock Cylinder Removal and Installation of Axle Lock Cylinder .............................. W3-6-1 Disassembly and Assembly of Axle Lock Cylinder .............................. W3-6-4

Group 7 Operate Check Valve

Removal and Installation of Operate Check Valve (for Axle Lock Cylinder) .................W3-7-1 Structure of Operate Check Valve (For Axle Lock Cylinder)..........................W3-7-2

Group 8 Solenoid Valve

Removal and Installation of Outrigger/BladeSolenoid Valve Unit......W3-8-1

Structure of Solenoid Valve Unit ...............W3-8-3

Group 9 Transmission Changeover Solenoid Valve

Removal and Installation of Transmission Changeover Solenoid Valve..................W3-9-1

Group 10 Propeller Shaft Removal and Installation of Propeller Shaft.....................................W3-10-1

CJBW-3-2

(Blank)

UNDERCARRIAGE / Swing Bearing

W3-1-1

REMOVAL AND INSTALLATION OF SWING BEARING Before removing and installing the swing bearing, the upperstructure must be removed first. For removal and installation of the upperstructure, refer to the REMOVAL AND INSTALLATION OF MAIN FRAME on W2-3-1. The procedure starts on the premise that the upper-structure has already been removed.

Removal 1. Put the matching marks on inner race (1) of the

swing bearing and track frame (2).

2. Remove knock pin (3) from outer race (4) of the swing bearing.

3. Remove bolts (5) (36 used) from track frame (2).

: 30 mm

CAUTION: Swing bearing weight: 230 kg (510 lb)

4. Install special tools (ST 0050) (3 used) to swing

bearing. Attach a wire rope onto special tool. Hoist and remove swing bearing from track frame (2).

WCJB-02-03-003

WCJB-03-01-003

W110-03-01-004

Matching Mark 1

2

2

54 3

ST 0050

Swing Bearing


W3-1-2

Installation Clean the mounting surfaces of track frame (2) and swing bearing.

1. Apply THREEBOND #1102 onto the swing bear-

ing mounting surface of track frame (2).


IMPORTANT: If the matching mark do not align,

the soft zone position of the inner race will be dislocated.

2. Hoist and align swing bearing with the mounting holes on track frame (2).

3. Install inner race (1) of the swing bearing to track fame (2) with bolts (5) (36 used).

: 30 mm : 500 N⋅m (51 kgf⋅m, 368 lbf⋅ft)

4. Install knock pin (3) to outer race (4) of the swing

bearing.

W110-03-01-004

WCJB-03-01-002

WCJB-03-01-003

2

Machine Front

“S” (Soft Zone) Marking Position

25.8°

25°

49°

Position for Grease Fitting

Position for Plug

Position for Knock Pin

1

2

5 4 3

31°

Position for Grease Fitting

Swing Bearing


W3-1-3

5. After installing swing bearing, add grease (Shell Alvania EP2 or equivalent) up to 28 mm (1.1 in) height from the bottom of the grease bath.

WCEB-03-01-004

Swing Bearing Grease Level

Grease Bath

Pinion

28 mm (1.1 in)


W3-1-4

DISASSEMBLY OF SWING BEARING

WCJB-03-01-001

W157-03-01-002

1 - Plug 4 - Outer Race 6 - Seal 8 - Support (111 Used) 2 - Pin 5 - Ball (111 Used) 7 - Inner Race 9 - Grease Fitting (2 Used) 3 - Seal

2

8 7 6 5

9

4

3

7

9

8

5

6

1

3 4


W3-1-5

Disassembly of Swing Bearing

1. Tap and remove pin (3) of plug (4) upward from the bottom side.

NOTE: After installing pin (3), pin (3) was crimped. Grind off the crimped part.

W105-03-01-007

2. Remove plug (1) from outer race (5). NOTE: Install the bolt into the screw hole (M10,

Pitch 1.5 mm) of plug (1). Tap or pull the bolt from the inner side.

W105-03-01-008


3. Place inner race (7) of the swing bearing onto a

wooden block by using special tool (ST 0050). Hoist and hold outer race (4) slightly.

4. Remove balls (5) (111 used) and supports (8)

(111 used) from the plug hole while rotating outer race (4). Use magnet (A) when removing ball (5). Use wire (B) and remove support (8).

W105-03-01-009

W105-03-01-010

5. Separate outer race (4) from inner race (7).

6. Remove seals (3, 6) from outer race (4) and in-

ner race (7) respectively by using a scrapper.

2

1

1

4

7

3

4

A

5 6

8

B


W3-1-6

ASSEMBLY OF SWING BEARING

WCJB-03-01-001

W157-03-01-002

1 - Plug 4 - Outer Race 6 - Seal 8 - Support (111 Used) 2 - Pin 5 - Ball (111 Used) 7 - Inner Race 9 - Grease Fitting (2 Used) 3 - Seal

2

8 7 6 5

9

4

3

7

9

8

5

6

1

3 4


W3-1-7

Assembly of Swing Bearing IMPORTANT: Apply grease onto balls (5) (111

used) and supports (8) (111 used)

CAUTION: Outer race (4) weight: 96 kg (211 lb) Inner race (7) weight: 114 kg (251 lb)

1. Hoist outer race (4) horizontally and align outer

race (4) with inner race (7) coaxially. While rotating outer race (4), insert balls (5) and supports (8) into the plug hole by using a round bar.

W142-03-01-005

W142-03-01-006

2. Tap and install plug (1) into outer race (4). Secure plug (1) to outer race (4) with pin (2). Crimp the head of pin (2) by using a punch.

W142-03-01-007


3. Install lifting tool (ST 0050) to outer race (4).

Hoist outer race (4). Thoroughly degrease the slots for seals (3, 6). Apply THREEBOND #1745 to seal (3) and #1530D to seal (6). Install seals (3, 6) to outer race (4) and inner race (7).

4. Add grease 0.5 L (0.1 US gal.) (Alvania EP2

grease or equivalent) to the swing bearing through grease fitting (9). At this time, rotate outer race (4) and add grease.

5

8

6

3

4

4

1

4

2


W3-1-8

(Blank)

UNDERCARRIAGE / Travel Motor

W3-2-1

REMOVAL AND INSTALLATION OF TRAVEL MOTOR


Before removing and installing travel motor (7), the propeller shaft must be removed first. For removal and installation of the propeller shaft, refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-10-1. Therefore, in this section, the procedure starts from the premise that the propeller shaft has already been removed.

Removal IMPORTANT: Attach an identification tag onto the

disconnected hoses for assembling. 1. Disconnect hoses (1) (7 used) and connector (3)

from travel motor (2). Cap the disconnected hoses.

: 19 mm, 22 mm, 27 mm

CAUTION: Travel motor (2) weight: 80 kg (180 lb)

2. Loosen socket bolts (4) (4 used) of travel motor

(2). While holding the lower side of travel motor (2) by using a forklift, remove socket bolts (4) (4 used).

: 14 mm

3. Remove travel motor (2) from transmission (5).

WCGB-03-05-030

1

2

3

4

5


W3-2-2

Installation


1. Install travel motor (2) to transmission (5) with

socket bolts (4) (4 used). : 14 mm : 270 N·m (27.5 kgf·m, 199 lbf·ft)

2. Connect hoses (1) (7 used) and connector (3) to

travel motor (2). : 19 mm : 29.5 N·m (3 kgf·m, 22 lbf·ft) : 22 mm : 39 N·m (4 kgf·m, 29 lbf·ft) : 27 mm : 64 N·m (6.5 kgf·m, 47 lbf·ft) : 12 mm : 180 N·m (18 kgf·m, 133 lbf·ft)

3. Install the propeller shaft to transmission (5).

(Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-10-1.)

IMPORTANT: After installing the travel motor (2),

fill hydraulic oil into the travel motor (2). Perform break-in operation after installing the travel motor (2) in order to prevent the travel motor (2) and/or travel reduction gear from seizuring.

Condition 1.Engine control dial: Slow idle 2.Travel speed mode switch: Slow

speed 3.Operation duration: Over 2 minutes

WCGB-03-05-030

1

2

3

4

5


W3-2-3

(Blank)


W3-2-4

DISASSEMBLY OF TRAVEL MOTOR

WCGB-03-02-004

WCGB-03-02-002

WCGB-03-02-001

28, 53, 54

37, 38

29 28 27 26 25 24 23 22 21

47 1 2 3 4 5 6 7 8 9 10 11 12 13

14

15

16

17

18

19

20

35

34

33 32 31 30

41

40

39

36

42

43

44

45

46

37, 38

49

51

56

4, 55

50

8

View A48

49

5052

37, 38

51 8

A


W3-2-5

1 - Adjusting Screw 15 - Shim 29 - Socket Bolt 43 - Spring Collar 2 - Lock Nut 16 - Retaining Ring 30 - Ring (2 Used) 44 - Retaining Ring 3 - Pin 17 - Adjusting Shim 31 - Servo Piston 45 - Control Piston 4 - Solenoid Valve 18 - Retaining Ring 32 - Lock Pin 46 - Sleeve 5 - O-Ring 19 - Screw Bolt (7 Used) 33 - Pin 47 - Retaining Ring 6 - Adjusting Screw 20 - Drive Shaft 34 - Valve Plate 48 - Socket Bolt (2 Used) 7 - Lock Nut 21 - Center Shaft 35 - Spring 49 - Relief Valve (2 Used) 8 - Housing 22 - Spring 36 - Head Cover 50 - Plug (2 Used) 9 - Plunger (7 Used) 23 - Rotor 37 - Brake Valve 51 - Socket Bolt (8 Used)

10 - Retainer Plate 24 - Lock Nut 38 - O-Ring (2 Used) 52 - Socket Bolt (4 Used) 11 - Bearing 25 - Adjusting Screw 39 - Spring 53 - O-Ring 12 - Ring 26 - O-Ring 40 - Collar 54 - O-Ring 13 - Bearing 27 - Piston 41 - Bushing 55 - O-Ring (4 Used) 14 - Oil Seal 28 - Cover 42 - Spring 56 - Socket Bolt (4 Used)


W3-2-6

WCGB-03-02-004

WCGB-03-02-002

WCGB-03-02-001

37, 38

49

56

4, 55

50

28

47 1 2 3 4 5

20

35

41

40

39

37, 38

36

42

43

44

45

46

View A48

49

50

28, 53, 54

52

37, 38

A


W3-2-7

Disassembly of Travel Motor

CAUTION: Travel motor weight: 80 kg (180 lb)

1. Set the travel motor onto a wooden block

(100×500 mm, 3.9×19.7 in) with the drive shaft (20) side facing downward.

NOTE: When the workbench is used. Workbench: ST 5092 Upper Plate: ST 7333

2. Remove socket bolts (48) (2 used). Remove

brake valve (37) and O-rings (38) (2 used). : 5 mm

IMPORTANT: Do not disassemble relief valves

(49) (2 used). 3. Remove relief valves (49) (2 used) and plugs

(50) (2 used) from head cover (36). : 27 mm, 32 mm

4. Before removing, record the dimension of part A.

W1GL-03-02-006


solenoid valve (4) from head cover (36). When removing solenoid valve (4), prevent spring (39) from flying out.

: 6 mm

6. Remove the bushing (41) assembly, spring (39), collar (40) and spring (35) from head cover (36) in this order.

7. Remove spring collar (43) and spring (42) from

the bushing (41) assembly.

8. Remove O-ring (5), O-rings (55) (4 used), adjusting screw (1), lock nut (2) and pin (3) from solenoid valve (4).

9. Remove retaining ring (44) from solenoid valve

(4). Remove the sleeve (46) assembly. 10. Remove control piston (45) from sleeve (46).

Remove retaining ring (47) from control piston (45).


cover (28) and O-rings (53, 54) from head cover (36).

: 6 mm

1

A

2


W3-2-8

WCGB-03-02-004

WCGB-03-02-002

WCGB-03-02-001

51

8

26 25 24 23 21

6 7 8 9

14

15

16

20

36

View A

51 8

A


W3-2-9

12. Before removing, record the dimensions of part B and part C.

W1GL-03-02-005

13. Loosen lock nuts (7, 24). Remove adjusting

screws (6, 25) from housing (8). 14. Install adjusting screw (25) (M12, Pitch 1.75 mm,

Length 100 mm) to adjusting screw (6) mounting part, so that the angle of center shaft (21) should be zero.

W1GL-03-02-004

15. Put the matching marks on the contacting surface

of head cover (36) and housing (8). Remove socket bolts (51) (8 used). Remove head cover (36) from housing (8).

16. Secure rotor (23), center shaft (21) and plungers (9) (7 used) by using a screw bar (M8, Pitch 1.25 mm, Length 120 mm). Remove adjusting screw (25) from housing (8).

W1GL-03-02-003

17. Remove retaining ring (16) and shim (15) from

housing (8). 18. Set the housing (8) assembly in a vise with the

rotor (23) side facing downward. Remove the drive shaft (20) assembly from housing (8).

19. Remove oil seal (14) from housing (8).

21

25

B

C

26

7 68

Screw Bar Lock Nut

Washer

21

9

9

23

25


W3-2-10

WCGB-03-02-004

WCGB-03-02-002

WCGB-03-02-001

29 27

34

33 32 31 30

36

View A

A


W3-2-11

20. Set head cover (36) in a vise with the valve plate (34) side facing upward.

21. Remove socket bolt (29) and piston (27) from

servo piston (31). 22. Remove rings (30) (2 used) from piston (27).

CAUTION: Warm up lock pin (32). Take care not to burn yourself.

23. Warm up the mounting part of lock pin (32) by

using a torch. NOTE: Adhesive has been applied onto lock pin

(32). Warm up the adhesive by using slow fire.

24. Remove pin (33) from servo piston (31).

25. Remove servo piston (31) from head cover (36).


W3-2-12

ASSEMBLY OF TRAVEL MOTOR

WCGB-03-02-004

WCGB-03-02-002

WCGB-03-02-001

48

49

37, 38

49

50

28, 53, 54

52

37, 38

51 8

51

56

4, 55

50

8

29 28 27 26 25 24 23 22 21

47 1 2 3 4 5 6 7 8 9 10 11 12 13

14

15

16

17

18

19

20

35

34

33 32 31 30

41

40

39

37, 38

36

42

43

44

45

46

View A

A


W3-2-13

1 - Adjusting Screw 15 - Shim 29 - Socket Bolt 43 - Spring Collar 2 - Lock Nut 16 - Retaining Ring 30 - Ring (2 Used) 44 - Retaining Ring 3 - Pin 17 - Adjusting Shim 31 - Servo Piston 45 - Control Piston 4 - Solenoid Valve 18 - Retaining Ring 32 - Lock Pin 46 - Sleeve 5 - O-Ring 19 - Screw Bolt (7 Used) 33 - Pin 47 - Retaining Ring 6 - Adjusting Screw 20 - Drive Shaft 34 - Valve Plate 48 - Socket Bolt (2 Used) 7 - Lock Nut 21 - Center Shaft 35 - Spring 49 - Relief Valve (2 Used) 8 - Housing 22 - Spring 36 - Head Cover 50 - Plug (2 Used) 9 - Plunger (7 Used) 23 - Rotor 37 - Brake Valve 51 - Socket Bolt (8 Used)

10 - Retainer Plate 24 - Lock Nut 38 - O-Ring (2 Used) 52 - Socket Bolt (4 Used) 11 - Bearing 25 - Adjusting Screw 39 - Spring 53 - O-Ring 12 - Ring 26 - O-Ring 40 - Collar 54 - O-Ring 13 - Bearing 27 - Piston 41 - Bushing 55 - O-Ring (4 Used) 14 - Oil Seal 28 - Cover 42 - Spring 56 - Socket Bolt (4 Used)


W3-2-14

WCGB-03-02-004

WCGB-03-02-002

WCGB-03-02-001

56

4, 55

29 28 27

47 1 2 3 4 5

35

34

33 32 31 30

41

40

39

36

42

43

44

45

46

View A

28, 53, 54

52

A


W3-2-15

Assembly of Travel Motor

1. Set head cover (36) in a vise with the valve plate (34) side facing upward.

2. Apply hydraulic oil onto servo piston (31). Insert

servo piston (31) into head cover (36). Install pin (33).

3. Apply LOCTITE #241 onto lock pin (32). Insert

lock pin (32) into servo piston (31). Secure pin (33).

4. Install rings (30) (2 used) to piston (27). Install

piston (27) to servo piston (31) with socket bolt (29).

5. Install O-rings (53, 45) and cover (28) to head

cover (36). Install cover (28) to head cover (36) with socket bolts (52) (4 used).

: 6 mm : 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

6. Install adjusting screw (1) and lock nut (2) to

solenoid valve (4) with the dimension of part A recorded before disassembling.

W1GL-03-02-006

7. Install retaining rings (47, 44) to control piston (45) and sleeve (46).

8. Apply hydraulic oil onto solenoid valve (4), control

piston (45) and sleeve (46).

9. Install O-ring (5) to solenoid valve (4). 10. Install control piston (45) to sleeve (46). Insert the

sleeve (46) assembly and pin (3) into solenoid valve (4).

11. Install spring collar (43) and spring (42) to the

solenoid valve (4) assembly. 12. Install O-rings (55) (4 used) to the mounting

surface of head cover (36) and solenoid valve (4). 13. Install springs (35, 39), collar (40) and bushing

(41) to the large chamber side of head cover (36).

14. Install the solenoid valve (4) assembly to head

cover (36) with socket bolts (56) (4 used).

1

A

2


W3-2-16

WCGB-03-02-004

WCGB-03-02-002

WCGB-03-02-001

51

8

25 24 23 21

6 7 8

14

15

16

20

36

View A

51 8

A


W3-2-17

CAUTION: After warming up housing (8), start the work.

15. Warm up housing (8) to 50 to 80 °C (122 to

176 °F). Install the drive shaft (20) assembly to housing (8). If the drive shaft (20) assembly cannot be inserted, insert it by using a bar.

16. Face the rotor (23) side in housing (8) downward.

Install oil seal (14), shim (15) and retaining ring (16) to housing (8).

17. Set the travel motor onto a wooden block

(100×500 mm, 3.9×19.7 in) with the drive shaft (20) side facing downward.

NOTE: When the workbench is used. Workbench: ST 5092 Upper Plate: ST 7333

18. Remove the screw bar, the lock nut and the

washer from rotor (23).

W1GL-03-02-003

19. Temporarily install adjusting screw (25) (M12, Pitch 1.75 mm, Length 100 mm) to the adjusting screw (6) mounting part, so that the angle of center shaft (21) should be zero.

W1GL-03-02-008

20. Align the matching marks. Install head cover (36)

to housing (8) with socket bolts (51) (8 used). 21. Remove temporarily installed adjusting screw

(25) from housing (8). 22. Install adjusting screw (25), lock nut (24),

adjusting screw (6) and lock nut (7) to housing (8) so that the dimensions of part B and part C should be the same dimensions before disassembling.

W1GL-03-02-005

Screw Bar Lock Nut

Washer

23

21

24

B

C

25

7 68

25


W3-2-18

WCGB-03-02-004

WCGB-03-02-002

WCGB-03-02-001

37, 38

49

50

View A48

49

50

37, 38

A


W3-2-19

23. Install relief valves (49) (2 used) and plugs (50) (2 used) to head cover (36).

: 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 32 mm : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)

24. Install brake valve (37) and O-rings (38) (2 used)

to head cover (36) with socket bolts (48) (2 used).

: 5mm


W3-2-20

DISASSEMBLY OF BRAKE VALVE

WCGB-03-02-002

WCGB-03-02-001

WCGB-03-02-005

1 - Cover 6 - Orifice 10 - Socket Bolt (4 Used) 14 - O-Ring (2 Used) 2 - Socket Bolt (4 Used) 7 - Plug 11 - Plug 15 - O-Ring 3 - Valve Casing 8 - O-Ring (2 Used) 12 - Spring (2 Used) 16 - Shuttle Valve 4 - Counterbalance Valve 9 - Cover 13 - Check Valve 17 - Check Valve (2 Used) 5 - Plug

C

10

2

1

Section C

Section B 7

11

12

13

3 4 8 9

1417 1516

View A

7

5, 6

B

A

Brake Valve

Brake Valve


W3-2-21

Disassembly of Brake Valve

1. Remove socket bolts (2) (4 used). Remove cover (1) and O-ring (8) from valve casing (3).

: 10 mm

2. Remove socket bolts (10) (4 used). Remove cover (9) and O-ring (8) from valve casing (3).

: 10 mm IMPORTANT: When removing counterbalance

valve (4), remove counterbalance valve (4) by turning in order to prevent it from bounding.

3. Slowly remove counterbalance valve (4) from valve casing (3) by turning.

CAUTION: When removing plug (11), prevent spring (12) from flying out.

4. Remove plugs (11) (2 used), O-rings (14) (2

used), springs (12) (2 used) and check valve (13).

: 36 mm

5. Remove check valve (17) from valve casing (3) by using a socket wrench.

6. Remove plug (7) and O-ring (15) from valve

casing (3).

7. Remove shuttle valve (16) from valve casing (3) by using a socket wrench.

: 4 mm

8. Remove plug (5) from valve casing (3).

9. Remove orifice (6) from valve casing (3). : 3 mm


W3-2-22

ASSEMBLY OF BRAKE VALVE

WCGB-03-02-002

WCGB-03-02-001

WCGB-03-02-005

1 - Cover 6 - Orifice 10 - Socket Bolt (4 Used) 14 - O-Ring (2 Used) 2 - Socket Bolt (4 Used) 7 - Plug 11 - Plug 15 - O-Ring 3 - Valve Casing 8 - O-Ring (2 Used) 12 - Spring (2 Used) 16 - Shuttle Valve 4 - Counterbalance Valve 9 - Cover 13 - Check Valve 17 - Check Valve (2 Used) 5 - Plug

2

1

Section C

Section B 7

11

12

13

10

3 4 8 9

1417 1516

View A

Brake Valve

C

A

7

5, 6 Brake Valve

B


W3-2-23

Assembly of Brake Valve

1. Install orifice (6) and plug (5) to valve casing (3). : 3 mm

2. Install shuttle valve (16) and plug (7) to valve

casing (3).

3. Install check valves (17) (2 used) to valve casing (3).

4. Install check valve (13) to check valve (17).

5. Install springs (12) (2 used) to plugs (11) (2 used).

Install the plug (11) assemblies (2 used) and O-rings (14) (2 used) to valve casing (3).

: 36 mm : 167 N⋅m (17 kgf⋅m, 123 lbf⋅ft)

IMPORTANT: Slowly insert counterbalance valve

(4) into valve casing (3) by turning. Check if counterbalance valve (4) moves smoothly.

6. Insert counterbalance valve (4) into valve casing (3).

7. Install cover (1) and O-ring (8) to valve casing (3)

with socket bolts (2) (4 used). : 10 mm : 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)

8. Install cover (9) and O-ring (8) to valve casing (3)

with socket bolts (10) (4 used). : 10 mm : 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)


W3-2-24

(Blank)

UNDERCARRIAGE / Center Joint

W3-3-1

REMOVAL AND INSTALLATION OF CEN-TER JOINT


Removal

NOTE: If disconnecting the hoses (5 used) for the front attachment, the center joint can be removed easily. The number of hoses dif-fers depending on the front attachment specifications.


2. Remove bolt (3) and washer (4) from clips (1) (2

used). Remove clips (1) (2 used) from center joint (5).

: 10 mm


4. Remove bolt (9) and washer (10) from clip (7). Remove clip (7) from stopper (8).

: 17 mm

5. Remove sems bolts (11) (3 used) from slip ring (12). Remove the slip ring (12) assembly from stopper (8). (Length: approx. 670 mm (26.4 in))

: 10 mm

WCJB-03-03-002

WCJB-03-03-001

9, 10

6 87

53, 4 2

2

1

11

12


W3-3-2

6. Remove bolts (14) (5 used) and washers (15) (5 used) from stopper (8). Remove stopper (8) from center joint (5).

: 24 mm

7. Disconnect hoses (13) (13 used) from center joint (5). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm, 22 mm, 27 mm, 36 mm

8. Disconnect hoses (16) (23 used) from center joint (5). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm, 22 mm, 27 mm, 41 mm

9. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to the hole on bolt (14) of center joint (5). Attach a nylon sling onto eyebolts. Hoist and hold center joint (1).

CAUTION: The center joint (1) assembly weight: 90 kg (200 lb)

IMPORTANT: The propeller shaft and the travel

transmission are located under cen-ter joint (5). When hoisting and re-moving center joint (5), do not hit them.

10. Remove bolts (18) (4 used) and washers (19) (4 used) from center joint (5). Hoist and remove the center joint (5) assembly from track frame (17).

: 22 mm

WCJB-03-03-001

WCJB-03-03-002

WCJB-03-03-003

5

14, 15

18, 19

5

16

16

13 8

13

5

17


W3-3-3

Installation

CAUTION: The center joint (5) assembly weight: 90 kg (200 lb)

IMPORTANT: The propeller shaft and the travel

transmission are located under the center joint (5). Hoist center joint (5) in order not to hit them.

1. Install eyebolts (M16, Pitch 2.0 mm) (2 used) to center joint (5). Attach a nylon sling onto eyebolt. Hoist and align center joint (5) with the mounting hole on track frame (17).

2. Apply LOCTITE #262 onto bolts (18) (4 used).

Install center joint (5) to track frame (17) with bolts (18) (4 used) and washers (19) (4 used).

: 22 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

3. Connect hoses (16) (23 used) to center joint (5). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

WCJB-03-03-003

WCJB-03-03-002

18, 195

17

16

16

5

16

16


W3-3-4

4. Connect hoses (13) (13 used) to center joint (5). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)

5. Apply LOCTITE #262 onto bolts (14) (5 used).

Install stopper (8) to center joint (5) with bolts (14) (5 used) and washers (15) (5 used).

: 24 mm : 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft)

6. Install the slip ring (12) assembly to center joint (5). Install slip ring (12) to stopper (8) with sems bolts (11) (3 used).

: 10 mm : 3.3 to 4.2 N⋅m

(0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft)

7. Install clip (7) to stopper (8) with bolt (9) and washer (10).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)


WCJB-03-03-001

WCJB-03-03-001

5

14, 15

13 8

13

9, 10

6 87

11

12

5


W3-3-5

9. Install clips (1) (2 used) to center joint (5) with bolt (3) and washer (4).

: 10 mm : 3.3 to 4.2 N⋅m

(0.3 to 0.4 kgf⋅m, 2 to 3 lbf⋅ft) 10. Connect connectors (2) (2 used).

WCJB-03-03-002

53, 4 2

2

1


W3-3-6

DISASSEMBLY OF CENTER JOINT

WCGB-03-03-001

1 - Plug (2 Used) 5 - Body 8 - Bolt (4 Used) 11 - Socket Bolt (4 Used) 2 - O-Ring (2 Used) 6 - Oil Seal (15 Used) 9 - O-Ring 12 - O-Ring 3 - Spindle 7 - Cover 10 - Plate 13 - O-Ring 4 - O-Ring

1, 2

4

710

3

5

11

11

7

12

13

11

5

3

3

5

6

7

8

9


W3-3-7

Disassembly of Center Joint

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

1. Attach a nylon sling onto the body of body (5). Hoist the center joint. Secure the center joint on a workbench (ST 5109).

2. Remove socket bolts (11) (4 used) from cover (7).

Remove cover (7) and O-ring (12) from body (5). : 12 mm

3. Remove bolts (8) (4 used) from plate (10). Re-

move plate (10) from spindle (3). : 19 mm


the socket bolt (11) hole (2 places) on body (5). Hoist and hold body (5).

IMPORTANT: Do not damage the seal sliding sur-

face of spindle (3). 5. Install the puller to the body (5). Remove body (5)

from spindle (3). NOTE: There is a hole for the harness at the cen-

ter of spindle (3). Prepare a cover in order to cover the hole on spindle (3). Place the cover between the puller and spindle (3). Remove spindle (3).

W202-03-03-011

6. Install eyebolts (M14, Pitch 1.75 mm) (2 used) to the bolt (8) hole (2 places) on spindle (3). Hoist and place spindle (3) onto the wooden blocks horizontally.

7. Remove O-ring (9), plugs (1) (2 used) and O-rings

(2) (2 used) from spindle (3). : 12 mm

IMPORTANT: For easy removal, use the pins (2

used). Do not damage the seal groove by the pins.

8. Remove O-rings (4, 13) and oil seals (6) (15 used) from body (5).

W105-03-03-015

Puller

5

4, 13, 6


W3-3-8

ASSEMBLY OF CENTER JOINT

WCGB-03-03-001

1 - Plug (2 Used) 5 - Body 8 - Bolt (4 Used) 11 - Socket Bolt (4 Used) 2 - O-Ring (2 Used) 6 - Oil Seal (15 Used) 9 - O-Ring 12 - O-Ring 3 - Spindle 7 - Cover 10 - Plate 13 - O-Ring 4 - O-Ring

1, 2

4

710

3

5

11

11

7

12

13

11

5

3

3

5

6

7

8

9


W3-3-9

Assembly of Center Joint IMPORTANT: After installing the seals, apply

grease onto the inner surface of body (5), the inner surface of the circuit and the seals.

1. Install O-rings (4, 13) and oil seals (6) (15 used) to body (5).

2. Apply grease onto O-rings (2) (2 used). Install

O-rings (2) (2 used) to plugs (1) (2 used).

3. Apply grease onto O-ring (9). Install plugs (1) (2 used) and O-ring (9) to spindle (3).

: 12 mm : 147±14.7 N·m

(15±1.5 kgf·m, 108±11 lbf⋅ft)

4. Install eyebolts (M14, Pitch 1.75 mm) (2 used) into the bolt (8) hole (2 places) on spindle (3).

5. Hoist spindle (3). Secure spindle (3) on a work-

bench (ST 5109). IMPORTANT: There is almost no clearance be-

tween body (5) and spindle (3). In-sert body (5) along the axis straight and slowly.

6. Apply hydraulic oil onto the outer surface of spin-dle (3). Install eyebolts (M14, Pitch 2.0 mm) (2 used) to the bolt (8) hole (2 places) on body (5). Hoist and install body (5) to spindle (3).

7. Lightly tap body (5) by using a plastic hammer.

Insert body (5) until body (5) comes in contact with the flange of spindle (3).

8. Install plate (10) to spindle (3) with bolts (8) (4 used).

: 19 mm : 51 to 59 N⋅m

(5.2 to 6.0 kgf⋅m, 38 to 44 lbf⋅ft)

9. Install O-ring (12) to cover (7). 10. Install cover (7) to body (5) with socket bolts (11)

(4 used). : 12 mm : 206 to 216 N⋅m

(21 to 22 kgf⋅m, 152 to 159 lbf⋅ft)


W3-3-10

(Blank)

UNDERCARRIAGE / Transmission

W3-4-1

REMOVAL AND INSTALLATION OF TRANSMISSION


When removing and installing the transmission, the propeller shaft, the pipings of the travel motor and one part of the rear axle should be removed first. Refer to REMOVAL AND INSTALLATION OF PROPELLER SHAFT on W3-10-1, REMOVAL AND INSTALLATION OF TRAVEL MOTOR on W3-2-1 and REMOVAL AND INSTALLATION OF AXLE on W3-5-1. IMPORTANT: When removing and installing the

transmission, bleed air from the hydraulic port and the brake before doing any work. Refer to TROUBLESHOOTING / T5-7 Troubleshooting B in Technical Manual.

Removal

IMPORTANT: Remove the transmission with the

travel motor together in order to keep the balance of weight.

1. Loosen nuts (1) (20 used). Raise the machine until tire (3) at the rear axle side is raised. Place a stand under frame (4).

CAUTION: Tire (3) weight: 98 kg (220 lb) Tire ring (2) weight: 25 kg (60 lb)

2. Remove nuts (1) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used).

W1GL-03-05-003

4 3

2

3 1


W3-4-2

3. Remove plugs (8, 9). Drain oil from the transmission.

: 14 mm

CAUTION: Propeller shaft (11) weight: 35 kg (80 lb)

4. Place a wooden block under propeller shaft (11).

Remove nuts (10) (8 used). Remove propeller shaft (11) from the transmission.

: 14 mm

5. Disconnect hoses (7) (9 used) and connectors (6) (2 used) from the transmission and travel motor (5). Cap the disconnected hoses.

: 19 mm, 22 mm, 27 mm : 12 mm

CAUTION: The transmission assembly weight: 220 kg (490 lb)

6. Loosen bolts (13) (14 used).

: 19 mm

7. Support the travel motor (5) part by using a forklift and remove bolts (13) (14 used). Remove the transmission assembly from the rear axle.

: 19 mm


8. Remove socket bolts (12) (4 used). Remove travel

motor (5) from the transmission. : 14 mm

WCGB-03-05-033

WCGB-03-05-032

Transmission

Rear Axle

13

5

8

9 101112

76 Transmission


W3-4-3

Installation

CAUTION: Transmission weight: 135 kg (300 lb)

1. Install plug (9) to the transmission. Temporarily

install plug (8). : 14 mm : 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)


2. Install travel motor (5) onto the transmission with

socket bolts (12) (4 used). : 14 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

3. Install the transmission assembly to the rear axle

with bolts (13) (14 used). : 19 mm : 230 N⋅m (23 kgf⋅m, 170 lbf⋅ft)

4. Connect hoses (7) (9 used) and connectors (6) (2

used) to the transmission. : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) : 12 mm : 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft)

WCGB-03-05-033

WCGB-03-05-032

5

8

9 1011

Transmission76

Rear Axle

13

Transmission

12


W3-4-4


5. Install propeller shaft (11) to the transmission with

nuts (10) (8 used). : 14 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

6. Remove temporarily installed plug (8). Add oil to

the transmission. After adding oil, install plug (8) to the transmission.

NOTE: Gear oil: 2.5 L (0.7 US gal.) : 14 mm : 79 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

WCGB-03-05-033

9 1011

Transmission


W3-4-5

(Blank)


W3-4-6

DISASSEMBLY OF TRANSMISSION

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

1

2

3 4 5 6 7 8 9 10 9 11 12 13 14, 15 16, 17, 18, 19 20 21 22 23

24

25

26

27, 28

27, 28

29

30, 31

32 33 3435363738394041 42 43 44 45 46

47

48

49

50

51

52, 53

54


W3-4-7

WCGB-03-04-001

Part B

WCGB-03-04-003

55 56 57 5859

60

61

62

63

64 656667 22 68

69

70, 71

72

73

74

Part B


W3-4-8

1 - Cover 21 - Bearing 41 - Friction Plate (10 Used) 61 - Bearing 2 - Bolt (5 Used) 22 - Housing 42 - O-Ring 62 - Pinion 3 - O-Ring (5 Used) 23 - Bearing 43 - Ring 63 - Shim 4 - Oil Seal 24 - O-Ring (2 Used) 44 - Ring 64 - Bushing 5 - Pin (2 Used) 25 - Bolt (4 Used) 45 - Brake Piston 65 - Shaft Seal 6 - Oil Seal 26 - Shift Interlock Controller 46 - Disc Spring 66 - Cover 7 - Oil Seal 27 - Socket Bolt (5 Used) 47 - Clutch Piston 67 - Screen Sheet 8 - Seal Ring 28 - Washer (5 Used) 48 - Oil Seal 68 - Flange 9 - O-Ring (2 Used) 29 - Plate 49 - Shaft 69 - O-Ring

10 - Gasket 30 - Bearing 50 - Spring 70 - Bolt (2 Used) 11 - Plate (7 Used) 31 - Washer (2 Used) 51 - Holder 71 - Washer (2 Used) 12 - Friction Plate (6 Used) 32 - Planetary Carrier 52 - Bearing 72 - Plate 13 - Disc Plate 33 - Slot Pin (6 Used) 53 - Plate (2 Used) 73 - Plate 14 - Retaining Ring 34 - Ring Gear 54 - Disc Spring 74 - Shaft Seal 15 - Shim 35 - Retaining Ring 55 - Bearing 16 - Planetary Gear (3 Used) 36 - Retaining Ring 56 - Ring 17 - Retaining Ring (3 Used) 37 - Bearing 57 - Final Gear 18 - Washer (3 Used) 38 - Collar 58 - O-Ring (3 Used) 19 - Bearing 39 - Disc Plate 59 - O-Ring 20 - Retaining Ring 40 - Plate (9 Used) 60 - Cover


W3-4-9

(Blank)


W3-4-10

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

22 24

26

27, 28

27, 28


W3-4-11

Disassembly of Transmission

CAUTION: Transmission weight: 135 kg (300 lb)

1. Attach a nylon sling onto the transmission. Hoist

the transmission. Lower the transmission onto a workbench.

2. Remove bolts (75, 77) (2 used for each) and seal

rings (76, 78) (2 used for each) from the transmission. Disconnect pipes (79) (2 used) from the transmission.

: 22 mm, 24 mm

WCGB-03-04-005

3. Remove plugs (80) (2 used) and seal rings (81) (2

used) from housing (22). : 8 mm

WCGB-03-04-013

4. Remove socket bolts (27) (5 used) and washers (28) (5 used).

: 6 mm

5. Remove shift interlock controller (26) and O-rings (24) (2 used) from the transmission.

6. Remove socket bolt (83). Remove travel N sensor

(82) and O-rings (84) (2 used) from housing (22). : 6 mm

WCGB-03-04-006

Transmission

79 75, 7677, 78

83, 84

82

22

2280, 81


W3-4-12

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

1

2

3 4 5 7 22

45 46

47

54


W3-4-13

7. Remove bleeder (85), spring (87), steel ball (88), plug (90) and O-rings (86, 89) from housing (22).

: 27 mm : 8 mm

WCGB-03-04-007

8. Remove bleeder valve (93) and plugs (91, 92)

from housing (22). : 17 mm : 8 mm

WCGB-03-04-013

9. Remove bolts (2) (5 used). Remove cover (1) and

O-ring (3) from housing (22). : 19 mm

10. Remove spring (94), O-ring (95) and piston (96) from housing (22).

WCGB-03-04-014

11. Remove disc springs (46, 54) from housing (22).

Remove clutch piston (47). 12. Remove pins (5) (2 used) from housing (22).

13. Apply air to the hole of bleeder valve (93) on

housing (22). Remove brake piston (45). Remove fitting (97) from housing (22).

: 17 mm

WCGB-03-04-013

14. Remove oil seals (4, 7) from housing (22).

85

86

87

88

89

22

90

22

91

92 93

22

94, 95, 96

22

97

93

1

2


W3-4-14

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

6 8 9 10 11 12 13 14, 15 16, 17, 18, 19 20 21 22

23

25

29

30, 31

32 33 3435363738394041 42 43 44

48

49

50

51

52, 53

45


W3-4-15

15. Remove oil seals (6, 48) from brake piston (45). IMPORTANT: Do not remove bearing (52) unless

necessary. 16. Remove bearing (52) and plales (53) (2 used)

from shaft (49). 17. Remove holder (51) and spring (50) from shaft

(49). 18. Remove the ring (44) assembly from housing (22).

19. Remove ring (43), seal ring (8), O-rings (9) (2

used), O-ring (42) and gasket (10) from the ring (44) assembly.

20. Remove friction plates (12) (6 used), plates (11) (7

used) and disc plate (13) from housing (22). 21. Remove retaining ring (14) and shim (15) from

housing (22). 22. Remove friction plates (41) (10 used) and plates

(40) (9 used) from housing (22). 23. Remove disc plate (39) from housing (22).

24. Remove the shaft (49) assembly from housing

(22). 25. Remove shaft (49) from ring gear (34).

26. Remove retaining ring (20) from shaft (49). Remove collar (38).

IMPORTANT: Do not remove bearing (37) unless

necessary. 27. Remove retaining rings (35, 36) from ring gear

(34). Remove bearing (37). 28. Remove bearing (30) and washers (31) (2 used)

from planetary carrier (32). 29. Remove bolts (25) (4 used). Remove plate (29)

from housing (22). : 17 mm

30. Remove planetary carrier (32) from housing (22).

IMPORTANT: Do not remove bearings (21, 23)

unless necessary. 31. Remove the inner races of bearings (21, 23) from

planetary carrier (32). IMPORTANT: Do not remove bearings (21, 23)

unless necessary. 32. Remove the outer races of bearings (21, 23) from

housing (22). IMPORTANT: Do not remove bearing (19) unless

necessary. 33. Remove retaining rings (17) (3 used), washers

(18) (3 used) and bearings (19) (3 used) from planetary gears (16) (3 used).

34. Remove slot pins (33) (6 used) from planetary

gear (16).


W3-4-16

WCGB-03-04-001

Part B

WCGB-03-04-003

55 56 57 5859

60

61

62

63

64 656667 22 68

69

70, 71

72

73

74

Part B


W3-4-17

35. Remove bleeder valves (98) (2 used), plugs (99) (2 used), plugs (101) (3 used), seal rings (100) (2 used) and O-rings (102) (3 used) from housing (22).

: 17 mm : 8 mm

WCGB-03-04-008


used). Remove plate (72) and O-ring (69) from housing (22).

: 17 mm 37. Remove flange (68) and plate (73) from housing

(22). 38. Remove shaft seal (74) from housing (22).

39. Remove pinion (62) from housing (22).

40. Remove O-ring (59) and bushing (64) from pinion (62).


necessary. 41. Remove the inner race of bearing (61) from pinion

(62). IMPORTANT: Do not remove bearing (61) unless

necessary. 42. Remove shim (63) and the outer race of bearing

(61) from cover (60). 43. Remove cover (60) from housing (22).

44. Remove O-rings (58) (3 used) and shaft seal (65)

from cover (60). 45. Remove the final gear (57) assembly from

housing (22). 46. Remove cover (66) from final gear (57).

47. Remove screen sheet (67) from housing (22).


necessary. 48. Remove bearing (55) and ring (56) from housing

(22).

22 99, 100

98

101, 102


W3-4-18

ASSEMBLY OF TRANSMISSION

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

1

2

3 4 5 6 7 8 9 10 9 11 12 13 14, 15 16, 17, 18, 19 20 21 22 23 24

25

26

27, 28

27, 28

29

30, 31

32 33 3435363738394041 42 43 44 45 46

47

48

49

50

51

52, 53

54


W3-4-19

WCGB-03-04-001

Part B

WCGB-03-04-003

55 56 57 5859

60

61

62

63

64 656667 22 68

69

70, 71

72

73

74

Part B


W3-4-20

1 - Cover 21 - Bearing 40 - Friction Plate (10 Used) 61 - Bearing 2 - Bolt (5 Used) 22 - Housing 41 - O-Ring 62 - Pinion 3 - O-Ring (5 Used) 23 - Bearing 42 - Ring 63 - Shim 4 - Oil Seal 24 - O-Ring (2 Used) 43 - Ring 64 - Bushing 5 - Pin (2 Used) 25 - Bolt (4 Used) 44 - Brake Piston 65 - Shaft Seal 6 - Oil Seal 26 - Shift Interlock Controller 45 - Disc Spring 66 - Cover 7 - Oil Seal 27 - Socket Bolt (5 Used) 46 - Clutch Piston 67 - Screen Sheet 8 - Seal Ring 28 - Washer (5 Used) 47 - Oil Seal 68 - Flange 9 - O-Ring (2 Used) 29 - Plate 48 - Shaft 69 - O-Ring 10 - Gasket 30 - Bearing 49 - Spring 70 - Bolt (2 Used) 11 - Plate (7 Used) 31 - Washer (2 Used) 50 - Holder 71 - Washer (2 Used) 12 - Friction Plate (6 Used) 32 - Planetary Carrier 51 - Bearing 72 - Plate 13 - Disc Plate 33 - Slot Pin (6 Used) 52 - Plate (2 Used) 73 - Plate 14 - Retaining Ring 34 - Ring Gear 53 - Disc Spring 74 - Shaft Seal 15 - Shim 35 - Retaining Ring 54 - Bearing 16 - Planetary Gear (3 Used) 36 - Retaining Ring 55 - Ring 17 - Retaining Ring (3 Used) 37 - Bearing 56 - Final Gear 18 - Washer (3 Used) 38 - Collar 57 - O-Ring (3 Used) 19 - Bearing 39 - Disc Plate 58 - O-Ring 20 - Retaining Ring 40 - Plate (9 Used) 59 - Cover


W3-4-21

(Blank)


W3-4-22

WCGB-03-04-001

Part B

WCGB-03-04-003

55 57 58

60

61

63

656667 22

Part B


W3-4-23

Assembly of Transmission

1. Hoist housing (22) with the rear axle mounting side facing upward.

2. Install the outer race of bearing (55) to housing

(22).

3. Install screen sheet (67) to housing (22). At this time, the slot pin should pass through the hole on screen sheet (67).

WCGB-03-04-009

4. Install final gear (57) to housing (22).

5. Apply grease onto the seal and the dust lip part of shaft seal (65). Apply gear oil onto the outer circumference of shaft seal (65). Install shaft seal (65) to cover (60).

NOTE: Dimension A: 69.5-0.5 mm (2.7-0.02 in)

WCGB-03-04-015

6. Install shim (63) to cover (60).

7. Install the outer race of bearing (61) to cover (60).

8. Apply hydraulic oil onto O-ring (58). Install O-rings

(58) (3 used) to cover (60). IMPORTANT: Install cover (66) so that the convex

part of the cover (60) back side can enter the groove of cover (60).

9. Install cover (66) to cover (60).

WCGB-03-04-016

22

Slot Pin

A

65

60

66

60


W3-4-24

WCGB-03-04-001

Part B

WCGB-03-04-003

55 56 59

60

61

62

64 22 68

69

72

Part B

70


W3-4-25

10. Install the cover (60) assembly to housing (22). Temporarily tighten with nuts (103) (2 used) and washers (104) (2 used).

: 19 mm

WCGB-03-04-010

11. Install the inner race of bearing (61), bushing (64)

and O-ring (59) to pinion (62). 12. Install pinion (62) to housing (22). Install special

tool (ZF special tool No. 5870 654 049) to housing (22). Tighten pinion (62).

13. Hoist and turn over housing (22) with the rear axle

mounting side facing downward. 14. Install ring (56) and the inner race of bearing (55)

to pinion (62).

15. Install O-ring (69) and plate (72) to housing (22). Temporarily tighten with bolts (70) (2 used). At this time, turn pinion (62) to both directions 7 times and take up slack.

: 17 mm : 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft)

16. Turn pinion (62) and measure the preload. If the

proper preload cannot be obtained, reassemble from step 14.

NOTE: Proper preload: 1.5 to 3.0 N⋅m (0.2 to 0.3 kgf⋅m, 1.0 to 2.0 lbf⋅ft)

17. Tighten pinion (62) in a direction opposite to step

12 by using special tool (ZF special tool No. 5870 654 049). Remove special tool (ZF special tool No. 5870 654 049).

18. Turn pinion (62) and measure the preload. If the

proper preload cannot be obtained, reassemble from step 14.

NOTE: Proper preload: 1.5 to 3.0 N⋅m (0.2 to 0.3 kgf⋅m, 1.0 to 2.0 lbf⋅ft)

19. Remove temporarily installed bolts (70) (2 used).

Remove flange (68) and plate (72) from housing (22).

: 17 mm

60

22 103, 104


W3-4-26

WCGB-03-04-001

Part B

WCGB-03-04-003

55

60

62

22 68

69

70, 71

72

73

74

Part B


W3-4-27

20. Apply grease onto the seal and the dust lip part of shaft seal (74). Apply gear oil onto the outer circumference of shaft seal (74). Install shaft seal (74) to housing (22).

21. Install plate (73) to housing (22).

NOTE: Dimension B: 17.6-0.5 mm (0.7-0.02 in) Dimension C: 27.5+0.3 mm(1.1+0.01 in)

WCGB-03-04-011

22. Install flange (68), O-ring (69) and plate (72) to

housing (22) with bolts (70) (2 used) and washers (71) (2 used).

: 17 mm : 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft)

23. Remove nuts (103) (2 used) and washers (104) (2 used) which are installed temporarily.

: 19 mm

WCGB-03-04-010

24. Hoist housing (22) with the rear axle mounting

side facing upward. 25. Install the steel ball (diameter: 7.0 mm (0.3 in)) to

the center hole on pinion (62). Measure the dimension. If the proper dimension cannot be obtained, reassemble from step 12.

NOTE: Dimension D: 115.6 mm (4.6 in) Dimension E: 73±0.05 mm (2.9±0.002 in)

WCGB-03-04-012

74 55

22

73

B C

22103, 104

DE

62

60

22


W3-4-28

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

13 14, 15 16, 17, 18, 19 20 21 22 23

25

29

30, 31

32 33 343536373839

49


W3-4-29

26. Install the outer race of bearing (23) to housing (22).

27. Hoist housing (22) with the rear axle mounting

side facing downward. 28. Install the outer race of bearing (21) to housing

(22). 29. Apply grease onto slot pin (33). Install slot pins

(33) (6 used) to planetary carrier (32). NOTE: Dimension F: 28-1.0 mm (1.1-0.04 in)

WCGB-03-04-017

30. Install planetary gears (16) (3 used), bearings

(19) (3 used) and washers (18) (3 used) to planetary carrier (32) with retaining rings (17) (3 used).

31. Install the inner race of bearing (21) to planetary

carrier (32). 32. Install planetary carrier (32) to housing (22).

33. Tighten planetary carrier (32) to housing (22) by

using special tool (ZF special tool No. 5870 654 049).

34. Hoist housing (22) with the rear axle mounting side facing upward.

35. Install the inner race of bearing (23) to housing

(22). 36. Install plate (29) to housing (22) with bolts (25) (4

used). At this time, turn planetary carrier (32) to both directions several times.

: 17 mm : 46 N⋅m (4.7 kgf⋅m, 34 lbf⋅ft)

37. Install collar (38) to shaft (49). Secure with

retaining ring (20). 38. Secure bearing (37) to ring gear (34) with

retaining rings (36) (2 used). 39. Install shaft (49) to ring gear (34). Secure with

retaining ring (35). 40. Hoist housing (22) with the rear axle mounting

side facing downward. 41. Install bearing (30) and washers (31) (3 used) to

planetary carrier (32). 42. Install the shaft (49) assembly to housing (22).

43. Secure the shaft (49) assembly to housing (22)

with retaining ring (14) and shim (15). 44. Install disc plates (13, 39) to housing (22).

32 33

F


W3-4-30

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

11 12 22

4041 45 46

47

49

51

52, 53

54


W3-4-31

45. Install friction plates (12) (6 used) and plates (11) (7 used) to housing (22).

46. Remove friction plates (41) (10 used) and plates

(40) (9 used) from housing (22). 47. Apply hydraulic oil onto plate (53). Install holder

(51), bearing (52) and plates (53) (2 used) to shaft (49).

48. Install brake piston (45) without the seals to

housing (22). 49. Install clutch piston (47) without the seals to

housing (22). 50. Install disc springs (46, 54) to housing (22).

51. Install special tool (ZF special tool No. 5870 200

131) to housing (22) with the bolts (2 used). Measure dimensions G and H of disc springs (46, 54).

: 19 mm : 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)

NOTE: Dimension G: 2.4+0.3 mm (0.09+0.01 in) Dimension H: 1.8+0.3 mm (0.07+0.01 in)

WCGB-03-04-018

52. Measure dimension I of housing (22) and clutch piston (47).

NOTE: Dimension I: 22.5 mm (0.9 in)

WCGB-03-04-018

53. Measure dimension J of housing (22) and brake

piston (45). NOTE: Dimension J: 11.9 mm (0.47 in)

WCGB-03-04-018

54. Remove the bolts (2 used). Remove special tool

(ZF special tool No. 5870 200 131) and disc springs (46, 54) from housing (22).

: 19 mm 55. Remove brake piston (45), clutch piston (47),

holder (51), bearing (52) and plates (53) (2 used) from housing (22).

54 46

22

HG

22

I

47

22

J

45


W3-4-32

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

4 5 6 7 8 9 10 9 22

42 43 44 45 46

47

48

49

50

51

52, 53

54

1

2

3


W3-4-33

56. Apply hydraulic oil onto the seal surface of ring (43) and O-ring (9). Install O-ring (9) to ring (43).

57. Install ring (43) to housing (22) by using a plastic

hammer. 58. Apply hydraulic oil onto the seal surface of ring

(44) and O-rings (9, 42). Install O-rings (9, 42), oil seal (8) and gasket (10) to ring (44).

59. Install ring (44) to housing (22) by using a plastic

hammer. 60. Install spring (50) and holder (51) to shaft (49).

61. Apply hydraulic oil onto bearing (52). Install

bearing (52) and plates (53) (2 used) to shaft (49). 62. Apply hydraulic oil onto the seal surface of

housing (22). Install oil seals (4, 7) to housing (22).

63. Apply hydraulic oil onto the seal surface of brake

piston (45). Install oil seals (6, 48) to brake piston (45).

64. Install brake piston (45) to housing (22) by using a

plastic hammer. 65. Install pins (5) (2 used) to brake piston (45).

66. Install clutch piston (47) to housing (22). Push clutch piston (47) toward the shaft. Install plugs (80) (2 used) and seal rings (81) (2 used) to housing (22).

WCGB-03-04-013

67. Install disc springs (46, 54) to housing (22). 68. Install piston (96), spring (94) and O-ring (95) to

housing (22).

WCGB-03-04-014

69. Apply hydraulic oil onto O-ring (3). Install O-ring (3) to cover (1).

70. Install cover (1) to housing (22) with bolts (2) (5

used). : 19 mm : 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)

2280, 81

22

94, 95, 96


W3-4-34

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

22


W3-4-35

71. Install O-rings (86, 89), plug (90), steel ball (88) and spring (87) to housing (22).

: 8 mm : 24 N⋅m (2.4 kgf⋅m, 18 lbf⋅ft)

WCGB-03-04-007

72. Install bleeder valves (98) (2 used), plugs (99) (2

used), plugs (101) (3 used), seal rings (100) (2 used) and O-rings (102) (3 used) to housing (22). Bleeder valve (98)

: 17 mm : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)

Plug (99) : 8 mm : 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)

Plug (102) : 8 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

WCGB-03-04-008

73. Install bleeder (85), bleeder valve (93), fitting (97) and plugs (91, 92) to housing (22). Bleeder (85)

: 27 mm : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)

Bleeder valve (93) : 17 mm : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)

Fitting (97) : 17 mm : 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)

Plugs (91, 92) : 8 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

WCGB-03-04-013

9192 93

22 99, 100

98

101, 102

97

22

86

87

88

89

22

90

1

2

85


W3-4-36

WCGB-03-04-001

Part A

WCGB-03-04-002

Part A

22

26

27, 28

27, 28


W3-4-37

74. Install travel N sensor (82) to housing (22) with socket bolt (83) and O-ring (84).

: 6 mm : 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft)

WCGB-03-04-006

75. Install shift interlock controller (26) to housing (22)

with socket bolts (27) (5 used) and washers (28) (5 used).

: 6 mm : 23 N⋅m (2.3 kgf⋅m, 17 lbf⋅ft)

76. Connect pipes (81) (2 used) to the transmission

with bolts (75, 77) (2 used for each) and seal rings (76, 78) (2 used for each).

: 22 mm : 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 24 mm : 45 N⋅m (4.5 kgf⋅m, 33 lbf⋅ft)

WCGB-03-04-005

85, 86

84

22

Transmission

79 75, 7677, 79


W3-4-38

(Blank)

UNDERCARRIAGE / Axle

W3-5-1

REMOVAL AND INSTALLATION OF AXLE

Removal of Front Axle

1. Loosen nuts (1) (20 used) for tires (3) (4 used) and tire rings (2) (2 used).

: 30 mm

2. Swing the machine by 90º. Raise the front axle side of frame (4) until tire (3) is raised. Place a stand under frame (4).


3. Remove nuts (1) (20 used). Remove tires (3) (4

used) and tire rings (2) (2 used) from frame (4). : 30 mm

4. Disconnect brake hoses (5) (2 used) from the

right and left sides of the front axle. : 22 mm

W1GL-03-05-003

WCEB-03-05-021

Steering Cylinder 5 Front Axle

1

2 3 3 2 3 3 4


W3-5-2

5. Disconnect grease hose (8) from pin (7). : 17 mm

6. Disconnect steering hoses (6) (2 used) from the

steering cylinder. : 22 mm


7. Place a wooden block under propeller shaft (11).

Remove bolts (10) (8 used) and nuts (9) (8 used). Remove propeller shaft (11) from the front axle.

: 14 mm

8. Remove nuts (12) (2 used). Remove bolt (13) from pin (7).

: 24 mm

9. Hold the lower side of the front axle by using a forklift.

CAUTION: Front axle weight: ZX210W-3: 750 kg (1660 lb) ZX220W-3: 770 kg (1700 lb)

CAUTION: Pin (7) weight: 18 kg (40 lb) (outer diameter 70 mm (2.8 in))

10. Remove pin (7) from the front axle. Remove the

front axle from frame (4).

WCGB-03-05-024

WCGB-03-05-028

WCGB-03-05-027

11

9, 10

Front Axle

7 8 6

Steering Cylinder

4

13

7

12

4


W3-5-3

Installation of Front Axle


CAUTION: Pin (7) weight: 18 kg (40 lb) (outer diameter 70 mm (2.8 in))

1. Hold the front axle by using a forklift. Install the

front axle to frame (4) with pin (7).

2. Secure pin (7) with bolt (13) and nuts (12) (2 used).

: 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

3. Connect steering hoses (6) (2 used) to the steering cylinder.

: 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

4. Connect brake hoses (5) (2 used) to the right and left sides of the front axle.

: 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

5. Connect grease hose (8) to pin (7). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)


6. Install propeller shaft (11) to the front axle with bolts (10) (8 used) and nuts (9) (8 used).

: 14 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)

WCGB-03-05-027

WCGB-03-05-024

WCEB-03-05-021

WCGB-03-05-028

Front Axle

7

12

13

Steering Cylinder

5 6 Front Axle

9, 10

11

7 8 6

Steering Cylinder

4

4


W3-5-4


7. Install tire (3), tire ring (2) and tire (3) to the front

axle in this order. Temporarily tighten with nuts (1) (10 used).

: 30 mm

8. Install tire ring (2) and tires (3) (2 used) to the other side of the front axle in the same way as step 7.

9. Remove the stand from frame (4).

10. Tighten tires (3) (4 used) and tire rings (2) (2

used) with nuts (1) (20 used). : 30 mm : 600 N⋅m (60 kgf⋅m, 440 lbf⋅ft)

W1GL-03-05-003

1

2 3 3 2 3 3 4


W3-5-5

Removal of Rear Axle

1. Loosen nuts (1) (20 used) for tires (3) (4 used) and tire rings (2) (2 used).

: 30 mm

2. Swing the machine by 90°. Raise the rear axle side of frame (4) until tire (3) is raised. Place a stand under frame (4).


3. Remove nuts (1) (20 used). Remove tires (3) (4 used) and tire rings (2) (2 used) from frame (4).

: 30 mm


4. Place a wooden block under propeller shaft (6). Remove bolts (8) (8 used) and nuts (7) (8 used). Remove propeller shaft (6) from transmission (5).

: 14 mm

5. Disconnect hoses (9) (9 used) and connectors (11) (2 used) from transmission (5) and travel motor (10).

: 19 mm, 22 mm, 27 mm

W1GL-03-05-003

WCGB-03-05-033

WCGB-03-05-030

43

2

3 1

7, 8

5

6

10

119

5


W3-5-6

CAUTION: The transmission (5) assembly weight: 220 kg (490 lb)

6. Hold the lower side of the transmission (5)

assembly by using a forklift. Remove bolts (12) (14 used). Remove the transmission (5) assembly from the rear axle.

: 19 mm

7. Disconnect brake pipings (13) (2 used) from the right and left sides of the rear axle.

: 19 mm

CAUTION: Rear axle weight: ZX210W-3: 600 kg (1330 lb) ZX220W-3: 630 kg (1390 lb)

8. Hold the lower side of the rear axle by using a forklift.

9. Remove nuts (15) (8 used) from the right and left sides of the rear axle. Remove bolts (14) (8 used) from frame (4).

: 30 mm 10. Remove the rear axle from frame (4).

WCGB-03-05-032

WCGB-03-05-023

WCGB-03-05-022

W1GL-03-05-003

4

4 13

14

15

4

12

Rear Axle

5


W3-5-7

Installation of Rear Axle


1. Hold the rear axle by using a forklift. Install the

rear axle to frame (4) with bolts (14) (8 used) and nuts (15) (8 used).

: 30 mm : 560 N⋅m (57 kgf⋅m, 410 lbf⋅ft)

2. Connect brake pipings (13) (2 used) to the right and left sides of the rear axle.

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

CAUTION: The transmission (5) assembly weight: 220 kg (490 lb)

3. While holding the transmission (5) assembly by using a forklift, align it with the rear axle. Install the transmission (5) assembly to the rear axle with bolts (12) (14 used).

: 19 mm : 250 N⋅m (26 kgf⋅m, 185 lbf⋅ft)

4. Connect hoses (9) (9 used) and connector (11) to transmission (5) and travel motor (10). (Hose):

: 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

(Socket bolt): : 12 mm : 140 N⋅m (14 kgf⋅m, 105 lbf⋅ft)

WCGB-03-05-023

WCGB-03-05-022

WCGB-03-05-032

WCGB-03-05-030

4 13

14

15

4

12

Rear Axle

5

10

911


W3-5-8


5. Install propeller shaft (6) to transmission (5) with

nuts (7) (8 used) and bolts (8) (8 used). : 14 mm : 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)


6. Install tire (3), tire ring (2) and tire (3) to the rear

axle in this order. Temporarily tighten with nuts (1) (10 used).

: 30 mm

7. Install tire ring (2) and tires (3) (2 used) to the other side of the rear axle in the same way as step 6.

8. Remove the stand from frame (4).

9. Tighten tires (3) (4 used) and tire rings (2) (2

used) with nuts (1) (20 used). : 30 mm : 600 N⋅m (60 kgf⋅m, 440 lbf⋅ft)

WCGB-03-05-033

W1GL-03-05-003

43

2

3 1

7, 8

5

6


W3-5-9

(Blank)


W3-5-10

DISASSEMBLY OF FRONT AXLE

WCGB-03-05-001

12

3

45

6 7 8 91 10

11

12 789

13

14 15 16

17 18

19

20 21222324

25 26 27

28 29

30313233

34 35

36

37 38 39 4041 42

43

44 45

46

4748

49 50

51 52 53 5455

5856

57596061626364 65 66 67 68 69


W3-5-11

1 - Axle Casing 19 - Knuckle 37 - Hub Carrier 55 - Washer 2 - Bolt (16 Used) 20 - Bolt (4 Used) 38 - Bushing 56 - O-Ring 3 - Washer (16 Used) 21 - Bearing Pin 39 - Bearing 57 - Ring Gear 4 - Plug (2 Used) 22 - O-Ring 40 - O-Ring 58 - Knock Pin (4 Used) 5 - O-Ring (2 Used) 23 - Seal 41 - Friction Plate (6 Used) 59 - Backup Ring 6 - Drive Housing 24 - O-Ring 42 - Plate (5 Used) 60 - U-Ring 7 - Roller Bearing 25 - Bearing Nut 43 - Disc Plate 61 - U-Ring 8 - Shim 26 - Thrust Plate 44 - Planetary Carrier 62 - Backup Ring 9 - O-Ring 27 - Thrust Plate 45 - Plug 63 - Piston 10 - Bearing 28 - Socket Bolt 46 - O-Ring 64 - Spring (8 Used) 11 - Bearing 29 - Retaining Ring 47 - Socket Bolt (2 Used) 65 - Spring (8 Used) 12 - Tie Rod 30 - Seal 48 - Retaining Ring (3 Used) 66 - Spring Seat (8 Used) 13 - Tie Rod 31 - O-Ring 49 - Planetary Gear (3 Used) 67 - Bolt (8 Used) 14 - Bushing 32 - Shim 50 - Washer (3 Used) 68 - Disc Carrier 15 - Shaft Seal 33 - Bearing Pin 51 - Roller Bearing (3 Used) 69 - O-Ring 16 - Double Joint Shaft 34 - O-Ring 52 - Washer (3 Used) 17 - Shaft Seal 35 - Shaft Seal 53 - Retaining Ring (3 Used) 18 - Bushing 36 - Bearing 54 - Retaining Ring (3 Used)


W3-5-12

WCGB-03-05-001

45

6

12

13 19

25 26 27

28 29

37

4041 42

43

44 45

46

4748

49 50 51 52 53545558

5657596061

626364 65 66 67 68 69


W3-5-13

Disassembly of Front Axle


1. Hoist the front axle. Lower the front axle on a workbench.

2. Remove plugs (4) (2 used) and O-rings (5) (2

used) from drive housing (6). Remove plug (45) and O-ring (46) from planetary carriers (44) in the left and right sides. Drain gear oil from the front axle.

: 14 mm

3. Disassemble tie rods (12, 13). (Refer to DISASSEMBLY OF STEERING CYLINDER on W3-5-46.)

CAUTION: Planetary carrier (44) weight: 30 kg (70 lb)

4. Attach a nylon sling onto planetary carrier (44).

Hoist and hold planetary carrier (44).

5. Remove socket bolts (47) (2 used) from planetary carrier (44). Hoist and remove planetary carrier (44) from the front axle.

: 8 mm

6. Remove retaining rings (54) (3 used). Remove planetary gears (49) (3 used) and washer (55) from planetary carrier (44).

IMPORTANT: Do not remove roller bearing (51)

unless necessary. 7. Remove retaining rings (48, 53) (3 used for each),

washers (50, 52) (3 used for each) and roller bearings (51) (3 used) from planetary gears (49) (3 used).

8. Remove retaining ring (29) and thrust plates (26, 27) from knuckle (19).

9. Remove socket bolt (28) from bearing nut (25).

: 8 mm 10. Remove bearing nut (25) and O-ring (56) from

knuckle (19). : 41 mm

11. Pry the clearance between piston (63) and hub

carrier (37) by using a pry bar. Remove the ring gear (57) assembly from hub carrier (37).

IMPORTANT: Before removing bolt (67), record the

dimension of bolt (67) extended from piston (63).

12. Remove bolts (67) (8 used), spring seats (66) (8 used) and springs (64, 65) (8 used for each) from ring gear (57).

13. Remove piston (63) from ring gear (57). Remove

U-rings (60, 61), backup rings (59, 62) and knock pins (58) (4 used) from ring gear (57).

14. Remove disc plate (43) from hub carrier (37).

Remove plates (42) (5 used) and friction plates (41) (6 used).

15. Remove O-ring (40). Remove disc carrier (68)

from knuckle (19). Remove O-ring (69).


W3-5-14

WCGB-03-05-001

1

1 10

11

16

19

20 21222324

30313233

34

37 38 39

35 36


W3-5-15

CAUTION: Hub carrier (37) weight: 38 kg (84 lb)

16. Attach a nylon sling onto hub carrier (37). Hold

hub carrier (37). Hoist and remove hub carrier (37) from knuckle (19).

17. Remove O-ring (34) from knuckle (19).


unless necessary. 18. Remove shaft seal (35) from hub carrier (37).

Remove the outer race of bearing (36) and bearing (39).


necessary. 19. Remove bushing (38). Remove the inner race of

bearing (36) from knuckle (19). IMPORTANT: When removing bearing pin (21), the

inner race of bearing (10) is removed with bearing pin (21) together. Do not damage the inner race of bearing (10) and bearing pin (21).

20. Remove bolts (20) (4 used) from the upper side of knuckle (19). Remove bearing pin (21), O-rings (22, 24) and seal (23) from knuckle (19).

: 24 mm

CAUTION: The knuckle (19) assembly: 76 kg (170 lb)


the bolt (20) hole on the upper side of knuckle (19). Attach a nylon sling onto eyebolts (2 used). Hoist and hold knuckle (19).

IMPORTANT: When removing bearing pin (33), the inner race of bearing (11) is removed with bearing pin (33) together. Do not damage the inner race of bearing (11) and bearing pin (33).

22. Remove bolts (20) (4 used) from the lower side of knuckle (19). Remove bearing pin (33), shim (32), O-ring (31) and seal (30) from knuckle (19).

: 24 mm IMPORTANT: Do not remove bearings (10, 11)

unless necessary. 23. Remove the inner races of bearings (10, 11) from

bearing pins (21, 33). IMPORTANT: When removing double joint shaft

(16), do not damage the seal of axle casing (1).

24. Pull out knuckle (19) with double joint shaft (16) attached about 200 mm from axle casing (1). Hold the axis of double joint shaft (16). Hoist and remove the knuckle (19) assembly.

WCGB-03-05-002

16 19


W3-5-16

WCGB-03-05-001

1 2

3

6 7 8 91 10

11

789

14 15 16

17 18

19


W3-5-17

25. Remove double joint shaft (16) from knuckle (19). 26. Remove shaft seal (17) and bushing (18) from

knuckle (19). 27. Remove shaft seal (15) and bushing (14) from

axle casing (1). IMPORTANT: Do not remove bearings (10, 11)

unless necessary. 28. Remove the outer races of bearings (10, 11) from

axle casing (1).

CAUTION: Axle casing (1) weight: ZX210W-3: 98 kg (220 lb) ZX220W-3: 107 kg (240 lb)

29. Attach a nylon sling onto axle casing (1). Hoist

and hold axle casing (1). Remove bolts (2) (16 used) and washers (3) (16 used). Hoist and remove axle casing (1) from drive housing (6).

: 27 mm IMPORTANT: Do not remove roller bearing (7)

unless necessary. 30. Remove O-ring (9), shim (8) and roller bearing (7)

from axle casing (1). 31. Disassemble the other side of the front axle in the

same way as steps 4 to 30.

32. Remove differential (70) from drive housing (6).

WCGB-03-05-003

6

70


W3-5-18

ASSEMBLY OF FRONT AXLE Detail of Drive Housing Inside

WCGB-03-05-019

Detail of Planetary Carrier Inside

WCGB-03-05-005

1

2, 3

9

8 7

6

9

7 8

16

14

15

11

30, 31

20 33 32 19

35 36 40 38 37

39

41 42 43 61, 62

59, 60

16

21

10

22, 23

24

17 18

68

69 64, 65, 66, 67

63

34

A Detail A

54 53 52 50

44

48

4951

2527

29

55

26

2845

4657 56

1

2, 3

Planetary Carrier

Drive Housing


W3-5-19

1 - Axle Casing 19 - Knuckle 37 - Hub Carrier 55 - Washer 2 - Bolt (16 Used) 20 - Bolt (4 Used) 38 - Bushing 56 - O-Ring 3 - Washer (16 Used) 21 - Bearing Pin 39 - Bearing 57 - Ring Gear 4* - Plug (2 Used) 22 - O-Ring 40 - O-Ring 58*- Knock Pin (4 Used) 5* - O-Ring (2 Used) 23 - Seal 41 - Friction Plate (6 Used) 59 - Backup Ring 6 - Drive Housing 24 - O-Ring 42 - Plate (5 Used) 60 - U-Ring 7 - Roller Bearing 25 - Bearing Nut 43 - Disc Plate 61 - U-Ring 8 - Shim 26 - Thrust Plate 44 - Planetary Carrier 62 - Backup Ring 9 - O-Ring 27 - Thrust Plate 45 - Plug 63 - Piston 10 - Bearing 28 - Socket Bolt 46 - O-Ring 64 - Spring (8 Used) 11 - Bearing 29 - Retaining Ring 47* - Socket Bolt (2 Used) 65 - Spring (8 Used) 12* - Steering Cylinder 30 - Seal 48 - Retaining Ring (3 Used) 66 - Spring Seat (8 Used) 13* - Steering Cylinder 31 - O-Ring 49 - Planetary Gear (3 Used) 67 - Bolt (8 Used) 14 - Bushing 32 - Shim 50 - Washer (3 Used) 68 - Disc Carrier 15 - Shaft Seal 33 - Bearing Pin 51 - Roller Bearing (3 Used) 69 - O-Ring 16 - Double Joint Shaft 34 - O-Ring 52 - Washer (3 Used) 17 - Shaft Seal 35 - Shaft Seal 53 - Retaining Ring (3 Used) 18 - Bushing 36 - Bearing 54 - Retaining Ring (3 Used)



W3-5-20

WCGB-03-05-019

WCGB-03-05-005

6

2, 3

9

8 7

9

7 8

16

1

2, 3

1

14

15

11 30, 31

33 32

16

21

10 22, 23

17 18

A Detail A

19

Planetary Carrier

Drive Housing


W3-5-21

Assembly of Front Axle

1. Install differential (70) to drive housing (6).

WCGB-03-05-003

2. Install roller bearing (7), shim (8) and O-ring (9) to

the drive housing (6) mounting side on axle casing (1).


3. Hoist axle casing (1). Install axle casing (1) to

drive housing (6) with bolts (2) (16 used) and washers (3) (16 used).

: 27 mm : 390 N⋅m (40 kgf⋅m, 860 lbf⋅ft)

4. Apply grease onto the seal and the dust lip part of

shaft seal (15). Apply LOCTITE #574 onto the shaft seal (15) contact surface on axle casing (1). Install bushing (14) and shaft seal (15) to axle casing (1).

5. Tap and install the outer races of bearings (10, 11) to axle casing (1) by using a plastic hammer.

IMPORTANT: When installing double joint shaft

(16), do not damage the seal of axle casing (1).

6. Install double joint shaft (16) to axle casing (1).

7. Apply grease onto the seal and the dust lip part of shaft seal (17). Apply LOCTITE #574 onto the shaft seal (17) contact surface on knuckle (19). Install bushing (18) and shaft seal (17) to knuckle (19).

8. Install seal (30), O-ring (31), the inner race of

bearing (11) and washer (32) to bearing pin (33).

9. Apply anticorrosive (Weicon Antiseize (Never Seez) ZF special tool No. 0671 196 001) onto the collar part of bearing pin (33). Install seal (23) and O-ring (22) to bearing pin (21).

6

70


W3-5-22

WCGB-03-05-019

WCGB-03-05-005

1

1

20 33 19

35 36 40 38 37

39

16

21 24 68

69

A Detail A

25

57

Planetary Carrier

Drive Housing


W3-5-23

CAUTION: Knuckle (19) weight: 55.5 kg (130 lb)

IMPORTANT: When inserting double joint shaft

(16) to knuckle (19), do not damage the seal.

10. Apply grease onto bearing pin (33). Install eyebolts (M16, Pitch 1.75 mm) (2 used) to the bolt (20) hole on the upper side of knuckle (19). Hoist knuckle (19). Install knuckle (19) to axle casing (1). Install bearing pin (33) to the lower side of knuckle (19) with bolts (20) (4 used).

: 24 mm : 280 N⋅m (28 kgf⋅m, 205 lbf⋅ft)

11. Apply grease onto bearing pin (21). Remove

eyebolts (2 used) from the upper side of knuckle (19). Install bearing pin (21) and O-ring (24) to knuckle (19) with bolts (20) (4 used).

: 24 mm : 280 N⋅m (28 kgf⋅m, 205 lbf⋅ft)

12. Install the inner race of bearing (36) and bushing

(38) to knuckle (19). 13. Apply hydraulic oil onto O-ring (40). Install O-ring

(40), the outer race of bearing (36) and bearing (39) to hub carrier (37).

IMPORTANT: When installing shaft seal (35), check the mounting position and dimension A. Install shaft seal (35) with the marking of OUT-SIDE facing upward and outward.

14. Apply LOCTITE #574 onto the shaft seal (35) contact surface on hub carrier (37). Install shaft seal (35) to hub carrier (37).

NOTE: Dimension A: 0 to 0.3 mm (0 to 0.01 in)

WCGB-03-05-006


15. Hoist hub carrier (37). Install hub carrier (37) to

knuckle (19). 16. Install O-ring (69) and disc carrier (68) to knuckle

(19). 17. Install ring gear (57) to knuckle (19).

18. When installing bearing nut (25), apply lubricant

(ZF special tool No. 0671 195 042 MOLYKOTE PASTE 1000) onto the thread part of knuckle (19). Install bearing nut (25) to knuckle (19) by using special tool (ZF special tool No. 5870 656 097). At this time, turn hub carrier (37) in both directions several times in order to fit the rotor.

: 1400 N⋅m (140 kgf⋅m, 1040 lbf⋅ft)

A37

35


W3-5-24

WCGB-03-05-019

WCGB-03-05-005

19

37 41 42 43 61, 62

59, 6064, 65, 66, 67

63A Detail A

44

2527

29

55

26

28

57 56

Planetary Carrier

Drive Housing


W3-5-25

19. Remove bearing nut (25) from knuckle (19). Remove ring gear (57) from knuckle (19).

: 41 mm IMPORTANT: Check the mounting positions of

friction plate (41) and plate (42). 20. Install friction plates (41) (6 used) and plates (42)

(5 used) to hub carrier (37) alternately. Install disc plate (43).

21. Apply grease onto O-ring (34). Install O-ring (34)

to knuckle (19). 22. Apply hydraulic oil onto U-rings (60, 61) and

backup rings (59, 62). Install U-rings (60, 61) and backup rings (59, 62) to ring gear (57).

23. Install knock pins (58) (4 used) to piston (63).

NOTE: Dimension B: 16 mm (0.6 in)

WCGB-03-05-007

IMPORTANT: When tightening bolt (67), align with

the dimension before disassembling.

24. Install piston (63) to ring gear (57). Secure piston (63) with bolts (67) (8 used), spring seats (66) (8 used) and springs (64, 65).

: 10 mm : 11 N⋅m (1 kgf⋅m, 8 lbf⋅ft)

25. Align the marks and install the ring gear (57) assembly to knuckle (19).

WCGB-03-05-008

26. Apply hydraulic oil onto O-ring (56). Install O-ring

(56) to knuckle (19). 27. When installing bearing nut (25), apply lubricant

(ZF special tool No. 0671 195 042 MOLYKOTE PASTE 1000) onto the thread part of knuckle (19). Install bearing nut (25) to knuckle (19) by using special tool (ZF special tool No. 5870 656 097). Align the socket bolt (28) holes on knuckle (19) and bearing nut (25). If it is difficult to align the holes, retighten bearing nut (25).

: 1400+200 N⋅m (140+20 kgf⋅m, 1040+150 lbf⋅ft) 28. Install socket bolt (28) to bearing nut (25).

: 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

29. Install thrust plates (26, 27) to knuckle (19).

Secure with retaining ring (29). 30. Install washer (55) to planetary carrier (44).

63 58

B

57 19Mark


W3-5-26

WCGB-03-05-019

WCGB-03-05-005

6

A Detail A

54 53 52 50

44

48

49

51

45

46

Planetary Carrier

Drive Housing


W3-5-27

31. Install retaining rings (48, 53) (3 used for each), washers (50, 52) (3 used for each) and roller bearings (51) (3 used) to planetary gears (49) (3 used).

32. Install planetary gears (49) (3 used) to planetary

carrier (44) with retaining rings (54) (3 used).


33. Hoist planetary carrier (44). Install planetary

carrier (44) to the front axle with socket bolts (47) (2 used).

: 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

34. Assemble the other side of the front axle in the

same way as steps 2 to 33. 35. Assemble tie rods (12, 13). (Refer to ASSEMBLY

OF STEERING CYLINDER on W3-5-48.) 36. Add gear oil to drive housing (6) and planetary

carriers (44) in the left and right sides. Install plugs (4) (2 used) and O-rings (5) (2 used) to drive housing (6). Install plug (45) and O-ring (46) to planetary carriers (44) in the left and right sides.

: 14 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)


W3-5-28

DISASSEMBLY OF REAR AXLE

WCGB-03-05-009

1 3 4

54 3 2

1

6 7

8

8

109

13 14 15

16 18 17 19

2021 22 23 24 25

26 27

28

29

30

31

3233

34 35 36 37 3839

54 53 52 51 50 49 48 47 464544

43 4241

40

12 11

2


W3-5-29

1 - Axle Casing 15 - Bearing Nut 29 - Planetary Carrier 43 - Knock Pin (4 Used) 2 - O-Ring 16 - Washer 30 - Plug 44 - Backup Ring 3 - Shim 17 - Socket Bolt 31 - O-Ring 45 - U-Ring 4 - Roller Bearing 18 - Sun Gear Shaft 32 - Socket Bolt (2 Used) 46 - U-Ring 5 - Drive Housing 19 - O-Ring 33 - Retaining Ring (3 Used) 47 - Backup Ring 6 - Washer (14 Used) 20 - Shaft Seal 34 - Planetary Gear (3 Used) 48 - Piston 7 - Bolt (14 Used) 21 - Bearing 35 - Washer (3 Used) 49 - Spring (8 Used) 8 - Axle Shaft 22 - Hub Carrier 36 - Roller Bearing (3 Used) 50 - Spring (8 Used) 9 - Plug 23 - Bushing 37 - Washer (3 Used) 51 - Spring Seat (8 Used) 10 - O-Ring 24 - Bearing 38 - Retaining Ring (3 Used) 52 - Bolt (8 Used) 11 - Washer (16 Used) 25 - O-Ring 39 - Retaining Ring (3 Used) 53 - Disc Carrier 12 - Bolt (16 Used) 26 - Friction Plate (6 Used) 40 - Washer 54 - O-Ring 13 - O-Ring 27 - Plate (5 Used) 41 - O-Ring 14 - Knuckle 28 - Disc Plate 42 - Ring Gear


W3-5-30

WCGB-03-05-009

1

5

1

14 15

18 17

22 29

30

31

3233 34

35 36 37 38 39

52 51 50 49 48 4746

45 44 4342 41

40

109


W3-5-31

Disassembly of Rear Axle

1. Remove transmission (55) from the rear axle. (Refer to REMOVAL OF TRANSMISSION on W3-4-1.)


2. Hoist the rear axle. Lower the rear axle on a

workbench.

3. Remove plugs (9, 30) and O-rings (10, 31) from drive housing (5) and planetary carriers (29) in the left and right sides. Drain gear oil from the rear axle.

: 14 mm


4. Attach a nylon sling onto planetary carrier (29).

Hoist and hold planetary carrier (29).

5. Remove socket bolts (32) (2 used) from planetary carrier (29). Hoist and remove planetary carrier (29) from the rear axle.

: 8 mm

6. Remove retaining rings (39) (3 used). Remove planetary gears (34) (3 used) and washer (40) from planetary carrier (29).

IMPORTANT: Do not remove roller bearing (36)

unless necessary. 7. Remove retaining rings (33, 38) (3 used for each),

washers (35, 37) (3 used for each) and roller bearings (36) (3 used) from planetary gears (34) (3 used).

8. Remove sun gear shaft (18) from axle casing (1).

9. Remove socket bolt (17) from bearing nut (15).

: 8 mm 10. Remove O-ring (41) from knuckle (14).

11. Pry the clearance between piston (48) and hub

carrier (22) by using a pry bar. Remove the ring gear (42) assembly from hub carrier (22).

IMPORTANT: Before removing bolt (52), record the

dimension of bolt (52) extended from piston (48).

12. Remove bolts (52) (8 used), spring seats (51) (8 used) and springs (49, 50) (8 used for each) from ring gear (42).

13. Remove piston (48) from ring gear (42). Remove

U-rings (45, 46), backup rings (44, 47) and knock pins (43) (4 used) from ring gear (42).


W3-5-32

WCGB-03-05-009

1 3 4

54 3 2

1

6 7 8

8

13 14

1920

21 22

23 24 2526 27

28

54 53

12 11

2


W3-5-33

14. Remove disc plate (28) from hub carrier (22). Remove plates (27) (5 used) and friction plates (26) (6 used).

15. Remove disc carrier (53) from knuckle (14).

Remove O-ring (54).


16. Attach a nylon sling onto hub carrier (22). Hold

hub carrier (22). Hoist and remove hub carrier (22) from knuckle (14).

17. Remove O-ring (19) from knuckle (14).


unless necessary. 18. Remove shaft seal (20), O-ring (25), the outer

race of bearing (21) and bearing (24) from hub carrier (22).


necessary. 19. Remove bushing (23) and the inner race of

bearing (21) from knuckle (14).

CAUTION: Knuckle (14) weight: 34 kg (75 lb) 20. Attach a nylon sling onto knuckle (14). Hold

knuckle (14). Remove bolts (7) (14 used) and washers (6) (14 used). Hoist and remove knuckle (14) and O-ring (13) from the rear axle.

: 24 mm

21. Remove axle shaft (8) from axle casing (1).


22. Attach a nylon sling onto axle casing (1). Hold

axle casing (1). Remove bolts (12) (16 used) and washers (11) (16 used). Hoist and remove axle casing (1) from drive housing (5).

: 27 mm IMPORTANT: Do not remove roller bearing (4)

unless necessary. 23. Remove O-ring (2), shim (3) and roller bearing (4)

from axle casing (1). 24. Disassemble the other side of the rear axle in the

same way as steps 4 to 23. 25. Remove differential (55) from drive housing (5).

WCGB-03-05-011

5

55


W3-5-34

ASSEMBLY OF REAR AXLE

Detail of Drive Housing Inside

WCGB-03-05-012

Detail of Planetary Carrier Inside

T21W-03-05-022

1

76 13

4229

46, 4741

15

40

16

18

34

19 53 548

Drive Housing

14 20 21 22 25 23 24 26 27 28 49, 50, 51, 52 48 44, 45

1 12 11 2 3 4 5 4 3 2 11 12 1

8 8

Planetary Carrier


W3-5-35

1 - Axle Casing 15 - Bearing Nut 29 - Planetary Carrier 43* - Knock Pin (4 Used) 2 - O-Ring 16 - Washer 30* - Plug 44 - Backup Ring 3 - Shim 17* - Socket Bolt 31* - O-Ring 45 - U-Ring 4 - Roller Bearing 18 - Sun Gear Shaft 32* - Socket Bolt (2 Used) 46 - U-Ring 5 - Drive Housing 19 - O-Ring 33* - Retaining Ring (3 Used) 47 - Backup Ring 6 - Washer (14 Used) 20 - Shaft Seal 34 - Planetary Gear (3 Used) 48 - Piston 7 - Bolt (14 Used) 21 - Bearing 35* - Washer (3 Used) 49 - Spring (8 Used) 8 - Axle Shaft 22 - Hub Carrier 36* - Roller Bearing (3 Used) 50 - Spring (8 Used) 9* - Plug 23 - Bushing 37* - Washer (3 Used) 51 - Spring Seat (8 Used) 10* - O-Ring 24 - Bearing 38* - Retaining Ring (3 Used) 52 - Bolt (8 Used) 11 - Washer (16 Used) 25 - O-Ring 39* - Retaining Ring (3 Used) 53 - Disc Carrier 12 - Bolt (16 Used) 26 - Friction Plate (6 Used) 40 - Washer 54 - O-Ring 13 - O-Ring 27 - Plate (5 Used) 41 - O-Ring 14 - Knuckle 28 - Disc Plate 42 - Ring Gear



W3-5-36

WCGB-03-05-012

T21W-03-05-022

1 2 3 4 5 4 3 2 11 12 1

8

1

7 6 13 14 20 21 22 23 24

42

16

18

19 53 548

8

Planetary Carrier

Drive Housing


W3-5-37

Assembly of Rear Axle

1. Install differential (55) to drive housing (5).

WCGB-03-05-011

2. Install O-ring (2), shim (3) and roller bearing (4) to

axle casing (1).


3. Attach a nylon sling onto axle casing (1). Hoist

axle casing (1). Install axle casing (1) to drive housing (5) with bolts (12) (16 used) and washers (11) (16 used).

: 27 mm : 300 N⋅m (30 kgf⋅m, 220 lbf⋅ft)

4. Install axle shaft (8) to axle casing (1).

CAUTION: Knuckle (14) weight: 34 kg (75 lb)

5. Install O-ring (13) to knuckle (14). Hoist knuckle (14). Install knuckle (14) to the rear axle with bolts (7) (14 used) and washers (6) (14 used).

: 24 mm : 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)

6. Install the inner race of bearing (21) and bushing (23) to knuckle (14).

IMPORTANT: When installing shaft seal (20), check

the mounting position and dimension A. Install shaft seal (20) with the marking of OUT-SIDE facing upward and outward.

7. Apply LOCTITE #574 onto the shaft seal (20) contact surface on hub carrier (22). Install shaft seal (20) to hub carrier (22).

NOTE: Dimension A: 0 to 0.3 mm (0 to 0.01 in)

WCGB-03-05-006

8. Install the outer race of bearing (21) and bearing

(24) to hub carrier (22).

9. Apply hydraulic oil onto O-ring (19). Install O-rings (19, 54) and disc carrier (53) to knuckle (14).

10. Install ring gear (42) to knuckle (14).

11. Install washer (16) to sun gear shaft (18).

5

55 22

20

A


W3-5-38

WCGB-03-05-012

T21W-03-05-022

14 22 25 26 27 28 49, 50, 51, 52 48 44, 4542

46, 4741

15

18

Planetary Carrier

Drive Housing


W3-5-39

12. When installing bearing nut (15), apply lubricant (ZF special tool No. 0671 195 042 MOLYKOTE PASTE 1000) onto the thread part of knuckle (14). Install sun gear shaft (18) and bearing nut (15) to knuckle (14) by using special tool (ZF special tool No. 5870 656 097). At this time, turn hub carrier (22) in both directions several times in order to fit the rotor.

: 1400 N⋅m (140 kgf⋅m, 1040 lbf⋅ft) 13. Remove bearing nut (15) from knuckle (14).

Remove ring gear (42). : 41 mm

IMPORTANT: Check the mounting positions of

friction plate (26) and plate (27). 14. Install friction plates (26) (6 used) and plates (27)

(5 used) to hub carrier (42) alternately. Install disc plate (28).

15. Apply grease onto O-ring (25). Install O-ring (25)

to hub carrier (42). 16. Apply hydraulic oil onto U-rings (45, 46) and

backup rings (44, 47). Install U-rings (45, 46) and backup rings (44, 47) to ring gear (42).

17. Install knock pins (43) (4 used) to piston (48).

NOTE: Dimension B: 16 mm (0.6 in)

WCGB-03-05-007

IMPORTANT: When tightening bolt (52), align with the dimension before disassembling.

18. Install piston (48) to ring gear (42). Secure piston (48) with bolts (52) (8 used), spring seats (51) (8 used) and springs (49, 50).

: 10 mm : 11 N⋅m (1 kgf⋅m, 8 lbf⋅ft)

19. Align the marks and install the ring gear (42)

assembly to knuckle (14).

WCGB-03-05-008

20. Apply hydraulic oil onto O-ring (41). Install O-ring

(41) to knuckle (14). 21. When installing bearing nut (15), apply lubricant

(ZF special tool No. 0671 195 042 MOLYKOTE PASTE 1000) onto the thread part of knuckle (14). Install bearing nut (15) to knuckle (14) by using special tool (ZF special tool No. 5870 656 097). Align the holes on knuckle (14) and bearing nut (15). Secure with socket bolt (17).

: 1400+200 N⋅m (140+20 kgf⋅m, 1040+150 lbf⋅ft)

48 43

B

42 14Mark


W3-5-40

WCGB-03-05-012

T21W-03-05-022

5

29

40

34

14

15

Planetary Carrier

Drive Housing


W3-5-41

22. Install socket bolt (17) into bearing nut (15). If it is difficult to align the holes on knuckle (14) and bearing nut (15), retighten bearing nut (15).

: 8 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

23. Install washer (40) to planetary carrier (29).

24. Install retaining rings (33, 38) (3 used for each),

washers (35, 37) (3 used for each) and roller bearings (36) (3 used) to planetary gears (34) (3 used).

25. Install planetary gears (34) (3 used) to planetary

carrier (29) with retaining rings (39) (3 used).


26. Hoist planetary carrier (29). Install planetary

carrier (29) to the rear axle with socket bolts (32) (2 used).

: 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

27. Assemble the other side of the rear axle in the

same way as steps 2 to 26. 28. Add gear oil to drive housing (5) and planetary

carriers (29) in the left and right sides. Install plugs (9, 30) and O-rings (8, 31) to drive housing (5) and planetary carriers (29) in the left and right sides.

: 14 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)


W3-5-42

DISASSEMBLY OF DIFFERENTIAL

NOTE: Disassembly of the differential is common to the front axle and the rear axle. The illustration shows the front axle.

WCGB-03-05-013

1 - Bevel Gear 8 - Pinion Gear (2 Used) 15 - Washer (12 Used) 22 - Spacer 2 - Differential Case 9 - Spider 16 - Spider 23 - Bearing 3 - Washer (2 Used) 10 - Side Gear (2 Used) 17 - Spring Pin (4 Used) 24 - Seal 4 - Side Gear (2 Used) 11 - Washer (2 Used) 18 - Spring Pin (4 Used) 25 - Guard 5 - Pinion Gear (2 Used) 12 - Differential Case 19 - Drive Pinion 26 - Flange 6 - Washer (2 Used) 13 - Drive Housing 20 - Bearing 27 - Washer 7 - Washer (2 Used) 14 - Socket Bolt (12 Used) 21 - Shim 28 - Nut

1

32

45 6 7 8

910 11 12

14 157816

5617 18

1920

2122

2324

2526

27 28

13


W3-5-43

Disassembly of Differential

1. Remove nut (28) and washer (27) from drive pinion (19).

: 41 mm

2. Remove flange (26) and guard (25) from drive housing (13).

3. Float seal (24) by using a screwdriver. Remove

drive pinion (19) from drive housing (13).

4. Remove spacer (22) from drive pinion (19). IMPORTANT: Do not remove bearing (20) unless

necessary. 5. Remove the inner race of bearing (20) from drive

pinion (19). IMPORTANT: Do not remove bearing (20) unless

necessary. 6. Remove the outer race of bearing (20) from drive

pinion (19). IMPORTANT: Do not remove bearing (23) unless

necessary. 7. Remove shim (21) and bearing (23) from drive

pinion (19).


unless necessary. 8. Secure the differential in a vise. Remove the inner

races of bearings (29, 30) from the differential.

WCGB-03-05-014

9. Remove socket bolts (14) (12 used) and washers

(15) (12 used). Remove differential case (12). : 10 mm

10. Remove spring pins (17, 18) (4 used for each),

washers (3, 6, 7, 11) (2 used for each), pinion gears (5, 8) (2 used for each), side gears (4, 10) (2 used for each) and spiders (9, 16) from differential case (2).

11. Secure differential case (2) in a vise with bevel

gear (1) facing upward. Remove bevel gear (1) from differential case (2).

Differential

29

30


W3-5-44

ASSEMBLY OF DIFFERENTIAL

NOTE: Assembly of the differential is common to the front axle and the rear axle. The illustration shows the front axle.

WCGB-03-05-015

1 - Bevel Gear 8 - Pinion Gear (2 Used) 15 - Washer (12 Used) 22 - Spacer 2 - Differential Case 9 - Spider 16 - Spider 23 - Bearing 3 - Washer (2 Used) 10 - Side Gear (2 Used) 17 - Spring Pin (4 Used) 24 - Seal 4 - Side Gear (2 Used) 11 - Washer (2 Used) 18 - Spring Pin (4 Used) 25 - Guard 5* - Pinion Gear (2 Used) 12 - Differential Case 19 - Drive Pinion 26 - Flange 6* - Washer (2 Used) 13 - Drive Housing 20 - Bearing 27 - Washer 7 - Washer (2 Used) 14 - Socket Bolt (12 Used) 21 - Shim 28 - Nut


10

11

14 15 12 13 7 8 2 17, 18 1 3

4

16

9

19

20

23

24 25

2628

21

22

27


W3-5-45

Assembly of Differential

1. Install spring pins (17, 18) (4 used for each) to differential case (2).

2. Secure differential case (2) in a vise. Install bevel

gear (1) to differential case (2). IMPORTANT: Install washers (3, 11) and washers

(7) (2 used) with the lugs facing upward.

3. Install washers (3, 6, 7, 11) (2 used for each), pinion gears (5, 8) (2 used for each), side gears (4, 10) (2 used for each) and spiders (9, 16) to differential case (2).

4. Install differential case (12) to the differential case

(2) assembly. Secure socket bolt (14) and washer (15).

: 10 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

5. Secure the differential in a vise. Install the inner

races of bearings (29, 30).

WCGB-03-05-014

6. Install shim (21) and bearing (23) to drive pinion (19).

7. Install the outer race of bearing (20) to drive

pinion (19).

8. Install the inner race of bearing (20) to drive pinion (19).

9. Install spacer (22) to drive pinion (19).

10. Install drive pinion (19) to drive housing (13).

11. Install guard (26) and flange (25) to drive housing

(13). 12. Install washer (27) and nut (28) to drive pinion

(19). : 41 mm : 1050 N⋅m (105 kgf⋅m, 770 lbf⋅ft)

Differential

29

30


W3-5-46

DISASSEMBLY OF STEERING CYLINDER

T1GL-03-05-020

WCGB-03-05-016

1 - Axle Casing 6 - U-Ring 11 - Rod 16 - Cylinder Tube 2 - Drive Housing 7 - Wiper Ring 12 - Wiper Ring 17 - Guide Ring 3 - Tie Rod 8 - O-Ring 13 - U-Ring 18 - Guide Ring 4 - Piston Rod 9 - Guide Ring 14 - Retaining Ring 19 - Seal 5 - Retaining Ring 10 - Piston 15 - Flange 20 - Bolt (5 Used)

Connection Part

Connection Part

11 2

33 4

5 6 7 8 9 10 11

19 18

17

16

1514 13 12

20


W3-5-47

Disassembly of Steering Cylinder

1. Remove nut (21). Remove tie rod (3) from axle casing (1).

: 41 mm

WCGB-03-05-017

2. Warm up the connection part of piston rod (4) and

tie rod (3) by using a drier. Attach a spanner onto the connection part. Remove tie rod (3) from piston rod (4).

: 46 mm

3. Remove other tie rod (3) in the same way as steps 1 to 2.

4. Remove elbows (22) (2 used) from drive housing

(2).

WCGB-03-05-018

5. Remove bolts (20) (5 used). Warm up the connection part of the piston rod (4) assembly and drive housing (2) by using a drier.

6. Tap and remove the piston rod (4) assembly from

drive housing (2) by using a plastic hammer.

7. Remove bolts (20) (5 used). Remove flange (15) and retaining ring (14) from the piston rod (4) assembly.

8. Remove retaining ring (5) from the piston rod (4)

assembly. Tap piston (10) to the position where O-ring (8) can be removed by using a plastic hammer. Remove O-ring (8) from the piston rod (4) assembly.

9. Remove rod (11) and piston (10) from cylinder

tube (16). Remove piston (10) from rod (11). 10. Remove U-ring (13) and wiper ring (12) from

cylinder tube (16). 11. Remove U-ring (6), wiper ring (7), guide rings (9,

17, 18) and seal (19) from piston (10) and rod (11).

Connection Part

22

21 3

1

2

1

4


W3-5-48

ASSEMBLY OF STEERING CYLINDER

T1GL-03-05-020

T21W-03-05-020

1 - Axle Casing 6 - U-Ring 11 - Rod 16 - Cylinder Tube 2 - Drive Housing 7 - Wiper Ring 12 - Wiper Ring 17 - Guide Ring 3 - Tie Rod 8 - O-Ring 13 - U-Ring 18 - Guide Ring 4 - Piston Rod 9 - Guide Ring 14 - Retaining Ring 19 - Seal 5 - Retaining Ring 10 - Piston 15 - Flange 20* - Bolt (5 Used)


Connection Part

Connection Part

11 2

33 4

11 6 7 9 15 14 16 19 18 17 13 12

5 8 10


W3-5-49

Assembly of Steering Cylinder

1. Install U-ring (13) and wiper ring (12) to cylinder tube (16).

2. Install U-ring (6), wiper ring (7), guide rings (9, 17,

18) and seal (19) to piston (10) and rod (11).

3. When installing the rod (11) assembly to cylinder tube (16), apply hydraulic oil onto the seals. Install the rod (11) assembly to cylinder tube (16).

4. When installing piston (10) to rod (11), apply

hydraulic oil onto the seals. Install piston (10) to rod (11). Push piston (10) to the position where O-ring (8) can be installed.

5. Install retaining ring (5) to the piston rod (4)

assembly.

6. Install flange (15) and retaining ring (14) to the piston rod (4) assembly.

7. Apply LOCTITE #574 onto the drive housing (2)

contact surface (2 places) on the piston rod (4) assembly. Install piston rod (4) to drive housing (2).

8. Apply LOCTITE #243 onto bolt (20). Install bolts

(20) (5 used). : 19 mm : 79 N⋅m (7.9 kgf⋅m, 58 lbf⋅ft)

9. Install elbows (22) (2 used) to drive housing (2).

WCGB-03-05-018

IMPORTANT: Check the direction to install tie rod

(3). 10. Apply LOCTITE #243 onto the tie rod (3)

connection part of piston rod (4). Attach a spanner onto the connection part of piston rod (4) and tie rod (3). Install tie rod (3) to piston rod (4).

: 46 mm : 450 N⋅m (45 kgf⋅m, 330 lbf⋅ft)

11. Secure tie rod (3) to axle casing (1) with nut (21).

: 41 mm : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)

WCGB-03-05-017

12. Install other tie rod (3) in the same way as steps

10 to 11.

21 3

1

22 2

1

4

Connection Part


W3-5-50

(Blank)

UNDERCARRIAGE / Axle Lock Cylinder

W3-6-1

REMOVAL AND INSTALLATION OF AXLE LOCK CYLINDER

CAUTION: Release any pressure in the hydraulic oil tank before doing any work. (Refer to BLEED AIR FROM HYDRAULIC OIL TANK on W1-4-1.)

The procedure starts on the premise that the front axle has already been removed.

Removal 1. Disconnect hoses (1) (2 used) from operate check

valve (3). Cap the open ends. : 19 mm

IMPORTANT: Do not remove operate check valve

(3). If removing operate check valve (3), rod (4) may come off due to the entering air.

2. Remove socket bolts (2) (2 used) from operate check valve (3). Install eyebolts (M8, Pitch 1.25 mm) (2 used) into the hole. Attach a nylon sling onto eyebolts. Hoist and hold operate check valve (3).

: 6 mm

CAUTION: Axle lock cylinder (5) weight: 61 kg (134 lb)

3. Remove socket bolts (6) (3 used), washers (7) (3

used), bolt (8) and spacer (9) from axle lock cylinder (5).

: 19 mm : 36 mm

WCEB-03-06-001

WCEB-03-06-003

WCEB-03-06-001

1 2 3

4

5

6, 7

9

8

Pulling-Out Hole

Pulling-Out Hole

2


W3-6-2


4. Install the bolts (M12, Pitch 1.75 mm) (2 used) into

the pulling-out hole on axle lock cylinder (5). Tighten the bolts (2 used) alternately. Remove axle lock cylinder (5) from track frame (10).

: 19 mm

WCEB-03-06-001

5

Pulling-Out Hole

Pulling-Out Hole

10


W3-6-3

Installation


1. Apply LOCTITE #262 onto socket bolts (6) (3

used) and bolt (8).

2. Hoist and align axle lock cylinder (5) with the mounting hole on track frame (10). Install axle lock cylinder (5) to track frame (10) with socket bolts (6) (3 used), washers (7) (3 used), bolt (8) and spacer (9).


3. Remove eyebolts (2 used) from axle lock cylinder (5).

4. Install operate check valve (3) to axle lock cylinder

(5) with socket bolts (2) (2 used). : 6 mm : 29.4 to 34.3 N⋅m

(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

5. Connect hoses (1) (2 used) to operate check valve (3).

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

WCEB-03-06-001

WCEB-03-06-003

WCEB-03-06-001

5

6, 7

10

8

9

2

1 3

3 5


W3-6-4

DISASSEMBLY AND ASSEMBLY OF AXLE LOCK CYLINDER

WCEB-03-06-002

WCEB-03-06-003

1 - Retaining Ring 4 - Dust Seal 7 - Housing 9 - O-Ring 2 - Dust Seal 5 - Seal Ring 8 - Operate Check Valve 10 - Socket Bolt (4 Used) 3 - Air Ring (4 Used) 6 - Rod

10 78, 9

8, 9 10

7

6

3

5

4

3

2

1

A

View A


W3-6-5

Disassembly of Axle Lock Cylinder

CAUTION: Axle lock cylinder weight: 61 kg (134 lb)

1. Place the axle lock cylinder onto the workbench

horizontally.

2. Remove socket bolts (10) (4 used) from operate check valve (8). Remove operate check valve (8) and O-ring (9) from housing (7).

3. Apply air to the port hole on housing (7) and

remove rod (6).

4. Remove retaining ring (1) and dust seal (2) from housing (7).

5. Remove air rings (3) (4 used), dust seal (4) and

seal ring (5) from housing (7).

Assembly of Axle Lock Cylinder

1. Install seal ring (5), dust seal (4) and air rings (3) (4 used) to housing (7).

2. Install dust seal (2) and retaining ring (1) to

housing (7). IMPORTANT: Apply hydraulic oil onto the inner

surface of housing (7), dust seals (2, 4), seal ring (5) and air ring (3).

3. Install rod (6) to housing (7).

CAUTION: Axle lock cylinder weight: 61 kg (134 lb)

4. Install operate check valve (8) to housing (7) with

socket bolts (10) (4 used) and O-ring (9). : 6 mm : 29.4 to 34.3 N⋅m

(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)


W3-6-6

(Blank)

UNDERCARRIAGE / Operate Check Valve

W3-7-1

REMOVAL AND INSTALLATION OF OPERATE CHECK VALVE (FOR AXEL LOCK CYLINDER)


Removal 1. Disconnect hoses (1) (2 used) from operate check


2. Remove socket bolts (2) (4 used) from operate

check valve (3). Remove operate check valve (3) and O-ring (4) from axle lock cylinder (5). Cap the open ends.

: 6 mm

Installation 1. Apply grease onto O-ring (4). Install O-ring (4) to

operate check valve (3).

2. Install operate check valve (3) to axle lock cylinder (5) with socket bolts (2) (4 used).

: 6 mm : 29.4 to 34.3 N⋅m

(3 to 3.5 kgf⋅m, 22 to 25 lbf⋅ft)

3. Connect hoses (1) (2 used) to operate check valve (3).

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

WCEB-03-06-001

WCEB-03-06-001

1

5

2 3, 4

1

5

2 3, 4

UNDERCARRIAGE / Operate Check Valve

W3-7-2

STRUCTURE OF OPERATE CHECK VALVE (FOR AXEL LOCK CYLINDER)

WCEB-03-06-004

Tightening Torque No. Part Name Q’ty Wrench Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)

Remark

1 Plug 1 : 6.2 2±0.5 (0.2±0.05) (1.5±0.4) 2 O-Ring 1 1A P11 3 Plug 1 : 27 120±12 (12±1.2) (89±9) 4 O-Ring 1 1B P18 5 Piston 1 6 Body 1 7 Poppet 1 8 Sleeve 1 9 Spring 1

10 O-Ring 1 1B P11 11 Plug 1 : 36 500±50 (51±5) (369±37) 12 O-Ring 1 1B P26 13 Plug 1 : 6 34.3±3.4 (3.5±0.3) (25±2.5)

5 6 7 8 9 10 11 12 1 2 3 4 13

UNDERCARRIAGE / Solenoid Valve

W3-8-1

REMOVAL AND INSTALLATION OF OUTRIGGER / BLADE SOLENOID VALVE UNIT


IMPORTANT: One side of the solenoid valve unit

cannot be removed. Remove the plate (2) assembly.

Removal 1. Disconnect hoses (3) (8 used) from solenoid valve

units (4) (2 used). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm, 22 mm

2. Disconnect connectors (1) (4 used) from solenoid valve units (4) (2 used).

3. Remove sems bolts (7) (4 used) from plate (2).

Remove the plate (2) assembly from track frame (6).

: 17 mm

4. Remove sems bolts (5) (4 used) from plate (2). Remove solenoid valve units (4) (2 used) from plate (2).

: 17 mm

W1F3-04-04-004

WCEB-03-08-001

Solenoid Valve Unit

Solenoid Valve Unit

Solenoid Valve Unit Solenoid Valve Unit1 2 3

1

3

4, 5 7 6 3


W3-8-2

Installation 1. Install solenoid valve units (4) (2 used) to plate (2)


2. Install the plate (2) assembly to track frame (6)


3. Connect hoses (3) (8 used) to solenoid valve units

(4) (2 used). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)

4. Connect connectors (1) (4 used) to solenoid valve

units (4) (2 used).

W1F3-04-04-004

WCEB-03-08-001

Solenoid Valve Unit

Solenoid Valve Unit

Solenoid Valve UnitSolenoid Valve Unit

1 2 3

1

3

4, 5 7 6 3


W3-8-3

STRUCTURE OF SOLENOID VALVE UNIT

T1F3-03-08-001

Tightening Torque No. Part Name Q’ty Wrench Size (mm) N·m (kgf·m) (lbf·ft)

Remarks

1 Solenoid 2 2 Piston 2 3 O-Ring 2 1B P14 4 Body 1 5 Spool 2 6 Spring 2

1

2

3

4

6

5


W3-8-4

(Blank)

UPPERSTRUCTURE / Transmission Changeover Solenoid Valve

W3-9-1

REMOVAL AND INSTALLATION OF TRANSMISSION CHANGEOVER SOLENOID VALVE


Removal 1. Disconnect connectors (1) (2 used).

2. Disconnect hoses (2) (4 used) from transmission

changeover solenoid valve (3). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm

3. Remove socket bolts (4) (3 used) from transmission changeover solenoid valve (3). Remove transmission changeover solenoid valve (3) from bracket (5).

: 6 mm

Installation 1. Install transmission changeover solenoid valve (3)

to bracket (5) with socket bolts (4) (3 used). : 6 mm : 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)

2. Connect hoses (2) (4 used) to transmission

changeover solenoid valve (3). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Connect connectors (1) (2 used) to transmission

changeover solenoid valve (3).

WCEB-03-09-001

WCEB-03-09-001

21

3 5 4

21

3 5 4

UPPERSTRUCTURE / Transmission Changeover Solenoid Valve

W3-9-2

(Blank)

LOWERSTRUCTURE / Propeller Shaft

W3-10-1

REMOVEAL AND INSTALLATION OF PROPELLER SHAFT

Preparation 1. Place the machine on a solid, level surface.

Lower the front attachment onto the ground.

2. Lower the blade and the outrigger onto the ground.

3. Place the blocks in front of and behind the axle in

order to secure the machine.

WCJB-03-10-004


W3-10-2

Removal and Installation of Propeller Shaft

W1GL-03-08-001

WCJB-03-10-001

WCJB-03-10-002

WCJB-03-10-003

WCJB-03-10-005

WCEB-03-10-007

1 - Flange 5 - Sems Bolt (2 Used) 9 - Nut (8 Used) 13 - Nut 2 - Nut (8 Used) 6 - Bracket 10 - Flange 14 - Spline Seal 3 - Propeller Shaft 7 - Flange 11 - Bearing Assembly 15 - Grease Fitting 4 - Socket Bolt (4 Used) 8 - Propeller Shaft 12 - Yoke 16 - Fork

Front Axle

5

Rear Axle

A B

C

D

6

8

3

View A

3

View B

56

View D

8

9

Detail B

3

Detail C

12

13

11 8

14 15 16

2

1

43

710


W3-10-3

Removal

1. Remove grease fitting (15) from propeller shaft (3).

: 10 mm IMPORTANT: Propeller shaft (3) cannot be

removed individually. If removing propeller shaft (3) individually, spline seal (14) is damaged. Remove the propeller shaft (3) assembly.

2. Remove nuts (2) (8 used) from the flange part of propeller shaft (3).

: 14 mm

3. Insert a pry bar between flange (1) and the flange part of propeller shaft (3). Pry propeller shaft (3) toward fork (16) and place propeller shaft (3) on the ground.

4. Remove socket bolts (4) (4 used) from the flange

part of propeller shaft (3). Remove propeller shaft (3) from flange (7).

: 8 mm

5. Remove nuts (9) (8 used) from the flange part of propeller shaft (8).

: 14 mm

6. Remove sems bolts (5) (2 used) from bracket (6). Place bearing assembly (11) onto bracket (6).

: 17 mm

7. Move propeller shaft (8) toward bracket (6) side. Pull out propeller shaft (8).

IMPORTANT: Do not remove bearing assembly

(11) unless necessary. When removing bearing assembly (11), follow the procedure below. Dispose removed bearing assembly (11).

8. Remove nut (13) from propeller shaft (8). Remove yoke (12) from propeller shaft (8).

: 32 mm

9. Remove bearing assembly (11) from propeller shaft (8).


W3-10-4

W1GL-03-08-001

WCJB-03-10-001

WCJB-03-10-002

WCJB-03-10-003

WCJB-03-10-005

WCEB-03-10-007

Front Axle

5

Rear Axle

A B

C

D

6

8

3

View A

3

View B

56

View D

8

92

1

43

710

Detail B

3 14 15 16

Detail C

12

13

11 8


W3-10-5

Installation

1. Install bearing assembly (11) to propeller shaft (8).

2. Install yoke (12) to propeller shaft (8). Secure

yoke (12) to propeller shaft (8) with nut (13). : 32 mm : 370 to 440 N⋅m (38 to 45 kgf⋅m, 273 to

325 lbf⋅ft)

3. Apply LOCTITE #262 onto nuts (9) (8 used).

4. Insert the yoke (12) mounting side of propeller shaft (8) into bracket (6). Install the flange part of propeller shaft (8) to flange (10). Install propeller shaft (8) to flange (10) with nuts (9) (8 used).

: 14 mm : 76 N⋅m (7.8 kgf⋅m, 56 lbf⋅ft)

5. Apply LOCTITE #262 onto sems bolts (5) (2

used). Install the propeller shaft (8) assembly to bracket (6) with sems bolts (5) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m,37 lbf⋅ft)

6. Apply LOCTITE #262 onto socket bolts (4) (4 used). Align the flange part of propeller shaft (3) with the mounting hole on flange (7). Secure propeller shaft (3) to flange (7) with socket bolts (4) (4 used).

: 8 mm : 62 N⋅m (6.3 kgf⋅m, 46 lbf⋅ft)

7. Apply LOCTITE #262 onto nuts (2) (8 used).

Align the flange part of propeller shaft (3) with the mounting hole on flange (1). Secure propeller shaft (3) to flange (1) with nuts (2) (8 used).

: 14 mm : 76 N⋅m (7.8 kgf⋅m, 56 lbf⋅ft)

8. Install grease fitting (15) to fork (16). Apply

grease.


W3-10-6

(Blank)

M E M O

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CJBW-4-1

SECTION 4

FRONT ATTACHMENT

— CONTENTS — Group 1 Front Attachment

Hydraulic Circuit Pressure Release Procedure .............................. W4-1-1 Removal and Installation of Front Attachment .................................. W4-1-2 Maintenance Standard ......................... W4-1-12 Standard Dimensions for Arm and Bucket Connection .............. W4-1-15 Standard Dimensions for Arm and Boom Connection................ W4-1-16

Group 2 Cylinder

Hydraulic Circuit Pressure Release Procedure .............................. W4-2-1 Removal and Installation of Cylinder ..... W4-2-2 Disassembly of Boom, Arm and Bucket Cylinders ................................ W4-2-26 Assembly of Boom, Arm and Bucket Cylinders ................................ W4-2-32 Disassembly of Positioning Cylinder.... W4-2-38 Assembly of Positioning Cylinder ........ W4-2-42 Disassembly of Outrigger and Blade Cylinders .................................. W4-2-46 Assembly of Outrigger and Blade Cylinder .................................... W4-2-48 Maintenance Standard ......................... W4-2-54

Group 3 Hose Rupture Valve Hydraulic Circuit Pressure Release Procedure...............................W4-3-1 Removal and Installation of Hose Rupture Valve for Arm Cylinder ............W4-3-2 Removal and Installation of Hose Rupture Valve for Positioning Cylinder...............W4-3-3 Removal and Installation of Hose Rupture Valve for Boom Cylinder .........W4-3-5 Structure of Hose Rupture Valve for Arm Cylinder ....................................W4-3-8 Structure of Hose Rupture Valves for Boom Cylinder ...............................W4-3-12 Structure of Hose Rupture Valves for Positioning Cylinder.......................W4-3-16

Group 4 Operate Check Valve Remove and Install Operate Check Valve (for Blade and Outrigger) ............W4-4-1 Structure of Operate Check Valve ..........W4-4-3

CJBW-4-2

(Blank)

FRONT ATTACHMENT / Front Attachment

W4-1-1

HYDRAULIC CIRCUIT PRESSURE RE-LEASE PROCEDURE

NOTE: Operate the pilot pump by using the power from the battery without starting the engine and deliver the pilot pressure to the spool of the control valve.

1. Turn the pilot shut-off lever to the UNLOCK posi-

tion.

2. Turn the engine stop switch ON. NOTE: Perform steps 1, 2 and turn the key switch

to the START position. Although the starter rotates, the engine does not start.

IMPORTANT: The battery will deplete. Operate the

key switch for short period. 3. With the key switch in the START position, oper-

ate the lever 4 to 5 times in order to release any pressure in the hydraulic circuit.

4. Return the pilot shut-off lever to the LOCK posi-

tion.

5. Turn the engine stop switch OFF.

WCEB-02-01-002

Engine Stop Switch


W4-1-2

REMOVAL AND INSTALLATION OF FRONT ATTACHMENT

Removal 1. As for the lubrication hoses to the front attach-

ment, disconnect hoses (1) (2 used) to the boss at the boom cylinder (3) rod side from the adapter.

: 17 mm

2. Remove nuts (7) (4 used) from bolts (4) (2 used). Remove bolts (4) (2 used) and stoppers (5) (2 used) from pin (6).

: 24 mm

CAUTION: Boom cylinder (3) weight: Mono block boom: 172kg (380 lb) 2-piece boom: 161kg (360 lb)

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protec-tion, such as goggles, hard hats, etc in order to prevent personal injury.

3. Attach a nylon sling onto the end of the boom

cylinder (3) tube. Hoist and hold the boom cylin-der (3) tube. By using a bar and a hammer, tap pin (6) into the position where thrust plate (2) can be removed. Remove thrust plate (2).

NOTE: When pin (6) cannot be removed, start the engine and operate the boom lever. Adjust the rod pin hole on the boom cylinder.

WCGB-04-01-001

WCGB-04-01-002

1

3

1

3

1 2 3 4

56

7


W4-1-3

4. Place the tube end of boom cylinder (3) on a stand of 1 m (39 in) height. Start the engine. Operate the boom lever and re-tract boom cylinder (3). In order not to extend the rod, pass a wire through the rod hole and secure the rod to the cylinder tube. Stop the engine.

5. Remove boom cylinder (3) from the boom.

Refer to Removal of Boom Cylinder on W4-2-10.

6. Remove other boom cylinder (3) in the same way as steps 3, 4 and 5.

CAUTION: Do not stand toward the removal direction of the pins as the pins may fly off suddenly.

7. Slowly tap and remove pin (6) by using a bar and

a hammer. Remove thrust plate (2).

8. After stopping the engine, push the air bleed valve. Bleed air from the hydraulic oil tank and remove the cap. Release the pressure in the hydraulic circuit. Refer to HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE on W4-1-1.

9. Disconnect hoses (8) (6 used), (9) (4 used) (2) from the bucket cylinder and the arm cylinder. Cap the disconnected hoses and pipings.

: 19 mm, 27 mm, 36 mm, 41 mm

NOTE: The number of the hoses may differ de-pending on the front attachment specifica-tions.

W554-02-03-007

WCGB-04-01-002

WCJB-01-04-002

WCJB-04-01-001

Wire

Stand

3

2 3

6

9

8

8 98

Air Bleed Valve Cap

Hydraulic Oil Tank


W4-1-4

10. Open cover (10). 11. Remove sems bolts (12) (4 used) from cover

(13). : 17 mm

12. Remove sems bolts (16) (5 used) from cover

(15). : 17 mm

13. Remove cover (13) from cover (11), bracket (14)

and support (117). 14. Disconnect harness (20) from clips (21) (4 used)

at the back of cover (15). 15. Remove sems bolts (22) (2 used) from bracket

(19). Remove cover (15) from bracket (19) cover (18).

WCEB-02-05-002

WCJB-04-01-002

WCJB-04-01-004

WCJB-04-01-003

WCJB-04-01-005

10

12

14

11 13

15 16

19

22

20

21

15

15

16

18

12

17

13


W4-1-5

CAUTION: Boom foot pin (26) weight: 46 kg 16. Remove bolt (23), spring washer (27), plate (24)

and block (25) from the plate of boom foot pin (26).

: 27 mm

CAUTION: Front attachment weight: Mono block boom: 3430 kg (7570lb) 2-piece boom: 4190 kg (9240 lb)

17. Attach a wire rope onto the boom. Hoist and hold

the boom.

W178-04-01-001

Mono block Boom

WCJB-02-03-001

2-Piece Boom

WCJB-02-03-002

26

25

24

23

27

Boom

Boom


W4-1-6

CAUTION: Boom foot pin (26) weight: 46 kg 18. Insert a pry bar between the plate of boom foot

pin (26) and the bracket. Pull out the plate a little. : 30 mm

19. While turning the plate gradually by hand, re-

move boom foot pin (26). NOTE: When boom foot pin (26) cannot be re-

moved, adjust the position by using a lifting rope for the front attachment.

20. Hoist the front attachment assembly and move

the machine backward. 21. Place a wooden block. Lower the front attach-

ment assembly onto the wooden block.

W178-04-01-001

26

Plate

Bracket

Insert a Bar.


W4-1-7

Installation

CAUTION: Front attachment weight: Mono block boom: 3430 kg (7570lb) 2-piece boom: 4190 kg (9240 lb)

1. Hoist the front attachment assembly and move

the machine forward. Align the boom foot with the mounting hole on the frame. Insert the thrust plate into the left and right sides of the boom. Adjust the clearance between the plate and the frame within 1 mm (0.04 in). (Adjust the position by using a lifting rope for the front attachment.)


CAUTION: Boom foot pin (26) weight: 46 kg (101 lb)

2. Install boom foot pin (26).Secure boom foot pin

(26) to the main frame with bolt (23), washer (27). Plate (24) and block (25).

: 27 mm : 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)

Mono block Boom

WCJB-02-03-001

2-Piece Boom

WCJB-02-03-002

W178-04-01-001

26

25

24

23

27

Boom

Boom


W4-1-8

3. Install cover (15) to bracket (19) with sems bolts (22) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

4. Secure harness (20) to cover (15) with clips (21) (4 used).

5. Align cover (13) with the mounting holes on cover (11), bracket (14) and support (17).Install cover (13) to cover (11), bracket (14) and support (17) with sems bolts (12) (4 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

6. Install cover (15) to covers (13, 18) with sems bolts (16) (5used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)

7. Shut cover (10).

WCJB-04-01-005

WCJB-04-01-004

WCJB-04-01-003

WCJB-04-01-002

WCEB-02-05-002

10

19

22

20

21

15

15

16

18

12

17

13

12

14

11 13

15 16


W4-1-9

8. Remove the caps from the hoses and the pipings. Connect hoses (8) (6 used) and hoses (9) (4 used) to the bucket cylinder and the arm cylinder.

: 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft)

CAUTION: Boom cylinder (3) weight: Mono block boom: 172kg (380 lb) 2-piece boom: 161kg (360 lb)

9. Install boom cylinder (3).

Refer to Installation of Boom Cylinder on W4-2-12.


10. Remove the wire from boom cylinder (3). Attach a

nylon sling onto the end of the boom cylinder (3) tube. Hoist and align the boom cylinder (3) tube with the mounting hole on the boom.

11. Insert thrust plate (2) between the boom and

boom cylinder (3), and between boom cylinder (3) and collar (5). Install pin (6). Install boom cyl-inder (3) to the both sides.

12. Install stoppers (5) (2 used) to pin (6). Secure

stoppers (5) (2 used) to pin (6) with bolts (4) (2 used) and nuts (7) (4 used).

: 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf⋅ft)

WCJB-04-01-001

WCEB-04-01-003

W178-04-01-004

Wire

3

9

8

8 98

4

57

6 2

3


W4-1-10

13. Connect lubrication hoses (1) (2 used) to the boom cylinder (3) rod side.

: 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

14. Apply grease onto the boom cylinder (3) rod side,

the bottom side and the boom foot side.

WCGB-04-01-001

WCGB-04-01-004

1

3

1

3

Right Boom Cylinder Rod Side

Arm Cylinder Bottom Side

Left Boom Cylinder Rod Side

Boom Foot Side


W4-1-11

CAUTION: Arm bucket assembly weight: Mono block boom: 1650 kg (3640 lb) 2-piece boom : 1560 kg (3440lb)

IMPORTANT: When removing the arm from the

boom, perform the following steps when installing the arm.

15. Install thrust plates (28) to the left and right sides of the arm. Adjust total clearance of the left and right sides within 1.5 mm (0.06 in).

16. After installing the arm, apply grease onto grease

fitting (29) in the boom connecting boss of the arm.

IMPORTANT: For handling of HN bushing for the

front attachment, check the follow-ings.

Precautions when installing the bushing If a hammer is used, the bushing may be damaged. Use a press. Precautions when reinforcing the arm The heat when welding in order to reinforce the arm may cause oil leakage from HN bushing and decrease lubrication performance. When the welding heat causes the oil leakage of the bushing, replace the bushing. Use the special tool when removing or installing the bushing. Special tool: ST 1454

Mono block Boom

WCJB-02-03-001

Piece Boom

WCJB-02-03-002

M157-07-157

23

24

23

24

Boom

Boom

Arm

Arm


W4-1-12


Pin and Bushing

WCJB-02-03-001

WCJB-02-03-002

Unit: mm (in) Part Name Standard Allowable Limit Remedy

Pin 90 (3.5) 89.0 (3.5) A Bushing 90 (3.5) 91.5 (3.6) Pin 80 (3.1) 79.0 (3.1) Boss (Main Frame) 80 (3.1) 81.5 (3.2) B Bushing (Boom Cylinder) 80 (3.1) 81.5 (3.2) Pin 90 (3.5) 89.0 (3.5) Bushing (Boom Cylinder) 90 (3.5) 91.5 (3.6) C Boss (Boom) 90 (3.5) 91.5 (3.6) Pin 90 (3.5) 89.0 (3.5) D Bushing 90 (3.5) 91.5 (3.6) Pin 80 (2.8) 79.0 (3.1) Boss (Arm) 80 (2.8) 81.5 (3.2) E Bushing (Arm Cylinder) 80 (2.8) 81.5 (3.2) Pin 80 (2.8) 79.0 (3.1) Boss (Boom) 80 (2.8) 81.5 (3.2) F Bushing (Arm Cylinder) 80 (2.8) 81.5 (3.2)

Replace

F

C

E D

I K J

H

A B

G

D

E

J

M

GK

F C

AB

D

I

H


W4-1-13

Unit: mm (in)

Part Name Standard Allowable Limit Remedy Pin 71 (2.8) 70.0 (2.9) Boss (Arm) 71 (2.8) 72.5 (2.9) G Bushing (Bucket Cylinder) 71 (2.8) 72.5 (2.9) Pin 80 (3.1) 79.0 (3.1) Bushing 80 (3.1) 81.5 (3.2) H Bushing (Bucket Cylinder) 80 (3.1) 81.5 (3.2) Pin 71 (2.8) 70.0 (2.9) I Bushing 71 (2.8) 72.5 (2.9) Pin 80 (3.1) 79.0 (3.1) J Bushing 80 (3.1) 81.5 (3.2) Pin 80 (3.1) 79.0 (3.1) K Bushing 80 (3.1) 81.5 (3.2) Pin 100 (3.9) 99.0 (3.9) L Bushing 100 (3.9) 101.5 (4.0) Pin 100 (3.9) 99.0 (3.9) M Bushing 100 (3.9) 101.5 (4.0)

Replace

IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a press and special tool (ST 1454).


W4-1-14

Point

W105-04-01-020

Unit: mm (in) Standard Allowable Limit Remedy

A 215 107.5 (4.2) B 95 (3.7) - C 108 - D 95 -

Replace

Side Cutter

W155-04-01-002

Unit: mm (in) Standard Allowable Limit Remedy

A 278 (10.9) 181 (7.0) B 295 (11.6) - C 433 (17) - D 135 (5.3) -

Replace

D

CB

A

B

D

C

A


W4-1-15

STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION

W1CF-04-01-007

Unit: mm (in) a 450 (17.7) b 0 c 604 (23.8) d 580 (22.8) e - f 1471 (57.9) g 433 (17) h 305.5 (12) i 80 (3.2) j 475 (18.7) k 31 (1.2) l 433 (17)

m 307 (12) n 80 (3.2) o 3.7° p 3.7° q 449 (17.7)

Section B Section A


W4-1-16

STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION

WCJB-04-01-006

W1GL-04-01-010

Unit: mm (in) s 90 (3.5) t 352 (13.9) u 490 (19.3)

Section C

C

FRONT ATTACHMENT / Cylinder

W4-2-1

HYDRAULIC CIRCUIT PRESSURE RE-LEASE PROCEDURE


1. Turn the pilot shut-off lever to the UNLOCK posi-

tion.




key switch for short period. 3. With the key switch in the START position, oper-

ate the lever 4 to 5 times in order to release any pressure in the hydraulic circuit.

4. Return the pilot shut-off lever to the LOCK posi-

tion.


WCEB-02-01-002

Engine Stop Switch


W4-2-2

REMOVAL AND INSTALLATION OF CYL-INDER

Removal of Bucket Cylinder

1. Insert wooden block (3) between the ground and the end of arm (2), and between arm (2) and bucket cylinder (1).

2. Stop the engine. Push the air bleed button and

bleed air from the hydraulic oil tank. Remove the cap. Release the pressure in the bucket circuit. Refer to HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE on W4-2-1.

CAUTION: Before removing pin (7), fasten the link by using a wire in order not to fall off.


3. Remove nuts (6) (2 used) and bolt (4). Remove

pin (7) by tapping. Remove thrust plates (5) (4 used).

: 30 mm

4. In order not to extend rod (8) of bucket cylinder (1), pass wire (9) through the cylinder rod hole and secure to the bucket cylinder (1) tube.

W554-04-02-006

W158-04-02-006

W102-04-02-005

3

3

2

1

4 5

7 6

8 1

9


W4-2-3

5. Disconnect bucket cylinder hoses (12) (2 used) at the bottom of bucket cylinder (1). Cap the open ends

: 30 mm

CAUTION: Bucket cylinder (1) weight: 150 kg (340 lb)


6. Hoist and hold bucket cylinder (1). Remove nuts

(13) (2 used) and bolt (15). Remove pin (11) by tapping. Remove thrust plates (10) (2 used).

: 24 mm

7. Remove bucket cylinder (1).

W187-04-02-004

10

11

15

13

1

12


W4-2-4

Installation of Bucket Cylinder

CAUTION: Bucket cylinder (1) weight: 150 kg (340 lb)

CAUTION: Metal fragments may fly off when a hammer is used when installing pin (11). Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

1. Hoist bucket cylinder (1). Align the hole on the

cylinder tube side with the cylinder mounting hole on the arm. Install thrust plates (10) (2 used) and pin (11).

2. Install stopper (14) and pin (11) to the arm. Se-

cure with bolt (15) and nuts (13) (2 used). : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf·ft)

3. Connect bucket cylinder hoses (12) (2 used).

: 36 mm : 175 N⋅m (18 kgf⋅m, 140 lbf·ft)

4. Remove wire (9) from rod (8) of bucket cylinder

(1).

W187-04-02-004

W102-04-02-005

10

11

15

13

1

12

Arm

14

8 1

9


W4-2-5


5. Start the engine. Operate the lever and align the

hole on the bucket cylinder (1) rod side with those on links (16, 18). Install thrust plates (5) (4 used) and pin (7).

6. Secure stopper (17) and pin (7) with bolt (4) and

nuts (6) (2 used). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

IMPORTANT: In case link (18) has been removed

from the arm, insert thrust plate (19) when installing link (18).

IMPORTANT: After completing the work, add hy-draulic oil to the specified level. Operate bucket cylinder (1) to the stroke end several times and bleed air from the circuit. At the same time, check each con-nection of the hoses for any oil leaks.

W158-04-02-006

W157-04-01-015

16 4 17 5

7 18 6

19 19

18 18


W4-2-6

Removal of Arm Cylinder

1. Insert wooden block (3) between arm cylinder (1) and boom (2).


bleed air from the hydraulic oil tank. Remove the cap. Release the pressure in the arm circuit. Refer to HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE on W4-2-1.

3. Remove nuts (8) (2 used) and bolt (10) from pin

(5) at the rod side in arm cylinder (1). : 30 mm


4. Remove pin (5) by tapping. Remove thrust plates

(4) (4 used).

5. In order not to extend rod (6) of arm cylinder (1), pass wire (7) through the cylinder rod hole and secure to the arm cylinder (1) tube.

W187-04-02-005

W187-04-02-006

W187-04-02-010

1

3

2

6 1

7

10 4

1

5

8


W4-2-7

6. Disconnect pipings (11) (2 used) at the bottom of arm cylinder (1). Cap the open ends. (When a hose rupture valve is provided, refer to RE-MOVAL AND INSTALLATION OF HOSE RUP-TURE VALVE on W4-3-1.)

: 36 mm, 41 mm

7. Disconnect lubrication hose (12) from arm cylin-der (1).

: 17 mm

CAUTION: Arm cylinder (1) weight: 255 kg (570 lb)

8. Attach a nylon sling at the center of gravity of arm

cylinder (1). Hoist and hold arm cylinder (1).


9. Remove nuts (15) (2 used) and bolt (17) from the

tube side in arm cylinder (1). Remove pin (14). Remove thrust plate (13). Hoist and remove arm cylinder (1).

: 30 mm

WCGB-04-01-001

W102-04-02-016

W187-04-02-007

1

17 13

1

14

15

1

11

12


W4-2-8

Installation of Arm Cylinder

CAUTION: Arm cylinder (1) weight: 255 kg (5700 lb)

1. Attach a nylon sling at the center of gravity of arm

cylinder (1). Hoist arm cylinder (1). Align the hole on the cylinder tube side hole with the cylinder mounting hole on the boom.


2. Install thrust plate (13) and pin (14). Secure pin

(14) and stopper (16) with bolt (17) and nuts (15) (2 used).

: 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

3. Connect lubrication hose (12) and pipings (11) (2

used) of arm cylinder (1). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 129 lbf·ft) : 41 mm : 205 N⋅m (21 kgf⋅m, 151 lbf·ft)

IMPORTANT: Fill hydraulic oil to the specified

level. Start the engine and check for any oil leaks at the hose connec-tions.

W187-04-02-007

WCGB-04-01-001

17 13

1

14

1516

1

11

12


W4-2-9

4. Remove wire (7) from rod (6) of arm cylinder (1). Hold arm cylinder (1) and start the engine. Oper-ate the lever and align the hole at the rod (6) side with the mounting hole on arm (18).


5. Install thrust plate (4) and pin (5). Secure pin (5)

and stopper (9) with bolt (10) and nuts (8) (2 used).

: 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

IMPORTANT: When completing the work, operate

arm cylinder (1) to the stroke end several times and bleed air from the circuit.

W187-04-02-010

W187-04-02-006

3

6

1

1

10 4 5

8

9

18


W4-2-10

Removal of Boom Cylinder

1. Disconnect lubrication hose (1) from boom cylin-der (2).

: 17 mm

CAUTION: Boom cylinder (2) weight: Monoblock boom: 175 kg (390 lb) 2-piece boom: 165 kg (370 lb)

2. Attach a wire rope onto boom cylinder (2). Hoist

and hold boom cylinder (2).


3. Remove nuts (5) (2 used), bolt (7) and stopper

(6) from the boom cylinder (2) rod side. Remove pin (4) by tapping. Remove thrust plates (3) (2 used).

: 30 mm

4. Place the rod side of boom cylinder (2) on a stand. Remove other boom cylinder (2) in the same way.

5. Operate the lever and retract boom cylinder (2).

In order not to extend the rod, pass a wire through the rod hole and secure to the cylinder tube.


bleed air from the hydraulic oil tank. Release the pressure in the circuit. Refer to HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE on W4-2-1.

WCGB-04-01-002

W158-04-02-013

W105-04-02-035

2Stand

Boom

1

2

6

5 3 4 3 2

7


W4-2-11

7. Disconnect hoses (12) (4 used) at the bottom of boom cylinder (2). Attach a plug onto the open end of the hose. Cap the open end of boom cyl-inder (2). (When a hose rupture valve is provided, refer to REMOVEAL AND INSTALLATION OF HOSE RUPTURE VALVE on W4-3-1.) Plug 1 3/16-12UN

: 36 mm


8. Remove nuts (10) (2 used) and bolt (8) from the

cylinder bottom side of the main frame. Remove pin (9) by tapping. Remove thrust plate (11).

: 24 mm


9. Attach a wire rope at the center of gravity of

boom cylinder (2). Hoist and remove boom cyl-inder (2). Remove other boom cylinder (2) in the same way.

W105-04-02-036

W178-04-02-009

W105-04-02-040

2

2 8

12

11

9

109

10

2


W4-2-12

Installation of Boom Cylinder


1. Attach a wire rope at the center of gravity of

boom cylinder (2). Hoist boom cylinder (2). Align the hole at the boom cylinder tube side with the mounting hole on the main frame.


2. Install thrust plate (11) and pin (9). Secure with

bolt (8) and nuts (10) (2 used). : 24 mm : 270 N⋅m (27.5 kgf⋅m, 200 lbf·ft)

3. Install other boom cylinder (2) in the same way.

4. Connect hoses (12) (4 used) to boom cylinders

(2) (2 used). : 36 mm : 175 N⋅m (18 kgf⋅m, 130 lbf·ft)



W105-04-02-040

W178-04-02-009

2

2 8

12

11

9

109

10


W4-2-13

5. Hoist boom cylinder (2). Start the engine. Oper-ate the lever and align the hole at the cylinder rod side with the mounting hole on the boom.


6. Insert thrust plate (3) and install pin (4).

7. Secure pin (4) and stopper (6) with bolt (7) and

nut (5). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

8. Connect lubrication hose (1).

: 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft)

9. Install other boom cylinder (2) in the same way.


boom cylinder (2) to the stroke end several times and bleed air from the circuit.

W158-04-02-013

WCGB-04-01-002

Boom

1

2

7

4

6

5

6

5 3 4 3 2

7


W4-2-14

Removal of Positioning Cylinder (2-Piece Boom Only)

1. Disconnect lubrication hose (1) from positioning

cylinders (3) (2 used). : 17 mm, 19 mm

CAUTION: Positioning cylinder (3) weight: 170 kg (375 lb)

2. Attach a nylon sling onto positioning cylinder (3).

Hoist and hold positioning cylinder (3).


3. Remove nuts (7) (2 used) and bolt (6) from stop-

per (4) of the second boom. : 30 mm

4. Install pin (2) 160 mm by tapping. Remove thrust

plate (5).

5. Disconnect hoses (8) (3 used) and hoses (9) (3 used) from positioning cylinder (3). Cap the open ends of the disconnected hoses.

: 22 mm, 36 mm

W1GL-04-01-008

W1GL-04-03-004

1 2

6, 7 4, 5

3

3 9

8 9


W4-2-15

6. Remove nuts (13) (2 used) and bolt (14) from stopper (11) of the first boom. Install pin (12) 160 mm by tapping by using a ham-mer and a bar. Remove thrust plate (10).

: 30 mm


7. Hoist and remove positioning cylinder (3).

8. Remove other positioning cylinder (3) in the

same way steps 2 to 7.

W1GL-04-03-004

12

10

11

1314 3


W4-2-16

Installation of Positioning Cylinder (2-Piece Boom Only)



1. Hoist positioning cylinder (3). Align the pin holes

at the bottom side with those of the first boom. Insert thrust plate (10) and install pin (12) by tap-ping.

2. Align the pin holes of stopper (11) and pin (12).

Install and secure with bolt (14) and nuts (13) (2 used).

: 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft)



3. Connect hoses (8) (3 used) and hoses (9) (3 used) to positioning cylinder (3).

: 22 mm : 39 N⋅m (4 kgf⋅m, 29 lbf·ft) : 36 mm : 175 N⋅m (18 kgf⋅m, 130 lbf·ft)

W1GL-04-03-004

9

8 9

12

10

11

1314 3


W4-2-17

4. Start the engine and extend positioning cylinder (3). Align the rod hole of positioning cylinder (3) with the hole of the second boom. Insert thrust plate (5) and install pin (4) by tapping.

5. Align the pin holes of stopper (4) and pin (2). In-

stall bolt (6) and nuts (7) (2 used). : 30 mm : 550 N⋅m (56 kgf⋅m, 410 lbf·ft)

6. Connect lubrication hose (1) to positioning cylin-

der (3). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)


positioning cylinder (3) to the stroke end several times and bleed air from the circuit.

W1GL-04-01-008

1 2

6, 7 4, 5

3


W4-2-18

Removal of Blade Cylinder IMPORTANT: Before starting the work, lower the

blade onto the ground.

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

Removal 1. Remove bolts (2) (4 used) and washers (3) (4

used) from cover (4). Remove cover (4) from bracket (1).

: 19 mm

2. Disconnect hoses (5) (4 used) from blade cylinder (6). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm, 27 mm

CAUTION: Blade cylinder (6) weight: 50 kg (110 lb)

3. Attach a nylon sling onto blade cylinder (6). Hoist

and hold blade cylinder (6).

4. Remove nuts (10) (4 used) from bolts (8) (2 used). Remove bolts (8) (2 used) from pins (9, 13). Re-move pins (9, 13) from bracket (11) and link (12).

: 24 mm

5. Remove thrust plates (7) (6 used) between the bottom part and bracket (11) and between the rod part and link (12) in blade cylinder (6).

WCEB-04-02-001

WCEB-04-02-002

WCEB-04-02-001

2, 3

4

13

6

1

10

7

12

8

7

10

65 8 9

11


W4-2-19


6. Remove blade cylinder (6) from bracket (11) and

link (12).

Installation of Blade Cylinder


1. Attach a nylon sling onto blade cylinder (6). Hoist

blade cylinder (6). Align the bottom and rod parts of blade cylinder (6) with the mounting holes on bracket (11) and link (12).

2. Install thrust plates (7) (6 used) to the bottom and

rod parts of blade cylinder (6). Install blade cylin-der (6) to bracket (11) and link (12) with pins (9, 13).

3. Secure pins (9, 13) to bracket (11) and link (12)

with bolts (8) (2 used) and nuts (10) (4 used). : 24 mm : 210 N⋅m (21.5 kgf⋅m, 155 lbf·ft)

4. Connect hoses (5) (4 used) to blade cylinder (6). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf·ft)

WCEB-04-02-002

WCEB-04-02-002

WCEB-04-02-001

WCEB-04-02-002

11 6

12

7

10

6 8 9

11

13

6

10

7

12

8

65


W4-2-20

5. Install cover (4) to bracket (1) with bolts (2) (4 used) and washers (3) (4 used).

: 19 mm : 90 N⋅m (9.2 kgf⋅m, 66 lbf·ft)


the blade cylinder to the stroke end several times and bleed air from the circuit.

WCEB-04-02-001

1 2, 3

4


W4-2-21

Removal of Outrigger Cylinder

CAUTION: Metal fragments may fly off when a hammer is used. Wear necessary protection, such as goggles, hard hats, etc in order to prevent personal injury.

1. Remove sems bolts (4) (3 used), washers (5) (2

used) and collars (6) (2 used) from cover (3). Remove cover (3) from outrigger cylinder (2).

: 17 mm

2. Disconnect hoses (1) (4 used) from outrigger cyl-inder (2). Cap the open ends. Attach an identifica-tion tag onto the disconnected hoses for assem-bling.

: 19 mm, 27 mm

3. Remove operate check valve (9) from outrigger cylinder (2). (Refer to REMOVAL AND INSTAL-LATION OF OPERATE CHECK VALVE on W4-4-1.)

4. Disconnect piping (7) from outrigger cylinder (2).

Remove O-ring (8) from piping (7). : 6 mm

CAUTION: Outrigger cylinder (2) weight: 90 kg (200 lb)

5. Attach a nylon sling onto the rod side of the out-

rigger cylinder (2) tube. Hoist and hold outrigger cylinder (2).

WCEB-04-02-004

WCEB-04-02-003

1 2 3 4, 5, 6 4

7, 8 9

2


W4-2-22



used) from pin (13). Remove pin (13) and thrust plates (14) (3 used) from outrigger (12).

: 19 mm

7. Hoist outrigger cylinder (2) a little. Insert a wooden block under outriger cylinder (2). Lower outrigger cylinder (2).

CAUTION: The outrigger (12) assembly weight: 145 kg (320 lb)

8. Attach a nylon sling onto outrigger (12). Hoist and

hold outrigger (12). Remove lock pin (11) from pin (10). Remove pin (10) from outrigger beam (17). Lower the outrigger (12) assembly.


9. Attach a nylon sling onto outrigger cylinder (2).

Hoist and hold outrigger cylinder (2). 10. Remove ring (18) from pin (19). Remove lock pin

(20) from pin (19). Remove pin (19) and thrust plates (21) (3 used) from outrigger beam (17).

11. Remove outrigger cylinder (2) from outrigger

beam (17).

WCEB-04-02-003

W1GL-04-02-006

WCEB-04-02-003

2

12

15, 16

13, 14

10, 11

17

17

12Wooden Block

2

10, 11

17 18

2 19, 20, 21


W4-2-23

Installation of Outrigger Cylinder


1. Attach a nylon sling onto outrigger cylinder (2).

Hoist and align the hole on the bottom side with the outrigger beam (17) mounting hole. Install outrigger cylinder (2) to outrigger beam (17) with thrust plates (21) (3 used) and pin (19).

2. Secure pin (19) to outrigger beam (17) with lock

pin (20) and ring (18).

3. Install O-ring (8) to piping (7). Connect piping (7) to outrigger cylinder (2).

: 6 mm : 78±19 N⋅m (8±2 kgf⋅m, 58±6 lbf·ft)

4. Install operate check valve (9) to outrigger cylin-

der (2). (Refer to REMOVAL AND INSTALLATION OF OPERATE CHECK VALVE on W4-4-1.)

5. Connect hoses (1) (4 used) to operate check

valve (9). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf·ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf·ft)

6. Install cover (3) to outrigger cylinder (2) with sems

bolts (4) (3 used), washers (5) (2 used) and col-lars (6) (2 used).

: 17 mm : 50 N⋅m (5 kgf⋅m, 37 lbf·ft)

WCEB-04-02-003

WCEB-04-02-004

WCEB-04-02-004

17 18

2 19, 20, 21

2 3 4, 5, 6 4

1 2

7, 8 9


W4-2-24

IMPORTANT: After the hose is connected, operate the outrigger cylinder to the stroke end several times and bleed air from the circuit.

7. Extend the rod of outrigger cylinder (2) and align with the mounting hole on outrigger (12). Install the rod part of outrigger cylinder (2) to outrigger (12) with thrust plates (14) (3 used) and pin (13).

8. Install pin (13) to outrigger (12) with bolts (15) (3

used) and washers (16) (3 used). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf·ft)

9. Remove the wooden block from the inside of out-rigger beam (17).

10. Operate outrigger cylinder (2) and align the

mounting hole on outrigger (12) with that on out-rigger beam (17). Secure outrigger (12) to outrig-ger beam (17) with pin (10) and lock pin (11).

W1GL-04-02-006

WCEB-04-02-003

17

13, 14

12Wooden Block

215, 16

10, 11

17

2

12

10, 11


W4-2-25

(Blank)


W4-2-26

DISASSEMBLY OF BOOM, ARM AND BUCKET CYLINDERS

Boom Cylinder

W1V1-04-02-007

Arm Cylinder

W1V1-04-02-008

1 2 43 5 6 7 8 9 10 11

121920

1726 25 17 18 19 24 21 18

22 23

1 2 3 4 5 6 8 9 10 11

20 19 16 15 14 1322 23

18 17

12

7

21 19 26 25 17 18 24


W4-2-27

Bucket Cylinder

W1V1-04-02-009

1 - Piston Rod 8 - Bushing 15 - Cushion Seal 21 - Seal Ring 2 - Wiper Ring 9 - Snap Ring 16 - Snap Ring 22 - Set Screw 3 - Backup Ring 10 - Backup Ring 17 - Slide Ring (2 Used) 23 - Steel Ball 4 - U-Ring 11 - O-Ring 18 - Slide Ring (2 Used) 24 - Piston Nut 5 - Buffer Ring 12 - Cylinder Tube 19 - Backup Ring (2 Used) 25 - Cushion Bearing 6 - Socket Bolt (12 Used) 13 - Stopper (2 Used) 20 - O-Ring 26 - Cushion Seal 7 - Cylinder Head 14 - Cushion Bearing

1 2 3 4 5 6 7 8 9 10 11

1219 18

1717 18 24 19 21 20

22 23


W4-2-28

W1V1-04-02-008

1 6

14

24

12

7


W4-2-29

Disassembly of Boom, Arm and Bucket Cylinders • The disassembling procedure starts on the

premise that the hydraulic pipings and the bands securing the pipings have been removed.

NOTE: The procedure for the arm cylinder is ex-plained.

CAUTION: Boom cylinder weight: Monoblock boom: 175 kg (390 lb) 2-piece boom: 165 kg (370 lb) Arm cylinder weight: 225 kg (550 lb) Bucket cylinder weight: 150 kg (335 lb)

1. Hoist the cylinder. Secure the cylinder horizontally

on a workbench. Drain hydraulic oil from the cyl-inder.

W102-04-02-027

2. Fully extend piston rod (1). Attach a nylon sling

onto piston rod (1). Hold piston rod (1). Remove socket bolts (6) (12 used) from cylinder head (7).

: 14 mm

IMPORTANT: Pull out piston rod (1) straight in order not to damage the sliding surface.

3. Tap and remove cylinder head (7) with piston rod (1) together from cylinder tube (12) by using a plastic hammer.

4. Secure piston rod (1) to special tool (ST 5908).

Put the matching marks on piston rod (1) and the end of piston (24) (Arm cylinder: cushion bearing (14)).

W158-04-02-022

Special Tool: ST 5908


W4-2-30

W1V1-04-02-008

1 2 43 5 6 7 8 9 10 11

1920

1726 25 17 19 21 18

22 23

16 15 14 13

18 24


W4-2-31

5. Cut away the crimped part by using a hand drill and remove set screw (22). Remove steel ball (23).

NOTE: Set screw (22) has been crimped by using a punch at 2 places after installing.

: 6 mm

6. Remove piston nut (24) by using special tool (ST 5908) and the special tool. Remove cushion bearing (25) and cushion seal (26) from piston rod (1). (Cushion bearing (25) and cushion seal (26) are not equipped for the bucket cylinder.) Special tool (outer diameter at nut part): Bucket cylinder: (ST 3244: 90 mm) Boom cylinder: Monoblock boom: (ST 3245: 95 mm) 2-piece boom: (ST 3246: 100 mm) Arm cylinder: (ST 3249: 110 mm)

W158-04-02-022

7. Remove slide rings (17) (2 used), slide rings (18) (2 used), backup rings (19) (2 used), O-ring (20) and seal ring (21) from piston nut (24).

8. Remove cylinder head (7) from piston rod (1).

9. Remove O-ring (11) and backup rings (10, 3) from

cylinder head (7). Remove wiper ring (2), U-ring (4), buffer ring (5), snap ring (9) and bushing (8) by using the special tool. Special tool (rod outer diameter): Bucket cylinder: (ST 8019: 80 mm) Boom cylinder: (ST 8020: 85 mm) Arm cylinder: (ST 8025: 95 mm)

10. (Arm cylinder only)

Remove stoppers (13) (2 used) from piston rod (1) by using a screwdriver. Remove cushion bearing (14), cushion seal (15) and snap ring (16).



W4-2-32

ASSEMBLY OF BOOM, ARM AND BUCKET CYLINDERS

Boom Cylinder

W1V1-04-02-005

Arm Cylinder

W1V1-04-02-003

Bucket Cylinder

W1V1-04-02-001

1 2 4 5 6 7 12 25 17 18 19 18 17

3 8 9 10, 11 26 24 20, 21 23

22

1 2 4 5 6 7 12 25 17 18 19 18 17

3 8 9 10, 11 26 24 20, 21 23

22 14

16 15

1 2 4 5 6 7 12 17 18 19 18 17

3 8 9 10, 11 20, 21 23

22


W4-2-33

1 - Piston Rod 8 - Bushing 15 - Cushion Seal 21 - Seal Ring 2 - Wiper Ring 9 - Snap Ring 16 - Snap Ring 22 - Set Screw 3 - Backup Ring 10 - Backup Ring 17 - Slide Ring (2 Used) 23 - Steel Ball 4 - U-Ring 11 - O-Ring 18 - Slide Ring (2 Used) 24 - Piston Nut 5 - Buffer Ring 12 - Cylinder Tube 19 - Backup Ring (2 Used) 25 - Cushion Bearing 6 - Socket Bolt (12 Used) 13 - Stopper (2 Used) 20 - O-Ring 26 - Cushion Seal 7 - Cylinder Head 14 - Cushion Bearing


W4-2-34

W1V1-04-02-003

NOTE: The illustration shows the arm cylinder.

1 2 4 5 7 17 18 19 18 17

3 8 9 10, 11 24 20, 21 16 15

14

13


W4-2-35

Assembly of Boom, Arm and Bucket Cylinders

NOTE: The procedure for the arm cylinder is ex-plained.

1. Install bushing (8) to cylinder head (7) by using

the special tool. Special tool (rod outer diameter): Bucket cylinder: (ST 8019: 80 mm) Boom cylinder: (ST 8020: 85 mm) Arm cylinder: (ST 8025: 90 mm)

IMPORTANT: Check the direction to install.

2. Install U-ring (4), backup ring (3), buffer ring (5) and snap ring (9) to cylinder head (7).

3. Install wiper ring (2) to cylinder head (7) by using

the special tool and a plastic hammer. Special tool (rod outer diameter): Bucket cylinder: (ST 8019: 80 mm) Boom cylinder: (ST 8020: 85 mm) Arm cylinder: (ST 8025: 90 mm)

4. Install O-ring (11) and backup ring (10) to cylinder

head (7).

5. Install O-ring (20) and seal ring (21) to piston nut (24) by using special tool A. After installing seal ring (21), adjust seal ring (21) by using special tool B. Special tools A and B (tube inner diameter): Bucket cylinder: (ST 2963, 2207: 115 mm) Boom cylinder: Monoblock boom: (ST 2964, 2208: 120 mm) 2-piece boom: (ST 2965, 2088: 125 mm) Arm cylinder: (ST 2978, 2535: 135 mm)

6. Install backup rings (19) (2 used), slide rings (17)

(2 used) and slide rings (18) (2 used) to piston nut (24).

7. Install the cylinder head (7) assembly to piston

rod (1) by using the special tool. Special tool (rod outer diameter): Bucket cylinder: (ST 8019: 80 mm) Boom cylinder: (ST 8020: 85 mm) Arm cylinder: (ST 8025: 90 mm)

IMPORTANT: Face the slit in cushion seal (15) to

the piston nut (24) side. Check the direction of the oil groove in cushion bearing (14).

8. (Arm cylinder only) Install snap ring (16) and cushion seal (15) to piston rod (1). Install cushion bearing (14) and stoppers (13) (2 used).


W4-2-36

W1V1-04-02-003

NOTE: The illustration shows the arm cylinder.

1 6 7 12 25

26 24 23

22


W4-2-37

IMPORTANT: Face the slit in cushion seal (26) to the piston nut (24) side. Check the direction of the oil groove in cushion bearing (25).

9. Install cushion seal (26) and cushion bearing (25) to piston rod (1). (Cushion bearing (25) and cushion seal (26) are not equipped for the bucket cylinder.)

10. Align the matching marks and tighten piston nut

(24) by using special tool (ST 5908) and the spe-cial tool. Special tool (outer diameter at nut part): Bucket cylinder: (ST 3244: 90 mm)

: 5600 N⋅m (570 kgf⋅m, 4130 lbf·ft) Boom cylinder: Monoblock boom: (ST 3245: 95 mm)

: 5340 N⋅m (545 kgf⋅m, 3940 lbf·ft) 2-picece boom: (ST 3245: 95 mm)

: 6000 N⋅m (610 kgf⋅m, 4430 lbf·ft) Arm cylinder: Monoblock boom: (ST 3245: 95 mm)

: 8860 N⋅m (900 kgf⋅m, 6540 lbf·ft) 2-picece boom: (ST 3245: 95 mm)

: 7900 N⋅m (810 kgf⋅m, 5380 lbf·ft)

W158-04-02-022

11. Install steel ball (23) to piston rod (1). Tighten with set screw (22). Crimp set screw (22) by using a punch at 2 places.

: 6 mm : 57 N⋅m (5.8 kgf⋅m, 42 lbf·ft)

CAUTION: Align the piston rod (1) assembly with the center of cylinder tube (12) and in-sert straight in order not to damage the rings.

12. Secure cylinder tube (12) horizontally on a work-

bench. Insert the piston rod (1) assembly into cylinder tube (12).

13. Install cylinder head (7) to cylinder tube (12) with

socket bolts (6) (12 used). : 14 mm : 265 N⋅m (27 kgf⋅m, 195 lbf·ft)

IMPORTANT: When replacing the bushing from

piston rod (1) or cylinder tube (12) by using a hammer, the bushing may be damaged. Use a press and spe-cial tool (ST 1454) when removing and installing the bushing.



W4-2-38

DISASSEMBLY OF POSITIONING CYLIN-DER

WCGB-04-02-010

1 - Piston Rod 7 - U-Ring 13 - Backup Ring 18 - O-Ring 2 - Socket Bolt (14 Used) 8 - Buffer Ring 14 - Piston 19 - Backup Ring (2 Used) 3 - Cylinder Head 9 - Bushing 15 - Slide Ring (2 Used) 20 - Set Screw 4 - Retaining Ring 10 - Retaining Ring 16 - Wear Ring (2 Used) 21 - Piston Nut 5 - Dust Seal 11 - O-Ring 17 - Seal Ring 22 - Cylinder Tube 6 - Backup Ring 12 - O-Ring

1

14

2 3 4 5 6 7 8 9 10 11

12 13

15 16 17 1819 20 21

22


W4-2-39

Disassembly of Positioning Cylinder

NOTE: The disassembling procedure starts on the premise that the hydraulic pipings and the bands securing the pipings have been re-moved.

CAUTION: Positioning cylinder weight: 170 kg (375 lb)



W102-04-02-027

2. Fully extend piston rod (1). Attach a nylon sling

onto piston rod (1). Hold piston rod (1). Remove socket bolts (2) (14 used) from cylinder head (3).

: 14 mm

3. Remove cylinder head (3) from cylinder tube (22) by using a pry bar.

CAUTION: Do not drop piston rod (1) by tilt-ing.

IMPORTANT: Pull out piston rod (1) straight in

order not to damage the sliding surface.

4. Slowly remove piston rod (1) from cylinder tube (22). At this time, cylinder head (3) is removed with piston rod (1) together. Set a cloth onto a wooden block. Place piston rod (1) horizontally on the wooden block.


W4-2-40

WCGB-04-02-010

1

14

2 3 4 5 6 7 8 9 10 11

12 13

15 16 17 1819 20 21

22


W4-2-41

5. Cut away the crimped part by using a hand drill and remove set screw (20) from piston nut (21).


: 4 mm

6. Remove piston nut (21) from piston rod (1) by using special tool (ST 3327). Remove piston (14) from piston rod (1) by using special tool (ST 3339).

7. Remove seal ring (17), slide ring (15), wear ring

(16), O-ring (18), retaining rings (19) (2 used) and backup rings (17) (2 used) from piston (14).


9. Remove bushing (9) from cylinder head (3) by using special tool (ST 2613). Remove O-rings (11, 12), backup rings (6, 13), dust seal (5), U-ring (7), buffer ring (8) and retaining rings (4, 10) from bushing (9).


W4-2-42

ASSEMBLY OF POSITIONING CYLINDER

WCJB-04-02-002

1 - Piston Rod 7 - U-Ring 13 - Backup Ring 18 - O-Ring 2 - Socket Bolt (14 Used) 8 - Buffer Ring 14 - Piston 19 - Backup Ring (2 Used) 3 - Cylinder Head 9 - Bushing 15 - Slide Ring (2 Used) 20 - Set Screw 4 - Retaining Ring 10 - Retaining Ring 16 - Wear Ring 21 - Piston Nut 5 - Dust Seal 11 - O-Ring 17 - Seal Ring 22 - Cylinder Tube 6 - Backup Ring 12 - O-Ring

1

4, 5 6, 7 8 9, 10 2, 11 3 12, 13 22 14 15 16 17 18, 19 21 20


W4-2-43

Assembly of Positioning Cylinder 1. Install bushing (9) to cylinder head (3) by using

special tool (ST 2613). Install retaining ring (10).

2. Tap and install dust seal (5) to cylinder head (3) by using special tool (ST 2614) and a plastic hammer.

IMPORTANT: Check the installing direction.

3. Install U-ring (7), backup ring (2), buffer ring (8) and retaining ring (4) to cylinder head (3).

4. Install O-rings (11, 12) and backup ring (13) to

cylinder head (3).

5. Install O-ring (18), backup rings (19) (2 used),

seal ring (17), slide rings (15) (2 used) and wear ring (16) to piston (14) by using special tools (ST 2588, 2589).

6. Install the cylinder head (3) assembly to piston

rod (1) by using special tool (ST 2696).


W4-2-44

WCJB-04-02-002

1

2 3 22 14 21 20


W4-2-45

6. Apply hydraulic oil onto the inner surface of piston (14). Install piston (14) to piston rod (1) by using special tool (ST 3339).

: 980±98 N⋅m (100±10 kgf⋅m, 720±72 lbf·ft)

7. Apply hydraulic oil onto piston nut (21). Install piston nut (21) to piston rod (1) by using special tool (ST 3327).

: 1860±185 N⋅m (190±19 kgf⋅m, 1380±137 lbf·ft)

8. Apply LOCTITE #242 onto two to three threads of

set screw (20). Install set screw (20) to piston nut (21). After tightening set screw (20), crimp set screw (20) by using a punch at 2 places.

: 4 mm : 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)

IMPORTANT: Align the piston rod (1) assembly with the center of cylinder tube (22) and insert straight in order not to damage the rings.

10. Apply hydraulic oil onto the outer surface of piston (14). Hoist cylinder tube (22). Secure cylinder tube (22) horizontally on a workbench. Insert the piston rod (1) assembly into cylinder tube (22).

11. Install cylinder head (3) to cylinder tube (22) by

using special tool (ST 2696). Tighten cylinder head (3) with socket bolts (2) (14 used).

: 14 mm : 340 to 360 N⋅m

(35 to 37 kgf⋅m, 255 to 270 lbf·ft) IMPORTANT: When replacing the bushing from



W4-2-46

DISASSEMBLY OF OUTRIGGER AND BLADE CYLINDERS

WCGB-04-02-002

1 - Piston Rod 6 - Seal 11 - O-Ring 16 - O-Ring 2 - Cylinder Head 7 - Bushing 12 - Piston 17 - Set Screw 3 - Retaining Ring 8 - Retaining Ring 13 - Seal Ring 18 - Piston Nut 4 - Dust Seal 9 - O-Ring 14 - Wear Ring 19 - Backup Ring (2 Used) 5 - U-Ring 10 - Backup Ring 15 - Dust Ring 20 - Cylinder Tube

1

12

2 3

4 5 6 7

89

1011

1314

15 16

19

17

18

20


W4-2-47

Disassembly of Outrigger and Blade Cylinders

NOTE: The disassembling procedure starts on the premise that the hydraulic pipings and the bands securing the pipings have been re-moved.

CAUTION: Outrigger cylinder weight: 90 kg (200 lb) Blade cylinder weight: 50 kg (110 lb)



W102-04-02-027

2. Raise a detent (a part of cylinder tube (20)) in the

groove on cylinder head (2). Pry and remove cyl-inder head (2) from cylinder tube (20) by using a pry bar. R wrench: (ST 3221)

CAUTION: Do not drop piston rod (1) by tilt-ing.

IMPORTANT: Remove piston rod (1) straight in

order not to damage the rod surface. 3. Fully extend piston rod (1). Attach a nylon sling

onto piston rod (1). Hold piston rod (1). Slowly remove piston rod (1) from cylinder tube (20). Set a cloth onto a wooden block. Place piston rod (1) horizontally on the wooden block.

4. Cut away the crimped part by using a hand drill and remove set screw (17) from piston nut (18).


: 4 mm

5. Remove piston nut (18) by using special tool (ST 3334). Remove piston (12) from piston rod (1) by using special tool (ST 3337).


IMPORTANT: When removing the seals, do not

damage the parts. 7. Remove seal ring (13), wear ring (14), dust ring

(15) and O-ring (16) from piston (12).

8. Remove retaining rings (3, 8), U-ring (5), dust seal (4) and backup ring (10) from the inside of cylin-der head (2). Remove bushing (7) by using spe-cial tool (ST 2685).

9. Remove O-rings (9, 11) and backup ring (10) from

the outside of cylinder head (2).


W4-2-48

ASSEMBLY OF OUTRIGGER AND BLADE CYLINDER

Outrigger Cylinder

WCGB-04-02-004

Blade Cylinder

WCGB-04-02-003

16, 19 18 1720 12 13 14 156 7, 8 2 10, 111 3, 4 5 9

16, 19 18 17 20 12 13 14 156 7, 8 2 10, 111 3, 4 5 9


W4-2-49

1 - Piston Rod 6 - Seal 11 - O-Ring 16 - O-Ring 2 - Cylinder Head 7 - Bushing 12 - Piston 17 - Set Screw 3 - Retaining Ring 8 - Retaining Ring 13 - Seal Ring 18 - Piston Nut 4 - Dust Seal 9 - O-Ring 14 - Wear Ring 19 - Backup Ring (2 Used) 5 - U-Ring 10 - Backup Ring 15 - Dust Ring 20 - Cylinder Tube


W4-2-50

WCGB-04-02-004

NOTE: The illustration shows the outrigger cylinder.

16, 19 18 1712 13 14 156 7, 8 2 10, 111 3, 4 5 9


W4-2-51

Assembly of Outrigger and Blade Cylinders

1. Install bushing (7) to cylinder head (2) by using special tool (ST 2685). Install retaining ring (8).

IMPORTANT: Install U-ring (5) with its lip part fac-

ing to the bushing (7) side. Install seal (6) with its projection part and slit part facing to the bushing (7) side.

2. Install U-ring (5) and seal (6) to cylinder head (2).

3. Install dust seal (4) and retaining ring (3) to cyl-inder head (2) by using special tool (ST 2689).

IMPORTANT: Install backup ring (10) to the pin

hole side on piston rod (1). 4. Install O-rings (9, 11) and backup ring (10) to cyl-

inder head (2).

5. Install the cylinder head (2) assembly to piston rod (1) by using special tool (ST 2693).

IMPORTANT: After installing O-ring (16), check that O-ring (16) is not twisted.

6. Install O-ring (16), backup rings (19) (2 used), seal ring (13), wear ring (14) and dust ring (15) to piston (12).

7. Apply hydraulic oil onto the inner surface of piston

(12). Install piston (12) to piston rod (1) by using special tool (ST 3337).

: 740±69 N⋅m (75±7 kgf⋅m, 550±51 lbf·ft)

8. Apply hydraulic oil onto the threads of piston nut (18). Install piston nut (18) to piston rod (1) by using special tool (ST 3334).

: 1270±98 N⋅m (130±10 kgf⋅m, 940±72 lbf·ft)

9. Apply LOCTITE #242 onto set screw (17). Install

set screw (17). After tightening set screw (17), crimp set screw (17) by using a punch at 2 places.

: 4 mm : 15±1.5 N⋅m (1.5±0.15 kgf⋅m, 11±1 lbf·ft)


W4-2-52

WCGB-04-02-004

NOTE: The illustration shows the outrigger cylinder.

202 1


W4-2-53

IMPORTANT: Align the piston rod (1) assembly with the center of cylinder tube (20) and insert straight in order not to damage the rings.

10. Secure cylinder tube (20) horizontally on a work-

bench. Insert the piston rod (1) assembly into cylinder tube (20).

11. Apply hydraulic oil onto the threads of cylinder

head (2). Install cylinder head (2) to cylinder tube (20). Bend the detent and secure cylinder head (2). R wrench: (ST 3223)

: 490 to 690 N⋅m (50 to 70 kgf⋅m, 360 to 510 lbf·ft)

IMPORTANT: When replacing the bushing from



W4-2-54


Piston Rod

W105-04-02-094

Unit: mm (in)

Cylinder Name Recommended Size After Re-Manufacturing (A)

Boom 85 +0.027 -0.057

(3.3 +0.001-0.002

)

Arm 95 +0.027 -0.057

(3.7 +0.001-0.002

)

Bucket 80 +0.027 -0.053

(3.1 +0.001-0.002

)

Positioning 95 +0.027 -0.057

(3.7 +0.001-0.002

)

Blade 120 +0.023 -0.043

(4.7 +0.001-0.002

)

Outrigger 120 +0.023 -0.043

(4.7 +0.001-0.002

)

Rod Bend and Run Out of Piston Rod

W166-04-02-022

Unit: mm (in)

Bend Run Out Remedy

0.5 (0.02) 1.0 (0.04) Repair

1.0 (0.04) 2.0 (0.08) Replace

A Dial Gauge

Piston Rod

1 m V Block

FRONT ATTACHMENT / Hose Rupture Valve

W4-3-1

HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE


1. Turn the pilot shut-off lever to the UNLOCK

position.




key switch for short period. 3. With the key switch in the START position,

operate the lever 4 to 5 times in order to release any pressure in the hydraulic circuit.

4. Return the pilot shut-off lever to the LOCK

position.


WCEB-02-01-002

Engine Stop Switch


W4-3-2

REMOVAL AND INSTALLATION OF HOSE RUPTURE VALVE FOR ARM CYLINDER

CAUTION: Loosen the relief valve of hose rupture valve (3) slowly and release the pressure.

Removal 1. Disconnect hoses (1) (2 used) from hose rupture


2. Remove socket bolts (6) (4 used) from piping (5).

: 8 mm

3. Remove socket bolts (2) (4 used) from hose rupture valve (3). Remove hose rupture valve (3) and O-ring (4) from arm cylinder (7).

: 8 mm


hose rupture valve (3).

2. Align hose rupture valve (3) with the mounting holes on arm cylinder (7) and piping (5). Install hose rupture valve (3) to arm cylinder (7) and piping (5) with socket bolts (2, 6) (4 used for each).

: 8 mm : 52±10 N⋅m (5.2±1 kgf⋅m, 38±7 lbf⋅ft)

3. Connect hoses (1) (2 used) to hose rupture valve

(3). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

WCEB-04-03-003

WCEB-04-03-003

1 2 3, 4

6

1 2 3, 4 5

7

1 2 3, 4

6

1 2 3, 4 5

7


W4-3-3

REMOVAL AND INSTALLATION OF HOSE RUPTURE VALVE FOR POSITIONING CYLINDER


Removal 1. Remove bolts (4) (2 used) from clamp (5).

Remove clamp (5) from bracket (6). : 22 mm

2. Disconnect hoses (3) (3 used) from hose rupture

valve (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 19 mm

3. Remove socket bolts (1) (4 used). Disconnect piping (2) from positioning cylinder (7). Remove hose rupture valve (8) and O-ring (9) from positioning cylinder (7). Cap the open ends.

: 10 mm

WCJB-04-03-003

2

5

6

43 1

7 8, 9


W4-3-4



2. Install hose rupture valve (8) and piping (2) to positioning cylinder (7) with socket bolts (1) (4 used).

: 10 mm : 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft)


(8). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)

4. Secure piping (2) to bracket (6) with clamp (5) and

bolts (4) (2 used). : 22 mm : 137 N⋅m (14 kgf⋅m, 101 lbf⋅ft)

WCJB-04-03-003

2

5

6

43 1

7 8, 9


W4-3-5

REMOVAL AND INSTALLATION OF HOSE RUPTURE VALVE FOR BOOM CYLINDER


Removal 1. Remove bolt (4) from clamps (3) (2 used).

Remove clamps (3) (2 used) from bracket (2) and piping (5).

: 19 mm

2. Disconnect hoses (6) (6 used) from hose rupture valve (8). Cap the open ends. Attach an identification tag onto the disconnected hoses for assembling.

: 17 mm, 19 mm, 27 mm

3. Remove socket bolts (7) (4 used) from piping (5). Disconnect piping (5) from boom cylinder (1). Remove hose rupture valve (8) and O-ring (9) from boom cylinder (1). Cap the open ends.

: 10 mm

WCEB-04-03-002

5

6

321

7

4

68, 9


W4-3-6



2. Install hose rupture valve (8) and piping (5) to boom cylinder (1) with socket bolts (7) (4 used).

: 10 mm : 93±1.8 N⋅m (9.3±0.2 kgf⋅m, 69±1 lbf⋅ft)


(8). : 17 mm : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) : 19 mm : 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

4. Secure piping (5) to bracket (2) with clamps (3) (2

used) and bolt (4). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

WCEB-04-03-002

5

6

321

7

4

68, 9


W4-3-7

(Blank)


W4-3-8

STRUCTURE OF HOSE RUPTURE VALVE FOR ARM CYLINDER

WCEB-04-03-006

6

9 10 11 12 13 14 15

3 4 5 7 8

16

2

1

47

46

45

44

43

42

41

40

39

17

18

19

20

21

22

23

24

27

28

29

30

31

32

33

26

25

38

37

36

35

34


W4-3-9

Tightening Torque

No. Part Name Q’ty Wrench Size(mm) N⋅m (kgf⋅m, lbf⋅ft)

Remark

1 Spacer 1

2 Plug 3 : 5

3 O-Ring 3

4 Backup Ring 1

5 O-Ring 1

6 Orifice 2

7 Backup Ring 2

8 O-Ring 1

9 Lock Nut 1 : 17

10 Poppet 1

11 Set Screw 1 : 6

12 Spring 1

13 O-Ring 1

14 Washer 1

15 Adapter 1 : 24

16 O-Ring 1

17 Backup Ring 1

18 O-Ring 1

19 Casing 1

20 O-Ring 1

21 Plug 1 : 32

22 Stopper 1

23 Spool 1

24 Sleeve 1

25 Backup Ring 1

26 O-Ring 1

27 O-Ring 3

28 Plug 1


W4-3-10

WCEB-04-03-006

47

46

45

44

43

42

41

40

39 29

30

31

32

33

38

37

36

35

34


W4-3-11

Tightening Torque


Remark

29 Backup Ring 1

30 Spring 1

31 Holding Valve 1

32 Orifice 2

33 Body 1

34 O-Ring 1

35 O-Ring 1

36 Backup Ring 1

37 O-Ring 1

38 Backup Ring 1

39 Spring Seat 1

40 O-Ring 1

41 Piston 1

42 O-Ring 1

43 Cover 1 : 32

44 Stopper 1

45 Set Screw 1 : 3

46 Lock Nut 1 : 10

47 Spring 1

Casing (19) and body (33)mounting socket bolt 4 : 8


W4-3-12

STRUCTURE OF HOSE RUPTURE VALVES FOR BOOM CYLINDER

W1V1-04-03-001

83 4 5 6 7

9 10 11 12 13 14 15

17

18

19

20

21

22

232425

26

27

28

29

30

31

1

47

46

45

44

43

42

41

40

39

38

37

36

35

34

32

33

16

2


W4-3-13

Tightening Torque


Remark

1 Spacer 1

2 Plug 3 : 5

3 O-Ring 3

4 Backup Ring 1

5 O-Ring 1

6 Orifice 2

7 Backup Ring 2

8 O-Ring 1

9 Lock Nut 1 : 17

10 Poppet 1

11 Set Screw 1 : 6

12 Spring 1

13 O-Ring 1

14 Washer 1

15 Adapter 1 : 24

16 O-Ring 1

17 Backup Ring 1

18 O-Ring 1

19 Casing 1

20 O-Ring 1

21 Plug 1 : 32

22 Stopper 1

23 Spool 1

24 Sleeve 1

25 Backup Ring 1

26 O-Ring 1

27 O-Ring 3

28 Plug 1


W4-3-14

W1V1-04-03-001

29

30

31

47

46

45

44

43

42

41

40

39

38

37

36

35

34

32

33


W4-3-15

Tightening Torque


Remark

29 Backup Ring 1

30 Spring 1

31 Holding Valve 1

32 Orifice 2

33 Body 1

34 O-Ring 1

35 O-Ring 1

36 Backup Ring 1

37 O-Ring 1

38 Backup Ring 1

39 Spring Seat 1

40 O-Ring 1

41 Piston 1

42 O-Ring 1

43 Cover 1 : 32

44 Stopper 1

45 Set Screw 1 : 3

46 Lock Nut 1 : 10

47 Spring 1

Casing (19) and body (33)mounting socket bolt 4 : 8


W4-3-16

STRUCTURE OF HOSE RUPTURE VALVES FOR POSITIONING CYLINDER

WCJB-04-03-002

83 4 5 6 7

9 10 11 12 13 14 15

17

18

19

20

21

22

23242526272829

31

34

1

50

49

48

47

46

45

44

43

42

41

40

39

38

37

35

36

16

2

32

33

30


W4-3-17

Tightening Torque


Remark

1 Spacer 1

2 Plug 3 : 5

3 O-Ring 3

4 Backup Ring 1

5 O-Ring 1

6 Orifice 2

7 Backup Ring 2

8 O-Ring 1

9 Lock Nut 1 : 17

10 Poppet 1

11 Set Screw 1 : 6

12 Spring 1

13 O-Ring 1

14 Washer 1

15 Adapter 1 : 24

16 O-Ring 1

17 Backup Ring 1

18 O-Ring 1

19 Casing 1

20 O-Ring 1

21 Plug 1 : 32

22 Stopper 1

23 Spool 1

24 Sleeve 1

25 Backup Ring 1

26 O-Ring 1

27 O-Ring 3

28 Plug 1

29 Backup Ring 1

30 O-Ring 1

31 Plug 1

32 Orifice 1


W4-3-18

WCJB-04-03-002

34

50

49

48

47

46

45

44

43

42

41

40

39

38

37

35

36

33


W4-3-19

Tightening Torque


Remark

33 Spring 1

34 Holding Valve 1

35 Orifice 2

36 Body 1

37 O-Ring 1

38 O-Ring 1

39 Backup Ring 1

40 O-Ring 1

41 Backup Ring 1

42 Spring Seat 1

43 O-Ring 1

44 Piston 1

45 O-Ring 1

46 Cover 1 : 32

47 Stopper 1

48 Set Screw 1 : 3

49 Lock Nut 1 : 10

50 Spring 1

Casing (19) and body (36) mounting socket bolt 4 : 8


W4-3-20

(Blank)

FRONT ATTACHMENT / Operate Check Valve

W4-4-1

REMOVAL AND INSTALLATION OF OP-ERATE CHECK VALVE (FOR BLADE AND OUTRIGGER)

Removal

CAUTION: Lower the blade onto the ground before doing any work.

CAUTION: Secure the outrigger beam and the outrigger by using the lock pin before doing any work.

1. Remove bolts (1) (4 used) and washers (2) (4 used) from guard cover (3). Remove guard cover (3) from brackets (4) (2 used).

: 19 mm

2. Disconnect hoses (5) (4 used) from operate check valve (7). Cap the open ends.

: 19 mm, 27 mm

3. Remove socket bolts (10) (4 used) from piping (9). : 6 mm

4. Remove socket bolts (6) (4 used) from operate

check valve (7). Remove operate check valve (7) and O-rings (8) (2 used) from cylinder (11). Cap the open ends.

: 6 mm

WCEB-04-04-002

WCEB-04-02-001

WCEB-04-02-002

WCEB-04-04-001

11

5

Outrigger Beam Lock Pin Float

Outrigger

1, 2

3

4

7, 8

5

9

10

11

6

10

6 7, 8

9


W4-4-2

Installation 1. Apply grease onto O-rings (8) (2 used).

2. Install O-rings (8) (2 used) to operate check valve

(7).

3. Install operate check valve (7) to cylinder (11) with socket bolts (6) (4 used).

: 6 mm : 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft)

4. Connect piping (9) to operate check valve (7) with

socket bolts (10) (4 used). : 6 mm : 26.5 N⋅m (2.7 kgf⋅m, 20 lbf⋅ft)

5. Connect hoses (5) (4 used) to operate check

valve (7). : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) : 27 mm : 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)

6. Install guard cover (3) to brackets (4) (2 used) with

bolts (1) (4 used) and washers (2) (4 used). : 19 mm : 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)

WCEB-04-02-002

WCEB-04-04-001

WCEB-04-02-001

WCEB-04-04-002

Outrigger Beam Lock Pin Float

Outrigger

1, 2

3

4

11

11

5

7, 8

5

9

10

11

6

10

6 7, 8

9


W4-4-3

STRUCTURE OF OPERATE CHECK VALVE

WCEB-04-03-001

Tightening Torque Item Part Name Q’ty Wrench Size(mm) N⋅m (kgf⋅m) (lbf⋅ft)

Remark

1 Plug 2 : 6 mm 34.3±3.4 (3.5±0.3) (25±3) 2 O-Ring 2 1B P11 3 Plug 2 : 36 mm 500±50 (51±5) (369±37) 4 O-Ring 2 1B P26 5 Spring 2 6 Sleeve 2 7 Poppet 2 8 Piston 2 9 O-Ring 1 1B P18

10 Plug 1 : 36 mm 240±24 (24±2.4) (18±2)

11 Casing 1 12 Plug 1 : 36 mm 240±24 (24±2.4) (18±2) 13 O-Ring 1B P18

10

11

876543

12

13

2 91


W4-4-4

(Blank)

M E M O

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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No. Attn: Publications, Marketing & Product Support Fax: 81-29-831-1162

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(Copy this form for usage)

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hitachi zx 210w-3, 220w-3

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